Download Cushman 898628 Specifications
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® 4140039 By Jacobsen 6 5 9 11 16 15 13 7 8 18 1 - INCLUDES ITEMS 3 - 16 17 19 3 10 4 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 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 operator’s 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 owner’s 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 operator’s 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. 4 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 ! 1 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 operator’s 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. 5 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 No’s 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. 6 Internal Combustion Engine Powered Industrial Trucks: ANSI/UL 558 American National Standards Institute, Inc. 1430 Broadway New York, New York 10018 U.S.A. OR Underwriters Laboratories Inc. 333 Pfingsten Road Northbrook, Illinois 60062 U.S.A. Flammable and Combustible Liquids Code: ANSI/NFPA 30 American National Standards Institute, Inc. 1430 Broadway New York, New York 10018 U.S.A. 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 operator’s seated position. Record the Vehicle Identification information below for easy reference. Model Number: ______________________ Date Code: _________________________ Serial Number: ______________________ 3.2 3 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 7 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 engine, 4 speed manual transmission, 2 speed differential. EC approved. 898627............................ Turf Truckster liquid cooled gas engine, 4 speed manual 4.2 transmission, 2 speed differential. 898628............................ Turf Truckster liquid cooled diesel engine, 3 speed automatic transmission, 2 speed differential. 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: 8 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 4 (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 9 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 5 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. A 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. B Figure 5D C Figure 5E 11 5 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. D If tension is incorrect, loosen alternator mounting bolts (D) and adjust alternator until proper belt tension is achieved. Figure 5F 5.6 DIESEL ENGINE HYDRAULIC PUMP BELT_____________________________________ Inspect and adjust new belt after first 24-48 hours of operation. Adjust every 200 hours thereafter. Adjust hydraulic pump belt so belt deflects 1/4” to 1/2” (6 -12 mm) with a 20 lb. push at midpoint between pulleys. If tension is incorrect, loosen pump mounting bolts (E) and carefully pry away from the engine until proper belt tension is achieved. E Figure 5G 5.7 GAS ENGINE POWER STEERING-ALTERNATOR BELT __________________________ Inspect and adjust new belt after first 24-48 hours of operation. Adjust every 200 hours thereafter. Adjust power steering pump so belt deflects 1/4” to 1/2” (6 -12 mm) with a 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. F Figure 5H 12 ADJUSTMENTS 5.8 5 GAS ENGINE HYDRAULIC PUMP BELT _______________________________________ Inspect and adjust new belt after first 24-48 hours of operation. Adjust every 200 hours thereafter. Adjust hydraulic pump belt so belt deflects 1/4” to 1/2” (6 -12 mm) with a 20 lb. push at midpoint between pulleys. If tension is incorrect, loosen pump mounting bolts (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 5 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 6 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. 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. 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 manufacturer’s 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 engine’s life and avoid premature overhaul. During the break-in period, Jacobsen recommends the following: 1. During the first 50 hours of operation, a new engine should be allowed to reach an operating temperature of at least 140°F (60°C) prior to operation at full load. 2. Check the engine oil level twice daily during the first 50 hours of operation. Higher than normal oil consumption is not uncommon during the initial break-in period. 3. Change engine oil and oil filter element after first 35 hours of operation. 4. Check and adjust hydraulic pump and alternator belts. 5. Refer to Section 8.3 and Engine Manual for specific maintenance intervals. 15 6 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 °F -20 °C -30 0 -20 20 32 40 -10 0 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 77°F (25°C) SAE 30W or SAE10W30 32 to 77°F (0 to 25°C) SAE 20W or SAE 10W30 Below 32° (0°C) 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 6 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 6 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 6 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 A A 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 6 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 manufacturer’s 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 Charger’s manual for specific instructions. 2. Whenever possible, remove the battery from the vehicle before charging. If battery is not sealed, check that the electrolyte covers the plates in all the cells. Battery cables must be disconnected before using a “fast charger” or damage to the alternator may result. 3. Make sure the charger is “Off”. Then connect the charger to the battery terminals as specified in the charger’s manual. 4. Always turn the charger “Off” before disconnecting charger from the battery terminals. 20 MAINTENANCE 6 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 6 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 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 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. 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 operator’s seat. Always block the tire diagonally opposite the tire being raised. Never place hands, feet or any part of your body under the vehicle when raising it with a hoist or is not properly supported by jack stands. - 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 6 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 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 6 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) Fluid Type .............................. SAE EP 80-90 Gear Lube 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 If fluid is low, add gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. To change fluid, remove drain plug from rear of transmission. Allow fluid to drain into a suitable container. Dispose of used fluid properly according to local and state regulations. Apply pipe thread sealer to drain plug and install. Fill transmission with gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. 26 Figure 6P MAINTENANCE 6 6.24 GAS ENGINE MANUAL TRANSMISSION _______________________________________ The transmission fluid should be checked every 100 hours or 3 months. Fluid should be changed every 600 hours (or yearly). Fill transmission with gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. Differential Fluid Capacity ...... 1.3 qts (1.2 l) Fluid Type .............................. SAE EP 80-90 Gear Lube To check transmission fluid level, remove the filler plug from the front of the transmission. Fluid should be level with the bottom of filler hole. Fill Plug If fluid is low, add gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. To change fluid, remove drain plug from rear of transmission. Drain Plug Allow fluid to drain into a suitable container. Dispose of used fluid properly according to local and state regulations. Figure 6Q Apply pipe thread sealer to drain plug and install. 6.25 GAS ENGINE AUTOMATIC TRANSMISSION ____________________________________ The transmission fluid should be checked every 100 hours or 3 months. Fluid should be changed every 600 hours (or yearly). Differential Fluid Capacity ...... 3.7 qts (4.2 l) 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 Allow fluid to drain into a suitable container. Dispose of used fluid properly according to local and state regulations. Apply pipe thread sealer to drain plug and install. Fill transmission until fluid reaches proper mark on dipstick. Figure 6R 27 6 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. 6 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. K Perkins Diesel Sequence Code: 0 0 0 1 0 0 0 0 L The truckster with a Suzuki Gas engine uses the following sequence code for 1.5 pulses / revolution. M E B F G C 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 6 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 (Automatic Transmission only) 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 “2”position. 43 Shift Solenoid #3 (Automatic Transmission only) Open or short circuit at pin 29 (Blue/Red wire) of the 34 pin ECU connector. 46 Shift Switch (Automatic Transmission only) 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 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 80°F (27°C) or fall below 20°F (7°C) to prevent electrolyte from freezing. Engine (General) 1. While the engine is warm, remove the drain plug, drain the oil from the crankcase and change oil filter. Install drain plug and refill with fresh oil. Let engine cool before storing. 2. Clean exterior of engine. Paint exposed metal, or apply a 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 MAINTENANCE & LUBRICATION CHARTS 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 8 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 A D Fuse Box C D C B 33 8 MAINTENANCE & LUBRICATION CHARTS 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 C 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-R* I* R I 6.26 I I* I I I R***** I R* I R***** I 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 L I 8.2 I 6.5 I-C/AR 6.7 I* I 6.4 V C-A-R I I I-A 6.16 I R 6.23 6.24 III I R 6.25 VII Repack C - Clean I - Inspect L- Lubricate R - Repair or Replace AR - As Required MAINTENANCE & LUBRICATION CHARTS 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 8 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 C 10 9 8 7 20 22 23 24 12 5 11 26 25 12 21 19 6 27 37 12 ® By Jacobsen B 18 29 1 Turf Truckster Turf Truckster D ® ® By Jacobsen By Jacobsen 31 30 / 31 12 A 34 D 35 29 11 30 16 28 32 33 D 36 17 15 3 15 12 14 35 34 2 13 36 33 C 18 B 3 4 2 A 38 2 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 1 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 Serial Numbers/Notes 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 Flat Washer, 1/4 x 1-1/4” 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 C 7 U S H 16 M A N Engine Cover Lock 15 C U 6 5 S H M A N 8 17 1 4 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 1 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 Serial Numbers/Notes Cotter Pin, 3/32 x 3/4” Washer, 1/4 Nut, M6-1 Hex Flange Nut, M8-1.25 Hex Flange Nut, M10-1.5 Hex Flange Handold, Right Side Screw, M6-1 x 16 mm Hex Flange Screw, M8-1.25 x 20 mm Hex Flange Screw, M10-1.5 x 20 mm Hex Flange 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 > Change from previous revision 41 TURF TRUCKSTER Serial No. 84054 All 3.1 Upper ROPS 4 3 4 11 11 2 14 1 15 15 14 7 8 13 6 6 REF Engine Cover 8 12 7 10 7 8 9 5 11 6 9 8 7 9 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 1 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 Serial Numbers/Notes Upper ROPS • Decal, Warning and ROPS Cert. Foam, 1/2” Perforated ROPS Screw, M12-1.75 x 40 mm Flange Nut, M12-1.75 Hex Flange Seat Belt Assembly • Screw, 7/16-20 x 1” Hex Head • Flat Washer, 7/16 • Nut, 7/16-20 Hex Guard, Seat Belt Screw, M8-1.25 x 16 mm Flange Nut, M8-1.25 Hex Flange Backrest Support, Backrest Screw, M6-1 x 16 mm Pan Head See 2.1 > Change from previous revision 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 A 17 C 7 1 34 6 17 31 9 31 32 29 Hand Throttle Panel 39 40 21 19 B 41 37 D 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 1 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 Serial Numbers/Notes 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 Clevis Pin, 1/4 x 1-7/8” Cotter Pin, 3/32 x 3/4” 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 > Change from previous revision 45 TURF TRUCKSTER Serial No. All 5.1 Control Console 16 1 2 15 4/5 3 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 7 N 6 29 33 28 34 21 27 20 18 32 31 R 26 25 24 23 35 30 17 3 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 Serial Numbers/Notes 2700796 1 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 Screw, M8-1.25 x 50 mm Flange Plate, Stop Nut, M8-1.25 Hex Flange Washer, 1-5/8” Diameter Nut, 3/8-16 Hex Jam Rod, Extension Handle Nut, 3/8-24 Hex Jam Knob Plate, Float Latch Screw, M8-1.25 x 16 mm Flange 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 Cotter Pin, 1/16 x 1/2” Connector, Valve Clevis Pin, 5/16 x 1-1/8” Flat Washer, 5/16 Cotter Pin, 3/32 x 3/4” Handle, Lift Control Valve Screw, M10-1.5 x 70 mm Flange Spring, Compression Bushing, Lift Control Valve Nut, M10-1.5 Hex Flange Cover, Handle Adapter, 90° Fitting Adapter, 90° Fitting Adapter, Straight Fitting Adapter, 90° Swivel Fitting Used on 84044 Only Used on all, except 84044 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 > Change from previous revision 47 TURF TRUCKSTER Serial No. All 6.1 Parking Brake and High-Low Speed Control 22 23 21 20 21 19 18 16 24 14 3 11 3 17 15 13 12 7 1 5 6 5 10 9 8 10 2 5 5 3 48 4 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 1 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 Screw, M8-1.25 x 20 mm Flange Screw, M8-1.25 x 40 mm Flange Nut, M8-1.25 Flange Cable, Parking Brake Nut, M6-1 Staytite Pulley, 3” Cable Bushing, Pulley Flat Washer, 5/16 x 1-3/16” Equalizer, Parking Brake Locknut, 5/16-24 Bracket, Parking Brake Cables Screw, M10-1.5 x 20 mm Flange Nut, M10-1.5 Flange Parking Brake Cables Cable, High - Low Speed Control Screw, M6-1 x 12 mm Flange Nut, M6-1 Flange Bracket, High - Low Cable Nut, #10-32 Hex Clevis Pin, 5/16 x 31/32” Cotter Pin, 9/32 x 3/4” Cable Tie, 7-1/2” Serial Numbers/Notes See 39.1 Apply Locktite 242 > Change from previous revision 49 TURF TRUCKSTER Serial No. All 7.1 Brake Pedal 15 16 Route both hoses through opening in front clip 17 31 A 16 A 16 17 11 14 16 8 4 20 Lower ROPS 10 12 13 1 7 5 9 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 7 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 1 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 Serial Numbers/Notes Bracket, Master Cylinder Pedal, Brake Bearing, Brake Pivot Tube, Brake Pivot Tab, Locking Screw, M8-1.25 x 20 mm Flange Nut, M8-1.25 Flange Master Cylinder Screw, M8-1.25 x 16 mm Flange Rod, Brake Clevis Pin, 5/16 x 15/16” Flat Washer, 5/16 Cotter Pin, 3/32 x 3/4” Reservoir, Brake Fluid • Reservior • Electrical Connector, 2 Wire • Terminal, 1/4 “L” Male Screw, M6-1 x 16 mm Flange 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 Screw, M10-1.5 x 20 mm Flange 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 Screw, #10-14 x 5/8” Self Tapping 6 Foot Length, cut to 18” See 39.1 See 37.1 See 17.1 > Change from previous revision 51 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All Serial No. 898627 All Serial No. 84054 All 8.1 Clutch Pedal Linkage Lower ROPS 4 9 10 8 6 14 13 5 7 3 12 A 15 11 2 1 Cable Routing View Rotated 90 Degrees for Clarity View Rotated 90 Degrees for Clarity 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 1 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 Screw, M8-1.25 x 20 mm Flange 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 Clevis Pin, 5/16 x 15/16” Cotter Pin, 3/32 x 3/4” Pad, Pedal Bushing, Clutch Release Arm Bushing Nut, M6-1 Nylock Arm, Clutch Release Screw Nut Rear Alternator Bracket Serial Numbers/Notes 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 > Change from previous revision 53 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All Serial No. 898627 All Serial No. 84054 All 9.1 Manual Transmission Shifter Linkage 21 22 23 3 4 14 16 7 9 18 10 11 15 19 8 20 17 12 16 A 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 View Rotated 180 Degrees for Clarity 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 Serial Numbers/Notes 893966 1 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 • Screw, 1/2-20 x 2-1/4” Hex Head • Plate, Wear • Screw, M6-1 x 12 mm Self Tap • Flat Washer, 3/8” • Spring, Torsion • Bushing, Spring • Tab, Locating • Screw, M10-1.5 x 40 mm Flange • 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 • Screw, M6-1 x 20 mm Self Tap • Screw, 1/4-28 x 5/8” Hex Head • Lockwasher, 1/4 • Flat Washer, 1/4 • Cable, Shifter • Cable, Shifter Boot, Control Lever Knob, Shifter Flat Washer, 1/4 x 1-1/4” Flat Washer, 1/4 Connector, Shift Cable Connector, Shift Cable Flat Washer, 5/16 Hair Pin Panel, Right Side Dash Plate, Shifter Boot Screw, M6-1 x 12 mm Self Tap Insert, 1/4-20 Threaded Ring, Boot Hold Down Screw, M6-1 x 20 mm Self Tap Connector, Shift Cable 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 > Change from previous revision 55 SPRAYTEK DS 300 Serial No. 898628 All 10.1 Automatic Transmission Shifter 12 11 5 6 1 7 9 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 2 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 Serial Numbers/Notes > Change from previous revision 56 SPRAYTEK DS 300 11.1 Automatic Transmission Oil Cooler Serial No. 898628 All 6 5 3 6 5 3 6 2 1 2 2 Item Part No. 1 2 3 4 5 6 Qty. 838340 1 800789 826590 821893 809231 825264 1 AR AR 2 4 Description Serial Numbers/Notes Oil Cooler Kit, Oil Cooler Mounting Hose, 5/16 I.D. Trim, Push On Grommet Hose Clamp > Change from previous revision 57 TURF TRUCKSTER Serial No. All 12.1 Frame Attachments 9 9 13 9 9 13 9 9 18 11 12 20 9 22 17 9 10 A 10 10 10 14 15 21 16 23 10 19 A 1 9 7 2 10 6 3 10 4 5 58 9 8 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 1 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 Screw, M12-1.75 x 80 mm Flange Nut, M10-1.5 Hex Flange 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 Screw, M10-1.5 x 20 mm Flange Nut, M10-1.5 Hex Flange Fender, Right Side Fender, Left Side Screw, M10-1.5 x 25 mm Flange 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 Screw, M8-1.25 x 16 mm Flange Nut, M8--1.25 Hex Flange Radiator Support Frame, Lower ROPS and Platform Serial Numbers/Notes See 15.1, 16.1 and 17.1 Standard Optional Optional 3.94” Bolt Circle Used on 4139806G03, Obtain Locally Used on 4139806G01, Obtain Locally Used on 4139806G02, Obtain Locally See 5.1 Includes License Illuminator Lens See 13.1 > Change from previous revision 59 TURF TRUCKSTER Serial No. All 13.1 Frame, Lower ROPS and Platform 7 16 3 9 17 25 D C 7 22 24 9 17 2 B 15 6 19 A 14 8 13 6 12 8 C 10 Gas Engine and Transmission Mounts B 7 11 D 23 5 4 21 7 1 7 20 6 13 7 19 7 A 7 12 6 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 1 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 Serial Numbers/Notes Frame, Main 4 Wheel Standard Frame, Painted Black Frame, Galvanized Main 4 Wheel ROPS, Lower Platform, Truckster Platform, Galvanized Truckster Support, Platform Screw, M10-1.5 x 90 mm Flange Screw, M19-1.5 x 20 mm Flange Nut, M10-1.5 Hex Flange Nut, M12-1.75 Hex Flange Screw, M12-1.75 x 30 mm Flange Lockwasher, 1/2 Shakeproof Screw, M10-1.5 x 80 mm Flange 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 Screw, M10-1.5 x 60 mm Flange Screw, M10-1.5 x 50 mm Flange Guard, Hydraulic Tank Transmission Mount Transmission Mount Screw, M8-1.25 x 25 mm Flange Nut, M8-1.25 Flange Bracket, Fuel System Bracket, Fuel System Screw, M6-1 x 20 mm Hex Flange Nut, M6-1 Hex Flange 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 > Change from previous revision 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 5 19 4 1 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 Serial Numbers/Notes 893491 1 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 Screw, 1/2-13 x 3-1/2” Hex Head Nut, 1/2-13 Nylon Insert Shackle, Rear Spring Bushing, Nylatron Shock Absorber Bushing Washer, 7/16 Cupped Locknut, 7/16-14 Center Screw, 7/16-14 x 2-1/4” Hex Head Driveshaft, Complete Driveshaft, Complete 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 > Change from previous revision 63 TURF TRUCKSTER Serial No. All 15.1 Front Control Arms 13 10 9 5 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 2 20 6 17 7 8 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 1 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 • Screw, 5/16-24 x 1” Hex Head • 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 • Nut, 9/16-18 Slotted Hex • Cotter Pin, 1/8 x 1-1/4” • 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 Serial Numbers/Notes 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. Add or remove shims as required to adjust CAMBER angle. > Change from previous revision 65 TURF TRUCKSTER Serial No. All 16.1 Steering Linkage 1 4 5 B 3 A 7 5 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 A 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 1 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 Nut, M12-1.75 Hex Flange Screw, 7/16-14 x 2” 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 Cotter Pin, 1/8 x 1-1/8” 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 Serial Numbers/Notes Grade 10.9 Grade 10.9 > Change from previous revision 67 TURF TRUCKSTER Serial No. All 17.1 Front Brakes 11 10 9 8 5 1 2 ★ Hose Clamp Location 3 A 6 7 24 26 20 22 25 18 14 4 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 4 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 2 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 Serial Numbers/Notes 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 Cotter Pin, 1/8 x 1-1/8” 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 Cylinder Repair • Kit, Brake Shoe • Kit, Right Side Spring • Kit, Right Side Adjuster Repair Screw, M10-1.5 x 20 mm Hex Flange Tee, M10-1.0 Flare Union Clamp, Tee Screw, M6-1.0 x 12 mm Hex Flange Hose, Brake Protector, Brake Hose Bracket, Brake Tube Nut, M6-1.0 Hex Flange 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 Replacement of Cylinder Repair of Cylinder Includes Left and Right sides Grade 8.8 > Change from previous revision 69 TURF TRUCKSTER Serial No. All 18.1 Steering Column 12 13 11 3 2 10 8 Lower ROPS 9 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 1 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 Screw, M8-1.25 x 16 mm Flange 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 Screw, #10-14 x 5/8” Self Tapping Clamp, Tube Cable Tie, 7-1/2” Cable Tie, 15-1/2” 25 839328 1 Power Steering Pump with Reservior 26 2700573 REF 1 1 • Cap, Steering Reservior Gear, Steering 1 2 3 4 5 Serial Numbers/Notes 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 > Change from previous revision 71 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 19.1 Diesel Radiator 40 11 16 20 12 5 13 4 15 18 39 10 3 17 14 2 1 9 2 7 19 26 8 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 Serial Numbers/Notes 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 Screw, 1/4-20 x 3/4” Hex Head Lockwasher, 1/4 Flat Washer, 1/4 Nut, M6-1 Hex Flange Screw, M6-1 x 16 mm Hex Flange Screw, M6-1 x 20 mm Hex Flange 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 Nut, M8-1.25 Hex Flange Nut, M10-1.5 Hex Flange Screw, M8-1.25 x 20 mm Hex Flange Screw, M8-1.25 x 80 mm Hex Flange Screw, M10-1.5 x 20 mm Hex Flange Screw, M10-1.5 x 90 mm Hex Flange 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 > Change from previous revision 73 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 20.1 Gas Radiator 38 11 16 20 12 15 18 5 4 3 10 13 7 17 1 2 39 31 9 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 Screw, 1/4-20 x 3/4” Hex Head Lockwasher, 1/4 Flat Washer, 1/4 Nut, M6-1 Hex Flange Screw, M6-1 x 16 mm Hex Flange Screw, M6-1 x 20 mm Hex Flange 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 Nut, M8-1.25 Hex Flange Sender, Temperature Screw, M8-1.25 x 20 mm Hex Flange Screw, M8-1.25 x 80 mm Hex Flange Screw, M10-1.5 x 20 mm Hex Flange 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 Screw, M8-1.25 x 50 mm Flange Decal, Fan Warning Decal, Radiator Pressure Warning Serial Numbers/Notes 10 Foot Length, Cut to 8” > Change from previous revision 75 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 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 5 4 5 8 37 36 28 33 12 29 39 27 40 10 6 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 1 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 Screw, 3/8-16 x 2-1/4” Hex Head Flat Washer, 3/8 Mount, Engine Isolation Washer, Isolator Lockwasher, 3/8 Nut, 3/8-16 Hex Screw, M8-1.25 x 20 mm Flange Nut, M8-1.25 Flange Screw, M8-1.25 x 25 mm Flange Hose, Intake Air Filter • Element, Air Filter Bracket, Air FIlter Bracket, Air FIlter Mount Screw, M8-1.25 x 30 mm Flange 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 Screw, M10-1.5 x 40 mm Flange Screw, M8-1.25 x 50 mm Flange Lockwasher, 5/16 Flat Washer, 5/16 Screw, M10-1.25 x 50 mm Flange Screw, M10-1.25 x 35 mm Flange Sleeve, Alignment Cover, Starter Hole Screw, 3/8-16 x 4-3/4” Hex Head Mount, Transmission Adapter Temp Sender Serial Numbers/Notes See 24.1 See 12.1, Left shown, right similar Includes Clutch Disc and Cover See 12.1 > Change from previous revision 77 TURF TRUCKSTER Serial No. 898627 All Serial No. 84054 All 22.1 Gas Engine and MT Mounting 28 19 27 20 24 18 21 22 23 30 17 14 8 2 21 7 10 16 5 13 10 4 9 3 12 15 7 6 1 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 Serial Numbers/Notes REF 1 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 Screw, M10-1.25 x 75 mm Flange Screw, M10-1.25 x 55 mm Flange Alignment Pins Starter, Manual Transmission Screw, M8-1.25 x 30 mm Hex Flange Nut, M10-1.25 Hex Flange Bracket, Air Filter Screw, M8-1.25 x 25 mm Hex Flange Nut, M8-1.25 Hex Flange 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 Nut, M10-1.5 Hex Flange See... See 12.1 See 12.1 See 12.1 > Change from previous revision 79 TURF TRUCKSTER Serial No. 898628 All 23.1 Gas Engine and AT Mounting 27 29 12 11 28 8 19 20 24 18 21 22 7 23 10 10 32 17 14 9 30 21 2 16 31 4 13 5 3 6 15 1 13 28 28 25 29 80 29 26 7 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 Serial Numbers/Notes REF 1 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 Automatic Transmission Plate, Transmission Housing Torque Converter Plate, Drive Screw, M8-1.25 x 9.5 mm Flange Stud, M10-1.25 x 65 mm Screw, M10-1.25 x 55 mm Flange Screw, M10-1.25 x 50 mm Flange Alignment Pins Starter, Automatic Transmission Screw, M8-1.25 x 30 mm Hex Flange Nut, M10-1.25 Hex Flange Bracket, Air Filter Screw, M8-1.25 x 25 mm Hex Flange Nut, M8-1.25 Hex Flange 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 Nut, M10-1.5 Hex 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 > Change from previous revision 81 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 24.1 Diesel Engine and Clutch 15 11 21 19 13 22 23 8 16 18 12 14 36 17 20 3 35 ★ 15 23 14 37 14 15 31 24 30 38 27 29 28 4 31 5 1 10 25 9 8 ★ 6 5 27 7 26 34 33 82 32 2 4 32 23 TURF TRUCKSTER Item ★ Part No. Qty. 1 N/S 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 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 Screw, M12-1.25 x 25 mm Flange 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 Screw, M8-1.25 x 80 mm Flange Screw, M8-1.25 x 20 mm Flange 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 Screw, 5/16-18 x 1” Hex Head Lockwasher, 5/16 Screw, M8-1.25 x 30 mm Flange Screw, M8-1.25 x 70 mm Flange Pulley, 4” Screw, 3/8-16 x 1-1/4” Hex Head 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 Serial Numbers/Notes Spec HH70581U Order directly from Perkins See 35.1 See 18.1 Included with Transmission Included with Transmission Included with Transmission 48” Indicates hardware included with Engine. > Change from previous revision 83 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 25.1 Suzuki Gas Engine 28 6 32 29 39 26 25 38 3 2 27 35 1 28 36 7 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 9 31 15 25 14 16 21 84 33 32 TURF TRUCKSTER Item Part No. Qty. Description 1 N/S 1 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 Screw, 5/16-18 x 3/4” Hex Head 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 Screw, 3/8-16 x 1-1/2” Hex Head Pulley, 4-3/4” Diameter Belt, 7/16 x 54-1/4” V Bolt, M6-1 x 60 mm Hex Head Nut, M6-1 Hex Flange Bracket, Power Steering Pump Screw, M6-1 x 40 mm Hex Flange Spacer, 7/16 x 1-3/32” Screw, M8-1.25 x 25 mm Hex Flange Spacer, 7/16 x 11/32” Pump, Power Steering Screw, M8-1.25 x 80 mm Hex Flange Nut, M8-1.25 Hex Flange Pulley, 5.80” Diameter Belt, 7/16 x 25” V Bracket, Air Cleaner Plug, Tube Clamp, 5/8” to 1” Worm Drive Plug, Tube Clamp, 1/4” to 5/8” Worm Drive Lockwasher, 1/4 Flat Washer, 1/4 Serial Numbers/Notes 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 > Change from previous revision 85 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 26.1 Engine Speed Control 1 2 8 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 Serial Numbers/Notes 2703683 1 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 Clevis Pin, 5/16 x 3/4” Flat Washer, 5/16 Hair Pin Spring, Idle Return Screw, #10-24 x 1/2” Pan Head 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 > Change from previous revision 86 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 27.1 Exhaust 7 8 13 3 11 2 1 11 Tailpipe outlet to be parallel to ground. 12 10 10 5 4 9 6 9 Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Qty. Description 4119866.8 1 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 Serial Numbers/Notes Muffler Order directly from Perkins See 21.1 See 21.1 > Change from previous revision 87 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 28.1 Governor Linkage 29 31 10 20 30 22 3 26 32 35 4 4 41 20 19 28 A 33 9 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 1 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” Screw, M6-1 x 40 mm Hex Flange Spacer, 7/16 x 1” Lever, Governor Lever, Governor Arm Screw, M10-1.5 x 40 mm Hex Flange Ball Bearing Flat Washer, 3/8 Nut, M10-1.5 Hex Flange 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” Clevis Pin, 1/4 x 1/2” Screw, 1/4-20 x 1” Cotter Pin, 3/32 x 1/2” 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 Clevis Pin, 5/16 x 31/32” Flat Washer, 5/16 Lockwasher, 5/16 Special Serial Numbers/Notes See 4.1 Part of Engine > Change from previous revision 89 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 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 2 1 14 28 B A 24 / 25 27 A 12 26 7 17 21 18 16 90 11 3 4 8 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 1 Governor 111812 1 • 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 • Screw, 1/4-20 x 1” Hex Head • 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, 1/4-20 x 1” Hex Head 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 Serial Numbers/Notes Yoke, Spool See 4.1 > Change from previous revision 91 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 30.1 Gas Engine Remote Oil Fill 12 8 2 9 3 11 10 6 7 4 5 13 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part No. Qty. 6 1 2 Description 601942 1 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 Clamp, 1-7/8” Worm Drive Hose, Remote Oil Fill Adapter, Oil Cap Screw, M6-1 x 16 mm Hex Flange Screw, M6-1 x 12 mm Hex Head Lockwasher, 1/4 Cap, Oil FIll Bracket, Governor Serial Numbers/Notes Included with Engine See 25.1 > Change from previous revision 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 5 16 9 3 15 14 6 4 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 1 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 Serial Numbers/Notes Muffler Attaches to Transmission Case > Change from previous revision 93 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 32.1 Diesel Fuel System 34 35 20 36 37 21 2 C 15 29 28 8 24 2 23 27 30 2 2 2 6 10 1 22 25 7 3 B 2 2 12 2 13 11 26 16 14 18 4 17 2 13 2 19 32 31 A 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 1 Screw, M8-1.25 x 60 mm Flange 3 Nut, M8-1.25 Flange 1 Bracket, Fuel Pump Mounting 1 Grommet 2 Grommet, Split 2 Screw, M8-1.25 x 30 mm Flange 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 Serial Numbers/Notes 25 Foot Roll, Cut to 13-1/2” 25 Foot Roll, Cut to 9-1/2” 25 Foot Roll, Cut to 14” 25 Foot Roll, Cut to 21” 25 Foot Roll, Cut to 7” 25 Foot Roll, Cut to 15-1/2” Order Directly from Perkins See 13.1 See 21.1 See 12.1 > Change from previous revision 95 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 33.1 Gas Fuel System 40 4 41 20 2 42 43 21 18 13 C 29 28 32 2 16 8 24 2 23 27 33 34 8 22 2 2 2 7 2 1 11 36 8 26 8 34 8 37 8 8 44 19 6 31 45 36 C 39 96 8 9 15 17 35 2 30 25 14 10 5 3 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 1 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 Screw, M6-1 x 20 mm Hex Flange Nut, M6-1 Hex Flange Screw, M8-1.25 x 16 mm Hex Flange Nut, M8-1.25 Hex Flange Nut, M12-1.25 Hex Lockwasher, 1/2” External Tooth Bracket, Fuel System 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 Screw, #10-32 x 1/2” Pan Head 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 Serial Numbers/Notes 25 Foot Roll, Cut to 14” Cut to 3” 25 Foot Roll, Cut to 9” 25 Foot Roll, Cut to 4-1/4” 25 Foot Roll, Cut to 29” See 13.1 25 Foot Roll, Cut to 2” 25 Foot Roll, Cut to 18” 25 Foot Roll, Cut to 22” See 12.1 Cut to 5” > Change from previous revision 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 7 1 LIFT VALVE TRUCKSTER CYLINDER 4 19 2 9 8 20 5 3 FILTER HYD PUMP 21 6 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 4 22 13 / 15 12 / 14 7 16 6 18 17 5 2 1 8 10 9 5 11 98 3 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 1 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 Serial Numbers/Notes Tank, Hydraulic Screw, M8-1.25 x 20 mm Flange Nut, M8-1.25 Hex Flange Screw, M10-1.5 x 25 mm Flange Plug, 1/2 NPT Dipstick, Hydraulic Tank Valve, Pressure Relief Battery, 12 Volt Bracket, Battery Clamp Screw, M8-1.25 x 25 mm Flange Spacer, Battery Clamp Hydraulic Cover • Decal, Hydraulic Connections Hydraulic Cover, EC • Decal, Hydraulic Connections Screw, M8-1.25 x 16 mm Flange 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 all, except 84044 Used on 84044 Only > Change from previous revision 99 TURF TRUCKSTER Serial No. All 35.1 Hydraulic Pump and Filter 9 14 13 29 12 13 9 17 16 15 7 11 22 20 24 21 2 19 26 23 18 8 5 25 6 27 4 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 1 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 Screw, M6-1 x 40 mm Flange Bushing Nut, M6-1 Hex Flange 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 Serial Numbers/Notes See 35.1 See 35.1 Not Shown, Secures Nylon Sleeve > Change from previous revision 101 TURF TRUCKSTER Serial No. All 36.1 Lift Cylinder Circuit 2 3 3 18 1 19 3 2 3 17 13 14 12 6 11 5 7 13 6 14 5 14 7 4 Lift Cylinder Mounting 15 15 16 21 10 9 8 102 22 20 TURF TRUCKSTER Item Part No. Qty. 1 882993 1 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 Serial Numbers/Notes Cylinder, Dump Box • Seal Kit • Seal Kit • Seal Kit Pin, Clevis Hair Pin Trim, Push On Clamp, Hose Screw, M6-1 x 20 mm Hex Flange Nut, M6-1 Hex Flange 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 > Change from previous revision 103 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 37.1 Diesel Electrical Components 9 5 11 Item 8 Routing 10 5 5 12 1 2 3 Engine Harness Ground Wires 21 23 22 5 4 14 18 8 13 20 7 15 1 16 17 24 13 8 7 6 104 19 TURF TRUCKSTER Item Part No. Qty. Description Serial Numbers/Notes 450452 3 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 1 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 Screw, 1/4-20 x 1/2” Hex Head Lockwasher, 1/4 External Tooth Insulator Flat Washer, 1/4 Positive Battery Cable Negative Battery Cable Lockwasher, 5/16 Nut, M8-1.25 Hex Cable, Ground Nut, M8-1.25 Hex Flange Screw, M8-1.25 x 20 mm Flange Cover, Positive Battery Terminal Battery to Transmission 1 2 3 Nut, M6-1 Hex Flange Screw, M6-1 x 20 mm Hex Flange 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 Screw, M6-1 x 16 mm Hex Flange Harness, Main Socket, 12V Accessory Plug Panel, Instrument with Tachometer See 49.1 Transmission to Right Frame Rail > Change from previous revision 105 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 38.1 Gas Electrical Components 9 5 11 Item 8 Routing 10 5 5 12 2 29 2 28 1 1 3 2 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 8 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 1 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 Screw, 1/4-20 x 1/2” Hex Head Lockwasher, 1/4 External Tooth Insulator Flat Washer, 1/4 Positive Battery Cable Positive Battery Cable Negative Battery Cable Lockwasher, 5/16 Nut, M8-1.25 Hex Cable, Ground Nut, M8-1.25 Hex Flange Screw, M8-1.25 x 20 mm Flange 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 Serial Numbers/Notes Nut, M6-1 Hex Flange Screw, M6-1 x 20 mm Hex Flange 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 Screw, M6-1 x 16 mm Hex Flange Harness, Main Socket, 12V Accessory Plug Panel, Instrument with Tachometer See 49.1 Located inside front clip, behind dash panel Manual Transmission Automatic Transmission Battery to Transmission Transmission to Right Frame Rail Manual Transmission Automatic Transmission Not Shown > Change from previous revision 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 1 6 11 5 7 11 108 9 TURF TRUCKSTER Item 1 2 3 4 5 6 7 8 9 10 11 Part No. Qty. Description Serial Numbers/Notes 894509 893491 1 1 Differential Assembly Differential Assembly 14.21:1 Differential 11.16:1 Differential 891829 1 • 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 > Change from previous revision 109 TURF TRUCKSTER Serial No. All 40.1 Differential Housing Part Number 891829 29 30 26 2 3 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 4 20 6 22 11 19 23 24 25 110 12 7 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 1 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 Serial Numbers/Notes Differential Housing • Bearing Caps • Screw, 7/16-14 x 2” Hex Head • Flat Washer, 5/16 • Plug, Drain • Stud, 3/8-16 & 3/8-24 x 1-23/32 • Screw, 5/16-18 x 7/8” Hex Head • 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 • Screw, 3/8-24 x 13/16 Hex Head • 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 Add or remove shims as required to adjust gear backlash Add or remove shims as required to adjust gear backlash Add or remove shims as required to adjust gear backlash > Change from previous revision 111 TURF TRUCKSTER Serial No. All 41.1 Axle Tubes and Shafts 11 10 26 24 9 25 22 21 19 18 20 23 16 15 14 B B 8 2 13 12 28 27 1 27 28 14 4 15 12 16 13 20 A 19 3 21 22 A 24 17 23 25 26 112 5 6 7 TURF TRUCKSTER Item Part No. Qty. Description Serial Numbers/Notes 1 894509 1 Differential Assembly 14.21:1 Differential 1 2 3 4 893491 1 Differential Assembly 11.16:1 Differential 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 • Nut, 3/4-16 Slotted Hex • Cotter Pin, 1/8 x 1-1/8” Right Side Axle Assembly • Shaft, Right Side Axle • Washer • Nut, 3/4-16 Slotted Hex • Cotter Pin, 1/8 x 1-1/8” 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 Cylinder Repair • Kit, Brake Shoe • Kit, Left Side Spring • Kit, Left Side Adjuster Repair Right Side Brake Assembly • Kit, Brake Cylinder • Kit, Brake Cylinder Repair • 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 Replacement of Cylinder Repair of Cylinder Includes Left and Right sides Includes Parking Brake Lever Replacement of Cylinder Repair of Cylinder Includes Left and Right sides > Change from previous revision 113 TURF TRUCKSTER 42.1 Front and Shifter Cover Serial No. All 14.21:1 Differential (894509) 11.16:1 Differential (893491) 22 11 / 12 21 18 3 2 20 3 19 13 23 3 15 17 14 16 8 6 4 5 4 5 7 9 1 2 114 3 10 2 3 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 1 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 Serial Numbers/Notes Cover, Front Screw, 5/16-18 x 7/8” Hex Head Flat Washer, 5/16 Screw, 3/8-16 x 2-3/4” Hex Head 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” Screw, 5/16-18 x 1-3/4” Hex Head Screw, 5/16-18 x 1-1/4” Hex Head 14.21:1 Differential Only Right Side Brake Tube > Change from previous revision 115 TURF TRUCKSTER 43.1 Input, Main and Jack Shafts Serial No. All 14.21:1 Differential (894509) 11.16:1 Differential (893491) 27 12 13 5 11 10 17 22 14 15 18 20 19 2 16 21 26 8 9 24 1 24 2 25 3 4 5 2 6 7 116 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 1 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 Serial Numbers/Notes 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 Add or remove shims as required to adjust gear backlash. 14.21:1 Differential (894509) 11.16:1 Differential (893491) 14.21:1 Differential (894509) 11.16:1 Differential (893491) > Change from previous revision 117 TURF TRUCKSTER Serial No. 84043 - All Serial No. 84044 - All 44.1 Transmission Clutch Release-Shift Selector Diesel Engine Only 5 4 2 3 9 7 6 11 10 7 12 8 13 14 15 1 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 Serial Numbers/Notes REF 1 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 Screw, M8-1.25 x 40 mm Screw, M8-1.25 x 55 mm 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 > Change from previous revision 119 TURF TRUCKSTER Serial No. 84043 - All Serial No. 84044 - All 45.1 Transmission Case Diesel Engine Only 6 3 37 3 3 4 38 5 24 4 6 26 25 1 39 14 11 23 35 31 32 27 17 29 30 15 16 19 36 2 20 18 13 12 10 7 9 8 120 1 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 1 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 x 120 mm Flange • Screw, M8-1.25 x 30 mm Flange • Screw, M8-1.25 x 40 mm Flange • Screw, M8-1.25 Flange Retainer, Input Shaft Bearing Screw, M8-1.25 x 25 mm Flange 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 x 100 mm Flange Screw, M8-1.25 Flange Screw, M8-1.25 x 40 mm Flange Stud, M8-1.25 Nut, M8-1.25 Hex Flange 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 Serial Numbers/Notes Upper and Lower Half See 46.1 > Change from previous revision 121 TURF TRUCKSTER Serial No. 84043 - All Serial No. 84044 - All 46.1 Input and Main Shaft 10 9 8 7 6 7 8 4 2 5 1 12 3 11 4 20 18 19 16 15 14 6 14 28 15 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 1 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 Serial Numbers/Notes 4th Gear Includes Hub and Sleeve 3rd Gear Includes Hub and Sleeve 2nd Gear 1st Gear Includes Hub and Sleeve Reverse Gear > Change from previous revision 123 TURF TRUCKSTER Serial No. 84043 - All Serial No. 84044 - All 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 2 8 10 1 10 3 10 B 4 4 C 6 D A 9 7 124 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 Serial Numbers/Notes 25411-85201 1 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 > Change from previous revision 125 TURF TRUCKSTER Serial No. 84043 All Serial No. 84044 All 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 I S 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 2 Wh/Bn 3 Bn 4 Rd/Bk 5 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 9 Wh/Rd 8 Temp Gauge Rd Wh/Bk Bk 7 Bk 6 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 P Fan Relay Bk Bk Bk Rd Rd Rd S Rd Gn Pk Rd Wh/Gn 40 A Wh/Rd Rd Rd Wh/Rd Ye Starter Solenoid G B 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 1 Engine Harness Connector #2 Engine Harness Connector #1 2 6 5 Flasher (Option) 2 Tail Light Harness Connector 1 4 Brake Accessory (Option) Turn Signal (Option) 7 4 Cab Stop Light (Option) Jumper Plug 3 Engine Harness Connector (Gas Only) Engine Harness Connector #3 Brake Pedal Switch 8 Ignition Switch Horn Button 9 7 11 12 V Accessory Plug Light Switch Clutch Pedal Switch Buzzer 10 Right Headlight 4 4 Dash Panel Right Turn Signal (Option) 11 Left Headlight Ground Wires Left Turn Signal (Option) 4 Brake Accessory (Option) 4 4 Heater (Option) Optional Accessories 4 4 Automatic Transmission (Not Used) Horn 14 Brake Fluid Reservoir 13 130 15 30 Fuse Block #2 10 15 15 15 10 Fuse Block #1 10 4 16 12 15 TURF TRUCKSTER Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 Qty. 825973 3 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 Terminal, 1/4” Male 14-16 Gauge Connector, Two Female Terminal Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Flasher Terminal, 5/16” Female 14-16 Gauge Connector, Six Female Terminal Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Two Male Terminal Terminal, 1/4” Male 14-16 Gauge Connector, Ignition Switch Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Rocker Switch Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Eighteen Terminal Terminal Connector, Headlight Terminal, 5/16” Female 14-16 Gauge Terminal, 5/16” Female 14-16 Gauge 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 > Change from previous revision 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 4 Engine Harness Connector #2 Engine Harness Connector #3 6 Fuel Shutoff Relay 5 2 Engine Harness Connector #1 Fuel Pump Fuel Level Sender 4 1 4 10 4 12 Fan Harness Fan Relay Fuse 13 Pre-Heat Relay 8 14 17 16 10 Fan Motor Fan Relay 11 Glow Plug Fuse 7 9 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 8 9 10 11 12 13 14 15 16 17 18 19 Qty. Description 601572 1 Engine Harness 825877 2 • 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 • Terminal, 1/4” Male 10 Gauge • Diode Connector Assembly • Connector, Two Female Terminal • Terminal, 1/4” Fem. 14-16 Gauge • 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, Female Relay • Terminal, 3/8” Female Relay • Connector, 2 Contact • Terminal, 3/32” Female • Seal, Wire • Block, Single Fuse • Fuse Clip, 1 Term., 14-16 Gauge • Fuse Clip, 1 Term, 10 Gauge • 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 • Connector, Two Male Terminal • Terminal, 1/4” Male 14-16 Gauge • Connector, Two Female Terminal • Terminal, 1/4” Fem. 14-16 Gauge • Connector, 70 Amp Relay • Terminal, Female Relay • Terminal, 3/8” Female Relay • Relay, 12V, 70 Amp SPST • Block, Single Fuse • Fuse Clip, 1 Term., 14-16 Gauge • Fuse, 40 Amp Serial Numbers/Notes Connector, Six Female Terminal Single Wire Two Wire Two Wire Single Wire Two Wire > Change from previous revision 133 TURF TRUCKSTER Serial No. 898627 All Serial No. 898628 All Serial No. 84054 All 51.1 Gas Engine Electrical Schematic Bn/Ye Gn/Wh 1 2 Bk/Rd Bk/Rd Wh/Rd Wh/Rd Pk/Gn Pk/Gn 3 5 6 7 8 Pk Wh Rd/Wh Bk/Gn Gn/Wh Bk Gn/Wh 9 Bl/Wh 10 11 12 ECU 13 Timing Plug Bn 4 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 P Og/Gn R Bn Rd N Bk Og/Bu D Gn/Bl Gn 2 Gn Gn/Bu 1 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 (Manual Transmission) 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 (Manual Transmission) Ye/Rd 10 A A Accessory Accessory Accessory Accessory Accessory Connector 1 Connector 2 Connector 3 Connector 4 Connector 5 Ignition Switch I 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 S 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 1 Tachometer Gas Tach Input Brake Fluid Level 2 3 Bn 4 Rd/Bk Starter Solenoid Rd Brake Fluid Level Switch Rd/Bk Rd Wh/Rd Bk Wh/Og Wh/Rd Bk B S 5 Voltmeter 6 Pre-Heat Gn/Wh 7 8 Wh/Ye High Beam 9 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 M 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 2 4 7 21 35” 35” 16” 20 19 80” Right Headlight 4 20 14” Horn Button Buzzer 9“ Tach / Speedometer Dash Panel Signal 10 Light Switch Speedometer Tach Signal Signal Ground Wires Jumper Plug 7 Clutch Pedal Switch 11” 19 20 3 9 4 Heater (Option) 4 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 4 Brake Accessory (Option) 3 Positive Standoff Wires 13 6 Turn Signal (Option) Flasher (Option) 5 Left Turn Signal (Option) Right Turn Signal (Option) 1 11” 12 V Accessory Plug Left Headlight 11 21 20 13” 19 8 Ignition Switch Brake Pedal Switch 11 4 Transmission Ground Wires Cab Stop Light (Option) Brake Accessory (Option) 28 B+ Starter Radiator Fan Tail Light Harness Connector 7 29 Fuel Pump 30 22 20-1/2” Fuel Sender 4 27 31 32 33 TURF TRUCKSTER Item Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 16 17 18 19 20 Qty. 825973 1 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 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 Terminal, 1/4” Male 14-16 Gauge Connector, Two Female Terminal Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Flasher Terminal, 5/16” Female 14-16 Gauge Jumper Plug, Taillight • Connector, Six Female Terminal • Terminal, 1/4” Female 14 Gauge • Terminal, 1/4” Female 10 Gauge Connector, Two Male Terminal Terminal, 1/4” Male 14-16 Gauge Connector, Ignition Switch Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Rocker Switch Terminal, 1/4” Female 14-16 Gauge Terminal, 1/4” Female 10 Gauge Connector, Eighteen Terminal Terminal Connector, Headlight Terminal, 5/16” Female 14-16 Gauge Terminal, 5/16” Female 14-16 Gauge 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 Fuse, 25 Amp Connector, 15 Amp Relay Terminal, Female Relay Connector, 70 Amp Relay Terminal, 1/4” Female Relay Terminal, 3/8” Female Relay Tubing, 3/8” I.D. Black Convoluted Tubing, 1/2” 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 2 4 7 21 35” 35” 20 19 80” Right Headlight 4 20 14” Horn Button Buzzer 9“ Tach / Speedometer Dash Panel Signal 10 Light Switch Speedometer Tach Signal Signal Ground Wires Jumper Plug 7 Clutch Pedal Switch 11” 19 20 3 9 4 Heater (Option) 4 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 4 Brake Accessory (Option) 3 Positive Standoff Wires 13 6 Turn Signal (Option) Flasher (Option) 5 Left Turn Signal (Option) Right Turn Signal (Option) 1 11” 12 V Accessory Plug Left Headlight 11 21 16” 20 13” 19 8 Ignition Switch Brake Pedal Switch 11 4 Transmission Ground Wires Cab Stop Light (Option) Brake Accessory (Option) 28 B+ Starter Radiator Fan Tail Light Harness Connector 7 29 Fuel Pump 30 22 20-1/2” Fuel Sender 4 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, 3/4” I.D. Black Convoluted Tubing, 7/16” I.D. Green Convoluted Connector, 12 Contact Male Terminal, Female Seal, Wire Plug, Cavity Connector, 26 Contact Male Lock, 26 Contact Terminal, Fermale Seal, Wire Plug, ECU Connector Connector, 4 Contact Male Terminal, Female Seal, Wire Connector, 3 Contact Female Terminal Seal, Wire Connector, 9 Contact Female Terminal Seal, Wire Terminal Seal, Wire Plug, 2 Wire Deutsch Lock, 2 Wire Deustch Terminal, 18-20 AWG Male Pin Lock, 4 Wire Deutsch Terminal, 18-20 AWG Socket Plug, 4 Wire Deutsch Serial Number / Notes 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. 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