electrical 36v - Carrus Carts & Parts
Contents
1. Service Parts Manual Page G 4 MOTOR 36V SERIES 0 1 Includes Items 2 13 Service Parts Manual Page H 1 MOTOR 36V SERIES When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 73124 60602 MOTOR FLEET SPEED NON VENTED INCLUDES ITEMS 2 13 73120 GO9 COVER PLATE AND SCREW j ARMATURE 73120 G03 BRUSH SPRING 73120 G15 BRUSH PLATE AND BOX 73120 G25 BRUSH REPLACEMENT KIT INCLUDES HARDWARE 73120 G06 SNAP RING 73120 G07 BEARING 73120 G16 73120 G08 73277 G01 RETAINING RING 73120 G32 COMMUTATOR HEAD SCREW 73120 G29 FRAME AND FIELD COIL INCLUDES HARDWARE N A DPD po gt Service Parts Manual Page H 2 MOTOR 48V PDS 0 VD 1 Includes Items 2 11 4 6 5 3 OSS SN Y T IN n Me 0 Page H 3 Service Parts Manual MOTOR 48V 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION2. Service Parts Manual Page E 4 ELECTRICAL 36V Front of Vehicle 388 A 7 of Cowl Page F 1 Service Parts Manual ELECTRICAL 36V Front of Vehicle 7 _____ __ EE ET NO RTS dd dd LE m d a TT 22 471 du 0 O O pe ee ie RED WHT Wire From Control Harness To FNR Forward Microswitch n m A WHT YEL Wire From Contro yis Harness To FNR Forward Microswitch 4 Wire From FNR Harness mA To A Position on FNR ON TP RED Wire From Control Harness To FNR Reverse Microswitch 4 Wire From FNR Harness To B Position on FNR 4 Wire From FNR Harness To C Position on FNR WHT GRN Wire From Control Harness To FNR Reverse Microswitch 4 Wire From FNR Harness To D Position on FNR Service Parts Manual Page F 2 ELECTRICAL 36V 4 PASSENGER BATTERY HOLD DOWN AND BATTERY CONNECTIONS Front of Vehicle BLK Wire From Control Harness 28 2 LL From Solenoid c e E a IL Main Contactor 29 From B Controller Part of Body BATTERY RACK Service Parts Manual Page F 3 ELECTRICAL 36V Front of Vehicle 46 From So Main Co GRN Wire From Control Harness
3. Charger From B Power Harness To Controller From Solenoid To B Controller AWARNING A WIN Always select TOW MAINTENANCE position before towing D From M Power QS AD AN 1 lt gt wu Harness To Controller f MAINTENANCE electrical arc and battery explosion removing connecting and wire From B Controller N To 48V Included 00 with item 9 WHT BLU WHT GRN YEL From control Harness To Solenoid From WHT From Charger From ot To 48V RED GRN Control Harness Part Of Frame BLU From control From Solenoid Harness To Solenoid To Motor Page J 5 Service Parts Manual 48 VOLT ELECTRONIC SPEED CONTROL CONTROLLER COVER ET Q Front of Vehicle Service Parts Manual Page J 6 48 VOLT ELECTRONIC SPEED CONTROL When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600187 73098 G04 73231 G01 00565 G5 00526 G4 73446 G01 35211 G01 73290 G02 73354 G02 01041 G01 73440 G01 00414 G7 11027 G2 00414 G4 00379 G2 00559 G5 14390 G10 00565 G8 00544 G4 600551 35212 G01 00414 G7 16469 G1 14390 G4 11027 G2 600276 32804 G1 N O A DPD A
4. When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 17473 G1 BALL BEARING 601082 DIFFERENTIAL 1 601083 4 601084 LOCK NUT 4 15558 G1 SCREW TAPPING 10 601085 1 15118 G1 4 Page L 3 Service Parts Manual Notes Service Parts Manual Page L 4 REAR SUSPENSION Page M 1 Service Parts Manual REAR SUSPENSION When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION XXXXX GX 887004 829044 600182 STOP PLATE 306982 WASHER 7 16 548061 LOCK NUT 7 16 20 N O A 70492 G01 BUMPER 00968 G01 LOCK WASHER M10 00974 G01 NC IA Oe Tc N gt 829230 SHACKLE PLATE 00405 G8 BOLT 1 2 13 X 4 LG 120166 LOCK WASHER 1 2 308332 NUT 1 2 13 1 N oO A 00406 G4 BOLT 1 2 13 X 4 1 2 LG 829142 FLANGED BUSHING 829258 BUSHING 120166 LOCK WASHER 1 2 308332 NUT 1 2 13 m N N m nm
5. ITEM PART NO 2 3 4 5 DESCRIPTION 34190 G01 14651 G1 10606 G4 12835 G1 14628 G1 13514 G1 SCREW 6 32 X 1 4 LG BRASS 00645 G6 SCREW 46 32 X 1 3 4 LG 00565 G3 LOCK WASHER 46 00525 G5 NUT 46 32 12806 G1 SPACER 34169 G01 00544 G3 00565 G8 LOCK WASHER 5 16 34168 G01 SHIFTER ARM 00532 G6 NUT 3 8 24 00560 G1 WASHER 3 8 14390 G1 35209 G01 15461 G1 WASHER PLATE 00415 G2 BOLT 1 4 20 X 1 1 4 LG 23726 G1 SPACER 00559 G7 WASHER 1 4 14390 G4 LOCK NUT 1 4 20 70824 G01 SHIFT ARM SHAFT 70816 602 SHIFT LINK 22754 G3 BUSHING 600114 G01 PRIMARY LINK N O A DPD n N po a 4 a a a a c N o A C P N Oo Aa A N 00560 G1 WASHER 3 8 70815 G01 TRUNNION CO Service Parts Manual DIRECTION SELECTOR 36V 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600114 G02 SECONDARY LINK 01076 G01 COTTER PIN 00571 G2 WASHER 5 16 600043 G01 BRACKET 00559 G7 WASHER 1 4 11989 G1 SHIFTER ARM KNOB 25664 G2 BUSHING Page E 3 Service Parts Manual DIRECTION SELECTOR 36V Notes
6. Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 33725 G01 BRAKE ASSEMBLY PASSENGER SIDE INCLUDES ITEMS 3 18 33725 G02 BRAKE ASSEMBLY DRIVER SIDE INCLUDES ITEMS 3 18 21086 G1 TORQUE SPIDER 21094 G1 BLEEDER VALVE 21095 G1 LOWER SPRING 21096 G1 SHOE HOLD DOWN 21097 G1 ADJUSTER 21908 G1 DUST SHIELD 70669 G01 SPRING BLUE 70670 G01 SPRING YELLOW 33726 G01 BRAKE SHOE N O oOo A DPD N gt PARKING BRAKE LEVER ASSEMBLY INCLUDES ITEMS 14 18 13460 G1 CURVED LEVER 13463 G1 SPRING WASHER 13462 G1 CLEVIS PIN 13464 G1 CLEVIS PIN RETAINER 22604 G1 STRAIGHT LEVER 2 2 N Ff 13468 G1 33662 G01 21562 G1 n N N nm N XXXXX GX AXLE SHAFT PASSENGER SIDE SEE REAR AXLE SECTION FOR P N XXXXX GX AXLE SHAFT DRIVER SIDE SEE REAR AXLE SECTION FOR P N 17953 G2 BRAKE DRUM XXXXX GX WHEEL BOLT 1 2 20 SEE REAR AXLE SECTION FOR P N XXXXX GX LUG NUT 1 2 20 SEE WHEELS AND TIRES SECTION FOR P N Service Parts Manual Page D 14 When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 34 5 DESCRIPTION 30 31 21559 G1 WIPER SEAL 32
7. BOLT 3 8 16 X 1 LG LOCK WASHER 3 8 Service Parts Manual STEERING Notes Service Parts Manual Page P 4 WEATHER PROTECTION Page Q 1 Service Parts Manual WEATHER PROTECTION When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886468 CAB INCLUDES ITEMS 2 53 886950 SUPPORT PASSENGER SIDE 886951 SUPPORT DRIVER SIDE 800017 SCREW 1 4 20 X 1 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 N O oOo A DPD 112050 SCREW TAPPING 1 4 20 X 5 8 LG 800455 SCREW 1 4 20 X 1 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 A N gt 886682 800017 SCREW 1 4 20 X 1 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 7071 SEAL 50 15 2 M 830008 ROOF CAB 800026 SCREW 1 4 20 X 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 830007 FRONT CAB N PMO N N N N N N A N N 886503 WIPER MOTOR CO Service Parts Manual Page Q 2 WEATHER PROTECTION
8. When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 25977 G32 16 GA WIRE GREEN 4 00565 G4 LOCK WASHER 8 00526 G1 NUT 8 32 LABEL POWERWISETM 28667 G01 CONTROL BOARD 21971 G4 00138 G4 SCREW 6 32 X 1 2 LG 14390 G9 LOCK NUT 6 32 25977 G38 16 GA WIRE BLACK 4 from Relay 1 to Power Input Board COM 25977 G37 16 GA WIRE WHITE 5 from Relay 3 to Power Input Board WHT 25978 G161 18 GA WIRE BLUE 6 from Relay 4 to Heat Sink clip 25978 G162 18 GA WIRE YELLOW 6 from Relay 5 to DC Cord RED 25978 G163 18 GA WIRE BLACK 7 from Transformer S2 S3 to Control Module Black 17902 G1 TAB ADAPTER on Power Input Board WHT w 77 amp AC Cord WHT 28305 G01 TERMINAL ADAPTER on Relay 2 w Control Board RED 27285 G01 TERMINAL ADAPTER on Relay COM w 76 amp AC Cord BLk 00532 G1 LOCK NUT 1 4 20 00567 G7 LOCK WASHER 1 4 00469 G7 WASHER 1 4 Page B 7 Service Parts Manual BATTERY CHARGER ON BOARD 36V Notes Service Parts Manual Page B 8 BATTERY CHARGER ON BOARD 48V 48V BATTERY CHARGER es e Page B 9 Service Parts Manual BATTERY CHARGER ON BOARD 48V TH
9. 1 4 306375 NUT 1 4 20 800026 SCREW 1 4 20 X 3 4 LG 843678 CABLE DOOR STOP NO Popo N 886930 FRAME LEFT 886931 FRAME RIGHT 800059 NUT 1 4 20 308090 WASHER 1 4 nm N N N N O oci A C 830058 LATCH DOOR N nm 886934 TUBE LEFT 886935 TUBE RIGHT CO Service Parts Manual Page Q 10 WEATHER PROTECTION CLOTH DOORS When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 800075 CARRIAGE BOLT 1 4 20 X 1 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 800321 WING NUT 1 4 20 112050 SCREW TAPPING 1 4 20 X 5 8 LG 830510 112050 830350 SEAL 31 792 MM 112050 SCREW TAPPING 1 4 20 X 5 8 LG 830513 894790 548902 548911 NUT 5 16 18 886943 DOOR COVER RIGHT 886944 DOOR COVER LEFT 830193 TRIM PLATE DOOR LATCH 886932 TUBE LEFT 886933 TUBE RIGHT Page Q 11 Service Parts Manual WEATHER PROTECTION CLOTH DOORS Notes Service Parts Manual Page Q 12 WHEELS AND TIRES 1 Includes Items 2 3 4 Style of tire may differ from tire shown Page R 1 Service Parts Manual WHEELS AND TIRES When ordering parts ple
10. 7 OUNCE FOR WINDSHIELDS eee 28433 G01 PLEXUS CLEANER 13 OUNCE FOR WINDSHIELDS ee eee 28433 G02 BATTERY PROTECTOR 14 OUNCE SPRAY sereine 75500 G01 WHITE LITHIUM GREASE 14 OUNCE SPRAY rennes 75502 G01 PENETRANT LUBRICANT 15 OUNCE SPRAY sce teet ttt tec 75503 G01 WHEEL BEARING GREASE einer 12730 G1 PLUD DOT me ee ae EE LE EE E EU LUE 21504 G1 MULTI PURPOSE CLEANER amp DEGREASER 14 OUNCE SPRAY nr 75504 G01 MULTI PURPOSE HAND CLEANER 32 OUNCE LIQUID 75505 G01 BATTERY CLEANER 32 OUNCE WITH TRIGGER SPRAYER een 75506 G01 BIO DEGRADEABLE CLEANER 32 OUNCE W TRIGGER SPRAYER ccscssesssessecsecsesscsetsersetereeseeseeeeeneee 75507 G01 MULTI PURPOSE VALUE PACK eee 75508 G01 BATTERY PROTECTOR 4 OUNCE SPRAY e PENETRANT LUBRICANT 4 OUNCE SPRAY e WHITE LITHIUM GREASE 4 OUNCE SPRAY e CARBURETOR CHOKE CLEANER 4 OUNCE SPRAY Appendix A 2 Service Parts Manual Textron Company CL SFE NML AN A Textron Company 1451 Marvin Griffin Rd Augusta Georgia 30906 USA Inside USA Phone 1 800 241 5855 FAX 1 800 448 8124 Outside USA Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
11. 73291 G04 73120 G36 73120 G38 73120 G39 73120 G40 73120 G41 BRUSH REPLACEMENT KIT INCLUDES HARDWARE 73120 G07 BEARING 73120 G06 SNAP RING 73120 G43 HEADBAND 73120 G37 FRAME AND FIELD COIL INCLUDES HARDWARE 73120 G42 COVER COMMUTATOR END 73328 G01 MAGNET 01037 G02 SCREW 10 32 X 1 2 LG 73277 G01 RETAINING RING 73327 G01 SPEED SENSOR N O oOo A DPD N gt Service Parts Manual Page H 4 36 VOLT ELECTRONIC SPEED CONTROL BLK From Battery Harness to B on Controller BLK From Solenoid Harness to on Controller RED From Control Ps Harness to Reverse BLU Wire From Control Harness To Logic Power Front of Vehicle WHT Wire From Control BLK Wire From Control Harness To Throttle Sensor FNR Harness To M Controller FNR Harness To A2 Controller Power Harness To 25 RED A2 Controller 8 TH GRN BLK 22 2 9 ee 15 19 RED WHT BLU WHT GRN YEL From control WHT From Harness To Solenoid WHT From RED GRN Control Harness Of Frame From Control Harness To 36V BLU From control Harness To Solenoid From Solenoid To Motor Page J 1 Service Parts Manual 36 VOLT ELECTRONIC SPEED CONTROL CONTROLLER COVER lt I gt Front of Vehicle Service Parts Manual Page J 2 36 VOLT ELECTRONIC SPEED CONTROL When ordering parts please specify the mo
12. Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600120 7156 600103 71037 G02 831443 12064 G3 N O A N 800177 BOLT 5 16 18 X 3 4 LG 103867 WASHER 5 16 306932 NUT 5 16 18 ek N gt 306416 BOLT 5 16 18 X 1 LG 103867 WASHER 5 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 meek N 601092 55 71056 G01 SCREW 5 16 18 X 5 8 LG 01024 G01 J NUT 5 16 18 N N 837630 CARGO DECK 800017 SCREW 1 4 20 X 1 LG 800279 NUT 1 4 20 SPEED U TYPE nm N N N N O oci A C 841739 G01 ACCESS COVER 306419 BOLT 1 4 20 X 1 2 LG 800279 NUT 1 4 20 SPEED U TYPE m N O Service Parts Manual Page C 12 BODY 4 PASSENGER When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 36088 G01 CHARGER BOX 00438 G6 BOLT 5 16 18 X 3 4 LG 4 00559 G8 WASHER 5 16 4 00905 G8 LOCK WASHER 5 16 4 00532 G3 NUT 5 16 18 4 00114 G7 SCREW 1 4 10 X 7 8 LG 3 00532 G1 NUT 1 4 20 4 00567 G7 LOCK WASHER 1 4 4 16469 G1 WASHER 1 4 4 Page C 13 Service Parts Ma
13. LG WASHER SPACER WASHER 5 16 WING NUT 5 16 18 NUT 5 16 24 LOCK WASHER 5 16 WIRE 4 6 WIRE 4 55 WIRE 4 52 WIRE 4 10 1 2 Service Parts Manual ELECTRICAL 36V When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 3 4 5 DESCRIPTION 31 600459 BATTERY HOLD DOWN 829835 BATTERY HOLD DOWN END 806954 J BOLT 5 16 18 X 12 1 2 LG 809152 WASHER 818303 SPACER 103867 WASHER 5 16 800315 WING NUT 5 16 18 300646 SCREW 1 4 20 X 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 829997 RUBBER GROMMET 73864 G02 WIRE CLAMP 600783 WIRE 4 55 600554 WIRE 4 53 25971 G13 WIRE 4 10 1 2 00702 G2 NUT 5 16 24 00565 G8 LOCK WASHER 5 16 00797 G2 BOLT 1 4 20 X 1 1 4 LG 00559 G7 WASHER 1 4 27327 G02 TWISTED CLAMP 600556 POWER HARNESS Service Parts Manual Page F 8 ELECTRICAL 36V When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 00993 G01 LOCK WASHER 5 16 28418 G01 NUT 5 16 18 2 32860 G1 HORN INCLUDES ITEM 66 1 BRACKET 1
14. O 886226 BRAKE DRUM ASSEMBLY INCLUDES ITEMS 22 24 829247 BRAKE DRUM XXXXX SEE FRONT SUSPENSION XXXXX LUG BOLT 7 16 20 X 1 3 4 LG SEE FRONT SUSPENSION N MN N N N O amp N SEAL FRONT AXLE SEE FRONT SUSPENSION CONE BEARING SEE FRONT SUSPENSION CONE BEARING AND ROLLER SEE FRONT SUSPENSION WASHER 3 4 SEE FRONT SUSPENSION CASTLE NUT 3 4 16 SEE FRONT SUSPENSION N N N N Service Parts Manual Page D 10 FRONT BRAKE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 34 5 DESCRIPTION QTY 31 XXXXX COTTER PIN SEE FRONT SUSPENSION 2 32 XXXXX SPINDLE CAP SEE FRONT SUSPENSION 2 Page D 11 Service Parts Manual FRONT BRAKE Notes Service Parts Manual Page D 12 REAR BRAKE 1 Axle Tube 1 Includes Items 3 18 2 Includes Items 3 18 13 Includes 14 18 Front of Vehicle Brake Viewed From Underside Of The Vehicle Page D 13 Service Parts Manual When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part
15. m 00405 G8 BOLT 1 2 13 X 4 LG 120166 LOCK WASHER 1 2 308332 NUT 1 2 13 N N N N 70472 G01 SPACER Service Parts Manual Page M 2 REAR SUSPENSION When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 3 4 5 DESCRIPTION QTY 31 823621 BUSHING 4 32 807335 SHOCK ABSORBER 2 33 825500 WASHER 4 34 800294 LOCK NUT 7 16 14 4 Page M 3 Service Parts Manual REAR SUSPENSION Notes Service Parts Manual Page M 4 SEATING Front of Vehicle 3 e 4 eo 1 Service Parts Manual SEATING Front of Vehicle Service Parts Manual Page N 2 SEATING When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 3 886222 G01 800017 308090 306396 306375 35574 G01 00114 G6 886221 302288 30639
16. 33 14584 G1 BEARING RETAINER RING 34 14585 G1 INNER OIL SEAL 39 13084 G1 WHEEL BEARING Page D 15 Service Parts Manual Notes Service Parts Manual Page D 16 MASTER CYLINDER Part of Master Cylinder Page D 17 Service Parts Manual MASTER CYLINDER When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD A N gt 886752 120177 130981 306562 306835 603620 800227 810443 810444 812364 829844 839140 830817 21510 G1 MASTER CYLINDER LOCK WASHER 3 8 NUT 7 16 20 NUT 3 8 16 SCREW 3 8 16 X 1 1 4 LG WASHER 3 8 PLUG 1 8 27 SEALING WASHER OUTER SEALING WASHER BRAKE ROD BUSHING Service Parts Manual Page D 18 DIRECTION SELECTOR 36V 1 Includes Items 2 17 Page E 1 Service Parts Manual DIRECTION SELECTOR 36V 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 Indicates consult Customer Service Department for additional information
17. 8 16 886234 LEAF SPRING amp BUSHING 888203 PERCH SPRING 830012 SHACKLE PLATE 306982 WASHER 7 16 800294 LOCK NUT 7 16 14 N O A DPD 306414 BOLT 3 8 16 X 1 LG 306981 WASHER 3 8 120177 LOCK WASHER 3 8 306562 NUT 3 8 16 600061 G01 LOWER ARM REAR BRACKET M Ll cl N A CO 600342 G01 LOWER ARM FRONT BRACKET ASSEMBLY INCLUDES ITEMS 19 23 70581 G02 FLANGED BUSHING 600062 G01 SECONDARY BELLCRANK 12305 G1 34158 G05 600060 G01 MN N N N N O CO 888322 ECCENTRIC BOLT 833105 BELLEVILLE WASHER 832998 BUSHING 830477 ECCENTRIC WASHER N N N N N 00406 G4 BOLT 1 2 13 X 4 LG Service Parts Manual Page K 4 FRONT SUSPENSION 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION Page K 5 120166 308332 888325 831405 00405 G8 120166 308332 813850 829256 385174 103960 2 02247 304636 817250 048136 819804 886852 886237 311745 312272 829251 887012 827648 886227 886225 829252 829318 829229 LOCK WASHER 1 2 1 2 13 LOWER ARM AND BUSHING ASSEMBLY INCLUDES ITEM 35 GREASE FITTING
18. 9 y Z 8 9 2 Z Service Parts Manual Page L 1 When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600185 G01 AXLE ASSY 36V INCLUDES ITEMS 3 5 7 37 600185 G02 AXLE ASSY 48V INCLUDES ITEMS 3 4 6 8 37 601061 601068 601069 601062 601087 601063 23530 61 24628 61 23519 01 23520 01 N O A A N gt 601065 601066 601067 601070 601071 601072 601073 601074 PO N N N N amp 2 N N XXXXXX XXXXXX 601077 601078 601079 601064 601081 Co N N N N nm O N OD AXLE HOUSING INPUT GEAR KIT 48V AXLE INCLUDES ITEMS 6 8 12 INPUT GEAR KIT 36V AXLE INCLUDES ITEMS 7 12 INTERNAL GEARS KIT 48V AXLE INTERNAL GEARS KIT 36V AXLE O RING RETAINING RING O RING BALL BEARING BALL BEARING BALL BEARING OIL SEAL RETAINING RING TAPERED ROLLER BEARING OIL SEAL FLAT WASHER BRAKE ASSY DRIVER SIDE SEE BRAKE SECTION BRAKE ASSY PASSENGER SIDE SEE BRAKE SECTION AXLE SHAFT DRIVER SIDE AXLE SHAFT PASSENGER SIDE WHEEL BOLT END CAP PLUG O RING Service Parts Manual
19. BLK Wire From Control Harness Service Parts Manual Page F 4 ELECTRICAL 36V Front of Vehicle From A2 Position on From D Electronic Speed Controller From B Position on FNR Position on From Solenoid Page F 5 Service Parts Manual ELECTRICAL 36V Front of Vehicle HORN E gt Part of Frame Bd y Q TT GRN WHT Wire ilc rms BLK Wire 65 Part of Charger Box TAIL LIGHT 3 Pin Connector to Tail Light Service Parts Manual Page F 6 ELECTRICAL 36V When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 33636 G01 74665 G02 73877 G01 806791 800296 120052 306531 N O oOo A DPD 33639 G01 814924 600509 028247 mek N gt 00544 G3 00565 G8 73864 G02 890881 806954 809152 818303 103867 800315 N N 00702 G2 00565 G8 25971 G18 600783 600552 25971 G13 Co N N N N nm O N OD Page F 7 HORN BUTTON SCREW 10 24 X 3 4 LG LOCK WASHER NUT 10 24 IGNITION SWITCH W LIGHTS WIRE CLAMP CONTROL HARNESS RUBBER GROMMET NUT 5 16 18 LOCK WASHER 5 16 WIRE CLAMP BATTERY FRAME J BOLT 5 16 18 X 12 1 2
20. BOLT 1 2 13 X 4 LG LOCK WASHER 1 2 NUT 1 2 13 BUMPER RUBBER SEAL FRONT AXLE CONE BEARING AND ROLLER WASHER 3 4 CASTLE NUT 3 4 16 COTTER PIN SPINDLE CAP CONE BEARING LUG BOLT 7 16 20 X 1 3 4 LG KING PIN AND SPINDLE ASSEMBLY INCLUDES ITEMS 50 62 NUT 3 4 16 LOCK WASHER 3 4 RETAINER SPRING AND KING PIN SPINDLE INCLUDES ITEM 56 BUSHING KING PIN ASSEMBLY INCLUDES ITEMS 58 61 SUPPORT KING PIN Service Parts Manual FRONT SUSPENSION 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 829255 KING PIN 2 02168 GREASE FITTING 1 4 28 807332 FRONT SHOCK ABSORBER 888200 G01 BRACKET SPRING PERCH PASSENGER SIDE 888201 G01 BRACKET SPRING PERCH DRIVER SIDE 825500 WASHER 823621 BUSHING 800294 LOCK NUT 7 16 14 306835 BOLT 3 8 16 X 1 1 4 LG 306981 WASHER 3 8 120177 LOCK WASHER 3 8 306981 WASHER 3 8 306562 NUT 3 8 16 886458 G01 STUD PASSENGER SIDE 886459 G01 STUD DRIVER SIDE 829756 U BOLT 3 8 16 306981 WASHER 3 8 120177 LOCK WASHER 3 8 306562 NUT 3 8 16 Service Parts Manual Page K 6 Z G 8
21. INPUT BOARD INSTALLATION 3 2 4 62 E M Front of 2 63 E Charger GROUNDING DETAIL Page B 3 Service Parts Manual BATTERY CHARGER ON BOARD 36V BATTERY CHARGER INSTALLATION BLK to 3 2 D to BLU wire fran 4 5785 0 2222 AD Y TSO Front of Vehicle ISOLATION MOUNT Service Parts Manual Page B 4 BATTERY CHARGER ON BOARD 36V 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 5 28115 G06 00513 G6 00559 G4 11572 G3 28104 G01 00372 G4 00559 G4 00565 G4 00526 G1 28548 G01 01005 G01 00559 G3 28110 G01 28102 G01 00614 G4 28136 G01 28136 G02 26979 G01 28109 G01 00969 G01 00414 G5 11027 G2 19388 G5 13557 G2 POWERWISE CHARGER ON BOARD INCLUDES ITEMS 3 83 CHASSIS SCREW 8 18 X 1 3 4 LG WASHER 8 EXPANSION NUT HEAT SINK SCREW 8 32 X 1 2 LG WASHER 8 LOCK WASHER 8 SCREW 6 19 X 5 16 LG WASHER 6 ELECTRICAL CLIP SCREW 8 18
22. NUT 3 8 16 120177 LOCK WASHER 3 8 112050 SCREW 1 4 20 X 5 8 LG 11845 G5 600467 600468 302030 SCREW 1 4 20 X 1 1 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 830021 809137 830019 832587 832590 Page D 7 Service Parts Manual HYDRAULIC BRAKE Notes Service Parts Manual Page D 8 4S D S 99UM 1UOJJ UO seous uloq eoe doJ GL Vo ce Le GL Service Parts Manual Page D 9 FRONT BRAKE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886292 BRAKE AND SHOE ASSEMBLY 884399 BACKING PLATE 886371 WHEEL CYLINDER 306396 LOCK WASHER 1 4 306419 BOLT 1 4 20 X 1 2 LG 829348 HEEL PIN 306494 LOCK WASHER 5 8 304104 NUT 5 8 18 N O A DPD 4 e 809252 RETAINING RING 805441 SPRING 806761 ADJUSTMENT PIN 306353 LOCK WASHER 3 8 306319 NUT 3 8 24 887284 BRAKE SHOE REPLACE BOTH SHOES ON BOTH WHEELS lo cl cl N Oo Ci FP OO N gt 306450 BOLT 5 16 18 X 3 4 LG 306325 LOCK WASHER 5 16 330747 SCREW 5 16 18 X 3 4 LG N po
23. SET INCLUDES ITEMS 3 60 N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 830351 830245 830437 800026 308090 306396 306375 830350 830352 830353 112050 800039 800296 800059 800039 886 60 048247 830290 842291 830193 830058 800059 SEAL 27 1 8 694MM BRACKET RIGHT BRACKET LEFT SCREW 1 4 20 X 3 4 LG WASHER 1 4 LOCK WASHER 1 4 NUT 1 4 20 SEAL 31 792MM BRACKET LEFT BRACKET RIGHT SCREW TAPPING 1 4 20 X 5 8 LG ACORN NUT 10 24 SCREW 10 24 X 3 4 LG SEALANT CLEAR 1207 NOT ILLUSTRATED SCREW 10 24 X 1 2 LG ACORN NUT 10 24 DOOR FIBERGLASS INCLUDES ITEMS 24 25 RIVET POP REINFORCEMENT DOOR FRAME WINDOW TRIM PLATE LATCH DOOR LOCK NUT 1 4 20 Service Parts Manual WEATHER PROTECTION FIBERGLASS DOORS When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 3 4 5 DESCRIPTION 31 800271 SCREW 10 24 X 1 2 LG 308089 WASHER 10 823419 HANDLE 120052 LOCK WASHER 10 800039 ACORN NUT 10 24 800024 SCREW 1 4 20 X 1 1 2 LG 800037 ACORN NUT 1 4 20 886948 HINGE ASSEMBLY RIGHT 886949 HINGE ASSEMBLY LEFT 547444 CABLE ASSEMBLY DOOR S
24. When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 800215 SCREW 10 24 X 5 8 LG 821427 WASHER SEALING 306998 LOCK WASHER 10 306351 NUT 10 24 886613 WIRE HARNESS WIPER MOTOR 826037 WIPER BLADE 828682 WIPER ARM 830035 WINDSHIELD 7147 SEAL 50 15 2M 7022 STRIP 50 15 2M 811757 WINDOW REAR 7145 SEAL 50 15 2M 7022 STRIP 50 15 2M 830036 SPACER 80001 7 SCREW 1 4 20 X 1 LG 306832 SCREW 1 4 20 X2 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 800026 SCREW 1 4 20 X 3 4 LG 807404 MIRROR Page Q 3 Service Parts Manual WEATHER PROTECTION Notes Service Parts Manual Page Q 4 WEATHER PROTECTION FIBERGLASS DOORS 60 LEFT RIGHT 5 UN 4 RIGHT H st Q 5 Service Parts Manual WEATHER PROTECTION FIBERGLASS DOORS When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886469 FIBERGLASS DOOR
25. 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 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 Service Parts Manual TABLE OF CONTENTS SECTION Page No HOW TO USE THE SERVICE PARTS MANUAL V ILLUSTRATED PARTS BREAKDOWN 44444 44444 vii RC CEVERALOR EMT A 1 BATTERY CHARGER ON BOARD 36V B 1 BATTERY CHARGER ON BOARD 48V B 9 BODY 2 PASSENGER dust ind aera Ran a dE Meee BL da C 1 BODY 4 PASSENGEH z utate o Roig aa cats un ee es eva et data c bt na eee C 9 BODY ACCESSORIES suona taa ee atra bn opa ewes ON as eae tar Ead Pd C 15 ARK PRA E ura tette texte den ace UE RR AUR UTI EE D 1 HYDBAULIC RARES Read Gus ue ded dco a ns mil met D 5 FRONT ERAK E ee ans en est ie Ga D 9 PEAR BRAKE act EM MEL LIN DS D 13 MASTER CYLINDE Rear aiios as ida aoro Podere uq md ubi undas CR eta wd I Rares quu e T eo D 17 DIREC HON SELECTOR 36V s cavete seat Ebr pod dar a dco fl fo caes io psa E 1 EFECTRIC
26. specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 838598 838828 316945 PIN 1 4 X 1 3 4 827191 STEERING WHEEL 831298 NAME PLATE 307665 810666 819923 831135 N O A DPD 0 O 303459 BOLT 1 4 20 X 1 1 2 LG 306396 LOCK WASHER 1 4 306375 830392 808454 891730 948201 320107 831585 830482 887597 STEERING GEAR 311395 BOLT 7 16 14 X 1 3 4 303269 LOCK WASHER 7 16 no N N m po po po 3 a a a a fF A C N 887527 ROD END ASSY INCLUDES ITEMS 27 30 548224 GREASE FITTING 889682 TIE ROD END ASSY RH THREAD 889681 TIE ROD END ASSY LH THREAD 306328 COTTER PIN N N N N Service Parts Manual STEERING When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information 887497 886246 886 97 048224 889682 889681 306328 306414 120177 Page P 3 ITEM PART NO 12 34 5 DESCRIPTION 31 STEERING ARM LEFT STEERING ARM RIGHT TIE ROD ASSEMBLY INCLUDES ITEMS 35 38 GREASE FITTING TIE ROD END ASSEMBLY RH THREAD TIE ROD END ASSEMBLY LH THREAD COTTER PIN
27. 1076 61 601103 10385 64 10386 63 601110 70581 G02 34158 G05 12305 G1 34518 G01 34389 G01 28082 G01 00963 G01 00544 G4 12305 G01 28083 G01 73964 G02 10386 G3 10387 G3 70968 G14 XXXXX 600050 G02 HAND BRAKE ASSEMBLY BOLT 5 16 24 X 3 4 LG WASHER 5 16 LOCKNUT 5 16 24 CLEVIS PIN 5 16 X 3 4 LG HAIR PIN LINKAGE ROD CLEVIS YOKE CLEVIS PIN 5 16 X 13 16 BELLCRANK BUSHING LINK ASSEMBLY INCLUDES ITEMS 17 20 LINK CLEVIS BRACKET EQUALIZER SPHERICAL NUT 5 16 24 NUT 5 16 24 RETAINING RING BUMPER WIRE CLAMP 3 4 CLEVIS PIN 5 16 X 13 16 LG COTTER PIN 3 32 X 3 4 LG BRAKE CABLE SEE DIRECTION SELECTOR 36V PARK BRAKE AND CONTROLS Service Parts Manual When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 34 5 DESCRIPTION QTY 31 00438 G6 BOLT 5 16 18 X 3 4 LG 4 33 601108 PARK BRAKE COVER 36V 1 34 601107 PARK BRAKE COVER 48V 1 35 16705 G3 SCREW 1 4 20 X 3 4 LG 6 36 14776 G1 J NUT 1 4 20 6 Page D 3 Service Parts Manual PARK BRAKE Notes Service Parts Manual Page D 4 HYDRAULIC BRAKE Service Par
28. 32739 G3 TAIL LIGHT 2 Page F 9 Service Parts Manual ELECTRICAL 36V Notes Service Parts Manual Page F 10 ELECTRICAL 48V Front of Vehicle Part of Cowl Page F 11 Service Parts Manual ELECTRICAL 48V Front of Vehicle Yer TT ss 8 cR ue a T 33 GRN Wire From Control Harness 32 B Controller Service Parts Manual Page F 12 ELECTRICAL 48V Front of Vehicle From M Position on From B Electronic Position on Electronic Speed Controller From 2 Speed Controller Position on Electronic speed Controller From Solenoid Page F 13 Service Parts Manual ELECTRICAL 48V HORN Front of Vehicle Part of Frame GRN WHT Wire BLK Wire 49 Part of Charger Box TAIL LIGHT 3 Pin Connector to Tail Light Service Parts Manual Page F 14 ELECTRICAL 48V When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 15 33636 G03 74665
29. 6 308090 888464 800026 306396 308090 890880 890865 869042 8908 6 948333 306416 306325 306932 800290 048958 BACKREST PANEL SCREW 1 4 20 X 1 LG WASHER 1 4 LOCK WASHER 1 4 NUT 1 4 20 SEAT SWITCH SEE ELECTRICAL SECTION SCREW 1 4 14 X 3 4 LG SEAT BOTTOM SCREW 1 4 20 X 1 LG LOCK WASHER 1 4 WASHER 1 4 BACKREST SCREW 1 4 20 X 3 4 LG LOCK WASHER 1 4 WASHER 1 4 SEAT BACK SEAT FRAME PIVOT PIN SEAT BRACKET LOCK RING SCREW 5 16 18 X 1 LG LOCK WASHER 5 16 NUT 5 16 18 LOCK NUT 5 16 18 SCREW 5 16 18 X 3 1 2 LG Service Parts Manual SEATING When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 34 5 DESCRIPTION 31 888464 BACKREST 800026 SCREW 1 4 20 X 3 4 LG 306396 LOCK WASHER 1 4 308090 WASHER 1 4 820951 RUBBER BUMPER 837631 886221 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306832 SCREW 1 4 20 X2 LG 800296 SCREW 10 24 X 3 4 LG 048178 WASHER 891305 829950 Service Parts Manual Page N 4 STEERING 26 Includes Items 27 30 34 includes Items 35 38 a 2 P is 222 15 12 P ed a 14 9 Xo D Front of Vehicle Page P 1 Service Parts Manual STEERING When ordering parts please
30. 601027 A Textron Company CUSHVAIN A Textron Company SERVICE PARTS MANUAL ELECTRIC CARGO AND PERSONNEL CARRIERS INDUSTRIAL 875 amp TITAN STARTING MODEL YEAR 2005 SERVICE PARTS MANUAL ELECTRIC UTILITY VEHICLES INDUSTRIAL 875 36V INDUSTRIAL 875 36V PERSONNEL CARRIER INDUSTRIAL 875 48V TITAN 36V TITAN 36V PERSONNEL CARRIER TITAN 48V 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 informa tion 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 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PHONE 010 1 706 798 4311 FAX 010 1 706 771 4609 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN RD AUGUSTA GEORGIA USA 30906 Service Parts Manual Page i 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
31. AIE OU scorre Rare F 1 ELEC TRICAEAS EET D IEEE F 11 ELECTRICAL ACCESS demie ads arab dream G 1 MOTOR OOV 2250 nc ia tud etas H 1 87 PDS se eph dta H 3 36 VOLT ELECTRONIC SPEED CONTROL J 1 48 VOLT ELECTRONIC SPEED CONTROL J 5 FRONT SUSPENSION annie dt are dde K 1 FEAR AXPE ays UMP L 1 PEAR ant a opas beu dtu uox had I ep eee M 1 zw ce TU N 1 STEERING sestertia WEA eke toda bate afud a eg hart A os P 1 WEATHER PROTECTION CAB o ADU RCUR dan boob ur OE RS Ca EPA AR 1 WEATHER PROTECTION FIBERGLASS DOORS Q 5 WEATHER PROTECTION CLOTH DOORS 2 Q 9 Service Parts Manual Page iii TABLE OF CONTENTS SECTION Page No WHEELS AND TIRES 2 ue a b Rb Re EE RR rr rd 1 SPECIALTY PRODUCTS eua APPENDIX A 1 Page iv Service Parts Manual HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle APPENDIX Contains a listing of specialty products and options access
32. E 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886481 48V LESTER BATTERY CHARGER For charger service or replacement parts contact Lester Electrical 625 West A Street Lincoln NE 68522 Phone 402 477 8988 FAX 402 474 1769 Always provide the following information when requesting information or ordering replacement parts Model Number serial Number stamped into housing Service Parts Manual Page B 10 BODY 2 PASSENGER Page C 1 Service Parts Manual BODY 2 PASSENGER ACCESS PANEL amp CARGO DECK C G Service Parts Manual Page C 2 BODY 2 PASSENGER CHARGER BOX Service Parts Manual Page C 3 BODY 2 PASSENGER Part of Body 64 65 vfi y 0 6 Le de TT NS Part of Frame 61 60 SWINGOUT BATTERY RACK 48V 4 Front of Vehicle Service Parts Manual Page C 4 BODY 2 PASSENGER BATTERY RACK 36V Page C 5 Service Parts Manual BODY 2 PASSENGER When ordering parts please specify the model and serial number of th
33. G02 74323 G01 806791 800296 120052 306531 33639 G01 600510 814924 028247 600459 829835 800315 103867 818303 809152 806954 300646 308090 306396 306375 73864 G02 829997 25971 G13 600550 SOC METER 48V HOUR METER FNR SWITCH HORN BUTTON SCREW 10 24 X 3 4 LG LOCK WASHER 10 NUT 10 24 BATTERY HOLD DOWN BATTERY HOLD DOWN END WING NUT 5 16 18 WASHER 5 16 SPACER WASHER J BOLT 5 16 18 X 12 1 2 LG SCREW 1 4 20 X 3 4 LG WASHER 1 4 LOCK WASHER 1 4 NUT 1 4 20 WIRE CLAMP RUBBER GROMMET WIRE 4 WIRE 4 Service Parts Manual ELECTRICAL 48V When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600553 00702 G2 00565 G8 813840 00797 G2 27327 G02 00559 G7 WASHER 1 4 17618 G1 NYLON CLAMP 600785 POWER HARNESS 28418 G02 NUT 1 4 20 00993 G02 LOCK WASHER 28418 G01 NUT 5 16 18 00993 G01 LOCK WASHER 5 16 73277 G01 RETAINER RING 600784 SPEED SENSOR 01037 G02 SCREW 10 32 X 1 2 LG 73328 G01 MAGNET 32860 G1 HORN INCLUDES ITEM 50 i BRACKET 32739 G3 TAIL LIGHT Service Parts Manual Page F 16 ELECTRICAL ACCESSORY HEADLIGHT AND TURN SIGNAL INSTALLATION 1 Includes 3 12 2 Includes 3 12 Headlight BLK to
34. Harness Headlight BLU to Harness Turn Signal BLK to Harness gS Signal WHT to Harness 12 a 111111111711 111111111111 111111111111 1 Service Parts Manual ELECTRICAL ACCESSORY Steering Column Connected to Accessory Wiring Harness K gt WHT Ground Service Parts Manual Page G 2 ELECTRICAL ACCESSORY When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 34589 G01 34589 G02 20209 G2 00560 G3 00566 G3 00533 G1 21806 G1 18927 G1 00984 G01 19180 G2 00598 G4 17064 G2 830237 112050 17867 61 21640 01 G 3 HEAD LIGHT AND TURN SIGNAL PASSENGER SIDE OPTIONAL INCLUDES ITEMS 3 12 HEAD LIGHT AND TURN SIGNAL DRIVER SIDE OPTIONAL INCLUDES ITEMS 3 12 HEADLIGHT RECTANGULAR WASHER 1 2 LOCK WASHER 1 2 NUT 1 2 13 TURN SIGNAL LIGHT BRACKET ADAPTER MOUNT SCREW 8 10 X 1 2 LG TURN SIGNAL LIGHT SCREW 10 32 X 1 2 LG PUSH ON TERMINAL FEMALE WIRING COVER SCREW TAPPING 1 4 20 X 5 8 LG TURN SIGNAL WITH MOUNTING HARDWARE OPTIONAL INCLUDES ITEM 19 TURN SIGNAL FLASHER Service Parts Manual ELECTRICAL ACCESSORY Notes
35. N gt 16 N N N N N N N NO a N O o A N WO N Page J 7 CONTROLLER MOUNTING PLATE ELECTRONIC SPEED CONTROLLER SOLENOID LOCK WASHER 10 NUT 10 32 FASTON TAB FUSE BLOCK 6 POSITION CONTINUOUS TONE BUZZER TOGGLE SWITCH RIVET 1 8 X 13 16 LG LABEL TOW RUN SWITCH BOLT 1 4 20 X 7 8 LG LOCK NUT 1 4 20 BOLT 1 4 20 X 1 2 LG SCREW 10 24 X 1 1 4 LG WASHER 10 LOCK NUT 10 24 LOCK WASHER 5 16 NUT 5 16 24 4 GA WIRE SOL B FUSE 15 AMP BOLT 1 4 20 X 7 8 LG WASHER 1 4 LOCK NUT 1 4 20 LOCK NUT 1 4 20 CONTROLLER COVER Service Parts Manual 48 VOLT ELECTRONIC SPEED CONTROL Notes Service Parts Manual Page J 8 FRONT SUSPENSION Service Parts Manual Page K 1 FRONT SUSPENSION Service Parts Manual Page K 2 FRONT SUSPENSION SHOCK ABSORBER Page K 3 Service Parts Manual FRONT SUSPENSION 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 306835 BOLT 5 8 16 X 1 1 4 LG 306981 WASHER 3 8 120177 LOCK WASHER 3 8 306562 NUT 3
36. TAPPING 1 4 10 X 7 8 LG NUT 1 4 20 LOCK WASHER 1 4 WASHER 1 4 ISOLATION MOUNT NUT 1 4 20 BEARING BOLT 5 16 18 X 1 LG LOCK WASHER 5 16 NUT 5 16 18 BRACKET BOLT 5 16 18 X 1 LG WASHER 5 16 LOCK WASHER 5 16 NUT 5 16 18 LATCH HANDLE SPRING WASHER COTTER PIN CHANNEL Service Parts Manual BODY 2 PASSENGER When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 813850 BUMPER 306416 BOLT 5 16 18 X 1 LG 103867 WASHER 5 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 827880 829228 303459 BOLT 1 4 20 X 1 1 2 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 600191 BATTERY TRAY 00462 G8 BOLT 7 16 14X1 LG 00560 G2 WASHER 7 16 00734 61 7 16 14 Service Parts Manual Page C 8 BODY 4 PASSENGER Service Parts Manual Page C 9 BODY 4 PASSENGER ACCESS PANEL amp CARGO DECK 4 PASSENGER a Service Parts Manual Page C 10 BODY 4 PASSENGER CHARGER BOX 36V 11 Service Parts Manual BODY 4 PASSENGER When ordering parts please specify the model and serial number of the product
37. TOP 830291 PLATE DOOR 308090 WASHER 1 4 800017 SCREW 1 4 20 X 1 LG 800026 SCREW 1 4 20 X 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 800026 SCREW 1 4 20 X 3 4 LG 800026 SCREW 1 4 20 X 3 4 LG 306396 LOCK WASHER 1 4 800037 ACORN NUT 1 4 20 830355 SEAL 1 4 X 1 2 X 25 6 35MM X 12 7MM X 7 62 M 894028 WINDOW RIGHT 894029 WINDOW LEFT Page Q 7 Service Parts Manual WEATHER PROTECTION FIBERGLASS DOORS Notes Service Parts Manual Page Q 8 WEATHER PROTECTION CLOTH DOORS Page Q 9 Service Parts Manual WEATHER PROTECTION CLOTH DOORS When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886940 CLOTH DOOR SET INCLUDES ITEMS 2 49 830245 BRACKET TOP RIGHT 830437 BRACKET TOP LEFT 800026 CARRIAGE BOLT 1 4 20 X 1 3 4 LG 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 NUT 1 4 20 830351 SEAL 27 1 8 694MM N O A DPD 4 e 112050 SCREW TAPPING 1 4 20 X 5 8 LG 831017 BRACKET 830350 SEAL 31 792 MM N gt 302288 SCREW 1 4 20 X 1 LG 308090 1 4 306396 LOCK WASHER
38. X 1 2 LG LABEL VENTILATION LABEL CORD CONDITION CAPACITOR BRACKET CAPACITOR SCREW 8 32 X 3 8 LG BOLT 1 420 X 5 BIG LOCK NUT 1 4 20 AC CORD STRAIN RELIEF AC Service Parts Manual BATTERY CHARGER ON BOARD 36V 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 Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 13557 G3 STRAIN RELIEF DC 73344 G06 DC CORD ASSEMBLY INCLUDES ITEMS 33 37 28107 G01 11343 G3 11343 G1 17064 G2 22476 01 22009 61 00559 67 00565 67 00532 61 28105 G01 01051 G01 00559 G4 01003 G01 22589 G2 00771 G6 00528 G4 28106 G01 00565 G5 00378 G4 00526 G3 28103 G01 27877 G01 00372 G3 DC CORD RING TERMINAL 3 16 RING TERMINAL 5 16 FEMALE TERMINAL HEAT SHRINK TUBING ISOLATION MOUNT WASHER 1 4 LOCK WASHER 1 4 NUT 1 4 20 AMMETER SCREW 9 ne WASHER 8 BRASS WASHER 10 SHOULDER WASHER 10 NYLON WASHER 3 8 NUT 10 32 BRASS 50 AMP FUSE LOCK WASHER 10 SCREW 10 24 X 1 2 LG NUT 10 24 TRANSFORMER SPACER SUPPORT SCREW 8 32 X 3 8 Service Parts Manual Page B 6 BATTERY CHARGER ON BOARD 36V THE USE OF NON U L PARTS WILL VOID ANY U L LISTING
39. ase specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 3 4 5 DESCRIPTION QTY 1 600499 TIRE AND WHEEL ASSEMBLY INCLUDES ITEMS 2 3 4 888120 TIRE 5 70 8 LOAD RANGE C 832601 WHEEL RIM 886735 VALVE STEM 829441 LUG NUT 7 16 20 A C N Service Parts Manual Page R 2 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Service Parts Manual Appendix A 1 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO CURRENT INDICAT OR muc EE S 16489 G2 a 2 481 G01 CRIMPINS TOOLE EM cp 27765 G01 SLIDE HAMMER AXLE HUB REMOVAL en nn Re en 15947 G1 SLIDE HAMMER AXLE RS EMOVAE NEY SE tenue ie 18753 G1 FEELER GAUGE Mmm 72525 G01 BATTERY MAINTENANGE edet cda nine een ini 25587 G01 BATTERY SET DISCHARGER 36 VOLT AMP ts tent eee 28251 G01 BATTERY DISCHARGER 48 VOLT 56 AMP po Unna e tease 28251 G02 PAINT TOUGEFEUP PENsTNDUSTRIAL YELLOW cn toners ones 28432 G03 12 OUNCE SPRAY INDUSTRIAL YELLOW nenne enr nennen nn 28140 G14 PERFORMANCE PRODUCTS FORMULA 40 VIN VIC OA TO WEITE oett te tti ER im ii 28166 01 PLEXUS CLEANER
40. del and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD NO N N N N Po po po a a a NY O Ci A O Ci A N Page J 3 600187 73060 G01 20468 G1 00565 G5 00526 G4 73446 G01 35211 G01 73290 G02 00414 G5 11027 G2 00414 G4 00379 G2 14390 G4 14390 G10 01041 G01 00565 G8 00544 G4 600551 35212 G01 21764 1 30353 G1 00414 G7 16469 G1 00559 G5 11027 G2 600276 32804 G1 CONTROLLER MOUNTING PLATE ELECTRONIC SPEED CONTROLLER 36V SYSTEM SOLENOID LOCK WASHER 10 NUT 410 32 FASTON TAB FUSE BLOCK 6 POSITION CONTINUOUS TONE BUZZER BOLT 1 4 20 X 5 8 LG LOCK NUT 1 4 20 BOLT 1 4 20 X 1 2 LG SCREW 10 24 X 1 1 4 LG LOCK NUT 1 4 20 LOCK NUT 10 24 RIVET 1 8 X 13 16 LG LOCK WASHER 5 16 NUT 5 16 24 4 GA WIRE SOL B FUSE 15 AMP RESISTOR WASHER 1 4 WASHER 10 LOCK NUT 1 4 20 CONTROLLER COVER Service Parts Manual 36 VOLT ELECTRONIC SPEED CONTROL Notes Service Parts Manual Page J 4 48 VOLT ELECTRONIC SPEED CONTROL WHT From Power BLK From F2 Power Harness to F1Controller Harness To F2 Controller Front of Vehicle BLK From
41. dual part Indicates consult Customer Service Department for additional information ITEM PART NO 12 34 5 DESCRIPTION QTY 31 13437 G3 SCREW LOCK 5 16 18 X 1 LG 2 32 71056 G01 SCREW 5 16 18 X 5 8 LG 3 33 01024 G1 U NUT 5 16 18 5 Service Parts Manual Page A 4 BATTERY CHARGER ON BOARD 36V OC LHM NOILVTIVLSNI H3 L3ININV ejeun p em c 94M J9UJJ0JSUVU4 8 Suley sepniou Service Parts Manual Page B 1 BATTERY CHARGER ON BOARD 36V JWIOJSUBI NEN TT V SS peog A jndu lt Aejay OL of gt GG 14d 041002 NT pieog indu 01 08 gt 61 7 4 01 We A o vs 01 ol NOLLVTIV LSNI H3IANHOJSNVH L 8 2 Service Parts Manual BATTERY CHARGER ON BOARD 36V BRN from Control Board Pin 1 Wire 76 to Input Board COM ORN from Control Board Pin 2 Tab Adapter 82 RED wire from Control Board WHT from AC Cord Pin 3 Wire 77 to Input Board WHT Pin 4 Wire 78 to Heat Sink Clip WHT 77 from Relay Pin 3 Pin 5 Wire 79 to DC Cord RED Wire BLK from AC Cord BLK 76 from Relay Pin 1 83 BLK from Transformer BLK from Transformer RED from Control Board RELAY INSTALLATION POWER
42. e 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 Service Parts Manual ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Service Parts Manual Page vii 1 ACCELERATOR Front of Vehicle 28 NO SS gD E i 29 d ES a 30 1 Includes 2 30 25 Includes 26 M X K Su uc TN NS gt nu gt 2 LT TT NS Ex t SK lt 1 Service Parts Manual ACCELERATOR lt gt 22 of Body Front of Vehicle Yer Service Parts Manual Page A 2 ACCELERATOR When ordering parts please specify the model and serial number of the product I
43. e product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 600120 7156 600103 71037 G02 831443 12064 G3 N O A N 800177 BOLT 5 16 18 X 3 4 LG 103867 WASHER 5 16 306932 NUT 5 16 18 ek N gt 306416 BOLT 5 16 18 X 1 LG 103867 WASHER 5 16 306325 LOCK WASHER 5 16 306932 NUT 5 16 18 mk oO N 601092 55 71056 G01 BOLT 5 16 18 X 5 8 LG 01024 G01 J NUT 5 16 18 n MN N N N 829337 CARGO DECK 800017 SCREW 1 4 20 X 1 LG 800279 NUT 1 4 20 SPEED U TYPE N N N O A 36088 G01 CHARGER BOX 00438 G6 BOLT 5 16 18 X 3 4 LG 00559 G8 WASHER 5 16 00905 G8 LOCK WASHER 5 16 m nm O Service Parts Manual BODY 2 PASSENGER When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION ba 00532 G3 00114 G7 00532 G1 00567 G7 16469 G1 22009 G1 00532 G1 886313 G01 886300 830483 2702168 817891 306416 306325 306932 828192 800085 103867 306325 306932 886312 830013 304615 306981 306328 830151 7 5 16 18 SCREW SELF
44. ndicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD A N gt 16 O N N N N N N N N O N WO N Page A 3 600476 601091 01051 G01 25853 G01 00684 G6 25861 G01 01050 G01 25854 G01 00983 G01 28443 G01 25857 G01 28444 G01 17677 G1 17979 G1 73046 G01 17677 G2 73332 G01 00532 G4 10385 G4 10386 G3 17838 61 17255 61 01076 G01 601093 601150 601153 12064 G6 35679 G01 17313 G1 17618 G1 PEDAL BOX ASSEMBLY INCLUDES ITEMS 2 30 PEDAL BOX BRACKET SCREW 8 16 X 1 2 LG PEDAL BOX AND COVER SCREW 8 32 X 3 4 LG MICRO SWITCH SCREW 4 20 X 5 8 LG INDUCTIVE THROTTLE SENSOR SELF THREADING NUT 3 16 PLUNGER PLUNGER SLEEVE PLUNGER CAM SPRING RETAINER ACCELERATOR ROD BUSHING COMPRESSION SPRING SPRING RETAINER ACCELERATOR ROD LOCK NUT 5 16 24 CLEVIS YOKE ADJUSTABLE CLEVIS PIN 5 16 X 1 LG NYLON BUSHING TEFLON WASHER 5 16 HAIR PIN PEDAL PIVOT PIN ACCELERATOR PEDAL ASSEMBLY INCLUDES ITEM 26 PEDAL PAD PUSH NUT WIRE HARNESS PEDAL BOX FLEX LOOM BULK WIRE TIE Service Parts Manual ACCELERATOR When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an indivi
45. nual BODY 4 PASSENGER Notes Service Parts Manual Page C 14 BODY ACCESSORIES BUMPER FRONT amp REAR Page C 15 Service Parts Manual BODY ACCESSORIES When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 886325 G01 BUMPER 2 800352 CARRIAGE BOLT 5 16 18 X 3 LG 5 3 306325 LOCK WASHER 5 16 5 4 306932 NUT 5 16 18 5 Service Parts Manual Page C 16 e 30 31 16 Includes 17 20 Part of Frame 7 14 5 19 MM p Front of Vehicle 26 pA 17 48 3 20 22 25 lt P of Frame i 23 24 Part of K Suspension Page D 1 Service Parts Manual When ordering parts please specify model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 34380 G01 00276 G6 00559 G8 11098 G9 14443 G2 0
46. ories USE OF THE MANUAL To use this manual consult the TABLE OF CONTENTS 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 loca tion and note the complete number shown on the plate Service Parts Manual V HOW USE THE SERVICE PARTS MANUAL Left hand illustration page continued on right hand page Parts list continued on if required 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 appro priate 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 th
47. ts Manual Page D 5 HYDRAULIC BRAKE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION N O A DPD N N N N N N N NNN 2 2 N O N WO A N gt 810152 875212 601097 2702168 306414 120177 306562 311397 837612 303269 304364 103867 306328 306835 603620 120177 306562 800026 308090 306396 306375 817320 302030 BRAKE LEVER INCLUDES ITEM 4 GREASE FITTING SCREW 3 8 16 X 1 LG LOCK WASHER 3 8 NUT 3 8 16 SCREW 7 16 14 X 3 LG BUSHING LOCK WASHER 7 16 NUT 7 16 14 WASHER 5 16 HAIR PIN SCREW 3 8 16 X 1 1 4 LG WASHER 3 8 LOCK WASHER 3 8 NUT 3 8 16 SCREW 1 4 20 X 3 4 LG WASHER 1 4 LOCK WASHER 1 4 NUT 1 4 20 WIRE CLAMP SCREW 1 4 20 X 1 1 4 LG Service Parts Manual HYDRAULIC BRAKE When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 308090 WASHER 1 4 306396 LOCK WASHER 1 4 306375 112050 832584 820008 832585 BRACKET 306562
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