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Cushman TURF-TRUCKSTER Service & Repair Manual

Diesel & gasoline engines
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Litho in U.S.A. 08/00
Revised
12/01
CD-SRI-TRKMNL
SERVICE & REPAIR
TURF-TRUCKSTER
Register Your CD
Use the registration
on back of tray card.
GOLF, TURF & SPECIALTY PRODUCTS
WARNING: If incorrectly used this machine can cause severe injury. Those who
use and maintain the machine should be trained in its proper use, warned of its
dangers and should read the entire manual before attempting to set up, operate,
adjust or service the machine.
INSTRUCTIONS
DIESEL & GASOLINE ENGINES
MANUAL TRANSMISSION
Copyright 2001 Textron Golf, Turf & Specialty Products
"All rights reserved, including the right to reproduce this
material or portions thereof in any form."
®

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  • Page 1 SERVICE & REPAIR INSTRUCTIONS TURF-TRUCKSTER ® DIESEL & GASOLINE ENGINES Register Your CD Use the registration MANUAL TRANSMISSION on back of tray card. Copyright 2001 Textron Golf, Turf & Specialty Products Litho in U.S.A. 08/00 “All rights reserved, including the right to reproduce this GOLF, TURF &...
  • Page 2 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS & TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS...
  • Page 3 RETURN TO MAIN TABLE OF CONTENTS SECTION 1 INTRODUCTION 1A. General Information ............1A-1 Contents .

  • Page 4: Introduction

    RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION CONTENTS by understanding what you will be doing and how the component relates to others in its system. Lists of This manual contains repair instructions for truck com- repair tools and materials for each section of the man- ponents, attachments and options.
  • Page 5 RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION REPLACEMENT PARTS GENERAL CLEANING Use the appropriate parts manual when ordering re- Improper cleaning and lubrication of your vehicle placement parts. Follow installation instructions shipped results in many equipment failures. Before any repairs with service parts or kits.
  • Page 6 RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION TORQUE VALUES Torque values are given in the following “Torque Speci- fication Chart”. Special torque values are called out on illustrations and text throughout this manual. TORQUE SPECIFICATIONS STANDARD SAE GRADE #5 SCREWS Size Torque Values Size...
  • Page 7 RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION ACCESS LATCHES (See Figure 1A-2) DUMP BOX RELEASE LEVER For servicing drive train and other components ACCESS TO ENGINE mounted under the dump box, pull back the dump box lever to extend the hydraulic cylinder and raise the WARNING dump box.
  • Page 8 RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION JACKS, JACKING LOCATIONS AND Jack the vehicle to the appropriate height and place jack stands or equivalent support beneath the frame USING A HOIST near the jack. Lower the jack and allow the vehicle to A scissors type jack or a floor jack with a 1-1/2 ton rest on the jack stands.
  • Page 9 RETURN TO TABLE OF CONTENTS INTRODUCTION SECTION 1A. GENERAL INFORMATION TOWING If for any reason the vehicle needs to be towed, follow the guidelines below to properly tow the vehicle. If towing the vehicle with a tow-rope or a chain, an operator is required to steer the vehicle and to control the brakes.
  • Page 10 RETURN TO MAIN TABLE OF CONTENTS SECTION 2 CONTROLS 2A. Repair and Service Tools and Materials ......... 2A-1 2B.
  • Page 11 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Refer to Section 11. 2A-1...
  • Page 12 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2B. FAILURE ANALYSIS GENERAL The following table gives common problems, probable causes and suggested remedies. PROBLEM PROBABLE CAUSE REMEDY 1. Engine does not turn a. Battery dead. a. Charge or replace (Section 10). over when ignition switch b.
  • Page 13 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GENERAL 1. Only on diesel engine powered vehicles does the accelerator (foot) pedal retain full control of throt- This section covers adjustments to speed controls, tle lever position. An internal engine governor parking and service brakes, power take off (PTO) adjusts the injector pump to compensate for varia- controls, clutch interlocks, transmission gear selectors...
  • Page 14 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 5. Maximum RPM and low idle speeds for various Turf Truckster ® engines are as follows: Engine Maximum RPM Low Idle Suzuki 660 4450 RPM 950 ± 50 RPM gasoline Adjust governor to Adjust to 900 RPM.
  • Page 15 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 4. With the accelerator pedal fully depressed, adjust 6. With the accelerator pedal fully depressed, remove the second throttle stop screw (see Figure 2C-5). the cotter pin, turnbuckle pin and flat washer (see Adjust the second throttle stop screw so that it Figure 2C-7).
  • Page 16 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 8. Pull the turnbuckle to the full throttle position (see 10. Move the governor lever to the low RPM position Figure 2C-9). Install the turnbuckle pin, washer (see Figure 2C-11). Adjust the counterbalance and cotter pin so that the turnbuckle pin is snug spring by centering the jam nuts on the governor against the broken knee lever when pressure is...
  • Page 17 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 4-CYLINDER GASOLINE ENGINE 3. Depress the accelerator pedal down against the pedal stop screw (see Figure 2C-14). Turn (Suzuki 970) GOVERNOR AND the stop screw out of its bracket one revolution HAND THROTTLE ADJUSTMENTS counterclockwise (against the accelerator pedal) so that the pedal touches the stop screw before...
  • Page 18 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 5. With accelerator pedal fully depressed, check 7. Push the broken knee lever to its full at rest posi- throttle plate. Pull spring bracket toward you, the tion (see Figure 2C-18). throttle should be 5 degrees from full open (see Figure 2C-16).
  • Page 19 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS 9. Adjust the cable stop screw (see Figure 2C-20) to GOVERNOR AND HAND THROTTLE obtain 3600 RPM. Adjust the governor stop screw ADJUSTMENTS — DIESEL ENGINE so it just touches the governor body and lock the 1.
  • Page 20 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS Figure 2C-22. Choke Adjustment PARKING BRAKE ADJUSTMENT (See Figure 2C-23) 1. The parking brake activates only the two rear brakes of the vehicle. Raise the engine cover to gain access to the parking brake cables. 2.
  • Page 21 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS SERVICE BRAKES (See Figure 2C-24) 1. This vehicle is equipped with four hydraulic 5. Attach a hose to the bleeder screw on top of the brakes controlled by the brake pedal. Open the left rear dust shield and place the other end of the front cowl of the vehicle to gain access to the hose in a container to catch the fluid run-off when...
  • Page 22 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS CLUTCH PEDAL FREE TRAVEL CLUTCH INTERLOCK SWITCH (See Figure 2C-27) 1. Depress clutch pedal, stop as soon as clutch resistance is felt, and measure clutch pedal free A clutch interlock switch allows the engine starter to travel as shown in Figure 2C-25.
  • Page 23 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GEAR SELECTOR ADJUSTMENT (See Figure 2C-28) NOTE Before adjustment, check to make sure that each lubrication point is greased properly (see Section 11) and that bushings and linkages are not worn. Repair as necessary. If the gear shift control lever can be shifted from neu- tral (vertical) position to and between 3rd and 4th positions smoothly, the gear select cable is adjusted...
  • Page 24 RETURN TO TABLE OF CONTENTS CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS REPAIR (See Figure 2D-1) The instrument panel gauges are not individually replaceable. Replace the entire panel if the tachome- ter, hour meter, fuel gauge, voltmeter or water tem- perature gauge are defective. See Section 10 for electrical testing.
  • Page 25 RETURN TO MAIN TABLE OF CONTENTS SECTION 3 ENGINE 3A. Repair and Service Tools and Materials ......... 3A-1 3B.
  • Page 26 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Anti-rust Never-Seize. Lubricants: See Section 11. Other service items: Compressed air source. Engine hoist.
  • Page 27 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Engine will not start. a. Parking brake disengaged. a. Engage brake. b. Glow plug has not timed out b. Reset ignition switch and allow (diesel). glow plug to time out before cranking engine.
  • Page 28 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3C. GENERAL INSTRUCTIONS CONTENTS CLEANING AND LUBRICATION This section covers repairs to the engine associated Thoroughly clean each component after removal from components (eg. exhaust system, air cleaners, radia- the machine. Follow engine manufacturer’s instruc- tors).
  • Page 29 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE GENERAL Check the element for damage, pin holes, etc. by placing a light source such as a flashlight inside. Diesel engines used on this vehicle are 3-cylinder, 4- cycle, liquid cooled Perkins 100 Series. A “Workshop” Clean dust from inside of housing with damp cloth, making sure dust does not enter air intake.
  • Page 30 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE RADIATOR AND COOLING SYSTEM Cooling system capacity for the diesel engine is 5.0 qts. (4.7 L). The engine is equipped with a cooling radiator and an Unless the radiator is very low, always add coolant to electric cooling fan.
  • Page 31 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE Figure 3D-2. Radiator and Cooling System Repair 3D-3...
  • Page 32 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE MUFFLER AND EXHAUST SYSTEM INSPECTION (See Figure 3D-3) 1. Check rubber mountings for damage, deteriora- tion and out of position. 2. Check exhaust system for leakage, loose connec- WARNING tions, dents and damages. If nuts or bolts are loose, tighten them to 29 to 43 ft-lbs.
  • Page 33 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE FUEL FILTER SERVICE (See Figure 3D-4) There are two fuel filters in the diesel engine fuel sys- Moisture and other foreign matter accumulate in the tem. A pre-filter is located in-line between the fuel fuel filters.
  • Page 34 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE PURGING THE FUEL SYSTEM The diesel 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, or when the fuel filter and/or fuel lines have been loosened, removed or replaced.
  • Page 35 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3D. DIESEL ENGINE ENGINE REMOVAL ENGINE INSTALLATION 1. Raise dump box and open engine cover. 1. Using a suitable lifting device, lift engine and posi- tion in-line with transmission. 2. Disconnect NEG (–) battery cable from battery. 2.
  • Page 36 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES GENERAL SPARK PLUG WIRES The gasoline engine used on your vehicle is either a 1. Remove high tension coil cable at ignition coil 3-cylinder Suzuki 660 or 4-cylinder Suzuki 970. while gripping its cap.
  • Page 37 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES IGNITION SYSTEM — 3-CYLINDER ENGINE (SUZUKI 660) The 3-cylinder (Suzuki 660) engine uses a solid-state ignition system. The basic components of this ignition system are igni- tion coil, distributor and spark plugs. The components of the distributor are signal generator (signal rotor and pickup coil), igniter, rotor, cap and both vacuum and centrifugal advance.
  • Page 38 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES CARBURETOR Check the element for damage, pin holes, etc. by placing a light source such as a flashlight inside. Carburetor adjustments (choke/throttle) are covered in Section 2C. Cleaning and rebuilding of carburetors Clean dust from inside of housing with damp cloth, making sure dust does not enter air intake.
  • Page 39 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES RADIATOR AND COOLING SYSTEM Unless the radiator is very low, always add coolant to the overflow reservoir, not to the radiator. The engine is equipped with a cooling radiator and an With the park brake applied and the gear selector in electric cooling fan.
  • Page 40 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES Figure 3E-4. Radiator and Cooling System Repair — 3-Cylinder Engine (Suzuki 660) 3E-5...
  • Page 41 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES Figure 3E-5. Radiator and Cooling System — 4-Cylinder Engine (Suzuki 970) 3E-6...
  • Page 42 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES MUFFLER AND EXHAUST SYSTEM INSPECTION (See Figures 3E-6 and 3E-7) 1. Check rubber mountings for damage, deteriora- tion and out of position. 2. Check exhaust system for leakage, loose connec- WARNING tions, dents and damages.
  • Page 43 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES Figure 3E-7. Muffler and Exhaust System — 4-Cylinder Engine (Suzuki 970) FUEL FILTER SERVICE REMOVAL (See Figure 3E-8) 1. Remove negative (–) battery cable. 2. Remove fuel filler cap from fuel filler neck to release fuel vapor pressure in fuel tank.
  • Page 44 RETURN TO TABLE OF CONTENTS ENGINE SECTION 3E. GASOLINE ENGINES Figure 3E-8. Fuel System ENGINE REMOVAL ENGINE INSTALLATION 1. Raise dump box and open engine cover. 1. Using a suitable lifting device, lift engine and posi- tion in-line with transmission. 2.

  • Page 45: Drive Train

    RETURN TO MAIN TABLE OF CONTENTS SECTION 4 DRIVE TRAIN 4A. Repair and Service Tools and Materials ......... 4A-1 4B.
  • Page 46 RETURN TO MAIN TABLE OF CONTENTS 4H. Transmission (4-Cylinder 970 Gasoline or Diesel Engines) ..... . . 4H-1 General ............... 4H-1 Transmission Removal .
  • Page 47 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Blind hole bearing puller. Bearing and gear installation tools. Cleaning materials: Stoddard or equivalent solvent. Loctite ® “chisel” gasket remover or equivalent.
  • Page 48 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Noisy when vehicle a. Excessive gear backlash. a. Adjust (Section 4G or 4H). moving forward or reverse. b. Faulty U-joints. b. Repair (Section 4C). 2.
  • Page 49 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 7. Clutch vibration. a. Glazed (glass-like) clutch facings a. Repair or replace (Section 4D). or clutch facings dirty with oil. b. Wobbly clutch disc or poor facing b.
  • Page 50 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 11. Transmission jumps a. Shifting fork loose on shaft or a. Disassemble and check for wear out of gear. rail; worn or damaged fork or or damage.
  • Page 51 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 14. Transmission leakage. a. Vent or breather clogged. a. Remove vent or breather and clean or replace (Section 4G or 4H). b. Too much or improper lubricant. b.
  • Page 52 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4C. DRIVE SHAFT GENERAL 1. Disconnect control linkages and any cables that would prohibit pushing the drive shaft end of the The rear differential is driven by a universal joint type transmission downward about 4 inches. drive shaft connected between the transmission and 2.
  • Page 53 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4C. DRIVE SHAFT Figure 4C-2. Drive Shaft Removal and Installation — Vehicles with 4-Cylinder Gasoline Engines and Diesel Engines DISASSEMBLY (See Figure 4C-3) 1. Start one bearing in yoke ear and position center cross through yoke.
  • Page 54 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4C. DRIVE SHAFT Figure 4C-3. Drive Shaft Disassembly and Reassembly 4C-3...
  • Page 55 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4C. DRIVE SHAFT INSTALLATION (See Figures 4C-1 and 4C-2) 1. Make certain that the yokes of the drive shaft are correctly aligned with the yokes in the transmis- sion and differential. 2. Install the drive shaft yoke onto the differential input shaft.
  • Page 56 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4D. CLUTCH REMOVAL The clutch components can only be removed when the engine and transmission have been separated. See Figure 4D-1 for clutch arrangements. To gain access to the clutch components, either remove the engine as described in Section 3D or remove the transmission as described in Section 4H.
  • Page 57 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4D. CLUTCH Figure 4D-3. Clutch Repair 4. Remove clutch release lever from shaft/fork. With INSPECTION OF CLUTCH COMPONENTS clutch release bushing removal tool applied as 1. If the release bearing (Figure 4D-3) sticks, rattles shown in Figure 4D-4 tap its end to remove bush- or makes abnormal noise when turned by hand, ing.
  • Page 58 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4D. CLUTCH Figure 4D-4. Release Bushing Removal Figure 4D-6. Checking Backlash in Disc Serration 4. Refer to Figure 4D-5, check wear of facing by measuring depth of each rivet head depression, CLUTCH REASSEMBLY i.e.
  • Page 59 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4D. CLUTCH 3. After installing release shaft/fork bushings, caulk transmission case against bushings at two points. 4. Position the return spring (see Figure 4D-3) on the clutch release shaft/fork. 5. Install the clutch release shaft/fork in the bush- ings.
  • Page 60 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4E. GEAR SHIFT CABLES/CONNECTORS REPAIR (See Figures 4E-1 or 4E-2) Replace worn or damaged gear shift cables and con- nectors as shown in Figures 4E-1 or 4E-2. Adjust shift controls as described in Section 2C. Figure 4E-1.
  • Page 61 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4E. GEAR SHIFT CABLES/CONNECTORS Figure 4E-2. Gear Shift Cables/Connectors (4-Cylinder Gasoline or Diesel Engine) 4E-2...
  • Page 62 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4F. PRESSURE PLATE RING (DIESEL ONLY) REPAIR (See Figure 4F-1) If worn or damaged, replace the pressure plate ring as shown in Figure 4G-1. A pressure plate ring is used as an interface between the clutch disc and engine flywheel for diesel engine If necessary, repair the clutch as described in Section 4D.
  • Page 63 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) GENERAL 8. Attach a suitable hoist to the transmission. The transmission is a 4 speed manual shift type. The 9. Remove hardware that fastens the transmission shift pattern is a standard H pattern with reverse R to the engine.
  • Page 64 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) TRANSMISSION DISASSEMBLY GEAR SHIFT CASE (See Figure 4G-2) 1. Remove the mounting bolts, disengage the gear selector shaft from the gear shift lever in the transmission and lift the assembled gear shift case off the transmission case.
  • Page 65 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) Figure 4G-5. Gear and Shaft Arrangement 4G-3...
  • Page 66 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) COUNTERSHAFT 3. Remove the rubber plug and retaining ring from the countershaft (see Figure 4G-8). 1. Remove the two bolts securing the stop plate to the case. Remove the stop plate, reverse idle gear and shaft (see Figure 4G-6).
  • Page 67 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) Figure 4G-9. Input Shaft and Main Shaft — Steps 1 thru 5 4G-5...
  • Page 68 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) SHIFTER SHAFTS AND FORKS (See Figure 4G-10) are seated fully in the detents of respective shafts. If any of these interlock balls are out of the 1.
  • Page 69 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) 4. Move the low-speed fork shaft into the position for “second”. This will allow the spring pin to shift into the detent provided in the case. Using a spring remover tool, draw out the spring pin and pull out the fork shaft.
  • Page 70 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) Clean parts in a suitable non-flammable solvent. Check gear teeth for chips, see Figure 4G-13. Remove old sealant material being careful not to Parts with small chips shown in REPAIR column in damage seal surfaces.
  • Page 71 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) SPLINE TEETH 0.02 inch (0.5 mm) the ring and gear should be replaced. Check for broken or chipped spline teeth. Small chips may be blend-repaired in same manner as gear teeth. Inspect the external cone (of the gear) and internal cone (of the ring) for abnormal wear.
  • Page 72 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) the sleeve advances and slides into the ring, the ring them if their free lengths are less than 0.727 inch will be rotating nearly with the speed of the gear, so (18.45 mm).
  • Page 73 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) TRANSMISSION REASSEMBLY SHIFTER SHAFTS AND FORKS 1. See Figure 4G-20 for arrangement of shifter GENERAL shafts, forks and gear shift case. Normally, the entire transmission will not have been disassembled.
  • Page 74 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) 2. When feeding each shifter fork onto its shaft, be 4. The shifter fork shafts are to be installed sequen- sure to bring the boss (in which the hole for admit- tially.
  • Page 75 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) COUNTERSHAFT, MAIN SHAFT, INPUT SHAFT AND STOP PLATE 1. See Figure 4G-25 for general arrangement of the countershaft, main shaft, input shaft and stop plate. Figure 4G-25. Countershaft, Main Shaft, Input Shaft and Stop Plate 4G-13...
  • Page 76 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) 2. When assembling the two synchronizer hubs on main shaft, be sure to position the hub of each correctly as shown in Figure 4G-26. Figure 4G-28. Key and Slot Alignment 5.
  • Page 77 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) 2. When joining the two cases as shown in Figure 4G-32, be sure to guide each shifter fork into the groove of its synchronizer sleeve. After putting the upper case on the lower case, tighten the joint bolts uniformly and sequentially so as to equalize the joint pressure all around.
  • Page 78 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4G. TRANSMISSION (3-CYLINDER 660 GASOLINE ENGINE) TRANSMISSION INSTALLATION Following any clutch repair or any other procedure 7. Install and tighten all transmission-to-frame that involves removal of the transmission from the mounting hardware. vehicle the following steps should be taken.
  • Page 79 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) GENERAL 8. Disconnect the drive shaft at the transmission (see Section 4C). The transmission is a 4 speed manual shift type. The shift pattern is a standard H pattern with reverse R 9.
  • Page 80 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) TRANSMISSION DISASSEMBLY GEAR SHIFT CASE (See Figure 4H-2) 1. Remove the mounting bolts, disengage the gear selector shaft from the gear shift lever in the transmission and lift the assembled gear shift case off the transmission case.
  • Page 81 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) Figure 4H-5. Gear and Shaft Arrangement 4H-3...
  • Page 82 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) Figure 4H-6. Countershaft Disassembly COUNTERSHAFT 1. Use a bearing puller to pull the rear bearing (see Figure 4H-6) off the countershaft. 2. Remove the rear retaining ring and PTO drive gear. Figure 4H-8.
  • Page 83 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) Figure 4H-9. Input Shaft and Main Shaft 4H-5...
  • Page 84 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) 6. Remove bearing thrust washer and reverse gear 8. Remove low gear, needle bearing and synchro- bushing on main shaft by using hydraulic press as nizer ring from main shaft as shown in Figure shown in Figure 4H-10.
  • Page 85 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) 5. Drive yoke pin out of high speed gear shift fork as in Step 3, on previous page, and pull out fork shaft and fork. When removing yoke pin, be sure not to drive it out so far as to contact case, or it will cause damage to case.
  • Page 86 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) INSPECTION AND REPAIR GEAR TEETH Prior to cleaning, check bottom of transmission case for metal particles. If metal is detected, inspect parts closely for damage and/or wear. Clean parts in a suitable non-flammable solvent.
  • Page 87 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) Check gear tooth contact patterns (see Figure 4H-15). Check clutch teeth for rounding, see Figure 4H-17. Check gear teeth for chips, see Figure 4H-16. Face rounding will cause the clutch to jump out.
  • Page 88 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) SPLINE TEETH than 0.02 inch (0.5 mm) the ring and gear should be replaced. Check for broken or chipped spline teeth. Small chips may be blend-repaired in same manner as gear teeth. Inspect the external cone (of the gear) and internal cone (of the ring) for abnormal wear.
  • Page 89 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) the sleeve advances and slides into the ring, the ring replace them if their free lengths are less than 0.826 will be rotating nearly with the speed of the gear, so inch (21.0 mm).
  • Page 90 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) TRANSMISSION REASSEMBLY SHIFTER SHAFTS AND FORKS 1. See Figure 4H-23 for arrangement of shifter GENERAL shafts, forks and gear shift case. Normally, the entire transmission will not have been Note that three shift shafts individually have a disassembled.
  • Page 91 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) 4. Insert high speed gear shift shaft into upper case. Push down high speed gear shift shaft locating ball to pass shaft over it and keep inserting shaft until locating ball fits in center slot of 3 continuous slots in shaft.
  • Page 92 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) MAIN SHAFT AND INPUT SHAFT NOTE 1. See Figure 4H-26 for general arrangement of the Be careful to install each washer, gear, synchro- countershaft, main shaft and input shaft. nizer hub and sleeve in the proper direction.
  • Page 93 DRIVE TRAIN RETURN TO TABLE OF CONTENTS SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) 2. Install 2nd gear bearing, 2nd gear, synchronizer 5. Press-fit center bearing with bearing installation ring and low speed synchronizer hub/sleeve onto tool as shown in Figure 4H-29, using care for its main shaft, using care for installing direction of installing direction.
  • Page 94 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) 8. Install reverse gear bearing, reverse gear and COUNTERSHAFT AND REVERSE IDLE GEAR reverse drive hub/sleeve. For proper direction, 1. Drive countershaft front bearing into lower case. make sure to install hub so that the side whose Then, using plastic hammer, drive countershaft inside boss is smaller in diameter and longer is at...
  • Page 95 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) Figure 4H-33. Countershaft Reassembly 4. Install idle gear and washer onto reverse gear shaft and pin into it as shown in Figure 4H-34. Install above as assembled into lower case with pin and washer tongue aligned as shown in Figure 4H-34.
  • Page 96 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) JOINING UPPER AND LOWER CASES 2. Install the input shaft bearing retainer in the trans- (See Figure 4H-35) mission case and torque the engine mounting bolts to 13.5 to 20.0 ft-lbs.
  • Page 97 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) EXTENSION CASE (LATER SERIAL NUMBERS 1. If necessary, replace worn or damaged extension AND RETROFIT VEHICLES) case components as shown in Figure 4H-37. NOTE 2.
  • Page 98 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4H. TRANSMISSION (4-CYLINDER 970 GASOLINE OR DIESEL ENGINES) EXTENSION CASE (EARLY SERIAL NUMBERS, NOT RETROFIT) 1. Install the extension case oil seal (see Figure 4H-38). 2. Install the extension case on the transmission case and torque bolts to 13.5 to 20.0 ft-lbs.

  • Page 99: Rear Axle

    RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE GENERAL BRAKES AND WHEEL HUBS (See Figure 4I-2) The rear axle assembly consists of brakes, wheel hubs, axle shafts, axle housings (tubes) and a differ- REMOVAL ential/2-speed auxiliary transmission. 1.
  • Page 100 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE Figure 4I-2. Brake and Wheel Hub Repair AXLES AND AXLE HOUSINGS 6. Install the wheel hub castellated nut on the axle shaft (see Figure 4I-4) to protect the shaft threads REMOVAL and pull the axle shaft to remove the wheel bear- ing, collar and axle shaft.
  • Page 101 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE 9. Clean and inspect the axle shaft, wheel bearing, 2. Pack the wheel bearing with clean grease (see collar and wheel hub for damage or wear. Section 11). Reassemble the wheel bearing and Replace damaged or worn parts.
  • Page 102 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE Figure 4I-4. Axles and Axle Housings 4I-4...
  • Page 103 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE DIFFERENTIAL ASSEMBLY REMOVAL 1. Remove the brakes, wheel hubs, axles and axle 6. Disconnect the drive shaft yoke nut and special tubes as described in the preceding paragraphs. washer from the differential input shaft as shown in Figures 4C-1 and 4C-2.
  • Page 104 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE DIFFERENTIAL FRONT COVER 4. Use a curved bar to pry under the shift cable bracket and against the input shaft to “bump” the DISASSEMBLY input shaft bearing from the shaft as shown in Figure 4I-7.
  • Page 105 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE REASSEMBLY to a final torque of 26 to 30 ft-lbs. (35 to 40 N.m). The lower 3/8-16 screw is used to support the 1. Apply Loctite 290 adhesive around the O.D. of a right side brake fluid line.
  • Page 106 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE 4. Remove the shift shaft, lockwasher and shift fork. 2-SPEED AUXILIARY TRANSMISSION 5. Remove the two seals from the cover. Thoroughly DISASSEMBLY clean the cover and housing mating surface of all 1.
  • Page 107 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE Figure 4I-11. Auxiliary Transmission Disassembly 4I-9...
  • Page 108 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE NOTE 22. To replace the input shaft intermediate roller bear- ing, remove the outer and inner retaining rings Bearings are a slip fit in the bores of the housing. and use a split, knife-edge bearing remover and 14.
  • Page 109 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE REASSEMBLY (See Figure 4I-13) 18. Lubricate the jackshaft. Install the shaft through the bore of the housing only far enough to support NOTE one thrust washer. Retain the thrust washer on Lubricants to be added during reassembly are the shaft next to the housing with grease.
  • Page 110 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE Figure 4I-13. Auxiliary Transmission Reassembly 4I-12...
  • Page 111 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE 29. Install cover screws, flat washers and gear ratio 3. Install and align the auxiliary transmission shift tag. Torque screws alternately and evenly to 14 to cable on the mounting bracket. Install and tighten 18 ft-lbs.
  • Page 112 RETURN TO TABLE OF CONTENTS DRIVE TRAIN SECTION 4I. REAR AXLE Figure 4I-14. Differential and Axle Assembly Installation 4I-14...
  • Page 113 RETURN TO MAIN TABLE OF CONTENTS SECTION 5 BRAKE SYSTEM 5A. Repair and Service Tools and Materials ......... . 5A-1 5B.
  • Page 114 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Brake service tools. Brake shoe adjusting gauge. Cleaning materials: Stoddard solvent or equivalent. Lubricants: Refer to Section 11. Other service items: Brake repair parts.
  • Page 115 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Parking brake does not a. Brake is not properly adjusted. a. Adjust brake (Section 2C). hold truck in position. b. Worn brake linings. b. Replace lining (Section 5D). c.
  • Page 116 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5C. PARKING BRAKES PARKING BRAKE REPAIR The parking brake system consists of a control lever Parking brake control repairs consist of removal and and cables that mechanically control spring activated replacement of components shown in Figures 5C-1 and 5C-2.
  • Page 117 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5C. PARKING BRAKES PARKING BRAKE ADJUSTMENT (See Figure 5C-2) 1. Release the parking brake lever (lever fully down). 2. Tighten the adjustment nut (1 or 2 turns) and apply the brake lever. Continue tightening the adjustment nut until the lever is at approximately 45°...
  • Page 118 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5D. SERVICE BRAKES SERVICE BRAKES (See Figure 5D-1) BLEEDING BRAKES 1. When bleeding the brake system, bleed the left GENERAL rear brake first, then the right rear, then the right 1. This vehicle is equipped with four hydraulic front and finally the left front.
  • Page 119 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5D. SERVICE BRAKES BRAKE DISASSEMBLY (See Figure 5D-2) 1. Remove the wheels and brake drums (see 3. Slightly spread shoes at top, lift shoes, springs Section 4I for rear brakes and Section 6C for front and adjuster off backing plate.
  • Page 120 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5D. SERVICE BRAKES SERVICING exceed maximum inside diameter specification. This dimension is on each drum. Remove all dust from backing plate and parts. Inspect all wheel cylinder parts, discard and replace Inspect shoes for excessive lining wear or damage. If rubber boots if disassembled.
  • Page 121 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5D. SERVICE BRAKES TEP 6 TEP 8 Install the adjuster lever. Install upper retracting spring to leading shoe slot. Stretch spring to install to trail- STEP 7 ing shoe. If adjuster lever does not contact Install shoe hold down springs and pins.
  • Page 122 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5D. SERVICE BRAKES WHEEL CYLINDER (See Figure 5D-5) • If wet, rebuild. Continue with Step 2. NOTE • If dry, do not rebuild. Wheel cylinders should not be removed and/or NOTE disassembled unless they are leaking. Brake shoes must first be removed before pro- 1.
  • Page 123 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5E. MASTER CYLINDER REPAIR The master cylinder can not be repaired if (after 2. Disconnect the brake pedal linkage and remove checking brake lines and linkages, bleeding the sys- master cylinder mounting hardware as shown in tem, replenishing fluid in the brake fluid reservoir, and Figure 5E-1.
  • Page 124 RETURN TO TABLE OF CONTENTS BRAKE SYSTEM SECTION 5E. MASTER CYLINDER Figure 5E-2. Master Cylinder Connections 5E-2...

  • Page 125: Steering

    RETURN TO MAIN TABLE OF CONTENTS SECTION 6 STEERING 6A. Repair and Service Tools and Materials ......... . 6A-1 6B.
  • Page 126 RETURN TO TABLE OF CONTENTS STEERING SECTION 6A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Steering gear repair tools (available from AC Delco dealers). Pulley puller tool. Cleaning materials: Stoddard solvent or equivalent. Lubricants: Refer to Section 11. Other service items: Seal and Repair Kits (available from Textron dealers).
  • Page 127 RETURN TO TABLE OF CONTENTS STEERING SECTION 6B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. No steering. a. Steering gear excessive internal a. Test (Section 8). leakage or damage. Repair (Section 6D). b. Faulty steering pump. b. Repair (Section 6E). c.
  • Page 128 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM GENERAL (See Figure 6C-1) The steering gear is hydraulically assisted by a steer- ing pump to provide “power steering” similar to most The steering system utilizes a steering wheel/steering passenger cars. The steering pump has an integral shaft mechanical linkage to a steering gear assembly fluid reservoir.
  • Page 129 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM The steering gear assembly has an internal control valve which directs hydraulic fluid to either side of a rack piston. The rack piston converts hydraulic power into mechanical force. This force is transmitted through a pitman shaft to the pitman arm to the steer- ing linkage.
  • Page 130 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM Figure 6C-3. Tie Rods and Steering Knuckles STEERING COLUMN REPAIR NOTE (See Figure 6C-4) Whenever the pitman arm is removed, clean and inspect steering gear housing for pitting and If repairs to the steering wheel or shaft are required, rough spots and pitman shaft for burrs.
  • Page 131 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM Figure 6C-4. Steering Column 6C-4...
  • Page 132 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM REMOVING AND INSTALLING STEERING 5. Disassemble, inspect, repair and reassemble the steering gear assembly as described in Section 6D. GEAR ASSEMBLY (See Figure 6C-4) 6. Adjust the steering gear assembly as described in If tests (Section 8) and/or problem evaluation (Section Section 6D.
  • Page 133 RETURN TO TABLE OF CONTENTS STEERING SECTION 6C. STEERING SYSTEM REMOVING AND INSTALLING 5. Raise front end of vehicle so that wheels are off the ground. STEERING PUMP ASSEMBLY 6. Turn the wheels several times (off ground) right 1. Disconnect hoses at the steering pump (see and left, lightly contacting the wheel stops.
  • Page 134 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR GENERAL NOTE The steering gear assembly will rarely require com- Prior to removing and/or disassembling the plete disassembly to repair leaks or replace defective steering gear, carefully check Section 6B to determine causes of problems other than the components.
  • Page 135 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR DISASSEMBLY/REASSEMBLY HOUSING END PLUG O-RING (See Figure 6D-3) NOTE 1. Remove the retaining ring, end plug and O-ring. • The following repair procedures may be accomplished with the steering gear installed 2.
  • Page 136 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR 4. Remove the ball retainer, tool, clamp screws, clamp, ball retainer and balls from the rack piston. 5. Remove rack piston ring and O-ring. Replace O-ring and piston ring. 6. If no further disassembly is required, proceed with Steps 7 thru 14.
  • Page 137 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR Figure 6D-5. Rack Piston 6D-4...
  • Page 138 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR ADJUSTER PLUG (See Figure 6D-6) 3. Assemble new O-rings, seals, needle bearing and thrust bearing retainer to adjuster plug. If neces- 1. Remove lock nut and use spanner wrench to turn sary, install new thrust bearings and bearing out adjuster plug assembly.
  • Page 139 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR VALVE, THRUST BEARINGS AND WORM GEAR 4. Disengage the pin on the stub shaft from the hole (See Figure 6D-7) in the valve spool and disassemble the valve assembly as shown in Figure 6D-7. NOTE 5.
  • Page 140 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR PITMAN SHAFT BEARING ADJUSTMENTS NOTE THRUST BEARING PRELOAD (See Figure 6D-9) This procedure requires removal of the steering 1. Before adjusting bearing preload, rotate the stub gear as described in Section 6C. shaft back and forth to drain all oil from gear.
  • Page 141 RETURN TO TABLE OF CONTENTS STEERING SECTION 6D. STEERING GEAR 5. Turn the adjuster plug counterclockwise until the 3. Back off the preload adjuster plug until it stops, mark on the adjuster plug aligns with the second then turn the plug in one full turn. mark on the housing (made in Step 4 above).
  • Page 142 RETURN TO TABLE OF CONTENTS STEERING SECTION 6E. STEERING PUMP STEERING PUMP REMOVAL REPAIR (See Figure 6E-2) AND INSTALLATION Repair of the steering pump is limited to removal and replacement of the flow control valve, O-rings and 1. Disconnect hoses at the steering pump. Plug and drive shaft seal.
  • Page 143 RETURN TO TABLE OF CONTENTS STEERING SECTION 6E. STEERING PUMP Figure 6E-2. Steering Pump Repair 6E-2...
  • Page 144 RETURN TO TABLE OF CONTENTS STEERING SECTION 6F. WHEEL ALIGNMENT Before aligning, check the tire pressure. The front c. If more than 2 shims are added to front bolt, tires should be inflated to 20 psi (138 kPa). recheck camber angle (see Step 1 at left). Check wheel lug nut for proper torque, torque to 70 to 3.
  • Page 145 RETURN TO MAIN TABLE OF CONTENTS SECTION 7 WHEELS AND TIRES 7A. Repair and Service Tools and Materials ......... . 7A-1 7B.
  • Page 146 RETURN TO TABLE OF CONTENTS WHEELS & TIRES SECTION 7A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard solvent or equivalent. Lubricants: Refer to Section 11. Other service items: Commercially available tire sealant. Tire pressure gauge.
  • Page 147 RETURN TO TABLE OF CONTENTS WHEELS & TIRES SECTION 7B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Truck rides hard. a. Over inflated tires. a. Reduce tire pressure to: Front 20 psi (138 kPa) Rear 15 psi (110 kPa) 2. Truck wanders. a.
  • Page 148 RETURN TO TABLE OF CONTENTS WHEELS & TIRES SECTION 7C. TIRE SERVICE GENERAL The tires are subject to damage from sharp objects. If NOTE large punctures or tears occur, it is advisable to take Never use grease or oil on the rim when mount- the tire (installed on the wheel) to a qualified tire ing a tire.
  • Page 149 RETURN TO MAIN TABLE OF CONTENTS SECTION 8 HYDRAULICS 8A. Repair and Service Tools and Materials ......... . 8A-1 8B.
  • Page 150 RETURN TO MAIN TABLE OF CONTENTS 8J. Instrument Test ..............8J-1 General .
  • Page 151 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools, including torque wrench. Tachometer. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: See Section 11. Other service items: Seal and Repair Kits (available Textron Turf Care and Specialty Product dealers).
  • Page 152 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY BOX CIRCUIT 1. Box does not raise. a. Control lever not moving valve a. Check movement of control. spool. b. Lift cylinder leaking. b. Test cylinder (Section 8J). Repair (Section 8G).
  • Page 153 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS GENERAL • Hydraulic hose and tube lines should be inspected daily to check for loose connections, kinks, worn or NOTE cut hoses, etc. Be sure tubes and hoses do not con- Component location illustrations and hydraulic tact other frame parts which could cause abrasive system diagrams are located at the end of this...
  • Page 154 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS 2. When installing hoses, place fittings at angles to avoid contact with fixed parts when turning. Make sure hoses are assembled to proper “A” and “B” ports on components. O-RING BOSS FITTINGS On hoses with O-ring fittings, make sure O-rings are clean and hose fittings are properly seated before tightening.
  • Page 155 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS O-RING BOSS TORQUE RECOMMENDATIONS REPLACEMENT O-RING FOR ORS (FACE SEAL) FITTINGS ORS (Face Seal) ORS (Face Seal) Jacobsen Dash Thread Tube Torque Tube Size O-Ring Size Part No. Size Size O.D.
  • Page 156 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8D. STANDARD HYDRAULIC PUMP GENERAL DISASSEMBLY (See Figure 8D-1) The standard hydraulic pump is a single section pump 1. Clean exterior of pump with suitable solvent used when the vehicle does not have a hydraulic PTO before removing bolts.
  • Page 157 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8D. STANDARD HYDRAULIC PUMP 3. After removing bolts, disassemble pump as REASSEMBLY (See Figure 8D-1) shown in Figure 8D-1. Before removing gears, 1. Apply a coat of clean hydraulic oil to all parts to mark a line across meshing teeth to ensure that ease assembly.
  • Page 158 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8E. HYDRAULIC PUMP (USED WITH HYDRAULIC PTO) GENERAL DISASSEMBLY (See Figure 8E-1) This two-section hydraulic pump is used when the 1. Clean exterior of pump with suitable solvent vehicle is equipped with a hydraulic PTO accessory. before removing bolts.
  • Page 159 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8E. HYDRAULIC PUMP (USED WITH HYDRAULIC PTO) 3. After removing bolts, disassemble pump as REASSEMBLY (See Figure 8E-1) shown in Figure 8E-1. Before removing gears, 1. Apply a coat of clean hydraulic oil to all parts to mark a line across meshing teeth to ensure that ease assembly.
  • Page 160 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8F. HYDRAULIC MOTOR (USED WITH HYDRAULIC PTO) GENERAL DISASSEMBLY (See Figure 8F-1) The hydraulic motor is used to drive the hydraulic 1. Clean exterior of motor with suitable solvent PTO accessory. before removing bolts. NOTE 2.
  • Page 161 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8F. HYDRAULIC MOTOR (USED WITH HYDRAULIC PTO) 3. After removing bolts, disassemble motor as REASSEMBLY (See Figure 8F-1) shown in Figure 8F-1. Before removing gears, 1. Apply a coat of clean hydraulic oil to all parts to mark a line across meshing teeth to ensure that ease assembly.
  • Page 162 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8G. BOX CYLINDER DISASSEMBLY INSPECTION 1. Clean and air dry the exterior of the cylinder. 1. Inspect all parts for excessive wear, cracks and broken parts. 2. Disconnect hydraulic lines from cylinder. Plug and cap lines and ports.
  • Page 163 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8G. BOX CYLINDER Figure 8G-2. Seal Kit Installation 8G-2...
  • Page 164 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8H. CONTROL VALVE REPAIR (See Figure 8H-1) 1. Tag and remove hydraulic lines from valve. Cap 6. Reassemble as shown in Figure 8H-1. lines. 7. Install valve on mounting bracket and attach con- 2.
  • Page 165 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8I. SELECTOR VALVE REPAIR (See Figure 8I-1) 1. Tag and remove hydraulic lines from valve cap 4. Replace O-rings. lines. 5. Reassemble as shown in Figure 8I-1. 2. Remove valve from mounting bracket. 6.
  • Page 166 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST GENERAL The tests in this section are provided as a means of It is important to follow the instructions accurately and isolating a problem in the hydraulic system. completely. Make sure to plug lines and cap ports when so instructed.
  • Page 167 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST AS A SAFETY REMINDER 5. Connect the flowmeter “OUT” line to the adapter. • 6. Completely open the flowmeter load valve. Follow the procedures one step at a time. • 7.
  • Page 168 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-2. Standard Hydraulic System Pump Flow Test 8J-3...
  • Page 169 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST SELECTOR VALVE TEST (See Figure 8J-3) (See Figure 8J-4) NOTE 21. At the connection manifold, connect line 8 to port 7. A pump test should be performed before pro- 22. At selector valve remove line from bottom port. ceeding with a selector valve test.
  • Page 170 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-3. Selector Valve Test — Steps 13 to 20 8J-5...
  • Page 171 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-4. Selector Valve Test — Steps 21 to 29 8J-6...
  • Page 172 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST LIFT VALVE TEST (See Figure 8J-5) (See Figure 8J-6) NOTE a. Remove the acorn nut from side of valve. A pump flow and selector valve test should be b. Turn screw 1/8 turn, clockwise (CW) increases performed before proceeding with a lift valve pressure or counterclockwise (CCW) to test.
  • Page 173 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-5. Lift Valve Test — Steps 30 to 36 8J-8...
  • Page 174 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-6. Lift Valve Test — Steps 37 to 41 8J-9...
  • Page 175 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST CYLINDER TEST (See Figure 8J-7) 48. Open tester load valve. NOTE 49. Pull lift valve lever rearward into the lift position and hold. A pump, selector valve and lift valve test should be performed before proceeding with a lift valve test.
  • Page 176 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-7 Cylinder Test 8J-11...
  • Page 177 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST OPTIONAL HIGH/LOW SYSTEM BOTTOM SELECTOR VALVE TEST (See Figure 8J-9) PUMP FLOW TEST SECTION 1 (See Figure 8J-8) NOTE 1. At the pump, remove the outlet line from pump A pump test should be performed before pro- section 1.
  • Page 178 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-8. Pump Section 1 Flow Test 8J-13...
  • Page 179 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-9. Bottom Selector Valve Test 8J-14...
  • Page 180 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST LIFT VALVE TEST (See Figure 8J-10) a. Remove the acorn nut from side of valve. NOTE b. Turn screw 1/8 turn, clockwise (CW) increases pressure or counterclockwise (CCW) to A pump flow and selector valve test should be decrease pressure.
  • Page 181 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-10. Lift Valve Test 8J-16...
  • Page 182 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST CYLINDER TEST (See Figure 8J-11) NOTE 39. Open tester load valve. A pump, selector valve and lift valve test should 40. Pull lift valve lever rearward into the lift position be performed before proceeding with a lift valve and hold.
  • Page 183 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-11. Cylinder Test 8J-18...
  • Page 184 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST PUMP FLOW TEST SECTION 2 (See Figure 8J-12) b. Turn screw 1/8 turn, clockwise (CW) increases pressure or counterclockwise (CCW) to 1. At the pump, remove the outlet line from pump decrease pressure.
  • Page 185 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-12. Pump Section 2 Flow Test 8J-20...
  • Page 186 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8J. INSTRUMENT TEST Figure 8J-13. Bottom Selector Test 8J-21...
  • Page 187 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS HYDRAULIC GRAPHIC SYMBOLS These are hydraulic graphic symbols commonly used in Textron Golf, Turf & Specialty Products diagrams and schematics. Valve Envelope (used to show number of available spool positions) Tank or Reservoir Hydraulic Line...
  • Page 188 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS Solenoid Operated Valve Actuator Lever Operated Valve Actuator Restrictor (valve or orifice used to reduce flow in a line) Pedal Operated Valve Actuator Variable or Adjustable Restrictor (flow is controlled by pressure sensitive restrictors) Flowmeter...
  • Page 189 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K-3...
  • Page 190 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K-4...
  • Page 191 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K-5...
  • Page 192 RETURN TO TABLE OF CONTENTS HYDRAULICS SECTION 8K. HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K-6...

  • Page 193: Chassis

    RETURN TO MAIN TABLE OF CONTENTS SECTION 9 CHASSIS 9A. Repair and Service Tools and Materials ......... 9A-1 9B.
  • Page 194 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools including bearing pullers. Cleaning and Stoddard or equivalent solvent. refinishing materials: Detergent and water. Antiseize. Lubricants: Refer to Section 11. 9A-1...
  • Page 195 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Box lift/lower functions a. Linkage is worn. a. Replace linkage (Section 2). do not occur when lever b. Hydraulic lines are kinked. b. Replace lines (Section 8). is actuated.
  • Page 196 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9C. FUEL TANK GENERAL The fuel tank is a single piece tank which should 2. Remove attaching hardware, fuel tank and tank require no servicing unless punctured or otherwise mounting plate. accidentally damaged. The fuel tank should be 3.
  • Page 197 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9D. HYDRAULIC TANK GENERAL NOTE The hydraulic tank requires little or no service other The cap on the hydraulic tank is a vented cap. than removing and cleaning outlet strainer and adding If water, air or contamination is indicated, locate the hydraulic oil when indicated by checking the dipstick.
  • Page 198 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9E. FRONT SUSPENSION REPAIR (See Section 9E-1) Remove and replace damaged shocks and other After front suspension repairs, align the front wheels parts as shown in Figure 9E-1. as described in Section 6F. Figure 9E-1.
  • Page 199 RETURN TO TABLE OF CONTENTS CHASSIS SECTION 9F. REAR SUSPENSION REPAIR (See Section 9F-1) Remove and replace damaged shocks, leaf springs The left and right sides of the rear suspension are and other parts as shown in Figure 9F-1. symmetrical. The right side is shown in Figure 9F-1. Figure 9F-1.

  • Page 200: Electrical System

    RETURN TO MAIN TABLE OF CONTENTS SECTION 10 ELECTRICAL SYSTEM 10A. Repair and Service Tools and Materials ......... 10A-1 10B.
  • Page 201 RETURN TO MAIN TABLE OF CONTENTS 10L. Relays ............... . . 10L-1 Relay Test .
  • Page 202 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Multimeter. Jumper wires. 60 amp ammeter. Cleaning materials: Baking soda and water. Other service items: Electrical insulation compound P/N 365422. 10A-1...
  • Page 203 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Engine will not turn over a. Battery dead. a. Charge or replace (Section 10D). when ignition switch is b. Faulty starter solenoid. b. Test (Section 10G). turned on.
  • Page 204 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS GENERAL NOTE Repair of the electrical system, for the most part, is Before performing any component or wiring test, limited to the replacement of defective components or check for corrosion and loose or missing con- nections.
  • Page 205 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS 3. Read the Ω (ohms) on the multimeter. RESISTANCE TEST (See Figure 10C-2) • Contacts of a switch or a wire should have less than 0.5 Ω (ohms) reading. 1.
  • Page 206 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10D. BATTERY GENERAL tive battery terminal. Connect the negative (–) connector of the charger to the negative battery For normal service, use a battery rated 12V, 420 cold terminal. cranking amps at 0°F (–18°C) Group BCI24. WARNING WARNING To avoid possible injury, stand away from bat-...
  • Page 207 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10D. BATTERY TESTING (See Figure 10D-1) 3. Crank the engine — if battery voltage falls below 9 volts while cranking, the battery is run-down or Test battery voltage as follows: faulty. Charge and perform test again. 1.
  • Page 208 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM — 3-CYLINDER 660 GASOLINE AND DIESEL ENGINES GENERAL 2. Set multimeter to 20 VDC range. Connect POS (+) test lead to terminal B and NEG (–) test lead The charging system for 3-cylinder (Suzuki 660) to ground.
  • Page 209 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM — 3-CYLINDER 660 GASOLINE AND DIESEL ENGINES 5. Stop engine and replace battery with a known VOLTAGE TEST (See Figure 10E-1) good battery. Reconnect multimeter test leads as 1. Set multimeter to 20 VDC range. shown in Figure 10E-1.
  • Page 210 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10F. CHARGING SYSTEM — 4-CYLINDER 970 GASOLINE ENGINE GENERAL 1. Remove the RED wire from terminal B of the alternator. The charging system consists of a 40 amp alternator 2. Connect a 60 amp ammeter and multimeter as with a built-in regulator/rectifier.
  • Page 211 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10F. CHARGING SYSTEM — 4-CYLINDER 970 GASOLINE ENGINE 6. Stop engine and replace battery with a known 3. Connect NEG (–) test lead of the multimeter to a good battery. good ground. 7.
  • Page 212 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10F. CHARGING SYSTEM — 4-CYLINDER 970 GASOLINE ENGINE REGULATOR TEST (See Figure 10F-3) • Should have continuity in one direction ONLY. • 1. With the RED lead connected to terminal B of If NO continuity or continuity in both directions, the alternator, remove cable plug from side of regulator may be faulty.
  • Page 213 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10G. STARTER GENERAL 4. Crank engine, read/record voltage. • The repair of the starter is covered in the engine man- Voltage should not drop more than 0.58 volts ufacturer’s service manual which can be obtained from measured battery voltage.
  • Page 214 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10G. STARTER POWER 200 1000 750 200 200m 200m 200µ 200M 200m Ω 200m 200µ V - Ω 500V 1000V 750V 10A MAX POWER 1000 750 200 200m 200m 200µ 200M 200m Ω...
  • Page 215 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10G. STARTER STARTER SOLENOID TEST moves outward. If gear does not move, replace starter solenoid. (See Figure 10G-2) 5. While connected as in Step 4, disconnect nega- 1. Disconnect battery ground cable. tive lead from terminal M.
  • Page 216 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10G. STARTER NO-LOAD TEST 2. Connect the battery and an ammeter to the starter as shown in Figure 10G-3. 1. After conducting solenoid test on previous page 3. Check that starter rotates smoothly and that the reconnect the ignition coil lead to terminal M (for diesel engines start with Step 2).
  • Page 217 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES IGNITION SWITCH TEST c. Move the POS (+) test lead to terminal I. There should be a reading of 0 to 0.5 Ω (See Figure 10H-1) • ohms) on the multimeter. 1.
  • Page 218 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES STEP 4a Contacts Open (No Continuity) Position Continuity None NOTE G terminal not used. STEPS 4b & 4c Contact 0 to 0.5 Ω (ohms) Position Continuity A, B and I STEPS 4d &...
  • Page 219 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES HORN SWITCH TEST • There should be no reading on the multimeter. (See Figure 10H-2) 4. Push switch down to the ON position. See Figure 10H-2 and test switch as follows: There should be a reading of 0 to 0.5 Ω...
  • Page 220 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES LIGHT SWITCH TEST (See Figure 10H-3) 5. With switch in BRIGHT position 3, test as follows: a. Connect one multimeter test lead to terminal 1 1. Mark and disconnect switch connectors. and the other lead to terminal 4.
  • Page 221 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES BACKUP LIGHT/ALARM SWITCH TEST 3. Connect leads to switch as shown. (See Figure 10H-4) • There should be no continuity through the switch. The backup switch is normally open (NO). When the 4.
  • Page 222 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES COOLING FAN SWITCH TEST 5. Immerse switch into oil. Using a suitable ther- mometer to monitor oil temperature, slowly heat (See Figure 10H-5) oil. This temperature switch is a normally OPEN (NO) •...
  • Page 223 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES CLUTCH INTERLOCK AND BRAKE SWITCH TEST (See Figure 10H-6) 1. Disconnect ground cable at battery. 2. Identify (label) and disconnect electrical leads at switch. Ω (ohms) scale. 3. Set the multimeter to 200 4.
  • Page 224 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10H. SWITCHES 5. Depress switch lever. • There should be no reading at multimeter (no continuity). 6. Move test lead from NC to NO. • There should be no reading on the multimeter (no continuity).
  • Page 225 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10I. FUSES FUSE TEST See Figure 10I-1 and test fuse as follows: 1. Visually inspect and replace a blown fuse. 2. If fuse is not blown, check fuse as follows: Ω (ohms) scale. a.
  • Page 226 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10J. SENDERS AND ALARMS ENGINE OIL PRESSURE SWITCH TEST Remove WT wire from switch terminal. (See Figure 10J-1) • Light goes OFF, proceed with switch test, Step 1. The engine oil pressure switch is a normally CLOSED •...
  • Page 227 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10J. SENDERS AND ALARMS ENGINE COOLING WATER FIELD TEST TEMPERATURE SENDER TEST 1. Remove DK GRN wire from sender and ground. (See Figure 10J-2) • If gauge jumps to its highest reading sender is faulty.
  • Page 228 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10J. SENDERS AND ALARMS FUEL LEVEL SENDER TEST 3. With the float in: (See Figure 10J-3) Lowest Position (tank empty) .... 0.205 ohms Highest Position (tank full)....0.027 ohms 1. With the sender removed from the tank, connect one multimeter lead to the center terminal and the •...
  • Page 229 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10K. SOLENOIDS STARTER SOLENOID TEST 3. Connect multimeter test leads to terminals 1 and 2. Multimeter reading should be 0 to 0.5 Ω (ohms). (See Figure 10K-1) • 1. Connect the battery to terminals S and I. 4.
  • Page 230 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10L. RELAYS RELAY TEST (See Figure 10L-1) See Figure 10L-1 and test relay as follows: 5. Connect 12V across terminals 85 and 86. There should be an audible “click”. Ω (ohms). 1. Set multimeter to 200 6.
  • Page 231 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10M. ELECTRICAL FUEL PUMP (DIESEL) FUEL PUMP TEST (DIESEL) 5. Turn the ignition switch to the ON position. (If so equipped, PTO handle must be pushed down.) (See Figure 10M-1) • Multimeter should read battery voltage. 1.
  • Page 232 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10N. GLOW PLUGS GLOW PLUG TEST (DIESEL ONLY) 4. Connect one multimeter test lead to glow plug ter- minal and the other to housing. (See Figure 10N-1) • The multimeter reading should be approximate- Test a suspected faulty glow plug as follows: ly 1.6 ±...
  • Page 233 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS Figure 10O-1. Electrical Component Locations 10O-1...
  • Page 234 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS ELECTRICAL GRAPHIC SYMBOLS These are electrical graphic symbols commonly used in Textron Golf, Turf & Specialty Products diagrams and schematics. Switch (SPST)* Single Pole, Single Throw (shown in normally open Battery (NO) position)
  • Page 235 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS Diode Time Delay Relay Light Emitting Diode (LED) (opening delay) (see also below) Light Emitting Diode (LED) (alternative symbol) Motor with Solenoid Resistor or Glow Plug Adjustable Resistor Light (see also below) Potentiometer (POT) (a variable...
  • Page 236 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS TURN SIGNAL SWITCH TAILLIGHT ADAPTER LEFT INDUSTRIAL TAILLIGHT FLASHER BL/B LEFT TURN SIGNAL GY/B BL/B BL/B OR/B LEFT HEADLIGHT RIGHT INDUSTRIAL TAILLIGHT DISTRIBUTOR OR/B ALTERNATOR COIL W/BL BL/B...
  • Page 237 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS HEADLIGHT SWITCH IGNITION SWITCH HIGH HIGH HIGH BEAM BEAM BEAM BEAM BEAM BEAM ACC IGN ACC IGN ACC IGN ACC IGN DASH DASH DASH OFF" START"...
  • Page 238 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS TURN SIGNAL SWITCH TAILLIGHT ADAPTER LEFT INDUSTRIAL TAIL LIGHT FLASHER BL/B LEFT TURN SIGNAL GY/B BL/B BL/B OR/B LEFT HEADLIGHT RIGHT INDUSTRIAL TAIL LIGHT ALTERNATOR DISTRIBUTOR OR/B COIL...
  • Page 239 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS HEADLIGHT SWITCH IGNITION SWITCH HIGH HIGH HIGH BEAM BEAM BEAM BEAM BEAM BEAM ACC IGN ACC IGN ACC IGN ACC IGN DASH DASH DASH OFF" START"...
  • Page 240 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS TURN SIGNAL SWITCH TAILLIGHT ADAPTER LEFT INDUSTRIAL TAIL LIGHT FLASHER BL/B LEFT TURN SIGNAL GY/B BL/B BL/B OR/B LEFT HEADLIGHT RIGHT INDUSTRIAL TAIL LIGHT OR/B ALTERNATOR W/BL BL/B...
  • Page 241 RETURN TO TABLE OF CONTENTS ELECTRICAL SYSTEM SECTION 10O. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS HEADLIGHT SWITCH IGNITION SWITCH HIGH HIGH HIGH BEAM BEAM BEAM BEAM BEAM BEAM ACC IGN ACC IGN ACC IGN ACC IGN DASH DASH DASH OFF" START"...
  • Page 242 RETURN TO MAIN TABLE OF CONTENTS SECTION 11 PREVENTIVE MAINTENANCE 11A. General ............... 11A-1 Preventive Maintenance .

  • Page 243: Preventive Maintenance

    RETURN TO TABLE OF CONTENTS PREVENTIVE MAINTENANCE SECTION 11A. GENERAL PREVENTIVE MAINTENANCE While performing preventive maintenance tasks the individual should always be alert to conditions that may Preventive Maintenance (PM) is maintenance per- seem abnormal. If an abnormal condition is detected a formed to prevent malfunctions and parts breakdowns determination must be made to either correct the condi- by periodically and systematically checking equipment...
  • Page 244 RETURN TO TABLE OF CONTENTS 11A-2...
  • Page 245 RETURN TO TABLE OF CONTENTS PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION AND MAINTENANCE SCHEDULES GENERAL CAUTION Intervals are based on operating hours. These are suggested intervals only. As experience is gained in operating this machine, the schedule can be tailored Do NOT use compressed air grease guns. to your operating time.
  • Page 246 RETURN TO TABLE OF CONTENTS PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION AND MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE (See Figure 11B-2) FOOTNOTES a Fill overflow bottle to approximately 4 inches (102 mm). Make a 50/50 (never more than 50% antifreeze) mixture of antifreeze and water in separate container. Cooling system capacities for gasoline engines are 3.3 qts.

  • Page 247: Attachments

    RETURN TO MAIN TABLE OF CONTENTS SECTION 12 ATTACHMENTS 12A. Repair and Service Tools and Materials ........12A-1 12B.
  • Page 248 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools including bearing pullers. Cleaning and Stoddard or equivalent solvent. refinishing materials: Detergent and water. Antiseize. Lubricants: Refer to Section 11. 12A-1...
  • Page 249 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Noisy operation. a. Worn bearings. a. Replace (Section 12C). b. PTO sprockets misaligned b. Align (Section 12C) (mechanical PTOs). c. Loose chain or broken sprocket c.
  • Page 250 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12C. MECHANICAL PTO GENERAL Vehicles equipped with the mechanical PTO have modified transmissions and were built after January The mechanical Power Take-Off (PTO) accessory 1999. These vehicles have either 4-cylinder (Suzuki transmits power from the transmission through a 970) gasoline engines starting with vehicle Serial No.
  • Page 251 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12C. MECHANICAL PTO Figure 12C-3. Mechanical PTO Exploded View 12C-2...
  • Page 252 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12C. MECHANICAL PTO CONTROL CABLE OUTPUT SHAFT AND UNIVERSAL SHAFT (See Figures 12C-1 and 12C-3) (See Figure 12C-4) Whenever the PTO cable must be replaced, make 1. Remove the output shaft and universal shaft as sure the cable remains clear of moving parts or parts shown in Figure 12C-4.
  • Page 253 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12C. MECHANICAL PTO DRIVE SHAFT, SPROCKETS, CHAIN AND 5. When installing or replacing the sprockets, make sure the setscrews in the collars are turned out to TENSIONER (See Figure 12C-5) free the collars on the shafts. Then, install a key 1.
  • Page 254 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12C. MECHANICAL PTO 8. Remove the removable link from the chain and wrap the chain around the sprockets (see Figure 12C-6). Snug the bolts securing the wear tensioner bracket just enough to allow the bracket to move. Slide the bracket and wear block against the chain to remove excess slack from chain.
  • Page 255 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12D. HYDRAULIC PTO GENERAL Installation of a new hydraulic PTO system as an addition to a vehicle not so equipped is covered in a The hydraulic Power Take-Off (PTO) accessory trans- separate publication (Part No. 845385). mits power from a two section hydraulic pump to a A Complete exploded view of the hydraulic PTO hydraulic motor which drives a PTO output shaft at...
  • Page 256 RETURN TO TABLE OF CONTENTS ATTACHMENTS SECTION 12D. HYDRAULIC PTO 4. Install couplings and motor as shown in Figure HYDRAULIC MOTOR (See Figure 12D-3) 12D-3. 1. Tag and disconnect hydraulic hoses from the 5. Reconnect hydraulic lines. hydraulic motor. Plug and cap ports and hoses. 2.

  • Page 257: Options

    RETURN TO MAIN TABLE OF CONTENTS SECTION 13 OPTIONS Options for Truckster ® vehicles are covered in separate publications listed below and available from Textron dealers/distributors. OPTION PUBLICATION TD 1500 Manual 844910 DS175 Sprayer Manual 845205 Envirojet Manual 843655 GA 60 Aerator Manual 834619 Core Harvester Manual 841074 and Installation Instructions 844934...

  • Page 258: Miscellaneous

    RETURN TO MAIN TABLE OF CONTENTS SECTION 14 MISCELLANEOUS 14A. Precaution Decal Locations ........... . 14A-1 Precaution Decal Locations .
  • Page 259 RETURN TO TABLE OF CONTENTS MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS PRECAUTION DECAL LOCATIONS 14A-1...
  • Page 260 RETURN TO TABLE OF CONTENTS MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS Part No. Part No. Part No. 822819 840754 009034880 Part No. Part No. Part No. 844643 845027 840901 Part No. 845038 14A-2...
  • Page 261 RETURN TO TABLE OF CONTENTS MISCELLANEOUS SECTION 14B. CONVERSION CHARTS MILLIMETERS TO DECIMALS 14B-1...
  • Page 262 RETURN TO TABLE OF CONTENTS MISCELLANEOUS SECTION 14B. CONVERSION CHARTS DECIMALS TO MILLIMETERS, FRACTIONS TO DECIMALS TO MILLIMETERS 14B-2...
  • Page 263 RETURN TO TABLE OF CONTENTS MISCELLANEOUS SECTION 14B. CONVERSION CHARTS U.S. TO METRIC CONVERSIONS To Convert Into Multiply By Linear Miles Kilometers 1.609 Measurement Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area...

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