Cushman Front Line 17 HP Diesel Manuals

Manuals and User Guides for Cushman Front Line 17 HP Diesel. We have 1 Cushman Front Line 17 HP Diesel manual available for free PDF download: Service Manual

Cushman Front Line 17 HP Diesel Service Manual (83 pages)

17 HP Diesel and 22 HP Gas Powered models

Brand: Cushman | Category: Lawn Mower | Size: 9.61 MB

Safety Information
2
Table of Contents
3
Model Identification
4
Information Symbols
5
Safety Warning Symbols
5
Vehicle Specifications
6
Engine Troubleshooting
6
Periodic Maintenance
9
Fuel and Lubricant Recommendations and Capacities
10
Gasoline Containing Methanol or Ethanol
10
Chassis Lubrication Points
11
General Maintenance
12
Hardware Torque Recommendations
12
Tire and Wheel Service
13
Removal/Replacement
13
Air Cleaner Service
13
Combustion Air
13
Engine Cooling Air
14
Air Cleaner Assembly Sequence
14
Engine Cooling Air Intake
14
Filter Frame & Element
14
Power Take-Off Lever and Interlock Switches
15
Speed Control Neutral Switch Adjustment
15
P.T.O. Switch Adjustment
15
P.T.O. Switch Location
15
Starter Circuit
16
Ignition Circuit
16
Adjustment of the Second P.T.O. Switch
17
Battery Information
17
Seat Switch Adjustment
17
Battery Care
17
Booster or Jump Starting
18
Long Term Storage
18
Engine Tune-Up
19
Valve Lash Adjustment Procedure
19
Timing Mark Adjustment
19
Valve Lash Adjustment
19
Compression Test
20
Spark Plug Replacement
20
Contact Point Adjustment
20
Ignition Timing Adjustment and Spark Advance Mechanism Test
20
Governor Adjustment
21
Engine Speed below 700 RPM
21
Timing - Engine at Full Governed Speed
21
Fuel Filter Replacement
22
Carburetor Adjustment
22
Zenith Carburetor
23
Engine Repair
24
Removing the Engine Assembly from the Chassis
25
Table of Clearances
25
Engine Disassembly
26
Flywheel Retaining Nut Removal
27
Flywheel Removal
27
Pushrod Tube Removal
27
Valve Lifter Removal
27
Inspection and Repair of Engine Components
28
Camshaft Front Cover Removal
28
Alignment Pin and Crankcase Screw Locations
28
Crankcase
29
Crankshaft
29
Piston/Rod
29
Correct Wrist-Pin Removal
29
Engine Reassembly
30
Checking Timing Gear Backlash
30
Correct Rod Installation
30
Correct Installation Position
30
Checking Crankshaft End-Play
31
Assembling the Crankcase
31
Timing Mark Alignment
31
Checking Camshaft End Play
31
Sealant Application Pattern
32
Crankcase Screw Tightening Sequence
32
Rear Main Seal Installation
33
Front Main Seal Installation
33
Expansion Plug Installation
33
Bearing Insert Installation
33
Oil Pressure Relief Valve Preparation
34
Oil Pump Preparation
34
Cylinders and Valves
34
Valve and Valve Guide Preparation
34
Valve Guide Preparation
35
Valvetrain Preassembly
35
Cylinder Installation
35
Intake Valve and Seal Installed
35
Oil Supply Tube Installation
36
O Ring Installation - Pushrod Tube
36
Pushrod Tube Installation
36
Rocker Arm Assembly Sequence
36
Oil Pump Installation
37
Oil Strainer Installation
37
Flywheel Installation
37
Oil Filter Installation
37
Replacing the Engine Assembly into the Chassis
38
Timer/Governor Repair
38
Timer/Governor Component Identification
38
Separating the Timer from the Governor
39
Timer Disassembly
39
Timer Reassembly
39
Governor Unit Disassembly
40
Timer Weights Installed
40
Timer Spring Installation
40
Timer/Governor Installation
41
Correct Cam Positions
41
Initial Timer/Governor Installation
41
Completed Timer/Governor Installation
41
Fuel System Service
42
Carburetor Repair
42
Correct Lever Position
42
Carburetor Removal
43
Float Setting Test
44
Adjustment Needles
44
Float Meters Fuel Intake
44
Idle System Zenith Carburetor
45
Discharge Increased through Acceleration
45
Carburetor Parts Location
45
Carburetor Installation
46
Assembly of Bowl to Body
46
Ball Link Connector/Flange Alignment
47
Choke Cable Installation
47
Ball Link Connector Clearance
47
Fuel Pump Timing
48
Engine Break-In
48
Drivetrain/Chassis Service
49
P.T.O. Shaft Coupling
49
P.T.O. Shaft Alignment
49
Hardware Locations
50
Coupling Alignment Lift Point
50
P.T.O. Clutch Removal
51
P.T.O. Clutch Inspection and Repair
51
Control Rod Location
51
Damaged Clutch Cup
51
Clutch Reassembly
52
Disc Pack Component I.D. and Assembly Sequence
52
Correct Cam Plate Assembly
52
P.T.O. Clutch Installation
53
Measuring Operating Tolerances
53
P.T.O. Shaft/Tube Components
53
P.T.O. Shaft/Tube Repair
54
Lock Ring Location
54
Differential Service
55
Removal of the Differential from the Chassis
55
Checking P.T.O. Shaft End-Play
55
Correct Support Points for Differential Removal
55
Brake Control Rod
56
Differential/Axle Housing Assembly
56
Disassembling the Differential
57
Axle Removal
57
Carrier Removal
57
Bearing Cup Removal
57
Carrier Disassembly and Inspection
58
Carrier Assembly
58
Planet Gear Positions Marked
58
Measuring Shaft Boss Wear
58
Driven Worm (Ring) Gear Replacement
59
New Hole Locations
59
Correct Drilling & Tapping Procedure
59
Drive Worm Repair
60
Installing Worm (Drive) Gear into Differential Housing
60
Gear Retaining Screw
60
Worm Bearing Cap Installation
60
Carrier Installation
61
Assembling the Differential Halves
61
Checking Drive Worm End-Play
61
Correct Inner Oil Seal Position
61
Steering System
62
Brakes
62
Steering Cable Tension Adjustment
62
Steering Cable Assembly Repair/Replacement
62
Traction Assist Pedal Adjustment
63
Brake Pedal and Parking Brake
63
Oil Cooler
63
Adjusting Clevis Locations
63
Hydrostat
64
Wiring Diagram
64
Cylinder with Snap-Ring Retainer
64
Cylinder with Lock-Wire Retainer
64
Fuel, Lubricant and Coolant Recommendations and Capacities
67
Fan Belt Tension
69
Filter, Frame and Element
69
Proper Fan Belt Tension
69
Fuel Control System
70
Cooling System Service
71
Cooling System Troubleshooting
71
Cooling System Condition Check
71
Overheat Condition
72
Cooling System Maintenance
73
Testing the Condenser for Leaks
73
Cooling System Cleaning
73
Testing the Heat Sensor Switch and Warning Devices
74
Testing Sensor
74
Water Separator Service
75
Draining Procedure
75
Purging the Fuel System of Air
75
Air Vent Screws
75
Long-Term Storage
76
Returning to Operation
76
Injection Nuts
76

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