Electric Service Parts Manual

Transcription

1 Electric ISSUED AUGUST 2011 REVISED APRIL 2014

2

3 SERVICE PARTS MANUAL ELECTRIC UTILITY VEHICLE HAULER 800 HAULER 1000 STARTING MODEL YEAR 2012 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: , FAX: SERVICE PARTS PHONE: GET-EZGO ( ), FAX: INTERNATIONAL: PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA Page i

4 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) parts may void the warranty. Overfilling of batteries may void the warranty. 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). As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL Vii ACCELERATOR A - 1 BATTERY CHARGER B - 1 BODY C - 1 BRAKES - MECHANICAL AND FRONT DISC BRAKES D - 1 CAB F - 1 ELECTRICAL SYSTEM H - 1 ELECTRONIC SPEED CONTROL J - 1 FRONT SUSPENSION & STEERING K - 5 MOTOR L -1 REAR AXLE M - 1 REAR SUSPENSION N - 1 SEATING S - 1 TRUCK BED T - 1 WEATHER PROTECTION U - 1 WHEELS AND TIRES V - 1 Page iii

6 NOTES Page v

7 HOW TO USE THE 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 location) and note the complete number shown on the plate. Page vi

8 Front of Vehicle ,88 81,86 84,89 82, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 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. Page vii

9 HOW TO USE THE 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 CODE # DESCRIPTION 01 NO PAINT 53 MOSSY OAK NEW BREAK UP - DIPPED 02 SPECIAL COLOR 54 MOSSY OAK OBSESSION - DIPPED 05 JACOBSEN ORANGE 55 REALTREE ADVANTAGE MAX 4 - DIPPED 06 LIGHT GOLD PEARL 56 REALTREE HARDWOOD BROWN - DIPPED 07 SILVER PEARL METALIC 57 REALTREE AP HOT PINK - DIPPED 11 BLACK 58 BLACK / SILVER MARBLE - DIPPED 12 EMERALD GREEN PEARL 59 RED / SILVER MARBLE - DIPPED 13 CLOUD GRAY 60 HOT PINK / SILVER MARBLE - DIPPED 14 VIPER BLUE METALLIC 61 REALTREE AP 19 PATRIOT BLUE PEARL 62 REALTREE MAX 4 20 INFERNO RED METALLIC 63 MOSSY OAK BREAKUP 23 ADVANTAGE CLASSIC CAMO 64 MOSSY OAK TREESTAND 24 NATURAL 65 REALTREE APG 25 VIVID NEW HOLLAND BLUE 66 REALTREE MAX 1 26 STEEL BLUE PEARL 67 REALTREE AP PINK 27 BRIGHT SILVER METALLIC 68 REALTREE AP - DIPPED 29 PRIMER ONLY 30 HD ADVANTAGE CAMO 31 METALLIC CHARCOAL 32 LIGHT ALMOND PEARL 33 TIMBERLINE GREEN 34 DEEP MOLTEN RED 35 SAFETY YELLOW 36 IVORY 37 FOREST GREEN 38 BRIGHT WHITE 39 FLAME RED 40 BLACK 41 ELECTRIC BLUE 42 PLATINUM 43 BURGUNDY 44 ALMOND 45 BLACK 46 FLAME RED 47 BURLINGTON GREEN 48 BLACK 49 FLAME RED 50 RECON GREEN 51 SUNBURST ORANGE 52 BRITISH RACING GREEN Page viii

10 ACCELERATOR 1 41 HAULER 1000 PEDAL BOX ASSEMBLY Includes Items, 2-37 HAULER 800 PEDAL BOX ASSEMBLY Includes Items, 2-27, 30-37, RED GRN BLK WHT To Harness from Direction Selector Part of Frame Page A - 1

11 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. ACCELERATOR ITEM PART NO DESCRIPTION QTY G11 PEDAL BOX ASSEMBLY (HAULER 1000 ONLY) (INCLUDES ITEMS 2-37) G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-10 X 1/2" LG G01 PEDAL BOX AND COVER G6 SCREW, #8-32 X 3/4" LG (STAINLESS STEEL) G02 MICRO SWITCH G01 SCREW, #4-20 X 5/8" LG G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT PLUNGER G1 SPRING RETAINER G1 BUSHING G01 COMPRESSION SPRING G2 SPRING RETAINER, 3/8" G01 ACCELERATOR ROD G4 NUT, 5/ G4 CLEVIS YOKE (ADJUSTABLE) G3 CLEVIS PIN, 5/16" X 13/16" LG G1 NYLON BUSHING G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 PEDAL PIVOT PIN G6 PUSH NUT, 5/16" G08 PEDAL HARNESS G1 LOOM FLEX, 3/8" X 6" LG (BULK)... 1 Page A - 2

12 ACCELERATOR 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 PART NO DESCRIPTION QTY G1 WIRE TIE G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 34-37) G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 35-36) G1 OVAL RIVET, 3/16" X 7/16" LG G01 ACCELERATOR PEDAL PAD * ACCELERATOR PEDAL G2 BOLT, 5/16-18 X 4/5" LG PEDAL BOX ASSEMBLY (HAULER 800 ONLY) (INCLUDES ITEMS 2-27, 30-37, 42) PEDAL HARNESS, 48V... 1 Page A - 3

13 ACCELERATOR Notes: Page A - 4

14 BATTERY CHARGER 51 48V BATTERY CHARGER WITH 3 METER CORD includes items 8, 11 & V BATTERY CHARGER WITH 5.5 METER CORD includes items 8, 11 & 12 FOR HAULER 800 ONLY Page B-1

15 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. BATTERY CHARGER ITEM PART NO DESCRIPTION QTY V BATTERY CHARGER, 3 meter CORD (INCLUDES ITEMS 8,11, & 12) V BATTERY CHARGER, 5.5 meter CORD (INCLUDES ITEMS 8, 11, & 12) NYLON CLAMP 36" (NOT SHOWN IN ILLUSTRATION) AC CORD, DOMESTIC V CHARGER COVER KIT (INCLUDES ITEM 12) CHARGER HANDLE Page B-2

16 BATTERY CHARGER FOR HAULER 800 ONLY Page B-3

17 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. BATTERY CHARGER ITEM PART NO DESCRIPTION QTY WORLD CHARGER, 48V, 3M CORD WORLD CHARGER, 48V, 5.5M CORD NYLON CLAMP 36" (NOT SHOWN IN ILLUSTRATION)... 1 Page B-4

18 BATTERY CHARGER VOLT PORTABLE CHARGER Includes Items 2 & 3 48 VOLT BATTERY CHARGER Includes Items 6 & 7 FOR HAULER 1000 ONLY Page B-5

19 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. BATTERY CHARGER ITEM PART NO DESCRIPTION QTY V DELTA-Q PORTABLE CHARGER WITH 10 DC CORD (INCLUDES ITEMS 2-3) G02 48V DC CABLE ASSEMBLY G01 AC POWER CORD (NOT SHOWN) V DELTA-Q BATTERY CHARGER WITH 18 DC CORD (INCLUDES ITEMS 6-7) G03 48V DC CABLE ASSEMBLY G01 AC POWER CORD (NOT SHOWN)... 1 Page B-6

20 BATTERY CHARGER Notes: Page B-7

21 BATTERY CHARGER Notes: Page B-8

22 BODY FRONT BASKET ASSEMBLY includes items INSTRUMENT PANEL ASSEMBLY includes items Page C-1

23 BODY See Electrical Page C-2

24 BODY Page C-3

25 BODY HITCHES HEAVY DUTY HITCH KIT includes items 224, ANGLE HITCH KIT includes items 225, 230, 231, 235, 236 CLEVIS HITCH KIT includes items 226, 230, 231, 235, 236 DROP ANGLE HITCH KIT includes items 227, 230, 231 DROP BALL HITCH KIT includes items 228, DROP CLEVIS HITCH KIT includes items 229, 230, 231, 235, 236 Bumper Mounting Hole (4) Clevis Hitch Angle Hitch Heavy Duty Hitch Drop Angle Hitch Drop Ball Hitch Drop Clevis Hitch 236 Page C-4

26 BODY ASH TRAY FLOOR MOUNT GUN HOLDER Page C-5

27 BODY 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 PART NO DESCRIPTION QTY UPPER FLOORPAN G11 RIVET (ALUMINUM), 3/16" X 9/16" LG G01 LOWER FLOORPAN G11 RIVET (ALUMINUM), 3/16" X 9/16" LG G01 ACCESS COVER G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G02 SELF TAPPING SCREW, 1/4" - 20 X 1/2" LG G01 RIVET (ALUMINUM), 3/16" X 1 1/8" LG G02 FRONT BASKET ASSEMBLY (INCLUDES ITEMS 18-23) G01 FRONT BASKET G01 BASKET MOUNTING BRACKET (DRIVER SIDE) G02 BASKET MOUNTING BRACKET (PASSENGER SIDE) G1 CARRIAGE BOLT (SS), 3/8" - 16 X 1" LG G5 LOCK NUT, 3/8" G01 LABEL, FRONT BASKET (WARNING) DECAL,CUSHMAN COWL G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 26-30) G01 DEFLECTOR (PASSENGER SIDE) G01 DEFLECTOR (DRIVER SIDE) G5 SELF DRILL SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (FOUR CUP) G01 INSTRUMENT PANEL LABEL (SAFETY)... 1 Page C-6

28 BODY 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 PART NO DESCRIPTION QTY G01 LABEL (ANTI - ROLLBACK) G01 LABEL (T - HOLDER COVER) G01 VINYL TRIM G01 RIVET (ALUMINUM), 3/16" X 1" LG G01 GLOVE BOX DOORS (BOTH SIDES) G02 GLOVE BOX DOOR (DRIVER SIDE) G03 GLOVE BOX DOOR (PASSENGER SIDE) FRONT FASCIA COWL GRILL COVER G02 FRONT SHIELD BRACE GXXX COWL (See COLOR CODE in HOW TO USE Section of Manual) G01 RIVET (ALUMINUM), 3/16" X 1" LG G1 FENDER WASHER, 9/32" G01 SWAGEFORM SCREW, 1/4" - 20 X 0.7" LG G1 RIVET (ALUMINUM), 0.87" LG G01 SELF THREADING NUT, 5 X 10 X 15MM FENDER FLARE (DRIVER SIDE) FENDER FLARE (PASSENGER SIDE) G01 RIVET (ALUMINUM), 3/16" X 1" LG FASCIA BRACKET G4 LOCK NUT, 1/4" G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG Page C-7

29 BODY 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 PART NO DESCRIPTION QTY BRUSHGUARD G6 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG G02 SPACER, 0.328" X 1.31" G8 LOCK WASHER, 5/16" G2 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG G04 SPACER, 0.328" X 0.75" G8 FLAT WASHER, 5/16" G06 FLOORMAT WITH HORN HOLES, DIAMOND PLATE G01 PEDAL PIVOT COVER G03 SPLASH PANEL G2 HEX HEAD BOLT, 5/16" - 18 X 4/5" LG G8 HEX HEAD BOLT, 5/16" - 18 X 1" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT (SS), 5/16" G01 SPLASH PANEL G6 SELF THREADING SCREW, #12-24 X 3/4" LG Page C-8

30 BODY 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 PART NO DESCRIPTION QTY SEAT FRAME G2 HEX HEAD BOLT, 5/16" - 18 X 4/5" LG GXX SEAT WRAP WITH LOUVERS (HAULER 800 ONLY) (See COLOR CODE in HOW TO USE Section) G10 RIVET (SS), 5/32" X 9/16" LG G01 SEAT HINGE PLATE G11 RIVET (SS), 3/16" X 3/4" LG G02 HOLE PLUG (HAULER 1000 ONLY) G1XX SIDE PANEL (DRIVER SIDE) ( HAULER 1000 ONLY ) (See COLOR CODE in HOW TO USE Section) G2XX SIDE PANEL (PASSENGER SIDE) ( HAULER 1000 ONLY ) (See COLOR CODE in HOW TO USE Section) G10 RIVET (SS), 5/32" X 9/16" LG G12 RIVET (ALUMINUM), 1/4" X 9/16" LG G1 FENDER WASHER, 1/4" G1XX SIDE PANEL (DRIVER SIDE) ( HAULER 800 ONLY ) (See COLOR CODE in HOW TO USE Section) G2XX SIDE PANEL (PASSENGER SIDE) ( HAULER 800 ONLY ) (See COLOR CODE in HOW TO USE Section) ROCKER PANEL (DRIVER SIDE) (HAULER 1000 ONLY) ROCKER PANEL (PASSENGER SIDE) (HAULER 1000 ONLY) G03 BRACE (DRIVER SIDE) (HAULER 1000 ONLY) G04 BRACE (PASSENGER SIDE) (HAULER 1000 ONLY)... 1 Page C-9

31 BODY 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 PART NO DESCRIPTION QTY G2 PHILLIPS TRUSS HEAD SCREW, #10-24 X 1 1/4" LG G4 SPACER, 1/4" G5 FLAT WASHER (SS), # G10 LOCK NUT, # G1 PHILLIPS TRUSS HEAD SCREW (SS), 1/4" - 20 X 1" LG G4 SPACER, 1/4" G4 LOCK NUT, 1/4" G01 FENDER (DRIVER SIDE) (HAULER 1000 ONLY) G02 FENDER (PASSENGER SIDE) (HAULER 1000 ONLY) G03 FENDER WITH TAILLIGHT OPENING (DRIVER SIDE) (HAULER 1000 ONLY) G04 FENDER WITH TAILLIGHT OPENING (PASSENGER SIDE) (HAULER 1000 ONLY) G2 RATCHET FASTENER, 1/4" X 3/4" LG ROCKER PANEL (DRIVER SIDE) (HAULER 800 ONLY) ROCKER PANEL (PASSENGER SIDE) (HAULER 800 ONLY) Page C-10

32 BODY 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 PART NO DESCRIPTION QTY G2 RATCHET FASTENER, 1/4 X 3/4 LG G01 REAR PANEL G01 RIVET (ALUMINUM), 3/16 X 1" LG G01 SEAT FILLER PANEL (DRIVER SIDE) (HAULER 1000 ONLY) G02 SEAT FILLER PANEL (PASSENGER SIDE) (HAULER 1000 ONLY) G10 RIVET (SS), 5/32 X 9/16 LG DECAL, CUSHMAN LOGO (HAULER 800) G01 LABEL (TILT WARNING) DECAL, CUSHMAN LOGO (HAULER 1000) SEAT FRAME G2 HEX HEAD BOLT, 5/16" - 18 X 4/5" LG Page C-11

33 BODY 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 PART NO DESCRIPTION QTY G6 RIVET (ALUMINUM), 3/16" X 15/16" LG G01 FENDER (DRIVER SIDE) (HAULER 800 ONLY) G02 FENDER (PASSENGER SIDE) (HAULER 800 ONLY) G03 FENDER WITH TAILLIGHT (DRIVER SIDE) (HAULER 800 ONLY) G04 FENDER WITH TAILLIGHT (PASSENGER SIDE) (HAULER 800 ONLY) G2 RATCHET FASTENER, 1/4" X 3/4" LG G4 LOCK NUT, 1/4" G7 FLAT WASHER, 1/4" G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G02 HITCH RECEIVER G8 HEX HEAD BOLT, 5/16" - 18 X 1" LG G2 FLAT WASHER, 1/4" G6 LOCK NUT (SS), 5/16" G4 HEX HEAD BOLT, 7/16" - 14 X 1 1/2" LG G3 FLAT WASHER, 7/16"... 4 Page C-12

34 BODY 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 PART NO DESCRIPTION QTY G1 LOCK NUT, 7/16" G02 HEAVY DUTY BALL HITCH KIT (INCLUDES ITEMS 224, ) G04 ANGLE HITCH KIT (INCLUDES ITEMS 225, 230, 231) G06 CLEVIS HITCH KIT (INCLUDES ITEMS 226, 230, 231, 235, 236) G08 DROP ANGLE HITCH KIT (INCLUDES ITEMS 227, 230, 231) G10 DROP BALL HITCH KIT (INCLUDES ITEMS 228, ) G12 DROP CLEVIS HITCH KIT (INCLUDES ITEMS 229, 230, 231, 235, 236) G02 HEAVY DUTY HITCH G02 ANGLE HITCH G02 CLEVIS HITCH G02 DROP ANGLE HITCH G02 DROP BALL HITCH G02 DROP CLEVIS HITCH G1 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 1/16" LG G1 HITCH BALL, 1 7/8" G6 LOCK WASHER, 3/4" G2 HEX NUT, 5/16" G10 CLEVIS PIN, 1/2" X 3" LG G1 COTTER PIN, 5/2" LG G01 ASH TRAY G01 GASKET G02 BRACKET G4 HEX HEAD BOLT, #10-16 X 1/2" LG G01 SWIVEL GUN HOLDER WITH BASE PLATE (HAULER 1000 ONLY) G01 GUN HOLDER REMOVABLE FLOOR MOUNT (HAULER 1000 ONLY)... 1 Page C-13

35 BODY Notes: Page C-14

36 BRAKES BRAKE PEDAL ASSEMBLY includes items 2-10 COMPENSATOR ASSEMBLY includes items Part of Frame Accelerator Pedal Page D-1

37 BRAKES BRAKE PEDAL ASSEMBLY (with Brake Light) includes items WHT BLK BRAKE PEDAL (Vehicle With Brake Lights) Page D-2

38 BRAKES BRAKE ASSEMBLY ( Driver Side ) includes items BRAKE ASSEMBLY ( Passenger Side ) includes items 84-89, 93 BRAKE DRUM ASSEMBLY ( HAULER 800 ONLY ) includes items 101, BRAKE DRUM ASSEMBLY ( HAULER 1000 ONLY ) includes items 114, TOP PULL ADJUSTER ASSEMBLY 106 Page D-3

39 BRAKES BOTTOM PULL TENSION PIN ADJUSTER ASSEMBLY BRAKE ASSEMBLY ( Driver Side ) includes items BRAKE ASSEMBLY ( Passenger Side ) includes items 84-89, 93 BRAKE DRUM ASSEMBLY ( HAULER 800 ONLY ) includes items 101, 102 BRAKE DRUM ASSEMBLY ( HAULER 1000 ONLY ) includes items 114, 115 Page D-4

40 BRAKES 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 PART NO DESCRIPTION QTY G02 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-10) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/ G02 BRAKE PEDAL G02 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 7/16" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G01 FLANGED BUSHING G01 TORSION SPRING G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/ G01 SWAGEFORM SCREW - 1/4-20 (NOT ILLUSTRATED) G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED)... AR G01 BRAKE COMPENSATOR BUMPER BRAKE CABLE (DRIVER SIDE) (FOR CUSHMAN HAULER 800) BRAKE CABLE (PASSENGER SIDE) (FOR CUSHMAN HAULER 800) BRAKE CABLE (DRIVER SIDE) (FOR CUSHMAN HAULER 1000) BRAKE CABLE (PASSENGER SIDE) (FOR CUSHMAN HAULER 1000) G01 RETAINING RING, 13/32" (STAINLESS STEEL)... 4 Page D-5

41 BRAKES 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 PART NO DESCRIPTION QTY G3 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 5/8" LG G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 FLAT WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16-18" G02 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G4 LOCK NUT, 1/4-20 (STAINLESS STEEL) G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) G02 BRAKE PEDAL G02 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PAD... 1 Page D-6

42 BRAKES 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 PART NO DESCRIPTION QTY G1 OVAL RIVET, 3/16" x 7/16" LG G03 SERVICE BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 7/8" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G2 HEX BOLT, #6-32 X 1 1/4" LG G5 FLAT WASHER, # G3 FLAT WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, # G8 FLAT WASHER, 4-5/ G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84-92) BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84-91, 93) BRAKE SHOE, L BRAKE SHOE, T DUST COVER BRAKE SPRING BRAKE SPRING... 1 Page D-7

43 BRAKES 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 PART NO DESCRIPTION QTY SHOE CLAMP GEAR ADJUSTER GEAR ADJUSTER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 LOCK WASHER, 13/16" (HAULER 800) G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) (HAULER 800 ONLY) G2 BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 FLAT WASHER, 1 3/8" O.D. X 21/32" (HAULER 800) CASTELLATED NUT, 5/8-18 (HAULER 800) G1 COTTER PIN, 1/8" X 1 1/2" LG BRAKE CABLE BRACKET (PASSENGER SIDE) BRAKE CABLE BRACKET (DRIVER SIDE) G2 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) (HAULER1000 ONLY) G1 BRAKE DRUM G2 LUG BOLT G1 FLAT WASHER, INNER WHEEL RIM (HAULER 1000) G1 FLAT WASHER - BRAKE DRUM (HAULER 1000) G8 SLOTTED HEX NUT, 3/4-16 (HAULER 1000)... 2 Page D-8

44 BRAKES 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 PART NO DESCRIPTION QTY COMPENSATOR ASSEMBLY (INCLUDES ITEMS ) G4 HEX NUT HEX NUT, 5/ G01 EQUALIZER BRACKET G1 FLAT WASHER - 5/ G1 ACCELERATOR ROD BUSHING G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 HEX LOCK NUT, 5/ COMPENSATOR LINK ROD... 1 Page D-9

45 BRAKES Notes: Page D-10

46 BRAKES - FRONT DISC Part of Frame Accelerator Pedal BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) includes items COMPENSATOR ASSEMBLY includes items Page D-11

47 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY G01 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-11) G01 TORSION SPRING G01 PARKING BRAKE PEDAL PIN G01 PUSHNUT, 5/16" G02 BRAKE PEDAL G01 PARK BRAKE PEDAL G01 BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 NYLON WASHER, 3/8" G01 SHOULDER BOLT, 3/8" - 16 X 4" LG G01 FLANGED BUSHING G01 TORSION SPRING G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G01 SWAGEFORM SCREW, 1/4" - 20 (NOT ILLUSTRATED) G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED)... A/R G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER BRAKE CABLE (DRIVER SIDE) (FOR CUSHMAN HAULER 800) BRAKE CABLE (PASSENGER SIDE) (FOR CUSHMAN HAULER 800) BRAKE CABLE (DRIVER SIDE) (FOR CUSHMAN HAULER 1000) BRAKE CABLE (PASSENGER SIDE) (FOR CUSHMAN HAULER 1000) G01 RETAINING RING (SS) G3 CLEVIS PIN, 5/16" X 1"... 2 Page D-12

48 BRAKES - FRONT DISC 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 PART NO DESCRIPTION QTY G3 COTTER PIN, 3/32" X 3/4" G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 FLAT WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SET SCREW WITH PATCHLOCK, 1/4" - 20 X 1/2" LG G4 SPACER, 1.25" G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16" G02 CATCH BRACKET G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G4 LOCK NUT, 1/4" - 20" COMPENSATOR ASSEMBLY (INCLUDES ITEMS 53-61) G4 HEX NUT, 1/4" HEX NUT, 5/16" G1 FLAT WASHER, 5/16" G1 ACCELERATOR ROD BUSHING G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 HEX LOCK NUT, 5/16" COMPENSATOR LINK ROD... 1 Page D-13

49 BRAKES - FRONT DISC Notes: Page D-14

50 BRAKES - FRONT DISC 62 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHT) includes items WHT BLK BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Page D-15

51 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY G01 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 63-90) G01 BRAKE PEDAL PARK BRAKE PEDAL G01 BRAKE PAD G01 PARK BRAKE PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 LOCTITE (262) (NOT ILLUSTRATED)... A/R G03 BRAKE PEDAL PLATE G01 PARKING BRAKE PEDAL PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 FLAT HEAD PHILLIPS SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 LIMIT SWITCH (3 POLE) G1 HEX HEAD CAP SCREW, #6-32 X 1 1/4" LG G5 FLAT WASHER, # G3 FLAT WASHER, # G3 LOCK WASHER, # G5 HEX NUT, # G1 BRASS LIMIT SWITCH SCREW, #6-32 X 7/32" LG G1 NYLON WASHER, 3/8" G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE G8 FLAT WASHER, 5/16"... 2 Page D-16

52 BRAKES - FRONT DISC DISC HUB ASSEMBLY (DRIVER SIDE) includes items DISC HUB ASSEMBLY (PASSENGER SIDE) includes items , Disc Hub Front Brake Line Caliper Page D-17

53 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY G02 SPRING PLATE (PASSENGER SIDE) G01 SPRING PLATE (DRIVER SIDE) G01 FOUR LINK ROD HEX NUT, M BRAKE LINE G01 SWAGEFORM SCREW, 1/4" - 20 X 1/2" LG G01 WIRE RETAINER SPINDLE, CALIPER AND DISC HUB ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS ) DISC BRAKE SPINDLE (DRIVER SIDE) G1 SLOTTED NUT, 17/32" G01 DRIVE FLANGE STUD G2 ROLLER BEARING G1 BEARING RACE DISC BRAKE HUB G01 FLANGED BEARING G1 FLAT WASHER, 3/8" G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG G01 BEARING G8 COTTER PIN, 5/32" X 1 3/4" G1 GREASE SEAL G02 CALIPER (DRIVER SIDE) SPINDLE, CALIPER AND DISC HUB ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS , 115) DISC BRAKE SPINDLE (PASSENGER SIDE) G01 KINGPIN TUBE G01 THRUST WASHER,.995" I.D. X 1.38" O.D G3 LOCK WASHER, 1/2"... 4 Page D-18

54 BRAKES - FRONT DISC 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 PART NO DESCRIPTION QTY G6 LOCK NUT, 1/2" G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG G01 CALIPER (PASSENGER SIDE) CRUSH WASHER, M BANJO BOLT, M10-1" X 20" LG Page D-19

55 BRAKES - FRONT DISC Notes: Page D-20

56 BRAKES - FRONT DISC Front of Vehicle FRONT DISC BRAKE ACTUATOR ASSEMBLY includes items Page D-21

57 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY FRONT DISC BRAKE BRAKE ACTUATOR ASSEMBLY (INCLUDES ITEMS ) G3 COTTER PIN, 3/32" X 3/4" LG G3 CLEVIS PIN, 5/16" X 1" UPPER ACTUATOR PIVOT G02 ACETAL BUSHING G01 ACTUATOR PIVOT BOLT, 3/4" - 16 X 3/4" LG G1 HEX HEAD BOLT, 1/2" - 13 X 6" LG G6 LOCK NUT, 5/16" MASTER CYLINDER MASTER CYLINDER WELDMENT MOUNT G5 LOCK NUT, 3/8" G1 LOCK WASHER (SS), 3/8" LOWER ACTUATOR PIVOT ACTUATOR ASSEMBLY COVER G01 SWAGEFORM SCREW, 1/4" - 20 X 1/2" LG G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G4 LOCK NUT, 1/4" G3 COTTER PIN,.094" X.75" G1 NYLON BUSHING ACTUATOR LINKAGE G5 FLAT WASHER, 3/8" (NOT ILLUSTRATED) G1 BRAKE FLUID (NOT ILLUSTRATED)... A/R G3 CLEVIS PIN, 5/16" X 1"... 2 Page D-22

58 BRAKES - FRONT DISC Notes: Page D-23

59 BRAKES - FRONT DISC Notes: Page D-24

60 CAB CAB * 8* *Steel Doors Shown Page F-1

61 CAB 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 PART NO DESCRIPTION QTY G01 STEEL CAB (WITHOUT DOORS) - TAN G02 STEEL CAB (WITHOUT DOORS) - WHITE G03 STEEL CAB (WITHOUT DOORS) - OTHER G01 VINYL DOOR KIT - TAN G02 VINYL DOOR KIT - WHITE G03 VINYL DOOR KIT - OTHER G01 STEEL DOOR KIT - TAN G03 STEEL DOOR KIT - OTHER... 1 REPACEMENT PARTS AND ACCESSORIES MAY BE OBTAINED FROM CURTIS CAB, INC Page F-2

62 CAB Notes: Page F-3

63 CAB Notes: Page F-4

64 ELECTRICAL SYSTEM - HAULER 800 A A A A Page H-1

65 ELECTRICAL SYSTEM - HAULER OFF ON 50 KEY SWITCH AND KEY SET GRN Page H-2

66 ELECTRICAL SYSTEM - HAULER 800 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 PART NO DESCRIPTION QTY. 1 *** 8 VOLT BATTERY G01 HOLD DOWN BOLT (STAINLESS STEEL) BATTERY RETAINER G1 LOCK NUT, 5/16" AWG WIRE, BLUE 380mm (15") AWG WIRE, BLUE 150mm (5.90") G2 NUT, 5/16" G11 RIVET, 3/16" X 0.70" G02 LOCK WASHER, 1/4 " (SILICON BRONZE) G02 NUT, 1/4-20 (BRASS) CHARGER RECEPTACLE 48V * CHARGER HARNESS MAIN WIRE HARNESS, VPS 48V G01 PLUG G01 RIVET, 3/16" X 1" LG (ALUMINUM) G1 NYLON CLAMP Page H-3

67 ELECTRICAL SYSTEM - HAULER 800 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 PART NO DESCRIPTION QTY G02 CABLE CLAMP SPEED SENSOR G01 RETAINING RING G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16" - 18" (BRASS) G6 SCREW, 5/16" G1 FENDER WASHER, 1/4" G1 FUSE BLOCK G01 RIVET, 1/8" X 13/16" LG G1 15 AMP FUSE... AR G01 KEY SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" P1 FACE NUT, 3/ Page H-4

68 ELECTRICAL SYSTEM - HAULER 800 HEAD LIGHT & TURN SIGNAL TAILLIGHT Rear Fender Page H-5

69 ELECTRICAL SYSTEM - HAULER 800 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 PART NO DESCRIPTION QTY HEADLIGHT W/O TURN SIGNAL (PASSANGER SIDE) HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) LED HEADLIGHT W/O TURN SIGNAL (PASSANGER SIDE) LED HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) G01 SELF THREADING NUT G02 VINYL TAPE WIRE HARNESS (ACCESSORY), 48V DC,SWB JUMPER PLUG, TAIL LIGHT G2 TAIL LIGHT TURN SIGNAL KIT INCLUDES ITEM TURN SIGNAL BULB TURN SIGNAL SWITCH ASSEMBLY INCLUDES ITEM G01 TURN SIGNAL FLASHER UNIT G1 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER... 1 Page H-6

70 ELECTRICAL SYSTEM - HAULER 800 REVERSE BUZZER RED 13 GRN/ BLK 14 Control Harness Accessory Harness OFF ON DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE 20 DC TO DC CONVERTER KIT Page H-7

71 ELECTRICAL SYSTEM - HAULER 800 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 PART NO DESCRIPTION QTY PLATE CONSOLE DECALS G02 DRIVE RIVET, 3/16" X 3/8" LG G10 PLUG HOLE G01 DIRECTION SELECTOR SWITCH (DASH MOUNTED) G05 STATE OF CHARGE METER (VERTICAL) G74 18 GA WIRE (RED 6") BUZZER (CONTINUOUS TONE) G01 RIVET, 1/8" X 13/16" LG DC TO DC CONVERTER BRACKET DC TO DC WIRING HARNESS G4 PHILIPS PAN HEAD SCREW G5 CHRISTMAS TREE RIVET, X Page H-8

72 ELECTRICAL SYSTEM - HAULER 800 Notes: Page H-9

73 ELECTRICAL SYSTEM - HAULER 800 Notes: Page H-10

74 ELECTRICAL SYSTEM - HAULER CHARGER RECEPTACLE A B CHARGER RECEPTACLE ASSEMBLY Includes Items A Controller (See Electronic Speed Control Section) B Page H-11

75 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY. 1 *** 6 VOLT BATTERY BATTERY RETAINER G01 HOLD DOWN BOLT (STAINLESS STEEL) G1 LOCK NUT, 5/ G02 BATTERY RETAINER ANGLE G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G1 BATTERY RETAINER ANGLE INNER G01 HOLD DOWN BOLT (STAINLESS STEEL) G1 LOCK NUT, 5/ G18 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 6") G13 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 10 1/2") G14 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 15") G8 LOCK WASHER, 5/16" G2 NUT, 5/ G15 4 GA WIRE (BATTERY +, BLACK, 17") G16 4 GA WIRE (BATTERY -, BLACK, 19") G01 POWER HARNESS G01 CONTROL HARNESS... 1 Page H-12

76 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY CHARGER RECEPTACLE ASSEMBLY (INCLUDES ITEMS 32-40) * RECEPTACLE COVER * RECEPTACLE BOTTOM G23 FEMALE CONNECTOR G24 INSULATOR SLEEVE G25 18 GA WIRE (RED 9") G08 SCREW, #10-32 X 1/2" LG (BRASS) G09 SCREW, #6-32 X 1 3/4" LG (STAINLESS STEEL) G10 LOCK NUT, # WIRE HARNESS (CHARGER) G10 RIVET, 3/16" X 1" LG (ALUMINUM) G1 WIRE TIE G02 CABLE CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G1 WIRE TIE G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16-18 (BRASS) G02 LOCK WASHER, 1/4" (SILICON BRONZE) G02 NUT, 1/4-20 (BRASS)... 2 Page H-13

77 ELECTRICAL SYSTEM - HAULER 1000 FUSE BLOCK HORN Seatwrap Support YEL BLK GRN 4 HORN BUTTON Floorboard HORN HOUR METER KIT Includes Items OFF ON KEY SWITCH AND KEY SET HOUR METER DETAIL Page H-14

78 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY G01 FUSE BLOCK (6 POSITION) G2 SCREW, #10-24 X 1 1/4" LG G5 WASHER, # G10 LOCK NUT, # G01 FUSE, 15 AMP... AR G1 PUSH ON MALE TERMINAL G5 LOCK WASHER, # G4 NUT, # G2 HORN G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 RIVET, 3/16" X 1" LG (ALUMINUM) G02 HOUR METER KIT (INCLUDES ITEMS 18-22) G02 HOUR METER G01 HOUR METER RETAINER CLIP G02 HOUR METER BRACKET G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 WIRE HARNESS (HOUR METER) G03 KEY SWITCH (WITH LIGHTS - INDIVIDUALLY KEYED) G** KEY SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ Page H-15

79 ELECTRICAL SYSTEM - HAULER 1000 HEAD LIGHT & TURN SIGNAL TAILLIGHT Rear Fender Page H-16

80 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY HEADLIGHT W/O TURN SIGNAL (PASSANGER SIDE) HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) LED HEADLIGHT W/O TURN SIGNAL (PASSANGER SIDE) LED HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) G01 SELF THREADING NUT G02 VINYL TAPE WIRE HARNESS (ACCESSORY), 48V DC,SWB JUMPER PLUG, TAIL LIGHT G2 TAIL LIGHT TURN SIGNAL KIT INCLUDES ITEM TURN SIGNAL BULB TURN SIGNAL SWITCH ASSEMBLY INCLUDES ITEM G01 TURN SIGNAL FLASHER UNIT G1 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER... 1 Page H-17

81 ELECTRICAL SYSTEM - HAULER 1000 REVERSE BUZZER RED GRN/ BLK 20 Control Harness Accessory Harness OFF ON 9 12 DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE Page H-18

82 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY PLATE (KEY SWITCH, DIRECTION SELECTOR) G06 PLATE (KEY SWITCH, DIRECTION SELECTOR, CHARGE METER) LABEL G01 LABEL (KEY SWITCH WITH LIGHTS, DIRECTION SELECTOR, CHARGE METER) G02 DRIVE RIVET, 3/16" X 3/8" LG G01 DIRECTION SELECTOR SWITCH (DASH MOUNTED) G05 STATE OF CHARGE METER (VERTICAL) G74 18 GA WIRE (RED 6") G02 REVERSE WARNING BUZZER (CONTINUOUS TONE) G01 RIVET, 1/8" X 13/16" LG... 2 Page H-19

83 ELECTRICAL SYSTEM - HAULER 1000 WORK AND STROBE LIGHTS WORK LIGHT BAR Includes Items 2-19, 22 and/or HARD WARE KIT Includes Items Front of Vehicle WORK LIGHT KIT Includes Items STROBE LIGHT Kit Includes Items Front of Vehicle Front of Vehicle Page H-20

84 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY G** WORK LIGHT BAR WITH LIGHTS AND/OR STROBE (INCLUDES ITEMS 2-19, 22 AND/OR 30) G03 STRUT (DRIVER SIDE) G04 STRUT (PASSENGER SIDE) G01 WIRE HARNESS (WORK LIGHT) G02 BRACE G02 COVER PLATE G01 SWITCH HARNESS G** CONSOLE INSERT PLATE G03 STROBE LIGHT MOUNT (USED ONLY WITH STROBE LIGHT) G01 HARDWARE KIT (INCLUDES ITEMS 11-19) G7 BOLT, 5/16-18 X 1 3/4" LG G8 FLAT WASHER, 5/16" G1 FLAT WASHER, 3/8" X 1 1/4" G01 LOCK NUT, 5/ G3 ACORN NUT, 5/ G02 DRIVE RIVET, 3/16" X 3/8" LG G1 GROMMET G3 SCREW, 1/4-20 X 3/4" LG G4 LOCK NUT, 1/ G2 WORK LIGHT KIT (INCLUDES ITEMS 23-28) G2 WORK LIGHT (RECTANGULAR) G3 LOCK WASHER, 1/2" G1 NUT, 1/ G1 LIGHT SWITCH G1 TAB ADAPTER G1 16 GA WIRE (RED 5 3/8") Page H-21

85 ELECTRICAL SYSTEM - HAULER 1000 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 PART NO DESCRIPTION QTY G01 STROBE LIGHT KIT (INCLUDES ITEMS 31-36) G4 STROBE LIGHT G4 SCREW, #10-24 x 1/2" LG G10 LOCK NUT, # G1 LIGHT SWITCH G1 TAB ADAPTER G1 16 GA WIRE (RED 5 3/8") G10 HOLE PLUG Page H-22

86 ELECTRICAL SYSTEM - HAULER 1000 Notes: Page H-23

87 ELECTRICAL SYSTEM - HAULER 1000 Notes: Page H-24

88 ELECTRONIC SPEED CONTROL (HAULER 800) ELECTRONIC SPEED CONTROL ASSEMBLY includes items 2-12, 31 SOLENOID ASSEMBLY includes items RESISTER ASSEMBLY includes items COVER ASSEMBLY includes items AWG WHITE MOTOR WIRE 10AWG BLACK MOTOR WIRE FOR HAULER 800 ONLY Page J-1

89 ELECTRONIC SPEED CONTROL (HAULER 800) 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 PART NO DESCRIPTION QTY ELECTRONIC SPEED CONTROL ASSEMBLY, 48V (INCLUDES ITEMS 2-12, 31) CONTROLLER, 48V G01 HEX HEAD CAP SCREW, 1/4" - 20 X.90" LG G01 HEATSINK G01 HEX HEAD BOLT, M X 16MM G8 LOCK WASHER, 5/16" G8 FLAT WASHER, 5/16" G01 THERMAL MOUNTING PAD G1 NYLON CLAMP (NOT ILLUSTRATED) POWER HARNESS WIRE ASSEMBLY (BLUE), 6AWG, 675MM WIRE ASSEMBLY (GREEN), 4AWG, 400MM MAIN WIRE HARNESS (VPS), 48V SOLENOID ASSEMBLY (INCLUDES ITEMS 18-30) G01 BRACKET G5 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG SOLENOID, 48V WIRE ASSEMBLY (GREEN), 4AWG, 28" RESISTOR ASSEMBLY, 500 OHM (INCLUDES ITEMS 23-25) G1 RING TERMINAL RESISTOR, 500 OHM, 6.5W G1 VINYL TUBING, 3/8" G4 HEX JAM NUT, 1/4" G8 LOCK WASHER, 5/16" G01 FLAT WASHER, 1/4" G02 FLANGED NUT, 5/16-18"... 2 Page J-2

90 ELECTRONIC SPEED CONTROL (HAULER 800) 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 PART NO DESCRIPTION QTY COVER ASSEMBLY (INCLUDES ITEMS 32-36) G01 COVER LABEL TOGGLE SWITCH G01 SEALED NUT, 15/32" G01 COVER G1 FLAT WASHER,1/4" G6 TAPPING SCREW, 1/4" - 10 X 3/4" LG... 1 Page J-3

91 ELECTRONIC SPEED CONTROL (HAULER 800) Notes: Page J-4

92 P/N G01 ELECTRONIC SPEED CONTROL (HAULER 1000) ELECTRONIC SPEED CONTROL ASSEMBLY includes items 2-17 WALKAWAY RELAY HARNESS ASSEMBLY includes items Walkaway Fuse 5 Walkaway Relay 28 #10 Black From Motor F2 (Power Harness) PURPLE From Walkaway Fuse To Solenoid (+) #4 Black From Motor A1 (Power Harness) #4 Black From Motor A2 (Power Harness) 2 4 J3 F2 J2 J1 F1 B+ M- B- 13 #18 Yellow From J1 Pin 5 (Control Harness) #18 Blue From J1 Pin 17 (Control Harness) #18 Red From Tow Switch and Reverse Buzzer (Control Harness) #10 White From Charger Receptacle Speed Sensor Harness Charger Receptacle Harness RED From Walkaway Relay To Solenoid (-) #4 Black From Charger (Charger Harness) #18 Red/White From Tow Switch (Control Harness) To Ignition Interlock (Charger Receptacle) 26 #4 Black From Battery (-) #4 Black (Power Harness From Motor A1 (Power Harness) Power Harness 27 Code Fault Code Symptoms Corrective Action 1-1 HW FAILSAFE Vehicle will not run Check motor wiring, replace controller 1-2 THROTTLE FAULT 1 Vehicle will not run Check pedal box adjustment, connections, replace ITS 1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring, replace sensor if required 1-4 HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries 2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC 2-3 THERMAL CUTBACK Vehicle performance reduced Allow controller to cool 2-4 MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller 2-5 VDD FAULT Vehicle will not run Replace controller 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller 3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to B+, replace controller 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring. not run Replace power harness and motor if required. 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted. Verify, replace motor if necessary. 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 AUX CONT DNC Vehicle will not run Replace controller 4-5 WELDED AUX CONT Vehicle runs slowly Replace controller 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring. Replace solenoid if necessary 5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring. Replace solenoid if necessary 5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring. Replace solenoid if necessary Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close), HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor), M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault) DIAGNOSTIC FAULT CODES The LED will flash a diagnostic fault code when a fault is detected Some faults may only be detected by operating the vehicle with the rear of the vehicle raised and supported on safety stands Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery compartment) to the 'TOW/MAINTENANCE' position before performing any repairs or maintenance to the vehicle Select 'RUN' before returning the vehicle to service Page J - 5

93 ELECTRONIC SPEED CONTROL (HAULER 1000) 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 PART NO DESCRIPTION QTY G04 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-17) G01 CONTROLLER MOUNT ELECTRONIC SPEED CONTROLLER G2 RIVET, 0.25 X G01 48 VOLT SOLENOID G5 LOCK WASHER, # G4 HEXAGONAL NUT, # G8 LOCK WASHER, 5/16" G4 JAM NUT, 5/ G5 RIVET, 0.18 X G01 FASTON TAB G01 IN-LINE FUSE COVER G2 LOCK NUT, 1/ G1 PLASTIC FASTENER G17 4 GA WIRE (BLK 9") G01 CONTROLLER COVER G01 DOUBLE TUBE CLAMP G2 LOCK NUT, 1/ G01 BOLT, 8MM X 16MM LG G01 LOCK WASHER, 5/16" G01 BOLT, 6MM X 1 X 12MM LG G02 LOCK WASHER, 1/4" G01 CONTROL HARNESS G01 DIAGNOSTIC LABEL (FAULT CODE) WALKAWAY RELAY HARNESS ASSEMBLY (INCLUDES ITEMS 29) RELAY Page J - 6

94 ELECTRONIC SPEED CONTROL (HAULER 1000) Notes: Page J - 7

95 ELECTRONIC SPEED CONTROL (HAULER 1000) Notes: Page J - 8

96 FRONT SUSPENSION AND STEERING Part of Frame Front of Vehicle Part of Frame LUG *NOTE: Tie Rod Not Shown for Clarity SPINDLE & HUB ASSEMBLY (PASSENGER SIDE) includes items 4-13 WHEEL HUB ASSEMBLY includes item 10 SPINDLE & HUB ASSEMBLY (DRIVER SIDE) includes items 7-13, 17 Page K-1

97 FRONT SUSPENSION AND STEERING RACK AND PINION UNIT (COMPLETE) includes items Page K-2

98 FRONT SUSPENSION AND STEERING STEERING COLUMN KIT includes items TIE ROD ASSEMBLY includes items Front of Vehicle Page K-3

99 FRONT SUSPENSION AND STEERING 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 PART NO DESCRIPTION QTY FRONT AXLE G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-13) G04 SPINDLE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 5-6) G01 BEARING G01 BEARING, DP G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G1 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 10) G1 LUG BOLT, 1/2" - 20 X 1 7/32" LG G1 SLOTTED NUT, 1" G8 COTTER PIN, 5/32" X 1 3/4" LG G2 SPINDLE CAP G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 7-13 & 17) G02 SPINDLE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 5-6) G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG G3 FLAT WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (SS) G6 LOCK NUT, 1/2" G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING... 8 Page K-4

100 FRONT SUSPENSION AND STEERING 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 PART NO DESCRIPTION QTY G6 HEX NUT, 3/8" G01 VINYL CAP G03 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) G03 SPRING PLATE G1 LOCK NUT, 7/16" G11 HEX HEAD BOLT, 7/16" - 14 X 1 3/4" LG G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 42-65) G01 STEERING RACK COVER & BEARING * STEERING BOX INSTALLATION TAG * JAM NUT, 1/2" G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 PINION G01 RETAINING RING (INTERNAL) G01 SEAL PINION G01 RACK STEERING G01 SET SCREW, #10-32 X.25" LG G01 RACK LOADER G01 SPRING COMPRESSION G01 GASKET RACK LOADER G01 COVER RACK LOADER G01 HEX WASHER HEAD SCREW, 1/4" - 20 X 3/4" LG G3 GREASE FITTING, STRAIGHT G01 TIE ROD END - OUTER * GROMMET - TIE ROD END... 1 Page K-5

101 FRONT SUSPENSION AND STEERING 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 PART NO DESCRIPTION QTY. 60 * SLOTTED NUT, 7/16" G01 ROD END (INNER) G01 BELLOWS, RACK COVER G2 WIRE TIE G8 CLAMP, HOSE G2 COTTER PIN, 3/32" X 1" LG G8 HEX HEAD BOLT, 7/16" - 14 X 2 3/4" LG G01 HEX HEAD BOLT, 7/16" - 14 X 3 1/2" LG G02 SPACER, 1.21" LG G04 STEERING HOUSING SPACER G7 HEX NUT, 7/16" G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/16" G05 STEERING COLUMN KIT (INCLUDES ITEMS ) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 HEX WASHER HEAD SCREW, #6-20 X 5/16" LG G01 STEERING SHAFT... 1 Page K-6

102 FRONT SUSPENSION AND STEERING 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 PART NO DESCRIPTION QTY G01 INTERMEDIATE SHAFT G01 HEX HEAD BOLT, M8 X G G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER STEERING WHEEL PREMIUM (OPTIONAL) G01 STEERING WHEEL COVER STEERING WHEEL G01 HEX HEAD WASHER WITH PATCHLOCK BOLT, 3/8" - 16 X 1 1/4" LG G1 LOCK WASHER, 3/8" STEERING WHEEL DECAL (CUSHMAN) G2 LOCK NUT, 5/8" G02 TIE ROD ASSEMBLY (INCLUDES ITEMS ) G01 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS)... 1 Page K-7

103 FRONT SUSPENSION AND STEERING 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 PART NO DESCRIPTION QTY G01 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G02 JAM NUT, M12 X (RIGHT HAND THREADS) G1 LOCK NUT, 7/16" Page K-8

104 FRONT SUSPENSION AND STEERING Notes: Page K-9

105 FRONT SUSPENSION AND STEERING Notes: Page K-10

106 MOTOR 1 Motor Includes Items Page L-1

107 MOTOR 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 PART NO DESCRIPTION QTY MOTOR 48V (INCLUDES ITEMS 2-10) COMMUNTATOR END HEAD ARMATURE FRAME AND FILED ASSEMBLY BRUSH BOX ASSEMBLY G03 BRUSH SPRING G25 BRUSH AND TERMINAL SERVICE KIT G06 RETAINING RING G07 BEARING COVER G01 RETAINING RING G01 SPEED SENSOR MAGNET G02 THREADED SCREW SPEED SENSOR HARNESS G1 BUMPER SPLINE O-RING... 1 Page L-2

108 MOTOR 1 MOTOR 48V Includes Items HAULER Page L-3

109 MOTOR 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 PART NO DESCRIPTION QTY G04 MOTOR, 48V (INCLUDES ITEMS 2-12) G36 A RMATURE ASSEMBLY G38 BRUSH SPRING G39 BRUSH G40 BRUSH BOX ASSEMBLY G41 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G43 HEADBAND G37 FRAME AND FIELD COIL (INCLUDES HARDWARE) G42 COVER COMMUTATOR END G01 RETAINING RING G02 SCREW, #10-32 X 1/2" LG G01 MAGNET G02 SPEED SENSOR... 1 Page L-4

110 MOTOR Notes: Page L-5

111 MOTOR Notes: Page L-6

112 REAR AXLE REAR ASSEMBLY ( Hauler 800 ) Includes Items REAR ASSEMBLY ( Hauler 1000) Includes Items 2-7 NOTE: Apply a light coat of anti-sieze compound to male spline before assembly. Reference part number Page M-1

113 REAR AXLE 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 PART NO DESCRIPTION QTY G01 REAR AXLE ASSEMBLY, 12.44:1 (INCLUDES ITEMS 2-7) (HAULER 800 ONLY) G12 AXLE SHAFT (PASSENGER SIDE) G11 AXLE SHAFT (DRIVER SIDE) * DIFFERENTIAL COVER G01 FILL/CHECK PLUG G1 SCREW, 5/16-18 X 3/4" LG G01 VENT PLUG G02 DIFFERENTIAL GUARD G1 BUMPER SPLINE (HAULER 800 ONLY) G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) * ANTI-SIEZE COMPOUND... AR G02 CLAMP TWISTED G01 REAR AXLE ASSEMBLY, 14.76:1 (INCLUDES ITEMS 2-7) (HAULER 1000 ONLY)... 1 Page M-2

114 REAR AXLE Notes: Page M-3

115 REAR AXLE Notes: Page M-4

116 REAR SUSPENSION FOR HAULER 800 ONLY Page N-1

117 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. REAR SUSPENSION ITEM PART NO DESCRIPTION QTY G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 SHOCK ABSORBER RUBBER BUSHING G6 HEX NUT, 3/8" G01 VINYL CAP G03 LEAF SPRING (HEAVY DUTY) G01 U BOLT, 3/8" - 16 X 2" X 2 1/2" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G02 SPLIT STEEL SPACER FLANGED BUSHING G02 SHACKLE PLATE G9 HEX HEAD BOLT, 3/8" - 16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/8" G1 SHOULDER BOLT, 3/8" - 16 X 3 1/4" LG G1 FLANGED LOCK NUT, 3/8" Page N-2

118 REAR SUSPENSION REAR SUSPENSION Includes Items FOR HAULER 1000 ONLY Page N-3

119 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. REAR SUSPENSION ITEM PART NO DESCRIPTION QTY G01 REAR SUSPENSION (INCLUDES ITEMS 2-23) (For Hauler 1000 ONLY) G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING G6 HEX NUT, 3/8" G01 VINYL CAP G03 LEAF SPRING G01 U BOLT, 3/8" - 16 X 2.5" LG G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G02 SPLIT STEEL SPACER FLANGED BUSHING G02 SHACKLE PLATE G9 HEX BOLT, 3/8" - 16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/8" G1 SHOULDER BOLT, 3/8" - 16 X 3 1/4" LG G1 LOCK NUT, 3/8" G01 AXLE BUMPER BRACKET G01 RUBER BUMPER SPLIT LOCK WASHER, M G01 LOCK NUT, M G01 SHOCK ABSORBER... 2 Page N-4

120 REAR SUSPENSION Notes: Page N-5

121 REAR SUSPENSION Notes: Page N-6

122 SEATING V 14 SEAT BACK ASSEMBLY Includes Items 15, SEAT BOTTOM ASSEMBLY Includes Items Front of Vehicle Page S-1

123 SEATING 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 PART NO DESCRIPTION QTY G04 SEAT BACK SUPPORT ( HAULER 800 ONLY ) G2 HEX BOLT, 5/16-18 X 13/16" LG G8 HEX BOLT, 5/16-18 X 3/4" LG G8 LOCK WASHER, 5/16" G6 LOCK NUT, 5/ G01 SEAT BACK SUPPORT ( HAULER 1000 ONLY ) G01 ACCESS COVER G1 DRIVE RIVET SEAT BACK SUPPORT BRACKET ( HAULER 800 ONLY ) G02 SEAT BACK SUPPORT BRACKET( HAULER 1000 ONLY ) G2 HEX BOLT, 3/8-16 X 1-1/4" LG G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/ *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 15, 16) 71274G04 GRAY 71274G02 BLACK 71274G01 WHITE 71274G03 TAN 71274G07 BROWN 71274G05 OYSTER 15 *** VINYL COVER 18144G5 GRAY 18144G3 BLACK 18144G2 WHITE 18144G3 TAN 18144G3 BROWN 18144G6 OYSTER G01 PLASTIC SEAT BACK COVER Page S-2

124 SEATING 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 PART NO DESCRIPTION QTY HEX SCREW, 1/4-20 X 1" W/PATCH LOC G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 31-38) 71611G01 WHITE 71611G17 BLACK 71611G07 TAN 71611G16 BROWN 71611G05 OYSTER 71611G03 GRAY G01 VINYL TRIM (SEAT BOTTOM) G01 HIP RESTRAINT (DRIVER SIDE) G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG G01 HEX BOLT, 1/4-20 X 7/8" LG G01 HIP RESTRAINT (PASSENGER SIDE) G** SEAT BOTTOM COVER 71602G G G G G G02 WHITE BLACK TAN BROWN OYSTER GRAY Page S-3

125 SEATING Notes: Page S-4

126 TRUCK BED - PLASTIC 1 36 PLASTIC BED ASSEMBLY includes items A B A B Page T-1

127 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 36" PLASTIC TRUCK BED ASSEMBLY (INCLUDES ITEMS 2-11) G01 36" PLASTIC BED G01 36" PLASTIC TAILGATE G01 BOWED ANGLE G01 PIVOT SHAFT G02 TAILGATE CABLE ASSEMBLY G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G01 SHOULDER BOLT, 1/4" - 20 X 3/4" LG G01 TAILGATE CAP G2 PAN HEAD PHILLIPS SCREW, 1/4" - 2 X 5/8" LG G5 RACHET FASTENER G2 RATCHET FASTENER LABEL CUSHMAN HAULER G05 BED CAPACITY LABEL (250 LB) G01 RIVET (ALUMINUM), 3/16" Page T-2

128 TRUCK BED - PLASTIC Page T-3

129 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 TRUCK BED FRAME G02 ELECTRIC LIFT BRACKET G2 HEX HEAD BOLT, 5/16" - 18 X 1 1/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G6 HEX HEAD BOLT, 1/4" - 20 X 1 3/4" LG G4 LOCK NUT, 1/4" G7 HEX HEAD BOLT, 7/16" - 14 X.875" LG G1 LOCK NUT, 7/16" Page T-4

130 TRUCK BED - PLASTIC A A Page T-5

131 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 CLEVIS PIN,.50" X 5.25" G5 FLAT WASHER, 5/16" G1 COTTER PIN, 15/32" X 2 13/16" G02 GAS SPRING G01 HEX HEAD BOLT WITH PATCHLOCK, 1/4" - 20 X.62" LG G7 FLAT WASHER, 1/4" G02 GAS SPRING CHANNEL FLANGED BUSHING CABLE ASSEMBLY G10 CLEVIS PIN,.50 X 3" G12 CLEVIS PIN, 1/2" X 1 3/4" G1 HAIR CLIP Page T-6

132 TRUCK BED - PLASTIC AS VIEWED FROM THE BOTTOM 64 Page T-7

133 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 BED LATCH WELDMENT G02 BRACKET G02 LATCH PLATE G01 TORSION SPRING G01 HEX HEAD CAP SCREW, 1/4" - 2 X 5/8" LG G01 HANDLE GRIP G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16" G01 BUMPER BRACKET LATCH PLATE (DRIVER SIDE) LATCH PLATE (PASSENGER SIDE) G03 CARRIAGE BOLT, 1/4" - 20 X.75" LG G7 FLAT WASHER, 1/4" G4 LOCK NUT, 1/4" Page T-8

134 TRUCK BED - PLASTIC 80 ELECTRIC DUMP KIT includes items Front of Vehicle UP 85 DOWN WHT from Actuator BLK from Battery RED from Battery RED from Actuator 94 Battery Connections Front of Vehicle BLK Lead RED Lead Front of Vehicle To Circuit Breaker and Toggle Switch 81 To Control Harness Rear Frame Member Page T-9

135 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G04 ELECTRIC DUMP KIT (INCLUDES ITEMS 81-98) G02 ELECTRIC ACTUATOR G01 TOGGLE SWITCH G01 TOGGLE GUARD G02 CIRCUIT BREAKER MOUNTING BRACKET G4 ROUND HEAD SLOTTED SCREW, #10-24 X 3/8" LG G5 LOCK WASHER, # G3 CIRCUIT BREAKER 15A, 24V G1 WIRE TIE G3 HEX NUT, # G9 RIVET (ALUMINUM), 1/8" X 11/32" G14 14 GA WIRE ASSEMBLY (RED 5") G01 DECAL G01 WIRE HARNESS, ELECTRIC DUMP G10 CLEVIS PIN,.50" X 3" G11 CLEVIS PIN,.50" X 1.92" G1 COTTER PIN, 15/32" X 2 13/16" G01 SPACER,.75" O.D. X.50" I.D Page T-10

136 TRUCK BED - PLASTIC Page T-11

137 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G02 OUTRIGGER CHANNEL G7 FLAT WASHER, #4-5/16" G01 HEX HEAD BOLT, 1/4" - 20 X.62" LG Page T-12

138 TRUCK BED - PLASTIC Notes: Page T-13

139 TRUCK BED - PLASTIC Notes: Page T-14

140 74821G01 MAX 14 o / 25% TRUCK BED - PLASTIC 1 40 PLASTIC BED ASSEMBLY includes items MAX 500 lbs. 255 kg MAX 5 in. 12 cm P P MAX 100 lbs. 45 kg A B A A B B Page T-15

141 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 BED ASSEMBLY, 40" (INCLUDES ITEMS 2-11) G01 PLASTIC BED, 40" G01 PIVOT SHAFT G01 SHOULDER BOLT, 1/4" - 20 X 3/4" LG G01 TAILGATE CABLE G01 BOWED ANGLE G2 PAN HEAD SCREW (SS), 1/4" - 20 X 5/8" LG G01 TAILGATE CAP G5 RATCHET FASTENER G2 HEX HEAD CAP SCREW, 1/4" - 20 X 1 1/4" LG G01 BED CAPACITY LABEL G01 RIVET (ALUMINUM), 3/16" X 1" LABEL CUSHMAN HAULER G2 RATCHET FASTNER Page T-16

142 TRUCK BED - PLASTIC A B B C C A B 28 C C Page T-17

143 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/16" G01 BED LATCH G01 LATCH TORSION SPRING G02 LATCH PLATE G02 RETAINER BRACKET G01 HEX HEAD CAP SCREW, 1/4" - 20 X 5/8" LG G01 HANDLE GRIP G01 BUSHING G01 CLEVIS PIN,.50" X 5.25" G5 FLAT WASHER, 5/16" G1 HAIR CLIP FLANGED BUSHING G02 SPRING CHANNEL G01 HEX HEAD CAP SCREW, 1/4" - 20 X 5/8" LG BED TETHER CABLE G7 FLAT WASHER, 1/4" G01 BRACKET, BUMPER G02 GAS SPRING G10 CLEVIS PIN, 1/2" X 2-27/32" G12 CLEVIS PIN, 1/2" X 1 3/4" G1 HAIR CLIP Page T-18

144 TRUCK BED - PLASTIC Actuator may be rotated 90 on some models Front of Vehicle ELECTRIC DUMP KIT includes items UP 60 DOWN WHT from Actuator BLK from Battery RED from Battery RED from Actuator Page T-19

145 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. TRUCK BED - PLASTIC ITEM PART NO DESCRIPTION QTY G7 FLAT WASHER, 1/4" G01 HEX HEAD CAP SCREW, 1/4" - 20 X 5/8" LG G02 OUTRIGGER CHANNEL G01 ELECTRIC DUMP KIT (INCLUDES ITEMS 56-66) G02 ELECTRIC ACTUATOR, 12V, 1500 LBS G01 TOGGLE SWITCH G01 TOGGLE GUARD G02 CIRCUIT BREAKER MOUNTING BRACKET G4 ROUND HEAD SLOTTED SCREW, #10-24 X 3/8" LG G5 LOCK WASHER, # G4 CIRCUIT BREAKER, 15A, 24V G1 WIRE TIE G3 HEX NUT, # G9 RIVET, 5/32" X.55" G14 14 GA WIRE (RED 5") G01 SPACER,.75 O.D. X.50 I.D. (NOT ILLUSTRATED) G01 HARNESS G01 DECAL Page T-20

146 TRUCK BED - PLASTIC Notes: Page T-21

147 TRUCK BED - PLASTIC Notes: Page T-22

148 TRUCK BED - METAL ALUMINUM BED ELECTRIC LIFT includes items 14, ALUMINUM BED MANUAL LIFT includes items 3-6, 14, 43 ALUMINUM BED LARGE includes items B C 8 19 A A B C Page T-23

149 TRUCK BED - METAL Outer Nut Seat Frame Support RED 59 Page T-24

150 TRUCK BED - METAL B C A B 33 A 35 C 15 Page T-25

151 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. TRUCK BED - METAL ITEM PART NO DESCRIPTION QTY ALUMINUM BED, ELECTRIC LIFT (INCLUDES ITEMS 14, 43-60) ALUMINUM BED, MANUAL LIFT (INCLUDES ITEMS 3-6, 14, 43) G02 GAS SPRING TETHER CABLE ASSEMBLY G1 COTTER PIN, 5/16" X 1/2" G12 CLEVIS PIN, 1/2 x 1 3/4" LATCH INSTALLTION (INCLUDES ITEMS 74-79) G01 LATCH BED WELDMENT G02 LATCH RETAINER BRACKET G02 LATCH KEEPER PLATE G01 LATCH TORSION SPRING G01 HEX SCREW, 1/4" - 20 X 8" G01 HANDLE GRIP ALUMINUM BED, LARGE (INCLUDES ITEMS 15-42) PAN HEAD SCREW, X 1/2" LG HEX HEAD BOLT, 1/4" -20 X 3/8" LG TORX SCREW, 1/4" -20 X.1/2" FLAT WASHER,1/4" HEX NUT, 3/ EDGE PROTECTOR EDGE PROTECTOR EDGE PROTECTOR CLEVIS PIN, 1/2" X 3" LG TRUCK BED FLOOR SIDE PANEL WELDMENT (DRIVER SIDE) SIDE PANEL WELDMENT(PASSENGER SIDE) FRONT PANEL TAILGATE TAILGATE PIVOT PIN, TAILGATE HINGE, (DRIVER SIDE) RUE RING PIVOT CLIP... 3 Page T-26

152 TRUCK BED - METAL 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 PART NO DESCRIPTION QTY LEVELING PAD DRAW LATCH KEEPER DRAW LATCH ASSY BUMPER INSERT,RUBBER TAILGATE HINGE, (PASSENGER SIDE) MAT RETAINER RIVET, 3/16" HINGE SUPPORT HEX NUT,# HEX BOLT, 5/16" -18 X 7/8" RUBBER MAT FLANGED BUSHING G1 NYLON CLAMP (NOT SHOWN) G02 CIRCUIT BREAKER MOUNTING BRACKET G4 SCREW, #10-24 X 1/2 LG G5 LOCK WASHER, # G3 HEX NUT, # G01 TOGGLE SWITCH G01 TOGGLE GUARD ASSEMBLY G9 RIVET, 1/8 X 11/32 LG (ALUMINUM) G14 14 GA WIRE (RED 5") G11 CLEVIS PIN, 1/2 X 1 3/4 LG G01 SPACER G1 COTTER PIN, 15/32 X 2 13/16 LG G01 DUMP HARNESS (48V) (NOT SHOWN) G3 INSULATED CABLE CLAMP, 11/16 (NOT SHOWN) G3 HEX NUT, 5/16" - 18 (NOT SHOWN) G3 CIRCUIT BREAKER (30 AMP 12V) G04 ELECTRIC ACTUATOR, 48V CUSHMAN REAR BED DECAL G01 BED CAPACITY LEBEL... 1 Page T-27

153 TRUCK BED - METAL Notes: Page T-28

154 H O R N WEATHER PROTECTION Front of Vehicle Front of Vehicle B CANOPY STRUTS KIT includes items D D 18 HARDWARE KIT includes items 9-16 B C A Bumper 9 3 A C 5 11 seat back support 10 6 Front of Vehicle 1 Front of Vehicle seat Page U-1

155 HORN WEATHER PROTECTION 32 1 FULL WINDSHIELD KIT includes items SPLIT WINDSHIELD KIT includes items 34-37, REAR VIEW MIRROR ENCLOSURE Windshield Retainer Rubber Latch Strut Front of Vehicle Page U-2

156 WEATHER PROTECTION FULL WINDSHIELD KIT includes items 73, FULL WINDSHIELD ASSEMBLY includes items 57, FULL WINDSHIELD HARDWARE KIT includes items SPLIT WINDSHIELD KIT includes items 50, SPLIT WINDSHIELD ASSEMBLY includes items SPLIT WINDSHIELD HARDWARE KIT includes items Page U-3

157 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. WEATHER PROTECTION ITEM PART NO DESCRIPTION QTY G01 SPACER, 1/2" CANOPY STRUTS KIT (INCLUDES ITEMS 3-8) CANOPY SUPPORT, (DRIVER SIDE FRONT) CANOPY SUPPORT, (PASSENGER SIDE FRONT) CANOPY SUPPORT, (DRIVER SIDE REAR) CANOPY SUPPORT, (PASSENGER SIDE REAR) CANOPY SUPPORT, CROSS TUBE HARDWARE KIT (INCLUDES ITEMS 9-16) SPACER, 3/4" G6 LOCK NUT, PLASTIC INSERT, 5/16" G7 HEX HEAD BOLT, 5/16" - 18 X 7/8" LG G5 LOCK NUT, 3/8" G2 HEX HEAD BOLT, 3/8" - 16 X 2 1/4" LG G1 FLAT WASHER, 3/8" G1 BONDED SEAL WASHER, 1/4" LOCK NUT, M CANOPY, BLACK TORX BOLT, M6-1 X 40MM LG BLACK TOP ENCLOSURE GRAY TOP ENCLOSURE GREEN TOP ENCLOSURE WHITE TOP ENCLOSURE TAN TOP ENCLOSURE * VELCRO... AR Page U-4

158 WEATHER PROTECTION 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 PART NO DESCRIPTION QTY G03 FULL WINDSHIELD KIT (INCLUDES ITEMS 33-38) G01 FULL WINDSHIELD G03 HEX HEAD BOLT, 1/4" - 20 X 1 3/4 LG G04 FLAT WASHER (SS), 1/ G06 RUBBER GROMMET G05 LOCK NUT (SS), 1/4" SASH, 26" LG G04 SPLIT WINDSHIELD KIT (INCLUDES ITEMS 34-37, 42-43) SPORT WINDSHIELD SASH, 12" LG G01 MIRROR ASSEMBLY SPLIT WINDSHIELD KIT, CLIP - ON (INCLUDES ITEMS 50, 58) SPLIT WINDSHIELD ASSEMBLY (INCLUDES ITEMS 51-57) WINDSHIELD LOWER WINDSHIELD UPPER HINGE GROMMET UPPER LATCH LOWER LATCH G01 WARNING DECAL HARDWARE KIT, SPLIT WINDSHIELD (INCLUDES ITEMS 59-64) TUBE CLAMP, 1.5" DIA FASTENER GROMMET PAN HEAD BOLT, 3/8" - 16 X 1 1/2" LG G5 LOCK NUT, 3/8" Page U-5

159 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. WEATHER PROTECTION ITEM PART NO DESCRIPTION QTY FLAT WASHER, 3/8" GROMMET ASSEMBLY, 1/4" (INCLUDES ITEMS 65-66) GROMMET, 1/4" SLEEVE, 1/4" FULL WINDSHIELD KIT, CLIP - ON (INCLUDES ITEMS 73, 76) FULL WINDSHIELD ASSEMBLY (INCLUDES ITEMS 57, 74-75) FULL WINDSHIELD GROMMET HARDWARE KIT, FULL WINDSHIELD (INCLUDES ITEMS 77-82) TUBE CLAMP, 1.5" DIA FASTENER GROMMET PAN HEAD BOLT, 3/8" - 16 X 1 1/2" LG G5 LOCK NUT, 3/8" FLAT WASHER, 3/8" GROMMET ASSEMBLY, 1/4" (INCLUDES ITEMS 83-84) GROMMET, 1/4" SLEEVE, 1/4"... 1 Page U-6

160 WEATHER PROTECTION Notes: Page U-7

161 WEATHER PROTECTION Notes: Page U-8

162 WHEELS AND TIRES WHEEL AND TIRE ASSEMBLY (Links) Includes Items 2, 19, 20 WHEEL AND TIRE ASSEMBLY (Turf saver) Includes Items 5, 19, 20 WHEEL AND TIRE ASSEMBLY (Sure Trail) Includes Items 8, 19, 20 WHEEL AND TIRE ASSEMBLY (Turf saver) Includes Items 10, 11, 12 Tire design may vary by Part Number Page V1

163 WHEELS AND TIRES FRONT HUB CAP ASSEMBLY Includes Items 15, 16 HUB CAP ASSEMBLY Includes Items 21, REAR Page V2

164 WHEELS AND TIRES 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 PART NO DESCRIPTION QTY G01 WHEEL AND TIRE ASSEMBLY, LINKS (INCLUDES ITEMS 2, 19, 20) G01 CARLISLE TIRE (LINKS 18 X 8.5-8, 4 PLY RATED) G03 WHEEL AND TIRE ASSEMBLY, TURF SAVER (INCLUDES ITEMS 5, 19, 20) G03 CARLISLE TIRE (TURF SAVER 18 X 8.5-8, 4 PLY RATED) G01 WHEEL AND TIRE ASSEMBLY, SURE TRAIL (INCLUDES ITEMS 8, 19, 20) G08 CARLISLE TIRE (USA TRAIL LOAD RANGE C) HUB CAP ASSEMBLY ( INCLUDES ITEMS 15, 16 ) HUBCAP GOLD CLIP ( NOT SHOWN) G01 DUST CAP G2 SPINDLE CAP G01 WHEEL RIM (4 LUG) G2 VALVE STEM G1 LUG NUT 1/ A/R Page V3

165 WHEELS AND TIRES Notes: Page V4

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168 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA s, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department