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Cushman Front Line 17 HP Diesel Service Manual

17 hp diesel and 22 hp gas powered models

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Table Of Contents

Table of Contents

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

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1 Model Identification
2 Engine Troubleshooting
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22 hp gas powered front line

Cushman Front Line 17 HP Diesel Service Manual

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