Cushman 1600XD 4X4 User manual

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™
OWNER’S MANUAL
1600XD 4X4
25045G-GB (Rev.0)
RJL 100 May 2012

TABLE OF CONTENTS
[ENGINE]
3C100LWU-E010 CYLINDER BLOCK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . .1
3C100LWU-E020 OIL PAN GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3C100LW-E030 CYLINDER HEAD COVER GROUP. . . . . . . . . . . . . . . . . . . . .4
3C100A-E040 GEAR CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3C100LW-E040 GEAR CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3C100A-E050 MAIN BEARING CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . .11
3C100A-E080 VALVE ROCKER ARM GROUP. . . . . . . . . . . . . . . . . . . . . . . .12
3C093LW-E090 CYLINDER HEAD COVER GROUP. . . . . . . . . . . . . . . . . . . . .13
3C100A-E100 CAMSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3C100A-E110 PISTON & CRANKSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . 15
3C100LWU-E110 PISTON & CRANKSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . 17
3C100LWU-E120 FLYWHEEL GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3C100LWU-E130 NOZZLE HOLDER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3C100LWU-E140 FUEL CAMSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3C100A-E150 SPEED CONTROL LEVER GROUP. . . . . . . . . . . . . . . . . . . . .22
3C100LW-C-E160 ENGINE STOP LEVER GROUP. . . . . . . . . . . . . . . . . . . . . . . .24
3C100A-E170 GOVERNOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3C100LWU-E190 WATER HOSE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3C100LWU-E200 ALTERNATOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3C100LWU-E220 MANIFOLD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
[FRONT AXLE]
U1-T230A BEVEL PINION SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . 31
U1-U0550A Front Axle Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
[TRANSMISSION]
U1-T100A TRANSMISSION CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . 33
U1-U0100A TRANSMISSION GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
U1-T110A DRIVE SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
U1-T120A SHIFT SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
U1-T130A SPRIAL BEVEL GEAR GROUP. . . . . . . . . . . . . . . . . . . . . . . . 38
U1-T140A REAR WHEEL DRIVING SHAFT GROUP. . . . . . . . . . . . . . . . 39
U1-T150A FRONT WHEEL DRIVE SHAFT GROUP. . . . . . . . . . . . . . . . . 40
U1-T160A FRONT DRIVE FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . .41
U1-T170A SHIFT FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
U1-T180A REAR AXLE CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . .43
U1-T190A REAR DIFF SYSTEM GROUP. . . . . . . . . . . . . . . . . . . . . . . . . 44
U1-T200A REAR DIFF FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
U1-T210A FRONT AXLE CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . .47
U1-T220A FRONT DIFF SYSTEM GROUP. . . . . . . . . . . . . . . . . . . . . . . .48
U1-U0230A Front Axle Drive Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
U1-U0235A Rear Differential Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
U1-U0240A Rear Axle Drive Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- i -

- ii -
U1-U0245A Propeller Shaft Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
U1-U0300A Rear Differential Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
[CHASSIS]
U3-U0200A Structure Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
U1-U0210A Guard Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
U3-U0220A ROPS GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
U1-U0250A ENGINE MOUNTING GROUP. . . . . . . . . . . . . . . . . . . . . . . . . 59
U1-U0260A LEVER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
U1-U0270A Accelerator Pedal Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
U1-U0284A CVT Group, DC(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
U3-U0287A CLUTCH COVER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
U1-U0290A Wheel & Tire Group(WORK). . . . . . . . . . . . . . . . . . . . . . . . . . .69
U1-U0400A Front Break Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
U1-U0410A Rear Break Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
U1-U0420A BRAKE PEDAL GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
U1-U0430A PACKING BACKE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . .75
U1-U0500A Front Suspension Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . 76
U1-U0510A Rear Suspension Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . 79
U1-U0522A Steering Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
U1-U0700A Fuel System Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
U1-U0710A Intake System Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
U3-U0720A Exhaust System Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . . 88
U1-U0730A RADIATOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
U1-U0800A IP GROUP(KIOTI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
U1-U0802A IP Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
U3-U0811A Seat Group(With SUS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
U3-U0858A Label Group(1600XD-EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
U3-U0900A Molding Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
U1-U0922A Deck Group(STD-BLACK). . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
U3-U0990A MIRROR GROUP(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
U3-U1020A FRONT HITCH GROUP(EEC)- STD. . . . . . . . . . . . . . . . . . . . .104
U3-U1110A SWING DRAWBAR GROUP(EEC)- STD. . . . . . . . . . . . . . . . . 105
U1-U1670A PARKING LOCK BUZZER GROUP. . . . . . . . . . . . . . . . . . . . . 106
U1-U1680A NUMBER PLATE GROUP (STD). . . . . . . . . . . . . . . . . . . . . . . 107
U3-U1750A ALARM SYSTEM BACKUP, GROUP(STD). . . . . . . . . . . . . . . 108
U1-U3950A HAND THROTTLE GROUP-OPT. . . . . . . . . . . . . . . . . . . . . . . 109
U1-U5030A WINCH GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
U1-U5080A SUSP DUST SHIELD GROUP-OPT. . . . . . . . . . . . . . . . . . . . .111
[ELECTRICAL]
U1-U0600A ELECTRICAL SYSTEM 1 GROUP. . . . . . . . . . . . . . . . . . . . . .112
U1-U0610A ELECTRICAL SYSTEM 2 GROUP. . . . . . . . . . . . . . . . . . . . . .113
U1-U0620A ELECTRICAL SYSTEM 2 GROUP. . . . . . . . . . . . . . . . . . . . . .114
U1-U0630A Battery Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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- iii -
U1-U0640A HEAD LIGHT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
U1-U3933A WIPER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
U1-U3936A WIPER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
[OPTION]
U1-U0820A HEAD REST GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
U1-U0913A HOOD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
U3-U0980A OPTIONAL LAMP GROUP(EU). . . . . . . . . . . . . . . . . . . . . . . . 123
U1-U1000A Gas Spring GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
U1-U3291A Wheel & Tire Group(OPT-Mud). . . . . . . . . . . . . . . . . . . . . . . . .127
U1-U3292A Wheel & Tire Group(OPT-Turf). . . . . . . . . . . . . . . . . . . . . . . . .128
U1-U3830A REAR SCREEN GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
U3-U3931A SAFTY GLASS GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
U3-U3932A WIND SHIELD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
U1-U3940A HYDRAULIC SYSTEM GROUP (1)-OPT. . . . . . . . . . . . . . . . . 133
U1-U3941A HYDRAULIC SYSTEM GROUP (2)-OPT. . . . . . . . . . . . . . . . . 138
U1-U3960A SKID PLATE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
U1-U3970A CANOPY GROUP-OPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
U3-U5650A WORKING LAMP 2 GROUP(OPTION). . . . . . . . . . . . . . . . . . .141
U1-U5660A WORKING LAMP GROUP(OPTION). . . . . . . . . . . . . . . . . . . . 142
U1-U5920A DECK EXTENSION GROUP(OPTION). . . . . . . . . . . . . . . . . . 143
INDEX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INDEX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INDEX 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3C100LWU-E010 CYLINDER BLOCK GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5763-A0012 1 CYLINDER BLOCK ASSY
1 E5763-A0013 1<---- CYLINDER BLOCK ASSY
2 06311-75015 3T1.6*18*18 PLUG
3 06311-75040 1 PLUG
4 15321-9626-3 6 PLUG
5 E5900-96021 9 PLUG
6 E5900-96031 1 PLUG
7 05012-00609 4 PIN, PARALLEL
8 05012-00814 2DIA10*20 PIN, PARALLEL
9 E5205-33961 2 TUBE PIN
10 15221-3365-1 1 PIN, TUBE
11 E5500-33702 1 O RING
12 E5205-73911 1 COVER
13 E5700-73922 1 GASKET
14 01023-50618 2 BOLT, WASHER
15 06312-10020 1PT1/4 PLUG
16 E5700-35012 1 OIL PUMP ASSY
17 E5700-35154 1 GASKET, OIL PUMP
18 E5205-91021 4 BOLT, WASHER
- 1 -

3C100LWU-E010 CYLINDER BLOCK GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
19 E5700-35662 1 GEAR, OIL PUMP DRIVE
20 05712-00408 15*5*12 KEY
21 E5753-35681 1 NUT, FLANGE
22 E5500-39013 1 OIL SWITCH
23 E5760-23471 1 METAL 1, CRANKSHAFT
- 2 -

3C100LWU-E020 OIL PAN GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5775-A0071 1 FAN OIL ASSY
1 E5775-A0072 1<---- ASSY FAN,OIL
2 15221-3375-2 1 PLUG, OIL DRAIN
2 E1100-33752 1<---- PLUG, OIL DRAIN
3 04717-01200 1 WASHER, SEAL
3 E6303-33661 1<---- GASKET
4 E5700-01624 1 GASKET, OIL PAN
5 E5700-91094 18 BOLT
6 E5775-32111 1 FILTER 1, OIL
7 04811-00140 1 O RING
8 01654-50820 1 BOLT, FLANGE WITH PIN
9 E5752-35692 1 GUIDE, OIL GAUGE
10 E5752-36422 1 GUIDE PIPE, OIL GAUGE
11 E7310-36431 1 PACKING
12 E5752-36412 1 OIL GAUGE
- 3 -

3C100LW-E030 CYLINDER HEAD COVER GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5763-A0302 1 CYLINDER HEAD TOTAL ASSY
1 E5763-A0303 1<---- TOTAL CYLINDER HEAD ASSY
1 E5763-A0304 1<---- TOTAL CYLINDER HEAD ASSY
2 E5205-03371 5 CAP
3 15321-9626-3 1 PLUG
4 E5900-96021 2 PLUG
5 E5205-13542 3 GUIDE, INTAKE VALVE
6 E5205-13562 3 GUIDE, VALVE
7 E5760-03141 3 HOT FLUG
8 E5770-03451 14 BOLT, CYLINDER HEAD
9 E5760-03313 1 GASKET, CYLINDER HEAD
9 E5760-03314 1<---- GASKET, HEAD
10 15221-0175-1 1 ENGINE HOOK
11 E5760-01751 1 ENGINE HOOK
12 01123-50816 1M8*P1.25 BOLT, WASHER
13 01513-50822 1M8*1.25 STUD
14 02156-50080 1M8XP1.25 NUT
14 02763-50080 1<---> M8XP1.25 FLANGE NUT
15 04512-50080 1M08 SPRING WASHER
- 4 -

3C100LW-E030 CYLINDER HEAD COVER GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
16 01513-50620 6 STUD
- 5 -