Jacobsen Hauler 800 Owner'S Manual And Service Manual Download

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ELECTRIC POWERED UTILITY VEHICLES

ISSUED APRIL 2005

OWNER’S MANUAL

AND SERVICE GUIDE

28805-G01

Summary of Contents for Hauler 800

Page 1: ...ELECTRIC POWERED UTILITY VEHICLES ISSUED APRIL 2005 OWNER S MANUAL AND SERVICE GUIDE 28805 G01 ...

Page 2: ...peeds 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 Limit speed by applying the service brake Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessiv...

Page 3: ...ect to change without notice 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 CUSTOMER SERVICE DEPARTMENT IN USA PHOTO 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 39...

Page 4: ... batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger and...

Page 5: ...ig 8 Run Tow Maintenance Switch 4 HORN 4 Fig 9 Horn Button 4 ELECTRIC LIFT SWITCH 5 STEEL LOADBED 5 MANUAL LIFT BED OPERATION 5 Fig 10 Manual Bed Latch 5 Fig 11 Bed Prop Rod 5 ELECTRIC LIFT BED OPERATION 5 Fig 12 Electric Lift Switch 6 PLASTIC LOADBED 6 MANUAL LIFT BED OPERATION 6 Fig 13 Manual Bed Latch 6 TAILGATE OPERATION 6 Fig 14 Gas Strut 7 ELECTRIC LIFT BED OPERATION 7 Fig 15 Electric Lift S...

Page 6: ... Level 18 LUBRICATION 18 Fig 23 Add Check and Drain Axle Lubricant 19 Fig 24 Lubrication Points 19 PDS SYSTEM TEST 19 HARDWARE 19 Fig 26 Torque Specifications and Bolt Grades 20 CAPACITIES AND REPLACEMENT PARTS 19 Fig 25 Capacities and Replacement Parts 19 BATTERIES AND CHARGING 19 SAFETY 19 BATTERY 20 BATTERY MAINTENANCE 21 At Each Charging Cycle 21 Monthly 21 Electrolyte Level and Water 21 Fig 2...

Page 7: ...ABLE OF CONTENTS Owner s Manual and Service Guide JACOBSEN 1000 29 LIMITED WARRANTIES 33 DOMESTIC WARRANTY 34 INTERNATIONAL WARRANTY 35 DECLARATION OF CONFORMITY EUROPE ONLY 37 LABELS AND PICTOGRAMS Appendix A ...

Page 8: ...Page vi TABLE OF CONTENTS Owner s Manual and Service Guide ...

Page 9: ...ED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E Z GO I am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dea...

Page 10: ...no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Always read and observe all warnings and operation instruction labels affixed to the vehicle Alway...

Page 11: ...ons that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic Always test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Always replace damaged or missing wa...

Page 12: ...Owner s Manual and Service Guide SAFETY INFORMATION Page x Notes ...

Page 13: ...on which affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 4 3 3 As required under paras 4 3 1 or 4 3 2 the manufacturer sha...

Page 14: ...vious experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were ...

Page 15: ...g brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arranged loads When handling off center loads which...

Page 16: ...luids for cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use l Brakes steering mechanisms speed and direc tional control mechanisms warning devices lights gov ernors guards and safety devices shall be inspected regularly and maintained in a safe operating ...

Page 17: ...he chance of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydrogen gas is generated in the charging cycle of bat teries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings ne...

Page 18: ...not damaged and is inserted into a grounded receptacle The power AC cord is equipped with a grounded plug do not attempt to pull out cut or bend the ground post The charging DC cord is equipped with a polarized con nector which fits into a matching receptacle on the vehi cle The power AC cord is equipped with a grounded plug Do not attempt to remove cut or bend the ground post On board Charger The...

Page 19: ... direction selector is shifted before the vehicle comes to a complete stop a warning beeper will activate Located on the seat support panel or the dash panel this lever or switch permits the selection of either F for ward R reverse or neutral the position between for ward and reverse Vehicle should be left in neutral when unattended Ref Fig 6 on page 3 STATE OF CHARGE METER Located in the dash the...

Page 20: ...n Tow Maintenance switch to the Tow Maintenance position Failure to do so will damage the controller or motor Before disconnecting or connecting a battery or any other wir ing move the Run Tow Maintenance switch to the Tow Mainte nance position After connecting a battery or any other wiring wait a minimum of 30 seconds before moving the Run Tow Maintenance switch to the Run position The PDS vehicl...

Page 21: ...he edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards Before operating loadbed check to ensure no one is behind the vehicle 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 Never fill a ga...

Page 22: ... to the edge of a drop off such as a loading dock or 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 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 Never fill a gas c...

Page 23: ...errain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in designated areas and avoid extremely rough terrain Maintain a safe speed when driving down hill Use service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control To prevent los...

Page 24: ...the above option numbers Regenerative Braking To prevent the possibili ty of loss of control that could cause severe inju ry or death use service brake to control speed The PDS system is not a substitute for the service brake PDS models are equipped with a regenerative motor control system Example If all of the following events occur a the vehicle is being driven down a slope b the vehicle attempt...

Page 25: ...em senses that the accelerator pedal is depressed power applied to motor b the brake is engaged so as to prevent vehicle motion the PDS system will sense a stalled motor condition and remove power from the motor When the brake pedal is released the vehicle will roll backwards slightly before power is returned to the motor High Pedal Disable Feature High pedal disable prevents undesired acceleratio...

Page 26: ...loss of control is costly is consid ered abuse and will not be covered under warranty LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illus trates and explains pictograms that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle SUN TOP AND WINDSHIELD The sun top does not provide pro...

Page 27: ...st Qty Required Floor jack 1 Jack stands 4 Chocks 4 Some servicing operations may require the front wheels the rear wheels or the entire vehicle be raised To reduce the possibility of severe injury or death from a vehicle falling from a jack Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the veh...

Page 28: ...d is to use a commercial tire plug Tire plug tools and plugs are available at most automotive parts outlets and have the advan tage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufact...

Page 29: ...dge of the taillight and remove lens Install replacement bulb and replace lens FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new auto motive type fuse Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department Fig 18 Wheel Installation Fig 19 Headlight ...

Page 30: ...is in a no load condition Wear eye protection when working on the vehicle Use extra care when work ing around batteries or using sol vents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl tape to reduce the possibility of a dropped ...

Page 31: ...enance lift or remove seat For major repair refer to appropriate Tech nician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information SERIAL NUMBER PLATE LOCATION The serial number and manufacture date code label are on the vehicle One is placed on the body below the front driver side o...

Page 32: ...bent rims missing or loose lug nuts MONTHLY 20 HOURS includes items listed in previous table the following BATTERIES Clean batteries terminals See BATTERY CLEANING Check charge condition and all connections WIRING Check all wiring for loose connections and broken missing insulation CHARGER RECEPTACLE Clean connections keep receptacles free of dirt and foreign matter ACCELERATOR Check for smooth mo...

Page 33: ...es installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latch ing the parking brake to eliminate different pedal pres sures and to include the affects of linkage mis adjustment FRONT SPRINGS Check for loose hardware cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear align if required PARK BRAKE Check for bent binding linka...

Page 34: ...with hydraulic front disc brakes check master cylinder fluid annually or if there is a decrease in braking effectiveness Inspect components for damage or wear It is unlikely that fluid will need to be added unless there is a leak in the system Raise the front of the vehicle See raising the vehicle Remove passenger side wheel tire Carefully wipe off dirt and debris from master cylinder and cap befo...

Page 35: ...Manual for specific torque values Generally three grades of hardware are used in the vehi cle Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head Unmarked hardware is Grade 2 Ref Fig 26 on page 20 CAPACITIES AND REPLACEMENT PARTS BATTERIES AND CHARGING SAFETY Always observe the following warnings when working on or n...

Page 36: ...the possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe personal injury or death BATTERY A battery is defined as two dissimilar metals immersed in an acid If the acid is absent or if the metals are not dis similar a battery has not been created The batteries most commonly used in these vehicles are lead acid A battery does not store electricity...

Page 37: ...ual importance is too much water which will result in electrolyte being forced out of the battery due to gassing and the increase in volume of the electrolyte that results from the charging cycle Do not overfill batteries The charging cycle will expel electrolyte and result in component damage A battery being charged will gas with the majority of the gassing taking place at the end of the charging...

Page 38: ...o clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbon ate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle The solution should consist of the ingredients sho...

Page 39: ...losion Use care to connect the battery wires as shown Ref Fig 31 on page 23 Tighten the battery post hardware to 50 70 in lbs 6 8 Nm torque Protect the battery terminals and battery wire terminals with a commercially available protective coating Prolonged Storage Battery charger controller and other electronic devices need to be discon nected since they will contribute to the premature discharge o...

Page 40: ...in all cells must be at the rec ommended level and cover the plates The charging must take place in an area that is well ventilated and capable of removing the hydro gen gas that is generated by the charging pro cess A minimum of five air exchanges per hour is recommended The charging connector components are in good condition and free from dirt or debris The charger connector is fully inserted in...

Page 41: ...ting batteries Specific gravity is the measurement of a liquid that is compared to a baseline The baseline is water which is assigned a base number of 1 000 The concentration of sulfuric acid to water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully charged bat tery will test at 1 275 1 280 while a discharged batt...

Page 42: ...ry ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells are within fifty points of each other Since the hydrometer test is in response to a vehicle exhibiting a performance problem the vehicle should be recharged and the test repeated If the results indicate a weak cell the battery or batteries should be removed a...

Page 43: ...Page 27 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS ...

Page 44: ...rvice park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant with four drink holders SEATING Formed fabric backed vinyl covers over cushion foam Seating for...

Page 45: ... with clipboard BRAKES Dual rear wheel mechanical self adjusting drum brakes Combination service park brake with automatic parking brake release accelerator kick off FRONT SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers REAR SUSPENSION Heavy duty leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant with...

Page 46: ... Dimensions JACOBSEN 800 JACOBSEN 1000 103 in 262 cm Rear 38 in 97 cm Front 38 in 97 cm 35 in 89 cm 10 in 25 cm 47 in 119 cm 47 in 119 cm 66 in 168 cm 111 in 282 cm 11 5 in 29 cm 18 in 46 cm 42 5 in 108 cm 50 in 127 cm Rear 38 in 97 cm Front 38 in 97 cm 47 in 119 cm 77 in 196 cm ...

Page 47: ...Service Guide Fig 37 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEARANCE DIAMETER JACOBSEN 800 19 ft 5 8 m JACOBSEN 1000 22 ft 6 7 m ...

Page 48: ...Page 32 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Notes ...

Page 49: ...Page 33 Owner s Manual and Service Guide WARRANTY LIMITED WARRANTIES ...

Page 50: ... 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 ...

Page 51: ...R FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHICLE BATTERY CHARGER No agent employee or representative of E Z GO or any person has any authority to bind E Z GO to any other agreement representation or warranty concerning the go...

Page 52: ...Page 36 Owner s Manual and Service Guide WARRANTY Notes ...

Page 53: ...Page 37 Owner s Manual and Service Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY ...

Page 54: ...Page 38 Owner s Manual and Service Guide DECLARATION OF CONFORMITY ...

Page 55: ...Page 39 DECLARATION OF CONFORMITY Owner s Manual and Service Guide NOT AVAILABLE AT TIME OF PUBLICATION ...

Page 56: ...Page 40 Owner s Manual and Service Guide DECLARATION OF CONFORMITY Notes ...

Page 57: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS ...

Page 58: ...lanation Of Pictogram 30 See Following Pages For Explanation Of Pictogram 1 25 26 43 44 WARNING Keep entire body inside car 27653G01 See Following Pages For Explanation Of Pictogram 49 74821G02 For 600 lb Cap 74821G03 For 800 lb Cap 74821G01 For 500 lb Cap 35980G02 For 500 lb Cap Metal Bed 35980G03 For 600 lb Cap Metal Bed 35980G04 For 800 lb Cap Metal Bed See Following Pages For Explanation Of Th...

Page 59: ...cm LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL MAX xxx lbs xxx kg SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED P P DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED x in x in xx cm xx cm MAX LOAD MAX LOAD XXX LBS XXX LBS XXX KG XXX KG WARNING MAXIMUM LOAD CENTER OF GRAVITY KEEP LOAD AS...

Page 60: ...NNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY LOW OIL PRESSURE WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO SMOKING HO...

Page 61: ...SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD P N TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL ON OFF KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED ON POSITION OFF POSITION HEADLIGHTS UNLOCKED LOCKED DIFFEREN...

Page 62: ...Appendix A 6 Owner s Manual and Service Guide LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD 51 Ref Pic 1 4 ...

Page 63: ...components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care w...

Page 64: ...unications Department 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 ...

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