Cushman HAULER 800X Guide

Service Parts Manual
Hauler 800X
ELECTRIC POWERED VEHICLE
REVISED OCTOBER 2018ISSUED MARCH 2015
643789-AA

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC POWERED UTILITY VEHICLE
HAULER 800X
STARTING MODEL YEAR 2015
CALIFORNIA Proposition 65 Warning
WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which
contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth
defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new
and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates,
all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.
DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual,
without obligation to include these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically E-Z-GO, and therefore is subject to change without notice.
E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL: PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906-3852

Page ii Service Parts Manual
GENERAL INFORMATION
This vehicle has been designed and manufactured in the United States of America (USA).
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.
Failure to properly maintain batteries may void the warranty. Refer to the battery manual for
instructions on the proper maintenance and care of the batteries.
BATTERY PROLONGED STORAGE
Batteries self-discharge over time. The rate of self-discharge varies depending on the
ambient temperature, the age and condition of the batteries.
Fully charged batteries 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 may be left connected to the vehicle to maintain a full charge on the
batteries, provided the charger is plugged into an active electrical source. If power to the
electrical source is disconnected or interrupted, the battery charger will continue to check
the charge on the battery pack. This will draw power from the battery pack and eventually
drain the batteries if power is not restored in a timely manner.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Check and maintain the proper fluid level in all battery cells during the storage period.
Proper fluid level is required for maximum battery performance.
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 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1
ELECTRONIC SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1
FRONT SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
TRUCK BED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1
ROLL OVER PROTECTIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q - 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
•APPENDIX
The first section, GENERAL INFORMATION, contains the following information:
•WARRANTY INFORMATION
•GENERAL INDEX
•HOW TO USE THE SERVICE PARTS MANUAL
The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your
vehicle.
The third section, APPENDIX, contains a listing of specialty products and accessories.
USE OF THE MANUAL
To use this manual, consult the GENERAL INDEX 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 of your vehicle and its
model number be supplied to Service Parts when ordering any replacement components.
Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its loca-
tion) and note the complete number shown on the plate.
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 General Index 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
(continued on right hand page
if required) 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
81,8684,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 - Includes 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

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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
79 JACOBSEN ORANGE 172
HOW TO USE THE SERVICE PARTS MANUAL

Page A-1 643789 Service Parts Manual
ACCELERATOR
PEDAL BOX ASSEMBLY includes items 2 - 33
34
35
36
42
21
24
20
22
19
18
27
26
7
6
41 2
3
17
16
15
14
1
PEDAL HARNESS 48V ASSEMBLY includes items 30, 31
29
ACCELERATOR PEDAL ASSEMBLY includes items 34 - 36
33
11
12
5
10
9
4
29 30
4
To Harness
from Direction
Selector
BLK
WHT
RED
GRN
Part of
Frame

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
643789 Service Parts Manual
ACCELERATOR
1 613163 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 PHILLIPS SCREW (SS), #8 - 32 X 3/4” LG ..................... 2
6 25861G01 MICRO SWITCH ...................................................................................... 1
7 01050G01 PAN HEAD TORX SCREW, #4 - 20 X 5/8” LG......................................... 2
8
9 25854G01 INDUCTIVE THROTTLE SENSOR.......................................................... 1
10 00983G01 SELF THREADING NUT, .187" DIA......................................................... 2
11 602484 PLUNGER AND SLEEVE ASSEMBLY..................................................... 1
12 28444G01 ACCELERATOR ROD CAM..................................................................... 1
13
14 17677G1 SPRING RETAINER................................................................................. 1
15 17979G1 BUSHING, .75” DIA.................................................................................. 1
16 73046G01 COMPRESSION SPRING........................................................................ 1
17 17677G2 SPRING RETAINER, 3/8” I.D................................................................... 1
18 73332G01 ACCELERATOR ROD.............................................................................. 1
19 00532G4 HEX NUT, 1/4” - 20................................................................................... 1
20 10385G4 CLEVIS YOKE (ADJUSTABLE)................................................................ 1
21 10386G3 CLEVIS PIN, 5/16” X 13/16” LG............................................................... 1
22 17838G1 NYLON BUSHING, .37” O.D. X.31” I.D.................................................... 3
23
24 10387G3 COTTER PIN, 3/32” X 3/4” LG ................................................................. 1
25
26 74432G01 PEDAL PIVOT PIN................................................................................... 1
27 12064G6 PUSH NUT, 5/16” ..................................................................................... 1
28
29 620418 PEDAL HARNESS 48V (INCLUDES ITEMS 30, 31)................................ 1
30 17313G1 FLEX LOOM, 3/8” X 6” LG ................................................................. 1
31 17618G1 NYLON CLAMP (NOT ILLUSTRATED) .............................................. 2

Page A-3 643789 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
33 25799G03 ACCELERATOR PEDALASSEMBLY (INCLUDES ITEMS 34 - 36)......... 1
34 652824 ACCELERATOR PEDAL.................................................................... 1
35 27512G01 ACCELERATOR PEDAL PAD............................................................ 1
36 16409G1 OVAL RIVET, 3/16" X 7/16" LG .......................................................... 6
37
38
39
40
41 00715G2 HEX WASHER HEAD BOLT, 5/16” - 18 X 3/4” LG.......................................... 4
42 70135G01 PEDAL PIVOT COVER ................................................................................... 1

Page A-4
643789 Service Parts Manual
Notes:
ACCELERATOR

Page B-1 643789 Service Parts Manual
BATTERY CHARGER
12
67

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
643789 Service Parts Manual
BATTERY CHARGER
1 635669 48V BATTERY CHARGER, 3 METER DC CORD ........................................... 1
2 635670 48V BATTERY CHARGER, 5.5 METER DC CORD ........................................ 1
3 605834 NYLON CLAMP, 36" (NOT ILLUSTRATED) .................................................... 1
4
5
6 622419 WORLD CHARGER, 48V, 3 METER DC CORD ............................................ 1
7 622667 WORLD CHARGER, 48V, 5.5 METER DC CORD ......................................... 1
8 605834 NYLON CLAMP 36" (NOT ILLUSTRATED) ..................................................... 2

Page B-3 643789 Service Parts Manual
BATTERY CHARGER
To BL +
To BL -
1
10
12
4
4
11
3
9
8
Front of Vehicle
7ON-BOARD CHARGER ASSEMBLY includes items 8 - 12

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-4
643789 Service Parts Manual
BATTERY CHARGER
1 800706 FLANGED LOCK NUT, 1/4" - 20...................................................................... 2
2
3 631543 CHARGER INTERLOCK JUMPER.................................................................. 1
4 17618G1 NYLON CLAMP ............................................................................................... 3
5
6
7 638578 ON-BOARD CHARGER ASSEMBLY (INCLUDES ITEMS 8 - 12)................... 1
8 637104 CHARGER BRACKET............................................................................... 1
9 632744 ON-BOARD CHARGER, 48V.................................................................... 1
10 16705G3 TRUSS HEAD MACHINE SCREW (SS), 1/4" - 20 X 3/4" LG ................... 4
11 11027G2 FLANGED LOCK NUT, 1/4" - 20 ............................................................... 4
12 600462G03 AC CORD, SHIELDED, 6’ 7" LG ............................................................... 1

Page B-5 643789 Service Parts Manual
Notes:
BATTERY CHARGER

Page B-6
643789 Service Parts Manual
Notes:
BATTERY CHARGER

Page C-1 643789 Service Parts Manual
BODY
35
36
37
1
6
7
8
9
10
30
13
24 31
14
23
26
28
27
15
22
20
21
21
16
18
17
19
2
3
4
5
Front of Vehicle