Page 1 Service Manual Liquid Cooled Gasoline Engine Haulster®/Turf-Truckster® PART NO. 836278...
Page 2: Section Index
SECTION INDEX GENERAL INFORMATION ENGINE TUNE-UP THE ENGINE PROPER FUEL SYSTEM LUBRICATION SYSTEM COOLING SYSTEM ENGINE ELECTRICAL SYSTEM EMISSION CONTROL SYSTEM HYDRAULICS CLUTCH TRANSMISSION DIFFERENTIAL STEERING BRAKES SERVICE SPECIFICATIONS IMPORTANT To make sure you are fully aware of safety and service Information, the following two symbols are used throughout this Instruction.
Page 3: Section 1 General Information
AND ENGINE NUMBER The engine type and number is stamped on the front side of the cylinder block. Figure 1. Engine Serial Number ENGINE SPECIFICATIONS Engine type MODEL 327 Item Gasoline, 4-cycle Type Cylinder No. and arrangement 3 cylinder-in-line, mounted longitudinally...
Page 4 Engine type MODEL327 Item Water cooled, fan Cooling method Radiator type Corrugation forced circulation Cooling System Water pump type Centrigugal "V" belt driven Wax pellet Thermostat type Mechanical Fuel pump type Manufacturer AISAN Fuel Carburetor Style Side---<lraft, single barrel System Auto choke Choke valve 12 (Negative ground)
Page 5 INSTRUCTIONS ON SERVICE Checks to be performed during disassembly. Each ti me a part is removed, check conditions under OPERATIONS which the part has been assembled. Also, check to see if the part exhibits any evidence of distortion, Make sure that only the specified bolts and nuts are breakage, wear or scores, etc.
Page 7: Safety Warning
TUNE-UP SECTION 2 Engine Tune-Up Procedure Special tools required in this section: & Timing light Compression tester SAFETY WARNING 5/8 inch spark-plug socket • The cooling fan is thermostatically controlled Spark-plug feeler gage (wire) and MAY start at any time. Disconnect fan at the Feeler gage switch on the engine.
Page 8 The COLD valve setting is: Adjust governor. Intake 0.006 inch (0.150 mm} 0.008 inch (0.203 mm} Exhaust Maximum engine speed ....3600 rpm (Models 898466, 898630 & 898632) When the number 1 piston is at TDC, of the com...
Page 9: Battery Servicing
Battery Servicing I N O TE I • When the distributor body is turned counter-clock Visually inspect the battery for the following: wise, the ignition timing will be advanced, when the Corrosion distributor body is turned clockwise, the ignition tim Frayed or broken cables ing will be retarded.
Page 10 Jump Starting With Booster Battery Attach one end of the remaining cable to the nega tive terminal of the booster battery and the other end to a good ground on the vehicle or engine away from the discharged battery. Do not lean over Both booster and discharged battery should be the battery when making this connection.
Page 11 RECORD ALL MAINTENANCE PERFORMED ON YOUR VEHICLES IN THE CHART BELOW Supervisor Work Performed Date Vehicle Serial No. Mechanic Figure 3.
Page 13 The cooling fan is thermostatically controlled When replacement parts are required, use genu and MAY start at any time. DO NOT attempt to ine Cushman parts or parts with equivalent service without disconnecting. characteristics including type, strength and ma terial. Failure to do so may result in product...
Page 14 Engine 16. Unbolt transmission mounting at rear cross mem ber. Removal 17. Unbolt front cross member at frame. Leave cross Drain antifreeze solution from radiator. member mounted to the engine. It can be used as a stand for partial disassembly. Drain oil from engine.
Page 15: Disassembly Of Cylinder Block
Remove the distributor, clutch, pressure plate, and flywheel. Remove the exhaust manifold, water bypass pipe, and oil filter. Loosen all valve tappet adjusting screws (intake and exhaust). I NO T E I • This must be done BEFORE removing the timing Figure 4.
Page 16: Assembly Note
Remove the oil pan. After removing all screws and nuts use tool CU40001 to remove gasket material from the block. See Figure 6. Figure 7. Bearing Cap Arrow and Number Stamp Figure 6. Tool CU40001 Remove the engine crankshaft. Remove the oil strainer and oil pick-up tube. Clean all parts thoroughly.
Page 17 With the bearing caps removed, check the crank shaft thrust clearance. If the clearance exceeds the limits, replace the thrust washer. Thrust clearance: 0.0007 to 0.0118 inch (0.022 to 0.30 mm) Remove the crankshaft, crankshaft bearings and thrust washers. Check the cylinder block for cracks, damage, and distortion.
Page 18 � Front ... Figure 14. 1. Axial Direction Figure 12. 2. Thrust Direction Oil Clearance Check 13. · Measure the piston diameter in the thrust direction. 11. Remove the piston pin using tool CU40007. See Calculate the cylinder-to-piston clearance. Figure 13. Figure 15.
Page 19 15. Check the piston ring gaps. See Figure 16. No. 1 ring 0.0098 to 0.0256 inch (0.25 to 0.65 mm) 0.0079 to 0.0138 inch No. 2 ring (0.20 to 0.80 mm) Oil ring 0.0079 to 0.0394 (0.20 to 1.00 mm) Figure 18.
Page 20: Cylinder Block Assembly
Prepare the connecting rod and piston for assembly. The top of the piston has an arrow that must face the same direction as the front mark on the connecting rod. See Figure 22. Front mark Figure 20. Crankshaft Timing Belt Pulley Check Figure 22.
Page 21 ·r· mark •l" Compression ring No.1 or H N mark .___.___· Front Compression ring No.2 .,.,-, mark Front Oil ring Figure 26. Front Marks Figure 24. 12. Install the oil pump assembly. Piston Ring Installation Torque: 7 to 11 ft lbs (9.5 to 15 N·m) 13.
Page 22: Cylinder Head Disassembly
Inspection of Cylinder Head 16. Install the water pump assembly. Torque: 11 to 17 ft lbs (15 to 23 N·m) NOTE Cylinder Head Disassembly • Thoroughly clean the head and all related parts. All Remove the valve rocker shafts. carbon, and dirt must be removed before proper in spection can be performed Remove the flange bolt for the camshaft thrust ring.
Page 23 • The original valve guide has no stop ring. The re placement valve guide has a stop ring that positions the valve guide at a depth of 0.598 to 0.622 inch (15.2 to 15.8 mm). • Be sure to install an oversized, .0012 inch (0.03 mm), valve guide for replacement.
Page 24 Check the valve stem headfor wear. SeeFigure37. Check the valve spring squareness with a square Allowable limit: .008 inch (0.22 mm) and measure the free length. See Figure 39. Squareness limit: .0629 inch (1.6 mm) Free length limit: 1.7441 inch (44.3 mm) Figure 37.
Page 25: Camshaft Inspection
Camshaft Inspection Measure the camshaft for bending. See Figure 41. Bend limit: 0.0018 inch (0.03mm) Measure the cam lobe height. (Measure the run-out, and calculate the bend Allowable limits: amount) Intake: 1.3701 to 1.3807 inch (34.80 to 35.07 mm) Measure the camshaft-to-cylinder head bearing Exhaust: 1.3681 to 1.3783 inch clearance.
Page 26 The valve spring coils are closer together on the bot tom than on the top. Ensure that they are installed with the closer coils on the bottom. (Normally the top of the spring will be painted) See Figure 45. Figure 47. Tool CU40006 I N O T E •...
Page 28: Timing Belt Adjustment
The timing marks on the belt must be aligned with IN O T E the marks on the respective pulley and the marks on the timing cover and oil pump case. See Figure 53. • To protect the surface of the timing belt tensioner pulley place a feeler gauge between the screw and the pulley surface.
Page 29: Engine Installation
Install the intake manifold. Slit is off center 1 mm (0.04 inch) Torque: 11 to 17 ft lbs (15 to 23 N·m) · to right side Install the fuel pump with push rod. 11 to 17 ft lbs (15 to 23 N·m) Torque: Install the Carburetor assembly.
Page 30: Safety Warning
14. Connect transmission shift linkage at frame and transmission. 15. Corinect clutch linkage at clutch bell housing. See section 1 0 for clutch free-play adjustment 16. Install clutch safety switch bracket to the transmis sion. Connect clutch safety switch, and safety switch spring.
Page 31: Fuel System
SECTION 4 FUEL SYSTEM Special tools required in this section: • Metric Hand Tools • Carburetor Tool Kit Part No. CU40002 • Vacuum Pump • Choke Plate Angle Tool General Information Fuel Pump. A mechanical type fuel pump is installed to the cylinder head, and is driven by the fuel pump cam on the camshaft through a push rod, delivering fuel to the carburetor.
Page 32: Side View
Carburetor, Main System. The fuel arrives at the carburetor bowl and is metered by the main jet. The fuel is mixed with air entering from the main air bleed. Fuel is then discharged into the small venturi from the main nozzle. See Figure 2.
Page 33 Carburetor, Acceleration Pump System. When the throttle is opened suddenly, the acceleration diaphragm is pushed by means of the pump lever. Then the fuel inside the acceleration pump is injected from the pump jet via the dis charge check valve. When the throttle valve is returned to the ori g inal position, the fuel in the float chamber enters into the acceleration pump via the check valve.
Page 34 Carburetor, Automatic Choke System. The automatic choke mechanism regulates the opening of the choke plate and throttle plate in accordance with the temperature of the coolant. This regulation is performed automatically, using wax pellet. See Figure 5. Wax adapter (wax sealed) Idle adjusting screw Choke breaker Pinion gear...
Page 35 Choke Pull-Off. The negative pressure of the intake manifold actuates the choke breaker diaphragm during a period immediately after starting. As a result, the choke valve is forcibly opened so as to prevent the fuel and air mixture from becoming too rich. A limiter provided between the intake manifold and the choke breaker prevents the choke valve from being opened too suddenly.
Page 36: Fuel Pump
Fuel Pump & Apply pressure (2 psi) to the outlet. T here should be no air flow from the inlet , mounting area or where the SAFETY WARNING pump halves are bolted together. If there are leaks replace the fuel p ump. See Figure 7. •...
Page 37: Carburetor Removal
Standard Carburetor (49 State) Carburetor Removal Disconnect throttle link from carburetor to governor linkage. Disconnect air cleaner hose at carburetor inlet. Remove carburetor mounting bolts and remove car Remove fuel supply line from carburetor. buretor from the vehicle. Disconnect vacuum hoses (2), and water lines (2) at INOTE I carburetor.
Page 38 Carburetor, Disassemble and Inspection Bowl, float and related parts Disassemble float bowl cover mounting screws. See Figure 11. INOTEI • One mounting screw is shorter than the other two. Failure to return screw to their proper location may cause damage to the carburetor body. Figure 10.
Page 39 Disassemble main air bleed, and slow jet Disassemble main air bleed, slow jet plug, slow jet and idle mixture screw. See Figure 12. ©- � '· c:--- _,,.,,- Figure 12. 1. Main Air Bleed 2. Slow Jet Plug 3. Slow Jet 4.
Page 40 Acceleration Pump, Power Valve, and Related Parts Check the diaphragm for damage. Remove acceleration pump lever pivot bolt, and Check rod sliding surface for damage or wear. pivot arm. See Figure 14. Check power valve for damage or rust. Remove diaphragm cover mounting bolts and dis assemble diaphragm cover.
Page 41 Acceleration Pump Cleaning I N O TE Assemble the power valve, check valve and dis charge check valve. See Figure 14. Care must be used in cleaning the carburetor. Plug the water :nlet and outlet to prevent the cleaning so Assemble the spring , diaphragm and gasket.
Page 42 Air Bleed, Slow Jet, and Idle Adjusting Screw Assemble the idle adjusting screw, slow jet, slow jet plug and main air bleed. See Figure i 9. Figure 21. 1. Float 2. Bowl Cover 3. Float Lever Pin Figure 19. Adjust the Float Position 1.
Page 44 The California carburetor has a vent solenoid valve Adjust by bending the adjusting lever. located on the bowl cover. See Figure 29. The func Figure 28. tion of this solenoid is to allow the fumes from the carburetor bowl to be sucked into the vacuum canis ter.
Page 45: Carburetor Installation
Carburetor Installation Attach carburetor to intake manifold with original mounting bolts. Tighten to 90 to 136 inch pounds (1.04 to 1.56 kg-m) torque. Connect throttle link from carburetor to governor linkage. Connect Electrical wire connector at main engine harness. Connect vacuum hoses (2), and water lines (2) at carburetor.
Page 47: Section 5 Lubrication System
SECTION 5 LUBRICATION SYSTEM OIL PRESSURE CHECK Oil level should be between the two small marks on the level gauge. If low, check for leakage and add oil up to the upper mark. � - - Upper limit - - Lower limit Figure 1.
Page 48: Oil Pump
PUMP COMPONENTS Q) "T type oil seal ® OilpumpAy @ Compression spring ® @ Cotterpin Oil pump relief valve @ Oil pump relief valve retainer ® ® (?) Gasket ® Oil pump drive gear Oil pump driven gear @) Oil pump cover ®...
Page 49: Gear Inspection
GEAR INSPECTION Measure the tip clearance of the drive and driven gears with a thickness gauge. Tip Clearance: .0067 to .0138 in. (0.17 to 0.35 mm) Figure 7. Tip Clearance Measurement Measure the side clearance as shownwith a thick ness gauge and flat block. Side Clearance: .0014 to .0059 in.
Page 50 Install the new oil seal. Install the new oil seal using a seal driver. • The new oil seal must be installed straight. Figure 11. Oil Seal Installation Coat the oil seal lightly with grease. Figure 12. Grease Coating ASSEMBLY OF OIL PUMP Relief valve.
Page 51 Insert the "O" ring onto the groove provided at the oil pump cover. Then press the "O" ring at the three points of em bossed marks on the cover (for fixing the "O" ring). Embossed marks Figure 15. 'O' Ring Installation...
Page 52 CHASSIS LUBRICATION CHART MODELS: 898464, 898465 898466,898467 CHASSIS LUBRICATION GUIDE Perform every 100 hours or 1000 miles NUMBER OF LUBRICATION AREA GREASE FITTINGS* 1. Rear spring shackles 2. Drive shaft 3. Clutch bellcrank (pivot bushing) 4. Leading link bushinngs 5. Lower fork pivot bearing 6.
Page 53 CHASSIS LUBRICATION CHART MODEL 898630 CHASSIS LUBRICATION GUIDE Perform every 100 hours or 1000 miles NUMBER OF LUBRICATION AREA GREASE FITTINGS* 1. Rear spring shackles 2. Drive shaft 3. Clutch bellcrank(pivot bushing) 4. Leading link bushings 5. Lower fork pivot bearing 6.
Page 54 CHASSIS LUBRICATION CHART MODEL 898632 CHASSIS LUBRICATION GUIDE Perform every 100 hours or 1000 miles NUMBER OF LUBRICATION AREA GREASE FITTINGS* 1. Rear spring shackles 2. Drive shaft 3. Clutch bellcrank (pivot bushing) 4. King pin bushings 5. Steering linkage 6.
Page 55: Cooling System Check
6 COOLING SYSTEM Cooling System Check • When adding or replacing coolant a 50-50 mixture of a good grade of ethylene glycol antifreeze and dis tilled water is recommended. This will provide pro ° ° tection to -34 F (-37 It is extremely important that the antifreeze and water is mixed in a separate container before adding the mixture to the cooling system.
Page 56: Engine Coolant
Installation The radiator fan control switch may be tested follow Install the thermostat into the thermostat housing. ing these procedures: See Figure 5. Install new gasket. Attach housing assembly to the (A) Remove the switch from the engine. cylinder head. See Figure 3. (8) Connect a continuity light to the switch Torque: (C)Place the switch in water and watch the meter...
Page 57: Safety Warning
Figure 6. 1. Loosening Bleeder Plug Fill the coolant in the reserve tank until the coolant level reaches the "FULL" line. Fill the coolant in the radiator until the coolant flows from the bleeder plug. Tighten the bleeder plug. Continue filling the system until coolant flows into the reserve tank.
Page 60: Starter Disassembly
STARTER DISASSEMBLY Remove solenoid (1) Remove the nut, and disconnect the lead wire from the solenoid terminal. (2) Loosen the two nuts holding the solenoid to the starter housing. Lift the solenoid up and out to unhook the plunger from the starter drive lever. Figure 3.
Page 61 Remove field frame from drive housing Pull apart by hand. Remove armature (1) Remove the drive lever from the drive housing. (2) Pull the armature from the drive housing. Figure 7. Armature Removal Remove starter clutch (1) Using a flat blade screwdriver, push the stop collar towards the pinion gear.
Page 62: Field Coil
Check the commutator for open circuit Using an ohmmeter, check for continuity between segments of the commutator. If there is no continu ity between any two segment; replace the armature. Figure 11. Commutator Check FIELD COIL Check field coil for open circuit Using an ohmmeter, check for continuity between the field coil brush leads.
Page 63: Starter Clutch
Perform pull-in coil open circuit test Terminal C Using an ohmmeter, check for continuity between terminal 50 and terminal C. If there is no continuity, replace the solenoid. -------- --<:::7· -,,_...-/ . Te rm in a I 50 Perform hold-in coil open circuit test Figure 15.
Page 64 ASSEMBLY Use high temperature grease to lubricate the bear ings and sliding parts when assembling the starter. Assemble starter clutch to armature Figure 19. Starter Clutch Assembly (2) (1) Place a new stop collar on the armature. (2) Push the snap ring onto the shaft with a 1/2 in. (14 mm) socket.
Page 65 Install brush holder and brushes (1) Place the brush holder over the armature shaft. (2) Using a piece of steel wire, hold the brush spring back and install the brush in the brush holder. Install all four brushes. Install end frame (1) Apply grease to the end frame bushing.
Page 66: Performance Test
PERFORMANCE TEST Terminal 50 Terminal C • These tests must not be run for more than 3 to 5 sec onds to avoid burning out the coil. Perform pull-in test Figure 26. Pull-in Test (1) Disconnect the field coil lead from terminal C. (2) Connect the battery to the solenoid as shown.
Page 67: Ignition System
(2) Move the pinion gear toward the armature. Measure the clearance between the p inion and the stop coll" a r. Standard clearance: .004 to .157 in. (0.1 to 4.0 mm) No-load performance test (1) Connect the field coil lead to terminal C. Make sure the lead is not grounded.
Page 68 Spark plug Check for damage (1) Remove the spark plug. Check for damage (2) Inspect the spark plugs for thread damage and insulator damage. Figure 34. Spark Plug Check (3) Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap.
Page 69 (4) Inspect coil case continuity. Using an ohmme ter, measure the resistance between positive (+) terminal and coil case. Coil case continuity: Infinity Figure 38. Coil Case Resistance Check (5) Inspect the ignition resistor resistance. Using an ohmmeter, measure the resistance of the re sistor.
Page 70 DISTRIBUTOR COMPONENTS © Distributor cap @ Rotor @ Condenser r / � . , @ Point kit I � � @ Breaker plate @ Governor S/A ® (V Packing - - - @ Housing a � � ® :.,. .. -----��----------- Figure 42.
Page 71 Remove the vacuum advance. (1) Remove the condenser mounting screw and condenser from the distributor housing. (2) Remove the E-ring. Turn and pull the vacuum advance from the housing. Figure 45. E-Ring Removal Remove the breaker plate. (1) Remove the mounting screws, ground wire and advance plate clamps.
Page 72 Governor Temporarily install the cam on the shaft and check for looseness. If necessary, replace the cam. Distributor shaft and housing Check for wear, or damage. If necessary, replace Figure 49. Distributor Check the housing. ASSEMBLY Cam and weights. Figure 50. Distributor Shaft and Housing Check (1) Install the cam with advance weights.
Page 73 Install the breaker plate. (1) Fit the four clips on the breaker plate into the housing slots. (2) Install one end of the ground wire and two plate clamps with mounting screws. Install the vacuum advance. Figure 53. Breaker Plate Installation (1) Insert the advance into the distributor and posi...
Page 74: Wiring Diagram
WIRING DIAGRAM COLOR CODE BLACK BLUE BROWN GREEN ORANGE PINK WHITE YELLOW WHITE-BLACK STRIPE WHITE-GREEN STRIPE WHITE-RED STRIPE � WHITE-BROWN STRIPE W/BR W/OR WHITE-ORANGE STRIPE ALTERNATOR W/BL WHITE-BLUE STRIPE OIL PRESSURE SWITCH rP : D -oto ALTERNATOR RESISTOR r w l fl7t:::!-+ FUEL GAUGE SENDER LEFT TAIL, STOP...
Page 75 WIRING DIAGRAM 3 - W H EEL +-- - HORN BUTTON 3 - W H EE C T OR -HO RN CON NE 4 WHEEL . N M ICRO S W I : � W H EEL HORN HARNESS -®--f- �...
Page 77: Section 8 Emission Control System
SECTION 8 EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM Vacuum Hose Routing CHOKE PULL-OFF VACUUM RESTRICTIOR � WHITE � -;,;;,: MANl SIDE SIDE GREEN FIGURE 1 BLOW-BY GAS RECIRCULATION SYSTEM AIR CLEANER HOSE BLOW-BY HOSE OIL SEPARATOR HEAD COVER AIR CLEANER - FRESH AIR •-- BLOW-BY GAS FIGURE2...
Page 78 EXHAUST EMISSION CONTROL SYSTEM Vacuum Hose Routing (California Modification) THROTTLE POSITIONER VACUUM RESTRICTOR CARBURETOR MANIFOLD� SIDE SIDE BLUE GREEN CHOKE PULL-OFF VACUUM RESTRICTOR CARBURETOR MANIFOLD SIDE SIDE FIGURE 3...
Page 79 SECTION 9 HYDRAULICS Fully retract any hydraulic cylinders that are ex Special tools required in this section: tended. Stop the vehicle engine. •Hydraulic flow meter •Hydraulic pressure gage Remove engine cover. Remove the vehicle left side General Maintenance panel located under the control console. Here are key maintenance problems: Remove the dipstick/breather assembly from the •...
Page 80: Checking For Internal Leaks
Notice if the equipment settles toward the ground. If Examine the system the equipment settles, temporarily support it and Check the fluid level disconnect the return line between the control valve and reservoir, then plug the line. See Figure 1. Check the fluid for discoloration.
Page 81 Connect flow meter and pressure gage. Figure 3. ( Some hydraulic systems may have a se Disconnect lector valve in the system. Always connect the hy and RJ..yg_ draulic tester after the pump and before any hose here other components). Packing leaking Hydraulic...
Page 82: System Testing
Gallons Per Minute @ PSI 1000 1250 1500 1750 2000 2250 230( Pump test(Gal. / min.) 4. 0 3. 7 Circuit test Cylinder Circuit Motor Circuit This chart shows the correct readings for the pump. A blank form that you may copy is at the end of this chapter. Figure 4.
Page 83 Interrupting pump test results If flow at each pressure is same as for pump test: All components are okay. If pressure begins to drop before full load is • reached: One of the circuits is bad. (Such as the cyl Mounting screws for the lift valve must not be inder lower circuit in Figure 5.) torqued more than 6 to 8 ft.
Page 84: Operation
HYDRAULIC DIAGRAM FOR TURF-TRUCKSTER 9110 AND LATER Ga-60 Lift Cylinder �� .... ·•·•·• •.•: • . -,.,;-. ······ ,:•. •,;,; Truckster Cylinder Selector Valve Pressure Return Hydraulic Suction Tank k: : \ : : : : \ ::- < : \ l Pressure or Return Filter GA-60 OPERATION Specifications:...
Page 85 HYDRAULIC DIAGRAM FOR TURF-TRUCKSTER 9110 AND LATER Flow Control Valve Cylinder Pilot Check Valve Truckster Cylinder Selector Valve Pressure Return Hydraulic Suction Tank f, : : : ' \2<\:'\l Pressure or Return Filter Fifth Wheel Dump Box operation Specifications: Pump - 3.46 GPM at 2000 psi - Relief set at 2300 psi Filter - 25 micron full flow - 25 psi bypass in base Truck cylinder - 2"...
Page 86 HYDRAULIC DIAGRAM FOR TURF-TRUCKSTER 9110 AND LATER Core harvester accessory Truckster Cylinder Selector Valve Pressure Return Hydraulic Suction Tank J< . ; . : , .. '::. , : : v ] Pressure or Return Filter Core Harvester Specifications: Pump - 3.46 GPM at 2000 psi - Relief set at 2300 psi Filter - 25 micron full flow - 25 psi bypass in base Truck cylinder - 2"...
Page 87 HYDRAULIC DIAGRAM FOR TURF-TRUCKSTER 9110 AND LATER Fifth wheel top dressor accessory Truckster Cylinder Selector Valve Pressure Return Hydraulic Suction Tank (:::: , , . : · · : \ : : , , : , , , : : :::: , : ->, ) Pressure or Return Filter FIFTH WHEEL TOP DRESSOR Specifications:...
Page 88 HYDRAULIC DIAGRAM FOR TURF-TRUCKSTER 9110 AND LATER ..· . : - : - .· · : • : , .·,: , : - .·- : · : · .·,: , : - . · - : - : - .·-: - : - .·-: - : - .·-z . . · ·: - : - .·-: - : - .·-:-: - .--... - Truckster Cylinder ··- .
Page 89 Motor Driven Accessory © Lift Valve Accessory Cylinder Truckster Cylinder Selector Valve Pressure Return Hydraulic Suction (::: , , . : - , , , , , . : - , , , , , . : - , , , , , . : - , , 1 Tank Pressure or Return Filter...
Page 90 HYDRAULIC DIAGRAM FOR REFUSE HAULSTER 9110 AND LATER Lift Valve Flow Control Valve Cylinder ... . . ··.· : ·.·· : •. , , · ..Pilot Check Valve Pressure Return Hydraulic Suction Tank...
Page 91: Troubleshooting
TROUBLE SHOOTING Comments Solution Probable Cause Symptom System Inoperative •No oil in system Fill to full mark. Check for leaks •oil low in reservoir Fill to full mark. Check for leaks •Oil of wrong viscosity Refer to specifications Drain oil, replace filters •Filter dirty or plugged •...
Page 92 TROUBLE SHOOTING Symptom Probable Cause Solution Comments Overheating of • Control valve stuck open Clean and repair valve oil; Continued Foaming of Oil in • Low oil level Fill to full mark. Check for leaks System •water in oil Drain and replace oil •wrong kind of oil being used Use recommended oil •...
Page 93: General Information
SECTION 10 CLUTCH General Information Remove clutch housing and remove clutch. Lower differential; the drive shaft will separate. This is a dry, single disc, diaphragm automotive type clutch. The outer diameter is 6.7 inches. It is oper If the throw out bearing actuator fork needs replac ated by a foot pedal through linkage to the throw out ing, drive out the roll pins and install new actuator.
Page 94 NO T E • Using more than a thin film could cause clutch slippage. Install the clutch disc and pressure plate using align ment tool. See Figure 4. T orque: 5 to 7 ft. lbs (7 to 9 N ·m) !'llllla- Figure 2.
Page 95: Clutch Adjustment
..Clutch Return Spring (red) F,oe navel 1/8- 3/16" (3mm- smm) -1 ( Clevls Correct Hole � <: / Clutch � I � Lever � Jam nut � � � �� - , � Clutch Rod Swttch Sprlng @__ � ------ "-sa1e1y Do Not Overtlghten Hanlwa,e, Washe,s M,st ..
Page 96: Clutch Slips
Trouble-shooting Correct adjustment is accomplished by moving the switch mounting bracket on the safety switch slide bracket until the spring is pulled tight. (Not pulling on Clutch Slips the switch activating plunger.) See Figure 6. Insufficient pedal travel, linkage adjustment needed.
Page 97: Section 11 Transmission
SECTION 11 TRANSMISSION Inspection of Parts Check interlock sleeve for correct clearance in all four gear positions, (low, second, high, and reverse. DO N O T check in neutral). See Figure 2. Disassembly Clearance must be: Drain lubricant from transmission and clean case .005 in.
Page 98 Figure 4. 1. Second-high Shift lever Insert the low-reverse shift lever into the housing, Figure 3. but before pushing it all the way in, insert a thick, 1. Interlock ball 3. Spring .018" (0.46 mm) or thicker, feeler gauge between 2.
Page 99 Transmission Case Inspection Disassembly of Main Shaft and Cluster Gear Remove the main drive gear from the transmission Examine the surfaces of the bearing recesses in the transmission case for wear or scoring which would case. indicate that the bearings have been revolving in Remove the cluster gear from the transmission their housings.
Page 100 Cluster Gear Assembly If the bushings or bearings (9120 models and later) are worn and need to be replaced they must be pressed into position flush with the end of the cluster gear. The oil hole in the bushing installed in the rear of the cluster gear must be aligned with the hole in the rear of the cluster gear.
Page 101 USE SHIMS AS REQUIRED TO GIVE SELECT WASHER TO LOCATE CLUSTER GEAR .oos" TO .017" (0.13 TO 0.43 mm) CLEARANCE TO DIMENSIONS SHOWN AT SECOND GEAR Figure 9. Shifter Hub And Sleeve Assembly The shifter hub and sleeve assembly consists of the following: - Second and high clutch hub -Second and high clutch sleeve...
Page 102 Second Gear Assembly 9120 and later: If the needle bearing is worn it must be replaced. In stall new needle bearing flush to 1 /16" recessed with the face of the gear. 911 0 and earlier: Remove the old bushing and press the new into the gear.
Page 103 Figure 15. 1. Lock-plate 13. Coat expansion plug OD with sealer 3M #EC847. Figure 14. Install in front countershaft hole and set. Rear of 1. Retaining Nut (2) countershaft must rest against a flat solid surface so that when the expansion plug is being set counter shaft will not move.
Page 104 When in gear, the transmission must drive through Coat both sides of the gasket with 3M #EC847 without binding. Check to make certain the trans sealer. mission cannot be shifted into two gears at the same time by attempting to move one control lever when the other control lever is shifted into gear.
Page 105 Trouble Shooting Synchronizer ring teeth that engage second gear Leaks Oil are worn Oil level too high Gears Clash When Shifted Oil too thin Mis-alignment between transmission and clutch Low grade oil-oil foams excessively housing Leakage at rear oil seal because of wear or loose Dragging clutch bearing Synchronizer rings worn or damaged...
Page 106: Power Take-Off Assembly
Power Take-Off Assembly Install shim onto shifter lever shaft. Install PTO shif ter arm onto shifter lever. Secure with lock washer and nut. Disassembly Torque 50± 2 ft. lbs. (68± 2 Nm) Drain oil from transmission and remove power take Check shifter lever end play.
Page 107: Auxiliary Transmission
Auxiliary Transmission Remove the main shaft retaining nut and pull the main shaft and shift collar from the differential worm shaft. See Figure 16. Overhaul Procedure Drain the auxiliary transmission oil. • The auxiliary transmission may be controlled by ca ble or by shift linkage.
Page 108 Install sufficient shims over the worm shaft, behind the driven gear to allow .01 O to .020 (0.25 to 0.51 mm) clearance between the driven gear and the • This will eliminate the necessity of several installa brass thrust washer when the worm shaft nut has tion and removing operations to acquire the desired been securely tightened.
Page 109: Differential Disassembly
Bearing Cone Puller General Information Servicing this differential is a major service opera tion and should be performed by an authorized Cushman dealer who has the necessary equipment and information. To keep your differential performing at it's peak, you should: 1 .
Page 110 Figure 3. Drive Worm Removal Figure 2. Clean and visually inspect the worm and bearings 1. Brake Backing Plate for excessive wear or damage. 2. Shims Check the bearing cups inside the differential hous ing. Remove and discard bearings and cups if nec essary.
Page 111 Carrier Disassembly and Inspection Lay a metal straightedge across the top of the planet gear shaft bosses, and use a feeler gauge to check for wear at the axle bosses, (Two places.) Permanently mark (punch, stamp, etc.) the carrier Allowable limit: .010 in.
Page 112 INOTE • Exact alignment of the drill and gear surface is criti cal for proper results. DO NOT attempt this opera tion with a hand held drill. It is critical that the threads be half in the bronze gear and half in the car rier case.
Page 113 Press the bearing cone on using a bearing cone 12. Place the three lock plates in position, each covering two holes, and install the special screws into the dif driver and an arbor press, press on the outer bearing ferential carrier housing and worm gear. first.
Page 114: Carrier Installation
Install worm shaft assembly (oil slinger end first) into axle housing half. Insert the worm bearing retainer, over worm shaft, into housing opening, using shim pack and two or more gaskets (with minimum of one gasket on each side of the shim pack). Worm Preload I N OT EI •...
Page 115: Axle Installation
• Lubricate bearing surface near splines on axle shaft. Install bearing cup over the axle bearing. Ensure that the bearing cup seats properly into the axle housing. Replace the existing shims (if damaged). Install the bearing gasket. Install new seal into the seal retainer. Install the brake backing plate and seal retainer onto Figure 16.
Page 116 Install the shock absorbers. TROUBLE SHOOTING Fill the differential with proper lubricant to the level pl ug . Noise Under Power Specification: EPS0-90 gear oil 12 oz. (0.4 L) Worm shaft bearing bad or adjusted too tight Low oil level Install the wheels.
Page 117: Section 13 Steering
There is a special bearing washer inside the up per steering gear housing, and below the idler gear cluster. If these are worn or damaged they must be replaced with genuine Cushman parts or parts with equivalent characteristics. Failure to do so may result in product malfunction and possible injury to the operator and/or bystand- ers.
Page 118 Place a liberal amount of Mobil HP grease in the re cess of the idler adjusting bolt. Install (special) washer into lower housing. Place idler adjusting bolt into lower housing. Install knurled washer. Secure with nut, finger tight. Place the cluster gear over the idler adjusting bolt. Determine the correct keyway in the driven gear and install gear.
Page 119: Front Fork
Steering Backlash Adjustment (3 - Wheel) SAFETY WARNING Loosen the upper and lower idler adjustment bolt nuts. • When it is necessary to raise the vehicle for any repair or service, use jackstands to provide ade The weight of the vehicle must be on the wheels. quate support.
Page 120 REASSEMBLE Place 1 /4 ball bearings in lower bearing cone. Apply SAFETY WARNING a liberal amount of wheel bearing grease. Place felt dust shield around bearings to hold them in place. See figure 7. • When it is necessary to raise the vehicle for any repair or service, use jackstands to provide ade...
Page 121 Lubricate fork tube grease fitting. See Figure 9. Figure 10. 1. Axle Nut 7. Lock Washer Figure 9. 2. Axle Lock 8. Special Washer 1. Fork tube grease fitting 3. Jam Nut 9. Bearing Adjusting Nut 1 O. Oil Slinger 4.
Page 122: Front Wheel Installation
10. Install hub onto axle. Tighten the bearing adjust ment nut 7 to 13 lbs. ft. (10 to 17 N·m) torque while rotating the hub by hand. Back off nut 1 /6 turn. This will allow the hub to rotate freely without drag. A slight amount of end play is allowed.
Page 123 & Lower the vehicle to the floor so the weight of the ve hicle is on the front wheel. Tighten the axle nuts 70- SAFETY WARNING 1 00 lbs. (95 to 1 00N·m) torque. When reinstalling the front wheel and axle as sembly to the fork side arm, the front axle lock If the brake lines were removed, reattach the brake must be positioned over the side arm (as shown...
Page 124 FOUR WHEEL STEERING SERVICE • Do not reuse the grease seals after they have been removed. Replace with new parts to prevent dam age to bearings and other components. Tie rods have left and right hand threads. The left Assemble bearings, lubricate seal, and hub. Mount hand threads are identified by red jam nuts.
Page 125: Toe-In Adjustment
Toe In Adjustment Tightening torque for the drag link jam nut is 50 ± 2 lbs. ft. (65 to 70 N·m). After adjustment and parts are properly torqued, be sure tie rod nuts are secured keyed with new cotter pins if they have been re Before attempting adjustment , check for worn spin...
Page 126: Steering Stop Adjustment
Steering Stop Adjustment The distance from one tie rod end on the radius rod to the other tie rod end is 23". Loosen the tie rod jam Toe in must be set prior to steering stop adjustment. nuts and turn radius rod to obtain this adjustment. See Figure 16.
Page 127 Setting Steering Gear Backlash (4-WHEEL) Loosen the worm bearing adjuster until all endplay has been removed, then loosen 1 /4 turn. See Figure 18. Figure 18. 1. Worm bearing adjuster locknut 2. Worm bearing adjuster 3. Backlash adjuster 4. Backlash lock nut Carefully turn the steering wheel all the way to the right, then turn it back about 1/2 turn.
Page 129: Section 14 Brakes
SECTION 14 BRAKES Special tools required in this section: Foot pound torque wrench Inch pound torque wrench Knock off Part no. 809315 Common Brake Tools & SAFETY WARNING To AVOID LOSS OF BRAKES, adjust or repair brakes if the brake pedal travels closer than one inch to the vehicle floorboard.
Page 130 I NOTE • The large flat washers located on the ends of the axle must be positioned on the inside of the sidearm assembly. See Figure 2. & SAFETY WARNING • To PREVENT ERRATIC STEERING and/or LOSS OF CONTROL OF THE VEHICLE, make sure the front axle lock is positioned over the sidearm (as shownFigure 2.) before the axle nuts are tightened.
Page 131 Figure 3. After orientation of screws is achieved the lock plate tabs must be bent over top Brake Shoe Replacement of all four screws. (Cushman Small Brake) Reassemble Disassemble Install the shoe hold down springs, and brake shoes. Remove the wheel and hub assembly. See Front Wheel and Hub Service, Three Wheel or Rear Install adjusting screw, pivot and socket.
Page 132 Service, Three Wheel or Rear Wheel Service or draulic wheel cylinder. Remove the snap ring secur Front Wheel Service Four Wheel. ing the shoes to the heel pin. Remove the shoes Cushman Brake Adjustment (Small Brake) from the backing plate. Raise the vehicle. INOTEI &.
Page 133 70 - 100 lbs. ft. (95 - 135 Nm). • Examine the wheel cylinder for leaks before reas sembly. If repair is needed , follow the p rocedures Adjust brakes. See Cushman Brake Adjustment (Small) or (Large). under "Wheel Cylinder Service." Brake Shoe Replacement Clean the brake backing p late.
Page 134 Install new seals, pack bearings, and install wheel assembly onto vehicle. See Front Wheel and Hub Service, Three Wheel or Rear Wheel Service. Adjustment (Cushman Large Brake) Front I NOT E • This brake is self adjusting and needs adjustment only on initial installation.
Page 135 Master Cylinder Service Raise the vehicle off the ground. INOTE SAFETY WARNING • Check the master cylinder and the immediate area • Support the vehicle on approved jackstands, to for signs of leaking fluid. prevent it from falling and causing injury. DO •...
Page 136 Slip the master cylinder boot over the push rod. Reinstall master cylinder into vehicle. Install the brass banjo fitting to the master cylinder with the bolt. See Figure 12. Fill the cylinder with fluid and bleed the brake system by following the procedure in "Brake Line Bleeding". Brake Pedal Free Travel INOTEI Insufficient free travel of the brake pedal may cause...
Page 137 Wheel Cylinder Repair I N O TE • If honing does not clean up the wheel cylinder walls, Cushman Brakes replace the wheel cylinder. Remove the hub and drum. See procedures under Clean wheel cylinder again with alchol after honing Front Wheel and Hub Service, Three wheel or and dry with compressed air.
Page 138: Parking Brake
Hydraulic Mico Brake Lock Check the fluid level. The master cylinder reservoir should be full or within 3/8 inch (9.5 mm) of the top Some models use a hydraulic micro lock to lock the edge (replace master cylinder cap to avoid splash rear brakes.
Page 139 TROUBLE SHOOTING Adjustment is made by turning nut on conduit. See Figure 15. Brake Drag Improper brake shoe adjustment Improper adjustment of master cylinder Brake shoes froze to heel pin Corrosion between parking brake, cable and t;iousing Broken brake lever spring Loose wheel bearings Wheel cylinder stuck Brakes Grab...
Page 141: Section 15 Service Specifications
SECTION 15 SERVICE SPECIFICATIONS Cylinder Head inch (mm) Service Dimensions and Clearances Item .004 (0.10) max. Cylinder head gasket surface distortion Cylinder head grinding height (minimum) 3.929 (99.8) Manifold gasket surface distortion . 004 (0.10) max . ° ° IN 45 - EX 45 Seat angle Valve seat...
Page 142 Valve rocker shaft & rocker arm inch (mm) Service Dimensions and Clearances Item Rocker arm inner diameter .6299 to .6313 (16.000 to 16.035) .6281 to .6294 (15.955 to 15.988) Valve rocker shaft outer diameter .0005 to .0031 (0.012 to 0.8) Shaft to arm oil clearance Cylinder Block inch (mm)
Page 143 Connecting rod inch (mm) Service Dimensions and Clearances Item .002 (0.05) Rod bend & twist .7874 to .7894 (20.00 to 20.05) Pin bore width .7795 to .7815 (19.80 to 19.85) Rod width .006 to .01 0 (0.15 to 0.25) Rod to crankshaft thrust clearance .0008 to .0017 (0.020 to 0.043) Connecting rod bearing oil clearance Crankshaft...
Page 144 Manifolds inch (mm) Service Dimensions and Clearances Item .004 (0.10) Intake manifold surface distortion .020 (0.51) Exhaust manifold surface distortion Flywheel inch (mm) Service Dimensions and Clearances Item .004 (0.10) Fly-wheel run-out Timing belt pulley inch (mm) Item Service Dimensions 4.3531 to 4.3627 (110.57 to 110.813) Camshaft pulley Pulley outer diameter...
Page 145 Piston inch (mm) Service Dimensions 2.6201 to 2.6213 (66.55 to 66.58) Standard o.s. 2.6299 to 2.6311 (66.80 to 66.83) .0098 (.025) o.s. 2.6398 to 2.6409 (67.05 to 67.08) .0197 (0.50) o.s . . 0295 (0.75) 2.6496 to 2.6508 (67.30 to 67.33) o.s.
Page 146 Radiator Specified value Item psi (kg/cm2 ) Radiator cap relief pressure 8.5 to 15.0 (0.60 to 1.05) Thermostat Specified value Item ° ° ° to 185 F (82 Start to open at ± Valve opening temperature ° ° F (95 Full opens at Radiator fan control switch Specified value...
Page 147 Distributor Specified value Item Breaker point gap .018 in (0.45 mm) ° ° to 65 Dwell angle 0.27 ± 0.027 µF Condenser capacity Resistive wire Specified value Item 60. to 13.2 No. 1 wire No. 2 wire 5.0 to 11.0 Wire resistance No.
Page 148 TORQUE SPECIFICATIONS HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specific torque values are not given. U.S. Standard Hardware Shank Size (Diameter in inches, fine or coarse thread) Grade 1/4 5/16 3/8 7/16 1/2 1 1/8 9/16 3/ 4...
Page 149 TABLE OF TORQUE VALUES Foot lbs. Inch lbs N·m Application Engine 39-48 53-65 Bearing cap mounting screws 7-11 Camshaft thrust ring 63-94 11-15 90-136 Carburetor 23-30 Connecting rod cap 17-22 11-16 15-22 Clutch 36-43 49-58 Crankshaft pulley 49-58 Cylinder head 36-43 15-23 Exhaust manifold...
Page 152 RANSOMES 8Ell§HM4A Cushman Inc. • A Ransomes Company P.O. Box 82409, Lincoln, Nebraska 68501-9971 U.S.A.

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