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Cushman Manuals
Utility Vehicle
HAULER 1200
Repair manual
Table Of Contents - Cushman HAULER 1200 Repair Manual
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Table Of Contents
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Contents
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Table of Contents
Battery Prolonged Storage
2
Battery Disposal
2
Safety Information
5
General
5
General Operation
6
Maintenance
6
Ventilation
6
Table Of Contents
7
General Information And Routine Maintenance
19
Serial Number Label Location
19
Vehicle With A Discharged Battery
19
Starting Vehicle On A Hill
19
Servicing The Vehicle
20
Initial Service Chart
20
Warnings On Fuel
20
Fuel Tank
20
Fuel Tank View
21
Powertrain Maintenance
21
Battery
21
Routine Maintenance
21
Brakes
21
Tires
21
Light Bulb Replacement
21
Towing
22
Neutral Lock
22
Hauling
22
Winter Or Prolonged Storage
22
Transporting Vehicle
22
Canopy And Windshield
22
Vehicle Cleaning And Care
23
Vehicle Care Production
24
Torque Specifications
24
Hardware
24
Before Servicing The Vehicle
25
Safety
25
Notices, Cautions, Warnings And Dangers
25
Important Safety Warning
25
Modifications To Vehicle
25
General Maintenance
25
Battery Removal And Installation
27
Lifting Front Of Vehicle
27
Lifting Rear Of Vehicle
27
Lowering Vehicle
28
Body Component Replacement
31
Front Body Components
32
Instrument Panel Replacement
32
Brush Guard Replacement
33
Cowl Replacement
33
Front Bumper Replacement
34
Rocker Panel Replacement
34
Side Panel Replacement
34
Tool List Quantity
34
Drill
34
Drill Bit
34
Punch, Small
34
Pop Rivet Tool
34
Hammer
34
Notice: The Cowl (2) Can Be Removed Along With
34
The Front Fenders
34
Remove The Brush Guard, See Brush Guard Replace- Ment
34
Seat Filler Panel Replacement
35
Rear Body Panel Replacement
35
Painting
36
Rear Fender Replacement
36
Minor Scratches
36
Larger Scratches
36
Item Torque Specification
36
Ratchet
36
Torque Wrench, Ft. Lbs
36
Complete Panel Repair
37
Truck Bed Replacement (Optional Electric Lift)
39
Truck Bed Removal
40
Speed Control
43
Pedal Box Operation
43
Governor Operation
43
Ccelerator And Speed Control System View
43
Speed Control Fault Testing
44
Accelerator Cable Removal At Pedal Box
44
Pedal Box Adjustments
45
Accelerator Cable Installation
45
Throttle Rod Removal
45
Accelerator Pedal Arm Adjustment
45
Micro Switch Adjustment
46
Pedal Box Micro Switch
46
Road Test
46
Weather Protection
49
Rear Support Installation
49
Front Strut Installation
49
Canopy Top Installation
49
To Decrease The Risk Of Personal
49
Flat Windshield
51
Split Windshield
52
Wheel And Tire Service
55
Recommended Tire Pressure
55
Tire Repair
55
Wheel Installation
56
Mechanical Brake System View
59
Brake System Overview
59
General Description
59
How The Brake Works
59
Equalizer Link
60
Automatic Adjuster Mechanism
60
How The Parking Brake Works
60
Compensator Assembly
60
Kick-Off Actuating Linkage
60
Fault Testing Flowchart
61
Fault Testing Table
63
Brakes Fault Diagnosis And Inspection
64
Brake Pedal And Linkage Inspection
64
New Vehicle
64
Fault Diagnosis And Inspection Procedures
64
Brake Pedal Inspection
65
Checking Parking Brake Latching Pressure
65
Check Clevis Pins
66
Equalizer And Compensator View
66
Parking Brake Pedal Hinge Inspection
66
Daily Brake Performance Test
67
Brake System Inspection
67
Wheel Brake Inspection
67
Brakes Maintenance And Repair
69
Adjusting Brake Pedal Free Travel
70
Brake Drum Removal And Installation
71
Wheel Brake Service
71
Backing Plate/Entire Wheel Brake Assembly Removal And Installation
72
Brake Shoe Removal
73
Brake Shoes And Springs View
74
Brake Shoe Installation
75
Brake Cable And Equalizer Assembly Removal And Installation
76
Compensator Assembly, Removal And Installation
76
Brake Pedal Removal And Installation
76
Parking Brake Catch Bracket Removal And Installation
77
Pedal Bumper Adjustment
78
Parking Brake Release Linkage Removal And Replacement
78
Parking Brake Kick-Off Cam Removal, Replacement And Installation
78
Front Hydraulic Brake
81
Master Cylinder Replacement
81
System Description
81
Remove Master Cylinder
81
Master Cylinder Fluid
82
Brake Pad Replacement
82
Check Brake Fluid
82
Install Master Cylinder
82
Flush Hydraulic Brake System
82
Replacement Of Wear Items
82
Bleeding Brakes
83
Rotor Replacement
83
Actuator Linkage Bushings
83
Actuator Pivot Bushings
83
Spindle Replacement
83
General Information About Bleeding Brakes
83
Rear Hydraulic Brakes
87
Wheel Brake Components
88
Wheel Brake Cleaning And Inspection
89
Rear Hydraulic Brakes Reassembly
90
Park Brake
93
Park Brake Cable Replacement
94
Front Suspension And Steering
97
Axle Mounted Steering And Front Suspension View
97
Wheel Bearing And King Pin Bushing Inspection
98
Wheel Bearing Packing
98
Wheel Bearing Adjustment
99
Wheel Alignment
99
Front Suspension
101
Front Shock Absorber Replacement
101
Front Axle Replacement
102
Axle Linkage Rod Replacement
102
Front Spring Replacement
103
Hub Replacement
104
Wheel Bearing And Race Replacement
105
Steering
106
Rack Ball Joint Replacement
106
Tie Rod Inspection/Replacement
107
Bellows Replacement
108
Pinion Seal Replacement
108
Rack And Pinion Unit Disassembly And Inspection
110
Rack And Pinion Unit Replacement
111
Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance
111
Steering Wheel Replacement
112
Steering Shaft And Column Replacement
113
Rear Axle
117
Checking The Lubricant Level (Rear Axle)
117
Rear Axle Disassembly
118
Axle Shaft Removal And Disassembly
118
Axle Shaft Seal Removal And Replacement
118
Axle Shaft Replacement
119
Rear Suspension
121
Shock Absorber Removal
121
Rear Leaf Spring Removal
121
Rear Suspension Exploded View
122
Continuously Variable Transmission (Cvt)
125
Primary Clutch
125
Secondary Clutch
126
Increased Load
126
Removing The Transmission Belt
126
Primary Clutch Removal
126
Cvt Components View
127
Primary Clutch Installation
128
Secondary Clutch Removal
128
Secondary Clutch Assembly
128
Secondary Clutch Installation
128
Engine
131
Four Cycle Engine Specifications
131
Oil Dipstick
131
Changing The Oil
132
Remove Oil Filter
133
Inspect Oil Filter
133
Add Engine Oil
133
Air Filter Inspection/Replacement
134
Starter/Generator Belt Tension
134
Clean The Air Filter Element
134
Adjusting The Belt
135
Starter/Generator Replacement
136
Cooling System Cleaning
136
Starter/Generator Wire Connections
136
Spark Plug
137
Cylinder Head
137
Compression Leak Down Test
137
Rocker Cover Removal
138
Valve Clearance Inspection
138
Valve Clearance Adjustment
138
Engine Removal
139
Drive Clutch Removal
140
Engine Installation
140
Fuel System Diagram
143
Carburetor Operation
144
Float System
144
Main Jet System
144
Choke System
144
Choke Cable And Housing Removal
145
Choke Cable Attachment
145
Choke Cable And Housing Installation
146
Carburetor Removal
146
Carburetor Disassembly
146
Float Level Alignment
147
Carburetor Installation
147
Fuel Pump Replacement
148
Fuel Lines And Filter
148
Fuel Tank Removal
148
Carbon Canister
149
Carb Hoses View
149
Electrical
151
Starter
151
Generator
151
Testing The Ignition Circuit
151
Main Harness Wiring Diagram
152
Testing The Magneto
153
Testing The Starting Circuit
154
Testing The Charging Circuit
154
Starter/Generator View
155
Voltage Test For Battery
156
Starter/Generator Disassembly
156
Starter/Generator Repair And Replacement
156
Starter/Generator Brush Removal
156
Storage Of Battery
157
Dvom (Digital Volt Ohm Meter)
157
Fault Testing
157
Power Supply
158
Accessory Wiring
158
Headlight Bulb Replacement
158
Taillight Replacement
159
Continuity Check
161
Testing A Switch For Continuity
161
Testing The Ignition System
161
Testing Fuses
161
Powertrain Performance
162
Starter Fault Testing
164
Suspension And Steering Fault Testing
164
Specifications
167
Scheduled Maintenance
171
Initial Service Requirements
171
Severe Use Conditions
171
Recommended Lubricants And Fluids
173
Replacement Of Maintenance Items
174
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Table of Contents
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