Cushman HAULER 800X Guide

ISSUED JANUARY 2019
HAULER 800X ELiTE
Service Parts Manual
688549 - D
REVISED SEPTEMBER 2019

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC POWERED VEHICLE
HAULER 800X ELiTE
STARTING MODEL YEAR 2019
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed be-
yond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits
and dis-claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
TSV reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these
changes on units sold previously.
The information contained in this manual may be revised periodically by TSV, and therefore is subject to change without notice.
TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
These are the original instructions as defined by 2006/42/EC.
TO CONTACT US:
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
NORTH AMERICA:
Technical Assistance & Warranty PHONE: [phone], FAX: [phone]
Service Parts PHONE: [phone], FAX: [phone]
International: PHONE: [phone], FAX: [phone]

Page ii Service Parts Manual
GENERAL INFORMATION
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 code.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
All 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).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, place residue in acid-resistant
containers with absorbent material, sand or earth and dispose of in accordance with local,
state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

Page iii
TABLE OF CONTENTS
Service Parts Manual
SECTION Page No.
HOW TO USE THE SERVICE PARTS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
BATTERY CHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1
ELECTRONIC SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1
DECALS AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R - 1

Page iv
NOTES
Service Parts ManualService Parts Manual

Page v
Service Parts Manual
This manual is divided into several sections:
•GENERAL INFORMATION
•ILLUSTRATED PARTS BREAKDOWN
The first section, GENERAL INFORMATION, contains the following information:
•WARRANTY INFORMATION
•TABLE OF CONTENT
•HOW TO USE THE SERVICE PARTS MANUAL
The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your
vehicle.
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENT to locate the information or illustration required.
Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation and then contact the Service Parts Department. It is important that the serial number or VIN of your vehicle and
the model name be supplied to Service Parts when ordering any replacement components.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the Table of Content and select the most
appropriate title.
•Turn to the page number indicated and locate the desired part on the illustration.
•From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying
description for specific information regarding the part.
2. IF YOU KNOW THE PART NUMBER
•Locate the part number or description in the appropriate column on the parts list page.
NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on
the illustrated page.
Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted
is not available for purchase.
NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
Title Title
Left hand
illustration page Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74
70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,86
84,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 -Incl
udes Items 71 - 74
81- Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - Includes Items 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

Page vii
Service Parts Manual
3. COLOR CODE FOR BODY COMPONENTS
The last two digits of the part number for the body part will denote the color code, locate the part number for the cowl,
rear body, seat pod, side panel or seat wrap then locate your color in the list below, replace the last ** or XX with the two
digit color code.
CODE # DESCRIPTION
11 BLACK
19 PATRIOT BLUE PEARL
20 INFERNO RED METALLIC
26 STEEL BLUE PEARL
31 METALLIC CHARCOAL
35 SAFETY YELLOW
36 IVORY
37 FOREST GREEN
38 BRIGHT WHITE
39 FLAME RED
41 ELECTRIC BLUE
42 PLATINUM
43 BURGUNDY
44 ALMOND
51 SUNBURST ORANGE
52 BRITISH RACING GREEN
69 MONSTER GREEN
72 MATTE BLACK
73 MATTE GREEN
74 BARLEY GOLD
75 OASIS GREEN
76 JAVA BROWN
78 REAL TREE XTRA DIPPED
79 JACOBSEN ORANGE 172
82 NEW HOLLAND BLUE
HOW TO USE THE SERVICE PARTS MANUAL

Page A-1 688549 Service Parts Manual
ACCELERATOR
37
Front of Vehicle
32
33
28
22
29
30
22
24 20
15
14
26
25
36
2
3
4
10
11
21
19
18 17
16
4
5
7
8
To harness
from direction
selector
Part of Frame
1Pedal Box Assembly includes items 2 - 33
27 Accelerator Pedal Assembly includes items 28 - 30

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page A-2
688549 Service Parts Manual
ACCELERATOR
1 654643 Pedal Box Assembly (Includes Items 2 - 33).................................................... 1
2 652241G03 Accelerator Pedal Bracket......................................................................... 1
3 01051G01 Pan Head Phillips Screw, #8 - 10 x 1/2" Lg............................................... 4
4 25853G01 Pedal Box and Cover................................................................................. 1
5 00684G6 Truss Head Screw (SS), #8 - 32 x 3/4" Lg................................................. 2
6
7 01050G02 Pan Head Torx Screw, #4 - 20 x 5/8" Lg.................................................... 2
8 28444G01 Accelerator Rod Cam ................................................................................ 1
9
10 00983G01 Self Threading Nut, .38" ............................................................................ 2
11 602484 Plunger...................................................................................................... 1
12
13
14 17677G1 Spring Retainer.......................................................................................... 1
15 17979G1 Bushing, .75" x 2" Lg ................................................................................. 1
16 73046G01 Compression Spring.................................................................................. 1
17 17677G2 Spring Retainer, 3/8".................................................................................. 1
18 73332G01 Accelerator Rod......................................................................................... 1
19 00532G4 Hex Nut, 5/16" - 24.................................................................................... 1
20 10385G4 Clevis Yoke (Adjustable)............................................................................ 1
21 10386G3 Clevis Pin, 5/16" x 13/16" Lg ..................................................................... 1
22 17838G1 Nylon Bushing, .37" x .31" Lg.................................................................... 3
23
24 10387G3 Cotter Pin, 3/32" x 3/4" Lg ......................................................................... 1
25 74432G01 Pedal Pivot Pin .......................................................................................... 1
26 12064G6 Push Nut, 5/16".......................................................................................... 1
27 25799G03 Accelerator Pedal Assembly (Includes Items 28 - 30)............................... 1
28 16409G1 Oval Rivet, 3/16" x 7/16" Lg................................................................ 6
29 27512G01 Accelerator Pedal Pad ........................................................................ 1
30 652824 Accelerator Pedal................................................................................ 1
31

Page A-3 688549 Service Parts Manual
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
ACCELERATOR
32 654644 Pedal Harness........................................................................................... 1
33 654645 Grommet (Rubber).................................................................................... 1
34
35
36 00715G2 Hex Head Bolt, 5/16" - 18 x 3/4" Lg................................................................. 4
37 70135G01 Pedal Pivot Cover............................................................................................ 1

Page A-4
688549 Service Parts Manual
Notes:
ACCELERATOR

Page B-1 688549 Service Parts Manual
BATTERY CHARGER
1
3
2

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-2
688549 Service Parts Manual
BATTERY CHARGER
1 653213 Battery Charger, 51V, 3 Meter Chord.............................................................. 1
2 653216 Battery Charger, 51V, 5.5 Meter Chord........................................................... 1
3 657667 Battery Charger Paddle................................................................................... 1

Page B-3 688549 Service Parts Manual
Notes:
BATTERY CHARGER

Page B-4
688549 Service Parts Manual
Notes:
BATTERY CHARGER

Page C-1 688549 Service Parts Manual
BODY
11 12
5
7
9
6
8
2
18
17
19 20
15
19
16
20
16
21 2
1
13
11
Front of Vehicle
16
16
21
22
25 24
23

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page C-2
688549 Service Parts Manual
BODY
1 648566G00XX Cowl (See COLOR CODE in HOW TO USE section) ..................................... 1
2 71055G02 Rivet (Aluminum), 3/16” x 1.18" Lg ................................................................. 4
3
4
5 613273 Front Fascia .................................................................................................... 1
6 654275 Mounting Bracket ............................................................................................ 1
7 00414G6 Hex Head Bolt, 1/4" - 20 x 3/4" Lg .................................................................. 2
8 14390G4 Lock Nut, 1/4" - 20 .......................................................................................... 2
9 15058G1 Rivet (Aluminum), 3/16" x .45" Lg ................................................................... 2
10
11 01038G01 Hex Washer Head Swageform Screw, 1/4" - 20 x .70" Lg .............................. 4
12 16469G1 Fender Washer ............................................................................................... 2
13 654276 Front Fascia Mounting Brace .......................................................................... 1
14
15 662022 Brush Guard .................................................................................................... 1
16 652311 Round Head Torx Bolt, 5/16" - 18 x 3" Lg ....................................................... 4
17 75048G03 Spacer, .328" I.D. x .75" O.D. x 1.5" Lg .......................................................... 2
18 75048G04 Spacer, .328'' I.D. x .75'' O.D. x 1'' Lg.............................................................. 4
19 00559G8 Flat Washer, .349" I.D. x .692" O.D. x .066" Lg ............................................... 4
20 00441G2 Hex Head Bolt, 5/16'' - 18 x 3 1/4'' Lg.............................................................. 2
21 00440G6 Hex Head Bolt, 5/16'' - 18 x 2 3/4'' Lg.............................................................. 2
FOR VEHICLES FITTED WITH CAB
22 662016 Brush Guard .................................................................................................... 1
23 600530 Button Head Torx Bolt, M10 - 1.5 x 25mm Lg .................................................. 4
24 603823 Flat Washer, M10 x 22mm x 2.5mm ................................................................ 4
25 600525 Flanged Lock Nut, M10 - 15 ............................................................................ 4

Page C-3 688549 Service Parts Manual
BODY
1
5
67
10
9
9
8
2
3
4
Front of Vehicle