601027
A Textron Company
SERVICE PARTS MANUAL
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 |
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Includes Items 63--7466, 69 - 74 |
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62 -Includes Items 7184 |
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70--Includes Items878289 |
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81Includes |
Items95, 96 |
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9486Includes |
Items 112 |
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- 114 |
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111 - Includes |
Itemss 119 |
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121 |
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118 |
- Includes |
Items 127 - |
131 |
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126 - |
Includes |
Item |
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74
70
120
71
Left hand illustration page |
Parts list (continued on |
(continued on right hand page |
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if required) |
rear of page if required) |
1.WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the General Index and select the most 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 |
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN
Service Parts Manual |
Page vii |
ACCELERATOR |
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Front of Vehicle |
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25 - Includes 26 |
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3 |
Page A-1 |
Service Parts Manual |
ACCELERATOR |
32 |
Part of Body |
26 |
25 |
Front of Vehicle |
21 |
22 |
21 |
23 |
20 |
33 |
27 |
24 |
33 |
2 |
31 |
Service Parts Manual |
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. |
1 2 3 4 5 |
DESCRIPTION |
QTY. |
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1 |
600476 |
PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 30) ........................................ |
1 |
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2 |
601091 |
PEDAL BOX BRACKET................................................................................ |
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1 |
3 |
01051-G01 |
SCREW, #8 - 16 X 1/2" LG ........................................................................... |
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4 |
4 |
25853-G01 |
PEDAL BOX AND COVER ........................................................................... |
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1 |
5 |
00684-G6 |
SCREW, #8 - 32 X 3/4" LG ........................................................................... |
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4 |
6 |
25861-G01 |
MICRO SWITCH........................................................................................... |
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1 |
7 |
01050-G01 |
SCREW, #4 - 20 X 5/8" LG ........................................................................... |
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2 |
8 |
25854-G01 |
INDUCTIVE THROTTLE SENSOR .............................................................. |
1 |
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9 |
00983-G01 |
SELF THREADING NUT, 3/16" .................................................................... |
2 |
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10 |
28443-G01 |
PLUNGER..................................................................................................... |
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1 |
11 |
25857-G01 |
PLUNGER SLEEVE...................................................................................... |
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1 |
12 |
28444-G01 |
PLUNGER CAM............................................................................................ |
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1 |
13 |
17677-G1 |
SPRING RETAINER ..................................................................................... |
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1 |
14 |
17979-G1 |
ACCELERATOR ROD BUSHING ................................................................. |
1 |
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15 |
73046-G01 |
COMPRESSION SPRING ............................................................................ |
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1 |
16 |
17677-G2 |
SPRING RETAINER ..................................................................................... |
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1 |
17 |
73332-G01 |
ACCELERATOR ROD .................................................................................. |
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18 |
00532-G4 |
LOCK NUT, 5/16 - 24 .................................................................................... |
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19 |
10385-G4 |
CLEVIS YOKE (ADJUSTABLE).................................................................... |
1 |
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20 |
10386-G3 |
CLEVIS PIN, 5/16" X 1" LG |
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1 |
21 |
17838-G1 |
NYLON BUSHING ........................................................................................ |
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22 |
17255-G1 |
TEFLON WASHER, 5/16"............................................................................. |
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1 |
23 |
01076-G01 |
HAIR PIN ...................................................................................................... |
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1 |
24 |
601093 |
PEDAL PIVOT PIN ....................................................................................... |
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1 |
25 |
601150 |
ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEM 26) ...................... |
1 |
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26 |
601153 |
PEDAL PAD............................................................................................ |
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1 |
27 |
12064-G6 |
PUSH NUT.................................................................................................... |
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28 |
35679-G01 |
WIRE HARNESS (PEDAL BOX) .................................................................. |
1 |
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29 |
17313-G1 |
FLEX LOOM (BULK)..................................................................................... |
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AR |
30 |
17618-G1 |
WIRE TIE ...................................................................................................... |
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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. |
1 2 3 4 5 |
DESCRIPTION |
QTY. |
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31 |
13437-G3 |
SCREW, LOCK, 5/16 - 18 X 1" LG...................................................................... |
2 |
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32 |
71056-G01 |
SCREW, 5/16 - 18 X 5/8" LG |
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3 |
33 |
01024-G1 |
U - NUT, 5/16 - 18 ............................................................................................... |
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Service Parts Manual |
Page A-4 |
<![endif]>1-B Page
<![if ! IE]><![endif]>Manual Parts Service
1 - Includes Items 3 - 83
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A |
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9 |
Transformer
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Wire |
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BLU from |
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Relay Pin 4 |
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13 14 |
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D
AMMETER INSTALLATION
WHT from DC Cord
Chassis
65
45
4849
10
0 20
DC
30 AMPERES 
46 47 
54 |
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48 |
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53 |
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525351 |
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48 51 |
53 48
Heat Sink
<![endif]>36V BOARD, ON CHARGER, BATTERY
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TRANSFORMER INSTALLATION |
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To Diode |
54 |
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To Capacitor |
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BLK to |
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To XF |
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DC Cord |
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on Power |
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80 to |
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Input Board |
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Control |
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22 |
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Board |
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BLK |
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To Normally |
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Open on Relay |
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at Power Input |
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Board |
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| <![if ! IE]> <![endif]>Manual Parts Service |
18 |
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<![if ! IE]> <![endif]>CHARGER,BATTERY |
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32 - Includes Items 33 - 37 |
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BLK from |
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Transformer |
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<![if ! IE]> <![endif]>ON |
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<![if ! IE]> <![endif]>36VBOARD, |
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C |
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BATTERY CHARGER, ON BOARD, 36V
Pin 1 - Wire 76 to Input Board "COM" |
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B |
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Pin 2 - Tab Adapter 82, RED wire from Control Board |
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Pin 3 |
- Wire 77 to Input Board "WHT" |
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Pin 4 |
- Wire 78 to Heat Sink Clip |
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Pin 5 |
- Wire 79 to DC Cord RED Wire |
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<![if ! IE]> <![endif]>3 |
79 |
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<![if ! IE]> <![endif]>4 |
76 |
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BRN
ORN
73 |
82 78 |
81 |
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RED from Control Board |
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WHT
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 |
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OM |
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Transformer |
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GRN to |
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Ground |
XF |
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RN |
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66
57
RELAY INSTALLATION
POWER INPUT BOARD
INSTALLATION
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61 |
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GRN from |
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AC Cord |
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AC Cord |
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Port |
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62 |
Front of |
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63 |
Charger |
GROUNDING
DETAIL
Page B-3 |
Service Parts Manual |
BATTERY CHARGER, ON BOARD, 36V
BATTERY CHARGER INSTALLATION
BLK to B- on ESC
RED to BLU wire from
Control Harness
WHT to SOL+
Cord
Front of Vehicle
86
85
84
43
42 D
41
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. |
1 2 3 4 5 |
DESCRIPTION |
QTY. |
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1 |
28115-G06 |
POWERWISE™ CHARGER (ON BOARD) (INCLUDES ITEMS 3 - 83)............. |
1 |
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2 |
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3 |
* |
CHASSIS ...................................................................................................... |
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1 |
4 |
00513-G6 |
SCREW, #8 - 18 X 1 3/4" LG ........................................................................ |
2 |
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5 |
00559-G4 |
WASHER, #8 ................................................................................................ |
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2 |
6 |
11572-G3 |
EXPANSION NUT......................................................................................... |
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2 |
7 |
28104-G01 |
HEAT SINK ................................................................................................... |
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1 |
8 |
00372-G4 |
SCREW, #8 - 32 X 1/2" LG ........................................................................... |
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4 |
9 |
00559-G4 |
WASHER, #8 ................................................................................................ |
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8 |
10 |
00565-G4 |
LOCK WASHER, #8 ..................................................................................... |
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4 |
11 |
00526-G1 |
NUT, #8 - 32.................................................................................................. |
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4 |
12 |
28548-G01 |
DIODE........................................................................................................... |
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1 |
13 |
01005-G01 |
SCREW, #6 - 19 X 5/16" LG ......................................................................... |
3 |
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14 |
00559-G3 |
WASHER, #6 ................................................................................................ |
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3 |
15 |
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16 |
28110-G01 |
ELECTRICAL CLIP....................................................................................... |
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1 |
17 |
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18 |
* |
COVER ......................................................................................................... |
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1 |
19 |
28102-G01 |
HANDLE ....................................................................................................... |
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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. |
1 2 3 4 5 |
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 |
HEAT 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. |
1 2 3 4 5 |
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 |
BATTERY CHARGER, ON BOARD, 36V
Notes:
Service Parts Manual |
Page B-8 |
BATTERY CHARGER, ON BOARD, 48V
48V BATTERY CHARGER
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. |
1 2 3 4 5 |
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)
|
|
2 |
4 |
|
|
|
7 |
|
|
10 |
|
|
11 |
|
5 |
|
|
6 |
|
16 17 |
9 |
15 |
|
|
14 |
|
Page C-1 |
Service Parts Manual |
BODY (2 PASSENGER)
ACCESS PANEL & CARGO DECK |
20 |
19 |
21 |
23 |
24 |
25 |
Service Parts Manual |
Page C-2 |
BODY (2 PASSENGER)
48V |
|
|
36V |
37 |
|
36 |
|
29 |
28 |
|
|
30 |
|
31 |
|
|
27 |
|
32 |
|
35 |
|
34 |
|
33 |
CHARGER BOX |
|
Page C-3 |
Service Parts Manual |
BODY (2 PASSENGER)
46 |
45 |
|
|
|
|
|
SWINGOUT BATTERY RACK (48V) |
|
|
|
|
|
|
|
|
|
41 |
|
|
|
|
40 |
|
|
|
|
|
44 |
|
|
|
|
Front of Vehicle |
|
Part of Body |
|
39 |
|
|
|
|
|
||
|
52 |
|
|
|
|
51 |
|
|
|
|
50 |
|
|
|
|
48 |
|
|
|
|
|
|
|
55 |
|
49 |
|
56 |
54 |
|
|
|
|
|
|
43 |
|
|
|
|
42 |
|
|
|
|
|
|
69 |
|
|
|
|
67 |
|
|
|
|
57 |
58 |
|
|
|
68 |
|
|
63 |
62 |
|
|
|
|
|
|
|
|
64 |
|
|
|
65 |
|
|
|
|
|
|
61 |
70 |
|
|
|
71 |
|
|
|
|
|
|
|
|
|
60 |
72 |
|
|
Part of Frame |
|
|
|
Service Parts Manual |
Page C-4 |
BODY (2 PASSENGER)
BATTERY RACK (36V) |
|
75 |
74 |
76 |
|
76 |
|
77 |
|
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. |
1 2 3 4 5 |
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. |
1 2 3 4 5 |
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. |
1 2 3 4 5 |
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 |
BOLT, 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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