Cushman Haulster 84065, Parts & Maintenance Manual

Page 1: ... should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine By Jacobsen When Performance Matters GB Cushman Haulster With Four Post ROPS 84065 Kubota D1105 E3B Diesel Engine MT 84070 Suzuki K6 Gas Engine MT 84071 Suzuki K6 Gas Engine AT 84072 Suzuki K6 Gas Engine RV and Utility 4241726 Rev A ...

Page 2: ...WORD Suggested Stocking Guide To Keep your equipment fully operational and productive Cushman suggests you maintain a stock of the more commonly used maintenance items We have also included part numbers for additional support materials and training aids To order any of the following material 1 Write your full name and complete address on your order form 2 Explain where and how to make shipment UPS...

Page 3: ...7 5 7 Cooling System 18 5 8 Air Filter 19 5 9 Jump Starting 19 5 10 Battery 20 5 11 Charging Battery 20 5 12 Fuel 21 5 13 Fuel System 21 5 14 Tire Pressure 21 5 15 Tire Removal and Installation 22 5 16 Raising the vehicle 22 5 17 Towing the Vehicle 23 5 18 Governor Oil Level 23 5 19 Hydraulic Brakes 24 5 20 Differential Fluid 25 5 21 Diesel Engine Manual Transmission 25 5 22 Gas Engine Manual Tran...

Page 4: ...ent that is not in perfect working order or is without decals guards shields or other protective devices securely fastened in place 12 Never disconnect or bypass any switch 13 Do not change the engine governor setting or overspeed the engine 14 Carbon monoxide in the exhaust fumes can be fatal when inhaled Never operate the engine without proper ventilation or in an enclosed area 15 Fuel is highly...

Page 5: ...ciency Adjustments and maintenance should always be performed by a qualified technician If additional information or service is needed contact your Authorized Cushman Dealer who is kept informed of the latest methods to service this equipment and can provide prompt and efficient service WARNING The Interlock System on this vehicle prevents the vehicle from starting unless the clutch pedal is depre...

Page 6: ...ring replacement parts or requesting service information Vehicle Identification Numbers must appear on all correspondence concerning this vehicle 2 2 ENGINE IDENTIFICATION NUMBERS _________________________________________ The Haulster is equipped with either a Kubota three cylinder diesel powered liquid cooled four cycle engine or a Suzuki three cylinder gas powered liquid cooled four cycle engine...

Page 7: ... 1300 RPM High Idle 3180 RPM Lubrication Capacity 5 4 quarts 5 1 liters Below 32 F 0 C SAE 10W or 10W 30 10W 40 32 77 F 0 25 C SAE 20W or 10W 30 10W 40 Above 77 F 25 C SAE 30W or 10W 30 10W 40 API Classification CD or CE Air Filter Dry type with evacuator valve Alternator 60 amp Cooling System Liquid Cooled Capacity 5 1 qt 4 8 l 50 50 water ethylene glycol mix Gas Engine Make Suzuki Model K6 Horse...

Page 8: ..._________________________________________ Diesel Engine Manual Transmission Gear Ratios 4th Gear 1 000 1 3rd Gear 1 423 1 2nd Gear 1 947 1 1st Gear 3 652 1 Reverse 3 463 1 Hydpoid Differential 11 16 1 Gas Engine 5 Speed Manual Transmission Gear Ratios 5th Gear 1 000 1 4th Gear 1 264 1 3rd Gear 1 908 1 2nd Gear 3 017 1 1st Gear 5 106 1 Reverse 5 151 1 Hypoid Differential 11 16 1 Gas Engine Automati...

Page 9: ... The four post ROPS equipped as standard equipment on this vehicle cannot be used with cab attachments If an enclosed cab is desired the four post ROPS must be replaced with Upper ROPS 894761 Truck Attachments Front Bumper 894778 Rear Bumper 894779 Protecto Seal Gas Cap 894720 Turn Signal with Right Taillight 894764 Back up Alarm 2703183 Exhaust Spark Arrestor 882574 Heater Defroster 894760 Rear S...

Page 10: ...push the engine cover latch towards the rear of the unit and tilt cover forward When replacing the engine cover make sure the retaining tabs located at the front corners of the engine cover are inserted into the slots in the floorboard Tilt seat to the rear until the engine latch engages Lock key lock if equipped Figure 4A Figure 4B WARNING To prevent injury depress clutch pedal and shift transmis...

Page 11: ...up when the release lever is pulled and so must be lifted manually Figure 4C 4 4 ACCESS PANELS__________________________________________________________ There are two access panels located under the front cowl and one located in the middle of the floorboard Remove panel A under cowl to access the shifter linkage and wiring for the instrument panel Remove panel B under cowl to access the front susp...

Page 12: ...t and adjust new belt after first 24 48 hours of operation Adjust every 200 hours thereafter Adjust power steering pump so belt deflects 1 4 to 1 2 in 6 to 12 mm with a 20 lb push at midpoint between pulleys If tension is incorrect loosen power steering pump mounting bolts F and carefully pry pump away from the engine until proper belt tension is achieved Figure 4G 4 7 GAS GOVERNOR BELT __________...

Page 13: ...d at least two wheels at opposite corners of vehicle 2 Engage parking brake If handle is at an angle greater than 45 to the panel adjustment is required 3 Disengage parking brake 4 Tighten adjustment nut E a couple of turns 5 Engage parking brake Repeat steps 3 and 4 until handle is at an approximate 45 angle when parking brake is engaged Figure 4I E ...

Page 14: ...lbs Nm 30 40 7 40 54 2 3 8 24 ft lbs Nm 35 47 5 45 61 0 7 16 14 ft lbs Nm 50 67 8 65 88 1 7 16 20 ft lbs Nm 55 74 6 70 94 9 1 2 13 ft lbs Nm 75 101 7 100 135 6 1 2 20 ft lbs Nm 85 115 3 110 149 2 9 16 12 ft lbs Nm 105 142 4 135 183 1 9 16 18 ft lbs Nm 115 155 9 150 203 4 5 8 11 ft lbs Nm 150 203 4 195 264 4 5 8 18 ft lbs Nm 160 217 0 210 284 8 3 4 10 ft lbs Nm 170 230 5 220 298 3 3 4 16 ft lbs Nm ...

Page 15: ...e manufacturer The proper break in of a new engine can make a considerable difference to the performance and life of the engine Note The vehicle is designed to operate most efficiently at the preset governor setting Do not change the engine governor settings or overspeed the engine During the break in period Cushman recommends the following 1 During the first 50 hours of operation a new engine sho...

Page 16: ...l loss can damage the engine Considerable oil loss could be due to a loose or incorrectly installed drain plug cracked gaskets or a loose oil filter Drain plugs are located beneath the engine in the oil pan Remove both plugs when changing the oil Check drain plugs and oil for metal chips that could indicate engine damage Immediately replace drain plugs with damaged gasket surfaces After oil has co...

Page 17: ...ds follow this procedure 1 Stop the vehicle DO NOT shut the engine off Place vehicle in Neutral and engage the parking brake 2 Immediately disengage any accessories that are operating 3 Slow the engine speed to a fast idle 4 Remove any dirt chaff debris etc from the radiator intake screen located on the right side of the vehicle Temperature gauge needle should start to go down approximately 30 sec...

Page 18: ...n Remove lower radiator hose Close both drains and install lower radiator hose once system has completely drained d Empty and clean the recovery bottle e Fill radiator to the bottom of the filler neck with 50 50 antifreeze water mixture f Fill recovery bottle to full mark with 50 50 antifreeze water mixture 3 Keep radiator air passages clean Use compressed air 30 psi maximum to clean the fins Wate...

Page 19: ...an the inside of the filter housing without allowing dust into the air intake 7 Inspect the new element Do not use a damaged element and never use an incorrect element 8 Assemble the new element and make sure it seats properly 9 Assemble cap making sure it seals completely around the filter housing Dust evacuator A must be facing down 10 Install air cleaner assembly into the vehicle Secure with ha...

Page 20: ...o Section 5 10 Read the battery s and charger s manuals for specific instructions 2 Whenever possible remove the battery from the vehicle before charging If battery is not sealed check that the electrolyte covers the plates in all the cells Battery cables must be disconnected before using a fast charger or damage to the alternator may result 3 Make sure the charger is Off Then connect the charger ...

Page 21: ..._____________________________________ The Kubota diesel engine in the Haulster is self priming It is not required to purge air from the system Refer to Section 7 3 for specific maintenance intervals Before replacing any filter thoroughly clean the filter housing and the area around the filter Dirt must not be allowed to enter into fuel system 5 14 TIRE PRESSURE ____________________________________...

Page 22: ...into 1st gear or Park and apply the parking brake Chock or block the tire diagonally opposite the side being raised Raise the vehicle only enough to perform maintenance required Jack the vehicle to an appropriate height and place jack stands or equivalent support beneath the frame near the jack Lower the jack and allow the vehicle to rest on jack stands Do not remove jack When using a hoist to rai...

Page 23: ... type Remove the plug from the rear of the governor remove the plug from the top of the governor and add a SAE 20W motor oil until the oil begins to leak from the rear port Replace both plugs When replacing the plugs use Teflon tape or a Permatex 20 sealant or equivalent pipe thread sealant on the threads of the plug Torque the plugs to 95 10 in lb 10 7 1Nm Figure 5G WARNING To prevent injury or v...

Page 24: ...se to the bleeder screw and place the other end of the hose in a container to catch fluid from brake when bleeding the system 3 Bleed brake a Have an assistant push down on the brake pedal and hold the pedal down b Loosen the bleeder screw allowing fluid to flow c Tighten the bleeder screw d Have assistant release pedal NOTE Do Not release brake pedal until the bleeder screw is tightened or air wi...

Page 25: ... begins to leak from hole Apply pipe thread sealant and install filler plug Figure 5L Figure 5M 5 21 DIESEL ENGINE MANUAL TRANSMISSION ____________________________________ The transmission fluid should be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Differential Fluid Capacity 1 35 qts 1 28 l Fluid Type SAE EP 80 90 gear lube To check transmission fluid lev...

Page 26: ...RANSMISSION ____________________________________ The transmission fluid should be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Differential Fluid Capacity 3 8 qts 3 6 l Fluid Type Mercon Dexron II To check transmission fluid level the engine must be running Place the gear selector in Park apply the parking brake and start the engine With engine running remo...

Page 27: ...ector for easier access to rear of panel Light Bulb Replacement 1 Determine which bulb needs to be replaced 2 Rotate bulb holder 1 4 turn counter clockwise and pull up and away from dash panel 3 Replace old bulb with a new bulb of equal type Location Replacement Bulb A Voltmeter C658 B Temperature Gauge C658 C Fuel Gauge C658 D Hour Meter C658 E Tachometer C161 F Left Turn Signal C161 G Oil Pressu...

Page 28: ...egative BLACK battery cable 2 Remove the four screws securing the headlight bezel to the front cowl 3 Pull headlight and bezel forward out of the front clip opening 4 Disconnect the electrical connector from the rear of the headlight 5 Remove the headlight from the bezel Properly dispose of old bulb 6 Install new headlight in reverse order of removal Figure 5S 5 27 TAIL LIGHT REPLACEMENT__________...

Page 29: ..._________________________ Wash the vehicle after each use Keep the equipment clean Note Do not wash any portion of the equipment while it is hot Do not use high pressure spray or steam Use cold water and automotive cleaners 1 Use compressed air to clean engine and radiator fins A special blow gun is available through Cushman Dealer 2 Use only fresh water for cleaning your equipment Note Use of sal...

Page 30: ...ischarge rate room temperature should not rise above 80 F 27 C Room temperature should not fall below 20 F 7 C to prevent electrolyte from freezing Engine General 1 While the engine is warm remove the drain plug drain the oil from the crankcase and change oil filter Install drain plug and refill with fresh oil Let engine cool before storing 2 Clean exterior of engine Paint exposed metal or apply a...

Page 31: ...hard to start or runs poorly 1 Fuel level low Fuel or fuel filter dirty 1 Fill with fresh fuel Change fuel filter Bleed fuel lines 2 Air cleaner dirty 2 Inspect and replace air filter 3 Injectors fuel pump 3 Consult engine manual 4 Engine problem 4 Consult engine manual Engine stops 1 Fuel tank empty 1 Fill with fresh fuel and bleed fuel lines Engine overheating 1 Coolant level low 1 Inspect and a...

Page 32: ...her friction points that are not shown on the lubrication chart apply several drops of SAE 30 oil every 40 hours or as necessary 4 Grease fittings every 100 hours Do not over grease drive shaft fittings A Too much grease will damage the seals 7 2 LUBRICATION CHART _____________________________________________________ WARNING Before you clean adjust or repair this equipment disengage all drives low...

Page 33: ...Cooling System I C A I R 5 7 IV Differential Fluid I R R 5 20 III Electrical System I I 5 24 Engine Glow Plugs I Engine Idle Speed I I Engine Noise Vibration I Engine Oil Suzuki I R R 5 3 Engine Oil Kubota I R R 5 3 II Engine Oil Filter I R R 5 3 Engine Oil Filter I R R 5 3 Engine Valve Clearance I I Fluid Leaks I R Fuel System I I 5 13 Fuel Filter R 5 13 Fuel Water Separator Diesel Only I C Gover...

Page 34: ...llowing common engine parts are provided for reference only Parts may be obtained from your nearest Kubota Engine Dealer Part Number Part Description 840352 Gas Air Filter Element 5000919 Diesel Air Filter Element 4113986 Diesel Oil Filter 2701809 Gas Oil Filter 4183591 Diesel Fuel Filter 2701898 Gas Fuel Filter 4175560 Diesel Alternator Belt 841966 Diesel Hydraulic Pump Belt 4139265 Gas Alternato...

Page 35: ...NOTES 8 35 8 NOTES ...

Page 36: ... on the order 2 Explain where and how to make shipment 3 Give product number name and serial number that is stamped on the name plate or serial plate of your product 4 Order by the quantity desired the part number and description of the part as given in the parts list 5 Send or bring the order to an authorized Cushman Distributor 6 Inspect all shipments on receipt If any parts are dam aged or miss...

Page 37: ... Clutch 86 26 1 Suzuki Gas Engine 88 27 1 Diesel Engine Speed Control 90 28 1 Diesel Engine Air Filter 92 29 1 Diesel Engine Exhaust and Remote Oil Filter 94 30 1 Governor Linkage 96 31 1 Governor 98 32 1 Gas Engine Air Filter 100 33 1 Gas Engine Remote Oil Fill 102 34 1 Gas Engine Exhaust 103 35 1 Fuel Tank 104 36 1 Diesel Fuel System 106 37 1 Gas Fuel System 108 38 1 Diesel Electrical Components...

Page 38: ...C B B 2 2 3 3 5 6 7 8 9 10 12 12 12 12 11 11 13 14 16 18 18 19 20 21 22 23 24 27 28 28 29 29 30 31 30 31 4 17 15 25 26 1 33 33 34 34 35 35 32 HAULSTER HAULSTER CUSHMAN a Com pa ny HAULSTER 1 1 Front Body Serial No All ...

Page 39: ... 4 x 1 1 4 in 15 800943 8 Screw 10 14 Self Tapping 16 837303 2 Headlight Rectangular 17 841428 2 Bezel Headlight 18 828382 AR Seal Foam 19 452398 4 Screw M8 1 25 x 25 mm Hex Head 20 2702198 1 Latch Hood 21 841715 1 Rod Hood Release 22 303952 1 Flat Washer 10 23 306463 1 Cotter Pin 1 16 x 1 2 in 24 841753 1 Bracket Hood Latch 25 306419 2 Screw 1 4 20 x 1 2 in Hex Head 26 306488 2 Lockwasher 1 4 in ...

Page 40: ...PERATING TEMPERATURE SPARK PLUG GAP 032 035 0 8 0 9mm EMISSION CONTROL SYSTEM or ECS TWC SFI HO2S VALVE LASH COLD IN 0 18 0 23mm EX 0 30 0 35mm NO OTHER ADJUSTMENTS NEEDED FUEL THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE DO NOT PUT GASOLINE CONTAINING MORE THAN 10 ETHANOL IN THIS VEHICL E CO 400 HC NOx 13 4 LUBRICANT SAE 10W 40 EPA CO 400 HC NOx 12 0 CARB EMISSION STANDARDS g kW hr T...

Page 41: ...Right Side 7 450541 10 Screw M6 1 x 16 mm Pan Head 8 452388 2 Screw M8 1 25 x 20 mm Hex Flange 9 302288 8 Screw 1 4 20 x 1 in 10 523085 1 Latch Engine Cover 11 816401 1 Spring Torsion 12 830784 1 Clevis Pin 1 4 x 1 7 8 in 13 2702199 1 Catch Engine Latch 14 4139939 1 Insulation Engine Cover 15 893632 4 Mount Backrest See 3 1 or See 4 1 16 601937 2 Seat Base 17 893322 2 Backrest 18 893375 14 1 Cover...

Page 42: ... 1 REF Engine Cover REF Control Console WARNING This structure s proctective capability may be impaired by structural damage overturn or alteration If any of these conditions occur this structure must be replaced WARNING Use seat belt HAULSTER 3 1 Upper ROPS Serial No All ...

Page 43: ... 75 x 30 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S 2 Screw 7 16 20 x 1 in Hex Head 8 N S 2 Flat Washer 7 16 9 N S 2 Nut 7 16 20 Hex 10 841799 1 Guard Seat Belt 11 800930 4 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 450401 1 Flat Washer M10 14 450412 1 Lockwasher M10 15 893632 4 Support Backrest See 2 1 16 800930 8 Screw M8 1 25 x 16 m...

Page 44: ...truck models with matching lower structure The protection offered by this ROPS will be impaired if it has been subjected to any modification or structural damage This ROPS must be replaced after a rollover Seat belts must be worn at all times Manufactured by JACOBSEN a Textron Company 11524 Wilmar Blvd Charlotte NC 28273 WARNING HAULSTER 4 1 Upper ROPS Optional Kit Serial No All ...

Page 45: ...1 Foam 1 2 in Perforated ROPS 4 452411 6 Screw M12 1 75 x 40 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S 2 Screw 7 16 20 x 1 in Hex Head 8 N S 2 Flat Washer 7 16 9 N S 2 Nut 7 16 20 Hex 10 841799 1 Guard Seat Belt 11 800930 12 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 893632 4 Support Backrest See 2 1 ...

Page 46: ...d and constructed for OFF ROAD USE ONLY Do not use this vehicle on any public roadway where automobiles or other motor vehicles are present Such use can be hazardous to the operator and other drivers passengers or bystanders 29165G01 THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE DEFINITION OF THE NATIONAL TRAFFIC MOTOR VEHICLE SAFETY ACT IT IS NOT DESIGNED OR MANUFACTURED FOR USE ON ROADS STREETS OR...

Page 47: ...28 4 Cotter Pin 3 32 x 3 4 in 15 843563 2 Plate Pivot 16 843561 1 Link Throttle Pivot 17 806714 3 Clevis Pin 5 16 x 3 4 in 18 844224 2 Roll Pin 3 16 x 1 3 4 in 19 515268 2 Bushing 20 844223 2 Spring Torsion 21 2703683 1 Throttle Cable Diesel Vehicles See 27 1 21 2703684 1 Throttle Cable Gas Vehicles See 30 1 22 800582 6 Screw 1 4 10 x 3 4 in Truss Head 23 2700496 4 Insert 1 4 20 Threaded 24 270185...

Page 48: ...48 2 3 3 3 5 5 5 5 6 7 8 9 10 10 12 11 13 14 16 4 15 1 HAULSTER 6 1 Parking Brake Serial No All ...

Page 49: ...1 25 x 40 mm Flange 5 450453 6 Nut M8 1 25 Flange 6 845133 1 Cable Parking Brake 7 450377 1 Nut M6 1 Staytite 8 827182 1 Pulley 3 in Cable 9 843359 1 Bushing Pulley 10 809152 2 Flat Washer 5 16 x 1 3 16 in 11 843356 1 Equalizer Parking Brake 12 800446 1 Locknut 5 16 24 13 843158 1 Bracket Parking Brake Cables 14 452398 2 Screw M10 1 5 x 20 mm Flange 15 450454 2 Nut M10 1 5 Flange 16 893583 2 Parki...

Page 50: ...hoses through opening in front clip Route front brake tube through opening in front clip Route rear brake tube under floor access panel Lower ROPS 2 3 5 6 6 7 7 8 9 10 12 11 13 14 16 16 16 16 18 19 20 21 22 22 23 24 27 28 29 29 30 34 33 32 31 4 17 17 15 25 26 1 HAULSTER 7 1 Brake Pedal Serial No All ...

Page 51: ...uid 826006 1 Electrical Connector 2 Wire 825886 2 Terminal 1 4 L Male 15 800934 2 Screw M6 1 x 16 mm Flange 16 832033 4 Clamp Hose 17 4194500 2 Hose 5 16 x 18 in Brake 18 810152 1 Pad Pedal 19 894308 1 Switch Brake Micro 20 450510 2 Screw M3 0 5 x 20 mm Pan Head 21 452424 2 Nut M3 0 5 Hex 22 452398 7 Screw M10 1 5 x 20 mm Flange 23 843021 1 Tube Front Brake 24 4194421 1 Tube Rear Brake 25 842103 1...

Page 52: ... 90 Degrees for Clarity Lower ROPS A A 2 3 5 6 7 8 9 10 12 11 13 23 14 16 12 18 19 20 21 22 4 17 15 1 Cable Routing Gas Units Diesel Units A 24 25 Diesel Units HAULSTER 8 1 Clutch Pedal Linkage Serial No 84065 All Serial No 84070 All Serial No 84072 All ...

Page 53: ...2281 1 Cable Clutch Diesel Units 11 895013 1 Cable Clutch Gas Units 12 844202 2 Washer Slotted 13 806703 1 Clevis Pin 5 16 x 31 32 14 306328 1 Cotter Pin 3 32 x 3 4 15 810152 1 Pad Pedal 16 842010 1 Bushing Clutch Release Arm Diesel Units Only 17 833273 1 Bushing Diesel Units Only 18 450377 1 Nut M6 1 Nylock Diesel Units Only 19 23266 85002 1 Arm Clutch Release Diesel Units Only 20 01550 08353 1 S...

Page 54: ... 20 20 21 22 36 32 33 34 1 25 26 27 28 Shifter Mounting and Cable Routing View Rotated 90 Degrees for Clarity 29 29 31 4 17 15 15 23 35 24 30 30 Diesel Unit Cable Attachment HAULSTER 9 1 Manual Transmission Shifter Linkage Diesel Units Serial No 84065 All ...

Page 55: ... 1 5 Flange 15 894179 2 Cable Shifter Diesel Units 16 842774 2 Ball Joint 1 4 28 17 816307 1 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 21 300977 1 Screw 1 4 28 x 5 8 in Hex Head 22 306396 1 Lockwasher 1 4 23 2702996 1 Boot Control Lever 24 2702695 1 Knob Shifter 25 548175 3 Flat Washer 1 4 x 1 1 4 in 26 308090 1 Flat Washer 1 4 27 84...

Page 56: ...1 22 35 23 31 32 33 37 27 28 Shifter Mounting and Cable Routing View Rotated 90 Degrees for Clarity 30 4 17 24 15 15 25 34 26 A 36 29 1 Gas Unit Cable Attachment HAULSTER 10 1 Manual Transmission Shifter Linkage Gas Units Serial No 84070 All Serial No 84072 All ...

Page 57: ...er 16 842774 2 Ball Joint 1 4 28 17 816307 1 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 21 300977 1 Screw 1 4 28 x 5 8 in Hex Head 22 306396 1 Lockwasher 1 4 23 308090 1 Flat Washer 1 4 24 4146818 1 Retaining Ring M5 25 2702696 1 Boot Control Lever 26 4140431 1 Knob Shifter 27 548175 3 Flat Washer 1 4 x 1 1 4 in 28 308090 1 Flat Washe...

Page 58: ...bers Notes 1 103867 2 Flat Washer 5 16 2 302030 1 Screw 1 4 20 x 1 1 4 in 3 306375 1 Nut 1 4 20 Hex 4 306396 1 Lockwasher 1 4 5 800582 4 Screw 1 4 20 x 3 4 in 6 821164 2 Hair Pin 1 4 x 1 1 8 in 7 842740 1 Lever Shifter 8 845345 7 1 Bracket Shifter Cable Mount 9 894584 1 Shifter with Cable 10 894508 1 Cable Shifter 11 892164 1 Kit Cable Mounting Hardware 12 2700496 4 Insert 1 4 20 ...

Page 59: ...ER Item Part No Qty Description Serial Numbers Notes 1 838340 1 Oil Cooler 2 800789 1 Kit Oil Cooler Mounting 3 826590 AR Hose 5 16 in I D 4 821893 AR Trim Push On 5 809231 2 Grommet 6 825624 4 Hose Clamp 12 1 Automatic Transmission Oil Cooler Serial No 84071 All ...

Page 60: ...60 9 9 10 6 8 7 9 16 1 2 2 3 4 5 5 10 10 10 10 11 12 13 21 22 14 15 17 17 17 18 18 19 19 20 HAULSTER 13 1 Frame Attachments Serial No All ...

Page 61: ...t Side Engine 9 450398 6 Screw M10 1 5 x 20 mm Flange 10 450454 15 Nut M10 1 5 Hex Flange 11 452399 5 Screw M10 1 5 x 25 mm Flange 12 452402 4 Screw M10 1 5 x 50 mm Flange 13 452414 2 Screw M12 1 75 x 70 mm Flange 14 809156 2 Flat Washer 1 2 15 450455 2 Nut M12 1 75 Hex Flange 16 894314 1 Harness Taillight 829630 1 Connector Male 4 Terminal 825886 4 Terminal 1 4 in Male 14 16 AWG 829631 1 Connecto...

Page 62: ... A A B B 2 5 5 6 6 7 7 7 8 8 8 9 9 9 10 10 12 19 19 Gas Engine and Transmission Mounts 27 28 13 14 4 4 15 1 13 12 9 23 20 16 6 30 21 17 18 3 11 26 22 24 25 HAULSTER 14 1 Frame and Lower ROPS Serial No All ...

Page 63: ...Gas Engine Gas Units 13 894582 1 Mount Right Side Diesel Engine Diesel Units 13 2701697 7 1 Mount Right Side Gas Engine Gas Units 14 842870 1 Angle Support 15 844647G01 1 Angle Hold Down 16 4185841 1 Battery Tray 17 N S 1 Battery 18 844601 1 Battery Clamp 19 452389 1 Screw M8 1 25 x 25 mm Flange 20 4174281 1 Transmission Mount Diesel Units 20 4179803 1 Transmission Mount Gas Units 21 452406 2 Scre...

Page 64: ...64 2 3 5 5 6 7 8 9 10 12 12 11 13 13 14 14 19 19 20 21 4 15 17 18 1 16 Gas Units Diesel Units HAULSTER 15 1 Rear Axle Serial No All ...

Page 65: ...t Circle N S 1 Tire 20 5 x 8 00 10 USA Trail Obtain Locally 11657G3 1 Valve Stem 12 311398 6 Screw 1 2 13 x 3 1 2 in Hex Head 13 800602 6 Nut 1 2 13 Nylon Insert 14 843876 4 Shackle Rear Spring 15 843238 2 Bushing Nylatron 16 829045 2 U Bolt 2 1 2 in 17 4174288 1 Driveshaft Complete Diesel Engine 17 4144334 1 Driveshaft Complete Gas Engine MT 17 4140071 1 Driveshaft Complete Gas Engine AT 18 41742...

Page 66: ...9 10 12 12 11 11 13 13 14 14 16 16 18 18 19 19 19 19 19 19 19 19 20 20 20 20 20 20 21 22 21 24 27 28 4 17 17 15 15 25 25 27 1 23 22 22 22 22 22 22 22 28 8 9 10 26 26 26 29 29 26 HAULSTER 16 1 Front Control Arms Serial No All ...

Page 67: ... in 13 471221 1 Grease Fitting 1 4 28 90 14 841429 2 Lower Ball Joint 15 N S 1 Boot 16 800861 1 Nut 9 16 18 Slotted Hex 17 460030 1 Cotter Pin 1 8 x 1 1 4 in 18 548224 1 Grease Fitting 1 4 28 Straight Special Drive Thread 19 841167 8 Bushing Silentbloc 20 450382 8 Nut M16 2 Locking Insert 21 450077 4 Bolt M16 2 x 90 mm Hex Head Grade 8 8 22 450393 8 Washer M16 23 894573 1 Knuckle Left Side Steerin...

Page 68: ...68 A A B B 2 3 5 5 6 6 7 7 8 9 10 10 12 12 11 11 13 13 14 14 16 16 16 18 18 19 19 20 20 21 21 22 23 4 17 17 17 17 15 15 1 HAULSTER 17 1 Steering Linkage Serial No All ...

Page 69: ... 16 14 x 2 in Hex Head 9 303269 3 Lockwasher 7 16 10 889681 2 End Left Hand Thread Tie Rod 11 816586 1 Retainer Grease 12 306825 1 Nut 7 16 20 Castle 13 887512 2 End Right Hand Thread Tie Rod 14 816586 1 Retainer Grease 15 306825 1 Nut 7 16 20 Castle 16 304636 4 Cotter Pin 1 8 x 1 1 8 in 17 831405 4 Grease Fitting 18 841404 2 Tie Rod 19 800485 2 Nut 9 16 18 Left Hand Thread Jam 20 302944 2 Nut 9 1...

Page 70: ...70 A A 2 2 3 3 5 6 7 7 8 8 9 9 10 10 12 11 11 13 14 14 16 18 18 19 19 20 20 14 14 22 22 21 21 4 4 17 15 1 1 HAULSTER 18 1 Front Brakes Serial No All ...

Page 71: ...der 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894933 1 Kit Left Side Spring 894935 1 Kit Left Side Adjuster Repair 13 893586 1 Front Right Side Brake Assembly 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894934 1 Kit ...

Page 72: ...72 Lower ROPS Power Steering Hose Routing 2 3 5 6 6 7 7 8 9 10 12 11 13 14 16 18 19 20 21 22 23 24 25 4 17 15 15 1 HAULSTER 19 1 Steering Column Serial No All ...

Page 73: ...g Tube 10 892228 1 Steering Wheel 11 450457 1 Nut M16 2 Flange 12 892486 1 Cover Steering Wheel 13 841255 1 Gear Steering See 17 1 14 843767 1 Hose Power Steering Pressure 15 111838 2 O Ring 16 843768 1 Hose Power Steering Return 17 111838 1 O Ring 18 840222 1 Hose Formed 19 832033 2 Clamp Hose 20 450739 1 Screw M10 1 5 x 30 mm Socket 21 800943 1 Screw 10 14 x 5 8 in Self Tapping 22 809092 2 Clamp...

Page 74: ...74 6 6 7 8 8 9 10 12 11 14 16 18 20 21 21 21 23 23 24 28 29 30 30 30 30 30 30 31 33 15 25 34 37 38 39 39 35 36 32 840754 009034880 2 19 1 3 4 5 13 17 HAULSTER 20 1 Diesel Radiator Serial No 84065 All ...

Page 75: ...Foam 19 553926 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 3 Nut M8 1 25 Hex Flange 22 4179800 1 Harness Oil Cooler Fan Wiring Not Shown See 50 1 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 4179801 1 Harness Radiator Fan Wiring Not Shown See 50 1 27 4174321 1 Harness Kubota Engine Wiring No...

Page 76: ...6 7 8 9 10 12 11 14 16 18 19 20 21 21 22 23 24 27 28 29 30 30 30 31 33 35 15 25 26 34 37 39 38 36 1 40 41 42 43 3 4 5 13 17 HAULSTER 21 1 Gas Radiator Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 77: ... 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 2 Nut M8 1 25 Hex Flange 22 843857 1 Sender Temperature 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 4120076 1 Cap Water Thermostat 27 4148206 1 Thermostat 88 C 28 2701442 1 Housing Temperature Sender 29 2701513 1 Gasket Thermostat 30 820889 4 Cla...

Page 78: ... 5 5 6 6 7 7 8 8 8 9 9 10 10 12 11 11 11 16 22 23 10 28 30 30 31 32 4 4 25 24 33 36 26 18 18 19 20 34 34 35 5 1 15 13 14 21 29 17 31 27 HAULSTER 22 1 Diesel Engine and Transmission Mounting Serial No 84065 All ...

Page 79: ...sher 1 4 16 4174285 1 Bracket Air FIlter Mount 17 452390 3 Screw M8 1 25 x 30 mm Flange 18 450412 2 Lockwasher M10 19 800571 1 Nut M10 1 25 Hex 20 4191140 1 Bracket Muffler 21 4174200 1 Mount Hydraulic Pump 22 894066 1 Transmission Assembly MT5 Includes Clutch Disc and Cover 23 11741 85200 1 Support Transmission 24 08310 00103 1 Nut 25 11710 77100 1 Bracket Rear Mount 26 4174281 1 Mount Transmissi...

Page 80: ...80 1 2 3 4 5 6 7 7 8 9 10 10 11 12 13 13 14 15 18 19 20 21 21 21 22 22 22 23 24 25 16 26 26 26 16 16 17 17 17 HAULSTER 23 1 Gas Engine and MT Mounting Serial No 84070 All Serial No 84072 All ...

Page 81: ... M10 1 25 x 55 mm Flange 10 2702690 2 Alignment Pins 11 4148360 1 Starter Manual Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 4233440 2 Cover Belt 15 4235369 1 Standoff M6 1 x 25 mm 16 450169 3 Screw M6 1 x 14 mm Hex Head 17 450410 3 Lockwasher M6 18 894998 7 1 Left Engine Mount See 14 1 19 2701697 7 1 Right Engine Mount See 14 1 20 4179803 1 T...

Page 82: ...82 13 18 19 20 21 21 21 22 22 22 3 2 7 7 10 10 11 12 9 8 4 5 23 24 25 6 1 14 15 16 26 26 26 16 16 17 17 17 HAULSTER 24 1 Gas Engine and AT Mounting Serial No 84071 All ...

Page 83: ...ge 10 2702690 2 Alignment Pins 11 4148361 1 Starter Automatic Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 4233440 2 Cover Belt 15 4235369 1 Standoff M6 1 x 25 mm 16 450169 3 Screw M6 1 x 14 mm Hex Head 17 450410 3 Lockwasher M6 18 894998 7 1 Left Engine Mount See 14 1 19 2701697 7 1 Right Engine Mount See 14 1 20 4179803 1 Transmission Mount S...

Page 84: ...84 2 4 5 8 7 10 10 10 10 12 13 14 15 16 17 18 19 19 6 21 12 22 3 19 11 1 20 20 9 24 23 25 26 HAULSTER 25 1 Diesel Engine and Clutch Serial No 84065 1651 XXXX ...

Page 85: ...Flange 11 450453 2 Nut M8 1 25 Flange 12 4173262 1 Ring Pressure Plate 13 4175560 1 Belt Alternator Power Steering 46 6 in 14 4174282 1 Bracket Alternator Adjusting 15 452402 1 Screw M10 1 5 x 50mm Flange 16 450454 1 Nut M10 1 5 Flange 17 361005 1 Screw M8 1 25 x 25 mm Hex Head 18 306325 3 Lockwasher 5 16 19 452379 3 Screw M6 1 x 25 mm Flange 20 09111 08035 2 Bolt M8 Special Included with Transmis...

Page 86: ...86 4 5 10 10 10 12 13 14 15 16 17 18 19 19 6 21 12 22 3 19 1 20 20 24 23 25 26 2 8 7 9 10 11 HAULSTER 25 2 Diesel Engine and Clutch Serial No 84065 xxxx and Up ...

Page 87: ...m Flange 11 450453 2 Nut M8 1 25 Flange 12 4173262 1 Ring Pressure Plate 13 4175560 1 Belt Alternator Power Steering 46 6 in 14 4174282 1 Bracket Alternator Adjusting 15 452402 1 Screw M10 1 5 x 50mm Flange 16 450454 1 Nut M10 1 5 Flange 17 361005 1 Screw M8 1 25 x 25 mm Hex Head 18 306325 3 Lockwasher 5 16 19 452379 3 Screw M6 1 x 25 mm Flange 20 09111 08035 2 Bolt M8 Special Included with Transm...

Page 88: ...88 1 4 5 7 22 16 8 10 11 12 13 14 15 9 17 19 20 23 24 2 3 25 26 27 27 29 28 25 30 31 31 21 21 18 6 32 HAULSTER 26 1 Suzuki Gas Engine Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 89: ...r 5 16 14 4139288 1 Pulley 4 Groove Micro V 4 4 in Dia Includes two set screws 15 4146490 1 Plate Hose Clamp 16 4235370 1 Belt 7 16 x 26 1 2 in V Alternator and Power Steering 17 4150138 1 Screw 3 8 16 x 2 1 4 in Hex Flange 18 4210205 1 Pulley 5 80 in Diameter 19 4143072 1 Tensioner Rotary 20 4144332 1 Pulley 2 3 4 in Idler 21 450453 3 Nut M8 1 25 Hex Flange 22 4142186 1 Belt 45 3 in Micro V 23 31...

Page 90: ...90 5 6 7 12 4 1 9 10 3 8 11 19 2 HAULSTER 27 1 Diesel Engine Speed Control Serial No 84065 All ...

Page 91: ...ubota Diesel Engine See 25 1 3 4174720 1 Bracket Throttle 4 452390 1 Screw M8 1 25 x 30 mm Flange 5 450453 2 Nut M8 1 25 Flange 6 800547 1 Screw M8 1 25 x 16 mm Hex Head 7 452388 1 Screw M8 1 25 x 20 mm Flange 8 4175021 1 Lever Throttle 9 103867 1 Flat Washer 5 16 10 821164 1 Hair Pin 11 450452 1 Nut M6 1 Flange 12 452738 1 Screw M6 1 x 20 mm Flange ...

Page 92: ...92 1 2 3 4 5 5 5 5 6 7 8 9 10 11 12 13 14 15 16 17 HAULSTER 28 1 Diesel Engine Air Filter Serial No 84065 All ...

Page 93: ...r 5000919 1 Element Air Filter 5000920 1 Cover 5000914 1 Vactuator Valve 7 4174620 1 Hose Intake 8 4174285 1 Bracket Air FIlter Mount See 22 1 for Mounting 9 3001388 1 Bracket Air FIlter 10 400184 1 Screw 5 16 18 x 3 4 in Hex Head 11 445795 1 Nut 5 16 18 Spiralock Flange 12 601595 1 Plate Blockoff 13 300646 2 Screw 1 4 20 x 3 4 in Hex Head 14 306396 2 Lockwasher 1 4 15 308090 2 Flat Washer 1 4 16 ...

Page 94: ... 11 12 13 14 14 15 15 16 View Rotated 180 17 17 18 19 3 20 21 22 23 24 25 26 27 28 29 29 30 30 31 31 32 33 34 Tailpipe Outlet to be parallel to ground HAULSTER 29 1 Diesel Engine Exhaust and Remote Oil Filter Serial No 84065 All ...

Page 95: ...ooler 14 48540 01 2 Clamp Hose 15 4176960 1 Remote Oil Cooler 16 4177560 1 Fan 7 1 2 in Push 17 4185240 2 Bracket Fan Mount 18 548910 4 Nut 1 4 20 Hex Flange 19 800017 4 Screw 1 4 20 x 1 in Pan Head 20 443102 4 Nut 1 4 20 Hex 21 4179161 1 Muffler 22 4174560 1 Tube Exhaust Inlet 23 4190700 1 Fitting Straight 24 452389 4 Screw M8 1 25 x 25 mm Flange 25 838295 8 1 Strap Muffler Hanger 26 450193 2 Scr...

Page 96: ...0 11 11 12 12 14 15 16 17 18 19 20 20 21 22 22 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 35 36 37 38 39 25 41 13 41 A 5 6 5 6 7 HAULSTER 30 1 Governor Linkage Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 97: ... Jam 17 2700335 1 Spring Governor 18 2700334 1 Spring Governor 19 111893 1 Screw 10 32 Special 20 2702244 2 Nut 10 32 Hex 21 800024 1 Screw 1 4 20 x 1 1 2 in Truss Head 22 306375 3 Nut 1 4 20 Hex 23 2703684 1 Throttle Cable See 4 1 24 308089 1 Flat Washer M6 25 821164 2 Hair Pin 1 4 x 1 1 8 in 26 818395 1 Clevis Pin 1 4 x 1 2 in 27 302288 1 Screw 1 4 20 x 1 in 28 306372 1 Cotter Pin 3 32 x 1 2 in ...

Page 98: ...98 A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 26 25 27 28 B 30 31 32 33 33 34 B 29 HAULSTER 31 1 Governor Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 99: ... 603102 1 Roll Pin 1 8 x 3 4 in 14 548325 1 Ring Retaining 15 800227 2 Plug 1 8 NPT 16 800558 1 Set Screw 3 8 16 x 5 16 in 17 833056 1 Gasket Governor 18 4189960 1 Seal Oil 19 835271 1 Nut Governor Arm 20 843537 1 Bracket Governor Knee 21 4114867 1 Head Governor 22 894471 1 Reservior Governor 23 833103 1 Bearing Needle 24 4119678 1 Shaft Governor Complete 25 833104 1 Ring Retaining 26 833345 1 Bea...

Page 100: ...100 1 2 3 3 3 4 4 5 6 7 8 9 9 9 9 10 11 12 13 14 15 16 17 18 19 HAULSTER 32 1 Gas Engine Air Filter Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 101: ...r Filter 5000914 1 Vactuator Valve 6 4139211 1 Hose Engine Air Intake 7 4140617 1 Grommet 8 4140618 1 Sensor Air Temp 9 11391G7 4 Clamp 2 3 4 in Worm Drive 10 4118423 1 Elbow 1 4 NPT Street 11 4118422 1 Hose Fitting 1 4 NPT Brass 12 2702484 1 Clamp 13 4231620 1 Bracket Air Cleaner 14 2702489 1 Bolt Included with Engine 15 300646 2 Screw 1 4 20 x 3 4 Hex Head 16 306396 2 Lockwasher 1 4 17 308090 2 ...

Page 102: ...Oil FIll Included with Engine 4 843420 1 O Ring 5 843399 1 Adapter Valve Cover 6 836206 2 Clamp 1 7 8 Worm Drive 7 4139271 1 Hose Remote Oil Fill 8 2701640 1 Adapter Oil Cap 9 4117892 4 Screw M6 1 x 16 mm Hex Flange 10 800425 2 Screw M6 1 x 12 mm Hex Head 11 306396 2 Lockwasher 1 4 12 4188387 1 Bracket Governor See 26 1 13 443810 2 Nut 3 8 16 Hex Jam 14 548804 2 Nut 3 8 16 Whizlock 15 548041 2 Scr...

Page 103: ...ad 7 64237 05 2 Locknut M8 1 25 8 4240882 1 Bracket Muffler Attaches to Transmission Case 9 841982 1 Clamp 1 1 2 in Exhaust 10 306419 4 Screw 1 4 20 x 1 2 in Hex Head 11 306396 4 Lockwasher 1 4 12 2702500 1 Ring Muffler Flange 13 4233160 1 Shield Muffler 14 306555 4 Screw 5 16 18 x 5 8 in Hex Head 15 306325 6 Lockwasher 5 16 16 103867 4 Flat Washer 5 16 17 4144336 2 Shield Catalytic Converter 18 4...

Page 104: ...104 Right Frame Rail 1 2 3 7 8 9 10 11 12 13 14 15 16 16 16 17 Gas Vehicles Diesel Vehicles 18 19 19 20 20 21 22 23 4 5 6 24 25 26 27 28 29 HAULSTER 35 1 Fuel Tank Serial No All ...

Page 105: ...87 2 Terminal 1 4 in Male 14 894201 1 Harness Fuel Sender 15 843078 1 Support Fuel Tank 16 452398 5 Screw M10 1 5 x 20 mm Flange 17 450454 1 Nut M10 1 5 Hex Flange 18 894922 1 Panel Fuel Tank 18 894922G 1 Panel Galvanized Fuel Tank Optional Galvanized Panel 19 800930 4 Screw M8 1 25 x 16 mm Flange 20 829997 2 Grommet 21 4174289 1 Bracket Fuel Filter Diesel Vehicles Only 22 452378 2 Screw M6 1 x 20...

Page 106: ...106 15 2 2 2 5 6 9 10 12 11 13 14 16 3 8 2 2 7 2 2 2 17 1 4 8 HAULSTER 36 1 Diesel Fuel System Serial No 84065 All ...

Page 107: ...90 1 Hose Fuel Filter to Engine 5 16 in 25 Foot Roll Cut to 19 1 2 in 6 831039 1 Hose Engine Fuel Return 3 16 in 25 Foot Roll Cut to 2 3 4 in 7 4139967 1 Connector 5 16 to 3 16 in Hose 8 825264 2 Clamp Hose 9 REF 1 Engine 10 550553 1 Fuel Filter 550489 1 Element Fuel Filter 11 894638 1 Pump Electric Fuel 12 452394 1 Screw M8 1 25 x 70 mm Flange 13 450453 1 Nut M8 1 25 Flange 14 838154 1 Bracket Fu...

Page 108: ... 23 23 23 23 23 23 23 23 23 23 23 23 23 24 25 25 22 26 CONNECT TO FUEL INJECTOR RAIL CONNECT TO REAR FACING PORT ON INTAKE MANIFOLD 23 23 30 8 37 32 31 36 23 33 21 34 29 35 HAULSTER 37 1 Gas Fuel System Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 109: ...5 x 16 mm Hex Flange 15 450453 2 Nut M8 1 25 Hex Flange 16 800875 1 Nut M12 1 25 Hex 17 309067 1 Lockwasher 1 2 in External Tooth 18 REF 1 Bracket Fuel System See 14 1 19 REF 1 Grommet See 35 1 20 4218622 1 Hose Regulator to Tee 6 In length cut to 2 in 21 4218620 1 Hose Rollover Valve to Canister 5 Ft length cut to 27 in 22 4218620 1 Hose Tank Return to Regulator 5 Ft length cut to 20 in 23 825624...

Page 110: ...110 2 3 5 5 5 9 10 Item 8 Routing 12 11 1 13 13 14 15 16 8 7 5 6 7 8 4 1 17 18 19 20 21 Engine Harness Ground Wires 22 23 24 HAULSTER 38 1 Diesel Electrical Components Serial No 84065 All ...

Page 111: ...66 1 Harness Main See 49 1 9 843942 1 Socket 12V Accessory Plug 10 2701658 1 Panel Instrument with Tachometer 11 890000 1 Buzzer High Temperature Located inside front clip behind dash panel 12 831225 3 Clamp Wire Harness 13 306419 2 Screw 1 4 20 x 1 2 in Hex Head 14 306488 1 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 1 Flat Washer 1 4 17 4183304 1 Positive RED Battery Cable 18 4...

Page 112: ...13 Red Wires Black Wires 14 14 15 15 16 16 8 7 31 5 5 6 7 8 4 1 25 26 17 18 19 20 21 Engine Harness Ground Wires 22 23 24 27 2 3 1 28 29 30 5 32 33 HAULSTER 39 1 Gas Electrical Components Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 113: ... 2 in Hex Head 14 306488 1 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 1 Flat Washer 1 4 17 4183304 1 Positive RED Battery Cable Manual Transmission 17 4183303 1 Positive RED Battery Cable Automatic Transmission 18 4183301 1 Negative BLACK Battery Cable Battery to Transmission 19 306325 1 Lockwasher 5 16 20 450324 1 Nut M8 1 25 Hex 21 894602 1 Cable Frame Ground Manual Transmissi...

Page 114: ...114 1 2 3 5 6 7 8 9 10 11 11 4 HAULSTER 40 1 Differential Assembly Part Number 2701165 Serial No All ...

Page 115: ...Differential Housing See 41 1 2 N S 1 Axle Tubes and Shafts See 42 1 3 N S 1 Input Shaft See 44 1 4 N S 1 Front Cover See 43 1 5 112050 1 Screw 1 4 20 x 5 8 in Self Tap 6 820008 1 Fitting Hydraulic Brake Tee 7 832584 1 Clamp Tee Fitting 8 832587 1 Hose Brake 9 2703170 1 Tube Left Side Brake 10 2703171 1 Tube Right Side Brake 11 893583 2 Cable Parking Brake ...

Page 116: ...2 2 3 5 6 7 8 9 10 12 11 13 14 16 18 19 20 21 22 23 24 27 28 29 29 30 30 4 4 17 15 25 26 1 31 31 33 33 34 34 32 32 35 36 36 37 HAULSTER 41 1 Differential Housing Part Number 891829 Serial No 84065 1651 1692 ...

Page 117: ...h 16 836689 AR Shim 005 Thick 17 836690 AR Shim 010 Thick 18 836691 AR Shim 030 Thick 19 836692 1 Baffle Oil 20 836685 AR Shim 003 Thick Add or remove shims as required to adjust gear backlash 21 836686 AR Shim 005 Thick 22 836687 AR Shim 010 Thick 23 836677 1 Cup Bearing 2 84 in O D 24 836678 1 Cone Bearing 1 3 8 in I D 889870 1 Gear Set 25 N S 1 Pinion Gear and Shaft 26 N S 1 Ring Gear 27 N S 1 ...

Page 118: ... 18 19 20 21 22 23 24 27 28 29 29 30 30 4 4 17 15 25 26 1 38 31 31 33 33 34 34 32 32 35 36 36 37 HAULSTER 41 2 Differential Housing Part Number 891829 Serial No 84065 1693 and Up Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 119: ...im 005 Thick 17 836690 AR Shim 010 Thick 18 836691 AR Shim 030 Thick 19 836692 1 Baffle Oil 20 836685 AR Shim 003 Thick Add or remove shims as required to adjust gear backlash 21 836686 AR Shim 005 Thick 22 836687 AR Shim 010 Thick 23 836677 1 Cup Bearing 2 84 in O D 24 836678 1 Cone Bearing 1 3 8 in I D 889870 1 Gear Set 25 N S 1 Pinion Gear and Shaft 26 N S 1 Ring Gear 27 N S 1 Differential Carr...

Page 120: ...120 A A B B 2 3 5 6 7 8 9 10 12 12 11 13 13 14 14 16 16 18 19 19 20 20 21 21 22 22 23 23 24 24 27 27 28 28 4 17 15 15 25 25 26 26 1 HAULSTER 42 1 Axle Tubes and Shafts Serial No All ...

Page 121: ...pered Roller 17 893581 1 Left Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894933 1 Kit Left Side Spring 894935 1 Kit Left Side Adjuster Repair 18 893582 1 Right Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylin...

Page 122: ...122 2 2 3 3 5 5 6 7 7 8 9 11 10 4 4 1 HAULSTER 43 1 Front Cover 11 16 1 Differential 2701165 Serial No All ...

Page 123: ...nt 2 306322 9 Screw 5 16 18 x 7 8 in Hex Head 3 103867 8 Flat Washer 5 16 4 307776 3 Screw 3 8 16 x 2 3 4 in Hex Head 5 810437 2 Clamp 1 2 in P 6 810435 1 Clamp Right Side Brake Tube 7 306981 2 Flat Washer 3 8 8 836852 1 Breather 9 111074 1 Plug Fill 10 836959 1 Bracket Brake Tee Mounting 11 800227 1 Plug 1 2 NPT ...

Page 124: ...124 2 2 3 3 5 11 6 7 8 9 10 12 4 1 HAULSTER 44 1 Input Shaft 11 16 1 Differential 2701165 Serial No 84065 1651 1692 ...

Page 125: ...1 Shaft Input 2 836693 2 Bearing Ball 3 800695 2 Ring External Retaining 4 800737 1 Ring Internal Retaining 5 812335 1 Seal Oil 6 836428 1 Spacer Bearing 7 548952 1 Lockring 8 836420 1 Spacer Pinion 9 836440 1 Pinion 18 Tooth 10 800559 1 Nut 1 2 20 Crown Lock 11 836441 1 Gear 49 Tooth 12 809180 1 Spacer ...

Page 126: ...126 2 2 3 3 5 11 6 7 8 9 10 12 4 1 HAULSTER 44 2 Input Shaft 11 16 1 Differential 2701165 Serial No 84065 1693 and Up Serial No 84070 All Serial No 84071 All Serial No 84072 All ...

Page 127: ... Shaft Input 2 836693 2 Bearing Ball 3 800695 2 Ring External Retaining 4 800737 1 Ring Internal Retaining 5 812335 1 Seal Oil 6 836428 1 Spacer Bearing 7 548952 1 Lockring 8 836420 1 Spacer Pinion 9 4211960 1 Pinion 18 Tooth 10 800911 1 Nut 9 16 18 Crown Lock 11 836441 1 Gear 49 Tooth 12 809156 1 Spacer ...

Page 128: ...128 2 3 5 6 7 7 8 9 10 12 11 13 14 14 16 4 17 15 1 18 HAULSTER 45 1 Transmission Clutch Release Shift Selector Diesel Engine Only Serial No 84065 All ...

Page 129: ...w M8 1 25 x 55 mm 6 844228 1 Stop 5th Gear Lockout 7 548222 2 Set Screw 8 32 8 2702684 1 Plug Drain 9 11741 85200 1 Support Transmission 10 2702475 4 Screw 11 37610 80023 1 Switch Backup Light 12 09280 11002 1 O Ring 13 23260 85203 1 Shaft Clutch Release 14 09300 14017 2 Bushing Clutch Release 15 09448 20007 1 Spring Clutch Release 16 23265 85200 1 Bearing Clutch Release 17 REF 1 Shift Assembly Se...

Page 130: ...130 2 3 3 3 5 6 6 7 8 9 10 12 11 13 14 16 18 19 20 21 22 23 24 27 28 29 30 31 33 4 4 17 15 25 26 34 37 38 39 35 36 32 1 1 HAULSTER 46 1 Transmission Case Diesel Engine Only Serial No 84065 All ...

Page 131: ... Main Shaft See 47 1 15 09283 25088 1 Seal Oil 16 09390 68002 1 C Ring 17 09390 62010 1 C Ring 18 24560 83001 1 Gear Reverse Idle 19 24551 83010 1 Shaft Reverse Idle Gear 20 09261 06003 1 Pin 21 2702586 1 Cir Clip 22 09103 08132 3 Screw M8 1 25 x 100 mm Flange 23 01550 08353 5 Screw M8 1 25 Flange 24 2702659 4 Screw M8 1 25 x 40 mm Flange 25 01421 08303 1 Stud M8 1 25 26 2703002 1 Nut M8 1 25 Hex ...

Page 132: ...132 2 3 5 6 6 7 7 8 8 9 10 12 11 13 14 14 16 16 18 18 18 19 19 20 21 21 22 23 24 27 28 28 4 4 4 17 15 15 25 26 1 HAULSTER 47 1 Input and Main Shaft Serial No 84065 All ...

Page 133: ...52 1 Shaft Main 12 06111 06003 2 Ball 13 24400 83002 1 Low Speed Syncronizer Includes Hub and Sleeve 14 24436 83000 2 Spring Low Speed Syncronizer 15 2703580 2 Spring Low Speed 16 24431 83001 2 Ring Low Speed Syncronizer 17 24220 60A01 1 Gear Main Shaft 2nd 2nd Gear 18 09263 35015 3 Bearing Needle 19 09300 30003 2 Bushing 20 24211 83011 1 Gear Main Shaft Low 1st Gear 21 09166 30007 2 Washer 22 092...

Page 134: ...134 A A B C D B C D 2 3 5 6 7 8 9 10 10 10 12 11 13 14 16 18 19 20 21 22 23 24 27 28 29 30 31 33 4 4 4 17 15 25 26 32 1 HAULSTER 48 1 Gear Shift Fork Linkage Serial No 84065 All ...

Page 135: ...ring 11 09250 10006 1 Plug Locating 12 2703454 1 Case Gear Shift Lever 13 25520 85203 1 Shaft Grear Shift Lever 14 09284 17004 1 Seal Oil 15 25576 70D00 1 Spring 16 09160 17035 1 Washer 17 x 32 x 1 2 mm 17 25541 85201 1 Lever Gear Select 18 25545 85055 1 Dog Reverse Shift Limit 19 25546 60C01 1 Spring 20 09128 10002 1 Bolt M10 x 9 mm Retaining 21 09168 10007 1 Gasket 22 25547 70D00 1 Spring 23 091...

Page 136: ...nnector Gas Only Engine Harness Connector 1 Engine Harness Connector 2 Engine Harness Connector 3 Flasher Option Turn Signal Option Jumper Plug Brake Pedal Switch Horn Button Light Switch Clutch Pedal Switch Right Headlight Right Turn Signal Option Left Headlight Left Turn Signal Option Heater Option Ground Wires Automatic Transmission Not Used Optional Accessories 17 17 17 18 18 18 18 19 19 81 8 ...

Page 137: ... Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 7 826006 2 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 i...

Page 138: ...15 15 Pre Heat Relay Fan Relay Fan Motor Fan Relay Fuse 8 9 16 17 18 20 18 16 17 Starter Ground Wires Ground Alternator Starter Solenoid Glow Plug Fuel Solenoid 10 11 Glow Plug Fuse Temperature Sender Fan Switch Radiator Fan Harness Oil Cooler Fan Harness Radiator Fan Motor Fuse Oil Cooler Fan Motor Fuse Starter Ground Oil Cooler Fan Motor HAULSTER 50 1 Diesel Engine and Fan Harness Part Numbers 4...

Page 139: ...ay 842966 AR Terminal Female Relay 2700869 AR Terminal 3 8 in Female Relay 9 842959 1 Connector 2 Contact 833257 2 Terminal 3 32 in Female 838463 2 Seal Wire 10 NS 2 Block Maxi Fuse 11 1 Fuse 50 Amp Maxi Fuse 12 4113261 1 Fuse 25 Amp 13 4221100 1 Relay 12V 70 Amp SPST 4179801 1 Radiator Fan Harness 14 836536 1 Fuse 40 Amp 15 826006 1 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16...

Page 140: ...edal Switch Brake Pedal Switch Radiator Fan Fuel Sender Right Headlight Right Turn Signal Option Left Headlight Left Turn Signal Option 7 7 5 6 8 1 Ignition Switch Cab Stop Light Option Flasher Option Turn Signal Option Jumper Plug Tail Light Harness Connector Transmission Ground Wires B Starter Fuel Pump Starter Solenoid Parking Brake Switch Shift Switch Back Up Alarm Back Up Switch Speed Sensor ...

Page 141: ...Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 10 843550 1 Connector Eighteen Terminal 843551 AR T...

Page 142: ...Switch Brake Pedal Switch Radiator Fan Fuel Sender Right Headlight Right Turn Signal Option Left Headlight Left Turn Signal Option 7 7 5 6 8 1 Ignition Switch Cab Stop Light Option Flasher Option Turn Signal Option Jumper Plug Tail Light Harness Connector Transmission Ground Wires B Starter Fuel Pump Starter Solenoid Parking Brake Switch Shift Switch Back Up Alarm Back Up Switch Speed Sensor AT MT...

Page 143: ...33257 4 Terminal Female 838463 4 Seal Wire 26 845327 1 Connector 3 Contact Female 2700380 3 Terminal 2700381 3 Seal Wire 27 845328 1 Connector 9 Contact Female 2700385 2 Terminal 2700387 2 Seal Wire 2700384 7 Terminal 2700386 7 Seal Wire 28 839917 1 Plug 2 Wire Deutsch 29 839921 1 Lock 2 Wire Deustch 30 524358 2 Terminal 18 20 AWG Male Pin 31 838768 2 Lock 4 Wire Deutsch 32 838769 4 Terminal 18 20...

Page 144: ...Used CAN Connector 1 3 4 5 6 7 8 9 10 11 12 13 14 15 AT Engine Harness Connector Shift Solenoid Automatic Transmission Bk Rd Bk Rd Rd Gn Wh Bn Ye Bk Gn Og Wh Rd Rd Bk Wh Bk Wh Wh Pk Pk Wh Pk Wh Ye Bu Gn Wh Bk Wh Bk Wh Ye Bu Bu Bk Bu Wh Bk Rd Gn Wh Bn Ye 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52...

Page 145: ... Ye Gn Wh Bn Ye Pk Pk Bu Pk Bu Bk Gn Bk Gn Backup Alarm Bk Speedometer Signal Speed Sensor Og Og Og Wh Rd Wh Rd Bk Fuel Pump Fan Motor Fuel Relay Fan Relay Main Relay Shifter Light Rd Rd Rd Bn Ye Bn Ye Reverse Switch Manual Transmission Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Gn Bk Wh Ye Bu Wh Pk Wh Pk Wh Pk Pk Wh Pk Gn Wh Wh Ye Bu Gn Wh Rd HAULSTER ...

Page 146: ... Rd Bk Rd Bk Wh Ye Wh Ye Wh Og Bu Bu Wh Pk Wh Pk Gn Wh Gn Wh Og Og Pk Bu Gn Bk Wh Rd Ye Bk Bk Wh Bu Wh Bu Bk Wh 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Coolant Overheat Alarm 12 V Overheat Alarm Right Turn Tach Input Tachometer Voltmeter Temp Gauge Fuel Guage Left Turn Parking Brake Fuel Sender Oil Pressure High Beam Pre Heat 12 V Brake Fluid Level Gas Tach Input B S Wh Og Wh Og Wh Rd Wh Rd R...

Page 147: ... Bk Gn Bk Ye Bk Gn Bk Bu Wh Og Wh Og Wh Bu Bu Bu Bn Bn Wh Wh Wh Gn Bk Ye Bk Ye Bk Og Og Og Cab Stop Light Accessory Right Turn Signal Light Accessory Left Turn Signal Light Accessory Brake Accessory Connector 2 Horn Button 15 A 10 A 10 A 15 A Horn Brake Pedal Switch Flasher Turn Signal Accessory Single Tail Light Harness Jumper Plug Low Beam High Beam Low Beam High Beam Brake Light Tail Light Powe...

Page 148: ...Pk Ye Bk Bk Rd Bu Wh Bk Wh Og Bk 1 3 4 5 6 7 8 9 10 11 12 13 AT Engine Harness Connector Bk Wh Og Bk Ye Bu Bk Pk Ye Bu Ye Bk Bu Wh Bk Rd Og Bk Gn Bu Wh Bu 14 Gn 15 Bn Rd Wh Gn Rd Bk 44 Bk Bu 47 Bu Ye Bu Ye 50 Og 52 Bu Ye 53 Gn Bk 56 Rd Bu 57 Rd Ye 58 Bk Bu 59 Bu Bk 60 28 Bu Wh Bu Gn Bk Bu Ye Bu Ye Bn Bk Bn Wh Bk Rd Bk Rd Gn Bn Rd Bk Rd Bu Wh Rd Wh Wh Bk Rd Bk Wh Og Rd Bu Wh Rd Ye Bk Wh Bk Rd Ye Bu...

Page 149: ...l 1 Coil 2 Coil 3 M Injector 1 Injector 2 Injector 3 Gn Br Bk Bn Wh Bn Rd Bk Rd Ye Rd Bk Rd Bu Wh Br Bk Bn Wh Bk Rd Gn Bn Gn Wh Rd Bk Rd Bk Rd Ye Rd Bu Wh Gy Bu Gy Bu Wh Rd Wh Wh Bk Og Wh Bk Wh Bk Rd Wh Bk Wh Bk Wh Bk Wh Bk Rd Bk Rd Bk Rd Bk Rd Bk Rd Bk Rd Bk Rd Og Bk Rd HAULSTER ...

Page 150: ...ssory Connector 1 Accessory Connector 2 Accessory Connector 3 Accessory Connector 4 Brake Fluid Level Switch Dash Panel 10 A 10 A 20 A Ignition Switch Clutch Switch Wh Bn Bn Rd Bk Rd Bk Wh Bk Wh Ye Wh Og Wh Og Pk Bu Gn Bk Wh Rd Ye Bk Bk Wh Bu Wh Bu Gn 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Overheat Alarm Power Point 12 V Overheat Alarm Right Turn Diesel Tach Input Tachometer Voltmeter Temp G...

Page 151: ...Ye Bk Gn Bk Bu Wh Og Wh Bu Bu Bu Bn Bn Wh Wh Wh Gn Bk Ye Bk Ye Bk Og Og Og Cab Stop Light Accessory Right Turn Signal Light Accessory Left Turn Signal Light Accessory Brake Accessory Connector 2 Horn Button 15 A 10 A 10 A 15 A Horn Brake Pedal Switch Flasher Turn Signal Accessory Tail Light Harness 894314 Jumper Plug 2700913 Low Beam High Beam Low Beam High Beam Brake Light Brake Light Tail Light ...

Page 152: ...Diode Diode Fuel Pump Fuel Sender Fuel Solenoid Fuel Shutoff Relay Temp Sender Main Harness Connector 1 Main Harness Connector 2 Main Harness Connector 3 Glow Plugs Radiator Fan Relay Wires marked with are part of the radiator fan harness Fan Switch Resistor Plug Radiator Fan Motor Pre Heat Relay Alternator 25 A 40 A Bk Bk Bk Bk 30 85 86 87 87A Oil Pressure Switch Parking Brake Switch Wh Bk Ye Ye ...

Page 153: ...411 85201 135 25415 83000 135 25420 85201 135 25451 85261 135 25520 85203 135 25530 79501 135 25535 85412 135 25536 84200 135 25541 85201 135 25545 85055 135 25546 60C01 135 25547 70D00 135 25576 70D00 135 26121 85202 133 26131 85201 131 2700166 109 2700177 109 2700275 47 2700334 97 2700335 97 2700380 143 2700381 143 2700384 143 2700385 143 2700386 143 2700387 143 2700453 73 2700496 47 55 57 58 27...

Page 154: ...5 77 4140269 43 45 4140431 57 4140617 101 4140618 101 4140899 81 4141031 97 4141037 133 4141425 89 99 4142186 89 4142627 57 4142630 57 4142772 81 4142796 57 4143072 89 4144332 89 4144334 65 4144345 65 4146818 57 4146819 57 4148065 83 4148082 81 4148150 77 4148206 77 4148212 83 4148213 83 4148360 81 4148361 83 4149901 89 4150138 89 4154081 113 4166840 105 4166841 105 4166842 105 4168131 105 4168143...

Page 155: ...7 517226 117 119 523085 41 524358 143 524633 47 524643 47 548041 102 548079 67 548155 89 548159 39 548175 39 55 57 61 111 113 548222 129 548224 67 548325 99 548804 102 548849 79 548910 95 548911 47 548952 125 127 550489 107 550553 107 553020 95 553926 75 77 554663 65 558019 139 600992 75 600993 85 601585 63 93 601592 75 77 601595 93 601937 41 603102 99 604174 55 57 64237 05 95 103 7033 75 7162 75 ...

Page 156: ...7295 47 837296 137 141 837298 47 837301 137 141 837303 39 838154 107 838295 8 95 103 838340 59 838427 61 838463 139 143 838539 121 838602 79 838768 143 838769 143 838770 143 839917 143 839921 143 840222 73 840436 41 840508 39 840725 51 53 840726 51 53 840754 75 77 841167 67 841255 69 73 841336 69 841404 69 841428 39 841429 67 841430 71 121 841477G01 39 841630 67 841637 39 841663 47 841715 39 84173...

Page 157: ...3 893581 121 893582 121 893583 49 115 893585 71 893586 71 893613 65 893632 41 43 45 893862 65 894066 79 894159 47 894167 51 894179 55 894201 105 894232 61 894266 111 894308 51 53 894314 61 894348 75 894456 51 894471 99 894508 58 894573 67 894574 67 894581 63 894582 63 894584 58 894602 111 113 894635 69 894638 107 894922 105 894922G 105 894930 71 121 894931 71 121 894933 71 121 894934 71 121 894935...

Page 158: ...en Performance Matters Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technicians backed by Genuine Jacobsen Parts provide reliable high quality product support ...