electrical 36v

A Textron Company

SERVICE PARTS MANUAL

601027

1 - INCLUDES ITEMS 3 - 16

ELECTRIC CARGO AND PERSONNEL

CARRIERS (INDUSTRIAL 875 & 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 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: 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 self discharge varies depending on the ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals.

Page ii Service Parts Manual

TABLE OF CONTENTS

SECTION Page No.

HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1

BATTERY CHARGER, ON BOARD, 36V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1

BATTERY CHARGER, ON BOARD, 48V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 9

BODY (2 PASSENGER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1

BODY (4 PASSENGER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 9

BODY (ACCESSORIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 15

PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1

HYDRAULIC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 5

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 9

REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 13

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 17

DIRECTION SELECTOR 36V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1

ELECTRICAL 36V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1

ELECTRICAL 48V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 11

ELECTRICAL (ACCESSORY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 1

MOTOR 36V SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1

MOTOR 48V PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 3

36 VOLT ELECTRONIC SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1

48 VOLT ELECTRONIC SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 5

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1

SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1

WEATHER PROTECTION (CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q - 1

WEATHER PROTECTION (FIBERGLASS DOORS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q - 5

WEATHER PROTECTION (CLOTH DOORS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q - 9

Service Parts Manual Page iii

TABLE OF CONTENTS

SECTION Page No.

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R - 1

SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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/accessories

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 location) and note the complete number shown on the plate.

Service Parts Manual v

HOW TO USE THE SERVICE PARTS MANUAL

Title

Title

112

115

111

114

128

129

116

113

106

Front of Vehicle

102,104

107

103

79

105

92

62

91

69

82,87

67

83,88

81,86

84,89

95

65

96

66

94

63

64

71

98

99

100

101

62 - Include

81 - Includes I

94 - Includ s Items 63 -

4

111 - Inc es Items 95, 96 ludes Items 112 ludes Item s 127 - 131

74

120

70

123

121

118

122

119

72

73

130 131

127

126

Left hand illustration page

(continued on right hand page if required)

Parts list (continued on rear of page if required)

1. WHEN THE PART NUMBER IS NOT KNOWN

• Determine the function and application of the part required. Turn to the General Index and select the most appropriate title.

• Turn to the page number indicated and locate the desired part on the illustration.

• From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part.

2. IF YOU KNOW THE PART NUMBER

• Locate the part number or description in the appropriate column on the parts list page.

NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page.

Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted is not available for purchase.

NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached.

To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is available from the Service Parts Department.

vi Service Parts Manual



Service Parts Manual Page vii

ACCELERATOR

Front of Vehicle

4

12

19

18

17

16

15

14

13

11

10

8

5

9

28

4

6

7

29

30

1 - Includes 2 - 30

25 - Includes 26

3

Page A-1 Service Parts Manual

32

ACCELERATOR

Part of Body

25

21

21

20

26

22

Front of Vehicle

24

33

27

2

33

31

Service Parts Manual Page A-2

ACCELERATOR

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3

28444-G01

17677-G1

17979-G1

73046-G01

17677-G2

73332-G01

00532-G4

10385-G4

10386-G3

17838-G1

17255-G1

01076-G01

601093

601150

601153

12064-G6

35679-G01

17313-G1

17618-G1

600476

601091

01051-G01

25853-G01

00684-G6

25861-G01

01050-G01

25854-G01

00983-G01

28443-G01

25857-G01

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.

1 2 3 4 5 DESCRIPTION QTY.

PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 30) ........................................

1

PEDAL BOX BRACKET................................................................................

1

SCREW, #8 - 16 X 1/2" LG ...........................................................................

4

PEDAL BOX AND COVER ...........................................................................

1

SCREW, #8 - 32 X 3/4" LG ...........................................................................

4

MICRO SWITCH...........................................................................................

1

SCREW, #4 - 20 X 5/8" LG ...........................................................................

2

INDUCTIVE THROTTLE SENSOR ..............................................................

1

SELF THREADING NUT, 3/16" ....................................................................

2

PLUNGER.....................................................................................................

1

PLUNGER SLEEVE......................................................................................

1

PLUNGER CAM............................................................................................

1

SPRING RETAINER .....................................................................................

1

ACCELERATOR ROD BUSHING .................................................................

1

COMPRESSION SPRING ............................................................................

1

SPRING RETAINER .....................................................................................

1

ACCELERATOR ROD ..................................................................................

1

LOCK NUT, 5/16 - 24 ....................................................................................

1

CLEVIS YOKE (ADJUSTABLE) ....................................................................

1

CLEVIS PIN, 5/16" X 1" LG ..........................................................................

1

NYLON BUSHING ........................................................................................

3

TEFLON WASHER, 5/16" .............................................................................

1

HAIR PIN ......................................................................................................

1

PEDAL PIVOT PIN .......................................................................................

1

ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEM 26) ......................

1

PEDAL PAD............................................................................................

1

PUSH NUT....................................................................................................

1

WIRE HARNESS (PEDAL BOX) ..................................................................

1

FLEX LOOM (BULK).....................................................................................

AR

WIRE TIE ......................................................................................................

2

Page A-3 Service Parts Manual

ACCELERATOR




ITEM PART NO.

1 2 3 4 5 DESCRIPTION

31

32

33

13437-G3

71056-G01

01024-G1

QTY.

SCREW, LOCK, 5/16 - 18 X 1" LG......................................................................

2

SCREW, 5/16 - 18 X 5/8" LG...............................................................................

3

U - NUT, 5/16 - 18 ...............................................................................................

5

Service Parts Manual Page A-4

BATTERY CHARGER, ON BOARD, 36V

50

DC

AMPERES

Page B-1 Service Parts Manual


Service Parts Manual Page B-2


Pin 1 - Wire 76 to Input Board "COM"

Pin 2 - Tab Adapter 82, RED wire from Control Board

Pin 3 - Wire 77 to Input Board "WHT"

Pin 4 - Wire 78 to Heat Sink Clip

Pin 5 - Wire 79 to DC Cord RED Wire A

74 72

73

82

78

RED from Control Board

RELAY INSTALLATION

79

77

76

B

BRN

ORN

81

BRN from Control Board

ORN from Control Board

WHT from AC Cord

WHT 77 from Relay Pin 3

BLK from AC Cord

BLK 76 from Relay Pin 1

83

BLK from Transformer

COM

NO

NC BLK from

Transformer

GRN to

Ground

WHT

XF

GRN

66

57

POWER INPUT BOARD

INSTALLATION

Page B-3

61

GRN from

AC Cord

60

C

AC Cord

Port

62

63

GROUNDING

DETAIL

Front of

Charger

Service Parts Manual


86

85

84

1

BATTERY CHARGER INSTALLATION

BLK to B- on ESC

RED to BLU wire from

Control Harness

WHT to SOL+

AC Cord

Front of Vehicle

43

42

41

D

40

ISOLATION MOUNT



THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.




ITEM PART NO.


28115-G06

QTY.

POWERWISE™ CHARGER (ON BOARD) (INCLUDES ITEMS 3 - 83).............

1

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3 *

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

CHASSIS ......................................................................................................

SCREW, #8 - 18 X 1 3/4" LG ........................................................................

WASHER, #8 ................................................................................................

ELECTRICAL CLIP.......................................................................................

COVER .........................................................................................................

1

2

2

EXPANSION NUT .........................................................................................

2

HEAT SINK ...................................................................................................

1

SCREW, #8 - 32 X 1/2" LG ...........................................................................

4

WASHER, #8 ................................................................................................

8

LOCK WASHER, #8 .....................................................................................

4

NUT, #8 - 32..................................................................................................

4

DIODE...........................................................................................................

1

SCREW, #6 - 19 X 5/16" LG .........................................................................

3

WASHER, #6 ................................................................................................

3

HANDLE .......................................................................................................

1

SCREW, #8 - 18 X 1/2" LG ...........................................................................

6

LABEL (VENTILATION) ................................................................................

1

LABEL (CORD CONDITION)........................................................................

1

CAPACITOR BRACKET ...............................................................................

CAPACITOR .................................................................................................

SCREW, #8 - 32 X 3/8" LG ...........................................................................

1

1

1

1

3

BOLT, 1/4 - 20 X 5/8" LG. ..............................................................................

3

LOCK NUT, 1/4 - 20 ......................................................................................

3

AC CORD .....................................................................................................

1

STRAIN RELIEF (AC)...................................................................................

1



53

54

55

56

49

50

51

52

57

58

59

60

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35





ITEM PART NO.


13557-G3

73344-G06

28107-G01

11343-G3

11343-G1

17064-G2

22476-G1

QTY.

STRAIN RELIEF (DC)...................................................................................

1

DC CORD ASSEMBLY (INCLUDES ITEMS 33 - 37) ...................................

1

DC CORD...............................................................................................

1

RING TERMINAL, 3/16" .........................................................................

2

RING TERMINAL, 5/16" .........................................................................

2

FEMALE TERMINAL ..............................................................................

2

HEAT SHRINK TUBING ......................................................................... A/R

22009-G1

00559-G7

00565-G7

00532-G1

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

ISOLATION MOUNT.....................................................................................

WASHER, 1/4" ..............................................................................................

LOCK WASHER, 1/4" ...................................................................................

NUT, 1/4 - 20.................................................................................................

AMMETER ....................................................................................................

SCREW, #8 - 32 X 3/8" LG. ..........................................................................

4

4

4

4

1

SCREW, #8 - 10 X 1/2" LG. ..........................................................................

2

WASHER, #8 ................................................................................................

2

BRASS WASHER, #10 .................................................................................

4

SHOULDER WASHER, #10 .........................................................................

1

NYLON WASHER, 3/8".................................................................................

1

NUT, #10 - 32 (BRASS) ................................................................................

3

50 AMP FUSE...............................................................................................

1

LOCK WASHER, #10 ...................................................................................

4

SCREW, #10 - 24 X 1/2" LG. ........................................................................

2

NUT, #10 - 24................................................................................................

2

TRANSFORMER ..........................................................................................

1

SPACER SUPPORT .....................................................................................

4

1



81

82

83

84

85

86

69

70

71

66

67

68

61

62

63

64

65

76

77

78

72

73

74

75

79

80





ITEM PART NO.


25977-G32

00565-G4

00526-G1

QTY.

16 GA WIRE (GREEN 4") .............................................................................

1

LOCK WASHER, #8 .....................................................................................

1

NUT, #8 - 32..................................................................................................

1

*

28667-G01

21971-G4

00138-G4

14390-G9

25977-G38

25977-G37

25978-G161

25978-G162

25978-G163

17902-G1

28305-G01

27285-G01

00532-G1

00567-G7

00469-G7

LABEL (POWERWISE™) ............................................................................

CONTROL BOARD.......................................................................................

RELAY ..........................................................................................................

SCREW, #6 - 32 X 1/2" LG ...........................................................................

LOCK NUT, #6 - 32 .......................................................................................

16 GA WIRE (BLACK 4") (from Relay 1 to Power Input Board "COM") .......

16 GA WIRE (WHITE 5") (from Relay 3 to Power Input Board "WHT")........

18 GA WIRE (BLUE 6") (from Relay 4 to Heat Sink clip)..............................

1

1

1

2

2

1

1

1

18 GA WIRE (YELLOW 6") (from Relay 5 to DC Cord "RED").....................

1

18 GA WIRE (BLACK 7") (from Transformer S2/S3 to

Control Module "Black") ................................................................................

1

TAB ADAPTER (on Power Input Board "WHT" w/ 77 & AC Cord WHT) ......

1

TERMINAL ADAPTER (on Relay 2 w/ Control Board RED) .........................

1

TERMINAL ADAPTER (on Relay "COM" w/ 76 & AC Cord BLK).................

1

LOCK NUT, 1/4 - 20 ............................................................................................

4

LOCK WASHER, 1/4"..........................................................................................

4

WASHER, 1/4" ....................................................................................................

4


Notes:




48V BATTERY CHARGER

1







ITEM PART NO.


1 886481

QTY.

48V LESTER BATTERY CHARGER...................................................................

1

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)


BODY (2 PASSENGER)

1

Page C-1

4

5

6

9

14

7

10

11

15

16

17


2


ACCESS PANEL & CARGO DECK

21

20

19

23

24

25

Service Parts Manual Page C-2


48V

36V

37

36

Page C-3

29

28

30

31

32

27

33

34

35

CHARGER BOX



46

45

Part of Body

52

51

50

48

41

40

44

SWINGOUT BATTERY RACK (48V)

Front of Vehicle

39

65

64

49

43

42

63

62

60

61

Part of Frame


56

55

54

69

67

68

57

58

70

71

72

Page C-4


BATTERY RACK (36V)

75

76

74

76

77

Page C-5 Service Parts Manual


1

4

5

2

3




ITEM PART NO.


600120

7156

QTY.

BODY FRAME WELDMENT (2 PASSENGER)...................................................

1

TRIM....................................................................................................................

1

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

600103

71037-G02

831443

12064-G3

800177

103867

306932

306416

103867

306325

306932

601092

71056-G01

01024-G01

829337

800017

800279

36088-G01

00438-G6

00559-G8

00905-G8

COWL..................................................................................................................

NAME PLATE, E-Z-GO .......................................................................................

NAME PLATE, CUSHMAN, SELF ADHESIVE....................................................

PUSHNUT 3/16" (E-Z-GO NAME PLATE ONLY)................................................

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

WASHER, 5/16" ..................................................................................................

NUT, 5/16 - 18 .....................................................................................................

BOLT, 5/16 - 18 X 1" LG ......................................................................................

WASHER, 5/16" ..................................................................................................

LOCK WASHER, 5/16"........................................................................................

NUT, 5/16 - 18 .....................................................................................................

ACCESS COVER ................................................................................................

BOLT, #5/16 - 18 X 5/8" LG .................................................................................

’J’ NUT, 5/16 - 18 .................................................................................................

CARGO DECK ....................................................................................................

SCREW, 1/4 - 20 X 1" LG....................................................................................

NUT, 1/4 - 20, (SPEED U-TYPE) .......................................................................

CHARGER BOX..................................................................................................

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

WASHER, 5/16" ..................................................................................................

LOCK WASHER, 5/16"........................................................................................

1

1

1

2

2

2

2

7

7

7

7

1

3

3

1

2

2

1

4

4

4



53

54

55

56

49

50

51

52

57

58

59

60

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35




ITEM PART NO.


00532-G3

00114-G7

00532-G1

00567-G7

16469-G1

22009-G1

00532-G1

QTY.

NUT, 5/16 - 18 .....................................................................................................

4

SCREW, SELF TAPPING, 1/4 - 10 X 7/8" LG .....................................................

3

NUT, 1/4 - 20 .......................................................................................................

4

LOCK WASHER, 1/4"..........................................................................................

4

WASHER, 1/4" ....................................................................................................

4

ISOLATION MOUNT ...........................................................................................

4

NUT, 1/4 - 20 .......................................................................................................

4

886313-G01 SWING OUT BATTERY RACK ...........................................................................

2

886300 PIVOT..................................................................................................................

1

830483

2702168

817891

306416

306325

306932

828192

800085

103867

306325

306932

886312

830013

304615

306981

306328

830151

SHIM ................................................................................................................... A/R

GREASE FITTING ..............................................................................................

BEARING ............................................................................................................

BOLT, 5/16 - 18 X 1" LG ......................................................................................

LOCK WASHER, 5/16"........................................................................................

NUT, 5/16 - 18 .....................................................................................................

BRACKET ...........................................................................................................

2

2

4

4

4

BOLT, 5/16 - 18 X 1" LG ......................................................................................

4

WASHER, 5/16" ..................................................................................................

4

LOCK WASHER, 5/16"........................................................................................

4

NUT, 5/16 - 18 .....................................................................................................

4

LATCH HANDLE .................................................................................................

SPRING...............................................................................................................

PIN ......................................................................................................................

WASHER.............................................................................................................

COTTER PIN.......................................................................................................

CHANNEL ...........................................................................................................

4

2

2

2

2

2

2



69

70

71

66

67

68

61

62

63

64

65

72

73

74

75

76

77




ITEM PART NO.


813850

306416

103867

306325

306932

QTY.

BUMPER .............................................................................................................

2

BOLT, 5/16 - 18 X 1" LG ......................................................................................

4

WASHER, 5/16" ..................................................................................................

8

LOCK WASHER, 5/16"........................................................................................

4

NUT, 5/16 - 18 .....................................................................................................

4

827880

829228

303459

308090

306396

306375

600191

00462-G8

00560-G2

00734-G1

SHAFT.................................................................................................................

ROLLER ..............................................................................................................

LOCK WASHER, 1/4"..........................................................................................

NUT, 1/4 - 20 .......................................................................................................

BATTERY TRAY..................................................................................................

BOLT, 7/16 - 14 X 1" LG ......................................................................................

WASHER, 7/16" ..................................................................................................

NUT, 7/16 - 14 .....................................................................................................

6

6

BOLT, 1/4 - 20 X 1 1/2" LG ..................................................................................

12

WASHER, 1/4" ....................................................................................................

12

12

12

2

8

16

8



1

Page C-9

4

5

6

9

14

7

10

11

15

16

17


2


ACCESS PANEL & CARGO DECK (4 PASSENGER)

21

20

19

23

24

25

29

27

28



CHARGER BOX (36V)

34

35

33 32

36

31

38

39

40



1

4

5

2

3




ITEM PART NO.


600120

7156

QTY.

BODY FRAME WELDMENT (4 PASSENGER)...................................................

1

TRIM....................................................................................................................

1

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

600103

71037-G02

831443

12064-G3

800177

103867

306932

306416

103867

306325

306932

601092

71056-G01

01024-G01

837630

800017

800279

841739-G01

306419

800279

COWL..................................................................................................................

NAME PLATE, E-Z-GO .......................................................................................

NAME PLATE, CUSHMAN, SELF ADHESIVE....................................................

PUSHNUT, 3/16" (E-Z-GO NAME PLATE ONLY) ...............................................

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

WASHER, 5/16" ..................................................................................................

NUT, 5/16 - 18 .....................................................................................................

BOLT, 5/16 - 18 X 1" LG ......................................................................................

WASHER, 5/16" ..................................................................................................

LOCK WASHER, 5/16"........................................................................................

NUT, 5/16 - 18 .....................................................................................................

ACCESS COVER ................................................................................................

SCREW, 5/16 - 18 X 5/8" LG...............................................................................

’J’ NUT, 5/16 - 18 .................................................................................................

CARGO DECK ....................................................................................................

SCREW, 1/4 - 20 X 1" LG....................................................................................

NUT, 1/4 - 20, (SPEED U-TYPE) ........................................................................

ACCESS COVER ................................................................................................

BOLT, 1/4 - 20 X 1/2" LG .....................................................................................

NUT, 1/4 - 20, (SPEED U-TYPE) ........................................................................

1

1

1

2

2

2

2

7

7

7

7

1

3

3

1

2

2

1

4

4



36

37

38

39

40

31

32

33

34

35




ITEM PART NO.


36088-G01

00438-G6

00559-G8

00905-G8

00532-G3

00114-G7

QTY.

CHARGER BOX..................................................................................................

1

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

4

WASHER, 5/16" ..................................................................................................

4

LOCK WASHER, 5/16"........................................................................................

4

NUT, 5/16 - 18 .....................................................................................................

4

SCREW, 1/4 - 10 X 7/8" LG.................................................................................

3

00532-G1

00567-G7

16469-G1

NUT, 1/4 - 20 .......................................................................................................

4

LOCK WASHER, 1/4"..........................................................................................

4

WASHER, 1/4" ....................................................................................................

4


Notes:



BODY (ACCESSORIES)

BUMPER (FRONT & REAR)

2

1

3

4


BODY (ACCESSORIES)




ITEM PART NO.


1

2

3

4

QTY.

886325-G01 BUMPER .............................................................................................................

1

800352

306325

306932

CARRIAGE BOLT, 5/16 - 18 X 3" LG ..................................................................

LOCK WASHER, 5/16"........................................................................................

NUT, 5/16 - 18 .....................................................................................................

5

5

5


PARK BRAKE

33

35

36

2

3

1

Part of Body

4

30

29

34

31 16 Includes 17 - 20

7

12

11

10

8

6

9

7

13

14

Part of Frame

25

Part of Frame

Front of Vehicle

26

17 18

19

20

22

23

Part of

Suspension

24

Part of Frame

27

26

25

Page D-1 Service Parts Manual

PARK BRAKE

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


34380-G01

00276-G6

00559-G8

11098-G9

QTY.

HAND BRAKE ASSEMBLY .................................................................................

1

BOLT, 5/16 - 24 X 3/4" LG ...................................................................................

4

WASHER, 5/16" ..................................................................................................

4

LOCKNUT, 5/16 - 24 ...........................................................................................

4

14443-G2

01076-G1

601103

10385-G4

10386-G3

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

CLEVIS PIN, 5/16" X 3/4" LG ..............................................................................

1

HAIR PIN .............................................................................................................

2

LINKAGE ROD ....................................................................................................

BELLCRANK .......................................................................................................

BUSHING ............................................................................................................

SHAFT.................................................................................................................

RETAINING RING ...............................................................................................

LINK ASSEMBLY (INCLUDES ITEMS 17 - 20)...................................................

LINK, CLEVIS ...............................................................................................

BRACKET EQUALIZER................................................................................

SPHERICAL NUT, 5/16 - 24 .........................................................................

NUT, 5/16 - 24...............................................................................................

RETAINING RING ...............................................................................................

SEE DIRECTION SELECTOR 36V.....................................................................

PARK BRAKE AND CONTROLS ........................................................................

1

CLEVIS YOKE.....................................................................................................

1

CLEVIS PIN, 5/16" X 13/16"................................................................................

1

1

2

1

2

1

1

1

1

1

4

BUMPER .............................................................................................................

2

WIRE CLAMP, 3/4"..............................................................................................

2

CLEVIS PIN, 5/16" X 13/16" LG ..........................................................................

2

COTTER PIN, 3/32" X 3/4" LG ............................................................................

1

BRAKE CABLE ...................................................................................................

2

1

1

Service Parts Manual Page D-2

PARK BRAKE




ITEM PART NO.


00438-G6

QTY.

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

4 31

32

33

34

35

36

601108

601107

16705-G3

14776-G1

PARK BRAKE COVER, 36V................................................................................

1

PARK BRAKE COVER, 48V................................................................................

1

SCREW, 1/4 - 20 X 3/4" LG.................................................................................

’J’ NUT, 1/4 - 20 ...................................................................................................

6

6


Notes:

PARK BRAKE


HYDRAULIC BRAKE


HYDRAULIC BRAKE

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


810152

875212

601097

2702168

QTY.

PEDAL COVER ...................................................................................................

1

PEDAL.................................................................................................................

1

BRAKE LEVER (INCLUDES ITEM 4) .................................................................

1

GREASE FITTING ........................................................................................

1

306414

120177

306562

311397

837612

303269

304364

103867

306328

306835

603620

120177

306562

800026

308090

306396

306375

817320

302030

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..............................................................................

4

WASHER, 3/8" ....................................................................................................

4

LOCK WASHER, 3/8"..........................................................................................

NUT, 3/8 - 16 .......................................................................................................

SCREW, 1/4 - 20 X 3/4" LG.................................................................................

WASHER, 1/4" ....................................................................................................

1

1

1

1

1

1

1

1

1

4

4

2

2

LOCK WASHER, 1/4"..........................................................................................

2

NUT, 1/4 - 20 .......................................................................................................

2

WIRE CLAMP......................................................................................................

2

SCREW, 1/4 - 20 X 1 1/4" LG..............................................................................

2


HYDRAULIC BRAKE

49

50

51

52

53

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35




ITEM PART NO.


308090

306396

306375

112050

832584

820008

832585

306562

120177

112050

11845-G5

600467

600468

QTY.

WASHER, 1/4" ....................................................................................................

2

LOCK WASHER, 1/4"..........................................................................................

2

NUT, 1/4 - 20 .......................................................................................................

2

SCREW, 1/4 - 20 X 5/8" LG.................................................................................

4

CLAMP ................................................................................................................

1

TEE, UNION ........................................................................................................

1

BRACKET ...........................................................................................................

1

NUT, 3/8 - 16 .......................................................................................................

1

LOCK WASHER, 3/8"..........................................................................................

1

SCREW, 1/4 - 20 X 5/8" LG.................................................................................

2

CLAMP ................................................................................................................

2

REAR BRAKE LINE ............................................................................................

1

FRONT BRAKE LINE ..........................................................................................

1

302030

308090

306396

306375

830021

809137

830019

832587

832590

SCREW, 1/4 - 20 X 1 1/4" LG..............................................................................

2

WASHER, 1/4" ....................................................................................................

2

LOCK WASHER, 1/4"..........................................................................................

2

NUT, 1/4 - 20 .......................................................................................................

2

BRACKET ...........................................................................................................

2

CLIP ....................................................................................................................

2

TUBE ...................................................................................................................

2

HOSE, REAR ......................................................................................................

1

HOSE, FRONT ....................................................................................................

1


Notes:

HYDRAULIC BRAKE


FRONT BRAKE


FRONT BRAKE

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


886292

884399

886371

306396

306419

829348

306494

304104

QTY.

BRAKE AND SHOE ASSEMBLY ( INCLUDES ITEMS 2 - 15 )...........................

2

BACKING PLATE..........................................................................................

1

WHEEL CYLINDER ......................................................................................

1

LOCK WASHER, 1/4" ...................................................................................

2

BOLT, 1/4 - 20 X 1/2" LG...............................................................................

2

HEEL PIN......................................................................................................

1

LOCK WASHER, 5/8" ...................................................................................

1

NUT, 5/8 - 18.................................................................................................

1

809252

805441

806761

306353

306319

887284

306450

306325

330747

886226

829247

XXXXX

XXXXX

XXXXX

XXXXX

XXXXX

XXXXX

XXXXX

RETAINING RING.........................................................................................

SPRING ........................................................................................................

ADJUSTMENT PIN.......................................................................................

2

LOCK WASHER, 3/8" ...................................................................................

2

NUT, 3/8 - 24.................................................................................................

2

BRAKE SHOE (REPLACE BOTH SHOES ON BOTH WHEELS) ................

4

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

LOCK WASHER, 5/16"........................................................................................

SCREW, 5/16 - 18 X 3/4" LG...............................................................................

BRAKE DRUM ASSEMBLY ( INCLUDES ITEMS 22 - 24 ).................................

BRAKE DRUM ..............................................................................................

HUB ( SEE FRONT SUSPENSION )............................................................

LUG BOLT, 7/16 - 20 X 1 3/4" LG ( SEE FRONT SUSPENSION )...............

SEAL, FRONT AXLE ( SEE FRONT SUSPENSION ) ........................................

1

1

3

6

1

2

1

1

5

2

CONE BEARING ( SEE FRONT SUSPENSION ) ..............................................

2

CONE BEARING AND ROLLER ( SEE FRONT SUSPENSION ) ......................

2

WASHER, 3/4" ( SEE FRONT SUSPENSION ) ..................................................

2

CASTLE NUT, 3/4 - 16 ( SEE FRONT SUSPENSION )......................................

2


FRONT BRAKE




ITEM PART NO.


31

32

XXXXX

XXXXX

QTY.

COTTER PIN ( SEE FRONT SUSPENSION ) ....................................................

2

SPINDLE CAP ( SEE FRONT SUSPENSION ) ..................................................

2


Notes:

FRONT BRAKE


REAR BRAKE


REAR BRAKE

19

20

21

22

23

24

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


33725-G01

33725-G02

21086-G1

21094-G1

21095-G1

21096-G1

21097-G1

21908-G1

70669-G01

70670-G01

33726-G01

QTY.

BRAKE ASSEMBLY ( PASSENGER SIDE ) ( INCLUDES ITEMS 3 - 18 ) .........

1

BRAKE ASSEMBLY ( DRIVER SIDE ) ( INCLUDES ITEMS 3 - 18 ) ..................

1

TORQUE SPIDER ........................................................................................

1

BLEEDER VALVE .........................................................................................

1

LOWER SPRING ..........................................................................................

1

SHOE HOLD DOWN ....................................................................................

1

ADJUSTER ...................................................................................................

1

DUST SHIELD ..............................................................................................

1

SPRING ( BLUE ) .........................................................................................

1

SPRING ( YELLOW )....................................................................................

1

BRAKE SHOE...............................................................................................

2

25

*

13460-G1

13463-G1

13462-G1

13464-G1

22604-G1

13468-G1

33662-G01

21562-G1

XXXXX-GX

XXXXX-GX

17953-G2

PARKING BRAKE LEVER ASSEMBLY ( INCLUDES ITEMS 14 - 18 ) ........

CURVED LEVER....................................................................................

SPRING WASHER .................................................................................

CLIP ....................................................................................................................

STUD, 5/16 - 24 ..................................................................................................

NUT, 5/16 - 24 .....................................................................................................

1

1

1

CLEVIS PIN............................................................................................

1

CLEVIS PIN RETAINER.........................................................................

1

STRAIGHT LEVER ................................................................................

2

2

4

4

AXLE SHAFT ( PASSENGER SIDE )

( SEE REAR AXLE SECTION FOR P/N ) ...........................................................

1

AXLE SHAFT ( DRIVER SIDE )

( SEE REAR AXLE SECTION FOR P/N ) ...........................................................

1

BRAKE DRUM ....................................................................................................

2 26

27

28

29

XXXXX-GX

XXXXX-GX

WHEEL BOLT, 1/2 - 20 (SEE REAR AXLE SECTION FOR P/N ) ......................

LUG NUT, 1/2 - 20 (SEE WHEELS AND TIRES SECTION FOR P/N ) ..............

5

5


REAR BRAKE




ITEM PART NO.


30

31

32

33

34

35

21559-G1

14584-G1

14585-G1

13084-G1

WIPER SEAL ......................................................................................................

BEARING RETAINER RING ...............................................................................

INNER OIL SEAL ................................................................................................

WHEEL BEARING ..............................................................................................

QTY.

1

1

1

1


Notes:

REAR BRAKE


MASTER CYLINDER

1

13

8

14

9

10

15

12

6

7

6

2

5

Part of

Master Cylinder

3

11


MASTER CYLINDER

9

10

11

6

7

8

12

13

14

15

1

4

5

2

3




ITEM PART NO.


886752

120177

130981

QTY.

MASTER CYLINDER ..........................................................................................

1

LOCK WASHER, 3/8"..........................................................................................

3

NUT, 7/16 - 20 .....................................................................................................

1

306562

306835

603620

800227

810443

810444

812364

829844

839140

830817

21510-G1

NUT, 3/8 - 16 .......................................................................................................

3

SCREW, 3/8 - 16 X 1 1/4" LG..............................................................................

3

WASHER 3/8" .....................................................................................................

1

PLUG, 1/8 - 27 .....................................................................................................

1

SEALING WASHER ............................................................................................

2

OUTER SEALING WASHER...............................................................................

1

BRAKE ROD .......................................................................................................

1

BUSHING ............................................................................................................

1

BOLT ...................................................................................................................

1

MANIFOLD ..........................................................................................................

1

STOPLIGHT SWITCH .........................................................................................

1


DIRECTION SELECTOR 36V

1 - Includes Items 2 - 17

30

33

25

26

27

23

22

17

31

15

32

16

29

14

36

34

19

20

11 21

10

37

24

9 8 12

13

2

35

3

5

6

7

4

18

Page E-1 Service Parts Manual


23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3





ITEM PART NO.


34190-G01

14651-G1

10606-G4

12835-G1

14628-G1

13514-G1

00645-G6

00565-G3

00525-G5

12806-G1

34169-G01

DIRECTION SELECTOR ASSEMBLY ( INCLUDES ITEMS 2 - 17 ) ..................

1

CONTACT BOARD ASSEMBLY ...................................................................

1

MICRO SWITCH (HEAVY DUTY).................................................................

2

CAM ..............................................................................................................

1

FASTON TAB ................................................................................................

4

SCREW, #6 - 32 X 1/4" LG (BRASS) ...........................................................

4

SCREW, #6 - 32 X 1 3/4" LG ........................................................................

4

LOCK WASHER, #6 .....................................................................................

4

NUT, #6 - 32..................................................................................................

4

SPACER .......................................................................................................

4

SHAFT ..........................................................................................................

1

00544-G3

00565-G8

34168-G01

00532-G6

00560-G1

14390-G1

35209-G01

NUT, 5/16 - 18...............................................................................................

8

LOCK WASHER, 5/16" .................................................................................

4

SHIFTER ARM..............................................................................................

1

NUT, 3/8 - 24.................................................................................................

2

WASHER, 3/8" ..............................................................................................

1

LOCK NUT, 3/8 - 24 ......................................................................................

1

BOOT ..................................................................................................................

1

15461-G1

00415-G2

23726-G1

00559-G7

14390-G4

70824-G01

70816-G02

22754-G3

WASHER PLATE.................................................................................................

BOLT, 1/4 - 20 X 1 1/4" LG ..................................................................................

SPACER ..............................................................................................................

WASHER, 1/4" ....................................................................................................

LOCK NUT, 1/4 - 20 ............................................................................................

SHIFT ARM SHAFT ............................................................................................

SHIFT LINK .........................................................................................................

BUSHING ............................................................................................................

1

3

3

4

3

1

1

2

600114-G01 PRIMARY LINK ...................................................................................................

1

00560-G1

70815-G01

WASHER, 3/8" ....................................................................................................

TRUNNION .........................................................................................................

3

1

Service Parts Manual Page E-2


31

32

33

34

35

36

37





ITEM PART NO.


600114-G02 SECONDARY LINK.............................................................................................

1

01076-G01

00571-G2

COTTER PIN.......................................................................................................

1

WASHER, 5/16" ..................................................................................................

1

600043-G01 BRACKET ...........................................................................................................

1

00559-G7 WASHER, 1/4" ....................................................................................................

4

11989-G1

25664-G2

SHIFTER ARM KNOB .........................................................................................

1

BUSHING ............................................................................................................

1

Page E-3 Service Parts Manual

Notes:


Service Parts Manual Page E-4

ELECTRICAL 36V

Front of Vehicle

4

5

3

2

1

Part of Cowl

7

6

11

12

13

10

Page F-1 Service Parts Manual

ELECTRICAL 36V

Front of Vehicle

#4 Wire From FNR Harness

To "A" Position on FNR


To "B" Position on FNR


To "C" Position on FNR


To "D" Position on FNR

15

16

RED/WHT Wire From Control

Harness To FNR Forward Microswitch

WHT/YEL Wire From Control

Harness To FNR Forward Microswitch

RED Wire From Control

Harness To FNR Reverse Microswitch

WHT/GRN Wire From Control

Harness To FNR Reverse Microswitch

17

Service Parts Manual Page F-2

ELECTRICAL 36V

18

4 PASSENGER BATTERY HOLD DOWN AND BATTERY CONNECTIONS

23

22

21

20

Front of Vehicle

25

26

27

19

GRN Wire From

Control Harness

BLK Wire From

Control Harness

30

28

From Solenoid

Main Contactor

29

From

B - Controller

Part of Body

Page F-3

BATTERY RACK


2 PASSENGER BATTERY CONNECTIONS

ELECTRICAL 36V

39

38

37

36

43

42

41

40

33

Front of Vehicle

49

50

44

45

35

47

48

34

46 From Sol

Main Con

GRN Wire From

Control Harness

From

B - Controller

BLK Wire From

Control Harness


ELECTRICAL 36V

Front of Vehicle

From "D"

Position on FNR

From "A2"

Position on

Electronic

Speed Controller

From "B"

Position on FNR

From Solenoid

58

57

62

61

S1 56

55

A1

A2

S2


ELECTRICAL 36V

Front of Vehicle

HORN

GRN / WHT Wire

BLK Wire

65

TAIL LIGHT

66

Part of Charger Box

Part of Frame

3 Pin Connector to Tail Light

67


ELECTRICAL 36V

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


33636-G01

74665-G02

73877-G01

806791

800296

120052

306531

QTY.

SOC METER, 36V...............................................................................................

1

HOUR METER ....................................................................................................

1

PLUG...................................................................................................................

1

HORN BUTTON ..................................................................................................

1

SCREW, #10 - 24 X 3/4" LG................................................................................

2

LOCK WASHER ..................................................................................................

2

NUT, #10 - 24 ......................................................................................................

2

33639-G01

814924

600509

828247

00544-G3

00565-G8

73864-G02

890881

806954

809152

818303

103867

800315

00702-G2

00565-G8

25971-G18

600783

600552

25971-G13

IGNITION SWITCH W/LIGHTS ...........................................................................

WIRE CLAMP......................................................................................................

CONTROL HARNESS ........................................................................................

RUBBER GROMMET..........................................................................................

NUT, 5/16 - 18 .....................................................................................................

NUT, 5/16 - 24 .....................................................................................................

LOCK WASHER, 5/16"........................................................................................

1

1

1

1

8

LOCK WASHER, 5/16"........................................................................................

4

WIRE CLAMP......................................................................................................

8

BATTERY FRAME...............................................................................................

1

J - BOLT, 5/16 - 18 X 12 1/2" LG .........................................................................

2

WASHER.............................................................................................................

2

SPACER ..............................................................................................................

2

WASHER, 5/16" ..................................................................................................

2

WING NUT, 5/16 - 18 ..........................................................................................

2

16

16

WIRE, #4, 6"........................................................................................................

4

WIRE, #4, 55"......................................................................................................

1

WIRE, #4, 52"......................................................................................................

1

WIRE, #4, 10 1/2"................................................................................................

1


ELECTRICAL 36V




ITEM PART NO.


53

54

55

56

49

50

51

52

57

58

59

60

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35

600459

829835

806954

809152

818303

103867

800315

300646

308090

306396

306375

829997

73864-G02

600783

600554

25971-G13

00702-G2

00565-G8

00797-G2

00559-G7

27327-G02

600556

QTY.

BATTERY HOLD DOWN.....................................................................................

4

BATTERY HOLD DOWN END ............................................................................

4

J - BOLT, 5/16 - 18 X 12 1/2" LG .........................................................................

WASHER.............................................................................................................

4

SPACER ..............................................................................................................

4

WASHER, 5/16" ..................................................................................................

WING NUT, 5/16 - 18 ..........................................................................................

4

SCREW, 1/4 - 20 X 3/4" LG.................................................................................

8

WASHER, 1/4" ....................................................................................................

LOCK WASHER, 1/4"..........................................................................................

8

NUT, 1/4 - 20 .......................................................................................................

8

RUBBER GROMMET..........................................................................................

4

WIRE CLAMP......................................................................................................

9

WIRE, #4, 55"......................................................................................................

WIRE, #4, 53"......................................................................................................

WIRE, #4, 10 1/2"................................................................................................

NUT, 5/16 - 24 .....................................................................................................

LOCK WASHER, 5/16"........................................................................................

BOLT, 1/4 - 20 X 1 1/4" LG ..................................................................................

WASHER, 1/4" ....................................................................................................

TWISTED CLAMP ...............................................................................................

POWER HARNESS ............................................................................................

4

4

8

1

1

4

12

12

1

1

1

1


ELECTRICAL 36V




ITEM PART NO.


61

62

63

64

65

66

67

00993-G01

28418-G01

32860-G1

*

32739-G3

QTY.

LOCK WASHER, 5/16"........................................................................................

2

NUT, 5/16 - 18 .....................................................................................................

2

HORN ( INCLUDES ITEM 66 )............................................................................

1

BRACKET .....................................................................................................

1

TAIL LIGHT .........................................................................................................

2


Notes:

ELECTRICAL 36V


ELECTRICAL 48V

Front of Vehicle

4

5

3

2

1

Part of Cowl

7

6

12

11

13

10


Front of Vehicle

31

32

33

28

27

GRN Wire From

Control Harness

BLK Wire From

Control Harness

16

ELECTRICAL 48V

17

18

19

20

26

25

24

23

15

21

29

34

30

From Solenoid

Main Contactor

From

B - Controller


ELECTRICAL 48V

Front of Vehicle

42

43

From "B-"

Position on Electronic

Speed Controller

From Solenoid

From "M-"

Position on

Electronic

Speed Controller

From "F2"

Position on Electronic speed Controller

38

39

37

36

F1

A1

41

40

A2

F2

35

44

45

46 47


ELECTRICAL 48V

HORN

Front of Vehicle

GRN / WHT Wire

BLK Wire

49

50

Part of Charger Box

TAIL LIGHT

Part of Frame

3 Pin Connector to Tail Light

51


ELECTRICAL 48V

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


33636-G03

74665-G02

74323-G01

806791

800296

120052

306531

QTY.

SOC METER, 48V...............................................................................................

1

HOUR METER ....................................................................................................

1

FNR SWITCH ......................................................................................................

1

HORN BUTTON ..................................................................................................

1

SCREW, #10 - 24 X 3/4" LG................................................................................

2

LOCK WASHER, #10 ..........................................................................................

2

NUT, #10 - 24 ......................................................................................................

2

33639-G01

600510

814924

828247

600459

829835

800315

103867

818303

809152

806954

300646

308090

306396

306375

73864-G02

829997

25971-G13

600550

IGNITION SWITCH W/LIGHTS ...........................................................................

CONTROL HARNESS ........................................................................................

CLAMP ................................................................................................................

RUBBER GROMMET..........................................................................................

BATTERY HOLD DOWN.....................................................................................

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 .............................................................................................................

1

1

1

1

4

BATTERY HOLD DOWN END ............................................................................

4

WING NUT, 5/16 - 18 ..........................................................................................

4

WASHER, 5/16" ..................................................................................................

4

SPACER ..............................................................................................................

4

WASHER.............................................................................................................

4

J - BOLT, 5/16 - 18 X 12 1/2" LG .........................................................................

4

8

8

8

8

9

4

6

1


ELECTRICAL 48V

46

47

48

42

43

44

45

49

50

51

39

40

41

36

37

38

31

32

33

34

35




ITEM PART NO.


600553

00702-G2

00565-G8

813840

00797-G2

27327-G02

00559-G7

17618-G1

600785

28418-G02

00993-G02

28418-G01

00993-G01

73277-G01

600784

01037-G02

73328-G01

QTY.

WIRE, #4 .............................................................................................................

1

NUT, 5/16 - 24 .....................................................................................................

16

LOCK WASHER, 5/16"........................................................................................

16

CLIP ....................................................................................................................

4

BOLT, 1/4 - 20 X 1 1/4" LG ..................................................................................

1

CLAMP ................................................................................................................

1

WASHER, 1/4" ....................................................................................................

1

NYLON CLAMP...................................................................................................

4

POWER HARNESS ............................................................................................

1

NUT, 1/4 - 20 .......................................................................................................

2

LOCK WASHER ..................................................................................................

2

NUT, 5/16 - 18 .....................................................................................................

2

LOCK WASHER, 5/16"........................................................................................

2

RETAINER RING.................................................................................................

1

SPEED SENSOR ................................................................................................

1

SCREW, #10 - 32 X 1/2" LG................................................................................

1

MAGNET .............................................................................................................

1

32860-G1

*

32739-G3

HORN ( INCLUDES ITEM 50 )............................................................................

BRACKET .....................................................................................................

TAIL LIGHT .........................................................................................................

1

1

2


ELECTRICAL (ACCESSORY)

HEADLIGHT AND TURN SIGNAL INSTALLATION

3

15

16

1 Includes 3-12

2 Includes 3-12

10

9

8

7

11

4

5

6

Headlight BLK to Harness

Headlight BLU to Harness

Turn Signal BLK to Harness

Turn Signal WHT to Harness

12

Page G-1 Service Parts Manual


18

Steering Column


WHT Ground

Connected to

Accessory Wiring

Harness

19

Page G-2


12

13

14

15

9

10

11

16

17

18

7

8

5

6

3

4




ITEM PART NO.


1

2

34589-G01

34589-G02

20209-G2

00560-G3

00566-G3

00533-G1

21806-G1

18927-G1

00984-G01

19180-G2

00598-G4

17064-G2

QTY.

HEAD LIGHT AND TURN SIGNAL (PASSENGER SIDE - OPTIONAL)

(INCLUDES ITEMS 3 - 12)..................................................................................

1

HEAD LIGHT AND TURN SIGNAL (DRIVER SIDE - OPTIONAL)

(INCLUDES ITEMS 3 - 12)..................................................................................

1

HEADLIGHT (RECTANGULAR) ...................................................................

2

WASHER, 1/2" ..............................................................................................

2

LOCK WASHER, 1/2" ...................................................................................

2

NUT, 1/2 - 13.................................................................................................

2

TURN SIGNAL LIGHT BRACKET ................................................................

1

ADAPTER MOUNT .......................................................................................

1

SCREW, # 8 - 10 X 1/2" LG ..........................................................................

2

TURN SIGNAL LIGHT ..................................................................................

1

SCREW, #10 - 32 X 1/2" LG .........................................................................

2

PUSH ON TERMINAL (FEMALE).................................................................

2

830237

112050

17867-G1

WIRING COVER .................................................................................................

SCREW, TAPPING, 1/4 - 20 X 5/8" LG ...............................................................

1

2

19 21640-G1

TURN SIGNAL (WITH MOUNTING HARDWARE) (OPTIONAL)

(INCLUDES ITEM 19) .........................................................................................

1

TURN SIGNAL FLASHER ............................................................................

1

Page G-3 Service Parts Manual

Notes:


Service Parts Manual Page G-4

MOTOR 36V SERIES


2

S

1

S

2

A

1

A

4

5

6

2

10

12

7

8

11

9

3

13

Page H-1 Service Parts Manual

MOTOR 36V SERIES




ITEM PART NO.


9

10

11

6

7

8

12

13

1

4

5

2

3

73124-G02

73120-GO9

*

73120-G03

73120-G15

73120-G25

73120-G06

73120-G07

73120-G16

73120-G08

73277-G01

73120-G32

73120-G29

QTY.

MOTOR, FLEET SPEED, NON - VENTED (INCLUDES ITEMS 2 - 13) .............

1

COVER PLATE AND SCREW......................................................................

1

ARMATURE..................................................................................................

1

BRUSH SPRING ..........................................................................................

4

BRUSH PLATE AND BOX............................................................................

1

BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) ...........................

1

SNAP RING ..................................................................................................

1

BEARING......................................................................................................

1

CAP ..............................................................................................................

1

COMMUTATOR END HEAD.........................................................................

1

RETAINING RING ........................................................................................

1

COMMUTATOR HEAD SCREW...................................................................

4

FRAME AND FIELD COIL (INCLUDES HARDWARE).................................

1

Service Parts Manual Page H-2

MOTOR 48V PDS


3

5

4

6

2

X

X

2

A

1

A

8

7

2

10

11

9

12

13 14

14

15

Page H-3 Service Parts Manual

MOTOR 48V PDS

9

10

11

6

7

8

12

13

14

15

1

4

5

2

3





ITEM PART NO.


73291-G04 MOTOR (SEPARATELY EXCITED) (PDS) (INCLUDES ITEMS 2 - 11) ..............

1

73120-G36 ARMATURE ..................................................................................................

1

73120-G38 BRUSH SPRING...........................................................................................

8

73120-G39

73120-G40

BRUSH .........................................................................................................

BRUSH BOX.................................................................................................

8

1

73120-G41

73120-G07

73120-G06

73120-G43

73120-G37

73120-G42

73328-G01

01037-G02

73277-G01

73327-G01

BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) ...........................

BEARING......................................................................................................

SNAP RING ..................................................................................................

MAGNET .............................................................................................................

SCREW, #10 - 32 X 1/2" LG................................................................................

RETAINING RING ...............................................................................................

SPEED SENSOR ................................................................................................

1

1

1

HEADBAND ..................................................................................................

1

FRAME AND FIELD COIL (INCLUDES HARDWARE).................................

1

COVER COMMUTATOR END ......................................................................

1

1

1

2

1

Service Parts Manual Page H-4

36 VOLT ELECTRONIC SPEED CONTROL

BLK From Battery

Harness to B- on Controller

BLK From Solenoid

Harness to B+ on Controller

18

RED From Control

Harness to Reverse

2

BLU Wire From Control

Harness To Logic Power

WHT Wire From Control

Harness To Throttle Power

BLK Wire From Control

Harness To Throttle Sensor

FNR Harness To

M- Controller

FNR Harness To

A2 Controller

Power Harness To

A2 Controller

22

23

1

10

Front of Vehicle

13

Part Of Frame

From Control

Harness To +36V

5

4

11

6

17

16

20

21

3

12

24

25

8

RED

GRN / BLK

15

19

RED

WHT/BLU

WHT/GRN

7

14

9

WHT From

Charger

YEL From control

Harness To Solenoid (+)

RED/GRN

WHT From

Control Harness

From Solenoid

To Motor

BLU From control

Harness To Solenoid (-)

Page J-1 Service Parts Manual


27

CONTROLLER COVER

26

Front of Vehicle

Service Parts Manual Page J-2


23

24

25

26

19

20

21

22

27

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3

00379-G2

14390-G4

14390-G10

01041-G01

00565-G8

00544-G4

600551

35212-G01

21764 -G1

30353-G1

00414-G7

16469-G1

00559-G5

11027-G2

600276

32804-G1

600187

73060-G01

20468-G1

00565-G5

00526-G4

73446-G01

35211-G01

73290-G02

00414-G5

11027-G2

00414-G4




ITEM PART NO.


CONTROLLER MOUNTING PLATE ...................................................................

1

ELECTRONIC SPEED CONTROLLER ( 36V SYSTEM ) ...................................

1

SOLENOID ..........................................................................................................

1

LOCK WASHER, #10 ..........................................................................................

2

NUT, #10 - 32 ......................................................................................................

2

FASTON TAB ......................................................................................................

4

FUSE BLOCK (6 POSITION) ..............................................................................

1

CONTINUOUS TONE BUZZER ..........................................................................

1

BOLT, 1/4 - 20 X 5/8" LG .....................................................................................

4

LOCK NUT, 1/4 - 20 ............................................................................................

4

BOLT, 1/4 - 20 X 1/2" LG .....................................................................................

2

SCREW, #10 - 24 X 1 1/4" LG.............................................................................

2

LOCK NUT, 1/4 - 20 ............................................................................................

4

LOCK NUT, #10 - 24 ...........................................................................................

2

RIVET, 1/8" X 13/16" LG .....................................................................................

2

LOCK WASHER, 5/16"........................................................................................

2

NUT, 5/16 - 24 .....................................................................................................

2

4 GA WIRE SOL - B+ ..........................................................................................

1

FUSE, 15 AMP ....................................................................................................

3

RESISTOR ..........................................................................................................

1

DIODE .................................................................................................................

1

BOLT, 1/4 - 20 X 3/4" LG .....................................................................................

4

WASHER, 1/4" ....................................................................................................

4

WASHER, #10.....................................................................................................

2

LOCK NUT, 1/4 - 20 ............................................................................................

2

CONTROLLER COVER ......................................................................................

1

TRIM....................................................................................................................

1


Notes:




BLK From F2 Power

Harness To F2 Controller

From B+ Power

Harness To Controller

From Solenoid

To B+ Controller

From M- Power

Harness To Controller

From B- Controller

To 48V

WHT From Power

Harness to F1Controller

BLK From

Charger

2

Front of Vehicle

1

22

23

Part Of Frame

24

13

19

18

3

15

16

25

11

14

5

4

6

(Included with item 9)

21

8

RED

WHT/BLU

WHT/GRN

10

7

17

12

9

WHT From

Charger

YEL From control

Harness To Solenoid (+)

RED/GRN

WHT From

Control Harness

From Solenoid

To +48V

20

From Solenoid

To Motor

BLU From control

Harness To Solenoid (-)



27

CONTROLLER COVER

26

Front of Vehicle



23

24

25

26

19

20

21

22

27

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3

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

600187

73098-G04

73231-G01

00565-G5

00526-G4

73446-G01

35211-G01

73290-G02

73354-G02

01041-G01

73440-G01




ITEM PART NO.


CONTROLLER MOUNTING PLATE ...................................................................

1

ELECTRONIC SPEED CONTROLLER ..............................................................

1

SOLENOID ..........................................................................................................

1

LOCK WASHER, #10 ..........................................................................................

2

NUT, #10-32 ........................................................................................................

2

FASTON TAB ......................................................................................................

4

FUSE BLOCK (6 POSITION) ..............................................................................

1

CONTINUOUS TONE BUZZER ..........................................................................

1

TOGGLE SWITCH ..............................................................................................

1

RIVET, 1/8" X 13/16" LG .....................................................................................

2

LABEL - TOW/RUN SWITCH..............................................................................

1

BOLT, 1/4 - 20 X 7/8" LG .....................................................................................

4

LOCK NUT, 1/4 - 20 ............................................................................................

4

BOLT, 1/4 - 20 X 1/2" LG .....................................................................................

2

SCREW, #10 - 24 X 1 1/4" LG.............................................................................

2

WASHER, #10.....................................................................................................

2

LOCK NUT, #10 - 24 ...........................................................................................

2

LOCK WASHER, 5/16"........................................................................................

2

NUT, 5/16 - 24 .....................................................................................................

2

4 GA WIRE SOL - B+ ..........................................................................................

1

FUSE, 15 AMP ....................................................................................................

3

BOLT, 1/4 - 20 X 7/8" LG .....................................................................................

4

WASHER, 1/4" ....................................................................................................

4

LOCK NUT, 1/4 - 20 ............................................................................................

4

LOCK NUT, 1/4 - 20 ............................................................................................

2

CONTROLLER COVER ......................................................................................

1

TRIM....................................................................................................................

1


Notes:



FRONT SUSPENSION

1

25

39

6

30

44

42

45

43

41

48

47

36

46

40

49

20

19

18

22

23

21

26

27

39

31

32

3

2

4

7

8

9

15

14

13

5

16

34

37

38

35

28

12

Page K-1 Service Parts Manual

55

56

61

60

58

59

57

53

54

50

51

52

62

49


Service Parts Manual Page K-2


80

65

66

73

74

75

76

72

SHOCK ABSORBER

67

68

67

69

78

79

81

82

83

64

67

68

67

69



23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3

Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING.




ITEM PART NO.


306835

306981

120177

306562

886234

888203

830012

306982

800294

QTY.

BOLT, 5/8 - 16 X 1 1/4" LG ..................................................................................

4

WASHER, 3/8" ....................................................................................................

4

LOCK WASHER, 3/8"..........................................................................................

4

NUT, 3/8 - 16 .......................................................................................................

4

LEAF SPRING & BUSHING ................................................................................

2

PERCH, SPRING ................................................................................................

1

SHACKLE PLATE ...............................................................................................

2

WASHER, 7/16" ..................................................................................................

4

LOCK NUT, 7/16 - 14 ..........................................................................................

4

306414

306981

120177

306562

600061-G01 LOWER ARM REAR BRACKET .........................................................................

1

600342-G01

70581-G02

600062-G01

12305-G1

34158-G05

600060-G01

888322

833105

832998

830477

00406-G4

BOLT, 3/8 - 16 X 1" LG ........................................................................................

WASHER, 3/8" ....................................................................................................

LOCK WASHER, 3/8"..........................................................................................

NUT, 3/8 - 16 .......................................................................................................

LOWER ARM FRONT BRACKET ASSEMBLY (INCLUDES ITEMS 19 - 23 ) ....

FLANGED BUSHING....................................................................................

SECONDARY BELLCRANK.........................................................................

RETAINING RING.........................................................................................

SHAFT ..........................................................................................................

LOWER ARM FRONT BRACKET ................................................................

ECCENTRIC BOLT .............................................................................................

BELLEVILLE WASHER.......................................................................................

BUSHING ............................................................................................................

ECCENTRIC WASHER.......................................................................................

BOLT, 1/2 - 13 X 4" LG ........................................................................................

4

4

4

4

1

2

1

2

1

1

2

4

2

2

2







ITEM PART NO.


120166

308332

QTY.

LOCK WASHER, 1/2"..........................................................................................

2

NUT, 1/2 - 13 .......................................................................................................

2

887012

827648

886227

*

886225

829252

829318

829229

548136

819804

886852

886237

311745

312272

829251

888325

831405

00405-G8

120166

308332

813850

829256

385174

103960

2702247

304636

817250

53

54

55

56

49

50

51

52

57

58

59

60

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35

LOWER ARM AND BUSHING ASSEMBLY ( INCLUDES ITEM 35 ) ..................

GREASE FITTING ........................................................................................

2

2

BOLT, 1/2 - 13 X 4" LG ........................................................................................

2

LOCK WASHER, 1/2"..........................................................................................

2

NUT, 1/2 - 13 .......................................................................................................

2

BUMPER, RUBBER ............................................................................................

4

SEAL, FRONT AXLE...........................................................................................

2

CONE BEARING AND ROLLER .........................................................................

2

WASHER, 3/4" ....................................................................................................

2

CASTLE NUT, 3/4 - 16 ........................................................................................

2

COTTER PIN.......................................................................................................

2

SPINDLE CAP.....................................................................................................

2

CONE BEARING.................................................................................................

2

LUG BOLT, 7/16 - 20 X 1 3/4" LG........................................................................

5

HUB.....................................................................................................................

2

KING PIN AND SPINDLE ASSEMBLY ( INCLUDES ITEMS 50 - 62 )................

2

NUT, 3/4 - 16.................................................................................................

1

LOCK WASHER, 3/4" ...................................................................................

1

RETAINER SPRING AND KING PIN ............................................................

1

BEARING......................................................................................................

1

SHIM .............................................................................................................

3

SPINDLE ( INCLUDES ITEM 56 ) ................................................................

1

BUSHING ...............................................................................................

2

KING PIN ASSEMBLY ( INCLUDES ITEMS 58 - 61 ) ..................................

1

SUPPORT, KING PIN.............................................................................

1

PIN .........................................................................................................

2

BUSHING ...............................................................................................

1



79

80

81

82

83

76

77

78

72

73

74

75

69

70

71

66

67

68

61

62

63

64

65





ITEM PART NO.


829255

2702168

QTY.

KING PIN................................................................................................

1

GREASE FITTING, 1/4 - 28 ..........................................................................

1

807332

888200-G01

FRONT SHOCK ABSORBER .............................................................................

BRACKET, SPRING PERCH ( PASSENGER SIDE )..........................................

888201-G01 BRACKET, SPRING PERCH ( DRIVER SIDE ) ..................................................

1

825500

823621

800294

306835

306981

120177

306981

306562

886458-G01

306562

WASHER.............................................................................................................

BUSHING ............................................................................................................

LOCK NUT, 7/16 - 14 ..........................................................................................

BOLT, 3/8 - 16 X 1 1/4" LG ..................................................................................

10

WASHER, 3/8" ....................................................................................................

24

LOCK WASHER, 3/8"..........................................................................................

14

WASHER, 3/8" ....................................................................................................

24

NUT, 3/8 - 16 .......................................................................................................

STUD ( PASSENGER SIDE )..............................................................................

NUT, 3/8 - 16 .......................................................................................................

2

1

8

4

4

14

1

886459-G01 STUD ( DRIVER SIDE ) ......................................................................................

1

829756 U - BOLT, 3/8 - 16................................................................................................

2

306981

120177

WASHER, 3/8" ....................................................................................................

LOCK WASHER, 3/8"..........................................................................................

24

14

14


REAR AXLE

Page L-1 Service Parts Manual

REAR AXLE

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


600185-G01 AXLE ASSY 36V (INCLUDES ITEMS 3, 5, 7 - 37) .............................................

1

600185-G02 AXLE ASSY 48V (INCLUDES ITEMS 3, 4, 6, 8 - 37) .........................................

1

601061 AXLE HOUSING ...........................................................................................

1

601068

601069

INPUT GEAR KIT, 48V AXLE (INCLUDES ITEMS 6, 8 - 12) .......................

INPUT GEAR KIT, 36V AXLE (INCLUDES ITEMS 7 - 12) ...........................

1

1

601062

601087

601063

23530-G1

24628-G1

23519-G1

23520-G1

INTERNAL GEARS KIT, 48V AXLE .......................................................

1

INTERNAL GEARS KIT, 36V AXLE .......................................................

1

"O" RING ................................................................................................

BALL BEARING .....................................................................................

BALL BEARING .....................................................................................

1

RETAINING RING ..................................................................................

3

"O" RING ................................................................................................

3

1

1

601065

601066

601067

601070

601071

601072

601073

601074

XXXXXX

XXXXXX

601077

601078

601079

601064

601081

BALL BEARING ............................................................................................

2

OIL SEAL ......................................................................................................

2

RETAINING RING.........................................................................................

2

TAPERED ROLLER BEARING.....................................................................

2

OIL SEAL ......................................................................................................

2

FLAT WASHER.............................................................................................

8

LOCK NUT....................................................................................................

8

SCREW.........................................................................................................

8

BRAKE ASSY DRIVER SIDE (SEE BRAKE SECTION) ..............................

BRAKE ASSY PASSENGER SIDE (SEE BRAKE SECTION) ......................

AXLE SHAFT (DRIVER SIDE)......................................................................

1

1

1

AXLE SHAFT (PASSENGER SIDE) .............................................................

1

WHEEL BOLT ...............................................................................................

10

END CAP PLUG ...........................................................................................

2

"O" RING.......................................................................................................

2

Service Parts Manual Page L-2

REAR AXLE




ITEM PART NO.


31

32

33

34

35

36

37

17473-G1

601082

601083

601084

15558-G1

601085

15118-G1

QTY.

BALL BEARING ............................................................................................

2

DIFFERENTIAL ............................................................................................

1

BOLT .............................................................................................................

4

LOCK NUT....................................................................................................

4

SCREW, TAPPING .......................................................................................

10

CARRIER COVER KIT .................................................................................

1

BOLT .............................................................................................................

4

Page L-3 Service Parts Manual

Notes:

REAR AXLE

Service Parts Manual Page L-4

REAR SUSPENSION

25

23

22 19

27

26

Page M-1

2

4

10

11

34

33

9

6

5

4

31

30

16

15

20

21

20

13

32

14

1

34

33

31

3

30


REAR SUSPENSION

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


XXXXX-GX

887004

829044

600182

306982

548061

QTY.

SEE REAR AXLE SECTION FOR P/N ...............................................................

1

LEAF SPRING.....................................................................................................

2

U - BOLT .............................................................................................................

4

STOP PLATE.......................................................................................................

2

WASHER, 7/16" ..................................................................................................

8

LOCK NUT, 7/16 - 20 ..........................................................................................

8

70492-G01

00968-G01

00974-G01

829230

00405-G8

120166

308332

00406-G4

829142

829258

120166

308332

00405-G8

120166

308332

70472-G01

BUMPER .............................................................................................................

LOCK WASHER, M10 .........................................................................................

NUT, M10 X 1.5 ...................................................................................................

LOCK WASHER, 1/2"..........................................................................................

NUT, 1/2 - 13 .......................................................................................................

BOLT, 1/2-13 X 4" LG ..........................................................................................

LOCK WASHER, 1/2"..........................................................................................

NUT, 1/2 - 13 .......................................................................................................

SPACER ..............................................................................................................

2

2

2

SHACKLE PLATE ...............................................................................................

4

BOLT, 1/2-13 X 4" LG ..........................................................................................

2

2

2

BOLT, 1/2-13 X 4 1/2" LG ....................................................................................

2

FLANGED BUSHING ..........................................................................................

4

BUSHING ............................................................................................................

2

LOCK WASHER, 1/2"..........................................................................................

2

NUT, 1/2 - 13 .......................................................................................................

2

2

2

2

10

Service Parts Manual Page M-2

REAR SUSPENSION




ITEM PART NO.


31

32

33

34

823621

807335

825500

800294

QTY.

BUSHING ............................................................................................................

4

SHOCK ABSORBER...........................................................................................

2

WASHER.............................................................................................................

4

LOCK NUT, 7/16 - 14 ..........................................................................................

4

Page M-3 Service Parts Manual

Notes:

REAR SUSPENSION

Service Parts Manual Page M-4

SEATING

Front of Vehicle

8

2

15

14

13

12

1

2

6

7 3

4

5

3

4

5

11

10

9

Page N-1 Service Parts Manual

46

45

SEATING

47

Front of Vehicle

39

40

20

32

25 21

22

36

26

27

41

42

43

18

49

35

34

33

28

29

19

Service Parts Manual Page N-2

SEATING

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


886222-G01 BACKREST PANEL.............................................................................................

1

800017

308090

306396

306375

SCREW, 1/4 - 20 X 1" LG....................................................................................

WASHER, 1/4" ....................................................................................................

LOCK WASHER, 1/4"..........................................................................................

NUT, 1/4 - 20 .......................................................................................................

9

9

9

9

35574-G01

00114-G6

886221

302288

306396

308090

888464

800026

306396

308090

SEAT SWITCH ( SEE ELECTRICAL SECTION ) ...............................................

SCREW, 1/4 - 14 X 3/4" LG.................................................................................

SEAT BOTTOM ...................................................................................................

BACKREST .........................................................................................................

SCREW, 1/4 - 20 X 3/4" LG.................................................................................

LOCK WASHER, 1/4"..........................................................................................

WASHER, 1/4" ....................................................................................................

1

2

2

SCREW, 1/4 - 20 X 1" LG....................................................................................

6

LOCK WASHER, 1/4"..........................................................................................

6

WASHER, 1/4" ....................................................................................................

6

1

2

2

2

890880

890865

869042

890876

548333

306416

306325

306932

800290

548958

SEAT BACK ........................................................................................................

SEAT FRAME......................................................................................................

1

PIVOT PIN...........................................................................................................

3

SEAT BRACKET .................................................................................................

3

LOCK RING.........................................................................................................

3

SCREW, 5/16 - 18 X 1" LG..................................................................................

LOCK WASHER, 5/16"........................................................................................

1

6

6

NUT, 5/16 - 18 .....................................................................................................

6

LOCK NUT, 5/16 - 18 ..........................................................................................

2

SCREW, 5/16 - 18 X 3 1/2" LG............................................................................

2

Page N-3 Service Parts Manual

SEATING




ITEM PART NO.


39

40

41

36

37

38

31

32

33

34

35

46

47

48

42

43

44

45

49

888464

800026

306396

308090

820951

837631

886221

308090

306396

306832

800296

548178

891305

829950

BACKREST .........................................................................................................

1

SCREW, 1/4 - 20 X 3/4" LG.................................................................................

4

LOCK WASHER, 1/4"..........................................................................................

4

WASHER, 1/4" ....................................................................................................

4

RUBBER BUMPER .............................................................................................

SEAT MOUNTING BOARD .................................................................................

SEAT ...................................................................................................................

WASHER, 1/4" ....................................................................................................

LOCK WASHER, 1/4"..........................................................................................

SCREW, 1/4 - 20 X 2" LG....................................................................................

SCREW, #10 - 24 X 3/4" LG................................................................................

2

1

2

8

8

8

1

WASHER.............................................................................................................

1

STRAP ................................................................................................................

1

WARNING LABEL, PINCH POINT......................................................................

QTY.

2

Service Parts Manual Page N-4

STEERING

8

9

5

6

7

4

13

12

14

3

1

15

11

2


34 - includes Items 35 - 38

18

21

Part of Frame

9

16

17

19

20

30

28

29

27

26

23

22

Front of Vehicle

38

40

41

32

34

36

37

33

35

Page P-1 Service Parts Manual

STEERING

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


838598

838828

316945

827191

831298

307665

810666

819923

831135

QTY.

STEERING COLUMN .........................................................................................

1

BOOT ..................................................................................................................

1

PIN, 1/4" X 1 3/4" ................................................................................................

1

STEERING WHEEL ............................................................................................

1

NAME PLATE ......................................................................................................

1

NUT, 3/4 - 16 .......................................................................................................

1

COVER................................................................................................................

1

COLLAR ..............................................................................................................

1

BEARING ............................................................................................................

2

303459

306396

306375

830392

808454

891730

548201

320107

831585

830482

887597

311395

303269

887527

548224

889682

889681

306328

BOLT, 1/4 - 20 X 1 1/2" LG ..................................................................................

TIE ROD END ASSY (INCLUDES ITEMS 27 - 30) .............................................

2

LOCK WASHER, 1/4"..........................................................................................

2

NUT, 1/4 - 20 .......................................................................................................

2

PLATE .................................................................................................................

3

BRACKET, STEERING COLUMN ......................................................................

1

SHAFT.................................................................................................................

1

BOLT, 5/16 - 18 X 5/16" LG .................................................................................

1

WIRE TIE ............................................................................................................

1

COVER................................................................................................................

1

STEERING ARM .................................................................................................

1

STEERING GEAR ...............................................................................................

1

BOLT, 7/16 - 14 X 1 3/4" LG ................................................................................

3

LOCK WASHER, 7/16"........................................................................................

3

2

GREASE FITTING ........................................................................................

2

TIE ROD END ASSY, RH THREAD..............................................................

1

TIE ROD END ASSY, LH THREAD ..............................................................

1

COTTER PIN ................................................................................................

2

Service Parts Manual Page P-2

STEERING




ITEM PART NO.


39

40

41

36

37

38

31

32

33

34

35

887497

886246

886797

548224

889682

889681

306328

306414

120177

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 ................................................................................................

BOLT, 3/8 - 16 X 1" LG ........................................................................................

LOCK WASHER, 3/8"..........................................................................................

QTY.

1

1

1

2

1

1

2

4

4

Page P-3 Service Parts Manual

Notes:

STEERING

Service Parts Manual Page P-4

WEATHER PROTECTION (CAB)

Page Q-1 Service Parts Manual


23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


886468

886950

886951

800017

308090

306396

306375

QTY.

CAB (INCLUDES ITEMS 2 - 53) .........................................................................

1

SUPPORT, PASSENGER SIDE ...................................................................

1

SUPPORT, DRIVER SIDE ............................................................................

1

SCREW, 1/4 - 20 X 1" LG .............................................................................

4

WASHER, 1/4" ..............................................................................................

4

LOCK WASHER, 1/4" ...................................................................................

4

NUT, 1/4 - 20.................................................................................................

4

112050

800455

308090

306396

306375

886682

800017

308090

306396

306375

7071

830008

800026

308090

306396

306375

830007

886503

SCREW, TAPPING, 1/4 - 20 X 5/8" LG .........................................................

SCREW, 1/4 - 20 X 1 3/4" LG .......................................................................

WASHER, 1/4" ..............................................................................................

LOCK WASHER, 1/4" ...................................................................................

NUT, 1/4 - 20.................................................................................................

BACK, CAB...................................................................................................

1

SCREW, 1/4 - 20 X 1" LG .............................................................................

4

WASHER, 1/4" ..............................................................................................

4

LOCK WASHER, 1/4" ...................................................................................

4

NUT, 1/4 - 20.................................................................................................

4

SEAL, 50' (15.2 M)........................................................................................

AR

ROOF, CAB...................................................................................................

1

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

16

WASHER, 1/4" ..............................................................................................

16

LOCK WASHER, 1/4" ...................................................................................

16

NUT, 1/4 - 20.................................................................................................

16

FRONT, CAB.................................................................................................

1

WIPER MOTOR ............................................................................................

8

4

4

4

4

1

Service Parts Manual Page Q-2


49

50

51

52

53

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35




ITEM PART NO.


800215

821427

306998

306351

886613

QTY.

SCREW, #10 - 24 X 5/8" LG .........................................................................

1

WASHER, SEALING.....................................................................................

1

LOCK WASHER, #10 ...................................................................................

1

NUT, #10 - 24................................................................................................

1

WIRE, HARNESS, WIPER MOTOR .............................................................

1

826037

828682

830035

7147

7022

811757

7145

7022

830036

800017

306832

308090

306396

306375

800026

807404

WIPER BLADE .............................................................................................

WIPER ARM .................................................................................................

STRIP, 50' (15.2M)........................................................................................

1

1

WINDSHIELD ...............................................................................................

1

SEAL, 50' (15.2M).........................................................................................

AR

AR

WINDOW, REAR ..........................................................................................

2

SEAL, 50' (15.2M).........................................................................................

AR

STRIP, 50' (15.2M)........................................................................................

SCREW, 1/4 - 20 X 2" LG .............................................................................

MIRROR .......................................................................................................

AR

SPACER .......................................................................................................

2

SCREW, 1/4 - 20 X 1" LG .............................................................................

2

2

WASHER, 1/4" ..............................................................................................

4

LOCK WASHER, 1/4" ...................................................................................

4

NUT, 1/4 - 20.................................................................................................

4

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

2

1


Notes:



WEATHER PROTECTION (FIBERGLASS DOORS)






ITEM PART NO.


886469

QTY.

FIBERGLASS DOOR SET (INCLUDES ITEMS 3 - 60) ......................................

1

23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3 830351

830245

830437

800026

308090

306396

306375

830350

830352

830353

112050

800039

800296

*

800059

800039

886760

548247

830290

842291

830193

830058

800059

SEAL, 27 1/8" (694MM) ................................................................................

2

BRACKET, RIGHT ........................................................................................

1

BRACKET, LEFT...........................................................................................

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

6

WASHER, 1/4" ..............................................................................................

6

LOCK WASHER, 1/4" ...................................................................................

NUT, 1/4 - 20.................................................................................................

SEAL, 31" (792MM) ......................................................................................

BRACKET, LEFT...........................................................................................

BRACKET, RIGHT ........................................................................................


ACORN NUT, #10 - 24..................................................................................

SCREW, #10 - 24 X 3/4" LG .........................................................................

SEALANT, CLEAR, 12OZ (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 ......................................................................................

1

6

6

2

1

1

6

4

4

1

12

12

2

12

1

4

2

2

8






ITEM PART NO.


53

54

55

56

49

50

51

52

57

58

59

60

46

47

48

42

43

44

45

39

40

41

36

37

38

31

32

33

34

35

800271

308089

823419

120052

800039

800024

800037

886948

886949

547444

830291

308090

800017

800026

308090

306396

306375

800026

800026

306396

800037

830355

894028

894029

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

LOCK WASHER, 1/4" ...................................................................................

ACORN NUT, 1/4 - 20...................................................................................

SEAL, 1/4" X 1/2" X 25' (6.35MM X 12.7MM X 7.62 M)................................

WINDOW, RIGHT .........................................................................................

WINDOW, LEFT............................................................................................

QTY.

SCREW, #10 - 24 X 1/2" LG .........................................................................

4

WASHER, #10 ..............................................................................................

4

HANDLE .......................................................................................................

2

LOCK WASHER, #10 ...................................................................................

4

ACORN NUT, #10 - 24..................................................................................

SCREW, 1/4 - 20 X 1 1/2" LG .......................................................................

4

2

ACORN NUT, 1/4 - 20...................................................................................

2

HINGE ASSEMBLY, RIGHT..........................................................................

1

HINGE ASSEMBLY, LEFT ............................................................................

1

CABLE ASSEMBLY, DOOR STOP ...............................................................

2

PLATE, DOOR ..............................................................................................

2

WASHER, 1/4" ..............................................................................................

WASHER, 1/4" ..............................................................................................

LOCK WASHER, 1/4" ...................................................................................

NUT, 1/4 - 20.................................................................................................

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

2

SCREW, 1/4 - 20 X 1" LG .............................................................................

2

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

2

2

2

2

2

4

4

4

AR

1

1


Notes:



WEATHER PROTECTION (CLOTH DOORS)

47

11

12

10

4

5

6

7

2

3

8

48

49

15

16

20

18

17

19

22

23

25

24

31

35

36

37

37

32

43

29

30

39

40

41

44

33

34

45

46

42

27



23

24

25

26

19

20

21

22

27

28

29

30

16

17

18

12

13

14

15

9

10

11

6

7

8

1

4

5

2

3




ITEM PART NO.


886940

830245

830437

800026

308090

306396

306375

830351

QTY.

CLOTH DOOR SET (INCLUDES ITEMS 2 - 49).................................................

1

BRACKET, TOP RIGHT ................................................................................

1

BRACKET, TOP LEFT ..................................................................................

1

CARRIAGE BOLT, 1/4 - 20 X 1 3/4" LG........................................................

6

WASHER, 1/4" ..............................................................................................

6

LOCK WASHER, 1/4" ...................................................................................

6

NUT, 1/4 - 20.................................................................................................

6

SEAL, 27 1/8" (694MM) ................................................................................

2

112050

831017

830350

302288

308090

306396

306375

800026

843678

886930

886931

800059

308090

830058

886934

886935


BRACKET .....................................................................................................

SEAL, 31" (792 MM) .....................................................................................

SCREW, 1/4 - 20 X 1" LG .............................................................................

WASHER, 1/4" ..............................................................................................

2

LOCK WASHER, 1/4" ...................................................................................

2

NUT, 1/4 - 20.................................................................................................

2

SCREW, 1/4 - 20 X 3/4" LG ..........................................................................

2

CABLE, DOOR STOP...................................................................................

2

FRAME, LEFT...............................................................................................

2

1

FRAME, RIGHT ............................................................................................

1

NUT, 1/4 - 20.................................................................................................

8

WASHER, 1/4" ..............................................................................................

8

LATCH, DOOR..............................................................................................

TUBE, LEFT..................................................................................................

TUBE, RIGHT ...............................................................................................

6

2

4

2

1

1



39

40

41

36

37

38

31

32

33

34

35

46

47

48

42

43

44

45

49




ITEM PART NO.


800075

308090

306396

800321

112050

830510

112050

QTY.

CARRIAGE BOLT, 1/4 - 20 X 1 3/4" LG........................................................

4

WASHER, 1/4" ..............................................................................................

4

LOCK WASHER, 1/4" ...................................................................................

4

WING NUT, 1/4 - 20 ......................................................................................

4


4

COVER .........................................................................................................

2


8

830350

112050

830513

894790

548902

548911

886943

886944

830193

886932

886933

SEAL, 31" (792 MM) .....................................................................................

4


6

STRIP ...........................................................................................................

TUBE, LEFT..................................................................................................

TUBE, RIGHT ...............................................................................................

2

HIP RESTRAINT...........................................................................................

2

SCREW, 5/16 - 18 X 1" LG ...........................................................................

4

NUT, 5/16 - 18...............................................................................................

4

DOOR COVER, RIGHT ................................................................................

1

DOOR COVER, LEFT...................................................................................

1

TRIM PLATE, DOOR LATCH........................................................................

2

1

1


Notes:



WHEELS AND TIRES

5

1 - Includes Items 2, 3, 4

4

3

(Style of tire may differ from tire shown)

2

Page R-1 Service Parts Manual

WHEELS AND TIRES




ITEM PART NO.


1

4

5

2

3

600499

888120

832601

886735

829441

QTY.

TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 2, 3, 4) .............................

AR

TIRE, 5.70 - 8 LOAD RANGE C ...................................................................

1

WHEEL RIM..................................................................................................

1

VALVE STEM ................................................................................................

1

LUG NUT, 7/16 - 20 .............................................................................................

AR

Service Parts Manual Page R-2

SPECIALTY PRODUCTS


Service Parts Manual Appendix - A - 1


SPECIAL TOOLS PART NO.

CURRENT INDICATOR ...................................................................................................................................... 16489-G2

DIGITAL MULTI-METER ................................................................................................................................... 27481-G01

CRIMPING TOOL ............................................................................................................................................ 27765-G01

SLIDE HAMMER (AXLE/HUB REMOVAL) ......................................................................................................... 15947-G1

SLIDE HAMMER (AXLE REMOVAL ONLY) ....................................................................................................... 18753-G1

FEELER GAUGE .............................................................................................................................................. 72525-G01

BATTERY MAINTENANCE KIT ........................................................................................................................ 25587-G01

BATTERY SET DISCHARGER, 36 VOLT, 75 AMP .......................................................................................... 28251-G01

BATTERY SET DISCHARGER, 48 VOLT, 56 AMP .......................................................................................... 28251-G02

PAINT

TOUCH UP PEN - INDUSTRIAL YELLOW ...................................................................................................... 28432-G03

12 OUNCE SPRAY - INDUSTRIAL YELLOW .................................................................................................. 28140-G14

PERFORMANCE PRODUCTS

FORMULA 40 VINYL-COAT

®

- WHITE ............................................................................................................ 28166-G01

PLEXUS

®

CLEANER, 7 OUNCE (FOR WINDSHIELDS)................................................................................. 28433-G01

PLEXUS

®

CLEANER, 13 OUNCE (FOR WINDSHIELDS)............................................................................... 28433-G02

BATTERY PROTECTOR, 14 OUNCE SPRAY ................................................................................................. 75500-G01

WHITE LITHIUM GREASE, 14 OUNCE SPRAY .............................................................................................. 75502-G01

PENETRANT/LUBRICANT, 15 OUNCE SPRAY .............................................................................................. 75503-G01

WHEEL BEARING GREASE .............................................................................................................................. 12730-G1

BRAKE FLUID (DOT 3) ...................................................................................................................................... 21504-G1

MULTI-PURPOSE CLEANER & DEGREASER, 14 OUNCE SPRAY............................................................... 75504-G01

MULTI-PURPOSE HAND CLEANER, 32 OUNCE LIQUID............................................................................... 75505-G01

BATTERY CLEANER, 32 OUNCE WITH TRIGGER SPRAYER ...................................................................... 75506-G01

BIO-DEGRADEABLE CLEANER, 32 OUNCE W/ TRIGGER SPRAYER ......................................................... 75507-G01

MULTI-PURPOSE VALUE PACK...................................................................................................................... 75508-G01

• BATTERY PROTECTOR, 4 OUNCE SPRAY

• PENETRANT/LUBRICANT, 4 OUNCE SPRAY

• WHITE LITHIUM GREASE, 4 OUNCE SPRAY

• CARBURETOR & CHOKE CLEANER, 4 OUNCE SPRAY

Appendix - A - 2 Service Parts Manual

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

electrical 36v

SERVICE PARTS MANUAL

ELECTRIC CARGO AND PERSONNEL

CARRIERS (INDUSTRIAL 875 & TITAN)

SERVICE PARTS MANUAL

ELECTRIC UTILITY VEHICLES

ILLUSTRATED PARTS BREAKDOWN

SPECIALTY PRODUCTS

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