Cushman HAULER 800, Service & Parts Manual

Page 1: ...ISSUED JANUARY 2019 HAULER 800X ELiTE Service Parts Manual 688549 D REVISED SEPTEMBER 2019 ...

Page 2: ......

Page 3: ...hanges to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by TSV and therefore is subject to change without notice TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE QUENTIAL DAMAGES resulting from the use of the information ...

Page 4: ...tates of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C BATTERY DISP...

Page 5: ...USE THE SERVICE PARTS MANUAL V ACCELERATOR A 1 BATTERY CHARGER B 1 BODY C 1 BRAKES D 1 ELECTRICAL E 1 ELECTRONIC SPEED CONTROL F 1 FRONT SUSPENSION G 1 MOTOR H 1 REAR AXLE J 1 REAR SUSPENSION K 1 SEATING L 1 WEATHER PROTECTION N 1 WHEELS AND TIRES P 1 DECALS AND LABELS R 1 ...

Page 6: ...Page iv NOTES Service Parts Manual Service Parts Manual ...

Page 7: ...THE MANUAL To use this manual consult the TABLE OF CONTENT to locate the information or illustration required Introduction of some revisions varies due to supply of components therefore it is possible that various combinations of components may be found that are not directly reflected by each illustration Consult the illustration that best suits your situation and then contact the Service Parts De...

Page 8: ...found The part number is the lowest assembly sold by Service Parts and the asterisk indicates that the part depicted is not available for purchase NOTE Descriptions are indented under the assembly that they are used on That assembly is in turn listed under the assembly that it is used on This process is repeated until the highest final assembly is reached To facilitate the maintenance and repair o...

Page 9: ...the two digit color code CODE DESCRIPTION 11 BLACK 19 PATRIOT BLUE PEARL 20 INFERNO RED METALLIC 26 STEEL BLUE PEARL 31 METALLIC CHARCOAL 35 SAFETY YELLOW 36 IVORY 37 FOREST GREEN 38 BRIGHT WHITE 39 FLAME RED 41 ELECTRIC BLUE 42 PLATINUM 43 BURGUNDY 44 ALMOND 51 SUNBURST ORANGE 52 BRITISH RACING GREEN 69 MONSTER GREEN 72 MATTE BLACK 73 MATTE GREEN 74 BARLEY GOLD 75 OASIS GREEN 76 JAVA BROWN 78 REA...

Page 10: ...ERATOR 37 Front of Vehicle 32 33 28 22 29 30 22 24 20 15 14 26 25 36 2 3 4 10 11 21 19 18 17 16 4 5 7 8 To harness from direction selector Part of Frame 1 Pedal Box Assembly includes items 2 33 27 Accelerator Pedal Assembly includes items 28 30 ...

Page 11: ...ss Head Screw SS 8 32 x 3 4 Lg 2 6 7 01050G02 Pan Head Torx Screw 4 20 x 5 8 Lg 2 8 28444G01 Accelerator Rod Cam 1 9 10 00983G01 Self Threading Nut 38 2 11 602484 Plunger 1 12 13 14 17677G1 Spring Retainer 1 15 17979G1 Bushing 75 x 2 Lg 1 16 73046G01 Compression Spring 1 17 17677G2 Spring Retainer 3 8 1 18 73332G01 Accelerator Rod 1 19 00532G4 Hex Nut 5 16 24 1 20 10385G4 Clevis Yoke Adjustable 1 ...

Page 12: ...number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY ACCELERATOR 32 654644 Pedal Harness 1 33 654645 Grommet Rubber 1 34 35 36 00715G2 Hex Head Bolt 5 16 18 x 3 4 Lg 4 37 70135G01 Pedal Pivot Cover 1 ...

Page 13: ...Page A 4 688549 Service Parts Manual Notes ACCELERATOR ...

Page 14: ...Page B 1 688549 Service Parts Manual BATTERY CHARGER 1 3 2 ...

Page 15: ...omponent that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page B 2 688549 Service Parts Manual BATTERY CHARGER 1 653213 Battery Charger 51V 3 Meter Chord 1 2 653216 Battery Charger 51V 5 5 Meter Chord 1 3 657667 Battery Charger Paddle 1 ...

Page 16: ...Page B 3 688549 Service Parts Manual Notes BATTERY CHARGER ...

Page 17: ...Page B 4 688549 Service Parts Manual Notes BATTERY CHARGER ...

Page 18: ...Page C 1 688549 Service Parts Manual BODY 11 12 5 7 9 6 8 2 18 17 19 20 15 19 16 20 16 21 2 1 13 11 Front of Vehicle 16 16 21 22 25 24 23 ...

Page 19: ...Head Bolt 1 4 20 x 3 4 Lg 2 8 14390G4 Lock Nut 1 4 20 2 9 15058G1 Rivet Aluminum 3 16 x 45 Lg 2 10 11 01038G01 Hex Washer Head Swageform Screw 1 4 20 x 70 Lg 4 12 16469G1 Fender Washer 2 13 654276 Front Fascia Mounting Brace 1 14 15 662022 Brush Guard 1 16 652311 Round Head Torx Bolt 5 16 18 x 3 Lg 4 17 75048G03 Spacer 328 I D x 75 O D x 1 5 Lg 2 18 75048G04 Spacer 328 I D x 75 O D x 1 Lg 4 19 005...

Page 20: ...Page C 3 688549 Service Parts Manual BODY 1 5 6 7 10 9 9 8 2 3 4 Front of Vehicle ...

Page 21: ...NO 1 2 3 4 5 DESCRIPTION QTY Page C 4 688549 Service Parts Manual BODY 1 74523G01 Front Basket 1 2 651010G01 Front Basket Bracket Driver Side 1 3 651010G02 Front Basket Bracket Passenger Side 1 4 00769G2 Round Head Carriage Bolt 3 8 16 x 1 25 Lg 4 5 11098G5 Lock Nut 3 8 16 4 6 619586 Spacer 328 O D x 75 I D x 75 Lg 4 7 634807 Spacer 328 O D x 75 I D x 50 Lg 2 8 75048G04 Spacer 328 O D x 75 I D x 1...

Page 22: ...e C 5 688549 Service Parts Manual BODY 35 36 18 18 16 14 17 23 22 7 3 5 33 6 13 1 15 11 10 2 3 17 Front of Vehicle 4 25 Glove Box Door Assembly Passenger Side includes items 26 29 A A 26 29 32 30 31 28 27 ...

Page 23: ... x 75 x 5 2 8 9 10 648562 Cup Holder Driver Side 1 11 613373 Pan Head Tapping Screw with Washer M4 8 1 6 x 22mm Lg 4 12 13 650913 Single Center Cup Holder 2 14 666298 Instrument Panel Support 1 15 645323 Pan Washer Head Torx Screw M6 1 x 23 4mm Lg 2 16 602409 Barrel Clip M6 1 2 17 71597G01 Self Threading Nut 5mm x 10mm x 15mm 3 18 01038G01 Hex Washer Head Swageform Screw 1 4 20 x 70 Lg 4 19 20 21 ...

Page 24: ...d serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY BODY 32 652390 Glove Box Striker 1 33 648561 Tray Panel Passenger Side 1 34 35 660844 Center IP Mat 1 36 660880 Glove Box Mat 1 ...

Page 25: ...Page C 8 688549 Service Parts Manual Notes BODY ...

Page 26: ...Page C 9 688549 Service Parts Manual BODY 9 3 1 7 8 27 15 16 18 17 28 10 11 21 22 23 24 16 17 18 13 14 Front of Vehicle ...

Page 27: ...r Side 1 9 10 654378G01 Small Front Fender Flare Driver Side 1 11 654378G02 Small Front Fender Flare Passenger Side 1 12 13 615239 Rocker Panel Driver Side 1 14 617333 Rocker Panel Passenger Side 1 15 15058G6 Rivet Aluminum 3 16 x 95 Lg 2 16 645323 Pan Washer Head Torx Screw M6 1 x 23 4mm Lg 4 17 23726G4 Spacer 5 O D x 38 I D x 325 Lg 4 18 601476 Flanged Lock Nut M6 1 4 19 20 21 655917G01 Upper Ro...

Page 28: ...Page C 11 688549 Service Parts Manual BODY 4 4 2 2 1 5 7 Front of Vehicle 6 11 10 ...

Page 29: ...ustomer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 12 688549 Service Parts Manual BODY 1 641260 Upper Floor Panel 1 2 14601G11 Rivet Aluminum 3 16 x 575 Lg 7 3 4 14601G11 Rivet Aluminum 3 16 x 575 Lg 6 5 664052G02 Lower Floor Panel 1 6 665025 Access Cover 1 7 664735 Floorboard Spacer 2 8 9 10 70244G05 Splash Pan 1 11 00715G2 Flanged Hex Head Bolt 5 ...

Page 30: ...88549 Service Parts Manual BODY 2 38 23 10 11 2 2 2 3 17 1 16 4 8 Side Panel Driver Side includes items 10 12 9 Side Panel Passenger Side includes items 11 12 2 14 18 15 Front of Vehicle 12 29 28 31 26 27 30 20 24 ...

Page 31: ...Passenger Side Includes Items 11 12 1 10 649388G04 Side Panel Driver Side 1 11 649388G05 Side Panel Passenger Side 1 12 602409 Barrel Clip M6 1 3 13 14 649657G01 Hip Restraint Closeout Driver Side 1 15 649657G02 Hip Restraint Closeout Passenger Side 1 16 613373 Pan Head Tapping Screw M4 5 1 6 x 22mm Lg 2 17 634161 Button Head Torx Screw M6 1 x 30mm Lg 6 18 10570G10 Rivet SS 5 32 x 55 Lg 1 19 20 10...

Page 32: ...of Vehicle 5 6 15 16 13 Center hole on frame 11 Rocker Panel Floorboard Front of Vehicle 12 Accelerator Pedal Guard Kit includes items 13 14 14 Accelerator Pedal Guard Hardware Kit includes items 15 16 Dash Panel Existing Gauge Plate Hardware Front of Vehicle 7 ...

Page 33: ...549 Service Parts Manual BODY 1 653010 Base Bracket 1 2 800385 Flanged Hex Head Bolt 3 8 16 x 3 4 Lg 1 3 11027G5 Flanged Lock Nut 3 8 16 1 4 00114G6 Hex Washer Head Screw 1 4 14 x 3 4 Lg 3 5 74365G01 Gun Mount Plate 1 6 Screw 4 7 664044 Radio Clip 1 8 9 10 11 661653 Floorboard Mount 1 12 666379 Accelerator Pedal Guard Kit Includes Items 13 14 1 13 662991 Accelerator Pedal Guard 1 14 666380 Acceler...

Page 34: ...Page C 17 688549 Service Parts Manual BODY 7 4 3 1 2 11 12 5 6 15 16 13 14 20 21 19 Front of Vehicle ...

Page 35: ... Lg 4 3 00922G3 Flat Washer 7 16 4 4 00734G1 Lock Nut 7 16 14 4 5 00198G8 Flat Head Machine Screw 5 16 18 x 1 Lg 1 6 00571G2 Flat Washer 5 16 1 7 11098G6 Lock Nut 5 16 18 1 8 9 10 11 74890G01 Rear Valance Panel 1 12 16816G2 Ratchet Rivet 25 x 887 2 13 74892G01 Rear Fender without Taillight Driver Side 1 14 74892G02 Rear Fender without Taillight Passenger Side 1 15 74892G03 Rear Fender with Taillig...

Page 36: ...arts Manual BODY 3 Clevis Hitch Drop Ball Hitch Drop Angle Hitch Drop Clevis Hitch Heavy Duty Hitch Kit Angle Hitch Rear Bumper Rear Hitch Receiver 4 6 1 20 20 21 21 2 4 3 8 3 12 3 2 3 14 16 15 4 4 3 4 18 10 9 4 Front of Vehicle ...

Page 37: ...ge C 20 688549 Service Parts Manual BODY 1 646730 Heavy Duty Hitch 1 2 31757G1 Hitch Ball 1 7 8 1 3 21317G1 Clevis Pin 5 8 x 3 Lg 1 4 21683G1 Cotter Pin 15 32 x 2 1 16 Lg 1 5 6 646729 Angle Hitch 1 7 8 646727 Clevis Hitch 1 9 14443G10 Clevis Pin 1 2 x 3 Lg 1 10 19314G1 Cotter Pin 5 2 Lg 1 11 12 646743 Drop Ball Hitch 1 13 14 646744 Drop Clevis Hitch 1 15 14443G10 Clevis Pin 1 2 x 3 Lg 1 16 19314G1...

Page 38: ...Page C 21 688549 Service Parts Manual Notes BODY ...

Page 39: ...Page C 22 688549 Service Parts Manual Notes BODY ...

Page 40: ... Manual BRAKES 3 10 26 27 6 5 7 9 6 11 13 23 19 23 24 25 20 21 22 14 16 15 17 18 12 4 1 Brake Pedal Assembly without Light includes items 3 9 2 Brake Pedal Assembly with Light includes items 3 5 28 28 4 WHEEL DRUM BRAKES 8 29 9 28 ...

Page 41: ... Pivot Pin 314 Dia x 5 25 Lg 1 6 658825 Push Nut 5 16 24 2 7 70257G01 Brake Pad 1 8 665987 Park Brake Pad 1 9 Oval Rivet 375 x 468 Lg 9 10 651207G0103 Brake Pedal with Lights 1 11 652820 Brake Pedal Plate 1 12 00737G8 Flat Head Phillips Screw 10 24 x 875 Lg 4 13 00739G1 Well Nut Rubber 10 24 2 14 27137G01 Conical Spring 2 15 652355 Brake Pedal Spacer 2 16 00642G8 Flat Washer 5 16 2 17 00559G5 Flat...

Page 42: ...ront Brake Drum Pedal Brake Front of Vehicle To Rear Brake Drum Rear Axle Passenger Side Front of Vehicle 2 3 4 4 2 6 7 5 5 8 18 21 22 15 16 20 17 18 21 25 26 23 23 9 10 23 12 11 17 1 Compensator Assembly 4 Wheel Drum Brakes includes items 2 12 4 WHEEL DRUM BRAKES ...

Page 43: ...83G01 Compensator Bumper 56 Dia 4 9 624690 Front Brake Cable 37 06 Lg Driver Side 1 10 624691 Front Brake Cable 46 81 Lg Driver Side 1 11 652751 Rear Brake Cable 98 Lg Passenger Side 1 12 652752 Rear Brake Cable 103 Lg Passenger Side 1 13 14 15 00643G1 Flat Washer 3 8 1 16 11098G5 Lock Nut 3 8 16 1 17 10386G3 Clevis Pin 313 x 84 Lg 2 18 10387G3 Cotter Pin 094 x 75 2 19 20 70582G01 Shoulder Bolt 49...

Page 44: ...Page D 5 688549 Service Parts Manual BRAKES 12 16 13 16 15 14 17 17 1 11 10 3 7 5 4 6 5 2 14 15 Part of Frame Front of Vehicle Front of Vehicle 4 WHEEL DRUM BRAKES ...

Page 45: ... 1 2 00414G6 Hex Head Bolt 1 4 20 x 75 Lg 2 3 14390G4 Lock Nut 1 4 20 2 4 70587G01 Park Brake Cam 1 5 10097G6 Flanged Bearing 502 O D x 378 I D x 380 Lg 2 6 14134G4 Spacer 76 O D x 405 I D x 1 25 Lg 1 7 71215G01 Square Head Set Screw with Patch Lock 1 4 20 x 5 Lg 2 8 9 10 70113G01 Adjustable Rubber Bumper 1 11 11027G1 Flanged Lock Nut 5 16 18 1 12 70098G01 Kick off Cam Pivot 1 13 70601G01 Kick off...

Page 46: ...S 11 3 6 7 15 24 28 23 22 21 18 29 9 20 22 19 27 25 4 30 13 14 16 17 26 12 10 5 Brake Pedal Assembly without Brake Lights includes items 3 12 Brake Pedal Assembly with Brake Lights includes items 3 5 30 Front of Vehicle 1 2 2 WHEEL DRUM BRAKES ...

Page 47: ... 1 7 658825 Push Nut 5 16 24 2 8 9 70257G01 Service Brake Pad 1 10 16409G1 Oval Rivet 375 x 468 Lg 6 11 70256G01 Park Brake Pedal Pad 1 12 16409G1 Oval Rivet 375 x 468 Lg 3 13 652820 Service Brake Pedal Plate 1 14 00737G8 Flat Head Phillips Screw 10 24 x 875 Lg 4 15 00739G1 Rubber Well Nut 10 24 2 16 652355 Brake Pedal Spacer 2 17 27137G01 Conical Spring 2 18 14390G10 Lock Nut 10 24 2 19 10606G8 M...

Page 48: ...ES Part of Frame Accelerator Pedal 1 12 21 29 30 13 47 48 2 15 17 17 27 28 18 19 18 19 16 16 20 24 25 26 31 3 4 5 49 11 36 37 40 43 41 42 40 44 46 39 38 45 Compensator Assembly includes items 37 49 Front of Vehicle 32 11 33 2 WHEEL DRUM BRAKES ...

Page 49: ...trated 1 7 12416G2 Wedge Clamp Nylon 11 8 Lg Not Illustrated 4 8 9 10 11 01111G01 Retaining Ring 8 O D x 39 I D x 42 4 12 10386G3 Clevis Pin 313 x 84 Lg 1 13 10387G3 Cotter Pin 094 x 75 1 14 15 70601G01 Kick off Linkage Rod 1 16 17838G1 Flanged Nyliner Bushing 374 O D x 313 I D x 312 Lg 2 17 20835G1 Washer 62 O D x 39 I D x 135 2 18 00559G8 Flat Washer 1 4 20 2 19 10387G3 Cotter Pin 094 x 75 2 20 ...

Page 50: ...86G3 Clevis Pin 313 x 84 Lg 1 33 10387G3 Cotter Pin 094 x 75 1 34 35 36 654663 Compensator Assembly Includes Items 37 49 1 37 00532G4 Hex Nut 5 16 24 2 38 629486 Spherical Hex Nut 5 16 24 1 39 28082G01 Equalizer Bracket 1 40 15121G1 Flat Washer 3 8 2 41 17979G1 Accelerator Rod Bushing 464 I D x 1 O D x 2 Lg 1 42 23061G2 Tube 1 43 23463G1 Compression Spring 1 44 652256 Brake Yoke 1 45 11098G9 Lock ...

Page 51: ...Page D 12 688549 Service Parts Manual Notes BRAKES ...

Page 52: ...nual BRAKES 14 4 17 26 25 9 10 18 1 2 16 Brake Assembly Driver Side includes items 3 9 Brake Assembly Passenger Side includes items 3 8 10 Brake Drum Assembly includes items 17 18 22 15 5 21 24 3 6 7 8 Adjuster Assembly Tension Pin 13 ...

Page 53: ...ading 1 4 612412 Brake Shoe Trailing 1 5 612413 Dust Cover 1 6 612415 Brake Spring Top 1 7 612414 Brake Spring Bottom 1 8 612416 Shoe Clamp 2 9 612418 Gear Adjuster Driver Side 1 10 612417 Gear Adjuster Passenger Side 1 11 12 13 17083G2 Hex Head Bolt 5 16 24 x 1 Lg 8 14 15126G1 Lock Nut 5 16 24 8 15 612928 Castle Nut 5 8 18 2 16 19186G1 Brake Drum Assembly Includes Items 17 18 2 17 18500G2 Brake D...

Page 54: ... orientation will be different based on the vehicle model 8 Drum And Hub Assembly includes items 9 11 9 6 Brake Plate Assembly RH includes items 23 40 21 Adjuster Assembly includes item 25 24 Adjuster Body includes items 26 27 25 Adjuster Body includes item 39 38 Brake Plate Assembly LH includes items 22 24 40 20 33 32 31 34 28 26 25 27 30 29 ...

Page 55: ...7 8 652164 Drum And Hub Assembly Includes Items 9 11 1 9 19862G2 Wheel Hub Bolt 1 2 20 x 1 718 Lg 4 10 51141G1 Race Bearing 2 11 647535 Hub 1 12 13 14 00798G8 Cotter Pin 5 32 x 1 3 4 Lg 1 15 648617G01 Brake Cable Bracket Driver Side 1 16 648617G02 Brake Cable Bracket Passenger Side 1 17 18 19 20 20938G1 Brake Assembly LH Includes Items 22 24 40 1 21 20938G2 Brake Assembly RH Includes Items 23 40 1...

Page 56: ...s not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY BRAKES 32 22513G1 Lever Pin 1 33 22514G1 U Clip 1 34 22515G1 Sliding Block 1 35 22511G1 Dust Cover 1 36 17292G1 Tension Pin 2 37 17291G1 Spring Clamp 2 38 23398G1 Brake Shoe Set Includes Item 39 1 39 23355G1 Brake Shoe 2 40 17290G1 Brake Spring 2 ...

Page 57: ...Page D 18 688549 Service Parts Manual Notes BRAKES ...

Page 58: ...Page E 1 688549 Service Parts Manual CAB 2 1 3 4 ...

Page 59: ...al information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page E 2 688549 Service Parts Manual CAB 1 652854 Cab ROPS Kit 1 2 652855 Cab Utility Kit 1 3 652856 Cab Ball Cage Kit 1 4 666496 Cab Ball Cage NON ROPS Kit 1 5 6 652191 DFK Cab Seat Belt Kit Not Illustrated 1 Replacement Parts and Accessories may be obtained from DFK AMERICA INC 2215 W Curtiss Street Downers Grove IL 60515 U S A PHONE 1 630 32...

Page 60: ...Page E 3 688549 Service Parts Manual Notes CAB ...

Page 61: ...Page E 4 688549 Service Parts Manual Notes CAB ...

Page 62: ...Page F 1 688549 Service Parts Manual ELECTRICAL Note FRAME SHOWN PARTIALLY 3 4 9 1 ...

Page 63: ...onsult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page F 2 688549 Service Parts Manual ELECTRICAL 1 678072 Main Harness 1 2 3 20965G3 Steering Column Cover 1 4 615236 Turn Signal Switch Assembly 1 5 6 19344G1 Vinyl Tape Not Illustrated 1 7 8 31539G1 Nylon Clamp 15 5 Not Illustrated 7 9 664706 Horn Jumper 1 10 11 17618G1 Nylon Clamp 15 5 Not Illust...

Page 64: ...Page F 3 688549 Service Parts Manual ELECTRICAL ADVANCED BATTERY 2 MODULE Front of Vehicle Frame 1 10 15 10 16 14 17 17 15 15 10 11 9 6 8 12 11 11 12 9 2 6 7 11 12 9 4 3 2 ...

Page 65: ...1 665953 Battery Management System 1 2 665954 Cell Module 2 3 663490 Battery Tray 1 4 651809 Bottom Tray 1 5 6 01101G01 Tie Down Bolt 2 7 654002G01 Hold Down Bracket Driver Side 1 8 654002G02 Hold Down Bracket Passenger Side 1 9 11027G1 Flanged Lock Nut 5 16 18 4 10 00715G2 Hex Washer Head Bolt 5 16 18 x 80 Lg 4 11 13437G9 Serrated Head Lock Screw 1 4 20 x 3 4 Lg 8 12 14390G4 Lock Nut 1 4 20 8 13 ...

Page 66: ...Page F 5 688549 Service Parts Manual ELECTRICAL 6 3 10 7 9 5 1 2 11 4 8 10 Front of Vehicle Battery Pack ADVANCED BATTERY 2 MODULE 13 14 ...

Page 67: ...ice Parts Manual ELECTRICAL 1 651878 Top Cover 1 2 654616 Button Head Tapping Screw 10 X 625 Lg 5 3 652090 Harness BMS to Main Harness 1 4 654863 Flanged Hex Head Bolt 1 4 10 x 8 3 4 Lg 2 5 651960 Battery Communication Cable 60AH 1 6 652002 Battery Cable Red 6AWG 122mm Lg 1 7 653432 Battery Cable Black 6AWG 122mm Lg 1 8 653449 Battery Cable Red 6AWG 145mm Lg 1 9 651811 Battery Cable Black 6AWG 595...

Page 68: ...DVANCED BATTERY 3 MODULE Front of Vehicle 4 3 1 16 19 20 17 18 2 Front of Vehicle NOTE Refer to ADVANCED BATTERY 2 MODULE for exploded view of battery pack NOTE Refer to ADVANCED BATTERY 2 MODULE for exploded view of battery pack ADVANCED BATTERY 4 MODULE ...

Page 69: ...549 Service Parts Manual ELECTRICAL 1 651961 Battery Communication Cable 90AH 1 2 653431 Battery Cable Black 6AWG 154mm Lg 1 3 653433 Battery Cable Red 6AWG 154mm Lg 1 4 654488 Battery Tray Spacer 2 5 659134 Conical Hex Nut M8 1 25 2 6 7 8 9 10 11 12 13 14 15 16 651962 Battery Communication Cable 120AH 1 17 653431 Battery Cable Black 6AWG 154mm Lg 1 18 653432 Battery Cable Black 6AWG 122mm Lg 1 19...

Page 70: ... 6 8 9 10 7 11 Strobe Light Kit includes items 12 21 12 Strobe Light Assembly includes items 13 14 Canopy Shown for Reference only Canopy Top 13 14 18 16 17 15 DC DC Converter Assembly includes items 5 7 4 HOUR METER Front of Vehicle 1 Controller Splash Shield 2 3 Front of Vehicle Seat Wrap ...

Page 71: ...2372 Self Tapping Screw 10 32 x 3 4 Lg 4 8 00414G6 Hex Head Bolt 1 4 20 x 3 4 Lg 2 9 00559G7 Flat Washer 1 4 2 10 11027G2 Flanged Lock Nut 1 4 20 2 11 618916 Strobe Light Kit Includes Items 12 21 1 12 638496 Strobe Light Assembly Includes Items 13 14 1 13 639425 Strobe Light 1 14 17064G1 Female Push on Terminal 2 15 00979G01 Socket Head Screw 10 24 x 7 8 Lg 3 16 00559G5 Flat Washer 10 3 17 14390G1...

Page 72: ...r Fender TAILLIGHT 6 A Front of Vehicle 13 HEADLIGHTS 1 Front Grille Assembly with Lights includes items 3 5 2 Front Grille Assembly with Led Lights includes items 3 4 9 5 Headlight includes item 6 3 4 19 11 15 16 12 10 5 9 B 18 A 8 7 B Front of Vehicle ...

Page 73: ...5 1 2 651698G03 Front Grille Assembly with Led Lights Includes Items 3 4 9 1 3 648564 Front Grille 1 4 651437 Lens Cover 2 5 651411G01 Headlight Includes Item 6 2 6 619100 Headlight Bulb 1 7 651897G02 Headlight Switch 2 Position For Halogen Light 1 8 651897G03 Headlight Switch 3 Position For LED Light 1 9 651411G03 LED Headlight 2 10 71597G01 Self Threading Nut 5 x 10 x 15mm 9 11 71781G02 Vinyl Ta...

Page 74: ...27 28 26 27 13 13 Gauge Plate with Fuel Assembly includes items 5 9 10 1 Gauge Plate with USB Fuel Assembly includes items 7 9 10 13 16 19 21 3 Gauge Plate 12V USB Fuel Assembly includes items 7 14 17 19 21 4 USB Port Housing Assembly includes items 22 23 21 Gauge Plate with 12V Fuel Assembly includes items 6 9 10 12 14 2 10 10 22 23 17 7 ...

Page 75: ... 16 19 21 1 4 666085G08 Gauge Plate with 12V USB Fuel Assembly Includes Items 7 14 17 19 21 1 5 662083G01 Gauge Plate 1 6 662083G02 Gauge Plate with 12V 1 7 662083G03 Gauge Plate with 12V USB 1 8 9 612314 State of Charge Fuel Meter 1 10 651897G01 Horn Switch 2 Position 1 11 12 71078G01 12V Power Outlet 1 13 627035 Plug 1 14 71055G01 Rivet 3 16 Dia 2 15 16 20271G10 Hole Plug 1 125 Lg 1 17 638233 El...

Page 76: ...Page F 15 688549 Service Parts Manual Notes ELECTRICAL ...

Page 77: ...Page F 16 688549 Service Parts Manual Notes ELECTRICAL ...

Page 78: ...Page G 1 688549 Service Parts Manual ELECTRONIC SPEED CONTROL Front of Vehicle Part of Solenoid 3 9 3 4 5 5 10 16 16 17 6 2 7 8 14 14 11 12 15 18 13 8 4 1 Controller Assembly includes items 2 13 ...

Page 79: ...ontroller 1206AC 1 3 01110G01 Flat Washer 1 4 2 4 11027G2 Flanged Lock Nut 1 4 20 2 5 00414G5 Hex Head Bolt 1 4 20 x 1 2 Lg 2 6 663609G06 Controller Bracket Front 1 7 663609G08 Controller Bracket Rear 1 8 606264 Flanged Hex Head Bolt M6 1 x 20mm Lg 4 9 612711 Solenoid 48V 1 10 12914G1 Push on Male Terminal 2 11 73876G01 Flanged Hex Head Bolt M6 1 x 12mm Lg 2 12 653471 Negative Battery Cable B 480m...

Page 80: ...Page G 3 688549 Service Parts Manual Notes ELECTRONIC SPEED CONTROL ...

Page 81: ...Page G 4 688549 Service Parts Manual Notes ELECTRONIC SPEED CONTROL ...

Page 82: ...and Hub Assembly 4 Lug Passenger Side includes items 4 13 Spindle and Hub Assembly Driver Side includes items 5 13 17 3 16 Front of Vehicle Steering Box Assembly 25 2 2 24 15 1 19 18 20 5 14 4 6 7 8 13 12 13 8 11 9 10 17 19 22 27 27 21 26 26 28 30 Part of Frame 25 24 23 23 15 ...

Page 83: ...28mm 1 7 25146G1 Grease Seal 1 8 11750G2 Roller Bearing and Race Assembly 2 9 70589G01 Wheel Hub 1 10 19862G1 Wheel Hub Bolt 1 2 20 x 1 218 Lg 4 11 12093G1 Slotted Nut 1 14 1 12 00798G8 Cotter Pin 5 32 x 1 3 4 Lg 1 13 51141G1 Race Bearing 2 14 70754G01 Thrust Washer SS 1 3 1 15 652258 Spring Plate 2 16 70673G03 Spindle and Hub Assembly 4 Lug Driver Side Includes Items 5 13 17 1 17 70742G02 Spindle...

Page 84: ...ervice Parts Manual FRONT SUSPENSION AND STEERING Front of Vehicle Steering Box Assembly 2 1 17 16 17 18 11 12 10 13 24 24 28 23 23 25 27 Part of Frame 15 14 19 For Vehicles with Mechanical Drum Brakes 7 8 29 3 7 8 29 3 ...

Page 85: ... 5 6 7 650940 Hex Head Bolt 7 16 14 x 2 Lg 6 8 00734G1 Lock Nut 7 16 14 6 9 10 10389G3 Grease Fitting 1 11 674927 Spindle Passenger Side 1 12 674883 Spindle Driver Side 1 13 632926 Sleeve Bushing 28mm O D x 25mm I D x 15mm Lg 1 14 632925 Flanged Bushing 28mm O D x 25mm I D x 16 5mm Lg 1 15 70745G01 King Pin Tube 1 16 00407G6 Hex Head Bolt 1 2 13 x 6 Lg 1 17 00560G3 Flat Washer 1 2 2 18 14390G6 Loc...

Page 86: ...Page H 5 688549 Service Parts Manual FRONT SUSPENSION AND STEERING 2 1 3 Front of Vehicle ...

Page 87: ...tes a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page H 6 688549 Service Parts Manual FRONT SUSPENSION AND STEERING 1 652258 Spring Plate 2 2 00463G11 Hex Head Bolt 7 16 14 x 1 1 2 Lg 5 3 00734G1 Lock Nut 7 16 14 5 ...

Page 88: ... Manual FRONT SUSPENSION AND STEERING Steering Box Assembly includes items 3 26 1 Rack Ball Joint includes items 24 25 23 Steering Box Assembly includes items 3 23 27 2 9 8 7 6 12 13 14 15 16 21 10 26 20 4 17 24 25 28 19 11 5 3 27 ...

Page 89: ... Bearing 1 4 Jam Nut 1 2 20 1 5 70750G01 Retaining Ring External 1 6 15112G1 Ball Bearing 1 7 70603G01 Pinion 1 8 70751G01 Retaining Ring Internal 1 9 70638G01 Seal Pinion 1 10 70604G01 Steering Rack 1 11 Set Screw 10 32 x 25 Lg 1 12 70590G01 Rack Loader 1 13 70666G01 Compression Spring 1 14 70645G01 Gasket Rack Loader Cover 1 15 652259 Cover Rack Loader 1 16 71102G01 Hex Washer Head Bolt 1 4 20 x...

Page 90: ...SPENSION AND STEERING Steering Column Kit includes items 13 25 Tie Rod Assembly includes items 37 41 10 32 42 42 37 3 29 16 18 17 24 22 21 20 30 31 7 41 40 38 39 27 28 14 13 6 1 15 12 36 8 4 2 25 9 Axle shown for reference only Front of Vehicle 44 ...

Page 91: ... 7 00734G1 Lock Nut 7 16 14 3 8 00532G7 Hex Nut 1 4 20 1 9 01006G01 Hex Washer Head Bolt 3 8 16 x1 1 4 Lg 4 10 00879G1 Lock Washer 3 8 4 11 12 70758G05 Steering Column Assembly Includes Items 13 25 1 13 70610G03 Steering Column 1 14 28569G01 Steering Column Bushing 1 15 01022G01 Hex Washer Head Bolt 6 20 x 5 16 Lg 1 16 70607G01 Steering Shaft 1 17 15112G1 Ball Bearing O D 1 65 x I D 78 1 18 70887G...

Page 92: ... additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY FRONT SUSPENSION AND STEERING 32 14390G2 Lock Nut 5 8 18 1 33 34 35 36 74604G01 Tie Rod Assembly 26 44 Lg Includes Items 37 41 1 37 74603G01 Threaded Rod 24 Lg 1 38 70902G01 Tie Rod End Left Hand Threads 1 39 01069G01 Jam Nut M12 x 1 25 05 Left Hand Threads 1 40 70902G02 Tie Rod End Right Hand Threads 1 41 01069G02 Jam Nut M12 x 1 25 0...

Page 93: ...Page H 12 688549 Service Parts Manual Notes FRONT SUSPENSION AND STEERING ...

Page 94: ...Page J 1 688549 Service Parts Manual MOTOR Axle Assembly Front of Vehicle 5 2 4 1 6 8 7 ...

Page 95: ...individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page J 2 688549 Service Parts Manual MOTOR 1 680638 Motor 48V AC 1 2 605714 Flexloom 1 3 4 605741 Hex Head Bolt M6 1 x 25mm Lg 6 5 601327 Lock Washer 6mm 6 6 668275 End Cap 1 7 616716 Hex Head Bolt M6 1 x 16mm Lg 3 8 00915G1 Bonded Seal Washer 1 4 I D 3 ...

Page 96: ...Page J 3 688549 Service Parts Manual Notes MOTOR ...

Page 97: ...Page J 4 688549 Service Parts Manual Notes MOTOR ...

Page 98: ...LE 24 12 13 10 23 11 17 21 29 20 31 8 30 22 19 37 18 37 9 33 4 5 25 9 14 29 32 19 37 18 37 36 35 34 28 35 36 17 Front of Vehicle 1 Rear Axle with Limited Slip Differential 16 99 1 includes items 5 37 2 Rear Axle 16 99 1 includes items 4 8 37 8 39 ...

Page 99: ... 3 4 601082 Differential Assembly 1 5 614059 Limited Slip Differential Carrier with CC Clutch 1 6 7 8 15558G1 Hex Head Bolt 5 16 18 x 75 Lg 10 9 17473G1 Bearing Assembly 2 10 23519G2 Ball Bearing Single Lip Seal 1 11 23520G1 Ball Bearing 1 12 23530G1 Retainer Ring 1 13 24628G1 O ring Seal 1 14 601084 Lock Nut 3 8 24 4 15 16 17 608811 End Cap 2 18 620343 Ball Bearing 2 19 620344 Oil Seal 2 20 61282...

Page 100: ...es a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR AXLE 32 620349 Intermediate Gear Assembly 1 33 620350 Drive Gear 1 34 620355 Ball Bearing 1 35 620358 O ring 18mm 2 36 620359 Retaining Ring 2 37 620342 Retaining Ring 4 38 39 72763G02 Scuff Guard 1 ...

Page 101: ...Page K 4 688549 Service Parts Manual Notes REAR AXLE ...

Page 102: ...Page L 1 688549 Service Parts Manual REAR SUSPENSION 3 2 4 12 12 12 6 8 7 13 15 13 14 11 3 2 3 9 2 2 3 1 5 Front of vehicle 18 17 10 10 4 ...

Page 103: ...2 10435G1 Shock Absorber Washer I D 406 x O D 1 25 4 3 10194G1 Rubber Bushing 4 4 00532G6 Hex Nut 3 8 24 2 5 10044G01 Vinyl Cap 1 6 74207G03 Leaf Spring 2 7 72618G04 U Bolt 3 8 16 x 4 1 2 Lg 2 8 620733 Shock Absorber Mounting Plate Driver Side 1 9 620736 Shock Absorber Mounting Plate Passenger Side 1 10 12262G1 Lock Nut M10 4 11 70289G02 Split Steel Spacer I D 376 x O D 1 x 1 Lg 2 12 624030 Flange...

Page 104: ...Page L 3 688549 Service Parts Manual Notes REAR SUSPENSION ...

Page 105: ...Page L 4 688549 Service Parts Manual Notes REAR SUSPENSION ...

Page 106: ...Page M 1 688549 Service Parts Manual SEATING 2 4 3 7 12 18 19 17 13 16 14 6 5 15 1 Seat Back Assembly includes items 2 4 11 Seat Bottom Assembly includes items 12 20 Front of Vehicle ...

Page 107: ...20G06 Black 644820G04 Gray 3 605529 Seat Back Cover 1 4 644268 Seat Back Hip Base 1 5 605056 Hex Head Bolt SS 1 4 20 x 1 Lg 2 6 00664G7 Lock Washer 1 4 2 7 617533 Push Rivet 4 8 9 10 11 629269G15 Seat Bottom Assembly Includes Items 12 20 1 629269G1501 Oyster 629269G1502 Stone Beige 629269G1506 Black 629269G1504 Gray 12 644819G Vinyl Seat Bottom Cover 1 644819G01 Oyster 644819G02 Stone Beige 644819...

Page 108: ...9 Service Parts Manual SEATING 19 28 27 32 29 25 31 24 26 Seat Back Assembly includes items 16 17 15 Seat Bottom Assembly includes items 24 34 23 16 17 9 20 19 Front of Vehicle 30 1 4 5 2 7 8 3 13 12 34 18 11 11 6 6 ...

Page 109: ... 2 5 11098G6 Lock Nut 5 16 18 2 6 01006G01 Hex Washer Head Thread Forming Screw 3 8 16 x 1 1 4 Lg 2 7 657165 Closeout Cover 1 8 18436G1 Drive Rivet 3 9 652243G03 Seat Back Support Bracket 1 10 11 00427G2 Hex Head Bolt 3 8 16 x 1 1 4 Lg 2 12 00560G1 Lock Washer 3 8 1 13 11098G5 Lock Nut 3 8 16 1 14 15 71274G Seat Back Assembly Includes Items 16 17 1 71274G01 White 71274G02 Black 71274G03 Tan 71274G...

Page 110: ...udes Items 24 34 1 629269G0101 Oyster 629269G0103 Tan 629269G0104 Gray 629269G0105 White 629269G0106 Black 629269G0107 Brown 24 71602G Vinyl Seat Bottom Cover 1 71602G01 White 71602G02 Gray 71602G03 Oyster 71602G04 Tan 71602G06 Black 71602G07 Brown 25 71012G01 Vinyl Trim Seat Bottom 1 26 71603G02 Foam Padding Seat Bottom 1 27 71610G01 Seat Hinge 2 28 00720G08 Flat Head Phillips Tapping Screw 12 14...

Page 111: ...Page M 6 688549 Service Parts Manual Notes SEATING ...

Page 112: ...688549 Service Parts Manual Page N 1 TRUCK BED Front of Vehicle 1 Truck Bed Assembly 36 Plastic includes items 2 16 2 3 8 6 4 5 5 16 9 7 10 10 13 13 15 11 15 11 14 14 14 8 12 PLASTIC TRUCK BED ...

Page 113: ...ssembly 36 Plastic Includes Items 2 16 1 2 663898 Bed 36 1 3 649872 Tailgate 40 1 4 651108 Lower Stiffener 1 5 663506 Pan Head Phillips Screw 1 4 20 x 5 8 Lg 9 6 651107 Upper Stiffener 1 7 663506 Pan Head Phillips Screw 1 4 20 x 5 8 Lg 3 8 663143 Tailgate Latch 2 9 663718 Pan Head Phillips Screw 1 4 20 x 3 Lg 4 10 663527 Lock Nut 1 4 20 4 11 651635 Tailgate Cable Assembly 2 12 663506 Pan Head Phil...

Page 114: ...s Manual Page N 3 TRUCK BED Front of Vehicle Front of Vehicle 1 2 6 25 13 26 11 27 28 12 7 8 5 4 CIRCUIT BREAKER Electric Dump Assembly includes items 25 30 24 30 29 27 9 10 22 19 17 17 16 21 20 15 18 14 Instrument Panel ...

Page 115: ...G02 Channel Outrigger 1 9 70113G01 Adjustable Rubber Bumper 2 10 11027G1 Lock Nut 5 16 18 2 11 14443G10 Clevis Pin 5 x 3 Lg 1 12 14443G12 Clevis Pin 5 x 2 22 Lg 1 13 21683G1 Cotter Pin 320 x 2 969 2 14 76423G01 Truck Bed Frame 1 15 71283G02 Electric Lift Bracket 1 16 00439G2 Hex Head Bolt 5 16 18 x 1 1 4 Lg 4 17 00642G8 Flat Washer 5 16 8 18 11098G6 Lock Nut 5 16 18 4 19 00415G6 Hex Head Bolt 1 4 ...

Page 116: ...BED A 21 Front of Vehicle 1 2 8 5 13 11 12 10 6 7 40 37 38 4 39 41 9 38 18 36 27 29 28 33 26 31 32 A 28 Front of Vehicle 17 22 20 20 19 24 23 25 Truck Bed Latch Assembly includes items 36 41 35 TRUCK BED MANUAL LIFT WITH SPRING ASSEMBLY 14 15 16 ...

Page 117: ...9 21683G1 Cotter Pin 320 x 2 969 1 10 71569G02 Gas Spring Channel 1 11 01118G01 Hex Head Bolt with Patch Lock 1 4 20 x 62 Lg 6 12 00642G7 Flat Washer 1 4 6 13 14443G10 Clevis Pin 5 Dia x 3 Lg 1 14 21683G1 Cotter Pin 320 x 2 969 1 15 70113G01 Adjustable Rubber Bumper 2 16 11027G1 Lock Nut 5 16 18 2 17 76423G01 Truck Bed Frame 1 18 71283G02 Electric Lift Bracket 1 19 00439G2 Hex Head Bolt 5 16 18 x ...

Page 118: ...artment for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY TRUCK BED 688549 Service Parts Manual 32 00560G1 Flat Washer 3 8 4 33 00426G8 Hex Head Bolt 3 8 16 x 3 4 Lg 4 34 35 665990 Truck Bed Latch Assembly Includes Items 36 41 1 36 666224 Latch 1 37 652440G03 Latch Retainer Bracket 1 38 01118G01 Hex Head Bolt with Patch Lock 1 4 20 x 62 Lg 4 39 71704G01 Handle Grip 2 40 657267 Reta...

Page 119: ...Page N 8 Notes TRUCK BED 688549 Service Parts Manual ...

Page 120: ... Page N 9 TRUCK BED A Front of Vehicle 1 2 5 15 13 4 14 16 13 11 27 29 28 25 26 31 24 28 Front of Vehicle 8 22 20 20 19 Truck Bed Latch Assembly includes items 11 16 10 TRUCK BED MANUAL LIFT WITHOUT SPRING ASSEMBLY 21 6 7 12 A 23 ...

Page 121: ... Lock Nut 5 16 18 2 8 76423G01 Truck Bed Frame 1 9 10 665990 Truck Bed Latch Assembly Includes Items 11 16 1 11 666224 Latch 1 12 652440G03 Latch Retainer Bracket 1 13 01118G01 Hex Head Bolt with Patch Lock 1 4 20 x 62 Lg 4 14 71704G01 Handle Grip 2 15 657267 Retainer Bracket 2 16 71538G01 Torsion Spring 1 17 18 19 00439G2 Hex Head Bolt 5 16 18 x 1 1 4 Lg 4 20 00642G8 Flat Washer 5 16 8 21 11098G6...

Page 122: ...688549 Service Parts Manual Page N 11 TRUCK BED A Front of Vehicle 10 12 11 8 9 14 7 A 11 Front of Vehicle 1 5 3 3 2 6 4 17 15 16 ...

Page 123: ... 76423G01 Truck Bed Frame 1 2 00439G2 Hex Head Bolt 5 16 18 x 1 1 4 Lg 4 3 00642G8 Flat Washer 5 16 8 4 11098G6 Lock Nut 5 16 18 4 5 00415G6 Hex Head Bolt 1 4 20 x 1 3 4 Lg 2 6 548910 Lock Nut 1 4 20 2 7 00560G1 Flat Washer 3 8 4 8 00426G8 Hex Head Bolt 3 8 16 x 3 4 Lg 4 9 663002 Bed Latch Bracket 2 10 01014G03 Carriage Bolt 1 4 20 x 75 Lg 2 11 11098G5 Lock Nut 3 8 16 6 12 548910 Lock Nut 1 4 20 2...

Page 124: ...688549 Service Parts Manual Page N 13 TRUCK BED Front of Vehicle 4 5 Plastic Bed Front of Vehicle 1 Plastic Bed 3 D ring Kit for Plastic Bed includes items 4 5 ...

Page 125: ...not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page N 14 TRUCK BED 688549 Service Parts Manual 1 652838 Mesh Net Kit Includes Mounting Hardware 1 2 3 652349 D ring Kit for Plastic Bed Includes 4 5 1 4 650566 D ring 4 5 73296G01 Hex Head Bolt M8 1 5 x 16mm Lg 4 ...

Page 126: ...688549 Service Parts Manual Page N 15 TRUCK BED Front of Vehicle Plastic Bed 2 3 Existing Hardware 1 Tool Holder Kit Plastic Bed includes items 2 6 4 5 5 6 4 ...

Page 127: ...ndicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page N 16 TRUCK BED 688549 Service Parts Manual 1 652510 Tool Holder Kit Plastic Bed Includes Items 2 6 1 2 652657 Bed Divider 1 3 651732 Long Handler Tool Holder 1 4 630419 Hex Head Bolt 1 4 20 x 3 Lg 4 5 14390G4 Lock Nut 1 4 20 4 6 16705G2 Pan Head Phillips Screw SS 1 4 20 x 5 8 Lg 1 ...

Page 128: ...ge N 17 TRUCK BED 5 7 8 10 3 4 2 9 6 Plastic Bed 1 Equipment Rack Kit includes items 2 10 Front of Vehicle 14 13 12 Tool Mount Kit includes items 13 14 Plastic Bed Front of Vehicle 20 19 17 18 16 Quick Fist Kit includes items 17 20 ...

Page 129: ...Equipment Rack Bar 2 3 616693 Hex Head Bolt M8 1 25 x 45mm Lg 2 4 664140 Clamp 2 5 649803 Pan Head Torx Screw M6 2 65 x 25mm Lg 4 6 11027G1 Lock Nut 5 16 18 10 7 651379 Hook 4 8 665181 Round Head Torx Screw 5 16 18 x 1 75 Lg 10 9 00520G3 Cap Nut 10 10 652697 End Cap 1 x 1 1 2 2 11 12 664374 Tool Mount Kit Includes Items 13 14 1 13 663992 Upper Moisture Meter Mounting 2 14 649803 Pan Head Torx Scre...

Page 130: ...ont of Vehicle Refresher Drop In Assembly includes items 7 30 Refresher Drop In Tub Assembly includes items 20 22 Refresher Drop In Closeout Assembly includes items 24 29 Dry Goods Drop In Assembly includes items 31 41 Front of Vehicle Front of Vehicle Refresher Drop In Kit includes items 6 41 Refresher Drop In Ice bin Kit includes items 4 6 41 Truck Bed ...

Page 131: ... 4 6 41 1 3 4 666955 Refresher Drop In Ice Bin 1 5 6 666939 Refresher Drop In Assembly Includes Items 7 30 1 7 666953 Tray 2 8 666952 Divider 2 9 666951 Latch Plate 2 10 666960 Label 2 11 71055G01 Rivet 3 16 Dia 4 12 667938 Round Washer Head Bolt M6 1 x 16mm Lg 14 13 14 15 16 17 18 19 666940 Refresher Drop In Tub Assembly Includes Items 20 22 1 20 Drop In Cooler 1 21 666941 Refresher Drop In Drain...

Page 132: ...PART NO 1 2 3 4 5 DESCRIPTION QTY TRUCK BED 688549 Service Parts Manual 30 666933 Dry Goods Drop In Assembly Includes Items 31 41 1 31 665973 Dry Goods Drop In 1 32 665975 Dry Goods Drop In Door 2 33 667097 Spring Hinge 2 34 662020 Rivet 3 16 x 7 16 Lg 16 35 677415 Strike Plate 2 36 677417 Magnet 2 37 677423 Flat Head Slotted Screw SS M3 5 x 10mm Lg 2 38 677437 Acorn Nut M3 5 2 39 676505 Round Bum...

Page 133: ...Page N 22 Notes TRUCK BED 688549 Service Parts Manual ...

Page 134: ...f Vehicle 4 11 14 18 15 17 20 16 19 11 13 8 9 12 1 Canopy Top Kit Black includes items 4 7 20 2 Canopy Top Kit Tan includes items 5 7 20 Canopy Top Kit Beige includes items 6 7 20 3 Canopy Strut Set includes items 8 10 7 Hardware Kit includes items 11 20 10 5 6 23 ...

Page 135: ...Items 5 7 20 1 3 651917G03 Canopy Top Kit Beige Includes Items 6 7 20 1 4 625292 Canopy Top 1 5 625290 Canopy Top 1 6 625291 Canopy Top 1 7 654452 Strut Set Includes Items 8 10 1 8 658690 Rear Strut 1 9 648270 Front Strut 1 10 652328 Hardware Kit Includes Items 11 20 1 11 652324 Flat Washer O D 692 x I D 349 8 12 652326 Hex Head Bolt 1 4 20 x 2 3 4 Lg 4 13 652319 Lock Nut 1 4 20 4 14 625301 Spacer...

Page 136: ...s items 26 28 25 Split Windshield Utility Kit includes items 11 17 25 10 Split Windshield Assembly includes items 14 17 13 Full Windshield Utility Kit includes items 21 25 20 1 2 3 Rear View Mirror Setscrew Front Top Strut Enclosure Full Windshield Split Windshield 7 8 6 22 12 23 11 21 15 16 17 14 27 26 Front of Vehicle Front of Vehicle 28 ...

Page 137: ...Includes Items 6 8 1 6 19496G1 Rear View Mirror 1 7 19502G2 Support Bracket 1 8 19527G1 Pan Head Screw SS 8 32 x 5 8 Lg 1 9 10 649825 Split Windshield Kit Includes Items 11 17 25 1 11 613136 Sash 2 12 649836 Seal 1 13 649849 Split Windshield Assembly Includes Items 14 17 1 14 649824 Windshield 1 15 603201 Lower Latch 2 16 603198 Upper Latch 2 17 604115 Grommet 2 18 19 20 649883 Full Windshield Kit...

Page 138: ...Page P 5 688549 Service Parts Manual Notes WEATHER PROTECTION ...

Page 139: ...Page P 6 688549 Service Parts Manual Notes WEATHER PROTECTION ...

Page 140: ... 6 1 Wheel and Tire Assembly Trail Wolf Driver Side includes items 3 5 2 Wheel and Tire Assembly Trail Wolf Passenger Side includes items 3 5 8 Wheel and Tire Assembly Kenda includes items 9 11 14 Wheel and Tire Assembly Kenda includes items 15 17 Tire design may vary by part number ...

Page 141: ... Wheel and Tire Assembly Trail Wolf Driver Side Includes Items 3 5 1 2 74842G04 Wheel and Assembly Trail Wolf Passenger Side Includes Items 3 5 1 3 74842G05 Tire 20 x 11 10 1 4 Valve Stem 1 5 Wheel 1 6 14723G1 Lug Nut 1 2 20 4 7 8 652392 Wheel and Tire Assembly Kenda Includes Items 9 11 1 9 652992 Tire 205 65 10 6 Ply 1 10 643934 Wheel 10 x 6 1 11 643948 Valve Stem 1 12 14723G1 Lug Nut 1 2 20 4 13...

Page 142: ...Page R 3 688549 Service Parts Manual WHEELS AND TIRES Front 3 3 1 Rear 2 ...

Page 143: ...e product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page R 4 688549 Service Parts Manual WHEELS AND TIRES 1 74175G01 Dust Cap 1 2 12091G2 Spindle Cap 1 3 665151 Wheel Cover 10 Silver 1 ...

Page 144: ...Page R 5 688549 Service Parts Manual Notes WHEELS AND TIRES ...

Page 145: ...Page R 6 688549 Service Parts Manual Notes WHEELS AND TIRES ...

Page 146: ...14 25 6516 54 R F I O F R F I O R N I O R F N 651671 Front of Vehicle Instrument Panel Side Panel Cowl Front of Vehicle Side Panel Front of Vehicle Front of Vehicle 11 4 6 2 1 9 14 Plastic Bed 8 MAX 14o 25 MAX 400 lb 180 kg MAX 5 in 12 cm P P MAX 100 lb 45 kg 74821G06 13 16 ...

Page 147: ...ation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page S 2 688549 Service Parts Manual DECALS AND LABELS 1 650284 Cowl Decal 1 2 649875G01 Cowl Logo Attachment 1 3 4 651654 Operating Instruction Label 1 5 6 651671 Pinch Warning Label 1 7 8 665021 Side Panel Decal 1 9 681541 ELiTE Side Panel Decal 1 10 11 74099G01 Bed Latch Warning Label 1 12 13 74821G08 Load Bed Label Plastic 325 Lbs 1 14 71055G01 Rive...

Page 148: ...ake even when the key is in the OFF position the vehicle may move when the accelerator pedal is pressed Unintentional movement of the vehicle can cause injury or death Do not allow anyone to stand directly in front or behind the vehicle Driver must have a valid driver s license Do not operate vehicle until all occupants are properly seated with their backs against the seat and feet flat on the flo...

Page 149: ...r Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page S 4 688549 Service Parts Manual DECALS AND LABELS 1 71415G01 Electric Shock Warning Label 1 2 71931G01 Front Gasket Decal 1 3 4 618086 Steering Wheel Decal 1 5 664789 Steering Wheel Warning Label 1 6 7 651671 Pinch Warning Label 1 8 75696G01 Hot Exhaust Decal 1 9 665229 Tow Switch Decal 1 10 655748 Li Ion B...

Page 150: ...Page S 5 688549 Service Parts Manual Notes DECALS AND LABELS ...

Page 151: ...Page S 6 688549 Service Parts Manual Notes DECALS AND LABELS ...

Page 152: ...n Specialized Vehicles Technical Publications Department Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Owner s Guides and Repair Manuals are available from a local Distributor an authorized Branch Parts Accessories Department or at www cushman txtsv com CONTACT INFORMATION ...