Textron Jacobsen Hauler 800 2004 Owner's Manual And Service Manual
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Textron Jacobsen Hauler 800 2004 Owner's Manual And Service Manual

Textron Jacobsen Hauler 800 2004 Owner's Manual And Service Manual

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28808-G01
OWNER'S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED UTILITY VEHICLES
ISSUED APRIL 2005

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Summary of Contents for Textron Jacobsen Hauler 800 2004

  • Page 1 28808-G01 OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLES ISSUED APRIL 2005...

  • Page 2: Safety

    SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLES ™ Hauler ™ Hauler 1200 Starting Model Year 2004 Jacobsen Turf, Commercial and Specialty Equipment reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ....................... ii SAFETY INFORMATION ......................v BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ......................1 CONTROLS AND INDICATORS ....................1 KEY/LIGHT SWITCH ............................1 Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge ..........2 DIRECTION SELECTOR .............................2 Fig.
  • Page 6 TABLE OF CONTENTS FUSE REPLACEMENT ............................ 11 Fig. 19 Tail and Brake Light Bulb Replacement ..............11 VEHICLE WITH A DISCHARGED BATTERY ....................11 TRANSPORTING VEHICLE ....................12 TOWING ................................12 NEUTRAL LOCK .............................. 12 Fig. 20 Neutral Lock ....................... 12 HAULING ................................

  • Page 7: Safety Information

    SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed: Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z- GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph.
  • Page 8 SAFETY INFORMATION Standards of the United States of America (USA) and are not equipped for operation on public streets. Some commu- nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi- nances.
  • Page 9 SAFETY INFORMATION • Use recommended tools. • Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle. • Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift the vehicle in accordance with the manufacturer’s instructions.
  • Page 10 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page viii...

  • Page 11: Before Initial Use

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the Check for correct tire inflation. See GENERAL SPECIFI- vehicle, we ask you to spend some time reading this CATIONS.

  • Page 12: Direction Selector

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Key/Light Switch Fuel Gauge Low Oil Pressure Indicator Light Ref Kes 2 Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge DIRECTION SELECTOR To reduce the possibility of component...

  • Page 13: Combination Brake And Park Brake Pedal

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Park Service Horn Brake Brake Accelerator Ref Hor 1 Ref Abc 1 Fig. 6 Horn Button Fig.

  • Page 14: Manual Lift Bed Operation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MANUAL LIFT BED OPERATION Severe injury could result if bed is lowered and traps fingers or other body parts. Exercise caution while operating the manual lift.

  • Page 15: Manual Lift Bed Operation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards. Before operating, check to ensure no one is behind the vehicle.

  • Page 16: Operating The Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OPERATING THE VEHICLE Always bring the vehicle to a complete stop before shifting the direction selector. Improper use of the vehicle or the lack Do not take vehicle out of ‘gear’...

  • Page 17: Starting And Driving

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings if required. Accelerate slowly and push the choke in com- Place left foot on service brake and release the park pletely when the engine runs smoothly.

  • Page 18: Battery

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To prevent damage to the vehicle, do not hold on to sun top struts and stand on body panels.

  • Page 19: Vehicle Cleaning And Care

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings VEHICLE CLEANING AND CARE REPAIR VEHICLE CLEANING LIFTING THE VEHICLE Tool List Qty. Required To reduce the possibility of severe injury or vehi- Floor jack..............

  • Page 20: Wheels And Tires

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Use caution when inflating tires. Overinflation could cause the tire to separate from the wheel or Center of cause the tire to explode, either of which could Front Axle...

  • Page 21: Light Bulb Replacement

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings It is important to follow the ‘cross sequence’ To replace the turn signal light bulb, support turn signal pattern when installing lug nuts.

  • Page 22: Transporting Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps Hole in Direction Hole in Direction or less.

  • Page 23: Serial Number Label Location

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings off all electrical loads from the battery before SERIAL NUMBER LABEL LOCATION removing battery wires. Two serial number and manufacture date code label are Wrap wrenches with vinyl on the vehicle.

  • Page 24: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle.
  • Page 25 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FRONT SHOCK ABSORBERS Check for oil leakage and loose fasteners FRONT SPRINGS Check for loose hardware, cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear, align if required Check for bent/binding linkage rod...

  • Page 26: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 500 HOURS (includes items listed in previous tables & the following) TIMING BELT Check tension and for signs of wear/damage, replace if worn or damaged CARBURETOR Clean Remove carbon from cylinder head and pistons...
  • Page 27 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Large HEAVY DUTY WORK 'O' Ring 10W-40 10W-40 10W-30 10W-30 Filter LIGHT DUTY WORK Small 'O' Ring Inside End Of Oil Filter Ref Rof 1 10W-30...

  • Page 28: Starter/Generator Belt Tension

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings the filter mounting plate with the holes in the engine. Wrench, 3/4" ..............1 Install and hand tighten the bolts before tightening them Wrench, 9/16"...

  • Page 29: Battery Cleaning

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Adjusting the Belt injury or death, do not use metallic spray wand to clean battery and keep all smoking materials, open Loosen the starter/generator pivot bolt.
  • Page 30 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Periodic Brake Test for Mechanical Brakes The purpose of this test is to compare the braking perfor- mance of the vehicle to the braking performance of new or ‘known to be good’...

  • Page 31: Air Intake And Cooling Fins

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 1/4" below top of reservoir. Add DOT 3 or 4 fluid as required. AIR INTAKE AND COOLING FINS Fill Plug T o p r e v e n t p o s s i b l e b u r n s , e n g i n e p a r t s...

  • Page 32: Lubrication

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings correctly installed. Insert cover into the lower portion of the enclosure and swing it up into place. Squeeze hous- Air Filter ing together and secure with top clips.

  • Page 33: Prolonged Storage

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Remove and inspect the spark plugs at intervals indi- Remove spark plugs (Refer to SPARK PLUGS on cated in the Periodic Service Schedule (Ref.
  • Page 34 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.

  • Page 35: Capacities And Replacement Parts

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Fuel Tank / Fuel 6.0 gal (22.5 L) / 87 Octane Engine Oil 1 1/2 qt (1.4 L) Oil Filter P/N 26591-G01...
  • Page 36 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Owner’s Manual and Service Guide Page 26...

  • Page 37: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27...

  • Page 38: Hauler 800

    GENERAL SPECIFICATIONS ™ HAULER STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 780 lbs (355 kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 800 lbs.
  • Page 39 GENERAL SPECIFICATIONS ™ HAULER 1200 STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 860 lbs (390 kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 18 x 5.70 x 8 (4 ply rated) TIRE PRESSURE 35 - 45 psi (241 - 310 kPa) LOAD CAPACITY 1200 lbs (544 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE...

  • Page 40: Hauler™ 1200

    GENERAL SPECIFICATIONS 10 in (25 cm) 47 in (119 cm) 66 in (168 cm) (Front) 37.5 in (95 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in HAULER™ 800 (119 cm) 18 in (46 cm) 47 in ( 119 cm)
  • Page 41 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER HAULER ™ 800 19 ft (5.8 m) HAULER ™ 1200 22 ft (6.7 m) Fig. 44 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Owner’s Manual and Service Guide Page 31...
  • Page 42 GENERAL SPECIFICATIONS Notes: Owner’s Manual and Service Guide Page 32...

  • Page 43: Limited Warranties

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 33...

  • Page 44: Domestic Warranty

    VEHICLE WARRANTIES DOMESTIC WARRANTY (U.S. AND CANADA) To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code. Owner’s Manual and Service Guide Page 34...

  • Page 45: International Warranty (2004)

    RIZED BY E-Z-GO, OR WERE NOT INSTALLED PER E-Z-GO'S INSTRUCTIONS, OR, FOR GASOLINE VEHI- CLES, THE USE OF NON-RECOMMENDED FUELS AND LUBRICANTS. FOR FURTHER INFORMATION, CALL 1-706-798-4311 OR WRITE TO E-Z-GO Division of Textron, Inc. ATTEN- TION: WARRANTY DEPARTMENT, P.O. BOX 388, AUGUSTA, GEORGIA 30903-0388.
  • Page 46 VEHICLE WARRANTIES Notes: Owner’s Manual and Service Guide Page 36...

  • Page 47: Federal Emission Component Defect Warranty

    EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Fuji Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 48 VEHICLE WARRANTIES - FEDERAL (2004) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 49: California Emission Control Warranty Statement

    You are responsible for presenting your engine to a dealer, distributor or service provider authorized by E- Z-GO Division of Textron Augusta, Georgia, (herein "E-Z-GO") to which FUJI supplies the engine as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to ex- ceed 30 days.
  • Page 50 VEHICLE WARRANTIES - CALIFORNIA (2004) part which is scheduled for replacement as required maintenance shall be warranted for the pe- riod of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider.
  • Page 51 VEHICLE WARRANTIES - CALIFORNIA (2004) (iii) Spark advance/retard system, if applicable (4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assy (gaseous fuel, if applicable) I.
  • Page 52 VEHICLE WARRANTIES - CALIFORNIA (2004) Owner’s Manual and Service Guide Page 42...

  • Page 53: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Page 43...
  • Page 54 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Owner’s Manual and Service Guide Page 44...

  • Page 55: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 56 LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 35962-G01 38,39,40,29) 35962G01 35964G01 See Following Pages For Explanation Of These Pictograms: 71131-G01 (19,43,44,45) 71131G01 74443G01 74443G01 See Following Pages For See Following Pages Explanation For Explanation Of Of These These Pictograms: Pictograms:...
  • Page 57 LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD xxx lbs . AS POSSIBLE. xxx kg MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
  • Page 58 LABELS AND PICTOGRAMS DO NOT CLEAN UP GASOLINE SPILLS WITH WATER EXPOSE TO FLAME BEFORE STARTING ENGINE UNLEADED DO NOT GASOLINE DISPOSE OF BATTERIES DO NOT IN LANDFILL SPILL FUEL ON A HOT ENGINE DO NOT DRIVE ON GROUND HIGHWAY FUEL PUMP WINDSHIELDS LOW OIL PRESSURE...
  • Page 59 LABELS AND PICTOGRAMS KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS TO OPERATE VEHICLE IN FORWARD: TURN KEY TO ON UNLOCKED MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY LOCKED...
  • Page 60 LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD Ref Pic 1-4 Owner’s Manual and Service Guide Appendix A - 6...
  • Page 61 Read and understand the following warnings Some components are heavy, spring loaded, highly cor- before attempting to operate the vehicle: rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, prevent personal battery acid and hydrogen gas could result in serious injury or death, observe bodily injury to the technician/mechanic and bystanders if the following:...
  • Page 62 Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department...

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Jacobsen hauler 1200 2004

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