Cushman Turf Truckster 84043 User manual

Parts & Maintenance Manual
Cushman Turf Truckster
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4140039-CZ

Copyright 2005, Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”
This manual is designed for the Maintenance and Adjustment of this equipment.
Use the maintenance and adjustment instructions included in this manual and the operating
instructions included in the Safety and Operation Manual to service the machine.
The Safety and Operation Manual must be kept in the pouch on the back of the seat at all times
for reference by the operator.
Table of Contents
1 Safety
1.1 Operating Safety.................................................. 4
1.2 Important Safety Notes ........................................5
2 Standards and Publications
2.1 Standards and Publications................................. 6
3 Vehicle Identification Numbers
3.1 Vehicle Identification Number.............................. 7
3.2 Engine Identification Numbers .............................7
4 Specifications
4.1 Product Identification ........................................... 8
4.2 Engine ..................................................................8
4.3 vehicle ..................................................................8
4.4 Gear Ratios ..........................................................9
4.5 Weights and Dimensions .....................................9
4.6 Accessories & Support Literature ........................ 9
5 Adjustments
5.1 General.............................................................. 10
5.2 Engine Access ...................................................10
5.3 Front Cowl Access .............................................11
5.4 Access Panels ...................................................11
5.5 Diesel Engine Alternator Belt .............................12
5.6 Diesel Engine Hydraulic Pump Belt ...................12
5.7 Gas Engine Power Steering-Alternator Belt ......12
5.8 Gas Engine Hydraulic Pump Belt ......................13
5.9 Parking Brake Cable ..........................................13
5.10 Torque Specification ..........................................14
6 Maintenance
6.1 General.............................................................. 15
6.2 Engine ................................................................15
6.3 Engine Oil ..........................................................16
6.4 Power Steering Reservoir ..................................17
6.5 Muffler and Exhaust ...........................................17
6.6 Engine Overheat Procedure ..............................17
6.7 Cooling System ..................................................18
6.8 Air Filter .............................................................19
6.9 Jump Starting .................................................... 19
6.10 Battery ............................................................... 20
6.11 Charging Battery ................................................ 20
6.12 Hydraulic Hoses ................................................ 21
6.13 Hydraulic Reservoir and Filter ........................... 21
6.14 Fuel .................................................................... 22
6.15 Fuel System ....................................................... 22
6.16 Tire Pressure ..................................................... 22
6.17 Tire Removal and Installation ............................ 23
6.18 Raising the vehicle ............................................ 23
6.19 Towing the Vehicle ............................................ 24
6.20 Governor Oil Level ............................................. 24
6.21 Hydraulic Brakes ............................................... 25
6.22 Differential Fluid ................................................. 26
6.23 Diesel Engine Manual Transmission ................. 26
6.24 Gas Engine Manual Transmission ..................... 27
6.25 Gas Engine Automatic Transmission ................ 27
6.26 Electrical System ............................................... 28
6.27 Dash Panel ........................................................ 28
6.28 Headlight Replacement ..................................... 29
6.29 Tail Light Replacement ...................................... 29
6.30 EFI Diagnostic Check ........................................ 30
6.31 Care and Cleaning ............................................. 31
6.32 Storage .............................................................. 31
7 Troubleshooting
7.1 General.............................................................. 32
8 Maintenance & Lubrication Charts
8.1 General.............................................................. 33
8.2 Lubrication Chart ............................................... 33
8.3 Maintenance Charts .......................................... 34
9Notes
10 Parts Catalog
10.1 Table Of Contents ............................................. 37
Litho in U.S.A. 8-2005

3
Suggested Stocking Guide
To Keep your Equipment fully operational and productive, maintain a stock of the more commonly used maintenance
items. We have included part numbers for additional support materials and training aids. A more complete listing of
accessories and attachments can be found in the Specifications Section.
How To Use This Manual
Abbreviations
N/S - Not serviced seperately, can only be obtained by ordering main component or kit.
AR -Variable quantity or measurement is required to obtain correct adjustment.
Symbols such as ▲, next to the item number, indicate that a note exists which contain additional information
important in ordering that part.
Indented Items
Bulleted items indicate component parts that are included as part of an assembly or another component. These parts
can be ordered separetely or as part of the main component.
Item Part No. Qty Description Serial Numbers/Notes
▲1 123456 1 Mount, Valve Indicates a piece part
2 789012 1 Valve, Lift Includes Items 2 and 3
3 345678 1 • Handle Serviced part included with Item 2
4 N/S 1 • Seal Kit Non serviced part included with Item 2
5 901234.6 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Orange
5 901234.2 1 Screw, 1/4-20 x 2” Hex Head Indicates part 901234 painted Green
Service Parts
Qty. Part No. Description Qty. Part No. Description
842553 Diesel Engine Oil Filter 2701908 Gas Engine Oil Filter
2208175 Diesel Engine Fuel Filter 2701898 Gas Engine Fuel Filter
600997 Diesel Alternator-Power Steering Belt 4115406 Gas Alternator-Power Steering Belt
841966 Diesel Hydraulic Pump Belt 4115404 Gas Governor-Hydraulic Pump Belt
885249 Hydraulic FIlter Element 840352 Air Filter Element (Gas and Diesel)
4140040 Safety and Operation Manual 4140039 Parts and Maintenance Manual
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, paint
code, and description of the part as given in the parts list.
5. Send or bring the order to an authorized Jacobsen
Dealer.
6. Inspect all shipments on receipt. If any parts are
damaged 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.

1 SAFETY
GB-4
1 SAFETY
1.1 OPERATING SAFETY ______________________________________________________
1. Safety is dependent upon the awareness, concern and
prudence of those who operate or service the equip-
ment. Never allow minors to operate any equipment.
2. It is your responsibility to read this manual and all
publications associated with this equipment (Safety
and operation manual, engine manual, accessories
and attachments). If the operator can not read English
it is the owner’s responsibility to explain the material
contained in this manual to them.
3. 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.
4. 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.
5. 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.
6. 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.
7. Stay alert for holes in the terrain and other hidden
hazards.
8. Inspect the area where the equipment will be used.
Pick up all the debris you can find before operating.
Beware of overhead obstructions (low tree limbs,
electrical wires, etc.) and also underground obstacles
(sprinklers, pipes, tree roots, etc.) Enter a new area
cautiously. Stay alert for hidden hazards.
9. Never allow anyone near the machine while in
operation. The owner/operator can prevent and is
responsible for injuries inflicted to themselves, to
bystanders and damage to property.
10. Do not carry passengers. Keep bystanders and pets a
safe distance away.
11. Never operate equipment that is not in perfect working
order or is without decals, guards, shields or other
protective devices securely fastened in place.
12. Never disconnect or bypass any switch.
13. Do not change the engine governor setting or
overspeed the engine
14. Carbon monoxide in the exhaust fumes can be fatal
when inhaled. Never operate the engine without proper
ventilation or in an enclosed area.
15. Fuel is highly flammable, handle with care.
16. Keep the engine clean. Allow the engine to cool before
storing and always remove the ignition key.
17. Place transmission in neutral, depress clutch and
engage parking brake before starting the engine
(motor). Start the engine only when sitting in operator’s
seat, never while standing beside the unit.
18. Equipment must comply with the latest federal, state,
and local requirements when driven or transported on
public roads. Watch out for traffic when crossing or
operating on or near roads.
19. Local regulations may restrict the age of the operator.
20. Operate the machine up and down the face of the
slopes (vertically), not across the face (horizontally).
21. To prevent tipping or loss of control, do not start or
stop suddenly on slopes. Reduce speed when making
sharp turns. Use caution when changing directions.
22. Always use the seat belt when operating vehicles
equipped with a ROPS.
Never use a seat belt when operating vehicle
without a ROPS.
23. Keep legs, arms and body inside the seating
compartment while the vehicle is in motion.
24. Always shift transmission to Neutral (Manual
Transmission) or Park (Automatic Transmission) and
engage parking brake before leaving the vehicle.
WARNING
EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS.
Familiarize yourself with the location and proper use of all controls. Inexperienced operator’s should receive
instruction from someone familiar with the equipment before being allowed to operate the machine.
!

SAFETY 1
GB-5
1.2 IMPORTANT SAFETY NOTES________________________________________________
This safety alert symbol is used to alert you to
potential hazards.
DANGER - Indicates an imminently hazardous
situation which, if not avoided, WILL result in death or
serious injury.
WARNING - Indicates a potentially hazardous situation
which, if not avoided, 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.
For pictoral clarity, some illustrations in this manual may
show shields, guards or plates open or removed. Under
no circumstances should this equipment be operated
without these devices securely fastened in place
By following all instructions in this manual, you will prolong the life of your machine and maintain its maximum
efficiency. Adjustments and maintenance should always be performed by a qualified technician.
If additional information or service is needed, contact your Authorized Jacobsen Dealer who is kept informed of the
latest methods to service this equipment and can provide prompt and efficient service. Use of other than original or
authorized Jacobsen parts and Accessories will void the warranty.
!
WARNING
The Interlock system on this vehicle prevents the vehicle from starting unless
the clutch pedal is depressed (Manual Transmission) or gear selector is in
Park (P) or Neutral (N) (Automatic Transmission).
NEVER operate vehicle unless the Interlock system is working.
!
WARNING
1. Before leaving the operator’s position for any reason:
a. Remove foot from accelerator pedal.
b. Slow vehicle using service brake.
c. Depress clutch and shift transmission to neutral.
d. Engage parking brake.
e. Stop engine and remove the ignition key.
2. Keep hands, feet, and clothing away from moving parts. Wait for all
movement to stop before you clean, adjust or service the machine.
3. Keep the area of operation clear of all bystanders and pets.
4. Never carry passengers, unless a seat is provided for them.
!

2 STANDARDS AND PUBLICATIONS
GB-6
2 STANDARDS AND PUBLICATIONS
2.1 STANDARDS AND PUBLICATIONS ___________________________________________
This product meets requirements of ANSI B56.8 and has
been approved by the Factory Mutual Research
Corporation to meet all Powered Industrial Truck portions
(classification D or G) of the OSHA requirements (as
stated in section 1910.178). Approved power trucks shall
bear a label or some other identifying mark indicating
approval by the testing laboratory. This product conforms
to EC directives and amendment 89/392 & 91/368.
Users, operators and service persons should be familiar
with the following standards and publications: (The
material may be obtained from the address shown)
Factory Mutual Approval Standard:
Class No’s 7811 & 7813; Gasoline or Diesel
Powered Trucks, Types G, GS, D or DS.
Factory Mutual Research Corp.
1151 Boston-Providence Highway
Norwood, Massachusetts 02062 U.S.A.
National Fire Protection Association:
ANSI/NFPA #505; Powered Industrial Trucks
National Fire Prevention Association
Batterymarch Park
Quincy, Massachusetts 02269 U.S.A.
Personal Burden Carriers:
ANSI/ASME B56.8
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
Internal Combustion Engine Powered Industrial Trucks:
ANSI/UL 558
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
OR
Underwriters Laboratories Inc.
333 Pfingsten Road
Northbrook, Illinois 60062 U.S.A.
Flammable and Combustible Liquids Code:
ANSI/NFPA 30
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
OR
National Fire Prevention Association
Batterymarch Park
Quincy, Massachusetts 02269 U.S.A.

VEHICLE IDENTIFICATION NUMBERS 3
GB-7
3 VEHICLE IDENTIFICATION NUMBERS
3.1 VEHICLE IDENTIFICATION NUMBER__________________________________________
The Vehicle Identification Number (VIN), consisting of the
model number, date code and serial number are all
printed on the Nameplate/Identification Decal attached to
the cross member under the dash.
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: ______________________
Figure 3A
Always provide the Vehicle Identification Number of the
unit when ordering replacement parts or requesting service
information. Vehicle Identification Numbers must appear
on all correspondence concerning this vehicle.
3.2 ENGINE IDENTIFICATION NUMBERS _________________________________________
The Truckster is equipped with either a Perkins 3
cylinder, diesel powered, liquid cooled, four cycle engine
or a Suzuki 3 cylinder, gas powered, liquid cooled, four
cylinder engine.
The Engine Serial Number for the Perkins engine is
stamped onto the engine block on the right side of the
engine near the alternator.
The Engine Serial Number for the Suzuki engine is
stamped onto the upper engine block on the right side of
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: _________________________
Figure 3B
MODEL
DATE CODE
LABEL #
SERIAL #
84043
Augusta Georgia, USA
1 800 241 5855
This vehicle may be covered
by one or more of the
following U.S. patents:
M1903
Lb/kg W Batt
Nom Power Hp/kw
75984G55
*2128855*
GOLF, TURF & SPECIALTY PRODUCTS
Engine Serial No.
Perkins Diesel
Engine Serial No.
K6A Suzuki

4 SPECIFICATIONS
GB-8
4 SPECIFICATIONS
4.1 PRODUCT IDENTIFICATION_________________________________________________
84043..............................Turf Truckster liquid cooled diesel
engine, 4 speed manual
transmission, 2 speed differential.
84044..............................Turf Truckster liquid cooled diesel
engine, 4 speed manual
transmission, 2 speed differential.
EC approved.
898627............................Turf Truckster liquid cooled gas
engine, 4 speed manual
transmission, 2 speed differential.
898628............................ Turf Truckster liquid cooled diesel
engine, 3 speed automatic
transmission, 2 speed differential.
4.2 ENGINE__________________________________________________________________
Diesel Engine:
Make...............................Perkins
Model..............................403C.11
Horsepower ....................26.4 hp (19.7 kW) @3000 rpm
Note: Actual sustained horsepower will likely be lower
than listed in specifications due to operating limitations
and environmental factors
Displacement..................69 cu. In. (1131 cc)
Torque.............................49 ft. lbs. (67 Nm) @ 2600 rpm
Fuel:
Type..........................No. 2 Diesel
Rating .......................Min. Cetane rating 45
Capacity....................6.55 U.S. Gal. (24.5 liters)
Governor.........................All Speed Mechanical
Low Idle ................... 1300 RPM
High Idle ................... 3180 RPM
Lubrication:
Capacity.................... 3.7 quarts (3.5 liters)
Below 32° F (0° C) ... SAE 10W
32-77° F (0-25° C).... SAE 20W or 10W30
Above 77° F (25 ° C) SAE 30W or 10W30
API Classification ..... CH4
Air Filter.......................... Dry type with evacuator valve.
Alternator........................ 55 amp
Cooling System .............. Liquid Cooled
Capacity...................... 5.1 qt. (4.8 l) 50/50 water ethylene
glycol mix
Gas Engine:
Make...............................Suzuki
Model..............................K6A
Horsepower ....................39 hp (29.1 kW) @ 4450 rpm
Note: Actual sustained horsepower will likely be lower
than listed in specifications due to operating limitations
and environmental factors
Displacement..................40.2 cu. In. (658 cc)
Torque.............................45.7 ft. lbs. (62 Nm) @ 4000 rpm
Fuel:
Type..........................Unleaded Gasoline
Rating .......................Min. Octane rating 87
Capacity....................6.55 U.S. Gal. (24.5 liters)
Governor.........................External Mechanical
Low Idle ................... 950 RPM
High Idle ................... 4450 RPM
Lubrication:
Capacity.................... 3.3 quarts (3.0 liters)
Below 32° F (0° C) ... SAE 10W30
32-86° F (0-30° C).... SAE 10W30
Above 86° F (30 ° C) SAE 10W30W or 10W40
API Classification ..... SL
Air Filter.......................... Dry type with evacuator valve.
Alternator........................ 55 amp
Cooling System .............. Liquid Cooled
Capacity...................... 3.3 qt. (3.0 l) 50/50 water ethylene
glycol mix
4.3 VEHICLE_________________________________________________________________
Tires:
Front .........................20 x 10 - 10 Multi Rib
Rear..........................24 x 13 -12 Titan Ultra Trac
Tire Pressure:
Front .........................20 psi (138 kPa)
Rear..........................Varies by load, See Section 6.16
Battery:
Type..........................12 Volt Lead/Acid
Group........................ 24
Service Brake................. 4 Wheel hydraulic drum brakes
Brake Fluid ............... DOT 3
Parking Brake................. Integral to rear drum, hand lever
actuated
Steering ......................... Front wheel power steering
Product EEC Sound
Power Vibration M/S2
Arms Body
84044 103 dB(A) 2.14 .096

SPECIFICATIONS 4
GB-9
4.4 GEAR RATIOS ____________________________________________________________
Diesel Engine Manual Transmission Gear Ratios:
4th Gear ...................1.000:1
3rd Gear ...................1.423:1
2nd Gear...................1.947:1
1st Gear....................3.652:1
Reverse.....................3.463:1
Hydpoid Differential...11.16:1
Gas Engine Manual Transmission Gear Ratios:
4th Gear ...................1.000:1
3rd Gear ...................1.513:1
2nd Gear................... 2.391:1
1st Gear....................4.031:1
Reverse ....................4.173:1
Hypoid Differential ....14.21:1
Gas Engine Automatic Transmission Gear Ratios:
3rd Gear ...................1.000:1
2nd Gear................... 1.536:1
1st Gear....................2.727:1
Reverse ....................2.222:1
Hypoid Differential ....14.21:1
4.5 WEIGHTS AND DIMENSIONS ________________________________________________
Dimensions: Inches (mm)
Length............................................................114 (2897)
Height.............................................................. 49 (1245)
Wheel Base.................................................. 58.2 (1478)
Turning Radius (Outside).............................. 242 (6146)
Weights: Lbs. (kg)
84043.......................................................... 1604 (823)
84044.......................................................... 1604 (727)
898627........................................................ 1572 (713)
898628........................................................ 1619 (734)
4.6 ACCESSORIES & SUPPORT LITERATURE_____________________________________
Contact your area Jacobsen Dealer for a complete listing of accessories and attachments.
Flatbeds and Boxes
47” Quick Disconnect Flatbed................................... 889983
60” Quick Disconnect Flatbed................................... 894769
47” Box Assembly (Requires 889983) ...................... 890010
60” Box Assembly (Requires 894769) .................... 2703394
Poly Box Assembly................................................... 892530
Box Liner (for 890010).............................................. 888532
Hitches
Fifth wheel ball hitch ................................................. 894690
Receiver Style drawbar hitch ...................................4114386
Flat bar style hitch....................................................4114566
ROPS Attachments
Upper ROPS (Roll Over Protective Structure) .......... 894761
Steel Door, Left Side (Requires 894761) ................ 2701303
Steel Door, RIght Side (Requires 894761).............. 2701304
Outside Mirrors (Left and Right)................................ 894768
Rear Window ............................................................ 894758
Windshield with Wiper............................................... 894757
Hydraulic Attachments
High/Low Gas Hydraulics.......................................... 894712
High/Low Diesel Hydraulics...................................... 894713
Implement Lift (“A” Frame)........................................ 892493
Dry seal coupler, 1 set .............................................. 894604
Hydraulic PTO (Requires 894712 and 894713)........ 894644
Truck Attachments
Heavy Duty Mechanical PTO...................................4112981
Quick Aerator...........................................................2701529
Ram Mount (Sprayer control mount)........................4119631
1500 Top Dresser ....................................................2701650
Turn Signal with Right Taillight...................................894764
VICON Spreader (Requires 2701601 or 2701602)..2701600
VICON hydraulic power kit.......................................2701601
VICON mechanical power kit...................................2701602
Back-up Alarm.........................................................2703183
Exhaust Spark Arrestor..............................................882574
Heater Defroster........................................................894760
Support Literature
Safety & Operation Manual......................................4140040
Parts & Maintenance Manual...................................4140039
Service & Repair Manual
CAUTION
Use of other than Jacobsen authorized parts and accessories may cause personal injury or damage to the
equipment and will void the warranty
!

5 ADJUSTMENTS
GB-10
5 ADJUSTMENTS
5.1 GENERAL________________________________________________________________
1. Adjustments and maintenance should always be
performed by a qualified technician. If proper
adjustment cannot be made, contact an authorized
Jacobsen Dealer.
2. Replace, do not adjust, worn or damaged
components.
3. Long hair, jewelry or loose fitting clothing may get
tangled in moving parts.
4. Do not change governor settings or overspeed the
engine.
5.2 ENGINE ACCESS__________________________________________________________
Never remove or install the engine cover while the engine
is running. The engine cover is a machinery guard and its
removal exposes you to moving parts. Keep hands, hair
and clothing away from flywheel, radiator cooling fan,
alternator fan, engine belts, pulleys and air intake.
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 tabs located at the front corners of the engine
cover are inserted into the slots in the floorboard. Tilt
seat to the rear until the engine latch engages. Lock
key-lock if equipped.
Figure 5A
Figure 5B
WARNING
To prevent injury, depress clutch pedal and shift
transmission to neutral, engage parking brake, stop
engine and remove key from ignition switch before
making any adjustments or performing maintenance.
Make sure the vehicle is parked on a solid and level
surface. Never work on a vehicle that is supported
only by the jack. Always use jack stands.
If only the front or rear of the vehicle is raised, place
chocks in front of and behind the wheels that are not
raised.
!
CAUTION
Be careful to prevent entrapment of the hands and
fingers between moving and fixed components of the
machine.
!
WARNING
Keep clothing, hands and hair away from moving
parts. These items could become entangled, causing
serious personal injury.
WARNING
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.
!
!
Engine Cover
Latch
Retaining Tab
In Slot On
Floor board

ADJUSTMENTS 5
GB-11
5.3 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, it must be lifted manually.
Figure 5C
5.4 ACCESS PANELS _________________________________________________________
There are two access panels located under the front cowl
and one located in the middle of the floorboard.
Remove panel (A) under cowl to access the shifter
linkage and wiring for the instrument panel.
Remove panel (B) under cowl to access the front
suspension.
Remove the center panel (C) in the middle of floorboard
to access the throttle cable, accelerator pedal linkage,
wire harness and rear hydraulic brake line.
NOTE: It will be necessary to remove the accelerator
pedal in order to completely remove the center floorboard
panel.
Figure 5D
Figure 5E
Front Cowl
Release Lever
Pull Lever
To Release
Cowl Latch
A
B
C

5 ADJUSTMENTS
GB-12
5.5 DIESEL ENGINE ALTERNATOR BELT ________________________________________
Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust alternator pulley so belt deflects 1/4” to 1/2” (6 -12
mm) with a 20 lb. push at midpoint between water pump
and alternator pulleys.
If tension is incorrect, loosen alternator mounting bolts
(D) and adjust alternator until proper belt tension is
achieved.
Figure 5F
5.6 DIESEL ENGINE HYDRAULIC PUMP BELT_____________________________________
Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust hydraulic pump belt so belt deflects 1/4” to 1/2” (6
-12 mm) with a 20 lb. push at midpoint between pulleys.
If tension is incorrect, loosen pump mounting bolts (E)
and carefully pry away from the engine until proper belt
tension is achieved.
Figure 5G
5.7 GAS ENGINE POWER STEERING-ALTERNATOR BELT __________________________
Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust power steering pump so belt deflects 1/4” to 1/2”
(6 -12 mm) with a 20 lb. push at midpoint between
pulleys.
If tension is incorrect, loosen power steering pump
mounting bolts (F) and carefully pry away from the
engine until proper belt tension is achieved.
Figure 5H
D
E
F

ADJUSTMENTS 5
GB-13
5.8 GAS ENGINE HYDRAULIC PUMP BELT _______________________________________
Inspect and adjust new belt after first 24-48 hours of
operation. Adjust every 200 hours thereafter.
Adjust hydraulic pump belt so belt deflects 1/4” to 1/2” (6
-12 mm) with a 20 lb. push at midpoint between pulleys.
If tension is incorrect, loosen pump mounting bolts (G)
and carefully pry away from the engine until proper belt
tension is achieved.
Figure 5I
5.9 PARKING BRAKE CABLE ___________________________________________________
1. Remove the engine cover. Put chocks in front of and
behind at least two wheels at opposite corners of
vehicle.
2. Engage parking brake. If handle is at an angle
greater than 45° to the panel, adjustment is
required.
3. Disengage parking brake.
4. Tighten adjustment nut (E) a couple of turns.
5. Engage parking brake. Repeat steps 3 and 4 until
handle is at approximately a 45° angle when parking
brake is engaged. Figure 5J
G
E

5 ADJUSTMENTS
GB-14
5.10 TORQUE SPECIFICATION___________________________________________________
Jacobsen uses Grade 5 bolts as standard, unless otherwise noted.
CAUTION
All torque values included in these charts are approximate and are for reference only. Use of these torque values is
at your sole risk. Jacobsen is not responsible for any loss, claim, or damage arising from the use of these charts.
Extreme caution should always be used when using any torque value.
AMERICAN NATIONAL STANDARD FASTENERS
SIZE UNITS
GRADE 5 GRADE 8
#6-32 in-lbs (Nm) 20 (2.3) –
#8-32 in-lbs (Nm) 24 (2.7) 30 (3.4)
#10-24 in-lbs (Nm) 35 (4.0) 45 (5.1)
#10-32 in-lbs (Nm) 40 (4.5) 50 (5.7)
#12-24 in-lbs (Nm) 50 (5.7) 65 (7.3)
1/4-20 in-lbs (Nm) 95 (10.7) 125 (14.1)
1/4-28 in-lbs (Nm) 95 (10.7) 150 (17.0)
5/16-18 in-lbs (Nm) 200 (22.6) 270 (30.5)
5/16-24 in-lbs (Nm) 240 (27.1) 300 (33.9)
3/8-16 ft-lbs (Nm) 30 (40.7) 40 (54.2)
3/8-24 ft-lbs (Nm) 35 (47.5) 45 (61.0)
7/16-14 ft-lbs (Nm) 50 (67.8) 65 (88.1)
7/16-20 ft-lbs (Nm) 55 (74.6) 70 (94.9)
1/2-13 ft-lbs (Nm) 75 (101.7) 100 (135.6)
1/2-20 ft-lbs (Nm) 85 (115.3) 110 (149.2)
9/16-12 ft-lbs (Nm) 105 (142.4) 135 (183.1)
9/16-18 ft-lbs (Nm) 115 (155.9) 150 (203.4)
5/8-11 ft-lbs (Nm) 150 (203.4) 195 (264.4)
5/8-18 ft-lbs (Nm) 160 (217.0) 210 (284.8)
3/4-10 ft-lbs (Nm) 170 (230.5) 220 (298.3)
3/4-16 ft-lbs (Nm) 175 (237.3) 225 (305.1)
7/8-14 ft-lbs (Nm) 300 (406.8) 400 (542.4)
AMERICAN NATIONAL STANDARD FASTENERS
SIZE UNITS
GRADE 5 GRADE 8
METRIC FASTENERS
SIZE UNITS Non Critical
Fasteners
into
Aluminum
M4 Nm (in-lbs) 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 Nm (in-lbs) 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 Nm (in-lbs) 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 Nm (in-lbs) 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
M10 Nm (ft-lbs) 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 Nm (ft-lbs) 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 Nm (ft-lbs) 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
4.8
5.8
8.8 10.9 12.9

MAINTENANCE 6
GB-15
6 MAINTENANCE
6.1 GENERAL ________________________________________________________________
1. Adjustment and maintenance should always be
performed by a qualified technician. If proper
adjustments cannot be made, contact an Authorized
Jacobsen 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 moving parts properly adjusted and lubri-
cated.
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 get
tangled in moving parts.
4. Use the illustrations in the Parts Catalog as reference
for the disassembly and reassembly of components.
5. Recycle or dispose of all hazardous materials
(batteries, fuel, lubricants, anti-freeze, etc.) according
to local, state or federal regulations.
6.2 ENGINE _________________________________________________________________
IMPORTANT: A separate Engine Manual, prepared by
the engine manufacturer, is supplied with this vehicle.
Read the engine manual carefully until you are familiar
with the operation and maintenance of the engine.
Proper attention to the engine manufacturer’s directions
will assure maximum service life of the engine. To order
replacement engine manuals contact the engine
manufacturer.
The proper break-in of a new engine can make a
considerable difference to the performance and life of the
engine.
Note: The vehicle is designed to operate most efficiently
at the preset governor setting. Do not change the engine
governor settings or overspeed the engine.
During the break-in period, Jacobsen recommends the
following:
1. During the first 50 hours of operation, a new engine
should be allowed to reach an operating temperature of
at least 140°F (60°C) prior to operation at full load.
2. Check the engine oil level twice daily during the first 50
hours of operation. Higher than normal oil consumption
is not uncommon during the initial break-in period.
3. Change engine oil and oil filter element after first 35
hours of operation.
4. Check and adjust hydraulic pump and alternator belts.
5. Refer to Section 8.3 and Engine Manual for specific
maintenance intervals.
6. If the injection pump, injectors or the fuel system
require service, contact an authorized Jacobsen
Dealer.
Keep your engine clean. If dirt has accumulated on the
engine, it should be washed with a non-flammable
solvent or strong detergent.
When washing becomes necessary, it can be carried out
simultaneously when servicing the vehicle.
In order to maintain reliable service from your engine, a
regular check-up and maintenance scedule should be
followed. Proper maintenance will prolong the engine’s
life and avoid premature overhaul.
WARNING
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 the jack. Always use jack stands.
!

6 MAINTENANCE
GB-16
6.3 ENGINE OIL ______________________________________________________________
Check the engine oil at the start of each day, before
starting the engine.
To check the engine oil, remove the dipstick and wipe it
with a clean rag. Reinsert the dipstick until it contacts the
oil tube, remove the dipstick and read the oil level.
The oil level should always be between the ADD and
FULL mark on the dipstick. If oil level is below the add
mark, remove filler cap and add oil to bring the level up
between marks. Do Not Overfill.
NOTE: If the engine has recently been running, allow
time (with engine turned off) to let the oil settle to obtain a
correct oil level reading.
Diesel Engine: Use only engine oils with API
classification CH4.
Gas Engine: Use only engine oils with API classification
xxx.
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 even 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. Replace drain plugs with
damaged gasket surfaces immediately.
After oil has completely drained, clean excess oil from oil
pan and drain plugs. Install drain plugs and tighten
securely. Refer to engine manual for proper torque.
Always replace the engine oil filter when changing the
engine oil. Apply a light coat of engine oil to the rubber
gasket surface of new filter before installing.
Diesel Engine: Fill Perkins engine with approximately
3.7 qts. (3.5 l) of clean engine oil. Check oil level and add
additional oil if required.
Gas Engine: Fill Suzuki engine with approximately 3.3
qts. (3.0 l) of clean engine oil. Check oil level and add
additional oil if required.
Figure 6A
Figure 6B
Replacement Oil Filters
Diesel Engine:
Above 77°F (25°C) SAE 30W or SAE10W30
32 to 77°F (0 to 25°C) SAE 20W or SAE 10W30
Below 32° (0°C) SAE10W or SAE 10W30
Gas Engine:
All temperature ranges SAE 10W30
Above 85° F (29° C) SAE 10W 40
Perkins Diesel 842553
Suzuki Gas 2701908
Engine Dipstick
Oil Level Must
Be Between Marks
DO NOT OVERFILL
ADD Diesel
Engine
Gas
Engine
ADD
FULL
FULL
-20 0 20 32 40 60 8077 100
-30 -20 -10 0 10 20 3025 40
Suzuki Gas
Perkins Diesel
SAE 10W/10W-30 SAE 20W/10W-30 SAE 30W/10W-30
10W-40
SAE 10W-30 for all temperature ranges
°F
°C

MAINTENANCE 6
GB-17
6.4 POWER STEERING RESERVOIR _____________________________________________
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 70 hours. After that level should be checked
every 100 hours.
When checking the fluid level before the engine has been
warmed up, the level should be at the COLD mark on the
dipstick. After the engine has been warmed up and the
fluid is warm, the level should be between the COLD and
HOT marks. Use General Motors Power Steering Fluid
as required to bring fluid up to proper level.
Figure 6C
6.5 MUFFLER AND EXHAUST___________________________________________________
To protect from carbon monoxide poisoning, inspect the
complete exhaust system regularly and always replace a
defective muffler.
If you notice a change in the color or sound of the
exhaust, stop the engine immediately. Identify the
problem and have the system repaired.
Torque all exhaust manifold hardware evenly. Tighten or
replace exhaust clamps.
6.6 ENGINE OVERHEAT PROCEDURE ___________________________________________
During vehicle operation, if the water temperature gauge
shows 230° F (110° C) or above, and/or the overheat
warning buzzer sounds, follow this procedure.
1. Stop the vehicle. DO NOT shut the engine off.
Place vehicle in neutral and engage the parking
brake.
2. Immediately disengage any accessories that are
operating.
3. Slow the engine speed to a fast idle.
4. Remove any dirt, chaff, debris, etc. from the radiator
intake screen located on the right side of the
vehicle.
Temperature gauge needle should start to go down
approximately 30 seconds after the screen is cleaned. If
temperature does not go down, STOP the engine and
check the following.
1. Check to see if cooling fan is operating. Fan should
be turning with coolant above 180° F, even with
ignition switch in OFF position.
2. Check engine oil level.
3. Check for a leak in the cooling system. Do not open
radiator when hot. Check coolant levels after system
completely cools.
Failure to heed the overheat warning and properly
maintain the cooling system will cause permanent engine
damage.
WARNING
Before servicing or doing any maintenance work around
the engine area, make sure the engine has had time to
cool. Serious burns can result if the engine or
surrounding surfaces are hot.
!
HOT
FULL
COLD
ADD
Power Steering Dipstick
WARNING
Exhaust fumes contain carbon monoxide that is toxic and
can be fatal when inhaled.
NEVER operate an engine without proper ventilation.
!
CAUTION
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.
!

6 MAINTENANCE
GB-18
6.7 COOLING SYSTEM ________________________________________________________
This vehicle is equipped with a radiator, temperature
controlled fan, temperature gauge and an overheat
buzzer.
NEVER add straight antifreeze to the radiator. Mix equal
amounts of clean water with ethylene glycol based anti-
freeze in a separate container before adding it to the
cooling system. Do not use a mixture of more than 50%
antifreeze.
Always recycle or dispose of used antifreeze in a
responsible manner. Used antifreeze can be harmful to
the environment.
1. Check coolant level daily. Radiator should be full and
recovery bottle should be up to the cold mark.
a. Tilt engine cover forward to gain access to the
radiator.
b. With the engine stopped and cool, remove
radiator cap and check coolant level. The coolant
level should be at or within 1/4 in. (6 mm) of the
filler port. Fill with a 50/50 antifreeze/water
mixture if required.
c. Visually check the reservoir tank. Coolant level
should be at or above FULL line but less than 4
in. (102 mm). Add a 50/50 antifreeze/water
mixture if required.
2. Drain and refill cooling system every 400 hours or 9
months, whichever comes first. Allow system to cool
before draining.
a. Remove the cooling fan fuse
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.
d. Empty and clean the recovery bottle.
e. Fill radiator to the bottom of the filler neck with
50/50 antifreeze/water mixture.
f. Fill recovery bottle to full mark with 50/50
antifreeze/water mixture.
3. Keep radiator air passages clean. Use compressed
air (30 psi maximum) to clean the fins. Water left
between the fins will collect dirt and reduce the
amount of air flow to properly cool the engine.
4. To provide proper air flow, do not obstruct the air
intake screen on the right side of the vehicle. Keep
screen clean.
5. Check and tighten the fan belt. Replace clamps and
hoses every two years.
6. If you have to add coolant more than once a month,
or add more than one quart at a time, have a
authorized Jacobsen Dealer check the cooling
system.
WARNING
To prevent serious bodily injury from hot coolant or steam
blow-out, never attempt to remove the radiator cap while
the engine is running. Stop the engine and wait several
hours until it is cool. Even then, use extreme care when
removing the cap.
CAUTION
Do not pour cold water into a hot radiator. Do not
operate engine without a proper coolant mixture.
Install cap and tighten securely.
WARNING
The cooling fan is controlled by a temperature switch and
may start at any time coolant temperature is above 150°
F (65 ° C), even with the ignition switch in the OFF
position. Do not attempt to service the cooling system
without first disconnecting the negative battery cable or
removing the fan fuse.
!
!
!

MAINTENANCE 6
GB-19
6.8 AIR FILTER _______________________________________________________________
Do not remove the element for inspection or cleaning.
Unnecessary removal of the filter increases the risk of
injecting dust and other impurities into the engine.
When service is required, first clean the outside of the
filter housing; then remove the old element as gently as
possible and discard.
1. Carefully clean the inside of the filter housing without
allowing dust into the air intake.
2. Inspect the new element. Do not use a damaged
element and never use an incorrect element.
3. Assemble the new element and make sure it seats
properly.
4. Reassemble cap making sure it seals completely
around the filter housing. Dust evacuator (A) must be
facing down.
5. Check all hoses and air ducts. Tighten hose clamps.
Figure 6D
6.9 JUMP STARTING __________________________________________________________
Before attempting to “jump start” the vehicle, check the
condition of the discharged battery.
Engage parking brake of both vehicles, shift transmission
to neutral and turn off all electrical loads
When connecting jumper cables:
1. Stop the engine on the vehicle with a good battery.
2. Connect RED jumper cable to the positive (+) terminal
on the good battery and to the positive (+) terminal on
the “discharged” battery.
3. Connect the BLACK jumper cable from the negative
(-) terminal on the good battery to the frame of the
vehicle with the discharged battery.
After cables have been connected, start the engine on
the vehicle with the good battery then start the vehicle.
A
A
Gas Engine
Diesel
Engine
WARNING
Batteries generate explosive hydrogen gas. To reduce
the chance of an explosion, avoid creating sparks near
battery. Always connect the negative jumper cable to the
frame of the vehicle with the discharged battery, away
from the battery.
!

6 MAINTENANCE
GB-20
6.10 BATTERY ________________________________________________________________
Make absolutely certain the ignition switch is “Off” and
the key has been removed before servicing the battery.
Tighten cables securely to battery terminals and apply a
light coat of silicone dielectric grease to terminals and
cable ends to prevent corrosion. Keep vent caps and
terminal covers in place.
Keep the top of the battery clean and free of corrosion by
washing with a solution of baking soda and water. Rinse
with clean water.
Verify battery polarity before connecting or disconnecting
the battery cables.
1. When installing the battery, always assemble the RED,
positive (+) battery cable first and the ground, BLACK,
negative (-) cable last.
2. When removing the battery, always remove the
ground, BLACK, negative (-) cable first and the RED,
positive (+) cable last.
3. Make sure battery is properly installed and secured to
the battery tray.
6.11 CHARGING BATTERY _____________________________________________________
1. Refer to Section 6.10. Read the Battery and Charger’s
manual for specific instructions.
2. Whenever possible, remove the battery from the
vehicle before charging. If battery is not sealed, check
that the electrolyte covers the plates in all the cells.
Battery cables must be disconnected before using a “fast
charger” or damage to the alternator may result.
3. Make sure the charger is “Off”. Then connect the
charger to the battery terminals as specified in the
charger’s manual.
4. Always turn the charger “Off” before disconnecting
charger from the battery terminals.
CAUTION
Always use insulated tools, wear protective glasses or
goggles and protective clothing when working with
batteries. You must read and obey all battery
manufacturer’s instructions.
!
WARNING
Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and
reproductive harm. Wash your hands after
handling.
!
WARNING
Charge battery in a well ventilated area. Batteries
generate explosive gases. To prevent an explosion, keep
any device that may create sparks or flames away from
the battery.
To prevent injury, stand away from battery when the
charger is turned on. A damaged battery could explode.
!