Cushman HAULSTER 898487 User manual

PARTS AND
MAINTENANCE MANUAL
HAULSTER POLICE VEHICLE
MODEL 898487

Part No. 2702455 Rev. A

1 GENERAL INFORMATION
250–6–01–CU
2001 Textron Inc.
Lincoln, Nebraska •All Rights Reserved.
Printed in U.S.A.
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 IS 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.
!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.
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
•damage the equipment.
This manual contains essential 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.
WARNING
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. Box 82409
Lincoln, NE 68501–2409 USA
In the USA and Canada call 1–888–922–8873 (dealer
information only).

1
TABLE OF CONTENTS
SECTION PAGE
1 General Information Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Identification
2.1 Vehicle Identification 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Serial & Model Number 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Engine Serial Number 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Specifications
3.1 Vehicle 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Dimensions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Capacities 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Battery 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Brake Fluid 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Engine Oil 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Lubrication 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Gear Ratios 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Engine 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Maintenance
4.1 Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Maintenance Guide 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Lubrication Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Bulbs and Flasher 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Fuses 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Engine Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Engine Access 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Engine Oil Level 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Battery 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Jump Starting With Booster Battery 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Engine Cooling System 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Draining The Cooling System 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Filling the Cooling System 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Air Cleaner 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Servicing Air Cleaner Element 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16 Checking Air Cleaner Element 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.17 Installing Air Cleaner Element 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.18 Lubricating Brake Pedal Bushings 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.19 Automatic Transmission 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.20 Differential 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.25 Tire Replacement 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.26 Extended Storage 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Torque Chart 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Parts
6.1 Engine Gaskets 18–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Cylinder Head 20–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Cylinder Block 22–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Crankshaft, Pistons 24–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Camshaft 26–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Timing Belt & Cover 28–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Intake Manifold/Throttle Body 30–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 PVC Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9 Exhaust Manifold 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Oil Pump 34–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 Water Pump & Outlet, Thermostat 36–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12 Starter 38–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.13 Drive Shaft, Torque Converter 40–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14 Automatic Transmission 42–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
TABLE OF CONTENTS
SECTION PAGE
6.15 Automatic Transmission Pan, Dipstick & Gaskets 44–45. . . . . . . . . . . . . . . .
6.16 Transmission Tubes, Oil Pump, Solenoids & Shift Switch 46–47. . . . . . . . .
6.17 Transmission Input Shaft & Clutch 48–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.18 Transmission Planetary Gears & Output Shaft 50–51. . . . . . . . . . . . . . . . . .
6.19 Brake Band & Shift Shaft 52–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20 Transmission Valve 54–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.21 Main Frame 56–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.22 Platform Frame 58–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.23 Front Body 60–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.24 Engine Cover 62–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.25 Floormat, Insulation, Weatherstrip & Moldings 64–65. . . . . . . . . . . . . . . . . . .
6.26 Rear Box & Sides (Side Opening) 66–67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.27 Rear Spring 68–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.28 Front Fork 70–71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.29 Steering Gear, Wheel & Horn 72–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.30 Throttle Pedal 74–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.31 Alternator & Governor 76–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.32 Hoses & Air Filter 78–79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.33 Oil Fill & Filter 80–81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.34 Shifter & Shift Cable 82–83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.35 Front Brakes, Axle & Hub 84–85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.36 Rear Brakes, Hub & Wheel Cylinder 86–87. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.37 Hydraulic Brake System 88–89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.38 Master Cylinder & Brake Rod 90–91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.39 Parking Brake 92–93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.40 Seat Belt 94–95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.41 Seat & Backrest 96–97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.42 Fuel System 98–99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.43 Exhaust System 100–101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.44 Differential 102–105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.45 Cooling System 106–107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.46 Heater/Defroster 108–109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.47 Electrical Components (Front) 110–111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.48 Electrical Components (Main) 112–113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.49 Decals 114–115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.50 Headlights, Taillights & Turn Signals 116–117. . . . . . . . . . . . . . . . . . . . . . . . .
6.51 Rotating Light 118–119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.52 Turn Signal Switch 120–121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.53 Front Shock Absorber 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.54 Wheel Measurement 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.55 Tires 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.56 Front Bumper 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.57 Cab 126–129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.58 Steel Doors 130–133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION 2
3
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.
3834
Nameplate/Identification Decal
2.2 SERIAL & MODEL NUMBER
3824
Serial Number And Model Number
2.3 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
1. Stamped Engine Serial Number
A hand lettered engine serial number has been placed on
the left side of the engine below the oil fill.
1
1. Hand Lettered Engine Serial Number

3 SPECIFICATIONS
4
3.1 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 lbs. (455 kg). . . . . . . . . . .
Overall Height (w/cab) 70” (1.8 m). . . . . . . . . . . . . . . . .
Overall Length 111” (2.8 m). . . . . . . . . . . . . . . . . . . . . . . .
Overall Width 48” (1.2 m). . . . . . . . . . . . . . . . . . . . . . . . .
Outside Clearance Circle 17’ (5.2 m). . . . . . . . . . . . . . . .
Inside Clearance Circle 36” (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 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 qts. (3.1 L). . . . . . . . . . . . . . . . . . .
Crankcase (including filter): 3.3 qts. (3.1 L). . . . . . .
3.4 BATTERY
Volts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BCI Group Size 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amps Minimum 420. . . . . . . . . . . . . . . . .
Reserve Capacity Minutes Minimum 70. . . . . . . . . . . . .
Ground Terminal Polarity NEGATIVE. . . . . . . . . . . . . . .
3.5 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.
WARNING
!
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 stiffness, 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 DOT (3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 825622
WARNING
3.7 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.
3.8 LUBRICATION
Automatic Transmission Fluid Mercon/Dexron II. . . . . .
Differential Oil SAE EP 80–90 Gear Lube. . . . . . . . . . .
Pressure Gun Lubricant Lithium Based. . . . . . . . . . . . . .

SPECIFICATIONS 3
5
3.9 GEAR RATIOS
Automatic Transmission
3rd Gear 1.008:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd Gear 1.536:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1st Gear 2.727:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear 2.222:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential worm gear 8.2:1. . . . . . . . . . . . . . . . . . . . . . . or
10.25:1
3.10 ENGINE
Suzuki 660 Engine
Horsepower (SAE hp) 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). . . . . . . . . . .
Stroke 2.60” (66 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore 2.56” (65 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement 40.1 cu in. (657 cm3). . . . . . . . . . . . . . . . .
Compression Ratio 10.5:1. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Compression 178 PSI (1,228 kPa). . . . . . . . .
Engine Rotation
(viewed from flywheel) Counterclockwise. . . . . . . . . . .
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 Number NGK DCPR7E. . . . . . . . . . . . . . . . .
OR Nippon Denso XU22ERR–U
Spark Plug Torque 18.5–21.5 ft. lbs.(25–30 N⋅m). . . . .
Ignition Timing 4–5°BTDC @ 950 RPM. . . . . . . . . . . . .
Idle Speed 950 ±50 RPM. . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
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
6
4.1 MAINTENANCE
WARNING
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
operator and/or bystanders.
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.
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.
To avoid unexpected vehicle movement,
ALWAYS set the parking brake and make sure
the transmission is in PARK (out of gear) before
working on a running engine.
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 or sparks when performing any
maintenance function involving fuel.
!
4.2 MAINTENANCE GUIDE
The following maintenance charts have been compiled
as a general guideline for service intervals, based on
hours of operation. AS REQUIRED
Service air cleaner element
(Severe conditions may require more frequent
service – refer to Air Cleaner section.
DAILY
Check engine oil level
Check cooling system levels
Clean radiator intake screen, fins, & oil cooler fins
Check fuel level
Check engine for loose parts, damage or leaks
Check for engine noise or vibration
FIRST 50 HOURS OR 500 MILES
Perform previous services
Change Engine Oil*
Change Engine Oil Filter*
EVERY 100 HOURS OR 1000 MILES
Perform previous services
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
EVERY 200 HOURS OR 2000 MILES
Perform previous services
Check spark plugs for fouling
(regap or replace spark plugs as necessary)

MAINTENANCE 4
7
EVERY 600 HOURS, 6000 MILES OR YEARLY
Perform previous services
Clean battery and terminals
Replace fuel filter
Repack front wheel bearings
Repack rear wheel bushings
Check starter motor brushes
Check brake linings
Change differential oil
Change transmission oil
Check alternator
Check fuel hoses and clamps
Drain and replace radiator coolant
Check radiator hoses and clamps
Check valve clearance
EVERY 1500 HOURS OF OPERATION
Replace timing belt after every 1500
hours of operation
See Specifications section for recommended lubri-
cants and brake fluid.
*Depending on operating conditions, the engine oil
and oil filter may need more frequent replacement to
maintain engine performance and help avoid unnec-
essary repairs.
** The differential oil MUST be changed after the first
100 hours of operation.
4.3 LUBRICATION CHART
*
Ref. No.
No. Description Req’d.
1
11
1
3
4
5
2
Lubricate all chassis fittings with lithium based lubricant every 100 hours or 1000 miles.
◊
◊Too much lubricant can and will damage these seals.
*Indicates Jacking Locations
♦Indicates Emergency Tow Line Attachment Locations
*
*
*♦
♦
1 Rear Spring Shackles 6. . . . . . . . . . . . . . . . . . .
2 Drive Shaft 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Brake Pedal Bellcrank Pivot Bushings 1. . . .
4 Lower Fork Pivot Bearing 1. . . . . . . . . . . . . . .
5 Leading Link Bushing 2. . . . . . . . . . . . . . . . . . .
Ref. No.
No. Description Req’d.

4 MAINTENANCE
8
4.4 BULBS, FUSES AND FLASHER
Description Specification or Trade No. Cushman Part No.
BULBS
Ammeter light 1 CP No. 53 811953. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight 65–45 Watt No. H6545 837303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight 32–4 CP No. 1157 822049. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal, front 21 CP No. 1156 837670. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure warning light 2 CP No. 1893 828473. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMS light 2 CP No. 1893 828473. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer light 1 CP No. 53 811953. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water temperature gauge light 1 CP No. 53 811953. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gauge light 1 CP No. 53 811953. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSES 20 Amp 826000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 Amp 833038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLASHER, turn signal 825501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 FUSES
Fuses are located on the kick panel just below the instru-
ment panel. They protect the lighting circuits and acces-
sory circuits such as windshield wiper motor and heater/
defroster blower. Remove fuses by pulling straight out.
Fuse Block On Kick Panel
20
1515
15 20 20 30
30
15 15 15
Horn
Brake
Lights
Head
Lights
Tail
Lights
Heater Engine
Cooling
Fans
Optional
Cab
Lights
Turn
Signals Dome Light
Wiper
Speed
Limit
Solenoid
Transmission Power
Point Main
Relay Engine
Instrument
Panel
10
Fuse Box Panel
4.6 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-
rized Cushman dealer.

MAINTENANCE 4
9
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 check–up schedule should be carried out. Proper
maintenance will prolong the engines life and avoid pre-
mature overhaul.
NOTICE
•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
WARNING
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
3500
1. Engine Cover Latch
When replacing the cover, make sure the retaining tabs,
located at the front corners of the engine cover are
inserted into the slots in the floorboard.
1
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
1. Engine Oil Fill
The engine 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
10
4.9 BATTERY
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
WARNING
DO NOT allow open flames or sparks near a bat-
tery when connecting for jump starting or while
recharging 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.
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
WARNING
The cooling fan is thermostatically controlled
and may start at any time. DO NOT attempt to
service the fan without first disconnecting it.
!
WARNING
KEEP HANDS CLEAR, ELECTRIC FAN
MAY ENGAGE WITHOUT WARNING,
EVEN WITH IGNITION OFF!
833607
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:
•DO NOT obstruct or cover the air intake screen in
front of the radiator.

MAINTENANCE 4
11
•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
1. Radiator
NOTE: If 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 important 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:
WARNING
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.
WARNING
832130
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.
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
•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-
flow 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
12
1
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
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.
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 flashlight 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.
3. Check all gaskets to be sure they are NOT damaged.
4. Insert element in housing.
5. Apply a light grease film to the wing nut screw.
6. Resecure the housing halves with the wing nut
screw.
5409
1
23
1. Air Cleaner Halves
2. Air Cleaner Element
3. Wing Nut Screw
4.18 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.

MAINTENANCE 4
13
1
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.
840395
TRANSMISSION FLUID LEVEL
CHECK UNDER THIS COVER
– REFER TO SERVICE MANUAL
FOR PROPER PROCEDURE
1
1. Transmission Dipstick
The engine must be running with the transmission in
PARK (or neutral) when checking the transmission fluid
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
5404
1. Transmission Drain Plug
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.
3098
1
2
1. Filler Plug
2. Drain Plug
IMPORTANT!
DIFFERENTIAL LUBRICANT MUST BE CHANGED
ACCORDING TO THE MAINTENANCE GUIDE
SCHEDULE TO AVOID EXPENSIVE REPAIR.

4 MAINTENANCE
14
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
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 ft. lbs.
(95 to 140 N⋅m).
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. Pull the link straight off the mounting studs. Retain
the bushings located in the holes at each end of the
brake anchor link.
1
2
3
45
6
2
3584
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.

MAINTENANCE 4
15
1
2
3
4
3585
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) large 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. lbs.
(95 to 140 N⋅m).
3. 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
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.
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
Front 32 PSI (220 kPa). . . . . . . . . . . . . . . . . . . . . . . .
Rear 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 of two or
three seconds.
4.25 TIRE REPLACEMENT
Always use replacement tires equivalent to or exceeding
original equipment specifications.
4.26 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).
WARNING
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:
•Fill the vehicle fuel tank.
•Check engine oil level.
•Check engine for loose parts.
•Start the engine and check for fuel or oil leaks and
check the operation of all controls.

TORQUE CHART 5
16
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27
ft.-lbs. 1.5 3 5.2 8.2 13.5 24 43.5 70.5 108 142 195 276 353 530
N·m 2 4 7 11 18 32 58 94 144 190 260 368 470 707
ft.-lbs. 2.2 4.5 7.5 12 18.8 35.2 62.2 100 147 202 275 390 498 747
N·m 3 6 10 16 25 47 83 133 196 269 366 520 664 996
ft.-lbs. 2.7 5.2 8.2 15 21.8 43.5 75 119 176 242 330 471 596 904
N·m 3.6 7 11 20 29 58 100 159 235 323 440 628 794 1205
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8
ft.-lbs. 9 18 31 50 75 110 150 250 378 583 782
N·m 12 24 42 68 102 150 203 339 513 790 1060
ft.-lbs. 13 28 46 75 115 165 225 370 591 893 1410
N·m 18 38 62 108 156 224 305 502 801 1211 1912
ft.-lbs. 24 40
N·m 33 54
TORQUE SPECIFICATIONS
HEX HEAD CAP SCREWS
* Grade 5 marking – Minimum commercial quality (Lower quality not recommended).
U.S. Standard Hardware
Grade Shank Size (Diameter in inches, fine or coarse thread)
SAE
grade
5 *
SAE
grade
8 **
Flangelock
Screw w/
Flangelock
Nut
The torque values shown should be used as a general guideline when specific torque values are not given.
** Grade 8 marking –
Grade Shank Size (Diameter in millimeters, fine or coarse thread)
Grade
8.8*
Grade
10.9**
Grade
12.9 ***
Metric Standard Hardware
* Grade 8.8 marking – ** Grade 10.9 marking – *** Grade 12.9 marking –
8.8 10.9 12.9

17
PROBLEM SERVICE PERFORMEDDATE INITIALS
SERVICE AND MAINTENANCE RECORD

6.1 ENGINE GASKETS
18
1
2
3
4
5
6
7
8
9
10
11
FRONT OF VEHICLE