Cushman AC TUG Guide

ISSUED OCTOBER 2017
AC TUG
Service Parts Manual
668734 - D
REVISED MAY 2019

CALIFORNIA Proposition 65
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, 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, service your
vehicle in a well-ventilated area and wear gloves or wash your hands fre-
quently when servicing your vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC INDUSTRIAL TOW TRACTOR
AC TUG
STARTING MODEL YEAR 2017
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed be-
yond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits
and dis-claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
TSV reserves the right to incorporate engineering and design changes 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 to change without notice.
TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
These are the original instructions as defined by 2006/42/EC.
TO CONTACT US:
Textron Specialized Vehicles, Inc.
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
NORTH AMERICA:
Technical Assistance & Warranty PHONE: [phone], FAX: [phone]
Service Parts PHONE: [phone], FAX: [phone]
International: PHONE: [phone], FAX: [phone]

Page ii Service Parts Manual
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) approved parts may void the
warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States 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 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).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, place residue in acid-resistant
containers with absorbent material, sand or earth and dispose of in accordance with local,
state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

Page iii
TABLE OF CONTENTS
Service Parts Manual
SECTION Page 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 - 1
SEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1
DECALS AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1

Page iv
NOTES
Service Parts ManualService Parts Manual

Page v
Service Parts Manual
This manual is divided into several sections:
•GENERAL INFORMATION
•ILLUSTRATED PARTS BREAKDOWN
The first section, GENERAL INFORMATION, contains the following information:
•WARRANTY INFORMATION
•TABLE OF CONTENT
•HOW TO USE THE SERVICE PARTS MANUAL
The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your
vehicle.
USE OF THE 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 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 or VIN of your vehicle and
the model name be supplied to Service Parts when ordering any replacement components.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi Service Parts Manual
HOW TO USE THE SERVICE PARTS MANUAL
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the Table of Content 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.
Title Title
Left hand
illustration page Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74
70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,86
84,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 -Incl
udes Items 71 - 74
81- Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - Includes Items 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

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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
02 HUNTER GREEN
10 ARCTIC WHITE
30 FLAME RED
43 SAFETY YELLOW
HOW TO USE THE SERVICE PARTS MANUAL

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

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
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 PARTNO. 12345 DESCRIPTION QTY.
Page A-2
668734 Service Parts 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 POSITION) ............................................................... 1
6 612889 PEDAL SWITCH........................................................................................ 1
7 620030 SOCKET HEAD BOLT, M5 - .8 X 10MM LG.............................................. 4
8 600543 BUTTON HEAD TORX BOLT, M4 - .75 X 12MM LG................................. 2
9 658319 SPEED CONTROL SWITCH BRACKET................................................... 1
10 658775 SWITCH BRACKET................................................................................... 1
11 661992 PEDAL BRACKET..................................................................................... 1
12 840688 SPRING SUPPORT TAB........................................................................... 1
13 00702G2 HEX NUT, 5/16" - 18.................................................................................. 1
14 661800 PEDALARM.............................................................................................. 1
15 833104 RETAINING RING (EXTERNAL)............................................................... 1

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

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
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 PARTNO. 12345 DESCRIPTION QTY.
Page A-4
668734 Service Parts Manual
ACCELERATOR
1 661799 PEDAL GUARD ............................................................................................... 1
2 800026 PAN HEAD SCREW, 1/4" - 20 X 3/4" LG......................................................... 2
3 306375 HEX NUT, 1/4" - 20 .......................................................................................... 2
4 306396 LOCK WASHER, 1/4" ...................................................................................... 2
5 800557 CARRIAGE BOLT, 5/16" - 18 X 3/4" LG........................................................... 4
6 548911 HEX NUT, 5/16" - 18 ........................................................................................ 4
7 840419 SPEED CONTROL PEDAL.............................................................................. 1
8 00565G8 LOCK WASHER, 5/16" .................................................................................... 2

Page A-5 668734 Service Parts Manual
Notes:
ACCELERATOR

Page A-6
668734 Service Parts Manual
Notes:
ACCELERATOR

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

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
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 PARTNO. 12345 DESCRIPTION QTY.
Page B-2
668734 Service Parts Manual
BATTERY 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" X .69" X .06" .................................................................. 2
7 818303 SPACER (RUBBER) ........................................................................................ 2
8 306325 LOCK WASHER, 5/16" .................................................................................... 2
9 809152 FLAT WASHER, .31" X 1.12" X .10" ................................................................ 2
10 800315 WING NUT, 5/16" - 18...................................................................................... 2
11 840695 BATTERY HOLD DOWN PLATE ..................................................................... 2
12 806954 BATTERY HOOK BOLT................................................................................... 2
13 25971G16 #4 AWG WIRE ASSEMBLY.............................................................................. 1
14 628788 #4 AWG WIRE (BLACK), 10" LG..................................................................... 4
15 634270G09 #4 AWG BATTERY WIRE (BLACK), 22" LG.................................................... 1
16 103867 FLAT WASHER, .31" X .69" X .06" .................................................................. 2

Page B-3 668734 Service Parts Manual
Notes:
BATTERY SYSTEM

Page B-4
668734 Service Parts Manual
Notes:
BATTERY SYSTEM

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