Cushman 4 Cycle 3 Cylinder Haulster Turf Truckster 327 Engine Complete Workshop Service Repair Manual
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SERVICE & REPAIR
INSTRUCTIONS
TURF-TRUCKSTER
®
DIESEL & GASOLINE ENGINES
MANUAL TRANSMISSION
Litho in U.S.A. 08/00
Revised 12/01
WARNING: If incorrectly used this machine can cause severe injury. Those who
use and maintain the machine should be trained in its proper use, warned of its
dangers and should read the entire manual before attempting to set up, operate,
adjust or service the machine.
!
CD-SRI-TRKMNL
Copyright 2001 Textron Golf, Turf & Specialty Products
“All rights reserved, including the right to reproduce this
material or portions thereof in any form.” GOLF , TURF & SPECIALTY PRODUCTS
Publication Registration
Information, specifications, illustrations and procedures in this
manual are based on information in effect at the time of publication.
Product improvements and changes due to advancements of product
design may not be included in this manual. This manual is reviewed
and updated as required to include changes and product improve-
ments. By returning the completed Registration below TGTSP will
notify you when an update is available.
Send Registration to:
Textron Golf,Turf & Specialty Products
P.O. Box 7708
11524 Wilmar Blvd.
Charlotte, NC 28273
Litho Date:
Company Name __________________________________________
Your Name ______________________________________________
Your E-mail Address ______________________________________
Address ________________________________________________
City, State __________________________________ Zip ________
Register Your CD
Use the registration
on back of tray card.
Attn. Service Department
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1
14
2
3
4
5
6
7
8
9
10
11
12
13
INTRODUCTION
CONTROLS
ENGINE
DRIVE TRAIN
BRAKE SYSTEM
STEERING
WHEELS & TIRES
HYDRAULICS
CHASSIS
ELECTRICAL SYSTEM
PREVENTIVE MAINTENANCE
ATTACHMENTS
OPTIONS
MISCELLANEOUS
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1
1A. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Index Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Standard SAE Grade #5 Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Access Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Access to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Dump Box Release Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Front Cowl Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Jacks, Jacking Locations and Using a Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-6
SECTION 1
INTRODUCTION
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CONTENTS
This manual contains repair instructions for truck com-
ponents, attachments and options. The Table of
Contents at the start of each section lists contents of
that section. Sections are identified by tabs in the right
hand margin.
This manual is to be used in conjunction with appropri-
ate operations and parts manuals for this equipment.
This manual is for trucks equipped with hydraulic actu-
ated dump boxes. Manuals covering optional acces-
sories (such as sprayers and core harvesters) are list-
ed in Section 13 of this manual.
This manual covers models with engine and rear axle
variations listed in the table below.
Normal maintenance, adjustment, and operating proce-
dures are also covered in the user operator’s manuals
and are only included where appropriate in this manual.
Engine repair is not covered in this manual. Refer to
the appropriate engine manufacturer’s instructions for
engine service and repair.
This manual includes all removal, disassembly, inspec-
tion, repair, reassembly, installation, adjustment, and
testing procedures. If you, as user of this machine, do
not consider yourself or your repair facilities capable
of a given procedure, please consult your dealer or
distributor.
Information, specifications, illustrations, and procedures
in this manual are based on information in effect at the
time this manual was published. Improvements and
product changes due to continual advancements of the
product design may cause changes to your product
that may not be included in this manual. Each manual
is reviewed and updated as required to include changes
and product improvements.
Read each section completely before proceeding with
specific repairs in that section. You will minimize errors
by understanding what you will be doing and how the
component relates to others in its system. Lists of
repair tools and materials for each section of the man-
ual are given at the start of that section.
The designations L.H. (left hand) and R.H. (right hand)
used throughout this manual refer to the operator’s left
or right when sitting in the normal operating position.
REGISTRATION
A registration card is provided in the back of this man-
ual (bottom portion of page). Fill out the card, remove
and mail immediately upon opening the manual for the
first time.
The registration entitles you to receive manual updates
for a period of two years. Updates are sent free of
charge.
NOTE
Only the original registration card will be accept-
ed. Photo copies, cards from other manuals, sug-
gestion cards, or any facsimile are not acceptable
and will not constitute a registration.
INDEX NUMBERS
Illustrations showing removal, disassembly, reassembly
and installation may have index numbers to call out the
sequence of procedure.
Where the sequence of procedure is not important or
self-evident (eg. linkages, hoses, clamps, etc.) index
numbers are not included.
Repair procedures for items not subject to wear (eg.
panels, brackets, frames) are not included in this man-
ual except for the general procedures given below.
Exercise common sense during disassembly or reas-
sembly; remove only the items required to accomplish
necessary repair or service.
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-1
1A
Engine Rear Axle
Suzuki 660, 3-cylinder, gasoline, 31 hp (23.1 kW) at 4450 RPM, 2-speed hypoid,
6.7" (170 mm) clutch 14.21:1 ratio
Suzuki 970, 4-cylinder, gasoline, 34 hp (25.4 kW) at 3600 RPM, 2-speed hypoid,
7.1" (180 mm) clutch 11.16:1 ratio
Perkins 103-10, 3-cylinder, diesel, 22.3 hp (16.6 kW) at 3000 RPM, 2-speed hypoid,
7.1" (180 mm) clutch 11.16:1 ratio
MODEL DIFFERENCES
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REPLACEMENT PARTS
Use the appropriate parts manual when ordering re-
placement parts. Follow installation instructions shipped
with service parts or kits. When ordering parts, always
give the model number and serial number of your
machine as well as quantity, part number and descrip-
tion of the parts needed (see Figure 1A-1 for model
and serial number location).
To eliminate error and speed delivery:
1. Write your NAME and ADDRESS on your order
plainly.
2. Explain WHERE and HOW to make shipment.
3. Give MODEL (or PRODUCT) NUMBER, NAME
and SERIAL NUMBER that is stamped on name
and serial number plates on your unit.
4. Order by QUANTITY DESIRED, the PART NUM-
BER and the DESCRIPTION OF PART.
5. Send your order to or visit your nearest AUTHO-
RIZED TURF EQUIPMENT dealer and distributor.
6. INSPECT ALL SHIPMENTS ON RECEIPT. If any
parts are damaged or missing, file a claim with the
carrier before accepting.
7. Do not return material to your AUTHORIZED deal-
er or distributor without a letter of explanation.
Make a list of all returned parts, show your name
and address, and include it with the shipment.
TRANSPORTATION CHARGES MUST BE PRE-
PAID.
IDENTIFICATION NUMBERS
See Figure 1A-1 for location of vehicle model and serial
numbers.
GENERAL CLEANING
Improper cleaning and lubrication of your vehicle
results in many equipment failures. Before any repairs
are undertaken, thoroughly clean the exterior of the
component to be removed.
Use a clean surface to lay out parts being removed.
Keep lubricants clean and cover containers not being
used. Plug or cap all hydraulic lines and ports to hy-
draulic components immediately after disconnecting.
SAFETY
Safety should always be the rule when working on or
with machinery. Always use safe practices and com-
mon sense when using hand or power tools. Use the
suggested procedures in this manual when working
with the vehicle.
Throughout this manual signal words will be used to
highlight special procedures. The signal words and
their meaning are as follows:
NOTE
Any procedure needing special care when per-
forming a procedure.
Decals on the machine denote cautions, warnings and
dangers. These cautions, warnings and danger decals
must be on the machine at all times. If they become
worn, torn or painted over, new decals should be in-
stalled as shown in Section 14 of this manual.
In addition to the decals on the vehicle, you must know
and observe all cautions, warnings and danger precau-
tions given in your vehicle’s Safety and Operation
Manual(s).
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-2
Figure 1A-1. Identification
! CAUTION
Hazards or unsafe practices which could result
in personal injury or product or property damage.
! WARNING
Hazards or unsafe practices which could result
in severe personal injury or death.
! DANGER
Imminent hazards which will result in severe per-
sonal injury or death if precautions are not taken.
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TORQUE VALUES
Torque values are given in the following “Torque Speci-
fication Chart”. Special torque values are called out on
illustrations and text throughout this manual.
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-3
1A
TORQUE SPECIFICATIONS
STANDARD SAE GRADE #5 SCREWS
Size Torque Values Size Torque Values
8-32 27-33 in-lbs. (3-4 N.m)
1
/ 2-13 67-83 ft-lbs. (90-113 N.m)
8-36 28-34 in-lbs. (3-4 N.m)
1
/ 2-20 81-99 ft-lbs.(110-134 N.m)
10-24 39-47 in-lbs. (4-5 N.m)
9
/ 16-12 99-121 ft-lbs. (134-164 N.m)
10-32 44-54 in-lbs. (5-6 N.m)
9
/ 16-18 108-132 ft-lbs. (146-179 N.m)
1
/ 4-20 7-9 ft-lbs. (9-12 N.m)
5
/ 8-11 135-165 ft-lbs. (183-223 N.m)
1
/ 4-28 9-11 ft-lbs. (12-15 N.m)
5
/ 8-18 162-198 ft-lbs. (220-268 N.m)
5
/ 16-18 15-18 ft-lbs. (20-24 N.m)
3
/ 4-10 234-286 ft-lbs. (317-388 N.m)
5
/ 16-24 17-21 ft-lbs. (23-28 N.m)
3
/ 4-16 270-330 ft-lbs. (366-447 N.m)
3
/ 8-16 27-33 ft-lbs. (37-45 N.m)
7
/ 8-9 360-440 ft-lbs. (488-597 N.m)
3
/ 8-24 31-39 ft-lbs. (42-53 N.m)
7
/ 8-14 396-484 ft-lbs. (537-656 N.m)
7
/ 16-14 45-55 ft-lbs. (61-75 N.m) 1-8 522-638 ft-lbs. (708-865 N.m)
7
/ 16-20 49-61 ft-lbs. (66-83 N.m) 1-12 576-704 ft-lbs. (780-954 N.m)
NOTE: These torque values are to be used for all hardware excluding: locknuts, self-tapping
screws, thread forming screws, sheet metal screws and socket head setscrews.
Metric Grade
Diameter —
5.6 8.8 10.9 12.9
Coarse Thread N.m ft-lbs. N.m ft-lbs. N.m ft-lbs. N.m ft-lbs.
M6 4.6 3.3 10.5 7.7 15 11 18 13
M7 7.8 5.6 17.5 12.9 26 18.4 29 21.3
M8 11 8.1 26 19 36 26 43 31
M10 22 16 51 37 72 53 87 64
M12 39 28 89 66 125 92 150 110
M14 62 45 141 103 198 146 240 177
M16 95 70 215 158 305 224 365 269
M18 130 95 295 217 420 309 500 368
M20 184 135 470 309 590 435 710 623
METRIC
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ACCESS LATCHES (See Figure 1A-2)
ACCESS TO ENGINE
For servicing the engine and related components, the
engine cover can be tilted forward or removed. To
gain access to the engine, push the engine cover
latch to the rear of the unit, tilt cover forward. The
latch is located at the center rear on top of the engine
cover (between the seat cushion(s) and backwall).
NOTE
European market (CE compliant) vehicles have
a key which is used to release a locking handle
at the side of the engine cover latch. Turn the
key to allow the latch to be pushed back.
DUMP BOX RELEASE LEVER
For servicing drive train and other components
mounted under the dump box, pull back the dump box
lever to extend the hydraulic cylinder and raise the
dump box. Push forward on the dump box lever to
lower the dump box.
FRONT COWL ACCESS
The front cowl opens to gain access to the fuse panel,
the horn, the master cylinder reservoir as well as vari-
ous access panels which when removed, allow
access to the shifting lever linkage and front suspen-
sion.
To open the front cowl, locate the release lever next
to the left side headlight.
Pull the lever to the right to release the front cowl
latch and at the same time pull up on the front cowl.
Open the cowl allowing it to rest against the ROPS
structure (if equipped) or the steering wheel.
The front cowl will not “spring up” when the release
lever is pulled. The cowl will have to be raised when
the latch is released.
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-4
! WARNING
The engine cover is a MACHINERY GUARD
and its removal exposes you to moving parts.
Keep hands, hair and clothing away from fly-
wheel, radiator cooling fan, alternator fan, engine
belts, pulleys and air intake. Never remove or
install the engine cover while engine is running.
Figure 1A-2. Access Latches
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JACKS, JACKING LOCATIONS AND
USING A HOIST
A scissors type jack or a floor jack with a 1-1/2 ton
(minimum) capacity that can be lowered to 3-3/8 inches
(86 mm) height is required.
The jacking locations are shown in Figure 1A-3.
Put the gear selector in 1st gear. Apply the park
brake. Raise the vehicle only enough to perform
maintenance required.
Place a jack in the appropriate location (see Figure
1A-3) and place a block behind (or in front) of the tire
diagonally opposite the side which is being raised
(see Figure 1A-4).
Jack the vehicle to the appropriate height and place
jack stands or equivalent support beneath the frame
near the jack. Lower the jack and allow the vehicle to
rest on the jack stands. Raise the vehicle only enough
to perform the maintenance required.
Make sure to block the tire diagonally opposite of the
side which is being raised (see Figure 1A-4).
When using a hoist to raise the vehicle, use the same
procedure for supporting the frame and blocking the
tires as you would when using a jack.
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-5
1A
! WARNING
Do not rely solely on hydraulic or mechanical
jacks for support. Use appropriate jack stands or
equivalent for supporting the vehicle. If using a
hoist, raise vehicle to appropriate height and
support using jack stands or equivalent support.
Never place feet, hands or any part of your body
under the vehicle when raising it with a hoist.
Figure 1A-3. Jacking Locations
Figure 1A-4. Blocking
! CAUTION
To prevent damage to the vehicle or attached
accessory, never use a hoist to raise only one
corner of the vehicle. Always raise both front or
rear corners equally.
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TOWING
If for any reason the vehicle needs to be towed, follow
the guidelines below to properly tow the vehicle.
If towing the vehicle with a tow-rope or a chain, an
operator is required to steer the vehicle and to control
the brakes.
Attach a tow line only to the front vertical frame mem-
ber on either side of vehicle as shown in Figure 1A-5.
Make sure the drive transmission is in “neutral” (out of
gear) and the park brake is released.
With the tow line attached, have the towing vehicle
move forward until the tow line becomes tight.
While towing, try to keep the tow line taut at all times.
Be cautious going down inclines and while turning
corners.
INTRODUCTION
SECTION 1A. GENERAL INFORMATION
1A-6
! WARNING
Never tow the vehicle faster than 5 M.P.H. (8
km/h). Towing at excessive speed could cause
either vehicle to lose proper steering control.
Figure 1A-5. Tow Line Attachment Locations
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2
2A. Repair and Service Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
2B. Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
2C. Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Speed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
3-Cylinder Gasoline Engine (Suzuki 660) Governor and
Hand Throttle Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2
4-Cylinder Gasoline Engine (Suzuki 970) Governor and
Hand Throttle Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5
Governor and Hand Throttle Adjustments — Diesel Engine . . . . . . . . . . . . . . . . . . . . . . 2C-7
Choke Adjustments — 4-Cylinder Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7
Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-9
Clutch Pedal Free Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10
Clutch Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10
Gear Selector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-11
Power Take Off (PTO) Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-11
2D. Gauges and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
SECTION 2
CONTROLS
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Thank you for considering this comprehensive Service Repair Workshop Manual for the Cushman 4 Cycle 3 Cylinder Haulster Turf Truckster 327 Engine.
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