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Cushman TURF-TRUCKSTER, Service & Repair Manual

The Cushman TURF-TRUCKSTER is a versatile vehicle designed for various commercial applications. Ensure you keep your TURF-TRUCKSTER running smoothly with the comprehensive Service & Repair Manual available for free download from manualshive.com. This manual provides detailed instructions for maintenance and repairs to keep your vehicle in top condition.

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4

4A. Repair and Service Tools and Materials  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
4B. Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
4C. Drive Shaft  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1

General   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4

4D. Clutch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-1
Clutch Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-1
Inspection of Clutch Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Clutch Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-3
Clutch Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-4

4E. Gear Shift Cables/Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-1

Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-1

4F. Pressure Plate Ring (Diesel Only)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-1

Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-1

4G. Transmission (3-Cylinder 660 Gasoline Engine)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-1

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-1
Transmission Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-1
Input Shaft Bearing Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-1
Transmission Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2

Gear Shift Case  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Extension Case  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Splitting the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Gear and Shaft Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Countershaft  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4
Input Shaft and Main Shaft  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4
Shifter Shafts and Forks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-6

Inspection and Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-7

Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-7
Spline Teeth  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-9
Gear Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-9
Synchronizer Rings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-9
Ring (External) and Gear Sleeve (Internal) Teeth  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-9
Fork Shaft Locating Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-10
Gear Shift Fork Shafts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-10
Extension Case Bushing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-10

Transmission Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-11

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-11
Shifter Shafts and Forks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-11
Countershaft, Main Shaft, Input Shaft and Stop Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-13
Joining Upper and Lower Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-15
Extension Case  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-15
Gear Shift Case  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-15

Transmission Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-16

SECTION 4

DRIVE TRAIN

Summary of Contents for TURF-TRUCKSTER

Page 1: ...n this manual are based on information in effect at the time of publication Product improvements and changes due to advancements of product design may not be included in this manual This manual is rev...

Page 2: ...14 2 3 4 5 6 7 8 9 10 11 12 13 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOU...

Page 3: ...on Numbers 1A 2 General Cleaning 1A 2 Safety 1A 2 Torque Values 1A 3 Torque Specifications 1A 3 Standard SAE Grade 5 Screws 1A 3 Metric 1A 3 Access Latches 1A 4 Access to Engine 1A 4 Dump Box Release...

Page 4: ...s in that section You will minimize errors by understanding what you will be doing and how the component relates to others in its system Lists of repair tools and materials for each section of the man...

Page 5: ...ore any repairs are undertaken thoroughly clean the exterior of the component to be removed Use a clean surface to lay out parts being removed Keep lubricants clean and cover containers not being used...

Page 6: ...234 286 ft lbs 317 388 N m 5 16 24 17 21 ft lbs 23 28 N m 3 4 16 270 330 ft lbs 366 447 N m 3 8 16 27 33 ft lbs 37 45 N m 7 8 9 360 440 ft lbs 488 597 N m 3 8 24 31 39 ft lbs 42 53 N m 7 8 14 396 484...

Page 7: ...COWL ACCESS The front cowl opens to gain access to the fuse panel the horn the master cylinder reservoir as well as vari ous access panels which when removed allow access to the shifting lever linkage...

Page 8: ...hicle only enough to perform the maintenance required Make sure to block the tire diagonally opposite of the side which is being raised see Figure 1A 4 When using a hoist to raise the vehicle use the...

Page 9: ...5 Make sure the drive transmission is in neutral out of gear and the park brake is released With the tow line attached have the towing vehicle move forward until the tow line becomes tight While towi...

Page 10: ...Cylinder Gasoline Engine Suzuki 970 Governor and Hand Throttle Adjustments 2C 5 Governor and Hand Throttle Adjustments Diesel Engine 2C 7 Choke Adjustments 4 Cylinder Gasoline Engines 2C 7 Parking Br...

Page 11: ...equired Standard automotive hand tools Cleaning materials Stoddard or equivalent solvent Detergent and water Lubricants Refer to Section 11 CONTROLS SECTION 2A REPAIR AND SERVICE TOOLS AND MATERIALS 2...

Page 12: ...aulty glow plug switch diesel d Test Section 10 e Faulty glow plugs diesel e Test Section 10 f Faulty system relay f Test Section 10 g Faulty fuel solenoid diesel g Test Section 10 h Faulty ignition s...

Page 13: ...ted to the engine governor which in turn controls the opening and closing of the car buretor butterfly plate 4 The engine governor is preset to control engine ground vehicle speeds to design limits No...

Page 14: ...against the pedal stop screw see Figure 2C 4 Turn the stop screw out of its bracket one revolution counter clockwise against the accelerator pedal so that the pedal touches the stop screw before reach...

Page 15: ...from full open see Figure 2C 6 6 With the accelerator pedal fully depressed remove the cotter pin turnbuckle pin and flat washer see Figure 2C 7 Disconnect the turnbuckle from the broken knee lever 7...

Page 16: ...00 RPM Adjust the governor stop screw so it just touches the governor body and lock the jam nut 10 Move the governor lever to the low RPM position see Figure 2C 11 Adjust the counterbalance spring by...

Page 17: ...ccelerator pedal down against the pedal stop screw see Figure 2C 14 Turn the stop screw out of its bracket one revolution counterclockwise against the accelerator pedal so that the pedal touches the s...

Page 18: ...he broken knee lever to its full at rest posi tion see Figure 2C 18 8 Pull the turnbuckle to the full throttle position see Figure 2C 19 Install the turnbuckle pin washer and cotter pin so that the tu...

Page 19: ...ake manifold vac uum rises As the engine is warmed up and the cool ing water temperature exceeds 64 F 18 C the hoses of BVSV are connected through and the intake manifold vacuum pulls the diaphragm Th...

Page 20: ...parking brake cables 2 Release the parking brake lever lever fully down 3 Tighten the adjustment nut 1 or 2 turns and apply the brake lever Continue tightening the adjustment nut until the lever is at...

Page 21: ...system bleed the left rear brake first then the right rear then the right front and finally the left front 5 Attach a hose to the bleeder screw on top of the left rear dust shield and place the other...

Page 22: ...joint nut as shown in Figure 2C 26 CLUTCH INTERLOCK SWITCH See Figure 2C 27 A clutch interlock switch allows the engine starter to operate only when the clutch pedal is depressed closing the switch If...

Page 23: ...ition If it can be shifted smoothly to and between 3rd and 4th positions from there loosen cable clamp A shown in Figure 2C 28 and tighten select cable adjusting nut A until control lever can be shift...

Page 24: ...sconnect the battery cables and tag instrument panel wiring prior to replacement If a bulb needs replacement remove the four screws that secure the instrument panel to the dash and tilt the panel forw...

Page 25: ...tem without the Use of a Jumper Wire 3D 6 Engine Removal 3D 7 Engine Installation 3D 7 3E Gasoline Engine 3E 1 General 3E 1 Ignition System 4 Cylinder Engine Suzuki 970 3E 1 General 3E 1 Ignition Coil...

Page 26: ...r Anti rust Never Seize Lubricants See Section 11 Other service items Compressed air source Engine hoist Oil filter Fuel filter Air cleaner element Fan belt Loctite 565 Textron P N 2810299 Loctite 243...

Page 27: ...10 h Clutch pedal not depressed h Depress clutch pedal 2 Engine hard to start or a Fuel level low fuel or fuel filter a Fill with fresh fuel Change fuel runs poorly dirty filter Bleed fuel lines Secti...

Page 28: ...cluded in Section 10 of this manu al If these components are found faulty refer to the engine manufacturer s manual for repair instructions Unlatch and tilt the engine cover forward to gain access to...

Page 29: ...r cleaner element release the latches securing the cover to the air cleaner assembly Remove the filter element Check the element for damage pin holes etc by placing a light source such as a flashlight...

Page 30: ...mixture to the overflow reservoir until proper level is reached CHANGING COOLANT See Figure 3D 2 1 Remove the radiator cap when the engine is cool 2 Remove drain pug and drain coolant 3 Remove and dr...

Page 31: ...ENGINE SECTION 3D DIESEL ENGINE 3D 3 3D Figure 3D 2 Radiator and Cooling System Repair...

Page 32: ...for damaged missing or mispositioned parts open seams holes loose connections or other defects which could permit exhaust fumes to seep into the vehicle REPAIR Remove and replace damaged mufflers hose...

Page 33: ...A larger cartridge filter is located between the outlet of the fuel pump and the engine fuel injection pump Moisture and other foreign matter accumulate in the fuel filters Periodically clear and repl...

Page 34: ...purring sound when this occurs tighten the bleeder plug 7 Turn the ignition key to the OFF position remove the jumper wire and reconnect the white with red wire onto the starter solenoid PURGING FUEL...

Page 35: ...NOTE Clutch disc and cover will be removed with engine ENGINE INSTALLATION 1 Using a suitable lifting device lift engine and posi tion in line with transmission 2 Push engine toward transmission so d...

Page 36: ...its cap 2 Remove distributor cap with spark plug wires installed 3 Remove high tension cable clamp from cylinder head cover 4 Pull out spark plug wire from each spark plug while gripping its cap 5 Use...

Page 37: ...oil primary current Thus the high voltage is induced in the secondary winding of ignition coil and ignition sparks are gener ated at the spark plugs The spark advance is produced by the vacuum advance...

Page 38: ...ove the air cleaner element release the latches securing the cover to the air cleaner assembly Remove the filter element Check the element for damage pin holes etc by placing a light source such as a...

Page 39: ...o the overflow reservoir until proper level is reached CHANGING COOLANT See Figures 3E 4 and 3E 5 1 Remove the radiator cap when the engine is cool 2 Remove drain pug and drain coolant 3 Remove and dr...

Page 40: ...ENGINE SECTION 3E GASOLINE ENGINES 3E 5 3E Figure 3E 4 Radiator and Cooling System Repair 3 Cylinder Engine Suzuki 660...

Page 41: ...ENGINE SECTION 3E GASOLINE ENGINES 3E 6 Figure 3E 5 Radiator and Cooling System 4 Cylinder Engine Suzuki 970...

Page 42: ...ng or mispositioned parts open seams holes loose connections or other defects which could permit exhaust fumes to seep into the vehicle REPAIR Remove and replace damaged mufflers hoses and other exhau...

Page 43: ...et and outlet hoses from fuel filter using two wrenches 6 Remove fuel filter from body INSTALLATION 1 Position the new filter in place and connect the inlet and outlet hoses to it 2 Lower vehicle and...

Page 44: ...smission to remove NOTE Clutch disc and cover will be removed with engine ENGINE INSTALLATION 1 Using a suitable lifting device lift engine and posi tion in line with transmission 2 Push engine toward...

Page 45: ...ent 4G 1 Transmission Disassembly 4G 2 Gear Shift Case 4G 2 Extension Case 4G 2 Splitting the Transmission 4G 2 Gear and Shaft Repair 4G 2 Countershaft 4G 4 Input Shaft and Main Shaft 4G 4 Shifter Sha...

Page 46: ...4H 12 General 4H 12 Shifter Shafts and Forks 4H 12 Main Shaft and Input Shaft 4H 14 Countershaft and Reverse Idler Gear 4H 16 Joining Upper and Lower Cases 4H 18 Input Shaft Bearing Retainer 4H 18 Ex...

Page 47: ...leaning materials Stoddard or equivalent solvent Loctite chisel gasket remover or equivalent Loctite Sealant 518 Textron P N 2811582 50 ml btl Lubricants Refer to Section 11 Loctite Blue 243 Textron P...

Page 48: ...for damaged parts Replace damaged parts Section 4G or 4H d Binding of sliding synchronizer d Remove shifter case cover Check or gears that synchronizers and gears parts with shifting grooves slide fr...

Page 49: ...diaphragm e Replace Section 4D spring rattling 9 Grabbing clutch a Clutch facings soaked with oil a Replace Section 4D b Excessively worn clutch facings b Replace Section 4D c Rivet heads showing out...

Page 50: ...rail and or attached parts as required Section 4G or 4H b Worn or damaged forks offset b Remove extension or adapter lever shaft or rail and case cover Check for wear or damage Replace damaged parts...

Page 51: ...b Damaged gear teeth or improper b Replace or adjust Section 4I mesh of drive pinion and ring gear c Improper tooth contact in the mesh c Adjust Section 4I between drive pinion and ring gear d Insuff...

Page 52: ...ng the drive shaft end of the transmission downward about 4 inches 2 Remove hardware at transmission mounting brackets as shown in Figures 4C 1 and 4C 2 3 Push down on the transmission upper mounting...

Page 53: ...t one bearing in yoke ear and position center cross through yoke 2 Drive the first bearing flush with outside surface of ear NOTE Do not bend ears of yokes 3 Support the yoke and using a socket or man...

Page 54: ...DRIVE TRAIN SECTION 4C DRIVE SHAFT 4C 3 4C Figure 4C 3 Drive Shaft Disassembly and Reassembly...

Page 55: ...r and yoke nut and use a box wrench to tighten the nut to approximately 64 to 74 ft lbs 87 to 100 N m NOTE The torque of the yoke nut can only be approxi mately determined 3 Loosely install the drive...

Page 56: ...4H CLUTCH DISASSEMBLY 1 Use a flywheel holder tool to hold the engine fly wheel see Figure 4D 2 in place and remove the six bolts that secure the clutch cover to the fly wheel and remove the clutch co...

Page 57: ...S 1 If the release bearing Figure 4D 3 sticks rattles or makes abnormal noise when turned by hand replace the bearing 2 Inspect clutch cover for evidence of diaphragm spring rivets getting loose If ri...

Page 58: ...ith a dial indicator CLUTCH REASSEMBLY 1 Before reassembling the clutch lubricate the fol lowing components see Section 11 for recom mended lubricants Clutch release bearing lubricate inner diam eter...

Page 59: ...tall the clutch release bearing on the transmis sion input shaft retainer 8 Refer to Figure 4D 9 use a flywheel holder tool to hold the engine flywheel Use a clutch center guide tool to install the di...

Page 60: ...maged gear shift cables and con nectors as shown in Figures 4E 1 or 4E 2 Adjust shift controls as described in Section 2C DRIVE TRAIN SECTION 4E GEAR SHIFT CABLES CONNECTORS 4E 1 4E Figure 4E 1 Gear S...

Page 61: ...DRIVE TRAIN SECTION 4E GEAR SHIFT CABLES CONNECTORS 4E 2 Figure 4E 2 Gear Shift Cables Connectors 4 Cylinder Gasoline or Diesel Engine...

Page 62: ...equipped vehicles only If worn or damaged replace the pressure plate ring as shown in Figure 4G 1 If necessary repair the clutch as described in Section 4D Adjust the clutch as described in Section 2...

Page 63: ...e shaft at the transmission see Section 4C 8 Attach a suitable hoist to the transmission 9 Remove hardware that fastens the transmission to the engine 10 Remove any remaining transmission hardware fro...

Page 64: ...ch the extension case and mounting bracket 2 If necessary remove the mounting bracket from the extension case SPLITTING THE TRANSMISSION See Figure 4G 4 1 Remove the bolts that fasten the upper and lo...

Page 65: ...DRIVE TRAIN SECTION 4G TRANSMISSION 3 CYLINDER 660 GASOLINE ENGINE 4G 3 4G Figure 4G 5 Gear and Shaft Arrangement...

Page 66: ...shaft by hand taking care not to drop the high speed synchronizer rings 2 Remove the retaining ring high speed synchro nizer rings needle bearings high speed hub assembly and third driven gear from t...

Page 67: ...DRIVE TRAIN SECTION 4G TRANSMISSION 3 CYLINDER 660 GASOLINE ENGINE 4G 5 4G Figure 4G 9 Input Shaft and Main Shaft Steps 1 thru 5...

Page 68: ...re that the interlock balls between two adjacent shafts are seated fully in the detents of respective shafts If any of these interlock balls are out of the detents some of the fork shafts will refuse...

Page 69: ...the detent provided in the case draw out the spring pin by using a spring pin remover tool and remove the shaft by pulling it out INSPECTION AND REPAIR GEAR TEETH Prior to cleaning check bottom of tr...

Page 70: ...chips shown in REPAIR column in Figure 4G 13 may be blend repaired and reused Chips or broken teeth as shown in REJECT column in Figure 4G 13 are not repairable and the part must be rejected Check clu...

Page 71: ...the surfaces are free from any wavy wear A badly worn ring or gear must be replaced Proper synchronizing action on gear shifting can be expected only when the ring to gear clearance and the condition...

Page 72: ...rk shafts If gears have been slipping out of mesh check these springs for strength by measuring their free lengths see Figure 4G 18 and replace them if their free lengths are less than 0 727 inch 18 4...

Page 73: ...ially the reverse of disassembly however special procedures are included in the following paragraphs SHIFTER SHAFTS AND FORKS 1 See Figure 4G 20 for arrangement of shifter shafts forks and gear shift...

Page 74: ...ence is indicated in the ascending order of numbers as shown in Figure 4G 23 5 Holes for installing the interlock steel balls are in the side wall next to the reverse shifter fork shaft of the transmi...

Page 75: ...LATE 1 See Figure 4G 25 for general arrangement of the countershaft main shaft input shaft and stop plate DRIVE TRAIN SECTION 4G TRANSMISSION 3 CYLINDER 660 GASOLINE ENGINE 4G 13 4G Figure 4G 25 Count...

Page 76: ...low gear bushing use hydraulic press and bearing installation tool 6 The two reverse gears have their teeth chamfered on one end and the reverse idle gear is similarly chamfered When mounting the rev...

Page 77: ...lower case tighten the joint bolts uniformly and sequentially so as to equalize the joint pressure all around Torque bolts to 13 5 to 20 0 ft lbs 18 to 28 N m EXTENSION CASE 1 When installing the ext...

Page 78: ...37 ft lbs 51 N m Diesel only Install the two lower socket head capscrews Torque to 37 ft lbs 51 N m 7 Install and tighten all transmission to frame mounting hardware 8 Install mounting brackets to tra...

Page 79: ...ee Section 12 8 Disconnect the drive shaft at the transmission see Section 4C 9 Attach a suitable hoist to the transmission 10 Remove hardware that fastens the transmission to the engine 11 Remove any...

Page 80: ...ring the extension case to he transmission case and detach the extension case and mounting bracket SPLITTING THE TRANSMISSION See Figure 4H 4 1 Remove the bolts that fasten the upper and lower transmi...

Page 81: ...DRIVE TRAIN SECTION 4H TRANSMISSION 4 CYLINDER 970 GASOLINE OR DIESEL ENGINES 4H 3 4H Figure 4H 5 Gear and Shaft Arrangement...

Page 82: ...retain ing ring bearing and input shaft Pull out the input shaft by hand taking care not to drop the high speed synchronizer rings 2 Remove the retaining ring high speed synchro nizer rings springs ne...

Page 83: ...DRIVE TRAIN SECTION 4H TRANSMISSION 4 CYLINDER 970 GASOLINE OR DIESEL ENGINES 4H 5 4H Figure 4H 9 Input Shaft and Main Shaft...

Page 84: ...k make sure that all the shifter fork shafts in place are in neutral position 2 It is important that the three shifter fork shafts be kept in neutral position in order to make sure that the interlock...

Page 85: ...us page and pull out fork shaft and fork DRIVE TRAIN SECTION 4H TRANSMISSION 4 CYLINDER 970 GASOLINE OR DIESEL ENGINES 4H 7 4H Figure 4H 13 Shifter Shafts and Forks When removing yoke pin be sure not...

Page 86: ...rd any parts that show signs of damage or wear Pack bearings with grease and wrap to protect from dirt see Section 11 NOTE Do not confuse gear contact patterns with nor mal tool marks that are a resul...

Page 87: ...unding will cause the clutch to jump out Clutch teeth with rounding on the end are usable but will cause hard shifting Clutch teeth with chips may be blend repaired in the same manner as gear teeth DR...

Page 88: ...e surfaces are free from any wavy wear A badly worn ring or gear must be replaced Proper synchronizing action on gear shifting can be expected only when the ring to gear clearance and the condition of...

Page 89: ...s If gears have been slipping out of mesh check these springs for strength by measur ing their free lengths see Figure 4H 21 and replace them if their free lengths are less than 0 826 inch 21 0 mm GEA...

Page 90: ...aphs SHIFTER SHAFTS AND FORKS 1 See Figure 4H 23 for arrangement of shifter shafts forks and gear shift case Note that three shift shafts individually have a locating ball and locating spring and that...

Page 91: ...e fork pin into fork and shaft 5 Refer to Figures 4H 24 and 4H 25 Install inter lock ball and locating ball in upper case After installing interlock roller in low speed gear shift shaft insert shaft i...

Page 92: ...shaft and input shaft NOTE Be careful to install each washer gear synchro nizer hub and sleeve in the proper direction Make sure that balls are installed on the main shaft DRIVE TRAIN SECTION 4H TRANS...

Page 93: ...n Figure 4H 28 Fit ball into hole in shaft and install washer so that its slot comes over ball Install washer so that its chamfered side is on the main shaft center bearing side 5 Press fit center bea...

Page 94: ...ometer drive gear on the main shaft 12 Install synchronizer ring needle bearing and input shaft COUNTERSHAFT AND REVERSE IDLE GEAR 1 Drive countershaft front bearing into lower case Then using plastic...

Page 95: ...wer case with pin and washer tongue aligned as shown in Figure 4H 34 5 Install the PTO drive gear see Figure 4H 33 rear retaining ring and rear bearing DRIVE TRAIN SECTION 4H TRANSMISSION 4 CYLINDER 9...

Page 96: ...r case to the lower case by align ing the three shift forks with the three grooves in the synchronizer sleeve on the main shaft 7 Check that transmission input shaft rotates easily when turned by hand...

Page 97: ...your vehicle does not have this extension case refer to EXTENSION CASE WITHOUT PTO GEARING 1 If necessary replace worn or damaged extension case components as shown in Figure 4H 37 2 Install the exten...

Page 98: ...transmission mounting hardware do not tighten 6 Use Loctite 242 blue Install transmission bell housing to engine Mount with socket head cap screws Torque to 37 ft lbs 51 N m Diesel only Install the tw...

Page 99: ...ve the brake drum 5 Remove the cotter pin hub nut washer and wheel hub Use a bearing puller to remove the wheel hub 6 Remove the four screws backing ring wheel bearing seal retainer and wheel bearing...

Page 100: ...ellated nut on the axle shaft see Figure 4I 4 to protect the shaft threads and pull the axle shaft to remove the wheel bear ing collar and axle shaft It may be necessary to tap the back of the bearing...

Page 101: ...eal must face inward Use a plastic tube or seal driver to seat the oil seal 2 Pack the wheel bearing with clean grease see Section 11 Reassemble the wheel bearing and collar being careful not to damag...

Page 102: ...DRIVE TRAIN SECTION 4I REAR AXLE 4I 4 Figure 4I 4 Axles and Axle Housings...

Page 103: ...ntial in accordance with environmental regula tions Re install and tighten the drain plug 6 Disconnect the drive shaft yoke nut and special washer from the differential input shaft as shown in Figures...

Page 104: ...as shown in Figure 4I 7 NOTE Pressure must be held on the end of the input shaft to hold the shaft rearward in the case This will prevent the shaft and rear bearing from com ing forward out of the ca...

Page 105: ...cover engages the two pilot bushings 9 Install the 5 16 18 retaining screws and flat wash ers Draw all retaining screws up evenly until the cover is firmly against the differential housing Tighten th...

Page 106: ...4I 9 2 Remove the front cover as described in Steps 1 thru 5 of Differential Front Cover Repair 3 Refer to Figure 4I 11 remove the rear cover screws flat washers and gear ratio tag Remove the rear cov...

Page 107: ...DRIVE TRAIN SECTION 4I REAR AXLE 4I 9 4I Figure 4I 11 Auxiliary Transmission Disassembly...

Page 108: ...ing from the shaft 23 If it is necessary to remove the pilot bearing press the pilot bearing off the shaft 24 Use a hydraulic press to install new intermediate and pilot bearings Be certain the beari...

Page 109: ...the shaft through the bore of the housing only far enough to support one thrust washer Retain the thrust washer on the shaft next to the housing with grease 19 Install and align the cluster gear in t...

Page 110: ...DRIVE TRAIN SECTION 4I REAR AXLE 4I 12 Figure 4I 13 Auxiliary Transmission Reassembly...

Page 111: ...rew will engage the center hole in the axle spring mounting pads see Figure 4I 14 Install the axle U bolt clamps and brackets Tighten the U bolts alternately and evenly until tight 3 Install and align...

Page 112: ...DRIVE TRAIN SECTION 4I REAR AXLE 4I 14 Figure 4I 14 Differential and Axle Assembly Installation...

Page 113: ...es 5C 1 Parking Brake 5C 1 Repair 5C 1 Parking Brake Adjustment 5C 2 5D Service Brakes 5D 1 Service Brakes 5D 1 General 5D 1 Bleeding Brakes 5D 1 Brake Disassembly 5D 2 Servicing 5D 3 Brake Shoe Reass...

Page 114: ...e tools Brake shoe adjusting gauge Cleaning materials Stoddard solvent or equivalent Lubricants Refer to Section 11 Other service items Brake repair parts Brake linings Brake service kits BRAKE SYSTEM...

Page 115: ...ction 5E c Worn brake linings c Replace Section 5D 3 Service brake pedal a Brake line leaks a Repair Section 5D fades when pushed b Air in line b Bleed Section 5D 4 Service brakes do not a Binding ped...

Page 116: ...s and release brake shoes See Figure 5C 1 for parking brake arrangement Raise the engine cover front seat frame and dump box if so equipped to gain access to the parking brake cables REPAIR Parking br...

Page 117: ...er 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 when the brake is applied BRAKE SY...

Page 118: ...brake system BLEEDING BRAKES 1 When bleeding the brake system bleed the left rear brake first then the right rear then the right front and finally the left front 2 Attach a hose to the bleeder screw...

Page 119: ...on 6C for front brakes 2 Remove shoe hold down springs and pins 3 Slightly spread shoes at top lift shoes springs and adjuster off backing plate 4 Disconnect parking brake cable 5 Disassemble to exten...

Page 120: ...h drum Inspect all wheel cylinder parts discard and replace rubber boots if disassembled Inspect cylinder bore hone if necessary NOTE Cylinder should not be honed more than 0 003 inch 0 08 mm BRAKE SH...

Page 121: ...ster lever STEP 7 Install shoe hold down springs and pins STEP 8 Install upper retracting spring to leading shoe slot Stretch spring to install to trail ing shoe If adjuster lever does not contact sta...

Page 122: ...ake fluid NOTE A slight amount of fluid is always present for lubrication this is normal If wet rebuild Continue with Step 2 If dry do not rebuild NOTE Brake shoes must first be removed before pro cee...

Page 123: ...master cylinder may require replacement as follows 1 Disconnect brake lines at the master cylinder as shown in Figure 5E 1 cap lines to prevent contamination 2 Disconnect the brake pedal linkage and r...

Page 124: ...BRAKE SYSTEM SECTION 5E MASTER CYLINDER 5E 2 Figure 5E 2 Master Cylinder Connections...

Page 125: ...ling Steering Pump Assembly 6C 6 Bleeding the Steering System 6C 6 6D Steering Gear 6D 1 General 6D 1 Disassembly Reassembly 6D 2 Pitman Shaft Seals 6D 2 Housing End Plug O Ring 6D 2 Pitman Shaft 6D 2...

Page 126: ...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 dea...

Page 127: ...eels out of adjustment d Adjust Section 6F e Faulty steering gear e Repair replace Section 6D 4 Shimmy a Tire mounting nuts loose a Tighten Section 7 b Loose or worn steering linkage b Tighten or repl...

Page 128: ...directs motion of the front wheels through tie rod connections The steering gear is hydraulically assisted by a steer ing pump to provide power steering similar to most passenger cars The steering pu...

Page 129: ...rease seal 4 If required repair brakes as described in Section 5D 5 Install brake assemblies wheel hubs brake drums wheels and tires and torque mounting hardware as shown in Figure 6C 1 6 Connect brak...

Page 130: ...tman arm as shown in Figure 6C 4 NOTE Whenever the pitman arm is removed clean and inspect steering gear housing for pitting and rough spots and pitman shaft for burrs Remove pitting rough spots and b...

Page 131: ...STEERING SECTION 6C STEERING SYSTEM 6C 4 Figure 6C 4 Steering Column...

Page 132: ...n Figure 6C 4 5 Disassemble inspect repair and reassemble the steering gear assembly as described in Section 6D 6 Adjust the steering gear assembly as described in Section 6D 7 Insert the steering gea...

Page 133: ...the wheel stops 7 Add oil if necessary 8 Lower the vehicle and turn wheels right and left on the ground 9 Check oil level and refill as required 10 If oil is extremely foamy allow vehicle to stand a f...

Page 134: ...s is shown in Figure 6D 1 NOTE Prior to removing and or disassembling the steering gear carefully check Section 6B to determine causes of problems other than the steering gear Also perform all steerin...

Page 135: ...washers as shown in Figure 6D 2 and secure with retaining ring HOUSING END PLUG O RING See Figure 6D 3 1 Remove the retaining ring end plug and O ring 2 Replace the O ring and install the plug and re...

Page 136: ...he black balls are smaller than the silver balls The black and silver balls must be installed alter nately into the rack piston and return guide to maintain rack piston to worm gear preload 9 Lubricat...

Page 137: ...STEERING SECTION 6D STEERING GEAR 6D 4 Figure 6D 5 Rack Piston...

Page 138: ...allet to drive the needle bearing and seals out of the adjuster plug 3 Assemble new O rings seals needle bearing and thrust bearing retainer to adjuster plug If neces sary install new thrust bearings...

Page 139: ...lve body Pull the valve assem bly off the worm 4 Disengage the pin on the stub shaft from the hole in the valve spool and disassemble the valve assembly as shown in Figure 6D 7 5 Replace O rings seals...

Page 140: ...thrust bearing valve adjuster plug rack piston pitman shaft and pitman shaft seals as described in previous paragraphs in this section 5 Perform adjustments in the following paragraphs ADJUSTMENTS THR...

Page 141: ...ock tooth on the pitman shaft should be in line with the over center preload adjuster plug 3 Back off the preload adjuster plug until it stops then turn the plug in one full turn 4 With the gear at ce...

Page 142: ...nting bracket 4 Reconnect hoses to pump and bleed the system as described in Section 6C REPAIR See Figure 6E 2 Repair of the steering pump is limited to removal and replacement of the flow control val...

Page 143: ...STEERING SECTION 6E STEERING PUMP 6E 2 Figure 6E 2 Steering Pump Repair...

Page 144: ...aster angle change a Increase caster angle by adding shims to front bolt b Decrease caster angle by adding shims to rear bolt c If more than 2 shims are added to front bolt recheck camber angle see St...

Page 145: ...7 7A Repair and Service Tools and Materials 7A 1 7B Failure Analysis 7B 1 7C Tire Service 7C 1 General 7C 1 Service 7C 1 SECTION 7 WHEELS AND TIRES...

Page 146: ...aterials Stoddard solvent or equivalent Lubricants Refer to Section 11 Other service items Commercially available tire sealant Tire pressure gauge Compressed air with tire valve fitting WHEELS TIRES S...

Page 147: ...to Front 20 psi 138 kPa Rear 15 psi 110 kPa b Steering malfunctioning b Test steering Section 8 Repair Section 6 c Wheel nuts loose c Tighten wheel nuts to 70 to 100 ft lbs 95 to 140 N m d Steer wheel...

Page 148: ...g to tire manufacturer s specifications This assures proper seating of the tire bead to the rim Then reduce the pressure to the specified service level before using NOTE Never use grease or oil on the...

Page 149: ...ng for ORS Face Seal Fittings 8C 3 O Ring Face Seal Torque Recommendations 8C 3 8D Standard Hydraulic Pump 8D 1 General 8D 1 Removal 8D 1 Disassembly 8D 1 Inspection 8D 2 Reassembly 8D 2 Installation...

Page 150: ...st 8J 7 Cylinder Test 8J 10 Optional High Low System 8J 12 Pump Flow Test Section 1 8J 12 Bottom Selector Valve Test 8J 12 Lift Valve Test 8J 15 Cylinder Test 8J 17 Pump Flow Test Section 2 8J 19 Top...

Page 151: ...chometer 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 deal...

Page 152: ...Low hissing sound a Normal wheel is turned b Relief valve squeals when b Normal steering to maximum turn 3 Steering wanders a Tire pressure incorrect a Properly inflate tires Section 7C b Steering ge...

Page 153: ...g with a plastic mallet is recommended unless otherwise specified in the repair instruction Unless otherwise indicated apply a light coat of clean hydraulic fluid to parts as each is reassem bled Appl...

Page 154: ...OSS FITTINGS NOTE O rings should be lubricated with the fluid to be used in the system prior to assembly HYDRAULICS SECTION 8C GENERAL INSTRUCTIONS 8C 2 FIgure 8C 1 Reference Marking SAE Dash Thread T...

Page 155: ...6 120 4 7 16 20 0 250 168 192 5 1 2 20 0 312 216 240 6 9 16 18 0 375 288 312 8 3 4 16 0 500 600 720 10 7 8 14 0 625 864 960 12 11 16 12 0 750 1500 1620 14 13 8 12 0 875 1920 2160 16 15 16 12 1 000 240...

Page 156: ...and remove pump from pump bracket DISASSEMBLY See Figure 8D 1 1 Clean exterior of pump with suitable solvent before removing bolts 2 Before disassembly mark housing and covers to ensure correct order...

Page 157: ...during assembly Use clean grease to keep seals in position 4 Remove alignment mark from gears after they have been installed with teeth in mesh 5 Rotate drive shaft to make sure there is no bind ing...

Page 158: ...pump bracket DISASSEMBLY See Figure 8E 1 1 Clean exterior of pump with suitable solvent before removing bolts 2 Before disassembly mark housing and covers to ensure correct order and position of parts...

Page 159: ...assembly Use clean grease to keep seals in position 4 Remove alignment mark from gears after they have been installed with teeth in mesh 5 Rotate drive shaft to make sure there is no bind ing between...

Page 160: ...r mount DISASSEMBLY See Figure 8F 1 1 Clean exterior of motor with suitable solvent before removing bolts 2 Before disassembly mark housing and covers to ensure correct order and position of parts whe...

Page 161: ...kit during assembly Use clean grease to keep seals in position 4 Remove alignment mark from gears after they have been installed with teeth in mesh 5 Rotate drive shaft to make sure there is no bind...

Page 162: ...O rings and backup rings from the rod guide and piston INSPECTION 1 Inspect all parts for excessive wear cracks and broken parts 2 Discard all O rings seals and backup rings replace with new seal kit...

Page 163: ...HYDRAULICS SECTION 8G BOX CYLINDER 8G 2 Figure 8G 2 Seal Kit Installation...

Page 164: ...valve from mounting bracket 4 Disassemble as shown in Figure 8H 1 5 Replace O rings 6 Reassemble as shown in Figure 8H 1 7 Install valve on mounting bracket and attach con trol handle 8 Reconnect hydr...

Page 165: ...s 2 Remove valve from mounting bracket 3 Disassemble as shown in Figure 8I 1 4 Replace O rings 5 Reassemble as shown in Figure 8I 1 6 Reconnect hydraulic lines 7 Test valve operation see Section 8 HYD...

Page 166: ...te test procedures It is important to follow the instructions accurately and completely Make sure to plug lines and cap ports when so instructed Also read and follow the Preliminary Checks before proc...

Page 167: ...remove the outlet line from pump section 1 Plug line 2 Install a tee to pump outlet port 3 Connect flowmeter IN port line to the pump tee Cap remaining port of tee 4 Install a 1 2 14 pipe to 7 8 14 3...

Page 168: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 3 8J Figure 8J 2 Standard Hydraulic System Pump Flow Test...

Page 169: ...replaced 20 Completely open tester load valve and shut down engine Proceed with Step 21 See Figure 8J 4 21 At the connection manifold connect line 8 to port 7 22 At selector valve remove line from bot...

Page 170: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 5 8J Figure 8J 3 Selector Valve Test Steps 13 to 20...

Page 171: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 6 Figure 8J 4 Selector Valve Test Steps 21 to 29...

Page 172: ...e acorn nut from side of valve b Turn screw 1 8 turn clockwise CW increases pressure or counterclockwise CCW to decrease pressure Replace acorn nut c Set the brake start the engine and advance the thr...

Page 173: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 8 Figure 8J 5 Lift Valve Test Steps 30 to 36...

Page 174: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 9 8J Figure 8J 6 Lift Valve Test Steps 37 to 41...

Page 175: ...ith Step 48 More than 1 gpm 3 78 lpm leakage will notice ably reduce performance The cylinder may have to be rebuilt or replaced 48 Open tester load valve 49 Pull lift valve lever rearward into the li...

Page 176: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 11 8J Figure 8J 7 Cylinder Test...

Page 177: ...n 1 1 2 gpm 5 68 lpm leakage will noticeably reduce performance The pump may have to be repaired or replaced Section 8D 11 Open tester load valve and shut down engine Proceed with Step 12 BOTTOM SELEC...

Page 178: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 13 8J Figure 8J 8 Pump Section 1 Flow Test...

Page 179: ...HYDRAULICS SECTION 8J INSTRUMENT TEST Figure 8J 9 Bottom Selector Valve Test 8J 14...

Page 180: ...ceed with Step a a Remove the acorn nut from side of valve b Turn screw 1 8 turn clockwise CW increases pressure or counterclockwise CCW to decrease pressure Replace acorn nut c Set the brake start t...

Page 181: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 16 Figure 8J 10 Lift Valve Test...

Page 182: ...m the valve is marginal proceed with Step 39 More than 1 gpm 3 78 lpm leakage will notice ably reduce performance The cylinder may have to be rebuilt or replaced 39 Open tester load valve 40 Pull lift...

Page 183: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 18 Figure 8J 11 Cylinder Test...

Page 184: ...nut from side of valve b Turn screw 1 8 turn clockwise CW increases pressure or counterclockwise CCW to decrease pressure Replace acorn nut c Set the brake start the engine and advance the throttle to...

Page 185: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 20 Figure 8J 12 Pump Section 2 Flow Test...

Page 186: ...HYDRAULICS SECTION 8J INSTRUMENT TEST 8J 21 8J Figure 8J 13 Bottom Selector Test...

Page 187: ...positions indicate that flow can be directed in infinite variables between valve positions Hydraulic Pressure Switch Valve Function Symbols Varies with circuit requirements Lines extending outside the...

Page 188: ...i Directional can be turned in both directions Uni Directional can be turned only counterclockwise Uni Directional Motor rotates in one direction Bi Directional Motor rotates in both directions Lever...

Page 189: ...AND COMPONENT LOCATIONS 8K 3 8K PUMP Relief Valve 2500 psi Selector Valve Relief Valve 2000 psi Control Valve Filter Truck Cylinder 8M 7F 1F 3F A B 2M 4M TRUCKSTER Hydraulic System P P P2 B A T Figure...

Page 190: ...ontrol Valve Filter Motor Driven Accessory Accessory Cylinder 8M 7F 1F 3F A A A 2M 4M 11F 9F 10M 12M 6F 5M Selector Valve Top Selector Valve Bottom PUMP 2 Relief Valve 2500 psi Low High Speed Selector...

Page 191: ...HYDRAULICS SECTION 8K HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K 5 8K Figure 8K 4 Hydraulic Component Locations Standard Hydraulic System...

Page 192: ...HYDRAULICS SECTION 8K HYDRAULIC DIAGRAMS AND COMPONENT LOCATIONS 8K 6 Figure 8K 5 Hydraulic Component Locations High Low Hydraulic System...

Page 193: ...1 9B Failure Analysis 9B 1 9C Fuel Tank 9C 1 General 9C 1 Removal and Installation 9C 1 9D Hydraulic Tank 9D 1 General 9D 1 Removal and Installation 9D 1 9E Front Suspension 9E 1 Repair 9E 1 9F Rear...

Page 194: ...ve hand tools including bearing pullers Cleaning and Stoddard or equivalent solvent refinishing materials Detergent and water Antiseize Lubricants Refer to Section 11 CHASSIS SECTION 9A REPAIR AND SER...

Page 195: ...Test pump Section 8 d Hydraulic cylinder is not d Test repair cylinder Section 8 functioning e Lift and lower control valve is e Test repair valve Section 8 malfunctioning 2 Slow or noisy lift lower a...

Page 196: ...is connect input and output fuel lines and drain the tank 2 Remove attaching hardware fuel tank and tank mounting plate 3 Test fuel sender as described in Section 10 If necessary replace fuel sender 4...

Page 197: ...sive heat or after a major compo nent failure the hydraulic fluid should be changed NOTE The cap on the hydraulic tank is a vented cap If water air or contamination is indicated locate the source of t...

Page 198: ...d replace damaged shocks and other parts as shown in Figure 9E 1 After front suspension repairs align the front wheels as described in Section 6F CHASSIS SECTION 9E FRONT SUSPENSION 9E 1 9E Figure 9E...

Page 199: ...shocks leaf springs and other parts as shown in Figure 9F 1 The left and right sides of the rear suspension are symmetrical The right side is shown in Figure 9F 1 CHASSIS SECTION 9F REAR SUSPENSION 9F...

Page 200: ...t Current Test 10F 1 Voltage Test 10F 2 Regulator Test 10F 3 10G Starter 10G 1 General 10G 1 Starting Circuit Resistance Test 10G 1 Starter Solenoid Test 10G 3 No Load Test 10G 4 10H Switches 10H 1 Ig...

Page 201: ...el Pump Diesel 10M 1 Fuel Pump Test Diesel 10M 1 10N Glow Plugs 10N 1 Glow Plug Test Diesel Only 10N 1 10O Wiring Diagrams and Component Location Illustrations 10O 1 Component Location 10O 1 Electrica...

Page 202: ...timeter Jumper wires 60 amp ammeter Cleaning materials Baking soda and water Other service items Electrical insulation compound P N 365422 ELECTRICAL SYSTEM SECTION 10A REPAIR AND SERVICE TOOLS AND MA...

Page 203: ...nd 2 Engine turns over but a Battery low charge a Charge or replace Section 10D will not start b No fuel obstructed fuel supply b Check and correct fuel level and or obstruction c Internal engine prob...

Page 204: ...continuity check as described below NOTE Before performing any component or wiring test check for corrosion and loose or missing con nections If a component switch relay etc is removed for test or rep...

Page 205: ...ohms readings are above 0 5 the switch or wire is questionable ELECTRICAL SYSTEM SECTION 10C GENERAL INSTRUCTIONS 10C 2 POWER OFF ON 200m 2 20 200 1000 750200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV...

Page 206: ...performance or early failure due to loss of electrolyte 2 Keep terminals and top of battery clean Wash with baking soda and rinse with clear water Do not allow soda solution to enter cells as this wil...

Page 207: ...g the battery is run down or faulty Charge and perform test again ELECTRICAL SYSTEM SECTION 10D BATTERY 10D 2 POWER OFF ON 200m 2 20 200 1000 750200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV ACV ACA 20...

Page 208: ...ne RPM increases voltage should in crease to 14 to 14 5 volts Current output should increase to a maximum of 55 amps NOTE Charge condition of battery will affect current amp output As the battery begi...

Page 209: ...ent amp output As the battery begins to charge the current out put will slowly decrease If NO voltage and or current is measured alter nator is faulty VOLTAGE TEST See Figure 10E 1 1 Set multimeter to...

Page 210: ...p ammeter and multimeter as shown 3 Set multimeter to 20 VDC range 4 Reconnect battery NEG cable 5 Start the engine As engine RPM increases voltage should in crease to 14 to 14 5 volts Current output...

Page 211: ...re 10F 2 1 Set multimeter to 20 VDC range 2 Disconnect RED lead from terminal B of the alternator 3 Connect NEG test lead of the multimeter to a good ground 4 Touch the POS lead of the multimeter to t...

Page 212: ...eter leads to the two terminals of the alternator connector then switch terminals Should have continuity in one direction ONLY If NO continuity or continuity in both directions regulator may be faulty...

Page 213: ...ngine ground 4 Crank engine read record voltage Voltage should not drop more than 0 58 volts from measured battery voltage If voltage drops below 0 58 a high resistance fault exists in the wiring conn...

Page 214: ...00V MAX POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV ACV ACA 200 2m 200m 2 2 200m 20m 10A 2m 200 DCA 20m 10A V COM A 10A 1000V 750V MAX 2A MAX 10A MAX 500V MAX POWE...

Page 215: ...pinion gear moves outward If gear does not move replace starter solenoid 5 While connected as in Step 4 disconnect nega tive lead from terminal M Check that gear remains out If gear returns inward re...

Page 216: ...minal M for diesel engines start with Step 2 2 Connect the battery and an ammeter to the starter as shown in Figure 10G 3 3 Check that starter rotates smoothly and that the pinion moves outward Ammete...

Page 217: ...connect the POS lead to terminal B and the NEG test lead to terminal I There should be a reading of 0 to 0 5 ohms e Continue to hold switch in START position Move the NEG test lead to terminal I Ther...

Page 218: ...Contacts Open No Continuity NOTE G terminal not used Position Continuity OFF None STEPS 4b 4c Contact 0 to 0 5 ohms Position Continuity ON A B and I STEPS 4d 4e Contact 0 to 0 5 ohms Position Continu...

Page 219: ...ition There should be a reading of 0 to 0 5 ohms on the multimeter Replace a switch that does not meet the above test results ELECTRICAL SYSTEM SECTION 10H SWITCHES 10H 3 10H Figure 10H 2 Horn Switch...

Page 220: ...t one multimeter test lead to terminal 1 and the other lead to terminal 4 There should be 0 to 0 5 ohms on the multimeter b Move one multimeter test lead to terminal 3 There should be 0 to 0 5 ohms on...

Page 221: ...nto reverse There should be a reading of 0 to 0 5 ohms at multimeter Replace switch that does not meet the above test results ELECTRICAL SYSTEM SECTION 10H SWITCHES 10H 5 10H Figure 10H 4 Backup Light...

Page 222: ...itor oil temperature slowly heat oil At approximately 190 F 88 C switch should CLOSE and meter should read 0 to 0 5 ohms Replace a switch that does not meet the above test results ELECTRICAL SYSTEM SE...

Page 223: ...0 to 0 5 ohms on multimeter ELECTRICAL SYSTEM SECTION 10H SWITCHES 10H 7 10H Figure 10H 6 Clutch Interlock and Brake Switch Test POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M 200M 20K 2K 20...

Page 224: ...6 Move test lead from NC to NO There should be no reading on the multimeter no continuity 7 Depress switch lever There should be a reading of 0 to 0 5 ohms on multimeter Replace a switch that does not...

Page 225: ...e a reading continuity on the meter scale If not replace fuse ELECTRICAL SYSTEM SECTION 10I FUSES 10I 1 10I POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV ACV ACA 200...

Page 226: ...switch test Step 1 Light does not go OFF check circuit wiring for ground SWITCH TEST 1 Set multimeter to 200 ohms scale 2 Connect test leads as shown There should be continuity and the meter should r...

Page 227: ...ading gauge or wiring may be faulty Replace a sender or gauge that does not meet all the above tests ELECTRICAL SYSTEM SECTION 10J SENDERS AND ALARMS 10J 2 POWER OFF ON 200m 2 20 200 1000 750 200 20 2...

Page 228: ...ull 0 027 ohms If fuel level sender tests do not fall within the above limits replace If fuel level sender tests fall within limits check wiring and or gauge see Section 10N ELECTRICAL SYSTEM SECTION...

Page 229: ...d be no continuity on the meter Replace a solenoid that does not meet the above test results ELECTRICAL SYSTEM SECTION 10K SOLENOIDS 10K 1 10K Figure 10K 1 Starter Solenoid POWER OFF ON 200m 2 20 200...

Page 230: ...here should be an audible click 6 Connect black NEG lead from multimeter to terminal 30 7 Connect red POS lead from multimeter to ter minal 87a Open when coil is energized 8 Move red lead to terminal...

Page 231: ...he BRN wire on the wiring har ness connector Connect the NEG lead to a good ground 5 Turn the ignition switch to the ON position If so equipped PTO handle must be pushed down Multimeter should read ba...

Page 232: ...the reading is at infinity or 0 ohms the glow plug is faulty and must be replaced Replace a glow plug that does not meet the above tests ELECTRICAL SYSTEM SECTION 10N GLOW PLUGS 10N 1 10N Figure 10N 1...

Page 233: ...ELECTRICAL SYSTEM SECTION 10O WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATIONS 10O 1 10O Figure 10O 1 Electrical Component Locations...

Page 234: ...trical Solenoid Coil hydraulic Solenoid with Blocking Diode used to suppress inductive loads produced by coil shut off Direct Current DC Alternating Current AC Ground to Earth Ground to Chassis Wires...

Page 235: ...mbol Resistor or Glow Plug Adjustable Resistor Potentiometer POT a variable resistor with a fixed reference Normally Closed Relay Normally Open Relay Time Delay Relay opening delay Motor with Solenoid...

Page 236: ...W OR G B G B R B BL B BR B B R B B G OR P W OR P W B B R B R R B R B R OR C R M L OR R Y B W R B B Y R B R B B B B B B B B B B R OR B R Y R Y R B B Y R W B B R R BR BL BL R B BL B B B G B G B Y R BR...

Page 237: ...TION SWITCH IGNITION COIL WIPER MOTOR ACC POWER ACC POWER ACC POWER DOME LIGHT HEATER FAN HEATER SWITCH CARB SOL TEMP SENDER FUEL SENDER COOLENT OVERHEAT ALARM OIL PRESS SENDER SERVICE BRAKE RESV PARK...

Page 238: ...W OR P W B B R B R R B R B R OR C R M L OR R Y B W R B B Y R B R B B B B B B B B B B R OR B R Y R Y R B B Y R W B B R R BR BL BL R B BL B B B G B G B Y R BR B BR R B B BL B B Y R B W BL B B B G B W O...

Page 239: ...TION SWITCH IGNITION COIL WIPER MOTOR ACC POWER ACC POWER ACC POWER DOME LIGHT HEATER FAN HEATER SWITCH CARB SOL TEMP SENDER FUEL SENDER COOLENT OVERHEAT ALARM OIL PRESS SENDER SERVICE BRAKE RESV PARK...

Page 240: ...R B OR B BR TAILLIGHT ADAPTER TURN SIGNAL SWITCH FLASHER LEFT TURN SIGNAL LEFT HEADLIGHT RIGHT HEADLIGHT RIGHT TURN SIGNAL CAB STOP LIGHT HEADLIGHT SWITCH BL B OR B BR TRAILER BRAKES W R BRAKE FLUID R...

Page 241: ...85 85 87 87 87a 87a 30 30 MOTOR ACC POWER ACC POWER ACC POWER DOME LIGHT HEATER FAN HEATER SWITCH FUEL SOL TEMP SENDER FUEL SENDER COOLENT OVERHEAT ALARM OIL PRESS SENDER SERVICE BRAKE RESV PARK BRAKE...

Page 242: ...Maintenance 11A 1 Scheduling 11A 1 Administration 11A 1 PMMRS Program Kits 11A 1 11B Lubrication and Maintenance Schedules 11B 1 General 11B 1 Lubrication Schedule 11B 1 Maintenance Schedule 11B 2 SE...

Page 243: ...n which it operates While performing preventive maintenance tasks the individual should always be alert to conditions that may seem abnormal If an abnormal condition is detected a determination must b...

Page 244: ...RED __________ Kit consists of 10 ea 8476 TS Maintenance Summary Sheets 20 ea 8477 TS Service Order Sheets 5 ea 8478 TS Folders check color desired ____Orange Turf Tractors ____Gray Reel Mowers ____Lt...

Page 245: ...on bearings and pivot points reducing performance of the machine PREVENTIVE MAINTENANCE SECTION 11B LUBRICATION AND MAINTENANCE SCHEDULES 11B 1 11B CAUTION Do NOT use compressed air grease guns Figure...

Page 246: ...ller plug hole Ref Description Remarks 1 Air Cleaner Element X Replace 2 Radiator Screen X Check clean 2 a Cooling System X Check coolant level replenish 2 a Coolant X Change coolant 2 Radiator Hoses...

Page 247: ...l 12C 1 Preparation for Repair 12C 1 Control Cable 12C 3 Output Shaft and Universal Shaft 12C 3 Drive Shaft Sprockets Chain and Tensioner 12C 4 12D Hydraulic PTO 12D 1 General 12D 1 Preparation for Re...

Page 248: ...and tools including bearing pullers Cleaning and Stoddard or equivalent solvent refinishing materials Detergent and water Antiseize Lubricants Refer to Section 11 ATTACHMENTS SECTION 12A REPAIR AND SE...

Page 249: ...d all the way Section 2 c Broken or loose shaft c Repair replace Section 12C or 12B 3 No PTO output while a Broken chain or sprocket a Replace Section 12C vehicle is stationary mechanical PTOs b Hi Lo...

Page 250: ...12C 3 Specific repair procedures are covered in the following paragraphs PREPARATION FOR REPAIR 1 Place vehicle on a hard level surface remove the ignition key and apply the park brake If the vehi cl...

Page 251: ...ATTACHMENTS SECTION 12C MECHANICAL PTO 12C 2 Figure 12C 3 Mechanical PTO Exploded View...

Page 252: ...al shaft as shown in Figure 12C 4 2 Repair the universal shaft if necessary following the same procedures as for the vehicle drive shaft see Section 4C 3 Replace worn bearings 4 When installing the un...

Page 253: ...he shaft to rotate freely 5 When installing or replacing the sprockets make sure the setscrews in the collars are turned out to free the collars on the shafts Then install a key on the slot in the upp...

Page 254: ...1 4 inch 6 mm of deflection to the chain with 20 lbs 9 kg of pressure DO NOT over tighten chain If the chain is too tight the PTO may make excessive noise when engaged Tighten nuts A and B when alignm...

Page 255: ...een see Figure 3D 2 of this manual PTO front and rear shields and PTO cover see Figure 12C 3 to gain access to components to be repaired NOTE The PTO cover is spring loaded Make sure to disconnect spr...

Page 256: ...as shown in Figure 12D 3 HYDRAULIC MOTOR See Figure 12D 3 1 Tag and disconnect hydraulic hoses from the hydraulic motor Plug and cap ports and hoses 2 Remove the motor as shown in Figure 12D 3 3 If n...

Page 257: ...lers 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 84...

Page 258: ...ations 14A 1 Precaution Decal Locations 14A 1 14B Conversion Charts 14B 1 Millimeters to Decimals 14B 1 Decimals to Millimeters Fractions to Decimals to Millimeters 14B 2 U S to Metric Conversions 14B...

Page 259: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 1 14A PRECAUTION DECAL LOCATIONS...

Page 260: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 2 1 Part No 822819 2 Part No 840754 3 Part No 009034880 6 Part No 840901 5 Part No 845027 4 Part No 844643 7 Part No 845038...

Page 261: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 1 14B MILLIMETERS TO DECIMALS...

Page 262: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 2 DECIMALS TO MILLIMETERS FRACTIONS TO DECIMALS TO MILLIMETERS...

Page 263: ...cre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp...

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