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Table Of Contents - Cushman HAULER 1200 Repair Manual

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Contents
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Table of Contents

Battery Prolonged Storage2

Battery Disposal2

Safety Information5

General Operation6

Table Of Contents7

General Information And Routine Maintenance19

Serial Number Label Location19

Vehicle With A Discharged Battery19

Starting Vehicle On A Hill19

Servicing The Vehicle20

Initial Service Chart20

Warnings On Fuel20

Fuel Tank View21

Powertrain Maintenance21

Routine Maintenance21

Light Bulb Replacement21

Winter Or Prolonged Storage22

Transporting Vehicle22

Canopy And Windshield22

Vehicle Cleaning And Care23

Vehicle Care Production24

Torque Specifications24

Before Servicing The Vehicle25

Notices, Cautions, Warnings And Dangers25

Important Safety Warning25

Modifications To Vehicle25

General Maintenance25

Battery Removal And Installation27

Lifting Front Of Vehicle27

Lifting Rear Of Vehicle27

Lowering Vehicle28

Body Component Replacement31

Front Body Components32

Instrument Panel Replacement32

Brush Guard Replacement33

Cowl Replacement33

Front Bumper Replacement34

Rocker Panel Replacement34

Side Panel Replacement34

Tool List Quantity34

Pop Rivet Tool34

Notice: The Cowl (2) Can Be Removed Along With34

The Front Fenders34

Remove The Brush Guard, See Brush Guard Replace- Ment34

Seat Filler Panel Replacement35

Rear Body Panel Replacement35

Rear Fender Replacement36

Minor Scratches36

Larger Scratches36

Item Torque Specification36

Torque Wrench, Ft. Lbs36

Complete Panel Repair37

Truck Bed Replacement (Optional Electric Lift)39

Truck Bed Removal40

Speed Control43

Pedal Box Operation43

Governor Operation43

Ccelerator And Speed Control System View43

Speed Control Fault Testing44

Accelerator Cable Removal At Pedal Box44

Pedal Box Adjustments45

Accelerator Cable Installation45

Throttle Rod Removal45

Accelerator Pedal Arm Adjustment45

Micro Switch Adjustment46

Pedal Box Micro Switch46

Weather Protection49

Rear Support Installation49

Front Strut Installation49

Canopy Top Installation49

To Decrease The Risk Of Personal49

Flat Windshield51

Split Windshield52

Wheel And Tire Service55

Recommended Tire Pressure55

Wheel Installation56

Mechanical Brake System View59

Brake System Overview59

General Description59

How The Brake Works59

Equalizer Link60

Automatic Adjuster Mechanism60

How The Parking Brake Works60

Compensator Assembly60

Kick-Off Actuating Linkage60

Fault Testing Flowchart61

Fault Testing Table63

Brakes Fault Diagnosis And Inspection64

Brake Pedal And Linkage Inspection64

Fault Diagnosis And Inspection Procedures64

Brake Pedal Inspection65

Checking Parking Brake Latching Pressure65

Check Clevis Pins66

Equalizer And Compensator View66

Parking Brake Pedal Hinge Inspection66

Daily Brake Performance Test67

Brake System Inspection67

Wheel Brake Inspection67

Brakes Maintenance And Repair69

Adjusting Brake Pedal Free Travel70

Brake Drum Removal And Installation71

Wheel Brake Service71

Backing Plate/Entire Wheel Brake Assembly Removal And Installation72

Brake Shoe Removal73

Brake Shoes And Springs View74

Brake Shoe Installation75

Brake Cable And Equalizer Assembly Removal And Installation76

Compensator Assembly, Removal And Installation76

Brake Pedal Removal And Installation76

Parking Brake Catch Bracket Removal And Installation77

Pedal Bumper Adjustment78

Parking Brake Release Linkage Removal And Replacement78

Parking Brake Kick-Off Cam Removal, Replacement And Installation78

Front Hydraulic Brake81

Master Cylinder Replacement81

System Description81

Remove Master Cylinder81

Master Cylinder Fluid82

Brake Pad Replacement82

Check Brake Fluid82

Install Master Cylinder82

Flush Hydraulic Brake System82

Replacement Of Wear Items82

Bleeding Brakes83

Rotor Replacement83

Actuator Linkage Bushings83

Actuator Pivot Bushings83

Spindle Replacement83

General Information About Bleeding Brakes83

Rear Hydraulic Brakes87

Wheel Brake Components88

Wheel Brake Cleaning And Inspection89

Rear Hydraulic Brakes Reassembly90

Park Brake Cable Replacement94

Front Suspension And Steering97

Axle Mounted Steering And Front Suspension View97

Wheel Bearing And King Pin Bushing Inspection98

Wheel Bearing Packing98

Wheel Bearing Adjustment99

Wheel Alignment99

Front Suspension101

Front Shock Absorber Replacement101

Front Axle Replacement102

Axle Linkage Rod Replacement102

Front Spring Replacement103

Hub Replacement104

Wheel Bearing And Race Replacement105

Rack Ball Joint Replacement106

Tie Rod Inspection/Replacement107

Bellows Replacement108

Pinion Seal Replacement108

Rack And Pinion Unit Disassembly And Inspection110

Rack And Pinion Unit Replacement111

Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance111

Steering Wheel Replacement112

Steering Shaft And Column Replacement113

Checking The Lubricant Level (Rear Axle)117

Rear Axle Disassembly118

Axle Shaft Removal And Disassembly118

Axle Shaft Seal Removal And Replacement118

Axle Shaft Replacement119

Rear Suspension121

Shock Absorber Removal121

Rear Leaf Spring Removal121

Rear Suspension Exploded View122

Continuously Variable Transmission (Cvt)125

Primary Clutch125

Secondary Clutch126

Increased Load126

Removing The Transmission Belt126

Primary Clutch Removal126

Cvt Components View127

Primary Clutch Installation128

Secondary Clutch Removal128

Secondary Clutch Assembly128

Secondary Clutch Installation128

Four Cycle Engine Specifications131

Oil Dipstick131

Changing The Oil132

Remove Oil Filter133

Inspect Oil Filter133

Add Engine Oil133

Air Filter Inspection/Replacement134

Starter/Generator Belt Tension134

Clean The Air Filter Element134

Adjusting The Belt135

Starter/Generator Replacement136

Cooling System Cleaning136

Starter/Generator Wire Connections136

Cylinder Head137

Compression Leak Down Test137

Rocker Cover Removal138

Valve Clearance Inspection138

Valve Clearance Adjustment138

Engine Removal139

Drive Clutch Removal140

Engine Installation140

Fuel System Diagram143

Carburetor Operation144

Float System144

Main Jet System144

Choke System144

Choke Cable And Housing Removal145

Choke Cable Attachment145

Choke Cable And Housing Installation146

Carburetor Removal146

Carburetor Disassembly146

Float Level Alignment147

Carburetor Installation147

Fuel Pump Replacement148

Fuel Lines And Filter148

Fuel Tank Removal148

Carbon Canister149

Carb Hoses View149

Testing The Ignition Circuit151

Main Harness Wiring Diagram152

Testing The Magneto153

Testing The Starting Circuit154

Testing The Charging Circuit154

Starter/Generator View155

Voltage Test For Battery156

Starter/Generator Disassembly156

Starter/Generator Repair And Replacement156

Starter/Generator Brush Removal156

Storage Of Battery157

Dvom (Digital Volt Ohm Meter)157

Fault Testing157

Power Supply158

Accessory Wiring158

Headlight Bulb Replacement158

Taillight Replacement159

Continuity Check161

Testing A Switch For Continuity161

Testing The Ignition System161

Testing Fuses161

Powertrain Performance162

Starter Fault Testing164

Suspension And Steering Fault Testing164

Specifications167

Scheduled Maintenance171

Initial Service Requirements171

Severe Use Conditions171

Recommended Lubricants And Fluids173

Replacement Of Maintenance Items174

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