Textron Jacobsen 3500 Owner's Manual And Service Manual
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Textron Jacobsen 3500 Owner's Manual And Service Manual

Gasoline powered utility vehicle
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28835-G01
OWNER'S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED UTILITY VEHICLE
ISSUED APRIL 2005

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Summary of Contents for Textron Jacobsen 3500

  • Page 1 28835-G01 OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLE ISSUED APRIL 2005...

  • Page 2: Safety

    SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen- tative for clarification. 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 AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLE JACOBSEN 3500 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: Notes

    NOTES 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 A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C). Owner’s Manual and Service Guide Page iii...
  • Page 6 NOTES Owner’s Manual and Service Guide Page iv...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Safety ........................Inside Covers NOTES ............................ii SAFETY INFORMATION ......................vii OPERATION AND SERVICE INFORMATION ................1 BEFORE INITIAL USE ....................... 1 Fig. 1 Initial Service Chart ......................1 Fig. 2 Typical Safety and Operation Label (Text and Pictogram) ..........2 TERRAIN ............................
  • Page 8 TABLE OF CONTENTS OPERATING THE VEHICLE ....................10 Cold Starting ..............................11 Starting the Vehicle on a Hill ..........................11 Starting the Vehicle with a Discharged Battery ....................11 COASTING ..........................12 FUEL ............................12 Fig. 19 Fuel Tank Location .....................12 TOWING ...........................12 SERVICING THE VEHICLE ......................12 NEUTRAL LOCK ........................13 Direction Selector Mounted Neutral Lock ......................
  • Page 9 TABLE OF CONTENTS TRAILERING ..........................22 HARDWARE ..........................23 TORQUE SPECIFICATIONS ....................23 Fig. 42 Torque Specifications ....................23 PERIODIC SERVICE SCHEDULE ..................23 Fig. 43 Periodic Service Schedule ..................23 GENERAL SPECIFICATIONS....................25 Fig. 44 Vehicle Dimensions ......................27 Fig. 45 Vehicle Turning Clearance Diameter................28 Fig.
  • Page 10 TABLE OF CONTENTS Owner’s Manual and Service Guide Page vi...

  • Page 11: 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 12 SAFETY INFORMATION These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety 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 13 SAFETY INFORMATION • Use specified replacement parts. Never use replacement parts of lesser quality. • 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. •...
  • Page 14 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page x...
  • Page 15 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL addition which affects capacity or safe operation, or make any change not in accordance with the owner’s The following text is provided as recommended by part II manual without the manufacturer’s prior written authori- of American Society of Mechanical Engineers / American...
  • Page 16 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings equip the carrier with appropriate lights in accordance 5.2.3 The user should include in the operators’ train- with the manufacturer’s recommendations. ing program the following: (a) instructional material provided by the manufac- Control of Noxious Gases and Fumes...
  • Page 17 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings building structures, and equipment. 5.5.13 Avoid running over loose objects, potholes, and bumps. 5.4.8 Operators shall not add to, or modify, the car- 5.5.14 To negotiate turns, reduce speed to improve rier.
  • Page 18 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 6.1.1 Carriers may become hazardous if mainte- inspected to ensure that maintenance preserves the orig- nance is neglected. Therefore, maintenance facilities, inal approved safe operating features.

  • Page 19: Operation And Service Information

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings severe injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).
  • Page 20 GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 35962-G01 WARNING WARNING WARNING WARNING WARNING WARNING WARNING To go forward, To go in reverse, To park, set WARNING Read Owner's Use caution...

  • Page 21: Vehicle Capacity

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings VEHICLE CAPACITY and/or cause the vehicle to tip over. Operate the vehicle with awareness of the load. Due to the variety of ways Do not drive the vehicle with the load bed raised or with the vehicle may be used, it is...

  • Page 22: Environmental Concerns

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Protective clothing and an approved motorcycle helmet At the front, it is mounted under the center of the front are recommended for operator and passenger at all cowl to a bracket attached to the front axle as shown (Ref times.

  • Page 23: Winch Applications

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings seat. Read the following section (Winch Applications) The rear drive axle is equipped with a differential. All before attempting to operate winch.
  • Page 24 GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Damper Nylon Fig. 7 Never Operate Winch with Less Than Sling Five Turns Around Drum To pull out the cable, the free spool clutch knob Ref Wcd 2 must be used.

  • Page 25: Towing A Trailer

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings discharge of the battery even though the engine is run- ning and the generator operating. Discharging the bat- tery is known as deep cycling.

  • Page 26: Controls And Indicators

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CONTROLS AND INDICATORS To prevent engine damage, do not operate engine until oil pressure is corrected. Vehicle controls and indicators consist of: If oil level is below ADD mark on dipstick, add oil to bring •...

  • Page 27: Accelerator Pedal

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Accelerator Pedal A 12 volt power outlet is located to the left side of the key/ light switch (Ref Fig. 16 on page 9). It provides constant Depressing the accelerator pedal starts the engine.

  • Page 28: Run-In

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Run-In conditions and the environmental factors which effect the terrain and the ability to control the An initial oil change is required at 100 hours. Check for vehicle.

  • Page 29: Cold Starting

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The vehicle should be operated by persons with a vice brake pedal. Slowly depress the accelerator pedal to valid driver’s license.

  • Page 30: Coasting

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The vehicle is equipped with a starter/generator. When starting the engine, the starter/generator functions as a starter and with the engine running, it functions as a gen- erator.

  • Page 31: Neutral Lock

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings In the best interest of both vehicle owner and servicing • Dizziness dealer, carefully follow the procedures recommended in •...

  • Page 32: Lifting The Vehicle

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE Tool List Qty. Required Floor jack..............1 Jack stands ..............4 Chocks ................ 4 To prevent possible injury or death resulting from a vehi- cle falling from a jack, be...

  • Page 33: Replacing The Fuel Filter

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Checking the Oil Level Do not overfill engine. Too much oil may King Pin King Pin cause smoking and/or allow oil to enter Idler Arm the air intake system.

  • Page 34: Changing The Oil

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings When adding oil between oil changes, do not mix brands and viscosity grades of oil. HEAVY DUTY WORK 10W-30 10W-40 Both the oil dipstick and fill cap must be in place before operat-...

  • Page 35: Air Cleaner Inspection/Replacement

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Clean the filter by washing in any shop degreaser and brushing the metal screen clean with a soft brush (Ref Fig.

  • Page 36: Rear Axle

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings REAR AXLE Tighten a new starter/generator belt to 90 - 110 lbs. (41 - 50 kg) tension when a gauge is applied half way between The rear axle is provided with a lubricant level check plug the two pulleys (Ref Fig.

  • Page 37: Air Intake And Cooling Fins

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings AIR INTAKE AND COOLING FINS Spark Plug To prevent possible burns, engine parts should be kept clean to reduce risk of over- heating and ignition of accumulated debris.

  • Page 38: Wheel And Tire Service

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Schedule when the tires are cool. Be sure to install valve Tire plug tools and plugs are available at most automotive parts outlets and have the advantage dust cap after checking or inflating.

  • Page 39: Light Bulb Replacement

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIGHT BULB REPLACEMENT local distributor, an authorized Branch or the Service Parts Department. For vehicles with headlights mounted in cowl, locate the two screws on backside of cowl that secure headlight PROLONGED STORAGE (Ref Fig.

  • Page 40: Care And Cleaning Of The Vehicle

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CARE AND CLEANING OF THE VEHICLE TRAILERING To prevent personal injury to When pressure washing vehicle, do not occupants of other highway use pressure in excess of 700 psi.

  • Page 41: Hardware

    GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HARDWARE Generally, two grades of hardware are used in the vehi- cle. Grade 5 hardware can be identified by the three Periodically, the vehicle should be inspected for loose marks on the hexagonal head.
  • Page 42 GASOLINE UTILITY VEHICLES Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings DIRECTION SELECTOR Check attachment, adjust as required ENGINE Check for unusual noise, vibration, acceleration, oil leaks STARTER/GENERATOR BELT Check for tension, wear, cracks COOLING FAN Check for build-up of foreign matter inside blower housing and fins, clean if required...

  • Page 43: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 25...
  • Page 44 GENERAL SPECIFICATIONS JACOBSEN 3500 STANDARD EQUIPMENT: CHASSIS Welded Tubular Steel; Powder Coated (DuraShield™) BODY (Front) Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base Coat/Clear Coat BODY (Rear) Lightweight, replaceable steel panels BATTERY One 12 Volt Maintenance Free (360 CCA, 51 Minute Reserve) ENGINE 11 hp (8.2 kW) 21 ci (350 cc) Twin Cylinder, Air Cooled,...
  • Page 45 GENERAL SPECIFICATIONS 110 in (280 cm) 18 in (46 cm) 49 in 11.5 in (125 cm) (29 cm) 32 in (81 cm) 76 in 6 in 77 in (196 cm) (193 cm) (15 cm) 50 in (127 cm) Rear 38 in (96 cm) Front 38.5 in (97 cm) 42.5 in (108 cm)
  • Page 46 GENERAL SPECIFICATIONS TURNING CLEARANCE DIA. Approx. 23.5 ft (7.2 m) Ref Tur 7S Fig. 45 Vehicle Turning Clearance Diameter Maximum Recommended Side Tilt Maximum Recommended Ramp Grade 25% or 14˚ Max. 25% or 14˚ Max. Ref Vis 4S Fig. 46 Vehicle Incline Specifications Owner’s Manual and Service Guide Page 28...

  • Page 47: Limited Warranty

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 29...
  • Page 48 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 30...
  • Page 49 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 50 VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 32...
  • Page 51 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 52 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 53 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 54 VEHICLE WARRANTIES - CALIFORNIA (2004) Owner’s Manual and Service Guide Page 36...
  • Page 55 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 56 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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