Cushman AC TUG, Service & Parts Manual

Page 1: ...ISSUED OCTOBER 2017 AC TUG Service Parts Manual 668734 D REVISED MAY 2019...

Page 2: ...ead which are known to the State of California to cause can cer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary ser...

Page 3: ...ges to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by TSV and therefore is subject...

Page 4: ...ates of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies d...

Page 5: ...age No HOW TO USE THE SERVICE PARTS MANUAL V ACCELERATOR A 1 BATTERY SYSTEM B 1 BATTERY CHARGER C 1 BODY D 1 BRAKES E 1 ELECTRICAL F 1 FORK AND HANDLEBAR G 1 MOTOR H 1 REAR AXLE J 1 REAR SUSPENSION K...

Page 6: ...Page iv NOTES Service Parts Manual Service Parts Manual...

Page 7: ...HE MANUAL To use this manual consult the TABLE OF CONTENT to locate the information or illustration required Introduction of some revisions varies due to supply of components therefore it is possible...

Page 8: ...ound 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...

Page 9: ...rt 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 co...

Page 10: ...Page A 1 668734 Service Parts Manual ACCELERATOR 1 ACCELERATOR ASSEMBLY includes items 2 15 Front of Vehicle 2 10 15 13 4 8 5 9 6 12 11 3 14 3 7 2...

Page 11: ...s Manual ACCELERATOR 1 662468 ACCELERATOR ASSEMBLY INCLUDES ITEMS 2 15 1 2 840494 FLANGED BEARING 625 I D 2 3 548478 FLAT WASHER 641 X 1 188 X 04 3 4 840435 TORSION SPRING 1 5 600019 SENSOR ROTARY POS...

Page 12: ...Page A 3 668734 Service Parts Manual ACCELERATOR Front of Vehicle Floor Panel Accelerator Pedal Assembly 1 2 7 2 6 6 8 5 5 3 4 3 4...

Page 13: ...tes consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page A 4 668734 Service Parts Manual ACCELERATOR 1 661799 PEDAL GUARD 1 2 800026 PAN HEAD SCRE...

Page 14: ...Page A 5 668734 Service Parts Manual Notes ACCELERATOR...

Page 15: ...Page A 6 668734 Service Parts Manual Notes ACCELERATOR...

Page 16: ...Page B 1 668734 Service Parts Manual BATTERY SYSTEM 1 11 15 3 16 9 10 8 7 4 12 13 14 14 14 14 5 6 2 Front of Vehicle Battery Pan Part of Body Part of Battery...

Page 17: ...SYSTEM 1 612626 TROJAN BATTERY 8V T875 1 2 614015 TROJAN BATTERY 8V T890 1 3 628530 BATTERY RACK ASSEMBLY 1 4 628099 BATTERY HOLD DOWN BOLT 2 5 800697 CROWN LOCK NUT 5 16 18 2 6 103867 FLAT WASHER 31...

Page 18: ...Page B 3 668734 Service Parts Manual Notes BATTERY SYSTEM...

Page 19: ...Page B 4 668734 Service Parts Manual Notes BATTERY SYSTEM...

Page 20: ...Page C 1 668734 Service Parts Manual BATTERY CHARGER Front of Vehicle Inner Fender Part of Body Cord Storage Panel Part of Body 11 1 3 9 8 2 4 Rear Panel Part of Body 12 13 5 6 7 10...

Page 21: ...2 668734 Service Parts Manual BATTERY CHARGER 1 642629 ON BOARD CHARGER 48V 1000W 1 2 642451 ON BOARD CHARGER 48V 1500W 1 3 600462G01 AC CORD NEMA 5 15 PLUG 1 4 600462G02 AC CORD NEMA 6 15 PLUG 1 5 80...

Page 22: ...Page C 3 668734 Service Parts Manual Notes BATTERY CHARGER...

Page 23: ...Page C 4 668734 Service Parts Manual Notes BATTERY CHARGER...

Page 24: ...Page D 1 668734 Service Parts Manual BODY Front of Vehicle 1 2 4 5 6 11 7 9 10 8...

Page 25: ...rvice Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page D 2 668734 Service Parts Manual BODY 1 628871GXX BODY See COLOR CODE in HOW TO USE section 1 2 656574 DECKBOARD...

Page 26: ...Page D 3 668734 Service Parts Manual BODY Front of Vehicle 1 4 5 2 3 5 Front of Vehicle 25 24 22 22 23 21...

Page 27: ...dditional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page D 4 668734 Service Parts Manual BODY 1 893025G01 CLEVIS HITCH 1 2 308332 HEX NUT 1 2 13 4 3 120166 LOCK WASHER 1 2 4 4 311401 HEX HEAD...

Page 28: ...Page D 5 668734 Service Parts Manual Notes BODY...

Page 29: ...Page D 6 668734 Service Parts Manual Notes BODY...

Page 30: ...34 Service Parts Manual BRAKES Front of Vehicle 1 10 26 35 25 15 24 12 32 21 14 11 7 8 9 6 17 36 37 18 22 13 44 46 51 47 48 49 50 34 41 43 39 42 27 20 4 5 2 31 3 33 23 Fork Assembly Part of Body Frame...

Page 31: ...G FOR VEHICLES WITHOUT FRONT WHEEL BRAKE 1 7 629111 AXLE DRUM 5 LUG 160MM 2 8 75683G01 BANJO BOLT 2 9 75684G01 GASKET COPPER 4 10 800026 PAN HEAD PHILLIPS SCREW 1 4 20 X 3 4 LG 4 11 800869 HEX WASHER...

Page 32: ...OVER 1 34 812445 CLAMP 188 I D 1 35 306416 HEX HEAD BOLT 5 16 18 X 1 LG 4 36 820008 TEE FITTING 1 37 831930 BRAKE LINE MASTER CYLINDER TO TEE 1 38 670652 NYLON CLAMP 1 39 670897 CLAMP BRACKET T FITTIN...

Page 33: ...Page E 4 668734 Service Parts Manual Notes BRAKES...

Page 34: ...EL BRAKES Front of Vehicle 1 BRAKE HUB ASSEMBLY includes items 2 27 2 FRONT BRAKE SHOE ASSEMBLY includes items 3 15 20 FRONT AXLE HUB ASSEMBLY includes items 21 27 Fork Assembly 16 16 18 23 26 27 24 2...

Page 35: ...8 X 07 2 5 306396 LOCK WASHER 1 4 2 6 306419 HEX HEAD BOLT 1 4 20 X 1 2 LG 2 7 306494 LOCK WASHER 636 X 1 082 X 201 1 8 601084 LOCK NUT 3 8 24 2 9 805441 EXTENSION SPRING 1 10 806761 ADJUSTING PIN 2 1...

Page 36: ...REAR WHEEL BRAKE 1 HYDRAULIC BRAKE ASSEMBLY DRIVER SIDE includes items 4 19 21 2 HYDRAULIC BRAKE ASSEMBLY PASSENGER SIDE includes items 4 18 20 21 4 ADJUSTER KIT includes items 5 8 11 HARDWARE KIT inc...

Page 37: ...75685G02 HYDRAULIC BRAKE ASSEMBLY PASSENGER SIDE INCLUDES ITEMS 4 18 20 21 1 3 4 75826G01 ADJUSTER KIT INCLUDES ITEMS 5 8 1 5 4170096 ADJUSTER LEVER 1 6 4170339 HEX HEAD BOLT 1 4 28 X 1 2 LG 4 7 4170...

Page 38: ...Page E 9 668734 Service Parts Manual Notes BRAKES...

Page 39: ...Page E 10 668734 Service Parts Manual Notes BRAKES...

Page 40: ...Page F 1 668734 Service Parts Manual ELECTRICAL Seat Front of Vehicle 1 5 4 15 17 18 21 27 28 11 12 13 24 10 22 23 16 19 20 3 6 7 25 26 9 8 2 Part of Main Harness 29 31 29 29 30...

Page 41: ...8 810446 GROMMET RUBBER 1 9 660475 MAIN HARNESS 1 10 00439G4 HEX HEAD BOLT 5 16 18 X 1 1 2 LG 1 11 800874 FLAT WASHER 34 X 1 25 X 04 1 12 800315 WING NUT 5 16 18 1 13 800290 HEX CENTER LOCK NUT 5 16...

Page 42: ...68734 Service Parts Manual ELECTRICAL Front of Vehicle 1 7 7 11 12 7 18 20 20 19 19 8 17 17 15 14 16 8 8 10 4 4 3 3 2 22 2 Part of Solenoid Solenoid To Battery Positive Center Panel Part of Body 24 26...

Page 43: ...6 7 630763 CARRIAGE BOLT 1 4 20 X 1 1 2 LG 4 8 548910 HEX NUT 1 4 20 4 9 10 73290G02 BUZZER 1 11 00645G5 PAN HEAD PHILLIPS SCREW 6 32 X 62 LG 2 12 00525G5 HEX NUT 6 32 2 13 14 621330 SOLENOID 1 15 308...

Page 44: ...Page F 5 668734 Service Parts Manual ELECTRICAL Front of Vehicle Front of Vehicle Front of Vehicle 1 5 6 2 3 Main Harness Motor Part of Motor 11 12 13 14 18 19 20 21 Front Fork Part of Headlight...

Page 45: ...PTION QTY Page F 6 668734 Service Parts Manual ELECTRICAL 1 632185 DC DC CONVERTER 1 2 800296 PAN HEAD PHILLIPS SCREW 10 24 X 3 4 LG 4 3 00526G3 HEX NUT 10 24 4 4 5 667007 LED TAIL LIGHT WITH GANG CON...

Page 46: ...Service Parts Manual ELECTRICAL Front of Vehicle Front of Vehicle Solenoid 1 2 5 3 3 2 5 5 2 4 FOR CE EE VEHICLES Tube Support Weldment Part of Body 6 7 8 9 13 14 Front of Vehicle Seat Panel Body Pane...

Page 47: ...ER SPARK PROTECTOR 2 2 306932 HEX NUT 5 16 18 4 3 548604 HEX HEAD BOLT 5 16 18 X 3 4 LG 4 4 828247 GROMMET RUBBER 1 5 306325 LOCK WASHER 5 16 4 6 00568G4 EXTERNAL LOCK WASHER TOOTH TYPE 1 7 35213G02 G...

Page 48: ...Page F 9 668734 Service Parts Manual Notes ELECTRICAL...

Page 49: ...Page F 10 668734 Service Parts Manual Notes ELECTRICAL...

Page 50: ...668734 Service Parts Manual FORK AND HANDLE BAR Front of Vehicle 1 2 6 21 7 16 19 22 23 3 5 3 11 17 14 13 13 11 17 12 10 10 4 2 20 8 15 9 18 Fork Tube on Body FOR VEHICLES WITHOUT FRONT WHEEL BRAKES...

Page 51: ...LY 2 4 840689 FORK BRACKET LEFT SIDE 1 5 632673 FORK BRACKET RIGHT SIDE 1 6 120166 LOCK WASHER 1 2 1 7 305134 HEX JAM NUT 7 8 14 1 8 520231 THRUST WASHER 1 25 X 1 92 X 03 1 9 551041 WOODRUFF KEY 157 X...

Page 52: ...17 18 25 20 23 1 3 14 14 5 13 8 4 13 3 7 8 7 6 9 9 11 11 11 12 10 10 12 10 12 12 9 11 9 10 Fork Tube on Body Front Brake Hub Part of Brake Hub Part of Brake Hub FOR VEHICLES WITH FRONT WHEEL BRAKES 26...

Page 53: ...FT SIDE 1 5 882188 ARM ASSEMBLY RIGHT SIDE 1 6 805383 SUSPENSION SPRING 2 7 808969 BUSHING 2 8 311396 HEX HEAD BOLT 7 16 14 X 2 1 4 LG 2 9 306414 HEX HEAD BOLT 3 8 16 X 1 LG GRADE 5 4 10 120177 LOCK W...

Page 54: ...Page G 5 668734 Service Parts Manual Notes FORK AND HANDLE BAR...

Page 55: ...Page G 6 668734 Service Parts Manual Notes FORK AND HANDLE BAR...

Page 56: ...Page H 1 668734 Service Parts Manual MOTOR Front of Vehicle Rear Axle 1 2 5 6 4 3...

Page 57: ...as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page H 2 668734 Service Parts Manual MOTOR 1 681071 AC MOTOR 1 2...

Page 58: ...Page H 3 668734 Service Parts Manual Notes MOTOR...

Page 59: ...Page H 4 668734 Service Parts Manual Notes MOTOR...

Page 60: ...Parts Manual REAR AXLE Front of Vehicle Powertrain Mounting Weldment 1 36 32 33 34 33 35 2 14 20 22 21 16 15 25 5 17 7 28 27 27 9 9 3 4 4 8 19 8 6 6 10 13 11 12 23 10 24 11 18 13 12 REAR AXLE 17 05 1...

Page 61: ...X 1 1 4 LG 12 8 110060 HEX LOCK NUT 5 16 24 8 9 125064 PIN 5 16 X 1 2 10 130111 RETAINING RING INTERNAL 52MM 2 11 130290 RETAINING RING EXTERNAL 2 12 150388 SPACER 3 8 X 1 5 O D 2 13 180237 BALL BEARI...

Page 62: ...roduct Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR AXLE 32 62...

Page 63: ...Page J 4 668734 Service Parts Manual Notes REAR AXLE...

Page 64: ...Page K 1 668734 Service Parts Manual REAR SUSPENSION Front of Vehicle 1 5 4 3 11 14 14 13 8 8 2 6 7 9 12 10 Body 11...

Page 65: ...734 Service Parts Manual REAR SUSPENSION 1 661750 POWERTRAIN MOUNTING WELDMENT 1 2 667012 SHOCK ABSORBER 2 3 664446 SHOCK ABSORBER MOUNTING BRACKET 2 4 624030 FLANGED BUSHING 4 5 641289 FLANGED HEX HE...

Page 66: ...Page K 3 668734 Service Parts Manual Notes REAR SUSPENSION...

Page 67: ...Page K 4 668734 Service Parts Manual Notes REAR SUSPENSION...

Page 68: ...Page L 1 647694 Service Parts Manual SEATING 2 3 4 5 6 7 8 9 10 11 12 1 Front of Vehicle 7 Body...

Page 69: ...5 DESCRIPTION QTY Page L 2 647694 Service Parts Manual SEATING 1 198057 SEAT GREY 1 2 831187 SEAT ADJUSTER LEFT SIDE 1 3 831188 SEAT ADJUSTER RIGHT SIDE 1 4 664415GXX SEAT PANEL WELDMENT See COLOR COD...

Page 70: ...Page L 3 647694 Service Parts Manual Notes SEATING...

Page 71: ...Page L 4 647694 Service Parts Manual Notes SEATING...

Page 72: ...ND TIRES Style of tire may differ from tire shown Foam Filled Tire Solid Non marking Tire WHEEL AND TIRE ASSEMBLY FRONT 4 LUG RIM includes items 2 4 1 WHEEL AND TIRE ASSEMBLY REAR 5 LUG RIM includes i...

Page 73: ...34 Service Parts Manual WHEELS AND TIRES 1 886378 WHEEL AND TIRE ASSEMBLY FRONT 4 LUG RIM INCLUDES ITEMS 2 4 1 2 602494 TIRE 1 3 WHEEL 1 4 886735 VALVE STEM 1 5 6 7 670355 WHEEL AND TIRE ASSEMBLY REAR...

Page 74: ...Page M 3 668734 Service Parts Manual Notes WHEELS AND TIRES...

Page 75: ...Page M 4 668734 Service Parts Manual Notes WHEELS AND TIRES...

Page 76: ...ECALS AND LABELS 665817 Front of Vehicle Front of Vehicle 2A 2A 10A 2A 2A 15A 7 5A 666035 6683 75 F R N 63 55 25 M A X 8000 lb s 3628 kg M A X 8000 lb s 3628 kg 4000 lb s 1814 kg 4000 lb s 1814 kg Fro...

Page 77: ...sult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page N 2 668734 Service Parts Manual DECALS AND LABELS 1 624539 CUSHMAN EMBLEM 1 2 71597G01 SELF THRE...

Page 78: ...Page N 3 668734 Service Parts Manual Notes DECALS AND LABELS...

Page 79: ...Page N 4 668734 Service Parts Manual Notes DECALS AND LABELS...

Page 80: ...GO Division of Textron Inc Technical Communications Department Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Owner s guides and repair manuals are available...