ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR

Transcription

1 INCLUDES ITEMS A Textron Company SERVICE PARTS MANUAL ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR STARTING MODEL YEAR: 2005

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3 SERVICE PARTS MANUAL ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CARS SHUTTLE/BELLHOP 2 SHUTTLE/BELLHOP 4 SHUTTLE/BELLHOP 6 TE5 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., 1451 MARVIN GRIFFIN RD., 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. Overfilling of batteries may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75 F (-60 C). As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals. Page ii

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

6 TABLE OF CONTENTS Notes: Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION ILLUSTRATED PARTS BREAKDOWN APPENDIX The first section, GENERAL INFORMATION, contains the following information: WARRANTY INFORMATION GENERAL INDEX HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle. The third section, APPENDIX, contains a listing of specialty products and accessories. USE OF THE MANUAL To use this manual, consult the GENERAL INDEX to locate the information or illustration required. Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its location) and note the complete number shown on the plate. v

8 ,87 67 Front of Vehicle 83,88 81,86 84, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the General Index and select the most appropriate title. Turn to the page number indicated and locate the desired part on the illustration. From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part. 2. IF YOU KNOW THE PART NUMBER Locate the part number or description in the appropriate column on the parts list page. NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 - Includes Items 3-19, 21, 23, Includes Items 3-17, 20, 21, Includes Items Includes Items 34, To Direction Selector Harness Ref Acl 7-1 Page A-1

11 ACCELERATOR Ref Acl 7-2 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 G08 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3-19, 21, 23, 26-43) G07 PEDAL BOX ASSEMBLY, PDS MODEL ONLY (INCLUDES ITEMS 3-17, 20, 21, 24-43) G01 PEDAL BOX AND COVER (SEAL AND BEARING) G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" G01 PLUNGER SLEEVE G01 PLUNGER G01 PLUNGER CAM G01 ACCELERATOR ROD G4 LOCK NUT, 5/ G4 YOKE (ADJUSTABLE) G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G01 MICRO SWITCH G02 MICRO SWITCH (PDS MODEL ONLY) G01 SCREW, #4-20 X 5/8" LG G07 WIRING HARNESS (PEDAL BOX ASSEMBLY) G06 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY) G6 SCREW, #8-32 X 3/4" LG G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG... 4 Page A-3

13 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32-35) * ACCELERATOR PEDAL G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35) G01 ACCELERATOR PEDAL PAD G1 OVAL RIVET 3/16" X 7/16" LG G1 BUSHING G01 PEDAL PIVOT PIN G6 PUSHNUT, 9/32" I.D G3 CLEVIS PIN, 5/16" X 13/16" LG G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G2 BOLT, 5/16-18 X 13/16" LG G01 PEDAL PIVOT COVER... 1 Page A-4

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

15 BATTERY CHARGER (PORTABLE) THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 48V LESTER BATTERY CHARGER G01 48V LESTER BATTERY CHARGER WITH SWITCHABLE INPUT G05 48V LESTER BATTERY CHARGER CE APPROVED... 1 For service or replacement parts, contact: Lester Electrical 625 West A Street Lincoln, NE Phone: (402) , FAX: (402) Always provide the following information when requesting information or ordering replacement parts: Model Number: Serial Number: (stamped into housing) Page B-2

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

17 BODY Ref Bod 7-2 Page C-2

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

19 BODY Ref Bod 7-4 Page C-4

20 BODY Ref Bod 7-5 Page C-5

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

22 BODY Front of Vehicle SHUTTLE Page C-7

23 BODY SHUTTLE 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 G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 2-5) G01 DEFLECTOR (PASSENGER SIDE) G01 DEFLECTOR (DRIVER SIDE) G5 SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (4 CUP HOLDER) G01 LABEL (ANTI-ROLLBACK) G01 LABEL (SAFETY) (SHUTTLE) G01 LABEL (SAFETY) (TE5) G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 FRONT SHIELD BRACE G04 FRONT SHIELD G01 BOLT, 1/4-20 X 11/16" LG G1 WASHER, 1/4" G01 RIVET, KTR, 1/4" X 3/4" LG G01 UPPER FLOORPAN G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ACCESS COVER... 1 Page C-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 G01 REAR FLOORPAN G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G0* FLOORMAT G** COWL G02 E-Z-GO NAMEPLATE (GOLD) G01 PUSHNUT, 3/16" G01 RIVET, 3/16" X 1" LG G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 BOLT, 5/16-18 X 5/8" LG (WITHOUT SUN TOP) G2 WASHER, 5/16 (WITHOUT SUN TOP) G6 BOLT, 5/16-18 X 5/8" LG (WITHOUT SUN TOP) G2 WASHER, 5/16 (WITHOUT SUN TOP) G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG G01 SEAT FRAME G02 BATTERY RACK G2 BOLT, 5/16-18 X 13/16" LG G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 SCREW, 3/8-16 X 3/4" LG G01 SPLASH PAN (PASSENGER SIDE)... 1 Page C-10

26 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 SPLASH PAN (DRIVER SIDE) G2 BOLT, 5/16-18 X 13/16" LG G01 FENDER LINER (PASSENGER SIDE) (SHUTTLE) G02 FENDER LINER (DRIVER SIDE) (SHUTTLE) G05 FENDER LINER, EXTENDED (PASSENGER SIDE) (TE5) G05 FENDER LINER, EXTENDED (DRIVER SIDE) (TE5) G2 RATCHET FASTENER, 1/4" X 3/4" LG (SHUTTLE - QTY 4) (TE5 - QTY 8)... AR G** REAR BODY ASSEMBLY (WITH TAILLIGHTS) (INCLUDES ITEMS 73, 74) G** REAR BODY ASSEMBLY (W/OUT TAILLIGHTS) (INCLUDES ITEMS 73, 74) G01 BAGWELL LINER G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 HINGE PLATE G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 PLUG G01 ACCESS PANEL G01 SCREW, #8 X 5/8" LG G02 J CLIP G12 RIVET, 1/4" X 9/16" LG (ALUMINUM) G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" LG G02 REAR BUMPER (SHUTTLE 4, TE5 PDS) G01 REAR BUMPER (SHUTTLE 6) (INCLUDES ITEM 91)... 1 Page C-11

27 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 STAY G01 BOLT, 1/4-20 X 1 1/4" LG (SHUTTLE 4 - QTY 4) (SHUTTLE 6 - QTY 2)... AR G2 WASHER, 5/16" (SHUTTLE 4 - QTY 4) (SHUTTLE 6 - QTY 2)... AR G01 BUMPER PLUG G03 BOLT, 1/4-20 x 11/16" LG G01 J-TYPE NUT RETAINER, 1/ G01 REAR BUMPER (TE5) G01 BOLT, 1/4-20 X 3/4" LG G2 WASHER, 5/16" G01 BUMPER PLUG G17 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ROCKER PANEL (FRONT, DRIVER SIDE) G02 ROCKER PANEL (FRONT, PASSENGER SIDE) G01 ROCKER PANEL (REAR, DRIVER SIDE) G02 ROCKER PANEL (REAR, PASSENGER SIDE) G01 SILL PLATE (PASSENGER SIDE) G02 SILL PLATE (DRIVER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G4 SPACER, 5/16" G2 LOCK NUT, 1/ G6 RIVET, 3/16" X 15/16" LG (ALUMINUM) G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE) G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) G4 BOLT, 3/8-16 X 1 1/2" LG (SHUTTLE 4) G6 BOLT, 3/8-16 X 1 3/4" LG (SHUTTLE 6)... 2 Page C-12

28 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 SEAT BACK SUPPORT (SHUTTLE) G01 SPACER (TE5 & SHUTTLE 6) G02 BOLT, 3/8-16 X 1 1/4" LG G8 BOLT, 3/8-16 X 1" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 VALANCE PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 LABEL (SHUTTLE) G13 LABEL (6) G14 LABEL (4) G01 LABEL (PRECISION DRIVE SYSTEM) (TE5) G01 LABEL (F-R) G01 LABEL (F-R) (EC) G01 FENDER SCUFFGUARD (DRIVER SIDE) (TE5) G02 FENDER SCUFFGUARD (PASSENGER SIDE) (TE5) G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 HOLD DOWN BRACKET G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G01 CARGO DECK... 1 Page C-13

29 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 NOISE SUPPRESSOR G01 STEEL DECK G01 CARGO BED MAT G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL) G4 LOCK NUT, 1/ G01 LATCH G6 SCREW - # X 3/4 HW - SDT - ZP G02 FRONT/REAR CARGO RACK G01 SIDE CARGO RACK G01 TAILGATE RETAINER BRACKET G6 SCREW, #10-12 X 3/4" LG G1 BUSHING G4 BOLT, 5/16-18 X 2 1/2" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G01 LABEL (WARNING) (BED LATCH - SHUTTLE 4) G01 LABEL (WARNING) (LOAD BED - SHUTTLE 4) G02 FOOT REST ASSEMBLY (INCLUDES ITEMS ) G01 FOOT REST G01 FLOOR MAT G01 REFLECTOR G1 END CAP... 2 Page C-14

30 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 LABEL (WARNING) (EC) G2 CARRIAGE BOLT, 3/8-16 X 1 1/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G6 BOLT, 3/8-16 X 1 3/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G01 PEDAL PIVOT COVER G01 FENDER FLAIR G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 SPACER, DRIVER SIDE G02 SPACER, PASSENGER SIDE G01 SILL PLATE TREAD G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G2 SPACER, 1/4" G7 WASHER, 1/4" G4 LOCK NUT, 1/ G01 ROCKER PANEL, DRIVER SIDE G02 ROCKER PANEL, PASSENGER SIDE G2 SCREW, #10-24 X 1 1/4 LG G2 SPACER, 1/4" G5 WASHER, # G7 LOCK NUT, # Page C-15

31 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 CARGO DECK G01 HINGE G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL) G9 SCREW, 1/4-20 X 1 1/4" LG (STAINLESS STEEL) G7 WASHER, 1/4" G7 WASHER, 1/4" G2 LOCK NUT, 1/ G01 BED FRAME G01 SCREW, 3/8-16 X 2 3/4" LG G3 WASHER, 3/ G6 SCREW, 5/16-18 X 1 3/4" LG G8 WASHER, 5/ G6 LOCK NUT, 5/ G01 BRACKET G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/ G6 LOCK NUT, 5/ G01 BED MOUNT BRACKET G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL) G7 WASHER, 1/4" G2 LOCK NUT, 1/ G01 BULKHEAD G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL)... 4 Page C-16

32 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 G7 WASHER, 1/4" G2 LOCK NUT, 1/ G03 FLOORMAT G01 FENDER (DRIVER SIDE) G02 FENDER (PASSENGER SIDE) G03 FENDER WITH TAILLIGHT (DRIVER SIDE) G04 FENDER WITH TAILLIGHT (PASSENGER SIDE) G02 REAR PANEL G01 RIVET, 3/16" X 1" LG G2 LOCK NUT, 1/ G7 WASHER, 1/4" G7 BOLT, 1/4-20 X 7/8" LG G01 SIDE PANEL, DRIVER SIDE G02 SIDE PANEL, PASSENGER SIDE G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 SEAT HINGE G01 SEAT WRAP PANEL G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G12 RIVET, 1/4" X 9/16" LG G01 WASHER, 1/4" G01 SEAT FRAME WELDMENT G8 BOLT, 5/16-18 x 1"LG G8 WASHER, 5/ G6 LOCK NUT, 5/ Page C-17

33 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 G2 BOLT, 5/16-18 X 13/16" LG G01 BOLT, 3/8-16 X 3/4" LG G02 SEAT BACK BRACKET G8 BOLT, 3/8-16 X 1" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 SEAT FRAME G01 BATTERY RACK WELDMENT G2 BOLT, 5/16-18 X 13/16" LG G8 BOLT, 5/16-18 x 1"LG G8 WASHER, 5/ G6 LOCK NUT, 5/ G2 BOLT, 5/16-18 X 13/16" LG G6 LOCK NUT, 5/ G01 BOLT, 3/8-16 X 3/4" LG... 2 Page C-18

34 BRAKES - MECHANICAL Part of Frame Accelerator Pedal Includes Items 19, Includes Items Ref Brm 8-1 Page D-1

35 BRAKES - MECHANICAL WHT BLK Includes Items Includes Items BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Ref Brm 8-2 Page D-2

36 BRAKES - MECHANICAL Front of Vehicle Includes Items 84-92, 94, Includes Items 84-91, Includes Items Includes Items Includes Items 94, Includes Items 94, Includes Items 101, 102 Ref Brm 8-3 Page D-3

37 BRAKES - MECHANICAL 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 2-10) 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 7/16" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) 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/ G06 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-24) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER G01 RETAINING RING, 13/32" (STAINLESS STEEL) Page D-4

38 BRAKES - MECHANICAL 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 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 5/8" 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/ G01 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) 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 D-5

39 BRAKES - MECHANICAL 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 7/16" LG G02 BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 7/8" LG G1 RUBBER NUT, # G03 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G7 LOCK NUT, # G8 MICRO SWITCH G1 BOLT, #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 84-92, 94, 95) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84-91, 93-95) G01 BRAKE SHOE KIT (INCLUDES ITEM 85) * BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 87-91) * UPPER SPRING... 1 Page D-6

40 BRAKES - MECHANICAL 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. 88 * LOWER SPRING * 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, 1 5/16" OD X 1" ID X 1/32" G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) * BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 OUTER BRAKE DRUM WASHER G8 SLOTTED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP G01 BRAKE CABLE BRACKET (PASSENGER SIDE) G02 BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-7

41 BRAKES - MECHANICAL Page D-8

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

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

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

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

46 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

47 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/ G01 CATCH BRACKET G6 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

48 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 G02 BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G3 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G7 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

49 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 SPINDLE, CALIPER AND DISC HUB ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS ) G01 DISC BRAKE SPINDLE (DRIVER SIDE) G02 CALIPER (DRIVER SIDE) G1 SLOTTED NUT G01 DRIVE FLANGE STUD G2 ROLLER BEARING G1 BEARING RACE G01 DISC BRAKE HUB G01 FLANGED BEARING G8 WASHER, 3/8" G8 BOLT, 3/8-16 X G01 BEARING G8 COTTER PIN G1 GREASE SEAL G01 SPINDLE, CALIPER AND DISC HUB ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS , 106, 107) G01 DISC BRAKE SPINDLE (PASSENGER SIDE) G01 CALIPER (PASSENGER SIDE) G01 DISC BRAKE SERVICE HUB (INCLUDES ITEMS 94-97, 103) G01 KINGPIN TUBE G01 THRUST WASHER G3 WASHER, 1/2" G6 LOCKNUT, 1/ G6 CAPSCREW, 1/2-13 X 6" LG G01 FRONT DISC BRAKE BRAKE ACTUATOR ASSEMBLY (INCLUDES ITEMS ) G3 COTTER PIN, 3/32 X 3/4" LG... 1 Page E-8

50 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 G2 WASHER, 5/16" STAINLESS G3 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

51 BRAKES - FRONT DISC Page E-10

52 ELECTRICAL SYSTEM A1 F A2 F Includes Items Includes Items Page F-1

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

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

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

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

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

58 ELECTRICAL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G0* CHARGER HARNESS / RECEPTACLE (INCLUDES ITEMS 2-11) G0* CHARGER HARNESS G30 CHARGER HARNESS RECEPTACLE (INCLUDES ITEMS 4-11) G22 RECEPTACLE BOTTOM G21 RECEPTACLE COVER G08 SCREW, #10-32 X 1/2" LG G09 SCREW, #6-32 X 1 3/4" LG G10 LOCK NUT, # G23 FEMALE CONTACT G24 FEMALE CONTACT, INSULATED G01 RIVET, 3/16" X 1" LG G01 POWER HARNESS G01 LOCK WASHER, 5/16" G01 NUT, 5/ G0* CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) XXXXX-G** 6 VOLT BATTERY G01 BATTERY RETAINER G01 HOLD DOWN BOLT G1 LOCK NUT, 5/ G01 HOLD DOWN BOLT G01 BATTERY RETAINER G18 4 GA WIRE (BLK 6")... 4 Page F-7

59 ELECTRICAL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G16 4 GA WIRE (BLK 19") G13 4 GA WIRE (BLK 10 1/2") G2 NUT, 5/ G02 CONSOLE INSERT PLATE G02 LABEL, CONSOLE INSERT PLATE (WITHOUT LIGHTS) G01 LABEL, CONSOLE INSERT PLATE (WITH LIGHTS) G02 RIVET, 3/16" X 3/8" LG G1 IGNITION SWITCH KIT (INCLUDES ITEMS 41-43) G1 IGNITION SWITCH (WITHOUT LIGHTS, STANDARD KEY) G6 LOCK WASHER, 3/4" G1 FACE NUT G1 IGNITION SWITCH (WITHOUT LIGHTS, NON-STANDARD KEY) G1 IGNITION SWITCH (WITHOUT LIGHTS, INDIVIDUALLY KEYED) G01 IGNITION SWITCH (WITH LIGHTS, STANDARD KEY) G02 IGNITION SWITCH (WITH LIGHTS, NON-STANDARD KEY) G03 IGNITION SWITCH (WITH LIGHTS, INDIVIDUALLY KEYED) G01 WIRE HARNESS (KEY SWITCH) G1 WIRE TIE G03 STATE OF CHARGE METER G74 18 GA WIRE (RED 6") G02 WIRE HARNESS (STATE OF CHARGE METER) G1 FUSE BLOCK G01 RIVET, 5/32" X 3/8" LG G1 FUSE, 15 AMP G02 WIRE HARNESS (ACCESSORY) Page F-8

60 ELECTRICAL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 HORN G03 HEADLIGHT MOUNT BRACKET (PASSENGER SIDE) G04 HEADLIGHT MOUNT BRACKET (DRIVER SIDE) G6 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/ G01 HEADLIGHT AND TURN SIGNAL LIGHT BAR G6 SCREW, 1/4-20 X 3/4" LG XXXXX-XX SEE BODY SECTION G01 HEADLIGHT BULB G01 MARKER LIGHT BULB G01 TURN SIGNAL BULB G2 TAILLIGHT ASSEMBLY G01 BEZEL (DRIVER SIDE) G02 BEZEL (PASSENGER SIDE) G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G02 J CLIP G01 COUNTERSUNK SCREW, #3-18 X 3/4" LG G1 TAILLIGHT BULB G1 TURN SIGNAL (WITH MOUNTING HARDWARE) (INCLUDES ITEM 88) G1 TURN SIGNAL FLASHER G3 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE... 2 Page F-9

61 ELECTRICAL SYSTEM THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 STEERING COLUMN COVER G06 HOUR METER KIT (INCLUDES ITEMS 94-98) G1 HOUR METER ASSEMBLY G02 HOUR METER BRACKET G4 SCREW, #10-24 X 1/2" LG G7 LOCK NUT, # G04 WIRE HARNESS (HOUR METER) G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 RIVET, 3/16" X 1" LG G06 CONSOLE INSERT PLATE G01 LABEL, DIRECTION SELECTOR AND STATE OF CHARGE METER G01 LABEL, LIGHTS, DIRECTION SELECTOR & STATE OF CHARGE METER G01 DIRECTION SELECTOR SWITCH G05 STATE OF CHARGE METER (VERTICAL) G02 RIVET, 3/16" X 3/8" LG G01 HARNESS (CONTROL) G02 BUZZER G01 RIVET, 5/32" X 3/4" LG... 2 Page F-10

62 l P/N G01 ELECTRONIC SPEED CONTROL - PDS 1 - Includes , 24 #10 Black 21, 22 From Motor F2 (Power Harness) J3 J2 J1 F2 B+ F1 M- B- 16 #4 Black From Motor A1 (Power Harness) #4 Black From Motor A2 (Power Harness) #18 Yellow From J1 Pin 5 (Control Harness) #18 Blue From J1 Pin 17 (Control Harness) 9, 10 7, 8, 12 6 #18 Red From Tow Switch and Reverse Buzzer (Control Harness) #10 White From Charger Receptacle Speed Sensor Harness 26 Charger Receptacle Harness #4 Black From Charger (Charger Harness) #18 Red/White From Tow Switch (Control Harness) To Ignition Interlock (Charger Receptacle) #4 Black From Motor A1 (Power Harness) 27 #4 Black From Battery (-) (Power Harness Power Harness 29 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 Always select 'TOW / MAINTENANCE' position before towing. RUN WARNING TOWING MAINTENANCE TOW MAINTENANCE Possibility of electrical arc and battery explosion. Before removing/connecting batteries or electrical components turn switch to 'TOW/MAINTENANCE' position. To disable electrical system place switch in 'TOW/MAINTENANCE' position and remove battery wire. After reconnecting batteries, allow a minimum of 30 seconds before selecting 'RUN' position 73340G HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries 2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC 2-3 THERMAL CUTBACK Vehicle performance reduced Allow controller to cool 2-4 MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller 2-5 VDD FAULT Vehicle will not run Replace controller 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller 3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to B+, replace controller 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring. not run Replace power harness and motor if required. 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted. Verify, replace motor if necessary. 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 AUX CONT DNC Vehicle will not run Replace controller 4-5 WELDED AUX CONT Vehicle runs slowly Replace controller 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring. Replace solenoid if necessary 5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring. Replace solenoid if necessary 5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring. Replace solenoid if necessary Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close), HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor), M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault) DIAGNOSTIC FAULT CODES The LED will flash a diagnostic fault code when a fault is detected Some faults may only be detected by operating the vehicle with the rear of the vehicle raised and supported on safety stands Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery compartment) to the 'TOW/MAINTENANCE' position before performing any repairs or maintenance to the vehicle Select 'RUN' before returning the vehicle to service Ref Esp 7 Page G-1

63 ELECTRONIC SPEED CONTROL - PDS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-16) G02 CONTROLLER MOUNT G04 ELECTRONIC SPEED CONTROLLER G01 48 VOLT SOLENOID (INCLUDES ITEMS 7-10) * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * JAM NUT, 5/ G01 FASTON TAB G2 LOCK NUT, 1/ G17 6 GA WIRE (BLK 9") G01 DOUBLE TUBE CLAMP G2 LOCK NUT, 1/ G01 BOLT, 8MM X 16MM LG G01 LOCK WASHER, 5/16" G01 BOLT, 6MM X 1 X 12MM LG G02 LOCK WASHER, 1/4" G01 CONTROL HARNESS G06 4 GA WIRE (BLK 59 1/2") (SOL - BATTERY +) G01 TOW-MAINTENANCE SWITCH G01 RIVET, 5/32" X 3/4" LG G01 DIAGNOSTIC LABEL (FAULT CODE)... 1 Page G-2

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

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