SERVICE PARTS MANUAL

Transcription

1 INCLUDES ITEMS G01 SERVICE PARTS MANUAL Ref Fcv 7 ELECTRIC & PRECISION DRIVE SYSTEM PERSONNEL CARRIERS AND 5 PASSENGER GOLF CAR STARTING MODEL YEAR: 2002 REVISED: 12/2002

2 SERVICE PARTS MANUAL ELECTRIC AND PRECISION DRIVE SYSTEM PERSONNEL CARRIERS AND 5 PASSENGER GOLF CAR VEHICLES SHUTTLE 4 SHUTTLE 6 TE5 TE5 PDS Textron Golf, Turf & Specialty Products reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. Textron Golf, Turf & Specialty Products is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: FAX: OUTSIDE USA PHONE: , FAX: TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, P.O.BOX 388, AUGUSTA, GEORGIA USA Page i

3 NOTES 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

4 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ILLUSTRATED PARTS BREAKDOWN vii ACCELERATOR A-1 BATTERY CHARGER (PORTABLE) B-1 BATTERY CHARGER (ON BOARD) B-3 BODY C-1 BRAKES - HYDRAULIC D-1 DIRECTION SELECTOR E-1 ELECTRICAL SYSTEM F-1 ELECTRONIC SPEED CONTROL G-1 ELECTRONIC SPEED CONTROL - PDS G-3 FRONT SUSPENSION/STEERING H-1 ELECTRIC MOTOR J-1 REAR AXLE - HYDRAULIC K-1 REAR SUSPENSION L-1 SEATING M-1 WEATHER PROTECTION N-1 WHEELS AND TIRES P-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 INDEX OF MAJOR COMPONENTS INDEX-1 Page iii

5 TABLE OF CONTENTS Notes: Page iv

6 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 INDEX OF MAJOR COMPONENTS Contains a listing of parts (excluding hardware) grouped by part number and description and indicates on which page(s) they can be found USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS (page iii) or the INDEX OF MAJOR COMPONENTS (located at rear of this manual) 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. 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. 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 vii

7 ,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 INDEX OF MAJOR COMPONENTS and select the most appropriate component description. Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying description for specific information regarding the part that was not shown in the index. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. 2. IF YOU KNOW THE PART NUMBER Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on. Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying description for specific information regarding the part. From the parts list, obtain the item number assigned to it and 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. 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 viii

8 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page ix

9 HOW TO USE THE SERVICE PARTS MANUAL Page x

10 Page xi

11 ACCELERATOR 1 - Includes Items Includes Items Includes Items 34, To Direction Selector Harness Ref Acl 7-1 Page A-1

12 ACCELERATOR Ref Acl 7-2 Page A-2

13 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G08 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3-19, 21, 23, 26-43) G07 PEDAL BOX ASSEMBLY, PDS MODEL ONLY (INCLUDES ITEMS 3-17, 20, 21, 24-43) G01 PEDAL BOX AND COVER (SEAL AND BEARING) G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" G01 PLUNGER SLEEVE G01 PLUNGER G01 PLUNGER CAM G01 ACCELERATOR ROD G4 LOCK NUT, 5/ G4 YOKE (ADJUSTABLE) G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G01 MICRO SWITCH G02 MICRO SWITCH (PDS MODEL ONLY) G01 SCREW, #4-20 X 5/8" LG G07 WIRING HARNESS (PEDAL BOX ASSEMBLY) G06 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY) G6 SCREW, #8-32 X 3/4" LG G01 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG... 4 Page A-3

14 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32-35) * ACCELERATOR PEDAL G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35) G01 ACCELERATOR PEDAL PAD G1 OVAL RIVET 3/16" X 7/16" LG G1 BUSHING G01 PEDAL PIVOT PIN G6 PUSHNUT, 9/32" I.D G3 CLEVIS PIN, 5/16" X 13/16" LG G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G2 BOLT, 5/16-18 X 13/16" LG G01 PEDAL PIVOT COVER... 1 Page A-4

15 BATTERY CHARGER (PORTABLE) Ref Bcp 7 Page B-1

16 BATTERY CHARGER (PORTABLE) 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 48V LESTER BATTERY CHARGER G01 48V LESTER BATTERY CHARGER WITH SWITCHABLE INPUT G05 48V LESTER BATTERY CHARGER CE APPROVED... 1 For service or replacement parts, contact: Lester Electrical 625 West A Street Lincoln, NE Phone: (402) , FAX: (402) Always provide the following information when requesting information or ordering replacement parts: Model Number: Serial Number: (stamped into housing) Page B-2

17 BATTERY CHARGER (ON BOARD) Ref Bco 7 Page B-3

18 BATTERY CHARGER (ON BOARD) 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G07 48V LESTER BATTERY CHARGER G01 CHARGER RECEPTACLE COVER PLATE G10 RIVET, 1/8" X 7/16" LG (ALUMINUM) G01 COVER G4 SCREW, #10-32 X 1/2" LG G5 LOCK WASHER, # G01 CORD REEL G6 BOLT, 5/16-18 X 3/4" LG G1 LOCK NUT, 5/ G2 LOCK NUT, 1/ For charger service or replacement parts, contact: Lester Electrical 625 West A Street Lincoln, NE Phone: (402) , FAX: (402) Always provide the following information when requesting information or ordering replacement parts: Model Number: Serial Number: (stamped into housing) Page B-4

19 BODY 1 - Includes Items Ref Bod 7-1 Page C-1

20 BODY Ref Bod 7-2 Page C-2

21 BODY Includes Items 73, Includes Items 73, Includes Items TE TE Ref Bod Page C-3

22 BODY Ref Bod 7-4 Page C-4

23 BODY Ref Bod 7-5 Page C-5

24 BODY Includes Items Ref Bod 7-6 Page C-6

25 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 2-5) G01 DEFLECTOR (PASSENGER SIDE) G01 DEFLECTOR (DRIVER SIDE) G5 SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (4 CUP HOLDER) G01 LABEL (ANTI-ROLLBACK) G01 LABEL (SAFETY) (SHUTTLE) G01 LABEL (SAFETY) (TE5) * SERIAL NUMBER PLATE G01 RIVET, 1/8" X 13/16" LG G01 CAPACITY PLATE (SHUTTLE) G01 RIVET, 1/8" X 13/16" LG G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 FRONT SHIELD BRACE G02 FRONT SHIELD G01 BOLT, 1/4-20 X 11/16" LG G1 WASHER, 1/4" G01 RIVET, KTR, 1/4" X 3/4" LG G01 UPPER FLOORPAN G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ACCESS COVER... 1 Page C-7

26 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 REAR FLOORPAN G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G0* FLOORMAT G** COWL G02 E-Z-GO NAMEPLATE (GOLD) G3 PUSHNUT, 3/16" G01 RIVET, 3/16" X 1" LG G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 BOLT, 5/16-18 X 5/8" LG (WITHOUT SUN TOP) G2 WASHER, 5/16 (WITHOUT SUN TOP) G6 BOLT, 5/16-18 X 5/8" LG (WITHOUT SUN TOP) G2 WASHER, 5/16 (WITHOUT SUN TOP) G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG G01 SEAT FRAME G01 BATTERY RACK G2 BOLT, 5/16-18 X 13/16" LG G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 SCREW, 3/8-16 X 3/4" LG G01 SPLASH PAN (PASSENGER SIDE)... 1 Page C-8

27 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 SPLASH PAN (DRIVER SIDE) G2 BOLT, 5/16-18 X 13/16" LG G01 FENDER LINER (PASSENGER SIDE) (SHUTTLE) G02 FENDER LINER (DRIVER SIDE) (SHUTTLE) G05 FENDER LINER, EXTENDED (PASSENGER SIDE) (TE5) G05 FENDER LINER, EXTENDED (DRIVER SIDE) (TE5) G2 RATCHET FASTENER, 1/4" X 3/4" LG (SHUTTLE - QTY 4) (TE5 - QTY 8)... AR G3** REAR BODY ASSEMBLY (WITH TAILLIGHTS) (INCLUDES ITEMS 73, 74) G6** REAR BODY ASSEMBLY (W/OUT TAILLIGHTS) (INCLUDES ITEMS 73, 74) G01 BAGWELL LINER G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 HINGE PLATE G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 PLUG G01 ACCESS PANEL G01 SCREW, #8 X 5/8" LG G02 J CLIP G12 RIVET, 1/4" X 9/16" LG (ALUMINUM) G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" LG G02 REAR BUMPER (SHUTTLE 4, TE5 PDS) G01 REAR BUMPER (SHUTTLE 6) (INCLUDES ITEM 91)... 1 Page C-9

28 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 STAY G01 BOLT, 1/4-20 X 1 1/4" LG (SHUTTLE 4 - QTY 4) (SHUTTLE 6 - QTY 2)... AR G8 WASHER, 5/16" (SHUTTLE 4 - QTY 4) (SHUTTLE 6 - QTY 2)... AR G01 BUMPER PLUG G01 BOLT, 1/4-20 x 11/16" LG G01 J-TYPE NUT RETAINER, 1/ G01 REAR BUMPER (TE5) G01 BOLT, 1/4-20 X 5/8" LG G8 WASHER, 5/16" G01 BUMPER PLUG G17 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ROCKER PANEL (FRONT, DRIVER SIDE) G02 ROCKER PANEL (FRONT, PASSENGER SIDE) G01 ROCKER PANEL (REAR, DRIVER SIDE) G02 ROCKER PANEL (REAR, PASSENGER SIDE) G01 SILL PLATE (PASSENGER SIDE) G02 SILL PLATE (DRIVER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G4 SPACER, 5/16" G2 LOCK NUT, 1/ G6 RIVET, 3/16" X 15/16" LG (ALUMINUM) G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE) G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) G4 BOLT, 3/8-16 X 1 1/2" LG (SHUTTLE 4) G6 BOLT, 3/8-16 X 1 3/4" LG (SHUTTLE 6)... 2 Page C-10

29 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 SEAT BACK SUPPORT (SHUTTLE) G01 SPACER (TE5 & SHUTTLE 6) G01 BOLT, 3/8-16 X 1 1/4" LG G8 BOLT, 3/8-16 X 1" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 VALANCE PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 LABEL (SHUTTLE) G13 LABEL (6) G14 LABEL (4) G01 LABEL (PRECISION DRIVE SYSTEM) (TE5) G01 LABEL (F-R) G01 LABEL (F-R) (EC) G01 FENDER SCUFFGUARD (DRIVER SIDE) (TE5) G02 FENDER SCUFFGUARD (PASSENGER SIDE) (TE5) G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 HOLD DOWN BRACKET G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G01 CARGO DECK... 1 Page C-11

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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 NOISE SUPPRESSOR G01 STEEL DECK G01 CARGO BED MAT G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL) G4 LOCK NUT, 1/ G01 LATCH G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G4 WASHER, # G02 FRONT/REAR CARGO RACK G01 SIDE CARGO RACK G01 TAILGATE RETAINER BRACKET G6 SCREW, #10-12 X 3/4" LG G1 BUSHING G4 BOLT, 5/16-18 X 2 1/2" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 LABEL (WARNING) (BED LATCH - SHUTTLE 4) G01 LABEL (WARNING) (LOAD BED - SHUTTLE 4) G02 FOOT REST ASSEMBLY (INCLUDES ITEMS ) G01 FOOT REST G01 FLOOR MAT G01 REFLECTOR G1 END CAP... 2 Page C-12

31 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 LABEL (WARNING) G01 LABEL (WARNING) (EC) G2 CARRIAGE BOLT, 3/8-16 X 1 1/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G6 BOLT, 3/8-16 X 1 3/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ Page C-13

32 BODY Page C-14

33 BRAKES - HYDRAULIC Includes Items Includes Items Includes Items Includes Items (without lights) 44 (with lights) Rear Axle Ref Brh 7-1 Page D-1

34 BRAKES - HYDRAULIC Front of Vehicle Includes Items Includes Items Includes Items Includes Items Axle Tube Ref Brh 7-2 Page D-2

35 BRAKES - HYDRAULIC Includes Items Ref Brh 7-3 Page D-3

36 BRAKES - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 BRAKE PEDAL (INCLUDES ITEMS 2-4) G01 PEDAL G01 PAD G1 OVAL RIVET, 1/8" X 15/32" LG G01 FLANGED BUSHING G01 TORSION SPRING G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/ G8 LINKAGE ROD ASSEMBLY (INCLUDES ITEMS 17-19) G8 THREADED ROD G4 CLEVIS YOKE ADJUSTABLE G4 JAM NUT, 5/ G3 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G01 BRAKE BELLCRANK G01 FLANGED BUSHING G01 BELLCRANK SHAFT G1 RETAINING RING, 13/32" ID G3 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG Page D-4

37 BRAKES - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 MASTER CYLINDER REPAIR KIT (NOT SHOWN)... AR G03 MASTER CYLINDER SERVICE KIT (INCLUDES ITEMS 33-35) * MASTER CYLINDER G1 BOOT G1 WASHER, 3/8" G2 PUSH ROD ASSEMBLY (INCLUDES ITEMS 38-40) G2 PUSH ROD, 3 1/8" LG G1 CLEVIS YOKE G6 JAM NUT, 3/ G01 TEE BRANCH (MALE) G1 PIPE PLUG... A/R G1 STOPLIGHT SWITCH (IF EQUIPPED WITH BRAKE LIGHTS) G4 BOLT, 3/8-16 X 1 1/2" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 SCREW, 3/8-16 X 1" LG G1 LOCK WASHER, 3/8" G3 CLEVIS PIN, 5/16" X 1 " LG G3 COTTER PIN, 3/32" X 3/4" LG G01 INVERTED FLARE FITTING G11 BRAKE LINE WITH NUTS, 60" LG G5 INSULATED CABLE CLAMP, 3/8" G6 SELF THREADING SCREW, #10 X 3/4" LG Page D-5

38 BRAKES - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SPACER G01 HYDRAULIC HOSE /2" LG G1 FLEX HOSE CLIP G6 LOCK NUT, 5/ G9 BRAKE LINE WITH NUTS - 30" LG G6 BRAKE LINE WITH NUTS - 8" LG G02 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 71-92) G01 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 71-92) G1 TORQUE SPIDER G01 WHEEL CYLINDER REPAIR KIT (INCLUDES ITEMS 74-76) G1 WHEEL CYLINDER PISTON G1 HYDRAULIC CUP G1 SEAL G1 BLEEDER VALVE G1 LOWER SPRING G1 SHOE HOLD DOWN G1 ADJUSTER G1 DUST SHIELD G01 SPRING (YELLOW) G01 SPRING (BLUE) G01 BRAKE SHOE * PARKING BRAKE LEVER ASSEMBLY (INCLUDES ITEMS 88-92) G1 CURVED LEVER G1 SPRING WASHER G1 CLEVIS PIN... 1 Page D-6

39 BRAKES - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 CLEVIS PIN RETAINER G1 STRAIGHT LEVER G1 CLIP G1 WIPER SEAL G01 STUD, 5/16-24 X 1 5/8" LG G1 NUT, 5/ XXXXX-XX AXLE SHAFT (DRIVER SIDE) (SEE REAR AXLE SECTION FOR P/N) XXXXX-XX AXLE SHAFT (PASSENGER SIDE) (SEE REAR AXLE SECTION FOR P/N) XXXXX-XX BEARING RETAINER RING (SEE REAR AXLE SECTION FOR P/N) XXXXX-XX WHEEL BEARING (SEE REAR AXLE SECTION FOR P/N) XXXXX-XX INNER OIL SEAL (SEE REAR AXLE SECTION FOR P/N) G2 BRAKE DRUM G01 SHIFT BRACKET AND SWITCH (INCLUDES ITEMS ) G01 BRACKET G01 LIMIT SWITCH G2 SCREW, #6-32 X 1 1/4" LG G3 WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 FASTON TAB, 9/32" X 11/32" G02 BRAKE LEVER WITH CABLE G01 PULLY BRACKET G01 PULLY, 2"... 1 Page D-7

40 BRAKES - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G9 SPACER, 3/4" G4 BOLT, 5/16-18 X 1 1/2" LG G6 LOCK NUT, 5/ G3 CLEVIS PIN, 5/16" X 1" G01 COTTER PIN, 1 3/16" G01 BRAKE CABLE EQUALIZER G01 EQUALIZER BUMPER G12 BRAKE CABLE G1 RETAINING RING G1 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G8 BOLT, 3/8-16 X 2" LG G1 WASHER, 3/8" G1 LOCK NUT, 3/ Page D-8

41 DIRECTION SELECTOR Includes Items Includes Items For dash mounted direction selector, see ELECTRICAL SYSTEM Ref Dsl 7 Page E-1

42 DIRECTION SELECTOR 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 2-26) G1 CONTACT BOARD ASSEMBLY (INCLUDES ITEMS 3-5) G1 STOP G7 LOCK WASHER, 1/4" G6 BOLT, 1/4-20 X 3/4" LG G1 CAM G8 LOCK WASHER, 5/16" G3 NUT, 5/ G01 SHAFT G1 WASHER, 3/8" G6 NUT, 3/ G01 SHIFT ARM G3 BUSHING G1 LOCK NUT, 3/ G2 MICRO SWITCH (HEAVY DUTY) G1 SPACER G6 SCREW, #6-32 X 1 3/4" LG G3 LOCK WASHER, # G5 NUT, # G1 SCREW #6-32 X 1/4" LG (BRASS) G1 FASTON TAB G19 10 GA WIRE (RED 5") G GA WIRE (RED 6") G1 PLATE G8 SCREW, 1/4-20 X 1" LG G7 WASHER, 1/4"... 4 Page E-2

43 DIRECTION SELECTOR 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G4 LOCK NUT, 1/ G02 REVERSE WARNING BUZZER G4 SCREW, #6-32 X 1/2" LG G9 LOCK NUT, # G01 SHIFTER HANDLE G1 SHIFT KNOB G01 SHAFT G2 BEARING, DU G1 WASHER, 3/8" G01 SHIFT ARM G3 BUSHING G1 LOCK NUT, 3/ G01 SHIFT LINK G01 TRUNNION G2 WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG... 1 Page E-3

44 DIRECTION SELECTOR Page E-4

45 ELECTRICAL SYSTEM A2 S A1 S A D B C Includes Items Includes Items Ref Ele 7-1 Page F-1

46 ELECTRICAL SYSTEM PDS MODELS ONLY RED GRN/BLK OFF ON OFF ON Includes Items STATE OF CHARGE METER AND KEY SWITCH 113 PDS MODELS ONLY: DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER AND KEY SWITCH Ref Ele 7-2 Page F-2

47 ELECTRICAL SYSTEM BLU/WHT ORN/WHT RED GRN 58 COLUMN MOUNTED HORN BUTTON FLOOR MOUNTED HORN BUTTON Electrical Tape 61 Floorboard HORN Front of Vehicle YEL BLK Ref Ele 7-3 Page F-3

48 ELECTRICAL SYSTEM HEADLIGHT R G 76 Y R Driver Side Passenger Side Ref Ele 7-4 Page F-4

49 ELECTRICAL SYSTEM Rear Fender TURN SIGNAL Ref Ele 7-5 Page F-5

50 ELECTRICAL SYSTEM HOUR METER 93 - Includes Items HOUR METER BLK YEL (-) (+) Solenoid Ref Ele 7-6 Page F-6

51 ELECTRICAL SYSTEM 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G0* CHARGER HARNESS / RECEPTACLE (INCLUDES ITEMS 2-11) G0* CHARGER HARNESS G30 CHARGER HARNESS RECEPTACLE (INCLUDES ITEMS 4-11) G22 RECEPTACLE BOTTOM G21 RECEPTACLE COVER G08 SCREW, #10-32 X 1/2" LG G09 SCREW, #6-32 X 1 3/4" LG G10 LOCK NUT, # G28 REED SWITCH, ENCAPSULATED G23 FEMALE CONTACT G24 FEMALE CONTACT, INSULATED G01 RIVET, 3/16" X 1" LG G08 4 GA WIRE (BLK 95") (DIRECTION SELECTOR - MOTOR: B - S1) G07 4 GA WIRE (BLK 90") (DIRECTION SELECTOR - MOTOR: D - S2) G09 4 GA WIRE (BLK 88") (ESC - MOTOR: A2 - A2) G10 4 GA WIRE (BLK 92 1/2") (ESC - MOTOR: B+ - A1) G8 LOCK WASHER, 5/16" G3 NUT, 5/ G0* CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) XXXXX-G** 6 VOLT BATTERY G01 BATTERY RETAINER G01 HOLD DOWN BOLT G1 LOCK NUT, 5/ G01 HOLD DOWN BOLT G01 BATTERY RETAINER G40 6 GA WIRE (BLK 6")... 4 Page F-7

52 ELECTRICAL SYSTEM 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 6 GA WIRE (BLK 21") G1 6 GA WIRE (BLK 8 1/2") G2 NUT, 5/ G02 CONSOLE INSERT PLATE G02 LABEL, CONSOLE INSERT PLATE (WITHOUT LIGHTS) G01 LABEL, CONSOLE INSERT PLATE (WITH LIGHTS) G02 RIVET, 3/16" X 3/8" LG G1 IGNITION SWITCH KIT (INCLUDES ITEMS 41-43) G1 IGNITION SWITCH (WITHOUT LIGHTS, STANDARD KEY) G6 LOCK WASHER, 3/4" G1 FACE NUT G1 IGNITION SWITCH (WITHOUT LIGHTS, NON-STANDARD KEY) G1 IGNITION SWITCH (WITHOUT LIGHTS, INDIVIDUALLY KEYED) G01 IGNITION SWITCH (WITH LIGHTS, STANDARD KEY) G02 IGNITION SWITCH (WITH LIGHTS, NON-STANDARD KEY) G03 IGNITION SWITCH (WITH LIGHTS, INDIVIDUALLY KEYED) G01 WIRE HARNESS (KEY SWITCH) G1 WIRE TIE G03 STATE OF CHARGE METER G74 18 GA WIRE (RED 6") G02 WIRE HARNESS (STATE OF CHARGE METER) G1 FUSE BLOCK G01 RIVET, 5/32" X 3/8" LG G1 FUSE, 15 AMP G01 WIRE HARNESS (ACCESSORY) Page F-8

53 ELECTRICAL SYSTEM 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 HORN SWITCH G8 RIVET, 3/16" X 7/16" LG (ALUMINUM) G3 STEERING COLUMN COVER G1 HORN G01 HEADLIGHT MOUNT BRACKET (PASSENGER SIDE) G02 HEADLIGHT MOUNT BRACKET (DRIVER SIDE) G6 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/ G01 HEADLIGHT AND TURN SIGNAL LIGHT BAR G6 SCREW, 1/4-20 X 3/4" LG XXXXX-XX SEE BODY SECTION G01 HEADLIGHT BULB G01 MARKER LIGHT BULB G01 TURN SIGNAL BULB G2 TAILLIGHT ASSEMBLY G01 BEZEL (DRIVER SIDE) G02 BEZEL (PASSENGER SIDE) G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G02 J CLIP G01 COUNTERSUNK SCREW, #3-18 X 3/4" LG G1 TAILLIGHT BULB G1 TURN SIGNAL (WITH MOUNTING HARDWARE) (INCLUDES ITEM 88) G1 TURN SIGNAL FLASHER G3 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE... 2 Page F-9

54 ELECTRICAL SYSTEM 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 STEERING COLUMN COVER G06 HOUR METER KIT (INCLUDES ITEMS 94-98) G1 HOUR METER ASSEMBLY G01 HOUR METER BRACKET G4 SCREW, #10-24 X 1/2" LG G7 LOCK NUT, # G04 WIRE HARNESS (HOUR METER) G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 RIVET, 3/16" X 1" LG G06 CONSOLE INSERT PLATE G01 LABEL, DIRECTION SELECTOR AND STATE OF CHARGE METER G01 LABEL, LIGHTS, DIRECTION SELECTOR & STATE OF CHARGE METER G01 DIRECTION SELECTOR SWITCH G05 STATE OF CHARGE METER (VERTICAL) G02 RIVET, 3/16" X 3/8" LG G01 HARNESS (CONTROL) G02 BUZZER G01 RIVET, 5/32" X 3/4" LG... 2 Page F-10

55 ELECTRONIC SPEED CONTROL From Control Harness WHT BLK RED BLK ORN Includes Items Includes Items B- B+ M- 26 A To Batteries To Accelerator Harness 11 To 12 Direction Selector Ref Esc 7 Page G-1

56 ELECTRONIC SPEED CONTROL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G05 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-24) G01 CONTROLLER MOUNT G1 TRIM G01 ELECTRONIC SPEED CONTROLLER G5 BOLT, 1/4-20 X 5/8" LG G7 WASHER, 1/4" G2 LOCK NUT, 1/ G05 WIRE HARNESS (CONTROL) G83 6 GA WIRE (BLK 9") (CONTROLLER B+ - SOL ) G80 6 GA WIRE (BLK 19") (CONTROLLER A2 - DIRECTION SELECTOR A) G84 6 GA WIRE (BLK 26") (CONTROLLER M- - DIRECTION SELECTOR C) G6 BOLT, 5/16-18 X 3/4" LG G1 FLANGED NUT, 5/ G01 SOLENOID BRACKET G01 48 VOLT SOLENOID (INCLUDES ITEMS 18-21) * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/ * JAM NUT, 5/ G1 DIODE G1 RESISTOR G2 LOCK NUT, 1/ G06 4 GA WIRE (BLK 59 1/2") (SOL - BATTERY +) G05 4 GA WIRE (BLK 56") (CONTROLLER B- - BATTERY -) G6 INSULATED CABLE CLAMP, 1" G7 WASHER, 1/4" G4 LOCK NUT, 1/ Page G-2

57 ELECTRONIC SPEED CONTROL - PDS , 24 #10 Black 21, 22 From Motor F2 (Power Harness) J3 F2 B+ 16 #4 Black From Motor A1 (Power Harness) #4 Black From Motor A2 (Power Harness) #18 Yellow From J1 Pin 5 (Control Harness) #18 Blue From J1 Pin 17 (Control Harness) J2 M- 9, 10 7, 8, 12 6 J1 F1 B- #18 Red From Tow Switch and Reverse Buzzer (Control Harness) #10 White From Charger Receptacle Speed Sensor Harness 26 Charger Receptacle Harness #4 Black From Charger (Charger Harness) #18 Red/White From Tow Switch (Control Harness) To Ignition Interlock (Charger Receptacle) #4 Black From Motor A1 (Power Harness) #4 Black From Battery (-) (Power Harness 27 Power Harness 29 Code Fault Code Symptoms Corrective Action Always select 'TOW / MAINTENANCE' position before towing. RUN WARNING l TOWING MAINTENANCE TOW MAINTENANCE Possibility of electrical arc and battery explosion. Before removing/connecting batteries or electrical components turn switch to 'TOW/MAINTENANCE' position. To disable electrical system place switch in 'TOW/MAINTENANCE' position and remove battery wire. After reconnecting batteries, allow a minimum of 30 seconds before selecting 'RUN' position 73340G HW FAILSAFE Vehicle will not run Check motor wiring, replace controller 1-2 THROTTLE FAULT 1 Vehicle will not run Check pedal box adjustment, connections, replace ITS 1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring, replace sensor if required 1-4 HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries 2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC 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 VDD FAULT Vehicle will not run Replace controller 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 B+, replace controller 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring. not run Replace power harness and motor if required. 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted. Verify, replace motor if necessary. 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 AUX CONT DNC Vehicle will not run Replace controller 4-5 WELDED AUX CONT Vehicle runs slowly Replace controller 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring. Replace solenoid if necessary 5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring. Replace solenoid if necessary 5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring. Replace solenoid if necessary 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 G01 Ref Esp 7 Page G-3

58 ELECTRONIC SPEED CONTROL - PDS 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-16) G01 CONTROLLER MOUNT G01 ELECTRONIC SPEED CONTROLLER G01 48 VOLT SOLENOID (INCLUDES ITEMS 7-10) * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * JAM NUT, 5/ G1 FASTON TAB G2 LOCK NUT, 1/ G83 6 GA WIRE (BLK 9") G01 DOUBLE TUBE CLAMP G2 LOCK NUT, 1/ G01 BOLT, 8MM X 16MM LG G01 LOCK WASHER, 5/16" G01 BOLT, 6MM X 1 X 12MM LG G02 LOCK WASHER, 1/4" G01 CONTROL HARNESS G06 4 GA WIRE (BLK 59 1/2") (SOL - BATTERY +) G01 TOW-MAINTENANCE SWITCH G01 RIVET, 5/32" X 3/4" LG G01 DIAGNOSTIC LABEL (FAULT CODE)... 1 Page G-4

59 FRONT SUSPENSION/STEERING Front of Vehicle *Truck Models Only 41* 42* 40 Part of Frame Part of Frame 4,15 19, , 49 4 LUG LUG , *NOTE: Tie Rod Not Shown for Clarity Includes Items Includes Item Includes Items 5-10, Includes Items Includes Item Includes Items 20-25, , 29 Ref Fss 1-1 Page H-1

60 FRONT SUSPENSION/STEERING 114 Front of Vehicle OR ,88 81,86 84,89 82, Includes Items Includes Items Includes Items Includes Items Includes Items 101, Includes Items Ref Fss 1-2 Page H-2

61 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 FRONT AXLE G01 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-10) G02 SPINDLE ASSEMBLY (PASSENGER SIDE) G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 8) G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 CASTELLATED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G2 SPINDLE CAP G01 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 5-10, 15) G02 SPINDLE ASSEMBLY (DRIVER SIDE) G01 SPINDLE AND HUB ASSEMBLY, 5 LUG (PASSENGER SIDE) (INCLUDES ITEMS 19-25) G02 SPINDLE ASSEMBLY (PASSENGER SIDE) G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, 5 LUG (INCLUDES ITEM 23) G1 LUG BOLT, 1/2-20 X 1 7/32" LG G1 CASTELLATED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG Page H-3

62 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SPINDLE AND HUB ASSEMBLY, 5 LUG (DRIVER SIDE) (INCLUDES ITEMS 20-25, 30) G02 SPINDLE ASSEMBLY (DRIVER SIDE) G6 BOLT, 1/2-13 X 6" LG G3 WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER, 1" (STAINLESS STEEL) G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G01 SHOCK ABSORBER BOOT G1 WIRE TIE G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 NUT, 3/ G02 LEAF SPRING (SEE PART NUMBER ON SPRING) G02 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) G02 SPRING PLATE G4 BOLT, 7/16-14 X 1 1/2" LG G1 LOCK NUT, 7/ G6 BOLT, 7/16-14 X 1 3/4" LG G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 57-68) G01 RACK EXTENSION... 1 Page H-4

63 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 58 * JAM NUT, 1/ G01 RACK BOOT G2 WIRE TIE G8 CLAMP, 1 13/16-2 3/8" G01 PINION SEAL G01 RACK BALL JOINT (INCLUDES ITEMS 65-68) G1 RUBBER BOOT G2 CASTELLATED NUT, 7/ G2 COTTER PIN, 3/32" X 1" LG G3 GREASE FITTING, STRAIGHT G6 BOLT, 7/16-14 X 2 3/4" LG G01 BOLT, 7/16-14 X 3 1/2" LG G02 SPACER G03 SPACER (SHORT) G7 NUT, 7/ G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/ G01 STEERING SHAFT G03 STEERING COLUMN KIT (INCLUDES ITEMS 82-84) G01 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG G04 STEERING COLUMN KIT (HORN) (INCLUDES ITEMS 87-89) G02 STEERING COLUMN... 1 Page H-5

64 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG G01 BOLT, 3/8-16 X 1 1/4" LG G1 LOCK WASHER, 3/8" G01 COVER G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 101, 102) G01 BOLT, M8 X G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER G01 STEERING WHEEL G01 STEERING WHEEL COVER G01 LABEL (E-Z-GO) G01 LABEL (CUSHMAN) G01 STEERING WHEEL G01 CLIPBOARD G01 HUB COVER G2 LOCK NUT, 5/ Page H-6

65 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 TIE ROD ASSEMBLY (INCLUDES ITEMS ) G02 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS) G01 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G02 JAM NUT, M12 X (RIGHT HAND THREADS) G1 LOCK NUT, 7/ Page H-7

66 FRONT SUSPENSION/STEERING Notes: Page H-8

67 ELECTRIC MOTOR 1 - Includes Items Includes Items X1 X2 A2 A PDS ONLY 28 Ref Mtr 7 Page J-1

68 ELECTRIC MOTOR 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 MOTOR, FLEET SPEED, NON-VENTED (INCLUDES ITEMS 2-11) G01 ARMATURE G03 BRUSH SPRING G15 BRUSH PLATE AND BOX G25 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G09 COVER PLATE AND SCREW G08 COVER COMMUTATOR END G16 CAP G29 FRAME AND FIELD COIL (INCLUDES HARDWARE) G04 MOTOR (SEPARATELY EXCITED) (PDS) (INCLUDES ITEMS 15-28) G32 ARMATURE G35 BRUSH SPRING G34 BRUSH G36 BRUSH BOX G37 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G39 HEADBAND G33 FRAME AND FIELD COIL (INCLUDES HARDWARE) G38 COVER COMMUTATOR END G01 MAGNET G02 SCREW, #10-32 X 1/2" LG G01 RETAINING RING G01 SPEED SENSOR... 1 Page J-2

69 REAR AXLE - HYDRAULIC NOTE: Apply a light coat of moly grease to male spline before assembly. Reference item 10 Front of Vehicle Includes Items Includes Items A2 S Brake Drum Axle Tube 19 Brake Mechanism Ref Rax 7 Page K-1

70 REAR AXLE - HYDRAULIC 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 REAR AXLE AND BRAKE ASSEMBLY (INCLUDES ITEMS 3-8) G03 REAR AXLE AND BRAKE ASSEMBLY, PDS (INCLUDES ITEMS 3-8) AXLE SHAFT (DRIVER SIDE) AXLE SHAFT (PASSENGER SIDE) G01 DIFFERENTIAL COVER G01 FILL/CHECK PLUG WITH O-RING G1 BOLT, 5/16-18 X 3/4" LG G01 VENT G01 MOLY LUBE, 2 OZ... AR G1 BUMPER SPLINE G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" G02 CABLE CLAMP G7 WASHER, 1/4" G1 INNER OIL SEAL G1 WHEEL BEARING ASSEMBLY G1 BEARING RETAINER RING... 2 Page K-2

71 REAR SUSPENSION Ref Rsp 7 Page L-1

72 REAR 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 LEAF SPRING G01 PLATE G1 U BOLT, 3/8-16 X 2 1/8" X 5" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 FLANGED BUSHING G1 SHOULDER BOLT, 3/8-16 X 3 1/4" LG G1 LOCK NUT, 3/ G01 FLANGED BUSHING G02 SPACER G01 SHACKLE PLATE G4 BOLT, 3/8-16 X 3 1/2" LG G5 LOCK NUT, 3/ G01 SHOCK ABSORBER G01 SPACER, SHOCK ABSORBER G3 WASHER, 1/2" G1 LOCK NUT, 1/ G1 RUBBER BUSHING G1 WASHER, SHOCK ABSORBER G6 NUT, 3/ Page L-2

73 SEATING 32 Passenger Side TE5 Driver Side 31 SHUTTLE Floormat Ref Sea 7-1 Page M-1

74 SEATING Ref Sea 7-2 Page M-2

75 SEATING TE Includes Items SHUTTLE Includes Items See Body Section Ref Sea 7-3 Page M-3

76 SEATING SHUTTLE Includes Items Includes Items Ref Sea 7-4 Page M-4

77 SEATING 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G00* SEAT POD G01 PLUG, 1 1/8" G01 RIVET, 3/16" X 1" LG G01 VENT PLUG G6 TRIM, BLACK G01 ASHTRAY G8 BOLT, 5/16-18 X 2" LG G1 WASHER, 1 1/4" X 3/8" G01 RUBBER WASHER, 5/8" G9 SPACER, 3/4" G6 LOCK NUT, 5/ G01 SEAT BACK SUPPORT G06 SCREW, 5/16-18 X 3/4" LG G6 LOCK NUT, 5/ G8 BOLT, 3/8-16 X 2" LG G1 WASHER, 1 1/4" X 3/8" G4 SPACER, 5/16" G5 ACORN NUT, 3/ G** SEAT BACK ASSEMBLY G01 HAND GRIP G02 BOLT, 1/4-20 X 2" LG G01 CONSOLE COVER (WITHOUT DIRECTION SELECTOR) G02 CONSOLE COVER (WITH DIRECTION SELECTOR) G01 SEAL (DIRECTION SELECTOR) G01 SEAL (BRAKE LEVER) Page M-5

78 SEATING 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G** SEAT BOTTOM (SHUTTLE) G** SEAT BOTTOM (TE5) G01 T KNOB G** SEAT BACK G8 BOLT, 1/4-20 X 1" LG G7 LOCK WASHER, 1/4" G** SEAT BOTTOM (INCLUDES ITEMS 42-48) (SHUTTLE 4 & 6) G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG G01 FRONT EDGE TRIM G01 BACK EDGE TRIM G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 BOLT, 1/4-20 X 7/8" LG G01 SEAT BACK SUPPORT (TE5) G01 BOLT, 3/8-16 X 1 1/4" LG (TE5) G** SEAT BOTTOM (TE5) G01 HAND HOLD KIT (INCLUDES ITEMS 55-58) G01 HIP RESTRAINT, REAR SEAT (DRIVER SIDE) G02 HIP RESTRAINT, REAR SEAT (PASSENGER SIDE) G7 WASHER, 1/4" G2 BOLT, 1/4-20 X 1 1/4" LG Page M-6

79 SEATING 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G** SEAT ASSEMBLY (INCLUDES ITEMS 62-73) (SHUTTLE 6) G01 SEAT SUPPORT BRACKET G** SEAT BACK G** SEAT BOTTOM (INCLUDES ITEMS 65-71) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G8 BOLT, 1/4-20 X 1" LG G7 LOCK WASHER, 1/4" G7 WASHER, 1/4" G01 SEAT TRIM (REAR) G01 SEAT TRIM (FRONT) G01 BOLT, 1/4-20 X 7/8" LG G1 NYLON BUSHING G4 BOLT, 5/16-18 X 2 1/2" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ Page M-7

80 SEATING Page M-8

81 WEATHER PROTECTION 8 Strut 9 2 Front of Vehicle Strut FOLD DOWN WINDSHIELD 1 - Includes Items 2-9 Windshield Retainer Front of Vehicle Strut REAR WINDSHIELD 11 - Includes Items Front of Vehicle Strut FULL WINDSHIELD 19 - Includes Items Front of Vehicle Ref Wea 7-1 Page N-1

82 WEATHER PROTECTION D A 32 Rear of Vehicle Rear Strut , (Driver Side Shown) D E A C B C Sun Top Front of Vehicle Front Strut 38 SUN TOP (SHUTTLES) 27 - Includes Items B E Front of Vehicle 43 (Inside) (Front Passenger Side Shown) Ref Wea 7-2 Page N-2

83 WEATHER PROTECTION (Driver Side Rear Shown) Front Of Vehicle 67 Front Of Vehicle 68 A B (Driver Side Shown) A C 66 B 64 D C Front Of Vehicle SUN TOP (TE5/TG5) 51 - Includes Items D 63 Ref Wea 7-3 Page N-3

84 WEATHER PROTECTION 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 WINDSHIELD KIT, FOLD DOWN (INCLUDES ITEMS 2-9) E950WSB3 FOLD DOWN WINDSHIELD EGWHC24 SASH, 3/4" X 14" LG EGWHS12 SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) EGWHW12 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN12 LOCK NUT, 1/4-20 (STAINLESS STEEL) TOP GRIP FASTENER G01 WINDSHIELD KIT, REAR (INCLUDES ITEMS 12-17) EIRWFB3 REAR WINDSHIELD EGWHC14 SASH, 1" X 15 9/16" LG EGWHS14 SCREW, 1/4-20 X 2" LG (STAINLESS STEEL) EGWHW13 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN13 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 WINDSHIELD KIT, FULL (INCLUDES ITEMS 20-25) EISWFB3 FULL, WINDSHIELD EGWHC13 SASH, 3/4" X 22 7/16" LG EGWHS13 SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) EGWHW13 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN13 LOCK NUT, 1/4-20 (STAINLESS STEEL) G0* SUN TOP KIT (SHUTTLE) (INCLUDES ITEMS 28-49) G0* SUN TOP G03 FRONT STRUT G01 REAR STRUT (DRIVER SIDE)... 1 Page N-4

85 WEATHER PROTECTION 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 REAR STRUT (PASSENGER SIDE) G1 END CAP, 1" G5 BOLT, 3/8-16 X 1 3/4" LG (STAINLESS STEEL) G1 WASHER, 3/8" (STAINLESS STEEL) G5 NYLON WASHER, 3/8" G5 LOCK NUT, 3/ G4 BOLT, 5/16-18 X 2 1/2" LG G2 BOLT, 5/16-18 X 3 1/4" LG G1 WASHER, 3/8" G01 SPACER, 1/2" G8 LOCK WASHER, 5/16" G01 BOLT, 5/16-18 X 2 1/4" LG G01 HANDLE G2 SCREW, 1/4-20 X 1 1/4" LG G8 WASHER, 5/16" G01 LOCK NUT, 5/16-18 (STAINLESS STEEL) G2 SPACER, 1" G8 LOCK WASHER, 5/16" G01 TEE NUT, 1/ G01 SUN TOP KIT (TE5/TG5) (INCLUDES ITEMS 52-69) G02 REAR SUPPORT (DRIVER SIDE) G01 REAR SUPPORT (PASSENGER SIDE) G5 BOLT, 3/8-16 X 1 3/4" LG (STAINLESS STEEL) G1 WASHER, 3/8" (STAINLESS STEEL) G5 NYLON WASHER, 3/8" G5 LOCK NUT, 3/ G1 END CAP, 1" G01 FRONT SUPPORT G01 BOLT, 5/16-18 X 2 1/4" LG... 4 Page N-5

86 WEATHER PROTECTION 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. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G1 LOCK WASHER, 3/8" G01 SUN TOP G10 BOLT, 5/16-18 X 2 3/4" LG (STAINLESS STEEL) G2 WASHER, 5/16" (STAINLESS STEEL) G8 WASHER, 5/16" (STAINLESS STEEL) G01 LOCK NUT, 5/16-18 (STAINLESS STEEL) G11 BOLT, 5/16-18 X 3 1/4" LG (STAINLESS STEEL)... 4 Page N-6

87 WHEELS AND TIRES 1 - Includes Items Includes Items " CHROME HUBCAP 13 8" CHROME HUBCAP 14 SILVER / GOLD SPOKE HUBCAP 15, 16 Ref Whl 7 Page P-1