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Cushman® Turf Truckster® Parts and Maintenance

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1. Gn Bk Bk Wh Bk Wh Bk Wh Bk Wh Bk Wh Gn Bk Wh 20A Ye 10A Ye Rd Clutch Switch Manual Transmission Ye Rd 10A ua ila on Pk Bu Wh O Rd Wh Gn o pq Os e Bk Bk Bk Bk Bk g a x 10A 5 6 u E 5 777 amp amp 5 e 3 E E g S Accessory Accessory Accessory Accessory Accessory ignition BC a Connector 1 Connector 2 Connector 3 Connector 4 Connector5 Switch OH 5 Bra Start B l S oB O c Rd Bn Wh Pk Pk Rd Wh Wh Engine Starter i Harness 4 e Solenoid Tachometer lt Connector 2 Ha Wh Rd Gas Tach Input Lk 2 Brake Fluid e o o XX po po pog PO lt Bn Level Switch BK OY Wh Og ju xx Brake Fluid Level L 4 Rd Bk Rd Bk d Bk LI APA Voltmeter a 17 4 bed Pre Heat lt Gn Wh ke Xx Temp Gauge 8 Wh Ye g lt Starter 4 High Beam lt lt 9 Wh Og i 10 4 xx Oil Pressure lt Bu gt k JET Fuel Sonder ent Og Og amp M TH Fuel Guage 4 ce Parking Brake ak Pk Bu P ibis XX ender 3 13 i xx Left Turn lt lt Gn Bk Gn Bk Tach Input Aki Wh Rd gt Right Turn E Ye Bk Ye Bk 12V 16 Bk Overheat lt 177 o Alarm amp Wh Bu Wh Bu Bk Pk Bu RR 12V 18 BkWh Coolant pas
2. dC TO Na If Using Jack Here Figure 5G 5 19 TOWING THE VEHICLE 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 Never tow the vehicle faster than 5 mph 8 km h Towing at excessive speed could cause either vehicle to lose proper steering control Adjust your speed for weather and surface conditions rain snow ice hills etc when towing Use care when loading or unloading machine onto a trailer or truck 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 towed vehicle and to control the brakes 2 Attach a tow rope to the front vertical frame member on either side of the vehicle only 3 Shift transmission into Neutral and release parking brake 5 20 GOVERNOR OIL LEVEL Suzuki Gas Engine only Check the oil level in the governor every 100 hours of use Check only when engine is cool 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 Capacity 1 5 oz 44 me Oil Type SAE 20W engine oil If fluid level is l
3. 10 gt Bk Rd AN N o s NG a 2 Engine Harness Connector 2 Pins 2 3 5 7 9 MT Engine AT Engine Pins 2 and 16 and 12 Not Used Harness Connector Harness Connector Not Used 158 TURF TRUCKSTER Injector 1 Br Bk Br Bk Bk Rd Bn Wh Bk Rd Injector 2 Gn Bk Rd Bn e Injector 3 Bn Wh Bk Rd Gn Wh Crank Angle o o Sensor 7 Bn Rd Bk POLE io BkIRd A Rd Bk Gn Rd Ye UR Rd Bk CA a Rd Bk Rd Bu d d Oxygen Wh ISC M Og Sensor Gy Bu Rave o Rd Bu Bk Rd a Bk Rd wh Knock ung Sensor Wh Wh Bk Bk Rd Gy Bu Wh a Crank Position 3 Sensor Bk Wh Bk Wh Bk Wh D o Coil Coil Coil 4 1 2 3 w 77 KK T Bk Wh Bk Rd 159 TURF TRUCKSTER 59 1 Diesel Engine Electrical Schematic Serial No 84063 All Serial No 84064 All
4. Tail Light N Pa UN NA Bn gt Bn gt Bn Bk Bk Bk 22 gt S Og N Bu Bk Bu Bk XA 5 c Rd Bk Brake Ingle Light Tail Light Horn nn Harness Button 9 68k 5 T dq Bk B Tn Cab Stop Og Bk Light Bk Accessory Brake P Wh Rd Accessory Bk Connector 1 gt o Brake og Accessory Bn Connector 2 e bud Brake 15A Pedal WEE Switch Wh O Og Bk Jumper ah dg Plug Bu Bk Og Ye Bk Wh Bu Flasher Ye Rd Bk N Og e 15A Turn Signal ag Ye Rd o Accessory S Og Bk Og amp Gn Bk E ilo KS Main Harness to Bu Bnd ee Engine Harness Left Headlight 5 Connector 4 N 7 Gas Units Low Beam y Bu Wh Bu Gn Bk d hd e BK Ng a 2 r Wh Bn Left Turn Gn Bk gt High B Signal Light m ea Accessory S LL Low Beam Bk e Right Turn paa Signal Light Bk High Beam N A Accessory i t Right Headlight Wh Og 161 TURF TRUCKSTER yg Juge YA UM IgM epoiq ma Pt Sus SO plousjog A s nid 777 epoiq epoiq 5 ei MOJI Wen en De NT sg yg oo Jd ya e lt Japuas ion jong je0H 01d PHUM e Loya plousjos kejay JOLIS Pa yoinus g uN u9 4M jong NA x o V 0S ce u9 50 1 O 5g pg v rpg ki 28 a RE YIUIMS 13 1 ot A ueg o N uo 9X na vZ8 pa L ES B
5. Automatic gt Gn Transmission Bk Controller gt 3 Heater Ye Gn Accessory Bk 20 A Accessory Ye Rd Connector 1 Bk Clutch Switch mE Pk Pk Accessory Ye Rd Wh Gn o d Connector 2 Bk S re 5 P s 6 a Accessory Bi A 19 s Connector 3 Bk ACC B A It Ignition OFF None I Switch ON B A l eng Start B l S Accessory Rd B Q Connector 4 Bk gt o o Overheat Alarm oo Wh Bu Bk Bk A Brake Fluid Power 4 Level Switch Point Tachometer LL Gas Tach Input lt 2 Wh Bn s S SUE FO lt 3 Bn re Brake Fluid Level lt 4 Rd Bk Pee Voltmeter ge 6 pq Pre Heat lt c ba lt 7 Wh Bk AA E O o x 1 Temp Gauge 8 Wh Ye a a x a lt PE 3H AHH sal al 2l al x R i 9 xx High Beam lt Wh Og V Nx NA RV ji vv vw sag i 0 O ERU ya EH Main Harness to Main Harness to Main Harness to en Fuel Sender lt 1 0g Engine Harness Engine Harness Engine Harness Fuel Guage Connector 1 Connector 2 Connector 3 vx Parking Brake lt 2 Pk Bu AA Ww Left Turn 3 Gn Bk XX nn Diesel Tach Input lt 4 Wh Rd Right Turn 5 Ye Bk 12V lt 6 Bk Overheat Alarm CRM Wh Bu 12 V lt 8 Gn Dash Panel 160 TURF TRUCKSTER
6. 113 AQOB0A4 iiem ASE 125 41130195 0 tak 113 EE 113 4113022 111 AB 149 151 4113986 91 93 101 4114867 cens 105 4115083 ceca 83 ABA 83 4115584 105 EU 125 AN TO 91 93 4117153 7 67 111 115 EE 43 EE 87 4118027 107 4i180995 tes 153 4418492 ea 107 ABA 107 4119760 oca 119 AAT OOOO iani o 141 4119866 8 101 4119867 8 101 DEER 89 4420070 co ese ties 83 4120096 89 4120097 89 4190098 onim 89 Ee ahead cor 73 4124567 121 4124568 121 4138391 enden 87 EE eege 103 4139209 103 EE 103 4139211 oce 107 4139442 ee s 83 4139601 s 43 4130794 xL sitis 45 4139939 elim 45 4139967 E 111 4140067 71 4140069 71 4140071 n 71 4140072 e 71 4140075 Peace 71 4140090 81 83 4140269 47 49 4140431 iin 63 4440617 kit 107 4140618 2 7 107 4140899 87 4141031 103 41410937 nie 141 4141425 uii 105 4142627 ivika 63 4142630 63 4142772 ee 87 4142796 pe 63 4144394 71 4144345 71 4146818 63 4146819 63 4147584 ee 45 4
7. 129 840754 81 83 815093 ses 145 827485 s 117 836536 149 840857 117 815182 145 SEN 51 836657 ss 133 840877 119 121 816307 61 63 828049 51 836698 133 8411647 irem 73 816401 45 828057 53 836682 133 841255 75 79 816586 75 828231 123 125 836675 129 04 T204 aaa 51 817104 51 105 828382 ees 43 836676 129 841330 oranes 75 817250 ime TLC 3828590 oe 79 836677 129 841404 eric 75 817320 121 828629 147 151 836678 129 841428 43 817397 euet 145 BEER eeneg deer 67 836680 129 041429 aaa aka 73 817928 a 77 829630 147 149 836681 129 841430 77 131 8183994 semi nene 103 BZ eege e 151 836682 129 841477G01 43 819923 79 829787 111 115 8368683 129 841630 73 820889 83 829954 111 115 836684 129 8410637 ineo 43 820899
8. 77 893586 nen 77 BEIENEE 67 833613 caosa 71 8936325 2 45 47 49 TEEN 71 894066 iced 85 894159 51 GIE 57 894179 Km 61 894201 111 115 894250 issiria 123 894308 57 59 894313 eine 67 894348 reete 81 894434 aa 105 894435 La 105 8944560 uin 57 894471 105 894508 ene 64 894519 nman 135 8945793 ila 73 894574 sse ne 73 894581 nee 69 894582 ala 69 894584 64 894602 123 125 894635 APA AP 75 894638 111 894675G01 117 894691 119 894696 53 119 894701 119 894702 iet 119 894825 71 127 131 894826 71 127 131 894886 135 894930 77 131 894931 77 131 894933 77 131 894934 77 131 894935 77 131 894936 77 131 894947 E 145 8949695 145 894989 niet 145 894998 7 69 87 89 BOOTS nine 57 167 World Class Quality Performance And Support Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technicians backed by Genuine Jacobsen Parts provide reliable high quality product support Pa
9. 87 89 452405 69 87 89 99 603102 105 807366 133 450193 101 109 452406 69 604174 61 63 Spend 145 450324 123 125 139 452408 75 64237 05 101 109 808060 79 450377 ain 55 59 452410 47 69 EE 81 2809099 ma 79 450369 scende TS 452441 ccrte 49 en 81 83 38090137 5s 57 77 4508995 ae Za 452445 oc tuna 67 800017 c cse 101 809152 un 55 INDEX 809174 ie 85 825886 57 147 151 832900 121 837301 147 151 809180 67 71 825889 151 833056 105 837303 43 809231 65 111 825894 147 151 833101 105 838154 issue 111 809254 etes 135 825899 147 151 833103 105 838295 8 101 109 8092695 121 825961 147 149 151 833104 105 838340 65 810152 57 59 825973 147 151 833257 149 153 838463 149 153 810435 57 133 825996 147 151 833273 59 838539 enne 131 810437 73 77 133 825997 147 149 151 833349 105 838602 85 810722 103 82
10. Diode Connectors 4 Ej L 2 1 4 e E 3 15 E Fuel Fuel Level Pump Sender 10 Diodes ee a Fan Relay EA Fuse 15 A Ground Pre Heat F 19 Relay 17 16 EZ Fan 13 10 e Relay L on Glow Plug Fuse Fan Motor Er Starter 9 Fan Radiator Fan F Switch DL Motor Fuse 18 14 03 EZ 20 18 Oil Cooler Fan Motor Fuse Temperature V Sender d d e Ground Starter Oil Cooler Alternator Solenoid Fan Motor 19 Radiator Fan Oil Cooler Fan Harness Harness 148 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 4174321 1 Engine Harness 1 825877 2 Connector Six Female Terminal 825748 AR Terminal 1 4 in Fem 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Fem 10 Gauge Two Wire 2 829630 1 Connector Four Male Terminal 825961 AR Terminal 1 4 in Male 10 Gauge Two Wire 3 884398 3 Diode Connector Assembly 4 826005 6 e Connector Two Female Terminal 825748 AR Terminal 1 4 in Fem 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Fem 10 Gauge Two Wire 5 843168 1 Connector Relay 842966 AR Terminal Female Relay 6 843167 1 Relay 12V 15 Amp DPST
11. Part Number Part Description 2811021 Fuel Solenoid 5000894 Injection Pump 5000901 Injection Pipe 1 5000902 Injection Pipe 2 5000903 Injection Pipe 3 4183586 Fuel Injector 5001265 Injector Return Pipe 4177227 Glow Plug 556412 Thermostat 4134370 Thermostat Gasket 4165525 Water Pump 557867 Water Pump Gasket 4177260 Oil Pan Drain Plug 2500811 Oil Pan Drain Plug Gasket 4113986 Oil Filter 4145944 Oil Fill Cap en 38 Part Number Part Description 2809955 Oil Fill Cap Seal 2500856 Valve Cover Gasket 557888 Starter Motor 4183623 Alternator NOTES 8 en 39 9 PARTS CATALOG 9 1 HOW TO USE THE PARTS CATALOG Abbreviations N S Not serviced separately 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 indicates that a note exists which contains additional information important in ordering that Indented Items Indented items indicate component parts that are included as part of an assembly or another component These parts can be ordered separately or as part of the main component part Item PartNo Qty Description Serial Numbers Notes e 1 123456 1 Mount Valve Indicates a piece part ug 789012 1 Valve Lift Includes Items 2 and 3 3 345678 1 Handle Serviced part included with Item 2 4 SD 1 Seal Kit Non serviced part inc
12. Power Port 15A Fan 15 A ECU Main Relay Headlights 15 A e Injectors Brake Light A P 10 A Backup Alarm 5th Wheel Brake 10 j Shift oc Flashers amp 10A OMOWO Moa Ecu Horn Heater 10A 10 A Wiper Accessary Dome Light amp Back Up Alarm Figure 5S K Right Turn C161 L Parking Brake C161 M High Beam C658 N Alternator Battery C161 1 4 turn clockwise to Place bulb and holder back into panel Turn holder secure into panel Ensure base of holder is properly seated in panel en 31 5 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 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 Kubota Diesel engine uses the following sequence code for 10 5 pulses revolution Kubota Diesel Sequence Code 00010100 The Truckster with a Suzuki Gas engine uses the following sequence code for 1 5 pulses revolution Suzuki Gas Sequence Code 00000010 5 28 HEADLIGHT REPLACEMENT Using a small blade screwdriver or similar tool push the Switch levers either up or down to match the sequence code for this unit Diesel Engine Setti
13. Gas Units Nang Diesel Units 17 70 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 894825 1 11 16 1 Rear Differential Assembly 84063 84064 and 84069 See 44 1 1 894826 1 14 21 1 Rear Differential Assembly 84067 and 84068 See 44 1 2 800198 1 Locknut 1 2 20 3 809180 1 Flat Washer 1 2 4 893862 2 Spring Leaf 5 843238 2 e Bushing Nylatron 6 893613 2 Upstop 7 813850 2 Bumper Travel Limiting 8 887187 4 U Bolt 2 x 5 1 4 in 9 444730 8 Nut 7 16 14 10 800909 10 Nut M12 1 5 Wheel Lug 11 4243008 2 Wheel and Tire Ultra Chevron 4243003 1 Tire 24 x 13 12 4 Ply 4243002 Ile Tire 24x 13 12 6 Ply Optional Tire 4243006 1 Rim 12x 10 50 360111 1 Stem Valve 12 311398 6 Screw 1 2 13 x 3 1 2 in Hex Head 13 800602 6 Nut 1 2 13 Nylon Insert 14 843876 4 Shackle Rear Spring 15 843238 2 Bushing Nylatron 16 807332 2 Shock Absorber 17 823621 4 Bushing 18 825500 4 Washer 7 16 Cupped 19 800294 4 Locknut 7 16 14 Center 20 311396 2 Screw 7 16 14 x 2 1 4 in Hex Head 21 4174288 1 Driveshaft Complete Diesel Engine 21 4144334 1 Driveshaft Complete Gas Engine MT 21 4140071 1 Driveshaft Complete Gas Engine AT 22 4174287 1 Shaft Drive Diesel Engine 22 4144345 1 Shaft Drive Gas Engine MT 22 4140067 1 Shaft Drive Gas Engine AT 23 554663 2 Cross and Bearing Kit Includes Grease Fitting 24 4140069 1 Yoke Dif
14. Cab Stop Light Option Option Brake Pedal lt Switch ei 12V Accessory gi Plug Left Turn TG Speed Sensor Shift 25 p Back Up Solenoid DP Switch e Shift Switch 27 Back Up Alarm 21 35 I 19 Signal Left Headlight Right Turn Signal Ex 4 Option Q Right Headlight 3 11 Tach Speedometer Dash Panel Signal Positive CO CAN Block 1 150 Wires Turn Signal 5 Option Jumper Plug Ke Flasher Option Clutch Pedal 7 Switch Horn Button lt Aa Light Switch o Speedometer dpa Signal A igna Ground Heater Wires i Option Optional Accessories A X Brake Accessory Option b 33 Shifter 32 Light 31 Le Diagnostic aj Plug Fan Relay Main K e Brake Fluid Reservoir Fuel Relay Relay Fuse Fuse e 17 Block Block 2 ock 3 3 amp TURF TRUCKSTER Item Part No Qty Description Serial Number Notes 1 825973 1 Connecter Six Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge Single Wire 8
15. tem 8 Routing 124 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 450452 4 Nut M6 1 Hex Flange 2 450544 4 Screw M6 x 30 mm Pan Head 3 2701464 1 Solenoid Starter 120052 2 Lockwasher 10 2702244 2 Nut 10 32 Hex 306325 2 Lockwasher 5 16 443106 2 Nut 5 16 18 Hex 4 4244442 1 Bracket Horn Brake Fluid Reservior 5 800943 16 Screw 410 16 x 3 4 in Thread Cutting 6 886090 1 Horn 7 800934 3 Screw M6 1 x 16 mm Hex Flange 8 4238042 1 Harness Main See 54 1 9 843942 1 Socket 12V Accessory Plug 10 2701658 1 Panel Instrument with Tachometer 11 890000 1 Buzzer High Temperature Located NISI TORO Sole dash panel 12 831225 4 Clamp Wire Harness 13 306419 4 Screw 1 4 20 x 1 2 in Hex Head 14 306488 2 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 2 Flat Washer 1 4 17 4183304 1 Positive RED Battery Cable Manual Transmission 17 4183303 1 Positive RED Battery Cable Automatic Transmission 18 4183301 1 Negative BLACK Battery Cable Battery to Manual Transmission 18 4183302 1 Negative BLACK Battery Cable Battery to Automatic Transmission 19 306325 1 Lockwasher 5 16 20 450324 1 Nut M8 1 25 Hex 21 894602 1 Cable Frame Ground Manual Transmission 21 884513 1 Cable Frame Ground Automatic Transmission 22 450453 1 Nut M8 1 25 Hex Flange 23 452388 1 Screw M8 1 25 x 20 mm Flange 24 4154081 1 Cover Positive Battery
16. 103 105 4205580 47 450410 57 87 89 45269543 51 59 61 63 800026 67 4206760 det ABO 47 85 452738 97 800073 ausis 91 93 4208620 43 450422 91 deng TO 800113 RE 117 4209665 93 45045245 51 55 69 81 d nne 119 800146 81 4210205 coc 93 83 97 113 119 4719914 cnc 73 8001727 22 67 81 83 4211800 129 121 123 125 429149 naam 43 79 800198 71 4211960 135 45045345 47 49 53 55 48540 01 101 800221 111 115 4216305 93 57 59 67 69 5000913 107 BOUDOT I ue 105 4218650 a 113 79 81 83 85 5000914 99 107 800271 51 97 105 4218621 113 91 93 97 107 5000919 99 800279 steiere 117 4218622 113 111 113 117 5000920 99 800294 71 4221100 81 125 149 TE EINE 125 515268 51 3800844 es 43 4223561 113 45045453 55 57 61 63 517226 129 800425 145 Ee 107 4867 89 87 89 Slide 53 800446 55 4232042 suem 109 91 93 99 103 523085 45 800485 75 4233001 119
17. 83 845231 ae 45 845234 na 45 9045257 ciis 145 845327 sss 153 845328 oid 153 845330 153 845345 7 e 64 845356 131 869154 ies 64 879807 145 882971 69 882998 121 8832396 121 884398 paaa 149 884513 nn 125 884574 121 885249 ne 119 886001 121 886090 123 125 886270 ea 53 Belege 119 BOT ABT uio sen ee 71 887259 79 e EEN 75 887994 91 93 95 119 888549 107 889681 75 889780 costes nce 133 BBOBT dossiers 129 889871 uc ecd 129 889925 133 890000 123 125 890930 113 891089 exis laeta 135 891829 127 129 8921645 iioc 64 Dees 79 B3246D a cito ius 79 892534 AMMAS 91 892601 BEEN 119 892051 sa dnas 57 8985039 cota 59 893067 eut derit 55 893145 7 as 69 893199 7 2 c unice 69 893199 G02 69 893233 nie ka 73 893234 EE 73 893266 73 893322 nie 45 893344 nn 79 BMBF ne 67 893488 67 893519 131 893525 69 893539 117 893541 45 EE 79 893581 RE 131 EE 131 893583 127 893585
18. 137 130728 97 103 105 2700514 131 2702548 nc 87 061 11 06003 141 160410 105 2700515 131 21702559 s 141 06111 12004 143 17680 50F70 81 2700525 es 105 2702561 141 08310 00103 85 18292 G1 113 2700530 131 2702659 137 139 09103 08152 139 22100 85200 91 93 2700531 131 2702662 139 09111 08035 91 93 22400 85141 91 93 2700540 103 2702665 139 09128 10002 143 23260 85203 137 2700757 59 125 2702683 139 09135 08005 143 23265 85200 137 2700792 43 2702684 137 09160 17035 143 23266 85002 59 X 2700796 53 X 2702686 87 89 09162 080068 143 24110 80410 141 21400797 en 53 2702687 87 09166 16014 145 24121 85252 141 2700800 117 2702688 87 89 09166 30007 141 24131 83002 139 2700801 117 2702689 87 89 09168 10007 143 24211 83011 141 2700859
19. All Views Rotated 90 for Clarity 50 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 841663 1 Panel Floor Access 2 800943 10 Screw 1110 14 x 5 8 in Self Tapping 3 894159 1 Pedal Throttle 4 524633 2 Bolt 5 16 18 x 1 in Shoulder 5 524643 2 Bearing Split 6 548911 2 Nut 5 16 18 Flange 7 2703257 7 1 Bracket Foot Throttle 8 452378 6 Screw M6 1 x 20 mm Flange 9 450452 6 Nut M6 1 Flange 10 843997 1 Bracket Pedal Stop 11 843562 1 Mount Channel 12 452695 1 Screw M6 1 x 20 mm Self Tapping 13 830784 1 Clevis Pin 1 4 x 1 7 8 in 14 306328 4 Cotter Pin 3 32 x 3 4 in 15 843563 2 Plate Pivot 16 843561 1 Link Throttle Pivot 17 806714 3 Clevis Pin 5 16 x 3 4 in 18 844224 2 Roll Pin 3 16 x 1 3 4 in 19 515268 2 Bushing 20 844223 2 Spring Torsion 21 2703683 1 Throttle Cable Diesel Vehicles See 28 1 21 2703684 1 Throttle Cable Gas Vehicles See 31 1 22 828049 1 Throttle Hand 23 843607 1 Bushing Throttle Cable 24 817104 1 Stop Wire 25 111898 2 Clamp Cable 26 800271 6 Screw 10 24 x 1 2 in Pan Head 27 120052 6 Lockwasher 10 28 306531 6 Nut 410 24 Hex 29 844116 1 Decal Speed Control Panel 30 841264 1 Panel Speed Control 31 830366 1 Switch Horn 32 843581 1 Switch Light 33 844130 1 Cable Governor Control See 28 1 or See 32 1 34 827821 2 Knob 35 800582 6 Screw 1 4 10 x 3 4 in Truss Head 36 2700496 4 Insert 1 4
20. Item Part No Qty Description Serial Numbers Notes 1 882993 1 Cylinder Dump Box 883236 Ile Seal Kit Texas Hydraulics 884574 Ile Seal Kit Columbus Hydraulics 886001 Ile Seal Kit DANA Hydraulics 2 830810 2 Pin Clevis 3 809265 4 Hair Pin 4 821893 AR Trim Push On 5 817320 1 Clamp Hose 6 452378 2 Screw M6 1 x 20 mm Hex Flange 7 450452 2 Nut M6 1 Hex Flange 8 826558 1 Fitting 9 16 18 90 9 844019 1 Hose Selector Valve to Control Valve 10 4124567 1 Hose Control Valve to Coupler Control Valve Port B 11 4233001 1 Bushing Flip Lock 12 840877 1 Sleeve Nylon 13 832408 2 Coupler Half Male 14 832414 4 Ring Retaining 15 832409 2 Coupler Half Female 16 835101 2 Fitting 3 8 in NPT 90 17 832900 1 Hose Lift Cylinder to Coupler 18 823119 1 Fitting 1 4 in NPT 19 840877 1 Sleeve Nylon 20 844598 1 Hose Control Valve to Coupler Control Vale Port A 21 REF 1 Control Valve See 6 1 22 REF 1 Selector Valve See 6 1 23 320107 4 Tie 7 1 2 in Cable Not Shown Secures Nylon Sleeve 24 4124568 1 Hose Lift Valve to Coupler 25 842800 1 Clamp Hose Change from previous revision 121 TURF TRUCKSTER 42 1 Diesel Electrical Components Serial No 84064 All H NIS gt Engine Harness N i Ground Wires 122 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 450452 4
21. Procedure for overensstemmelsesvurdering St j Procedure van de conformiteitsbeoordeling geluid Vastavushindamismenetlus m ra Vaatimustenmukaisuuden arviointimenettely Melu Proc dure d valuation de conformit bruit Konformit tsbeurteilungsverfahren Ger usch Ara ikaoia Ag oA ynong Xuup pouong O pu og Megfelel s g rt kel si elj r s Zaj Procedura di valutazione della conformit rumore Atbilst bas nov rt juma proced ra troksnis Atitikties vertinimo proced ra garsas Procedura tal Valutazzjoni tal Konformit Hoss Procedura oceny zgodno ci poziom ha asu Processo de avalia o de conformidade nivel sonoro Procedura de evaluare a conformit ii zgomot Postup vyhodnocovania zhodnosti hluk Postopek za ugotavljanje skladnosti hrup Procedimiento de evaluaci n de conformidad ruido Procedur f r bed mning av verensst mmelse buller 2000 14 EC Annex V UK Notified Body for 2000 14 EC Hotupnynpan opran B ObenuHeHoTo kpancteo 3a 2000 14 EO ad certifikovan podle sm rnice 2000 14 EC Det britiske bemyndigede organ for 2001 14 EF Engels adviesorgaan voor 2000 14 EG hendkuningriigi teavitatud asutus direktiivi 2000 14 E m istes Direktiivin 2000 14 EY mukainen ilmoitettu tarkastuslaitos Isossa Britanniassa Organisme notifi concernant la directive 2000 14 CE Britische benannte Stelle f r 2000 14 EG Koivotroinu vog Opyaviou
22. e dem he Headlight KB we y RY Kai PR Es Remove The Four 4 Screws For Headlight Removal Remove The Two 2 en Screws For Bulb d Or Lens Replacement E Figure 5V 5 30 EFI DIAGNOSTIC CHECK Suzuki Gas Engine units only The electrical system is equipped with an OBD II diagnostic connector Manual transmission Engage parking brake shift transmission to Neutral and turn the ignition switch to the OFF position Automatic Transmission Engage parking brake place gear selector in Park and turn the ignition switch to the OFF position 5 31 CARE AND CLEANING MAINTENANCE 5 Open the front cowl and locate the OBD II connector on the brake fluid reservoir bracket Plug an OBD II reader into the connector turn ignition switch to the ON position do not start engine and refer to the instructions included with the reader to retrieve diagnostic codes Refer to the Truckster Technical Repair Manual for code descriptions Wash the vehicle after each use Keep the equipment clean Note Do not wash any portion of the equipment while it is hot Do not use high pressure spray or steam Use cold water and automotive cleaners 1 Use compressed air to clean engine and radiator fins A special blow gun is available through Cushman Dealer 2 Use only fresh water for cleaning your equipment Note Use of salt water or affluent water has been known to encourage rust and corrosion of metal par
23. o BNG Ny rii gt v E amp 76 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 2702257 7 2 Front Hub Includes cup portion of Items 3 amp 4 2 800908 4 Bolt M12 1 5 x 42 mm Wheel 3 500534 2 Outer Bearing Cup and Cone 4 500596 2 Inner Bearing CUp and Cone 5 2702217 1 Tube Left Front Brake 6 841839 1 Tube Right Front Brake 7 817928 2 Seal Grease 8 2702247 2 Nut 3 4 16 Castle 9 304636 2 Cotter Pin 1 8 x 1 1 8 in 10 817250 2 Cap Grease 11 841430 2 Brake Drum 12 893585 1 Front Left Side Brake Assembly 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894933 1 Kit Left Side Spring 894935 1 Kit Left Side Adjuster Repair 13 893586 1 Front Right Side Brake Assembly 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894934 1 Kit Right Side Spring 894936 Ile Kit Right Side Adjuster Repair 14 452398 10 Screw M10 1 5 x 20 mm Hex Flange Grade 8 8 15 841842 1 Tee M10 1 0 Flare Union 16 843418 1 Clamp Tee 17 452692 1 Screw M6 1 0 x 12 mm Taptite 18 841841 2 Hose Brake 19 2703081 2 Protector Brake Hose 20 842104 2 Bracket Brake Tube 21 810437 2 Clamp Hose 22 8091
24. 103 2702690 87 89 139 09205 03019 137 24220 60A01 141 2700888 149 151 2102695 c 61 09205 05012 143 24400 83002 141 2700869 149 151 2702696 63 09246 16010 145 24410 83000 141 2700913 151 21021950 namain 89 09250 10006 143 24420 83000 141 2700933 153 2702883 143 09261 03017 143 24431 83001 141 EAR LAKE 117 2702996 61 09262 2801 9 139 24432 83001 141 2701129 103 2703002 59 09262 28020 139 24436 83000 141 2 012293 ote 45 2703081 77 09262 30086 141 24471 60400 141 2701253 77 131 2703158 43 09263 30031 141 24473 70D10 141 27012795 ues 63 2703257 7 51 09263 35015 141 24671 83000 139 2701371 63 2703294 69 09280 11002 137 24700 85200 139 27014068 131 2703309 131 09283 25088 139 24741 83001 139 2701442 83 2703453 141 09284 17004 143 24821 09001 143 27014
25. Change from previous revision 129 TURFTRUCKSTER 000000 46 1 Axle Tubes and Shafts Serial No All 130 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 894826 1 Differential Assembly 14 21 1 Differential 1 894825 1 Differential Assembly 11 16 1 Differential 2 2702535 7 1 Tube Right Side Axle 3 2702534 7 1 Tube Left Side Axle 4 2700530 1 Left Side Axle Assembly 2700514 1 Shaft Left Side Axle 5 845356 1 e Washer 6 800743 1 Nut 5 8 18 Slotted Hex 7 304636 1 Cotter Pin 1 8 x 1 1 8 in 8 2700531 1 Right Side Axle Assembly 2700515 1 e Shaft Right Side Axle 9 845356 1 e Washer 10 800743 1 Nut 5 8 18 Slotted Hex 11 304636 1 Cotter Pin 1 8 x 1 1 8 in 12 836694 2 Seal 1 3 4 in I D O Ring 13 2703481 2 Seal 2 in I D O Ring 14 4171761 2 Collar Axle Bearing 15 838539 2 Seal Oil 16 836695 2 Bearing Tapered Roller 17 893581 1 Left Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894933 1 Kit Left Side Spring 894935 1 Kit Left Side Adjuster Repair 18 893582 1 Right Side Brake Assembly Includes Parking Brake Lever 894930 1 Kit Brake Cylinder Replacement of Cylinder 894931 1 Kit Brake Cylinder Repair Repair of Cylinder 2701253 1 Kit Brake Shoe Includes Left and Right sides 894934 1 Kit Right Sid
26. Stud M10 1 25 x 65 mm 8 2702686 1 Screw M10 1 25 x 55 mm Flange 9 2702756 1 Screw M10 1 25 x 50 mm Flange 10 2702690 2 Alignment Pins 11 4148361 1 Starter Automatic Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 4233440 2 Cover Belt 15 4235369 1 Standoff M6 1 x 25 mm 16 450169 3 Screw M6 1 x 14 mm Hex Head 17 450410 3 Lockwasher M6 18 894998 7 1 Left Engine Mount See 14 1 19 2701697 7 1 Right Engine Mount See 14 1 20 4179803 1 Transmission Mount See 14 1 21 452405 3 Screw M10 1 5 x 80 mm Flange 22 450454 3 Nut M10 1 5 Hex Flange 23 4120098 1 Plate Rear Drive 24 4120096 1 Flange Drive Plate 25 4119955 6 Screw M10 1 25 x 18 5 mm gt Change from previous revision 89 TURF TRUCKSTER 26 1 Diesel Engine and Clutch Serial No 84064 1651 xxxx 90 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4173201 1 Engine Kubota D1105 E3B 4113986 1 Engine Oil Filter 4183623 Ile Alternator 2 4174200 1 Bracket Hydraulic Pump 3 4174440 1 Mount Right Side Engine 4 800547 8 Screw M10 1 25 x 20 mm Flange 5 303269 8 Lockwasher 7 16 6 887994 1 Pump Hydraulic See 40 1 7 4174260 1 Reducer 3 8 NPSF to 1 8 BPT 8 103867 1 Flat Washer 5 16 9 843857 1 Temperature Sender 10 452389 9 Screw M8 1 25 x 25 mm Flange 11 892534 1 Pump
27. Washer 17 x 32 x 1 2 mm 17 25541 85201 1 Lever Gear Select 18 25545 85055 1 Dog Reverse Shift Limit 19 25546 60C01 1 Spring 20 09128 10002 1 Bolt M10 x 9 mm Retaining 21 09168 10007 1 Gasket 22 25547 70D00 1 Spring 23 09135 08005 1 Ball 24 2701953 1 Pin 25 25530 79501 1 Shaft Gear Select 26 09286 09001 1 Seal Oil 27 25535 85412 1 Arm Gear Select 28 09162 08008 1 Washer 29 2702883 1 Washer 30 2702494 1 Nut M8 1 25 Hex 31 25536 84200 1 Boot Gear Select 32 09135 08005 1 Bolt Retaining 33 24821 09001 1 Plug Breather Change from previous revision 143 TURF TRUCKSTER 53 1 Mechanical PTO a Diesel Units Only 144 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 845257 1 Housing Mechanical PTO 2 N S 1 Bushing Output Shaft 3 2700121 1 Gasket PTO Housing to Trasmission 4 2700120 1 Gasket Bearing Housing 5 894989 1 Housing Bearing 6 844188 1 Seal Oil 7 815093 Ile Bearing Ball 8 452389 3 Screw M8 1 25 x 25 mm Flange 9 844185 1 Shaft PTO Output 10 815182 1 Gear 21 Tooth PTO Sliding 11 844187 1 Bearing Ball 12 815085 1 Fork Sliding 13 879807 1 Arm PTO Shifter 14 548477 AR Shim 15 812419 AR Shim Transmission 16 807624 1 O Ring 17 817397 1 Arm PTO Shifter 18 120166 1 Lockwasher 1 2 19 301988 1 Nut 1 2 20 Hex 20 548204 1 Set Screw 3 8 16 x 3 8
28. sloven ina EAAnvika Svenska en 11 4 ADJUSTMENTS 4 1 GENERAL 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 adjustment cannot be made contact an authorized Cushman Dealer 4 2 ENGINE ACCESS Never remove or install the engine cover while the engine is running The engine cover is a machinery guard and its removal exposes you to moving parts Keep hands hair and clothing away from flywheel radiator cooling fan alternator fan engine belts pulleys and air intake Keep clothing hands and hair away from moving parts These items could become entangled causing serious personal injury 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 When replacing the engine cover make sure the retaining t
29. 37 1 Gas Fuel System Serial No 84068 All Serial No 84069 All CONNECT TO FUEL INJECTOR RAIL nat lt CONNECT TO REAR FACING i PORT ON INTAKE MANIFOLD CQ EN 22 22 33 35 N 112 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4218621 1 Hose Fuel Tank to Adapter 5 16 in 6 Ft Length Cut to 14 in 2 830930 2 Clamp Hose 3 4218622 1 Hose Adapter to Pump 7 16 in 6 In Length Cut to 3 in 4 4218621 1 Hose Pump to Fuel Filter 5 16 in 6 Ft Length Cut to 9 in 5 4218621 1 Hose Fuel Filter to Tee 1 4 in 6 Ft Length Cut to 4 1 4 in 6 4218621 1 Hose Tee to Engine 1 4 in 6 Ft Length Cut to 29 in 7 4113019 1 Adapter 5 16 to 7 16 in Hose 8 4223561 1 Clamp Hose Clutch Type 3 8 O D 9 2701897 1 Pump Electric Fuel 10 2701898 1 Fuel Filter 11 2700177 1 Regulator Fuel 12 452378 2 Screw M6 1 x 20 mm Hex Flange 13 450452 2 Nut M6 1 Hex Flange 14 800930 2 Screw M8 1 25 x 16 mm Hex Flange 15 450453 2 Nut M8 1 25 Hex Flange 16 800875 1 Nut M12 1 25 Hex 17 309067 1 Lockwasher 1 2 in External Tooth 18 2701693 7 1 Bracket Fuel Pump See 15 1 19 829997 1 Grommet 20 4218621 2 Hose Adapter to Regulator 1 4 6 Ft Length Cut to 2 in 21 4218620 1 Hose Tank Return to Adapter 5 Ft Length Cut to 20 in 22 825624 15 Clamp Hose 23 831039 1 Hose Regulator to Tee 25 Ft Length Cut to 2 in 24 2700166 1 Clamp
30. 4175401 67 4175402 81 83 4175560 91 93 41759551 missest sdai 101 4175952 ae 101 4175620 101 4176248 113 4176887 81 4176960 101 ANT dE ees 81 4177560 101 4179800 81 149 4179801 81 149 4179802 5 5 111 4179803 69 87 89 4179842 101 4180501 113 4180601 111 115 4183301 123 125 4183302 125 4183303 123 125 4183304 125 4183623 91 93 4183634 101 4184320 49 4184900 135 4184901 135 4185240 101 4185540 69 111 4186780 91 93 4186900 135 4188387 95 108 4189960 105 4190700 101 4190701 101 4191140 85 101 4192125 85 4194420 ie 57 4194421 57 4194500 57 4202860 55 INDEX 4203360 87 450400 43 452424 57 59 800021 111 115 420338 asa ipsios 87 450801 usate 47 452692 61 63 77 113 800024
31. All 118 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 844564 1 Hose Tank to Filter 2 836206 4 Clamp Hose 3 844583 1 Fitting 90 4 844566 1 Fitting Straight 5 844628 1 Hose Pump to Selector Valve 6 844652 1 Fitting 9 16 18 x 3 4 16 Straight 7 844600 1 Hose Selector Valve to Coupler 8 844571 1 Fitting 9 16 18 x 3 4 16 90 9 835101 2 Fitting 3 8 in NPT 90 10 840877 1 Sleeve Nylon 11 4233001 1 Bushing Flip Lock 12 894702 1 Coupler Half Dry Seal Male 13 832414 2 Ring Rataining 14 894701 1 Coupler Half Dry Seal Female 15 452380 2 Screw M6 1 x 00 mm Flange 16 844973 2 Bushing 17 450452 2 Nut M6 1 Hex Flange 18 844600 1 Hose Coupler to Filter 19 844627 4 Fitting 3 4 16 Tee 20 4118760 1 Hose Control Valve to Filter 21 844590 1 Fitting 3 4 16 x 1 1 16 12 Straight 22 894691 1 Head Filter 23 885249 1 Filter Element 24 3001025 1 Fitting 90 25 844565 1 Hose Filter to Tank 26 REF 1 Control Valve See 6 1 27 894696 1 Selector Valve See 6 1 892601 1 Seal Kit 28 887994 1 Pump Hydraulic 463005 1 Key Woodruff 5 887017 1 Seal Kit 29 844937 1 Plate Coupler Retainer 30 320107 2 Tie 7 1 2 in Cable Not Shown Secures Nylon Sleeve Change from previous revision 119 TURF TRUCKSTER 41 1 Lift Cylinder Circuit Serial No All 120 TURF TRUCKSTER
32. Automatic NG Transmission 5 Bu Bk 7 Og Gn p Wh Ye 6 Rd Ro Pk Rd Og Bu N AT Engine o n O C Bn Ye WA Harness a y BU E Do Bk Gn Connector Bu Wh Gn Pk 2 Bk Rd Pins 2 and 16 Bk Rd Gn Bu 1 Not Used 10 o Bn Ye 11 N23 Bu Wh Pk 12 Gn Bu PK B Sb huir Gn Wh 18 PK Gn 14 Rd Gn Pk Bk Wh e o FE y gun Bu Bk A Shift Solenoid MT Engine o Bu Wh I Automatic Harness me 777 o 7 Transmission e Connector 6 gt 8 Bu Wh Ye Pins 2 3 5 7 9 and 12 10 5 Eu Rd Bu Not Used 44 Gn Wh e Gn Wh 154 TURF TRUCKSTER Gn Bk Bk Wh B Rave Shifter Bk Wh e D Light N 7 25A Bk Wh Bk Wh Wh Rd LA Rd Bk p A 15 A Rd O Bn Ye Bn Ye g 10A Gn Wh Gn Wh bag Pr 10A Bk Rd Fan Wh Rd Motor Bu oT Ye Ye Bk Fan Me Rd Gn Relay RaGn Bk Rd 77 V O Bk G Ng Bk Gn OT PiBu PkBu Fuel Je Fuel Pump pee Relay Bkwh j Pk Rd Wh Pk Wh Rd o BkRd Pk Main Relay Wh Rd Bk Gn Wh Bk Wh Og Og Speedometer Wh Rd Signal A Bk Rd fe Og Bk Speed 7 Pk Sensor Wh Bk Gn Bk Rd Bn Ye Wh Pk Pk Rd Bk Wh Reverse Switch Manual Transmission Bn Ye Rd Rd D dq bd Backup Alarm Bk 4 Wh Ye Wh Ye Bu Bu Gn Wh Gn Wh 155 TURF TRUCKSTER
33. Strap Assembly Fuel Tank 19 834005 1 Seal Foam 20 103867 1 Washer Flat 21 800221 1 Nut Hex Crownlock 5 16 24 Change from previous revision 115 TURF TRUCKSTER Serial No All 39 1 Hydraulic Tank and Filter 116 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 894675G01 1 Tank Hydraulic 2 452388 2 Screw M8 1 25 x 20 mm Flange 3 450453 2 Nut M8 1 25 Hex Flange 4 452399 2 Screw M10 1 5 x 25 mm Flange 5 800113 2 Plug 1 2 NPT 6 893539 1 Dipstick Hydraulic Tank 7 827486 1 Valve Pressure Relief 8 N S 1 Battery 12 Volt 9 844601 1 Bracket Battery Clamp 10 452389 1 Screw M8 1 25 x 25 mm Flange 11 844729 AR Spacer Battery Clamp Add as required to secure battery 12 2700800 1 Hydraulic Cover Used on all except 84064 13 837270 1 Decal Hydraulic Connections 14 2700801 1 Hydraulic Cover EC Used on 84064 Only 15 840857 1 Decal Hydraulic Connections 16 800930 4 Screw M8 1 25 x 16 mm Flange 17 REF 1 Hydraulic Filter 18 548827 2 Screw 1 4 20 x 1 2 in Hex Flange 19 2701107 7 1 Panel Access Diesel Vehicles 19 841805 1 Panel Access Gas Vehicles 20 300646 4 Screw 1 4 20 x 3 4 in Truss 21 308090 4 Flat Washer 1 4 22 800279 4 Nut 1 4 20 Speed 23 821893 1 Trim Push On Change from previous revision 117 TURF TRUCKSTER 40 1 Hydraulic Pump and Filter Serial No
34. There are two access panels located under the front cowl and one located in the middle of the floorboard Remove panel A under cowl to access the shifter linkage and wiring for the instrument panel Remove panel B under cowl to access the front suspension Remove the center panel C in the middle of floorboard to access the throttle cable accelerator pedal linkage wire harness and rear hydraulic brake line NOTE t will be necessary to remove the accelerator pedal in order to completely remove the center floorboard panel ADJUSTMENTS 4 Pull Lever To Release Cowl Latch E Ko Front Cowl ls A Release Lever gt Figure 4E en 13 4 ADJUSTMENTS 4 5 DIESEL 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 in 6 to 12 mm with a 20 Ib push at midpoint between water pump and alternator pulleys If tension is incorrect loosen alternator mounting bolts D and adjust alternator until proper belt tension is achieved 4 6 DIESEL 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 in 6 to 12 mm with a 20 Ib push at midpoint between pulleys If tension is incorrect loosen pump mounting bolts E and carefully pry pump awa
35. 1 Cap Water Thermostat 27 4148206 1 Thermostat 88 C 28 2701442 1 Housing Temperature Sender 29 2701513 1 Gasket Thermostat 30 820889 4 Clamp Hose 31 2701108 2 Clamp Hose 32 4140090 1 Foam 1 1 4 x 1 x 13 in 33 11391G4 1 Clamp 1 4 to 5 8 in Worm Drive 34 4139442 1 Hose Upper 35 4115400 1 Hose Lower Radiator 36 833715 1 Plug Tube 37 452392 2 Screw M8 1 25 x 50 mm Flange 38 009034880 1 Decal Fan Warning 39 840754 1 Decal Radiator Pressure Warning 40 832033 1 Clamp Hose 41 4148150 1 Sensor Water Temperature 42 548910 2 Nut 1 4 20 Hex Flange 43 548827 2 Screw 1 4 20 x 1 2 in Hex Flange Change from previous revision 83 TURF TRUCKSTER Serial No 84063 All Serial No 84064 All 23 1 Diesel Engine and Transmission Mounting 84 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine and Clutch See 26 1 2 4192125 1 Frame Engine Mount 3 REF 1 Mount Engine See 14 1 Left shown right similar 4 306836 2 Screw 3 8 16 x 2 1 4 in Hex Head 5 306981 6 Flat Washer 3 8 6 841885 2 Mount Engine Isolation 7 809174 2 Washer Isolator 8 120177 4 Lockwasher 3 8 9 306562 2 Nut 3 8 16 Hex 10 452388 6 Screw M8 1 25 x 20 mm Flange 11 450453 12 Nut M8 1 25 Flange 12 452389 8 Screw M8 1 25 x 25 mm Flange 13 825884 1 Clamp 14 400108 1 Screw 1 4 20 x 1
36. 1 Counter Shaft 12 09262 28020 1 Bearing Center 13 24671 83000 1 Gear Countershaft Reverse 14 REF 1 Input and Main Shaft See 51 1 15 09283 25088 1 Seal Oil 16 09390 68002 1 C Ring 17 09390 62010 1 C Ring 18 844184 1 Spacer 5th Gear 19 452381 1 Screw M6 1 x 40 mm Flange 20 844186 1 Washer Special 21 2702662 1 Plug Inspection Timing 22 452396 7 Screw M8 1 25 x 90 mm Flange 23 2702683 1 Seal Extension Case 24 452390 1 Screw M8 1 25 x 30 mm Flange 25 01421 08303 1 Stud M8 1 25 26 450324 1 Nut M8 1 25 Hex Flange 27 2702690 2 Pin Alignment 28 N S 1 Mechanical PTO Assembly See 53 1 29 28391 85202 1 Bracket Shift Cables Change from previous revision 139 TURF TRUCKSTER 51 1 Input and Main Shaft EUNDEM 140 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 24110 80410 1 Shaft Input 4th Gear 2 2702561 1 Bearing Needle 3 4141037 1 Bearing Input Shaft Ball 4 09380 28007 3 Cir Clip 5 24410 83000 1 High Speed Syncroniser Includes Hub and Sleeve 6 24471 60A00 6 Key Syncronizer 7 2703581 2 Spring High Speed Syncronizer 8 24432 83001 3 Ring Syncronizer 9 2703453 1 Gear Main Shaft 3rd 3rd Gear 10 09263 30031 1 Bearing Needle 11 24121 85252 1 Shaft Main 12 06111 06003 2 Ball 13 24400 83002 1 Low Speed Syncronizer Includes Hub and Sleeve 14 24436 83000 2 Spr
37. 10 841799 Ile Guard Seat Belt 11 800930 4 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 450401 1 Flat Washer M10 14 450412 1 Lockwasher M10 15 893632 4 Support Backrest See 2 1 16 800930 8 Screw M8 1 25 x 16 mm Flange Change from previous revision 47 TURF TRUCKSTER 4 1 Upper ROPS Optional Kit Serial No All 48 REF Engine Cover Control Console TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4184320 1 Upper ROPS 2 4175340 Ile Decal Warning and ROPS Cert 3 844988 1 Foam 1 2 in Perforated ROPS 4 452411 6 Screw M12 1 75 x 40 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S 2 Screw 7 16 20 x 1 in Hex Head 8 N S 2 Flat Washer 7 16 9 N S 2 Nut 7 16 20 Hex 10 841799 1 Guard Seat Belt 11 800930 12 Screw M8 1 25 x 16 mm Flange 12 450453 4 Nut M8 1 25 Hex Flange 13 893632 4 Support Backrest See 2 1 Change from previous revision 49 TURF TRUCKSTER 5 1 Throttle Control Serial No All Attach Pivot Link U in Bottom Hole PP ad 31 ad Hand Throttle Panel 39 40 CA 37 2 Ef T dej I 7 S J 8 D CH 9 A 42 N3 i 15 gt KY NI i O v IB OBR 15 we Ignition Switch Panel 17 Throttle Pivot 16
38. 102 mm Add a 50 50 antifreeze water mixture if required en 20 Drain and refill cooling system every 400 hours or 9 months whichever comes first Allow system to cool before draining a Remove the cooling fan fuse b Remove the radiator cap c 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 Empty and clean the recovery bottle Fill radiator to the bottom of the filler neck with 50 50 antifreeze water mixture f Fil recovery bottle to full mark with 50 50 antifreeze water mixture 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 To provide proper air flow do not obstruct the air intake screen on the right side of the vehicle Keep screen clean Replace clamps and hoses every two years If you have to add coolant more than once a month or add more than one quart at a time have a authorized Cushman Dealer check the cooling system 5 8 AIR FILTER Do not remove the element for inspection or cleaning Unnecessary removal of the filter increases the risk of injecting dust and other impurities into the engine When service is required first clean the outside of the filter housing then remove the old element as gently as possible and discard 1 C
39. 2703953 1 Selector Gear 4 842773 1 Rod End 1 2 20 5 308091 1 Flat Washer 1 2 6 311763 1 Screw 1 2 20 x 2 1 4 in Hex Head 7 843679 1 Plate Wear 8 452692 4 Screw M6 1 x 12 mm Self Tap 9 604174 1 Flat Washer 3 8 in 10 843614 1 Spring Torsion 11 843685 1 Bushing Spring 12 2703951 1 Tab Locating 13 452401 1 Screw M10 1 5 x 40 mm Flange 14 450454 1 Nut M10 1 5 Flange 15 894179 1 Cable Shifter Diesel Units 16 842774 2 Ball Joint 1 4 28 17 816307 1 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 21 300977 1 Screw 1 4 28 x 5 8 in Hex Head 22 306396 2 Lockwasher 1 4 23 308090 1 Flat Washer 1 4 24 894179 1 Cable Shifter 25 2702696 1 Boot Control Lever 26 2702695 1 Knob Shifter 27 548175 3 Flat Washer 1 4 x 1 1 4 in 28 308090 1 Flat Washer 1 4 29 843778 1 Connector Shift Cable 30 2703707 1 Connector Shift Cable 31 103867 2 Flat Washer 5 16 32 821164 2 Hair Pin 33 2703964 7 1 Panel Right Side Dash 34 843792 1 Plate Shifter Boot 35 2700496 4 Insert 1 4 20 Threaded 36 2703931 7 1 Ring Boot Hold Down 37 452695 4 Screw M6 1 x 20 mm Self Tap Change from previous revision 61 TURF TRUCKSTER 11 1 Manual Transmission Shifter Linkage Serial No 84069 All Gas Units Shifter Mounting and Cable Routing View Rotated 90 D
40. 3 844611 1 Spring Torsion 4 840725 1 Tube Pedal Pivot 5 842935 1 Tab Locking 6 452388 1 Screw M8 1 25 x 20 mm Flange 7 450453 1 Nut M8 1 25 Flange 8 894308 1 Switch Clutch Micro 9 450510 2 Screw M3 0 5 x 20 mm Pan Head 10 452424 2 Nut M3 0 5 Flange 11 4192281 1 Cable Clutch Diesel Units 11 4154481 1 Cable Clutch Gas Units 12 844202 2 Washer Slotted 13 806703 1 Clevis Pin 5 16 x 31 32 in 14 306328 1 Cotter Pin 3 32 x 3 4 in 15 810152 1 Pad Pedal 16 842010 1 Bushing Clutch Release Arm Diesel Units Only 17 833273 1 Bushing Diesel Units Only 18 450377 1 Nut M6 1 Nylock Diesel Units Only 19 23266 85002 1 Arm Clutch Release Diesel Units Only 20 01550 08353 1 Screw Diesel Units Only 21 2703002 1 Nut Diesel Units Only 22 REF 1 Rear Alternator Bracket Diesel Units Only See 26 1 23 103867 1 Flat Washer 24 2700757 1 Clamp 1 7 16 I D Diesel Units Only 25 452695 1 Screw M6 1 x 20 mm Taptite Diesel Units Only Change from previous revision 59 TURF TRUCKSTER 10 1 Manual Transmission Shifter Linkage Serial No 84064 All Diesel Units p Diesel Unit Cable Attachment Shifter Mounting and Cable Routing View Rotated 90 Degrees for Clarity o o TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 800582 4 Screw 1 4 20 x 3 4 in Truss Head Diesel Units 2 2703956 7 1 Mount Shifter 3
41. 5 16 in 25 Foot Roll Cut to 7 in 5 826590 1 Hose Fuel Filter to Engine 5 16 in 25 Foot Roll Cut to 19 1 2 in 6 831039 1 Hose Engine Fuel Return 3 16 in 25 Foot Roll Cut to 2 3 4 in 7 4139967 1 Connector 5 16 to 3 16 in Hose 8 825264 2 Clamp Hose 9 REF 1 Engine 10 550553 1 Fuel Filter 550489 1 Element Fuel Filter 11 894638 1 Pump Electric Fuel 12 452394 1 Screw M8 1 25 x 70 mm Flange 13 450453 2 Nut M8 1 25 Flange 14 838154 1 Bracket Fuel Pump Mounting 15 829997 1 Grommet 16 834691 1 Cap Protectoseal Optional Accessory 17 841853 1 Coupler Gas Cap Optional Accessory 18 4185540 1 Bracket Fuel System See 15 1 19 841969 1 Fuel Tank 20 843726 1 Tube Fuel Pick Up 21 843727 1 Elbow 90 Fuel 22 361117 2 Grommet Fuel Tank 23 836852 1 Breather 24 4179802 1 Cap Diesel Fuel 25 843298 1 Sender Fuel Level 26 829954 1 Gasket Fuel Tank 27 833953 1 Cover Fuel Sender 28 800021 5 Screw 10 32 x 1 2 in Pan Head 29 120052 5 Lockwasher 10 30 829787 2 Terminal 1 4 in Male 31 4174285 1 Bracket Air Filter Mount See 23 1 32 894201 1 Harness Fuel Sender 33 4117153 7 1 Support Tank See 14 1 34 4180601 1 Strap Tank 35 834005 1 Seal Foam 36 103867 1 Flat Washer 5 16 37 800221 1 Locknut 5 16 18 Center 38 452388 1 Screw M8 1 25 x 20 mm Flange 39 809231 1 Grommet Split Change from previous revision 111 TURF TRUCKSTER
42. 8 16 x 1 3 4 Hex Flange 18 N S 1 Plate Tensioner 108 gt Change from previous revision TURF TRUCKSTER Serial No All 35 1 Gas Engine Exhaust Tailpipe outlet to be parallel to ground 16 or ag 13 17 9 11 big Item Part No Qty Description Serial Numbers Notes 1 4233161 1 Muffler 2 4232042 1 Catalytic Converter 3 2702502 2 Bolt Muffler Flange 4 2702501 2 Spring Muffler Flange 5 838295 8 1 Strap Muffler Hanger 6 450193 2 Screw M8 1 25 x 30 mm Hex Head 7 64237 05 2 Locknut M8 1 25 8 4240882 1 Bracket Muffler Attaches to Transmission Case 9 841982 1 Clamp 1 1 2 in Exhaust 10 306419 4 Screw 1 4 20 x 1 2 in Hex Head 11 306396 4 Lockwasher 1 4 12 2702500 1 Ring Muffler Flange 13 4233160 1 Shield Muffler 14 306555 4 Screw 5 16 18 x 5 8 in Hex Head 15 306325 6 Lockwasher 5 16 16 103867 4 Flat Washer 5 16 17 4144336 2 Shield Catalytic Converter 18 4235966 1 O2 Sensor Included with Engine Change from previous revision 109 TURF TRUCKSTER 36 1 Diesel Fuel System Serial No 84064 All 110 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 826590 1 Hose Fuel Tank to Fuel Pump 5 16 in 25 Foot Roll Cut to 10 in 2 4113022 8 Clamp Hose 3 826590 1 Hose Fuel Return 25 Foot Roll Cut to 21 1 2 in 4 826590 1 Hose Pump to Fuel Filter
43. 81 91 93 829997 69 111 113 836685 129 841663 51 821071 SS 51 830140 103 836686 129 BAT e aeter 43 821164 61 64 97 103 830366 51 836687 129 a KREE 73 821893 65 69 117 121 830784 45 51 836688 129 841738 eene 73 022049 la 67 830810 121 836689 129 8411531 dine 43 822419 53 830930 79 836690 129 841799 is 47 49 822819 53 831039 111 113 836691 129 841805 117 BING es 53 831099 133 836692 129 8418375 cec 127 823119 eee 121 831225 123 125 836693 135 841838 127 823225 iin 53 831405 75 836694 131 a WE 77 823621 71 831586 103 836695 131 841841 nalaban 77 825264 65 111 113 831846 81 83 836841 133 841842 77 127 825500 etus 71 831888 97 836852 111 133 E nose 127 825538 538 831889 97 8936892 147 151 841853 iei 111 825
44. 826006 2 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 10 843550 1 Connector Eighteen Terminal 843551 AR Terminal 11 837301 2 Connector Headlight 825899 AR Terminal 5 16 in Female 14 16 Gauge One Wire 828629 AR Terminal 5 16 in Female 14 16 Gauge Two Wire 12 825996 1 Fuse Holder 13 825997 4 Fuse Clip 1 Term 14 16 Gauge 14 825998 6 Fuse Clip 1 Term 10 Gauge 15 825999 2 Fuse Clip 3 Term 14 16 Gauge 16 836892 5 Fuse 10 Amp 16 842983 2 Fuse 15 Amp 16 826000 1 Fuse 20 Amp 17 826190 AR Tubing 3 8 in I D Black Convoluted 18 826191 AR Tubing 1 2 in I D Black Convoluted 19 826192 AR Tubing 3 4 in I D Black Convoluted Change from previous revision 147 TURF TRUCKSTER 55 1 Diesel Engine and Fan Harness Serial No 84064 All Part Numbers 4174321 4179800 and 4179801 Starter a FPO Oil Pressure Switch amp O 7 Ground Wires go Parking Brake Cl 9 Glow Plug Fuel Solenoid Engine Harness Connector 1 Engine Harness Connector 2 Engine Harness Connector 3
45. 843614 61 63 AGB Oki 61 63 843685 61 63 843724 n cann 61 63 843726 111 115 843727 cu pagos 111 HA3758 KA state 53 HA37BO D c sur etn 53 EE 79 BAS 7B ih 79 HAGZTB ante 61 843792 eiie 61 63 843857 83 91 93 BASED DU usce de 83 843866 105 843876 occu Ma 71 843942 123 125 KEE 51 844019 acera 121 E LE 53 844087 135 844116 ae 51 INDEX 844130 51 97 105 8441498 nene 73 8444177 53 SAT Ile 53 844184 139 844105 145 844186 139 844 197 siti 145 844188 145 844202 255 dere 59 844223 inten 51 E 51 844564 nee 119 844569 119 844566 119 844511 gem 119 844582 ees 53 844583 119 844590 119 844598 121 844600 119 844601 117 84406 T1 ehe 59 8440627 nee 119 844628 119 844647001 69 844692 119 844729 cone 117 844813 131 844937 119 844951 135 844952 EEE 135 844953 ee 135 844956 135 844973 119 844988 49 845034 135 8451390 ates 55 845134 se 55 845185 n 53 845223 epus 137 845224
46. All Serial No 84064 All 49 1 Transmission Clutch Release Shift Selector Diesel Engine Only 136 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Transmission Case See 50 1 2 REF 1 Shift Assembly See 52 1 3 845223 1 Gasket Shift Case 4 2702659 3 Screw M8 1 25 x 40 mm 5 01550 08553 1 Screw M8 1 25 x 55 mm 6 23265 85200 1 Bearing Clutch Release 7 09205 03019 1 Roll Pin 8 2702684 1 Plug Drain 9 11741 85200 1 Support Transmission 10 2702475 4 Screw 11 37610 80043 1 Switch Backup Light 12 09280 11002 Ile O Ring 13 23260 85203 1 Shaft Clutch Release 14 09300 14017 2 Bushing Clutch Release 15 09448 20007 1 Spring Clutch Release Change from previous revision 137 TURF TRUCKSTER 50 1 Transmission Case Diesel Engine Only Serial No 84063 All Serial No 84064 All 138 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 24700 85200 1 Case Transmission Upper and Lower Half 2 2702690 2 Pin Alignment 3 2702665 4 e Screw M8 1 25 x 120 mm Flange 4 2702470 3 Screw M8 1 25 x 30 mm Flange 5 2702659 1 Screw M8 1 25 x 40 mm Flange 6 2702471 2 e Screw M8 1 25 Flange 7 24741 83001 1 Retainer Input Shaft Bearing 8 09103 08152 8 Screw M8 1 25 x 25 mm Flange 9 09380 28007 1 Cir CLip 10 09262 28019 1 Bearing Front 11 24131 83002
47. Hex Head 15 452004 1 Flat Washer 1 4 16 4174285 1 Bracket Air Filter Mount 17 548849 2 Screw 3 8 16 x 4 3 4 in Hex Head 18 450412 2 Lockwasher M10 19 800571 1 Nut M10 1 25 Hex 20 4191140 1 Bracket Muffler 21 4174286 1 Cover Starter Hole 22 894066 1 Transmission Suzuki MT5 Includes Clutch Disc and Cover 23 11741 85200 1 Support Transmission 24 08310 00103 1 Nut 25 11710 77100 1 Bracket Rear Mount 26 452390 3 Screw M8 1 25 x 30 mm Flange 27 842961 2 Sleeve Alignment 28 4173062 1 Adapter Transmission 29 838602 2 Screw M10 1 5 x 50 mm Hex Head 30 452393 5 Screw M8 1 25 x 60 mm Flange 31 303269 2 Lockwasher 7 16 32 4174281 1 Mount Transmission See 14 1 33 800949 1 Screw M10 1 25 x 50 mm Socket 34 800948 1 Screw M10 1 25 x 35 mm Socket Change from previous revision 85 TURF TRUCKSTER 24 1 Gas Engine and MT Mounting Bond o kA 7 Io Kr GENE lt 267 y OS 2 REIT AI IN d 86 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine Assembly See 27 1 2 N S 1 Manual Transmission Order with engine 3 4140899 1 Plate Clutch Housing 4 2702548 1 Clutch Disc and Pressure Plate Set 5 4117900 1 Pressure Plate Limited Availability 6 2702547 6 Screw M8 1 25 x 16 mm Lockwasher 7 2702688 2 Stud M10 1 25 x 65 mm 8 2702687 1 Screw M10 1 25 x 75 mm F
48. Nut M6 1 Hex Flange 2 452378 2 Screw M6 1 x 20 mm Hex Flange 3 2701465 1 Solenoid Starter 120052 2 Lockwasher 10 2702244 2 Nut 10 32 Hex 306325 2 Lockwasher 5 16 443106 2 Nut 5 16 18 Hex 4 4244442 1 Bracket Horn Brake Fluid Reservior 5 800943 7 E 10 16 x 3 4 in Thread Cut 6 886090 1 Horn 7 800934 3 Screw M6 1 x 16 mm Hex Flange 8 894266 1 Harness Main See 54 1 9 843942 1 Socket 12V Accessory Plug 10 2701658 1 Panel Instrument with Tachometer 11 890000 1 Buzzer High Temperature located inside frontelip behing dash panel 12 831225 4 Clamp Wire Harness 13 306419 2 Screw 1 4 20 x 1 2 in Hex Head 14 306488 1 Lockwasher 1 4 External Tooth 15 828231 1 Insulator 16 548175 1 Flat Washer 1 4 17 4183303 1 Positive RED Battery Cable 18 4183301 1 Negative BLACK Battery Cable Battery to Transmission 19 306325 1 Lockwasher 5 16 20 450324 1 Nut M8 1 25 Hex 21 894602 1 Cable 32 in Ground Transmission to Right Frame Rail 22 450453 1 Nut M8 1 25 Hex Flange 23 452388 1 Screw M8 1 25 x 20 mm Flange 24 306396 1 Lockwasher 1 4 gt Change from previous revision 123 TURF TRUCKSTER No 84067 All rial No 84068 All No 84069 All S Se S 43 1 Gas Electrical Components Z ngine Harne Ground Wires Mo gt 3 a N D 2 NI E D D o
49. Power Steering See 20 1 12 600993 1 Pulley 5 8 in Power Steering 13 452395 2 Screw M8 1 25 x 80 mm Flange 14 452388 5 Screw M8 1 25 x 20 mm Flange 15 450453 2 Nut M8 1 25 Flange 16 4173262 1 Ring Pressure Plate 17 4117092 1 Belt Hydraulic Pump 18 4175560 1 Belt Alternator Power Steering 19 4174282 1 Bracket Alternator Adjusting 20 452402 1 Screw M10 1 5 x 50mm Flange 21 450454 1 Nut M10 1 5 Flange 22 361005 1 Screw M8 1 25 x 25 mm Hex Head 23 306325 3 Lockwasher 5 16 24 2500917 2 Screw M6 1 x 25 mm Flange Included with Engine 25 09111 08035 2 Screw M8 1 25 Special Included with Transmission 26 4173980 1 Pulley Hydraulic Pump Drive 27 22100 85200 1 Cover Clutch Included with Transmission 28 22400 85141 1 Disc Clutch Included with Transmission 29 306835 1 Screw 3 8 16 x 1 1 4 in Hex Head 30 800073 1 Carriage Bolt 3 8 16 x 1 1 4 in 31 306981 2 Flat Washer 3 8 32 120177 2 Lockwasher 3 8 33 306562 2 Nut 3 8 16 Hex 34 820899 2 Clamp Hose Used to protect hose from belt 35 4186780 1 Plate Spacer Located behind water pump pulley 36 450422 2 Lockwasher M8 Change from previous revision 91 TURF TRUCKSTER 26 2 Diesel Engine and Clutch Serial No 84063 xxxx and Up Serial No 84064 xxxx and Up lt l AN oA Fall ty N e N R SN Ni Ww kv mi gt P J wa C LA el So ahy 273 A zl AA
50. Ratio Sensor Gn 5 Og Bk 6 Ye Bu 7 gt 8 gt Gn Wh Gn Wh Bn Wh Gn Ye Ye Bk 9 gt Gy Bu 10 Ye Bu Bn T Bn Wh Rd Bk 12 Bn Rd Bk 13 gt Bn Bk Rd Ye 14 gt Gn Ye Rd Bu 15 Gn Wh 16 gt Bk Bu Gy Bu 18 Ye 19 gt Gn Bu 20 gt Bn Rd 21 Gn 24 gt Bu Wh Engine Harness ECU Connector Pins 17 22 23 28 29 30 31 32 43 45 46 26 Wh 48 49 51 54 and 55 Not Used 275 Wh Bk 33 Bk 34 y Wh Gn Ye er 35 Wh z AW Bu Ye Gn Rd Gn Rd 25 gt Wh Rd NW 37 gt Gn Ye Pressure Sensor Gn Wh a 1 39 Gn Rd Gn Rd Bu Ye e 40 Give Gy Ye Rd Bk Throttle Sensor Rd Bk 44 ENB Water ex DI 47 gt Bue BUY Temperature GW 505 93 Sensor Temperature Sender 52 Eure Ye Bk ee 53 y Gn Bk ob 56 DOE Bu Ye Intake Air Grek Oil Pressure Rd Ye Temperature Sender Bk Bu 58 Bu Bk Bu Wh 60 gt Wh Bu rare Bu Wh It I Bk Rd Ye Bk Bk Rd Og Bk Bk Wh Bk Ye Bu Bk Ye Bu Ye Bk Bu Wh Og Bk Gn Bu Wh Bu Bn Rd Wh Gn Gn Ei A A e o We
51. Terminal 25 4221100 1 Relay EFI 12 V 70A SP 26 843167 2 Relay 12V 15A DPST 27 4116017 1 Harness Generator 28 4249342 1 Controller EFI Engine Manual Transmission 28 4249343 1 Controller EFI Engine Automatic Transmission 29 4244712 1 Cover Engine Controller 30 4242482 1 Bracket ECU Mounting See 15 1 31 2700757 1 Clamp Wire 32 409804 2 Screw 4410 24 x 1 2 Thread Cutting Change from previous revision 125 TURF TRUCKSTER 44 1 Differential Assembly Part Number 894826 14 21 1 Differntial Part Number 894825 11 16 1 Differential 126 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 894826 1 Differential Assembly 14 21 1 Differential 894825 1 Differential Assembly 11 16 1 Differential 1 891829 Ile Differential Housing See 45 1 2 N S 1 Axle Tubes and Shafts See 46 1 3 N S Ile Input Main and Jack Shaft See 48 1 4 N S Ile Front and Shift Cover See 47 1 5 112050 1 Screw 1 4 20 x 5 8 in Self Tap 6 841842 1 Fitting Hydraulic Brake Tee 7 832584 1 Clamp Tee Fitting 8 841844 1 Hose Brake 9 841838 1 Tube Left Side Brake 10 841837 1 Tube Right Side Brake 11 893583 2 Cable Parking Brake Change from previous revision 127 TURF TRUCKSTER 45 1 Differential Housing Part Number 891829 Serial No All 128 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 891829 1 D
52. VASTAVUSDEKLARATSIOON VAATIMUSTENMUKAISUUSVAKUUTUS DECLARATION DE CONFORMITE KONFORMIT TSERKL RUNG AHAQEH ZYMMOP OSHE MEGFELEL S GI NYILATKOZAT DICHIARAZIONE DI CONFORMIT ATBILSTIBAS DEKLAR CIJA ATITIKTIES DEKLARACIJA DIKJARAZZJONI TAL KONFORMIT DEKLARACJA ZGODNO CI DECLARA O DE CONFORMIDADE DECLARA IE DE CONFORMITATE VYHL SENIE O ZHODE IZJAVA O SKLADNOSTI DECLARACI N DE CONFORMIDAD DEKLARATION OM VERENSST MMELSE Business name and full address of the manufacturer TbproBcko nme n nmbneH anpec Ha nponsgeogutena Obchodn jm no a pln adresa v robce Producentens firmanavn og fulde adresse Bedrijfsnaam en volledig adres van de fabrikant Tootja rinimi ja t ielik aadress Valmistajan toiminimi ja t ydellinen osoite Nom commercial et adresse compl te du fabricant Firmenname und vollst ndige Adresse des Herstellers Emwvupia Kai raxu popikrj dieuduvon karaokeuaorr A gy rt zleti neve s teljes c me Ragione sociale e indirizzo completo del fabbricante Uz muma nosaukums un pilna ra ot ja adrese Verslo pavadinimas ir pilnas gamintojo adresas Isem kummer jali u indirizz shih tal fabbrikant Nazwa firmy i pe ny adres producenta Nome da empresa e endere o completo do fabricante Denumirea comercial si adresa complet a produc torului Obchodn n zov a pln adresa v robcu Naziv podjetja in polni naslov proizvajalca Nombre de la empresa y direc
53. aa aaaea a uaaa 31 Headlight Replacement 32 Tail Light Replacement 32 EFI Diagnostic Check 33 Care and Cleaning nenn 33 Storage anne urteilen 34 Troubleshooting General rn du 35 Maintenance amp Lubrication Charts General ser ina EEES 36 Lubrication Chart c0 cccsssccesteeeeeenee 36 Maintenance Charts een 37 Common Replacement Parts 38 Kubota Diesel Engine Service Parts 38 Notes Parts Catalog How To Use The Parts Catalog 40 To Order P rts u 40 Table Of Contents nen 41 en 3 1 1 1 SAFETY OPERATING SAFETY EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS Familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine 1 12 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 amp Operation Manual Engine Manual accessories and attachments If the operator cannot read English it is the owner s responsibility to explain the material contained in this man
54. c Sorozatsz m Numero di serie S rijas numurs Serijos numeris Numru Serjali Numer seryjny Numero de S rie Num r de serie S riov slo Serijska tevilka N mero de serie Serienummer 8406401651 8406404500 Engine Deuraren Motor Motor Motor Mootor Moottori Moteur Motor Mnxavrj Moduln v Motore Dzin js Variklis Sahha Netta Installata Silnik Motor Motor Motor Motor Motor Motor Kubota D1105 E3B Net Installed Power HerHa nHcTanupaHa MOLIIHOCT ist instalovan v kon Installeret nettoeffekt Netto ge nstalleerd vermogen Installeeritud netov imsus Asennettu nettoteho Puissance nominale nette Installierte Nettoleistung Kadapri eykateotnuevn vc Nett be p tett teljes tm ny Potenza netta installata Paredzeta t kla jauda Grynoji galia Wisa tal Qtug Moc zainstalowana netto Pot ncia instalada Puterea instalat neta ist in talovan v kon Neto vgrajena mo Potencia instalada neta Nettoeffekt 18 5 kW 3200 RPM Cutting Width Lllupouuha Ha pasahe ka ezu Skeerebredde Maaibreedte L ikelaius Leikkuuleveys Largeur de coupe Schnittbreite Mfjkoc pioiv a V g si sz less g Larghezza di taglio Grie anas platums Pjovimo plotis Tikkonforma mad Direttivi SzerokoS ci cia Largura de Corte L imea de t iere Sirka z beru irina reza Anchura de corte Klippbre
55. c Hvwp vou BaoiAgiou yia 2000 14 EK 2000 14 EK egyes lt kir lys gbeli bejelentett szervezet Organismo Notificato in GB per 2000 14 CE 2000 14 EK AK re istr t organiz cija JK notifikuotosios jstaigos 2000 14 EC Korp Notifikat tar Renju Unit ghal 2000 14 KE Dopuszczona jednostka badawcza w Wielkiej Brytanii wg 2000 14 WE Entidade notificada no Reino Unido para 2000 14 CE Organism notificat in Marea Britanie pentru 2000 14 CE Notifikovany organ Spojen ho kr lovstva pre smernicu 2000 14 ES Britanski prigla eni organ za 2000 14 ES Cuerpo notificado en el Reino Unido para 2000 14 CE Anm lt organ f r 2000 14 EG i Storbritannien Number 1088 Sound Research Laboratories Limited Holbrook House Little Waldingfield Sudbury Suffolk CO10 OTH Operator Ear Noise Level Oneparop Ha HuBoTO Ha A0NOBNM or yxoro Lym Hladina hluku v oblasti u oper tora St jniveau i forers erehgjde Geluidsniveau oor bestuurder M ratase operaatori k rvas Melutaso k ytt j n korvan kohdalla Niveau de bruit hauteur des oreilles de l op rateur Schallpegel am Bedienerohr Etrittedo Gop Bou oe Aerroupy a A kezel f l n l m rt zajszint Livello di potenza sonora all orecchio dell operatore Trok a l menis pie operatora auss Dirban iojo su ma ina patiriamo triuk mo lygis Livell tal Hoss fil Widna tal Operatur Dopuszczalny poziom ha asu dla operatora Nivel sonoro nos ouvidos do operador
56. filter housing without allowing dust into the air intake 7 Inspect the new element Do not use a damaged element and never use an incorrect element 8 Assemble the new element and make sure it seats properly 9 Assemble cap making sure it seals completely around the filter housing Dust evacuator A must be facing down 10 Install air cleaner assembly into the vehicle Secure with hardware B 11 Connect both hoses and tighten hose clamps Diesel Engine When connecting jumper cables 1 Stop the engine on the vehicle with a good battery 2 Connect RED jumper cable to the Positive 4 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 with the discharged battery en 21 5 MAINTENANCE 5 10 BATTERY Make absolutely certain the ignition switch is OFF and the key has been removed before servicing the battery 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 ca
57. 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 federal state and local 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 5 15 FUEL SYSTEM Refer to Section 7 3 for specific maintenance intervals Before replacing any filter thoroughly clean the filter housing and the area around the filter Dirt must not be allowed to enter into fuel system Turn the key switch to the ON position to start the fuel pump and bleed the fuel system if the fuel filter and lines have been removed or the fuel tank has become empty See Engine Manual en 24 Check fuel lines and clamps every 50 hours Replace fuel lines and clamps at the first sign of damage The fuel tank capacity is 6 5 gal 24 5 1 Fill tank using the following fuel recommendations Diesel Engine a Use clean fresh 2 Low or Ultra Low Sulfur Diesel fuel Minimum Cetane rating 45 Refer to Engine Manual for additional information b Use clean fresh 1 Low or Ultra Low Sulfur 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 ca
58. pa lt Overheat i Dash Parking Brake Alarm i Panel Switch Wh Ye Bu Wh Og Gn Wh 156 TURF TRUCKSTER I il N Ed a SH B B B Light N gt gt gt gt e Bk N Bk Bk Brake O ogy BuBk 33 BulBk 77 Light 4 Rd Bk Rd Bk gt Single gt gt s Tail Light Horn Harness Button 55 Bk 6 o BWRd B Rd 177 Cab Stop Og Bk Light B Accessory 77 Brake a Wh Rd Accessory Bk Connector 1 p m 1 77 Brake ES Og Bk Accessory Bn Connector 2 Bn o Rd Wh Brake 15A py Pedal Wh Rd Switch Turn Signal Jumper Wh O Og Bk p d Accessory Plug Bu Bk o a Ye Bk iua Flasher Rask og 15A Turn Signal vend Pe 7 9 Accessory gt P a i Gn Bk gt Bu Bn e Left Headlight x 7 Q O Low Beam B O Wh Bu Gn Bk p d o Bk Ld SA 77 N 7 o to ve sk Left Turn y Gne High Beam Wh wh A Bn Signal Light Bk AN Accessor d Ec Low Beam YY Bu AA Bk Right Turn Ye Bk L kae d Wh Signal Light S zB High Beam Accessory EE 177 Right Headlight e Wh Og Wh Og 157 TURF TRUCKSTER 58 1 Gas Engine Schematic 1 gt Bk Bn Bk Wh 3 Rd Rd Air Fuel Bk Rd Bk Rd 45 Gn Gn
59. 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 4 Perform required service on tire MAINTENANCE 5 Rear Varies determined by load See Chart 28 1 93 7 23 1 59 F Rear 18 1 24 Tire Pressure 13 0 90 F psi BAR 8 0 55 I I Load Pounds O 400 800 1200 1500 Figure 5F 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 ensure 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 70 100 ft Ibs 95 140 Nm torque is maintained en 25 5 MAINTENANCE 5 18 RAISING THE VEHICLE Make sure the vehicle is parked on a solid and level surface Never work on a vehicle that is supported only by a jack Always use jack stands Whenever possible empty the truck bed before raisin
60. 0 1 Tube Exhaust Inlet 23 4190700 1 Fitting Straight 24 452389 4 Screw M8 1 25 x 25 mm Flange 25 838295 8 1 Strap Muffler Hanger 26 450193 2 Screw M8 1 25 x 30 mm Hex Head 27 64237 05 2 Locknut M8 1 25 28 4191140 1 Bracket Muffler See 23 1 841982 2 Clamp 1 1 2 in Exhaust 29 N S Ile U Bolt 30 N S 1 Bracket 31 N S 2 Nut 5 16 18 Hex 32 103867 6 Flat Washer 5 16 33 4174286 1 Cover Starter Hole See 23 1 34 4179842 1 Left Side Screen See 14 1 35 4119867 8 1 Shield Muffler 36 306450 4 Screw 5 16 18 x 3 4 in Hex Head 37 306325 8 Lockwasher 5 16 Change from previous revision 101 TURF TRUCKSTER 31 1 Gas Engine Governor Linkage Serial No 84068 All Serial No 84069 All 102 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4139208 1 Plate Governor 2 4141031 2 Bolt Intake Manifold Included with Engine 3 306396 1 Lockwasher 1 4 4 308090 1 Flat Washer 1 4 5 845224 2 Plug Tube 6 11391G4 2 Clamp 1 4 in to 5 8 in Worm Drive 7 4144145 1 Plug 3 8 x 1 in Tube 8 2700540 1 Lever Governor 9 2700859 1 Lever Governor Arm 10 01116G01 1 Screw M10 1 5 x 40 mm Hex Flange 11 830140 2 Ball Bearing 12 306981 5 Flat Washer 3 8 13 450454 1 Nut M10 1 5 Hex Flange 14 2701129 1 Arm Throttle 15 835271 1 Nut Governor 16 130728 3 Nut 1 4 20 Hex Jam 17 2700335 1 Spring Governor 18
61. 1 Clevis Pin 3 16 x 1 in 23 308089 1 Flat Washer 10 24 306463 1 Cotter Pin 1 16 x 1 2 in 25 839213 1 Connector Valve 26 814079 1 Clevis Pin 5 16 x 1 1 8 in 27 103867 1 Flat Washer 5 16 28 306328 1 Cotter Pin 3 32 x 3 4 in 29 843758 1 Handle Lift Control Valve 30 452404 1 Screw M10 1 5 x 70 mm Flange 31 825538 1 Spring Compression 32 843759 1 Bushing Lift Control Valve 33 450454 1 Nut M10 1 5 Hex Flange 34 521144 1 Cover Handle 35 826558 2 Adapter 90 Fitting ORB to JIC 37 Flare 36 828057 1 Adapter 90 Fitting ORB to JIC 37 Flare 37 823118 1 Adapter Straight Fitting ORB to JIC 37 Flare Change from previous revision 53 TURF TRUCKSTER 7 1 Parking Brake and High Low Speed Control Serial No All ia SE e K gt Pe me KN Be nG p 4 2 77 1 Bia 2 i H Ting a nd 1 f 1 Lei xor A a i Ss Yo e 1 z sech bib 44 SON Ab s lt 1 1 ar t ET TNR I 1 y Nec gt H 1 SAS il 1 maa 1 sa 4 4 1 1 A TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4202860 1 Lever Parking Brake 2 845134 1 Bracket Parking Brake Lever 3 452388 5 Screw M8 1 25 x 20 mm Flange 4 452391 1 Screw M8 1 25 x 40 mm Flange 5 450453 6 Nut M8 1 25 Flange 6 845133 1 Cable Parking Brake 7 450377 1 Nut M6 1 Staytite 8 827182 1 Pulley 3 in Cable 9 84335
62. 1 2 Flat Washer 3 8 18 120177 2 Lockwasher 3 8 19 306562 2 Nut 3 8 16 Hex 20 4144332 1 Pulley 2 3 4 Idler 21 4144005 1 Pulley 4 Groove Micro V 4 06 in Dia Used on 84069 Only 22 4139351 1 Belt 52 8 in Micro V Used on 84067 and 84068 22 4144006 1 Belt 52 5 in Micro V Used on 84069 23 312176 1 Screw 1 2 13 x 1 3 4 in Hex Head 24 800602 1 Nut 1 2 13 Nylon Insert 25 4231362 1 Bracket Power Steering Pump 26 452378 1 Screw M6 1 x 20 mm Hex Flange 27 4231600 1 Bracket Power Steering Adjuster Mounts using lower alternator bolt 28 452396 1 Screw M8 1 25 x 90 mm Hex Flange 29 4149901 1 Pulley Alternator 30 4216305 1 Pump Power Steering See 20 1 31 452395 2 Screw M8 1 25 x 80 mm Hex Flange 32 450453 3 Nut M8 1 25 Hex Flange 33 4210205 1 Pulley 5 80 in Diameter 34 4235370 1 Belt 7 16 x 26 1 2 in V Alternator and Power Steering 35 4143072 1 Tensioner Rotary 36 4146490 1 Plate Hose Clamp 37 4234080 1 Bracket Belt Cover 38 4150138 1 Screw 3 8 16 x 2 1 4 in Hex Flange Change from previous revision 95 TURF TRUCKSTER Serial No 84063 All Serial No 84064 All 28 1 Diesel Engine Speed Control 96 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 2703683 1 Throttle Cable See 5 1 for other end of cable 2 844130 1 Cable Governor Control See 5 1 for other end of cable 3 4174720 1 Bracket Throttle 4 4
63. 10 Nut M12 1 5 Wheel Lug 6 REF 1 Panel Console See 6 1 7 800026 7 Screw 1 4 20 Truss Head 8 4179842 1 Cover Left Side Engine 9 452398 18 Screw M10 1 5 x 20 mm Flange 10 450454 18 Nut M10 1 5 Hex Flange 11 893488 1 Fender Right Side 12 893487 1 Fender Left Side 13 452399 2 Screw M10 1 5 x 25 mm Flange 14 893602 1 Stop and Tail Light 822049 Ile Bulb No 1157 312288 2 Lens Screw 829099 1 Lens and Gasket Includes License Illuminator Lens 15 548910 2 Nut 1 4 20 Serrated Flange 16 894313 1 Harness Taillight Wire 17 4117153 7 1 Support Fuel Tank 18 800177 1 Screw 5 16 18 x 3 4 in Truss 19 548911 1 Nut 5 16 18 Hex Flange 20 800930 1 Screw M8 1 25 x 16 mm Flange 21 450453 1 Nut M8 1 25 Hex Flange 22 REF 1 Radiator Support 23 REF 1 Frame Lower ROPS and Platform See 15 1 24 809180 8 Washer 1 2 x 1 1 8 in Change from previous revision 67 TURF TRUCKSTER 15 1 Frame Lower ROPS and Platform Serial No All 9 1 gt A ns ji 13 Gas Engine and Transmission Mounts 68 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 N S 1 Frame Main 4 Wheel Standard Frame Painted Black 1 N S 1 Frame Galvanized Main 4 Wheel Optional Galvanized Frame 2 893145 7 1 ROPS Lower 3 893199 7 1 Platform Truckster Standard Platform Painted Black 3 893199G02 1 Platform Galvan
64. 121 115 524358 153 800547 47 91 93 97 4233160 109 450455 47 49 69 75 524633 51 101 4233161 EE 109 450457 nn 79 524643 naa wada 51 800558 105 4233440 87 89 450510 59 548041 108 800571 ite 85 4235369 87 89 450541 43 45 81 83 548079 73 800582 51 61 63 64 4235740 107 450544 125 548159 43 800602 un 71 4235968 109 450730 as xcci 28 7 SADAT ae 53 800695 135 4237525 menge 108 452004 85 548175 43 61 63 123 Son 108 4938049 einen 125 452006 81 83 113 125 800717 use ec d 129 4238925 81 83 45237851 55 69 81 83 548201 135 1800737 diens 135 4238927 ess 81 83 wl ue 113 121 123 548204 133 145 800748 Hunti 151 4240882 109 452380 119 145 548224 73 2800788 Aakash 65 4241843 ET B3 EE 139 546395 ann 105 800861 73 4242482 69 125 45238845 55 57 59 81 548477 145 800875 113 4243002 et 71 83 85 91 93 548804 108 800908 77 131 4243003 71 97 111 117 548897 onn 117 800909 67 71 4243004
65. 147586 45 41480695 89 4148082 87 4148150 83 4148206 83 4148212 ree 89 4148213 89 4148360 87 4148361 89 4149901 95 4150138 95 4150957 105 4154081 125 4154480 59 4154481 59 4158740 43 4158744 43 4158742 diese 43 4166840 115 4166841 115 4166842 115 4168131 115 4168143 113 4170802 113 4170840 115 TATA AE ADA 131 4173062 85 4173201 91 93 4173262 91 93 4173980 91 93 4174200 91 93 4174260 91 93 4174281 85 4174282 91 93 41742895 85 99 111 4174286 85 101 4174287 iie 71 4174288 i 71 4174290 ns 101 4174321 81 149 AN 74440 5 in 91 4174560 oie 101 41745623 ree 81 4174620 99 41746060 u kennen 81 4174662 97 4174720 iine 97 4174820 5 e 81 4175021 une 97 4175340 e 49
66. 174662 1 Lever Governor 5 835271 1 Nut 1 4 20 Lever Pivot 6 130728 1 Nut 1 4 20 Hex Jam 7 840473 1 Spring Governor Lever 8 4175021 1 Lever Throttle 9 103867 1 Flat Washer 5 16 10 821164 1 Hair Pin 11 REF 1 Kubota Diesel Engine See 26 1 12 800271 1 Screw 10 24 x 1 2 in Pan Head 13 120052 1 Lockwasher 10 14 111898 1 Clamp Cable 15 831888 1 Swivel 16 831889 1 Washer Swivel 17 831890 1 Screw Swivel Throttle Cable 18 452390 1 Screw M8 1 25 x 30 mm Flange 19 450453 2 Nut M8 1 25 Flange 20 800547 1 Screw M8 1 25 x 16 mm Hex Head 21 452388 1 Screw M8 1 25 x 20 mm Flange 22 452738 1 Screw M6 1 x 20 mm Flange 23 450452 1 Nut M6 1 Flange Change from previous revision 97 TURF TRUCKSTER Serial No 84063 All Serial No 84064 All 29 1 Diesel Engine Air Filter E va Ae 98 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 601585 1 Box Air 2 452405 2 Screw M10 1 5 x 80 mm Hex Flange 3 450454 2 Nut M10 1 5 Hex Flange 4 36092 G01 1 Hose 2 in x 16 in High Temp Air 5 11391G7 4 Clamp Hose 6 3001965 1 Air Filter 5000919 Ile Element Air Filter 5000920 1 Cover 5000914 Ile Vactuator Valve 7 4174620 1 Hose Intake 8 4174285 1 Bracket Air Fliter Mount See 23 1 for Mounting 9 3001388 1 Bracket Air Fllter 10 400184 1 Screw 5 16 18 x 3 4 in Hex Head 11 445795 1 Nut 5 16
67. 18 Spiralock Flange 12 601595 1 Plate Blockoff 13 300646 2 Screw 1 4 20 x 3 4 in Hex Head 14 306396 2 Lockwasher 1 4 15 308090 2 Flat Washer 1 4 16 REF 1 Radiator Assembly See 21 1 17 REF 1 Diesel Engine Assembly See 26 1 or 26 2 Change from previous revision 99 TURF TRUCKSTER 30 1 Diesel Engine Exhaust and Remote Oil Filter Serial No 84063 All Serial No 84064 All Tailpipe Outlet to be parallel to ground Ks N 3 MD A N ASS P K A KON 7124 jw UNG i K NB ie N A G N SES LA y View Rotated 180 100 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Kubota Engine See 26 1 2 553020 1 Gasket Exhaust 3 4183634 1 Head Remote Filter 4 4113986 1 Engine Oil Filter 5 4190701 1 Fitting 90 6 4174290 1 Bracket Remote Filter 7 800547 4 Screw M10 1 25 x 20 mm Hex Head 8 303269 2 Lockwasher 7 16 9 306325 8 Lockwasher 5 16 10 120177 2 Lockwasher 3 8 11 4175620 2 Fitting 90 12 4175561 1 Hose Remote Oil Filter 13 4175562 2 Hose Remote Oil Cooler 14 48540 01 2 Clamp Hose 15 4176960 1 Remote Oil Cooler 16 4177560 1 Fan 7 1 2 in Push 17 4185240 2 Bracket Fan Mount 18 548910 4 Nut 1 4 20 Hex Flange 19 800017 4 Screw 1 4 20 x 1 in Pan Head 20 443102 4 Nut 1 4 20 Hex 21 4179161 1 Muffler 22 417456
68. 20 Threaded 37 2701850 7 1 Panel Ignition Switch 38 2702014 1 Decal Ignition Switch Panel 39 837295 1 Ignition Switch 40 837298 1 Spacer 3 16 in 41 29165G01 1 Decal Off Road Use 42 2702012 1 Strap Nut 1 4 20 x 2 in 43 821071 1 Decal Not Motor Vehicle Notice Change from previous revision 51 TURF TRUCKSTER 6 1 Control Console Serial No All View Rotated for Clarity 52 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 2700796 1 Console Used on all except 84064 1 2700797 1 Console EC Used on 84064 Only 2 844177 Ile Decal Aux Transmission 3 844179 Ile Decal Hydraulic Controls 4 822819 1 Decal Parking Brake Used on all except 84064 5 845185 1 Decal EC Parking Brake Used on 84064 Only 6 894696 1 Valve Hydraulic Selector 7 452392 2 Screw M8 1 25 x 50 mm Flange 8 832798 1 Plate Stop 9 450453 6 Nut M8 1 25 Hex Flange 10 822419 1 Washer 1 5 8 in Diameter 11 443810 1 Nut 3 8 16 Hex Jam 12 844582 1 Rod Extension Handle 13 306388 1 Nut 3 8 24 Hex Jam 14 548171 1 Knob 15 844051 1 Plate Float Latch 16 800930 4 Screw M8 1 25 x 16 mm Flange 17 886270 1 Valve Hydraulic Lift Control Discard Decal included with Valve 18 843355 1 Mount Lift Control Valve 19 316907 4 Screw 1 4 20 x 2 3 4 in Hex Head 20 306834 1 Screw 3 8 16 x 3 4 in Hex Head 21 548910 4 Nut 1 4 20 Hex Flange 22 823225
69. 21 815012 1 Spring 22 815013 1 Button 23 452380 1 Screw M6 1 x 30 mm Flange 24 800425 1 Screw M6 1 x 12 mm Hex Head 25 894965 1 Gear Idler 26 N S 2 Bushing Countershaft 27 894947 1 Shaft Idler 28 316942 1 Pin 1 4 x 1 2 in Spirol 29 09166 16014 1 Washer 30 805307 1 Washer 5 8 x 1 31 09246 16010 2 Plug 1 2 NPT Change from previous revision 145 TURF TRUCKSTER 54 1 Diesel Engine Main Harness Part Number 894266 Serial No 84063 All Serial No 84064 All o Light Switch E Clutch Pedal Switch 11 146 Right Headlight Right Turn Signal Option TG P Option e Brake Fluid e Reservoir B Z Engine Harness Engine Harness Brake Accessory Optional Accessories Left Headlight Left Turn Signal L Buzzer e a Connector 2 Connector 1 2 n rnm Engine Harness Connector 3 SS Engine Harness Gas Only Sr Connector 3 4 Cab Stop Light 2 E 5 Option BH E Flasher 2 Jumper Plug Option 12 172 Tail Light Harness LP 18 Connector SS l Brake Accessory 4 Turn Signal 18 Option 2 Opti
70. 25961 AR Terminal 1 4 in Male 10 Gauge Two Wire 2 829631 1 Connector Four Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 in Female 10 Gauge Two Wire 3 826726 2 Connector One Female Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 4 826005 12 Connector Two Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 5 825894 1 Connector Flasher 825889 AR Terminal 5 16 in Female 14 16 Gauge 6 2700913 1 Jumper Plug Taillight 825877 1 Connector Six Female Terminal 825748 AR Terminal 1 4 in Female 14 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 7 826006 3 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 8 837296 1 Connector Ignition Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 9 843598 1 Connector Rocker Switch 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 10 843550 1 Connector Eighteen Terminal 843551 AR Terminal 11 837301 2 Connector Headlight 825889 AR Terminal 5 16 in Female 14 16 Gauge One Wire 828629 AR Terminal 5 16 in Female 14 16 Gauge Two Wire 12 825996 3 Fuse Holder 13 825997 12 Fuse Clip 1 Term 14 16 Gauge 14 825998 6 Fuse Clip 1 Term 10 Gaug
71. 2700334 1 Spring Governor 19 111893 1 Screw 4410 32 Special 20 2702244 2 Nut 10 32 Hex 21 800024 1 Screw 1 4 20 x 1 1 2 in Truss Head 22 306375 3 Nut 1 4 20 Hex 23 2703684 1 Throttle Cable See 5 1 24 308089 1 Flat Washer M6 25 821164 2 Hair Pin 1 4 x 1 1 8 in 26 818395 1 Clevis Pin 1 4 x 1 2 in 27 302288 1 Screw 1 4 20 x 1 in 28 306372 1 Cotter Pin 3 32 x 1 2 in 29 4139209 1 Cable Throttle 30 4237525 1 Bracket Throttle Cable 31 843013 1 Pulley Governor 32 800927 1 Shoulder Bolt 1 4 20 x 5 8 in 33 REF 2 Bolt Part of Engine 34 831586 1 Ball Joint 35 306320 3 Nut 5 16 24 Hex 36 4139210 1 Rod Governor 37 810722 1 Yoke 38 806703 1 Clevis Pin 5 16 x 31 32 in 39 103867 1 Flat Washer 5 16 40 306325 1 Lockwasher 5 16 Special Change from previous revision 103 TURF TRUCKSTER 32 1 Gas Engine Governor end hie AGER All Serial No 84069 All 104 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 4141425 1 Governor 1 111812 Ile Yoke Spool 2 111814 1 Washer Thrust 3 359864 1 Washer Thrust 4 111817 1 Spool Governor 5 112840 1 Bearing Thrust 6 130728 1 Nut 1 4 20 Hex Jam 7 111813 Ile Seal Shaft 8 160410 1 Carrier amp Weights 9 302288 2 Screw 1 4 20 x 1 in Hex Head 10 306396 2 Lockwasher 1 4 11 306506 2 Lockwasher 6 12 306915 2 Screw 6 32 x 5 16 in Machin
72. 3 7 ACCESSORIES amp SUPPORT LITERATURE Contact your area Jacobsen Dealer for a complete listing of accessories and attachments 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 Flatbeds and Boxes 47 in Quick Disconnect Flatbed 889983 60 in Quick Disconnect Flatbed 894769 47 in Box Assembly Requires 889983 890010 60 in Box Assembly Requires 894769 2703394 Poly Box Assembly sess 892530 Box Liner for 890010 sese 888532 Hitches Fifth Wheel Ball Hitch en 894690 Receiver Style Drawbar Hitch 4114386 Flat bar Style Hitch nennen 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 WITIdOW tco AA 894758 Windshield with Wiper esses 894757 Replacement Four Post ROPS 4205580 NOTE The four post ROPS equipped as standard equipment on this vehicle cannot be used with cab attachments If an enclosed cab is desired the four post ROPS must be r
73. 3 p I e utt d WII S 2 el S Ass NU Es AA CBN 1 NP NG 3 ANI A IS LEER i i P SL Npa Ke i 0 Q M NI E Ze d EDER Pia 1 77 d al p Y Za i y INA NE RN ue NL RK NI 92 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4173201 1 Engine Kubota D1105 E3B 4113986 1 Engine Oil Filter 4183623 Ile Alternator 2 4174200 1 Bracket Hydraulic Pump 3 4209665 1 Mount Right Side Engine 4 800547 8 Screw M10 1 25 x 20 mm Flange 5 303269 8 Lockwasher 7 16 6 887994 1 Pump Hydraulic See 40 1 7 4174260 1 Reducer 3 8 NPSF to 1 8 BPT 8 103867 1 Flat Washer 5 16 9 843857 1 Temperature Sender 10 452389 9 Screw M8 1 25 x 25 mm Flange 11 4216305 1 Pump Power Steering See 20 1 12 4210205 1 Pulley 5 8 in Power Steering 13 452395 2 Screw M8 1 25 x 80 mm Flange 14 452388 5 Screw M8 1 25 x 20 mm Flange 15 450453 2 Nut M8 1 25 Flange 16 4173262 1 Ring Pressure Plate 17 4117092 1 Belt Hydraulic Pump 18 4175560 1 Belt Alternator Power Steering 19 4174282 1 Bracket Alternator Adjusting 20 452402 1 Screw M10 1 5 x 50mm Flange 21 450454 1 Nut M10 1 5 Flange 22 361005 1 Screw M8 1 25 x 25 mm Hex Head 23 306325 3 Lockwasher 5 16 24 2500917 2 Screw M6 1 x 25 mm Flange Included with Engine 25 09111 08035 2 Screw M8 1 25 Special Included with Transmission 26 4173980 1 Pulley Hydraulic Pump Drive 27 22100 85200 1 Cover
74. 37 2 Clip Brake Hose Retaining Change from previous revision 77 TURF TRUCKSTER 20 1 Steering Column Serial No All 78 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 893571 1 Tube Steering Mount 2 800930 4 Screw M8 1 25 x 16 mm Flange 3 306799 4 Lockwasher 5 16 External Tooth 4 450453 4 Nut M8 1 25 Flange 5 893344 1 Shaft Steering 887259 2 Bearing Assembly 6 828590 1 Housing Bearing 7 808060 1 Bearing Needle 8 819923 2 Collar Foam 9 2700453 1 Cover Steering Tube 10 892228 1 Steering Wheel 11 450457 1 Nut M16 2 Flange 12 892486 1 Cover Steering Wheel 13 841255 1 Gear Steering See 18 1 14 843767 1 Hose Power Steering Pressure 15 111838 2 O Ring 16 843768 1 Hose Power Steering Return 17 111838 Ile O Ring 18 840222 1 Hose Formed 19 830930 2 Clamp Hose 20 450739 1 Screw M10 1 5 x 30 mm Socket 21 800943 1 Screw 10 14 x 5 8 in Self Tapping 22 809092 2 Clamp Tube 23 320107 3 Cable Tie 7 1 2 in Secure hoses together 24 473142 4 Cable Tie 15 1 2 in Secure Hoses to Frame 25 REF 1 Power Steering Pump with Reservior See 26 1 or 27 1 Change from previous revision 79 TURF TRUCKSTER 21 1 Diesel Radiator Serial No 84064 All 80 TURF TRUCKSTER Item Part No Qty Description Se
75. 4241724 GB Rev A CUSHMAN By Jacobsen Parts and Maintenance Manual Cushmane Turf Truckstere With Four Post ROPS 84063 Kubota D1105 E3B Diesel Engine MT 84064 Kubota D1105 E3B Diesel Engine MT EC 84067 Suzuki K6 Gas Engine MT 84068 Suzuki K6 Gas Engine AT 84069 Suzuki K6 Gas Engine RV and Utility WARNING If incorrectly used this machine can cause severe injury Those _ AMA A Textron Company who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine When Performance Matters United Kingdom FOREWORD This manual contains adjustment maintenance troubleshooting instructions and parts list for your new Jacobsen machine This manual should be stored with the equipment for reference during operation Before you operate your machine you and each operator you employ should read the manual carefully in its entirety By following the safety operating and maintenance instructions you will prolong the life of your equipment and maintain its maximum efficiency If additional information is needed contact your Jacobsen Dealer Suggested Stocking Guide The serial plate is located on the frame rail under the steering wheel Jacobsen recommends you record these numbers below for easy reference CHARLOTTE NC USA 1 800 848 1636 Jacobsen com JA
76. 5 1 qt 4 81 50 50 water ethylene glycol mix Goverfnor External Mechanical Low ldle 950 RPM High Idle 4450 RPM Lubrication Capacity 3 6 quarts 3 4 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 60 amp Cooling System Liquid Cooled Capacity 3 3 qt 3 0 I 50 50 water ethylene glycol mix Spark Plugs NGK 3932 DCPR7E Gap Denso XU22bPR U Gap AA 0 032 0 035 in 0 8 1 27 mm en 7 3 SPECIFICATIONS 3 4 VEHICLE Tires actuated Fromt iieii 20 x 10 10 Multi Rib Steering Front wheel power steering Heart anan 24 x 13 12 Titan Ultra Trac Hitch Capacity Tire Pressure Max trailer GVWR 1500 Ib 680 kg Front eres 20 psi 1 38 BAR Tounge Weight 200 Ib 90 7 kg Beat andis 15 18 psi 1 1 2 BAR Vehicle Rated Capacity 2850 Ib 1293 kg Battery NOTE When calculating load weight include 118 Ib Tales 12 Volt Lead Acid 53 5 kg for the standard four post ROPS Do not Group 24 exceed Vehicle Rated Capacity Service Brake 4 Wheel hydraulic drum brakes Brake Fluid DOT 3 Parking Brake Integral to re
77. 5 AT Truck Service Manual 4160162 Kubota D1105 Engine Parts Manual 4171985 Suzuki K6A Service Manual 4241728 Suzuki K6A Engine Parts Manual 4239442 Accessory Manual These are the original instructions verified by Jacobsen A Textron Company O Copyright 2011 Jacobsen A Textron Company All rights reserved including the right to reproduce this material or portions thereof in any form en 2 Proposition 65 Warning This product contains or emits chemicals known to State of California to cause cancer and birth defects or other reproductive harm Litho in U S A 1 2011 Table of Contents Safety Operating Safety 4 Important Safety Notes 5 Vehicle Identification Numbers Vehicle Identification Number 6 Engine Identification Numbers 6 Specifications Product Identification 7 Diesel Engine eese 7 Gas ENGINE uocis teens 7 VIe este rr 8 Gear RaliOS ma ennt n a 8 Weights and Dimensions 8 Accessories amp Support Literature 9 Declaration of Conformity 10 Adjustments General moe etes 12 Engine Access sees 12 Front Cowl Access e 13 Access Panels u 13 Diesel Alternator Belt 14 Diesel Hydraulic Pump Belt 14 Gas Power Ste
78. 50F70 1 Switch Fan 38 825884 2 Clamp Hose 39 840754 1 Decal Radiator Pressure Warning Update kit 4239742 is required to update vehicles with the following serial numbers 8406301651 8406301856 8406401651 8406401860 Change from previous revision 81 TURF TRUCKSTER A Serial No 84067 All 22 1 Gas Radiator Serial No 84068 All Serial No 84069 All 82 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 843862 AR Tube 1 4 in I D Clear Vinyl 10 Foot Length Cut to 12 2 835805 AR Hose Radiator Overflow 3 452006 2 Flat Washer 5 16 4 446134 2 Lockwasher 5 16 5 443106 2 Nut 5 16 18 Hex 6 450452 4 Nut M6 1 Hex Flange 7 450541 4 Screw M6 1 x 16 mm Hex Flange 8 452378 4 Screw M6 1 x 20 mm Hex Flange 9 4115033 1 Fan 13 in Radiator 10 4241843 1 Panel Fan Mounting 11 4238927 1 Frame Radiator 12 601592 1 Radiator 13 400184 2 Screw 5 16 18 x 3 4 Hex Head 14 845224 1 Cap 1 4 x 1 in 15 800177 4 Screw 5 16 18 x 3 4 in 16 831846 4 Nut Isolation 17 4238925 1 Bracket Radiator Bottle 18 833512 2 Seal Radiator Foam 19 553926 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 2 Nut M8 1 25 Hex Flange 22 843857 1 Sender Temperature 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 4120076
79. 52389 4 Screw M8 1 25 x 25 mm Flange 20 2702198 1 Latch Hood 21 841715 1 Rod Hood Release 22 303952 1 Flat Washer 10 23 306463 1 Cotter Pin 1 16 x 1 2 in 24 841753 1 Bracket Hood Latch 25 306419 2 Screw 1 4 20 x 1 2 in Hex Head 26 306488 2 Lockwasher 1 4 in Shakeproof 27 2703158 1 Decal Fuses Diesel Engine 27 4117221 1 Decal Fuses Gas Engine 28 473142 2 Cable Tie 15 1 2 in 29 4158740 1 Decal Cushman 30 4158741 1 Decal Left Side Turf Truckster 31 4158742 1 Decal Right Side Turf Truckster 32 38541 1 Tube Clear Document 33 38061A 2 Cap Vinyl 34 840508 2 Mount Cable Tie 35 800344 2 Screw 10 Type AB Self Tapping Change from previous revision 43 TURF TRUCKSTER 2 1 Engine Cover Serial No All Vehicles with Four Post ROPS 7 1 16 20 N 21 v Ka Engine Cover Lock 2 KA e MPH x FOE RECOMMENDED SPEED SETTINGS 22 84063 and 84064 22 84056 KPH KPH MPH 49 MPH ED CEN IMA IAI EEJ EHA RECOMMENDED SPEED SETTINGS 22 84057 E 22 84061 44 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 306328 1 Cotter Pin 3 32 x 3 4 in 2 308090 9 Washer 1 4 3 450452 2 Nut M6 1 Hex Flange 4 450453 2 Nut M8 1 25 Hex Flange 5 R
80. 56 9 1 Clutch Pedal Linkage 58 10 1 Manual Transmission Shifter Linkage 60 11 1 Manual Transmission Shifter Linkage 62 12 1 Automatic Transmission Shifter 64 13 1 Automatic Transmission Oil Cooler 65 14 1 Frame Attachments sees 66 15 1 Frame Lower ROPS and Platform 68 16 1 Rear Axle nsennnunannnananenanenennenannnanasannes 70 17 1 Front Control Arms eere 72 18 1 Steering Linkage eere 74 19 1 Front Brakes unnnnnnannnnnannnnnannnnnnanannnna 76 20 1 Steering Column eere 78 21 1 Diesel Radiator eene 80 22 1 Gas Radiator eene 82 23 1 Diesel Engine and Transmission Mounting 84 24 1 Gas Engine and MT Mounting 86 25 4 Gas Engine and AT Mounting 88 26 1 Diesel Engine and Clutch 90 26 2 Diesel Engine and Clutch 92 27 4 Suzuki Gas Engine ses 94 28 1 Diesel Engine Speed Control 96 29 1 Di
81. 5998 147 151 833512 81 83 838768 153 811992 ns 135 825999 147 151 8337152 eue 83 838769 153 8119983 135 826000 147 151 833953 111 115 838770 nue 153 812006 135 826005 147 149 151 834006 111 115 839213 cinese 53 812009 135 826006 57 149 834691 111 839917 nie 153 812335 135 826190 147 151 835101 119 121 839921 ne 153 812419 Ben 145 826191 147 151 835271 97 103 105 839948 e 129 RK rd 57 826192 147 153 836206 119 840222 aan 79 813850 71 75 826193 149 153 836420 135 840436 45 814079 58 826254 149 836421 135 840473 AA 97 814476 sss 129 826558 53 121 836429 135 840508 43 815012 nte 145 826590 65 111 836431 133 840725 57 59 8100195 een 145 826726 147 151 836441 135 840726 57 59 815085 145 827182 naia aaa 55 836443
82. 636 75 77 131 305134 75 GE 103 305459 ote e see 133 306325 91 93 101 103 109 123 125 30632845 51 53 55 57 NORMA 59 197555 7 oco Std 103 306375 64 103 105 Sie aa 53 306396 61 63 64 99 103 105 107 Dor MNA 123 806397 nnn 61 63 306405 131 GOGAT Gerda 129 306419 43 109 123 125 10157 E 133 306435 133 306450 101 306463 43 53 306488 43 123 125 306506 105 306531 nt apod 51 306555 109 306562 85 91 93 306799 irritas 79 DEE nennen 75 306829 ccce 129 BODBSA Gu hada 53 306835 91 93 306836 85 enc AM MA A 73 See 85 306915 105 306981 91 93 103 108 306982 129 SOT TG censos 133 SOBOUB cete 75 3008 Ir 53 103 308090 45 61 63 99 103 105 107 117 308091 anakan 61 63 309067 69 113 809488 secs 45 BEE 75 STE IYO C ae 71 kah LLL cnn 71 Ian 61 63 Ch seat ee 67 BIO mananahan 53 164 INDEX 316949 sco sinat 145 320107 55 79 119 121 359864 105 BONA Tee cate 67 71 36092 G01 99 361005 91 93 360117 ss 111 115 37610 80043 187 38061A nn 43 B8541 s ics cic ahead 43 4001085 etes 85 400184 81 83 99 400188
83. 65 123 125 2703454 143 09286 09001 143 2500917 91 93 2701513 83 2703481 131 09300 14017 137 25411 85201 143 2701658 123 125 2703580 141 09300 30003 141 25415 83000 143 2701693 7 69 113 2703581 141 09380 28007 139 141 25420 85201 143 2701697 69 87 89 2703582 143 09390 62010 139 25451 85261 143 2701737 7 57 2703683 51 97 09390 68002 189 25520 85203 143 2701850 51 2703684 51 103 09448 20007 137 25530 79501 143 2701897 113 2703699 143 10386753 57 59 61 64 25535 85412 143 2701898 113 2703707 61 91 93 97 101 25536 84200 143 2701953 143 2703931 7 61 63 103 109 111 25541 85201 143 2702012 51 2703951 61 63 115 129 133 25545 85055 143 2702014 51 2703953 AA 61 111074 129 133 25546 60C01 143 2702198 43 27083956 61 1117582 129 2554
84. 7 558019 1 Resistor Plug 8 2700868 1 Connector 70 Amp Relay 842966 AR Terminal Female Relay 2700869 AR Terminal 3 8 in Female Relay 9 842959 1 Connector 2 Contact 833257 2 Terminal 3 32 in Female 838463 2 Seal Wire 10 NS 2 Block Maxi Fuse 11 1 Fuse 50 Amp Maxi Fuse 12 4113261 1 Fuse 25 Amp 13 4221100 Ile Relay 12V 70 Amp SPST 4179801 1 Radiator Fan Harness 14 836536 1 Fuse 40 Amp 15 826006 1 Connector Two Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 16 2700868 1 Connector 70 Amp Relay 842966 AR Terminal Female Relay 2700869 AR Terminal 3 8 in Female Relay 17 4221100 Ile Relay 12V 70 Amp SPST 18 826254 2 Block Single Fuse 825997 AR Fuse Clip 1 Term 14 16 Gauge 826193 7 1 2 Tubing 7 16 in I D Green 25 Foot Bulk 4179800 1 Oil Cooler Fan Harness Includes Items 15 18 19 826005 1 Connector Two Female Terminal 825748 AR Terminal 1 4 in Fem 14 16 Gauge 826193 58 Tubing 7 16 in I D Green 25 Foot Bulk 20 842983 1 Fuse 15 Amp Change from previous revision 149 TURF TRUCKSTER 56 1 Gas Main Harness Part Number 4238042 Serial No 84067 All Serial No 84068 All Serial No 84069 All AT MT Engine Harness Connectors ECU Connector Switch Starter Solenoid 2 Fuel Sender 4 Radiator Fan lt gt Tail Light Harness Connector
85. 7 70D00 143 2702199 45 2708961 69 T812 aka aa 105 25576 70D00 143 2702217 77 2703964 61 63 111813 105 26121 85202 141 2702244 55 103 123 28391 85202 139 RBE E R AEA 105 2700120 145 125 29165G01 51 VIENT i pe 105 2700121 145 2702247 77 3001025 119 141998 itn 79 2700166 113 2702257 77 3001388 99 1118993 108 2700177 113 2702470 87 89 139 3001965 99 111898 51 97 105 2700334 103 2702471 139 300646 99 107 117 112050 s 127 2700339 103 2702475 137 300977 61 63 RK EE 105 2700380 153 2702484 107 301988 145 11391G4 83 2700381 153 2702489 107 302090 64 11391G7 99 107 2700384 153 2702494 143 302288 45 103 105 11710 77100 85 2700385 153 2702500 109 302944 75 303269 75 85 91 93 101 EE 43 304
86. 748 147 149 151 831890 97 8936959 133 841885 85 153 832033 5 837020 135 KK ene 43 825866 147 149 832408 121 837043 heen cere 55 841969 a 111 825877 147 149 151 832409 121 B37210 edes 117 841982 101 109 825878 147 149 151 832414 119 121 897295 ues 51 842010 59 825880 153 E eie 127 837296 147 151 042033 naaa 75 825884 81 85 832798 53 837298 51 842103 57 166 BAD TOM en 77 842360 135 EE 64 842773 OU eec 61 63 842774 61 63 842800 roi alia 121 842870 An 69 842915 SAMANA 107 842935 57 59 842959 149 842961 cse ut 85 842966 149 151 842983 147 149 151 BA 103 ER 57 843158 aan 55 843167 125 149 843168 eg 149 151 843238 na Lomas 71 843998 5 s 111 115 ER ae 53 843355 Gio totas 55 843359 55 843418 an 77 BABES Teksad 105 843550 147 151 843551 147 151 843561 een 51 843562 51 EE 51 843568 69 BASES cipe 51 843598 147 151 843607 cutter 51
87. 8027 1 Air Filter 5000913 1 Element Alr Filter 5000914 Ile Vactuator Valve 6 4139211 1 Hose Engine Air Intake 7 4140617 1 Grommet 8 4140618 1 Sensor Air Temp 9 11391G7 4 Clamp 2 3 4 in Worm Drive 10 4118423 1 Elbow 1 4 NPT Street 11 4118422 1 Hose Fitting 1 4 NPT Brass 12 2702484 1 Clamp 13 4231620 1 Bracket Air Cleaner 14 2702489 1 Bolt Included with Engine 15 300646 2 Screw 1 4 20 x 3 4 Hex Head 16 306396 2 Lockwasher 1 4 17 308090 2 Flat Washer 1 4 18 888549 1 Connector Hose 19 4235740 1 Hose Air Cleaner Intake Change from previous revision 107 TURF TRUCKSTER 34 1 Gas Engine Remote Oil Fill Serial No 84067 All Serial No 84068 All Serial No 84069 All Item Part No Qty Description Serial Numbers Notes 1 4188041 1 Bracket Valve Cover 2 548971 2 Screw 5 16 18 x 5 8 Hex Flange 3 4148202 1 Cap Oil EI Included with Engine 4 843420 1 O Ring 5 843399 1 Adapter Valve Cover 6 836206 2 Clamp 1 7 8 Worm Drive 7 4139271 1 Hose Remote Oil Fill 8 2701640 1 Adapter Oil Cap 9 4117892 4 Screw M6 1 x 16 mm Hex Flange 10 800425 2 Screw M6 1 x 12 mm Hex Head 11 306396 2 Lockwasher 1 4 12 4188387 1 Bracket Governor See 27 1 13 443810 2 Nut 3 8 16 Hex Jam 14 548804 2 Nut 3 8 16 Whizlock 15 548041 2 Screw 3 8 16 x 1 Flat Socket Head 16 306981 1 Flat Washer 3 8 17 800711 Ile Screw 3
88. 9 1 Bushing Pulley 10 809152 2 Flat Washer 5 16 x 1 3 16 in 11 843356 1 Equalizer Parking Brake 12 800446 1 Locknut 5 16 24 13 843158 1 Bracket Parking Brake Cables 14 452398 2 Screw M10 1 5 x 20 mm Flange 15 450454 2 Nut M10 1 5 Flange 16 REF 2 Parking Brake Cables See 44 1 17 893067 1 Cable High Low Speed Control 18 452378 1 Screw M6 1 x 12 mm Flange 19 450452 1 Nut M6 1 Flange 20 837043 1 Bracket High Low Cable 21 2702244 2 Nut 10 32 Hex Apply Locktite 242 22 806703 1 Clevis Pin 5 16 x 31 32 in 23 306328 1 Cotter Pin 9 32 x 3 4 in 24 320107 1 Cable Tie 7 1 2 in Change from previous revision 55 TUHF TRUCKSTER 8 1 Brake Pedal Serial No All 56 Route both hoses through opening in front clip Pedal Mounting View Rotated 90 Degrees for Clarity Route front brake tube through opening in front clip NG 9 32 Route rear brake tube under floor access panel 22 Left Frame Rail Tube Routing TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 2701737 7 1 Bracket Master Cylinder 2 892921 1 Pedal Brake 3 840726 1 Bearing Brake Pivot 4 840725 1 Tube Brake Pivot 5 842935 1 Tab Locking 6 452388 2 Screw M8 1 25 x 20 mm Flange 7 450453 2 Nut M8 1 25 Flange 8 895113 1 Master Oylinder 9 800930 2 Screw M8 1 25 x 16 mm Flange 10 894167 1 Rod Brake 11 806714 1 Cl
89. COBSZN A Texron Company MODEL xxxxx DATE CODE xxxxx LABEL Lb kg W Batt SERIAL st XXXXXXXX Nom Power Hp kw CE XXXXXXXX To Keep your equipment fully operational and productive Jacobsen suggests you maintain a stock of the more commonly used maintenance items We have also included part numbers for additional support materials and training aids To order any of the following material 1 Write your full name and complete address on your order form 2 Explain where and how to make shipment O Overnight Q 2nd Day 3 Order by the quantity desired the part number and the description of the part 4 Send or bring the order to your authorized Jacobsen Dealer Q UPS O Regular Mail Service Parts Qty Part No Description Qty Part No Description 4113986 Diesel Engine Oil Filter 550489 Diesel Engine Fuel Filter Element 4175560 Diesel Alternator Power Steering Belt 4117092 Diesel Hydraulic Pump Belt 2701908 Gas Engine Oil Filter 2701898 Gas Engine Fuel Filter 4139265 Gas Alternator Power Steering Belt 4235370 Gas Governor Hydraulic Pump Belt 5000919 Diesel Engine Air Filter Element 840352 Gas Engine Air Filter Element 885249 Hydraulic Fllter Element Service Support Material Qty Part No Description Qty Part No Description 4241725 Safety amp Operation Manual 4171642 MT Truck Service Manual 4241724 Parts amp Maintenance 417167
90. Clutch Included with Transmission 28 22400 85141 1 Disc Clutch Included with Transmission 29 306835 1 Screw 3 8 16 x 1 1 4 in Hex Head 30 800073 1 Carriage Bolt 3 8 16 x 1 1 4 in 31 306981 2 Flat Washer 3 8 32 120177 2 Lockwasher 3 8 33 306562 2 Nut 3 8 16 Hex 34 820899 2 Clamp Hose Used to protect hose from belt 35 4186780 1 Plate Spacer Located behind water pump pulley Change from previous revision 93 TURF TRUCKSTER 27 1 Suzuki Gas Engine end fic AGER All Serial No 84069 All JJ 14 84067 and 84068 14 21 84069 94 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 N S 1 Suzuki K6 Engine See Engine Parts Manual 2701908 Ile Oil Filter 4140919 1 Belt Water Pump and Alternator 2 4120017 1 Right Side Engine Mount 3 4140905 3 Bolt Right Side Engine Mount 4 4120018 Ile Left Side Engine Mount 5 2701827 4 Bolt Left Side Engine Mount 6 2702469 3 Bolt 7 830425 AR Fuel Hose 1 4 in 25 Foot Roll Cut to 24 Inches 8 4188387 1 Bracket Governor See 34 1 9 2702249 1 Key Woodruff 1 8 x 1 2 in 10 4141425 1 Governor See 32 1 11 306450 2 Screw 5 16 18 x 3 4 in Hex Head 12 306325 2 Lockwasher 5 16 13 548155 2 Flat Washer 5 16 14 4139288 AR Pulley 4 Groove Micro V 4 4 in Dia Includes two set screws 15 887994 1 Pump Hydraulic See 40 1 16 13437G5 2 Screw 3 8 16 x 1 1 2 in Whizlock 17 30698
91. EE 67 Den 125 548849 85 soo 135 4243005 67 45238943 69 85 87 91 548910 53 67 101 800927 103 4943006 nae 71 93 101 107 117 548911 51 67 80093043 47 49 53 57 4243008 ceeceeceeseeesees 71 452390 85 97 139 548937 133 67 79 113 117 4243009 09 012 67 452391 45 0 55 548952 135 800934 43 57 123 125 4244442 123 125 452399 Lus 53 83 550489 111 800943 43 51 57 79 4244712 irr wiih 125 452998 x ez 85 550553 111 EI 125 4245130 118 153 452394 1 Lo cote 111 553020 101 800944 131 4249342 insat 125 452395 81 83 91 93 553926 81 83 800945 73 75 4249343 octets 125 452396 189 554663 71 800948 ann 85 EE 101 45239855 57 67 69 77 558019 149 800949 nen 85 443106 81 83 123 1254 chances 81 83 600992 81 8000735 etes 129 AASB Ostia 53 108 452399 67 115 117 600993 91 8053071 iuis 145 EE 71 452401 61 63 601585 99 805387 131 E 99 452402 69 91 93 601592 81 83 806703 55 59 103 446134 oaia 81 83 452403 in 69 601595 og 806714 51 57 45007 Piltide mis 73 452404 cto 5 801939 be 45 807332 asii 71 450169
92. EF 1 Decal Emission Gas Units 6 893541 1 Handold Right Side 7 450541 10 Screw M6 1 x 16 mm Hex Flange 8 452388 2 Screw M8 1 25 x 20 mm Hex Flange 9 4139724 1 Decal 104 dBa Noise CE Diesel Units Only 10 523085 1 Latch Engine Cover 11 816401 1 Spring Torsion 12 830784 1 Clevis Pin 1 4 x 1 7 8 in 13 2702199 1 Catch Engine Latch 14 4139939 1 Insulation Engine Cover 15 893632 4 Mount Backrest 16 601937 2 Seat Base 17 893322 4 Backrest See 3 1 or See 4 1 18 2701223 1 Cover Engine 19 302288 8 Screw 1 4 20 x 1 in Hex Head 20 840436 1 Lock Engine Cover Optional Required in Europe 21 309488 2 Washer Optional Required in Europe 22 845234 1 Decal Ground Speed Diesel Engines 84063 and 84064 22 4147584 1 Decal Ground Speed Gas Engine MT 84067 22 845231 1 Decal Ground Speed Gas Engine AT84068 22 4147586 1 Decal Ground Speed Gas Engine MT 84069 Change from previous revision 45 TURFTRUCKSTER OO 3 1 Four Post ROPS Serial No All Control Console 46 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4205580 1 Four Post ROPS 2 Ile Decal ROPS Warning 3 800547 Ile Screw M10 1 25 x 20 mm Hex Head 4 452410 Die Screw M12 1 75 x 30 mm Flange 5 450455 3 Nut M12 1 75 Hex Flange 6 4140269 2 Seat Belt Assembly 7 N S 2 Screw 7 16 20 x 1 in Hex Head 8 N S 2 Flat Washer 7 16 9 N S 2 Nut 7 16 20 Hex
93. Filter 25 4113020 1 Adapter 1 4 in Tee 26 4245130 1 Flex Guard 30 In Length Cut to 5 in 27 18292 G1 1 Clamp Tubing 28 4218620 1 Hose Rollover Valve to Canister 5 Ft Length Cut to 17 1 2 in 29 4170802 1 Canister Carbon 30 4172648 1 Bracket Canister 31 400188 2 Screw 5 16 18 x 1 in Hex HD 32 452006 2 Washer Flat 33 4168143 1 Adapter 5 32 in Tee 34 831039 1 Hose Tee to Engine Intake Manifold 25 Ft Length Cut to 20 in 35 831039 1 Hose Tee to Carbon Canister 25 Ft Length Cut to 17 1 4 in 36 4180501 1 Clamp Canister 37 452692 2 Screw M6 1 x 12mm Taptite Change from previous revision 113 TURF TRUCKSTER 38 1 Gas Fuel System Serial No 84068 All Serial No 84069 All Right Frame Rail 114 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4166842 1 Fuel Tank AY 2 843726 Ile Tube Fuel Pick Up 3 4166841 1 Elbow 90 1 4 4 361117 2 Bushing 5 4170840 1 e Rollover Valve 6 4168131 Ile Grommet Fuel Tank 7 4166840 1 Cap Unvented Fuel Ratchet 8 843298 1 Sender FuelTank 9 829954 1 Gasket Fuel Tank 10 833953 1 Cover Fuel Sender 11 800021 5 Screw 10 32 x 1 2 in Pan Head 12 120052 5 Flat Washer 13 829787 2 Terminal Male 14 894201 1 Harness Fuel Sender 15 4117153 7 1 Support Fuel Tank 16 452399 1 Screw 5 16 18 x 3 4 in Truss 17 450454 3 Nut M10 1 5 Hex Flange 18 4180601 1
94. HICLE IDENTIFICATION NUMBERS 2 1 VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number VIN consisting of the model number date code and serial number is printed on the Nameplate ldentification Decal attached to the cross member under the dash 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 2 2 ENGINE IDENTIFICATION NUMBERS The Truckster is equipped with either a Kubota9 three cylinder diesel powered liquid cooled four cycle engine or a Suzuki three cylinder gas powered liquid cooled four cycle engine The Engine Serial Number for the Kubota engine is on a plate located on the valve cover 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 Record the Engine Serial Number below for easy reference Engine Serial Number en 6 CHARLOTTE NC USA 1 800 848 1636 Jacobsen com MODEL xxxxx C DATE CODE xxxxx LABEL ff Lb kg W Batt SERIAL XXXXXXXX Nom Power Hp k
95. ICATION All torque values included in these charts are approximate and are for reference only Use of these torque values is at your sole risk Cushman 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 Inch or Grade 8 8 Metric bolts as standard unless otherwise noted AMERICAN NATIONAL STANDARD FASTENERS AMERICAN NATIONAL STANDARD FASTENERS SIZE UNITS SIZE UNITS xz CO Cj GRADE 5 GRADE 8 GRADE 5 GRADE 8 6 32 in Ibs Nm 20 2 3 7 16 14 ft lbs Nm 50 67 8 65 88 1 8 32 in Ibs Nm 4 2 7 30 3 4 7 16 20 ft lbs Nm 55 74 6 70 94 9 310 24 in Ibs Nm 5 4 0 45 5 1 1 2 13 ft lbs Nm 75 101 7 100 135 6 340 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 Ibs Nm 0 5 7 65 7 3 9 16 12 ft lbs Nm 105 142 4 135 183 1 1 4 20 in Ibs Nm 95 10 7 125 14 1 9 16 18 ft lbs Nm 115 155 9 150 203 4 1 4 28 in Ibs Nm 95 10 7 150 17 0 5 8 11 ft lbs Nm 150 203 4 195 264 4 5 16 18 in Ibs Nm 200 22 6 270 30 5 5 8 18 ftlbs 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
96. ION CHARTS 7 1 GENERAL Before you clean adjust or repair this equipment disengage all drives lower implements to the ground 3 engage parking brake stop engine and remove key i from ignition switch to prevent injuries 1 Always clean the grease fitting before and after 4 lubricating 7 2 LUBRICATION CHART 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 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 necessary Grease fittings every 100 hours Do not over grease drive shaft fittings A Too much grease will damage the seals Fitting DOWST Description Drive Shaft Upper Ball Joints Lower Ball Joints Tie Rod Ends Qty BNN NN D Brake Fluid Reservoir D A Fuse Box NG O o E T H On IL je I D en 36 MAINTENANCE amp LUBRICATION CHARTS 7 7 3 MAINTENANCE CHARTS Air Filter Recommended Service and Lubr
97. JACOBSEN When Performance Matters A Textron Company CUSHMAN JACOBSEN RANSOMES Jacobsen A Textron Company Ransomes Jacobsen Limited 11108 Quality Drive Charlotte West Road Ransomes Europark Ipswich IP3 9TT NC 28273 USA www Jacobsen com 800 848 1636 English Company Registration No 1070731 www ransomesjacobsen com 44 0 1473 270000
98. Nivelul zgomotului la urechea operatorului Hladina hluku p sobiaca na sluch oper tora Raven hrupa pri u esu upravljavca Nivel sonoro en el o do del operador Ljudniv vid f rarens ra 84 dB a Leq 2006 42 EC SPECIFICATIONS 3 Harmonised standards used Vsnon3BaHn XapmoHu3npaHn CTaHgapTu Pou it harmonizovan normy Brugte harmoniserede standarder Gebruikte geharmoniseerde standaards Kasutatud htlustatud standardid K ytetyt yhdenmukaistetut standardit Normes harmonis es utilis es Angewandte harmonisierte Normen Evappoviop va TTPOTUTTA Trou xpnoiporroirj8nkav Harmoniz lt szabv nyok Standard armonizzati applicati Izmantotie saskanotie standarti Panaudoti suderinti standartai Standards armonizzati u ati Normy sp jne powi zane Normas harmonizadas usadas Standardele armonizate utilizate Pou it harmonizovan normy Uporabljeni usklajeni standardi Est ndares armonizados utilizados Harmoniserade standarder som anv nds BS EN ISO 20643 BS EN ISO 5349 1 BS EN ISO 5349 2 Technical standards and specifications used Wsnon3BaHu TexHnyecKn cTaHgaptn n cneundnkaumn Pou it technick normy a specifikace Brugte tekniske standarder og specifikationer Gebruikte technische standaards en specificaties Kasutatud tehnilised standardid ja spetsifikatsioonid K ytetyt tekniset standardit ja eritelm t Sp cifications et normes techniques utilis es Angewand
99. ORTANT 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 moving parts properly adjusted and The proper break in of a new engine can make a considerable difference to the performance and life of the engine The vehicle is designed to operate most efficiently at the preset governor setting Do not change the engine governor settings or overspeed the engine During the break in period 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 break in period 3 Change engine oil and oil filter element after first 35 hours of operation MAINTENANCE 5 lubricated c Replace worn or damaged parts before operating the machine d Keep all fluids at their proper levels e Keep shields in place and all hardware securely fastened f Keep tires properly inflated 3 Long hair jewelry or loose fitting clothing may g
100. abs 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 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 en 12 2 Replace do not components adjust worn or damaged 3 Long hair jewelry or loose fitting clothing may get tangled in moving parts 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 5 Keep hands and feet away from moving parts If possible do not make adjustments with the engine running e Retaining Tab x In Slot On Floor board Figure 4B 4 3 FRONT COWL ACCESS The front cowl opens to gain access to two access panels fuse panel horn and master cylinder reservoir 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 The front cowl will not spring up when the release lever is pulled and so must be lifted manually 4 4 ACCESS PANELS
101. ar drum hand lever 3 5 GEAR RATIOS 84067 Gear Ratios 84069 Gear Ratios 5th Gear 1 000 1 5th Gear 1 000 1 4th Gear 1 264 1 4th Gear 1 264 1 3rd Gear 1 908 1 3rd Gear oo 1 908 1 2nd Gear 3 017 1 2nd Gear 3 017 1 1st Gear 5 106 1 1st Gear 5 106 1 Reverse 5 151 1 Reverse 5 151 1 Hypoid Differential 14 21 1 with 3 2 1 Reduction Hypoid Differential 11 16 1 with 3 2 1 Reduction 84068 Gear Ratios 84063 and 84064 Gear Ratios Ird Gear eee 1 000 1 4th Gear 1 000 1 2nd Gear 1 536 1 3rd Gear oo 1 42311 1st Gear 2 7271 2nd Gear 1 947 1 Reverse 2 222 1 1st Gear 3 652 1 Hypoid Differential 14 21 1 with 3 2 1 Reduction Reverse 3 463 1 Hypoid Differential 11 16 1 with 3 2 1 Reduction 3 6 WEIGHTS AND DIMENSIONS Dimensions Inches mm Weights Lbs kg Length ede onus 114 2897 84063 5 2er a er 1838 834 Height casco el 74 5 1892 84064 na iced ens 1849 838 Wheel Base eene 58 2 1478 84067 sse 1690 766 Turning Radius Outside 242 6146 e UE 1503 682 84069 aachen 1690 766 en 8 SPECIFICATIONS 3
102. arefully 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 Replacement Diesel Only 1 Clean the outside of the filter housing especially around hose connections and cover 2 Note location of hoses Loosen hose clamps and remove both hoses from air cleaner Use caution to prevent dust or other debris from entering engine intake hose 3 Remove air cleaner mounting hardware B Air filter is secured with a single screw and nut 4 Liftthe air cleaner assembly out of the vehicle 5 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 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 MAINTENANCE 5 5 Unsnap retaining clamps and remove the old element as gently as possible and discard 6 Carefully clean the inside of the
103. ble 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 battery with a solution of baking soda and water Rinse with clean water Verify battery polarity before connecting or disconnecting the battery cables 5 11 CHARGING BATTERY 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 5 10 Read the Battery s and Charger s manuals for specific instructions 2 Whenever possible remove the battery from the vehicle before charging If battery is not sealed check that the electrolyte covers the plates in all the cells Battery cables must be disconnected before using a fast charger or damage to the alternator may result 3 Make sure the charger is Off Then connect the charger to the battery terminals as specified in the charger s manual 4 Always turn the charger Off before disconnecting charger from the battery terminals en 22 When installing the battery always assemble the Positive RED battery cable first and the Negative BLACK battery cable last When removing the battery always remove the Negative BLACK battery cable first and Positive RED battery ca
104. ble last Make sure battery is properly installed and secured to the battery tray 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 5 12 HYDRAULIC HOSES 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 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 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 4 Thoroughly inspect all tubes hoses and connections every 250 hours 5 13 HYDRAULIC RESERVOIR AND FILTER Refer to Section 7 3 for specific maintenance intervals 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 hydraul
105. ci n completa del fabricante Tillverkarens f retagsnamn och kompletta adress Jacobsen A Textron Company 11524 Wilmar Blvd Charlotte NC 28273 USA Product Code Kog Ha nponykra K d v robku Produktkode Productcode Toote kood Tuotekoodi Code produit Produktcode Kw ik G rrpoi vroc Term kk d Codice prodotto Produkta kods Produkto kodas Kodi i tal Prodott Kod produktu C digo do Produto Cod produs K d v robku Oznaka proizvoda C digo de producto Produktkod 84064 Machine Name HawmeHoBaHve Ha MauiHara N zev stroje Maskinnavn Machinenaam Masina nimi Laitteen nimi Nom de la machine Maschinenbezeichnung Ovoyaoia unxavrjuaroc G pn v Denominazione della macchina lek rtas nosaukums Ma inos pavadinimas Isem tal Magna Nazwa urz dzenia Nome da M quina Numele echipamentului N zov stroja Naziv stroja Nombre de la m quina Maskinens namn Diesel Turf Truckster Designation MpenHa3HayeHne Ozna en Betegnelse Benaming Nimetus Tyyppimerkint Pa ym jimas Bezeichnung Xapakrnpioy g Megnevez s Funzione Apz m jums Lithuanian Denominazzjoni Oznaczenie Designa o Specificatie Ozna enie Namen stroja Descripci n Beteckning Article 13 Serial Number CepneH Homep S riov slo Serienummer Serienummer Seerianumber Valmistusnumero Num ro de s rie Seriennummer Zeipiak apiBu
106. contact your area Jacobson Dealer Symptoms Possible Causes Action Engine will not start Clutch pedal not depressed 1 Check start up procedure 2 Battery low on charge or 2 Inspect condition of battery and battery defective connections 3 Fuel tank empty or dirty Fuel 3 Fill with fresh fuel Change fuel filter Bleed fuel shut off valve closed lines Open fuel shut off valve 4 Fuse blown 4 Replace fuse Engine hard to start or 1 Fuel level low Fuel or fuel filter 1 Fill with fresh fuel Change fuel filter Bleed fuel runs poorly dirty 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 3 Replace or tighten belt loose 4 Engine overload 4 Reduce forward speed Vehicle does not react 1 Parking brake engaged Disengage parking brake to throttle pedal 2 Transmission in Neutral Depress brake and clutch pedals Shift to proper gear for desired ground speed Release brake pedal Slowly let out clutch while pressing the throttle pedal 3 Clutch Pedal Depressed Slowly let out clutch pedal en 35 7 MAINTENANCE amp LUBRICAT
107. dd NA Conforms to Directives B cboTBeTcTBne c AupektuBuTe Spl uje podminky sm rnic Er i overensstemmelse med direktiver Voldoet aan de richtlijnen Vastab direktiividele Direktiivien mukainen Conforme aux directives Entspricht Richtlinien AkoAou note mot ri Odnyiec Megfelel az ir nyelveknek Conforme alle Direttive Atbilst direkt v m Atitinka direktyv reikalavimus Valutazzjoni tal Konformit Dyrektywy zwi zane Cumpre as Directivas Respect Directivele Je v s lade so smernicami Skladnost z direktivami Cumple con las Directivas Uppfyller direktiv 2004 108 EC 2006 42 EC 2000 14 EC 2005 88 EC 2006 66 EC Conformity Assessment Ouenka 3a cboTBeTcTBNe Hodnocen pln n podm nek Overensstemmelsesvurdering Conformiteitsbeoordeling Vastavushindamine Vaatimustenmukaisuuden arviointi Evaluation de conformit Konformit tsbeurteilung Aatriotwon Zupp pquong Megfelel s g rt kel s Valutazione della conformit Atbilstibas nov rt jums Atitikties vertinimas Livell tal Qawwa tal Hoss Imkejjel Ocena zgodno ci Avalia o de Conformidade Evaluarea conformit tii Vyhodnotenie zhodnosti Ocena skladnosti Evaluaci n de conformidad Bed mning av verensst mmelse 2006 42 EC Annex VIII Measured Sound Power Level M3mepeHo HBO H 3BykoBa MOLLIHOCT Nam en akustick v kon Malte lydstyrkeniveau Gemeten geluidsniveau M detud h
108. 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 Kubota engine with approximately 5 4 ats 5 1 I of clean engine oil Check oil level and add additional oil if required Gas Engine Fill Suzuki engine with approximately 3 6 ats 3 4 I of clean engine oil Check oil level and add additional oil if required en 18 Oil Level Must Be Between Marks DO NOT OVERFILL 9 AD Diesel ADD Engine FULL o ADD FULL D Gas Engine Figure 5A Kubota Diesel SAE 10W 10W 30 SAE 20W 10W 30 SAE 30W 10W 30 Suzuki Gas SAE 10W 30 for all temperature ranges F 20 0 C 30 20 32 40 l 20 10 0 60 7780 l 10 20 25 30 10w 40 100 40 Figure 5B Diesel Engine Above 77 F 25 C SAE 30W or SAE10W30 10W40 32 to 77 F 0 to 25 C SAE 20W or SAE 10W30 10W40 Below 32 0 C SAE10W or SAE 10W30 10W40 Gas Engine All temperature SAE 10W30 ranges Above 85 F 29 C SAE 10W 40 Replacement Oil Filters Kubota Diesel 4113986 Suzuki Gas 2701908 5 4 POWER STEERING RESERVOIR Before servicing or doing any mainte
109. e 13 603102 Ile Roll Pin 1 8 x 3 4 in 14 548325 Ile Ring Retaining 15 800227 2 Plug 1 8 NPT 16 800558 Ile Set Screw 3 8 16 x 5 16 in 17 833056 Ile Gasket Governor 18 4189960 Ile Seal Oil 19 835271 1 Nut Governor Arm 20 843537 Ile Bracket Governor Knee 21 4114867 Ile Head Governor 22 894471 1 Reservior Governor 23 833103 1 Bearing Needle 24 4150957 Ile Shaft Governor Complete 25 833104 Ile Ring Retaining 26 833345 1 Bearing Ball 27 4115584 1 Ring Support 28 2700525 1 Lever Governor Control 29 306396 3 Lockwasher 1 4 30 894435 1 Bracket Throttle 31 894434 1 Arm 32 843866 1 Bushing Governor 33 302288 1 Screw 1 4 20 x 1 in Hex Head 34 00414G5 2 Screw Hex Head 35 308090 1 Flat Washer 1 4 36 833101 1 Spring Extension 37 111898 2 Clamp Cable 38 120052 1 Lockwasher 6 39 800271 1 Screw 4410 24 x 1 2 in Pan Head 40 844130 1 Governor Cable See 5 1 41 817104 1 Stop Wire 42 800024 1 Screw 1 4 20 x 1 1 2 in 43 306375 1 Nut 1 4 20 Hex Change from previous revision 105 TURF TRUCKSTER 33 1 Gas Engine Air Filter Seral No 84068 All Serial No 84069 All Paga NG TA gt e gt 106 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine Assembly See 27 1 2 842915 1 Bracket Air Filter 3 452389 3 Screw M8 1 25 x 25 mm Hex Flange 4 450453 3 Nut M8 1 25 Hex Flange 5 411
110. e 15 825999 2 Fuse Clip 3 Term 14 16 Gauge 16 836892 7 Fuse 10 Amp 16 842983 3 Fuse 15 Amp 16 826000 1 Fuse 20 Amp 16 4113261 1 Fuse 25 Amp 17 843168 2 Connector 15 Amp Relay 842966 8 Terminal Female Relay 18 2700868 1 Connector 70 Amp Relay 842966 2 Terminal 1 4 in Female Relay 2700869 2 Terminal 3 8 in Female Relay 19 826190 AR Tubing 3 8 in I D Black Convoluted 50 Foot Bulk 20 826191 AR Tubing 1 2 in I D Black Convoluted 25 Foot Bulk 151 TURF TRUCKSTER 56 1 Gas Main Harness Continued Part Number 4238042 Serial No 84067 All Serial No 84068 All Serial No 84069 All AT MT Engine Harness Connectors ECU Parkin Switch Starter Solenoid 2 Fuel Sender 4 Radiator Fan lt Tail Light Harness Connector Cab Stop Light Option 19 0 Brake Accessory Option 7 E Brake Pedal 12 V Accessory N Switch Left Turn Left Headlight Right Turn Signal Ex Option 2 Right R 7 7 TG Tach Speedometer Signal Si h Positive c Standoff E Wires Z 34 10 CAN Connector 37 Horn 152 Speed Sensor Shift 25 Back Up Solenoid D Switch 7 Shift Switch 27 Back Up Alarm W
111. e Spring 894936 1 Kit Right Side Adjuster Repair 19 893519 2 Retainer Complete 20 838539 1 Seal Oil 21 2703309 2 Washer Hardened 22 844813 4 Ring Backing 23 800944 8 Screw M10 1 5 x 25 mm 24 2701408 2 Hub Rear Wheel 25 800908 5 Bolt Wheel 26 841430 2 Drum Brake 27 306405 10 Washer 3 8 28 805387 10 Locknut 3 8 24 Special Change from previous revision 131 TURF TRUCKSTER 47 1 Front and Shifter Cover Serial No All 14 21 1 Differential 894826 11 16 1 Differential 894825 132 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 836431 1 Cover Front 2 306322 12 Screw 5 16 18 x 7 8 in Hex Head 3 103867 14 Flat Washer 5 16 4 307776 3 Screw 3 8 16 x 2 3 4 in Hex Head 5 810437 2 Clamp 1 2 in P 14 21 1 Differential Only 6 810435 1 Clamp Right Side Brake Tube 7 836841 1 Bracket Shift Cable 8 836852 1 Breather 9 111074 1 Plug Fill 10 836959 1 Bracket Brake Tee Mounting 11 889780 1 Shift Cover Assembly 12 889925 Ile Cover 13 N S 1 Bushing 14 836658 1 Shaft Shift 15 831099 2 Seal Oil 16 548937 Ile Lockwasher 7 16 17 836657 Ile Fork Shift 18 836662 Ile Bushing Guide 19 807366 Ile Button Positioning 20 2700493 1 Spring 21 548204 Ile Set Screw 3 8 16 x 3 8 in 22 306423 2 Screw 5 16 18 x 1 3 4 in Hex Head 23 306435 1 Screw 5 16 18 x 1 1 4 in Hex Head Change from prev
112. ee la documentaci n t cnica y est autorizada para recopilar el archivo t cnico y que est establecido en la Comunidad Undertecknas av den som bemyndigad att uppr tta deklarationen tillverkarens v gnar innehar den tekniska dokumentationen och r bemyndigad att sammanst lla den tekniska informationen och som r etablerad i gemenskapen 2006 42 EC Annex Il 1 A 2 Tim Lansdell Technical Director Ransomes Jacobsen Limited West Road Ransomes Europark Ipswich IP3 9TT England 2006 42 EC Annex Il 1 A 10 So a Vasant Godhalekar VP of Engineering Jacobsen A Textron Company 11524 Wilmar Blvd Charlotte NC 28273 USA Certificate Number Homep Ha ceprwcpwxar islo osv d en Certifikatnummer Certificaatnummer Sertifikaadi number Hyv ksynt numero Numero de certificat Bescheinigungsnummer Api8p g Miototrointikou Hiteles t si sz m Numero del certificato Sertifikata numurs Sertifikato numeris Numru ta ertifikat Numer certyfikatu Numero do Certificado Num r certificat slo osved enia tevilka certifikata Numero de certificado Certifikatsnummer 4175887 Rev B CEB Ba CD CDK CNL CEED CHO CFR DE CBR CHU English bnrapcku e tina dansk Nederlands eesti suomi frangais Deutsch EAAnvika magyar CT Gv AD ADP CD CD RO GIO CSI CES CSED latvieSu Malki Romana sloven ina valoda italiano lietuvi kalba polski portugu s
113. egrees for Clarity Gas Unit Cable Attachment TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4146819 1 Retaining Ring M6 2 4142630 1 Mount Shifter 3 4142627 1 Selector Gear 4 842773 1 Rod End 1 2 20 5 308091 1 Flat Washer 1 2 6 311763 1 Screw 1 2 20 x 2 1 4 Hex Head 7 843679 1 Plate Wear 8 452692 4 Screw M6 1 x 12 mm Self Tap 9 604174 1 Flat Washer 3 8 10 843614 1 Spring Torsion 11 843685 1 Bushing Spring 12 2703951 1 Tab Locating 13 452401 1 Screw M10 1 5 x 40 mm Flange 14 450454 1 Nut M10 1 5 Flange 15 2701273 2 Cable Shifter 16 842774 2 Ball Joint 1 4 28 17 816307 2 Flat Washer 1 4 18 306397 1 Nut 1 4 28 Hex 19 843724 2 Clamp Cable 20 452695 4 Screw M6 1 x 20 mm Self Tap 21 300977 1 Screw 1 4 28 x 5 8 Hex Head 22 306396 3 Lockwasher 1 4 23 800582 4 Screw 1 4 20 x 3 4 Truss Head 24 4146818 1 Retaining Ring M5 25 2702696 1 Boot Control Lever 26 4140431 1 Knob Shifter 27 548175 3 Flat Washer 1 4 x 1 1 4 28 308090 1 Flat Washer 1 4 29 4142796 1 Connector Shift Cable 30 2703964 7 1 Panel Right Side Dash 31 843792 1 Plate Shifter Boot 32 2700496 4 Insert 1 4 20 Threaded 33 2703931 7 1 Ring Boot Hold Down 34 452695 4 Screw M6 1 x 20 mm Self Tap 35 2701371 1 Connector Shift Cable Change from previous revision 63 TURF TRUCKSTER 12 1 Automatic Transmissio
114. eliv imsuse tase Mitattu nitehotaso Niveau de puissance sonore mesur Gemessener Schalldruckpegel Zra piop vo err rre o nynrikic IoxUog M rt hangteljes tm nyszint Livello di potenza sonora misurato Izm ritais ska as jaudas l menis ISmatuotas garso stiprumo lygis Livell tal Qawwa tal Hoss Iggarantit Moc akustyczna mierzona Nivel sonoro medido Nivelul m surat al puterii acustice Nameran hladina akustick ho v konu Izmerjena raven zvo ne mo i Nivel de potencia sonora medido Uppm tt ljudeffektsniv 103 dB A LWA Guaranteed Sound Power Level apaurupauo HBO Ha 3BykoBa MoujHocr Garantovan akustick v kon Garanteret lydstyrkeniveau Gegarandeerd geluidsniveau Garanteeritud helivdimsuse tase Taattu nitehotaso Niveau de puissance sonore garanti Garantierter Schalldruckpegel Eyyunp vo ettitredo nynrikric IoxUog Szavatolt hangteljes tm nyszint Livello di potenza sonora garantito Garant tais ska as jaudas l menis Garantuotas garso stiprumo lygis Livell tal Qawwa tal Hoss Iggarantit Moc akustyczna gwarantowana Nivel sonoro farantido Nivelul garantat al puterii acustice Garantovan hladina akustick ho v konu Zajam ena raven zvo ne mo i Nivel de potencia sonora garantizado Garanterad ljudeffektsniv 104 dB A LWA Conformity Assessment Procedure Noise OueHxa 3a cborBercrBue Ha npouenypara Lym Postup hodnocen pln n podm nek hluk
115. ent 40 2 cu in 658 cc Toroue nenn 38 3 ft Ibs 51 9 Nm 3200 rpm Fuel Type Unleaded Gasoline Rating Min Octane rating 87 Capacity 6 55 U S Gal 24 5 liters The use of any fuel containing greater than 1096 ethanol may harm the engine s emission control system and therefore invalidate the emission related warranty through the improper action of the operator SPECIFICATIONS 3 differential and four post ROPS 84068 eren Turf Truckster liquid cooled gas engine 3 speed automatic transmission 14 21 1 2 speed differential and four post ROPS 84069 1 Turf Truckster liguid cooled gas engine 5 speed manual transmission 11 16 1 2 speed differential and four post ROPS EEC Sound Operator Vibration M S Product Power Ear Arms Body 84064 103 dB A 84 dB A 2 14 096 Governor All Speed Mechanical Low Idle 1300 RPM High Idle 3180 RPM Lubrication Capacity 5 4 quarts 5 1 liters Below 32 F 0 C SAE 10W or 10W 30 10W 40 32 77 F 0 25 C SAE 20W or 10W 30 10W 40 Above 77 F 25 C SAE 30W or 10W 30 10W 40 API Classification CD or CE Air Filter Dry type with evacuator valve Alternator 60 amp Cooling System Liquid Cooled Capacity
116. eplaced with Upper ROPS 894761 Hydraulic Attachments High Low Gas Hydraulics 4147940 High Low Diesel Hydraulics 894713 Implement Lift A Frame 892493 Dry Seal Coupler 1 eet 894604 Hydraulic PTO Requires 894712 and 894713 894644 Truck Attachments Heavy Duty Mechanical PTO 4112981 Quick Aerator aaa 2701529 Ram Mount Sprayer Control Mount 4119631 1500 Top Dreseer eee eeeeeeeeeeeeeeeeeeeeeeeeeees 2701650 Turn Signal with Right Taillight 894764 VICON Spreader Requires 2701601 or 2701602 2701600 VICON Hydraulic Power Kit 2701601 VICON Mechanical Power Kit 2701602 Backup Alarm ea 2703183 Exhaust Spark Arre Stor cccccseeeceereeessteeeeenees 882574 Heater Defroster A 894760 Support Literature Safety 8 Operation Manual 4175886 Parts amp Maintenance Manual 4175887 Suzuki Engine Parts Manual 4140632 Kubota Engine Parts Manual 4160162 Service amp Repair Manual en 9 3 SPECIFICATIONS 3 8 DECLARATION OF CONFORMITY en 10 DECLARATION OF CONFORMITY DEKIIAPAUNSI 3A CbOTBETCTBVE PROHL EN O SHOD OVERENSSTEMMELSESERKL ERING CONFORMITEITSVERKLARING
117. ering Alternator Belt 14 Gas Hydraulic Pump Belt 15 Parking Brake Cable 15 Torque Specification 16 Maintenance Generali Re eet tes etes 17 Engine niit de tetas 17 Ge UE 18 Power Steering Reservoir 19 Muffler and Exhaust ceeceteeeeeteees 19 Engine Overheat Procedure 19 Cooling System sssssesssss 20 AT aaa erben 21 Jump Starting sesssssseeeees 21 Battery LANANG 22 5 11 5 12 5 13 5 14 5 15 5 16 5 17 5 18 5 19 5 20 5 21 5 22 5 23 5 24 5 25 5 26 5 27 5 28 5 29 5 30 5 31 5 32 6 6 1 7 7 1 7 2 7 3 7 4 7 5 8 9 9 1 9 2 9 3 Charging Battery sssssssss 22 Hydraulic Hoses renirensiusrina 23 Hydraulic Reservoir and Filter 23 Fuel ea thee teet hin at 24 Fuel System essssssseese 24 Tire Pressure ete 25 Tire Removal and Installation 25 Raising the Vehicle nn 26 Towing the Vehicle esses 27 Governor Oil Level seessssss 27 Hydraulic Brakes AA 28 Differential Fluid een 29 Diesel Engine Manual Transmission 29 Gas Engine Manual Transmission 30 Gas Engine Automatic Transmission 30 Electrical System sssuss 31 Dashi Panel
118. esel Engine Air Filter 98 30 1 Diesel Engine Exhaust and Remote Oil Filter 100 31 1 Gas Engine Governor Linkage 102 32 1 Gas Engine Governor 33 1 Gas Engine Air Filter 34 1 Gas Engine Remote Oil Fill 108 35 1 Gas Engine Exhaust esses 109 36 1 Diesel Fuel System s 110 37 4 Gas Fuel System eese 112 38 1 Gas Fuel System esses 114 39 1 Hydraulic Tank and Filter 116 40 1 Hydraulic Pump and Filter 118 41 1 Lift Cylinder Circuit 120 42 1 Diesel Electrical Components 122 43 1 Gas Electrical Components 124 44 1 Differential Assembly 126 45 1 Differential Housing eese 128 46 1 Axle Tubes and Shafts 130 47 1 Front and Shifter Cover 132 48 1 Input Main and Jack Shafts 134 49 1 Transmission Clutch Release Shift Selector 136 50 1 Transmissi
119. et tangled in moving parts 4 Use the illustrations in the Parts amp Maintenance Manual as reference for the disassembly and assembly of components 5 Recycle or dispose of all hazardous materials batteries fuel lubricants anti freeze etc according to federal state and local regulations 6 Keep hands and feet away from moving parts Whenever possible do not make adjustments with the engine running 4 Check and adjust hydraulic pump and alternator belts See Sections 4 5 4 6 4 7 and 4 8 5 Refer to Section 7 3 and Engine Manual for specific maintenance intervals 6 If the injection pump injectors or the fuel system require service contact an authorized Jacobsen Dealer Keep your engine clean f dirt has accumulated on the engine it should be washed with a nonflammable solvent or strong detergent When washing becomes necessary it can be carried out concurrent with servicing the vehicle In order to maintain reliable service from your engine a regular check up and maintenance schedule should be followed Proper maintenance will prolong the engine s life and avoid premature overhaul en 17 5 MAINTENANCE 5 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 The oil level should always be bet
120. evel should be between the COLD and HOT marks Use General Motors Power Steering Fluid as required to bring fluid up to proper level Power Steering Dipstick 4109 TINA 3 Figure 5C 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 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 82 C on diesel units or 208 F 97 7 C on gas units 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 en 19 5 MAINTENANCE 5 7 COOLING SYSTEM This vehicle is equipped with a radiator temperature controlled fan temperature gauge and an overheat buzzer To prevent serious bodily injury from hot coolant or steam blow out never attempt to remo
121. evis Pin 5 16 x 15 16 in 12 103867 1 Flat Washer 5 16 13 306328 1 Cotter Pin 3 32 x 3 4 in 14 894456 1 Reservoir Brake Fluid 894456 1 Reservior 826006 Ile Electrical Connector 2 Wire 825886 2 Terminal 1 4 L Male 15 800934 2 Screw M6 1 x 16 mm Flange 16 832033 4 Clamp Hose 17 4194500 2 Hose 5 16 x 18 in Brake 18 810152 1 Pad Pedal 19 894308 1 Switch Brake Micro 20 450410 2 Screw M3 0 5 x 20 mm Pan Head 21 452424 2 Nut M3 0 5 Hex 22 452398 7 Screw M10 1 5 x 20 mm Flange 23 843021 1 Tube Front Brake 24 4194421 1 Tube Rear Brake 25 842103 1 Union M10 1 26 4194420 1 Tube Rear Brake Line 27 809137 1 Clip Brake Line 28 REF 1 Rear Brake Hose See 44 1 29 810435 2 Clamp Brake Tube 30 450454 1 Nut M10 1 5 Flange 31 REF 1 Bracket Reservoir Horn See 42 1 and 43 1 32 REF 1 Tee M10 1 0 Flare Union See 19 1 33 812445 1 Clamp Tube 34 800943 1 Screw 10 14 x 5 8 in Self Tapping Change from previous revision 57 TURF TRUCKSTER 9 1 Clutch Pedal Linkage Serial No 84063 All Serial No 84064 All Serial No 84067 All Serial No 84069 All View Rotated 90 Degrees for Clarity Cable View Rotated 90 Degrees for Clarity Diesel Units Gas Units 58 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 892933 1 Pedal Clutch 2 840726 1 Bearing Brake Pivot
122. ferential 25 4140075 1 Yoke Transmission Diesel Engine 25 4140072 1 Yoke Transmission Gas Engine gt Change from previous revision 71 TURF TRUCKSTER 17 1 Front Control Arms Serial No All 72 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 4120138 1 Frame 4 Wheel Steering 2 893266 2 Upper Control Arm 3 893233 1 Left Side Lower Control Arm 4 893234 1 Right Side Lower Control Arm 5 844148 2 Upper Ball Joint 6 N S Ile Boot 7 N S 1 Boot Retainer 8 N S 4 Screw 5 16 24 x 1 in Hex Head Black Oxide Finish Grade 8 9 N S 4 Lockwasher 5 16 Black Oxide Finish 10 548079 4 Nut 5 16 24 Hex Black Oxide Finish 11 306839 Ile Nut 5 8 18 Slotted Hex 12 460030 1 e Cotter Pin 1 8 x 1 1 4 in 13 471221 Ile Grease Fitting 1 4 28 90 14 841429 2 Lower Ball Joint 15 N S Ile Boot 16 800861 Ile Nut 9 16 18 Slotted Hex 17 460030 1 e Cotter Pin 1 8 x 1 1 4 in 18 548224 Ile Grease Fitting 1 4 28 Straight Special Drive Thread 19 841167 8 Bushing Silentbloc 20 450382 8 Nut M16 2 Locking Insert 21 450077 4 Bolt M16 2 x 90 mm Hex Head Grade 8 8 22 450393 8 Washer M16 23 894573 1 Knuckle Left Side Steering 24 894574 1 Knuckle Right Side Steering 25 841630 2 Trunnion Control Arm 26 800945 4 Bolt M12 1 75 x 60 mm Hex Head Grade 10 9 l Add or remove shims as required to 27 841738 AR Shim 024 in Th
123. 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 en 28 4 Repeat Step 3 for each brake 5 Most communities have a disposal system for DOT 3 brake fluid Please dispose of fluids properly E i B gt ME Brake Fluid PRR Reservoir SS P N D P os Y West Brake Fluid Lever Indic ator Light mm 7 Gm TIIT D Bleeder pE Screw gt Figure 5M 5 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 3 qts 2 84 Fluid Type o oo eee eeeeeeeeeeeee SAE EP 80 90 gear lube 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 federal state and local regulations Apply pipe thread sealer to drain plug and install Fill differential with gear lube until fluid begins to leak from hole Apply pipe thread
124. ft lbs Nm 30 40 7 40 54 2 3 4 16 ftlbs Nm 175 237 3 225 305 1 3 8 24 ft Ibs Nm 35 47 5 45 61 0 7 8 14 ft lbs Nm 300 406 8 400 542 4 METRIC FASTENERS SIZE UNITS Non Critical o uH Aluminum M4 m in Ibs 1 2 11 1 7 15 9 26 4 1 36 5 0 44 2 0 18 M5 m in Ibs 2 5 22 3 2 28 8 51 8 1 72 9 7 86 4 0 35 M6 m in Ibs 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 M8 m in Ibs 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 M10 m ft lbs 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 m ft lbs 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 m ft lbs 58 3 43 76 4 b5 131 5 97 184 4 136 219 7 162 94 9 70 en 16 5 1 GENERAL Before you clean adjust or repair this equipment depress clutch pedal and shift transmission to Neutral engage parking brake stop engine and remove key from ignition switch to prevent injuries Make sure the vehicle is parked on a solid and level surface Never work on a vehicle that is supported only by a jack Always use jack stands 1 Adjustment and maintenance should always be performed by a qualified technician If proper adjustments cannot be made contact an Authorized Cushman Dealer 2 Inspect the equipment on a regular basis establish a maintenance schedule and keep detailed records a Keep the equipment clean b Keep all 5 2 ENGINE IMP
125. g the vehicle Loads moving inside the bed can cause an unbalanced load that could tip the vehicle 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 if vehicle is not properly supported by jack stands A scissors type jack or a floor jack with a 1 1 2 ton minimum capacity that can be lowered to a height of 3 3 8 in 86 mm is required Refer to Figure 5G for jacking locations Shift the transmission into 1st gear manual or Park automatic and apply the parking brake Chock or block the tire diagonally opposite the side being raised Raise the vehicle only enough to perform maintenance required Jack the vehicle to an appropriate height and place jack stands or equivalent support beneath the frame near the jack Lower the jack and allow the vehicle to rest on jack stands Do not remove jack When using a hoist to 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 en 26 Block Tire Herem CET Jacking Location
126. ic fluid escaping when the system is being used or if a leak is suspected turn off all hydraulic functions and stop the engine Periodically check the hydraulic fluid level hydraulic level should be checked every 100 hours of operation Loss of fluid can signal a small leak before 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 Add GreensCare 68 fluid as required The hydraulic system is protected by one 10 micron filter The filter is located under the side console near the parking brake lever MAINTENANCE 5 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 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 clea
127. ication Intervals 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 See Section Lubricant Type Alternator Battery Belts Brake Fluid Brake Linings Clutch Cooling System Differential Fluid Electrical System Engine Glow Plus o oo LL Engine Idle Speed Engine Noise Vibration Engine Oil Suzuki pres Rt 5 3 Engine Oil Filter Suzuki l pres Ke 5 3 Engine Oil Kubota R R 5 3 I Engine Oil Filter Kubota R R 5 3 Engine Valve Clearance pee Mars Fluid Leaks I R Fuel System 5 15 Fuel Filter R 5 15 Fuel Water Separator bo Diesel Only Governor Fluid LA IX Hydraulic Filter R Hydraulic Fluid LA R VIII Injection Pump Timing l Lubricate Chassis L L 7 2 I Muffler and Exhaust 5 5 Radiator Screens I C AR 5 7 Power Steering Fluid hi 5 4 V Spark Plugs Gas only C A R Starter Motor Brushes l Tires I A 5 16 Transmission Fluid S 5 23 it Manual Transmission 9 24 Transmission Fluid Automatic Transmission l N ar Wheel Bearings Repack A Add or Adjust C Clean I Inspect L Lubricate R Repair or Replace AR As Required en 37 7 MAINTENANCE amp LUBRICATION CHARTS Notes Indicates initial service for new machi
128. ick adjust CASTER angle q e Add or remove shims as required to 28 841737 AR Shim 060 in Thick adiust CAMBER angle q 29 810437 2 Clamp gt Change from previous revision 73 TURF TRUCKSTER 18 1 Steering Linkage Serial No All N On 5 gt SSR an Poa hy 4 D Ca wx Vi wh 74 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 841255 1 Steering Gear 2 305134 1 Nut 7 8 14 Hex Jam 3 308008 1 Lockwasher 7 8 4 841336 1 Arm Pitman 5 894635 2 Strut Assembly 6 800945 4 Screw M12 1 75 x 60 mm Hex Head 7 450455 4 Nut M12 1 75 Hex Flange Grade 10 9 8 311392 3 Screw 7 16 14 x 2 in Hex Head 9 303269 3 Lockwasher 7 16 10 889681 2 End Left Hand Thread Tie Rod 11 816586 1 Retainer Grease 12 306825 Ile Nut 7 16 20 Castle 13 887512 2 End Right Hand Thread Tie Rod 14 816586 Ile Retainer Grease 15 306825 Ile Nut 7 16 20 Castle 16 304636 4 Cotter Pin 1 8 x 1 1 8 in 17 831405 4 Grease Fitting 18 841404 2 Tie Rod 19 800485 1 Nut 9 16 18 Left Hand Thread Jam 20 302944 2 Nut 9 16 18 Right Hand Thread Jam 21 813850 2 Bumper Travel Limiting 22 842033 1 Plate Skid 23 452408 6 Screw M10 1 75 x 20 mm Grade 10 9 Change from previous revision 75 TURF TRUCKSTER 19 1 Front Brakes Serial No All Hose Clamp Location N Nas AN Jw RO
129. ifferential Housing 2 N S 2 e Bearing Caps 3 306829 4 Screw 7 16 14 x 2 in Hex Head 4 103867 Die Flat Washer 5 16 5 111074 Ile Plug Drain 6 111758 10 Stud 3 8 16 amp 3 8 24 x 1 23 32 7 306416 9 Screw 5 16 18 x 7 8 in Hex Head 8 306982 4 Flat Washer 7 16 9 517226 2 Bushing 10 800973 Ile Nut 3 4 16 Hex Lock 11 836443 Ile Rear Cover 12 4211800 Ile Spacer Differential 13 814476 1 Cup Bearing 2 17 32 in O D 14 836680 1 Cone Bearing 1 1 8 in I D 15 836688 AR Shim 003 Thick 16 836689 AR Shim 005 Thick Add or remove shims as required to 17 836690 AR Shim 010 Thick adjust gear backlash 18 836691 AR Shim 030 Thick 19 836692 Ile Baffle Oil 20 836685 AR Shim 003 Thick 21 836686 AR Shim 005 Thick Add or remove shims as required to adjust gear backlash 22 836687 AR Shim 010 Thick 23 836677 1 Cup Bearing 2 84 in O D 24 836678 1 Cone Bearing 1 3 8 in I D 25 889870 Ile Gear Set 26 N S Ile Pinion Gear and Shaft N S 1 Ring Gear 27 889871 1 Differential Carrier 28 800717 10 Screw 3 8 24 x 13 16 Hex Head 29 836675 2 Cup Bearing 2 89 in O D 30 836676 2 Cone Bearing 1 5 8 in I D 31 836681 AR Shim 003 Thick 32 836682 AR Shim 005 Thick Add or remove shims as required to 33 836683 AR Shim 010 Thick adjust gear backlash 34 836684 AR Shim 030 Thick 35 839948 1 Tag 14 21 1 Ratio
130. ing Low Speed Syncronizer 15 2703580 2 Spring Low Speed 16 24431 83001 2 Ring Low Speed Syncronizer 17 24220 60A01 1 Gear Main Shaft 2nd 2nd Gear 18 09263 35015 3 Bearing Needle 19 09300 30003 2 Bushing 20 24211 83011 1 Gear Main Shaft Low 1st Gear 21 09166 30007 2 Washer 22 09262 30086 1 Bearing Ball 23 24420 83000 1 Syncronizer Reverse Drive Includes Hub and Sleeve 24 24473 70D10 3 Key Syncronizer 25 2703581 1 Spring Reverse Syncronizer 26 4119000 1 Gear Main Shaft Reverse Reverse Gear 27 26121 85202 1 Gear Speedometer Drive 28 2702559 2 Cir Clip Change from previous revision 141 TURF TRUCKSTER 52 1 Gear Shift Fork Linkage Ee A 32 142 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 25411 85201 1 Shaft Low Speed Fork 1st and 2nd Gear 2 25420 85201 1 Shaft High Speed Fork 3rd and 4th Gear 3 25451 85261 1 Shaft Reverse Fork Reverse 4 06111 12004 5 Ball 5 25415 83000 3 Spring Detent 6 09261 03017 1 Roller 7 2703699 1 Fork Low Gear Shift 1st and 2nd Gear 8 2703699 1 Fork High Gear Shift 3rd and 4th Gear 9 2703582 1 Fork Reverse Gear Shift Reverse 10 09205 05012 3 Pin 4 x 25 mm Spring 11 09250 10006 1 Plug Locating 12 2703454 1 Case Gear Shift Lever 13 25520 85203 1 Shaft Grear Shift Lever 14 09284 17004 1 Seal Oil 15 25576 70D00 1 Spring 16 09160 17035 1
131. inue to be offered for all equipment currently covered This allows for the outfitting of any machines without previous ROPS installations or replacement of damaged structures Keep legs arms and body inside the seating compartment while the vehicle is in motion Always shift transmission to 1st Gear Manual Transmission or Park Automatic Transmission engage parking brake and stop engine before leaving the vehicle Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting and disconnecting charger from battery Wear protective clothing and use insulated tools Disconnect the battery cables before performing any welding operations on this vehicle SAFETY 1 1 2 IMPORTANT SAFETY NOTES A This safety alert symbol is used to alert you to potential hazards DANGERE 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 COULD result in death or serious injury CAUTION 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 i ex 0 J Indicates a potentially hazardous situation which if not avoided MAY result in property damage It may also be used to alert against unsafe practices For pictorial clarity some illustra
132. ious revision 133 TURF TRUCKSTER 48 1 Input Main and Jack Shafts Serie A 14 21 1 Differential 894826 11 16 1 Differential 894825 134 TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 836421 1 Shaft Input 2 836693 3 Bearing Ball 3 809254 1 Ring External Retaining 4 800695 1 Ring External Retaining 5 800737 2 Ring Internal Retaining 6 837020 1 Baffle Vent 7 812335 1 Seal Oil 8 4184901 1 Shaft Main 9 812009 1 Bearing Ball 10 836429 1 Collar Engaging 11 844956 1 Bearing Bronze Thrust 12 894886 1 Gear Driven 13 812006 1 Bushing 14 811993 1 Bearing Thrust 15 844951 AR Shim 003 Thick 15 844952 AR Shim 005 Thick Add or remove shims as required to adjust gear backlash 15 844953 AR Shim 010 Thick 16 845034 1 Collar Thrust 17 548952 1 Lockring 18 836420 1 Spacer Pinion 19 4184900 1 Pinion 15 Tooth 14 21 1 Differential 894826 19 4211960 1 Pinion 18 Tooth 11 16 1 Differential 894825 20 800911 1 Nut 9 16 18 Crown Lock 21 891089 1 Jackshaft 22 548201 1 Set Screw 5 16 18 x 5 16 23 894519 1 Cluster Gear 24 844087 2 Bushing 25 811992 3 Shim CLuster Gear 26 842360 1 Gear 52 Tooth 14 21 1 Differential 894826 26 836441 1 Gear 49 Tooth 11 16 1 Differential 894825 27 4186900 1 Baffle Oil Scoop Change from previous revision 135 TURF TRUCKSTER Serial No 84063
133. ires 21 20 35 sia fe Turn Signal 5 Option Jumper Plug e Flasher Option U Tach Signal Ground Wires oo HO gt Shifter Light Brake Fluid Heater de A ption A Ks Brake Accessory Option Diagnostic Plug 18 NG Fan Relay Main Reservoir Fuel Relay Relay 1 2 S Fuse 2 17 Block tt 16 Block 2 A 14 TURF TRUCKSTER Item Part No Qty Description Serial Number Notes 21 826192 AR Tubing 3 4 in I D Black Convoluted 25 Foot Bulk 22 826193 AR Tubing 7 16 in I D Green Convoluted 25 Foot Bulk 23 N S 1 Connector 12 Contact Male MT Engine Harness Connector 833257 6 Terminal Female 838463 6 Seal Wire 2700933 6 Plug Cavity 24 N S 1 Connector 16 Contact Male AT Engine Harness Connector 833257 14 Terminal Female 838463 14 Seal Wire 2700933 2 Plug Cavity 4118039 7 Plug ECU Connector 25 845330 1 Connector 4 Contact Male 833257 4 Terminal Female 838463 4 Seal Wire 26 845327 1 Connector 3 Contact Female 2700380 3 Terminal 2700381 3 Seal Wire 27 845328 1 Connector 9 Contact Female 2700385 2 Terminal 2700387 2 Seal Wire 2700384 7 Terminal 2700386 7 Seal Wire 28 839917 1 Plug 2 Wire Deutsch 29 839921 1 Lock 2 Wire Deustch 30 524358 2 Ter
134. ized Truckster Optional Galvanized Platform 4 893525601 2 Support Platform 5 452406 6 Screw M10 1 5 x 90 mm Flange Grade 8 8 6 452398 5 Screw M10 1 5 x 20 mm Flange Grade 8 8 7 450454 20 Nut M10 1 5 Hex Flange 8 450455 8 Nut M12 1 75 Hex Flange 9 452410 12 Screw M12 1 75 x 30 mm Flange 10 309067 2 Lockwasher 1 2 Shakeproof 11 452405 3 Screw M10 1 5 x 80 mm Flange 12 894581 1 Mount Left Side Diesel Engine Diesel Units 12 894998 7 1 Mount Left Side Gas Engine Gas Units 13 894582 1 Mount Right Side Diesel Engine Diesel Units 13 2701697 7 1 Mount Right Side Gas Engine Gas Units 14 842870 1 Angle Support 15 844647G01 1 Angle Hold Down 16 452403 4 Screw M10 1 5 x 60 mm Flange 17 452402 6 Screw M10 1 5 x 50 mm Flange 18 2703294 7 1 Guard Hydraulic Tank 19 4174281 1 Transmission Mount Diesel Units 19 4179803 1 Transmission Mount Gas Units 20 452389 4 Screw M8 1 25 x 25 mm Flange 21 450453 4 Nut M8 1 25 Flange 22 4185540 1 Bracket Fuel System Diesel Units 23 2701693 7 1 Bracket Fuel System Gas Units 24 452378 2 Screw M6 1 x 20 mm Hex Flange 25 450452 2 Nut M6 1 Hex Flange 26 882971 2 Pin Box Pivot 27 4242482 1 Bracket ECU Mounting Gas Units Only 28 821893 4 INTRIM Push On Black 2 ED Not Shown 29 2703961 1 Decal Hitch Capacity 30 829997 1 Grommet Change from previous revision 69 TURF TRUCKSTER 16 1 Rear Axle Serial No All
135. lange 9 2702686 1 Screw M10 1 25 x 55 mm Flange 10 2702690 2 Alignment Pins 11 4148360 1 Starter Manual Transmission 12 2702470 2 Screw M8 1 25 x 30 mm Hex Flange 13 2702689 2 Nut M10 1 25 Hex Flange 14 4233440 2 Cover Belt 15 4235369 1 Standoff M6 1 x 25 mm 16 450169 3 Screw M6 1 x 14 mm Hex Head 17 450410 3 Lockwasher M6 18 894998 7 1 Left Engine Mount See 14 1 19 2701697 7 1 Right Engine Mount See 14 1 20 4179803 1 Transmission Mount See 14 1 21 452405 3 Screw M10 1 5 x 80 mm Flange 22 450454 3 Nut M10 1 5 Hex Flange 23 4138391 1 Switch Reverse 24 4148082 1 O Ring 25 4142772 1 Bracket Cable Mounting 26 4203381 1 Cover Vent Hole Cut into two pieces One 4 1 2 in Ar Kee SS 114 mm one 2 1 4 in 57 mm 28 452389 1 Screw M8 1 25 x 25 mm Hex Flange Change from previous revision 87 TURF TRUCKSTER 25 1 Gas Engine and AT Mounting Serial No 84068 All AMN gt D 4 Va m Ng Sa Ze IN g 88 oi 5 G NN Zo 7 is NG I KHA WA IN SI fa BY AN Va CH Gu AY st o N TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Engine Assembly See 27 1 2 4148212 1 Automatic Transmission 3 4140900 1 Plate Transmission Housing 4 4148213 1 Torque Converter 5 4120097 1 Plate Drive 6 4148065 6 Screw M8 1 25 x 9 5 mm Flange 7 2702688 2
136. lled 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 properly c DO NOT use Aviation Fuel JP4 Refer to Engine Manual for additional information Gas Engine Use clean fresh Unleaded Gasoline with 87 octane or higher rating The use of any fuel containing greater than 1096 ethanol may harm the engine s emission control system and therefore invalidate the emission related warranty through the improper action of the operator 5 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 1 93 BAR 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 over inflation may be reached in a matter of two to three seconds Keep tires inflated to Front 20 psi 1 38 BAR 5 17 TIRE REMOVAL AND INSTALLATION Removal 1 Park the vehicle on a flat and level surface Apply parking brake shut off engine and shift transmission to 1st gear manual or Park automatic 2 Refer to Section 5 18 for proper lifting procedures Always
137. luded with Item 2 5 901234 1 1 4 20 x 2 Hex Head 9 2 TO ORDER PARTS 1 Write your full name and complete address on the order 2 Explain where and how to make shipment 3 Give product number name and serial number that is stamped on the name plate or serial plate of your product 4 Order by the quantity desired the part number and description of the part as given in the parts list 5 Send or bring the order to an authorized Jacobsen Distributor 6 Inspect all shipments on receipt If any parts are dam aged or missing file a claim with the carrier before accepting 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 will void the warranty en 40 PARTS CATALOG 9 9 3 TABLE OF CONTENTS E Front Bogy esee 42 58 1 Gas Engine Schematic 160 24 KT Engine ei een 44 59 1 Diesel Engine Electrical Schematic 162 3 1 Four Post ROPS eene 46 4 1 Upper ROPS ee esee 48 5 1 Throttle Control eene 50 6 1 Control Console eene 52 TA Parking Brake and High Low Speed Control 54 8 1 Brake Pedal eene
138. minal 18 20 AWG Male Pin 31 838768 2 Lock 4 Wire Deutsch 32 838769 4 Terminal 18 20 AWG Socket 33 838770 2 Plug 4 Wire Deutsch 34 4245130 AR Turbing 1 2 in I D Green Convoluted 30 Inch Length 35 N S 1 Connector 60 Contact 36 825880 2 Connector One Male Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge 37 N S 1 CAN Connector 153 TURF TRUCKSTER 57 1 Gas Engine Electrical Schematic end fic AGER All Serial No 84069 All ECU 15 14 13 12 11 10 9 2220080 SEREEBHBERMUSU See page 158 for Engine Harness CN CJ p pag g BOBOOO ODDO AAAH 60 pin connector ooosoooooososoooo DD 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 Bn Ye Gn Wh B 2 Bk Rd Wh Rd 6 gt Wh Rd Bk Bn 7 O 4 Bk Wh 10 gt 5 CAN Rd Gn Gn Connector 18 6 i Gn Wh Pins 1 3 7 13 14 gt 14 and 16 Not Used 60 Pin Bk Rd i ECU AG BuWh gt _ Connector 25 gt Diagnostic Ye Bk Pins 1 3 5 8 9 11 28 lt Plug 12 16 24 26 27 Lee p Gn ITI 2A 31 34 44 46 56 Bind and 58 60 Not Used 30 Rd Gn 32 gt Wh 33 P 45 gt 57 99 Bk Wh MN Se SE Shifter Switch 3 y Oen
139. n Shifter Serial No 84068 All 64 Item Part No Qty Description Serial Numbers Notes 1 103867 2 Flat Washer 5 16 2 302030 1 Screw 1 4 20 x 1 1 4 in 3 306375 1 Nut 1 4 20 Hex 4 306396 1 Lockwasher 1 4 5 800582 4 Screw 1 4 20 x 3 4 in 6 821164 2 Hair Pin 1 4 x 1 1 8 in 7 842740 1 Lever Shifter 8 845345 7 1 Bracket Shifter Cable Mount 9 894584 1 Shifter with Cable 10 894508 Ile Cable Shifter 11 892164 1 Kit Cable Mounting Hardware 12 869154 1 Shifter Handle 13 2700496 4 Insert 1 4 20 gt Change from previous revision 13 1 Automatic Transmission Oil Cooler TURF TRUCKSTER Serial No 84068 All Item Part No Qty Description Serial Numbers Notes 1 838340 1 Oil Cooler 2 800789 1 Kit Oil Cooler Mounting 3 826590 AR Hose 5 16 I D 4 821893 AR Trim Push On Not Shown 5 809231 2 Grommet 6 825624 4 Hose Clamp Change from previous revision 65 TURF TRUCKSTER 14 1 Frame Attachments TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 REF 1 Front Suspension See 17 1 18 1 and 19 1 2 452415 8 Screw M12 1 75 x 80 mm Flange 3 450455 8 Nut M12 1 75 Hex Flange 4 4243009 2 Wheel and Tire Straight Rib 4243005 1 Rim 10 00 x 7 in Five Bolt 3 94 in Bolt Circle 4243004 1 Tire 20 x 10 00 10 Straight Rib 360111 1 Valve Stem 5 800909
140. n and hose fittings are properly seated before tightening d Keep the hose from twisting Twisted hoses can cause couplers to loosen as the hose flexes during operation resulting in oil leaks e Kinked or twisted hoses can restrict the oil flow causing the system to malfunction the oil to overheat and also lead to hose failure To replace hydraulic oil filter 1 Remove the old filter 2 Fill new filter with GreensCare 68 fluid 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 with GreensCare 68 to knurled mark on gauge NS KNURLED PORTION HYDRAULIC OF DIPSTICK RESERVOIR DIPSTICK SHOWN AS REFERENCE ONLY Figure 5E en 23 5 MAINTENANCE 5 14 FUEL Handle fuel with care it is highly flammable Use an approved container The spout must fit inside the fuel filler neck Do not use cans and funnels to transfer fuel JAWARNING 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
141. nance 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 The power steering reservoir is located on the right side of the engine below the alternator The level in the reservoir should be checked after the first 35 and again at 70 hours After that the level should be checked every 100 hours 5 5 MUFFLER AND EXHAUST Exhaust fumes contain carbon monoxide that is toxic and can be fatal when inhaled NEVER operate an engine without proper ventilation 5 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 Slow the engine speed to a fast idle Remove any dirt chaff debris etc from the radiator intake screen located on the right side of the vehicle 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 MAINTENANCE 5 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 l
142. nen Jacobsen A Textron Company 11524 Wilmar Blvd Charlotte NC 28273 USA January 1 2011 Signature of the person empowered to draw up the declaration on behalf of the manufacturer holds the technical documentation and is authorised to compile the technical file and who is established in the Community Nognuc Ha uoBeka yrrenHoMouieH Aa CbCTaBN neknapauysra or Mero Ha NPON3BOANTENA KONTO NOMAbPXALI rexaeckara nokyMeurauws N e oropuaupaH na n3roTBn TexHu4eckna pain n e perucrpupaH B O LIHOCTTA Podpis osoby opr vn n sestavit prohl eni jm nem vyrobce dr et technickou dokumentaci a osoby opr vn n sestavit technick soubory a zalo ene v r mci Evropsk ho spole enstv Underskrift af personen der har fuldmagt til at udarbejde erkl ringen p vegne af producenten der er indehaver af dokumentationen og er bemyndiget til at udarbejde den tekniske journal og som er baseret i n romr det Handtekening van de persoon die bevoegd is de verklaring namens de fabrikant te tekenen de technische documentatie bewaart en bevoegd is om het technische bestand samen te stellen en die is gevestigd in het Woongebied henduse registrisse kantud isiku allkiri kes on volitatud tootja nimel deklaratsiooni koostama kes omab tehnilist dokumentatsiooni ja kellel on igus koostada tehniline toimik Sen henkil n allekirjoitus jolla on valmistajan valtuutus vakuutuksen laadintaan jolla on hallussaan tekniset asiakirjat joka on valtuutett
143. nes Engine oil oil filter and air filter may require more frequent replacement depending on operating conditions 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 hours kk 7 4 COMMON REPLACEMENT PARTS Part Number Part Description 5000919 Diesel Air Filter Element 840352 Gas Air Filter Element 4113986 Diesel Oil Filter 2701809 Gas Oil Filter 4183591 Diesel Fuel Filter 2701898 Gas Fuel Filter 4175560 Diesel Alternator Belt 4117092 Diesel Hydraulic Pump Belt Lubricants I Manual grease gun with NLGI Grade 2 Service Class LB II Engine Oil See Section 5 3 III SAE EP 80 90 gear lube IV Capacity 3qt 2 8 1 50 50 water ethylene glycol mix V GM Power Steering Fluid VI DOT 3 brake fluid VII Mercon Dextron II automatic transmission fluid VIIIGreensCare 68 hydraulic fluid 5003102 55 gallon drum GreensCare 68 5003103 5 gallon pail GreensCare 68 IX SAE 20W oil Part Number Part Description 4140919 Gas Water Pump Belt 4139265 Gas Alternator Power Steer ing Belt 4139351 Gas Hydraulic Pump Belt Plug 2701832 B XU22EPR U Spark 7 5 KUBOTA DIESEL ENGINE SERVICE PARTS The following common engine parts are provided for reference only Refer to the Engine Parts Manual for a complete list of service parts
144. ng Gas Engine Setting Figure 5T 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 Jacobson Part No Headlight H6545 837303 1 Disconnect the Negative BLACK battery cable 2 Remove the four screws securing the headlight bezel to the front cowl 3 Pull headlight and bezel forward and out of the front clip opening 4 Disconnect the electrical connector from the rear of the headlight 5 29 TAIL LIGHT REPLACEMENT The tail light should be repaired as soon as it stops 7 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 Jacobson Part No Tail light bulb 1157 822049 1 Remove the two screws securing lens Remove lens and gasket 2 Push bulb in turn 1 4 turn and remove bulb 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 frame Disconnect harness and remove tail light from frame en 32 5 Remove the headlight from the bezel Properly dispose of old bulb 6 Install new headlight in reverse order of removal
145. nid AX 10 s1say XA youms T Ll ao Oya m aunssaid WO 1epueg narid olo m T duet youms PH d N m s ayeig Buried pu pip VOX SO pu al EIS X e 2 5 5 di alo lp 2 N AAAAA WAV SSOUJEY uej JojeipeJ ay JO Wed are YIM Pawel SM 10120uuo2 ssauJeH UPN Z 10 Jauu09 ssauleH ule SSOUIEY UEL 19 009 IO ay Jo Wed 218 YIM payIgw SAIMA 10120uu02 SsauJeH UPN RER I9 UM Ye gt K Wh Bk S Wh Bk aj 0 2g uM ar ed uM VSL od Aejay ue JOJBIPEH S EI vor A PH 1010 UB Jojeipey wld o Kejay ue 19 009 IO 1010 N UB 19 002 IIO Da PH 162 INDEX 00414 G5 105 11741 85200 85 137 2700386 153 2702501 109 009034880 81 83 120052 51 97 105 111 2700387 153 2702602 109 01116 G01 103 15 sa 123 125 27004538 I9 2702534 7 sse 131 01421 08303 139 120166 145 2700493 1383 2702535 131 01550 08353 59 120177 85 91 93 101 2700496 51 61 63 64 2702547 87 01550 08553
146. nomas kuriam gamintojas suteik galiojimus sudaryti i deklaracij ir kuris j pasira turi vis technin informacij ir yra galiotas sudaryti technin s informacijos dokument I firma tal persuna awtorizzata li tfassal id dikjarazzjoni fisem il fabbrikant g andha d dokumentazzjoni teknika u hija awtorizzata li tikkompila l fajl tekniku u li hija stabbilita fil Komunit Podpis osoby upowa nionej do sporz dzenia deklaracji w imieniu producenta przechowuj cej dokumentacj techniczn upowa nion do stworzenia dokumentacji technicznej oraz wyznaczonej ds wsp lnotowych Assinatura da pessoa com poderes para emitir a declara o em nome do fabricante que possui a documenta o t cnica que est autorizada a compilar o processo t cnico e que est estabelecida na Comunidade Semn tura persoanei mputernicite s elaboreze declara ia n numele produc torului care de ine documenta ia tehnic este autorizat s compileze dosarul tehnic si este stabilit n Comunitate Podpis osoby poverenej vystaven m vyhl senia v mene v robcu ktor m technick dokument ciu a je opr vnen spracova technick podklady a ktor je umiestnen v Spolo enstve Podpis osebe poobla ene za izdelavo izjave v imenu proizvajalca ki ima tehni no dokumentacijo in lahko sestavlja spis tehni ne dokumentacije ter ima sede v Skupnosti Firma de la persona responsable de la declaraci n en nombre del fabricante que pos
147. oling fan 5 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 MAINTENANCE Diesel Engine 20 A Dash Panel Fuel Pump amp Ignition Power Port 15 A E Brake Light 5th Wheel Brake 10 Aim Flashers 8 10 A e Horn A Bush 10A Accessary set 10 A Heater Accessary Headlights 15 A Lo Gas Engine Accessary 10A 10 A Wiper Dome Light amp Back Up Alarm Noy Dash Panel ECU Fuel 20 A 8 Engine Coils 25 A Radiator
148. on 72 Lo Brake Pedal AT QS 1 2 po d ES Switch J 17 12 5 Ignition Switch ING Horn Button 12V Accessory Plug 18 20 8 1 2 men ev 17 67 Option le L 17 1 1 19 O i Ground O Wires O O Dash Panel t Heater Option E Horn Automatic Transmission Not Used Fuse Block 1 Fuse Block 2 lt gt e g8888 9 e 8888 9 16 TURF TRUCKSTER Item Part No Qty Description Serial Number Notes 1 825973 3 Connecter Six Male Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge Single Wire 825961 AR Terminal 1 4 in Male 10 Gauge Two Wire 2 829630 2 Connector Four Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 3 826726 1 Connector One Female Terminal 825886 AR Terminal 1 4 in Male 14 16 Gauge 4 826005 13 Connector Two Female Terminal 825748 AR Terminal 1 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 5 825894 1 Connector Flasher 825899 AR Terminal 5 16 in Female 14 16 Gauge 6 825877 1 Connector Six Female Terminal 825748 AR Terminal 1 4 in Female 14 16 Gauge Single Wire 825878 AR Terminal 1 4 in Female 10 Gauge Two Wire 7
149. on Case eese 138 51 1 Input and Main Sharft 140 52 1 Gear Shift Fork Linkage 142 53 1 Mechanical PTO esee 144 54 1 Diesel Engine Main Harness 146 55 4 Diesel Engine and Fan Harness 148 56 1 Gas Main Harness eese 152 56 1 Gas Main Harness Continued 154 57 1 Gas Engine Electrical Schematic 156 en 41 TURF TRUCKSTER 1 1 Front Body Serial No All 42 27 Gas Units i TURF TRUCKSTER Item Part No Qty Description Serial Numbers Notes 1 2700792 1 Front Clip Includes decals 821071 amp 840901 2 800930 2 Screw M8 1 25 x 16 mm Hex Flange 3 548159 4 Flat Washer 5 16 x 1 1 4 in 4 450400 2 Washer M8 5 4206760 1 Hood Orange 6 4208620 1 Weather Seal 7 841477G01 1 Hinge Hood 8 841637 1 Angle Front Clip Mounting 9 450541 7 Screw M6 1 x 16 mm Round Head 10 452695 6 Screw 1 4 20 x 5 8 in Taptite 11 841913 2 Plate Access 12 800934 20 Screw M6 1 x 16 mm Hex Flange 13 4139691 2 Fender Flexible 14 548175 8 Flat Washer 1 4 x 1 1 4 in 15 800943 8 Screw 10 14 Self Tapping 16 837303 2 Headlight Rectangular 17 841428 2 Bezel Headlight 18 828382 AR Seal Foam 19 4
150. on fluid level remove the filler plug from the front of the transmission Fluid should be level with the bottom of filler hole If fluid is low add gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug To change fluid rear of transmission remove drain plug from Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state and local 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 Fill transmission with gear lube until fluid begins to leak from hole Apply pipe thread sealant and install filler plug Figure 5Q 5 25 GAS ENGINE AUTOMATIC TRANSMISSION The transmission fluid should be checked every 100 hours or 3 months Fluid should be changed every 600 hours or yearly Transmission Fluid Capacity 3 8 ats 3 6 Fluid Type Mercon Dextron Il To check transmission fluid level the engine must be running Place the gear selector in Park P apply the parking brake and start the engine With engine running remove the dipstick and wipe it with a clean rag Insert the dipstick into the extension tube until it contacts the tube Remove the dipstick and read the fluid level Fluid must be kept between the two marks on the dipstick If fluid is low add fl
151. ow add the recommended oil type Remove the plug from the rear of the governor and remove the plug from the top of the governor Add 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 Ib 10 741 Nm MAINTENANCE 5 4 Slowly drive towing vehicle forward until tow line is pulled tight 5 While towing try to keep the tow line taught at all times Be careful going down inclines and turning corners Tow Line Attachment 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 Figure 5H 4 S wil i A Governor Oil Fill Plug ze T Ix gt Figure 51 en 27 5 MAINTENANCE 5 21 HYDRAULIC BRAKES N 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 This vehicle is equipped with four wheel hydra
152. rial Numbers Notes 1 843862 AR Tube 1 4 in I D Clear Vinyl 10 Foot Length Cut to 12 in 2 835805 AR Hose Radiator Overflow 3 452006 2 Flat Washer 5 16 4 446134 2 Lockwasher 5 16 5 443106 2 Nut 5 16 18 Hex 6 450452 6 Nut M6 1 Hex Flange 7 450541 4 Screw M6 1 x 16 mm Hex Flange 8 452378 6 Screw M6 1 x 20 mm Hex Flange 9 4176887 1 Fan 12 in Hi Perf Puller 10 600992 1 Panel Shroud 11 4238927 1 Frame Radiator 12 601592 1 Radiator 13 400184 2 Screw 5 16 18 x 3 4 Hex Head 14 4177253 1 Shroud 12 in Fan 15 800177 4 Screw 5 16 18 x 3 4 in 16 831846 4 Nut Isolation 17 4238925 1 Bracket Radiator Bottle 18 833512 2 Seal Radiator Foam 19 553926 1 Overflow Bottle 20 4175402 1 Screen Right Side 21 450453 3 Nut M8 1 25 Hex Flange 22 4179800 1 Harness Oil Cooler Fan Wiring Not Shown See 55 1 23 452388 2 Screw M8 1 25 x 20 mm Hex Flange 24 452395 1 Screw M8 1 25 x 80 mm Hex Flange 25 452398 2 Screw M10 1 5 x 20 mm Hex Flange 26 4179801 1 Harness Radiator Fan Wiring Not Shown See 55 1 27 4174321 1 Harness Kubota Engine Wiring Not Shown See 55 1 28 800146 1 Screw 10 x 3 4 Thread Cutting 29 4221100 1 Relay 12V 70A 30 820889 6 Clamp Hose 31 009034880 1 Decal Fan Warning 32 4140090 1 Foam 1 25 x 1 00 x 13 50 33 4174820 1 Hose Upper Radiator 34 4174660 1 Hose Upper 35 4174563 1 Hose Lower Radiator 36 894348 1 Tube Fan Switch 37 17680
153. s while in storage To reduce the self discharge rate room temperature should not rise above 80 F 27 Room temperature should not fall below 20 F 7 C to prevent electrolyte from freezing en 34 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 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 c RON D Check and reinstall battery Check or service fuel filter and air cleaner Check the radiator coolant level Check oil level in the engine crankcase Fill the fuel tank with fresh fuel Open fuel shut off valve and bleed the fuel system Make certain that the tires are properly inflated Start and operate the engine at 1 2 throttle Allow sufficient time for the engine to become properly warmed and lubricated Never operate the engine without proper ventilation Exhaust fumes can be fatal when inhaled 6 1 GENERAL The troubleshooting chart below lists basic problems that up and operation For more may occur during start TROUBLESHOOTING 6 detailed information regarding the electrical system
154. sealant and install filler plug 5 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 Transmission Fluid Capacity 1 35 qts 1 28 1 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 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 federal state and local 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 MAINTENANCE 5 Level Check And Fill Plug Figure 5N Drain Plug Figure 50 Transmission Drain Plug Figure 5P en 29 5 MAINTENANCE 5 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 Transmission Fluid Capacity 1 1 qts 1 1 Fluid Type SAE EP 80 90 gear lube To check transmissi
155. shields or other protective devices securely fastened in place Never disconnect or bypass any switch en 4 13 14 15 16 19 20 21 22 23 24 25 26 Do not change the engine governor overspeed the engine setting or Carbon monoxide in the exhaust fumes can be fatal when inhaled Never operate the engine without proper ventilation or in an enclosed area Fuel is highly flammable handle with care Keep the engine clean Allow the engine to cool before storing and always remove the ignition key 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 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 Local regulations may restrict the age of the operator Operate the machine up and down the face of the slopes vertically not across the face horizontally 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 Always use the seat belt when operating vehicles equipped with a Roll Over Protective Structure ROPS Never use a seat belt when operating vehicle without a ROPS Accessory ROPS will cont
156. te technische Normen und Spezifikationen Texvika rrp rurra kai TTPO IAYPAPEG Trou xpnoiporroirjenkav M szaki szabv nyok s specifik ci k Standard tecnici e specifiche applicati Izmantotie tehniskie standarti un specifik cijas Panaudoti techniniai standartai ir technin informacija Standards u specifikazzjonijiet tekni i u ati Normy i specyfikacje techniczne powi zane Normas t cnicas e especifica es usadas Standardele tehnice si specifica iile utilizate Pou it technick normy a pecifik cie Uporabljeni tehni ni standardi in specifikacije Est ndares y especificaciones t cnicas utilizadas Tekniska standarder och specifikationer som anv nds ISO 2631 1 SAE 21299 The place and date of the declaration Macro n nara Ha neknapauusrra Misto a datum prohl en Sted og dato for erkl ringen Plaats en datum van de verklaring Deklaratsiooni v ljastamise koht ja kuup ev Vakuutuksen paikka ja p iv m r Lieu et date de la d claration Ort und Datum der Erkl rung T rrog kai nuepoyunv a rj uong A nyilatkozat kelte hely s id Luogo e data della dichiarazione Deklar cijas vieta un datums Deklaracijos vieta ir data Il post u d data tad dikjarazzjoni Miejsce i data wystawienia deklaracji Local e data da declara o Locul si data declara iei Miesto a datum vyhl senia Kraj in datum izjave Lugar y fecha de la declaraci n Plats och datum f r deklaratio
157. tions 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 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 erore leaving the operator s position Tor any reason a Remove foot from accelerator pedal b Slow vehicle using service brake c Depress clutch and shift transmission to 1st Gear Manual Transmission or Park Automatic Trnasmission d Engage parking brake e Stop engine and remove the ignition key 2 Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine 3 Keep the area of operation clear of all bystanders and pets 4 Never carry passengers unless a seat is provided for them By following all instructions in this manual you will prolong the life of your machine and maintain its maximum efficiency Adjustments and maintenance should always be performed by a qualified technician If additional information or service is needed contact your Authorized Jacobsen Dealer who is kept informed of the latest methods to service this equipment and can provide prompt and efficient service en 5 2 VE
158. ts resulting in premature deterioration or failure Damage of this nature is not covered by the factory warranty 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 touch up paint Wax the equipment for maximum paint protection Clean grass and debris from drives muffler and engine to prevent fires en 33 5 MAINTENANCE 5 32 STORAGE General 1 Wash the vehicle thoroughly and lubricate as necessary Repair and paint damaged or exposed metal Inspect the vehicle tighten all hardware replace worn or damaged components Drain and refill radiator 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 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 nonconductive surface wood in a cool dry place To prevent accelerated discharge do not store battery on concrete or steel surface Check and recharge battery every 60 to 90 day
159. u laatimaan tekniset asiakirjat ja joka on sijoittautunut yhteis n Signature de la personne habilit e r diger la d claration au nom du fabricant d tenir la documentation technique compiler les fichiers techniques et qui est implant e dans la Communaut Unterschrift der Person die berechtigt ist die Erkl rung im Namen des Herstellers abzugeben die die technischen Unterlagen aufbewahrt und berechtigt ist die technischen Unterlagen zusammenzustellen und die in der Gemeinschaft niedergelassen ist YTroypapr at pou EEOUOIOdOTNHEVOU yia TNV O VTAEN TNG HAWONG EK HEPOUG rou Karaokeuaorr o OTTOIOG KAT XEI TNV TEXVIK K EON KAI EXEI TNV E OUOIO TNON va ra amp ivourjosi TOV TEXVIK PAKEAO kal O OTTOIOG Eival lopIouEvog OTNV Korv rnra A gy rt nev ben meghatalmazott szem ly akinek jog ban all m dos tania a nyilatkozatot a m szaki dokument ci t rzi enged llyel rendelkezik a m szaki f jl ssze ll t s hoz s aki a k z ss gben letelepedett szem ly Firma della persona autorizzata a redigere la dichiarazione a nome del fabbricante in possesso Della documentazione tecnica ed autorizzata a costituire il fascicolo tecnico che deve essere stabilita nella Comunit T s personas paraksts kura ir pilnvarota deklar cijas sast d anai ra ot ja v rd kurai ir tehnisk dokument cija kura ir pilnvarota sagatavot tehnisko re istru un kura ir apstiprin ta Kopien Asmuo kuris yra gana i
160. ual 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 Stay alert for holes in the terrain and other hidden hazards 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 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 Do not carry passengers Keep bystanders and pets a safe distance away Never operate equipment that is not in perfect working order or is without decals guards
161. uid 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 Allow fluid to drain into a suitable container Dispose of used fluid properly according to federal state and local regulations Apply pipe thread sealer to drain plug and install Fill transmission until fluid reaches proper mark on dipstick en 30 Transmission Fluid Dipstick and Fill Tube d OS IS Mt EI pp x rei i NG Drain Plug Automatic Transmission e u et EE EEE aa e mcm NEL Figure 5R 5 26 ELECTRICAL SYSTEM Always turn the ignition switch to the OFF position and remove the Negative BLACK battery cable before inspecting or working on the electrical system General precautions that can be taken to reduce electrical problems are listed below 1 Ensure all terminals and connections are clean and properly secured 2 Checkthe Interlock System and fuses regularly If the Interlock System does not function properly and the problem cannot be corrected contact an authorized Jacobson Dealer 3 Keep the wire harness and all individual wires away from moving parts to prevent damage Check the battery and battery charging circuit 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 co
162. ulic brakes controlled by the brake pedal and a hand operated parking brake lever Keep your brake system clean and properly maintained Do not operate the truck if the brakes do not stop vehicle properly The brake fluid master cylinder reservoir is located under the front cowl The fluid level in the master cylinder reservoir must be kept between the MIN minimum and MAX maximum marks Add DOT 3 type brake fluid as necessary If the brake fluid indicator light comes on and remains on check the fluid level in the reservoir Bleeding Hydraulic Brakes If the brakes do not hold properly if they feel spongy or if the brake fluid reservoir is allowed to run dry it may be required to bleed the system in order to remove air from the brake lines 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 from brake when bleeding the system 3 Bleed brake a Have an assistant push down on the brake pedal and hold the pedal down b Loosen the bleeder screw allowing fluid to flow c Tighten the bleeder screw d Have assistant release pedal NOTE Do Not release brake pedal until the bleeder screw is tightened or air 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
163. ve 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 Do not pour cold water into a hot radiator Do not operate engine without a proper coolant mixture Install cap and tighten securely 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 anti freeze in a separate container before adding it to the cooling system Do not use a mixture of more than 5096 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
164. w n Company XXXXXXXX Figure 2A 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 3 1 PRODUCT IDENTIFICATION B4069 iicitirieibeee a Turf Truckster liquid cooled diesel engine 4 speed manual transmission 11 16 1 2 speed differential mechanical PTO and four post ROPS 84064 Turf Truckster liguid cooled diesel engine 4 speed manual transmission 11 16 1 2 speed differential mechanical PTO and four post ROPS EC approved 84067 nennt Turf Truckster liquid cooled gas engine 5 speed manual transmission 14 21 1 2 speed 3 2 DIESEL ENGINE Make seeren Kubota Model D1105 E3B Horsepower 26 hp 19 4 kW 23000 rpm Note Actual sustained horsepower will likely be lower than listed in specifications due to operating limitations and environmental factors Displacement 68 5 cu in 1123 cc TOIQUE 0 ee eee eeeeeteeeeeeeees 52 7 ft lbs 71 5 Nm 2200 rpm Fuel Type No 2 Low or Ultra Low Sulfur Diesel Rating Cetane Rating 45 Capacity 6 55 U S Gal 24 5 liters 3 3 GAS ENGINE Make Suzuki Model tet K6 Horsepower 34 hp 25 35 kW 5000 rpm Displacem
165. ween the ADD and FULL mark on the dipstick If oil level is below the ADD mark remove the filler cap and add oil to bring the level up between marks Do Not Overfill NOTE f the engine has recently been running allow time with engine turned off to let the oil settle to obtain an accurate oil level reading Diesel Engine Use only engine oils with API classification CD or CE 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 Significant oil loss can damage the engine Considerable oil loss could be due to a loose or incorrectly installed drain plug cracked gaskets or a loose oil filter Drain plugs are located beneath the engine in the oil pan Remove both plugs when changing the oil Check drain plugs and oil for metal chips that could indicate engine damage Immediately replace drain plugs with damaged gasket surfaces After oil has completely drained clean excess oil from oil pan and
166. y from the engine until proper belt tension is achieved Figure 4G 4 7 GAS 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 in 6 to 12 mm with a 39 Ib push at midpoint between pulleys If tension is incorrect loosen power steering pump mounting bolts F and carefully pry pump away from the engine until proper belt tension is achieved en 14 DU gt I 4 IS NG O KALONG gt ZE NG Figure 4H 4 8 GAS HYDRAULIC PUMP BELT Inspect new belt after first 24 48 hours of operation Belt is dynamically adjusted with a spring loaded tensioner to 12 ft Ibs No adjustment is required To remove belt rotate tensioner towards radiator to release tension and remove belt from pulleys 4 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 Disengage parking brake Tighten adjustment nut G a couple of turns Engage parking brake Repeat steps 3 and 4 until handle is at an approximate 45 angle when parking brake is engaged ADJUSTMENTS 4 Sa Figure 4l Figure 4J en 15 4 ADJUSTMENTS 4 10 TORQUE SPECIF

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