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

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28805-G01
OWNER'S MANUAL
AND SERVICE GUIDE
ELECTRIC POWERED UTILITY VEHICLES
ISSUED APRIL 2005

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  • Page 1 28805-G01 OWNER’S MANUAL AND SERVICE GUIDE ELECTRIC POWERED UTILITY VEHICLES ISSUED APRIL 2005...
  • Page 2 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 (See GENERAL SPECIFICATIONS).
  • Page 3 Jacobsen Turf, Commercial and Specialty Equipment is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

  • 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 INFORMATION ......................VII BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ......................1 PORTABLE CHARGER INSTALLATION ......................1 Fig. 2 Proper Charger Installation .....................2 Fig. 3 Charger Receptacle Location ..................2 On-board Charger ..............................2 Fig. 4 On-board Charger ......................2 CONTROLS AND INDICATORS ....................
  • Page 6 AC Voltage ............................24 TROUBLESHOOTING ............................24 Hydrometer ............................25 Fig. 34 Hydrometer ........................ 25 Using A Hydrometer ..........................25 Fig. 35 Hydrometer Temperature Correction ................. 26 GENERAL SPECIFICATIONS ....................27 JACOBSEN 800..............................28 Owner’s Manual and Service Guide Page iv...
  • Page 7 TABLE OF CONTENTS JACOBSEN 1000 ...............................29 LIMITED WARRANTIES......................33 DOMESTIC WARRANTY ...........................34 INTERNATIONAL WARRANTY .........................35 DECLARATION OF CONFORMITY (EUROPE ONLY)............37 LABELS AND PICTOGRAMS .................. Appendix A Owner’s Manual and Service Guide Page v...
  • Page 8 TABLE OF CONTENTS Owner’s Manual and Service Guide Page vi...

  • Page 9: Safety Information

    SAFETY INFORMATION This manual has been designed to assist the owner-operator 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 and/or property damage, the following instructions 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 10: General Operation

    SAFETY INFORMATION This vehicle conforms to the current applicable standard for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.
  • Page 11 SAFETY INFORMATION Always check the polarity of each battery terminal and be sure to rewire the batteries correctly. Always use specified replacement parts. Never use replacement parts of lesser quality. Always use recommended tools. Always 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 12 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page x...

  • Page 13: General Safety Practices

    SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL manual without the manufacturer’s prior written authori- zation. Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988.
  • Page 14 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes turer; 4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads, bustion engines is used in enclosed areas, the atmo- carrier operator, and other employees;...
  • Page 15 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion. such that they block or obstruct fire aisles, access to Loading stairways, or fire equipment.
  • Page 16 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Maintenance Procedures prevent the use of the carrier until the leak has been eliminated. 6.2.1 Maintenance and inspection of all carriers The carrier manufacturer’s capacity, operation, shall be performed in conformance with the manufac- and maintenance instruction plates, tags, or decals shall...

  • Page 17: Operation And Service Information

    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 Five air exchanges per hour is considered the minimum vehicle, we ask you to spend some time reading this requirement.

  • Page 18: On-Board Charger

    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 reduce the possibility of a physical hazard that Provide Protection From Elements could result in an electri- cal shock or electrocution, be sure that the charger plug is not damaged and is inserted into a grounded receptacle.

  • Page 19: Key/Light Switch

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • hour meter • accelerator pedal Neutral • combination service and park brake pedal • horn Reverse Forward KEY/LIGHT SWITCH...

  • Page 20: Combination Service 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 Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehi- cle is not driven with the park brake engaged.

  • Page 21: Electric Lift Switch

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ELECTRIC LIFT SWITCH one of the slots before releasing. Severe injury could result if bed is released and traps fingers or other The optional electric lift switch is located on the seat body parts.

  • Page 22: Plastic Loadbed

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and cause an explosion. Always place a gas can on the ground before filling.

  • Page 23: Electric 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 Read and understand the following warnings before attempting to operate the vehicle. To reduce the possibility of severe injury or death resulting from loss of vehicle control, the following warnings must be...

  • Page 24: Precision Drive System

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Always bring the vehicle to a complete stop The vehicle performance option can be determined by before shifting the direction selector.

  • Page 25: Walk-Away Feature

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Walk-Away Feature High Pedal Disable Feature High pedal disable prevents undesired acceleration if the Walk-Away limits vehicle movement without driver input, direction selector lever is changed, or the key is turned slowing the vehicle to 2 mph (3 kph) and sounding an on while the accelerator is depressed.

  • Page 26: Coasting

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Do not hold vehicle on hill by using SUN TOP AND WINDSHIELD accelerator and motor. Leaving motor The sun top does not in a stalled condition for more than 3 - 4 seconds will cause per- provide protection from...

  • Page 27: Repair

    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 that proper techniques and cleaning mate- Never get under a vehicle while it is supported by rials be used.

  • Page 28: Lifting 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 mum handling characteristics. Be sure to install the valve dust cap after checking or inflating. Center of Front Axle The vehicle is fitted with low pressure tubeless tires mounted on one piece rims;...

  • Page 29: Fuse 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 Roll Rubber Bezel Away From Body Tail/Brake Tire/wheel style Light may vary Rear 'Cross Sequence' 'Cross Sequence' Fender Ref Tlr 2 Ref Whi 2...

  • Page 30: 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 TRANSPORTING VEHICLE Wear eye protection when working on the vehicle. Use extra care when work- TOWING ing around batteries, or using sol- vents or compressed air.

  • Page 31: Serial Number Plate 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 To prolong vehicle life, some mainte- nance items must be serviced more fre- quently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, fre- quent use with maximum load.

  • Page 32: 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 33: 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 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 Check for damage or wear to latch arm or catch bracket PARK BRAKE...

  • Page 34: Hydraulic Front Disc Brakes

    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 standard with a new vehicle. Drive the vehicle at maximum speed on a flat, dry, clean, paved surface (Ref.

  • Page 35: Pds System Test

    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 care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific torque values.

  • Page 36: 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 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 37: Battery Maintenance

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings results must be corrected to compensate for temperature differences. Vent Cap Expansion As a battery ages, it still performs adequately except that Space its capacity is diminished.

  • Page 38: 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 ize acid before rinsing battery. To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer. Cleaning should take place per the Periodic Service Schedule (Ref.

  • Page 39: 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 70 in. lbs. (6 - 8 Nm) torque Protect the battery terminals and battery wire terminals with a commercially available protective coating.

  • Page 40: Battery Charging

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings can be used to determine the specific gravity and there- when the battery set is fully charged. Always refer to the fore the state of charge of a battery.

  • Page 41: Hydrometer

    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 second reason is to determine why a particular vehi- cle does not perform adequately. Performance problems Bulb may result in a vehicle that runs slowly or in a vehicle that Cylinder...

  • Page 42: Fig. 35 Hydrometer Temperature Correction

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 4. Add or subtract four points (.004) to the reading for every 10° F (6°C) the electrolyte temperature is Electrolyte above or below 80°...

  • Page 43: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27...
  • Page 44 GENERAL SPECIFICATIONS Hauler STANDARD EQUIPMENT: WEIGHT (without batteries) 675 lbs. (306 kg) TIRES 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 800 lbs. (362 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.
  • Page 45 GENERAL SPECIFICATIONS Hauler 1000 STANDARD EQUIPMENT: WEIGHT (without batteries) 809 lbs. (374 kg) TIRES (4 ply rated) 18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE 18 - 22 psi (120 - 150 kPa) LOAD CAPACITY 1000 lbs. (454 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE 4.75 in.

  • Page 46: Jacobsen 800

    66 in (168 cm) (Front) 38 in (97 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in JACOBSEN ™ 800 (119 cm) 18 in (46 cm) 47 in ( 119 cm) 11.5 in (29 cm)
  • Page 47 RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER JACOBSEN ™ 800 19 ft (5.8 m) JACOBSEN ™ 1000 22 ft (6.7 m) Fig. 37 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Owner’s Manual and Service Guide...
  • Page 48 GENERAL SPECIFICATIONS Notes: Owner’s Manual and Service Guide Page 32...

  • Page 49: Limited Warranties

    WARRANTY LIMITED WARRANTIES Owner’s Manual and Service Guide Page 33...

  • Page 50: Domestic Warranty

    WARRANTY 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 51: International Warranty

    WARRANTY 2004 INTERNATIONAL WARRANTY (ALL COUNTRIES OUTSIDE THE U.S. AND CANADA) E-Z-GO Division of Textron, Inc. ("E-Z-GO") warrants to the Original Retail Purchaser or the Original Retail Lessee that any 2004 E-Z-GO vehicle and/or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer's location with respect to parts and labor.
  • Page 52 WARRANTY Notes: Owner’s Manual and Service Guide Page 36...

  • Page 53: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Page 37...
  • Page 54 DECLARATION OF CONFORMITY Owner’s Manual and Service Guide Page 38...
  • Page 55 DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Owner’s Manual and Service Guide Page 39...
  • Page 56 DECLARATION OF CONFORMITY Notes: Owner’s Manual and Service Guide Page 40...

  • Page 57: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 58 LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 35964-G01 38,39,40,29) 35964G01 See Following Pages For Explanation Of These Pictograms 71129-G02 71129G02 (43,44,45) See Following Pages For Explanation Of This Pictogram: (1, 2) 71489G01 See Following Pages For Explanation Of This Pictogram: On Battery Under Seat...
  • Page 59 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 60 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 61 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 62 LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD Ref Pic 1-4 Owner’s Manual and Service Guide Appendix A - 6...
  • Page 63 Read and understand the following warnings Read and understand the following text and before attempting to operate the vehicle: warnings before attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. prevent personal It is virtually impossible to anticipate all possible compo-...
  • Page 64 Jacobsen Turf, Commercial and Specialty Equipment 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: 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 is also suitable for:

Hauler 1000

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