Cushman HAULER 800 Guide

ISSUED FEBRUARY 2018
HAULER 800
Service Parts Manual
666414–F
REVISED MAY 2019

CALIFORNIA Proposition 65
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of California to cause can-
cer and birth defects or other reproductive harm. To minimize exposure, avoid
breathing exhaust, do not idle the engine except as necessary, service your
vehicle in a well-ventilated area and wear gloves or wash your hands fre-
quently when servicing your vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.

Page i
666414 Service Parts Manual
SERVICE PARTS MANUAL
GASOLINE POWERED VEHICLE
HAULER 800
STARTING MODEL YEAR 2018
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 (TSV) pro-
hibits and disclaims 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]
[email protected]

Page ii
GENERAL INFORMATION
666414 Service Parts Manual
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
Batteries self-discharge over time. The rate of self-discharge varies depending on the ambi-
ent 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).
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 contain-
ers with absorbent material such as sand. Dispose in accordance with local, state and fed-
eral regulations for acid and lead compounds. Contact local and/or state environmental
officials regarding disposal information.

SECTION Page No.
Service Parts Manual
TABLE OF CONTENTS
Page iii
666414 Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1
CARBURETOR AND CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1
DIRECTION SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1
ENGINE AND MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M - 1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R - 1
STATER GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S - 1
TRUCK BED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T - 1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U - 1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-1
DECALS AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .W - 1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X - 1

NOTES
Page iv 666414 Service Parts Manual

Page v
HOW TO USE THE SERVICE PARTS MANUAL
666414 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.
The third section, APPENDIX, contains a listing of specialty products and accessories.
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENTS 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.

Page vi
HOW TO USE THE SERVICE PARTS MANUAL
666414 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 Contents 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: Confirm the part selected is correct by verifying it with the illustration.
If an asterisk (*) appears in the part number column on the parts list page, read upward until a part number is found. The
part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates 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
HOW TO USE THE SERVICE PARTS MANUAL
666414 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

666414 Service Parts Manual
Page A-1
ACCELERATOR
To Governor
3
8
9
10
28
27
29 1
12
13
14
2
11
31
20
4
15
16
17
18
21
22
23
24
19
17 25
3
3
5
7
ACCELERATOR PEDAL BOX ASSEMBLY includes items 2 - 26
26
ACCELERATOR PEDAL ASSEMBLY includes items 27 - 29
Front of Vehicle
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
ACCELERATOR
666414 Service Parts Manual
1 606990 ACCELERATOR PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 26).......... 1
2 74432G01 PEDAL PIVOT PIN .................................................................................... 1
3 17838G1 NYLINER BUSHING.................................................................................. 3
4 12064G6 PUSH NUT ................................................................................................ 1
5 10386G3 CLEVIS PIN, 5/16" X 13/16"...................................................................... 1
6
7 10387G3 COTTER PIN, 3/32" X 3/4"........................................................................ 1
8 01051G01 PAN HEAD PHILLIPS SCREW, #8 - 16 X 1/2" LG.................................... 4
9 25853G03 PEDAL BOX AND COVER ........................................................................ 1
10 00684G6 TRUSS HEAD PHILLIPS SCREW, #8 - 16 X 1/2" LG............................... 2
11 652241G03 ACCELERATOR PEDAL BRACKET ......................................................... 1
12 25861G01 MICRO SWITCH, V-TYPE......................................................................... 1
13 01050G01 PAN HEAD TORX SCREW, #4 - 20 X 5/8" LG.......................................... 2
14 72201G04 PEDAL BOX HARNESS............................................................................ 1
15 608608 ACCELERATOR CABLE ........................................................................... 1
16 10385G4 CLEVIS YOKE........................................................................................... 1
17 00532G4 HEX NUT, 5/16" - 24.................................................................................. 2
18 72072G01 ACCELERATOR ROD............................................................................... 1
19 17677G2 SPRING RETAINER.................................................................................. 1
20 15126G1 LOCK NUT, 5/16" - 24 ............................................................................... 1
21 73046G01 COMPRESSION SPRING......................................................................... 1
22 17979G1 ACCELERATOR ROD BUSHING.............................................................. 1
23 17677G1 SPRING RETAINER.................................................................................. 1
24 72716G01 CAM (MICRO SWITCH) ............................................................................ 1
25 00487G3 SOCKET HEAD SCREW, 1/4" - 20 X 3/8" LG........................................... 1
26 25799G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 27 - 29).......... 1
27 652824 ACCELERATOR PEDAL..................................................................... 1
28 27512G01 ACCELERATOR PEDAL PAD............................................................. 1
29 16409G1 OVAL HEAD RIVET, 3/16” X 7/16” LG ................................................ 6
30
31 00715G2 HEX HEAD BOLT, 5/16” - 18 X 3/4” LG ........................................................... 4

666414 Service Parts Manual
Page A-3
ACCELERATOR
DO NOT TAMPER WITH OR ATTEMPT TO CHANGE THE ADJUSTMENT OF THEDO NOT TAMPER WITHOR ATTEMPTTO CHANGE THE ADJUSTMENT OF THE
GOVERNOR. GOVERNOR TAMP ERING CAN RESULT IN SERIOUS PERSONALGOVERNOR.GOVERNOR TAMPERING CAN RESULTIN SERIOUS PERSONAL
INJURY AND WILL VOID THE VEHICLE WARRANTY.INJURY AND WILL VOID THE VEHICLE WARRANTY.
608527
5
1
8
6
2
10
9
4
13
16
3
12 18
14
To Direction Selector
Shifter Cable
Rear Axle
Engine
Front of Vehicle

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-4
ACCELERATOR
666414 Service Parts Manual
1 606005 GOVERNOR BRACKET (LOWER).................................................................. 1
2 606284 GOVERNOR LINK ROD .................................................................................. 1
3 603890 GOVERNOR GUARD BRACKET .................................................................... 1
4
5 606083 GOVERNOR BRACKET (UPPER) .................................................................. 1
6 632936 GOVERNOR CABLE/DIRECTION SELECTOR BRACKET ............................ 1
7
8 606283 GOVERNOR LEVER BUSHING ...................................................................... 1
9 606421 FLANGED HEX HEAD BOLT, M6 - 1 X 30MM LG........................................... 1
10 606256 FLANGED HEX HEAD BOLT, M10 - 1.25 X 25MM LG.................................... 2
11
12 606264 FLANGED HEX HEAD BOLT, M6 - 1 X 20MM LG........................................... 1
13 73876G01 FLANGED HEX HEAD BOLT, M6 - 1 X 12MM LG........................................... 1
14 606262 FLANGED HEX HEAD BOLT, M8 - 1.25 X 16MM LG...................................... 1
15
16 450452 FLANGED HEX NUT, M6 - 1............................................................................ 1
17
18 608527 GOVERNOR WARNING LABEL...................................................................... 1

Page A-5
Notes:
ACCELERATOR
666414 Service Parts Manual

Page A-6
Notes:
ACCELERATOR
666414 Service Parts Manual

666414 Service Parts Manual
Page B-1
AIR FILTER
Carburetor
3
4
5
2
AIR CLEANER ASSEMBLY includes items 2 - 6
1
13
11
10
1
9
12
6

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
AIR FILTER
666414 Service Parts Manual
1 658941 AIR CLEANER (INCLUDES ITEMS 2 - 6) ....................................................... 1
2 659139 AIR CLEANER BODY................................................................................ 1
3 658957 AIR CLEANER COVER............................................................................. 1
4 72604G01 AIR CLEANER CLIP.................................................................................. 2
5 28463G01 AIR FILTER ELEMENT.............................................................................. 1
6 28462G01 DUST EJECTOR VALVE .......................................................................... 1
7
8
9 11391G7 HOSE CLAMP.................................................................................................. 1
10 601910 HOSE............................................................................................................... 1
11 11391G1 HOSE CLAMP.................................................................................................. 1
12 606261 FLANGED HEX HEAD BOLT, M8 - 1.25 X 20MM LG...................................... 2
13 606272 LOCK WASHER, 8 MM.................................................................................... 2

Page B-3
Notes:
AIR FILTER
666414 Service Parts Manual

Page B-4
Notes:
AIR FILTER
666414 Service Parts Manual

666414 Service Parts Manual
Page C-1
BODY
11 12
5
7
9
6
8
2
15
2
1
13
11
Front of Vehicle
19
16
20
16
21
19 20
16
16
21
18
17