Cushman TURF-TRUCKSTER Manuals

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Cushman TURF-TRUCKSTER Service & Repair Manual (264 pages)

DIESEL & GASOLINE ENGINES

Brand: Cushman | Category: Utility Vehicle | Size: 17 MB

Table of Contents
3
Model Differences
4
Introduction
4
General Information
4
Contents
4
Index Numbers
4
Replacement Parts
5
Identification Numbers
5
General Cleaning
5
Safety
5
Torque Values
6
Torque Specifications
6
Front Cowl Access
7
Access Latches
7
Dump Box Release Lever
7
Access to Engine
7
Jacks, Jacking Locations and Using a Hoist
8
Towing
9
Tow Line Attachment Locations
9
Controls
10
Repair and Service Tools and Materials
11
Failure Analysis
12
Control Adjustments
13
Speed Controls
13
3-Cylinder Gasoline Engine Governor and Hand Throttle Adjustments
14
Idle Speed Setscrew
14
Cable Deflection Adjustment
14
Accelerator Pedal Stop Screw
14
Second Throttle Stop Screw Adjustment
15
Throttle Plate Check
15
Disconnect Turnbuckle from Broken Knee Lever
15
Broken Knee Lever to Full at Rest Position
15
Connect Turnbuckle to Broken Knee Lever
16
Governor High RPM Adjustment
16
Governor Low RPM Adjustment
16
4-Cylinder Gasoline Engine Governor and Hand Throttle Adjustments
17
Governor and Hand Throttle Adjustments - Diesel Engine
19
Choke Adjustments - 4-Cylinder Gasoline Engines
19
Choke Adjustment
20
Parking Brake Adjustment
20
Service Brake System
21
Service Brakes
21
Clutch Pedal Free Travel
22
Clutch Interlock Switch
22
Gear Selector Adjustment
23
Power Take off (PTO) Adjustments
23
Repair
24
Instrument Panel and Bulb Replacement
24
Engine
25
Cleaning and Lubrication
28
Diesel Engine
29
Air Cleaner
29
Radiator and Cooling System
30
Inspecting the Cooling System
30
Adding Anti-Freeze to the Cooling System
30
Changing Coolant
30
Radiator and Cooling System Repair
31
Muffler and Exhaust System
32
Fuel Filter Service
33
Purging Fuel System Using a Jumper Wire
34
Purging Fuel System Without the Use of a Jumper Wire
34
Engine Removal/Installation
35
Ignition System - 4-Cylinder Engine
36
Ignition Coil Test
36
Spark Plug Wires
36
Spark Plugs
36
Ignition System - 3-Cylinder Engine
37
Carburetor
38
Gasoline Engines
38
Drive Train
45
Drive Train Failure Analysis
48
Drive Shaft General
52
Drive Shaft Removal
52
Drive Shaft Removal and Installation — Vehicles with 3-Cylinder Gasoline Engines
52
Drive Shaft Disassembly
53
Drive Shaft Reassembly
53
Drive Shaft Installation
55
Clutch Cover and Disc Removal and Replacement
56
Clutch Removal
56
Clutch Disassembly
56
Inspection of Clutch Components
57
Clutch Repair
57
Clutch Reassembly
58
Release Bushing Removal
58
Clutch Disc Facing Inspection
58
Checking Backlash in Disc Serration
58
Clutch Adjustments
59
Clutch Release Lever Installation
59
Clutch Cover and Disc Installation
59
Gear Shift Cables/Connectors
60
Pressure Plate Ring Repair
62
Transmission General
63
Transmission Removal
63
Input Shaft Bearing Replacement
63
Extension Case
64
Splitting the Transmission
64
Gear and Shaft Repair
64
Input Shaft and Main Shaft
66
Countershaft
66
Transmission
68
Shifter Shafts and Forks
68
Transmission Inspection and Repair
69
Gear Teeth
69
Normal Gear Tooth Tool Marks
69
Gear Tooth Contact Patterns
69
Gear Tooth Chips
70
Ring and Gear Sleeve Teeth
71
Gear Repair
71
Synchronizer Rings
71
Spline Teeth
71
Fork Shaft Locating Springs
72
Gear Shift Fork Shafts
72
Extension Case Bushing
72
Checking Key Clearance
72
Transmission Reassembly
73
Shifter Shaft and Forks
73
Interlock Ball and Pin Installation
74
Shifter Fork and Shaft Orientation
74
Shifter Fork Assembly
74
Spring and Locating Ball Assembly
74
Countershaft, Main Shaft, Input Shaft and Stop Plate
75
Synchronizer Hub Installation
76
Positioning Synchronizers
76
Key and Slot Alignment
76
Low Gear Bushing Installation
76
Extension Case Oil Seal
77
Reverse and Idler Gear Positioning
77
Joining Upper and Lower Cases
77
Transmission Installation
78
Gear Shift Case
80
Gear and Shaft Disassembly
80
Countershaft Disassembly
82
Rear Axle
99
Brakes/Wheel Hubs
99
Brake System
99
Brake and Wheel Hub Repair
100
Axles and Axle Housings Removal
100
Rear Axle
100
Axles and Axle Housings Installation
101
Axle Housings and Differential
101
Differential Assembly Removal
103
Differential Front Cover Disassembly
104
Front Cover Disassembly
104
Removing Input Shaft Bearing
104
Shift Control Cover
105
Front Cover Installation
105
Shift Control Cover Disassembly
105
2-Speed Auxiliary Transmission Disassembly
106
Installing Shift Control Cover
106
Auxiliary Transmission Disassembly
107
Input Shaft and Gear Removal
108
Differential and Axle Assembly Installation
111
Brake System
113
Brake System Failure Analysis
115
Parking Brake Arrangement
116
Parking Brake
116
Service Brakes General
118
Bleeding Brakes
118
Brake Disassembly
119
Brake Shoe Reassembly
120
Wheel Cylinder
122
Master Cylinder Repair
123
Master Cylinder Removal and Replacement
123
Master Cylinder Connections
124
Steering
125
Steering Failure Analysis
127
Steering System General
128
Steering System Arrangement
128
Steering Wheels, Hubs and Brakes
129
Tie Rods, Ball Joints and Steering Knuckles
129
Steering Column Repair
130
Pitman Arm
130
Removing and Installing Steering Gear Assembly
132
Removal and Replacement of Steering Pumps
132
Bleeding the Steering System
133
Removing and Installing Steering Pump Assembly
133
Steering Gear General
134
Steering Gear Major Components
134
Steering Gear Disassembly/Reassembly
135
Housing End Plug O-Ring
135
Rack Piston
136
Adjuster Plug
138
Valve, Thrust Bearings and Worm Gear
139
Thrust Bearing Preload
140
Pitman Shaft Bearing
140
Pitman Shaft "Over-Center" Sector Adjustment
141
Steering Pump Removal and Installation
142
Steering Pump Repair
142
Wheel Alignment
144
Wheels and Tires
145
Wheels & Tires Failure Analysis
147
Tire Service
148
Hydraulics
149
37 Flare Fittings
153
Hydraulic Tube and Hose Fitting
153
Hydraulics General Instructions
153
O-Rings Boss Fittings
154
Special Hose Installation Instructions
154
Reference Marking
154
Replacement O-Ring for ORS (Face Seal) Fittings
155
O-Ring Face Seal Torque Recommendations
155
ORS (Face Seal) Fittings
155
O-Ring Boss Torque Recommendations
155
Standard Hydraulic Pump General
156
Standard Hydraulic Pump Removal
156
Standard Hydraulic Pump Disassembly
156
Hydraulic Pump — Standard (Without Hydraulic PTO Accessory)
156
Standard Hydraulic Pump Inspection
157
Standard Hydraulic Pump Reassembly
157
Marking Gear Teeth
157
Two-Section Hydraulic Pump for Vehicles with Hydraulic PTO Accessory
158
Hydraulic Motor Disassembly
160
Hydraulic Motor Removal
160
Hydraulic Motor General
160
Hydraulic Motor Inspection
161
Hydraulic Motor Reassembly
161
Hydraulic Motor Installation
161
Box Cylinder Disassembly
162
Box Cylinder Inspection
162
Box Cylinder Reassembly
162
Box Cylinder Disassembly and Reassembly
162
Seal Kit Installation
163
Control Valve Repair
164
Selector Valve Repair
165
Instrument Test General
166
In-Line Tester
166
Instrument Test Preliminary Checks
167
Standard Hydraulic System
167
Standard Hydraulic System Pump Flow Test
168
Selector Valve Test
169
Lift Valve Test
172
Cylinder Test
175
Bottom Selector Valve Test
177
Optional High/Low System
177
Pump Flow Test Section 1
177
Hydraulic Diagrams and Component Locations
187
Hydraulic Graphic Symbols
187
Hydraulic Schematic Symbols
187
Standard Hydraulic System Schematic
189
High/Low Hydraulic System Schematic
190
Hydraulic Component Locations (Standard Hydraulic System)
191
Chassis
193
Chassis Repair and Service Tools and Materials
194
Chassis Failure Analysis
195
Fuel Tank General
196
Fuel Tank Removal and Installation
196
Electrical System
200
Electrical System Repair and Service Tools and Materials
202
Electrical System Failure Analysis
203
Electrical System General Instructions
204
Wire Continuity Test
204
Resistance Test
205
Maintenance/Cleaning
206
Charging a Maintenance Free Battery
206
Battery General
206
Testing
207
Battery Test
207
Charging System - 3-Cylinder 660 Gasoline and Diesel Engines
208
Output Current Test
208
Voltage Test
209
Charging System - 4-Cylinder 970 Gasoline Engine
210
Starter
213
Starting Circuit Resistance Test
213
Starter Solenoid Test
215
No-Load Test
216
Ignition Switch Test
217
Horn Switch Test
219
Light Switch Test
220
Backup Light/Alarm Switch Test
221
Cooling Fan Switch Test
222
Clutch Interlock and Brake Switch Test
223
Fuse Test
225
Engine Oil Pressure Switch Test
226
Engine Cooling Water Temperature Sender Test
227
Fuel Level Sender Test
228
Relay Test
230
Fuel Pump Test (Diesel)
231
Glow Plug Test
232
Wiring Diagrams and Component Location Illustrations
233
Electrical Graphic Symbols
234
Truckster with 660 Gasoline Engine Electrical Diagram
236
Truckster with 660 Gasoline Engine Electrical Schematic
237
Truckster with 970 Gasoline Engine Electrical Diagram
238
Truckster with 970 Gasoline Engine Electrical Schematic
239
Truckster with Diesel Engine Electrical Diagram
240
Truckster with Diesel Engine Electrical Schematic
241
Preventive Maintenance
242
Scheduling
243
Administration
243
PMMRS Program Kits
243
Preventive Maintenance
243
Lubrication and Maintenance Schedules
245
Attachments
247
Mechanical PTO
250
Preparation for Repair
250
PTO Output Shaft
250
PTO Control Handle
250
Mechanical PTO Exploded View
251
Control Cable
252
Output Shaft and Universal Shaft
252
Drive Shaft, Sprockets, Chain and Tensioner
253
Chain and Tensioner
254
Hydraulic PTO General
255
Hydraulic PTO Preparation for Repair
255
Hydraulic Motor and Couplings
255
Options
257
Miscellaneous
258
Table of Contents
258
Precaution Decal Locations
259
Conversion Charts
261

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Cushman TURF-TRUCKSTER Service & Repair Manual (264 pages)

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