Property of American Airlines

Transcription

1 MODEL CT5G 600 MOUNTAIN LANE P.O. BOX 968 BLUEFIELD, VA TELEPHONE: (276) FAX: (276) SPARE PARTS FAX: (276) AMERICAN AIRLINES - E 12/8/17 THIS GUIDE IS TO BE USED ONLY WITH THE MODEL CT5G. OTHER MODELS IN THIS SERIES MAY HAVE OPERATING FEATURES UNLIKE THE MODEL CT5G.

2 CHAPTER 3 ILLUSTRATED PARTS LIST TABLE OF CONTENTS CHAPTER/SECTION PAGE I. DESCRIPTION A. Introduction B. General Information II. DRAWING AND PARTS LIST A. Figure Index B. Illustrated Parts List... Figures thru III. NUMERICAL PARTS LIST IV. ALPHABETICAL PARTS LIST V. LIST NOTICE FOR ADDITIONAL INFORMATION ON PARTS, ASSEMBLIES, AND TECHNICAL INFORMATION REFER TO CHAPTER 5. VI. WARRANTY INFORMATION Chapter 3 Contents Jan. 17

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4 I. DESCRIPTION A. Introduction CHAPTER 3 ILLUSTRATED PARTS LIST The illustrated parts list contains exploded and sectional view drawings and the associated parts list. Replacement parts can be purchased from Charlatte of America, Inc. using the part number listed. An additional column is available for the end user to assign another set of numbers if desired. B. General Information A large number of fasteners used on the unit are metric and are listed by diameter and number of threads. If these are replaced make sure the grade is 8 or higher. To ensure proper fit and function use only replacement parts supplied by the original equipment manufacturer. Several of the larger components used on the unit can be rebuilt and returned to operation. These include the drive motor and rear axle. Due to the need for special tools and equipment required to rebuild these components, availability may be on a service exchange basis only. Chapter 3 Page 1-1 May 11

5 C. Hardware Part Numbering Chart The various fasteners used on the unit are assigned part numbers that can be interpreted with the following charts. SIZE: THREAD: LENGTH: GRADE PITCH (Metric) = Thread Dia. C Coarse Same as Size = G or A & No. Same as Size Ex: ¼ = 025 F Fine Ex: ¼ = 025 Ex: G5 = Grade 5 Ex: P0.7 =0.7 mm ¾ = 075 M - Metric ¾ = 075 G8.8 = Grade 8.8 P1.25 = 1.25 mm 1-¾ = ¾ = 175 A307 = ASTM A 307 P3.0 = 3.0 mm BOLTS & SCREWS SIZE THD LENGTH CODE GRADE PITCH* X X X X X X X X X X X X X * - Pitch is used with Metric bolts only. BOLT CODES: HB HEX HEAD CAP SCREW FS FLAT SOCKET HEAD CAP SCREW LB LOCKING BOLT FH FLAT HEAD CAP SCREW MS MACHINE SCREW NB NYLON HEX HEAD CAP SCREW BS BUTTON SOCKET HEAD CAP SCREW BH BUTTON HEAD CAP SCREW RH ROUND HEAD CAP SCREW OH OVAL HEAD CAP SCREW SS SET SCREW EXAMPLES: 025C125HBG8 = ¼-20UNC X 1-1/4 LG. HEX HEAD CAP SCREW GRADE 8 050F075OHG5 = ½-20UNF X ¾ LG. OVAL HEAD CAP SCREW GRADE 5 12M25FSG12.9P1.75 = M12 X 25 LG. FLAT SOCKET HEAD CAP SCREW GRADE 12.9 PITCH 1.75 NUTS SIZE THD CODE PITCH* X X X X X X X X * - Pitch is used with Metric bolts only. NUT CODES: SN SLOTTED NUT LN LOCKNUT NL NYLON LOCK NUT EXAMPLES: 025CHN = ¼-20UNC HEX NUT 050FLN = ½-20UNF LOCKNUT 20MNLP2.5 = M20 NYLON LOCK NUT PITCH 2.5 HN HEX NUT CN CASTLE NUT NN NYLON NUT (MATERIAL) Chapter 3 Page 1-2 May 11

6 WASHERS SIZE THD* CODE X X X X X X * - Thread is used with Metric bolts only. WASHER CODES: FW FLATWASHER SW STARWASHER EXAMPLES: 025FW = ¼ FLATWASHER 050LW = ½ LOCKWASHER 24MSW = M24 STARWASHER LW LOCKWASHER Chapter 3 Page 1-3 May 11

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8 II. DRAWING AND PARTS LIST A. Figure Index Figure Front Axle Installation Front Axle, Complete Rear Drive Assembly Rear Axle Assembly Front Brake Calipers Rear Brake Calipers Engine/Transmission Installation Fuel Tank Installation Power Steering System Electrical Components Lighting Installation Drivers Control Panel Steering Column Assembly Brake Pedal Assembly Service Brakes Accelerator Pedal Installation Transmission Shifter Installation Transmission Shifter Assembly Drive Shaft Assembly Parking Brake Assembly Covers And Guards Hood Assembly Rear Hitch Assembly Cab Assembly Seat Installation Tire And Wheel Assembly Tractor Trim & Decals CHAPTER 3 ILLUSTRATED PARTS LIST Description Chapter 3 Page 2-1 Jan. 17

9 CT5G FRONT AXLE INSTALLATION FIGURE: REV /

10 CT5G FRONT AXLE INSTALLATION FIGURE: ITEM QTY. PART DESCRIPTION 1 1 SEE FIG 2 FRONT AXLE ASSEMBLY 2 2 A00798 LEAF SPRING, FRONT 3 2 F07299 SPRING PLATE, TOP 4 2 F06092 SPRING PLATE, BOTTOM 5 8 1/2 X 4 BOLT /2 WASHER 7 8 1/2 LOCKNUT 8 6 1/2 x 4 1/2 BOLT /2 FLAT WASHER /2 LOCKNUT 11 2 F07513 BOLT GUARD, LEAF SPRING, FRONT 12 4 F05845 SPACER, LEAF SPRING, FRONT 13 2 F07125 BLOCK, LEAF SPRING, FRONT 14 2 A00003 PIN, LEAF SPRING, FRONT MM WASHER MM LOCKNUT 17 2 A00614 NIPPLE, GREASE 18 2 F07520 SPACER, FRONT AXLE 19 2 R00262* RUBBER BUMPER REV CODE 1/3 CROSS REF. AS OF SEPTEMBER 2017, RUBBER BUMPER HAS BEEN SUPERCEDED BY R00262.

11 CT5G FRONT AXLE INSTALLATION FIGURE: REV /

12 CT5G FRONT AXLE INSTALLATION FIGURE: ITEM QTY. PART DESCRIPTION 1 1 SEE FIG 2 FRONT AXLE ASSEMBLY 2 2 A00798 LEAF SPRING, FRONT 3 2 F07299 SPRING PLATE, TOP 4 2 F06092 SPRING PLATE, BOTTOM 5 8 1/2 X 4 BOLT /2 WASHER 7 8 1/2 LOCKNUT 8 6 1/2 x 4 1/2 BOLT /2 FLAT WASHER /2 LOCKNUT 11 2 F07513 BOLT GUARD, LEAF SPRING, FRONT 12 4 F05845 SPACER, LEAF SPRING, FRONT 13 2 F07125 BLOCK, LEAF SPRING, FRONT 14 2 A00003 PIN, LEAF SPRING, FRONT MM WASHER MM LOCKNUT 17 2 A00614 NIPPLE, GREASE 18 2 F07520 SPACER, FRONT AXLE 19 2 R00262* RUBBER BUMPER REV CODE 3/3 CROSS REF. AS OF SEPTEMBER 2017, RUBBER BUMPER HAS BEEN SUPERCEDED BY R00262.

13 CT5G FRONT AXLE INSTALLATION FIGURE: REV /

14 CT5G FRONT AXLE INSTALLATION FIGURE: ITEM QTY. PART DESCRIPTION 1 1 SEE FIG 2 FRONT AXLE ASSEMBLY 2 2 A00798 LEAF SPRING, FRONT 3 2 F07299 SPRING PLATE, TOP 4 2 F06092 SPRING PLATE, BOTTOM 5 8 1/2 X 4 BOLT /2 WASHER 7 8 1/2 LOCKNUT 8 6 1/2 x 4 1/2 BOLT /2 FLAT WASHER /2 LOCKNUT 11 2 F07513 BOLT GUARD, LEAF SPRING, FRONT 12 4 F05845 SPACER, LEAF SPRING, FRONT 13 2 F07125 BLOCK, LEAF SPRING, FRONT 14 2 A00003 PIN, LEAF SPRING, FRONT MM WASHER MM LOCKNUT 17 2 A00614 NIPPLE, GREASE 18 2 F07520 SPACER, FRONT AXLE 19 2 R00262* RUBBER BUMPER REV CODE 3/3 CROSS REF. AS OF SEPTEMBER 2017, RUBBER BUMPER HAS BEEN SUPERCEDED BY R00262.

15 CT5G FRONT AXLE COMPLETE FIGURE: REV /

16 CT5G FRONT AXLE COMPLETE FIGURE: ITEM QTY. PART DESCRIPTION 1 ASSY. A00954 FRONT AXLE (INCLUDES ALL ITEMS LISTED) 2 1 A MAIN AXLE BEAM 3 1 A00987 TIE ROD 4 2 A JAM NUT, TIE ROD 5 2 A THREADED BALL JOINT 6 2 A SLEEVE, THREADED BALL JOINT 7 1 A STEERING CYLINDER, COMPLETE 8 1 A JAM NUT, STEERING CYLINDER 9 1 A SWIVEL END, STEERING CYLINDER 10 2 A BOLT, STEERING CYLINDER 11 2 A WASHER, STEERING CYLINDER 12 2 A HUB CAP 13 2 A PIN, SPINDLE 14 2 A SLOTTED NUT 15 2 A OUTER TAPERED ROLLER BEARING 16 2 A WASHER 17 2 A BRASS BUSHING A WHEEL STUD 19 2 A HUB 20 2 A INNER TAPERED ROLLER BEARING 21 2 A BRASS BUSHING 22 2 A SEAL 23 2 A SEAL BUSH 24 1 A RIGHT SPINDLE 1 A LEFT SPINDLE 25 4 A CAP, KINGPIN A STEERING BUSHING 27 2 A KINGPIN 28 2 A RETAINING SET SCREW, KINGPIN 29 2 A THRUST BEARING SEE FIG. 5 FRONT BRAKE CALIPERS REV CODE 1/2 CROSS REF.

17 CT5G FRONT AXLE COMPLETE FIGURE: REV /

18 CT5G FRONT AXLE COMPLETE FIGURE: ITEM QTY. PART DESCRIPTION 1 ASSY. A00954 FRONT AXLE (INCLUDES ALL ITEMS LISTED) 2 1 A MAIN AXLE BEAM 3 1 A00987 TIE ROD 4 2 A JAM NUT, TIE ROD 5 2 A THREADED BALL JOINT 6 2 A SLEEVE, THREADED BALL JOINT 7 1 A STEERING CYLINDER, COMPLETE 8 1 A JAM NUT, STEERING CYLINDER 9 1 A SWIVEL END, STEERING CYLINDER 10 2 A BOLT, STEERING CYLINDER 11 2 A WASHER, STEERING CYLINDER 12 2 A HUB CAP 13 2 A PIN, SPINDLE 14 2 A SLOTTED NUT 15 2 A OUTER TAPERED ROLLER BEARING 16 2 A WASHER 17 2 A BRASS BUSHING A WHEEL STUD 19 2 A HUB 20 2 A INNER TAPERED ROLLER BEARING 21 2 A BRASS BUSHING 22 2 A SEAL 23 2 A SEAL BUSH 24 1 A RIGHT SPINDLE 1 A LEFT SPINDLE 25 4 A CAP, KINGPIN A STEERING BUSHING 27 2 A KINGPIN 28 2 A RETAINING SET SCREW, KINGPIN 29 2 A THRUST BEARING SEE FIG. 5 FRONT BRAKE CALIPERS REV CODE 2/2 CROSS REF.

19 CT5G REAR DRIVE ASSEMBLY FIGURE: REV /

20 CT5G REAR DRIVE ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 A00923 REAR AXLE 2 -- SEE FIG. 6 REAR BRAKE CALIPER 3 2 S00147 SPRING LEAF WITH BUSHING 4 4 A00924 U BOLT 5 2 F05837 BOTTOM SPRING LEAF PLATE 6 8 5/8 HARDENED WASHER 7 8 5/8 LOCKNUT 8 6 1/2 X 4 3/4 BOLT /2 WASHER /2 LOCKNUT /8 X 5 1/2 BOLT /8 WASHER /8 LOCKNUT 14 2 F07126 SPRING BLOCK 15 6 F05846 SPRING SPACER 16 A/R F07339* SHIM.125 A/R F07340* SHIM.078 A/R F07341* SHIM.063 REV CODE 1/2 CROSS REF. BECAUSE OF DEVIATION IN SPACE BETWEEN WELD AND LEAF SPRINGS, A VARYING COMBINATION OF SHIM SIZES ARE REQUIRED TO FILL IN THE GAP.

21 CT5G REAR DRIVE ASSEMBLY FIGURE: REV /

22 CT5G REAR DRIVE ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 A00923 REAR AXLE 2 -- SEE FIG. 6 REAR BRAKE CALIPER 3 2 S00147 SPRING LEAF WITH BUSHING 4 4 A00924 U BOLT 5 2 F05837 BOTTOM SPRING LEAF PLATE 6 8 5/8 HARDENED WASHER 7 8 5/8 LOCKNUT 8 6 1/2 X 4 3/4 BOLT /2 WASHER /2 LOCKNUT /8 X 5 1/2 BOLT /8 WASHER /8 LOCKNUT 14 2 F07126 SPRING BLOCK 15 6 F05846 SPRING SPACER 16 A/R F07339* SHIM.125 A/R F07340* SHIM.078 A/R F07341* SHIM.063 REV CODE 2/2 CROSS REF. BECAUSE OF DEVIATION IN SPACE BETWEEN WELD AND LEAF SPRINGS, A VARYING COMBINATION OF SHIM SIZES ARE REQUIRED TO FILL IN THE GAP.

23 CT5G REAR AXLE ASSEMBLY FIGURE: /4 REV

24 CT5G REAR AXLE ASSEMBLY FIGURE: REV ITEM QTY. PART DESCRIPTION 1 1 M20 NUT M12 NUT COUPLING WASHER A HS1310 INPUT COUPLING A COUPLING SEAL A TAPER ROLLER BEARING 055C020 U043H 7 1 A :1 INPUT PINION DOWEL A TRANSFER CASE REAR M12 X 80 MM BOLT M12 X 45 MM BOLT P 12 1 A END COVER M8 X 20 MM BOLT P 14 4 M10 X 20 MM BOLT P 15 1 A LOWER END COVER M24 FLANGE NUT A LEVEL / FILLER PLUG CP DOWTY WASHER PINION WASHER A FRONT PINION TAPER ROLLER 055CU02 BEARING 4H 21 1 A REAR PINION TAPER ROLLER 055CU02 BEARING 4T 22 1 A :1 INPUT WHEEL A PINION SPACER A TRANSFER CASE FRONT A CROWN WHEEL AND PINION A/R A SHIM 0.25 MM (0.010 ) A/R A SHIM 0.40 MM (0.016 ) A/R A SHIM 0.30 MM (0.012 ) A/R A SHIM 0.05 MM (0.002 ) A A/R A SHIM 0.08 MM (0.003 ) B A/R A SHIM 0.25 MM (0.010 ) C 28 1 A OIL SEAL COVER M12 WASHER 30 1 A SOLID SPACER SHIM / Q1 CODE 1/4 CROSS REF.

25 CT5G REAR AXLE ASSEMBLY FIGURE: /4 REV

26 CT5G REAR AXLE ASSEMBLY FIGURE: REV ITEM QTY. PART DESCRIPTION 31 3 M16 x 12 MM CAP BOLT P 32 1 A BEARING ADJUSTER NUT A BREATHER A MAIN CASE A BEARING ADJUSTER NUT A BEARING HOUSING M8 X 20 MM BOLT P 38 1 A BEARING ADJUSTER LOCK PLATE A /2 BSP DRAIN PLUG M10 X 120 MM BOLT H T 41 2 A TAPER ROLLER BEARING 055C028 UO49H 42 1 A DIFFERENTIAL CASE DIFFERENTIAL WHEEL THRUST WASHER 44 4 DIFFERENTIAL PINION THRUST WASHER 45 4 A DIFFERENTIAL PINION A DIFFERENTIAL SPIDER A DIFFERENTIAL WHEEL M10 NUT H T CODE 2/4 CROSS REF.

27 CT5G REAR AXLE ASSEMBLY FIGURE: /4 REV

28 CT5G REAR AXLE ASSEMBLY FIGURE: REV ITEM QTY. PART DESCRIPTION 50 2 DOWEL PLANET PIN THRUST WASHER A NEEDLE ROLLER BEARING A PLANET GEAR A PLANET CARRIER SPRING PIN SPACER CIRCLIP A SHORT ARM SUN GEAR A LONG ARM SUN GEAR A ANNULUS CODE 3/4 CROSS REF.

29 CT5G REAR AXLE ASSEMBLY FIGURE: /4 REV

30 CT5G REAR AXLE ASSEMBLY FIGURE: /4 REV ITEM QTY. PART DESCRIPTION 61 2 M70 LOCK NUT LOCKING WASHER THRUST WASHER A TAPER ROLLER BEARING H 65 2 A BRAKE CALIPER (INCLUDES ITEMS & 77 ) 66 4 A BRAKE PAD KIT KIT M16 X 40 MM CAP BOLT P 68 2 A CALIPER CARRIER A LONG AXLE ARM (COMMON PAD) A SHORT AXLE ARM (COMMON PAD) M10 X 25 MM CAP BOLT P 71 2 A SHORT AXLE SHAFT A LONG AXLE SHAFT A O RING A /16 UNF X 18 WHEEL STUD A * WHEEL HUB / DISC BRAKE A * WHEEL HUB / DISC BRAKE A * HUB SEAL A * HUB SEAL CALIPER CARRIER WASHER CALIPER MOUNTING BOLT M12 X 35 MM BOLT H TP /16 UNF X WHEEL NUT CODE THERE ARE TWO (2) PART NUMBERS FOR ORDERING THE WHEEL HUB AND HUB SEAL FOR THE NEWAGE / PRM AXLE. TO ORDER THE CORRECT PART FOR THE AXLE, THE AXLE SERIAL PLATE NUMBER MUST BE CHECKED FIRST. IF THE SERIAL NUMBER IS W15455 OR HIGHER THE AXLE IS FITTED WITH WHEEL HUB: A AND HUB SEAL: A IF THE SERIAL NUMBER IS W15454 OR LOWER THE AXLE IS FITTED WITH WHEEL HUB: A AND HUB SEAL: A CROSS REF.

31 CT5G FRONT BRAKE CALIPERS FIGURE: /1 REV

32 CT5G FRONT BRAKE CALIPERS FIGURE: REV ITEM QTY. PART DESCRIPTION ASSY 1 B00755 DISC BRAKE ASSEMBLY, RIGHT RFBXX SIDE ASSY 1 B00756 DISC BRAKE ASSEMBLY, LEFT SIDE RFBXX CODE 1/1 CROSS REF. 2 1 B00671 BRAKE FITTINGS RETXX ,4,7 1 B00757 PADS KIT RGAXX B00673 RUBBER SLEEVE RACXX B00674 CONTROL AXIS RACXX B00675 BRAKE PAD SPRING RACXX ,9 1 B00676 PISTON SEALS KIT RKIXX ,9,10 1 B00677 REPAIRING KIT (PISTON + SEALS) RACXX B00678 BLEED SCREW RRAXX B00679 BLEED SCREW CAP RRAXX B00680 BLEED SCREW AND CAP RRAXX100038

33 CT5G REAR BRAKE CALIPERS FIGURE: /1 REV

34 CT5G REAR BRAKE CALIPERS FIGURE: ITEM PART QTY. DESCRIPTION 1 -- SEE FIG. 4 WHEEL HUB / DISC BRAKE REV A REAR BRAKE CALIPER (INCLUDES ITEM 3 & 4) 3 4 A BRAKE PADS KIT 4 4 CALIPER MOUNTING BOLT 5 2 A CALIPER CARRIER SEE FIG. 4 TAPER ROLLER BEARING 7 -- SEE FIG. 4 HUB SEAL 8 16 M16 X 40 MM CAP BOLT P 9 16 CALIPER CARRIER WASHER SEE FIG. 4 9/16 UNF X 18 WHEEL STUD CODE 1/1 CROSS REF.

35 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / ENGINE SUPPORT RIGHT SIDE 5 ENGINE SUPPORT - LEFT SIDE

36 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 1 1 P00221* FORD MOTOR KIT MSG F06050 MOTOR WALL MOUNT 3 1 P00015 TWO PIECE MOTOR MOUNT 4 1 F MOTOR MOUNT, LEFT 5 1 F MOTOR MOUNT, RIGHT 6 1 F07101 CROSS TUBE ASSEMBLY 7 1 F06677 TRANSMISSION MOUNT 8 1 T00035 REAR ENGINE MOUNT FIGURE: REV CODE 1/14 CROSS REF. FOR A COMPLETE AND COMPREHENSIVE LIST OF INDIVIDUAL ENGINE PARTS, SEE THE MSG425 SERVICE PARTS MANUAL LOCATED IN CHAPTER 5 MANUALS. THE FORD MOTOR KIT INCLUDES MANY INDIVIDUAL ITEMS THAT ARE LISTED IN THE VARIOUS CHAPTER 3 FIGURES. FOR A COMPLETE LIST OF PARTS INCLUDED WITH THE FORD MOTOR KIT, PLEASE CONTACT CHARLATTE AMERICA.

37 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / B

38 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 1 1 P00221 FORD MOTOR KIT MSG F06050 MOTOR WALL MOUNT 3 1 P00015 TWO PIECE MOTOR MOUNT 4 1 F MOTOR MOUNT, LEFT 5 1 F MOTOR MOUNT, RIGHT 6 1 F07101 CROSS TUBE ASSEMBLY, BLACK 7 1 F06677 TRANSMISSION MOUNT 7B 1 T00035 REAR ENGINE MOUNT FIGURE: REV CODE 2/14 CROSS REF.

39 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /14 8A 8B 8C 8F 8G 8D 8E

40 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 8A 1 P ECU CONTROLLER B 1 P ENGINE HARNESS C -- SEE FIG 10 STARTER RELAY D 1 P DIPSTICK BB3G6750AC 8E 1 P WIRING HARNESS F8JL14324AC 8F 1 P PIN TERMINAL KIT G 1 P STARTER DS7T GA 8H 1 P FAN BELT I 1 P LOWER IDLER PULLEY AB3919A 216AA 8J 1 P FAN ASSEMBLY ENG K 1 P FAN BEARING AND BRACKET L 1 P FAN MOUNTING BRACKET M 1 P ALTERNATOR N 1 P ALTERNATOR HEAT SHIELD FIGURE: REV CODE 3/14 CROSS REF.

41 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /14 8J 8L 8K 8I 8H

42 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 8A 1 P ECU CONTROLLER B 1 P ENGINE HARNESS C -- SEE FIG 10 STARTER RELAY D 1 P DIPSTICK BB3G6750AC 8E 1 P WIRING HARNESS F8JL14324AC 8F 1 P PIN TERMINAL KIT G 1 P STARTER DS7T GA 8H 1 P FAN BELT I 1 P LOWER IDLER PULLEY AB3919A 216AA 8J 1 P FAN ASSEMBLY ENG K 1 P FAN BEARING AND BRACKET L 1 P FAN MOUNTING BRACKET M 1 P ALTERNATOR NOT SHOWN P FAN BRACKET SUPPORT (THROUGH IDLER) FIGURE: REV CODE 4/14 CROSS REF.

43 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /14 8M 8P 8O 8N

44 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 8A 1 P ECU CONTROLLER B 1 P ENGINE HARNESS C -- SEE FIG 10 STARTER RELAY D 1 P DIPSTICK BB3G6750AC 8E 1 P WIRING HARNESS F8JL14324AC 8F 1 P PIN TERMINAL KIT G 1 P STARTER DS7T GA 8H 1 P FAN BELT I 1 P LOWER IDLER PULLEY AB3919A 216AA 8J 1 P FAN ASSEMBLY ENG K 1 P FAN BEARING AND BRACKET L 1 P FAN MOUNTING BRACKET M 1 P ALTERNATOR N 1 P ALTERNATOR HEAT SHIELD O 1 P FLYWHEEL D5TZ6375A 8P 1 P FLYWHEEL BOLT S100 FIGURE: REV CODE 5/14 CROSS REF.

45 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /

46 ITEM CT5G ENGINE/TRANSMISSION INSTALLATION PART FIGURE: REV QTY. DESCRIPTION EXHAUST SYSTEM 9 1 M00145 EXHAUST, ENGINE TO MUFFLER 10 1 M00155 EXHAUST FLANGE 11 1 P EXHAUST GASKET AB399451AA 12 2 M00159 EXHAUST SENSOR 13 1 F CONVERTER HANGER, TOP 14 1 F CONVERTER HANGER, BOTTOM 15 2 M00132 RUBBER MOUNT, CONVERTER 16 1 M00160 MUFFLER 17 2 M /4 MUFFLER CLAMP 18 2 M00144 MUFFLER BAND 19 1 M00149 TAIL PIPE 20 1 M00072 HANGER, TAIL PIPE 21 1 M MUFFLER CLAMP CODE 6/14 CROSS REF.

47 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / A

48 ITEM CT5G ENGINE/TRANSMISSION INSTALLATION PART FIGURE: REV QTY. DESCRIPTION EXHAUST SYSTEM 9 1 M00145 EXHAUST, ENGINE TO MUFFLER 10 1 M00155 EXHAUST FLANGE 11 1 P EXHAUST GASKET AB399451AA 12 2 M00159 EXHAUST SENSOR 13 1 F CONVERTER HANGER, TOP 14 1 F CONVERTER HANGER, BOTTOM 15 2 M00132 RUBBER MOUNT, CONVERTER 16 1 M00160 MUFFLER 16A 1 P M18 PLUG 17 2 M /4 MUFFLER CLAMP 18 2 M00144 MUFFLER BAND 19 1 M00149 TAIL PIPE 20 1 M00072 HANGER, TAIL PIPE 21 1 M MUFFLER CLAMP CODE 7/14 CROSS REF.

49 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / AIR CLEANER ASSEMBLY

50 ITEM CT5G ENGINE/TRANSMISSION INSTALLATION PART QTY. DESCRIPTION AIR CLEANER ASSEMBLY 22 1 P00230 AIR CLEANER FILTER 23 1 P00184 SILICONE REDUCER 90 DEGREE 3" TO 2" 24 1 F06650 AIR TUBE EXTENSION 25 1 P00219 SILICONE 90 DEG ELBOW 2" 26 1 Q /8 BRAKE HOSE 27 1 C HOSE CLAMP 1 5/8 3 1/ C HOSE CLAMP 2 1/ C HOSE CLAMP 1/2 7/8 FIGURE: REV CODE 8/14 CROSS REF.

51 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /

52 ITEM CT5G ENGINE/TRANSMISSION INSTALLATION PART QTY. DESCRIPTION RADIATOR ASSEMBLY 30 1 P00243 RADIATOR 31 2 M00096 VIBRATION MOUNT 32 1 F06648 TOP RADIATOR BRACKET 33 1 F06989 INNER RADIATOR SHROUD - LEFT SIDE 34 1 F06609 INNER RADIATOR SHROUD RIGHT SIDE 35 1 F06647 ANGLE SUPPORT 36 2 F06646 BOTTOM ANGLE SUPPORT ASSY 1 P RADIATOR BRACKET KIT (INCLUDES ITEMS 37-40) 37 1 SHORT RADIATOR HOSE 38 1 LONG RADIATOR HOSE 39 1 RADIATOR MOUNTING KIT 40 1 RADIATOR OVERFILL TANK 41 1 H00124 TRANSMISSION COOLER 42 1 F06611 TRANSMISSION COOLER MOUNT 43 1 F06321 TRANSMISSION COOLER FITTING SUPPORT /32 HOSE* FIGURE: REV CODE OVERFILL TANK HOSE IS MADE FROM RAW MATERIAL. CONTACT CHARLATTE FOR MORE INFORMATION. 9/14 CROSS REF.

53 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /

54 ITEM CT5G ENGINE/TRANSMISSION INSTALLATION PART QTY. DESCRIPTION RADIATOR ASSEMBLY 30 1 P00243 RADIATOR 31 2 M00096 VIBRATION MOUNT 32 1 F06648 TOP RADIATOR BRACKET 33 1 F06989 INNER RADIATOR SHROUD - LEFT SIDE 34 1 F06609 INNER RADIATOR SHROUD RIGHT SIDE 35 1 F06647 ANGLE SUPPORT 36 2 F06646 BOTTOM ANGLE SUPPORT ASSY 1 P RADIATOR BRACKET KIT (INCLUDES ITEMS 37-40) FIGURE: REV SHORT RADIATOR HOSE 38 1 LONG RADIATOR HOSE 39 1 RADIATOR MOUNTING KIT 40 1 P RADIATOR OVERFILL TANK H00124 TRANSMISSION COOLER 42 1 F06611 TRANSMISSION COOLER MOUNT 43 1 F06321 TRANSMISSION COOLER FITTING SUPPORT /32 HOSE* CODE 10/14 CROSS REF. OVERFILL TANK HOSE IS MADE FROM RAW MATERIAL. CONTACT CHARLATTE FOR MORE INFORMATION.

55 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /

56 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV PART QTY. DESCRIPTION 45 1 T00044 TRANSMISSION, C T00045 C6 ADAPTER PLATE 47 1 T00580 FLEX PLATE 48 1 P00101 DIPSTICK 49 1 P DIPSTICK TUBE 50 1 P O-RING, DIPSTICK TUBE 51 1 F07178 BRAKE LEVER 52 1 B00705 PARKING BRAKE KIT, C ITEM CODE 11/14 CROSS REF.

57 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / TRANSMISSION COOLER HOSES (C6 TRANSMISSION SETUP)

58 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 40 1 H00124 TRANSMISSION COOLER 45 1 T00044 TRANSMISSION, C H01406 TRANSMISSION COOLER HOSE, H01405 TRANSMISSION COOLER HOSE, MALE JIC TO 6 MALE JIC STRAIGHT MALE JIC TO 6 FEMALE JIC SWIVEL 90 DEG FIGURE: REV CODE 12/14 CROSS REF.

59 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV /

60 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV PART QTY. DESCRIPTION 51 1 F07178 BRAKE LEVER 52 1 B00705 PARKING BRAKE KIT T00673 GM TRANSMISSION 58 1 T TCM-2600 CONTROLLER A-TCM F07723 TCM-2600 BRACKET 60 1 T DIPSTICK KIT TRN T ADAPTER KIT TRN T FLEX PLATE TRN8350 ITEM CODE 13/14 CROSS REF.

61 CT5G ENGINE/TRANSMISSION INSTALLATION FIGURE: REV / TRANSMISSION COOLER HOSES (GM TRANSMISSION SETUP)

62 CT5G ENGINE/TRANSMISSION INSTALLATION ITEM PART QTY. DESCRIPTION 40 1 H00124 TRANSMISSION COOLER MALE JIC TO 6 MALE JIC STRAIGHT MALE JIC TO 6 FEMALE JIC SWIVEL 90 DEG 57 1 T00673 GM TRANSMISSION 63 1 H01444 TRANSMISSION COOLER HOSE, H01445 TRANSMISSION COOLER HOSE, FSO- 06X06 6 MALE JIC TO MALE O.R.B. FIGURE: REV CODE 14/14 CROSS REF.

63 CT5G FUEL TANK INSTALLATION FIGURE: /3 REV A 3B 3C 3 3A

64 CT5G FUEL TANK INSTALLATION FIGURE: REV ITEM QTY. PART DESCRIPTION 1 1 F FUEL TANK 2 1 P FUEL FILTER F89Z-9155-A 3 1 P00237 FUEL PUMP A 8 P FUEL ADAPTER B 1 P FUEL PUMP FITTING M C 1 P FUEL PUMP FITTING WASHER FUEL FILTER MOUNT* 5 1 P00239 FUEL PUMP MOUNT H00122 FUEL CAP STRAINER 7 1 F06095 BOTTOM SUPPORT 8 1 F06094 CORNER MOUNT 9 1 E02204 FUEL SENDER 10 1 E02203 FUEL PUMP HARNESS 11 5 FUEL LINES* P00231 RETURN TUBE ASSEMBLY HP-6 FUEL TANK PLUG, 14 1 P00225 PICKUP TUBE ASSEMBLY 15 1 P /8 MALE PIPE TO 5/16 PRESSLOCK ADAPTER P FUEL LINE CLAMP 9C P00238 FUEL BLOCK A 2 P FUEL BLOCK FITTING SAE B 1 P FUEL BLOCK FITTING SAE S00237 SPACER 19 1 E02210 HARNESS, REGULATOR P00227 ADAPTER, FUEL PUMP FOR MORE DETAILED INFORMATION PLEASE CONTACT CHARLATTE. CODE 1/3 CROSS REF.

65 CT5G FUEL TANK INSTALLATION FIGURE: /3 REV B A A 19

66 CT5G FUEL TANK INSTALLATION FIGURE: REV ITEM QTY. PART DESCRIPTION 1 1 F FUEL TANK 2 1 P FUEL FILTER F89Z-9155-A 3 1 P00237 FUEL PUMP A 8 P FUEL ADAPTER B 1 P FUEL PUMP FITTING M C 1 P FUEL PUMP FITTING WASHER FUEL FILTER MOUNT* 5 1 P00239 FUEL PUMP MOUNT H00122 FUEL CAP STRAINER 7 1 F06095 BOTTOM SUPPORT 8 1 F06094 CORNER MOUNT 9 1 E02204 FUEL SENDER 10 1 E02203 FUEL PUMP HARNESS 11 5 FUEL LINES* P00231 RETURN TUBE ASSEMBLY HP-6 FUEL TANK PLUG, 14 1 P00225 PICKUP TUBE ASSEMBLY 15 1 P /8 MALE PIPE TO 5/16 PRESSLOCK ADAPTER P FUEL LINE CLAMP 9C P00238 FUEL BLOCK A 2 P FUEL BLOCK FITTING SAE B 1 P FUEL BLOCK FITTING SAE S00237 SPACER 19 1 E02210 HARNESS, REGULATOR P00227 ADAPTER, FUEL PUMP FOR MORE DETAILED INFORMATION PLEASE CONTACT CHARLATTE. CODE 2/3 CROSS REF.

67 CT5G FUEL TANK INSTALLATION FIGURE: /3 REV A PUMP 3

68 CT5G FUEL TANK INSTALLATION FIGURE: REV ITEM QTY. PART DESCRIPTION 1 1 F FUEL TANK 2 1 P FUEL FILTER F89Z-9155-A 3 1 P00237 FUEL PUMP A 8 P FUEL ADAPTER B 1 P FUEL PUMP FITTING M C 1 P FUEL PUMP FITTING WASHER FUEL FILTER MOUNT* 5 1 P00239 FUEL PUMP MOUNT H00122 FUEL CAP STRAINER 7 1 F06095 BOTTOM SUPPORT 8 1 F06094 CORNER MOUNT 9 1 E02204 FUEL SENDER 10 1 E02203 FUEL PUMP HARNESS 11 5 FUEL LINES* P00231 RETURN TUBE ASSEMBLY HP-6 FUEL TANK PLUG, 14 1 P00225 PICKUP TUBE ASSEMBLY 15 1 P /8 MALE PIPE TO 5/16 PRESSLOCK ADAPTER P FUEL LINE CLAMP 9C P00238 FUEL BLOCK A 2 P FUEL BLOCK FITTING SAE B 1 P FUEL BLOCK FITTING SAE S00237 SPACER 19 1 E02210 HARNESS, REGULATOR P00227 ADAPTER, FUEL PUMP FOR MORE DETAILED INFORMATION PLEASE CONTACT CHARLATTE. CODE 3/3 CROSS REF.

69 CT5G POWER STEERING SYSTEM FIGURE: REV /

70 CT5G POWER STEERING SYSTEM FIGURE: REV ITEM QTY. PART DESCRIPTION 1 1 H01434 HOSE, POWER STEERING RESERVOIR TO POWER STEERING PUMP, 5/8 X H01409 HOSE, STEERING VALVE PRESSURE TO STEERING PUMP H01410 HOSE, STEERING VALVE TANK RETURN TO POWER STEERING RESERVOIR H01407 HOSE, STEERING VALVE, R STEER TO STEER CYLINDER H01408 HOSE, STEERING VALVE, L STEER TO STEER CYLINDER P POWER STEERING PUMP AB31-3A696-BC 7 1 T00679 POWER STEERING RESERVOIR 8 1 SEE FIG. 2 STEERING CYLINDER 9 1 S00235 STEERING VALVE 10 2 H01415 COPPER CRUSH WASHER 11 1 H01416 BANJO FITTING, M14 X P BANJO BOLT M14 AB AA MALE BARB TO 8 FEMALE JIC 08-B SWIVEL STRAIGHT 14 2 HOSE CLAMP MALE JIC TO 6 MALE PIPE 90 DEG MALE JIC TO 8 MALE O-RING STRAIGHT 17 1 F07327 RESERVOIR MOUNT (NOT SHOWN) CODE 1/1 CROSS REF.

71 CT5G ELECTRICAL COMPONENTS FIGURE: REV /

72 CT5G ELECTRICAL COMPONENTS FIGURE: ITEM QTY. PART DESCRIPTION 1 -- SEE FIG 11 HEADLIGHT 2 -- SEE FIG 11 TURN SIGNAL 3 -- SEE FIG 11 TAILLIGHT 4 -- SEE FIG 12 DASH CONTROLS 5 -- SEE FIG 16 HARNESS, ACCELERATOR PEDAL 6 1 E00267 BACKUP ALARM 7 1 E WAY FUSE BLOCK 8 1 E AMP ATC CIRCUIT BREAKER 9 5 E AMP ATC CIRCUIT BREAKER 10 1 F07477 CIRCUIT BREAKER BLOCK COVER 11 1 E00270 RELAY 12 1 E01411 RELAY BASE 13 1 E00112 HORN 14 1 E02195 FORD MAIN HARNESS 15 1 SEE FIG 8 FUEL REGULATOR 16 1 SEE FIG 8 REGULATOR HARNESS 17 1 E VOLT BATTERY 18 1 E02033 MARINE COATED BATTERY TERMINAL ASSEMBLY 19 1 F05852 BATTERY RACK 20 1 F06101 BATTERY HOLD DOWN 21 1 P STARTER RELAY REV CODE 1/2 CROSS REF.

73 7 8 CT5G ELECTRICAL COMPONENTS FIGURE: REV /

74 CT5G ELECTRICAL COMPONENTS FIGURE: ITEM QTY. PART DESCRIPTION 1 -- SEE FIG 11 HEADLIGHT 2 -- SEE FIG 11 TURN SIGNAL 3 -- SEE FIG 11 TAILLIGHT 4 -- SEE FIG 12 DASH CONTROLS 5 -- SEE FIG 16 HARNESS, ACCELERATOR PEDAL 6 1 E00267 BACKUP ALARM 7 1 E WAY FUSE BLOCK 8 1 E AMP ATC CIRCUIT BREAKER 9 5 E AMP ATC CIRCUIT BREAKER 10 1 F07477 CIRCUIT BREAKER BLOCK COVER 11 1 E00270 RELAY 12 1 E01411 RELAY BASE 13 1 E00112 HORN 14 1 E02195 FORD MAIN HARNESS 15 1 SEE FIG 8 FUEL REGULATOR 16 1 SEE FIG 8 REGULATOR HARNESS 17 1 E VOLT BATTERY 18 1 E02033 MARINE COATED BATTERY TERMINAL ASSEMBLY 19 1 F05852 BATTERY RACK 20 1 F06101 BATTERY HOLD DOWN 21 1 P STARTER RELAY REV CODE 2/2 CROSS REF.

75 CT5G LIGHTING INSTALLATION FIGURE: REV /

76 CT5G LIGHTING INSTALLATION FIGURE: ITEM QTY. PART DESCRIPTION 1 2 F07190 HEADLIGHT GUARD 2 2 E01598 HEADLIGHTS, LED 3 4 E01494 TURN SIGNAL, LED 4 4 S00230 SPACER, NYLON 5 2 F04851 TAILLIGHT GUARD 6 2 E02183 ROUND BRAKE/REVERSE LIGHT, LED 7 2 E01559 MOUNT FLANGE, E01563 PIGTAIL, PLUG-IN, 3 WIRE 9 -- SEE FIG 24 BEACON, FLASHING REV CODE 1/1 CROSS REF.

77 CT5G DRIVERS CONTROL PANEL FIGURE: REV / A

78 CT5G DRIVERS CONTROL PANEL FIGURE: ITEM QTY. PART DESCRIPTION 1 1 F LEFT HAND DASH 1 F LEFT HAND DASH (NO CAB) 2 2 E00075 MAIN SWITCH 3 1 E00177 SIGNAL LIGHT SWITCH 4 1 E02036 GREEN INDICATOR LIGHT 5 1 E02035 BLUE INDICATOR LIGHT 6 1 E00937 HORN BUTTON 7 4 E02119 CHECK LIGHT 8 1 SEE FIG 17 SHIFTER HANDLE 9 1 E00245 HOURMETER 10 1 E02216 FUEL GAUGE 11 1 E01078 ANTI-RESTART KEYLESS IGNITION SWITCH* 11A 1 E02238 PUSH BUTTON SWITCH KIT* 12 1 T00262 TAG OFF IGNITION START 13 1 E PRONG LED FLASHER 14 1 E01411 RELAY BASE 15 1 E01058 TOGGLE SWITCH 16 1 F05788 SWITCH MOUNT 17 1 E02196 DASH HARNESS (INCLUDES ITEMS 14, 20, 21, 24, 25, 26, 33, 34, & 35) REV CODE UNIT WILL COME EQUIPPED WITH EITHER AN IGNITION SWITCH OR A PUSH BUTTON SWITCH. 1/4 CROSS REF.

79 CT5G DRIVERS CONTROL PANEL FIGURE: REV / E02196 DASH HARNESS

80 CT5G DRIVERS CONTROL PANEL FIGURE: ITEM QTY. PART DESCRIPTION 1 1 F LEFT HAND DASH 1 F LEFT HAND DASH (NO CAB) 2 2 E00075 MAIN SWITCH 3 1 E00177 SIGNAL LIGHT SWITCH 4 1 E02036 GREEN INDICATOR LIGHT 5 1 E02035 BLUE INDICATOR LIGHT 6 1 E00937 HORN BUTTON 7 4 E02119 CHECK LIGHT 8 1 SEE FIG 17 SHIFTER HANDLE 9 1 E00245 HOURMETER 10 1 E02216 FUEL GAUGE 11 1 E01078 ANTI-RESTART KEYLESS IGNITION SWITCH* 11A 1 E02238 PUSH BUTTON SWITCH KIT* 12 1 T00262 TAG OFF IGNITION START 13 1 E PRONG LED FLASHER 14 1 E01411 RELAY BASE 15 1 E01058 TOGGLE SWITCH 16 1 F05788 SWITCH MOUNT 17 1 E02196 DASH HARNESS (INCLUDES ITEMS 14, 20, 21, 24, 25, 26, 33, 34, & 35) REV CODE UNIT WILL COME EQUIPPED WITH EITHER AN IGNITION SWITCH OR A PUSH BUTTON SWITCH. 2/4 CROSS REF.

81 CT5G DRIVERS CONTROL PANEL FIGURE: REV / PIN MALE DEUTSCH PLUG 31 PIN FEMALE DEUTSCH PLUG POSITION DEUTSCH PLUGS

82 ITEM CT5G DRIVERS CONTROL PANEL FIGURE: PART QTY. DESCRIPTION 31 PIN MALE DEUTSCH PLUG 20 1 E PIN MALE DEUTSCH PLUG E01956 DEUTSCH PLUG PINS REV CODE 3/4 CROSS REF. 31 PIN FEMALE DEUTSCH PLUG 22 1 E PIN FEMALE DEUTSCH PLUG E01953 DEUTSCH PLUG RECEPTACLES 12 POSTION DEUTSCH PLUGS 24 1 E01951 FEMALE DEUTSCH PLUG E01953 DEUTSCH PLUG RECEPTACLES 26 1 E01952 FEMALE WEDGE LOCK 27 1 E01954 MALE DEUTSCH PLUG E01956 DEUTSCH PLUG PINS 29 1 E01955 MALE WEDGE LOCK

83 CT5G DRIVERS CONTROL PANEL FIGURE: REV / PIN DEUTSCH PLUG AND SOCKET PIN DEUTSCH PLUG AND SOCKET

84 ITEM CT5G DRIVERS CONTROL PANEL FIGURE: PART QTY. DESCRIPTION 4 PIN DEUTSCH PLUG AND SOCKET 30 1 E PIN DEUTSCH SOCKET 31 4 E01956 DEUTSCH PLUG PINS 32 1 E PIN DEUTSCH SOCKET WEDGE LOCK 33 1 E PIN DEUTSCH PLUG 34 4 E01953 DEUTSCH PLUG RECEPTACLES 35 1 E PIN DEUTSCH PLUG WEDGE LOCK 6 PIN DEUTSCH PLUG AND SOCKET 36 1 E PIN DEUTSCH PLUG 37 6 E01956 DEUTSCH PLUG PINS 38 1 E PIN DEUTSCH PLUG WEDGE LOCK 39 1 E PIN DEUTSCH SOCKET 40 6 E01953 DEUTSCH PLUG RECEPTACLES 41 1 E PIN DEUTSCH PLUG WEDGE LOCK REV CODE 4/4 CROSS REF.

85 CT5G STEERING COLUMN ASSEMBLY FIGURE: REV /

86 CT5G STEERING COLUMN ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 S00235 STEERING VALVE 2 1 F06127 MOUNT, STEERING VALVE 3 1 S00236 STEERING COLUMN 4 1 S FORCE STYLE STEERING WHEEL 5 1 H NUT M20 X S CAP, STEERING WHEEL 7 1 F05841 DASH, CT5G 8 1 F05842 SHIFTER MOUNT COVER PLATE REV CODE 1/1 CROSS REF.

87 CT5G BRAKE PEDAL ASSEMBLY FIGURE: REV /

88 CT5G BRAKE PEDAL ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 F BRAKE PEDAL WELDMENT 2 1 B00704 MASTER CYLINDER 3 1 B00703 VACUUM BOOSTER 4 1 F07300 RETURN SPRING MOUNT RETURN SPRING 6 -- See Fig 15 BRAKE FITTING 7 2 B00657 BRONZE FLANGE BEARING 8 1 B00816 BRONZE FLANGE BUSHING REV CODE 1/1 CROSS REF.

89 CT5G SERVICE BRAKES FIGURE: REV /

90 CT5G SERVICE BRAKES FIGURE: ITEM QTY. PART DESCRIPTION 1 1 SEE FIG 6 BRAKE CALIPER, LEFT FRONT 2 1 SEE FIG 6 BRAKE CALIPER, RIGHT FRONT 3 1 SEE FIG 14 MASTER CYLINDER 4 2 B00436SS BRAKE HOSE, STAINLESS STEEL 5 2 F06447 BOLT ON BRAKE TAB HOSE CLIP 7 2 B00405 BRAKE FITTING, ADAPTER 8 1 E00106 BRAKE LIGHT SWITCH 9 1 E00418 SHIFT LOCK PRESSURE SWITCH TEE 11 4 B00488 BRAKE FITTING 12 1 B00491 BRAKE FITTING 13 2 B /16 TEE BRAKE HOSE, REAR 15 1 SEE FIG 6 BRAKE CALIPER, LEFT REAR 16 1 SEE FIG 6 BRAKE CALIPER, RIGHT REAR B00812 BRAKE LINE SET (INCLUDES ITEMS 17-24) 17 1 BRAKE LINE* 18 1 BRAKE LINE* 19 1 BRAKE LINE* 20 2 BRAKE LINE* 21 2 BRAKE LINE* 22 1 BRAKE LINE* 23 1 BRAKE LINE* 24 1 BRAKE LINE* * - ALL BRAKE LINES ARE MANUFACTURED FROM RAW MATERIAL REV CODE 1/2 CROSS REF.

91 CT5G SERVICE BRAKES FIGURE: REV / REAR BRAKE HOSE INSTALLATION

92 CT5G SERVICE BRAKES FIGURE: ITEM QTY. PART DESCRIPTION BANJO BOLT BANJO BOLT WASHER REV CODE 2/2 CROSS REF.

93 CT5G ACCELERATOR PEDAL INSTALLATION FIGURE: /1 REV

94 CT5G ACCELERATOR PEDAL INSTALLATION FIGURE: /1 ITEM REV QTY. PART DESCRIPTION 1 1 P * ACCELERATOR PEDAL 2 1 P HARNESS, ACCELERATOR PEDAL 2U1L AA 3 1 F06773 MOUNT, ACCELERATOR PEDAL 4 1 F ACCELERATOR PEDAL BOX ASSEMBLY CODE CROSS REF. THE ACCELERATOR PEDAL PART P COMES WITH A PLASTIC PAD. IF REPLACING AN AMERICAN AIRLINES ACCELERATOR PEDAL, THE ITEM WILL NEED TO BE SPECIFIED AS NEEDING PART F07501, WHICH IS THE METAL PAD.

95 CT5G TRANSMISSION SHIFTER INSTALLATION FIGURE: REV / C6 TRANSMISSION GM TRANSMISSION

96 ITEM CT5G TRANSMISSION SHIFTER INSTALLATION FIGURE: REV QTY. PART DESCRIPTION 1 1 SEE FIG 18 TRANSMISSION SHIFTER HANDLE 2 1 SEE FIG 18 SHIFTER SOLENOID 3 1 F06651 UPPER SHIFT LINK ROD 4 3 B /16 CLEVIS YOKE AND PIN 5 1 F SHIFT LEVER 6 2 F06100 MOUNT, SHIFT LEVER 7 2 B00716 BUSHING 8 1 F06652 SHIFT LINKAGE ROD 9 1 T SHIFT ARM TRN F03194 SHIFT ARM EXTENSION 11 1 SHIFT LINKAGE ROD* CODE THE SHIFT LINKAGE ROD FOR THE GM TRANSMISSION IS MADE FROM RAW MATERIAL. CONTACT CHARLATTE FOR PURCHASING INFORMATION. 1/1 CROSS REF.

97 CT5G TRANSMISSION SHIFTER HANDLE ASSEMBLY FIGURE: REV / STOP BRACKET

98 CT5G TRANSMISSION SHIFTER HANDLE ASSEMBLY FIGURE: REV ITEM QTY. PART DESCRIPTION ASSY 1 T00436 SHIFTER PLUS LOCK KIT (INCLUDES ITEMS 1-9) 1 1 T00025 TRANSMISSION SHIFTER 2 1 F07404 SHIFT LOCK LATCH WELDMENT 3 1 F07453 SOLENOID MOUNT ASSEMBLY 4 1 E PIN DEUTSCH PLUG 5 4 E01956 DEUTSCH PLUG PINS 6 1 E PIND DEUTSCH PLUG WEDGELOCK 7 1 E00413 SOLENOID 12A6U2B E00518 SHIFT LOCK PLUNGER 9 1 E00519 SPRING, SOLENOID 10 1 F07342 STOP BRACKET, SHIFTER CODE 1/1 CROSS REF.

99 CT5G DRIVE SHAFT ASSEMBLY & INSTALLATION FIGURE: REV /

100 CT5G DRIVE SHAFT ASSEMBLY & INSTALLATION ITEM QTY. PART DESCRIPTION 1 1 T00683 DRIVE SHAFT 2 1 T00122 UNIVERSAL STRAP KIT 3 1 T00191 TRANSMISSION FLANGE 4 1 T OUTPUT FLANGE MOUNT 1 T OUTPUT FLANGE MOUNT BOLT, DRIVE LINE FIGURE: REV CODE 1/1 CROSS REF.

101 CT5G PARKING BRAKE ASSEMBLY FIGURE: REV /

102 CT5G PARKING BRAKE ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 B00030 PARK BRAKE HANDLE 2 1 F05934 PARK BRAKE SUPPORT 3 4 B /16 CLEVIS YOKE AND PIN 4 1 F06653 PARK BRAKE LINK ROD 5 1 F05872 BRAKE LINK SUPPORT 6 1 F PARK BRAKE CRANK WELDMENT BRONZE BUSHING 8 1 F06654 PARK BRAKE CRANK LINK ROD 9 1 F07178 C6 BRAKE LEVER REV CODE 1/1 CROSS REF.

103 CT5G COVERS & GUARDS FIGURE: REV /

104 CT5G COVERS & GUARDS FIGURE: ITEM QTY. PART DESCRIPTION 1 -- SEE FIG 13 DASH WELDMENT 2 -- SEE FIG 13 SHIFTER MOUNT COVER PLATE 3 -- SEE FIG 16 ACCELERATOR PEDAL BOX 4 -- SEE FIG 22 HOOD ASSEMBLY 5 -- SEE FIG 11 HEADLIGHT GUARD 6 -- SEE FIG 6 PARK BRAKE SUPPORT 7 -- SEE FIG 24 CAB 8 -- SEE FIG 11 TAILLIGHT GUARD 9 1 F05815 CENTER HUMP FLOOR 10 1 F07349 FUEL FILL COVER PLATE 11 2 F06021 HIP RESTRAINT 12 1 F05933 SEAT MOUNT PLATE 13 2 F05811 SEAT WEIGHT 14 2 F REAR COUNTERWEIGHT WITH CUTOUT 15 2 F REAR COUNTERWEIGHT PLATE COVER 17 1 F07726 COUNTERWEIGHT WEDGE REV CODE 1/2 CROSS REF.

105 CT5G COVERS & GUARDS FIGURE: REV /

106 CT5G COVERS & GUARDS FIGURE: ITEM QTY. PART DESCRIPTION 1 -- SEE FIG 13 DASH WELDMENT 2 -- SEE FIG 13 SHIFTER MOUNT COVER PLATE 3 -- SEE FIG 16 ACCELERATOR PEDAL BOX 4 -- SEE FIG 22 HOOD ASSEMBLY 5 -- SEE FIG 11 HEADLIGHT GUARD 6 -- SEE FIG 6 PARK BRAKE SUPPORT 7 -- SEE FIG 24 CAB 8 -- SEE FIG 11 TAILLIGHT GUARD 9 1 F05815 CENTER HUMP FLOOR 10 1 F07349 FUEL FILL COVER PLATE 11 2 F06021 HIP RESTRAINT 12 1 F05933 SEAT MOUNT PLATE 13 2 F05811 SEAT WEIGHT 14 2 F REAR COUNTERWEIGHT WITH CUTOUT 15 2 F REAR COUNTERWEIGHT PLATE COVER 17 1 F07726 COUNTERWEIGHT WEDGE REV CODE 2/2 CROSS REF.

107 CT5G HOOD ASSEMBLY FIGURE: REV /

108 CT5G HOOD ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 F HOOD WELDMENT 2 2 C00363 LATCH 3 4 C00658 HOOD BUMPER 4 2 H01398 AIR SHOCK CYLINDER 5 2 H AIR SHOCK BALL STUD 6 2 C00748 HINGE 7 2 F06155 HINGE SPACER 8 1 F07474 UPPER SAFETY PROP LATCH BRACKET 9 1 F07484 SAFETY PROP WELDMENT 10 1 F07454 AIRSHOCK SAFETY PROP LUG 11 1 F07502 LOWER SAFETY PROP LATCH BRACKET 12 1 H00831 AIR SHOCK LUG REV CODE 1/2 CROSS REF.

109 CT5G HOOD ASSEMBLY FIGURE: REV /

110 CT5G HOOD ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 1 F HOOD WELDMENT 2 2 C00363 LATCH 3 4 C00658 HOOD BUMPER 4 2 H01398 AIR SHOCK CYLINDER 5 2 H AIR SHOCK BALL STUD 6 2 C00748 HINGE 7 2 F06155 HINGE SPACER 8 1 F07474 UPPER SAFETY PROP LATCH BRACKET 9 1 F07484 SAFETY PROP WELDMENT 10 1 F07454 AIRSHOCK SAFETY PROP LUG 11 1 F07502 LOWER SAFETY PROP LATCH BRACKET 12 1 H00831 AIR SHOCK LUG REV CODE 2/2 CROSS REF.

111 CT5G REAR HITCH ASSEMBLY FIGURE: REV /1 1

112 CT5G REAR HITCH ASSEMBLY FIGURE: ITEM PART QTY. DESCRIPTION 1 1 C00717 HITCH, TOW REV CODE 1/1 CROSS REF.

113 CT5G CAB ASSEMBLY FIGURE: /4 REV

114 CT5G CAB ASSEMBLY FIGURE: /4 ITEM QTY. PART DESCRIPTION ASSY. C00747 OVERALL CAB ASSEMBLY 1 1 E02019 DOME LIGHT 2 1 E02237 WIPER MOTOR 3 1 O00183 REARVIEW MIRROR 4 1 O00193 WIPER ARM 5 1 O00194 WIPER BLADE 6 2 C00768 HEATER VENT 7 1 F07458 MOUNT, VINYL DOOR STRIP, PASSENGER SIDE 8 1 F07459 MOUNT, VINYL DOOR STRIP, DRIVERS SIDE 9 2 C00769 GRAB HANDLE, CAB (NOT SHOWN) 10 1 C00674-BLUE VINYL DOOR, PASSENGER SIDE 11 1 C00675-BLUE VINYL DOOR, DRIVER SIDE 12 2 C FRONT UPPER DOOR STRIP 13 4 C TOP DOOR STRIP 14 2 C REAR DOOR STRIP REV CODE * - CHARLATTE RECOMMENDS LOCAL SUPPLIERS FOR PROPER SELECTION AND FITTING OF REPLACEMENT GLASS CROSS REF.

115 CT5G CAB ASSEMBLY FIGURE: /4 REV

116 CT5G CAB ASSEMBLY FIGURE: /4 ITEM QTY. PART DESCRIPTION 15 1 E01111 BEACON, FLASHING 16 1 C00763 REAR WINDOW GUARD 17 1 F05538 HITCH RELEASE COMPARTMENT 18 1 H01273 AIR CYLINDER 19 1 F05524 CAB REAR BASE REV CODE * - CHARLATTE RECOMMENDS LOCAL SUPPLIERS FOR PROPER SELECTION AND FITTING OF REPLACEMENT GLASS CROSS REF.

117 CT5G CAB ASSEMBLY FIGURE: /4 REV HEATER HOSE FROM HEATER VALVE TO REDUCER TO ENGINE 32 31

118 CT5G CAB ASSEMBLY FIGURE: /4 ITEM QTY. PART DESCRIPTION 20 1 F07466 HEATER BOX WELDMENT 21 2 H01429 HEATER VENT 22 1 F07465 HANDLE, HEATER VALVE 23 1 E02209 FAN SPEED TOGGLE SWITCH 24 1 F07464 FRONT MOUNT, HEATER BOX 25 1 F07463 REAR MOUNT, HEATER BOX 26 1 H01422 HEATER PARTS KIT 27 1 O DEG HEATER HOSE 28 1 O00189 HEATER VALVE 29 1 O00190 REDUCER, HEATER HOSE 30 1 *5/8 HEATER HOSE (FROM HEATER VALVE TO REDUCER) 31 1 *3/4 HEATER HOSE (FROM REDUCER TO ENGINE) 32 5 C HOSE CLAMP 1/2 1 1/4 REV CODE CROSS REF. HEATER HOSES ARE MADE FROM RAW MATERIAL. CONTACT CHARLATTE FOR MORE INFORMATION.

119 CT5G CAB ASSEMBLY FIGURE: /4 REV

120 CT5G CAB ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 33 1 W00297 SLIDING WINDOW ASSEMBLY (LEXAN) 34 2 W00298 SLIDING WINDOW TRACK 35 2 W00299 SLIDING WINDOW PANEL (LEXAN) REV CODE 4/4 CROSS REF.

121 CT5G SEAT INSTALLATION FIGURE: /1 REV

122 CT5G SEAT INSTALLATION FIGURE: /1 ITEM QTY. PART DESCRIPTION 1 2 O00155 SEAT W/ LOGO 2 2 C00524 RETRACTABLE SEAT BELT 3 -- SEE FIG 21 SEAT PLATE 4 -- SEE FIG 21 SEAT WEIGHT REV CODE CROSS REF.

123 CHARLATTE OF AMERICA, INC. CT5G TIRE & WHEEL ASSEMBLY FIGURE: REV /1 1 2

124 CHARLATTE OF AMERICA, INC. CT5G TIRE & WHEEL ASSEMBLY FIGURE: ITEM QTY. PART DESCRIPTION 1 2 W FRONT RIM, AMERICAN GRAY 2 2 W REAR RIM, AMERICAN GRAY REV CODE 1/1 CROSS REF.

125 CT5G TRACTOR TRIM & DECALS FIGURE: REV /

126 CT5G TRACTOR TRIM & DECALS FIGURE: ITEM QTY. PART DESCRIPTION 1 1 T DECAL, CHARLATTE AMERICA 2 2 T00293 DECAL, MAX PRESSURE T00613 DECAL, GASOLINE ONLY 4 1 T00689 DECAL, STARTUP INSTRUCTIONS 5 1 T00695 DECAL, LOW FUEL 6 1 T DECAL, PARK BRAKE 7 2 T DECAL, MAX PRESSURE T DECAL, MAX TOW 9 1 T00700 DECAL, WARNING, HOOD PROP 10 1 T00701 DECAL, WARNING, PULLEY BOLT 11 1 T00500 DECAL, BRAKE FLUID 12 1 T ID TAG, MANUFACTURER (NOT SHOWN) 13 1 T00719 DECAL. OPERATION INSTRUCTIONS (PUSH BUTTON SWITCH) REV CODE 1/2 CROSS REF.

127 CT5G TRACTOR TRIM & DECALS FIGURE: REV /

128 CT5G TRACTOR TRIM & DECALS FIGURE: ITEM QTY. PART DESCRIPTION 1 1 T DECAL, CHARLATTE AMERICA 2 2 T00293 DECAL, MAX PRESSURE T00613 DECAL, GASOLINE ONLY 4 1 T00689 DECAL, STARTUP INSTRUCTIONS 5 1 T00695 DECAL, LOW FUEL 6 1 T DECAL, PARK BRAKE 7 2 T DECAL, MAX PRESSURE T DECAL, MAX TOW 9 1 T00700 DECAL, WARNING, HOOD PROP 10 1 T00701 DECAL, WARNING, PULLEY BOLT 11 1 T00500 DECAL, BRAKE FLUID 12 1 T ID TAG, MANUFACTURER (NOT SHOWN) 13 1 T00719 DECAL. OPERATION INSTRUCTIONS (PUSH BUTTON SWITCH) REV CODE 2/2 CROSS REF.

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130 III. NUMERICAL PARTS LIST CHAPTER 3 ILLUSTRATED PARTS LIST PART DESCRIPTION REFERENCE B 10 MALE BARB TO 8 FEMALE JIC SWIVEL STRAIGHT FIGURE MALE JIC TO 6 MALE JIC STRAIGHT FIGURE MALE JIC TO 6 MALE PIPE 90 DEG FIGURE HP-6 PLUG, FUEL TANK FIGURE MALE JIC TO 8 MALE O-RING STRAIGHT FIGURE MALE JIC TO 6 FEMALE JIC SWIVEL 90 DEG FIGURE BRONZE BUSHING FIGURE BANJO BOLT FIGURE BANJO BOLT WASHER FIGURE TEE FIGURE BRAKE HOSE, REAR FIGURE HOSE CLIP FIGURE RETURN SPRING FIGURE BOLT, DRIVE LINE FIGURE 19 A00003 PIN, LEAF SPRING, FRONT FIGURE 1 A00614 NIPPLE, GREASE FIGURE 1 A00798 LEAF SPRING, FRONT FIGURE 1 A00923 REAR AXLE FIGURE 3 A HUB SEAL FIGURE 4 A LEVEL / FILLER PLUG FIGURE 4 A FRONT PINION TAPER ROLLER BEARING FIGURE 4 A REAR PINION TAPER ROLLER BEARING FIGURE 4 A :1 INPUT WHEEL FIGURE 4 A PINION SPACER FIGURE 4 A TRANSFER CASE FRONT FIGURE 4 A CROWN WHEEL AND PINION FIGURE 4 A SHIM 0.25 MM (0.010 ) FIGURE 4 A SHIM 0.40 MM (0.016 ) FIGURE 4 A SHIM 0.30 MM (0.012 ) FIGURE 4 A O RING FIGURE 4 A SHIM 0.05 MM (0.002 ) FIGURE 4 A SHIM 0.08 MM (0.003 ) FIGURE 4 A SHIM 0.25 MM (0.010 ) FIGURE 4 A OIL SEAL COVER FIGURE 4 A SOLID SPACER SHIM FIGURE 4 A BEARING ADJUSTER NUT FIGURE 4 A BREATHER FIGURE 4 A MAIN CASE FIGURE 4 A BEARING ADJUSTER NUT FIGURE 4 A BEARING HOUSING FIGURE 4 A HS1310 INPUT COUPLING FIGURE 4 A BEARING ADJUSTER LOCK PLATE FIGURE 4 A /2 BSP DRAIN PLUG FIGURE 4 A TAPER ROLLER BEARING FIGURE 4 Chapter 3 Page 3-1 Feb. 17

131 PART DESCRIPTION REFERENCE A DIFFERENTIAL CASE FIGURE 4 A DIFFERENTIAL PINION FIGURE 4 A DIFFERENTIAL SPIDER FIGURE 4 A DIFFERENTIAL WHEEL FIGURE 4 A NEEDLE ROLLER BEARING FIGURE 4 A PLANET GEAR FIGURE 4 A PLANET CARRIER FIGURE 4 A COUPLING SEAL FIGURE 4 A SHORT ARM SUN GEAR FIGURE 4 A LONG ARM SUN GEAR FIGURE 4 A ANNULUS FIGURE 4 A TAPER ROLLER BEARING FIGURE 4 A BRAKE CALIPER FIGURE 4 A BRAKE PAD KIT FIGURE 4 A CALIPER CARRIER FIGURE 4 A LONG AXLE ARM (NARROW PAD) FIGURE 4 A SHORT AXLE ARM (NARROW PAD) FIGURE 4 A SHORT AXLE SHAFT FIGURE 4 A TAPER ROLLER BEARING FIGURE 4 A LONG AXLE SHAFT FIGURE 4 A /16 UNF X 18 WHEEL STUD FIGURE 4 A WHEEL HUB / DISC BRAKE FIGURE 4 A HUB SEAL FIGURE 4 A WHEEL HUB / DISC BRAKE FIGURE 4 A :1 INPUT PINION FIGURE 4 A TRANSFER CASE REAR FIGURE 4 A END COVER FIGURE 4 A LOWER END COVER FIGURE 4 A00924 U BOLT FIGURE 3 A00954 FRONT AXLE (INCLUDES ALL ITEMS LISTED) FIGURE 2 A MAIN AXLE BEAM FIGURE 2 A WASHER, STEERING CYLINDER FIGURE 2 A HUB CAP FIGURE 2 A PIN, SPINDLE FIGURE 2 A SLOTTED NUT FIGURE 2 A HUB FIGURE 2 A WHEEL STUD FIGURE 2 A OUTER TAPERED ROLLER BEARING FIGURE 2 A WASHER FIGURE 2 A BRASS BUSHING FIGURE 2 A INNER TAPERED ROLLER BEARING FIGURE 2 A BRASS BUSHING FIGURE 2 A SEAL FIGURE 2 A SEAL BUSH FIGURE 2 A RIGHT SPINDLE FIGURE 2 A LEFT SPINDLE FIGURE 2 A CAP, KINGPIN FIGURE 2 A STEERING BUSHING FIGURE 2 A KINGPIN FIGURE 2 A RETAINING SET SCREW, KINGPIN FIGURE 2 A THRUST BEARING FIGURE 2 Chapter 3 Page 3-2 Feb. 17