Ransomes Truckster LS/LX User manual

Type
User manual
TECHNICIAN’S REPAIR AND
SERVICE MANUAL
649287
ISSUED DECEMBER 2015
TRUCKSTER LS
TRUCKSTER LX
Gasoline Powered Vehicle
NOTICES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER.
SAFETY
For any questions about material in this manual, contact an authorized representative.
Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.
Steep hills allow the vehicle to move at faster speeds than on a flat surface. To prevent loss of vehicle control and possible injury, speeds
must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control
the speed.
If you operate the vehicle above the maximum specified speed, you can damage the drivetrain components. Damaged drivetrain compo-
nents can cause loss of vehicle control. Damage to the drivetrain caused by excessive speed is abusive, and will not be covered under
the warranty.
Use caution when you tow the vehicle. Towing the vehicle at above the recommended speed can cause personal injury or damage to the
vehicle and other property.
If the vehicle is used in a commercial environment, signs must be in position to inform of possible conditions that can be dangerous.
Examples shown below.
NOTICES, CAUTIONS, WARNINGS
AND DANGERS
Observe the NOTICES, CAUTIONS, WARNINGS, and DAN-
GERS;
be aware that servicing a vehicle requires mechanical
skill and a regard for conditions that could be hazardous.
Improper service or repair may damage the vehicle or render it
unsafe for use.
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, will result in death or serious
injury.
The exhaust emissions of this vehicle engine complies
with regulations set forth by the Environmental Protection
Agency (EPA) of the United States of America (USA) at
time of manufacture. Significant fines could result from
modifications or tampering with the engine, fuel, ignition
or air intake systems.
Engine exhaust from this product contains
chemicals known, in certain quantities, to cause
cancer, birth defects, or other reproductive
harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
CALIFORNIA Proposition 65 Warning
WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which
contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth
defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new
and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates,
all identified by the State of California to potentially cause cancer and birth defects or other reproductive harm.
Posted in accordance with Proposition 65 and California Health and Safety Code Section 25249.5, et seq.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles (TSV
Augusta), prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety
of the vehicle.
Textron Specialized Vehicles reserves the right to incorporate engineering and design changes to products in this manual, without obliga-
tion to include these changes on units sold previously.
The information contained in this manual may be revised periodically by Textron Specialized Vehicles, and therefore is subject to change
without notice.
TEXTRON SPECIALIZED VEHICLES DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY
FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the original instructions as defined by 2006/42/EC.
CONTACT INFORNATION:
JACOBSEN, A Textron Company
11108 Quality Drive
Charlotte, NC, USA 28273
1-800-848-1636
www.Jacobsen.com
i
Repair and Service Manual
649287
REPAIR AND SERVICE MANUAL
GASOLINE POWERED VEHICLES
TRUCKSTER LS
TRUCKSTER LX
STARTING MODEL YEAR 2016
NOTES
ii
Repair and Service Manual
649287
This vehicle has been designed and manufactured in the United States of America (USA).
The standards and specifications listed in the following text originate in the USA unless oth-
erwise indicated.
The use of non-Original Equipment Manufacturer (OEM) approved parts void the
warranty.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit the vehicle to operate above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be as per orig-
inal vehicle specifications in order to maintain the United States of America Federal and
State emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
Battery self-discharge over time. The rate of self-discharge varies depending on the ambient
temperature, the age and condition of the battery.
Fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75°F (- 60°C).
BATTERY DISPOSAL
Lead-acid battery is recyclable. Return whole scrap battery to distributor, manufacturer or
lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers
with absorbent material such as sand. Dispose of in accordance with local, state and federal
regulations for acid and lead compounds. Contact local and/or state environmental officials
regarding disposal information.
iii
Repair and Service Manual
SAFETY INFORMATION
649287
SAFETY INFORMATION
This manual contains recommended maintenance procedures from the manufacturer. Follow these procedures and
fault isolation information to get the best service from the product. To decrease the risk of personal injury or property
damage, obey all the information in this manual.
GENERAL
Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate
and warn against every possible combination of circumstances that may occur. Warnings cannot replace good common
sense and prudent driving practices. Common sense and prudent driving practices do more to decrease the risk of
accidents and injury than warnings and instructions can provide.
The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s guide provided with the pur-
chase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within.
For any questions or concerns, contact the closest representative, or write to the address on the back cover of this pub-
lication, Attention: Customer Care Department.
Textron Specialized Vehicles (TSV) reserves the right to make design changes without obligation to make these
changes on units previously sold and the information contained in this manual is subject to change without notice.
TSV is not liable for errors in this manual or for incidental or consequential damages that result from the use of the
material in this manual.
This vehicle conforms to the current applicable standard for safety and performance requirements.
This vehicle is designed and manufactured for off-road use. It does not conform to Federal Motor Vehicle Safety Stan-
dards and is not equipped for operation on public streets. Some communities may permit these types of vehicles to be
operated on their streets on a limited basis and in accordance with local ordinances.
Ensure all electrical accessories are grounded directly to the battery (-) post. Never use the chassis or body as a
ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. Do not exceed number of occupants indicated.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease
its stability, increase the speed or extend the stopping distance beyond the factory specification.
Such modifications can result in serious personal injury or death.
Do not change the vehicle in any manner that changes the weight distribution, decreases stability, increases speed or
extends the necessary distance to stop more than the factory specification. TSV is not responsible for changes that
cause the vehicle to be dangerous.
Do not let anyone below the height of 59 inches (150 cm) operate the vehicle.
GENERAL OPERATION
ALWAYS:
• Use the vehicle in a responsible manner.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• When there is a risk of lightning, leave the vehicle and look for a safe location to wait until the lightning has
stopped.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control the speed on steep grades.
• Reduce speed in damp or wet areas.
• Reduce speed and use caution when approaching sharp or blind turns.
iv
Repair and Service Manual
SAFETY INFORMATION
649287
• Reduce speed and use caution when driving over loose terrain.
• Reduce speed and use caution when driving in areas where pedestrians are present.
• Keep enough distance between vehicles to stop safely.
MAINTENANCE
ALWAYS:
• Replace damaged or missing warning, caution or information labels.
• Service the vehicle in accordance with the manufacturer's periodic service schedule.
• Make sure that repairs are performed by trained and qualified personnel.
• Follow the manufacturers maintenance procedures.
• Use insulated tools within the battery area to decrease the risk of sparks or battery explosion.
• Use specified replacement parts. DO NOT use replacement parts of lesser quality.
• Use recommended tools.
• Make sure tools and procedures not specified by the manufacturer will not be a safety risk to personnel or oper-
ation of the vehicle.
• Use wheel chocks and support the vehicle on jack stands. Never get under a vehicle that is supported by a jack.
Lift the vehicle in accordance with the manufacturer's instructions.
• Make sure you service the vehicle in an area away from open flame or sparks.
• Know that a vehicle in need of repair does not operate correctly and can be dangerous to operate.
• After completing repairs or maintenance, test the vehicle in a safe area where there are no vehicles or pedestrian
traffic.
• Make sure you record and keep all of the maintenance history of the vehicle.
VENTILATION
ALWAYS:
• Always store gasoline vehicles in a well ventilated area. Good ventilation decreases the risk of gasoline fumes
accumulating.
• Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
water heaters and furnaces.
• Never work around or operate a vehicle in an environment that does not allow ventilation of exhaust gases from
the area. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.
Notes:
v
Repair and Service Manual
SAFETY INFORMATION
649287
Notes:
vi
Repair and Service Manual
SAFETY INFORMATION
649287
B
TABLE OF CONTENTS
vii
Repair and Service Manual
649287
SAFETY INFORMATION
GENERAL......................................................................................................................... iii
GENERAL OPERATION................................................................................................... iii
MAINTENANCE................................................................................................................ iv
VENTILATION................................................................................................................... iv
GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER LABEL LOCATION............................................................................. 1
VEHICLE WITH A DISCHARGED BATTERY................................................................... 1
STARTING VEHICLE ON A HILL ..................................................................................... 1
SERVICING THE VEHICLE.............................................................................................. 2
FUEL................................................................................................................................. 2
FUEL TANK ...................................................................................................................... 3
Early Production Fuel Tank .................................................................................. 3
Late Production Fuel Tank ................................................................................... 3
BATTERY.......................................................................................................................... 3
ROUTINE MAINTENANCE............................................................................................... 3
POWERTRAIN MAINTENANCE....................................................................................... 4
BRAKES............................................................................................................................ 4
TIRES................................................................................................................................ 4
LIGHT BULB REPLACEMENT ......................................................................................... 4
TRANSPORTING VEHICLE ............................................................................................. 4
Towing .................................................................................................................. 4
Neutral Lock ......................................................................................................... 4
Hauling ................................................................................................................. 5
CANOPY AND WINDSHIELD........................................................................................... 5
WINTER OR PROLONGED STORAGE........................................................................... 5
VEHICLE CLEANING AND CARE.................................................................................... 6
VEHICLE CARE PRODUCTS........................................................................................... 6
HARDWARE ..................................................................................................................... 6
TORQUE SPECIFICATIONS............................................................................................ 7
SAFETY
NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................... 9
IMPORTANT SAFETY WARNING.................................................................................... 9
MODIFICATIONS TO VEHICLE ....................................................................................... 9
GENERAL MAINTENANCE.............................................................................................. 9
B
viii
Repair and Service Manual
TABLE OF CONTENTS
649287
BEFORE SERVICING VEHICLE....................................................................................... 9
Battery Removal and Installation ........................................................................10
LIFTING THE VEHICLE................................................................................................... 11
Lift the Vehicle ....................................................................................................11
Lift Rear of Vehicle Only .....................................................................................12
Lift Front of Vehicle Only .....................................................................................12
Lower the Vehicle ...............................................................................................12
BODY
GENERAL........................................................................................................................ 15
BODY COMPONENT REPLACEMENT .......................................................................... 15
Instrument Panel Replacement ...........................................................................16
Cowl Replacement ..............................................................................................17
Brush Guard Replacement .................................................................................17
Rocker Panel Replacement ................................................................................17
Side Panel Replacement ....................................................................................18
Seat Filler Panel Replacement ...........................................................................18
Rear Fender Replacement ..................................................................................19
Rear Body Panel Replacement ...........................................................................19
PAINTING........................................................................................................................ 20
Minor Scratches ..................................................................................................20
Larger Scratches .................................................................................................20
Complete Panel Repair .......................................................................................20
WHEELS AND TIRES
WHEEL AND TIRE SERVICE.......................................................................................... 23
Tire Repair ..........................................................................................................23
Wheel Installation ................................................................................................23
FRONT SUSPENSION AND STEERING
MAINTENANCE............................................................................................................... 27
Lubrication ..........................................................................................................28
Wheel Bearing and King Pin Bushing Inspection ................................................28
Wheel Bearing Packing .......................................................................................28
Wheel Bearing Adjustment .................................................................................29
Wheel Alignment .................................................................................................29
FRONT SUSPENSION.................................................................................................... 31
B
TABLE OF CONTENTS
ix
Repair and Service Manual
649287
Front Shock Absorber Replacement .................................................................. 32
Front Axle Replacement ..................................................................................... 32
Axle Linkage Rod Replacement ......................................................................... 33
Front Spring Replacement ................................................................................. 33
Hub Replacement .............................................................................................. 34
Wheel Bearing and Race Replacement ............................................................. 35
STEERING...................................................................................................................... 37
Rack Ball Joint Replacement ............................................................................. 37
Tie Rod Inspection/Replacement ....................................................................... 38
Bellows Replacement ......................................................................................... 39
Pinion Seal Replacement ................................................................................... 39
Spindle Replacement ......................................................................................... 40
Rack and Pinion Unit Disassembly and Inspection ............................................ 41
Rack and Pinion Unit Replacement ................................................................... 42
Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance .......... 42
Steering Wheel Replacement ............................................................................ 43
Steering Shaft and Column Replacement .......................................................... 44
SPEED CONTROL
SYSTEM OPERATION.......................................................................................................... 47
Pedal Box Operation .......................................................................................... 47
Governor Operation ........................................................................................... 48
FAULT TESTING............................................................................................................ 48
SPEED CONTROL ......................................................................................................... 48
Accelerator Cable Removal at Governor ........................................................... 48
Accelerator Cable Removal at Pedal Box .......................................................... 49
Accelerator Cable Installation ............................................................................ 49
Accelerator Cable Adjustment ............................................................................ 49
Throttle Rod Removal ........................................................................................ 49
Throttle Rod Adjustment .................................................................................... 49
PEDAL BOX ADJUSTMENTS........................................................................................ 50
Accelerator Pedal Arm Adjustment .................................................................... 50
Micro Switch Adjustment .................................................................................... 50
Road Test ........................................................................................................... 51
B
x
Repair and Service Manual
TABLE OF CONTENTS
649287
ENGINE
GENERAL........................................................................................................................ 53
FOUR CYCLE ENGINE................................................................................................... 53
Engine Specifications ..........................................................................................53
Engine Description ..............................................................................................53
POWERTRAIN MAINTENANCE ..................................................................................... 53
Checking the Oil Level ........................................................................................53
Changing the Oil .................................................................................................54
AIR FILTER INSPECTION/REPLACEMENT................................................................... 56
Clean the Air Filter Element ................................................................................56
STARTER/GENERATOR BELT TENSION ..................................................................... 56
Adjusting the Belt ................................................................................................57
STARTER/GENERATOR REPLACEMENT .................................................................... 58
COOLING SYSTEM CLEANING..................................................................................... 58
SPARK PLUG.................................................................................................................. 59
CYLINDER HEAD............................................................................................................ 59
Compression Leak Down Test ............................................................................59
Rocker Cover Removal .......................................................................................60
Valve Clearance Inspection ................................................................................60
Valve Clearance Adjustment ...............................................................................60
ENGINE REMOVAL......................................................................................................... 61
Controls and Wiring ............................................................................................62
Removing the Engine from the Vehicle ...............................................................62
Engine Installation ...............................................................................................62
DRIVE CLUTCH REMOVAL............................................................................................ 62
FUEL SYSTEM
GENERAL........................................................................................................................ 66
Early Production Fuel Tank .................................................................................66
Late Production Fuel Tank ..................................................................................66
CARBURETOR OPERATION.......................................................................................... 66
Float System .......................................................................................................66
Pilot Jet System ..................................................................................................67
Main Jet System .................................................................................................67
Choke System .....................................................................................................67
Carburetor Service ..............................................................................................67
B
TABLE OF CONTENTS
xi
Repair and Service Manual
649287
Choke Operation ................................................................................................ 67
FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT ................................. 68
Choke Cable and Housing Removal .................................................................. 68
Choke Cable and Housing Installation ............................................................... 68
Carburetor Removal ........................................................................................... 69
Carburetor Disassembly ..................................................................................... 69
Float Level Alignment ......................................................................................... 70
Carburetor Installation ........................................................................................ 70
FUEL PUMP.................................................................................................................... 71
Fuel Pump Replacement .................................................................................... 71
Fuel Lines and Filter ........................................................................................... 71
FUEL TANK REMOVAL.................................................................................................. 72
Early Production Vehicles .................................................................................. 72
Late Production Vehicles ................................................................................... 72
CARBON CANISTER...................................................................................................... 73
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GENERAL....................................................................................................................... 75
CLUTCHES..................................................................................................................... 75
Primary Clutch .................................................................................................... 75
Secondary Clutch ............................................................................................... 76
Increased Load .................................................................................................. 76
Equilibrium ......................................................................................................... 76
Removing the Transmission Belt ....................................................................... 76
Transmission Belt Service .................................................................................. 76
Primary Clutch Removal .................................................................................... 76
Primary Clutch Installation ................................................................................. 78
Secondary Clutch Removal ................................................................................ 78
Secondary Clutch Repair ................................................................................... 78
Secondary Clutch Assembly .............................................................................. 78
Secondary Clutch Installation ............................................................................. 78
STORAGE....................................................................................................................... 78
DIRECTION SELECTOR
DIRECTION SELECTOR................................................................................................ 81
Removing Direction Selector .............................................................................. 81
Replacing a Micro Switch ................................................................................... 82
B
xii
Repair and Service Manual
TABLE OF CONTENTS
649287
Shift Cable Adjustment .......................................................................................82
Neutral Lock Operation .......................................................................................82
ELECTRICAL
CIRCUITS AND CONTROLS .......................................................................................... 85
STARTER........................................................................................................................ 85
GENERATOR.................................................................................................................. 85
WIRING............................................................................................................................ 85
TESTING THE IGNITION CIRCUIT................................................................................. 85
Testing the Magneto ...........................................................................................87
TESTING THE STARTING CIRCUIT .............................................................................. 88
TESTING THE CHARGING CIRCUIT............................................................................. 88
INSPECTION................................................................................................................... 89
STARTER/GENERATOR ................................................................................................ 90
Starter/Generator Removal .................................................................................90
Disassembly ........................................................................................................90
Repair and Replacement ....................................................................................90
VOLTAGE TEST FOR BATTERY.................................................................................... 90
STORAGE OF BATTERY................................................................................................ 91
DVOM (DIGITAL VOLT OHM METER) ........................................................................... 91
FAULT TESTING............................................................................................................. 91
POWER PROVIDE.......................................................................................................... 92
ACCESSORY WIRING.................................................................................................... 92
LIGHT BULB REPLACEMENT........................................................................................ 92
Headlight Bulb Replacement ..............................................................................92
BRAKES
BRAKE SYSTEM OVERVIEW......................................................................................... 97
General Description ............................................................................................97
How the Brake Works .........................................................................................97
Equalizer Link .....................................................................................................98
Automatic Adjuster Mechanism ..........................................................................98
How the Parking Brake Works ............................................................................98
Kick-Off Actuating Linkage ..................................................................................98
Compensator Assembly ......................................................................................98
FAULT TESTING FLOWCHART..................................................................................... 99
FAULT TESTING TABLE............................................................................................... 101
B
TABLE OF CONTENTS
xiii
Repair and Service Manual
649287
FAULT DIAGNOSIS AND INSPECTION ...................................................................... 102
New Vehicle ..................................................................................................... 102
Fault Diagnosis and Inspection Procedures ..................................................... 102
Brake Pedal and Linkage Inspection ................................................................ 102
Daily Brake Performance Test ......................................................................... 105
Brake System Inspection ................................................................................. 105
Wheel Brake Inspection ................................................................................... 105
MAINTENANCE AND REPAIRS................................................................................... 107
Adjusting Brake Pedal Free Travel .................................................................. 108
Brake Drum Removal and Installation .............................................................. 109
Wheel Brake Service ........................................................................................ 110
Backing Plate/Entire Wheel Brake Assembly Removal and Installation .......... 110
Brake Shoe Removal ....................................................................................... 111
Brake Shoe Installation .................................................................................... 113
Brake Cable and Equalizer Assembly Removal and Installation ..................... 114
Compensator Assembly, Removal and Installation .......................................... 114
Brake Pedal Removal and Installation ............................................................. 114
Parking Brake Catch Bracket Removal and Installation ................................... 115
Parking Brake Pedal Removal and Installation ................................................ 115
Pedal Bumper Adjustment ............................................................................... 116
Parking Brake Release Linkage Removal and Replacement .......................... 116
Parking Brake Kick-Off Cam Removal, Replacement and Installation ............. 116
FRONT HYDRAULIC BRAKES (ONLY FOR TRUCKSTER LS) .................................. 117
SYSTEM DESCRIPTION.............................................................................................. 117
MASTER CYLINDER REPLACEMENT........................................................................ 117
Remove Master Cylinder .................................................................................. 117
Install Master Cylinder ...................................................................................... 117
MASTER CYLINDER FLUID......................................................................................... 118
Flush Hydraulic Brake System ......................................................................... 118
Check Brake Fluid ............................................................................................ 118
ROUTINE MAINTENANCE........................................................................................... 118
REPLACEMENT OF WEAR ITEMS ............................................................................. 118
Brake Pad Replacement .................................................................................. 118
Rotor Replacement .......................................................................................... 119
Spindle Replacement ....................................................................................... 119
Actuator Linkage Bushings .............................................................................. 119
B
xiv
Repair and Service Manual
TABLE OF CONTENTS
649287
Actuator Pivot Bushings ....................................................................................119
BLEEDING BRAKES..................................................................................................... 119
General Information about Bleeding Brakes .....................................................119
Brake Bleeding Procedure ................................................................................120
REAR AXLE
NEUTRAL LOCK ........................................................................................................... 123
Checking the Lubricant Level ............................................................................123
REAR AXLE DISASSEMBLY ........................................................................................ 124
Axle Shaft Removal and Disassembly ..............................................................124
Axle Shaft Seal Removal and Replacement .....................................................125
Axle Shaft Replacement ...................................................................................125
REAR SUSPENSION
REAR SUSPENSION .................................................................................................... 127
General .............................................................................................................127
Shock Absorber Removal .................................................................................127
Shock Absorber Installation ..............................................................................127
Rear Leaf Spring ...............................................................................................127
Removal ............................................................................................................128
Installation .........................................................................................................128
TRUCK BED
TRUCK BED REPLACEMENT...................................................................................... 132
WEATHER PROTECTION
CANOPY TOP AND WINDSHIELD............................................................................... 135
Transporting Vehicles .......................................................................................135
CANOPY TOP ............................................................................................................... 135
Rear Support Installation ..................................................................................135
Front Strut .........................................................................................................135
Canopy Top ......................................................................................................135
SPLIT WINDSHIELD ..................................................................................................... 137
FULL WINDSHIELD....................................................................................................... 138
SPLIT WINDSHIELD (CLIP-ON TYPE)......................................................................... 139
FULL WINDSHIELD (CLIP-ON TYPE).......................................................................... 140
B
TABLE OF CONTENTS
xv
Repair and Service Manual
649287
FAULT TESTING
GASOLINE VEHICLE PERFORMANCE ...................................................................... 143
FUEL ACCUMULATION IN THE CRANKCASE........................................................... 147
CARBURETOR............................................................................................................. 148
STARTER / GENERATOR............................................................................................ 149
SUSPENSION AND STEERING................................................................................... 150
BRAKE SYSTEM ......................................................................................................... 151
GENERAL SPECIFICATIONS
VEHICLE DIMENSIONS............................................................................................... 157
TURNING DIAMETER AND INCLINE INFORMATION ................................................ 158
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE ............................................................................... 161
xvi
Repair and Service Manual
TABLE OF CONTENTS
Notes:
649287
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
1
Repair and Service Manual
649287
GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER LABEL LOCATION
The vehicle has two serial number and manufacture date
code plates. PART C label is found on the body panel
below the driver seat. PART D is found on the frame tube
below the floorboard. The other (PARTS A and B) is
found on the frame crossmember below the front seat.
Lift the seat and the flap to access PARTS A and B
(Figure 1).
Design changes occur continuously. When you order ser-
vice parts, the PIN number, manufacture date code or
serial number must be available.
Figure 1 Serial Number Locations
VEHICLE WITH A DISCHARGED BAT-
TERY
To decrease the risk of severe injury or death
from accidental movement, do not use jumper
cables to start a vehicle.
The vehicle has a starter/generator and does not idle.
When you start the engine, the starter/generator func-
tions as a starter and with the engine running, it functions
as a generator.
The generator can keep the battery charged with the
short run times with this type of vehicle. The generator
will not charge a discharged battery.
When the engine starts, the clutches engage and cause
the vehicle to move making jump starting both dangerous
and impractical.
Since the engine stops when the accelerator is released,
jump starting should not be attempted.
If the battery has discharged, charge it with a 12-volt
charger that is rated at 10 amps or less and according to
instructions supplied by the manufacturer of the charger.
STARTING VEHICLE ON A HILL
To decrease the risk of roll-back, do not
release the service brake until the engine has
started.
Do not use the accelerator and engine to hold the
vehicle on a hill. Doing so will cause early and
excessive wear to the drive train components.
To decrease the risk of permanent damage to the
drive train, do not allow roll-back when you start
the vehicle on a hill.
Put left foot on service brake and release the parking
brake. Press the accelerator with right foot and release
the service brake.
V
PART B
PART C/D
PART A
Part C
Lift Flap on Access Panel
Part A
Part B
Part D
V
Serial Number
Labels
B
2
Repair and Service Manual
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
649287
SERVICING THE VEHICLE
To decrease the risk of severe injury or death,
resulting from improper servicing techniques,
observe the following Warnings:
Do not attempt any type of servicing
operations before reading and under-
standing all notices, cautions and
warnings in this manual.
The drive wheels must be lifted and
supported on jack stands before you
do any service to the powertrain when
the engine is in operation.
Wear eye protec-
tion when you ser-
vice the vehicle.
Be careful when
you do work
around battery,
use solvents or compressed air.
To decrease the risk of electrical arc,
which can cause a battery explosion,
disable all electrical loads from the
battery before you remove the battery
wires.
To decrease the risk of engine dam-
age, do not operate the vehicle at full
throttle for more than 5 seconds with
the drive wheels lifted off the ground.
The vehicle owner and service technician must carefully
follow the procedures recommended in this manual. The
preventative maintenance, applied at recommended
intervals, keeps the vehicle dependable and decreases
the costs for the repairs.
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible compo-
nent failures or the manner in which each component
may fail.
A vehicle requiring repair indicates the vehicle is no lon-
ger functioning as designed and should be considered
potentially hazardous. Use extreme care when working
on a vehicle. When diagnosing, removing or replacing
any components that are not operating properly, consider
the safety of yourself and those around you, should the
component move unexpectedly.
Some components are heavy, spring loaded, highly corro-
sive, explosive, may produce amperage or reach high
temperatures. Gasoline, carbon monoxide, battery acid
and hydrogen gas could result in serious bodily injury to
the technician/mechanic and bystanders, if not treated
with the utmost caution. Be careful not to place hands,
face, feet or body in a location that could expose them to
injury should an unforeseen dangerous situation occur.
Always use the appropriate tools listed in the tool list and
wear approved safety equipment.
Before a new vehicle is put into operation, do the items
shown in the INITIAL SERVICE CHART.
Figure 2 Initial Service Chart
FUEL
To decrease the risk of severe injury or death
from improper fuel handling:
Do not smoke near the fuel tank.
Do not add fuel near open flame or electrical
items which can cause a spark.
Always handle gasoline in a well ventilated
area.
Always wear eye protection to protect against
splashed fuel and fuel vapors.
Inspect the fuel cap, tank and other compo-
nents for leaks or damage that can cause a
hazardous condition.
Item Service Operation
Battery Charge battery.
Seats Remove protective plastic covering.
Brakes
Check operation and adjust if necessary.
Establish new vehicle braking distance.
Tires Check pressure.
Fuel Fill tank with correct fuel.
Engine Check oil level.
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120
  • Page 121 121
  • Page 122 122
  • Page 123 123
  • Page 124 124
  • Page 125 125
  • Page 126 126
  • Page 127 127
  • Page 128 128
  • Page 129 129
  • Page 130 130
  • Page 131 131
  • Page 132 132
  • Page 133 133
  • Page 134 134
  • Page 135 135
  • Page 136 136
  • Page 137 137
  • Page 138 138
  • Page 139 139
  • Page 140 140
  • Page 141 141
  • Page 142 142
  • Page 143 143
  • Page 144 144
  • Page 145 145
  • Page 146 146
  • Page 147 147
  • Page 148 148
  • Page 149 149
  • Page 150 150
  • Page 151 151
  • Page 152 152
  • Page 153 153
  • Page 154 154
  • Page 155 155
  • Page 156 156
  • Page 157 157
  • Page 158 158
  • Page 159 159
  • Page 160 160
  • Page 161 161
  • Page 162 162
  • Page 163 163
  • Page 164 164
  • Page 165 165
  • Page 166 166
  • Page 167 167
  • Page 168 168
  • Page 169 169
  • Page 170 170
  • Page 171 171
  • Page 172 172
  • Page 173 173
  • Page 174 174
  • Page 175 175
  • Page 176 176
  • Page 177 177
  • Page 178 178
  • Page 179 179
  • Page 180 180
  • Page 181 181
  • Page 182 182
  • Page 183 183
  • Page 184 184

Ransomes Truckster LS/LX User manual

Type
User manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI