2011 Parts Manual. SCOUT Electric PS10E. Find replacement parts for your cart faster at CartPros.com

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1 2011 Parts Manual SCOUT Electric PS10E 2013

2 PREFACE Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your vehicle has been designed and manufactured to conform to applicable sections of ANSI B56.8. Your safe use and operation of your vehicle is important to us. Any alteration of your Columbia vehicle that results in the vehicle being in noncompliance with applicable ANSI standards is strictly prohibited. Columbia ParCar Corp. is not responsible or liable for any damage that results from any such alteration, and all warranties for any such altered vehicles are null and void. These vehicles are not designed for over-the-road use. They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations, and are not equipped for operation on public streets, roads, or highways. 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 ParCar 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 A member of the Nordic Group of Companies 1115 Commercial Avenue, Reedsburg, WI Phone Fax i

3 INDEX SECTION 1 Accelerator and Brake Linkage Accelerator Assembly Mechanical Brakes Mechanical Brake Pedal Assembly w/ Lights Mechanical Brake Pedal Assembly w/o Lights Mechanical Brake Pedal Rod Attachment Parking Brake Catch SECTION 2 Steering and Front Suspension Front Wheel Assembly Front Suspension Steering Column Rack & Pinion Assembly SECTION 3 Rear Suspension, Motor and Axles Rear Suspension and Motor Axle Gear Set Axle Brace Kit Mechanical Brake Assembly Motor, Sep Ex SECTION 4 Body, Seating and Console Instrumentation Body Bucket Seats Bucket Seats Body Bench Seats Console Dash Front Hood and Cover Front Wraparound Bumper & Receiver Rear Bumpers Rear Bumper with Receiver Seat Belts Bench Seat Belts Bucket Steel Deck Wheels SECTION 5 Electrical System Main Wire Harness Main Wire Harness Schematic V Electrical Accessory Supply DC/DC Converter Wiring V Electrical Accessory DC-DC Converter Schematic V Accessory Schematic Back-Up Lights Harness Schematic with DC-DC Converter Back-Up Lights Harness Schematic Ace Control Panel Components Charger & Battery Delta Q Charger with Remote LED Pot Box Adapter Harness

4 SECTION 6 Accessories Cargo Steel Sides Folding Steel Sides Poly Cargo Dump Box Battery Watering System Enclosure Amber Strobe Light Cab/Suntop Amber Strobe Light w/mast Mirrors Windshields Windshield Wiper Raindrain Suntop, Bench Raindrain Suntop, Bucket Suntop, Bench Suntop, Bucket Suntop Handle Front Rack Rear Facing Seat & Footrest Cargo Rear Facing Seat Rear Facing Seat Cushions Cab Dome Light Can Fan Heater Poly Cargo Dump Box CHANGE HISTORY S10 DATE DESCRIPTION BY 9/29/11 Issued TS 10/23/13 Updated accessory harness & wheel information TS 10/28/13 Added side panels to console TS 5/6/14 Added note that windshields cannot ship UPS. TS 7/17/14 Deleted 1008 seats TS 2/10/15 Changed heater information TS iv

5 Scout Parts Manual Section 1 Accelerator and Brake Linkage

6 ACCELERATOR ASSEMBLY- MECHANICAL BRAKES SCOUT

7 ACCELERATOR ASSEMBLY- MECHANICAL BRAKES SCOUT Cont PEDAL ACCELERATOR ACCELERATOR PEDAL PAD SPEEDNUT 1/ BUSHING PLASTIC (Both sides) N/A ACCELERATOR PEDAL ASSY (Includes Items 1 thru 4) LINK ASSEMBLY PIN, ROLL.133X3/ A SHAFT, KICKOFF BUSHING, KICKOFF SHAFT W PIN, COTTER 1/8X A LINK W WASHER, STEEL CLEVIS PIN 5/16X7/ CLEVIS PIN 1/4X3 1/ WASHER # PALNUT, 1/ CAP, BLACK VINYL B NUT, 1/4-20, L/N SER-FLG EYEBOLT, 1/4-20X1, TURNED SPRING, EXTENSION 8.2 LBS/IN MOUNTING BRACKET SEVCON LINEAR ACCEL M CLEVIS YOKE SCREW, 10-24X3/ WASHER # NUT 10-24, NYLOCK N/A SEVCON LAD ASSEMBLY (Includes Item 20 and two (2) each Items 21 thru 25) SPACER, BRASS A CABLE, SPEED SWITCH LAD, W/ANTIFREEZE SCREW, 1/4-20X1 HHC NUT, 1/4-20 NYLOCK

8 MECHANICAL BRAKE PEDAL ASSEMBLY W/LIGHTS SCOUT

9 MECHANICAL BRAKE PEDAL ASSEMBLY W/LIGHTS SCOUT Cont PARKING BRAKE PEDAL BRAKE PEDAL TAPESWITCH BRAKE LIGHT A BRAKE PAD N/A PARKING BRAKE CATCH (See page 1-8 for components) A BRAKE TUBE BUSHING RETURN SPRING PEDAL PAD GREASE FITTING SCREW, 8-32X1, PFH SCREW, 5/8X.25 SHR PIN, CLEVIS, 3/16X PIN, 1/4X1 1/ COTTER PIN, 1/16X3/ COTTER PIN, 5/64X ROLLED PIN,.25X B WASHER, 1/ WASHER, # B WASHER # B LOCK WASHER # A CLEVIS YOKE, 1/4-28 RH W NUT, NYLOCK # W NUT, NYLOCK, 3/8X SPEED NUT 1/

10 MECHANICAL BRAKE PEDAL ASSEMBLY W/O LIGHTS SCOUT

11 MECHANICAL BRAKE PEDAL ASSEMBLY W/O LIGHTS SCOUT Cont PARKING BRAKE PEDAL BRAKE PEDAL N/A PARKING BRAKE CATCH (See page 1-23 for components) A BRAKE TUBE BUSHING STOP PAD RETURN SPRING PEDAL PAD GREASE FITTING SCREW, 5/8X.25 SHR PIN, CLEVIS, 3/16X PIN, 1/4X1 1/ COTTER PIN, 1/16X3/ COTTER PIN, 5/64X ROLLED PIN,.25X B WASHER, 1/ WASHER, # A CLEVIS YOKE, 1/4-28 RH W NUT, NYLOCK, 3/8X SPEED NUT 1/

12 MECHANICAL BRAKE PEDAL ROD ATTACHMENT SCOUT A YOKE, CLEVIS RH SPRING EXTENSION NUT, 1/4-28 HHC ROD, EQUALIZER PL B WASHER 1/ NUT, 1/4-28, NYLOCK

13 PARKING BRAKE CATCH SCOUT CLEVIS CLEVIS W/O THREADS SPRING ROD RATCHET BUSHING, NYLON PIN, 3/16X3/4, CLEVIS * 515 PIN, 1/6X3/4 COTTER WASHER, # NUT, #10-32 HEX

14 Scout Parts Manual Section 2 Steering and Front Suspension

15 FRONT WHEEL ASSEMBLY - SCOUT * N/A HUB, 4.90 FLNG (Only available as Item 6) * BEARING SET, TPRD, 15.26MM T, OUTER * BEARING SET, TPRD, 15MM T, INNER * OIL SEAL * WHEEL BOLT, 1/2-20X1 1/2 G HUB DISC ASSEMBLY, 4.90 OD (Includes Items 1 5)) CAP, CHROME CENTER, 13" WHEEL B WASHER, 9/16", FLT STL STD B NUT, 5/8-18 SLOTTED HEX, GR 2 (See NOTE) W PIN, COTTER 1/8 X HUB GREASE CAP NUT, 1/2-20, LUG (Torque to 65 ft. lbs. against wheel.) * NOT SHOWN NOTE: Tighten until resistance is felt when turning wheel hub to preload bearing then back off until cotter pin can be inserted 2-1

16 FRONT SUSPENSION - SCOUT NOTES: 1. Assemble all hardware finger tight. torque to the following specs after complete assembly. 2. Torque Specifications: Item 36 to 25 ft. lbs. after final camber adjustment Item 20 to 40 ft. lbs. Item 31 to 30 ft. lbs. Item 18 to ft. lbs. Items 16 & 17 to 45 ft. lbs. Item 11 to 25 ft. lbs 13 Camber adjuster (item 13) shown in start position. Torque to 25 ft. lbs. after final camber adjustment. 2-2

17 FRONT SUSPENSION - SCOUT Cont. NOTES: Assemble all hardware finger tight except Items 19 & 34. Torque these to 30 ft. lbs as assembling. After all components are assembled torque Item 32 to 45 ft lbs. 2-3

18 FRONT SUSPENSION - SCOUT Cont. 2-4

19 FRONT SUSPENSION - SCOUT Cont KINGPIN, SCOUT LIFT SCOUT FRONT LIFT BLOCK SCOUT LIFT SHOCK MOUNT A-ARM ASSEMBLY * BUSHING.75 ID SINTERED (Included w/item 4) * BUSHING.75 ID BRONZE (Included w/item 4) ASSY, LIFTED LH STEERING ARM * BUSHING.75 ID SINTERED (Included w/item 5) ASSY, LIFTED RH STEERING ARM * BUSHING.75 ID SINTERED (Included w/item 5) SPACER, RACK AND PINION MOUNT PLATE RETAINER CPC A-ARM MOUNTING BRACKET SPACER ID X OD X PL SCREW, 5/16-18 X 1 HH CAP, GRD-8, YLW SHOCK ABSORBER CAMBER ADJUSTER, SINTERED METAL RACK & PINION ASSEMBLY (See Page 2-8) A SPRING, 4-LEAF A SPRING, 4-LEAF HD * BUSHING SPRING EYE (Included w/item 15) SCREW, 1/2-13 X 3 GRD 5 HHC SCREW 1/2-13 X 2-1/4 HEX CAP SCREW, 3/8-24 X 3 GRD 5 HHC /8-16 x 2 HHCS SCR, HX HD 7/16-20 X 3.5 G SPACER,.750/.747 X 5.92/ SPACER,.750/.747 X W PIN, COTTER 1/8 X 1 YELLOW/ZINC WASHER 7/16 STD W WASHER FLT STL YWZC.390 X.910 X B WASHER -3/8" REG SPRG, LOCK, BLK ZC LOCKNUT, 5/16-18 HEX FLG WHIZ NUT, 1/2-13 A NTE NYLON LOCK NUT, 3/8-24 GR A NE NYLON INS LOCK NUT, 7/16-20, LOCK, GA, NE, NYLON INSERT NUT 7/16-20 GR 5 SLOTTED HEX BLK ZC SCREW, 3/8-16 X 2, CARR., G NUT,3/8-16,L/N,GB,YWZC SCREW, 3/8-16 X 1.25, CARR., G * 5714 WASHER,.760X1.25X.010 F/W 18-8SS A* 5715 WASHER,.760X1.25X.020 F/W 18-8SS A SCREW, 3/8-24 X 9, HHCS, GR A WASHER,.406 X X.134, FLAT * P&A KIT, 9" A-ARM BOLT (Includes Items 10, 25, 35-37) U * USE 5714 AND/OR 5715 AS REQUIRED TO ACHIEVE SNUG FIT 2-5

20 STEERING COLUMN - SCOUT 2-6

21 STEERING COLUMN SCOUT Cont BS SCREW, HEX HEAD CAP 5/16-18X3/4 G B WASHER FLT STL 5/16 BLK MAXCOAT BALL BEARING,.75 ID NUT 5/16-18 GR A SERRATED FLNG LOCK STEERING SHAFT ASSY, " OAL SCR, 5/16-18 X 1-3/4 HHCS, G8, ZC NUT, 5/16-18, NYLOK, G8, YWZC BUSHING 3/4 X 1-1/2 X 14GA WIDE RIM YWZ SCREW, #6X3/4, PPH (Used with Item 11) N/A STEERING WHEEL ASSY (Includes Items 8, 9, 10, & 11) STEERING WHEEL, SPORT STEERING HUB COVER (Used with Item 10) SCREW, #10 X 1, PPH, TAPPING, T-A BLACK NUT, 5/16-18 GR A NTE NYLON JAM INSERT SCORECARD HOLDER STEERING COLUMN YOKE ASSEMBLY, BOLT-WELD ROLL PIN 1/4X1 3/ N/A INTERMEDIATE SHAFT 1 N/A YOKE ASSEMBLY, WELD-WELD NOTE: If replacing only the splined yoke see Service Bulletin SB

22 RACK & PINION ASSEMBLY SCOUT ROD END NUT, M14 X 1.5, JAM - TIE ROD BOOT, STEERING N/A CLAMP, STEERING BOOT 2 N/A SEAL, OIL- PINION RING, RETAINING - PINION RING, RETAINING BEARING BALL - PINION PINION STEERING GEAR BUSHING PINION BALL JOINT, TIE ROD LOCK WASHER, STEERING WASHER, STEERING STOP BUSHING RACK HOUSING, RACK & PINION RACK STEERING GEAR O-RING, #22 1 X 1-1/8 X 1/16 BUNA PLUG 1" 12 PRONG HOLE ZNC/CLEAR RACK & PINION ASM (Includes Items 1-18) * BALL JOINT REPLACEMENT KIT (Includes Items 1, 3, 7, 11 13) SEE NOTE * NOTE: Kit services one side. Item 4 is replaced with a cable tie, P/N U 2-8

23 Scout Parts Manual Section 3 Rear Suspension, Motor and Axles

24 REAR SUSPENSION, AXLE AND MOTOR - SCOUT

25 REAR SUSPENSION, AXLE AND MOTOR - SCOUT Cont. A C B Loosely tighten screws (Item # 20) A & B. Loosely tighten screw C to draw face of motor up to flange on axle evenly. Torque A & B to 100 ft. lbs. then torque C to 100 ft. lbs. 3-2

26 REAR SUSPENSION, AXLE AND MOTOR - SCOUT Cont

27 REAR SUSPENSION, AXLE AND MOTOR SCOUT Cont. ITEM CPC P/N DESCRIPTION QTY SEATSI P/N REAR FORK, P4E * ASSEMBLY, SHORT ACE+ PANEL WHEEL SPACER (See NOTE) PL LIFT BLOCK REAR SHOCK ABSORBER BUSHING, REAR FORK SPRING, REAR COIL, HD RESILIENT BUMPER-ELEC MOTOR A AXLE, ELECTRIC, MECHANICAL BRAKES 12: A A AXLE, ELECTRIC, MECHANICAL BRAKES 14: B A AXLE, ELECTRIC, MECHANICAL BRAKES 16: MOTOR, ELEC 48V SEP EX, STD DUTY NUT, 3/8-16 NYLOCK SCREW,1/4-20X1 1/4 HHC G NUT, 3/8-24, NYLOC, GR A SCREW, 1/2-13 X 2 1/4, HHCS (Torque to 45 ft. lbs.) SCREW, 1/2-20 X 4 1/2, HHCS, GR 5 (Torque to 45 ft. lbs.) NUT, 5/16-18 NYLOCK GA W SCREW, 3/8-24 X 3 1/4, HHCS, GR 5 (Torque to 35 ft.lbs.) W SCREW, 3/8-16 X 1 1/4, HHCS, GR 5 (Torque to 35 ft.lbs. See Note) U-BOLT, 5/16-18X2 11/16X2X B WASHER, 5/ B WASHER,.515 X.812 X.134, FLT STL B WASHER, 1/4, SAE FLT STL B WASHER, 1/4, REGULAR SPRING LOCK NUT, 1/2-13, NTE NYLOC, GR A * SPECIAL ORDER NOTE: REQUIRED WITH STANDARD DUTY AXLE AND 12 OR GREATER WHEELS 3-4

28 AXLE - SCOUT 3-5

29 AXLE - SCOUT Cont. 1 N/A HOUSING, AXLE 1 N/A 2 N/A BOLT, DIFFERENTIAL CAP (Included with Item 1) 4 N/A 3 N/A SHAFT, INPUT (See gear set info) 1 N/A RING, SNAP O-RING A BEARING, BALL BEARING, BALL N/A PLUG, END CAP 2 N/A BEARING, BALL N/A SHAFT, INTERMEDIATE GEAR 1 N/A O-RING N/A GEAR, FINAL DRIVE (See gear set info) 1 N/A BEARING, BALL DIFFERENTIAL ASSEMBLY N/A SCREW, CAP 4 N/A 16 N/A NUT, LOCK 4 N/A PLATE, COVER PLUG, DRAIN/FILL N/A SCREW, TAPPING 10 N/A VENT N/A SCREW, FLANGE HEAD LONG 4 N/A 22 N/A SCREW, FLANGE HEAD SHORT 4 N/A NUT, LOCK N/A SPACER BRACKET 2 N/A 25* BRACKET, BRAKE CABLE (MECHANICAL BRAKES) BRACKET, BRAKE CABLE (HYDRAULIC BRAKES) * BRACKET, BRAKE CABLE (MECHANICAL BRAKES) BRACKET, BRAKE CABLE (HYDRAULIC BRAKES) * B ASSEMBLY, BRAKE, LH (MECHANICAL BRAKES) ASSEMBLY, BRAKE, LH (HYDRAULIC BRAKES) ** B ASSEMBLY, BRAKE, RH (MECHANICAL BRAKES) ASSEMBLY, BRAKE, RH (HYDRAULIC BRAKES) SHAFT, AXLE, LH (LONG) SHAFT, AXLE, RH (SHORT) PIN, COTTER SEAL, OIL RING, RETAINING BEARING, BALL N/A ASSEMBLY, HUB, WHEEL (Includes Item 36 & 47 See Item 44) 2 N/A BOLT, WHEEL (1.680" LONG) N/A DRUM, BRAKE (See Item 44) 2 N/A 38 N/A NUT, LOCKING 5/8-18 HEX FLANGE 2 N/A 3-6

30 AXLE - SCOUT Cont. 39 N/A SEALANT, ANAEROBIC A/R N/A 40* N/A KIT, INPUT GEAR (Includes Items 3-7 & 45 see gear info) 1 N/A 41* N/A KIT, GEAR (Includes Items 3, 10 & 12 see gear info) 1 N/A 42* N/A KIT, BEARING (Includes Items 6, 7, 9 & 13) 1 N/A 43* N/A KIT, COVER PLATE (Includes Items 17 & 18) 1 N/A 44* KIT, HUB/DRUM (Includes Items 35 & 37) OIL SEAL INPUT SHAFT * A KIT, INPUT BEARING & O-RING (Includes Items 4-7 & 45 see gear info) U 47* N/A HUB (See Item 44) 2 N/A * Special Order ** Not Shown AXLE DESCRIPTIONS SCOUT 3-7

31 GEAR SET - SCOUT 3-8

32 AXLE BRACE KIT - SCOUT NOTE: Only available as a kit. P/N A. See Service Bulletin SB10-004A. ITEM DESCRIPTION QTY 1 BRACKET 2 2 STRAP 2 3 SCREW, 5/16-18X1 HHCS 8 4 U-BOLT, # WASHER, 5/16 USS/STD 18 6 NUT, 5/16-18 NYLOCK

33 MECHANICAL BRAKE ASSEMBLY - SCOUT (Left Hand Shown)

34 MECHANICAL BRAKE ASSEMBLY SCOUT Cont. ITEM CPC P/N DESCRIPTION QTY SI P/N B MECH. BRAKE ASSY, LH (Includes Items 2-19) A* B MECH. BRAKE ASSY, RH (Includes Items 2-19) N/A ADJUSTER, LH 1 N/A 2A* N/A ADJUSTER, RH 1 N/A 3 N/A PUSH ROD 1 N/A 4 N/A WASHER, FLAT 2 N/A 5 N/A SHIM A/R N/A 6 N/A LEVER, ACTUATOR 1 N/A 7 N/A PIN, PIVOT 1 N/A 8* N/A WASHER, WAVE, ACTUATOR PIVOT 1 N/A 9* N/A WASHER, FLAT, ACTUATOR PIVOT 1 N/A 10 N/A E-CLIP 1 N/A 11 N/A PROTECTOR BOOT 1 N/A 12 N/A SELF ADJUSTER, LH 1 N/A 12A* N/A SELF ADJUSTER, RH 1 N/A C SET, SHOE & LINING ASSEMBLY (2 Shoes) N/A SPRING, RETURN (See Item 20.) 1 N/A 15 N/A SPRING, SELF ADJUSTER (See Item 20.) 1 N/A 16 N/A SPRING, SHOE RETAINING (See Item 20.) 1 N/A 17 N/A SPRING CLIP, SHOE RETAINER (See Item 20.) 2 N/A 18 N/A PIN, SHOE RETAINING (See Item 20.) 2 N/A 19 N/A SHIELD, DUST 1 N/A 20* B KIT, SPRING (Includes Items 14-18) * B BRAKE CABLE ASSEMBLY * NOT SHOWN 3-11

35 MOTOR, SEP EX SCOUT 1 * HOLE PLUG 1 N/A 2 * COMMUTATOR END HEAD (Includes Fasteners) 1 N/A BEARING * RETAINING RING 1 N/A BRUSH ASSY. (Includes Fasteners) BRUSH BOX ASSY. (Includes Fasteners) * MOTOR FRAME 1 N/A 8 * POLE SHOE ASSY. (Includes Fasteners) 4 N/A 9 * SHUNT COIL ASSY. (Includes Fasteners) 1 N/A 10 * ARMATURE ASSY. 1 N/A N/A MOTOR, COMPLETE (INCLUDES ITEMS 1-10) * SPECIAL ORDER 3-12

36 Scout Parts Manual Section 4 Body, Seating and Console Instrumentation

37 BODY BUCKET SEATS - SCOUT SEAT BASE DETAIL ITEM

38 BODY BUCKET SEATS - SCOUT (Cont.) BODY S (Includes 10 treaded inserts Item 2) THREADED INSERT, 5/ SEAT SUPPORT SCREW, 5/16-18X2 1/4 HHC B WASHER 5/ ** SEAT BASE W/COVER (Includes Items 2 & 14-19) SCREW, 5/16-18X2 1/4 HHC G SEAT PIVOT LH EP 8A* SEAT PIVOT RH EP NUT 5/16-18 NYLOCK A HINGE BRACKET SCREW, 5/16-18X7/8 HHC G B WASHER, 5/16 R-SPLIT CHARGER CORD W/RECEPTACLE ZZ TRIM SEAL.06X.38X SEAT BASE HAND BRAKE COVER ZZ TAPE 3/4 FOAM DOUBLE SIDED BLK NYLON FASTENER B WASHER 1/ HEADER PANEL * NOT SHOWN ** SPECIAL ORDER 4-2

39 BUCKET SEATS SCOUT LH SEAT ASSEMBLY W/TRACKS %LA 2* RH SEAT ASSEMBLY W/TRACKS %RA 3* SEAT ASSEMBLY, NO ARMS W/TRACKS % ARM KIT, LH (Includes mounting bracket & hardware) BLU 5* ARM KIT, RH (Includes mounting bracket & hardware) BRU TRACK, NON-LOCKING TRACK, LOCKING * NOT SHOWN 4-3

40 BODY BENCH SEAT- SCOUT

41 BODY BENCH SEAT- SCOUT BODY (Includes 10 treaded inserts 5/16-18 P/N 8206) DECK STEEL SCREW 5/16-18X3/4 SS * FOAM TAPE AR PUSHNUT RETAINER ZZ FENDER TRIM ** SIDE TRIM EXTRU B SCREW, 10-16X3/4 HWH, TEK HANDRAIL * 5405-B SCREW 1/4-20X3/4 CARR G5 (To attach Item 9) * 6703-B WASHER 1/4 (To attach Item 9 & 13) * 7686 NUT 1/4-20 NYLOCK (To attach Item 9) PAINTED HEADER PANEL * 3787-B SCREW 1/4-20X3/4 HHCS (To attach Item 13) * 7724-B NUT 1/4-20 SERR FLANGE (To attach Item 13) SEAT BACK BLACK * CUSHION BACK (See Note) CUSHION, BOTTOM (See Note) SEAT TAB B WASHER 1/ B WASHER LOCK 1/ B SCREW, 1/4-20X3/ B WASHER 5/16 R-SPLIT A FRONT HINGE BRACKET SCREW, 5/16-18X7/ CHARGER CORD W/RECEPTACLE * NOT SHOWN ** SPECIAL ORDER NOTE: Include VIN to insure correct color. 4-5

42 CONSOLE SCOUT FRONT CONSOLE (Drilled, includes Items 2, 6 8, 14 16) NUT, JACK, 1/ B WASHER 5/16 FLT STL B WASHER 1/4, LOCK` SCREW, 1/4-20X1 1/4 PPH RIVET, BLIND 3/16 AL, BH # CUP HOLDER, DUAL STRAP, CUP HOLDER SIDE PANEL, LH (Attach using Items 11 & 12) * SIDE PANEL, RH (Attach using Items 11 & 12) B SCREW, #10-16X3/4, HWH, TEK WASHER, #10, SAE * 1787 SCREW, #14-15X3/4 PPH DECAL, DASH (Shown on Page 4-10) A GROMMET (Shown on Page 4-10) FRONT CONSOLE (not drilled) * NOT SHOWN

43 DASH SCOUT

44 DASH SCOUT (Cont.) BDI, 48V -VOLTMETER STYLE DASH OVERLAY SET -ELECTRIC VEHICLE DECAL, WARNING/OP INST SWITCH, TOGGLE, ON/OFF A GROMMET, 2775 EPDM, 3/16 GROOVE GROMMET, A2766S RUBBER PLATE, SWITCH RETAINER DIRECTIONAL KEYSWITCH POWER KEYSWITCH KEYSET, UNIV. 2 KEYS W/RING ASSY, KEY, NON-REMOVABLE, W/COVER A HOUR METER VOLT DC SYSTEM STATUS LIGHT ASM, HORN EXTRUSION * COLUMN COVER. (Included W/Item 14) * HORN SWITCH (Included W/Item 14) * 2612-B SCREW #8-322X1/2 (Included W/Item 14) * 7609-W NUT 8-32 (Included W/Item 14) * DECAL, HORN (Included W/Item 14) * HARNESS, HORN SWITCH (Included W/Item 14) * GLOVE BOX SET, BLACK * NOT SHOWN 3 POSITION POWERSWITCH 2 POSITION POWERSWITCH STANDARD KEYS KEYSET CPC P/N SI P/N CPC P/N SI P/N CPC P/N SI P/N A B B B B C C C C D D D D E E E E

45 FRONT HOOD AND COVER - SCOUT FRONT HOOD FRONT COVER, BUMPER A FRONT COVER, BUMPER DELUXE W SCREW, 1/4-20X1, HHC B SCREW, 10-16X3/ B WASHER, 1/ B WASHER, # NUT, 1/4-20 NYLOCK NUT, 1/2-13 HEX SPR. WASHER * A COLUMBIA DECAL * NOT SHOWN

46 FR0NT WRAPAROUND BUMPER & RECEIVER - SCOUT FRONT RECEIVER HITCH BUMPER, FRONT WRAPAROUND SCREW, 5/16-18X1, HHCS, G SCREW, 3/8-16X2 HHC G B WASHER, 5/16 USS/STD WASHER 3/ W WASHER,.391X1.125X.120 F/W NUT, 3/8-16 SERR FLANGE LOCK NUT, 5/16 GR A, SERRATED FLNG LOCK (3X) 4-10

47 REAR BUMPERS - SCOUT ALUMINUM - STEEL BUMPER - ALUMINUM A BUMPER - STEEL BUMPER SPACER BS SCREW 5/16-18X2 1/2 CARR B WASHER, 5/16, USS/STD NUT, 5/16 NYLOCK * 5460 SCREW, 5/16-18X1 1/4, HHC * BODY MOUNTING BRACKET * NOT SHOWN DURO BUMPER MZ DURO BUMPER * 3787-B SCREW, 1/4-20X3/ * 6703-B WASHER 1/ * 7036-B WASHER LOCK 1/ N/A REAR DURO BUMPER KIT (Includes Items 6 9) u * NOT SHOWN USED TO ATTACH ITEM 6 TO ITEM

48 REAR BUMPER WITH RECEIVER - SCOUT HD BUMPER UTIL-S W SCREW, 5/16-18X1 1/4, CARR, G B WASHER, 5/16, USS/STD NUT, 5/16 NYLOCK HOLE PLUG 1 3/4 BLACK N/A KIT, UTIL-S REAR BUMPER W/RECEIVER U * NOT SHOWN 4-12

49 BENCH SEAT BELTS SCOUT 1 * SEATBELT BRACKET SEATBELT BRACKET SCREW, HHC, 7/16-18X7/8 G SCREW, HX HD, 7/16-20X1.5 G WASHER FLT STL 3/8 STD B WASHER FLT STL 5/ NUT 5/16-18 NE NYLON INSERT NUT 7/16-20 LOCK NYLON INSERT SEAT BELT, SEAT BELT, ATS BUCKLE ONLY, 6 STRAP * SPECIAL ORDER 4-13

50 SEATBELTS BUCKET SEATS- SCOUT SEATBELT BRACKET SCREW, 5/16-18X7/8 HHC G SCREW, 7/16-20X1.5 HX HD G WASHER FLAT STL 3/ B WASHER FLAT STL 5/ NUT, 5/16-18 NYLOCK NUT, 7/16-20 NYLOCK SEAT BELT 48 BLK 1.3 MOUNT ATS BUCKLE W/OFFSET STRAP SEAT BELT

51 STEEL DECK - SCOUT DECK NUT, 5/16 PUSHNUT FOAM TAPE SCREW 5/16-18X3/5 S/S WHEELS - SCOUT TIRE/WHL ASSY RH AGGRESSIVE 22X TIRE/WHL ASSY LH AGGRESSIVE 22X TIRE/WHL ASSY, 22X LIFTED TURF LUG NUT, 1/2-20 TAPERED WHEEL (Used with above Items ) * KIT, REAR WHEEL SPACER, (See NOTE) U * NOT SHOWN NOTE: Kit contains spacers (P/N PL & ), lug nuts for both rear wheels. Used with Item

52 Scout Parts Manual Section 5 Electrical Systems

53 MAIN WIRE HARNESS SCOUT P/N

54 MAIN WIRE HARNESS SCHEMATIC SCOUT P/N BDI METER, 48V A HOUR METER SPEED SWITCH, TOGGLE DIRECTION SWITCH LIGHT, LED, GREEN KEYSWITCH ACCELERATOR, LINEAR CHARGER DELTA Q (See Page 5-13) FUSE AMP A CONTROLLER, SEVCON REGEN HP, SEPEX 24/-48 (Programmed ) A ALARM, AUDIBLE RESISTOR, ASSEMBLY A CONTACTOR W/ MTG BRKT - 24 V (SW80) MAIN HARNESS (See Note) NOTE: For use with vehcles with a pot box, an adapter is required. See page

55 12V ELECTRICAL ACCESSORY WIRING SCOUT P/N

56 DC/DC CONVERTER WIRING - SCOUT

57 12V ELECTRICAL ACCESSORY - SCOUT IITEM HEADLIGHTS, GLASS (PAIR, RECTANGULAR) ASSY, FRONT TURN LIGHT SWITCH, TOGGLE LIGHT, DASH SIGNAL INDICATOR FLASHER ASSY, TURN SWITCH W/GROMMET ALARM, AUDIBLE FUSE, 15 AMP ATO/ATC LIGHT,4 TAIL LAMP ASSY W/PLUG HARNESS, 12V ACCESSORY, GOLF & UTILITY HARNESS, UNIVERSAL HORN SWITCH, HORN, SURFACE MOUNT A HORN, 12V (See Note) A HORN 48V HARNESS, BACK UP LIGHTS, ACE V RELAY LIGHT, ROUND 2" BACK UP FUSE, 10 AMP ATO/ATC HARNESS, DC-DC CONVERTER V TO 12V DC-DC CONVERTER POWER DISTRIBUTION BLOCK A CONTACTOR & MOUNT BRACKET 24V A CONTROLLER, SEVCON RGEN-SEPEX (Program ) DIRECTION KEYSWITCH WIRE HARNESS, TURN SIGNAL BYPASS PLUG * NOT SHOWN NOTE: Vehicle produced after mid 2012 are equipped with a 48 V horn. If replacing a 12V horn it is recommended replacing it with a 48V horn. See Horn Harness information page

58 DC-DC CONVERTER SCHEMATIC - SCOUT 5-6

59 12V ACCESSORY SCHEMATIC - SCOUT 5-7

60 BACK UP LIGHTS HARNESS SCHEMATIC WITH DC-DC CONVERTER - SCOUT 5-8

61 BACK UP LIGHTS HARNESS SCHEMATIC ACE + - SCOUT 5-9

62 CONTROL PANEL COMPONENTS - SCOUT MOUNTING BRKT - PANEL CONTROLLER A CONTROLLER, SEVCON REGEN HP, SEPEX 24/-48 (Programmed ) 3 AXLE, ELECTRIC (See Section 3) A ALARM, BACK UP NUT, 5/16-18, NE, NYLON INSERT, GA, YWZC A CONTACTOR W/ MTG BRKT - 24 V (SW80) W SCREW,1/4-20X1, HHCS,G5, YWZC B WASHER FLAT STL 1/4 SAE - BLK NUT 1/4-20 NYLOCK, GA YWZC W SCREW, #10-24 X 5/8 HWH TRD ROL NUT, #10-24 GR A NM MACH NYLON LOCK U-BOLT, #014,ZC B WASHER, 5/16,USS, STD, F/W BLK MAX SCREW, 1/4-20 X 1 1/4" HHCS, G5, YWZC B WASHER, LOCK 1/4 BLACK ZINC B WASHER, FLAT STL 1/4 SAE- BLK

63 CHARGER & BATTERY - SCOUT

64 CHARGER & BATTERY - SCOUT (Cont.) 1 CHARGER, DELTA Q (See Page 5-13) BRACKET, CHARGER MOUNT, DELTA Q SUPPORT N/A CHARGER CORD (Item # 5) W/RECEPTACLE (Item # 4) RECEPTACLE, POWER INLET (120V) W/ HARDWARE CHARGER CORD, 6 FT 14/3 WIRE BLACK B SCREW, HEX HEAD CAP 1/4-20 X 3/4 G BS SCREW, 5/16-18X1 CARR B WASHER FLAT STL 5/ B WASHER FLAT STL 1/4 SAE UNHARD BLK B NUT 1/4-20 GR A SERRATED FLNG LOCK NUT, 5/16-18 NYLOCK BATTERY TRAY SW WASHER,3/8",STD FLAT, STAINLESS LH NUT, 3/8-16 NYLOCK, WAXED, SS A HOLD DOWN, BATTERY J-HOOK, Ø2.60 X BATTERY, 6V, DC, US A BATTERY, 6V DC, SEALED, AGM,GC B BATTERY, 6V DC, US * CABLE, 4GA, * A EXTENSION CORD * EXTENSION CORD 9, GFIC * NOT SHOWN 5-12

65 DELTA Q CHARGER WITH REMOTE LED S 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) NOTE: SEE SERVICE BULLETIN SB IF REPLACING A NON-LED CHARGER. 5-13

66 HARNESS, POT BOX ADAPTER S10 P/N HORN HARNESS S10 P/N

67 Scout Parts Manual Section 6 Accessories

68 CARGO STEEL SIDES SCOUT A HINGE PANEL RH SIDE * PANEL LH SIDE TAILGATE LANYARD * 2653-B SCREW 10-16X3/4 HWH TEK HC BLACK * 3787-B SCREW 1/4-20X3/4 HHCS G * 3987-BS SCREW 5/116-18X3/4 HHCS G5 (Hinge attachment) * 6702-B WASHER 5/16 (Hinge attachment) * 6703-B WASHER 1/ * 7525 NUT 5/16-18 SERR FLANGE LOCK (Hinge attachment) * 7724-B NUT 1/4-20 SERR FLANGE LOCK * 799 HITCH PIN, 5/16X N/A KIT, FIXED STEEL SIDES (Includes above items) U * NOT SHOWN 6-1

69 FOLDING STEEL SIDES - SCOUT MOUNT PLATE NUT 1/4-20 NYLOCK B WASHER, 1/ W SCREW, 1/4-20X1 HHC BS SCREW, 5/16-18X2 PAN NUT, 5/16-18 NYLOCK BUMPER BLACK TAILGATE CAPLUG * FOLDING SIDE LH * FOLDING SIDE RH RAIL SPACER B * SPECIAL ORDER 6-2

70 POLY CARGO DUMP BOX SCOUT 6-3

71 POLY CARGO DUMP BOX SCOUT Cont

72 POLY CARGO DUMP BOX SCOUT Cont FRAME LATCH BAR LATCH HANDLE PROP ROD SUPPORT BRACKET LATCH BRACKET TAILGATE HINGE PIN TAILGATE PIVOT ROD PIVOT PLATE PROD ROD PIN 1/8X1 1/4 COTTER BOOT, RUBBER BUMPER LANYARD QUICK RELEASE PIN, 5/16X BOLT, 5/16-18X7/8, HHCS G BS SCREW 1/4-20X1 3/4 HHCS G SCREW 1/4-20X3 HHCS G B SCREW 3/8-16X1 3/4 HHC G WASHER FLT STL.513X1.09X B WASHER 1/ NUT 3/8-16 SERR FLANGE GR A NUT 1/2-13 NYLOCK NUT 1/4-20 NYLOCK GR A CARGO BOX W/TAILGATE SPRING.734X2.63X PS SCREW 1/2-13X3 1/4 HHCS G ** 8206 THREADED INSERT, 5/16-18 (Used with Item 23) N/A* KIT, POLY CARGO DUMP BOX U * Kit includes two (2) rear inner compression springs. P/N ** NOT SHOWN 6-5

73 BATTERY WATERING SYSTEM - SCOUT WATERING ASSEMBLY PUMP

74 ENCLOSURE - SCOUT ITEM CPC/OPTION NUM DESCRIPTION QTY SEATS P/N ALUM CAB ENCLOSURE U 2* WINDSHIELD WIPER KIT, ALUM CAB U * NOT SHOWN 1 HITCHES SCOUT PINDLE HOOK HITCH HITCH PLATE HITCH PIN 5/8 OD (used with Items 2 & 6) * 7812-W NUT, 1/2-20 NYLOK GR A (Used with Item 1) * 4010 SCREW, 1/2-20x1.5 HHCS G5 (Used with Item 1) BALL MOUNT RECEIVER TRAILER HITCH BALL, CHROME 1 7/ A HITCH BALL, * NOT SHOWN 6-7

75 AMBER STROBE LIGHT CAB/SUNTOP SCOUT STROBE LIGHT ASSY * CABLE TIE * CABLE TIE 5 3/ * CABLE TIE MOUNTING BRACKET ** HARNESS, LIGHT CAB * 2339 SCREW, #10-24X3/4, HH * 7624 NUT, 1/4-20 NYLOCK * 6716 WASHER # * KIT, STROBE LIGHT AMBER CAB U * NOT SHOWN ** SPECIAL ORDER 6-8

76 AMBER STROBE LIGHT W/MAST SCOUT STROBE LIGHT ASSY * CABLE TIE * CABLE TIE 5 3/ * CABLE TIE MOUNTING BRACKET * GROMMET 3/8X7/ * 2339 SCREW, #10-24X3/4, HH LIGHT MAST(Mounts to body with Items 9 11) ** HARNESS, LIGHT MAST * 3787-B SCREW 1/4-20X3/4 HHC * 6703-B WASHER 1/ * 7692 NUT, 1/4-20 NYLOCK * 7624 NUT, 1/4-20 NYLOCK * KIT, STROBE LIGHT AMBER W/MAST U * NOT SHOWN ** SPECIAL ORDER 6-9

77 MIRRORS - SCOUT SIDE MIRROR, 5 ROUND * SCREW 5/16-18X1 HHC (Use with 1 - Bench Seats) * 6000-B WASHER, 5/16 (Use with 1 - Bench & Bucket Seats) * 7525 NUT 5/16 SERR. FLNG LOCK (Use with 1 - Bench Seats) * 4017 SCREW, 5/16-18X1 HHC (Use with 1 -Bucket Seats) * 7041-B WASHER 5/16 LOCK (Use with 1 - Bucket Seats) * NUT, JACK #8 (Use with 1 - Bucket Seats & 8)) PANEL REAR VIEW MIRROR * MOUNTING BRACKET (Use with 8) * 3787-B SCREW 1/4-20X3/4 HHC(Use with 8) * 6703-B WASHER 1/4 (Use with 8) * 7036-B WASHER, LOCK (Use with 8) MIRROR CAB SIDE MOUNT * 7739 NUT 5/16-18 NYLOCK (Used with Item 13) * 6702-B WASHER 5/16 (Used with Item 13) * 3991 SCREW 5/16-19X7/8 HHCS (Used with Item 13) ** MIRROR BRACKET (Used with Item 13) B SCREW 10-16X3/4 HWH TEK HC BLK (See NOTE) N/A N/A ** KIT, ROUND MIRROR, PAIR BENCH SEATS (Includes Items 1-4 ) KIT, ROUND MIRROR, PAIR BUCKET SEATS (Includes Items 1, 3, 5-7) KIT, 5 PANEL MIRROR SUNTOP (Includes Items N/A ) NOTE: Used with Item 8 in cabs * NOT SHOWN ** SPECIAL ORDER U U U

78 WINDSHIELDS - SCOUT WINDSHIELD, HARDCOAT 40 (See Note 2) A B ** WINDSHIELD, ACRYLIC 40 (78 DEG) W/EXT (See Note 2) WINDSHIELD, HARDCOAT 40 FOR WIPER (See Note 2) WINDSHIELD, FOLDING, TINTED (See Note 2) * BRACKET * BUMPER (See Note) * 8675 RIVET N/A N/A N/A N/A * NOT SHOWN ** SPECIAL ORDER KIT, WINDSHIELD, HARDCOAT 40 (Includes Items 1, 3, 4, 5 & 6) (See Note 2) KIT, WINDOWSHIELD, ACRYLIC 40 (Includes Items 1A, 3, 4, 5 & 6) (See Note 2) KIT, WINDSHIELD HARDCOAT WIPER (Includes Items 1B, 3, 4, 5 & 6) (See Note 2) KIT, WINDSHIELD, FOLDING, TINTED (Includes Items 2, 3, 4, 5, 7 & 8) (See Note 2) U U U U NOTE: 1. Item 4 used only with vehicles with horizontal cross bars. Placed between windshield and cross bars to reduce excessive noise. 2. Items cannot be shipped UPS. Must ship via freight or local pickup. 6-11

79 WINDSHIELD WIPER - SCOUT 6-12

80 WINDSHIELD WIPER - SCOUT Cont WIPER BAR MOTOR WIPER WIRING HARNESS B CROWN NUT, 3/8-16 (SUPPLIED WITH ITEM 9) WIPER SPACER A MOTOR MOUNTING BRACKET WASHER, NEOPRENE * WIPER ARM * WIPER BLADE WIPER MOTOR * CABLE TIES 11 ¾ RUBBER GROMMET B NUT, HEX, BLK RUBBER GROMMET SCREW, 10-24X5/8 PH SCREW, 5/16-18X1 ½ SCREW, 3/8-16X2 HC B WASHER, FLAT 5/ WASHER, FLAT 3/ B LOCK WASHER 5/ LOCK WASHER, ITEM # 10 EXTERNAL TOOTH NYLOCK NUT /8X7/8 GROMMET N/A BRACKET (SUPPLIED WITH ITEM 7) 1 N/A N/A KIT, WINDSHIELD WIPER U * NOT SHOWN 6-13

81 RAINDRAIN SUNTOP, BENCH - SCOUT SEATBACK FRAME FLOOR 6-14

82 RAINDRAIN SUNTOP, BENCH SCOUT Cont RAINDRAIN SUNTOP SHELL BIRCH FRONT SUNTOP SUPPORT SUNTOP TUBE BRACKET SCREW 5/16-18 X 7/8 HEX B WASHER, ¼ W, PLAIN LOCKNUT. 5/16-18 NYLOK B SCREW, 3/8-16 X 3/4 BLACK LOCKNUT. 3/8-16 NYLOK BS SCREW, ¼-20 X 1 ¾ HEX B WASHER, ¼ N-PLAIN W WASHER. ¼ FENDER LOCKNUT, ¼-20, 3 WAY CROWN SCREW 5/16-18X2 HHC NUT 5/16-18 NYLOCK SPACER,.3/8 ID X 27/32 LONG * REAR SUNTOP TUBE SUPPORT (RH) REAR SUNTOP TUBE SUPPORT (LH) PLUG FINISH, 7/ WASHER, NYLON WASHER, RUBBER * NOT SHOWN 6-15

83 RAINDRAIN SUNTOP, BUCKET - SCOUT FLOOR 6-16

84 RAINDRAIN SUNTOP, BUCKET - SCOUT Cont RAINDRAIN SUNTOP SHELL BIRCH A RAINDRAIN SUNTOP SHELL BRIGHT FRONT SUNTOP SUPPORT SUNTOP TUBE BRACKET SCREW 5/16-18 X 7/8 HEX B WASHER, ¼ W, PLAIN LOCKNUT. 5/16-18 NYLOK B SCREW, 3/8-16 X 3/4 BLACK LOCKNUT. 3/8-16 NYLOK BS SCREW, ¼-20 X 1 ¾ HEX B WASHER, ¼ N-PLAIN W WASHER. ¼ FENDER LOCKNUT, ¼-20, 3 WAY CROWN * REAR SUNTOP BRACKET (RH) REAR SUNTOP BRACKET (LH) PLUG FINISH, 7/ PLUG FINISH, 3/ WASHER, RUBBER WASHER, NYLON * BUMPER, BLACK (See Note) B WASHER, 5/ N/A KIT, UTILITRUCK BIRCH, RAINDRAIN BUCKET U * NOT SHOWN Note: Place on rear support tubes to prevent contact with vehicle body. 6-17

85 80 SUNTOP, BENCH - SCOUT SEATBACK FRAME FLOOR 6-18

86 80 SUNTOP, BENCH - SCOUT Cont SUNTOP SHELL BIRCH FRONT SUNTOP SUPPORT SUNTOP TUBE BRACKET SCREW 5/16-18 X 7/8 HEX B WASHER, ¼ W, PLAIN LOCKNUT. 5/16-18 NYLOK B SCREW, 3/8-16 X 3/4 BLACK LOCKNUT. 3/8-16 NYLOK SCREW, ¼-20 X 2 1/2 HHC B WASHER, ¼ N-PLAIN SPACER,.3/8 ID X 27/32 LONG NUT, 1/4-20 NYLOCK WASHER, NYLON PLUG FINISH, 7/ * REAR SUNTOP TUBE SUPPORT (RH) REAR SUNTOP TUBE SUPPORT (LH) SCREW 5/16-18X NUT 5/15-18 NYLOCK * NOT SHOWN 6-19

87 80 SUNTOP, BUCKET - SCOUT FLOOR 6-20

88 80 SUNTOP, BUCKET - SCOUT Cont SUNTOP SHELL BIRCH A W 80 SUNTOP SHELL BRIGHT FRONT SUNTOP SUPPORT SUNTOP TUBE BRACKET SCREW 5/16-18 X 7/8 HEX B WASHER, ¼ W, PLAIN LOCKNUT. 5/16-18 NYLOK B SCREW, 3/8-16 X 3/4 BLACK LOCKNUT. 3/8-16 NYLOK W SCREW, 1/4-20X1 1/2 HHC G B WASHER, ¼ N-PLAIN NUT, 1/4-20 NYLOCK * REAR SUNTOP BRACKET (RH) REAR SUNTOP BRACKET (LH) PLUG FINISH, 7/ PLUG FINISH, 3/ WASHER, NYLON * BUMPER, BLACK (See Note) B WASHER, 5/ SUPPORT PLATE N/A KIT, UTILITRUCK BIRCH, 80 BUCKET U N/A KIT, UTILITRUCK BRIGHT, 80 BUCKET U * NOT SHOWN Note: Place on rear support tubes to prevent contact with vehicle body. SUNTOP HANDLE, PAIR - SCOUT SUNTOP HANDLE, PAIR U 6-21

89 FRONT RACK SCOUT ** FRONT RACK SCREW 5/16-18X3 HHCS * 6702-B WASHER 5/ * 7739 NUT 5/16-18 NYLOCK N/A KIT, FRONT RACK (Contains above items) U * NOT SHOWN ** SPECIAL ORDER NOTE: Requires front wraparound bumper P/N

90 REAR FACING SEAT & FOOTREST SCOUT

91 REAR FACING SEAT & FOOTREST SCOUT (Cont.) a FOOTREST HANDRAIL EP CARGO SEAT EP CLAMP WASHER,.34X1.25X.09 NEOPRENE TAB B SCREW, X2 1/2 HHC COVER, SEAT BACK COVER, FOOTREST CAPLUG BS SCREW, 1/4-20X2 PCH SCREW, 5/16-18X2 HHC FASTENER B SCREW, 1/4-20X3/4 HHC SCREW, 3/8-16X4 HHC BS SCREW, 5/16-18X1 CARR NUT, 5/16-18 NYLOCK W WASHER,.28X1.375X B WASHER, 5/16 BLK B WASHER 1/4 BLK B WASHER, LOCK 1/ B WASHER, 5/16 SPRING LOCK NUT, 1/4-20 NYLOCK NUT 3/8-16 SERRATED N/A B KIT, REAR FACING SEAT & FOOTREST U NOTE: 1. Cushions shown for reference only. 2. Vehicle must have inner rear springs installed (CPC P/N ). 6-24

92 CARGO REAR FACING SEAT- SCOUT ADJUST SO TAB STICKS OUT 1/4 PAST HANDRAIL 6-25

93 CARGO REAR FACING SEAT SCOUT (Cont.)

94 CARGO REAR FACING SEAT SCOUT (Cont.) a FOOTREST HANDRAIL EP FOLDING DECK EP CARGO SEAT FRAME EP CARGO SEAT HINGE PL CLAMP WASHER,.34X1.25X.09 NEOPRENE COVER, SEAT BACK COVER, FOOTREST CAPLUG BS SCREW, 1/4-20X2 PCH BS SCREW, 1/4-20X1 3/4 HHC B SCREW, 1/4-20X2 1/2 HHC SCREW, 3/8-16X4 HHC BUMPER, BLACK BS SCREW, 5/16-18X1 CARR W WASHER,.28X1.375X B WASHER, 5/16 BLK B WASHER 1/4 BLK NUT 3/8-16 SERRATED NUT, 1/4-20 NYLOCK NUT, 5/16-18 NYLOCK FASTENER N/A KIT, P4/SM2 CARGO REAR FACING SEAT U NOTE: 1. Cushions shown for reference only. 2. Vehicle must have inner rear springs installed (CPC P/N ). 6-27

95 SEAT BELTS/ REAR FACING SEATS - SCOUT

96 SEAT BELTS/REAR FACING SEATS SCOUT Cont SEATBELT BRACKET SPACER HINGE W SCREW, 3/8-16X3 HHC SCREW, 3/8-16X2 HHC SCREW, 7/16-20X1 1/2 HHC W SCREW, 3/8-16X3/4 HHC B WASHER, 5/ WASHER, 3/ NUT, 3/8-16 FLANGE, LOCK NUT, 3/8-16 NYLOCK NUT, 7/16-20 NYLOCK SEAT BELT SEAT BELT, BUCKLE

97 CAB DOME LIGHT - SCOUT DOME LIGHT MOUNTING PLATE * HARNESS ** CABLE TIE 5 3/ ** CABLE TIE ** CABLE TIE 11 3/ ** GROMMET RUBBER ** 2616 SCREW #8-32X1 PFH ** 2685-W SCREW 10-24X5/8 HWH TRD ROL ** 3716 WASHER # ** 7609-W NUT 8-32 NYLOCK ** 7624 NUT NYLOCK ** 9906 TERMINAL 16/14 INS, 1/4 MALE TAB * SPECIAL ORDER ** NOT SHOWN 6-30

98 CAB FAN - SCOUT 2 1 * FAN WIRE HARNESS * FAN ** 2646 SCREW 6-32X5/8 PHM ** 6717 WASHER # ** 7592 NUT 6-32 NYLOCK ** CABLE TIE ** CABLE TIE 11 3/ * SPECIAL ORDER ** NOT SHOWN 6-31

99 HEATER SCOUT HEATER 48V ** HEATER HARNESS ASSEMBLY 48V WINDSHIELD WIPER BAR DOME LIGHT MOUNT MOLDING, BLACK * CABLE, TIE B SCREW, #10X3/4 HWH, TEK ** SCREW, 5/16-18X1 1/ BS SCREW, 1/4-20X1 3/4, HHCS, G B WASHER, 5/16 USS, STD ** WASHER,.375X1.5X.5 F/W, NYLON B WASHER, 1/4 F/W, SAE, STL ** WASHER, 5/16, REG-SPRG, LOCK NUT, 1/4-20 NYLOCK * NOT SHOWN **ITEMS NOT USED WITH VEHICLES HAVING WINDSHIELD WIPERS NOTE: 1. If the toggle switch is in the Fan/Heat position and no heat is occurring, a circuit reset may be needed. On a heater side panel is a 3/8 hole. Inside is a circuit reset tab. Using a non-conductive device push the tab to reset the circuit. 2. This heater/harness is not interchangeable with heater/harness installed on vehicles prior to 8/10/2010. Connect black wire to 48V negative and red wire to 48V positive. 3. If previous heater had a three (3) wire harness, a new two (2) wire harness (Item 2) is required. 6-32

100 POLY CARGO DUMP BOX- SCOUT NOTE: Colors shown for contrast purposes only. 6-33

101 POLY CARGO DUMP BOX- SCOUT (Cont.) 6-34

102 POLY CARGO DUMP BOX- SCOUT (Cont.) 6-35

103 POLY CARGO DUMP BOX- SCOUT (Cont.) FRAME LATCH BAR LATCH HANDLE PROP ROD SUPPORT BRACKET LATCH BRACKET TAILGATE HINGE PIN TAILGATE PIVOT ROD PIVOT PLATE PROD ROD PIN 1/8X1 1/4 COTTER BOOT, RUBBER BUMPER LANYARD B SCREW, #10X3/4 HHCS, G BS SCREW 1/4-20X1 3/4 HHCS G SCREW 1/4-20X3 HHCS G SCREW 5/16-18X7/8 HHC G B SCREW, 3/8-16X1 3/4 HHCS G WASHER FLT STL.513X1.09X B WASHER 1/ B WASHER #8 PLAIN B WASHER, 5/16 LOCK NUT 3/8-16 SERR FLANGE GR A NUT 1/2-13 NYLOCK NUT 1/4-20 NYLOCK GR A PIN, 5/16X KNURLED INSERT 5/ CARGO BOX W/TAILGATE SPRING.734X2.63X PS SCREW 1/2-13X3 1/4 HHCS G REAR INNER COMPRESSION SPRINGS N/A* KIT, POLY CARGO DUMP BOX U 6-36