2013 Carryall 242 & XRT 800 Illustrated Parts List Gasoline and Electric Vehicles

Transcription

1 2013 Carryall 242 & XRT 800 Illustrated Parts List asoline and lectric Vehicles Manual Number dition Code 0712C0912B

2

3 USIN TH ILLUSTRAT PARTS LIST ý WARNIN This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all 2013 Carryall 242 and XRT 800 gasoline and electric vehicles. The manual is divided into sections. Note that there are flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flags contain the letters or, signifying that the page pertains to either the gasoline vehicle, the electric vehicle, or both. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. The index is divided into numerical and alphabetical listings with the page numbers in italic text. There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. HOW TO ORR PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at and clicking on the istributor Search link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) or (706) , extension P. O. Box Augusta, eorgia USA Telephone Service Parts Fax

4 NOT: This illustrated parts list represents the most current information at the time of publication. Club Car, LLC. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, LLC. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright 2012 Club Car, LLC. Club Car and ArmorFlex are registered trademarks of Club Car, LLC. This manual effective July 18, Carryall 242 Illustrated Parts List

5 CONTNTS SCTION 1 BOY AN TRIM Bumper asoline Vehicles Bumpe lectric Vehicles Brush uard Front Body Side Trim Nerf Bar (Optional) ash Components ash Trim Rear Body and Fender asoline Vehicle Rear Body and Fender lectric Vehicle Access Panel Front Seat Bottom and Armrests Seat Back Bed Hinge Cargo Bed SCTION 2 WHLS AN TIRS Wheels and Tires Hubcap (Optional) SCTION 3 CALS Safety ecals asoline Vehicles Safety ecals asoline Vehicles, Continued Safety ecals lectric Vehicles Safety ecals lectric Vehicles, Continued Logo ecals Carryall Logo ecals XRT SCTION 4 BRAK SYSTMS Rear Brake Assembly Brake Pedal Assembly Brake Cables, qualizer, and qualizer Rod Accelerator Pedal Assembly asoline Vehicles Accelerator Pedal Assembly lectric Vehicles Accelerator Rod Carryall 242 Illustrated Parts List Page 1

6 CONTNTS SCTION 5 STRIN AN SUSPNSION Steering Column Steering Wheel Steering ear Assembly Front Suspension, Upper Front Suspension, Lower-asoline Vehicles Front Suspension, Lower-lectric Vehicles Front Spindles and Hubs Rear Suspension SCTION 6 LCTRICAL SYSTM ASOLIN VHICLS Wiring asoline Vehicles Headlights Taillights lectrical Component Box-asoline Vehicles Controls and Indicators asoline Vehicles Starter/enerator Assembly asoline Vehicles F350 Starter/enerator Mounting asoline Vehicles Battery asoline Vehicles SCTION 7 F350 NIN S27 F350 ngine (AS26) Ignition Components and Flywheel F350 ngine (AS26) Oil Circulation F350 ngine (AS26) Cylinder Head F350 ngine (AS26)- Crankcase, Camshaft and Oil Sensor F350 ngine (AS26) Crankcase and Crankshaft F350 ngine (AS26) Mounting F350 ngine without ACR (Automatic Compression Release) Shrouds and Brackets SCTION 8 FUL, INTAK, AN OVRNOR SYSTMS Fuel System Fuel Tank with Fuel Level Sending Unit Carburetor Assembly F350 (AS26) Carburetor Installation F overnor and Accelerator Cables Intake uct, Choke, and Air Box Assembly Page Carryall 242 Illustrated Parts List

7 CONTNTS SCTION 9 XHAUST SYSTM xhaust System F SCTION 10 TORQU CONVRTR riven Clutch rive Clutch SCTION 11 TRANSAXL AN FNR SHIFTR- ASOLIN VHICL raziano Transaxle ear Cases and Levers raziano Transaxle F&R Transmission and ear Reduction raziano Transaxle -ifferential and Axles Forward/Reverse Shifter Assembly asoline Vehicles Forward/Reverse Shifter Cable asoline Vehicles ifferential uard SCTION 12 LCTRICAL SYSTM LCTRIC VHICLS Wiring Headlights Instrument Panel Components Motor Controller Output Regulator (MCOR) Battery Charger Receptacle Taillights Batteries 6 X 8V, lectric Vehicle OBC, Controller, and Solenoid lectric Vehicle Forward/Reverse Switch, Tow/Run Switch SCTION 13 LCTRIC MOTOR Motor (Model J8-4001A) lectric Vehicle SCTION 14 TRANSAXL LCTRIC VHICLS Transaxle lectric Vehicles ifferential uard SCTION 15 BATTRY CHARR Powerrive 3 Battery Charger, omestic Powerrive Battery Charger (Model 17930), omestic Powerrive Battery Charger (Model 18780), xport Carryall 242 Illustrated Parts List Page 3

8 CONTNTS Powerrive Battery Charger (Model 20310), uropean SCTION 16 MAINTNANC AN SRVIC TOOLS Maintenance and Service Tools olf Maintenance and Service Tools olf, Continued Maintenance and Service Tools olf, Continued SCTION i INX Page Carryall 242 Illustrated Parts List

9 BOY AN TRIM 1

10 Page Carryall 242 Illustrated Parts List

11 ITM PART NO. SCRIPTION BUMPR ASOLIN VHICLS Screw, M8 X 1.25 X 30 Tri, Blk Bolt, Flange Head, M X Lock Nut, Flg M8 X 1.25 Nylon Bumper, Cast... 1 QTY Carryall 242 Illustrated Parts List Page 1-3

12 Page Carryall 242 Illustrated Parts List

13 ITM PART NO. SCRIPTION BUMP LCTRIC VHICLS Kit, Front Bumper (includes items 2 through 5) Front Bumper Blind Rivet, Push Type Screw, 5/16-18 x 1.0 Truss-Head Locknut, 5/16-18 Nylon Insert... 2 QTY 1 Note: Item 3 is not used in this application Carryall 242 Illustrated Parts List Page 1-5

14 Page Carryall 242 Illustrated Parts List

15 ITM PART NO. SCRIPTION BRUSH UAR Kit, Brush uard (includes items 2 through 6) Screw, M8 X 1.25 X 30 Tri, Blk Bolt, Flange Head, M X Lock Nut, Flg M8 X 1.25 Nylon uard, Brush Support, Brush uard... 1 QTY Carryall 242 Illustrated Parts List Page 1-7

16 Page Carryall 242 Illustrated Parts List

17 ITM PART NO. SCRIPTION FRONT BOY Cowl, Red, Common Cowl, k reen, Common Cowl, Cl Blue, Common Cowl, Black, Common Cowl, Camo Hwhd, Common Cowl, Silver, Common Cowl, White, Common Cowl, k ray, Common Cowl, Beige, Common... 1 QTY Carryall 242 Illustrated Parts List Page 1-9

18 Page Carryall 242 Illustrated Parts List

19 ITM PART NO. SCRIPTION SI TRIM Bumper, Side Trim Screw, #8-18 x 0.375, Hex-Head Washer... 8 QTY Carryall 242 Illustrated Parts List Page 1-11

20 1 ITMS 2 THROUH Page Carryall 242 Illustrated Parts List

21 ITM PART NO. SCRIPTION NRF BAR (OPTIONAL) Kit, Nerf Bar (black) (includes items 2 through 7) Washer, 3/8 Flat Tape, Non-skid Nerf Bar Assy, river Nerf Bar Assy, Passngr Screw, 3/8-16 X 1.00 Hex-Head Cap Locknut, 3/8-16 Hex... 6 QTY Carryall 242 Illustrated Parts List Page 1-13

22 Page Carryall 242 Illustrated Parts List

23 ITM PART NO. SCRIPTION ASH COMPONNTS ash Component, Passenger-Side, Black ash Component, river-side Snap Washer Kit, Black (includes items 4 through 7) Nut, Speed Washer, #10 Pan-Head Screw Cover, Screw Head Screw, #10-16 X 0.75 Pan-Head Tap ash Panel, Black Center Floor Mat, s/utl, Std Rivet, 3/16 X.400 Blind... 5 QTY Carryall 242 Illustrated Parts List Page 1-15

24 Page Carryall 242 Illustrated Parts List

25 ITM PART NO. SCRIPTION ASH TRIM 1 N/A Instl, Closeout, ash (includes items 2 through 17) Screw, #8-32 X #8-32 Unc-2b Slub Base Teenut Screw, 1/4-20 X 0.75 Hex-Head Cap Screw, 1/4-20 X.75 Torx Pn Hd Cap, 1/4" Plastic Screw Head Washer, 1/4 Id Scalloped Plast Screw, 5/16-18 X 3/4 Hex-Head with Patch Support, Upper Cowl Asm, Brace, Canopy, Tube, Xrt Panel, Closeout, ash Strip, Trim, ash, Black Plate, Retention, Closeout Washer, 5/16 Type A Flat Rivet, 3/16 X.500 Alum Pop Washer, 1/4 Type A Narrow Flat Locknut, 1/4-20 Nylon Insert... 2 QTY Carryall 242 Illustrated Parts List Page 1-17

26 Page Carryall 242 Illustrated Parts List

27 ITM PART NO. SCRIPTION RAR BOY AN FNR ASOLIN VHICL Body Kick Plate Body, Hinge Plate Washer, 1/4" Type B Flat Body Support Weldment Cable Retainer Wear Pad Fender, river Side (includes item 8) U-Nut, 1/ Fender, Passenger Side (includes item 10) U-Nut, 1/ Body, Rear, as, Red Body, Rear, as, reen Body, Rear, as, Classic Blue Body, Rear, as, Cut, Black Body, Rear, as, Cut, White Body, Rear, as, Cut, ray Body, Rear, as, Cut, Beige Body, Rear, as, Cut, Camo Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 6 QTY Carryall 242 Illustrated Parts List Page 1-19

28 Page Carryall 242 Illustrated Parts List

29 ITM PART NO. SCRIPTION RAR BOY AN FNR LCTRIC VHICL Body Kick Plate Body, Hinge Plate Washer, 1/4" Type B Flat Body Support Weldment Cable Retainer Wear Pad Fender, river Side (includes item 8) U-Nut, 1/ Fender, Passenger Side (includes item 10) U-Nut, 1/ Body, Rear, Cut, l, Red Body, Rear, Cut, l, rn Body, Rear, Cut, l, Cl Blue Body, Rear, Cut, l, Black Body, Rear, Cut, l, White Body, Rear, Cut, l, ray Body, Rear, Cut, l, Beige Body, Rear, Cut, l, Camo Washer, 1/4 Type A Narrow Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 1/4-20 X 1.0 Truss-Head Machine... 6 QTY Carryall 242 Illustrated Parts List Page 1-21

30 Page Carryall 242 Illustrated Parts List

31 ITM PART NO. SCRIPTION ACCSS PANL Access Panel - Black, Cut ecal, Rotating Parts/Hot Manifold... 1 QTY Carryall 242 Illustrated Parts List Page 1-23

32 Page Carryall 242 Illustrated Parts List

33 ITM PART NO. SCRIPTION FRONT SAT BOTTOM AN ARMRSTS Insert - Wood Hinge Plate Screw, 1/4-20 X 1.50 Hex-Head Cap Screw, 1/4-20 X 0.75 Hex-Head Cap Seat Bottom Assembly, ray (includes items 6 through 9) N/A Plywood Assy Vinyl Cover, Seat Bottom, ray N/A Foam, Seat asket, Seat Hip Restraint, rvr Side Hip Restraint, Pass Side Washer, 1/4 Type A Narrow Flat... 8 QTY Carryall 242 Illustrated Parts List Page 1-25

34 TYPICAL 2 PLACS 4 6 TYPICAL 2 PLACS 9 21 TYPICAL 2 PLACS TYPICAL 2 PLACS TYPICAL 2 PLACS 1 TYPICAL 2 PLACS TYPICAL 2 PLACS ON ACH SI OF VHICL 13 TYPICAL 2 PLACS TYPICAL 2 PLACS Items Items TYPICAL 2 PLACS through through Page Carryall 242 Illustrated Parts List

35 ITM PART NO. SCRIPTION SAT BACK Washer, 1/4 Flat Body Spacer Screw, 5/16-18 X 1.25 Thrd Frm Screw - M6 X 1.0 X 30 Sems Service Backrest Asm, ray Screw, M6 Hex Plug, Square mm Weldment, Bed Support Seat Support, Cross Brace Seat Support W/striker, rv (includes items 11 through 14) Seat Support, river-side Striker Plate Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Support, Seat, Right (passenger) (includes items 16 through 19) Seat Support, Passenger-Side Striker Plate Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Washer, 5/16 Type A Flat Screw, 1/4-20 X 2.00 Hex-Head Cap Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Screw, 5/16-18 X 1.75 Hex-Head Cap... 2 QTY Carryall 242 Illustrated Parts List Page 1-27

36 Page Carryall 242 Illustrated Parts List

37 ITM PART NO. SCRIPTION B HIN Bumper, Rubber Bushing, Steel Bushing, Urethane Locknut, 1/4-20 Hex Whiz Locknut, 3/8-16 Flanged imple Screw, M8X1.25X30, Hex Rue Ring - 1/2" Hinge, Roto Bed Support, Hinge Stiffener, Bed Support Bushing, Steel Pin, Clevis, 3/ Screw, 3/8-16 X 1.00 Hex-Head Cap Washer, 1/4 Type A Narrow Flat Washer, 3/8 Type A Flat Screw, 1/4-20 X 0.75 Hex-Head Cap Locknut, 1/4-20 Nylon Insert Screw, 3/8-16 X Hex Cap... 2 QTY Carryall 242 Illustrated Parts List Page 1-29

38 Page Carryall 242 Illustrated Parts List

39 ITM PART NO. SCRIPTION CARO B Lanyard, Tailgate Bolt Lanyard Tailgate Bed Assembly (includes items 5 through 17) Locknut, 3/8-16 impled Pushnut, 3/ xtension, Spring Latch N/A Washer, 3/8 Flat Type A N/A Bed Support, Latch Link N/A Pin, Support Rod, Long Link Rod, Bed Lift, Short Bent Catch, Tilt Bed Bearing, Bronze, 1/2x9/ Screw, 1/4-20 X 1.0 Hex-Head Cap Screw, 3/8-16 X 1.00 Hex-Head Cap Kit, Plastic Bed Box Latch (includes items 19 through 21) Screw, Hex Washer Head 1/4-14 X Washer, 5/16 Type B Flat Spring, Tilt Latch 3.4 Lb/in... 2 QTY Carryall 242 Illustrated Parts List Page 1-31

40 1

41 WHLS AN TIRS 2

42 Page Carryall 242 Illustrated Parts List

43 ITM PART NO. SCRIPTION WHLS AN TIRS Unf Lug Nut Tire Assembly, All Trail II (includes items 3 through 5) Wheel Rim, ray Tire, Unmounted, All Trail II Valve Stem... 1 QTY Carryall 242 Illustrated Parts List Page 2-3

44 Page Carryall 242 Illustrated Parts List

45 ITM PART NO. SCRIPTION HUBCAP (OPTIONAL) Hub Cap Kit, Prec (includes item 2) Hub Cap, 7 Prong... 4 QTY Carryall 242 Illustrated Parts List Page 2-5

46 2

47 CALS 3

48 Page Carryall 242 Illustrated Parts List

49 ITM PART NO. SCRIPTION SAFTY CALS ASOLIN VHICLS ecal, Trailer Hitch ecal, Off/On ecal, Vehicle Loading ecal, Young river Warning ecal, Crush Warning, river-side ecal, Crush Warning, Passenger-Side ecal, Maintenance N/A ecal, Plastic Bed Load Warn ecal, Op Instr, as Ps ecal, Warn, Rollover, s Utl... 1 QTY Carryall 242 Illustrated Parts List Page 3-3

50 Page Carryall 242 Illustrated Parts List

51 SAFTY CALS ASOLIN VHICLS, CONTINU ITM PART NO. SCRIPTION ecal, asoline xplosion/fire Warning ecal, Frame round and overnor Warning ecal, Rotating Parts/Hot Manifold... 1 QTY Carryall 242 Illustrated Parts List Page 3-5

52 Page Carryall 242 Illustrated Parts List

53 ITM PART NO. SCRIPTION SAFTY CALS LCTRIC VHICLS ecal, Trailer Hitch ecal, Off/On ecal, Vehicle Loading ecal, Young river Warning N/A ecal, Plastic Bed Load Warn ecal, Op Instr, le ecal, Warn, Rollover, s Utl... 1 QTY Carryall 242 Illustrated Parts List Page 3-7

54 Page Carryall 242 Illustrated Parts List

55 ITM PART NO. SCRIPTION SAFTY CALS LCTRIC VHICLS, CONTINU ecal, Tow/Run Switch Warning ecal, Component Cover ecal, Crush Warning, river-side ecal, Crush Warning, Passenger-Side ecal, Maintenance... 1 QTY Carryall 242 Illustrated Parts List Page 3-9

56 Page Carryall 242 Illustrated Parts List

57 ITM PART NO. SCRIPTION LOO CALS CARRYALL ecal, Ca242, rv ecal, Ca242, Pass... 1 QTY Carryall 242 Illustrated Parts List Page 3-11

58 Page Carryall 242 Illustrated Parts List

59 ITM PART NO. SCRIPTION LOO CALS XRT ecal, Club Car ecal, 800 rv ecal, 800 Pass... 1 QTY Carryall 242 Illustrated Parts List Page 3-13

60 3

61 BRAK SYSTMS 4

62 Page Carryall 242 Illustrated Parts List

63 ITM PART NO. SCRIPTION RAR BRAK ASSMBLY Nut, 5/16-24 Hex Head Cone Bolt, Brake Cluster Mounting rum without Center Hole, Brake Asm, Brake Cluster, Mech, rvr (includes items 5 through 16) Lever Assembly, Self-Adjusting Brake, Left Adjusting Mechanism, Self-Adjusting Brake, Left Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Washer, Brake, Self-Adjusting Back Plate, Lh Kit, Shoe Retainer (includes items 12 and 13) N/A Pin N/A Spring, Shoe, Clamp Package Brake Spring Self Adj Cover, ust Brake Block Asm, Brake Cluster, Mech, Pass (includes items 18 through 29) Lever Assembly, Self-Adjusting Brake, Right (Passenger) Adj Mechanism, S.A. Brakes, Right (Passenger) Package, Brake Shoe, Self-Adjusting Plate, Washer, Brake, Self-Adjusting Washer, Brake, Self-Adjusting N/A Back Plate, Rh Kit, Shoe Retainer (includes items 25 and 26) N/A Pin N/A Spring, Shoe, Clamp Package Brake Spring Self Adj Cover, ust Brake Block... 1 QTY 4 Note: river-side brake cluster not shown. Components have a similar appearance to passenger-side brake cluster components Carryall 242 Illustrated Parts List Page 4-3

64 Page Carryall 242 Illustrated Parts List

65 ITM PART NO. SCRIPTION BRAK PAL ASSMBLY Bumper, Rubber Screw, 5/16-18 X 2.50 Hex Cap Hill Brake Spacer Spring, Hill Brake Torsion Package, Brake Mounting Block Kit, Hill Brake Pedal (includes items 7 through 11) Pad, Hill Brake Pushnut, 3/ N/A Hill Brake Weld Assembly Bushing, Nylon Screw, #10-16 Type AB, Sheet Metal Kit, Hill Brake Latch (includes items 13 through 19) Sleeve, Hill Brake Rod Pushnut, 3/ Ball Joint, 1/ N/A Rod, Hill Brake Pin, Cotter, 7/64 x 1/2 Stainless-Steel N/A Pawl, Hill Brake Ratchet Assembly Brake Pedal Kit (includes items 21 through 23) Pad, Brake Pedal N/A Weldment, Brake Pedal 4wb Std Screw, #10-16 Type AB, Sheet Metal Pin, Bow Tie Locking Pin, 3/8 X 1-5/16 Clevis Nut, 1/4-20 Hex Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert... 4 QTY Carryall 242 Illustrated Parts List Page 4-5

66 Page Carryall 242 Illustrated Parts List

67 ITM PART NO. SCRIPTION BRAK CABLS, QUALIZR, AN QUALIZR RO Spring, Brake Return Rod, qualizer, 8.91" qualizer Bracket Brake Cable Kit (includes items 5 through 8) Pin, Clevis, 5/16 X 3/ Clip, 1/ N/A Cable, Brake, 41" Cotter Pin, 3/32 x Kit, Field P-clamp, Brake Line (includes items 10 through 12) Screw, 3/8-16 X 3.50 Hex Cap P-clamp, Brake Line N/A Instr Fd. P-clamp, Brake Line Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Locknut, 5/16-18 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 4-7

68 Page Carryall 242 Illustrated Parts List

69 ACCLRATOR PAL ASSMBLY ASOLIN VHICLS ITM PART NO. SCRIPTION Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Spring, Accelerator Return Retainer, Spring Stud, 1/4-28 X 1.35 Ball Screw, 1/4-20 X Hex Cap Kit, Accelerator Pivot Rod Assembly (includes items 12 through 14) Spacer Assembly (includes item 13) Spacer, Accelerator Pivot Rod Weldment Pedal, Accel, Insert Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 4-9

70 Page Carryall 242 Illustrated Parts List

71 ACCLRATOR PAL ASSMBLY LCTRIC VHICLS ITM PART NO. SCRIPTION Accelerator Bracket and Bearing Assembly Washer, 1/4 Flat Washer, 1/4 Flat Cup, Spring Bumper, Spring Return Bearing, Pivot Support Spring, Accelerator Return Retainer, Spring Screw, 1/4-20 X Hex Cap Screw, 1/4-20 X Flange Kit, Accelerator Pivot Rod Assembly (includes items 12 through 14) Spacer Assembly (includes item 13) Spacer, Accelerator Pivot Rod Weldment Pedal, Accel, Insert Washer, 5/16 Type A Flat Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Locknut, 5/16-18 Nylon Insert Locknut, 1/4-20 Nylon Insert Locknut, 1/4-28 Nylon Insert Locknut, 3/8-16 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 4-11

72 Page Carryall 242 Illustrated Parts List

73 ITM PART NO. SCRIPTION ACCLRATOR RO Rod, Accelerator (includes items 2 through 4) Nut, 1/4-28 Hex Jam Joint, Ball N/A Accelerator Rod... 1 QTY Carryall 242 Illustrated Parts List Page 4-13

74 4

75 STRIN AN SUSPNSION 5

76 Page Carryall 242 Illustrated Parts List

77 ITM PART NO. SCRIPTION STRIN COLUMN Washer, 5/16 Type B Flat Washer, 5/16 Flat Screw, 5/16-18 X 0.75 Thread-Forming Screw, 3/8-16 X 7.00 Hex Cap Screw, 5/16-18 Thrd Forming Steering Shaft Assembly (includes items 7 through 15) Washer, I X 1.19 O Ring, Internal Retaining Wedge, Molded Seat, Plastic Bearing Bearing, Ball Ring, Retaining Spring, Steering Shaft Column, Aluminum Steering Shaft Steering Column Tube Cover, Steering Column Kit, Steering Column Mounting Bracket (includes items 18 and 19) N/A Bracket, RH Steering Column Mount N/A Bracket, LH Steering column mount Boot, Steering Column Round Shaft, Intermediate Steering (includes items 22 and 23) Bolt, Hex-Head, 8mm X Lockwasher, 5/16 Split Washer, 3/8 Type A Flat Locknut, 3/8-16 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 5-3

78 Page Carryall 242 Illustrated Parts List

79 ITM PART NO. SCRIPTION STRIN WHL Nut, 5/8-18 Nylon Insert Jam Screw, #12-16 X 0.50 Washer-Head Hi-Lo Steering Wheel, Spl Cover, Steering Wheel, eneric... 1 QTY Carryall 242 Illustrated Parts List Page 5-5

80 Page Carryall 242 Illustrated Parts List

81 ITM PART NO. SCRIPTION STRIN AR ASSMBLY Nut, 12mm Hex nd, Tie Rod, M12 X 1.25, Lh Nut - Hex Locking, M12 X Asm, Steering Rack And Pinion (includes items 5 through 24) Bellows, Long Rack Screw Locknut Snap Ring Seal, Steering Pinion ust Bearing, Ball Stop Washer Stop Ring, C-Type Support Yoke Rack uide Pressure Spring Ring, Stop, C-Type Bellows, Short ust Seal Retaining Ring Inner Ball Joint Asm Washer, Tab N/A Box, Steering ear N/A Bearing, Lower Pinion N/A Pinion, Steering N/A Screw, Rack uide N/A Rack, Steering Tie Wrap, 8" Nylon Link, rag, Male Thd Screw, 3/8-16 X 1.50 Hex-Head Cap Washer, 3/8 Type A Flat Nut, 1/2-20 Hex, Left-Hand Thread Locknut, 3/8-16 Hex... 3 QTY Carryall 242 Illustrated Parts List Page 5-7

82 Page Carryall 242 Illustrated Parts List

83 ITM PART NO. SCRIPTION FRONT SUSPNSION, UPPR Locknut, 3/8-16 impled Sub-Assembly, elta A-Plate (includes items 3 through 6) Bushing, Urethane Sleeve, elta Inner Sleeve, elta Outer elta A-Plate elta Shock and ear Support Assembly A-Plate Strap Nut - Hex Locking, M12 X Shock Absorber, Front, Common N/A Asm, Tie Rod (includes items 12 through 16) Nut, 12mm Hex nd, Tie Rod M12 X 1.25 Rh nd, Tie Rod, M12 X 1.25, Lh Rod, Tie, Male Thd Nut, Jam, M , Lh Screw, 3/8-16 X 2.25 Hx Hd Cap Locknut, 3/8-16 Hex Bolt, 3/8-16 X 1.75 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 5-9

84 Page Carryall 242 Illustrated Parts List

85 ITM PART NO. SCRIPTION FRONT SUSPNSION, LOWR-ASOLIN VHICLS Plate, Spring Mount Bearing, Thrust Plate, Front Spring Retainer Clevis, elta Upper King Pin Assembly Screw, 3/8-16 X 2.75 Hx Hd Cap Washer, Od Wave Locknut, 1/2-20 Nylon Insert Washer-1/2 Conical, Yellow Washer, M12 Hard Regular Support, Brush uard Screw, 3/8-16 X 5.50 Hx Hd Cap ccentric Bolt Common Spring Asm, Front, 1 Leaf (includes items 15 through 17) Bushing, Steel Bushing, Urethane Spring, Front, 1 Leaf Nut, Hex 3/ Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 2 QTY Carryall 242 Illustrated Parts List Page 5-11

86 Page Carryall 242 Illustrated Parts List

87 ITM PART NO. SCRIPTION FRONT SUSPNSION, LOWR-LCTRIC VHICLS Plate, Spring Mount Bearing, Thrust Plate, Front Spring Retainer Clevis, elta Upper King Pin Assembly Screw, 3/8-16 X 2.75 Hx Hd Cap Washer, Od Wave Locknut, 1/2-20 Nylon Insert Washer-1/2 Conical, Yellow Washer, M12 Hard Regular Screw, 3/8-16 X 5.50 Hx Hd Cap ccentric Bolt Common Spring Asm, Front, 1 Leaf (includes items 14 through 16) Bushing, Steel Bushing, Urethane Spring, Front, 1 Leaf Nut, Hex 3/ Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 2 QTY Carryall 242 Illustrated Parts List Page 5-13

88 Page Carryall 242 Illustrated Parts List

89 ITM PART NO. SCRIPTION FRONT SPINLS AN HUBS Replacement Kit, Front Hub (includes items 2 through 5) N/A Front Hub, Ball Bearing Cap, Front Hub Hex Nut, Locking Flange, M14x Lug Stud, 1/2-20 UNF, 4037 Stl Asm, Frt Hub & Spndle, Rh, xt (includes items 7 through 14) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 10 through 13) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud Asm, Spindle, Rh, xt (includes items 15 through 18) Fitting, 1/4-28 Thread-Forming rease Subasm, Spndle, Rh 2wb xt Bushing, Flanged Bronze Bushing, Bronze Spindle Asm, Frt Hub & Spndle, Lh, xt (includes items 20 through 27) Cap, Front Hub Hex Nut, Locking Flange, M14x N/A Asm, Front Hub, Bb, Long Stud (includes items 23 through 26) N/A Bearing, Ball, N/A Spacer, Bearing, Front Hub, Pm Lug Stud, 1/2-20 Unf, N/A Front Hub, Ball Brg, Long Stud Asm, Spindle, Lh, xt (includes items 28 through 31) Fitting, 1/4-28 Thread-Forming rease Subasm, Spndle, Lh, 2wb xt Bushing, Flanged Bronze Bushing, Bronze Spindle... 1 QTY Carryall 242 Illustrated Parts List Page 5-15

90 5 Items 3 through 2 Items 10 through Page Carryall 242 Illustrated Parts List

91 ITM PART NO. SCRIPTION RAR SUSPNSION Nut, 3/8-24 Hex Kit, Shock Absorber Cushion (includes items 3 and 4) N/A Cushion, Shock Absorber N/A Retainer, Shock Absorber Cushion Bracket, Shock Mounting, Right (Passenger) Bracket, Shock Mounting, Left (river) Bushing, Steel Shackle, Rear Spring Shock Absorber Kit (includes items 10 through 12) N/A Cushion, Shock Absorber N/A Retainer, Shock Absorber Cushion Shock Absorber Rear Prv Spd Bumper Mount, Angled Locknut, 7/16-14 Nylon Hex Spring Retainer Spacer, Overload Bumper U-Bolt Bushing, Urethane Bumper, Jounce Asm-rear Leaf Spring, Ca1-vill (includes items 21 through 23) Bushing, Steel Bushing, Urethane N/A Leaf Spring, Rear, Ca1-vill Locknut, 3/8-16 Hex Screw, 3/8-16 X Hex Cap... 6 QTY Carryall 242 Illustrated Parts List Page 5-17

92 5

93 LCTRICAL SYSTM ASOLIN VHICLS 6

94 18_BLK(W15) _OR(W17) 16_BLK(W19) FUL TANK SNIN UNIT CNTR ASH PANL ASM. OIL LIHT 18_YL(W08) 18_YL(W14) ( ) OIL SNIN UNIT FORWAR & RVRS LIMIT SWITCHS 18_BLK(W10) COM 18_RN(W11) NO NC 1 2 FUL/HOUR MTR UA RVRS BUZZR FRONT POS (+) 18_WHT(W03) COM N (-) 18_R_WHT(W05) NO 18_WHT(W16) 18_BLU(W18) 18_YL(W01) 18_WHT_BLK(W06) NO NC COM 1 16_BLU(W09) 16_OR(W27) 18_WHT_BLK(W04) M+ KY 1 SWITCH 2 18_BLK(W23) 16_OR(W02) 18_BLK(W25) NO COM 2 18_BLK(W24) ( ) M- 16_R(W07) TO NIN KILL HOOK UP FUS BLOCK 16_BLK(W22) 10_R(W26) Page Carryall 242 Illustrated Parts List

95 6 1 6_BLK(W29) NIN BAR 10_NON_INSUL(W21) 3 - BATTRY _R(W28) 6_WHT(W12) 18_WHT(W16) 16_BLU(W09) 16_OR(W27) SOLNOI VOLTA RULATOR 18_R(W32) 16_YL(W13) STARTR NRATOR F A1 A2 F2 F1 6_RN_HIH_TMP(W30) 7 10_R(W26) 18_YL(W20) 6_BLK(W31) 6 16_BLK(W22) 16_BLK(W22) 10_R(W26) 4 LCTRICAL COMPONNT BOX Carryall 242 Illustrated Parts List Page 6-3

96 6 See previous two pages for illustration. Page Carryall 242 Illustrated Parts List

97 ITM PART NO. SCRIPTION WIRIN ASOLIN VHICLS Wire Assy, #6 Black Wire Assembly #6 Red Wire Assembly, #10, Uninsulated Wire Assy, #10 Red Wire Assy, #6 White round Wire Assembly Assy Wire Harness as V4 Kit... 1 QTY Carryall 242 Illustrated Parts List Page 6-5

98 Page Carryall 242 Illustrated Parts List

99 ITM PART NO. SCRIPTION HALIHTS Headlight Assembly, river-side Single Beam (includes items 2 through 10) Screw, #10-16 Hex-Head Hi-Lo Headlight Bezel, Left Nut, #10-24 Stainless-Steel Hex Machine Turn Signal Lens Assy Mounting Bracket Retainer, Headlight Connector Harness Assembly, Headlight Bulb, Headlight Lens, Headlight Headlight Assy, Passenger-Side Single Beam (includes items 12 through 20) Screw, #10-16 Hex-Head Hi-Lo Headlight Bezel, Right Nut, #10-24 Stainless-Steel Hex Machine Turn Signal Lens Assy Mounting Bracket Retainer, Headlight Connector Harness Assembly, Headlight Bulb, Headlight Lens, Headlight... 1 QTY Carryall 242 Illustrated Parts List Page 6-7

100 Page Carryall 242 Illustrated Parts List

101 ITM PART NO. SCRIPTION TAILLIHTS Kit, Tail Lights (includes items 2 through 12) Screw, #12-16 X Hi-Lo Light Assembly, Stop/Taillight (includes items 4 through 8) Taillight Bulb N/A Housing, Taillight N/A asket, Taillight N/A Lens, Taillight N/A Screw, Taillight Lens Locknut, 1/4-20 Hex Whiz Support, Tail Light Asm, Wire Harness Screw, 1/4-20 X 0.75 Hex-Head Cap... 2 QTY 6 Note: Taillights are optional for Carryall 242 and XRT 800 vehicles Carryall 242 Illustrated Parts List Page 6-9

102 Page Carryall 242 Illustrated Parts List

103 LCTRICAL COMPONNT BOX-ASOLIN VHICLS ITM PART NO. SCRIPTION Screw, #12-16 X Hi-Lo Fuse, 20-Amp Asm, le Comp Box, 800 as Ps (includes items 4 through 34) Stud, 1/4-28 X Ball Fuse, 10-Amp Washer, #4 Flat Ring, 0.338" Internal Retaining Solenoid, 12-Volt Washer, 0.38" I elrin Flat Wire Assembly #6 Red Bushing, Secondary Weight, Split Switch, Limit Switch, Limit iode Bell Crank and Shaft Assembly Box, lectrical Component Cover, lectric Box Cam, lectric Box Bolt, Carriage, 5/16-18 X Wire Assy, #10 Red Fuse Block Screw, #12-16 X Hi-Lo Screw, #4-40 Hex Head Machine Wire Assy, #16 Orange Screw, 1/4-15 X 1.50 Hi-lo Hex Voltage Regulator N/A Washer, Nylon Retaining * Assy Wire Harness as V Nut, 5/16-18 Hex Nut, #10-32 Hex Nut, #4-40 Hex Machine Lockwasher, #4 Split Locknut, 1/4-28 Nylon Insert Tie Wrap, 8" Nylon Washer, 5/16 Type A Flat Locknut, 5/16-18 Nylon Insert Bolt, Carriage, 5/16-18 X QTY 6 * Note: Not used. Item is for shipping purposes only Carryall 242 Illustrated Parts List Page 6-11

104 Page Carryall 242 Illustrated Parts List

105 ITM PART NO. SCRIPTION CONTROLS AN INICATORS ASOLIN VHICLS Locknut, #6-32 Whiz Keys (set of 2) Lockwasher, M Screw, #6-32 X 1/2 Hex Washer-Head Light, Oil Kit, Reverse Buzzer (includes items 7 through 15) Locknut, #6-32 Whiz Washer, #4 Flat Screw, #6-32 X 1/2 Hex Washer-Head Screw, #4-24 X 0.33 Pan-Head Machine Buzzer, Reverse (9-48 VC) Wire Assembly Black # Screw, #4-40 X 0.75 Round-Head Machine Nut, #4-40 Hex Machine Lockwasher, #4 Split Key Switch, 12-Volt, Off/On Screw and Washer Assembly Nut, Key Switch Cap, Black Key Switch Washer, Key Switch Harness Retainer auge, Fuel/Hour, with Bracket (includes items 23 and 24) Bracket, Fuel auge/hour Meter N/A auge, Fuel/Hour Nut, M QTY 6 Note: Items 7 through 9, and 13 through 15 are included in the reverse buzzer kit, but are not used in this application Carryall 242 Illustrated Parts List Page 6-13

106 Page Carryall 242 Illustrated Parts List

107 ITM PART NO. SCRIPTION STARTR/NRATOR ASSMBLY ASOLIN VHICLS Asm, St/gen, Bi-rot, Ks, Svc (includes items 2 and 3) ecal, Rotating Parts/Hot Manifold N/A St/gen, Bi-rot, Util, Ks (includes items 4 through 24) Wire Assy, #6 reen Pulley, V-Belt Nut, Hex, M14x2, S/ Retainer, Front, S/ Bearing, Ball, Front, S-g Bearing, Ball, Front, S-g Washer, Lock M14x2, S-g Washer, Wave, S-g Asm, Armature, Starter/enerator Head, rive nd, S-g Asm, Frame and Field, Starter/enerator Kit, Spring Brush, Starter/enerator (includes item 16) N/A Spring, Brush, S-g Set, Brush Term, S-g Head, Comm nd, S-g Set, Fastener, Ceh eh, S-g Set, Term Hardware, S/ Kit, Cover, Brush Insp, Starter/enerator (includes items 22 and 23) N/A Plug, Rubber rain, Start/enerator N/A Cover, Inspection, S-g Kit, Brush And Brush Holder... 1 QTY Carryall 242 Illustrated Parts List Page 6-15

108 Page Carryall 242 Illustrated Parts List

109 F350 STARTR/NRATOR MOUNTIN ASOLIN VHICLS ITM PART NO. SCRIPTION Screw, M8-125 X 22 Hex-Head Bracket, Starter/enerator Mounting Bolt, Carriage, 5/ Screw, M X 18mm Torx Bracket, Starter/enerator Adjustment Wire Assy, #6 reen V-Belt Washer, 5/16 Type A Flat Nut, 5/16-18 Hex Screw, Cap-hex Hd 3/8-16x Lockwasher, 5/16 Split Locknut, 3/8-16 Hex... 2 QTY Carryall 242 Illustrated Parts List Page 6-17

110 Page Carryall 242 Illustrated Parts List

111 ITM PART NO. SCRIPTION BATTRY ASOLIN VHICLS Screw, 5/16-18 X 1.00 Hex Cap Screw, 5/16-18 X 0.75 Thread-Forming Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head Clamp, Battery Lockwasher, #10 Split Ss Battery, Start, 12v Washer, 5/16 Type A Flat Screw, 5/16-18 X 0.75 Hex-Head Cap Locknut, 5/16-18 Nylon Insert... 2 QTY Carryall 242 Illustrated Parts List Page 6-19

112 6

113 F350 NIN S27 7

114 Page Carryall 242 Illustrated Parts List

115 F350 NIN (AS26) INITION COMPONNTS AN FLYWHL ITM PART NO. SCRIPTION Bolt, Flange Head Screw Clamp Key Clamp Tube, 7mm X 10mm X 70mm Bolt, Flanged Plate, Flywheel Fan Cap Asm, Plug Washer, Flat Fan (cw) Nut, Hex, 18 mm Fine Coil Asm, Ignition Flywheel, Complete Wire Lead, Ignition rommet AM Spark Plug, BPR2S... 1 QTY Carryall 242 Illustrated Parts List Page 7-3

116 Page Carryall 242 Illustrated Parts List

117 ITM PART NO. SCRIPTION F350 NIN (AS26) OIL CIRCULATION Seat, Value Oil Press Relief asket, rain Plug Bolt, Flange Head Filter, Oil Plate, Oil Pump Oil Pump And Rotor Bracket, Oil Filter Mount Ball, Steel, Press, Relief O-Ring Plug, rain Spring asket Bolt, Flanged Filter Cover, Pump Plug... 2 QTY Carryall 242 Illustrated Parts List Page 7-5

118 Page Carryall 242 Illustrated Parts List

119 ITM PART NO. SCRIPTION F350 NIN (AS26) CYLINR HA asket, Rocker Case Retainer, Valve Spring Collet Arm, Rocker Shaft, Rocker Bolt, Flange Head, M8 x 1.25 x 45 mm Plate Seat, Spring Valve Stud, Two-nded, M Circlip, Type Screw Screw Nut Washer, 12.1x19x Pin Seal, Oil O-Ring Bolt, 6x asket, Head Valve, xhaust Rod, Push Spring, ngine Valve Kit, asket, F350 (includes items 25 through 28) asket, ngine to Insulator asket, xhaust asket, Head asket, Crankcase Cover Cylinder Head (includes items 30 through 32) uide, Valve, xhaust uide, Valve Snap Ring Case, Rocker Valve, Intake, Hard Tip... 1 QTY 7 Note: Item 25 is not a component of the F350 engine Carryall 242 Illustrated Parts List Page 7-7

120 Page Carryall 242 Illustrated Parts List

121 F350 NIN (AS26)- CRANKCAS, CAMSHAFT AN OIL SNSOR ITM PART NO. SCRIPTION Tappet Bolt, Flange Head, M5 x 0.8 x 8 mm Plate, Oil Filter Screen Sensor, Oil Level Screw, Cross Pan-Head, M4 x 0.7 x 8 mm Clamp Bracket, Switch, Oil Level Screen, Oil Filter Connector, Cord O-Ring Screw Pin Bolt, Two-nded, M8 x 1.25 x 69 mm Cover Crankcase Bearing, Ball Seal, Oil Plug Bolt Switch Bracket Screw, M X 45mm Hex Shim, Shim, Shim, asket, Crankcase Cover Camshaft, Complete... 1 QTY Carryall 242 Illustrated Parts List Page 7-9