Parts e Maintenance Cushman Turf Truckster PDF

4140039
By Jacobsen
6
5
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18
1 - INCLUDES ITEMS 3 - 16
17
19
10
Parts & Maintenance

Manual
Cushman Turf Truckster
84043 Perkins 403 Diesel Engine, Manual Transmission
84044 Perkins 403 Diesel Engine, Manual Transmission, EC
898627 Suzuki K6 Gas Engine, Manual Transmission
898628 Suzuki K6 Gas Engine, Automatic Transmission
84052 Suzuki K6 Gas Engine, 5 Speed Manual Transmission
GB
Table of Contents
1
1.1
1.2
2
2.1
3
3.1
3.2
4
4.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
Safety
Operating Safety.................................................. 4
Important Safety Notes ........................................ 5
Standards and Publications
Standards and Publications ................................. 6
Vehicle Identification Numbers
Vehicle Identification Number .............................. 7
Engine Identification Numbers ............................. 7
Specifications
Product Identification ........................................... 8
Engine .................................................................. 8
vehicle .................................................................. 8
Gear Ratios .......................................................... 9
Weights and Dimensions ..................................... 9
Accessories & Support Literature ........................ 9
Adjustments
General .............................................................. 10
Engine Access ................................................... 10
Front Cowl Access ............................................. 11
Access Panels ................................................... 11
Diesel Engine Alternator Belt ............................. 12
Diesel Engine Hydraulic Pump Belt ................... 12
Gas Engine Power Steering-Alternator Belt ...... 12
Gas Engine Hydraulic Pump Belt ...................... 13
Parking Brake Cable .......................................... 13
Torque Specification .......................................... 14
Maintenance
General .............................................................. 15
Engine ................................................................ 15
Engine Oil .......................................................... 16
Power Steering Reservoir .................................. 17
Muffler and Exhaust ........................................... 17
Engine Overheat Procedure .............................. 17
Cooling System .................................................. 18
Air Filter ............................................................. 19
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
6.31
6.32
7
7.1
8
8.1
8.2
8.3
9
10
10.1
Jump Starting .................................................... 19

Battery ............................................................... 20
Charging Battery ................................................ 20
Hydraulic Hoses ................................................ 21
Hydraulic Reservoir and Filter ........................... 21
Fuel .................................................................... 22
Fuel System ....................................................... 22
Tire Pressure ..................................................... 22
Tire Removal and Installation ............................ 23
Raising the vehicle ............................................ 23
Towing the Vehicle ............................................ 24
Governor Oil Level ............................................. 24
Hydraulic Brakes ............................................... 25
Differential Fluid ................................................. 26
Diesel Engine Manual Transmission ................. 26
Gas Engine Manual Transmission ..................... 27
Gas Engine Automatic Transmission ................ 27
Electrical System ............................................... 28
Dash Panel ........................................................ 28
Headlight Replacement ..................................... 29
Tail Light Replacement ...................................... 29
EFI Diagnostic Check ........................................ 30
Care and Cleaning ............................................. 31
Storage .............................................................. 31
Troubleshooting
General.............................................................. 32
Maintenance & Lubrication Charts
General.............................................................. 33
Lubrication Chart ............................................... 33
Maintenance Charts .......................................... 34
Notes
Parts Catalog
Table Of Contents ............................................. 37
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 2005, Textron Inc.
All rights reserved, including the right to reproduce this material or portions thereof in any form.
Litho in U.S.A. 2-2006
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.
842553
2208175
600997
841966
885249
4140040
Description
Qty. Part No.
Diesel Engine Oil Filter

Diesel Engine Fuel Filter
Diesel Alternator-Power Steering Belt
Diesel Hydraulic Pump Belt
Hydraulic FIlter Element
Safety and Operation Manual
2701908
2701898
4115406
4115404
840352
4140039
Description
Gas Engine Oil Filter
Gas Engine Fuel Filter
Gas Alternator-Power Steering Belt
Gas Governor-Hydraulic Pump Belt
Air Filter Element (Gas and Diesel)
Parts and Maintenance Manual
To Order Parts
1. Write your full name and complete address on the
order.
5. Send or bring the order to an authorized Jacobsen

Dealer.
2. Explain where and how to make shipment.
6. Inspect all shipments on receipt. If any parts are

damaged or missing, file a claim with the carrier before
accepting.
3. Give product number, name and serial number that is

stamped on the name plate or serial plate of your
product.
4. Order by the quantity desired, the part number, paint
code, and description of the part as given in the parts list.
7. Do not return material without a letter of explanation,

listing the parts being returned. Transportation charges
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.
1
2
3
4
5
5
123456
789012
345678
N/S
901234.6
901234.2
Qty
1
1
1
1
1
1
Description
Mount, Valve
Valve, Lift
Handle
Seal Kit
Screw, 1/4-20 x 2 Hex Head
Serial Numbers/Notes
Indicates a piece part
Includes Items 2 and 3
Serviced part included with Item 2
Non serviced part included with Item 2
Indicates part 901234 painted Orange
Indicates part 901234 painted Green
3
1
1
1.1
SAFETY
SAFETY
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 operators should receive
instruction from someone familiar with the equipment before being allowed to operate the machine.
1.
2.
3.
4.
5.
6.
Safety is dependent upon the awareness, concern and

prudence of those who operate or service the equipment. Never allow minors to operate any equipment.
It is your responsibility to read this manual and all
publications associated with this equipment (Safety
and operation manual, engine manual, accessories
and attachments). If the operator can not read English
it is the owners responsibility to explain the material
contained in this manual to them.
Learn the proper use of the machine, the location and
purpose of all the controls and gauges before you
operate the equipment. Working with unfamiliar
equipment can lead to accidents.
Never allow anyone to operate or service the machine
or its attachments without proper training and
instructions; or while under the influence of alcohol or
drugs.
Wear all the necessary protective clothing and
personal safety devices to protect your head, eyes,
ears hands and feet. Operate the machine only in
daylight or in good artificial light.
Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments
approved by Jacobsen.
12. Never disconnect or bypass any switch.

13. Do not change the engine governor setting or
overspeed the engine
14. Carbon monoxide in the exhaust fumes can be fatal
when inhaled. Never operate the engine without proper
ventilation or in an enclosed area.
15. Fuel is highly flammable, handle with care.
16. Keep the engine clean. Allow the engine to cool before
storing and always remove the ignition key.
17. Place transmission in neutral, depress clutch and
engage parking brake before starting the engine
(motor). Start the engine only when sitting in operators
seat, never while standing beside the unit.
18. Equipment must comply with the latest federal, state,
and local requirements when driven or transported on
public roads. Watch out for traffic when crossing or
operating on or near roads.
19. Local regulations may restrict the age of the operator.
20. Operate the machine up and down the face of the
slopes (vertically), not across the face (horizontally).
21. To prevent tipping or loss of control, do not start or
stop suddenly on slopes. Reduce speed when making
sharp turns. Use caution when changing directions.
7.
Stay alert for holes in the terrain and other hidden

hazards.
22. Always use the seat belt when operating vehicles

equipped with a ROPS.
8.
Inspect the area where the equipment will be used.

Pick up all the debris you can find before operating.
Beware of overhead obstructions (low tree limbs,
electrical wires, etc.) and also underground obstacles
(sprinklers, pipes, tree roots, etc.) Enter a new area
cautiously. Stay alert for hidden hazards.
Never use a seat belt when operating vehicle

without a ROPS.
9.
Never allow anyone near the machine while in

operation. The owner/operator can prevent and is
responsible for injuries inflicted to themselves, to
bystanders and damage to property.
10. Do not carry passengers. Keep bystanders and pets a

safe distance away.
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.
23. Keep legs, arms and body inside the seating

compartment while the vehicle is in motion.
24. Always shift transmission to Neutral (Manual
Transmission) or Park (Automatic Transmission) and
engage parking brake before leaving the vehicle.
SAFETY
1.2
IMPORTANT SAFETY NOTES ________________________________________________

CAUTION - Indicates a potentially hazardous situation
This safety alert symbol is used to alert you to
potential hazards.
DANGER - Indicates an imminently hazardous

situation which, if not avoided, WILL result in death or
serious injury.
WARNING - Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate

injury and property damage. It may also be used to alert
against unsafe practices.
For pictoral clarity, some illustrations in this manual may
show shields, guards or plates open or removed. Under
no circumstances should this equipment be operated
without these devices securely fastened in place
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 operators position for any reason:
a.
b.
c.
d.
e.
Remove foot from accelerator pedal.

Slow vehicle using service brake.
Depress clutch and shift transmission to neutral.
Engage parking brake.
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.
2
2
2.1
STANDARDS AND PUBLICATIONS

STANDARDS AND PUBLICATIONS
STANDARDS AND PUBLICATIONS ___________________________________________
This product meets requirements of ANSI B56.8 and has

been approved by the Factory Mutual Research
Corporation to meet all Powered Industrial Truck portions
(classification D or G) of the OSHA requirements (as
stated in section 1910.178). Approved power trucks shall
bear a label or some other identifying mark indicating
approval by the testing laboratory. This product conforms
to EC directives and amendment 89/392 & 91/368.
Users, operators and service persons should be familiar
with the following standards and publications: (The
material may be obtained from the address shown)
Factory Mutual Approval Standard:
Class Nos 7811 & 7813; Gasoline or Diesel
Powered Trucks, Types G, GS, D or DS.
Factory Mutual Research Corp.
1151 Boston-Providence Highway
Norwood, Massachusetts 02062 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.
Internal Combustion Engine Powered Industrial Trucks:

ANSI/UL 558
1430 Broadway
OR
Underwriters Laboratories Inc.
333 Pfingsten Road
Northbrook, Illinois 60062 U.S.A.
Flammable and Combustible Liquids Code:
ANSI/NFPA 30
1430 Broadway
OR
National Fire Prevention Association
Batterymarch Park
Quincy, Massachusetts 02269 U.S.A.
VEHICLE IDENTIFICATION NUMBERS

3
3.1
VEHICLE IDENTIFICATION NUMBERS
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.
This vehicle may be covered

by one or more of the
following U.S. patents:
GOLF, TURF & SPECIALTY PRODUCTS
The serial number is also stamped on the cross member.

It is located to the left of the Nameplate/Identification
Decal.
NOTE: Reference to the Front, Rear, Left and Right sides
of the vehicle are always determined by the operators
seated position.
Record the Vehicle Identification information below for
easy reference.
Model Number: ______________________
Date Code: _________________________
Serial Number: ______________________
3.2
Augusta Georgia, USA

1 800 241 5855
MODEL
84043
DATE CODE
M1903
LABEL # 75984G55
SERIAL # *2128855*
Lb/kg W Batt
Nom Power Hp/kw
Figure 3A
Always provide the Vehicle Identification Number of the
unit when ordering replacement parts or requesting service
information. Vehicle Identification Numbers must appear
on all correspondence concerning this vehicle.
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
the engine, under the engine mount and may be partially
hidden by the electrical harness. The serial number is
also hand printed on the fuel rail.
Engine Serial No.

Perkins Diesel
Record the Engine Serial Number below for easy

reference.
Figure 3B
Engine Serial Number: _________________________
Engine Serial No.

K6A Suzuki
4
4
4.1
SPECIFICATIONS
SPECIFICATIONS
PRODUCT IDENTIFICATION_________________________________________________
84043.............................. Turf Truckster liquid cooled diesel

engine, 4 speed manual
transmission, 2 speed differential.
84044.............................. Turf Truckster liquid cooled diesel
EC approved.
898627............................ Turf Truckster liquid cooled gas
4.2

898628............................ Turf Truckster liquid cooled diesel
engine, 3 speed automatic
Product
EEC Sound
Power
84044
103 dB(A)
Vibration M/S2
Arms
Body
2.14
.096
ENGINE__________________________________________________________________
Diesel Engine:
Make ............................... Perkins
Model .............................. 403C.11
Horsepower .................... 26.4 hp (19.7 kW) @3000 rpm
Note: Actual sustained horsepower will likely be lower

than listed in specifications due to operating limitations
and environmental factors
Displacement .................. 69 cu. In. (1131 cc)
Torque ............................ 49 ft. lbs. (67 Nm) @ 2600 rpm
Fuel:
Type .......................... No. 2 Diesel
Rating ....................... Min. Cetane rating 45
Capacity .................... 6.55 U.S. Gal. (24.5 liters)
Governor ......................... All Speed Mechanical
Low Idle ................... 1300 RPM

High Idle ................... 3180 RPM
Lubrication:
Capacity.................... 3.7 quarts (3.5 liters)
Below 32 F (0 C) ... SAE 10W
32-77 F (0-25 C) .... SAE 20W or 10W30
Above 77 F (25 C) SAE 30W or 10W30
API Classification ..... CH4
Air Filter .......................... Dry type with evacuator valve.
Alternator ........................ 55 amp
Cooling System .............. Liquid Cooled
Capacity...................... 5.1 qt. (4.8 l) 50/50 water ethylene
glycol mix
Gas Engine:
Make ............................... Suzuki
Model .............................. K6A
Horsepower .................... 39 hp (29.1 kW) @ 4450 rpm
Displacement .................. 40.2 cu. In. (658 cc)
Torque ............................ 45.7 ft. lbs. (62 Nm) @ 4000 rpm
Fuel:
Type .......................... Unleaded Gasoline
Rating ....................... Min. Octane rating 87
Capacity .................... 6.55 U.S. Gal. (24.5 liters)
CAUTION
The use of any fuel containing greater than 10%
ethanol may harm the engine's emission control
system and therefore invalidate the emission-related
warranty through the improper action of the operator.
4.3
Capacity...................... 3.3 qt. (3.0 l) 50/50 water ethylene

glycol mix
Spark Plugs:
NGK 3932................. DCPR7E Gap .032 - .035
Denso ....................... XU22EPR-U Gap .032 - .035
VEHICLE_________________________________________________________________
Tires:
Front ......................... 20 x 10 - 10 Multi Rib
Rear .......................... 24 x 13 -12 Titan Ultra Trac
Tire Pressure:
Governor......................... External Mechanical

Low Idle ................... 950 RPM
High Idle ................... 4450 RPM
Lubrication:
Capacity.................... 3.3 quarts (3.0 liters)
Below 32 F (0 C) ... SAE 10W30
32-86 F (0-30 C) .... SAE 10W30
Above 86 F (30 C) SAE 10W30W or 10W40
API Classification ..... SJ
Air Filter .......................... Dry type with evacuator valve.
Alternator ........................ 55 amp
Cooling System .............. Liquid Cooled
Front ......................... 20 psi (138 kPa)

Rear.......................... Varies by load, See Section 6.16
Battery:
Type.......................... 12 Volt Lead/Acid
SPECIFICATIONS
Group ........................ 24
Service Brake.................. 4 Wheel hydraulic drum brakes
Brake Fluid................ DOT 3
4.4
2nd Gear................... 2.391:1

1st Gear .................... 4.031:1
Reverse .................... 4.173:1
Hypoid Differential .... 14.21:1
Gas Engine Automatic Transmission Gear Ratios:
3rd Gear ................... 1.000:1
2nd Gear................... 1.536:1
1st Gear .................... 2.727:1
Reverse .................... 2.222:1
Hypoid Differential .... 14.21:1
WEIGHTS AND DIMENSIONS ________________________________________________
Dimensions:
Inches
Length ........................................................... 114
Height.............................................................. 49
Wheel Base.................................................. 58.2
Turning Radius (Outside) .............................. 242
4.6
Parking Brake ................. Integral to rear drum, hand lever

actuated
Steering ......................... Front wheel power steering
GEAR RATIOS ____________________________________________________________
Diesel Engine Manual Transmission Gear Ratios:

4th Gear ................... 1.000:1
3rd Gear ................... 1.423:1
2nd Gear ................... 1.947:1
1st Gear .................... 3.652:1
Reverse..................... 3.463:1
Hydpoid Differential... 11.16:1
Gas Engine Manual Transmission Gear Ratios:
4th Gear ................... 1.000:1
3rd Gear ................... 1.513:1
4.5
(mm)
(2897)
(1245)
(1478)
(6146)
Weights:
Lbs.
84043 .......................................................... 1604
84044 .......................................................... 1604
898627 ........................................................ 1572
898628 ........................................................ 1619
(kg)
(823)
(727)
(713)
(734)
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
47 Quick Disconnect Flatbed................................... 889983
60 Quick Disconnect Flatbed................................... 894769
47 Box Assembly (Requires 889983) ...................... 890010
60 Box Assembly (Requires 894769) .................... 2703394
Poly Box Assembly ................................................... 892530
Box Liner (for 890010) .............................................. 888532
Hitches
Fifth wheel ball hitch ................................................. 894690
Receiver Style drawbar hitch .................................. 4114386
Flat bar style hitch ................................................... 4114566
ROPS Attachments
Upper ROPS (Roll Over Protective Structure) .......... 894761
Steel Door, Left Side (Requires 894761) ................ 2701303
Steel Door, RIght Side (Requires 894761) ............. 2701304
Outside Mirrors (Left and Right)................................ 894768
Rear Window ............................................................ 894758
Windshield with Wiper............................................... 894757
Hydraulic Attachments
High/Low Gas Hydraulics.......................................... 894712
High/Low Diesel Hydraulics ...................................... 894713
Implement Lift (A Frame)........................................ 892493
Dry seal coupler, 1 set ...............................................894604

Hydraulic PTO (Requires 894712 and 894713).........894644
Truck Attachments
Heavy Duty Mechanical PTO...................................4112981
Quick Aerator...........................................................2701529
Ram Mount (Sprayer control mount) .......................4119631
1500 Top Dresser ....................................................2701650
Turn Signal with Right Taillight ..................................894764
VICON Spreader (Requires 2701601 or 2701602)..2701600
VICON hydraulic power kit.......................................2701601
VICON mechanical power kit...................................2701602
Back-up Alarm .........................................................2703183
Exhaust Spark Arrestor..............................................882574
Heater Defroster ........................................................894760
Support Literature
Safety & Operation Manual......................................4140040
Parts & Maintenance Manual...................................4140039
Service & Repair Manual
5
5
5.1
ADJUSTMENTS
ADJUSTMENTS
GENERAL________________________________________________________________
! WARNING
To prevent injury, depress clutch pedal and shift
transmission to neutral, engage parking brake, stop
engine and remove key from ignition switch before
making any adjustments or performing maintenance.
Make sure the vehicle is parked on a solid and level
surface. Never work on a vehicle that is supported
only by the jack. Always use jack stands.
If only the front or rear of the vehicle is raised, place
chocks in front of and behind the wheels that are not
raised.
1. Adjustments and maintenance should always be
performed by a qualified technician. If proper
5.2
adjustment cannot be made, contact an authorized

Jacobsen Dealer.
2. Replace, do
components.
not
adjust,
worn
or
damaged
3. Long hair, jewelry or loose fitting clothing may get

tangled in moving parts.
! CAUTION
Be careful to prevent entrapment of the hands and
fingers between moving and fixed components of the
machine.
4. Do not change governor settings or overspeed the
engine.
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,
push the engine cover latch towards the rear of the unit
and tilt cover forward.
Figure 5A
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.
! WARNING
Retaining Tab
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
10
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 Release
Cowl Latc h
To open the front cowl, locate the release lever at the

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
wheel or upper ROPS structure (if installed).
Front Cowl
Release Lever
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
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
pedal in order to completely remove the center floorboard
panel.
Figure 5D
Figure 5E
11
ADJUSTMENTS
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
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_____________________________________

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 __________________________

Adjust power steering pump 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 power steering pump
mounting bolts (F) and carefully pry away from the
engine until proper belt tension is achieved.
Figure 5H
12
ADJUSTMENTS
5.8
GAS ENGINE HYDRAULIC PUMP BELT _______________________________________

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 (G)
and carefully pry away from the engine until proper belt
tension is achieved.
G
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.
5. Engage parking brake. Repeat steps 3 and 4 until
handle is at approximately a 45 angle when parking
brake is engaged.
E
Figure 5J
13
ADJUSTMENTS
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
SIZE
UNITS
GRADE 5
GRADE 8
UNITS
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
4.8
5.8
8.8
10.9
12.9
Non Critical
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)
14
MAINTENANCE
6
6.1
MAINTENANCE
GENERAL ________________________________________________________________
a.
Keep the equipment clean.
b.
Keep all moving parts properly adjusted and lubricated.
depress clutch pedal and shift transmission to neutral,

engage parking brake, stop engine and remove key from
ignition switch to prevent injuries
c.
Replace worn or damaged parts before operating

the machine.
d.
Keep all fluids at their proper levels.

surface. Never work on a vehicle that is supported only
by the jack. Always use jack stands.
e.
Keep shields in place and all hardware securely

fastened.
f.
Keep tires properly inflated.
! WARNING
Before you clean, adjust, or repair this equipment,
1.
2.
6.2
Adjustment and maintenance should always be

performed by a qualified technician. If proper
adjustments cannot be made, contact an Authorized
Jacobsen Dealer.
Inspect the equipment on a regular basis, establish a
maintenance schedule and keep detailed records.
3.
Long hair, jewelry or loose fitting clothing may get

tangled in moving parts.
4.
Use the illustrations in the Parts Catalog as reference

for the disassembly and reassembly of components.
5.
Recycle or dispose of all hazardous materials

(batteries, fuel, lubricants, anti-freeze, etc.) according
to local, state or federal regulations.
ENGINE _________________________________________________________________
IMPORTANT: A separate Engine Manual, prepared by

the engine manufacturer, is supplied with this vehicle.
Read the engine manual carefully until you are familiar
with the operation and maintenance of the engine.
Proper attention to the engine manufacturers directions
will assure maximum service life of the engine. To order
replacement engine manuals contact the engine
manufacturer.
The proper break-in of a new engine can make a
considerable difference to the performance and life of the
engine.
Note: The vehicle is designed to operate most efficiently
at the preset governor setting. Do not change the engine
governor settings or overspeed the engine.
6. If the injection pump, injectors or the fuel system

require service, contact an authorized Jacobsen
Dealer.
Keep your engine clean. If dirt has accumulated on the
engine, it should be washed with a non-flammable
solvent or strong detergent.
When washing becomes necessary, it can be carried out
simultaneously when servicing the vehicle.
In order to maintain reliable service from your engine, a
regular check-up and maintenance scedule should be
followed. Proper maintenance will prolong the engines
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 140F (60C) 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.
5.
Refer to Section 8.3 and Engine Manual for specific

maintenance intervals.
15
MAINTENANCE
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
with a clean rag. Reinsert the dipstick until it contacts the
oil tube, remove the dipstick and read the oil level.
Oil Level Must

Be
Between
Marks
Engine
Dipstick
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
between marks. Do Not Overfill.
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.
Diesel Engine: Use
classification CH4.
only
engine
oils
with
Diesel
Engine
ADD
FULL
ADD
API
Gas
Engine
Gas Engine: Use only engine oils with API classification

SJ.
Using oil other than the service class listed, or oil change
intervals longer than recommended could reduce engine
life. Damage to engine due to improper maintenance or
use of incorrect oil quality and/or viscosity is not covered
by the engine warranty.
Diesel Engine: Perform initial oil change after first 35
hours of operation and every 75 hours or two months
thereafter. See Engine Manual.
Gas Engine: Perform initial oil change after first 50 hours
of operation and every 100 hours or three months
thereafter. See Engine Manual.
FULL
Figure 6A
Perkins Diesel
SAE 10W/10W-30
SAE 20W/10W-30
SAE 30W/10W-30
Suzuki Gas
SAE 10W-30 for all temperature ranges
-20
C -30
0
-20
20 32 40
-10
10W-40
60
10
7780
20 25 30
100
40
Figure 6B
Significant oil loss can damage the engine. Considerable

oil loss could be due to a loose or incorrectly installed
drain plug, cracked gaskets, or even a loose oil filter.
Diesel Engine:
Drain plugs are located beneath the engine in the oil pan.
Remove both plugs when changing the oil.
Above 77F (25C)
SAE 30W or SAE10W30
32 to 77F (0 to 25C)
SAE 20W or SAE 10W30
Below 32 (0C)
SAE10W or SAE 10W30
Check drain plugs and oil for metal chips that could
indicate engine damage. Replace drain plugs with
damaged gasket surfaces immediately.
After oil has completely drained, clean excess oil from oil
pan and drain plugs. Install drain plugs and tighten
securely. Refer to engine manual for proper torque.
Always replace the engine oil filter when changing the
engine oil. Apply a light coat of engine oil to the rubber
gasket surface of new filter before installing.
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.
16
Gas Engine:
All temperature ranges SAE 10W30
Above 85 F (29 C)
SAE 10W 40
Replacement Oil Filters

Perkins Diesel
842553
Suzuki Gas
2701908
MAINTENANCE
6.4
POWER STEERING RESERVOIR _____________________________________________
! WARNING
Before servicing or doing any maintenance work around
the engine area, make sure the engine has had time to
cool. Serious burns can result if the engine or
surrounding surfaces are hot.
When checking the fluid level before the engine has been
warmed up, the level should be at the COLD mark on the
dipstick. After the engine has been warmed up and the
fluid is warm, the level should be between the COLD and
HOT marks. Use General Motors Power Steering Fluid
as required to bring fluid up to proper level.
The power steering reservoir is located on the right side

of the engine, below the alternator.
HOT
FULL
COLD
ADD
The level in the reservoir should be checked after the first

35 and 70 hours. After that level should be checked
every 100 hours.
Power Steering Dipstick
Figure 6C
6.5
MUFFLER AND EXHAUST___________________________________________________
! WARNING
Exhaust fumes contain carbon monoxide that is toxic and
can be fatal when inhaled.
NEVER operate an engine without proper ventilation.
To protect from carbon monoxide poisoning, inspect the

complete exhaust system regularly and always replace a
defective muffler.
If you notice a change in the color or sound of the
exhaust, stop the engine immediately. Identify the
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

shows 230 F (110 C) or above, and/or the overheat
warning buzzer sounds, follow this procedure.
1. Stop the vehicle. DO NOT shut the engine off.
Place vehicle in neutral and engage the parking
brake.
2. Immediately disengage any accessories that are
operating.
3. Slow the engine speed to a fast idle.
4. Remove any dirt, chaff, debris, etc. from the radiator
intake screen located on the right side of the
vehicle.
! CAUTION
Temperature gauge needle should start to go down

approximately 30 seconds after the screen is cleaned. If
temperature does not go down, STOP the engine and
check the following.
1. Check to see if cooling fan is operating. Fan should
be turning with coolant above 180 F, even with
ignition switch in OFF position.
2. Check engine oil level.
3. Check for a leak in the cooling system. Do not open
radiator when hot. Check coolant levels after system
completely cools.
Failure to heed the overheat warning and properly
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.
17
MAINTENANCE
6.7
COOLING SYSTEM ________________________________________________________
This vehicle is equipped with a radiator, temperature

controlled fan, temperature gauge and an overheat
buzzer.
a. Remove the cooling fan fuse

b. Remove the radiator cap.
c.
! WARNING
To prevent serious bodily injury from hot coolant or
steam blow-out, never attempt to remove the radiator
cap while the engine is running. Stop the engine and wait
several hours until it is cool. Even then, use extreme care
when removing the cap.
! CAUTION
Do not pour cold water into a hot radiator. Do not
operate engine without a proper coolant mixture.
Install cap and tighten securely.
! WARNING
The cooling fan is controlled by a temperature switch and
may start at any time coolant temperature is above 150
F (65 C), even with the ignition switch in the OFF
position. Do not attempt to service the cooling system
without first disconnecting the negative battery cable or
removing the fan fuse.
NEVER add straight antifreeze to the radiator. Mix equal

amounts of clean water with ethylene glycol based antifreeze 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.
18
Open the engine block drain and the radiator

drain. Remove lower radiator hose. Close both
drains and install lower radiator hose once
system has completely drained.
d. Empty and clean the recovery bottle.

e. Fill radiator to the bottom of the filler neck with
50/50 antifreeze/water mixture.
f.
Fill recovery bottle to full mark with 50/50

antifreeze/water mixture.
3. Keep radiator air passages clean. Use compressed

air (30 psi maximum) to clean the fins. Water left
between the fins will collect dirt and reduce the
amount of air flow to properly cool the engine.
4. To provide proper air flow, do not obstruct the air
intake screen on the right side of the vehicle. Keep
screen clean.
5. Check and tighten the fan belt. Replace clamps and
hoses every two years.
6. If you have to add coolant more than once a month,
or add more than one quart at a time, have a
authorized Jacobsen Dealer check the cooling
system.
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
possible and discard.
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.
Diesel
Engine
Gas Engine
Figure 6D
6.9
JUMP STARTING __________________________________________________________
Before attempting to jump start the vehicle, check the

condition of the discharged battery.
Engage parking brake of both vehicles, shift transmission
to neutral and turn off all electrical loads
! WARNING
Batteries generate explosive hydrogen gas. To reduce
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.
2.
Connect RED jumper cable to the positive (+) terminal

on the good battery and to the positive (+) terminal on
the discharged battery.
3.
Connect the BLACK jumper cable from the negative

(-) terminal on the good battery to the frame of the
vehicle with the discharged battery.
After cables have been connected, start the engine on

the vehicle with the good battery then start the vehicle.
When connecting jumper cables:

1.
Stop the engine on the vehicle with a good battery.
19
MAINTENANCE
6.10 BATTERY ________________________________________________________________

Make absolutely certain the ignition switch is Off and
the key has been removed before servicing the battery.
! CAUTION
Always use insulated tools, wear protective glasses or
goggles and protective clothing when working with
batteries. You must read and obey all battery
manufacturers instructions.
Tighten cables securely to battery terminals and apply a
light coat of silicone dielectric grease to terminals and
cable ends to prevent corrosion. Keep vent caps and
terminal covers in place.
Keep the top of the battery clean and free of corrosion by
washing with a solution of baking soda and water. Rinse
with clean water.
1.
When installing the battery, always assemble the RED,

positive (+) battery cable first and the ground, BLACK,
negative (-) cable last.
2.
When removing the battery, always remove the

ground, BLACK, negative (-) cable first and the RED,
positive (+) cable last.
3.
Make sure battery is properly installed and secured to

the battery tray.
! WARNING
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and
reproductive harm. Wash your hands after
handling.
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 Chargers

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
chargers manual.
4.
Always turn the charger Off before disconnecting

charger from the battery terminals.
20
MAINTENANCE
6.12 HYDRAULIC HOSES _______________________________________________________

IMPORTANT: The hydraulic system can be
permanently damaged if the oil becomes
contaminated. Before disconnecting any hydraulic
component, clean the area around the fittings and the
hose ends to keep impurities out of the system.
! WARNING
To prevent serious injury from hot, high pressure oil,
never use your hands to check for oil leaks, use paper or
cardboard.
Hydraulic fluid escaping under pressure can have
sufficient force to penetrate skin. If fluid is injected into
the skin it must be surgically removed within a few hours
by a doctor familiar with this form of injury or gangrene
may result.
1.
Always disengage all drives, engage parking brake,

stop engine and remove key before inspecting or
disconnecting hydraulic lines or hoses.
a.
Before disconnecting any hydraulic component, tag

or mark the location of each hose then clean the
area around the fittings.
b.
As you disconnect the component, be prepared to

assemble plugs or caps to the hose ends and open
ports. This will keep impurities out of the hydraulic
system and also prevent oil spills.
c.
Make sure O rings are clean and hose fittings are

properly seated before tightening.
2.
Check visible hoses and tubes daily. Look for wet

hoses or oil spots. Replace worn or damaged hoses
and tubes before operating the machine.
d.
Keep the hose from twisting. Twisted hoses can

cause couplers to loosen as the hose flexes during
operation resulting in oil leaks.
3.
The replacement tube or hoses must be routed in the

same path as the existing hose, do not move clamps,
brackets and ties to a new location.
e.
Kinked or twisted hoses can restrict the oil flow

causing the system to malfunction and the oil to
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.

Sometimes a leak may develop causing the system to
require repair and refilling. If you notice a hydraulic fluid
escaping when the system is being used or if a leak is
suspected, turn off all hydraulic functions and stop the
engine.
1.
Remove the old filter.
2.
Fill new filter with oil then install new filter. Hand
tighten only.
3.
Operate engine at idle speed with hydraulic system in

neutral for five minutes.
4.
Check hydraulic oil level and fill to knurled mark on

gauge.
Periodically check the hydraulic fluid level (hydraulic level

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
the tank. Wipe the dipstick, then place in tank with
the threaded flange resting on the tank (do not
screw in), Fluid should show on the knurled portion
of the dipstick.
The hydraulic system is protected by one 10 micron filter
(A). The filter is located under the side console, near the
parking brake lever.
HYDRAULIC
RESERVOIR DIPSTICK
KNURLED PORTION
OF DIPSTICK
SHOWN AS
REFERENCE ONLY
Figure 6E
21
MAINTENANCE
6.14 FUEL ____________________________________________________________________

Handle fuel with care - it is flammable and highly
explosive under certain conditions. Use an approved
container, the spout must fit inside the fuel filler neck.
Avoid using cans and funnels to transfer fuel.
! WARNING
Remove the fuel cap slowly. Fuel may be under
pressure. Spray could cause serious injury.
Never remove the fuel cap from the fuel tank, or add fuel,
when the engine is running or while the engine is hot.
Do not smoke when handling fuel. Never fill or drain the
fuel tank indoors.
Do not spill fuel and clean spilled fuel immediately.
Never handle or store fuel containers near an open flame
or any device that may create sparks and ignite the fuel
or fuel vapors.
Be sure to reinstall and tighten fuel cap securely.
1. Fill the fuel tank to within 1 in. (25 mm) of the bottom
of the filler neck.
2. Store fuel according to local, state or federal
ordinances and recommendations from your fuel
supplier.
3. Never overfill or allow the tank to become empty.
Check fuel level in the tank by turning the ignition
switch to the ON position and reading the level
indicated by the fuel gauge.
4. Check fuel lines and clamps every 50 hours.

Replace fuel lines and clamps at the first sign of
damage.
5. The fuel tank capacity is 6.5 gal. (24.5 l). Fill tank
using the following fuel recommendations:
Diesel Engine
a. Use clean, fresh, #2 Diesel fuel when operating
temperature is above 20 F (-7 C). Minimum
Cetane rating 45.
b. Use clean, fresh, #1 Diesel fuel when operating
temperature is below 20 F (-7 C). If #1D fuel is
not available, a winterized blend of #1D and #2D
may be available. This blended fuel is usually
called #2D and may be used in colder climates.
Do not use #2D unless you are sure it has been
winterized. Cold temperatures may cause it to
thicken, which will keep your vehicle from
running.
c.
DO NOT use Aviation Fuel JP4. Refer to Engine

Manual for additional information.
Gas Engine: Use clean fresh Unleaded Gasoline, 87

octane or higher.
CAUTION
The use of any fuel containing greater than 10%
ethanol may harm the engine's emission control
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
priming. It is not required to purge air from the system.
Refer to Section 8.3 for specific maintenance intervals.
Before replacing any filter, thoroughly clean the filter

housing and the area around the filter. Dirt must not be
allowed to enter into fuel system.
6.16 TIRE PRESSURE __________________________________________________________

Keep tires properly inflated to prolong tire life. Check
inflation pressure while the tires are cool. Inspect tread
wear.
Lower pressure will help avoid leaving tire marks in soft
turf. Higher pressures may be required for heavier loads.
Rear tire pressure must be set at 28 psi (193 kPa) when
operating with a full load. Never exceed the maximum
pressure indicated on the tire.
Check the pressure with an accurate, low pressure tire
gauge. Due to the low volume of air needed, overinflation may be reached in a matter of two to three
seconds.
Keep tires inflated to:
22
Front - 20 psi - (138 kPa)

Rear - Varies, determined by load. (See Chart)
28 (193)
23 (159)
Rear 18 (124)
Tire
Pressure 13 (90)
psi
(kPa)
8 (55)
Load (Pounds) 0
400
800
1200
1500
Figure 6F
MAINTENANCE
6.17 TIRE REMOVAL AND INSTALLATION _________________________________________

Removal:
! CAUTION
1. Park the vehicle on a flat and level surface. Apply

parking brake, shut off engine and shift transmission
to 1st gear.
2. Refer to Section 6.18 for proper lifting procedures.
Always use jack stands, never rely only on a jack for
support.
Raise the vehicle only enough to remove the tire.
Never place feet hands or any part of your body
under the vehicle when raising it.
3. Remove the wheel retaining nuts and remove wheel
and tire assembly from the hub.
Unless you have the proper training, tools and

experience, DO NOT attempt to mount a tire on a rim.
Improper mounting can produce an explosion which
may result in serious injury.
Installation:
1.
Remove dirt, grease and oil from stud thread. Do not

lubricate threads.
2.
Position wheel on hub and inspect to insure full contact

between mounting surface of wheel and hub or brake
drum. Make sure valve stem is located towards the
outside. Finger tighten all hardware then torque
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)
4. Perform required service on tire.
6.18 RAISING THE VEHICLE _____________________________________________________
! WARNING
surface. Never work on a vehicle that is supported only
by the jack. Always use jack stands.
Whenever possible empty the sprayer tank before raising
the vehicle. Liquid moving inside the tank can cause an
unbalanced load that could tip the vehicle.
When using a hoist to raise the vehicle, use the same

procedure for supporting the frame and blocking the tires
as you would when using a jack.
To prevent damage to the vehicle or attached accessory,
never use a hoist to raise only one corner of the vehicle.
Always raise BOTH front or rear corners equally.
Block Tire Here
Never raise the vehicle with the engine running or with a

person sitting in the operators 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.
- Jacki ng Locat ion
A scissors type jack or a floor jack with a 1-1/2 ton

(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

Figure 6G
Jack the vehicle to the appropriate height and place jack

stands or equivalent support beneath the frame near the
jack. Lower the jack and allow the vehicle to rest on jack
stands.
23
MAINTENANCE
6.19 TOWING THE VEHICLE_____________________________________________________
! WARNING
To prevent injury or vehicle damage, the following
guidelines should always be followed.
Never accelerate or stop suddenly when towing

a vehicle.
Never change the direction of the vehicle
abruptly or make sharp turns on an incline when
towing a vehicle.
4. Slowly drive towing vehicle forward until tow-line is

pulled tight.
5. While towing, try to keep the tow light taught at all
times. Be careful going down inclines and turning
corners.
Tow Line Attachment
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.).
If for any reason the vehicle needs to be towed, follow the
procedures below.
1. If towing the vehicle with a tow-rope or chain, an
operator is required to steer the vehicle and to
control the brakes.
2. Attach a tow-roper only to the front vertical frame
member on either side of the vehicle.
A Front Bumper Accessory (Part No. 894778)

is available for use with the Truckster. If a
Front Bumper is mounted to your vehicle,
make sure to follow the instructions included
with the bumper for proper connection of the
chain or tow rope
3. Shift transmission Neutral and release parking

brake.
Figure 6H
6.20 GOVERNOR OIL LEVEL ____________________________________________________

Suzuki Gas Engine only
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
the plug from the top of the governor and add a SAE 20W
motor oil until the oil begins to leak from the rear port.
Replace both plugs.
When replacing the plugs, use teflon tape or a Permatex
20 sealant (or equivalent pipe thread sealant) on the
threads of the plug.
Torque the plugs to 95 10 in. lb.
24
Governor Oil
Level Check Plug
Figure 6I
MAINTENANCE
6.21 HYDRAULIC BRAKES ______________________________________________________
! WARNING
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
5. Most communities have a disposal system for DOT

3 brake fluid. Please dispose of fluids properly.
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 Spraytek if the brakes do not stop
vehicle properly.
The brake fluid master cylinder reservoir is located under
the front cowl.
Figure 6J
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,
check the fluid level in the reservoir.
Fluid Level
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
run-off when bleeding the system.
Brake Fluid Lever

Indic ator Light
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.
f.
Periodically check fluid level in reservoir. Do not

allow the reservoir to fully empty or bleeding
procedure will need to be repeated.
4. Repeat Step 3 for each brake.
Bleeder
Screw
Figure 6M
25
MAINTENANCE
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
used fluid properly according to local and state
regulations.
Figure 6N
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
hours or 3 months. Fluid should be changed every 600
hours (or yearly).
Differential Fluid Capacity ...... 1.35 qts (1.3 l)
To check transmission fluid level, remove the filler plug

from the front of the transmission. Fluid should be level
with the bottom of filler hole.
Level Check And

Filler Plug
Transmi ssi on
Drain Plug
To change fluid, remove drain plug from rear of
transmission.
regulations.
Fill transmission with gear lube until fluid begins to leak
26
Figure 6P
MAINTENANCE
6.24 GAS ENGINE MANUAL TRANSMISSION _______________________________________

hours (or yearly).
Fill transmission with gear lube until fluid begins to leak


To check transmission fluid level, remove the filler plug

from the front of the transmission. Fluid should be level
with the bottom of filler hole.
Fill Plug
To change fluid, remove drain plug from rear of
transmission.
Drain
Plug

regulations.
Figure 6Q
6.25 GAS ENGINE AUTOMATIC TRANSMISSION ____________________________________

hours (or yearly).
Fluid Type .............................. Mercon / Dexron II
To check transmission fluid level, the engine must be

running. Place the gear selector in P PARK, apply the
parking brake and start the engine.
Transmission
Fluid Dipstick
and Fill Tube
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.
To change fluid, remove drain plug from bottom of
transmission.
Drain Plug
Automatic Transmission

regulations.
Fill transmission until fluid reaches proper mark on
dipstick.
Figure 6R
27
MAINTENANCE
6.26 ELECTRICAL SYSTEM _____________________________________________________
! CAUTION
Always turn the ignition switch off and remove the
negative battery cable (Black) before inspecting or
working on the electrical system.
General precautions that can be taken to reduce
electrical problems are listed below.
1.
Make certain all terminals and connections are clean

and properly secured.
2.
Check the Interlock system, and fuses regularly.

If the Interlock does not function properly and the
problem cannot be corrected, contact an authorized
Jacobsen Dealer.
3.
Keep the wire harness and all individual wires away

from moving parts to prevent damage.
4.
Check the battery and battery charging circuit.
5.
Do not wash or pressure spray around electrical

connections and components.
6. Circuits are protected by fuses located under the

front cowl and a fuse located near the cooling fan.
Diesel Engine
Power Port 15 A
Brake Light,
5th Wheel Brake 10 A
20 A Dash Panel,
Fuel Pump
& Ignition
10 A Accessary
Flashers & 10 A
Horn
10 A Heater
Accessary
Headlights 15 A
10 A Wiper,
Dome Light &
Back-Up Alarm
Gas Engine
Accessary 10 A
Dash Panel,
ECU, Fuel
20 A & Engine Coils
Power Port 15 A
25 A Radiator
Fan
Headlights 15 A
15 A ECU, Main Relay,

Injectors
Brake Light,
5th Wheel Brake 10 A
Flashers & 10 A
Horn
Heater 10 A
Accessary
10 A Backup Alarm
Shift Switch
10 A ECU
10 A Wiper,
Dome Light &
Back-Up Alarm
Figure 6S
6.27 DASH PANEL _____________________________________________________________

The dash panel contains gauges and instrument lights to
display unit functions. Maintenance of the panel is limited
to replacing bulbs and setting the DIP switches. Remove
the four screws securing the instrument panel to the
dash.
Pull panel out, tilt panel forward and disconnect electrical
connector for easier access to rear of panel.
Light Bulb Replacement:
1. Determine which bulb needs to be replaced.
2. Rotate bulb holder 1/4 turn counter-clockwise and
pull up and away from dash panel.
3. Replace old bulb with a new bulb of equal type.
Location ........................... Replacement Bulb
A Voltmeter ............................C658
B Temperature Gauge ...........C658
C Fuel 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
28
K
L
M
N
Right Turn........................... C161

Parking Brake..................... C161
High Beam.......................... C658
Alternator / Battery ............. C161
4. Place bulb and holder back into panel. Turn holder

1/4 turn clockwise to secure into panel. Ensure base
of holder is properly seated in panel.
MAINTENANCE
Tachometer DIP Switch Setting:
The dash panel uses a DIP Switch sequence code to
identify the number of input pulses per engine revolution
and engine type to correctly display the engine RPM on
the tachometer.
Using a small blade screwdriver or similar tool, push the

switch levers either up or down to match the sequence
code for this unit.
Dipswitch Setting
1
0
If you are replacing the dash panel or if the tachometer is

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.
Perkins Diesel Sequence Code: 0 0 0 1 0 0 0 0
The truckster with a Suzuki Gas engine uses the

following sequence code for 1.5 pulses / revolution.
F
G
A
D
H
J
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
functioning or is damaged. The headlight is a sealed unit
and can only be replaced as a complete unit.
Description ................ Bulb Type
Headlight................... H6545
5. Remove the headlight from the bezel. Properly

dispose of old bulb.
6. Install new headlight in reverse order of removal.
Jacobsen Part No.

837303
1. Disconnect the negative battery cable.

2. Remove the four screws securing the headlight
bezel to the front cowl.
Headlight
Bezel
3. Pull headlight and bezel forward, out of the front clip

opening.
4. Disconnect the electrical connector from the rear of
the headlight,
Remove The Four (4) Screws

For Headlight Removal
Figure 6U
6.29 TAIL LIGHT REPLACEMENT_________________________________________________

The tail light should be repaired as soon as it stops
functioning or is damaged. The tail light bulb, and lens
are replaceable components. Damage to the body of the
tail light requires a complete replacement.
Description ................ Bulb Type
Tail light bulb............. 1157
frame. Disconnect harness and remove tail light

from frame.
Jacobsen Part No.

822049
1. Remove the two screws securing lens. Remove lens

and gasket.
2. Push bulb in, turn 1/4 turn and remove bulb.
Dispose of old bulb properly.
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
Remo ve The Two (2)

Screws For Bulb
Or Lens Replacemen t
Figure 6V
29
MAINTENANCE
6.30 EFI DIAGNOSTIC CHECK ___________________________________________________

Suzuki Gas Engine units only
The electrical system is equipped with a plug in
connector which, when used with the diagnostic jumper
accessory (Part No. 2700920) will perform diagnostic
checks on various engine components.
position. The brake fluid light at the lower left corner of

the dash panel will flash a diagnostic code.
The first digit of the code will be given first with a full
second pause between each 0.3 second flash, followed
by the second digit with no pause.
Manual transmission: Engage parking brake, shift

transmission to neutral and turn the ignition switch to the
OFF position.
A code of 12 (System Normal) would turn the light on

for 0.3 seconds, a full second pause then two fast
flashes. (Flash-Pause-Flash-Flash)
Automatic Transmission: Engage parking brak, place

gear selector in PARK and turn the ignition switch to the
OFF position.
A code of 46 (Shift swicth) would turn the light on four

times for 0.3 seconds and a full second pause, then
six fast flashes. (Flash-Pause-Flash-Pause-FlashPause-Flash-Pause-Flash-Flash-Flash-FlashFlash-Flash)
Open the front cowl and locate the plug in connector

(Black/White and Black Wires) coming from the wire
harness below the brake fluid reservior.
To run the diagnostic test, plug the diagnostic jumper into
the plug-in connector. Turn ignition switch to the ON
Code
Engine Component
11
Pressure Sender
12
Normal
13
Throttle Sensor
30
The following list shows which code number

coresponds to which component and list possible
causes for each fault.
Possible Causes
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.
System operating normally
Voltage at pin 33 (Gray/Yellow wire) of the 34 pin ECU connector is higher than 4.73 Volts or
lower than 0.25 Volts
14
O2 Sensor
15
Crank Angle Sensor
No signal for a length of time at pin 24 (Red/Blue wire) of the 34 pin ECU connector
16
Vehicle Speed Sensor
19
Water Temperature Sensor
41
Shift Solenoid #1
(Automatic Transmission only)
Open or short circuit at pin 27 (Blue/Black wire) of the 34 pin ECU connector. Should be 12 Volts
if gear selector is in the L position.
42
Shift Solenoid #2
Open or short circuit at pin 28 (Blue/White wire) of the 34 pin ECU connector. Should be 12 Volts
if gear selector is in the L or 2position.
43
Shift Solenoid #3
Open or short circuit at pin 29 (Blue/Red wire) of the 34 pin ECU connector.
46
Shift Switch
No sigal present at pin 18 (Green/Pink wire), and pin 19 (Orange Blue wire), and pin 20 (Orange/
Green wire), and pin 24 (Green/Blue wire), and pin 25 (Green wire) and pin 26 (Red wire) of the
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
While in starting mode, no signal is seen at pin 16 (Brown/Red wire) of the 34 pin ECU connector
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
lower than 0.15 Volts.
MAINTENANCE
6.31 CARE AND CLEANING _____________________________________________________

Wash the vehicle after each use. Keep the equipment
clean.
Note: Do not wash any portion of the equipment while it is
hot. Do not use high pressure spray or steam. Use cold
water and automotive cleaners.
1.
Use compressed air to clean engine and radiator fins. A

special blow gun is available through Jacobsen Dealer.
2. Use only fresh water for cleaning your equipment.
3.
Do not spray water directly at the dash panel, ignition

switch, controls or any other electrical components, or
at bearing housings and seals.
4.
Clean all plastic or rubber trim with a mild soap

solution or use commercially available vinyl/rubber
cleaners.
Repair damaged metal surfaces and use Jacobsen

touch-up paint. Wax the equipment for maximum paint
protection.
Note: Use of salt water or affluent water has been known

to encourage rust and corrosion of metal parts resulting
in premature deterioration or failure. Damage of this
nature is not covered by the factory warranty.
! CAUTION
Clean grass and debris from drives, muffler and
engine to prevent fires.
6.32 STORAGE ________________________________________________________________

General
1.
Wash the vehicle thoroughly and lubricate. Repair and

paint damaged or exposed metal.
2.
Inspect the vehicle, tighten all hardware, replace worn

or damaged components.
3.
Drain and refill radiator.
4.
Clean the tires thoroughly and store the vehicle so the

load is off the tires. If vehicle is not on jack stands,
check tires at regular intervals and reinflate as
necessary.
5.
Keep the machine and all its accessories clean, dry

and protected from the elements during storage. Never
store equipment near an open flame or spark which
could ignite fuel or fuel vapors.
Battery
1.
Remove, clean and store battery in upright position on a

non-conductive surface (wood) in a cool, dry place. To
prevent accelerated discharge, do not store battery on
concrete or steel surface.
2.
Check and recharge battery every 60 to 90 days while

in storage.
3.
To reduce the self discharge rate, room temperature

should not be above 80F (27C) or fall below 20F (7C) to prevent electrolyte from freezing.
Engine (General)
1.
While the engine is warm, remove the drain plug, drain

the oil from the crankcase and change oil filter. Install
drain plug and refill with fresh oil. Let engine cool before
storing.
2.
Clean exterior of engine. Paint exposed metal, or apply

a light coat of rust preventative oil.
Add a fuel conditioner or biocide to prevent gelling or

bacterial growth in fuel. See your local fuel supplier.
If storing indoors, drain fuel from tank.
Close fuel shut off valve.
After Storage
1.
Check and reinstall battery
2.
Check or service fuel filter and air cleaner.
3.
Check the radiator coolant level.
4.
Check oil level in the engine crankcase.
5.
Fill the fuel tank with fresh fuel. Open fuel shut off
valve and bleed the fuel system.
6.
Remove antifreeze mixture from sprayer pump.
7.
Assembly boom hoses, no-drip valves, nozzle tips
and strainers.
8.
Make certain that the tires are properly inflated.
9.
Start and operate the engine at 1/2 throttle. Allow

enough time for the engine to become properly
warmed and lubricated.
! WARNING
Never operate the engine without proper ventilation;
exhaust fumes can be fatal when inhaled.
31
7
7
7.1
TROUBLESHOOTING
TROUBLESHOOTING
GENERAL________________________________________________________________
The troubleshooting chart below lists basic problems that

may occur during start-up and operation. For more
detailed information regarding the electrical system

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

defective.
2.
Inspect condition of battery and battery connections.
3.
Fuel tank empty or dirty. Fuel shut

off valve closed
3.
Fill with fresh fuel. Change fuel filter. Bleed fuel lines.
Open fuel shut off valve
4.
Fuse blown.
4.
Replace fuse.
Fuel level low, fuel or fuel filter

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

runs poorly.
vehicle does not react 1.

to throttle pedal
2.
Parking brake engaged
Disengage parking brake.
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
32
MAINTENANCE & LUBRICATION CHARTS

8
8.1
GENERAL ________________________________________________________________
! WARNING
Before you clean, adjust, or repair this equipment,
disengage all drives, lower implements to the ground,
engage parking brake, stop engine and remove key
from ignition switch to prevent injuries
1. Always clean the grease fitting before and after
lubricating.
8.2
2. Lubricate with grease that meets or exceeds NLGI

Grade 2 LB specifications. Apply grease with a
manual grease gun and fill slowly until grease begins
to seep out. Do not use compressed air guns.
3. For smooth operation of all levers, pivot points and
other friction points that are not shown on the
lubrication chart apply several drops of SAE 30 oil
every 40 hours or as required.
4. Grease fittings every 100 hours. Do not over grease
drive shaft fittings (A). Too much grease will damage
the seals.
LUBRICATION CHART______________________________________________________
Brake Fluid
Reservoir
Fitting
A
B
C
D
Description
Drive Shaft
Upper Ball Joints
Lower Ball Joints
Tie Rod Ends
Qty
2
2
2
4
Fuse Box
D
C
33
8.3
MAINTENANCE CHARTS ___________________________________________________

Recommended Service and Lubrication Intervals
Daily
Air Filter
Alternator
Battery
Belts
Brake Fluid
Brake Linings
Clutch
Cooling System
Differential Fluid
Electrical System
Engine Glow Plugs
Engine Idle Speed
Engine Noise / Vibration
Engine Oil (Suzuki)
Engine Oil (Perkins)
Engine Oil Filter
Engine Oil Filter
Engine Valve Clearance
Fluid Leaks
Fuel System
Fuel Filter
Fuel Water Separator
(Diesel Only)
Governor Fluid
Hydraulic Filter
Hydraulic Fluid
Injection Pump / Timing
Lubricate Chassis
Muffler and Exhaust
Radiator Screens
Power Steering Fluid
Spark Plugs (Gas only)
Starter Motor Brushes
Tires
Transmission Fluid
(Manual Transmission)
Transmission Fluid
(Automatic Transmission)
Wheel Bearings
A - Add or Adjust
34
First
35
Hours
Every
75
Hours or
2 Months
Every
100
Hours or
3 Months
Every
200
Hours or
6 Months
Every 400
Hours or
9 Months
Every
600
Hours or 12
Months
R**
See
Section
Lubricant
Type
6.8
I
I
I-A*
I-A
6.10
I-A
4., 5.2
I-A
I-A*
I-A
6.21
VI
6.7
IV
6.22
III
I-A
I-A
I-C-A
I-R*
I*
6.26
I
I*
I
I
R*****
R*
R*****
R*
R**
6.3
R**
6.3
R**
6.3
R**
II
6.3
I****
I****
I-R
I*
I
R
6.15
6.15
I-C
I-A
R
I-A
I
L
I
8.2
6.5
I-C/AR
6.7
I*
6.4
C-A-R
I
I
I-A
6.16
I
6.23
6.24
III
6.25
VII
Repack
C - Clean
I - Inspect
L- Lubricate
R - Repair or Replace
AR - As Required

Notes:
* Indicates initial service for new machines.
** Depending on operating conditions, engine oil, oil
filter and air filter may require more frequent
replacement.
*** Inspect visible hoses and tubes for leaks or oil
marks.
**** Must be done at Authorized Dealer
***** Change oil and filter on Suzuki Engines after first
fifty hous
Common Replacement Parts:
Engine Air Filter - 840352
Diesel Engine Oil Filter - 842553
Gas Engine Oil Filter - 2701809
Diesel Engine Fuel Filter - 2208175
Gas Engine Fuel Filter - 2701898
Diesel Engine Alternator Belt - 600997
Diesel Engine Hydraulic Pump Belt - 841966
Gas Engine Alternator-Power Steering Belt - 4115406
Gas Engine Hydraulic Pump Belt - 4115404
NGK 3932 (DCPR7E) Spark Plug - 4119606
Denso XU22EPR-U Spark Plug - 2701832
Lubricants
I Manual grease gun with NLGI Grade 2 (Service
Class LB).
II Engine Oil - See Section 6.3
III SAE EP 80-90 Gear Lube
IV Capacity: 3qt. (2.8 l) 50/50 water ethylene glycol mix
V GM Power Steering Fluid
VI DOT 3 Brake Fluid
VII Mercon/Dextron II Automatic Transmission Fluid
35
9
9
36
NOTES
NOTES
PARTS CATALOG
10
10
PARTS CATALOG
10.1 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 ....... Automatic Transmission Shifter...................... 56
11.1 ....... Automatic Transmission Oil Cooler ................ 57
12.1 ....... Frame Attachments .......................................... 58
13.1 ....... Frame, Lower ROPS and Platform .................. 60
14.1 ....... Rear Axle ........................................................... 62
15.1 ....... Front Control Arms ........................................... 64
16.1 ....... Steering Linkage ............................................... 66
17.1 ....... Front Brakes ...................................................... 68
18.1 ....... Steering Column ............................................... 70
19.1 ....... Diesel Radiator.................................................. 72
20.1 ....... Gas Radiator...................................................... 74
21.1 ....... Diesel Engine and Transmission Mounting ... 76
22.1 ....... Gas Engine and MT Mounting ......................... 78
23.1 ....... Gas Engine and AT Mounting .......................... 80
24.1 ....... Diesel Engine and Clutch ................................. 82
25.1 ....... Suzuki Gas Engine............................................ 84
26.1 ....... Engine Speed Control ...................................... 86
27.1 ....... Exhaust .............................................................. 87
28.1 ....... Governor Linkage ............................................. 88
29.1 ....... Governor ............................................................ 90
30.1 ....... Gas Engine Remote Oil Fill .............................. 92
31.1 ....... Gas Engine Exhaust ......................................... 93
32.1 ....... Diesel Fuel System ........................................... 94
33.1 ....... Gas Fuel System ............................................... 96
34.1 ....... Hydraulic Tank and Filter ................................. 98
35.1 ....... Hydraulic Pump and Filter ............................. 100
36.1 ....... Lift Cylinder Circuit......................................... 102
37.1 ....... Diesel Electrical Components ....................... 104
38.1 ....... Gas Electrical Components ........................... 106
39.1 ....... Differential Assembly ..................................... 108
40.1 ....... Differential Housing ........................................ 110
41.1 ....... Axle Tubes and Shafts ................................... 112
42.1 ....... Front and Shifter Cover .................................. 114
43.1 ....... Input, Main and Jack Shafts........................... 116
44.1 ....... Transmission Clutch Release-Shift Selector 118
45.1 ....... Transmission Case ......................................... 120
46.1 ....... Input and Main Shaft....................................... 122
47.1 ....... Gear Shift Fork Linkage ................................. 124
48.1 ....... Diesel Engine Electrical Schematic .............. 126
49.1 ....... Diesel Engine Main Harness .......................... 130
50.1 ....... Diesel Engine and Fan Harness .................... 132
51.1 ....... Gas Engine Electrical Schematic .................. 134
52.1 ....... Gas Engine Schematic ................................... 138
53.1 ....... Gas Main Harness ........................................... 140
53.1 ....... Gas Main Harness (Continued)...................... 142
37
TURF TRUCKSTER
Serial No. All
1.1 Front Body
10
9
8
7
20
22
23
24
12
11
26
25
12
21
19
27
37
12
By Jacobsen
B
18
29
1
Turf Truckster
Turf Truckster
By Jacobsen
By Jacobsen
31
30 / 31
12
34
35
29
11
30
16
28
32
33
36
17
15
15
12 14
35 34
13
36
33
C
18
B
4
2
38
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
37
Part No.
Qty.
2700792
800930
548159
450400
601940G05
601939
841477G01
841637
450541
112050
841913
800934
4139691
548175
800943
837303
841428
828382
894030
2702198
841715
303952
306463
841753
306419
306488
450410
844293
74765G01
74793G01
74767G01
38541
38061A
840508
800344
823549
2703158
4117221
6
4
2
1
AR
1
1
7
6
2
22
2
8
10
2
2
AR
1
1
1
1
1
1
2
2
2
3
1
1
1
1
2
2
2
2
1
1
Description
Front Clip
Includes decals 821071 & 840901
Screw, M8-1.25 x 16 mm Hex Flange

Flat Washer, 5/16 x 1-1/4
Washer, M8
Hood, Orange
Weather Seal
Hinge, Hood
Angle, Front Clip Mounting
Screw, M6-1 x 16 mm Round Head
Screw, 1/4-20 x 5/8 Taptite
Plate, Access
Screw, M6-1 x 16 mm Hex Flange
Flap, Mud
Screw, #10-14 Self Tapping
Headlight, Rectangular
Bezel, Headlight
Seal, Foam
Striker, Hood
Latch, Hood
Rod, Hood Release
Flat Washer, #10
Cotter Pin, 1/16 x 1/2
Bracket, Hood Latch
Screw, 1/4-20 x 1/2 Hex Head
Lockwasher, 1/4 Shakeproof
Lockwasher, M6
Plug, Panel
Decal, Cushman
Decal, Left Side Turf Truckster
Decal, RIght Side Turf Truckster
Tube, Clear Document
Cap, Vinyl
Mount, Cable Tie
Screw, #10 Type AB Self Tapping
Cable Tie, 15-1/2
Decal, Fuses
Decal, Fuses
Diesel Engine
Gas Engine
> Change from previous revision

39
TURF TRUCKSTER
Serial No. All
2.1 Engine Cover
21
20
7
20
17
7
U
16
A
N
Engine Cover Lock
15
C
5
S
A
N
8
17
2 11
10
16
12
22
19
18
23
7
24
9
13
14
3
40
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
22
22
23
24
Part No.
Qty.
306328
308090
450452
450453
450454
893541
450541
452388
452398
523085
816401
830784
2702199
841804
842030
601937
893322
893375-G05
845038
840436
309488
845234
845232
845231
800263
36085G01
1
2
2
3
1
10
2
3
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
8
1
Description

Washer, 1/4
Nut, M6-1 Hex Flange
Nut, M8-1.25 Hex Flange
Handold, Right Side
Latch, Engine Cover
Spring, Torsion
Clevis Pin, 1/4 x 1-7/8
Catch, Engine Latch
Insulation, Engine Cover
Mount, Backrest
Seat Base
Backrest
Cover, Engine
Decal, Operation
Lock, Engine Cover
Washer
Decal, Ground Speed
Decal, Ground Speed
Decal, Ground Speed
Screw, 1/4-20 x 1-1/4
Decal, Carb Suzuki K6
Optional, Required in Europe

Optional, Required in Europe
Diesel Engines
Gas Engine, MT
Gas Engine, AT

41
TURF TRUCKSTER
Serial No. 84054 All
3.1 Upper ROPS
4
3
11
11
2
14
15
15
14
7
8
13
6
6
REF
Engine
Cover
12
10
7
8
9
5
11
6
9
8
7
REF
Control
Console
2
PART NUMBER: 893146
Meets SAE: J1040 MAY94
Only to be used on Cushman and EZ-GO truck models

with matching lower structure
Manufactured by E-Z-GO a Textron Company
1451 Marvin Griffin Rd. Augusta, Georgia 30906
42
WARNING
The protection offered by this ROPS will be impaired if it has

been subjected to any modification or structural damage.
This ROPS must be replaced after a rollover. Seat belts must
be worn at all times.
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part No.
Qty.
36097-G01
36091-G01
844988
452411
450455
4140269
N/S
N/S
N/S
841799
800930
450453
REF
893632
450541
1
1
6
3
2
2
2
2
1
12
4
1
4
8
Description
Upper ROPS
Decal, Warning and ROPS Cert.
Foam, 1/2 Perforated ROPS
Screw, M12-1.75 x 40 mm Flange
Seat Belt Assembly
Flat Washer, 7/16
Nut, 7/16-20 Hex
Guard, Seat Belt
Backrest
Support, Backrest
Screw, M6-1 x 16 mm Pan Head
See 2.1

43
TURF TRUCKSTER
Serial No. All
4.1 Throttle Control
Attach Pivot Link

in Bottom Hole
44
2
27
28
A
43
22
26
8
25
10
D C
To Engine
Cable Routing
12
3
14
8
36
28
11
27
B
14
9
13
33
30
5
4
20
35
14
22
20
26
17
34
6
17
31
31
32
29
Hand Throttle Panel

39 40
21
19
B
41
37
14
23
39
STOP
24
15
42
38
35
Ignition Switch Panel
18
15
17
All Views Rotated 90 for Clarity

44
Throttle Pivot
16
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Part No.
Qty.
841663
800943
894159
524633
524643
548911
2703257.7
452378
450452
843997
843562
452695
830784
306328
843563
843561
806714
844224
515268
844223
REF
828049
843607
817104
111898
800271
120052
306531
844116
841264
830366
843581
REF
827821
800582
2700496
2701850.7
2702014
837295
837299
837300
2702012
821071
29165G01
10
1
2
2
2
1
6
6
1
1
1
1
4
2
1
3
2
2
2
1
1
1
1
2
6
6
6
1
1
1
1
1
2
6
4
1
1
1
1
1
1
1
1
Description
Panel, Floor Access

Screw, #10-14 x 5/8 Self Tapping
Pedal, Throttle
Bolt, 5/16-18 x 1 Shoulder
Bearing, Split
Nut, 5/16-18 Flange
Bracket, Foot Throttle
Screw, M6-1 x 20 mm Flange
Nut, M6-1 Flange
Bracket, Pedal Stop
Mount, Channel
Screw, M6-1 x 20 mm Self Tapping
Plate, Pivot
Link, Throttle Pivot
Clevis Pin, 5/16 x 3/4
Roll Pin, 3/16 x 1-3/4
Bushing
Spring, Torsion
Throttle Cable
Throttle, Hand
Bushing, Throttle Cable
Stop, Wire
Clamp, Cable
Screw, #10-24 x 1/2 Pan Head
Lockwasher, #10
Nut, #10-24 Hex
Decal, Speed Control Panel
Panel, Speed Control
Switch, Horn
Switch, Light
Cable, Governor Control
Knob
Screw, 1/4-10 x 3/4 Truss Head
Insert, 1/4-20 Threaded
Panel, Ignition Switch
Decal, Ignition Switch Panel
Ignition Switch
Spacer, 3/32
Spacer, 1/16
Strap Nut, 1/4-20 x 2
Decal, Not Motor Vehicle Notice
Decal, Off Road Use
See 26.1 or See 28.1
See 26.1 or See 29.1

45
TURF TRUCKSTER
Serial No. All
5.1 Control Console
16
15
4/5
5
14
!
13
WARNING
PA R K I N G B R A K E S A R E N O T A U T O 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
A P P LY H A N D O R F O O T B R A K E S .
12
11
10
4
8
9
9
29
33
28
34
21
27
20
18
32
31
26
25
24 23
35
30
17
22
19
N
36
35
37
38
46
2
View Rotated for Clarity
TURF TRUCKSTER
Item
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Part No.
Qty.
Description
2700796
Console
Used on all, except 84044
2700797
844177
844179
822819
845185
894696
452396
832798
450453
822419
304632
844582
306388
548171
844051
800930
886270
843355
316907
306396
306375
823225
308089
306463
839213
814079
103867
306328
843758
452404
825538
843759
450454
521144
826558
828057
823118
828056
1
1
1
1
1
1
2
1
6
1
1
1
1
1
1
4
1
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Console, EC
Decal, Aux. Transmission
Decal, Hydraulic Controls
Decal, Parking Brake
Decal, EC Parking Brake
Valve, Hydraulic Selector
Plate, Stop
Washer, 1-5/8 Diameter
Nut, 3/8-16 Hex Jam
Rod, Extension Handle
Nut, 3/8-24 Hex Jam
Knob
Plate, Float Latch
Valve, Hydraulic Lift Control
Mount, Lift Control Valve
Screw, 1/4-20 x 2-3/4 Hex Head
Lockwasher, 1/4
Nut, 1/4-20 Hex
Clevis Pin, 3/16 x 1
Flat Washer, #10
Connector, Valve
Flat Washer, 5/16
Handle, Lift Control Valve
Spring, Compression
Bushing, Lift Control Valve
Cover, Handle
Adapter, 90 Fitting
Adapter, 90 Fitting
Adapter, Straight Fitting
Adapter, 90 Swivel Fitting
Used on 84044 Only

Used on 84044 Only
Discard Decal included with Valve
ORB to JIC 37 Flare

ORB to JIC 37 Flare
ORB to JIC 37 Flare
JIC 37 Flare

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
3
11
3
17
15 13
12
7
5
6
5
10
9
8
10
2
5
5
3
48
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Part No.
Qty.
Description
894317
Lever, Parking Brake
845134
452388
452391
450453
845133
450377
827182
843359
809152
843356
800446
843158
452398
450454
REF
889106
452378
450452
837043
2702244
806703
306328
320107
1
5
1
6
1
1
1
1
2
1
1
1
2
2
2
1
1
1
1
2
1
1
1
Bracket, Parking Brake Lever

Nut, M8-1.25 Flange
Cable, Parking Brake
Nut, M6-1 Staytite
Pulley, 3 Cable
Bushing, Pulley
Equalizer, Parking Brake
Locknut, 5/16-24
Bracket, Parking Brake Cables
Nut, M10-1.5 Flange
Parking Brake Cables
Cable, High - Low Speed Control
Nut, M6-1 Flange
Bracket, High - Low Cable
Nut, #10-32 Hex
Cable Tie, 7-1/2
See 39.1
Apply Locktite 242

49
TURF TRUCKSTER
Serial No. All
7.1 Brake Pedal
15
16
Route both hoses through
opening in front clip
17
31
A
16
16
17
11
14
16
4
20
Lower
ROPS
10
12
13
7
5
6
18
19
21
2
22
3
Pedal Mounting
View Rotated 90 Degrees for Clarity
27
28
Route front brake

tube through opening
in front clip
23
29
24
25
34
33
32
Route rear brake

tube under floor
access panel
6
29
30
22
Tube Routing
50
26
Left Frame Rail
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Part No.
Qty.
2701737.7
892921
840726
840725
842935
452388
450453
895113
800930
894167
806714
103867
306328
894456
2702215
826006
825886
800934
830930
7040
810152
894308
450410
452424
452398
843021
843022
842103
842051
809137
REF
810435
450454
REF
REF
812445
800943
1
1
1
1
2
2
1
2
1
1
1
1
1
1
1
2
2
4
AR
1
1
2
2
7
1
1
1
1
1
1
2
1
1
1
1
1
Description
Bracket, Master Cylinder

Pedal, Brake
Bearing, Brake Pivot
Tube, Brake Pivot
Tab, Locking
Nut, M8-1.25 Flange
Master Cylinder
Rod, Brake
Flat Washer, 5/16
Reservoir, Brake Fluid
Reservior
Electrical Connector, 2 Wire
Terminal, 1/4 L Male
Clamp, Hose
Hose, 5/16 Brake
Pad, Pedal
Switch, Brake Micro
Screw, M3-0.5 x 20 mm Pan Head
Nut, M3-0.5 Hex
Tube, Front Brake
Tube, Rear Brake
Union, M10-1
Tube, Rear Brake Line
Clip, Brake Line
Rear Brake Hose
Clamp, Brake Tube
Nut, M10-1.5 Flange
Bracket, Reservoir / Horn
Tee, M10-1.0 Flare Union
Clamp, Tube
6 Foot Length, cut to 18
See 39.1
See 37.1
See 17.1

51
TURF TRUCKSTER
8.1 Clutch Pedal Linkage
Lower
ROPS
4
9
10
8
6
14
13
7
3
12
15
11
2
Cable Routing
21
20
22
19
A
16
17 18
A
12
Gas Units
52
Diesel Units
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
11
12
13
14
15
16
17
18
19
20
21
22
Part No.
Qty.
Description
892933
Pedal, Clutch
840726
844611
840725
842935
452388
450453
894308
450510
452424
4119634
895013
844202
806714
306328
810152
842010
833273
450377
23266-85002
01550-08353
2703002
REF
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
Bearing, Brake Pivot

Spring, Torsion
Tube, Pedal Pivot
Tab, Locking
Nut, M8-1.25 Flange
Switch, Clutch Micro
Screw, M3-0.5 x 20 mm Pan Head
Nut, M3-0.5 Flange
Cable, Clutch
Cable, Clutch
Washer, Slotted
Pad, Pedal
Bushing, Clutch Release Arm
Bushing
Nut, M6-1 Nylock
Arm, Clutch Release
Screw
Nut
Rear Alternator Bracket
Diesel Units
Gas Units
Diesel Units Only

Diesel Units Only
Diesel Units Only
Diesel Units Only
Diesel Units Only
Diesel Units Only
Diesel Units Only, See 24.1

53
TURF TRUCKSTER
9.1 Manual Transmission Shifter Linkage
21 22
23
3
14
16
7
9
18
10
11
15
19
20
17
12
16
13
24
2
5
6
B 19
20
32
40
33
31
31
29
26
36
1
32
30
34
35
37
25
B
A
Diesel Unit Cable Attachment

39
32
A
39
28
B
27
Shifter Mounting and Cable Routing

54
32
38
Gas Unit Cable Attachment
TURF TRUCKSTER
Item
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
23
24
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part No.
Qty.
Description
893966
Shifter Assembly
Diesel Units
2701274
2703956.7
2703953
842773
308091
311763
843679
452692
604174
843614
843685
2703951
452401
450454
894179
2701273
842774
816307
306397
843724
452695
300977
306396
308090
894179
2701328
2702996
2702695
548175
308090
843778
2703707
103867
821164
2703964.7
843792
452692
2700496
2703931.7
452695
2701371
800582
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
2
4
1
1
1
1
1
1
1
3
1
1
1
2
2
1
1
2
4
1
4
2
4
Shifter Assembly
Mount, Shifter
Selector, Gear
Rod End, 1/2-20
Flat Washer, 1/2
Plate, Wear
Screw, M6-1 x 12 mm Self Tap
Flat Washer, 3/8
Spring, Torsion
Bushing, Spring
Tab, Locating
Nut, M10-1.5 Flange
Cable, Shifter
Cable, Shifter
Ball Joint, 1/4-28
Flat Washer, 1/4
Nut, 1/4-28 Hex
Clamp, Cable
Lockwasher, 1/4
Flat Washer, 1/4
Cable, Shifter
Cable, Shifter
Boot, Control Lever
Knob, Shifter
Flat Washer, 1/4
Connector, Shift Cable
Flat Washer, 5/16
Hair Pin
Panel, Right Side Dash
Plate, Shifter Boot
Insert, 1/4-20 Threaded
Ring, Boot Hold Down
Screw, 1/4-20 x 3/4 Truss Head
Gas Units
Diesel Units
Gas Units
Diesel Units
Gas Units
Diesel Units Only

Diesel Units Only
Diesel Units Only
Gas Units Only

55
SPRAYTEK DS 300
10.1 Automatic Transmission Shifter
12
11
1
7
11
8
11
11
6
1
3
11
4
2
10
Item
1
2
3
4
5
6
7
8
9
10
11
12
Part No.
Qty.
Description
103867
Flat Washer, 5/16
302030
306375
306396
800582
821164
842740
845345.7
894584
894508
892164
2700496
1
1
1
4
2
1
1
1
1
1
4
Screw, 1/4-20 x 1-1/4

Nut, 1/4-20 Hex
Lockwasher, 1/4
Screw, 1/4-20 x 3/4
Hair Pin, 1/4 x 1-1/8
Lever, Shifter
Bracket, Shifter Cable Mount
Shifter with Cable
Cable, Shifter
Kit, Cable Mounting Hardware
Insert, 1/4-20

56
SPRAYTEK DS 300
11.1 Automatic Transmission Oil Cooler
6
5
2
1
Item
Part No.
1
2
3
4
5
6
Qty.
838340
800789
826590
821893
809231
825264
1
AR
AR
2
4
Description
Oil Cooler
Kit, Oil Cooler Mounting
Hose, 5/16 I.D.
Trim, Push On
Grommet
Hose Clamp

57
TURF TRUCKSTER
Serial No. All
12.1 Frame Attachments
9
9
13
9
13
9
9
18
11
12
20
9
22
17
10 A
10
10
10
14
15
21
16
23
10
19
A
1
9
7
10
6
3
10
4
58
TURF TRUCKSTER
Item
Part No.
1
2
3
4
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Qty.
REF
452415
450454
4139806G03
4139806G03
4139806G03
4139793
N/S
N/S
N/S
886735
800909
REF
800026
894232
452398
450454
893488
893487
452399
893602
822049
312288
829099
548910
894313
4117153.7
800177
548911
800930
450453
REF
REF
8
8
2
2
2
1
1
1
1
1
2
1
7
1
18
20
1
1
2
1
1
2
1
2
1
1
1
1
1
1
1
1
Description
Front Suspension
Wheel and Tire, Multi Rib
Wheel and Tire, Turf Master
Wheel and Tire, USA Trail
Rim, 10.00 x 7 Five Bolt
Tire, 20 x 10.00 - 10 Multi Rib
Tire, 20 x 10.00 - 10 Turf Master
Tire, 20.5 x 8.00 - 10 USA Trail
Valve Stem
Nut, M12-1.5 Wheel Lug
Panel, Console
Screw, 1/4-20 Truss Head
Cover, Left Side Engine
Fender, Right Side
Fender, Left Side
Stop and Tail Light
Bulb, No. 1157
Lens, Screw
Lens and Gasket
Nut, 1/4-20 Serrated Flange
Harness, Taillight Wire
Support, Fuel Tank
Screw, 5/16-18 x 3/4 Truss
Nut, 5/16-18 Hex Flange
Nut, M8--1.25 Hex Flange
Radiator Support
Frame, Lower ROPS and Platform
See 15.1, 16.1 and 17.1
Standard
Optional
Optional
3.94 Bolt Circle
Used on 4139806G03, Obtain Locally
See 5.1
Includes License Illuminator Lens
See 13.1

59
TURF TRUCKSTER
Serial No. All
13.1 Frame, Lower ROPS and Platform
7
16
3
9
17
25
7
22 24
9
17
B
15
6
19
A
14
13
12
8
C
10
Gas Engine and

Transmission Mounts
B
7
11
D
23
5
4
21
7
20
13
7
19
7
7
12
7
9
10
9
18
6
4
5
11
5
60
TURF TRUCKSTER
Item
1
1
2
3
3
4
5
6
7
8
9
10
11
12
12
13
13
14
15
16
17
18
19
19
20
21
22
23
24
25
Part No.
Qty.
893235.7
893235G
893145.7
893199.7
893199-G02
893525G01
452406
452398
450454
450455
452410
309067
452405
893581
894998.7
893582
2701697.7
842870G01
844647G01
452403
452402
2703294.7
843568
845206.7
452389
450453
4139924
2701693.7
452378
450452
1
1
1
1
2
4
8
20
8
12
2
5
1
1
1
1
2
1
4
6
1
1
1
4
4
1
1
2
2
Description
Frame, Main 4 Wheel
Standard Frame, Painted Black
Frame, Galvanized Main 4 Wheel

ROPS, Lower
Platform, Truckster
Platform, Galvanized Truckster
Support, Platform
Lockwasher, 1/2 Shakeproof
Mount, Left Side Diesel Engine
Mount, Left Side Gas Engine
Mount, Right Side Diesel Engine
Mount, Right Side Gas Engine
Angle, Support
Angle, Hold Down
Guard, Hydraulic Tank
Transmission Mount
Transmission Mount
Nut, M8-1.25 Flange
Bracket, Fuel System
Optional Galvanized Frame

Standard Platform, Painted Black
Optional Galvanized Platform
Grade 8.8
Grade 8.8
Diesel Units
Gas Units
Diesel Units
Gas Units
Diesel Units
Gas Units
Diesel Units
Gas Units

61
TURF TRUCKSTER
Serial No. All
14.1 Rear Axle
15
20
12
19
13
14
12
17
7
16
9
5
6
13
14
16
19
17
18
8
24
11
23
21 / 22
23
25
3
2
10
62
TURF TRUCKSTER
Item
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
21
22
22
23
24
25
25
25
Part No.
Qty.
Description
893491
11.16:1 Rear Differential Assembly
Diesel Units, See 39.1
894509
800198
809180
893862
843238
893613
813850
829044
548061
800909
2701174
2218140-01
841434
886735
311398
800602
843876
843238
807332
823621
825500
800294
311396
894272.7
2701321.7
895112.7
548482
894433
895126
826284
826285
894432
894192
895125
1
1
1
2
2
2
2
4
8
10
2
1
1
1
6
6
4
2
2
4
4
4
2
1
1
1
3
1
1
2
1
1
1
1
14.21:1 Rear Differential Assembly

Locknut, 1/2-20
Flat Washer, 1/2
Spring, Leaf
Bushing, Nylatron
Upstop
Bumper, Travel Limiting
U-Bolt, 2 x 5-1/4
Nut, 7/16-14
Nut, M12-1.5 Wheel Lug
Wheel and Tire Assembly
Tire. 6 Ply
Rim, 12 x 10.50
Stem, Valve
Nut, 1/2-13 Nylon Insert
Shackle, Rear Spring
Bushing, Nylatron
Shock Absorber
Bushing
Washer, 7/16 Cupped
Locknut, 7/16-14 Center
Driveshaft, Complete
Plug, Expansion
Shaft, Drive
Shaft, Drive
Cross and Bearing Kit
Yoke, Differential
Yoke, Transmission
Yoke, Transmission
Yoke, Transmission
Gas Units, See 39.1
Diesel Engine
Gas Engine, MT
Gas Engine, AT
Diesel Engine
Gas Engines
Includes Grease Fitting
Diesel Engine
Gas Engine, MT
Gas Engine, AT

63
TURF TRUCKSTER
Serial No. All
15.1 Front Control Arms
13
10
9
20
19
2
6
7
19
24
27
26
8
28
20
11
12
25
28
17
15
27
16
25
19
20
10
4
9
13
19
26
5
14
18
19
19
20
6
17
16
11
12
1
23
22
21
21
19
22
15
22
20
19
3
22
20
14
18
64
TURF TRUCKSTER
Item
Part No.
Qty.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
36106G01
Frame, 4 Wheel Steering
893266
893233
893234
844148
N/S
N/S
N/S
N/S
548079
306839
460030
471221
841429
N/S
800861
460030
548224
841167
450382
450077
450393
894573
894574
841630
800945
2
1
1
2
1
1
4
4
4
1
1
1
2
1
1
1
1
8
8
4
8
1
1
2
2
Upper Control Arm

Left Side Lower Control Arm
Right Side Lower Control Arm
Upper Ball Joint
Boot
Boot Retainer
Lockwasher, 5/16
Nut, 5/16-24 Hex
Nut, 5/8-18 Slotted Hex
Cotter Pin, 1/8 x 1-1/4
Grease Fitting, 1/4-28 90
Lower Ball Joint
Boot
Grease Fitting, 1/4-28 Straight
Bushing, Silentbloc
Nut, M16-2 Locking Insert
Bolt, M16-2 x 90 mm Hex Head
Washer, M16
Knuckle, Left Side Steering
Knuckle, Right Side Steering
Trunnion, Control Arm
Bolt, M12-1.75 x 60 mm Hex Head
27
841738
AR
Shim, .024 Thick
28
841737
AR
Shim, .060 Thick
Black Oxide Finish, Grade 8

Black Oxide Finish
Black Oxide Finish
Special Drive Thread
Grade 8.8
Grade 10.9
Add or remove shims as required to
adjust CASTER angle.
adjust CAMBER angle.

65
TURF TRUCKSTER
Serial No. All
16.1 Steering Linkage
4
5
A
7
2
12
15
6
16
9
17
8
10
20
11
12
16
17
18
19
13
14
B
17
21
10
16
20
6
11
15
21
7
18
14
19
13
17
23
66
22
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Part No.
Qty.
Description
841255
Steering Gear
305134
308008
841336
894635
452413
450455
311392
303269
889681
816586
306825
889682
816586
306825
304636
831405
841404
800485
302944
813850
842033
452408
1
1
1
2
4
4
3
3
2
1
1
2
1
1
4
4
2
2
2
2
1
6
Nut, 7/8-14 Hex Jam

Lockwasher, 7/8
Arm, Pitman
Strut Assembly
Screw, M12-1.75 x 60 mm Hex Head
Lockwasher, 7/16
End, Left Hand Thread Tie Rod
Retainer, Grease
Nut, 7/16-20 Castle
End, Right Hand Thread Tie Rod
Retainer, Grease
Nut, 7/16-20 Castle
Grease Fitting
Tie Rod
Nut, 9/16-18 Left Hand Thread Jam
Nut, 9/16-18 Right Hand Thread Jam
Bumper, Travel Limiting
Plate, Skid
Screw, M10-1.75 x 20 mm
Grade 10.9
Grade 10.9

67
TURF TRUCKSTER
Serial No. All
17.1 Front Brakes
11
10
Hose Clamp Location

3
6
7
24
26
20 22
25
18
14
15
19
17
21
16
A
14
18
23
14
13
22
20
26
19
25
12
21
25
25
7
6
14
3
1
2
5
68
8
9
10
11
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Part No.
Qty.
2702257.7
808088
814474
800908
385174
815403
817928
2702247
304636
817250
841430
893585
894930
894931
894932
894933
894935
893586
894930
894931
894932
894934
894936
452398
841842
843418
452692
841841
2703081
842104
840452
809137
2702217
841839
810437
452378
1
1
4
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
10
1
1
1
2
2
2
2
2
1
1
4
2
Description
Front Hub
Outer Bearing Cup
Inner Bearing Cup
Bolt, M12-1.5 x 42 mm Wheel
Outer Bearing Cone
Inner Bearing Cone
Seal, Grease
Nut, 3/4-16 Castle
Cap, Grease
Brake Drum
Front Left Side Brake Assembly
Kit, Brake Cylinder
Kit, Brake Cylinder Repair
Kit, Brake Shoe
Kit, Left Side Spring
Kit, Left Side Adjuster Repair
Front Right Side Brake Assembly
Kit, Brake Cylinder
Kit, Brake Shoe
Kit, Right Side Spring
Kit, Right Side Adjuster Repair
Tee, M10-1.0 Flare Union
Clamp, Tee
Hose, Brake
Protector, Brake Hose
Bracket, Brake Tube
Clip, Brake Hose Retaining
Tube, Left Front Brake
Tube, Right Front Brake
Clamp, Hose
Screw, M6-1.0 x 20mm Hex Flange
Replacement of Cylinder
Repair of Cylinder
Includes Left and Right sides
Repair of Cylinder
Grade 8.8

69
TURF TRUCKSTER
Serial No. All
18.1 Steering Column
12
13
11
3
2
10
8
Lower
ROPS
7
6
1
23 / 24
6
7
22
21
4
5
Power Steering Hose Routing

18
25
14
19
15
16
26
15
17
20
70
TURF TRUCKSTER
Item
Part No.
Qty.
Description
893571
Tube, Steering Mount
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
800930
306799
450453
893344
887259
828590
808060
819923
2700453
892228
450457
892486
839862
843767
111838
843768
111838
840222
830930
450739
800943
809092
320107
823549
4
4
4
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
2
1
1
2
3
4

Lockwasher, 5/16 External Tooth
Nut, M8-1.25 Flange
Shaft, Steering
Bearing Assembly
Housing, Bearing
Bearing, Needle
Collar, Foam
Cover, Steering Tube
Steering Wheel
Nut, M16-2 Flange
Cover, Steering Wheel
Decal, Steering Wheel
Hose, Power Steering Pressure
O-Ring
Hose, Power Steering Return
O-Ring
Hose, Formed
Clamp, Hose
Screw, M10-1.5 x 30 mm Socket
Clamp, Tube
Cable Tie, 7-1/2
Cable Tie, 15-1/2
25
839328
Power Steering Pump with Reservior
26
2700573
REF
1
1
Cap, Steering Reservior

Gear, Steering
1
2
3
4
5
Secure hoses together

Secure Hoses to Frame
See 24.1 or 25.1 for mounting. Service parts for pump are available at
most automotive parts centers.
Refer to 1991-1992 Buick Regal
with a 3.8 liter V6 Engine. (Saginaw
Pump # 26025515)
See 16.1

71
TURF TRUCKSTER
19.1 Diesel Radiator
40
11
16
20
12
5
13
15
18
39
10
3
17
14
2
7
19
26
23
27
6
21
24
22
31
21
33
30
30
29
28
23
32
30
37
25
34
36
31
30
21
30
6
35
8
38
72
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Part No.
Qty.
Description
843862
AR
Tube, 1/4 I.D. Clear Vinyl
10 Foot Length, Cut to 8
835805
300646
306396
308090
450452
450541
452378
600991
600992
601591
601592
601595
601596
800177
831846
833440
833512
889050
893554
450453
450454
452388
452395
452398
452406
601585
800146
2700867
820889
11391G7
36092G01
4139196
2703281
844391
894348
17680-50F70
825884
840754
009034880
601586
601572
AR
2
2
2
7
4
7
1
1
1
1
1
1
4
4
1
2
1
1
3
2
2
1
2
2
1
1
1
6
2
1
1
1
1
1
1
3
1
1
1
1
Hose, Radiator Overflow

Lockwasher, 1/4
Flat Washer, 1/4
Fan, 13 Hi-Perf Puller
Panel, Shroud
Frame, Radiator
Radiator
Plate, Blockoff
Shroud, 13 Fan
Screw, 5/16-18 x 3/4
Nut, Isolation
Cap, Overflow Bottle
Seal, Radiator Foam
Overflow Bottle
Screen, Right Side
Box, Air
Screw, #10 x 3/4 Thread Cutting
Relay, 12V 70A
Clamp, Hose
Clamp, Hose
Hose, 2 x 16 High Temp Air
Hose, Upper Radiator
Hose, Upper
Hose, Lower Radiator
Tube, Fan Switch
Switch, Fan
Clamp, Hose
Decal, Radiator Pressure Warning
Decal, Fan Warning
Harness, Fan Wiring
Harness, Perkins Engine Wiring
Not Shown, See 50.1

Not Shown, See 50.1

73
TURF TRUCKSTER
20.1 Gas Radiator
38
11
16
20
12
15
18
5 4
3
10
13
7
17
1
39
31
2
32
31
19
8
6
23
21
24
21
33
30
30
25
34
30
35
74
36
14
26
33
29
37
27
28
22
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Part No.
Qty.
Description
843296
AR
Tube, 1/4 I.D. Clear Vinyl
835805
300646
306396
308090
450452
450541
452378
4115033
4115029.7
893388
894590
889049
833433
833442
888549
845224
800177
831846
833440
833512
889050
893554
450453
843857
452388
452395
452398
4120076
4120079
4116997
2701513
820889
825358
36092-G01
825624
2701639
4115400
841230
28825-G01
009034880
840754
AR
2
2
2
7
4
7
1
1
1
1
1
1
1
1
1
4
4
1
2
1
1
3
1
2
1
2
1
1
1
1
4
2
1
2
1
1
1
2
1
1
Hose, Radiator Overflow

Lockwasher, 1/4
Flat Washer, 1/4
Fan, 13 Radiator
Panel, Shroud
Frame, Radiator
Radiator
Cap, Radiator
Plug, Drain
O-RIng
Connector, Hose
Cap, 1/4 x 1
Screw, 5/16-18 x 3/4
Nut, Isolation
Cap, Overflow Bottle
Seal, Radiator Foam
Overflow Bottle
Screen, Right Side
Sender, Temperature
Cap, Water Thermostat
Thermostat
Housing, Temperature Sender
Gasket, Thermostat
Clamp, Hose
Clamp, Hose
Hose, 2 x 16 High Temp Air
Clamp, 1/4 to 5/8 Worm Drive
Hose, Upper
Hose, Lower Radiator
Connector, 1/8 NPT 3/8 Hose
Decal, Fan Warning
Decal, Radiator Pressure Warning
10 Foot Length, Cut to 8

75
TURF TRUCKSTER
21.1 Diesel Engine and Transmission Mounting
15
25
17
21
38
19
18
26
13
14
30
18
22
23
31
32
21
11
24
16
12
34
1
35
4
5
37
36
28
33
12
29
39
27
40
10
4
20
5
10
2
6
12
3
7
8
9
11
7
8
76
11
9
11
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part No.
Qty.
REF
894580
REF
306836
306981
841885
809174
120177
306562
452388
450453
452389
600985
893182
840352
842915
601587
452390
450412
800571
2703835.8
11391G7
2701430
11741-85200
01550-08163
11710-77100
08310-00103
09103-08132
843323
452401
28825-G01
306325
103867
01117-G02
01117-G01
842961
844198
548849
REF
600989
843857
1
1
2
4
2
2
4
2
4
14
13
1
1
1
1
1
2
2
1
1
2
1
1
4
1
1
2
1
2
2
2
2
1
1
2
1
2
1
1
1
Description
Engine and Clutch
Frame, Engine Mount
Mount, Engine
Flat Washer, 3/8
Mount, Engine Isolation
Washer, Isolator
Lockwasher, 3/8
Nut, 3/8-16 Hex
Nut, M8-1.25 Flange
Hose, Intake
Air Filter
Element, Air Filter
Bracket, Air FIlter
Bracket, Air FIlter Mount
Lockwasher, M10
Nut, M10-1.25 Hex
Bracket, Muffler
Clamp, Hose
Transmission, Suzuki MT5
Support, Transmission
Screw
Bracket, Rear Mount
Nut
Bolt, #1 M8 x 100 mm
Adapter, Transmission
Lockwasher, 5/16
Flat Washer, 5/16
Sleeve, Alignment
Cover, Starter Hole
Mount, Transmission
Adapter
Temp Sender
See 24.1
See 12.1, Left shown, right similar
Includes Clutch Disc and Cover
See 12.1

77
TURF TRUCKSTER
22.1 Gas Engine and MT Mounting
28
19
27
20
24
18
21
22
23
30
17
14
21
7
10
16
5
13
10
3
12
15
7
6
13
28
28
25
29
29
78
26
11
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Part No.
Qty.
Description
REF
Engine Assembly
See 25.1
4138963
11311-67H00
2702548
4117900
2702547
2702688
2702687
2702686
2702690
2702893
2702470
2702689
842915
452389
450453
4118027
840352
36116G01
4140617
4140618
825358
4118423
4118422
832033
REF
REF
REF
452405
450454
1
1
1
1
6
2
1
1
2
1
2
2
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
3
3
Manual Transmission
Plate, Clutch Housing
Clutch Disc
Pressure Plate
Screw, M8-1.25 x 16 mm Lockwasher
Stud, M10-1.25 x 65 mm
Alignment Pins
Starter, Manual Transmission
Bracket, Air Filter
Air Filter
Element, AIr Filter
Hose, Engine Air Intake
Grommet
Sensor, Air Temp
Clamp, 2-3/4 Worm Drive
Elbow, 1/4 NPT Street
Hose Fitting, 1/4 NPT Brass
Clamp, 5/8 to 1 Worm Drive
Left Engine Mount
Right Engine Mount
Transmission Mount
Screw, M10--1.5 x 80 mm Flange
See...
See 12.1
See 12.1
See 12.1

79
TURF TRUCKSTER
23.1 Gas Engine and AT Mounting
27
29
12
11
28
8
19
20
24
18
21
22
23
10
10
32
17
14
30
21
16
31
4
13
5
3
15
13
28
28
25
29
80
29
26
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Part No.
Qty.
Description
REF
Engine Assembly
See 25.1
4138668
11311-67H20
2702701
4120097
2702702
2702688
2702686
2702756
2702690
2702906
2702470
2702689
842915
452389
450453
4118027
840352
36116G01
4140617
4140618
825358
4118423
4118422
832033
REF
REF
REF
452405
450454
4120098
4120096
4119955
1
1
1
1
6
2
1
1
2
1
2
2
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
3
3
1
1
6
Plate, Transmission Housing
Torque Converter
Plate, Drive
Screw, M8-1.25 x 9.5 mm Flange
Stud, M10-1.25 x 65 mm
Alignment Pins
Starter, Automatic Transmission
Bracket, Air Filter
Air Filter
Element, AIr Filter
Hose, Engine Air Intake
Grommet
Sensor, Air Temp
Elbow, 1/4 NPT Street
Hose Fitting, 1/4 NPT Brass
Left Engine Mount
Right Engine Mount
Transmission Mount
Screw, M10--1.5 x 80 mm Flange
Plate, Rear Drive
Flange, Drive Plate
Screw, M10-1.25 x 18.5 mm
See...
See 12.1
See 12.1
See 12.1

81
TURF TRUCKSTER
24.1 Diesel Engine and Clutch
15
11
21
19
13
22
23
8
16
18
12
14
36
17
20
35
15
23
14
37
14
15
31
24
30
38
27
29
28
4
31
1
10
25
9
8
6
5
27
7
26
34
33
82
32
32
23
TURF TRUCKSTER
Item
Part No.
Qty.
N/S
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
842553
185086321
843760
844272
838440
120166
REF
800073
306981
120177
306562
REF
844268
452395
452388
450453
893633
844270
844271
600981
311213
548804
306416
306325
452390
452394
842996
306835
894645
22400-85141
22100-85200
839752
09111-08035
841966
600997
103867
600993
REF
821893
1
1
1
1
8
8
1
1
2
2
2
1
1
2
5
7
1
1
1
1
1
1
1
3
3
2
1
1
1
1
1
3
2
1
1
1
1
1
AR
Description
Engine, Perkins Model 403C-11
Engine Oil Filter
Starter
Bracket, Hydraulic Pump
Mount, Right Side Engine
Lockwasher, 1/2
Pump, Hydraulic
Carriage Bolt, 3/8-16 x 1-1/4
Flat Washer, 3/8
Lockwasher, 3/8
Nut, 3/8-16 Hex
Pump, Power Steering
Bracket, Rear Power Steering Mount
Nut, M8-1.25 Flange
Alternator
Bracket, Front Alternator Mount
Bracket, Rear Alternator Mount
Bracket, Alternator Adjusting
Screw, 3/8-16 x 3 Flange
Nut, 3/8-16 Flange
Lockwasher, 5/16
Pulley, 4
Ring, Pressure Plate
Disc, Clutch
Cover, Clutch
Dowel Pin, 8 x 18 mm
Screw, M8-1.25 Special
Belt, Hydraulic Pump
Belt, Alternator - Power Steering
Flat Washer, 3/8
Pulley, 5.8 Power Steering
Throttle Bracket
Trim, Push On
Spec HH70581U
Order directly from Perkins
See 35.1
See 18.1
Included with Transmission

48
Indicates hardware included with Engine.

83
TURF TRUCKSTER
25.1 Suzuki Gas Engine
28
32
29
39
26
25
38
2
27
35
28
36
34
37
6
24
4
22
5
23
40
41
10
8
17
18
19
31
30
12
13
32
11
20
17
19
17 18
31
15
25
14
16
21
84
33
32
TURF TRUCKSTER
Item
Part No.
Qty.
Description
N/S
Suzuki K6 Engine
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
2701908
4120026
4120017
01550-10253
11710-65H01
2701827
2702469
4119603
601599
2702249
4115000
306450
306325
103867
842996
REF
13437G5
306981
120177
306562
302600
600994
4115406
450179
450452
4115183.7
452381
4117464
452389
4117459
REF
452395
450453
600993
4115404
4115792.7
833715
832033
845224
825624
306396
308090
1
1
1
3
1
4
4
1
1
1
1
2
2
2
1
1
1
3
2
2
1
1
1
1
1
1
1
1
2
1
1
2
3
1
1
1
1
1
4
4
1
1
Oil Filter
Belt, Water Pump and Alternator
Right Side Engine Mount
Bolt, RIght Side Engine Mount
Left Side Engine Mount
Bolt, Left Side Engine Mount
Bolt
Bolt, M8 x 25 mm Hex Flange
Bracket, Governor
Key, Woodruff 1/8 x 1/2
Governor
Lockwasher, 5/16
Flat Washer, 5/16
Pulley, 4-1/4 Diameter
Pump, Hydraulic
Screw, 3/8-16 x 1-1/2 Whizlock
Flat Washer, 3/8
Lockwasher, 3/8
Nut, 3/8-16 Hex
Pulley, 4-3/4 Diameter
Belt, 7/16 x 54-1/4 V
Bolt, M6-1 x 60 mm Hex Head
Bracket, Power Steering Pump
Spacer, 7/16 x 1-3/32
Spacer, 7/16 x 11/32
Pump, Power Steering
Pulley, 5.80 Diameter
Belt, 7/16 x 25 V
Bracket, Air Cleaner
Plug, Tube
Plug, Tube
Clamp, 1/4 to 5/8 Worm Drive
Lockwasher, 1/4
Flat Washer, 1/4
See ... through ... for Service
See ...
Includes two set screws

See 35.1
Includes two set screws

Hydraulic Pump and Governor
See 18.1
Alternator and Power Steering

85
TURF TRUCKSTER
26.1 Engine Speed Control
1
2
12
13
11
9
Part of
Engine
15
10
16
17
7
14
6
5
3
4
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part No.
Qty.
Description
2703683
Throttle Cable
See 4.1 for other end of cable
844130
894591
844274
835271
130728
840473
812444
103867
821164
842785
800271
120052
111898
831888
831889
831890
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Cable, Governor Control

Bracket, Throttle
Lever, Governor
Nut, 1/4-20 Lever Pivot
Nut, 1/4-20 Hex Jam
Spring, Governor Lever
Flat Washer, 5/16
Hair Pin
Spring, Idle Return
Lockwasher, #10
Clamp, Cable
Swivel
Washer, Swivel
Screw, Swivel Throttle Cable
See 4.1 for other end of cable

See 24.1 for Mounting Location

86
TURF TRUCKSTER
27.1 Exhaust
13
3
11
2
11
Tailpipe outlet to be parallel to ground.
12
10
10
5
9
6
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Qty.
Description
4119866.8
2703800.8
314990013
452389
838295.8
450193
450378
REF
841982
N/S
N/S
N/S
103867
REF
1 Tube, Exhaust Inlet

1 Gasket, Exhaust
4 Screw, M8-1.25 x 25 mm Flange
1 Strap, Muffler Hanger
2 Screw, M8-1.25 x 30 mm Hex Head
2 Locknut, M8-1.25
1 Bracket, Muffler
2 Clamp, 1-1/2 Exhaust
1 U-Bolt
1 Bracket
2 Nut, 5/16-18 Hex
2 Flat Washer, 5/16
1 Cover, Starter Hole
Muffler
Order directly from Perkins
See 21.1
See 21.1

87
TURF TRUCKSTER
28.1 Governor Linkage
29
31
10
20
30
22 3
26
32
35
41
20
19
28
A
33
25
17
11
12
18
16
15
24
34
35
21
36
22
14
23
35
8
11
39
2
37
12
3
4
38
27
13
1
6
22
A
88
25
7
5
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part No.
Qty.
Description
4115258
Plate, Governor
450010
306396
308090
4119526
452381
2700522
2700540
2700859
01116-G01
830140
306981
450454
2701129
835271
130728
2700335
2700334
111893
2702244
800024
306375
2703684
450399
821164
818395
302288
306372
4116159
2701510
843013
800927
REF
831586
306320
4117352
810722
806703
103867
306325
2
2
4
2
1
1
1
1
1
2
5
1
1
1
3
1
1
1
2
1
3
1
1
2
1
1
1
1
1
1
1
2
1
3
1
1
1
1
1
Screw, M6-1 x 75 mm Hex Head

Lockwasher, 1/4
Flat Washer, 1/4
Spacer, 7/16 x 2-1/8
Spacer, 7/16 x 1
Lever, Governor
Lever, Governor Arm
Ball Bearing
Flat Washer, 3/8
Arm, Throttle
Nut, Governor
Nut, 1/4-20 Hex Jam
Spring, Governor
Spring, Governor
Screw, #10-32 Special
Nut, #10-32 Hex
Screw, 1/4-20 x 1-1/2 Truss Head
Nut, 1/4-20 Hex
Throttle Cable
Flat Washer, M6
Hair Pin, 1/4 x 1-1/8
Screw, 1/4-20 x 1
Cable, Throttle
Bracket, Throttle Cable
Pulley, Governor
Shoulder Bolt, 1/4-20 x 5/8
Bolt
Ball Joint
Nut, 5/16-24 Hex
Rod, Governor
Yoke
Flat Washer, 5/16
Lockwasher, 5/16 Special
See 4.1
Part of Engine

89
TURF TRUCKSTER
29.1 Governor
33
29
35
41
31
42
40
43
39
38
34
29
32
37
30
36
B
15
22
15
23
13
6
5
20
19
1
14
28
A
24 / 25
27
12
26
7
17
21
18
16
90
11
9
10
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Part No.
Qty.
Description
4115000
Governor
111812
111814
111816
111817
112840
130728
111813
160410
302288
306396
306506
306915
603102
548325
800227
800558
833056
833102
835271
843537
4114867
894471
833103
4119678
4117681
833104
833345
2700525
306396
894435
894434
843866
302288
00414-G5
308090
833101
111898
120052
306514
844130
817104
800024
306375
1
1
1
1
1
1
1
2
2
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
2
1
1
1
1
1
1
Washer, Thrust
Washer, Thrust
Spool, Governor
Bearing, Thrust
Nut, 1/4-20 Hex Jam
Seal, Shaft
Carrier & Weights
Lockwasher, 1/4
Lockwasher, #6
Screw, #6-32 x 5/16 Machine
Roll Pin, 1/8 x 3/4
Ring, Retaining
Plug, 1/8 NPT
Set Screw, 3/8-16 x 5/16
Gasket, Governor
Seal, Oil
Nut, Governor Arm
Bracket, Governor Knee
Head, Governor
Reservior, Governor
Bearing, Needle
Shaft, Governor Complete
Shaft, Governor
Ring, Retaining
Bearing, Ball
Lever, Governor Control
Lockwasher, 1/4
Bracket, Throttle
Arm
Bushing, Governor
Screw, Hex Head
Flat Washer, 1/4
Spring, Extension
Clamp, Cable
Lockwasher, #6
Screw, #10-32 x 1/2 Truss
Governor Cable
Stop, Wire
Screw, 1/4-20 x 1-1/2
Nut, 1/4-20 Hex
Yoke, Spool
See 4.1

91
TURF TRUCKSTER
30.1 Gas Engine Remote Oil Fill
12
8
2
9
3
11
10
6
7
13
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Part No.
Qty.
1
2
Description
601942
Brace, Governor
548827
601580
843420
843399
836206
2701636
2701640
800934
800425
306396
16920-83G00
REF
4
1
1
1
2
1
1
3
2
2
1
1
Screw, 1/4-20 x 1/2 Hex Flange

Bracket, Remote Oil Fill
O-Ring
Adapter, Valve Cover
Hose, Remote Oil Fill
Adapter, Oil Cap
Screw, M6-1 x 12 mm Hex Head
Lockwasher, 1/4
Cap, Oil FIll
Bracket, Governor
Included with Engine

See 25.1

92
TURF TRUCKSTER
Serial No. All
31.1 Gas Engine Exhaust
7
8
Tailpipe outlet to be parallel to ground.
11
1
10
2
12
16
9
3
15
14
13
17
20
19
18
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Qty.
Description
4116284.8
36072-G01
2700144
2700145
838295.8
450193
450378
4114221.8
841982
N/S
N/S
N/S
2700143
4121517.8
306450
306325
103867
4121525.8
306419
306396
815680
1 Catalytic Converter
2 Bolt, Muffler Flange
2 Spring, Muffler Flange
1 Strap, Muffler Hanger
2 Screw, M8-1.25 x 30 mm Hex Head
2 Locknut, M8-1.25
1 Bracket, Muffler
2 Clamp, 1-1/2 Exhaust
1 U-Bolt
1 Bracket
2 Nut, 5/16-18 Hex
1 Ring, Muffler Flange
1 Shield, Muffler
4 Screw, 5/16-18 x 3/4 Hex Head
4 Lockwasher, 5/16
4 Flat Washer, 5/16
1 Shield, Catalytic Converter
2 Screw, 1/4-20 x 1/2 Hex Head
2 Lockwasher, 1/4
2 Washer, Special
Muffler
Attaches to Transmission Case

93
TURF TRUCKSTER
32.1 Diesel Fuel System
34
35
20
36
37
21
2
C
15
29
28
24
23
27
30
6 10
22
25
B
2
12
2
13
11
26
16
14
18
4
17
2
13
2
19
32
31
2 9
5
A
16
2
B
C
33
38
94
TURF TRUCKSTER
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
826590
825624
826590
826590
826590
831039
834036
830425
REF
2208175
130306380
894638
452393
450453
838154
829997
809231
452390
REF
841969
843726
148231
48310
836852
843343
843298
829954
833953
800021
120052
829787
REF
894201
REF
893555
834005
103867
800221
Qty.
1
Description
Hose, Fuel Tank to Trap 5/16
12 Clamp, Hose
1 Hose, Pre Filter to Pump 5/16
1 Hose, Pump to Fuel Filter 5/16
1 Hose, Fuel Filter to Engine 5/16
1 Hose, Engine Fuel Return 3/16
1 Connector, 1/4 Hose to 3/16 Hose
1 Hose, Fuel Return 1/4
1 Engine
1 Fuel Filter
1 Trap, Fuel Water
1 Pump, Electric Fuel
3 Nut, M8-1.25 Flange
1 Bracket, Fuel Pump Mounting
1 Grommet
2 Grommet, Split
1 Bracket, Fuel System
1 Fuel Tank
1 Tube, Fuel Pick Up
1 Elbow, 90 Fuel
2 Grommet, Fuel Tank
1 Breather
1 Cap, Unvented Fuel
1 Sender, Fuel Level
1 Gasket, Fuel Tank
1 Cover, Fuel Sender
5 Screw, #10-32 x 1/2 Pan Head
5 Lockwasher, #10
2 Terminal, 1/4 Male
1 Bracket, Air Filter Mount
1 Harness, Fuel Sender
1 Support, Tank
1 Strap, Tank
1 Seal, Foam
1 Flat Washer, 5/16
1 Locknut, 5/16-18 Center
25 Foot Roll, Cut to 13-1/2
25 Foot Roll, Cut to 14
Order Directly from Perkins
See 13.1
See 21.1
See 12.1

95
TURF TRUCKSTER
33.1 Gas Fuel System
40
4
41
20
42
43
21
18
13
C
29
28
32
16
8
24
23
27
33
34
22
2
2
2
7
1
11
36
8
26
34
8
37
8
8
44
19
6
31
45
36
C
39
96
15
17
35
30
25
14
10
38
12
38
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Part No.
Qty.
Description
826590
Hose, Fuel Tank to Adapter 5/16
11391G4
7332
826590
830425
830425
4113019
18292G1
2701897
2701898
2701899
452378
450452
800930
450453
800875
309067
REF
841969
843726
148231
48310
836852
843343
843298
829954
833953
800021
120052
829787
894201
829997
4113018
830425
826590
825264
831039
2700166
REF
893555
834005
103867
800221
4115904
7301
8
1
1
1
1
1
8
1
1
1
2
2
2
2
1
1
1
1
1
1
2
1
1
1
1
1
5
5
2
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
Clamp, Hose
Hose, Adapter to Pump 7/16
Hose, Pump to Fuel Filter 5/16
Hose, Fuel Filter to Tee 1/4
Hose, Tee to Engine 1/4
Adapter, 5/16 to 7/16 Hose
Clamp, Hose
Pump, Electric Fuel
Fuel Filter
Regulator, Fuel
Nut, M12-1.25 Hex
Fuel Tank
Tube, Fuel Pick Up
Elbow, 90 Fuel
Grommet, Fuel Tank
Breather
Cap, Unvented Fuel
Sender, Fuel Level
Gasket, Fuel Tank
Cover, Fuel Sender
Lockwasher, #10
Terminal, 1/4 Male
Harness, Fuel Sender
Grommet
Adapter,, 5/16 to 1/4 Hose
Hose, Adapter to Regulator 1/4
Hose, Tank Return to Adapter
Clamp, Hose
Hose, Regulator to Vacuum Port
Clamp, Filter
Support, Tank
Strap, Tank
Seal, Foam
Flat Washer, 5/16
Locknut, 5/16-18 Center
Adapter, 1/4 Tee
Flex Guard
Cut to 3
See 13.1

See 12.1
Cut to 5
97
TURF TRUCKSTER
Serial No. All
34.1 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
10
LIFT
VALVE
TRUCKSTER
CYLINDER
19
9
8
20
5
3
FILTER
HYD
PUMP
21
SELECTOR
VALVE
HYDRAULIC
TANK
PRESSURE
RETURN
SUCTION
PRESSURE & RETURN
ACCESSORY
CYLINDER
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
FOR MOTOR DRIVEN ACCESSORY AND INOPERABLE

TRUCKSTER CYLINDER
PLUG 1-2. 3-4. 8-9. 7-10
FOR ACCESSORY CYLINDER OPERATION

PLUG 1-5. 2-6. 4-3. 7-8
20
21
23
13
15
22
13 / 15
12 / 14
7
16
6
18
17
5
8
10
9
5
11
98
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Part No.
Qty.
894675
452388
450453
452399
800113
893539
827486
829800
844601
452389
844729
2700800
837270
2700801
840857
800930
REF
548827
2701107.7
300646
308090
800279
821893
2
2
2
2
1
1
1
1
1
AR
1
1
1
1
4
1
2
1
4
4
4
1
Description
Tank, Hydraulic
Plug, 1/2 NPT
Dipstick, Hydraulic Tank
Valve, Pressure Relief
Battery, 12 Volt
Bracket, Battery Clamp
Spacer, Battery Clamp
Hydraulic Cover
Decal, Hydraulic Connections
Hydraulic Cover, EC
Decal, Hydraulic Connections
Hydraulic Filter
Screw, 1/4-20 x 1/2 Hex Flange
Panel, Access
Screw, 1/4-20 x 3/4 Truss
Flat Washer, 1/4
Nut, 1/4-20 Speed
Trim, Push On
Add as required to secure battery

Used on 84044 Only

99
TURF TRUCKSTER
Serial No. All
35.1 Hydraulic Pump and Filter
9
14
13
29
12
13
17
16
15
7
11
22
20
24
21
19
26
23
18
8
5
25
6
27
2
3
2
28
2
1
100
10
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part No.
Qty.
Description
844564
Hose, Tank to Filter
836206
844583
844566
844628
844652
844600
844571
835101
840877
844584
894702
832414
894701
452381
844973
450452
844600
844627
844630
844590
894691
885249
523768
844565
REF
REF
888042
306560
887017
844937
320107
4
1
1
1
1
1
1
2
1
1
1
2
1
2
2
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
2
Clamp, Hose
Fitting, 90
Fitting, Straight
Hose, Pump to Selector Valve
Fitting, 9/16-18 x 3/4-16 Straight
Hose, Selector Valve to Coupler
Fitting, 9/16-18 x 3/4-16 90
Fitting, 3/8 NPT 90
Sleeve, Nylon
Bushing, Flip Lock
Coupler Half, Dry Seal Male
Ring, Rataining
Coupler Half, Dry Seal Female
Bushing
Hose, Coupler to Filter
Fitting, 3/4-16 Tee
Hose, Control Valve to Filter
Fitting, 3/4-16 x 1-1/16-12 Straight
Head, FIlter
Filter Element
Fitting, 90
Hose, Filter to Tank
Control Valve
Selector Valve
Pump, Hydraulic
Key, Woodruff #5
Seal Kit
Plate, Coupler Retainer
Tie, 7-1/2 Cable
See 35.1
See 35.1
Not Shown, Secures Nylon Sleeve

101
TURF TRUCKSTER
Serial No. All
36.1 Lift Cylinder Circuit
18
19
3
2
17
13
14
12
6
11
5
7
13
14
5
14
7
4
Lift Cylinder Mounting
15
15
16
21
10
102
22
20
TURF TRUCKSTER
Item
Part No.
Qty.
882993
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
883236
884574
886001
830810
809265
821893
817320
452378
450452
826558
844019
841892
844584
840877
832408
832414
832409
835101
832900
823119
840877
844598
REF
REF
320107
1
1
1
2
4
AR
2
2
2
1
1
1
1
1
2
4
2
2
2
1
1
1
1
1
4
Description
Cylinder, Dump Box

Seal Kit
Seal Kit
Seal Kit
Pin, Clevis
Hair Pin
Trim, Push On
Clamp, Hose
Fitting, 9/16-18 90
Hose, Selector Valve to Control Valve
Hose, Control Valve to Coupler
Bushing, Flip Lock
Sleeve, Nylon
Coupler Half, Male
Ring, Retaining
Coupler Half, Female
Fitting, 3/8 NPT 90
Hose, Lift Cylinder to Coupler
Fitting, 1/4 NPT
Sleeve, Nylon
Hose, Control Valve to Coupler
Control Valve
Selector Valve
Tie, 7-1/2 Cable
Texas Hydraulics
Columbus Hydraulics
DANA Hydraulics
Control Valve Port B
Control Vale Port A

See 35.1
See 35.1
Not Shown, Secures Nylon Sleeve

103
TURF TRUCKSTER
37.1 Diesel Electrical Components
9
5
11
Item 8 Routing
10
5
5
12
1
2
Engine Harness
Ground Wires
21
23
22
5
4
14
18
13
20
15
16
17
24
13
8
7
6
104
19
TURF TRUCKSTER
Item
Part No.
Qty.
Description
450452
4
5
6
7
8
9
10
452378
2701465
120052
132520
306325
306932
844167
800943
886425
800934
894266
843942
4116941
2
1
2
2
2
2
1
15
1
3
1
1
1
11
890000
Buzzer, High Temperature
Located inside front clip, behind

dash panel
12
13
14
15
16
17
18
19
20
21
22
23
24
831225
306419
306488
828231
548175
894596
884513
306325
450324
892811
450453
452388
841895
3
2
1
1
1
1
1
1
1
1
1
1
1
Clamp, Wire Harness

Insulator
Flat Washer, 1/4
Positive Battery Cable
Negative Battery Cable
Lockwasher, 5/16
Nut, M8-1.25 Hex
Cable, Ground
Cover, Positive Battery Terminal
Battery to Transmission
1
2
3

Solenoid, Starter
Lockwasher, #10
Nut, #10-32 Hex
Lockwasher, 5/16
Nut, 5/16-18 Hex
Bracket, Horn, Brake Fluid Reservior
Screw, #10-16 x 3/4 Thread Cutting
Horn
Harness, Main
Socket, 12V Accessory Plug
Panel, Instrument with Tachometer
See 49.1
Transmission to Right Frame Rail

105
TURF TRUCKSTER
38.1 Gas Electrical Components
9
5
11
Item 8 Routing
10
5
5
12
2
29
2
28
1
1
30
Engine Harness
Ground Wires
21
23
5
13
Black
14
Wires
15
8
16
4
22
8
7
13
1
13
14
Red
15
Wires
13 16
19
18
20
7
25
6
26
5
106
27
24
17
TURF TRUCKSTER
Item
Part No.
Qty.
Description
450452
4
5
6
7
8
9
10
452378
2701465
120052
132520
306325
306932
844167
800943
886425
800934
4115709
843942
4116941
5
1
2
2
2
2
1
15
1
3
1
1
1
11
890000
Buzzer, High Temperature
12
13
14
15
16
17
17
18
19
20
21
22
23
24
25
26
27
28
28
29
30
31
831225
306419
306488
828231
548175
894596
2701502
884513
306325
450324
892811
450453
452388
841895
2700867
843167
4116017
4140994
4140995
2700993-G01
450544
4116018
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
Clamp, Wire Harness

Insulator
Flat Washer, 1/4
Negative Battery Cable
Lockwasher, 5/16
Nut, M8-1.25 Hex
Cable, Ground
Cover, Positive Battery Terminal
Relay, EFI 12 V 70A SP
Relay, 12V 15A DPST
Harness, Generator
Controller, EFI Engine
Controller, EFI Engine
Cover, Engine Controller
Screw, M61 x 30 mm Pan Head
Harness, Temp Sender
1
2
3

Solenoid, Starter
Lockwasher, #10
Nut, #10-32 Hex
Lockwasher, 5/16
Nut, 5/16-18 Hex
Bracket, Horn, Brake Fluid Reservior
Screw, #10-16 x 3/4 Thread Cutting
Horn
Harness, Main
Socket, 12V Accessory Plug
Panel, Instrument with Tachometer
See 49.1
Located inside front clip, behind

dash panel
Manual Transmission
Battery to Transmission
Transmission to Right Frame Rail
Manual Transmission
Not Shown

107
TURF TRUCKSTER
39.1 Differential Assembly
Serial No. All
Part Number 894509 (14.21:1 Differntial)

Part Number 893591 (11.16:1 Differential)
8
4
2
10
3
6
11
11
108
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
Part No.
Qty.
Description
894509
893491
1
1
Differential Assembly
14.21:1 Differential
891829
See 40.1
N/S
N/S
N/S
112050
841842
832584
841844
841838
841837
893583
1
1
1
1
1
1
1
1
1
2
Axle Tubes and Shafts

Input, Main and Jack Shaft
Front and Shift Cover
Screw, 1/4-20 x 5/8 Self Tap
Fitting, Hydraulic Brake Tee
Clamp, Tee Fitting
Hose, Brake
Tube, Left Side Brake
Tube, Right Side Brake
Cable, Parking Brake
Differential Housing
See 41.1
See 43.1
See 42.1

109
TURF TRUCKSTER
Serial No. All
40.1 Differential Housing

Part Number 891829
29
30
26
31
32
8
28
33
34
31
27
30
29
34
33
32
1
2
7
18
17
16 15
10
14
13
9
35
5
21
20
22
11
19
23
24
25
110
12
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Part No.
Qty.
891829
N/S
306829
103867
111074
111758
306322
306982
517226
800718
836443
2702146
814476
836680
836688
836689
836690
836691
836692
836685
836686
836687
836677
836678
889870
N/S
N/S
N/S
800717
836675
836676
836681
836682
836693
836694
839948
2
4
8
1
10
9
4
2
1
1
1
1
1
AR
AR
AR
AR
1
AR
AR
AR
1
1
1
1
1
1
10
2
2
AR
AR
AR
AR
1
Description
Differential Housing
Bearing Caps
Flat Washer, 5/16
Plug, Drain
Stud, 3/8-16 & 3/8-24 x 1-23/32
Flat Washer, 7/16
Bushing
Nut, 3/4-16 Hex Lock
Rear Cover
Spacer, 14.21:1 Differential
Cup, Bearing (2-17/32 O.D.)
Cone, Bearing (1-1/8 I.D.)
Shim, .003 Thick
Shim, .005 Thick
Shim, .010 Thick
Shim, .030 Thick
Baffle, Oil
Shim, .003 Thick
Shim, .005 Thick
Shim, .010 Thick
Cup, Bearing (2.84 O.D.)
Cone Bearing (1-3/8 I.D.)
Gear Set
Pinion Gear and Shaft
Ring Gear
Differential Carrier
Cup, Bearing (2.89 O.D.)
Cone, Bearing, (1-5/8 I.D.)
Shim, .003 Thick
Shim, .005 Thick
Shim, .010 Thick
Shim, .030 Thick
Tag, 14.21:1 Ratio
Used on 14.21:1 Differential Only

adjust gear backlash



111
TURF TRUCKSTER
Serial No. All
41.1 Axle Tubes and Shafts

11
10
26
24
25
22
21
19
18
20
23
16
15
14
B
B
8
2
13
12
28
27
1
27
28
14
15
12
16
13
20
A
19
3
21
22
24
17
23
25
26
112
5 6
TURF TRUCKSTER
Item
Part No.
Qty.
Description
894509
1
2
3
4
893491
2702535.7
2702534.7
2700530
2700514
845356
800743
304636
2700531
2700515
845356
800743
304636
836694
2703481
836426
838539
836695
893581
894930
894931
894932
894933
894935
893582
894930
894931
894932
894934
894936
893519
838539
2703309
844813
800944
2701408
800908
841430
306405
805387
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
4
8
2
5
2
10
10
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Tube, Right Side Axle

Tube, Left Side Axle
Left Side Axle Assembly
Shaft, Left Side Axle
Washer
Right Side Axle Assembly
Shaft, Right Side Axle
Washer
Seal, 1-3/4 I.D. O-Ring
Seal, 2 I.D. O-Ring
Collar, Axle Bearing
Seal, Oil
Bearing, Tapered Roller
Left Side Brake Assembly
Kit, Brake Cylinder
Kit, Brake Shoe
Kit, Left Side Spring
Kit, Left Side Adjuster Repair
Right Side Brake Assembly
Kit, Brake Cylinder
Kit, Brake Shoe
Kit, Right Side Spring
Kit, Right Side Adjuster Repair
Retainer , Complete
Seal, Oil
Washer, Hardened
Ring, Backing
Screw, M10-1.5 x 25 mm
Hub, Rear Wheel
Bolt, Wheel
Drum, Brake
Washer, 3/8
Locknut, 3/8-24 Special
Includes Parking Brake Lever

Repair of Cylinder
Includes Parking Brake Lever

Repair of Cylinder

113
TURF TRUCKSTER
42.1 Front and Shifter Cover
Serial No. All
14.21:1 Differential (894509)

22
11 / 12
21
18
20
19
13
23
3
15
17
14
16
8
6
4
5
7 9
1
2
114
10
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Part No.
Qty.
836431
306322
103867
307776
810437
810435
836841
836852
111074
836959
889780
889925
N/S
836658
831099
548937
836657
836662
807366
2700493
548204
306423
306435
12
14
3
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
Description
Cover, Front
Flat Washer, 5/16
Clamp, 1/2 P
Clamp
Bracket, Shift Cable
Breather
Plug, Fill
Bracket, Brake Tee Mounting
Shift Cover Assembly
Cover
Bushing
Shaft, Shift
Seal, Oil
Lockwasher, 7/16
Fork, Shift
Bushing, Guide
Button, Positioning
Spring
Set Screw, 3/8-16 x 3/8
14.21:1 Differential Only

Right Side Brake Tube

115
TURF TRUCKSTER
43.1 Input, Main and Jack Shafts
Serial No. All

27
12
13
11
10
17
22
14
15
18
20
19
16
21
26
8
9
24
1
24
25
4
5
2
6
116
23
25
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
16
17
18
19
19
20
21
22
23
24
25
26
26
27
Part No.
Qty.
836421
836693
809254
800695
800737
837020
812325
836422
812009
836429
844956
894886
812006
811993
844951
844952
844953
845034
548952
836420
842359
836440
800559
891089
548201
894519
844087
811992
842360
836441
837198
3
1
1
2
1
1
1
1
1
1
1
1
1
AR
AR
AR
1
1
1
1
1
1
1
1
1
2
3
1
1
1
Description
Shaft, Input
Bearing, Ball
Ring, External Retaining
Ring, External Retaining
Ring, Internal Retaining
Baffle, Vent
Seal, Oil
Shaft, Main
Bearing, Ball
Collar, Engaging
Bearing, Bronze Thrust
Gear, Driven
Bushing
Bearing, Thrust
Shim, .003 Thick
Shim, .005 Thick
Shim, .010 Thick
Collar, Thrust
Lockring
Spacer, Pinion
Pinion, 15 Tooth
Pinion, 18 Tooth
Nut, 1/2-20 Crown Lock
Jackshaft
Set Screw, 5/16-18 x 5/16
Cluster Gear
Bushing
Shim, CLuster Gear
Gear, 52 Tooth
Gear, 49 Tooth
Baffle, Oil Scoop

adjust gear backlash.



117
TURF TRUCKSTER
Serial No. 84043 - All
44.1 Transmission Clutch Release-Shift Selector

Diesel Engine Only
5
4
3
9
7
6
11
10
7
12
13
14
15
17
14
16
118
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part No.
Qty.
Description
REF
Transmission Case
See 45.1
REF
845223
2702659
01550-08553
844228
548222
2702684
11741-85200
2702475
37610-80023
09280-11002
23260-85203
09300-14017
09448-20007
23265-85200
09205-03019
1
1
3
1
1
2
1
1
4
1
1
1
2
1
1
1
Shift Assembly
Gasket, Shift Case
Stop, 5th Gear Lockout
Set Screw, #8-32
Plug, Drain
Support, Transmission
Screw
Switch, Backup Light
O-Ring
Shaft, Clutch Release
Bushing, Clutch Release
Spring, Clutch Release
Bearing, Clutch Release
Roll Pin
See 47.1

119
TURF TRUCKSTER
45.1 Transmission Case

Diesel Engine Only
37
3
38
5
24
4
6
26
25
39
14
11
23
35
31
32
27
17
29
30
15
16
19
36
2
20
18
13
12
10
120
21
34
28
22
33
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Part No.
Qty.
Description
24700-85200
Case, Transmission
2702690
09103-08131
2702470
2702659
2702471
24741-83001
09103-08152
09380-28007
09262-28019
24131-83002
09262-28020
24671-83000
REF
09283-25088
09390-68002
09390-62010
24560-83001
24551-83010
09261-06003
2702586
09103-08132
01550-08353
2702659
01421-08303
2703002
2702690
24770-85252
26131-85201
29431-85400
09282-08001
09280-19001
09280-21014
843754
09128-06032
09166-16014
28391-85202
2702662
24780-83010
2
4
3
1
2
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
3
5
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Pin, Alignment
Screw, M8-1.25 Flange
Retainer, Input Shaft Bearing
Cir CLip
Bearing, Front
Counter Shaft
Bearing, Center
Gear, Countershaft Reverse
Input and Main Shaft
Seal, Oil
C-Ring
C-Ring
Gear, Reverse Idle
Shaft, Reverse Idle Gear
Pin
Cir Clip
Screw, M8-1.25 Flange
Stud, M8-1.25
Pin, Alignment
Case, Extension
Gear, Speedometer Driven
Case, Seepometer Gear
Seal, Oil
O-Ring
O-Ring
Plug
Bolt, Retaining
Washer
Bracket, Shift Cables
Plug, Inspection Timing
Seal, Extension Case
Upper and Lower Half
See 46.1

121
TURF TRUCKSTER
46.1 Input and Main Shaft
10
9
8
7
6
7
8
4
2
12
3
11
20
18
19
16
15
14
6
14
28
15
24
16
17
13
28
4
25
27
26
18
18
19
21
22
21
122
23
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Part No.
Qty.
Description
24110-80410
Shaft, Input
2702561
4141037
09380-28007
24410-83000
24471-60A00
24442-81A20
24432-83001
24230-83001
09263-30031
24121-85252
06111-06003
24400-83000
24436-83000
24441-85F41
24431-83001
24220-60A01
09263-35015
09300-30003
24211-83011
09166-30007
09262-30086
24420-83000
24473-70D10
2703581
24681-83000
26121-85202
2702559
1
1
3
1
6
2
3
1
1
1
2
1
2
2
2
1
3
2
1
2
1
1
3
1
1
1
2
Bearing, Needle
Bearing, Input Shaft Ball
Cir Clip
High Speed Syncroniser
Key, Syncronizer
Spring, High Speed Syncronizer
Ring, Syncronizer
Gear, Main Shaft 3rd
Bearing, Needle
Shaft, Main
Ball
Low Speed Syncronizer
Spring, Low Speed Syncronizer
Spring, Low Speed
Ring, Low Speed Syncronizer
Gear, Main Shaft 2nd
Bearing, Needle
Bushing
Gear, Main Shaft Low
Washer
Bearing, Ball
Syncronizer, Reverse Drive
Key, Syncronizer
Spring, Reverse Syncronizer
Gear, Main Shaft Reverse
Gear, Speedometer Drive
Cir Clip
4th Gear
Includes Hub and Sleeve
3rd Gear
2nd Gear
1st Gear
Reverse Gear

123
TURF TRUCKSTER
47.1 Gear Shift Fork Linkage
31
30
29
28
27
20
21
22
23
13
33
12
14
32
24
26
B
C
25
D
15
16
17
11
A
5
4
8 10
1
10
3
10
B
4
4
C
A
9
124
18
19
TURF TRUCKSTER
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part No.
Qty.
Description
25411-85201
Shaft, Low Speed Fork
1st and 2nd Gear
25420-85201
25451-85261
06111-12004
25415-83000
09261-03017
25211-85201
25221-85202
25221-83002
09205-05012
09250-10006
25121-85051
25520-85203
09284-17004
25576-70D00
09160-17035
25541-85201
25545-85055
25546-60C01
09128-10002
09168-10007
25547-70D00
09135-08005
2701953
25530-79501
09286-09001
25535-85412
09162-08008
2702883
2702494
25536-84200
09135-08005
24821-09001
1
1
5
3
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Shaft, High Speed Fork

Shaft, Reverse Fork
Ball
Spring, Detent
Roller
Fork, Low Gear Shift
Fork, High Gear Shift
Fork, Reverse Gear Shift
Pin, 4 x 25 mm Spring
Plug, Locating
Case, Gear Shift Lever
Shaft. Grear Shift Lever
Seal, Oil
Spring
Washer, 17 x 32 x 1.2 mm
Lever, Gear Select
Dog, Reverse Shift Limit
Spring
Bolt, M10 x 9 mm Retaining
Gasket
Spring
Ball
Pin
Shaft, Gear Select
Seal, Oil
Arm, Gear Select
Washer
Washer
Nut, M8-1.25 Hex
Boot, Gear Select
Bolt, Retaining
Plug, Breather
3rd and 4th Gear

Reverse
1st and 2nd Gear

3rd and 4th Gear
Reverse

125
TURF TRUCKSTER
48.1 Diesel Engine Electrical Schematic
Automatic
Transmission
Controller
Gn
Heater
Accessory
Ye
Bk
Gn
20 A
Bk
Ye
Accessory
Connector 1
Ye/Rd
Accessory
Connector 2
Ye/Rd
Accessory
Connector 3
Rd
Accessory
Connector 4
Rd
10 A
Clutch
Switch
Ye/Rd
Bk
10 A
Pk
Wh/Gn
Wh/Gn
A
Bk
Pk
Pk
10 A
Bk
Gn
Rd
ACC - B + A
OFF - None
ON - B +A+I
Start - B+I+S
Ignition
Switch
B
Rd
Bk
Bk
Bk
Wh/Bu
Bk
Power
Point
Brake Fluid
Level Switch
1
Tachometer
Gas Tach Input
Brake Fluid Level
Wh/Bn
Bn
Rd/Bk
Voltmeter
Pk/Bu
Left Turn
13
Gn/Bk
14
Wh/Rd
Right Turn
15
Ye/Bk
- 12 V
16
Bk
17
Wh/Bu
18
Gn
Diesel Tach Input
Overheat
Alarm
+ 12 V
Dash
Panel
126
Bk
12
Main Harness to
Engine Harness
Connector 2
Og
Parking Brake
Fuel Guage
Main Harness to
Engine Harness
Connector 1
Rd
Og
Wh
Fuel Sender
Gn
Wh
11
Pk
Wh/Og
10
Rd/Bk
High Beam
Oil Pressure
Wh/Ye
Wh/Ye
Wh/Rd
Temp Gauge
Rd
Wh/Bk
Bk
Bk
Pre-Heat
Wh/Bk
Rd/Bk
Pk/Bu
Overheat
Alarm
Main Harness to
Engine Harness
Connector 3
TURF TRUCKSTER
Tail
Light
Bn
Bn
Bn
Bk
Bk
Bk
Og
Bu/Bk
Bu/Bk
Rd/Bk
Rd/Bk
Single
Tail Light
Harness
Brake
Light
Horn
Horn
Button
Bk
Cab Stop
Light
Accessory
Bk
Bk
Rd
Og/Bk
Bk
Brake
Accessory
Connector 1
Wh/Rd
Bk
Brake
Accessory
Connector 2
Og/Bk
Bn
Brake
Pedal
Switch
15 A
Wh/Rd
10 A
Wh/Og
Jumper
Plug
Og/Bk
Wh/Og
Rd
10 A
Bu/Bk
Ye
Wh/Bu
Flasher
(Turn Signal
Accessory)
Rd/Bk
Ye
Ye/Rd
Og
Gn/Bk
Main Harness to
Engine Harness
Connector 4
(Gas Units)
Gn/Bk
Left Turn
Signal Light
Accessory
Og
Ye/Rd
Og/Bk
Wh/Bn
15 A
Og
Ye/Bk
Bu
Bn
Left Headlight
Low Beam
Bu
Turn Signal
Accessory
Wh/Bu
Bk
Wh
Gn/Bk
Wh
Bn
High Beam
Bk
Low Beam
Bu
Bk
Right Turn
Signal Light
Accessory
Ye/Bk
Bk
Ye/Bk
Wh
High Beam
Right Headlight
Wh/Og
127
Rd
Rd/Bk
Bk
25 A
B S
Wh/Rd
Fan
Switch
Ye
Starter
Rd
Ye
Wh/Bk
Rd
Rd
Rd
Wh/Gn
EXC
Fan
Relay
Bk
Bk
Bk
Rd
Rd
Rd
Rd
Gn
Pk
Rd
Wh/Gn
40 A
Wh/Rd
Rd
Rd
Wh/Rd
Ye
Starter
Solenoid
Alternator
Wh/Bk
Gn
Rd
Bk
Pre-Heat
Relay
Bk
Diode
Wh/Gn
Rd
Gn
Wh/Gn
Wh/Bk
Ye
Wh/Gn
Wh/Gn
Wh/Gn
Pk/Bu
Fuel
Pump
Diode
Diode
Pk/Bu
Parking Brake
Switch
Bk
Wh/Bk
Wh/Bk
Bu
Ye
Main Harness
Connector 2
Wh/Rd
Main Harness
Connector 1
Temp
Sender
Rd/Bk
Bk
Glow
Plugs
Fuel
Sender
Bk
Bk
Og
Main Harness
Connector 3
Pk
Bn
Wh/Ye
Wh/Ye
Ye
Wh
40 A
Rd
128
Og
Rd
Fan
Motor
Gn
Gn
Gn
85
87
Wh
Bk
Fuel
Solenoid
Fuel
Shutoff
Relay
86
30
87A Bu
Oil Pressure
Switch
Wh
TURF TRUCKSTER
Gn
129
TURF TRUCKSTER
Serial No. All
49.1 Diesel Engine Main Harness

Part Number 894266
1
Engine Harness
Connector #2
Engine Harness
Connector #1
5
Flasher
(Option)
Tail Light Harness

Connector
Brake Accessory
(Option)
Turn Signal
(Option)
Cab Stop Light

(Option)
Jumper Plug
Engine Harness Connector

(Gas Only)
Engine Harness
Connector #3
Brake Pedal
Switch
Ignition Switch
Horn Button
11
12 V Accessory
Plug
Light Switch
Clutch Pedal
Switch
Buzzer
10
Right Headlight
Dash Panel
Right Turn Signal

(Option)
11
Left Headlight
Ground
Wires
Left Turn Signal

(Option)
Brake Accessory
(Option)
4
Heater
(Option)
Optional
Accessories
4
4
(Not Used)
Horn
14
Brake Fluid
Reservoir
13
130
15
30
Fuse Block #2
10
15
15
15
10
Fuse Block #1
10
16
12
15
TURF TRUCKSTER
Item
Part No.
1
3
4
5
6
7
8
10
11
12
13
14
15
16
16
16
Qty.
825973
825886
825961
829630
825748
825878
826726
825886
826005
825748
825878
825894
825899
825877
825748
825878
826006
825886
837296
825748
825878
843598
825748
825878
843550
843551
837301
825899
828629
825996
825997
825998
825999
836892
842983
826000
AR
AR
2
AR
AR
1
AR
13
AR
AR
1
AR
1
AR
AR
2
AR
1
AR
AR
1
AR
AR
1
AR
2
AR
AR
1
4
6
2
5
2
1
Description
Serial Number / Notes
Connecter, Six Male Terminal

Terminal, 1/4 Male 14-16 Gauge
Terminal, 1/4 Male 10 Gauge
Connector, Four Female Terminal
Terminal, 1/4 Female 14-16 Gauge
Terminal, 1/4 Female 10 Gauge
Connector, One Female Terminal
Connector, Two Female Terminal
Connector, Flasher
Connector, Six Female Terminal
Connector, Two Male Terminal
Connector, Ignition Switch
Connector, Rocker Switch
Connector, Eighteen Terminal
Terminal
Connector, Headlight
Fuse Holder
Fuse Clip, 1 Term., 14-16 Gauge
Fuse Clip, 1 Term, 10 Gauge
Fuse Clip, 3 Term. 14-16 Gauge
Fuse, 10 Amp
Fuse, 15 Amp
Fuse, 20 Amp
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
One Wire
Two Wire

131
TURF TRUCKSTER
Serial No. All
50.1 Diesel Engine and Fan Harness

Part Numbers 601572 & 601586
Starter
Ground Wires
Parking Brake
Glow Plug
Starter
Solenoid
7
Fuel Solenoid
3
Diode
Connectors
Diodes
Engine Harness
Connector #2
Engine Harness
Connector #3
6
Fuel Shutoff
Relay
Engine Harness
Connector #1
Fuel
Pump
Fuel Level
Sender
4
10
12
Fan Harness
Fan Relay
Fuse
13
Pre-Heat
Relay
14
17
16
10
Fan
Motor
Fan
Relay
11
Glow Plug
Fuse
18
Fan Motor
Fuse
19
Engine Oil
Pressure
Fan
Switch
Temperature
Sender
Ground
Alternator
132
Starter
Solenoid
15
TURF TRUCKSTER
Item
Part No.
1
2
3
4
5
6
7
10
11
12
13
14
15
16
17
18
19
Qty.
Description
601572
Engine Harness
825877
825748
825878
829630
825961
884398
826005
825748
825878
843168
842966
843167
4129717
4129730
4129733
4129747
2700868
842966
2700869
842959
833257
838463
826584
825997
825998
836536
4113261
2700867
AR
AR
1
AR
3
6
AR
AR
1
AR
1
2
AR
AR
AR
1
AR
AR
1
2
2
2
AR
AR
1
1
1
Terminal, 1/4 Fem. 14-16 Gauge

Terminal, 1/4 Fem. 10 Gauge
Connector, Four Male Terminal
Diode Connector Assembly
Terminal, 1/4 Fem. 10 Gauge
Connector, Relay
Terminal, Female Relay
Relay, 12V 15 Amp DPST
Plug, 2 Wire Deutsch
Socket, 16-18 Gauge Solid
Wedge, 2 Wire Deutsch
Gasket, 2 Wire Deutsch
Connector, 70 Amp Relay
Terminal, 3/8 Female Relay
Connector, 2 Contact
Terminal, 3/32 Female
Seal, Wire
Block, Single Fuse
Fuse, 40 Amp
Fuse, 25 Amp
Relay, 12V, 70 Amp SPST
601586
826006
825886
826005
825748
2700868
842966
N/S
2700867
826584
825997
836536
1
1
AR
1
AR
1
AR
AR
1
2
AR
1
Fan Harness
Relay, 12V, 70 Amp SPST
Block, Single Fuse
Fuse, 40 Amp

Single Wire
Two Wire
Two Wire
Single Wire
Two Wire

133
TURF TRUCKSTER
51.1 Gas Engine Electrical Schematic
Bn/Ye
Gn/Wh
1
2
Bk/Rd
Bk/Rd
Wh/Rd
Wh/Rd
Pk/Gn
Pk/Gn
5
6
7
8
Pk
Wh
Rd/Wh
Bk/Gn
Gn/Wh
Bk
Gn/Wh
Bl/Wh
10
11
12
ECU
13
Timing
Plug
Bn
Bk
Rd/Wh
Diagnostic
Plug
Bl/Wh
Bk/Wh
14
Bk/Wh
15
16
Og
Og
Shifter Switch
(Automatic
Transmission)
17
18
19
20
Gn/Pk
Og/Bu
Og/Gn
Gn/Pk
Og/Gn
Bn
Rd
Bk
Og/Bu
Gn/Bl
Gn
Gn
Gn/Bu
21
22
23
24
25
26
Rd
Pk
C
Bn/Ye
Wh
Bk/Gn
Bk/Rd
Rd
Pk
Wh/Bu
Wh/Pk
Pk
Rd
1
2
3
4
5
Engine
Harness
Connector 1
Wh/Ye
Bu
Bu/Rd
Bu/Rd
6
7
8
Bu/Wh
Bu/Bk
9
10
11
12
134
Bk/Wh
Bk/Wh
Bu/Wh
Bu/Bk
Shift Solenoid
(Automatic
Transmission)
Wh/Ye
Bk/Rd
Bu
Gn/Wh
Gn/Wh
TURF TRUCKSTER
Gn/Bk
Bk/Wh
Shifter
Light
Rd/Ye
Bu
25 A
Bk/Wh
Bk/Wh
Bk/Wh
Rd/Bk
Wh/Rd
15 A
Bn/Ye
Bn/Ye
Gn/Wh
Gn/Wh
Rd/Og
10 A
Gn/Bk
10 A
Fan
Motor
Bk/Rd
Wh/Rd
Pk/Gn
Fan
Relay
Bu
Ye
Pk/Gn
Bk/Rd
Ye
Bk
Bk/Rd
Bk/Rd
Fuel
Relay
Pk/Bu
Pk/Bu
Pk
Bk/Wh
Fuel
Pump
Bk
Rd
Wh/Pk
Wh/Rd
Main
Relay
Pk
Bk/Rd
Bk/Gn
Wh/Rd
Wh
Bk/Wh
Og
Og
Wh/Rd
Speedometer
Signal
Bk/Rd
Og
Bk
Speed
Sensor
Pk
Wh
Bk/Gn
Bk/Rd
Wh/Pk
Pk
Rd
Bk/Wh
Reverse Switch
Bn/Ye
Rd
Rd
Backup Alarm
Bk
Wh/Ye
Wh/Ye
Bu
Bu
Gn/Wh
Gn/Wh
135
TURF TRUCKSTER
Gn/Bk
Bk/Wh
Bk/Wh
Bk/Wh
Bk/Wh
Bk/Wh
Bk/Wh
Gn
20 A
Ye
10 A
Clutch Switch
Ye/Rd
10 A
Accessory Accessory Accessory Accessory Accessory

Connector 1 Connector 2 Connector 3 Connector 4 Connector 5
Ignition
Switch
Wh/Og
Pk
Wh/Pk
Gn/Bk
10 A
Wh/Gn
Rd
Bk
Rd
Bk
Ye/Rd
Bk
Ye/Rd
Bk
Ye
Bk
Pk/Bu
Wh/Gn
Pk/Bu
Rd
Gn
Ye/Rd
ACC - B + A
OFF - None
ON - B +A+I
Start - B+I+S
Rd
B
Rd
Bn
Wh/Pk
Pk
Rd
Wh
Wh
Engine
Harness
Connector 2
Tachometer
Gas Tach Input
Brake Fluid Level
2
3
Bn
Rd/Bk
Starter
Solenoid
Rd
Brake Fluid
Level Switch
Rd/Bk
Rd
Wh/Rd
Bk
Wh/Og
Wh/Rd
Bk
B S
Voltmeter
Pre-Heat
Gn/Wh
7
8
Wh/Ye
High Beam
Wh/Og
Oil Pressure
Temp Gauge
10
Bu
Fuel Sender
11
Og
Parking Brake
12
Pk/Bu
Left Turn
13
Gn/Bk
Tach Input
14
Wh/Rd
Right Turn
15
Ye/Bk
- 12 V
16
Bk
Starter
Bk
Og
Fuel Guage
Overheat
Alarm
+ 12 V
17
Wh/Bu
18
Bk/Wh
Dash
Panel
Fuel
Sender
Gn/Bk
Ye/Bk
Wh/Bu
Coolant
Overheat
Alarm
Bk
Pk/Bu
Parking Brake
Switch
Wh/Ye
Bu
Gn/Wh
136
Wh/Og
TURF TRUCKSTER
Tail
Light
Bn
Bn
Bn
Bk
Bk
Bk
Og
Brake
Light
Bu/Bk
Bu/Bk
Rd/Bk
Rd/Bk
Single
Tail Light
Harness
Bk
Cab Stop
Light
Accessory
Horn
Horn
Button
Bk
Bk
Rd
Og/Bk
Bk
Brake
Accessory
Connector 1
Wh/Rd
Bk
Brake
Accessory
Connector 2
Og/Bk
Bn
Bn
Rd
Rd
Power
Point
Wh
Rd
Rd
Bk/Ye
Brake
Pedal
Switch
15 A
Wh/Rd
10 A
Turn Signal Jumper

Accessory
Plug
Og/Bk
Wh/Og
Wh/Og
Rd
10 A
Wh
Bu/Bk
Ye
Og
Ye/Bk
Flasher
(Turn Signal
Accessory)
Wh/Bu
15 A
Ye
Rd/Bk
Ye/Rd
Ye/Rd
Og/Bk
Og
Og
Gn/Bk
Bu
Bn
Left Headlight
Low Beam
Gn/Bk
Ye/Bk
Bu
Wh/Bu
Bk
Left Turn
Signal Light
Accessory
Wh
Gn/Bk
Wh
Bn
High Beam
Bk
Low Beam
Bu
Bk
Right Turn
Signal Light
Accessory
Wh/Og
Ye/Bk
Bk
Wh
High Beam
Right Headlight
Wh/Og
137
TURF TRUCKSTER
52.1 Gas Engine Schematic
1
2
Br/Bk
Br/Bk
Bn/Wh
Bn/Wh
Gy
Gy
3
4
5
6
Og/Gn
7
8
9
10
11
12
13
14
15
16
17
Wh/Gn
Bk/Bu
Bn
Bn
Rd/Bu
Rd/Bu
Rd
Rd
Rd/Ye
Rd/Ye
Rd/Pk
Rd/Pk
Wh
Wh
Bn/Rd
Bn/Rd
Bk
18
19
20
ECU
21
Wh/Rd
Wh/Rd
Wh
Wh
Wh/Bk
Wh/Bk
22
23
24
Bu/Ye
Gn
Bu/Ye
Gn/Ye
Ignition Resistor
Rd/Bu
Rd/Bu
25
26
27
28
29
30
31
32
Gn/Ye
Gn/Rd
Bu/Ye
Bu/Bk
Bu/Wh
Gn/Bk
Bu/Rd
Manifold
Temperature
Gn/Rd
Bu/Ye
Pressure Sensor
Gn/Bk
Gn/Rd
Gy/Ye
Gy/Ye
Gn/Wh
Bu/Ye
Throttle Sensor
33
34
Bu/Ye
Bu/Ye
Pk
1
2
3
4
5
Engine
Harness
Connector 1
8
9
10
11
12
Engine
Harness
Connector 2
138
Temperature
Sender
Pk
Oil Pressure
Sender
Ye/Bk
Bk/Wh
Bk/Wh
Bu/Rd
Ye/Wh
6
7
Ye/Bk
Ye/Wh
Bu/Wh
Manifold
Temperature
Sensor
Bu/Ye
Bk/Wh
Bu/Bk
Bk/Ye
Wh/Gn
Bk/Rd
Wh/Rd
Wh/Gn
Ye/Bk
Alt
Wh/Rd
Wh/Gn
Bk/Rd
TURF TRUCKSTER
Injector #1
Br/Bk
Bk/Rd
Br/Bk
Bn/Wh
Injector #2
Gy
Bk/Rd
Bn/Wh
Injector #3
Bk/Rd
Bn
Bn
Rd/Bu
Bk/Rd
Bk/Rd
Rd
Gy
Rd/Ye
Rd/Bu
Rd/Bu
Rd
Rd/Pk
Wh
Oxygen
Sensor
Rd/Pk
Rd/Ye
Bn/Rd
Bu/Ye
Bk/Wh
Bk/Rd
Wh
Wh/Rd
Knock
Sensor
Bk/Rd
Wh
Bk/Rd
Wh/Bk
Bu/Ye
Bu/Ye
Crank Position
Sensor
Rd/Bu
Bk/Wh
Coil
1
Coil
2
Bk/Wh
Bk/Wh
Coil
3
Bu/Ye
Bk/Wh
Bk/Rd
139
TURF TRUCKSTER
Serial No. All
53.1 Gas Main Harness

Part Number 4115709
Engine
Harness
Connector
ECU
Connector
24
Speed
Sensor
23
17
Shift
Switch
22
Parking Brake
Switch
25
Shift
Solenoid
Back-Up
Switch
Back-Up
Alarm
26
30
22
Starter
Solenoid
22 21
18
22
4
7
21
35
35
16
20
19 80
Right Headlight
20 14
Horn Button
Buzzer
Tach / Speedometer
Dash Panel
Signal
10
Light Switch
Speedometer
Tach
Signal
Signal
Ground
Wires
Jumper Plug
Clutch Pedal
Switch
11
19
20
Heater
(Option)
Optional
Accessories
14
16
140
12
15
Timing
Plug
16
Diagnostic
21
Plug
Fan
Relay 18
Main
Brake Fluid
Reservoir Fuel Relay
17
Relay
Fuse
17
Block #3
4
Shifter
Light
Horn
Fuse
Block #1
Fuse
Block #2
Brake Accessory
(Option)
Positive
Standoff
Wires
13
Turn Signal
(Option)
Flasher
(Option)
Left Turn
Signal
(Option)
Right Turn Signal

(Option)
11
12 V Accessory
Plug
Left Headlight
11
21
20 13
19
Ignition Switch
Brake Pedal
Switch
11
Transmission Ground
Wires
Cab Stop Light

(Option)
Brake Accessory
(Option)
28
B+ Starter
Radiator Fan
Tail Light Harness

Connector
29
Fuel Pump
30
22 20-1/2
Fuel Sender
27
31
32
33
TURF TRUCKSTER
Item
Part No.
1
3
4
5
6
7
8
10
11
12
13
14
15
16
16
16
16
17
18
19
20
Qty.
825973
825886
825961
829631
825748
825878
826726
825886
826005
825748
825878
825894
825889
2700913
825877
825748
825878
826006
825886
837296
825748
825878
843598
825748
825878
843550
843551
837301
825889
828629
825996
825997
825998
825999
836892
842983
826000
4113261
843168
842966
2700868
842966
2700869
826190
826191
AR
AR
1
AR
AR
2
AR
12
AR
AR
1
AR
1
1
AR
AR
3
AR
1
AR
AR
1
AR
AR
1
AR
2
AR
AR
3
12
6
2
7
3
1
1
2
8
1
2
2
AR
AR
Description
Connecter, Six Male Terminal

Connector, Four Female Terminal
Connector, One Female Terminal
Connector, Flasher
Jumper Plug, Taillight
Connector, Ignition Switch
Connector, Rocker Switch
Connector, Eighteen Terminal
Terminal
Connector, Headlight
Fuse Holder
Fuse Clip, 3 Term. 14-16 Gauge
Fuse, 10 Amp
Fuse, 15 Amp
Fuse, 20 Amp
Fuse, 25 Amp
Tubing, 3/8 I.D. Black Convoluted
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
Single Wire
Two Wire
One Wire
Two Wire
50 Foot Bulk
25 Foot Bulk
141
TURF TRUCKSTER
53.1 Gas Main Harness (Continued)
Part Number 4115709
Engine
Harness
Connector
ECU
Connector
24
Speed
Sensor
23
17
Shift
Switch
22
Parking Brake
Switch
25
Shift
Solenoid
Back-Up
Switch
Back-Up
Alarm
26
30
22
Starter
Solenoid
22 21
18
22
4
7
21
35
35
20
19 80
Right Headlight
20 14
Horn Button
Buzzer
Tach / Speedometer
Dash Panel
Signal
10
Light Switch
Speedometer
Tach
Signal
Signal
Ground
Wires
Jumper Plug
Clutch Pedal
Switch
11
19
20
Heater
(Option)
Optional
Accessories
14
16
142
12
15
Timing
Plug
16
Diagnostic
21
Plug
Fan
Relay 18
Main
Brake Fluid
Reservoir Fuel Relay
17
Relay
Fuse
17
Block #3
4
Shifter
Light
Horn
Fuse
Block #1
Fuse
Block #2
Brake Accessory
(Option)
Positive
Standoff
Wires
13
Turn Signal
(Option)
Flasher
(Option)
Left Turn
Signal
(Option)
Right Turn Signal

(Option)
11
12 V Accessory
Plug
Left Headlight
11
21
16
20 13
19
Ignition Switch
Brake Pedal
Switch
11
Transmission Ground
Wires
Cab Stop Light

(Option)
Brake Accessory
(Option)
28
B+ Starter
Radiator Fan
Tail Light Harness

Connector
29
Fuel Pump
30
22 20-1/2
Fuel Sender
27
31
32
33
TURF TRUCKSTER
Item
21
22
23
24
25
26
27
28
29
30
31
32
33
Part No.
826192
826193
4116015
833257
838463
2700933
845329
2700852
2700470
2700851
4118039
845330
833257
838463
845327
2700380
2700381
845328
2700385
2700387
2700384
2700386
839917
839921
524358
838768
838769
838770
Qty.
AR
AR
1
8
8
4
1
1
19
19
7
1
4
4
1
3
3
1
2
2
7
7
1
1
2
2
4
2
Description
Tubing, 7/16 I.D. Green Convoluted
Connector, 12 Contact Male
Terminal, Female
Seal, Wire
Plug, Cavity
Lock, 26 Contact
Terminal, Fermale
Seal, Wire
Plug, ECU Connector
Terminal, Female
Seal, Wire
Connector, 3 Contact Female
Terminal
Seal, Wire
Connector, 9 Contact Female
Terminal
Seal, Wire
Terminal
Seal, Wire
Lock, 2 Wire Deustch
Terminal, 18-20 AWG Male Pin
Lock, 4 Wire Deutsch
Terminal, 18-20 AWG Socket

25 Foot Bulk
25 Foot Bulk
143
INDEX
00414-G5.....................91
009034880.............73, 75
01116-G01...................89
01117-G01...................77
01117-G02...................77
01421-08303 .............121
01550-08163 ...............77
01550-08353 .......53, 121
01550-08553 .............119
06111-06003 .............123
06111-12004 .............125
08310-00103 ...............77
09103-08131 .............121
09103-08132 .......77, 121
09103-08152 .............121
09111-08035 ...............83
09128-06032 .............121
09128-10002 .............125
09135-08005 .............125
09160-17035 .............125
09162-08008 .............125
09166-16014 .............121
09166-30007 .............123
09168-10007 .............125
09205-03019 .............119
09205-05012 .............125
09250-10006 .............125
09261-03017 .............125
09261-06003 .............121
09262-28019 .............121
09262-28020 .............121
09262-30086 .............123
09263-30031 .............123
09263-35015 .............123
09280-11002 .............119
09280-19001 .............121
09280-21014 .............121
09282-08001 .............121
09283-25088 .............121
09284-17004 .............125
09286-09001 .............125
09300-14017 .............119
09300-30003 .............123
09380-28007 .....121, 123
09390-62010 .............121
09390-68002 .............121
09448-20007 .............119
10386747, 51, 55, 56, 77,
.... 83, 86, 87, 89,
93, . 95, 97, 111,
115
111074...............111, 115
111758.......................111
111812.........................91
111813.........................91
111814.........................91
144
111816.........................91
111817.........................91
111838.........................71
111893.........................89
111898............ 45, 86, 91
112050................ 39, 109
112840.........................91
11311-67H00 ...............79
11311-67H20 ...............81
11391G4 ......................97
11391G7 ............... 73, 77
11710-77100................77
11741-85200....... 77, 119
12005245, 86, 91, 95, 97,
......................107
120166.........................83
120177.................. 77, 83
130306380...................95
130728............ 86, 89, 91
132520.......................107
148231.................. 95, 97
160410.........................91
17680-50F70 ...............73
18292G1 ......................97
185086321...................83
2208175.......................95
22100-85200................83
2218140-01..................63
22400-85141................83
23260-85203..............119
23265-85200..............119
23266-85002................53
24110-80410..............123
24121-85252..............123
24131-83002..............121
24211-83011..............123
24220-60A01 .............123
24230-83001..............123
24400-83000..............123
24410-83000..............123
24420-83000..............123
24431-83001..............123
24432-83001..............123
24436-83000..............123
24441-85F41 .............123
24442-81A20 .............123
24471-60A00 .............123
24473-70D10 .............123
24551-83010..............121
24560-83001..............121
24671-83000..............121
24681-83000..............123
24700-85200..............121
24741-83001..............121
24770-85252..............121
24780-83010..............121
24821-09001............. 125
25121-85051............. 125
25211-85201............. 125
25221-83002............. 125
25221-85202............. 125
25411-85201............. 125
25415-83000............. 125
25420-85201............. 125
25451-85261............. 125
25520-85203............. 125
25530-79501............. 125
25535-85412............. 125
25536-84200............. 125
25541-85201............. 125
25545-85055............. 125
25546-60C01 ............ 125
25547-70D00 ............ 125
25576-70D00 ............ 125
26121-85202............. 123
26131-85201............. 121
2700143 ...................... 93
2700144 ...................... 93
2700145 ...................... 93
2700166 ...................... 97
2700334 ...................... 89
2700335 ...................... 89
2700380 .................... 143
2700381 .................... 143
2700384 .................... 143
2700385 .................... 143
2700386 .................... 143
2700387 .................... 143
2700453 ...................... 71
2700470 .................... 143
2700493 .................... 115
2700496 ................ 55, 56
2700514 .................... 113
2700515 .................... 113
2700522 ...................... 89
2700525 ...................... 91
2700530 .................... 113
2700531 .................... 113
2700540 ...................... 89
2700573 ...................... 71
2700792 ...................... 39
2700796 ...................... 47
2700797 ...................... 47
2700800 ...................... 99
2700801 ...................... 99
2700851 .................... 143
2700852 .................... 143
2700859 ...................... 89
2700867 ...... 73, 107, 133
2700868 ............ 133, 141
2700869 ............ 133, 141
2700913 .................... 141
2700933 .................... 143

2700993-G01 ............ 107
2701107.7 ................... 99
2701129 ...................... 89
2701174 ...................... 63
2701273 ...................... 55
2701274 ...................... 55
2701328 ...................... 55
2701371 ...................... 55
2701408 .................... 113
2701430 ...................... 77
2701465 ............ 105, 107
2701502 .................... 107
2701510 ...................... 89
2701513 ...................... 75
2701639 ...................... 75
2701693.7 ................... 61
2701697.7 ................... 61
2701737.7 ................... 51
2701850.7 ................... 45
2701897 ...................... 97
2701898 ...................... 97
2701899 ...................... 97
2701953 .................... 125
2702012 ...................... 45
2702014 ...................... 45
2702146 .................... 111
2702198 ...................... 39
2702199 ...................... 41
2702215 ...................... 51
2702217 ...................... 69
2702244 ................ 49, 89
2702247 ...................... 69
2702257.7 ................... 69
2702470 ........79, 81, 121
2702471 .................... 121
2702475 .................... 119
2702494 .................... 125
2702534.7 ................. 113
2702535.7 ................. 113
2702547 ...................... 79
2702548 ...................... 79
2702559 .................... 123
2702561 .................... 123
2702586 .................... 121
2702659 ............ 119, 121
2702662 .................... 121
2702684 .................... 119
2702686 ................ 79, 81
2702687 ...................... 79
2702688 ................ 79, 81
2702689 ................ 79, 81
2702690 ........79, 81, 121
2702695 ...................... 55
2702701 ...................... 81
2702702 ...................... 81
INDEX
2702756...................... 81
2702883.................... 125
2702893...................... 79
2702906...................... 81
2702996...................... 55
2703002.............. 53, 121
2703081...................... 69
2703158...................... 39
2703257.7................... 45
2703281...................... 73
2703294.7................... 61
2703309.................... 113
2703481.................... 113
2703581.................... 123
2703683...................... 86
2703684...................... 89
2703707...................... 55
2703800.8................... 87
2703835.8................... 77
2703931.7................... 55
2703951...................... 55
2703953...................... 55
2703956.7................... 55
2703964.7................... 55
28391-85202............. 121
28825-G01............ 75, 77
29165G01 ................... 45
29431-85400............. 121
300646............ 73, 75, 99
300977........................ 55
302030........................ 56
302288.................. 89, 91
302944........................ 67
303269........................ 67
303952........................ 39
304632........................ 47
304636.......... 67, 69, 113
305134........................ 67
306320........................ 89
306322.............. 111, 115
306325..... 77, 83, 89, 93,
105, ............. 107
30632841, 45, 47, 49, 51,
....................... 53
306372........................ 89
306375...... 47, 56, 89, 91
306388........................ 47
30639647, 55, 56, 73, 75,
........... 89, 91, 93
306397........................ 55
306405...................... 113
306416........................ 83
306419.. 39, 93, 105, 107
306423...................... 115
306435...................... 115
306450........................ 93
306463 .................. 39, 47

306488 ........ 39, 105, 107
306506 ........................ 91
306514 ........................ 91
306531 ........................ 45
306560 ...................... 101
306562 .................. 77, 83
306799 ........................ 71
306825 ........................ 67
306829 ...................... 111
306835 ........................ 83
306836 ........................ 77
306839 ........................ 65
306915 ........................ 91
306932 ...................... 107
306981 ............ 77, 83, 89
306982 ...................... 111
307776 ...................... 115
308008 ........................ 67
308089 ........................ 47
30809041, 55, 73, 75, 89,
................. 91, 99
308091 ........................ 55
309067 .................. 61, 97
309488 ........................ 41
311213 ........................ 83
311392 ........................ 67
311396 ........................ 63
311398 ........................ 63
311763 ........................ 55
312288 ........................ 59
314990013 .................. 87
316907 ........................ 47
320107 ..49, 71, 101, 103
36072-G01 .................. 93
36085G01 ................... 41
36091-G01 .................. 43
36092-G01 ............ 73, 75
36097-G01 .................. 43
36106G01 ................... 65
36116G01 ............. 79, 81
37610-80023 ............. 119
38061A........................ 39
385174 ........................ 69
38541 .......................... 39
4113018 ...................... 97
4113019 ...................... 97
4113261 ............ 133, 141
4114221.8 ................... 93
4114867 ...................... 91
4115000 ...................... 91
4115029.7 ................... 75
4115033 ...................... 75
4115258 ...................... 89
4115400 ...................... 75
4115709 .................... 107
4115904 ...................... 97
4116015 .................... 143
4116017 .................... 107
4116018 .................... 107
4116159 ...................... 89
4116284.8 ................... 93
4116941 .................... 107
4116997 ...................... 75
4117153.7 ................... 59
4117352 ...................... 89
4117681 ...................... 91
4117900 ...................... 79
4118027 ................ 79, 81
4118039 .................... 143
4118422 ................ 79, 81
4118423 ................ 79, 81
4119526 ...................... 89
4119634 ...................... 53
4119678 ...................... 91
4119866.8 ................... 87
4119955 ...................... 81
4120076 ...................... 75
4120079 ...................... 75
4120096 ...................... 81
4120097 ...................... 81
4120098 ...................... 81
4121517.8 ................... 93
4121525.8 ................... 93
4129717 .................... 133
4129730 .................... 133
4129733 .................... 133
4129747 .................... 133
4138668 ...................... 81
4138963 ...................... 79
4139196 ...................... 73
4139691 ...................... 39
4139806G01 ............... 59
4139806G02 ............... 59
4139806G03 ............... 59
4139924 ...................... 61
4140269 ...................... 43
4140617 ................ 79, 81
4140618 ................ 79, 81
4140994 .................... 107
4140995 .................... 107
4141037 .................... 123
450010 ........................ 89
450077 ........................ 65
450193 .................. 87, 93
450324 .............. 105, 107
450377 .................. 49, 53
450378 .................. 87, 93
450382 ........................ 65
450393 ........................ 65
450399 ........................ 89
450400 ........................ 39
450410 ..................39, 51
450412 ........................77
45045241, 45, 49, 61, 73,
75, 97, 101, 103,
107
45045341, 43, 47, 49, 51,
.... 53, 59, 61, 71,
73, ... 75, 77, 79,
81, ... 83, 95, 97,
99, .......105, 107
45045441, 47, 49, 51, 55,
.... 59, 61, 73, 79,
81, .................89
450455 ........... 43, 61, 67
450457 ........................71
450510 ........................53
450541 39, 41, 43, 73, 75
450544 ......................107
450739 ........................71
45237845, 49, 61, 69, 73,
. 75, 97, 103, 107
452381 ................89, 101
45238841, 49, 51, 53, 73,
.... 75, 77, 83, 99,
105, .............107
45238961, 77, 79, 81, 87,
........................99
452390 ........... 77, 83, 95
452391 ........................49
452393 ........................95
452394 ........................83
452395 ........... 73, 75, 83
452396 ........................47
45239841, 49, 51, 59, 61,
........... 69, 73, 75
452399 ..................59, 99
452401 ..................55, 77
452402 ........................61
452403 ........................61
452404 ........................47
452405 ........... 61, 79, 81
452406 ..................61, 73
452408 ........................67
452410 ........................61
452411 ........................43
452413 ........................67
452415 ........................59
452424 ..................51, 53
452692 ..................55, 69
452695 ..................45, 55
460030 ........................65
471221 ........................65
48310 ....................95, 97
515268 ........................45
517226 ......................111
521144 ........................47
145
INDEX
523085.........................41
523768.......................101
524358.......................143
524633.........................45
524643.........................45
548061.........................63
548079.........................65
548159.........................39
548171.........................47
548175.. 39, 55, 105, 107
548201.......................117
548204.......................115
548222.......................119
548224.........................65
548325.........................91
548482.........................63
548804.........................83
548827.........................99
548849.........................77
548910.........................59
548911...................45, 59
548937.......................115
548952.......................117
6.................................141
600981.........................83
600985.........................77
600989.........................77
600991.........................73
600992.........................73
600993.........................83
600997.........................83
601572.........................73
601585.........................73
601586.................73, 133
601587.........................77
601591.........................73
601592.........................73
601595.........................73
601596.........................73
601937.........................41
601939.........................39
601940G05..................39
603102.........................91
604174.........................55
7040.............................51
7301.............................97
7332.............................97
74765G01....................39
74767G01....................39
74793G01....................39
800021...................95, 97
800024...................89, 91
800026.........................59
800073.........................83
800113.........................99
800146.........................73
146
800177............ 59, 73, 75

800198.........................63
800221.................. 95, 97
800227.........................91
800263.........................41
800271.................. 45, 86
800279.........................99
800294.........................63
800344.........................39
800446.........................49
800485.........................67
800558.........................91
800559.......................117
800571.........................77
800582............ 45, 55, 56
800602.........................63
800695.......................117
800717.......................111
800718.......................111
800737.......................117
800743.......................113
800789.........................57
800861.........................65
800875.........................97
800908................ 69, 113
800909.................. 59, 63
800927.........................89
80093039, 43, 47, 51, 59,
........... 71, 97, 99
800934.......... 39, 51, 107
800943..... 39, 45, 51, 71,
107
800944.......................113
800945.........................65
805387.......................113
806703.................. 49, 89
806714............ 45, 51, 53
807332.........................63
807366.......................115
808060.........................71
808088.........................69
809092.........................71
809137.................. 51, 69
809152.........................49
809174.........................77
809180.........................63
809231.................. 57, 95
809254.......................117
809265.......................103
810152.................. 51, 53
810435................ 51, 115
810437................ 69, 115
810722.........................89
811992.......................117
811993.......................117
812006.......................117
812009 ...................... 117

812325 ...................... 117
812444 ........................ 86
812445 ........................ 51
813850 .................. 63, 67
814079 ........................ 47
814474 ........................ 69
814476 ...................... 111
815403 ........................ 69
815680 ........................ 93
816307 ........................ 55
816401 ........................ 41
816586 ........................ 67
817104 .................. 45, 91
817250 ........................ 69
817320 ...................... 103
817928 ........................ 69
818395 ........................ 89
819923 ........................ 71
820889 .................. 73, 75
821164 ......55, 56, 86, 89
821893 ....57, 83, 99, 103
822049 ........................ 59
822419 ........................ 47
822819 ........................ 47
823118 ........................ 47
823119 ...................... 103
823225 ........................ 47
823549 .................. 39, 71
823621 ........................ 63
825264 .................. 57, 97
825358 .................. 79, 81
825500 ........................ 63
825538 ........................ 47
825624 .................. 75, 95
825748 ...... 131, 133, 141
825866 .............. 131, 133
825877 ...... 131, 133, 141
825878 ...... 131, 133, 141
825884 ........................ 73
825886 ........ 51, 131, 141
825889 ...................... 141
825894 .............. 131, 141
825899 .............. 131, 141
825961 ...... 131, 133, 141
825973 .............. 131, 141
825996 .............. 131, 141
825997 ...... 131, 133, 141
825998 ...... 131, 133, 141
825999 .............. 131, 141
826000 .............. 131, 141
826005 ...... 131, 133, 141
826006 51, 131, 133, 141
826190 ...................... 141
826191 ...................... 141
826192 ...................... 143
826193 ...................... 143

826284 ........................ 63
826285 ........................ 63
826558 ................ 47, 103
826584 ...................... 133
826590 ............57, 95, 97
826726 .............. 131, 141
827182 ........................ 49
827486 ........................ 99
827821 ........................ 45
828049 ........................ 45
828056 ........................ 47
828057 ........................ 47
828231 .............. 105, 107
828382 ........................ 39
828590 ........................ 71
828629 .............. 131, 141
829044 ........................ 63
829099 ........................ 59
829630 .............. 131, 133
829631 ...................... 141
829787 .................. 95, 97
829800 ........................ 99
829954 .................. 95, 97
829997 .................. 95, 97
830140 ........................ 89
830366 ........................ 45
830425 .................. 95, 97
830784 .................. 41, 45
830810 ...................... 103
830930 .................. 51, 71
831039 .................. 95, 97
831099 ...................... 115
831225 .............. 105, 107
831405 ........................ 67
831586 ........................ 89
831846 .................. 73, 75
831888 ........................ 86
831889 ........................ 86
831890 ........................ 86
832033 .................. 79, 81
832408 ...................... 103
832409 ...................... 103
832414 .............. 101, 103
832584 ...................... 109
832798 ........................ 47
832900 ...................... 103
833056 ........................ 91
833101 ........................ 91
833102 ........................ 91
833103 ........................ 91
833104 ........................ 91
833257 .............. 133, 143
833273 ........................ 53
833345 ........................ 91
833433 ........................ 75
INDEX
833440.................. 73, 75
833442........................ 75
833512.................. 73, 75
833953.................. 95, 97
834005.................. 95, 97
834036........................ 95
835101.............. 101, 103
835271............ 86, 89, 91
835805.................. 73, 75
836206...................... 101
836420...................... 117
836421...................... 117
836422...................... 117
836426...................... 113
836429...................... 117
836431...................... 115
836443...................... 111
836536...................... 133
836657...................... 115
836658...................... 115
836662...................... 115
836675...................... 111
836676...................... 111
836677...................... 111
836678...................... 111
836680...................... 111
836681...................... 111
836682...................... 111
836685...................... 111
836686...................... 111
836687...................... 111
836688...................... 111
836689...................... 111
836690...................... 111
836691...................... 111
836692...................... 111
836693.............. 111, 117
836694.............. 111, 113
836695...................... 113
836841...................... 115
836852.......... 95, 97, 115
836892.............. 131, 141
836959...................... 115
837020...................... 117
837043........................ 49
837198...................... 117
837270........................ 99
837295........................ 45
837296.............. 131, 141
837299........................ 45
837300........................ 45
837301.............. 131, 141
837303........................ 39
838154........................ 95
838295.8............... 87, 93
838340........................ 57
838440 ........................ 83
838463 .............. 133, 143
838539 ...................... 113
838768 ...................... 143
838769 ...................... 143
838770 ...................... 143
839213 ........................ 47
839328 ........................ 71
839752 ........................ 83
839862 ........................ 71
839917 ...................... 143
839921 ...................... 143
839948 ...................... 111
840222 ........................ 71
840352 ............ 77, 79, 81
840436 ........................ 41
840452 ........................ 69
840473 ........................ 86
840508 ........................ 39
840725 .................. 51, 53
840726 .................. 51, 53
840754 .................. 73, 75
840857 ........................ 99
840877 .............. 101, 103
841167 ........................ 65
841230 ........................ 75
841255 ........................ 67
841264 ........................ 45
841336 ........................ 67
841404 ........................ 67
841428 ........................ 39
841429 ........................ 65
841430 ................ 69, 113
841434 ........................ 63
841477G01 ................. 39
841630 ........................ 65
841637 ........................ 39
841663 ........................ 45
841715 ........................ 39
841737 ........................ 65
841738 ........................ 65
841753 ........................ 39
841799 ........................ 43
841804 ........................ 41
841837 ...................... 109
841838 ...................... 109
841839 ........................ 69
841841 ........................ 69
841842 ................ 69, 109
841844 ...................... 109
841885 ........................ 77
841892 ...................... 103
841895 .............. 105, 107
841913 ........................ 39
841966 ........................ 83
841969 .................. 95, 97
841982 .................. 87, 93

842010 ........................ 53
842030 ........................ 41
842033 ........................ 67
842051 ........................ 51
842103 ........................ 51
842104 ........................ 69
842359 ...................... 117
842360 ...................... 117
842553 ........................ 83
842740 ........................ 56
842773 ........................ 55
842774 ........................ 55
842785 ........................ 86
842870G01 ................. 61
842915 ............77, 79, 81
842935 .................. 51, 53
842959 ...................... 133
842961 ........................ 77
842966 .............. 133, 141
842983 .............. 131, 141
842996 ........................ 83
843013 ........................ 89
843021 ........................ 51
843022 ........................ 51
843158 ........................ 49
843167 .............. 107, 133
843168 .............. 133, 141
843238 ........................ 63
843296 ........................ 75
843298 .................. 95, 97
843323 ........................ 77
843343 .................. 95, 97
843355 ........................ 47
843356 ........................ 49
843359 ........................ 49
843418 ........................ 69
843537 ........................ 91
843550 .............. 131, 141
843551 .............. 131, 141
843561 ........................ 45
843562 ........................ 45
843563 ........................ 45
843568 ........................ 61
843581 ........................ 45
843598 .............. 131, 141
843607 ........................ 45
843614 ........................ 55
843679 ........................ 55
843685 ........................ 55
843724 ........................ 55
843726 .................. 95, 97
843754 ...................... 121
843758 ........................ 47
843759 ........................ 47
843760 ........................ 83
843767 ........................71
843768 ........................71
843778 ........................55
843792 ........................55
843857 ..................75, 77
843862 ........................73
843866 ........................91
843876 ........................63
843942 ......................107
843997 ........................45
844019 ......................103
844051 ........................47
844087 ......................117
844116 ........................45
844130 ..................86, 91
844148 ........................65
844167 ......................107
844177 ........................47
844179 ........................47
844198 ........................77
844202 ........................53
844223 ........................45
844224 ........................45
844228 ......................119
844268 ........................83
844270 ........................83
844271 ........................83
844272 ........................83
844274 ........................86
844293 ........................39
844391 ........................73
844564 ......................101
844565 ......................101
844566 ......................101
844571 ......................101
844582 ........................47
844583 ......................101
844584 ..............101, 103
844590 ......................101
844598 ......................103
844600 ......................101
844601 ........................99
844611 ........................53
844627 ......................101
844628 ......................101
844630 ......................101
844647G01..................61
844652 ......................101
844729 ........................99
844813 ......................113
844937 ......................101
844951 ......................117
844952 ......................117
844953 ......................117
844956 ......................117
844973 ......................101
147
INDEX
844988.........................43
845034.......................117
845038.........................41
845133.........................49
845134.........................49
845135.7......................59
845185.........................47
845206.7......................61
845223.......................119
845224.........................75
845231.........................41
845232.........................41
845234.........................41
845327.......................143
845328.......................143
845329.......................143
845330.......................143
845345.7......................56
845356.......................113
882993.......................103
883236.......................103
884398.......................133
884513...............105, 107
884574.......................103
885249.......................101
886001.......................103
886270.........................47
886425...............105, 107
886735...................59, 63
887017.......................101
888042.......................101
888549.........................75
889049.........................75
889050...................73, 75
889106.........................49
889681.........................67
889682.........................67
889780.......................115
889870.......................111
889925.......................115
890000.......................107
891089.......................117
891829...............109, 111
892164.........................56
892228.........................71
892486.........................71
892811...............105, 107
892921.........................51
892933.........................53
893145.........................61
893145.7......................61
893182.........................77
893199.7......................61
893199-G02.................61
893233.........................65
893234.........................65
148
893235.7......................61
893235G ......................61
893266.........................65
893322.........................41
893344.........................71
893375-G05.................41
893388.........................75
893487.........................59
893488.........................59
893491.............. 109, 113
893519.......................113
893525.........................61
893539.........................99
893541.........................41
893554.................. 73, 75
893555.................. 95, 97
893571.........................71
893581................ 61, 113
893582................ 61, 113
893583.......................109
893585.........................69
893586.........................69
893602.........................59
893613.........................63
893632.........................43
893633.........................83
893862.........................63
893966.........................55
894030.........................39
894159.........................45
894167.........................51
894179.........................55
894201.................. 95, 97
894232.........................59
894272.........................63
894308.................. 51, 53
894313.........................59
894317.........................49
894348.........................73
894432.........................63
894433.........................63
894434.........................91
894435.........................91
894456.........................51
894471.........................91
894508.........................56
894509........ 63, 109, 113
894519.......................117
894573.........................65
894574.........................65
894580.........................77
894584.........................56
894590.........................75
894591.........................86
894596.............. 105, 107
894635.........................67
894638 ........................ 95
894645 ........................ 83
894675 ........................ 99
894691 ...................... 101
894696 ........................ 47
894701 ...................... 101
894702 ...................... 101
894886 ...................... 117
894930 ................ 69, 113
894931 ................ 69, 113
894932 ................ 69, 113
894933 ................ 69, 113
894934 ................ 69, 113
894935 ................ 69, 113
894936 ................ 69, 113
894998.7 ..................... 61
895013 ........................ 53
895113 ........................ 51
INDEX
149
Equipment from Jacobsen is built to exacting

standards ensured by ISO 9001 and ISO 14001
registration at all of our manufacturing locations.
A worldwide dealer network and factory trained
technicians backed by Textron Parts Xpress
provide reliable, high-quality product support.
Textron Golf, Turf & Specialty Products

PO Box 7708, Charlotte, NC 28241-7708
www.ttcsp.com

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Parts & Maintenance

Jump Starting .................................................... 19

Litho in U.S.A. 2-2006

Suggested Stocking Guide

Qty. Part No.

Diesel Engine Oil Filter

5. Send or bring the order to an authorized Jacobsen

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

7. Do not return material without a letter of explanation,

How To Use This Manual

OPERATING SAFETY ______________________________________________________

Safety is dependent upon the awareness, concern and

12. Never disconnect or bypass any switch.

Stay alert for holes in the terrain and other hidden

22. Always use the seat belt when operating vehicles

Inspect the area where the equipment will be used.

Never use a seat belt when operating vehicle

Never allow anyone near the machine while in

10. Do not carry passengers. Keep bystanders and pets a

23. Keep legs, arms and body inside the seating

IMPORTANT SAFETY NOTES ________________________________________________

DANGER - Indicates an imminently hazardous

WARNING - Indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate

which, if not avoided, COULD result in death or serious

Remove foot from accelerator pedal.

STANDARDS AND PUBLICATIONS

STANDARDS AND PUBLICATIONS ___________________________________________

This product meets requirements of ANSI B56.8 and has

National Fire Protection Association:

Personal Burden Carriers:

Internal Combustion Engine Powered Industrial Trucks:

VEHICLE IDENTIFICATION NUMBERS

VEHICLE IDENTIFICATION NUMBERS

VEHICLE IDENTIFICATION NUMBER __________________________________________

The Vehicle Identification Number (VIN), consisting of the

This vehicle may be covered

GOLF, TURF & SPECIALTY PRODUCTS

The serial number is also stamped on the cross member.

Augusta Georgia, USA

ENGINE IDENTIFICATION NUMBERS _________________________________________

The Truckster is equipped with either a Perkins 3

Engine Serial No.

Record the Engine Serial Number below for easy

Engine Serial Number: _________________________

Engine Serial No.

84043.............................. Turf Truckster liquid cooled diesel

transmission, 2 speed differential.

Note: Actual sustained horsepower will likely be lower

Low Idle ................... 1300 RPM

Capacity...................... 3.3 qt. (3.0 l) 50/50 water ethylene

Governor......................... External Mechanical

Front ......................... 20 psi (138 kPa)

2nd Gear................... 2.391:1

WEIGHTS AND DIMENSIONS ________________________________________________

Parking Brake ................. Integral to rear drum, hand lever

GEAR RATIOS ____________________________________________________________

Diesel Engine Manual Transmission Gear Ratios:

ACCESSORIES & SUPPORT LITERATURE _____________________________________

Dry seal coupler, 1 set ...............................................894604