Cushman Hauler 800XE Owner's Manual
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Cushman Hauler 800XE Owner's Manual

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OWNER'S GUIDE
HAULER 800XE
642988-B
ISSUED FEBRUARY 2015
REVISED FEBRUARY 2016

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  • Page 1 OWNER’S GUIDE HAULER 800XE 642988-B ISSUED FEBRUARY 2015 REVISED FEBRUARY 2016...
  • Page 2 WELCOME Thank you for purchasing this vehicle. Before you drive the vehicle, read this Owner’s Guide. This guide contains mainte- nance and operation information. The illustrations can show items that are optional for your vehicle. You can do most of the service procedures in this guide with common, automotive hand tools. If necessary, contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule.
  • Page 3 OWNER’S GUIDE ELECTRIC POWERED VEHICLE HAULER 800XE STARTING MODEL YEAR 2015 CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids con- tained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 4 FORWARD This vehicle was designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless other- wise indicated. Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective. If you do not correctly do maintenance on the batteries, you will cancel the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY GENERAL ......................... 1 NOTICES, CAUTIONS, WARNINGS AND DANGERS ............ 1 GENERAL OPERATION....................3 MAINTENANCE ........................ 4 LABELS AND PICTOGRAMS................... 5 GENERAL SPECIFICATIONS VEHICLE DIMENSIONS ....................8 TURNING DIAMETER AND INCLINE INFORMATION ............ 9 INTRODUCTION FEATURES ........................11 General Information ..................
  • Page 6 TABLE OF CONTENTS OPERATING PROCEDURES SERIAL NUMBER LOCATION ..................15 BEFORE INITIAL USE..................... 15 PORTABLE CHARGER INSTALLATION ................ 16 UNDERSTAND THE CHARGER..................18 LED Operation Codes ..................18 LED Fault Codes ....................19 HOW TO USE THE CHARGER..................19 CHARGER MAINTENANCE.................... 19 HOW TO OPERATE THE VEHICLE ................
  • Page 7 TABLE OF CONTENTS MAINTENANCE VEHICLE CLEANING AND CARE.................. 31 ENVIRONMENTAL CONCERNS..................31 Battery Disposal ....................32 LIFTING THE VEHICLE....................32 WHEELS AND TIRES..................... 33 Tire Repair ......................34 Wheel Installation ....................34 LIGHT BULB REPLACEMENT ..................35 Headlight ......................35 Taillight .......................
  • Page 8 TABLE OF CONTENTS Battery Charging ....................46 AC Voltage ......................47 Fault Diagnosis ....................47 Hydrometer ......................47 Using A Hydrometer ....................48 Battery Charger Maintenance ................48 PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE .................. 51 Owner’s Guide...

  • Page 9: Safety

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY GENERAL For any questions about material in this manual, contact an authorized representative. Read and understand all labels on the vehicle. Always replace any damaged or missing labels. Steep hills allow the vehicle to move at faster speeds than on a flat surface.
  • Page 10 All users must read and obey this manual. Make sure you give special attention to the CAUTIONS, WARNINGS and DANGERS. For questions about this vehicle, contact your E-Z-GO/CUSHMAN dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

  • Page 11: General Operation

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL OPERATION Read the following warnings before attempting to operate the vehicle. When you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle. Drive the vehicle only as fast as terrain and conditions allow.

  • Page 12: Maintenance

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove all jewelry before you service the vehicle. Do not allow loose clothing or hair to contact the moving parts. Do not touch hot objects.

  • Page 13: Labels And Pictograms

    SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LABELS AND PICTOGRAMS TO OPERATE VEHICLE: - TURN KEY TO ON FOR INFORMATION DO NOT OPERATE REMAIN SEATED - MOVE DIRECTION SELECTOR TO REFER TO OWNERS NO PUBLIC UNDER DRUG/ALCOHOL...
  • Page 14 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 15: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS MODEL: HAULER 800X TYPE: ELECTRIC 48V POWERED TRUCK MODEL YEAR: 2015 Part No: 641725 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS TrueCourse Technology: Programmable to multiple vehicle terrains, with expanded regenerative braking function, and vehicle charger lockout...

  • Page 16: Vehicle Dimensions

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE DIMENSIONS 15 in. (38 cm) 49 in. (126 cm) 9.5 in. (24 cm) Front 65.5 in. (166 cm) 37 in.

  • Page 17: Turning Diameter And Incline Information

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING DIAMETER AND INCLINE INFORMATION TURNING CLEARANCE DIAMETER 24 ft (7.3 m) Owner’s Guide...
  • Page 18 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 19: Introduction

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INTRODUCTION FEATURES General Information If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key switch in the OFF position.

  • Page 20: Accelerator Pedal

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4. Accelerator Pedal Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause severe injury or death. With the key switch in the ON position, press the accelerator pedal to start the motor.

  • Page 21: Weather Enclosure (If Equipped)

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 15. Weather Enclosure (if equipped) A weather enclosure supplies protection from strong weather conditions. 16. DC to DC Converter The DC to DC converter supplies power to the power accessories.

  • Page 22: Run/Tow Switch

    INTRODUCTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 19. Run/Tow Switch The run/tow switch is used when the vehicle is stopped, does not operate or removed from service. The switch is found below the seat on the passenger side of the vehicle. To prevent severe injury or death caused from loss of vehicle control, set the parking brake before you move the switch to TOW position.

  • Page 23: Operating Procedures

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. OPERATING PROCEDURES SERIAL NUMBER LOCATION The vehicle has two serial number and manufacture date code plates. PART C label is found on the body panel below the driver seat.

  • Page 24: Portable Charger Installation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Explosive hydrogen gas is created during the charge cycle of the batteries. Good ventilation is necessary to remove gas from closed spaces.
  • Page 25 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Supply enough ventilation during the charge cycle. Never charge a frozen battery. Read all of the manufacturers specified precautions for the battery. For example, recommended rates of charge and removal of cell caps during charge cycle.

  • Page 26: Understand The Charger

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hanging Holes Provide Protection From Elements Keep cooling fins clean and free of dirt and debris NEMA 15 - 5R Grounded AC Receptacle 110 - 120 VAC.

  • Page 27: Led Fault Codes

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LED Fault Codes • RED FLASH: The light turns on quickly, and does not flash after that - check for valid AC voltage. •...

  • Page 28: How To Operate The Vehicle

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HOW TO OPERATE THE VEHICLE Incorrect use of the vehicle or lack of maintenance can cause damage or decreased performance.

  • Page 29: Key And Headlight Switch Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. When you drive the vehicle at full speed on a dirt road, loose surface or wet grass, the necessary distance to stop the vehicle will increase.

  • Page 30: Accelerator Pedal Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Pedal Operation Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause severe injury or death.

  • Page 31: Truck Bed Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. With the switch in TOW position: • the controller is deactivated • the electronic braking system is deactivated which allows the vehicle to be towed or roll freely •...

  • Page 32: Truck Bed Latch Operation

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Never fill a gas container in the truck bed. Static discharge can ignite gasoline vapor and cause an explosion.

  • Page 33: Trucourse Technology System™ (Tct)

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCOURSE TECHNOLOGY SYSTEM™ (TCT) Performance Options TruCourse Technology (TCT) system vehicles are operated in one of four performance options. All options have standard features that control, protect and diagnose the vehicle.
  • Page 34 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TCT Operation With the switch in TOW position: • the controller is deactivated • the electronic braking system is deactivated which allows the vehicle move freely •...

  • Page 35: General

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. General The motor speed is sensed and controlled by the controller. When the vehicle moves faster downhill, the speed sensor causes the motor to electrically control the speed of the vehicle through regenerative braking.

  • Page 36: Walk-Away Feature

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. between 8 and 3 mph (5 kph), or the accelerator pedal is applied. The warning beeper will not activate. When pedal-up braking is activated by this sequence of occurrences, the motor generates power which is returned to the batteries.

  • Page 37: Starting And Driving

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTING AND DRIVING To decrease the risk of roll-back, do not release the brake pedal until the motor has started. All vehicles have an interlock system that disables the controller and prevents operation or tow of the vehicle while the charger is connected.

  • Page 38: Coasting

    OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Coasting Do not allow the vehicle to coast at above recommended speeds. Control vehicle speed with the brake. The vehicle has a braking feature (pedal-up) that decreases the speed when the accelerator pedal is released.

  • Page 39: Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE VEHICLE CLEANING AND CARE Read and understand all instructions supplied by the manufacturer of the pressure washer before use.

  • Page 40: Battery Disposal

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Disposal Return used batteries to the manufacturer or lead smelter for recycling purposes. For neutralized spills, put residue in acid-resistant containers with absorbent material, sand or earth and discard according to state and federal regulations for acid and lead compounds.

  • Page 41: Wheels And Tires

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Put the jack at the center of the front axle. Lift the vehicle enough to put two jack stands below the front frame crossmember as shown. Lower the jack and test the stability of the vehicle on the two jack stands.

  • Page 42: Tire Repair

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tire Repair Tool List Quantity Tool List Quantity Lug Wrench, 3/4”............1 Impact Socket, 3/4” ............. 1 Impact Wrench ............1 Torque Wrench, ft.

  • Page 43: Light Bulb Replacement

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIGHT BULB REPLACEMENT To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry paper or paper towels to touch the glass part of the bulb.

  • Page 44: Transporting Vehicle

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRANSPORTING VEHICLE Towing Do not ride or allow other people on the vehicle being towed. Do not try to tow the vehicle with ropes, chains or any device different from a tow bar approved by the factory.

  • Page 45: Routine Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disconnect the negative battery terminal before you service the vehicle to prevent accidental operation. Wear eye protection when you service the vehicle. Be careful when you do work around batteries, use solvents or compressed air.

  • Page 46: Brakes

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Dry, Level, Clean, Paved Surface Accelerate to maximum speed. Always inspect the pedal travel before you operate a vehicle to confirm some brake function is found.

  • Page 47: Rear Axle

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE The only maintenance necessary for the first five years is the inspection of the rear axle for lubricant leakage. Unless leakage is visible, the lubricant needs to be replaced after five years.

  • Page 48: Hardware

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE Normally, three classes of standard hardware and three classes of metric hardware are used in the vehicle. Grade 5 hardware is identified by the three marks on the hexagonal head;...

  • Page 49: Battery Charging And Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGING AND MAINTENANCE Safety Always obey the following warnings when working on or near batteries. To prevent the risk of battery explosion, keep all flammable materials, open flames or sparks away from the batteries.

  • Page 50: Battery Maintenance

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A battery does not store electricity, but it can produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy.
  • Page 51 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A battery being charged will ’gas’ with most gassing occurring at the end of the charging cycle. This gas is hydrogen which is Vent Cap lighter than air.

  • Page 52: Battery Cleaning

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Clean all electrolyte spills to the body and eyes with clear water.

  • Page 53: Battery Replacement

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement Before you disconnect or connect a battery or any other wires, move the run/tow switch to TOW position. After you connect a battery or any other wires, wait a minimum of 30 seconds before you move the run/tow switch to the RUN position.

  • Page 54: Battery Charging

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. During storage, the batteries need attention to keep them maintained and prevent discharge. In high temperatures the chemical reaction is faster, while low temperatures cause the chemical reaction to slow.

  • Page 55: Ac Voltage

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. AC Voltage The battery charger output is directly related to the input voltage. If the vehicle receives an incomplete charge in a nor- mally adequate time period, low AC voltage can be the cause.

  • Page 56: Using A Hydrometer

    MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Using A Hydrometer ELECTROLYTE TEMPERATURE Draw electrolyte into the hydrometer and release it sev- eral times to permit the thermometer to adjust to the °F °C electrolyte temperature and note the reading.
  • Page 57 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
  • Page 58 MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...

  • Page 59: Periodic Service Schedule

    PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - Check pressure and inspect condition of tires &...
  • Page 60 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Owner’s Guide...
  • Page 63 Normal use, age, wear or abuse can cause some components on the vehicle to fail. The manufacturer can not know all possi- ble component failures or the methods that failures can occur. A vehicle in need of repair does not operate correctly and can be dangerous.
  • Page 64 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906-3852 USA CONTACT US: North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GETEZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts &...

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