Jacobsen Truckster XD Operation & Maintenance Manual Download Page 66 | Manualshive

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9 MAINTENANCE

en-65

K

3

15

5

10

F

8

10

3

5

F19

5

5

3

0

3

0

10

3

0

F

3

F4

F6

K9

F11

F12

RB2

RB1

RAC

3

RAC2

F9

F10

F7

F1

F2

K1

K2

F15

F16

F5

F1

8

K4

K7

K

8

K5

K6

K12

K1

3

K14

K10

K

3

Die

s

el En

g

ine Option Fu

s

e/Relay Panel

Ga

s

oline En

g

ine Option Fu

s

e/Relay Panel

15

5

10

F

8

10

5

5

5

10

3

0

3

0

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F6

K9

F11

F12

RB2

RB1

RAC

3

RAC2

F9

F10

F7

F1

F2

K1

K2

D1

F15

F5

F16

F17

K4

K7

K

8

K5

K6

K11 K12

K1

3

K15

K10

10

10

F1

8

F19

K14

Diesel Engine Option Relays



K1 - Right Turn Relay



K2 - Left Turn Relay

K3 - Light Relay
K4 - Start Interlock Relay
K5 - RAC2 Post Relay
K6 - RAC3 Post Relay
K7 - Accessory Relay
K8 -



K9 - Flasher Relay

K10 - Start Relay
K12 - Main Power Relay
K13 - Radiator Fan Relay
K14 - Glow Relay

Diesel Engine Option Fuses



F1 - 5 Amp Right Brake Jumper Fuse



F2 - 5 Amp Left Brake Jumper Fuse

F3 - 15 Amp Lights Fuse
F4 - 5 Amp Start Interlock Fuse
F5 - 10 Amp Accessory 12V Plug Fuse
F6 - 10 Amp Differential Lock Fuse
F7 - 10 Amp Key Switched Power Fuse
F8 - Extra Fuse Tap Fuse
F9 - 35 Amp RAC2 Post Fuse
F10 - 35 Amp RAC3 Post Fuse
F11 - 50 Amp RB1 Post Fuse
F12 - 50 Amp RB2 Post Fuse
F15 - 30 Amp Radiator Fan Fuse
F16 - 30 Amp Starter Power Fuse
F18 - 30 Amp Main Power Fuse
F19 - 35 Amp Glow Plug Fuse

Gasoline Engine Option Fuses



F1 - 5 Amp Right Brake Jumper Fuse



F2 - 5 Amp Left Brake Jumper Fuse

F3 - 15 Amp Lights Fuse
F4 - 5 Amp Start Interlock Fuse
F5 - 10 Amp Accessory 12V Plug Fuse
F6 - 10 Amp Differential Lock Fuse
F7 - 10 Amp Key Switched Power Fuse
F8 - Extra Fuse Tap Fuse
F9 - 35 Amp RAC2 Fuse
F10 - 35 Amp RAC3 Fuse
F11 - 50 Amp RB1 Fuse
F12 - 50 Amp RB2 Fuse
F15 - 5 Amp Key Power Fuse
F16 - 30 Amp Fan Power Fuse
F17 - 30 Amp ECU Power Fuse
F18 - 10 Amp Fuel Pump Fuse
F19 - 10 Amp Differential Lock Fuse

Gasoline Engine Option Relays



K1 - Right Turn Relay



K2 - Left Turn Relay

K3 - Light Relay
K4 - Start Interlock Relay
K5 - RAC2 Post Relay
K6 - RAC3 Post Relay
K7 - Accessory Relay
K8 -



K9 - Flasher Relay

K10 - Fuel Relay
K11 - ETV Relay
K12 - OEM Relay
K13 - Radiator Fan Relay
K14 - Start Relay
K15 - ECU Power Relay



Remove when Turn Signal Accessory

is installed.



Included with the Turn Signal

Accessory

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Summary of Contents for Truckster XD

Page 1: ...to set up operate adjust or service the machine GB Truckster XD 84082 Truckster XD Kubota D1105 E4B Diesel Engine Option Kubota WG972 EFI Gasoline Engine Option 2 Post 4 Post ROPS Options 2WD 4WD Opt...

Page 2: ...c Accessory Operation 49 7 11 Towing The Vehicle 50 Maintenance and Lubrication Charts 8 1 Maintenance Chart 51 8 2 Lubrication Chart 52 8 3 Fluid Requirements 52 Maintenance 9 1 General Precautions 5...

Page 3: ...fety and road traffic regulations You must not make any changes to the vehicle that the manufacturer does not approve This type of change can release the manufacturer from the liability for any damage...

Page 4: ...nd on the engine valve cover Label shows the engine group and serial number The engine serial number is also found on the engine block 2 3 SERIAL NUMBERS Record the vehicle and engine numbers shown be...

Page 5: ...e all of the necessary lifting equipment Use the correct tools and Personal Protective Equipment PPE and take instruction from the technical manuals applicable to the vehicle Remove and keep correctly...

Page 6: ...stem disconnected or the system does not operate correctly Do not disconnect or prevent the operation of any switch c Never operate equipment that is not in correct order or without decals guards shie...

Page 7: ...s in the terrain and other hazards that are not visible g When you drive in the reverse direction look behind you and down to make sure the path is clear Do not operate the attachments when you drive...

Page 8: ...only and do not smoke when you add fuel Extinguish all types of ignition g The fuel nozzle must touch the rim of the fuel tank when you add fuel to the vehicle Do not use a device to lock the fuel noz...

Page 9: ...torque Make sure the hydraulic system is in good condition before you start the engine o Keep the vehicle and the engine clean p Allow the engine to become cool before storage and always remove the i...

Page 10: ...If additional information or service is needed contact your Authorized Jacobsen Dealer Your Dealer knows the current methods to service this equipment WARNING The Interlock System on this vehicle pre...

Page 11: ...00 rpm 51 6 ft Lb 69 96 Nm 2600 rpm Maximum Speed 3220 50 rpm No Load 3600 50 rpm No Load Low Idle 1000 50 rpm No Load 1000 50 rpm No Load Rotation Counter clockwise viewed at flywheel Counter clockwi...

Page 12: ...ht of 4WD Diesel unit with fuel tank filled High Low hydraulics 2717 lb 1232 kg Weight of 2WD Gasoline unit with fuel tank filled High Low hydraulics 2487 lb 1128 kg Weight of 4WD Gasoline unit with f...

Page 13: ...SPECIFICATIONS 4 en 12 C D A F G E B...

Page 14: ...wer steering 2WD Traction Drive Five speed transmission and two speed rear axle 4WD Traction Drive Five speed transmission two speed rear axle and front axle Transmission Gear Ratios 1st Gear 3 652 1...

Page 15: ...hicle with two hands on the steering mechanism The Machinery Safety Directive 2006 42 EC By compliance to Whole Body EN1032 2003 Information Supplied for Physical Agents Directive 2002 44 EC By refere...

Page 16: ...3744 2010 was used Measured Sound Power Diesel Engine Option 100 dB A 1 1 LWA Measured Sound Power Gasoline Engine Option 96 dB A 1 1 LWA 4 7 SLOPES __________________________________________________...

Page 17: ...440 System 4320026 Raven 440 Sharpshooter System 4322364 Envisio Pro II Sharpshooter System 4322546 15 Foot HD Boom 4323390 15 Foot Sharpshooter Boom 4323391 18 Foot HD Boom 4320589 18 Foot Sharpshoo...

Page 18: ...IFICATIONS en 17 4 9 4 TOP DRESSER 1500 _______________________________________________________ Kit Number 4309575 4 9 5 CORE HARVESTER________________________________________________________ Kit Numb...

Page 19: ...apter 4336048 4 9 8 CAB _____________________________________________________________________ Factory Installed TBD Dealer Installed TBD 4 10 SUPPORT LITERATURE Contact your Jacobsen Dealer for a comp...

Page 20: ...el Kubota WG972 EFI Net Installed Power ist instalovan v kon Installeret nettoeffekt Netto ge nstalleerd vermogen Installeeritud netov imsus Asennettu nettoteho Puissance nominale nette Installierte N...

Page 21: ...velul 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 H va astig fyrir stj...

Page 22: ...ura 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...

Page 23: ...itive battery terminal of the charged battery to positive battery terminal of drained battery 2 Connect the negative battery terminal of the charged battery to frame of vehicle with drained battery WA...

Page 24: ...r Read the manual 4321746 4181861 NOTICE DO NOT USE START ASSIST FLUIDS Start assist fluids in the air intake system can be explosive or cause an engine condition that is not controlled and can cause...

Page 25: ...ION DECALS ____________________________________________________ Center Console Decals P 4319449 4319451 4319450 Low Speed Range High Speed Range 4WD Bed Float Bed lower Retract Bed lift Extend Parking...

Page 26: ...5 DECALS en 25 Right Side Control Panel 4319447 Cab Work Light Differential Lock OFF RUN START 12 Volt Accessory High Low Left Turn Signal Right Turn Signal...

Page 27: ...DECALS 5 en 26 Standard Left Side Control Panel Decal 4319448 Headlight Horn...

Page 28: ...5 DECALS en 27 Diesel Speed Control Option Decal 4319448 Headlight Horn Hand Throttle Engine Governor Fast Slow...

Page 29: ...DECALS 5 en 28 Gasoline Speed Control Option Decal 4319666 Headlight Horn Decrease Engine Speed Increase Engine Speed...

Page 30: ...OST 1 RB2 REMOTE BATTERY POST 2 RAC2 REMOTE ACCESSORY POST 2 RAC3 REMOTE ACCESSORY POST 3 4322031 GAS FUSE PANEL K1 K2 K5 K6 K10 K11 K12 K13 K15 4322027 K3 K4 K7 K8 F1 RIGHT BRAKE JUMPER 5A F2 LEFT BR...

Page 31: ...CONTROLS 6 en 30 6Controls 6 1 OPERATOR COMPARTMENT________________________________________________ 6 2 6 3 6 4 6 8 6 9 6 10 6 7 6 6 6 5...

Page 32: ...______ The LCD screen shows the vehicle speed the system voltage and the hour meter The speed of the vehicle is shown at the top of the LCD screen The speed is shown in mph or kph The system voltage i...

Page 33: ...ke is engaged Do not press the accelerator pedal with the light illuminated The amber glow plug light indicates that the glow plugs are active Do not turn the ignition switch to the start position unt...

Page 34: ...ill improve traction When the vehicle is turned to the left or right direction the differential lock can cause the outside rear wheel to mark the turf Release the switch to disengage the differential...

Page 35: ...e high low hydraulic system switch is part of the high low hydraulic system option The switch has three positions OFF HIGH and LOW The high low switch must be in the OFF position to start the engine P...

Page 36: ...________________________________ The light switch controls the operation of the headlights and tail lights Press the top of the switch to turn on the headlights and the tail lights Press the bottom of...

Page 37: ...control system When the stationary cruise switch is in the center position the set resume switch does not function When the stationary cruise switch is in the cruise control position the cruise contr...

Page 38: ...ectronically 6 6 BRAKE PEDAL ___________________________________________________________ Press the brake pedal to decrease the vehicle speed or stop the vehicle If the brakes do not stop the vehicle t...

Page 39: ...drive the vehicle with the parking brake engaged To disengage the parking brake lower the parking brake lever to the disengaged position 6 8 2 GEAR SELECTOR __________________________________________...

Page 40: ...led Move the lever to the 4WD position to engage the 4WD output to the front axle Move the lever to the 2WD position to disengage the 4WD output to the front axle If the lever does not move easily do...

Page 41: ...trol knob to the correct position for the weight of the operator Do not operate the vehicle with the armrests in the lifted position 6 9 2 STANDARD SEAT _______________________________________________...

Page 42: ...f these tests to make sure the Interlock System operates correctly If any of the tests fail stop the test and have the system inspected and repaired as shown below The engine does not start during tes...

Page 43: ...damage to the equipment 9 Before you move across or operate on paths or roads travel at decreased speed Look for traffic 10 When you hit an object or vehicle starts to cause vibration that is not norm...

Page 44: ...e starter motor to become cool When the engine starts all of the warning lights will turn off Allow the engine to become warm before you operate the vehicle 7 5 TO STOP THE ENGINE ____________________...

Page 45: ...ve long distances in the reverse direction 6 When the vehicle has enough speed release the accelerator pedal while you press the clutch pedal Change the transmission to the next higher gear and releas...

Page 46: ...5 2 9 3 9 5 6 7 1 4 92 9 24 12 64 17 99 22 62 2300 1 00 1 87 2 56 3 65 4 59 3 20 6 00 8 21 11 68 14 70 1 6 3 0 4 1 5 9 7 4 5 15 9 66 13 21 18 80 23 65 2400 1 04 1 96 2 68 3 81 4 79 3 34 6 26 8 57 12 1...

Page 47: ...vehicle with the switch in the stationary position Press the accelerator pedal until the needed RPM is shown on the tachometer Hold the left side of the set resume switch for 1 2 second The light on t...

Page 48: ...e is necessary for maximum traction See Section 9 15 WARNING To make sure that the vehicle does not turn over the safest method to drive up and down on the face of slopes vertically You must not drive...

Page 49: ...s with 1 Yard Level A Millimeters with 1 Meter Level A Slope in Degrees Slope Grade 3 4 8 8 3 100 5 7 10 0 150 8 5 15 6 9 5 16 7 200 11 3 20 0 7 5 11 8 20 8 225 12 7 22 5 9 250 14 25 0 275 15 4 27 5 1...

Page 50: ...r the hydraulic accessory 3 Remove the yellow connector cover and connect to return hose for the hydraulic accessory 4 Read the hydraulic accessory manual for the correct operation and needed flow rat...

Page 51: ...u turn the vehicle 7 When the vehicle gets to the service area engage the parking brake and put the transmission in 1st gear To put the vehicle on a trailer Be careful when you load or unload the vehi...

Page 52: ...on Lubricate spindles and casters See 9 4 See 9 4 See 9 14 See 10 5 See 9 19 See 10 2 See 8 2 Each week 50 Hours Check fuel lines and fittings Inspect parking brake cables Check for loose components S...

Page 53: ...lter 3 6 Quart 3 4 liter 10W 30 API Classification CJ 4 Transmission 1 34 Quart 1 27 liter SAE EP 80W 90 Gear Lube Rear Axle Standard hydraulic reservoir 2 7 U S Gallon 10 2 liter 10W 30 API Classific...

Page 54: ...tank or other accessory The truck bed must be completely lifted and the cylinder support installed before you can service the vehicle To do service on the vehicle 1 Start the engine 2 Pull the lift c...

Page 55: ...engine oil level two times each day Higher than normal oil use can occur during the first 50 hours Change the engine oil and oil filter after the first 50 hours of operation Check the fan belt Refer t...

Page 56: ...clean Removal of the filter that is not necessary increases the risk of dust and other particles to enter the engine When service is needed first clean the outside of the filter housing then remove th...

Page 57: ...lend with methanol Refer to the engine s operator manual for fuel recommendations when using blended fuel Check fuel hoses and clamps every 50 hours Replace fuel hoses and clamps at first indication o...

Page 58: ...t the engine How To Bleed The Air From The Diesel Fuel System After the fuel filter element is replaced or the fuel hoses are replaced bleed the air from the fuel system a Open the bleeder valve on th...

Page 59: ...jump start the vehicle check the condition of the drained battery b Connect the positive battery terminal of the charged battery to positive battery terminal of the drained battery c Connect the nega...

Page 60: ...ructure ROPS is included with this vehicle Inspect the ROPS periodically for loose hardware or damage Every 400 hours inspect the seat seat belt ROPS mounting hardware and ROPS frame for damage Replac...

Page 61: ...aulic component tag or mark the location of each hose then clean the area around the fittings To prevent dirt to enter the hydraulic system when you disconnect the component be prepared to assemble pl...

Page 62: ...bottom of the fill port Install the fill plug e Start the engine and remove the air from the hydraulic system Operate the steering and bed lift functions for 1 minute to remove the air and to balance...

Page 63: ...e recovery bottle must be at the cold mark Drain and fill the cooling system each year Empty and clean the recovery bottle Mix clean water with ethylene glycol anti freeze for the coldest ambient temp...

Page 64: ...n When possible tighten nuts in the top position Check and torque hardware each day until torque is kept at 85 95 ft lb 115 128Nm CAUTION DO NOT try to put a tire on a rim unless you have the correct...

Page 65: ...of the level plug Install the level plug Torque the level plug to 9 14 ft lb 12 19 Nm 9 19 ELECTRICAL SYSTEM _____________________________________________________ General precautions to decrease elec...

Page 66: ...Fuse F8 Extra Fuse Tap Fuse F9 35 Amp RAC2 Post Fuse F10 35 Amp RAC3 Post Fuse F11 50 Amp RB1 Post Fuse F12 50 Amp RB2 Post Fuse F15 30 Amp Radiator Fan Fuse F16 30 Amp Starter Power Fuse F18 30 Amp...

Page 67: ...gine Use clean water to wash your equipment Do not spray water at the control panel ignition switch controller or other electrical components Clean all plastic or rubber parts with a weak soap solutio...

Page 68: ...n 80 F 27 C or less than 20 F 7 C Engine While the engine is warm remove the drain plug drain the oil from the crankcase and change the oil filter Install the drain plug and fill the engine with oil T...

Page 69: ...rdous materials batteries lubricants fuel anti freeze follow your local state or federal recommended procedures 10 2 BELT ADJUSTMENT _______________________________________________________ Inspect and...

Page 70: ...he transmission in Neutral and stop the engine The vehicle must not move with the parking brake engaged If the vehicle does move start the engine drive the vehicle to the bottom of the hill and adjust...

Page 71: ...aight position b Loosen the jam nuts on both ends of the axial rods c Rotate the axial rods to get the correct toe in the Toe in must not be more than 1 4 inch 0 63 cm d Tighten the jam nuts X X X 1 1...

Page 72: ...09 1 4 20 in lb Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159 215 211 286 5...

Page 73: ...el filter Bleed fuel lines 5 Fuse blown 5 Replace fuse 6 Relay s defective 6 Test and replace relay Engine hard to start or runs poorly 1 Fuel level low fuel or fuel filter dirty 1 Fill with fresh fue...

Page 74: ...N bus connectors are found to the left side of the fuse relay panel The four pin connector is for the Kubota Engine Controller ECU CAN bus connector The three pin connector is for the vehicle s CAN bu...

Page 75: ...PROBLEM SOLVING 11 en 74...

Page 76: ...n Performance Matters Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory...

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