Cushman 898627 manuals

Cushman 898627 Service Manual (202 pages)

Brand: Cushman | Category: Engine | Size: 2.30 MB |

English

Table of contents

HAULSTER POLICE VEHICLE

1

25–6–00–CU

2

SECTION 1

3

MANAGEMENT SYSTEM DESCRIPTION

4

Technical Instruction

5

Input circuit

6

A/D Converter

6

Microcomputer

6

Output circuit

6

(1) Fuel injection control

8

(2) Idle speed control

8

Intake air system

9

Ignition system

9

Control system

9

Air intake system

10

Description of intake system

11

Throttle body

11

Idle speed control (ISC)

11

ISC solenoid valve

11

COOLANT TEMPERATURE

12

COMPENSATION

12

ENGINE SPEED (RPM)

12

KEY SWITCH

13

Fuel pump control

14

Conditions Pump ON time

14

Fuel pressure control system

15

Pressure regulator

15

Pulsation damper

15

Drive circuit of injector

16

Asynchronous injection

22

(CONTINUED ON NEXT PAGE)

23

Ignition signal system

25

Ignition control system

26

Fixed ignition

26

Soft ignition control

26

ENGINE SPEED

27

BASE IGNITION ADVANCE

27

PERIODIC MAINTENANCE

29

ALTERNATOR BELT INSPECTION

30

VALVE LASH INSPECTION

30

ENGINE OIL FILTER CHANGE

31

ENGINE OIL CHANGE

31

ENGINE OIL CAPACITY

32

ENGINE COOLANT CHANGE

32

IGNITION COIL

33

TROUBLE SHOOTING

35

 Specified

41

ALTERNATOR

43

ENGINE MECHANICS

45

ENGINE BODY

48

Thrust bearings

50

25.6 φ22.4

53

LUBRICATION SYSTEM

54

INTAKE SYSTEM

56

EXHAUST SYSTEM

56

ENGINE REPAIR

57

 Runout of camshaft:

70

 Cam wear:

70

 Journal wear:

71

 Cylinder bore:

71

 Piston Diameter:

72

 Piston ring end gap:

73

 Big–end thrust clearance:

73

 Connecting rod alignment:

73

 Runout:

75

 Crankshaft thrust play:

75

 Radial clearance:

78

 Side clearance:

78

ENGINE REASSEMBLY

79

CRANKSHAFT

85

PUNCH MARK

87

EMBOSSED MARK

87

ENGINE MAINTENANCE SERVICE

89

ENGINE CONTROL SYSTEM

95

SYSTEM FLOWCHART

99

SYSTEM WIRING DIAGRAM

100

FUEL SYSTEM

101

AIR INTAKE SYSTEM

103

ISC Valve

104

INPUT–OUTPUT SYSTEM

105

PRESSURE SENSOR (PM)

106

SENSOR (OX)

106

Crank Angle Sensor (CAS)

107

Vehicle Speed Sensor (SPD)

107

EMISSION SYSTEM

108

Information Decal

108

Blow–by Gas Recovery Device

109

[Under low engine load]

109

[Under high engine load]

109

Ternary Catalyst Device

109

CONTROL SYSTEM

110

FUEL INJECTION CONTROL

111

ISC STEPPER MOTOR CONTROL

113

MAIN RELAY CONTROL

114

FUEL PUMP RELAY CONTROL

114

CODE RETRIEVAL PROCEDURE

116

ENGINE REMOVAL

119

IGNITION SYSTEM

125

GENERAL DESCRIPTION

126

SPARK PLUGS

127

IGNITION TIMING

128

ADJUSTMENT REGISTER

128

IGNITION TIMING CONTROL

129

ENGINE CONTROL MODULE (ECM)

129

AIR CLEANER

132

FUEL PUMP, FILTER AND LINES

133

 Clamp hoses securely

136

COOLING SYSTEM

137

ENGINE COOLING SYSTEM

138

COMPONENT REMOVAL

139

7) Remove water pump

141

CRANKING SYSTEM

147

Operation

148

CRANKING CIRCUIT

149

STARTING MOTOR

150

STARTER MOTOR INSPECTION

153

PERFORMANCE TEST

155

NO–LOAD PERFORMANCE TEST

155

CHARGING SYSTEM

157

ALTERNATOR DESCRIPTION

158

CARRIER AND HOLDDOWN

159

VISUAL INSPECTION

159

JUMP STARTING

159

UNDERCHARGED BATTERY

162

SPEED LIMITER

163

SYSTEM OPERATION

164

TROUBLESHOOTING HINTS

164

SPEED LIMITING CIRCUIT

165

SECTION 14

167

CHASSIS LUBRICATION CHART

168

MAINTENANCE GUIDE

169

BRAKE FLUID

169

BRAKE SHOE REPLACEMENT

169

FRONT BRAKE ADJUSTMENT

170

REAR BRAKE ADJUSTMENT

171

MASTER CYLINDER

172

BRAKE PEDAL FREE TRAVEL

172

BLEEDING THE BRAKES

174

TROUBLESHOOTING

174

BRAKE SYSTEM

174

STEERING GEAR

175

FRONT FORK

177

FORK BEARING ADJUSTMENT

177

FRONT WHEEL BEARINGS

178

REAR TIRE AND WHEEL REMOVAL

179

FRONT TIRE REMOVAL

179

TRANSMISSION

181

AUTOMATIC

181

POWER TRANSMISSION MECHANISM

184

HYDRAULIC MECHANISM

189

CONTROL MECHANISM

197

DIAGNOSTIC

200

CONNECTOR ON

200

MAIN HARNESS

200

(SECONDS)

201

OTHER MECHANISMS

202

Cushman devices