Electric Service Parts Manual

Transcription

1 Electric ISSUED APRIL 2012 REVISED MARCH 2014

2

3 SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLE LSV 800 STARTING MODEL YEAR 2012 DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically E-Z-GO, and therefore is subject to change without notice. E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE- QUENTIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL. TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: , FAX: SERVICE PARTS PHONE: GET-EZGO ( ), FAX: INTERNATIONAL: PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA Page i

4 GENERAL INFORMATION To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75 F (-60 C). As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL V ACCELERATOR PEDAL ASSEMBLY A - 1 BATTERY CHARGER B - 1 BODY C - 1 BRAKES D - 1 ELECTRICAL SYSTEM E - 1 ELECTRONIC SPEED CONTROL F - 1 FRAME G - 1 FRONT SUSPENSION H - 1 MOTOR J - 1 REAR AXLE K - 1 REAR SUSPENSION L - 1 SEATING M - 1 STEERING N - 1 WEATHER PROTECTION P - 1 WHEELS AND TIRES Q - 1 TRUCK BED T - 1 Page iii

6 NOTES Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION ILLUSTRATED PARTS BREAKDOWN APPENDIX The first section, GENERAL INFORMATION, contains the following information: WARRANTY INFORMATION GENERAL INDEX HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle. The third section, APPENDIX, contains a listing of specialty products and accessories. USE OF THE MANUAL To use this manual, consult the GENERAL INDEX to locate the information or illustration required. Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. 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. Page v

8 Front of Vehicle ,88 81,86 84,89 82, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on 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 General Index and select the most appropriate title. Turn to the page number indicated and locate the desired part on the illustration. From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part. 2. IF YOU KNOW THE PART NUMBER Locate the part number or description in the appropriate column on the parts list page. NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 ACCELERATOR PEDAL ASSEMBLY includes items Page A-1

11 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 2-6) ACCELERATOR PEDAL MOLEX SWITCH SOCKET HEAD CAP SCREW, M5-0.8 X ROTARY POSITION SENSOR BUTTON HEAD TORX BOLT, M X ACCELERATOR PEDAL PAD BOSS SCREW, M6-1.0 X ACCELERATOR PEDAL INSERT... 1 Page A-2

12 ACCELERATOR Notes: Page A-3

13 ACCELERATOR Notes: Page A-4

14 BATTERY CHARGER 48V ON-BOARD BATTERY CHARGER WITH DC TO DC CONVERTER Page B-1

15 BATTERY CHARGER When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY V ON-BOARD BATTERY CHARGER WITH DC TO DC CONVERTER CHARGER FRONT BRACKET BOSS HEAD TORX SCREW, M8 X 29MM LG LOCK NUT, M HEX HEAD FLANGED BOLT, M6-1 X 20MM LG CHARGER SUPPORT BRACKET PAN HEAD TORX TAPTITE BOLT, M X 25MM LG V BATTERY CHARGER, AC CHARGER CORD CHARGER RECEPTACLE, 48V DELTA-Q BARREL CLIP, M BUTTON HEAD TORX BOLT, M6-1 X 20MM LG... 4 Page B-2

16 BATTERY CHARGER Notes: Page B-3

17 BATTERY CHARGER Notes: Page B-4

18 BODY 4 7 ACCESS COVER ASSEMBLY includes item 5 INSTRUMENT PANEL COVER ASSEMBLY includes item Page C-1

19 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 6XXXXX*** FRONT COWL, WITH HEADLIGHTS (SEE COLORS BELOW) IVORY FOREST GREEN PATRIOT BLUE BLACK BURGANDY BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED SUN BURST ORANGE BRITISH RACING GREEN YELLOW BARLEY GOLD OASIS GREEN JAVA BROWN METALLIC CHARCOAL INSTRUMENT PANEL TRIM, KS, SPEEDOMETER, & LIGHT SWITCH BALL HOLDER INSERT, DRIVER SIDE ACCESS COVER ASSEMBLY (INCLUDES ITEM 5) U-CLIP BOSS HEAD TORX SCREW, M6-1.0 X 25mm LG INSTRUMENT PANEL (INCLUDES ITEM 8) SPRING CLIP GLOVE BOX, DRIVER SIDE GLOVE BOX, PASSENGER SIDE FRONT SPLASH GUARD G2 CHRISTMAS TREE RIVET (.25" X.88") PAN HEAD TORX BOLT, M10-15 X 25mm LG G01 TRUSS HEAD TORX 3 BOLT FLAT WASHER, M Page C-2

20 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT REFLECTOR (DRIVER SIDE) FRONT REFLECTOR (PASSENGER SIDE) CUSHMAN COWL DECAL Page C-3

21 BODY Notes: Page C-4

22 BODY Page C-5

23 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY CUSHMAN CUP HOLDER DECAL G01 RIVET, 3/16" CUPHOLDER ASSEMBLY (INCLUDES ITEM 23) WARNING AND INSTRUCTION DECAL G01 SELF THREADING NUT LOCK NUT, M BUTTON HEAD TORX BOLT, M X 12mm LG G01 POWER OUTLET 12V SPEED SELECTOR SWITCH ASH TRAY FRONT BUMPER FRONT FASCIA ASSEMBLY W/LIGHTS PAN HEAD PHILLIPS SELF TAPPING SCREW, #10-16 X.75" LG PAN HEAD TORX SCREW WITH WASHER, X 22mm LG FLAT WASHER, M X FLANGED HEX NUT, M Page C-6

24 BODY Page C-7

25 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY UPPER ROCKER PANEL (DRIVER SIDE) UPPER ROCKER PANEL (PASSENGER SIDE) BUTTON HEAD TORX SCREW, M8 X 29mm LG LOWER ROCKER PANEL (DRIVER SIDE) LOWER ROCKER PANEL (PASSENGER SIDE) BUTTON HEAD TORX SCREW, M8 X 29mm LG FLOORMAT G2 CHRISTMAS TREE RIVET (.25" X.88") PEDAL COVER PLATE G2 CHRISTMAS TREE RIVET (.25" X.88") FLOOR BOARD FLAT WASHER, M TORX SOCKET HEAD CAP SCREW, M X 50mm LG G1 CHRISTMAS TREE RIVET (.25" X.68")... 2 Page C-8

26 BODY Failure to follow these instructions will result in DEATH or SERIOUS INJURY High voltage cables and terminals are contained in this compartment. Battery electrolyte contains caustic substances. Batteries must be connected properly (see Owner s Manual). Connect battery charger to properly rated electrical receptacle with GFCI. Do not attempt to charge frozen, leaking or damaged batteries. ONLY charge batteries in a well ventilated area away from flammable materials BAGWELL CLOSEOUT ASSEMBLY includes items Page C-9

27 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 6XXXXX REAR BODY ASSEMBLY WITH TAIL LIGHT OPENINGS... (SEE COLORS BELOW, INCLUDES ITEM 2 & 3) IVORY FOREST GREEN PATRIOT BLUE BLACK BURGANDY BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED SUN BURST ORNAGE BRITISH RACING GREEN YELLOW BARLEY GOLD OASIS GREEN JAVA BROWN METALLIC CHARCOAL REAR BODY ACCESS PANEL BARREL CLIP, M BUTTON HEAD TORX BOLT, M6-1 X PAN HEAD TORX BOLT, M X FLAT WASHER, M X SEAT HINGE PLATE PAN HEAD TORX BOLT, M X FRONT SEAT SUPPORT ASSEMBLY PAN HEAD TORX BOLT, M X REAR SPLASH GUARD, DRIVER SIDE G2 CHRISTMAS TREE RIVET (.25" X.88") REAR SPLASH GUARD, PASSENGER SIDE... 1 Page C-10

28 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 CHRISTMAS TREE RIVET (.25" X.88") DANGER HIGH VOLTAGE, DECAL G2 CHRISTMAS TREE RIVET (.25" X.88") FLAT WASHER, M10, 10.5 X BUTTON HEAD TORX SCREW, M8 X VEHICLE EMISSION CONTROL, LABEL CUSHMAN LSV 800 DECAL BAGWELL CLOSEOUT ASSEMBLY (INCLUDES ITEMS 25-27) BAGWELL CLOSEOUT OVAL RED REFLECTOR WITH ADHESIVE G02 RIVET 3/16"... 4 Page C-11

29 BODY Notes: Page C-12

30 BRAKES 1 BRAKE PEDAL ASSEMBLY includes items BRAKE PEDAL RETURN ASSEMBLY includes items Page D-1

31 BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY BRAKE PEDAL ASSEMBLY (HYDRAULIC), (INCLUDES ITEMS 2-5) BRAKE PEDAL PAD ROTARY POSITION SENSOR BUTTON HEAD TORX BOLT, M4-7 X SWITCH BUTTON BRACKET SOCKET HEAD CAP SCREW M X BRAKE PEDAL COVER BUTTON HEAD TORX BOLT, M4-0.7 X G01 COMPRESSION SPRING CLEVIS PIN E-RING, 8mm BRAKE PEDAL RETURN ASSEMBLY (INCLUDES ITEMS 14-18) PARK BRAKE ROD FLANGED BUSHING, 8mm FLANGED HEX HEAD LOCK NUT, M10 X BUSHING WASHER, 34MM X 10MM MASTER CYLINDER BRAKE CABLE SPACER, M13 X 25 OD X Page D-2

32 BRAKES Page D-3

33 BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY MASTER CYLINDER MASTER CYLINDER BRACKET G01 ACETAL BUSHING BELL CRANK BRAKE CABLE PIN LOCK NUT, 3/ G2 CLEVIS PIN, 8 X 24mm G01 COTTER PIN BELL CRANK WELDMENT BOSS HEAD TORX SCREW, M8 X 29mm BELL CRANK SHAFT G8 HEX HEAD CAP SCREW, 5/16-18 X 2.00" G01 RETAINING RING CROWN LOCK NUT, 5/ TORX HEAD TAPTITE SCREW, M X FRONT BRAKE LINE WIRE FORM (DRIVER SIDE) FRONT BRAKE LINE WIRE FORM (PASSENGER SIDE) CRUSH WASHER, M BANJO BOLT, M X FRONT BRAKE LINE Page D-4

34 BRAKES Page D-5

35 BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FLANGED HEX HEAD BOLT, M6 - X REAR BRAKE LINE G01 CABLE CLIP G01 DOUBLE TUBE CLAMP DRIVER SIDE CALIPER PASSENGER SIDE CALIPER (NOT SHOWN) FLANGED HEX HEAD BOLT, M X BRAKE LINE HANGER G1 NYLON CLIP BRAKE PADS KIT (INCLUDES 4 PADS - 4 RATTLE SPRINGS) BRAKE PADS KIT (INCLUDES 2 PADS - 2 RATTLE SPRINGS)... 1 Page D-6

36 BRAKES 1 MOTOR BRAKE ASSEMBLY includes items Page D-7

37 BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY " MOTOR BRAKE ASSEMBLY (INCLUDES ITEMS 2-4) " MOTOR BRAKE G01 FLANGED HEX HEAD SCREW, M6-1 X G7 LOCK WASHER, STAINLESS STEEL, 1/4"... 3 Page D-8

38 BRAKES Notes: Page D-9

39 BRAKES Notes: Page D-10

40 ELECTRICAL SYSTEM 1 MAIN ELECTRICAL HARNESS (NOT ILLUSTRATED) includes items 2, 3, 7 & 11 (RED, YELLOW, BLACK WIRES are from MAIN HARNESS) REVERSE WARNING INDICATOR REPLACEMENT KIT includes items KEY SWITCH ASSEMBLY includes items RUN TOW SWITCH REPLACEMENT KIT includes items RUN PLUG SPEEDOMETER Page E-1

41 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY MAIN ELECTRICAL HARNESS (NOT ILLUSTRATED) (INCLUDES ITEMS 2, 3, 7 & 11) V HEAVY DUTY SOLENOID ASSEMBLY REVERSE WARNING INDICATOR REPLACEMENT KIT (INCLUDES ITEMS 4-6) REVERSE WARNING INDICATOR WATERPROOF BUTT SPLICE G01 PAN HEAD PHILLIPS SCREW, # RUN/TOW SWITCH REPLACEMENT KIT (INCLUDES ITEMS 8-10) RUN TOW SWITCH WATERPROOF BUTT SPLICE RUBBER BOOT RUN PLUG KEY SWITCH ASSEMBLY (INCLUDES ITEMS 13-14) KEY SWITCH, F-N-R KEY GREEN WIRE ASSEMBLY, 4 AWG X 280MM GREEN WIRE ASSEMBLY, 4 AWG X 700MM SPEEDOMETER... 1 Page E-2

42 ELECTRICAL SYSTEM 4-12V BATTERY SYSTEM Page E-3

43 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HIGH SPEED BATTERY TRAY WELDMENT OUTTER BATTERY HOLD DOWN MIDDLE BATTERY HOLD DOWN HEX HEAD FLANGED BOLT, M X 25MM LG FLANGED HEX LOCK NUT, M BARREL CLIP, M PAN HEAD TORX BOLT, M X 25MM LG BLUE WIRE ASSEMBLY, 6 GA X 261MM BLUE WIRE ASSEMBLY, 6 GA X 325MM BATTERY TRAY LINER REMOVABLE UPRIGHT HOLDOWN *** BATTERY US, 12V *** US T HYDROLINK BATTERY HYDROLINK SNAKE HAND PUMP, HYDROLINK FLAT WASHER, M MM X 30MM... 2 Page E-4

44 ELECTRICAL SYSTEM 6-8V BATTERY SYSTEM Page E-5 4

45 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 *** BATTERY, 8V - T8V *** BATTERY, 8V - T8V, HYDROLINK *** BATTERY US, 8V *** BATTERY US, 8V, FLOWRITE BATTERY RETAINER - TALL BATTERY RETAINER - TALL, GALVANIZED BATTERY TRAY WELDMENT BATTERY TRAY WELDMENT - GALVANIZED BATTERY RETAINER - SHORT BATTERY RETAINER - SHORT, GALVANIZED SNAKE, HYDROLINK G01 TIE DOWN BOLT G1 FLANGED LOCK NUT, 5/16" LOCK NUT, M (NOT ILLUSTRATED) PAN HEAD TAPTITE BOLT, M X 25MM LG HEX HEAD BOLT, M X 25MM LG BARREL CLIP, M RETAINER BLUE WIRE ASSEMBLY - 6AWG, 380MM BLUE WIRE ASSEMBLY - 6AWG, 150MM LOCK NUT, M8 X PAN HEAD TAPTITE BOLT, M X 30MM LG G1 FLAT WASHER, 5/16" G2 FLAT WASHER, 5/16" TERMINAL BOOT... 3 Page E-6

46 ELECTRICAL SYSTEM 1 ACCESSORY HARNESS (NOT ILLUSTRATED) View from front driver side 3 HORN ASSEMBLY KIT includes items HORN BUTTON SWITCH ASSEMBLY View from front driver side ROOF PANEL STROBE LIGHT KIT includes items Page E-7

47 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY ACCESSORY HARNESS (NOT ILLUSTRATED) G2 CHRISTMAS TREE RIVET,.25" X.88" LG HORN ASSEMBLY KIT (INCLUDES ITEMS 4-9) HORN ASSEMBLY HORN BUTTON SWITCH ASSEMBLY BUTTON HEAD TORX BOLT, M6-1 X 20MM LG LOCK NUT, M G01 CABLE CLIP HORN PLATE STROBE - LIGHT KIT (INCLUDES ITEMS 11-14) STROBE LIGHT ASSEMBLY AMBER STOBE LIGHT G10 PLASTIC INSERT LOCK NUT, # G01 SOCKET HEAD CAP SCREW, # X.875" LG A / C FAN CONTROLLER ASSEMBLY A / C FAN CONTROLLER BRACKET BOSS HEAD TORX SCREW, M6-1.0 X 25MM LG PAN HEAD TORX SCREW, M4 -.7 X 50MM LG LOCK NUT, M STROBE LIGHT AND WIPER HARNESS (NOT ILLUSTRATED)... 1 Page E-8

48 ELECTRICAL SYSTEM HEADLIGHT ASSEMBLY, DRIVER SIDE includes items 4-10 HEADLIGHT ASSEMBLY, PASSENGER SIDE includes items TAIL LIGHT ASSEMBLY, DRIVER SIDE includes items 17 & TAIL LIGHT ASSEMBLY, PASSENGER SIDE includes items 17 & Page E-9

49 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEADLIGHT SWTICH HEADLIGHT ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 4-10) HEADLIGHT ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 5-11) GASKET, DRIVER SIDE G01 HEADLIGHT BULB TURN SIGNAL BULB BULB RETAINER BUTTON HEAD TORX SCREW, M3-1.3 X 14MM LG TURN SIGNAL WIRE HARNESS HEADLIGHT RETAINING CLIP GASKET, PASSENGER SIDE BUTTON HEAD TORX BOLT, M6-1 X 20MM LG BARRELL CLIP, M TAIL LIGHT ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 17 & 18) TAIL LIGHT ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 17 & 18) TAIL LIGHT BULB TAIL LIGHT LENS TURN SIGNAL SWITCH ASSEMBLY W/ HORN G3 STEERING COLUMN COVER RUBBER ISOLATION STRIP G5 CHRISTMAS TREE RIVET,.18" X.55"... 2 Page E-10

50 ELECTRICAL SYSTEM 1 DEFROSTER / HEATER KIT includes items Page E-11

51 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY DEFROSTER / HEATER KIT (INCLUDES ITEMS 2-9) DEFROSTER / HEATER 48V DEFROSTER UPPER BRACKET DEFROSTER LOWER BRACKET BARREL CLIP, M BUTTON HEAD TORX BOLT, M6-1 X 20MM LG G6 FLAT TYPE A WASHER SELF TAPPING SCREW, # X.75" LG G1 NYLON CLAMP... 1 Page E-12

52 ELECTRICAL SYSTEM TRUCK BACKUP LIGHT KIT (NOT ILLUSTRATED) includes items 2-8 Page E-13

53 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY TRUCK BACKUP LIGHT KIT (NOT ILLUSTRATED) (INCLUDES ITEMS 2-8) BACKUP LIGHT HARNESS W / 48V RELAY BACKUP LIGHT HARNESS LED BACKUP LIGHT BACKUP LIGHT BRACKET SELF STRIPPING SPLICE G5 INSULATED CABLE CLIP G1 RATCHET RIVET..25" X.680"... 1 Page E-14

54 ELECTRICAL SYSTEM Notes: Page E-15

55 ELECTRICAL SYSTEM Notes: Page E-16

56 Failure to follow these instructions can result in SERIOUS INJURY or DEATH IF VEHICLE VEHICLE IS IS INOPERABLE INOPERABLE AND AND NEEDS NEEDS TO TO BE BE MOVED: MOVED: Turn the the ignition ignition key key to to the the N N position position and and chock chock tires tires to to prevent prevent inadvertent inadvertent movement. movement. Flip Flip the the RUN-TOW RUN-TOW switch switch to to the the TOW TOW position position and and move move vehicle vehicle to to the the desired desired location location and and park park it it properly properly on on level level ground ground and and chock chock tires tires immediately. immediately. Turn Turn the the ignition ignition key key to to the the OFF OFF position, position, remove remove key key and and perform perform required required service service procedures procedures following following all all Safety Safety Guidelines Guidelines as as outlined outlined in in your your repair repair manual. manual. In Case Case of of Total Total Power Power Loss Loss and and the the Run-tow Run-tow Switch Switch DOES DOES NOT NOT Release Release the the Brake Brake to to Move Move the the Vehicle Vehicle :: Remove this this plastic plastic cover cover by by removing removing 33 plastic plastic fasteners. fasteners. See See illustrations illustrations below. below. See emergency emergency brake brake release release instruction instruction under under this this panel. panel. Push center of fastener with vehicle key, When center is depressed lift fastener to remove. To reuse fastener push center stem up then install fastener through shield into hole. To secure fastener in place press down on center stem until flush with head of fastener DO NOT NOT alter alter or or tamper tamper with with this this unit. unit. Unauthorized Unauthorized modifications modifications can can result result in in SERIOUS INJURY INJURY or or damage damage to to the the vehicle vehicle and and will will void void the the warranty. warranty. To disable disable electrical electrical system, system, turn turn key key switch switch to to OFF OFF and and remove remove battery battery wires. wires. ALWAYS turn turn key key to to OFF OFF before before disconnecting disconnecting or or reconnecting reconnecting battery wires. wires. ELECTRICAL ELECTRICAL ARC ARC or or BATTERY BATTERY EXPLOSION EXPLOSION can can occur if if key key is is not not in in the the OFF OFF position. position. WAIT seconds seconds after after reconnecting reconnecting batteries batteries BEFORE BEFORE turning turning key key switch switch to to REVERSE, FORWARD FORWARD or or NEUTRAL NEUTRAL positions. positions. TOWING - Always select TOW position before towing ELECTRONIC SPEED CONTROL TO - 48V BATTERY CURTIS CONTROLLER KIT includes items 2-13 CONTROLLER SPLASH SHIELD ASSMBLY includes items Failure to follow these instructions can result in SERIOUS INJURY or DEATH THIS PROCEDURE SHOULD ONLY BE TO CLEAR VEHICLE FROM AN UNSAFE AREA AND BE PERFORMED ONLY BY QUALIFIED TRAINED PERSONNEL In Case Of Total Power Loss And The Run-tow Switch DOES NOT Release The Brake To Move The Vehicle: Turn the ignition key to the OFF position and chock tires to prevent inadvertent movement. Identify the Auxiliary Power line (3) and remove the Weather Pack Seal (4) from the connector. Identify the Primary Power line (1) connector and disconnect the line (2). Connect Auxiliary Power line (3) to Primary Power line (1) which will release the brake. THIS WILL CAUSE THE VEHICLE TO MOVE IMMEDIATELY IF NOT ON LEVEL GROUND. Move vehicle to desired location and park it properly on level ground, chock tires, IMMEDIATELY DISCONNECT AUXILIARY POWER AND RECONNECT PRIMARY POWER (1, 2) FOR SAFETY AND TO AVOID BATTERY DRAIN. Reconnect the Weather Pack Seal (4) to the Auxiliary Power line (3) and perform required service procedures following all Safety guidelines as outlined in your repair manual Page F-1

57 ELECTRONIC SPEED CONTROL When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY CURTIS CONTROLLER KIT (INCLUDES ITEMS 2-13) CONTROLLER, 1206AC CONTROLLER BRACKET, LH CONTROLLER BRACKET, RH BLACK WIRE, 6AWG (830mm) BOSS SCREW, M G01 FLANGED BOLT, M6-1.00" X 12mm LG HEX BOLT, M6-1" X 20mm LG ADAPTOR HARNESS ASSEMBLY SOLENOID BRACKET ADAPTOR, 23 PIN TO 23 PIN SPLICE, 2 / 3 WIRE SELF TAPPING SCREW, #10-16 (NOT ILLUSTRATED) CONTROLLER SPLASH SHIELD ASSEMBLY (INCLUDES ITEMS 15-18) SPLASH SHIELD CONTROLLER RUN/TOW SWITCH DECAL MAINTENANCE/TOWING DECAL TOWING INSTRUCTION NOTICE DECAL PLASTIC RIVET... 3 Page F-2

58 ELECTRONIC SPEED CONTROL Notes: Page F-3

59 ELECTRONIC SPEED CONTROL Notes: Page F-4

60 FRAME For models manufactured before 29th April For models manufactured after 29th April Page G-1

61 FRAME When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRAME WELDMENT (FOR MODELS MANUFACTURED AFTER 29TH APRIL 2013) FRAME WELDMENT (FOR MODELS MANUFACTURED AFTER 29TH APRIL 2013) IP SUPPORT WELDMENT SEAT SUPPORT DRIVER SIDE WELDMENT SEAT SUPPORT PASSENGER SIDE WELDMENT SEAT BELT FRONT CENTER WELDMENT PAN HEAD TORX BOLT, M X 25MM LG HEX HEAD FLANGED BOLT, M X 23MM LG FLANGED HEX NUT, M FLAT WASHER, M Page G-2

62 FRAME Notes: Page G-3

63 FRAME Notes: Page G-4

64 FRONT SUSPENSION 1 SHOCK ABSORBER ASSEMBLY, DRIVER SIDE includes items SPINDLE HUB ASSEMBLY, DRIVER SIDE includes items 4-7, 37 SPINDLE ASSEMBLY, DRIVER SIDE includes items 39, 41 & SHOCK ABSORBER ASSEMBLY, PASSENGER SIDE includes items SPINDLE HUB ASSEMBLY, PASSENGER SIDE includes items 18-21, 38 SPINDLE ASSEMBLY, PASSENGER SIDE includes items Page H-1

65 FRONT SUSPENSION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SHOCK ABSORBER ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 2-12) SPINDLE HUB ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 4-7, 37) DISC HUB ASSEMBLY G1 HEX NUT, SLOTTED, G8 COTTER PIN, 5/32" X 1.75" G2 SPINDLE CAP STRUT ASSEMBLY, DRIVER SIDE KINGPIN TUBE THRUST WASHER (SS), 2.5MM HEX HEAD FLANGE BOLT, M X 145MM LG FLANGE HEX NUT, M SHOCK ABSORBER ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 16-26) SPINDLE HUB ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 18-21, 38) DISC HUB ASSEMBLY G1 HEX NUT, SLOTTED G8 COTTER PIN, 5/32 X 1.75" G2 SPINDLE CAP STRUT ASSEMBLY, PASSENGER SIDE KINGPIN TUBE THRUST WASHER (SS), 2.5MM HEX HEAD FLANGE BOLT, M X 145MM LG HEX FLANGE NUT, M HEX HEAD FLANGE BOLT, M X 80MM LG HEX FLANGE NUT, M Page H-2

66 FRONT SUSPENSION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY A - ARM ASSEMBLY A - ARM BUSHING A - ARM CARRIER TUBE HEX HEAD FLANGE BOLT, M X 100MM LG HEX FLANGE NUT, M HEX HEAD FLANGE BOLT, M X 80MM LG SPINDLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 39, 41 & 42) SPINDLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 40-42) SPINDLE, DRIVER SIDE SPINDLE, PASSENGER SIDE FLANGED BUSHING, 25MM, DP BUSHING, 25MM, DP Page H-3

67 FRONT SUSPENSION Notes: Page H-4

68 MOTOR Page J-1

69 MOTOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY V AC ELECTRIC MOTOR FLEXLOOM SLEEVE LOCK WASHER, M HEX HEAD BOLT, M6-1 X 25 (GRADE 10.9) SPEED SENSOR PAN HEAD PHILIPS SCREW M6X1, 12MM LG G02 TWISTED CLAMP (NOT ILLUSTRATED)... 1 Page J-2

70 MOTOR Notes: Page J-3

71 MOTOR Notes: Page J-4

72 REAR AXLE 1 HEAVY DUTY ELECTRIC AXLE ASSEMBLY includes items REAR HUB ASSEMBLY includes items Page K-1

73 REAR AXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEAVY DUTY REAR AXLE ASSEMBLY 14.76:1 (INCLUDES ITEMS 2-7) RETAINING RING BALL BEARING OIL SEAL AXLE SHAFT, DRIVER SIDE (LONG) AXLE SHAFT, PASSENGER SIDE (SHORT) RUBBER PLUG REAR HUB ASSEMBELY (INCLUDES ITEMS 9, 10) DISC BRAKE REAR HUB WHEEL STUD G1 BRAKE DRUM WASHER,.765" ID X 1.5" OD X.12" CASTLE NUT, 3/4" G1 COTTER PIN,.125" X 1.50" G1 FLAT WASHER, 1.3" X.98" FILL PLUG... 1 Page K-2

74 REAR AXLE Notes: Page K-3

75 REAR AXLE Notes: Page K-4

76 REAR SUSPENSION For models manufactured before 29th April Page L-1

77 When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. REAR SUSPENSION ITEM PART NO DESCRIPTION QTY TAPERED HEAVY DUTY LEAF SPRING U-BOLT, M X 141.0MM LG LEAF SPRING PLATE FLANGED HEX NUT, M FLANGED BUSHING (LARGE) SPLIT STEEL SPACER,.394" I. D. X.51" O. D. X 2.65" LG HEX HEAD FLANGED BOLT, M X 100MM LG FLANGED HEX NUT, M FLANGED BUSHING (SMALL) SPLIT STEEL SPACER,.394" I. D. X.51" O. D. X 2.65" LG SHACKLE PLATE HEX HEAD FLANGED BOLT, M X 100MM LG FLANGED HEX NUT, M SHOCK ABSORBER HEX HEAD FLANGED BOLT, M X 65MM LG FLAT WASHER, M Page L-2

78 REAR SUSPENSION For models manufactured after 29th April 2013 Front of Vehicle Page L-3

79 When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. REAR SUSPENSION ITEM PART NO DESCRIPTION QTY HEAVY DUTY TAPERED LEAF SPRING LOCK NUT, M SHACKLE PLATE FLANGED BUSHING (small) FLANGED BUSHING (large) FLANGED HEX HEAD BOLT, M X 100MM LG SPLIT STEEL SPACER,.394" I. D. X.51" O. D. X 2.65" LG SHOCK MOUNT PLATE (PASENGER SIDE) SHOCK MOUNT PLATE (DRIVER SIDE) AXLE SUPPORT BRACKET G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 SHOCK RUBBER BUSHING G6 HEX NUT U-BOLT, 3/8" - 16 X 2 3/8" DIA X 5.75" LG G4 PLASTIC LOCK NUT, 3/8" G2 FLAT WASHER... 8 Page L-4

80 REAR SUSPENSION Notes: Page L-5

81 REAR SUSPENSION Notes: Page L-6

82 SEATING BUCKET SEAT BOTTOM ASSEMBLY includes items 2-22 BUCKET SEAT BOTTOM SUB - ASSEMBLY (DRIVER SIDE) includes items 4-7, 9, 10 BUCKET SEAT BOTTOM SUB - ASSEMBLY (PASSENGER SIDE) includes items 4-8, Page M-1

83 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 *** BUCKET SEAT BTM ASSY (INCLUDES ITEMS 2-22) (SELECT COLOR BELOW) G STONE BIEGE G OYSTER 2 *** BUCKET SEAT BTM SUB-ASSY (DRIVER SIDE) (SELECT COLOR BELOW) (INCLUDES ITEMS 4-7, 9, 10) STONE BIEGE OYSTER 3 *** BUCKET SEAT BTM SUB-ASSY (PASSENGER SIDE) (SELECT COLOR BELOW) (INCLUDES ITEMS 4-8, 10) STONE BIEGE OYSTER BUCKET SEAT FOAM BUCKET SEAT BOTTOM BOARD G01 SEAT HINGE G08 FLAT HEAD PHILLIPS TAPPING SCREW, #12-14 X 1" LG BUCKET SEAT BOTTOM TRIM (PASSENGER SIDE) BUCKET SEAT BOTTOM TRIM (DRIVER SIDE) *** BUCKET SEAT BOTTOM VINYL COVER (SELECT COLOR BELOW) STONE BIEGE OYSTER FRONT BUCKET SEAT STRAP BOSS HEAD TORX BOLT, M X 25 MM LG HIP RESTRAINT (PASSENGER SIDE) HIP RESTRAINT (DRIVER SIDE) BOSS HEAD TORX BOLT, M X 25 MM LG FRONT BUCKET SEAT CENTER CONSOLE PAN HEAD PHILLIPS SELF TAPPING SCREW, #10-16 X.75" LG... 8 Page M-2

84 SEATING 28 SEAT BACK ASSEMBLY includes items & Page M-3

85 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY *** SEAT BACK ASSY (INCLUDES ITEMS & 35) (SELECT COLOR BELOW) STONE BIEGE OYSTER 29 *** SEAT BACK VINYL COVER, (SELECT COLOR BELOW) STONE BIEGE OYSTER SEAT BACK COVER SEAT BACK BASE (WOOD) ASSY G01 SEAT BACK PADDING (FOAM) FLAT WASHER, M BOSS HEAD TORX BOLT, M X 25 MM LG G1 FLAT STAPLE (SS), 3/8"... AR SELF TAPPING SCREW, # CENTER CLOSEOUT CONSOLE... 1 Page M-4

86 SEATING SEAT BELT KIT includes items Page M-5

87 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SEAT BELT KIT, (INCLUDES ITEMS 2-9) * SEAT BELT RETRACTOR ASSEMBLY * SEAT BELT BUCKLE LATCH, 6" * HEX HEAD SHOLDER BOLT, 7/16" * PLASTIC INSERT LOCK NUT * HEX HEAD BOLT, 7/16" - 20 X 1" LG * FLAT WASHER, 1.25 X 500 X.084" * HOLE PLUG MM * FLAT WASHER, X.615 X.145", EPDM FLANGED HEX LOCK NUT, M HEX HEAD FLANGED BOLT, M X 50 MM LG HEX HEAD BOLT, 7/16" - 20 X 3/2" LG SEAT BELT BRACKET (PASSENGER SIDE) SEAT BELT BRACKET (DRIVER SIDE)... 1 Page M-6

88 SEATING Notes: Page M-7

89 SEATING Notes: Page M-8

90 STEERING RACK COVER BELLOWS KIT includes items STEERING RACK ASSEMBLY includes items STEERING COLUMN ASSEMBLY inculdes items Page N-1

91 STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY STEERING RACK ASSEMBLY (INCLUDES ITEMS 2-7) * STEERING ROD * ROD END * RACK COVER BELLOWS KIT (INCLUDES ITEMS 5-7) * BELLOWS * BELLOWS CLAMP (SMALL END) * BELLOWS CLIP (LARGE END) TORX SOCKET HEAD CAP SCREW, M X CASTLE HEX NUT, M G2 COTTER PIN STEERING COLUMN ASSEMBLY (INCLUDES ITEMS 13-17) STEERING COLUMN SUB ASSEMBLY STEERING YOKE SOCKET HEAD BOLT, M X LOCK WASHER, M HEX NUT, M PAN HEAD TORX BOLT, M X STEERING WHEEL LOCK NUT, M G01 STEERING WHEEL COVER CUSHMAN DECAL, STEERING WHEEL ROUND... 1 Page N-2

92 STEERING Notes: Page N-3

93 STEERING Notes: Page N-4

94 WEATHER PROTECTION 10 WINDSHIELD ASSEMBLY includes Items WINDSHIELD TRIM ASSEMBLY includes items Page P-1

95 WEATHER PROTECTION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEX HEAD FLANGED BOLT, M X 25MM LG FLANGED HEX LOCK NUT, M G1 BONDED SEAL WASHER, # LOCK NUT, M HEX HEAD FLANGED BOLT, M6-1 X 20MM LG G5 PAN HEAD PHILLIPS SELF TAPPING SCREW, #6-18 X.625" LG CANOPY KIT (INCLUDES ITEMS 8 & 9) SHORT CANOPY CANOPY WEATHER SEAL WINDSHIELD ASSEMBLY (INCLUDES ITEMS 11-12) WINDSHIELD WINDSHIELD MIRROR MOUNT (NOT SHOWN) CANOPY W/MIRROR TUBE WELDED CANOPY WELDMENT, SUPPORT TUBE G1 PLASTIC DRIVE RIVET, 3/16" HEX HEAD FLANGED BOLT, M6-1 X 30MM LG WINDSHIELD SEAL CENTER BRAKE LIGHT ASSEMBLY WINDSHIELD TRIM ASSEMBLY (INCLUDES ITEMS 20-21) WINDSHIELD TRIM G1 BLACK TRIM,.52 SINGLE LIP - 10" LG REAR OVAL REFLEX REFLECTOR REAR REFLEX REFLECTOR TUBE PLUG (PLASTIC), 1.5" O.D SIDE VIEW MIRROR KIT (PASSENGER SIDE) (INCLUDES ITEMS 26-27) G5 PAN HEAD SELF TAPPING SCREW, # 8-18 X 5/8" LG SIDE VIEW MIRROR (PASSENGER SIDE) SIDE VIEW MIRROR KIT (DRIVER SIDE) (INCLUDES ITEMS 30-31) G5 PAN HEAD SELF TAPPING SCREW, # 8-18 X 5/8" LG SIDE VIEW MIRROR (DRIVER SIDE)... 1 Page P-2

96 WEATHER PROTECTION WIPER ASSEMBLY KIT includes items SIDE VIEW MIRROR KIT (PASSENGER SIDE) includes Items SIDE VIEW MIRROR KIT (DRIVER SIDE) includes items Page P-3

97 WEATHER PROTECTION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G4 FLAT WASHER,.18" G4 PAN HEAD PHILLIPS SELF DRILL SCREW, #8-18 X 1/2" LG PLASTIC SCREW ANCHOR REAR VIEW MIRROR OPERATING INSTRUCTIONS DECAL MPH VEHICLE DECAL WIPER ASSEMBLY KIT (INCLUDES ITEMS 43-49) WIPER MOTOR COVER WIPER MOTOR ASSEMBLY WIPER ARM WIPER BLADE, 22" NYLON TUBE G1 BRAKE DRUM WASHER,.76" FLAT WASHER, 1.313" X.615 X.145" G1 TUBE CAP HOLE PLUG, 25.4MM GRAB HANDLE MOUNT PAN HEAD PHILLIPS TORX SCREW, 12" - 14 X 1" LG GRAB HANDLE... 2 Page P-4

98 WEATHER PROTECTION Notes: Page P-5

99 WEATHER PROTECTION Notes: Page P-6

100 WHEELS AND TIRES 1 WHEEL & TIRE ASSEMBLY includes items 2, 3 & WHEEL AND TIRE ASSEMBLY includes items 8, 9 & Page Q-1

101 WHEELS AND TIRES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY WHEEL & TIRE ASSEMBLY (INCLUDES ITEMS 2, 3 & 4) KENDA RADIAL PRO TOUR TIRE, 205/50 R VALVE STEM SILVER CHROME WHEEL, 10 X G1 LUG NUT, 1/2-20 UNF RALLY WHEEL COVER, 10" TIRE AND MAG WHEEL ASSEMBLY(INCLUDES ITEMS 8, 9 & 10) KENDA RADIAL PRO TOUR TIRE, 205/50 R MAG WHEEL, 10" X 7" VALVE STEM, CHROME DIAMOND WHEEL CAP LUG NUT, CHROME 1/2-20 UNF WHEEL SPACER CUSHMAN HUB CAP DECAL... 4 Page Q-2

102 WHEELS AND TIRES Notes: Page Q-3

103 WHEELS AND TIRES Notes: Page Q-4

104 TRUCK BED MANUAL LIFT 1 36 PLASTIC BED ASSEMBLY includes items A B A B Page T-1

105 TRUCK BED MANUAL LIFT When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 36" PLASTIC TRUCK BED ASSEMBLY ( INCLUDES ITEMS 2-11 ) G01 36" PLASTIC BED G01 36" PLASTIC TAILGATE G01 BOWED ANGLE G01 PIVOT SHAFT G02 TAILGATE CABLE ASSEMBLY G2 HEX HEAD BOLT, 1/4-20 X 1.25" LG G01 PHILLIPS SHOULDER SCREW, 1/4-20 X.75" G01 TAILGATE CAP G2 PAN HEAD PHILLIPS SCREW, 1/4-2 X.62" LG G5 RACHET FASTENER G02 RACHET FASTENER, 0.25" X 0.887" CUSHMAN TAILGATE DECAL G07 BED CAPACITY LABEL, 300LB G01 RIVET, 3/16"... 6 Page T-2

106 TRUCK BED MANUAL LIFT Page T-3

107 TRUCK BED MANUAL LIFT When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRAME MOUNTED BED SUPPORT (PASSENGER SIDE) FRAME MOUNTED BED SUPPORT (DRIVER SIDE) TOP RAILS REAR BED SUPPORT SQUARE TUBE, PLUG, 2" G1 SQUARE TUBE, CAP, 1" HEX HEAD FLANGED BOLT, M X FLANGED HEX LOCK NUT, M TORX HEAD BOLT, M X BARREL CLIP, M Page T-4

108 TRUCK BED MANUAL LIFT Page T-5

109 TRUCK BED MANUAL LIFT When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G5 FLAT WASHER, 5/16" G01 HEX HEAD BOLT, 1/4-20 X 0.62" G1 FLANGED HEX NUT, 5/ G1 COTTER PIN, 2.9" BED TETHER CABLE ASSEMBLY FLAT WASHER, M HEX HEAD FLANGED BOLT, M X FLANGED HEX NUT, M G01 ADJUSTABLE RUBBER BUMPER G01 FLANGED BUSHING G02 LATCH PLATE KEEPER G02 BRACKET, LATCH RETAINER G01 LATCH TORSION SPRING G01 CLEVIS PIN, 5.25" G01 HANDLE GRIP G01 BED LATCH WELDMENT... 1 Page T-6

110 TRUCK BED MANUAL LIFT Notes: Page T-7

111

112 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA s, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at Copyrighted Material 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