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1 COLUMBIA

2 Welcome, and congratulations on your choice of the Columbia Electric Vehicle from Columbia ParCar Corp.! Some of the equipment in this manual may not apply to your vehicle, depending on which model you have. If your vehicle is a Neighborhood Electric Vehicle (NEV) or a Low Speed Vehicle (LSV) they meet the requirements of the National Highway Traffic & Safety Administration (NHTSA) as stated in the Code of Federal Regulations, Title 49, Part 571, Standard 500, Low Speed Vehicles. To the best knowledge of Columbia ParCar Corp., the material contained herein is accurate as of the date this publication was approved for printing. Columbia Par-Car Corp. 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. Columbia ParCar Corp. reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation. This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of this manual may be photocopied, reproduced, or translated to another language without the written consent of Columbia ParCar Corp. Columbia ParCar Corp. products are manufactured under one or more of the following U.S. Patents , , , , , , , , , , , , , Des Commercial Avenue Reedsburg, WI Phone: (608) Fax: (608) (800) Web: i

3 INDEX - MEGA SECTION 1 Engine & Electrical DC Engine Components 1-1 DC Power Parts 1-2 AC Engine/Power Parts 1-4 Battery and Wire Harness 1-6 Delta Q Charger with Remote LED 1-7 Lights 1-8 Main Harness Schematic 1-9 Harness Controller to MDI 1-10 AC Controller Adapter Harness 1-10 SECTION 2 Body Chassis 2-1 Chassis Supports 2-2 Front 2-3 Door - Panel 2-5 Door Window Mechanism 2-6 Door, Complete 2-6 Door Lock Mechanism 2-7 Glazing 2-8 Front/Rear Bumpers 2-9 SECTION 3 Accelerator & Brakes Accelerator and Brake Cluster 3-1 Hydraulic Brakes 3-3 Hydraulic Brake Lines 3-4 Mechanical Brakes 3-5 SECTION 4 Steering and Suspension Wheels 4-1 Front Axle 4-2 Drive Shaft and Rear Axle 4-3 Steering 4-4 SECTION 5 Interior Heating System 5-1 Seats and Dash 5-2 Seat Belts 5-3 Instruments 5-4 Windshield Wiper, Horn & Sun Visor 5-5 Interior Dome Light 5-6 SECTION 6 Options Tail Gate 6-1 Van Side Roller Door 6-2 Van Sides 6-3 Van Doors 6-4 Dropside Body 6-6

4 INDEX - MEGA Tipper Body 6-7 Rear Deck Boards 6-8 Refuse Body 6-9 Refuse Dump Mechanism 6-10 Van Enclosure 6-11 Dropside HVAC 6-12 HAVC 6-16 Note: Starting in February of 2015, Columbia started implementing the use of textured black paint instead of satin black on certain accessories. When ordering black coated parts it may be necessary to state if they have the satin finish or the textured finish. CHANGE HISTORY MEGA DATE DESCRIPTION BY 4/15/2011 Issued TS 9/12/13 Changed AC Controller P/N & included replacement instructions. TS 11/13/13 Deleted seat belt washer. Added brake line connections. TS 11/25/13 Added wire harnesses TS 12/3/13 Added dropside HVAC TS 12/11/13 Changed brake reservoir & deleted silver door assemblies. TS 1/15/14 Added dropside locks. TS 1/29/14 Added motor port power support TS 6/11/14 Added door decal P/N s TS 6/24/14 Changed Drop-side HVAC TS 7/17/14 Added HVAC group TS 3/3/15 Added note about the black finish changing TS 5/6/15 Added 3 parts to Page 5-4 (ECR ), changed steering wheel TS iii

5 MEGA PARTS MANUAL SECTION 1 ENGINE and ELECTRICAL

6 DC ENGINE COMPONENTS - MEGA MOTOR 48V COOLING FAN SUPPORT THROTTLE PEDAL RETURN SPRING ENGINE MOUNT ENGINE SUPPORT FRAME INLET AIR HOSE AXLE, 8.41: ** SPEED SENSOR KIT (Includes Item 9) * ** MAGNET 1 N/A 10 * ** COMMUTATOR END HEAD 1 N/A 11 * ** HEAD BAND 1 N/A BEARING * RETAINING RING 1 N/A ** BRUSH ASSY ** BRUSH BOX ASSY * MOTOR FRAME 1 N/A 17 * ** POLE SHOE ASSY. 4 N/A 18 * ** SHUNT COIL ASSY 1 N/A 19 * ARMATURE ASSY. 1 N/A MOTOR, COMPLETE (Includes Items 8-19) * SPECIAL ORDER ** ITEM INCLUDES ALL NECESSARY HARDWARE 1-1

7 DC POWER PARTS - MEGA 1-2

8 DC POWER PARTS - MEGA Cont TRAY, ELECTRICAL COMP SUPPORT, FAN A CONTROLLER, SEVCON REGEN, SEPEX, 24-48V (Programmed ) DC/DC CONVERTER, 36/48V, 13.4V FUSED SPACER, NYLON, 2"L X.5 OD X.266 ID SUPPORT, FRONT, ELECTRICAL TRAY COVER SUPPORT, REAR, ELECTRICAL TRAY COVER BRACKET, CONTACTOR, MAIN CONTACTOR, SINGLE - 48V COIL FUSE HOLDER A AMP FUSE COVER, ELECTRICAL COMPONENTS SWITCH, MASTER DISCONNECT CLAMP, #36 HOSE CONT, SW60, 48V COIL COOLING FAN BRACKET MOTOR COOLING FAN FILTER, FOAM, MOTOR FAN SUPPORT, ELECTRICAL COMPONENTS, L/H SUPPORT, ELECTRICAL COMPONENTS R/H HARNESS, ENCODER ADAPTER * CABLE, CONTACTOR TO CONTROL B * CABLE, MAIN FUSE TO MAIN CONTACTOR * CABLE, BATTERY 48V(-) TO CONTROL B * CABLE, MAIN DISCONNECT SWITCH TO MAIN FUSE * CABLE, MAIN DISCONNECT SWITCH TO BATTERY 48V(+) * CABLE, A1 MOTOR TO M1 CONTROLLER * CABLE, A2 MOTOR TO M2 CONTROLLER * CABLE, F1 MOTOR TO F1 CONTROLLER * CABLE, F2 MOTOR TO F2 CONTROLLER * HARNESS, MAIN * NOT SHOWN 1-3

9 AC ENGINE/POWER PARTS MEGA

10 AC ENGINE/ POWER PARTS MEGA (Cont.) TRAY, ELECTRICAL COMP. ZAPI AC CONTROLLER, AC 450A-T (Programed with instructions) U DC/DC CONVERTER, 36/48V, 13.4V FUSED SPACER, NYLON, 2"L X.5 OD X.266 ID SUPPORT, FRONT, ELECTRICAL TRAY COVER SUPPORT, REAR, ELECTRICAL TRAY COVER BRACKET, CONTACTOR, MAIN CONTACTOR, SINGLE - 48V COIL FUSE HOLDER A AMP FUSE SWITCH, MASTER DISCONNECT CONTACTOR, SW60, 48V COIL SUPPORT, ELECTRICAL COMPONENTS, L/H SUPPORT, ELECTRICAL COMPONENTS R/H MOTOR, 5KW AC ENGINE MOUNT ENGINE SUPPORT FRAME AXLE, 8.41: COVER, ELECTRICAL COMPONENTS SUPPORT, PORT POWER AC (Item 14 replacement part) * CABLE, CONTACTOR TO CONTROL B * CABLE, MAIN FUSE TO MAIN CONTACTOR * CABLE, BATTERY 48V(-) TO CONTROL B * * CABLE, MAIN DISCONNECT SWITCH TO MAIN FUSE (See Note) CABLE, MAIN DISCONNECT SWITCH TO BATTERY 48V(+) * CABLE, MOTOR, AC DRIVE * HARNESS, MAIN * NOT SHOWN NOTE: Vehicles with a 300 amp fuse will have this cable replaced with a 12 cable, P/N

11 BATTERY and WIRE HARNESSES - MEGA VEHICLE FRONT BATTERY TRAY BATTERY, 6V, DEEP CYCLE (US2200) A BATTERY, 6V, DEEP CYCLE (US 145) B BATTERY, 6V, DEEP CYCLE (AGM GC2) A BATTERY HOLD DOWN A ROD, BATTERY HOLD DOWN WASHER, FLT STAINLESS.28X1.375X NUT ¼-20 NE 316 STAINLESS NYLON CABLE, 4GAX8.75, 5/16 TERM BATTERY WATERING SYSTEM * HAND PUMP, BATTERY WATERING SYSTEM DASHBOARD HARNESS FRONT HARNESS REAR HARNESS LICENSE LIGHT ASSY NON-VAN REVERSE ALARM * REVERSE LIGHT HARNESS * CHARGER DELTA Q 48V (AGM Battery ALG 42) * NOT SHOWN 1-6

12 DELTA Q CHARGER WITH REMOTE LED MEGA CR-174 CLIP & RING LED FRONT LABEL CHARGER, DELTA Q 48V W/LED, STANDARD A CHARGER, DELTA Q 48V W/LED, AGM PLUG, POWER INLET 120V SEALED CHARGER CORD LED 25 CABLE N/A ASSEMBLY, CORD W/ RECEPTACLE (Includes Item 4 & 5)

13 LIGHTS - MEGA L/H HEADLIGHT A R/H HEADLIGHT L/H HEADLIGHT BRACKET A R/H HEADLIGHT BRACKET STROBE LIGHT, AMBER TAIL LIGHT TAIL LIGHT BOX LIGHT, LICENSE PLATE

14 MAIN HARNESS SCHEMATIC MEGA P/N

15 HARNESS CONTROLLER to MDI P/N AC CONTROLLER ADAPTER HARNESS MEGA P/N

16 AC CONTROLLER ADAPTER HARNESS MEGA (Cont.) P/N

17 MEGA PARTS MANUAL SECTION 2 BODY

18 CHASSIS CHASSIS LEG LONG CABIN REAR SUPPORT OUTRIGGER CENTRAL AND REAR CROSSMEMBER UPPER REAR SUPPORT REAR ARCH OUTRIGGER SUPPORT REAR OUTRIGGER SUPPORT

19 CHASSIS SUPPORT HEADLIGHT BRACKET, BAR FRONT SUPPORT L/H FRONT SUPPORT R/H ENGINE FRAME (SEE NOTE) BUMPER SUPPORT BAR CONNECTOR MEMBER ARCH BRACKET L/H A CONNECTOR MEMBER ARCH BRACKET R/H CABIN FRAME LHD A * CABIN FRAME RHD CABIN SUPPORT L/H CABIN SUPPORT R/H CAB DOOR FRAME L/H A CAB DOOR FRAME R/H SPACER, HEADLIGHT NOTE: This applies to vehicle having an 8 or 9 as the 10th VIN digit. If replacing Item 4 also order the following parts: *, SCREW, M10-1.5X50MM, HHCS, 2 ea. 7266, WASHER 1/4X1, FENDER, 12 ea SP, SCREW, 1/4-14X1, HWH, TEK, 12 ea. * SPECIAL ORDER 2-2

20 FRONT (See Note page 2-4) 2-3

21 FRONT (Cont.) CABIN FRONT PANEL See NOTE FRONT PLATFORM LHD See NOTE A * FRONT PLATFORM RHD See NOTE SUN VISOR WITH MAP POUCH CAB FLOOR R/H DASH FRONT PANEL See NOTE SOUND PANEL INNER WING L/H SOUND PANEL INNER WING R/H LOWER SOUND PANEL L/H/F WING CAPPING PANEL See NOTE A R/H/F WING CAPPING PANEL See NOTE REAR TRAY. LONG, -D (N), -T(N), -C(N) A REAR TRAY. POLYESTER, -V(N) CAB REAR PANEL See NOTE PANEL LEFT CAB See NOTE A RIGHT REAR WING See NOTE TRIM PANEL LEFT A TRIM PANEL RIGHT PLATE, CHARGER CABLE L/H EXTENSION DGRABBET See NOTE A R/H EXTENSION DGRABBET See NOTE CAB ROOF See NOTE DECAL, DOMED EAGLE LOGO HOOD, RED See NOTE A HOOD, SILVER See NOTE B HOOD, BLUE See NOTE C HOOD, WHITE See NOTE FRONT BUMPER See NOTE HOOD BUMPER R/H FRONT WING See NOTE A L/H FRONT WING See NOTE HOOD PROP ROD PL FRONT BUMPER FASTENER HOOD RELEASE CABLE HOOD LOCK HOOK HOOD CATCH HOOD HINGE L/H A HOOD HINGE R/H SOUND PLATE R/H ** 8698 BUMPER RIVETS ** COLUMBIA DECAL ** LABEL, OPERATING RESTRICTIONS * SPECIAL ORDER ** NOT SHOWN NOTE: Many of the body components must be secured with an adhesive sealant. Order P/N which is an 8 1/2 tube containing 10.3 oz. (305 ml). A tube will cover approximately 12. Prior to use of the adhesive, components must be treated with a primer such as Sika Primer 215 (obtain locally). 2-4

22 DOOR PANEL LEFT MAIN CAB DOOR SEAL A RIGHT MAIN CAB DOOR SEAL CAB DOOR TOP SEAL L/H CAB DOOR UPPER FRAME A R/H CAB DOOR UPPER FRAME L/H CAB DOOR LOWER FRAME A R/H CAB DOOR LOWER FRAME DOOR PANEL, RH OUTER, WHITE DOOR PANEL, RH OUTER, BLUE DOOR PANEL, RH OUTER, RED DOOR PANEL, RH OUTER, GRAY A DOOR PANEL, LH OUTER, WHITE A DOOR PANEL, LH OUTER, BLUE A DOOR PANEL, LH OUTER, RED A DOOR PANEL, LH OUTER, GRAY R/H INNER DOOR PANEL A L/H INNER DOOR PANEL CAB DOOR SEAL GLOVE TRAY, BLACK * DECAL, DOOR SILVER L & R (Used with blue) * DECAL, DOOR BLACK L & R (Used with red & white) * NOT SHOWN 2-5

23 DOOR WINDOW MECHANISM QUARTER GLASS DOOR SEAL DROP DOOR GLASS L/H WINDOW WINDER A R/H WINDOW WINDER WINDOW WINDER HANDLE (Includes clip) INTERIOR DOOR LOCK BUTTON L/H A INTERIOR DOOR LOCK BUTTON R/H INNER DOOR LOCK GROMMET L/H BARREL TO LOCK ROD A R/H BARREL TO LOCK ROD DOOR LOCK ROD, SHORT L/H A DOOR LOCK ROD, SHORT R/H DOOR LOCK ROD, LONG COMPLETE DOORS * ** DOOR ASSEMBLY, COMPLETE LH RED * ** DOOR ASSEMBLY, COMPLETE RH RED * ** DOOR ASSEMBLY, COMPLETE LH BLUE * ** DOOR ASSEMBLY, COMPLETE RH BLUE * ** DOOR ASSEMBLY, COMPLETE LH WHITE * ** DOOR ASSEMBLY, COMPLETE RH WHITE * NOT SHOWN ** SPECIAL ORDER 2-6

24 DOOR LOCK MECHANISM MOUNTING BRACKET R/H A MOUNTING BRACKET L/H PLATE INNER DOOR HANDLE CHECK LINK DOOR HINGE SHIM CAB DOOR HINGE FIXED. RIGHT A CAB DOOR HINGE FIXED. LEFT PLATE, INNER CAB HANDLE MOUNTING PLATE, DOOR L/H A PLATE, DOOR R/H KEY BARREL FIXING CLIP SLEEVE L/H OUTER DOOR HANDLE A R/H OUTER DOOR HANDLE SQUARE NUT, OUTER DOOR HANDLE L/H DOOR LOCK SUPPORT A R/H DOOR LOCK SUPPORT L/H DOOR LOCK A R/H DOOR LOCK SPACER.252 (ID) X.591 (OD) BRACKET STRIKER BOLT SPACER, REAR VIEW MIRROR SUPPORT

25 GLAZING WINDSHIELD TRIM SEAL WINDSHIELD. TINTED CAB DOOR DROP WINDOW TINTED DOOR QUARTER GLASS CAB REAR WINDOW, TINTED INTERIOR REAR VIEW MIRROR REAR VIEW MIRROR L/H REAR VIEW MIRROR R/H

26 FRONT/REAR BUMPERS - MEGA FRONT BUMPER BRACKET. FRONT BUMPER B BOLT, 5/16-18X2 CARR. G BS BOLT, 5/16-18X1 CARR. G B WASHER, 5/16 USS/STD,F/W BLK MAX 8/ NUT, 5/16-18 L/N NYLOCK, NE,GA, BLK MAX REAR BUMPER SCREW, 5/16-18X1 HHC G8 YLW PLUG, 1.75 BLACK KNURLED INSERT 5/16-18 YWZC

27 MEGA PARTS MANUAL SECTION 3 ACCELERATOR AND BRAKES

28 ACCELERATOR AND BRAKE CLUSTER 3-1

29 ACCELERATOR AND BRAKE CLUSTER (Cont.) STEERING COLUMN SUPPORT LH BRAKE PEDAL LH BEARING, FLANGED.5X5/ WASHER, 1/4X1, FENDER SCREW, M6-20 CLS 10.9 HHC PAD, BRAKE PEDAL INSERT, M8X PLATE INSERT, ALS , 6X PEDAL ASSY, ACCELERATOR & HARNESS WASHER, 6MM SCREW, M6X25MM HHC * 7961 NUT, M6X1.0, NYLOCK WASHER, 8MM SCREW, M8, CLASS CLEVIS, #52 5/ MASTER CYL PUSH ROD NUT, 5/16-24 HEX JAM CLEVIS PIN, 5/16X W COTTER PIN, 1/8X STEERING COLUMN SUPPORT RH BRAKE PEDAL RH PEDAL PAD REPLACEMENT (Recommend gluing in place) * HARNESS, PAD ADAPTER * NOT SHOWN 3-2

30 HYDRAULIC BRAKES BLEED VALVE BRAKE PADS KIT L/H/F BRAKE CALIPER COMPLETE A R/H/F BRAKE CALIPER COMPLETE BRAKE PAD RETAINING PIN FRONT BRAKE DISC ANTI LOCK SPRING BRAKE SHOES (Must replace as a set of 4) SPRING, SHORT BRAKE SHOE RETURN SPRING BRAKE REAR R/H A BRAKE REAR L/H WHEEL CYLINDER SPRING R/H A SPRING L/H REAR BRAKE DRUM MASTER CYLINDER SPACER MASTER CYLINDER RESERVOIR BRAKE LIGHT SWITCH MASTER CYLINDER * SPECIAL ORDER 3-3

31 BRAKES LINES R/H FRONT BRAKE LINE L/H FRONT BRAKE LINE FRONT TO REAR BRAKE LINE * BOLT, BANJO, M10X * BOLT BANJO, M10X * WASHER, COPPER CRUSH, M10X14MMX2MM * SPECIAL ORDER 3-4

32 BRAKES - MECHANICAL HANDBRAKE LEVER HANDBRAKE LIGHT SWITCH SUPPORT PLATE HAND BRAKE WARNING LIGHT SWITCH HANDBRAKE CABLE HANDBRAKE LEVER RUBBER HAND BRAKE LEVER MOUNTING PLATE

33 MEGA PARTS MANUAL SECTION 4 STEERING AND SUSPENSION

34 WHEELS WHEEL/TIRE ASSEMBLY (TIRE NOT SHOWN) WHEEL NUT 19 MM LUG WRENCH VEHICLE JACK BOX, POLY HUB CAP SPARE TIRE RETAINER SPARE TIRE SECURING HOOK * TIRE, 145/70R * NOT SHOWN 4-1

35 FRONT AXLE FRONT SHOCK ABSORBER L/H HUB ASSEMBLY FRONT A R/H HUB ASSEMBLY FRONT FRONT WHEEL BEARING CIRCLIP BALL JOINT A-ARM RUBBER BUSHING DRIVE FLANGE * STUD, WHEEL, FRONT * NOT SHOWN 4-2

36 DRIVE SHAFT and REAR AXLE REAR TRAILING ARM REAR HUB 4 BOLT BEARING TWIN RACE B WASHER, FLANGE NUT WASHER 12MM RUBBER BUSHING, REAR TRAIL ARM SPACER WASHER, SHOULDER REAR SUSPENSION REAR SHOCK ABSORBER N/A CIRCLIP. DRIVESHAFT SPLINE (Included with Item 11) 2 N/A DRIVESHAFT R/H A DRIVESHAFT L/H * PLAIN WASHER 16MM DIA 2 N/A 13 * NUT 16X150 ( LOCKNUT) 2 N/A KIT CV BOOT, WHEEL SIDE A KIT CV BOOT, AXLE SIDE * OBTAIN LOCALLY 4-3

37 STEERING STEERING RACK BOOT RACK & PINION LHD A * RACK & PINION RHD TIE ROD END STEERING COLUMN ISOLATOR STEERING COLUMN, SEAL COVER INNER STEERING COLUMN SHAFT D WASHER EC IGNITION LOCK+4 BARRELS STEERING WHEEL (See Note) UPPER STEERING COLUMN STEERING WHEEL CENTER CAP IGNITION BARREL TRIM SPACER, STEERING RACK MOUNT ** * LOWER STEERING COLUMN COVER, RHD ** * STEERING COLUMN SEAL RHD * SPECIAL ORDER ** NOT SHOWN NOTE: Steering wheel and cap changed in 5/2015. Steering wheel used prior to 5/2015 must use a cap.

38 4-4

39 MEGA PARTS MANUAL SECTION 5 INTERIOR

40 HEATING SYSTEM - MEGA I SHROUD ELECTRIC HEATER FAN CAGE SCREEN HEATER HOSE * FOAM TAPE * 2531 SCREW, #10-5/8, PPH TAPPING * CABLE TIE * 2638 SCREW, #6X3/4, PPH T/S, TA * 2641 SCREW, #10X1, PPH, T/S, TA * HEATER KIT (Includes above Items) U * NOT SHOWN 5-1

41 SEATS and DASH - MEGA R/H SEAT L/H SEAT L/H ADJUSTABLE SEAT SLIDE A R/H ADJUSTABLE SEAT SLIDE R/H SEAT SLIDE FREE MOVING A L/H SEAT SLIDE FREE MOVING FASTENER, PUSHPNL FLOOR MAT DASH LH DRIVE A ** DASH RH DRIVE GLOVE BOX LID ** FASTENER, PUSHPNL GLOVE BOX CATCH CLIP DASHBOARD ATTACHMENT BRACKET, DASH MOUNT DASH STORAGE TRAY MULTIFUNCTIONAL DIGITAL INDICATOR * IGNITION, LOCK W/4 BARRELS * HAZARD WARNING SWITCH * NOT SHOWN ** SPECIAL ORDER 5-2

42 SEAT BELTS - MEGA SEAT BELT 3 PT BUCKLE KIT * SEAT BELT BUCKLE * N/A BLACK SCREW COVER 6 N/A 4* N/A WASHER, FLT STL N/A 5* N/A BOLT, HX HD 7/16-20X1.5 G5 (Bottom) 2 N/A 6* N/A BOLT, HX HD 7/16-20X1.5 G5 (Top) 2 N/A 7* N/A UPPER COVER 2 N/A 8* N/A SCREW, HX HD 7/16-20X1 G5 4 N/A * INCLUDED WITH ITEM 1 5-3

43 INSTRUMENTS - MEGA INSTRUMENT PANEL LIGHT SWITCH WINDSHIELD WIPER SWITCH SWITCH SUPPORT BRACKET STEERING COLUMN LOWER COVER STEERING COLUMN UPPER COVER IGNITION LOCK SHROUD HAZARD WARNING SWITCH V POWER OUTLET INTERIOR LIGHT HOUSING DOOR CONTACT SWITCH * SEAL, DOME LIGHT INTERIOR LAMP V POWER OUTLET HARNESS * TERMINAL, #10 STUD TO 1/4 MALE TAB * 2646 SCREW, #6-32X5/8 PPHMS * 7592 NUT, #6-32 GR A, NM MACH, NYLON * NOT SHOWN 5-4

44 WINDSHIELD WIPER, HORN & SUNVISOR - MEGA WIPER BLADE WIPER ARM LEFT HAND DRIVE A * WIPER ARM RIGHT HAND DRIVE WIPER MOTOR LEFT HAND DRIVE A * WIPER MOTOR RIGHT HAND DRIVE FLUID RESERVOIR 2 QT HOSE, WINDSHIELD WASHER ** * TANK MOUNTING BRACKET A HORN 12V SUNVISOR ** 8689 RIVET N/A KIT, SUNVISOR (Includes Items 7 & 8) U * SPECIAL ORDER ** NOT SHOWN 5-5

45 INTERIOR DOME LIGHT - MEGA LAMP HOUSING LAMP ASSEMBLY DOOR CONTACT SWITCH * 8675-B RIVET, #610X3/16 AL, DH, L-FLG * ** MOLDING, BLACK, KIT, DOME LIGHT (Includes above items) U * NOT SHOWN ** SPECIAL ORDER 5-6

46 MEGA PARTS MANUAL SECTION 6 OPTIONS

47 TAILGATE TAILGATE OUTER PANEL TAILGATE MAIN FRAME TAILGATE INNER PANEL, CARGO A TAILGATE INNER PANEL, TILT BED B TAILGATE INNER PANEL, DROP SIDE TAILGATE LOWER HINGE REAR DOOR SEAL TAILGATE SUPPORT CABLE TAILGATE LOCK PIN BRACKET TAILGATE CONICAL LOCK PIN TAILGATE RELEASE LEVER BRACKET TAILGATE LOCK OPERATING PLATE DROP SIDE TAILGATE KEY BARREL PLATE TAILGATE LOCK BARREL AND HANDLE LICENSE PLATE LIGHT BRACKET DECAL, TAILGATE WARNING * SPECIAL ORDER 6-1

48 VAN SIDE ROLLER DOOR 1 * SIDE ROLLER DOOR 1 * ROLLER SHUTTER DOOR HANDLE * FRAME KIT, SIDE ROLLER DOOR 1 * 4 * VERTICAL GUIDE RAIL KIT 2 * 5 * GUIDE CORNER. L/H SIDE ROLLER DOOR 1 * 5A * GUIDE CORNER. R/H SIDE ROLLER DOOR 1 * 6 * HORIZONTAL GUIDE RAIL KIT 2 * 7 * SIDE ROLLER DOOR TRIM R/H 1 * 7A * SIDE ROLLER DOOR TRIM L/H 1 * 8 * KEY BARREL PLATE. SIDE 1 * 9 * SIDE ROLLER DOOR LOCK COVER 1 * 10** LOCK OPERATING PLATE KEY BARREL FIXING CLIP IGNITION LOCK, 4 BARRELS (Lock cylinders not sold as separate units.) ROLLER DOOR LOCK RETURN SPRING * No longer available ** Limited quantities NOTE: Fiberglass van is being replaced with a aluminum van. See page

49 VAN SIDES CAB TO VAN BODY JOINT * ATTACHMENT BRACKET 2 * 3 * ATTACH CELL POLYESTER 4 * 4 * REAR ARCH 1 * 5 * L/H VAN SIDE 1 * 6 * REAR CAP, VAN 1 * 7 * R/H VAN SIDE 1 * 8** R/H REAR DOOR GLASS TINTED * L/H PRECUT DOOR 1 * 10 * UPPER BRACKET 1 * 11** L/H REAR DOOR GLASS TINTED * R/H PRECUT DOOR 1 * REAR DOOR SEAL, VAN R/H OUTER DOOR HANDLE DOOR SEAL KEY BARREL FIXING CLIP ** SECOND DOOR CATCH ** HINGE * HINGE SUPPORT PLATE 4 * LICENSE PLATE LIGHT (NEV ONLY) DOOR STOP IGNITION LOCK, 4 BARRELS DOOR PLATE L/H * No longer available. ** Limited Quantities NOTE: Fiberglass van is being replaced with a aluminum van. See page

50 VAN DOORS 6-4

51 VAN DOORS (Cont.) 1 * R/H PRECUT DOOR 1 * 2** SECOND DOOR CATCH REAR DOOR SEAL, VAN L/H PRECUT DOOR LICENSE PLATE LIGHT (NEV ONLY) DOOR LOCK STRIKER PIN IGNITION LOCK, 4 BARRELS * NUT 1 * 9** REAR WINDOW, TINTED L/H ** REAR WINDOW, TINTED R/H R/H OUTER DOOR HANDLE L/H DOOR LOCK DOOR PLATE L/H DOOR LOCK ROD, SHORT L/H SLEEVE KEY BARREL FIXING CLIP L/H LOCK ROD * TAILGATE KEY BARREL PLATE 1 * 19 * LOCK COVER 1 * INTERIOR DOOR LOCK BUTTON R/H DOOR LOCK BUTTON GROMMET * No longer available. ** Limited Quantities NOTE: Fiberglass van is being replaced with a aluminum van. See page

52 DROPSIDE BODY CPC P/N DESCRIPTION QTY SEATS P/N DECK, FRONT DECK, REAR SUPPORT, MID DROPSIDE END PANEL DROPSIDE SIDE PANEL REAR FLOOR SUPPORT HINGE HINGE MOUNTING PLATE, REAR HINGE MOUNTING PLATE SECURING PLATE LOCK, LEFT INNER PROFILE (Used with Item 4) LOCK, RIGHT INNER PROFILE (Used with Item 4) LOCK, DROPSIDE, RIGHT (Used with Item 5) LOCK, DROPSIDE, LEFT (Used with Item 5) SCREW, M8-1.25X25MM (Used with Item 7) WASHER, 8MM, F/W ZC (Used with Item 7) NUT, M8-1.25, L/N NYLOCK, ZC (Used with Item 7) SCREW, M6X35MM CARR ZC (Used with Items 8 & 9) WASHER, 6MM, F/W ZC (Used with Items 8 & NUT, M6-1.0, L/N NYLOCK, ZC (Used with Items 8 & 9) * NOT SHOWN SPECIAL ORDER 6-6

53 TIPPER BODY PLATE BODY LANDING RUBBER SUPPORT TIPPER KIT LOWER FRAME MOUNT REMOTE CONTROL

54 REAR DECK BOARDS REAR TRAY, ELECTRIC ANGLE SUPPORT, DECK, FRONT SUPPORT, LONG, DECK SUPPORT, SHORT, DECK BOARD, DECK, FORWARD BOARD, DECK, REAR BOARD, DIVIDER BRACKET, DIVIDER BOARD REAR SUPPORT BAR

55 REFUSE BODY ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 A_TRADUIRE:SUPPORT PLAQUE 1 7 SIDE DOOR 1 2 SHAFT 2 8 KNOB 2 3 SHAFT 2 9 LEVER 2 4 ABUTMENT 1 10 LEVER MOUNTING PLATE 2 5 HINGE STOP 2 NOTE: ALL PARTS ARE SPECIAL ORDER CONTACT CPC FOR ASSISTANCE 6-9

56 REFUSE DUMP MECHANISM ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 ABUTMENT 2 11 DOUBLE ACTION RAM 2 2 CHASSIS BRACKET 4 12 CONNECTOR 4 3 PLATE 4 13 HYDRAULIC CONNECTOR 4 4 SLEEVE 8 14 SHAFT 2 5 ELECTRICALLY OPERATED VALVE 1 15 FIXING 1 6 SUB CHASSIS ASSY 1 16 HYDRAULIC VALVE BLOCK 1 7 LAMP 1 17 STAY BAR 1 8 HYDRAULIC CONNECTOR 2 18 HYDRAULIC PUMP 1 9 BANJO BOLT 2 19 PUMP PROTECTION COVER 1 10 VALVE 2 NOTE: ALL PARTS ARE SPECIAL ORDER CONTACT CPC FOR ASSISTANCE 6-10

57 VAN ENCLOSURE -MEGA 1* FOAM TAPE 1/8T X 1W * 3454-BS SCREW, 1/4-20X 1 3/4 HHCS G * 6703-B WASHER 1/ * 7686 NUT, 1/4-20 NYLOCK, GA ** ENCLOSURE, COMPLETE, WHITE * NOT SHOWN ** SPECIAL ORDER 6-11

58 DROPSIDE HVAC - MEGA 6-12

59 DROPSIDE HVAC - MEGA (Cont.) 6-13

60 DROPSIDE HVAC - MEGA (Cont.) 6-14

61 DROPSIDE HVAC - MEGA (Cont.) LICENSE LIGHT END PANEL DROPSIDE PLATE, HINGE MOUNT, HINGE MOUNTING PLATE, REAR * REAR TRAY SUPPORT BAR ** DECK, FRONT ** DECK, REAR ** SUPPORT, MID, DECK ** TRAY, REAR ** TAILGATE ** BRKT, CPRSR/COND ASSY, LH ** BRKT, CPRSR/COND ASSY, RH ** PANEL, DUCT, LH ** PANEL, DUCT, RH ** AIR INLET SCREEN ** NUT,M8-1.25,L/N,NYLOCK,ZC LOCK NUT, M6 x SCREW, 10-24X1/2PHILLIPS,BLK ZNC SCREW, X 5/8 PHILLIPS PHM W SCREW, 5/16-18 X 1-1/4, HHCS, G5, YWZC ID X 1.63 OD X.06 STL FW SCREW, M6 X 20 CLS10.9, HHCS ZC * 6703-B WASHER, 1/4, SAE,F/W,BLK MAX WASHER, #10, SAE,F/W,BLK MAX NUT GR A NM MACH NYLON LOCK KNURLED INSERT, 5/16-18 YWZC B RIVET, #68 X 3/6, ABA, LF, BLK ANNODIZED TAIL LIGHT TAILIGHT HOUSING HINGE, PANEL PLATE, REAR FLOOR SUPPORT PLATE, BODY SECURING ** SCREW, 5/16-12 X 1, HWH, T/S, ZC WASHER, 8MM,F/W,ZC WASHER, 6MM,F/W,ZC ** SCREW, M6-1.0 X 35MM, CARR, C8.8, ZC ** SCREW, M X 25MM, FSHCS, ZC WASHER, 3/16X3/4 FENDER ** WASHER, 3/16 X 3/4, FENDER, ZC ** WASHER x x 0.062, ZC SCREW, 5/16-18X3/4,TSL,M/S,18-8,S/S KNRL INSERT 5/16-18 RNG * NOT SHOWN ** SPECIAL ORDER 6-15

62 HVAC MEGA 1** MACH, MEGA HEATER AIR HOSE ** * PLATE, DASH VENT, HVAC ** * BRACKET, HTR/EVAP ASSY ** * HOSE, DASH VENT, HVAC ** SCREW, 1/4-14X1 HWH TEK ZC LOCK NUT, M6 x ** CABLE TIE, BLACK,.18 X 11-3/4, STD, 50LB ** 2638 SCREW,#6X3/4,PPH, TAP SCREW, M6X20 CLS10.9, HHCS ZC ** 7266 WASHER, 1/4 X 1", FENDER, BLK ZC ** 9906 TERMINAL,16/14 INS, 1/4 MALE TAB ** CAGE, FAN WINDSCREEN * KIT, HVAC ** * CONTACT, DEUTSCH, ** * RECEPTACLE, DEUTSCH, DTP04-2P ** * WEDGE LOCK, DEUTSCH, WP-2P WASHER,6MM,F/W,ZC ** * SCREW, 1/4-14X1 1/4 HWH TEK ZC * SPECIAL ORDER ** NOT SHOWN 6-16