Cushman Hauler 800 & Hauler 1000 Electric Utility Vehicle Service Parts Manual 2012 – PDF
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Illustrated service parts manual for the Cushman Hauler 800 and Hauler 1000 electric utility vehicles from the 2012 model year. Document 624951 with exploded views, item numbers and part numbers for every major assembly from accelerator pedal to rear axle.
Description
The Cushman Hauler 800 & Hauler 1000 Electric Utility Vehicle Service Parts Manual is the illustrated parts breakdown released by Cushman for both electric utility truck models starting with the 2012 model year. Published under document number 624951, it was issued in August 2011 and carries a revision dated October 2012. Across 156 pages it takes the whole vehicle apart on paper, assembly by assembly, so a part can be identified visually, matched to an item number, and then ordered by its correct part number.
File Details
- Manual type: Illustrated Service Parts Manual
- Brand: Cushman (E-Z-GO Division of Textron Inc.)
- Models covered: Hauler 800, Hauler 1000 (electric utility vehicles)
- Model year: Starting model year 2012
- Document number: 624951
- Issued: August 2011 — Revised: October 2012
- Language: English
- Page count: 156 pages
- File format: PDF
Chapters Covered
The manual is organised as a general information section, an illustrated parts breakdown covering every vehicle system, and an appendix of specialty products and accessories.
- How to Use the Service Parts Manual
- Accelerator — pedal box assemblies for Hauler 1000 and Hauler 800, accelerator pedal, rod, spring, micro switch, inductive throttle sensor
- Battery Charger — 48V charger with 3 metre and 5.5 metre cords, world chargers, Delta-Q portable and on-board chargers
- Body — floorpans, access cover, front basket, instrument panel, cowl, fenders, rocker panels, brushguards, splash panels, seat wrap, side panels
- Brakes – Mechanical and Front Disc Brakes — brake pedal assemblies with and without brake lights, compensator assembly, brake cables, brake assemblies, brake drum assemblies, disc hub assemblies, calipers, master cylinder
- Cab — steel cab, vinyl door kits and steel door kits
- Electrical System — batteries, wire harnesses, charger receptacle, headlights, tail lights, turn signal kit, dash direction selector, state of charge meter, reverse buzzer, DC to DC converter kit, fuse block, horn, hour meter kit, key switch, work light bar, work light kit, strobe light kit
- Electronic Speed Control — controller, heatsink, solenoid assembly, resistor assembly, tow switch cover assembly, walkaway relay harness
- Front Suspension & Steering — front axle, spindle and hub assemblies, shock absorbers, leaf spring, rack and pinion unit, steering column kit, steering wheel, tie rod assembly
- Motor — 48V motor with commutator end head, armature, brush box assembly, bearings, speed sensor
- Rear Axle — rear axle assembly 12.44:1 for Hauler 800 and 14.76:1 for Hauler 1000, axle shafts, differential guard, fill/check plug
- Rear Suspension — shock absorbers, leaf springs, U-bolts, shackle plates, rubber bushings, axle bumper bracket
- Seating — seat back support, seat back assembly, seat bottom assembly, vinyl covers, hip restraints, seat hinges
- Truck Bed — 36 inch and 40 inch plastic beds, aluminium bed in manual lift and electric lift versions, tailgates, gas springs, latch assemblies, electric dump kits
- Weather Protection — canopy struts kit, black top enclosure, full windshield, split windshield, windshield kits, mirror assembly
- Wheels and Tires — wheel and tire assemblies in Links, Turf Saver and Sure Trail treads, wheel rims, hub caps, valve stems, lug nuts
What makes this particular document useful is not the chapter list but the way each chapter is built. Every system is presented as a numbered exploded illustration with the components drawn in their true assembly order, and each callout number on the drawing is tied back to a parts list giving the part number, description and quantity. Assemblies that are sold complete are marked and the components inside them indented beneath, so it is immediately clear whether a bearing, seal or brush can be bought separately or only as part of a larger unit. Where a part is shown but cannot be purchased on its own, the parts list uses an asterisk and directs you upward to the lowest assembly that Cushman actually sells — a small detail that saves a lot of wasted ordering time.
Where the Hauler 800 and Hauler 1000 Differ
Both models share the same manual, and the parts lists state the distinction directly at the line level. The Hauler 1000 pedal box assembly is listed separately from the Hauler 800 pedal box assembly, and each has its own page range and item block. The rear axle is split by ratio — 12.44:1 for the Hauler 800 and 14.76:1 for the Hauler 1000 — and the brake drum assemblies are listed as Hauler 800 only and Hauler 1000 only with their own internal item numbers. Truck bed listings repeat the same pattern, with 36 inch and 40 inch plastic beds plus the aluminium bed in manual and electric lift forms. Weather protection hardware and several body panels such as seat wrap, side panels and rocker panels are also flagged as belonging to one model or the other. Checking the model note on the page before ordering is the single most important habit this manual teaches.
Colour Codes and Part Number Lookup
The opening section explains how body component part numbers work. The last two digits of a body part number carry the colour code, so the same cowl, rear body, seat pod, side panel or seat wrap is listed once and then finished with the two-digit code matching the vehicle. A full code table is printed in the manual, covering no paint, primer only, special colours, and the complete range of production and camouflage finishes. The manual also explains the reverse lookup route — if you already know the part number you go straight to the parts list column, and if you do not, you start at the general index, find the illustration, read the item number, and take the part number from the matching line.
How This Manual Helps You
Owners and workshops working on a Cushman Hauler 800 or Hauler 1000 electric utility vehicle can identify and order the correct component for almost any job the machine needs. Accelerator linkage faults, charger and receptacle problems, brake shoe, cable and compensator work, disc brake caliper and master cylinder service, steering rack and tie rod replacement, motor brush and bearing renewal, rear axle and differential parts, suspension springs and shock absorbers, seat and body panel replacement, truck bed hydraulics and dump kits, canopy and windshield assemblies, and wheels, rims and tyres are all broken down in exploded form.
Ordering the wrong part is the most expensive mistake in utility vehicle repair, and it usually happens because a component looks similar to another version or belongs to the other model. Working from an exploded illustration with the correct item number and part number beside it removes that guesswork. Torque values, fitment and assembly order stay consistent because the drawing shows how the pieces actually stack.
IMAGES PREVIEW
Delivery is instant. The PDF is available to download immediately after payment, there is no shipping and nothing to wait for in the post. Keep it on a phone or tablet in the workshop, open it on a laptop at the parts counter, or print the pages you need for the job in front of you.
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