SERVICE PARTS MANUAL

Transcription

1 INCLUDES ITEMS A Textron Company SERVICE PARTS MANUAL Ref Fcv ELECTRIC POWERED UTILITY VEHICLES ISSUE DATE: APRIL 2006

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3 SERVICE PARTS MANUAL ELECTRIC UTILITY VEHICLES MPT 1000 INDUSTRIAL 1000 COMMANDER 2100 JACOBSEN HAULER 1000 STARTING MODEL YEAR E-Z-GO Division of TEXTRON, Inc. 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. E-Z-GO Division of TEXTRON, Inc. 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: E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA Page i

4 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. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture. 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). Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ILLUSTRATED PARTS BREAKDOWN vii ACCELERATOR A-1 BATTERY CHARGER (LESTER) B-1 BODY C-1 BRAKES D-1 BRAKES - FRONT DISC E-1 CAB F-1 ELECTRICAL G-1 ELECTRONIC SPEED CONTROL - PDS H-1 FRONT SUSPENSION/STEERING J-1 MOTOR K-1 REAR AXLE L-1 REAR SUSPENSION M-1 SEATING N-1 TRUCK BED, PLASTIC P-1 WEATHER PROTECTION Q-1 WHEELS AND TIRES R-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 Page iii

6 TABLE OF CONTENTS SECTION Page No. Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle APPENDIX Contains a listing of specialty products and options/accessories I USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS (page iii) (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. Page v

8 ,87 67 Front of Vehicle 83,88 81,86 84, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the 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 vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 - Includes Items RED GRN BLK WHT To Harness from Direction Selector Part of Frame Ref Acl 4-1 Page A-1

11 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2-37) G01 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-10 X 1/2" LG G01 PEDAL BOX AND COVER G6 SCREW, #8-32 X 3/4" LG G01 MICRO SWITCH G01 SCREW, #4-14 X 5/8" LG G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" PLUNGER G1 SPRING RETAINER, 1/2" G1 BUSHING G01 COMPRESSION SPRING G2 SPRING RETAINER, 3/8" G01 ACCELERATOR ROD G4 LOCK NUT, 5/ G4 CLEVIS YOKE (ADJUSTABLE) G3 CLEVIS PIN, 5/16" X 1" LG G1 NYLON BUSHING G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 PEDAL PIVOT PIN G01 PUSH NUT, 9/32" G03 WIRING HARNESS (PEDAL BOX ASSEMBLY) G1 LOOM FLEX, 3/8" X 6" LG (BULK)... 1 Page A-2

12 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 G1 WIRE TIE G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 34-37) G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 35-36) G1 OVAL RIVET, 3/16" X 3/8" LG G01 ACCELERATOR PEDAL PAD * ACCELERATOR PEDAL G2 BOLT, 5/16-18 X 13/16" LG... 4 Page A-3

13 ACCELERATOR Page A-4

14 BATTERY CHARGER (LESTER) 1 Ref Bcl 4-1 Page B-1

15 BATTERY CHARGER (LESTER) 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 BATTERY CHARGER, LESTER, 36 VOLT, PORTABLE WITH POWERWISE CONNECTOR, CE APPROVED (OPTIONAL) 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

16 BODY Includes Items Page C-1

17 Page C BODY

18 BODY ASH TRAY Includes Items HITCHES 168 Bumper Mounting Hole (4) Clevis Hitch Angle Hitch Heavy Duty Hitch Drop Angle Hitch Drop Ball Hitch Drop Clevis Hitch 161 Ref Bod 21-3 Page C-3

19 BODY Page C-4

20 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 UPPER FLOORPAN (AXLE MOUNTED STEERING) G11 RIVET, 3/16" X 9/16" LG G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG G01 ACCESS COVER G03 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 9-12) G01 DEFLECTOR (PASSENGER SIDE) G01 DEFLECTOR (DRIVER SIDE) G5 SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (FOUR CUP) G01 LABEL (SAFETY) (PICTOGRAPH) G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG G** COWL G01 NAMEPLATE (E-Z-GO) (OVAL) G01 NAMEPLATE (JACOBSEN) (OVAL) G01 NAMEPLATE (CUSHMAN) (OVAL) G01 RIVET, 3/16" X 1" LG G01 RIVET, 3/16" X 1" LG G01 FENDER FLARE (DRIVER SIDE) G02 FENDER FLARE (PASSENGER SIDE)... 1 Page C-5

21 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 G04 FRONT SHIELD G02 FRONT SHIELD BRACE G01 SCREW, 1/4-20 X 1/2" LG G1 WASHER, 1/4" G01 RIVET, KTR, 1/4" X 1" LG G02 BUMPER G2 WASHER, 5/16" G04 SPACER, 1" G01 SPACER, 1/2" G8 LOCK WASHER, 5/16" G02 BOLT, 5/16-18 X 2 1/2" LG G02 COWL SUPPORT BRACKET G02 SELF TAPPING SCREW, 1/4-20 X 1/2" LG G01 RIVET, 3/16" X 1 1/8" LG G01 GLOVE BOX DOORS (BOTH SIDES) G02 GLOVE BOX DOOR (DRIVER SIDE) G03 GLOVE BOX DOOR (PASSENGER SIDE) LABEL (MPT ) G01 LABEL, TILT WARNING PICTOGRAPH G01 LABEL (JACOBSEN HAULER ) (DRIVER SIDE) G02 LABEL (JACOBSEN HAULER ) (PASSENGER SIDE)... 1 Page C-6

22 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY * SERIAL NUMBER PLATE G03 ROCKER PANEL (DRIVER SIDE) G04 ROCKER PANEL (PASSENGER SIDE) G01 FENDER SPACER (DRIVER SIDE) G02 FENDER SPACER (PASSENGER SIDE) G03 BRACE (DRIVER SIDE) G04 BRACE (PASSENGER SIDE) G2 SCREW, #10-24 X 1 1/4" LG G2 SPACER, 1/4" G5 WASHER, # G10 LOCK NUT, # G1 SCREW, 1/4-20 X 1" LG G2 SPACER, 1/4" G7 WASHER, 1/4" G4 LOCK NUT, 1/ G9 HOLE PLUG, 1/2" G04 FLOORMAT (AXLE MOUNTED STEERING)... 1 Page C-7

23 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 SEAT SUPPORT PANEL G10 RIVET, 5/32" X 9/16" LG G01 SEAT HINGE PLATE G11 RIVET, 3/16" X 3/4" LG G01 SIDE PANEL (DRIVER SIDE) G02 SIDE PANEL (PASSENGER SIDE) G10 RIVET, 5/32" X 9/16" LG G12 RIVET, 1/4" X 1/2" LG G7 WASHER, 1/4" G03 SPLASH PANEL G2 BOLT, 5/16-18 X 13/16" LG G8 BOLT, 5/16-18 X 1" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 FENDER (DRIVER SIDE) G02 FENDER (PASSENGER SIDE) G03 FENDER WITH TAILLIGHT (DRIVER SIDE) G04 FENDER WITH TAILLIGHT (PASSENGER SIDE) G4 LOCK NUT, 1/ G7 WASHER, 1/4" G6 BOLT, 1/4-20 X 7/8" LG G01 REAR PANEL G01 RIVET, 3/16" X 1" LG G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 SEAT FILLER PANEL (DRIVER SIDE) G02 SEAT FILLER PANEL (PASSENGER SIDE)... 1 Page C-8

24 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 G10 RIVET, 5/32" X 9/16" LG G01 LABEL (E-SHIELD ) G02 HITCH RECEIVER G4 BOLT, 7/16-14 X 1 1/2" LG G3 WASHER, 7/16" G1 LOCK NUT, 7/ G8 SCREW, 5/16-18 X 1" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G02 CLEVIS HITCH G7 CLEVIS PIN, 1/2" X 2 1/2" LG G1 COTTER PIN, 2 1/2" LG G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG G02 ANGLE HITCH G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG G02 HEAVY DUTY HITCH G1 HITCH BALL, 1 7/8" G6 LOCK WASHER, 3/4" G11 NUT, 3/ G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG G02 DROP ANGLE HITCH G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG... 1 Page C-9

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 G02 DROP BALL HITCH G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG G1 HITCH BALL, 1 7/8" G6 LOCK WASHER, 3/4" G11 NUT, 3/ G02 DROP CLEVIS HITCH G01 CLEVIS PIN, 5/8" X 3" LG G1 COTTER PIN, 15/32" X 2 11/16" LG G7 CLEVIS PIN, 1/2" X 2 1/2" LG G1 COTTER PIN, 2 1/2" LG G04 ASH TRAY KIT (INCLUDES ITEMS ) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SCREW, #10-16 X 1/2" LG G6 LOCK NUT, 5/ G02 SEAT FRAME G8 WASHER, 5/16" G6 BOLT, 5/16-18 X 3/4" LG G01 SCREW, 3/8-16 X 1/4" LG G2 BOLT, 5/16-18 X 13/16" LG G02 BATTERY RACK G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16"... 3 Page C-10

26 BRAKES! If item 6 does not have hole indicated, order the following replacement parts: item 2: G1 item 3: G2 item 6: G ! 4 3! 1 2! 6! Part of Frame Accelerator Pedal Includes Items 19, Includes Items Ref Brk 4-1 Page D-1

27 BRAKES WHT BLK Includes Items Includes Items Brake Pedal (Vehicle With Brake Lights) Ref Brk 4-2 Page D-2

28 BRAKES Front of Vehicle Includes Items Includes Itmes 84-91, Includes Items Includes Items Includes Items 94, Includes Items 94, Includes Items 101, Ref Brk 4-3 Page D-3

29 BRAKES 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 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-10) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" * BRAKE PEDAL G02 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 8-10) * SERVICE BRAKE PAD * PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 3/8" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG G01 FLANGED BUSHING G01 TORSION SPRING G1 WASHER, 3/8" G5 LOCK NUT, 3/ G04 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) G01 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G05 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-26) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER * BRAKE CABLE (DRIVER SIDE) * BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, 13/32" (STAINLESS STEEL) Page D-4

30 BRAKES 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 CLEVIS PIN, 5/16" X 1" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 3/4" LG G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G02 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/ G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) * BRAKE PEDAL G02 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 57-59) * SERVICE BRAKE PAD * PARK BRAKE PAD... 1 Page D-5

31 BRAKES 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 OVAL RIVET, 3/16" x 3/8" LG G03 SERVICE BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G1 SCREW, #6-32 X 1 1/4" LG G5 WASHER, # G3 WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, # G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84-95) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84-95) G01 BRAKE SHOE KIT (INCLUDES ITEM 85) * BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 87-91) * UPPER SPRING * LOWER SPRING... 1 Page D-6

32 BRAKES 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. 89 * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 94, 95) G02 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCL. ITEMS 94, 95) * ADJUSTER * TEFLON WASHER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 INNER BRAKE DRUM WASHER G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) * BRAKE DRUM G1 LUG BOLT, 1/ G1 WASHER, 1 3/8" O.D. X 21/32" G8 SLOTTED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP G03 BRAKE CABLE BRACKET (PASSENGER SIDE) G04 BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-7

33 BRAKES Page D-8

34 BRAKES - FRONT DISC Part of Frame Accelerator Pedal Includes Items 19, Includes Items Ref Brh 21-1 Page E-1

35 BRAKES - FRONT DISC WHT BLK Includes Items Includes Items BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Ref Brh 21-2 Page E-2

36 BRAKES - FRONT DISC Includes Items Includes Items , 106, Includes Items 94-97, Ref Brh 21-3 Page E-3

37 BRAKES - FRONT DISC Front of Vehicle Includes FRONT DISC BRAKE ACTUATOR ASSEMBLY Ref Brh 21-4 Page E-4

38 BRAKES - FRONT DISC 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 ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-11) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" * BRAKE PEDAL G01 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 8-10) * SERVICE BRAKE PAD * PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 WASHER, TEFLON, 3/8" G01 SHOULDER BOLT, 3/8-16 X 4" LG G01 FLANGED BUSHING G01 TORSION SPRING G1 WASHER, 3/8" G5 LOCK NUT, 3/ G04 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) G01 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G05 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-26) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER * BRAKE CABLE (DRIVER SIDE) * BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, S.S Page E-5

39 BRAKES - FRONT DISC 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 CLEVIS PIN, 5/16" X 1" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 3/4" LG G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G02 CATCH BRACKET G8 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/ G01 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) * BRAKE PEDAL G01 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 57-59) * SERVICE BRAKE PAD * PARK BRAKE PAD... 1 Page E-6

40 BRAKES - FRONT DISC 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 OVAL RIVET, 3/16" X 15/32" LG G03 BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G1 SCREW, #6-32 X 1 1/4" LG G5 WASHER, # G3 WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, # G1 WASHER, TEFLON, 3/8" G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE G02 SPRING PLATE (PASSENGER SIDE) G01 SPRING PLATE (DRIVER SIDE) G01 FOUR LINK ROD G01 LOCK NUT, M G01 BRAKE LINE G01 SCREW, 1/4-20 X 4444" LG G01 WIRE RETAINER... 2 Page E-7

41 BRAKES - FRONT DISC 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 SPINDLE, CALIPER AND DISC HUB ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS ) DISC BRAKE SPINDLE (DRIVER SIDE) G1 SLOTTED NUT G01 DRIVE FLANGE STUD G2 ROLLER BEARING G1 BEARING RACE G01 DISC BRAKE HUB G01 FLANGED BEARING G1 WASHER, 3/8" G8 BOLT, 3/8-16 X G01 BEARING G8 COTTER PIN G1 GREASE SEAL G02 CALIPER (DRIVER SIDE) SPINDLE, CALIPER AND DISC HUB ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS , 106, 107) DISC BRAKE SPINDLE (PASSENGER SIDE) G01 KINGPIN TUBE G01 THRUST WASHER G3 WASHER, 1/2" G6 LOCKNUT, 1/ G6 CAPSCREW, 1/2-13 X 6" LG G01 CALIPER (PASSENGER SIDE) G01 FRONT DISC BRAKE BRAKE ACTUATOR ASSEMBLY (INCLUDES ITEMS ) G3 COTTER PIN, 3/32 X 3/4" LG... 1 Page E-8

42 BRAKES - FRONT DISC 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 NYLON BUSHING G3 CLEVIS PIN, 5/16 X 1" LG G01 UPPER ACTUATOR PIVOT G02 ACETAL BUSHING G01 SHOULDER BOLT G3 WASHER, 1/2" G3 BOLT, 1/2-13 X 6" LG LOCKNUT, 5/ G01 MASTER CYLINDER G01 BRAKE ACTUATOR ASSEMBLY HOUSING G5 LOCKNUT, 3/ G1 WASHER, 3/8" STAINLESS G01 LOWER ACTUATOR PIVOT G4 CLEVIS YOKE G01 BRAKE ACTUATOR ASSEMBLY COVER G01 SCREW, 1/4-20 SWAGEFORM G8 BOLT, 1/4-20 X 1 1/4" LG G2 LOCKNUT, 1/ G3 COTTER PIN, 3/32 X 3/ G1 WASHER, NYLON G1 NYLON BUSHING G01 ACTUATOR LINKAGE G5 WASHER, 3/8" G01 DISC BRAKE PAD AND PIN KIT (SERVICES ONE CORNER) (INCLUDES ITEMS ) * BRAKE PADS * BRAKE PAD RETAINER PINS... 2 Page E-9

43 BRAKES - FRONT DISC Page E-10

44 CAB 1 CAB 3,4* *Steel Doors Shown For Cab Accessories, See ACCESSORIES LISTING in Appendix B Page F-1

45 CAB 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** STEEL CAB (WITHOUT DOORS) REPACEMENT PARTS AND ACCESSORIES MAY BE OBTAINED FROM CURTIS CAB, INC G01 VINYL DOOR KIT G** STEEL DOOR KIT... 1 For Cab replacement parts and accessories, contact Curtis Cab at: Curtis Cab, Inc. 111 Higgins Street, Worcester, Massachusetts, Tel.: Toll free: Page F-2

46 ELECTRICAL 44 CHARGER RECEPTACLE A 31 - Includes Items B A Controller (See Electronic Speed Control Section) B Clamp (See REAR AXLE Section) Ref Ele 20-1 Page G-1

47 ELECTRICAL 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. 1 XXXXX-GXX 6 VOLT BATTERY G01 BATTERY RETAINER G01 HOLD DOWN BOLT (STAINLESS STEEL) G1 LOCK NUT, 5/ G02 BATTERY RETAINER ANGLE G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G1 BATTERY RETAINER ANGLE INNER G01 HOLD DOWN BOLT (STAINLESS STEEL) G1 LOCK NUT, 5/ G18 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 6") G13 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 10 1/2") G14 4 GA WIRE (BATTERY INTERCONNECT, BLACK, 15") G8 LOCK WASHER, 5/16" G2 NUT, 5/ G15 4 GA WIRE (BATTERY +, BLACK, 17") G16 4 GA WIRE (BATTERY -, BLACK, 19") G01 POWER HARNESS G01 CONTROL HARNESS... 1 Page G-2

48 ELECTRICAL 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 G03 CHARGER RECEPTACLE ASSEMBLY (INCLUDES ITEMS 32-40) * RECEPTACLE COVER * RECEPTACLE BOTTOM G23 FEMALE CONNECTOR G24 INSULATOR SLEEVE G25 18 GA WIRE (RED 9") G08 SCREW, #10-32 X 1/2" LG (BRASS) G09 SCREW, #6-32 X 1 3/4" LG (STAINLESS STEEL) G10 LOCK NUT, # * WIRE HARNESS (CHARGER) G10 RIVET, 3/16" X 1" LG (ALUMINUM) G1 WIRE TIE G02 CABLE CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G1 WIRE TIE G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16-18 (BRASS) G02 LOCK WASHER, 1/4" (SILICON BRONZE) G02 NUT, 1/4-20 (BRASS)... 2 Page G-3

49 Page G-4

50 ELECTRICAL FUSE BLOCK GRN 3 4 HORN HORN BUTTON Seatwrap Support YEL Floorboard BLK HORN 10 HOUR METER DETAIL 17 - Includes Items , 25 26, OFF ON KEY SWITCH AND KEY SET Ref Ele 20-2 Page G-5

51 ELECTRICAL 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 FUSE BLOCK (6 POSITION) G2 SCREW, #10-24 X 1 1/4" LG G5 WASHER, # G10 LOCK NUT, # G01 FUSE, 15 AMP... AR G1 PUSH ON MALE TERMINAL G5 LOCK WASHER, # G4 NUT, # G2 HORN G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 RIVET, 3/16" X 1" LG (ALUMINUM) G02 HOUR METER KIT (INCLUDES ITEMS 18-22) G02 HOUR METER G01 HOUR METER RETAINER CLIP G02 HOUR METER BRACKET G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 WIRE HARNESS (HOUR METER) G1 KEY SWITCH KIT (W/O LIGHTS - STANDARD - WITH HARDWARE) G02 KEY SWITCH (WITHOUT LIGHTS - NON STANDARD) G03 KEY SWITCH (WITHOUT LIGHTS - INDIVIDUALLY KEYED) G** KEY SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ G1 KEY (SET)... 1 Page G-6

52 ELECTRICAL HEADLIGHT Includes Items 7-12 TAILLIGHT Rear Fender TURN SIGNAL or Ref Ele 20-3 Page G-7

53 ELECTRICAL 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 G1 HEADLIGHT (RECTANGULAR) (INCLUDES ITEM 2) G6 SCREW, #10-16 X 1" LG G01 JUMPER WIRE (HEADLIGHT) G3 TURN SIGNAL LIGHT (INCLUDES ITEMS 7-12) G3 TURN SIGNAL LIGHT G7 WASHER, 1/4" (STAINLESS STEEL) G1 WIRE G7 LOCK WASHER, 1/4" G1 NUT, 1/ G1 PUSH-ON MALE TERMINAL G5 LENS, AMBER G5 SCREW, #6-18 X 5/8" LG G01 WIRE HARNESS (ACCESSORY) G3 TAILLIGHT (WITH SEALED CONNECTORS) G1 TAILLIGHT BULB... AR G01 TAILLIGHT JUMPER PLUG (FOR VEHICLE W/OUT TURN SGL) G02 TURN SIGNAL KIT (INCLUDES ITEMS 26-30) G1 TURN SIGNAL (WITH MOUNTING HARDWARE) G1 TURN SIGNAL FLASHER G3 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER... 1 Page G-8

54 ELECTRICAL REVERSE BUZZER RED 19 GRN/ BLK 20 Control Harness Accessory Harness OFF ON 9 12 DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE GROUND STRAP Ref Ele 20-4 Page G-9

55 ELECTRICAL 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 PLATE (KEY SWITCH, DIRECTION SELECTOR) G01 LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR) G06 PLATE (KEY SWITCH, DIRECTION SELECTOR, CHARGE METER) G01 LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR, CHARGE METER) G01 LABEL (KEY SWITCH WITH LIGHTS, DIRECTION SELECTOR, CHARGE METER) G02 DRIVE RIVET, 3/16" X 3/8" LG G01 DIRECTION SELECTOR SWITCH (DASH MOUNTED) G05 STATE OF CHARGE METER (VERTICAL) G74 18 GA WIRE (RED 6") G02 REVERSE WARNING BUZZER (CONTINUOUS TONE) G01 RIVET, 1/8" X 13/16" LG G02 GROUND STRAP, 16" (EE ONLY) G8 BOLT, 3/8-16 X 1" LG G1 WASHER, 3/8" G4 LOCK NUT, 3/ Page G-10

56 ELECTRICAL WORK AND STROBE LIGHTS 14 Front of Vehicle Includes Items 2-19, 22 and/or Includes Items Includes Items Includes Items Front of Vehicle Front of Vehicle Ref Ele 20-5 Page G-11

57 ELECTRICAL 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 G** WORK LIGHT BAR WITH LIGHTS AND/OR STROBE (INCLUDES ITEMS 2-19, 22 AND/OR 30) G03 STRUT (DRIVER SIDE) G04 STRUT (PASSENGER SIDE) G01 WIRE HARNESS (WORK LIGHT) G02 BRACE G02 COVER PLATE G01 SWITCH HARNESS G** CONSOLE INSERT PLATE G03 STROBE LIGHT MOUNT (USED ONLY WITH STROBE LIGHT) G01 HARDWARE KIT (INCLUDES ITEMS 11-19) G7 BOLT, 5/16-18 X 1 3/4" LG G8 WASHER, 5/16" G1 WASHER, 3/8" X 1 1/4" G01 LOCK NUT, 5/ G3 ACORN NUT, 5/ G02 DRIVE RIVET, 3/16" X 3/8" LG G1 GROMMET G3 SCREW, 1/4-20 X 3/4" LG G4 LOCK NUT, 1/ G2 WORK LIGHT KIT (INCLUDES ITEMS 23-28) G2 WORK LIGHT (RECTANGULAR) G3 LOCK WASHER, 1/2" G1 NUT, 1/ G1 LIGHT SWITCH G1 TAB ADAPTER G1 16 GA WIRE (RED 5 3/8") Page G-12

58 ELECTRICAL 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 G3 STROBE LIGHT KIT (INCLUDES ITEMS 31-36) G4 STROBE LIGHT G4 SCREW, #10-24 x 1/2" LG G10 LOCK NUT, # G1 LIGHT SWITCH G1 TAB ADAPTER G1 16 GA WIRE (RED 5 3/8") G10 HOLE PLUG... 1 Page G-13

59 Page G-14

60 ELECTRONIC SPEED CONTROL - PDS 1 - Includes Items Includes Items Code Fault Code Symptoms Corrective Action 1-1 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 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid FAULT Vehicle will not run Check for additional electronics attached to B+, replace controller Solenoid closes, vehicle will Check wiring. run Replace power harness and motor if required. not run Field windings or power harness shorted. Verify, replace motor if necessary. Replace controller Check M- wiring and repair, replace controller controller FIELD MISSING 3-5 FIELD OVERCURRENT 4-1 CURRENT SENSE FAULT 4-3 M- FAULT AUX CONT DNC AUX Vehicle will not Vehicle will not Vehicle will not CONT Vehicle runs Vehicle will Vehicle will Replace run Replace controller run Check coil connections/wiring. Replace solenoid if necessary not run Check all solenoid wiring. Replace solenoid if necessary Check all solenoid wiring. Replace solenoid if necessary 3-2 PRECHARGE not Vehicle will controller run not run Replace EEPROM MAIN COIL OPEN Vehicle stops 5-2 MAIN CONT DNC Vehicle 4-4 WELDED FAILSAFE will 5-3 MISSING CONTACTOR 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 P/N G01 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 Ref Esp 20-1 Page H-1

61 ELECTRONIC SPEED CONTROL - PDS 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 G03 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-16) G02 CONTROLLER MOUNT G04 ELECTRONIC SPEED CONTROLLER G2 LOCK NUT, 1/ G01 SOLENOID (INCLUDES ITEMS 6-9) * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * JAM NUT, 5/ G2 LOCK NUT, 1/ G01 FASTON TAB, G17 4 GA WIRE (BLACK 9") G01 IN-LINE FUSE COVER G1 RIVET, 3/16" X 7/16" LG (ALUMINUM) G01 COVER G1 RATCHET FASTENER, 1/4" X 9/16" LG G05 FUSE, 7.5 AMP G2 LOCK NUT, 1/ G01 BOLT, 8MM X 16MM LG G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 BOLT, 6MM X 1 X 12MM LG G02 LOCK WASHER, 1/4" (SILICON BRONZE) G01 TOW-MAINTENANCE SWITCH G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 DIAGNOSTIC LABEL (FAULT CODE)... 1 Page H-2

62 FRONT SUSPENSION/STEERING Front of Vehicle Part of Frame Part of Frame 9 4, LUG ,16 Ref Fss Includes Items Includes Item Includes Items 7-13, 17 *NOTE: Tie Rod Not Shown for Clarity Page J-1

63 41- Includes Items FRONT SUSPENSION/STEERING Page J-2

64 FRONT SUSPENSION/STEERING Front of Vehicle OR Includes Items Includes Items Includes Items 99, Includes Items Ref Fss 21-2 Page J-3

65 FRONT SUSPENSION/STEERING 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 FRONT AXLE G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-13) G04 SPINDLE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 5-6) G01 BEARING G01 BEARING, DP G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G1 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 10) G1 LUG BOLT, 1/2-20 X 1 7/32" LG G1 SLOTTED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G2 SPINDLE CAP G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 7-13 & 17) G02 SPINDLE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 5-6) G6 BOLT, 1/2-13 X 6" LG G3 WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (STAINLESS STEEL) G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING... 8 Page J-4

66 FRONT SUSPENSION/STEERING 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 G6 NUT, 3/ G01 VINYL CAP G03 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) G03 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 G02 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 42-65) G01 STEERING RACK COVER & BEARING * JAM NUT, 1/ G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 PINION G01 RETAINING RING (INTERNAL) G01 SEAL PINION G01 RACK STEERING G01 SCREW, G01 RACK LOADER G01 SPRING COMPRESSION G01 GASKET RACK LOADER G01 COVER RACK LOADER G01 SCREW, 1/ G3 GREASE FITTING, STRAIGHT G01 RACK BALL JOINT (INCLUDES ITEMS 58-60) G1 RUBBER BOOT G2 SLOTTED NUT, 7/ Page J-5

67 FRONT SUSPENSION/STEERING 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 G2 COTTER PIN, 3/32" X 1" LG G01 ROD END (INNER) G01 RACK BOOT G2 WIRE TIE G8 WIRE TIE TAG STEERING WHEEL 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 G05 STEERING COLUMN KIT (INCLUDES ITEMS 86-88) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG Page J-6

68 FRONT SUSPENSION/STEERING 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 BOLT, 3/8-16 X 1 1/4" LG WITH PATCHLOCK G1 LOCK WASHER, 3/8" G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 99, 100) G01 BOLT, M8 X 1 1/4" LG G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER STEERING WHEEL G01 STEERING WHEEL COVER G01 LABEL (E-Z-GO) G01 LABEL (CUSHMAN) G2 LOCK NUT, 5/ G01 LABEL (JACOBSEN) G01 TIE ROD ASSEMBLY (INCLUDES ITEMS ) G01 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS)... 1 Page J-7

69 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 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 J-8

70 MOTOR 1 - Includes Items X1 X2 A2 A Page K-1

71 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 G04 MOTOR (SEPARATELY EXCITED) (PDS) (INCLUDES ITEMS 15-28) G36 ARMATURE G38 BRUSH SPRING G39 BRUSH G40 BRUSH BOX G41 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G43 HEADBAND G37 FRAME AND FIELD COIL (INCLUDES HARDWARE) G42 COVER COMMUTATOR END G01 MAGNET G02 SCREW, #10-32 X 1/2" LG G01 RETAINING RING G01 SPEED SENSOR... 1 Page K-2

72 REAR AXLE 1 - Includes Items 2-7 NOTE: Apply a light coat of moly grease to male spline before assembly. Reference part number Ref Rax 1 Page L-1

73 REAR AXLE 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 REAR AXLE ASSEMBLY 14.76:1 (INCLUDES ITEMS 2-7) G12 AXLE SHAFT (PASSENGER SIDE) G11 AXLE SHAFT (DRIVER SIDE) * DIFFERENTIAL COVER G01 FILL PLUG WITH 'O' RING G1 BOLT, 5/16-18 X 3/4" LG G01 VENT G1 SPLINE BUMPER G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G7 WASHER, 1/4" (STAINLESS STEEL) G01 MOLY LUBE, 2 OZ... AR Page L-2

74 REAR SUSPENSION Page M-1

75 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 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING G6 NUT, 3/ G01 VINYL CAP G03 LEAF SPRING G01 U BOLT, 3/ G1 WASHER, 3/8" G5 LOCK NUT, 3/ G02 SPACER G01 RUBBER BUSHING G02 SHACKLE PLATE G9 BOLT, 3/8-16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/ G1 SHOULDER BOLT, 3/8-16 X 3 1/4" LG G1 LOCK NUT, 3/ G01 AXLE BUMPER BRACKET G01 RUBER BUMPER G01 LOCK WASHER, M G01 NUT, M Page M-2

76 SEATING 15 - Includes Items 16, Includes Items Front of Vehicle Ref Sea Page N-1

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 G01 SEAT BACK SUPPORT G2 BOLT, 5/16-18 X 13/16" LG G8 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 ACCESS COVER G1 DRIVE RIVET G02 SEAT BACK SUPPORT BRACKET G01 BOLT, 3/8-16 X 1 1/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G** SEAT BACK ASSEMBLY (INCLUDES ITEMS 16, 17) G** VINYL SEAT BACK COVER G01 PLASTIC SEAT BACK COVER (BLACK) G12 SCREW, 1/4-20 X 1" LG G7 LOCK WASHER, 1/4" G01 WASHER, 1/4" G** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 24-32) G** VINYL SEAT BOTTOM COVER G01 VINYL TRIM (SEAT BOTTOM) G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG G01 HIP RESTRAINT (PASSENGER SIDE)... 1 Page N-2

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 G01 HIP RESTRAINT (DRIVER SIDE) G01 BOLT, 1/4-20 X 7/8" LG G1 BUMPER... 2 Page N-3

79 SEATING Page N-4

80 TRUCK BED, PLASTIC A B 7 6 A 3 B Page P-1

81 TRUCK BED, PLASTIC A B C A B C Ref Tbp 21-2 Page P-2

82 TRUCK BED, PLASTIC Actuator may be rotated 90 on some models Ref Tbp 21-3 Page P-3

83 TRUCK BED, PLASTIC 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 BED ASSEMBLY, 40" (INCLUDES ITEMS 2-11) G01 PLASTIC BED, 40" G01 PIVOT SHAFT G01 SHOULDER BOLT, 1/4-20 X 3/4" LG G01 TAILGATE G01 BOWED ANGLE G2 SCREW, 1/4-20 X 5/8" LG (STAINLESS STEEL) G01 EXTRUSION CHANNEL G01 TAILGATE CABLE G2 SCREW, 1/4-20 X 5/8" LG (STAINLESS STEEL) G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/ G01 BED LATCH G01 LATCH TORSION SPRING G02 KEEPER PLATE G02 RETAINER BRACKET G01 SCREW, 1/4-20 X 5/8" LG G01 HANDLE GRIP G01 BUSHING G01 CLEVIS PIN G5 WASHER, 1/2" G1 COTTER PIN... 2 Page P-4

84 TRUCK BED, PLASTIC 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 BUSHING G02 SPRING CHANNEL G01 SCREW, 1/4-20 X 5/8" LG G7 WASHER, 1/4" G02 GAS SPRING G10 CLEVIS PIN, 1/2" X 2 27/32" LG G11 CLEVIS PIN, 1/2" X 1 3/4" LG G1 COTTER PIN, G02 OUTRIGGER CHANNEL G02 ELECTRIC ACTUATOR, 12 VOLT, 1500 LBS G02 PLASTIC BED HEAT SHIELD (GASOLINE VEHICLE ONLY) G7 WASHER, 1/4" G01 SCREW, 1/4-20 X 5/8" Page P-5

85 TRUCK BED, PLASTIC 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 JACOBSEN PLATE G01 CUSHMAN PLATE G2 RATCHET FASTENER G01 LOAD BED DECAL G01 RIVET... 5 Page P-6

86 WEATHER PROTECTION 3 Front of Vehicle 6 7 8, DETAIL A DETAIL B Front of Vehicle Front of Vehicle DETAIL C (FRONT) , 9 DETAIL D (REAR) Page Q-1

87 WEATHER PROTECTION 23 Front Top Strut 24 REAR VIEW MIRROR 21 - Includes Items Setscrew SIDED SOFT ENCLOSURE 26 - Includes Items Ref Wea 20-2 Page Q-2

88 WEATHER PROTECTION Strut Front of Vehicle Windshield Retainer Rubber Latch Strut Front of Vehicle Page Q-3

89 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 G** SUN TOP KIT (INCLUDES ITEMS 2-19) G01 SUN TOP G05 FRONT STRUT G2 BOLT, 5/16-18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G2 WASHER, 5/16" G04 REAR STRUT (PASSENGER SIDE) G03 REAR STRUT (DRIVER SIDE) G7 BOLT, 5/16-18 X 1 3/4" LG G03 WASHER, 5/16" G6 LOCK NUT, 5/ G5 SCREW, 1/4-20 X 2" LG (STAINLESS STEEL) G6 SCREW, 1/4-20 X 2 1/4" LG (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) G01 SPACER G2 LOCK NUT, 1/ G1 END CAP, 1" G2 REAR VIEW MIRROR KIT (REQUIRES SUN TOP) (INCLUDES ITEMS 22-24) G1 REAR VIEW MIRROR G2 SUPPORT BRACKET G1 SCREW, #8-32 X 5/8" LG (STAINLESS STEEL) G** 3-SIDED SOFT ENCLOSURE (REQUIRES SUN TOP) (INCL ITEMS 27-28) * ENCLOSURE * VELCRO... AR 29 Page Q-4

90 WEATHER PROTECTION Replacement parts for the windshield may be obtained from Eagle Parts, Inc Marvin Griffin Rd. Augusta, GA Telephone (706) * 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 (FULL) (INCLUDES ITEMS 32-38) G01 WINDSHIELD (FULL) (LEXAN) EGWHC12 SASH, 26" LG EGWHS12 BOLT, 1/4-20 X 1 3/4" LG. (STAINLESS STEEL) EGWHG12 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN12 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 SAFETY LABEL G03 WINDSHIELD KIT (FULL) (INCLUDES ITEMS 45, 33-37) G01 WINDSHIELD (FULL) G04 WINDSHIELD KIT (SPLIT) (INCLUDES ITEMS 48, 49, 34-37) G01 WINDSHIELD (SPLIT) EGWHC10 SASH, 12" LG G02 WINDSHIELD KIT (SPLIT) (INCLUDES ITEMS 55, 56, 34-37) G01 WINDSHIELD (SPLIT) (LEXAN) EGWHC10 SASH, 12" LG... 2 Page Q-5

91 WEATHER PROTECTION Page Q-6

92 WHEELS AND TIRES 1 - Includes Items 2, 19, Includes Items 5, 19, Includes Items 8, 19, Includes Items 14, 15, 16 Tire design may vary by Part Number Ref Whl 3-1 Page R-1

93 WHEELS AND TIRES GOLD / SILVER SPOKE HUBCAP 22, 23 Page R-2

94 WHEELS AND TIRES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 WHEEL AND TIRE ASSEMBLY, LINKS (INCLUDES ITEMS 2, 19, 20) G01 CARLISLE TIRE (LINKS 18 X 8.5-8, 4 PLY RATED) G03 WHEEL AND TIRE ASSEMBLY, TURF SAVER (INCLUDES ITEMS 5, 19, 20) G03 CARLISLE TIRE (TURF SAVER 18 X 8.5-8, 4 PLY RATED) G01 WHEEL AND TIRE ASSEMBLY, LINKS (INCLUDES ITEMS 8, 19, 20) G08 CARLISLE TIRE (USA TRAIL LOAD RANGE C) G06 WHEEL AND TIRE ASSEMBLY, USA TRAIL (INCLUDES ITEMS 14, 15 16) G07 CARLISLE TIRE (USA TRAIL 5.70 X 8) G02 WHEEL RIM (4 LUG) G01 VALVE STEM G01 WHEEL RIM (4 LUG) G2 VALVE STEM G* GOLD SPOKE HUBCAP (OPTIONAL)... A/R G* SILVER SPOKE HUBCAP (OPTIONAL)... A/R Page R-3

95 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Appendix A-1

96 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO. BATTERY MAINTENANCE KIT G01 SEAL INSTALLATION TOOL (REAR AXLE SHAFT SEAL) G1 BATTERY SET DISCHARGER, 36 VOLT, 75 AMP G01 CURRENT INDICATOR G2 DIGITAL MULTI-METER G01 CRIMPING TOOL G01 SLIDE HAMMER (AXLE/HUB REMOVAL) G1 SLIDE HAMMER (AXLE REMOVAL ONLY) G1 TOUCH UP PAINT PART NO. PEN 3 OUNCE (89 ML) - HUNTER GREEN G02 PEN 3 OUNCE (89 ML) - CHAMPAGNE BEIGE G01 PEN 3 OUNCE (89 ML) - WHITE G05 PEN 3 OUNCE (89 ML) - INDUSTRIAL YELLOW G03 PEN 3 OUNCE (89 ML) - ORANGE G04 PEN 3 OUNCE (89 ML) - STEEL BLUE PEARL G** PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS) G01 AEROSOL 12 OUNCE (360 ML) - HUNTER GREEN G09 AEROSOL 12 OUNCE (360 ML) - CHAMPAGNE BEIGE G15 AEROSOL 12 OUNCE (360 ML) - WHITE G03 AEROSOL 12 OUNCE (360 ML) - INDUSTRIAL YELLOW G14 AEROSOL 12 OUNCE (360 ML) - ORANGE G13 AEROSOL 12 OUNCE (360 ML) - STEEL BLUE PEARL G** MAINTENANCE PRODUCTS PART NO. FORMULA 40 VINYL-COAT - WHITE G01 PLEXUS CLEANER, 7 OUNCE (210 ML) (FOR WINDSHIELDS) G01 PLEXUS CLEANER, 13 OUNCE (380 ML) (FOR WINDSHIELDS) G02 BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY G01 WHITE LITHIUM GREASE, 14 OUNCE (410 ML) SPRAY G01 PENETRANT/LUBRICANT, 15 OUNCE (440 ML) SPRAY G01 MULTI-PURPOSE CLEANER & DEGREASER, 14 OUNCE (410 ML) SPRAY G01 MULTI-PURPOSE HAND CLEANER, 32 OUNCE (950 ML) LIQUID G01 Appendix A-2

97 SPECIALTY PRODUCTS BATTERY CLEANER, 32 OUNCE (950 ML) WITH TRIGGER SPRAYER G01 BIO-DEGRADEABLE CLEANER, 32 OUNCE (950 ML) WITH TRIGGER SPRAYER G01 MULTI-PURPOSE VALUE PACK G01 BATTERY PROTECTOR, 4 OUNCE (120 ML) SPRAY PENETRANT/LUBRICANT, 4 OUNCE (120 ML) SPRAY WHITE LITHIUM GREASE, 4 OUNCE (120 ML) SPRAY CARBURETOR & CHOKE CLEANER, 4 OUNCE (120 ML) SPRAY Appendix A-3

98 SPECIALTY PRODUCTS Notes: Appendix A-4

99 OPTIONS/ACCESSORIES OPTIONS/ACCESSORIES Appendix B-1

100 OPTIONS/ACCESSORIES ITEM KIT NO. COMMENTS ACCESSORIES LISTING KIT NO. ASHTRAY KIT G See BODY BALL HITCH KIT G See BODY CLEVIS HITCH KIT G See BODY DEFROSTER/COOLING FAN G See CAB DOOR SET G0* See CAB DOOR SET (VINYL) G See CAB ELECTRIC DUMP KIT G See TRUCKBED GLOVE BOX DOOR G0* See BODY HOUR METER KIT G See ELECTRICAL SYSTEM INSIDE MIRROR G See WEATHER PROTECTION INSTRUMENT/SWITCH PANEL G See CAB REAR VIEW MIRROR KIT G See WEATHER PROTECTION SOFT ENCLOSURE G** See WEATHER PROTECTION STEEL CAB, W/O DOORS G0* See CAB STROBE LIGHT G See CAB SUN TOP KIT G** See WEATHER PROTECTION TURN SIGNAL KIT G See ELECTRICAL SYSTEM GOLD SPOKE WHEEL COVERS G* See WHEELS AND TIRES SILVER SPOKE WHEEL COVERS G* See WHEELS AND TIRES WINDSHIELDS G0* See WEATHER PROTECTION WINDSHIELD WIPER G See CAB WORK LIGHTS G See CAB WORK LIGHT BAR WITH LIGHTS G See ELECTRICAL SYSTEM WORK LIGHT BAR WITH STROBE G See ELECTRICAL SYSTEM WORK LIGHT BAR WITH LIGHTS AND STROBE G See ELECTRICAL SYSTEM Appendix B-2

101

102 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA TO CONTACT US North America: Technical Assistance & Warranty Phone: , FAX: Service Parts Phone: GET-EZGO ( ), FAX: International: Phone: , FAX: Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department