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Page iv

Owner’s Manual and Service Guide

TABLE OF CONTENTS

REPAIR .................................................................................................................................... 11

LIFTING THE VEHICLE .................................................................................................................................... 12

Fig. 17 Lifting the Vehicle ....................................................................................................... 12

WHEELS AND TIRES ....................................................................................................................................... 11

Tire Repair ........................................................................................................................................... 11
Wheel Installation ................................................................................................................................. 12

Fig. 18 Wheel Installation ....................................................................................................... 13

LIGHT BULB REPLACEMENT ......................................................................................................................... 12

Fig. 19 Headlight and Turn Signal Bulb Replacement ........................................................... 13
Fig. 20 Tail and Brake Light Bulb Replacement ..................................................................... 13

FUSE REPLACEMENT .................................................................................................................................... 13

TRANSPORTING VEHICLE .................................................................................................... 14

TOWING ........................................................................................................................................................... 14
HAULING .......................................................................................................................................................... 14

SERVICE AND MAINTENANCE .............................................................................................. 14

SERIAL NUMBER PLATE LOCATION ............................................................................................................. 15
PERIODIC SERVICE SCHEDULE .................................................................................................................. 16

Fig. 21 Periodic Service Schedule .......................................................................................... 16

TIRE INSPECTION ........................................................................................................................................... 17
BRAKES ........................................................................................................................................................... 17

Periodic Brake Test for Mechanical Brakes ......................................................................................... 17

Fig. 22 Typical Brake Performance Test ................................................................................ 18

HYDRAULIC FRONT DISC BRAKES ............................................................................................................... 18
REAR AXLE ...................................................................................................................................................... 18

Checking the Lubricant 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. 27 Correct Electrolyte Level  ............................................................................................ 21
Fig. 28 Water Purity Table  ..................................................................................................... 22
Fig. 29 Automatic Watering Gun  ............................................................................................ 22

Battery Cleaning ................................................................................................................................... 22
Battery Replacement ............................................................................................................................ 22

Fig. 30 Preparing Acid Neutralizing Solution .......................................................................... 23
Fig. 31 36V Battery Connections ........................................................................................... 23
Fig. 32 48V Battery Connections ........................................................................................... 23

Prolonged Storage ............................................................................................................................... 23

Fig. 33 Freezing Point of Electrolyte ...................................................................................... 24

BATTERY CHARGING ..................................................................................................................................... 24

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