Ransomes 648600G01, 648601G01 User manual

Brand: Ransomes

Model: 648600G01, 648601G01

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

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REPAIR AND SERVICE MANUAL

GASOLINE POWERED VEHICLES

TRUCKSTER LS

TRUCKSTER LX

STARTING MODEL YEAR 2016

NOTES

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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.

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SAFETY INFORMATION

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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.

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SAFETY INFORMATION

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• 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:

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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.

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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.

PART B

PART C/D

PART A

Part C

Lift Flap on Access Panel

Part A

Part B

Part D

Serial Number

Labels

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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.

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Ransomes 648600G01, 648601G01 User manual

Ransomes 648600G01, 648601G01 User manual

Ransomes 648600G01, 648601G01 User manual

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