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1998 ILLUSTRATED PARTS LIST CARRYALL I, CARRYALL II, CARRYALL TURF II, CARRYALL II PLUS, AND CARRYALL VI VEHICLES MANUAL NUMBER 101968302 EDITION CODE 1197C0508B USING THE ILLUSTRATED PARTS LIST WARNING • THIS MANUAL IS TO BE USED ONLY FOR IDENTIFICATION AND ORDERING OF SERVICE PARTS. BE SURE TO READ AND USE THE MAINTENANCE AND SERVICE MANUAL BEFORE ATTEMPTING ANY VEHICLE REPAIRS. This manual covers all 1998 Carryall® vehicles. The manual is divided into 16 sections. Sections 1 through 6 pertain to both gasoline and electric vehicles, sections 7 through 12 pertain to gasoline vehicles only, and sections 13 through 16 pertain to electric vehicles only. Note that there are two or three flags on the outside edge of each page. The first flag contains the section number of which that page is a part. The other flag (or flags) contains either the letter G or E, signifying that the page pertains to either the gasoline or electric vehicle only, or to both the gasoline and electric vehicles. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section titles and numbers, and under them, the individual page titles and numbers to be found in that section. Unless a page title specifies a particular vehicle(s), the page applies to all Carryall vehicles. Typically, there is a two-page spread for each individual page title in the Table of Contents (however, some titles require several spreads). On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Some item numbers have more than one part number because several models and/or configurations of a component are represented together on one spread. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 © 1997, CLUB CAR, INC. All rights reserved. This manual effective August 18, 1997 CONTENTS MAINTENANCE AND SERVICE TOOLS SECTION MAINTENANCE AND SERVICE TOOLS ..................................................................................................... BODY AND TRIM 1-3 - 1-5 SECTION FRONT BODY ........................................................................................................................................................ 2-3 SEATS AND SUPPORT STRUCTURE—CARRYALL I, II, TURF II AND II PLUS ................................................. 2-5 SEATS AND SUPPORT STRUCTURE—CARRYALL VI ........................................................................................ 2-7 TILT BED, HINGE, AND LATCH—CARRYALL I ..................................................................................................... 2-9 HINGE PLATE—CARRYALL I, II, TURF II AND II PLUS; PROP ROD—CARRYALL II, TURF II AND II PLUS .... 2-11 TILT BED AND LATCH—CARRYALL II, TURF II AND II PLUS ............................................................................. 2-13 CARGO BOX–CARRYALL TURF II......................................................................................................................... 2-15 ACCESS DOOR AND SIDE DOORS—CARRYALL VI .......................................................................................... 2-17 FLAT BED ASSEMBLY—CARRYALL VI ................................................................................................................ 2-19 FLAT BED TRIM—CARRYALL VI .......................................................................................................................... 2-21 REAR COVER—CARRYALL I, II, TURF II AND II PLUS ....................................................................................... 2-23 REAR COVER—CARRYALL VI ............................................................................................................................. 2-25 WHEELS AND TIRES SECTION WHEELS AND TIRES ............................................................................................................................................ SAFETY DECALS SECTION 4-3 - 4-5 SAFETY DECALS—CARRYALL VI ............................................................................................................. 4-7 - 4-9 SECTION REAR BRAKE ASSEMBLY, SELF-ADJUSTING—CARRYALL I ............................................................................ 5-3 REAR BRAKE ASSEMBLY, MANUALLY ADJUSTED—CARRYALL II, TURF II, II PLUS, AND VI ........................ 5-5 BRAKE PEDAL AND CABLE ASSEMBLY—VEHICLE WITH 2-WHEEL BRAKING .............................................. 5-7 BRAKE PEDAL AND CABLE ASSEMBLY—VEHICLE WITH 4-WHEEL BRAKING .............................................. 5-9 FRONT BRAKE ASSEMBLY—VEHICLE WITH 4-WHEEL BRAKING .................................................................. 5-11 ACCELERATOR PEDAL ASSEMBLY—ELECTRIC CARRYALL I AND ALL GASOLINE VEHICLES ................... 5-13 ACCELERATOR PEDAL ASSEMBLY—ELECTRIC CARRYALL II AND VI ............................................................ 5-15 STEERING, FRONT AND REAR SUSPENSION SECTION STEERING COLUMN ............................................................................................................................................ 2 3 3-3 SAFETY DECALS—CARRYALL I, II, TURF II AND II PLUS ....................................................................... BRAKES, PEDAL, AND CABLE ASSEMBLIES 1 6-3 STEERING GEAR ASSEMBLY .............................................................................................................................. 6-5 FRONT SUSPENSION, UPPER—VEHICLE WITH 2-WHEEL BRAKING ............................................................ 6-7 FRONT SUSPENSION, LOWER—VEHICLE WITH 2-WHEEL BRAKING............................................................. 6-9 FRONT SUSPENSION, UPPER—VEHICLE WITH 4-WHEEL BRAKING ............................................................ 6-11 FRONT SUSPENSION, LOWER—VEHICLE WITH 4-WHEEL BRAKING............................................................. 6-13 REAR SUSPENSION ............................................................................................................................................ 6-15 STABILIZER BAR—ELECTRIC CARRYALL II, GASOLINE CARRYALL II, TURF II, II PLUS AND VI ................... 6-17 4 5 6 CONTENTS ELECTRICAL SYSTEM—GASOLINE VEHICLE SECTION FORWARD AND REVERSE SHIFTER ASSEMBLY—GASOLINE VEHICLE ....................................................... 7-3 WIRING—GASOLINE CARRYALL I ...................................................................................................................... 7-5 WIRING—GASOLINE CARRYALL II ..................................................................................................................... 7-7 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE—CARRYALL I, II, AND TURF II ............................... 7-9 ELECTRICAL COMPONENTS, FRONT BODY—GASOLINE CARRYALL I, II, TURF II AND II PLUS .................. 7-11 HEADLIGHTS AND HOUR METER—GASOLINE CARRYALL TURF II ............................................................... 7-13 WIRING—GASOLINE CARRYALL TURF II ........................................................................................................... 7-15 WIRING—GASOLINE CARRYALL II PLUS ........................................................................................................... 7-17 WIRING—GASOLINE CARRYALL VI .................................................................................................................... 7-19 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE—CARRYALL II PLUS AND VI .................................. 7-21 ELECTRICAL COMPONENTS, FRONT BODY—GASOLINE CARRYALL VI ....................................................... 7-23 CONTROLS AND GAUGES—GASOLINE CARRYALL VI ..................................................................................... 7-25 ELECTRICAL COMPONENTS, REAR BODY—GASOLINE CARRYALL VI .......................................................... 7-27 STARTER/GENERATOR ASSEMBLY .................................................................................................................... 7-29 STARTER/GENERATOR MOUNTING ................................................................................................................... 7-31 BATTERY—GASOLINE VEHICLE ......................................................................................................................... 7-33 ENGINE SECTION FE 290 ENGINE—CARRYALL I AND II ...................................................................................................... 8-3 - 8-13 FE 350 ENGINE —CARRYALL TURF II, II PLUS AND VI ........................................................................... 8-14 - 8-25 ENGINE MOUNTING ............................................................................................................................................. FUEL, INTAKE, AND GOVERNOR SYSTEMS SECTION 9-3 CARBURETOR ASSEMBLY, FE 290 ENGINE—CARRYALL I AND II ................................................................... 9-5 CARBURETOR ASSEMBLY, FE 350 ENGINE—CARRYALL TURF II, II PLUS AND VI ........................................ 9-7 CARBURETOR INSTALLATION ............................................................................................................................ 9-9 GOVERNOR AND ACCELERATOR CABLES ....................................................................................................... 9-11 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY—CARRYALL I .................................................................... 9-13 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY—CARRYALL II, TURF II AND II PLUS ............................... 9-15 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY—CARRYALL VI .................................................................. 9-17 SECTION EXHAUST SYSTEM, FE 290—CARRYALL I AND II ............................................................................................. 10-3 EXHAUST SYSTEM, FE 350—CARRYALL TURF II, II PLUS AND VI .................................................................. 10-5 TORQUE CONVERTER 8 8-27 FUEL SYSTEM ...................................................................................................................................................... EXHAUST SYSTEM 7 SECTION DRIVE CLUTCH .................................................................................................................................................... 11-3 DRIVEN CLUTCH .................................................................................................................................................. 11-5 9 10 11 CONTENTS UNITIZED TRANSAXLE—GASOLINE VEHICLE SECTION UNITIZED TRANSAXLE—GASOLINE VEHICLE ........................................................................................ ELECTRICAL SYSTEM—ELECTRIC VEHICLE 12 12-3 - 12-7 SECTION FORWARD AND REVERSE SWITCH—POWERDRIVE ELECTRIC VEHICLE..................................................... 13-3 MULTI-STEP POTENTIOMETER—CARRYALL I POWERDRIVE ELECTRIC VEHICLE ...................................... 13-5 WIRING—CARRYALL I POWERDRIVE ELECTRIC VEHICLE ............................................................................. 13-7 ELECTRICAL COMPONENTS, FRONT BODY—CARRYALL I AND II POWERDRIVE VEHICLES ..................... 13-9 13 BATTERIES, CHARGER RECEPTACLE—CARRYALL I POWERDRIVE ELECTRIC VEHICLE ........................... 13-11 COMPUTER, CONTROLLER, AND SOLENOID—CARRYALL I POWERDRIVE VEHICLE ................................. 13-13 CONTINUOUSLY VARIABLE POTENTIOMETER—CARRYALL II AND VI POWERDRIVE VEHICLES ............... 13-15 WIRING—CARRYALL II POWERDRIVE ELECTRIC VEHICLE ............................................................................ 13-17 COMPUTER, CONTROLLER, AND SOLENOID—CARRYALL II POWERDRIVE VEHICLE ................................ 13-19 BATTERIES, CHARGER RECEPTACLE—CARRYALL II POWERDRIVE ELECTRIC VEHICLE .......................... 13-21 WIRING—CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ........................................................................... 13-23 ELECTRICAL COMPONENTS, FRONT BODY—CARRYALL VI POWERDRIVE ELECTRIC VEHICLE .............. 13-25 CONTROLS AND GAUGES—CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ............................................ 13-27 ELECTRICAL COMPONENTS, CENTER BODY—CARRYALL VI POWERDRIVE VEHICLE .................. 13-29 - 13-31 ELECTRICAL COMPONENTS, REAR BODY—CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ................. 13-33 BATTERY CHARGER SECTION POWERDRIVE BATTERY CHARGER, DOMESTIC—CARRYALL I AND II .......................................................... 14-3 POWERDRIVE BATTERY CHARGER, EXPORT—CARRYALL I AND II .............................................................. 14-5 POWERDRIVE BATTERY CHARGER, EUROPEAN—CARRYALL I AND II ......................................................... 14-7 ON-BOARD POWERDRIVE BATTERY CHARGER, DOMESTIC—CARRYALL VI ............................................... 14-9 14 ON-BOARD POWERDRIVE BATTERY CHARGER, EXPORT—CARRYALL VI ................................................... 14-11 ELECTRIC MOTOR SECTION MOTOR—POWERDRIVE ELECTRIC VEHICLE ................................................................................................... TRANSAXLE—ELECTRIC VEHICLE 15 15-3 SECTION TRANSAXLE, TYPE G—POWERDRIVE ELECTRIC VEHICLE ............................................................................ 16-3 TRANSAXLE, TYPE K—POWERDRIVE ELECTRIC VEHICLE ............................................................................ 16-5 16 1 G 1 E 1 Page 1-6 MAINTENANCE AND SERVICE TOOLS 1 G E 11 1G AC PE CE DA LE L RA HE TO IG R HT 1E 1 2 3 5 4 6 7 10 8 9 CALIBRATION & TEST MODULE INSTRUCTIONS SPEED CONTROL SET POWER SWITCH TO "ON". TEST PEDAL CIRCUIT POT CALIBRATION: SET MODE SWITCH TO "POT". CHECK INTERNAL 4.30±.03 VOLT SIGNAL BY PRESSING "TEST" BUTTON. CONNECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/ WHITE POT LIMIT SWITCH LEAD, CONNECT BLUE LEAD TO BATTERY POSITIVE. ILLUMINATION OF THE L.E.D. INDICATES A CLOSED PEDAL LIMIT SWITCH, READ THE POTENTIOMETER SET VOLTAGE FROM THE L.C.D. DISPLAY. SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE. SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL. SEE OPERATING INSTRUCTIONS FOR MORE DETAIL 12 POWER ON OFF R Club Car MODE SSAM POT 11 15 14 13 16 WARNIN G COMMUNICATION DISPLAY MODULE DISPLAY FUNCTIONS: PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER. RELEASE BUTTON TO SHOW FUNCTION VALUE. Func1 - Battery voltage. Func2 - Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). 17 POWER ON OFF 20 19 R Club Car PART #17075 21 18 22 23 Page 1-2 24 25 26 27 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 3 QTY QTY GAS ELEC 4 1018710-01 1016985 1018132-02 1017295 1018319-01 1014305 1011767 1016417 1016416 1012811 1012812 1013582 ACCELERATOR PEDAL ADJUSTMENT TOOL ......................................................... ADHESION PROMOTER - ARMORFLEX® ............................................................... ADHESIVE, GUIDE RING, 3 GRAM TUBE ................................................................ ARMORFLEX REPAIR KIT ......................................................................................... BATTERY DISCHARGE MACHINE, 36/48 VOLT ....................................................... BATTERY TERMINAL PROTECTOR SPRAY ............................................................. BATTERY THERMOMETER ....................................................................................... BEARING AND OIL SEAL REMOVER ASSEMBLY ................................................... BEARING DRIVER SET ............................................................................................. BEARING PULLER .................................................................................................... BEARING PULLER WEDGE ATTACHMENT ............................................................. BRAKE ADJUSTMENT TOOL (USED ONLY ON VEHICLES WITH 1018871-01 1018084-01 1014510 1014498 1014496 1014497 1014508 1014507 1015524 1018091-01 1018318-01 1016410-02 1011273 1012151 1016627 1016418 MANUALLY ADJUSTED BRAKES) ............................................................................. CALIBRATION TEST MODULE .................................................................................. CAM INSTALLATION TOOL ....................................................................................... CLUTCH TOOL KIT (INCLUDES ITEMS 15 - 21 ) ..................................................... CLUTCH ALIGNMENT TOOL ................................................................................ DRIVE CLUTCH PULLER ..................................................................................... DRIVE CLUTCH HUB PULLER ............................................................................. DRIVEN CLUTCH CAM PULLER .......................................................................... DRIVEN CLUTCH PULLER PLUG ........................................................................ DRIVE CLUTCH HOLDER TOOL ASSEMBLY ...................................................... PRESS WELDMENT ............................................................................................. COMMUNICATION DISPLAY MODULE ..................................................................... COMPRESSION GAUGE AND ADAPTER ................................................................. CONTINUITY TESTER ............................................................................................... DRY MOLY LUBRICANT ............................................................................................ FLY WHEEL PULLER KIT .......................................................................................... GEAR YOKE ............................................................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PLEASE REFER TO THE MAINTENANCE AND SERVICE MANUAL FOR PROPER TOOL APPLICATION. Page 1-3 1 G E 11 1G 1E 28 33 29 35 34 30 31 32 PULSE ENGINE TACHOMETER PET-1000 Club Car POSTION 38 36 40 39 RESET 41 42 37 48 47 44 - + 45 43 46 WAVETEK V 5XL 1000 OFF V 500 200 200 20 200 2m 2 200 m 20 m 200 m 2000 k 200k 20k Ω 45° 45° V Ω ! 200 ! COM MAX 1000 --750V 49 Page 1-4 50 51 52 53 A 2k FUSED 54 200nA MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. DESCRIPTION 1 2 3 QTY QTY GAS ELEC 4 28 29 30 31 32 33 34 35 36 37 38 39 1019331-01 1011478 1013593 1019287-01 1016414 1016415 1012549 1012560 1018231-01 1012809 1014264 1014259 GOVERNOR SHAFT INSTALLATION TOOL .............................................................. HYDROMETER .......................................................................................................... INTERNAL RETAINING RING PLIERS ...................................................................... LIQUID GASKET (TRANSAXLE CASE) .................................................................... PISTON RING COMPRESSOR KIT ........................................................................... PISTON RING PLIERS ............................................................................................... RETAINING RING PLIERS - 45° EXTERNAL ............................................................ RETAINING RING PLIERS - 90° INTERNAL ............................................................. SAFETY FIRST CARD (50 PER PACK) ..................................................................... SEAL PULLER ........................................................................................................... STEERING COLUMN BEARING PRESS TOOL ........................................................ STEERING COLUMN RETAINING RING TOOL ........................................................ 1 1 1 1 1 1 1 1 1 1 1 1 40 41 42 42 42 42 42 42 43 44 45 46 47 48 49 50 51 52 53 54 55 1020612 1016112 1017097-01 1017097-02 1017097-04 1017097-06 1017097-08 1017097-09 1014115 1014161 1014162 1016413 1016412-01 1016412-02 1016551 1016552 1016553 1016554 1016411-01 1011480 1016110-02 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 56 1016110-03 STEERING WHEEL PULLER TOOL .......................................................................... TACHOMETER ........................................................................................................... TOUCH-UP PAINT, LACQUER - BEIGE ..................................................................... TOUCH-UP PAINT, LACQUER - WHITE .................................................................... TOUCH-UP PAINT, LACQUER - GREY ...................................................................... TOUCH-UP PAINT, LACQUER - RED ........................................................................ TOUCH-UP PAINT, LACQUER - DARK BLUE ........................................................... TOUCH-UP PAINT, LACQUER - DARK GREEN ........................................................ TRANSMISSION TOOL KIT ....................................................................................... TRANSAXLE PINION SEAL TOOL ............................................................................ TRANSAXLE AXLE SEAL TOOL ............................................................................... VALVE CLEARANCE ADJUSTER SCREW HOLDER ............................................... VALVE GUIDE REAMER ........................................................................................... ARBOR ....................................................................................................................... VALVE SEAT CUTTER T-WRENCH ........................................................................... VALVE SEAT CUTTER GUIDE ................................................................................... VALVE SEAT CUTTER, 45° (32mm DIAMETER) ....................................................... VALVE SEAT CUTTER, 32° AND 45° (35mm DIAMETER) ....................................... VALVE SPRING COMPRESSOR ............................................................................... VOLT OHM METER .................................................................................................... TUNE-UP KIT (FE 290 ENGINE) (INCLUDES AIR FILTER, SPARK PLUG, OIL FILTER, FUEL FILTERS) (NOT SHOWN) ............................................................ TUNE-UP KIT (FE 350 ENGINE) (INCLUDES AIR FILTER, SPARK PLUG, OIL FILTER, FUEL FILTERS) (NOT SHOWN) ............................................................ 1 G 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PLEASE REFER TO THE MAINTENANCE AND SERVICE MANUAL FOR PROPER TOOL APPLICATION. Page 1-5 E 11 1G 1E Page 1-6 BODY AND TRIM 2 G E 12 TYPICAL 2 PLACES 15 16 1G TYPICAL 2 PLACES 13 17 18 14 1E TYPICAL 6 PLACES 19 12 11 Club 6 Car 7 1 20 TYPICAL 2 PLACES TYPICAL 8 PLACES TYPICAL 2 PLACES 10 2 TYPICAL 2 PLACES 3 21 4 8 8 9 5 TYPICAL 2 PLACES CARRYALL I ONLY 9 FRONT BODY CENTER DASH FRAME 3 DASH CARRYALL II, II PLUS AND VI 33 31 23 30 32 29 ST OP 24 25 TYPICAL 2 PLACES 26 22 18 27 GO FRAME 34 DASH BOTTOM CARRYALL TURF II ONLY 28 Page 2-2 TYPICAL: 3 PLACES RIGHT DASH 2 PLACES LEFT DASH FRONT BODY ITEM PART NO. DESCRIPTION 1 1 1017348-02 2 3 4 5 6 7 8 9 10 11 12 12 12 13 14 15 16 17 18 19 20 20 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 2 3 QTY QTY GAS ELEC 4 2 G 1010435 0007473 1010546 1015405 1017080 1016868 0007251 0007473 1016967 1016702-01 KIT, HEAVY DUTY BUMPER (INCLUDES ITEMS 2 - 5) (CARRYALL II, TURF II, II PLUS AND VI) .................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................ NUT, NYLON LOCK, 5/16 - 18 ............................................................................... SPACER ................................................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 2 ............................................................................ KIT, FRONT BUMPER (INCLUDES ITEMS 7 - 10) .................................................... BUMPER, FRONT ................................................................................................. SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 ................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................... RIVET, BLIND PUSH TYPE ................................................................................... NAMEPLATE, CLUB CAR (SILVER) .......................................................................... 1 2 4 2 2 1 1 2 2 2 1 1 2 4 2 2 1 1 2 2 2 1 1016925-04 1016939-04 1016939-09 1011014 0007251 1010435 0001241 0007473 1011017 1011394 1013475-01 1013475-02 1013475-03 1012047 1014645 N/A N/A N/A N/A 0007973 1015032 1013343 1016604-04 1013344 1013422 1010545 1013421 BODY, FRONT (GRAY) ............................................................................................... BODY, FRONT WITH HEADLIGHT OPENING (GRAY) (CARRYALL VI ONLY) ......... BODY, FRONT WITH HEADLIGHT OPENING (GREEN) (CARRYALL TURF II) ....... TRIM, FRONT BODY .................................................................................................. SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 ....................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 ................................................................................ WASHER, FLAT, 5/16 ................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................... SCREW, FLANGE LOCK ........................................................................................... NUT, SLAB BASE “T” (PACKAGE OF 4) .................................................................... TRIM, SIDE BUMPER GUARD (CARRYALL I ONLY) ................................................ TRIM, SIDE BUMPER GUARD (CARRYALL II, TURF II, AND II PLUS) .................... TRIM, SIDE BUMPER GUARD (CARRYALL VI ONLY) .............................................. SCREW, SELF-TAPPING, #8 - 32 x 3/8 ..................................................................... KIT, SNAP WASHER, BLACK (INCLUDES ITEMS 23 - 26) ....................................... NUT, SPEED, #10 - 32 ........................................................................................... WASHER, CUP, #10 ............................................................................................... SCREW, SHEET METAL, #10 x 3/4 ....................................................................... COVER, SCREW HEAD ........................................................................................ RIVET, ALUMINUM POP, 3/16 ................................................................................... MAT, FLOOR, FRONT ................................................................................................ COMPONENT, DASH, PASSENGER SIDE (BLACK) ................................................ PANEL, CENTER DASH (BLACK) .............................................................................. COMPONENT, DASH, DRIVER SIDE (BLACK) ......................................................... KIT, CUP HOLDER (INCLUDES ITEMS 33 AND 34) (CARRYALL TURF II ONLY) ... SCREW, HEX HEAD, 1/4 - 20 x 3/4 ....................................................................... NUT, TWIN SPEED, 1/4 - 20 .................................................................................. 1 1 1 1 2 2 2 2 6 1 2 2 2 8 1 1 1 1 1 5 1 1 1 1 2 2 1 1 1 1 1 2 2 2 2 6 1 2 2 2 8 1 1 1 1 1 5 1 1 1 1 2 2 1 Page 2-3 E 12 14 1G 13 15 1E TYPICAL 8 PLACES 19 16 TYPICAL 10 PLACES 18 17 20 22 21 11 10 5 7 9 12 7 2 1 23 8 TYPICAL 4 PLACES 3 24 4 5 25 26 TYPICAL 2 PLACES 6 Page 2-4 SEATS AND SUPPORT STRUCTURE— CARRYALL I, II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1 1 1 2 3 4 5 6 7 8 8 8 9 10 11 12 13 14 15 16 16 16 17 17 17 18 19 20 21 22 23 24 25 26 1015645-02 1015645-03 1015645-05 1013309 1019543-01 0000332 1018943-03 1010086 1013311 1015627-02 1015627-04 1015627-10 1013312 1018885-01 1018885-02 1015239 1010434 1019639-01 1019640-01 1015652-02 1015652-05 1015652-06 1015626-02 1015626-04 1015626-05 1013335 1019462-01 0008248 1019586-01 1018356-01 1019633-01 1019634-01 1014387 1014321 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, SEAT BOTTOM - WHITE (INCLUDES ITEMS 2 - 9) .............................. ASSEMBLY, SEAT BOTTOM - BLACK (INCLUDES ITEMS 2 - 9) ............................. ASSEMBLY, SEAT BOTTOM - GRAY (INCLUDES ITEMS 2 - 9) ............................... STRAP, SEAT BOTTOM ......................................................................................... SCREW, HEX HEAD, 1/4 - 20 x 1 ......................................................................... WASHER, FLAT, 1/4 ............................................................................................... STIFFENER, SEAT ................................................................................................ T-NUT ..................................................................................................................... BUMPER, SEAT, SHORT ....................................................................................... COVER, VINYL SEAT BOTTOM - WHITE .............................................................. COVER, VINYL SEAT BOTTOM - BLACK ............................................................. COVER, VINYL SEAT BOTTOM - GRAY ............................................................... BUMPER, SEAT, LONG ......................................................................................... ASSEMBLY, ARM REST, PASSENGER ..................................................................... ASSEMBLY, ARM REST, DRIVER ............................................................................. PANEL, SEAT SUPPORT ........................................................................................... BARREL, PLASTIC ..................................................................................................... TRIM, SEAT BOTTOM, REAR .................................................................................... TRIM, SEAT BOTTOM, FRONT ................................................................................. ASSEMBLY, SEAT BACK - WHITE (INCLUDES ITEMS 17 AND 18) ......................... ASSEMBLY, SEAT BACK - BLACK (INCLUDES ITEMS 17 AND 18) ........................ ASSEMBLY, SEAT BACK - GRAY (INCLUDES ITEMS 17 AND 18) .......................... COVER, VINYL SEAT BACK - WHITE ................................................................... COVER, VINYL SEAT BACK - BLACK ................................................................... COVER, VINYL SEAT BACK - GRAY ..................................................................... CAP, SEAT BACK - BLACK .................................................................................... WASHER, EXTERNAL TOOTH LOCK, 1/4 ................................................................ SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 3/4 ...................................................... BOLT, CARRIAGE, 1/4 - 20 x 3/4 ............................................................................... NUT, FLANGE, 1/4 - 20 .............................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 3/4 ............................................................................. NUT, FLANGE, 5/16 - 18 ............................................................................................ CAP, CORNER ........................................................................................................... SCREW, TRUSS TORX HEAD, 1/4 - 14 x 3/4 ............................................................ 1 1 1 1 5 5 1 5 4 1 1 1 1 1 1 1 5 1 1 2 2 2 1 1 1 1 8 8 10 10 4 4 2 4 1 1 1 1 5 5 1 5 4 1 1 1 1 1 1 1 5 1 1 2 2 2 1 1 1 1 8 8 10 10 4 4 2 4 Page 2-5 2 G E 12 TYPICAL 4 PLACES 19 1G 14 13 1E 15 20 TYPICAL 10 PLACES 16 17 18 22 21 11 10 5 7 23 9 12 7 2 8 1 24 3 28 4 29 25 5 26 27 TYPICAL 2 PLACES 6 Page 2-6 TYPICAL 4 PLACES SEATS AND SUPPORT STRUCTURE— CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 1 1 2 3 4 5 6 7 8 8 8 9 10 11 12 13 14 15 16 16 16 17 17 17 18 19 20 21 22 23 24 25 26 27 28 29 1015645-02 1015645-03 1015645-05 1013309 1019543-01 0000332 1018943-03 1010086 1013311 1015627-02 1015627-04 1015627-10 1013312 1018885-01 1018885-02 1018010-01 1010434 1019639-01 1019640-01 1016777-01 1016777-02 1016777-05 1016755-02 1016755-04 1016755-06 1016751 1019462-01 0008251 1019586-01 1018356-01 1016723 1019633-01 1019634-01 1014387 1014321 1016673 0008796 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, SEAT BOTTOM - WHITE (INCLUDES ITEMS 2 - 9) .............................. ASSEMBLY, SEAT BOTTOM - BLACK (INCLUDES ITEMS 2 - 9) ............................. ASSEMBLY, SEAT BOTTOM - GRAY (INCLUDES ITEMS 2 - 9) ............................... STRAP, SEAT BOTTOM ......................................................................................... SCREW, HEX HEAD, 1/4 - 20 x 1 .......................................................................... WASHER, FLAT, 1/4 ............................................................................................... STIFFENER, SEAT ................................................................................................ T-NUT ..................................................................................................................... BUMPER, SEAT, SHORT ....................................................................................... COVER, VINYL SEAT BOTTOM - WHITE .............................................................. COVER, VINYL SEAT BOTTOM - BLACK ............................................................. COVER, VINYL SEAT BOTTOM - GRAY ............................................................... BUMPER, SEAT, LONG ......................................................................................... ASSEMBLY, ARMREST, PASSENGER ...................................................................... ASSEMBLY, ARMREST, DRIVER .............................................................................. PLATE, RECEPTACLE BACKING (ELECTRIC VEHICLE ONLY) .............................. BARREL, PLASTIC ..................................................................................................... TRIM, SEAT BOTTOM, REAR .................................................................................... TRIM, SEAT BOTTOM, FRONT ................................................................................. ASSEMBLY, SEAT BACK - WHITE (INCLUDES ITEMS 17 AND 18) ......................... ASSEMBLY, SEAT BACK - BLACK (INCLUDES ITEMS 17 AND 18) ........................ ASSEMBLY, SEAT BACK - GRAY (INCLUDES ITEMS 17 AND 18) .......................... COVER, VINYL SEAT BACK - WHITE ................................................................... COVER, VINYL SEAT BACK - BLACK ................................................................... COVER, VINYL SEAT BACK - GRAY ..................................................................... CAP, SEAT BACK ................................................................................................... WASHER, EXTERNAL TOOTH LOCK, 1/4 ................................................................ SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 1 ......................................................... BOLT, CARRIAGE, 1/4 - 20 x 3/4 ............................................................................... NUT, FLANGE, 1/4 - 20 .............................................................................................. PANEL, SEAT SUPPORT ........................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 3/4 ............................................................................. NUT, FLANGE, 5/16 - 18 ............................................................................................ CAP, CORNER ........................................................................................................... SCREW, TRUSS TORX HEAD, 1/4 - 14 x 3/4 ............................................................ HOUSING, CORD (ELECTRIC VEHICLE ONLY) ....................................................... SCREW, PHILLIPS HEAD, #7 - 19 x 3/4 (ELECTRIC VEHICLE ONLY) .................... 1 1 1 1 5 5 1 5 4 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 8 8 10 10 1 4 4 2 4 1 1 1 1 5 5 1 5 4 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 8 8 10 10 1 4 4 2 4 1 4 Page 2-7 2 G E TYPICAL 2 PLACES 7 12 5 1G TYPICAL 4 PLACES 1E 6 8 TYPICAL 2 PLACES TYPICAL 2 PLACES 3 1 2 4 8 9 TYPICAL 4 PLACES TYPICAL 2 PLACES 10 TYPICAL 4 PLACES 18 19 15 20 16 BOTTOM OF SEAT BACK PANEL TYPICAL 2 PLACES 11 12 13 14 14 21 TYPICAL 2 PLACES 17 TYPICAL 2 PLACES Page 2-8 TYPICAL 2 PLACES 18 TILT BED, HINGE, AND LATCH—CARRYALL I ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1015427 1015391 1015252 1015400 1014471 0000403 1018356-01 1010435 0007473 1015399 0007532 1017976 0000706 0000357 1011990 0008755 0008754 1015507 1015583 1015356 1012303 0008861 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, TILT BED AND LATCH, CARRYALL I (INCLUDES ITEMS 1 - 9)............ SPRING, LATCH EXTENSION .............................................................................. ASSEMBLY, LATCH WELD .................................................................................... HAND GRIP, TILT LATCH ....................................................................................... INSULATION, BULK, (42" LONG) .......................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 5/8 ............................................................... NUT, FLANGED LOCK, 1/4 - 20 ............................................................................ BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................ NUT, NYLON LOCK, 5/16 - 18 ............................................................................... SCREW, TORX TRUSS HEAD, 5/16 - 18 x 3/4 ...................................................... RIVET, 5/16 ................................................................................................................ SEAL, BED ................................................................................................................. NUT, HEX, 3/18 - 16 ................................................................................................... WASHER, LOCK, 3/8 .................................................................................................. WASHER, FLAT, 3/8 ................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 3 3/8 ................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SHIM, TILT BED PIVOT ............................................................................................... BUSHING, URETHANE ............................................................................................. ASSEMBLY, TILT BED HINGE WELD ........................................................................ BUSHING, STEEL ...................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 1 3/4 ................................................................ 1 2 1 1 A/R 4 4 2 6 4 4 1 4 4 8 2 2 A/R 4 2 2 4 1 2 1 1 A/R 4 4 2 6 4 4 1 4 4 8 2 2 A/R 4 2 2 4 FOR LATCH PLATE COMPONENTS, SEE PAGE 2 - 11. Page 2-9 2 G E 12 1G 1E 10 17 11 12 17 15 TYPICAL 4 PLACES TYPICAL 2 PLACES 2 1 6 13 16 TYPICAL 2 PLACES 8 3 14 4 7 5 Page 2-10 TYPICAL 2 PLACES 9 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES LATCH PLATE—CARRYALL I, II, TURF II AND II PLUS PROP ROD—CARRYALL II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1019586-01 1015277 1016078 1016060 1018356-01 1010878 0008233 1016201 0000332 1019228-01 0000334 N/A 0007847 0000332 0008233 1017328 N/A 0001035 2 3 QTY QTY GAS ELEC 4 ITEMS 1 - 9: CARRYALL I, II, TURF II AND II PLUS BOLT, CARRIAGE, 1/4 - 20 x 1 .................................................................................. PLATE, TILT BED LATCH ........................................................................................... SHIM, LATCH PLATE ................................................................................................. SUPPORT, LATCH PLATE ......................................................................................... NUT, FLANGE, 1/4 - 20 .............................................................................................. BUMPER, RUBBER ................................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... WASHER, WAVE ......................................................................................................... WASHER, FLAT, 1/4 .................................................................................................... KIT, PROP ROD (CARRYALL II, TURF II AND II PLUS) (INCLUDES ITEMS 10 - 17) WASHER, FLAT, 3/8 ............................................................................................... ROD, PROP ........................................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 3/4 ............................................................... WASHER, FLAT, 1/4 ............................................................................................... NUT, NYLON LOCK, 1/4 - 20 ................................................................................. WASHER, CONVEX, 3/8 ....................................................................................... TRACK, PROP ROD .............................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... 2 G 4 2 A/R 2 4 2 2 2 2 1 1 1 2 2 2 1 1 2 4 2 A/R 2 4 2 2 2 2 1 1 1 2 2 2 1 1 2 Page 2-11 E 7 TYPICAL 4 PLACES 12 1G 3 TYPICAL 4 PLACES 1E 4 6 5 1 TYPICAL 4 PLACES TYPICAL 2 PLACES 8 9 10 2 6 11 TYPICAL 4 PLACES 12 TYPICAL 4 PLACES BOTTOM OF SEAT BACK PANEL TYPICAL 2 PLACES 17 20 14 15 22 20 16 23 TYPICAL 2 PLACES 16 19 TYPICAL 2 PLACES Page 2-12 21 18 TYPICAL 4 PLACES 13 TYPICAL 2 PLACES TILT BED, HINGE AND LATCH— CARRYALL II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1015429-01 2 3 QTY QTY GAS ELEC 4 1 2 3 4 5 6 7 8 9 10 1015391 1015252 0000403 1018356-01 1015400 0007473 1010435 1014471 1014471 1014471 ASSEMBLY, TILT BED, MANUAL LIFT, CARRYALL II, TURF II AND II PLUS ............ (INCLUDES ITEMS 1 - 11) SPRING, LATCH EXTENSION .............................................................................. ASSEMBLY, LATCH WELD .................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 5/8 ............................................................... NUT, FLANGED LOCK, 1/4 - 20 ............................................................................ HAND GRIP, TILT LATCH ....................................................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................ INSULATION, BULK (4" LONG) ............................................................................. INSULATION, BULK (8" LONG) ............................................................................. INSULATION, BULK (46" LONG) ........................................................................... 11 12 13 14 15 16 17 18 19 20 21 22 23 1015399 0007532 1017976 0000706 0000357 1011990 0008755 0008754 1015507 1015583 1015356 1012303 0008861 SCREW, TORX TRUSS HEAD, 5/16 - 18 x 5/8 ...................................................... RIVET, 5/16 ................................................................................................................ SEAL, BED ................................................................................................................. NUT, HEX, 3/8 - 16 ..................................................................................................... WASHER, LOCK, 3/8 ................................................................................................. WASHER, FLAT, 3/8 ................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 3 3/8 ................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SHIM, TILT BED PIVOT ............................................................................................... BUSHING, URETHANE ............................................................................................. ASSEMBLY, TILT BED HINGE WELD ........................................................................ BUSHING, STEEL ...................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 1 3/4 ................................................................ 1 1 2 1 4 4 1 8 4 A/R A/R A/R 2 1 4 4 1 8 4 A/R A/R A/R 4 4 1 4 4 8 2 2 A/R 4 2 2 4 4 4 1 4 4 8 2 2 A/R 4 2 2 4 FOR LATCH PLATE AND PROP ROD COMPONENTS, SEE PAGE 2 - 11. Page 2-13 2 G E TYPICAL 2 PLACES 12 28 27 1G 20 31 TYPICAL 2 PLACES 1E 29 25 30 TYPICAL 9 PLACES TYPICAL 4 PLACES 26 2 4 TYPICAL 2 PLACES 26 15 VEHICLE FLATBED 1 19 REF. 18 3 22 7 32 5 6 REF. 24 B CLU TYPICAL 8 PLACES CAR 25 14 TYPICAL 2 PLACES 26 23 21 8 16 7 19 17 TYPICAL 2 PLACES 10 9 6 Page 2-14 TYPICAL 2 PLACES 12 13 11 CARGO BOX–CARRYALL TURF II ITEM PART NO. DESCRIPTION 1 1 2 3 4 1015607 1015412 1015539-01 1015368 1015366 5 6 7 8 9 10 1014513 1014514 1014537 0001241 0007174 0001242 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1015400 1015390 0001032 0001231 1010434 1015363 1011990 1015313 1015245 1010934 1015424 1013317 0007049 1018947-02 1015399 0007473 1014387 1014321 1014415 0000332 0008233 1019634-01 2 3 QTY QTY GAS ELEC 4 KIT, CARGO BOX (INCLUDES ITEMS 1 - 32) ........................................................... FRONT PANEL ASSEMBLY (INCLUDES ITEM 2) ................................................ DECAL, BED LOAD .......................................................................................... SIDE PANEL ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 5 AND 7 - 18) ....... SIDE PANEL ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 6 - 17 AND 19) .................................................................................................................. BRACKET, TAILGATE, DRIVER SIDE .............................................................. BRACKET, TAILGATE, PASSENGER SIDE ...................................................... STUD, FLUSH HEAD ........................................................................................ WASHER, FLAT, 5/16 ....................................................................................... WASHER, LOCK, 5/16 ..................................................................................... NUT, HEX, 5/16 - 18 ......................................................................................... 1 1 1 1 1 1 1 1 1 1 1 8 4 4 4 1 1 1 8 4 4 4 GRIP, HAND ...................................................................................................... SPRING, COMPRESSION ............................................................................... BUSHING, NYLON ........................................................................................... ROLL PIN, 1/8 x 1 ............................................................................................. BARREL, PLASTIC (BLACK) ........................................................................... BUSHING .......................................................................................................... WASHER, FLAT, 3/8 ......................................................................................... LATCH, DRIVER SIDE ...................................................................................... LATCH, PASSENGER SIDE ............................................................................. SCREW, HEX HEAD CAP, 5/16 - 18 x 1 ................................................................ TAILGATE ASSEMBLY (INCLUDES ITEM 22) ...................................................... DECAL, CLUB CAR TAILGATE ........................................................................ BUSHING, NYLON ................................................................................................ KIT, TAILGATE ANGLE .......................................................................................... SCREW, TORX TRUSS HEAD, 5/16 - 18 x 3/4 ...................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................... CAP, CORNER ....................................................................................................... SCREW, TORX TRUSS HEAD, #10 - 24 x 3/8 ....................................................... SCREW, TORX TRUSS HEAD, 1/4 - 20 x 3/4 ........................................................ WASHER, FLAT, 1/4 ............................................................................................... NUT, NYLON LOCK, 1/4 - 20 ................................................................................. NUT, FLANGE LOCK, 5/16 - 18 ............................................................................. 2 2 2 2 2 2 2 1 1 2 1 2 2 1 17 19 2 4 4 4 4 4 2 2 2 2 2 2 2 1 1 2 1 2 2 1 17 19 2 4 4 4 4 4 Page 2-15 2 G E TYPICAL 2 PLACES 12 1G 1 1E 2 3 4 5 6 TYPICAL 3 PLACES TYPICAL 3 PLACES 7 TYPICAL 2 PLACES AT BODY 11 10 8 18 15 19 14 12 13 Page 2-16 17 TYPICAL 2 PLACES AT DOOR 16 9 ACCESS DOOR AND SIDE DOORS—CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1016914 1016891-01 1016881 1014471 1010435 1017077 0007473 0000403 1013280 0008233 1012285 1016955 13 1016954 14 15 16 17 18 19 1016918 1016909 0008233 0000403 1016914 1016920 2 3 QTY QTY GAS ELEC 4 LATCH, COMPARTMENT DOOR ............................................................................... PLATE, LONG BED ACCESS DOOR ......................................................................... HINGE, LONG BED ACCESS DOOR ........................................................................ INSULATION, BULK (8-1/2" LONG) ........................................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 ................................................................................ BOLT, CARRIAGE, 5/16 - 18 x 5/8 ............................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 5/8 ................................................................... CLIP, ANGLE, CARRYALL .......................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 .............................................................. ASSEMBLY, COMPARTMENT DOOR (DRIVER SIDE) (INCLUDES ITEMS 14, 16 - 19) ................................................................................. ASSEMBLY, COMPARTMENT DOOR (PASSENGER SIDE) (INCLUDES ITEMS 15 - 19) ....................................................................................... ASSEMBLY, COMPARTMENT DOOR WELD (DRIVER SIDE)............................... ASSEMBLY, COMPARTMENT DOOR WELD (PASSENGER SIDE) ..................... NUT, NYLON LOCK, 1/4 - 20 ................................................................................. SCREW, HEX HEAD CAP, 1/4 - 20 x 5/8 ............................................................... LATCH, COMPARTMENT DOOR .......................................................................... HINGE, COMPARTMENT DOOR .......................................................................... 2 1 1 A/R 3 3 6 2 2 2 2 2 1 1 A/R 3 3 6 2 2 2 2 1 1 1 1 1 2 2 2 2 1 1 1 2 2 2 2 Page 2-17 2 G E 12 1 1G 2 1E TYPICAL 21 PLACES 4 5 7 6 TYPICAL 2 PLACES TYPICAL 2 PLACES AT ITEM 4 3 PLACES AT ITEM 5 8 6 PLACES AT ITEM 7 3 9 10 11 21 19 24 20 TYPICAL 2 PLACES 28 27 19 20 25 Page 2-18 14 18 TYPICAL 2 PLACES 23 13 TYPICAL 2 PLACES 26 22 12 TYPICAL 2 PLACES 17 16 15 TYPICAL 2 PLACES 11 FLAT BED ASSEMBLY—CARRYALL VI ITEM PART NO. DESCRIPTION 1 3 4 6 7 8 9 10 1014471 1016893 1014471 0008755 0008754 ASSEMBLY, FLAT BED (INCLUDES ITEMS 1 - 8) ..................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................ NUT, NYLON LOCK, 5/16 - 18 ............................................................................... FRAME, BED ......................................................................................................... PLATE, FORWARD FLOOR .................................................................................. ACCESS DOOR, LATCH, AND MOUNTING HARDWARE (SEE PAGE 2-15) INSULATION, BULK (20" LONG) ........................................................................... PLATE, REAR FLOOR ........................................................................................... INSULATION, BULK (8" LONG) ............................................................................. SCREW, HEX HEAD CAP, 3/8 - 16 x 3-3/8 ................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1015583 1015507 1012303 1015356 0008861 1011990 0008754 1013872 0000332 0008233 1015727 1013413 1017213 1010878 0001035 1013357 1018370-01 1016201 BUSHING, URETHANE ............................................................................................. SHIM, TILT BED PIVOT ............................................................................................... BUSHING, STEEL ...................................................................................................... ASSEMBLY, TILT BED HINGE WELD ........................................................................ SCREW, HEX HEAD CAP, 3/8 - 16 x 1 3/4 ................................................................ WASHER, FLAT, 3/8 ................................................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 4 ...................................................................... WASHER, FLAT, 1/4 ................................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... RIVET, POP ................................................................................................................ CLIP, ROD, 3/8 ............................................................................................................ ROD, PROP, LONG BED ............................................................................................ BUMPER, RUBBER ................................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. RIVET, POP ................................................................................................................ INSULATOR, BATTERY .............................................................................................. WASHER, WAVE ......................................................................................................... 1 2 3 4 5 1016942 1010435 0007473 1016878 1016892 2 QTY QTY GAS ELEC 1 21 21 1 1 1 21 21 1 1 A/R 1 A/R 2 2 A/R 1 A/R 2 2 4 A/R 2 2 4 8 4 2 6 4 1 1 1 2 1 4 A/R 2 2 4 8 4 2 6 4 1 1 1 2 1 2 1 2 2 Page 2-19 2 G E 12 1G 1E 4 5 6 TYPICAL 4 PLACES 3 2 1 3 6 4 TYPICAL 16 PLACES Page 2-20 7 TYPICAL 8 PLACES FLAT BED TRIM—CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 1016944 1016948 1016943 1010934 0001241 0007473 1016077 2 3 QTY QTY GAS ELEC 4 TRIM, LONG BED, DRIVER SIDE .............................................................................. TRIM, LONG BED, PASSENGER SIDE ...................................................................... TRIM, LONG BED, FRONT AND REAR...................................................................... BOLT, HEX HEAD, 5/16 - 18 x 1 .................................................................................. WASHER, FLAT, 5/16 .................................................................................................. NUT, NYLON LOCK, 5/16 - 18 .................................................................................... BRACKET, STAKE SIDE ............................................................................................. 1 1 2 20 4 20 8 1 1 2 20 4 20 8 Page 2-21 2 G E 12 1G 1E 5 2 3 3 4 14 15 10 16 1 13 12 8 9 11 2 3 4 17 7 6 TYPICAL 2 PLACES 11 12 10 Page 2-22 9 REAR COVER—CARRYALL I, II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 1016679 0000304 1014306 0008233 1015530 1012285 1015445 8 9 10 11 12 13 14 15 16 17 2 3 QTY QTY GAS ELEC 4 2 8 8 8 1 2 2 8 8 8 1 2 1013483 1010934 0001241 0007174 FENDER, REAR ......................................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 1 ...................................................................... WASHER, FLAT, TYPE B, 1/4 ..................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... TAILSKIRT .................................................................................................................. SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ............................................................. KIT, TRAILER HITCH (CARRYALL II, TURF II AND II PLUS) (INCLUDES ITEMS 8 - 17) ......................................................................................... BRACE, TRAILER HITCH ...................................................................................... SCREW, HEX HEAD CAP, 5/16 - 18 x 1 ................................................................ WASHER, FLAT, 5/16 ............................................................................................. WASHER, LOCK, 5/16 ........................................................................................... 1 2 4 4 4 1 2 4 4 4 0001242 0000705 0000706 0000357 1011990 1011553 NUT, HEX, 5/16 - 18 ............................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 1 1/4............................................................. NUT, HEX, 3/8 - 16 ................................................................................................. WASHER, LOCK, 3/8 ............................................................................................. WASHER, FLAT, 3/8 ............................................................................................... DECAL ................................................................................................................... 4 2 2 2 2 1 4 2 2 2 2 1 Page 2-23 2 G E 12 1G 1E 4 TYPICAL 2 PLACES AT EACH FENDER TYPICAL 2 PLACES 2 5 4 1 3 2 1 6 TYPICAL 2 PLACES AT EACH FENDER 9 12 3 TYPICAL 2 PLACES 11 8 11 12 TYPICAL 2 PLACES 10 9 11 7 10 Page 2-24 REAR COVER—CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1014306 0000304 0008233 1015530 1012285 1016679 1017079 1016379 1016875 0007473 1011697 1016876 2 3 QTY QTY GAS ELEC 4 WASHER, FLAT, 1/4 ................................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 1 ...................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... TAILSKIRT .................................................................................................................. SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 .............................................................. FENDER, REAR ......................................................................................................... KIT, REAR BUMPER (INCLUDES ITEMS 8 - 12) ...................................................... BUMPER, REAR .................................................................................................... PLATE, MOUNTING, LONG .................................................................................. NUT, NYLON LOCK, 5/16 - 18 ............................................................................... WASHER, FLAT, 5/16 ............................................................................................. BOLT, PHILLIPS TRUSS HEAD SHOULDER, 3/8 - 18 x 2 .................................... 12 8 8 1 2 2 1 1 1 4 6 4 12 8 8 1 2 2 1 1 1 4 6 4 Page 2-25 2 G E 12 1G 1E Page 2-26 WHEELS AND TIRES 3 G E 13 1G 1E ST OP GO 5 2 1 4 3 PREMIUM TREAD Page 3-2 EXTRA TRACTION WHEELS AND TIRES ITEM PART NO. DESCRIPTION 1 1 2 2 2 2 3 4 4 4 5 1010984 1016514-02 1016514-06 1016514-07 1016514-09 1014771 1015672-02 1017370-02 1017693-02 0007310 2 3 QTY QTY GAS ELEC 4 NUT, LUG .................................................................................................................. ASSEMBLY, WHITE WHEEL AND TIRE, PREMIUM TREAD, 4-PLY (18 x 8.5 - 8) (CARRYALL I ONLY) ................................................................................................... ASSEMBLY, WHITE WHEEL AND TIRE, PREMIUM TREAD, 6-PLY (18 x 8.5 - 8)..... ASSEMBLY, WHITE WHEEL AND TIRE, EXTRA TRACTION, 6-PLY (18 x 8.5 - 8) ... ASSEMBLY, WHITE WHEEL AND TIRE (18.5 x 6.5 - 8) (CARRYALL I, II, AND VI) .. WHEEL RIM, WHITE (8 INCHES WIDE) .................................................................... TIRE, UNMOUNTED, PREMIUM TREAD, 4-PLY (18 x 8.5 - 8) (CARRYALL I ONLY) TIRE, UNMOUNTED, PREMIUM TREAD, 6-PLY (18 x 8.5 - 8) .................................. TIRE, UNMOUNTED, EXTRA TRACTION, 6-PLY (18 x 8.5 - 8) ................................ STEM, VALVE ............................................................................................................. 16 16 2 2 2 2 4 2 2 2 4 2 2 2 2 4 2 2 2 4 Page 3-3 3 G E 13 1G 1E Page 3-4 SAFETY DECALS 4 G E OPERATING INSTRUCTIONS DECAL 14 KEY SWITCH DECAL 1G 1E ! WARNING OFF READ AND FOLLOW THESE WARNINGS AND THE OPERATING INSTRUCTIONS BEFORE USING VEHICLE. FAILURE TO DO SO CAN CAUSE SEVERE INJURY OR DEATH. OPERATING INSTRUCTIONS • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • Make sure wheels are turned in desired direction. • Turn key to “ON” position and be sure nothing is in your path. • While vehicle is stopped, select direction by placing shift lever or switch in desired position: F – Forward N – Neutral R – Reverse (Buzzer will sound) • Vehicle will start moving when accelerator pedal is depressed. • Slowly depress accelerator pedal to increase speed. Park brake will release when accelerator pedal is depressed. • To stop, release accelerator pedal and depress brake pedal. • After stopping, firmly depress park brake until it locks. • Place forward and reverse switch in neutral position. Turn key “OFF” and remove key when not in use. ON CARRYALL I, II, AND TURF II Operation from driver side by authorized persons only and only in designated areas - not on public roads. • DO NOT start vehicle until all occupants (two (2) per seat maximum) are seated. • Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times. • Drive slowly in turns and straight up and down slopes. • Never stand in front of or behind vehicle. • DO NOT operate while under the influence of alcohol or drugs. • DO NOT leave children unattended on vehicle at any time. • OFF ON START CCI 1016216-01 CARRYALL II PLUS CCI 1019606-01 DRIVER/PASSENGER WARNING DECAL CARRYALL I, II, AND TURF II 3 2 OPERATING INSTRUCTIONS 1 • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • To start engine: – Place shift lever in “N”– Neutral position. – Depress brake pedal. – Turn key switch to “START” position and release. • To operate vehicle: – Make sure wheels are turned in desired direction. – Be sure nothing is in your path. – While vehicle is stopped, select vehicle direction by placing shift lever or switch in desired position. F – Forward N – Neutral R – Reverse (Buzzer will sound) – Park brake will release when accelerator pedal is pushed. – Slowly push accelerator pedal to increase speed. – Accelerator pedal must be released to shift vehicle to neutral. • To stop vehicle: – Release accelerator pedal and push brake pedal. – After stopping, firmly push park brake until it locks. – Turn key to “OFF” position, remove key and place shift lever in straight up neutral position when not in use. CCI 1016932-01 CARRYALL II PLUS WARNING Riding in cargo bed can cause severe injury or death. Do not ride in cargo bed. 4 CCI 1015539-01 BED LOAD WARNING DECAL WARNING 8 CARRYALL TURF II DECAL CRUSH AREA 7 5 CARRYALL DECAL 6 WARNING Crush area. Can cause severe injury. Stay clear when closing bed. 9 • • Read Owner's Manual and warnings on dash. • Vehicle rated capacity - 800 lbs. on level surface only. Weight to include passengers, cargo bed load, and gross trailer weight. See Owner's Manual. Maximum cargo load - 300 lbs. Weight to include cargo bed load and gross trailer weight. Maximum trailer hitch tongue weight - 150 lbs. • • • • Cargo should be evenly spread over the floor of the cargo bed as far forward as possible and secured. For vehicle stability, when fully loaded, drive slowly and avoid stopping on or backing down steep hills. Avoid top heavy loads. See Owner's Manual. When driving on uneven terrain or down steep hills, reduce speed and load. CCI 1019601-01 CARRYALL I ONLY • VEHICLE LOADING • Read Owner's Manual and warnings on dash. • Vehicle rated capacity - 1200 lbs. on level surface only. Weight to include passengers, cargo bed load, and gross trailer weight. See Owner's Manual. Maximum cargo load - 800 lbs. Weight to include cargo bed load and gross trailer weight. Maximum trailer hitch tongue weight - 150 lbs. CARRYALL II, TURF II, AND II PLUS Page 4-2 CCI 1016094-01 0 P E N CCI 1015437-01 BED LATCH WARNING DECAL VEHICLE LOADING DECAL VEHICLE LOADING STAY CLEAR L A T C H • • • • Cargo should be evenly spread over the floor of the cargo bed as far forward as possible and secured. For vehicle stability, when fully loaded, drive slowly and avoid stopping on or backing down steep hills. Avoid top heavy loads. See Owner's Manual. When driving on uneven terrain or down steep hills, reduce speed and load. CCI 1019602-01 CRUSH AREA DECAL SAFETY DECALS— CARRYALL I, II, TURF II, AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 2 3 3 4 5 6 7 7 7 7 7 7 7 7 8 9 9 1019606-01 1018251-01 1018251-02 1016216-01 1016932-01 1015539-01 1016094-01 1015437-01 1015397 1015396 1015394 1015395 1016086 1016085 1019725-02 1019725-01 1019737-01 1019601-01 1019602-01 2 3 QTY QTY GAS ELEC 4 DECAL, DRIVER/PASSENGER WARNING ............................................................... DECAL, KEY SWITCH (CARRYALL I, II, AND TURF II) ............................................ DECAL, KEY SWITCH (CARRYALL II PLUS ONLY) .................................................. DECAL, OPERATING INSTRUCTIONS (CARRYALL I, II, AND TURF II) .................. DECAL, OPERATING INSTRUCTIONS (CARRYALL II PLUS ONLY) ...................... DECAL, BED LOAD WARNING ................................................................................. DECAL, CRUSH AREA .............................................................................................. DECAL, BED/LATCH WARNING ................................................................................ DECAL, CARRYALL I (DRIVER SIDE) ....................................................................... DECAL, CARRYALL I (PASSENGER SIDE) .............................................................. DECAL, CARRYALL II (DRIVER SIDE) ...................................................................... DECAL, CARRYALL II (PASSENGER SIDE) ............................................................. DECAL, CARRYALL II PLUS (DRIVER SIDE) ........................................................... DECAL, CARRYALL II PLUS (PASSENGER SIDE) ................................................... DECAL, CARRYALL TURF II (GREEN STRIPE) (DRIVER SIDE) ............................. DECAL, CARRYALL TURF II (GREEN STRIPE) (PASSENGER SIDE) ..................... DECAL, CARRYALL TURF II ...................................................................................... DECAL, VEHICLE LOADING (CARRYALL I ONLY) ................................................... DECAL, VEHICLE LOADING (CARRYALL II, TURF II, AND II PLUS) ....................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Page 4-3 4 G E ! DANGER / POISON NO SHIELD EYES 14 • SPARKS • FLAMES • SMOKING EXPLOSIVE GASES CAN CAUSE SULFURIC ACID 1 FLUSH EYES IMMEDIATELY WITH WATER CAN CAUSE BLINDNESS OR SEVERE BURNS GET MEDICAL HELP FAST BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVEL BATTERY DANGER DECAL 1G 1E ELECTRIC VEHICLE LOCATION OF I/R DECAL FOR CARRYALL TURF II ONLY ALL CARRY 2 INGERSOLL-RAND DECAL 3 POTENTIOMETER CAUTION DECAL (ON WIPER SWITCH COVER) HOT MANIFOLD AND MUFFLER DECAL WARNING (CARRYALL I ONLY) CAN CAUSE SEVERE INJURY Rotating parts GASOLINE DANGER DECAL HOT manifold & muffler 4 KEEP CLEAR CCI 1019605-01 (ON STARTER/GENERATOR AND ENGINE) 5 GASOLINE VEHICLE ALL CARRY 6 TRAILER HITCH DECAL NOTICE PERIODIC SERVICE SCHEDULE DECAL 7 8 FRAME GROUND WARNING DECAL (ON FRAME) (ON INTAKE BOX) Page 4-4 MAXIMUM TONGUE WEIGHT - 150 lbs. CCI 1011553 SAFETY DECALS— CARRYALL I, II, TURF II, AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 1013677 1019219-01 1016109-01 1015476-01 1019605-01 1011553 1019152-01 1019443-01 2 3 QTY QTY GAS ELEC 4 DECAL, BATTERY DANGER/POISON ...................................................................... DECAL, INGERSOLL-RAND ...................................................................................... DECAL, POTENTIOMETER CAUTION (CARRYALL I ONLY) .................................... DECAL, GASOLINE DANGER ................................................................................... DECAL, HOT MANIFOLD AND MUFFLER ................................................................ DECAL, TRAILER HITCH (CARRYALL II, TURF II AND II PLUS) ............................. DECAL, FRAME GROUND ........................................................................................ DECAL, PERIODIC SERVICE SCHEDULE ............................................................... 2 1 2 1 1 2 1 1 1 1 Page 4-5 4 G E OPERATING INSTRUCTIONS DECAL 14 1G OPERATING INSTRUCTIONS 1E • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • Make sure wheels are turned in desired direction. • Turn key to “ON” position and be sure nothing is in your path. • While vehicle is stopped, select direction by placing shift lever or switch in desired position: F – Forward N – Neutral R – Reverse (Buzzer will sound) • Vehicle will start moving when accelerator pedal is depressed. • Slowly depress accelerator pedal to increase speed. Park brake will release when accelerator pedal is depressed. • To stop, release accelerator pedal and depress brake pedal. • After stopping, firmly depress park brake until it locks. • Place forward and reverse switch in neutral position. Turn key “OFF” and remove key when not in use. KEY SWITCH DECAL OFF ON START GASOLINE VEHICLE CCI 1016216-01 ELECTRIC VEHICLE WARNING READ AND FOLLOW THESE WARNINGS AND THE OPERATING INSTRUCTIONS BEFORE USING VEHICLE. FAILURE TO DO SO CAN CAUSE SEVERE INJURY OR DEATH. Operation from driver side by authorized persons only and only in designated areas - not on public roads. DO NOT start vehicle until all occupants (two (2) per seat maximum) are seated. • Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times. • Drive slowly in turns and straight up and down slopes. • Never stand in front of or behind vehicle. • DO NOT operate while under the influence of alcohol or drugs. • DO NOT leave children unattended on vehicle at any time. • OFF ON ELECTRIC VEHICLE OPERATING INSTRUCTIONS • 2 3 CCI 1019606-01 DRIVER/PASSENGER WARNING DECAL • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • To start engine: – Place shift lever in “N”– Neutral position. – Depress brake pedal. – Turn key switch to “START” position and release. • To operate vehicle: – Make sure wheels are turned in desired direction. – Be sure nothing is in your path. – While vehicle is stopped, select vehicle direction by placing shift lever or switch in desired position. F – Forward N – Neutral R – Reverse (Buzzer will sound) – Park brake will release when accelerator pedal is pushed. – Slowly push accelerator pedal to increase speed. – Accelerator pedal must be released to shift vehicle to neutral. • To stop vehicle: – Release accelerator pedal and push brake pedal. – After stopping, firmly push park brake until it locks. – Turn key to “OFF” position, remove key and place shift lever in straight up neutral position when not in use. CCI 1016932-01 1 GASOLINE VEHICLE WARNING CRUSH AREA 4 STAY CLEAR CCI 1016094-01 CRUSH AREA DECAL 5 VEHICLE LOADING DECAL • VEHICLE LOADING • Read Owner's Manual and warnings on dash. Page 4-6 • Vehicle rated capacity - 1500 lbs. on level surface only. Weight to include passengers, cargo bed load, and gross trailer weight. See Owner's Manual. Maximum cargo load - 1000 lbs. Weight to include cargo bed load (500 lbs. MAX) and gross trailer weight. Maximum trailer hitch tongue weight - 150 lbs. • • • • Cargo should be evenly spread over the floor of the cargo bed as far forward as possible and secured. For vehicle stability, when fully loaded, drive slowly and avoid stopping on or backing down steep hills. Avoid top heavy loads. See Owner's Manual. When driving on uneven terrain or down steep hills, reduce speed and load. CCI 1019600-01 SAFETY DECALS— CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 2 3 3 4 5 1019606-01 1018251-01 1018251-02 1016216-01 1016932-01 1016094-01 1019600-01 2 3 QTY QTY GAS ELEC 4 DECAL, DRIVER/PASSENGER WARNING ............................................................... DECAL, KEY SWITCH ............................................................................................... DECAL, KEY SWITCH ............................................................................................... DECAL, OPERATING INSTRUCTIONS ..................................................................... DECAL, OPERATING INSTRUCTIONS ..................................................................... DECAL, CRUSH AREA .............................................................................................. DECAL, VEHICLE LOADING ..................................................................................... 1 1 1 1 1 1 2 1 2 1 Page 4-7 4 G E 14 ! DANGER / POISON NO SHIELD EYES ELECTRICAL COMPONENT COVER CAUTION DECAL (ON COVER) 1G EXPLOSIVE GASES CAN CAUSE SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS BLINDNESS OR INJURY FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST KEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVEL BATTERY DANGER DECAL (ON FRAME) 2 1E • SPARKS • FLAMES • SMOKING 3 1 BED LOAD WARNING DECAL ELECTRICAL COMPONENT MOUNTING PLATE NOTICE (ON PLATE) 4 ELECTRIC VEHICLE CAR SIDE FRONT DECAL R YA LL V I 9 8 INGERSOLL-RAND DECAL 7 6 CARRYALL VI DECAL 5 BED BOLT WARNING DECAL GASOLINE DANGER DECAL (ON FRAME ADJACENT TO FUEL TANK) GASOLINE VEHICLE HOT MANIFOLD AND MUFFLER DECAL 10 11 CAR (ON STARTER/GENERATOR AND ENGINE) R YA LL V I 13 12 FRAME GROUND WARNING DECAL PERIODIC SERVICE SCHEDULE DECAL (ON INTAKE BOX) (ON FRAME) Page 4-8 SAFETY DECALS— CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1019646-01 1019315-01 1013677 1015539-01 1017078-01 1016971-02 1016971-01 1019219-01 1016757 1015476-01 1019605-01 1019152-01 1019443-01 2 3 QTY QTY GAS ELEC 4 DECAL, NO GROUND ............................................................................................... DECAL, COMPONENT COVER ................................................................................. DECAL, BATTERY DANGER/POISON ...................................................................... DECAL, BED LOAD ................................................................................................... DECAL, BED BOLT .................................................................................................... DECAL, CARRYALL VI (DRIVER SIDE) ..................................................................... DECAL, CARRYALL VI (PASSENGER SIDE) ............................................................ DECAL, INGERSOLL-RAND ...................................................................................... DECAL, SIDE PANEL ................................................................................................. DECAL, GASOLINE DANGER ................................................................................... DECAL, HOT MANIFOLD AND MUFFLER ................................................................ DECAL, FRAME GROUND WARNING ...................................................................... DECAL, PERIODIC SERVICE SCHEDULE ............................................................... 1 1 1 1 2 4 1 2 1 1 1 1 1 1 1 1 1 2 4 Page 4-9 4 G E 14 1G 1E Page 4-10 BRAKES, PEDAL, AND CABLE ASSEMBLIES 5 G E 15 1G 10 TYPICAL 4 PLACES 1E TYPICAL 4 PLACES 11 8 6 8 15 yy ;; ;; y;yy ;; y;yy 1 7 TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 6 12 9 13 16 4 5 3 2 14 14 ELECTRIC VEHICLE GASOLINE VEHICLE SEE REAR SUSPENSION SECTION 6 FOR MOUNTING Page 5-2 REAR BRAKE ASSEMBLY, SELF-ADJUSTING— CARRYALL I ITEM PART NO. DESCRIPTION 1 3 4 1 2 2 3 4 5 6 7 1018240-02 1018165-01 1018165-02 1018239-01 1018238-01 1010850 1018232-01 1011466 CLUSTER, PASSENGER SIDE BRAKE (INCLUDES ITEMS 1 - 9) .......................... CLUSTER, DRIVER SIDE BRAKE (INCLUDES ITEMS 1 - 9) ................................... ASSEMBLY, BACKING PLATE, PASSENGER SIDE (INCLUDES ITEMS 2, 3 AND 4) ............................................................................ ASSEMBLY, BACKING PLATE, DRIVER SIDE (INCLUDES ITEMS 2, 3 AND 4) .. MECHANISM, ADJUSTING, PASSENGER SIDE ............................................ MECHANISM, ADJUSTING, DRIVER SIDE ..................................................... WASHER .......................................................................................................... WASHER, PLATE ............................................................................................. COVER, DUST ....................................................................................................... PACKAGE, BRAKE SHOE (FOUR PIECES) ......................................................... KIT, SHOE RETAINER (FOUR PIECES) ............................................................... 8 9 9 10 11 12 13 14 14 15 16 1018163-01 1018155-01 1018155-02 1013924 1014153 1010829 0001035 1019008-01 1013207 1017911-01 1011779 PACKAGE, BRAKE SPRING (FOUR PIECES) ...................................................... ASSEMBLY, LEVER, PASSENGER SIDE .............................................................. ASSEMBLY, LEVER, DRIVER SIDE ...................................................................... NUT, HEX HEAD LOCK, GRADE 8, 5/16 - 24 ........................................................... BOLT, BRAKE CLUSTER MOUNTING ...................................................................... PIN, CLEVIS, 5/16 ...................................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. HANGER, BRAKE CABLE (GASOLINE VEHICLE ONLY) ......................................... HANGER, BRAKE CABLE (ELECTRIC VEHICLE ONLY) .......................................... DRUM, BRAKE ........................................................................................................... E-CLIP, 1/2 .................................................................................................................. 1 1018233-01 1018233-02 1018240-01 2 QTY QTY GAS ELEC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 2 2 1 1 1 8 8 2 2 2 2 2 2 2 Page 5-3 5 G E 15 3 1G 7 6 8 TYPICAL 2 PLACES 9 1E 4 5 19 TYPICAL 4 PLACES 12 10 FRONT OF VEHICLE TYPICAL 2 PLACES TYPICAL 2 PLACES 1 20 11 TYPICAL 4 PLACES 21 yy ;; ;; yy ;; yy ;;yy yy ;; 11 10 16 15 18 17 13 14 22 SEE REAR SUSPENSION SECTION 5 FOR MOUNTING 2 Page 5-4 REAR BRAKE ASSEMBLY, MANUALLY ADJUSTED— CARRYALL II, TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1016573 1016557 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1011494 1011154 1011465 1011467 1011114 0000451 N/A N/A N/A 1011303 1011463-02 1011466 1011464 N/A 1010850 1011403 1010829 0001035 1011779 1013924 1014153 1017911-01 1013207 2 3 QTY QTY GAS ELEC 4 CLUSTER, PASSENGER SIDE BRAKE, WITHOUT BRAKE DRUM (INCLUDES ITEMS 1 - 14) ......................................................................................... CLUSTER, DRIVER SIDE BRAKE, WITHOUT BRAKE DRUM (INCLUDES ITEMS 1 - 14) ......................................................................................... PLATE, BACKING, DRIVER SIDE ......................................................................... PLATE, BACKING, PASSENGER SIDE ................................................................. KIT, BRAKE ACTUATOR ........................................................................................ KIT, ANCHOR BODY (INCLUDES ITEMS 4 - 9) .................................................... NUT, M6 x 1 ...................................................................................................... WASHER, LOCK, 1/4 ....................................................................................... PISTON, ANCHOR ........................................................................................... BOLT, ADJUSTMENT ....................................................................................... BODY, ANCHOR ............................................................................................... CAP, ADJUSTMENT BOLT ............................................................................... PACKAGE, BRAKE SHOE (FOUR PIECES) ......................................................... KIT, SHOE RETAINER (FOUR PIECES) ............................................................... PACKAGE, BRAKE SPRING (FOUR PIECES) ...................................................... ARM, BRAKE LEVER ............................................................................................ COVER, DUST ....................................................................................................... KIT, EQUALIZER AND PIVOT LIMITER (INCLUDES ITEMS 16, 17 AND 18) ........... PIN, CLEVIS, 5/16 ................................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... E-CLIP, 1/2 ............................................................................................................. NUT, CONE LOCK, GRADE 8, 5/16 - 24 ................................................................... BOLT, BRAKE CLUSTER MOUNTING ...................................................................... DRUM, BRAKE ........................................................................................................... HANGER, BRAKE CABLE ......................................................................................... 5 G 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 8 8 2 2 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 8 8 2 2 Page 5-5 E 15 1G OFF ON 1E 13 10 P O T S FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 14 5 23 18 22 30 17 12 15 19 16 21 TYPICAL 4 PLACES 24 20 17 TYPICAL 2 PLACES 31 26 25 TYPICAL 2 PLACES 27 TYPICAL 4 PLACES 29 33 TYPICAL 2 PLACES 28 7 30 32 4 5 1 11 2 3 2 9 8 6 TYPICAL 2 PLACES Page 5-6 BRAKE PEDAL AND CABLE ASSEMBLY— VEHICLE WITH 2-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 0001242 1018653-01 1017211 N/A 0007473 1011403 1011779 0001035 1010829 1019540-01 1013531 0007716 1013869 1019531-01 1019531-02 1019530-01 0007473 1011877-02 17 18 19 20 21 22 23 24 25 26 N/A 1017029 1010877 1010805 1010932 1010933 1010927 1010878 0001028 1011402 27 28 29 30 31 32 33 0001241 1010921 1011418 0001032 0007716 1013876 1013870 2 3 QTY QTY GAS ELEC 4 NUT, HEX, 5/16 - 18 ................................................................................................... SPACER, EQUALIZER ............................................................................................... KIT, EQUALIZER AND PIVOT LIMITER (INCLUDES ITEM 4) ................................... PIN, EQUALIZER PIVOT ....................................................................................... NUT, NYLON LOCK, 5/16 - 18 ................................................................................... KIT, BRAKE CABLE, REAR (INCLUDES ITEMS 7 - 9) .............................................. E-CLIP, 1/2 ............................................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... PIN, CLEVIS, 5/16 ................................................................................................. KIT, BRAKE PEDAL (INCLUDES ITEMS 11 - 16, 19 AND 32) .................................. SPRING, BRAKE RETURN ................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... PAD, BRAKE PEDAL .............................................................................................. ROD, EQUALIZER (CARRYALL I ONLY) ............................................................... ROD, EQUALIZER (CARRYALL II ONLY) .............................................................. BOLT, HEX HEAD SHOULDER, 3/8 x 1 ................................................................ NUT, NYLON LOCK, 5/16 - 18 .............................................................................. KIT, PARK BRAKE LATCH (INCLUDES ITEMS 17 - 21 AND ITEM 25 ON PAGE 5-13) ................................................................................... ROD AND PAWL ..................................................................................................... PIN, COTTER, 7/64 x 1/2 ....................................................................................... NUT, PUSH, 5/16 ................................................................................................... SLEEVE, PARK BRAKE ROD ................................................................................ JOINT, BALL, 1/4 - 28 ............................................................................................ SPRING, PARK BRAKE TORSION ............................................................................ SPACER, PARK BRAKE ............................................................................................. BUMPER, RUBBER ................................................................................................... NUT, HEX, 1/4 - 20 ..................................................................................................... PACKAGE, BRAKE MOUNTING BLOCK (CONTAINS UPPER AND LOWER FOR LEFT AND RIGHT SIDES) ................................................................................ WASHER, FLAT, 5/16 ................................................................................................. SCREW, HEX HEAD CAP, 5/16 - 18 x 2 1/2 .............................................................. KIT, PARK BRAKE PEDAL (INCLUDES ITEMS 30 - 33) ........................................... BUSHING, NYLON ................................................................................................ SCREW, SLOTTED HEX WASHER HEAD, #10 -16 x 1/2 ..................................... NUT, PUSH, 3/8 ..................................................................................................... PAD, PARK BRAKE ................................................................................................ 1 2 1 1 5 2 2 2 2 1 1 4 1 1 1 1 1 1 2 1 1 5 2 2 2 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 2 1 1 1 4 4 1 2 2 1 1 Page 5-7 5 G E 15 OFF ON 1G 1E FLOORBOARD REMOVED FOR CLARITY P O T 11 S TYPICAL 4 PLACES 5 26 14 25 22 20 13 15 21 33 24 TYPICAL 4 PLACES 17 16 27 23 18 20 19 TYPICAL 2 PLACES 7 34 29 28 TYPICAL 2 PLACES 30 32 TYPICAL 4 PLACES TYPICAL 2 PLACES 31 36 8 33 35 4 5 12 1 2 3 2 10 9 6 TYPICAL 2 PLACES Page 5-8 BRAKE PEDAL AND CABLE ASSEMBLY— VEHICLE WITH 4-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0001242 1018653-01 1017211 N/A 0007473 1011403 1018746-01 1011779 0001035 1010829 1019540-01 1013531 0007716 1013869 1019530-01 0007473 1019531-01 1019531-02 1019531-03 1011877-02 20 21 22 23 24 25 26 27 28 29 N/A 1017029 1010877 1010805 1010932 1010933 1010927 1010878 0001028 1011402 30 31 32 33 34 35 36 0001241 1010921 1011418 0001032 0007716 1013876 1013870 2 3 QTY QTY GAS ELEC 4 NUT, HEX, 5/16 - 18 ................................................................................................... SPACER, EQUALIZER ............................................................................................... KIT, EQUALIZER AND PIVOT LIMITER (INCLUDES ITEM 4) ................................... PIN, EQUALIZER PIVOT ....................................................................................... NUT, NYLON LOCK, 5/16 - 18 ................................................................................... KIT, BRAKE CABLE, REAR (INCLUDES ITEMS 8 - 10) ............................................ KIT, BRAKE CABLE, FRONT (INCLUDES ITEMS 8 - 10) ......................................... E-CLIP, 1/2 ............................................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... PIN, CLEVIS, 5/16 ................................................................................................. KIT, BRAKE PEDAL (INCLUDES ITEMS 12 - 18, 22 AND 35) .................................. SPRING, BRAKE RETURN ................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... PAD, BRAKE PEDAL .............................................................................................. BOLT, HEX HEAD SHOULDER, 3/8 x 1 ................................................................ NUT, NYLON LOCK, 5/16 - 18 .............................................................................. ROD, EQUALIZER, FRONT ................................................................................... ROD, EQUALIZER, REAR (CARRYALL II AND II PLUS) ...................................... ROD, EQUALIZER, REAR (CARRYALL VI ) ............................................................... KIT, PARK BRAKE LATCH (INCLUDES ITEMS 20 - 24 AND ITEM 25 ON PAGE 5-13) ................................................................................... ROD AND PAWL ..................................................................................................... PIN, COTTER, 7/64 x 1/2 ....................................................................................... NUT, PUSH, 5/16 ................................................................................................... SLEEVE, PARK BRAKE ROD ................................................................................ JOINT, BALL, 1/4 - 28 ............................................................................................ SPRING, PARK BRAKE TORSION ............................................................................ SPACER, PARK BRAKE ............................................................................................. BUMPER, RUBBER ................................................................................................... NUT, HEX, 1/4 - 20 ..................................................................................................... PACKAGE, BRAKE MOUNTING BLOCK (CONTAINS UPPER AND LOWER FOR LEFT AND RIGHT SIDES) ................................................................................ WASHER, FLAT, 5/16 ................................................................................................. SCREW, HEX HEAD CAP, 5/16 - 18 x 2 1/2 .............................................................. KIT, PARK BRAKE PEDAL (INCLUDES ITEMS 33 - 36) ........................................... BUSHING, NYLON ................................................................................................ SCREW, SLOTTED HEX WASHER HEAD, #10 -16 x 1/2 ..................................... NUT, PUSH, 3/8 ..................................................................................................... PAD, PARK BRAKE ................................................................................................ 1 2 1 1 5 2 2 2 2 2 1 1 4 1 2 2 1 1 1 1 2 1 1 5 2 2 2 2 2 1 1 4 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 2 1 1 1 4 4 1 2 2 1 1 Page 5-9 5 G E 15 18 1G 17 1E 15 14 16 11 TYPICAL 2 PLACES 2 10 11 TYPICAL 2 PLACES 22 1 23 4 13 5 TYPICAL 2 PLACES 21 9 20 19 TYPICAL 4 PLACES TYPICAL 2 PLACES 7 12 10 Page 5-10 3 6 8 FRONT BRAKE ASSEMBLY— VEHICLE WITH 4-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1016573 1016557 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1011154 1011494 1011465 1011467 1011114 0000451 N/A N/A N/A 1011303 1011463-02 1011466 1011464 N/A 1010850 1018746-01 1010829 0001035 1011779 1018727-01 0007174 1018690-01 1017232 1011137 2 3 QTY QTY GAS ELEC 4 CLUSTER, PASSENGER SIDE BRAKE, WITHOUT BRAKE DRUM (INCLUDES ITEMS 1 - 14) ........................................................................................ CLUSTER, DRIVER SIDE BRAKE, WITHOUT BRAKE DRUM (INCLUDES ITEMS 1 - 14) ......................................................................................... PLATE, BACKING, PASSENGER SIDE ................................................................. PLATE, BACKING, DRIVER SIDE ......................................................................... KIT, BRAKE ACTUATOR ........................................................................................ KIT, ANCHOR BODY (INCLUDES ITEMS 4 - 9) .................................................... NUT, M6 x 1 ...................................................................................................... WASHER, LOCK, 1/4 ....................................................................................... PISTON, ANCHOR ........................................................................................... BOLT, ADJUSTMENT ....................................................................................... BODY, ANCHOR ............................................................................................... CAP, ADJUSTMENT BOLT ............................................................................... PACKAGE, BRAKE SHOE (FOUR PIECES) ......................................................... KIT, SHOE RETAINER (FOUR PIECES) ............................................................... PACKAGE, BRAKE SPRING (FOUR PIECES) ...................................................... ARM, BRAKE LEVER ............................................................................................ COVER, DUST ....................................................................................................... KIT, BRAKE CABLE, FRONT (INCLUDES ITEMS 16, 17 AND 18) ........................... PIN, CLEVIS, 5/16 ................................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... E-CLIP, 1/2 ............................................................................................................. NUT, HEX, 5/16 - 24 ................................................................................................... WASHER, LOCK, 5/16 x 24 ....................................................................................... WASHER, CONE ........................................................................................................ BOLT, HEX HEAD, 5/16 - 24 x 1 ................................................................................. DRUM, BRAKE ........................................................................................................... 5 G 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 8 8 8 8 2 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 8 8 8 8 2 Page 5-11 E GO 15 1G 2 TYPICAL 4 PLACES 7 3 1E 5 10 11 6 1 12 13 5 14 4 9 8 19 18 17 17 18 19 TYPICAL 4 PLACES 21 22 23 20 TYPICAL 4 PLACES 24 7 23 25 OFF ON Page 5-12 15 16 ACCELERATOR PEDAL ASSEMBLY— ELECTRIC CARRYALL I AND ALL GASOLINE VEHICLES ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1017696 1013871 0007716 0001624 0000334 1017325 0008754 1018188-01 1017424 1019669-01 1018174-01 1017962-01 1017378 1017380 0001241 0007473 1018719-01 17 1019124-01 17 1018220-01 17 1016747-02 18 19 20 21 22 23 24 1011084 1011734 1011700 0008233 1014007 1011694 1018619-01 1011877-02 25 N/A 2 3 QTY QTY GAS ELEC 4 SUB-ASSEMBLY, ACCELERATOR PEDAL (INCLUDES ITEMS 2 AND 3) ............... PAD, PEDAL ........................................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... SCREW, HEX CAP, 3/8 - 16 x 1 1/2 ........................................................................... WASHER, FLAT, 3/8 ................................................................................................... ASSEMBLY, ACCELERATOR PIVOT ROD ................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... STUD, BALL ............................................................................................................... BEARING, PIVOT SUPPORT ..................................................................................... NUT, FLANGE, 1/4 - 28 .............................................................................................. RETAINER, SPRING .................................................................................................. SPRING, RETURN ..................................................................................................... CUP, SPRING ............................................................................................................. BUMPER, RETURN SPRING .................................................................................... WASHER, FLAT, 5/16 ................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................... ASSEMBLY, ACCELERATOR ROD (ELECTRIC CARRYALL I ONLY) (INCLUDES ITEMS 18 AND 19) ............................................................................... ASSEMBLY, ACCELERATOR ROD (GASOLINE CARRYALL I ONLY) (INCLUDES ITEMS 18 AND 19) ................................................................................ ASSEMBLY, ACCELERATOR ROD (GASOLINE CARRYALL II, TURF II AND II PLUS) (INCLUDES ITEMS 18 AND 19) ........................................................ ASSEMBLY, ACCELERATOR ROD (GASOLINE CARRYALL VI ONLY) (INCLUDES ITEMS 18 AND 19) ................................................................................ NUT, UNF HEX JAM, 1/4 - 28 ............................................................................... JOINT, SPRING-LOADED BALL ........................................................................... SPACER .................................................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... WASHER, FLAT, TYPE B, 1/4 ..................................................................................... SUPPORT, ACCELERATOR PIVOT ROD .................................................................. SCREW, HEX CAP, 1/4 - 20 x 1 1/8 ........................................................................... KIT, PARK BRAKE LATCH (INCLUDES ITEM 25 AND ITEMS 17 - 21 ON PAGE 5-7) ................................................................................................................... ASSEMBLY, RACHET ............................................................................................ 1 1 4 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 4 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 4 4 2 4 2 2 1 4 4 2 4 1 1 1 1 Page 5-13 5 G E GO 15 1G 2 TYPICAL 4 PLACES 3 1E 5 24 8 10 11 1 4 12 6 5 13 14 25 9 8 16 17 TYPICAL 4 PLACES 18 19 15 18 TYPICAL 2 PLACES REFERENCE CONTINUOUSLY VARIABLE POTENTIOMETER— SECTION 13 TYPICAL 4 PLACES 22 20 24 REFERENCE WIRE HARNESS— SECTION 13 23 21 OFF ON Page 5-14 7 ACCELERATOR PEDAL ASSEMBLY— ELECTRIC CARRYALL II AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1017696 1013871 0007716 0001624 0000334 1017325 0007473 1018620-01 1017424 1015661 1018174-01 1017962-01 1017378 1017380 1017400 1018042-01 1017743 0008233 1014007 1018043-01 1011694 1018619-01 1011877-02 N/A 0008754 0001241 2 3 QTY QTY GAS ELEC 4 SUB-ASSEMBLY, ACCELERATOR PEDAL (INCLUDES ITEMS 2 AND 3) ............... PAD, PEDAL ........................................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... SCREW, HEX CAP, 3/8 - 16 x 1 1/2 ........................................................................... WASHER, FLAT, 3/8 ................................................................................................... ASSEMBLY, ACCELERATOR PIVOT ROD ................................................................ NUT, NYLON LOCK, 5/16 - 18 ................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 1 3/8 ................................................................ BEARING, PIVOT SUPPORT ..................................................................................... NUT, FLANGE LOCK, 1/4 - 20 ................................................................................... RETAINER, SPRING .................................................................................................. SPRING, RETURN ..................................................................................................... CUP, SPRING ............................................................................................................. BUMPER, RETURN SPRING .................................................................................... LEVER, ACTUATOR ................................................................................................... WASHER, PLASTIC, 1/2 ............................................................................................ COVER, ACCELERATOR ........................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... WASHER, FLAT, TYPE B, 1/4 ..................................................................................... SCREW, HI-LO HEX HEAD, #8 - 18 x 1/2 .................................................................. SUPPORT, ACCELERATOR PIVOT ROD .................................................................. SCREW, HEX CAP, 1/4 - 20 x 1 1/8 ........................................................................... KIT, PARK BRAKE LATCH (INCLUDES ITEM 23 AND ITEMS 17 - 21 ON PAGE 5-7) ................................................................................................................... ASSEMBLY, RATCHET .......................................................................................... NUT, NYLON LOCK, 3/8 x 16 ..................................................................................... WASHER, FLAT, 5/16 ................................................................................................. 1 1 4 1 2 1 1 2 1 1 1 1 1 1 1 1 1 5 4 2 1 4 1 1 2 1 Page 5-15 5 G E 15 1G 1E Page 5-16 STEERING, FRONT AND REAR SUSPENSION 6 G E 16 31 1G 1E 27 29 28 30 21 24 26 19 20 25 17 13 12 18 15 22 16 5 18 14 23 17 21 19 9 7 7 11 8 10 TYPICAL 2 PLACES 20 6 24 2 TYPICAL 3 PLACES 3 4 1 Page 6-2 TYPICAL 2 PLACES TYPICAL 2 PLACES STEERING COLUMN ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 1013861 1017226 0007174 1019848-01 1016663 1016269 0000334 1016183 0008754 1014288 1011697 1012499 1016181 1012605 1012604 1014217 1014125 1014213 1014126 1015545 1016622 1014214 1014211 1016263 1016156 1017273 1016155-02 1016219 1012565 1012566 1016214 1016154 2 3 QTY QTY GAS ELEC 4 JOINT, COMPOUND STEERING (INCLUDES ITEMS 2 AND 3) ............................... SCREW, HEX HEAD CAP, M8 x 1.25 x 30MM ...................................................... WASHER, LOCK, 5/16 ........................................................................................... KIT, STEERING COLUMN, MOUNTING BRACKET .................................................. SCREW, PHILLIPS, TYPE A, #12 - 11 x 5/8 .............................................................. SCREW, HEX WASHER HEAD THREAD FORMING, 5/16 - 18 x 2 .......................... WASHER, FLAT, 3/8 ................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 7 ...................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX WASHER HEAD THREAD FORMING, 5/16 - 18 x 3/4 ....................... WASHER, FLAT, 5/16 ................................................................................................. BOOT, STEERING COLUMN ..................................................................................... ASSEMBLY, STEERING COLUMN (INCLUDES ITEMS 14 - 23) .............................. RING, RETAINING ................................................................................................. WASHER, STEEL, 5/8 ........................................................................................... SPRING, COMPRESSION .................................................................................... WEDGE ................................................................................................................. ASSEMBLY, BEARING .......................................................................................... SEAT, BEARING .................................................................................................... SHAFT, STEERING COLUMN ............................................................................... COLUMN, ALUMINUM STEERING ....................................................................... RING, RETAINING ................................................................................................. SEAL, BEARING .................................................................................................... COVER, STEERING COLUMN .................................................................................. WHEEL, STEERING .................................................................................................. NUT, NYLON LOCK, 5/8 - 18 ..................................................................................... PLATE, SCORECARD (CARRYALL I, II, II PLUS AND VI)......................................... ASSEMBLY, SCORECARD PLATE (INCLUDES ITEMS 28 - 31) (CARRYALL TURF II ONLY) ....................................................................................... SCREW, ROUND HEAD, #12 - 14 x 1 ................................................................... SPRING, TAPERED COMPRESSION ................................................................... GRIP, PENCIL ........................................................................................................ CLIP, SCORE CARD .............................................................................................. 1 3 3 1 2 2 4 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 3 3 1 2 2 4 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 2 2 2 1 1 2 2 2 1 Page 6-3 6 G E 25 24 28 16 29 30 1G 1 1E 2 27 3 4 23 26 12 11 10 5 9 6 8 7 13 31 32 TYPICAL 3 PLACES 22 TYPICAL 3 PLACES 17 18 19 2 Page 6-4 20 21 14 15 16 STEERING GEAR ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1018783-02 1013035 0008990 1018802-01 1018803-01 N/A N/A N/A N/A 1018794-01 1018799-01 1013051 1013052 1018797-01 1018798-01 1013044 N/A N/A 1018795-01 1018796-01 1018800-01 1018801-01 8754 0001035 0007540 1015597 0007602 1011930 0007555 1012467 1013042 0001624 0000334 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, STEERING GEAR BOX (INCLUDES ITEMS 1 - 21) ............................. SEAL, DUST, PASSENGER SIDE ......................................................................... WRAP, TIE .............................................................................................................. ASSEMBLY, INNER BALL JOINT .......................................................................... WASHER, TAB ....................................................................................................... BUSHING, RACK ................................................................................................... BOX, STEERING GEAR ........................................................................................ BEARING, LOWER PINION .................................................................................. PINION, STEERING .............................................................................................. BEARING, UPPER PINION ................................................................................... RING, C-TYPE STOP ............................................................................................ RING, SNAP .......................................................................................................... SEAL, DUST, STEERING PINION ......................................................................... GUIDE, STEERING RACK .................................................................................... SPRING, YOKE ...................................................................................................... NUT, LOCK, RACK SCREW .................................................................................. SCREW, RACK GUIDE .......................................................................................... RACK, STEERING ................................................................................................. WASHER, STOP .................................................................................................... RING, C-TYPE STOP ............................................................................................ SEAL, DUST, DRIVER SIDE .................................................................................. RING, RETAINING ................................................................................................. NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. BALL JOINT, LEFT HAND THREAD (INCLUDES ITEMS 25, 26 AND 27) ................ FITTING, THREAD FORM GREASE, 1/4 - 28 ....................................................... NUT, HEX SLOTTED, 3/8 - 24 ............................................................................... BOOT, DUST........................................................................................................... NUT, HEX, LEFT HAND THREAD, 1/2 - 20 ................................................................ LINK, RACK AND PINION DRAG .............................................................................. NUT, HEX, M12 x 1.75 ............................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 1 1/2 ............................................................................. WASHER, FLAT, 3/8 ................................................................................................... 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 3 3 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 3 3 Page 6-5 6 G E 16 TYPICAL 2 PLACES 1G 9 8 1E REFERENCE STEERING GEAR 6 7 18 5 11 TYPICAL 4 PLACES 10 9 12 13 2 19 14 15 TYPICAL 3 PLACES 5 10 4 2 3 2 14 5 TYPICAL 2 PLACES 2 4 1 2 16 17 TYPICAL 4 PLACES 20 TYPICAL 3 PLACES 21 Page 6-6 FRONT SUSPENSION, UPPER— VEHICLE WITH 2-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1016353 1016346 1016350 1016349 0008754 0007539 0001308 0001624 1010138 0002402 1010219 0007555 0007540 1017266 1014235 1010124 1010200 1016385 1011930 0007602 0001035 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, DELTA A-PLATE (INCLUDES ITEMS 2, 3 AND 4) ................................. BUSHING, URETHANE ......................................................................................... SLEEVE, DELTA OUTER ....................................................................................... SLEEVE, DELTA INNER ........................................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... BALL JOINT ............................................................................................................... NUT, HEX, 1/2 - 20 ..................................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 1 1/2 ............................................................................. NUT, DIMPLED LOCK, 3/8 - 16 .................................................................................. SCREW, HEX CAP, 3/8 - 16 x 2 1/4 ........................................................................... ROD, TIE ..................................................................................................................... NUT, HEX, LEFT HAND THREAD, 1/2 - 20 ................................................................ BALL JOINT, LEFT HAND THREAD .......................................................................... STRAP, A-PLATE ........................................................................................................ SHOCK ABSORBER, FRONT ................................................................................... PLATE, SPRING MOUNTING .................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 4 1/4 ............................................................................. ASSEMBLY, DELTA SHOCK AND GEAR SUPPORT ................................................. SEAL, DUST ............................................................................................................... NUT, SLOTTED HEX, 3/8 - 24 .................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. 2 6 1 2 8 1 1 2 4 4 1 1 1 2 2 1 4 1 3 3 1 2 6 1 2 8 1 1 2 4 4 1 1 1 2 2 1 4 1 3 3 1 Page 6-7 6 G E 16 REFERENCE STEERING GEAR ASSEMBLY 1G 1E 15 17 18 14 16 19 3 30 TYPICAL 4 PLACES PASSENGER SIDE ONLY 2 1 5 DRIVER SIDE ONLY TYPICAL 4 PLACES 11 21 4 7 22 20 12 8 10 27 TYPICAL 4 PLACES 31 9 29 28 25 27 26 14 Page 6-8 23 13 6 32 10 24 FRONT SUSPENSION, LOWER— VEHICLE WITH 2-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1010348 1010347 0008067 0007048 1015597 1012030 0008745 0000706 1011892 1011393 1011304 1013135 1011887 0008754 1016387 1016384 1019031-01 1010028 1010150 1016389 1010984 1010005 0007840 0007910 0008755 1016386 1015583 1012303 1014276 0001624 0000357 0000706 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, SPINDLE, DRIVER SIDE (INCLUDES ITEMS 3, 4 AND 5) ................... ASSEMBLY, SPINDLE, PASSENGER SIDE (INCLUDES ITEMS 3, 4 AND 5) .......... BUSHING, BRONZE SPINDLE ............................................................................. BUSHING, BRONZE .............................................................................................. FITTING, GREASE, 1/4 - 28 .................................................................................. SPRING, TAPERED LEAF ......................................................................................... ECCENTRIC ............................................................................................................... NUT, HEX, 3/8 - 16 ..................................................................................................... ASSEMBLY, HUB (INCLUDES ITEMS 10 - 13) .......................................................... PACKAGE, HUB BEARING .................................................................................... STUD, LUG, 1/2 - 20 ............................................................................................... SEAL, DOUBLE LIP ............................................................................................... COVER, DUST ....................................................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 2 3/4 ................................................................ CLEVIS, UPPER DELTA ............................................................................................. NUT, NYLON LOCK, 1/2 - 20 ..................................................................................... WASHER, FLAT, 1/2 ................................................................................................... BEARING, THRUST ................................................................................................... WASHER, KINGPIN WAVE ........................................................................................ NUT, LUG ................................................................................................................... WASHER, FLAT, 3/4 ................................................................................................... NUT, HEX SLOTTED, 3/4 - 16 .................................................................................... PIN, COTTER, 5/32 x 1 .............................................................................................. SCREW, HEX HEAD CAP, 3/8 - 16 x 3 3/8 ................................................................ KINGPIN ..................................................................................................................... BUSHING, URETHANE ............................................................................................. BUSHING, STEEL ...................................................................................................... PLATE, FRONT SPRING RETAINER ......................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 1 1/2 ................................................................ WASHER, LOCK, 3/8 ................................................................................................. NUT, HEX, 3/8 - 16 ..................................................................................................... 1 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 1 1 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 Page 6-9 6 G E 16 REFERENCE STEERING GEAR 1G 8 1E 18 6 7 22 23 5 5 TYPICAL 4 PLACES 5 10 12 13 9 2 19 11 14 15 TYPICAL 3 PLACES 5 10 4 2 2 3 2 24 5 2 4 1 2 16 17 TYPICAL 4 PLACES 20 TYPICAL 3 PLACES 21 Page 6-10 FRONT SUSPENSION, UPPER— VEHICLE WITH 4-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1016353 1016346 1016350 1016349 0008754 0007539 0001308 0008861 1010138 0002402 1010219 0007555 0007540 1017266 1018706-01 1010124 1018705-01 1016385 1011930 0007602 0001035 0000320 1019353-01 1019550-01 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, DELTA A-PLATE (INCLUDES ITEMS 2, 3 AND 4) ................................. BUSHING, URETHANE ......................................................................................... SLEEVE, DELTA OUTER ....................................................................................... SLEEVE, DELTA INNER ........................................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... BALL JOINT ............................................................................................................... NUT, HEX, 1/2 - 20 ..................................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 2 3/4 ............................................................................. NUT, DIMPLED LOCK, 3/8 - 16 .................................................................................. BOLT, HEX HEAD, 3/8 - 16 x 2 1/4 ............................................................................. ROD, TIE ..................................................................................................................... NUT, HEX, LEFT HAND THREAD, 1/2 - 20 ................................................................ BALL JOINT, LEFT HAND THREAD .......................................................................... STRAP, A-PLATE ........................................................................................................ SHOCK ABSORBER, FRONT ................................................................................... PLATE, SPRING MOUNTING .................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 4 3/4 ............................................................................. ASSEMBLY, DELTA SHOCK AND GEAR SUPPORT ................................................. SEAL, DUST ............................................................................................................... NUT, SLOTTED HEX, 3/8 - 24 .................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. BOLT, HEX HEAD, 3/8 - 16 x 1 ................................................................................... CLAMP, BRAKE CABLE (PART OF BRAKE CABLE ASSEMBLY) ............................. BRACKET, BRAKE CABLE GUIDE ............................................................................ 2 6 1 2 11 1 1 2 2 4 1 1 1 1 2 3 4 1 3 3 1 1 2 1 2 6 1 2 11 1 1 2 2 4 1 1 1 1 2 3 4 1 3 3 1 1 2 1 Page 6-11 6 G E 16 REFERENCE STEERING GEAR ASSEMBLY 1G 1E 15 17 18 14 30 16 19 TYPICAL 4 PLACES PASSENGER SIDE ONLY 3 2 1 5 DRIVER SIDE ONLY TYPICAL 4 PLACES 11 21 4 7 22 20 12 8 10 27 TYPICAL 4 PLACES 31 9 29 28 25 27 26 14 Page 6-12 23 13 6 32 10 24 FRONT SUSPENSION, LOWER— VEHICLE WITH 4-WHEEL BRAKING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1018769-01 1018770-01 0008067 0007048 1015597 1012030 0008745 0000706 1011892 1011393 1011304 1013135 1011887 0008754 1016387 1016384 1019031-01 1010028 1010150 1016389 1010984 1010005 0007840 0007910 0008755 1016386 1015583 1012303 1014276 1010177 0000357 0000706 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, SPINDLE, DRIVER SIDE (INCLUDES ITEMS 3, 4 AND 5) ................... ASSEMBLY, SPINDLE, PASSENGER SIDE (INCLUDES ITEMS 3, 4 AND 5) .......... BUSHING, BRONZE SPINDLE ............................................................................. BUSHING, BRONZE .............................................................................................. FITTING, GREASE, 1/4 - 28 .................................................................................. SPRING, TAPERED LEAF ......................................................................................... ASSEMBLY, ECCENTRIC .......................................................................................... NUT, HEX, 3/8 - 16 ..................................................................................................... ASSEMBLY, HUB (INCLUDES ITEMS 10 - 13) .......................................................... PACKAGE, HUB BEARING .................................................................................... STUD, LUG, 1/2 - 20 .............................................................................................. SEAL, DOUBLE LIP ............................................................................................... COVER, DUST ....................................................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 2 3/4 ................................................................ CLEVIS, UPPER DELTA ............................................................................................. NUT, NYLON LOCK, 1/2 - 20 ..................................................................................... WASHER, FLAT, 1/2 ................................................................................................... BEARING, THRUST ................................................................................................... WASHER, KINGPIN WAVE ........................................................................................ NUT, LUG ................................................................................................................... WASHER, FLAT, 3/4 ................................................................................................... NUT, HEX SLOTTED, 3/4 - 16 .................................................................................... PIN, COTTER, 5/32 x 1 .............................................................................................. SCREW, HEX HEAD CAP, 3/8 - 16 x 3 3/8 ................................................................ KINGPIN ..................................................................................................................... BUSHING, URETHANE ............................................................................................. BUSHING, STEEL ...................................................................................................... PLATE, FRONT SPRING RETAINER ......................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 2 ...................................................................... WASHER, LOCK, 3/8 ................................................................................................. NUT, HEX, 3/8 - 16 ..................................................................................................... 1 1 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 1 1 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 Page 6-13 6 G E 16 15 1G 1E 2 CARRYALL I GAS ONLY TYPICAL ON BOTH SIDES 17 TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE REAR BRAKE CABLE 18 1 ELECTRIC VEHICLES ONLY 4 3 4 3 15 4 12 2 1 19 21 4 22 7 3 6 9 11 10 16 10 9 13 14 Page 6-14 15 2 20 5 8 TYPICAL 2 PLACES 4 REAR SUSPENSION ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 20 21 22 0007569 1012304 0008754 1012303 1015583 1010145 1013164 1014236 1011415 N/A N/A 1014902 1014675 1014557 1014555 0008755 1019265-01 1019294-01 1019008-01 1013207 1017235 1014546-02 1014549-02 1014901 1014573 2 3 QTY QTY GAS ELEC 4 SHACKLE, REAR SPRING (ELECTRIC VEHICLE) ................................................... SHACKLE, REAR SPRING (GASOLINE VEHICLE) .................................................. NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... BUSHING, STEEL ...................................................................................................... BUSHING, URETHANE ............................................................................................. NUT, UNF HEX, 3/8 - 24 ............................................................................................. KIT, SHOCK ABSORBER (INCLUDES ITEMS 7, 9 AND 10) .................................... SHOCK ABSORBER, REAR ................................................................................. KIT, SHOCK ABSORBER CUSHION (INCLUDES 2 EACH OF ITEMS 9 AND 10) ... RETAINER, SHOCK ABSORBER CUSHION ........................................................ CUSHION, SHOCK ABSORBER ........................................................................... U-BOLT ....................................................................................................................... SPRING, REAR LEAF ................................................................................................ WASHER, FLAT, 7/16 ................................................................................................. NUT, NYLON LOCK, 7/16 - 24 ................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 3 3/8 ................................................................ PAD, SPRING, DRIVER SIDE .................................................................................... PAD, SPRING, PASSENGER SIDE ............................................................................ HANGER, BRAKE CABLE (GASOLINE CARRYALL I ONLY) .................................... HANGER, BRAKE CABLE (ALL OTHER VEHICLES) .............................................. BUMPER, JOUNCE ................................................................................................... MOUNT, BUMPER (GASOLINE VEHICLE ONLY) ..................................................... MOUNT, BUMPER (ELECTRIC VEHICLE ONLY) ...................................................... SPACER, OVERLOAD BUMPER ............................................................................... RETAINER, SPRING .................................................................................................. 4 4 6 4 12 4 1 2 4 8 8 2 2 4 4 6 1 1 2 2 2 2 2 2 6 4 12 4 1 2 4 8 8 2 2 4 4 6 1 1 2 2 2 2 2 Page 6-15 6 G E 16 TYPICAL BOTH SIDES OF VEHICLE 1G 2 1E 3 4 6 y ; y ; ;yy; ;; yy 7 4 3 ;y yy ;; y ; ;; yy 5 8 10 4 3 3 2 11 9 TYPICAL 4 PLACES 1 4 REF. 7 6 1 TYPICAL 4 PLACES 14 1 15 12 13 REFERENCE REAR SUSPENSION Page 6-16 TYPICAL 4 PLACES STABILIZER BAR—ELECTRIC CARRYALL II, GASOLINE CARRYALL II, TURF II, II PLUS, AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1015760 1015457 1015453 0000808 1016814 0008861 0000357 1016813 0007173 0007174 0001242 1015614 1015613 0007311 0008233 2 3 QTY QTY GAS ELEC 4 BAR, STABILIZER, 3/4 DIAMETER ........................................................................... SPACER ..................................................................................................................... MOUNT, COMPRESSION .......................................................................................... WASHER, FLAT, 3/8 ................................................................................................... LINK, STABILIZER BAR ............................................................................................. SCREW, HEX HEAD CAP, 3/8 - 16 x 1 3/4 ................................................................ WASHER, LOCK, 3/8 ................................................................................................. BRACKET, STABILIZER BAR MOUNTING ................................................................ SCREW, HEX HEAD CAP, 5/16 - 18 x 3/4 ................................................................. WASHER, LOCK, 5/16 ............................................................................................... NUT, HEX, 5/16 - 18 ................................................................................................... SUPPORT, STABILIZER BAR BUSHING ................................................................... BUSHING, STABILIZER BAR ..................................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 2 ...................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... 1 4 8 8 2 4 4 2 8 8 8 2 2 8 8 1 4 8 8 2 4 4 2 8 8 8 2 2 8 8 Page 6-17 6 G E 16 1G 1E Page 6-18 ELECTRICAL SYSTEM— GASOLINE VEHICLE 7 G TYPICAL 4 PLACES 17 22 23 1G 21 2 1 24 3 6 4 5 7 8 3 25 9 9 10 12 11 20 19 14 18 13 26 16 17 15 19 20 27 28 24 29 CARRYALL I VEHICLE ONLY REFERENCE UNITIZED TRANSAXLE TYPICAL 3 PLACES 32 33 TYPICAL 2 PLACES 33 Page 7-2 31 30 Clu bC ar FORWARD AND REVERSE SHIFTER ASSEMBLY— GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 1016947 1012594 1016342 0008057 1012431 1014808 1014727 1014807 0008058 1014145 1014089 1014065 1013590 1013589 1013587 1013591 0008717 1010954 1019515-01 1015409 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1016727-01 0007893 1012333 1013198 1012987 0008248 0008233 1016201 0008251 1018558-01 0000332 1019226-01 1012285 1018962-01 32 33 1010434 1014306 2 3 QTY 4 ASSEMBLY, FORWARD AND REVERSE SHIFTER (INCLUDES ITEMS 1 - 17) ................... SCREW, MACHINE, #4 - 40 x 1 1/2 ................................................................................... BASE, FORWARD AND REVERSE SHIFTER ................................................................... NUT, HEX HEAD, #4 - 40 .................................................................................................... WASHER, FLAT, #4 ............................................................................................................. SWITCH, LIMIT ................................................................................................................... WASHER, NYLON FLAT, #4 ............................................................................................... SWITCH, LIMIT ................................................................................................................... WASHER, LOCK, #4 ........................................................................................................... BUSHING, BRONZE ........................................................................................................... KIT, NEUTRAL LOCK-OUT CAM (INCLUDES ITEM 11) ................................................... WASHER, FLAT ............................................................................................................. SPRING, FORWARD AND REVERSE CAM ...................................................................... RING, RETAINING .............................................................................................................. WELDMENT, FORWARD AND REVERSE BELL CRANK ................................................. PIN, ROLL, 1/8 .................................................................................................................... NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. STUD, BALL, 1/4 - 28 x 1/4 ................................................................................................. CABLE, TRANSMISSION (INCLUDES ITEMS 19 AND 20) (CARRYALL I ONLY) ................. CABLE, TRANSMISSION (INCLUDES ITEMS 19 AND 20) (CARRYALL II, TURF II, AND II PLUS) ......................................................................................................................... CABLE, TRANSMISSION (INCLUDES ITEMS 19 AND 20) (CARRYALL VI ONLY) ............... NUT, HEX, #10 - 32 ............................................................................................................. JOINT, BALL ....................................................................................................................... SCREW, PHILLIPS OVAL COUNTERSUNK MACHINE, #8 - 32 x 5/8 ................................... HANDLE, FORWARD AND REVERSE SWITCH .................................................................... SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 3/4 ................................................................... NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. WASHER, WAVE, 3/8 .............................................................................................................. SCREW, PHILLIPS HEAD, 1/4 - 20 x 1 (CARRYALL I ONLY) ................................................. RETAINER, CABLE (CARRYALL I ONLY) ............................................................................... WASHER, FLAT, 1/4 (CARRYALL I ONLY) .............................................................................. BRACKET, TRANSMISSION CABLE SUPPORT .................................................................... SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... KIT, FORWARD AND REVERSE SWITCH COVER (INCLUDES ITEM 32) (CARRYALL I, II, TURF II AND II PLUS) ................................................................................. BARREL, PLASTIC ............................................................................................................. WASHER, FLAT, TYPE B, 1/4 .................................................................................................. 1 2 1 4 4 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 4 5 1 1 1 1 1 3 1 2 4 Page 7-3 7 G 17 1G 14 2 13 FORWARD / REVERSE ASSEMBLY CK B LA FRAME GROUND RE D 12 E WHIT CK 1 RE WHIT TE I H D/W YE L CK B LA 2 1 O E BL U LOW GE RA N / RED BLA E WHIT REVERSE BUZZER I OIL LIGHT S E WHIT ITE / WH RED ORANGE LIMIT SWITCHES CK BLA REEN G ORA CK BLA ITE/ E WHIT CK / BLA 5 18 4 17 NGE FUEL TANK 2 E WHIT BLA ORANGE BLACK WH CK BL U E FRAME GROUND RED VOLTAGE REGULATOR RE D R ED E BL U O RA FUSE BLOCK YELLOW BLACK UND ED RAID B GRO IRE W IRE ND W ROU DG AIDE BR WHIT E/B K LAC WHIT 22 E STARTER / GENERATOR F2 DF A1 8 F1 A2 N EE GR RPM LIMITER RED ENGINE WHITE / BLACK YELLOW OIL SENDING UNIT BLACK 11 BATTERY YELLOW BLA C K 16 FRAME GROUND 19 20 RED ITE WH NGE 9 ORA N G E YE L L O W 21 RED WHITE / BLACK SOLENOID YELLOW WHITE 23 7 Page 7-4 1 EN GRE 3 15 FUEL GAUGE CK BL A 10 CK 6 G RED / WHITE 2 M- M+ LOW YEL BLUE WHITE BLUE LIMIT SWITCHES KEY SWITCH E YELLOW YELLOW BLA BL U CK A L E/B WIRING—GASOLINE CARRYALL I ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1018893-02 N/A N/A N/A 1015769 N/A N/A N/A N/A N/A N/A 1014119 N/A N/A N/A N/A 1012382 N/A N/A N/A 1015920 1015737 1015332 1018373-01 2 3 QTY 4 WIRE HARNESS ASSEMBLY (INCLUDES ITEMS 1 - 10) ..................................................... WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 WHITE, #18 WHITE/BLACK .......................................................... WIRE ASSEMBLY, #18 YELLOW, #16 BLUE ...................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #18 BLACK ........................................................................................... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 RED, #16 ORANGE ...................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK (PART OF REVERSE BUZZER KIT) ..................................... WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 ORANGE (PART OF ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #18 ORANGE ........................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #6 BRAIDED GROUND ............................................................................ WIRE ASSEMBLY, #10 RED (PART OF ELECTRICAL COMPONENT BOX) ......................... WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 7-5 7 G 17 1G 15 2 14 FORWARD / REVERSE ASSEMBLY CK B LA FRAME GROUND RE D 13 E WHIT K 1 RE E WHIT E T I H D/W YE L CK B LA 2 1 ORA E BL U LOW BLA ITE / WH RED N GE G 3 REVERSE BUZZER I OIL LIGHT S RED 16 ITE / WH ORANGE E WHIT LIMIT SWITCHES CK BLA EEN GR FUEL GAUGE ORA K AC E/BL E WHIT 5 19 4 18 NGE FUEL TANK CK / BLA 2 E WHIT BLA CK BL U E FRAME GROUND SOLENOID 21 16 RED VOLTAGE REGULATOR RE D E BL U R ED N O RA IRE ND W ROU DG AIDE BR GE CK BLA WHIT YELLOW BLACK 22 E STARTER / GENERATOR DF F1 A2 N EE GR RPM LIMITER 11 12 ENGINE RED YELLOW WHITE OIL SENDING UNIT / BLACK BLA C K YE L YELLOW LOW WHITE BLA C K BATTERY K LAC F2 A1 9 ORA N G YE L L O W E E/B WHIT FUSE BLOCK 10 FRAME GROUND 17 20 7 RED ITE WH RED WHITE / BLACK 1 N RE E ORANGE BLACK T WHI CK BL A 23 8 Page 7-6 CK 6 G RED / WHITE 2 M- M+ LOW YEL BLUE WHITE BLUE LIMIT SWITCHES KEY SWITCH E YELLOW YELLOW C BLA BL U K C A / BL WIRING—GASOLINE CARRYALL II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1016299-02 N/A N/A N/A 1015769 1016297 N/A 1016380 N/A N/A N/A N/A 1014119 N/A N/A N/A N/A 1012382 N/A N/A N/A 1015737 1015332 1018373-01 2 3 QTY 4 WIRE HARNESS ASSEMBLY (INCLUDES ITEMS 1 - 11) ..................................................... WIRE ASSEMBLY, #16 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 WHITE, #18 WHITE/BLACK .......................................................... WIRE ASSEMBLY, #18 YELLOW, #16 BLUE ...................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 GREEN .......................................................................................... WIRE ASSEMBLY, #6 BLACK ............................................................................................. WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 RED, #16 ORANGE ...................................................................... WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK (PART OF REVERSE BUZZER KIT) ..................................... WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 ORANGE (PART OF ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #18 ORANGE ........................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #10 RED (PART OF ELECTRICAL COMPONENT BOX) ......................... WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 7-7 7 G 17 2 1G 1 10 TYPICAL 2 PLACES 11 REFERENCE ACCELERATOR CABLE 12 3 13 ORANGE WIRE ASSEMBLY 15 10 19 TYPICAL 2 PLACES 14 17 TYPICAL 2 PLACES 20 4 18 2 5 TYPICAL 2 PLACES 16 TYPICAL 2 PLACES 10 21 22 23 2 TYPICAL 2 PLACES 26 TYPICAL 2 PLACES 24 5 25 TO FRAME GROUND 6 REFERENCE ACCELERATOR ROD FRO NT VEH OF ICLE 7 8 28 Page 7-8 27 9 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE— CARRYALL I, II, AND TURF II ITEM PART NO. DESCRIPTION 1 1018276-01 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1015372 1015752 1013589 1015373 1014145 1014065 1010954 1015345 0008717 0008057 0008058 1014807 1014808 1012431 N/A BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 25 AND 1018893-02 - SEE PAGE 7-5) (CARRYALL I ONLY) ............ BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 25 AND 1016299-02 - SEE PAGE 7-7 or 7-15) (CARRYALL II AND TURF II) ................................................................................................... COVER, ELECTRICAL COMPONENT BOX ...................................................................... SCREW, HI-LO, #12 - 16 x 5/8 ............................................................................................ RING, RETAINING .............................................................................................................. CAM, ELECTRICAL BOX .................................................................................................... BUSHING, BRONZE ........................................................................................................... WASHER, FLAT .................................................................................................................. STUD, BALL, 1/4 - 28 .......................................................................................................... ASSEMBLY, BELL CRANK SHAFT ..................................................................................... NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SWITCH, LIMIT ................................................................................................................... SWITCH, LIMIT ................................................................................................................... WASHER, FLAT, #4 ............................................................................................................. WIRE ASSEMBLY, #16 ORANGE ....................................................................................... 16 17 18 19 20 21 22 23 24 25 26 27 28 1015878 1018561-02 1015777 0007893 0001242 1013609 1012295 1015737 1015741 1015371 1015405 0001241 0007473 SCREW, HEX HEAD MACHINE, #4 - 40 x 1 5/8 ................................................................ SCREW, HEX WASHER HEAD HI-LO, 1/4 - 15 x 1 1/2 ..................................................... ASSEMBLY, VOLTAGE REGULATOR ................................................................................. NUT, HEX, #10 - 32 ............................................................................................................. NUT, HEX, 5/16 - 18 ............................................................................................................ SOLENOID, 12 VOLT .......................................................................................................... FUSE, 10 AMP .................................................................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... BLOCK, FUSE .................................................................................................................... BOX, ELECTRICAL COMPONENT .................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 2 ............................................................................................. WASHER, FLAT, 5/16 .............................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ 1018276-02 7 G 1 1 1 5 1 1 2 1 1 1 1 4 2 1 1 2 1 2 1 1 2 2 1 1 1 1 1 2 2 2 Page 7-9 17 1G TYPICAL 4 PLACES ON OFF 7 5 6 10 M- 1 8 2 TYPICAL 4 PLACES 11 12 9 M+ AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED 4 3 2 1 OFF ON 19 TYPICAL 2 PLACES 17 18 13 CA RR YA L L 15 16 15 20 TYPICAL 3 PLACES Page 7-10 14 ELECTRICAL COMPONENTS, FRONT BODY— GASOLINE CARRYALL I, II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 1016859 1016849 1016851 N/A 1011229 1015720 1018306-01 1018263-01 1018264-01 1018511-01 1018307-01 1018345-02 1012505 1016630 1015103 N/A N/A 1015104 1011610 1011571 1019009-01 2 3 QTY 4 KIT, REVERSE BUZZER (INCLUDES ITEMS 2, 3 AND 4) ..................................................... SCREW, PAN HEAD HILO, #4 - 24 x 5/16 .......................................................................... BUZZER, REVERSE ........................................................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... NUT, K LOCK, #6 - 32 ............................................................................................................. BOLT, HEX WASHER HEAD, # 6 - 32 x 1/2 ............................................................................ ASSEMBLY, SCREW AND WASHER (QUANTITY OF 5 FOR CARRYALL II PLUS) .............. SWITCH, KEY (CARRYALL I, II AND TURF II) ....................................................................... SWITCH, KEY (CARRYALL II PLUS ONLY) ............................................................................ WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH ................................................................................................................. KEY (PAIR) .............................................................................................................................. LIGHT, OIL WARNING ............................................................................................................. GAUGE, FUEL (INCLUDES ITEMS 15 AND 16) .................................................................... NUT, BRASS ....................................................................................................................... WASHER, EXTERNAL TOOTH LOCK ................................................................................ BRACKET, FUEL GAUGE ....................................................................................................... WASHER, LOCK, #8 ............................................................................................................... NUT, HEX, #8 - 32 .................................................................................................................. RETAINER, HARNESS ........................................................................................................... 1 2 1 1 1 1 4 1 1 1 1 1 1 1 1 6 3 1 2 2 3 Page 7-11 7 G 17 22 23 H 1G O U R S 24 1 28 2 3 VOLTAGE LIMITER MOUNTING 4 TIE WRAP 5 29 30 25 27 TYPICAL 3 PLACES 26 HOUR METER MOUNTING TYPICAL 2 PLACES 6 8 7 19 15 14 13 12 11 10 9 16 18 HEADLIGHT SWITCH 21 17 20 HEADLIGHT MOUNTING Page 7-12 HEADLIGHTS AND HOUR METER— GASOLINE CARRYALL TURF II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0007893 0001016 0000183 1017721 1010909 0008990 1016897-01 1016897-02 1017066 1017059 1013461 1017060 1017065 1017061 1017062 0007893 1017064 1016880 1016879 0004034 1013857 1013578 1012285 1013547 N/A N/A 1016862 N/A N/A N/A 2 3 QTY 4 NUT, HEX, #10 - 32 ................................................................................................................. WASHER, LOCK, #10 ............................................................................................................. WASHER, FLAT, #10 ............................................................................................................... VOLTAGE LIMITER ................................................................................................................. SCREW, MACHINE HEAD, #10 - 32 x 1 1/4 ........................................................................... WRAP, TIE ............................................................................................................................... ASSEMBLY, HEADLIGHT, DRIVER SIDE (INCLUDES ITEMS 9 - 18) ................................... ASSEMBLY, HEADLIGHT, PASSENGER SIDE (INCLUDES ITEMS 9 - 17 AND 19) ............. HARNESS, HEADLIGHT WIRE .......................................................................................... LOCK, BULB COLLAR ........................................................................................................ SCREW, HI-LO, #10 - 16 .................................................................................................... BULB, HALOGEN ............................................................................................................... RETAINER, HEADLIGHT .................................................................................................... LENS, HEADLIGHT ............................................................................................................ ASSEMBLY, TURN SIGNAL LENS ..................................................................................... NUT, HEX, #10 - 32 ............................................................................................................. BRACKET, MOUNTING ...................................................................................................... BEZEL, HEADLIGHT, DRIVER SIDE................................................................................... BEZEL, HEADLIGHT, PASSENGER SIDE ......................................................................... SWITCH, LIGHT (INCLUDES ITEM 21) .................................................................................. KNOB, LIGHT SWITCH ...................................................................................................... KIT, HOUR METER, 12 VOLT (INCLUDES ITEMS 23 - 30) ................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ..................................................................... BRACKET, HOUR METER MOUNTING ............................................................................. WIRE ASSEMBLY, #18 BLACK ........................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... KIT, HARDWARE, HOUR METER MOUNTING (INCLUDES ITEMS 28 - 30) .................... SCREW, ROUND HEAD, #6 - 32 x 1/2 .......................................................................... NUT, HEX, #6 - 32 ......................................................................................................... WASHER, LOCK, #6 - 32 .............................................................................................. 1 1 1 1 1 4 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 3 3 3 Page 7-13 7 G RIGHT HEADLIGHT 17 GRE EN BLUE VOLTAGE LIMITER WHIT E 1G LEFT HEADLIGHT K 25 AC UE BL BL 24 K AC N GREE BLUE BL K AC BL WHIT 15 2 E 14 UE BL B BLA RE D E WHIT CK RE E WHIT E T HI D/W YE BLU CK A L B / KEY SWITCH E CK B LA 2 E BL U W L LO 2 ORANGE RED / WHITE S WHITE BLUE ORA REVERSE BUZZER OIL LIGHT G FUEL GAUGE 13 YEL LOW LIGHT SWITCH /W RED E HITE LIMIT SWITCHES CK BLA EEN GR YELLOW ORA K LAC E WHIT HOUR METER 2 BLA CK 31 K RE D SOLENOID 16 21 RED FRAME GROUND RED ITE WH K AC BL RED LOW O FUEL TANK 4 VOLTAGE REGULATOR R ED UND RO ED G E ID BRA GE R AN CK BLA WHIT YELLOW BLACK 22 29 A2 N EE GR ENGINE RED YELLOW WHITE OIL SENDING UNIT / BLACK BLA C K 12 BATTERY DF RPM LIMITER CK YELL YELLOW OW BLA C K FRAME GROUND 17 STARTER / GENERATOR F1 9 BLA E F2 A1 ORA N G YE L L O W E 28 K LAC E/B WHIT 10 WHITE 23 7 20 WIR FUSE BLOCK 11 19 30 L UE FUSE E BL U BLAC NGE 27 B YEL 6 FRAME GROUND CK / BLA E WHIT 1 ORANGE BLACK WH CK EN GRE RED CK BL A BLA 18 B ITE/ WHITE / BLACK / RED E WHIT U BL Page 7-14 N GE E WHIT 1 26 5 3 16 I BLUE LIMIT SWITCHES 1 LOW YEL BLUE BLACK FORWARD / REVERSE ASSEMBLY M- M+ YELLOW YELLOW FRAME GROUND K LAC 8 WIRING— GASOLINE CARRYALL TURF II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1016299-02 N/A N/A N/A 1015769 1016297 N/A 1016380 N/A N/A N/A N/A 1014119 N/A N/A N/A N/A 1012382 N/A N/A N/A 1015737 1015332 1018373-01 1016858 N/A N/A N/A 0008106 N/A N/A N/A N/A 2 3 QTY 4 WIRE HARNESS ASSEMBLY (INCLUDES ITEMS 1 - 11) ..................................................... WIRE ASSEMBLY, #16 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 WHITE, #18 WHITE/BLACK .......................................................... WIRE ASSEMBLY, #18 YELLOW, #16 BLUE ...................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 GREEN .......................................................................................... WIRE ASSEMBLY, #6 BLACK ............................................................................................. WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 RED, #16 ORANGE ...................................................................... WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK (PART OF REVERSE BUZZER KIT) ..................................... WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 ORANGE (PART OF ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #18 ORANGE ........................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #10 RED (PART OF ELECTRICAL COMPONENT BOX) ......................... WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ WIRE HARNESS, HEADLIGHT (INCLUDES ITEMS 24 - 29) ................................................. WIRE ASSEMBLY, #16 BLUE ............................................................................................. WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 YELLOW (INCLUDES ITEM 27) .................................................... FUSE, 20 AMP .............................................................................................................. WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #18 RED (PART OF HOUR METER KIT) ................................................. WIRE ASSEMBLY, #18 BLACK (PART OF HOUR METER KIT) ............................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 7-15 7 G 17 1G 2 15 16 CK B LA RE D 1 CK B LA E WHIT ORA N GE ITE / WH GRE CK / BLA EN B FORWARD / REVERSE ASSEMBLY S K LAC MM+ ITE / WH RED A YE L BL U LOW KEY SWITCH 3 REVERSE BUZZER I G FUEL GAUGE /W RED HITE ORA N GE BR 4 ITE / WH CK / BLA RED ROWN B LIMIT RELAY NC 6 FUEL TANK WN BRO ROWN ITE B WH NO CK GREEN NO COIL WHITE 20 18 ORANG E BLU E RED FRAME GROUND SOLENOID RED RE D VOLTAGE REGULATOR WHIT RED WHITE / BLACK 18 5 COIL SONIC WELD 19 ORANG E ORANG / WHITE E NC CK BLA BL A O RA R ED E IDED BRA NGE ND ROU G E WHIT YELLOW BLACK CK / BLA BLACK E/ H W IT LACK B E WHIT 24 STARTER / GENERATOR F2 DF A1 F1 YE L L O W RED 9 A2 RPM LIMITER 10 OIL SENDING UNIT WHITE / BLACK WHITE / BLACK BLA C K YE L L YELLOW OW WHITE BLA C K 23 N EE GR ENGINE YELLOW 13 BATTERY 21 E WIR FUSE BLOCK 11 ORANGE 1 OWN ORANGE BLACK TE WHI FRAME GROUND BLA C K 8 22 Page 7-16 R ED 17 SWITCH ORANGE RED / WHITE ORA ITE / WH RED N GE OIL LIGHT S ORANGE / WHITE 2 E LOW YEL L U E B WHITE / BLACK LIMIT SWITCHES B YELLOW YELLOW FRAME GROUND 14 12 7 WIRING—GASOLINE CARRYALL II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1016895-02 N/A N/A N/A N/A N/A 1015769 N/A 1016380 N/A N/A N/A N/A 1014119 N/A N/A N/A N/A N/A N/A N/A 1015332 1018373-01 1012382 1015737 2 3 QTY 4 WIRE HARNESS ASSEMBLY, CARRYALL II PLUS (INCLUDES ITEMS 1 - 12) .................... WIRE ASSEMBLY, #16 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 ORANGE/WHITE .......................................................................... WIRE ASSEMBLY, #18 YELLOW/#18 GREEN ................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 BROWN ......................................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #6 BLACK ............................................................................................. WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #16 RED, #16 ORANGE ...................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #18 ORANGE (PART OF ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #18 ORANGE ........................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #10 RED (PART OF ELECTRICAL COMPONENT BOX) ......................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 7-17 7 G 17 RIGHT HEADLIGHT VOLTAGE LIMITER 1G GRE GROUND TERMINAL BLOCK EN BLUE HORN WHIT E 6 BL LEFT HEADLIGHT 4 5 N GREE A BL K AC BL UE ITE K WH AC K BL AC BL 32 CK K AC BL E T CK GE HI AN BLA W OR U BL 1 K AC BL UE BL FRAME GROUND E 31 ITE WH K AC BL 3 D RE K AC BL N EE GR 2 RE HIT D/W BL E YE UE O LL W L YE ORANGE RED/WHITE M- A KEY SWITCH 34 OIL LIGHT S BLUE BLUE S B FRONT REVERSE BUZZER G BLACK ORANGE M+ W LO I WHITE 33 K AC / BL E WHIT E BLU BLUE 7 FUEL GAUGE GE AN OR N OW BR 10 OW LL YE TE HI /W LIGHT SWITCH 15 11 29 ORANGE YELLOW GREEN RED/WHITE WHITE/BLACK RED/WHITE YELLOW RED BLUE BROWN BLACK NC COM THREE PIN CONNECTOR 24 PARK LIMIT SWITCH 28 25 DIMMER SWITCH GE AN OR RED TWO PIN CONNECTOR E HIT D/W RE 21 NC 22 COM BRAKE LIMIT SWITCH 23 27 26 Page 7-18 BROW HORN BUTTON N ORANGE/WHITE 12 71 G1 FORWARD / REVERSE LEVER LIMIT SWITCHES 8 2 D ORA NGE N OW BR WH RED K AC /BL ITE NC K AC BL N OW BR N W O BR IT E WH NC NO COIL K AC BL ORA NGE BLU E RED FRAME GROUND SOLENOID UE BL ED AID BR YELLOW ND OU GR WH FUSE BLOCK YEL 37 D RE E IT WH IT E WH D/ RE LOW L YE ED R GE AN OR IT E WH N/ E E GR 14 36 35 UE BL VOLTAGE REGULATOR N EE GR 13 COIL NO RED SONIC WELD WH I T E FUEL TANK LIMIT SWITCH RELAY ORA NGE / ITE RE WI K CK LA AC /B BL IT E WH ITE WH K AC BL STARTER / GENERATOR 38 F2 DF A1 BLU E F1 LOW 16 A2 N EE GR RPM LIMITER ENGINE WHIT E/BL ACK BLAC K OIL SENDING UNIT YE L LOW BLAC K YELL FRAME GROUND WHI BLA CK BLACK 40 39 BLACK WHITE/BLACK YELLOW RE E HIT D /W RE 35 YELLOW D/W RE 9 1 E HIT RED O E NG RA TE OW YELL OW 17 18 19 30 BLUE GREEN/WHITE 20 7 YELLOW WHITE YEL L K AC BL D RE RED/WHITE RED/WHITE K AC BL REAR REVERSE BUZZER BATTERY 33 BRO WN B LA CK BL AC K OW RE D FRAME GROUND BR OW N N W TE HI BRO W K AC BL RIGHT BRAKE LIGHT BLA BR CK OW N RE D LEFT BRAKE LIGHT WIRING—GASOLINE CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1019695-02 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1016380 1015769 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1014119 N/A N/A N/A N/A N/A N/A 1015332 1015737 1018373-01 1012382 2 3 QTY 4 HARNESS, WIRE (INCLUDES ITEMS 1 - 29) ........................................................................ WIRE ASSEMBLY, #16 WHITE ........................................................................................... WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #14 BLACK, #18 BLACK ...................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 BROWN ......................................................................................... WIRE ASSEMBLY, #14 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 BROWN ......................................................................................... WIRE ASSEMBLY, #18 GREEN AND #18 YELLOW .......................................................... WIRE ASSEMBLY, #16 RED AND #16 ORANGE ............................................................... WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 ORANGE ....................................................................................... WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, # 6 BLACK ............................................................................................ WIRE ASSEMBLY, # 6 WHITE ............................................................................................ WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #18 GREEN/WHITE AND #18 BLUE ................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 WHITE ........................................................................................... WIRE ASSEMBLY, #16 ORANGE/WHITE .......................................................................... WIRE ASSEMBLY, #16 BROWN ......................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #16 RED/WHITE .................................................................................. WIRE ASSEMBLY, #16 ORANGE ....................................................................................... WIRE ASSEMBLY, #16 ORANGE/WHITE .......................................................................... WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK (PART OF REVERSE BUZZER KIT) ..................................... WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #18 ORANGE (PART OF ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #10 BRAIDED GROUND WIRE ................................................................ WIRE ASSEMBLY, #10 RED (PART OF ELECTRICAL COMPONENT BOX) ......................... WIRE ASSEMBLY, #6 GREEN ............................................................................................... WIRE ASSEMBLY, #6 BLACK ................................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Page 7-19 7 G 8 17 7 1G 2 TYPICAL 2 PLACES 9 3 4 10 5 6 REFERENCE ACCELERATOR CABLE DIODE ASSEMBLY 30 1 14 15 11 31 16 TYPICAL 2 PLACES 33 12 30 ORANGE WIRE ASSEMBLY 29 8 17 27 28 TYPICAL 2 PLACES 13 23 24 20 26 20 20 10 32 TYPICAL 2 PLACES FRO NT VEH OF ICLE 17 8 18 TYPICAL 2 PLACES 22 TYPICAL 2 PLACES 35 34 25 REFERENCE ACCELERATOR ROD 19 20 21 Page 7-20 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE— CARRYALL II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1018277-01 2 3 QTY 4 G 1 2 3 4 5 6 7 8 9 10 11 1017239 0008450 0000183 1017243 0001016 0001017 1015372 1015752 0001242 0007893 1014948 BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 31 AND WIRE HARNESS 1016895-02 - SEE PAGE 7-17) (FOR CARRYALL II PLUS ONLY) ............................................................................................ BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 31 AND WIRE HARNESS 1019695-02 - SEE PAGE 7-19) (FOR CARRYALL VI ONLY) ..................................................................................................... RELAY ................................................................................................................................. SCREW, HEX HEAD MACHINE, #10 - 24 x 1/2 ................................................................. WASHER, FLAT, #10 ........................................................................................................... BRACKET, RELAY MOUNTING .......................................................................................... WASHER, LOCK, #10 ......................................................................................................... NUT, HEX, #10 - 24 ............................................................................................................. COVER, ELECTRICAL COMPONENT BOX ...................................................................... SCREW, HI-LO, #12 - 16 x 5/8 ............................................................................................ NUT, HEX, 5/16 - 18 ............................................................................................................ NUT, HEX, #10 - 32 ............................................................................................................. ASSEMBLY, DIODE ............................................................................................................ 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 N/A 1013609 1014807 1013589 1015373 1014145 1014065 1015345 1010954 0008717 1016997 1012295 1015737 1015741 1015405 1017238 1015878 1012431 0008057 WIRE ASSEMBLY, #18 ORANGE ....................................................................................... SOLENOID ......................................................................................................................... SWITCH, LIMIT ................................................................................................................... RING, RETAINING .............................................................................................................. CAM, ELECTRICAL BOX .................................................................................................... BUSHING, BRONZE ........................................................................................................... WASHER, FLAT .................................................................................................................. ASSEMBLY, BELL CRANK SHAFT ..................................................................................... STUD, BALL, 1/4 - 28 .......................................................................................................... NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. BOX, ELECTRICAL COMPONENT ..................................................................................... FUSE, 10 AMP..................................................................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... BLOCK, FUSE .................................................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 2 ........................................................................................ REGULATOR, VOLTAGE ..................................................................................................... SCREW, HEX HEAD MACHINE, #4 - 40 x 1 5/8 ................................................................ WASHER, FLAT, #4 ............................................................................................................. NUT, HEX, #4 - 40 ............................................................................................................... 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 4 31 32 33 34 35 0008058 1016423 1018561-02 0001241 0007473 WASHER, LOCK, #4 ........................................................................................................... FUSE, 20 AMP (CARRYALL VI ONLY) .................................................................................... SCREW, HEX WASHER HEAD HI-LO, 1/4 - 15 x 1 1/2 .......................................................... WASHER, FLAT, 5/16 .............................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ 2 3 1 2 2 1018277-02 7 1 1 1 1 1 1 1 1 1 5 2 2 1 Page 7-21 17 14 13 1G M- 1 2 11 10 AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED M+ 8 9 12 6 7 5 3 1 TYPICAL 2 PLACES 4 2 23 19 22 34 32 27 31 26 30 25 24 20 28 21 33 29 17 16 18 15 Page 7-22 ELECTRICAL COMPONENTS, FRONT BODY— GASOLINE CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 0008639 1016859 1016851 1016849 N/A 1017721 1010909 0000183 0001016 0007893 1016356 1013357 1015720 1011229 0004029 0007820 1019551-01 1011825 0000304 0000332 0008233 1016897-01 1016897-02 1017066 1017059 1017060 1017061 1017064 0007893 1013461 1017065 1017062 1016880 1016879 2 3 QTY 4 WRAP, TIE ............................................................................................................................... KIT, REVERSE BUZZER (INCLUDES ITEMS 3, 4 AND 5) ..................................................... BUZZER, REVERSE ........................................................................................................... SCREW, PAN HEAD HILO, #4 - 24 x 5/16 .......................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... LIMITER, VOLTAGE (FOR GASOLINE VEHICLE LIGHTING INSTALLATION) ...................... SCREW, MACHINE, #10 - 32 x 1 1/4 ...................................................................................... WASHER, FLAT, #10 ............................................................................................................... WASHER, LOCK, #10 ............................................................................................................. NUT, HEX, #10 - 32 ................................................................................................................. BLOCK, TERMINAL ................................................................................................................ RIVET, ALUMINUM POP, 5/32 ................................................................................................ BOLT, HEX WASHER HEAD, #6 - 32 x 1/2 ............................................................................. NUT, “K” LOCK, #6 - 32 ........................................................................................................... ASSEMBLY, HORN (INCLUDES ITEMS 16, 17 AND 18) ....................................................... WASHER, INTERNAL TOOTH, 5/16 ................................................................................... NUT, M6 x 1.25 ................................................................................................................... BRACKET, HORN ............................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 1 ................................................................................................ WASHER, FLAT, 1/4 ................................................................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. ASSEMBLY, HEADLIGHT, DRIVER SIDE (INCLUDES ITEMS 24 - 33) ................................. ASSEMBLY, HEADLIGHT, PASSENGER SIDE (INCLUDES ITEMS 24 - 32 AND 34) ........... HARNESS, HEADLIGHT WIRE .......................................................................................... LOCK, BULB COLLAR ........................................................................................................ BULB, HALOGEN ............................................................................................................... LENS, HEADLIGHT ............................................................................................................ BRACKET, MOUNTING ...................................................................................................... NUT, HEX, #10 - 32 ............................................................................................................. SCREW, HI-LO, #10 - 16 x 7/16 .......................................................................................... RETAINER, HEADLIGHT .................................................................................................... ASSEMBLY, TURN SIGNAL LENS ..................................................................................... BEZEL, HEADLIGHT, DRIVER SIDE .................................................................................. BEZEL, HEADLIGHT, PASSENGER SIDE ......................................................................... 4 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 2 2 2 1 1 1 1 Page 7-23 7 G 17 6 TYPICAL 2 PLACES 7 5 1G TYPICAL 4 PLACES OFF ON 9 1 3 TYPICAL 2 PLACES 8 7 10 4 13 12 11 2 16 15 17 K AR 19 P 22 21 26 25 20 23 19 24 17 27 Page 7-24 18 18 14 CONTROLS AND GAUGES—GASOLINE CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1016630 1015103 N/A N/A 1015104 1011571 1011610 1016092 1018306-01 1018264-01 1018511-01 1018307-01 1018345-02 1012505 0004034 1013857 1011439 1011557 1019322-01 1019571-01 1011280 1019698-01 1018713-01 1018712-01 0008049 0007893 1019697-01 2 3 QTY 4 LIGHT, OIL WARNING ............................................................................................................. GAUGE, FUEL (INCLUDES ITEMS 3 AND 4) ........................................................................ NUT, BRASS ....................................................................................................................... WASHER, EXTERNAL TOOTH LOCK ................................................................................ BRACKET, FUEL GAUGE ....................................................................................................... NUT, HEX, #8 - 32 .................................................................................................................. WASHER, LOCK, #8 ............................................................................................................... SCREW, PAN HEAD MACHINE, #8 - 32 x 7/16 ...................................................................... ASSEMBLY, SCREW AND WASHER ...................................................................................... SWITCH, KEY ......................................................................................................................... WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH ................................................................................................................. KEY (PAIR) .............................................................................................................................. SWITCH, LIGHT (INCLUDES ITEM 16) .................................................................................. KNOB, LIGHT SWITCH ..................................................................................................... SWITCH, LIMIT ....................................................................................................................... SCREW, HEX HEAD MACHINE, #6 - 32 x 1 ........................................................................... NUT, NYLON LOCK, #6 - 32 ................................................................................................... BRACKET, BRAKE LIGHT SWITCH ....................................................................................... NUT, LOCK, 5/16 - 18 .............................................................................................................. SWITCH, DIMMER .................................................................................................................. STAND-OFF, DIMMER SWITCH ............................................................................................. SCREW, MACHINE, #10 - 32 x 1 ............................................................................................ WASHER, INTERNAL TOOTH LOCK, #10 ............................................................................. NUT, HEX, #10 - 32 ................................................................................................................. BUTTON, HORN ..................................................................................................................... 1 1 6 3 1 2 3 1 4 1 1 1 1 1 1 1 2 4 4 1 1 1 2 2 2 2 1 Page 7-25 7 G 8 17 1G 10 12 13 9 11 14 15 11 2 7 1 3 4 5 6 Page 7-26 ELECTRICAL COMPONENTS, REAR BODY— GASOLINE CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1016717 N/A 1011582 N/A N/A N/A 1015752 1016859 1016851 1016849 N/A 1015720 0007591 1011622 1011558 2 3 QTY 4 ASSEMBLY, TAILLIGHT (INCLUDES ITEMS 2 - 6) ................................................................. HOUSING, TAILLIGHT......................................................................................................... BULB ................................................................................................................................... GASKET ............................................................................................................................. LENS ................................................................................................................................... SCREW, LENS .................................................................................................................... SCREW, HEX WASHER HEAD, #12 - 16 x 1/2 ....................................................................... KIT, REVERSE BUZZER (INCLUDES ITEMS 9 - 15) ............................................................. BUZZER, REVERSE ........................................................................................................... SCREW, PAN HEAD HILO, #4 - 24 x 5/16 .......................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... SCREW, HEX WASHER HEAD, #6 - 32 x 1/2 .................................................................... WASHER, FLAT .................................................................................................................. WASHER, LOCK, #6 ........................................................................................................... NUT, HEX, #6 - 32 ............................................................................................................... 2 1 1 1 1 2 4 1 1 2 1 1 1 1 1 Page 7-27 7 G 17 1G TYPICAL 2 PLACES TYPICAL 3 PLACES 30 TYPICAL 4 PLACES 15 27 29 21 TYPICAL 2 PLACES TYPICAL 25 2 PLACES 24 23 14 TYPICAL 4 PLACES TYPICAL 4 PLACES 22 18 TYPICAL 2 PLACES AT F1 AND F2 TERMINALS 20 TYPICAL 2 PLACES AT A1 AND A2 TERMINALS 17 19 26 DF TERMINAL 16 28 TYPICAL 2 PLACES 12 1 TYPICAL 3 PLACES 7 11 5 8 9 2 3 10 4 6 13 31 Page 7-28 STARTER/GENERATOR ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1018337-01 1018752-01 1018751-01 1018750-01 1013001 1013005 1019399-01 1013003 1018765-01 N/A N/A N/A 1018965-01 1018749-01 1018753-01 1018754-01 1018755-01 1018756-01 1018776-01 1018757-01 1018777-01 1013011-02 1018781-01 1018693-02 1018762-02 1018758-02 1018760-01 1018763-01 1017653 1018764-02 1018790-01 1014289 2 3 QTY 4 STARTER/GENERATOR (CLOCKWISE ROTATION) (INCLUDES ITEMS 1 - 30) .................. HOUSING, FIELD COIL ...................................................................................................... ASSEMBLY, ARMATURE (INCLUDES ITEMS 3, 4 AND 5) ................................................ RETAINER, BEARING ................................................................................................... BALL BEARING, OUTPUT SHAFT ............................................................................... COMMUTATOR, BALL BEARING .................................................................................. SPACER, 5/16 .................................................................................................................... KEY, WOODRUFF ............................................................................................................... KIT, PULLEY NUT AND SCREW (INCLUDES ITEMS 9 - 12) ............................................ WASHER, LOCK, M14 .................................................................................................. NUT, HEX, M14 x 2 ........................................................................................................ SCREW, CROSS - RECESSED, M5 x .8 x 18MM ......................................................... SCREW, CROSS - RECESSED, M5 x .8 x 16MM (WITH LOCK WASHER) ................. END BELL, OUTPUT SHAFT ............................................................................................. SET, POLE (SET OF 4) ....................................................................................................... SCREW, POLE PIECE (SET OF 4) .................................................................................... ASSEMBLY, FIELD COIL .................................................................................................... SET, F INSULATOR ............................................................................................................ PACKAGE, TERMINAL HARDWARE (F1 AND F2) ............................................................ SET, DF INSULATOR .......................................................................................................... PACKAGE, TERMINAL HARDWARE (DF) ......................................................................... HOLDER, BRUSH (INCLUDES ITEMS 22 - 25) ................................................................. SPRING, BRUSH ........................................................................................................... PACKAGE, BRUSH (INCLUDES 4 BRUSHES, 4 SCREWS, 4 WASHERS) ................. ASSEMBLY, BRUSH CONNECTOR .............................................................................. A CONNECTOR (SET OF 2) ......................................................................................... PACKAGE, TERMINAL HARDWARE (A1 AND A2) ............................................................ COVER, BRUSH INSPECTION PORT (SET OF 4) (INCLUDES ITEM 28) ........................ COVER, BRUSH INSPECTION PORT, WITH DRAIN ................................................... END BELL, COMMUTATOR ................................................................................................ BOLT, CLAMP, M6 x 1 x 180MM ......................................................................................... PULLEY (SILVER COLOR) ..................................................................................................... 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 2 2 1 1 1 4 1 2 1 2 1 1 1 2 1 Page 7-29 7 G CARRYALL I ONLY 16 17 17 1G AS VIEWED FROM DRIVER SIDE OF VEHICLE SEAT 15 CARRYALL II, TURF II, II PLUS, AND VI BACK A1 F1 A2 14 A1 F1 REFERENCE STARTER/GENERATOR ASSEMBLY 13 A2 TYPICAL 2 PLACES 7 8 5 13 9 6 8 REFERENCE STARTER/GENERATOR ASSEMBLY 9 1 2 F2 DF 12 4 3 9 AS VIEWED FROM PASSENGER SIDE OF VEHICLE Page 7-30 11 10 REFERENCE STARTER/GENERATOR ASSEMBLY STARTER/GENERATOR MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1018337-01 1015240-01 1015240-02 1019167-01 1016883 0008754 1015075 0000705 1019035-01 0007174 1016074 1015932 0001242 1018373-01 1015920 0007173 0007473 0001241 2 3 QTY 4 STARTER/GENERATOR ......................................................................................................... BRACKET, MOUNTING, FE 290 (CARRYALL I AND II)........................................................... BRACKET, MOUNTING, FE 350 (CARRYALL TURF II, II PLUS, AND VI) ............................. BELT ........................................................................................................................................ BRACKET, ADJUSTING .......................................................................................................... NUT, NYLON LOCK, 3/8 - 16 .................................................................................................. WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 3/8 - 16 x 1 1/4 .......................................................................................... SCREW, HEX HEAD CAP, M8 x 1.25 x 24MM ........................................................................ WASHER, LOCK, 5/16 ............................................................................................................ SCREW, TORX HEAD, M8 x 1.25 x 18MM ............................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................................. NUT, HEX, 5/16 - 18 ................................................................................................................ WIRE ASSEMBLY, #6 GREEN ............................................................................................... WIRE ASSEMBLY, #6 BRAIDED GROUND (CARRYALL I ONLY) .......................................... SCREW, HEX HEAD CAP, 5/16 - 18 x 3/4 (CARRYALL I ONLY) ............................................ NUT, NYLON LOCK, 5/16 - 18 (CARRYALL I ONLY) .............................................................. WASHER, FLAT, 5/16 (CARRYALL I ONLY) ............................................................................ 1 1 1 1 1 2 1 2 2 3 1 1 1 1 1 1 1 1 Page 7-31 7 G AS SEEN FROM THE PASSENGER SIDE OF VEHICLE 17 1G 2 3 4 5 TO NEGATIVE BATTERY POST TERMINAL 9 7 8 7 8 Page 7-32 AS SEEN FROM DRIVER SIDE OF VEHICLE 6 1 BATTERY—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 1012328 1014374 1014375 1010934 1018980-01 0007173 0001241 0007473 1014288 2 3 QTY 4 BATTERY, 12 VOLT ................................................................................................................. SPACER, BATTERY TERMINAL BOLT ................................................................................... SCREW, HEX HEAD CAP, STAINLESS STEEL, 3/8 - 16 x 1/2 ............................................... BOLT, HEX HEAD, 5/16 - 18 x 1 ............................................................................................. CLAMP, BATTERY ................................................................................................................... SCREW, HEX CAP, 5/16 - 18 x 3/4 ......................................................................................... WASHER, FLAT, 5/16 .............................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ SCREW, THREAD-FORMING, 5/16 - 16 x 3/4 ........................................................................ 1 2 2 1 1 1 2 2 1 Page 7-33 7 G 17 1G Page 7-34 ENGINE 8 G 18 FE 290 ENGINE 1G 1 TYPICAL 6 PLACES 8 3 4 2 9 TYPICAL 4 PLACES 17 18 TYPICAL 4 PLACES 4 TYPICAL 2 PLACES 5 7 6 TYPICAL 2 PLACES CARBURETOR REMOVED FOR CLARITY 16 15 5 10 TYPICAL 3 PLACES 4 14 12 11 Page 8-2 13 FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1019539-01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1016507 1016512 1016524 1016456 1016547 1019097-01 1016526 1017221 1019156-01 1016525 1016443 1016539 1016536 1016531 1011114 1015332 1015969 1015649 2 3 QTY 4 FE 290 OHV GASOLINE ENGINE (CLOCKWISE ROTATION) WITH CARBURETOR (DOES NOT INCLUDE ITEMS 15 THROUGH 18) .................................................................. BOLT, 2-ENDED, M6 x 1 x 29MM ....................................................................................... WASHER, FLAT, 6MM ......................................................................................................... SHROUD, ENGINE, FE 290 ............................................................................................... BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... NUT, FLANGE, M6 x 1 ........................................................................................................ BOLT, 2-ENDED, M6 x 1 x 27MM ....................................................................................... SHROUD, ENGINE, FE 290 (LOWER) ............................................................................... BOLT, 2-ENDED, M6 x 1 x 46MM ....................................................................................... HOUSING, FAN .................................................................................................................. SHROUD, ENGINE, FE 290 (UPPER) ................................................................................ BRACKET ............................................................................................................................ O-RING ............................................................................................................................... TUBE, OIL FILLER, FE 290 ................................................................................................ DIPSTICK ........................................................................................................................... NUT, M6 x1 .............................................................................................................................. WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... SCREW, PAN HEAD, M6 x 1 x 14MM ..................................................................................... SHROUD, FAN ........................................................................................................................ 8 G 1 1 1 1 15 3 1 1 1 1 1 1 1 1 1 1 1 4 1 Page 8-3 18 FE 290 ENGINE 1G 11 12 13 10 9 8 7 TYPICAL 2 PLACES 1 2 TYPICAL 3 PLACES 3 19 yy ;; ;; yy 18 16 17 15 14 TYPICAL 2 PLACES Page 8-4 24 23 5 22 21 20 4 25 6 FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1019157-01 1019158-01 1017448 1016548 1016505 1017455 1016562 1016455 1019092-01 1016578 1016588 1016493 1018811-01 1016456 1012981 1016579 1016586 1019094-01 1016445 1019095-01 1016497 1016544 1016561 1016587 1019093-01 2 3 QTY 4 FLYWHEEL ......................................................................................................................... FAN, FLYWHEEL, GREY .................................................................................................... SCREW, FLANGED HEX HEAD, M6 x 1 x 10MM .............................................................. WASHER, FLAT, 16MM ....................................................................................................... NUT, HEX, M16 x 2 ............................................................................................................. PLATE, FLYWHEEL FAN .................................................................................................... KEY ..................................................................................................................................... BOLT, FLANGED, M5 x .8 x 25MM ..................................................................................... COIL, IGNITION (WITH INTERNAL IGNITER) ................................................................... GROMMET ......................................................................................................................... TUBE, 7MM x 70MM ........................................................................................................... ASSEMBLY, PLUG CAP ..................................................................................................... SPARK PLUG ..................................................................................................................... BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... CLAMP ................................................................................................................................ MOUNT, RPM LIMITER ...................................................................................................... DAMPER, RPM LIMITER .................................................................................................... LIMITER, RPM - OHV ......................................................................................................... BRACKET, RPM LIMITER .................................................................................................. CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD, M5 x .8 x 8MM .................................................................... SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... CLAMP ................................................................................................................................ CLAMP ................................................................................................................................ WIRE, LEAD ....................................................................................................................... 1 1 3 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Page 8-5 8 G 18 FE 290 ENGINE 1G 14 13 4 12 15 11 TYPICAL 2 PLACES 9 10 8 3 TYPICAL 2 PLACES 6 5 2 1 7 TYPICAL 6 PLACES Page 8-6 FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1016467 1016502 1016457 1016570 1016576 1016432 1017456 1016484 1016435 1016473 1016482-03 1016429 1016537 1016581 1017507 2 3 QTY 4 ASSEMBLY, OIL FILTER, OHV ........................................................................................... BRACKET, OIL FILTER ....................................................................................................... BOLT, FLANGED HEX HEAD, M6 x 1 x 40MM ................................................................... O-RING, OIL FILTER MOUNT ............................................................................................ PLUG, DRAIN, FE 290 ....................................................................................................... GASKET, DRAIN PLUG ...................................................................................................... SCREW, FLANGED HEX HEAD, M6 x 1 x 12MM .............................................................. COVER, PUMP ................................................................................................................... GASKET, OIL PUMP ........................................................................................................... PLATE, OIL PUMP .............................................................................................................. PUMP, OIL, AND ROTOR ................................................................................................... SEAT, VALVE ....................................................................................................................... BALL, STEEL, PRESSURE RELIEF .................................................................................. SPRING .............................................................................................................................. PLUG ................................................................................................................................... 1 1 2 1 1 1 6 1 1 1 1 1 1 1 2 Page 8-7 8 G 18 FE 290 ENGINE 1G 5 6 7 TYPICAL 2 PLACES 8 9 10 14 1 15 2 12 13 EXHAUST 16 18 INTAKE 19 17 20 22 11 TYPICAL 2 PLACES AT EXHAUST CONNECTION TYPICAL 2 PLACES 21 3 4 TYPICAL 2 PLACES 23 25 26 24 TYPICAL 2 PLACES Page 8-8 27 TYPICAL 6 PLACES 28 FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1016442 1016436 1016583 1016569 1016545 1016542 1016451 1016450 1016449 1016523 1016431 1016560 1016519 1016479 1016566 1016448 1016447 1016544 1016474 1016483 1016563 1016489 1016452 1016471 1016549 1016517 1016458 1016430 2 3 QTY 4 CASE, ROCKER ................................................................................................................. GASKET, ROCKER CASE .................................................................................................. BOLT, FLANGED, M6 x 1 x 35MM ...................................................................................... O-RING ............................................................................................................................... NUT, HEX, M5 x .8 .............................................................................................................. SCREW, STUD, M5 x .8 ...................................................................................................... ARM, ROCKER ................................................................................................................... COLLET ............................................................................................................................... RETAINER, VALVE SPRING ............................................................................................... SPRING, ENGINE VALVE ................................................................................................... ASSEMBLY, CYLINDER HEAD, OHV (INCLUDES ITEMS 12 AND 13) ............................. RING, SNAP .................................................................................................................. GUIDE, VALVE ............................................................................................................... SEAT, SPRING .................................................................................................................... SEAL, VALVE ...................................................................................................................... VALVE, EXHAUST .............................................................................................................. VALVE, INTAKE ................................................................................................................... SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... PLATE ................................................................................................................................. VALVE ................................................................................................................................. PIN ...................................................................................................................................... BOLT, STUD, M8 x 1.25 x 29MM ........................................................................................ SHAFT, ROCKER ............................................................................................................... ROD, PUSH ........................................................................................................................ WASHER, FLAT, M12 .......................................................................................................... CIRCLIP, TYPE E ................................................................................................................ BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. GASKET, HEAD .................................................................................................................. 1 1 2 2 2 2 2 2 2 2 1 2 2 2 2 1 1 1 1 1 2 2 1 2 1 1 6 1 Page 8-9 8 G 18 FE 290 ENGINE 1G TYPICAL 2 PLACES 5 1 CLAMP ONLY 2 yyyyy ;;;;; ;;;;; yyyyy ;;;;; yyyyy ;;;;; yyyyy ;;;;; yyyyy ;;;;; yyyyy ;;;;; yyyyy ;;;;; yyyyy 4 3 7 6 18 17 16 15 14 13 TYPICAL 2 PLACES TYPICAL 3 PLACES 12 11 TYPICAL 2 PLACES 10 20 20 19 9 8 TYPICAL 2 PLACES Page 8-10 TYPICAL 6 PLACES FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1016535 1016538 1016506 1016544 1016564 1016565 1016567 1016584 1016458 1016520 1016446 1016456 1016510 1016494 1016496 1016454 1016472 1016521 1019154-01 1016453 2 3 QTY 4 CONNECTOR, CORD ........................................................................................................ O-RING ............................................................................................................................... CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... PIN ...................................................................................................................................... BEARING, BALL ................................................................................................................. SEAL, CRANKSHAFT ........................................................................................................ BOLT, 2-ENDED, M8 x 1.25 x 69MM .................................................................................. BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. COVER, CRANKCASE ....................................................................................................... GASKET, CRANKCASE COVER ........................................................................................ BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... BRACKET, OIL LEVEL SWITCH ........................................................................................ SENSOR, OIL LEVEL ......................................................................................................... SCREW, CROSS PAN HEAD, M4 x .7 x 8MM .................................................................... BOLT, FLANGED, M5 x .8 x 8MM ....................................................................................... PLATE, OIL FILTER SCREEN ............................................................................................ SCREEN, OIL FILTER ........................................................................................................ CAMSHAFT, COMPLETE ................................................................................................... TAPPET ............................................................................................................................... 1 1 1 1 2 1 1 2 6 1 1 2 1 1 3 2 1 1 1 2 Page 8-11 8 G 18 FE 290 ENGINE 1G 6 3 4 1 2 8 TYPICAL 2 PLACES 3 5 7 7 9 14 16 12 13 12 17 13 TYPICAL 4 PLACES 11 20 TYPICAL 4 PLACES 18 Page 8-12 21 10 15 19 FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 5 5 6 6 6 7 7 1016568 1019155-01 1016558 1016460 1016459-01 1016459-02 1016459-03 1016461-01 1016461-02 1016461-03 1016475-01 1016475-02 8 9 10 11 12 13 14 15 15 15 15 15 15 15 15 15 16 17 18 19 20 21 1016509 1019223-01 1016533 1016532 1016516 1016580 1016562 1016550-01 1016550-02 1016550-03 1016550-04 1016550-05 1016550-06 1016550-07 1016550-08 1016550-09 1016559 1016541 1016547 1016470 1016571 1016469 2 3 QTY 4 SEAL, OIL ........................................................................................................................... CRANKCASE, COMPLETE, OHV ...................................................................................... RING, SNAP ....................................................................................................................... PIN, PISTON ....................................................................................................................... PISTON, STANDARD .......................................................................................................... PISTON, .25MM OVERSIZED ............................................................................................ PISTON, .50MM OVERSIZED ............................................................................................ RING SET, PISTON, STANDARD ....................................................................................... RING SET, PISTON, .25MM OVERSIZED .......................................................................... RING SET, PISTON, .50MM OVERSIZED .......................................................................... ASSEMBLY, CONNECTING ROD, STANDARD (INCLUDES 2 EACH OF ITEM 8) ............ ASSEMBLY, CONNECTING ROD, .50MM UNDERSIZED (INCLUDES 2 EACH OF ITEM 8) ....................................................................................... BOLT, HEX HEAD, M7 x 1 x 36MM ................................................................................ CRANKSHAFT, OHV (INCLUDES ITEMS 10, 11 AND ONE EACH OF ITEM 12) ............. GEAR, HELICAL ............................................................................................................ GEAR, SPUR ................................................................................................................. ASSEMBLY, CONNECTING ROD (INCLUDES ONE EACH OF ITEM 13) .................... BEARING, PLAIN ..................................................................................................... KEY ..................................................................................................................................... SHIM, CRANKSHAFT, 1.13MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.18MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.23MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.28MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.33MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.38MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.43MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.48MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.53MM THICK ............................................................................... SPACER .............................................................................................................................. BOLT, STUD, M6 x 1 x 22MM ............................................................................................. NUT, FLANGED, M6 x 1 ...................................................................................................... SHAFT, GUIDE COUNTERBALANCE ................................................................................ O-RING ............................................................................................................................... WEIGHT, COUNTERBALANCE .......................................................................................... 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 A/R A/R A/R A/R A/R A/R A/R A/R A/R 1 4 4 1 1 1 Page 8-13 8 G 18 FE 350 ENGINE 1G TYPICAL 6 PLACES FOR ITEM 5 3 4 4 2 1 5 TYPICAL 4 PLACES FOR ITEM 16 16 15 TYPICAL 4 PLACES FOR ITEM 3 4 TYPICAL 2 PLACES FOR ITEM 6 6 TYPICAL 2 PLACES 2 7 CARBURETOR REMOVED FOR CLARITY 1 8 TYPICAL 2 PLACES 2 1 14 9 7 13 TYPICAL 2 PLACES FOR ITEM 9 4 12 10 Page 8-14 11 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1019538-01 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 1016507 1016512 1017474 1016456 1019161-01 1017476 1016547 1017500 1017475 1016539 1017486 FE 350 OHV GASOLINE ENGINE, COMPLETE (CLOCKWISE ROTATION) WITH CARBURETOR (WITH COMPRESSION RELEASE) (CARRYALL II PLUS AND VI) (DOES NOT INCLUDE ITEMS 13 - 16)........................................................................................................ FE 350 OHV GASOLINE ENGINE, COMPLETE (CLOCKWISE ROTATION) WITH CARBURETOR (WITHOUT COMPRESSION RELEASE) (CARRYALL TURF II) (DOES NOT INCLUDE ITEMS 13 - 16)........................................................................................................ BOLT, 2-ENDED, M6 x 1 x 29MM ....................................................................................... WASHER, FLAT, 6 MM ........................................................................................................ SHROUD, CYLINDER HEAD .............................................................................................. BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... HOUSING, FAN .................................................................................................................. SHROUD, LOWER CYLINDER ........................................................................................... NUT, FLANGE, M6 x 1 ........................................................................................................ SPACER .............................................................................................................................. SHROUD, UPPER CYLINDER ........................................................................................... O-RING ............................................................................................................................... TUBE, OIL FILLER ............................................................................................................. 12 13 14 15 16 1016531 1011114 1015332 1015649 1015969 DIPSTICK ........................................................................................................................... NUT, M6 x 1 ............................................................................................................................. WIRE ASSEMBLY, #10 BLACK ............................................................................................... SHROUD, FAN ........................................................................................................................ SCREW, PAN HEAD, M6 x 1 x 14 MM .................................................................................... 1019538-02 8 G 1 1 3 3 1 14 1 1 3 2 1 1 1 1 1 1 1 4 Page 8-15 FE 350 ENGINE 18 1G 11 12 10 13 9 8 7 TYPICAL 2 PLACES 1 2 TYPICAL 3 PLACES 3 15 16 ;yy; y; 24 4 23 22 20 14 5 21 6 19 25 17 18 TYPICAL 2 PLACES Page 8-16 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1019162-01 1019163-01 1017448 1017467 1017490 1017455 1016562 1016455 1019092-01 1016578 1016588 1017463 1018811-01 1016445 1019094-01 1016579 1012981 1016456 1016586 1019095-01 1016497 1016544 1016561 1016587 1019093-01 2 3 QTY 4 FLYWHEEL ......................................................................................................................... FAN, FLYWHEEL—GREY .................................................................................................. SCREW, FLANGED HEX HEAD, M6 x 1 x 10MM .............................................................. NUT, HEX, 18MM FINE ....................................................................................................... WASHER, FLAT, 18MM ....................................................................................................... PLATE, FLYWHEEL FAN .................................................................................................... KEY ..................................................................................................................................... SCREW, HEX HEAD FLANGED, M5 x 0.8 x 25MM ........................................................... COIL, IGNITION (WITH INTERNAL IGNITER) ................................................................... GROMMET ......................................................................................................................... TUBE, 7MM I.D. x 10MM O.D. x 70MM LG. ......................................................................... ASSEMBLY, PLUG CAP ..................................................................................................... PLUG, SPARK ..................................................................................................................... BRACKET, RPM LIMITER .................................................................................................. LIMITER, RPM .................................................................................................................... BAND, RPM LIMITER MOUNT ........................................................................................... CLAMP ................................................................................................................................ SCREW, FLANGED HEX HEAD, M6 x 1 x 12MM .............................................................. DAMPER ............................................................................................................................. CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD, M5 x .08 x 8MM .................................................................. SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x 12MM .............................................. CLAMP ................................................................................................................................ CLAMP ................................................................................................................................ WIRE, LEAD ....................................................................................................................... 1 1 3 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Page 8-17 8 G 18 FE 350 ENGINE 1G 16 15 5 14 4 13 TYPICAL 2 PLACES 10 11 9 3 12 TYPICAL 2 PLACES 6 2 7 1 8 TYPICAL 6 PLACES Page 8-18 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1016467 1016502 1016457 1017507 1016570 1016432 1016576 1017456 1017460 1017442 1016473 1016482-03 1017458 1016429 1016537 1016581 2 3 QTY 4 OIL FILTER ......................................................................................................................... BRACKET, OIL FILTER ....................................................................................................... BOLT, FLANGED HEX HEAD, M6 x 1 x 40MM ................................................................... PLUG .................................................................................................................................. O-RING ............................................................................................................................... GASKET, DRAIN PLUG ...................................................................................................... PLUG, DRAIN ..................................................................................................................... SCREW, FLANGED HEX HEAD, M6 x 1 x 12MM .............................................................. COVER, PUMP ................................................................................................................... GASKET, OIL PUMP ........................................................................................................... PLATE, OIL PUMP .............................................................................................................. PUMP, OIL, AND ROTOR ................................................................................................... FILTER ................................................................................................................................ SEAT, VALVE ....................................................................................................................... BALL, STEEL, PRESSURE RELIEF .................................................................................. SPRING .............................................................................................................................. 1 1 2 2 1 1 1 6 1 1 1 1 1 1 1 1 Page 8-19 8 G 18 FE 350 ENGINE 1G 5 TYPICAL 2 PLACES 6 7 8 1 12 2 13 10 11 EXHAUST 14 16 INTAKE 17 15 18 20 9 TYPICAL 2 PLACES AT EXHAUST CONNECTION TYPICAL 2 PLACES 19 3 4 TYPICAL 2 PLACES 21 23 24 22 TYPICAL 2 PLACES Page 8-20 25 TYPICAL 6 PLACES 26 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1016442 1016436 1016583 1016569 1017446 1016450 1016449 1017473 1017435 1016560 1016519 1016479 1016566 1017445 1017444 1016544 1016474 1016483 1016563 1016489 1016452 1017454 1016549 1016517 1016458 1017434 2 3 QTY 4 CASE, ROCKER ................................................................................................................. GASKET, ROCKER CASE .................................................................................................. BOLT, FLANGED, M6 x 1 x 35MM ...................................................................................... O-RING ............................................................................................................................... ARM, ROCKER ................................................................................................................... COLLET .............................................................................................................................. RETAINER, VALVE SPRING ............................................................................................... SPRING, ENGINE VALVE ................................................................................................... ASSEMBLY, CYLINDER HEAD, FE 350 (INCLUDES ITEMS 10 AND 11) ......................... RING, SNAP .................................................................................................................. GUIDE, VALVE ............................................................................................................... SEAT, SPRING .................................................................................................................... SEAL, VALVE ...................................................................................................................... VALVE, EXHAUST .............................................................................................................. VALVE, INTAKE ................................................................................................................... SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... PLATE ................................................................................................................................. VALVE ................................................................................................................................. PIN ...................................................................................................................................... BOLT, STUD, M8 x 1.25 x 29MM ........................................................................................ SHAFT, ROCKER ............................................................................................................... ROD, PUSH ........................................................................................................................ WASHER, FLAT, M12 .......................................................................................................... CIRCLIP, TYPE-E ................................................................................................................ BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. GASKET, HEAD .................................................................................................................. 1 1 2 2 2 4 2 2 1 2 2 2 2 1 1 1 1 1 2 2 1 2 1 1 6 1 Page 8-21 8 G FE 350 ENGINE 18 1G TYPICAL 2 PLACES 7 2 3 4 yyyyyy ;;;;;; ;;;;;; yyyyyy ;;;;;; yyyyyy ;;;;;; yyyyyy ;;;;;; yyyyyy ;;;;;; yyyyyy ;;;;;; yyyyyy ;;;;;; yyyyyy 6 5 1 8 9 20 19 18 17 TYPICAL 2 PLACES TYPICAL 3 PLACES 16 23 15 14 13 TYPICAL 2 PLACES 24 12 24 22 11 10 TYPICAL 2 PLACES Page 8-22 TYPICAL 6 PLACES 21 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 21 22 22 23 24 1016538 1017508 1016535 1016538 1016506 1016544 1016564 1017487 1017504 1016584 1017514 1017472 1017443 1017513 1016510 1016494 1016496 1016454 1016472 1016521 1017518-01 1017518-02 1017518-03 1019476-01 1019159-01 1017511 1017447 2 3 QTY 4 O-RING ............................................................................................................................... PLUG .................................................................................................................................. CONNECTOR, OIL SENDING UNIT .................................................................................. O-RING ............................................................................................................................... CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ...................................... PIN ...................................................................................................................................... BEARING, CRANKSHAFT ................................................................................................. SEAL, CRANKSHAFT ........................................................................................................ BOLT, 2-ENDED FLANGED, M8 x 1.25 x 69MM ................................................................ BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. COVER, CRANKCASE ....................................................................................................... GASKET, CRANKCASE COVER ........................................................................................ BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... BRACKET, OIL LEVEL SWITCH ........................................................................................ SENSOR, OIL LEVEL .......................................................................................................... SCREW, CROSS PAN HEAD, M4 x .7 x 8MM .................................................................... BOLT, FLANGED, M5 x .8 x 8MM ....................................................................................... PLATE, OIL FILTER SCREEN ............................................................................................ SCREEN, OIL FILTER ........................................................................................................ SHIM, 0.3MM THICK .......................................................................................................... SHIM, 0.4MM THICK .......................................................................................................... SHIM, 0.5MM THICK .......................................................................................................... CAMSHAFT (WITHOUT COMPRESSION RELEASE) (CARRYALL TURF II ONLY) ......... CAMSHAFT (INCLUDES ITEM 23) (CARRYALL II PLUS AND VI) .................................... SPRING ......................................................................................................................... LIFTER, HYDRAULIC ......................................................................................................... 1 1 1 1 1 1 2 1 1 2 6 1 1 2 1 1 3 2 1 1 A/R A/R A/R 1 1 1 2 Page 8-23 8 G 18 FE 350 ENGINE 1G 6 3 4 1 TYPICAL 2 PLACES 2 8 3 5 7 7 9 10 15 13 13 16 TYPICAL 4 PLACES 12 21 19 TYPICAL 4 PLACES 17 Page 8-24 18 11 20 14 FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 5 6 6 7 7 1017503 1019160-01 1017502 1017450 1017449-01 1017449-02 1017451-01 1017451-02 1017457-01 1017457-02 8 9 10 11 12 13 14 14 14 14 14 14 14 14 14 14 14 15 16 17 18 19 20 21 1017512 1019223-02 1016562 1017484 1017483 1017471 1017733-01 1017733-02 1017733-03 1017733-04 1017733-05 1017733-06 1017733-07 1017733-08 1017733-09 1017733-10 1017733-11 1017501 1016541 1016547 1016470 1016571 1017453 1017510 2 3 QTY 4 SEAL, OIL ........................................................................................................................... CRANKCASE, COMPLETE, FE 350 (CLOCKWISE ROTATION) ....................................... RING, SNAP ....................................................................................................................... PIN, PISTON ....................................................................................................................... PISTON, STANDARD........................................................................................................... PISTON, .50MM OVERSIZED ............................................................................................ RING SET, PISTON, STANDARD ....................................................................................... RING SET, PISTON, .50MM OVERSIZED .......................................................................... ASSEMBLY, CONNECTING ROD, STANDARD (INCLUDES 2 EACH OF ITEM 8) ............ ASSEMBLY, CONNECTING ROD, .50MM UNDERSIZED) (INCLUDES 2 EACH OF ITEM 8) ....................................................................................... BOLT, HEX HEAD, M7 x 1 x 36MM ................................................................................ CRANKSHAFT, COMPLETE, FE 350 (INCLUDES ITEMS 10 - 13) ................................... KEY ................................................................................................................................ GEAR, HELICAL ............................................................................................................ GEAR, SPUR ................................................................................................................. ROD, CONNECTING ..................................................................................................... SHIM, CRANKSHAFT, 1.18MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.25MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.32MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.39MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.46MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.53MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.60MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.67MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.74MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.11MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.81MM THICK ............................................................................... SPACER .............................................................................................................................. BOLT, STUD, M6 x 1 x 22MM ............................................................................................. NUT, FLANGED, M6 x 1 ..................................................................................................... SHAFT, GUIDE COUNTERBALANCE ................................................................................ O-RING ............................................................................................................................... WEIGHT, COUNTERBALANCE (INCLUDES ITEM 21) ..................................................... BEARING ....................................................................................................................... 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 2 A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R 1 4 4 1 1 1 1 Page 8-25 8 G 18 FE 350 ENGINE 3 1 2 1G TYPICAL 2 PLACES 4 TYPICAL 2 PLACES FR O VE NT O HIC F LE REFERENCE ENGINE SECTION 8 TYPICAL 4 PLACES 5 Clu 9 TYPICAL 2 PLACES bC ar 12 13 10 6 TYPICAL 2 PLACES 10 6 7 TYPICAL 4 PLACES 6 11 14 8 15 TYPICAL 4 PLACES 16 17 Clu bC ar TYPICAL 2 PLACES 18 9 10 TYPICAL 4 PLACES Page 8-26 REFERENCE UNITIZED TRANSAXLE SECTION 12 ENGINE MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0007473 0001241 1018646-01 0007818 1012164 1013924 1018346-01 1018271-01 1018330-01 1018848-01 1018333-01 1018332-01 1018321-01 1018326-01 1018329-01 1012571 1018559-01 1018327-01 2 3 QTY 4 NUT, NYLON LOCK, 5/16 - 18 (CARRYALL I ONLY) .............................................................. WASHER, FLAT, 5/16 - 18 (CARRYALL I ONLY) ..................................................................... RETAINER, SNUBBER (CARRYALL I ONLY) ......................................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 1/2 (CARRYALL I ONLY) ..................................................... SNUBBER ............................................................................................................................... NUT, HEX LOCK, 5/16 - 24, UNF ........................................................................................... BRACKET, SNUBBER ............................................................................................................. PLATE, MOUNTING ................................................................................................................ NUT, FLANGE, M8 x 1.25 ....................................................................................................... SCREW, HEX WASHER, 5/16 -24 x 7/8 .................................................................................. SCREW, HEX HEAD CAP, M10 x 1.25 x 30MM ...................................................................... STUD, M8 x 1.25 ..................................................................................................................... SPACER .................................................................................................................................. STIFFENER, DRIVE CLUTCH SIDE ....................................................................................... NUT, FLANGE, M10 x 1.25 ..................................................................................................... WASHER, HEAVY FLAT, 5/16 ................................................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 43MM ........................................................................ STIFFENER, FLYWHEEL SIDE .............................................................................................. 2 2 1 2 1 10 1 1 6 10 4 2 2 1 4 4 4 1 Page 8-27 8 G 18 FE 290 ENGINE 1G Page 8-28 FUEL, INTAKE, AND GOVERNOR SYSTEMS 9 G TANK CONNECTION 16 19 24 6 1G 25 4 FRAME CONNECTION 5 27 2 24 3 9 11 27 10 7 8 1 26 LOCATION OF FUEL PUMP MOUNTING BRACKET— CARRYALL I AND VI LOCATION OF FUEL PUMP MOUNTING BRACKET— CARRYALL II, TURF II, AND II PLUS SEE ABOVE GAS TANK FUEL PICKUP TUBE 29 TYPICAL 2 PLACES 14 19 28 28 17 18 28 12 15 19 13 17 21 TYPICAL 2 PLACES 19 14 23 20 28 20 21 22 6 21 TO ENGINE CRANKCASE Page 9-2 FUEL SYSTEM ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 1016004 1015188 1014535 1015143 1015139 1015137 1016059 1018244-01 1018969-01 1014928 1019553-01 1014523 1014524 1012285 1019295-01 N/A 1013134-01 1013684 1012293 1013692 1012649 1014522 1013687 1014116 1013746 1019556-01 1011988 1013134-02 1019183-01 2 3 QTY 4 KIT, FUEL TANK, WITH SENDING UNIT (INCLUDES ITEMS 2 - 9) ....................................... CAP, FUEL TANK, NONVENTED (INCLUDES ITEM 3) .................................................... GASKET, FUEL CAP ..................................................................................................... ASSEMBLY, FUEL TANK VENT .......................................................................................... GROMMET, INSULATION ................................................................................................... LINE, BULK VENT (AVAILABLE BY THE FOOT) ............................................................... CLIP, STUD ......................................................................................................................... BARB, VENT ....................................................................................................................... VALVE, FUEL PICKUP TUBE WITH SHUT-OFF ................................................................ ASSEMBLY, REAR FUEL STRAP ........................................................................................... ASSEMBLY, FRONT FUEL STRAP ......................................................................................... PUMP, FUEL IMPULSE ............................................................................................................ KIT, REBUILD, FUEL IMPULSE PUMP.................................................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... BRACKET, FUEL PUMP MOUNTING ..................................................................................... WIRE ASSEMBLY, #16 BLACK ............................................................................................... CLAMP, HOSE (BLACK) .......................................................................................................... FILTER , PRIMARY FUEL (WHITE) ........................................................................................ LINE, BULK FUEL (YELLOW) ................................................................................................. LINE, BULK FUEL (BLACK) .................................................................................................... CLAMP, HOSE (RED) .............................................................................................................. FILTER, SECONDARY FUEL (BLUE) ..................................................................................... CLAMP, HOSE, 3/8 .................................................................................................................. NUT, U-TYPE SPEED, 1/4 - 20 ............................................................................................... CLAMP, HOSE (GREY) ........................................................................................................... T-FITTING ............................................................................................................................... SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2 ...................................................................... CLAMP, HOSE (GREEN) ........................................................................................................ CLAMP, WIRE .......................................................................................................................... 1 1 1 1 1 A/R 1 1 1 1 1 1 1 4 1 1 2 1 A/R A/R 3 1 1 3 1 1 3 4 1 Page 9-3 9 G 19 1G 2 3 1 4 5 8 6 9 7 10 11 Page 9-4 CARBURETOR ASSEMBLY, FE 290 ENGINE— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 1019056-01 1016501 N/A 1019731-01 1016486 1019732-01 7 7 7 7 7 8 9 10 11 1016425-82 1016425-80 1016425-78 1016425-75 1016425-72 1016437 1017461 1016499 1016585 2 3 QTY 4 ASSEMBLY, CARBURETOR (INCLUDES ITEMS 2 - 11) ....................................................... ASSEMBLY, IDLE SCREW ................................................................................................. ASSEMBLY, PILOT AIR SCREW ........................................................................................ JET, PILOT, #40 .................................................................................................................. ASSEMBLY, FLOAT ............................................................................................................. NOZZLE, MAIN ................................................................................................................... STANDARD JETTING: JET, MAIN, 0 - 3,000 FEET ................................................................................................. JET, MAIN, 3,000 - 5,000 FEET .......................................................................................... JET, MAIN, 5,000 - 8,000 FEET .......................................................................................... JET, MAIN, 8,000 - 10,000 FEET ........................................................................................ JET, MAIN, 10,000 FEET AND ABOVE .............................................................................. GASKET, FLOAT CHAMBER .............................................................................................. ASSEMBLY, FLOAT CHAMBER (INCLUDES ITEM 10) ..................................................... ASSEMBLY, SCREW ..................................................................................................... ASSEMBLY, BOLT ............................................................................................................... 1 1 1 1 1 1 A/R A/R A/R A/R A/R 1 1 1 1 Page 9-5 9 G 19 1G 2 3 1 4 5 8 6 9 7 10 11 Page 9-6 CARBURETOR ASSEMBLY, FE 350 ENGINE— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 1019059-01 1016501 N/A 1019731-01 1016486 1019733-01 7 7 7 7 7 8 9 10 11 1016425-85 1016425-82 1016425-80 1016425-78 1016425-75 1016437 1017461 1016499 1016585 2 3 QTY 4 ASSEMBLY, CARBURETOR (INCLUDES ITEMS 2 - 11) ....................................................... ASSEMBLY, IDLE SCREW ................................................................................................. ASSEMBLY, PILOT AIR SCREW ........................................................................................ JET, PILOT, #40 .................................................................................................................. ASSEMBLY, FLOAT ............................................................................................................. NOZZLE, MAIN ................................................................................................................... STANDARD JETTING: JET, MAIN, 0 - 3,000 FEET ................................................................................................. JET, MAIN, 3,000 - 5,000 FEET .......................................................................................... JET, MAIN, 5,000 - 8,000 FEET .......................................................................................... JET, MAIN, 8,000 - 10,000 FEET ........................................................................................ JET, MAIN, 10,000 FEET AND ABOVE .............................................................................. GASKET, FLOAT CHAMBER .............................................................................................. ASSEMBLY, FLOAT CHAMBER (INCLUDES ITEM 10) ..................................................... ASSEMBLY, SCREW ..................................................................................................... ASSEMBLY, BOLT ............................................................................................................... 1 1 1 1 1 1 A/R A/R A/R A/R A/R 1 1 1 1 Page 9-7 9 G 19 8 1G 7 5 6 yyy ;;; ;;; ;;;yyy yyy ;;; yyy ;;;; yyyy ;;;; yyyy 1 2 3 4 10 11 13 15 yyy ;;; ;;; yyy ;;; yyy 13 18 TYPICAL 2 PLACES Page 9-8 19 9 16 14 17 12 CARBURETOR INSTALLATION ITEM PART NO. DESCRIPTION 1 1 2 3 3 1016440 1016481-02 1016439 1019734-01 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 1016444 1018202-01 1016103 1011697 1018876-01 1013746 1016441 1016582 1019056-01 1019059-01 1017466 1015137 1016572 1016438 1016480 1016490-02 1016547 2 3 QTY 4 GASKET, INSULATOR ............................................................................................................ INSULATOR, CARBURETOR .................................................................................................. GASKET, CARBURETOR INSULATOR TO THROTTLE BRACKET (CARRYALL I AND II) .... GASKET, CARBURETOR INSULATOR TO THROTTLE BRACKET (CARRYALL TURF II, II PLUS AND VI) ...................................................................................................................... BRACKET, THROTTLE ............................................................................................................ GUARD, GOVERNOR (CARRYALL I AND II) .......................................................................... SCREW, PAN/TORX HEAD SELF-TAPPING, #6 - 32 x 1/4 (CARRYALL I AND II) ................. WASHER, FLAT, 5/16 (CARRYALL I AND II) ........................................................................... NUT, NYLON LOCK, M6 x 1 (CARRYALL I AND II) ................................................................ CLAMP, HOSE ......................................................................................................................... GASKET, THROTTLE BRACKET TO CARBURETOR ............................................................ SPRING, THROTTLE RETURN .............................................................................................. ASSEMBLY, CARBURETOR (CARRYALL I AND II) ................................................................ ASSEMBLY, CARBURETOR (CARRYALL TURF II, II PLUS AND VI) ..................................... CLAMP, HOSE ......................................................................................................................... LINE, BULK VENT ................................................................................................................... TUBE, CRANKCASE VENT ..................................................................................................... GASKET, CARBURETOR TO INTAKE MANIFOLD ................................................................. PIPE, INTAKE .......................................................................................................................... SCREW, 2-ENDED STUD, M6 x 1 x 90MM ............................................................................. NUT, FLANGED, M6 x 1 .......................................................................................................... 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 2 2 Page 9-9 9 G 19 7 1G 6 5 4 TYPICAL 2 PLACES 3 1 2 7 8 9 10 7 8 12 13 14 11 9 Page 9-10 6 GOVERNOR AND ACCELERATOR CABLES ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1018325-01 1018324-01 1018324-02 1013700 1016546 1018323-01 1012285 1016202 1015408 1014413 1018322-01 1015845 1019035-01 0007174 1011697 2 3 QTY 4 CABLE, ACCELERATOR ........................................................................................................ CABLE, GOVERNOR (CARRYALL I AND II) ........................................................................... CABLE, GOVERNOR (CARRYALL TURF II , II PLUS AND VI) ............................................... CLAMP, CABLE RETAINING ................................................................................................... NUT, FLANGED HEX, M8 x 1.25 ............................................................................................ BRACKET, ACCELERATOR SUPPORT .................................................................................. SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... E-RING ..................................................................................................................................... PIN, GOVERNOR CABLE CLEVIS ......................................................................................... PIN, HAIR SPRING COTTER, 1/8 I.D. x 5/8 ............................................................................ BRACKET, SUPPORT .............................................................................................................. BRACKET, GOVERNOR CABLE ENGINE .............................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 24 MM ....................................................................... WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. 1 1 1 2 2 1 4 3 2 2 1 1 1 1 1 Page 9-11 9 G 19 17 REFERENCE CARBURETOR 1G 18 5 16 6 15 7 1 TYPICAL 2 PLACES 4 2 15 3 8 TYPICAL 3 PLACES 11 17 12 19 9 20 21 10 22 13 14 23 24 25 TYPICAL 3 PLACES 26 27 27 Page 9-12 TYPICAL 2 PLACES INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY— CARRYALL I ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1018215-01 1018043-01 1018817-01 1019257-01 1019728-01 1018130-01 1019176-01 1019443-01 N/A N/A N/A 1018123-01 1015426 1018119-01 1019215-01 1019713-01 1018371-01 1018503-01 1019177-01 1018057-01 1018115-01 1018562-01 1018114-01 0000332 1015752 1019581-01 0001606 0000183 1019710-01 2 3 QTY 4 ASSEMBLY, AIR BOX (INCLUDES ITEMS 1 - 14) .................................................................. SCREW, HI-LO HEX HEAD, #8 - 1/2 .................................................................................. WASHER, STAINLESS STEEL, #8 ..................................................................................... LATCH, WIRE ..................................................................................................................... ASSEMBLY, AIR BOX TOP (INCLUDES ITEMS 5 - 11) ..................................................... E-CLIP ........................................................................................................................... LEVER, CHOKE ............................................................................................................ DECAL, SERVICE ......................................................................................................... O-RING, 5/16 (RED) ...................................................................................................... O-RING, 3/8 (GREEN) ................................................................................................... VALVE, CHOKE ............................................................................................................. SPRING, RETURN ........................................................................................................ FILTER, AIR ........................................................................................................................ BOTTOM, AIR BOX ............................................................................................................. SEAL, INTAKE .................................................................................................................... CLAMP, HOSE (AIR INTAKE) .................................................................................................. HOSE, INTAKE ........................................................................................................................ SCREW, HI-LO, #12 x 1/2 ....................................................................................................... POSITIONER, CHOKE ............................................................................................................ ASSEMBLY, CHOKE BUTTON (INCLUDES ITEMS 20, 21 AND 22) ...................................... GUIDE, CHOKE LEVER ..................................................................................................... SPRING, COMPRESSION ................................................................................................. LEVER, CHOKE ................................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................. SCREW, HI-LO, #12 - 16 x 5/8 ................................................................................................ ASSEMBLY, AIR DUCT ........................................................................................................... RIVET, POP, 3/16 .................................................................................................................... WASHER, FLAT, #10 ............................................................................................................... AIR DUCT REPAIR KIT (NOT SHOWN) .................................................................................. 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 3 3 1 2 4 A/R Page 9-13 9 G REFERENCE CARBURETOR 19 17 15 5 16 6 1G 15 1 TYPICAL 2 PLACES 18 2 7 4 3 8 TYPICAL 3 PLACES 21 9 20 11 12 19 10 13 14 TYPICAL 2 PLACES 26 25 22 23 TYPICAL 3 PLACES 24 26 TYPICAL 2 PLACES Page 9-14 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY— CARRYALL II, TURF II AND II PLUS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1018215-01 1018043-01 1018817-01 1019257-01 1019728-01 1018130-01 1019176-01 1019443-01 N/A N/A N/A 1018123-01 1015426 1018119-01 1019215-01 1019713-01 1018371-01 1018043-01 1019268-01 0001631 0000183 1012438 0000332 1015752 1019581-02 0001606 0000183 1019710-01 2 3 QTY 4 ASSEMBLY, AIR BOX (INCLUDES ITEMS 1 - 14) .................................................................. SCREW, HI-LO HEX HEAD, #8 - 1/2 .................................................................................. WASHER, STAINLESS STEEL, #8 ..................................................................................... LATCH, WIRE ..................................................................................................................... ASSEMBLY, AIR BOX TOP (INCLUDES ITEMS 5 - 11) ..................................................... E-CLIP ........................................................................................................................... LEVER, CHOKE ............................................................................................................ DECAL, SERVICE ......................................................................................................... O-RING, 5/16 (RED) ...................................................................................................... O-RING, 3/8 (GREEN) ................................................................................................... VALVE, CHOKE ............................................................................................................. SPRING, RETURN ........................................................................................................ FILTER, AIR ........................................................................................................................ BOTTOM, AIR BOX ............................................................................................................. SEAL, INTAKE .................................................................................................................... CLAMP, HOSE (AIR INTAKE) .................................................................................................. HOSE, INTAKE ........................................................................................................................ SCREW, HEX HEAD HI-LO, #8 x 1/2 ...................................................................................... CABLE, CHOKE ...................................................................................................................... SCREW, PAN HEAD, #10 - 24 x 3/4 ........................................................................................ WASHER, #10 ......................................................................................................................... NUT, NYLON LOCK, #10 - 24 ................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................. SCREW, HI-LO, #12 - 16 x 5/8 ................................................................................................ ASSEMBLY, AIR DUCT ........................................................................................................... RIVET, POP, 3/16 .................................................................................................................... WASHER, FLAT, #10 ............................................................................................................... AIR DUCT REPAIR KIT (NOT SHOWN) .................................................................................. 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 3 3 3 3 1 2 4 A/R Page 9-15 9 G 19 REFERENCE CARBURETOR 17 15 5 16 1G 15 1 TYPICAL 2 PLACES 6 18 7 2 4 3 8 TYPICAL 3 PLACES 9 21 11 10 20 12 19 TYPICAL 2 PLACES 23 13 22 14 27 24 25 28 26 29 28 Page 9-16 TYPICAL 3 PLACES INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY— CARRYALL VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 1018215-01 1018043-01 1018817-01 1019257-01 1019728-01 1018130-01 1019176-01 1019443-01 N/A N/A N/A 1018123-01 1015426 1018119-01 1019215-01 1019713-01 1018371-01 1018043-01 1019268-02 0001631 0000183 1012438 1015139 0008168 0000332 1015752 1018113-01 0007973 0000183 1018257-01 1019710-01 2 3 QTY 4 ASSEMBLY, AIR BOX (INCLUDES ITEMS 1 - 14) .................................................................. SCREW, HI-LO HEX HEAD, #8 - 1/2 .................................................................................. WASHER, STAINLESS STEEL, #8 ..................................................................................... LATCH, WIRE ..................................................................................................................... ASSEMBLY, AIR BOX TOP (INCLUDES ITEMS 5 - 11) ..................................................... E-CLIP ........................................................................................................................... LEVER, CHOKE ............................................................................................................ DECAL, SERVICE ......................................................................................................... O-RING, 5/16 (RED) ...................................................................................................... O-RING, 3/8 (GREEN) ................................................................................................... VALVE, CHOKE ............................................................................................................. SPRING, RETURN ........................................................................................................ FILTER, AIR ........................................................................................................................ BOTTOM, AIR BOX ............................................................................................................. SEAL, INTAKE .................................................................................................................... CLAMP, HOSE (AIR INTAKE) .................................................................................................. HOSE, INTAKE ........................................................................................................................ SCREW, HEX HEAD HI-LO, #8 x 1/2 ...................................................................................... CABLE, CHOKE ...................................................................................................................... SCREW, PAN HEAD, 10 - 24 x 3/4 .......................................................................................... WASHER, #10 ......................................................................................................................... NUT, NYLON LOCK, #10 - 24 ................................................................................................. GROMMET .............................................................................................................................. TIE, WIRE ................................................................................................................................ WASHER, FLAT, 1/4 ................................................................................................................. SCREW, HI-LO, #12 - 16 x 5/8 ................................................................................................ DUCT, AIR ............................................................................................................................... RIVET, POP, 3/16 .................................................................................................................... WASHER, FLAT, #10 ............................................................................................................... BRACKET, RETAINING ........................................................................................................... AIR DUCT REPAIR KIT (NOT SHOWN) .................................................................................. 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 3 3 1 2 3 3 1 2 4 1 A/R Page 9-17 9 G 19 1G Page 9-18 EXHAUST SYSTEM 10 G 110 1G 7 8 y ; ; y ;y y ; 6 9 12 10 11 TYPICAL 2 PLACES 5 1 4 3 2 TYPICAL 2 PLACES REFERENCE ENGINE MOUNTING SECTION 8 Page 10-2 EXHAUST SYSTEM, FE 290— CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1018593-01 1015814 0000332 0000451 0007847 1017689 1019035-01 0007174 1015075 1012528 1013734 1015330 2 3 QTY 4 SYSTEM, EXHAUST ............................................................................................................... BRACKET, MUFFLER MOUNTING ......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. SCREW, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ CLAMP, MUFFLER .................................................................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 24MM ........................................................................ WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. NUT, HEX, M8 x 1.25 .............................................................................................................. WASHER, LOCK, 8MM ........................................................................................................... GASKET, EXHAUST ................................................................................................................ 1 1 2 2 2 1 1 1 1 2 2 1 Page 10-3 10 G 110 1G 7 8 9 y ; ; y ;y y ; 6 12 10 11 TYPICAL 2 PLACES 1 5 4 2 3 TYPICAL 2 PLACES REFERENCE ENGINE MOUNTING SECTION 8 Page 10-4 EXHAUST SYSTEM, FE 350— CARRYALL TURF II, II PLUS AND VI ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1018594-01 1015814 0000332 0000451 0007847 1017689 1019035-01 0007174 1011697 1012528 1013734 1016904 2 3 QTY 4 SYSTEM, EXHAUST ............................................................................................................... BRACKET, MUFFLER MOUNTING ......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. SCREW, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ CLAMP, MUFFLER .................................................................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 24MM ........................................................................ WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. NUT, HEX, M8 x 1.25 .............................................................................................................. WASHER, LOCK, 8MM ........................................................................................................... GASKET, EXHAUST ................................................................................................................ 1 1 2 2 2 1 1 1 1 2 2 1 Page 10-5 10 G 110 1G Page 10-6 TORQUE CONVERTER 11 G 111 1G 4 1 3 2 5 10 6 7 14 8 14 9 13 16 12 11 19 18 21 20 Page 11-2 17 15 DRIVE CLUTCH ITEM PART NO. DESCRIPTION 1 1 2 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 1018339-02 1018339-04 1016801 1019298-01 1017383-01 N/A N/A 1014049 1014050 1014051 1016901 1016289 1014057 1014059 1019256-01 1014453 1014058 1014056 1014052 N/A 1014055 1016203 1017188 1019167-01 1019165-01 1017328 2 3 QTY 4 ASSEMBLY, DRIVE CLUTCH (CARRYALL I, II AND TURF II) (INCLUDES ITEMS 1 - 17) ... ASSEMBLY, DRIVE CLUTCH (CARRYALL II PLUS AND VI) (INCLUDES ITEMS 1 - 17) ...... KIT, DRIVE CLUTCH WEIGHT ........................................................................................... ASSEMBLY, FIXED FACE (CARRYALL I, II AND TURF II) (INCLUDES ITEMS 3 AND 4) ASSEMBLY, FIXED FACE (CARRYALL II PLUS AND VI) (INCLUDES ITEMS 3 AND 4) ... PULLEY .......................................................................................................................... SCREW, WASHER HEAD HEX MACHINE ................................................................... BEARING, IDLER ............................................................................................................... SPRING, RETAINER ........................................................................................................... SPRING, DRIVE CLUTCH—BLACK (CARRYALL I, II AND TURF II) ................................. SPRING, DRIVE CLUTCH—DARK GREEN (CARRYALL II PLUS AND VI) ...................... SPACER, FIXED FACE SHAFT .......................................................................................... RING, RETAINING .............................................................................................................. ASSEMBLY, DRIVE HUB .................................................................................................... PLUG, DRIVE CLUTCH ...................................................................................................... KIT, DRIVE CLUTCH BUTTON ........................................................................................... WASHER, THRUST ............................................................................................................ RING, SPIRAL BACK-UP ................................................................................................... ASSEMBLY, MOVABLE FACE (INCLUDES ITEMS 16 AND 17) ........................................ BUSHING ....................................................................................................................... RETAINER ..................................................................................................................... BELT, DRIVE (CARRYALL I) .................................................................................................... BELT, DRIVE (CARRYALL II, TURF II, II PLUS AND VI) ......................................................... BELT, STARTER/GENERATOR ............................................................................................... SCREW, HEX HEAD CAP (LEFT HAND THREADS), 3/8 - 24 x 5 1/2 ................................... WASHER, MOUNTING—GREEN ........................................................................................... 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Page 11-3 11 G 111 1G 8 6 7 5 4 3 2 9 12 11 1 10 Page 11-4 DRIVEN CLUTCH ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 5 6 7 8 9 10 10 11 12 1018340-01 1018340-03 1014080 1014078 1017686 1018362-01 1018362-02 1014454 1014072 1014070 1018334-01 1016203 1017188 0007173 1017327 2 3 QTY 4 ASSEMBLY, DRIVEN CLUTCH (INCLUDES ITEMS 2 - 8) (CARRYALL I, II, TURF II AND VI) ASSEMBLY, DRIVEN CLUTCH (INCLUDES ITEMS 2 - 8) (CARRYALL II PLUS ONLY) ........ RING, RETAINING .............................................................................................................. KEY ..................................................................................................................................... CAM .................................................................................................................................... SPRING—GREEN (CARRYALL I, II, TURF II AND VI) ....................................................... SPRING—PURPLE (CARRYALL II PLUS ONLY) ............................................................... KIT, BUTTON (INCLUDES 3 BUTTONS AND 3 SCREWS) ............................................... ASSEMBLY, MOVEABLE FACE, WITH BUSHING ............................................................. ASSEMBLY, FIXED FACE ................................................................................................... KEY, SQUARE TRANSMISSION ............................................................................................. BELT, DRIVE (CARRYALL I ONLY) ......................................................................................... BELT, DRIVE (CARRYALL II, TURF II, II PLUS AND VI) ......................................................... SCREW, HEX HEAD CAP, 5/16 - 18 x 3/4 .............................................................................. WASHER, MOUNTING—YELLOW ......................................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 11-5 11 G 111 1G Page 11-6 UNITIZED TRANSAXLE— GASOLINE VEHICLE 12 G 3 112 5 7 4 1G 17 18 6 19 8 REFERENCE FORWARD AND REVERSE SHIFTER— GASOLINE ELECTRICAL SECTION 10 9 11 16 27 12 13 21 15 20 31 1 22 2 28 14 23 24 Clu bCa 30 32 r 25 REFERENCE AXLE TUBES ON PAGE 12-6 26 ClubC ar Page 12-2 29 UNITIZED TRANSAXLE—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1019226-01 1012285 1018336-01 1013061 0000183 1010954 1016341 1017082 0008717 1018902-01 1017231 1019273-01 1018929-01 1019272-01 1018901-01 1012752 1018348-01 1018861-01 1014007 0008233 1019286-01 1016513 1019271-01 1018938-01 1018913-01 1018906-01 1018905-01 1019269-01 1012896 1013759 1016432 1012711 1019287-01 2 3 QTY 4 BRACKET, TRANSMISSION CABLE SUPPORT .................................................................... SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... UNITIZED TRANSAXLE (INCLUDES ITEMS 3 - 90) .............................................................. NUT, NYLON LOCK, #10 - 32 ............................................................................................. WASHER, FLAT, #10 ........................................................................................................... STUD, BALL, 1/4 - 28 x 9/16 ............................................................................................... LEVER, TRANSMISSION SHIFTER ................................................................................... SCREW, HEX WASHER HEAD, #10 - 32 x 3/4 .................................................................. NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. SHAFT, SHIFTER ............................................................................................................... KEY, WOODRUFF ............................................................................................................... RING, SNAP ....................................................................................................................... WASHER, FLAT .................................................................................................................. SEAL, OIL ........................................................................................................................... LEVER, SHIFTER ............................................................................................................... PIN, ROLL ........................................................................................................................... ARM, GOVERNOR LEVER ................................................................................................ SCREW, SQUARE HEAD, 1/4 - 20 x 1 ............................................................................... WASHER, FLAT, TYPE B, 1/4 ............................................................................................. NUT, NYLON LOCK, 1/4 - 20 .............................................................................................. PIN, COTTER ..................................................................................................................... WASHER, FLAT .................................................................................................................. SEAL, OIL ........................................................................................................................... WASHER ............................................................................................................................ ARM, PIVOT ........................................................................................................................ GEAR CASE (RIGHT) ......................................................................................................... GEAR CASE (LEFT) ........................................................................................................... BOLT, FLANGED, M8 x 1.25 x 40MM ................................................................................. PIN, DOWEL ....................................................................................................................... PLUG, DRAIN (INCLUDES ITEM 30) ................................................................................. GASKET ......................................................................................................................... BREATHER ......................................................................................................................... GASKET, LIQUID, 8.8 OZ. (250 GRAMS) ........................................................................... 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 2 2 1 1 A/R Page 12-3 12 G 36 112 35 34 1G 33 47 48 49 46 41 45 43 42 46 44 55 54 48 39 41 40 53 39 52 38 37 43 41 45 51 50 59 58 57 56 38 61 60 66 65 66 REFERENCE DRIVER SIDE CASE 64 63 62 Clu bC Page 12-4 ar REFERENCE PASSENGER SIDE CASE UNITIZED TRANSAXLE—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 1018920-01 1018900-01 1012748 1012747 1018894-01 0007336 1016338 1018924-01 1018922-01 1018897-01 1019276-01 1019275-01 1012742 1012741 1019280-01 1012740 1019279-01 1019277-01 1018899-01 1018896-01 1016337 1019278-01 1012714 1018926-01 1018932-01 1018925-01 1019281-01 1018895-01 1019282-01 1018939-01 1018923-01 1018916-01 1018919-01 0007335 2 3 QTY 4 ROD, SHIFT ........................................................................................................................ FORK, SHIFT ...................................................................................................................... SPRING .............................................................................................................................. BALL, STEEL ...................................................................................................................... GUIDE ................................................................................................................................. BEARING, BALL ................................................................................................................. WASHER, SPRING ............................................................................................................. GEAR, SPUR ...................................................................................................................... PLATE, THRUST ................................................................................................................. GEAR ASSEMBLY, 28 TOOTH, INPUT ............................................................................... BEARING, NEEDLE ........................................................................................................... BEARING, NEEDLE ........................................................................................................... RING, SYNCHRONIZER .................................................................................................... SPRING, SYNCHRONIZER ................................................................................................ HUB, SYNCHRONIZER CLUTCH ....................................................................................... INSERT, SYNCHRONIZER ................................................................................................. SLEEVE, SYNCHRONIZER ................................................................................................ PIN, DOWEL ....................................................................................................................... SHAFT, INPUT .................................................................................................................... GEAR ASSEMBLY, 25 TOOTH, INPUT ............................................................................... WASHER, THRUST ............................................................................................................ BEARING, BALL ................................................................................................................. SEAL, OIL, INPUT SHAFT ................................................................................................. GEAR, 17 TOOTH ............................................................................................................... KEY ..................................................................................................................................... GEAR, 61 TOOTH ............................................................................................................... BEARING, BALL ................................................................................................................. GUIDE, OIL FLOW............................................................................................................... SCREW, M8 x 1.25 x 10 MM .............................................................................................. WASHER ............................................................................................................................. GOVERNOR ASSEMBLY ................................................................................................... SLEEVE .............................................................................................................................. GEAR, CLUSTER IDLER ................................................................................................... BEARING, BALL ................................................................................................................. 1 1 1 1 1 2 2 1 3 1 3 1 2 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Page 12-5 12 G 112 1G 75 73 78 71 77 69 REFERENCE PASSENGER SIDE CASE 74 80 72 70 88 67 85 90 89 90 81 79 82 89 84 Clu 85 bC ar 86 87 74 77 83 79 78 REFERENCE DRIVER SIDE CASE 76 68 71 70 72 73 69 Page 12-6 UNITIZED TRANSAXLE—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 1018915-01 1018914-01 1013787 1013792 1011291 1014207 1016672 1013794 1018910-01 1018909-01 1013790 1013791 0007330 1019283-01 1018927-01 1014193 1019105-01 1013768 1013774 1013773 1013769 1013772 1013770 1013771 2 3 QTY 4 AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 69 - 73) ......................................... AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 69 - 73) ................................ STUD, LUG .................................................................................................................... RING, RETAINING ......................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... BUSHING, 25 MM I. D. ................................................................................................... RING, RETAINING ......................................................................................................... SEAL, OIL ........................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... BOLT, M10 x 1.5 x 30MM .................................................................................................... WASHER, LOCK, M10 ........................................................................................................ BEARING, INNER AXLE TUBE .......................................................................................... BOLT, M8 x 1.25 x 37MM .................................................................................................... GEAR, OUTPUT ................................................................................................................. PIN, DOWEL ....................................................................................................................... KIT, DIFFERENTIAL GEAR CASE (INCLUDES ITEMS 84 - 87) ........................................ CASE, GEAR CARRIER ................................................................................................ PLATE, THRUST (IDLER GEAR) .................................................................................. PLATE, THRUST (DIFFERENTIAL GEAR) ................................................................... COVER, GEAR CASE ................................................................................................... PIN, DIFFERENTIAL .......................................................................................................... GEAR, DIFFERENTIAL IDLER ........................................................................................... GEAR, DIFFERENTIAL ...................................................................................................... 1 1 4 1 1 1 1 1 1 1 14 14 2 8 1 1 1 1 2 1 1 1 2 2 Page 12-7 12 G 112 1G Page 12-8 ELECTRICAL SYSTEM— ELECTRIC VEHICLE 13 E 113 4 TYPICAL 2 PLACES 1E 3 10 2 SEAT SUPPORT FRONT PANEL 11 5 6 TYPICAL 3 PLACES 12 TYPICAL 2 PLACES 1 9 8 TYPICAL 2 PLACES 13 7 TYPICAL 3 PLACES 15 16 TYPICAL 2 PLACES 16 OFF ON CA RR YA L L Page 13-2 14 FORWARD AND REVERSE SWITCH— POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1017530-05 1014807 1014808 0008057 0008058 1014871 1017799 0000451 0001028 1012987 1013198 1016845 0008233 1018962-01 1010434 1014306 2 3 QTY 4 ASSEMBLY, FORWARD AND REVERSE SWITCH (INCLUDES ITEMS 2 - 9) ...................... SWITCH, LIMIT .................................................................................................................. SWITCH, LIMIT .................................................................................................................. NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SCREW, HEX WASHER HEAD, #4 - 40 x 2 ....................................................................... BAR, BUS ........................................................................................................................... WASHER, LOCK, 1/4 .......................................................................................................... NUT, HEX, 1/4 - 20 .............................................................................................................. HANDLE, FORWARD AND REVERSE SWITCH .................................................................... SCREW, PHILLIPS HEAD MACHINE, #8 - 32 x 5/8 .............................................................. SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2 1/8 ................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. KIT, FORWARD AND REVERSE SWITCH COVER (INCLUDES ITEM 15) (CARRYALL I AND II) .............................................................................................................. BARREL, PLASTIC ............................................................................................................. WASHER, FLAT, TYPE B, 1/4 (CARRYALL I AND II) .............................................................. 1 1 2 2 2 2 2 4 4 1 1 3 3 1 2 4 Page 13-3 13 E 2 11 3 1E 31 NO TI TYPICAL 7 PLACES 36 10 9 4 C E 113 6 5 15 12 14 1 13 16 27 17 24 26 14 38 25 7 23 21 9 22 32 20 30 8 19 REFERENCE ACCELERATOR ROD 30 28 9 33 22 18 35 29 39 Club Car 40 41 37 Page 13-4 34 MULTI-STEP POTENTIOMETER— CARRYALL I POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 1019320-03 1014999 1019580-02 1019326-01 N/A N/A N/A N/A N/A 0000451 0001014 1019469-01 1019711-01 0008056 0008058 1014807 0008057 1014414 1014413 0007893 1014017 1013998 1012903 1014000 1014010 1014019 1013887 1013860 1013461 1014189 1014253 0008990 0007473 1012353 1014003 0008449 1016109-01 1013886 1014109 1019492-01 1016175 0001017 2 3 QTY 4 ASSEMBLY, WIPER SWITCH (INCLUDES ITEMS 1 - 37) ...................................................... ASSEMBLY, WIPER SWITCH CASE, 6 SPEED ................................................................. ASSEMBLY, 5-WIRE AND RECEPTACLE (INCLUDES ITEMS 3 - 8) ................................ KIT, 6-PIN RECEPTACLE .............................................................................................. WIRE ASSEMBLY, #18 GREEN/WHITE ........................................................................ WIRE ASSEMBLY, #18 BLUE ........................................................................................ WIRE ASSEMBLY, #18 BLACK/WHITE ......................................................................... WIRE ASSEMBLY, #18 PURPLE.................................................................................... WIRE ASSEMBLY, #18 YELLOW.................................................................................... WASHER, LOCK, 1/4 .......................................................................................................... NUT, BRASS HEX, 1/4 - 20 ................................................................................................ PROTECTOR, WIPER SWITCH RESISTOR ...................................................................... KIT, RESISTOR ASSEMBLY ............................................................................................... SCREW, ROUND HEAD MACHINE, #4 - 40 x 3/4 ........................................................... WASHER, LOCK, #4 .......................................................................................................... SWITCH, LIMIT.................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... BUMPER, WIPER SWITCH ................................................................................................ PIN, HAIR SPRING COTTER ............................................................................................. NUT, HEX, #10 - 32 ............................................................................................................. CARRIER, WIPER SWITCH ARM ...................................................................................... SPRING, WIPER SWITCH BRUSH .................................................................................... BEARING, BRONZE ........................................................................................................... STUD, WIPER SWITCH ADJUSTING ................................................................................ GROMMET, SPLIT .............................................................................................................. SCREW, SELF-TAPPING, #4 - 40 x 3/8 ............................................................................. ARM, SPEED SWITCH ....................................................................................................... ASSEMBLY, SWITCH BRUSH ............................................................................................ SCREW, HEX HEAD HI-LO, #10 - 16 x 1/2 ........................................................................ SCREW, HEX HEAD CAP, 1/4 - 20 x 2 ............................................................................... NUT, BRASS HEX JAM, 1/4 - 20 ........................................................................................ WRAP, TIE ........................................................................................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................................ STUD, SHORT BALL, 1/4 - 28 ............................................................................................ CRANK, BELL ..................................................................................................................... NUT, DIMPLED LOCK, 1/4 - 28 .......................................................................................... DECAL, WIPER SWITCH WARNING ................................................................................. COVER, WIPER SWITCH ................................................................................................... BOLT, CARRIAGE, #10 - 24 x 1 ............................................................................................... SHIM, WIPER SWITCH ........................................................................................................... WASHER, LOCK, #10 ............................................................................................................. NUT, HEX, #10 - 24 ................................................................................................................. 1 1 1 1 1 1 1 1 1 17 15 1 1 2 3 1 2 1 1 1 1 1 2 1 1 1 1 1 2 1 3 1 1 1 1 1 1 1 2 1 2 2 Page 13-5 13 E 113 N EE GR 1E 2 1 D RE E NG A R KEY SWITCH ITE H E/W O G AN N OR OW BR REVERSE BUZZER 10 25 FORWARD / REVERSE SWITCH WARNING LIGHT 3 1 UE BLUE OR AN UE WH ITE LIMIT SWITCHES E W H YE T/B L L N LO K /W W H T PL R 8 PU 1 K AC E E BL HIT HIT W / W / N D E EE RE ANG N GR EE OR GR R G 7 W N BL N 27 26 LE RP PU EY GR D BLK D R - + - GREY - 3 + 4 RE 3 2 M- YELLOW RED BROWN + BLACK - D A2 BLACK BLACK 6 YELLOW 1 + BLUE TYPICAL 5 PLACES BATTERY BANK YELLOW - 2 18 GREEN + 24 SOLENOID 29 ED RED + 23 5 28 RE FUSE RE RED/WHITE PURPLE CK A BL + EN W LO 21 L YE - - FUSE RED 14 GRE 22 RED D RE 17 WHITE/ BLACK 16 FUSE AND RECEPTACLE ORANGE PU EE U BL WHITE TE LL O BL W RP AC LE K YE GE E K AC HI BLUE 15 13 N/ D GR 12 6 EE OW AN ITE GR BR RE 3 WH 5 OR 2 E/ IT WH SIX PIN CONNECTOR 4 GE BL 9 2 11 BL MULTI-STEP POTENTIOMETER 1 CONTROLLER B- LE E RP HIT PU D/W E R OW L ITE L WH YE E G AN OR B+ WHIT E GRE EN WHIT E UE BL 32 BL 20 AC K ON-BOARD COMPUTER 34 - Page 13-6 33 THREE PIN CONNECTOR 19 A2 31 S1 S2 A1 30 MOTOR WIRING— CARRYALL I POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1019110-02 N/A 1019327-01 N/A N/A N/A N/A 1018830-02 N/A N/A 1019014-01 1019012-01 1019111-01 N/A N/A N/A N/A N/A N/A 1019013-01 N/A N/A N/A N/A 1017957-01 N/A 1014947 1019028-01 1014948 1019030-01 1019029-01 1014856 N/A 1019201-01 1018278-01 2 3 QTY 4 WIRE HARNESS (INCLUDES ITEMS 1 - 20) ......................................................................... WIRE ASSEMBLY, #18 BROWN ......................................................................................... KIT, 6-PIN PLUG ASSEMBLY ............................................................................................. WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #18 PURPLE ........................................................................................ WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 GREEN/WHITE ............................................................................. WIRE ASSEMBLY, #18 BLACK (INCLUDES RESISTOR AND #18 WHITE WIRE) ............ WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #6 BLUE ............................................................................................... WIRE ASSEMBLY, #6 ORANGE ......................................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 ORANGE ....................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #6 BLUE ............................................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #18 GRAY (PART OF ON-BOARD COMPUTER ASSEMBLY) ................. WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 ORANGE/WHITE (PART OF BATTERY LIGHT) ................................ ASSEMBLY, RESISTOR .......................................................................................................... WIRE ASSEMBLY, #6 RED .................................................................................................... ASSEMBLY, DIODE ................................................................................................................. WIRE ASSEMBLY, #6 YELLOW .............................................................................................. WIRE ASSEMBLY, #6 GREEN ................................................................................................ WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... KIT, 3-PIN PLUG ASSEMBLY .................................................................................................. KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 Page 13-7 13 E 113 1E TYPICAL 2 PLACES AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED OFF ON 4 7 5 6 2 1 3 OFF ON 10 11 Page 13-8 8 9 ELECTRICAL COMPONENTS, FRONT BODY— CARRYALL I AND II POWERDRIVE ELECTRIC VEHICLES ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 1016859 1016851 1016849 1018306-01 1018262-01 1018511-01 1018307-01 1018345-02 1012505 0008990 1019355-01 2 3 QTY 4 KIT, REVERSE BUZZER (INCLUDES ITEMS 2 AND 3) ......................................................... BUZZER, REVERSE ........................................................................................................... SCREW, PAN HEAD HI-LO, #4 - 24 x 5/16 ......................................................................... ASSEMBLY, SCREW AND WASHER ...................................................................................... SWITCH, KEY ......................................................................................................................... WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH (BLACK) .................................................................................................. KEY (PAIR) .............................................................................................................................. TIE, WIRE ................................................................................................................................ LIGHT, BATTERY WARNING (AMBER) .................................................................................. 1 1 2 2 1 1 1 1 1 2 1 Page 13-9 13 E 113 11 TYPICAL 4 PLACES 1E 10 TYPICAL 2 PLACES 6 5 7 8 2 TYPICAL 3 PLACES 17 TYPICAL 6 PLACES 16 18 15 TYPICAL 12 PLACES 19 TYPICAL 6 PLACES 13 12 Page 13-10 TYPICAL 6 PLACES 14 TYPICAL 5 PLACES 1 9 3 4 TYPICAL 3 PLACES BATTERIES, CHARGER RECEPTACLE— CARRYALL I POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 1018021-01 1017965-01 N/A N/A N/A 1017968-01 1013061 1017705 1018949-01 1018010-01 1018320-01 1017977-01 1017977-02 1017978-01 1017957-01 1014304 1018030-01 1015072 1011578 1013683 2 3 QTY 4 KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 2 - 9) ..................................................... BEZEL, RECEPTACLE ....................................................................................................... WIRE ASSEMBLY, SENSE LEAD, GRAY ........................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... WIRE ASSEMBLY, #10 BLACK ........................................................................................... ASSEMBLY, FUSE, 48 VOLT (INCLUDES ITEM 7) ............................................................ NUT, NYLON LOCK, #10 ............................................................................................... SCREW, PHILLIPS PAN HEAD, #8 TYPE AB .................................................................... ASSEMBLY, FUSE, 3/8 AMP .............................................................................................. PLATE, RECEPTACLE BACKING ........................................................................................... SCREW, PHILLIPS PAN HEAD, #7 - 18 x 3/4 ......................................................................... BATTERY, 8 VOLT POWERDRIVE .......................................................................................... BATTERY, 8 VOLT POWERDRIVE, DRY ................................................................................. CAP, BATTERY, 4 PORT GANG .............................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. NUT, HEX, STAINLESS STEEL, 5/16 - 18 .............................................................................. HOLD-DOWN, BATTERY ........................................................................................................ NUT, NYLON LOCK, STAINLESS STEEL, 5/16 - 18 .............................................................. WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... J-BOLT ..................................................................................................................................... 1 1 1 1 1 1 2 3 1 1 4 6 6 6 5 12 3 6 6 6 Page 13-11 13 E 19 113 TYPICAL 2 PLACES 1E 1 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 7 3 4 8 20 SOLENOID 9 10 TYPICAL 4 PLACES 11 TYPICAL 2 PLACES 2 12 10 TYPICAL 2 PLACES ON-BOARD COMPUTER 14 12 17 CONTROLLER 5 6 13 16 15 12 12 10 5 12 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 18 12 13 Page 13-12 6 COMPUTER, CONTROLLER, AND SOLENOID— CARRYALL I POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1019652-01 1014288 0007893 1014948 0001242 0007174 1019026-01 1014947 1018836-01 1012285 1018402-03 0001241 0007173 0001218 1019099-01 1018949-01 1018278-01 1019423-01 1017237 1019579-01 2 3 QTY 4 PLATE, COMPONENT MOUNTING ........................................................................................ SCREW, THREAD-FORMING, 5/16 - 18 x 3/4 ........................................................................ NUT, HEX, #10 - 32 ................................................................................................................. ASSEMBLY, DIODE ................................................................................................................. NUT, HEX, 5/16 - 18 ................................................................................................................ WASHER, LOCK, 5/16 ............................................................................................................ BOOT, WIRE ............................................................................................................................ ASSEMBLY, RESISTOR .......................................................................................................... SOLENOID, 48 VOLT (WITH MOUNTING BRACKET) ............................................................ SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... CONTROLLER, 48 VOLT (300 AMP) ...................................................................................... WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... BOLT, HEX HEAD, 5/16 - 18 x 1 1/4 ........................................................................................ COMPUTER, ON-BOARD (INCLUDES ITEMS 16, 17 AND 18) ............................................. FUSE ASSEMBLY, 3/8 AMP ............................................................................................... KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. KIT, 3-PIN RECEPTACLE .................................................................................................. NUT, FLANGE, 5/16 - 24 ......................................................................................................... BRACKET, MOUNTING ........................................................................................................... 1 4 2 1 5 5 1 1 1 8 1 6 3 1 1 2 1 1 2 1 Page 13-13 13 E 113 13 14 1E 11 12 9 10 1 19 6 4 18 5 17 2 3 7 8 NO F FO 15 16 FLOORBOARD REMOVED FOR CLARITY Page 13-14 CONTINUOUSLY VARIABLE POTENTIOMETER— CARRYALL II AND VI POWERDRIVE ELECTRIC VEHICLES ITEM PART NO. DESCRIPTION 1 1017392-01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 N/A 1017830 1018226-01 1018090-01 1017853 1011229 N/A N/A N/A 0008990 N/A 1017424 1018951-01 1019201-01 1018043-01 1017743 0008233 0000332 1018619-01 2 3 QTY 4 ASSEMBLY, POTENTIOMETER HOUSING WITH GREY PLUG (INCLUDES ITEMS 1 - 13) ...................................................................................................... HOUSING, POTENTIOMETER .......................................................................................... SWITCH, LIMIT ................................................................................................................... SCREW, HEX HEAD, #4 - 24 .............................................................................................. LEVER, POTENTIOMETER ............................................................................................... SCREW, HEX HEAD, #6 - 32 x 3/4 ..................................................................................... NUT, LOCK, “K”, #6 - 32 ..................................................................................................... WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #18 GREEN/WHITE ............................................................................. POTENTIOMETER ............................................................................................................. WRAP, TIE ........................................................................................................................... CONDUIT, ELECTRICAL .................................................................................................... BEARING, PIVOT SUPPORT ............................................................................................. RECEPTACLE, 3-PIN ......................................................................................................... KIT, 3-PIN PLUG ..................................................................................................................... SCREW, HI-LO HEX HEAD, #8 - 18 x 1/2 ............................................................................... COVER, ACCELERATOR ........................................................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................ SCREW, HEX HEAD CAP, 1/4 - 20 x 1 1/8 ............................................................................. 13 E 1 1 1 2 1 1 1 1 1 1 3 1 1 1 1 2 1 4 4 4 Page 13-15 N KEY SWITCH EE GR E BLU 113 2 1 1 D RE 1E E NG A OR E HIT 13 E/W G AN N OW REVERSE BUZZER OR BR 11 12 HT /W N GR UE WARNING LIGHT BL UE BL N OW BR ON-BOARD COMPUTER CW 6 GR PU EEN /W YE RP HI LL LE TE W OW HT /B LK S CONTINUOUSLY VARIABLE POTENTIOMETER 10 RE D/W HIT E GR 3 EE N 2 1 5 14 CONTROLLER ROTATED 180° B- M- 15 K A2 UE ITE N EE GR WH GE O LL OW W HI 17 TE LIMIT SWITCHES /B LA 18 ED R CK 1 2 E HIT D/W RE G YELLOW 8 ITE N/W RED UE WH AN N EE OR GR SOLENOID ITE D RE WH AC K 19 N EE GR D E R 3 GE BL 22 D RE GREEN W O BLK 21 - BLACK FUSE AND RECEPTACLE + E + NG Y 25 FUSE 24 1 - Page 13-16 S1 MOTOR 2 20 6 27 S2 5 + BLUE A2 + - GREEN E - 3 - IT + - + - H 26 + RED 29 28 W RA D RE A GR CK LA /B TE HI BLACK 23 FUSE YE BL E RE CK E IT WH N RA E HIT K AC BL Y A GR AC BL B+ A BL BL YELLOW 16 3 FORWARD / REVERSE SWITCH 9 RED GREEN ORANGE BROWN 2 RP LE K AC HITE BL /W EN E N GR OW BR EEN R E G HIT D/W RE 4 7 PU BLACK THREE WIRE PLUG BROWN CCW 4 BATTERIES A1 WIRING— CARRYALL II POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 1019116-01 N/A N/A 1018651-06 1018830-02 N/A N/A 1019308-01 N/A N/A N/A N/A N/A N/A 1019088-01 1016729 N/A 1016732 1014948 1014947 1017957-01 N/A N/A N/A 1018278-03 1019045-01 1019046-01 1019047-01 1019089-01 1019044-01 2 3 QTY 4 WIRE HARNESS (INCLUDES ITEMS 1 - 9) ........................................................................... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 ORANGE ....................................................................................... ASSEMBLY, 3-PIN PLUG (INCLUDES #18 PURPLE, #18 YELLOW AND ITEM 4) ........... WIRE ASSEMBLY, #18 BLACK (INCLUDES RESISTOR AND #18 WHITE WIRE) ....... WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 GREEN .......................................................................................... ASSEMBLY, 3-PIN PLUG (INCLUDES #18 BROWN, #18 YELLOW, AND #18 RED) ........ WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #18 GREEN/WHITE ................................................................................. WIRE ASSEMBLY, #18 ORANGE/WHITE (PART OF BATTERY LIGHT) ................................ WIRE ASSEMBLY, #18 RED ................................................................................................... WIRE ASSEMBLY, #18 BLUE (PART OF POTENTIOMETER ASSEMBLY) ........................... WIRE ASSEMBLY, #6 BLUE ................................................................................................... WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #6 YELLOW .............................................................................................. ASSEMBLY, DIODE ................................................................................................................. ASSEMBLY, RESISTOR .......................................................................................................... WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 GREY (PART OF ON-BOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #6 BLUE ................................................................................................... WIRE ASSEMBLY, #6 ORANGE ............................................................................................. WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #6 GREEN ................................................................................................ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 Page 13-17 13 E 113 1 1E 2 4 13 12 2 14 2 15 3 2 16 1 3 3 2 4 19 2 5 2 1 2 1 17 SOLENOID 4 18 TYPICAL 2 PLACES 8 6 7 MOUNTING PLATE 4 8 18 11 TYPICAL 4 PLACES 7 8 CONTROLLER 9 8 7 18 8 7 10 TYPICAL 6 PLACES 21 23 Page 13-18 ON-BOARD COMPUTER TYPICAL 2 PLACES 7 20 22 TYPICAL 2 PLACES COMPUTER, CONTROLLER, AND SOLENOID— CARRYALL II POWERDRIVE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0007174 0001241 0007173 0001242 0001218 1019183-01 1012285 0000451 1018402-03 1019243-01 1019117-01 1019026-01 1017237 1014947 0007893 1014948 1018836-01 0000332 1019344-01 1019099-05 1018949-01 1018278-03 1019423-01 2 3 QTY 4 WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... NUT, HEX, 5/16 - 18 ................................................................................................................ BOLT, HEX HEAD, 5/16 - 18 x 1 1/4 ........................................................................................ CLAMP, WIRE .......................................................................................................................... SCREW, HEX HEAD THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................ WASHER, LOCK, 1/4 .............................................................................................................. CONTROLLER, 48 VOLT (300 AMP) ...................................................................................... BUSHING, SNAP .................................................................................................................... PLATE, MOUNTING ................................................................................................................ BOOT, WIRE ............................................................................................................................ NUT, FLANGE, 5/16 - 24 ......................................................................................................... ASSEMBLY, RESISTOR .......................................................................................................... NUT, HEX, #10 - 32 ................................................................................................................. ASSEMBLY, DIODE ................................................................................................................. SOLENOID, 48 VOLT (WITH MOUNTING BRACKET) ........................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. COMPUTER, ON-BOARD (INCLUDES ITEMS 21, 22 AND 23) ............................................. FUSE ASSEMBLY, 3/8 AMP ............................................................................................... KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. KIT, 3-PIN RECEPTACLE .................................................................................................. 4 8 3 4 1 2 10 10 1 6 1 1 2 1 2 1 1 5 2 1 1 1 1 Page 13-19 13 E TYPICAL 2 PLACES 6 7 6 113 5 5 1E TYPICAL 2 PLACES 4 TYPICAL 12 PLACES 8 9 4 3 1 2 BATTERY MOUNTING 20 TYPICAL 4 PLACES 19 TYPICAL 2 PLACES 15 14 16 17 TYPICAL 3 PLACES 11 18 12 10 Page 13-20 13 BATTERIES, CHARGER RECEPTACLE— CARRYALL II POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1017977-01 1017977-02 1017978-01 1017957-01 1016682-01 1011578 1015072 1018030-02 1018030-01 1014304 1018021-01 1017965-01 N/A N/A N/A 1017968-01 1013061 1017705 1018949-01 1018010-01 1018320-01 2 3 QTY 4 BATTERY, 8-VOLT POWERDRIVE .......................................................................................... BATTERY, 8-VOLT POWERDRIVE, DRY ................................................................................. CAP, BATTERY, 4 PORT GANG .............................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. ROD, BATTERY HOLD-DOWN ............................................................................................... WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... NUT, NYLON LOCK, STAINLESS STEEL, 5/16 - 18 .............................................................. HOLD-DOWN, BATTERY, LONG ............................................................................................ HOLD-DOWN, BATTERY, SHORT .......................................................................................... NUT, HEX, STAINLESS STEEL, 5/16 -18 ............................................................................... KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 11 - 18) ................................................. BEZEL, RECEPTACLE ....................................................................................................... WIRE ASSEMBLY, SENSE LEAD, GRAY ........................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... WIRE ASSEMBLY, #10 BLACK ........................................................................................... ASSEMBLY, FUSE, 48 VOLT (INCLUDES ITEM 16) .......................................................... NUT, NYLON LOCK, #10 ............................................................................................... SCREW, PHILLIPS PAN HEAD, TYPE AB, #8 .................................................................... ASSEMBLY, FUSE, 3/8 AMP .............................................................................................. PLATE, RECEPTACLE BACKING ........................................................................................... SCREW, PHILLIPS PAN HEAD, #7 - 18 x 3/4 ......................................................................... 6 6 6 5 8 8 8 2 2 12 1 1 1 1 1 1 2 3 1 1 4 Page 13-21 13 E RIGHT HEADLIGHT GRE WHIT E 2 1E BL BL UE ITE WH K K AC LAC BL B 47 1 GRE EN BLUE W WHIT E N EE GR 25 TE HI UE BL O BR 4 GE AN OR WN /W 1 KEY SWITCH 46 WARNING LIGHT BATTERY CONDITION INDICATOR BLACK VOLTAGE LIMITER 44 45 ORANGE TE OW HI LL /W YE GE N N A OW OR BR GROUND TERMINAL BLOCK LIGHT SWITCH B BLACK E LU BLUE 6 GRN/WHT BLUE WHITE FRONT REVERSE BUZZER BLACK ORANGE 2 1 E HIT D RE 5 2 D RE GE AN OR GE AN OR BLACK LEFT HEADLIGHT K AC 3 BL UE 1 13 GROUND TERMINAL BLOCK EN BLUE HORN 31 CW CCW GR EE N PU /W HI R T YE PLE E LL W OW HT /B LK S CONTINUOUSLY VARIABLE POTENTIOMETER 7 THREE PIN PLUG 9 23 24 THREE PIN CONNECTOR BLACK BROWN ORANGE GREEN HORN BUTTON BROWN YELLOW DIMMER SWITCH RED/WHITE 8 NC COM TWO PIN CONNECTOR RE D/W PARK LIMIT SWITCH E HIT 14 13 ORANGE/WHITE N 10 BROW BRAKE LIMIT RED COM 11 NC SWITCH GREEN/WHITE YELLOW WHITE Page 13-22 15 12 FUSE BLOCK RE D 16 17 18 ON-BOARD COMPUTER BROWN 32 BLA CK FUSE 48 K AC LE BL RP W PU LO L K YE AC N BL OW E BR HIT D/W N RE EE R G FORWARD / REVERSE SWITCH 29 28 2 53 42 40 RED 1 CONTROLLER ROTATED 180° B- M- 50 49 A2 SOLENOID K AC BL K AC BL K AC K BL W AC LO BL ACK K AY YEL ED BL D AC R GR N RE /B L EE ITE D R K E H G R W AC BL B+ UE BL GE AN OR - + N EE GR A BL - N EE GR + 2 5 27 2 E HIT E D/W NG A RE OR 1 3 - LIMIT SWITCHES E HIT /W - 41 4 + 3 BATTERIES 6 43 CK D RE - 35 FUSE W CONNECTOR H IT E GREEN BLUE E NG RA O 37 39 EN 38 A2 S1 BLUE E GR CHARGER S2 36 A1 MOTOR BLACK RED 22 20 OR AN GE 19 REAR REVERSE BUZZER - - + ITE ITE WH 25 + + 1 26 34 RE D UE BL WH E1 LO W 51 TERMINAL BLOCK 3 YE L 131 52 30 N OW K BR LAC B 21 RE D RE D BLA CK BR OW N RIGHT BRAKE LIGHT D RE K AC N BL OW W R B O LL E YE HIT W BLA CK BR OW N RE D LEFT BRAKE LIGHT 33 WIRING— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 1019693-01 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 1016698 N/A N/A N/A N/A N/A 1019116-01 N/A 1018651-06 1018830-02 N/A N/A N/A N/A N/A 1019308-01 N/A 1019101-02 1019099-03 1018278-02 1019045-02 1019089-02 1019044-02 1019046-02 1019047-02 1018291-01 1014947 1017957-01 N/A N/A N/A N/A N/A N/A N/A 1019088-01 1016729 N/A 1016732 1014948 2 3 QTY 4 WIRE HARNESS, LIGHTING (CONTAINS ITEMS 1 - 21) ...................................................... WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE ASSEMBLY, #14 BLACK ........................................................................................... WIRE ASSEMBLY, #16 WHITE ........................................................................................... WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #16 BROWN ......................................................................................... WIRE ASSEMBLY, #16 ORANGE/WHITE .......................................................................... WIRE ASSEMBLY, #16 ORANGE ....................................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... WIRE ASSEMBLY, #16 BROWN ......................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #16 RED/WHITE .................................................................................. WIRE ASSEMBLY, #16 ORANGE/WHITE .......................................................................... WIRE ASSEMBLY, #16 GREEN/WHITE ............................................................................. WIRE ASSEMBLY, #14 YELLOW ........................................................................................ WIRE ASSEMBLY, #10 RED ............................................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 WHITE ........................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 ORANGE ....................................................................................... WIRE ASSEMBLY, #16 BLACK ........................................................................................... WIRE HARNESS, POWER (INCLUDES ITEMS 22 - 31) ........................................................ WIRE ASSEMBLY, #18 GREEN .......................................................................................... ASSEMBLY, 3-WIRE PLUG (INCLUDES #18 PURPLE, #18 YELLOW AND ITEM 24) ...... WIRE ASSEMBLY, #18 BLACK (INCLUDES RESISTOR AND #18 WHITE WIRE) ...... WIRE ASSEMBLY, #18 ORANGE ....................................................................................... WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. ASSEMBLY, 3-PIN PLUG (INCLUDES #18 BROWN, #18 YELLOW, AND #18 RED) ........ WIRE ASSEMBLY, #18 GREEN/WHITE ............................................................................. WIRE HARNESS, POWER (INCLUDES ITEMS 32 - 38) ........................................................ COMPUTER, ON-BOARD (SEE PAGE 12-30) (INCLUDES ITEM 33) ............................... KIT, WIRE AND TERMINAL, #6 BLACK ........................................................................ WIRE ASSEMBLY, #6 RED ................................................................................................. WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #6 GREEN ............................................................................................ WIRE ASSEMBLY, #6 BLUE ............................................................................................... WIRE ASSEMBLY, #6 ORANGE ......................................................................................... DC CORD, #10 BLUE, #10 RED, #10 BLACK (PART OF CHARGER) ................................... ASSEMBLY, RESISTOR .......................................................................................................... WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #18 GREY (PART OF ON-BOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #16 RED ................................................................................................... WIRE ASSEMBLY, #18 BLUE (PART OF POTENTIOMETER ASSEMBLY) ........................... WIRE ASSEMBLY, #18 ORANGE/WHITE ............................................................................... WIRE ASSEMBLY, #18 RED ................................................................................................... WIRE ASSEMBLY, #10 BLACK (PART OF VOLTAGE LIMITER ASSEMBLY) ......................... WIRE ASSEMBLY, #6 BLUE ................................................................................................... WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #6 YELLOW .............................................................................................. ASSEMBLY, DIODE ................................................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 Page 13-23 13 E 6 113 11 12 1E 5 13 9 3 8 10 4 2 7 TYPICAL 2 PLACES 1 15 14 26 24 19 23 18 22 17 16 21 25 20 Page 13-24 ELECTRICAL COMPONENTS, FRONT BODY— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 0008639 1016859 1016851 1016849 1016356 1013357 0004029 0007820 1019551-01 1011825 0000304 0000332 0008233 1016897-01 1016897-02 1017066 1017059 1017060 1017061 1017064 0007893 1013461 1017065 1017062 1016880 1016879 2 3 QTY 4 WRAP, TIE ............................................................................................................................... KIT, REVERSE BUZZER (INCLUDES ITEMS 3 AND 4) ......................................................... BUZZER, REVERSE ........................................................................................................... SCREW, PAN HEAD HI-LO, #4 - 24 x 5/16 ......................................................................... BLOCK, TERMINAL ................................................................................................................ RIVET, ALUMINUM POP, 5/32 ................................................................................................ ASSEMBLY, HORN (INCLUDES ITEMS 8, 9 AND 10) ........................................................... WASHER, INTERNAL TOOTH, 5/16 ................................................................................... NUT, M6 x 1 1/4 .................................................................................................................. BRACKET, HORN ............................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 1 ................................................................................................ WASHER, FLAT, 1/4 ................................................................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. ASSEMBLY, HEADLIGHT, DRIVER SIDE (INCLUDES ITEMS 16 - 25) ................................. ASSEMBLY, HEADLIGHT, PASSENGER SIDE (INCLUDES ITEMS 16 - 24 AND 26) ........... HARNESS, HEADLIGHT WIRE .......................................................................................... LOCK, BULB COLLAR ....................................................................................................... BULB, HALOGEN ............................................................................................................... LENS, HEADLIGHT ............................................................................................................ BRACKET, MOUNTING ...................................................................................................... NUT, HEX, #10 - 32 ............................................................................................................. SCREW, HI-LO, #10 - 16 .................................................................................................... RETAINER, HEADLIGHT .................................................................................................... ASSEMBLY, TURN SIGNAL LENS ..................................................................................... BEZEL, HEADLIGHT, DRIVER SIDE................................................................................... BEZEL, HEADLIGHT, PASSENGER SIDE ......................................................................... 2 1 1 2 1 2 1 1 1 1 2 2 2 1 1 1 1 1 1 2 2 2 1 1 1 1 Page 13-25 13 E 113 1E OFF ON 4 3 5 2 1 6 10 9 8 7 13 12 14 RK 16 PA 19 18 23 22 17 20 16 21 14 24 Page 13-26 15 15 11 CONTROLS AND GAUGES— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1019355-01 1018142-01 1018147-01 1011610 1016092 1018306-01 1018262-01 1018511-01 1018307-01 1018345-02 1012505 0004034 1013857 1011439 1011557 1019322-01 1019571-01 1011280 1019698-01 1018713-01 1018712-01 0008049 0007893 1019697-01 2 3 QTY 4 LIGHT, BATTERY WARNING (AMBER) .................................................................................. INDICATOR, BATTERY ........................................................................................................... RETAINER, PUSH ON ............................................................................................................ WASHER, LOCK, #8 ............................................................................................................... SCREW, PAN HEAD MACHINE, #8 - 32 x 7/16 ...................................................................... ASSEMBLY, SCREW AND WASHER ...................................................................................... SWITCH, KEY ......................................................................................................................... WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH ................................................................................................................. KEY (PAIR) .............................................................................................................................. SWITCH, LIGHT (INCLUDES ITEM 13) .................................................................................. KNOB, LIGHT SWITCH ...................................................................................................... SWITCH, LIMIT ....................................................................................................................... SCREW, HEX HEAD MACHINE, #6 - 32 x 1 ........................................................................... NUT, NYLON LOCK, #6 - 32 ................................................................................................... BRACKET, BRAKE LIGHT SWITCH ....................................................................................... NUT, LOCK, 5/16 - 18 .............................................................................................................. SWITCH, DIMMER .................................................................................................................. STAND-OFF, DIMMER SWITCH ............................................................................................. SCREW, MACHINE, #10 - 32 x 1 ............................................................................................ WASHER, INTERNAL TOOTH LOCK, #10 ............................................................................. NUT, HEX, #10 - 32 ................................................................................................................. BUTTON, HORN ..................................................................................................................... 1 1 2 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 1 2 2 2 2 1 Page 13-27 13 E 13 113 12 14 20 1E TERMINAL BLOCK MOUNTING 21 15 16 TYPICAL 2 PLACES 2 2 19 1 17 3 SOLENOID 18 4 8 7 5 2 2 1 TYPICAL 2 PLACES TYPICAL 2 PLACES 6 7 TYPICAL 2 PLACES 8 18 4 TYPICAL 4 PLACES 7 8 9 4 1 10 TYPICAL 6 PLACES 2 2 3 11 MOUNTING PLATE 24 TYPICAL 2 PLACES 25 3 2 26 27 2 28 1 25 4 TYPICAL 2 PLACES 23 TYPICAL 3 PLACES 29 22 28 30 Page 13-28 FUSE BLOCK MOUNTING ELECTRICAL COMPONENTS, CENTER BODY— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0007174 0001241 0007173 0001242 0001218 1019183-01 1012285 0000451 1018402-03 1019243-01 1019117-01 1019026-01 1017237 1014947 0007893 1014948 1018836-01 0000332 1019344-01 1016356 1013357 1015741 1016423 1012438 0000183 1016363 0001017 0001016 1016631 1016366 2 3 QTY 4 WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... NUT, HEX, 5/16 - 18 ................................................................................................................ BOLT, HEX HEAD, 5/16 - 18 x 1 1/4 ........................................................................................ CLAMP, WIRE .......................................................................................................................... SCREW, HEX HEAD THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................ WASHER, LOCK, 1/4 .............................................................................................................. CONTROLLER, 48 VOLT (300 AMP) ...................................................................................... BUSHING, SNAP .................................................................................................................... PLATE, MOUNTING ................................................................................................................ BOOT, WIRE ............................................................................................................................ NUT, FLANGE, 5/16 - 24 ......................................................................................................... ASSEMBLY, RESISTOR .......................................................................................................... NUT, HEX, #10 - 32 ................................................................................................................. ASSEMBLY, DIODE ................................................................................................................. SOLENOID, 48 VOLT (WITH MOUNTING BRACKET)............................................................. WASHER, FLAT, 1/4 ................................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. BLOCK, TERMINAL ................................................................................................................ RIVET, ALUMINUM POP, 5/32 ................................................................................................ BLOCK, FUSE ......................................................................................................................... FUSE, 20 AMP ........................................................................................................................ NUT, NYLON LOCK, #10 - 24 ................................................................................................. WASHER, FLAT, #10 ............................................................................................................... COVER, FUSE BLOCK ........................................................................................................... NUT, HEX, #10 - 24 ................................................................................................................. WASHER, LOCK, #10 ............................................................................................................. NUT, PUSH .............................................................................................................................. SCREW, ROUND HEAD, #10 - 24 x 3 ..................................................................................... 4 8 3 4 1 2 8 8 1 6 1 1 2 1 2 1 1 4 2 1 2 1 3 2 4 1 2 4 2 2 Page 13-29 13 E 113 1E 11 10 NOT ICE DO NO TU SE AS CC GR OU I1 01 ND 96 7 46 -01 9 16 15 8 17 13 12 4 14 13 12 2 TO CHON-B AR OA GE RD 1 R ON-BOARD COMPUTER 6 5 APPLY HEAT SINK COMPOUND TO BACK OF VOLTAGE LIMITER BEFORE INSTALLING 3 20 13 TYPICAL 2 PLACES 14 19 21 18 Page 13-30 VOLTAGE LIMITER MOUNTING ELECTRICAL COMPONENTS, CENTER BODY, CONTINUED— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1019099-03 1018949-01 1019423-01 1018278-02 1018844-01 0008168 1019349-01 1019575-01 1018949-01 0008990 1019316-01 1012285 0000451 0000332 1017853 1011229 1019668-01 1018108-01 1018367-02 0001028 1018024-01 2 3 QTY 4 COMPUTER, ON-BOARD (INCLUDES ITEMS 2 - 7) ............................................................. FUSE ASSEMBLY, 3/8 AMP ............................................................................................... CONNECTOR, 3-PIN .......................................................................................................... KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. LABEL ................................................................................................................................. WRAP, TIE ........................................................................................................................... LABEL ................................................................................................................................. ADAPTER, TWO-WAY (INCLUDES ITEM 9)............................................................................ FUSE ASSEMBLY, 3/8 AMP ............................................................................................... TIE, WIRE ................................................................................................................................ ASSEMBLY, COMPONENT COVER ....................................................................................... SCREW, HEX HEAD THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................ WASHER, LOCK, 1/4 .............................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................ SCREW, HEX HEAD MACHINE, #6 - 32 x 3/4 ........................................................................ NUT, K LOCK, #6 - 32 ............................................................................................................. BLOCK, TERMINAL ................................................................................................................ LIMITER, VOLTAGE (INCLUDES ITEM 19) ............................................................................ COMPOUND, HEAT SINK .................................................................................................. NUT, HEX, 1/4 - 20 .................................................................................................................. GROMMET, 5/8 ....................................................................................................................... 1 1 1 1 1 2 1 1 1 1 1 2 4 3 2 2 1 1 A/R 2 1 Page 13-31 13 E TYPICAL 2 PLACES 113 19 6 19 4 4 1E TYPICAL 2 PLACES 7 TYPICAL 12 PLACES 5 3 7 2 1 ; 8 BATTERY MOUNTING BRAKE LIGHT MOUNTING 16 15 10 9 11 18 17 12 13 14 REAR REVERSE BUZZER MOUNTING Page 13-32 ELECTRICAL COMPONENTS, REAR BODY— CARRYALL VI POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1017977-01 1017977-02 1017957-01 1014304 1011578 1018030-01 1018030-02 1016682-01 1017978-01 1016717 N/A 1011582 N/A N/A N/A 1015752 1016859 1016851 1016849 1015072 2 3 QTY 4 BATTERY, 8-VOLT POWERDRIVE .......................................................................................... BATTERY, 8-VOLT POWERDRIVE, DRY ................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. NUT, HEX, STAINLESS STEEL, 5/16 -18 ............................................................................... WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... HOLD-DOWN, BATTERY, SHORT .......................................................................................... HOLD-DOWN, BATTERY, LONG ............................................................................................ ROD, BATTERY HOLD-DOWN ............................................................................................... CAP, BATTERY, 4 PORT GANG .............................................................................................. ASSEMBLY, TAILLIGHT (INCLUDES ITEMS 10 - 14) ............................................................. HOUSING, TAILLIGHT ........................................................................................................ BULB ................................................................................................................................... GASKET ............................................................................................................................. LENS ................................................................................................................................... SCREW, LENS .................................................................................................................... SCREW, HI-LO, #12 - 16 x 5/8 ................................................................................................ KIT, REVERSE BUZZER (INCLUDES ITEMS 17 AND 18) ..................................................... BUZZER, REVERSE ........................................................................................................... SCREW, PAN HEAD HI-LO, #4 - 24 x 5/16 ......................................................................... NUT, NYLON LOCK, STAINLESS STEEL, 5/16 - 18 .............................................................. 6 6 5 12 8 2 2 8 6 2 1 1 1 1 2 4 1 1 2 8 Page 13-33 13 E 113 1E Page 13-34 BATTERY CHARGER 14 E 114 1E 1 2 4 3 5 6 1 7 8 9 10 C lu b C ar R 11 13 Page 14-2 14 12 POWERDRIVE BATTERY CHARGER, DOMESTIC—CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1018022-01 2 3 QTY 4 E 1 2 1018283-01 0007577 CHARGER, BATTERY, POWERDRIVE, DOMESTIC 120VAC 48VDC 60 HZ (MODEL NUMBER 17930-11) (INCLUDES ITEMS 1 - 14) 103 IN. DC CORD WITH MALE 3-PIN PLUG, 12 AWG 74 IN. AC CORD WITH MALE GROUNDED PLUG ................................................................ CHARGER, BATTERY, POWERDRIVE 120VAC 48VDC 60 HZ (MODEL NUMBER 17930-18) (INCLUDES ITEMS 1 - 14) 144 IN. DC CORD WITH MALE 3-PIN PLUG, 12 AWG 108 IN. AC CORD WITH MALE GROUNDED PLUG .............................................................. CHARGER, BATTERY, POWERDRIVE 120VAC 48VDC 60 HZ (MODEL NUMBER 17930-19) (INCLUDES ITEMS 1 - 14) 240 IN. DC CORD WITH MALE 3-PIN PLUG, 12 AWG 108 IN. AC CORD WITH MALE GROUNDED PLUG .............................................................. ASSEMBLY, CASE (INCLUDES ITEM 2) ............................................................................ SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ................................................... 3 4 5 6 7 7 7 1018197-01 1015914 1018285-01 1018311-01 1018289-01 1018289-02 1018289-03 ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ AMMETER (INCLUDES MOUNTING HARDWARE) .......................................................... KIT, WIRE ASSEMBLY ........................................................................................................ CORDSET, DC, 113 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... CORDSET, DC, 154 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... CORDSET, DC, 250 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... 1 1 1 1 1 1 1 8 9 10 11 12 13 13 14 1012101 1012098 1019144-01 1018287-01 1018286-01 1018288-01 1018288-02 1015917 ASSEMBLY, FUSE (INCLUDES MOUNTING HARDWARE) .............................................. BUSHING, STRAIN RELIEF, DC CORD, 12 AWG .............................................................. ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. BREAKER, CIRCUIT, 15 AMP ............................................................................................ RELAY, POWER, 48 VDC ................................................................................................... CORDSET, AC, 80 INCHES LONG .................................................................................... CORDSET, AC, 116 INCHES LONG .................................................................................. BUSHING, STRAIN RELIEF, AC CORD ............................................................................. 1 1 1 1 1 1 1 1 1018022-02 1018022-03 14 1 1 1 1 10 Page 14-3 114 1E 1 2 4 3 7 6 5 8 9 11 1 12 13 C lu b C ar R 14 15 Page 14-4 10 16 POWERDRIVE BATTERY CHARGER, EXPORT—CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1018315-03 1018315-04 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 15 16 N/A 0007577 1018382-01 1015914 1019144-01 1018385-01 1018285-01 1018383-01 1018387-01 1018386-01 1018289-01 1018289-02 1018289-03 1012101 1012098 1018384-01 1018317-01 1018317-02 1015917 2 3 QTY 4 CHARGER, BATTERY, POWERDRIVE, EXPORT WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48 VDC 50/60 HZ (MODEL NUMBER 18780-11) (INCLUDES ITEMS 1 - 16) 103 IN. DC CORD WITH MALE 3-PIN PLUG, 12 AWG 74 IN. AC CORD WITH NO PLUG .......................................................................................... CHARGER, BATTERY, POWERDRIVE EXPORT WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48 VDC 50/60 HZ (MODEL NUMBER 18780-18) (INCLUDES ITEMS 1 - 16) 144 IN. DC CORD WITH MALE 3-PIN PLUG, 12 AWG 108 IN. AC CORD WITH NO PLUG ........................................................................................ ASSEMBLY, CASE (INCLUDES ITEM 2) ............................................................................ SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ................................................... ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. KIT, WIRE ASSEMBLY ........................................................................................................ AMMETER (INCLUDES HARDWARE) ............................................................................... RELAY, POWER, 48 VDC (INCLUDES MOUNTING HARDWARE) ................................... BRACKET, POWER RELAY MOUNTING ........................................................................... SWITCH, 4-POSITION, SLIDE ........................................................................................... CORDSET, DC, 113 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... CORDSET, DC, 154 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... CORDSET, DC, 250 INCHES LONG WITH MALE 3-PIN PLUG, 12 AWG ......................... ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... BUSHING, STRAIN RELIEF, DC CORD, 12 AWG .............................................................. BREAKER, CIRCUIT, 15 AMP ............................................................................................ CORDSET, AC, 80 INCHES LONG, WITH LEADS (NO PLUG) ......................................... CORDSET, AC, 116 INCHES LONG, WITH LEADS (NO PLUG) ....................................... BUSHING, STRAIN RELIEF, AC CORD ............................................................................. 14 E 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 14-5 114 1E 1 2 4 3 7 6 5 8 9 11 1 12 13 C lu b C ar R 14 15 16 17 Page 14-6 10 POWERDRIVE BATTERY CHARGER, EUROPEAN—CARRYALL I AND II ITEM PART NO. DESCRIPTION 1 1019562-01 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 11 1018381-02 0007577 1018382-01 1015914 1019144-01 1018385-01 1019766-01 1019875-01 1018387-01 1018386-01 1018289-01 1018289-02 CHARGER, BATTERY, POWERDRIVE, EUROPEAN WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48 VDC 50/60 HZ (MODEL NUMBER 20300) (INCLUDES ITEMS 1 - 15) 103" DC CORD WITH MALE 3-PIN PLUG, 12 AWG .............................................................. CHARGER, BATTERY, POWERDRIVE EUROPEAN WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48 VDC 50/60 HZ (MODEL NUMBER 20310) (INCLUDES ITEMS 1 - 15) 144" DC CORD WITH MALE 3-PIN PLUG, 12 AWG .............................................................. ASSEMBLY, CASE (INCLUDES ITEM 2) ............................................................................ SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ................................................... ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. KIT, WIRE ASSEMBLY ........................................................................................................ AMMETER (INCLUDES HARDWARE) ............................................................................... RELAY, POWER, 48 VDC (INCLUDES MOUNTING HARDWARE) ................................... BRACKET, POWER RELAY MOUNTING ........................................................................... SWITCH, 4-POSITION, SLIDE ........................................................................................... CORDSET, DC, 103" LONG WITH MALE 3-PIN PLUG, 12 AWG ...................................... CORDSET, DC, 144" LONG WITH MALE 3-PIN PLUG, 12 AWG ...................................... 11 12 13 14 15 16 17 1018289-03 1012101 1012098 1018384-01 1019735-01 1019583-01 1019582-01 CORDSET, DC, 250" LONG WITH MALE 3-PIN PLUG, 12 AWG ...................................... ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... BUSHING, STRAIN RELIEF, DC CORD, 12 AWG .............................................................. BREAKER, CIRCUIT, 15 AMP ............................................................................................ RECEPTACLE, AC CORD .................................................................................................. CORDSET, AC, CONTINENTAL EUROPE, 96" LONG (WITH MALE 2-PIN PLUG) ............... CORDSET, AC, U.K., 96" LONG (WITH MALE 3-PIN PLUG) ................................................. 1019562-02 14 E 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 14-7 114 1E 2 1 3 20 4 5 19 6 18 7 1 21 8 22 16 17 15 23 C lu b 9 10 C ar R 14 13 Page 14-8 11 12 24 ON-BOARD POWERDRIVE BATTERY CHARGER, DOMESTIC—CARRYALL VI ITEM PART NO. DESCRIPTION 1 1018143-01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1018161-01 0007577 1017187 1015914 1018197-01 1018417-01 1018419-01 1018387-01 1011707 0008233 0007847 1015917 1018290-01 1018287-01 1012098 1018291-01 1012101 1018285-01 1018286-01 1019144-01 0007479 1014306 0000451 0001028 2 3 QTY 4 ASSEMBLY, POWERDRIVE BATTERY CHARGER WITH REEL, ON-BOARD 120VAC 48VDC 60 HZ (INCLUDES ITEMS 1 - 20) ............................................................. ASSEMBLY, CASE (INCLUDES ITEM 2) ............................................................................ SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ................................................... ASSEMBLY, RETRACTABLE CORD REEL ........................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES HARDWARE) ................................. ASSEMBLY, TRANSFORMER ............................................................................................ KIT, WIRE ASSEMBLY ........................................................................................................ BOARD, CONTROL ............................................................................................................ BRACKET, RELAY AND RESET BOARD MOUNTING ...................................................... BRACKET, MOUNTING ...................................................................................................... NUT, LOCK, 1/4 - 20 ........................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ BUSHING, STRAIN RELIEF, AC CORD ............................................................................. CORDSET, AC, 24 INCHES WITH GROUNDED PLUG ..................................................... BREAKER, CIRCUIT, 15 AMP ............................................................................................ BUSHING, STRAIN RELIEF, DC CORD, 12 AWG .............................................................. CORDSET, DC, 90 INCHES LONG WITH LEADS, 12 AWG .............................................. ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... AMMETER (INCLUDES HARDWARE) ............................................................................... RELAY, POWER, 48 VDC ................................................................................................... ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. BOLT, HEX HEAD, 1/4 - 20 x 1 1/4 .......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. NUT, HEX, 1/4 - 20 .................................................................................................................. 14 E 1 1 12 1 1 1 1 1 1 2 4 4 1 1 1 1 1 1 1 1 1 4 4 4 4 Page 14-9 114 1E 1 5 2 4 3 19 20 21 6 1 22 7 9 23 8 17 18 16 24 C lu b C ar 11 R 12 15 13 14 Page 14-10 10 25 ON-BOARD POWERDRIVE BATTERY CHARGER, EXPORT—CARRYALL VI ITEM PART NO. DESCRIPTION 1 1018143-02 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1018416-01 0007577 1018382-01 1015914 1017187 1018383-01 1018419-01 1018387-01 1018386-01 1011707 0008233 0007847 1015917 1018290-01 1018384-01 1012098 ASSEMBLY, POWERDRIVE BATTERY CHARGER AND REEL, ON-BOARD WITH 4-POSITION SWITCH, 100 - 200 - 220 - 240 VAC, 48 VDC 50/60 HZ (INCLUDES ITEMS 1 - 21) ...................................................................................................... ASSEMBLY, CASE (INCLUDES ITEM 2) ............................................................................ SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ................................................... ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ ASSEMBLY, RETRACTABLE CORD REEL ........................................................................ RELAY, POWER (INCLUDES MOUNTING HARDWARE) .................................................. BOARD, CONTROL ............................................................................................................ BRACKET, MOUNTING, RELAY AND RESET BOARD ..................................................... SWITCH, 4-POSITION, SLIDE ........................................................................................... BRACKET, MOUNTING ...................................................................................................... NUT, LOCK, 1/4 - 20 ........................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ BUSHING, STRAIN RELIEF, AC CORD ............................................................................. CORDSET, AC, 3 x 1.5MM x 24 INCHES LONG, WITH GROUNDED PLUG .................... BREAKER, CIRCUIT .......................................................................................................... BUSHING, STRAIN RELIEF, DC CORD, 12 AWG .............................................................. 17 18 19 20 21 22 23 24 25 1018291-01 1012101 1018285-01 1018418-01 1019144-01 0007479 1014306 0000451 0001028 CORDSET, DC, 90.5 INCHES LONG WITH LEADS, 12 AWG ........................................... ASSEMBLY, FUSE (INCLUDES HARDWARE).................................................................... AMMETER (INCLUDES HARDWARE) ............................................................................... KIT, WIRE ASSEMBLY ........................................................................................................ ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. BOLT, HEX HEAD, 1/4 - 20 x 1 1/4 .......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. NUT, HEX, 1/4 - 20 .................................................................................................................. 14 E 1 1 12 1 1 1 1 1 1 1 2 4 4 1 1 2 1 1 1 1 1 1 4 4 4 4 Page 14-11 114 1E Page 14-12 ELECTRIC MOTOR 15 E TYPICAL 2 PLACES TYPICAL 2 PLACES 115 12 1E 9 11 13 10 14 7 19 17 8 TYPICAL 4 PLACES 15 16 2 24 23 18 20 1 6 5 4 22 21 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE— SECTION 16 Page 15-2 MOTOR—POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1017857-01 1017944 1017958 1017947 N/A N/A N/A N/A 1017961 1017953 1017951 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1017891-01 1018132-02 1018228-01 1014201 0000451 1010934 0007174 2 3 QTY 4 ASSEMBLY, 48 VOLT MOTOR, 3.10 HP (INCLUDES ITEMS 1 - 20) ...................................... SHIELD, END ...................................................................................................................... ASSEMBLY, STATOR SHELL AND WINDING .................................................................... PACKAGE, HARDWARE (INCLUDES ITEMS 4 - 7) ........................................................... BUSHING, INSULATOR ................................................................................................. WASHER, FLAT, 5/16 .................................................................................................... NUT, HEX, 5/16 - 18 ...................................................................................................... BUSHING, INSULATOR ................................................................................................. SCREW, CLAMP, UNF, #10 - 32 x 8 5/8 ............................................................................. SCREW, BEARING RETAINER, #8 - 32 x 7/8 .................................................................... SHIELD, END ...................................................................................................................... SCREW, BRUSH HOLDER, #6 - 32 x 1/2 ........................................................................... RIGGING, BRUSH .............................................................................................................. PACKAGE, BRUSH (2 PIECES) ......................................................................................... PACKAGE, BRUSH SPRING (4 PIECES) .......................................................................... BEARING, BALL ................................................................................................................. RETAINER, BEARING ........................................................................................................ ARMATURE ........................................................................................................................ RING, GUIDE ...................................................................................................................... ADHESIVE, GUIDE RING, 3 GRAM TUBE ........................................................................ RING, INTERNAL RETAINING ........................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 1 .............................................................................................. WASHER, LOCK, 5/16 ............................................................................................................ 1 1 1 1 2 4 4 2 4 2 1 2 1 1 1 1 1 1 1 A/R 1 3 3 1 1 Page 15-3 15 E 115 1E Page 15-4 TRANSAXLE— ELECTRIC VEHICLE 16 E 116 1E y;y; ;yy;y;y;y;y; REFERENCE MOTOR— SECTION 15 38 37 12 11 10 9 8 3 1 20 16 17 24 7 36 15 16 16 19 14 4 18 23 5 21 6 22 25 6 32 5 34 4 36 26 33 13 15 13 35 7 30 31 30 28 29 27 Page 16-2 2 8 27 9 36 3 TRANSAXLE, TYPE G— POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1018960-01 1018958-01 1018959-01 1019222-01 1019723-01 1011291 1018971-01 1019754-01 1019760-01 1018979-01 1019235-01 1018955-01 1018972-01 0007330 1018956-01 1013794 0007335 1019237-01 0007336 1019069-01 1018954-01 1019722-01 1019721-01 1019232-01 1018970-01 1018976-01 1019236-01 1019239-01 1019036-01 1019230-01 1019037-01 1019221-01 1019062-01 1018974-01 1019724-01 1018957-01 1019287-01 0000451 1014201 2 3 QTY 4 TRANSAXLE, TYPE G (INCLUDES ITEMS 1 - 36) ................................................................ AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 3 - 7) .................................... AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 3 - 7) ............................................. STUD, LUG .................................................................................................................... SLEEVE ......................................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... RING, RETAINING ......................................................................................................... RING, RETAINING ......................................................................................................... BOLT, M10 x 1.5 x 35MM .................................................................................................... WASHER, LOCK, 20MM ..................................................................................................... SEAL, OIL, INPUT SHAFT ................................................................................................. GEAR CASE, PASSENGER SIDE ...................................................................................... BREATHER ......................................................................................................................... BEARING, DIFFERENTIAL ................................................................................................ ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... SEAL, OIL, AXLE SHAFT ................................................................................................... BEARING, INPUT GEAR ..................................................................................................... SHAFT, INPUT .................................................................................................................... BEARING, INTERMEDIATE GEAR .................................................................................... ASSEMBLY, INTERMEDIATE GEAR .................................................................................. GEAR CASE, DRIVER SIDE .............................................................................................. PLUG, FILL ......................................................................................................................... PLUG, MAGNETIC ............................................................................................................. GASKET, PLUG .................................................................................................................. BOLT, M8 x 1.25 x 60MM .................................................................................................... PIN, DOWEL ....................................................................................................................... HOUSING, DIFFERENTIAL ................................................................................................ GEAR, DIFFERENTIAL ...................................................................................................... PLATE, THRUST (IDLER GEAR) ........................................................................................ GEAR, DIFFERENTIAL IDLER ........................................................................................... PLATE, THRUST ................................................................................................................. PIN, DIFFERENTIAL .......................................................................................................... GEAR, OUTPUT ................................................................................................................. BOLT, M10 x 1.5 x 25MM .................................................................................................... PIN, DOWEL ....................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... GASKET, LIQUID, 8.8 OZ. (250 GRAM) ............................................................................. WASHER, LOCK, 1/4 ............................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... 1 1 1 8 1 2 2 2 10 10 1 1 1 2 1 2 3 1 1 1 1 1 1 2 11 2 1 2 2 2 2 1 1 4 1 1 A/R 3 3 NOTE: TRANSAXLE TYPE IS IDENTIFIED BY ORIENTATION OF GEAR CASE BOLTS. THE TYPE G TRANSAXLE HAS GEAR CASE BOLT HEADS FACING TOWARD THE PASSENGER SIDE OF THE VEHICLE. Page 16-3 16 E 116 1E y;y; ;yy;y;y;y;y; REFERENCE MOTOR— SECTION 15 12 43 42 11 13 10 9 8 3 1 24 18 15 26 19 7 18 17 16 4 25 18 5 TYPICAL 2 PLACES 23 6 22 30 21 28 27 29 20 6 14 5 41 31 4 37 17 40 38 7 37 33 34 14 34 36 Page 16-4 2 8 35 9 32 39 15 3 TRANSAXLE, TYPE K— POWERDRIVE ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 1017683-02 1013785 1013786 1013787 1014207 1011291 1013792 1016672 1013790 1013791 1013775 1013756 1012711 1013758 0007330 1013789 1017704 1013794 0007335 1013764 0007336 1013766 1013780 1013765 1013757 1013759 1013763 1012710 1013779 1013782 1013767 1013772 1019105-01 1013768 1013773 1013774 1013769 1013771 1013770 1013781 1017703 1014193 1014201 0000451 2 3 QTY 4 TRANSAXLE, TYPE K (INCLUDES ITEMS 1 - 41) ................................................................. AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 3 - 7) .................................... AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 3 - 7) ............................................. STUD, LUG .................................................................................................................... BUSHING, 25 MM I. D. ................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... CIRCLIP, TYPE C ........................................................................................................... RING, RETAINING ......................................................................................................... BOLT, M10 x 1.5 x 30MM .................................................................................................... WASHER, LOCK, 13/32 ...................................................................................................... SEAL, INPUT SHAFT OIL .................................................................................................. GEAR CASE, PASSENGER SIDE ...................................................................................... BREATHER ......................................................................................................................... GASKET, CASE .................................................................................................................. BEARING, INNER AXLE TUBE .......................................................................................... GASKET, AXLE TUBE ........................................................................................................ ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... SEAL, AXLE SHAFT OIL .................................................................................................... BEARING, INPUT GEAR .................................................................................................... SHAFT, INPUT .................................................................................................................... BEARING, INTERMEDIATE GEAR .................................................................................... GEAR, INTERMEDIATE, SMALL ........................................................................................ KEY, SUNK ......................................................................................................................... GEAR, INTERMEDIATE, LARGE ....................................................................................... GEAR CASE, DRIVER SIDE .............................................................................................. PLUG, FILL, WITH GASKET .............................................................................................. BOLT, M6 x 1 x 50MM ......................................................................................................... PIN, DOWEL ....................................................................................................................... BOLT, M8 x 1.25 x 37MM .................................................................................................... PLATE, LOCK ..................................................................................................................... GEAR, OUTPUT ................................................................................................................. PIN, DIFFERENTIAL .......................................................................................................... KIT, DIFFERENTIAL GEAR CASE (INCLUDES ITEMS 33 - 36) ........................................ GEAR CASE, DIFFERENTIAL (DRIVER SIDE) ............................................................. PLATE, THRUST (DIFFERENTIAL GEAR) .................................................................... PLATE, THRUST (IDLER GEAR) ................................................................................... GEAR CASE, DIFFERENTIAL (PASSENGER SIDE)..................................................... GEAR, DIFFERENTIAL ...................................................................................................... GEAR, DIFFERENTIAL IDLER ........................................................................................... SHIM ................................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... PIN, DOWEL ....................................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. 1 1 1 8 1 2 2 2 10 10 1 1 1 1 2 2 1 2 3 1 1 1 1 1 1 2 10 2 8 4 1 1 1 1 2 2 1 2 2 1 1 1 3 3 NOTE: TRANSAXLE TYPE IS IDENTIFIED BY ORIENTATION OF GEAR CASE BOLTS. THE TYPE K TRANSAXLE HAS GEAR CASE BOLT HEADS FACING TOWARD THE DRIVER SIDE OF THE VEHICLE. Page 16-5 16 E NOTES NOTES 116 1E Page 16-8 Transportation and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658