Cushman HAULER 800X Owner's Manual
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Cushman HAULER 800X Owner's Manual

Issued july 2011 gasoline powered vehicle
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Owner's Guide
623718
ISSUED JULY 2011

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  • Page 1 Owner’s Guide 623718 ISSUED JULY 2011...
  • Page 2 WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehi- cles;...
  • Page 3 Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. OWNER’S GUIDE GASOLINE POWERED VEHICLE HAULER 800X STARTING MODEL YEAR 2012 Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications.
  • Page 4 FOREWORD Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SECTION PAGE NO. SAFETY..................................1-3 to 1-12 GENERAL SPECIFICATIONS..........................2-1 to 2-6 INTRODUCTION............................... 3-1 to 3-8 OPERATING PROCEDURES ..........................4-1 to 4-10 MAINTENANCE...............................5-1 to 5-26 APPENDIX................................
  • Page 6 TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: Page iv...

  • Page 7: Safety

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SAFETY................................. 1-3 NOTICES, CAUTIONS, WARNINGS, AND DANGERS..................1-3 GENERAL ................................1-5 GENERAL OPERATION ............................1-5 MAINTENANCE ..............................

  • Page 8: Safety

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 1 - 2...

  • Page 9: Notices, Cautions, Warnings, And Dangers

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface.
  • Page 10 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. The exhaust emissions of this vehicles’...

  • Page 11: General

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. GENERAL All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur.

  • Page 12: Maintenance

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. • apply service brake to control speed on steep grades • maintain adequate distance between vehicles • maintain adequate distance between vehicles •...

  • Page 13: Labels And Pictograms

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LABELS AND PICTOGRAMS MIN 150 6 4 2 6 4 2 35962 G0 35962G01 35964G01 71131G01 74443G01 74443G01 www ezgo com 71489G01...
  • Page 14 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD xxx lbs.
  • Page 15 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. CLEAN UP GASOLINE DO NOT EXPOSE SPILLS WITH WATER H O 2 BEFORE STARTING TO FLAME ENGINE UNLEADED DO NOT GASOLINE...
  • Page 16 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS...
  • Page 17 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ENGINE CRANKING START POSITION REAR DIFFERENTIAL LOCK SWITCH PULL HANDLE UP TO ENGAGE PARK BRAKE FRONT DIFFERENTIAL LOCK SWITCH. WARNING READ OWNER'S MANUAL BEFORE ENGAGING FRONT DIFFERENTIAL...
  • Page 18 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 1 - 12...

  • Page 19: General Specifications

    Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. Hauler 800X Vehicle Specifications ..........................2 - 3 Hauler 800X Vehicle Dimensions ............................ 2 - 4 Hauler 800X Vehicle Incline Information and Turning Diameter................... 2 - 5 2 - 1...

  • Page 20: Read All Of This Manual To Become Thoroughly Familiar With This Vehicle. Pay Particular Attention To All Notices, Cautions, Warnings, And

    GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 2 - 2...
  • Page 21 Forward - Reverse Rear Axle Ratio 11.42:1 (Forward) 15.78:1 (Reverse) Some items shown may be optional equipment 2012 Hauler 800X G Released: 10/15/2011 Specifications are subject to change without notice Revised: 10/15/2011 * Field installed accessories may require installation charges...
  • Page 22 49.0 in. (124.0 cm) 9.5 in. (24.0 cm) (Front) 65.5 in. (166.0 cm) 37.0 in. (94.0 cm) 103.5 in. (261.0 cm) (Rear) 38.0 in (97.0 cm) 46.5 in. HAULER 800X (118.0 cm) 36.0 in. (91.5 cm) Vehicle Dimensions 2 - 4...
  • Page 23 Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 ◦ MAX 25% or 14 ◦ MAX TURNING CLEARANCE DIA. 24 ft (7.3 m) HAULER 800X Vehicle Turning Clearance Diameter 2 - 5...
  • Page 24 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 2 - 6...

  • Page 25: Introduction

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. FEATURES..................................3-3 General Information ....................................3-3 Key Switch / Headlight Switch..................................3-4 Low Oil Pressure Indicator Light ................................. 3-4 Fuel Guage .........................................
  • Page 26 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 2...

  • Page 27: Features

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. FEATURES General Information If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’...

  • Page 28: Key Switch / Headlight Switch

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 1. Key Switch / Headlight Switch Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key.

  • Page 29: Horn

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 7. Horn The horn is operated by pushing the horn button located on the floor to the left of the brake pedal. 8.

  • Page 30: Brake Light/Turn Signal

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 11. Brake Light/Turn Signal The combination brake light/turn signal assemblies are located on the rear fenders. 12. Glove Box A passenger-side locking glove box is standard, driver-side is offered as an option.
  • Page 31 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 7...
  • Page 32 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 3 - 8...

  • Page 33: Operating Procedures

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SERIAL NUMBER LOCATION ............................4-3 BEFORE INITIAL USE ................................ 4-4 OPERATING THE VEHICLE ............................... 4-4 Run-in..........................................
  • Page 34 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 4 4 4 4 4 - 2...

  • Page 35: Serial Number Location

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SERIAL NUMBER LOCATION Two serial number and manufacture date code plates are on the vehicle. One is placed on the body below the front, driver side of the seat.

  • Page 36: Before Initial Use

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. BEFORE INITIAL USE Read and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle and its equipment as well as how to use it safely.

  • Page 37: Run-In

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. down an incline. A sudden stop or change of direction may result in loss of control. Slow down before and during turns.

  • Page 38: Cold Starting

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure. NOTICE The oil dipstick/fill cap must be in place before operating the engine.

  • Page 39: Starting The Vehicle On Hill

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. • When the accelerator pedal is released, the ignition circuit is de-energized and the engine stops. To stop the vehicle more quickly, depress the service brake pedal NOTICE When the direction selector is in the reverse position, a warning signal will sound to indicate that the vehicle is ready to...

  • Page 40: Battery

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The fuel tank is located under the seat on the passenger side of the vehicle (Ref ). Fill the tank with fresh, clean, automotive grade gasoline.

  • Page 41: Towing A Trailer

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The windshield does not provide protection from tree limbs or flying objects. To prevent damage to the vehicle, do not hold on to sun top struts and stand on body panels. The sun top and windshield provide some protection from the elements;...
  • Page 42 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 4 4 4 4 4 - 10...

  • Page 43: Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. VEHICLE CLEANING AND CARE ............................5-4 Vehicle Cleaning ......................................5-4 REPAIR ....................................5-5 Lifting the Vehicle......................................5-5 WHEELS AND TIRES................................
  • Page 44 MAINTENANCE SPARK PLUGS..................................5-21 PROLONGED STORAGE ..............................5-22 PERIODIC SERVICE SCHEDULE .............................5-23 CAPACITIES AND REPLACEMENT PARTS ........................5-25 Hardware ........................................5-25 5 - 2...
  • Page 45 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 5 - 3...

  • Page 46: Vehicle Cleaning And Care

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Vehicle Cleaning And Care Vehicle Cleaning To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

  • Page 47: Repair

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Repair Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle to be raised. To reduce the possibility of severe injury or death from a vehicle falling from a jack: Be sure the vehicle is on a firm and level surface.

  • Page 48: Wheels And Tires

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Center of Front Axle Flat Portion of Frame Outside End of Rear Axle View from Underside of Vehicle Lifting the Vehicle WHEELS AND TIRES A tire explosion can cause severe injury or death.

  • Page 49: Wheel Installation

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Use caution when inflating tires. Due to the low volume of the small tires, overinflation can occur in seconds. Overin- flation could cause the tire to separate from the wheel or cause the tire to explode.

  • Page 50: Light Bulb Replacement

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LIGHT BULB REPLACEMENT Inside of Cowl Headlight Casing To reduce the possibility of premature bulb failure, do Screw not touch new bulbs with bare fingers.

  • Page 51: Towing

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less.

  • Page 52: Service And Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Always remove the windshield before transporting. If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom secured. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points.

  • Page 53: Routine Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ROUTINE MAINTENANCE To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, or frequent use with maximum load.

  • Page 54: Changing The Oil

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Remove the dipstick and wipe off the entire area with a lint free cloth. Clean Entire Dipstick Insert the dipstick fully into the dipstick hole and remove.
  • Page 55 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. The selection of oil is dependent upon the service that the vehicle will perform. Most vehicles require 10W-30 oil, whereas vehicles used at capacity or near capacity load applications will utilize 10W-40 oil after a break-in period of 100 hours.
  • Page 56 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Clean the area around filter. Using a filter wrench, strap wrench or other suitable wrench, remove the filter (B) from the engine and allow the oil to drain.

  • Page 57: Starter Generator Belt Tension

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1 1/3 quarts (1.3 liters) to allow for possible residual oil left in engine.

  • Page 58: Adjusting The Belt

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Tighten a new starter/generator belt to 90 - 110 lbs. (41-50 kg) tension when a gauge is applied half way between the two pulleys.

  • Page 59: Brakes

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Use of a water hose without first neutralizing any acid, will move acid from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor.

  • Page 60: Periodic Brake Test For Mechanical Brakes

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC BRAKE TEST FOR MECHANICAL BRAKES Dry, Level, Clean, Paved Surface Accelerate To Maximum Speed Latch Parking Brake Line or Marker and Take Foot Off Pedal...

  • Page 61: Rear Axle

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. up of dirt and debris in the air intake and cooling fins. Dirt and debris may clog the engine’s air cooling system.

  • Page 62: Air Cleaner Inspection And Replacement

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Fill / Check Plug Drain Plug Add, Check and Drain Rear Axle Lubricant AIR CLEANER INSPECTION AND REPLACEMENT The air cleaner unit on the vehicle is a dry unit.

  • Page 63: Lubrication

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LUBRICATION Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

  • Page 64: Prolonged Storage

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PROLONGED STORAGE To reduce the possibility of severe injury or death resulting from a possible explosion: Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

  • Page 65: General Operation

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle.

  • Page 66: Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket PARK BRAKE Lubricate as required, use light oil.

  • Page 67: Capacities And Replacement Parts

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. CAPACITIES AND REPLACEMENT PARTS Hardware Fuel Tank / Fuel 6.0 gal (22.5 liters) / 87 Octane Min. Periodically, the vehicle should be inspected for loose Engine Oil 1.4 US qt (1.3 liters)
  • Page 68 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: 5 - 26...
  • Page 70 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, 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 www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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