Cushman 898627 User manual

X
SUZUKI 970 LIQUID COOLED GASOLINE ENGINE
MODEL: 898671
PERKINS LIQUID COOLED DIESEL ENGINE
MODEL: 898673
EC MODEL: 898695
4120402
SUZUKI K6A LIQUID COOLED GASOLINE ENGINE MT
MODEL: 898627
SUZUKI K6A LIQUID COOLED GASOLINE ENGINE AT
MODEL: 898628

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 also 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.
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
not serviced by Cushman Textron.
:The addition of accessories not of manufacturer’s design may
result in erratic vehicle operation, improper battery charging
and discharging, and failure of vehicle components.
Direct any inquiries to:
Customer Service Department
P.O. Box 388
Augusta, GA 30903--0388 USA
Illustrations in this manual are a reference 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.
Always Think Safety!

VEHICLE IDENTIFICATION NUMBERS
1
WARNING
!
•Altering this equipment in any manner which adversely affects the equipments operation,
performance, durability or use, may cause hazardous conditions.
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.
•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.
NOTICE
IMPORTANT!
THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED
TO WITHOUT THE MANUFACTURER’S AUTHORIZATION.
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 & 91/368.
STANDARDS AND PUBLICATIONS
Users, operators and service persons should be familiar with the following standards and publications:
(The material may be obtained from the addresses shown).
•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.
•Factory Mutual Approval Standard:
Class No’s. 7811 & 7813; Gasoline or Diesel
Powered Trucks, Types G, GS, D or DS.
ADDRESS:
Factory 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.
•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.

2
OPERATION CONTROL SYMBOLS
And DECALS
NOTICE
821071
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 TO BE LICENSED
AS A MOTOR VEHICLE.
WARNING
PARKING BRAKES ARE NOT AUTO-
MATICALLY APPLIED. VEHICLE MAY
MOVE CAUSING PERSONAL INJURY
AND/OR PROPERTY DAMAGE. ALWAYS
APPLY HAND OR FOOT BRAKES. 822819
X 100
This symbol indicates
engine rpm’s.
Engine RPM
This decal lets the operator know that the
vehicle is not defined as a motor vehicle and
therefore should not be driven on streets,
roads or highways
Motor Vehicle Compliance
This decal informs the operator to read
and understand the Operator’s manual.
To prevent injury, they must be familiar
with the operation of this product and be
fully aware of safe operating procedures.
Read the Operator’s Manual
This decal warns the operator that the
park brake is not automatically applied.
Park Brake Warning
Engine Oil Pressure Light
This light will come on when the ignition key
is turned to the ON position and when the
engine is started (it will shut off once the
engine is running). Its main function is to
warn the operator if the oil pressure gets
to low. If this light comes on during nor-
mal vehicle operation, stop the vehicle
and check for problems
OFF DIM BRIGHT
These symbols appear on the light
switch. As indicated, each one repre-
sents the headlights functions.
Headlight Switch Positions
This symbol appears on the fuel
gauge. The fuel gauge indicates
the amount of fuel in the fuel tank
Fuel Level Indicator
This symbol appears on the volt-
meter gauge. This gauge indi-
cates the charging of the battery.
Battery (Voltmeter) Charging
This light will come on when
the park brake is applied.
Park Brake Indicator Light
This symbol appears on the water
temperature gauge. This gauge warns
the operator if the coolant system is
overheating.
Water Temperature Gauge
This decal warns the operator keep
hands away from the cooling fan, the
cooling fan can start at any time even
with the ignition key in the OFF position.
Electric Cooling Fan Warning
009034880
This decal warns the operator not to remove the radiator cap
when the engine is hot. Refer to the Cooling System Section
in this manual for proper safety and operating instructions.
Radiator Coolant Warning
840748
840845
This symbol indicates
diesel fuel only
840901
844643
This decal warns the operator that
an uncovered P.T.O. can cause
entanglement of clothing and/or
body parts.
P. T. O . W a rn i n g
845038
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.
Vehicle Operation
WARNING
FAILURE TO HEED THESE
WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH
1. READ AND UNDERSTAND ALL LABELS AND THE OPERATOR’S MANUAL.
2. DO NOT ALLOW UNTRAINED PERSONNEL TO OPERATE THIS VEHICLE.
3. DO NOT MODIFY THIS VEHICLE WITHOUT MANUFACTURER’S AUTHORIZATION.
4. PLACE LOADS FORWARD OF REAR AXLE.
5. TOP HEAVY LOADS CAN CAUSE UPSETTING. DO NOT EXCEED PAYLOAD
CAPACITY.
6. DO NOT OPERATE IF REPAIRS ARE REQUIRED.
7. KEEP ALL SHIELDS IN PLACE.
8. SHIFT INTO NEUTRAL OR PARK BEFORE STARTING ENGINE.
9. ONLY CARRY PASSENGERS IN SEATS PROVIDED.
10. WHEN PARKING (LEAVING) VEHICLE, FOLLOW ALL INSTRUCTIONS IN
OPERATOR’S MANUAL.
11. AVOID SUDDEN STARTS, STOPS AND SHARP TURNS ESPECIALLY ON SLOPES, OR
WITH HEAVY LOADS
12. KEEP ALL LABELS AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT.
13. KEEP ARMS AND LEGS WITHIN VEHICLE BODY.

3
SERVICE and MAINTENANCE INDEX
Page Page
A
Accelerator Pedal 13.........................
Accessories, list of 42.........................
Accessory Power Plug 10.....................
Access Panels 32............................
Air Cleaner 31...............................
Air Cleaner Element 31.......................
B
Battery 26..................................
Brake Lever, Parking 12.......................
Brake Pedal, Service 13......................
Brake Fluid Indicator Light 10, 37...............
Brake Fluid Level & Bleeding 37...............
Bulbs and Bulb Replacement 34, 39............
C
Choke knob (970 Suzuki only) 12...............
Clutch Interlock Switch 12.....................
Clutch Pedal 12, 22...........................
Controls 10-13...............................
Cooling System 18-19........................
D
Dash Panel Dipswitch Settings 43..............
Decals 2....................................
Differential, 11.16:1 & 14.21:1 40...............
Differential, 2-Speed (operation) 44.............
E
Engine:
Access 14-15............................
Break--in 14.............................
Cooling 18-19............................
Identification Numbers 6-7..................
Oil Level 15-16...........................
Pre-starting Check 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........................
Fuses 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 & 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........................
I
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 8, 33............
M
Maintenance Guide 35-36.....................
Master Cylinder Reservoir (brake fluid) 37.......
Mechanical P.T.O. 46-47......................
O
Oil Warning Light 10, 16.......................
Oil Level (engine) 15-16......................
P
Park Brake Lever and Adjustment 12, 38........
Parts Illustrations 52-177......................
Power Steering Reservoir 21..................
Pre-Starting Check List 15.....................
P.T.O. Operation 46-50.......................
Purge Fuel System (Diesel) 24-25..............
R
Remote Hydraulics 45........................
Reservoir, Hydraulic 51.......................
S
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
Tachometer 10...............................
Taillight Replacement 39......................
Tire Air Pressure 21..........................
Tire Removal and Replacement:
Front 30................................
Rear 30.................................
Towing a Trailer 43...........................
Towing The Vehicle:
Automatic Transmission 28................
Manual Transmission 27-28...............
Transmission, Manual 41......................
Automatic 42............................
V
Vehicle Identification Number 6................
Voltmeter 10.................................
W
Water Temp. Gauge & Overheat Buzzer 10, 17-18

PARTS ILLUSTRATIONS
4
PARTS INDEX
Page Page
A
Accelerator pedal 71.................................
Accessory power plug (12 volt) 92--93..................
Air cleaner, Bracket and Filter:
Suzuki K6A 62..................................
Suzuki 970 & Perkins diesel 63....................
Alternator, Engine belts, Pulleys & Brackets:
Suzuki K6A 96..................................
Suzuki 970 97, 164..............................
Perkins diesel 98................................
Automatic transmission (Suzuki K6A) 120,121...........
Axle, rear 83........................................
B
Belts, engine 96, 97, 98...............................
Body, Hood, Headlights 54--55........................
Brake band (automatic transmission) 132...............
Brake lever (parking) 70..............................
Brake pedal (service) 64--65..........................
Brake lines 64--65...................................
Brake cylinder (master) 64--65.........................
Brake fluid reservoir and bracket 64--65.................
Brakes, front & rear 64--65............................
C
Cables:
Choke (Suzuki 970 only) 52--53....................
Clutch 79.......................................
Shifter 81--82...................................
Two-speed differential control 88, 89................
Cam Chain (Suzuki K6A) 107--108.....................
Camshaft & components (Suzuki K6A) 105--106.........
Camshaft & components (Suzuki 970) 123..............
Carburetor (Suzuki K6A) 109--110, 112..................
Carburetor (Suzuki 970) 125..........................
Catalytic convertor (Suzuki K6A) 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 K6A) 79, 118--119.....................
(Perkins diesel & Suzuki 970) 80, 100--101.......
Clutch pedal cable (gasoline) 79.......................
Clutch linkage (diesel) 80.............................
Cover, engine 52--53.................................
Cooling System 94--95...............................
Cowl, front 54--55....................................
Crankshaft (Suzuki K6A) 96, 154--155...................
Crankshaft (Suzuki 970) 97, 159.......................
Cylinder, hydraulic lift 85..............................
Cylinder block, engine: (Suzuki K6A) 150--151..........
(Suzuki 970) 158...............
Cylinder head, engine: (Suzuki K6A) 148--149..........
(Suzuki 970) 157...............
D
Decals 104.........................................
Delivery pipe (Suzuki K6A) 141........................
Differential (two-speed) 88...........................
Dipstick, oil: (Suzuki K6A) 121, 152--153...............
(Suzuki 970) 158.......................
Dipstick, transmission (Suzuki K6A auto.) 121...........
Distributor (Suzuki K6A) 136..........................
Distributor (Suzuki 970) 157, 165.......................
Drawbar 56--57......................................
Driveshaft: (Suzuki K6A) 118--119.....................
(Perkins diesel & Suzuki 970) 100--101.......
Automatic transmission 120, 121............
E
Electrical components 92--93..........................
Emissions control (Suzuki K6A) 139....................
Emissions control (Suzuki 970) 126....................
Engine mounts: (Suzuki K6A & 970) 102................
(Perkins diesel) 103...................
Exhaust system: (Suzuki K6A) 58, 139.................
(Suzuki K6A)(Catalytic Converter) 59...
(Suzuki 970 & Perkins diesel) 60--61....
F
Fan, radiator cooling 94--95...........................
Fenders (rear) 56--57.................................
Filter, air cleaner (Suzuki K6A) 62......................
Filter, air cleaner (Suzuki 970 & diesel) 63...............
Filter, oil: (Suzuki K6A) 150--151.......................
(Suzuki 970) 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 & 970 66--67................
Filter 66--67...........................
Pump 66--67, 140......................
Tank 66--67...........................
Fuel system: Perkins diesel 68--69...................
Filter 68--69...........................
Pump 68--69..........................
Tank 68--69...........................
Frame 56--57.......................................
Front Cowl 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 & Perkins diesel) 162.........
Generator (Suzuki K6A) 143..........................
Governor (Suzuki K6A & 970) 90, 99...................
Governor hand control (Perkins diesel) 89..............
Governor hand control (Suzuki K6A & 970) 88, 99........
Governor & throttle linkage (Suzuki K6A & 970) 90.......
H
Hand controls (gasoline) 88...........................
Hand controls (diesel) 89.............................
Headlights 54--55....................................
Horn 54--55.........................................
Horn button 92--93...................................
Hood release latch 54--55.............................
Housing, transmission: automatic (Suzuki K6A) 121....
manual (Suzuki K6A) 116--117..
Housing, transmission Suzuki 970 & diesel 161..........
Hubs, wheel: front 74--75, 76--77.......................

5
H
Hydraulic brake lines 64--65...........................
Hydraulics:
Control box cover 84, 87..........................
Control valve 86.................................
Filter 87........................................
Lift cylinder 85..................................
Lift system 85...................................
Pump 84, 87....................................
Reservoir 87....................................
Selector valve 84................................
Valve system 84.................................
Hydraulic reservoir guard 56--57.......................
I
Idle-up controller (automatic transmission) 93............
Ignition switch 92--93.................................
Input shaft & gears:
Suzuki K6A manual transmission 116--117..........
Suzuki K6A automatic transmission 128, 120, 121....
Suzuki 970 & diesel 160..........................
Instrument panel w/tach 92--93........................
Intake manifold (Suzuki K6A) 109--110..................
Intake manifold (Suzuki 970) 125......................
L
Leaf springs 83.....................................
Light switch 92--93...................................
Lower ROPS 56--57..................................
M
Manifold, exhaust (Suzuki K6A) 139....................
Manifold, exhaust (Suzuki 970) 126....................
Master cylinder reservoir 64--65........................
Mudflap(front) 54--55................................
Muffler: (Suzuki K6A) 58.............................
(Suzuki 970) 60.............................
(Perkins diesel) 61...........................
Motor mounts: (Suzuki K6A & 970) 102................
(Perkins diesel) 103...................
O
Oil cooler (automatic transmission) 94--95..............
Oil filter (Suzuki K6A) 150--151........................
(Suzuki 970) 158............................
Oil pan, Gasket and Dipstick:
(Suzuki K6A) manual transmission 152--153.........
(Suzuki K6A) automatic transmission 121, 122.......
(Suzuki 970) 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 and Cable 68.......................
Parking brake (automatic transmission)(Suzuki K6A) 131..
Perkins Diesel Engine Information 68--69...............
PCV valve (Suzuki K6A) 111...........................
PCV valve (Suzuki 970) 126..........................
Pistons (Suzuki K6A) 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 K6A) 96..............................
Pulleys (Suzuki 970) 97..............................
Pulleys (Perkins diesel) 98............................
R
Radiator 94--95......................................
Rear platform 56--57.................................
Rear springs, shackles 83............................
S
Seats 52--53........................................
Shifter & shifter linkage: 81--82........................
Shifter & shifter linkage (970 Suzuki & diesel) 100--101....
Shifter gears:
Suzuki K6A manual transmission 114--115..........
Shift shaft (automatic transmission) 122................
Shift switch (automatic transmission) 122...............
Shock absorbers: rear 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...................
(Suzuki 970) 157........................
Starter: manual transmission 142......................
automatic transmission 135....................
Starter (Suzuki 970) 163..............................
Steering wheel, Shaft & Pump 72--73...................
Struts, front (spring & shock) 74--75, 76--77..............
Suspension, front 74--75, 76--77........................
T
Taillight 92--93.......................................
Tailpipe: (Suzuki K6A) 58............................
(Suzuki K6A) (Catalytic converter) 59..........
(Suzuki 970 & Perkins diesel) 60--61..........
Thermostat (Suzuki 970) 95, (Suzuki K6A) 138..........
Throttle hand control (Perkins diesel) 89................
Throttle hand control (Suzuki K6A & 970) 88............
Throttle linkage (Suzuki K6A & 970) 90.................
Tie rods 74--75, 76--77................................
Timing belts & cover (Suzuki K6A) 107--108.............
Timing belts & cover (Suzuki 970) 124..................
Tires, front and rear 78...............................
Torque chart and torque specifications 168..............
Torque converter (automatic transmission) 120..........
Transmissions: (Suzuki K6A) (manual) 116--117, , 144--145
(Suzuki K6A) (automatic) 120-131.......
(Suzuki 970 & Perkins diesel) 161.......
Transmission mounts: (Suzuki K6A & 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 91........................................
Fuel tank 92--93...................................
Main 91.........................................
Taillight 92--93....................................
Wiring diagrams 170--173, 178--179, 182--183...........
Wiring schematics 175--177, 180--181, 184--185.........

VEHICLE IDENTIFICATION NUMBERS
6
Vehicle Serial No.
Stamped Into Crossmember
VEHICLE IDENTIFICATION NUMBERS
THE FOLLOWING IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE
CONCERNING THIS VEHICLE.
•Reference to the front, rear, left and right sides of the vehicle
are always determined by the operator’s seated position.
NOTICE
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).
Figure 1
Nameplate / Identification Decal
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).
Figure 2
Serial Number And Model Number
Vehicle
Model and Serial No.
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.
SPARK ARRESTERS ARE REQUIRED BY
CALIFORNIA PUBLIC RESOURCES CODE, SEC-
TIONS 4428--4442, WHEN OPERATING ANY IN-
TERNAL COMBUSTION ENGINE ON HYDRO-
CARBON FUELS, ON FOREST--, BRUSH--, OR
GRASS--COVERED LANDS.
IMPORTANT!
ENGINE IDENTIFICATION NUMBERS
a Suzuki 970 4-cylinder, 4-cycle, liquid-cooled gasoline powered engine,
Perkins 103-10, 3-cylinder, 4-cycle liquid-cooled diesel powered engine.
Your Cushman Turf-Truckster is equipped with one of three power sources:
A Suzuki K6A 3 cylinder, 4 cycle, liquid--cooled gasoilne powered engine;
or a

VEHICLE IDENTIFICATION NUMBERS Cont.
7
Engine Serial No.
970 Suzuki
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.
Figure 4
Suzuki 970 Engine Serial Number
(As Viewed From the Drivers Side of Vehicle)
Figure 5
Perkins Diesel Engine Serial Number
Engine Identification Numbers (con’t.)
The Engine Serial No. for the Suzuki K6A engine is
stamped onto the upper engine block on the left side of
the engine.
Figure 3
Suzuki K6A Engine Serial Number
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. for the Suzuki 970 engine is
stamped onto the lower engine block on the right side of
the engine.
It’s located on the lower engine block beneath the air
cleaner.
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.
Engine Serial No.
Perkins Diesel
The engine serial no. is also hand printed on the
engine cylinder cover (See Fig. 3).
The 970 engine serial no. is also hand printed on
the engine cylinder cover.
Engine Serial No.
K6A Suzuki

SPECIFICATIONS
8
SPECIFICATIONS
Specifications subject to change without notice.
Rear Axles: Models 898671, 898673 & 898695 11.16:1 2-speed hypoid differential...........
CAPACITIES
Transmission (K6A manual) 1.05 qt. (1.0 L);
(970 & diesel manual) 1.4 qt. (1.3 L)..
(automatic) 3.7 qt. (3.5 L)...........
Crankcase (including filter):
Suzuki K6A 3.3 qt. (3.0 L).....................
Suzuki 970 3.7 qt. (3.5 L)......................
Perkins Diesel 3.7qt. (3.5 L)....................
Cooling System:
Suzuki K6A 3.3 qts. (3.0 L.....................
Suzuki 970 3.3 qts. (3.0 L).....................
Perkins Diesel 5 qts. (4.7 L)....................
Transmission: Models 898671, 898673 & 898695 4-speed manual with low-low (creeper) 1st gear,...........
synchronized in all forward speeds
Fuel Tank 6.5 gal. (24.5 L)........................
LUBRICATION RECOMMENDATIONS
Hydraulic System Hyd Benz Bio 377............
Transmission Fluid
(4-speed manual) SAE EP 80-90 Gear Lube....
(automatic) Mercon/Dexron II.................
Hydraulic System
Standard hydraulics 4 gal. (15.0 L)...............
Hi-Lo hydraulic accessory 7.6 gal. (28.8 L)........
All turf models are equipped with a hydraulic brake system and a lever operated parking brake integral to the rear
brake drums.
BRAKE FLUID
Use type Dot 3..................................
FUEL
Gasoline Engines Unleaded gasoline...........
87 Octane or higher
Diesel Engines No. 2-D (ASTM D975)...........
(see the Fuel Recommendation Section, Page 20)
Differential (11.16:1) 5.2 Pints (2.5 L). .............
Differential Oil SAE EP 80-90 Gear Lube........
Pressure Gun Grease Lithium Base.............
Power Steering Power Steering Fluid (GM)......
TIRES
Front 20 x 10.00-10 Multi-Rib.....................
Rear 24 x 13.00-12 Titan Ultra Trac................
SUSPENSION
Front Double A-arm independent with two...........
spring-over-shock absorbers
Rear Heavy-duty multiple leaf springs............
with shock absorbers
STEERING
14.1 ratio Saginaw power steering and a 14 inch
(355.6 mm) steering wheel
BATTERY
Volts 12.......................................
BCI Group Size 24.............................
Cold Cranking Amps (minimum) 420.............
Reserve Capacity Minutes (minimum) 70..........
Ground Terminal Polarity Negative...............

SPECIFICATIONS Cont.
9
ENGINE SPECIFICATIONS
Horsepower (SAE hp) 34......................
Max. Engine Speed 3600 RPM................
Stroke 2.83” (72 mm)........................
Bore 2.58” (65.5 mm).........................
Displacement 59.2 cu in. (970 cm3)............
Compression Ratio 8.8:1.....................
Cylinder Compression 178 PSI (1,228 kPa)....
Engine Rotation
(viewed from flywheel) Counterclockwise......
Valve Clearance (intake) .0031scold (0.08 mm)
(intake) .0047shot (0.12 mm)
(exhaust) .0039scold (0.10 mm)
(exhaust) .0047shot (0.12 mm)
Spark Plug Gap .032-.035 (0.8-0.9 mm)........
Spark Plug Number NGK BP5ES..............
OR Denso W16EX-U
Spark Plug Torque 18.5-21.5 lb. ft. (25-30 Nm)..
Breaker Point Gap .008-.015 (0.2-0.4 mm)......
Ignition Timing 4-5EBTDC @ 950 RPM........
Idle Speed 950 ¦50 RPM....................
Suzuki 970 Engine
Horsepower (SAE hp) 22.3....................
Max. Engine Speed 3000 RPM................
Stroke 2.83” (72 mm)........................
Bore 2.9” (75 mm)...........................
Displacement 58.2 cu in. (954 cm3)............
Compression Ratio 23:1......................
Cylinder Compression 425 PSI (2,932 kPa)....
Engine Rotation
(viewed from flywheel) Counterclockwise......
Valve Clearance (intake) .008scold (0.2 mm)
(intake) .010shot (.25 mm)
(exhaust) .008scold (0.2 mm)
(exhaust) .012shot (.30 mm)
Spark Plug Gap NA.............
Spark Plug Number NA..........
Spark Plug Torque NA...........
Breaker Point Gap NA...........
Injection Timing 22EBTDC @ 1,000 RPM’s.......
Idle Speed 950 ¦50 RPM....................
Perkins Model 103.10 - Spec KD70377
•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 R.P.M.
WARNING
!
NOTICE
•The engine governor controls are preset to control
engine and ground speeds to design limits.
Sound Level (Perkins Diesel):
Pressure Level (right ear) dB(A) 79.2 LpA.......
Pressure Level (left ear) dB(A) 79.2 LpA........
Sound power level dB(A) 95 LWA...............
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.......
2
2
2
2
Horsepower (SAE hp) 31......................
Max. Engine Speed 4450 RPM................
Stroke 2.60” (66mm).........................
Bore 2.56” (65mm)...........................
Displacement 40.1 cu in. (657 cm3)............
Compression Ratio 10.5:1....................
Cylinder Compression 178 PSI (1,228 kPa)....
Engine Rotation
(viewed from flywheel) Counterclockwise......
Valve Clearance (intake) .0031scold (0.08 mm)
(intake) .0047shot (0.12 mm)
(exhaust) .0039scold (0.10 mm)
(exhaust) .0047shot (0.12 mm)
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 lb. ft. (25-30 Nm)..
Ignition Timing 4-5EBTDC @ 950 RPM........
Idle Speed 950 ¦50 RPM....................
Suzuki K6A Engine

CONTROLS
10
The following pages contain information which will help you become more familiar with the dif-
ferent gauges and controls used while operating this vehicle.
Figure 7
Dash Panel Identification
OIL PRESSURE WARNING LIGHT (4)
The red oil pressure light (See Fig. 6) indicates oil pres-
sure is too low for engine operation.
WATER TEMPERATURE GAUGE, AND
OVERHEAT WARNING BUZZER (7)
GAUGES, WARNING LIGHTS and CONTROLS
Figure 6
Dash Panel Identification
The purpose of this system is to warn the operator if the
engine temperature exceeds the normal operating
range.
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.
TACHOMETER (1)
Indicates the engine speed (x 100) in revolutions per
minute(SeeFig.6).
FUEL GAUGE (3)
The fuel gauge (See Fig. 6) indicates the amount of fuel
remaining in the fuel tank.
7
If the water temperature gauge (See Fig. 7) raises above
the 230EF(110EC mark), a heat sensor is activated
causing the overheat warning buzzer to sound.
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.
BRAKE FLUID LEVEL WARNING LIGHT (6)
This light (See Fig. 7) indicates the brake fluid level is
low.
6
Figure 8
Accessory Power Plug
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 Fig. 8).
Accessory
Power Plug
3
1
2
4
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).
5
8

CONTROLS Cont.
11
3. ON POSITION -- Key is placed in this position for normal
engine operation.
4. 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-
vated.
IGNITION SWITCH
Figure 9
Four Position Ignition Switch
•DO NOT turn key to START position with vehicle engine
running. Damage to flywheel teeth may result.
NOTICE
1. ACCESSORY POSITION -- Allows use of various instruments and accessories without causing ignition
system damage.
2. 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.
•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.
DANGER
!
Ignition Switch Position
(Shown as reference only)
•If the engine will start without depressing the clutch pedal the clutch interlock system
should be repaired immediately by your authorized Cushman dealer.
Figure 10
Horn Button and Light Switch Location
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.
OFF DIM
(1st Detent)
BRIGHT
(2nd Detent)
HEADLIGHT OPERATION SYMBOLS
Light Switch
Horn Button

CONTROLS Cont.
12
Choke
Knob
Figure 11
Park Brake Lever and Choke Knob
Park Brake
Lever
FOOT CONTROL PEDALS
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.
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 pre-
vents the starter from operating unless the clutch is dis-
engaged (the clutch pedal is depressed).
CLUTCH PEDAL (Manual Transmission Only)
Clutch Pedal
Figure 12
Clutch Pedal Location
The clutch pedal has to be depressed:
:before starting the vehicle
:before shifting into any of the gears and
:before coming to a complete stop
DANGER
!
•Never start the engine unless the clutch pedal is depressed (pushed down). If the vehicle is in
any gear other than neutral, with the clutch pedal not depressed and the engine is started, the
vehicle will lurch forward or backward depending which gear the vehicle is in. This lurching
could cause serious personal injury or death.
The park brake lever is located to the left side of the
drivers seat. To engage the brake, pull up on the lever
until park brake is applied.
PARKING BRAKE LEVER
To release, while slightly pulling 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 (See Fig. 11).
•Parking brakes are not automatically applied. Make
sure and set the park brake when leaving the
vehicle.
Thechokeisusedtoassistthestartingofacold
engine. Pull up on the choke knob and hold in the full
or partially open position. When the engine has
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).
CHOKE (Suzuki 970 engines Only)

CONTROLS Cont.
13
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)
1
2
3
4R
N
Push pedal down to open throttle (increase speed), release to return throttle to idle position (decrease speed).
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.
SERVICE BRAKE PEDAL
CAUTION
!
•Improper maintenance 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
the brakes are applied too hard and fast.
Brake Pedal
Figure 13
Foot Control Pedals
Accelerator
Pedal
FOOT THROTTLE (ACCELERATOR) PEDAL
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.
GEAR SELECTOR
Manual Transmission
Figure 15
Automatic Transmission Gear Selector
Automatic Transmission
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.
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.

SERVICE & MAINTENANCE
14
The following maintenance information covers basic engine service only.
For extensive service and repairs, we recommend contacting the authorized Cushman dealer nearest you.
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.
Proper maintenance will prolong the engine’s life and avoid premature overhaul.
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.
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.
SERVICE and MAINTENANCE
•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 in 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.
WARNING
!
Think Ahead! Work Safely!
ENGINE BREAK IN
•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 R.P.M.
WARNING
!
The service life of your engine is dependent upon how
your engine is operated during the first 50 hours of
operation.
ALWAYS: :Use care not to overload your engine
:Maintain engine oil level
:Maintain cooling system
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).

SERVICE & MAINTENANCE Cont.
15
Engine Cover
Latch
Figure 16
Engine Cover Latch
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.
Figure 17
Engine Cover Retaining Tab
•Failure to latch the seat properly can result in the engine cover tipping forward
causing loss of control of the vehicle and possible personal injury.
WARNING
!
Before starting your engine for the first time; after a prolonged shutdown; and before each days use,
check the following:
1. Check the engine oil level.
2. Check the radiator coolant level and radiator intake screen.
3. Check the fuel level.
4. 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).
Retaining Tab
In Slot On
Floorboard
PRE--STARTING CHECKLIST
Access to Engine (con’t.)
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.
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
to be pushed back (the locking handle can also be used
as an accessory on any of the other turf vehicles).

SERVICE & MAINTENANCE Cont.
16
Figure 18
Oil Level Reading
Figure 19
Oil Pressure Warning Light
NOTICE
•If you notice the oil pressure warning light coming
on, STOP the vehicle and check for problems.
Figure 20
Dipstick Location, Perkins Diesel Engine
Remove the oil fill cap and add the appropriate amount
of engine oil. Use the dip stick to check the level again, if
oil level is sufficient, replace oil fill cap.
DO NOT OVERFILL
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).
Oil Pressure
Light
Engine Oil Capacity
Suzuki K6A 3.3 qts. (3.0 L)..................
Suzuki 970 3.7 qts. (3.5 L)...................
Perkins Diesel 3.7 qts. (3.5 L)...............
Engine Oil Level (con’t.)
Dipstick
Engine Oil Replacement Filters:
Suzuki K6A Order Part No. 16510-82703.....
Suzuki 970 Order Part No. 16510-82703......
Perkins Diesel Order Part No. 842553.......
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.
°F
°C
--20 0 20 32 40 60 77 80 100
40302520100-- 1 0-- 2 0-- 3 0
Temperature Range Anticipated Before Next Oil Change
SAE 10W-30 for all temperature ranges
Using multi grade oils (5W-20, 10W-30, and 10W-40) will
increase oil consumption. Check oil level more frequently
when using them.
10W-40
SAE 10W/10W-30
Suzuki K6A & 970
Perkins Diesel
SAE 20W/10W-30 SAE 30W/10W-30
Do Not
Overfill
Oil Dipsticks May
Vary In Appearance
Add Oil If The Level
Is At Or Below This Mark
Oil Level Must
Be Between The Marks

SERVICE & MAINTENANCE
17
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.
3. Slow the engine to a “fast idle”.
4. Remove any dirt, chaff, debris, etc. from the radiator
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).
Figure 23
Water Temperature Gauge
Water Temp
Gauge
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.).
•Failure to:
(2) maintain cooling system, will cause permanent
damage.
If the water temperature gauge raises above the 230EF(110EC) mark, a heat sensor is activated causing the
overheat warning buzzer to sound.
(1) heed the overheat warning and
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.
Dipstick
Figure 22
Dipstick Location, 970cc Suzuki Engine
Engine Oil Level (con’t.)
Dipstick
Figure 21
Dipstick Location, K6A Suzuki Engine

SERVICE & MAINTENANCE Cont.
18
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
!
•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.
•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.
1. 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).
2. 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.
3. Check oil engine level.
4. Check radiator and coolant reservoir levels.
Water Temperature Gauge and Overheat Warning Buzzer (con’t.)
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.
RADIATOR COOLANT LEVEL
009034880
Fan Warning Decal
Radiator Warning Decal
840748
•DO NOT obstruct or cover the intake screen in front of the radiator.
Keep the fins and radiator screens clean.
•If the radiator fins or intake screen become dirty, air cannot circulate
well enough to cool the engine sufficiently, therefore you risk the
chance of the engine overheating. Engines damaged due to
overheating caused by plugged radiators WILL NOT be war-
ranted.
WARNING
!
•The cooling fan is thermostatically controlled and may start 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.
The vehicle is equipped with a cooling radiator and an electric cooling fan.
Also refer to page 37 for Dash Panel Bulb Replacement.