2006 Cushman Tug (Electric)
Contents
1. LIMS SYIJ NIJSSYd AYYVI LON OG 173 YJANN Q31V201 IVNNVN SYOLYYIdO GNVLSH3GNn ANY ENEE EEE SH2H10 40 OL 110544 AVIN ONINAVM AL31VS 4390 OL JANI 77130 10 88 O1 LON SI ASN HONS ALVINdOUddV LI SI YON YO 13331 SAvO NO ASN GAYNLOVANNVIN YO GANSISAC LON SI LI LOW ALSSVS FTSIHSA YOLOW 2133V3 L TVNOLLVN JHL 30 AHL NIHLIM 3191H3A V LON SI SIHL 11V13q veesze S 4SNMO 335 IRIS NOLLdNYYALNI 30 359 NI 915 01 55 V 03001003 1 372143 SIHL W140 286068 97 0001 SHATIVEL 97 0051 SHATIVEL Z 810005 049 WNWIXVW 1103 E IEEE NVO X3LVJ X9 MOL 4191H2A SIHL 76130 2 Service Parts Manual THE OF NON U L PARTS WILL VOID 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 887192 BODY amp FRAME COMPLETE WITH SPINDLE BEARING AND DECALS 831938 DECK REAR 887921 COVER MASTE2. When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 891657 CONNECTOR 36V COMPLETE 891693 CONNECTOR BATTERY 36V EC 800024 BOLT 1 4 20 X 1 1 2 LG 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 813997 GROMMET o BB 882954 WIRE 6 GA BLACK 825947 TUBING 837297 COVER KEY HEAD 837462 BOOT BATTERY TERMINAL 837408 DECAL BATTERY IDENTIFICATION zo LIES yo a amp N 836890 836889 828247 7X N 837322 Service Parts Manual Page G 2 ELECTRICAL COMPONENTS 1 INCLUDES ITEMS 2 3 3 INCLUDES ITEM 4 O Front of Vehicle Page H 1 Service Parts Manual ELECTRICAL COMPONENTS 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 892942 HEADLIGHT SET ACCESSORY 1 INCLUDES ITEMS 2 3 840854 BRACKET HEADLIGHT 892523 HEADLIGHT 3 INCLUDES ITEM 4 840860 BULB HEADLIGHT 836354 SWITCH FORWARD REVERSE 886311 SWITCH IGNITION 830640 SWITCH ROCKER 841111 GAU
3. INCLUDES ITEMS 2 3 819936 DECAL WARNING BATTERY CHARGING 824061 DECAL LIFT OUT WARNING 887783 HOLD DOWN BATTERY 800315 WING NUT 5 16 18 103867 WASHER 5 16 818303 SPACER RUBBER 883078 WIRE BATTERY CONNECTION 809152 WASHER SPECIAL 885278 RECEPTACLE WITH HARDWARE 50 AMP 308087 WASHER 6 306990 LOCK WASHER 6 302437 NUT 6 32 120052 LOCK WASHER 10 306531 NUT 10 24 308090 WASHER 1 4 800059 NUT 1 4 20 LOCK 887205 WIRE ASS Y 50 AMP 20 INCLUDES ITEM 21 825341 PLUG 50 AMP 313062 SCREW 6 32 X 1 LG 303459 SCREW 1 4 20 X 1 1 2 LG 306396 LOCK WASHER 1 4 887204 WIRE 28 INCLUDES ITEM 29 Page N 3 Service Parts Manual LIFT OUT BATTERY RACK THE USE OF 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 822821 PLUG 175 AMP 822904 BUSHING 884045 WIRE BATTERY DISCONNECT 30 INCLUDES ITEM 31 822821 PLUG 175 AMP 822904 BUSHING 800271 SCREW 10 24 841821 MOUNT CONNECTOR BODY 893557 WIRE ASS Y SINGLE 893558 WIRE ASS Y SINGLE 887819 WIRE CHARGER RECEPTACLE BLACK 887818 WIRE CHARGER RECEPTACLE RED 320107 WIRE TIE 7 841851 GAUGE BATTERY CONDITION METER 841852 BATTERY BATTERY CONDITION METER 893700 H
4. SIN3 LI SHQfYTIONI 86 9 6L SWALI SAGNTONI 8 Service Parts Manual Page Q 1 REAR WHEEL BRAKE Where applicable THE USE OF NON UL PARTS WILL VOID ANY UL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 304636 COTTER PIN 1 8 X 1 1 8 805843 NUT 5 8 18 836674 805875 805860 806274 o a BB 821152 WHEEL 805030 BRAKE DRUM Aa OO N 306932 NUT 5 16 18 306325 LOCK WASHER 5 16 810380 SPRING ji N 01 886291 SHIELD WITH BRAKE SHOES 18 INCLUDES ITEMS 19 38 304104 NUT 5 8 18 306494 LOCK WASHER 5 8 876519 SHIELD DUST 829348 N N N N N N N a A N 806761 ADJUSTMENT PIN 306353 LOCK WASHER 3 8 306319 NUT 3 8 24 306419 BOLT 1 4 20 X 1 2 LG 306396 LOCK WASHER 1 4 N Service Parts Manual REAR WHEEL BRAKE Where applicable THE USE OF NON UL PARTS WILL VOID ANY UL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTIO
5. TIMES DO NOT SHORT ACROSS BATTERIES TO CHECK CONDITION OF BATTERIES BATTERIES MAY EXPLODE BATTERY ACID CAN CAUSE SEVERE DAMAGE EYES SKIN AND CLOTHING FLUSH CONTAMINATED AREA IMMEDIATELY WITH WATER WHEN CLEANING BATTERIES KEEP SOLUTION AND WATER AWAY FROM CHARGER AND SWITCHES 819936 TO AVOID INJURY TO HANDS ON FINGERS WHEN REMOVING OR INSTALLING LIFT OUT BATTERY PACK 1 USE ADEQUATE LIFTING DEVICE BATTERIES ARE HEAVY 2 DO NOT PLACE HANDS ON BATTERIES OR RACK 3 DO NOT ALLOW HANDS TO REST ON VEHICLE OR GUIDES 824061 Page C 1 Service Parts Manual H3NIVLNOO Q3 1V3S WO AINT L 0 a ASN EHI YALSVIN W150 Gaariddv ATIVOILVWOLRQV LON 3HVH9 ONIHUVd 1005 YO SNVYE GNVH A TddV ONINSVM ASN LON OG SI LNIWLSNFAY YO SH990 NOILONNATVW HI JAOWJY ANY NOLLISOd dHO TWOILYSA OL 150 01 50199195 15 372143 541 737 380339 ANY 3 TOIHSA 30 S33INMMOVP ANY SGVOT ONILHIHS 01 SdOLS 515715 N3aans dioAv WHOFLV Td OL G3ernoas 39 LSNW o9svo SNOLLIGNOO OL LASdN ASNVO SGVOT AAVSH dOL HO SNYNL dYVHS N3aans 1925 NI AVLS 1 AGISNI AGOg EEN 4191H3A ONILVHAdO 3TIHM AYAHdSOWLV ATEILSNGNOD 4 5 NI 3175390 LON OQ YYYdS SJH
6. 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 198057 831188 SEAT ADJUSTER RIGHT 831187 SEAT ADJUSTER LEFT 158135 01 SEAT SWITCH 831053 SPACER 306325 LOCK WASHER 5 16 548901 BOLT 31 18 X 1 2 LG 548013 SCREW 1 4 20 X 1 3 4 LG o Iv i 810446 GROMMET 7156 TRIM BLACK 887777 SEAT PANEL 832156 DECAL WIRING a A N 819936 DECAL WARNING 800215 BOLT 10 24 X 5 8 LG 308089 WASHER 10 814924 D O 120052 LOCK WASHER 10 306531 10 24 103867 WASHER 5 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 m N N a amp N Service Parts Manual Page S 2 SPEED CONTROL PEDAL 1 INCLUDES ITEMS 2 22 Front of Vehicle Page T 1 Service Parts Manual SPEED CONTROL PEDAL THE USE OF 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION E 897184 SPEED CONTROL ASSEMBLY 1 INCLUDES ITEMS 2 22 897183 BRACKET S
7. _ 4 n 2n n a amp N 875212 PEDAL BRAKE ok ox N 306562 NUT 3 8 16 120177 LOCK WASHER 3 8 810149 BUMPER RUBBER 887771 BRAKE PEDAL amp BUSHING 21 INCLUDES ITEM 22 807439 FITTING LUBRICATION 306416 BOLT 5 16 18 X 1 LG N N N N N O Service Parts Manual Page D 2 DIFFERENTIAL A 36 1 INCLUDES ITEMS 2 72 INCLUDES ITEMS 15 16 INCLUDES ITEM 47 INCLUDES ITEM 50 53 INCLUDES ITEMS 54 66 INCLUDES ITEM 75 REFER CHAPTER M 1 FOR HYDRAULIC LINES AND RELATED PARTS Page E 1 Service Parts Manual DIFFERENTIAL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 887996 DIFFERENTIAL COMPLETE 1 INCLUDES ITEMS 2 72 883436 HOUSING RIGHT 880639 HOUSING LEFT 806251 BOLT SPECIAL LG 827486 VALVE BREATHER 800290 NUT 5 16 18 LOCK 103867 WASHER 5 16 304055 BOLT 5 16 18 X 1 3 8 LG 816046 TAG RATIO 15 67 1 800356 PLUG FILLER DRAIN o BB ln N 880986 WORM WITH BEARING amp SLINGER 14 INCLUDES ITEMS 15 16 814475 BEARING CONE ROLLER 886706 SLINGER SET OIL 814476 CUP ROLLER BEARING 814465 GASKET 814226 8123
8. index From the parts list obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page 2 IF YOU KNOW THE PART NUMBER Turn to the page number indicated and locate the part number in the parts list Refer to the accompanying description for specific information regarding the part From the parts list obtain the item number assigned to it and 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 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 Page vi Service Parts Manual HOW TO USE THE SERVICE PARTS MANUAL When replacement parts are required use genuine Cushman parts or parts with equivalent characteris tics including type strength and material Failure to use proper replacement parts may result in pr
9. 000 N 4 HN hd tal 99 1 514 sanarlivs Nad d hd L 3d UI110ULNOI TOZ lt 14 lt i al 1 1 1 1 1 1 1 1 EMI 3 2 1 CUSHIVIAIN A Textron Company E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance amp Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET E Z GO 1 888 438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
10. 1 GROMMET Service Parts Manual LIFT OUT BATTERY RACK 1 INCLUDES ITEMS 2 3 20 INCLUDES ITEM 21 28 INCLUDES ITEM 29 30 INCLUDES ITEM 31 6 GA RED TO NEGATIVE BATTERY POST gt 6 GA BLACK TO NEGATIVE BATTERY POST TO BATT ON KEY SWITCH RED MODELS ONLY PART OF MAIN HARNESS 898340 MODEL ONLY 20 CIRCUIT BREAKER WHITE BLACK WHITE BLACK POSITIVE Page N 1 26 27 a 28 225 pots TO B ON 5 5 CONTROLLER Shs 2 og BLACK TO 36V NEGATIVE TO CIRCUIT BREAKER 150 AMP RED TO 36V POSITIVE WHITE BLACK TO 20 AMP CIRCUIT BREAKER VEHICLE Service Parts Manual LIFT OUT BATTERY RACK TO B AT EXITING HARNESS CONTROLLER TO KEY SWITCH FROM B AT BLACK WHITE BLUE CONTROLLER N TO BATTERY SIDE BLACK JUMPER WIRE OF MAIN CONNECTOR bium M POST 2 BATTERY CONDITION BATTERY METER CONDITION METER JUMPER WIRE MEMORY MODULE Service Parts Manual Page N 2 LIFT OUT BATTERY RACK 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 887637 5 887197 RACK BATTERY W DECALS 1
11. 30 BOLT 1 4 20 X 1 1 4 LG 306396 LOCK WASHER 1 4 306832 BOLT 1 4 20 X 2 LG 800612 NUT 7 16 20 816449 KNURLED WASHER 800022 BOLT 10 24 X 3 8 LG 807035 TERMINAL 816455 RETAINING RING 816456 BALL BEARING 816447 816660 816446 883317 Service Parts Manual STEERING KIT 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION z 830168 GEAR CLUSTER 886913 GEAR DRIVEN 33 INCLUDES ITEM 34 310546 PIN ROLL 1 2 X 1 1 2 833182 HOUSING LOWER 35 INCLUDES ITEMS 36 37 830370 BUSHING 515511 BUSHING 823932 PLATE RETANER 306325 LOCK WASHER 5 16 306322 BOLT 5 16 18 X 7 8 LG 302600 BOLT 3 8 16 X 1 1 2 LG 306981 WASHER 3 8 825493 SUPPORT HOUSING LEFT 120177 LOCK WASHER 3 8 306835 BOLT 3 8 16 X 1 1 4 LG 825492 SUPPORT HOUSING RIGHT 808935 SPACER Page U 3 Service Parts Manual STEERING KIT Service Parts Manual Page U 4 03104 SSAINN 091268 NI 777 11888 T H21IMS 8818 18 908 043069 aazzna 42888 Noina HOLIMS SNINSVM 888888 HOLIMS 888528 10 961 851 188258 060668 NYOH NYOH NOIL9
12. 31 INCLUDES ITEMS 32 33 34 INCLUDES ITEM 35 FRONT OF VEHICLE WHEEL 1 Service Parts Manual FORK AND HANDLE BAR 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION ES 884127 FORK COMPLETE 1 INCLUDES ITEMS 2 14 120177 LOCK WASHER 3 8 306414 BOLT 3 8 16 X 1 LG 306562 NUT 3 8 16 306981 WASHER 3 8 311396 BOLT 7 16 14 X2 LG 800293 NUT 7 16 14 805383 SPRING 808969 SPACER 882188 ARM SIDE RIGHT 894070 ARM SIDE LEFT o A N n n n N 884064 FORK 14 INCLUDES ITEMS 15 16 805189 BEARING FORK 807439 GREASE FITTING 1 4 28 O o N 120166 LOCK WASHER 1 2 301988 NUT 1 2 20 305134 NUT 7 8 14 551041 WOODRUFF KEY 6 N N N N N N N ON amp Ivo 807472 831909 Service Parts Manual FORK AND HANDLE BAR 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 G Indicates consult Customer Service Department for additional informa
13. 34I1Q HOLIMS 1 5 HOLIMS 1V3S AV 104 MH3JOHVHO 1 4 v A D lt lt gt 1 18111311 Md act w m m QU ama 8 Tr EXE 2 8 BES RS MOTI3AV ya 9 Wo ET 18 4 a 016 n 1 40 GOW 133HM 331 NOLLO3NNO2 NYOH 19 3 825 8 NAOH 181828 23339 3131123 02 agaia 123NNOOSIG AIND 1VNOILdO 21121515 ug 881289 18 1O93NNOOSIG H9IND TWNOILdO QV3H n M 11 11 1 W uM 14 HOLIMS id 1 HDLIMS apo NETS na 8 15 i AJA HDLIMS 1 SHE 33 E uc uie HOLIMS 1 35 2 Oc DV 1 111 N02
14. 35 N N N N N ON FS a A N O N Q 551094 BOLT 3 8 16 X 1 3 4 LG 120177 LOCK WASHER 3 8 814466 SHIM 005 814467 SHIM 814468 SHIM 816515 SHIM m N N Service Parts Manual Page E 2 DIFFERENTIAL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 815597 PULLEY 140 MM 829455 HUB REAR 816446 WASHER SPECIAL 306982 WASHER 7 16 303269 LOCK WASHER 7 16 306838 BOLT 7 16 14 X 1 LG 809180 WASHER 800198 CONE LOCK NUT 1 2 20 814474 CUP ROLLER BEARING 805320 SHIM 005 805321 SHIM 010 805322 SHIM 030 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 882052 AXLE LEFT 15 7 8 403 MM 46 INCLUDES ITEM 47 814473 BEARING CONE ROLLER 814477 SEAL REAR AXLE 883422 AXLE RIGHT 14 9 16 370 MM 49 INCLUDES ITEM 50 814473 BEARING ROLLER 880176 GEAR CARRIER 15 67 1 RATIO 53 INCLUDES ITEMS 54 66 386767 BEARING CONE CARRIER HOUSING CARRIER 816038 GEAR WORM 15 67 1 RATIO 816824 PLATE LOCKING 816823 PLATE RETAINER 306555 BOLT 5 16 18 X 3 4 LG 842093 GEAR AXLE SHAFT Page E 3 Service Parts Manual DIFFERENTIAL THE USE OF NON U L PARTS WILL V
15. 4 o BB 2702117 BOLT 3 8 16 X 2 LG 306982 WASHER 7 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 815558 ADJUSTING ROD 306414 BOLT 3 8 16 X1 LG 303269 LOCK WASHER 7 16 306981 WASHER 3 8 120177 LOCK WASHER 3 8 306562 NUT 3 8 16 881759 BRACKET N N N N N N N oa N 311397 BOLT 7 16 14 X 3 LG 880093 SUPPORT MOUNT 800292 NUT CENTRE LOCK 3 8 16 883921 V BELT SET 3 800198 NUT CONE LOCK 1 2 20 N F 3 Service Parts Manual DRIVE MOTOR Where applicable THE USE OF NON UL PARTS WILL VOID ANY UL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 815582 PULLEY 4 1 2 O D 114 885535 MOTOR 3 HP 37 INCLUDES ITEMS 38 60 306932 NUT 5 16 18 824713 WASHER 824718 WASHER INSULATING 824711 BUSHING 824710 886026 824754 823023 BOLT HOLDER E BOLT POLE BOLT CLAMP 826681 836253 ARMATURE 832498 BEARING COMMUTATOR 889712 FIELD COIL Service Parts Manual EC CONVERSION KIT T Page G 1 Service Parts Manual EC CONVERSION KIT THE USE OF NON U L PARTS WILL VOID ANY U L LISTING
16. ARNESS JUMPER CONDITION METER Service Parts Manual Page N 4 PARK BRAKE LEVER 1 INCLUDES ITEM 2 21 TO CLAMP ON SUPPORT TUBE FRONT OF VEHICLE Page P 1 Service Parts Manual PARK BRAKE LEVER 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 831263 LEVER PARK BRAKE WITH HARDWARE 1 INCLUDES ITEM 2 807472 GRIP HAND 306423 BOLT 5 16 18 X 1 3 4 LG 103867 WASHER 5 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 306416 BOLT 5 16 18 X 1 LG o N L2 O 831540 SPACER 306375 NUT 1 4 20 306396 LOCK WASHER 1 4 879859 BRACKET CABLE a A N 800073 BOLT CARRIAGE 3 8 16 X 1 1 4 LG 120177 LOCK WASHER 3 8 306562 NUT 3 8 16 325380 CLAMP CABLE 300646 BOLT 1 4 20 X 3 4 LG PO N N N 800331 SCREW 14A X 3 4 LG 831094 PARK BRAKE CABLE FRONT 829637 BRACKET PARK BRAKE 306320 NUT 5 16 24 814079 PIN CLEVIS 306328 PIN COTTER 3 32 X 3 4 810380 SPRING 831093 PARK BRAKE CABLE REAR 831978 RETAINER CABLE m N N N N M A Service Parts Manual REAR WHEEL BRAKE SIN3 LI SAGNTONI 66 6
17. CLE Repair and Service Manual VEHICLE MODEL NUMBER MODEL YEAR amp SERIAL NUMBER The vehicle model number decal is located on upper left portion of kick panel The complete 10 ten digit number is required to identify certain parts PT 7 Serial Number on Decal The vehicle serial number and model number are stamped on top of the left rear wheel well under the deck Vehicle Serial and Model Number on Top of Wheel Well Page vii HOW TO USE THE SERVICE PARTS MANUAL SERVICE PUBLICATIONS IMPORTANT INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY ALSO Operator s Manual Part No 841463 AFTER YOU IDENTIFY A PART BY THE REFERENCE NUMBER AND THE SIX DIGIT CUSHMAN PART NUM BER ALWAYS READ THE DESCRIPTION OF THE PART TO BE SURE IT IS WHAT YOU WANT Order for a minimum charge at this address EZ GO 1451 MARVIN GRIFFIN RD AUGUSTA GEORGIA 30906 TOUCH UP PAINT Safety Yellow lead free 16 oz 0 5L spray Part No 833252 1 qt 0 95L Part No 833251 Page viii Repair and Service Manual ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Service Parts Manual Page ix BATTERY CHARGER 1 INCLUDES ITEMS 2 13 Page A 1 Service Parts Manual BATTERY CHARGER THE USE OF NON U L PARTS WILL VOID ANY U L LISTING When ordering parts please specify the mo
18. CUYSAMAN A Textron Company 605248 heeled Vehtete Electrice Thre ISSUE DATE JUNE 2006 SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLES TUG STARTING MODEL YEAR 2006 E Z GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the infor mation contained in this manual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PHONE 001 706 798 4311 FAX 001 706 771 4609 E Z GO DIVISION OF TEXTRON INC P O BOX 388 AUGUSTA GEORGIA USA 30906 3852 Service Parts Manual Page i NOTES Page ii Service Parts Manual TABLE OF CONTENTS SECTION Page No HOW TO USE THE SERVICE PARTS ILLUSTRATED PARTS heb A DAD ix BATTERY CHARGER nimes dic aAA aei ee Nt A 1 BATTERY RACK amp HOLD unis iles ame Mat a a e c ERR B 1 BODY bore etes A A C 1 BRAKE MASTER CYLINDER rhet ered wd eaten x dee M NOE D 1 DIFFERENT Abs iu oa
19. GE BATTERY CONDITION 120052 WASHER 10 306531 NUT 10 24 840496 PANEL CONTROL 548013 SCREW TAPPING 1 4 20 X 1 2 LG bo vC a A N 893142 RESISTOR 2703802 CONTACTOR 548910 NUT 1 4 20 800026 BOLT 1 4 20 X 1 3 4 LG 20468 05 SOLENOID 840273 BAR SOLENOID BUS 306320 NUT 5 16 X 24 103867 WASHER 5 16 893392 CONTROLLER SPEED 306932 NUT 5 16 18 306325 LOCK WASHER 5 16 306450 BOLT 5 16 18 X 3 4 LG 885240 HOUR METER m N N NYO a N CO Service Parts Manual Page H 2 ELECTRICAL COMPONENTS 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 892676 886425 829694 800017 829780 800271 800587 800439 890000 840679 800299 824800 Page H 3 BRACKET HORN SCREW 1 4 20 X 1 LG CIRCUIT BREAKER 20 AMP SCREW 10 24 X 1 2 LG NUT 4 40 WITH LOCK WASHER SCREW 4 40 X 3 4 LG BUZZER RECTIFIER BRIDGE SCREW 10 24 X 1 LG CIRCUIT BREAKER 150 AMP Service Parts Manual ELECTRICAL COMPONENTS Service Parts Manual Page H 4 FORK AND HANDLE BAR 1 INCLUDES ITEMS 2 14 14 INCLUDES ITEMS 15 16
20. INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle USE OF THE MANUAL To use this manual consult the TABLE OF CONTENTS page iii 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 Locate the serial number plate see BODY located in the Illustrated Parts Breakdown section of this manual for its location and note the complete number shown on the plate It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components Service Parts Manual Page v HOW TO USE THE SERVICE PARTS MANUAL Left hand illustration page continued on right hand page Parts list continued on if required rear of page if required 1 WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required Turn to the TABLE OF CONTENTS and select the most appropriate component description Turn to the page number indicated and locate the part description in the parts list Read the full accompanying description for specific information regarding the part that was not shown in the
21. KIT 811794 SCREW BLEEDER 811910 PISTON 811911 SPRING 887284 BRAKE SHOE 805860 WHEEL NUT Page L 3 Service Parts Manual FRONT AXLE HUB AND BRAKES Service Parts Manual Page L 4 HYDRAULIC LINES AND RELATED PARTS w ZZ ED Ed Tm eo Page M 1 Service Parts Manual HYDRAULIC LINES AND RELATED PARTS 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION E 887364 CYLINDER MASTER 831930 TUBE HYDRAULIC MASTER CYLINDER TO TEE 820008 FITTING HYDRAULIC TEE 831977 TUBE HYDRAULIC TEE TO FRONT BRAKE HOSE 2703211 TUBE HYDRAULIC TEE TO REAR BRAKE HOSE 817938 HOSE FLEXIBLE REAR 809137 CLIP HYDRAULIC FITTING 21510 G1 SWITCH STOPLIGHT ON KR N 0 841354 CYLINDER WHEEL SEE WHEEL CYLINDER SECTION FOR REPLACEMENT PARTS 831976 TUBE HYDRAULIC TEE TO LEFT BRAKE CYLINDER 832584 BRACKET 112050 SCREW 1 4 X 5 8 LG 831975 TUBE HYDRAULIC TEE TO BRAKE LIGHT SWITCH 826587 FITTING HYDRAULIC TEE 831974 TUBE HYDRAULIC TEE TORIGHT BRAKE CYLINDER 300646 812445 832287 306396 306375 814924 112050 SCREW TAPPING 320107 WIRE TIE 7 178 MM 826603 HOSE FLEXIBLE 38 1 2 FRONT 80923
22. N EN 876732 805441 887284 809252 841354 841450 811794 841451 841452 Page Q 3 BRAKE LEVER SPRING BRAKE SHOE WITH LINERS RETAINING RING WHEEL CYLINDER COMPLETE 38 INCLUDES ITEM 39 WHEEL CYLINDER REPAIR KIT 39 INCLUDES ITEMS 40 42 SCREW BLEEDER PISTON SPRING Service Parts Manual REAR WHEEL BRAKE Service Parts Manual Page Q 4 REAR WHEEL FRAME amp SHOCK ABSORBER FRONT OF VEHICLE Page R 1 Service Parts Manual REAR WHEEL FRAME 4 SHOCK ABSORBER 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 308332 1 2 13 120166 LOCK WASHER 1 2 876660 RETAINER 825435 SPRING BUMPER 805437 REAR SPRING 825500 CUP WASHER 823621 BUSHING 800294 LOCK NUT 7 16 14 807332 SHOCK ABSORBER X LE LX 0 A N 306835 BOLT 3 8 16 X 1 1 4 LG 306981 WASHER 3 8 887782 RETAINER 120177 LOCK WASHER 3 8 306562 NUT 3 8 16 816667 RUBBER BUSHING 887196 N N N NO FS N oc Service Parts Manual Page R 2 SEATING Front of Vehicle Page S 1 Service Parts Manual SEATING THE USE OF NON U L PARTS WILL VOID ANY
23. OID 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 814484 SPACER 816825 SHAFT DIFFERENTIAL GEAR 842094 GEAR DIFFERENTIAL PLANET 814483 SPACER 815794 PLATE LOCKING 306835 BOLT SPECIAL LG 320122 CUP ROLLER BEARING 814469 SHIM 003 814470 SHIM 005 814471 SHIM 010 808303 GASKET BEARING 879476 SEAL amp RETAINER 74 INCLUDES ITEM 75 814488 SEAL BEARING 836674 WASHER SPECIAL 805843 NUT 5 8 18 CASTLE 304636 PIN COTTER 1 8 X 1 1 8 809180 WASHER SPECIAL 800198 NUT 1 2 20 CONELOCK 805875 KEY HUB Service Parts Manual Page E 4 DRIVE MOTOR FRONT OF VEHICLE e Page F 1 Service Parts Manual DRIVE MOTOR 37 INCLUDES ITEMS 38 60 NOT OFFERED Service Parts Manual Page F 2 DRIVE MOTOR Where applicable THE USE OF NON UL PARTS WILL VOID ANY UL 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 887778 MOUNTING PLATE 306416 BOLT 5 16 18 X 1 LG 103867 WASHER 5 16 551041 KEY WOODRUFF 6 304364 NUT 7 16 1
24. PEED CONTROL MOUNT 840494 BEARING FLANGED 548478 SPACER 833104 RETAINING RING o A2 840435 TORSION SPRING 897182 SPEED CONTROL ARM 800225 SCREW SET 10 24 X 1 4 LG 800587 NUT WITH LOCK WASHER 44 40 829754 SWITCH 316056 SCREW 6 32 X 3 4 LG IX 240 JE Vi WO 4119768 30 DEG Lene od te idee 869184 BRACKET MOUNT 805421 INDEX SPRING 840688 N N N N N N 088 N 800557 BOLT CARRIAGE 5 16 18 X 3 4 LG 548911 LOCK NUT 5 16 18 840419 SPEED CONTROL PEDAL N N Service Parts Manual Page T 2 STEERING KIT 33 INCLUDES ITEM 34 35 INCLUDES ITEMS 36 37 _ FORK SPINDLE FORK PART NO 884064 FRONT OF VEHICLE Page U 1 Service Parts Manual STEERING KIT 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 885009 STEERING SET COMPLETE 892228 WHEEL STEERING 833903 BUTTON HORN 825370 SPRING HORN 825369 INSULATOR HORN 816652 NUT HORN BUTTON 311496 WASHER 5 8 826736 828380 831909 832555 3020
25. R CYLINDER 800026 SCREW 1 4 20 X 3 4 LG 869138 BEARING 829997 GROMMET 800279 NUT 1 4 20 A2 i 841366 GUARD ACCELERATOR PEDAL 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 821606 GROMMET 831443 NAMEPLATE CUSHMAN 825153 PINTLE HITCH ho Rho IX 240 0445 L LX 822829 HITCH PLATE N N M N 819936 DECAL BATTERY CHARGING 824061 DECAL WARNING 830982 DECAL TOWING WARNING 825394 DECAL INTERLOCK 821071 DECAL NOTICE 832135 DECAL WARNING 825622 DECAL BRAKE FLUID WARNING N N N N N O A Page 3 Service Parts Manual BODY Service Parts Manual Page C 4 BRAKE MASTER CYLINDER 1 INCLUDES ITEM 2 21 INCLUDES ITEM 22 Page D 1 Service Parts Manual BRAKE MASTER CYLINDER 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 887364 836873 306932 NUT 5 16 18 306325 LOCK WASHER 5 16 306435 BOLT 5 16 18 X 1 1 4 LG 805444 SPRING BRAKE PEDAL RETURN o A N 306328 PIN COTTER 3 32 X 3 4 103867 WASHER 5 16 806714 PIN CLEVIS 306414 BOLT 3 8 16 X 1 LG 810152 COVER BRAKE PEDAL
26. del and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 893090 CHARGER COMPLETE MODEL 17670 25 AMP 120 VAC 60 HZ 1 INCLUDES ITEMS 2 13 CASE LESTER 241895 822048 883844 A 886435 892893 823749 CAPACITOR 6 0 MFD inner 883216 893364 4 n n n N o 800026 SCREW 1 4 20 X 3 4 LG 308090 WASHER 1 4 Service Parts Manual Page A 2 BATTERY RACK amp HOLD DOWNS 0 9 9 0 0 Ds 9 00 Service Parts Manual Page B 1 BATTERY RACK amp HOLD DOWNS 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION z 893147 RACK BATTERY 806954 J BOLT 840695 BATTERY HOLD DOWN 818303 SPACER RUBBER 809152 WASHER 11 32 103867 WASHER 11 32 306325 LOCK WASHER 5 16 800315 WING NUT 5 16 18 883078 WIRE 10 o lt Service Parts Manual Page B 2 BODY PROVIDE BATTERY VENTILATION DURING CHARGING KEEP OPEN FLAMES OR SPARKS AWAY FROM BATTERIES AT ALL
27. oduct malfunction and possible injury to the operator and or by standers Illustrations in this manual are for parts identification ONLY These illustrations may not depict actual posi tioning of component parts and should NOT be used as assembly diagrams Doing so may result in improper assembly leading to sudden failure Cushman Inc a Textron Company reserves the right to make changes at any time without notice in specifica tions and models and also to discontinue models and accessories designed to be used on these models The right is also reserved to change specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change While the information contained in this parts manual is based on the latest product information available at the time of publication the continuing accuracy of this parts manual cannot be guaranteed ACCESSORIES In some cases accessories must be used in conjunc tion with other accessories to maintain safe operating conditions for a vehicle Display of an accessory in this manual does not imply it can be used on any oth er vehicle Using an accessory in a non recommend ed application may create unsafe operating conditions NEVER attach ANY electrical device or accessory to this vehicle which is grounded to the vehicle frame VEHICLE IDENTIFICATION THESE IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE CONCERNING THE VEHI
28. ov nodu Lows Dido bate eau Lowe Busta ul ius E 1 DRIVE MOTORS ah eed ane alt 1 EC CONVERSION d bri 8 1 ELECTRICAL COMPONENTS 3 4 x tc trea pnto dec weal ead daa ue wees paced H 1 FORK AND HANDLE SUUS as Suc RD YE CUM Sr det a J 1 FRONT amp REAR WHEELS AND TIRES K 1 HYDRAULIC LINES AND RELATED M 1 LIFT OUT BATTERY RACK ax doin us DEF adve Ee Terr bd de Lens N 1 BRAKE FEVER tiie eame bnt AE s RM A er P 1 REAR WHEEL BRAKE 522 aliens e hol Q 1 REAR WHEEL FRAME amp SHOCK R 1 SEATING edu Ae au enis de acc ook 54 SPEED CONTROL PEDAL 202054 5588 QU edet feda de A den T 1 STEERING 68902 oh do diede d efr pts C U 1 Service Parts Manual Page iii TABLE OF CONTENTS Page iv Service Parts Manual HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections GENERAL
29. tes a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION m 887194 FRONT AXLE HUB BRAKE COMPLETE 1 INCLUDES ITEMS 2 24 887193 AXLE FRONT 304104 NUT 5 8 18 306494 LOCK WASHER 5 8 307665 NUT 3 8 16 385174 CONE BEARING 805030 BRAKE DRUM 806274 BOLT WHEEL MOUNT 807630 809156 809229 oL 240 ns LX Ve LX Oo 8 N 832492 836719 876409 ASSEMBLY 19 INCLUDES ITEMS 20 21 808088 ROLLER BEARING 809268 N N FS N 878482 SHIELD amp BRAKE SHOES 24 INCLUDES ITEMS 25 37 304104 NUT 5 8 18 306319 NUT 3 8 24 306353 LOCK WASHER 3 8 306396 LOCK WASHER 1 4 306419 BOLT 1 4 20 X 1 2 LG m N N N m Service Parts Manual Page L 2 FRONT AXLE HUB AND BRAKES 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 12 3 4 5 DESCRIPTION 31 306494 LOCK WASHER 5 8 805441 SPRING 829348 806761 PIN ADJUSTMENT 809252 SNAP RING 878483 SHIELD DUST 886371 WHEEL CYLINDER 40 INCLUDES ITEMS 41 44 811775 WHEEL CYLINDER REPAIR
30. tion ITEM PART NO 2 3 4 5 DESCRIPTION m 880363 816198 807439 880364 815695 885010 840411 806791 807290 800144 809069 Page J 3 BEARING UPPER 31 INCLUDES ITEMS 32 33 BEARING GREASE FITTING 1 4 28 BEARING LOWER 34 INCLUDES ITEM 35 GREASE FITTING 10 32 HANDLE BAR NUT SPINDLE 7 8 14 HORN BUTTON INSULATOR SCREW 10 16 X 5 8 LG CLAMP HORN Service Parts Manual FORK AND HANDLE BAR Service Parts Manual Page J 4 FRONT amp REAR WHEELS AND TIRES TIRE 4 80 X 8 00 LOAD RANGE B OBTAIN LOCALLY Page K 1 Service Parts Manual FRONT 4 REAR WHEELS AND TIRES 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 G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 824989 WHEEL 8 00 X 3 75 FOUR BOLT HOLES 886735 STEM VALVE 886378 805860 893042 Service Parts Manual Page K 2 FRONT AXLE HUB AND BRAKES Front Fork Front Fork Front Wheel INCLUDES ITEMS 2 24 INCLUDES ITEMS 20 21 INCLUDES ITEMS 25 37 INCLUDES ITEMS 41 44 Page L 1 Service Parts Manual FRONT AXLE HUB AND BRAKES 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 Indica
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