Jacobsen Cushman Turf Truckster User manual

Parts & Maintenance Manual
Manuel de Maintenance &
Nomenclature des Pièces de Rechange
By Jacobsen
When Performance Matters.
™
AVERTISSEMENT
Risque de blessures graves en cas d’utilisation incorrecte de la machine.
Les opérateurs et le personnel d’entretien doivent être formés et conscients
des dangers encourus. Ils doivent lire avec attention le manuel avant
d’essayer de monter, d’utiliser, de régler ou maintenir la machine.
WARNING
If incorrectly used, this machine can cause severe injury. Those 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
GB FR
United France
Kingdom
Cushman®Turf Truckster®
With Four Post ROPS
Avec structure de protection anti-retournement à 4 montants
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
84063 – Moteur Diesel Kubota®D1105-E3B, MT
84064 – Moteur Diesel Kubota®D1105-E3B, MT, EC
84067 – Moteur Essence Suzuki®K6, MT
84068 – Moteur Essence Suzuki®K6, AT
84069 – Moteur Essence Suzuki®K6, RV et utilitaires
4241724-FR-Rev A

© Copyright 2011, Jacobsen, A Textron Company. “All rights
reserved, including the right to reproduce this material or portions
thereof in any form.”
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.
The serial plate is located on the frame rail under the
steering wheel. Jacobsen recommends you record these
numbers below for easy reference.
MODEL
DATE CODE
LABEL #
SERIAL #
xxxxx
CHARLOTTE, NC, USA
1 800 848 1636
Jacobsen.com
xxxxx
Lb/kg W Batt
Nom Power Hp/kw
xxxxxxxx
*xxxxxxxx*
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Proposition 65 Warning
This product contains or emits
chemicals known to State of California
to cause cancer and birth defects or
other reproductive harm.
FOREWORD
Suggested Stocking Guide
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:
❑UPS ❑Regular Mail
❑Overnight ❑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.
Litho in U.S.A. 1-2011
Service Parts
Service Support Material
Qty. Part No. Description Qty. Part No. Description
4113986 Diesel Engine Oil Filter 2701908 Gas Engine Oil Filter
550489 Diesel Engine Fuel Filter Element 2701898 Gas Engine Fuel Filter
4175560 Diesel Alternator-Power Steering Belt 4139265 Gas Alternator-Power Steering Belt
4117092 Diesel Hydraulic Pump Belt 4235370 Gas Governor-Hydraulic Pump Belt
5000919 Diesel Engine Air Filter Element 840352 Gas Engine Air Filter Element
885249 Hydraulic FIlter Element
Qty. Part No. Description
4241725 Safety & Operation Manual
4241724 Parts & Maintenance
4160162 Kubota D1105 Engine Parts Manual
4241728 Suzuki K6A Engine Parts Manual
Qty. Part No. Description
4171642 MT Truck Service Manual
4171675 AT Truck Service Manual
4171985 Suzuki K6A Service Manual
4239442 Accessory Manual
These are the original instructions verified by
Jacobsen A Textron Company

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Table of Contents
1 Safety
1.1 Operating Safety........................................ 4
1.2 Important Safety Notes .............................. 5
2 Vehicle Identification Numbers
2.1 Vehicle Identification Number.................... 6
2.2 Engine Identification Numbers ................... 6
3 Specifications
3.1 Product Identification ................................. 7
3.2 Diesel Engine ............................................. 7
3.3 Gas Engine ................................................ 7
3.4 vehicle ........................................................ 8
3.5 Gear Ratios ................................................ 8
3.6 Weights and Dimensions ........................... 8
3.7 Accessories & Support Literature .............. 9
3.8 Declaration of Conformity ........................ 10
4 Adjustments
4.1 General.................................................... 12
4.2 Engine Access ......................................... 12
4.3 Front Cowl Access ................................... 13
4.4 Access Panels ......................................... 13
4.5 Diesel Alternator Belt ............................... 14
4.6 Diesel Hydraulic Pump Belt ..................... 14
4.7 Gas Power Steering - Alternator Belt ....... 14
4.8 Gas Hydraulic Pump Belt ......................... 15
4.9 Parking Brake Cable ................................ 15
4.10 Torque Specification ................................ 16
5 Maintenance
5.1 General.................................................... 17
5.2 Engine ...................................................... 17
5.3 Engine Oil ................................................ 18
5.4 Power Steering Reservoir ........................ 19
5.5 Muffler and Exhaust ................................. 19
5.6 Engine Overheat Procedure .................... 19
5.7 Cooling System ........................................ 20
5.8 Air Filter ................................................... 21
5.9 Jump Starting ........................................... 21
5.10 Battery ..................................................... 22
5.11 Charging Battery .......................................22
5.12 Hydraulic Hoses ........................................23
5.13 Hydraulic Reservoir and Filter ..................23
5.14 Fuel ...........................................................24
5.15 Fuel System ..............................................24
5.16 Tire Pressure ............................................25
5.17 Tire Removal and Installation ...................25
5.18 Raising the vehicle ....................................26
5.19 Towing the Vehicle ...................................27
5.20 Governor Oil Level ....................................27
5.21 Hydraulic Brakes .......................................28
5.22 Differential Fluid ........................................29
5.23 Diesel Engine Manual Transmission ........29
5.24 Gas Engine Manual Transmission ............30
5.25 Gas Engine Automatic Transmission ........30
5.26 Electrical System ......................................31
5.27 Dash Panel ...............................................31
5.28 Headlight Replacement ............................32
5.29 Tail Light Replacement .............................32
5.30 EFI Diagnostic Check ...............................33
5.31 Care and Cleaning ....................................33
5.32 Storage .....................................................34
6 Troubleshooting
6.1 General..................................................... 35
7 Maintenance & Lubrication Charts
7.1 General..................................................... 36
7.2 Lubrication Chart ......................................36
7.3 Maintenance Charts ..................................37
7.4 Common Replacement Parts ....................38
7.5 Kubota Diesel Engine Service Parts .........38
8Notes
9 Parts Catalog
9.1 How To Use The Parts Catalog................ 40
9.2 To Order Parts ..........................................40
9.3 Table Of Contents .....................................41

1 SAFETY
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1 SAFETY
1.1 OPERATING SAFETY ______________________________________________________
1. Safety is dependent upon the awareness, concern
and prudence of those who operate or service the
equipment. Never allow minors to operate any
equipment.
2. It is your responsibility to read this manual and all
publications associated with this equipment (Safety &
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 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 Roll Over Protective Structure
(ROPS).
Never use a seat belt when operating vehicle
without a ROPS.
Accessory ROPS will continue 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.
23. Keep legs, arms, and body inside the seating
compartment while the vehicle is in motion.
24. Always shift transmission to 1st Gear (Manual
Transmission) or Park (Automatic Transmission),
engage parking brake, and stop engine before leaving
the vehicle.
25. 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.
26. Disconnect the battery cables before performing any
welding operations on this vehicle.
WARNING
EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS.
Familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction
from someone familiar with the equipment before being allowed to operate the machine.
!

SAFETY 1
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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.
NOTICE - 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 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.
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 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.
!