WARNING Washington Road P.O. Box Augusta, Georgia USA Telephone: FAX:

Transcription

1 049B00000

2 WARNING This manual is to be used for identification and ordering of service parts only. Be sure to read and use the maintenance and service manual for any repair. 45 Washington Road P.O. Box Augusta, Georgia USA Telephone: FAX: 99, Club Car Inc. All Rights Reserved

3 INDEX MAINTENANCE AND SERVICE TOOLS CONTENTS BODY AND TRIM SECTION Trim... - Front Cowl -- Carryall-l Front Cowl -- Carryall-I Rear Covers -- Carryall-l and Carryall-I Seat Bottomandseat Backs TiltBedand Latch -- Carryall-l... - TiltBedandPropRod -- Carryall-ll Tilt Bedand Latch -- Carryall-ll DRIVE UNIT SECTION Drive Unit... - BRAKES. PEDAL AND CABLE ASSEMBLY SECTION 3 Brake Cluster. Right and Left Hand BrakePedalandCableAssembly Accelerator Pedal Assembly STEERING AND FRONT SUSPENSION SECTION 4 Steering Column -- Steel Steering Column -- Aluminum Steering Assembly Front Suspension Assembly -- A-Plate Front Suspension Assembly -- Delta A-Plate ELECTRICAL AND BATTERY SECTION 5 Wiring -- Gas Vehicle ElectricalComponent Box Starter Generator -- Mounting Starter Generator Assembly F&R Shifter Assembly Reverse Buzzer Battery ENGINE SECTION 6 Engine FUEL AND INTAKE SYSTEM SECTION 7 Fuel System Assembly Carburetor Assembly Governor Guard Expansionchamber. Chokeand Filter Governorand Acceleratorcables EXHAUST SYSTEM SECTION 8 Exhaust System TORQUE CONVERTER SECTION 9 Drive Clutch Assembly DrivenClutch Assembly TRANSMISSION AND GOVERNOR SECTION 0 Transmission Assembly Governor REAR SUSPENSION -- GAS VEHICLE SECTION RearSuspension Assembly... - Inner Frame Assembly ELECTRICAL -- ELECTRIC VEHICLE SECTION Power Wiring -- Electric Vehicle -... V-Glidewiperswitch Resistorand Board Assembly-V-Glide Forward and Reverse Switch Assembly Power Wiring -- Solid State Controller Forward and Reverse Switch -- Solid State Controller... - V-Glide Wiper Switch -- Solid State Controller Reverse Buzzer -- Frame Mounted ReverseBuzzer-DashMounted CHARGERS SECTION 3 Model3800Accu-Power Modell4000Ultra-Power MOTOR SECTION 4 CLUB CARModel#09 and# REAR SUSPENSION ASSEMBLY -- ELECTRIC VEHICLE SECTION 5 Rear Suspension Assembly -- Electric Vehicle... 5-

4 USING THE ILLUSTRATED PARTS LIST This Parts List Manual is to be used for identification and ordering of Service Parts for the Carryall-l and Carryall- utility vehicles. The first four (4) sections include information common to both the Carryall Gas and Carryall Electric vehicles. Sections 5 through contain information related solely to the Carryall Gas vehicles while sections through 5 relate solely to the Carryall-l Electric. The Manual Numerical Index will help provide quick reference to each section.

5 INDEX GAS b.

6

7 INDEX

8

9 INDEX ELECTRIC 3 ELECTRICAL BATTERY CHARGER MOTOR REAR SUSPENSION

10

11 MAINTENANCE SERVICE TOOLS DESCRIPTION PART NO. Internal Retaining Pliers Brake Adjusting Tool Volt Ohm Meter Continuity Tester Retaining Ring Pliers (45" External) Retaining Ring Pliers (90" Internal) Keyswitch Tool Seal Puller Bearing Puller Bearing Puller Wedge Attachment Tachometer Drive Clutch Puller Clutch Alignment Tool Touch-Up Paint - Beige Touch-Up Paint - White Transmission Tool Kit Drive Unit Pinion Seal Tool Drive Unit Axle Seal Tool Steering Column Bearing Press Tool Steering Column Retaining Ring Tool Battery Terminal Protector Dry Moly Lubricant Flexible Cowl Repair Kit Hydrometer Battery Tester (Discharge Machine) Battery Thermometer Fly Wheel Puller Kit Valve Seat Cutter Holder Bar Valve Seat Cutter Holder Valve Seat Cutter 45" (3mm Diameter) Valve Seat Cutter 45" (35mm Diameter) Valve Seat Cutter 3" (35mm Diameter) Clutch Tool Kit Spring Tune-up Kit (OHV Engine) Compression Gauge Adapter Valve Spring Compressor Adapter Valve Guide Reamer Arbor Valve Clearance Adjuster Screw Holder Piston Ring Compressor Kit Piston Ring Plier Bearing Driver Set Bearing and Oil Seal Remover Assembly Gear Yoke Generator Belt Tension Tool Muffler Spring Tool Please refer to the Maintenance and Service Manual for proper tool application.

12

13 Section BODY AND TRIM FRONT AND REAR COVERS

14 DETAIL A TRIM

15 TRIM ITEM NUMBER PART NUMBER 3 DESCRIPTION UNITS PER VEHICLE CA-I GAS UNITS PER VEHICLE CA-II GAS UNITS PER VEHICLE CA-I ELEC A 0A 0A 0A 0A DASH WARNING DECAL STEERING COLUMN BOOT DASH COMPONENT, LEFT (BLACK) OIL LIGHT CENTER DASH PANEL WITHOUT OIL LIGHT OPENING (BLACK) CENTER DASH PANEL WITH OIL LIGHT OPENING (BLACK) DASH COMPONENT, RIGHT (BLACK) MAT, FLOOR LUG NUT PACKAGE DUST SEAL TIRE AND WHEEL ASSEMBLY, STANDARD RIB TIRE AND WHEEL ASSEMBLY, POWER RIB TIRE AND WHEEL ASSEMBLY, SOFT TRAC TIRE AND WHEEL ASSEMBLY, TERRAGARD UNMOUNTED TIRE, STANDARD RIB UNMOUNTED TIRE, POWER RIB UNMOUNTED TIRE, SOFT TRAC UNMOUNTED TIRE, TERRAGARD UNMOUNTED TIRE, INDUSTRIAL KEY SWITCH, KEY - VOLT INLCUDES ITEM SWITCH, KEY - 36 VOLT INLCUDES ITEM DECAL, ON/OFF SNAP WASHER KIT (BLACK) VEHICLE LOADING DECAL VEHICLE LOADING DECAL TILT BED DECAL BOOT BACKUP STRIP DECAL - LEFT HAND SIDE DECAL - RIGHT HAND SIDE DECAL - LEFT HAND SIDE DECAL - RIGHT HAND SIDE PINCH DECAL LATCH DECAL MOVING PARTS DECAL (ON FRAME) DANGER DECAL (NOT SHOWN) HOT MANIFOLD DECAL WHEEL RIM, WHITE NR NR NR NR AIR PR NR NR N R NR NR NR PR NR NR NR NR NR NR PR NR

16 3 TYPICAL \ TYPICAL 5 PLACES DETAIL A DETAIL B I DETAIL C DETAIL D 3 4 TYPICAL PLACES TYPICAL 6 PLACES, ITEM I TYPICAL 4 PLACES. ITEM 3 PLACES TYPICAL PLACES FRONT COWL - CARRYALL-I

17 FRONT COWL - CARRYALL-I

18 TYPICAL 5 PLACES / DETAIL A DETAIL B DETAIL C DETAIL D DETAIL E 0 4 TYPICAL PLACES TYPICAL 6 PLACES, ITEM TYPICAL 4 PLACES, ITEM 3 PLACES TYPICAL PLACES TYPICAL PLACES FRONT COWL - CARRYALL-II

19 FRONT COWL - CARRYALL-II

20 DETAIL A DETAIL B DETAIL C DETAIL D TYPICAL 3 PLACES AT EACH FENDER TYPICAL PLACES TYPICAL PLACES TYPICAL 4 PLACES REAR COVER - CARRYALL-I AND CARRYALL-I

21

22 LOCATED AT 4 REAR OF ITEM 3 DETAIL A DETAIL B DETAIL C I DETAIL 0 DETAIL E I TYPICAL 8 PLACES I TYPICAL 6 PLACES I TYPICAL 4 PLACES / TYPICAL PLACES TYPICAL 4 PLACES, ITEM 8,s TYPICAL PLACES, ITEM 8 A SEAT BOTTOM AND SEAT BACKS - CARRYALL-I AND CARRYALL-II

23

24 DETAIL A I DETAIL B DETAIL C I DETAIL D 8 TYPICAL 4 PLACES TYPICAL PLACES TYPICAL 4 PLACES TYPICAL PLACES TILT BED AND LATCH - CARRYALL-I

25 TILT BED AND LATCH - CARRYALL-I

26 DETAIL A I DETAIL B I DETAIL C DETAIL D I TYPICAL 4 PLACES I TYPICAL 4 PLACES TYPICAL PLACES 3 TILT BED PROP ROD AND HINGE - CARRYALL-II

27

28 DETAIL A DETAIL B DETAIL C DETAIL D 8 0 TYPICAL 4 PLACES I TYPICAL PLACES TYPICAL 4 PLACES TYPICAL PLACES TILT BED AND LATCH - CARRYALL-II

29 TILT BED AND LATCH - CARRYALL-II

30

31 Section DRIVE UNIT

32 DRIVE UNIT

33 ITEM NUMBER PART NUMBER 3 4 DRIVE UNlT DESCRIPTION UNITS PER VEHICLE DRIVE UNlT INCLUDES ALL ITEMS EXCEPT 8, 9, 0, AND 43 AXLE ASSEMBLY, RIGHT INCLUDES ITEMS, 6, 8 AND 9 LUG STUD BOLT (0 X 30) LOCKWASHER INPUT SHAFT OIL SEAL GEAR CASE - RIGHT HAND BREATHER PLUG SHIFT CABLE SUPPORT BRACKET KIT (GAS VEHICLE ONLY) INCLUDES ITEMS 9, 0, AND 43 /4" FLATWASHER /4-0 X 4" HEX BOLT /4-0 X 3-/" HEX BOLT GASKET INNER AXLE, TUBE BEARING GASKET - AXLE TUBE AXLE TUBE ASSEMBLY - RIGHT HAND BUSHING WlTH GROOVE IN END AXLE SHAFT OIL SEAL OUTER AXLE TUBE BEARING CIRCLIP, TYPE-C INPUT GEAR BEARING SHAFT, INPUT INTERMEDIATE GEAR BEARING INTERMEDIATE GEAR - SMALL KEY, SUNK INTERMEDIATE GEAR - LARGE GEAR CASE - LEFT HAND FILL PLUG WlTH GASKET BOLT (6 X 50) PIN, DOWEL BOLT (8 X 37) PLATE, LOCK OUTPUT GEAR DIFFERENTIAL PIN DIFFERENTIAL GEAR CASE - LEFT HAND PLATE, THRUST (DIFFERENTIAL GEAR) DIFFERENTIAL GEAR PLATE, THRUST (IDLER GEAR) DIFFERENTIAL IDLER GEAR DIFFERENTIAL GEAR CASE - RIGHT HAND SHIM AXLE TUBE ASSEMBLY - LEFT HAND AXLE ASSEMBLY, LEFT INCLUDES ITEMS, 6, 8 AND 9 /4-0 NYLON LOCKNUT

34

35 Section 3 BRAKES, PEDAL AND CABLE ASSEMBLY

36 BRAKE CLUSTER, RIGHT HAND AND LEFT HAND

37

38 BRAKE PEDAL AND CABLE ASSEMBLY

39

40 ACCELERATOR PEDAL ASSEMBLY

41

42

43 Section 4 STEERING AND FRONT SUSPENSION

44 STEERING COLUMN ASSEMBLY - STEEL

45 STEERING COLUMN ASSEMBLY - STEEL

46 STEERING COLUMN - ALUMINUM

47 STEERING COLUMN - ALUMINUM

48 STEERING ASSEMBLY

49

50 FRONT SUSPENSION ASSEMBLY - A-PLATE

51 ITEM NUMBER PART NUMBER 3 4 FRONT SUSPENSION ASSEMBLY - A-PLATE DESCRIPTION UNITS PER VEHICLE JOINT, RIGHT HAND BALL INCLUDES ITEM 3 /4-8 THREAD FORMING GREASE FITTING NUT, /-0 HEX ROD, TIE NUT, /-0 LEFT HAND HEX JOINT, LEFT HAND BALL INCLUDES ITEM 3 BOLT, 33/8-6 SHOULDER HEX ABSORBER, SHOCK BOLT, 3/8-6 HEX LOCKNUT, 3/8-6 SHOCK SUPPORT WELD ASSEMBLY "A" PLATE SUBASSEMBLY (LEFT HAND) INCLUDES ITEMS AND 3 AND 9 BUSHING, BRONZE BOLT, 3/8-6 SHOULDER HEX LOCKWASHER, /" CLEVIS, UPPER LOCKNUT, 3/8-6 NYLON WASHER, THRUST SPINDLE LEFT HAND ASSEMBLY INCLUDES ITEMS, 0, AND BUSHING, SPINDLE BUSHING, 3/4" BRONZE KING PIN ASSEMBLY NUT, 3/8-4 SLOTTED HEX PIN, COTTER 3/3 X " BOLT, 3/8-6 HEX PLATE, FRONT SPRING MOUNTING ADJUSTER, FRONT SPRING ECCENTRIC SPRING, FRONT - CARRYALL-! AND CARRYALL-II INCLUDES ITEMS 7 AND 3 BUSHING, URETHANE BUSHING, 3/8" STEEL PLATE, FRONT SPRING RETAINER NUT, 3/8-6 HEX LOCKWASHER, 3/8" BOLT, 33/8-6 SPINDLE RIGHT HAND ASSEMBLY INCLUDES ITEMS, 0 AND FLATWASHER, 3/8 FLATWASHER, SPECIAL NUT, 3/4-6 SLOTTED HEX COVER, DUST PIN, COTTER 5/3 X " HUB ASSEMBLY INCLUDES ITEMS 4 AND 43 BEARING, HUB PACKAGE ( PIECES) STUD, LUG NUT, LUG SEAL, DUST "A PLATE ASSEMBLY, RIGHT HAND INCLUDES ITEMS, 3 AND

52 FRONT SUSPENSION ASSEMBLY - DELTA A-PLATE

53

54

55 Section 5 ELECTRICAL AND BATTERY

56 VOLTAGE REGULATOR REVERSE I lv BATTERY

57 WIRING - GAS VEHICLE

58 ELECTRICAL COMPONENT BOX

59 ELECTRICAL COMPONENT BOX

60 STARTER-GENERATOR MOUNTING NUMBER PART NUMBER??.=!A DESCRIPTION STARTER-GENERATOR MOUNTING BRACKET BELT PULLEY ADJUSTING BRACKET HEX HEAD SCRNV, 3/8-6 X -/4 LOCKWASHER, 38'' DIAMETER HEX NUT, 3/8-6 HEX HEAD SCREW, M8.5 X 5MM LOCKWASHER, 5/6" DIAMETER TORX HEAD SCREW, M8.5 X 8MM ROUND HEAD SQUARE NECK BOLT, 5/6-8 X HEX NUT, 5/6-8 #6 BLACK WIRE ASSEMBLY GROUND WlRE NYLON LOCK NUT, 5/6-8 FLATWASHER, 5/6" DIAMETER HEX HEAD CAP SCREW, 5/6-8 X 3/4

61 STARTER-GENERATOR ASSEMBLY ITEM NUMBER PART NUMBER 3 DESCRIPTION UNITS PER VEHICLE NO # NO # NO # NO # NO # 0307 NO # NO # HEX NUT, MI4 X.5 LOCKWASHER, MI4 SPACER CROSS-RECESSED SCREW, M5 X 8 WITH LOCKWASHERS AND FLATWASHERS OUTPUT SHAFT END BELL DOUBLE SEALED BALL BEARING BEARING RETAINER KEY ARMATURE ASSEMBLY INCLUDES ITEMS 3, 6, 7, 0 AND ARMATURE DOUBLE SEALED BALL BEARING FRAME ASSEMBLY INCLUDES ITEMS THRU 8 AND FRAME POLE PIECE POLE PIECE SCREW FIELD COIL ASSEMBLY TERMINAL HARDWARE KIT INCLUDES NUTS, LOCKWASHERS AND FLATWASHERS INSULATOR TERMINAL HARDWARE KIT INCLUDES NUTS, LOCKWASHERS AND FLATWASHERS INSULATOR CROSSOVER LEAD BRUSH HOLDER SCREW, M5 X 6 WITH LOCKWASHER SCREW, M4 X 0 WITH LOCKWASHER BRUSH PACKAGE INCLUDES 4 BRUSHES BRUSH SPRING TERMINAL HARDWARE KIT INCLUDES NUTS, LOCKWASHERS, FLATWASHERS AND INSULATORS CLAMP BOLT, 6 X 80 COMMUTATOR END BELL BRUSH INSPECTION PORT COVER

62 F&R SHIFTER ASSEMBLY

63 F&R SHIFTER ASSEMBLY

64 qg TYP BUZZER SHOWN REPLACED BY ITEM #9 (0685)

65 CENTER DASH PANEL 8 REVERSE BUZZER - DASH MOUNTED ITEM NUMBER PART NUMBER 3 4 DESCRIPTION UNITS PER VEHICLE 9 0 REVERSE BUZZER #4-4 X,330 SCREW PAN HEAD HI-LO WIRE ASSEMBLY, BLACK (GAS VEHICLE ONLY - NOT SHOWN) 5-

66 BATTERY

67

68

69 Section 6 ENGINE Effective Carryall-l Serial Number FG Effective Carryall-ll Serial Number EG For engine prior to above, see CLUB CAR Illustrated Parts List #I04650 or #0393.

70 ENGINE

71

72 ENGINE

73 ENGINE

74 ENGINE

75 ENGINE

76 ENGINE

77 ITEM NUMBER PART NUMBER 3 4 ENGINE DESCRIPTION UNITS PER VEHICLE ROCKER CASE ROCKER CASE GASKET FLANGED BOLT, M6 X.0 X 35MM LONG O-RING SCREW HEX NUT ROCKER ARM COLLET VALVE SPRING RETAINER ENGINE VALVE SPRING SPRING SEAT SNAP RING VALVE GUIDE (EXHAUST) OIL SEAL VALVE GUIDE (INTAKE) EXHAUST VALVE INTAKE VALVE SCREW PLATE VALVE CYLINDER HEAD INCLUDES ITEMS, 3 AND 5 PIN STUD BOLT ROCKER SHAFT PUSH ROD WASHER TYPE-E ClRCLlP FLANGED BOLT, M8 X.5 X 45MM LONG HEAD GASKET I I 6

78 TYPICAL PLACES ENGINE

79 ENGINE

80 ENGINE

81

82

83 Section 7 FUEL, INTAKE AND GOVERNOR SYSTEM

84 DETAIL A DETAIL B DETAIL C TANK CONNECTION FRAME CONNECTION FUEL SYSTEM ASSEMBLY

85

86 CARBURETOR ASSEMBLY

87

88 GOVERNOR GUARD AND INTAKE HOSE

89

90 EXPANSION CHAMBER, CHOKE AND FILTER

91

92 GOVERNOR AND ACCELERATOR CABLES

93 GOVERNOR AND ACCELERATOR CABLES

94

95 Section 8 EXHAUST SYSTEM

96 EXHAUST SYSTEM

97

98

99 Section 9 TORQUE CONVERTER

100 DRIVE CLUTCH ASSEMBLY

101

102 DRIVEN CLUTCH ASSEMBLY

103 DRIVEN CLUTCH ASSEMBLY ITEM NUMBER PART NUMBER 4 DESCRIPTION UNITS PER VEHICLE DRIVEN CLUTCH ASSEMBLY (CARRYALL-I AND CARRYALL-II) SHAFT KEY DRIVE BELT HEX HEAD BOLT, 5/6-8 X 3/4 LOCKWASHER, 5/6" DIAMETER HEAVY FLATWASHER, 5/6 DIAMETER DRIVEN CLUTCH ASSEMBLY INCLUDES ITEMS 7 THRU 4 RETAINING RING SHORT KEY CAM 75" SPRING SOC HEAD CAP SCREW, #8-3 X 3/4 DRIVE BUTTON MOVABLE FACE ASSEMBLY FIXED FACE ASSEMBLY DRIVEN CLUTCH BUTTON KIT INCLUDES ITEMS AND 3 3

104

105

106 TRANSMISSION ASSEMBLY

107 ITEM NUMBER PART NUMBER TRANSMISSION ASSEMBLY 3 4 DESCRIPTION UNITS PER VEHICLE A TRANSMISSION ASSEMBLY BALL BEARING SPACER-THICK GOVERNOR GEAR, 4 TOOTH GOVERNOR SHAFT GOVERNOR SHAFT KEY SCREW, M4 X 0.7 X 6MM GOVERNOR ARM, INTERNAL GOVERNOR SLEEVE SPACER-THIN BOLT, M6 X X 5MM HEX GOVERNOR ARM PIVOT GOVERNOR ARM, EXTERNAL WASHER, FLAT NUT, M6 X SNAP RING WASHER GOVERNOR ARM SHAFT BALL STUD CAP SCREW, SOCKET HEAD, 0-4 X 3/8" TRANSMISSION SHIFTER ARM, OUTSIDE SHIFTER SHAFT KEY SHIFTER SHAFT O-RING OIL SEAL LOCKNUT, /4-8 NYLON BREATHER OIL SEAL DRAIN PLUG WITH GASKET GEAR CASE BOLT, M6 X X 4MM HEX DOWEL PIN CASE GASKET BALL BEARING THRUST WASHER PLUG GEAR ASSEMBLY, 36 TOOTH SYNCHRONIZER RING THRUST WASHER OUTPUT SHAFT SYNCHRO SPRING CLUTCH HUB SYNCHRO INSERT SLEEVE GEAR ASSEMBLY, 34 TOOTH SHIM 0.MM SHIM O.MM FLANGE NUT, MI X.5 BOLT, M6 X X 0MM HEX COVER O-RING THRUST WASHER NEEDLE BEARING REVERSE IDLER GEAR IDLER SHAFT NEEDLE BEARING THRUST WASHER, 3.OMM THRUST WASHER, 3.3MM WHITE THRUST WASHER, 3.6MM YELLOW GEAR, 5 TOOTH SNAP RING GEAR, 7 TOOTH INPUT SHAFT ROLL PIN SHIFTER ARM LEVER, INSIDE SHIFTER SPRING SHIFTER BALL SLEEVE SHIFT ARM SHIFT ROD ROLL PIN BELLEVILLE SPRING 3 3 NR NR 4 NR NR AJR

108

109 Section REAR SUSPENSION

110 REAR SUSPENSION ASSEMBLY

111 ITEM NUMBER PART NUMBER REAR SUSPENSION ASSEMBLY 3 4 DESCRIPTION UNITS PER VEHICLE REAR SPRING SHACKLE DIMPLED LOCKNUT, 3/8-6 UNC STEEL BUSHING URETHANE BUSHING NUT, 3/8-4 UNC HEX SHOCK ABSORBER CUSHION KIT SHOCK ABSORBER KIT INCLUDES ITEM 6 "U" BOLT REAR SPRING FLATWASHER, 7/6" NYLON LOCKNUT, 7/6-4 BOLT, HEX, 3/8-6 UNC X 3-3/8" DIMPLED LOCKNUT, 5/8- FLATWASHER, 58 OVERLOAD BUMPER OVERLOAD BUMPER MOUNT FLATWASHER, 5/6 NYLON LOCKNUT, 5/6-8 SPRING RETAINER SPACER - OVERLOAD BUMPER

112

113

114

115 Section ELECTRICAL

116 DETAIL A 44 FRAME DETAIL B POWER WIRING - ELECTRIC VEHICLE

117 ITEM NUMBER PART NUMBER POWER WIRING - ELECTRIC VEHICLE 3 4 DESCRIPTION UNITS PER VEHICLE WIRE ASSEMBLY #6 BROWN WIRE ASSEMBLY #6 PURPLE WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 GREY WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 YELLOW WIRE ASSEMBLY #6 ORANGE WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #8 RED WIRE ASSEMBLY #0 RED WIRE ASSEMBLY #8 ORANGE WIRE ASSEMBLY #8 WHITE WIRE ASSEMBLY #8 GREEN WIRE ASSEMBLY #0 RED WIRE ASSEMBLY #0 WHITE WIRE ASSEMBLY #8 RED WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #8 BLUE WIRE ASSEMBLY #6 RED WIRE ASSEMBLY #8 YELLOW WIRE ASSEMBLY #6 BLACK NUT #lo-3, BRASS FUSE LENS FUSE, 80 AMP FUSE HOLDER FUSE AND RECEPTACLE MOUNTING BRACKET RECEPTACLE BEZEL CHARGER RECEPTACLE SCREW, PHILLIPS HEAD, TYPE BT, #8-8 X /" CLUB CAR 6 VOLT BATTERY SELF TAPPING SCREW, PHILLIPS PAN HEAD # 7 X -34" SELF TAPPING SCREW, PHILLIPS PAN HEAD # 7 X 3/4" CABLE CLAMP POP RIVET, 3/6" BATTERY HOLD DOWN "J" BOLT HEX NUT, 5/6-8 UNC S.S. FLATWASHER, TYPE B, 5/6" #0 SPLIT LOCKWASHER FUSE LINK KIT (NOT SHOWN) INCLUDES ITEMS 7, 8, 9, 30 AND 44 SOLENOID - 36 VOLT /4-0 X 5/8" THREAD ROLLING SCREW #lo-3 HEX NUT 5/6 X 8 HEX NUT WASHER, 5/6 HELICAL SPRING

118 V-GLIDE WIPER SWITCH

119

120 RESISTOR AND BOARD ASSEMBLY - V-GLIDE

121

122 FORWARD AND REVERSE SWITCH ASSEMBLY - V-GLIDE

123 PART NUMBER FORWARD AND REVERSE SWITCH ASSEMBLY - V-GLIDE 3 4 DESCRIPTION FORWARD AND REVERSE SWITCH ASSEMBLY COMPLETE EXCLUDING ITEMS AND AND MOUNTING HARDWARE, ITEMS 4, 5, 6 AND 8 SCREW, PHILLIPS MACHINE, #8-3 SWITCH HANDLE, FORWARD AND REVERSE ROLL PIN, /8 X " SHAFT, FORWARD AND REVERSE SWITCH NUT, HEX, #4-40 UNC LOCKWASHER, #4 LIMIT SWITCH, FORWARD AND REVERSE SCREW, SLOTTED ROUND HEAD, #4-40 X -/8" ROTOR CONTACT SWITCH ROTOR, FORWARD AND REVERSE ROLL PIN, 3/6" X -3/8" FLATWASHER, 3/8 SHAFT SPRING, FORWARD AND REVERSE SCREW, HEX HEAD MACHINE, #lo-4 LOCKWASHER, INTERNAL TOOTH #0 LOCKNUT, NYLON, /4-0 SWITCH CASE, FORWARD AND REVERSE SCREW, TRUSS HEAD PHILLIPS, /4-0 X " WASHER, PLASTIC, 3/8" BEARING - UNITS PER VEHICLE - 3 3

124 DETAIL A POWER WIRING - SOLID STATE CONTROLLER

125 ITEM NUMBER PART NUMBER 3 4 POWER WIRING - SOLID STATE CONTROLLER DESCRIPTION UNITS PER VEHICLE CONTROLLER WIRING ASSEMBLY WIRE ASSEMBLY #6 GREEN WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 BLACK WIRE ASSEMBLY #6 WHITE WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #8 BLACK WIRE ASSEMBLY #8 WHITE WIRE ASSEMBLY #8 YELLOW WIRE ASSEMBLY #I8 RED WIRE ASSEMBLY #8 GREEN WIRE ASSEMBLY #6 YELLOW WIRE ASSEMBLY #I8 RED WIRE ASSEMBLY #8 RED WIRE ASSEMBLY #8 ORANGE WIRE ASSEMBLY #I8 BLUE WIRE ASSEMBLY #I8 BLACWHITE SOLENOID - 36 VOLT DIODE ASSEMBLY RESISTOR ASSEMBLY /4-0 X 34 HEX HEAD SCREW 4 HELICAL SPRING LOCKWASHER /4-0 HEX NUT PUSH NUT,87 5/6 HELICAL SPRING LOCKWASHER (ATTACHES WIRES TO MOTOR) 5/6-8 HEX NUT (ATTACHES WIRES TO MOTOR) /4-0 X 5/8 HEX HEAD BOLT (ATTACh5S WIRES TO FORWARD & REVERSE CONTACT BARS) /4 LOCKWASHER (ATTACHES WIRES TO FORWARD & REVERSE CONTACT BARS) /4-0 HEX NUT (ATTACHES WIRES TO FORWARD & REVERSE CONTACT BARS) #lo-4 X / HEX HEAD SCREW (ATTACHES WIRES TO FORWARD & REVERSE ROTOR) #I0 LOCKWASHER (ATTACHES WIRES TO FORWARD & REVERSE ROTOR) 3/6 POP RIVET CABLE CLAMP WIRE ASSEMBLY #6 ORANGE WIRE ASSEMBLY #6 BLUE WIRE ASSEMBLY #8 BLUE WIRE ASSEMBLY #8 WHITE WIRE ASSEMBLY #I8 GREENWHITE WIRE ASSEMBLY #I8 BLACK ELECTRONIC CONTROLLER CLUB CAR 6 VOLT BATTERY BATTERY HOLD DOWN (NOT SHOWN) "J" BOLT (NOT SHOWN) HEX NUT, 5/6-8 UNC STAINLESS STEEL (NOT SHOWN) FLATWASHER, TYPE B, 5/6 (NOT SHOWN)

126 F&R SWITCH - SOLID STATE CONTROLLER

127

128 i, 9,m \,, BACK VIEW " f V-GLIDE WIPER SWITCH - SOLID STATE CONTROLLER

129 ITEM NUMBER PART NUMBER V-GLIDE WlPER SWITCH - SOLID STATE CONTROLLER 3 4 DESCRIPTION UNITS PER VEHICLE I V-GLIDE WlPER SWITCH - SOLID STATE CONTROLLER SPEED CONTROLLER CASE /4-0 UNC HEX NUT, BRASS /4 SPLIT LOCKWASHER /4"-0 BRASS JAM NUT 5/6"-8 UNC NYLON LOCKNUT /4" X /4-8, SHORT BALL STUD SPEED CONTROLLER BELL CRANK /4-8 DIMPLED LOCKNUT 3/8" X /" FLANGE BEARING /4"-0 X.00 HEX CAP SCREW, BRONZE SPEED CONTROLLER COVER #I03 UNF HEX NUT SPEED CONTROLLER SHAFT AND CARRIER SPEED CONTROLLER BRUSH SPRING SPEED CONTROLLER ADJUSTING STUD M-40 UNC TYPE "F SCREW #4 SPLIT LOCKWASHER SPEED CONTROLLER ARM SPEED CONTROLLER BRUSH M-40 UNC X 3/4 ROUND HEAD SCREW LIMIT SWITCH SPLIT GROMMET M-40 UNC HEX NUT #lo-4 X 3/4 ROUND HEAD BOLT #0 SPLIT LOCKWASHER #0 HEX NUT ACCELERATOR ROD /4-8 JAM NUT BALL JOINT BUMPER, SPEED CONTROLLER SHIM, SPEED CONTROLLER HAIR SPRING COTTER PIN SPEED CONTROLLER DECAL WIPER SWITCH RESISTOR PROTECTOR WIRE ASSEMBLY #8 BLACK RESISTOR ASSEMBLY 90R RESISTOR ASSEMBLY 60R RESISTOR ASSEMBLY 750R RESISTOR ASSEMBLY 80R RESISTOR ASSEMBLY 00R #8 GREENNHITE WIRE ASSEMBLY #8 BLUE WIRE ASSEMBLY #8-3 X.44 PAN HEAD SCREW (NOT SHOWN) (ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8 PLAIN WASHER (NOT SHOWN) (ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8-3 HEX NUT (NOT SHOWN) (ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8-3 HEX MALWFEMALE STANDOFF (NOT SHOWN) (ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE) #8 EXTERNAL TOOTH LOCKWASHER (NOT SHOWN) (ATTACHES RESISTOR PROTECTOR #34 TO WlPER SWITCH CASE)

130 REVERSE BUZZER - FRAME MOUNTED ITEM NUMBER PART NUMBER 3 4 DESCRIPTION BUZZER KIT INCLUDES ITEMS THRU 8 SCREW, ROUND HEAD #4-40 X 3/4 NYLON SHOULDER WASHER #4 FLATWASHER #4 LOCKWASHER #4 HEX NUT

131 REVERSE BUZZER - DASH MOUNTED ITEM NUMBER PART NUMBER 3 4 DESCRIPTION UNITS PER VEHICLE REVERSE BUZZER #4-4 X 330 SCREW, PAN HEAD HI-LO

132

133 Section 3 BATTERY CHARGER USE THIS INFORMATION MODEL: I't5'~) INPUT: 0'ds-

134 MODEL 3800 ACCU-POWER CHARGER u

135

136 MODEL 4000 ULTRA-POWER CHARGER

137 MODEL 4000 ULTRA-POWER CHARGER ITEM NUMBER PART NUMBER, DESCRIPTION UNITS PER VEHICLE CASE ASSEMBLY INCLUDES FASTENERS STRAIN RELIEF, DC CORD STRAIN RELIEF, AC CORD DC CORDSET, AWG X 0 INCHES LONG DC CORDSFT, AWG X 46 INCHES LONG DC CORDSET, 0 AWG X 4 INCHES LONG DC CORDSFT, 0 AWG X 0 INCHES LONG AC CORDSET, 6 AWG X 80 INCHES LONG AC CORDSFT, 6 AWG X 0 INCHES LONG TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY WITH DIODES 36 VDC RELAY CAPACITOR TIMER KIT ASSEMBLY CONTROL CABLE ASSEMBLY FUSE ASSEMBLY ULTRA-POWER CHARGER ASSEMBLY INCLUDES ITEMS THRU 3, 6 THRU, EACH OF ITEMS 4 AND 5

138

139 Section 4 MOTOR

140 MOTOR ASSEMBLY FOR CLUB CAR MODELS 09 AND 04678

141 MOTOR ASSEMBLY FOR CLUB CAR MODELS 09 AND 04678

142

143 Section 5 REAR SUSPENSION

144 REAR SUSPENSION ASSEMBLY - CARRYALL-I ELECTRIC

145 pr NUMBER PART NUMBER REAR SUSPENSION ASSEMBLY - CARRYALL-I ELECTRIC 3 4 DESCRIPTION DIMPLED LOCKNUT, 3/8-6 UNC URETHANE BUSHING REAR SPRING BOLT, HEX, 3/8-6 UNC X 3-3/8 LOCKNUT, NYLON 5/6-8 FLATWASHER, 5/6 BUMPER BUMPER MOUNT - ANGLED "U BOLT REAR SPRING SHACKLE SPRING RETAINER SHOCK MOUNT, RIGHT-HAND (NOT SHOWN) SHOCK MOUNT, LEFT-HAND FLATWASHER, 7/6 LOCKNUT, NYLON 7/6-4 SHOCK ABSORBER CUSHION KIT SHOCK NUT, HEX 3/8-4 BRAKE CABLE HANGER SHOCK ABSORBER KIT INCLUDES ITEMS 5 (4) AND 6 () STEEL BUSHING

146

147

148 Club Car, Inc. P.O. Box Augusta, GA USA Web Phone ClubCar Int l Fax