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Cushman Haulster (898487) - Parts & Maintenance

Contents

1. 10 4 12 Draining The Cooling System 11 4 13 Filling the Cooling System 11 4 14 AirGl aner ensure abad 12 4 15 Servicing Air Cleaner Element 12 4 16 Checking Air Cleaner Element 12 4 17 Installing Air Cleaner 12 4 18 Lubricating Brake Pedal Bushings 13 4 19 Automatic Transmission 13 a NA NAD gu ages REALL EIR ar aka IN IA ag RI ERAN 13 4 24 Master Cylinder Access 14 4 22 Jacks Jacking Locations And Using A Hoist 14 4 23 Changing The Rear Wheel 14 4 24 Changing The Front Wheel 14 425 Tire Replacement ada SE 15 4 26 Extended Storage 15 5 TORQUE Chait A ads 16 6 Parts 6 1 Engine Gaskets 18 19 6 2 Cylinder Head ised eect tenes 20 21 6 3 22 23 6 4 Crankshaft Pistons isses 24 25 6 5 Camada aceasta 26 27 6 6 T
2. 106 107 6 46 Heater Defroster 108 109 6 47 Electrical Components Front 110 111 6 48 Electrical Components Main 112 113 6 49 DEGAS Hexen tear ete riv ae ser ded tre 114 115 6 50 Headlights Taillights amp Turn Signals 116 117 6 51 Rotating obt 118 119 6 52 Turn Signal Switch 120 121 6 53 Front Shock Absorber 122 6 54 Wheel Measurement nennen nn 123 6 55 Sn 124 6 56 Front Bumper 125 ea E uu Iu RU ILI EE 126 129 6 58 Steel DOOLS cunas rara 130 133 2 1 VEHICLE IDENTIFICATION NOTE The following identification numbers MUST appear on all correspondence concerning this vehicle The Vehicle Identification Number VIN model number and serial number are all printed on the Nameplate Iden tification decal attached to the upper left portion of the kick panel Nameplate Identification Decal 2 2 SERIAL amp MODEL NUMBER Serial Number And Model Number IDENTIFICATION 2 23 ENGINE SERIAL NUMBER The engine serial number is stamped into the right hand skirt of the cylinder block located directly below the air intake manifold 1 Stamped Eng
3. 33 52916515757 Leren 18 OSOS tit ir DUEB eh pene d 78 Intake Manifold 30 2 Fill 80 Olla ie 80 Oil PUMP te FEL ra 34 PISTONS ur EE MET 24 PVC Valve ur una Ed ei na GE yw a 32 E vec KEES 38 Thermostat y e ee onde a 36 Throttle Body 30 Timing Belt amp Cover 28 Torque Converter 40 Water Pump amp Outlet 36 Engine Cover 62 Exhaust System 100 Floormat Insulation Weatherstrip amp Moldings 64 Frame Main EEE S best 56 Platform nennen nennen 58 Front Fork xa o soto der rien 70 Fuel System 98 teen Ra eR 76 Headlights Y 116 Heater Defroster 108 Boru ar a 72 Hub amp Wheel Cylinder Rear 86 Master Cylinder 90 Rear Box Sides Side Opening 66 Rear Spring 68 Rotating Light 118 Seat A Backrest 96 Seat Bell aret dis 94 Shock Absorber Front 122 Steering
4. 87 888815 129 888831 129 888832 129 888835 129 888836 129 888842 129 888856 109 888861 87 889050 107 889051 107 889065 105 889159 ee 61 889350 85 87 889445 125 889596 109 889906 85 889924 iilam 85 889930 85 87 890000 111 890817 91 891246 119 891250 iu Roles 67 891563 119 891649 119 129 891764 71 891765 tefa 71 891767 71 891795 eve aca 57 891811 ees 87 891812 L evi 87 892471 85 87 892807 ste 73 8931 2 Loi ns 124 893395 113 893876 77 894057 57 894108 129 894109 111 127 894132 ie recess 129 894136 o oie 97 894211 eo Seo 129 894212 oe nas 129 894511 ie bn nee 109 894590 107 894031 eiii ins 67 894706 77 894708 77 894835 129 894836 129 894851 111 121 894853 111 121 894854 111 121 894901 107 894906 103 895125 ii tii 41
5. 89 834979 69 105 835062 77 835218 59 67 835805 107 835905 un ua 124 836024 109 836206 81 836389 57 837298 111 837308 61 117 837462 113 837581 ana nn 97 837670 117 837690 57 837960 67 837961 67 83 962 uke eie 67 838053 67 838072 67 838095 93 838096 93 838109 93 838158 119 838223 67 838340 107 838354 111 838355 85 87 838361 119 838402 87 838403 87 838404 87 838409 69 838477 ibid Be lima 57 838688 57 838706 57 65 839168 111 839197 111 121 839229 4 284 83 839905 57 63 840230 57 840233 57 840394 115 840395 115 840408 59 840404 59 840436 67 840438 67 841982 101 842462 131 842463 133 842464 t ee etes 133 842647 129 842740 47 77 842767 113 842782 107 8
6. 99 2700178 99 2700220 121 2700335 77 2700508 77 2700511 113 2700615 7 59 2700616 7 59 2700819 7 107 2700867 111 2700875 117 121 2700904 111 2700910 7 75 2700911 7 75 2700918 111 2700938 75 2701002 75 2701043 107 2701045 8 101 2701089 101 2701105 7 113 2701129 0 77 2701236 77 2701326 75 2701329 115 2701409 7 111 2701419 7 57 2701434 7 77 2701442 79 2701461 7 41 2701463 41 2701466 103 2701510 77 2701511 77 2701513 37 79 2701514 7 81 2701516 79 2701517 77 27015212 7 79 2701636 81 2 01697 u er ah 37 2701638 ore d te 37 2701640 81 2701652 tin 79 27101720552 ets 83 27001727552 37 2701776 19 21 136 PART NUMBER INDEX us i 19 2701795 19 21 2701796 19 31 2701797 19 33 2701798 19 21 2701799 19 21 2701800 19 35 2701801 19 37 2701802
7. 57 830780 63 Part Page No No 830781 63 830902 127 830904 127 830908 61 63 65 127 131 830920 81 830929 81 831004 63 65 67 133 831006 109 831225 113 831582 127 831603 cie eren 101 831604 101 832033 107 109 832094 111 9832115 cenas 129 a CO 528 115 882555 ib bed 73 832584 89 832585 ossi 89 892587 uo en 89 832649 113 832804 109 115 833512 107 833607 115 833745 65 833846 109 833850 85 87 833851 65 109 127 833857 109 833858 atar 109 93386255225 109 833879 87 833891 87 833912 85 87 833916 85 87 833918 en ene 85 87 833939 109 833940 109 833943 61 833949 109 833958 109 833971 129 83397245555 ait 129 833974 109 833984 109 833985 109 833986 109 833993 85 87 833999 131 834007 109 834036 99 834077 129 834099 105 834161 87 89 834582 99 834888
8. 69 814204 105 814226 103 814465 103 814466 103 814467 103 814468 103 814469 103 814470 103 814471 103 814474 sci eva 103 814475 103 814476 103 814477 103 814481 105 814482 105 814483 105 814484 105 814488 103 91158257 85 67 814924 127 129 815403 103 815421 89 815490 103 815794 105 815847 59 816045 103 816447 73 816455 73 816456 73 816515 cor 103 816653 73 816654 c 73 816659 71 73 816660 73 816674 aan eden 73 816675 mans dr dett 73 816697 71 816823 105 816824 105 816825 105 816991 115 817019 44 ie web 83 TM ida 75 817307 Li iex 89 817309 kie 111 818226 103 819923 121 820008 89 820889 79 107 821068 129 821153 c aaa 87 821606 57 821734 69 821893 65 109 822049 117 822819 WEE 115 823089 91 138 823201
9. 45 6 16 TRANSMISSION TUBES OIL PUMP SOLENOIDS amp SHIFT SWITCH To Oil Cooler A FRONT OF VEHICLE 46 TRANSMISSION TUBES OIL PUMP SOLENOIDS 8 SHIFT SWITCH 6 16 Pump oil Geal oil pump Bolt oil pump Ring set oil pump seal Solenoid direct clutch O ring 1 NN Solenoid 2nd brake Switch shift Joint transmission shifter Bushing Lever shifter Clamp hose Hose 5 16 i d eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 47 6 17 TRANSMISSION INPUT SHAFT amp CLUTCH FRONT F VEHICLE TRANSMISSION INPUT SHAFT amp CLUTCH 6 17 Shaft set input Plate set forward clutch O ring set forward clutch Bearing set thrust No 1 Clutch assembly direct Plate set direct clutch O ring set direct clutch Washer set direct clutch eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 49 6 18 TRANSMISSION PLANETARY GEARS 8 OUTPUT SHAFT A FRONT OF VEHICLE TRANSMISSION PLANETARY GEARS 8 OUTPUT SHAFT 6 18 Bearing set thrust No 3 Gear assembly forward planetary link Bearing set thrust No 4 Gear assembly front Bearing set thrust No 5 Gear planetary sun Washer set thrust Bearing set thrust No 1 Gear rear planetary Clutch set 1 way Plate set 1st reverse Piston set 1st reverse O ring set 1st reverse
10. 31 2702473 31 2702474 31 2702476 31 2702477 31 2702478 31 2702479 31 2702480 31 2702481 31 2702484 32 2702485 32 2702488 32 2702489 32 2702490 32 2702491 32 2702492 33 2702496 33 2702497 33 2702501 33 2702508 33 2702515 35 2702516 35 2702518 35 2102522 2 eg 37 2702525 ie 37 2702539 52255 37 2702542 37 2702548 37 2702594 115 2702662 43 2702683 43 2702690 43 2702697 41 2702698 41 2702699 41 2702700 41 2702701 41 2702748 45 2702749 45 2702750 43 2702751 43 2702752 43 2702754 43 2102759 7 itr ees ee 43 2702760 43 2702761 43 2702763 43 2702765 47 2702766 47 2702768 47 2702769 27525552425 49 2702770 e 49 2702771 e 49 2102 733 oe eee 49 2702774 ann 49 2702775 49 LIO Por s rt 51 2702775 588 84 25
11. 127 823549 79 823621 oca 122 823752 aia 91 824060 85 8242192548 ans 89 824484 parata 67 62405146 55 25 67 824731 mania 89 824833 85 87 824925 87 825126 24200288 93 825358 79 109 111 121 825403 71 825404 85 825405 uie 85 825477 Less oie eril 89 825502 vegger pre mas 115 825602 97 825608 97 825622 115 825624 37 47 79 81 99 107 825629 115 825642 129 825679 71 825681 71 825682 71 825779 107 109 825819 2555855558 133 825823 131 825840 65 133 8258427 reins 65 825844 127 825850 117 825851 ona 117 825859 au nun 127 825877 121 825880 121 825893 una aire 111 825894 121 825924 65 133 825933 ann en es 57 825967 97 825978 119 825994 have vat eik 109 826005 119 826006 119 826037 129 826284 eis create ees 41 826285 41 826294 59 826491 73 826590 47 79 99 826726 111 117 121 129 827018 ori la 103 827486 105 827769 65 127 828072 eoi etes 89 828231 zi vix s 111
12. 39 2702906 39 2702907 39 2702909 39 2702970 131 2703090 81 2703091 81 2708127 127 820122 i Ere 103 385174 an ne 85 986767 4 105 4109361 89 4109420 89 4109580 81 521679 ua nee 75 548482 41 800128 innen e 71 800130 71 800227 89 91 800356 103 800789 107 805189 cio aia 71 805196 I ln 69 805245 i sense 129 805320 103 805321 103 805322 103 805451 crea 129 805875 103 807332 122 807442 24 5 sus a 71 807630 85 808076 71 808088 85 808303 103 808969 71 809018 87 809092 113 809229 85 809231 107 809255 71 73 809257 anne 87 809268 85 809423 89 91 810149 67 71 810152 Ana 57 810379 129 810437 camp 93 810441 59 67 810446 129 811650 85 87 811928 enger deg 91 812098 71 812167 eius 71 812208 59 67 97 812218 69 105 812313 eiii 59 812335 103 812445 secus 89 137 No No 813850
13. 72 Steering 72 Page Taille 116 Throttle Pedal 74 Lesson 124 Transmission 42 Brake Band 52 6 10 ETT 48 Dipstick sesa 44 EE EE 44 Input Shaft vaks nece tr ex eese 48 Oil PUMP ine era 46 Output Shaft 50 PAA rial ab 44 Planetary Gears 50 Shift Sait cos Te rea acted 52 Shift SWILCD ix 55585 er Pad 46 Shifter amp Shifter Cable 82 Solenoids Sanne ii td 46 TUDES avia tarta L dd onde ati dis ee 46 VT VE 54 Turn Signal Switch 120 TUM Signals 22 ee nena pas 116 Wheel Measurement 123 Page 5 Specifications 1811 4 Brake Fluid 4 Capacities 4 Dimensions 4 EOI A LEM 5 Engine Oil scc ei 4 UCL Lites eteren 0883 4 55211721103 o daa EE en 5 Lubrication 4 MIND 4 T Torque Chart 16 135 Part Page No No 09119 10039 101 111836 81 11610 60C01 81 11640 53F20 81 13701 53F20 79 13780 79201 79 14183 82050 101 14492 82001 101 2700031 37 79 2700161 99 2700166
14. KEEP HANDS CLEAR ELECTRIC FAN MAY ENGAGE WITHOUT WARNING EVEN WITH IGNITION OFF 833607 oh NEVER attempt to clean or service the cooling system with the engine running ALWAYS allow the engine to cool before servicing the cooling system The vehicle is equipped with a cooling radiator and elec tric fan located below the right side from operators posi tion of the engine cover To provide proper engine cool ing e DO NOT obstruct or cover the air intake screen in front of the radiator e ALWAYS keep the screen radiator and oil cooler fins clean NOTE Clean the radiator and oil cooler fins with com pressed air If water is used to clean the radiator or oil cooler use compressed air to blow ALL the water from the radiator or oil cooler fins Water left between the fins will collect dirt and clog the radia tor Keep the proper amount of coolant in the cooling system Check coolant level in radiator and reservoir bottle The coolant should be up to the filler port of the radiator and between the FULL and LOW lines in the reservoir bottle Level should not be higher than the FULL line 1 Radiator NOTE f the coolant level is low check for leaks and repair as necessary If additional coolant is required a 50 50 mixture of a good grade of ethylene glycol antifreeze and clean water is recommended This will provide protection to 34 F 37 C It is extremely import
15. 10 Draining the Cooling System 11 Filling the Cooling System 11 UU elisa ai OTRO 9 Extended Storage 15 FUSES dr a AA 8 GUIDE SSS Scc EH 6 Jacks Jacking Locations 14 Lubricating Brake Pedal Bushings 12 Lubrication Chart 7 Master Cylinder 14 Tire Replacement 15 P Parts Alai 76 Axle 8 Hub Front 84 Body Frontinus satsen ete ee reed 60 Brake Parking 92 Brake Rod 90 Brakes Folat 84 Flydraulle sener ehe 88 Hear iunc ise RE AES YR 86 134 Page Bumper Front 125 Cass arepas ia RS 126 Cooling System 106 19607157477 ue itera en 114 102 Doors Steel 130 Electrical Components FLOM e Seege 110 a pra IRR RM 112 Se SARA maaa VELO ER 78 Gamsh ll ee e 26 Crankshaft a 24 Cylinder Block 22 Cylinder Head 20 Driveshaft 40 Exhaust Manifold
16. 308089 Washer 10 308090 Washer 1 4 800271 Screw P T H 10 24 x 1 2 884302 Backrest 825967 Cover backrest black 894136 Seat w hinge 800215 812208 885947 817606 eeNut tee 10 24 Not illustrated 837581 eeBag literature 825602 eeBoard seat Not illustrated 825603 eePad seat Not illustrated 884177 eeCover black 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 97 6 42 FUEL SYSTEM 98 FUEL SYSTEM 6 42 2700161 Connector tee 5 16 2700166 Clamp fuel pump 2701897 Pump fuel 2701898 Filter fuel 2701899 Regulator 2700178 Connector union 2702303 Tube fuel 2702388 Half clamp 300646 Screw 1 4 20 x 3 4 306325 Lockwasher 5 16 306375 Nut 1 4 20 306836 Screw 3 8 16 x 2 1 4 306932 Nut 5 16 18 320107 Tie cable 7 1 2 191 mm Not illustrated 548804 Nut 3 8 16 548900 Screw 10 24 x 1 2 800875 Nut 12 1 25 800974 Screw 10 x 1 tapping 816307 Washer 9 32 825624 Clamp hose 826590 Hose fuel 25 7 6 M 829954 Gasket 834036 Connector hose 834582 Sender fuel level 844637 7 Bracket canister 2702436 Cap fuel 844654 7 Tank fuel 844670 Canister carbon 844748 O 071 OO N 99 6 43 EXHAUST SYSTEM REF EXHAUST MANIFOLD REF CROSSMEMBER 11 EXHAUST SYSTEM 6 43 2701045 8 Muffler 2701089 C
17. 810444 eeWasher sealing 830817 eeFitting banjo brass 839140 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 91 6 39 PARKING BRAKE P O55 LO 92 1 2 3 4 5 6 7 8 9 103867 306325 306328 306416 306450 306932 800290 800446 806703 810437 825126 838095 838096 838109 884189 884204 Washer 5 16 Lockwasher 5 16 Pin cotter 3 32 x 3 4 Screw 5 16 18 x 1 Screw 5 16 18 x 3 4 Nut 5 16 18 Nut lock 5 16 18 Nut stop 5 16 24 Pin clevis 5 16 x Cable parking brake RIGHT 67 15 16 1745 mm Cable parking brake LEFT 44 15 16 1146 mm Bracket brake cable Lever park brake Screw adjusting PARKING BRAKE 6 39 93 6 40 SEAT BELT 12 94 1 2 3 4 5 6 7 8 9 120177 304364 306562 306834 306981 311395 316942 821702 831783 843081 843173 843182 845082 7 Description Lockwaasher 3 8 Nut 7 16 14 Nut 3 8 16 Screw 3 8 16 x 3 4 Washer 13 32 Screw 7 16 14 x 1 3 4 Pin spirol 1 4 x 1 2 Washer 29 64 Washer 17 32 Plate reinforcement Brace seat belt Seat belt Spacer seat belt interior SEAT BELT 6 40 95 6 41 SEAT 8 BACKREST 96 Cover Black Cover Black SEAT 8 BACKREST 6 41 120052 Lockwasher 10 300646 Screw 1 4 20 x 3 4 306396 Lockwasher 1 4 306531 Nut 10 24
18. eRing retainer ePlug hole eGear speedometer 34 tooth eCover adjustment hole eSpring retainer eeKit brake lever and adjuster eLever brake RIGHT Not offered separately Bolt M6 eRetainer shoe eCylinder wheel 13 16 21mm eLever park brake RIGHT eRetainer park brake lever pin eWasher spring eDust shield RIGHT eCa eBrake kit two brake shoes eeSpring retainer eePin brake eeGuide brake spring Not illustrated eeShoe brake Not offered separately Shoe w dust shield complete LEFT ePlug hole eCover adjustment hole eSpring retainer Bolt M6 eDust shield LEFT eRetainer shoe eKit brake lever and adjuster sel ever brake LEFT Not offered separately eCylinder wheel 13 16 21mm eL ever park brake LEFT eRetainer park brake lever pin eWasher spring eBrake kit two brake shoes eeSpring retainer eePin brake eeGuide spring Not illustrated eeShoe brake Not offered separately Kit wheel cylinder i Not illustrated Cable speedometer 1 Not illustrated e INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 87 6 37 HYDRAULIC BRAKE SYSTEM 88 CO OO O OO N HYDRAULIC BRAKE SYSTEM 6 37 Description 103867 Washer 5 16 112050 Screw tapping 1 4 20 x 5 8 306325 Lockwasher 5 16 306375 Nut 1 4 20 306396 Lockwasher 1 4 306435 Screw 5 16 18 x 1 1 4 306932 Nut 5 16 18 320107 Tie
19. 2 Spring 2nd brake No 2 Spring 2nd brake No 3 TRANSMISSION VALVE 6 20 Spring accumulator forward piston lower 55 6 21 MAIN FRAME TO REAR PLATFORM 41 LEFT 39 RIGHT 2 56 1 1 103867 112050 120177 2701419 7 2702232 7 2702236 300646 306322 306325 306375 306396 306414 306416 306450 306464 306487 306562 306932 306981 308090 548175 548911 800290 800390 810152 821606 825933 828577 828998 829880 830762 836389 837690 838477 838688 838706 839905 840230 Washer 5 16 Screw 1 4 20 x 5 8 tapping Lockwasher 3 8 Motor mount LEFT Frame main Motor mount RIGHT Screw 1 4 20 x 3 4 Screw 5 16 18 x 7 8 Lockwasher 5 16 Nut 1 4 20 Lockwasher 1 4 Screw 3 8 16 x 1 Screw 5 16 18 x 1 Screw 5 16 18 x 3 4 Screw 5 16 18 x 2 1 2 Screw 1 4 20 x 5 8 Nut 3 8 16 Nut 5 16 18 Washer 13 32 Washer 1 4 Washer 1 4 Nut 5 16 18 Nut 5 16 18 centerlock Rivet 1 8 x 25 64 Cover Reflector yellow Pad Seal foam Gasket horn Guard splash Guard throttle pedal Cover foam Mat floor Pan skid Panel RIGHT Panel RIGHT side Plate oil deflector Panel LEFT filler Angle platform support cover pad Pad brake Panel LEFT MAIN FRAME 6 21 57 6 22 PLATFORM FRAME Touch Up Paint 12 oz Spray Can Part No 843311 Part No 843312 4 LEFT 5 RIGHT 10 TO MAIN
20. 828378 59 63 65 67 828379 119 828384 129 828388 127 828577 i vea 57 828613 111 828668 129 828682 129 828694 133 828697 133 828698 133 828699 133 828700 131 828718 133 828719 133 828731 133 828733 65 133 828734 133 828735 133 828736 129 828834 65 133 828934 127 828935 127 828946 69 828972 129 828976 65 67 127 131 828998 57 829038 131 829040 131 829049 ies 89 829071 127 829099 117 829100 117 829101 eerie erws 61 829187 131 829155 91 829158 c rene 91 829285 it 71 829536 127 829558 ves 91 829717 Is 129 829735 65 129 829754 75 ve 113 829787 37 829880 63 829954 ieu 99 829966 127 830135 111 830140 77 830165 aen 75 830167 4 arx 73 830168 73 830175 ee 81 830176 81 830355 61 65 109 127 830369 sien 73 830370 73 830557 105 830658 eiii lina 63 830762
21. Bolt 1 4 20 x 1 1 4 800296 Screw 10 24 x 3 4 800299 Screw 10 44 x 1 809092 Clamp 829754 Switch snap action 831225 Clamp 831889 Washer swivel 832649 Guard tail light 837462 Boot battery terminal 842767 Clamp fuel tube 845218 Solenoid with cable 845219 Module control 879945 Solenoid 12V 888089 Taillight RIGHT 888090 Taillight LEFT Not illustrated 893395 Terminal battery cO oo O1 N 113 6 49 DECALS 114 NOTICE I THIS IS A NEGATIVE GROUND SYSTEM REVERSING BATTERY CONNECTION WILL DAMAGE 4 ALTERNATOR RECTIFIER 2 BOOSTER BATTERIES USED FOR STARTING MUST BE CONNECTED WITH PROPER POLARITY BATTERY CABLES SHOULD BE DISCONNECTED BEFORE USING A FAST CHARGER ae f CF ERRORES A WARNING amt PARKING BRAKES ARE NOT AUTO 5 uama curso MATICALLY APPLIED VEHICLE MAY MOVE CAUSING PERSONAL INJURY lencrne IDLE SPEED 950250 ECU CONTROLLED AND OR
22. Box 82409 Lincoln NE 68501 2409 USA In the USA and Canada call 1 888 922 8873 dealer information only 2001 Textron Inc Lincoln Nebraska All Rights Reserved 250 6 01 CU Printed in U S A TABLE OF CONTENTS SECTION PAGE 1 General Information Inside Front Cover 2 Identification 2 1 Vehicle Identification Yus NASA YN nen 3 22 Serial 8 Model Number 3 2 3 Engine Serial Number 3 Specifications 341 Venicle eee aed ene eat eid Eileen 4 3 2 DIMENSIONS coc ee ee ee 4 3 3 Capacities ofa cach iat As 4 34 B llery aan anni A hoe view Glades eh 4 4 3 6 Lnr 4 344 EngNet ee 4 3 8 10101102110 Zaun lan 4 3 9 Gear o atu kane 5 IE 5 4 Maintenance AT M lmenance cuchara 6 42 Maintenance Guide 6 4 3 Lubrication Chatto uu ide da riu du Pire 7 44 Bube and eee AAA A 8 US 8 46 Engine Maintenance 8 AT ue UE E 9 48 Engine Oil Level 9 4 9 BADER amateure eier Deren 10 4 10 Jump Starting With Booster Battery 10 4 11 Engine Cooling System
23. Fr nt Body ses oed ert bnr ask 60 61 6 24 Engine Cover 62 63 6 25 Floormat Insulation Weatherstrip amp Moldings 64 65 6 26 Rear Box Sides Side Opening 66 67 6 277 Rear Spring ed etus A aine 68 69 6 28 Fr nt Fork iis e nU Get 70 71 6 29 Steering Gear Wheel amp Horn 72 73 6 30 Throttle Pedal 74 75 6 31 Alternator amp Governor 76 77 6 32 Hoses 8 Air Filter es m 78 79 6 33 Oil Fill amp Filter 80 81 6 34 Shifter 8 Shift Cable 82 83 6 35 Front Brakes Axle amp Hub 84 85 6 36 Rear Brakes Hub amp Wheel Cylinder 86 87 6 37 Hydraulic Brake System 88 89 6 38 Master Cylinder 8 Brake Rod 90 91 GC Blo le BEE 92 93 0 40 Seat ea 8 94 95 6 41 Seat amp Backrest nennen nenn 96 97 6 42 Fuel SyStem rin ahaa dal 98 99 6 43 Exhaust System 100 101 6 44 Differential 102 105 6 45 Cooling System
24. IF A MALFUNCTION OCCURS CEASE OPERATION DO NOT 8 OPERATE VEHICLE UNTIL CONDITION IS CORRECTED LOUD NOISE OCCURS IF FRONT SKID P M M M BAR STRIKES ROAD SURFACE THIS INDICATES VEHICLE IS BEING OPERATED RECKLESSLY RANES ROWER MAIN INSTR MENT AND IS NEAR UPSET MISSION POINT RELAY PANEL BEFORE LEAMNG VEHICLE TURN IGNITION TO OFF POSITION AND REMOVE KEY APPLY PARKING BRAKE PARKING BRAKE IS NOT AUTOMATICALLY APPLIED FOLLOW PROCEDURE IN NS 2192801 OPERATOR S MANUAL FOR PARKING ON AN INCLINE IT IS YOUR RESPONSIBILITY TO KEEP ALL LABELS DECALS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT REPLACEMENT LABELS DECALS AND LITERATURE ARE AVAILABLE FROM THE FACTORY 825629 SN M 2 NOTICE DO NOT_TOW OR PUSH THIS 12 VEHICLE AT SPEEDS IN EXCESS OF IO MPH OR TRANSMISSION WARNING 9 DAMAGE WILL OCCUR PEN TO PREVENT POSSIBLE SEVERE 2 M BURNS TO YOU OR OTHERS DO NOT REMOVE PRESSURE CAP Vehicle Emission Control Information N WHEN HOT CONTENTS UNDER CUSHMAN a Textron Company TRANSMISSION FLUID LEVEL PRESSURE CHECK AND ADD fe speed B80 2 S0 ppm e CHECK UNDER THIS COVER FLUID AT RESERVOIR IX ROAD d 44 REFER TO SERVICE MANUAL 1 832130 Engine oil SE Sr SF S FOR PROPER PROCEDURE M 840395 This vehicle conforms to USEPA ee applicable to Model Year New Motorcycles KEEP VALVE S CLOSED WHEN 10 ENGINE COOLANT RESERVOIR HEATER 1S CHECK UNDER THIS COVER NOT IN USE REFER TO SERVICE MANUAL 15 porn FOR PROPER PROCEDURE
25. Shaft output Ring snap Ring speedometer exciter Cir clip exciter ring Bearing thrust Set No 6 1 2 3 4 5 6 7 8 9 eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 51 BRAKE BAND amp SHIFT SHAFT 6 19 VEHICLE 2702800 Band set second brake 2702805 Spring second brake piston return 2702801 Piston assembly second brake 2702804 Cover set 2nd brake Ring set 2nd brake seal Pole set parking Shaft set lever Lever shifter eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 53 6 20 TRANSMISSION VALVE N T T T COW T 10 Wi 00900 an e comm mmm 07 ING cam N m T a FRONT OF VEHICLE 54 1 2 3 4 5 6 7 8 9 2702821 2702825 2702826 2702827 2702836 2702834 2702835 2702837 2702838 2702828 2702829 2702830 2702833 2702831 2702839 2702840 2702841 2702842 2702832 Body assembly transmission valve Strainer transmission Bolt valve body No Bolt valve body No Bolt valve body No Bolt valve body No Bolt valve body No Bolt valve body No Bolt valve body No Piston set C1 accumulator Spring forward piston Piston set B1 accumulator Seal ring set accumulator Spring accumulator 2nd brake position Bolt valve body No 1 Bolt valve body No
26. exhaust Spring valve Retainer valve spring Cotter valve Seat valve spring Seal valve stem Nut adjusting exhaust CAMSHAFT 6 5 27 6 6 TIMING BELT amp COVER C 2 M Dr 1 2 3 4 5 6 7 8 9 2701973 2701974 2701975 2701976 2701977 2701978 2701834 2701980 2701981 Cover timing belt inside Cover timing belt outside Grommet Spacer Seal cover outside Seal Seal set Belt timing Tensioner assembly TIMING BELT amp COVER 6 6 29 6 7 INTAKE MANIFOLD THROTTLE BODY 30 INTAKE MANIFOLD THROTTLE BODY 6 7 Stud bolt Tank surge 1 Bracket intake manifold No 2 Bracket surge tank Body throttle eSensor throttle position eSensor pressure eValve isc eGasket Hose water inlet Hose water outlet Clip Sensor water temperature Plug Hose brake vacuum eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 31 6 8 PVC VALVE TO AIR CLEANER 5 x FRONT OF VEHICLE Hose breather Clip hose Hose PVC Seal Valve POV 1 2 3 4 5 6 7 8 2702491 32 TO INTAKE MANIFOLD 9 EXHAUST MANIFOLD 6 9 8 VEHICLE 10 Cover manifold upper Cover manifold lower Stud bolt 1 Bolt 6x10 Ring seal Spring Bolt 10x65 Sensor oxygen 33 6 10 OIL PUMP FRONT OF VEHIC
27. ioi san 105 883883 59 884022 25853 5 85 884177 au 97 884183 59 139 No No 884189 93 884302 97 884654 133 884750 73 884823 87 885033 103 885034 103 885833 61 885911 127 885912 127 885927 67 133 885928 133 885947 97 885964 111 117 885965 117 886014 69 886016 69 886090 111 886148 117 886162 133 886163 133 886164 133 886165 133 886204 105 886205 105 886257 67 886448 129 886519 91 886600 71 886706 103 886 35 as 124 886874 91 886875 89 91 886883 73 140 886999 105 8871752258 101 887187 69 105 887188 69 105 887246 127 887443 63 888089 113 888090 113 888386 63 888451 85 888497 107 888524 nn Lae 85 888610 85 888663 131 888684 129 888777 osos tas oss 87 888793
28. spring 840402 Hinge cover 840436 Lock paddle handle w key 840438 Bushing cover spring 843169 Angle cover mount 843213 Bracket spring bushing 843217 Cover box to cab 843276 Spring cover 843474 Angle platform support 844417 Panel floor 844880 Door 885927 Handle paddle with key 886257 Spring gas 891250 Cover police box 894631 Box lower 67 6 27 REAR SPRING 68 REAR SPRING 6 27 Description 800294 Nut lock 7 16 14 2702168 Fitting lubrication 1 4 28 812218 Plate 813850 Bumper rubber 828946 Bushing 828948 Screw shackle 7 16 14 x 3 1 4 834979 Upstop 886014 Spring rear 821734 eBushing 886016 Shackle spring 805196 eBushing 887187 U bolt 2 51 mm w nuts 548061 Nut lock 7 16 20 887188 U bolt 2 1 2 64 mm w nuts 548061 Nut lock 7 16 20 838409 Spacer leaf spring INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 69 6 28 FRONT FORK 70 FRONT FORK 6 28 305134 Nut jam 7 8 14 800128 Ball bearing 3 16 5mm 800130 Ball bearing 1 4 6mm 808076 Cone upper bearing 809221 Washer wave 809255 Cover dust shield 812167 Seal dust 814961 816659 Key 5 32 x 5 32 x 1 1 4 825679 Shield felt dust 825681 Cup bearing 825682 Cone bearing 825683 Washer front fork 891767 Fork complete 120177 eLockw
29. 19 37 2701803 19 31 2701804 19 31 2701813 a aint 21 2701814 21 27018152355 as 21 2701816 21 2701819 21 23 2701820 21 23 2701821 21 2701824 21 2701825 21 2701826 21 2701828 21 2701830 21 2701831 21 2701832 21 2701833 21 2701835 Ra 21 2701837 23 2701838 23 2701849 7 111 2701869 111 2701870 81 2701897 99 2701898 99 2701899 99 2701900 23 2701902 23 2701904 23 2701905 23 2701906 23 2701911 23 2701913 23 27019155555 23 2701916 23 2701918 23 2701919 23 2701920 23 2701922 Ses 25 2701923 Lene des 25 2701924 ci ar 25 2701925 bese s 25 2701926 25 27019212578 282 Eee 25 27011928255 8 25 2701929 EE 25 2701930 25 2701932 25 2701933 25 2701934 25 2701935 25 2701936 25 270193755 8 25 2701938_ ess 25 2701939 25 2701940 25 2701942 ores 25 27019
30. Description Washer 5 16 Nut 1 4 20 Spring governor Cable carburetor Arm throttle Spring extension Bracket alternator Bracket pulley throttle cable Bracket throttle cable Post throttle Lockwasher 5 16 Pin cotter Nut 1 4 20 Lockwasher 1 4 Screw 5 16 18 x 1 Pin cotter Washer 13 32 Washer 1 4 Screw 3 8 16 x 3 Nut M10 1 Screw M8 1 25 x 20 Nut 3 8 16 Screw 1 4 20 x 5 8 Pin clevis 1 4 x 1 2 Bearing ball Belt fan Nut 1 4 20 Lever shifter Pulley governor Bracket shift cable mount Alternator 65 AMP Arm governor Lever throttle ALTERNATOR 8 GOVERNOR 6 31 77 6 32 HOSES 8 AIR FILTER EXISTING Ee 1 e MS PS 7 Sy 13 4 EXISTING N u EXISTING 2 a e TO RADIATOR 5 1 18 N INES I TOA LAG SANN UT 197 e Ay A ESS OE Z a Se E N amp CARES lt 16 II 2 REF ENGINE TO LEFT SIDE BODY PANEL 78 1 2 3 4 5 6 7 8 9 1 2700031 2701442 27015212 7 2701513 2701516 2701652 2702037 2702301 452392 820889 823549 825358 825624 826590 843545 843857 845224 845365 845409 13701 53 20 13780 79201 O ring 15 16 1 D 1 8 Housing temperature sender Bracket air cleaner Gasket thermostat spacer Hose radiator lower Hose radiator upper Intake hose Hose high temperature air Bolt M8 1 25 x 50 Clam Tie cable 15 5 394 mm p Hose fuel 25
31. FRAME TO MAIN FRAME 58 1 1 103867 120052 120177 2700615 7 2700616 7 2702277 12 300646 303952 306325 306375 306396 306414 306416 306487 306531 306562 306932 306981 308090 548238 800177 800271 800449 800696 810441 812208 812313 815847 826294 828378 835213 840403 840404 843206 883883 884183 Washer 5 16 Lockwasher 10 Lockwasher 3 8 Channel LEFT Channel RIGHT Cover Screw 1 4 20 x 3 4 Washer 13 64 Lockwasher 5 16 Nut 1 4 20 Lockwasher 1 4 Screw 3 8 16 x 1 Screw 5 16 18 x 1 Screw 1 4 20 x 5 8 Nut 10 24 Nut 3 8 16 Nut 5 16 18 Washer 13 32 Washer 1 4 Rivet 3 16 x 5 8 Screw 5 16 18 x 3 4 Screw 1410 24 x 1 2 Nut 1 4 20 Nut 5 16 18 Grommet Hinge continuous J bolt Hold down battery Plate mounting Latch slide Bumper rear Bracket rear bumper PLATFORM FRAME 6 22 59 6 23 FRONT BODY 60 1 1 306375 306396 308090 800026 800169 800279 800449 800495 885833 800582 800739 889159 829101 837303 843210 843209 830355 842863 830908 843208 843212 833830 833943 843211 Screw 1 4 20 x 3 4 Nut 1 4 20 Lockwasher 1 4 Washer 1 4 Screw P T H 1 4 20 x 3 4 Nut speed 1 4 20 Nut speed 1 4 20 Nut speed 1 4 20 Nut speed 1 4 20 Body front Screw P T H 1 4 20 x 3 4 Screw P T H 1 4 20 x 1 1 2 Panel dash Plug hole defroste
32. cable 7 1 2 191mm 800277 809137 809196 810437 812445 p 815421 Tube brake left rear 817307 Grommet 820008 Tee union 824219 Protector brake hose 824731 Protector brake hose 825477 Clip 828072 Tube brake front 829049 Tube brake right rear 832584 Clamp tee mounting 832585 Bracket brake fitting 832587 Hose hydraulic brake 834161 Adapter brake line 834888 Hose hydraulic brake 886875 Oylinder master 3 4 19mm bore 800227 Plug pipe 1 8 27 NPT 809423 Plug brake line Not illustrated 839140 Bolt master cylinder Not illustrated 888742 Tube hydraulic 4109420 Bracket INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 89 6 38 MASTER CYLINDER 8 BRAKE ROD 90 CO OO O OO N MASTER CYLINDER amp BRAKE ROD 6 38 Description 103867 Washer 5 16 120177 Lockwasher 3 8 130981 Nut jam 7 16 20 306328 Pin cotter 3 32 x 3 4 306562 Nut 3 8 16 306837 Screw 3 8 16 x 3 1 4 823089 Spring extension 829158 Rod brake 886875 Oylinder master complete 823752 Rod push 886519 Plug set filler includes parts shown 829155 eel abel warning 829558 eeGasket filler plug 886874 Kit repair includes parts shown 811928 892040 Bolt kit master cylinder 800227 eePlug 1 8 27 NPT 809423 eePlug brake line 810443 eeWasher sealing
33. se ee e es es e ve e ne n e ne mr ppp pps pn mn n Grade 8 8 marking 41 Grade 10 9 marking SE Grade 12 9 marking e 16 SERVICE AND MAINTENANCE RECORD PROBLEM SERVICE PERFORMED INITIALS 6 1 ENGINE GASKETS ENGINE GASKETS 6 1 Gasket set eGasket cylinder head eGasket chylinder head cover eGasket intake manifold eGasket exhaust manifold O ring cam position sensor eGasket cylinder plate eGasket oil pump case eGasket water pump eGasket water inlet eGasket throttle body eGasket surge tank 1 2 3 4 5 6 7 8 9 1 1 eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 19 6 2 CYLINDER HEAD 20 CYLINDER HEAD 6 2 Gasket head Gasket valve cover O ring distributor drive Head cylinder Plug oil venturi Guide valve 2701819 2701820 2701821 2701822 2701823 Bolt cylinder head Plate cylinder head Cover cylinder head Cap oil filler O ring spark plug pipe Plug spark Nippon Denso XU22EPR U Case distributor Cover cylinder eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 21 6 3 CYLINDER BLOCK 22 VEHICLE CYLINDER BLOCK 6 3 Plate clutch hsng upper Plate clutch hsng lower 1 Sender oil pressure Wire oil pressure Plug oil drain Gasket oil drain plug Dipstick oil level 2701919 Strainer oil pump 2701920 2701
34. 01309 2701750 306375 306396 306372 800146 817019 839229 1 2 3 4 5 6 7 8 9 1 1 0 1 Washer 5 16 Shifter complete eNut 1 4 20 eLockwasher 1 4 U bolt cable clamp eBracket cable clamp ePin rod connecting Pin cotter 3 32 x 1 2 Screw 10 tapping Bushing Cable shifter Not offered separately Not offered separately Not offered separately INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 83 6 35 FRONT BRAKES AXLE 8 HUB 84 FRONT BRAKES AXLE 8 HUB 6 35 306328 Pin cotter 3 32 x 3 4 306825 Nut castle 7 16 20 306982 Washer 7 16 800573 Nut wheel retaining 1 2 20 825404 Bushing 825405 Link brake anchor 889924 Hub axle shield and drum 304104 eNut jam 5 8 18 306494 eLockwasher 5 8 548183 eLockwasher 5 16 800422 Washer spring 800600 eScrew 5 16 18 x 5 8 grade 8 836674 eWasher thrust 9 16 813717 eLockwasher 835072 Plate lock 888451 eArm brake 824060 eBushing 888610 Hub and drum 307665 eeNut jam 3 4 16 385174 eeCone tapered roller bearing 523474 eeScrew grade 8 1 2 20 x 1 13 16 807630 809229 eeSlinger oil 831199 eeNut bearing adjusting 833993 eeDrum brake 884022 888524 808088 eeeCup tapered roller bearing 809268 eeeRing bearing backing 889906 eShoe assembly 811650 eePlug 824833 eeCover adjustm
35. 16 18 ePlug 1 2 14 eShim 005 As Req d eShim 010 As Req d eShim 030 As Req d eScrew 5 16 18 x 15 16 8 eSeal oil eHousing bearing eGasket eShim eShim eShim eShim eShim eShim eCup roller bearing eCup roller bearing eSeal rear axle eTag ratio 8 2 1 ratio eTag ratio 10 25 1 ratio eShim 003 ePlug expansion 2 1 2 6 cm eWorm w bearings amp slinger 8 2 1 ratio eWorm w bearings amp slinger 10 25 1 ratio eeCone tapered roller bearing eeSlinger set oil eAxle RIGHT w bearings 20 1 32 51 cm eeCone tapered roller bearing eeRing backing eAxle LEFT w bearings 23 1 4 59cm eeCone tapered roller bearing eeRing backing INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 103 6 44 DIFFERENTIAL 104 DIFFERENTIAL 6 44 Description 886204 Housing axle RIGHT 812218 eePlate 834979 eePlate upstop 887187 eeU bolt w nuts 2 5 cm 548061 eeeNut lock 7 16 20 887188 eeU bolt w nuts 2 1 2 6 cm 548061 eeeNut lock 7 16 20 886205 eHousing axle LEFT 812218 eePlate 827486 eeValve breather 834979 eePlate upstop 887187 eeU bolt w nuts 2 5 cm 548061 eeeNut lock 7 16 20 887188 eeU bolt w nuts 2 1 2 6 cm 548061 eeeNut lock 7 16 20 886999 eGear carrier 8 2 1 ratio OR 879962 Gear carrier 10 25 ratio 9 eeHousing carrier Not Offered 306
36. 4 eeWindow stationary front 828735 eeWindow movable rear 828834 eeFoam door 886165 eeBracket upper door pivot right 830209 eeNut tee 10 24 831004 eeWeatherstrip 25 7 6M As Req d Not illustrated 884654 eeWeatherstrip As Req d 885927 eeHandle paddle locking 885928 eeHandle paddle plain 886162 eeBracket lower door pivot left 886163 eeBracket lower door pivot right 886164 eeBracket upper door pivot left INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 133 INDEX Page G General Information Inside Front Cover Identification Engine Serial Number 3 Model Number 3 SerialNumber Vella used released eae anes 3 M Maintenance 6 Air Cleaner 12 Checking Element 12 Installing Element 12 Servicing Element 12 Automatic Transmission 13 Battery Z un R 10 Jump Starting with Booster Battery 10 Bulbs Fuses amp Flasher 8 Changing the Front Wheel 14 Changing the Rear Wheel 14 Differential ee 13 ENGINE san ren u h RR HAUS RR 8 ACCESS ni ene da a stet TIS 9 Cooling
37. 42863 61 842868 usina 57 842884 101 842918_ c 109 842919 a sels Beware 109 842944 81 107 109 842990 115 843018 77 843014 1 e 75 843025 ities ian 87 843026 85 87 843081 s rin 95 843120 129 843167 one 111 84316955555 uen 67 843173 88 95 843182 95 129 843200 109 843206 59 843207 63 843208 61 843209 eius 61 843210 61 843211 err e 61 843212 orice 61 843213 en 67 94321 iia ans 67 843218 u 57 843219 cate Hai 57 843276 ii 67 843306 111 843399 81 843420 81 843439 115 843441 ca 115 843443 115 849474 2 67 843857 37 79 843942 111 67 844637 7 99 844654 7 aene 99 844670 i Nenn 99 844748 isc 99 844880 67 845050 111 845072 7 107 845073 7 57 107 845074 sass 107 845075 7 107 845082 7 95 849218 oe aa ee 113 9845219 u a 113 845224 37 79 81 845345 7 vase su secte 77 845365 37 845409 37 79 879476 i ces sake 103 879748 103 879945 113 879961 un asua ya 103 879962
38. 43 25 2701945 25 2701946 25 2101947 5 scena 27 2701949 25 35 2701952 nennen 25 2701954 25 2701955 27 2701956 27 2701957 27 2701958 27 2701959 27 2701960 27 2701966 27 2701967 27 2701969 27 2701970 27 2701971 27 ANE KEE 27 2 01973 ya etes 29 2101974 rie d sus 29 2101975 urbane 29 2101976 ne 29 2701979 iii ic 29 2701980 29 2701981 29 2701982 29 2701983 29 2701984 29 2701985 29 2701986 29 2701988 29 2701990 29 2701995 31 2702000 31 2702037 aaa 79 2702089 75 27021 36 7 113 2702138 111 2702168 69 2702232 7 57 2702236 57 2702266 81 2702267 81 2702268 81 2702277 12 59 2702300 7 81 2102301 79 2702303 99 2702374 7 101 2702388 99 2702429 31 Part Page No No 2702434 31 2702432 31 2702433 31 2702436 99 2702467 31 2702468
39. 51 27027791255 das te avanse 51 2702780 51 2702784 51 2702782 51 2702784 51 2702785 51 2702786 51 2702787 51 2702788 51 2702789 erui 51 2702790 51 2702792 ostias Game 51 2702798 51 2702795 51 2702796 53 2702797 53 2702798 53 2702800 53 2702801 53 2702804 53 2702805 53 2702806 45 2702808 45 2702809 45 2702810 vr necne 45 2702811 tes redi whims 45 2702813 45 2702814 45 2702816 45 2702817 45 2702821 55 2702822 47 2702828 47 2702824 47 2702825 55 2702828 55 2702829 55 2702830 55 2702831 55 2702832 55 2702838 55 2702844 55 2702842 55 2702843 47 2702845 47 2702861 115 2702881 47 2702882 47 2702885 icon 47 2702896 39 2702897 anna 39 2702898 ce riei t 39 2702899 ian od he 39 2702900 39 2702908 39 2702904
40. 555 eeScrew 5 16 18 x 5 8 386767 eCone tapered roller bearing 814481 eeGear axle shaft 814482 eeGear differential planet 814483 eeSpacer 814484 eeSpacer 815794 eePlate locking 816812 eeScrew 3 8 16 x 1 1 4 816823 eePlate retainer 816824 eePlate locking 816825 eeShatt differential gear eeGear worm 8 2 1 ratio ee 3ear worm 10 25 1 ratio eRetainer seal 834099 eeGeal bearing INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 105 6 45 COOLING SYSTEM 106 COOLING SYSTEM 6 45 300646 Screw 1 4 20 x 3 4 306325 Lockwasher 5 16 306375 Nut 1 4 20 306396 Lockwasher 1 4 306419 Screw 1 4 20 x 1 2 306450 Screw 5 16 18 x 3 4 306932 Nut 5 16 18 308090 Washer 1 4 450452 Nut M6 1 00 800582 Screw 1 4 20 x 3 4 800390 Rivet 1 8 x 25 64 800177 Screw 5 16 18 x 3 4 800279 Nut 1 4 20 speed 800789 Kit oil cooler mounting 809231 820889 825624 p 828162 Screw M6 1 0 x 16 832033 Clamp 831846 Nut isolation 835805 Hose radiator overflow 4 1 2 M 833512 Foam 838340 Cooler oil 842782 Bracket overflow bottle 842
41. 7 6 M Bolt air cleaner Sender water tempature Cap Tube water inlet Bracket u water inlet Cleaner air Element air cleaner HOSES amp AIR FILTER 6 32 No Description Req d Not illustrated 79 6 33 OIL FILL FILTER REF ENGINE EXISTING Ey s Rel 9 KE NDA JANG N J N do 9 NA 4 9 RON NO s lt Z Z M 412 Sa x IN 12 80 O Y O C1 O N 111836 2701514 7 2701636 2701640 2701870 2702266 2702267 2702268 2702300 7 303269 450410 800425 800548 800571 825624 830929 836206 842944 843058 843399 843420 845224 11640 53F20 2703091 2703090 11610 60 01 830920 830176 830175 4109580 Description Filter oil Bracket remote oil fill cap Hose oil fil Adapter oil cap Harness main Wire 4ga red Wire 4ga black Wire 6ga red Bracket clamp Lockwasher 7 16 Lockwasher M6 Screw M6 1 00 x 12 Screw M8 1 25 x 20 Nut 10 1 25 Clamp hose Clamp hose Fitting Nut starter motor Support engine RIGHT Bracket front mounting LEFT Cover front mounting Mount engine O ring Connector Plate oil filter adapter OIL FILL amp FILTER 6 33 81 6 34 SHIFTER amp SHIFT CABLE REF CONSOLE MAT S p REF CABLE BRACKET ON TRANSMISSION REF SHIFT LEVER pe a 6 ON TRANSMISSION pa A Is AN 1 A 82 SHIFTER 8 SHIFT CABLE 6 34 No Description Req d 27
42. 7303 Headlight rectangle 885964 Lamp turn signal 825850 eLens black 825851 eLens amber 837670 eBulb 1156 885965 Wire flasher turn signal 826726 Connector male 1 contact 886148 Light stop and tail 312288 Screw 6 32 x 5 8 822049 eBulb 1157 826726 Connector male 1 contact 829099 eKit lens and gasket 829100 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 117 6 51 ROTATING LIGHT 118 Standard on New York City Police Modification 53749 Obtain Service Parts from Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60466 Phone 800 433 9132 ext 4794 Customer Service ROTATING LIGHT 6 51 891649 Light rotating 120052 eLockwasher 410 302288 eScrew 1 4 20 x 1 306375 eNut 1 4 20 306396 eLockwasher 1 4 306527 eScrew slotted head 4 10 24 x 3 4 306531 eNut machine 10 24 308089 eWasher 410 308090 eWasher 1 4 825973 Connector 6 contact male Not illustrated 826005 Connector 2 contact male Not illustrated 826006 Connector 2 contact female Not illustrated 828379 eTubing 838158 eTaillight red 838361 ePlate light mounting 891246 Bar rotating light 891563 Wire harness rotating light Not illustrated 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN P
43. 825622 37 _ ENGINE OIL Recommended Viscosity SAE 10W40 for all temperature ranges Use only oils recommended for service class SF SG or SH NOTE Using oil other than the service classes listed or oil change intervals longer than recommended can reduce engine life Damage to engines due to improper maintenance or use of incorrect oil quality and or viscosity is not covered by the engine manufacturers warranty 8 8 LUBRICATION Automatic Transmission Fluid Mercon Dexron Differential Oil SAE EP 80 90 Gear Lube Pressure Gun Lubricant Lithium Based 3 9 GEAR RATIOS Automatic Transmission KEE EEN 1 008 1 SEN 1 536 1 A EE 2 727 1 Reverse 2 222 1 Differential worm gear 8 2 1 or 10 25 1 3 10 T ENGINE Suzuki 660 Engine Horsepower SAE 41 Max Engine Speed 7800 RPM Ground Speed with 8 2 1 differential 43 MPH 69 km with 10 25 1 differential 34 MPH 55 km Stoke N Arne ee Gules 2 60 66 mm 2 56 65 mm Displacement 40 1 cu in 657 cm Compression Ratio 10 5 1 Cylinder Compression 178 PSI 1 228 kPa SPECIFICATIONS 3 Engine Rotation viewed from flywheel Cou
44. 843439 AN WARNING NOTICE WARNING KEEP HANDS CLEAR ELECTRIC FAN MAY ENGAGE WITHOUT WARNING THIS VEHICLE HAS A SPEED LIMITER THAT CLEAN MASTER CYLINDER FILLER CAP BEFORE EVEN WITH IGNITION OFF 833607 SLOWS THE ENGINE WHEN EXCEEDING TOP FAILURES USE ONLY DOT 3 FLUID FROM AT 7 SPEED ES SEALED CONTAINER BER WHEN THIS HAPPENS LET UP ON THE 1 GAS PEDAL AND LET THE VEHICLE SLOW ENGINE COOLANT RESERVOIR REAPPLY THE GAS PEDAL TO RESUME SPEED S 2701329 ENGINE OIL DIPSTICK 843440 DECALS 6 49 2701329 Decal speed limiter 2702594 Decal carb EFI 2702861 Decal fuses 816991 Decal Notice Alt Batt 822819 Decal Warning Parking Brake 825502 Decal Notice Motorcycle 825622 Decal Warning Brake Fluid 825629 Decal Warning Vehicle Operation 832130 Decal Warning Liquid Pressure 832804 Decal Information 833607 Decal Warning Electrical Fan 840394 Decal Notice 840395 Decal Transmission Fluid 842990 Decal EMS Control Information 843439 Decal Coolant 843441 Decal Coolant Reservoir 843443 Decal Engine Dipstick 1 2 3 4 5 6 7 8 9 115 6 50 HEADLIGHTS TAILLIGHTS amp TURN SIGNALS 116 HEADLIGHTS TAILLIGHTS amp TURN SIGNALS 6 50 Description 306375 Nut 1 4 20 306419 Screw 1 4 20 x 1 2 306488 Lockwasher 1 4 320107 Tie cable 7 1 2 191 mm 2700875 Flasher turn signal 826726 Connector male 1 contact 83
45. 9 Armature Ring assembly Clutch assembly eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 39 6 13 DRIVESHAFT TORQUE CONVERTER 40 VEHICLE DRIVESHAFT TORQUE CONVERTER 6 13 2701461 7 Driveshaft complete 548482 Plug expansion 826284 Cross u joint 826285 Yoke universal Yoke front Ghaft drive Transmission complete Flange drive plate Plate drive flywheel Plate drive rear 1 2 3 4 5 6 7 8 9 Converter torque eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 41 6 14 AUTOMATIC TRANSMISSION FRONT OF VEHICLE 42 AUTOMATIC TRANSMISSION 6 14 Case transmission Breather Housing torque converter Plug booster Cap Housing extension Seal extension case Hook engine Bolt transmission case Bracket connector clamp eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 43 6 15 AUTOMATIC TRANSMISSION PAN DIPSTICK amp GASKETS FRONT OF VEHICLE 44 AUTOMATIC TRANSMISSION PAN DIPSTICK 8 GASKETS 6 15 Plug transmission drain Gasket plug Magneto fluid cleaner Tube transmission dipstick 1 2 3 4 5 6 7 8 9 Harness solenoid wire Plate solenoid harness Set transmission gasket Gasket transmission pan Dipstick transmission eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY
46. 921 eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 23 6 4 CRANKSHAFT PISTONS CRANKSHAFT PISTONS 6 4 2701922 Ring piston standard 2701923 Ring piston OS 0 25 2701924 Ring piston OS 0 50 2701925 Piston standard 2701926 Piston OS 0 25 2701927 Piston OS 0 50 2701928 Pin piston 2701929 Ring snap 2701930 Rod connecting 2701931 Nut connecting rod 2701932 Bearing connecting rod 2701933 Bearing connecting rod US 0 25 2701934 Crankshaft 2701935 Bearing set crankshaft 2701936 Bearing set crankshaft US 0 25 2701937 Bearing set crank thrust 2701938 Bearing set crank thrust US 0 25 2701939 Seal front 2701940 Pulley timing belt 2701942 Pulley crankshaft 2701943 2701944 2701945 Seal rear main 2701946 Plate rear 2701834 2701948 2701949 2701954 2701952 eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 25 6 5 CAMSHAFT er 12 E FRONT 17 OF VEHICLE 413 1 2 3 4 5 6 7 8 9 2701947 2701955 2701956 2701957 2701958 2701959 2701960 2701961 2701962 2701963 2701965 Camshaft Seal camshaft Shaft rocker arm No 1 Shaft rocker arm No 2 Arm valve rocker intake No 1 Arm valve rocker intake No 2 Arm rocker exhaust Screw adjusting Screw valve adjusting Nut adjusting intake Washer wavy Valve intake Valve
47. 944 Fitting hose 1 2 ID 845072 7 Bracket fan 845073 7 Panel left oil cooler cover 845074 Fan 845075 7 Bracket oil cooler 888497 Mount radiator 889050 Reservoir coolant 889051 Cap coolant reservior 2700819 7 Screen 894590 Radiator 894901 Cooler oil electric fan 825779 Grommet 2701043 Hose hydraulic 25 7 6 M 2701167 2701166 O 071 O N 107 6 46 HEATER DEFROSTER REF WITH BODY AY mo 108 HEATER DEFROSTER 6 46 120052 Lockwasher 10 132520 Nut 10 32 306375 Nut 1 4 20 306396 Lockwasher 1 4 306487 Screw 1 4 20 x 5 8 308090 Washer 1 4 320107 Tie cable 7 1 2 191 mm 548045 Screw 1 4 20 x 3 4 800026 Screw 1 4 20 x 3 4 800384 Screw 1 4 x 1 tapping 800630 Screw 12 24 x 3 4 tapping 800869 Screw 1 4 20 x 3 8 tapping 800929 820889 p 821893 Trim push on 12 3 7 M 825358 Clamp worm drive hose 825779 Grommet 825994 Resistor 829815 Stud threaded 830355 Weather seal 35 10 7 M 831006 832033 832804 Decal information 833846 Louver air 833851 Seal 833857 Valve ball check 833858 Fitting hose 833862 Hose heater 833939 Hose air 833940 Hose air 833949 Core heater 833958 Housing 833974 Diffuser air 833984 Panel core housing 833985 Clamp valve 833986 Intake cab air 834007 Duct defroster 836024 Bracket heater blower 842918
48. LE 34 OIL PUMP 6 10 Pump oil Rotor oil pump Valve oil relief Gasket oil pump cover Pin 1 2 3 4 5 6 7 8 eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 35 6 11 WATER PUMP amp OUTLET THERMOSTAT 36 NOTE ON EARLY VERSIONS THE TEMPERATURE SENSOR WAS MOUNTED IN ITEM 17 LATER VERSIONS HAVE THE TEMPERATURE SENSOR ITEM 21 MOUNTED IN THE INTAKE MANIFOLD WATER PUMP amp OUTLET THERMOSTAT 6 11 2702522 Pump water 2701801 Gasket water pump 2702523 2702537 2701914 2702519 2702525 Pulley water pump 2702543 Case water inlet 2701802 2701834 452378 Screw M6 1 00 x 20 845409 Bracket u water inlet 845365 Tube water inlet 2700031 O ring 845224 Cap 313x 1 825624 Clamp hose 2701637 Housing thermostat 452392 Screw M8 1 25 x 50 2701638 Spacer thermostat 2701513 Gasket thermostat spacer 2701757 Switch fan 2702539 Cap thermostat 843857 Sender water temperature 829787 Terminal 45 1 4 male 2702541 Washer bleed valve 2702540 Bolt bleed valve 2702542 Thermostat 82 C eINDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 37 6 12 STARTER VEHICLE 38 STARTER 6 12 Motor assembly starting Yoke assembly Screw assembly Bushing Bushing Holder assembly brush Lever assembly Switch assembly 1 2 3 4 5 6 7 8
49. MBER SECOND NUMBER 123 6 55 TIRES Description 893172 Tire and wheel set radial 835905 Wheel 4 00 x 12 five on 4 1 2 bolt circle 886735 eStem valve eTire 4 80 x 12 load range C Obtain locally e INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 124 FRONT BUMPER 6 56 889445 Bumper set complete 103867 eWasher 5 16 306325 eLockwasher 5 16 306416 Screw 5 16 18 x 1 306932 Nut 5 16 18 eBumper Not offered separately INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 125 6 57 CAB o Touch Up Paint 12 02 Part No 843312 126 CAB 6 57 Description 825844 Adhesive foam Not illustrated 103867 Washer 5 16 6 302288 Screw 1 4 20 x 1 306325 Lockwasher 5 16 306375 Nut 1 4 20 306396 Lockwasher 1 4 306450 Screw 5 16 18 x 3 4 306932 Nut 5 16 18 308090 Washer 1 4 320107 Tie cable 7 1 2 191 mm 548910 Nut flangelock 1 4 20 800026 Screw P T H 1 4 20 x 3 4 800030 Screw P T H 5 16 18 x 1 800167 Nut speed 1 4 20 800456 Nut acorn 1 4 20 814924 Clamp 825859 Foam sound 827769 Insulation engine 828388 Seal seat 828934 Angle RIGHT 828935 Angle LEFT 828976 Weatherstrip 25 7 6M 829071 Sea
50. PARTS AND MAINTENANCE MANUAL HAULSTER POLICE VEHICLE MODEL 898487 Part No 2702455 Rev A 1 GENERAL INFORMATION 1 1 GENERAL INFORMATION IMPORTANT THIS MANUAL WILL AID YOU IN THE SAFE OPERATION AND PROPER MAINTENANCE OF YOUR EQUIPMENT READ MANUAL THOROUGHLY BEFORE ATTEMPTING OPERATION IF ANY PORTION 15 NOT CLEARLY UNDERSTOOD CONTACT AN AUTHORIZED DEALER FOR CLARIFICATION To make sure you are fully aware of safety and service information the following two symbols are used throughout this manual A This symbol is used throughout the manual to alert you to information about unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER _ indicates immediate hazards that may result in severe injury or death WARNING indicates unsafe actions or situations that may cause severe injury death and or major equipment or property damage CAUTION indicates unsafe actions or situations that may cause injury and or minor equipment or property damage NOTE This appears next to information or instructions which will help you operate and maintain your equipment the right way A WARNING The information and instructions included in this manual alert you to certain things you should do very carefully If you do not you could hurt yourself or others hurt the next person who operates the equipment e damage the equipment This manual contains essen
51. PROPERTY DAMAGE ALWAYS faces Us canna THAT TE APPLY HAND OR FOOT BRAKES 822819 nine tre 10039 IN 10 EXHAUST mar EA 217778 NOTICE m THIS VEHICLE IS A MOTORCYCLE ET ween AND MUST BE OPERATED IN 6 ACCORDANCE WITH MOTORCYCLE LAWS AND REGULATIONS 825502 M 7 SN WARNING FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL OR FATAL INJURY Z N TO YOU OR OTHERS AND MAY ALSO RESULT IN EQUIPMENT AND OR PROPERTY DAMAGES FUSE PANEL NEVER ALLOW UNSKILLED OR IMPROPERLY TRAINED PERSONNEL TO OPERATE THIS EQUIPMENT BEFORE OPERATING READ STUDY AND UNDERSTAND ALL WARNING LABELS AND OPERATING N q N INSTRUCTIONS FURNISHED WITH THIS EQUIPMENT PRIOR TO USE IF ANY PART OF THIS E S MATERIAL IS UNCLEAR CONTACT YOUR FACTORY REPRESENTATIVE FOR CLARIFICATION DO NOT EXCEED PAYLOAD CAPACITY GIVEN ON VEHICLE NAME PLATE OR PERMIT PASSENGERS REIS e ico S ANY PLACE ON VEHICLE CORNERING ABILITY OF A 3 WHEEL VEHICLE IS NOT AS GREAT AS A 4 WHEEL VEHICLE PLACE HEAVY LOADS FORWARD OF REAR AXLE UNBALANCED OR N N N A TOP HEAVY LOADS CAN CAUSE UPSET HELMET IS RECOMMENDED 8 M M 2 3 WHILE OPERATING REMAIN SEATED USE BOTH HANDS FOR STEERING KEEP ARMS AND LEGS eres e WITHIN VEHICLE BODY AVOID SUDDEN STARTS AND STOPS SUDDEN SHARP TURNS CAN CAUSE 80175521681 VIPER SOLENOID UPSET REGULATE SPEED TO MEET ROAD AND WEATHER CONDITIONS DO NOT OPERATE IN OR NEAR AN EXPLOSIVE ENVIRONMENT
52. Part No BULBS Ammeter light Headlight Taillight Turn Signal front Oil pressure warning light EMS light Speedometer light Water temperature gauge light Fuel gauge light 826000 833038 825501 4 5 FUSES H g 20 0 Hu Fuses are located on the kick panel just below the instru m ment panel They protect the lighting circuits and acces Horn Heater Engine d s Brake Ligh Cooling sory circuits such as windshield wiper motor and heater Lights Fans defroster blower Remove fuses by pulling straight out L DJ N GN Optional Turn Dome Cab Signals Ligh Lights Wiper Solenoid o SIS kh Wa Transmission Power Main Engine Point Relay Instrument Panel Fuse Box Panel 4 6 P ENGINE MAINTENANCE The following maintenance information covers basic engine service only For more elaborate service and nec essary repairs we recommend you contact your autho Fuse Block On Kick Panel rized Cushman dealer Always keep your engine clean If dirt has accumulated on the engine it should be washed with a non flammable solvent or a strong detergent When washing becomes necessary it can be carried out simultaneously with serv icing and will maintain cool and efficient operation In order to maintain reliable service from your engine a reg ular c
53. RECEDING ASSEMBLY 119 6 52 TURN SIGNAL SWITCH 120 TURN SIGNAL SWITCH 6 52 Description 306310 Lockwasher 78 308089 Washer 410 819923 Collar foam Not illustrated 825358 Clamp worm drive 839197 Bracket turn signal 840187 Bracket sensor indexing 2700220 Sensor steering position 894851 Switch turn signal 894854 Module control 825877 Connector female 6 contact 825894 eConnector female 3 contact 826726 Connector male 1 contact 825880 eConnector female 1 contact 2700875 Flasher turn signal 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 121 6 53 FRONT SHOCK ABSORBER 122 308091 311396 800294 807332 823621 825500 Description Washer 1 2 Screw 7 16 14 x 2 1 4 Nut lock 7 16 14 Absorber shock Bushing Washer cupped WHEEL MEASUREMENT 6 54 WHEEL SIZE MEASUREMENT Previously tire and wheel size were specified the same Example a 9 50 x 8 00 tire was mounted on a 9 50 x 8 00 wheel Wheel size is now determined by measuring the wheel at the bead seat The first number is wheel diameter measured at bead seat The second number is wheel width measured at bead seat Example a 9 50 x 8 00 tire is mounted on a 8 00 x 7 00 wheel The wheel size did not change just the method of measurement See illustration below BEAD SEAT WHEEL I T 8 00 FIRST NU
54. Tube heater supply 842919 Tube heater return 842944 Fitting hose 843200 Tube heater return 25 7 6 M 888856 Tube Y 889596 Blower 894511 Switch heater 2 speed O 71 Q N 109 6 47 ELECTRICAL COMPONENTS FRONT NOTE For Dipswitches setting for Modification 53749 32 New York City Police DIPSWITCHES SETTING FOR 25456008 INSTRUMENT PANEL i A A 01010101 01001111 REF CABLE FROM STARTER REF STEERING GEAR 28 REF HEATER BRACKET 110 ELECTRICAL COMPONENTS FRONT 6 47 120052 Lockwasher 10 133079 2700867 Relay 12V 70A 2700904 Panel w speedometer instrument 2700918 Module speed limit 2701409 7 Panel instrument 2701849 7 Bracket relay 2701869 Harness front Not illustrated 2702138 Flasher 12V 300646 Screw 1 4 20 x 3 4 302437 Nut 46 32 306310 Lockwasher 8 306375 Nut 1 4 20 306419 Screw 1 4 20 x 1 2 306488 Lockwasher 1 4 306531 Nut 10 24 306990 Lockwasher 6 shakeproof external 308089 Washer 10 316056 Screw 446 32 x 3 4 548175 Washer 1 4 800178 Screw 48 32 x 1 2 800271 Screw 10 24 x 1 2 800296 Screw 10 24 x 3 4 800882 Screw 6 32 x 3 4 800911 Screw 10 24 x 2 1 4 800943 Screw 10 14 x 5 8 tapping 817309 Switch d
55. al neoprene 1 2 x 1 2 x 7 13 mm x 13 mm x 178 mm Mat floor 65 6 26 REAR BOX amp SIDES SIDE OPENING 66 REAR BOX 8 SIDES SIDE OPENING 6 26 Description 103867 Washer 5 16 120052 Lockwasher 10 2702098 Screw 5 16 18 x 2 1 4 300646 Screw 1 4 20 x 3 4 303952 Washer 13 64 306325 Lockwasher 5 16 306375 Nut 1 4 20 306396 Lockwasher 1 4 306487 Screw 1 4 20 x 5 8 306531 Nut 10 24 306932 Nut 5 16 18 308089 Washer 410 308090 Washer 1 4 450324 Nut M8 548238 Rivet pop 3 16 800021 Screw 10 32 x 1 2 800026 Screw 1 4 20 x 3 4 800059 Nut lock 1 4 20 800169 Nut lock 1 4 20 800177 Screw P T H 5 16 18 x 3 4 800263 Screw P T H 1 4 20 x 1 1 4 800384 Screw 1 4 x 1 tapping 800390 Rivet pop 1 8 800475 Rivet pop 13 64 800483 Rivet pop 3 16 809183 Washer 1 4 810149 Bumper rubber 810441 Grommet 812208 Hinge continuous 814585 Bushing 816307 Washer 17 64 821164 Pin hair 1 4 x 1 1 8 821427 Washer sealing 1 4 824484 824576 828378 Weatherstripping 828879 Stud ball 10mm x 8mm x 1 25mm 828976 Weatherstrip 831004 Weatherstripping 835213 Latch slide 837960 Rod short 837961 Rod medium 837962 Rod long 838053 Spring box latch 838072 Support box 838223 Box battery plastic marine 838225 Clip
56. ant that the antifreeze and water be mixed in a separate container before adding to radiator NEVER add straight antifreeze to the radiator The mixture must NEVER be more than 50 antifreeze 4 12 DRAINING THE COOLING SYSTEM NOTE Drain the cooling system every 600 hours and refill with a 50 50 mixture of water and ethylene gly col antifreeze Drain the cooling system using the following procedure MAINTENANCE 4 D arme DO NOT attempt to remove radiator cap until engine is allowed to cool Radiator contents are under pressure which can cause spraying of scalding hot water Hot water spray can cause serious injuries 1 Remove radiator cap when engine is cool Discon nect radiator cooling fan Open drain cock on bottom of radiator ide N A WARNING TO PREVENT POSSIBLE SEVERE BURNS TO YOU OR OTHERS DO NOT REMOVE PRESSURE CAP WHEN HOT CONTENTS UNDER PRESSURE CHECK AND ADD FLUID AT RESERVOIR 832130 2 Remove bottom radiator hose from radiator to com pletely drain engine block 3 Disconnect hose from water overflow tank and drain tank Close radiator drain cock tightly and reinstall overflow tank hose when both have finished drain ing NOTICE e ALWAYS recycle or dispose of used antifreeze in a responsible manner Used antifreeze can be harmful to the environment 4 13 FILLING THE COOLING SYSTEM 1 Fill radiator to the base of the filler neck and the over f
57. ase including filter 3 3 gts 3 1 L 34 BATTERY 12 BC Group erre teen Size 24 Cold Cranking Amps Minimum 420 Reserve Capacity Minutes Minimum 70 Ground Terminal Polarity NEGATIVE 35 FUEL Unleaded Gasoline 87 Octane or higher NOTE We DO NOT recommend the use of ALCOHOL bearing fuels in any of our products The use of these fuels may create a potential safety hazard Are Gasoline containing ALCOHOL can cause deterioration of some non metallic materials in the fuel system Gasoline containing ALCOHOL will attract and hold moisture inside fuel tanks Moisture may cause corrosion of metallic parts within the fuel system All fuel hoses MUST be inspected frequently and replaced if excessive stif ness deteriora tion or fuel leakage is found Fuel leakage from a fuel system can occur while the system is in use in transit or in stor age Such leakage can contribute to an explo sion or fire causing serious bodily injury or death NOTE The use of alcohol bearing fuels can cause engine malfunction particularly vapor lock at tem peratures above 50 F 10 C 3 6 BRAKE FLUID Use Type er Rn bedt DOT 3 WARNING CLEAN MASTER CYLINDER FILLER CAP BEFORE REMOVING CONTAMI NATES MAY CAUSE BRAKE FAIL URE USE ONLY D O T 3 FLUID FROM A SEALED CONTAINER
58. asher 3 8 306562 Nut 3 8 16 306835 Screw 3 8 16 x 1 1 4 311396 eScrew 7 16 14 x 2 1 4 604174 eWasher 3 8 800293 Nut lock 7 16 14 808969 eBushing 810149 eBumper rubber 816697 eBushing 825403 eSpring 891764 eTube fork 805189 eeBushing 807442 eeFitting lubrication 1 4 28 891765 Tube axle mounting 886600 Cup bearing complete 812098 Cup bearing 829285 eBushing upper fork CO OO O OO N INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 71 6 29 STEERING GEAR WHEEL 8 HORN 72 120177 302030 305134 306396 306414 306562 306832 306835 306981 311496 809255 816446 816447 816449 816455 816456 816652 816653 816654 816659 816660 816674 816675 825672 830167 830168 832555 883317 800612 884750 826491 880365 886883 830369 830370 892807 CO OO O OO N e INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY STEERING GEAR WHEEL amp HORN 6 29 Description Lockwasher 3 8 Screw 1 4 20 x 1 1 4 Nut jam 7 8 14 Lockwasher 1 4 Screw 3 8 16 x 1 Nut 3 8 16 Screw 1 4 20 x 2 Screw 3 8 16x 1 1 4 Washer 3 8 Washer 11 16 Cover dust shield Washer 7 16 Ring retaining Washer knurled 3 8 Ring retaining Bearing ball Nut steering wheel Plate horn button contact Butt
59. e washers at either end of the axle inside the fork arms and the axle locks hooked over the top of the fork arms Torque the axle nuts to 70 to 100 ft Ibs 95 to 140 N m Reconnect the left shock absorber 4 Reinstall the brake anchor link using NEW cotter pins to secure the castle nuts Make sure the bushings are in place in both ends of the brake anchor link A CAUTION The brake link bushings MUST be in place in brake anchor link and the link reinstalled to prevent the brake stator and drum from turning when the brakes are applied Turning could result in brake hose damage and sudden brake failure ALWAYS use NEW cotter pins when reinstal ling brake anchor link castle nuts to make sure they are secure MAINTENANCE 4 Your vehicle is equipped with 145 R 12 radial tires load range C mounted on 4 80 x 12 rims Always keep tires inflated according to the following specifications Cold Inflation Pressure o com isse 32 PSI 220 kPa Rear sr 32 PSI 220 kPa NOTE NEVER exceed the maximum pressure indi cated on the tire Improper inflation will considerably shorten the life of your tires Fill tires with care Use a pressure gauge before connecting an air hose to a partly inflated tire Due to the low air volume needed over inflation may be reached in a matter oftwo or three seconds 4 25 _ _ _ __ TIRE REPLACEMENT Always use replacement tires equivalent to or exce
60. eding original equipment specifications 426 EXTENDED STORAGE If the vehicle must be stored with fuel in the fuel system DO NOT store the vehicle in an enclosure with open flame Example Furnace or water heater pilot light Anne Storing unit in an enclosed area with an open flame may result in an explosion or fire Perform the following steps when putting the vehicle back into operation after an extended storage period exceeding 30 days e Fil the vehicle fuel tank e Check engine oil level e Check engine for loose parts e Start the engine and check for fuel or oil leaks and check the operation of all controls 15 TORQUE CHART 5 TORQUE SPECIFICATIONS HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specific torque values are not given U S Standard Hardware Shank Size Diameter in inches fine or coarse thread Shank Size Diameter in inches fine or coarse thread Ee E fel ppp mee naaa F e mes e em S S s se e ss sor ss eso Grade 5 marking Minimum commercial quality Lower quality not recommended Grade 8 marking Metric Standard Hardware Shank Size Diameter in millimeters fine or coarse thread em er o e e e e 5 ss vo en ees e e pee e ad rs n ee parara er
61. ent hole 833850 eeSpring retainer 892471 eeCylinder wheel 833911 eeScrew M6 833912 eeDust shield 833916 eeRetainer shoe 843026 eeKit brake lever and adjuster eee ever brake Not offered separately 889350 eeBrake kit two brake shoes 833918 eeeSpring retainer 834723 eeePin brake 838355 eeeGuide spring Not illustrated eeeShoe brake Not offered separately 889930 Kit wheel cylinder CO OO O OO N e INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 85 6 36 REAR BRAKES HUB amp WHEEL CYLINDER o 30 R be 48 L Q 25 R lt a 45 L Be ES 24 R Va L 17 R 36 L 86 800573 833993 834161 888793 523474 833891 888861 523474 833879 833891 891811 809018 809257 811650 821153 824833 833850 843025 CO OO O OO N 833911 833916 892471 838403 838404 838405 888777 824925 889350 833918 834723 838355 891812 811650 824833 833850 833911 833912 833916 843026 892471 838402 838404 838405 889350 833918 834723 838355 889930 884823 REAR BRAKES HUB amp WHEEL CYLINDER 6 36 Description Nut wheel retaining 1 2 20 Drum brake Adapter brake line Hub LEFT eScrew 1 2 20 x 1 13 16 grade 8 Hub RIGHT eScrew 1 2 20 x 1 13 16 grade 8 eGear speedometer drive eHub Shoe w dust shield complete RIGHT eBushing speedometer
62. ft Ibs 95 to 140 N m 14 4 24 CHANGING THE FRONT WHEEL IMPORTANT BE SURE TO READ THIS ENTIRE SECTION BEFORE ATTEMPTING FRONT TIRE REMOVAL To remove the front wheel and hub 1 Remove the cotter pins washers and castle nuts attaching the brake anchor link to the front fork and brake arm NOTE DO NOT disconnect the front brake hose 2 Pullthe link straight off the mounting studs Retain the bushings located in the holes at each end of the brake anchor link Front Fork Right Side 1 Brake Anchor Link 2 Cotter Pin Washer And Castle Nut 3 Brake Arm 4 Axle Nut 5 Axle Lock 6 Brake Hose And Protector 3 Disconnect the bottom of the LEFT shock absorber Retain and note the position of the attaching hard ware 4 Loosen the axle nuts on both sides of the axle until the axles locks both sides will clear the fork arms and lower the entire axle brake and wheel assembly from the fork Front Fork Left Side 1 Axle Lock 2 Axle Nut 3 Wheel Retaining Nut 4 Valve Stem 5 Support the brake assembly so that the brake hose and protector will not be damaged 6 Remove the wheel retaining nuts and remove the wheel from the hub To reinstall the front wheel and hub 1 Reassemble the wheel to the hub be sure valve stem is on side opposite the brake Torque the wheel retaining nuts to 70 to 100 ft lbs 95 to 140 N m 2 Reinstall the hub assembly into the fork with the two 2 larg
63. g 4 20 DIFFERENTIAL The worm gear differential filler plug and drain plug are shown in the following photograph Oil should always be up to the level of the filler hole 1 Filler Plug 2 Drain Plug IMPORTANT DIFFERENTIAL LUBRICANT MUST BE CHANGED ACCORDING TO THE MAINTENANCE GUIDE SCHEDULE TO AVOID EXPENSIVE REPAIR 13 4 MAINTENANCE 4 21 MASTER CYLINDER ACCESS The master cylinder reservoir is located under the floor board with an access hole shown below Fill the reservoir with DOT 3 brake fluid 1 Master Cylinder Access 4 22 JACKS JACKING LOCATIONS AND USING A HOIST A scissors or hydraulic type jack with a 1 1 2 ton mini mum capacity that can be lowered to 3 3 8 86 mm is required to jack up the vehicle The jacking locations are shown on the Chassis Lubrica tion Chart Raise the vehicle ONLY enough to place jack stands under vehicle when performing required mainte nance NOTE To prevent damage to the vehicle or attached accessory NEVER use a hoist to raise one corner of the vehicle ALWAYS raise BOTH front or rear cor ners equally 4 23 CHANGING THE REAR WHEEL 1 Raise rear of vehicle with a hydraulic jack and place on jackstands 2 Remove and retain the wheel retaining nuts and remove wheel from the hub 3 Reinstall the wheel with the valve stem on the out side of the wheel 4 Torque the wheel retaining nuts to 70 to 100
64. ging the battery with a charger Hydrogen gas is produced during the charging process and can be very explosive Provide adequate ventilation to prevent possible explo sion Both booster battery and discharged battery should be treated carefully when using jumper cables Follow exactly the procedure outlined being careful not to cause sparks 10 1 Apply parking brake put transmission in PARK and turn off all electrical loads 2 Attach one end of one jumper cable to the positive terminal of the booster battery and the other end to the positive terminal of the discharged battery DO NOT permit vehicles to touch each other at any time 3 Attach one end of remaining cable to the negative terminal of the booster battery and the other end to a good ground on the vehicle or engine away from the discharged battery DO NOT lean over the bat tery when making this connection 4 Reverse this sequence exactly when removing the jumper cables NOTE This is a negative ground wiring system revers ing battery connection WILL damage the alternator rectifier Booster batteries used for starting MUST be con nected with correct polarity Vehicle battery cables should be disconnected before using a Fast Charger 4 11 ENGINE COOLING SYSTEM The cooling fan is thermostatically controlled and may start at any time DO NOT attempt to service the fan without first disconnecting it 4 gt WARNING
65. heck up schedule should be carried out Proper maintenance will prolong the engines life and avoid pre mature overhaul NOTICE e DO NOT wash the engine while it is running Water vapor may enter the engine through the air intake causing serious engine damage 4 7 ENGINE ACCESS 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 loose clothing away from flywheel radiator cooling fan alternator fan belts pulleys air intake etc The seat cushion may be raised by pivoting forward to provide engine access for minor service work For major repair the engine cover assembly may be removed To remove engine cover loosen the engine cover latch pivot the engine cover forward and lift upward 1 Engine Cover Latch When replacing the cover make sure the retaining tabs located at the front corners of the engine cover are MAINTENANCE 4 inserted into the slots in the floorboard 1 Engine Cover Retaining Tab Resecure the engine cover latch Failure to follow instructions will allow the seat and engine cover assembly to move out of proper position 4 8 ENGINE OIL LEVEL NOTE When checking engine oil level BE SURE vehicle is resting on a level surface A correct read ing can not be made if the vehicle is not on a level surface 1 Engine Oil Fill The eng
66. iming Belt amp 28 29 6 7 Intake Manifold Throttle Body 30 31 6 8 PVC Valve 32 6 9 Exhaust Manifold u y s BG K KR A Es 33 6 10 OLPUMpPp Le toss A ee ara 34 35 6 11 Water Pump amp Outlet Thermostat 36 37 6127 Staltel tot ant desi paka tup aus aus ha queshua 38 39 6 13 Drive Shaft Torque Converter 40 41 6 1 4 Automatic Transmission 42 43 TABLE OF CONTENTS SECTION PAGE 6 15 Automatic Transmission Pan Dipstick amp Gaskets 44 45 6 16 Transmission Tubes Oil Pump Solenoids amp Shift Switch 46 47 6 17 Transmission Input Shaft 8 Clutch 48 49 6 18 Transmission Planetary Gears amp Output Shaft 50 51 6 19 Brake Band 8 Shift 52 53 6 20 Transmission Valve 54 55 6 24 Main Frame 56 57 6 22 Plattorm Frame ai 58 59 6 23
67. immer 825358 Clamp worm drive hose 825893 Bushing strain rif 826726 Connector 1 contact female 828231 Insulator 828613 830135 g 832094 Switch dome light 837298 Spacer 838354 Switch ignition NYC 839168 Grommet 839197 Bracket turn signal 843167 Relay 12V 15A 843306 Plug panel 843942 Socket 12V accessory plug 845050 Grease electrical connector Not illustrated 885964 Lamp turn signal 886090 Horn 890000 Not illustrated 894109 Harness wiper Not illustrated 894851 Switch turn signal 894853 Sensor steering position 894854 Module control 111 6 48 ELECTRICAL COMPONENTS MAIN REF REAR PLATFORM REF REAR PLATFORM CLAMP BRACKET ON ENGINE 9 og REF FRAME 112 ELECTRICAL COMPONENTS MAIN 6 48 Description 103867 Washer 5 16 120052 Lockwasher 10 2700511 Harness diode Not illustrated 2701105 7 Cover engine control unit 2702136 7 Bracket park brake switch 300646 Screw 1 4 20 x 3 4 302437 Nut 6 32 306325 Lockwasher 5 16 306375 Nut 1 4 20 306396 Lockwasher 1 4 306450 Screw 5 16 18 x 3 4 306531 Nut 10 24 306932 Nut 5 16 18 306990 Lockwasher 76 shakeproof ext 2 308089 Washer 410 308090 Washer 1 4 316056 Screw 6 32 x 3 4 450452 Nut M6 1 00 452380 Bolt M6 1 00 548159 Washer 5 16 548175 Washer 1 4 548910 Nut 1 4 20 800074
68. ine Serial Number A hand lettered engine serial number has been placed on the left side of the engine below the oil fill 3 SPECIFICATIONS 3 4 VEHICLE All specifications subject to change without prior notifica tion Your Haulster is powered by a 3 cylinder gasoline pow ered liquid cooled four cycle engine with a single over head camshaft 12 valve electronic ignition automatic choke The block is cast iron and the cylinder head is alu minum Power is transmitted to the rear wheels by a electroni cally controlled three speed automatic transmission dri veshaft with two universal joints and a worm gear differ ential 3 2 DIMENSIONS Rated Weight Capacity 1000 Ibs 455 kg Overall Height w cab 70 1 8 m Overall Length 111 2 8 m Overall Width ni 1 2 m Outside Clearance Circle 7 5 2 m Inside Clearance Circle 91 cm Weight w fuel and battery 1490 lbs 676 kg Wheelbase 78 2 0 m Rear Wheel Tread 42 1 1 m Tires 145R12 Radial Load Range C 3 3 O CAPACITIES Fuel Tank 7 5 gal 28 5 L Transmission automatic 3 7 qt 4 2 L Differential 8 2 1 or 10 25 1 12 oz 0 4 L Cooling System 3 3 gts 3 1 L Crankc
69. ine oil level should be between the two marks FULL and ADD marks on the dipstick Either too much OR too little oil can cause the engine to overheat Engine overheating can cause severe engine damage 4 MAINTENANCE 4 9 BATTERY A CAUTION UNTRAINED or UNAUTHORIZED persons should NEVER attempt to service or recharge the battery in this vehicle Battery electrolyte is an acidic solution and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain immediate medi cal aid ALWAYS wear adequate eye protection when working on or around a vehicle battery The battery is located in the side opening box located at the rear of the vehicle The battery in this vehicle is a low maintenance Add distilled water whenever required NOTE Keep the top of battery clean and free of corro sion by washing with a solution of baking soda and water or ammonia and water Rinse with clean water Terminals with heavy corrosion should be removed and cleaned with solution Replace termi nal and resecure To contact your nearest Trojan battery dealer for war ranty or other information call Trojan battery at 1 800 423 6569 and ask for customer service 4 10 JUMP STARTING WITH BOOSTER BATTERY DO NOT allow open flames or sparks near a bat tery when connecting for jump starting or while rechar
70. ler 3092 tube Not illustrated 829536 Strip filler 829815 Stud threaded 829966 Pad foam 830355 Seal door 830902 Decal instruction 1 Not illustrated 830904 Insulation 830908 Seal 25 7 6M 831582 Bracket mirror 833851 Seal 885911 Support pivot LEFT 885912 Support pivot RIGHT 887246 Mirror set 306375 Nut 1 4 20 823201 888641 2703127 Cab and vent complete 300646 Screw 1 4 20 x 3 4 302437 Nut 6 32 303459 Screw 1 4 20 x 1 1 2 303916 Lockwasher 10 Not illustrated 306328 Pin cotter 3 32 x 3 4 306375 Nut 1 4 20 306396 Lockwasher 1 4 306463 Pin cotter 1 16 x 1 2 306487 Screw 1 4 20 x 5 8 894109 Harness 2 speed wiper switch Not illustrated 308089 Washer 10 306506 Lockwasher spring 6 306531 Nut machine 10 24 306982 Washer 7 16 CO OO O UO QO N 127 6 57 CAB o Touch Up Paint 12 02 Part No 843312 128 306998 308087 308088 308090 316056 894211 800026 800296 805245 805451 810379 810446 814924 821068 821427 826726 891649 306527 828384 826037 828682 828736 828972 842647 829735 832115 833971 834077 825642 894108 828668 843120 894835 894836 886448 888684 888815 800736 829717 833972 888831 888832 888835 316946 888836 888842 843182 894132 894212 120052 306531 De
71. low tank to the FULL mark with a 50 50 water and antifreeze mixture Reinstall reservoir tank cap 2 Loosen the air bleeding bolt shown below until coolant comes out through the air bleeding hole of bolt Resecure the bleeding bolt 4 MAINTENANCE 1 Air Bleeding Bolt 3 Run engine with radiator cap removed until upper radiator hose is warm thermostat has opened 4 With engine idling add coolant mixture to radiator until level reaches the bottom of the filler neck Install radiator cap Reconnect radiator cooling fan 4 14 AIR CLEANER This is a large capacity dry type air cleaner with a replaceable paper element The air cleaner assembly is located under the right side cover panel directly behind the cab 1 Air Cleaner Assembly 4 15 SERVICING AIR CLEANER ELEMENT NOTE DO NOT use a damaged air cleaner assembly DO NOT use bent or damaged air cleaner elements Use ONLY Cushman approved air cleaner replace ment elements 12 We recommend the air cleaner element be replaced before engine performance is affected This may occur at 250 hours of service in very dirty operating conditions or at 500 hours in normal operating conditions We DO NOT recommend cleaning the air cleaner ele ment because of the possibility of damaging the element 4 16 CHECKING AIR CLEANER ELEMENT Check the element for damage pin holes etc by placing a light source such as a flashligh
72. ng 828976 eSeal push on 25 7 6M 829038 eBracket retainer door strap 829040 eBracket retainer latch mounting 829137 eSpacer door pivot 830908 eSeal push on 25 7 6M 833999 eAngle seal mounting door RIGHT 2702589 7 Angle seal mounting door LEFT 306463 eePin cotter 1 16 x 1 2 306532 eeScrew 10 24 x 5 8 308089 eeWasher 710 312288 eeScrew pan head 46 32 548971 eeScrew flangelock 5 16 18 x 5 8 800053 eeNut lock 10 24 800059 eeNut lock 1 4 20 800135 eeScrew tapping 8 x 1 2 800263 eeScrew P T H 1 4 20 x 1 1 4 O OO N INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 131 6 58 STEEL DOORS 132 STEEL DOORS 6 58 Description 800306 eeScrew 10 24 x 1 2 800339 eeNut speed 10 800344 eeScrew P T H 10 24 x 1 2 800631 eeRivet 5 32 823418 eeGuide lower 842463 eel atch door left 842464 eel atch door right 825819 eel atch window 825826 eeNut latch mounting 825839 eeNut speed 8 825840 110101170 window 825924 eeSeal push on 22 1 2 57cm 828694 eeCover latch 828697 eeArm latch control 828698 eeRod latch control inside 828699 eeRod latch control outside 828718 eeRetainer window left 828719 eeRetainer window right 828731 eeGuide window upper 828733 eeMolding window 82873
73. nterclockwise Valve Clearance intake 0 0031 cold 0 08 mm intake 0 0047 hot 0 12 mm exhaust 0 0039 cold 0 10 mm exhaust 0 0047 hot 0 12 mm Spark Plug Gap 0 032 0 035 0 8 0 9 mm Spark Plug NGK DCPR7E OR Nippon Denso XU22ERR U Spark Plug Torque 18 5 21 5 ft Ibs 25 30 N m Ignition Timing 4 5 BTDC 950 RPM Idle Speed 950 50 RPM ina To prevent premature engine failure and speed greater than design limits NEVER alter the governor controls in any manner to increase engine speed beyond recommended maximum RPM NOTE The governor controls are preset to control ground speeds to design limits 4 MAINTENANCE 4 1 MAINTENANCE 4 2 MAINTENANCE GUIDE The following maintenance charts have been compiled as a general guideline for service intervals based hours of operation When replacement parts are required use only genuine Cushman parts or parts with equiva lent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the DAILY operator and or bystanders AS REQUIRED Service air cleaner element Severe conditions may require more frequent service refer to Air Cleaner section Check engine oil level Check cooling system levels Clean radiator intake sc
74. on horn Key 5 32 x 5 32 x 1 1 4 Shaft pinion gear Support steering housing front Support steering housing rear Nut special 1 2 20 Gear steering driven Gear steering idler cluster Housing upper steering gear Bolt idler adjusting eNut crownlock 7 16 20 Wire and spring set eSpring eWire and connector Housing lower steering gear Wheel steering 73 6 30 THROTTLE PEDAL REF TOP OF GOVERNOR REF WELDED TO FLOORBOARD 74 130728 2700910 7 2700911 7 2700938 2701002 2701326 2702089 306414 306555 306981 521679 800290 800292 800927 817119 818395 821164 830165 843014 Description Nut 1 4 20 Pedal throttle Bracket cable Retainer cable Mount throttle cable Tread pedal Cable throttle police EFI Screw 3 8 16 x 1 Screw 5 16 18 x 5 8 Spring extension Pin clevis 1 4 x 1 2 Pin hair 1 4 x 1 1 8 Bushing Pulley pedal THROTTLE PEDAL 6 30 75 6 31 ALTERNATOR 8 GOVERNOR EXISTING Z NW ES S N 104 N 2 RA 9 0 57 9 N Q AS 0 o 6 6 N Di N Z NAN N E e e 7 A A 26 76 CO OO O OO N 103867 130728 2700335 2700503 2701129 2701236 2701434 7 2701510 2701511 2701517 306325 306372 306375 306396 306416 306463 306981 308090 311213 450454 452388 548804 800927 818395 830140 835062 835271 842740 843013 845345 7 893876 894706 894708
75. onverter catalytic 2702374 7 Bracket muffler hanger 306325 Lockwasher 5 16 306416 Screw 5 16 18 x 1 306932 Nut 5 16 18 548159 Washer 5 16 841982 Clamp tubing 14183 82050 Seal ring muffler flange 09119 10039 Bolt muffler flange 14492 82001 Spring muffler flange 842884 Tailpipe 887175 Hanger assembly muffler 306322 eScrew 5 16 18 x 7 8 548159 eWasher 5 16 800290 eNut 5 16 831603 eBracket 831604 eStrap tailpipe hanger 1 2 3 4 5 6 7 8 9 e INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 101 6 44 DIFFERENTIAL 102 304636 306325 306932 800198 805843 805875 808303 809156 809180 879476 814488 2701466 OR 894906 103867 120177 304055 306405 320122 2702248 800290 800356 805320 805321 805322 806251 812335 814226 814465 814466 814467 814468 814469 814470 814471 814474 814476 814477 827018 DIFFERENTIAL 6 44 Description Pin cotter 1 8 x 1 1 8 Lockwasher 5 16 Nut 5 16 18 Nut lock 1 2 20 Nut castle 5 8 18 Key hub 3 16 x 3 16 x 1 3 4 Gasket bearing Washer thrust 5 8 Washer 7 16 Retainer seal Seal bearing Differential complete 8 2 1 ratio Differential complete 10 25 1 ratio eWasher 5 16 eLockwasher 3 8 eScrew 5 16 18 x 1 3 8 eWasher 3 8 eCup tapered roller bearing eScrew 3 8 16 x 1 3 4 eNut lock 5
76. r Headlight rectangular Panel front body Panel headlight Seal rubber 35 10 7M Plug access Seal push on 25 7 6M Panel glove box Brace dash Screw shoulder 1 4 20 x 3 4 Bracket clamping Panel retainer FRONT BODY 6 23 61 6 24 62 ENGINE COVER 1 2 3 4 5 6 7 9 103867 112050 306325 306416 800279 800390 828378 829880 830780 830781 830908 831004 843207 839905 887443 316935 830658 888386 Washer 5 16 Screw tapping 1 4 20 x 5 8 Lockwasher 5 16 Screw 5 16 18 x 1 Nut speed 1 4 20 Rivet pop 1 8 Weatherstrip 50 15 2M Pad panel Catch latching Retainer engine cover Seal push on 25 7 6M Weatherstrip 25 7 6M Panel left cover Pan skid Latch engine cover Pin spirol 5 32 x 5 8 Spring Cover engine ENGINE COVER 6 24 63 6 25 FLOORMAT INSULATION WEATHERSTRIP 8 MOLDINGS 1 2 3 4 5 6 7 9 FLOORMAT INSULATION WEATHERSTRIP 8 MOLDINGS 6 25 821893 825840 825842 825924 827769 828378 828733 828834 828976 829735 830355 830908 831004 833745 833851 838706 Molding 12 3 7M Molding window Weatherstrip Seal push on Insulation engine cover Weatherstrip Molding window Foam Seal push on 25 7 6 M Foam roof Seal rubber 35 10 7M As Req d Seal push on 25 7 6M As Req d Weatherstrip As Req d Insulation engine cover 1 Se
77. r sparks when performing any maintenance function involving fuel EVERY 200 HOURS OR 2000 MILES Perform previous services Check spark plugs for fouling regap or replace spark plugs as necessary MAINTENANCE 4 EVERY 600 HOURS 6000 MILES OR YEARLY EVERY 1500 HOURS OF OPERATION Perform previous services Clean battery and terminals Replace timing belt after every 1500 Replace fuel filter hours of operation Repack front wheel bearings Repack rear wheel bushings Check starter motor brushes Check brake linings See Specifications section for recommended lubri Change differential oil cants and brake fluid Change transmission oil Depending on operating conditions the engine oil Check alternator and oil filter may need more frequent replacement to pad Ee maintain engine performance and help avoid unnec rain and replace radiator coola serende Check radiator hoses and clamps Check valve clearance The differential oil MUST be changed after the first 100 hours of operation 4 S 00889108710 CHART Ref Description Rear Spring Shackles 6 4 Lower Fork Pivot Bearing Drive Shaft Leading Link Bushing Brake Pedal Bellcrank Pivot Bushings 9 Too much lubricant can and will damage these seals Indicates Jacking Locations Indicates Emergency Tow Line Attachment Locations 4 MAINTENANCE 44 BULBS FUSES AND FLASHER Description Specification or Trade No Cushman
78. reen fins amp oil cooler fins Check fuel level Check engine for loose parts damage or leaks Check for engine noise or vibration NEVER attempt to perform service or mainte nance functions on this vehicle if you re UNTRAINED or UNAUTHORIZED Improper maintenance can cause hazardous conditions See your authorized Cushman dealer for nec essary maintenance and service FIRST 50 HOURS OR 500 MILES When it is necessary to raise the vehicle for any repair or service use jackstands to provide adequate support DO NOT rely on hydraulic or mechanical jacks for support Perform previous services Change Engine Oil Change Engine Oil Filter To avoid unexpected vehicle movement EVERY 100 HOURS OR 1 ALWAYS set the parking brake and make sure O POURS OR 1000 MILES the transmission is in PARK out of gear before Perform previous services working on a running engine Check automatic transmission fluid level Lubricate chassis see lube chart Check tire pressure Check differential oil level Check hydraulic brake fluid Check brake adjustment Check valve clearance first 100 hours then yearly ALWAYS replace immediately any warning decals that become damaged or hard to read To reduce risk of fire always keep the engine free of excessive grease If fuel system leakage is detected repair leak immediately Fuel is flammable and explosive under certain condi tions ALWAYS stop engine and do not allow open flames o
79. scription Lockwasher 410 Washer 6 Washer 8 Washer 1 4 Screw 86 32 x 3 4 Taillight Screw P T H 1 4 20 x 3 4 Screw P T H 1410 24 x 3 4 Bushing steel Washer sealing Connector single contact Light rotating Screw 10 24 x 3 4 Seal window 50 15 2M Blade wiper Arm wiper Trough drip RIGHT Trough drip LEFT Pad cab back Foam sound roof Decal CUSHMAN Screen vent opening Member Windshield Motor 2 speed wiper Window rear Bracket wiper switch Window pop out RIGHT Window pop out LEFT Wire wiper Pivot Cover vent Rivet pop 1 8 Belt seat shoulder Switch 2 speed wiper Harness taillight Lockwasher 10 Nut 10 24 CAB 6 57 Not illustrated Not illustrated NYC police mod Not illustrated Not illustrated Not illustrated 129 6 58 STEEL DOORS 130 STEEL DOORS 6 58 Description 888663 Steel door set complete RH OR 2702970 Steel door set complete LH 103867 eWasher 5 16 112050 eScrew tapping 1 4 20 x 5 8 306325 eLockwasher 5 16 306328 Pin cotter 3 32 x 3 4 306416 Screw 5 16 18 x 1 306932 Nut 5 16 18 306982 Washer 7 16 308090 eWasher 1 4 516634 ePin clevis 3 8 x 1 3 4 800270 eScrew tapping 10 16 x 1 2 800294 eNut lock 7 16 14 825500 eWasher cupped 7 16 842462 eStriker door 825823 Strap door 828700 eBracket striker mounti
80. t inside the element 4 17 INSTALLING AIR CLEANER ELEMENT 1 Loosen wing nut screw securing air cleaner halves and remove element 2 Clean dust from inside of housing with damp cloth making sure dust DOES NOT enter the air intake Check all gaskets to be sure they are NOT damaged Insert element in housing Apply a light grease film to the wing nut screw o moo Resecure the housing halves with the wing nut Screw 1 Air Cleaner Halves 2 Air Cleaner Element 3 Wing Nut Screw 4 18 n LUBRICATING BRAKE PEDAL BUSHINGS The pedal pivot lubrication fitting is located just below the hole in the floorboard near the pedal Refer to following illustration 1 Lubrication Access Hole 4 19 AUTOMATIC TRANSMISSION The transmission filler tube and dipstick are located beneath the left access panel directly behind the cab Ge 23 TRANSMISSION FLUID LEVEL CHECK UNDER THIS COVER REFER TO SERVICE MANUAL FOR PROPER PROCEDURE 840395 1 Transmission Dipstick The engine must be running with the transmission in PARK or neutral when checking the transmission fluid MAINTENANCE 4 level The level should be kept between the two marks on the dipstick Capacity is 3 7 quarts 4 2L DO NOT over fill transmission The drain plug is on the bottom of the transmission case in the left rear corner of the pan 1 Transmission Drain Plu
81. tial operation and safety information and must remain with the unit at all times within easy access of any op erator Additional manuals are available through your dealer IMPORTANT THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED TO WITHOUT THE MANUFACTURER S AUTHORIZATION P E Altering this equipment in any manner which adversely affects the equipments operation performance durability or use may cause haz ardous conditions Direct any inquiries to Textron Turf Care and Specialty Products Attn Director of Engineering Services P O Box 82409 Lincoln NE 68501 2409 USA SPECIFICATION INFORMATION All information contained in this manual is the latest available at the time of printing Textron Turf Care and Specialty Products reserves the right to make changes at any time without notice Whenever a name brand product is specified an equivalent product may be used unless stated otherwise CHANGE OF OWNERSHIP OR ADDRESS Textron Turf Care and Specialty Products makes every effort to keep owners informed of all safety related information Therefore changes in ownership and or address should be reported to the manufacturer Your dealer has REGISTRATION CHANGE FORMS which will be filled out and filed by the dealer for his records and a copy will be sent to the manufacturer DEALER INFORMATION For your nearest dealer location write to Textron Turf Care and Specialty Products Attn Sales Coordinator P O

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