®

4140625-Rev A

By Jacobsen 13

18
9

11
16

15

7
6

17 1 - INCLUDES ITEMS 3 - 16

19 3
10

Parts & Maintenance

Manual
Cushman Turf Truckster
84043 – Perkins 403C-11 Diesel Engine, MT
84044 – Perkins 403C-11 Diesel Engine, MT, EC
84056 – Suzuki K6 Gas Engine, MT
84057 – Suzuki K6 Gas Engine, AT
84061 – Suzuki K6 Gas Engine, RV and Utility

GB
 Table of Contents
1 Safety 6.9 Jump Starting .................................................... 20
1.1 Operating Safety.................................................. 4 6.10 Battery ............................................................... 21
1.2 Important Safety Notes ........................................ 5 6.11 Charging Battery ................................................ 21
2 Standards and Publications 6.12 Hydraulic Hoses ................................................ 22
2.1 Standards and Publications ................................. 6 6.13 Hydraulic Reservoir and Filter ........................... 22
3 Vehicle Identification Numbers 6.14 Fuel .................................................................... 23
3.1 Vehicle Identification Number .............................. 7 6.15 Fuel System ....................................................... 23
3.2 Engine Identification Numbers ............................. 7 6.16 Tire Pressure ..................................................... 23
4 Specifications 6.17 Tire Removal and Installation ............................ 24
4.1 Product Identification ........................................... 8 6.18 Raising the vehicle ............................................ 24
4.2 Engine .................................................................. 8 6.19 Towing the Vehicle ............................................ 25
4.3 vehicle .................................................................. 9 6.20 Governor Oil Level ............................................. 25
4.4 Gear Ratios .......................................................... 9 6.21 Hydraulic Brakes ............................................... 26
4.5 Weights and Dimensions ..................................... 9 6.22 Differential Fluid ................................................. 27
4.6 Accessories & Support Literature ...................... 10 6.23 Diesel Engine Manual Transmission ................. 27
5 Adjustments 6.24 Gas Engine Manual Transmission ..................... 28
5.1 General .............................................................. 11 6.25 Gas Engine Automatic Transmission ................ 28
5.2 Engine Access ................................................... 11 6.26 Electrical System ............................................... 29
5.3 Front Cowl Access ............................................. 12 6.27 Dash Panel ........................................................ 29
5.4 Access Panels ................................................... 12 6.28 Headlight Replacement ..................................... 30
5.5 Diesel Engine Alternator Belt ............................. 13 6.29 Tail Light Replacement ...................................... 30
5.6 Diesel Engine Hydraulic Pump Belt ................... 13 6.30 EFI Diagnostic Check ........................................ 31
5.7 Gas Engine Power Steering-Alternator Belt ...... 13 6.31 Care and Cleaning ............................................. 32
5.8 Gas Engine Hydraulic Pump Belt ...................... 14 6.32 Storage .............................................................. 32
5.9 Parking Brake Cable .......................................... 14 7 Troubleshooting
5.10 Torque Specification .......................................... 15 7.1 General.............................................................. 33
6 Maintenance 8 Maintenance & Lubrication Charts
6.1 General .............................................................. 16 8.1 General.............................................................. 34
6.2 Engine ................................................................ 16 8.2 Lubrication Chart ............................................... 34
6.3 Engine Oil .......................................................... 17 8.3 Maintenance Charts .......................................... 35
6.4 Power Steering Reservoir .................................. 18 8.4 Common Replacement Parts ............................ 36
6.5 Muffler and Exhaust ........................................... 18 8.5 Perkins Diesel Engine Service Parts ................. 36
6.6 Engine Overheat Procedure .............................. 18 9 Parts Catalog
6.7 Cooling System .................................................. 19 9.1 Table Of Contents ............................................. 37
6.8 Air Filter ............................................................. 20

This manual is designed for the Maintenance and Adjustment of this equipment.
Use the maintenance and adjustment instructions included in this manual and the operating
instructions included in the Safety and Operation Manual to service the machine.

The Safety and Operation Manual must be kept in the pouch on the back of the seat at all times
for reference by the operator.
Copyright 2006, Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”
Litho in U.S.A. 6-2006
 Suggested Stocking Guide
To Keep your Equipment fully operational and productive, maintain a stock of the more commonly used maintenance
items. We have included part numbers for additional support materials and training aids. A more complete listing of
accessories and attachments can be found in the Specifications Section.

Service Parts

Qty. Part No. Description Qty. Part No. Description

842553 Diesel Engine Oil Filter 2701908 Gas Engine Oil Filter
2208175 Diesel Engine Fuel Filter 2701898 Gas Engine Fuel Filter
600997 Diesel Alternator-Power Steering Belt 4139265 Gas Alternator-Power Steering Belt
841966 Diesel Hydraulic Pump Belt 4139351 Gas Governor-Hydraulic Pump Belt
885249 Hydraulic FIlter Element
840352 Air Filter Element (Gas and Diesel)

To Order Parts
1. Write your full name and complete address on the 5. Send or bring the order to an authorized Jacobsen
order. Dealer.
2. Explain where and how to make shipment. 6. Inspect all shipments on receipt. If any parts are
3. Give product number, name and serial number that is damaged or missing, file a claim with the carrier before
stamped on the name plate or serial plate of your accepting.
product. 7. Do not return material without a letter of explanation,
4. Order by the quantity desired, the part number, paint listing the parts being returned. Transportation charges
code, and description of the part as given in the parts list. must be prepaid.
Use of other than Jacobsen authorized parts, excluding emission related components defined in the
Emission Warranty, will void the warranty.

How To Use This Manual

Abbreviations
N/S - Not serviced seperately, can only be obtained by ordering main component or kit.
AR -Variable quantity or measurement is required to obtain correct adjustment.
Symbols such as ▲, next to the item number, indicate that a note exists which contain additional information
important in ordering that part.

Indented Items
Bulleted items indicate component parts that are included as part of an assembly or another component. These parts
can be ordered separetely or as part of the main component.
Item Part No. Qty Description Serial Numbers/Notes
▲ 1 123456 1 Mount, Valve Indicates a piece part
2 789012 1 Valve, Lift Includes Items 2 and 3
3 345678 1 • Handle Serviced part included with Item 2
4 N/S 1 • Seal Kit Non serviced part included with Item 2
5 901234.6 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Orange
5 901234.2 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Green

3
1 SAFETY
1 SAFETY

1.1 OPERATING SAFETY ______________________________________________________

! WARNING
EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS.
Familiarize yourself with the location and proper use of all controls. Inexperienced operator’s should receive
instruction from someone familiar with the equipment before being allowed to operate the machine.

1. Safety is dependent upon the awareness, concern and 12. Never disconnect or bypass any switch.
prudence of those who operate or service the equip-
13. Do not change the engine governor setting or
ment. Never allow minors to operate any equipment.
overspeed the engine
2. It is your responsibility to read this manual and all
14. Carbon monoxide in the exhaust fumes can be fatal
publications associated with this equipment (Safety
when inhaled. Never operate the engine without proper
and operation manual, engine manual, accessories
ventilation or in an enclosed area.
and attachments). If the operator can not read English
it is the owner’s responsibility to explain the material 15. Fuel is highly flammable, handle with care.
contained in this manual to them.
16. Keep the engine clean. Allow the engine to cool before
3. Learn the proper use of the machine, the location and storing and always remove the ignition key.
purpose of all the controls and gauges before you
17. Place transmission in neutral, depress clutch and
operate the equipment. Working with unfamiliar
engage parking brake before starting the engine
equipment can lead to accidents.
(motor). Start the engine only when sitting in operator’s
4. Never allow anyone to operate or service the machine seat, never while standing beside the unit.
or its attachments without proper training and
18. Equipment must comply with the latest federal, state,
instructions; or while under the influence of alcohol or
and local requirements when driven or transported on
drugs.
public roads. Watch out for traffic when crossing or
5. Wear all the necessary protective clothing and operating on or near roads.
personal safety devices to protect your head, eyes,
19. Local regulations may restrict the age of the operator.
ears hands and feet. Operate the machine only in
daylight or in good artificial light. 20. Operate the machine up and down the face of the
slopes (vertically), not across the face (horizontally).
6. Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform 21. To prevent tipping or loss of control, do not start or
the job. Only use accessories and attachments stop suddenly on slopes. Reduce speed when making
approved by Jacobsen. sharp turns. Use caution when changing directions.
7. Stay alert for holes in the terrain and other hidden 22. Always use the seat belt when operating vehicles
hazards. equipped with a ROPS.
8. Inspect the area where the equipment will be used. Never use a seat belt when operating vehicle
Pick up all the debris you can find before operating. without a ROPS.
Beware of overhead obstructions (low tree limbs,
electrical wires, etc.) and also underground obstacles 23. Keep legs, arms and body inside the seating
(sprinklers, pipes, tree roots, etc.) Enter a new area compartment while the vehicle is in motion.
cautiously. Stay alert for hidden hazards. 24. Always shift transmission to Neutral (Manual
9. Never allow anyone near the machine while in Transmission) or Park (Automatic Transmission) and
operation. The owner/operator can prevent and is engage parking brake before leaving the vehicle.
responsible for injuries inflicted to themselves, to 25. Charge batteries in an open well ventilated area, away
bystanders and damage to property. from spark and flames. Unplug charger before
10. Do not carry passengers. Keep bystanders and pets a connecting and disconnecting from battery. Wear
safe distance away. protective clothing and use insulated tools.

11. Never operate equipment that is not in perfect working

order or is without decals, guards, shields or other
protective devices securely fastened in place.

4
 SAFETY 1
1.2 IMPORTANT SAFETY NOTES ________________________________________________
CAUTION - Indicates a potentially hazardous situation
! This safety alert symbol is used to alert you to which, if not avoided, MAY result in minor or moderate
injury and property damage. It may also be used to alert
potential hazards. against unsafe practices.
DANGER - Indicates an imminently hazardous For pictoral clarity, some illustrations in this manual may
situation which, if not avoided, WILL result in death or show shields, guards or plates open or removed. Under
serious injury. no circumstances should this equipment be operated
without these devices securely fastened in place
WARNING - Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious
injury.

! WARNING
The Interlock system on this vehicle prevents the vehicle from starting unless
the clutch pedal is depressed (Manual Transmission) or gear selector is in
Park (P) or Neutral (N) (Automatic Transmission).

NEVER operate vehicle unless the Interlock system is working.

! WARNING
1. Before leaving the operator’s position for any reason:
a. Remove foot from accelerator pedal.
b. Slow vehicle using service brake.
c. Depress clutch and shift transmission to neutral.
d. Engage parking brake.
e. Stop engine and remove the ignition key.
2. Keep hands, feet, and clothing away from moving parts. Wait for all
movement to stop before you clean, adjust or service the machine.
3. Keep the area of operation clear of all bystanders and pets.
4. Never carry passengers, unless a seat is provided for them.
By following all instructions in this manual, you will prolong the life of your machine and maintain its maximum
efficiency. Adjustments and maintenance should always be performed by a qualified technician.
If additional information or service is needed, contact your Authorized Jacobsen Dealer who is kept informed of the
latest methods to service this equipment and can provide prompt and efficient service. Use of other than original or
authorized Jacobsen parts, excluding emission related components defined in the Emission Warranty, and
Accessories will void the warranty.

5
2 STANDARDS AND PUBLICATIONS
2 STANDARDS AND PUBLICATIONS

2.1 STANDARDS AND PUBLICATIONS ___________________________________________

This product meets requirements of ANSI B56.8 and has Internal Combustion Engine Powered Industrial Trucks:
been approved by the Factory Mutual Research ANSI/UL 558
Corporation to meet all Powered Industrial Truck portions
(classification D or G) of the OSHA requirements (as American National Standards Institute, Inc.
stated in section 1910.178). Approved power trucks shall 1430 Broadway
bear a label or some other identifying mark indicating New York, New York 10018 U.S.A.
approval by the testing laboratory. This product conforms OR
to EC directives and amendment 89/392 & 91/368.
Underwriters Laboratories Inc.
Users, operators and service persons should be familiar
333 Pfingsten Road
with the following standards and publications: (The
Northbrook, Illinois 60062 U.S.A.
material may be obtained from the address shown)
Flammable and Combustible Liquids Code:
ANSI/NFPA 30
Factory Mutual Approval Standard:
Class No’s 7811 & 7813; Gasoline or Diesel American National Standards Institute, Inc.
Powered Trucks, Types G, GS, D or DS. 1430 Broadway
New York, New York 10018 U.S.A.
Factory Mutual Research Corp.
1151 Boston-Providence Highway OR
Norwood, Massachusetts 02062 U.S.A.
National Fire Prevention Association
Batterymarch Park
Quincy, Massachusetts 02269 U.S.A.
National Fire Protection Association:
ANSI/NFPA #505; Powered Industrial Trucks

National Fire Prevention Association

Batterymarch Park
Quincy, Massachusetts 02269 U.S.A.

Personal Burden Carriers:

ANSI/ASME B56.8

American National Standards Institute, Inc.

1430 Broadway
New York, New York 10018 U.S.A.

6
 VEHICLE IDENTIFICATION NUMBERS 3
3 VEHICLE IDENTIFICATION NUMBERS

3.1 VEHICLE IDENTIFICATION NUMBER __________________________________________

The Vehicle Identification Number (VIN), consisting of the

model number, date code and serial number are all
printed on the Nameplate/Identification Decal attached to
the cross member under the dash. GOLF, TURF & SPECIALTY PRODUCTS
This vehicle may be covered
by one or more of the
Augusta Georgia, USA
The serial number is also stamped on the cross member. 1 800 241 5855
following U.S. patents:

It is located to the left of the Nameplate/Identification

MODEL 84043
Decal. DATE CODE M1903
LABEL # 75984G55
NOTE: Reference to the Front, Rear, Left and Right sides SERIAL # *2128855*
Lb/kg W Batt
Nom Power Hp/kw
of the vehicle are always determined by the operator’s
seated position.
Record the Vehicle Identification information below for
easy reference. Figure 3A
Model Number: ______________________ Always provide the Vehicle Identification Number of the
unit when ordering replacement parts or requesting service
Date Code: _________________________ information. Vehicle Identification Numbers must appear
Serial Number: ______________________ on all correspondence concerning this vehicle.

3.2 ENGINE IDENTIFICATION NUMBERS _________________________________________

The Truckster is equipped with either a Perkins 3
cylinder, diesel powered, liquid cooled, four cycle engine
or a Suzuki 3 cylinder, gas powered, liquid cooled, four
cylinder engine.
The Engine Serial Number for the Perkins engine is
stamped onto the engine block on the right side of the
engine near the alternator.
The Engine Serial Number for the Suzuki engine is
stamped onto the upper engine block on the right side of Engine Serial No.
the engine, under the engine mount and may be partially Perkins Diesel
hidden by the electrical harness. The serial number is
also hand printed on the fuel rail.
Record the Engine Serial Number below for easy
Figure 3B
reference.
Engine Serial Number: _________________________

Engine Serial No.

K6A Suzuki

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4 SPECIFICATIONS
4 SPECIFICATIONS

4.1 PRODUCT IDENTIFICATION_________________________________________________

84043.............................. Turf Truckster liquid cooled diesel 84057.............................. Turf Truckster liquid cooled diesel
engine, 4 speed manual engine, 3 speed automatic
transmission, 11.16:1 2 speed transmission, 14.21:1 2 speed
differential. differential.
84044.............................. Turf Truckster liquid cooled diesel 84061.............................. Turf Truckster liquid cooled gas
engine, 4 speed manual engine, 5 speed manual
transmission, 11.16:1 2 speed transmission, 11.16:1 2 speed
differential. EC approved. differential and upper ROPS.
84056.............................. Turf Truckster liquid cooled gas
engine, 5 speed manual EEC Sound Vibration M/S2
Product
transmission, 14.21:1 2 speed Power Arms Body
differential. 84044 103 dB(A) 2.14 .096

4.2 ENGINE__________________________________________________________________
Diesel Engine:
Make ............................... Perkins Low Idle ................... 1300 RPM
Model .............................. 403C.11 High Idle ................... 3180 RPM
Horsepower .................... 26.1 hp (19.5 kW) @3000 rpm Lubrication:
Note: Actual sustained horsepower will likely be lower Capacity.................... 3.7 quarts (3.5 liters)
than listed in specifications due to operating limitations Below 32° F (0° C) ... SAE 10W
and environmental factors 32-77° F (0-25° C) .... SAE 20W or 10W30
Displacement .................. 69 cu. In. (1131 cc) Above 77° F (25 ° C) SAE 30W or 10W30
Torque ............................ 49 ft. lbs. (67 Nm) @ 2100 rpm API Classification ..... CH4
Fuel: Air Filter .......................... Dry type with evacuator valve.
Type .......................... No. 2 Diesel Alternator ........................ 55 amp
Rating ....................... Min. Cetane rating 45 Cooling System .............. Liquid Cooled
Capacity...................... 5.1 qt. (4.8 l) 50/50 water ethylene
Capacity .................... 6.55 U.S. Gal. (24.5 liters)
glycol mix
Governor ......................... All Speed Mechanical

Gas Engine:
Make ............................... Suzuki Governor......................... External Mechanical
Model .............................. K6 Low Idle ................... 950 RPM
Horsepower .................... 32 hp (23.8 kW) @ 4600 rpm High Idle ................... 4450 RPM
Displacement .................. 40.2 cu. In. (658 cc) Lubrication:
Torque ............................ 38.3 ft. lbs. (51.9 Nm) @3200 rpm Capacity.................... 3.3 quarts (3.0 liters)
Fuel: Below 32° F (0° C) ... SAE 10W30
Type .......................... Unleaded Gasoline 32-86° F (0-30° C) .... SAE 10W30
Rating ....................... Min. Octane rating 87 Above 86° F (30 ° C) SAE 10W30W or 10W40
Capacity .................... 6.55 U.S. Gal. (24.5 liters) API Classification ..... SJ
Air Filter .......................... Dry type with evacuator valve.
CAUTION Alternator ........................ 60 amp
The use of any fuel containing greater than 10% Cooling System .............. Liquid Cooled
ethanol may harm the engine's emission control Capacity...................... 3.3 qt. (3.0 l) 50/50 water ethylene
glycol mix
system and therefore invalidate the emission-related
Spark Plugs:
warranty through the improper action of the operator.
NGK 3932................. DCPR7E Gap .032” - .035”
Denso ....................... XU22EPR-U Gap .032” - .035”

8
 SPECIFICATIONS 4
4.3 VEHICLE _________________________________________________________________
Tires: Type.......................... 12 Volt Lead/Acid
Front.......................... 20 x 10 - 10 Multi Rib Group........................ 24
Rear .......................... 24 x 13 -12 Titan Ultra Trac Service Brake ................. 4 Wheel hydraulic drum brakes
Tire Pressure: Brake Fluid................ DOT 3
Front.......................... 20 psi (138 kPa) Parking Brake ................. Integral to rear drum, hand lever
Rear .......................... Varies by load, See Section 6.16 actuated
Battery: Steering ......................... Front wheel power steering

4.4 GEAR RATIOS ____________________________________________________________

84043 and 84044 Gear Ratios: 84057 Gear Ratios:
4th Gear ................... 1.000:1 3rd Gear ................... 1.000:1
3rd Gear ................... 1.423:1 2nd Gear................... 1.536:1
2nd Gear ................... 1.947:1 1st Gear .................... 2.727:1
1st Gear .................... 3.652:1 Reverse .................... 2.222:1
Reverse..................... 3.463:1 Hypoid Differential .... 14.21:1 with 3.2:1 Reduction
Hypoid Differential..... 11.16:1 with 3.2:1 Reduction 84061 Gear Ratios:
84056 Gear Ratios: 5th Gear.................... 1.000:1
5th Gear .................... 1.000:1 4th Gear ................... 1.264:1
4th Gear ................... 1.264:1 3rd Gear ................... 1.908:1
3rd Gear ................... 1.908:1 2nd Gear................... 3.017:1
2nd Gear ................... 3.017:1 1st Gear .................... 5.106:1
1st Gear .................... 5.106:1 Reverse .................... 5.151:1
Reverse..................... 5.151:1 Hypoid Differential .... 11.16:1 with 3.2:1 Reduction
Hypoid Differential..... 14.21:1 with 3.2:1 Reduction

4.5 WEIGHTS AND DIMENSIONS ________________________________________________

Dimensions: Inches (mm) Weights: Lbs. (kg)
Length ........................................................... 114 (2897) 84043 .......................................................... 1604 (823)
Height.............................................................. 49 (1245) 84044 .......................................................... 1604 (727)
Wheel Base.................................................. 58.2 (1478) 84056 .......................................................... 1572 (713)
Turning Radius (Outside) .............................. 242 (6146) 84057 .......................................................... 1619 (734)
84061 .......................................................... 1572 _713)

9
4 SPECIFICATIONS
4.6 ACCESSORIES & SUPPORT LITERATURE ____________________________________
Contact your area Jacobsen Dealer for a complete listing of accessories and attachments.

! CAUTION
Use of other than Jacobsen authorized parts, excluding emission related components defined in the Emission
Warranty, and accessories may cause personal injury or damage to the equipment and will void the warranty
Flatbeds and Boxes Hydraulic Attachments
47” Quick Disconnect Flatbed....................................889983 High/Low Gas Hydraulics ........................................ 4147940
60” Quick Disconnect Flatbed....................................894769 High/Low Diesel Hydraulics....................................... 894713
47” Box Assembly (Requires 889983) .......................890010 Implement Lift (“A” Frame) ........................................ 892493
60” Box Assembly (Requires 894769) .....................2703394 Dry seal coupler, 1 set............................................... 894604
Poly Box Assembly ....................................................892530 Hydraulic PTO (Requires 894712 and 894713) ........ 894644
Box Liner (for 890010) ...............................................888532 Truck Attachments
Hitches Heavy Duty Mechanical PTO .................................. 4112981
Fifth wheel ball hitch ..................................................894690 Quick Aerator........................................................... 2701529
Receiver Style drawbar hitch ...................................4114386 Ram Mount (Sprayer control mount) ....................... 4119631
Flat bar style hitch....................................................4114566 1500 Top Dresser.................................................... 2701650
ROPS Attachments Turn Signal with Right Taillight .................................. 894764
Upper ROPS (Roll Over Protective Structure) ...........894761 VICON Spreader (Requires 2701601 or 2701602) . 2701600
Steel Door, Left Side (Requires 894761) .................2701303 VICON hydraulic power kit ...................................... 2701601
Steel Door, RIght Side (Requires 894761) ..............2701304 VICON mechanical power kit................................... 2701602
Outside Mirrors (Left and Right) ................................894768 Back-up Alarm ......................................................... 2703183
Rear Window .............................................................894758 Exhaust Spark Arrestor ............................................. 882574
Windshield with Wiper ...............................................894757 Heater Defroster ........................................................ 894760
Support Literature
Safety & Operation Manual ..................................... 4140626
Parts & Maintenance Manual .................................. 4140625
Suzuki Engine Parts Manual ................................... 4140632
Service & Repair Manual

10
 ADJUSTMENTS 5
5 ADJUSTMENTS

5.1 GENERAL ________________________________________________________________

2. Replace, do not adjust, worn or damaged

! WARNING components.

To prevent injury, depress clutch pedal and shift 3. Long hair, jewelry or loose fitting clothing may get
transmission to neutral, engage parking brake, stop tangled in moving parts.
engine and remove key from ignition switch before
making any adjustments or performing maintenance. ! CAUTION
Make sure the vehicle is parked on a solid and level Be careful to prevent entrapment of the hands and
surface. Never work on a vehicle that is supported fingers between moving and fixed components of the
only by the jack. Always use jack stands. machine.
If only the front or rear of the vehicle is raised, place
chocks in front of and behind the wheels that are not 4. Do not change governor settings or overspeed the
raised. engine.
5. Keep hands and feet away from moving parts. If
1. Adjustments and maintenance should always be possible do not make adjustments with the engine
performed by a qualified technician. If proper running.
adjustment cannot be made, contact an authorized
Jacobsen Dealer.

5.2 ENGINE ACCESS __________________________________________________________

Never remove or install the engine cover while the engine
is running. The engine cover is a machinery guard and its
removal exposes you to moving parts. Keep hands, hair
and clothing away from flywheel, radiator cooling fan,
alternator fan, engine belts, pulleys and air intake.

! WARNING
Keep clothing, hands and hair away from moving
parts. These items could become entangled, causing
serious personal injury. Engine Cover
Latch
For servicing the engine and related components, the
engine cover can be tilted forward or removed.
To gain access to the engine, unlock key-lock if installed, Figure 5A
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.
Retaining Tab
! WARNING In Slot On
Floor board
Failure to latch the seat properly can result in the
engine cover tipping forward causing loss of control of
the vehicle and possible personal injury.

Figure 5B

11
5 ADJUSTMENTS
5.3 FRONT COWL ACCESS ____________________________________________________
The front cowl opens to gain access to two access
panels, fuse panel, horn and master cylinder reservoir.
Pull Lever
To open the front cowl, locate the release lever at the To Release
Cowl Latc h
upper left corner of front clip, near the left side headlight.
Pull the lever toward the headlight to release the front
cowl latch and at the same time pull up on the front cowl.
Fully open the cowl and allow it to rest on the steering Front Cowl
Release Lever
wheel or upper ROPS structure (if installed).
The front cowl will not “spring up” when the release lever
is pulled, it must be lifted manually.

Figure 5C

5.4 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 A
linkage and wiring for the instrument panel.
Remove panel (B) under cowl to access the front
suspension.
Remove the center panel (C) in the middle of floorboard
to access the throttle cable, accelerator pedal linkage,
wire harness and rear hydraulic brake line.
NOTE: It will be necessary to remove the accelerator
B
pedal in order to completely remove the center floorboard
panel.

Figure 5D

Figure 5E

12
 ADJUSTMENTS 5
5.5 DIESEL ENGINE ALTERNATOR BELT _________________________________________
Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust alternator pulley so belt deflects 1/4” to 1/2” (6 -12
mm) with a 20 lb. push at midpoint between water pump D
and alternator pulleys.
If tension is incorrect, loosen alternator mounting bolts
(D) and adjust alternator until proper belt tension is
achieved.

Figure 5F

5.6 DIESEL ENGINE HYDRAULIC PUMP BELT _____________________________________

Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust hydraulic pump belt so belt deflects 1/4” to 1/2” (6
-12 mm) with a 20 lb. push at midpoint between pulleys.
If tension is incorrect, loosen pump mounting bolts (E)
and carefully pry away from the engine until proper belt
tension is achieved.

Figure 5G

5.7 GAS ENGINE POWER STEERING-ALTERNATOR BELT __________________________

Inspect 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”
(6 -12 mm) with a 39 lb. push at midpoint between
pulleys.
If tension is incorrect, loosen power steering pump
mounting bolts (F) and carefully pry away from the F
engine until proper belt tension is achieved.

Figure 5H

13
5 ADJUSTMENTS
5.8 GAS ENGINE HYDRAULIC PUMP BELT _______________________________________
Inspect new belt after first 24-48 hours of operation.
Belt is dynamically adjusted with a spring loaded
tensioner to 12 ft-lbs. No adjustment is required.
To remove belt, rotate tensioner towards radiator to
release tension and remove belt from pulleys.

Figure 5I

5.9 PARKING BRAKE CABLE___________________________________________________

1. Remove the engine cover. Put chocks in front of and
behind 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. E
5. Engage parking brake. Repeat steps 3 and 4 until
handle is at approximately a 45° angle when parking Figure 5J
brake is engaged.

14
 ADJUSTMENTS 5
5.10 TORQUE SPECIFICATION___________________________________________________

CAUTION
All torque values included in these charts are approximate and are for reference only. Use of these torque values is
at your sole risk. Jacobsen is not responsible for any loss, claim, or damage arising from the use of these charts.
Extreme caution should always be used when using any torque value.

Jacobsen uses Grade 5 bolts as standard, unless otherwise noted.

AMERICAN NATIONAL STANDARD FASTENERS AMERICAN NATIONAL STANDARD FASTENERS

SIZE UNITS SIZE UNITS

GRADE 5 GRADE 8 GRADE 5 GRADE 8

#6-32 in-lbs (Nm) 20 (2.3) – 7/16-14 ft-lbs (Nm) 50 (67.8) 65 (88.1)

#8-32 in-lbs (Nm) 24 (2.7) 30 (3.4) 7/16-20 ft-lbs (Nm) 55 (74.6) 70 (94.9)

#10-24 in-lbs (Nm) 35 (4.0) 45 (5.1) 1/2-13 ft-lbs (Nm) 75 (101.7) 100 (135.6)

#10-32 in-lbs (Nm) 40 (4.5) 50 (5.7) 1/2-20 ft-lbs (Nm) 85 (115.3) 110 (149.2)

#12-24 in-lbs (Nm) 50 (5.7) 65 (7.3) 9/16-12 ft-lbs (Nm) 105 (142.4) 135 (183.1)

1/4-20 in-lbs (Nm) 95 (10.7) 125 (14.1) 9/16-18 ft-lbs (Nm) 115 (155.9) 150 (203.4)

1/4-28 in-lbs (Nm) 95 (10.7) 150 (17.0) 5/8-11 ft-lbs (Nm) 150 (203.4) 195 (264.4)

5/16-18 in-lbs (Nm) 200 (22.6) 270 (30.5) 5/8-18 ft-lbs (Nm) 160 (217.0) 210 (284.8)

5/16-24 in-lbs (Nm) 240 (27.1) 300 (33.9) 3/4-10 ft-lbs (Nm) 170 (230.5) 220 (298.3)

3/8-16 ft-lbs (Nm) 30 (40.7) 40 (54.2) 3/4-16 ft-lbs (Nm) 175 (237.3) 225 (305.1)

3/8-24 ft-lbs (Nm) 35 (47.5) 45 (61.0) 7/8-14 ft-lbs (Nm) 300 (406.8) 400 (542.4)

METRIC FASTENERS
SIZE UNITS Non Critical
4.8 5.8 8.8 10.9 12.9
Fasteners
into
Aluminum
M4 Nm (in-lbs) 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 Nm (in-lbs) 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 Nm (in-lbs) 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 Nm (in-lbs) 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
M10 Nm (ft-lbs) 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 Nm (ft-lbs) 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 Nm (ft-lbs) 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

15
6 MAINTENANCE
6 MAINTENANCE

6.1 GENERAL________________________________________________________________

cated.
! WARNING c. Replace worn or damaged parts before operating
the machine.
Before you clean, adjust, or repair this equipment,
depress clutch pedal and shift transmission to neutral, d. Keep all fluids at their proper levels.
engage parking brake, stop engine and remove key from e. Keep shields in place and all hardware securely
ignition switch to prevent injuries fastened.

Make sure the vehicle is parked on a solid and level f. Keep tires properly inflated.
surface. Never work on a vehicle that is supported only 3. Long hair, jewelry or loose fitting clothing may get
by the jack. Always use jack stands. tangled in moving parts.

1. Adjustment and maintenance should always be 4. Use the illustrations in the Parts Catalog as reference
performed by a qualified technician. If proper for the disassembly and reassembly of components.
adjustments cannot be made, contact an Authorized 5. Recycle or dispose of all hazardous materials
Jacobsen Dealer. (batteries, fuel, lubricants, anti-freeze, etc.) according
2. Inspect the equipment on a regular basis, establish a to local, state or federal regulations.
maintenance schedule and keep detailed records. 6. Keep hands and feet away from moving parts. If
a. Keep the equipment clean. possible do not make adjustments with the engine
running.
b. Keep all moving parts properly adjusted and lubri-

6.2 ENGINE _________________________________________________________________

IMPORTANT: A separate Engine Manual, prepared by 5. Refer to Section 8.3 and Engine Manual for specific
the engine manufacturer, is supplied with this vehicle. maintenance intervals.
Read the engine manual carefully until you are familiar
6. If the injection pump, injectors or the fuel system
with the operation and maintenance of the engine.
require service, contact an authorized Jacobsen
Proper attention to the engine manufacturer’s directions
Dealer.
will assure maximum service life of the engine. To order
replacement engine manuals contact the engine Keep your engine clean. If dirt has accumulated on the
manufacturer. engine, it should be washed with a non-flammable
solvent or strong detergent.
The proper break-in of a new engine can make a
considerable difference to the performance and life of the When washing becomes necessary, it can be carried out
engine. simultaneously when servicing the vehicle.
Note: The vehicle is designed to operate most efficiently In order to maintain reliable service from your engine, a
at the preset governor setting. Do not change the engine regular check-up and maintenance scedule should be
governor settings or overspeed the engine. followed. Proper maintenance will prolong the engine’s
life and avoid premature overhaul.
During the break-in period, Jacobsen recommends the
following:
1. During the first 50 hours of operation, a new engine
should be allowed to reach an operating temperature of
at least 140°F (60°C) prior to operation at full load.
2. Check the engine oil level twice daily during the first 50
hours of operation. Higher than normal oil consumption
is not uncommon during the initial break-in period.
3. Change engine oil and oil filter element after first 35
hours of operation.
4. Check and adjust hydraulic pump and alternator belts.
See Sections 5.5, 5.6, 5.7 and 5.8.

16
 MAINTENANCE 6
6.3 ENGINE OIL ______________________________________________________________
Check the engine oil at the start of each day, before
starting the engine.
To check the engine oil, remove the dipstick and wipe it Oil Level Must
with a clean rag. Reinsert the dipstick until it contacts the Be Between
Engine Marks
Dipstick
oil tube, remove the dipstick and read the oil level. DO NOT OVERFILL
The oil level should always be between the ADD and
FULL mark on the dipstick. If oil level is below the add
mark, remove filler cap and add oil to bring the level up Diesel
between marks. Do Not Overfill. ADD Engine FULL
NOTE: If the engine has recently been running, allow
time (with engine turned off) to let the oil settle to obtain a
correct oil level reading.
ADD FULL
Diesel Engine: Use only engine oils with API
classification CH4. Gas
Engine
Gas Engine: Use only engine oils with API classification
SJ. Figure 6A
Using oil other than the service class listed, or oil change
intervals longer than recommended could reduce engine Perkins Diesel
life. Damage to engine due to improper maintenance or
use of incorrect oil quality and/or viscosity is not covered SAE 10W/10W-30 SAE 20W/10W-30 SAE 30W/10W-30
by the engine warranty.
Diesel Engine: Perform initial oil change after first 35 Suzuki Gas
hours of operation and every 75 hours or two months SAE 10W-30 for all temperature ranges 10W-40
thereafter. See Engine Manual.
Gas Engine: Perform initial oil change after first 50 hours °F -20 0 20 32 40 60 7780 100
of operation and every 100 hours or three months °C -30 -20 -10 0 10 20 25 30 40
thereafter. See Engine Manual.
Significant oil loss can damage the engine. Considerable Figure 6B
oil loss could be due to a loose or incorrectly installed Diesel Engine:
drain plug, cracked gaskets, or even a loose oil filter.
Above 77°F (25°C) SAE 30W or SAE10W30
Drain plugs are located beneath the engine in the oil pan.
Remove both plugs when changing the oil. 32 to 77°F (0 to 25°C) SAE 20W or SAE 10W30
Check drain plugs and oil for metal chips that could Below 32° (0°C) SAE10W or SAE 10W30
indicate engine damage. Replace drain plugs with Gas Engine:
damaged gasket surfaces immediately.
All temperature ranges SAE 10W30
After oil has completely drained, clean excess oil from oil
pan and drain plugs. Install drain plugs and tighten Above 85° F (29° C) SAE 10W 40
securely. Refer to engine manual for proper torque.
Replacement Oil Filters
Always replace the engine oil filter when changing the
engine oil. Apply a light coat of engine oil to the rubber Perkins Diesel 842553
gasket surface of new filter before installing.
Suzuki Gas 2701908
Diesel Engine: Fill Perkins engine with approximately
3.7 qts. (3.5 l) of clean engine oil. Check oil level and add
additional oil if required.
Gas Engine: Fill Suzuki engine with approximately 3.3
qts. (3.0 l) of clean engine oil. Check oil level and add
additional oil if required.

17
6 MAINTENANCE
6.4 POWER STEERING RESERVOIR _____________________________________________
When checking the fluid level before the engine has been
! WARNING warmed up, the level should be at the COLD mark on the
dipstick. After the engine has been warmed up and the
Before servicing or doing any maintenance work around fluid is warm, the level should be between the COLD and
the engine area, make sure the engine has had time to HOT marks. Use General Motors Power Steering Fluid
cool. Serious burns can result if the engine or as required to bring fluid up to proper level.
surrounding surfaces are hot.

The power steering reservoir is located on the right side

of the engine, below the alternator. Power Steering Dipstick

COLD
FULL
The level in the reservoir should be checked after the first

ADD

HOT
35 and 70 hours. After that level should be checked
every 100 hours.
Figure 6C

6.5 MUFFLER AND EXHAUST __________________________________________________

To protect from carbon monoxide poisoning, inspect the
! WARNING complete exhaust system regularly and always replace a
defective muffler.
Exhaust fumes contain carbon monoxide that is toxic and
can be fatal when inhaled. If you notice a change in the color or sound of the
exhaust, stop the engine immediately. Identify the
NEVER operate an engine without proper ventilation. problem and have the system repaired.
Torque all exhaust manifold hardware evenly. Tighten or
replace exhaust clamps.

6.6 ENGINE OVERHEAT PROCEDURE ___________________________________________

During vehicle operation, if the water temperature gauge Temperature gauge needle should start to go down
shows 230° F (110° C) or above, and/or the overheat approximately 30 seconds after the screen is cleaned. If
warning buzzer sounds, follow this procedure. temperature does not go down, STOP the engine and
check the following.
1. Stop the vehicle. DO NOT shut the engine off.
Place vehicle in neutral and engage the parking 1. Check to see if cooling fan is operating. Fan should
brake. be turning with coolant above 180° F (82° C) on
diesel units, 208° F (97.7° C) on gas units , even with
2. Immediately disengage any accessories that are
ignition switch in OFF position.
operating.
2. Check engine oil level.
3. Slow the engine speed to a fast idle.
3. Check for a leak in the cooling system. Do not open
4. Remove any dirt, chaff, debris, etc. from the radiator
radiator when hot. Check coolant levels after system
intake screen located on the right side of the
completely cools.
vehicle.
Failure to heed the overheat warning and properly
! CAUTION maintain the cooling system will cause permanent engine
damage.
Be careful when opening the engine access cover or
cleaning the intake screen. Metal surfaces near the
radiator and engine may be hot to the touch. Use a
brush or gloves to clean screen.

18
 MAINTENANCE 6
6.7 COOLING SYSTEM ________________________________________________________
This vehicle is equipped with a radiator, temperature b. Remove the radiator cap.
controlled fan, temperature gauge and an overheat c. Open the engine block drain and the radiator
buzzer. drain. Remove lower radiator hose. Close both
drains and install lower radiator hose once
! WARNING system has completely drained.
d. Empty and clean the recovery bottle.
To prevent serious bodily injury from hot coolant or
steam blow-out, never attempt to remove the radiator e. Fill radiator to the bottom of the filler neck with
cap while the engine is running. Stop the engine and wait 50/50 antifreeze/water mixture.
several hours until it is cool. Even then, use extreme care f. Fill recovery bottle to full mark with 50/50
when removing the cap. antifreeze/water mixture.
3. Keep radiator air passages clean. Use compressed
! CAUTION air (30 psi maximum) to clean the fins. Water left
Do not pour cold water into a hot radiator. Do not between the fins will collect dirt and reduce the
operate engine without a proper coolant mixture. amount of air flow to properly cool the engine.
Install cap and tighten securely. 4. To provide proper air flow, do not obstruct the air
intake screen on the right side of the vehicle. Keep
! WARNING screen clean.
5. Replace clamps and hoses every two years.
The cooling fan is controlled by a temperature switch and
may start at any time coolant temperature is above 150° 6. If you have to add coolant more than once a month,
F (65 ° C), even with the ignition switch in the OFF or add more than one quart at a time, have a
position. Do not attempt to service the cooling system authorized Jacobsen Dealer check the cooling
without first disconnecting the negative battery cable or system.
removing the fan fuse.

NEVER add straight antifreeze to the radiator. Mix equal

amounts of clean water with ethylene glycol based anti-
freeze in a separate container before adding it to the
cooling system. Do not use a mixture of more than 50%
antifreeze.
Always recycle or dispose of used antifreeze in a
responsible manner. Used antifreeze can be harmful to
the environment.
1. Check coolant level daily. Radiator should be full and
recovery bottle should be up to the cold mark.
a. Tilt engine cover forward to gain access to the
radiator.
b. With the engine stopped and cool, remove
radiator cap and check coolant level. The coolant
level should be at or within 1/4 in. (6 mm) of the
filler port. Fill with a 50/50 antifreeze/water
mixture if required.
c. Visually check the reservoir tank. Coolant level
should be at or above FULL line but less than 4
in. (102 mm). Add a 50/50 antifreeze/water
mixture if required.
2. Drain and refill cooling system every 400 hours or 9
months, whichever comes first. Allow system to cool
before draining.
a. Remove the cooling fan fuse
19
6 MAINTENANCE
6.8 AIR FILTER_______________________________________________________________
Do not remove the element for inspection or cleaning.
Unnecessary removal of the filter increases the risk of
injecting dust and other impurities into the engine.
When service is required, first clean the outside of the
filter housing; then remove the old element as gently as Diesel
possible and discard. Engine A
1. Carefully clean the inside of the filter housing without
allowing dust into the air intake.
2. Inspect the new element. Do not use a damaged
element and never use an incorrect element.
3. Assemble the new element and make sure it seats
properly.
4. Reassemble cap making sure it seals completely
around the filter housing. Dust evacuator (A) must be
facing down.
5. Check all hoses and air ducts. Tighten hose clamps.

A
Gas Engine

Figure 6D

6.9 JUMP STARTING __________________________________________________________

Before attempting to “jump start” the vehicle, check the 2. Connect RED jumper cable to the positive (+) terminal
condition of the discharged battery. on the good battery and to the positive (+) terminal on
the “discharged” battery.
Engage parking brake of both vehicles, shift transmission
to neutral and turn off all electrical loads 3. Connect the BLACK jumper cable from the negative
(-) terminal on the good battery to the frame of the
vehicle with the discharged battery.
! WARNING After cables have been connected, start the engine on
Batteries generate explosive hydrogen gas. To reduce the vehicle with the good battery then start the vehicle.
the chance of an explosion, avoid creating sparks near
battery. Always connect the negative jumper cable to the
frame of the vehicle with the discharged battery, away
from the battery.

When connecting jumper cables:

1. Stop the engine on the vehicle with a good battery.

20
 MAINTENANCE 6
6.10 BATTERY ________________________________________________________________
Make absolutely certain the ignition switch is “Off” and 1. When installing the battery, always assemble the RED,
the key has been removed before servicing the battery. positive (+) battery cable first and the ground, BLACK,
negative (-) cable last.

! CAUTION 2. When removing the battery, always remove the

ground, BLACK, negative (-) cable first and the RED,
Always use insulated tools, wear protective glasses or positive (+) cable last.
goggles and protective clothing when working with
batteries. You must read and obey all battery 3. Make sure battery is properly installed and secured to
the battery tray.
manufacturer’s instructions.

Tighten cables securely to battery terminals and apply a

light coat of silicone dielectric grease to terminals and
! WARNING
cable ends to prevent corrosion. Keep vent caps and Battery posts, terminals and related accessories
terminal covers in place. contain lead and lead compounds, chemicals known
to the State of California to cause cancer and
Keep the top of the battery clean and free of corrosion by
reproductive harm. Wash your hands after
washing with a solution of baking soda and water. Rinse
handling.
with clean water.
Verify battery polarity before connecting or disconnecting
the battery cables.

6.11 CHARGING BATTERY _____________________________________________________

! WARNING
Charge battery in a well ventilated area. Batteries
generate explosive gases. To prevent an explosion, keep
any device that may create sparks or flames away from
the battery.

To prevent injury, stand away from battery when the

charger is turned on. A damaged battery could explode.

1. Refer to Section 6.10. Read the Battery and Charger’s

manual 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 to the battery terminals as specified in the
charger’s manual.
4. Always turn the charger “Off” before disconnecting
charger from the battery terminals.

21
6 MAINTENANCE
6.12 HYDRAULIC HOSES _______________________________________________________
IMPORTANT: The hydraulic system can be
! WARNING permanently damaged if the oil becomes
contaminated. Before disconnecting any hydraulic
To prevent serious injury from hot, high pressure oil, component, clean the area around the fittings and the
never use your hands to check for oil leaks, use paper or hose ends to keep impurities out of the system.
cardboard.
a. Before disconnecting any hydraulic component, tag
Hydraulic fluid escaping under pressure can have or mark the location of each hose then clean the
sufficient force to penetrate skin. If fluid is injected into area around the fittings.
the skin it must be surgically removed within a few hours
b. As you disconnect the component, be prepared to
by a doctor familiar with this form of injury or gangrene
assemble plugs or caps to the hose ends and open
may result.
ports. This will keep impurities out of the hydraulic
system and also prevent oil spills.
1. Always disengage all drives, engage parking brake,
stop engine and remove key before inspecting or c. Make sure “O” rings are clean and hose fittings are
disconnecting hydraulic lines or hoses. properly seated before tightening.
2. Check visible hoses and tubes daily. Look for wet d. Keep the hose from twisting. Twisted hoses can
hoses or oil spots. Replace worn or damaged hoses cause couplers to loosen as the hose flexes during
and tubes before operating the machine. operation resulting in oil leaks.
3. The replacement tube or hoses must be routed in the e. Kinked or twisted hoses can restrict the oil flow
same path as the existing hose, do not move clamps, causing the system to malfunction and the oil to
brackets and ties to a new location. overheat and also lead to hose failure.
4. Thoroughly inspect all tubes, hoses and connections
every 250 hours.

6.13 HYDRAULIC RESERVOIR AND FILTER________________________________________

Refer to Section 8.3 for specific maintenance intervals. To replace hydraulic oil filter:

Normally the hydraulic system will not need additional fluid. 1. Remove the old filter.
Sometimes a leak may develop causing the system to 2. Fill new filter with GreensCare 68 fluid then install new
require repair and refilling. If you notice a hydraulic fluid filter. Hand tighten only.
escaping when the system is being used or if a leak is
suspected, turn off all hydraulic functions and stop the 3. Operate engine at idle speed with hydraulic system in
engine. neutral for five minutes.
4. Check hydraulic oil level and fill with GreensCare 68 to
Periodically check the hydraulic fluid level (hydraulic level knurled mark on gauge.
should be checked every 100 hours of operation). Loss of
fluid can signal a small leak befor it becomes worse.

To check the fluid level:

1. Place vehicle on a flat and level surface. Fully lower

any accessory attachment, including the dump box.
Stop the vehicle engine.
2. Remove the dipstick/breather tube from the top of KNURLED PORTION
the tank. Wipe the dipstick, then place in tank with HYDRAULIC
OF DIPSTICK
RESERVOIR DIPSTICK
the threaded flange resting on the tank (do not
screw in), Fluid should show on the knurled portion SHOWN AS
REFERENCE ONLY
of the dipstick. Add GreensCare 68 Fluid as
required.
Figure 6E
The hydraulic system is protected by one 10 micron filter.
The filter is located under the side console, near the parking
brake lever.

22
 MAINTENANCE 6
6.14 FUEL ____________________________________________________________________
Handle fuel with care - it is flammable and highly 4. Check fuel lines and clamps every 50 hours.
explosive under certain conditions. Use an approved Replace fuel lines and clamps at the first sign of
container, the spout must fit inside the fuel filler neck. damage.
Avoid using cans and funnels to transfer fuel.
5. The fuel tank capacity is 6.5 gal. (24.5 l). Fill tank
using the following fuel recommendations:
! WARNING
Diesel Engine
Remove the fuel cap slowly. Fuel may be under
pressure. Spray could cause serious injury. a. Use clean, fresh, #2 Diesel fuel when operating
temperature is above 20° F (-7° C). Minimum
Never remove the fuel cap from the fuel tank, or add fuel, Cetane rating 45.
when the engine is running or while the engine is hot.
b. Use clean, fresh, #1 Diesel fuel when operating
Do not smoke when handling fuel. Never fill or drain the temperature is below 20° F (-7° C). If #1D fuel is
fuel tank indoors. not available, a winterized blend of #1D and #2D
may be available. This blended fuel is usually
Do not spill fuel and clean spilled fuel immediately.
called #2D and may be used in colder climates.
Never handle or store fuel containers near an open flame Do not use #2D unless you are sure it has been
or any device that may create sparks and ignite the fuel winterized. Cold temperatures may cause it to
or fuel vapors. thicken, which will keep your vehicle from
running.
Be sure to reinstall and tighten fuel cap securely.
c. DO NOT use Aviation Fuel JP4. Refer to Engine
1. Fill the fuel tank to within 1 in. (25 mm) of the bottom Manual for additional information.
of the filler neck.
Gas Engine: Use clean fresh Unleaded Gasoline, 87
2. Store fuel according to local, state or federal octane or higher.
ordinances and recommendations from your fuel
supplier.
CAUTION
3. Never overfill or allow the tank to become empty.
Check fuel level in the tank by turning the ignition The use of any fuel containing greater than 10%
switch to the ON position and reading the level ethanol may harm the engine's emission control
indicated by the fuel gauge. system and therefore invalidate the emission-related
warranty through the improper action of the operator.

6.15 FUEL SYSTEM ____________________________________________________________

Then Perkins diesel engine in the Truckster is self Before replacing any filter, thoroughly clean the filter
priming. It is not required to purge air from the system. housing and the area around the filter. Dirt must not be
allowed to enter into fuel system.
Refer to Section 8.3 for specific maintenance intervals.

6.16 TIRE PRESSURE __________________________________________________________

Keep tires properly inflated to prolong tire life. Check Front - 20 psi - (138 kPa)
inflation pressure while the tires are cool. Inspect tread Rear - Varies, determined by load. (See Chart)
wear. 28 (193)
Lower pressure will help avoid leaving tire marks in soft
turf. Higher pressures may be required for heavier loads. 23 (159)
Rear tire pressure must be set at 28 psi (193 kPa) when
Rear 18 (124)
operating with a full load. Never exceed the maximum
Tire
pressure indicated on the tire.
Pressure 13 (90)
Check the pressure with an accurate, low pressure tire psi
gauge. Due to the low volume of air needed, over- (kPa) 8 (55)
inflation may be reached in a matter of two to three
seconds. Load (Pounds) 0 400 800 1200 1500
Keep tires inflated to:

23
6 MAINTENANCE
Figure 6F

6.17 TIRE REMOVAL AND INSTALLATION _________________________________________

Removal:
1. Park the vehicle on a flat and level surface. Apply ! CAUTION
parking brake, shut off engine and shift transmission Unless you have the proper training, tools and
to 1st gear. experience, DO NOT attempt to mount a tire on a rim.
2. Refer to Section 6.18 for proper lifting procedures. Improper mounting can produce an explosion which
Always use jack stands, never rely only on a jack for may result in serious injury.
support.
Installation:
Raise the vehicle only enough to remove the tire. 1. Remove dirt, grease and oil from stud thread. Do not
Never place feet hands or any part of your body lubricate threads.
under the vehicle when raising it.
2. Position wheel on hub and inspect to insure full contact
3. Remove the wheel retaining nuts and remove wheel between mounting surface of wheel and hub or brake
and tire assembly from the hub. drum. Make sure valve stem is located towards the
outside. Finger tighten all hardware then torque
4. Perform required service on tire.
hardware in criss-cross order; always tighten nuts in
the top position.
3. Check and retorque daily until torque is maintained,
70-100 ft.lbs. (95-140 Nm)

6.18 RAISING THE VEHICLE_____________________________________________________

jack. Lower the jack and allow the vehicle to rest on jack
stands.
! WARNING When using a hoist to raise the vehicle, use the same
Make sure the vehicle is parked on a solid and level procedure for supporting the frame and blocking the tires
surface. Never work on a vehicle that is supported only as you would when using a jack.
by the jack. Always use jack stands.
To prevent damage to the vehicle or attached accessory,
Whenever possible empty the truck bed before raising never use a hoist to raise only one corner of the vehicle.
the vehicle. Loads moving inside the bed can cause an Always raise BOTH front or rear corners equally.
unbalanced load that could tip the vehicle.

Never raise the vehicle with the engine running or with a Block Tire Here
person sitting in the operator’s seat.

Always block the tire diagonally opposite the tire being

raised.

Never place hands, feet or any part of your body under

the vehicle when raising it with a hoist or is not properly
supported by jack stands.

A scissors type jack or a floor jack with a 1-1/2 ton

- Jacki ng Locat ion
(minimum) capacity that can be lowered to 3-3/8” (86
mm) height is required. Refer to figure for jacking
locations.
Shift the transmission into 1st gear 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. If Using Jack Here

Jack the vehicle to the appropriate height and place jack Figure 6G
stands or equivalent support beneath the frame near the
24
 MAINTENANCE 6
6.19 TOWING THE VEHICLE _____________________________________________________
4. Slowly drive towing vehicle forward until tow-line is
! WARNING pulled tight.

To prevent injury or vehicle damage, the following 5. While towing, try to keep the tow light taught at all
guidelines should always be followed. times. Be careful going down inclines and turning
corners.
• Never accelerate or stop suddenly when towing
a vehicle.
• Never change the direction of the vehicle Tow Line Attachment

abruptly or make sharp turns on an incline when

towing a vehicle.
• Never tow the vehicle faster than 5 m.p.h. (8
km/h). Towing at excessive speed could cause
either vehicle to lose proper steering control
• Adjust your speed for weather and surface
conditions when towing (rain, snow, ice, hills,
etc.).
• Use care when loading or unloading machine
into a trailer or truck.

If for any reason the vehicle needs to be towed, follow the

procedures below.
A Front Bumper Accessory (Part No. 894778)
1. If towing the vehicle with a tow-rope or chain, an is available for use with the Truckster. If a
Front Bumper is mounted to your vehicle,
operator is required to steer the vehicle and to make sure to follow the instructions included
control the brakes. with the bumper for proper connection of the
chain or tow rope
2. Attach a tow-roper only to the front vertical frame
member on either side of the vehicle.
Figure 6H
3. Shift transmission Neutral and release parking
brake.

6.20 GOVERNOR OIL LEVEL ____________________________________________________

Suzuki Gas Engine only Torque the plugs to 95 ±10 in. lb.
Check the oil level in the governor every 100 hours of
use. To check the level, remove the plug from the back
side of the governor. Oil level should be up to the level of
the plug opening. Governor Oil
Fill Plug
Governor Oil Capacity . . . . . . .1.5 oz. (44 ml)
Oil Type . . . . . . . . . . . . . . . . . . .SAE 20W engine Oil
If fluid level is low, add the recommended oil type.
Remove the plug from the rear of the governor, remove
Governor Oil
the plug from the top of the governor and add a SAE 20W Level Check Plug
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 Figure 6I
threads of the plug.

25
6 MAINTENANCE
6.21 HYDRAULIC BRAKES ______________________________________________________
5. Most communities have a disposal system for DOT
! WARNING 3 brake fluid. Please dispose of fluids properly.

Improper maintenance of the brake system may result in

loss of vehicle control by the operator. Losing control of
the vehicle due to brake loss may cause injury to the
operator or bystanders and vehicle damage Brake Fluid
Reser vo ir
This vehicle is equipped with four wheel hydraulic brakes
controlled by the brake pedal and a hand operated
parking brake lever.
Keep your brake system clean and properly maintained.
Do not operate the truck if the brakes do not stop vehicle
properly.
The brake fluid master cylinder reservoir is located under Figure 6J
the front cowl.
The fluid level in the master cylinder reservoir must be
kept between the MIN (minimum) and MAX (maximum)
marks. Add DOT 3 type brake fluid as required.
If the brake fluid indicator light comes on and remains on, Fluid Level
check the fluid level in the reservoir.
Bleeding Hydraulic Brakes:
If the brakes do not hold properly, if they feel spongy or if
the brake fluid reservoir is allowed to “run-dry”, it may be
required to bleed the system in order to remove air from
the brake lines. Figure 6K
1. Bleed the brakes in the following order, Left Rear,
Right Rear, Right Front and Left Front.
2. Attach a hose to the bleeder screw and place the
other end of the hose in a container to catch fluid Brake Fluid Lever
Indic ator Light
run-off when bleeding the system.
3. Bleed brake.
a. Loosen the bleeder screw.
b. Have an assistant push down on the brake pedal
and hold the pedal down.
c. Tighten the bleeder screw. Figure 6L
d. Have assistant release pedal.

NOTE: Do Not release brake pedal until the bleeder

screw is tightened or air will be sucked back into the
brake lines

e. Repeat steps a through d as required until all air

bubbles are purged from the system and a
steady flow of fluid comes from the brake line.
Bleeder
f. Periodically check fluid level in reservoir. Do not Screw
allow the reservoir to fully empty or bleeding
procedure will need to be repeated.
Figure 6M
4. Repeat Step 3 for each brake.

26
 MAINTENANCE 6
6.22 DIFFERENTIAL FLUID ______________________________________________________
The differential fluid should be checked every 100 hours
or 3 months. Fluid should be changed after the first 100
hours and every 600 hours (or yearly) thereafter.
Differential Fluid Capacity ...... 5.2 pints (2.5 l)
Fluid Type .............................. SAE EP 80-90 Gear Lube Level Check And
Fill Plug
To check differential fluid level, remove the filler plug
from the front of the differential. Fluid should be level with
the bottom of filler hole.
If fluid is low, add gear lube until fluid begins to leak from
hole. Apply pipe thread sealant and install filler plug.
To change differential fluid, remove drain plug from rear
of differential.
Allow fluid to drain into a suitable container. Dispose of Figure 6N
used fluid properly according to local and state
regulations.
Apply pipe thread sealer to drain plug and install.
Fill differential with gear lube until fluid begins to leak
from hole. Apply pipe thread sealant and install filler plug.

Drain Plug

Figure 6O
6.23 DIESEL ENGINE MANUAL TRANSMISSION ____________________________________
The transmission fluid should be checked every 100 Fill transmission with gear lube until fluid begins to leak
hours or 3 months. Fluid should be changed every 600 from hole. Apply pipe thread sealant and install filler plug.
hours (or yearly).
Transmission Fluid Capacity .. 1.35 qts (1.3 l)
Fluid Type .............................. SAE EP 80-90 Gear Lube
To check transmission fluid level, remove the filler plug Level Check And
Filler Plug
from the front of the transmission. Fluid should be level
with the bottom of filler hole.
If fluid is low, add gear lube until fluid begins to leak from Transmi ssi on
Drain Plug
hole. Apply pipe thread sealant and install filler plug.
To change fluid, remove drain plug from rear of
transmission.
Allow fluid to drain into a suitable container. Dispose of
used fluid properly according to local and state
regulations.
Figure 6P
Apply pipe thread sealer to drain plug and install.

27
6 MAINTENANCE
6.24 GAS ENGINE MANUAL TRANSMISSION_______________________________________
The transmission fluid should be checked every 100 Fill transmission with gear lube until fluid begins to leak
hours or 3 months. Fluid should be changed every 600 from hole. Apply pipe thread sealant and install filler plug.
hours (or yearly).
Transmission Fluid Capacity.. 1.3 qts (1.2 l)
Fluid Type .............................. SAE EP 80-90 Gear Lube
To check transmission fluid level, remove the filler plug
Fill Plug
from the front of the transmission. Fluid should be level
with the bottom of filler hole.
If fluid is low, add gear lube until fluid begins to leak from
hole. Apply pipe thread sealant and install filler plug.
To change fluid, remove drain plug from rear of
Drain
transmission. Plug
Allow fluid to drain into a suitable container. Dispose of
used fluid properly according to local and state
regulations.
Figure 6Q
Apply pipe thread sealer to drain plug and install.

6.25 GAS ENGINE AUTOMATIC TRANSMISSION____________________________________

The transmission fluid should be checked every 100
hours or 3 months. Fluid should be changed every 600
hours (or yearly).
Transmission Fluid Capacity.. 3.7 qts (4.2 l)
Transmission
Fluid Type .............................. Mercon / Dexron II Fluid Dipstick
To check transmission fluid level, the engine must be and Fill Tube
running. Place the gear selector in “P” PARK, apply the
parking brake and start the engine.
With engine running, remove the dipstick and wipe it with
a clean rag. Insert the dipstick into the extension tube
until it contacts the tube. Remove the dipstick and read
the fluid level.
Fluid must be kept between the two marks on the
dipstick. If fluid is low, add fluid to obtain the proper level.
Do Not Overfill. Add fluid using the extension tube as a
fill tube.
Drain Plug
To change fluid, remove drain plug from bottom of Automatic Transmission
transmission.
Allow fluid to drain into a suitable container. Dispose of
used fluid properly according to local and state
regulations.
Apply pipe thread sealer to drain plug and install.
Fill transmission until fluid reaches proper mark on
dipstick.
Figure 6R

28
 MAINTENANCE 6
6.26 ELECTRICAL SYSTEM _____________________________________________________

! CAUTION Diesel Engine

20 A Dash Panel,
Power Port 15 A Fuel Pump
Always turn the ignition switch off and remove the & Ignition
negative battery cable (Black) before inspecting or Brake Light,
5th Wheel Brake 10 A 10 A Accessary
working on the electrical system.
Flashers & 10 A 10 A Heater
General precautions that can be taken to reduce Horn Accessary
electrical problems are listed below. Headlights 15 A 10 A Wiper,
Dome Light &
1. Make certain all terminals and connections are clean Back-Up Alarm
and properly secured.
2. Check the Interlock system, and fuses regularly. Gas Engine Dash Panel,
If the Interlock does not function properly and the ECU, Fuel
Accessary 10 A 20 A & Engine Coils
problem cannot be corrected, contact an authorized
Jacobsen Dealer. 25 A Radiator
Power Port 15 A
Fan
3. Keep the wire harness and all individual wires away
from moving parts to prevent damage. Headlights 15 A
15 A ECU, Main Relay,
Injectors
4. Check the battery and battery charging circuit. Brake Light, 10 A Backup Alarm
5th Wheel Brake 10 A Shift Switch
5. Do not wash or pressure spray around electrical
connections and components. Flashers & 10 A 10 A ECU
Horn
6. Circuits are protected by fuses located under the Heater 10 A 10 A Wiper,
front cowl and a fuse located near the cooling fan. Accessary Dome Light &
Back-Up Alarm

Figure 6S

6.27 DASH PANEL _____________________________________________________________

The dash panel contains gauges and instrument lights to K Right Turn........................... C161
display unit functions. Maintenance of the panel is limited L Parking Brake ..................... C161
to replacing bulbs and setting the DIP switches. Remove M High Beam.......................... C658
the four screws securing the instrument panel to the N Alternator / Battery ............. C161
dash.
4. Place bulb and holder back into panel. Turn holder
Pull panel out, tilt panel forward and disconnect electrical 1/4 turn clockwise to secure into panel. Ensure base
connector for easier access to rear of panel. of holder is properly seated in 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 Gage ...........................C658
D Hour Meter..........................C658
E Tachometer.........................C161
F Left Turn Signal ..................C161
G Oil Pressure ........................C161
H Glow Plug ...........................C161
J Brake Fluid..........................C161

29
6 MAINTENANCE
Tachometer DIP Switch Setting: Using a small blade screwdriver or similar tool, push the
switch levers either up or down to match the sequence
The dash panel uses a DIP Switch sequence code to
code for this unit.
identify the number of input pulses per engine revolution
and engine type to correctly display the engine RPM on
the tachometer. Dipswitch Setting
1
If you are replacing the dash panel or if the tachometer is
0
not operating correctly, check to be sure the sequence
code is set correctly.
The Truckster with a Perkins Diesel engine uses the
following sequence code for 8.5 pulses / revolution. K E B F

Perkins Diesel Sequence Code: 0 0 0 1 0 0 0 0 L G

The truckster with a Suzuki Gas engine uses the M
C
H
A
following sequence code for 1.5 pulses / revolution. J
D
Suzuki Gas Sequence Code: 0 0 0 0 0 0 1 0
Figure 6T

6.28 HEADLIGHT REPLACEMENT ________________________________________________

The headlight should be replaced as soon as it stops 5. Remove the headlight from the bezel. Properly
functioning or is damaged. The headlight is a sealed unit dispose of old bulb.
and can only be replaced as a complete unit.
6. Install new headlight in reverse order of removal.
Description ................ Bulb Type Jacobsen Part No.
Headlight................... H6545 837303
1. Disconnect the negative battery cable. Headlight
Bezel
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.
Remove The Four (4) Screws
4. Disconnect the electrical connector from the rear of For Headlight Removal
the headlight,
Figure 6U

6.29 TAIL LIGHT REPLACEMENT ________________________________________________

The tail light should be repaired as soon as it stops frame. Disconnect harness and remove tail light
functioning or is damaged. The tail light bulb, and lens from frame.
are replaceable components. Damage to the body of the
tail light requires a complete replacement.
Description ................ Bulb Type Jacobsen Part No.
Tail light bulb............. 1157 822049
1. Remove the two screws securing lens. Remove lens
and gasket.
2. Push bulb in, turn 1/4 turn and remove bulb.
Remo ve The Two (2)
Dispose of old bulb properly. Screws For Bulb
Or Lens Replacemen t
3. Install new bulb in reverse order of removal. Ensure
lens gasket is properly positioned.
4. To remove complete tail light assembly, remove two
nuts and shake proof washer securing tail light to
Figure 6V
30
 MAINTENANCE 6
6.30 EFI DIAGNOSTIC CHECK ___________________________________________________
Suzuki Gas Engine units only position. The brake fluid light at the lower left corner of
the dash panel will flash a diagnostic code.
The electrical system is equipped with a plug in
connector which, when used with the diagnostic jumper The first digit of the code will be given first with a full
accessory (Part No. 2700920) will perform diagnostic second pause between each 0.3 second flash, followed
checks on various engine components. by the second digit with no pause.
Manual transmission: Engage parking brake, shift A code of 12 (System Normal) would turn the light on
transmission to neutral and turn the ignition switch to the for 0.3 seconds, a full second pause then two fast
OFF position. flashes. (Flash-Pause-Flash-Flash)
Automatic Transmission: Engage parking brak, place A code of 46 (Shift swicth) would turn the light on four
gear selector in PARK and turn the ignition switch to the times for 0.3 seconds and a full second pause, then
OFF position. six fast flashes. (Flash-Pause-Flash-Pause-Flash-
Open the front cowl and locate the plug in connector Pause-Flash-Pause-Flash-Flash-Flash-Flash-
(Black/White and Black Wires) coming from the wire Flash-Flash)
harness below the brake fluid reservior.
The following list shows which code number
To run the diagnostic test, plug the diagnostic jumper into coresponds to which component and list possible
the plug-in connector. Turn ignition switch to the ON causes for each fault.

Code Engine Component Possible Causes

11 Pressure Sender Voltage at pin 25 (Green/Yellow wire) of the 34 pin ECU connector is higher than 4.5 Volts or
lower than 0.19 Volts.
12 Normal System operating normally
Voltage at pin 33 (Gray/Yellow wire) of the 34 pin ECU connector is higher than 4.73 Volts or
13 Throttle Sensor lower than 0.25 Volts
14 O2 Sensor No signal for a length of time at pin 24 (Red/Blue wire) of the 34 pin ECU connector
15 Crank Angle Sensor While in starting mode, no signal is seen at pin 16 (Brown/Red wire) of the 34 pin ECU connector
16 Vehicle Speed Sensor No signal for a length of time at pin 16 (Orange wire) of the 26 pin ECU connector
Voltage at pin 32 (Green/White wire) of the 34 pin ECU connector is higher than 4.85 Volts or
19 Water Temperature Sensor
lower than 0.15 Volts.

41 Shift Solenoid #1 Open or short circuit at pin 27 (Blue/Black wire) of the 34 pin ECU connector. Should be 12 Volts
(Automatic Transmission only) if gear selector is in the “L” position.
Shift Solenoid #2 Open or short circuit at pin 28 (Blue/White wire) of the 34 pin ECU connector. Should be 12 Volts
42 (Automatic Transmission only) if gear selector is in the “L” or “2”position.
Shift Solenoid #3
43 Open or short circuit at pin 29 (Blue/Red wire) of the 34 pin ECU connector.
(Automatic Transmission only)
No sigal present at pin 18 (Green/Pink wire), and pin 19 (Orange Blue wire), and pin 20 (Orange/
Shift Switch Green wire), and pin 24 (Green/Blue wire), and pin 25 (Green wire) and pin 26 (Red wire) of the
46 (Automatic Transmission only) 26 pin ECU connector. OR signal present at more than one of pins 18, 19, 20, 24, 25 and 26 of
the 26 pin ECU connector

31
6 MAINTENANCE
6.31 CARE AND CLEANING _____________________________________________________
Wash the vehicle after each use. Keep the equipment 3. Do not spray water directly at the dash panel, ignition
clean. switch, controls or any other electrical components, or
at bearing housings and seals.
Note: Do not wash any portion of the equipment while it is
hot. Do not use high pressure spray or steam. Use cold 4. Clean all plastic or rubber trim with a mild soap
water and automotive cleaners. solution or use commercially available vinyl/rubber
cleaners.
1. Use compressed air to clean engine and radiator fins. A
special blow gun is available through Jacobsen Dealer. Repair damaged metal surfaces and use Jacobsen
touch-up paint. Wax the equipment for maximum paint
2. Use only fresh water for cleaning your equipment. protection.
Note: Use of salt water or affluent water has been known
to encourage rust and corrosion of metal parts resulting ! CAUTION
in premature deterioration or failure. Damage of this
nature is not covered by the factory warranty. Clean grass and debris from drives, muffler and
engine to prevent fires.

6.32 STORAGE________________________________________________________________
General 2. Clean exterior of engine. Paint exposed metal, or apply
a light coat of rust preventative oil.
1. Wash the vehicle thoroughly and lubricate. Repair and
paint damaged or exposed metal. Add a fuel conditioner or biocide to prevent gelling or
bacterial growth in fuel. See your local fuel supplier.
2. Inspect the vehicle, tighten all hardware, replace worn
or damaged components. If storing indoors, drain fuel from tank.
3. Drain and refill radiator. Close fuel shut off valve.
4. Clean the tires thoroughly and store the vehicle so the
After Storage
load is off the tires. If vehicle is not on jack stands,
check tires at regular intervals and reinflate as 1. Check and reinstall battery
necessary.
2. Check or service fuel filter and air cleaner.
5. Keep the machine and all its accessories clean, dry
3. Check the radiator coolant level.
and protected from the elements during storage.
4. Check oil level in the engine crankcase.

! WARNING 5. Fill the fuel tank with fresh fuel. Open fuel shut off
valve and bleed the fuel system.
Never store equipment near an open flame or spark
which could ignite fuel or fuel vapors. 6. Remove antifreeze mixture from sprayer pump.

Battery 7. Assembly boom hoses, no-drip valves, nozzle tips

and strainers.
1. Remove, clean and store battery in upright position on a
non-conductive surface (wood) in a cool, dry place. To 8. Make certain that the tires are properly inflated.
prevent accelerated discharge, do not store battery on 9. Start and operate the engine at 1/2 throttle. Allow
concrete or steel surface. enough time for the engine to become properly
2. Check and recharge battery every 60 to 90 days while warmed and lubricated.
in storage.
3. To reduce the self discharge rate, room temperature ! WARNING
should not be above 80°F (27°C) or fall below 20°F (- Never operate the engine without proper ventilation;
7°C) to prevent electrolyte from freezing. exhaust fumes can be fatal when inhaled.
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.

32
 TROUBLESHOOTING 7
7 TROUBLESHOOTING

7.1 GENERAL ________________________________________________________________

The troubleshooting chart below lists basic problems that detailed information regarding the electrical system
may occur during start-up and operation. For more contact your area Jacobsen Dealer.

Symptoms Possible Causes Action

Engine will not start. 1. Clutch pedal not depressed. 1. Check start-up procedure.
2. Battery low on charge or 2. Inspect condition of battery and battery connections.
defective.
3. Fuel tank empty or dirty. Fuel shut 3. Fill with fresh fuel. Change fuel filter. Bleed fuel lines.
off valve closed Open fuel shut off valve
4. Fuse blown. 4. Replace fuse.
Engine hard to start or 1. Fuel level low, fuel or fuel filter 1. Fill with fresh fuel. Change fuel filter. Bleed fuel lines.
runs poorly. dirty.
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 add coolant.
2. Air intake restricted. 2. Clean cooling air intake.
3. Water pump belt broken or loose. 3. Tighten or replace belt.
4. Engine overload 4. Reduce forward speed
vehicle does not react 1. Parking brake engaged Disengage parking brake.
to throttle pedal 2. Transmission in Neutral Depress brake and clutch pedals. Shift to proper gear
for desired ground speed. Release brake pedal.
Slowly let out clutch while pressing the throttle pedal
3. Clutch Pedal Depressed Slowly let out clutch pedal

33
8 MAINTENANCE & LUBRICATION CHARTS
8 MAINTENANCE & LUBRICATION CHARTS

8.1 GENERAL________________________________________________________________

2. Lubricate with grease that meets or exceeds NLGI

! WARNING Grade 2 LB specifications. Apply grease with a
manual grease gun and fill slowly until grease begins
Before you clean, adjust, or repair this equipment, to seep out. Do not use compressed air guns.
disengage all drives, lower implements to the ground,
engage parking brake, stop engine and remove key 3. For smooth operation of all levers, pivot points and
from ignition switch to prevent injuries other friction points that are not shown on the
lubrication chart apply several drops of SAE 30 oil
every 40 hours or as required.
1. Always clean the grease fitting before and after
lubricating. 4. Grease fittings every 100 hours. Do not over grease
drive shaft fittings (A). Too much grease will damage
the seals.

8.2 LUBRICATION CHART _____________________________________________________

Brake Fluid
Reservoir D

Fitting Description Qty A

Fuse Box
A Drive Shaft 2
B Upper Ball Joints 2
C Lower Ball Joints 2
D Tie Rod Ends 4

C
D
C

34
 MAINTENANCE & LUBRICATION CHARTS 8
8.3 MAINTENANCE CHARTS ___________________________________________________
Recommended Service and Lubrication Intervals
Every Every Every Every
First 75 100 200 Every 400 600 See Lubricant
Daily 35 Hours or
Hours Hours or Hours or Hours or 9 Months Hours or 12 Section Type
2 Months 3 Months 6 Months Months

Air Filter R** 6.8

Alternator I
Battery I C 6.10
Belts I-A* I-A I-A 4., 5.2
Brake Fluid I-A 6.21 VI
Brake Linings I-A* I-A I-A
Clutch I-A
Cooling System I-C-A I R 6.7 IV
Differential Fluid I-R* R 6.22 III
Electrical System I* I 6.26
Engine Glow Plugs I
Engine Idle Speed I* I
Engine Noise / Vibration I
Engine Oil (Suzuki) I R***** R** 6.3
Engine Oil (Perkins) I R* R** 6.3 II
Engine Oil Filter I R***** R** 6.3
Engine Oil Filter I R* R** 6.3
Engine Valve Clearance I**** I****
Fluid Leaks I-R
Fuel System I* I 6.15
Fuel Filter R 6.15
Fuel Water Separator
I-C
(Diesel Only)
Governor Fluid I-A IX
Hydraulic Filter R
Hydraulic Fluid I-A R VIII
Injection Pump / Timing I
Lubricate Chassis L L 8.2 I
Muffler and Exhaust I I 6.5
Radiator Screens I-C/AR 6.7
Power Steering Fluid I* I 6.4 V
Spark Plugs (Gas only) C-A-R
Starter Motor Brushes I
Tires I I-A 6.16
Transmission Fluid 6.23
I R 6.24 III
(Manual Transmission)
Transmission Fluid
I R 6.25 VII
(Automatic Transmission)
Wheel Bearings Repack

A - Add or Adjust C - Clean I - Inspect L- Lubricate R - Repair or Replace AR - As Required

35
8 MAINTENANCE & LUBRICATION CHARTS
Notes: Lubricants
* Indicates initial service for new machines.
I Manual grease gun with NLGI Grade 2 (Service
** Depending on operating conditions, engine oil, oil
Class LB).
filter and air filter may require more frequent
II Engine Oil - See Section 6.3
replacement.
III SAE EP 80-90 Gear Lube
*** Inspect visible hoses and tubes for leaks or oil
IV Capacity: 3qt. (2.8 l) 50/50 water ethylene glycol mix
marks.
V GM Power Steering Fluid
**** Must be done at Authorized Dealer
VI DOT 3 Brake Fluid
***** Change oil and filter on Suzuki Engines after first
VII Mercon/Dextron II Automatic Transmission Fluid
fifty hours
VIIIGreensCare 68 Hydraulic Fluid
5003102 55 Gallon Drum GreensCare 68
5003103 5 Gallon Pail GreensCare 68
IX SAE 20W Oil

8.4 COMMON REPLACEMENT PARTS ___________________________________________

Part Number Part Description Part Number Part Description
840352 Engine Air Filter Element 4139265 Gas Alternator - Power
Steering Belt
842553 Diesel Oil Filter
4139351 Gas Hydraulic Pump Belt
2701809 Gas Oil Filter
4119606 NGK 3932 (DCPR7E) Spark
2701898 Gas Fuel Filter Plug
600997 Diesel Alternator Belt Denso XU22EPR-U Spark
2701832
841966 Diesel Hydraulic Pump Belt Plug

8.5 PERKINS DIESEL ENGINE SERVICE PARTS ___________________________________

The following common engine parts are provided for reference only. Parts may be obtained from your nearest Perkins
Engine Dealer
Perkins Part Number Part Description Perkins Part Number Part Description
185206450 Fuel Solenoid 145996850 Thermostat Gasket
025100016 Gasket, Fuel Solenoid Mount 145017960 Water Pump
131017950 Injection Pump 145336490 Water Pump Pulley
131507740 Injection Pipe #1 010211216 Oil Pan Drain Plug
131507750 Injection Pipe #2 025100015 Oil Pan Drain Plug Gasket
131507760 Injection Pipe #3 140517050 Oil Filter
131406340 Fuel Injector 198436350 Oil Fill Cap
131606920 Injector Return Pipe 052100400 Oil Fill Cap Seal
185366220 Glow Plug 111996420 Valve Cover Gasket
145206062 Thermostat 185086610 Starter Motor

36
 PARTS CATALOG 9
9 PARTS CATALOG

9.1 TABLE OF CONTENTS _____________________________________________________

1.1 ......... Front Body ......................................................... 38

2.1 ......... Engine Cover..................................................... 40
3.1 ......... Upper ROPS ...................................................... 42
4.1 ......... Throttle Control ................................................. 44
5.1 ......... Control Console ................................................ 46
6.1 ......... Parking Brake and High-Low Speed Control.. 48
7.1 ......... Brake Pedal ....................................................... 50
8.1 ......... Clutch Pedal Linkage........................................ 52
9.1 ......... Manual Transmission Shifter Linkage ............ 54
10.1 ....... Manual Transmission Shifter Linkage ............ 56
11.1 ....... Automatic Transmission Shifter...................... 58
12.1 ....... Automatic Transmission Oil Cooler ................ 59
13.1 ....... Frame Attachments .......................................... 60
14.1 ....... Frame, Lower ROPS and Platform .................. 62
15.1 ....... Rear Axle ........................................................... 64
16.1 ....... Front Control Arms ........................................... 66
17.1 ....... Steering Linkage ............................................... 68
18.1 ....... Front Brakes ...................................................... 70
19.1 ....... Steering Column ............................................... 72
20.1 ....... Diesel Radiator.................................................. 74
21.1 ....... Gas Radiator...................................................... 76
22.1 ....... Diesel Engine and Transmission Mounting ... 78
23.1 ....... Gas Engine and MT Mounting ......................... 80
24.1 ....... Gas Engine and AT Mounting .......................... 82
25.1 ....... Diesel Engine and Clutch ................................. 84
26.1 ....... Suzuki Gas Engine............................................ 86
27.1 ....... Engine Speed Control ...................................... 88
28.1 ....... Exhaust .............................................................. 89
29.1 ....... Governor Linkage ............................................. 90
30.1 ....... Governor ............................................................ 92
31.1 ....... Gas Engine Remote Oil Fill .............................. 94
32.1 ....... Gas Engine Exhaust ......................................... 95
33.1 ....... Diesel Fuel System ........................................... 96
34.1 ....... Gas Fuel System ............................................... 98
35.1 ....... Hydraulic Tank and Filter ............................... 100
36.1 ....... Hydraulic Pump and Filter ............................. 102
37.1 ....... Lift Cylinder Circuit......................................... 104
38.1 ....... Diesel Electrical Components ....................... 106
39.1 ....... Gas Electrical Components ........................... 108
40.1 ....... Differential Assembly ..................................... 110
41.1 ....... Differential Housing ........................................ 112
42.1 ....... Axle Tubes and Shafts ................................... 114
43.1 ....... Front and Shifter Cover .................................. 116
44.1 ....... Input, Main and Jack Shafts........................... 118
45.1 ....... Transmission Clutch Release-Shift Selector 120
46.1 ....... Transmission Case ......................................... 122
47.1 ....... Input and Main Shaft....................................... 124
48.1 ....... Gear Shift Fork Linkage ................................. 126
49.1 ....... Mechanical PTO .............................................. 128
50.1 ....... Diesel Engine Electrical Schematic .............. 130
51.1 ....... Diesel Engine Main Harness .......................... 134
52.1 ....... Diesel Engine and Fan Harness .................... 136
53.1 ....... Gas Engine Electrical Schematic .................. 138
54.1 ....... Gas Engine Schematic ................................... 142
55.1 ....... Gas Main Harness ........................................... 144
55.1 ....... Gas Main Harness (Continued)...................... 146

37
TURF TRUCKSTER
Serial No. All
1.1 Front Body

C
10

9
8
7
23 12
20 22 5
24 11
26
25
12 21
19 27 6
37 12 ®

By Jacobsen

B
18 29
1
Turf Truckster Turf Truckster

D ® ®

By Jacobsen By Jacobsen

30 / 31 31 30

12 A
34 D
35
29
11
16 28 33 32
D
17 36

15 35 34
2
15 3
13
12 14 36
33
C
18

B 2
3

4
2

38
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 2700792 1 Front Clip Includes decals 821071 & 840901
2 800930 6 Screw, M8-1.25 x 16 mm Hex Flange
3 548159 4 Flat Washer, 5/16 x 1-1/4”
4 450400 2 Washer, M8
5 601940G05 1 Hood, Orange
6 601939 AR Weather Seal
7 841477G01 1 Hinge, Hood
8 841637 1 Angle, Front Clip Mounting
9 450541 7 Screw, M6-1 x 16 mm Round Head
10 112050 6 Screw, 1/4-20 x 5/8” Taptite
11 841913 2 Plate, Access
12 800934 22 Screw, M6-1 x 16 mm Hex Flange
13 4139691 2 Flap, Mud
14 548175 8 Flat Washer, 1/4 x 1-1/4”
15 800943 10 Screw, #10-14 Self Tapping
16 837303 2 Headlight, Rectangular
17 841428 2 Bezel, Headlight
18 828382 AR Seal, Foam
19 894030 1 Striker, Hood
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”
24 841753 1 Bracket, Hood Latch
25 306419 2 Screw, 1/4-20 x 1/2” Hex Head
26 306488 2 Lockwasher, 1/4” Shakeproof
27 450410 2 Lockwasher, M6
28 844293 3 Plug, Panel
29 74765G01 1 Decal, Cushman
30 74793G01 1 Decal, Left Side Turf Truckster
31 74767G01 1 Decal, RIght Side Turf Truckster
32 38541 1 Tube, Clear Document
33 38061A 2 Cap, Vinyl
34 840508 2 Mount, Cable Tie
35 800344 2 Screw, #10 Type AB Self Tapping
36 823549 2 Cable Tie, 15-1/2”
37 2703158 1 Decal, Fuses Diesel Engine
37 4117221 1 Decal, Fuses Gas Engine

> Change from previous revision

39
TURF TRUCKSTER
Serial No. All
2.1 Engine Cover

7
20 21
20

17 7
C
U
S
H
M
A
N 15
16
Engine Cover Lock C 5
U
S
H
M
6 A
N
8
17

4 1
2 11
10 16

22 12

19 18

23

24

13
14
3

40
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 306328 1 Cotter Pin, 3/32 x 3/4”
2 308090 1 Washer, 1/4
3 450452 2 Nut, M6-1 Hex Flange
4 450453 2 Nut, M8-1.25 Hex Flange
5 450454 3 Nut, M10-1.5 Hex Flange
6 893541 1 Handold, Right Side
7 450541 10 Screw, M6-1 x 16 mm Hex Flange
8 452388 2 Screw, M8-1.25 x 20 mm Hex Flange
9 452398 3 Screw, M10-1.5 x 20 mm Hex Flange
10 523085 1 Latch, Engine Cover
11 816401 1 Spring, Torsion
12 830784 1 Clevis Pin, 1/4 x 1-7/8”
13 2702199 1 Catch, Engine Latch
14 4139939 1 Insulation, Engine Cover
15 842030 1 Mount, Backrest
16 601937 2 Seat Base
17 893322 2 Backrest
18 2701223 1 Cover, Engine
19 845038 1 • Decal, Operation
20 840436 1 Lock, Engine Cover Optional, Required in Europe
21 309488 2 Washer Optional, Required in Europe
22 845234 1 Decal, Ground Speed Diesel Engines, 84043 and 84044
22 4147584 1 Decal, Ground Speed Gas Engine, MT 84056
22 845231 1 Decal, Ground Speed Gas Engine, AT84057
22 4147586 1 Decal,Ground Speed Gas Engine, MT 84061
23 800263 8 Screw, 1/4-20 x 1-1/4”

> Change from previous revision

41
TURF TRUCKSTER
Serial No. 84061 All
3.1 Upper ROPS

4
4 3
11
11
2

1 14
15

15
7 14
8
6 13
6 7 12
REF 8
Engine
Cover 10
7
8

9
5
11 6
9 8
7
9

REF
Control
Console

2
PART NUMBER: 893146 Meets SAE: J1040 MAY94 ! WARNING !
Only to be used on Cushman and EZ-GO truck models
The protection offered by this ROPS will be impaired if it has
with matching lower structure
been subjected to any modification or structural damage.
Manufactured by E-Z-GO a Textron Company This ROPS must be replaced after a rollover. Seat belts must
1451 Marvin Griffin Rd. Augusta, Georgia 30906 be worn at all times.

42
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 36097-G01 1 Upper ROPS
2 36091-G01 1 • Decal, Warning and ROPS Cert.
3 844988 1 Foam, 1/2” 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” 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 REF 1 Backrest See 2.1
14 893632 4 Support, Backrest
15 450541 8 Screw, M6-1 x 16 mm Pan Head

> Change from previous revision

43
TURF TRUCKSTER
Serial No. All
4.1 Throttle Control

Attach Pivot Link

41
in Bottom Hole

2
27
28
43 A
22
26 8
25 10
D C
To Engine 12 3
Cable Routing 14

8
36
28 B
11 14
27 17
9 5
33
13 4
30 20
35 14
22 20
26 7
A C 1
34

17 6
9
31 32 31 29
D
Hand Throttle Panel 21
19
39 40 B 14
37 23
39 STOP

24
42 15
38
35 18 15

Ignition Switch Panel 17 Throttle Pivot 16

All Views Rotated 90° for Clarity

44
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 841663 1 Panel, Floor Access
2 800943 10 Screw, #10-14 x 5/8” Self Tapping
3 894159 1 Pedal, Throttle
4 524633 2 Bolt, 5/16-18 x 1” Shoulder
5 524643 2 Bearing, Split
6 548911 2 Nut, 5/16-18 Flange
7 2703257.7 1 Bracket, Foot Throttle
8 452378 6 Screw, M6-1 x 20 mm Flange
9 450452 6 Nut, M6-1 Flange
10 843997 1 Bracket, Pedal Stop
11 843562 1 Mount, Channel
12 452695 1 Screw, M6-1 x 20 mm Self Tapping
13 830784 1 Clevis Pin, 1/4 x 1-7/8”
14 306328 4 Cotter Pin, 3/32 x 3/4”
15 843563 2 Plate, Pivot
16 843561 1 Link, Throttle Pivot
17 806714 3 Clevis Pin, 5/16 x 3/4”
18 844224 2 Roll Pin, 3/16 x 1-3/4”
19 515268 2 Bushing
20 844223 2 Spring, Torsion
21 REF 1 Throttle Cable See 27.1 or See 29.1
22 828049 1 Throttle, Hand
23 843607 1 Bushing, Throttle Cable
24 817104 1 Stop, Wire
25 111898 2 Clamp, Cable
26 800271 6 Screw, #10-24 x 1/2” Pan Head
27 120052 6 Lockwasher, #10
28 306531 6 Nut, #10-24 Hex
29 844116 1 Decal, Speed Control Panel
30 841264 1 Panel, Speed Control
31 830366 1 Switch, Horn
32 843581 1 Switch, Light
33 REF 1 Cable, Governor Control See 27.1 or See 30.1
34 827821 2 Knob
35 800582 6 Screw, 1/4-10 x 3/4” Truss Head
36 2700496 4 Insert, 1/4-20 Threaded
37 2701850.7 1 Panel, Ignition Switch
38 2702014 1 Decal, Ignition Switch Panel
39 837295 1 Ignition Switch
40 837298 1 Spacer, 3/16”
41 29165G01 1 Decal, Off Road Use
42 2702012 1 Strap Nut, 1/4-20 x 2”
43 821071 1 Decal, Not Motor Vehicle Notice
44

> Change from previous revision

45
TURF TRUCKSTER
Serial No. All
5.1 Control Console

16 1
2

15
4/5
3
5
14
! WARNING
PA R K I N G B R A K E S A R E N O T A U T O -
13 12
M A T I C A L LY A P P L I E D . V E H I C L E M AY
M OV E C AU S I N G P E R S O N A L I N J U RY
A N D / O R P R O P E R T Y D A M A G E . A L W AY S
11 A P P LY H A N D O R F O O T B R A K E S .

10 4
8
9

7 9
6 N
20

29

34
33
28
27 21

26 32 18
25
31 R
24 23
35
17 30
3
22
19

N
36
35
2
37
38 View Rotated for Clarity

46
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 2700796 1 Console Used on all, except 84044
1 2700797 1 Console, EC Used on 84044 Only
2 844177 1 • Decal, Aux. Transmission
3 844179 1 • Decal, Hydraulic Controls
4 822819 1 • Decal, Parking Brake Used on all, except 84044
5 845185 1 • Decal, EC Parking Brake Used on 84044 Only
6 894696 1 Valve, Hydraulic Selector
7 452392 2 Screw, M8-1.25 x 50 mm Flange
8 832798 1 Plate, Stop
9 450453 6 Nut, M8-1.25 Hex Flange
10 822419 1 Washer, 1-5/8” Diameter
11 304632 1 Nut, 3/8-16 Hex Jam
12 844582 1 Rod, Extension Handle
13 306388 1 Nut, 3/8-24 Hex Jam
14 548171 1 Knob
15 844051 1 Plate, Float Latch
16 800930 4 Screw, M8-1.25 x 16 mm Flange
17 886270 1 Valve, Hydraulic Lift Control Discard Decal included with Valve
18 843355 1 Mount, Lift Control Valve
19 316907 4 Screw, 1/4-20 x 2-3/4” Hex Head
20 306834 1 Screw, 3/8-16 x 3/4” Hex Head
21 548910 4 Nut, 1/4-20 Hex Flange
22 823225 1 Clevis Pin, 3/16 x 1”
23 308089 1 Flat Washer, #10
24 306463 1 Cotter Pin, 1/16 x 1/2”
25 839213 1 Connector, Valve
26 814079 1 Clevis Pin, 5/16 x 1-1/8”
27 103867 1 Flat Washer, 5/16
28 306328 1 Cotter Pin, 3/32 x 3/4”
29 843758 1 Handle, Lift Control Valve
30 452404 1 Screw, M10-1.5 x 70 mm Flange
31 825538 1 Spring, Compression
32 843759 1 Bushing, Lift Control Valve
33 450454 1 Nut, M10-1.5 Hex Flange
34 521144 1 Cover, Handle
35 826558 2 Adapter, 90° Fitting ORB to JIC 37° Flare
36 828057 1 Adapter, 90° Fitting ORB to JIC 37° Flare
37 823118 1 Adapter, Straight Fitting ORB to JIC 37° Flare
38 828056 1 Adapter, 90° Swivel Fitting JIC 37° Flare

> Change from previous revision

47
TURF TRUCKSTER
Serial No. All
6.1 Parking Brake and High-Low Speed Control

22
23 21
20
21
19

18
16

24
14

11

3 17 15 13 12
7
1
5

5
10
9
8
10

5 5
3 4

48
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 894317 1 Lever, Parking Brake
2 845134 1 Bracket, Parking Brake Lever
3 452388 5 Screw, M8-1.25 x 20 mm Flange
4 452391 1 Screw, M8-1.25 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” Cable
9 843359 1 Bushing, Pulley
10 809152 2 Flat Washer, 5/16 x 1-3/16”
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 REF 2 Parking Brake Cables See 40.1
17 893067 1 Cable, High - Low Speed Control
18 452378 1 Screw, M6-1 x 12 mm Flange
19 450452 1 Nut, M6-1 Flange
20 837043 1 Bracket, High - Low Cable
21 2702244 2 Nut, #10-32 Hex Apply Locktite 242
22 806703 1 Clevis Pin, 5/16 x 31/32”
23 306328 1 Cotter Pin, 9/32 x 3/4”
24 320107 1 Cable Tie, 7-1/2”

> Change from previous revision

49
TURF TRUCKSTER
Serial No. All
7.1 Brake Pedal

15

16
Route both hoses through 17
opening in front clip
31
A 16 A 16
17 8
11
16 14
10
4 1 12
Lower 20 13
ROPS 7

5
9
6

18

19
21
2
22
3

Pedal Mounting
View Rotated 90 Degrees for Clarity

27
Route front brake 28
tube through opening
in front clip

23 29
24
25 6 7
26
34
33 29
32 Route rear brake
30 22 Left Frame Rail
tube under floor
access panel

Tube Routing

50
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 2701737.7 1 Bracket, Master Cylinder
2 892921 1 Pedal, Brake
3 840726 1 Bearing, Brake Pivot
4 840725 1 Tube, Brake Pivot
5 842935 1 Tab, Locking
6 452388 2 Screw, M8-1.25 x 20 mm Flange
7 450453 2 Nut, M8-1.25 Flange
8 895113 1 Master Cylinder
9 800930 2 Screw, M8-1.25 x 16 mm Flange
10 894167 1 Rod, Brake
11 806714 1 Clevis Pin, 5/16 x 15/16”
12 103867 1 Flat Washer, 5/16
13 306328 1 Cotter Pin, 3/32 x 3/4”
14 894456 1 Reservoir, Brake Fluid
2702215 1 • Reservior
826006 1 • Electrical Connector, 2 Wire
825886 2 • Terminal, 1/4 “L” Male
15 800934 2 Screw, M6-1 x 16 mm Flange
16 830930 4 Clamp, Hose
17 7040 AR Hose, 5/16” Brake 6 Foot Length, cut to 18”
18 810152 1 Pad, Pedal
19 894308 1 Switch, Brake Micro
20 450410 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 843022 1 Tube, Rear Brake
25 842103 1 Union, M10-1
26 842051 1 Tube, Rear Brake Line
27 809137 1 Clip, Brake Line
28 REF 1 Rear Brake Hose See 40.1
29 810435 2 Clamp, Brake Tube
30 450454 1 Nut, M10-1.5 Flange
31 REF 1 Bracket, Reservoir / Horn See 38.1 and 39.1
32 REF 1 Tee, M10-1.0 Flare Union See 18.1
33 812445 1 Clamp, Tube
34 800943 1 Screw, #10-14 x 5/8” Self Tapping

> Change from previous revision

51
TURF TRUCKSTER
Serial No. 84043 All
8.1 Clutch Pedal Linkage Serial No. 84044 All
Serial No. 84056 All
Serial No. 84061 All

Lower
ROPS

9 10
8
14
23
6 5 7
13
3

15
11
12 A 2
1
Cable Routing
View Rotated 90 Degrees for Clarity
View Rotated 90 Degrees for Clarity

21

A 20

22

19

17 18
16

A
12
Gas Units Diesel Units

52
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 892933 1 Pedal, Clutch
2 840726 1 Bearing, Brake Pivot
3 844611 1 Spring, Torsion
4 840725 1 Tube, Pedal Pivot
5 842935 1 Tab, Locking
6 452388 1 Screw, M8-1.25 x 20 mm Flange
7 450453 1 Nut, M8-1.25 Flange
8 894308 1 Switch, Clutch Micro
9 450510 2 Screw, M3-0.5 x 20 mm Pan Head
10 452424 2 Nut, M3-0.5 Flange
11 4119634 1 Cable, Clutch Diesel Units
11 895013 1 Cable, Clutch Gas Units
12 844202 2 Washer, Slotted
13 806714 1 Clevis Pin, 5/16 x 15/16”
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 Screw Diesel Units Only
21 2703002 1 Nut Diesel Units Only
22 REF 1 Rear Alternator Bracket Diesel Units Only, See 25.1

> Change from previous revision

53
TURF TRUCKSTER
Serial No. 84043 All
9.1 Manual Transmission Shifter Linkage Serial No. 84044 All
Diesel Units

21 22
23
3

4
14

16 7
18 9
10
11
15
19 8
20 17 12
16 13
A 24
2 5
6 B 19
20
32
1
32
33 31
26 31
36 29
34 30
37
25
35
B
A

Diesel Unit Cable Attachment

28

27

38
Shifter Mounting and Cable Routing
View Rotated 90 Degrees for Clarity

54
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 800582 4 Screw, 1/4-20 x 3/4” Truss Head Diesel Units
2 2703956.7 1 Mount, Shifter
3 2703953 1 Selector, Gear
4 842773 1 Rod End, 1/2-20
5 308091 1 Flat Washer, 1/2
6 311763 1 Screw, 1/2-20 x 2-1/4” Hex Head
7 843679 1 Plate, Wear
8 452692 2 Screw, M6-1 x 12 mm Self Tap
9 604174 1 Flat Washer, 3/8”
10 843614 1 Spring, Torsion
11 843685 1 Bushing, Spring
12 2703951 1 Tab, Locating
13 452401 1 Screw, M10-1.5 x 40 mm Flange
14 450454 1 Nut, M10-1.5 Flange
15 894179 1 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” Hex Head
22 306396 1 Lockwasher, 1/4
23 308090 1 Flat Washer, 1/4
24 894179 1 Cable, Shifter
25 2702996 1 Boot, Control Lever
26 2702695 1 Knob, Shifter
27 548175 3 Flat Washer, 1/4 x 1-1/4”
28 308090 1 Flat Washer, 1/4
29 843778 1 Connector, Shift Cable
30 2703707 1 Connector, Shift Cable
31 103867 2 Flat Washer, 5/16
32 821164 2 Hair Pin
33 2703964.7 1 Panel, Right Side Dash
34 843792 1 Plate, Shifter Boot
35 452692 2 Screw, M6-1 x 12 mm Self Tap
36 2700496 4 Insert, 1/4-20 Threaded
37 2703931.7 1 Ring, Boot Hold Down
38 452695 4 Screw, M6-1 x 20 mm Self Tap
39

> Change from previous revision

55
TURF TRUCKSTER
Serial No. 84056 All
10.1 Manual Transmission Shifter Linkage Serial No. 84061 All
Gas Units

11
10
13 9
12 16
7 2
15 14
17
20 8 3
19
B 18 4 23
21
5 16
6
19 15 22
20

A
37

30 26
33 31
34
25
32

1
29

28 36

27
24
35 A
Shifter Mounting and Cable Routing
View Rotated 90 Degrees for Clarity Gas Unit Cable Attachment

56
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 4146819 1 Retaining Ring M6
2 4142630 1 Mount, Shifter
3 4142627 1 Selector, Gear
4 842773 1 Rod End, 1/2-20
5 308091 1 Flat Washer, 1/2
6 311763 1 Screw, 1/2-20 x 2-1/4” Hex Head
7 843679 1 Plate, Wear
8 452692 2 Screw, M6-1 x 12 mm Self Tap
9 604174 1 Flat Washer, 3/8”
10 843614 1 Spring, Torsion
11 843685 1 Bushing, Spring
12 2703951 1 Tab, Locating
13 452401 1 Screw, M10-1.5 x 40 mm Flange
14 450454 1 Nut, M10-1.5 Flange
15 2701273 2 Cable, Shifter
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” 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”
28 308090 1 Flat Washer, 1/4
29 4142796 1 Connector, Shift Cable
30 2703964.7 1 Panel, Right Side Dash
31 843792 1 Plate, Shifter Boot
32 452692 2 Screw, M6-1 x 12 mm Self Tap
33 2700496 4 Insert, 1/4-20 Threaded
34 2703931.7 1 Ring, Boot Hold Down
35 452695 4 Screw, M6-1 x 20 mm Self Tap
36 2701371 1 Connector, Shift Cable
37 800582 4 Screw, 1/4-20 x 3/4” Truss Head
38
39

> Change from previous revision

57
SPRAYTEK DS 300
Serial No. 84057 All
11.1 Automatic Transmission Shifter

12
5 6
13 1
11
7
11 9
8
11
11
6
1 11
3
4

10

Item Part No. Qty. Description Serial Numbers/Notes

1 103867 2 Flat Washer, 5/16
2 302030 1 Screw, 1/4-20 x 1-1/4”
3 306375 1 Nut, 1/4-20 Hex
4 306396 1 Lockwasher, 1/4
5 800582 4 Screw, 1/4-20 x 3/4”
6 821164 2 Hair Pin, 1/4 x 1-1/8”
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 869154 1 • Shifter Handle
13 2700496 4 Insert, 1/4-20

> Change from previous revision

58
 SPRAYTEK DS 300
Serial No. 84057 All
12.1 Automatic Transmission Oil Cooler

6
3
5 6

5
3

1 2

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 I.D.
4 821893 AR Trim, Push On
5 809231 2 Grommet
6 825264 4 Hose Clamp

> Change from previous revision

59
TURF TRUCKSTER
Serial No. All
13.1 Frame Attachments

9
9
9 13 9

13

9 9
18
11
20 12
9

22 17 9
10 A

10
10
10
14

15
21

16

23 10
19

1 9

2 7 10

10
4 9 8
24
3

60
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 REF 1 Front Suspension See 16.1, 17.1 and 18.1
2 452415 8 Screw, M12-1.75 x 80 mm Flange
3 450455 8 Nut, M12-1.75 Hex Flange
4 4139806G03 2 Wheel and Tire, Multi Rib Standard
4 4139806G01 2 Wheel and Tire, Turf Master Optional
4 4139806G02 2 Wheel and Tire, USA Trail Optional
4139793 1 • Rim, 10.00 x 7” Five Bolt 3.94” Bolt Circle
N/S 1 • Tire, 20 x 10.00 - 10 Multi Rib Used on 4139806G03, Obtain Locally
N/S 1 • Tire, 20 x 10.00 - 10 Turf Master Used on 4139806G01, Obtain Locally
N/S 1 • Tire, 20.5 x 8.00 - 10 USA Trail Used on 4139806G02, Obtain Locally
886735 1 • Valve Stem
5 800909 2 Nut, M12-1.5 Wheel Lug
6 REF 1 Panel, Console See 5.1
7 800026 7 Screw, 1/4-20 Truss Head
8 894232 1 Cover, Left Side Engine
9 452398 18 Screw, M10-1.5 x 20 mm Flange
10 450454 20 Nut, M10-1.5 Hex Flange
11 893488 1 Fender, Right Side
12 893487 1 Fender, Left Side
13 452399 2 Screw, M10-1.5 x 25 mm Flange
14 893602 1 Stop and Tail Light
822049 1 • Bulb, No. 1157
312288 2 • Lens, Screw
829099 1 • Lens and Gasket Includes License Illuminator Lens
15 548910 2 Nut, 1/4-20 Serrated Flange
16 894313 1 Harness, Taillight Wire
17 4117153.7 1 Support, Fuel Tank
18 800177 1 Screw, 5/16-18 x 3/4” Truss
19 548911 1 Nut, 5/16-18 Hex Flange
20 800930 1 Screw, M8-1.25 x 16 mm Flange
21 450453 1 Nut, M8--1.25 Hex Flange
22 REF 1 Radiator Support
23 REF 1 Frame, Lower ROPS and Platform See 14.1
24 809180 8 Washer, 1/2 x 1-1/8”

> Change from previous revision

61
TURF TRUCKSTER
Serial No. All
14.1 Frame, Lower ROPS and Platform

7
16
3
9 17
D 25 C
7

9
22 24
27
17

2 B

15 6

19

A
8 14
6 13
12
8
C
10
Gas Engine and
Transmission Mounts
B
7
11 26
D
23
5
7
20
4
21

7 19
6 7 A
1 13 7
12
7
7 6

9
10 18

9 6
4
5
11

62
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 N/S 1 Frame, Main 4 Wheel Standard Frame, Painted Black
1 N/S 1 Frame, Galvanized Main 4 Wheel Optional Galvanized Frame
2 893145.7 1 ROPS, Lower
3 893199.7 1 Platform, Truckster Standard Platform, Painted Black
3 893199-G02 1 Platform, Galvanized Truckster Optional Galvanized Platform
4 893525G01 2 Support, Platform
5 452406 4 Screw, M10-1.5 x 90 mm Flange Grade 8.8
6 452398 8 Screw, M19-1.5 x 20 mm Flange Grade 8.8
7 450454 20 Nut, M10-1.5 Hex Flange
8 450455 8 Nut, M12-1.75 Hex Flange
9 452410 12 Screw, M12-1.75 x 30 mm Flange
10 309067 2 Lockwasher, 1/2 Shakeproof
11 452405 5 Screw, M10-1.5 x 80 mm Flange
12 894581 1 Mount, Left Side Diesel Engine Diesel Units
12 894998.7 1 Mount, Left Side 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 842870G01 2 Angle, Support
15 844647G01 1 Angle, Hold Down
16 452403 4 Screw, M10-1.5 x 60 mm Flange
17 452402 6 Screw, M10-1.5 x 50 mm Flange
18 2703294.7 1 Guard, Hydraulic Tank
19 843568 1 Transmission Mount Diesel Units
19 4142849 1 Transmission Mount Gas Units
20 452389 4 Screw, M8-1.25 x 25 mm Flange
21 450453 4 Nut, M8-1.25 Flange
22 4139924 1 Bracket, Fuel System Diesel Units
23 2701693.7 1 Bracket, Fuel System Gas Units
24 452378 2 Screw, M6-1 x 20 mm Hex Flange
25 450452 2 Nut, M6-1 Hex Flange
26 882971 2 Pin, Box Pivot
27 4145325 1 Bracket, Starter Solenoid Gas Units Only

> Change from previous revision

63
TURF TRUCKSTER
Serial No. All
15.1 Rear Axle

15

20

12

19

13

14 17
12
7
9 16

5 13
6 14

5 16

4 19
1
17

18
8

24
11
23

21 / 22
23
25 3
2

10

64
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 894825 1 11.16:1 Rear Differential Assembly 84043, 84044 and 84061, See 40.1
1 894826 1 14.21:1 Rear Differential Assembly 84056 and 84057, See 40.1
2 800198 1 Locknut, 1/2-20
3 809180 1 Flat Washer, 1/2
4 893862 2 Spring, Leaf
5 843238 2 • Bushing, Nylatron
6 893613 2 Upstop
7 813850 2 Bumper, Travel Limiting
8 829044 4 U-Bolt, 2 x 5-1/4”
9 548061 8 Nut, 7/16-14
10 800909 10 Nut, M12-1.5 Wheel Lug
11 2701174 2 Wheel and Tire Assembly
2218140-01 1 • Tire. 6 Ply
841434 1 • Rim, 12 x 10.50
886735 1 • Stem, Valve
12 311398 6 Screw, 1/2-13 x 3-1/2” Hex Head
13 800602 6 Nut, 1/2-13 Nylon Insert
14 843876 4 Shackle, Rear Spring
15 843238 2 Bushing, Nylatron
16 807332 2 Shock Absorber
17 823621 4 Bushing
18 825500 4 Washer, 7/16 Cupped
19 800294 4 Locknut, 7/16-14 Center
20 311396 2 Screw, 7/16-14 x 2-1/4” Hex Head
21 4140074 1 Driveshaft, Complete Diesel Engine
21 4144334 1 Driveshaft, Complete Gas Engine, MT
21 4140071 1 Driveshaft, Complete Gas Engine, AT
22 4140076 1 • Shaft, Drive Diesel Engine
22 4144345 1 • Shaft, Drive Gas Engine, MT
22 4140067 1 • Shaft, Drive Gas Engine, AT
23 554663 2 • Cross and Bearing Kit Includes Grease Fitting
24 4140069 1 • Yoke, Differential
25 4140075 1 • Yoke, Transmission Diesel Engine
25 4140072 1 • Yoke, Transmission Gas Engine

> Change from previous revision

65
TURF TRUCKSTER
Serial No. All
16.1 Front Control Arms

10
13
9
5

20
19
2

6 26
29
7 19
24 27 28

20 26
8
11
25 28
12 27
25
17
15
16 29 20
19 10
4
9
13
19 26 26
5
14

18
19 19 2
20
6
17 7 8
16
11

12
1
23
21
22 19
22
21 15

20 19
22
3
22 14
20
18

66
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 4120138 1 Frame, 4 Wheel Steering
2 893266 2 Upper Control Arm
3 893233 1 Left Side Lower Control Arm
4 893234 1 Right Side Lower Control Arm
5 844148 2 Upper Ball Joint
6 N/S 1 • Boot
7 N/S 1 • Boot Retainer
8 N/S 4 • Screw, 5/16-24 x 1” Hex Head Black Oxide Finish, Grade 8
9 N/S 4 • Lockwasher, 5/16 Black Oxide Finish
10 548079 4 • Nut, 5/16-24 Hex Black Oxide Finish
11 306839 1 • Nut, 5/8-18 Slotted Hex
12 460030 1 • Cotter Pin, 1/8 x 1-1/4”
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”
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 Steering
24 894574 1 Knuckle, Right Side Steering
25 841630 2 Trunnion, Control Arm
26 800945 2 Bolt, M12-1.75 x 60 mm Hex Head Grade 10.9
Add or remove shims as required to
27 841738 AR Shim, .024” Thick
adjust CASTER angle.
Add or remove shims as required to
28 841737 AR Shim, .060” Thick
adjust CAMBER angle.
29 810437 2 Clamp

> Change from previous revision

67
TURF TRUCKSTER
Serial No. All
17.1 Steering Linkage

5
B 3
A
7 2 5

15 12

6 16

9
17 8
10
20
11

12

16
18 17
19
13
14 17
21
B 10 16
20
11 6
15
21
A

18 14
19
13
17
23 22

68
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 841255 1 Steering Gear
2 305134 1 • Nut, 7/8-14 Hex Jam
3 308008 1 • Lockwasher, 7/8
4 841336 1 Arm, Pitman
5 894635 2 Strut Assembly
6 452413 4 Screw, M12-1.75 x 60 mm Hex Head
7 450455 4 Nut, M12-1.75 Hex Flange Grade 10.9
8 311392 3 Screw, 7/16-14 x 2” 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 889682 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”
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, 9/16-18 Right Hand Thread Jam
21 813850 2 Bumper, Travel Limiting
22 842033 1 Plate, Skid
23 452408 6 Screw, M10-1.75 x 20 mm Grade 10.9

> Change from previous revision

69
TURF TRUCKSTER
Serial No. All
18.1 Front Brakes

11

10
9
8
5
2 1
★ Hose Clamp Location
3 A
6 24
7
20 22

14 18
4
15
19 ★
★
17
16

14 A
★ 18
23
13 14 22

★ 20

21 19

12
21

7 14
6
3 1

2
5
8
4 9 11
10

70
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 2702257.7 2 Front Hub
2 808088 1 • Outer Bearing Cup
3 814474 1 • Inner Bearing Cup
4 800908 4 • Bolt, M12-1.5 x 42 mm Wheel
5 385174 2 Outer Bearing Cone
6 815403 2 Inner Bearing Cone
7 817928 2 Seal, Grease
8 2702247 2 Nut, 3/4-16 Castle
9 304636 2 Cotter Pin, 1/8 x 1-1/8”
10 817250 2 Cap, Grease
11 841430 2 Brake Drum
12 893585 1 Front Left Side Brake Assembly
894930 1 • Kit, Brake Cylinder Replacement of Cylinder
894931 1 • Kit, Brake Cylinder Repair Repair of Cylinder
894932 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
894932 1 • Kit, Brake Shoe Includes Left and Right sides
894934 1 • Kit, Right Side Spring
894936 1 • Kit, Right Side Adjuster Repair
14 452398 10 Screw, M10-1.5 x 20 mm Hex Flange Grade 8.8
15 841842 1 Tee, M10-1.0 Flare Union
16 843418 1 Clamp, Tee
17 452692 1 Screw, M6-1.0 x 12 mm Hex Flange
18 841841 2 Hose, Brake
19 2703081 2 Protector, Brake Hose
20 842104 2 Bracket, Brake Tube
21 810437 2 Clamp, Hose
22 809137 2 Clip, Brake Hose Retaining
23 2702217 1 Tube, Left Front Brake
24 841839 1 Tube, Right Front Brake

> Change from previous revision

71
TURF TRUCKSTER
Serial No. All
19.1 Steering Column

12

11

3
2

10
8 9
Lower 7
ROPS
6

23 / 24 1

7
22
21
4
5

Power Steering Hose Routing

18
14 25
19

15
16

15 17
13
20

72
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 893571 1 Tube, Steering Mount
2 800930 4 Screw, M8-1.25 x 16 mm Flange
3 306799 4 Lockwasher, 5/16 External Tooth
4 450453 4 Nut, M8-1.25 Flange
5 893344 1 Shaft, Steering
887259 2 Bearing Assembly
6 828590 1 • Housing, Bearing
7 808060 1 • Bearing, Needle
8 819923 2 Collar, Foam
9 2700453 1 Cover, Steering Tube
10 892228 1 Steering Wheel
11 450457 1 Nut, M16-2 Flange
12 892486 1 Cover, Steering Wheel
13 REF 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 830930 2 Clamp, Hose
20 450739 1 Screw, M10-1.5 x 30 mm Socket
21 800943 1 Screw, #10-14 x 5/8” Self Tapping
22 809092 2 Clamp, Tube
23 320107 3 Cable Tie, 7-1/2” Secure hoses together
24 823549 4 Cable Tie, 15-1/2” Secure Hoses to Frame
See 25.1 or 26.1 for mounting. Ser-
vice parts for pump are available at
most automotive parts centers.
25 892534 1 Power Steering Pump with Reservior
Refer to 1991-1992 Buick Regal
with a 3.8 liter V6 Engine. (Saginaw
Pump # 26025515)
2700573 1 • Cap, Steering Reservior

> Change from previous revision

73
TURF TRUCKSTER
Serial No. 84043 All
20.1 Diesel Radiator Serial No. 84044 All

39
11

16
20

12
15
5
43 18

40
13 10
4
3
17 14
2
9
1 2
7

19

26 8
23
27
6
21

24 22
31

21
33
30 30 23
32
29
30
28
37
25 34
36
31
30
21
30
6
8 35

38

74
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 843862 AR Tube, 1/4” I.D. Clear Vinyl 10 Foot Length, Cut to 8”
2 835805 AR Hose, Radiator Overflow
3 300646 2 Screw, 1/4-20 x 3/4” Hex Head
4 306396 2 Lockwasher, 1/4
5 308090 2 Flat Washer, 1/4
6 450452 7 Nut, M6-1 Hex Flange
7 450541 4 Screw, M6-1 x 16 mm Hex Flange
8 452378 7 Screw, M6-1 x 20 mm Hex Flange
9 600991 1 Fan, 13” Hi-Perf Puller
10 600992 1 Panel, Shroud
11 601591 1 Frame, Radiator
12 601592 1 Radiator
13 601595 1 Plate, Blockoff
14 601596 1 Shroud, 13” Fan
15 800177 4 Screw, 5/16-18 x 3/4”
16 831846 4 Nut, Isolation
17 833440 1 Cap, Overflow Bottle
18 833512 2 Seal, Radiator Foam
19 889050 1 Overflow Bottle
20 893554 1 Screen, Right Side
21 450453 3 Nut, M8-1.25 Hex Flange
22 450454 2 Nut, M10-1.5 Hex Flange
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 452406 2 Screw, M10-1.5 x 90 mm Hex Flange
27 601585 1 Box, Air
28 800146 1 Screw, #10 x 3/4 Thread Cutting
29 2700867 1 Relay, 12V 70A
30 820889 6 Clamp, Hose
31 11391G7 2 Clamp, Hose
32 36092G01 1 Hose, 2” x 16” High Temp Air
33 4139196 1 Hose, Upper Radiator
34 2703281 1 Hose, Upper
35 844391 1 Hose, Lower Radiator
36 894348 1 Tube, Fan Switch
37 17680-50F70 1 Switch, Fan
38 825884 3 Clamp, Hose
39 840754 1 Decal, Radiator Pressure Warning
40 009034880 1 Decal, Fan Warning
41 601586 1 Harness, Fan Wiring Not Shown, See 52.1
42 601572 1 Harness, Perkins Engine Wiring Not Shown, See 52.1
43 4140090 1 Foam

> Change from previous revision

75
TURF TRUCKSTER
Serial No. 84056 All
21.1 Gas Radiator Serial No. 84057 All
Serial No. 84061 All

39
11

16
20
12 15

5 4 18
3 38
10
13
42
40
17
9
1 2 7
2
32 40

19

8
23
6

21

24 37
30
26 ●
21 14

● 27 33 22
30 28
29 41 ●
40
●
34
25 36
●
●
●
30 ●

43 35
31
44

76
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 843296 AR Tube, 1/4” I.D. Clear Vinyl 10 Foot Length, Cut to 8”
2 835805 AR Hose, Radiator Overflow
3 300646 2 Screw, 1/4-20 x 3/4” Hex Head
4 306396 2 Lockwasher, 1/4
5 308090 2 Flat Washer, 1/4
6 450452 4 Nut, M6-1 Hex Flange
7 450541 4 Screw, M6-1 x 16 mm Hex Flange
8 452378 4 Screw, M6-1 x 20 mm Hex Flange
9 4115033 1 Fan, 13” Radiator
10 600992 1 Panel, Shroud
11 601591 1 Frame, Radiator
12 601592 1 Radiator
13 888549 1 Connector, Hose
14 845224 1 Cap, 1/4 x 1”
15 800177 4 Screw, 5/16-18 x 3/4”
16 831846 4 Nut, Isolation
17 833440 1 Cap, Overflow Bottle
18 833512 2 Seal, Radiator Foam
19 889050 1 Overflow Bottle
20 893554 1 Screen, Right Side
21 450453 3 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
28 2701442 1 Housing, Temperature Sender
29 2701513 1 Gasket, Thermostat
30 820889 4 Clamp, Hose
31 2701108 2 Clamp, Hose
32 36092-G01 1 Hose, 2” x 16” High Temp Air
33 825624 1 Clamp, 1/4 to 5/8” Worm Drive
34 4139442 1 Hose, Upper
35 4115400 1 Hose, Lower Radiator
36 833715 1 Plug, Tube
37 452392 2 Screw, M8-1.25 x 50 mm Flange
38 009034880 1 Decal, Fan Warning
39 840754 1 Decal, Radiator Pressure Warning
40 11391G7 3 Clamp, Hose
● 41 4148150 1 Sensor, Water Temperature
42 601596 1 Fan Shroud
43 548827 2 Screw, 1/4-20 x 1/2” Hex Flange
44 548910 2 Nut, 1/4-20 Hex Flange
● Included with engine. See engine parts catalog for service

> Change from previous revision

77
TURF TRUCKSTER
Serial No. 84043 All
22.1 Diesel Engine and Transmission Mounting Serial No. 84044 All

15

25

17
21
38 19
18
18
26
13 22
14 30 23
31
21 32
11 24
16

12
34

1
37
8
35 5
4

5 36
28

33

12
29
39
40 27
6 10
4
20
5

2 10
6

12

3
7
8 11
9
7 11
8 9 11

78
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 REF 1 Engine and Clutch See 25.1
2 894580 1 Frame, Engine Mount
3 REF 1 Mount, Engine See 13.1, Left shown, right similar
4 306836 2 Screw, 3/8-16 x 2-1/4” Hex Head
5 306981 4 Flat Washer, 3/8
6 841885 2 Mount, Engine Isolation
7 809174 2 Washer, Isolator
8 120177 4 Lockwasher, 3/8
9 306562 2 Nut, 3/8-16 Hex
10 452388 4 Screw, M8-1.25 x 20 mm Flange
11 450453 14 Nut, M8-1.25 Flange
12 452389 13 Screw, M8-1.25 x 25 mm Flange
13 600985 1 Hose, Intake
14 893182 1 Air Filter
840352 1 • Element, Air Filter
15 842915 1 Bracket, Air FIlter
16 601587 1 Bracket, Air FIlter Mount
17 452390 2 Screw, M8-1.25 x 30 mm Flange
18 450412 2 Lockwasher, M10
19 800571 1 Nut, M10-1.25 Hex
20 2703835.8 1 Bracket, Muffler
21 11391G7 2 Clamp, Hose
22 2701430 1 Transmission, Suzuki MT5 Includes Clutch Disc and Cover
23 11741-85200 1 • Support, Transmission
24 01550-08163 4 • Screw
25 11710-77100 1 • Bracket, Rear Mount
26 08310-00103 1 • Nut
27 09103-08132 2 • Bolt, #1 M8 x 100 mm
28 843323 1 Adapter, Transmission
29 452401 2 Screw, M10-1.5 x 40 mm Flange
30 28825-G01 2 Screw, M8-1.25 x 50 mm Flange
31 306325 2 Lockwasher, 5/16
32 103867 2 Flat Washer, 5/16
33 01117-G02 1 Screw, M10-1.25 x 50 mm Flange
34 01117-G01 1 Screw, M10-1.25 x 35 mm Flange
35 842961 2 Sleeve, Alignment
36 844198 1 Cover, Starter Hole
37 548849 2 Screw, 3/8-16 x 4-3/4” Hex Head
38 REF 1 Mount, Transmission See 13.1
39 600989 1 Adapter
40 843857 1 Temp Sender

> Change from previous revision

79
TURF TRUCKSTER
Serial No. 84056 All
23.1 Gas Engine and MT Mounting Serial No. 84061 All

29
28
27
20
19
24 30
18 21 23 31
22 9 2

17
7
21
10
14 5
16 13 10
4
8
3

12

15 7
11
6

13

28
28

25
29
29 26

80
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 REF 1 Engine Assembly See 26.1
2 N/S 1 Manual Transmission Order with engine
3 4140899 1 Plate, Clutch Housing
4 2702548 1 Clutch Disc
5 4117900 1 Pressure Plate
6 2702547 6 Screw, M8-1.25 x 16 mm Lockwasher
7 2702688 2 Stud, M10-1.25 x 65 mm
8 2702687 1 Screw, M10-1.25 x 75 mm Flange
9 2702686 1 Screw, 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 842915 1 Bracket, Air Filter
15 452389 2 Screw, M8-1.25 x 25 mm Hex Flange
16 450453 2 Nut, M8-1.25 Hex Flange
17 4118027 1 Air Filter
840352 1 • Element, AIr Filter
18 4139211 1 Hose, Engine Air Intake
19 4140617 1 Grommet
20 4140618 1 Sensor, Air Temp
21 11391G7 2 Clamp, 2-3/4” Worm Drive
22 4118423 1 Elbow, 1/4 NPT Street
23 4118422 1 Hose Fitting, 1/4 NPT Brass
24 2702484 1 Clamp
25 REF 1 Left Engine Mount See 13.1
26 REF 1 Right Engine Mount See 13.1
27 REF 1 Transmission Mount See 13.1
28 452405 3 Screw, M10--1.5 x 80 mm Flange
29 450454 3 Nut, M10-1.5 Hex Flange
30 4138391 1 Switch, Reverse
31 4148082 1 O-Ring

> Change from previous revision

81
TURF TRUCKSTER
Serial No. 84057 All
24.1 Gas Engine and AT Mounting

27

29
28
11
12

20
19
24 7
18
21 23 10
22 10
32

17
9
30
21
14 2
31
16 13 7
4
5
3
6

15

13

28 28

25
29
29 26

82
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 REF 1 Engine Assembly See 26.1
2 4148212 1 Automatic Transmission
3 4140900 1 Plate, Transmission Housing
4 4148213 1 Torque Converter
5 4120097 1 Plate, Drive
6 4148065 6 Screw, M8-1.25 x 9.5 mm Flange
7 2702688 2 Stud, M10-1.25 x 65 mm
8 2702686 1 Screw, M10-1.25 x 55 mm Flange
9 2702756 1 Screw, M10-1.25 x 50 mm Flange
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 842915 1 Bracket, Air Filter
15 452389 2 Screw, M8-1.25 x 25 mm Hex Flange
16 450453 2 Nut, M8-1.25 Hex Flange
17 4118027 1 Air Filter
840352 1 • Element, AIr Filter
18 4139210 1 Hose, Engine Air Intake
19 4140617 1 Grommet
20 4140618 1 Sensor, Air Temp
21 1131G7 2 Clamp, 2-3/4” Worm Drive
22 4118423 1 Elbow, 1/4 NPT Street
23 4118422 1 Hose Fitting, 1/4 NPT Brass
24 2702484 1 Clamp
25 REF 1 Left Engine Mount See 13.1
26 REF 1 Right Engine Mount See 13.1
27 REF 1 Transmission Mount See 13.1
28 452405 3 Screw, M10--1.5 x 80 mm Flange
29 450454 3 Nut, M10-1.5 Hex Flange
30 4120098 1 Plate, Rear Drive
31 4120096 1 Flange, Drive Plate
32 4119955 6 Screw, M10-1.25 x 18.5 mm

> Change from previous revision

83
TURF TRUCKSTER
Serial No. 84043 All
25.1 Diesel Engine and Clutch Serial No. 84044 All

15
11 21
19

13
8
23
22
16
18
12
14

20 17
36 3

32
37 14 23

35 15 14
15 ★

24 31 32
30 23
29
38 27
28
4 31
5
1

10
25 9
8
★ 6
5
27 4

7 2

26

34

33

84
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 N/S 1 Engine, Perkins Model 403C-11 Spec HH70581U
842553 1 • Engine Oil Filter
185086321 1 • Starter Order directly from Perkins
2 843760 1 Bracket, Hydraulic Pump
3 844272 1 Mount, Right Side Engine
4 838440 8 Screw, M12-1.25 x 25 mm Flange
5 120166 8 Lockwasher, 1/2
6 REF 1 Pump, Hydraulic See 36.1
7 800073 1 Carriage Bolt, 3/8-16 x 1-1/4”
8 306981 2 Flat Washer, 3/8
9 120177 2 Lockwasher, 3/8
10 306562 2 Nut, 3/8-16 Hex
11 REF 1 Pump, Power Steering See 19.1
12 844268 1 Bracket, Rear Power Steering Mount
13 452395 2 Screw, M8-1.25 x 80 mm Flange
14 452388 5 Screw, M8-1.25 x 20 mm Flange
15 450453 7 Nut, M8-1.25 Flange
16 893633 1 Alternator
17 844270 1 Bracket, Front Alternator Mount
18 844271 1 Bracket, Rear Alternator Mount
19 600981 1 Bracket, Alternator Adjusting
20 311213 1 Screw, 3/8-16 x 3” Flange
21 548804 1 Nut, 3/8-16 Flange
22 306416 1 Screw, 5/16-18 x 1” Hex Head
23 306325 3 Lockwasher, 5/16
24 452390 3 Screw, M8-1.25 x 30 mm Flange
25 452394 2 Screw, M8-1.25 x 70 mm Flange
26 842996 1 Pulley, 4”
27 306835 1 Screw, 3/8-16 x 1-1/4” Hex Head
28 894645 1 Ring, Pressure Plate
29 22400-85141 1 Disc, Clutch Included with Transmission
30 22100-85200 1 Cover, Clutch Included with Transmission
31 839752 3 Dowel Pin, 8 x 18 mm
32 09111-08035 2 Screw, M8-1.25 Special Included with Transmission
33 841966 1 Belt, Hydraulic Pump
34 600997 1 Belt, Alternator - Power Steering 48-1/2”
35 103867 1 Flat Washer, 3/8
36 600993 1 Pulley, 5.8” Power Steering
37 REF 1 Throttle Bracket
38 821893 AR Trim, Push On

★ Indicates hardware included with Engine.

> Change from previous revision

85
TURF TRUCKSTER
Serial No. 84056 All
26.1 Suzuki Gas Engine Serial No. 84057 All
Serial No. 84061 All

28
6

29
26
25 3 32
2 39
27

40 1
35

38
23 28

20 A
7
24
A
34 37
6

4
36

22

10
8
30 31

9
13 32
12
11 33 31
19
15 17 18
16 25
14 (84056 and 84057) 32
14 21 (84061)

86
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 N/S 1 Suzuki K6 Engine See Engine Parts Manual
2701908 1 • Oil Filter
4140919 1 • Belt, Water Pump and Alternator
2 4120017 1 • Right Side Engine Mount
3 4140905 3 • Bolt, RIght Side Engine Mount
4 4120018 1 • Left Side Engine Mount
5 2701827 4 • Bolt, Left Side Engine Mount
6 2702469 4 • Bolt
7 830425 AR Fuel Hose, 1/4” 25 Foot Roll, Cut to 24 Inches
8 4139272 1 Bracket, Governor
9 2702249 1 Key, Woodruff 1/8 x 1/2”
10 4115000G01 1 Governor See ...
11 306450 2 Screw, 5/16-18 x 3/4” Hex Head
12 306325 2 Lockwasher, 5/16
13 548155 2 Flat Washer, 5/16
14 4139288 AR Pulley, 4 Groove Micro-V 4.4” Dia. Includes two set screws
15 REF 1 Pump, Hydraulic See 36.1
16 13437G5 2 Screw, 3/8-16 x 1-1/2” Whizlock
17 306981 2 Flat Washer, 3/8
18 120177 2 Lockwasher, 3/8
19 306562 2 Nut, 3/8-16 Hex
20 4144332 1 Pulley, 2-3/4” Idler
21 4144005 1 Pulley, 4 Groove Micro-V 4.06” Dia. Used on 84061 Only
22 4139351 1 Belt, 52.8” Micro-V Used on 84056 and 84057
22 4144006 1 Belt, 52.5” Micro-V Used on 84061
23 312176 1 Screw, 1/2-13 x 1-3/4” Hex Head
24 800602 1 Nut, 1/2-13 Nylon Insert
25 4139259 1 Bracket, Power Steering Pump
26 450452 1 Mut, M6-1 Hex Flange
27 4147588 1 Stand Off, M6-1
28 452389 2 Screw, M8-1.25 x 25 mm Hex Flange
29 4140264 1 Spacer, 7/16 x 25/64”
30 REF 1 Pump, Power Steering See 19.1
31 452395 2 Screw, M8-1.25 x 80 mm Hex Flange
32 450453 3 Nut, M8-1.25 Hex Flange
33 600993 1 Pulley, 5.80” Diameter
34 4139265 1 Belt, 7/16 x 26-1/2” V Alternator and Power Steering
35 4140241 1 Bracket, Air Cleaner
36 4146490 1 Plate, Hose Clamp
37 831225 1 Clamp, Hose
38 800713 1 Screw, 3/8-16 x 2-1/4” Hex Flange
39 548971 2 Screw, 5/16-18 x 5/8” Hex Flange
40 4143072 1 Tensioner, Rotary

> Change from previous revision

87
TURF TRUCKSTER
Serial No. 84043 All
27.1 Engine Speed Control Serial No. 84044 All

1
2
8

11 12
13
15 17
9 16 14
10 7

Part of 6
Engine 5
3
4

Item Part No. Qty. Description Serial Numbers/Notes

1 2703683 1 Throttle Cable See 4.1 for other end of cable
2 844130 1 Cable, Governor Control See 4.1 for other end of cable
3 894591 1 Bracket, Throttle See 25.1 for Mounting Location
4 844274 1 Lever, Governor
5 835271 1 Nut, 1/4-20 Lever Pivot
6 130728 1 Nut, 1/4-20 Hex Jam
7 840473 1 Spring, Governor Lever
8 812444 1 Clevis Pin, 5/16 x 3/4”
9 103867 1 Flat Washer, 5/16
10 821164 1 Hair Pin
11 842785 1 Spring, Idle Return
12 800271 1 Screw, #10-24 x 1/2” Pan Head
13 120052 1 Lockwasher, #10
14 111898 1 Clamp, Cable
15 831888 1 Swivel
16 831889 1 Washer, Swivel
17 831890 1 Screw, Swivel Throttle Cable

> Change from previous revision

88
 TURF TRUCKSTER
Serial No. 84056 All
28.1 Exhaust Serial No. 84057 All
Serial No. 84061 All

7
8

13

3
11 1
11

2 Tailpipe outlet to be parallel to ground.

12
10
10
5
4
9
6
9

Item Part No. Qty. Description Serial Numbers/Notes

1 4119866.8 1 Muffler
2 2703800.8 1 Tube, Exhaust Inlet
3 314990013 1 Gasket, Exhaust Order directly from Perkins
4 452389 4 Screw, M8-1.25 x 25 mm Flange
5 838295.8 1 Strap, Muffler Hanger
6 450193 2 Screw, M8-1.25 x 30 mm Hex Head
7 450378 2 Locknut, M8-1.25
8 REF 1 Bracket, Muffler See 22.1
841982 2 Clamp, 1-1/2” Exhaust
9 N/S 1 • U-Bolt
10 N/S 1 • Bracket
11 N/S 2 • Nut, 5/16-18 Hex
12 103867 2 Flat Washer, 5/16
13 REF 1 Cover, Starter Hole See 22.1

> Change from previous revision

89
TURF TRUCKSTER
Serial No. 84056 All
29.1 Governor Linkage Serial No. 84057 All
Serial No. 84061 All

29 10 26
31 32
20 35
30 4
4 41
22 3
25 20
19
A 33 28
9 17
11 18 16
12 24
15 34
35
21

22 36
14 23
35 25
8 39
11
37
12
38

27
2

13
22
A

6
5

5 7

90
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 4139208 1 Plate, Governor
2 4141031 2 Bolt, Intake Manifold Included with Engine
3 306396 1 Lockwasher, 1/4
4 308090 1 Flat Washer, 1/4
5 845224 2 Plug, Tube
6 825624 2 Clamp, 1/4” to 5/8” Worm Drive
7 4144145 1 Plug, 3/8 x 1” Tube
8 2700540 1 Lever, Governor
9 2700859 1 Lever, Governor Arm
10 01116-G01 1 Screw, M10-1.5 x 40 mm Hex Flange
11 830140 2 Ball Bearing
12 306981 5 Flat Washer, 3/8
13 450454 1 Nut, M10-1.5 Hex Flange
14 2701129 1 Arm, Throttle
15 835271 1 Nut, Governor
16 130728 3 Nut, 1/4-20 Hex 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” Truss Head
22 306375 3 Nut, 1/4-20 Hex
23 2703684 1 Throttle Cable See 4.1
24 450399 1 Flat Washer, M6
25 821164 2 Hair Pin, 1/4 x 1-1/8”
26 818395 1 Clevis Pin, 1/4 x 1/2”
27 302288 1 Screw, 1/4-20 x 1”
28 306372 1 Cotter Pin, 3/32 x 1/2”
29 4139209 1 Cable, Throttle
30 2701510 1 Bracket, Throttle Cable
31 843013 1 Pulley, Governor
32 800927 1 Shoulder Bolt, 1/4-20 x 5/8”
33 REF 2 Bolt Part of Engine
34 831586 1 Ball Joint
35 306320 3 Nut, 5/16-24 Hex
36 4139210 1 Rod, Governor
37 810722 1 Yoke
38 806703 1 Clevis Pin, 5/16 x 31/32”
39 103867 1 Flat Washer, 5/16
40 306325 1 Lockwasher, 5/16 Special

> Change from previous revision

91
TURF TRUCKSTER
Serial No. 84056 All
30.1 Governor Serial No. 84057 All
Serial No. 84061 All

33
29
41 35
31

42 39
43 40
38
34
32 29
37
30
36 B
15
22
15
23
27

13 9
8 10
4
6 3
20 5
19 2
1
28 14
B A

24
11
26 12
A
25
7

17

21
18
16

92
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
4115000 1 Governor
1 111812 1 • Yoke, Spool
2 111814 1 • Washer, Thrust
3 111816 1 • Washer, Thrust
4 111817 1 • Spool, Governor
5 112840 1 • Bearing, Thrust
6 130728 1 • Nut, 1/4-20 Hex Jam
7 111813 1 • Seal, Shaft
8 160410 1 • Carrier & Weights
9 302288 2 • Screw, 1/4-20 x 1” Hex Head
10 306396 2 • Lockwasher, 1/4
11 306506 2 • Lockwasher, #6
12 306915 2 • Screw, #6-32 x 5/16” Machine
13 603102 1 • Roll Pin, 1/8 x 3/4”
14 548325 1 • Ring, Retaining
15 800227 2 • Plug, 1/8 NPT
16 800558 1 • Set Screw, 3/8-16 x 5/16”
17 833056 1 • Gasket, Governor
18 833102 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 • • Bearing, Ball
27 4115584 1 • Ring, Support
28 2700525 1 • Lever, Governor Control
29 306396 2 Lockwasher, 1/4
30 894435 1 Bracket, Throttle
31 894434 1 Arm
32 843866 1 Bushing, Governor
33 302288 1 Screw, 1/4-20 x 1” Hex Head
34 00414-G5 2 Screw, Hex Head
35 308090 1 Flat Washer, 1/4
36 833101 1 Spring, Extension
37 111898 2 Clamp, Cable
38 120052 1 Lockwasher, #6
39 800271 1 Screw, #10-24 x 1/2” Pan Head
40 844130 1 Governor Cable See 4.1
41 817104 1 Stop, Wire
42 800024 1 Screw, 1/4-20 x 1-1/2”
43 306375 1 Nut, 1/4-20 Hex

> Change from previous revision

93
TURF TRUCKSTER
Serial No. 84056 All
31.1 Gas Engine Remote Oil Fill Serial No. 84057 All
Serial No. 84061 All

12
2 1
8

9
6
3 11

10

6
5

Item Part No. Qty. Description Serial Numbers/Notes

1 4139325 1 Bracket, Valve Cover
2 548971 2 Screw, 5/16-18 x 5/8” Hex Flange
3 REF 1 Bracket, Governor See 26.1
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 4148202 1 Cap, Oil FIll Included with Engine

> Change from previous revision

94
 TURF TRUCKSTER
Serial No. All
32.1 Gas Engine Exhaust

10
8
11

Tailpipe outlet to be parallel to ground.

9
15
1
9
2

12 5 16
15
9 14
4 3 6

17 13

11
10

Item Part No. Qty. Description Serial Numbers/Notes

1 4142914 1 Muffler
2 4144338 1 Catalytic Converter
3 2702502 2 Bolt, Muffler Flange
4 2702501 2 Spring, Muffler Flange
5 838295.8 1 Strap, Muffler Hanger
6 450193 2 Screw, M8-1.25 x 30 mm Hex Head
7 450378 2 Locknut, M8-1.25
8 4150237 1 Bracket, Muffler Attaches to Transmission Case
9 841982 1 Clamp, 1-1/2” Exhaust
10 306419 4 Screw, 1/4-20 x 1/2” Hex Head
11 306396 4 Lockwasher, 1/4
12 2702500 1 Ring, Muffler Flange
13 4121517.8 1 Shield, Muffler
14 306450 4 Screw, 5/16-18 x 3/4” Hex Head
15 306325 6 Lockwasher, 5/16
16 103867 4 Flat Washer, 5/16
17 4144336 2 Shield, Catalytic Converter

> Change from previous revision

95
TURF TRUCKSTER
Serial No. 84043 All
33.1 Diesel Fuel System Serial No. 84044 All

34

35 36
37
21
20
2
C
15
29 28 8
24
23 2
27 7 3
30 2 2 2
6 10
25 22 1
B
2 2 12

2
13
11
26
14 16
18 17
4 2
13
19 2
32 2 9
31 A
5
16 A
2
B
C
33
38

96
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 826590 1 Hose, Fuel Tank to Trap 5/16” 25 Foot Roll, Cut to 13-1/2”
2 825624 12 Clamp, Hose
3 826590 1 Hose, Pre Filter to Pump 5/16” 25 Foot Roll, Cut to 9-1/2”
4 826590 1 Hose, Pump to Fuel Filter 5/16” 25 Foot Roll, Cut to 14”
5 826590 1 Hose, Fuel Filter to Engine 5/16” 25 Foot Roll, Cut to 21”
6 831039 1 Hose, Engine Fuel Return 3/16” 25 Foot Roll, Cut to 7”
7 834036 1 Connector, 1/4” Hose to 3/16” Hose
8 830425 1 Hose, Fuel Return 1/4” 25 Foot Roll, Cut to 15-1/2”
REF 1 Engine
9 2208175 1 • Fuel Filter
10 130306380 1 • Trap, Fuel Water Order Directly from Perkins
11 894638 1 Pump, Electric Fuel
12 452393 1 Screw, M8-1.25 x 60 mm Flange
13 450453 3 Nut, M8-1.25 Flange
14 838154 1 Bracket, Fuel Pump Mounting
15 829997 1 Grommet
16 809231 2 Grommet, Split
17 452390 2 Screw, M8-1.25 x 30 mm Flange
18 REF 1 Bracket, Fuel System See 14.1
19 841969 1 Fuel Tank
20 843726 1 • Tube, Fuel Pick Up
21 148231 1 • Elbow, 90° Fuel
22 48310 2 • Grommet, Fuel Tank
23 836852 1 • Breather
24 843343 1 Cap, Unvented Fuel
25 843298 1 Sender, Fuel Level
26 829954 1 Gasket, Fuel Tank
27 833953 1 Cover, Fuel Sender
28 800021 5 Screw, #10-32 x 1/2” Pan Head
29 120052 5 Lockwasher, #10
30 829787 2 Terminal, 1/4” Male
31 REF 1 Bracket, Air Filter Mount See 22.1
32 894201 1 Harness, Fuel Sender
33 REF 1 Support, Tank See 13.1
34 893555 1 Strap, Tank
35 834005 1 Seal, Foam
36 103867 1 Flat Washer, 5/16
37 800221 1 Locknut, 5/16-18 Center

> Change from previous revision

97
TURF TRUCKSTER
Serial No. 84056 All
34.1 Gas Fuel System Serial No. 84057 All
Serial No. 84061 All

40

4
41
42 2
43 14
21 10
20
13 18

C 32 2
16
29 28 8
24 38
2 33 9
27 23 17 15
2 35
30 34
8 2 38
25 22
2 2 3 12
2 7
1
11

36
8
26 34 8

37 8

8 5
8
44
19
31 6

45

36
C 8

39

98
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 826590 1 Hose, Fuel Tank to Adapter 5/16” 25 Foot Roll, Cut to 14”
2 11391G4 8 Clamp, Hose
3 7332 1 Hose, Adapter to Pump 7/16” Cut to 3”
4 826590 1 Hose, Pump to Fuel Filter 5/16” 25 Foot Roll, Cut to 9”
5 830425 1 Hose, Fuel Filter to Tee 1/4” 25 Foot Roll, Cut to 4-1/4”
6 830425 1 Hose, Tee to Engine 1/4” 25 Foot Roll, Cut to 29”
7 4113019 1 Adapter, 5/16 to 7/16” Hose
8 18292G1 8 Clamp, Hose
9 2701897 1 Pump, Electric Fuel
10 2701898 1 Fuel Filter
11 2701899 1 Regulator, Fuel
12 452378 2 Screw, M6-1 x 20 mm Hex Flange
13 450452 2 Nut, M6-1 Hex Flange
14 800930 2 Screw, M8-1.25 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” External Tooth
18 REF 1 Bracket, Fuel System See 14.1
19 841969 1 Fuel Tank
20 843726 1 • Tube, Fuel Pick Up
21 148231 1 • Elbow, 90° Fuel
22 48310 2 • Grommet, Fuel Tank
23 836852 1 • Breather
24 843343 1 Cap, Unvented Fuel
25 843298 1 Sender, Fuel Level
26 829954 1 Gasket, Fuel Tank
27 833953 1 Cover, Fuel Sender
28 800021 5 Screw, #10-32 x 1/2” Pan Head
29 120052 5 Lockwasher, #10
30 829787 2 Terminal, 1/4” Male
31 894201 1 Harness, Fuel Sender
32 829997 1 Grommet
33 4113018 1 Adapter,, 5/16 to 1/4” Hose
34 830425 2 Hose, Adapter to Regulator 1/4 25 Foot Roll, Cut to 2”
35 826590 1 Hose, Tank Return to Adapter 25 Foot Roll, Cut to 18”
36 825624 2 Clamp, Hose
37 831039 1 Hose, Regulator to Vacuum Port 25 Foot Roll, Cut to 22”
38 2700166 1 Clamp, Filter
39 REF 1 Support, Tank See 13.1
40 893555 1 Strap, Tank
41 834005 1 Seal, Foam
42 103867 1 Flat Washer, 5/16
43 800221 1 Locknut, 5/16-18 Center
44 4115904 1 Adapter, 1/4” Tee
45 7301 1 Flex Guard Cut to 5”

> Change from previous revision

99
TURF TRUCKSTER
Serial No. All
35.1 Hydraulic Tank and Filter

NOTE: PREVENT HYDRAULIC SYSTEM DAMAGE

H O S E R E M OV E D F RO M AC C E S S O RY 8 M U S T
BE CLEANED AND PLUGGED INTO RETURN
P O RT 7 TO P R E V E N T DA M AG E D U E TO AC C -
I D E N T A L E N G A G E M E N T O F S E L E C T O R V A LV E

MOTOR DRIVEN
ACCESSORY

TRUCKSTER
CYLINDER
LIFT
1 4
10 7 VALVE

9 2
19 20
8 5
3

SELECTOR
VALVE
6
21
HYDRAULIC
TANK
HYD
PUMP
PRESSURE
RETURN
ACCESSORY
CYLINDER
20
SUCTION
FILTER PRESSURE & RETURN

FOR MOTOR DRIVEN ACCESSORY AND TRUCKSTER

DUMP BOX OPERATION
PLUG 1-4. 2-3. 8-9. 7-10
FOR TRUCKSTER CYLINDER OPERATION
PLUG 1-4. 2-3. 7-8 21
FOR MOTOR DRIVEN ACCESSORY AND INOPERABLE FOR ACCESSORY CYLINDER OPERATION
TRUCKSTER CYLINDER PLUG 1-5. 2-6. 4-3. 7-8
PLUG 1-2. 3-4. 8-9. 7-10

23
13 15
22 4

13 / 15

12 / 14

6
16
18

17
5

1
8
2 10
9
5
11 3

100
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 894675G01 1 Tank, Hydraulic
2 452388 2 Screw, M8-1.25 x 20 mm Flange
3 450453 2 Nut, M8-1.25 Hex Flange
4 452399 2 Screw, M10-1.5 x 25 mm Flange
5 800113 2 Plug, 1/2 NPT
6 893539 1 Dipstick, Hydraulic Tank
7 827486 1 Valve, Pressure Relief
8 829800 1 Battery, 12 Volt
9 844601 1 Bracket, Battery Clamp
10 452389 1 Screw, M8-1.25 x 25 mm Flange
11 844729 AR Spacer, Battery Clamp Add as required to secure battery
12 2700800 1 Hydraulic Cover Used on all, except 84044
13 837270 1 • Decal, Hydraulic Connections
14 2700801 1 Hydraulic Cover, EC Used on 84044 Only
15 840857 1 • Decal, Hydraulic Connections
16 800930 4 Screw, M8-1.25 x 16 mm Flange
17 REF 1 Hydraulic Filter
18 548827 2 Screw, 1/4-20 x 1/2” Hex Flange
19 2701107.7 1 Panel, Access
20 300646 4 Screw, 1/4-20 x 3/4” Truss
21 308090 4 Flat Washer, 1/4
22 800279 4 Nut, 1/4-20 Speed
23 821893 1 Trim, Push On

> Change from previous revision

101
TURF TRUCKSTER
Serial No. All
36.1 Hydraulic Pump and Filter

9
14

13 29

12
13
17 9
16
15
7

11
20 22 24
10
21
2
19
26

23
18
8
5 25

6
27 4
2
3
2
28 2
1

102
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 844564 1 Hose, Tank to Filter
2 836206 4 Clamp, Hose
3 844583 1 Fitting, 90°
4 844566 1 Fitting, Straight
5 844628 1 Hose, Pump to Selector Valve
6 844652 1 Fitting, 9/16-18 x 3/4-16 Straight
7 844600 1 Hose, Selector Valve to Coupler
8 844571 1 Fitting, 9/16-18 x 3/4-16 90°
9 835101 2 Fitting, 3/8” NPT 90°
10 840877 1 Sleeve, Nylon
11 844584 1 Bushing, Flip Lock
12 894702 1 Coupler Half, Dry Seal Male
13 832414 2 Ring, Rataining
14 894701 1 Coupler Half, Dry Seal Female
15 452380 2 Screw, M6-1 x 00 mm Flange
16 844973 2 Bushing
17 450452 2 Nut, M6-1 Hex Flange
18 844600 1 Hose, Coupler to Filter
19 844627 4 Fitting, 3/4-16 Tee
20 4118760 1 Hose, Control Valve to Filter
21 844590 1 Fitting, 3/4-16 x 1-1/16-12 Straight
22 894691 1 Head, FIlter
23 885249 1 Filter Element
24 523768 1 Fitting, 90°
25 844565 1 Hose, Filter to Tank
26 REF 1 Control Valve See 36.1
27 REF 1 Selector Valve See 36.1
28 888042 1 Pump, Hydraulic
306560 1 • Key, Woodruff #5
887017 1 • Seal Kit
29 844937 1 Plate, Coupler Retainer
30 320107 2 Tie, 7-1/2” Cable Not Shown, Secures Nylon Sleeve

> Change from previous revision

103
TURF TRUCKSTER
Serial No. All
37.1 Lift Cylinder Circuit

2
3
3 18
1
19
3
2
3
13 17
12 14

6
11
5
7 13
6 14

5
14
7
4

Lift Cylinder Mounting 15

15
16

21 10
20

8 22

104
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 882993 1 Cylinder, Dump Box
883236 1 • Seal Kit Texas Hydraulics
884574 1 • Seal Kit Columbus Hydraulics
886001 1 • Seal Kit DANA Hydraulics
2 830810G01 2 Pin, Clevis
3 809265 4 Hair Pin
4 821893 AR Trim, Push On
5 817320 2 Clamp, Hose
6 452378 2 Screw, M6-1 x 20 mm Hex Flange
7 450452 2 Nut, M6-1 Hex Flange
8 826558 1 Fitting, 9/16-18 90°
9 844019 1 Hose, Selector Valve to Control Valve
10 4124567 1 Hose, Control Valve to Coupler Control Valve Port B
11 844584 1 Bushing, Flip Lock
12 840877 1 Sleeve, Nylon
13 832408 2 Coupler Half, Male
14 832414 4 Ring, Retaining
15 832409 2 Coupler Half, Female
16 835101 2 Fitting, 3/8” NPT 90°
17 832900 2 Hose, Lift Cylinder to Coupler
18 823119 1 Fitting, 1/4” NPT
19 840877 1 Sleeve, Nylon
20 844598 1 Hose, Control Valve to Coupler Control Vale Port A
21 REF 1 Control Valve See 36.1
22 REF 1 Selector Valve See 36.1
23 320107 4 Tie, 7-1/2” Cable Not Shown, Secures Nylon Sleeve

> Change from previous revision

105
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Serial No. 84043 All
38.1 Diesel Electrical Components Serial No. 84044 All

9
5

11
Item 8 Routing 10

5
5
12

1
2 3

Engine Harness
Ground Wires
21

23

5 22
4

8 18
13 19
14 20
15 7
1 17
16
13 24
7
8
6

106
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 450452 3 Nut, M6-1 Hex Flange
2 452378 2 Screw, M6-1 x 20 mm Hex Flange
3 2701465 1 Solenoid, Starter
120052 2 • Lockwasher, #10
132520 2 • Nut, #10-32 Hex
306325 2 • Lockwasher, 5/16
306932 2 • Nut, 5/16-18 Hex
4 844167 1 Bracket, Horn, Brake Fluid Reservior
5 800943 15 Screw, #10-16 x 3/4” Thread Cutting
6 886425 1 Horn
7 800934 3 Screw, M6-1 x 16 mm Hex Flange
8 894266 1 Harness, Main See 51.1
9 843942 1 Socket, 12V Accessory Plug
10 4116941 1 Panel, Instrument with Tachometer
Located inside front clip, behind
11 890000 1 Buzzer, High Temperature
dash panel
12 831225 3 Clamp, Wire Harness
13 306419 2 Screw, 1/4-20 x 1/2” Hex Head
14 306488 1 Lockwasher, 1/4 External Tooth
15 828231 1 Insulator
16 548175 1 Flat Washer, 1/4
17 894596 1 Positive Battery Cable
18 884513 1 Negative Battery Cable Battery to Transmission
19 306325 1 Lockwasher, 5/16
20 450324 1 Nut, M8-1.25 Hex
21 892811 1 Cable, Ground Transmission to Right Frame Rail
22 450453 1 Nut, M8-1.25 Hex Flange
23 452388 1 Screw, M8-1.25 x 20 mm Flange
24 841895 1 Cover, Positive Battery Terminal

> Change from previous revision

107
TURF TRUCKSTER
Serial No. 84056 All
39.1 Gas Electrical Components Serial No. 84057 All
Serial No. 84061 All

9
5

11
Item 8 Routing 10

5 5
12
2

29
2
28

1
2 3
1
30

Engine Harness
Ground Wires
21

23
5

13 4
Black
14 22
Wires 8
15 8
16
7
13
1 19 18
13 27
14 7 20
6
Red 25
15
Wires 26
13 16

5 17 24

108
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 450452 8 Nut, M6-1 Hex Flange
2 452378 5 Screw, M6-1 x 20 mm Hex Flange
3 2701465 1 Solenoid, Starter
120052 2 • Lockwasher, #10
132520 2 • Nut, #10-32 Hex
306325 2 • Lockwasher, 5/16
306932 2 • Nut, 5/16-18 Hex
4 844167 1 Bracket, Horn, Brake Fluid Reservior
5 800943 15 Screw, #10-16 x 3/4” Thread Cutting
6 886425 1 Horn
7 800934 3 Screw, M6-1 x 16 mm Hex Flange
8 4115709 1 Harness, Main See 51.1
9 843942 1 Socket, 12V Accessory Plug
10 4116941 1 Panel, Instrument with Tachometer
Located inside front clip, behind
11 890000 1 Buzzer, High Temperature
dash panel
12 831225 3 Clamp, Wire Harness
13 306419 4 Screw, 1/4-20 x 1/2” Hex Head
14 306488 2 Lockwasher, 1/4 External Tooth
15 828231 1 Insulator
16 548175 1 Flat Washer, 1/4
17 894596 1 Positive Battery Cable Manual Transmission
17 2701502 1 Positive Battery Cable Automatic Transmission
18 884513 1 Negative Battery Cable Battery to Transmission
19 306325 1 Lockwasher, 5/16
20 450324 1 Nut, M8-1.25 Hex
21 892811 1 Cable, Ground Transmission to Right Frame Rail
22 450453 1 Nut, M8-1.25 Hex Flange
23 452388 1 Screw, M8-1.25 x 20 mm Flange
24 841895 1 Cover, Positive Battery Terminal
25 2700867 1 Relay, EFI 12 V 70A SP
26 843167 2 Relay, 12V 15A DPST
27 4116017 1 Harness, Generator
28 4147117 1 Controller, EFI Engine Manual Transmission
28 4147118 1 Controller, EFI Engine Automatic Transmission
29 2700993-G01 1 Cover, Engine Controller
30 450544 2 Screw, M61 x 30 mm Pan Head

> Change from previous revision

109
TURF TRUCKSTER
40.1 Differential Assembly Serial No. All

Part Number 894826 (14.21:1 Differntial)

Part Number 894825 (11.16:1 Differential)

8
4

10

3 1

6
11

7
5

11 9

110
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
894826 1 Differential Assembly 14.21:1 Differential
894825 1 Differential Assembly 11.16:1 Differential
1 891829 1 • Differential Housing See 41.1
2 N/S 1 • Axle Tubes and Shafts See 42.1
3 N/S 1 • Input, Main and Jack Shaft See 44.1
4 N/S 1 • Front and Shift Cover See 43.1
5 112050 1 Screw, 1/4-20 x 5/8” Self Tap
6 841842 1 Fitting, Hydraulic Brake Tee
7 832584 1 Clamp, Tee Fitting
8 841844 1 Hose, Brake
9 841838 1 Tube, Left Side Brake
10 841837 1 Tube, Right Side Brake
11 893583 2 Cable, Parking Brake

> Change from previous revision

111
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Serial No. All
41.1 Differential Housing
Part Number 891829

29
30

2 26

3 31
32 28
33
8 34
31
30
27 29
34
33
32
2 1

7 16 15
17 10
18

14
13

35
5
7
4
20 6
21
22
11
19
12
23
24

25

112
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 891829 1 Differential Housing
2 N/S 2 • Bearing Caps
3 306829 4 • Screw, 7/16-14 x 2” Hex Head
4 103867 8 • Flat Washer, 5/16
5 111074 1 • Plug, Drain
6 111758 10 • Stud, 3/8-16 & 3/8-24 x 1-23/32
7 306322 9 • Screw, 5/16-18 x 7/8” Hex Head
8 306982 4 • Flat Washer, 7/16
9 517226 2 • Bushing
10 800973 1 • Nut, 3/4-16 Hex Lock
11 836443 1 • Rear Cover
12 2702146 1 • Spacer, 14.21:1 Differential Used on 14.21:1 Differential Only
13 814476 1 • Cup, Bearing (2-17/32” O.D.)
14 836680 1 • Cone, Bearing (1-1/8” I.D.)
15 836688 AR • Shim, .003 Thick
16 836689 AR • Shim, .005 Thick Add or remove shims as required to
17 836690 AR • Shim, .010 Thick adjust gear backlash
18 836691 AR • Shim, .030 Thick
19 836692 1 • Baffle, Oil
20 836685 AR • Shim, .003 Thick
Add or remove shims as required to
21 836686 AR • Shim, .005 Thick
adjust gear backlash
22 836687 AR • Shim, .010 Thick
23 836677 1 • Cup, Bearing (2.84” O.D.)
24 836678 1 • Cone Bearing (1-3/8” 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 Carrier
28 800717 10 • Screw, 3/8-24 x 13/16 Hex Head
29 836675 2 • Cup, Bearing (2.89” O.D.)
30 836676 2 • Cone, Bearing, (1-5/8” I.D.)
31 836681 AR • Shim, .003 Thick
32 836682 AR • Shim, .005 Thick Add or remove shims as required to
33 836683 AR • Shim, .010 Thick adjust gear backlash
34 836684 AR • Shim, .030 Thick
35 839948 1 Tag, 14.21:1 Ratio

> Change from previous revision

113
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Serial No. All
42.1 Axle Tubes and Shafts

11
26

24
10
9
25
22
21
19
20 18
23

16
15
14

B
B
8

13
12
28
27

27
28
4 14
15 12
16 13

20
A 19 3
21
22
A
24
17

23
25
5 6
26 7
114
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 894826 1 Differential Assembly 14.21:1 Differential
1 894825 1 Differential Assembly 11.16:1 Differential
2 2702535.7 1 • Tube, Right Side Axle
3 2702534.7 1 • Tube, Left Side Axle
4 2700530 1 • Left Side Axle Assembly
2700514 1 • • Shaft, Left Side Axle
5 845356 1 • • Washer
6 800743 1 • • Nut, 5/8-18 Slotted Hex
7 304636 1 • • Cotter Pin, 1/8 x 1-1/8”
8 2700531 1 • Right Side Axle Assembly
2700515 1 • • Shaft, Right Side Axle
9 845356 1 • • Washer
10 800743 1 • • Nut, 5/8-18 Slotted Hex
11 304636 1 • • Cotter Pin, 1/8 x 1-1/8”
12 836694 2 • Seal, 1-3/4” I.D. O-Ring
13 2703481 2 • Seal, 2” I.D. O-Ring
14 836426 2 • Collar, Axle Bearing
15 838539 2 • Seal, Oil
16 836695 2 • Bearing, Tapered 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
894932 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 Cylinder Replacement of Cylinder
894931 1 • • Kit, Brake Cylinder Repair Repair of Cylinder
894932 1 • • Kit, Brake Shoe Includes Left and Right sides
894934 1 • • Kit, Right Side Spring
894936 1 • • Kit, Right Side Adjuster Repair
19 893519 2 • Retainer , Complete
20 838539 1 • • Seal, Oil
21 2703309 2 • Washer, Hardened
22 844813 4 • Ring, Backing
23 800944 8 • Screw, M10-1.5 x 25 mm
24 2701408 2 • Hub, Rear Wheel
25 800908 5 • • Bolt, Wheel
26 841430 2 • Drum, Brake
27 306405 10 • Washer, 3/8
28 805387 10 • Locknut, 3/8-24 Special

> Change from previous revision

115
TURF TRUCKSTER
43.1 Front and Shifter Cover Serial No. All

14.21:1 Differential (894826)

11.16:1 Differential (894825)

22
18
3
11 / 12
21 2
20
19 3
13 23
3
15
17
14 16

8
6
4
5

7 9
4 5

1
3
3 10 2
2

116
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 836431 1 Cover, Front
2 306322 12 Screw, 5/16-18 x 7/8” Hex Head
3 103867 14 Flat Washer, 5/16
4 307776 3 Screw, 3/8-16 x 2-3/4” Hex Head
5 810437 2 Clamp, 1/2” P 14.21:1 Differential Only
6 810435 1 Clamp Right Side Brake Tube
7 836841 1 Bracket, Shift Cable
8 836852 1 Breather
9 111074 1 Plug, Fill
10 836959 1 Bracket, Brake Tee Mounting
11 889780 1 Shift Cover Assembly
12 889925 1 • Cover
13 N/S 1 • • Bushing
14 836658 1 • Shaft, Shift
15 831099 2 • Seal, Oil
16 548937 1 • Lockwasher, 7/16
17 836657 1 • Fork, Shift
18 836662 1 • Bushing, Guide
19 807366 1 • Button, Positioning
20 2700493 1 • Spring
21 548204 1 • Set Screw, 3/8-16 x 3/8”
22 306423 2 Screw, 5/16-18 x 1-3/4” Hex Head
23 306435 1 Screw, 5/16-18 x 1-1/4” Hex Head

> Change from previous revision

117
TURF TRUCKSTER
44.1 Input, Main and Jack Shafts Serial No. All

14.21:1 Differential (894826)

11.16:1 Differential (894825)

20
27
12
19
13 18
11 5
10 2
17
16 21
15
22 14

26

8
9 25
24
1
24 23
2 25
3

4
5
2
6

118
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 836421 1 Shaft, Input
2 836693 3 Bearing, Ball
3 809254 1 Ring, External Retaining
4 800695 1 Ring, External Retaining
5 800737 2 Ring, Internal Retaining
6 837020 1 Baffle, Vent
7 812335 1 Seal, Oil
8 836422 1 Shaft, Main
9 812009 1 Bearing, Ball
10 836429 1 Collar, Engaging
11 844956 1 Bearing, Bronze Thrust
12 894886 1 Gear, Driven
13 812006 1 • Bushing
14 811993 1 Bearing, Thrust
15 844951 AR Shim, .003 Thick
Add or remove shims as required to
15 844952 AR Shim, .005 Thick
adjust gear backlash.
15 844953 AR Shim, .010 Thick
16 845034 1 Collar, Thrust
17 548952 1 Lockring
18 836420 1 Spacer, Pinion
19 842359 1 Pinion, 15 Tooth 14.21:1 Differential (894826)
19 836440 1 Pinion, 18 Tooth 11.16:1 Differential (894825)
20 800559 1 Nut, 1/2-20 Crown Lock
21 891089 1 Jackshaft
22 548201 1 Set Screw, 5/16-18 x 5/16
23 894519 1 Cluster Gear
24 844087 2 • Bushing
25 811992 3 Shim, CLuster Gear
26 842360 1 Gear, 52 Tooth 14.21:1 Differential (894826)
26 836441 1 Gear, 49 Tooth 11.16:1 Differential (894825)
27 837198 1 Baffle, Oil Scoop

> Change from previous revision

119
TURF TRUCKSTER
Serial No. 84043 - All
45.1 Transmission Clutch Release-Shift Selector Serial No. 84044 - All
Diesel Engine Only

5
2 4

3
9

11
10

12

14 13

15
1
7

14
6

120
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 REF 1 Transmission Case See 46.1
2 REF 1 Shift Assembly See 48.1
3 845223 1 Gasket, Shift Case
4 2702659 3 Screw, M8-1.25 x 40 mm
5 01550-08553 1 Screw, M8-1.25 x 55 mm
6 23265-85200 1 Bearing, Clutch Release
7 09205-03019 1 Roll Pin
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

> Change from previous revision

121
TURF TRUCKSTER
Serial No. 84043 - All
46.1 Transmission Case Serial No. 84044 - All
Diesel Engine Only

6 3
29

3
3 4
21

5
24

6
26
23
1
14 25

11
27
17

16
15
22
20
19 28
2 18
13
12

7 10
9
1

122
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 24700-85200 1 Case, Transmission Upper and Lower Half
2 2702690 2 • Pin, Alignment
3 09103-08131 4 • Screw, M8-1.25 x 120 mm Flange
4 2702470 3 • Screw, M8-1.25 x 30 mm Flange
5 2702659 1 • Screw, M8-1.25 x 40 mm Flange
6 2702471 2 • Screw, M8-1.25 Flange
7 24741-83001 1 Retainer, Input Shaft Bearing
8 09103-08152 8 Screw, M8-1.25 x 25 mm Flange
9 09380-28007 1 Cir CLip
10 09262-28019 1 Bearing, Front
11 24131-83002 1 Counter Shaft
12 09262-28020 1 Bearing, Center
13 24671-83000 1 Gear, Countershaft Reverse
14 REF 1 Input and Main Shaft See 47.1
15 09283-25088 1 Seal, Oil
16 09390-68002 1 C-Ring
17 09390-62010 1 C-Ring
18 844184 1 Spacer, 5th Gear
19 452381 1 Screw, M6-1 x 40 mm Flange
20 844186 1 Washer, Special
21 2702662 1 Plug, Inspection Timing
22 452396 7 Screw, M8-1.25 x 90 mm Flange
23 844906 1 Seal, Extension Case
24 452390 1 Screw, M8-1.25 x 30 mm Flange
25 01421-08303 1 Stud, M8-1.25
26 450324 1 Nut, M8-1.25 Hex Flange
27 2702690 2 Pin, Alignment
28 N/S 1 Mechanical PTO Assembly See 49.1
29 28391-85202 1 Bracket, Shift Cables

> Change from previous revision

123
TURF TRUCKSTER
Serial No. 84043 - All
47.1 Input and Main Shaft Serial No. 84044 - All

10
9

8
7
6

7
8

4
2 5

1
12

3
11
4
20

18
19
16

15
14
6

14
28
15
28
16 24 4
17 13
25
27
26
18

18
19 23
21
22
21

124
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 24110-80410 1 Shaft, Input 4th Gear
2 2702561 1 Bearing, Needle
3 4141037 1 Bearing, Input Shaft Ball
4 09380-28007 3 Cir Clip
5 24410-83000 1 High Speed Syncroniser Includes Hub and Sleeve
6 24471-60A00 6 Key, Syncronizer
7 24442-81A20 2 Spring, High Speed Syncronizer
8 24432-83001 3 Ring, Syncronizer
9 24230-83001 1 Gear, Main Shaft 3rd 3rd Gear
10 09263-30031 1 Bearing, Needle
11 24121-85252 1 Shaft, Main
12 06111-06003 2 Ball
13 24400-83000 1 Low Speed Syncronizer Includes Hub and Sleeve
14 24436-83000 2 Spring, Low Speed Syncronizer
15 24441-85F41 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 09262-30086 1 Bearing, Ball
23 24420-83000 1 Syncronizer, Reverse Drive Includes Hub and Sleeve
24 24473-70D10 3 Key, Syncronizer
25 2703581 1 Spring, Reverse Syncronizer
26 24681-83000 1 Gear, Main Shaft Reverse Reverse Gear
27 26121-85202 1 Gear, Speedometer Drive
28 2702559 2 Cir Clip

> Change from previous revision

125
TURF TRUCKSTER
Serial No. 84043 - All
48.1 Gear Shift Fork Linkage Serial No. 84044 - All

31

30
29
28
27
20
21 33
22
23
13
12
14
32
24

26
B
C
25
D

15
16
17
18
19

11

5
4 2
1
8 10 10
3

B
10

4 4

D 6 A
C

9
7

126
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 25411-85201 1 Shaft, Low Speed Fork 1st and 2nd Gear
2 25420-85201 1 Shaft, High Speed Fork 3rd and 4th Gear
3 25451-85261 1 Shaft, Reverse Fork Reverse
4 06111-12004 5 Ball
5 25415-83000 3 Spring, Detent
6 09261-03017 1 Roller
7 25211-85201 1 Fork, Low Gear Shift 1st and 2nd Gear
8 25221-85202 1 Fork, High Gear Shift 3rd and 4th Gear
9 25221-83002 1 Fork, Reverse Gear Shift Reverse
10 09205-05012 3 Pin, 4 x 25 mm Spring
11 09250-10006 1 Plug, Locating
12 25121-85051 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 09135-08005 1 Ball
24 2701953 1 Pin
25 25530-79501 1 Shaft, Gear Select
26 09286-09001 1 Seal, Oil
27 25535-85412 1 Arm, Gear Select
28 09162-08008 1 Washer
29 2702883 1 Washer
30 2702494 1 Nut, M8-1.25 Hex
31 25536-84200 1 Boot, Gear Select
32 09135-08005 1 Bolt, Retaining
33 24821-09001 1 Plug, Breather

> Change from previous revision

127
TURF TRUCKSTER
Serial No. All
49.1 Mechanical PTO
Diesel Units Only

24

17 5
A 6 4
19 15 7
9
18
20 10
21 11
22
2
23

30 2
25 26
3 1
29
27 16 13
15
26 14 12

28 A

128
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
1 844181 1 Housing, Mechanical PTO
2 844907 1 Bushing, Output Shaft
3 2700121 1 Gasket, PTO Housing to Trasmission
4 2700120 1 Gasket, Bearing Housing
5 894989 1 Housing, Bearing
6 844188 1 • Seal, Oil
7 815093 1 • Bearing, Ball
8 452389 3 Screw, M8-1.25 x 25 mm Flange
9 844185 1 Shaft, PTO Output
10 815182 1 Gear, 21 Tooth PTO Sliding
11 844147 1 Bearing, Ball
12 815085 1 Fork, Sliding
13 879807 1 Arm, PTO Shifter
14 548477 AR Shim
15 812419 AR Shim, Transmission
16 807624 1 O-Ring
17 817397 1 Arm, PTO Shifter
18 120166 1 Lockwasher, 1/2
19 301988 1 Nut, 1/2-20 Hex
20 548204 1 Set Screw, 3/8-16 x 3/8
21 815012 1 Spring
22 815013 1 Button
23 452380 1 Screw, M6-1 x 30 mm Flange
24 800425 1 Screw, M6-1 x 12 mm Hex Head
25 894965 1 Gear, Idler
26 844905 2 • Bushing, Countershaft
27 894947 1 Shaft, Idler
28 316942 1 • Pin, 1/4 x 1/2” Spirol
29 09166-16014 1 Washer
30 805307 1 Washer, 5/8 x 1
31 09246-16010 2 Plug, 1/2 NPT

> Change from previous revision

129
TURF TRUCKSTER
Serial No. 84043 All
50.1 Diesel Engine Electrical Schematic Serial No. 84044 All

Automatic Gn
Transmission Bk
Controller

Gn
Heater Ye
Accessory Bk 20 A
Ye

Accessory Ye/Rd 10 A
Connector 1 Bk Ye/Rd Clutch
Switch
10 A
Pk Pk
Accessory Ye/Rd Rd Wh/Gn
Connector 2 Bk 10 A

Wh/Gn

Gn

Pk
Accessory Rd A I S
Connector 3 Bk ACC - B + A
Ignition OFF - None
Switch ON - B +A+I
Start - B+I+S
Accessory Rd
B
Connector 4 Bk

Rd
Bk

Overheat
Alarm
Wh/Bu Bk

Rd/Bk Bk

Brake Fluid Power

Level Switch Point

1
Tachometer

Gas Tach Input 2 Wh/Bn

3 Bn

Brake Fluid Level 4 Rd/Bk

5
Voltmeter
6
Pre-Heat
7 Wh/Bk
Wh/Rd
Wh/Bk

Wh/Ye

Rd/Bk
Pk/Bu

Temp Gauge 8 Wh/Ye

Wh
Gn

Og
Rd
Pk

Bk
Rd
Bk

Bk

High Beam 9 Wh/Og

Oil Pressure 10 Wh
Main Harness to Main Harness to Main Harness to
Fuel Sender 11 Og Engine Harness Engine Harness Engine Harness
Fuel Guage Connector 1 Connector 2 Connector 3
Parking Brake 12 Pk/Bu

Left Turn 13 Gn/Bk

Diesel Tach Input 14 Wh/Rd

Right Turn 15 Ye/Bk

- 12 V 16 Bk
Overheat
Alarm 17 Wh/Bu

+ 12 V 18 Gn

Dash
Panel

130
 TURF TRUCKSTER

Tail
Light

Bn Bn Bn

Bk Bk Bk

Og Bu/Bk Bu/Bk

Rd/Bk Rd/Bk

Brake Single
Horn Horn
Light Tail Light
Harness Button

Bk Bk Bk Rd

Cab Stop Og/Bk

Light Bk
Accessory

Brake Wh/Rd
Accessory Bk
Connector 1

Brake Og/Bk
Accessory Bn
Connector 2

Brake
15 A Pedal
Switch
Wh/Rd

10 A Wh/Og Wh/Og Og/Bk Jumper

Plug
Rd Bu/Bk Og
10 A Ye
Ye/Bk
Wh/Bu Flasher Ye Rd/Bk Og

15 A (Turn Signal Ye/Rd Ye/Rd

Accessory)
Og/Bk Og
Wh/Bn

Gn/Bk

Turn Signal
Main Harness to Bu Bn
Accessory
Engine Harness Left Headlight
Connector 4
(Gas Units) Low Beam Bu
Wh/Bu
Gn/Bk
Bk

Wh Wh Bn
Left Turn Gn/Bk
High Beam
Signal Light Bk
Accessory
Low Beam Bu

Bk

Right Turn Ye/Bk Wh

Signal Light Bk High Beam
Accessory
Ye/Bk
Right Headlight
Wh/Og

131
132
Fan
Motor
Rd Ye Bn
Bk
40 A
Wh/Bk Ye

Fan
Relay Main Harness Main Harness Main Harness
Connector 1 Connector 2 Connector 3

Ye
Bk
Bk
Rd
Gn
Pk
Wh
Rd
Og
Bk

Wh/Bk
Pk/Bu
Wh/Bk
Wh/Rd
Wh/Ye
Rd/Bk

Rd/Bk
Rd
TURF TRUCKSTER

Rd
Wh/Gn EXC P Wh/Rd

Alternator Temp

Wh/Ye
Rd Parking Brake Sender Wh
Ye S B Rd
G Switch
25 A
Pk/Bu Oil Pressure
Wh/Bk Bk Bk Rd Switch

Rd
87A Bu
Wh/Gn Gn Gn
Fan 30
Switch 87
Gn Wh
Rd Rd Rd Rd Rd 86 85
Ye Og
40 A Fuel
Wh/Gn Wh/Bk Shutoff
Starter
Relay
Solenoid
Rd Wh/Rd Pre-Heat Fuel
Relay Sender Gn Bk
Bk Pk
Rd Bk
Gn Gn Wh/Gn Wh/Gn Ye Glow
Fuel
Diode Diode Plugs
Wh/Rd Solenoid
Wh/Gn Bu
B S
Diode

Wh/Gn Fuel Bk
Pump
Starter
Bk
133
TURF TRUCKSTER
Serial No. All
51.1 Diesel Engine Main Harness
Part Number 894266

1 1

Engine Harness Engine Harness

Connector #2 Connector #1
2 Engine Harness Connector 3
Engine Harness (Gas Only)
Connector #3
4
6 Cab Stop Light
5 (Option)

Flasher
Jumper Plug (Option) Tail Light Harness 2
Connector
1 Brake Accessory 4
Turn Signal (Option)
(Option)

7 Brake Pedal 8
Switch Ignition Switch

Horn Button

9 12 V Accessory
Light Switch Plug

7 4
Clutch Pedal Buzzer
Switch
10

11 Right Headlight Dash Panel

4 Right Turn Signal

(Option)

11 Left Headlight
Ground
Left Turn Signal Wires
(Option)

4 4
Brake Accessory
(Option)
Heater
4
(Option)
4 Optional 4
Automatic Transmission
Accessories (Not Used)

Horn

4 Brake Fluid 14
Reservoir
13
Fuse Block #1 Fuse Block #2
16 15
30
15

15

15
10

10

15
10

12

134
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Number / Notes
1 825973 3 Connecter, Six Male Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge Single Wire
825961 AR Terminal, 1/4” Male 10 Gauge Two Wire
2 829630 2 Connector, Four Female Terminal
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
3 826726 1 Connector, One Female Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge
4 826005 13 Connector, Two Female Terminal
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
5 825894 1 Connector, Flasher
825899 AR Terminal, 5/16” Female 14-16 Gauge
6 825877 1 Connector, Six Female Terminal
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
7 826006 2 Connector, Two Male Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge
8 837296 1 Connector, Ignition Switch
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
9 843598 1 Connector, Rocker Switch
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
10 843550 1 Connector, Eighteen Terminal
843551 AR Terminal
11 837301 2 Connector, Headlight
825899 AR Terminal, 5/16” Female 14-16 Gauge One Wire
828629 AR Terminal, 5/16” Female 14-16 Gauge Two Wire
12 825996 1 Fuse Holder
13 825997 4 Fuse Clip, 1 Term., 14-16 Gauge
14 825998 6 Fuse Clip, 1 Term, 10 Gauge
15 825999 2 Fuse Clip, 3 Term. 14-16 Gauge
16 836892 5 Fuse, 10 Amp
16 842983 2 Fuse, 15 Amp
16 826000 1 Fuse, 20 Amp

> Change from previous revision

135
TURF TRUCKSTER
Serial No. All
52.1 Diesel Engine and Fan Harness
Part Numbers 601572 & 601586

Starter

Parking Brake Ground Wires

Glow Plug

Starter 7
Solenoid
Fuel Solenoid

3
Diode 2
Engine Harness
Connectors
Diodes Connector #1
4
Engine Harness
Connector #2 1
6 Engine Harness
Fuel Shutoff Connector #3
5
Relay

Fuel Fuel Level

Pump Sender
4
10
4 4
12
Fan Harness
Fan Relay
Fuse
13 14
8 Pre-Heat
Relay 17
16 Fan
Fan 15
10 Motor
Relay
11
Glow Plug 18
Fuse Fan Motor
Fuse
7 19
Engine Oil
Pressure

9 Fan
Switch

Temperature
Sender
Ground Starter
Solenoid
Alternator

136
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Numbers/Notes
601572 1 Engine Harness
1 825877 2 • Connector, Six Female Terminal
825748 AR • Terminal, 1/4” Fem. 14-16 Gauge Single Wire
825878 AR • Terminal, 1/4” Fem. 10 Gauge Two Wire
2 829630 1 • Connector, Four Male Terminal
825961 AR • Terminal, 1/4” Male 10 Gauge Two Wire
3 884398 3 • Diode Connector Assembly
4 826005 6 • Connector, Two Female Terminal
825748 AR • Terminal, 1/4” Fem. 14-16 Gauge Single Wire
825878 AR • Terminal, 1/4” Fem. 10 Gauge Two Wire
5 843168 1 • Connector, Relay
842966 AR • Terminal, Female Relay
6 843167 1 • Relay, 12V 15 Amp DPST
7 4129717 2 • Plug, 2 Wire Deutsch
4129730 AR • Socket, 16-18 Gauge Solid
4129733 AR • Wedge, 2 Wire Deutsch
4129747 AR • Gasket, 2 Wire Deutsch
8 2700868 1 • Connector, 70 Amp Relay
842966 AR • Terminal, Female Relay
2700869 AR • Terminal, 3/8” Female Relay
9 842959 1 • Connector, 2 Contact
833257 2 • Terminal, 3/32” Female
838463 2 • Seal, Wire
10 826584 2 • Block, Single Fuse
825997 AR • Fuse Clip, 1 Term., 14-16 Gauge
825998 AR • Fuse Clip, 1 Term, 10 Gauge
11 836536 1 • Fuse, 40 Amp
12 4113261 1 • Fuse, 25 Amp
13 2700867 1 Relay, 12V, 70 Amp SPST

601586 1 Fan Harness

14 826006 1 • Connector, Two Male Terminal
825886 AR • Terminal, 1/4” Male 14-16 Gauge
15 826005 1 • Connector, Two Female Terminal
825748 AR • Terminal, 1/4” Fem. 14-16 Gauge
16 2700868 1 • Connector, 70 Amp Relay
842966 AR • Terminal, Female Relay
N/S AR • Terminal, 3/8” Female Relay
17 2700867 1 • Relay, 12V, 70 Amp SPST
18 826584 2 • Block, Single Fuse
825997 AR • Fuse Clip, 1 Term., 14-16 Gauge
19 836536 1 • Fuse, 40 Amp

> Change from previous revision

137
TURF TRUCKSTER
Serial No. 84056 All
53.1 Gas Engine Electrical Schematic Serial No. 84057 All
Serial No. 84061 All

ECU

207 206 205 204 203 202 201 9 8 7 6 5 4 3 2 1

See page 142 for 34 pin connector
213 212 211 210 209 208 17 16 15 14 13 12 11 10
220 219 218 217 216 215 214 26 25 24 23 21 20 19 18
226 225 224 223 222 221 34 33 32 31 30 29 28 27 Bn/Ye

Gn/Wh

Bk/Rd Bk/Rd
201
Wh/Rd Wh/Rd
202

203
Rd/Gn Rd/Gn
204
Pk
205
Wh
206 Rd/Wh
Bk/Gn Timing
207 Bk
Plug
Gn/Wh Gn/Wh
208
Bn

209
Bl/Wh
210 Diagnostic
Bk Plug
Rd/Wh
211
Bu/Wh
212
Bk/Wh
213
26 Pin
ECU 214
Bk/Wh
Connector 215
Og Og
216

217 Shifter Switch

Gn/Pk (Automatic
218
Og/Bu Transmission)
219
Og/Gn Og/Gn P
220
Rd R Pk
221
Bn Og/Bu N
222 C Bn/Ye Wh
Bk Gn D
223 Bk/Gn
Gn/Bu Gn/Pk 2 Bk/Rd
224
Gn Gn/Bu 1
225 Bn/Ye
Rd Rd
226 Wh/Pk
Pk Wh/Bu

Pk

Rd
1
Wh/Ye
2
Bu
3
Bk/Wh Bk/Wh
4
Bu/Rd
5 Bu/Rd
Engine 6
Harness 7
Bu/Wh Bu/Wh
Connector 1 Bu/Bk
8 Bu/Bk
Shift Solenoid
9 (Automatic
Wh/Ye
10 Transmission)
Bk/Rd Bu
11
Gn/Wh Gn/Wh
12

138
 TURF TRUCKSTER

Gn/Bk
Bk/Wh
Shifter
Bu Rd/Ye Bk/Wh
Light
25 A
Bk/Wh Bk/Wh
Wh/Rd Rd/Bk

15 A
Bn/Ye Bn/Ye Rd/Og

10 A
Gn/Wh Gn/Wh Gn/Bk

10 A
Bk/Rd Fan
Wh/Rd Motor
Bu Ye Ye Bk
Fan
Rd/Gn Relay Rd/Gn Bk/Rd

Bk/Gn

Bk/Gn
Pk/Bu Pk/Bu Fuel Bk
Fuel Pump
Relay Bk/Wh Pk Rd

Wh/Pk
Wh/Rd
Bk/Rd Pk
Main
Relay Wh/Rd Bk/Gn
Wh

Bk/Wh

Og Og
Speedometer
Wh/Rd
Signal
Bk/Rd

Og Bk

Speed
Pk Sensor
Wh
Bk/Gn

Bk/Rd

Bn/Ye

Wh/Pk

Pk

Rd

Bk/Wh

Reverse Switch
(Manual Transmission)
Bn/Ye Rd Rd
Backup Alarm
Bk

Wh/Ye Wh/Ye

Bu Bu

Gn/Wh Gn/Wh

139
TURF TRUCKSTER

Gn/Bk
Bk/Wh Bk/Wh

Bk/Wh

Bk/Wh Bk/Wh Gn
Bk/Wh 20 A
Ye

10 A
Ye/Rd Clutch Switch
(Manual Transmission)
Ye/Rd 10 A
Pk/Bu Wh/Og
Rd Wh/Gn

Gn/Bk

Wh/Pk

Pk
Bk Bk Bk Bk Bk 10 A

Gn
Wh/Gn

Pk/Bu
Ye/Rd

Ye/Rd

Rd

Rd
Ye

A I S
Accessory Accessory Accessory Accessory Accessory ACC - B + A
Ignition OFF - None
Connector 1 Connector 2 Connector 3 Connector 4 Connector 5
Switch ON - B +A+I
Start - B+I+S
B

Rd
Rd

Bn
Wh/Pk

Pk
Rd

Wh Wh
Engine Starter
Harness Solenoid
1
Tachometer Connector 2 Rd Wh/Rd
Gas Tach Input 2
Brake Fluid
Rd Bk Wh/Og
3 Bn Level Switch
4 Wh/Rd
Brake Fluid Level Rd/Bk Rd/Bk Bk
B S
5
Voltmeter
6 Gn/Wh
Pre-Heat
7

Temp Gauge 8 Wh/Ye

Starter
High Beam 9 Wh/Og

Oil Pressure 10 Bu
Bk
Fuel Sender 11 Og Og
Fuel Guage
Parking Brake 12 Pk/Bu Fuel
Sender
Left Turn 13 Gn/Bk Gn/Bk

Tach Input 14 Wh/Rd

Right Turn 15 Ye/Bk Ye/Bk

- 12 V 16 Bk
Overheat
Alarm 17 Wh/Bu Wh/Bu Bk Pk/Bu

+ 12 V 18 Bk/Wh Coolant
Overheat
Dash Parking Brake
Alarm
Panel Switch

Wh/Ye

Bu Wh/Og
Gn/Wh

140
 TURF TRUCKSTER

Tail Bn Bn Bn
Light
Bk Bk Bk

Og Bu/Bk Bu/Bk
Brake
Light Rd/Bk Rd/Bk
Single
Horn Horn
Tail Light
Harness Button

Bk Bk Bk Rd

Cab Stop Og/Bk

Light Bk
Accessory

Brake Wh/Rd
Accessory Bk
Connector 1

Brake Og/Bk
Accessory Bn
Connector 2

Bn

Rd

Rd Power
Wh Point
Rd Rd Bk/Ye Brake
15 A Pedal
Switch
Wh/Rd

10 A Wh/Og Wh/Og Og/Bk Turn Signal Jumper

Accessory Plug
Rd Bu/Bk Og
10 A Ye
Ye/Bk
Wh Wh/Bu Flasher Ye Rd/Bk Og

15 A (Turn Signal Ye/Rd Ye/Rd

Accessory)
Og/Bk Og

Gn/Bk

Bu Bn
Left Headlight
Low Beam Bu
Wh/Bu
Gn/Bk
Bk

Wh Wh Bn
Ye/Bk Left Turn Gn/Bk
High Beam
Signal Light Bk
Accessory
Low Beam Bu

Bk

Right Turn Ye/Bk Wh

Signal Light Bk High Beam
Accessory
Right Headlight
Wh/Og Wh/Og

141
TURF TRUCKSTER
54.1 Gas Engine Schematic

Br/Bk Br/Bk
1
Bn/Wh Bn/Wh
2

3
Gy Gy
4
Ye/Wh
5
Ye/Bu
6

8
Bk/Bu
9
Bn Bn
10
Rd/Bk Rd/Bk
11
Rd Rd
12
Rd/Ye Rd/Ye
13
Rd/Bu Rd/Bu
14
Wh Wh
15
Bn/Rd Bn/Rd
16
Bk
17
Pk/Wh
18
Wh/Rd Wh/Rd
19
Wh Wh
20
Wh/Bk Wh/Bk
21
ECU
Gn Gn Bu/Ye Bu/Ye
22
LG/Ye
23
Ignition Resistor
Rd/Bu Wire Shield Rd/Bu
24
LG/Rd
25
LG/Rd LG/Ye
26
Bu/Bk Bu/Ye
27
LG/Rd
28
Bu/Wh Gn/Bk Intake Air Bu/Ye
Temperature Pressure Sensor
29
LG/Bk LG/Rd Bu/Ye
30
Gy/Ye Gy/Ye
31
LG/Wh Throttle Sensor
32

33
Bu/Ye Bu/Ye
34

Pk Ye/Bk
Ye/Wh
1
Pk
Temperature
2 Sender Oil Pressure
3
Ye/Bk Sender
Bk/Wh Bk/Wh
4

5
Pk/Wh LG/Wh
Water
Engine 6 Bu/Ye
Temperature
Harness Bu/Wh
7 Sensor
Connector 1 Bu/Bk Bk/Wh
8
Ye/Bu Wh/Bu
9
Bk/Ye Alt
10 Wh/Gn
Bk/Rd Bk/Rd
11
Wh/Bu
12

Engine
Wh/Gn
Harness
Connector 2

142
 TURF TRUCKSTER

Injector #1
Br/Bk Br/Bk Bk/Rd

Bn/Wh

Injector #2
Gy Bn/Wh Bk/Rd

Injector #3
Bn Bk/Rd

Bn

Rd/Bk
Bk/Rd Bk/Rd
Rd Wire Gy
Rd/Ye Shield
Rd/Bk Rd Rd/Bu
Rd/Bu
Oxygen
Wh ISC M Bu/Ye Sensor
Rd/Ye Rd/Bu
Bn/Rd

Bk/Rd
Wire
Bk/Rd Shield
Wh Knock
Wh/Rd
Sensor
Wh

Wh/Bk Bk/Rd

Bu/Ye Bu/Ye

Crank Position
Rd/Bu
Sensor
Bk/Wh Bk/Wh Bk/Wh

Coil Coil Coil

1 2 3

Bu/Ye

Bk/Wh

Bk/Rd

143
TURF TRUCKSTER
Serial No. All
55.1 Gas Main Harness
Part Number 4115709

Engine
ECU Harness Speed
24 Connector Connector Sensor Shift 25
Back-Up Solenoid
23 Switch
17”
Shift
22 Switch 27

Parking Brake
26 Back-Up
Switch
Alarm
30”
22 28
Starter 22 21” 18” 22 30
Solenoid Fuel Pump 29
22 20-1/2”
Fuel Sender
4 Radiator Fan B+ Starter
2
Tail Light Harness Transmission Ground
Connector Wires

7 Cab Stop Light

8
Ignition Switch
(Option) 21 21 16”
20
35” 35”
Brake Accessory 20 13” 1 6
4 (Option) 11”
19 Turn Signal
7 Brake Pedal (Option) Jumper Plug
Switch 5
Flasher
12 V Accessory (Option)
11 Plug
Left Turn 11” Clutch Pedal 7
Signal
19 Switch
Left Headlight 4
(Option) 20 14”
Right Turn Signal Horn Button
4 (Option)
19 80” 9“ Buzzer 9
11 20 Light Switch
Right Headlight
3 Speedometer
Tach Signal
Tach / Speedometer
Signal 4
Dash Panel
Signal Ground
10 Heater
Wires (Option)
4

Optional
Accessories 4

Brake Accessory
(Option)
Positive 3
Standoff Timing 33
Shifter 32
Wires Plug 31
Light
16” Diagnostic
21
Horn Plug
Fan
Relay 18
14 Brake Fluid Main
13 Fuse Reservoir Fuel Relay
Relay 17
Block #1
Fuse
Fuse 17
16 15 Block #3 4
Block #2
12

144
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Number / Notes
1 825973 1 Connecter, Six Male Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge Single Wire
825961 AR Terminal, 1/4” Male 10 Gauge Two Wire
2 829631 1 Connector, Four Female Terminal
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
3 826726 2 Connector, One Female Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge
4 826005 12 Connector, Two Female Terminal
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
5 825894 1 Connector, Flasher
825889 AR Terminal, 5/16” Female 14-16 Gauge
6 2700913 1 Jumper Plug, Taillight
825877 1 • Connector, Six Female Terminal
825748 AR • Terminal, 1/4” Female 14 Gauge Single Wire
825878 AR • Terminal, 1/4” Female 10 Gauge Two Wire
7 826006 3 Connector, Two Male Terminal
825886 AR Terminal, 1/4” Male 14-16 Gauge
8 837296 1 Connector, Ignition Switch
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
9 843598 1 Connector, Rocker Switch
825748 AR Terminal, 1/4” Female 14-16 Gauge Single Wire
825878 AR Terminal, 1/4” Female 10 Gauge Two Wire
10 843550 1 Connector, Eighteen Terminal
843551 AR Terminal
11 837301 2 Connector, Headlight
825889 AR Terminal, 5/16” Female 14-16 Gauge One Wire
828629 AR Terminal, 5/16” Female 14-16 Gauge Two Wire
12 825996 3 Fuse Holder
13 825997 12 Fuse Clip, 1 Term., 14-16 Gauge
14 825998 6 Fuse Clip, 1 Term, 10 Gauge
15 825999 2 Fuse Clip, 3 Term. 14-16 Gauge
16 836892 7 Fuse, 10 Amp
16 842983 3 Fuse, 15 Amp
16 826000 1 Fuse, 20 Amp
16 4113261 1 Fuse, 25 Amp
17 843168 2 Connector, 15 Amp Relay
842966 8 Terminal, Female Relay
18 2700868 1 Connector, 70 Amp Relay
842966 2 Terminal, 1/4” Female Relay
2700869 2 Terminal, 3/8” Female Relay
19 826190 AR Tubing, 3/8” I.D. Black Convoluted 50 Foot Bulk
20 826191 AR Tubing, 1/2” I.D. Black Convoluted 25 Foot Bulk

145
TURF TRUCKSTER
55.1 Gas Main Harness (Continued)
Part Number 4115709

Engine
ECU Harness Speed
24 Connector Connector Sensor Shift 25
Back-Up Solenoid
23 Switch
17”
Shift
22 Switch 27

Parking Brake
26 Back-Up
Switch
Alarm
30”
22 28
Starter 22 21” 18” 22 30
Solenoid Fuel Pump 29
22 20-1/2”
Fuel Sender
4 Radiator Fan B+ Starter
2
Tail Light Harness Transmission Ground
Connector Wires

7 Cab Stop Light

8
Ignition Switch
(Option) 21 21 16”
20
35” 35”
Brake Accessory 20 13” 1 6
4 (Option) 11”
19 Turn Signal
7 Brake Pedal (Option) Jumper Plug
Switch 5
Flasher
12 V Accessory (Option)
11 Plug
Left Turn 11” Clutch Pedal 7
Signal
19 Switch
Left Headlight 4
(Option) 20 14”
Right Turn Signal Horn Button
4 (Option)
19 80” 9“ Buzzer 9
11 20 Light Switch
Right Headlight
3 Speedometer
Tach Signal
Tach / Speedometer
Signal 4
Dash Panel
Signal Ground
10 Heater
Wires (Option)
4

Optional
Accessories 4

Brake Accessory
(Option)
Positive 3
Standoff Timing 33
Shifter 32
Wires Plug 31
Light
16” Diagnostic
21
Horn Plug
Fan
Relay 18
14 Brake Fluid Main
13 Fuse Reservoir Fuel Relay
Relay 17
Block #1
Fuse
Fuse 17
16 15 Block #3 4
Block #2
12

146
 TURF TRUCKSTER
Item Part No. Qty. Description Serial Number / Notes
21 826192 AR Tubing, 3/4” I.D. Black Convoluted 25 Foot Bulk
22 826193 AR Tubing, 7/16” I.D. Green Convoluted 25 Foot Bulk
23 4116015 1 Connector, 12 Contact Male
833257 8 Terminal, Female
838463 8 Seal, Wire
2700933 4 Plug, Cavity
24 845329 1 Connector, 26 Contact Male
2700852 1 Lock, 26 Contact
2700470 19 Terminal, Fermale
2700851 19 Seal, Wire
4118039 7 Plug, ECU Connector
25 845330 1 Connector, 4 Contact Male
833257 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 AWG Socket
33 838770 2 Plug, 4 Wire Deutsch

147
 INDEX
00414-G5.....................93 111898............ 45, 88, 93 25530-79501............. 127 2701510 ...................... 91
009034880.............75, 77 112050................ 39, 111 25535-85412............. 127 2701513 ...................... 77
01116-G01...................91 112840.........................93 25536-84200............. 127 2701693.7 ................... 63
01117-G01...................79 11391G4 ......................99 25541-85201............. 127 2701697.7 ................... 63
01117-G02...................79 11391G7 ... 75, 77, 79, 81 25545-85055............. 127 2701737.7 ................... 51
01421-08303 .............123 11710-77100................79 25546-60C01 ............ 127 2701850.7 ................... 45
01550-08163 ...............79 11741-85200....... 79, 121 25547-70D00 ............ 127 2701897 ...................... 99
01550-08353 ...............53 12005245, 88, 93, 97, 99, 25576-70D00 ............ 127 2701898 ...................... 99
01550-08553 .............121 ......................109 26121-85202............. 125 2701899 ...................... 99
06111-06003 .............125 120166................ 85, 129 2700120 .................... 129 2701953 .................... 127
06111-12004 .............127 120177.................. 79, 85 2700121 .................... 129 2702012 ...................... 45
08310-00103 ...............79 130306380...................97 2700166 ...................... 99 2702014 ...................... 45
09103-08131 .............123 130728............ 88, 91, 93 2700334 ...................... 91 2702146 .................... 113
09103-08132 ...............79 132520.......................109 2700335 ...................... 91 2702198 ...................... 39
09103-08152 .............123 148231.................. 97, 99 2700380 .................... 147 2702199 ...................... 41
09111-08035 ...............85 160410.........................93 2700381 .................... 147 2702215 ...................... 51
09128-10002 .............127 17680-50F70 ...............75 2700384 .................... 147 2702217 ...................... 71
09135-08005 .............127 18292G1 ......................99 2700385 .................... 147 2702244 ................ 49, 91
09160-17035 .............127 185086321...................85 2700386 .................... 147 2702247 ...................... 71
09162-08008 .............127 2208175.......................97 2700387 .................... 147 2702257.7 ................... 71
09166-16014 .............129 22100-85200................85 2700453 ...................... 73 2702470 ........81, 83, 123
09166-30007 .............125 2218140-01..................65 2700470 .................... 147 2702471 .................... 123
09168-10007 .............127 22400-85141................85 2700493 .................... 117 2702475 .................... 121
09205-03019 .............121 23260-85203..............121 2700496 .......... 55, 57, 58 2702484 ................ 81, 83
09205-05012 .............127 23265-85200..............121 2700514 .................... 115 2702494 .................... 127
09246-16010 .............129 23266-85002................53 2700515 .................... 115 2702500 ...................... 95
09250-10006 .............127 24110-80410..............125 2700525 ...................... 93 2702501 ...................... 95
09261-03017 .............127 24121-85252..............125 2700530 .................... 115 2702502 ...................... 95
09262-28019 .............123 24131-83002..............123 2700531 .................... 115 2702534.7 ................. 115
09262-28020 .............123 24211-83011..............125 2700540 ...................... 91 2702535.7 ................. 115
09262-30086 .............125 24220-60A01 .............125 2700573 ...................... 73 2702547 ...................... 81
09263-30031 .............125 24230-83001..............125 2700792 ...................... 39 2702548 ...................... 81
09263-35015 .............125 24400-83000..............125 2700796 ...................... 47 2702559 .................... 125
09280-11002 .............121 24410-83000..............125 2700797 ...................... 47 2702561 .................... 125
09283-25088 .............123 24420-83000..............125 2700800 .................... 101 2702659 ............ 121, 123
09284-17004 .............127 24431-83001..............125 2700801 .................... 101 2702662 .................... 123
09286-09001 .............127 24432-83001..............125 2700851 .................... 147 2702684 .................... 121
09300-14017 .............121 24436-83000..............125 2700852 .................... 147 2702686 ................ 81, 83
09300-30003 .............125 24441-85F41 .............125 2700859 ...................... 91 2702687 ...................... 81
09380-28007 .....123, 125 24442-81A20 .............125 2700867 ...... 75, 109, 137 2702688 ................ 81, 83
09390-62010 .............123 24471-60A00 .............125 2700868 ............ 137, 145 2702689 ................ 81, 83
09390-68002 .............123 24473-70D10 .............125 2700869 ............ 137, 145 2702690 ........81, 83, 123
09448-20007 .............121 24671-83000..............123 2700913 .................... 145 2702695 ...................... 55
10386747, 51, 55, 58, 79, 24681-83000..............125 2700933 .................... 147 2702756 ...................... 83
.... 85, 88, 89, 91, 24700-85200..............123 2700993-G01 ............ 109 2702883 .................... 127
95, . 97, 99, 113, 24741-83001..............123 2701107.7 ................. 101 2702996 ...................... 55
117 24821-09001..............127 2701129 ...................... 91 2703002 ...................... 53
111074...............113, 117 25121-85051..............127 2701174 ...................... 65 2703081 ...................... 71
111758.......................113 25211-85201..............127 2701223 ...................... 41 2703158 ...................... 39
111812.........................93 25221-83002..............127 2701273 ...................... 57 2703257.7 ................... 45
111813.........................93 25221-85202..............127 2701371 ...................... 57 2703281 ...................... 75
111814.........................93 25411-85201..............127 2701408 .................... 115 2703294.7 ................... 63
111816.........................93 25415-83000..............127 2701430 ...................... 79 2703309 .................... 115
111817.........................93 25420-85201..............127 2701442 ...................... 77 2703481 .................... 115
111838.........................73 25451-85261..............127 2701465 ............ 107, 109 2703581 .................... 125
111893.........................91 25520-85203..............127 2701502 .................... 109 2703683 ...................... 88

148
 INDEX
2703684...................... 91 306982 ...................... 113 4129730 .................... 137 450393 ........................67
2703707...................... 55 307776 ...................... 117 4129733 .................... 137 450399 ........................91
2703800.8................... 89 308008 ........................ 69 4129747 .................... 137 450400 ........................39
2703835.8................... 79 308089 ........................ 47 4139196 ...................... 75 450410 ..................39, 51
2703931.7............. 55, 57 30809041, 55, 57, 75, 77, 4139208 ...................... 91 450412 ........................79
2703951................ 55, 57 ......... 91, 93, 101 4139209 ...................... 91 45045241, 45, 49, 63, 75,
2703953...................... 55 308091 .................. 55, 57 4139210 ...................... 91 77, 99, 103, 105,
2703956.7................... 55 309067 .................. 63, 99 4139211 ...................... 81 109
2703964.7............. 55, 57 309488 ........................ 41 4139272 ...................... 87 45045341, 43, 47, 49, 51,
28391-85202............. 123 311213 ........................ 85 4139442 ...................... 77 .... 53, 61, 63, 73,
28825-G01.................. 79 311392 ........................ 69 4139691 ...................... 39 75, ... 77, 79, 81,
29165G01 ................... 45 311396 ........................ 65 4139806G01 ............... 61 83, ... 85, 97, 99,
300646.......... 75, 77, 101 311398 ........................ 65 4139806G02 ............... 61 101, .....107, 109
300977.................. 55, 57 311763 .................. 55, 57 4139806G03 ............... 61 45045441, 47, 49, 51, 55,
301988...................... 129 312288 ........................ 61 4139924 ...................... 63 .... 57, 61, 63, 75,
302030........................ 58 314990013 .................. 89 4139939 ...................... 41 81, ...........83, 91
302288.................. 91, 93 316907 ........................ 47 4140067 ...................... 65 450455 ........... 43, 63, 69
302944........................ 69 316942 ...................... 129 4140069 ...................... 65 450457 ........................73
303269........................ 69 320107 ..49, 73, 103, 105 4140071 ...................... 65 450510 ........................53
303952........................ 39 36091-G01 .................. 43 4140072 ...................... 65 450541 39, 41, 43, 75, 77
304632........................ 47 36092-G01 ............ 75, 77 4140074 ...................... 65 450544 ......................109
304636.......... 69, 71, 115 36097-G01 .................. 43 4140075 ...................... 65 450739 ........................73
305134........................ 69 37610-80023 ............. 121 4140076 ...................... 65 45237845, 49, 63, 75, 77,
306320........................ 91 38061A........................ 39 4140269 ...................... 43 ....... 99, 105, 109
306322.............. 113, 117 385174 ........................ 71 4140431 ...................... 57 452380 ..............103, 129
306325..... 79, 85, 91, 95, 38541 .......................... 39 4140617 ................ 81, 83 452381 ......................123
107, ............. 109 4113018 ...................... 99 4140618 ................ 81, 83 45238841, 49, 51, 53, 75,
30632841, 45, 47, 49, 51, 4113019 ...................... 99 4140899 ...................... 81 .. 77, 79, 85, 101,
....................... 53 4113261 ............ 137, 145 4141031 ...................... 91 107, .............109
306372........................ 91 4114867 ...................... 93 4141037 .................... 125 45238963, 79, 81, 83, 89,
306375............ 58, 91, 93 4115000 ...................... 93 4142627 ...................... 57 ..............101, 129
306388........................ 47 4115033 ...................... 77 4142630 ...................... 57 452390 ... 79, 85, 97, 123
30639655, 57, 58, 75, 77, 4115400 ...................... 77 4142796 ...................... 57 452391 ........................49
........... 91, 93, 95 4115584 ...................... 93 4142849 ...................... 63 452392 ..................47, 77
306397.................. 55, 57 4115709 .................... 109 4144334 ...................... 65 452393 ........................97
306405...................... 115 4115904 ...................... 99 4144345 ...................... 65 452394 ........................85
306416........................ 85 4116015 .................... 147 4145325 ...................... 63 452395 ........... 75, 77, 85
306419.. 39, 95, 107, 109 4116017 .................... 109 4146818 ...................... 57 452396 ......................123
306423...................... 117 4116941 .................... 109 4146819 ...................... 57 45239841, 49, 51, 61, 63,
306435...................... 117 4117153.7 ................... 61 4147117 .................... 109 ........... 71, 75, 77
306450........................ 95 4117900 ...................... 81 4147118 .................... 109 452399 ................61, 101
306463.................. 39, 47 4118027 ................ 81, 83 4147584 ...................... 41 452401 ........... 55, 57, 79
306488........ 39, 107, 109 4118039 .................... 147 4147586 ...................... 41 452402 ........................63
306506........................ 93 4118422 ................ 81, 83 4148065 ...................... 83 452403 ........................63
306531........................ 45 4118423 ................ 81, 83 4148150 ...................... 77 452404 ........................47
306560...................... 103 4118760 .................... 103 4148206 ...................... 77 452405 ........... 63, 81, 83
306562.................. 79, 85 4119634 ...................... 53 4148212 ...................... 83 452406 ..................63, 75
306799........................ 73 4119678 ...................... 93 4148213 ...................... 83 452408 ........................69
306825........................ 69 4119866.8 ................... 89 4148360 ...................... 81 452410 ........................63
306829...................... 113 4119955 ...................... 83 4148361 ...................... 83 452411 ........................43
306835........................ 85 4120076 ...................... 77 450077 ........................ 67 452413 ........................69
306836........................ 79 4120096 ...................... 83 450193 .................. 89, 95 452415 ........................61
306839........................ 67 4120097 ...................... 83 450324 ......107, 109, 123 452424 ..................51, 53
306915........................ 93 4120098 ...................... 83 450377 .................. 49, 53 452692 ........... 55, 57, 71
306932...................... 109 4120138 ...................... 67 450378 .................. 89, 95 452695 ........... 45, 55, 57
306981............ 79, 85, 91 4129717 .................... 137 450382 ........................ 67 460030 ........................67

149
 INDEX
471221.........................67 800021.................. 97, 99 809254 ...................... 119 825894 .............. 135, 145
48310.....................97, 99 800024.................. 91, 93 809265 ...................... 105 825899 .............. 135, 145
515268.........................45 800026.........................61 810152 .................. 51, 53 825961 ......135, 137, 145
517226.......................113 800073.........................85 810435 ................ 51, 117 825973 .............. 135, 145
521144.........................47 800113.......................101 810437 .......... 67, 71, 117 825996 .............. 135, 145
523085.........................41 800146.........................75 810722 ........................ 91 825997 ......135, 137, 145
523768.......................103 800177............ 61, 75, 77 811992 ...................... 119 825998 ......135, 137, 145
524358.......................147 800198.........................65 811993 ...................... 119 825999 .............. 135, 145
524633.........................45 800221.................. 97, 99 812006 ...................... 119 826000 .............. 135, 145
524643.........................45 800227.........................93 812009 ...................... 119 826005 ......135, 137, 145
548061.........................65 800263.........................41 812335 ...................... 119 826006 51, 135, 137, 145
548079.........................67 800271............ 45, 88, 93 812419 ...................... 129 826190 ...................... 145
548159.........................39 800279.......................101 812444 ........................ 88 826191 ...................... 145
548171.........................47 800294.........................65 812445 ........................ 51 826192 ...................... 147
548175... 39, 55, 57, 107, 800344.........................39 813850 .................. 65, 69 826193 ...................... 147
109 800425.......................129 814079 ........................ 47 826558 ................ 47, 105
548201.......................119 800446.........................49 814474 ........................ 71 826584 ...................... 137
548204...............117, 129 800485.........................69 814476 ...................... 113 826590 ............59, 97, 99
548224.........................67 800558.........................93 815012 ...................... 129 826726 .............. 135, 145
548325.........................93 800559.......................119 815013 ...................... 129 827182 ........................ 49
548477.......................129 800571.........................79 815085 ...................... 129 827486 ...................... 101
548804.........................85 800582...... 45, 55, 57, 58 815093 ...................... 129 827821 ........................ 45
548827.......................101 800602.........................65 815182 ...................... 129 828049 ........................ 45
548849.........................79 800695.......................119 815403 ........................ 71 828056 ........................ 47
548910.........................61 800717.......................113 816307 .................. 55, 57 828057 ........................ 47
548911...................45, 61 800737.......................119 816401 ........................ 41 828231 .............. 107, 109
548937.......................117 800743.......................115 816586 ........................ 69 828382 ........................ 39
548952.......................119 800789.........................59 817104 .................. 45, 93 828590 ........................ 73
554663.........................65 800861.........................67 817250 ........................ 71 828629 .............. 135, 145
6.................................145 800875.........................99 817320 ...................... 105 829044 ........................ 65
600981.........................85 800908................ 71, 115 817397 ...................... 129 829099 ........................ 61
600985.........................79 800909.................. 61, 65 817928 ........................ 71 829630 .............. 135, 137
600989.........................79 800927.........................91 818395 ........................ 91 829631 ...................... 145
600991.........................75 80093039, 43, 47, 51, 61, 819923 ........................ 73 829787 .................. 97, 99
600992...................75, 77 ......... 73, 99, 101 820889 .................. 75, 77 829800 ...................... 101
600993.........................85 800934.......... 39, 51, 109 821164 ......55, 58, 88, 91 829954 .................. 97, 99
600997.........................85 800943..... 39, 45, 51, 73, 821893 ..59, 85, 101, 105 829997 .................. 97, 99
601572.........................75 109 822049 ........................ 61 830140 ........................ 91
601585.........................75 800944.......................115 822419 ........................ 47 830366 ........................ 45
601586.................75, 137 800945.........................67 822819 ........................ 47 830425 .................. 97, 99
601587.........................79 800973.......................113 823118 ........................ 47 830784 .................. 41, 45
601591...................75, 77 805307.......................129 823119 ...................... 105 830810 ...................... 105
601592...................75, 77 805387.......................115 823225 ........................ 47 830930 .................. 51, 73
601595.........................75 806703.................. 49, 91 823549 .................. 39, 73 831039 .................. 97, 99
601596...................75, 77 806714............ 45, 51, 53 823621 ........................ 65 831099 ...................... 117
601937.........................41 807332.........................65 825264 .................. 59, 99 831225 .............. 107, 109
601939.........................39 807366.......................117 825500 ........................ 65 831405 ........................ 69
601940G05..................39 807624.......................129 825538 ........................ 47 831586 ........................ 91
603102.........................93 808060.........................73 825624 .................. 77, 97 831846 .................. 75, 77
604174...................55, 57 808088.........................71 825748 ...... 135, 137, 145 831888 ........................ 88
7040.............................51 809092.........................73 825866 .............. 135, 137 831889 ........................ 88
7301.............................99 809137.................. 51, 71 825877 ...... 135, 137, 145 831890 ........................ 88
7332.............................99 809152.........................49 825878 ...... 135, 137, 145 832408 ...................... 105
74765G01....................39 809174.........................79 825884 ........................ 75 832409 ...................... 105
74767G01....................39 809180.........................65 825886 ........ 51, 135, 145 832414 .............. 103, 105
74793G01....................39 809231.................. 59, 97 825889 ...................... 145 832584 ...................... 111

150
 INDEX
832798........................ 47 837043 ........................ 49 841885 ........................ 79 843726 ..................97, 99
832900...................... 105 837198 ...................... 119 841895 .............. 107, 109 843758 ........................47
833056........................ 93 837270 ...................... 101 841913 ........................ 39 843759 ........................47
833101........................ 93 837295 ........................ 45 841966 ........................ 85 843760 ........................85
833102........................ 93 837296 .............. 135, 145 841969 .................. 97, 99 843767 ........................73
833103........................ 93 837298 ........................ 45 841982 .................. 89, 95 843768 ........................73
833104........................ 93 837301 .............. 135, 145 842010 ........................ 53 843778 ........................55
833257.............. 137, 147 837303 ........................ 39 842030 ........................ 41 843792 ..................55, 57
833273........................ 53 838154 ........................ 97 842033 ........................ 69 843857 ..................77, 79
833345........................ 93 838295.8 ............... 89, 95 842051 ........................ 51 843862 ........................75
833440.................. 75, 77 838340 ........................ 59 842103 ........................ 51 843866 ........................93
833512.................. 75, 77 838440 ........................ 85 842104 ........................ 71 843876 ........................65
833715........................ 77 838463 .............. 137, 147 842359 ...................... 119 843942 ......................109
833953.................. 97, 99 838539 ...................... 115 842360 ...................... 119 843997 ........................45
834005.................. 97, 99 838768 ...................... 147 842553 ........................ 85 844019 ......................105
834036........................ 97 838769 ...................... 147 842740 ........................ 58 844051 ........................47
835101.............. 103, 105 838770 ...................... 147 842773 .................. 55, 57 844087 ......................119
835271............ 88, 91, 93 839213 ........................ 47 842774 .................. 55, 57 844116 ........................45
835805.................. 75, 77 839752 ........................ 85 842785 ........................ 88 844130 ..................88, 93
836206...................... 103 839917 ...................... 147 842870G01 ................. 63 844147 ......................129
836420...................... 119 839921 ...................... 147 842915 ............79, 81, 83 844148 ........................67
836421...................... 119 839948 ...................... 113 842935 .................. 51, 53 844167 ......................109
836422...................... 119 840222 ........................ 73 842959 ...................... 137 844177 ........................47
836426...................... 115 840352 ............ 79, 81, 83 842961 ........................ 79 844179 ........................47
836429...................... 119 840436 ........................ 41 842966 .............. 137, 145 844181 ......................129
836431...................... 117 840473 ........................ 88 842983 .............. 135, 145 844184 ......................123
836443...................... 113 840508 ........................ 39 842996 ........................ 85 844185 ......................129
836536...................... 137 840725 .................. 51, 53 843013 ........................ 91 844186 ......................123
836657...................... 117 840726 .................. 51, 53 843021 ........................ 51 844188 ......................129
836658...................... 117 840754 .................. 75, 77 843022 ........................ 51 844198 ........................79
836662...................... 117 840857 ...................... 101 843158 ........................ 49 844202 ........................53
836675...................... 113 840877 .............. 103, 105 843167 .............. 109, 137 844223 ........................45
836676...................... 113 841167 ........................ 67 843168 .............. 137, 145 844224 ........................45
836677...................... 113 841255 ........................ 69 843238 ........................ 65 844268 ........................85
836678...................... 113 841264 ........................ 45 843296 ........................ 77 844270 ........................85
836680...................... 113 841336 ........................ 69 843298 .................. 97, 99 844271 ........................85
836681...................... 113 841404 ........................ 69 843323 ........................ 79 844272 ........................85
836682...................... 113 841428 ........................ 39 843343 .................. 97, 99 844274 ........................88
836683...................... 113 841429 ........................ 67 843355 ........................ 47 844293 ........................39
836684...................... 113 841430 ................ 71, 115 843356 ........................ 49 844391 ........................75
836685...................... 113 841434 ........................ 65 843359 ........................ 49 844564 ......................103
836686...................... 113 841477G01 ................. 39 843418 ........................ 71 844565 ......................103
836687...................... 113 841630 ........................ 67 843537 ........................ 93 844566 ......................103
836688...................... 113 841637 ........................ 39 843550 .............. 135, 145 844571 ......................103
836689...................... 113 841663 ........................ 45 843551 .............. 135, 145 844582 ........................47
836690...................... 113 841715 ........................ 39 843561 ........................ 45 844583 ......................103
836691...................... 113 841737 ........................ 67 843562 ........................ 45 844584 ..............103, 105
836692...................... 113 841738 ........................ 67 843563 ........................ 45 844590 ......................103
836693...................... 119 841753 ........................ 39 843568 ........................ 63 844598 ......................105
836694...................... 115 841799 ........................ 43 843581 ........................ 45 844600 ......................103
836695...................... 115 841837 ...................... 111 843598 .............. 135, 145 844601 ......................101
836841...................... 117 841838 ...................... 111 843607 ........................ 45 844611 ........................53
836852.......... 97, 99, 117 841839 ........................ 71 843614 .................. 55, 57 844627 ......................103
836892.............. 135, 145 841841 ........................ 71 843679 .................. 55, 57 844628 ......................103
836959...................... 117 841842 ................ 71, 111 843685 .................. 55, 57 844647G01..................63
837020...................... 119 841844 ...................... 111 843724 .................. 55, 57 844652 ......................103

151
 INDEX
844729.......................101 892921.........................51 894591 ........................ 88
844813.......................115 892933.........................53 894596 .............. 107, 109
844905.......................129 893067.........................49 894635 ........................ 69
844906.......................123 893145.........................63 894638 ........................ 97
844907.......................129 893145.7......................63 894645 ........................ 85
844937.......................103 893182.........................79 894675 ...................... 101
844951.......................119 893199.7......................63 894691 ...................... 103
844952.......................119 893199-G02.................63 894696 ........................ 47
844953.......................119 893233.........................67 894701 ...................... 103
844956.......................119 893234.........................67 894702 ...................... 103
844973.......................103 893266.........................67 894825 ................ 65, 111
844988.........................43 893322.........................41 894826 ................ 65, 111
845034.......................119 893344.........................73 894886 ...................... 119
845038.........................41 893487.........................61 894930 ................ 71, 115
845133.........................49 893488.........................61 894931 ................ 71, 115
845134.........................49 893491.......................115 894932 ................ 71, 115
845135.7......................61 893519.......................115 894933 ................ 71, 115
845185.........................47 893525.........................63 894934 ................ 71, 115
845223.......................121 893539.......................101 894935 ................ 71, 115
845224.........................77 893541.........................41 894936 ................ 71, 115
845231.........................41 893554.................. 75, 77 894947 ...................... 129
845234.........................41 893555.................. 97, 99 894965 ...................... 129
845327.......................147 893571.........................73 894989 ...................... 129
845328.......................147 893581.......................115 894998.7 ..................... 63
845329.......................147 893582.......................115 895013 ........................ 53
845330.......................147 893583.......................111 895113 ........................ 51
845345.7......................58 893585.........................71
845356.......................115 893586.........................71
879807.......................129 893602.........................61
882971.........................63 893613.........................65
882993.......................105 893632.........................43
883236.......................105 893633.........................85
884398.......................137 893862.........................65
884513...............107, 109 894030.........................39
884574.......................105 894159.........................45
885249.......................103 894167.........................51
886001.......................105 894179.........................55
886270.........................47 894201.................. 97, 99
886425...............107, 109 894232.........................61
886735...................61, 65 894308.................. 51, 53
887017.......................103 894313.........................61
888042.......................103 894317.........................49
888549.........................77 894348.........................75
889050...................75, 77 894434.........................93
889681.........................69 894435.........................93
889682.........................69 894456.........................51
889780.......................117 894471.........................93
889870.......................113 894508.........................58
889925.......................117 894509.......................115
890000.......................109 894519.......................119
891089.......................119 894573.........................67
891829...............111, 113 894574.........................67
892164.........................58 894580.........................79
892228.........................73 894581.........................63
892486.........................73 894582.........................63
892811...............107, 109 894584.........................58

152
INDEX

153
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