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Jacobsen Truckster XD Service Manual

Jacobsen Truckster XD
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Safety, Operation, & Maintenance Manual
WARNING
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 must read the entire
manual before attempting 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 Options
Standard Driver and Passenger Seat Option
Premium Driver and Passenger Seat Option
Premium Driver and Standard Passenger Seat Option
High-Low Hydraulic System Option
Ribbed / Tread Front Tire Options
Bed and Box Sides Option
No Bed Option
4330108-Rev A

Table of Contents

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Jacobsen Truckster XD Specifications

General IconGeneral
BrandJacobsen
ModelTruckster XD
CategoryUtility Vehicle
LanguageEnglish

Summary

Introduction

Important Information

Key guidelines for safe operation, maintenance, and authorized modifications.

Product Identification

Details on vehicle serial number plate and its components.

Serial Numbers

Section to record vehicle and engine serial numbers for identification.

Scrap Product Disposal Guidelines

Procedures for safely disposing of used fluids and vehicle components.

Safety

Safe Operation Practices

Essential safety rules for operating the vehicle and avoiding hazards.

Pre-Operation Checks

Steps to take before starting the vehicle to ensure safe operation.

Safe Vehicle Operation

Guidelines for operating the vehicle safely, including slope operation and reverse driving.

ROPS Safety

Information on Roll Over Protective Structure (ROPS) safety and maintenance.

Fuel Handling Safety

Precautions for safe refueling and handling of flammable fuels.

Maintenance & Storage Safety

Safety guidelines for cleaning, adjusting, repairing, and storing the vehicle.

Trailer Loading Safety

Precautions and procedures for safely loading the vehicle onto a trailer.

Key Safety Notes & Warnings

Explanation of hazard symbols (DANGER, WARNING, CAUTION, NOTICE) and interlock system.

Specifications

Engine Specifications

Detailed specifications for Diesel and Gasoline engine options.

Dimensions and Weights

Key physical dimensions and weight data for the vehicle.

Vehicle Specifications

Details on battery, brakes, fuel tank, hydraulic system, and transmission.

Hydraulic Specifications

Flow rates and relief valve pressures for hydraulic systems.

Vibration Levels

Hand/Arm and Whole Body vibration acceleration levels for different engine options.

Noise Levels

Measured sound pressure and sound power levels for operator ear and environment.

Slope Operation Limits

Maximum safe operating slope angle and precautions for gradients.

Recommended Lubricants

Specifications for engine oil, hydraulic fluid, gear lube, and grease.

Vehicle Accessories

List of available accessories including beds, sprayers, and hitches.

Top Dresser 1500

Information on the Top Dresser 1500 accessory kit.

Core Harvester

Information on the Core Harvester accessory kit.

Quick Aerator

Information on the Quick Aerator accessory kit.

Vicon Spreader

Information on the Vicon Spreader accessory kit.

Cab Option

Information on the Cab accessory option.

Support Literature

List of available technical manuals and literature for the vehicle.

Declaration of Conformity

Manufacturer's declaration of compliance with relevant EU directives and noise standards.

Decals

Safety Decals

Explanation of important safety decals related to batteries, coolant, and passenger safety.

More Safety Decals

Decals related to truck bed lifting, start assist fluids, and tailgate safety.

Instruction Decals - Center Console

Decals for High/Low speed ranges, 4WD/2WD, and bed controls.

Instruction Decals - Right Control Panel

Decals for turn signals, differential lock, ignition, and work lights.

Instruction Decals - Left Control Panel

Decals for headlights and horn on the standard control panel.

Instruction Decals - Diesel Speed Control

Decals for headlight, horn, and hand throttle/governor control.

Instruction Decals - Gasoline Speed Control

Decals for headlight, horn, and engine speed adjustment.

Fuse and Relay Panels

Diagrams and labels for diesel and gasoline fuse/relay panels.

Controls

Operator Compartment Overview

Diagram showing the layout of controls within the operator compartment.

Gauge Panel

Description of tachometer, engine temp, fuel gauge, LCD screen, and indicator lights.

Indicator Lights & Warnings

Explanation of warning lights for hydraulic fluid, coolant, oil pressure, parking brake, glow plugs, and fuel.

Right-Side Control Panel Functions

Details on differential lock switch and 12V accessory outlet.

Right-Side Control Switches

Operation of turn signals, ignition, high-low hydraulics, and work light switches.

Left-Side Control Panel Functions

Operation of horn and light switches on standard and optional panels.

Speed Control Options

Controls for hand throttle, governor, set/resume, and stationary/cruise switches.

Pedal Controls

Operation of accelerator, brake, and clutch pedals.

Center Console Controls

Operation of parking brake and gear selector.

Control Levers and Storage

Operation of axle speed, 2WD/4WD, lift control levers, and storage compartment.

Seat Controls & Adjustment

Adjustment procedures for premium and standard operator seats.

Operation

Daily Inspection & Interlock System Test

Procedure for daily checks and testing the vehicle's interlock system.

General Operating Procedures

Key steps and precautions for safe vehicle operation in various conditions.

Engine Start & Stop Procedures

Step-by-step instructions for starting and stopping the engine safely.

Driving the Vehicle

Instructions for engaging gears, accelerating, and shifting while driving.

Gear and Engine Speed Chart

Chart correlating vehicle speed with gear selection and engine RPM.

Gasoline Speed Control Operation

How to use normal, cruise control, and stationary modes for engine speed.

Operation on Slopes

Guidelines and precautions for operating the vehicle on inclines.

Hydraulic Accessory Operation

Procedures for operating hand-held and vehicle-mounted hydraulic accessories.

Towing the Vehicle

Instructions and safety warnings for towing the vehicle or placing it on a trailer.

Maintenance and Lubrication Charts

Maintenance Schedule

Interval-based maintenance tasks for the vehicle, referencing specific sections.

Lubrication Chart

Diagrams indicating lubrication points for 2WD and 4WD drive systems.

Fluid Requirements

Specifications for engine oil, transmission fluid, coolant, and fuel types.

Maintenance

General Maintenance Precautions

Safety guidelines and general advice before performing maintenance or service.

Servicing the Vehicle Safely

Procedure for safely lifting the truck bed for vehicle service.

Engine Maintenance

First 50-hour service recommendations and engine oil level checks.

Engine Oil Service

Procedures for checking and changing engine oil and filter.

Engine Air Filter Maintenance

How to check and replace the engine air filter element using the service indicator.

Fuel Handling & Recommendations

Guidelines for refueling, fuel types for Diesel and Gasoline engines.

Fuel System Maintenance

Procedures for replacing diesel and gasoline fuel filters and bleeding the system.

Battery Maintenance & Jump-Starting

Safety precautions, cable connections, and jump-starting procedures.

Battery Charging

Safe procedures for charging the vehicle battery.

Engine Exhaust System

Inspection of exhaust system for leaks, damage, and carbon monoxide hazards.

ROPS Inspection & Maintenance

Guidelines for inspecting and maintaining the Roll Over Protective Structure (ROPS).

Hydraulic Hose Inspection & Care

Procedures for checking hydraulic hoses for leaks, damage, and proper installation.

Hydraulic Fluid Replacement

Steps for draining and refilling hydraulic fluid in the rear axle and high/low system.

Hydraulic Filter Replacement

Procedure for replacing hydraulic filters and ensuring proper fluid level.

Radiator & Cooling System Care

Checks and maintenance for the radiator, expansion tank, and coolant.

Tire Care & Pressure

Guidelines for tire inflation, inspection, and pressure charts.

Wheel Mounting Procedure

Safe procedure for mounting wheels, including torque specifications.

Transmission Fluid Check

Procedure for checking and refilling transmission fluid level.

Electrical System Precautions

General precautions and troubleshooting tips for the electrical system.

Fuse and Relay Panel Details

Detailed explanation of fuses and relays for Diesel and Gasoline engine options.

Suspension Inspection

Inspection of suspension components for damage and wear.

Vehicle Cleaning & Care

Guidelines for cleaning the vehicle, including engine and exterior parts.

Vehicle Storage Procedures

Instructions for preparing and storing the vehicle for extended periods.

Adjustments

General Adjustment Precautions

Safety guidelines and general advice before performing adjustments.

Alternator Belt Adjustment

Procedure for inspecting and adjusting the alternator belt tension.

Parking Brake Adjustment

Procedure for checking and adjusting the parking brake for proper function.

Steering Toe-In Adjustment

Procedure for adjusting the front wheel toe-in for proper steering alignment.

Torque Specifications

Table of approximate torque values for various bolt sizes and grades.

Problem Solving

General Troubleshooting Guide

Chart listing common symptoms, possible causes, and actions for vehicle issues.

CAN Bus Connector Locations

Identification of CAN bus connectors for engine and vehicle communication.

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