Cushman LSV 800 Guide

Service Parts Manual
ELECTRIC POWERED VEHICLE
LSV 800
647699-AC
REVISED SEPTEMBER 2019ISSUED AUGUST 2015

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647699 Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC POWERED VEHICLE
LSV 800
STARTING MODEL YEAR 2016
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

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NOTES
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 such as sand. 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.

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TABLE OF CONTENTS
647699 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
FRAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1
TRUCK BED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q - 1

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NOTES
Service Parts Manual647699 Service Parts Manual

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647699 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
•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.
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 647699 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 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

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647699 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
74 BARLEY GOLD
75 OASIS GREEN
76 JAVA BROWN
79 JACOBSEN ORANGE 172
HOW TO USE THE SERVICE PARTS MANUAL

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ACCELERATOR
1ACCELERATOR PEDAL ASSEMBLY includes items 2 - 14
Acclerator Pedal
Harness
3
11
16
2
8
4
14
10
6
9
5
12
13
6
15
Front of Vehicle
Front of Vehicle
7

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.
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647699 Service Parts Manual
ACCELERATOR
1 671889 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 2 - 14) .................. 1
2 * ACCELERATOR PEDAL BRACKET ......................................................... 1
3 * ACCELERATOR PEDAL ........................................................................... 1
4 671848 ROTARY POSITION SENSOR.................................................................. 1
5 686390 SOCKET HEAD BOLT, M5 - .8 X 35MM LG.............................................. 2
6 * FLANGED BUSHING, 16MM X 12 MM ..................................................... 2
7 * ACCELERATOR PIVOT SHAFT................................................................ 1
8 600683 HEAVY DUTY SPIROL PIN, 4 MM X 26 MM............................................. 1
9 * TORSION SPRING, 4.5 MM DIA............................................................... 1
10 604097 BUMPER ................................................................................................... 1
11 610529 ACCELERATOR PEDAL COVER.............................................................. 1
12 620030 SOCKET HEAD BOLT, M5 - .8 X 15 MM LG............................................. 2
13 653242 PEDAL SWITCH........................................................................................ 1
14 672457 SENSOR SPACER .................................................................................... 1
15 649803 PAN HEAD TORX SCREW, M6 - 2.65 X 25 MM LG........................................ 3
16 614393 ACCELERATOR PEDAL INSERT.................................................................... 1

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Notes:
ACCELERATOR

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647699 Service Parts Manual
Notes:
ACCELERATOR

Page B-1 647699 Service Parts Manual
BATTERY CHARGER
5
4
1
2
CHARGER CORD KIT includes item 12
11
4
7
3
5
6
Front of Vehicle
9
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.
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647699 Service Parts Manual
BATTERY CHARGER
1 632862 48V ON-BOARD BATTERY CHARGER WITH DC TO DC CONVERTER ...... 1
2 613145 FRONT CHARGER BRACKET........................................................................ 1
3 649804 BUTTON HEAD TORX SCREW, M8 - 3.50 X 30 MM LG................................ 1
4 601476 FLANGED LOCK NUT, M6 - 1 ......................................................................... 4
5 606264 FLANGED HEX HEAD BOLT, M6 - 1 X 20 MM LG.......................................... 4
6 613148 CHARGER SUPPORT BRACKET................................................................... 1
7 602572 PAN HEAD TORX TAPTITE BOLT, M10 - 1.5 X 25 MM LG............................. 1
8 610536 CHARGER RECEPTACLE .............................................................................. 1
9 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG ................................................................ 4
10
11 652608 CHARGER CORD KIT, 5 METER DC CORD (INCLUDES ITEM 12).............. 1
12 652503 ON BOARD CHARGER CORD, 5 METER DC CORD ............................ 1

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Notes:
BATTERY CHARGER

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647699 Service Parts Manual
Notes:
BATTERY CHARGER

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BODY
Front of Vehicle
3
1
14
29
22
11
15
7
20
16
17
23 24
19
8
12
25 26
COWL WITH LIGHTS includes item 2
2COWL includes item 3
6INSTRUMENT PANEL ASSEMBLY includes items 7 - 8
10 STRUT COVER ASSEMBLY includes items 11 - 12
4
27
21
18
5

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.
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647699 Service Parts Manual
BODY
1 645759G01XX COWL WITH LIGHTS (INCLUDES ITEM 2)
(see COLOR CODES in HOW TO USE Section) ............................................ 1
2 645759G00XX COWL (INCLUDES ITEM 3)
(see COLOR CODES in HOW TO USE Section) ...................................... 1
3 645759G0024 FRONT COWL .................................................................................... 1
4 619135 DECAL ............................................................................................................. 1
5 601634 FRONT SPLASH GUARD
(FOR VEHICLES MANUFACTURED BEFORE JULY 21, 2019) ..................... 1
6 602387 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 7 - 8)........................ 1
7 600240 INSTRUMENT PANEL............................................................................... 1
8 602184 SPRING CLIP............................................................................................ 1
9
10 602388 STRUT COVER ASSEMBLY (INCLUDES ITEMS 11 - 12) .............................. 1
11 602386 STRUT COVER ......................................................................................... 1
12 602100 SPRING CLIP............................................................................................ 1
13
14 607533 GLOVE BOX (DRIVER SIDE).......................................................................... 1
15 607131 GLOVE BOX (PASSENGER SIDE) ................................................................. 1
16 600241 BALL HOLDER INSERT (PASSENGER SIDE) ............................................... 1
17 600243 BALL HOLDER INSERT (DRIVER SIDE) ........................................................ 1
18 16816G2 RATCHET RIVET, 1/4" X 3/4" LG
(FOR VEHICLES MANUFACTURED BEFORE JULY 21, 2019) ..................... 3
19 649803 PAN HEAD TORX SCREW, M6 - 2.65 X 25 MM LG........................................ 4
20 70200G01 TRUSS HEAD TORX SCREW, 3/8" - 16 X 3/4" LG ......................................... 2
21 16816G2 RATCHET RIVET, .25" X .887"
(FOR VEHICLES MANUFACTURED AFTER JULY 21, 2019) ........................ 1
22 610621 INSTRUMENT PANEL TRIM (OPENING FOR KEY SWITCH,
SPEEDOMETER AND LIGHT SWITCH)
(FOR VEHICLES MANUFACTURED BEFORE JULY 22, 2019) ..................... 1
23 604066 FLAT WASHER, M10 ....................................................................................... 4
24 602572 PAN HEAD TAPTITE BOLT, M10 - 1.5 X 25 MM LG ....................................... 4
25 609416 FRONT REFLEX REFLECTOR (PASSENGER SIDE) .................................... 1
26 609417 FRONT REFLEX REFLECTOR (DRIVER SIDE)............................................. 1

Page C-3 647699 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.
BODY
27 683595 FRONT COMPONENT MOUNT PLATE
(FOR VEHICLES MANUFACTURED AFTER JULY 21, 2019)........................ 1
28
29 698015 INSTRUMENT PANEL TRIM
(FOR VEHICLES MANUFACTURED AFTER JULY 22, 2019)........................ 1