SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLES TUG STARTING MODEL YEAR 2006+

Transcription

1 RELEASED: 2006 REVISED: AUGUST 2009

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3 SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLES TUG STARTING MODEL YEAR 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. 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 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 v ILLUSTRATED PARTS BREAKDOWN ix BATTERY CHARGER A-1 BATTERY RACK & HOLD DOWNS B-1 BODY C-1 BRAKE - MASTER CYLINDER D-1 DIFFERENTIAL E-1 DRIVE MOTOR F-1 EC CONVERSION KIT G-1 ELECTRICAL COMPONENTS H-1 FORK AND HANDLE BAR J-1 FRONT & REAR WHEELS AND TIRES K-1 HYDRAULIC LINES AND RELATED PARTS M-1 LIFT OUT BATTERY RACK N-1 PARK BRAKE LEVER P-1 REAR WHEEL BRAKE Q-1 REAR WHEEL FRAME & SHOCK ABSORBER R-1 SEATING S-1 SPEED CONTROL PEDAL T-1 STEERING KIT U-1 Page iii

6 TABLE OF CONTENTS 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 USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS (page iii) 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 Front of Vehicle ,88 81,86 84,89 82, , *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 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 HOW TO USE THE SERVICE PARTS MANUAL!! When replacement parts are required, use genuine Cushman parts or parts with equivalent characteristics including type, strength and material. Failure to use proper replacement parts may result in product malfunction and possible injury to the operator and/or by standers. Illustrations in this manual are for parts identification ONLY. These illustrations may not depict actual positioning of component parts and should NOT be used as assembly diagrams. Doing so may result in improper assembly, leading to sudden failure. VEHICLE MODEL NUMBER/ MODEL YEAR & SERIAL NUMBER The vehicle model number decal is located on upper left portion of kick panel. The complete (10) ten digit number is required to identify certain parts. Cushman Inc, a Textron Company, reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models and accessories designed to be used on these models. The right is also reserved to change specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change. While the information contained in this parts manual is based on the latest product information available at the time of publication, the continuing accuracy of this parts manual cannot be guaranteed. ACCESSORIES Model Number, Model Year and Serial Number on Decal The vehicle serial number and model number are stamped on top of the right rear wheel well under the deck.!! In some cases accessories must be used in conjunction with other accessories to maintain safe operating conditions for a vehicle. Display of an accessory in this manual does not imply it can be used on any other vehicle. Using an accessory in a non-recommended application may create unsafe operating conditions. NEVER attach ANY electrical device or accessory to this vehicle which is grounded to the vehicle frame. VEHICLE IDENTIFICATION THESE IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE CONCERNING THE VEHICLE. Vehicle Serial and Model Number on Top of Wheel Well Repair and Service Manual Page -vii

10 HOW TO USE THE SERVICE PARTS MANUAL SERVICE PUBLICATIONS IMPORTANT Additional Parts Manuals are available: ALSO Operator s Manual: Part No: INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY. INDICATES: PARTS NOT ILLUSTRATED INDICATES: SEE NOTE BELOW THE PARTS LIST Order for a minimum charge at this address: EZ-GO 1451, MARVIN GRIFFIN RD, AUGUSTA, GEORGIA AFTER YOU IDENTIFY A PART BY THE REFERENCE NUMBER AND THE SIX DIGIT CUSHMAN PART NUM- BER, ALWAYS READ THE DESCRIPTION OF THE PART TO BE SURE IT IS WHAT YOU WANT. TOUCH-UP PAINT Safety Yellow (lead free) 16 oz. (0.5L) spray can...part No qt. (0.95L) can.part No Page -viii Repair and Service Manual

11 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page -ix

12 BATTERY CHARGER 1 - INCLUDES ITEMS CUSHMAN Page A-1

13 BATTERY CHARGER 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 CHARGER, COMPLETE, MODEL 17670, 25 AMP, 120 VAC, 60 HZ... 1 (1 - INCLUDES ITEMS 2-13) 2 * CASE, LESTER NO S * TRANSFORMER, LESTER NO S BUSHING, A.C. CORD FUSE HEATSINK WITH DIODES RELAY CAPACITOR, 6.0 MFD A.C. CORDSET TIMER SCREW, 1/4-20 X 3/4" LG WASHER, 1/4"... 4 Page A-2

14 BATTERY RACK & HOLD DOWNS Page B-1

15 BATTERY RACK & HOLD DOWNS 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 RACK, BATTERY J BOLT BATTERY HOLD DOWN SPACER, RUBBER WASHER, 11/32" WASHER, 11/32" LOCK WASHER, 5/16" WING NUT, 5/ WIRE 10"... 5 Page B-2

16 BODY WARNING 20 PROVIDE BATTERY VENTILATION DURING CHARGING. KEEP OPEN FLAMES OR SPARKS AWAY FROM BATTERIES AT ALL TIMES. DO NOT SHORT ACROSS BATTERIES TO CHECK CONDITION OF BATTERIES. BATTERIES MAY EXPLODE. BATTERY ACID CAN CAUSE SEVERE DAMAGE TO EYES, SKIN AND CLOTHING. FLUSH CONTAMINATED AREA IMMEDIATELY WITH WATER. WHEN CLEANING BATTERIES, KEEP SOLUTION AND WATER AWAY FROM CHARGER AND SWITCHES BODY 21 WARNING TO AVOID INJURY TO HANDS ON FINGERS WHEN REMOVING OR INSTALLING LIFT- OUT BATTERY PACK: 1. USE ADEQUATE LIFTING DEVICE. BATTERIES ARE HEAVY. 2. DO NOT PLACE HANDS ON BATTERIES OR RACK. 3. DO NOT ALLOW HANDS TO REST ON VEHICLE OR GUIDES Page C-1

17 BODY DETAIL A WARNING THIS VEHICLE CAN TOW GREATER LOADS THAN CAN BE STOPPED UNDER SOME CONDITIONS RECOMMENDED MAXIMUM GROSS TOWED LOAD 1 TRAILER : 3000 LB 2 TRAILERS : 1500 LB EA. 3 TRAILERS : 1000 LB EA DETAIL B NOTICE THIS VEHICLE IS EQUIPPED WITH A THROTTLE-SOLENOID INTERLOCK SYSTEM. IN CASE OF POWER INTERRUPTION, RELEASE AND REAPPLY THROTTLE. (SEE OWNER'S MANUAL) DETAIL C NOTICE THIS UNIT IS NOT A MOTOR VEHICLE WITHIN THE DEFINITION OF THE NATIONAL TRAFFIC MOTOR VEHICLE SAFETY ACT. IT IS NOT DESIGNED OR MANUFACTURED FOR USE ON ROADS, STREETS OR HIGHWAYS, NOR IS IT APPROPRIATE FOR SUCH USE. IT IS NOT MEANT TO BE LICENSED AS A MOTOR VEHICLE A B 25 DETAIL D WARNING FAILURE TO OBEY A SAFETY WARNING MAY RESULT IN INJURY TO YOU OR OTHERS BEFORE OPERATING VEHICLE READ AND UNDERSTAND OPERATORS MANUAL (LOCATED UNDER SEAT). DO NOT CARRY PASSENGERS. SWITCHES SPARK-DO NOT OPERATE IN EXPLOSIVE OR COMBUSTIBLE ATMOSPHERE. WHILE OPERATING VEHICLE KEEP BODY INSIDE VEHICLE. STAY IN SEAT. SUDDEN SHARP TURNS, UNBALANCED OR TOP-HEAVY LOADS CAN CAUSE UPSET. ADJUST SPEED TO CONDITIONS. CARGO MUST BE SECURED TO PLATFORM. AVOID SUDDEN STARTS AND STOPS TO AVOID SHIFTING LOADS AND JACKKNIFE OF VEHICLE AND TRAILERS. BEFORE LEAVING VEHICLE SET DIRECTION SELECTOR TO 'OFF' TURN KEY TO VERTICAL 'OFF' POSITION AND REMOVE IF MALFUNCTION OCCURS, OR ADJUSTMENT IS NEEDED, DO NOT USE. WARNING-APPLY HAND BRAKE OR FOOT BRAKE- PARKING BRAKE NOT AUTOMATICALLY APPLIED C D E 26 DETAIL E WARNING CLEAN MASTER CYLINDER FILLER CAP BEFORE REMOVING. CONTAMINATES MAY CAUSE BRAKE FAILURE. USE ONLY D.O.T. 3 FLUID FROM A SEALED CONTAINER Page C-2

18 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. 1 XXXXXX BODY & FRAME, COMPLETE WITH SPINDLE BEARING AND DECALS SAFETY YELLOW BURLINGTON GREEN GALVANIZED YELLOW GALVANISED BURLINGTON GREEN DECK, REAR XXXXXX COVER, MASTER CYLINDER SAFETY YELLOW BURLINGTON GREEN SCREW, 1/4-20 X 3/4" LG BEARING GROMMET NUT, 1/ GUARD, ACCELERATOR PEDAL LOCK WASHER, 1/4" NUT, 1/ GROMMET NAME PLATE, CUSHMAN PINTLE HITCH HITCH PLATE DECAL, BATTERY CHARGING DECAL, WARNING DECAL, TOWING, WARNING DECAL, INTERLOCK DECAL, NOTICE DECAL, WARNING DECAL, BRAKE FLUID, WARNING... 1 Page C-3

19 BODY Page C-4

20 BRAKE - MASTER CYLINDER INCLUDES ITEM Front of Vehicle Page D-1

21 BRAKE - MASTER CYLINDER 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 CYLINDER, MASTER SHIM NUT, 5/ LOCK WASHER, 5/16" BOLT, 5/16-18 X 1 1/4" LG SPRING, BRAKE PEDAL RETURN PIN, COTTER, 3/32 X 3/ WASHER, 5/16" PIN, CLEVIS BOLT, 3/8-16 X 1" LG COVER, BRAKE PEDAL PEDAL, BRAKE NUT, 3/ LOCK WASHER, 3/ BUMPER, RUBBER BRAKE PEDAL & BUSHING (21 - INCLUDES ITEM 22) FITTING, LUBRICATION BOLT, 5/16-18 X 1" LG... 4 Page D-2

22 DIFFERENTIAL FRONT OF VEHICLE 55 NOT OFFERED INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEM INCLUDES ITEM INCLUDES ITEMS INCLUDES ITEM REFER CHAPTER M-1, FOR HYDRAULIC LINES AND RELATED PARTS Page E-1

23 DIFFERENTIAL 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 DIFFERENTIAL, COMPLETE (1 - INCLUDES ITEMS 2-72) HOUSING, RIGHT HOUSING, LEFT BOLT, SPECIAL LG VALVE, BREATHER NUT, 5/16-18, LOCK WASHER, 5/16" BOLT, 5/16-18 X 1 3/8" LG TAG, RATIO (15.67:1) PLUG, FILLER DRAIN WORM, WITH BEARING & SLINGER (14 - INCLUDES ITEMS 15-16) BEARING CONE, ROLLER SLINGER SET, OIL CUP, ROLLER BEARING GASKET RETAINER, BEARING SEAL BOLT, 3/8-16 X 1 3/4" LG LOCK WASHER, 3/8" SHIM, AR SHIM, AR SHIM, AR SHIM, AR Page E-2

24 DIFFERENTIAL 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 PULLEY (140 MM) HUB, REAR WASHER, SPECIAL WASHER, 7/16" LOCK WASHER, 7/16" BOLT, 7/16-14 X 1" LG WASHER CONE LOCK NUT, 1/ CUP, ROLLER BEARING SHIM, AR SHIM, AR SHIM, AR LOCK WASHER, 5/16" NUT, 5/ AXLE, LEFT, 15 7/8" (403 MM) (46 - INCLUDES ITEM 47) BEARING CONE, ROLLER SEAL, REAR AXLE AXLE, RIGHT, 14 9/16" (370 MM) (49 - INCLUDES ITEM 50) BEARING CONE, ROLLER GEAR CARRIER, (15.67:1 RATIO) (53 - INCLUDES ITEMS 54-66) BEARING CONE, CARRIER HOUSING, CARRIER GEAR, WORM (15.67:1 RATIO) PLATE, LOCKING PLATE, RETAINER BOLT, 5/16-18 X 3/4" LG GEAR, AXLE SHAFT... 2 Page E-3

25 DIFFERENTIAL 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 SPACER SHAFT, DIFFERENTIAL GEAR GEAR, DIFFERENTIAL PLANET SPACER PLATE, LOCKING BOLT, SPECIAL LG CUP, ROLLER BEARING SHIM, AR SHIM, AR SHIM, AR GASKET, BEARING SEAL & RETAINER (74 - INCLUDES ITEM 75) SEAL, BEARING WASHER, SPECIAL NUT, 5/8-18, CASTLE PIN, COTTER, 1/8 X 1 1/ WASHER, SPECIAL NUT, 1/2-20, CONELOCK KEY, HUB... 2 Page E-4

26 DRIVE MOTOR Frame FRONT OF VEHICLE Page F-1

27 DRIVE MOTOR 37 - INCLUDES ITEMS NOT OFFERED NOT OFFERED NOT OFFERED NOT OFFERED Page F-2

28 DRIVE MOTOR 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 MOUNTING PLATE BOLT, 5/16-18 X 1" LG WASHER, 5/16" KEY, WOODRUFF # NUT, 7/ BOLT, 3/8-16 X 2" LG WASHER, 7/16" LOCK WASHER, 5/16" NUT, ADJUSTING ROD BOLT, 3/8-16 X1" LG LOCK WASHER, 7/16" WASHER, 3/8" LOCK WASHER, 3/8" NUT, 3/ BRACKET BOLT, 7/16-14 X 3" LG SUPPORT MOUNT NUT, CENTRE LOCK, 3/ V-BELT SET (3) NUT, CONE LOCK, 1/ Page F-3

29 DRIVE MOTOR 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 PULLEY, 4 1/2" O.D (114 MM) MOTOR, 3 HP (37 - INCLUDES ITEMS 38-60) NUT, 5/ WASHER WASHER, INSULATING BUSHING WASHER, INSULATING BRUSH * BOLT POLE PIECE * BRUSH & SPRINGS BRUSH SPRING BOLT, HOLDER * BOLT, POLE * BOLT CLAMP * BOLT MOTOR CLAMP * WASHER SPRING * SPACER * SHIM... AR BEARING PULLEY ARMATURE BEARING COMMUTATOR FIELD COIL... 1 Page F-4

30 EC CONVERSION KIT Page G-1

31 EC CONVERSION KIT 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 CONNECTOR, 36V, COMPLETE CONNECTOR, BATTERY 36V, EC BOLT, 1/4-20 X 1 1/2" LG LOCK WASHER, 1/4" NUT, 1/ GROMMET WIRE, 6 GA, (BLACK) TUBING... AR COVER, KEY HEAD BOOT, BATTERY TERMINAL DECAL, BATTERY IDENTIFICATION CONNECTOR HANDLE GROMMET DECAL... 3 Page G-2

32 ELECTRICAL COMPONENTS A B 1 - INCLUDES ITEMS INCLUDES ITEM B A G E D 7 C F Front of Vehicle D C E NO TAG F G CUSHMAN Page H-1

33 ELECTRICAL COMPONENTS 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 HEADLIGHT SET(ACCESSORY) (1 - INCLUDES ITEMS 2-3) BRACKET, HEADLIGHT HEADLIGHT (3 - INCLUDES ITEM 4) BULB, HEADLIGHT SWITCH, FORWARD / REVERSE SWITCH, IGNITION SWITCH, ROCKER GAUGE BATTERY CONDITION WASHER, # NUT, # XXXXXX PANEL, CONTROL SAFETY YELLOW BURLINGTON GREEN SCREW, TAPPING, 1/4-20 X 1/2" LG RESISTOR G1 SOLENOID, 36 HD NUT, 1/ BOLT, 1/4-20 X 1 3/4" LG SOLENOID BAR, SOLENOID BUS NUT, 5/16 X WASHER, 5/16" CONTROLLER, SPEED NUT, 5/ LOCK WASHER, 5/16" BOLT, 5/16-18 X 3/4" LG SPLASH COVER BRACKET CONTROLLER SPLASH SHIELD SCREW, 1/4-20 X G01 FASTON- TAB 90DEG... 2 Page H-2

34 ELECTRICAL COMPONENTS 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 HOUR METER LIGHT, RED (TAIL LIGHT) HORN BRACKET, HORN SCREW, 1/4-20 X 1" LG CIRCUIT BREAKER, 20 AMP SCREW, #10-24 X 1/2" LG NUT, #4-40 WITH LOCK WASHER SCREW, #4-40 X 3/4" LG BUZZER RECTIFIER BRIDGE SCREW, #10-24 X 1" LG CIRCUIT BREAKER (150 AMP)... 1 Page H-3

35 ELECTRICAL COMPONENTS Page H-4

36 FORK AND HANDLE BAR INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEM FRONT OF VEHICLE FRONT WHEEL Page J-1

37 FORK AND HANDLE BAR 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 FORK COMPLETE (1 - INCLUDES ITEMS 2-14) LOCK WASHER, 3/8" BOLT, 3/8-16 X 1" LG NUT, 3/ WASHER, 3/8" BOLT, 7/16-14 X 2" LG NUT, 7/ SPRING SPACER ARM SIDE (RIGHT) ARM SIDE (LEFT) FORK (14 - INCLUDES ITEMS 15-16) BEARING, FORK GREASE FITTING, 1/ LOCK WASHER, 1/2" NUT, 1/ NUT, 7/ WOODRUFF KEY, # HAND GRIP BOOT... 1 Page J-2

38 FORK AND HANDLE BAR 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 BEARING UPPER (31 - INCLUDES ITEMS 32-33) BEARING GREASE FITTING, 1/ BEARING LOWER (34 - INCLUDES ITEM 35) GREASE FITTING, HANDLE BAR NUT, SPINDLE 7/ HORN BUTTON INSULATOR SCREW, # X 5/8" LG CLAMP HORN... 3 Page J-3

39 FORK AND HANDLE BAR Page J-4

40 FRONT & REAR WHEELS AND TIRES (Style of tire may differ from tire shown) 3 1 FOAM FILLED TIRE SOLID TIRE Page K-1

41 FRONT & REAR WHEELS AND TIRES 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 TIRE ( LOAD RANGE B), 4.80 x 8.00) WHEEL, 8.00 X 3.75, FOUR BOLT HOLES STEM, VALVE NUT FOAM FILLED TIRE AND WHEEL ASSSEMBLY, 4 X 8 SOLID NON MARK, NUT Page K-2

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44 FRONT AXLE, HUB AND BRAKES Front Fork Front Fork Front Wheel INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEMS Page L-1

45 FRONT AXLE, HUB AND 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 FRONT AXLE, HUB, BRAKE COMPLETE (1 - INCLUDES ITEMS 2-24) AXLE FRONT NUT, 5/ LOCK WASHER, 5/8" NUT, 3/ CONE BEARING BRAKE DRUM BOLT, WHEEL MOUNT SEAL THRUST WASHER SLINGER WASHER FRONT AXLE NUT HUB ASSEMBLY (19 - INCLUDES ITEMS 20-21) ROLLER BEARING RING SHIELD & BRAKE SHOES (24 - INCLUDES ITEMS 25-37) NUT, 5/ NUT, 3/ LOCK WASHER, 3/8" LOCK WASHER, 1/4" BOLT, 1/4-20 X 1/2" LG Page L-2

46 FRONT AXLE, HUB AND 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 LOCK WASHER, 5/8" SPRING PIN PIN, ADJUSTMENT SNAP RING SHIELD DUST WHEEL CYLINDER (40 - INCLUDES ITEMS 41-44) WHEEL CYLINDER REPAIR KIT SCREW, BLEEDER PISTON SPRING BRAKE SHOE WHEEL NUT... 4 Page L-3

47 FRONT AXLE, HUB AND BRAKES Page L-4

48 HYDRAULIC LINES AND RELATED PARTS FRONT OF VEHICLE Page M-1

49 HYDRAULIC LINES AND RELATED PARTS 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 CYLINDER, MASTER TUBE, HYDRAULIC, MASTER CYLINDER TO TEE FITTING, HYDRAULIC, TEE TUBE, HYDRAULIC, TEE TO FRONT BRAKE HOSE TUBE, HYDRAULIC, TEE TO REAR BRAKE HOSE HOSE, FLEXIBLE, REAR CLIP, HYDRAULIC FITTING G1 SWITCH, STOPLIGHT CYLINDER, WHEEL (SEE WHEEL CYLINDER SECTION FOR REPLACEMENT PARTS) TUBE, HYDRAULIC, TEE TO LEFT BRAKE CYLINDER BRACKET SCREW, 1/4 X 5/8" LG TUBE, HYDRAULIC, TEE TO BRAKE LIGHT SWITCH FITTING, HYDRAULIC, TEE TUBE, HYDRAULIC, TEE TORIGHT BRAKE CYLINDER BOLT, 1/4-20 X 3/4" LG CLAMP BRACKET LOCK WASHER, 1/4" NUT, 1/4-20 X 3/ CLAMP SCREW, TAPPING WIRE TIE, 7" (178 MM) HOSE, FLEXIBLE, 38 1/2", FRONT GROMMET... 1 Page M-2

50 LIFT OUT BATTERY RACK TO 36V NEGATIVE 1 - INCLUDES ITEMS INCLUDES ITEM INCLUDES ITEM INCLUDES ITEM 31 TO "BATT" ON KEY SWITCH (RED) 6 GA. RED TO NEGATIVE BATTERY POST 30 6 GA. BLACK TO NEGATIVE BATTERY POST TO CIRCUIT BREAKER (150 AMP) (RED) TO B- ON CONTROLLER (BLACK) BLACK 41 RED TO 36V POSITIVE 4 PART OF MAIN HARNESS MODEL ONLY "A" MODELS ONLY TO 20 AMP CIRCUIT BREAKER (WHITE/BLACK) WHITE/BLACK TO 20 AMP CIRCUIT BREAKER WHITE/BLACK 3 42 WHITE/RED 36V NEGATIVE 1 WHITE/BLACK FRONT OF VEHICLE 36V POSITIVE Page N-1

51 LIFT OUT BATTERY RACK TO 'B' AT CONTROLLER BLACK TO KEY SWITCH WHITE/BLUE EXITING HARNESS FROM 'B' AT CONTROLLER BLACK JUMPER WIRE RED TO BATTERY SIDE OF MAIN CONNECTOR BLACK 47 BLACK 45 BLACK RED BATTERY CONDITION METER POST #2 BATTERY CONDITION METER JUMPER WIRE 46 MEMORY MODULE Page N-2

52 LIFT OUT BATTERY RACK 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 LIFT OUT BATTERY RACK SET RACK, BATTERY W/DECALS (1 - INCLUDES ITEMS 2-3) DECAL, WARNING, BATTERY CHARGING DECAL, LIFT OUT, WARNING HOLD DOWN, BATTERY WING NUT, 5/ WASHER, 5/16" SPACER, RUBBER WIRE, BATTERY CONNECTION WASHER, SPECIAL RECEPTACLE WITH HARDWARE, 50 AMP WASHER, # LOCK WASHER, # NUT, # LOCK WASHER, # NUT, # WASHER, 1/4" NUT, 1/4-20, LOCK WIRE ASS Y (50 AMP) (20 - INCLUDES ITEM 21) PLUG (50 AMP) SCREW, #6-32 X 1" LG SCREW, 1/4-20 X 1 1/2" LG LOCK WASHER, 1/4" WIRE (28 - INCLUDES ITEM 29)... 1 Page N-3

53 LIFT OUT BATTERY RACK 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 PLUG, 175 AMP BUSHING WIRE, BATTERY DISCONNECT (30 - INCLUDES ITEM 31) PLUG (175 AMP) BUSHING SCREW, #10-24" MOUNT,CONNECTOR BODY WIRE ASS Y, SINGLE WIRE ASS Y, SINGLE WIRE, CHARGER RECEPTACLE, BLACK WIRE, CHARGER RECEPTACLE, RED WIRE TIE, 7" GAUGE, BATTERY CONDITION METER BATTERY, BATTERY CONDITION METER HARNESS, JUMPER CONDITION METER... 1 Page N-4

54 PARK BRAKE LEVER 1 - INCLUDES ITEM TO CLAMP ON SUPPORT TUBE 3 WITH WITH FRONT OF VEHICLE Page P-1

55 PARK BRAKE LEVER 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 LEVER, PARK BRAKE WITH HARDWARE (1 - INCLUDES ITEM 2) GRIP, HAND BOLT, 5/16-18 X 1 3/4" LG WASHER, 5/16" LOCK WASHER, 5/16" NUT, 5/ BOLT, 5/16-18 X 1" LG SPACER NUT, 1/ LOCK WASHER, 1/4" BRACKET, CABLE BOLT, CARRIAGE, 3/8-16 X 1 1/4" LG LOCK WASHER, 3/8" NUT, 3/ CLAMP (CABLE) BOLT, 1/4-20 X 3/4" LG SCREW, #14A X 3/4" LG PARK BRAKE CABLE ( FRONT) BRACKET, PARK BRAKE NUT, 5/ PIN, CLEVIS PIN, COTTER, 3/32 X 3/ SPRING PARK BRAKE CABLE (REAR) RETAINER CABLE... 1 Page P-2

56 REAR WHEEL BRAKE INCLUDES ITEMS INCLUDES ITEMS INCLUDES ITEMS Page Q-1

57 REAR WHEEL BRAKE 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 COTTER PIN, 1/8 X 1 1/8" NUT, 5/ WASHER KEY WHEEL NUT BOLT WHEEL HUB BRAKE DRUM NUT, 5/ LOCK WASHER, 5/16" SPRING SHIELD WITH BRAKE SHOES (18 - INCLUDES ITEMS 19-38) NUT, 5/ LOCK WASHER, 5/8" SHIELD DUST PIN ADJUSTMENT PIN LOCK WASHER, 3/8" NUT, 3/ BOLT, 1/4-20 X 1/2" LG LOCK WASHER, 1/4"... 2 Page Q-2

58 REAR WHEEL BRAKE 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 BRAKE LEVER SPRING BRAKE SHOE WITH LINERS RETAINING RING WHEEL CYLINDER COMPLETE (38 - INCLUDES ITEM 39) WHEEL CYLINDER REPAIR KIT (39 - INCLUDES ITEMS 40-42) SCREW, BLEEDER PISTON SPRING... 1 Page Q-3

59 REAR WHEEL BRAKE Page Q-4

60 REAR WHEEL FRAME & SHOCK ABSORBER FRONT OF VEHICLE AXLE BODY Page R-1

61 REAR WHEEL FRAME & SHOCK ABSORBER 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 NUT, 1/ LOCK WASHER, 1/2" RETAINER SPRING BUMPER REAR SPRING CUP WASHER BUSHING LOCK NUT, 7/ SHOCK ABSORBER BOLT, 3/8-16 X 1 1/4" LG WASHER, 3/8" RETAINER LOCK WASHER, 3/8" NUT, 3/ RUBBER BUSHING FRAME... 1 Page R-2

62 SEATING DETAIL A 1 Red 4 14 Red A Front of Vehicle Page S-1

63 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 SEAT SEAT ADJUSTER (RIGHT) SEAT ADJUSTER (LEFT) SEAT SWITCH SPACER LOCK WASHER, 5/16" BOLT, X 1/2" LG SCREW, 1/4-20 X 1 3/4" LG GROMMET TRIM BLACK... AR SEAT PANEL DECAL ( WIRING) DECAL (WARNING) BOLT, # X 5/8" LG WASHER, # CLAMP LOCK WASHER, # NUT, # WASHER, 5/16" LOCK WASHER, 5/16" NUT, 5/ Page S-2

64 SPEED CONTROL PEDAL 1 - INCLUDES ITEMS Front of Vehicle Page T-1

65 SPEED CONTROL PEDAL 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 SPEED CONTROL ASSEMBLY (1 - INCLUDES ITEMS 2-22) BRACKET, SPEED CONTROL MOUNT BEARING, FLANGED SPACER RETAINING RING TORSION SPRING SPEED CONTROL ARM SCREW, SET, #10-24 X 1/4" LG NUT (WITH LOCK WASHER), # SWITCH SCREW, #6-32 X 3/4" LG POTENTIOMETER, 30 DEG BRACKET, POT MOUNT INDEX SPRING TAB BOLT, CARRIAGE, 5/16-18 X 3/4" LG LOCK NUT, 5/ SPEED CONTROL PEDAL... 1 Page T-2

66 STEERING KIT INCLUDES ITEM INCLUDES ITEMS SEAT REF. FORK SPINDLE (FORK PART NO ) FRONT OF VEHICLE BODY Page U-1

67 STEERING KIT 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 STEERING SET, COMPLETE WHEEL, STEERING NUT, HORN BUTTON WASHER, 5/8" BOOT HOUSING, UPPER BOLT, 1/4-20 X 1 1/4" LG LOCK WASHER, 1/4" BOLT, 1/4-20 X 2" LG NUT, 7/ KNURLED WASHER BOLT, #10-24 X 3/8" LG TERMINAL RETAINING RING BALL BEARING RETAINING RING SHAFT, PINION GEAR SHIM STUD GEAR, CLUSTER... 1 Page U-2

68 STEERING KIT 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 NUT, STEERING BUSHING GEAR DRIVEN (33 - INCLUDES ITEM 34) PIN, ROLL, 1/2 X 1 1/ HOUSING, LOWER (35 - INCLUDES ITEMS 36-37) BUSHING BUSHING PLATE, RETANER LOCK WASHER, 5/16" BOLT, 5/16-18 X 7/8" LG BOLT, 3/8-16 X 1 1/2" LG WASHER, 3/8" SUPPORT HOUSING (LEFT) LOCK WASHER, 3/8" BOLT, 3/8-16 X 1 1/4" LG SUPPORT HOUSING (RIGHT) SPACER NUT, 3/ COVER, STEERING WHEEL G01 TERMINAL, RING G1 WIRE TIE G1 MOUNTING BASE, ADHESIVE... 1 Page U-3

69 STEERING KIT Page U-4

70 A2 B B- 14 M W OR KEY SWITCH BL W/B L W/G W/B W/B LIFTOUT RACK V 6V 6V W/B R R R B B BL WIRE DESTIN ATIONS SAME AS STD. METER W/B L OR MEMO RY MODULE LIF T OU T BATTE RY RACK APPLIC ATION 1 R G G G R R B R R B B R BL B B W/B L W/B L Y Y W/B L OR W/B W/B W/B L BR W BL BR OR R R B Y B R R R R B R B B B B B B B BATT IGN ACC REVERSE FO R W ARD BLACK BL BLUE BR BROWN GREEN OR ORANGE PK PINK RED W WHITE W/B WHITE/BLACK W/B L WHITE/BLUE W/BR WHITE/BROWN W/R WHITE/RED W/ Y WHITE/YELLOW YELLOW W/G WHITE/GREEN HOUR METER TAILLIGHT W CHARGER W/R W BL W POT AY W/ Y BL W BR OR W/B W/G A-YELLOW B-WHITE C-BLUE CONTROLLER W/ Y DIODE SEAT SWITCH AY BR STOPLIGHT SWITCH FWD G5 REV G MAIN CON TAC T W/R R B B B BR G Y OR Y Y Y Y BR DIRECTION BATTERY SWITCH CONDITION METER ALL WIRING IN MAIN HARNESS UNLESS NOTED OPTIONAL QUICK DISCONNECT RESIS T OR CIRCUI T BREAKER EC EC V 6V 6V 6V OPTIONAL QUICK DISCONNECT HEADLIGHT BRIDGE 20 AMP RECTIFIER CIRCUIT BREAKER BR BR HORN CONNECTION FOR STEERING OR WHEEL MOD OR REVERSE HEADLIGHT HORN HORN BATTERY WARNING SWITCH BUTTON CONDITION BUZZER METER B G R Y R R R R B R B B Y R Y G Y R R R G R B W/B L

71 P15 P5 P6 P7 P16 CONTROLLER P14 P12 P11 P4 P2 P3 M- B- REAR LIGH T BL(+) T L (+) B+ A2 120 AM P BREAKER MAIN CON TAC T FO R W ARD S1 S2 A1 A2 REVERSE 0V CCW 5V REAR LIGH T (COM) B- BATTERIES H R M E T AC R E W A L A R M B+ 20 AMP BREAKER AC SEAT SWITCH DIRECTION SWITCH HEADLIGHT SWITCH BRAKE LIGHT SWITCH HEAD LIGHT CHARGER AC RELAY KEY H O R N B C I

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