Cushman HAULER 1200 Repair Manual Download

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GENERAL SPECIFICATIONS

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

149

Repair and Service Manual

653045

GENERAL SPECIFICATIONS

HAULER 1200- GENERAL SPECIFICATIONS

Engine:

13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

•

Valve Train:

Overhead valve

•

Fuel System:

Fixed float bowl with remote pulse fuel pump

•

Lubrication:

Pressurized oil system, spin-on oil filter •

Ignition:

Electronic spark / magneto

•

Balancer:

Internal counter rotating balance shaft

•

Air Cleaner:

Replaceable dry cartridge

Electrical:

Starter / Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)

Drive Train:

Automatic, continuously variable transmission (CVT)

Brakes:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system

Transaxle:

Differential with helical gears, ground speed governor, forward / reverse

Cargo Bed:

Roto-molded cross-linked polyethylene. Lifts for access to powertrain. Removable hinged multi-position tailgate with cam over latch mechanism

Item

Specification

Overall Length

115.0 in (292.10 cm)

Overall Width

49.4 in (125.48 cm)

Overall Height (No Canopy)

47.3 in (120.14 cm)(Top of steering wheel)

Overall Height (With Canopy)

70.5 in (179.07 cm)

Wheel Base

76.8 in (195.07 cm)

Front Wheel Track

35.0 in (88.90 cm)

Rear Wheel Track

38.5 in (97.79 cm)

Ground Clearance (at Differential)

3.5 in (8.89 cm)

Cargo Box Width (inside)

44.0 in (111.76 cm)

Cargo Box Length (inside)

39.0 in (99.06 cm)

Cargo Box Depth (inside)

12 in (30.48 cm)

Cargo Box Capacity

12 cu ft (0.34 cu m)

Cargo Box material

Roto-molded polyethylene

Power Source

4 Cycle 24.5 cu in (401 cc)

Valve Train

Single Cylinder OHV

Horsepower (kW)

13.5 hp (10.1 kW) Exceeds SAE J1940 Std.

Electrical System

Starter / Generator. Solid State Regulator

Batteries (Qty, Type)

One, 12 Volt Maintenance Free

Key or Pedal Start

Pedal

Air Cleaner

Replaceable Dry Cartridge

Lubrication

Pressurized Oil System

Oil Filter

Spin-On

Cooling System

Air Cooled

Max Fuel Volume

6.0 Gallon (22.7 L) tank

Drive Train

Continuously variable transmission (CVT)

Transaxle

Differential with helical gears

Gear Selection

Forward - Reverse

Rear Axle Ratio

11.42:1 (Forward) 15.78:1 (Reverse)

Seating Capacity

2 Persons

Dry Weight

940 lb (426.38 kg)

Curb Weight

980 lb (444.52 kg)

Bed Load Capacity

800 lb (362.87 kg)

Vehicle Load Capacity

1200 lb (544.31 kg)

Outside Clearance Circle

21.5 ft (7.01 m)

Property of American Airlines

Summary of Contents for HAULER 1200

Page 1: ...HAULER 1200 Repair Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 2: ...f this vehicle MANUFACTURER S INTENDED USE This vehicle is designed and manufactured in the United States of America USA The standards and specifications listed in the following text originate in the USA unless oth erwise indicated EXHAUST EMISSION The exhaust emissions of this vehicle s engine complies with regulations set forth by the Environmental Protection Agency EPA of the United States of A...

Page 3: ... waste fluids grease fumes and particulates all identified by the State of California to potentially cause cancer birth defects and other reproductive harm This vehicle has been designed and manufactured in the United States of America USA The Standards and Specifi cations listed in the following text originate in the USA unless otherwise indicated The use of non Original Equipment Manufacturer OE...

Page 4: ...o maintain a full charge on the batteries If power to the char ger is disconnected or interrupted the battery charger continues to check the charge on the battery pack This pulls power from the battery pack and eventually drains the batteries if power is not restored in a timely manner As with all electric vehicles the batteries must be checked and recharged as required or at a minimum of 30 day i...

Page 5: ... variety of tasks beyond their original intended use therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur Warnings cannot replace good com mon sense driving practices Common sense driving practices do more to prevent accidents and injury than warnings and instructions can provide The manufacturer strongly suggests anyone operating the...

Page 6: ...n Use specified replacement parts DO NOT use replacement parts of lesser quality Use recommended tools Make sure tools and procedures not specified by the manufacturer will not be a safety risk to personnel or oper ation of the vehicle Use wheel chocks and support the vehicle on jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s...

Page 7: ... 3 ROUTINE MAINTENANCE 3 POWERTRAIN MAINTENANCE 3 BRAKES 3 TIRES 3 LIGHT BULB REPLACEMENT 3 TRANSPORTING VEHICLE 4 Towing 4 Neutral Lock 4 HAULING 4 CANOPY AND WINDSHIELD 4 WINTER OR PROLONGED STORAGE 4 VEHICLE CLEANING AND CARE 5 VEHICLE CARE PRODUCTS 6 HARDWARE 6 SAFETY NOTICES CAUTIONS WARNINGS AND DANGERS 7 IMPORTANT SAFETY WARNING 7 MODIFICATIONS TO VEHICLE 7 GENERAL MAINTENANCE 7 BEFORE SERV...

Page 8: ...Seat Filler Panel Replacement 17 Rear Body Panel Replacement 17 Rear Fender Replacement 18 PAINTING 18 Minor Scratches 18 Larger Scratches 18 Complete Panel Repair 19 TRUCK BED TRUCK BED REMOVAL 22 SPEED CONTROL SYSTEM OPERATION 25 Pedal Box Operation 25 Governor Operation 25 FAULT TESTING 26 SPEED CONTROL 26 Accelerator Cable Removal at Governor 26 Accelerator Cable Removal at Pedal Box 26 Accele...

Page 9: ...HEELS AND TIRES WHEEL AND TIRE SERVICE 37 Recommended Tire Pressure 37 Tire Repair 37 Wheel Installation 38 BRAKES BRAKE SYSTEM OVERVIEW 41 General Description 41 How the Brake Works 41 Equalizer Link 42 Automatic Adjuster Mechanism 42 How the Parking Brake Works 42 Kick Off Actuating Linkage 42 Compensator Assembly 42 FAULT TESTING FLOWCHART 43 FAULT TESTING TABLE 45 FAULT DIAGNOSIS AND INSPECTIO...

Page 10: ...g Brake Catch Bracket Removal and Installation 59 Parking Brake Pedal Removal and Installation 59 Pedal Bumper Adjustment 60 Parking Brake Release Linkage Removal and Replacement 60 Parking Brake Kick Off Cam Removal Replacement and Installation 60 FRONT HYDRAULIC BRAKE SYSTEM DESCRIPTION 63 MASTER CYLINDER REPLACEMENT 63 Remove Master Cylinder 63 Install Master Cylinder 64 MASTER CYLINDER FLUID 6...

Page 11: ...E 80 Lubrication 80 Wheel Bearing and King Pin Bushing Inspection 80 Wheel Bearing Packing 80 Wheel Bearing Adjustment 81 Wheel Alignment 81 FRONT SUSPENSION 83 Front Shock Absorber Replacement 83 Front Axle Replacement 84 Axle Linkage Rod Replacement 84 Front Spring Replacement 85 Hub Replacement 86 Wheel Bearing and Race Replacement 87 STEERING 88 Rack Ball Joint Replacement 88 Tie Rod Inspectio...

Page 12: ...ement 100 Axle Shaft Replacement 101 REAR SUSPENSION General 103 Shock Absorber Removal 103 Rear Leaf Spring Removal 103 CONTINUOUSLY VARIABLE TRANSMISSION CVT GENERAL 107 CLUTCHES 107 Primary Clutch 107 Secondary Clutch 108 Increased Load 108 Equilibrium 108 Removing the Transmission Belt 108 Transmission Belt Service 108 Primary Clutch Removal 108 109 Primary Clutch Installation 110 Secondary Cl...

Page 13: ...K PLUG 119 CYLINDER HEAD 119 Compression Leak Down Test 119 Rocker Cover Removal 120 Valve Clearance Inspection 120 Valve Clearance Adjustment 120 ENGINE REMOVAL 121 Controls and Wiring 122 Removing the Engine from the Vehicle 122 Engine Installation 122 DRIVE CLUTCH REMOVAL 122 FUEL SYSTEM GENERAL 126 Fuel Tank 126 CARBURETOR OPERATION 126 Float System 126 Pilot Jet System 126 Main Jet System 126...

Page 14: ... GENERATOR 133 WIRING 133 TESTING THE IGNITION CIRCUIT 133 Testing the Magneto 135 TESTING THE STARTING CIRCUIT 136 TESTING THE CHARGING CIRCUIT 136 INSPECTION 137 STARTER GENERATOR 138 Starter Generator Removal 138 Disassembly 138 Repair and Replacement 138 VOLTAGE TEST FOR BATTERY 138 STORAGE OF BATTERY 139 DVOM DIGITAL VOLT OHM METER 139 FAULT TESTING 139 POWER SUPPLY 140 ACCESSORY WIRING 140 L...

Page 15: ...E 144 STARTER FAULT TESTING 146 SUSPENSION AND STEERING FAULT TESTING 146 GENERAL SPECIFICATIONS HAULER 1200 GENERAL SPECIFICATIONS 149 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE 153 Initial Service Requirements 153 Severe Use Conditions 153 SCHEDULED MAINTENANCE CHART 153 RECOMMENDED LUBRICANTS AND FLUIDS 155 REPLACEMENT OF MAINTENANCE ITEMS 156 P r o p e r t y o f A m e r i c a n A i r l i n e ...

Page 16: ...B xiv Repair and Service Manual TABLE OF CONTENTS 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 17: ...B TABLE OF CONTENTS xv Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 18: ...B xvi Repair and Service Manual TABLE OF CONTENTS 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 19: ...r with the engine running it functions as a gen erator The generator can keep the battery charged with the short run times typical of this type of vehicle The genera tor will not charge a discharged battery When the engine starts the clutches engage and cause the vehicle to move making jump starting both dangerous and impractical Since the engine stops when the accelerator is released jump startin...

Page 20: ... components are heavy spring loaded highly corro sive explosive may produce amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforesee...

Page 21: ... service intervals NOTICE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions POWERTRAIN MAINTENANCE Access the powertrain by raising or removing the seat bottom Some service procedures may require the vehicle be lifted Refer to LIFTING THE VEHICLE in the SAFETY section for proper lifting procedure and safety information For maintenance procedur...

Page 22: ...on a trailer Do not allow any people on a vehicle being trans ported on a trailer Remove the windshield before you transport a vehi cle on a trailer Maximum speed with canopy installed is 50 mph 80 kph If you transport the vehicle on a trailer at highway speeds the canopy must be removed and the seat bottom secured If the vehicle is to be transported on a trailer below high way speeds check for ti...

Page 23: ...fogging oil into the cylinder Rotate the crankshaft by hand several times Install the spark plug Do not engage the park brake but secure the car from rolling Change the oil while the engine is warm Clean the body chassis and engine of debris mud chaff or grass VEHICLE CLEANING AND CARE Read and understand all instructions supplied by the manufacturer of the pressure washer before use NOTICE When y...

Page 24: ... Refer to the following table for torque values Ref Fig 6 Standard Grade 2 hardware is unmarked Grade 5 hardware can be identified by the three marks on the hex head Grade 8 hardware is identified by six marks on the head The class specification is marked on metric hardware Fig 6 Torque Specifications ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Un...

Page 25: ... should an unexpected situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment MODIFICATIONS TO VEHICLE Do not modify the vehicle in any manner that will change the weight distribution of the vehicle Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could result in injury or death...

Page 26: ...connect a circuit under load at a battery terminal Batteries are heavy Use proper lifting techniques when moving them Always lift the battery with a commercially available battery lifting device Use care not to tip the battery when removing or installing spilled electrolyte can cause burns and damage The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes...

Page 27: ...ing from a jack Place shifter in the P park position Always place chocks in front and behind the wheels Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported only by a jack Use jack stands and test the stability of the vehicle on the stands The vehicle is extremely unstable during the lifting process When lifting the vehicle position jacks and jack stan...

Page 28: ... chocks are still in place on any wheels that remain on the ground 2 Put the jack in the same location that was used to raise the vehicle 3 Raise the vehicle enough to remove the jack stands Remove the jack stands from underneath the vehi cle 4 Slowly lower the vehicle to the ground and remove the jack Fig 2 Lifting the Vehicle Fig 3 Wheel Chocks View from Underside of Vehicle Center of Front Axle...

Page 29: ...all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 11 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 30: ...d Service Manual SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 31: ...dy component replacement can be accomplished with a minimum of specialized tools Most body components are held in place with conventional removable hardware Some components are mounted with pop rivets which require the rivet head be removed in order to push out the shank of the rivet The rivet head can be removed by drill ing into the head with a sharp drill bit that is slightly larger than the sh...

Page 32: ...t of the cowl To decrease the risk of injury due to lack of vehicle information the cor rect safety label must be on the instrument panel at all times To decrease the risk of personal injury disconnect negative BL battery cables before ser vicing vehicle Pull up the front edge of the floor mat 3 to expose the rivets 4 that secure the instrument panel 1 to the vehi cle frame Figure 4 Drill out the ...

Page 33: ...Assemble brush guard 14 in the reverse order of removal Tighten the bolts 11 to the torque value specified below Cowl Replacement Tool List Quantity Drill 1 Drill Bit 1 Punch Small 1 Pop Rivet Tool 1 Hammer 1 NOTICE The cowl 2 can be removed along with the front fenders To decrease the risk of personal injury disconnect negative BL battery cables before servicing vehicle Remove the brush guard See...

Page 34: ...ified below Rocker Panel Replacement Tool List Quantity Phillips Screwdriver 1 Socket 3 8 1 Ratchet 1 Torque Wrench in lbs 1 Remove two screws 15 spacers 16 and nuts 17 from top portion of rocker panel 19 Retain hardware for later installation Figure 8 Drill out the rivets 18 that secure the rocker panel to the vehicle frame Remove rocker panel 19 Repeat the steps for the other side of vehicle if ...

Page 35: ... filler panel 31 to side panel 22 Figure 10 Remove seat filler panel 31 Install seat filler in reverse order of removal Tighten the screws 33 to the torque value specified below Figure 10 Seat Filler Panel Rear Body Panel Replacement Tool List Quantity Socket 7 16 1 Ratchet 1 Wrench 7 16 1 Remove two rivets 37 from each side securing the rear body panel 40 to the rear fenders 35 36 on each side Fi...

Page 36: ...ends the following steps be taken 1 Thoroughly clean the surface to be repaired with alcohol and allow to dry 2 Use a brush to apply a minimum of two coats of touch up paint to damaged area Allow 30 45 min utes between coats increase to 45 60 minutes in higher humidity The painted area should be slightly above the surface of the part 3 Use 400 grit wet sand paper to blend painted area level with t...

Page 37: ...r Do not wax flat finishes Complete Panel Repair In situations where large panels or areas must be painted touch up paint is not recommended In such cases professional painting or panel replacement is nec essary Body panel replacement is sometimes more cost effective than painting If the decision to paint is chosen it can be accomplished by any body panel repair shop with experience in painting th...

Page 38: ...nd Service Manual BODY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 39: ...ar attention to Notices Cautions Warnings and Dangers 21 Repair and Service Manual 653045 TRUCK BED Figure 1 Truck Bed Replacement Figure 2 Truck Bed Replacement Optional Electric Lift 3 1 2 4 Front of Vehicle 5 4 1 3 5 Electric lift assembly P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 40: ...ectric lift is installed remove and retain spacers 5 Figure 2 3 Rotate the gas spring 1 and bed tether cable 2 down to sit on the bracket Lower the truck bed 4 Remove the cotter pins 12 and clevis pins 13 from both sides of the truck bed Figure 3 Figure 4 5 If the vehicle is equipped with the standard plastic bed retain the flat washers 14 spacers 15 and pivot bushings 16 Figure 3 6 If the vehicle...

Page 41: ... all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 23 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 42: ...Service Manual TRUCK BED Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 43: ...es the parking brake is released the micro switch closes and activates the igni tion circuit The rear end of the accelerator rod is joined to the micro switch cam which connects to the accelerator cable As the micro switch cam moves to the rear it pulls the accelerator cable which pulls against the governor spring When the accelerator cable pulls against the accelerator cable governor spring the s...

Page 44: ...3 16 1 Pop Rivet Tool 1 Remove the negative battery cable from the battery to prevent the vehicle from moving and pos sible personal injury that may result Refer to SAFETY section of this manual for additional cautions and warnings NOTICE Be sure to follow the sequence indicated when making linkage adjustments Accelerator Cable Removal at Governor To remove the accelerator cable 9 from the governo...

Page 45: ...sen the bolt 18 between the two governor levers and rotate lower gover nor lever 19 counter clockwise until the carburetor throt tle plate is fully open Rotate upper governor lever 20 counter clockwise until it stops Tighten bolt that locks the governor levers in position to the torque value specified below Fig 6 Throttle Rod Adjustment PEDAL BOX ADJUSTMENTS Tool List Qty Needle Nose Pliers 1 Phil...

Page 46: ...edal Box Micro Switch Loosen the setscrew 9 in the cam 10 using a 1 8 Allen wrench Loosen the jam nut 12 and move the cam to adjust as needed Ref Fig 8 Adjust to permit 1 2 5 8 13 16 mm of accelerator pedal travel before the micro switch 11 clicks Measure the distance at the top of the pedal with the pedal arm contacting the pedal bracket Make sure the setscrew in the cam does not contact the micr...

Page 47: ... Distance in feet 5280 Time in seconds 3600 Rate in KPH Distance in meters 1000 Time in seconds 3600 For example 300 ft 5280 13 6 sec 3600 15 MPH 100 m 1000 15 sec 3600 24 KPH If the speed is not within the specified speed range stop the vehicle and adjust the governor compression spring as described in procedure above Tightening the spring results in a speed increase while loosening it will resul...

Page 48: ...rvice Manual SPEED CONTROL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 49: ...l A 2 Upper Hole Install the front strut 1 with bolt 2 lock washer 3 and flat washer 4 outside of the strut with the spacer 5 and flat washer 4 between the front cowl and strut If a brush guard 6 is to be installed you will add a spacer 5 between the brush guard and the strut 3 Lower Hole Install the strut with bolt 2 lock washer 3 and flat washer 4 outside of the strut with the a flat washer 4 be...

Page 50: ...ECTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 Figure 1 Canopy Top 5 5 4 1 8 7 11 C D B D A P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 51: ...dshield Pay careful attention to the orientation of each sash 3 Install the windshield fastener grommets 19 to the windshield assembly 17 4 Orient the windshield assembly 17 Align each windshield fastener grommet 19 with the mounting hole in each strut and clip the sashes 18 to the canopy struts 5 Insert torx bolts 20 through each windshield fas tener grommet 19 and strut leg secure with lock nuts...

Page 52: ...shield fastener grommets 25 to the windshield assembly 23 4 Orient the windshield assembly 23 Align each windshield fastener grommet 25 with the mounting hole in each strut and clip the sashes 24 to the canopy struts Clip the upper windshield latches 26 to the canopy struts 5 Insert torx bolts 27 through each windshield fas tener grommet 25 and strut leg secure with lock nuts 28 6 The upper portio...

Page 53: ... Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 35 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 54: ...ice Manual WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 55: ...recommended on the tire sidewall All four tires must have the same pressure for best control qualities Always install the valve stem cap after you check or inflate the tires Tire Repair The vehicle is equipped with low pressure tubeless tires mounted on one piece rims The most cost effective way to repair a flat tire with a puncture in the tread portion of the tire is to use a com mercial tire plu...

Page 56: ... evenly seated against the hub With the valve stem to the outside of wheel install the wheel onto the hub with lug nuts Finger tighten lug nuts 1 in the cross sequence pattern as shown Figure 1 Continue to tighten the lug nuts in 20 ft lbs 27 Nm increments in the cross sequence pattern until the correct torque value shown below is reached Figure 1 Wheels and Tires Item Torque Specification 1 65 85...

Page 57: ...Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 39 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 58: ...vice Manual WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 59: ...tion Free pedal travel pedal force shoe to drum clearance and braking capability are closely related It is very important to maintain the proper rela tionships to assure braking performance and the best wheel brake adjustment How the Brake Works Pressing the brake pedal pulls the compensator assem bly and equalizer link which are connected to the brake cables Figure 1 The first part of the pedal t...

Page 60: ...arking brake pedal moves the latch arm against the catch bracket attached to the chassis As the parking brake is pressed the brake is applied until the notch in the latch arm engages with the catch bracket The brake pedal is held in the applied down position by the catch bracket The latch arm is held in position by tension in the brake linkage The parking brake can be released by two meth ods 1 Pr...

Page 61: ...tension by the brake cables est sult Fails 2 out of 3 Fails 2 out of 3 rm the c Brake mance PBPT mes essive Test imes Seal Thrust W Cond Remove Brake D Brake Com 8 Yes Return To Service Go to 2 o 6 Remove B Don t Dist Mecha 6 9 Visually Dru 7 Go to Adjust Free Travel est sult External ection udes PT mes Both Rear and Tires Overh Worn L Spline Crac Grease Con Out of Sco Adju Arm Ben Contacting S Go...

Page 62: ... braking function exists then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving at maximum speed and brake aggressively 10 times At the spherical nut readjust the free travel Drive and brake aggressively 10 more times Repeat until the pedal free travel stabilizes within the specified range 19 Return to Service Whe...

Page 63: ...of adjustment Adjust per manual End of brake cable loose from anchor brackets Check and repair Wheel brake failure due to severely worn or damaged components Replace all severely worn or damaged com ponents System not adjusted properly Adjust per manual Less than 7 8 2 2 cm free pedal trav el Hard Pedal High pedal force at parking brake latch Adjust per manual Brake cables damaged or sticky Check ...

Page 64: ...rrect brake operation depends on mainte nance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return bumper Ensure that the pedal is contacting the return bumper when released that the bumper is in good condition and that a 1 4 3 8 6 9 5 mm gap exists between the pedal arm and the setscrew heads of the kick off cam Figure 7 Replace or adjust the bumper if required See the Pedal Bumper Adj...

Page 65: ...ce is to place a bathroom scale on the brake pedal Use both feet press the scale down equally against the parking brake pedal until it latches The parking brake must lock between 65 and 75 lbs 29 34 kg indicated on the scale Figure 10 If necessary adjust the spherical nut to achieve correct latching pressure Figure 10 Checking Parking Brake Latching Pressure Adjust the brake pedal free travel as d...

Page 66: ... Inspect parking brake pedal hinge Check for broken springs and correct retention of the hinge pin Operate the parking brake pedal to confirm smooth operation of the hinge mechanism Figure 13 Figure 12 Equalizer and Compensator Figure 13 Parking Brake Pedal Hinge Inspection 9 Check the condition and operation of the parking brake latching mechanism The parking brake should latch firmly and release...

Page 67: ...ual decrease in braking effect from the disc pads wearing away a loss of braking at one wheel or a sudden and complete failure with no brakes working except the parking brake If the brakes at one wheel become ineffective while the brakes at the other wheel functions properly remove the entire brake assembly and inspect the brake for signs of a leak ing or inoperative wheel cylinder assembly Wheel ...

Page 68: ...y indication of galling or gouging is not repairable and must be replaced with a new wheel brake assembly Always replace wheel brake assemblies in pairs 8 Inspect the backing plate Inspect for gouges galling or other damage particu larly where the backing plate is contacted by the brake shoes and by the moving anchor assembly Replace both backing plates if any gouges or galling is found 9 Measure ...

Page 69: ...t 1 2 1 Socket 3 4 1 Socket 11 16 1 Socket 15 16 1 Socket 1 1 8 1 Socket 1 4 1 Torque Wrench ft lbs 1 Torque Wrench in lbs 1 Extension 6 1 Ratchet 1 Open End Wrench 1 4 1 Open End Wrench 1 2 1 Open End Wrench 5 8 1 Straight Blade Screwdriver 1 Straight Blade Screwdriver Narrow 1 Pliers 1 Vernier Dial Calipers 1 Plastic Tipped Hammer 1 Puller P N 15947G1 1 Pry Bar 1 Dust Mask 1 Emery Cloth 1 Forwar...

Page 70: ...known free travel All brake tests must be done in a safe location with regard for the safety of all personnel In a safe location free from people and vehicles drive the vehicle at reduced speed and apply the brakes aggres sively As the brakes begin to adjust and stop the vehicle effectively start driving at maximum speed and brake aggressively 10 times At the spherical nut adjust the free travel a...

Page 71: ...y be on the axle shaft or attached to the rear of the drum hub This washer must be rein stalled when the brake is reassembled To install the brake drum clean the axle shaft and the splines on the brake drum to remove debris and grease Apply a small amount of anti seize compound to the axle spline Install the inner brake drum washer 6 and slide the brake drum 5 into place Figure 21 Make sure the no...

Page 72: ...oes See Brake Shoe Installation If the brake shoes and drum are not to be replaced sand the friction surfaces lightly with an emery cloth to remove any debris Be sure the adjusting screw is screwed into the star wheel nut until only 1 2 threads are exposed If brake shoes are replaced replace brake springs and adjuster components Replace springs one side at a time using the other side as a referenc...

Page 73: ...ease the tension in the brake springs 4 Remove the brake springs and remove the brake shoes Inspect the brake shoes If a brake shoe has less than 0 060 lining material thickness AT ANY POINT on either shoe both shoes MUST be replaced Check for free lateral front and back movement of the adjusting mechanism and for free movement of the star wheel Wear a dust mask and eye protec tion when working on...

Page 74: ...and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 Figure 24 Brake Shoes and Springs 97 ADJUSTER ASSEMBLY TOP PULL 9 5 4 4 3 7 2 6 8 10 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 75: ...rn springs Clean the axle shaft to remove debris and grease that may have accumulated Figure 26 Brake Shoe 17T Insert a straight blade screwdriver between the adjusting lever and the adjusting mechanism Rotate the star wheel left until the shoes have retracted sufficiently to allow installation of the brake drum Install washer 5 brake drum 6 washer 8 and castel lated nut 9 Tighten the castellated ...

Page 76: ... pedal by removing the cotter pin and clevis pin Figure 27 Loosen and remove the jam nut and the spherical nut connecting the compensator rod to the equalizer link Remove the compensator assembly Installation is the reverse of removal Use new cotter pin in the clevis pin Adjust the brake pedal free travel See Adjusting Brake Pedal Free Travel Brake Pedal Removal and Installation Disconnect the com...

Page 77: ...lue specified below Figure 29 If required adjust the kick off cam 3 See Parking Brake Kick Off Cam Removal Replacement and Installation Install the wheel See WHEELS AND TIRES section Figure 29 Catch Bracket and Latch Arm Parking Brake Pedal Removal and Installa tion Note the location and orientation of the two torsion springs 8 for reassembly purposes Remove the push nut s 9 and pin 10 Figure 28 a...

Page 78: ... bushings 4 Replace them if signs of wear are present Install in reverse order of removal If required adjust the kick off cam 6 See Parking Brake Kick Off Cam Removal Replacement and Installation Figure 31 Parking Brake Release Linkage and Kick Off Cam Removal and Installation Parking Brake Kick Off Cam Removal Replacement and Installation Disconnect the parking brake release linkage as described ...

Page 79: ...all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 61 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 80: ...d Service Manual BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 81: ...ake pedal by a linkage rod which rotates to contact the upper actuator pivot The upper actuator pivot is con nected to a clevis on the master cylinder plunger Move ment of the plunger hydraulically activates the caliper pistons forcing the brake pads against the rotors With the brake pedal released the upper actuator pivot and the plunger returns to the at rest position With the mas ter cylinder n...

Page 82: ...Service Schedule or immedi ately when fluid leaks are found Clean the cap with a shop rag and remove the cap from the master cylinder Use a mechanics mirror and a flash light to check the fluid level Add fluid if level is below 1 4 6 5 mm from the top of the reservoir Inspect for visible fluid leaks ROUTINE MAINTENANCE Tool List Quantity Shop Rag AR Mechanics Mirror 1 Flashlight 1 Transmission Flu...

Page 83: ...hat secures the lower actuator pivot to the actuator linkage Discard cotter pin Retain washer for reuse Install a new nylon bushing flange down to the lower actuator pivot Reconnect the actuator linkage using washer and a new cotter pin Actuator Pivot Bushings NOTICE Removing the front shield may improve accessibility to brake components Refer to the BODY section Both the upper and lower actuator ...

Page 84: ...r frequently during this operation to prevent air from entering the lines Figure 2 Bleeding Brakes Start with the passenger side rear brake and move to the driver side rear brake bleed the brakes using the follow ing procedure NOTICE The bleeder valve at the caliper must be closed at the end of each stroke and before the brake pedal is released to ensure air cannot enter the system It is important...

Page 85: ...ES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 67 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 86: ...e Manual FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 87: ...f the brake shoes should become wet with hydraulic fluid remove the brake drum and wipe the brake shoes and drum until they are dry Complete brake failure usually indicates a loss of hydrau lic fluid pressure The hydraulic system may be checked for leaks by apply ing pressure to the pedal gradually and steadily If the pedal sinks very slowly to the floor the system has a leak This is not to be con...

Page 88: ...d of the axle splines If not remove drum and install one additional inner brake drum washer total of 2 to obtain required spacing If two inner brake drum washers do not provide the required spacing the brake drum is incorrect and must be replaced with a new drum Do not back off nut to install cotter pin Install the remaining hardware and tighten the castellated nut to specified torque value Contin...

Page 89: ...repairable and must be replaced with a new wheel brake assembly Always replace wheel brake assemblies in pairs Inspect the brake drum Look for a blue coloration or blis tered paint that would indicate that it has overheated Check for evidence of scoring Check for excessive wear indicated by the friction surface being significantly worn and leaving a ledge of unworn drum Inspect the splines for gal...

Page 90: ...tion If the wheel cylinder was removed install it now into the backing plate Insert the wheel cylinder mounting bolts and torque to specific torque value Reconnect the brake fluid line using new copper gaskets and banjo bolts Tighten the banjo bolts to specific torque value Position shoes on backing plate and install hold down springs Install parking brake strut with tab on strut engaged in brake ...

Page 91: ...IC BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 73 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 92: ...l REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 93: ... procedure Pay particular attention to Notices Cautions Warnings and Dangers 75 Repair and Service Manual 653045 PARK BRAKE Figure 1 Park Brake Cable 7 1 2 3 6 4 5 7 Shown Partially for Clarity 9 10 8 11 Front of Vehicle P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 94: ...underneath to access the pivot arm and ratchet mechanism of the park brake Refer to the Scheduled Maintenance in the GENERAL INFORMATION AND ROUTINE MAINTENANCE section of this manual for recommended lubrication schedule Cable Replacement Tool List Quantity Needle Nose Pliers 1 Straight Blade Screwdriver 1 Wrench 7 16 1 Ratchet 1 Socket 7 16 1 Replace the cables when they become inoperable Remove ...

Page 95: ...d all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 77 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 96: ...Service Manual PARK BRAKE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 97: ...al 653045 FRONT SUSPENSION AND STEERING Figure 1 Axle Mounted Steering and Front Suspension Front of Vehicle Intermediate Shaft with U Joints Spindle and King Pin Bushing Tie Rod Rack Ball Joint Rack Extension Spacer Steering Wheel Steering Shaft Steering Column Scorecard Holder Steering Wheel Cover Axle Wave Washer Bearing Inner Snap Ring Outer Snap Ring P r o p e r t y o f A m e r i c a n A i r ...

Page 98: ...e sure vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test stability of vehicle on stands before starting any repair procedure Always place chocks in front and behind wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process Lift the front of the vehicle and support on jack stand...

Page 99: ...y retained on spindle 5 with the castellated nut Figure 4 Seat the bearings by rotating the wheel while tightening the castellated nut until slight resistance is felt Rotate the wheel two to three more turns to displace excess grease If required tighten the castellated nut 3 again until slight resistance is felt If the cotter pin hole in the spindle 5 aligns with a slot in the castellated nut inse...

Page 100: ...t threads on each end The end with the flat area has left hand threads clockwise to loosen while the end without the flat has conventional right hand threads counter clock wise to loosen To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Figure 5 Tighten jam nuts 1 to the torque value specified below Figure 6 Disconnect Intermediate Shaft to ...

Page 101: ...ve the nut 1 from the bottom of the shock absorber 2 at the front axle 3 Figure 7 Compress shock absorber to clear the mounting bracket Loosen the nut 30 securing the top of the shock absorber to the vehicle frame then rotate the shock absorber while holding the nut in place with a wrench Remove the shock absorber NOTE Tie Rod Not Shown for Clarity Part of Frame Part of Frame 22 2 30 5 4 1 24 20 1...

Page 102: ...the rack and pinion unit back to rest on top of the front springs 17 Secure the rack and pinion unit to the spring with wire to decrease the risk of pulling apart the intermediate shaft Remove three bolts 18 two bolts 28 spring plate 24 and five lock nuts 19 securing the axle 3 to the springs Discard the lock nuts 19 15 At the bolt 20 securing the front of the left spring 17 note the location of t...

Page 103: ... a single spring will result in over stressing the other spring therefore replace front springs as a set The following procedure will replace one spring at a time Loosen the front wheel lug nuts Lift and support the front of the vehicle as instructed in the SAFETY section Observe all warnings Remove the lug nuts and the front wheels from the hubs To detach the driver side spring Loosen the two rac...

Page 104: ...aced the axle will need to be aligned to the frame Unless the axle has been replaced wheel alignment will not be affected however it is always good practice to check wheel alignment any time the front end components are replaced or adjusted When the front springs are replaced the front axle must be aligned to the frame The distance from the center bolt at the rear left spring to the center bolt at...

Page 105: ...AND TIRES section Wheel Bearing and Race Replacement Tool List Quantity Non Ferrous Punch 1 Ball Peen Hammer 1 Bearing Driver 1 Remove the hub 1 from the spindle Figure 13 See Hub Replacement Remove the grease seal 3 inner wheel bearing 4 and bearing races 5 by tapping through the other side of hub the bearing race with a hammer and soft non ferrous punch Tap the race in a circular pattern while m...

Page 106: ... Ball Joint Replacement Tool List Quantity Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Tape Measure 1 Wrench 3 4 1 Torque Wrench ft lbs 1 Socket 11 16 1 To remove the rack ball joint 1 loosen the lug nuts on the passenger side front wheel Lift and support the front of the vehicle per the SAFETY section Figure 14 Remove the passenger side front wheel and turn t...

Page 107: ...the steering is turned fully to the right Figure 22 Check for proper rack extension to rack and pinion unit clearance before tightening the jam nut 4 to the torque value specified below See Checking Adjusting Rack Extension to Rack and Pinion Unit Clearance Install the passenger side front wheel per the WHEELS AND TIRES section Lower vehicle per the SAFETY sec tion Check the front wheel alignment ...

Page 108: ...nd support the front of the vehicle per the SAFETY section Remove passenger side front wheel and turn steering wheel fully to the left Figure 17 Remove the rack ball joint 2 and jam nut 3 from the rack extension 4 See Rack Ball Joint Replacement Cut the wire ties 5 6 and slide the bellows off the rack extension Install the new bellows align the small end over the groove in the rack extension and s...

Page 109: ...ed Hammer 1 Wrench 3 4 1 Socket 3 4 1 Socket 11 16 1 Torque Wrench ft lbs 1 The spindle bearings are designed to be used dry Lubrication attracts dirt and will ruin the bearings Do not apply grease to the spindle bearings Loosen the front wheel lug nuts Lift and support the front of the vehicle per the SAFETY section Remove the lug nuts and the front wheel To remove the tie rod loosen the lock nut...

Page 110: ...12 as an assembly Figure 20 Rack and Pinion Unit Disassembly Clean the rack pinion and housing Inspect the gear teeth bearing surfaces and the grease seal surfaces of the unit for excessive wear or damage If any damage or excessive wear is found the rack and pinion unit must be replaced as an assembly See Rack and Pinion Unit Replacement If the rack and pinion unit is still serviceable clean the c...

Page 111: ... in the reverse order of removal Install the new lock nuts 18 and tighten to the torque specified below Tighten the castellated nut 3 to the torque mentioned and continue to tighten as needed to insert the new cotter pin Tighten the bolt 13 securing the intermediate shaft to the pinion to the torque value specified below After replacing or servicing steering components always verify that a 1 8 gap...

Page 112: ...heel turn the wheels straight ahead To decrease the risk of damage to the clipboard perform the follow ing removal procedure Do not use a screwdriver to push or pry the retaining tabs From the front side of the steering wheel 4 remove the steering wheel cover by pulling straight up on the bottom of the steering wheel cover to release the two bottom retaining tabs Then using thumb for leverage as s...

Page 113: ... Torque Wrench in lbs 1 Wheel Bearing Grease AR To remove the steering shaft 4 Figure 24 remove the steering wheel See Steering Wheel Replacement Loosen the lug nuts on the front wheels Lift and support the front of the vehicle per the SAFETY section Remove the lug nuts and the front wheels Remove the bolt 1 and washer 2 that secure the inter mediate shaft 3 to the steering shaft 4 Remove the four...

Page 114: ... below Tighten the bolt 1 securing the intermediate shaft to the steering shaft to the torque value specified below Install the front wheel s per the WHEELS AND TIRES section Lower vehicle per the SAFETY section Install the steering wheel See Steering Wheel Replace ment Figure 26 Small Retaining Ring Orientation Item Torque Specification 5 29 ft lbs 39 Nm Item Torque Specification 1 13 18 ft lbs 1...

Page 115: ... AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 97 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 116: ...nual FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 117: ...k of possibility of fingers becoming pinched in the direction selector mechanism hold the direction selector lever when releasing neutral lock pin handle Fig 1 Neutral Lock Direction Selector Activate the direction selector by pulling the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole 3 in the direction selector cam Checking the Lubricant Level To...

Page 118: ...k stands before starting any repair procedure Never work on a vehicle that is supported by a jack alone Axle Shaft Removal and Disassembly Tool List Qty Arbor Press 1 Bearing Separator 1 Needle Nose Pliers 1 Internal Snap Ring Pliers 1 Slide Hammer P N 18753G1 1 For brake drum removal refer to the BRAKES section 1 Remove the outer snap ring from the axle tube Ref Fig 3 Fig 3 Removing Installing Ou...

Page 119: ...f ferential side gears Install the outer snap ring 3 Coat the outboard spline of the axle with an anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 7 NOTICE Tighten the castellated axle nut to 70 ft lbs 95 Nm torque minimum Continue to tighten until the slot in the nut aligns with the cotter pin hole 4 Tighten the axle nut to the torque value specified...

Page 120: ... Service Manual REAR AXLE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 121: ...r of the shock absorber washer 5 Rear Leaf Spring Removal To decrease the possibility of per sonal injury follow the lifting proce dure in SAFETY section of this manual Place wheel chocks in front and behind wheel not being raised and check stability of vehicle on jack stands before starting any repair procedure Never work on a vehicle that is supported by a jack alone NOTICE If both springs are t...

Page 122: ...is section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 Fig 1 Rear Suspension Front of the Vehicle 10 5 5 13 19 4 5 7 2 18 17 9 4 4 1 14 12 8 20 11 9 15 16 3 5 4 6 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 123: ...ead all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 105 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 124: ...rvice Manual REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 125: ...ed is increased which causes the cams weights within the centrifugal primary clutch to move outwards and force the movable sheave inwards The transmission belt is engaged by the clutch sheaves and begins to rotate As the engine speed continues to increase the primary clutch sheave continues to move inwards forcing the transmission belt to the outer diameter of the primary clutch sheaves which incr...

Page 126: ...pplies more torque to the rear axle without an appreciable change to the engine speed since the governor opens the carbure tor in direct the response to the decrease in ground speed Equilibrium The CVT functions because the primary and secondary clutches maintain equilibrium The clutch sets are adjusted to the vehicle that they are designed to operate Changes in vehicle weight or desired performan...

Page 127: ...g hanger Remove the front eye bolt from the spring hanger Install the clutch puller bolt using the impact tool and universal joint remove the primary clutch from the shaft Remove the clutch puller bolt NOTICE In some cases the clutch cannot separate from the crankshaft Remove the clutch puller and fill the cavity with grease Replace the clutch puller and tighten it with the impact wrench The combi...

Page 128: ...he secondary clutch Install the clutch puller bolt until it bottoms out Remove the clutch then remove the clutch puller bolt and slide the clutch from the rear axle input shaft Secondary Clutch Repair NOTICE The parts must be assembled again in same position as their original position Mark all components to facilitate accurate reassembly Some small field repairs may be made to the secondary clutch...

Page 129: ...SSION CVT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 111 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 130: ... CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 131: ...s with the leaf springs mounted on top of the rear axle will have an oil dipstick with an H stamped into the top The oil level should be checked with the engine warm The vehicle should be on a level surface with the parking brake engaged Ref Fig 1 Allow adequate time for the oil to drain into the crankcase before checking the oil 1 Clean the area around the oil fill cap 2 Remove the dipstick and w...

Page 132: ...ect skin from exposure to the old oil and degreaser The oil should be changed with engine warm Park the vehicle on a level surface engage parking brake and remove the key from the vehicle Ref Fig 4 Fig 4 Cleaning Top of Engine Be careful of hot oil when drained It may be hot enough to burn you severely 1 Wipe the top of the engine clean with a cloth Remove the oil fill cap 2 Place an oil drain pan...

Page 133: ... on the dipstick Oil should be slightly below the H mark to allow for oil expansion If necessary continue to add oil slowly and allow time for the oil to flow down into the engine 16 Check the oil level on the dipstick Do not overfill Do not overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure Fig 8 Add Engine Oil NOTICE Both the oil dipstick and the fill c...

Page 134: ...n loose dirt may be removed by tapping the filter lightly DO NOT use oil on the filter element or any part of the unit Install the element in the same way it was removed being sure that the cover clips are fastened securely STARTER GENERATOR BELT TEN SION Tool List Qty Belt Tension Gauge 1 Wrench 3 4 1 Wrench 9 16 2 Ratchet 1 Socket 3 4 1 The starter generator belt tension should be checked after ...

Page 135: ...starter generator Hold the lower nut 11 and loosen the upper nut 12 on the starter generator adjusting bolt Ref Fig 12 2 Move the lower nut 11 up or down the adjustment bolt until proper belt tension is achieved Hold the lower nut 11 in place and tighten the upper jam nut 12 against it the lower nut to the specified torque value below 3 Using a socket and open end wrench tighten the starter genera...

Page 136: ...olts 13 and hard ware loosely in place 6 Install the belt Tighten a new starter generator belt per STARTER GENERATOR BELT TENSION 7 Tighten the jam nut 12 pivot bolts 13 and nuts 14 to the torque value specified below 8 Install the wires as shown below and tighten the ter minals firmly into place 9 Reconnect the battery Fig 13 Starter Generator Wire Connections Fig 14 Starter Generator Wiring COOL...

Page 137: ...ons in the air intake system Incorrect valve adjustment Spark plug wire in poor condition Poor quality fuel Use care not to over tighten the spark plug Over tightening can cause damage to the aluminum cyl inder head threads Remove and inspect the spark plug at the intervals indicated in the Periodic Service Schedule The spark plug should be properly gapped CYLINDER HEAD Compression Leak Down Test ...

Page 138: ...ake valve Leaking from the tail pipe indicates poor exhaust valve sealing Air leaking around the outside of the head gasket flange indicates a blown head gasket Rocker Cover Removal Tool List Qty Ratchet 1 Extension 6 1 Socket 10 mm 1 1 Remove the four bolts 5 securing the rocker cover 2 Remove the rocker cover 6 and the gasket Fig 17 Rocker Cover Valve Clearance Inspection Tool List Qty Allen Bit...

Page 139: ... or an engine hoist will be needed to remove the engine If a hoist is employed it will be necessary to remove the canopy 1 Disconnect the negative battery cable 2 Disconnect the air hose at the carburetor 3 Lift the rear of vehicle as directed in the SAFETY section Use jack stands for stability 4 Remove the drive belt by rotating clutch toward the rear of the vehicle when the belt is slipped off t...

Page 140: ...particular attention to assure that the lines are connected correctly It is important to follow the assembly sequence rec ommended for the mounting hardware 1 With the assistance of a hoist or another person lower the engine into position over the engine sup port castings 2 Install one rear horizontal and one front bottom engine bolt through the casting and engine finger tighten 3 Install the rema...

Page 141: ...ll of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 123 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 142: ...d Service Manual ENGINE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 143: ...ular attention to Notices Cautions Warnings and Dangers 125 Repair and Service Manual 653045 FUEL SYSTEM Fig 1 Fuel System Front of Vehicle To Crankcase Pulse To Carburetor Fuel Pump Carbon Canister 32 17 24 20 31 26 14 Air Cleaner Fuel Tank P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 144: ... on the underside of the car buretor The correct fuel level is maintained by means of the float and needle valve As the fuel flows from the fuel pump it must pass through the needle valve and into the float chamber As the fuel enters the float chamber the float starts to rise against the needle valve When the buoyancy of the float exceeds the fuel pressure on the needle valve the float closes the ...

Page 145: ... cable must be removed from battery refer to SAFETY section FUEL SYSTEM COMPONENT SER VICE AND REPLACEMENT Choke Cable and Housing Removal Tool List Qty Open End Wrench 10 mm 2 Open End Wrench 7 8 1 1 Loosen the nuts 3 that secure the choke cable to the choke cable bracket 5 Ref Fig 3 Ref Fig 4 2 Lift the choke cable and housing 2 clear of the bracket and position it so that the bullet end of the ...

Page 146: ... choke knob are both in the open posi tion Adjust the position of the curved portion of the cable housing to ensure that the cable does not contact other moving parts Check the cable to be sure that there are no sharp bends or kinks in the cable before firmly tighten ing the nuts at both ends of the cable Fig 5 Carburetor Operation Carburetor Removal Tool List Qty Socket 10 mm 1 Ratchet 1 Extensio...

Page 147: ...the B side top edge of a properly adjusted float will be slightly above parallel to the bowl gasket surface and both sides of the float will be level with each other Ref Fig 7 If the sides of the float are not parallel or if the B side of the float is not slightly above parallel with the bowl gasket surface then the float should be replaced Reinstall the bowl washer and the screw Check for fuel le...

Page 148: ... screws that secure it to the bracket located on the seat support frame Ref Fig 8 Installation is in the reverse order of removal Be sure to connect the pulse line to the correct location on the pump Ref Fig 8 Fuel Lines and Filter Tool List Qty Pliers 1 Straight Blade Screwdriver 1 The fuel is supplied to the fuel pump and carburetor through flexible fuel hoses An in line filter 1 is installed in...

Page 149: ...er 1 pull and disconnect the EVAP hose 3 Ref Fig 10 and Ref Fig 11 To dis connect the fuel tank hose 2 disconnect the hose 6 from the CARB canister and remove the fuel hose reducer 7 from the fuel tank hose 2 Press the tabs 5 on the mounting bracket and slide the canister upward to clear the mounting bracket To install a CARB canister position the canister ears above the mounting bracket and push ...

Page 150: ...Service Manual FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 151: ...tor func tions as a generator This is used for charging the battery and for the ignition system Generated output is con trolled by the voltage regulator at 14 25 14 75 V without regard to engine speed However the charging current will vary depending on the condition of the battery If it is fully charged current is controlled at 3 to 5 amps WIRING Before performing any test of wiring components dis...

Page 152: ...LACK LT BLUE A B C D RED WHITE CONN1 KEY SW PUSH ON 1 MICRO SWITCH PUSH ON 9 OIL PRESSURE SENSOR PUSH ON 8 12V PUSH ON 13 USB PUSH ON 19 HORN RING 1 B BATT RING4 B BATT CONN14 ACCESS RELAY RING2 FUSE BLOCK PUSH ON 16 TURN SIGNAL PUSH ON 17 TURN SIGNAL CONN 11 FUEL TANK PUSH ON 3 FUSE BLOCK PUSH ON 12 USB CONN2 HEAD LIGHT SWITCH PUSH ON 14 BRAKE SWITCH PUSH ON 6 CONTROL HARNESS PUSH ON 20 BUZZER PU...

Page 153: ... try a new spark plug then check the condition and the tightness of the spark plug wire Check plug wires by substituting them with good ones 5 Replace the plug if necessary Gap the spark plug 028 030 71 76 mm using a wire type spark plug gauge Testing the Magneto Set the meter to the ohms scale and measure the resis tance as shown in the following illustrations A normal reading with the negative l...

Page 154: ...ood limit switch A reading of greater than 2 indicates that the switch terminals should be checked A reading of infinity a visual signal indicates that the switch must be replaced Connect the battery 3 Check the starting solenoid operation Turn the key switch to the ON position a Place the DVOM set to the appropriate DC volts scale negative probe on terminal A of the solenoid Place the positive pr...

Page 155: ...inding green lead is not grounded If it is not replace the regulator h If the reading is below 14 volts disconnect the regulator s green field wire from the system har ness Temporarily connect the green field wire to ground If the voltage rises above its prior read ing replace the regulator i If the above procedures do not correct the prob lem check for faults in the vehicles wiring har ness and o...

Page 156: ...lacement 1 Clean commutator with a soft clean cloth 2 Replace any damaged or cracked brush holders or brushes worn to less than 11 16 17mm in length or to the line marked on the brush 3 Test the insulation between the core and the commu tator segments and shaft with a circuit tester If conti nuity is indicated the insulation is defective and the armature must be replaced 4 With the brushes removed...

Page 157: ...use and care of the meter Fig 8 DVOM FAULT TESTING Knowledge of use of wiring diagrams and a Digital Volt Ohm Meter DVOM is necessary to effectively determine fault within the circuits that include the horn lighting brake turn signals and gages The wiring diagram shows the path followed by a voltage or signal from its origination point to its destination Each wire is indicated by color and is divi...

Page 158: ...lt age indicates that the power wire is in good condition NOTICE The power wire supplies power to the entire fuse block 4 Check fuse Place the red probe to each wire terminal on the fuse block A reading of battery voltage indicates that the fuse is in good condition No reading indicates a faulty fuse replace with a good 15 amp fuse ACCESSORY WIRING After determining that there is power to the fuse...

Page 159: ... Replace with a new LED headlight assembly and install headlight assembly in the reverse order of removal Taillight Replacement To replace the taillight bulb or the brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Ref Fig 9 Install replacement bulb and replace lens Headlight taillight bulbs and fuses are available from a local Distributor an authorized B...

Page 160: ...Service Manual ELECTRICAL Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 161: ...n before disconnecting power by removing the negative connection to the bat tery To check for continuity set the DVOM to the KΩ setting and select Continuity The meter will give an audible signal when it detects continuity If the meter does not have a continuity setting set it to KΩ the meter will indi cate 0 when it detects continuity Testing a Switch for Continuity Place one probe on one contact...

Page 162: ...ter Internal engine damage Inspect and repair Crankcase over filled with oil Drain and fill to recommended level with approved oil STARTER ROTATES BUT VEHICLE WILL NOT START OR HARD TO START Weak battery Recharge or replace as necessary Corroded or loose battery connec tions Clean and tighten battery connections Apply a coat of battery protectorate to terminals Check for adequate fuel level Fill w...

Page 163: ...t fuel check bulk storage tank for proper storage and handling See GENERAL SPECIFICATIONS Air leak allowing dirt to enter system Repair or replace air intake hose EXCESSIVE EXHAUST SMOKE Wrong oil weight Replace with recommended oil See GENERAL SPECIFICA TIONS Dirty oil Replace See GENERAL SPECIFICATIONS Crankcase overfilled with oil Drain and fill to recommended level See GENERAL SPECIFI CATIONS ...

Page 164: ...Incorrect tire pressure Inflate to recommended pressure See GENERAL SPECI FICATION Improper alignment Incorrect toe in Align front tires PLAY IN STEERING Steering wheel loose Inspect splines replace steering wheel if required Tighten steering wheel nut Steering components worn Replace Loose wheel bearings Adjust or replace VIBRATION Steering components worn Replace Loose wheel bearings Adjust or r...

Page 165: ...ad all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 147 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 166: ...ervice Manual FAULT TESTING Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 167: ...cification Overall Length 115 0 in 292 10 cm Overall Width 49 4 in 125 48 cm Overall Height No Canopy 47 3 in 120 14 cm Top of steering wheel Overall Height With Canopy 70 5 in 179 07 cm Wheel Base 76 8 in 195 07 cm Front Wheel Track 35 0 in 88 90 cm Rear Wheel Track 38 5 in 97 79 cm Ground Clearance at Differential 3 5 in 8 89 cm Cargo Box Width inside 44 0 in 111 76 cm Cargo Box Length inside 39...

Page 168: ...ering Self compensating rack and pinion Front Suspension Leaf springs with hydraulic shock absorbers Rear Suspension Leaf springs with hydraulic shock absorbers Service Brake Rear wheel mechanical self adjusting drum Parking Brake Self compensating single point engagement Front Tires K500 18 X 8 5 8 6 Ply Rated Rear Tires K500 18 X 8 5 8 6 Ply Rated Frame Welded steel with DuraShieldTM powder coat...

Page 169: ...S Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 151 Repair and Service Manual 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 170: ...vice Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 653045 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 171: ... use SCHEDULED MAINTENANCE CHART Perform all services at the maintenance interval reached first S Indicates operations that need to be performed on vehicles subjected to severe use E Indicates emission related services Failure to do this maintenance will not void the emissions warranty but may affect emissions D Indicates services that must be performed by an authorized dealer frequent or prolonge...

Page 172: ...rods loose or missing hardware Choke cable 20 Monthly Check for smooth movement Carburetor linkage 20 Monthly Check attachment adjust as necessary Engine 20 Monthly Check for unusual noise vibration acceleration oil leaks Rear axle 20 Monthly Check for leakage add oil as required S General lubrication 50 3 Months Lubricate all fittings pivots cables etc where required Throttle governor linkage 50 ...

Page 173: ...oose or missing hardware S Rear axle 250 300 Yearly Check fluid level add if required S Front wheel bearings 250 300 Yearly Check and adjust as necessary S Brakes 250 300 Yearly Clean and adjust Check brake shoe linings replace if necessary S Muffler exhaust system 250 300 Yearly Check hardware Inspect for leaks at head and muffler gas kets Valves intake exhaust 250 300 Yearly Check cold S E Spark...

Page 174: ... gal 22 7 L Unleaded 87 octane min 10 ethanol content max Rear axle oil 51 oz 1 5 L SAE 30 Rear axle friction modi fier 2 oz 60 ml Grease fittings Universal joint grease or equivalent Do not exceed 3 pumps of grease in each fitting Item Capacity Lubricants Fluids Notes Item Part Number Oil Filter 607454 Air Filter 28463G01 Spark Plug NGK BPR2ES 607462 Starter Generator Belt 26414G1 Clutch Belt 618...

Page 175: ...efore and during turns Bring the vehicle to a complete stop before you move the direction selector See GENERAL SPECIFICATIONS for the vehicle load and seat capacity NOTICE Read the following maintenance information and warnings before servicing or repairing the vehicle Follow the procedures and comply with the safety information in this manual while performing vehicle service or maintenance Use th...

Page 176: ...arvin Griffin Road Augusta Georgia USA 30906 3852 North America Technical Assistance Warranty PHONE 1 800 774 3946 Service Parts PHONE 1 888 438 3946 International PHONE 001 706 798 4311 cushmancomm textron com Service Parts Manuals and Repair and Service Manuals are available from a local Distributor or an authorized Branch CONTACT INFORMATION P r o p e r t y o f A m e r i c a n A i r l i n e s ...

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Cushman HAULER 1200, Repair Manual

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