Service Parts Manual ELECTRIC POWERED UTILITY VEHICLE

Transcription

1 Service Parts Manual ELECTRIC POWERED UTILITY VEHICLE ISSUED MARCH 2014 REVISED MAY 2014

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3 SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLES TITAN LD 36V TITAN HD 36V TITAN HD 48V STARTING MODEL YEAR 2014 CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its contstituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. 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. BATTERY DISPOSAL Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ACCELERATOR A BATTERY CHARGER B BODY C BRAKES D PARK BRAKE D - 1 HYDRAULIC BRAKE D - 3 FRONT BRAKE D - 7 REAR BRAKE D - 9 MASTER CYLINDER D - 11 ELECTRICAL SYSTEM E ELECTRICAL SYSTEM - 36V E - 1 ELECTRICAL SYSTEM - 48V E - 5 ELECTRONIC SPEED CONTROL F ELECTRONIC SPEED CONTROL - 36V F - 1 ELECTRONIC SPEED CONTROL - 48V F - 5 FRONT SUSPENSION G MOTOR H REAR AXLE J REAR SUSPENSION K SEATING L STEERING M WEATHER PROTECTION N WHEELS AND TIRES P Page iii

6 NOTES Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle APPENDIX Contains a listing of specialty products and options/accessories USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS 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 ,87 67 Front of Vehicle 83,88 81,86 84, , *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 Notes: HOW TO USE THE SERVICE PARTS MANUAL Page vii

10 ACCELERATOR 1 21 PEDAL BOX ASSEMBLY includes items 2-39 PLUNGER & SLEEVE ASSEMBLY includes items Front of Vehicle Page A-1

11 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ACCELERATOR ITEM PART NO DESCRIPTION QTY PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3-39) G01 PHILLIPS PAN HEAD SCREW, #8-16" X 1/2" LG G01 PEDAL BOX AND COVER G6 PHILLIPS TRUSS HEAD SCREW (SS), #8-32 X 3/4" LG G01 MICRO SWITCH G01 TORX HEAD SCREW, #4-20 X 5/8" LG G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" G01 PLUNGER CAM G1 SPRING RETAINER, 1/2" G1 ACCELERATOR ROD BUSHING G01 COMPRESSION SPRING G2 SPRING RETAINER, 3/8" G01 ACCELERATOR ROD G4 LOCK NUT, 5/16" G4 CLEVIS YOKE (ADJUSTABLE) PLUNGER & SLEEVE ASSEMBLY (INCLUDES ITEMS 22-23) G01 PLUNGER SLEEVE G01 PLUNGER G01 WIRE HARNESS (PEDAL BOX) G1 FLEX LOOM (BULK)... AR G1 WIRE TIE... 2 Page A-2

12 ACCELERATOR 36 ACCELERATOR PEDAL ASSEMBLY includes item Front of Vehicle Floor Panel Page A-3

13 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ACCELERATOR ITEM PART NO DESCRIPTION QTY G3 CLEVIS PIN, 5/16" X 1" LG G1 NYLON BUSHING G01 HAIRPIN COTTER PEDAL PIVOT PIN ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEM 37) PEDAL PAD G6 PUSH NUT, 9/32" PEDAL BOX BRACKET G3 HEX HEAD FLANGE BOLT, 5/16" - 18 X 1" LG G01 TRUSS HEAD BOLT, 5/16" - 18 X 5/8" LG G01 U - NUT, 5/16" Page A-4

14 ACCELERATOR Notes: Page A-5

15 ACCELERATOR Notes: Page A-6

16 BATTERY CHARGER Page B-1

17 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BATTERY CHARGER ITEM PART NO DESCRIPTION QTY V DELTA-Q ON-BOARD BATTERY CHARGER (FOR HD ONLY) V QUIQ ON-BOARD BATTERY CHARGER (FOR HD ONLY) V DELTA-Q ON-BOARD BATTERY CHARGER... 1 Page B-2

18 BATTERY CHARGER Notes: Page B-3

19 BATTERY CHARGER Notes: Page B-4

20 OFF ON replace ITS replace sensor if required 1-4 HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC not run 3-5 WALKAWAY RELAY DRIVER Vehicle will not run OFF 5-3 WALKAWAY RELAY DRIVER Vehicle will not run ON B+, replace controller Check wiring. Replace power harness and motor if required. Walkaway relay coil shorted. Controller defective. Replace solenoid if necessary Walkaway relay coil short to ground Controller defective walkaway relay. BODY CAUTION Failure to follow this warning can cause severe personal injury or death. FIRE DAMAGE MAY OCCUR TO WIRES AND ELECTRICAL COMPONENTS IF VEHICLE IS TOWED. REMOVE MOTOR LEAD CONNECTIONS IF VEHICLE IS TO BE TOWED This vehicle is designed and constructed for OFF-ROAD USE ONLY. Do not use this vehicle on any public roadway where automobiles or other motor vehicles are present. Such use can be hazardous to the operator and other drivers, passengers or bystanders G01 NOTICE THIS VEHICLE IS EQUIPPED WITH A THROTTLE-SOLENOID INTERLOCK SYSTEM. IN CASE OF POWER INTERRUPTION, RELEASE AND REAPPLY THROTTLE. (SEE OWNER S MANUAL) WARNING FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL OR FATAL INJURY TO YOU OR OTHERS AND MAY ALSO RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGES. READ, STUDY AND UNDERSTAND ALL WARNING LABELS AND OPERATING INSTRUCTIONS FURNISHED WITH THIS EQUIPMENT PRIOR TO USE. IF ANY PART OF THIS MATERIAL IS UNCLEAR, CONTACT YOUR FACTORY REPRE- SENTATIVE FOR CLARIFICATION. NEVER ALLOW UNSKILLED OR IMPROPERLY TRAINED PERSONNEL TO OPERATE THIS EQUIPMENT. BEFORE OPERATING VEHICLE DO NOT MODIFY OR ADD TO VEHICLE WITHOUT MANUFACTURER S AUTHORIZATION. CHECK VEHICLE CONDITION-DO NOT OPERATE IF MAINTENANCE OR REAPIRS ARE NEEDED. UNDERSTAND CONTROLS AND CHECK FUNCTIONS. KEEP CONTROLS FREE OF OBSTRUCTIONS. ALL PASSENGERS MUST BE SEATEDD IN MANUFACTURER S APPROVED SEATS. DO NOT OPERATE IN EXPLOSIVE OR COMBUSTIBLE ATMOSPHERE-SWITCHES SPART. CARGO MUST BE SECURED TO PLATFORM/ WHILE OPERATING VEHICLE KEEP BODY PARTS INSIDE VEHICLE. STAY IN SEAT, USE HAND HOLDS. AVOID SUDDEN STARTS, STOPS, TURNS, AND DIRECTION CHANGES TO AVOID UNSEATING PASSENGERS OR CAUSING UNSTABLE CONDITIONS. REVERSE SPEED IS EQUAL TO FORWARD SPEED ON ELECTRIC POWERED VEHICLE. VEHICLE WITH PROGRAMMAMBLE CONTROLLELR MAY HAVE SLOWER REVERSE SPEED. ADJUST OPERATION TO CONDITIONS OF CROUND, SPEED, LOAD, GRADES. ETC. MAINTAIN A SAFE DISTANCE FROM PEDESTRIANS, RAMP EDGES, PLATFORMS, ETC. OBSERVE ALL TRAFFIC REGULATIONS. OPERATE VEHICLE IN A RESPONSIBLE MANNER. BEFORE LEAVING VEHICLE SET DIRECTIONS SELECTOR IN NEUTRAL. TURN KEY TO VERTICAL OFF POSITION AND REMOVE. IF MALFUNCTION OCCURS, OR ADJUSTMENT IS NEEDED, HAVE ALL WORK PERFORMED BY AUTHORIZED PERSONNEL. BLOCK WHEEELS IF PARKED ON INCLINE. APPLY HAND PARKING BRAKE-PARKING BRAKE NOT AUTOMATICALLY SET. IT IS YOUR RESPONSIBILITY TO KEEP ALL LABELS (DECALS) AND INSTRUCTIONAL LITERATURE LEGIBLE AND INTACT. REPLACEMENT LABELS (DECALS) AND LITERATURE ARE AVAILABLE FROM THE FACTORY WARNING READ OPERATOR S MANUAL BEFORE OPERATING CHARGER. DO NOT CHARGE IN EXPLOSIVE ATMOSPHERE. DO NOT OPERATE VEHICLE WHILE CHARGING. SPARKS MAY IGNITE BATTERY GAS (HYDROGEN). TO PREVENT ELECTRICAL SHOCK, DO NOT USE 2-PRONG ADAPTORS. REPLACE DAMAGED CHARGER CORDS AND WIRES IMMEDIATELY. OPERATIN INSTRUCTIONS CONNECT CHARGER PLUG TO A GROUNDED RECEPTICLE WITH POWER RATING AS INDICATED ON CHARGER. CHARGER WILL TURN ON AUTOMATICALLY. AMMMETER SHOWS WHEN CHARGER IS OPERATING. CHARGER SHUTS OFF AUTOMATICALLY. KEEP CHARGER VENTILATION OPENINGS CLEAR. POOR VENTILATION CAN DAMAGE CHARGER. BATTERIES CHARGED IN UNHEATED AREAS (BELOW 65 F) SHOULD BE CHARGED AS SOON AFTER USE AS POSSSIBLE. CHARGE BATTERIES ONCE EACH WEEK FOR FOUR HOURS IN TEMPERATURE ABOVE 65 F TO IMPROVE STATE OF CHARGE AND BATTERY LIFE. Code Fault Code Symptoms Corrective Action 1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring, 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries 2-3 THERMAL CUTBACK Vehicle performance reduced Allow controller to cool 2-4 MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller 2-5 WALKAWAY RELAY FAULT Vehicle will not run Walkaway relay coil open or not connected 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller 3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to 3-4 FIELD MISSING Solenoid closes, vehicle will 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-2 DRIVER OVERCURRENT Vehicle will not run Contactor or walkaway coil relay shorted 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 WALKAWAY RELAY DNC Vehicle will not run Check walkaway circuit fuse & check walkaway relay 4-5 WELDED WALKWAY RELAY Vehicle runs slowly Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring BLOWN FUSE Vehicle will not run Check walkaway circuit fuse & check 5-5 MAIN DROPOUT Vehicle stops Main contactor defective Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close), HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor), M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault) DIAGNOSTIC FAULT CODES The LED will flash a diagnostic fault code when a fault is detected Some faults may only be detected by operating the vehicle with the rear of the vehicle raised and supported on safety stands Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery compartment) to the 'TOW/MAINTENANCE' position before performing any repairs or maintenance to the vehicle Select 'RUN' before returning the vehicle to service P/N 73398G For LD Only Page C-1

21 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY ITEM PART NO DESCRIPTION QTY. 1 XXXXXX BODY FRAME WELDMENT (FOR HD ONLY) SAFETY YELLOW FOREST GREEN FLAME RED ARCTIC WHITE 2 XXXXXX BODY FRAME WELDMENT (FOR LD ONLY) G35 SAFETY YELLOW G37 FOREST GREEN G38 ARCTIC WHITE G39 FLAME RED G05 ORANGE G47 BURLINGTON GREEN XXXXXX COWL G35 SAFETY YELLOW G37 FOREST GREEN G38 ARCTIC WHITE G39 FLAME RED G05 ORANGE G47 BURLINGTON GREEN C-BOLT, 5/16" - 18 X.75" LG FLAT WASHER,.31" X.69" X.06" G8 LOCK WASHER, 5/16" G3 ACORN - NUT THROTTLE SOLENOID INTERLOCK NOTICE DECAL G01 OFF ROAD USE DECAL CAUTION - NO TOWING DECAL WARNING - OPERATION DECAL WARNING DECAL G01 FAULT CODE DIAGNOSTIC LABEL IGNITION SWITCH DECAL... 1 Page C-2

22 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY DIRECTION SELECTOR LABEL CUSHMAN EMBLEM G01 SELF-THREADING NUT, 5MM X 10MM X 15MM... 3 Page C-3

23 BODY Notes: Page C-4

24 BODY ACCESS PANEL & CARGO DECK WARNING PROVIDE BATTERY VENTILATION DURING CHARGING. KEEP OPEN FLAMES OR SPARKS AWAY FROM BATERIES AT ALL TIMES. DO NOT SHORT ACROSS BATTERIES TO CHECK CONDITION OF BATTERIES. BATTERIES MAY EXPLODE. BATTERY ACID CAN CAUSE SEVERE DAMAGE TO EYES, SKIN, AND CLOTHING FLUST CONTAMINATED AREA IMMEDIATELY WITH WATER. WHEN CLANING BATTERIES, KEEP SOLUTION AND WATER AWAY FROM CHARGER AND SWITCHES P P x 2 x 4 MAX 2600 lbs kg MAX 2200 lbs kg MAX 1750 lbs. 794 kg P Page C-5

25 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY ITEM PART NO DESCRIPTION QTY. 1 *** ACCESS COVER BLACK G01 TRUSS HEAD MACHINE SCREW, 5/16" - 18 X 5/8" LG G01 U TYPE SPEED NUT, 5/8" CARGO DECK PHILLIPS PAN HEAD SCREW, 1/4" - 20 X 1" LG U TYPE SPEED NUT, 1/4" WARNING DECAL BED LOAD DECAL (FOR HD ONLY) BED LOAD DECAL (FOR LD ONLY)... 1 Page C-6

26 BODY Page C-7

27 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY ITEM PART NO DESCRIPTION QTY CHARGER BRACKET HEX HEAD BOLT, 3/8" - 16 X 3/4" LG G2 FLAT WASHER, 3/8" HEX NUT, 3/8" G2 FLANGED LOCK NUT, 1/4" G01 AC CORD G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" LOCK WASHER, 5/16" G3 HEX NUT, 5/16" G5 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG G1 BLACK TRIM... AR Page C-8

28 BODY Page C-9

29 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY ITEM PART NO DESCRIPTION QTY. 1 *** SWING OUT BATTERY RACK SAFETY YELLOW BLACK BURLINGTON GREEN HUNTER GREEN WHITE RED ORANGE LATCH LATCH SPRING G6 FLAT WASHER, # G1 HEX HEAD FLANGE BOLT, #12-24 X 1/2" LG LATCH LINKAGE ROD G4 FLIP-LOCK BUSHING BELLCRANK LATCH PIVOT TUBE BUSHING LATCH HANDLE G01 HANDLE GRIP G5 LOCK NUT G01 BELLEVILLE WASHER,.75" O.D X.38" I.D G2 FLAT WASHER, 7/16" G5 FLIP-LOCK BUSHING BEARING UPPER PIVOT ASSEMBLY HEX HEAD BOLT, 5/16" - 18 X 1" LG GREASE FITTING FLAT WASHER, 5/16"... 4 Page C-10

30 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEX NUT, 5/16" STOP BRACKET TRAVEL LIMITING BUMPER FLAT WASHER, 1/4" LOCK WASHER, 1/4" HEX NUT, 1/4" LOCK WASHER, 5/16" G01 ADJUSTABLE BUMPER G1 FLANGED LOCK NUT, 5/16" G8 HEX HEAD BOLT (SS), 1/4" - 20 X 1" LG SWING OUT BATTERY TRAY DECAL... 2 Page C-11

31 BODY Notes: Page C-12

32 BODY - ACCESSORIES BUMPER (FRONT & REAR) REAR BUMPER AND HITCHES Page C-13

33 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY - ACCESSORIES ITEM PART NO DESCRIPTION QTY BUMPER CARRIAGE BOLT, 5/16" - 18 X 3" LG LOCK WASHER, 5/16" HEX NUT, 5/16" PLUG, PLASTIC G01 SPACER, 1" O.D X 1 29/32" LG G8 HEX HEAD BOLT, 1/2" - 13 X 4" LG FLAT WASHER, 1/2" LOCK WASHER, 1/2" HEX NUT, 1/2" G01 SAFETY CHAIN BRACKET PINTLE HITCH CLEVIS HITCH HITCH BRACE HITCH MOUNTING BRACKET HEX HEAD BOLT, 3/8" - 16 X 1" LG LOCK WASHER, 3/8" HEX NUT, 3/8" G6 FLANGE HEAD BOLT, 1/4" - 14 X 3/4" LG... 3 Page C-14

34 BODY - ACCESSORIES BOX SIDES AND TAILGATE KIT includes items HARDWARE KIT includes items Page C-15

35 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BODY - ACCESSORIES ITEM PART NO DESCRIPTION QTY G01 DECK PLATE, REAR G01 DECK PLATE, FRONT G5 ROUND HEAD PHILLIPS SCREW, #10-13 X.62" LG GXX BOX SIDES AND TAILGATE KIT (INCLUDES ITEMS 7-18) G01 SAFETY YELLOW G02 ARCTIC WHITE G03 FOREST GREEN G04 RED G05 ORANGE GXX TAILGATE G01 SAFETY YELLOW G02 ARCTIC WHITE G03 FOREST GREEN G04 RED G05 ORANGE GXX PANEL ASSEMBLY, PASSENGER SIDE G01 SAFETY YELLOW G02 ARCTIC WHITE G03 FOREST GREEN G04 RED G05 ORANGE GXX PANEL ASSEMBLY, DRIVER SIDE G01 SAFETY YELLOW G02 ARCTIC WHITE G03 FOREST GREEN G04 RED G05 ORANGE G01 HARDWARE KIT (INCLUDES ITEMS 11-18) ROUND HEAD PHILLIPS SCREW, 1/4" - 20 X 3/4" LG FLAT WASHER, 1/4" LOCK WASHER, 1/4" HEX NUT, 1/4" TAPPING SCREW, 1/4" - 20 X 5/8" LG CONNECTOR LINK (NOT ILLUSTRATED) * TAILGATE CHAIN (NOT ILLUSTRATED) CHAIN COVER (NOT ILLUSTRATED)... 2 Page C-16

36 BODY Notes: Page C-17

37 BODY Notes: Page C-18

38 BRAKES - PARK BRAKE Page D-1

39 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BRAKES - PARK BRAKE ITEM PART NO DESCRIPTION QTY PARK BRAKE CONSOLE G01 CUP HOLDER LEVER ASSEMBLY G01 BRAKE CABLE PULLEY G01 BRAKE COMPENSATOR BUMPER G01 EQUALIZER BRACKET PARK BRAKE CABLE G3 TRUSS HEAD PHILLIPS SCREW, 1/4" - 20 X 3/4" LG G3 HEX HEAD FLANGE BOLT, 5/16" - 18 X 1" LG G01 U NUT, 5/16" G1 J TYPE RETAINER NUT, 1/4" G4 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G01 RETAINING RING, 13/32" SPHERICAL HEX NUT, 5/16" G4 HEX JAM NUT, 5/16" G3 CLEVIS PIN, 5/16" X 13/16" G3 COTTER PIN, 3/32" X 3/4" CENTRAL LOCK HEX NUT, 5/16" Page D-2

40 BRAKES - HYDRAULIC BRAKE BRAKE LEVER includes item Part of Frame 43 Part of Body Part of Frame Part of Body Page D-3

41 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BRAKES - HYDRAULIC BRAKE ITEM PART NO DESCRIPTION QTY PEDAL COVER BRAKE PEDAL BRAKE LEVER (INCLUDES ITEM 4) GREASE FITTING HEX HEAD BOLT, 3/8" - 16 X 1" LG LOCK WASHER, 3/8" HEX NUT, 3/8" SCREW, 7/16" - 14 X 3" LG BUSHING,.45 I.D X.62 O.D X 1.81" LG LOCK WASHER, 7/16" HEX NUT, 7/16" FLAT WASHER, 5/16" COTTER PIN, 3/32 X 3/4" HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG FLAT WASHER, 3/8" LOCK WASHER, 3/8" HEX NUT, 3/8" PAN HEAD MACHINE SCREW, 1/4" - 20 X 3/4" LG FLAT WASHER, 1/4" LOCK WASHER, 1/4" HEX NUT, 1/4" WIRE CLAMP HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG G01 MALE BRANCH TEE (NOT ILLUSTRATED)... 1 Page D-4

42 BRAKES - HYDRAULIC BRAKE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY LOCK WASHER, 3/8" HEX NUT, 3/8" TAPPING SCREW, 1/4" - 20 X 5/8" LG TEE MOUNTING CLAMP TEE, UNION BRACKET HEX NUT, 3/8" LOCK WASHER, 3/8" REAR BRAKE LINE FRONT BRAKE LINE HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG FLAT WASHER, 1/4" LOCK WASHER, 1/4" HEX NUT, 1/4" FRONT HOSE MOUNTING BRACKET CLIP HYDRAULIC BRAKE TUBE FLEXIBLE HOSE, 18" LG FLEXIBLE HOSE, 25" LG GROMMET G1 BRAKE LINE TEE TAPPING SCREW, 1/4" - 20 X 5/8" LG HYDRAULIC BRAKE FITTING BRACKET REAR BRAKE LINE (DRIVER SIDE) REAR BRAKE LINE (PASSENGER SIDE) G01 INVERTED FLARE FITTING (NOT ILLUSTRATED) FITTING (NOT ILLUSTRATED)... 1 Page D-5

43 BRAKES - HYDRAULIC BRAKE Notes: Page D-6

44 BRAKES - FRONT BRAKE 1 BRAKE AND SHOE ASSEMBLY includes items BRAKE DRUM ASSEMBLY includes items HUB ASSEMBLY includes item Page D-7

45 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BRAKES - FRONT BRAKE ITEM PART NO DESCRIPTION QTY BRAKE AND SHOE ASSEMBLY ( INCLUDES ITEMS 2-15 ) * BACKING PLATE WHEEL CYLINDER LOCK WASHER, 1/4" HEX HEAD BOLT, 1/4" - 20 X 1/2" LG HEEL PIN LOCK WASHER, 5/8" HEX NUT, 5/8" RETAINING RING SPRING ADJUSTMENT PIN LOCK WASHER, 3/8" HEX NUT, 3/8" BRAKE SHOE (REPLACE BOTH SHOES ON BOTH WHEELS) HEX HEAD BOLT, 5/16" - 18 X 3/4" LG LOCK WASHER, 5/16" SOCKET HEAD CAP SCREW, 5/16" - 18 X 3/4" LG BRAKE DRUM ASSEMBLY ( INCLUDES ITEMS ) BRAKE DRUM HUB ASSEMBLY (INCLUDES ITEM 24) LUG BOLT, 7/16" - 20 X 1 3/4" LG SPINDLE CAP SEAL CONE BEARING CONE BEARING AND ROLLER G1 BRAKE DRUM WASHER, 3/4" CASTLE NUT, 3/4" COTTER PIN... 2 Page D-8

46 BRAKES - REAR BRAKE Page D-9

47 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BRAKES - REAR BRAKE ITEM PART NO DESCRIPTION QTY BRAKE ASSEMBLY (DRIVER SIDE) BRAKE ASSEMBLY (PASSENGER SIDE) G01 BRAKE SHOE ASSEMBLY... 1 Page D-10

48 BRAKES - MASTER CYLINDER Part of Master Cylinder Page D-11

49 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. BRAKES - MASTER CYLINDER ITEM PART NO DESCRIPTION QTY MASTER CYLINDER LOCK WASHER, 3/8" G8 HEX NUT, 1/4" HEX NUT, 3/8" HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG FLAT WASHER, 3/8" PLUG, 1/8" SEALING WASHER, I.D..512" X O.D..812" OUTER SEALING WASHER, I.D..6" X O.D..812" BRAKE ROD BUSHING MASTER CYLINDER BOLT BRASS MANIFOLD STOPLIGHT SWITCH... 1 Page D-12

50 BRAKES - MASTER CYLINDER Notes: Page D-13

51 BRAKES - MASTER CYLINDER Notes: Page D-14

52 ELECTRICAL SYSTEM - 36V Front of Vehicle Part of Cowl From "D" Position on FNR From Solenoid 26 From "A2" Position on Electronic Speed Controller 22 From "B" Position on FNR Front of Vehicle A1 S1 A2 S Page E-1

53 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM - 36V ITEM PART NO DESCRIPTION QTY G01 STATE OF CHARGE METER, 36V HOUR METER DIRECTION SELECTOR HORN BUTTON WIRE ASSEMBLY, 18AWG PAN HEAD MACHINE SCREW, #10-24 X 3/4" LG LOCK WASHER,.194" HEX NUT, # G01 IGNITION SWITCH WITH LIGHTS G3 WIRE CLAMP CONTROL HARNESS HARNESS FUSE G01 TAILLIGHT JUMPER PLUG G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G7 FLAT WASHER, 1/4" G02 TWISTED CLAMP POWER HARNESS, 36V FNR HARNESS, 36V G7 LOCK WASHER, #1/ G01 LOCK WASHER, 5/16" G01 HEX NUT, 5/16" GROMMET, 2.0" Page E-2

54 ELECTRICAL SYSTEM - 36V From Solenoid Main Contactor Green wire from Control Harness From B- Controller Black wire From Control Harness Page E-3

55 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM - 36V ITEM PART NO DESCRIPTION QTY BATTERY HOLD DOWN (FOR LD ONLY) BATTERY HOOK BOLT, 5/16" - 18 X 10 3/4" LG *** BATTERY FLAT WASHER SPACER,.38" FLAT WASHER, 5/16" WING NUT, 5/16" BATTERY HOLD DOWN PLATE (FOR HD ONLY) BATTERY HOOK BOLT END BAR FLAT WASHER, 1/4" LOCK NUT, 1/4" G7 HEX HEAD BOLT, 1/4" - 20 X 1" LG G1 NYLON CLAMP G8 LOCK WASHER, 5/16" G2 HEX NUT, 5/16" RUBBER GROMMET WIRE ASSEMBLY, #4, 117" LG WIRE ASSEMBLY, #4, 126" LG WIRE ASSEMBLY, #4, 80" LG G13 WIRE ASSEMBLY, #4, 10" LG... 1 Page E-4

56 ELECTRICAL SYSTEM - 48V Front of Vehicle Part of Cowl From "B-" Position on Electronic Speed Controller From Solenoid From "M-" Position on Electronic Speed Controller From "F2" Position on Electronic speed Controller Front of Vehicle A1 F1 A2 F Page E-5

57 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM - 48V ITEM PART NO DESCRIPTION QTY G03 STATE OF CHARGE METER, 48V HOUR METER DIRECTION SELECTOR HORN BUTTON PAN HEAD MACHINE SCREW, #10-24 X 3/4" LG LOCK WASHER,.194" HEX NUT, # HARNESS FUSE G01 TAILLIGHT JUMPER PLUG G01 IGNITION SWITCH WITH LIGHTS G3 WIRE CLAMP CONTROL HARNESS GROMMET, 2.13" G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G02 CLAMP G7 FLAT WASHER, #1/ G1 WIRE TIE POWER HARNESS G02 LOCK NUT, 1/4" G02 LOCK WASHER, 1/4" G01 HEX NUT, 5/ G01 LOCK WASHER, 5/16" G01 RETAINING RING SPEED SENSOR G02 SCREW, #10-32 X 1/2" LG G01 MAGNET G7 LOCK WASHER, #1/ Page E-6

58 ELECTRICAL SYSTEM - 48V Front of Vehicle GRN Wire From Control Harness BLK Wire From Control Harness From B - Controller Page E-7

59 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM - 48V ITEM PART NO DESCRIPTION QTY. 1 *** BATTERY WING NUT, 5/16" FLAT WASHER, 5/16" SPACER FLAT WASHER BATTERY HOLD DOWN PLATE J - BOLT, 5/16" - 18 X 12 1/2" LG WIRE ASSEMBLY, #4, 117" LG G1 NYLON CLAMP G02 WIRE CLAMP RUBBER GROMMET G13 WIRE ASSEMBLY, #4, 10" LG WIRE ASSEMBLY, #4, 126" LG G2 HEX NUT, 5/16" G8 LOCK WASHER, 5/16" HYDROLINK BATTERY FILL SYSTEM POLYPROPYLENE CLAMP... 4 Page E-8

60 ELECTRICAL SYSTEM Front of Vehicle Part of Frame GRN / WHT Wire BLK Wire Part of Charger Box Part of Frame Front of Vehicle 8 Page E-9

61 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM ITEM PART NO DESCRIPTION QTY G1 HORN (INCLUDES ITEM 2) * BRACKET G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" G3 HEX NUT, 5/16" G3 TAILLIGHT G02 HARNESS CLAMP, 3/4" (NOT ILLUSTRATED) DC - DC CONVERTER, 36V - 48V DC - DC CONVERTER HARNESS TAPPING SCREW, #10-32 X 3/4" LG... 4 Page E-10

62 ELECTRICAL SYSTEM 1 2 HEADLIGHT AND TURN SIGNAL (PASSENGER SIDE) includes items 3-12 HEADLIGHT AND TURN SIGNAL (DRIVER SIDE) includes items Headlight BLK to Harness Headlight BLU to Harness Turn Signal BLK to Harness Turn Signal WHT to Harness Steering Column Connected to Accessory Wiring Harness 17 WHT Ground Page E-11

63 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRICAL SYSTEM ITEM PART NO DESCRIPTION QTY G3 HEADLIGHT AND TURN SIGNAL (PASSENGER SIDE) (INCLUDES ITEMS 3-12) G4 HEADLIGHT AND TURN SIGNAL (DRIVER SIDE) (INCLUDES ITEMS 3-12) G2 HEADLIGHT (RECTANGULAR) G3 FLAT WASHER, 1/2" G3 LOCK WASHER, 1/2" G1 HEX NUT, 1/2" G1 TURN SIGNAL LIGHT BRACKET G1 ADAPTER MOUNT G01 SCREW, # 8-10 X 1/2" LG G2 TURN SIGNAL LIGHT G4 SCREW, #10-32 X 1/2" LG G2 PUSH ON TERMINAL (FEMALE) WIRING COVER SCREW, TAPPING, 1/4" - 20 X 5/8" LG G1 TURN SIGNAL (WITH MOUNTING HARDWARE) (OPTIONAL) (INCLUDES ITEM 17) G1 TURN SIGNAL FLASHER... 1 Page E-12

64 ELECTRICAL SYSTEM Notes: Page E-13

65 ELECTRICAL SYSTEM Notes: Page E-14

66 ELECTRONIC SPEED CONTROL - 36V BLK From Battery Harness to B- on Controller BLK From Solenoid Harness to B+ on Controller RED From Control Harness to Reverse 2 24 BLU Wire From Control Harness To Logic Power WHT Wire From Control Harness To Throttle Power BLK Wire From Control Harness To Throttle Sensor FNR Harness To M- Controller FNR Harness To A2 Controller Power Harness To A2 Controller RED GRN / BLK Part of Frame Front of Vehicle 17 RED or WHT From Charger RED WHT/BLU WHT/GRN YEL From control Harness To Solenoid (+) RED/GRN From Control Harness To +36V BLU From control Harness To Solenoid (-) 3 SOLENOID includes items FUSE BLOCK (6 POSITION) includes items 12 & 13 From Solenoid To Motor Front of Vehicle Page F-1

67 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRONIC SPEED CONTROL - 36V ITEM PART NO DESCRIPTION QTY CONTROLLER MOUNTING PLATE G01 ELECTRONIC SPEED CONTROLLER (36V SYSTEM) G1 SOLENOID (INCLUDES ITEMS 4-7) G5 LOCK WASHER, # G4 LOCK NUT, # G8 LOCK WASHER, 5/16" G4 JAM NUT, 5/16" G01 FASTON TAB 90 DEGREE G01 FUSE BLOCK (6 POSITION) (INCLUDES ITEMS 12-13) G5 LOCK WASHER, # G4 LOCK NUT, # G02 CONTINUOUS TONE BUZZER G5 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG G2 LOCK NUT, 1/4" G5 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG G2 SCREW, #10-24 X 1 1/4" LG G4 LOCK NUT, 1/4" G10 LOCK NUT, # G01 RIVET, 1/8" X 13/16" LG G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G1 FLANGED LOCK NUT, 5/16" GA WIRE SOL - B G01 FUSE, 15 AMP G1 RESISTOR G1 DIODE, 3 AMP G7 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G1 FLAT WASHER, 1/4"... 4 Page F-2

68 ELECTRONIC SPEED CONTROL - 36V THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 LOCK NUT, 1/ CONTROLLER COVER G1 TRIM (14.5" REQUIRED)... A/R TERMINAL BOOT G1 FASTON TAB CONTACTOR, 36V CONTACTOR BRACKET G10 LOCK NUT, # G5 FLAT WASHER SCREW, #10-24 X 3/4" LG... 4 Page F-3

69 ELECTRONIC SPEED CONTROL - 36V Notes: Page F-4

70 24 ELECTRONIC SPEED CONTROL - 48V BLK From F2 Power Harness To F2 Controller From M- Power Harness To Controller From Solenoid To B+ Controller From B+ Power Harness To Controller 16 WHT From Power Harness to F1 Controller BLK Wire & WHITE Wire From Charger to B CONTROLLER SERVICE KIT INCLUDES ITEMS 39 & 41 From B- Controller To 48V Front of Vehicle Part of Frame RED WHT/BLU WHT/GRN RED From Charger YEL From control Harness To Solenoid (+) RED/GRN BLU From control Harness To Solenoid (-) Personality Plug Walkaway Fuse From Solenoid To +48V RED From Walkaway Relay 20 To Solenoid (-) From Solenoid To Controller B+ PURPLE From Walkaway Fuse To Solenoid (+) Front of Vehicle Walkaway Relay Page F-5

71 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ELECTRONIC SPEED CONTROL - 48V ITEM PART NO DESCRIPTION QTY CONTROLLER MOUNTING PLATE G01 SOLENOID G5 LOCK WASHER, # G4 LOCK NUT, # G1 FASTON TAB G01 FUSE BLOCK (6 POSITION) (NOT ILLUSTRATED) G02 CONTINUOUS TONE BUZZER G02 TOGGLE SWITCH G01 RIVET, 1/8" X 13/16" LG G01 LABEL - TOW/RUN SWITCH G7 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G2 LOCK NUT, 1/4" G5 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG G2 SCREW, #10-24 X 1 1/4" LG G01 HEX HEAD BOLT, M6 X 1 X 12MM LG G10 LOCK NUT, # G8 LOCK WASHER, 5/16" G4 JAM NUT, 5/16" GA WIRE G01 FUSE, 15 AMP G7 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G1 FLAT WASHER, 1/4" G4 LOCK NUT, 1/4" G2 LOCK NUT, 1/4" CONTROLLER COVER G1 TRIM, (14.5" REQUIRED)... A/R TERMINAL BOOT G03 TOW SWITCH HARNESS G01 HEX HEAD BOLT, M8 X 1.25 X 16MM LG Page F-6

72 ELECTRONIC SPEED CONTROL - 48V THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY RELAY G2 RIVET, 0.25" X 0.88" G5 RIVET, 0.18" X 0.55" CONTROLLER SERVICE KIT (INCLUDES ITEMS 39-41) ELECTRONIC SPEED CONTROLLER WALKAWAY RELAY HARNESS ASSEMBLY G1 NYLON WIRE TIE (NOT ILLUSTRATED)... 2 Page F-7

73 ELECTRONIC SPEED CONTROL - 48V Notes: Page F-8

74 FRONT SUSPENSION Front of Vehicle Page G-1

75 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. FRONT SUSPENSION ITEM PART NO DESCRIPTION QTY HEX FLANGED HEAD BOLT, 3/8" - 16 X 1 1/4" LG HEX FLANGED NUT, 3/8" LEAF SPRING AND BUSHING SPRING MOUNT SHACKLE PLATE FLAT WASHER, 7/16" LOCK NUT, 7/16" HEX FLANGED HEAD BOLT, 3/8" - 16 X 1 1/4" LG HEX FLANGED NUT, 3/8" LOWER ARM REAR BRACKET FLANGE BEARING, 3/4" HEX HEAD BOLT, 5/16" - 16 X 1 1/4" LG G5 LOCK NUT, 3/8" FLAT WASHER, 3/8" LOWER ARM FRONT BRACKET LOCK WASHER, 1/2" LOWER ARM BOLT, 1/2" CONICAL WASHER, 1.125" BUSHING, 1.117" O.D. X.502" I.D. X 5.405" LG LOWER ARM WASHER, 1/2" HEX NUT, 1/2" G4 HEX HEAD BOLT, 1/2" - 13 X 4 1/2" LG LOCK WASHER, 1/2"... 2 Page G-2

76 FRONT SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEX NUT, 1/2" LOWER ARM AND BUSHING ASSEMBLY G4 HEX HEAD BOLT, 1/2" - 13 X 4 1/2" LG LOCK WASHER, 1/2" HEX NUT, 1/2" G01 RUBBER BUMPER FLAT WASHER, M LOCK SPLIT WASHER, M G01 HEX NUT, M SPACER, 1.7" O.D. X 1.2" I.D. X.075" Page G-3

77 FRONT SUSPENSION Notes: Page G-4

78 FRONT SUSPENSION KING PIN AND SPINDLE ASSEMBLY includes items 2-14 KING PIN ASSEMBLY includes items SPINDLE ASSEMBLY includes item Page G-5

79 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. FRONT SUSPENSION ITEM PART NO DESCRIPTION QTY KING PIN AND SPINDLE ASSEMBLY (INCLUDES ITEMS 2-14) HEX NUT, 3/4" LOCK WASHER, 3/4" RETAINER SPRING AND KING PIN BALL BEARING SHIM,.010 THICK SPINDLE ASSEMBLY (INCLUDES ITEM 8) BUSHING, 30MM O.D. X 28.8MM I.D. X DIA 32MM KING PIN ASSEMBLY (INCLUDES ITEMS 10-13) * SUPPORT, KING PIN * PIN * BUSHING, 1.255" O.D. X.564" I.D. X 2.75" LG * KING PIN GREASE FITTING, 1/4" Page G-6