Yukon Trail Inc PARTS MANUAL. ELECTRIC 4x4 HUNTING VEHICLE
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1 Yukon Trail Inc PARTS MANUAL ELECTRIC 4x4 HUNTING VEHICLE
2 CONTENT Part 1 Body 1-1 Front Cover Instrument Board Rear Cover Rear Bumper Windshield Front Basket Brush Guard Roll Cage Roof and Roof rack Seat belt and mirror Flip seat Floor 20 Part 2 Chassis 2-1 Front Suspension Rear Suspension Drive system Front gear box Rear gear box Differential assembly Brake pedal, master cylinder Brake tubes Parking Brake System Steering System Tires 38 Part 3 Electric system 3-1 Controlling system (DC) Controlling system (AC) Battery Assembly (DC) Battery Assembly (AC) Lighting wiring harness (DC) Controlling wiring harness (DC) Transfer unit wiring harness (DC) Wiring harness (AC) DC converter Horn, backup buzzer 52 1
3 1-1 Front cover Item No. Part No. Description Qty Remark 1 GW Front cover 1 2 GW Front fender-right 1 3 GW Head light-right 1 4 GW Head light-left 1 5 GW Front fender-left 1 6 GW Net cover 1 7 GW Examine pot cover 1 8 GW Rivet 4.8*18 8 black 9 GW Plastic rivet 4 2
4 1-2 Instrument board (1/2) 3
5 1-2 Instrument board (2/2) Item No. Part No. Description Qty Remark 1 GW Dash board 1 2 GW Glove box cover-left 1 3 GW Hinge 2 4 GW Cup holder 2 5 GW Speedometer plate 1 6 GW Speedometer 1 7 GW Glove box cover-right 1 8 GW Rivet 4.8*18 20 black 9 GW Switch panel 1 10 Q A2 Tapping screw 4.2* GW Optional for DC car, 48V Coulometer GW Optional for AC car, 72V 12 GW cap 1 13 GW Headlight switch 1 14 GW Forward/reverse switch 1 15 GW reverse buzzer switch 1 16 GW Differential lock switch 1 17 GW Drive model switch 1 18 GW Cigar lighter 1 19 GW lock 2 4
6 1-3 Rear Cover (1/2) 5
7 1-3 Rear Cover (2/2) Item No. Part No. Description Qty Remark 1 GW Rear cover 1 2 GW Rivet 4.8*18 22 black 3 GW Rear fender-left 1 4 GW Plastic rivet 16 5 GW Tail light-left 1 6 GW Guard cover 1 7 GW Tail light-right 1 8 GW Rear fender-right 1 9 GW Motor cover 1 10 Q A2 Tapping screw 4.2* GW Charging receptacle 1 6
8 1-4 Rear Bumper Item No. Part No. Description Qty Remark 1 GW Rear bumper 1 2 Q A2 Bolt M6*25 4 Stainless steel 3 Q40306A2 Spring washer 6 4 Stainless steel 4 Q40206A2 Flat washer lager series 6 4 Stainless steel 5 GW Left mudguard 1 plastic 6 GW Right mudguard 1 plastic 7
9 1-5 Windshield Item No. Part No. Description Qty Remark 1 GW Spacer 4 2 GW Windshield bracket 2 3 Q Screw, spring washer and plain washer assembly 4 4 GW Windshield 1 5 Q A2-70 Cross pan head screw 2 Stainless steel 6 GB528706A2 Plain washer extra large series 6 2 Stainless steel 7 GW Bushing 2 8 GW Sash 2 9 Q40106A2 Plain washer 6 2 Stainless steel 10 GB88908A2 nut 2 Stainless steel 8
10 1-6 Front basket Item No. Part No. Description Qty Remark 1 GW Front basket 1 2 Q150B0870A2-70 Bolt M8*70 4 Stainless steel 3 Q40108A2 Plain washer 8 8 Stainless steel 4 GW Left bracket 1 5 GW spacer 4 6 GW Right bracket 1 7 GB88908A2 nut 4 Stainless steel 9
11 1-7 Brush guard Item No. Part No. Description Qty Remark 1 GW Brush guard 1 2 Q150B0616A2-70 Bolt M6*16 2 Stainless steel 3 Q40106A2 Plain washer 6 2 Stainless steel 4 Q40306A2 Spring washer 6 2 Stainless steel 5 GW Front basket rod 1 10
12 1-8 Roll cage 2, 3, , 3, , 7,
13 1-8 Roll cage Item No. Part No. Description Qty Remark 1 GW Roll cage - Right 1 2 Q150B0860A2-70 Bolt M8*60 12 Stainless steel 3 Q40308A2 Spring washer 8 16 Stainless steel 4 Q40108A2 Plain washer 8 16 Stainless steel 5 GW Front bar 1 6 Q150B1090 Bolt M10* Q40310 Spring washer Q40110 Plain washer GW Spacer 4 10 GW Roll cage - Left 1 11 GW Tube spacer 4 12 GW Upper bar 3 13 GW Lower rod 4 14 Q150B0825A2-70 Bolt M8*25 4 Stainless steel 12
14 1-9 Roof and roof rack
15 1-9 Roof and roof rack Item No. Part No. Description Qty Remark 1 Q150B0825A2-70 Bolt M8*25 4 Stainless steel 2 Q40308A2 Spring washer 8 8 Stainless steel 3 Q40108A2 Plain washer 8 10 Stainless steel 4 GW Roof rack 1 5 GW Spacer 4 6 GB528708A2 Plain washer extra large series 8 6 Stainless steel 7 GW Rubber seal 6 8 GW Roof 1 9 GW Roof spacer 6 10 Q150B0880A2-70 Bolt M8*80 6 Stainless steel 11 Q32808A2 Self lock nut M8 2 Stainless steel 12 Roll cage 14
16 1-10 Seat belt and mirror 8, , 9 3,4, ,4, , 3 1 Item No. Part No. Description Qty Remark 1 GW Seat 1 2 GW Bolt 4 3 Q40112 Plain washer Q40312 Spring washer GW Nut 7/ GW Seat belt 2 Set 7 GW Shoulder bolt 2 8 Q32806A2 Nylon insert nut M6 2 Stainless steel 9 Q40106A2 Plain washer 6 4 Stainless steel 10 Q150B0645A2 Bolt M6*45 2 Stainless steel 11 GW Mirror 1 12 GW Back rest 1 13 GW Bracket 1 14 GW Buckle 2 15
17 1-11 Flip seat (1/3) 16
18 1-11 Flip seat (1/3) Item No. Part No. Description Qty Remark 1 GW Lower bracket 2 2 Q150B1030 Bolt M Q40110 Flat washer Q40310 Spring washer Q32810 Nylon insert nut M Q40108 Flat washer Q32808 Nylon insert nut M Back rest assembly 1 10 GW Foot rest 1 11 GW Flip flop bracket 1 12 Q32806 Nylon insert nut M Q150B1040 Bolt M10* GW Plastic board 1 17 GW Side arm rest 2 18 Q Countersunk flat head screws 6 M Q Countersunk flat head screws 4 M8*35 21 Upper flip flop assembly 1 22 Q150B0840 Bolt M Q150B0825 Bolt M Q150B0865 Bolt M GW Rail 1 17
19 1-11 Flip seat (2/3) Item No. Part No. Description Qty Remark 1 GW Back rest bracket-left 1 2 Q A2 Pan head screw M Stainless steel 3 GW Left F bracket 1 4 Q150B0825A2 Bolt M Stainless steel 5 Q40108A2 Flat washer 8 4 Stainless steel 6 GW Right F bracket 1 7 GW Back rest 1 8 Q40306A2 Spring washer 6 4 Stainless steel 9 Q40106A2 Flat washer 6 4 Stainless steel 18
20 1-11 Flip seat (3/3) Item No. Part No. Description Qty Remark 1 GW Cushion 1 2 Q32806A2 Nylon insert nut M6 4 3 GW Upper flip flop bracket 1 4 GW Plastic board 1 5 Q Tapping screw Q Countersunk flat head screws 4 M
21 1-12 Floor Item No Part No Description Qty Remark 1 GW Floor mat 1 rubber 2 GW Bottom board 1 3 GW Front board 1 4 GW Left side board 1 5 GW Right side board 1 6 Q Rivet 5* Q A2-70 Pan head bolt M6*25 4 Stainless steel 8 Q A2-70 Pan head bolt M6*30 2 Stainless steel 9 Q40206 Plain washer-large series GW Bushing 4 plastic 11 Q40106A2 Plain washer 6 8 Stainless steel 12 Q32806A2 Nut 8 Stainless steel 13 GW Accelerator board 1 14 Q A2-70 Pan head bolt M6*35 2 Stainless steel 20
22 2-1 Front Suspension 21
23 2-1 Front Suspension Item No. Part No. Description Qty Remark 1 GB M Flange nut 12 M10* GW Cap for bushing 16 3 GW Bushing 8 4 GB16674M Bolt 8 M10*1.25*70 5 GW A arm front left lower 1 6 GW Brake assembly-front left 1 With spindle and hub 7 Q43134 Circlip for shaft 4 8 GW Ball joint 4 9 Q38312 Crown nut 4 10 Q Split pin 4 11 GB16674M Bolt 2 M10*1.25*50 12 GW A arm front left upper 1 13 GW Front shock absorber 2 14 GB16674M Bolt 2 M10*1.25*55 15 GW A arm front right upper 1 16 GW Brake assembly-front right 1 With spindle and hub 17 GW A arm front right lower 1 22
24 2-2 Rear Suspension 23
25 2-2 Rear Suspension Item No. Part No. Description Qty Remark 1 GB M Flange nut 16 M10* GW Cap for bushing 16 3 GW Bushing 8 4 GB16674M Bolt 8 M10*1.25*70 5 GW A arm Back Left Lower 1 6 GW Brake assembly-back Left 1 7 GB16674M Bolt 2 M10*1.25*160 8 GW Rear shock absorber 2 9 GB16674M Bolt 4 M10*1.25*50 10 GW A arm Back Left Upper 1 11 GB16674M Bolt 2 M10*1.25*90 12 GW A arm Back Right Upper 1 13 Q150B0820 Bolt 4 M8*20 14 Q40108 Plain washer 8 15 GW Sway bar for the rear 1 With ball joint rods 16 Q32808 Nut 4 M8 17 GW Brake assembly-back Right 1 18 GW A arm Back Right Lower 1 24
26 2-3 Drive system
27 2-3 Drive system Item No. Part No. Description Qty Remark 1 GW Optional for DC motor Motor GW Optional for AC motor 2 GW Optional for DC motor Rear gear box GW Optional for AC motor 3 GW Retainer ring for the rear 2 4 GW Right C.V axle, Back 1 5 Q Split pin 4 6 GW Crown nut 4 7 GW Left C.V axle, Back 1 8 Q150B0830 Bolt 5 M Q40108 Flat washer Q40308 Spring washer Q151B1235 Bolt 2 M Q40112 Flat washer Q40312 Spring washer GW Drive shaft 1 15 Q33008 Nut 4 M8 16 GW Front gear box 1 17 GW Right retainer ring, Front 1 18 GW Right C.V axle, Front 1 19 GB Bolt 4 M GW Left retainer ring, Front 1 21 GW Left C.V axle, Front 1 26
28 2-4 Front gear box 27
29 2-4 Front gear box Item No. Part No. Description Qty Remark 1 GW Front gear box assembly 1 2 GW Gear box case 1 3 GW Gear box cap 1 4 GW Plain washer 1 5 GW Drive gear 1 6 GW Drive flange 1 7 GW Flange nut 1 8 GW O ring 1 9 GW Seal for drive gear 1 10 GW Seal for C.V. axle 2 11 GW Adjusting shim 1 12 None 13 GW Differential assembly 1 14 GW Bolt 3 15 GW Screw 1 16 GW Bolt 6 17 GW Circlip for hole 2 18 GW Shift stem 1 19 GW Transfer unit 1 20 GW Spline sleeve 1 21 GW Rack 1 22 GW Shift fork 1 23 GW O ring for transfer unit 1 24 GW O ring for gearbox cap 1 25 GW Ball bearing 2 26 GW Ball bearing 1 27 GW Ball bearing 1 28 GW Needle bearing 1 29 GW Drain plug 1 30 GW Copper packing 1 31 GW Shift collar 1 32 GW Adjusting shim 1 33 GW Oil plug 1 34 GW Copper packing 1 35 GW Vent pipe 1 36 GW clip 1 28
30 2-5 Rear gear box 16 14, , 30 29
31 2-5 Rear gear box Item No. Part No. Description Qty Remark 1 GW Optional for DC motor Main case GW Optional for AC motor 2 GW Gear shaft 1 3 Q key 2 4 GW Spacer 1 5 GB Bearing 1 6 GB RS Bearing 1 7 GW Input shaft gear 1 8 GB Bearing 3 9 GW Idle gear 1 10 GW Gasket 1 11 GW Breathe plug 1 12 GW Sub case 1 13 Q Pin 2 14 Q150B1060 Bolt 12 M10*60 15 Q40310 Spring washer 12 D GW Speed sensor 1 17 GB810M Small round nut 2 M33* Q40833 Lock washer 1 19 GW Seal 1 20 GB O ring 1 35* GW Spacer 1 22 GB Bearing 1 23 GW Spacer 2 24 GW Output gear 1 25 GW Adjusting shim 1 26 GB O ring 1 20* GW Drain plug 1 28 GW Differential assembly 1 29 Q150B0820 Bolt 16 M8*20 30 Q40308 Spring washer 16 D 8 31 GW Seal 2 35*62* GW Housing plate 2 33 GW Copper packing 1 34 GW Oil plug 1 30
32 2-6 Differential assembly ,
33 2-6 Differential assembly Item No. Part No. Description Qt y Remark 1 GW Planetary gear shaft 1 2 GW Spherical washer 2 3 GW Planetary gear 2 4 GW Axle shaft gear 2 5 GW Adjusting shim 1 6 GW Differential case 1 7 GW lining 2 8 GW Adjusting shim 1 9 GB Bearing 2 40*68*19 10 GW Helical bevel gear 1 11 Q Spring pin 1 12 Q150B1025 Bolt 8 M10*25 13 Q40310 Spring washer 8 D GW Spacer 1 32
34 2-7 Brake pedal, master cylinder Item No Part No Description Qty Remark 1 GW Brake pedal assembly 1 2 GW Stop block assembly 1 3 GW Connecting bar 1 Q235 4 GW Torsion spring 1 5 GW Swing arm 1 Q235 6 GW Brake master cylinder 1 7 GW Shoulder bolt 1 8 GW Bushing 2 plastics 9 Q40110 Plain washer Q33008 Flange lock nut M Q Pin roll 10* Q Cotter pin 4 13 GW Bushing 2 plastics 14 Q40108 Plain washer M Q Pin roll 8* Q150B0830 Bolt M8* Q32808 Nylon insert lock nut 2 18 GW Pedal pad lower 1 19 GW Rivet 4.8*16 9 shining 20 GW Pedal pad upper 1 33
35 2-8 Brake tubes Item No. Part No. Description Qty Remark 1 GW Front brake tubes 1 2 GW Brake master cylinder 1 3 GW Low press tubes(f) 1 4 GW Low press tubes(r) 1 5 GW Brake liquid tank assembly 1 6 GW Rear brake tubes 1 7 GW Hollow bolt 2 M10*1*22 8 Q72310 Copper packing 12 9 GW Hollow bolt 4 M10*1.25*24 10 GW Bar clasp 4 34
36 2-9 Parking Brake System Item No. Part No. Description Qty Remark 1 GW Upper cover of brake pedal 1 2 Q150B0616A2 Bolt M6x16 3 Stainless steel 3 Q40306A2 Stainless spring washer 6 3 Stainless steel 4 Q40106A2 Stainless flat washer 3 Stainless steel 5 GW Parking brake pedal assembly 1 6 GW Lower cover of brake pedal 1 7 Q150B0620 Bolt M6x Q40106 Flat gasket Q40306 Spring washer GW E ring 1 11 GW Parking brake cable assembly 1 12 GW Protecting wire rubber 1 13 GW Clip 1 14 GW Returning spring 1 15 GW Parking brake cable assembly 1 35
37 2-10 Steering System (1/2) 36
38 2-10 Steering System (2/2) Item No. Part No. Description Qty Remark 1 GW Nut M GW Steering wheel 1 3 GW Connecter 1 4 GW Electrical brush base 1 5 GW Steering shaft house 1 6 GW Steering shaft 1 7 GW Steering assembly 1 8 GW Rubber boot 1 9 GW Steering ball joint 1 10 GB27M1035 Bolt M10* Q40110 Flat washer Q40310 Spring washer GW Steering actuator 1 14 GW Tie rod 2 15 GW Tie rod ball joint 2 Screw-right 16 GW Tie rod ball joint 2 Screw-left 17 GW Turn signal combination 1 18 GW Ignition switch and key 1 37
39 2-11 Tires Item No. Part No. Description Qty Remark 1 GW Tire 4 23* PLY 2 GW Rim 4 Aluminum, flat black 3 GW Wheel nut 16 Chrome plated 4 GW Rim center cap 1 Plastic flat black 5 GW Tire valve 1 38
40 3-1 Controlling system (DC)
41 3-1 Controlling system (DC) Item No. Part No. Description Qty Remark 1 GW Main contactor 1 2 GW Fuse 1 400A 3 GW Fuse 1 10A, 10*38 4 GW Controller 1 5 GW Wench contactor 1 6 GW F/R contactor 1 7 GW Aluminum board 1 8 GW Relay bracket 1 9 GW Flasher 1 12V130W 10 GW Relay for transfer unit 2 11 GW Contactor bracket 1 40
42 3-2 Controlling system (AC) 3-2 Controlling system (AC) Item No. Part No. Description Qty Remark 1 EM01355 Fuse 1 355A 2 GW Controller 1 41
43 3-3 Battery Assembly (DC) (1/2) 42
44 3-3 Battery Assembly (DC) (2/2) Item No. Part No. Description Qty Remark 1 GW Sub battery frame 2 2 GW Main battery frame 1 3 Q150B0825 Bolt M Q40108 Flat washer Q40308 Spring washer Q150B1025 Bolt M Q40110 Flat washer Q40310 Spring washer GW Battery pull staff 2 10 GW Battery press plate Q32006 Flange nut M Q40108 Flat washer GW Battery press plate GW Bottom rubber *30*3 15 GW Battery 6V225Ah 8 16 GW Top rubber 8 80*30*3 43
45 3-4 Battery Assembly(AC) (1/2) 44
46 3-4 Battery Assembly (AC) (2/2) Item No. Part No. Description Qty Remark 1 GW Sub battery frame 2 2 GW Main battery frame 1 3 Q150B0825 Bolt M Q40108 Flat washer Q40308 Spring washer Q150B1025 Bolt M Q40110 Flat washer Q40310 Spring washer GW Battery pull staff 2 10 GW Battery press plate Q32006 Flange nut M Q40108 Flat washer GW Bottom rubber *30*3 14 GW Battery 12V85Ah 6 GW Battery 12V110Ah 6 Optional 15 GW Top rubber 4 80*30*3 45
47 3-5 Lighting wiring harness (DC) Item No Part No Description Qty Remark 1 GW Lighting wiring harness 1 2 Horn 3 Horn switch 4 Turn signal switch 5 LH Head lamp 6 Power Transfer 7 Meter 8 Cigar lighter 9 Head light switch 10 RH Head lamp 11 Backup light switch 12 Backup switch 13 Flasher 14 DC-DC converter 15 RH Tail lamp 16 License lamp 17 LH Tail lamp 18 Reverse buzzer 19 Brake switch 46
48 HB05 MU05 MU03 SL02 Q1.0R Q0.5RB Q0.5L Q0.5Br HB01 SL01 MU06 Q1.0B Q0.5BrW Q0.5LB HB05 HB05 Q1.0R Q1.0R HB03 HB04 Q1.0L Q0.5Y MU03 HB04 Q0.5L Q0.5Y HB01 MU05 Q0.5B Q0.5RB HB03 HB04 Q1.0L Q0.5Y HB01 Q1.0B HB04 Q0.5Y MU06 Q0.5LB 3-6 Controlling wiring harness(dc) Item No Part No Description Qty Remark 1 GW Controlling wiring harness 1 2 Controller port 3 Electricity meter port 4 Accelerator port ` 5 Parking signal port 6 F/R switch 7 Ignition key 8 DC-DC converter input port 9 Parking circuit breaker 10 Charging circuit breaker 47
49 9 Br 14 W 8 RW GW 12 Gr Gr Br D1 D2 D3 D GW BW RW Gr W RW GW Gr Gr Lg A1 A2 A3 A4 A R P BW V Y R G Lg BW R G 5 4 Y V 3-7 Transfer unit wiring harness(dc) Q G 7 BW Q G 7 10 G 7 BW Item No Part No Description Qty Remark 1 GW Transfer unit wiring harness 1 GW Speed sensor wiring harness 1 2 Transfer unit port 4p 3 Transfer unit port 5p 4 Meter port for transfer unit 5 Power of transfer unit 6 2WD/4WD switch 7 Differential lock switch 8 D1 relay 9 D2 relay 10 Meter port for speed sensor 11 Speed sensor port 48
50 Wiring harness (AC) 6 GW 7 BW 8 RW 9 Gr D1 D2 D3 D4 1 R 2 P 7 BW 4 V 5 Y A1 A2 A3 A4 A5 9 Br 6 GW 8 RW 10 G 7 BW 10 G 1 R 7 BW 13 Q0.5 Lg 10 G 10 G 1 R 7 BW 13 Q0.5 Lg 10 G HB05 Q1.0R HB01 Q1.0B HB04 Q0.5Y HB05 Q1.0R HB04 Q0.5Y HB05 Q1.0R HB03 Q1.0L HB05 Q1.0R HB01 Q1.0B MU06 Q0.5LB SL02 Q0.5Br SL01 Q0.5BrW MU05 Q0.5RB MU03 Q0.5L MU06 Q0.5LB HB04 Q0.5Y HB03 Q1.0L HB01 Q1.0B HB04 Q0.5Y MU05 Q0.5RB MU03 Q0.5L HB04 Q0.5Y HB01 Q0.5B R 2 P 7 BW 4 V 5 Y A1 A2 A3 A4 A5 HB05 Q1.0R HB04 Q0.5Y HB05 Q1.0R HB03 Q1.0L 4 V 5 Y MU05 Q0.5RB MU03 Q0.5L HB04 Q0.5Y HB01 Q0.5B HB05 Q1.0R HB04 Q0.5Y HB05 Q1.0R HB03 Q1.0L
51 3-8 Wiring harness (AC) Item No Part No Description Qty Remark GW Wiring harness 1 1 Mileage 1 2 Vehicle speed sensor 1 3 Ignition switch 1 4 Horn switch 1 5 Steering switch 1 6 Transfer unit port 4p 1 7 Horn 1 8 Transfer unit port 5p 1 9 Parking switch 1 10 Brake switch 1 11 Charge Interlock switch 1 12 Contactor 1 13 B B Reverse buzzer 1 16 LH tail lamp 1 17 Diagnosis 1 18 Encoder 1 19 RH tail lamp 1 20 Insurance 1 21 Vehicle speed sensor 1 22 DC-DC converter input port 1 23 DC-DC converter 1 24 Accelerator sensor TPS 1 25 Motor controller 1 26 Differential Lock 1 27 Coulometer WD/4WD switch 1 29 Flasher Relay 1 30 Head lamp switch 1 31 Shift switch 1 32 RH Head lamp 1 33 Reverse buzzer switch 1 34 Transfer relay Cigar lighter 1 36 Transfer relay LH head lamp WD/4WD indication 1 39 Parking indication 1 50
52 3-9 DC converter Item No. Part No. Description Qty Remark 1 GW V/12V for DC car DC converter GW V/12V for AC car 2 Q Screw 4 M Q40105 Flat washer 4 D5 4 Q40305 Spring washer 4 D5 5 Q Riveted nut 4 6 GW DC converter bracket 1 51
53 3-10 Horn, backup buzzer Item No. Part No. Description Qty Remark 1 GW Horn 1 2 GW Backup buzzer 1 52
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