Cushman HAULSTER 898487 Parts And Maintenance Manual Download Page 3

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TABLE OF CONTENTS

SECTION PAGE
1

General Information

Inside Front Cover

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification
2.1

Vehicle Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Serial & Model Number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Engine Serial Number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications
3.1

Vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Capacities

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Fuel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

Brake Fluid

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Engine Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Lubrication

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Gear Ratios

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10

Engine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance
4.1

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Maintenance Guide

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Lubrication Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Bulbs and Flasher

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6

Engine Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

Engine Access

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8

Engine Oil Level

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10

Jump Starting With Booster Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11

Engine Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12

Draining The Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13

Filling the Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14

Air Cleaner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15

Servicing Air Cleaner Element

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16

Checking Air Cleaner Element

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.17

Installing Air Cleaner Element

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.18

Lubricating Brake Pedal Bushings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.19

Automatic Transmission

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.20 Differential

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.21

Master Cylinder Access

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.22

Jacks, Jacking Locations And Using A Hoist

. . . . . . . . . . . . . . . . . . . . . . .

4.23

Changing The Rear Wheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.24

Changing The Front Wheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25

Tire Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.26

Extended Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9

Exhaust Manifold

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for HAULSTER 898487

Page 1: ...PARTS AND MAINTENANCE MANUAL HAULSTER POLICE VEHICLE MODEL 898487 Part No 2702455 Rev A...

Page 2: ...his 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 IMPOR...

Page 3: ...illing 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...

Page 4: ...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 Hydrauli...

Page 5: ...hed 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 sta...

Page 6: ...s 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...

Page 7: ...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 P...

Page 8: ...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 mainten...

Page 9: ...ecommended 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 rep...

Page 10: ...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...

Page 11: ...an 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 remo...

Page 12: ...arefully 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...

Page 13: ...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 radi...

Page 14: ...ccur 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 damag...

Page 15: ...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 c...

Page 16: ...l 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...

Page 17: ...W 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...

Page 18: ...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 Grad...

Page 19: ...17 PROBLEM SERVICE PERFORMED DATE INITIALS SERVICE AND MAINTENANCE RECORD...

Page 20: ...6 1 ENGINE GASKETS 18 1 2 3 4 5 6 7 8 9 10 11 FRONT OF VEHICLE...

Page 21: ...sket intake manifold 1 4 2701797 Gasket exhaust manifold 1 5 2701798 O ring cam position sensor 1 6 2701799 Gasket cylinder plate 1 7 2701800 Gasket oil pump case 1 8 2701801 Gasket water pump 1 9 270...

Page 22: ...6 2 CYLINDER HEAD 20 20 21 19 17 16 4 24 23 3 15 22 8 7 12 13 11 9 10 6 5 14 14 1 2 18 FRONT OF VEHICLE 26 25...

Page 23: ...1 13 2701823 Bolt 13 14 2701824 Pin 2 15 2701825 Bolt cylinder head 8 16 2701826 Plate cylinder head 1 17 2701827 Screw 2 18 2701828 Cover cylinder head 1 19 2701829 Bolt 4 20 2701830 Cap oil filler 1...

Page 24: ...6 3 CYLINDER BLOCK 22 3 4 5 4 9 10 11 12 6 7 8 4 2 1 FRONT OF VEHICLE 21 16 17 15 19 20 22 18 13 14 16...

Page 25: ...re 1 10 2701905 Wire oil pressure 1 11 2701906 Clamp 1 12 2701907 Bolt 1 13 2701911 Pan oil 1 14 2701912 Bolt 14 15 2701913 Stud 2 16 2701914 Nut 2 17 2701915 Plug oil drain 1 18 2701916 Gasket oil dr...

Page 26: ...6 4 CRANKSHAFT PISTONS 24 1 4 4 3 2 5 6 7 9 14 8 10 15 13 12 11 18 19 16 17 20 21 FRONT OF VEHICLE 22...

Page 27: ...2701934 Crankshaft 1 9 2701935 Bearing set crankshaft 1 2701936 Bearing set crankshaft US 0 25 1 10 2701937 Bearing set crank thrust 1 2701938 Bearing set crank thrust US 0 25 1 11 2701939 Seal front...

Page 28: ...6 5 CAMSHAFT 26 4 5 11 10 8 5 3 16 15 14 18 17 12 13 17 18 14 9 7 16 15 6 2 1 FRONT OF VEHICLE 19...

Page 29: ...rm rocker exhaust 6 8 2701961 Screw adjusting 6 9 2701962 Screw valve adjusting 6 10 2701963 Nut adjusting intake 12 11 2701965 Washer wavy 4 12 2701966 Valve intake 6 13 2701967 Valve exhaust 6 14 27...

Page 30: ...6 6 TIMING BELT COVER 28 1 12 4 5 3 17 19 18 11 16 15 14 6 13 8 7 2 10 FRONT OF VEHICLE 13 9...

Page 31: ...t 4 6 2701978 Bolt 5 7 2701834 Bolt 3 8 2701980 E ring 1 9 2701981 Seal 1 10 2701979 Seal cover outside 1 11 2701982 Seal 1 12 2701983 Seal set 1 13 2701984 Cap 2 14 2701985 Belt timing 1 15 2701986 T...

Page 32: ...6 7 INTAKE MANIFOLD THROTTLE BODY 30 FRONT OF VEHICLE 27 29 18 22 21 20 19 24 23 26 28 11 34 1 9 10 25 32 32 32 31 32 30 8 33 4 4 5 3 6 12 35 7 14 13 16 15 14 TO WATER INLET PIPE...

Page 33: ...t 1 17 2701827 Bolt 1 18 2702476 Body throttle 1 19 2701995 Sensor throttle position 1 20 2701996 Screw 2 21 2702477 Sensor pressure 1 22 2701998 Screw 2 23 2702478 Valve isc 1 24 2702000 Gasket 1 25...

Page 34: ...ANER 1 4 5 8 7 1 2702488 Hose breather 1 2 2702484 Clip hose 1 3 2702485 Clamp 1 4 2702486 Bolt 1 5 2702488 Hose PVC 1 6 2702489 Seal 1 7 2702490 Valve PCV 1 8 2702491 Clip 2 Ref No Part No Descriptio...

Page 35: ...Nut 3 5 2702495 Bolt 1 6 2702496 Cover manifold upper 1 7 2702497 Cover manifold lower 1 8 2701913 Stud bolt 2 9 2702498 Nut 2 10 2702499 Bolt 6x10 5 11 2702500 Ring seal 1 12 2702501 Spring 2 13 2702...

Page 36: ...6 10 OIL PUMP 34 3 2 5 6 4 8 7 1 FRONT OF VEHICLE...

Page 37: ...ump 1 3 2702517 Screw 5 4 2702518 Valve oil relief 1 5 2701800 Gasket oil pump cover 1 6 2701949 Pin 2 7 2702519 Bolt 4 8 2702520 Bolt 4 Ref No Part No Description Notes No Req d INDENTED PART NAMES I...

Page 38: ...ET THERMOSTAT 36 6 7 4 5 2 1 3 25 26 19 20 21 22 23 24 17 18 16 15 27 NOTE ON EARLY VERSIONS THE TEMPERATURE SENSOR WAS MOUNTED IN ITEM 17 LATER VERSIONS HAVE THE TEMPERATURE SENSOR ITEM 21 MOUNTED IN...

Page 39: ...2700031 O ring 1 15 845224 Cap 313 x 1 1 16 825624 Clamp hose 1 17 2701637 Housing thermostat 1 18 452392 Screw M8 1 25 x 50 3 19 2701638 Spacer thermostat 1 20 2701513 Gasket thermostat spacer 1 21 2...

Page 40: ...6 12 STARTER 38 1 FRONT OF VEHICLE 8 7 10 12 11 4 3 14 2 6 13 5 3 9...

Page 41: ...6 2702898 Holder assembly brush 1 7 2702899 Lever assembly 1 8 2702900 Switch assembly 1 9 2702908 Bolt 2 10 2702909 Armature 1 11 2702903 Ring assembly 1 12 2702904 Clutch assembly 1 13 2702905 Wash...

Page 42: ...6 13 DRIVESHAFT TORQUE CONVERTER 40 13 12 10 9 11 3 6 2 1 3 4 5 8 7 FRONT OF VEHICLE...

Page 43: ...5 Yoke front 1 6 2701463 Shaft drive 1 7 2702697 Transmission complete 1 8 2702698 Flange drive plate 1 9 2702699 Plate drive flywheel 1 10 2702700 Plate drive rear 1 11 2701951 Bolt 6 12 2702701 Conv...

Page 44: ...6 14 AUTOMATIC TRANSMISSION 42 16 2 3 15 16 1 18 19 11 9 21 13 FRONT OF VEHICLE 14 17 4 7 17 12 11 10 8 5 6 20...

Page 45: ...ion 1 9 2702683 Seal extension case 1 10 2702755 Bolt 5 11 2702494 Nut 2 12 2702756 Bolt 1 13 2702686 Bolt 1 14 2702757 Stud 1 15 2702758 Stud 1 16 2702689 Nut 2 17 2702690 Collar 2 18 2702759 Hook en...

Page 46: ...6 15 AUTOMATIC TRANSMISSION PAN DIPSTICK GASKETS 44 2 1 6 7 3 4 5 9 10 11 12 13 FRONT OF VEHICLE 14 8...

Page 47: ...6 2702811 Tube transmission dipstick 1 7 2702813 O ring 1 8 2702475 Bolt 1 9 2702816 Harness solenoid wire 1 10 2701921 Bolt 1 11 2702817 Plate solenoid harness 1 12 2702748 Set transmission gasket 1...

Page 48: ...6 16 TRANSMISSION TUBES OIL PUMP SOLENOIDS SHIFT SWITCH 46 7 6 5 8 9 14 15 10 11 12 13 13 FRONT OF VEHICLE 2 1 3 4 4 21 22 To Oil Cooler 20 16 17 18 19...

Page 49: ...Solenoid direct clutch 1 10 2702823 O ring 1 11 2702824 Solenoid 2nd brake 1 12 2702823 O ring 1 13 2702764 Bolt 2 14 2702885 Switch shift 1 15 2702886 Bolt 1 16 2702881 Joint transmission shifter 2...

Page 50: ...6 17 TRANSMISSION INPUT SHAFT CLUTCH 48 7 6 5 8 1 2 4 3 FRONT OF VEHICLE...

Page 51: ...et forward clutch 1 4 2702772 Bearing set thrust No 1 1 5 2702773 Clutch assembly direct 1 6 2702774 Plate set direct clutch 1 7 2702775 O ring set direct clutch 1 8 2702776 Washer set direct clutch 1...

Page 52: ...6 18 TRANSMISSION PLANETARY GEARS OUTPUT SHAFT 50 FRONT OF VEHICLE 14 17 16 15 18 1 3 4 5 6 2 10 9 8 7 12 13 11...

Page 53: ...rust 1 8 2702785 Bearing set thrust No 1 1 9 2702784 Gear rear planetary 1 10 2702786 Clutch set 1 way 1 11 2702787 Plate set 1st reverse 1 12 2702788 Piston set 1st reverse 1 13 2702789 O ring set 1s...

Page 54: ...6 19 BRAKE BAND SHIFT SHAFT 52 2 3 4 1 FRONT OF VEHICLE 5...

Page 55: ...brake 1 4 2702804 Cover set 2nd brake 1 5 2702801 Ring set 2nd brake seal 1 6 2702796 Pole set parking 1 7 2701921 Bolt 3 8 2702797 Shaft set lever 1 9 2702798 Seal 2 10 842740 Lever shifter 1 Ref No...

Page 56: ...6 20 TRANSMISSION VALVE 54 1 2 14 11 13 12 10 4 9 4 5 6 5 8 3 8 7 4 3 6 5 5 5 5 FRONT OF VEHICLE 17 19 18 15 16 15 16...

Page 57: ...valve body No 4 2 9 2702838 Bolt valve body No 6 1 10 2702828 Piston set C1 accumulator 1 11 2702829 Spring forward piston 1 12 2702830 Piston set B1 accumulator 1 13 2702833 Seal ring set accumulator...

Page 58: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 27 LEFT RIGHT 9 18 13 9 30 28 20 20 LEFT 20 11 10 LEFT 1 20 7 10 11 7 10 11 20 33 7 RIGHT RIGH...

Page 59: ...Nut 5 16 18 12 19 306981 Washer 13 32 8 20 308090 Washer 1 4 22 21 548175 Washer 1 4 2 22 548911 Nut 5 16 18 1 23 800290 Nut 5 16 18 centerlock 2 24 800390 Rivet 1 8 x 25 64 2 25 810152 Cover 1 26 821...

Page 60: ...6 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 TO MAIN FRAME TO MAIN FRAME 8 31 34 REF LEFT RIGHT 1 19 REF 17 9 1 13 19 7 18 17 9 1 17 9 1 1 1 9 17 10 11 19 29 12 18 13 17 9 2 16 3 Touch U...

Page 61: ...x 5 8 2 15 306531 Nut 10 24 6 16 306562 Nut 3 8 16 3 17 306932 Nut 5 16 18 16 18 306981 Washer 13 32 10 19 308090 Washer 1 4 16 20 548238 Rivet 3 16 x 5 8 6 21 800177 Screw 5 16 18 x 3 4 4 22 800271 S...

Page 62: ...6 23 FRONT BODY 60 15 17 17 12 7 25 25 6 1 4 2 3 4 5 16 1 10 7 8 4 24 4 3 2 1 4 3 2 21 9 11 22 8 4 3 1 5 3 4 11 4 3 2 20 23 19 18 14 13 7 2 3 4 11 11 11 REF...

Page 63: ...crew P T H 1 4 20 x 3 4 10 12 800739 Screw P T H 1 4 20 x 1 1 2 6 13 889159 Panel dash 1 14 829101 Plug hole defroster 1 15 837303 Headlight rectangular 2 16 843210 Panel front body 1 17 843209 Panel...

Page 64: ...6 24 ENGINE COVER 62 14 8 5 2 13 11 18 1 3 4 6 7 9 10 12 15 16 17...

Page 65: ...378 Weatherstrip 50 15 2M As Req d 8 829880 Pad panel 1 9 830780 Catch latching 1 10 830781 Retainer engine cover 1 11 830908 Seal push on 25 7 6M As Req d 12 831004 Weatherstrip 25 7 6M As Req d 13 8...

Page 66: ...6 25 FLOORMAT INSULATION WEATHERSTRIP MOLDINGS 64 8 6 14 3 16 13 10 12 2 4 7 5 11 1 15 9...

Page 67: ...378 Weatherstrip As Req d 7 828733 Molding window 3 8 828834 Foam 1 9 828976 Seal push on 25 7 6 M As Req d 10 829735 Foam roof 1 11 830355 Seal rubber 35 10 7M As Req d 12 830908 Seal push on 25 7 6M...

Page 68: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 28 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 41 40 36 36 7 8 13 7 8 13 8 7 13 6 14 17 8...

Page 69: ...0441 Grommet 2 29 812208 Hinge continuous 1 30 814585 Bushing 2 31 816307 Washer 17 64 2 32 821164 Pin hair 1 4 x 1 1 8 6 33 821427 Washer sealing 1 4 11 34 824484 Latch 2 35 824576 Plate 2 36 828378...

Page 70: ...6 27 REAR SPRING 68 5 9 2 6 6 5 11 16 10 1 1 15 14 3 7 4 13 12 1 8 9 5 6 2...

Page 71: ...4 7 834979 Upstop 2 8 886014 Spring rear 2 9 821734 Bushing 2 10 886016 Shackle spring 2 11 805196 Bushing 2 12 887187 U bolt 2 51 mm w nuts 2 13 548061 Nut lock 7 16 20 2 14 887188 U bolt 2 1 2 64 mm...

Page 72: ...6 28 FRONT FORK 70 8 20cm 9 1 6 5 30 31 29 2 4 7 8 11 3 12 10 13 1 3cm 25 24 23 19 15 17 21 27 22 20 18 17 28 27 26 23 19 15 16 14...

Page 73: ...ork complete 1 15 120177 Lockwasher 3 8 4 16 306562 Nut 3 8 16 2 17 306835 Screw 3 8 16 x 1 1 4 4 18 311396 Screw 7 16 14 x 2 1 4 2 19 604174 Washer 3 8 4 20 800293 Nut lock 7 16 14 2 21 808969 Bushin...

Page 74: ...6 29 STEERING GEAR WHEEL HORN 72 3 11 8 9 1 5 9 1 6 22 29 14 33 31 32 30 19 18 17 10 36 7 4 29 14 2 4 27 12 15 16 13 21 28 24 25 20 26 12 34 35 23...

Page 75: ...rn button contact 1 19 816654 Button horn 1 20 816659 Key 5 32 x 5 32 x 1 1 4 1 21 816660 Shaft pinion gear 1 22 816674 Support steering housing front 1 23 816675 Support steering housing rear 1 24 82...

Page 76: ...6 30 THROTTLE PEDAL 74 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 REF TOP OF GOVERNOR REF WELDED TO FLOORBOARD 17...

Page 77: ...Cable throttle police EFI 1 8 306414 Screw 3 8 16 x 1 2 9 306555 Screw 5 16 18 x 5 8 2 10 306981 Washer 13 32 2 11 521679 Bushing 2 12 800290 Nut 5 16 2 13 800292 Nut 3 8 2 14 800927 Screw 1 4 20 x 5...

Page 78: ...6 31 ALTERNATOR GOVERNOR 76 G W G W R B R R 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 REF ENGINE EXISTING EXISTING 1 EXISTING EXISTING 17 17 25 17 18...

Page 79: ...20 1 14 306396 Lockwasher 1 4 1 15 306416 Screw 5 16 18 x 1 1 16 306463 Pin cotter 1 17 306981 Washer 13 32 5 18 308090 Washer 1 4 2 19 311213 Screw 3 8 16 x 3 1 20 450454 Nut M10 1 1 21 452388 Screw...

Page 80: ...6 32 HOSES AIR FILTER 78 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 EXISTING 12 EXISTING 11 EXISTING 12 10 EXISTING TO RADIATOR TO LEFT SIDE BODY PANEL REF ENGINE 20 EXISTING...

Page 81: ...8 2702301 Hose high temperature air 1 9 452392 Bolt M8 1 25 x 50 2 10 820889 Clamp 2 823549 Tie cable 15 5 394 mm 1 Not illustrated 11 825358 Clamp 3 12 825624 Clamp 4 13 826590 Hose fuel 25 7 6 M As...

Page 82: ...6 33 OIL FILL FILTER 80 REF ENGINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 17 14 EXISTING EXISTING REF ENGINE HARNESS GROUND WIRES 10 11 10 11 10 EXISTING 16 29...

Page 83: ...0425 Screw M6 1 00 x 12 4 12 800548 Screw M8 1 25 x 20 1 13 800571 Nut 10 1 25 1 14 825624 Clamp hose 3 15 830929 Hose 1 16 836206 Clamp hose 2 17 842944 Fitting 2 18 843058 Nut starter motor 1 19 843...

Page 84: ...6 34 SHIFTER SHIFT CABLE 82 1 2 3 4 5 6 7 8 9 10 REF CONSOLE MAT REF SHIFT LEVER ON TRANSMISSION REF CABLE BRACKET ON TRANSMISSION 11...

Page 85: ...amp 1 Not offered separately 6 Bracket cable clamp 1 Not offered separately 7 Pin rod connecting 2 Not offered separately 8 306372 Pin cotter 3 32 x 1 2 1 9 800146 Screw 10 tapping 4 10 817019 Bushing...

Page 86: ...6 35 FRONT BRAKES AXLE HUB 84 22 23 20 27 29 29 20 28 23 22 24 19 13 14 9 8 9 14 13 8 16 17 11 26 32 36 31 1 2 3 5 6 35 15 33 40 43 41 37 42 12 10 30 7 18 39 38 21 25 4 1 2 3 5 34...

Page 87: ...20 x 1 13 16 5 22 807630 Seal 2 23 809229 Slinger oil 2 24 831199 Nut bearing adjusting 1 25 833993 Drum brake 1 26 884022 Axle 1 27 888524 Hub 1 28 808088 Cup tapered roller bearing 2 29 809268 Ring...

Page 88: ...HEEL CYLINDER 86 1 2 4 L 7 R 6 L 10 R 11 R 33 L 26 R 38 L 5 L 8 R 9 29 R 47 L 17 R 36 L 15 12 13 21 R 39 L 16 R 35 L 23 R 43 L 28 R 46 L 41 L 19 R 18 R 40 L 3 27 22 R 42 L 25 R 45 L 24 R 44 L 14 R 34...

Page 89: ...777 Dust shield RIGHT 1 27 824925 Cap 1 28 889350 Brake kit two brake shoes 1 29 833918 Spring retainer 1 30 834723 Pin brake 1 31 838355 Guide brake spring 1 Not illustrated 32 Shoe brake 2 Not offer...

Page 90: ...6 37 HYDRAULIC BRAKE SYSTEM 88 22 16 6 1 2 14 25 23 1 3 7 25 24 11 10 13 29 13 28 27 9 5 4 13 15 20 10 26 17 18 8 12 19 19 19 21 30...

Page 91: ...17 824219 Protector brake hose 1 18 824731 Protector brake hose 1 19 825477 Clip 3 20 828072 Tube brake front 1 21 829049 Tube brake right rear 1 22 832584 Clamp tee mounting 1 23 832585 Bracket brak...

Page 92: ...6 38 MASTER CYLINDER BRAKE ROD 90 12 13 11 22 20 21 19 16 17 18 2 5 14 6 15 10 4 1 7 8 3 9...

Page 93: ...Rod push 1 11 886519 Plug set filler includes parts shown 1 12 829155 Label warning 1 13 829558 Gasket filler plug 1 14 886874 Kit repair includes parts shown 1 15 811928 Boot 1 16 892040 Bolt kit mas...

Page 94: ...6 39 PARKING BRAKE 92 5 2 1 14 7 3 8 12 10 11 15 6 9 13 4 11 11 16 8 11 11 6 2...

Page 95: ...t 5 16 18 3 7 800290 Nut lock 5 16 18 1 8 800446 Nut stop 5 16 24 2 9 806703 Pin clevis 5 16 x 1 1 10 810437 Clamp 1 11 825126 Bushing 5 12 838095 Cable parking brake RIGHT 67 15 16 1745 mm 1 13 83809...

Page 96: ...6 40 SEAT BELT 94 1 2 3 4 5 6 7 8 9 10 11 12 13 12 4 1 3 1 1 3 12 1 3...

Page 97: ...3 306562 Nut 3 8 16 4 4 306834 Screw 3 8 16 x 3 4 4 5 306981 Washer 13 32 2 6 311395 Screw 7 16 14 x 1 3 4 1 7 316942 Pin spirol 1 4 x 1 2 1 8 821702 Washer 29 64 4 9 831783 Washer 17 32 1 10 843081 P...

Page 98: ...6 41 SEAT BACKREST 96 12 10 7 11 4 1 5 6 3 8 9 Cover Black 13 15 Cover Black 14 2...

Page 99: ...71 Screw P T H 10 24 x 1 2 3 8 884302 Backrest 1 9 825967 Cover backrest black 1 10 894136 Seat w hinge 1 11 800215 Screw P T H 10 24 x 5 8 17 12 812208 Hinge 1 13 885947 Seat 1 817606 Nut tee 10 24 1...

Page 100: ...6 42 FUEL SYSTEM 98 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 16 17 18 19 21 22 23 24 25 26 27 28 9 20 20 20 13 18 17 18 11...

Page 101: ...306375 Nut 1 4 20 5 12 306836 Screw 3 8 16 x 2 1 4 4 13 306932 Nut 5 16 18 4 320107 Tie cable 7 1 2 191 mm 5 Not illustrated 14 548804 Nut 3 8 16 4 15 548900 Screw 10 24 x 1 2 5 16 800875 Nut 12 1 25...

Page 102: ...6 43 EXHAUST SYSTEM 100 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 REF CROSSMEMBER REF EXHAUST MANIFOLD 6 4 5 8...

Page 103: ...8 3 7 548159 Washer 5 16 1 8 841982 Clamp tubing 2 9 14183 82050 Seal ring muffler flange 1 10 09119 10039 Bolt muffler flange 2 11 14492 82001 Spring muffler flange 2 12 842884 Tailpipe 1 13 887175 H...

Page 104: ...31 32 33 10 78 21 22 23 28 29 30 38 4 9 25 26 27 35 18 14 16 20 35 42 41 41 40 19 37 15 49 15 13 39 43 46 20 58 7 34 6 36 48 47 24 56 1 5 2 3 8 11 79 64 68 71 76 69 70 68 72 73 31 32 33 66 74 75 67 17...

Page 105: ...16 8 25 812335 Seal oil 1 26 814226 Housing bearing 1 27 814465 Gasket 2 28 814466 Shim 005 As Req d 29 814467 Shim 010 As Req d 30 814468 Shim 030 As Req d 31 814469 Shim 003 As Req d 32 814470 Shim...

Page 106: ...31 32 33 10 78 21 22 23 28 29 30 38 4 9 25 26 27 35 18 14 16 20 35 42 41 41 40 19 37 15 49 15 13 39 43 46 20 58 7 34 6 36 48 47 24 56 1 5 2 3 8 11 79 64 68 71 76 69 70 68 72 73 31 32 33 66 74 75 67 17...

Page 107: ...nuts 2 5 cm 1 61 548061 Nut lock 7 16 20 2 62 887188 U bolt w nuts 2 1 2 6 cm 1 63 548061 Nut lock 7 16 20 2 64 886999 Gear carrier 1 8 2 1 ratio OR 879962 Gear carrier 1 10 25 1 ratio 65 Housing carr...

Page 108: ...1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 14 14 18 16 25 10 36 37 17 4 4 3 8 8 17 38 39 36 6 45 COOLING SYSTEM 106...

Page 109: ...mp 6 18 828162 Screw M6 1 0 x 16 8 19 832033 Clamp 2 20 831846 Nut isolation 4 21 835805 Hose radiator overflow 4 1 2 M As Req d 22 833512 Foam 2 23 838340 Cooler oil 1 24 842782 Bracket overflow bott...

Page 110: ...ROSTER 108 1 2 3 4 5 7 8 15 42 28 20 9 11 12 13 14 17 18 19 22 24 25 26 27 29 30 31 32 33 34 35 36 38 41 44 45 40 39 6 3 3 4 6 29 6 7 22 22 22 22 22 22 4 6 6 3 4 28 6 4 3 28 9 14 43 23 10 16 21 37 6 R...

Page 111: ...ud threaded 4 20 830355 Weather seal 35 10 7 M As Req d 21 831006 Gasket 1 22 832033 Clamp 10 23 832804 Decal information 1 24 833846 Louver air 2 25 833851 Seal 3 26 833857 Valve ball check 1 27 8338...

Page 112: ...44 34 37 37 12 13 14 13 12 14 1 9 15 17 10 19 16 10 19 1 13 12 DIPSWITCHES SETTING FOR INSTRUMENT PANEL REF CABLE FROM STARTER REF HARNESS WIRES REF FUSE BLOCKS REF HEATER BRACKET REF FRONT FRAME REF...

Page 113: ...Screw 8 32 x 1 2 4 20 800271 Screw 10 24 x 1 2 4 21 800296 Screw 10 24 x 3 4 2 22 800882 Screw 6 32 x 3 4 2 23 800911 Screw 10 24 x 2 1 4 4 24 800943 Screw 10 14 x 5 8 tapping 2 25 817309 Switch dimme...

Page 114: ...28 29 30 31 32 33 34 35 36 5 20 9 8 5 21 21 5 21 5 5 25 21 25 5 11 2 14 6 13 21 21 25 5 36 15 7 12 8 9 15 REF REAR PLATFORM REF CLAMP BRACKET ON ENGINE REF PLATFORM COVER REF ELECTRONIC CONTROL UNIT...

Page 115: ...er 6 shakeproof ext 2 14 308089 Washer 10 4 15 308090 Washer 1 4 11 16 316056 Screw 6 32 x 3 4 2 17 450452 Nut M6 1 00 2 18 452380 Bolt M6 1 00 2 19 548159 Washer 5 16 4 20 548175 Washer 1 4 3 21 5489...

Page 116: ...6 49 DECALS 114 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 117: ...2 Decal Notice Motorcycle 1 7 825622 Decal Warning Brake Fluid 1 8 825629 Decal Warning Vehicle Operation 1 9 832130 Decal Warning Liquid Pressure 1 10 832804 Decal Information 1 11 833607 Decal Warni...

Page 118: ...6 50 HEADLIGHTS TAILLIGHTS TURN SIGNALS 116 1 3 2 4 5 6 8 9 10 3 11 7 14 12 13 15 18 16 19 17...

Page 119: ...contact 2 7 837303 Headlight rectangle 2 8 885964 Lamp turn signal 1 9 825850 Lens black 1 10 825851 Lens amber 1 11 837670 Bulb 1156 1 12 885965 Wire flasher turn signal 1 13 826726 Connector male 1...

Page 120: ...3 1 2 9 10 11 6 7 5 8 8 Standard on New York City Police Modification 53749 Obtain Service Parts from Federal Signal Corporation 2645 Federal Signal Drive University Park IL 60466 Phone 800 433 9132...

Page 121: ...hine 10 24 4 7 308089 Washer 10 4 8 308090 Washer 1 4 8 825973 Connector 6 contact male 1 Not illustrated 826005 Connector 2 contact male 2 Not illustrated 826006 Connector 2 contact female 2 Not illu...

Page 122: ...6 52 TURN SIGNAL SWITCH 120 7 8 11 12 11 12 10 9 5 4 6 2 1 3 13...

Page 123: ...n signal 1 5 840187 Bracket sensor indexing 1 6 2700220 Sensor steering position 1 7 894851 Switch turn signal 1 8 894854 Module control 1 9 825877 Connector female 6 contact 1 10 825894 Connector fem...

Page 124: ...R 122 2 1 6 5 6 3 2 6 5 6 3 4 Ref No Part No Description Notes No Req d 1 308091 Washer 1 2 1 2 311396 Screw 7 16 14 x 2 1 4 3 3 800294 Nut lock 7 16 14 4 4 807332 Absorber shock 1 5 823621 Bushing 4...

Page 125: ...size is now determined by measuring the wheel at the bead seat The first number is wheel diameter measured at bead seat The second number is wheel width measured at bead seat Example a 9 50 x 8 00 tir...

Page 126: ...E THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY Ref No Part No Description Notes No Req d 1 893172 Tire and wheel set radial 1 2 835905 Wheel 4 00 x 12 1 five on 4 1 2 bolt circle 3 886735 Stem valve...

Page 127: ...ATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY Ref No Part No Description Notes No Req d 889445 Bumper set complete 1 1 103867 Washer 5 16 6 2 306325 Lockwasher 5 16 6 3 306416 Screw 5 16 18 x 1 6...

Page 128: ...61 55 41 42 52 14 4 5 8 75 53 83 85 73 74 58 62 50 46 38 4 5 8 From Heater Set 8 11 82 60 57 1 9 2 0 11 16 16 16 16 16 16 25 3 0 3 1 12 7 3 1 7 3 1 6 17 21 18 29 24 26 27 8 4 5 41 42 52 88 92 52 87 4...

Page 129: ...Sealer 3oz tube As Req d Not illustrated 22 829536 Strip filler 1 23 829815 Stud threaded 8 24 829966 Pad foam 1 25 830355 Seal door As Req d 830902 Decal instruction 1 Not illustrated 26 830904 Insu...

Page 130: ...61 55 41 42 52 14 4 5 8 75 53 83 85 73 74 58 62 50 46 38 4 5 8 From Heater Set 8 11 82 60 57 1 9 2 0 11 16 16 16 16 16 16 25 3 0 3 1 12 7 3 1 7 3 1 6 17 21 18 29 24 26 27 8 4 5 41 42 52 88 92 52 87 4...

Page 131: ...er 1 67 828682 Arm wiper 1 68 828736 Trough drip RIGHT 1 69 828972 Trough drip LEFT 1 70 842647 Pad cab back 1 71 829735 Foam sound roof 1 72 832115 Decal CUSHMAN 1 73 833971 Screen vent opening 1 74...

Page 132: ...DOORS 130 60 61 54 16 57 20 10 21 22 2 17 18 14 19 27 4 20 9 44 34 33 59 30 41 46 25 35 58 47 32 45 25 23 29 28 37 38 13 43 31 5 1 1 3 6 11 7 15 12 34 33 51 51 36 48 49 52 53 42 51 50 39 56 24 26 40...

Page 133: ...14 825823 Strap door 1 15 828700 Bracket striker mounting 1 16 828976 Seal push on 25 7 6M As Req d 17 829038 Bracket retainer door strap 1 18 829040 Bracket retainer latch mounting 1 19 829137 Spacer...

Page 134: ...DOORS 132 60 61 54 16 57 20 10 21 22 2 17 18 14 19 27 4 20 9 44 34 33 59 30 41 46 25 35 58 47 32 45 25 23 29 28 37 38 13 43 31 5 1 1 3 6 11 7 15 12 34 33 51 51 36 48 49 52 53 42 51 50 39 56 24 26 40...

Page 135: ...inside 1 47 828699 Rod latch control outside 1 48 828718 Retainer window left 1 49 828719 Retainer window right 1 50 828731 Guide window upper 1 51 828733 Molding window 3 52 828734 Window stationary...

Page 136: ...60 Brake Parking 92 Brake Rod 90 Brakes Front 84 Hydraulic 88 Rear 86 Page Bumper Front 125 Cab 126 Cooling System 106 Decals 114 Differential 102 Doors Steel 130 Electrical Components Front 110 Main...

Page 137: ...Output Shaft 50 Pan 44 Planetary Gears 50 Shift Shaft 52 Shift Switch 46 Shifter Shifter Cable 82 Solenoids 46 Tubes 46 Valve 54 Turn Signal Switch 120 Turn Signals 116 Wheel Measurement 123 Page S Sp...

Page 138: ...21 23 2701820 21 23 2701821 21 2701824 21 2701825 21 2701826 21 2701828 21 2701830 21 2701831 21 2701832 21 2701833 21 2701835 21 2701837 23 2701838 23 2701849 7 111 2701869 111 2701870 81 2701897 99...

Page 139: ...2702797 53 2702798 53 2702800 53 2702801 53 2702804 53 2702805 53 2702806 45 2702808 45 2702809 45 2702810 45 2702811 45 2702813 45 2702814 45 2702816 45 2702817 45 2702821 55 2702822 47 2702823 47 2...

Page 140: ...629 115 825642 129 825679 71 825681 71 825682 71 825779 107 109 825819 133 825823 131 825840 65 133 825842 65 825844 127 825850 117 825851 117 825859 127 825877 121 825880 121 825893 111 825894 121 82...

Page 141: ...6 93 838109 93 838158 119 838223 67 838340 107 838354 111 838355 85 87 838361 119 838402 87 838403 87 838404 87 838409 69 838477 57 838688 57 838706 57 65 839168 111 839197 111 121 839229 83 839905 57...

Page 142: ...888451 85 888497 107 888524 85 888610 85 888663 131 888684 129 888777 87 888793 87 888815 129 888831 129 888832 129 888835 129 888836 129 888842 129 888856 109 888861 87 889050 107 889051 107 889065 1...

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Cushman HAULSTER 898487, Parts And Maintenance Manual

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