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suzuki 970 liquid cooled gasoline engine perkins

1. Turn Signal Switch 894288 Taillight Adapter Flasher 825501 OR OR GY B Ye 28 H Left Turn G B GY B YIR Y Rog Signal Y B one Ke Left Headlight 837303 yin Y OR B BL a OR 4 BL WIBL Right Headlight RB W OR 837303 8 B 3 B g m Right Turn Signal K Sech B Trailer Brake BR
2. 1 t Headlight 15 Switch Ce Ce A m Flasher P4 p11 ps 17 P2 p a 18 P7 9 P10 ee P12 o x o 8 Turn g a 5 ii Si om Signal 4 g S o g N 99 ore Controller Switch E s BRUCH 5 5 3 H 5 5 9 me 3 8 ine Light 5 E LH FR RH FR ool 4 e Switch Turn 5 Turn 3 5 8 ir i gt 4 4 Switch Cab Sto LH RH LH 7 RH A Trailer Brake s Flasher Receptacle Light ai Head c Head light Light e 6 e TURN SIGNAL SWITCH SCHEMATIC Flasher Flasher 1 n ER ZS A d VE LH STOP RH LH RH LH STOP RH LH RH REAR SW REAR FRT REAR SW REAR ERT NEUTRAL HAZARD Flasher Flasher i n ORE 1 d f 1 f f f LH STOP RH LH RH LH STOP RH LH RH REAR SW REAR ERT REAR SW REAR ERT LH TURN RH TURN 185 186 NOTES CUSHMAN A Textron Company Cushman Products P O Box 388 Augusta Georgia 30903 0388 USA Inside USA
3. e 7L Ne 0 Left Turn G B GY B Y Signal vn EST i 9 ZP Y B one Left Headlight 837303 Y GB Y R B OR B ME M B w BL E d WIBL Right Headlight ap W OR 837303 Ze 6 A Soch a Headlight Switch Right Turn 843581 Signal 5 Trailer Brake Controller OR B ri Harness 893562 894597 aL BL HESE B B BR OR B OR B OR B L OR B 4 ons rene BL OR B BL BR ER en BR OR B PIN 1 NOT USED Trailer BR L 2 4 Dash Panel PIN 2 a DR Brakes wR WIR L orp d 8 sm 64166 NEN dence PIN 6 USED R weas rem EN ES ums ea P AB WIBR W BR Ke BINI2W RB D 698 E Brake Fluid SC NE WP m iL en LEI SA E 5 Reservoir 894456 WR wR B G PIN 15 W 36 Y B RB w EH 0 16 W 54 OR WIR W BL 17 W 30 W BL G PIN 18 28 G WIBL A B R Coolant 28 se WIBL Overheat Alarm Wiper Motor B GI 890000 886497 B B R R B w OR En A L R B Ze Laer Baer E Wiper Dome 16
4. Headlight Switch A T Heater Acc Controller Brake Fluid c Reservoir os C5 Mes Lo Fuse Panels Wd GH MES Lo Horn Button Power From Ignition Switch ACC Position Acc Brake Req d Turn Signal D 49 Brake Light gt Connect To Switch Main Flasher mu LJ N 27 Power Point TY Cab Stop Light Ignition Switch Tail Light 9 Harness Horn P894592 P894599 91 ELECTRICAL COMPONENTS and WIRING HARNESSES 6 Left Taillight OU 24 36 H 46 OU EN Right Taillight 00 Harness The wiring harnesses are shown as reference only Although the actual harness resembles the illustration s
5. Figure 42 Lubrication Points 33 SERVICE amp MAINTENANCE Cont FUSES The fuse box is located under the front cowl See Fig 43 The fuses protect the electrical lighting circuits and accessory circuits such as the windshield washers turn signals etc Dash Panel Fuel Pump Ignition Auto Trans Controller amp Fuel Cut Off Auto Trans ACC Power Port When replacing fuses be sure the replacement fuse is the same amp as the fuse being replaced 4 ACC Power o ppo DU Brakelight 5th Pull straight out to remove a fuse To install a fuse push Wheel Brake the new fuse into the appropriate fuse slot Heater ACC Power Flashers Horn oc Wiper Dome light Headlights Back up alarm Fuse Block Figure 44 Fuse Box Panel AN CAUTION Fuse Block Located Under Front Cowl S Electrical failure and or fire can result if the fuses are not the proper amperage BULBS FUSES AND FLASHER BULBS Voltmeter light Oil pressure warning light Tachometer Water temperature gauge light Fuel gauge light Hour Meter Light
6. LH TURN RH TURN 177 HEADLIGHT SWITCH SCHEMATIC B B Low HIGH Low HIGH LOW HIGH BEAM BEAM BEAM BEAM BEAM BEAM DASH DASH DASH TAIL TAIL TAIL OFF LOW BEAM HIGH BEAM e HEADLIGHT SWITCH E Si FLASHER KS p11 P8 Pi7 p2 14 Pi8 e P9 pis y P15 E lt 6 al zz TURN e bk it BRAKE HORN SIGNAL N u 5 p CONTROLLER SWITCH 5 ui nt 9 5 6 BRAKE l 5 El LIGHT 2 SWITCH A LHFR RH FR a Se tdi Se Ae ran OO Fe 5 a 9 2 HORN s 5 SWITCH RH Ess CAB LH G G HEAD 4 A Ak TRAILER STOP 2 TAIE RH is LIGHT P16 BRAKE TAIL HEAD G DASH PANEL RECEPTACLE ACC LIGHT 5 4 5 4 4 4 TURN SIGNAL SWITCH SCHEMATIC FLASHER FLASHER T Bi ree LH STOP RH LH RH LH STOP RH LH RH REAR SW REAR FRT REAR SW REAR NEUTRAL HAZARD FLASHER FLASHER 5 4 2 3 i LH STOP RH LH RH LH STOP RH LH RH REAR SW REAR Er REAR SW REAR WIRING DIAGRAM SUZUKI 970 TURF TRUCKSTER Left Industrial Taillight 892676 Right Industrial Taillight 892676 Industrial Taillight 8 Harness 892676 5 Distributor 33100 85750 Alternator
7. k IGNITION E 2 205 CLUTCH SWITCH STARTER SWITCH FUEL SOLENOID TT 1 ace HONG E IGNITION POWER OA er POINT 10A 10A SERVICE PARK BRAKE BRAKE c RESV SENDER pe WIPER ACC HEATER OIL FAN MOTOR POWER SWITCH DISTRIBUTOR SENDER SENDER SWITCH a 4 POWER POWER STARTER TIGHT HAN 4 gage 4 gi SPARK PLUGS HEADLIGHT SWITCH SCHEMATIC B B B Lt Ty a LOW HIGH LOW HIGH Low HIGH BEAM BEAM BEAM BEAM BEAM BEAM DASH DASH DASH TAIL TAIL TAIL OFF LOW BEAM HIGH BEAM IGNITION SWITCH SCHEMATIC BAT BAT BAT BAT ST ACC IGN ST ACC IGN ST ACC IGN ST ACC IGN OFF START ON ACC POSITION POSITION POSITION POSITION 174 WIRING SCHEMATIC SUZUKI K6A TURF TRUCKSTER con t a p RH SW REAR NEUTRAL LH LH REAR FRT FLASHER VTE RH FRT N LH STOP RH REAR SW REAR LH TURN LH FRT RH FRT RH TURN LH STOP RH LH RH REAR SW REAR FRT FRT
8. 19 Se 5 48 S5 Apply RN Loctite 222 Reference 90 5 28 Right Engine Mount 51 e 970 Suzuki eg y 299 6 Loctite 242 Reference Air Cleaner Brckt H Perkins Diesel Reference 3 Transmission With Perkins Diesel Reference 22 Diesel Engine All components are used with both the 970 Suzuki and the Perkins Diesel engines unless otherwise noted in the parts list shown on the following page 894197 893444 894198 893594 DRIVE SHAFT CLUTCH and TRANSMISSION SHIFTER LINKAGE PERKINS DIESEL and SUZUKI 970 Ref Part No Part No No Description No Description 103867 Washer 5 16 4 894645 Ring pressure plate Perkins 306325 Lockwasher 5 16 01550 08803 Screw 452389 Screw M8 1 25 x 25 8 8 01550 08403 Screw 450377 Nut nylock M6 1 00 8 8 01550 08553 Screw 548190 Hairpin 09103 08131 Screw 800934 Screw M6 1 00 x 16 8 8 39312 50F01 Wire noise suppressor 894272 Driveshaft complete 08321 01083 Lockwasher 548482 Plug expansion 09111 08035 Screw 826284 Cross u joint 09117 08096 Screw 826285 universal 28391 85202 Bracket shift cables 894432 front 01421 10403 Stud 894433 Shaft drive 08316 10103 Nut 833273 Bushing 01421 10503 Stud 842010 Bushing clutch arm 09205 03019 Pin roll 843830 Connector shift cable 23260 85203 Shaft clutch release 843778
9. Figure 66 Remote Hydraulics Control Handle Filter Hydraulic Hydraulic 550 i Cylinder When the remote hydraulics are not connected to equip PRESSURE DJ RETURN ment the male and female quick connectors must be con suction nected to form a closed loop See Fig 66 HETUON It is extremely important that the hose nipple be inserted For Motor Driven Accessory And For Truckster Cylinder i Truckster Dump Box Operation Operation into the quick connector to form a closed loop as shown Plug 1 4 2 3 8 9 7 10 Plug 1 4 2 3 7 8 This will prevent dirt from entering the system and prevent For Motor Driven Accessory And For Accessory Cylinder the hydraulic system from over heating leading to system Inoperable Truckster Cylinder Operation Plug 1 2 3 4 8 9 7 10 8 failure if the remote selector knob is accidentally pulled up re ae with the accessory removed AN WARNING The vehicle is equipped with a hydraulic system to operate equipment During operation ALWAYS stay clear of moving parts to prevent injury 45 OPERATING REMOTE HYDRAULICS Cont GOVERNOR CONTROL AND HAND THROTTLE Amanually set variable governor control is included with the P T O for regulation of P T O or ground speed The control lever is attached to the panel to the left of the 1 instrument panel The hand throttle
10. 35 8 Peele 8 8 8 844179 PARKING BRAKES ARE NOT AUTO MATICALLY APPLIED VEHICLE MAY MOVE CAUSING PERSONAL INJURY AND OR PROPERTY DAMAGE ALWAYS APPLY HAND OR FOOT BRAKES 822819 14 A WARNING 1 READ AND UNDERSTAND ALL LABELS AND THE OPERATOR S MANUAL 8 SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE 2 DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE 9 ONLY CARRY PASSENGERS IN SEATS PROVIDED 3 DO NOT MODIFY THIS VEHICLE WITHOUT MANUFACTURER S AUTHORIZATION 10 WHEN PARKING LEAVING VEHICLE FOLLOW ALL INSTRUCTIONS IN 4 PLACE LOADS FORWARD OF REAR AXLE OPERATOR S MANUAL FAILURE TO HEED THESE 5 TOP HEAVY LOADS CAN CAUSE UPSETTING DO NOT EXCEED PAYLOAD 11 AVOID SUDDEN STARTS STOPS AND SHARP TURNS ESPECIALLY ON SLOPES OR SN RUNG CAPACITY WITH HEAVY LOADS 6 DO NOT OPERATE IF REPAIRS ARE REQUIRED 12 KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT 7 KEEP ALL SHIELDS IN PLACE 13 KEEP ARMS AND LEGS WITHIN VEHICLE BODY Description i Description 821071 Decal Notice not motor vehicle 009034880 Decal Warning fan 822819 Decal Warning park brake 845038 Decal Vehicle Operation 837270 Decal remote hyd connections 845185 Decal Park brake CE 840754 Decal Warning pressure 845027 Decal Pinch point As Req d 840845 Decal diesel fuel only 840857
11. Fuel Pum Sender 15100 53F03 843298 2100799 COLOR CODE B BLACK W WHITE W BR WHITE w BROWN STRIPE BL BLUE Y YELLOW W G WHITE w GREEN STRIPE BR BROWN BL B BLUE w BLACK STRIPE W OR WHITE w ORANGE STRIPE G GREEN G B GREEN w BLACK STRIPE W R WHITE w RED STRIPE GY GREY OR B ORANGE w BLACK STRIPE W Y WHITE w YELLOW STRIPE OR ORANGE P BL PURPLE w BLUE STRIPE Y B YELLOW w BLACK STRIPE PK PINK R B RED w BLACK STRIPE Y R YELLOW w RED STRIPE P PURPLE W B WHITE w BLACK STRIPE R RED W BL WHITE w BLUE STRIPE 178 WIRING DIAGRAM SUZUKI 970 TURF TRUCKSTER Turn Signal Switch 894288 Taillight Adapter rea too Flasher 825501
12. 136 Distributor Suzuki 970 157 165 Drawbar a a 56 57 Driveshaft Suzuki K6A 118 119 Perkins diesel amp Suzuki 970 100 101 Automatic transmission 120 121 E Electrical components 92 93 Emissions control Suzuki 139 Emissions control Suzuki 970 126 Engine mounts Suzuki K6A amp 970 102 Perkins diesel 103 Exhaust system Suzuki K6A 58 139 Suzuki K6A Catalytic Converter 59 Suzuki 970 amp Perkins diesel 60 61 F Fan radiator cooling 94 95 Fenders rear 56 57 Filter air cleaner Suzuki 6 62 Filter air cleaner Suzuki 970 amp diesel 63 Filter oil Suzuki K6A 150 151 SUZUKI 970 REN 158 Flywheel Suzuki K6A 154 155 Flywheel Suzuki 970 159 Foot throttle Cable and Linkage 71 Fuel controller automatic transmission 92 93 Fuel injector assembly Suzuki K6A 141 Fuel system Suzuki K6A amp 970 66 67 Biller E 66 67 Pump o sse efe 66 67 140 x REG 66 67 Fuel system Perkins diesel
13. f Reference Lower Rops Part No 893145 Reference Console Panel 2 85 72 4 mm 44 11 2 8 amp S Apply Loctite 592 To Install Neoprene Cover and Hard To Bushing O D ware Use Neoprene Cover as a Tem plate Mark and Drill Six 6 140 3 5 mm Dia Holes Position Neoprene Cover and Secure Using Mounting Strips and Rivets as Shown Dm P893446 P2701428 P2700600 amp 8 Description 450377 Nut staytite M6 1 00 450453 Nut M8 1 25 G10 9 450454 Nut M10 1 50 10 9 452388 Screw M8 1 25 x 20 G8 8 452391 Screw M8 1 25 x 40 8 8 452398 Screw M10 1 50 x 20 8 8 800446 Locknut 5 16 24 809152 Washer 5 16 x 1 3 16 827182 Pulley 3 dia 76 mm dia 845134 Bracket park brake lever 843158 Bracket park brake cable 843356 Equalizer park brake 843359 Bushing park brake 845133 Cable park brake 894317 Lever park brake 893583 Cable park brake to rear brakes 133741 Rivet pop 12 5 clsd end 2701335 Mounting park brake 2701336 Cover parking brake 70 FOOT THROTTLE and LINKAGE 5 5 10 When attaching the throttle link to the pedal the pin Item No 11 will be inserted in the o second hole from the top amp 4 16 EE EC X LI gt 14 Front Of Vehicle 20
14. 123 Carburetor Suzuki 109 110 112 Carburetor Suzuki 970 125 Catalytic convertor Suzuki 59 Coil ignition Suzuki K6A 52 53 92 93 Suzuki 970 52 53 92 93 Console panel 52 53 56 57 Clutch assembly automatic transmission 128 Clutch Suzuki 79 118 119 Perkins diesel amp Suzuki 970 80 100 101 Clutch pedal cable gasoline 79 Clutch linkage diesel 80 Cover engine 52 53 Cooling System 94 95 eis aser c SI std eos 54 55 Crankshaft Suzuki 96 154 155 Crankshaft Suzuki 970 97 159 Cylinder hydraulic 85 Cylinder block engine Suzuki K6A 150 151 Suzuki 970 158 Cylinder head engine SuzukiK6A 148 149 Suzuki 970 157 D Decals re 104 Delivery pipe Suzuki 141 Differential two speed 88 Dipstick oil Suzuki K6A 121 152 153 Suzuki 970 158 Dipstick transmission Suzuki K6A auto 121 4 Page Distributor Suzuki K6A
15. Light Harness L Power Point G 5 BS y 894804 va 3 Acc Power ir Main Harness wa a 894266 4 D E2308 Auto Tran 6 Controller 2 78 Fuse Holder ptc B 825996 B e Ny 93 8 gt Ground Standoff I 1 7 828231 Y W BL R B R WIR gt Heater Switch S l 894801 oR 8 Heater Fan won YR 1 Acc Power dn on 894805 v B B W OR YIR wn RLor CR Se RNY YR Le WIR AK sv a B B B Heater Harness R R 894806 R Horn Button 5 830366 Clutch Switch _ Brake Lig 894308 Switch 894308 Power Point Key Switch 837295 843942 Horn 886090 179 WIRING SCHEMATIC SUZUKI 970 TURF TRUCKSTER d Ignition E 2 Ge Clutch Switch Starter Switch Id Pump olenoid 14 20 Fan eo 9 Ignition BENE Power 10A Coil Service Park Point san SE aomp Brake Brake Sender Wiper Acc Heater Coolant Fuel oil
16. Drain Plug Figure 55 Figure 56 Differential Filler and Level Check Plug Differential Drain Plug 40 SERVICE amp MAINTENANCE Cont DRIVE TRANSMISSION Maintaining proper lubrication level in the transmission is very important to the life of the gears and bearings Manual Transmission Suzuki K6A Engine Check transmission fluid level every 100 hours or 3 months Change transmission fluid every 600 hours or 12 months Transmission Capacity 1 05 qts 0 91 Recommended Lubricant SAE EP 80 90 Gear Lube The filler plug is located on the right side of the transmission When removed the filler plug opening is used to deter mine proper fluid level Transmission Drain Plug 57 58 Transmission Drain Plug Suzuki K6A Engine Transmission Filler Plug Suzuki K6A Engine The fluid level must be level with the bottom of the filler plug hole If level is low add fluid through the filler hole until it begins to flow from the filler hole Reinstall the plug To drain the transmission fluid remove the drain plug on the rear of the transmission When draining and filling the transmission use a pipe thread sealant on the plug threads before replacing them Manual Transmission Suzuki 970 amp Perkins Diesel Engines Check transmission fluid level every 100 hours or 3 months Change transmission fluid every 600 hours or 12 months Transmission Capacity 1 34 ats 1
17. Suzuki 970 To Engine Diesel P893675 P893657 P893972 P893595 P894659 Ref Part No Part No No Description i No Description 1 2 3 4 5 6 7 8 9 1 1 306328 Pin cotter 3 32 x 3 4 4 844223 Spring torsion 844224 Pin roll 3 16 x 1 3 4 830784 Pin clevis 1 4 x 1 7 8 450452 Nut M6 1 00 G10 9 841663 Panel floor access 452378 Screw M6 1 00 x 20 843360 Channel mount 452695 Screw M6 1 00 x 20 taptite 843561 Link throttle 515268 Bushing 843562 Mount channel 524633 Screw shoulder 5 16 18 1 843563 Plate pivot 524643 Bearing split 843997 Bracket stop 548911 Nut 5 16 18 894159 Pedal throttle 800943 Screw tap 10 14 x 5 8 894540 Cable throttle Suzuki Models 1 806714 Pin clevis 5 16 x 3 4 894618 Cable throttle Perkins 71 STEERING WHEEL STEERING SHAFT CONNECTING HOSES POWER STEERING PUMP and STEERING GEAR Also Reference Pulleys Belts And Brackets On Pages 101 102 amp 103 Suzuki 970 Bracket Shown Reference Front Clip Included Reference With Ref No 25 Lower ROPS P893331 72 STEERING WHEEL STEERING SHAFT CONNECTING HOSES POWER STEERING PUMP and STEERING GEAR Part Description 320107 Tie cable 7 1 2 190 mm 450453 Nut M8 1 25 G10 9 450457 Nut M16 2 00 800930 Screw M8 1 25 x 16 8 8 450739 Screw socket head M10 1 50 x 30
18. 8 33 M Maintenance Guide 35 36 Master Cylinder Reservoir brake fluid 37 Mechanical P T O 46 47 Oil Warning Light 10 16 Oil Level engine 15 16 Park Brake Lever and Adjustment 12 38 Parts Illustrations 52 177 Power Steering Reservoir 21 Pre Starting Check 15 P T O Operation 46 50 Purge Fuel System Diesel 24 25 R Remote Hydraulics 45 Reservoir Hydraulic 51 Safety Instructions Inside Front Cover 14 Specifications 8 9 Starting the engine With Automatic Transmission 22 With Manual Transmission 21 22 Diesel with manual transmission 23 24 T 10 Taillight Replacement 39 Tire Air PreSSUre 21 Tire Removal and Replacement Front ek d e de ed SERM 30 Bear ees Seer eee 30 Towing a Trailer 43 Towing The Vehicle Automatic Transmission 28 Manual Transmission 27 28 Transmission 41 Automati euere 42 V Vehicle Identification Number 6
19. After Setting Governor Spool Yoke to 321 319 Adujust Set Screw to Maintain That Dimension Then Apply GM a Ind Silicone Sealant or tele Equivalent P Set Screw 319 894080 894197 894588 894507 Ref Part No Part No No Description No Description 894080 Governor complete 800227 Plug 1 8 27 111812 spool 800558 Screw set 3 8 16 x 5 16 111814 Washer thrust 833056 Gasket governor 111816 Washer thrust 833102 oil 111817 Spool governor 835271 Nut governor arm 112840 Bearing thrust 843537 Bracket governor knee 130728 Nut jam 1 4 20 843149 Bushing steel 158061 18 843157 Head governor 160410 Carrier amp weights 894471 Reservoir governor 302288 Screw 1 4 20 x 1 833103 Bearing needle 306396 eLockwasher 1 4 888397 Shaft governor complete 306506 eLockwasher 6 833066 Shaft governor 306915 Screw machine 6 32 x 5 16 2 833104 Ring retaining 306966 roll 1 8 x 3 4 1 833345 ball 548325 Ring retaining 894067 eLever governor control 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 99 DRIVE SHAFT CLUTCH and TRANSMISSION SHIFTER LINKAGE PERKINS DIESEL and SUZUKI 970 3 1 4 797 Front Of Vehicle Reference Shift Lever Case
20. 10 Water Temp Gauge amp Overheat Buzzer 10 17 18 PARTS INDEX Page A Accelerator 71 Accessory power plug 12 volt 92 93 Air cleaner Bracket and Filter Suz kt KOA ee 62 Suzuki 970 amp Perkins 63 Alternator Engine belts Pulleys amp Brackets Suzukt K6A Se ae 96 S zukIl 970 s s te hernia aan 97 164 Perkins diesel 98 Automatic transmission Suzuki K6A 120 121 AXIS ROAM o cr Ed ac eiae ae ER 83 B Belts 96 97 98 Body Hood Headlights 54 55 Brake band automatic transmission 132 Brake lever parking 70 Brake pedal service 64 65 Brake oe greece Mata RA 64 65 Brake cylinder master 64 65 Brake fluid reservoir and bracket 64 65 Brakes front amp 64 65 Cables Choke Suzuki 970 52 53 Gl lcht Svat inning As 79 Shifter 81 82 Two speed differential control 88 89 Cam Chain Suzuki K6A 107 108 Camshaft amp components Suzuki K6A 105 106 Camshaft amp components Suzuki 970
21. J Front Of Vehicle Ref Part No No Description 4 Description 450193 Screw M8 1 25 x 30 2700144 Bolt muffler flange 450378 Locknut M8 1 25 staytite 2700145Spring muffler flange 838295 Strap muffler hanger 4114221 8 Bracket muffler 841982 Clamp exhaust tube 1 1 2 36074 G01 Tube assy muffler inlet 2700143Ring muffler flange 4119866 8 Muffler assy 58 Ref No 1 2 3 4 5 6 7 8 9 CALIFORNIA EXHAUST SYSTEM CATALYTIC CONVERTER SUZUKI K6A Part No Description 450193 Screw M8 1 25 x 30 Front Of Vehicle Description 841982 Decal carb Suzuki K6 450378 Locknut M8 1 25 staytite 412517 8 Shield muffler 8388295 8 Strap muffler hanger 841982 Clamp exhaust tube 1 1 2 270143 Ring muffler flange 2700144 Bolt muffler flange 2700145Spring muffler flan 41124517 8 Bracket muffler 306450 Screw 5 16 18 X 3 4 306325 Lockwasher 5 16 103867 Washer 5 16 306419 Screw 1 4 306396 Lockwasher 1 4 36072 G01 Converter AY catalytic 815680 Washer special 4116284 8 Muffler assembly 4121525 8 Shield catalytic converter 59 EXHAUST SYSTEM SUZUKI 970 Referenced From Power Assembly NOTE TAILPIPE TO BE 0 5 FROM FENDER TAILPIPE OUTLET TO BE PARALLEL TO GROUND Ref Part No Part No No Description No Description 450193 Screw M8 1 25 x 30 2 4119867 8 Shield muffler 450378 Locknut M8 1 25 Stayti
22. HARNESS AUTERRATOR en TURF TAILLIGHT 893602 893633 OIL PRESSURE 37820 80001 TEMP ae SENDER 6 9 R R w P BL wi R jh Y B Y c B 8 DN P BL ES B P BL wi E Re we B B WIR d ECH B R w B PK B PK n AB OR G B G EE BR 5 OR s PK B EA BR T Ar E RE 2 Se H Ss Ar ae PIN 1 WHITE BLUE B BW amp PIN 2 BROWN Gi m BL NV 5 PIN 3 PINK B eu PIN 4 YELLOW H a PING WHITE GREEN proc G B G G G Y Ci By PING GRAY e TS We WR p G WR B WIBL T PINS ORANGE e d n teme Da Ben Y 3 CARB vacuum FUEL CUTOFF NOISE vacuuM pmANGE WE PK SHIFT THROTTLE GE ie PIN 13 NOT USED FUEL PUMP FUEL LEVEL SWWCH 38850 51F10 3355352 00 VACUUM SPEED PIN 15 NOT USED 1510 5903 SENDER SOLENOID SENSOR PiN 17 BLACK GABLE PIN 18 CLEAR CABLE COLOR CODE B BLACK WHITE W BR WHITE w BROWN STRIPE BL BLUE Y YELLOW W G WHITE w GREEN STRIPE BR BROWN BL B BLUE w BLACK STRIPE W OR WHITE w ORANGE STRIPE G GREEN G B GREEN w BLACK STRIPE W R WHITE w RED STRIPE GY GREY ORANGE w BLACK STRIPE W Y WHITE w YELLOW STRIPE OR ORANGE P BL PURPLE w BLUE STRIPE Y B YELLOW w BLACK STRIPE PK PINK R B RED w BLACK STRIPE Y R YELLOW w RED STRIPE P PURPLE W B WHITE w BLACK STRIPE R RED W BL W
23. Description Clamp cable Lockwasher 10 Nut 10 32 Pin cotter 29 32 x 3 4 Screw 10 32 x 1 2 Nut 10 24 Tie cable 7 1 2 190 5 mm Nut M6 1 00 G10 9 Screw M6 1 00 x 20 Screw 10 24 x 1 2 G5 Screw 1 4 20 x 3 4 Pin clevis 5 16 x 31 32 x Apply Loctite 242 21 Reference Differential 11 16 1 amp 14 21 1 Must Attach Control Cable To Park Brake Cable w Cable Tie To Avoid Coming In Contact With The Muffler Part 817104 827821 828049 837043 841264 843607 844116 844130 893067 894743 307776 836841 893439 Description Stop wire Cable control hand throttle 1 Bracket cable to differential 1 Panel left hand turf Bushing throttle cable Decal left hand dash turf Cable governor control Cable control hi lo shift Nut double Screw 3 8 16 x 2 3 4 Bracket hi lo shift cable mount HAND CONTROLS GOVERNOR and THROTTLE DIESEL x APPLY LOCTITE 242 Reference Differential 11 16 1 amp 14 21 1 Reference Control Panel Reference Foot Throttle Must Attach Control Cable To Park Brake Cable w Cable Tie To Avoid Coming In Contact With The Muffler 894198 P894647 893594 893533 Part Description No Description Clamp cable Panel left hand turf Lockwasher 10 Bushing throttle cable N
24. Ring assembly Clutch assembly eWasher INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 135 DISTRIBUTOR SUZUKI K6A Front Of Vehicle Ref Part No No 33100 51F11 Distributor complete Description 33180 62D10 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 136 33321 50750 33278 85060 33310 51F10 33326 51F10 33140 64B70 33151 86240 33152 64B70 33375 62D10 33152 64B70 33370 76D20 02112 34103 33187 50F10 distributor Shield dust Coil pick up eConnector eScrew elgniter assembly eeScrew eeScrew 33230 51F10 08332 11033 33151 60B40 09138 08003 3341 0 50F20 33710 60621 33705 60611 33884 86510 33881 60 11 02112 06083 33460 50F30 Coil ignition Cord high tension No 1 1 Cord set high tension 09408 00013 C WATER PUMP SUZUKI K6A Front Of Vehicle r1 Description 4120074 Pump water 4119965 O ring 2702470 Bolt INDENTED PARTS NAME INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 137 WATER HOSE SUZUKI K6A 10 INTAKE MANIFOLD 7 WATER PUMP Description 4120076 Cap water thermostat 2702540 Union air vent 4120077 Cap water outlet 4120078 Hose water engine outlet 4120079 Thermostat water 4119967 Gasket thermo case 4119609 O ring water inlet pipe 4120081 Pipe water inlet 2702541 Gasket air
25. 68 69 Filter evacuees ee 68 69 Pump Hanser el 68 69 Tank iD ee 68 69 Frame SS dE E s sech 56 57 Front Cowl is usi el 54 55 G Gaskets engine Perkins 68 69 Gaskets engine Suzuki K6A 121 146 147 Gaskets engine Suzuki 970 156 Gear shift fork manual Suzuki K6A 114 115 Gear shift fork Suzuki 970 amp Perkins diesel 162 Generator Suzuki 6 143 Governor Suzuki K6A amp 970 90 99 Governor hand control Perkins diesel 89 Governor hand control Suzuki K6A amp 970 88 99 Governor amp throttle linkage Suzuki K6A amp 970 90 H Hand controls 88 Hand controls diesel 89 Headlights Here ent 54 55 HomM isse pe 54 55 Horn button ana 92 93 Hood release 54 55 Housing transmission automatic Suzuki K6A 121 manual Suzuki K6A 116 117 Housing transmission Suzuki 970 amp diesel 161 Hubs wheel front 74 75 76 77 H Hydraulic brake lines 64 65 Hydraulics Control box 84 87 Control 86 Eden rn ee ei 87 Lift cylinder oz xv Bine d 85 Liftsy
26. 1 Lever brake Cylinder brake dual Rod brake Reservoir brake fluid Switch micro Nut M10 1 50 G10 9 Screw M10 1 50 x 20 8 8 Nut 1 4 20 Screw 1 4 20 x 3 4 Clip Clamp Screw tap 10 14 x 5 8 Clamp tube wire Tee M10 1 00 Clamp tee Screw tap M6 1 00 x 12 The brake hose Part No 845380 is serviced as a 6 1 829 mm length 65 66 FUEL SYSTEM SUZUKI K6A and 970 To Main To Carburetor To Carburetor Frame Show For Reference Only 894475 Ref Part No No 120052 320107 450452 452378 452380 452398 829954 800021 843343 843298 833851 825624 826590 829787 829997 830425 833953 834037 1 2 3 4 5 6 7 8 9 FUEL SYSTEM SUZUKI K6A and 970 Description Lockwasher 10 Tie cable 7 1 2 190 5 mm Nut M6 1 00 G10 9 Screw M6 1 00 x 20 Screw M6 1 00 x 30 8 8 Screw M10 1 5 x 20 8 8 Screw 10 32 x 1 2 Cap fuel unvented Sender fuel Seal foam Clamp hose Hose fuel 5 16 i d As Terminal 45 1 4 male Grommet Hose fuel 1 4i d As Cover fuel sender Connector hose Part 841769 841969 836852 84310 843727 843726 842800 893527 Description Bracket reservoir mounting 1 Tank fuel eGrommet Elbow 90 Tube fuel pick up Clamp filter Support fuel t
27. TURN SIGNAL SWITCH 894288 WIRING DIAGRAM SUZUKI K6A FLASHER 825501 R ai OR SC N a OR 2 OS 1 LEFT TURN OR SIGNAL G B GY B Y R Y vn EIST op aoe RB BL B i 085 BL Y B Ye w LEFT HEADLIGHT 837303 w Y R BL w B OR B 2 a w w BL o RB 5 Jor wel RIGHT HEADLIGHT RB Y Won 837303 B B B Be m BR HEADLIGHT SWITCH RIGHT TURN T 843581 SIGNAL R B
28. WIRING SCHEMATIC DIESEL TURF TRUCKSTER Ignition E 2 u Clutch Switch Starter Switch 40 Solenoid 20 Ix L 9 are Fuel Shutoff 7 tlle d 10A 10A 10A 9 1 Temi Service Park Point p Brake Brake Pre Heat Sender o Fuel ES Rela Resv Sender a Wiper Acc Heater Coolant Fuel i Fan Mator Power Switch Overheat Sender Press Switch a Alarm Sender Acc Acc oH 2 zm Starter Dome Heater Fuel Light Fan Sol Glow Plugs A A 4 HEADLIGHT SWITCH SCHEMATIC LI LI Il Low High Low High Low High Beam Beam Beam Beam Beam Beam Dash Dash Dash Tail Tail Tail OFF LOW BEAM HIGH BEAM IGNITION SWITCH SCHEMATIC BAT BAT BAT BAT N aa ST ACC IGN ST ACC IGN ST ACC IGN ST ACC IGN OFF START ON ACC Position Position Position Position 184 WIRING SCHEMATIC DIESEL TURF TRUCKSTER con t
29. AUTOMATIC TRANSMISSION SUZUKI K6A Ref Part No Ref No No Description Req d No 14 26500 60HH2 Body assembly transmission valve 2702822 Solenoid direct clutch 2702823 O ring 2702824 Solenoid assembly 2nd brake position 2702823 O ring 2702764 Bolt solenoid 2702825 Strainer transmission oil 2702826 Bolt valve body No 5 2702827 Bolt valve body No 6 2702839 Bolt valve body No 1 2702840 Bolt valve body No 2 26531 67HTO Piston set C1 ACC 26563 67H10 Spring ACC Part 2702830 2702831 Description 2nd brake position Piston set B1 ACC Spring ACC 2nd brake position 26563 67H30 Spring ACC forward piston 1 26533 67 Seal ring set accumulator 2702834 2702835 2702836 2702837 2702838 2702841 2702842 Bolt valve body No 2 Bolt valve body No Bolt valve body No 1 2 ul Bolt valve body No 4 2 Bolt valve body No 6 1 Spring ACC 2nd brake position No 2 1 Spring ACC 2nd brake position No 3 1 Ref Part No No 1 2702906 2702907 2702895 2702896 2702897 2702898 2702899 STARTER AUTOMATIC TRANSMISSION SUZUKI K6A Description Motor assembly starting assembly Screw assembly Bushing Bushing Holder assembly brush eLever assembly Part 2702900 2702908 2702909 2702903 2702904 2702905 2702470 Front Of Vehicle Description Switch assembly Armature
30. Gasket and Dipstick Suzuki K6A manual transmission 152 153 Suzuki K6A automatic transmission 121 122 Suzuki 970 dee es 158 Oil pump Suzuki K6A 113 122 Oil pump Suzuki 970 127 Output gears automatic transmission 130 Output shaft automatic transmission Suzuki K6A 130 P Park brake Lever Cable 68 Parking brake automatic transmission Suzuki K6A 131 Perkins Diesel Engine Information 68 69 PCV valve Suzuki 111 PCV valve Suzuki 970 126 Pistons Suzuki 6 154 155 Pistons Suzuki 970 159 Planetary gears automatic transmission 129 Power steering pump 72 73 PTO mechanical Suzuki 970 and diesel only 166 167 Pulleys Suzuki 96 Pulleys Suzuki 970 97 Pulleys Perkins diesel 98 R Radiator ERI ER 94 95 Rear platform 56 57 Rear springs shackles 83 52 53 Shifter amp shifter linkage 81 82 Shifter amp shifter linkage 970 Suzuki amp diesel 100 101 Shifter gears Suzuki K6A manual transmission 114 11
31. Grade 5 marking C2 Minimum commercial quality Lower quality not recommended Grade 8 marking Metric Standard Hardware Shank Size Diameter in millimeters fine or coarse thread p e re mo n e ne ne no zz sss e e es fenfus e on on cor b pep prp mo pepe pe ps ae 83 133 196 520 520 664 996 Grade 8 8 marking Grade 10 9 marking Grade 12 9 marking 168 SERVICE DATE SERVICE DONE INITIAL WIRING DIAGRAM SUZUKI K6A TURF TRUCKSTER LEFT INDUSTRIAL TAILLIGHT 892676 INDUSTRIAL TAILLIGHT HARNESS 892676 B BL B zi po BR R B BR w BR RIGHT INDUSTRIAL pn TAILLIGHT 892676 DISTRIBUTOR 33100 51F10 B R B ALTERNATOR 8 893633 con 33410 50F20 RB EXC WR BL B G BR 9 RB G R T CARB 5 8
32. K6A Suzuki Engine Dipstick Location 970cc Suzuki Engine WATER TEMPERATURE GAUGE AND OVERHEAT WARNING BUZZER The purpose of this system is to warn the operator if the engine temperature exceeds the normal operating range If the water temperature gauge raises above the 230 F 110 C mark a heat sensor is activated causing the overheat warning buzzer to sound AN CAUTION Be careful when opening the engine cover when raising the seat and when cleaning the chaff from around the intake screen Parts that are metal may be hot to the touch The vehicle seat is a machinery guard To avoid injury use extreme caution and DO NOT place hands or clothing near moving parts belts fan etc During operation driving if the water temperature gauge shows 230 F 110 C or over and or the over heat warning buzzer sounds follow this procedure 1 STOP the vehicle DO NOT STOP THE ENGINE 2 Immediately disengage any accessories that are operating Slow the engine to a fast idle Remove any dirt chaff debris etc from the radiator Water Temp MP intake screen located on the right side of the engine cover the intake screen and surrounding area will be hot use caution when removing debris from this area Failure to 1 heed the overheat warning and Figure 23 E Water Temperatur 2 maintain cooling system will cause permanent mer Temperature Gauge damage 17 SERVICE amp MAINTENANCE Co
33. Lever select cable 2702642 Boot select lever inside 2702643 Boot select lever outside 4120093 Bracket select lever 2702645 Boot shift amp select shift oil 2702647 Washer 2702648 Spring pin 2702649 Spring pin 2702650 Spring pin 2702651 Spring pin 2702652 Spring pin 2702653 2702654 2701827 2702655 2702494 2702656 115 2702556 2702557 4120085 2702559 2702560 2702561 4120086 2702563 2702564 2702565 2702566 2702567 2702569 2702570 2702571 2702572 2702569 2702573 4120087 4120088 2702576 2702577 2702578 2702580 2702581 4120089 2702583 2702566 2702584 2702585 2702586 2702587 2702595 2702596 4120090 2702598 2702599 2702600 2702601 2702602 2702603 2702600 2702604 2702605 2702606 2702607 2702609 2702610 2702600 2702611 2702612 2702613 2702614 2701921 2702615 2702616 2702617 2702581 TRANSMISSION MANUAL SUZUKI K6A Description Seal input shaft oil Bearing Shaft transmission main Gear main shaft low Bearing Gear main shaft 274 Bearing Gear main shaft 37 Bearing Washer main shaft bearing C ring Gear main shaft 5 Bearing Washer main shaft 5 gear Shaft transmission counter Gear counter shaft drive Circlip Gear countershaft 5t Bearing counter shaft center Hub low speed sync Ring low speed sync Spring sync ring low Key high speed sync Hub high speed sync Ring 219 gear sync Spr
34. SERVICE amp MAINTENANCE Cont TIRE REMOVAL Front amp Rear With the vehicle on a flat level surface if possible put the gear selector in first gear and apply the park brake Place a block in front of or behind the tire diagonally opposite the side which is being raised Refer to the Jacks Jacking Locations and Using a Hoist sec tion Pages 26 27 in this manual Raise the vehicle only enough to perform the mainte nance required 1 Remove the wheel retaining nuts See Fig 36 and remove tire and wheel assembly from hub Install the tire and wheel by reversing the above sequence Make sure valve stem See Fig 36 is located toward the outside Tighten wheel retaining nuts to 70 to 100 ft Ibs Figure 36 95 to 140 N m torque Wheel Retaining Nuts and Valve Stem WARNING DO NOT rely solely on hydraulic or mechanical jacks for support Use appropriate jack stands or equivalent for supporting the vehicle Never place feet hands or any part of your body under the vehicle when raising it 30 SERVICING THE VEHICLE AIR CLEANER ELEMENT This is a large capacity dry type air cleaner with a replace able element We recommend the filter element be replaced before engine performance is effected This may occur at 250 hours of service in very dirty operating conditions or at 500 hours in normal operating conditions We DO NOT recommend cleaning the filter element because of the possibility of damagin
35. pull up on the lever until park brake is applied the park brake lever will be at approximate 45 angle when applied To release slightly pull up on the handle push the button at the end of the lever and while holding the button in lower the lever to it s original position Park Brake Adjustment Raise the engine cover and locate the park brake cable and bracket beneath the console panel See Fig 50 With the park brake released brake lever down tighten the adjustment nut a couple of turns and apply the park brake continue adjustment until the brake lever is at an approximate 45 when the brake is applied Park Brake Lever Brake Adjustment Nu 49 50 Park Brake Lever Location Park Brake Adjustment Nut 38 SERVICE amp MAINTENANCE Cont BULB REPLACEMENT DASH PANEL Remove the four 4 screws securing the instrument panel to the dash Pull the instrument panel out and tilt forward to gain access to the rear of the panel See Fig 51 Determine which bulb will be replaced Rotate the bulb holder 1 4 turn pull up and remove holder and bulb Remove the bulb from the holder and replace with the appropriate bulb Reverse this sequence to install the bulb and holder Use the number printed on the bulb to obtain the correct replacement bulb also refer to the chart on Page 29 for bulb specifications Figure 51 Dash Panel Bulb Removal HEADLIGH
36. retaining 800930 Screw M8 1 25 x 16 8 8 835101 Fitting hydraulic 90 823119 Adapter 90 832900 Hose hydraulic 1 4 x 38 882993 Cylinder lift 844051 Plate float latch 809265 Pin hair 821893 Trim push on 830810 clevis 844598 Hose hydraulic 1 4 x 30 883236 seal 817320 Clamp hose 884574 seal 320107 Tie cable 7 1 2 190 mm 886001 seal 840877 Sleeve nylon 1 2 3 4 5 6 7 8 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated 85 HYDRAULIC CONTROL VALVE 894233 Ref Part No No 1 2 3 4 5 6 7 8 9 1 1 86 103867 306328 306375 306396 306463 308089 316907 450454 452404 521144 814079 Description Washer 5 16 Pin cotter 3 32 x 3 4 Nut 1 4 20 Lockwasher 1 4 Pin cotter 1 16 x 1 2 Washer 10 Screw 1 4 20 x 2 3 4 Nut M10 1 50 G10 9 Screw M10 1 50 x 70 8 8 Cover handle Pin clevis 5 16 x 1 1 8 Part 823118 823225 825538 844454 828056 828057 839213 843355 843758 843759 886270 Description Fitting hydraulic straight Pin clevis 3 16 x 1 Spring compression Elbow 90 w o ring Fitting Fitting Connector valve Mount control valve Handle control valve Bushing control valve Valve hydraulic HYDRAULIC FILTER and RESERVOIR Reference Seal Kit Part Hydraulic Control No 887017 Valve And Control 893447 89
37. s n TRAILER BRAKE BR ORB STOP LIGHT en one HARNESS 894597 BL BL zt BR BR ORB OR B one OR B OR B Y OR B BL Bi BR BR OR B CIPIT mag 8 a DASH PANEL W21 E BRAKES WIR WIR OR B BR 841636 PIN 4 42 WIR WIR PIN 5 NOT USED 2 EM BY Ware Jaguar a WwW gt PIN8 W 31 W Y MB w ay PING W 53 WOR W B 10 W 4 W wen wen OR BIN 12 W Eet RB P BL P BL 2 P BL 13 W 33 GR B B BRAKE FLUID wy E WB Wy GiB 14W 34 WIR RESERVOIR 894456 WIR wR B PIN 15 W 36 R B w SH lj PIN 16 W 54 B m OR be WIR WIBL PIN 17 W 30 W BL if PIN 18 W 28 G RB WIOR kr A COOLANT B a p PE foes OVERHEAT ALARM WIPERMOTOR B 890000 b Y 886497 R R w R R CHR Bd D D m B R n B P m 9 RE WIPER DOME LIGHT Je be ACC POWER A HARNESS 894804 POWER POINT Be iy ER y acc POWER w MAIN HARNESS we B 894266 G R B DOME LIGHT 97 n 182399 AUTO TRAN CONTROLLER a FUSE HOLDER 825996 TN 862 9 GROUND STANDOFF gt 828231 a W BL RB 4 ar R Be WIR B HEATER SWITCH 894801 OR S Y R PP yR 54 1 ACC POWER Ze HENTE EAN B R ORs W OR Y R wR OR 9n ay Cp YR 4 g WR IE K Zum 9 en Y Y
38. 17131 80000 Hub cooling fan 16119 50 00 Gasket oil pump case 1 17110 77300 Fan cooling 01550 06303 01580 06503 01550 06353 17550 77X50 Pipe water inlet 04211 09109 Pi 01550 06203 17400 78821 Pump set water 09401 11415 17431 73001 Gasket water pump 17559 73000 H17 Gasket inlet pipe 1 01550 06303 09352 70121 00B Hose water bypass 1 OO JO PS ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 127 TRANSMISSION INPUT SHAFT and CLUTCH ASSEMBLY AUTOMATIC TRANSMISSION SUZUKI K6A p Front Of Vehicle Ref Part No No No Description i No Description 2702769 Shaft set input 2702773 Clutch assembly direct 2702770 Plate set forward clutch 2702774 set direct clutch 2702771 set forward clutch 2702775 O ring set direct clutch 2702772 Bearing set thrust No 1 2702776 Washer set direct clutch INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 128 TRANSMISSION PLANETARY GEARS AUTOMATIC TRANSMISSION SUZUKI K6A p Front Of Vehicle 2 Ref Part No No Description 2702777 Gear front planetary ring 2702784 2702778 Bearing set 3 thrust 2702785 2702779 Gear front planetary 4120107 2702780 Bearing set 4 thrust 4119614 2702781 Bearing set 5 thrust 2702788 2702782 Gear planetary sun 2702789 2702783 Washer set thrust 4120108 Description Gear rear planetary Bearing
39. 3 1 Recommended Lubricant SAE EP 80 90 Gear Lube The filler plug is located on the rear of the transmission When removed the filler plug opening is used to deter mine proper fluid level The fluid level must be level with the bottom of the filler E Transmission E Drain Plug plug hole em If level is low add fluid through the filler hole until it begins to flow from the filler hole Reinstall the plug To drain the transmission fluid remove the drain plug on the rear of the transmission When draining and filling the transmission use a pipe Figure 59 thread sealant on the plug threads before replacing them Transmission Drain amp Fill Plugs 41 SERVICE amp MAINTENANCE Cont Drive Transmission con t Automatic Transmission Check transmission fluid level every 100 hours or 3 months Transmission Capacity 3 7 qts 4 2 L Change transmission fluid every 600 hours or 12 months Recommended Lubricant Mercon Dexron 11 To check the transmission fluid the engine must be running Place the gear selector in P Park apply the park brake and start the engine With the engine running remove the dipstick and wipe it with a clean rag Insert the dipstick into the extension tube until it contacts the tube Remove the dipstick and read the fluid level Fluid must be kept between the two marks on the dipstick If necessary add fluid to obtain the proper level Do Not overfill Add fluid using the
40. 31400 60C11 Y Coil 33410 85010 H 95 E 3 RR BW BR ep Turf Taillight BR Turf Taillight Harness 894313 BW BR 893602 Start Solenoid 8 B Temp Sender 889673 22 843857 BR Carb zi opp SOL Park amp 4 Trailer Brake 5 Receptacle o ES s l W R P BL wy P RB Ve P BL N P BL wy P BL d W BR x NB WIR 5 amp TEL we SO ec PAYS MER W BR WIR WES Se SE R Es S B 3 R B K LY e B 1 d Ges 10 GAUGE 10GAUGE J R W B B B S 5 6 B OR R g OR 08 OR S c WR amp R R aR Starter BG s T 31100 79X50 ep GT 4 Ne A wd 20Amp Zeg e EB op B 9 y Fuse Pressure Code cd p BR B 1 BW 5 Fan Switch 17680 50F70 Engine B Harness 894283 0 Harness i 894201 Fuel Level
41. Clamp tube wire Suzuki 970 825724 Hose air cleaner 844313 Hose intake Perkins 817320 Clamp 841943 Inlet air Perkins 842915 Bracket air filter 842235 Gasket air inlet Perkins 843666 Hose air intake 452378 Screw M6 1 00 x 20 Perkins 843715 Bracket air cleaner Suzuki 970 1 800934 Screw M6 1 00 x 16 970 1 2 3 4 5 6 6 7 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 63 Mounts To Front Suspension Frame 64 HYDRAULIC BRAKE LINES Reference Frame Reference Frame To Rear Brake Hose Connection P893441 893523 Ref Part No No 103867 306328 450453 450510 452388 452424 845380 800934 806714 810152 825624 840725 840726 842051 842103 842935 843022 843021 1 2 3 4 5 6 7 8 9 HYDRAULIC BRAKE LINES Part Description Washer 5 16 844167 Pin cotter 3 32 x 3 4 892921 Nut M8 1 25 G10 9 895113 Screw M3 50 x 20 G10 9 894167 Screw M8 1 25 x 20 8 8 894456 Nut M3 50 890808 Hose 5 16 brake 450454 Screw M6 1 00 x16 8 8 452398 Pin clevis 5 16 x 15 16 548910 Cover brake pedal 800026 Clamp hose 809137 Pin brake pivot 810435 Bearing brake pivot 800943 Tube brake line rear 812445 Union brake fitting metric 841842 Tab locking 843418 Tube rear brake 452692 Tube front brake Description Bracket reservoir mounting
42. Connector shift cable 23265 85200 Bearing clutch release 894299 Cable clutch 09448 20007 Spring clutch release 844202 Washer slotted 09300 14017 Bushing clutch release 892811 Wire ground black 24 610 mm 1 845223 Gasket shifter case 452392 Screw M8 1 25 x 50 8 8 23266 85002 Arm clutch release 548222 Set screw 8 32 08316 10083 Nut 800948 Screw 10 1 25 x 35 12 9 01550 08353 Screw 800949 Screw M10 1 25 x 50 12 9 04211 13149 Sleeve alignment 839752 Pin dowel 8 mm x 18 mm 22100 85200 Cover assembly clutch 842961 Sleeve alignment 22400 85141 Disc compression clutch 843323 Adapter transmission Perkins 37610 80023 Switch backup lamp 843754 09280 11002 O ring 844228 Stop 5th gear lockout 09250 30003 Plug transmission 894179 Cable shifter inspection timing OO JO INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 101 With 970 Model 898662 All components are used with both the Suzuki K6A amp 970 engines unless otherwise noted in shown below Ref Part No No 303269 306982 450453 452454 450412 452389 452398 452406 800571 843444 SOOANOaoaRWD 843530 894009 894293 894010 894292 893525 102 ENGINE and TRANSMISSION MOUNTS SUZUKI K6A and 970 Use Loc tite 242 TO Engine Use Loc tite 242 the parts list Description Lock
43. D BUB Bw BR BR TURF TAILLIGHT B TURF TAILLIGHT HARNESS 894313 BR 893602 START SOLENOID B B TEMP SENDER 889673 843857 BR W R RJ OR B a TRAILER BRAKE RECEPTACLE m m 2 2 1 PBL WY Wi N oer W BR R B P BL B WN W B Cen A Se WR R _ uA 8 B JOGAUGE e 10 GAUGE 1 B B R R OR R OR 5 B n wB vr w R B Ee J CH WR B o R W B Y A Ye 20 AMP OIL T B FUSE PRESSURE STARTER SE Wen 31100 70050 170 55 894189 FAN SWITCH 17680 50F70 B B W op B 0 HARNESS N 894201 I SENDER 15100 580 age COLOR CODE BLACK W WHITE W BR WHITE w BROWN STRIPE BL BLUE Y YELLOW W G WHITE w GREEN STRIPE BR BROWN BL B BLUE w BLACK STRIPE W OR WHITE w ORANGE STRIPE G GREEN G B GREEN w BLACK STRIPE W R WHITE w RED STRIPE GY GREY OR B ORANGE w BLACK STRIPE W Y WHITE w YELLOW STRIPE OR ORANGE P BL PURPLE w BLUE STRIPE Y B YELLOW w BLACK STRIPE PK PINK RED w BLACK STRIPE Y R YELLOW w RED STRIPE P PURPLE WIB WHITE w BLACK STRIPE R RED W BL WHITE w BLUE STRIPE TAILLIGHT ADAPTER o
44. Decal Remote hydraulics CE 840901 Decal Warning read ops man 844643 Decal Warning pto 844116 Decal LH dash turf 009039290 Decal CE 844177 Decal aux transmission 844179 Decal hydraulic controls 74792 Decal turf LH 74766 Decal turf RH 74764 Decal Cushman Textron DO JO PS ob Not illustrated 104 106 4120030 4120031 4120032 4120033 4120034 4120035 2701970 2701972 2701971 4119911 4119912 4119913 4119914 4119915 4119916 4119917 4119918 4119919 4119920 4119921 4119922 4119923 4119924 4119925 4119926 4119927 4119928 4119929 4119930 4119931 4119932 4119933 4119934 4119935 4119936 4119937 4119938 4119939 4119940 4119941 4119942 4119943 4119944 4119945 4119946 4119947 4119948 4119949 4119950 4119951 4119952 4119953 CAMSHAFT and COMPONENTS SUZUKI K6A Description Camshaft intake Camshaft exhaust Valve intake Valve exhaust Spring valve Retainer spring Cotter valve Seal valve stem oil Seat spring Tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim t
45. ER NS An B B HEATERHARNESS R B 894806 L we R Ee ol mE Less 88 n Cup Horn Burton e 830366 IGN e CLUTCH BRAKE LIGHT SWITCH SWITCH 894308 894308 5 KEY SWITCH POWER 837295 POINT HORN 843942 886090 171 DISTRIBUTOR 33100 51F11 COIL 33410 50F20 WIRING DIAGRAM SUZUKI K6A TURF TRUCKSTER with AUTOMATIC TRANSMISSION con t LEFT INDUSTRIAL TAILLIGHT 892676 STARTER 31100 70D40 START SOLENOID BW on 879945 2700799 FAN wen 48 NUETRAL SWITCH T START swiTcH 17680 50F70 m wen e PK wer PK 20 RIGHT INDUSTRIAL g RI we FUSE TAILLIGHT 892676 g UI Y 3 won GI Pk Ve m R 5
46. Gasket set auto trans 13228 840TO Element thermo 13380 851 0 Gasket set mnl trans D Ts eet 1 2 3 4 5 6 7 7 8 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 112 OIL PUMP SUZUKI K6A Front Of Vehicle Description 4120068 Pump oil 4120069 set 2702517 Screw 4120070 4120071 2701820 2701949 2702519 2702001 2702659 4120072 Bolt 8x 40 2701904 Switch oil pressure 4120073 Collar oil gallery INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 113 GEAR SHIFT FORK MANUAL TRANSMISSION SUZUKI K6A 35 12 d d Front Of Vehicle GEAR SHIFT FORK MANUAL TRANSMISSION SUZUKI K6A e 2702618 Fork low speed gear shift 2702619 Fork high speed gear shift 2702620 Fork 5 amp reverse gear shift 2702621 Shaft low speed 4120091 Shaft high speed gear shift 2702625 Shaft 5 amp reverse 2702626 2702627 2702628 2702629 2702630 2701111 Plate gear shift interlock 4120092 Bolt gear shift stop 2702633 Lever gear shift amp select 2702634 Bush select lever boss 2702635 bush select lever shaft 2702636 Shaft gear shift amp select 2702637 Case gear shift guide 2702638 Spring low select 2702639 Cam 5 amp reverse gear shift 2702640 Spring cam guide return 2702641 Lever shift cable 2702646
47. Gauge oil level 1 Switch oil pressure Filter oil 158 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 01550 10603 11219 85200 09103 10063 01421 10403 01421 10503 08316 10103 04211 13149 11221 73000 11229 73000 02162 06103 Guide oil level gauge 1 Bolt 10 x 115 Stud bolt Stud bolt 11241 73003 11510 85201 09117 06059 01411 06163 08316 10063 09247 12101 09168 12018 16520 79101 09280 16005 01570 06163 Stand oil filter Bolt 6 x 16 Stud bolt Plug oil drain Strainer oil pump CRANKSHAFT FLYWHEEL and PISTONS SUZUKI 970 Front Of Vehicle Ref Part No Part No No Description i No Description 12140 75112 Ring piston standard 12300 73812 075 Bearing set crnkshft 12140 75112 025 Ring piston 12300 73812 100 Bearing set crnkshft 12140 75112 050 Ring piston 12300 73830 Bearing set crank thrust 12111 85201 080 Piston standard 12300 73830 012 Bearing set thrust 12111 85201 025 Piston 08 0 25 12300 73830 025 Bearing set thrust 12111 85201 050 Piston 05 0 50 09283 32040 Seal front 12151 29001 Pin piston 12635 78401 Guide timing belt 09381 16001 Circlip 12631 78401 Pulley timing belt 08341 31059 Key 12611 66C00 Pulley crank 12619 60B00 12160 73010 Rod connecting 09159 08033 Nut connecting rod 12181 81051 0A0 Bearing standard 09283 60005 Seal rear main 12181 81051 0
48. HAZARD FLASHER 1 LH STOP RH LH RH REAR SW REAR FRT FRT HEADLIGHT IRA SWITCH EN 10A Lu FLASHER 4 k gt pid P4 11 P 7 P2 14 18 12 amp amp 2 TURN Sa Pk 777 a CONTROLLER SWITCH S a 8B of St E i L 8 2 amp 5 J amp LIGHT o 2 SWITCH IS a 3 2 RH FR uz o TURN a 5 a EE HORN 2 S SWITCH CAB LH RH 4 HEAD TAIL TAIL 4 A TRAILER STOP LH LIGHT V P16 BRAKE LIGHT HEAD DASH PANEL RECEPTACLE ACC LIGHT 4 4 A TURN SIGNAL SWITCH SCHEMATIC FLASHER FLASHER 175 WIRING SCHEMATIC SUZUKI K6A TURF TRUCKSTER WITH AUTOMATIC TRANSMISSION SPARE IDLE UP 17
49. LL Motor Power Switch Distributor Overheat sender press Acc A 4 Power Power D H Starter ES A 4 ee e 4 4 A s A A 4 Spark Plugs HEADLIGHT SWITCH SCHEMATIC Spark Plugs LIU LL Low High Low High High Beam Beam Beam Beam Beam Beam DASH DASH DASH Tail Tail Tail Off Low Beam High Beam IGNITION SWITCH SCHEMATIC BAT BAT BAT BAT ST ACC IGN ST ACC IGN ST ACC IGN ST ACC IGN OFF START ON ACC Position Position Position Position 180 WIRING SCHEMATIC SUZUKI 970 TURF TRUCKSTER con t Headlight H 15 Switch e 10 L 4 Flasher In a ne Pio P2 P14 18 P7 12 15 EN 5 2 0n PA 28 Turn E N Ek Oly 5 Horn Signal T 5 3 9 oF E Controller Switch lt a a oa SE dE 3 B Brake a te Light Switch LH FR RH FR A 2 Turn Turn 5 5 2 N p 8 2 2 e S 9 Switch RH e Cab LH Han Head 4 4 4 ys Tail EG
50. OR B Controller Light me 3 894597 893562 BL BL BR BR B OR B ORB OR B H DEE ag SE One BL BL PIN 1 NOT USED n BR m one Trailer BL Dash Panel BIN 2 WS WER Brakes wR WR L L d 9 BR 841636 Y PINS NOT USED WIR 5 g WR W ESSE rae E e RBG won PINS W 83 WOR Ke ph We Sa i ee WER WBR ee w OR PIN 12 W 11 P BL 4 Le 0 Brake Fluid WB we d el 13W 39 ORB 2 Reservoir 894456 wY IP PIN 15 Win wm PIN 16 W 54 B BE OR td x WIR WIBL PIN 17 W 30 W BL G PIN 18 W 28 G won ies A Coolant B W BL WIBL 9 I R R B B Overheat Alarm Wiper Motor u 890000 886497 B BL R B fans xe Ger p al Rz Wiper Dome Light Acc Power Harness 894804 L Power Point G Yd Y R IP Acc Power Main Harness we IRE pe S Dome Light 894266 182399 Auto Tran rae Controller y s Fuse Holder Ee B 825996 LE Ground R R Sg StandOff 828231 Y RB d R EI IL XB Geet wR B Heater Switch o z 894801 SE E Heater Fan W OR YR Acc Power ds s 894805 M e Y B B OR H WIOR Y R WIR R oR OR um M We ID wm d K B B Heater Harness T B 894806 R R m B 5 5 Cap Horn Button 830366 Clutch Switch Light 894308 Switch 894308 N Point Horn 843942 886090 183
51. Phone 1 800 241 5855 FAX 1 800 448 8124 Outside USA Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
52. Rs s 7 R LEFT B oR dB TURN SIGNAL BR OR GB GY B Y R Y 894855 aus Pe ze BR BR As BL BL LEFT BR B w HEADLIGHT M BE 837303 m W B 5 z d 5 we Y R Y w 5 OR B BL 5 B m w BL RB 8 le gt RIGHT RB RB w HEADLIGHT BR M S W OR B 837303 B B LT B RB RB HEADLIGHT SWITCH RIGHT BR 843581 TURN SIGNAL 894855 as BUB g ad y Y B R TURF TAILLIGHT BR BR HARNESS 894313 CAB TRAILER BRAKE B TRAILER BRAKE ORB STOPLIGHT CONTROLLER 893562 RECEPTACLE ORB Pa HARNESS 894597 jena BL BL BR OR B OR B OR B ORB one opp L BL HARNESS ep ORB OR B 891296 See PIN 1 NOT USED zm BR BR one TRAILER BR L BL ER WR an PAS PANEL PINS W2t BA BRAKES WR WIR one BINS NOF USED m WIR wR W R Ww WIR 5 PIN 6 NOT USED Be DN PIN 8 WSI WY B w R Ba RB RB Y B PIN 11 W2 OR B B BRAKE FLUID per WER Ger PIN 13 W EE Weer 3 RESERVOIR W B PIN 14 W 34 W R B B e 894456 wy Wy PIN 15 W 36 1 W BR RB W R wR w PIN 16 W 54 B W BL A wR OR amp BIN 17 W 30 WBL wei g R COOLANT OVERHEAT R x B ALARM 890000 R 1 HARNESS 894815 10 GAUGE 2 La B w B Bu R WIR 35 4 BACK UP WIPER MOTOR 8 p d ALARM 886497 B B WR OR 5 R R R G R G R Bd D R B 8 Kl oa HARNESS SPARE I
53. Turn signal s front accessory 3 837670 Taillight s 822049 Headlight s 2 837303 836892 849983 826000 833038 FLASHER 825501 34 SERVICE amp MAINTENANCE Cont MAINTENANCE GUIDE The following maintenance charts have been compiled as a general guideline for service intervals based on hours of operation Refer to the Engine Owner s Manual for further service and maintenance schedules and intervals Every Every 75 100 Hrs Maintenance Operation ily or 2 months or 3 months Check engine oil level Check cooling system coolant level Clean radiator intake screen Check water separator drain as required diesel only Check fuel level Check engine for loose parts damage and leaks Check exhaust color diesel only Check for engine noise vibration Check tire pressure Change engine oil and filter Suzuki only Change engine oil Perkins Diesel Change engine oil filter Perkins Check valve clearance to be done by authorized dealer Check engine idle speed Check power steering fluid Change fuel filter Lubricate chassis see lube chart Check governor oil level Suzuki engines Check differential oil level Check transmission fluid level Check hydraulic tank fluid level Check brake fluid BF Check brake adjustment Check clutch adjustment Change differential oil 100 hrs Depending on operating conditions the engine oil and engine filter
54. add coolant to the and cool before removing the radiator cap overflow reservoir not to the radiator To prevent scalding by hot water NEVER remove cap while radiator is hot With the park brake applied and the gear selector in neu tral or park automatic transmissions start the engine and let idle Remove the overflow reservoir cap add the anti freeze mixture to the overflow bottle until the coolant level reaches approximately 4 102 mm in the bottle replace reservoir cap If the radiator level is very low add the anti freeze mixture directly to the radiator until it reaches approximately 1 4 6 mm from the bottom of the filler neck then start the engine and add mixture to the overflow reservoir until proper level is reached 19 SERVICE amp MAINTENANCE Cont FUEL LEVEL 1 Check fuel level in fuel tank Turn the ignition switch to the ON position fuel level will be determined by how far the fuel gauge needle rises The illustration below shows the various levels for reading the fuel gauge Fuel tank capacity is 6 5 gal 24 5 L Fill if necessary using the following fuel recommendations Gasoline Engines Unleaded gasoline with 87 or higher Octane reading Diesel Engines Diesel Fuel 2 D ASTM D975 Do Not use Aviation Fuel JP4 Fuel Tank Volume The fuel tank is located on the right side of the vehicle in front of the rear tire For vehicles using diesel fuel Use 1 diesel fu
55. assistant push down on the brake pedal and hold pedal down Tighten the bleeder screw and release the brake pedal Loosen the bleeder screw again press down on the brake pedal hold pedal down and tighten the bleeder screw release pedal Do Not release the brake pedal until the bleeder screw is tightened otherwise air will be sucked back into the brake lines Continue this procedure until all air bubbles are purged from the system and a steady flow of fluid comes from the brake line Repeat the procedure on the opposite side of the unit then on the front Rear Wheel Only Brakes Bleed the left rear brake first then the right rear Attach a hose to the bleeder screw on top of the dust shield and place the other end of the hose in a container to catch the run off when bleeding the system Loosen the bleeder screw Have an assistant push down on the brake pedal and hold pedal down Tighten the bleeder screw and release the brake pedal Loosen the bleeder screw again press down on the brake pedal hold pedal down and tighten the bleeder screw release pedal Do Not release the brake pedal until the bleeder screw is tightened otherwise air will be sucked back into the brake lines Continue this procedure until all air bubbles are purged from the system and a steady flow of fluid comes from the brake line Repeat the procedure on the opposite side of the unit PARK BRAKE The park brake applies the brakes to both rear wheels To engage the brake
56. discharging and failure of vehicle components WARNING Altering this equipment in any manner which adversely affects the equipments operation performance durability or use may cause hazardous conditions IMPORTANT THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED TO WITHOUT THE MANUFACTURER S AUTHORIZATION SPECIFICATION INFORMATION All information contained in this manual is the latest available at the time of printing Cushman Textron re serves the right to make changes at any time without notice NOTICE After you identify a part by the reference number and the six digit cushman part number always read the description of the part to be sure it is what you want STANDARDS AND PUBLICATIONS This product meets requirements of ANSI B56 8 and has been approved by Factory Mutual Research Corporation to meet all Powered Industrial Truck portions classification D or G of the OSHA requirements as stated in section 1910 178 Approved powered trucks shall bear a label or some other identifying mark indicating approval by the testing laboratory This product conforms to EC directives and amendments 89 392 amp 91 368 Users operators and service persons should be familiar with the following standards and publications The material may be obtained from the addresses shown Factory Mutual Approval Standard Class No s 7811 amp 7813 Gasoline or Diesel Powered Trucks Types G GS D or DS ADDRESS Fa
57. in an EMERGENCY and the vehicle must be towed and the drive shaft cannot be removed attach a tow line to the front vertical frame member ONLY Make sure the transmission is in N Neutral and the park brake is released Tow at a maximum speed of 5 m p h 8 km h 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 86 mm height is required The jacking locations are shown in the chart illustration on the following page Put the gear selector in 1st gear manual transmissions or in P Park for automatic transmissions Apply the park brake Raise the vehicle ONLY enough to perform maintenance required 28 SERVICE amp MAINTENANCE Cont Jacks Jacking Locations and Using a Hoist Place a jack in the appropriate location See Fig 35 and place a block behind or in front of the tire diagonally oppo site the side which is being raised See Fig 34 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 sup port 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 Jack the vehicle to the appropriate height and place jack stands or equivalent support beneath the frame near
58. lubrication Nut castle 7 16 20 Retainer grease Clamp Arm assembly upper control Bearing cone outer Bearing cone inner Seal grease Hub assembly Cup bearing outer Cup bearing inner Screw lug M12 1 50 x 42 Nut castle 3 4 16 Nut M6 1 00 flange G10 9 Screw M6 1 00 x 20 Nut M12 1 75 G10 9 Screw M12 1 75 x 60 Screw M12 1 75 x 80 8 8 Strut ay shock amp spring INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated Although this lubrication fitting is the standard fitting used with this tie rod it is not used in this application Use Ref No 15 Part No 831405 If ordering Ref No s 34 887512 or 44 887750 you will also need to order Ref No 15 831405 77 WHEEL SIZE MEASUREMENT Wheel size is determined by measuring the wheel at the bead seat The first number is the wheel diameter measured at the bead seat The second number is the wheel width measured at the bead seat The illustration below shows an example of how to measure the wheel to determine tire size Bead Seat IN Wheel First Number 10 00 Wheel Diameter Shown For Reference Only 7 50 Second Number Wheel Width FRONT and REAR TIRES FOR TURF MODELS 5 9 Wheel Mount Nuts Are The Same For All Wheels TIRES 20 x 10 00 10 Multi Rib front 24 x 13 00 12 Titan Ul
59. may need more frequent replacement f If coolant level is low add 50 50 mixture of water and anti freeze NEVER add straight anti freeze to the coolant system OIL FILTER HYDRAULIC FLUID Biodegradable FUEL FILTER Suzuki K6A Part No 16510 82703 2 1 2 gal 9 5 L Part No 65363 Suzuki K6A Part No 15410 50F00 Suzuki 970 Part No 16510 82703 5 gal 19 L Part No 65352 Perkins Diesel Part No 2208175 Perkins Diesel Part No 842553 55 gal 208 L Part No 65354 Suzuki 970 Part No 15410 50F00 35 SERVICE amp MAINTENANCE Cont Maintenance Guide con t Every Every Every 200 Hrs 400 Hrs 600 Hrs Every Maintenance Operation or 6 months or 9 months or 12 months 1500 Hrs Replace air cleaner element Check valve clearance See authorized dealer Check fan belt and tension Inspect radiator hoses and clamps Change coolant Replace hydraulic system filter Change hydraulic system oil tank only Clean battery and terminals Check alternator Repack front and rear wheel bearings Check starter motor brushes Check brake linings Change differential fluid Drain and replace radiator coolant Check engine idle speed Check glow plugs diesel only Check injection pump and timing diesel only Check fuel hoses and clamps Check all belts for tightness and cracking Adjust front brakes Replace timing belt Suzuki engines Change transmission fluid Check fuel hoses and clamps Check spark
60. p Shaft gear shift lever Seal oil 25546 60C01 09135 08005 06111 10003 25547 70D00 09168 10007 09128 10002 Spring Bolt 10 x 9 25530 79501 Shaft gear select 09286 09001 Seal oil 25536 84200 Boot gear select shaft 1 25535 85412 Arm gear select 09162 08008 08322 01083 25211 85201 Fork low speed gear shift 1 25221 85202 Fork high speed gear shift 1 25221 83002 Fork reverse gear shift 1 25411 85201 Shaft low speed fork 25420 85201 Shaft high speed fork 1 25451 85261 Shaft reverse fork 162 08310 00083 25541 85201 25576 70D00 09160 17035 25545 85055 Washer 17 x 32 1 2 Dog reverse shift limit 1 09261 03017 09205 05012 25415 83000 06111 12004 24821 09001 Spring pin Plug breather STARTER MOTOR SUZUKI 970 Front Of Vehicle Ref Part No No Description 4 Description 31100 79X50 Motor starting 31311 51A10 Armature 31152 51A10 Bushing 31110 52A50 assembly 31220 51A10 Switch assembly 31131 51A10 08316 10063 31135 51A10 Spring brush 31191 85020 el ever pinion drive 31173 51A10 Holder brush 08316 10083 Nut switch 31175 51A10 elInsulator 31153 51A10 Washer 31172 51A10 Bushing 31312 51A10 Ring snap 31281 51A10 31310 51A10 pinion stop 08316 10083 31320 51A10 assembly OO JO P ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 163 ALTE
61. set Float set eValve set needle Screw Jet main 7108 8 Weight set pump As eJet enrichment 65 Spring Gasket set INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 125 PCV VALVE EMISSIONS amp EXHAUST MANIFOLD SUZUKI 970 To Distribtor To To Carburtor Air Cleaer To Head Cover Ref Part No Part No No Description Description 09355 13207 600 Hose 14120 85220 Cover upper 09401 20301 14125 85201 Cover lower 09367 14002 01411 06123 Stud bolt 11193 85000 08361 35063 09401 13414 09103 06168 Bolt 6 10 18118 80010 14181 85200 Gasket exhaust pipe 09404 08420 Clamp breather hose 01411 10253 Stud bolt 14111 85210 Manifold exhaust 09355 35754 600 Hose 14140 85200 Gasket exhaust manifold 1 09404 08206 Clamp 01411 08253 Stud bolt 09408 00060 Clamp 08310 00083 OO JO Om P ob mo 126 OIL PUMP and WATER PUMP SUZUKI 970 For Thermostat and Housing See Radiator and Cooling System Pages 100 101 Reference Intake Manifold RO CD Ref Part No Part No No Description Description 16100 73004 Pump oil 01550 06403 09246 06002 Plug oil gallery 01411 06253 Stud bolt 16130 73000 Rotor set oil pump 08316 10063 16150 73000 Valve set oil pump relief 1 17511 73001 Pulley water pump 02122 06123
62. side 1 Controller vacuum 33882 85210 Spacer cord E ring 33883 85210 Clamp head 800934 Screw M6 1 00 x 16 10 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 165 MECHANICAL PTO SUZUKI 970 and PERKINS DIESEL O The parts breakdown illustration was not available at the time of this printing 38 The isometric view of the transmission shown 20 at the right references the location of the 1 housing Please use the illustrations shown below for individual PTO parts 3 Transmission fluid capacity is 2 6 pints 80W 90 gear oil Fill to bottom of threads oil fill plug hole located on right side of PTO housing Some of the parts shown above are also referenced in 4 the illustrations shown below i Oil 20 Holes Holes 1 Bushings 3 In reference to items 30 31 amp 32 make sure oil holes in gear align with oil holes in the bushings 166 120166 181027 301988 450324 452380 452381 452389 452390 452396 548204 548477 800425 805307 807624 812419 815012 815013 815085 815182 OONDOABRWN MECHANICAL PTO SUZUKI 970 and PERKINS DIESEL Description Lockwasher 1 2 Bearing ball mm 20 52 15 OP 1 Nut 1 2 20
63. the START posi tion e Pre Heat Proper pre heating time required is approxi Indicator Light mately 15 seconds Pre heating will take longer ZE lt om approximately 30 seconds when outside tem perature falls below 32 F 0 C Preheating time should never last more than 2 min utes or the life of the glow plugs will be shortened Hold ignition key in the START position to engage Figure 26 engine starter release key when engine starts Pre Heat Indicator Light Diesel Models Only upon release the key will automatically return to the ON position Ifthe engine does not start after operating starter for 10 seconds stop the starter Wait for 30 seconds then try to start the engine again The starter motor should never be run for more than 30 seconds After the engine has started make sure the oil pressure warning and service brake warning lights go off 23 SERVICE amp MAINTENANCE Cont Starting the Diesel Engine con t 6 Allow engine to warm up before driving the vehicle always idle and warm up the engine for at least one minute Check for abnormal noises such as knocking and excessive vibration Knocking sounds will be heard while the engine is cold during quick acceleration and while idling Knocking sounds will not be heard during normal operation Confirm the exhaust smoke is seen as follows While engine is cold White smoke When engine is warm and during normal operation Almost smokel
64. the level again if oil level is sufficient replace oil fill cap DO OVERFILL Engine Oil Capacity Suzuki K6A 3 3 qts 3 0 L Suzuki 970 3 7 qts 3 5 L Perkins Diesel 3 7 ats 3 5 L Oil Level Must Be Between The Marks Cil Dipsticks May Vary In Appearance pec gt SE E ADD FULL Add Oil If The Level Is At Or Below This Mark Do Not Overfill Figure 18 Oil Level Reading room III SAE 10W 10W 30 SAE 20W 10W 30 SAE 30W 10W 30 SAE 10W 30 for all temperature ranges 149 20 0 20 32 40 60 7780 100 Cap 20 10 0 10 20 25 30 40 Temperature Range Anticipated Before Next Oil Change Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them 16 NOTICE f you notice the oil pressure warning light coming on STOP the vehicle and check for problems mn AA Soest Light gt Figure 19 Oil Pressure Warning Light Engine Oil Replacement Filters Suzuki K6A Order Part No 16510 82703 Suzuki 970 Order Part No 16510 82703 Perkins Diesel Order Part No 842553 Figure 20 Dipstick Location Perkins Diesel Engine SERVICE amp MAINTENANCE Engine Oil Level con t Figure 21 Figure 22 Dipstick Location
65. to the rear brake drums CAPACITIES Fuel Tank 6 5 gal 24 5 L Cooling System Suzuki K6A Suzuki 970 Perkins Diesel Crankcase including filter Suzuki K6A Suzuki 970 Perkins Diesel Transmission K6A manual 970 amp diesel manual automatic Differential 11 16 1 3 3 qts 3 01 3 3 qts 3 0 L 5 qts 4 7 L Hydraulic System Standard hydraulics Hi Lo hydraulic accessory TIRES 20 x 10 00 10 Multi Rib 24 x 13 00 12 Titan Ultra Trac BRAKE FLUID Use type SUSPENSION Double A arm independent with two spring over shock absorbers Heavy duty multiple leaf springs with shock absorbers FUEL Gasoline Engines Unleaded gasoline 87 Octane or higher Diesel Engines No 2 D ASTM D975 see the Fuel Recommendation Section Page 20 LUBRICATION RECOMMENDATIONS Transmission Fluid 4 speed manual automatic SAE EP 80 90 Gear Lube Mercon Dexron II Hydraulic System Hyd Benz Bio 377 Differential Oil SAE EP 80 90 Gear Lube Pressure Gun Grease Lithium Base Power Steering Power Steering Fluid GM BATTERY BCI Group Cold Cranking Amps minimum Reserve Capacity Minutes minimum Ground Terminal Polarity STEERING 14 1 ratio Saginaw power steering and a 14 inch 355 6 mm steering wheel SPECIFICATIONS Cont ENGINE SPECIFICATIONS NOTICE The engine governor controls are preset to control Suzuki K6A Engine engine and ground speeds to design limits Ho
66. vent union 4120082 Clip water hose 4120083 Stud bolt outlet cap 2702486 Bolt water inlet pipe 2702469 Bolt thermostat cap 4120084 Bolt water outlet cap 2703002 Nut water outlet cap 2702481 Sensor water temperature OONODUIP ODPD 138 EXHAUST MANIFOLD SUZUKI K6A p Front Of Vehicle Description 1411 67H00 Exhaust manifold 14118 70650 Bolt 4120060 Cover exhaust manifold upper 4120061 Cover exhaust manifold lower 1414 83G00 2702499 Bolt 6 X 12 4120063 Stud bolt 4120064 2702475 2702759 Engine hook 2702500 Ring seal exhaust pipe 2702501 Spring exhaust pipe 2702502 Bolt 10 x 65 4120065 Sensor oxygen 139 140 2701897 2701898 2701899 5830 65 51 5835 65 00 4120066 2702475 FUEL PUMP SUZUKI K6A Front Of Vehicle Description Fuel pump assembly Fuel filter Regulator Assembly Fuel feed pipe Fuel feed hose Fuel hose clip DELIVERY PIPE SUZUKI K6A p Front Of Vehicle Description 4120067 Delivery pipe 2702486 Bolt 2701978 Bolt 15710 65H00 Injector assembly fuel 2702512 Grommet set 2702513 Cushion 2702514 Clamp INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 141 STARTER MANUAL TRANSMISSION SUZUKI K6A Front Of Vehicle Ref Part No Part No No Description Description 2702893 Motor assembly starting 1 2702900 Switch assembly 2702894 assembly 2
67. 056 2702491 4120057 2702486 2 3 4 5 6 7 8 9 1 111 CARBURETOR SUZUKI K6A Front Of Vehicle CH REIT Gig 16 amp 18 26 gt SE All components are used with both the manual and 17 N the automatic transmission unless otherwise noted in the parts list shown below Ref Part No Part No No Description Description 2700623 Carburetor 13275 63 Screw throttle adjustment automatic transmission auto trans 2700622 Carburetor 13275 851 0 Screw throttle adjustment manual transmission mnl trans 1 13310 53FTO Valve set piston 13494 78420 09404 06433 Clamp 02112 34253 13260 50FTO Solenoid set 13320 66 Valve set power 13270 850 0 Screw set idle adjust 95550 85010 Actuator idle up 13250 70DTO auto trans 13370 70DTO Valve needle 95550 85500 Actuator idle up 09491 92005 Jet main auto trans mnl trans 1 09491 92006 main mnl trans 13372 70D00 Bolt auto trans 09492 26002 Jet power auto trans 09137 05009 mnl trans 09492 27010 eJet power mnl trans 13384 78330 E ring 13240 60CTO Weight set pump 13601 05148 13251 77320 Gasket float bowl 13326 70000 Spring 13350 50700 Chamber depression 09404 06432 Clamp 02112 05107 13564 63CTO Sensor throttle position 13415 85010 13380 854 0
68. 1 4 male 800177 Screw 5 16 18 x 3 4 829997 Grommet 452394 Screw M8 1 25 x 70 8 8 830425 Hose fuel 1 4i d As Reqd 809231 Grommet 833953 Cover fuel sender 834036 Connector hose 834037 Connector hose 130306180 Pre filter fuel 838154 Bracket fuel pump mounting 843534 Bracket fuel filter 841969 Tank fuel 831039 Hose fuel 5 32 i d As Req d 836852 Breather 833851 Seal foam DO JO Om PS ob INDENTED PARTS NAME INDICATE THESE PARTS ARE INCLUDED WITH THE PRECEDING ASSEMBLY Certain engine parts will need to be ordered directly from Perkins Ref No 38 Fuel Pre filter shows the Perkin s part number and is one of the parts which would be obtained from Perkin s When ordering from Perkin s be sure to include the Engine Model and Spec No s The model and specification numbers for the Perkins engine are as follows Model 103 10 Spec KD70377 To locate the Perkin s Dealer nearest to you please call 1 888 737 5364 The parts listed below can be ordered from the Cushman Parts Department Ref Part No Part No No Description No Description 842553 Filter oil 1 842235 Gasket inlet 842555 Gasket manifold 4 2208175 Filter fuel 69 PARK BRAKE LEVER AND CABLE 4 The Neoprene Cover Pop Rivets and 6 c Mounting Strips are Generally used on Vehicles With Cab Sets but also be used on Vehicles Without Cabs Reference Console Panel
69. 2 5 x 32 4 5 Belt timing Tensioner timing belt Washer 8 5 x 26 x 1 6 1 Spacer 8 1 x 16 x 17 Spring tensioner 1 2 3 4 5 6 7 8 9 11480 78110 Seal set inside cover 11484 73000 Grommet outside 12741 78403 Pulley timing belt 09103 08152 Bolt 8 x 25 08321 01083 Lockwasher 09160 08126 Washer 8 5 x 20 x2 6 1 124 08341 31059 CARBURETOR amp INTAKE MANIFOLD Also See Item No 17 For a Breakdown of the Carburetor Ref Part No No OO JO Om PS ob Description 13110 85X57 Manifold intake 13119 73001 H17 Gasket intake mnfld 2 09246 04005 Plug boost 01550 08203 01411 08203 Stud bolt 01411 08253 Stud bolt 08316 10083 11851 62B00 Hook engine 2700621 Carburetor complete 13121 80000 Insulator carburetor 13125 80000 H17 Gasket carburetor 2 09108 08169 Stud bolt 08316 10083 Nut 34850 50A00 Gauge water temp 1 Hose brake vacuum No 1 51030 85051 09401 15404 Clamp 2700621 Carburetor complete 13270 855 0 Screw set idle adjust 1 4 E ds Clamp 15 Front Of Vehicle SUZUKI 970 17 No Hose Just Plug Part 09492 47006 13278 45010 13398 78110 02112 75103 13260 797 0 13250 852 0 13370 60 0 02112 04087 09491 21024 13251 79110 13240 852 0 02142 05163 09355 35754 09492 65005 13494 78420 02112 34253 13380 793TO Description Jet pilot 447 5 Screw Solenoid
70. 2 dia 1 894702 Nipple hydraulic dry seal 826558 Elbow 90 w o ring 2700800 Cover hydraulics w decal 832408 Coupler half male 837270 Decal hydraulic connections 844566 Fitting hydraulic 2700801 Cover hydraulics w decal EC 832798 Plate stop 840857 Decal remote hydraulics EC 835101 Fitting hydraulic 90 320107 Tie cable 7 1 2 190 mm 841892 Hose hydraulic 1 4 x 42 840877 Sleeve nylon 844019 Hose hydraulic 3 8 x 17 888042 Pump hydraulic 844571 Adapter 90 elbow 306560 Key woodruff 5 844582 Rod handle extension 887017 Kit seal hydraulic pump 844584 Bushing flip lok 844583 Fitting 90 adapter INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated Although Ref 27 hydraulic pump Part No 888042 is shipped with two hydraulic fittings these fittings are not used in this application When ordering Ref No 27 you will also need to order hydraulic fittings Ref No s 9 amp 29 These fittings are the correct fittings to use in this application 84 HYDRAULIC LIFT SYSTEM Seal Kits 883236 884574 amp 886001 Reference Hydraulic Control Valve 893447 Ref Part No Part No No Description No Description 452378 Screw M6 1 00 x 20 2 832408 Coupler half male 450452 Nut M6 1 00 G10 9 832409 Coupler half female 450453 Nut M8 1 25 G10 9 832414 Ring
71. 25 Bearing cnctng rod 11341 70B01 Housing oil seal 12181 81051 050 Bearing cnctng rod 01550 06203 12181 81051 075 Bearing cnctng rod 02122 06253 12181 81051 100 Bearing cnctng rod 04211 09109 12221 75104 Crankshaft 12620 85301 12300 73812 0A0 Bearing set crnkshft 09103 10097 12300 73812 025 Bearing set crnkshft 04421 06129 12300 73812 050 Bearing set crnkshft 12623 70B00 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 159 INPUT SHAFT and GEARS MANUAL TRANSMISSION SUZUKI 970 and PERKINS DIESEL p Front Of Vehicle al MR 4 EA 2 ded DI Description No No Description Shaft input 28 Bearing rear Bearing 29 Hub synchronizer low Bearing Ring synchronizer low Spring low 2nd 160 09380 28007 09283 25088 24121 85252 06111 06003 09166 30007 24211 83011 09300 30003 09263 35015 24220 60A01 09263 35015 24230 83001 09263 30031 09390 62010 09262 25073 09380 25011 24131 83002 24351 60A10 09262 28019 09262 28020 Seal oil Shaft main Gear main shaft low Bushing Bearing Gear main shaft 2nd Bearing Gear main shaft 3rd Bearing Gear main shaft 5th Washer Bearing Bearing C ring Bearing Circlip Shaft counter Gear counter shaft 5th 1 Bearing front Bearing center 24441 85F41 24410 83000 24432 83001 24442 81A20 09388 00019 24420 83000 24471 60A00 24473 70D10 24551
72. 4 Nut M10 1 50 G10 894453 Arm throttle 452378 Screw M6 1 00 x 20 894454 Arm governor 452401 Screw M10 1 50 x 40 8 8 894463 548190 Pin hair 11 16 x 1 7 8 894464 Base throttle Suzuki K6A 553046 Key woodruff 1 4 x 1 2 894482 Base throttle Suzuki 970 302288 Screw 1 4 20 x 1 894540 Cable throttle 800024 Screw 1 4 20 x 1 1 2 843866 Bushing governor 800927 Screw shoulder 1 4 20 x 5 8 894435 Bracket assembly governor 806773 Pin clevis 5 16 x 1 1 8 842753 Bracket carburetor Suzuki 970 1 To Accelerator Pedal 894197 894507 OONDARWN Spring extension 843013 Pulley governor 843536 Rod governor arm 90 ENGINE and MAIN WIRE HARNESS Part No Description Ref No 894266 894189 894283 894560 894637 Harness engine all diesel models Not Illustrated The wiring harness is shown as a reference only Although the actual harness resembles the illustration shown connections terminals and routing can change without notice Right Right Turn Headlight Signal Qua 025 Left Headlight Left Turn CH Signal No Harness main wire all models 1 Harness engine Model 898627 1 Harness engine Model 898671 1 Haress engine Model 898628 1
73. 4197 894198 Ref Part No No No Description j No Description 523768 Adapter 90 elbow 2700800 Cover hydraulics w decal 548827 Screw 1 4 20 x 1 2 837270 Decal hydraulic connections 1 844583 Fitting 90 adapter 2700801 Cover hydraulics w decal 827486 Valve pressure relief 840857 Decal hydraulic connections 1 832414 Ring retaining 894675 Tank hydraulic 835101 Fitting hydraulic 90 894691 Head filter 836206 Clamp hose 894701 Coupler hydraulic dryseal ONOaRWDND 450453 Nut M8 1 25 G10 9 254 452388 Screw 8 1 25 x 20 08 8 See 452399 Screw M10 1 50 x 25 8 8 844590 Adapter straight 800113 844600 Hose hydraulic 1 2 x 39 450452 Nut 6 1 00 10 9 844627 Fitting swivel tee 452381 Screw M6 1 00 x 40 8 8 844630 Hose hydraulic 3 8 x 21 844937 Plate coupler retainer 885249 Element filter 888042 Pump hydraulic 844973 Bushing 306560 Key woodruff 5 893539 Dipstick hydraulic tank 887017 Kit seal hydraulic pump 844564 Hose hydraulic 1 x 26 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated 87 88 1 2 3 4 5 6 7 8 9 111898 120052 132520 306328 306514 306531 320107 450452 452378 800271 800582 806703 HAND CONTROLS GOVERNOR and THROTTLE GASOLINE Reference Governor Reference Control Panel 6 Reference Foot Throttle
74. 5 Shift shaft automatic transmission 122 Shift switch automatic transmission 122 Shock absorbers 83 front strut assembly 74 75 76 77 Solenoid Suzuki K6A 92 93 Solenoid oil pump automatic transmission 121 122 Spark plugs Suzuki K6A 148 149 970 157 Starter manual transmission 142 automatic transmission 135 Starter Suzuki 970 163 Steering wheel Shaft amp Pump 72 73 Struts front spring amp shock 74 75 76 77 Suspension front 74 75 76 77 92 93 Tailpipe Suzuki 6 58 Suzuki K6A Catalytic converter 59 Suzuki 970 amp Perkins diesel 60 61 Thermostat Suzuki 970 95 Suzuki K6A 138 Throttle hand control Perkins diesel 89 Throttle hand control Suzuki K6A amp 970 88 Throttle linkage Suzuki K6A amp 970 90 WiC te Le dt utor aes 74 75 76 77 Timing belts amp cover Suzuki K6A 107 108 Timing belts amp cover Suzuki 970 124 Tires front and 78 Torque chart and torque specifica
75. 5 0 L 2 1 2 gal 9 5 L Part No 65363 Hi Lo Hydraulics 7 6 gal 28 8 L 5 gal 19 0 L Part No 65352 55 gal 208 0 L Part No 65354 Hydraulic x f Knurled Portion Hydraulic Of Dipstick Reservoir Dipstick Shown As Reference Only Figure 74 Figure 75 Hydraulic Reservoir Tank Hydraulic Tank Dipstick 51 ENGINE COVER a Reference Lower ROPS 13 Part No 893145 Pw With Ref No 25 P893436 P893976 P893972 P893400 P893328 P893595 P893657 P893444 52 Ref Part No No Description 306328 Pin cotter 09 x 75 308090 Washer 1 4 450452 Nut M6 1 00 G10 9 450453 Nut M8 1 25 G10 9 450454 Nut M10 1 50 G10 9 800026 Screw 1 4 20 x 3 4 450541 Screw M6 1 00 x 16 452388 Screw M8 1 25 x 20 8 8 452398 Screw M10 1 50 x 20 523085 Bracket 816401 Spring torsion 830784 Pin clevis 25 x 1 88 841789 Catch engine cover latch 841804 Insulation engine cover 842030 Mount backrest 893321 Seat base assembly 894822 Seat back assembly 2700789 Cover engine w decal 1 2 3 4 5 6 7 8 9 ENGINE COVER Part Description 845038 Decal Operation 893541 Handhold right side 894232 Cover left 2700796 Panel console w decals turf 822819 Decal Warning Park Brake 844177 Decal auxillary transmission 844179 Decal hydraulic controls 2700797 Panel console EC vehicles 845185 Decal Warnin
76. 55 841336 841404 844148 841429 304636 817250 841630 841737 841738 841839 841841 841842 842033 894574 842104 DO JO P ob Description Nut jam 9 16 18 Lockwasher 7 16 Screw 7 16 14 x 2 Bolt M16 2 00 x 90 Nut locking insert M16 2 00 Washer M16 Nut M16 2 00 flange G10 9 Screw M10 1 5 x 20 8 8 Screw M10 1 75 x 20 G10 9 Bolt M12 1 75 x 60 G10 9 Screw M6 1 00 x 12 Nut 9 16 18 left hand Bolt M10 1 5 x 30 Clip Fitting grease 1 4 28 90 Clamp tee Bushing silentbloc Gear power steering Arm pitman Req d Ball joint upper Ball joint lower Pin cotter 1 8 x 1 1 8 Cap grease Trunnion control arm Shim 060 Shim 024 Tube brake right Hose brake Tee union M10 1 00 flare Plate skid Knuckle steering right Bracket brake tube Ref Part 887512 306328 548224 306825 816586 893234 893421 841430 800909 306328 306825 887750 306328 548224 306825 816586 810437 893266 385174 815403 817928 893206 808088 814474 800908 311537 450452 452378 450455 452413 452415 894635 Description End tie rod RH thread Pin cotter 3 32 x 3 4 Fitting lubrication Nut castle 7 16 20 Retainer grease Arm assembly lower control Frame assembly front Drum brake Nut wheel retaining M12 1 50 Pin cotter 3 32 x 3 4 Nut castle 7 16 20 End tie rod LH thread cotter 3 32 x 3 4 Fitting
77. 6 IDLE UP t bf t CONTROLLER CH VACUUM SHIFT SPEED THROTTLE SWIFT SWITCH SOL SENSOR POSITION SWITCH D RANGE VAVE a VACUUM VACUUM Pig P8 P14P11 Pi P9 P5 P7 Pe VALVE VALVE CARB FUEL NOISE P2 AUTO TRANSMISSION CONTROLLER piel CUTOFF SOL RELAY FILTER A SHIFTER LIGHT k UR H NEUTRAL IGNITION 15A EM START SWITCH 6 1 STARTER SWITCH Eu SOLENOID fen 7 77 20A 0 4 D sr P10 EE lo H P12 ilc _ CH uh IGNITION POWER 2 coL ALT 5 10A SERVICE PARK a 0 POINT 20A 10 10A 2 ER BRAKE BRAKE D RESV SENDER SHIFT TEM SWITCH 55 ee WIPER COOLANT FUEL OIL E OVERHEAT PRESS MOTOR POWER SWITCH DISTRIBUTOR ym SENDER FAN x ACC ACC POWER POWER 9 DOME HEATER BACK UP STARTER LIGHT FAN ALARM a I SPARK PLUGS IGNITION SWITCH SCHEMATIC BAT BAT BAT BAT ST ACC IGN ST ACC IGN ST ACC IGN ST ACC IGN OFF START ON ACC POSITION POSITION POSITION POSITION WIRING SCHEMATIC SUZUKI K6A TURF TRUCKSTER WITH AUTOMATIC TRANSMISSION
78. 6 OPERATING REMOTE HYDRAULICS Cont Power Take Off Mechanical P T O con t ZN WARNING When an attachment is not connected to the P T O shaft disengage drive to the P T O by pushing control handle down P T O includes a spring loaded P T O cover This cover must remain on the vehicle and be used at all times An uncovered rotating spline can catch clothing and result in seri ous injury or death ALWAYS remain clear of the P T O shaft and all moving parts If you do not want the vehicle to move ALWAYS make sure the transmission is out of gear and the park brake is applied when the clutch pedal is released to activate the P T O shaft Make sure the vehicle is in Park with the park brake applied for automatic transmissions ALWAYS disengage the before attaching any equipment to the P T O shaft NOTICE To engage P T O ALWAYS STOP the vehicle For vehicles with manual transmissions stop the vehicle push the clutch pedal in THEN pull the control knob upward For Use When The Vehicle Is Stationary Make sure governor control is in the UP position Make sure differential is in either HIGH or LOW range NOT the NEUTRAL position Set engage the parking brake Put transmission in neutral out of gear and engage the clutch put automatic transmission in Park Push foot throttle pedal to floorboard Raise the hand throttle control lever to full engine R P M Move the governor con
79. 663 Case extension No 1 2702664 Case extension No 2 2702658 Pin 2702665 2702470 2702659 2702660 2702683 Seal extension case oil 2702684 Plug 2702685 Switch back up lamp 2702686 2702687 2702688 Stud bolt 2702689 2702690 2702691 Hook engine 2702692 Plug breather 2702693 Hose 2702694 Union breather INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 145 ENGINE GASKETS SUZUKI K6A Front Of Vehicle 146 ENGINE GASKETS SUZUKI K6A Description 4119954 Gasket set engine 4119957 Gasket cylinder head 4119958 Gasket cylinder head cover 4119959 Gasket intake manifold 2701803 Gasket throttle body 4119960 Gasket exhaust manifold 4119965 O ring water pump 4119967 Gasket thermostat case 4119609 O ring water inlet pipe 1 2 3 4 5 6 7 8 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 147 CYLINDER HEAD and COMPONENTS SUZUKI K6A A m 20 E 2 d f d E EP DER Front Of Vehicle 148 CYLINDER HEAD and COMPONENTS SUZUKI K6A Description 4119962 Head cylinder 4119963 Guide valve 2701816 4119964 2701821 4119956 4119966 4119957 4119968 Cover cylinder head 4119958 Gasket head upper cover 4119970 4119971 4119972 Gasket spark plug hole 4119973 filler 4119606 Spark plug NGK 3932 4117894 Cover cylinder h
80. 702901 2702895 Screw assembly 2702902 Armature 2702896 Bushing 2702903 Ring assembly 2702897 Bushing 2702904 Clutch assembly 2702898 Holder assembly brush 2702905 Washer 31132 80090 Brush 2702470 2702899 eLever assembly INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 142 GENERATOR SUZUKI K6A Front Of Vehicle Ref Part No No Description S Description 4120119 Generator assembly 4119616 set 4120120 Pulley 4120129 assembly 4119681 pulley 11551 65H00 Bracket generator 4119617 Screw set 11555 60G00 Bushing generator mounting1 4120121 Screw 4120130 Arm generator 4120122 Bearing 11851 65 00 Hook engine 4120123 Retainer bearing 4119603 Bolt 4120124 Bushing 2701827 Bolt 4120125 Rotor assembly 2702469 Bolt generaotr bracket 4119615 Bearing rear 31614 65H20 Bracket generator cover 1 4120126 Starter assembly 2702486 Bolt 4120127 Terminal set 4120131 Bolt 4120128 Regulator 2701914Nut PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated 1 2 3 4 5 6 7 8 9 4 143 144 TRANSMISSION CASE MANUAL SUZUKI K6A Front Of Vehicle TRANSMISSION CASE MANUAL SUZUKI K6A Description 4120094 Case transmission 2702658 9x16 2702659 2702660 Bolt crankcase 2702661 2702662 2702
81. 8 8 2700453 Cover 819923 Collar foam 823549 Tie cable 15 1 2 394 mm 830930 Clamp 809092 Clamp tube 892486 Cover steering wheel center 1 839862 Decal steering wheel 840222 Hose 3 8 i d x 90 elbow 843767 Hose steering pressure 111838 843768 Hose steering return 111838 O Ring 808060 Bearing needle 828590 Housing bearing 892228 Wheel steering w o horn 893344 Shaft steering Part 893571 303269 311392 841336 844301 836854 892534 839907 Description Tube steering mount Lockwasher 7 16 Screw 7 16 14 x 2 Arm pitman V belt 48 1219 mm Perkins V belt 42 1067 mm Suzuki 970 1 Pump power steering Pulley steering pump 2700573 steering pump reservoir Screw M8 1 25 x 70 8 8 452394 452388 841255 894362 844268 844272 306799 800943 Screw M8 1 25 x 20 8 8 Gear power steering Bracket steering pump and alt mounting Suzuki 970 Bracket steering pump rear Perkins Diesel Mount engine right Perkins Diesel Lockwasher 5 16 external shakeproof Screw tap 10 24 x 5 8 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEEDING ASSEMBLY Service Parts for the pump are available at automotive centers Refer to 1991 92 Buick Regal with a 3 8L V6 engine Saginaw Pump 26025515 73 FRONT SUSPENSION LEFT SIDE and TIE RODS Reference Union Tee Part No 841842 Se With Differe
82. 83010 09261 06003 24560 83001 09166 16014 24671 83000 24681 83000 09380 17008 26121 85202 26131 85201 29431 85400 09280 19001 09280 21014 09282 08001 09128 06032 09164 20008 Spring low Hub synchronizer high Ring synchronizer high Spring high Spring 5th speed Hub reverse drive Shaft reverse idle gear Gear reverse idle NT 33 Gear countershaft rev Gear mainshaft rev Circlip Gear speedometer drive Gear speedometer driven Case speedometer gear TRANSMISSION CASE SUZUKI 970 and PERKINS DIESEL Front Of Vehicle Ref Part No No Description 24700 85200 Case transmission 09250 10006 04211 13149 24770 85252 09103 08131 Bolt No 1 8 x 120 04211 13149 01550 08303 No 2 09103 08132 Bolt No 1 8 x 100 01550 08403 No 3 01550 08403 Bolt No 2 01550 08803 No 4 01550 08353 Bolt No 3 24741 83001 Retainer input shaft brng 1 01421 08303 Stud bolt 09103 08152 Bolt 8 x 25 08316 10083 09250 30003 Cap inspection timing 1 24780 83010 Seal extension case 37610 80023 Switch back up lamp 09246 16010 Plug oil filler 09280 11002 OO JO Om P ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 161 Front Of Vehicle 25121 85051 04221 06129 01550 08553 01550 08403 25520 85203 09284 17004 GEAR SHIFT FORK SUZUKI 970 and PERKINS DIESEL
83. 840726 842010 842935 892933 894299 844202 890808 844611 P893668 Description Pin brake pivot Bearing brake pivot Bushing clutch arm Tab locking Lever clutch Cable clutch Washer slotted Switch clutch interlock Spring torsion SHIFTER and SHIFTER LINKAGE P893434 81 Ref Part No No 82 308090 452695 548175 800582 843792 841265 1 2 3 4 5 6 7 8 9 893966 300977 306396 306397 308090 308091 450454 SHIFTER and SHIFTER LINKAGE Description Washer 1 4 Screw M6 1 00 x 20 taptite Washer 1 4 x 1 25 Screw 1 4 20 x 3 4 Plate shifter boot Panel dash right hand 28135 85503 5PK Boot shifter 28113 70B01 5PK Knob shifter Shifter complete Screw 1 4 28 x 5 8 eLockwasher 1 4 Nut 1 4 28 Washer 1 4 Washer 1 2 eNut M10 1 50 G10 9 Part 452400 452695 548008 842773 842774 843614 843679 843685 843686 843724 893967 893968 894179 894743 Description M10 1 50 x 30 8 8 1 Screw 6 1 00 x 20 taptite Screw 1 2 20 x 1 end 1 2 female joint 1 4 Spring torsion Plate wear Bushing spring locating cable Selector complete Mount shifter Cable shifter Nut assembly double 1 4 20 1 INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY REAR SPRING SHACKLES U BOL
84. 893594 894198 894533 Ref Part No Ref Part No No Description Req d No No Description 120177 Lockwasher 3 8 2 14 843760 Mount hydraulic pump 306562 Nut 3 8 16 844272 Mount engine right 306836 Screw 3 8 16 x 2 1 4 841885 Mourt isolation 306981 Washer 3 8 894581 Mount motor left 450453 Nut M8 1 25 G10 9 894582 Mount motor right 452454 Nut M10 1 50 10 9 893525 Support platform 450412 Lockwasher M10 894580 Frame engine mount 452389 Screw M8 1 25 x 25 8 8 452388 Screw M8 1 25 x 20 8 8 452398 Screw M10 1 50 x 20 8 8 01550 08163 Screw 452406 Screw M10 1 50 x 90 8 8 11741 85200 Support transmission 800571 Nut M10 1 25 8 8 11710 77100 Bracket rear mount 809174 Washer 3 8 1 94 dia 08310 00103 Nut 843568 Mount transmission 1 2 3 4 5 6 7 8 9 103 DECALS TURF MODELS NOTE PREVENT HYDRAULIC SYSTEM DAMAGE UST NOTICE THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE DEFINITION OF THE NATIONAL TRAFFIC MOTOR VEHICLE SAFETY ACT IT IS NOT DESIGNED OR MANUFACTURED FOR USE ON ROADS STREETS OR HIGHWAYS NOR IS IT APPROPRIATE FOR SUCH USE IT IS NOR MEANT BE LICENSED AS A MOTOR VEHICLE on 20 17 lolala aiala EERE Fa in lolol alert afer a
85. 91 AT Reference Alternator Part No 893633 Shown For Existing Reference Only Hardware Reference Pwr Strng Pump Part No 892534 Reference Hydraulic Pump Part No 888042 Existing Hardware Description 103867 Washer 3 8 1 548804 Nut flange 3 8 16 120166 Lockwasher 1 2 800073 Bolt carriage 3 8 16x11 4 120177 Lockwasher 3 8 800921 Screw M12 1 25 x 20 8 8 306325 Lockwasher 5 16 844301 V belt 48 1219 mm 306416 Screw 5 16 18 x 1 839907 Pulley 5 50 steering pump 306836 Screw 3 8 16 x 2 1 4 839911 Pulley 4 75 hydraulic pum vi 306835 Screw 3 8 16 x 1 1 4 hydraulic pump 306562 Nut 3 8 16 844269 Bracket adjusment 306981 Washer 3 8 841966 V belt 29 5 750 mm 311213 Screw 3 8 16 x 3 844271 Bracket alternator rear 450453 844268 Bracket power steering rear 452388 844270 Bracket alternator front 452394 844272 Mount engine right 452390 843760 Bracket hydraulic pump 452395 821893 Trim push on 98 GOVERNOR SUZUKI K6A and 970 Jam Nut Use Teflon Tape Permatex 2 Sealant or Equivalent 6 Torque to 95 10 in Ibs G Nut ovenor Nu d 19 0 15 lt gt T 9 Adjust Governor Nut e Use S Secure With Jam Nut gt Loctite 271 4 Allowing 006 152 mm Sideplay For Lever
86. CUSHMAN A Textron Company PARTS amp MAINTENANCE MANUAL 4120402 TURF TRUC KS SUZUKI K6A LIQUID COOLED GASOLINE ENGINE MT MODEL 898627 SUZUKI K6A LIQUID COOLED GASOLINE ENGINE AT MODEL 898628 SUZUKI 970 LIQUID COOLED GASOLINE ENGINE MODEL 898671 PERKINS LIQUID COOLED DIESEL ENGINE MODEL 898673 EC MODEL 898695 Always Think Safety Thank you for purchasing a Cushman Textron product You are one of our many customers who have voted their confidence in our company by purchasing our products This is one of the best designed and built pieces of commercial industrial and turf equipment available Many safety features have been designed and built into this product Please DO NOT remove or defeat any safety features as they were installed for your protection The useful life and good service you obtain from your vehicle depends to a large extent on the way it is maintained and operated Treat your equipment properly lubricate and adjust it as instructed in this manual and it will give you many years of reliable service See your Cushman Textron dealer for service and parts He stocks genuine Cushman Textron parts manufactured with the same precision and skill as the original parts Cushman Inc A Textron Company reserves the right to make changes at any time without notice in specifica tions and models and also to discontinue models and the accessories designed to be used on these models The right is al
87. Compliance n This decal lets the operator know that the vehicle is not defined as a motor vehicle and therefore should not be driven on streets Battery Voltmeter Charging roads or highways This symbol appears on the volt meter gauge This gauge indi Electric Cooling Fan Warning cates the charging of the battery eai This decal warns the operator keep hands away from the cooling fan the 3 cooling fan can start at any time even OFF DIM BRIGHT with the ignition key in the OFF position Headlight Switch Positions These symbols appear on the light A WARNING Warning switch As indicated each one repre This decal warns the operator that sents the headlights functions PARKING BRAKES ARE NOT AUTO an uncovered P T O can cause MOVE CAUSING PERSONAL INJURY entanglement of clothing and or body parts _ Park Brake Warning This decal warns the operator that the park brake is not automatically applied Fuel Level Indicator 1 This symbol appears on the fuel Engine Oil Pressure Light gauge The fuel gauge indicates Eh This light will come on when the ignition key the amount of fuel in the fuel tank is turned to the ON position and when the 840845 engine is started it will shut off once the This symbol indicates engine is running Its main function is to diesel fuel only warn the operator if the oil pressure gets to low If this light comes on during nor mal vehicle operation st
88. D INTACT 845038 Vehicle Operation This decal informs the operator of proper procedures for safely operating the vehicle Read this manual completely to become aware of other safety issues and operating procedures which will help you operate this vehicle in a safe and responsible manner SERVICE and MAINTENANCE INDEX Page A Accelerator Pedal 13 Accessories list 42 Accessory Power Plug 10 Access Panels 32 Air Cleaner 31 Air Cleaner Element 31 B 26 Brake Lever 0 12 Brake Pedal Service 13 Brake Fluid Indicator Light 10 37 Brake Fluid Level amp Bleeding 37 Bulbs and Bulb Replacement 34 39 Choke knob 970 Suzuki 12 Clutch Interlock Switch 12 Clutch 12 22 Controls dons 10 13 Cooling System 18 19 D Dash Panel Dipswitch Settings 43 Decals 30H eme mation amos duo dace ded 2 Differential 11 16 1 amp 14 21 1 40 Differential 2 Speed operation 44 E Engine ACCESS 14 15 Break in 14 0 18 19 Identificatio
89. DLE UP NEE Y A i d DOME LIGHT 894531 11 3 TO SHIFTER LIGHT Bc YIR Nm ACC POWER HARNESS G 894804 Le B as 9 B DOMELIGHT EG FUSE HOLDER 8778 KS 182399 825996 N B B B A GROUND STANDOFF y_WeL 828231 AR SE MIR HEATER SWITCH me 894801 e on xm i WIOR L k 894805 AUTO TRANS W I ps acc Y CONTROLLER B oR won YIR WR RLoR 894034 PP s i Se wis v c8 Lcx st da HEATERHARNESS R IGN er 894806 SHIELD GY B B CABLE DRAKE Cer WIN LIGHT HORN BUTTON 5 894792 SWITCH KEY SWITCH 830366 894308 837295 9 W BL BR POWER POINT 843942 PIN 1 WHITE BLUE PIN 10 NOT USED PIN 2 BROWN PIN 11 BLACK CABLE PIN 3 CLEAR CABLE PIN 12 NOT USED PIN 4 NOT USED PIN 13 GRAY PIN 5 PINK PIN 14 SHIELD CABLE PIN 6 GREEN PIN 15 BLACK PIN7 YELLOW PIN 16 BLACK PIN 8 WHITE GREEN PIN 17 GREEN PIN 9 WHITE YELLOW PIN 18 BLUE 173 WIRING SCHEMATIC SUZUKI K6A TURF TRUCKSTER
90. HITE w BLUE STRIPE 172 WIRING DIAGRAM SUZUKI K6A TURF TRUCKSTER with AUTOMATIC TRANSMISSION con t TURN SIGNAL SWITCH 894288 TAILLIGHT ADAPTER FLASHER INDUSTRIAL TAILLIGHT 825501 HARNESS 894314 OR OR x
91. ILL NOT be warranted The cooling system level and the intake screen should be checked every day before vehicle operation Along with th ily pre start list you should also Radiator And Radiator Fins Are ang Pre Starnllst Should alse Located Behind The Screen Check the radiator and coolant hoses for leaks and faulty connections repair as necessary Inspect the engine belts for fraying or cracking and check the engine for loose hardware Check the coolant reservoir there should be approx imately four 4 inches 102 mm of coolant in the res ervoir Remove the radiator cap and check the coolant level the coolant should be at or with in 1 4 6 mm from the bottom of the filler port if coolant is needed adda Figure 24 50 50 anti freeze water mixture following the proce Intake Screen Right Side of Vehicle dures stated below ADDING ANTI FREEZE TO THE COOLING SYSTEM The cooling system should be drained and refilled every 400 hours or nine 9 months Make a 50 50 mixture of anti freeze and water in a separate container before adding coolant to the radiator Never add straight anti freeze to the radiator the mixture must never be more than 50 anti freeze Cooling System Capacity Suzuki K6A Engine 3 3 ats 3 01 Suzuki 970 Engine 3 3 ats 3 01 WARNING Perkins Diesel 5 0 qts 4 7L SE ALWAYS make sure the engine is stopped Unless the radiator is very low always
92. L PEDALS CLUTCH PEDAL Manual Transmission Only The clutch pedal has to be depressed before shifting into any of the gears The clutch has a Safety Feature called a clutch interlock switch This switch vents the starter from operating unless the clutch is dis engaged the clutch pedal is depressed If the engine will start without depressing the clutch pedal E DO NOT operate the vehicle The clutch interlock system should be repaired immediately by your authorized Cushman dealer 5 The clutch pedal has to be depressed before starting the vehicle before shifting into any of the gears and Figure 12 before coming to a complete stop Clutch Pedal Location DANGER Never start the engine unless the clutch pedal is depressed pushed down If the vehicle 1 any gear other than neutral with the clutch pedal not depressed and the engine is started the vehicle will urch forward or backward depending which gear the vehicle is in This lurching could cause serious personal injury or death 12 CONTROLS Cont FOOT THROTTLE ACCELERATOR PEDAL Push pedal down to open throttle increase speed release to return throttle to idle position decrease speed SERVICE BRAKE PEDAL Depress the pedal to slow or stop the vehicle If the brakes DO NOT stop the vehicle properly the brakes must be adjusted or repaired de e A CAUTION 1 lt Improper main
93. N FOREST BRUSH OR GRASS COVERED LANDS NOTICE Reference to the front rear left and right sides of the vehicle are always determined by the operator s seated position THE FOLLOWING IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE CONCERNING THIS VEHICLE The Vehicle Identification Number VIN model number and serial number are all printed on the Nameplate Iden tification Decal attached to the crossmember under the dash See Fig 1 The serial number and model number are also stamped on the crossmember It is located to the left of the model and serial no decals See Fig 2 WI Vehicle Model and Serial No 4 CS Nameplate Identification Decal Figure 1 e Vehicle Serial No Stamped Into Crossmember Figure 2 Serial Number And Model Number ENGINE IDENTIFICATION NUMBERS Your Cushman Turf Truckster is equipped with one of three power sources A Suzuki K6A 3 cylinder 4 cycle liquid cooled gasoilne powered engine a Suzuki 970 4 cylinder 4 cycle liquid cooled gasoline powered engine ora Perkins 103 10 3 cylinder 4 cycle liquid cooled diesel powered engine VEHICLE IDENTIFICATION NUMBERS Cont Engine Identification Numbers con t Each engine has a serial number stamped onto the engine block The Perkins diesel s serial no is stamped on a metal plate which is attached to the engine block The Engine Serial No for the Suzuki K6A engine is p T stamped on
94. Nut M8 1 25 G8 8 Bolt M6 1 00 x 30 8 8 Screw M6 1 00 x 40 8 8 Screw M8 1 25 x 25 8 8 Bolt M8 1 25 x 30 8 8 Bolt M8 1 25 x 90 8 8 Set screw 3 8 16 x 3 8 Screw M6 1 00 x 12 8 8 Washer 5 8 O ring Shim transmission Fork shifter Gear PTO sliding Part Description 817397 Arm PTO shifter 844181 Housing PTO 844184 Spacer 5th gear 844185 Shaft output 844186 Washer special 844187 Bearing ball 59 1 65 51 844906 Seal tailshaft 879807 Arm assembly PTO shifter 894947 Shaft idler 316942 Pin spirol 894965 Gear assembly idler 844182 Gear idler 09304 16014 Bushing countershaft 894989 Housing bearing 815093 Bearing ball 998 2 05 59 OP 1 844188 oil 2700120 Gasket PTO housing to trans 2700121 Gasket PTO housing 09246 16010 Plug oil fill INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 167 TORQUE SPECIFICATIONS HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specific torque values are not given Note the minimum grade for the U S standard bolt is grade 5 U S Standard Hardware Shank Size Diameter in inches fine or coarse thread fof ffm grade 5 24 102 150 208 339 513 790 1060 kk grade g 18 38 108 156 224 305 502 801 1211 mai 2 E Screw w Flangelock m ps
95. OP the vehicle For vehicles with manual transmissions stop the vehicle push the clutch pedal in THEN pull the P T O control knob upward For Use When The Vehicle Is Stationary Make sure governor control is in UP position Set engage the parking brake Put transmission in neutral out of gear and engage the clutch put automatic transmission in Park Push foot throttle pedal to floorboard Raise the hand throttle control lever to full engine R P M Move the governor control lever to desired engine R P M WARNING Ifyou donot want the vehicle to move ALWAYS make sure the transmission is out of gear and the park brake is applied when the clutch pedal is released to activate the P T O shaft Make sure the vehicle is in Park with the park brake applied for automatic transmissions e ALWAYS disengage the P T O before attaching any equipment to the P T O shaft ALWAYS remain clear of the P T O shaft and all moving parts Figure 73 P T O Shaft Location For Use While Vehicle Is Moving 1 Refertothe Power Take Off R P M Vehicle Speed chart see Page 50 to select the proper P T O and ground speed combination for the accessory equipment being used there is also a decal representing the P T O and ground speed combinations located on the same panel as the P T O control handle Position the governor control lever to obtain engine R P M corresponding to the desired P T O and vehicle ground speed Put transmi
96. RNATOR SUZUKI 970 Dro Qe lt or Front Of Vehicle Ref Part Description Description 31400 60C11 Generator alternator 32500 60C11 Regulator 31771 82C20 Pulley 31631 60F30 Brush set 31775 50F20 31621 70011 Rectifier 31792 51F10 Spacer 31514 82630 Insulator 31582 50F20 Bearing 08316 10063 31585 60A10 Retainer bearing 31616 82C20 31586 60A10 08316 10063 31651 86520 Screw kit 01550 08303 31710 82C20 95110 66C00 31612 60A10 rear 01550 08163 31410 85320 Stator 1 2 3 4 5 6 7 8 9 1 1 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 164 1 2 3 4 5 6 7 8 9 Mounts To Control Panel 33100 85750 33321 60A10 33324 79610 33310 82010 33102 75110 33140 74010 33151 52011 33341 76410 33210 73010 33261 77090 33230 85730 33239 76410 33278 85310 33267 79610 DISTRIBUTOR SUZUKI 970 Only 1 Plug Wire 1 Shown There Are 4 Wires In The Set 19 Description Description Distributor 33268 72010 Cap distributor 09138 08003 Screw 8 x 30 Seal cap 33410 85010 Coil ignition 33710 85051 Cord high tension No 1 Breaker assembly coil wire eePoint assembly 33705 85220 Cord set high tension eeScrew point spark plug wire set eeWire read 33881 75100 Bracket cord clamp Terminal assembly 02112 06083 33881 85210 Clamp distributor
97. Ref Part No No Description 120177 Lockwasher 3 8 306835 Screw 3 8 16 x 1 3 4 306325 Lockwasher 5 16 306450 Screw 5 16 18 x 3 4 306932 Nut 5 16 18 306981 Washer 3 8 316909 Screw 5 16 18 x 4 1 2 450453 Nut M8 1 25 G10 9 452388 Screw M8 1 25 x 20 8 8 452394 Screw M8 1 25 x 70 8 8 800697 Nut crownlock 5 16 18 800950 Screw M6 1 00 x 10 844035 Pulley 4 75 governor 836854 V belt 42 1067 mm 1 2 3 4 5 6 7 8 9 SUZUKI 970 Reference Alternator 2 31400 60 11 Use Loctite 242 On These Items Part 839907 894362 844036 843702 800073 828100 Reference Governor Part No 894080 Reference Hydraulic Pump Part No 888042 894197 Description Pulley 5 50 steering pump Bracket alternator governor and power steering pump V belt 51 1295 mm Bracket hydraulic pump Bolt carriage 3 8 16 x 1 1 4 1 Pulley 5 50 hydraulic pump 95131 51F60 Pulley double groove 12619 60B00 Bolt crankshaft 09118 08107 Bolt 17511 73001 Pulley water pump 452389 Screw M8 1 25 x 25 8 8 08316 10083 Nut 97 ALTERNATOR ENGINE BELTS PULLEYS and BRACKETS DIESEL Reference a Fan Switch Tube 22 al u Part No 894348 Sa B VA With Radiator v Throttle Bracket 5 N 8945
98. T REPLACEMENT Headlight Remove the four 4 screws securing the headlight Bezel bezel to the front cowl See Fig 52 Pull the headlight and bezel from the front cowl opening Disconnect the electrical connector from the rear of the headlight and remove the headlight from the bezel Replace headlight and install in the reverse sequence LAM 1 For Headlight Removal Headlight Part No 837303 Figure 52 Part No 841428 Headlight Removal Mounting Screws Part No 800943 BULB REPLACEMENT TAILLIGHT Remove the two 2 screws securing the taillight lens to the taillight Remove the bulb and replace with a No 1157 bulb Replace the lens cover making sure the gasket is posi tioned correctly To remove the taillight from the vehicle remove the two 2 nuts and shakeproof washers securing the taillightto Remove The Two 2 E K Screws For Bulb 7 Or Lens Replacement E Taillight Assembly Part No 893602 len D Part No 822049 A a Lens Screws Part No 312288 a ES MU Lens and Gasket Part No 829099 Figure 53 License Illuminator Lens Part No 829099 Taillight Bulb Replacement 39 SERVICE amp MAINTENANCE GOVERNOR OIL LEVEL Suzuki K6A amp 970 Engines si Jil Check the oil level in the governor after every 100 hours m of use To check the level remove the plug from the back Ss side of the governor Oil should be up to the level of the plug opening Governo
99. TS and REAR SHOCK ABSORBERS p Front Of Vehicle Reference 10 39 2 Two Speed Differential P894510 P893435 P2701117 Ref Part No Part No No Description Description 1 2 3 4 5 6 7 8 9 311396 Screw 7 16 14 x 2 1 4 2 825500 Washer 3 8 311398 Screw 1 2 13 x 3 1 2 887187 800198 Nut 1 2 20 crownlock 548061 7 16 20 unitorq 800294 Nut 7 16 14 crownlock 843238 Bushing nylatron 800602 Nut 1 2 13 843876 Shackle rear spring 807332 Shock absorber 893862 Spring leaf 809180 Washer 7 16 843238 Bushing nylatron 813850 Bumper rubber 893613 Upstop 823621 Bushing 838409 Spacer leaf spring 970 only 2 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEEDING ASSEMBLY 83 HYDRAULIC CONTROL VALVE SYSTEM Refer to the Hook up Decal on back of the hydraulic box for hook up options With Perkins 25 Diesel Only Seal Kit Part No 887017 d Reference Hydraulic Control Valve 893447 894197 894198 Ref Part Part No No Description No Description 304632 Nut jam 3 8 16 844600 Hose hydraulic 1 2 x 39 306388 Nut jam 3 8 24 844628 Hose hydraulic 3 8 x 18 450453 Nut M8 1 25 G10 9 844652 Adapter straight 452392 Screw M8 1 25 x 50 8 8 844517 Fitting 45 swivel Perkins only 548171 894696 Valve hydraulic selector 822419 Washer flat 1 6
100. Tail LH Light Dash Panel 16 Light BT Receptacle Acc Light A 4 A TURN SIGNAL SWITCH SCHEMATIC Flasher Flasher i 5 a E N Cep 5 f STO RH LH STOP RH LH RH REAR SW HEAR REAR SW REAR NEUTRAL HAZARD eae Flasher Y T ro LH RH LH STOP RH RH REAR owe REAR FRT REAR SW REAR FRT r LH TURN RH TURN 181 WIRING DIAGRAM DIESEL TURF TRUCKSTER Left Industrial Taillight 892676 Right Industrial Taillight 892676 Industrial Taillight Harness 892676 g BUR BR BR Engine Harness B Alternator 894637 Ss 893633 BL B B BR d N RB 20 3 we 5 AMP 7 s Turf Taillight Er Fan Switch ge Turf Taillight Harness 894313 17680 50F70 R 893602 Start Temp s Solenoid Y Pre Heat Relay Sender eo wig iew Shown From A ed 589673 E ws gt 22 Of Connect
101. UZUKI K6A Description 4119978 Ring set piston Standard 4119979 Ring set piston OS 0 50 4119980 Standard Mark 1 4119981 i Standard Mark 2 4119982 OS 0 50 4119983 Pin piston 4119984 Circlip 4119985 Rod connecting 2701931 Nut 4119608 Bearing set connecting rod 4119986 Crankshaft 4119987 Bearing set crankshaft Green 4119988 Bearing set crankshaft Black 4119989 Bearing set crankshaft Non color 4119990 Bearing set crankshaft Yellow 4119991 Bearing set crankshaft Brown 2701937 Bearing set crank thrust Standard 2701938 Bearing set crank thrust OS T 2 563 2701955 Seal crankshaft front oil 4120019 Sprocket crank timing 4120020 Pulley crankshaft 4120021 4120022 4120023 4120024 Manual transmission 4119955 Bolt 10 x 18 5 Manual transmission 2701952 Bearing input shaft Manual transmission 4120026 Water pump belt 4120027 4120028 4120029 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 155 ENGINE GASKETS SUZUKI 970 Front Of Vehicle Ref Part No Part No No Description No Description 11401 85893 Gasket set complete 11229 73000 Gasket cylndr block plate 11141 75120 Gasket head 11399 73010 Gasket timing belt cover 11189 73004 Gasket valve cover 17569 60A10 Gasket thermostat cap 11173 73001 Gasket breather plate 16119 76000 Gasket oil pump case 11169 70000 Gasket distributor case 13119 73001 H17 Gaske
102. ace any decal which may become damaged and or hard to read For use with Turf Model 898628 Suzuki K6A with automatic transmission lt gt MPH 2500 13 5 119 7 16 7 24 41 3100 amp 7 2 lt gt 2 3 14 0 6 1 28 4 9 7 6 19 0 898659 13 1 19 1 25 40 6 0 4 7 8 2 1 5 21 0 30 7 3900 13 1 4 9 18 4 8 8 151 6 5 96 76 5 2 6 4 2 6 1 For use with Turf Models 898627 Suzuki K6A with manual transmission 8 4 7 75 2 898650 898652 For use with Turf Model 898671 Suzuki 970 manual transmission 3 6 14 9 7 o 6 2 7 1 2 12 8 5 25 4 36 2 3600 1 9 10 0 18 5 For use with Turf Models 898673 and Perkins Diesel with manual transmission 50 OPERATING REMOTE HYDRAULICS Cont HYDRAULIC RESERVOIR Normally the hydraulic system will not need additional fluid Sometimes a leak may develop causing the system to require repair and refilling If you notice hydraulic fluid escaping when the system is being used or if a leak is suspected turn off all hydraulic functions and stop the engine Check the hoses and fittings to determine where the fluid may be escaping from If necessary start the engine a
103. acement Compression Ratio Cylinder Compression 178 PSI 1 228 kPa Engine Rotation viewed from flywheel Counterclockwise Valve Clearance intake 0031 cold 0 08 mm intake 0047 hot 0 12 mm 008 cold 0 2 mm exhaust 0039 cold 0 10 mm intake 010 hot 25 mm exhaust 0047 hot 0 12 mm exhaust 008 cold 0 2 mm Spark Plug Gap 032 035 0 8 0 9 mm exhaust 012 hot 30 mm Spark Plug Number NGK BP5ES Displacement Compression Ratio Cylinder Compression 425 PSI 2 932 kPa Engine Rotation viewed from flywheel Valve Clearance intake Counterclockwise Spark Plug Gap OR Denso W16EX U Spark Plug Torque 18 5 21 5 Ib ft 25 30 N m Breaker Point Gap 008 015 0 2 0 4 mm Ignition Timing 4 57 BTDC 950 RPM Idle Speed 950 50 RPM Spark Plug Number Spark Plug Torque Breaker Point Gap Injection Timing Idle Speed GAUGES WARNING LIGHTS and CONTROLS The following pages contain information which will help you become more familiar with the dif ferent gauges and controls used while operating this vehicle TACHOMETER 1 Indicates the engine speed x 100 in revolutions per minute See Fig 6 HOUR METER 2 The hour meter See Fig 6 records the number of hours the engine has run The hour meter runs when the key switch is ON even if the engine is not running FUEL GAUGE 3 The fuel gauge See Fig 6 indicates the amount of fuel re
104. and possible personal injury PRE STARTING CHECKLIST Before starting your engine for the first time after a prolonged shutdown and before each days use check the following Check the engine oil level Check the radiator coolant level and radiator intake screen Check the fuel level Check tire pressure 5 Check brake fluid level If the diesel engine is being started for the first time or is being started after a prolonged shutdown it will be necessary to purge the fuel system see Purging the Fuel System Page 22 ENGINE OIL LEVEL Always turn the engine off when checking the oil level Oil level should be checked daily NOTICE Make sure vehicle is on level surface and the park brake is applied 15 SERVICE amp MAINTENANCE Cont Engine Oil Level con t Remove the dipstick and wipe with a clean rag reinsert the dipstick until it contacts the oil tube remove dipstick and read the oil level The oil level should always between the ADD and FULL mark on the dipstick DO NOT OVER FILL If the engine has recently been running allow time with the engine turned off to let the oil settle to obtain a correct level reading If the oil level is below the add mark add an SAE 10W 30 oil to bring the level up between the marks refer to the recommended oil weights in the chart for your particular climate range Remove the oil fill cap and add the appropriate amount of engine oil Use the dip stick to check
105. ank 15100 53F03 Pump fuel 15410 50F00 Filter fuel 893555 103867 800221 450454 548911 800177 845189 Strap fuel tank Washer 5 16 Nut crownlock 5 16 24 Nut M10 1 50 10 9 Nut 5 16 18 Screw 5 16 18 x 3 4 Connector hose INDENTED PARTS NAME INDICATE THESE PARTS ARE INCLUDED WITH THE PRECEDING ASSEMBLY 67 FUEL SYSTEM DIESEL Reference Frame And Lower ROPS N To Main Frame To Engine Fuel Return Re 13 a 28 gt To PS Engine Harness 2 36 12 Reference Air 12 Cleaner Bracket N 13 To Engine GG Fuel Inlet 893598 68 FUEL SYSTEM DIESEL Ref Part No Part No No Description Description 120052 Lockwasher 10 5 84310 450453 Nut M8 1 25 G10 9 843727 Elbow 90 450452 Nut M6 1 00 G10 9 843726 Tube fuel pick up 452378 Screw M6 1 00 x 20 842800 Clamp filter 452389 Screw M8 1 25 x 25 8 8 893527 Support fuel tank 452390 Screw M8 1 25 x 30 8 8 894638 Pump fuel 829954 2208175 Filter fuel 800021 Screw 10 32 x 1 2 893555 Strap fuel tank 843343 Cap fuel unvented 103867 Washer 5 16 843298 Sender fuel 821893 Trim push on 800697 Nut crownlock 5 16 18 825624 Clamp hose 450454 Nut M10 1 50 10 9 826590 Hose fuel 5 16 1 4 548911 Nut 5 16 18 829787 Terminal 45
106. apacity to stop either a loaded or unloaded vehicle and the trailer on the type s of surface s and grade s on which the vehicle will be operated Position the load on the trailer so that the tongue weight on the towing vehicle will not cause instability or affect steering control e NEVER make sudden stops turns or accelerations when towing a trailer or equipment This vehicle is capable of pulling trailers and other equip ment of greater weight than the vehicle itself so caution and good judgment must be used to avoid losing con trol of the vehicle while braking or cornering NE Connect the equipment to be pulled to the trailer hitch on the rear ofthe vehicle Secure using a tow pin or similar aem om object sure to secure the tow pin or similar object so S it cannot fall out of the mounting hole Figure 62 Trailer Hitch DASH PANEL DIPSWITCH SETTINGS Remove the four 4 screws securing the instrument panel to the dash rum Dipswitch Settings Location Pull the instrument panel out and tilt forward to gain access to the rear of the panel See Fig 63 Using a small blade screwdriver or similar tool push the switch levers either up or down using the following sequence codes the top of the dash panel will be refer enced as position 1 igure 63 Dash Panel Dipswitch Location MODELS 898671 amp 898673 MODELS 898627 amp 898628 MODEL 898695 anna
107. appet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet Shim tappet CAM CHAIN SUZUKI K6A Front Of Vehicle 107 CAM CHAIN SUZUKI K6A SST 4120037 Chain timing 4120038 Guide chain 4120039 Bolt 4120040 Tensioner chain 4120041 Spacer 2702469 Bolt 4120042 Pad tensioner 4120043 Link tensioner 2702486 Bolt 4120044 Adjuster tensioner 2701834 1 2 3 4 5 6 7 8 9 1 1 108 CARBURETOR and INTAKE MANIFOLD SUZUKI K6A Front Of Vehicle Water Inlet Pipe 109 CARBURETOR and INTAKE MANIFOLD SUZUKI K6A ED 4120045 Manifold intake 4119959 2702523 Stud bolt 4120047 Stud bolt 2701834 4120048 2701914 4120049 Body throttle 2701995 Sensor throttle position 2701996 Screw 2702477 Sensor pressure 2701998 Screw 2701999 Valve ISC 2702000 Gasket 2701998 2701803 4120025 Hose water 4120050 Hose water throttle inlet 4116846 Hose water 4120051 Sensor inlet air temperature 4120052 4120100 2702429 2702486 2702001 2702475 2702431 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 110 BREATHER HOSE SUZUKI K6A Front Of Vehicle a Intake Manifold 1 4120054 2702484 2702485 2702486 4120055 2702489 4120
108. art at any time even with the ignition key in the OFF position DO NOT attempt service without first disconnecting the negative battery cable or without first removing the fan fuse The cooling system is under pressure if a leak is present be careful when raising the seat or when opening the engine cover Hot coolant can be sprayed causing personal injury To provide proper engine cooling it is important to keep the cooling system properly maintained Part of maintaining the system involves making sure the intake screen radiator fins and surrounding engine areas remain free of debris e DO NOT obstruct or cover the intake screen in front of the radiator Keep the fins and radiator screens clean e Ifthe radiator fins or intake screen become dirty air cannot circulate Radiator Warning Decal well enough to cool the engine sufficiently therefore you risk the Warning Decal chance of the engine overheating Engines damaged due to overheating caused by plugged radiators WILL NOT be war ranted 18 SERVICE amp MAINTENANCE Cont Radiator Coolant Level con t NOTICE Clean the radiator fins with compressed air If water is used to clean the radiator use compressed air to blow all the water from the fins Water left between the fins will collect dirt and plug the radiator this will reduce the amount of air flow to properly cool the engine Engines damaged due to overheating caused by plugged radiators W
109. ble To Positive Terminal On Good Battery 4 Connect Cable To Frame Or Engine Of Disabled Vehicle 3 Connect Cable To Negative Terminal On Good Battery BOOSTER GOOD BATTERY DISCHARGED DEAD BATTERY Attach one end of remaining cable to the negative 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 the battery when making this connection Reverse this sequence exactly when removing the jumper cables NOTICE This is a negative ground wiring system reversing battery connection will damage alternator rectifier Booster batteries used for starting must be connected with proper polarity Vehicle battery cables should be disconnected before using a Fast Charger TOWING THE VEHICLE Manual Transmission 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 27 SERVICE amp MAINTENANCE Cont Towing the Vehicle a F TOW LINE ATTACHMENT Attach a tow line only to the front vertical frame member on either side of vehicle as shown in Figure 33 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 un
110. clip mount 841715 Rod hood release OO JO P ob Part 841753 841787 841264 844116 841913 74764 844167 74792 74766 886090 894030 844669 306488 548159 548175 800582 844049 844293 800344 823549 840508 38541 Description Bracket hood latch Latch hood Panel dash left Decal left dash panel turf Plate access Decal CUSHMAN Bracket horn brake reservoir Decal turf truckster left Decal turf truckster right Striker hood Seal weather As Req d Lockwasher 1 4 shakeproof 2 Washer 5 16 1 1 4 diameter 4 Washer 1 4 1 1 4 diameter Screw 1 4 20 x 3 4 Flap mud Plug Screw tapping 10 type 2 Tie cable 15 5 394 mm Mount cable tie Tube document INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated 55 FRAME Bolts To Radiator Bracket 4 Front Of Vehicle Reference Battery amp Hydraulic Tank Reference 4 Motor Mounts 3 Reference 20 Ground Wire 2 894602 5 893326 56 FRAME Ref Part No Part No No Description No Description 309067 Lockwasher 1 2 shakeproof 2 841805 Panel access 450453 Nut M8 1 25 G10 9 842870 Angle support 450454 Nut M10 1 50 G10 9 844601 Bracket battery clamp 450455 Nut 12 1 75 G10 9 882971 Pi
111. ctor 3 8T x 1 8MP 4118027 Filter assy air 832246 Hose 3 8 heater 840352 Element air cleaner 843666 Hose air inake 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 62 AIR CLEANER BRACKET and FILTER SUZUKI 970 and DIESEL To Radiator Mounting Frame Right Side Motor Mount SUZUKI 970 Shown For Reference Only Use Loctite 592 With Front Of Vehicle Perkins Diesel ez heme 1 14 amp 18 d 5 Shown Assembled 1 gt 23 e Depict Orientation On 0 24 All components shown used with both the 5 The Perkins Diesel Suzuki 970 and the Perkins diesel unless otherwise noted in the parts list shown below 893444 893594 894197 894198 Ref Part No Part No No Description 300646 Screw 1 4 20 x 3 4 2 844311 Bracket air cleaner Perkins 306396 Lockwasher 1 4 893182 Filter complete air 308090 Washer 1 4 840352 Element air cleaner 452388 Screw M8 1 25 x 20 8 8 888549 Connector hose air cleaner 1 452389 Screw M8 1 25 x 25 8 8 841230 Connector Suzuki 970 450453 Nut M8 1 25 8 8 Perkins 832246 Hose 3 8 heater 450453 Nut M8 1 25 8 8 Suzuki 970 4 Suzuki 970 As 452390 Screw M8 1 25 x 30 8 8 843831 Connector hose Suzuki 970 1 Perkins 842997 Cap 7 64 i d x 3 4 Suzuki 970 1 825358 Clamp worm drive 825884
112. ctory Mutual Research Corp 1151 Boston Providence Highway Norwood Massachusetts 02062 U S A National Fire Protection Association ANSI NFPA 505 Powered Industrial Trucks ADDRESS National Fire Prevention Association Batterymarch Park Quincy Massachusetts 02269 U S A e ANSI ASME B56 8 Personnel Burden Carriers ADDRESS American National Standards Institute Inc 1430 Broadway New York New York 10018 U S A ANSI UL 558 Internal Combustion Engine Powered Industrial Trucks ADDRESS American National Standards Institute Inc 1430 Broadway New York New York 10018 U S A OR Underwriters Laboratories Inc 333 Pfingsten Road Northbrook Illinois 60062 U S A Flammable and Combustible Liquids Code ANSI NFPA 30 ADDRESS American National Standards Institute Inc 1430 Broadway New York New York 10018 U S A OR National Fire Prevention Association Batterymarch Park Quincy Massachusetts 02269 U S A OPERATION CONTROL SYMBOLS And DECALS NOTICE THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE DEFINITION OF THE NATIONAL TRAFFIC MOTOR Engine RPM VEHICLE SAFETY ACT IT IS NOT DESIGNED 2 pn OR MANUFACTURED FOR USE ON ROADS STREETS Park Brake Indicator Light This symbol indicates OR HIGHWAYS NOR IS IT APPROPRIATE FOR ie i i SUCH USE IT iS NOR MEANT BE LICENSED This light will come on when engine rpm s AS AMOTOR VEHICLE 821071 the park brake is applied Motor Vehicle
113. e front suspension To open the front cowl locate the release lever at the upper left corner near 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 struc ture if equipped or the steering wheel Figure 41 The front cowl will not spring up when the release Release Lever For Front Cowl lever is pulled The cowl will have to be raised when the latch is released 32 SERVICE amp MAINTENANCE Cont LUBRICATION RECOMMENDATIONS Transmission Fluid SAE EP 80 90 Gear Lube Brake Fluid Automatic Transmission Fluid Mercon Dexron Il Differential Fluid SAE EP 80 90 Gear Lube Power Steering Power Steering Fluid GM Pressure Gun Grease Hydraulic Fluid Ransomes Turf Protector Biodegradable Hyd Benz Bio 377 LUBRICATION CHART Lubricate all chassis fittings with ithium base pressure gun grease every 100 hours or 1000 miles Ref Number Of Ref Number Of No Lubrication Area Grease Fittings No Lubrication Area Grease Fittings Drive shaft 3 Lower Ball Joint Upper Ball Joints 4 Tie Rod Ends NOTICE Reference to item 1 Too much grease can damage the seals Brake Fluid Reservoir Fuse Box
114. ead upper 4117892 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 149 CYLINDER BLOCK and COMPONENTS SUZUKI K6A Front Of Vehicle 150 CYLINDER BLOCK and COMPONENTS SUZUKI K6A Description 4119974 cylinder 4119956 crankcase 4120006 crankcase No 2 4119607 oil venturi 4120007 oil gallery 2 4120008 Gasket oil gallery plug 4119604 2701824 P 4120009 Stand oil filter 2701908 Filter oil 2701840 Plate clutch housing upper Manual transmission 4117895 Plate clutch HSG Manual transmission 2702537 Manual transmission 4120010 Sensor knock 4117899 Guard oil filter 2701827 4 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 151 OIL PAN and DIPSTICK SUZUKI K6A OIL PAN and DIPSTICK SUZUKI K6A Ae Description 4120011 Pan oil 4120012 Bolt 6x 16 4120013 Stud bolt 2701914 2701915 Plug drain 2701916 Gasket drain plug 4117897 Plate oil pan baffle 2702486 Bolt 4119975 Strainer oil pump 2701920 O ring 4120014 Stud bolt 2701914 2701921 4119976 Gauge oil level 4119977 Guide gauge 4119605 O ring 4120015 Stud bolt 2701914 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 153 CRANKSHAFT FLYWHEEL and PISTONS S
115. ehicle for the first time during the day or when the engine has cooled you will need to pre heat the glow plugs in order to start the engine If the engine has been running and is still hot it is not necessary to pre heat the glow plugs before starting the engine Apply the park brake the parking brake should have been applied when the vehicle was last parked Move the gear selector to NEUTRAL Push clutch pedal down starter will not operate unless clutch pedal is pushed down The clutch inter lock switch prevents the starter from operating unless the clutch is disengaged the clutch pedal is depressed If the engine will start without depressing the clutch pedal DO NOT operate the vehicle The clutch interlock system should be repaired immediately by your authorized Cushman dealer DANGER Never turn the key to the START position unless the clutch pedal is depressed pushed down or the gear selector is in neutral If the vehicle is in any gear other than neutral and the clutch pedal is not depressed when the engine is started the vehicle may lurch forward or backward depending which gear the vehicle is in This lurching could cause serious personal injury or death Turn the ignition key to the ON position Note the pre heat light at the lower left of the instrument panel The light will come on when the ignition switch is turned to the position When the pre heat light goes off turn the ignition key to
116. el ASTM No 1D when temperature is 20 F 7 C or below use 2 diesel fuel ASTM No 2D when temperature is above 20 F 7 If No 1D is not available a winterized blend of No 1D and No 2D may be available This blended fuel is usually called No 2D and may be used in colder climates Never use No 2D at temperatures below 20 F 7 C unless you are sure it has been winterized Cold temperatures may cause it to thicken which will keep your vehicle from running WARNING Remove fuel cap slowly Fuel may be under pressure Spray may cause serious injury Engine fuels are extremely flammable and highly explosive under certain conditions NEVER remove the fuel tank cap or attempt to refuel the unit while the engine is running NEVER refuel indoors NEVER smoke while refueling ALWAYS wipe up spilled fuel immediately NEVER operate the unit without an approved cap on the fuel tank filler opening GASOLINE CONTAINING ALCOHOL We DO NOT recommend the use of ALCOHOL bearing fuels in any of our products The use of these fuels may create a potential safety hazard WARNING Gasoline containing ALCOHOL can cause deterioration of some non metallic materials in the fuel system Fuel hoses must be inspected frequently and replaced if excessive stiffness deterioration or fuel leakage is found Gasoline containing ALCOHOL will attract and hold moisture inside fuel tanks Moisture may cause corrosion of metallic parts w
117. enoid direct clutch 842740 Lever shifter 2702823 O ring 825624 Clamp hose 2702824 Solenoid 2nd brake 826590 Hose 5 16i d As Req d OO JO Om P ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 122 CAMSHAFT amp COMPONENTS SUZUKI 970 Front Of Vehicle Ref Part No Part No No Description Description 12710 77314 Camshaft 09159 07002 09283 32040 Seal camshaft 12911 78101 Valve inlet 12749 73002 Plate cam shaft thrust 1 12915 84010 Valve exhaust 02122 06123 12921 73002 Spring valve 12860 73004 Shaft valve rocker 12900 82810 Retainer valve spring 02122 06163 12932 82000 valve 12841 77300 Arm valve rocker 12933 73000 Seat valve spring 12891 51900 Spring rocker arm 09289 07007 Seal oil 12848 73010 Screw valve adjusting 8 1 2 3 4 5 6 7 8 9 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 123 TIMING BELT amp TIMING COVER SUZUKI 970 Front Of Vehicle Ref Part No Part No No Description Description 11360 78100 Cover inside 11391 78113 11399 73010 11398 73000 09308 10004 09180 06106 09136 06139 02162 06103 Cover outside Gasket cover Grommet Grommet Spacer 6 x 10 x 17 Bolt 6 x 16 01500 12253 09160 12094 12761 78400 12810 53A00 01550 08403 09160 08133 09180 08111 12821 78100 Washer 1
118. ess When engine is heavily loaded Some black smoke NOTICE DO NOT use ether or starting fluid with diesel engines Severe engine damage will occur Starting under sub freezing conditions Make sure correct weight engine oil is used Make sure the battery is fully charged Pre heat glow plugs for the correct length of time Make sure cooling system is tested safe for the ambient temperature PURGING THE DIESEL FUEL SYSTEM The fuel system must be purged when Starting a new diesel engine for the first time After prolonged storage The fuel tank is allowed to run dry The fuel filter and or fuel lines have been loosened removed or replaced Purge the fuel system using one of the procedures as follows PURGING FUEL SYSTEM USING A JUMPER WIRE This method allows the fuel pump to run continu ously when purging the system ds A t Pen NAA 43 Disconnect Red White 1 Turn the ignition key to the off position 4 Wire From Starter s 2 Disconnect the white red wire form the starter coil WARNING e Failure to remove this wire may result in the starter engaging causing the vehicle to move This movement could result in per sonal injury and or property damage Figure 27 Purging Diesel Fuel System 24 SERVICE amp MAINTENANCE Cont Purging the Diesel Fuel System con t 3 one end of a jumper wire to the EXC terminal on the back of the alternator as shown in Figures 28 amp 29 thi
119. extension tube as the fill tube To drain the transmission fluid remove the drain plug located on the bottom left rear corner of the transmission pan 7 Drain Plug Automatic Transmission Bim Transmission Fluid Dipstick And Fill Tube HR ti FEN SZ gt Figure 60 Figure 61 Automatic Transmission Dip Stick Automatic Transmission Drain Plug Suzuki K6A Engine NOTICE Most communities have special sites to dispose of used petroleum based products such as transmission fluid engine oil and differential fluid Please use an appropriate container to catch any fluids and dispose of properly ACCESSORIES amp HYDRAULIC ATTACHMENTS and 5th WHEEL IMPLEMENTS There are numerous accessories attachments and implements available for your vehicle Some accessories include High Low Hydraulics System Steel Cab Sets Steel Door Sets Heater Defroster Upper ROPS W Seatbelt Dump Boxes and Platform Beds Also attachments and implements like the Quick Aerator Core Harvester TD 1500 amp 2000 Top Dressers the Vicon Spreader Turf Master Sprayers Seed amp Fertilizer Spreaders and more For information and availability on these accessories and others contact your local Cushman Dealer 42 ACCESSORIES TOWING A TRAILER Trailer Hitch WARNING NEVER pull loads which may exceed the braking capacity of the vehicle The operator must determine if the Cushman vehicle has adequate braking c
120. g 8 Accessory Power Plug Figure 8 Accessory Power Plug CONTROLS Cont IGNITION SWITCH 1 ACCESSORY POSITION Allows use of various instruments and accessories without causing ignition system damage OFF POSITION Prevents function of all vehicle electri cal power operated features except for the flasher haz ard lights and the radiator cooling fan Switch must be in OFF position for key removal ON POSITION Key is placed in this position for normal engine operation START POSITION Hold key in start position to engage engine starter Upon release key will return to ON position automatically Key must be returned to the OFF position before the starter can be reacti Ignition Switch Position vated Shown as reference only NOTICE Figure 9 e DO NOT turn key to START position with vehicle engine Four Position Ignition Switch running Damage to flywheel teeth may result DANGER Never turn the key to the START position unless the clutch pedal is depressed pushed down or the gear selector is in neutral If the vehicle is in any gear other than neutral and the clutch pedal is not depressed when the engine is started the vehicle may urch forward or backward depending which gear the vehicle is in This lurching could cause serious personal injury or death fthe engine will start without depressing the clutch pedal the clutch interlock system should be repaired immediately by your aut
121. g Park Brake EC 1 844177 Decal auxillary transmission 1 844179 Decal hydraulic controls 800934 Screw M6 1 00 x 16 G10 9 548175 Washer 1 4 x 1 1 4 dia 1 841813 Cable choke Suzuki 970 33410 85010 Coil ignition Suzuki 970 1 840436 Lock handle 309488 Washer 3410 50F20 Coil ignition Suzuki K6A INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated Although Item No s 27 amp 28 handle lock and washers are used on EC Models they may be obtained for use on any of the models listed above 53 BODY HOOD and HEADLIGHTS P893332 893439 ference lower ROPS Part No 893145 Re Front sion Frame Part No 893421 Suspen Front Of Vehicle BODY HOOD and HEADLIGHTS Ref Part No No Description 303952 Washer 10 894743 Nut ay double 1 4 20 306419 Screw 1 4 20 x 1 2 306463 Pin cotter 38061A Cap vinyl 450400 Washer 8 450410 Lockwasher M6 450452 Nut M6 1 00 450541 Screw M6 1 00 x 16 RPH 452695 Screw M6 1 00 x 20 taptite 800930 Screw M8 1 25 x 16 8 8 800934 Screw M6 1 00 x 16 8 8 800943 Screw tap 10 14 837303 Headlight rectangular 2700792 Clip front 821071 Decal notice not motor vehicle 1 840901 Decal Warning read ops manual 1 843854 Hood turf green 841428 Bezel headlamp 841477 Hinge hood 841637 Angle front
122. g the element WARNING Before servicing or doing any maintenance work around the engine area make sure the engine has had time to cool Serious burns can result if the engine or surrounding area is hot Checking and Installing the Element Tilt the engine cover forward and locate the air cleaner on the right rear of the engine See Fig 37 To remove the air cleaner element release the latches securing the cover to the air cleaner assembly Remove the filter element Check the element for damage pin holes etc by placing a light source such as a flashlight inside Clean dust from inside of housing with damp cloth making sure dust does NOT enter air intake Check all gaskets to be sure they are NOT damaged or loose Replace the element if it is damaged or is excessively clogged with dirt and or debris Insert element in housing open end first SERVICE amp MAINTENANCE Figure 37 Air Cleaner Assembly Air Cleaner Complete Part No 892679 Air Cleaner Element Part No 840352 Emu val Dust Cover V d Dust Collector Ms ee AR va Figure 38 Air Cleaner Element and Dust Cover Shown Removed From the Housing Position the cover so that the collector is pointing down Clamp cover into position with collector pointing down DO NOT use bent or dented air cleaner assemblies DO NOT use bent or damaged air cleaner element The dust collector empties automatically when properly installed with col
123. horized Cushman dealer HORN BUTTON The horn button is located to the left of the steering wheel below the dash panel Depress to sound horn Horn will not sound when the ignition switch is in the OFF position LIGHT SWITCH The light switch is used to turn the headlights and tail lights on The switch has three detents OFF DIM and BRIGHT Push switch up one detent for DIM or push switch up two detents for BRIGHT HEADLIGHT OPERATION SYMBOLS Figure 10 D Horn Button and Light Switch Location DIM BRIGHT 1st Detent 2nd Detent CONTROLS Cont CHOKE Suzuki 970 engines Only The choke is used to assist the starting of a cold engine Pull up on the choke knob and hold in the full or partially open position When the engine has ib eka warmed up and is running smoothly release the choke knob the choke knob is spring loaded in the open posi tion it will return to its normal position when released See Fig 11 PARKING BRAKE LEVER Parking brakes are not automatically applied Make sure and set the park brake when leaving the vehicle The park brake lever is located to the left side of the drivers seat To engage the brake pull up on the lever Park Brake ranis Choke Knob until park brake is applied Torelease while slightly pulling up on the handle push the button atthe end ofthe lever and while holding the button in lower the lever to it s original position See Fig 11 FOOT CONTRO
124. hown connections terminals and routing can change without notice 92 22 I 893442 893448 893972 ELECTRICAL COMPONENTS and WIRING HARNESSES To Shifter The items shown on this page are used Light with the auromatic transmission on vehicle Model 898628 To Main Harness Power Ground To Accessory Idle Up t To Engine Harness 27 S x D az bo Controller 55990609 U g The convoluted tubing used on the wiring harnesses be ordered in bulk length only Cut off the required amount for your particular application Order the tubing as follows Part No 826190 350 i d sold 50 15 2 m lengths Part No 826191 500 i d sold in 25 7 6 m lengths Ref Part No Part No No Description d No Description 450452 Nut M6 1 00 G10 837300 452378 Screw M6 1 00 x 20 890158 Connector and wire 800934 Screw M6 1 00 x 16 G10 894201 Harness wire fuel tank 830366 Switch push horn button 894308 Switch normally open 841636 Panel instrument w tach 894313 Harness wire taillight 2 Car e ae 39312 50F01 Wire noise suppressor 843581 Switch headlig
125. ht E DR 22 844942 Sockel TAV plug 894531 Harness ATM controller 900050 Horn Model 898628 889673 Solenoid Deeg 120052 eLockwasher 10 33410 50F20 Coil ignition Suzuki K6A 132520 1 0 32 18570 84000 Switch set vacuum 306325 eLockwasher 5 16 38850 51F10 Controller idle up 306932 5 16 18 38850 50741 Controller fuel 890000 Buzzer assembly 38880 51F13 Controller auto trans 1 890154 Switch ignition complete 33410 85010 Coil ignition Suzuki 970 1 837295 Switch ignition 17680 50F70 Switch fan 837296 Connector 843857 Sender water temperature 837299 Spacer 829787 Terminal 45 1 4 male Po INDENTED PARTS NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated 93 RADIATOR and COOLING SYSTEM Reference Platform Support With Automatic Transmission 26 12 Adhesive This Side Use Loctite 592 el 31 SEM eZ From Upper E Water Pung 8 SCH SE Diesel N Use 32 Loctite 592 Radiator Hoses for the S
126. iator x Reference Governor Part No gt Existing Hardware From Engine Reference Hydraulic Pump Part No 888042 Engine Belt Diagram B 9 Models 898627 amp 898628 894588 894507 MODEL 898627 Ref Part No Ref Part No No Description Req d No No Description 103867 Washer 3 8 3 15 844035 Pulley 4 75 governor 120177 Lockwasher 3 8 841027 V belt 53 1 4 1352 mm 306835 Screw 3 8 16 x 1 3 4 839907 Pulley 5 50 steering pump 306325 Lockwasher 5 16 2703818 7 Bracket alternator mounting 306375 Nut 1 4 20 843998 V belt 40 1016 mm 306396 Lockwasher 1 4 894375 Bracket governor mounting 306416 Screw 5 16 18 x 1 800073 Bolt carriage 3 8 16 x 1 1 4 306450 Screw 5 16 18 x 3 4 828100 Pulley 5 50 hydraulic pump 306562 Nut 3 8 16 548804 Nut 3 8 16 306981 Washer 3 8 12619 60B00 Bolt 311213 Screw 3 8 16 x 95131 51F60 Pulley crankshaft 450453 Nut M8 1 25 G10 9 manual transmission 452388 Screw M8 1 25 x 20 8 8 95131 51F50 Pulley crankshaft 452394 Screw M8 1 25 x 70 8 8 automatic transmission OO JO PS ob 96 ALTERNATOR ENGINE BELTS PULLEYS and BRACKETS Reference Power Steering Pump Part No 892534 Front Of Vehicle 22 ALTERNATOR WIRING d P RED GREEN WHITE
127. ing low speed sync Key high speed sync Circlip high speed sync hub Hub 5 speed sync Plate 5 sync hub Ring high speed sync Spring 5 sync Circlip sync hub Key high speed sync Shaft revers idle gear Gear reverse idle Washer Plate reverse gear shaft stop Bolt Gear main shaft reverse Bearing Ring speedometer exciter Circlip 117 CLUTCH and DRIVESHAFT SUZUKI K6A p Front Of Vehicle gt The Two 2 Tubing Clamps Ref No 19 Are Used to Help Secure the Shifter Cables 118 2701321 7 548482 826284 826285 894192 895126 4117900 2702547 2702548 2702549 2702550 2702551 2702552 2702553 2702554 2702555 2702470 800843 809092 821164 2701273 2701273 2701371 CLUTCH and DRIVESHAFT SUZUKI K6A Description Driveshaft complete Plug expansion Cross u joint Yoke universal Yoke front Shaft drive Cover clutch Bolt 8 x 16 Disc clutch Bearing clutch release Clip clutch release bearing Fork clutch release Support clutch release fork Clip clutch release fork Cap transmission case Bracket clutch cable Bolt Screw 10 14 taptite plastic Clamp tube wire Pin hair 25 x 1 12 x 06 Cable shifter 97 2464 mm Cable shifter 97 2464 mm Connector shifter lever 119 AUTOMATIC TRANSMISSION SUZUKI K6A Description 2702750 Case transmission 2702689 2702751 Breather 2702690 2702752 Housi
128. ission Model 898671 SEN 2 1 844391 Hose radiator lower Perkins 888549 Connector hose air cleaner 844390 Hose radiator Perkins 894590 Radiator 452393 Screw M8 1 25 x 60 8 8 833443 832033 Clamp 970 889049 radiator 833715 Plug 970 833442 833858 Fitting hose 970 889050 Reservoir coolant 843738 Housing fan sender 970 893388 Mount radiator 843856 Gasket fan switch housing 970 2 893554 009034880 Decal fan 2700799 Fan radiator cooling 17561 73000 Cap water 970 450453 Nut M8 1 25 G10 9 17600 85831 Thermostat 970 452388 Screw M8 1 25 x 20 8 8 17680 50F70 Switch fan 452395 Screw M10 1 50 x 80 8 8 17689 50F00 O ring Cooler oil automatic transmission 821893 Trim push on Model 898671 As INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY The parts illustration only shows two 2 of Item 12 825624 Hose Clamps The other two are used to secure the cooler hoses to the transmission lines Not Illustrated Item 42 821893 Push on Trim is used on Model 898671 to protect the automatic transmission hoses and is used on the right side motor mount and the frame rail 95 ALTERNATOR ENGINE BELTS PULLEYS and BRACKETS SUZUKI K6A Reference Power Steering Pump Reference Part No 892534 Alternator Reference Part No 893633 Fan Switch Tube Part No 894348 With Rad
129. ithin the fuel system Fuel leakage from a fuel system can occur while the system is in use in transit in storage Such leakage can contribute to an explosion or fire causing serious bodily injury or death 20 SERVICE amp MAINTENANCE Cont TIRE PRESSURE 1 Check alltires for proper inflation Keep tires inflated to the specifications corresponding to that particular tire size Air pressure needed is determined by the payload carried Adjust pressure as required Lower pressure will help avoid leaving tire marks in soft turf Higher pressures may be required for heavy loads NEVER exceed the maxi mum pressure indicated on the tire TIRE SIZE TIRE PRESSURE 20 8 00 X 10 4 PLY 20 PSI 138 KPA 20 10 00 X 10 20 PSI 138 KPA 24 13 00 X 12 15 PSI 110 KPA NOTICE Improper inflation will shorten the life of your tires considerably Fill tires with care Use a pressure gauge before connecting an air hose to a partly inflated tire Due to the low air volume needed over inflation may be reached in a matter of two or three seconds POWER STEERING The power steering reservoir is located on the right side of the engine below and to the right of the alternator The level in the reservoir should be checked after the first 35 hours and then again after another 35 hours after that the level should be checked every 100 hours Use GM power steering fluid to maintain the correct fluid level ES m Remove the power
130. ition and observe the warning lights and gages some of the warning lights will remain on until the engine has started and is running DANGER Never turn the key to the START position unless the gear selector is in Park or neutral If the vehicle is in any gear other than Park or neutral and the engine is started the vehicle may lurch forward or backward depending which gear the vehicle is in This lurching could cause serious personal injury or death Turn and hold ignition key in the START position to engage engine starter release key when engine starts upon release the key will automatically return to the ON position Ifthe engine does not start after operating starter for 10 seconds stop the starter Wait for 30 seconds then try to start the engine again The starter motor should never be run for more than 30 seconds Allow engine to warm up before driving the vehicle always allow at least one minute for the engine to warm up 22 SERVICE amp MAINTENANCE Cont STARTING THE ENGINE Diesel Engines Manual Transmission The diesel engine uses glow plugs to pre heat the combustion chamber and makes cold engines start easier When starting a new diesel engine for the first time or after prolonged storage or if the fuel tank is allowed to run dry the fuel system must be purged before attempting to start the engine refer to Purging the Diesel Fuel System Page 22 of this manual When starting the v
131. lector down A dirty clogged or damaged air filter will cause the engine to start hard as well as run rough and sluggish Don t forget to check the air cleaner element if the engine does not run smoothly and other problems cannot be found 31 SERVICE amp MAINTENANCE Cont ACCESS PANELS There are two access panels located under the front hood and one located in the middle of the floorboard Remove the screws securing the panel to the fire wall to gain access to the shifter linkage and some of the electrical wiring for the instrument panel Remove the screws securing the panel to the bottom of the front cowl to gain access to the front suspension Access Access Panel In Center Of Floorboard SS Access Panel Removed Figure 39 Figure 40 Access Panels Under Front Cowl Access Panel on Floorboard Remove the screws securing the panel to the floorboard This will give you access to the throttle cable linkage elec trical wire harness as well as the brake lines which run to the master cylinder It will be necessary to remove the accelerator pedal in order to completely remove the center floorboard panel FRONT COWL ACCESS The front cowl opens to gain access to the fuse panel the horn the master cylinder reservoir as well as vari Pull Lever ous access panels which when removed allow To Release zs Cowl Latch access to wiring for the dash panel shifting lever link age and the upper part of th
132. lever is attached to v aN 4 the same panel om overnor 1 Ga sur A e Hand Throttle kr Control e THROTTLE GOVERNOR Figure 68 The engine governor is preset to control engine vehicle Governor and Hand Throttle Controls ground speeds to design limits The engine governor is preset to control engine ground vehicle speeds to design limits Normal mode e Hand throttle control lever in DOWN position Variable governor control in UP position TN WARNING NOTICE To prevent speeds greater than design limits Diesel Only Inthe NORMAL MODE the foot pedal keete throttle retains full control of throttle lever position y An internal governor adjusts the injector pump to lls eet vate are Geer e A compensate for variations in power requirements maintains R P M dictated by position of foot pedal throttle POWER TAKE OFF Mechanical P T O There is also an optional hydraulic powered P T O system P T O available Refer to the section Power Take Off Hydraulic Control Handle P T O for proper operating instructions The P T O transmits power from the transmission to a splined shaft at the rear of the vehicle for easy hook up to optional equipment Figure 69 The control handle is located on the control panel to the left P T O Control Handle Location of the operator s seat PULL UP to engage PUSH DOWN to disengage 4
133. ly by your authorized Cushman dealer Never turn the key to the START position unless the clutch pedal is depressed pushed down or the gear selector is in neutral If the vehicle is in any gear other than neutral and the clutch pedal is not depressed when the engine is started the vehicle may lurch forward or backward depending which gear the vehicle is in This lurching could cause serious personal injury or death Turn and hold ignition key in the START position to engage engine starter release key when engine starts upon release the key will automatically return to the ON position e Ifthe engine does not start after operating starter for 10 seconds stop the starter Wait for 30 seconds then try to start the engine again The starter motor should never be run for more than 30 seconds Allow engine to warm up before driving the vehicle always idle and warm up the engine for at least one minute STARTING THE ENGINE Gasoline Engines Automatic Transmission Apply the park brake the parking brake should have been applied when the vehicle was last parked Make sure the gear selector is in Park engine will not start if gear selector is D 2 or L If the engine will start when the gear selector is in R D 2 or L DO NOT operate the vehicle The vehicle should be repaired immediately by your authorized Cushman dealer Turn the ignition key to the ON pos
134. maining in the fuel tank OIL PRESSURE WARNING LIGHT 4 The red oil pressure light See Fig 6 indicates oil pres sure is too low for engine operation VOLTMETER 5 The voltmeter See Fig 6 indicates the voltage level of the battery Under normal operation it will indicate 12 to 18 volts meaning the battery is being properly charged A reading below 12 volts indicates the bat tery is being drained this may indicate a malfunction in the charging system which should be checked immediately Figure 6 Dash Panel Identification GLOW PLUG INDICATOR 8 DIESEL ONLY The glow plugs must be preheated before the engine can be started The glow plug indicator is wired in the glow plug circuit and indicates when the glow plugs are being heated and when the engine is ready to start See Fig 7 10 BRAKE FLUID LEVEL WARNING LIGHT 6 This light See Fig 7 indicates the brake fluid level is low WATER TEMPERATURE GAUGE AND OVERHEAT WARNING BUZZER 7 The purpose of this system is to warn the operator if the engine temperature exceeds the normal operating range If the water temperature gauge See Fig 7 raises above the 230 F 110 C mark a heat sensor is activated causing the overheat warning buzzer to sound Figure 7 Dash Panel Identification ACCESSORY POWER PLUG A power port is available for plugging in laptop comput ers cellular phones and other accessory items which require a 12 volt plug in See Fi
135. milar accessory Hydraulic Lift Push the lever forward and to the right to latch it in the en float position the float position allows the accessory being used to follow the contour of the land the acces sory when in the lowered position will float over the ground even in undulating terrain Figure 65 Decal Shows Hydraulic Lift Control Handle Lever Positions and Their Function Pull back on the lever to extend the hydraulic cylinder ram raise the dump box push forward on the lever to retract the hydraulic cylinder ram lower the dump box 44 OPERATING REMOTE HYDRAULICS Cont REMOTE HYDRAULICS The hydraulic system has a remote selector valve located at the front of the control panel to operate accessories such as the Core Harvester or Top Dresser Decal Shows Remote Hydraulic Functions Make Sure Hose Is Inserted Into The Quick Coupler When An Accessory 15 Not Being Used NOTICE The DOWN position directs hydraulic oil to the stan dard vehicle hydraulic lift system The UP position directs hydraulic oil to the left side of Figure 67 the hydraulic panel for remote hydraulic system use Remote Hydraulics Closed Loop Shown Motor Driven Accessory Remote Hydraulics Control lt fa
136. n 6 7 15 16 Pre starting 15 Starting Automatic Transmission 22 Manual Transmission 21 22 Manual Transmission diesel 23 24 F Fuel Gauge 10 20 Fuel Specifications 20 Front Cowl Access 32 Release Lever 32 BUSES oh 34 G Gasoline Containing Alcohol 20 Gauges 10 Gear Selector Automatic Transmission 13 Manual Transmission 13 General Information Inside Front Cover Governor Oil Level 40 Governor amp Throttle Hand Control 46 H Headlight Replacement 39 Horn Button 11 Hour Meter 10 Hydraulic Lift System 44 Hydraulic P T O 48 49 Hydraulic Reservoir 51 Page Ignition Switch 11 Interlock Switch Clutch 12 J Jacks Jacking Locations And Using A Hoist 28 29 Jump Starting 26 27 L Light Switch 11 Lubrication Chart 33 Lubrication Recommendations
137. n disconnect 452389 Screw M8 1 25 x 25 8 8 809265 Pin hair 25 32 x 2 11 16 452398 Screw M10 1 50 x 20 8 8 893145 ROPS lower 452402 Screw M10 1 50 x 50 893199 7 Platform turf 452403 Screw M10 1 50 x 60 893199G Platform turf galvanized 452405 Screw M10 1 50 x 80 893220 Drawbar turf 492410 893235 Frame main 348911 893235G Frame main galv 800177 893487 Fender left 800279 Nut speed 1 4 20 893488 Fender right 800582 Screw 1 4 20 x 3 4 800930 Screw M8 1 25 x 16 8 8 893525 Support platform 841258 Bracket drawbar 893527 Support fuel tank 2700796 Panel console turf 894711 Guard hydraulic tank 822819 Decal Warning Park Brake 452406 Screw M10 1 50 x 90 8 8 844177 Decal auxillary transmission 452415 Screw M12 1 75 x 80 8 8 844179 hydraulic controls 844729 Spacer battery hold down 2700797 Panel console turf 844647 Angle hold down 845185 Decal Warning Park Brake 1 810437 Clamp tube Suzuki 970 844177 Decal auxillary transmission 1 828382 Seal foam 844177 Decal auxillary transmission 1 OO JO P ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated Item No 34 Battery Hold down Spacer Part No 844729 may be used on all vehicles If the battery clamp cannot be adjusted to properly secure the battery this spacer will be required 57 EXHAUST SYSTEM SUZUKI K6A
138. n product mal function and possible injury to the operator and or bystanders Never attempt to perform service or maintenance functions on this vehicle if you are UNTRAINED or UNAUTHORIZED Improper maintenance can cause hazardous conditions See your authorized CUSHMAN dealer for necessary maintenance and service Always replace any warning decal that becomes hard to read To reduce risk of fire always keep the engine free of excessive grease ENGINE MAINTENANCE Keep your engine clean If dirt has accumulated on the engine it should be washed with a non flammable solvent or strong detergent When washing becomes necessary it can be carried out simultaneously when servicing the vehicle In order to maintain reliable service from your engine a regular check up and maintenance schedule should be followed The following maintenance information covers basic engine service only For extensive service and repairs we recommend contacting the authorized Cushman dealer nearest you Proper maintenance will prolong the engine s life and avoid premature overhaul ENGINE BREAK IN The service life of your engine is dependent upon how WARNING your engine is operated during the first 50 hours of 2 To prevent premature engine failure and operation none speeds greater than design limits ALWAYS Use care not to overload your engine NEVER alter the governor controls in any Maintain engine oil level mannerto increase engine speed bey
139. n to a splined shaft at the rear of the vehicle for easy hook up to optional equipment The control handle is located on the control panel to the left of the operator s seat Control Handle Figure 71 P T O Control Handle Location PULL UP to engage PUSH DOWN to disengage To activate the P T O move the live hydraulic hose from the upper coupler on the left side of the hydraulic panel to the lower coupler on the left side of the panel Make sure the hydraulic P T O control handle is in the down position if the control handle is not down the P T O shaft can start rotating 48 Move Hose From Upper To Lower Coupler Figure 72 Moving Live Hydraulic Hose for Hydraulic P T O When an attachment is not connected to the P T O shaft disengage drive to the P T O by pushing the hydraulic control handle down and replacing the live hydraulic hose in the upper coupler The PTO runs when the control handle is up Depressing the clutch pedal Does Not stop the PTO from running the control handle must be in the down position for the PTO to stop P T O includes a spring loaded P T O cover This cover must remain on the vehicle and be used at all times An uncovered rotating spline can catch clothing and result in seri ous injury or death OPERATING REMOTE HYDRAULICS Cont Power Take Off Hydraulic P T O con t NOTICE To engage ALWAYS ST
140. nd using a piece of cardboard or similar material check areas where the leak is suspected Repair as needed WARNING Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious injury After applying pressure to the system use a piece of cardboard or wood NOT your hands to check for leaks If injured by escaping fluid see doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately Periodically check the hydraulic fluid level hydraulic level should be checked every 100 hours of operation Loss of fluid can signal a small leak before it becomes worse To check the hydraulic fluid level 1 Place vehicle on level surface Fully lower any accessory attachment including dump box Stop the vehicle engine 2 Remove the dipstick breather plug from the top of the tank See Figs 74 and 75 Wipe the dipstick then place in tank with the threaded flange resting on the tank do not screw Fluid should show on the knurled portion of the dipstick See Fig 75 Add fluid as required If additional fluid is needed add Ransomes Turf Protector Biodegradable hydraulic fluid Screw the dipstick breather plug securely in place NOTE Do Not overfill the hydraulic system Severe damage may result Always reinstall the dipstick breather plug Hydraulic System Capacity Hydraulic Fluid Biodegradable Standard Hydraulics 4 gal 1
141. ner 304636 Pin cotter 1 8 x 1 1 8 817928 Seal grease 841630 Trunnion control arm 893206 Hub assembly 841737 Shim 060 808088 bearing outer 841738 Shim 024 814474 bearing inner 841840 Tube brake left 800908 Screw lug M12 1 50 x 42 841841 Hose brake 450452 Nut M6 1 00 G10 9 894573 Knuckle steering left 452378 Screw M6 1 00 x 20 G10 9 842104 Bracket brake tube 450455 Nut M12 1 75 G10 9 887512 End tie rod RH thread 452413 Screw M12 1 75 x 60 306328 cotter 3 32 x 3 4 894635 Strut ay shock amp spring OO JO PS ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY Not Illustrated Although this lubrication fitting is the standard fitting used with this tie rod it is not used in this application Use Ref No 12 Part No 831405 If ordering Ref Nos 26 887512 or 35 887750 you will also need to order Ref 12 831405 75 FRONT SUSPENSION RIGHT SIDE TIE RODS and SKID PLATE Front Of Vehicle Reference Brakes and Brake Shoes With Item No 44 When ordering Items No 34 or No 44 You Will Need to Also Order Item No 15 76 FRONT SUSPENSION RIGHT SIDE TIE RODS and SKID PLATE Ref Part No No 302944 303269 311392 450077 450382 450393 450457 452398 452408 800945 452692 800485 800919 809137 831405 843418 841167 8412
142. ng torque converter 2702759 Hook engine 2702753 2702760 Plug booster 2702662 2702761 O ring 2702754 Housing extension 2702762 Bolt transmission case 2702683 Seal extension case 2702763 Bracket connector clamp 2702755 4120102 Bolt connector clamp bracket 2702494 2702764 2702756 24790 67H10 Engine amp t m stiffener 2702686 2702519 Bolt 2702688 2702470 Bolt OO JO Om P ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 120 AUTOMATIC TRANSMISSION PAN DIPSTICK and GASKETS p Front Of Vehicle 2702806 2702807 2702808 2702809 2702810 2702812 2702813 Description Pan transmission oil SUZUKI K6A Plug transmission oil Gasket plug Magneto oil cleaner Tube oil filler dipstick 2702475 4120110 2702816 2702817 2701921 2702818 Description Oil level gauge Solenoid wire harness Solenoid wire harness hold plate 1 Solenoid wire harness clamp 1 121 TRANSMISSION TUBES OIL PUMP SOLENOIDS and SHIFT SWITCH AUTOMATIC TRANSMISSION SUZUKI K6A 8 Front Of Vehicle To Oil Cooler Part Description No Description 2702843 Pipe assembly oil 2702823 i 2702849 2702764 2702847 Union bolt 2702885 2702845 2702886 2702765 Pump oil 2702881 Joint transmission shifter 2702766 oil pump 2702882 Bushing 2702767 Bolt oil pump 2702883 Washer 2702768 Ring set oil pump seal 2702884 2702822 Sol
143. nn Ire r A be 7 8 123 4567 8 12345678 SEQUENCE CODE 00000011 SEQUENCE CODE 00000010 SEQUENCE CODE 00010000 Tachometer Standard Tachometer Standard Tachometer Standard 43 OPERATING REMOTE HYDRAULICS EQUIPMENT The following information will tell you about the different controls and functions used when operating the P T O and hydraulics system These features are used when operating the accessories and implements often used with this vehicle TWO SPEED DIFFERENTIAL Two Speed Differential Control The two speed differential has a high and low operating range as well as a neutral position Shift the two speed differential ONLY when the vehicle is stopped Pull the control handle all the way UP to operate in the high range push it all the way DOWN to operate in the low range The two speed differential control is located on the con Figure 64 trol panel to the left of the operator s seat See Fig 64 Two speed Differential Control Handle POWER HYDRAULIC LIFT SYSTEM The power hydraulic lift system is referred to as a live system This means the hydraulic pump operates whenever the engine is running The hydraulic lift control lever is located on the control panel to the left of the driver s seat See Fig 65 The hydraulic lift is used when the vehicle is equipped with a dump box or si
144. nt Water Temperature Gauge and Overheat Warning Buzzer con t The temperature indicator on the gauge should go down within approximately 30 seconds after the intake screen is cleaned If the temperature does not go down STOP THE ENGINE and check the following areas WARNING ALWAYS make sure the engine is stopped and cool before removing the radiator cap or before performing any service or maintenance on or around the engine area To prevent scalding by hot water NEVER remove the radiator cap while radiator is hot cooling system is under pressure if a leak is present be careful when raising the seat or when opening the engine cover Hot coolant can be sprayed causing personal injury Raise vehicle seat and visually check to see if electric radiator fan is operating and check to determine if there may be a leak in the cooling system allow ample time for the engine and surrounding area to cool before attempting to perform any service or maintenance Check the radiator fins and screen If they are dirty they must be cleaned Engines damaged due to over heating caused by plugged radiators WILL NOT be warranted Check oil engine level Check radiator and coolant reservoir levels Also refer to page 37 for Dash Panel Bulb Replacement RADIATOR COOLANT LEVEL The vehicle is equipped with a cooling radiator and an electric cooling fan WARNING The cooling fan is thermostatically controlled may st
145. ntained If the brakes Do Not stop the vehicle properly they must be repaired before the vehicle is operated again The brake fluid master cylinder reservoir is located under the front cowl Figure 47 Brake Fluid Level Indicator Light If the brakes do not hold properly if they feel spongy or ifthe brake fluid reservoir is allowed to run dry it may be necessary to bleed the brake lines in orderto getfluid back into the system Follow the steps below to properly bleed the brake system 4 Wheel Brakes Figure 45 When bleeding the system bleed the left rear brake first Brake Fluid Reservoir Located Under Front Cowl then the right rear then the right front and finally the left front The fluid level must be kept within the MIN minimum Attach a hose to the bleeder screw on top of the left rear and MAX maximum levels as shown in Figure 46 dust shield and place the other end of the hose in a con If the brake fluid level indicator light See Fig 47 tainer to catch the fluid run off when bleeding the system comes on and remains on checkthe brake fluid level in the reservoir Most communities have a disposal system for this type of When it is necessary to add fluid use a DOT 3 type Please dispose ol MUAS DIODENY brake fluid Figure 46 Brake Fluid Level Reading Figure 48 Bleeder Screw on Top of Dust Shield 37 SERVICE amp MAINTENANCE Cont Four Wheel Brakes con t Loosen the bleeder screw Have an
146. ntial Reference Front Suspension Frame Part No 893421 Reference Pitman Arm Part No 841336 With Item No 26 When ordering Items No 35 or No 26 You 12 9 Will Need to Also Order Item No 12 Reference Brake Assembly Front Of Vehicle P893523 74 FRONT SUSPENSION LEFT SIDE and TIE RODS Ref Part No Part No No Description No Description 302944 Nut jam 9 16 18 548224 Fitting lubrication 450077 Bolt M16 2 00 x 90 311537 Nut castle 3 4 16 450382 Nut M16 2 00 locking insert 816586 Retainer grease 450393 Washer M16 893233 Arm assembly lower control 1 450457 Nut M16 2 00 flange G10 9 841430 Drum brake 452398 Screw M10 1 5 x 20 8 8 800909 Nut wheel retaining M12 1 50 5 800945 Bolt M12 1 75 x 60 G10 9 306328 Pin cotter 3 32 x 3 4 800485 Nut 9 16 18 left hand 306825 Nut castle 7 16 20 800919 Bolt M10 1 5 x 30 G10 9 887750 End tie rod LH thread 809137 Clip 306328 cotter 3 32 3 4 810437 Clamp 548224 Fitting lubrication 831405 Fitting grease 1 4 28 90 311537 Nut castle 3 4 16 841167 Bushing silentbloc 816586 Retainer grease 841404 893266 Arm assembly upper control 1 844148 Ball joint upper 311537 Nut castle 3 4 16 841429 Ball joint lower 385174 Bearing cone outer 817250 Cap grease 815403 Bearing cone in
147. ond Maintain cooling system recommended maximum R P M ACCESS TO ENGINE Never remove or install the engine cover while the engine is running The engine cover is a machinery guard and its removal exposes you to moving parts Keep hands hair and clothing away from flywheel radiator cooling fan alternator fan engine belts pulleys and air intake 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 14 SERVICE amp MAINTENANCE Cont When replacing the engine cover make sure the retaining tabs located at the front corners of the engine cover are inserted into the slots in the floorboard Access to Engine con t Engine Cover Latch Retaining Tab In Slot On Floorboard Figure 16 Engine Cover Latch To gain access to the engine on a CE compliant model insert the key into the locking handle located at the side of the engine cover latch turn the key to allow the latch Figure 17 to be pushed back the locking handle can also be used Engine Cover Retaining Tab as an accessory on any of the other turf vehicles WARNING Failure to latch the seat properly can result in the engine cover tipping forward causing loss of control of the vehicle
148. op the vehicle and check for problems _ Water Temperature Gauge This symbol appears on the water temperature gauge This gauge warns the operator if the coolant system is overheating Read the Operator s Manual This decal informs the operator to read Radiator Coolant Warning and understand the Operator s manual This decal warns the operator not to remove the radiator cap To prevent injury they must be familiar when the engine is hot Refer to the Cooling System Section with the operation of this product and be in this manual for proper safety and operating instructions fully aware of safe operating procedures FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH KEEP ALL SHIELDS PLACE 13 KEEP ARMS AND LEGS WITHIN VEHICLE BODY READ AND UNDERSTAND ALL LABELS AND THE OPERATOR S MANUAL 8 SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE 9 ONLY CARRY PASSENGERS IN SEATS PROVIDED DO NOT MODIFY THIS VEHICLE WITHOUT MANUFACTURER S AUTHORIZATION 10 WHEN PARKING LEAVING VEHICLE FOLLOW ALL INSTRUCTIONS IN PLACE LOADS FORWARD OF REAR AXLE OPERATOR S MANUAL TOP HEAVY LOADS CAN CAUSE UPSETTING DO NOT EXCEED PAYLOAD 11 AVOID SUDDEN STARTS STOPS AND SHARP TURNS ESPECIALLY ON SLOPES OR CAPACITY WITH HEAVY LOADS DO NOT OPERATE IF REPAIRS ARE REQUIRED 12 KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AN
149. or 843857 Rd P one BE mm mm H we hi Trailer Brake 6 6 R Receptacle Ft PBL Za p Fol ELT ve WER Fan B RIB Wm MP 2700799 oe e ee Be R Lo B Sr B ex B 10 GAUGE 1 R 10 GAUGE B B M __ R R G OR op w OR OR 1 R G w 3 G R R R R B w E cH WIR A N B m we on Y Bl Oil Pressure Starter D OR we DE 8 Nr B 2 OR Y gt G e CR BL An we we we Ne H 5 Glow OG solenoid Plugs Diodes Diode en Harness 884398 884398 eier Fuel Level Fuel Pump Sender 843298 894638 COLOR CODE BLACK W WHITE W BR WHITE w BROWN STRIPE BL BLUE Y YELLOW W G WHITE w GREEN STRIPE BROWN BL B BLUE w BLACK STRIPE W OR WHITE w ORANGE STRIPE G GREEN G B GREEN w BLACK STRIPE W R WHITE w RED STRIPE GY GREY OR B ORANGE w BLACK STRIPE W Y WHITE w YELLOW STRIPE OR ORANGE P BL PURPLE w BLUE STRIPE Y B YELLOW w BLACK STRIPE PK PINK R B RED w BLACK STRIPE Y R YELLOW w RED STRIPE P PURPLE W B WHITE w BLACK STRIPE R RED W BL WHITE w BLUE STRIPE 182 WIRING DIAGRAM DIESEL TURF TRUCKSTER con t
150. plugs for fouling clean and gap as necessary Depending on operating conditions the engine and engine filter may need more frequent replacement Depending on operating conditions the air filter element may require more frequent replacement SPARK PLUGS TIMING BELT ENGINE BELTS Suzuki K6A Suzuki K6A Suzuki K6A 11402 71D10 Part No 841027 gov hyd pump Part 09482 00448 DCPR7E Suzuki 970 12761 78400 53 1 4 1352 mm OR Part No 843998 alt pwr strng Part No 09482 00449 DensoXU22EPR U ENGINE BELTS Perkins Diesel 40 1016 mm gap 032 035 0 8 mm 0 9 mm Part No 844301 alt pwr strng SE P UN d yd pump gov E No 09482 00131 2 ENGINE BELTS Suz kd 970 Part No 09482 00123 Denso W16EX U Part No 836854 alt pwr strng 42 1067 mm Part No 844036 gov hyd pump 51 1295 mm gap 032 035 0 8 mm 0 9 mm AIR CLEANER ELEMENT All Models Part No 840352 36 SERVICE amp MAINTENANCE Cont BRAKES Service Brakes WARNING Improper maintenance of the brake system may result in loss of vehicle control by the operator Losing control of the vehicle due to brake loss may cause vehicle damage and or injury to the operator or bystanders This vehicle is equipped with either four wheel or two wheel rear only hydraulic brakes and a hand operated park brake lever Keep your brake system clean and properly mai
151. r Oil Capacity 1 5 oz 44 ml Oil Type SAE 20W engine oil If fluid level is low add the recommended oil type Remove the plug from the rear side of the governor remove the plug from the top of the governor and add an SAE 20W motor oil until the oil begins to leak from the rear port Replace both plugs Figure 54 When replacing the plug use Teflon tape or a Permatex Governor Fill Plug Suzuki Engines Only 20 sealant or equivalent pipe thread sealant on the threads of the plug Torque the plugs to 95 10 in lb DIFFERENTIAL 11 16 1 The differential fluid should be checked every 100 hours or 3 months and changed after the first 100 hours After the first change at 100 hours the fluid should be changed every 600 hours or 12 months Differential Fluid Capacity 5 2 pints 2 5 L Fluid Type SAE EP 80 90 Gear Lube To check fluid level remove the filler plug from the front of the differential Fluid should be level with the bottom of the filler hole If level is low add gear lube until the appropriate level is reached fluid will begin to leak from the filler hole when full level is reached Replace filler plug To drain the differential fluid remove the drain plug from the bottom rear of the differential and drain Replace drain plug and add fluid to the recommended level When draining and filling the differential use a pipe thread sealant on the plug threads before replacing them Level Check And Fill Plug
152. rsepower SAE hp Max Engine Speed Stroke Lo WARNING To prevent premature engine failure and speeds greater than design limits NEVER alter the governor controls in any manner to increase engine speed beyond recommended maximum 2 60 66mm 2 56 65mm Displacement 40 1 cu in 657 cm Compression Ratio Cylinder Compression 178 PSI 1 228 kPa Engine Rotation viewed from flywheel Counterclockwise Valve Clearance intake 0031 cold 0 08 mm intake 0047 hot 0 12 mm dB A 79 2 LpA exhaust 0039 cold 0 10 mm dB A 79 2 LpA exhaust 0047 hot 0 12 mm dB A 95 LWA Spark Plug Gap 032 035 0 8 0 9 mm Spark Plug Number NGK DCPR7E OR Denso XU22EPR U Spark Plug Torque 18 5 21 5 Ib ft 25 30 N m Ignition Timing 4 5 BTDC 950 RPM Idle Speed 950 50 RPM Sound Level Perkins Diesel Pressure Level right ear Pressure Level left ear Sound power level Vibration Level Perkins Diesel Whole Body seat buttocks 0248 m s Whole Body seat back 0257 m s Whole Body floor foot 0671 m s Hand arm steering wheel hand 486 m s Suzuki 970 Engine Horsepower SAE hp Max Engine Speed 3600 RPM Stroke 2 83 72 mm 2 58 65 5 mm 59 2 cu in 970 cm Perkins Model 103 10 Spec KD70377 Horsepower SAE hp Max Engine Speed 2 83 72 mm 2 9 75 mm 58 2 cu in 954 cm Displ
153. s terminal will have a green wire connected to it 4 Clip the other end of the jumper wire to the T terminal on the starter solenoid See Figs 28 amp 29 E I Terminal On The ANTES Hi Starter Solenoid PRESE ConnectTo i Ra EXC Terminal ER D ez am 4 Connect Jumper Wire To T Terminal d D 3 m Alternator Figure 28 Figure 29 Connect Jumper Wire to Alternator amp Solenoid Terminal Locations Open the bleeder port located on top of the fuel injec tor See Fig 30 Turn the ignition key to the ON position the fuel pump will begin to pump When the fuel pump is pumping fuel only the thump ing sound will become more of a purring sound when this occurs tighten the bleeder port Turn the ignition key to the OFF position remove the jumper wire and reconnect the white w red wire onto the starter coil Figure 30 Bleeder Port Location PURGING FUEL SYSTEM WITHOUT THE USE OF A JUMPER WIRE Fuel system bleed may be accomplished using the glow plug timer if no jumper wire is available The fuel pump will energize for approximately 20 seconds during start up from the glow plug pre heat timer 1 Open the bleeder port on top of the fuel injector See Fig 30 Turn the ignition key to the ON position The fuel pump will be activated for about 20 seconds until the glow plug timer
154. set 1 thrust Clutch set one way Plate set 1st reverse Piston set 1st reverse O ring set 1st reverse Retainer outer race INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 129 OUTPUT SHAFT AUTOMATIC TRANSMISSION SUZUKI K6A Front Of Vehicle Ref Part No Ref Part No No Description Description 1 3 2702792 Ring set shaft seal 2702795 Bearing set 6 thrust 2702790 Output shaft 4 2702793 Ring speedometer exciter 2 2702791 Ring snap 5 2702794 Circlip exciter ring 6 130 PARKING BRAKE AUTOMATIC TRANSMISSION SUZUKI K6A Front Of Vehicle Ref Part No Ref Part No No Description Req d No No Description 2702796 Parking pawl set 5 2702494 Nut 2701921 Bolt 6 2702799 Washer manual shift shaft 2702797 Shaft set manual lever 7 25951 67H10 Lever manual shift 2702798 Seal shift shaft oil 131 BRAKE BAND AUTOMATIC TRANSMISSION SUZUKI K6A Ref Part No Description 5 Description 1 2702800 Band set 2nd brake 1 4 2702804 Cover set 2nd brake piston 4120109 Piston AY 2nd brake 1 5 2702805 Spring 2nd brake piston 2702803 Sealing set 2nd brake 132 TRANSMISSION VALVE AUTOMATIC TRANSMISSION SUZUKI K6A Front Of Vehicle 133 134 TRANSMISSION VALVE
155. so reserved to change specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change While the information contained in this parts manual is based on the latest product information available at the time of publication the continuing accuracy of this parts manual cannot be guaranteed WARNING When replacement parts are required use genuine CUSHMAN parts or parts with equiva lent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or bystanders Illustrations in this manual are areference guide for parts identification only Since these illustrations may not depict actual positioning of component parts they should not be used as an assembly diagram Doing so may result in improper assembly leading to sudden failure MODIFICATIONS AND ACCESSORIES Factory installed modifications and accessories are available for use on this vehicle Read and understand all literature before attempting to operate this vehicle or any attached equipment NOTICE Some vehicles may be equipped with special options that are Direct any inquiries to not serviced by Cushman Textron Customer Service Department 388 The addition of accessories not of manufacturer s design result in erratic vehicle operation improper battery charging Augusta GA 30903 0388 USA and
156. ssion in desired gear engage clutch for vehicles with manual transmissions and depress foot throttle Pull up on the hydraulic P T O control handle to start P T O operation The can only be stopped by pushing the control handle down WARNING NEVER attempt to drive the vehicle with the engine speed increased by the hand throttle The hand throttle also controls the foot throttle so the foot throttle pedal cannot be used to reduce engine and vehicle speed FAILURE to obey this warning may result in you the operator losing vehicle control 49 OPERATING REMOTE HYDRAULICS Cont GROUND SPEED CHARTS m 49 N Fus o D gt 4 c gt o 5 m o o 0 gt o N cC gt bal 2 F 5 E 5 o gt o c m o E a E o o o o 7 o 5 un bal gt c pum um c a 0 tc 5 2 c be 2 o 0 be F Please repl
157. steering reservoir cap When check 2 ME gt ing the fluid level for the first time at the beginning of the yy day the fluid level should be at the cold mark on the dip Power Steering AN stick When checking the fluid level after the engine has Reservoir been running and the fluid is warm the level should read between the cold and hot marks WARNING Before servicing or doing any maintenance work around the engine area make sure the engine has had time to cool Serious burns can result if the engine and surrounding area is hot p SN Figure 25 Power Steering Reservoir STARTING THE ENGINE Gasoline Engines Manual Transmission 1 Makesurethe parking brake is applied the parking brake should have been applied when the vehicle was last parked Turn the ignition key to the ON position and observe the warning lights and gages some of the warning lights will remain on until the engine has started and is running 21 SERVICE amp MAINTENANCE Cont Starting the Engine 3 Move the gear selector to NEUTRAL 4 Push clutch pedal down starter will not operate unless clutch pedal is pushed down The clutch inter lock switch prevents the starter from operating unless the clutch is disengaged the clutch pedal is depressed If the engine will start without depressing the clutch pedal DO NOT operate the vehicle The clutch interlock system should be repaired immediate
158. stem Au 85 atte ety t UTE dette 84 87 Riesetvolr re 87 Selector valve 84 Valve 84 Hydraulic reservoir guard 56 57 Idle up controller automatic transmission 93 Ignition switch 92 93 Input shaft amp gears Suzuki K6A manual transmission 116 117 Suzuki K6A automatic transmission 128 120 121 Suzuki 970 amp 160 Instrument panel w tach 92 93 Intake manifold Suzuki 109 110 Intake manifold Suzuki 970 125 L Leaf springs i sce de rer 83 Eight 92 93 Lower ROPS 56 57 M Manifold exhaust Suzuki 139 Manifold exhaust Suzuki 970 126 Master cylinder reservoir eee eee 64 65 Mud flap 54 55 Muffler Suzuki K6A 58 Suzuki 970 60 Perkins diesel 61 Motor mounts Suzuki K6A amp 970 102 Perkins diesel 103 O Oil cooler automatic transmission 94 95 Oil filter Suzuki 6 150 151 Suz ki970 nd 158 Oil pan
159. stops When the timer stops turn the key to the Off position then turn it back to the ON position the fuel pump will run again for approximately 20 seconds when the glow plug timer stops turn the key off again Continue with this procedure until the system is purged When the fuel pump is pumping fuel only the thumping sound will be more of a purring sound when this occurs tighten the bleeder port 25 SERVICE amp MAINTENANCE BATTERY The battery is located on the left side of the vehicle directly behind the stopwall behind the drivers seat The battery is negative ground and if connected in the opposite polarity damage to the alternator will occur The same applies when connecting a booster battery to the system The battery in this vehicle is low maintenance Add distilled water as required The voltmeter indicates the voltage level of the battery Under normal operation it will indicate 12 to 18 volts meaning the battery is being properly charged A reading below 12 volts indicates the battery is being drained this may indicate a malfunction in the charging system which should be checked immediately NOTICE Keep top of battery clean and free of corrosion by washing with a solution of baking soda and water or Figure 31 ammonia and water Rinse with clean water Termi Voltmeter Battery Charging System nals with heavy corrosion should be removed and cleaned with solution For best res
160. t intake man 17431 73001 Gasket water pump 13125 80000 H17 carburetor 14140 85200 Gasket exhaust man 17559 73000 H17 Gasket water inlet INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 156 CYLINDER HEAD and COMPONENTS SUZUKI 970 Ref Part No Part No No Description Description 11110 80002 Head cylinder 11180 82010 Grommet head cover 4 11115 82000 001 eGuide valve 09103 06134 Bolt 6 x 65 11112 73002 Plug oil venturi 16920 86502 Cap oil filler 09241 20006 09482 00123 Plug spark 11141 75120 Gasket cylinder head W16EX U Denso 04211 13189 Pin 09482 00131 Plug spark 09116 10116 Bolt 10 x 87 BP5ES NGK 11170 79203 Cover cylinder head 11161 79120 Case distributor 11172 73000 Plate breather 11169 70D00 Gasket case 11173 73001 Gasket breather plate 1 04221 06129 Pi 02162 06103 09103 08153 11189 73004 Gasket head cover OO JO PS ob INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 157 Front Of Vehicle CYLINDER BLOCK OIL PAN and GASKET SUZUKI 970 Ref Part No No 11200 80001 09241 30009 09246 20006 09246 05006 09246 06002 Description Description 11311 79100 11320 77201 16910 85550 37820 82001 16510 82703 Block cylinder Plug OD 30 Plug OD 20 Plug oil gallery Plug oil gallery Plate clutch hsng upper 1 Plate clutch hsng lower 1
161. te 4119869 8 Shield inlet tube 800821 Nut M10 1 25 306450 Screw 5 16 18 x 3 4 4119866 8 Muffler 306325 Lockwasher 5 16 4119868 8 Tube inlet 103867 Washer 5 16 838295 8 Strap muffler hanger 306419 Screw 1 4 20 x 1 2 841982 Clamp exhaust tube 1 1 2 1 306396 Lockwasher 1 4 843539 Gasket exhaust 5 16 815680 Washer special 1 2 3 4 5 6 7 8 INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY 60 EXHAUST SYSTEM DIESEL Referenced From Power Assembly p Front Of Vehicle NOTE TAILPIPE TO BE 0 5 FROM FENDER TAILPIPE OUTLET TO BE PARALLEL TO GROUND Description 103867 Washer 5 16 2703800 8 Tube exhaust inlet 450193 Screw M8 1 25 staytite 841982 Clamp tubing 450378 Locknut M8 1 25 staytite 842234 Gasket exhaust 452389 Screw M8 1 25 x 25 838295 8 Strap muffler hanger 4119866 8 Muffler ay 61 AIR CLEANER BRACKET and FILTER SUZUKI K6A To Radiator Mounting Frame 16 Front Of Vehicle Ref Part No Part No No Description Description 300646 Screw 1 4 20 x 3 4 2 825358 Clamp worm drive 306396 Lockwasher 1 4 4115401 Hose air cleaner 308090 Washer 1 4 4118423 Elbow street 1 4 452389 Screw M8 1 25 x 25 8 8 4118422 Hose barb brass 1 4 450453 Nut verbus rib 8 832033 Clamp worm drive 4115792 7 Bracket air cleaner 825724 Hose air cleaner 842915 Bracket filter 841230 Conne
162. tenance of brake system can result in the operator losing control of vehicle Loads not properly secured can quickly shift causing personal injury or vehicle damage if Ke the brakes are applied too hard and fast Figure 13 Foot Control Pedals GEAR SELECTOR Manual Transmission The gear selector has an H pattern as shown in Figure 14 There is also a shift pattern design molded into the top of the gear selector handle Remember before shifting to any gear you have to depress the clutch pedal before you shift to that particu lar gear Figure 14 Shift Pattern Manual Transmission Automatic Transmission The gear selector has the gear selections listed on the left side of the shifter handle Some units may have the gear selections on the right side as shown in Fig 15 Push in the selector lever button when shifting in or out of P Park into N Neutral or when down shifting to 2 Second or L Low from D Drive It is not necessary to use the button when shifting up from Low Second or Drive to Neutral from Reverse R to Neutral or from Neutral to Drive Figure 15 Automatic Transmission Gear Selector 13 SERVICE amp MAINTENANCE SERVICE and MAINTENANCE Think Ahead Work Safely AN WARNING When replacement parts are required use genuine Cushman parts or parts with equivalent characteristics including type strength and material Failure to do so may result i
163. the jack Lower the jack and allow the vehicle to rest on the jack stands NOTICE e Raise the vehicle only enough to perform the maintenance required Raise the opposite side of the vehicle enough to allow the front tire to clear the ground Place supports under the frame and lower the jack to allow the vehicle to rest on the jack stands Make sure to block the tire diagonally opposite of the side which is being raised Example Block Tire Here x 2 r PES If Using 5 Jack Here If Using Jack Here Block Tire Here Figure 34 Blocking Tires The illustration shows the frame without the body in order to show the jacking locations more clearly Jacking Location X Figure 35 Jacking Locations NOTICE 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 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 29
164. til the tow line becomes tight WARNING NEVER tow the vehicle faster than 5 8 km h Towing at excessive speed could cause either vehicle to lose proper steering control A Front Bumper Accessory Part No 894778 While towing try to keep the tow line taught at all times Be cautious i Avaliable For Use the TAr Truck x A 2 Front Bumper is Mounted on Your Vehicle going down inclines and while turning corners Make Sure to Follow the Instructions Included With the Bumper For Proper Connection of the Chain or Tow Rope Figure 33 Tow Line Attachment Location Automatic Transmission When transporting the vehicle or when it is disabled the BEST method of moving the vehicle is on a trailer If that is not possible the driveshaft MUST be removed before towing 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 tow line attaching locations are shown in Figure 33 only to the front vertical frame member of the vehicle Release the park brake and slowly move the towing vehicle forward until the tow line becomes tight Tow at a maximum speed of 5 m p h 8 km h While towing try to keep the tow line taught at all times Be cautious going down inclines and while turning corners If
165. tions 168 Torque converter automatic transmission 120 Transmissions Suzuki K6A manual 116 117 144 145 Suzuki K6A automatic 120 131 Suzuki 970 amp Perkins diesel 161 Transmission mounts Suzuki K6A amp 970 102 Perkins diesel 103 Transmission tubes automatic transmission 122 Transmission valve automatic transmission 132 133 W Water hose Suzuki K6A 138 Water pump Suzuki K6A 137 Water pump Suzuki 970 127 Water temp sender 92 93 Wire harness ATM controller 92 93 Engine rain er tn 91 kret sea 92 93 Main rf ULP AE 91 55 E 92 93 Wiring diagrams 170 173 178 179 182 183 Wiring schematics 175 177 180 181 184 185 VEHICLE IDENTIFICATION NUMBERS VEHICLE IDENTIFICATION NUMBERS This unit is not a motor vehicle within the definition of the national traffic motor vehicle safety act It is not designed or manufactured for use on roads streets or highways It is not appropriate for such use This unit is not meant to be licensed as a mo tor vehicle IMPORTANT SPARK ARRESTERS ARE REQUIRED BY CALIFORNIA PUBLIC RESOURCES CODE SEC TIONS 4428 4442 WHEN OPERATING ANY IN TERNAL COMBUSTION ENGINE ON HYDRO CARBON FUELS O
166. to the upper engine block on the left side of I Engine Seria No NE s K6A Suzuki the engine WIN It s located on top of the engine beneath the governor bracket and may be partially hidden by the electrical convoluted tubing which passes through that area The engine serial no is also hand printed on the engine cylinder cover See Fig 3 Figure 3 Suzuki K6A Engine Serial Number The Engine Serial No for the Suzuki 970 engine is stamped onto the lower engine block on the right side of the engine Engine Serial 970 Suzuki It s located on the lower engine block beneath the air cleaner The 970 engine serial no is also hand printed on the engine cylinder cover Figure 4 Suzuki 970 Engine Serial Number As Viewed From the Drivers Side of Vehicle The Engine Serial No for the Perkins Diesel engine is stamped onto a metal plate on the upper engine block on the left side of the engine Fu D d Engine Serial No Perkins Diesel 7 Figure 5 Perkins Diesel Engine Serial Number SPECIFICATIONS SPECIFICATIONS Specifications subject to change without notice Rear Axles Models 898671 898673 amp 898695 Transmission Models 898671 898673 amp 898695 11 16 1 2 speed hypoid differential 4 speed manual with low low creeper 1st gear synchronized in all forward speeds All turf models are equipped with a hydraulic brake system and a lever operated parking brake integral
167. tra Trac rear or approved equal P894262 893492 894338 Obtain Locally if only replacing the tire Ref n Description Reo d No Description 894763 Tire and wheel front 894762 Tire and wheel rear 841433 Wheel 10 00 x 7 50 five bolt 9 24 x 13 00 12 Titan ultra trac 886735 Stem valve or approved equal rear 8 9 Tire 20 x 10 00 10 multi rib 1 Q0 841434 Wheel 12 00 x 10 50 800909 Nut wheel mount 886735 Stem valve INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY 0 Obtain locally 78 CLUTCH PEDAL and CABLE GASOLINE ANA oe p vj 9 So P2701278 450453 Nut M8 1 25 G10 9 450510 Screw 3 50 x 20 306328 Pin cotter 3 32 x 3 4 452388 Screw M8 1 25 x 20 8 8 452424 Nut flange M3 50 806714 Pin clevis 5 16 x 15 16 810152 Cover pedal 840725 Pin brake pivot 840726 Bearing brake pivot 842935 Tab locking 892933 Lever clutch 895013 Cable clutch 844202 Washer slotted 890808 Switch clutch interlock 844611 Spring torsion 79 Ref Part No No 1 2 3 4 5 6 7 8 9 80 450377 450453 450510 306328 452388 452424 806714 810152 833273 CLUTCH LINKAGE DIESEL Description Nut M6 1 00 staytite Nut M8 1 25 G10 9 Screw M3 50 x 20 Pin cotter 3 32 x 3 4 Screw M8 1 25 x 20 8 8 Nut flange M3 50 Pin clevis 5 16 x 15 16 Cover pedal Bushing Part 840725
168. trol lever to desired engine Figure 70 R P M P T O Shaft Location For Use While Vehicle Is Moving 1 Refertothe Power Take Off R P M Vehicle Speed chart see Page 50 to select the proper P T O and ground speed combination for the accessory equipment being used there is also a decal representing the P T O and ground speed combinations located on the same panel as the P T O control handle Make sure the governor control lever is all the way DOWN so that the engine is held at idle speed Push the foot throttle pedal to the floorboard Position the governor control lever to obtain engine R P M corresponding to the desired P T O and vehicle ground speed Put transmission in desired gear engage clutch for vehicles with manual transmissions and depress foot throttle 47 OPERATING REMOTE HYDRAULICS Cont Power Take Off Mechanical P T O con t The P T O may be stopped momentarily by pushing the clutch pedal in on vehicles with manual transmissions When the clutch pedal is released the P T O will start again WARNING NEVER attempt to drive the vehicle with the engine speed increased by the hand throttle The hand throttle also controls the foot throttle so the foot throttle pedal cannot be used to reduce engine and vehicle speed FAILURE to obey this warning may result in you the operator losing vehicle control POWER TAKE OFF Hydraulic P T O The hydraulic P T O transmits power from the transmis sio
169. ults clean both bat tery post and cable terminals until shiny Replace ter minals and tighten ZN WARNING Untrained Unauthorized persons should NEVER attempt to service or recharge the battery in this vehicle Battery electrolyte is an acidic solution and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with lib Figure 32 eral amounts of water and obtain medical aid Battery Location For Turf Vehicles immediately JUMP STARTING WITH A BOOSTER BATTERY WARNING DO NOT allow open flames or sparks near a battery when connecting for jump starting or while recharging the battery with a charger Hydrogen gas is produced during the charging process and can be explosive Provide adequate ventilation to prevent possible explosion 26 SERVICE amp MAINTENANCE Cont Jump Starting With a Booster Battery Both booster battery and discharged battery should be treated carefully when using jumper cables Follow exactly the procedure outlined being careful not to cause sparks 1 Apply parking brake put transmission in neutral and turn off all electrical loads 2 Attach one end of one jumper cable to the positive terminal of the booster battery and the other end to the positive terminal of the discharged battery DO NOT permit vehicles to touch each other 2 Connect Cable To Positive Terminal On Dead Battery 1 Connect Ca
170. ut 10 32 Decal left hand dash turf Pin cotter 29 32 x 3 4 Cable governor control Screw 10 32 x 1 2 Cable control hi lo shift Nut 10 24 Nut double Tie cable 7 1 2 190 5 mm Screw 3 8 16 x 2 3 4 Nut M6 1 00 G10 9 Bracket hi lo shift cable mount Screw M6 1 00 x 20 Washer 5 16 Screw 10 24 x 1 2 G5 Nut 1 4 20 jam Screw 1 4 20 x 3 4 Nut M8 1 25 G10 9 Pin clevis 5 16 x 31 32 Screw M8 1 25 x 70 28 8 Stop wire Pin clevis 5 16 x 3 4 Pin hair Spring extension Washer swivel Spring idle return Screw swivel throttle cable Lever governor Bracket Bracket throttle 89 GOVERNOR and THROTTLE LINKAGE To Carburetor 13 9 7 Existing Hardware Use Loctite 242 On These Items Reference Engine Bracket Assembly Part No 894362 Suzuki 970 shown Part O A No 894375 Suzuki K6A A Ref Part No No Description 103867 Washer 3 8 3 810722 111893 Screw special 10 32 813379 Pin clevis 1 4 x 3 8 130728 Nut 1 4 20 830140 Bearing ball 132520 Nut jam 10 32 831586 Ball joint 306320 Nut 5 16 24 833101 Spring extension 306325 Lockwasher 5 16 894434 Arm assembly governor 306372 Pin cotter 3 32 x 1 2 835271 306375 Nut 1 4 20 840473 306396 Lockwasher 1 4 306450 Screw 5 16 18 x 3 4 306487 Screw 1 4 20 x 5 8 306981 Washer 3 8 843567 Cable carburetor 308090 Washer 1 4 4115000 Governor complete 45045
171. uzuki 970 are shown on the following page All components shown are used with the Suzuki K6A 970 and Perkins Diesel engines unless otherwise noted in the parts list shown on the following page P893445 P893972 894614 P894615 894198 893594 893444 894197 94 RADIATOR and COOLING SYSTEM gt SE E ei Use Loctite 4 242 Pd 37 e n c Reference 47 4 4 7 Radiator 31 A 48 Ca With L gt it 7 Ze Si Suzuki 970 amp 46 4 Model 898671 Use Loctite 7 392 A Use Loctite 50 592 No Description Description 300646 Screw 1 4 20 x 3 4 452398 Screw M10 1 50 x 20 8 8 306396 Lockwasher 1 4 820889 Clamp tubing 308090 Washer 1 4 843857 Sender water temperature 450452 Nut M6 1 00 843638 Hose radiator upper K6A 450541 Screw M6 1 00 x 16 843639 Hose radiator K6A 452378 Screw M6 1 00 x 20 843646 Hose radiator lower K6A amp 970 1 835805 Hose radiator overflow As 894348 Tube fan switch K6A amp Perkins 1 825884 Clamp tube 844034 Hose radiator upper 970 809231 Grommet Model 898671 842746 Hose radiator upper Perkins 800177 Screw 5 16 18 x 3 4 829787 Terminal 45 1 4 male 831846 Nut isolation 826590 Hose 5 16 i d 825624 Clamp hose Model 898671 Model 898671 889051 Cap coolant reservoir 833512 838340 800789 Kit oil cooler mounting automatic transm
172. washer 7 16 Washer 7 16 Nut M8 1 25 G10 9 Nut M10 1 50 10 9 Lockwasher M10 Screw M8 1 25 x 25 8 8 Screw M10 1 50 x 20 8 8 Screw M10 1 50 x 90 8 8 Nut M10 1 25 8 8 Bracket transmission to frame Suzuki K6A Bracket transmission to frame Suzuki 970 Mount assembly motor left Suzuki K6A Mount assembly motor left Suzuki 970 Mount assembly motor right Suzuki K6A Mount assembly motor right Suzuki 970 Support platform Part 11616 85000 11640 53F20 11640 85201 11650 85561 11650 85550 11741 85510 11741 85000 11610 60001 11710 77100 08310 00103 01500 08953 01550 08163 08321 01083 08310 00083 11741 85200 01550 10203 With 970 Model 898662 Reference Frame 14 893972 P893657 P893595 894197 893444 Description Cover engine mount Support engine right Suzuki K6A Support engine right Suzuki 970 Support engine left Suzuki K6A Support engine left Suzuki 970 Support transmission automatic trans K6A Support transmission manual trans K6A Mount engine front Bracket rear mount Screw K6A Screw 970 Lockwasher K6A Nut K6A Support transmission 970 Bolt K6A eng mount ENGINE and TRANSMISSION MOUNTS DIESEL Use Loctite 242 Front Of Vehicle Loctite 242 Reference Frame

suzuki 970 liquid cooled gasoline engine perkins

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