EZ-GO Cushman Service Manual
A Textron Company
SERVICE PARTS MANUAL
601027
6
5
9
11
16
15
13
7
8
18
1 - INCLUDES ITEMS 3 - 16
17
19
3
10
4
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 man ual 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 vehicle s, the batt eries must be c hecked and recha rged 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 a re not di rect ly refle cted by each il lustrat ion. Cons ult the illustr ation th at best sui ts your
situation and then contact the Servic e 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
L
(
i
Title
106
*See Body Section for
decal information
102,104
107
Front of Vehicle
79
103
105
83,88
81,86
101
84,89
100
99
74
82,87
96
95
91
65
92
69
62
66
67
116
113
118
121
111
112
115
128
122
131
13
0
114
126
127
129
-
, 69
66
98
Items 63 -
s
lude
74
1-
62 - Inc
udes Items 7
4
l
nc
I
2 - 8
-
8
70
tems
- Includes I
s 87 - 89
81
Item
86 -Includes
Items 95, 96
es
ud
- 114
l
nc
I
94 -
94
ludes Items 112
9 - 121
Inc
s 11
111 -
131
-
7
Includes Item
s 12
118 -
Item
es
lud
126 - Inc
74
64
63
70
120
71
123
73
72
119
eft hand illustration page
continued on right hand page
f required)
Parts list (continued on
rear of page if required)
1. WHEN THE PART NUMBER IS NOT KNOWN
• Determine the funct ion and ap pli c atio n o f the part r eq ui red. Turn to th e Gen er al Inde x a nd select the most appro-
priate title.
• Turn to the page number indicated and locate the desired part on the illustration.
• From the illustratio n, obtain the item nu mber ass igned to the de sired part. Refer to the accom panying de scription
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 th e parts list page, read upwards until a part numbe r 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 ind ented un der the a ssembly that they are used on. That assembly is, in turn list ed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
vi
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN
Service Parts Manual
Page vii
Front of Vehicle
1
ACCELERATOR
9
18
17
16
15
14
12
13
11
4
10
7
6
5
9
8
28
29
4
30
1 - Includes 2 - 30
25 - Includes 26
3
Page A-1
Service Parts Manual
Part of Body
ACCELERATOR
32
26
25
Front of Vehicle
21
22
21
2323
20
33
27
24
2
Service Parts Manual
33
31
Page A-2
ACCELERATOR
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
1 600476 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 30) ........................................ 1
2 601091 PEDAL BOX BRACKET................................................................................ 1
3 01051-G01 SCREW, #8 - 16 X 1/2" LG........................................................................... 4
4 25853-G01 PEDAL BOX AND COVER ........................................................................... 1
5 00684-G6 SCREW, #8 - 32 X 3/4" LG........................................................................... 4
6 25861-G01 MICRO SWITCH............................ ...... ....... ...... ....... ...... ....... ...... .................. 1
7 01050-G01 SCREW, #4 - 20 X 5/8" LG........................................................................... 2
8 25854-G01 INDUCTIVE THROTTLE SENSOR .............................................................. 1
9 00983-G01 SELF THREADING NUT, 3/16" .................................................................... 2
10 28443-G01 PLUNGER..................................................................................................... 1
11 25857-G01 PLUNGER SLEEVE.......... ....... ...... ...... ....... ...... ............................................ 1
12 28444-G01 PLUNGER CAM................ ....... ...... ...... ....... ...... ....... ...... ............................... 1
13 17677-G1 SPRING RETAINER..................................................................................... 1
14 17979-G1 ACCELERATOR ROD BUSHING................................................................. 1
15 73046-G01 COMPRESSION SPRING ............................................................................ 1
16 17677-G2 SPRING RETAINER..................................................................................... 1
17 73332-G01 ACCELERATOR ROD.................................................................................. 1
18 00532-G4 LOCK NUT, 5/16 - 24.................................................................................... 1
19 10385-G4 CLEVIS YOKE (ADJUSTABLE).................................................................... 1
20 10386-G3 CLEVIS PIN, 5/16" X 1" LG .......................................................................... 1
21 17838-G1 NYLON BUSHING ........................................................................................ 3
22 17255-G1 TEFLON WASHER, 5/16"........................... ...... ....... ...... ....... ...... ....... ...... ..... 1
23 01076-G01 HAIR PIN ...................................................................................................... 1
24 601093 PEDAL PIVOT PIN ....................................................................................... 1
25 601150 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEM 26) ...................... 1
26 601153 PEDAL PAD............................................................................................ 1
27 12064-G6 PUSH NUT.................................................................................................... 1
28 35679-G01 WIRE HARNESS (PEDAL BOX) .................................................................. 1
29 17313-G1 FLEX LOOM (BULK)..................................................................................... AR
30 17618-G1 WIRE TIE...................................................................................................... 2
Page A-3
Service Parts Manual
ACCELERATOR
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
31 13437-G3 SCREW, LOCK, 5/16 - 18 X 1" LG...................................................................... 2
32 71056-G01 SCREW, 5/16 - 18 X 5/8" LG............................................................................... 3
33 01024-G1 U - NUT, 5/16 - 18 ............................................................................................... 5
Service Parts Manual
Page A-4
BATTERY CHARGER, ON BOARD, 36V
8
Wire
Transformer
9
8
12
A
9
9
11
10
9
10
11
D
53
55
51
51
53
48
52
50
51
54
48
50
WHT from DC Cord
49
48
45
Chassis
20
DC
10
0
AMPERES
30
AMMETER INSTALLATION
48
53
Heat Sink
47
46
7
6
16
3
1 - Includes Items 3 - 83
5
BLU from
4
Relay Pin 4
65
14
13
Page B-1
Service Parts Manual
54
BLK to
DC Cord
80 to
Control
Board
BLK
53
55
BATTERY CHARGER, ON BOARD, 36V
35
56
To Diode
TRANSFORMER INSTALLATION
To XF
on Power
To Capacitor
Input Board
To Normally
Open on Relay
22
20
Board
at Power Input
38
33
37
32 - Includes Items 33 - 37
36
34
B
28
31
26
29
30
C
27
21
19
20
18
Service Parts Manual
BLK from
Transformer
0
25
24
Page B-2
BATTERY CHARGER, ON BOARD, 36V
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
74
4
73
72
3
5
1
2
82
78
79
RED from Control Board
RELAY INSTALLATION
77
76
A
B
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
C
OM
N
O
N
C
BLK from
Transformer
GRN to
B
R
N
ORN
WHT
XF
G
RN
Ground
66
57
POWER INPUT BOARD
INSTALLATION
Page B-3
60
61
GRN from
AC Cord
62
C
63
GROUNDING
DETAIL
Service Parts Manual
AC Cord
Port
Front of
Charger
BATTERY CHARGER, ON BOARD, 36V
BATTERY CHARGER INSTALLATION
BLK to B- on ESC
RED to BLU wire from
Control Harness
WHT to SOL+
86
85
84
1
AC Cord
43
42
41
Front of Vehicle
D
40
ISOLATION MOUNT
Service Parts Manual
Page B-4
BATTERY CHARGER, ON BOARD, 36V
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
1 28115-G06 POWERWISE™ CHARGER (ON BOARD) (INCLUDES ITEMS 3 - 83)............. 1
2
3 * CHASSIS...................................................................................................... 1
4 00513-G6 SCREW, #8 - 18 X 1 3/4" LG........................................................................ 2
5 00559-G4 WASHER, #8....... ....... ...... ............................................. ....... ...... ....... ........... 2
6 11572-G3 EXP ANSION NUT......................................................................................... 2
7 28104-G01 HEA T SINK................................................................................................... 1
8 00372-G4 SCREW, #8 - 32 X 1/2" LG........................................................................... 4
9 00559-G4 WASHER, #8....... ....... ...... ............................................. ....... ...... ....... ........... 8
10 00565-G4 LOCK WASHER, #8 ..................................................................................... 4
11 00526-G1 NUT, #8 - 32.................................................................................................. 4
12 28548-G01 DIODE........................................................................................................... 1
13 01005-G01 SCREW, #6 - 19 X 5/16" LG......................................................................... 3
14 00559-G3 WASHER, #6....... ....... ............................................. ...... ....... ........................ 3
15
16 28110-G01 ELECTRICAL CLIP....................................................................................... 1
17
18 * COVER......................................................................................................... 1
19 28102-G01 HANDLE ....................................................................................................... 1
20 00614-G4 SCREW, #8 - 18 X 1/2" LG........................................................................... 6
21 28136-G01 LABEL (VENTILATION)................................................................................ 1
22 28136-G02 LABEL (CORD CONDITION)........................................................................ 1
23
24 26979-G01 CAPACITOR BRACKET ............................................................................... 1
25 28109-G01 CAPACITOR ................................................................................................. 1
26 00969-G01 SCREW, #8 - 32 X 3/8" LG........................................................................... 3
27 00414-G5 BOLT, 1/4 - 20 X 5/8" LG............................................................................... 3
28 11027-G2 LOCK NUT, 1/4 - 20...................................................................................... 3
29 19388-G5 AC CORD ..................................................................................................... 1
30 13557-G2 STRAIN RELIEF (AC)................................................................................... 1
Page B-5
Service Parts Manual
BATTERY CHARGER, ON BOARD, 36V
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
31 13557-G3 STRAIN RELIEF (DC)................................................................................... 1
32 73344-G06 DC CORD ASSEMBLY (INCLUDES ITEMS 33 - 37) ................................... 1
33 28107-G01 DC CORD............................................................................................... 1
34 11343-G3 RING TERMINAL, 3/16"......................................................................... 2
35 11343-G1 RING TERMINAL, 5/16"......................................................................... 2
36 17064-G2 FEMALE TERMINAL.............................................................................. 2
37 22476-G1 HEA T SHRINK TUBING......................................................................... A/R
38
39
40 22009-G1 ISOLATION MOUNT..................................................................................... 4
41 00559-G7 WASHER, 1/4"..... ....... ...... ....... ...... ...... ....... ...... ............................................ 4
42 00565-G7 LOCK WASHER, 1/4" ................................................................................... 4
43 00532-G1 NUT, 1/4 - 20................................................................................................. 4
44
45 28105-G01 AMMETER.................................................................................................... 1
46 01051-G01 SCREW, #8 - 10 X 1/2" LG. .......................................................................... 2
47 00559-G4 WASHER, #8....... ....... ............................................. ...... ....... ...... .................. 2
48 01003-G01 BRASS WASHER, #10................................................................................. 4
49 22589-G2 SHOULDER WASHER, #10 ......................................................................... 1
50 00771-G6 NYLON WASHER, 3/8"................................................................................. 1
51 00528-G4 NUT, #10 - 32 (BRASS)................................................................................ 3
52 28106-G01 50 AMP FUSE.......................... ............................................. ...... ....... ........... 1
53 00565-G5 LOCK WASHER, #10 ................................................................................... 4
54 00378-G4 SCREW, #10 - 24 X 1/2" LG. ......................................... ............................... 2
55 00526-G3 NUT, #10 - 24................................................................................................ 2
56 28103-G01 TRANSFORMER .......................................................................................... 1
57 27877-G01 SPACER SUPPORT..................................................................................... 4
58
59
60 00372-G3 SCREW, #8 - 32 X 3/8" LG. .......................................................................... 1
Service Parts Manual
Page B-6
BATTERY CHARGER, ON BOARD, 36V
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
61 25977-G32 16 GA WIRE (GREEN 4")............................................................................. 1
62 00565-G4 LOCK WASHER, #8 ..................................................................................... 1
63 00526-G1 NUT, #8 - 32.................................................................................................. 1
64
65 * LABEL (POWERWISE™) ............................................................................ 1
66 28667-G01 CONTROL BOARD....................................................................................... 1
67
68
69
70
71
72 21971-G4 RELAY .......................................................................................................... 1
73 00138-G4 SCREW, #6 - 32 X 1/2" LG........................................................................... 2
74 14390-G9 LOCK NUT, #6 - 32....................................................................................... 2
75
76 25977-G38 16 GA WIRE (BLACK 4") (from Relay 1 to Power Input Board "COM") ....... 1
77 25977-G37 16 GA WIRE (WHITE 5") (from Relay 3 to Power Input Board "WHT")........ 1
78 25978-G161 18 GA WIRE (BLUE 6") (from Relay 4 to Heat Sink clip).............................. 1
79 25978-G162 18 GA WIRE (YELLOW 6") (from Relay 5 to DC Cord "RED")..................... 1
80 25978-G163 18 GA WIRE (BLACK 7") (from Transformer S2/S3 to
Control Module "Black")................................................................................ 1
81 17902-G1 TAB ADAPTER (on Power Input Board "WHT" w/ 77 & AC Cord WHT) ...... 1
82 28305-G01 TERMINAL ADAPTER (on Relay 2 w/ Control Board RED)......................... 1
83 27285-G01 TERMINAL ADAPTER (on Relay "COM" w/ 76 & AC Cord BLK)................. 1
84 00532-G1 LOCK NUT, 1/4 - 20 ............................................................................................ 4
85 00567-G7 LOCK WASHER, 1/4".......................................................................................... 4
86 00469-G7 WASHER, 1/4" .................. ...... ....... ...... ............................................. ....... ...... ..... 4
Page B-7
Service Parts Manual
Notes:
BATTERY CHARGER, ON BOARD, 36V
Service Parts Manual
Page B-8
48V BATTERY CHARGER
BATTERY CHARGER, ON BOARD, 48V
1
Page B-9
Service Parts Manual
BATTERY CHARGER, ON BOARD, 48V
THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING.
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
1 886481 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)
Service Parts Manual
Page B-10
BODY (2 PASSENGER)
1
2
4
7
10
11
5
6
9
14
15
16
17
Page C-1
Service Parts Manual
4
5
ACCESS PANEL & CARGO DECK
BODY (2 PASSENGER)
20
19
21
Service Parts Manual
23
2
2
Page C-2
48V
BODY (2 PASSENGER)
37
36
36V
31
30
28
29
32
CHARGER BOX
27
35
34
33
Page C-3
Service Parts Manual
4
P
46
art of Body
BODY (2 PASSENGER)
45
SWINGOUT BATTERY RACK (48V)
41
40
44
Front of Vehicle
39
52
51
50
48
55
65
64
49
43
42
62
63
60
Part of Frame
61
70
71
72
69
67
56
68
57
5
58
Service Parts Manual
Page C-4
BATTERY RACK (36V)
BODY (2 PASSENGER)
76
77
75
76
74
Page C-5
Service Parts Manual
BODY (2 PASSENGER)
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
1 600120 BODY FRAME WELDMENT (2 PASSENGER)................................................... 1
2 7156 TRIM.................................................................................................................... 1
3
4 600103 COWL.................................................................................................................. 1
5 71037-G02 NAME PLATE, E-Z-GO........................ ...... .............................................. ...... ..... 1
6 831443 NAME PLATE, CUSHMAN, SELF ADHESIVE......................................... ...... ..... 1
7 12064-G3 PUSHNUT 3/16" (E-Z-GO NAME PLATE ONLY)................................................ 2
8
9 800177 BOLT, 5/16 - 18 X 3/4" LG................................................................................... 2
10 103867 WASHER, 5/16" ................ ...... ....... ...... ............................................. ....... ...... ..... 2
11 306932 NUT, 5/16 - 18..................................................................................................... 2
12
13
14 306416 BOLT, 5/16 - 18 X 1" LG...................................................................................... 7
15 103867 WASHER, 5/16" ................ ...... ....... ...... ............................................. ....... ...... ..... 7
16 306325 LOCK WASHER, 5/16"........................................................................................ 7
17 306932 NUT, 5/16 - 18..................................................................................................... 7
18
19 601092 ACCESS COVER................................................................................................ 1
20 71056-G01 BOLT, #5/16 - 18 X 5/8" LG................................................................................. 3
21 01024-G01 ’J’ NUT, 5/16 - 18................................................................................................. 3
22
23 829337 CARGO DECK .................................................................................................... 1
24 800017 SCREW, 1/4 - 20 X 1" LG.................................................................................... 2
25 800279 NUT, 1/4 - 20, (SPEED U-TYPE) ....................................................................... 2
26
27 36088-G01 CHARGER BOX.................................................................................................. 1
28 00438-G6 BOLT, 5/16 - 18 X 3/4" LG................................................................................... 4
29 00559-G8 WASHER, 5/16" ................ ...... ....... ...... ............................................. ....... ...... ..... 4
30 00905-G8 LOCK WASHER, 5/16"........................................................................................ 4
Service Parts Manual
Page C-6
BODY (2 PASSENGER)
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
31 00532-G3 NUT, 5/16 - 18..................................................................................................... 4
32 00114-G7 SCREW, SELF TAPPING, 1/4 - 10 X 7/8" LG ..................................................... 3
33 00532-G1 NUT, 1/4 - 20....................................................................................................... 4
34 00567-G7 LOCK WASHER, 1/4".......................................................................................... 4
35 16469-G1 WASHER, 1/4" .................. ...... ....... ...... ............................................. ....... ...... ..... 4
36 22009-G1 ISOLATION MOUNT........................................................................................... 4
37 00532-G1 NUT, 1/4 - 20....................................................................................................... 4
38
39 886313-G01 SWING OUT BATTERY RACK........................................................................... 2
40 886300 PIVOT.................................................................................................................. 1
41 830483 SHIM ................................................................................................................... A/R
42 2702168 GREASE FITTING .............................................................................................. 2
43 817891 BEARING ............................................................................................................ 2
44 306416 BOLT, 5/16 - 18 X 1" LG...................................................................................... 4
45 306325 LOCK WASHER, 5/16"........................................................................................ 4
46 306932 NUT, 5/16 - 18..................................................................................................... 4
47
48 828192 BRACKET ........................................................................................................... 4
49 800085 BOLT, 5/16 - 18 X 1" LG...................................................................................... 4
50 103867 WASHER, 5/16" ................ ...... ....... ...... ............................................. ....... ...... ..... 4
51 306325 LOCK WASHER, 5/16"........................................................................................ 4
52 306932 NUT, 5/16 - 18..................................................................................................... 4
53
54 886312 LATCH HANDLE ................................................................................................. 2
55 830013 SPRING............................................................................................................... 2
56 304615 PIN ...................................................................................................................... 2
57 306981 WASHER............................................................................................................. 2
58 306328 COTTER PIN....................................................................................................... 2
59
60 830151 CHANNEL ........................................................................................................... 2
Page C-7
Service Parts Manual
BODY (2 PASSENGER)
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
G** Indicates consult Customer Service Department for additional information.
ITEM PART NO. 12345 DESCRIPTION QTY.
61 813850 BUMPER............................................................................................................. 2
62 306416 BOLT, 5/16 - 18 X 1" LG...................................................................................... 4
63 103867 WASHER, 5/16" ................ ...... ....... ...... ............................................. ....... ...... ..... 8
64 306325 LOCK WASHER, 5/16"........................................................................................ 4
65 306932 NUT, 5/16 - 18..................................................................................................... 4
66
67 827880 SHAFT................................................................................................................. 6
68 829228 ROLLER.............................................................................................................. 6
69 303459 BOLT, 1/4 - 20 X 1 1/2" LG.................................................................................. 12
70 308090 WASHER, 1/4" .................. ...... ....... ............................................. ...... ....... ........... 12
71 306396 LOCK WASHER, 1/4".......................................................................................... 12
72 306375 NUT, 1/4 - 20....................................................................................................... 12
73
74 600191 BATTERY TRAY.................................................................................................. 2
75 00462-G8 BOL T, 7/16 - 14 X 1" LG...................................................................................... 8
76 00560-G2 WASHER, 7/16" ................ ...... ....... ...... ...... .............................................. ...... ..... 16
77 00734-G1 NUT, 7/16 - 14..................................................................................................... 8
Service Parts Manual
Page C-8
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