CPC - Manual - Parts - BC - Rev49

Parts Manual
Payloader
BC2, BC3, BC4
2012
Preface
Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your
vehicle has been designed and manufactured to conform to applicable sections of ANSI B56.8.
Your safe use and operation of your vehicle is important to us. Any alteration of your Columbia
vehicle that results in the vehicle being in noncompliance with applicable ANSI standards is
strictly prohibited. Columbia ParCar Corp. is not responsible or liable for any damage that
results from any such alteration, and all warranties for any such altered vehicles are null and
void.
These vehicles are not designed for over-the-road use. They do not conform to Federal Motor
Vehicle Safety Standards or EPA regulations, and are not equipped for operation on public
streets, roads, or highways.
To the best knowledge of Columbia ParCar Corp., the material contained herein is accurate as
of the date this publication was approved for printing. Columbia ParCar Corp. is not liable for
errors in this manual or for incidental or consequential damages that result from the use of the
material in this manual. Columbia ParCar Corp. reserves the right to change specifications,
equipment or designs at any time without notice and without incurring obligation.
This manual contains proprietary information that is protected by copyright. All rights are
reserved. No part of this manual may be photocopied, reproduced, or translated to another
language without the written consent of Columbia ParCar Corp. Columbia ParCar Corp.
products are manufactured under one or more of the following U.S. Patents - 2986162,
2987934, 3116089, 3144631, 3144860, 3229792, 3434887, 3559773, 3673359, 3680403,
3683716, 3709317, 4648473, Des. 225626.
1115 Commercial Avenue • Reedsburg, WI 53959

Phone: (608) 524-8888 • Fax: (608) 524-8380
(800) 222-4653 • Web: www.parcar.com
i
INDEX
SECTION 1 Accelerator and Brake Linkage

Pedal Accelerator .......................................................................................1-1
Parking Brake Linkage, Dana Axle .............................................................1-2
Brake Pedal Assembly ...............................................................................1-5
Master Cylinder & Fittings...........................................................................1-7
Conversion Kit – Add Front Hydraulic Brakes .............................................1-10
Parking Brake (IMAG) 20.1 Axle – BC-L .....................................................1-11
Parking Brake NKL Axle .............................................................................1-13
Master Cylinder w/Proportioning Valve (If Equipped) ..................................1-15
SECTION 2 Steering, Front Suspension and Wheels

Front Axle, Springs & Linkage ....................................................................2-1
Front Axle W/Brake - BC2/3/4 (Starting 1/2015) .........................................2-2
Front Axle W/Brake - BC2/3/4 (Not used after 1/2015) ...............................2-6
Front Axle Non-Brake - BC2/3 ....................................................................2-11
Steering Wheel & Gearbox .........................................................................2-14
Wheels .......................................................................................................2-16
SECTION 3 Rear Axle, Brakes and Suspension

NKL Axle Attachment – BC.........................................................................3-1
NKL Axle AC & DC Motors – BC ................................................................3-2
NKL Axle Assembly ....................................................................................3-4
NKL Axle Hydraulic Brakes.........................................................................3-7
Rear Axle/Body Attachment........................................................................3-9
Axle 16:77 AC Drive BC2 ..........................................................................3-10
Axle 20:1, AC Drive ..................................................................................3-13
Rear Axle and Brakes - DANA ....................................................................3-14
Rear Axle Assembly – BC2 ........................................................................3-19
Rear Axle and Brakes -BC3........................................................................3-22
Rear Axle Assembly - BC3 .........................................................................3-35
Rear Axle Assemblies - BC4 & 4SC ...........................................................3-31
Rear Axle/Brake Detail BC4 .......................................................................3-38
Rear Axle Center - BC4 & 4SC ...................................................................3-40
SECTION 4 Seats, Decks and Dash

Seats, Deck, Charger Mounting ..................................................................4-1
Delta Q Charger With Remote Led .............................................................4-3
2ND Seat – BC L Series ............................................................................4-4
Seat Belt.....................................................................................................4-8
Dash Panel .................................................................................................4-9
Turn Signal .................................................................................................4-10
Floor Mounted Horn Switch ........................................................................4-10
Adjustable Seats w/Risers ..........................................................................4-11
Reflectors ...................................................................................................4-12
Label Set ....................................................................................................4-12
Seat Belts, 2nd Seat ....................................................................................4-13
Supplemental Decal/Labels ........................................................................4-14
SECTION 5 Electrical Systems

Main Wire Harness .....................................................................................5-1
Main Wire Harness Schematic ...................................................................5-3
Accessory Wiring Diagram .........................................................................5-4
Accessory Wiring Schematic ......................................................................5-6
ii
Motor, SEP EX BC2 ...................................................................................5-7
Motor, BC3 & 4 ...........................................................................................5-8
Battery Hardware .......................................................................................5-9
Heater Harness and Schematic ..................................................................5-10
Trailer Brake Controller ..............................................................................5-11
Hand Brake Interlock Switch.......................................................................5-12
Work Light ..................................................................................................5-13
Sevcon AC Harness ...................................................................................5-14
Sevcon AC Panel .......................................................................................5-16
AC Cable & Harness Routing .....................................................................5-17
Sevcon AC Mounting ..................................................................................5-18
48V Charger w/Reel ...................................................................................5-19
Trailer Brake Harness & Schematic ............................................................5-20
Tilt Bed Schematic......................................................................................5-21
DC/DC Converter Schematic ......................................................................5-22
Ace+ Chassis Mounting ..............................................................................5-23
SECTION 6 Options
Battery Watering System ............................................................................6-1
Cab ............................................................................................................6-2
Door Assemblies ........................................................................................6-3
Door Hardware ...........................................................................................6-4
Cab Dome Light .........................................................................................6-5
Heater ........................................................................................................6-6
Hitches .......................................................................................................6-7
Combination Hitch Receiver .......................................................................6-8
Front Towing Receiver ...............................................................................6-9
Interior Mirrors ............................................................................................6-10
Exterior Mirrors ...........................................................................................6-11
Single Side Mirror .......................................................................................6-12
Strobe Lights ..............................................................................................6-13
Windshield Wiper .......................................................................................6-14
Inner Rear Fender Kit .................................................................................6-15
13” High Steel Folding Side –BC Short Bed ...............................................6-16
13” High Steel Folding Side –BC Long Bed ................................................6-17
18” High Steel Folding Side Rails ...............................................................6-18
Steel Folding Side –BC Second Seat .........................................................6-19
Second Seat Extended Folding Side Rail ...................................................6-20
63” Suntop, Thermoformed.........................................................................6-22
63” Suntop, Steel White .............................................................................6-24
Suntop Windshield......................................................................................6-26
Suntop Strobe Light ....................................................................................6-27
Cab W/Overhead Rack ...............................................................................6-28
Suntop W/Overhead Rack ..........................................................................6-29
Bulkhead ....................................................................................................6-30
12 Volt Outlet..............................................................................................6-31
Accelerator Pedal Guard ............................................................................6-32
Tilt Bed .......................................................................................................6-33
Tilt Bed Bulkhead .......................................................................................6-37
Operator Roof, Black, Powder Coated ........................................................6-38
Operator Roof w/Rack BC-L .......................................................................6-40
Full Length Roof BC-L ................................................................................6-43
Full Length Roof w/Rack BC-L ...................................................................6-46
Roof Panel Amber Strobe ...........................................................................6-49
Tool Rack ...................................................................................................6-50
iii
CHANGE HISTORY - BC
DATE DESCRIPTION BY
3/15/11 Issued TS
9/9/14 Added instructions for trailer brake controller TS
9/29/14 Added Supplemental Decal/Labels TS
10/6/14 Added washer to steering box. TS
10/22/14 Added DC/DC Converter TS
10/30/14 Changed note on attachment of front leaf spring bracket. TS
12/9/14 Added oil seal and dust cover kit hydraulic brakes TS
12/16/14 Added Ace+ Chassis Mounting TS
12/30/14 Changes to overheads TS
1/15/15 Added new front axle w/brakes TS
iv
Burden Carrier
Parts Manual
Section 1
Accelerator and
Brake Linkage
PEDAL ACCELERATOR - BC
ITEM CPC P/N DESCRIPTION QTY SEATS P/N

1 40610-10 PEDAL ASSY, ACCELERATOR & HARNESS 1 760635
2 5490 BOLT, 1/4-20X1 CARR 4 759116
3 6703-B WASHER 1/4 4 719811
4 7686 NUT, 1/4 NYLOCK 4 719879
5 40891-12 PEDAL PAD REPLACEMENT (Recommend gluing in place 1 760784
6 8486 RIVET, #66, 3/16, AL, BLIND (See Note) 1 719941
* SPECIAL ORDER
NOTE: To secure pedal pad.
1-1
PARKING BRAKE LINKAGE, DANA AXLE- BC
Handle & Mid Portion
1-2
PARKING BRAKE LINKAGE, DANA AXLE - BC (Cont.)
Rear Portion
1-3
PARKING BRAKE LINKAGE, DANA AXLE – BC (Cont.)

1 41231-00 HAND BRAKE MOUNTING BRACKET 1 306105
2 2879-W SCREW, 3/8-16 X 1, HHCS, GRD 5 2 707195
3 7778 NUT, 3/8-16, NYLOC 2 719902
4 41213-00 PARKING HAND BRAKE LEVER ASSEMBLY 1 709750
5 2818 SCREW, 5/16-18 X 1 1/2", HHCS 2 719589
6 7739 NUT, 5/16-18, NE, NYLOC, GR A 2 719892
7 42370-02 BRAKE CABLE, SHORT 42” (See Note) 2 709818
7A 42371-02 BRAKE CABLE, LONG 51” (See Note) 2 709819
8 41209-00 E-RING (BRAKE CABLE CLIP) 4 709187
9 73059-96 CLEVIS #52, 5/16-24 (ADJUSTABLE YOKE) 1 719852
10 781130 CLEVIS PIN, Ø5/16" X 1 1/2" 1 781130
11 6350 WASHER, .375" I.D. X .875" O.D. X .0781" 2 708682
12 500 HAIR PIN CLIP, #13 4 781013
13 73065-00 CLEVIS, 535 3 509240
14 7744 NUT 5/16-24, HEX JAM, GR 2 6 719895
15 494 CLEVIS PIN, Ø5/16" X 1" 3 719709
16 41202-00 PARKING BRAKE EXTENSION, SHORT 1 510421
16 41227-00 PARKING BRAKE EXTENSION, LONG 1 510375
17 11832 SPRING 2 709419
18 6200 WASHER, 7/16, SAE FLAT 2 708153
19 41215-00 BRAKE CABLE 46” (See Note) 1/3 709375
NOTE:
In mid 2012 a change was made to a NKL axle from a Dana axle. The Dana axle used 3 each of
Item 19 brake cables. Item 7 and 7A were not used with the Dana axle and are now used with
BC2/3.
1-4
BRAKE PEDAL ASSEMBLY
1-5
BRAKE PEDAL ASSEMBLY Cont.

MASTER CYLINDER, 4 WHEEL BRAKES, (Used On
1 41207-00 1 709794
Both Drum & Disk Brake Units)
MASTER CYLINDER, 2 WHEEL BRAKES (Master
41203-00 1 709780
Cylinders Furnished With Boots)
SCREW, 3/8-16 X 1 1/4 HEX HEAD CAP, G5 (Qty 2
2 4716-W 4 719694
For Units Having Master Cylinder 41203-00)
NUT, 3/8-16 NYLON INSERT LOCK (Qty 3 For Units
3 7778 5 719902
Having Master Cylinder 41203-00)
4 41232-00 BRAKE RETURN SPRING MOUNTNG BRACKET 1 510372
5 5405-B SCREW, 1/4-20 X 3/4 CARR, G5 2 719747
6 7686 NUT 1/4-20 NYLON INSERT LOCK, GR A 2 719879
7 52330-86 BUMPER, ADHESIVE BACKED (3M#SJ5023) 1 719738
8 41229-00 BRAKE LEVER ASSEMBLY 1 306125
9 2828-W SCREW, 3/8-16 X 3 HEX HEAD CAP, G 5 1 719591
10 11833 SPRING, BRAKE RETURN, 3/4 X 5 1 709745
11 41230-00 MASTER CYLINDER PUSH ROD 1 510408
12 7744 NUT, 5/16-24 HEX JAM, G 2 1 719895
13 73059-96 CLEVIS #52 5/16-24 (ADJUSTABLE YOKE) 1 719852
14 494 CLEVIS PIN, Ø5/16 X 1 1 719709
15 500 HAIR PIN CLIP, #13 1 781013
16 41350-00 BRAKE PEDAL PAD MOUNTING PLATE 1 510381
17 2008 SCREW, 1/4-20 X 5/8, PHILLIPS FLAT HEAD 2 719145
18 7724-B NUT, 1/4-20 SERRATED FLNG LOCK, GR A 2 719887
19 42407-00 PAD, BRAKE PEDAL, "STOP" 1 709048
20 8128 NUT, SELF-THREADING PALNUT (SR250) 2 719922
1-6
MASTER CYLINDER AND FITTINGS
1-7
MASTER CYLINDER AND FITTINGS Cont.
1-8
MASTER CYLINDER AND FITTINGS Cont.

1 41207-00 MASTER CYLINDER, BC, 4 WHEEL BRAKES 1 709794
1A 41203-00 MASTER CYLINDER, BC 2 WHEEL BRAKES 1 709780
2 41221-00 REDUCER, 1/4" MALE TO 3/16" FEMALE 2 709583
3 41222-00 BRAKE LINE, 3/16" X 20" * 709358
4 41842-94 UNION TEE, 3/16" FEMALE * 709377
5 41216-00 BRAKE HOSE, HYDRAULIC, FLEX, 22" 3 709430
6 9959 HOSE CLIP * 709591
7 41275-00 ELBOW, 90° MALE 2 729907
8 41313-00 BLEEDER SCREW * 719082
9 41224-00 ADAPTER, 1/8" PIPE MALE TO 3/16" FEMALE * 709618
10 41219-00 BRAKE LINE, 3/16" X 12" * 709607
11 69729-00 CONNECTOR, 3-WAY SWITCH 1 508959
12 41212-00 SWITCH, BRAKE LIGHT 1 709749
13 69708-00 TERMINAL, #10 STUD TO 1/4 MALE TAB 2 719825
14 41219-00 BRAKE LINE, 3/16”X12” (Regular Bed Vehicles Only) * 709607
BRAKE LINE, 3/16"X20" (Extended Bed Vehicles
14A 41222-00 * 709358
Only)
15 41206-00 UNION, 3/16" 1 719657
16 41269-00 BRAKE LINE, 3/16"X51" (Regular Bed Vehicles Only) * 709474
BRAKE LINE, 3/16" X 60" (Extended Bed Vehicles
16A 41220-00 * 709727
Only)
17 9995 TUBE CLAMP 3/8” 2 782210
18 9982 TUBE CLAMP 1/4” 1 719756
*NOTE: QUANTITIES AS REQUIRED PER YOUR VEHICLE
1-9
CONVERSION KIT- ADD FRONT HYDRAULIC BRAKES
(for vehicles with rear hydraulic brakes)

1 19368-00 KIT, BC2, BC3 FRONT WHEEL BRAKE CONVERSION 1 191788U
1-10
PARKING BRAKE (IMAG) 20:1 AXLE– BC-L
1-11
PARKING BRAKE (IMAG) 20:1 AXLE– BC-L (Cont.)

1 41231-00 HAND BRAKE MOUNTING. BRACKET 1 306105
2 42402-89 PLATED, BRAKE EQUALIZER 1 509154PL
3 2879-W SCREW, 3/8-16 X 1 HHC, G5 2 707195
4 41215-00 BRAKE CABLE 1 709375
5 41213-00 PARKING HAND BRAKE LEVER 1 709750
6 11040 E-RING, .562 REINFORCED PHOS 2 719515
7 3787-B SCREW,1/4-20X3/4,HHCS,G5,BLK150 1 719636
8 6702-B WASHER,5/16,SAE,F/W,BLK MAX 2 719810
9 73059-96 CLEVIS #52 5/16-24 1 719852
10 7525 LOCKNUT, 5/16-18 HEX FLG WHIZ 2 719864
11 7686 NUT, 1/4-20, NYLOCK, GA, YWZC 1 719879
12 7739 NUT,5/16-18,L/N,NYLOK,NE,GA,BLKMAX 2 719892
13 7744 NUT, 5/16-24 GR 2 HEX JAM YWZC 2 719895
14 7778 NUT,3/8-16,GA,NE,NYLON INSERT,YWZC 2 719902
15 * BUSHING, STL, 1" ODX9/16 IDX18GA, PLN 1 761002
16 40963-13 SUPPORT, BRAKE LINE 1 761003
17 * CABLE, BRAKE, IMAG, BC4 AXLE, 42.5" 2 761058
18 57111-11 SCREW, 5/16-18 X 1 1/2" LG HEX CAP 2 781924
19 9995 CLAMP, 3/8, STL TUBE, VINYL CUSHION 2 782210
* SPECIAL ORDER
1-12
PARKING BRAKE NKL AXLE – BC
1-13
PARKING BRAKE NKL AXLE – BC

1 41231-00 HAND BRAKE MOUNTING. BRACKET 1 306105
2 42402-89 PLATED, BRAKE EQUALIZER 1 509154PL
3 73065-00 CLEVIS-535 1 509240
4 2879-W SCREW, 3/8-16 X 1 HHC, G5 2 707195
5 41215-00 BRAKE CABLE 1 709375
6 41213-00 PARKING HAND BRAKE LEVER 1 709750
7 42370-02 BRAKE CABLE 42” 2 709818
8 11040 E-RING, .562 REINFORCED PHOS 6 719515
10 494 PIN, 5/16X1, CLEVIS 2 719709
11 499 CLEVIS PIN 1/4 DIA X 1 1/2" LG 1 719715
12 520-W PIN, 1/8X1, COTTER 2 719728
13 533 COTTER PIN 5/64 X 1 18-8 SS (Used only with BC-L) 1 719743
15 73059-96 CLEVIS #52 5/16-24 1 719852
16 7525 LOCKNUT, 5/16-18 HEX FLG WHIZ 2 719864
18 7739 NUT,5/16-18,L/N,NYLOK,NE,GA,BLKMAX 2 719892
19 7744 NUT, 5/16-24 GR 2 HEX JAM YWZC 2 719895
21 * BUSHING, STL, 1" ODX9/16 IDX18GA, PLN 1 761002
22 40963-13 SUPPORT, BRAKE LINE 1 761003
23 57111-11 SCREW, 5/16-18 X 1 1/2" LG HEX CAP 2 781924
24 9995 CLAMP, 3/8, STL TUBE, VINYL CUSHION 2 782210
1-14
MASTER CYLINDER W/PROPORTIONING VALVE – BC
(IF EQUIPPED)

1 41431-02 BRAKE LINE 3/16 X 6 1 709812
2 40915-14 BRACKET 1 515781
3 40914-14 VALVE, PROPORTIONING, BRAKE 1 761056
4 41219-00 BRAKE LINE 3/16 X 12 1 709607
5 41222-00 BRAKE LINE 3/16 X 20 1 709358
1-15
Burden Carrier
Parts Manual
Section 2
Steering, Front Suspension and Wheels

FRONT AXLE, SPRINGS & LINKAGE – BC

1 54814-00 LEAF SPRING, 4-LEAF (Used on BC 2 & 3) 2 709382
* 54818-00 LEAF SPRING, 6-LEAF (Used on BC 4) 2 709540
* 54819-00 LEAF SPRING, 7-LEAF (Used on BC 4SC) 2 739587
2 5203 U-BOLT, 1/2-13 X 5 1/4 (Used with 4 leaf springs) 4 709372
* 5209 U-BOLT, 1/2-13 X 5 7/8 (Used with 6 & 7 leaf springs) 4 739454
3 3453 SCREW, 3/8-16 X 3 3/4, HHCS GR5 4 719622
4 3416 SCREW, 3/8-16 X 3 1/2, HHCS GR5 2 708526
5 7778 NUT, 3/8-16, NE, NYLOC, GR A 6 719902
6 10505 BUSHING, RUBBER, 1/2 X 1 3/8 12 709015
7 5711 SPACER, .50X 2-1 6 709042
8 7948 NUT, 7/16-20, HEX CASTLE 4 719917
9 560 PIN, 1/8 X 1 1/4" 4 707337
* NOT SHOWN
2-1
FRONT AXLE W/BRAKE – BC(Starting 1/2015)
2-2
FRONT AXLE W/BRAKE – BC Cont. (Starting 1/2015)
2-3
FRONT AXLE W/BRAKE – BC Cont. (Starting 1/2015)

1 * ALUMINUM HUB 5H (for bolt on disc brake) 2 761180
2 54827-00 FRONT AXLE ASSEMBLY 1 306096
3 56864-00A SPINDLE LH 1 308224
4 56863-00A SPINDLE, RH 1 308225
5 56843-00 KING PIN 2 467952
6 56816-00 TIE ROD TUBE 1 510161
7 56814-00 DRAG LINK TUBE 1 510162
8 54800-00 FRONT AXLE SPRING PLATE 2 510276
9 54801-00 SUSPENSION SPRING SHACKLE 4 510364
10 560 PIN, 1/8"X1-1/4", COTTER, ZNC 3 707337
11 6038 SCREW, 5/16-18 X 1-1/2 HEX HEAD CAP WITH PATCH 10 707500
12 * WASHER, 1" SAE FLAT, PLTD. 2 707457
2-4
13 561 PIN, 1/8" X 1-1/2", COTTER, ZNC 8 707841
14 10505 BUSHING, RUBBER, 1/2X 1-3/8 4 709015
15 5711 SPACER, SPLIT SEAM,.50"X 2-1 1 709042
16 41200-94 LUG BOLT, WHEEL 2 709082
17 9800 GREASE FITTING, 1/4" DRIVE, STRAIGHT 1 709110
18 41268-00 BRAKE CALIPER, RH, FRONT 1 709148
19 41367-00 BRAKE CALIPER, LH, FRONT 4 709162
20 6042 WASHER, NEEDLE THRUST 4 709217
21 11100 O-RING, #332, 1-1/4 X 1/4 2 709218
22 56802-00 TIE ROD ASSY, RH 2 709415
23 56804-00 TIE ROD ASSY, LH 2 709416
24 541216-00 BRAKE HOSE, HYD, FLEX, 18" 4 709430
25 9087 TAPER BEARING CONE & CUP SET, 16128 HUB 2 709632
26 33438-00 DUST CAP, 12842 HUB 2 709831
27 3453 SCREW, 3/8-16 X 3-3/4 HHCS GR 4 719622
28 4713-W SCREW, HX HD CAP 3/8-16 X 3/4 G5 4 719693
29 7038-B WASHER - 3/8" REG SPRG, LOCK, BLK ZC 8 719836
30 7068 WASHER,1/2,ALLOY-SPLIT,L/W,YWZC 2 719840
31 7510 NUT 1-14 GR 5 SLOTTED HEX CLR ZINC 2 719859
32 7513 NUT, 3/4-16 GR A NTE STYLE JAM NYLON 2 719861
34 7880 NUT, 1/2-13 GR 2 HEX FULL YWZC 4 719913
35 9083 BUSHING, .751 X .878 X 1.25 OILITE 2 719961
36 9085 BEARING TORRINGTON NEEDLE THRUST 2 719962
37 12020 SEAL - 16128 HUB 2 729091
38 41275-00 ELBOW, #402X3, HEAVY WALL MALE 4 729907
39 * GREASE FITTING, 1/4"-28, SELF-TAPPING 2 760967
40 * ROTOR, DISC BRAKE - DUAL 2 761179
41 54814-00 LEAF SPRING, 4-LEAF (Used on BC 2 & 3) 2 709382
41A** 54818-00 LEAF SPRING, 6-LEAF (Used on BC 4) 2 709540
41B** 54819-00 LEAF SPRING, 7-LEAF (Used on BC 4SC) 2 739587
42 5203 U-BOLT, 1/2-13 X 5 1/4 (Used with 4 leaf springs) 4 709372
42A 5209 U-BOLT, 1/2-13 X 5 7/8 (Used with 6 & 7 leaf springs) 4 739454
43 41361-00 BOOT, DUST 4 729959
44 41359-00 PISTON 4 729957
45 41360-00 O-RING 4 729958
46 41313-00 BLEEDER VALVE (Position may vary) 2 719082
47 41297-00 BRAKE PADS 4 729920
_ N/A FRONT AXLE W/BRAKE BC 2,3 4 (Includes above) 1 467392/3
* SPECIAL ORDER
** NOT SHOWN
2-5
FRONT AXLE W/BRAKES – BC 2/3/4 (Not used after 1/2015)
41
USE PUNCH TO CREATE SPURS INSIDE

THE SPINDLE TUBES TO HOLD BUSHINGS.
2 SPURS TOP AND BOTTOM
34
28
40
15
31
14
35
TORQUE TO 65 FT/LBS
2-6
FRONT AXLE W/BRAKES – BC 2/3/4 Cont. (Not used after 1/2015)
17
36
3
NOTE:
WHEN TIGHTENED, THE NUT IS FLUSH 33 SEE
WITH THE BOTTOM OF THE KINGPIN NOTE
37
20
21
2-7
22
5
TORQUE TO 45
FT/LBS
23
17
23
11
6
23
22
18
24
29
30
39
19
38
9
25
26
12
32
27
2-8
10
16
TORQUE TO 65
FT/LBS
DISC BRAKE
DETAIL

1 44800-11 KINGPIN ASSY 2 306093
2 54827-00 FRONT AXLE ASSY 1 306096
3 56864-00A SPINDLE WLDMT, BC, LH 1 308224
4 56863-00A SPINDLE WLDMT, BC, RH 1 308225
5 56816-00 TIE ROD TUBE 1 510161
6 56814-00 DRAG LINK TUBE 1 510162
2-9
9 41279-00 ROTOR DISC BRAKE - FRONT 2 511943M
10 36505-07 SPACER, WHEEL 5 HOLE 2 512058PL
11 560 PIN, 1/8" X 1 1/4", COTTER 3 707337
12 6038 WASHER, 1” 2 707500
13 561 PIN, 1/8 X 1-1/2" 2 707841
14 10505 BUSHING, RUBBER, 1/2 X 1 3/8 8 709015
15 5711 SPACER, .50"X 2-1, SPLIT SEAM 4 709042
16 41200-94 LUG BOLT 10 709082
17 9800 GREASE FITTING, 1/4-28, SELF-TAPPING 6 709110
18 41268-00 BRAKE CALIPER, RH, FRONT 1 709148
19 41267-00 BRAKE CALIPER, LH, FRONT 1 709162
20 6042 WASHER NEEDLE THRUST 4 709217
21 11100 O-RING, #332, 1 1/4X1/4 4 709218
22 56802-00 TIE ROD ASSY, RH 2 709415
23 56804-00 TIE ROD ASSY, LH 2 709416
24 41216-00 BRAKE HOSE, HYD, FLEX 18” 2 709430
25 9028 TAPERED ROLLER BEARING, CUP 4 709455
26 9087 BEARING, 16128 HUB 4 709632
27 33438-00 DUST CAP, 12842 HUB 2 709831
28 3453 SCREW, 3/8-16 X 3 3/4, HHCS GR5 4 719622
29 4713-W SCREW, 3/8-16 X 3/4 GRADE 5, HEX HEAD CAP 4 719693
30 6000-B WASHER -5/16, USS/STD, F/W 4 719771
31 7068 WASHER, 1/2", SPRING LOCK 8 719840
32 7510 NUT 1-14 GRADE 5, HEX, CASTLE 2 719859
33 7513 NUT, 3/4-16, NTE, NYLOC, JAM, GR A 2 719861
34 7778 NUT, 3/8-16, NE, NYLOC, GR A 2 719902
35 7880 NUT, 1/2-13 HEX, FULL, GR 2 8 719913
36 9083 BUSHING, .751 X .878 X 1.25, OILITE 4 719961
37 9085 BEARING, NEEDLE THRUST 2 719962
38 12020 SEAL -16128 HUB 2 729091
39 41275-00 ELBOW, #402X3, HEAVY WALL MALE 2 729907
40 54814-00 4 LEAF SPRING ASSY BC2/3 2 709382
40A 54818-00 6 LEAF SPRING ASSY BC4 2 709540
40B 54819-00 7 LEAF SPRING ASSY BC4SC 2 739587
41 5203 U-BOLT BC 2/3 4 709372
41A 5209 U-BOLT BC4 & BC4SC 4 739454
42 41297-00 BRAKE PADS 4 729920
43 41361-00 BOOT, DUST 4 729959
44 41359-00 PISTON 4 729957
45 41360-00 O-RING 4 729958
46 41313-00 BLEEDER VALVE (Position may vary) 2 719082
2-10
FRONT AXLE NON-BRAKE – BC2/3
2-11
NOTE: WHEN TIGHTENED, NUT IS FLUSH WITH BOTTOM OF KING PIN.
2-12

1 44800-11 KINGPIN ASSY 2 306093
2 54827-00 FRONT AXLE ASSY 1 306096
3 56864-00A SPINDLE WLDMT, BC, LH 1 308224
4 56863-00A SPINDLE WLDMT, BC, RH 1 308225
5 56816-00 TIE ROD TUBE 1 510161
6 56814-00 DRAG LINK TUBE 1 510162
9 560 PIN, 1/8" X 1 1/4", COTTER 3 707337
10 6038 WASHER, 1” 2 707500
11 561 PIN, 1/8 X 1-1/2" 2 707841
12 10505 BUSHING, RUBBER, 1/2 X 1 3/8 8 709015
13 5711 SPACER, .50"X 2-1, SPLIT SEAM 4 709042
14 9800 GREASE FITTING, 1/4-28, SELF-TAPPING 6 709110
15 6042 WASHER NEEDLE THRUST 4 709217
16 11100 O-RING, #332, 1 1/4X1/4 4 709218
17 5203 U-BOLT 4 709372
18 54814-00 LEAF SPRING ASSY 2 709382
19* 56802-00 TIE ROD ASSY, RH 2 709415
20 56804-00 TIE ROD ASSY, LH 2 709416
21 33489-11 FRONT HUB ASSY 2 467799
21A ** FRONT HUB 1* 310599
21B 41199 WHEEL BOLT 1/2-20X1 1/2 G5 5* 719655
21C 9087 BEARING 16128 HUB 2* 709632
21D 12020 SEAL 16128 HUB 1* 729091
21E 9028 CUP, TAPERED ROLLER BEARING 2* 709455
22 3453 SCREW, 3/8-16 X 3 3/4, HHCS GR5 4 719622
23 7068 WASHER, 1/2", SPRING LOCK 8 719840
24 7510 NUT 1-14 GRADE 5, HEX, CASTLE 2 719859
25 7513 NUT, 3/4-16, NTE, NYLOC, JAM, GR A 2 719861
26 7778 NUT, 3/8-16, NE, NYLOC, GR A 2 719902
27 7880 NUT, 1/2-13 HEX, FULL, GR 2 8 719913
28 9083 BUSHING, .751 X .878 X 1.25, OILITE 4 719961
29 9085 BEARING, NEEDLE THRUST 2 719962
* QTY PER HUB ASSEMBLY
** SPECIAL ORDER
2-13
STEERING WHEEL AND GEAR BOX - BC
2-14
STEERING WHEEL AND GEAR BOX – BC – Cont.

1 56805-06 STEERING GEARBOX, MAVAL 1 759703
2 7039 WASHER, 7/16 SPRING LOCK 3 708188
3 3769 SCREW, 7/16-14 X 1 1/2 HEX HEAD CAP, G5 3 719632
4 56807-00A ASSY, STEERING SHAFT, BC (Furnished W/ Items 5, 6, & 22) 1 709718
5 N/A SCREW, 5/16-24 SOCKET SET, CUP PT (See Note) 1 N/A
6 7727 NUT, 5/16-24 NYLON INSERT LOCK, JAM 1 719889
7 56915-13 STEERING COLUMN WELDMENT 1 311694
8 57067-87 BEARING, COLUMN 1 739636
9 6703-B WASHER, 1/4, SA, FW, STL, HC BLACK 8 719811
10 3787-B SCREW, 1/4-20 X 3/4 HEX HEAD CAP, G5 4 719636
11 7686 NUT 1/4-20 NYLON INSERT LOCK, GR A 4 719879
12 11418-A GROMMET, 2775 EPDM 3/16 GROOVE 1 719523
13 56813-00 UPPER STEERING COLUMN SUPT. ASSY. (Includes Item 17) 1 306117
14 6416 WASHER 3/8 FLAT STD. 4 719796
15 2879-W SCREW, 3/8-16 X 1 HEX HEAD CAP ,G5 2 707195
16 7778 NUT, 3/8-16 NYLON INSERT LOCK 2 719902
17 9967 CLAMP, 1 3/4" 1 708748
18 7688-B NUT, 1/4-20 HEX, GR 2 2 719880
19 57069-84 STEERING WHEEL, SPORT 1 709056
20 57098-98 STEERING HUB COVER 1 709085
21 2638 SCREW, #6 X 3/4 PHILLIPS PAN HEAD 2 719577
22 781132 NUT, M16 X 2 STEEL INSERT LOCK 1 781132
23 57089-99 CARD HOLDER/STEERING WHEEL COVER 1 709043
24 2641 SCREW, #10 X 1 PHILLIPS PAN HEAD 3 729263
25 56817-06 PITMAN ARM, BC, MAVAL BOX 1 719498
26 781135 WASHER, 7/8 SPRING LOCK 1 781135
27 781134 NUT, 7/8 -14 HEX 1 781134
28 56804-00 TIE ROD ASSMY, LH (Furnished W/ Items 29 & 32) 1 709416
28A 56802-00 TIE ROD ASSY, RH (Furnished W/ Items 29 & 32) 709415
29 7948 NUT, 7/16-20, CASTLE, G5 1 719917
30 560 PIN, 1/8"X1-1/4" COTTER 1 707337
31 9800 GREASE FITTING, 1/4"-28, SELF-TAPPING 1 709110
32 7765 NUT, 9/16-18, HEX JAM L.H. THREAD 1 749300
32A 7764 NUT, 9/16-18, HEX JAM R.H. THREAD 749299
33 56814-00 DRAG LINK TUBE 1 510162
34 75052-01 BDI GAUGE (USED WITH 36V SYSTEMS) 1 709578
34A 75053-01 BDI GAUGE (USED WITH 48V SYSTEMS) 1 709183
35 75033-91A HOUR METER, 10-80 VOLT DC 1 709452
36* 71527-04 DECAL, SWTCH SET POSITION 1 719426
37 6038 WASHER, 1.00 SAE 1 707500
* NOT SHOWN
Note: Must be purchased locally.

.
2-15
WHEELS – BC

1 40998-00 TIRE/WHEEL ASSY, 5.70X8LRD 5H 1 709354
2 40996-03 TIRE/WHEEL ASSY, 5.0X5,7 - 8, 10 PLY 1 719263
3 40994-05 TIRE/WHEEL ASSY, FF, 5.7X8, LRD 5H 1 759713
4 40993-00 TIRE/WHEEL ASSY, 5.0X8 SLD LUG 5H 1 709905
5 40997-96 TIRE/WHEEL ASSY, 5.0X8 SLD NONMARK 5H 1 729879
6 40973-07 TIRE/WHEEL ASSY, 145R12 HIGH BSPEED 5H 1 759849
7 44100-10 TIRE/WHEEL ASSY, 5-H, 5.7X8, NM, LRC 1 760325
8 41010-00 TIRE/WHEEL ASSY, 18.5X8.5-8, 5-H 1 709907
9 41200-94 LUG BOLT,WHEEL 5 709082
10 43152-66 NUT, 1/2-20, TAPERED WHEEL 5 709002
2-16
Burden Carrier
Parts Manual
Section 3
Rear Axle, Brakes and Suspension

NKL AXLE ATTACHMENT – BC

1 54801-002 SHACKLE 4 510364
2 54804-12 REAR SPRING PLATE 4 514353
3 10505 BUSHING, RUBBER 1/2X1 3/8 8 709015
4 5711 SPACER, SPLIT SEAM 4 709042
5 54814-00 LEAF SPRING ASSEMBLY, 4 LEAF 2 709382
6 5214 U-BOLT, 1/2-13X5.75 2 709574
7 3453 SCREW, 3/8-16X3 3/4 HHCS, G5 2 719622
8 7068 WASHER, 1/2, ALLOY, SPLIT 8 719840
9 7778 NUT, 3/8-16 NYLOCK 2 719902
10 7880 NUT, 1/2-13 GR2, HEX 8 719913
11 82670-12 AXLE, HD, NKL 10.37:1 1 760734
11A 82669-12 AXLE, HD, NKL, 16.77:1 1 760733
12 54811-12 U-BOLT 1/2-13, 2.81X6.75 2 782102
3-1
NKL AXLE AC & DC MOTORS – BC
DC MOTOR
AC MOTOR
3-2
NKL AXLE AC & DC MOTORS – BC (Cont.)

1 3440 SCREW, 1/4-20X3/4 HHCS GD8 3 760827
2 7036-B WASHER, LOCK 1/4 3 719834
3 6703-B WASHER, 1/4 3 719811
4 9982 CLAMP STEEL TUBING 1/4 1 719756
5 11423 RESILIENT BUMPER 1 709050
6 6702-B WASHER 5/16 1 719810
7 69301-04 MOTOR, ELEC 48V HD DIRECT W/TACH 1 719339
8 10011 CABLE TIE 4” 2 719502
9 22370-96 END CAP PLUG 1 729161
10 72464-12 SCREW, M6X35MM HHCS 6 781478
11 46270-08 WASHER, 6MM L/W 6 781405
12 46265-08 WASHER, 6MM F/W 6 781406
13 72461-12 MOTOR, 7KW AC 1 760570
13A 69531-13 MOTOR 8KW AC 1 760957
3-3
NKL AXLE ASSEMBLY – BC
3-4
NKL AXLE ASSEMBLY – BC (Cont.)
43

1 * COVER CASE ASSEMBLY 1
2 * GEAR CASE 1
3 * CARRIER GEAR (See Item 40) 1
4 * GEAR 15T (See Item 41) 1
7 82904-13 BALL BEARING 6207 (See Item 40) 2 760926
11 82905-13 SHIM 61X69X1.5t (See Item 40) 2 760925
12 82871-13 SHIM 36X44X1.5t (See Item 41) 2 760919
13 82784-13 SHIM 32X40X1.0t (See Item 42) 1 760920
14 82781-13 SHIM 45X51X1.5t (See Item 42) 1 760923
15 * WASHER 1
16 * WASHER 1
17 82906-13 SEAL 28X55X9h 2 760924
18 82949-13 SEAL 25X47X6h 1 760993
19 * BOLT M8XP1.25X100L 7
20 * BOLT M8XP1.25X90L 3
21 * BOLT M8XP1.25X12L 1
22 * BOLT M14XP1.5X9.5L 1
23 * NUT M8XP1.25 10
24 * LOCATION PIN 2
25 * MACHINE KEY (See Item 30) 1
26 82785-13 CIRCLIP – SHAFT 32 (See Item 30) 1 760917
27 * BREATHER TUBE 1
28 * RING 1
3-5
NKL AXLE ASSEMBLY – BC (Cont.)

29 * GEAR BOX ASSY 1
30 82994-13 SHAFT ASSY R 1 760986
31 82995-13 SHAFT ASSY L 1 760987
32 * TUBE ASSY R 1
33 * TUBE ASSY L 1
34 82927-13 DRUM 2 760927
35 * BOLT M10X1.25X35L 12
36 * BOLT M8X1.25X40L 8
37 * NUT SHRAPNEL M8XP1.25 8
38 * NUT 10
39 82909-13 BRAKE SHOE 4 760928
40 82981-13 CARRIER GEAR ASSY 10.37:1 (Includes Items 3, 7 & 11) 1 760939
40A 82984-13 CARRIER GEAR ASSY 16.77:1 (Includes Items 3, 7 & 11) 760935
INTERM. GEAR ASSY 10.37:1 (Includes Items 4, 5, 8, 12,
41 82982-13 1
25 & 26) 760934
INTERM. GEAR ASSY 16.77:1 (Includes Items 4, 8, 12,
41A 82985-13 1
25 & 26) 760936
INPUT GEAR ASSY 10.37:1 (Includes Items 6, 9, 10, 13
42 82983-13 1
& 14) 760938
INPUT GEAR ASSY 16.77:1 (Includes Items 6, 9, 10, 13
42A 86986-13 1
& 14) 760937
43 82669-12 AXLE, HD, NKL, 16.77:1, COMPLETE 1 760733
43A 82670-12 AXLE, HD, NKL, 10.37:1, COMPLETE 1 760734
* Special Order
3-6
NKL AXLE HYDRAULIC BRAKES – BC
3-7
NKL AXLE HYDRAULIC BRAKES – BC (Cont.)

1 82987-13 MAIN BODY 1 760979
2 82988-13 COVER 1 760980
3 82989-13 SPRING (BLUE) 1 760981
4 82990-13 SPRING (YELLOW) 1 760982
5 * SPRING 1
6 * SPRING PIECE 2
7 82909-13 BRAKE SHOES 2 760928
8 * L-TYPE LEVER 1
9 * LEVER 1
10 40968-14 DUSTPROOF COVER KIT 2 192943U
11 * WASHER 1
12 * ADJUSTMENT ASSEMBLY L 1
12A * ADJUSTMENT ASSEMBLY R 1
13 * PISTON ASSEMBLY 2
14 * CIRCLIP 1
15 * EXHAUST VALVE ASSEMBLY 1
16 * BUSH ASSEMBLY 1
17 * COTTER PIN 2
18 * PIN 1
19 * OIL SEAL 1
LEFT BRAKE SET ASSEMBLY (Includes Items
19 82992-13 1 760984
12 – 19)
RIGHT BRAKE SET ASSEMBLY (Includes Items
20 82993-13 1 760985
12 – 19)
* SPECIAL ORDER
3-8
REAR AXLE/BODY ATTACHMENT – BC

1 * NKL AXLE ASSEMBLY, BC2/3 16.77 1 467836
1A * NKL AXLE ASSEMBLY, BC2 10.37 1 467940
1B * AXLE ASSEMBLY BC4 AC POWER 20:1 1 468825
2 3416 SCREW, 3/8-16 3 1/2HHCS, G5 2 708526
3 10505 BUSHING, RUBBER 1/2X1 3/8 4 709015
4 5711 SPACER, SPLIT SEAM 2 709042
5 3453 SCREW, 3/8-16X3 3/4 HHCS, G5 2 719622
6 7778 NUT, 3/8-16 NYLOCK 4 719902
7 43152-66 NUT, 1/2-20 TAPERED 10 709002
* SPECIAL ORDER
3-9
AXLE 16:77, AC DRIVE – BC
3-10
AXLE 16:77, AC DRIVE – BC (Cont.)
3-11
AXLE 16:77, AC DRIVE – BC (Cont.)

1 54801-00 CPC SUSPENSION SPRING SHACKLE 4 510364
2 54804-12 REAR SPRING PLATE 4 514353
3 10505 BUSHING, RUBBER, 1/2X 1-3/8 8 709015
4 5711 SPACER,SPLIT SEAM,.50X 2-1 " 4 709042
5 41440-02 BRAKE LINE, 3/16 X 30 (LH FORMED) 1 709232
6 41222-00 BRAKE LINE, 3/16 X 20 (RH FORMED) 709358
7 41842-94 UNION TEE, HYD BRAKE 1 709377
8 54814-00 LEAF SPRING ASSY,4-LEAF,SUSPENSION 2 709382
9 41216-00 BRAKE HOSE, HYD, FLEX, 22 " 1 709430
10 5214 U-BOLT, 1/2-13, 2.31 X 6.50, UNPLTD 2 709574
11 3453 SCREW, 3/8-16 X 3-3/4 HHCS GR5 2 719622
12 9982 CLAMP, STEEL TUBE, 1/4" VINYL CUSH 1 719756
13 7068 WASHER,1/2,ALLOY-SPLIT, L/W,YWZC 8 719840
16 82669-12 AXLE, HD NKL, 16.77:1 760733
17 69531-13 MOTOR,AC,8KW, SCHABMUELLER 1 760957
18 69532-13 BUMPER, MOTOR, SCHABMUELLER AC 1 760991
19 46270-08 WASHER, 6MM, L/W, ZC 6 781405
20 46265-08 WASHER,6MM,F/W,ZC 6 781406
21 72464-12 M6 X 35MM HHCS 6 781478
22 54811-12 U-BOLT, 1/2-13, 2.81 X 6.75 2 782102
3-12
AXLE 20:1, AC DRIVE – BC-4

1 54814-00 LEAF SPRING ASSY, 4-LEAF,SUSPENSION 2 709382
2 82699-14 AXLE, BC4, DUAL RATIO, HYD (10:1/20:1) 1 761055
3 * REAR SPRING PLATE, BC4 AC DRIVE 4 515775
4 5214 U-BOLT, 1/2-13, 2.31 X 6.50, UNPLTD 4 709574
5 7068 WASHER,1/2,ALLOY-SPLIT, L/W,YWZC 8 719840
7 5711 SPACER,SPLIT SEAM,.50X 2-1 " 4 709042
8 10505 BUSHING, RUBBER, 1/2X 1-3/8 8 709015
9 54801-00 CPC SUSPENSION SPRING SHACKLE 4 510364
10 3453 SCREW, 3/8-16 X 3-3/4 HHCS GR5 2 719622
13 41519-00 BRAKE LINE, 3/16 X 12 2 709607
14 41842-94 UNION TEE, HYD BRAKE 1 709377
15 41216-00 BRAKE HOSE, HYD, FLEX, 22 " 1 709430
16 69531-13 MOTOR,AC,8KW, SCHABMUELLER 1 760957
17 46265-08 WASHER,6MM,F/W,ZC 6 781406
18 72464-12 M6 X 35MM HHCS 6 781478
19 69532-13 BUMPER, MOTOR, SCHABMUELLER AC 1 760991
* SPECIAL ORDER
3-13
REAR AXLE AND BRAKES – DANA
See NOTE page 3-17
3-14
REAR AXLE AND BRAKES – DANA (Cont.)
See NOTE page 3-17
3-15

1 N/A HOUSING, AXLE 1 N/A
2 83165-08 SEAL, INPUT PINION 1 760371
3 * GEAR, INPUT PINION (Available as Kit Item 35 & 37) 1 *
4 90006-90 RING, SNAP (Available as Kit Item 35 & 44) 3 749701
5 11118 O-RING (Available as Kit Item 35 & 44) 3 729030
BEARING, BALL, INPUT SHAFT (Available as Kit Item
6 90003-90 1 719077
35, 38 & 44)
BEARING, BALL, INPUT GEAR (Available as Kit Item 35,
7 90004-90 1 749699
38 & 44)
8 82808-90 PLUG, END CAP 2 749418
9 82810-90 BEARING, BALL (Available as Kit Item 38) 2 749419
10 * SHAFT, INTERMEDIATE GEAR (Available as Kit Item 37) 1 *
11 11119 O-RING 2 719132
12 * GEAR, FINAL DRIVE (Available as Kit Item 38) 1 *
13 90005-90 BEARING, BALL (Available as Kit Item 37) 2 749700
14 83212-00 DIFFERENTIAL ASSEMBLY 1 749575
15 N/A SCREW, CAP 4 N/A
16 N/A NUT, LOCK 4 N/A
17 90007-00 PLATE, COVER (Available as Kit Item 39) 1 749702
18 90008-00 PLUG, DRAIN/FILL (Available as Kit Item 39) 1 749704
19 N/A SCREW, TAPPING 10 N/A
20 82701-90 VENT 1 759791
21 N/A SCREW, SOCKET HEAD 8 N/A
22 83160-93 SEAL, OIL 2 749547
23 83167-93 RING, RETAINING 2 749549
24 83100-73 ASSEMBLY, BEARING, TAPERED ROLLER 2 749522
25 41814-93 ASSEMBLY, BRAKE, LH (Hydraulic) 1 729996
26 41813-93 ASSEMBLY, BRAKE, RH (Hydraulic) 1 729993
27 82811-93 SEAL, OIL 2 749421
28 83114-93 WASHER, FLAT 8 749530
29 83120-93 NUT, LOCK 8 749532
30 N/A SHAFT, AXLE, LH LONG (Available as Kit Item 57) 1 N/A
31 82757-00 SHAFT, AXLE, RH SHORT(Available as Kit Item 58) 1 749403
32 41199 BOLT, WHEEL 1.500” (Available as Kit Item 57) 10 719655
32A 719463-05 BOLT, WHEEL 1.680" (Available as Kit Item 57) 10 719463
33 82830-93 DRUM, BRAKE 2 749427
34 82503-08 GASKET 1 759937
35* 83297-08 PINION & SEAL KIT 12.44:1 (Includes Items 2-7) 1 760373
35* 83219-08 PINION & SEAL KIT 16.99:1 (Includes Items 2-7) 1 760374
36* 82774-08 GEARSET KIT 12.44:1( Includes Items 4 – 13 & 35) 1 191701U
36A* 82776-08 GEARSET KIT 16.99:1( Includes Items 4 – 13 & 35) 1 191703U
37* 82817-09 RAW AXLE 12.44:1 (Obsolete - See Note) 1 759925
3-16

37A* 82819-09 RAW AXLE 16.99:1 (Obsolete - See Note) 1 759922
PINION SEAL KIT (INCLUDES ITEMS 2 & 4 – 7) ONLY
38 82779-08 1 191697U
FOR USE WITH ITEM 35.
39 41888-93 BLEEDER VALVE 2 719296
40 41890-93 HYDRAULIC CUP 4 739022
41 41886-93 BOOT & RING 4 739021
42 41892-93 PISTON, WHEEL CYLINDER (Includes Items 40 & 41) 4 739023
43 41884-93 TORQUE SPIDER (Includes Items 39-42) 2 719076
44 41928-93 SPRING, SHOE HOLD DOWN 4 719075
45 41926-93 DUST SHIELD 2 739030
46 41920-93 PIN, RETAINER, PARKING BRAKE LEVER 4 739029
46 41918-93 SPRING, ADJUSTING SCREW 2 739028
47 41880-93 ADJUSTING SCREW 2 719294
48 41878-93 NUT, PIVOT, ADJUSTING SCREW 2 719295
49 41882-93 SOCKET, ADJUSTING SCREW 2 739020
50 41894-93 STRUT & LEVER ASSEMBLY, PARKING BRAKE 2 739024
51 41912-93 SHOE & LINING ASSEMBLY SET 2 719046
52 41914-93 SPRING, SHOE RETURN, LH (GREEN OR BLUE) 2 739026
53 41916-93 SPRING, SHOE RETURN, RH (RED OR YELLOW) 2 739027
54 41918-93 SPRING, ADJUSTING SCREW 2 739028
56 19316-00 12.44 RATIO COMPLETE AXLE (Obsolete - See Note) 1 307242
56A 82886-05 16.99 RATIO COMPLETE AXLE (Obsolete - See Note) 1 307244
57 90013-08 KIT, SHAFT & BOLT LH (Includes Items 30 & 32) 1 759936
58 90012-00 KIT, SHAFT & BOLT RH (Includes Items 31 & 32) 1 719258
** NOT SHOWN
* SEE GEAR SETS PAGE 3-18
NOTE: The 12.44 axle has been replaced. Contact P&A for a special order.
The 16.99 axle has been replaced. Contact P&A for a special order.
Limited parts available for the obsolete axle assemblies.
3-17
REAR AXLE AND BRAKES – BC2 (Cont.)
GEAR SETS
3-18
REAR AXLE ASSEMBLY – BC 2
3-19
REAR AXLE ASSEMBLY – BC2 (Cont.)
MOTOR INSTALLATION
3-20
REAR AXLE ASSEMBLY – BC2 (Cont.)

1 82695-12 SPRING PLATE 4 513980
2 54801-00 SPRING SHACKLE 4 510364
3 708616 SCREW, 1/4-20-1 1/4 HHC 3 708616
4 6703-B WASHER, 1/4 3 719811
5 10505 BUSHING, RUBBER 1/2X1 3/8 8 709015
6 5711 SPACER, .5X2-1 4 709042
7 11423 RESILIENT BUMPER ELEC MOTOR 1 709050
8 7036-B WASHER, LOCK 1/4 3 719834
9 7068 WASHER, LOCK 1/2 8 719840
10 7778 NUT, 3/8-16 NYLOCK 2 719902
11 54814-00 LEAF SPRING ASSMY, 4 LEAF 2 709382
12 5205 U-BOLT, 4 709425
13 19316-00 AXLE, HD 12.44 1 307242
13A 82693-09 AXLE, HD 16.99 1 309692
14 69300-03 MOTOR, ELEC., 48V SEP EX STD DUTY 1 719135
15 7880 NUT, 1/2-13 HEX 8 719913
16 41199 SCREW, 3/8-16X3 1/2 HHC GR5 2 719655
17 9982 CLAMP STEEL TUBING 1/4 1 719756
18 6702-B WASHER, 5/16 1 719810
3-21
REAR AXLE AND BRAKES – BC3- DANA M18

1 * ASSMY, LOWER HOUSING & TUBES 1 N/A
2 * PLUG, FILL 1 N/A
3 * PIN, DOWEL 2 N/A
4 * VENT 1 N/A
5 * SCREW 8 N/A
6 12005 RETAINER, BEARING 2 759767
7 12008 SEAL, OIL 2 759761
8 83100-73 CUP W/CONE 2 749522
9 40893-12 SEAL, GREASE 2 760763
10 41601-06 ASSY, BRAKE RH 1 759763
11 41602-06 ASSY, BRAKE LH 1 759764
12 82830-93 DRUM, BRAKE 2 749427
13 * STUD, WHEEL 10 N/A
14 * AXLE SHAFT RH 1 N/A
15 * AXLE SHAFT LH 1 N/A
16 * GASKET SEALANT 1 N/A
17 * GASKET SEALANT 1 N/A
18 * NUT 8 N/A
19 * SCREW 8 N/A
20 * KIT, ASSY, (Includes Items 46 – 52) 1 N/A
3-22
21 * CONE, BEARING 2 N/A
22 * CUP, BEARING 2 N/A
23 * Kit, SHIM DIFFERENTIAL 2 N/A
24 * GEAR SET, GEAR & PINION 1 N/A
25 * SCREW 10 N/A
26 * SCREW, CAP, BEARING (Includes Item 29) 4 N/A
27 * CAP, BEARING (Includes Item 29) 2 N/A
28 * CARRIER SUBASSY (Includes Items 27 & 28) 1 N/A
31 * KIT, SHIM, PINION A/R N/A
32 * SPACER, PINION 1 N/A
35 * WASHER 1 N/A
36 12007 SEAL, OIL 1 759753
37 * FLANGE, COMPANION 1 N/A
38 * SPACER 1 N/A
39 40892-12 NUT, LOCK 1 760765
40 * O-RING 2 N/A
41 * SEAL, OIL 2 N/A
42 * GREASE FITTING 2 N/A
43 * KIT, SHIM A/R N/A
44 * PIN, COTTER 1 N/A
46 * WASHER, THRUST 2 N/A
47 * PIN, ROLL 1 N/A
48 * WASHER, THRUST 2 N/A
49 * SHAFT, CROSS, DIFFERENTIAL 1 N/A
50 * PINION, DIFFERENTIAL 2 N/A
51 * GEAR, DIFFERENTIAL 2 N/A
52 * CASE, DIFFERENTIAL 1 N/A
* SPECIAL ORDER
** NOT SHOWN
3-23
REAR AXLE AND BRAKES – BC3 DANA M18 -Cont.
ITEM CPC P/N DESCRIPTION QTY** SEATS P/N

1 41604-06 KIT, TORQUE SPIDER ASSY 1 759766
2 41603-06 KIT, SHOE AND LINING 2 759765
3 - DUST SHIELD 1 *
4 - MANUAL ADJUSTER 1
5 - PIVOT 1
6 - KIT, LEVER ASSY 1
7 - SPRING CLIP 2
8 - SPRING 1
9 - SPRING 1
10 - SPRING, TENSION 1
11 - SPRING, HOLD DOWN 2
12 - BLEEDER 1
13 - BLEEDER CAP 1
14* - KIT, SPRING (Includes Items 8-11) 1
15* 41602-06 LEFT HAND ASSY 1 759764
16* 41601-06 RIGHT HAND ASSY 1 759763
* NOT SHOWN ** QTY TO SERVICE ONE BRAKE ASSY
- SPECIAL ORDER
3-24
REAR AXLE ASSEMBLY – BC3 - DANA M18
3-25
REAR AXLE ASSEMBLY – BC3 - DANA M18 (Cont.)
3-26
REAR AXLE ASSEMBLY – BC3 -DANA M18 (Cont.)
3-27
REAR AXLE ASSEMBLY – BC3 - DANA M18 Cont.)
3-28
REAR AXLE ASSEMBLY – BC3 -DANA M18 (Cont.)
3-29
REAR AXLE ASSEMBLY – BC3 - DANA M18 (Cont.)

1 33420-09 WASHER ASSY, MOTOR ADJ. 1 306107
2 33480-02 M18 MOTOR MOUNT 1 307263
3 82980-01 M18 AXLE 1 307271
4 82697-12 SPRING PLATE 4 513979
5 54801-00 SPRING SHACKLE 4 510364
6 N/A BRACE, MOTOR MOUNT 1 513985
7 43152-66 NUT, 1/2-13 GR2, HEX 8 709002
8 10505 BUSHING, RUBBER 1/2X1 3/8 8 709015
9 5711 SPACER, .5X2-1 4 709042
10 54845-01 SPRING, 4 LEAF 6” DROP 1 709112
11 33481-02 COVER M18 DRIVE 1 709239
12 36384-02 BUSHING 7/8 1 709240
13 36385-02 SPROCKET BELT 40T 1 709241
14 36387-02 BELT, TOOTHED .960T 1 709242
15 36386-02 SPROCKET, BELT 56T 1 709260
16 6416 WASHER, 3/8 8 719796
17 7778 NUT, 3/8-16 NYLOCK 10 719902
18 7739 NUT, 5/16-18 NYLOCK 1 719892
19 5214 U-BOLT 1/2-13X5.75 4 709574
20 7538 LOCKNUT, 5/8-18 FLANGE 1 719044
21 69304-04 MOTOR, SEP EX SHAFT OUTPUT 1 719370
22 7686 NUT, 1/4-20 NYLOCK 7 719879
23 2551-W SCREW, 1/4-20X1 HHC G5 6 719564
24 7068 WASHER, LOCK 1/2 8 719840
25 2667 SCREW, 5/16-18X2 HHC G5 1 719585
26 2879-W BOLT 3/8-16X1 5 701795
27 3453 SCREW, 3/8-16X3 1/2 HHC G5 2 719622
28 41204-63A KEY, SQUARE 3/16X1 7/16 1 719656
29 4716-W SCREW, 3/8-16X1 1/4 HHC G5 7 719694
30 4720-B SCREW, 3/8-16X1 3/4 HHC G5 4 719696
31 7038-B WASHER, 3/8 SPRG LOCK 8 719836
32 6000-B WASHER, 5/16 1 719771
33 7624 NUT, 10-24 NYLOCK 1 719870
34 6703-B WASHER 1/4 12 719811
3-30
REAR AXLE ASSEMBLY – BC4 & 4SC
3-31
REAR AXLE ASSEMBLY – BC4 & 4SC (Cont.)
3-32
3-33
3-34
3-35

1 33420-09 WASHER ASSY, MOTOR ADJ. 1 306107
2 * AXLE HOUSING, FORD 1 307239
3 33415-00A CHAIN HOUSING BACK PLT 1 308235
4 33470-00 CHAIN, 47 LINK W/PIN 1 467289
4A 33407-00 CHAIN, 52 LINK W/PIN BC4-SC 1 461335
5 33404-06 COVER, CHAIN HOUSING 1 510261
6 54801-00 SPRING SHACKLE 4 510364
7 54815-02 RETAINER PLATE, AXLE SPRING 2 510370
8 33414-00 ADAPTER PLATE, DRIVE UNIT 2 510374
9 41234-00 CALIPER MOUNT, ADAPTER BRKT 2 510378
10 23680-00 CALIPER MOUNT, ADAPTER SHIM 4 510809
11 33405-00 HOUSING, CHAIN DRILLER 1 511364
12 4017 SCREW, 5/16-18X1 HHC G8 4 708085
13 54819-00 LEAF SPRING, 7 LEAF 2 739587
13A 54836-00 LEAF SPRING, 8 LEAF BC4-SC 2 709299
14 10505 BUSHING, RUBBER 1/2X1 3/8 8 709015
15 5711 SPACER, .5X2-1 4 709042
16 41226-00 BRAKE CALIPHER RH REAR 1 709133
17 41225-00 BRAKE CALIPHER LH REAR 1 709291
18 41238-00 ROTOR, DISC BRAKE, REAR 2 729888
19 33472-00 SPROCKET, 19T, 7/8B 1 729662
19A 33411-00 SPROCKET, 17T, 7/8B BS4-SC 1 709143
20 33432-00 SPROCKET, 67 TOOTH 1 729638
20A 33417-00 SPROCKET, 86 TOOTH 1 709145
21 7880 NUT, 1/2-13 G2 HEX 8 719913
22 5213 U-BOLT 1/2-13X7.93 4 709623
23 7778 NUT, 3/8-16 NYLOCK 4 719902
24 33448-00A AXLE SHAFT, LH FORD 1 719273
25 33447-00A AXLE SHAFT, RH FORD 1 719274
26 69304-04 MOTOR, SEP EX SHAFT OUTPUT 1 719370
27 82502-06 AXLE CENTER ASSY, 3.55 FORD 8” 1 719492
27A 82503-06 AXLE CENTER ASSY, 4.63 FORD 8” BC4-SC 1 719272
28 2247 SCREW, 1/4-20X1/4 SH SET 2 719550
29 2639 SCREW, #8X1/2 HEX WASHER HEAD TAP 3 719578
30 2879-W SCREW, 3/8-16X1 G5 HHC 7 707195
31 3413 SCREW, 1/4-20X3 1/4 HHC 10 719614
32 3453 SCREW, 3/8-16X3 1/2 HHC 2 719622
33 3651 SCREW, 1/4-20X3 1/2 HHC 4 719628
34 3987-BS SCREW, 5/16-18X3/4 HHC 8 719642
35 41204-63A KEY, SQUARE 3/16X1 7/16 1 719656
36 4713-W SCREW, 3/8-16X3/4 HHC G5 4 719693
37 4716-W SCREW, 3/8-16X1 1/4 HHC G5 1 719694
38 4740-b SCREW, SOCKET HD CAP 3/8-16X2 5 719698
3-36
REAR AXLE ASSEMBLY – BC4 & BC4SC (Cont.)

39 6416 WASHER, FLT 3/8 3 719796
40 6702-b WASHER, FLT 5/16 4 719810
41 6703-B WASHER, 1/4 4 719811
42 7038-b WASHER, 3/8, LOCK 12 719836
43 7041-b WASHER, 5/16, LOCK 8 719838
44 7068 WASHER, LOCK 1/2 8 719840
45 7686 NUT, 1/4-20 NYLOCK 14 719879
46 7739 NUT, 5/16-18 NYLOCK 4 719892
AXLE ASSY, 3.55 (Includes Items 2, 18, 24, 25, 27, 34, &
N/A 33430-06 1 467401
43)
AXLE ASSY, 4.62 (Includes Items 2, 18, 24, 25, 27, 34, &
N/A 33402-00 1 467070
43)
N/A 83229-11 KIT, HARDWARE FORD AXLE 1 719270
* SPECIAL ORDER
3-37
REAR AXLE/BRAKE DETAIL – BC4
3-38
REAR AXLE/BRAKE DETAIL– BC4 (Cont.)

1 33402-00 ASSEMBLY, AXLE, 4.62 RATIO BC 4 1 467070
1A 33430-06 ASSEMBLY, AXLE, 3.55 RATIO BC 4 1 467401
Axle assemblies include items 2-12 and a complete axle center
(see rear axle center section for parts breakdown).
ASSEMBLY, SHAFT, LH BC FORD AXLE (Includes items
2 33448-00A
8, 9, & 11)
1 719273
ASSEMBLY, SHAFT, RH BC FORD AXLE (Includes items
3* 33447-00A
8, 9, & 11)
1 719274
4 41238-00 ROTOR, DISC BRAKE -REAR 2 729888
5 3987-BS SCREW, 5/16-18 X 3/4, HHCS, G5 8 719642
6 7041-B WASHER, 5/16 SPRING LOCK 8 719838
7 82507-00 GASKET, AXLE, 1/8 2 749345
8 9082 BEARING, AXLE WITH RETAINER RING 2 749750
9 83111-06 SEAL, AXLE 2 759750
10 N/A NUT, 3/8-16 TOP LOCK (Available only as Item 30) 8 N/A
11 83110-06 RETAINER, BEARING 2 759752
12 41199 WHEEL BOLT, 1/2-20 X 1 1/2, GR 5 10 719655
13 41225-00 BRAKE CALIPER, LH, REAR 1 709291
14* 41226-00 BRAKE CALIPER, RH, REAR 1 709133
15 41234-00 CALIPER MOUNT, ADAPTER BRACKET 2 510378
16 23680-00 CALIPER MOUNT, ADAPTER SHIM A/R 510809
17 7739 NUT, 5/16-18, NE, NYLOCK, GR A 4 719892
18 6702-B WASHER, 5/16 FLAT 4 719810
19 4017 SCREW, 5/16-18 X 1, HHCS, GR 8 4 708085
20 7038-B WASHER -3/8 REG SPRG LOCK BLACK 4 719836
21 4713-W SCREW, HX HD CAP 3/8-16 X 3/4 G5 4 719693
22 41297-00 BRAKE PADS 4 729920
23 41361-00 BOOT, DUST 4 729959
24 41359-00 PISTON 4 729957
25 41360-00 O-RING 4 729958
26 41257-00 LEVER, PARKING BRAKE ** 2 729901
27 41224-00 CONNECTOR, MALE, BRASS ** 2 709618
28 41313-00 BLEEDER VALVE ** 2 719082
29* 43152-66 LUG NUTS, 1/2-20, (Torque to 65 Ft. Lbs.) 10 709002
KIT, HARDWARE, BC4 AXLE (Includes one third member
30* 83229-11 gasket, ten 3/8-24 top lock nuts, ten 3/8 aluminum flat 1 719270
washers and eight 3/8-16 top lock nuts.)
* NOT SHOWN
** POSITIONS WILL VARY FOR LEFT & RIGHT HAND CALIPERS
3-39
REAR AXLE CENTER - BC4 & 4SC
3-40
REAR AXLE CENTER - BC4 & 4SC (Cont.)

1* N/A RING AND PINION GEAR SET 1 N/A
2* N/A 28 SPLINE OPEN CARRIER UNIT 1 N/A
3* N/A GEAR CASE 1 N/A
4* N/A PINION SUPPORT 1 N/A
5 33418-00 INPUT SPROCKET MOUNTING FLANGE 1 759751
6 82500-06 THIRD MEMBER TO HOUSING GASKET 1 759749
7* N/A CARRIER BEARING 2 N/A
8* N/A CARRIER BEARING RACE 2 N/A
9 12013 PINION GEAR OIL SEAL 1 729088
10* N/A OUTER PINION BEARING RACE 1 N/A
11* N/A OUTER PINION BEARING 1 N/A
12* N/A INNER PINION BEARING RACE 1 N/A
13* N/A INNER PINION BEARING 1 N/A
14* N/A POCKET BEARIING 1 N/A
15* N/A POCKET BEARIING RETAINER 1 N/A
16* N/A PINION BEARING PRELOAD SPACER 1 N/A
17* N/A PINION BEARING PRELOAD SPACER SHIMS A/R N/A
18 82501-06 FLANGE RETAINING NUT, 3/4-16 FLANGE NUT 1 781131
19* N/A PIINION SUPPORT BOLT 5 N/A
20* N/A RING GEAR TO OPEN CARRIER UNIT BOLT 10 N/A
21 82505-00 PINION SUPPORT TO GEAR CASE O" RING " 1 749343
22* N/A PINION DEPTH SHIM A/R N/A
28 N/A AXLE HOUSING 1 N/A
38 N/A THIRD MEMBER TO HOUSING STUD 3/8-24 10 N/A
39 N/A SEALANT (RTV OR GASKET TYPE) A/R N/A
40** N/A DRAIN PLUG (TORQUE TO 35 FT/LBS) 1 N/A
41** 82502-06 BC 3.55 RATIO AXLE CENTER (Includes items 1-22) 1 719492
41A** 82503-06 BC 4.62 RATIO AXLE CENTER (Includes items 1-22) 1 719272
* SERVICED BY ITEM 41
** NOT SHOWN
3-41
Burden Carrier
Parts Manual
Section 4
Seats, Decks and Dash

SEATS, DECK, CHARGER MOUNTING – BC
4-1
SEATS, DECK, CHARGER MOUNTING – BC (Cont.)

1 - CHARGER, DELTA Q (See Page 4-3) 1 -
2 3787-B SCREW, 1/4-20 X 3/4, HHCS, G5 A/R 719636
3 6703-B WASHER, 1/4, SAE FLAT A/R 719811
4 7724-B NUT, 1/4-20, SERRATED FLANGE LOCK, GR A A/R 719887
5 66493-03 CHARGER CORD, 6' LONG, 14/3 WIRE BLK 1 719264
6 66034-02 CHARGER INLET PLUG 1 709558
N/A 70036-05 CHARGER CORD W/PLUG ASSY (Includes Items 5 & 6) 1 467405
* 66493-67A EXTENSION CORD 1 709890
7 90754-09 DECK BC-L MEZZTREAD 1 513012
7A 90753-09 DECK BC-S MEZZTREAD 1 513013
7B* 51322-00 DECK COVER, 14GA, BC-S, BC-L (Used w/ Item 7C) 1 509377
7C* 51320-00 DECK BOARD, PINE, BC-S, BC-L (Used w/ Item 7B) 1 510368
7D* 51323-00 DECK COVER, 14GA, BC-L (Used w/ Item 7E) 1 509378
7E* 51321-00 DECK BOARD, PINE, BC-L (Used w/ Item 7D) 1 510367
7F* 6350 WASHER, FLAT 5/16 (Used w/ Items 7B – 7E) 2 708682
7G* 1600 SCREW, 5/16-18X2 1/2 (Used w/ Items 7B – 7E) 2 709418
7H* 7739 NUT, 5/16-18 NYLOCK (Used w/ Items 7B – 7E) 2 719892
8 51701-00** 907 SEAT ASSEMBLY W/ LH ARM SEAT SWITCH 1 149596%LA
8A 51718-05** 907 SEAT ASSEMBLY W/ LH ARM NO SEAT SWITCH 1 177295%LA
* 51722-09** 907 SEAT ASSEMBLY – NO ARMS SEAT SWITCH 1 149596%
* 51723-09** 907 SEAT ASSEMBLY – NO ARMS, NO SEAT SWITCH 1 177259%
9 51700-00** 907 SEAT ASSEMBLY W/ RH ARM, NO SEAT SWITCH 1 177259%RA
* 51711-04** 907 BOTTOM CUSHION 1 307912%
* 51712-04** 907 BOTTOM CUSHION W/SWITCH 1 307911%
* 51710-04** 907 BACK CUSHION 1 307913%
10 6000-B WASHER, 5/16 SAE FLAT 8 719771
11 7810 NUT, 5/16-18, NYLOC, GR A 8 719906
12 51325-09 SEAT BOARD, MEZZTREAD 1 513014
13 70038-04 HARNESS, EXTENSION 1 467219
14 52610-97 907 ARM KIT, LH (Includes mounting bracket & hardware) 1 506613BU
15* 52611-97 907 ARM KIT, RH (Includes mounting bracket & hardware) 1 506614BU
16 91401-90 TRACK, NON-LOCKING 2 707005
17 69757-95 OPERATOR PRESENCE SWITCH 1 708455
18 91400-02 TRACK, LOCKING 1 301150
19 51900-11 SEAT HOLD DOWN BRACKET 1 514385
20 658 PLUG, 01.25” BLACK (Added after March 2014) 2 719803
21 69757-95 SEAT SWITCH, DELTA 1 708455
21A* 51713-04 SEAT SWITCH W/41” LEADS 1 307722
* 66014-03 BATTERY, 6V, DEEP CYCLE, (US-2000) 6/8 719229
* 66005-03 BATTERY, 6V, DEEP CYCLE, (US-145) 6/8 719231
* 66200-10 BATTERY, 6V, DEEP CYCLE, (AGM) 8 760586
* NOT SHOWN ** Include VIN for proper color
4-2
DELTA Q CHARGER WITH REMOTE LED – BC

1 9951 CR-174 CLIP & RING 1 781989
2 66584-12 LED FRONT LABEL 1 760754
3 66501-12 CHARGER, DELTA Q 36V W/LED, STANDARD 1 760743
3A 66583-12 CHARGER, DELTA Q 48V W/LED, STANDARD 1 760742
3B 66582-12 CHARGER, DELTA Q 48V W/LED, AGM 1 467839
4 66034-02 PLUG, POWER INLET 120V SEALED 1 709558
5 66493-03 CHARGER CORD 6’ 1 719264
6 66029-12 LED 25’ CABLE 1 760817
ASSEMBLY, CORD W/ RECEPTACLE (Includes Item 4 &
N/A 70036-05 1 467405
5)
NOTE: SEE SERVICE BULLETIN SB11-004 IF REPLACING A NON-LED CHARGER.
4-3
2nd SEAT w/MEZZ DECK– BC
4-4
2nd SEAT w/MEZZ DECK– BC (Cont.)
4-5
4-6

1 * ASSY, SEAT BASE -2ND SEAT BC 1 308241
2 51570-10 ASSY, SEAT BACK 1 308242
3 * CHANNEL -SEAT BOARD REINFORCEMENT 2 511000
4 * PLATE -HINGE RH 1 511001
5 * PLATE -HINGE LH 1 511002
6 * CHANNEL -SEAT BOARD REINFORCEMENT 1 511341
7 * STRAP, SEAT HOLD DOWN 1 511384
ND
8 * SEAT BOARD, 2 MESSTREAD 1 513015
ND
9 * DECK, 2 MEZZTREAD 1 513016
10 2879-W SCREW, 3/8-16 X 1 " HHC G5 2 707195
11 52948-96 COVER -SEAT BACK 2 709025
12 48457-ZZ MAT, RAW, BLACK VINYL 2 709373
13 11432 CAPLUG, FP-161 8 719525
14 2653-B SCREW, #10 X 3/4 SELF DRILLING 1 719583
15 2667 SCREW, 5/16-18 X 2 HHCS GRADE 5 " 2 719585
16 2821 SCREW, 1/4-20 X 2 1/4 HHCS GRADE 5 " 2 719590
17 3454-BS SCREW, 1/4-20 X 1-3/4 HHCS GRADE 5 " 6 719623
18 3860-B SCREW, 1/4-20 X 2-1/2 HHCS " 4 719637
19 5449-BS SCREW, 5/16-18 X 1-1/2 CARRIAGE GRADE 5 " 9 719750
20 6702-B WASHER, FLAT STEEL 5/16 BLACK " 17 719810
21 6703-B WASHER, FLAT STEEL 1/4 BLACK " 14 719811
22 6716 WASHER, FLAT STEEL #10 BLACK 1 719812
23 7686 NUT, 1/4-20, NYLOCK 2 719879
24 7739 NUT, 5/16-18, NYLOCK 15 719892
25 7778 NUT, 3/8-16, NYLOCK 2 719902
26 * PLUG, 1.50” SQUARE 6 781502
27 4023 SCREW, 5/16-18X1 HHC G5 TRIBLK 4 782037
N/A SEAT CUSHION (Must include VIN for correct color) 1 N/A
N/A SEAT BACK CUSHION (Must include VIN for correct color) 2 N/A
* SPECIAL ORDER
NOTE: Each end of the two lower support tubes will be closed with Items 26. Added March 2014.
4-7
SEAT BELT – BC

1 4256 SCREW, 7/16-20X1.5 HHC 4 719665
2 6416 WASHER 3/8 FLAT 8 719796
3 7825 NUT, 7/17-20 NYLOCK 4 719908
4 75504-09 SEAT BELT 48” BLK 2 741359
5 75502-09 SEAT BELT BUCKLE 2 741361
KIT, RETRACTABLE SEAT BELTS(Includes Items 1-5, seat
N/A 75513-00 1 191849U
belt bracket & attachment hardware, Items 6-8)
6* 4716-W SCREW 3/8-16X1 1/4 HHC 5 719694
7* 6000-B WASHER 5/16 10 719771
8* 7778 NUT, 3/8-16 NYLOCK 5 719902
* NOT IDENTIFIED
4-8
DASH PANEL – BC

1 50010-05 OVERLAY, DASHBOARD, BC 1 719478
2 39819-05 PANEL, DASH 1 510784
3 POSITION KEYSWITCH WITH HARDWARE (See table below
3 71730-01 1 709040
for alternate keysets)
2 POSITION POWERSWITCH WITH HARDWARE (See table
4 71732-06 1 759706
below for alternate keysets)
ASSY, KEY, NON-REMOVABLE, W/COVER (Used only with
5 71767-05 1 719432
Keyset A)
6 72000-10 SWITCH, TOGGLE A/R 760600
7* SCREW, 10-24X1/2 PHILLIPS 6 719467
8 71807-80 HORN SWITCH 1 709385
8A* ** HORN SWITCH ASSEMBLY, FLOOR MOUNT 1 468835
9** 653 1/2 HOLE PLUG (Used to fill unused toggle switch holes) A/R 719798
* SPECIAL ORDER
** NOT SHOWN
3 POSITION POWERSWITCH 2 POSITION POWERSWITCH STANDARD KEYS

KEYSET CPC P/N SI P/N CPC P/N SI P/N CPC P/N SI P/N
A 71730-01 709040 71732-06 759706 71731-01 749184
B 71730-03B 719297 71732-06B 759722 71731-03B 719301
C 71730-03C 719298 71732-06C 759723 71731-03C 719302
D 71730-03D 719299 71732-06D 759724 71731-03D 719303
E 71730-03E 719300 71732-06E 759721 71731-03E 719304
4-9
TURN SIGNAL – BC
P/N 71428-04
FLOOR MOUNTED HORN - BC

1 70086-14 FLOOR HORN SWITCH ASSEMBLY 1 468835
2 3615 SCREW, 10-24X1/2 PPH 2 719467
3 7624 NUT, 10-24 GR A NM NYLOCK 2 719870
4 * PLUG, .625 BLACK NYLON 1 782140
* SPECIAL ORDER
4-10
ADJUSTABLE SEATS W/RISERS– BC

1 51701-00 907-18 BUCKET SEAT, LA, SW (See Note) 1 149596%LA
2 51700-00 907-18 BUCKET SEAT, RA, NO SW (See Note) 1 177295%RA
3 51325-09 SEAT BOARD, BC MEZZTREAD 1 513014
4 * BRACKET, SEAT HOLD DOWN- BC 1 514385
5 * SEAT RISER, BC, A 2 515763
6 * SEAT RISER, BC, B 2 515764
7 2509 SCREW, HX HD, .25 x 1,THRD FRMING 2 719560
8 5400-BS BOLT, 5/16-18 X 1, CARRIAGE, GRADE 5 8 719744
9 7810 NUT 5/16-18 GR G FLANGE LOCK YWZC 16 719906
* SPECIAL ORDER
NOTE: Include VIN for correct color.
4-11
REFLECTORS – BC

1 68572-03 REFLECTOR, AMBER, 2 3/4X1 3/4 2 719336
2 68573-03 REFLECTOR, RED 4 5/16X13/16 719337
LABEL SET BC

1 53250-01 LABEL SET 1 709754
4-12
SEAT BELTS, 2ND SEAT – BC

1 75508-99 SEAT BELT BRACKET 1 306478
2 5845 SPACER 2 510324
3 75509-99 HINGE 2 709037
4 2828-W SCREW, HHC 3/8-16X3 G5 2 719591
5 3775 SCREW, HHC 3/8-16X2 G5 2 719634
6 4256 SCREW, HHC 7/16-20X1.5 G5 1 719665
7 4713-W SCREW, HHC 3/8-16X3/4 G5 2 719693
8 6000-B WASHER, 5/16, USS/STD 6 719771
9 6416 WASHER FLAT STL 2 719796
10 7825 NUT, 7/16-20 NYLOCK GA 1 719908
11 75504-09 SEAT BELT, 48” BLK, ALR ONLY, 1.3 MOUNT 2 741359
12 75502-09 SEAT BELT, ATS BUCKLE ONLY, 6” STRAP 2 741361
13 7755 NUT, 3/8-16 GR GT FLANGE 6 760721
4-13
SUPPLEMENTAL DECAL/LABELS – BC
1
2

1 53051-14 DISABLED VEHICLE TOWING DECAL 1 761150
2 53048-14 LABEL, BASIC TOWING 1 761148
3 53054-14 LABEL, INFORMATION, BC2 - 2 PASSENGER 1 761155
4-14
Burden Carrier
Parts Manual
Section 5
Electrical
MAIN WIRE HARNESS – BC
1
7
2
9
3
10
5
11
12
13
5-1
MAIN WIRE HARNESS – BC (Cont.)

1 75062-07 BDI METER 36V 1 759874
1A 75061-07 BDI METER, 48V 1 759842
2 75033-91A HOUR METER, 10-80 VDC 1 709452
3 72000-10 HIGH/LOW SPEED SWITCH 1 760600
4 71730-01 DIRECTION SWITCH 1 709040
5 71732-06 POWER SWITCH 1 759706
6 40610-10 PEDAL ASSY, ACCELERATOR & HARNESS 1 760635
7 51713-04 SEAT SWITCH 1 307722
8 - CHARGER, (See Page 4-3) 1 -
9 47895-05A CONTROLLER, RGEN 24/48 (Programmed 760576) 1 467696
10 75593-04 FUSE, 5 AMP ATO/ATC 1 719445
11 75594-04 FUSE, 1 AMP ATO/ATC 1 719444
12 71408-96A AUDIBLE ALARM, 12/48 SLOW PULSE BACK-UP 1 759831
13 71455-01A CONTACTOR & MOUNTING BRACKET 1 709166
14* 70448-90 CABLE, 6GAX20, 5/16 1 709012
15* 70447-90 CABLE, 6GAX14, 5/16 2 709033
16* 70443-01 CABLE, 6GAX18, 5/16 2 709215
17 70110-12 MAIN HARNESS W/PAD 1 760637
18* 70078-06 MAIN HARNESS W/ADAPTER (See note) 1 467707
* NOT SHOWN
NOTE:
Harness is required for pot box attachment. Part includes main harness (70110-12) and
adapter (70084-10) shown below.
5-2
MAIN WIRE HARNESS – BC (Cont.)
SCHEMATIC DIAGRAM
5-3
ACCESSORY WIRING – BC
5-4
ACCESSORY WIRING – BC (Cont.)
Item 21

1 66014-03 BATTERY, 6V, DEEP CYCLE, (US 2200) A/R 719229
1A 66005-03 BATTERY, 6V DEEP CYCLE HD, (US-145) 719231
1B 66200-10 BATTERY, 6V, AGM SEALED 760586
2 68869-02 WIRE HARNESS, BC, 12V, ACCESSORY 1 709252
3 68873-05 WIRE HARNESS, BC WINDSHIELD WIPER 1 467407
4 43795-ZZ WIRE, TWISTED PAIR 16GA W/JACKET B/W 1 719678
5 69836-00 TURN LIGHT PIGTAIL W/GROMMET 2 463979
6 71860-94 FUSE HOLDER A/R 719850
6A 74596-02 FUSE, 10 AMP ATO/ATC A/R 709786
7 74595-01 FUSE, 15 AMP ATO/ATC 1 709255
8 69001-76A HORN, 12V (2 TERMINAL) 1 709089
9 41212-00 SWITCH, BRAKE LIGHT 1 709749
10 71807-80 SWITCH, HORN 1 709385
11 72000-10 SWITCH, TOGGLE, OFF/NO SPEED CONTROL 1 760600
12 71428-04 TURN SWITCH ASSY 1 467279
13 71412-07 TURN SIGNAL AUDIBLE ALARM 1 759790
14 71977-04 TURN SIGNAL FLASHER UNIT 1 719366
15 67724-91 HEAD LIGHT 2 709389
16 68501-00 TURN LIGHT, AMBER, ROUND 2 709488
17 68020-92 BRAKE/TAIL LIGHT 2 709109
18 68029-06 STROBE LIGHT ASSY, AMBER 1 467408
19 84111-92 MOTOR, WINDSHIELD WIPER 1 709592
20 75321-00 FAN 1 749273
21 68867-02 WIRE HARNESS, TURN SIGNAL BYPASS PLUG 1 709861
* 84147-92 DOME LIGHT ASSY 1 709920
* 69510-11 DOME LIGHT HARNESS 1 467700
* 51150-11 DOME LIGHT MOUNTING BRACKET 1 510315
* 65199-11 HEATER KIT*(Kit include heater, mounting hardware & harness) 1 N/A
* 90140-00 STROBE KIT, POLE MOUNTED 1 190636U
* 90141-00 STROBE KIT, CAB MOUNTED 1 190637U
(Kits include strobe, mounting hardware & wires with terminals)
* 84114-06 WIPER KIT (Includes motor, mounting hardware & harness) 1 191275U
* NOT SHOWN
5-5
ACCESSORY WIRING – BC (Cont.)
SCHEMATIC DIAGRAM
5-6
MOTOR, SEP EX – BC 2

1 * HOLE PLUG 1 N/A
2 * COMMUTATOR END HEAD (Includes Fasteners) 1 N/A
3 83310-07 BEARING 1 759896
4 * RETAINING RING 1 N/A
5 30402-06 BRUSH ASSY. (Includes Fasteners) 2 759780
6 30403-06 BRUSH BOX ASSY. (Includes Fasteners) 1 759781
7 * MOTOR FRAME 1 N/A
8 * POLE SHOE ASSY. (Includes Fasteners) 4 N/A
9 * SHUNT COIL ASSY. (Includes Fasteners) 1 N/A
10 * ARMATURE ASSY. 1 N/A
N/A 69300-03 MOTOR, COMPLETE (Includes Items 1-10) 1 719135
* SPECIAL ORDER
5-7
MOTOR – BC3 & 4

1 * HOLE PLUG 1 N/A
2 * COMMUTATOR END HEAD (Includes fasteners) 1 N/A
3 * HEAD BAND (Includes fasteners) 1 N/A
4 * WAVY WASHER 1 N/A
5 83310-07 BEARING 2 759896
6 * LEAD WIRE ASSY.(Includes fasteners) 2 N/A
7 30404-06 BRUSH (Includes fasteners) 4 759782
8 30403-06 BRUSH BOX ASSY (Includes fasteners) 1 759781
9 * MOTOR FRAME 1 N/A
10 * POLE SHOE ASSY.(Includes fasteners) 4 N/A
11 * SHUNT COIL ASSEMBLY (Includes fasteners) 1 N/A
12 * ARMATURE ASSY. 1 N/A
13 * RETAINING RING 1 N/A
14 * DRIVE END HEAD (Includes fasteners) 1 N/A
15 * OIL SEAL 1 N/A
N/A 69304-04 MOTOR, COMPLETE (Includes Items 1 – 15) 1 719370
* SPECIAL ORDER
** SPECIAL ORDER, INCLUDES ALL NECESSARY FASTENERS
5-8
BATTERY HARDWARE – BC
2
15
10
11 1
13
18
14
12
16
17
5
5
4
QTY QTY
ITEM CPC P/N DESCRIPTION SEATS P/N
36V 48V
1 66561-90A HOLD DOWN ROD 2 3 709059
2 47711-98A HOLD DOWN 1 1 709196
3 70099-88 CABLE, 4GAX8.75 4 7 709004
4 70105-88 CABLE, 4GAX37 1 - 709019
5 70105-98 CABLE, 4GAX61.5 2 2 709411
6* 6256 WASHER, SS .28X1.375X.06 2 3 719786
7* 6703-B WASHER, 1/4 12 12 719811
8* 7036-B WASHER, LOCK 1/4 12 12 719834
9* 7680 NUT, 1/4-20 SS 2 3 719836
10 ** DOOR, 2 2 509591
11 51367-03 DOOR, PUSH PULL, ROLL OUT 1 1 307463
12 51368-03 LATCH 1 1 509577
13 314 LATCH PIN 1 1 709617
14 51359-00 SPRING, RETAINER 2 2 709619
15 805 LANYARD 1 1 709767
16 51366-03 BATTERY BOX, PUSH PULL 1 1 307462
17 ** BATTERY BOX, ROLL OUT 1 1 310015
18 9093 ROLLER, PUSH PULL, ROLL OUT 6 6 719156
19* 3787-B SCREW, 1/4-20X3/4 HHC 12 12 719636
20* 51358-03 KIT, WIDE PUSH PULL 1 1 190576U
* NOT SHOWN
** SPECIAL ORDER
5-9
HEATER HARNESS – BC
NOTE: Not available as a separate item. Included with heater
SCHEMATIC
5-10
TRAILER BRAKE CONTROLLER – BC

1 69924-14 BRACKET, TRAILER PLUG 1 515774
2 74591-96 CIRCUIT BREAKER 20 AMP 1 709398
3* 10043 CABLE TIE, BLACK 11 3/4" 2 719504
4 1005 SCREW, 10-24X1-1/4,PTH,MS,ZC 2 719505
5 2665 SCREW, 10-24 X 5/8 PHILLIPS PHM 6 719584
6 658 PLUG, 1.25" BLACK PLASTIC 1 719803
7 7624 NUT 10-24 GR A NM MACH NYLON LOCK 8 719870
8 42716-14 BRAKE CONTROLLER (See Instructions 712344) 1 760531
9 69925-14 WIRE HARNESS, MVP TRAILER RECEPTACLE 1 760572
10* ** BRAKE CONTROL HARNESS (See Page 5-20) 1 761070
11* 53048-14 TOWING SPECS DECAL (See Page 4-14) 2 761148
* NOT SHOWN
** SPECIAL ORDER
5-11
HANDBRAKE INTERLOCK SWITCH – BC

1 * HARNESS, HANDBRAKE INTERLOCK SWITCH 1 468827
2 * PLATE, HANDBRAKE INTERLOCK SWITCH 1 515776
4 6716 WASHER,#10, SAE, F/W,BLK MAX 2 719812
6 72546-08 SWITCH, HAND BRAKE LIGHT 1 759958
KIT, HANDBRAKE INTERLOCK SWITCH (Includes
7 40899-14 192712U
above items)
* SPECIAL ORDER
468827 HARNESS
5-12
WORK LIGHT – BC
HARNESS

1 69539-14 WORK LIGHT HARNESS 1 468837
2 72000-10 SWITCH, TOGGLE, ON-OFF 1 760600
3 67706-14 LIGHT, FLOOD, LED, 12-24V 761077
NOTE: Items 3 mounts using roof hardware and holes.
5-13
SEVCON AC HARNESS – BC
P/N 69915-14
5-14
SEVCON AC HARNESS – BC (Cont.)
5-15
SEVCON AC PANEL – BC

1 * PANEL, BC SEVCON AC 1 515761
2 71466-02 CONTACTOR, SINGLE -48V COIL, SW80 1 709590
3 66555-00 RELAY, 48VDC, SPSTNO, 20 1 759829
4 2646 SCREW,#6-32X5/8,PPH, M/S,YWZC 2 719581
5 71408-96A BUZZER, REVERSE - 9/48 V DC 1 759831
7 7624 7624NUT 10-24 GR A NM MACH NYLON LOCK 2 719870
8 7592 NUT 6-32 GR A NM MACH NYLON YWZC 2 719866
9 69533-13 GEN4 CONTROLLER -SEVCON 1 760956
10 69538-14 PLATE, HEAT SINK 2 515379
11 2010-B SCREW,1/4-20X1-1/2, SHCS,BLK MAX 4 719545
12 6703-B WASHER,1/4,SAE,F/W, BLK MAX 4 719811
14* 70099-88 CABLE, 4GA X 8.75 1 709004
15* 70105-89 CABLE, 4GA X 61.50 2 709411
16* 71582-84 WIRE MARKER,NEGATIVE 1 749181
17* 71581-84 WIRE MARKER,POSITIVE 1 749180
18* 69915-14 HARNESS -SEVCON AC, BC 1 761057
19* ** LABEL, WHITE, 1.9 WX50'L " 1 760792
20* 69916-14 CABLE, MOTOR, SEVCON AC, 25.5 " 3 761063
21 69913-14 AC PANEL (Includes above Items) 1 468820
* NOT SHOWN
5-16
AC CABLE & HARNESS ROUTING– BC
5-17
SEVCON AC MOUNTING – BC

1 52918-07 HINGE, CARGO SEAT 1 308737PL
2 ** UPPER STEERING COLUMN SUPPORT, AC DRIVE 1 312189
3 69913-14 PANEL, SEVCON AC 1 468820
4 ** PANEL, AC DISPLAY 1 515766
5 ** SUPPORT, AC DISPLAY PANEL 1 515767
6* 53250-01 LABEL SET 1 709754
7 71527-04 DECAL, SWITCH SET POSITION 1 719426
8 11735 NUT, TINNERMAN, J-TYPE 2 719537
10 3787-B SCREW,1/4-20X3/4,HHCS,G5, BLK150 4 719636
11 4716-W SCREW, 3/8-16 X 1-1/4, HHCS, G5, YWZC 2 719694
12 6416 WASHER FLT STL BLK ZNC 3/8 STD 4 719796
16 5490 CARRIAGE BOLT 1/4-20 X 1 GR5 BK 4 759116
17 66855-14 KNOB - 5/16-18 X1 1/2 LG 2 760023
18 40610-10 PEDAL ASSEMBLY, ACCEL 1 760635
19 69534-13 DISPLAY, CLEARVIEW, SEVCON 1 760958
20 11601 RIVNUT,10-24,LP,RIBBED, .020-.130,ZC 4 781599
21* 11497 CAP PLUG, SAE 3/8" OD BLACK 1 781642
* NOT SHOWN
** SPECIAL ORDER
5-18
48V CHARGER W/REEL - BC

1 2646 SCREW,#6-32X5/8,PPH,M/S, YWZC 3 719581
2 3787-B SCREW,1/4-20X3/4,HHCS,G5, BLK150 4 719636
3 3987-BS SCREW, 5/16-18 X 3/4 HHCS, GR 5 2 719642
6* 7592 NUT 6-32 GR A NM MACH NYLON YWZC 3 719866
7 7724-B NUT 1/4-20 GR A SERRATED FLNG LOCK 4 719887
8 7739 NUT,5/16-18,L/N,NYLOK,NE,GA, BLKMAX 2 719892
9 * CHARGER CORD, 6.5FT, 14/3 1 760691
10 66583-12 CHARGER, DELTA Q - 48V SEALED, W/LED 1 760742
11 * PLATE, BACKING, CORD REEL 1 C3999_5105
12 * ASM, CORD REEL 1 C3999_5108
13 * HOUSING, PLUG 1 C3999_5194
* SPECIAL ORDER
5-19
TRAILER BRAKE HARNESS& SCHEMATIC – BC
5-20
TILT BED SCHEMATIC – BC
2 3

1 71467-02 CONTACTOR, DOUBLE 1 709825
2 * REMOTE CONTROL 1 468004
3 * HARNESS, ACTUATOR 1 468839
* SPECIAL ORDER
5-21
DC/DC CONVERTER SCHEMATIC - BC

1 * DC/DC EXTENSION HARNESS 1 467618
2** 10043 CABLE TIE 8 719504
3** 2653-B SCREW, 10-16X3/4 HWH, TEK 6 719583
4** 6716 WASHER, #10 6 719812
5** 70030-06 WIRE HARNESS, DC/DC CONVERTER 1 759778
6** 71854-06 POWER DISTRIBUTION BLOCK 1 759792
7 69642-05 DC/DC CONVERTER, 36V/48V, 13.4V, FUSED 1 760378
8 69646-09 KIT, DC/DC CONVERTER (Includes above) 1 191727U
* SPECIAL ORDER
** NOT SHOWN
5-22
ACE+ CHASSIS MOUNTING- BC

1 * ASM, BC 4&5 ACE+ PANEL 1 467337
2 47220-02 RETAINER, ZEV COMP COVER 1 510412
3 47221-11 FLEXIBLE COVER PANEL,NEV 1 513991
4 2551-W SCREW, 1/4-20 X 1 GRD 5 HHC YEL 150 3 719564
6 7686 NUT 1/4-20 GR A NE NYLON INSERT LCK 3 719879
- N/A ACE+ CHASSIS MOUNTING (Includes above)
* SPECIAL ORDER
5-23
Burden Carrier
Parts Manual
Section 6
Options
BATTERY WATERING SYSTEM - BC

1 66210-07 WATERING ASSEMBLY 1 759857
2 66211-07 PUMP 1 759858
6-1
CAB – BC
ITEM CPC P/N DESCRIPTION QTY SI P/N

1* 90657-05 FRONT BRACKET, WHITE 1 511225W
2* 90655-00 CAB FRONT PANEL 1 511221W
3* 90653-05 CAB SIDE PANEL, R.H. 1 308433W
4* 90652-00 CAB SIDE PANEL, L.H. 1 308432W
5* 90654-00 CAB REAR PANEL 1 511222W
6* 90656-05 CAB TOP PANEL 1 308473W
7* 90118-00 WINDOW, FRONT CAB ASSEMBLY – See NOTE 1 709158
8* 90117-00 WINDOW, REAR CAB ASSEMBLY 1 709159
KIT BURDEN CARRIER WITH OUT DOORS (Includes above
9* 90628-06 1 467855
items and hardware. See NOTE)
* NOT IDENTIFIED
NOTE – MIRRORS AND WINDSHIELD WIPERS ARE NOT INCLUDED WITH ANY OF THE ABOVE.
6-2
DOOR ASSEMBLIES – BC
8 5
13
ITEM CPC P/N DESCRIPTION QTY SI P/N

1 ** LH STEEL DOOR ASM 1 467859
2* ** RH STEEL DOOR ASM 1 467860
3* ** LOCKING LH STEEL DOOR ASM 1 467861
4* ** LOCKING RH STEEL DOOR ASM 1 467862
5 84023-02 LH LIFT-OFF HINGE 2 509197
6* 84024-02 RH LIFT-OFF HINGE 2 509198
7 84101-06 DOOR HINGE SPACER 2 511269
8 90636-00 DOOR LATCH WHITE 2 511827W
9* 2551-W SCREW, 1/4-20X1 HHC 8 719564
10* 3787-B SCREW, 1/4-20X3/4 HHC 14 719636
11* 6703-B WASHER, 1/4 50 719811
12* 7686 NUT, 1/4-20 NYLOCK 22 719879
13 49090-ZZ TAPE, FOAM 1/8X1/2 (feet) 2 739272
14 90637-01 KIT, STEEL DOORS (Includes Items 1, 2, 5 – 13) 1 192454U
* NOT SHOWN
** SPECIAL ORDER
6-3
DOOR HARDWARE – BC

1 51204-10 STRAP, CAB DOOR 2 309370
2 90631-12 LH DOOR ** 1 311087W
2A* 90630-12 RH DOOR** 1 311086W
3 51355-00 CHROME DOOR HANDLE NON-LOCKING 2 709282
3A* 51353-00 CHROME DOOR HANDLE LOCKING 2 739427
4 90112-00 CAB LOCK W/INSIDE HANDLE LH 2 709524
4A* 90111-00 CAB LOCK W/INSIDE HANDLE RH 2 709523
5 11493 CAP PLUG, 1/2” BLACK 8 719425
6 11736 NUT, TINNERMAN 8 719538
7 2530 SCREW, #10X3/4 SHWT, T/S 8 719563
8 2592 SCREW, 10-24X1/2 PHILLIPS 4 719566
9 2653-B SCREW, 10-16X3/4 HWH TEK 32 719583
10 2665 SCREW, 10-24X5/8 PPH 4 719584
11 7220 WASHER, #10 TOOTHED 8 719851
12 7624 NUT, 10-24 GR A, NYLOCK 4 719870
13* 49090-ZZ FOAM TAPE 1/8X1/2 6” 739272
14 90104-01 WINDOW SLIDING LH 1 749709
14A* 84022-05 WINDOW SLIDING RH 1 759743
15 51208-10 STRAP BRACKET 2 760404
* NOT SHOWN ** Include VIN to insure correct color
6-4
CAB DOME LIGHT – BC

1* N/A** HARNESS 1 467700
2 51150-11 MOUNTING PLATE 1 510315
3 84147-92 DOME LIGHT ASSY 1 709920
4* 10020 CABLE TIE MOUNTING BRACKET 1 719503
5* 10043 CABLE TIE 18X11 3/4”, 50 LB 1 719504
6* 11409 GROMMET .25, RUBBER 1 719520
7* 24010-ZZ LOOM, BLACK 7.5’ 719557
8* 2616 SCREW, #8-32X1 PFH 4 719574
9* 2653-B SCREW, 10-16X3/4 HWH 1 719583
10* 2685-W SCREW, 10-24X5/8 HWHTR 2 719586
11* 3358 CLAMP, 1/2” BLACK NYLON 1 719602
12* 3380 CLAMP, 5/8” BLACK NYLON 8 719604
13* 6716 WASHER, #10 SAE 2 719812
14* 7609-W NUT, #8-32 GR A,NYLOCK 4 719868
15* 7624 NUT, 10-24 GR A, NYLOCK- 2 719870
16* 9906 TERMINAL, 16/14 INS, 1/4 MALE TAB 2 719973
* NOT SHOWN
** SPECIAL ORDER
6-5
HEATER – BC

HEATER/HARNESS, 48V -See Note (Includes Heater, P/N
1 20005-05B 1 192378U
65198-11 & Harness, Special Order P/N 467803)
2 3454-BS SCREW, 1/4-20X1 3/4 HHC, G5 1 719623
3 6703-B WASHER, 1/4 STL 2 719811
4 52329-85 WASHER, .375X1.50X.50 F/W, NYL 2 719737
5 7686 NUT, 1/4-20 NYLOCK 1 719879
NOTE:
1. If the toggle switch is in the Fan/Heat position and no heat is occurring, a circuit reset may be needed. On a
heater side panel is a 3/8” hole. Inside is a circuit reset tab. Using a non-conductive device push the tab to reset
the circuit.
2. This heater/harness is not interchangeable with heater/harness installed on vehicles prior to 8/10/2010. Connect
black wire to 48V negative and red wire to 48V positive.
6-6
HITCHES – BC
1
12
2
3 4

1 57315-96 PINTLE HOOK HITCH 1 709833
2 ** HITCH PLATE 1 307419
3 57307-00 REINF. MOUNTING BRACKET (Used w/ Items 1 & 2) 1 509268
4 57308-00 HITCH MOUNTING BRACKET(Used w/ Items 1 & 2) 1 509269
5* 2879-W SCREW, 3/8-16X1 HHCS G5 4 707195
6* 4716-W SCREW, 3/8-16X1 1/4 HHCS G5 (Used with Item 2) 4 719694
7* 6000-B WASHER 5/16 16 719771
8* 7778 NUT, 3/8-16 NYLOCK (Used with Item 2) 4 719902
9* 7812-w NUT, 1/2-20 NYLOK GR A 4 719907
10* 4010 SCREW, 1/2-20x1.5 HHCS G5 4 729809
11 6010 WASHER, .513X1.09X.125 F/W 4 729809
12 82065-98 HITCH BALL, CHROME 1 7/8” 1 719008
12A 82064-02 HITCH BALL, 2” 1 719207
13 82006-03 KIT, BALL HITCH, LESS BALL (Includes Items 2 – 10) 1 191171U
KIT, PINTLE HITCH, LESS PINTLE HITCH (Includes Items
14 57318-00 1 190625U
1, 3 – 11)
* NOT SHOWN
** SPECIAL ORDER
6-7
COMBINATION HITCH RECEIVER – BC

1 * REAR RECEIVER 1 312208
2 57307-00 REINFORCEMENT MTG. BRACKET. 1 509268
4 6000-B WASHER, 5/16, USS/STD,F/W, BLK MAX 10 719771
5 7778 NUT, 3/8-16, GA, NE, NYLON INSERT,YWZC 8 719902
6 781116 SCREW, 3/8-16 X 1-1/4, CARR, G8, YWZC 6 781116
KIT, COMBO HITCH RECEIVER (includes above
7 82039-14 1 192717U
Items)
* SPECIAL ORDER
6-8
FRONT TOWING RECEIVER – BC

1 * FRONT RECEIVER 1 312209
2 * BRACKET, SUPPORT 4 515812
4 6000-B WASHER, 5/16, USS/STD, F/W, BLK MAX 16 719771
5 7778 NUT, 3/8-16, GA, NE, NYLON INSERT,YWZC 8 719902
6 82038-14 KIT, FRONT TOWING RECEIVER 1 192719U
* SPECIAL ORDER
NOTE: Recommend using a receiver hitch ball mount (P/N 82003-12).
6-9
INTERIOR MIRRORS

1 84120-92 MIRROR, REAR VIEW, CAB 1 709837
2 84270-98 5 PANEL REAR VIEW MIRROR 1 709408
3* 51001-10 MOUNTING BRACKET (Use with 2 for suntop mount) 1 510334
4* 3787-B SCREW 1/4-20X3/4 HHC(Use with 2 for suntop mount ) 2 719636
5* 50190-86 NUT, JACK #8(Use with 2 for suntop mount ) 2 719717
6* 6703-B WASHER 1/4 (Use with 2 for suntop mount ) 2 719811
7* 7036-B WASHER, LOCK (Use with 2 for suntop mount) 2 719834
8 3615 SCREW, 10-24X1/2 PPH, M/S (Use with 2 for cab mount) 4 719467
9 6716 WASHER #10 SAE (Use with 2 for cab mount) 8 719812
10 7624 NUT, 10-24 (Use with 2 for cab mount) 4 719870
N/A 84288-98 KIT, 5 PANEL MIRROR, SUNTOP (Includes Items 2 thru 7) 1 190928U
N/A 64220-14 KIT, 5 PANEL MIRROR, CAB (Includes Items 2, 8 - 10) 1 192740U
* NOT SHOWN 1
9
8
2
10
6-10
EXTERIOR MIRRORS – BC

1 51006-11 BC MIRROR BRACKET RH 1 513335
2 51007-11 BC MIRROR BRACKET LH 1 513336
3 2551-W SCREW, 1/4-20X1 HHC 4 719564
4 6703-B WASHER, 1/4 STL 8 719811
5 7686 NUT 1/4-20 NYLOCK 12 719879
6 72667-08 MIRROR, REAR VIEW,LH 1 760201
7 72668-08 MIRROR, REAR VIEW, RH 1 760202
8 1400 SCREW, 1/4-20X1, PFH M/S 8 781601
6-11
SINGLE SIDE MIRROR– BC

1 91873-96 MIRROR, SIDE MOUNT, UNIVERSAL 1 749775
2* 2879-W SCREW, 3/8-16 X 1, HHCS 2 707195
3* 708859-SW WASHER, 3/8, SAE FLAT 4 708859
4* 42644-78 WASHER, .400/.380 ID X 1.10, NYLON FLAT 1 719667
5 84172-05 BRACKET, MIRROR 1 510682
6 2551-W SCREW, 1/4-20 X 1, HHCS, GR 5 2 719564
7 6703-B WASHER, 1/4, SAE FLAT 4 719811
8 7686 NUT, 1/4-20, NE NYLOC, GR A 2 719879
9* 91869-00 KIT, BC SIDE MIRROR, SINGLE (Includes above items) 1 191863U
* INCLUDED WITH ITEM 1
6-12
STROBE LIGHTS – BC
7
1
ITEM 2
ITEM 8

1 68029-06 STROBE LIGHT ASSY 1 467408
2 69528-13 HARNESS 1 467410
3* 10008 CABLE TIE 5 3/4” 2/7 719501
4* 10020 CABLE TIE MOUNTING BRACKET 2/4/7 719503
5* 11416 GROMMET 3/8X7/8 1/3 719522
6* 2339 SCREW, #10-24X3/4, HH 3 719551
7 68504-02 LIGHT MAST(Mounts to body with Items 9 – 11) 1 306164
8** HARNESS, LIGHT MAST 1 467441
9 3787-B SCREW 1/4-20X3/4 HHC 4 719636
10* 6703-B WASHER 1/4 8 719811
11* 7692 NUT, 1/4-20 NYLOCK 4 719882
12* 7625 NUT, 10-24 GR A, NYLOCK 3 719870
13* 10043 CABLE TIE, .18X11 3/4 4 719504
14 90140-00 KIT, STROBE LIGHT W/MAST (Includes Items 1 & 3 – 12) 1 190636U
15 90141-00 KIT, STROBE LIGHT, CAB (Includes Items 1 – 4, 6 &12) 1 190637U
16 69529-13 KIT, STROBE SUNTOP (Includes Items 1,2, 4 – 6, 12 &13) 1 192590U
* NOT SHOWN ** SPECIAL ORDER
6-13
WINDSHIELD WIPER – BC

1 68873-05 HARNESS, BC WINDSHIELD WIPER 1 467407
2 5712 WIPER SPACER 1 508993
3 10510 NYLON BEARING 1 709362
4 84111-92 MOTOR, WINDSHIELD WIPER 1 709592
5 84112-92 WIPER ARM 1 709790
6 84113-92 WIPER BLADE 16” 1 709791
7 11409 GROMMET, .25ID, DELTA FLEX 1 719520
8 11446 GROMMET, 5/8 X 1-1/8 X 3/8, 1/8 GROOVE 1 719529
9 2613-B SCREW, 8-32X1 1/2 PHILLIPS 1 719572
10 6912-B WASHER, #8, TYPE A PLAIN 1 719817
11 7220 WASHER, #10, EXTERNAL TOOTH LOCK 1 719851
12 7609-W NUT, #8-32 GR A, NYLOCK 1 719868
13 759824 SPACER, NYLON, .313 OD X .194 ID X .75 LG 1 759824
14 84114-06 KIT, BC WINDSHIELD WIPER (Includes above items) 1 191275U
6-14
INNER REAR FENDER – BC

1 50991-13 INNER FENDER, BC RH 1 515166
2 50992-13 INNER FENDER, BC LH 1 515167
3 5405-B CARRIAGE BOLT 1/4-20 X 3/4 GR 5 HC-BK 8 719747
5 7686 NUT, 1/4-20, NYLOCK, GA,YWZC 8 719879
6 51294-13 KIT, BC REAR FENDERS 1 192579U
6-15
13” HIGH STEEL FOLDING SIDES – BC SHORT
Note:
1. Locate bumpers such that they contact the rear rail when lowered.
2. Drill out pilot holes in body panels to .219 (7/32”) and through one wall of the tube on the chassis for the top hole
for the brackets.

1 51307-13 FOLDING TAILGATE 1 310680
2 51314-13 RH FOLDING SIDE, BC SHORT 1 310823
3 51315-13 LH FOLDING SIDE, BC SHORT 1 310824
4 52703-14 PLATE, MGT-A RAIL 4 515771
5 52704-14 PLATE, MGT-B RAIL 4 515772
6 11433 CAPLUG, 7/8 SQ 18 719526
7 2509 SCREW, 1/4-20X1 HWH 16 719560
8 52330-86 BUMPER 2 719738
9 6703-B WASHER, 1/4 SAE 24 719811
10 7686 NUT, 1/4-20 NYLOCK GA 8 719879
KIT, BC-S STEEL FOLDING SIDES (Includes
11 51313-13 1 192383U
above items)
6-16
13” HIGH STEEL FOLDING SIDES – BC LONG
Note:
for the brackets.

1 51317-13 RH FOLDING SIDE, BC LONG 1 310678
2 51318-13 LH FOLDING SIDE, BC LONG 1 310679
4 52703-14 PLATE, MTG-A RAIL 4 515771
5 52704-14 PLATE, MTG-B RAIL 4 515772
6 11433 CAPLUG, 7/8 SQ 18 719526
7 2509 SCREW, 1/4-20X1 HWH 16 719560
8 52330-86 BUMPER 2 719738
9 6703-B WASHER, 1/4 SAE 40 719811
10 7686 NUT, 1/4-20 NYLOCK CAP 16 719879
KIT, BC-L STEEL FOLDING SIDES (Includes
11 51316-13 1 192384U
above items)
6-17
18” HIGH STEEL FOLDING SIDE RAILS – BC LONG
Note:
for the brackets.

1 * 18" LH FOLDING SIDE 1 312217
2 * 18" RH FOLDING SIDE 1 312218
3 * 18" FOLDING TAILGATE 1 312219
4 52703-14 PLATE, MTG-A, RAIL 4 515771
5 52704-14 PLATE, MTG-B, RAIL 4 515772
6 11433 CAPLUG, FP-165, 1" SQ X .063 WALL 24 719526
8 52330-86 BUMPER BLACK 3M#SJ5023 2 719738
9 6703-b WASHER,1/4,SAE,F/W,BLK MAX 40 719811
KIT, 18” STEEL FOLDING SIDE RAILS (Includes
11 51419-14 1 192730U
above Items)
* SPECIAL ORDER
6-18
STEEL FOLDING SIDES – BC 2ND SEAT
Note:
for the brackets.

2 51292-13 RH FOLDING SIDE, BC 2ND 1 310825
3 51293-13 LH FOLDING SIDE, BC 2ND 1 310826
4 52703-14 PLATE, MTG-A RAIL 3 515771
5 52704-14 PLATE, MTG-B RAIL 3 515772
6 11433 CAPLUG, 7/8 SQ 14 719526
7 2509 SCREW, 1/4-20X1 HWH 12 719560
8 4720-B SCREW, 3/8-16X1 3/4 HHC 2 719696
9 52329-85 WASHER, .375X1.5X.5 DELRIN 2 719737
10 52330-86 BUMPER 2 719738
11 6000-B WASHER, 5/16 USS/STD 2 719771
12 6703-B WASHER, 1/4 SAE 18 719811
13 7686 NUT, 1/4-20 NYLOCK CAP 6 719879
KIT, BC-2ND SEAT STEEL FOLDING SIDES (Includes
51291-13 1 192385U
above items)
6-19
2ND SEAT EXTENDED FOLDING SIDE RAIL – BC
Note:
for the brackets.
6-20
2ND SEAT EXTENDED FOLDING SIDE RAIL – BC (Cont.)

2 * 2ND LEFT FRONT RAIL 1 312238
3 * 2ND LEFT REAR RAIL 1 312239
4 * 2ND RIGHT FRONT RAIL 1 312240
5 * 2ND RIGHT REAR RAIL 1 312241
6 52703-14 PLATE, MTG-A RAIL 3 515771
7 52704-14 PLATE, MTG-B RAIL 3 515772
8 * PLATE MTG, 2ND SIDE RAIL 2 515893
9 51540-14 KNOB, 1 1/4” BALL 2 707783
10 51541-14 SPRING, COMPRESSION 2 708058
11 11433 CAPLUG, 7/8 SQ 26 719526
12 2509 SCREW, 1/4-20X1 HWH 18 719560
13 4720-B SCREW, 7/16-20X3.5 HHC 4 719664
14 4740-B SCREW, 3/8-16X2 HHC 2 719698
15 52330-86 BUMPER 2 719738
16 6703-B WASHER, 1/4 SAE 30 719811
17 7686 NUT, 1/4-20 NYLOCK GA 12 719879
18 7825 NUT, 7/16-20 NYLOCK GA 4 719908
19 51105-10 WASHER. 0.440X0.750X0.093 F/W, BLK, NYLON 4 782003
KIT, BC-2ND SEAT STEEL FOLDING SIDES (Includes
20 51420-14 192738U
above items)
* SPECIAL ORDER
6-21
63” SUNTOP THERMOFORMED – BC
6-22
63” SUNTOP, THERMOFORMED – BC (Cont.)

1 89426-04 CROSS BRACE, UPPER 2 307854
2 89390-04 SUNTOP HANDLE, EP 2 307856EP
3 89305-13 TUBE, LH REAR 1 311576
4 89306-13 TUBE, RH REAR 1 311577
5 89307-13 TUBE, LH FRONT 1 311578
6 89308-13 TUBE, RH FRONT 1 311579
7 89002-99 RAINDRAIN TOP, BRIGHT WHITE 1 464764
7A 84154-98 RAINDRAIN TOP, BIRCH WHITE 1 464611
8 89470-74 WASHER,.34"X1.25"X.09",NEOPRENE 8 709003
10 3454-BS SCREW, 1/4-20 X 1-3/4 HHCS, G5 HCBLK 8 719623
11 3991 SCREW, 5/16-18X7/8,HHCS,G5,BLK MAX 8 719643
13 6257-W WASHER, FLT STL UNHARD .28 X1.375 X .05 8 719787
16 7041-B WASHER,5/16,REG-SPRG LOCK, BLK MAX 8 719838
17 7686 NUT, 1/4-20, NYLOCK, GA6-22, YWZC 8 719879
18 7742 NUT, 1/4-20 GR B TOP LOCK BLK ZINC 8 719894
19 8206 KNURLED INSERT, 5/16-18 YWZC 8 719929
20 89302-13 KIT, 63” SUNTOP, BRIGHT WHITE 1 192581U
21 89303-13 KIT, 63” SUNTOP, BIRCH WHITE 1 192582U
6-23
63” SUNTOP, STEEL WHITE – BC
6-24
63” SUNTOP, STEEL WHITE –BC (Cont.)

1 89426-04 CROSS BRACE, UPPER 2 307854
2 89390-04 SUNTOP HANDLE, EP 2 307856EP
3 89305-13 TUBE, LH REAR 1 311576
4 89306-13 TUBE, RH REAR 1 311577
5 89307-13 TUBE, LH FRONT 1 311578
6 89308-13 TUBE, RH FRONT 1 311579
7 89309-13 ROOF, WHITE 1 311580W
9 3454-BS SCREW, 1/4-20 X 1-3/4 HHCS, G5 HCBLK 8 719623
10 3991 SCREW, 5/16-18X7/8,HHCS,G5,BLK MAX 8 719643
14 7041-B WASHER,5/16,REG-SPRG LOCK, BLK MAX 8 719838
16 8206 KNURLED INSERT, 5/16-18 YWZC 8 719929
17 89304-13 KIT, 63” SUNTOP, STEEL WHITE 1 192583U
6-25
SUNTOP WINDSHIELD – BC

1 58042-13 WINDSHIELD, ACRYLIC 1 760949
6-26
SUNTOP STROBE LIGHT – BC
ITEM 2

1 68029-06 STROBE LIGHT (AMBER) 1 467408
2 69528-13 HARNESS, BC CAB STROBE LIGHT 1 467410
3 10020 CABLE TIE MOUNTING BRACKET 4A 4 719503
4* 10043 CABLE TIE, BLACK, .18 X 11 - 3/4, STD, 50LB 4 719504
5 11416 GROMMET, 3/8 X 7/8 3 719522
6 2339 SCREW, #10-24 X 3/4" HEX HD MACH 3 719551
7* 24010-ZZ LOOM, .413 X .594, SLIT, BLACK, 4.00" LG 1 719557
8* 24010-ZZ LOOM, .413 X .594, SLIT, BLACK, 26.00" LG 1 719557
69529-13 KIT, BC SUNTOP AMBER STROBE 1 192590U
* NOT SHOWN
6-27
CAB W/OVERHEAD RACK – BC

1 * OVERHEAD RACK 1 311556B
2 * UPRIGHT 2 515175
3 * BRACKET, REAR 2 515176
4 * CAB FRONT LH BRACKET 1 515177
5 * CAB FRONT RH BRACKET 1 515178
6 11432 CAPLUG 4 719525
7 11433 CAPLUG 2 719526
8 5207-BS SCREW, 5/16-18X2 PPH 8 719730
9 5208-B SCREW, 5/16-18X2-1/2, PPH 4 719731
10 5452-BS SCREW, 5/16-18 X 5/8, CARR, G5 8 719751
11 6702-B WASHER ,5/16, 24 719810
12 7739 NUT, 5/16-18, L/N,NYLOK,NE,GA 12 719892
13 7750 NUT, 5/16-18 FLANGE LOCK 8 719897
14 60102-12 KIT, CAB OVERHEAD RACK (Includes above) 1 192584U
* SPECIAL ORDER
6-28
SUNTOP W/OVERHEAD RACK – BC

2 * UPRIGHT 2 515175
3 * BRACKET, REAR 2 515176
4 * SUNTOP FRONT BRACKET 2 515179
5 11432 CAPLUG 4 719525
6 11433 CAPLUG 2 719526
7 5207-BS SCREW, 5/16-18X2 PPH 8 719730
8 5208-B SCREW, 5/16-18X2-1/2, PPH 4 719731
9 5452-BS SCREW, 5/16-18 X 5/8, CARR, G5 8 719751
10 6702-b WASHER ,5/16 24 719810
11 7739 NUT, 5/16-18, L/N,NYLOK,NE,GA 12 719892
12 7750 NUT, 5/16-18 FLANGE LOCK 8 719897
13 60103-12 KIT, SUNTOP OVERHEAD RACK (Includes above) 1 192585U
* SPECIAL ORDER
6-29
BULKHEAD – BC

1 * BULKHEAD PANEL 1 310731
2 2509 SCREW, HX HD, .25X1, THREAD FORMING 2 719560
3 3787-B SCREW, 1/4-20X3/4, HHCS, G5 5 719636
4 6703-B WASHER, 1/4, SAE 12 719811
5 7686 NUT, 1/4-20 NYLOCK GA 5 719879
* SPECIAL ORDER
6-30
12 VOLT OUTLET – BC
ITEM 2

1 66030-03 12 VOLT RECEPTACLE 1 719342
2 * 12 VOLT OUTLET HARNESS 1 467619
* SPECIAL ORDER
6-31
ACCELERATOR PEDAL GUARD – BC

1 40456-09 ACCELERATOR FOOT GUARD 1 512863
2 2653-B SCREW, #10X3/4 HWH TEK #3 3 719583
6-32
TILT BED– BC
6-33
TILT BED– BC (Cont.)
6-34
ITEM 10
6-35
1 52918-07 HINGE CARGO SEAT 2 308737PL
2 * TIPPER, BASE 1 312242
3 * LOWER DUMP BED SPRT 1 312243
4 * DUMP BED 1 312244
5 * DUMP BED F PANEL 1 312245
6 * DUMP BED PANEL RH 1 312246
7 * DUMP BOX PANEL LH 1 312247
8 * DUMP BED TAILGATE 1 312248
9** * ASM, REMOTE CONTROL (See Section 5) 1 468004
10 * HARNESS, POWER, BC REFUSE 1 468005
11** * HARNESS, 48V ACTR, BC DMP BOX (See Section 5) 1 468839
12 * BRKT, LATCH 4 515865
13 * HANDLE, LATCH 2 515866
14 * BRKT, DOWNSTOP BUMPER 1 515867
15 * BRKT, BC/SU5 TAILGATE STOP 2 515868
16 * SPACER, BC/SU5 DUMP BED ACTUATOR 8 515869
17 * COVER, BC DUMP BED 1 515870
18 * COVER LH/RH, BC DUMP BOX 2 516024
19 * COVER, BC CONTROL PANEL 1 516026
20 * END TIP, BLK 2 707613
21 11402 BOOT, RUBBER BUMPER 2 709011
22 48865-ZZ TRIM, PINCH WELT, 3/32 BLACK 5 709013
23 71467-02 CONTACTOR, DOUBLE - 48V COILS 1 709825
24 11403 BUMPER, 7/8 X 1.03 EPDM 70 DURO 2 719519
26 2685-W SCREW, 10-24 X 5/8 HWH TRD ROL 6 719586
27 3453 SCREW, 3/8-16 X 3-3/4 HHCS GR5 8 719622
29 3987-BS SCREW, 5/16-18 X 3/4 HHCS, GR 5 16 719642
30 4719-W SCREW, HX HD CAP 3/8-16 X 2-3/4 G5 2 719695
32* 5447-BS BOLT, 5/16-18 X 2-1/2, CARRIAGE, GRADE 5 6 719749
33 6005 WASHER, FTL STL, 1/2 STD UNHARD YWZC96 12 719772
34 6416 WASHER FLT STL BLK ZNC 3/8 STD 20 719796
37 6716 WASHER,#10,SAE,F/W,BLK MAX 4 719812
39 7685 NUT 1/2-13, GR A, NYLON LOCK 6 719878
41 * 48V ACTUATOR, 12'' STROKE 2 761071
42 * SCREW,1/2-13x3-1/4,HHCS,G2,ZC,P80X 6 781046
43 19148-13 NUT, 5/16-18, L/N, NYLOK, NE, G5, YWZC 16 782086
44 7534 NUT, 3/8-16, L/N, NYLOK, NE, G8, YWZC96 16 782118
45 4026 SCR, #10-16 X 1.25, HWH, T/S, ZC 8 782233
* SPECIAL ORDER
** NOT SHOWN HERE
6-36
TILT BED BULKHEAD – BC

1 * BULKHEAD 1 312260
2 5405-B SCREW 1/4-20 X 3/4 CARR GR 5 HC-BK 9 719747
5 51449-14 KIT, TILT BED BULKHEAD (Includes above) 1 192755U
* SPECIAL ORDER
6-37
OPERATOR ROOF, BLACK, POWDER COATED – BC
6-38
OPERATOR ROOF, BLACK, POWDER COATED – BC (Cont.)

1 * BLACK, ROOF PANEL, TOP 1 312256B
2 * LH MID UPRIGHT, TOP 1 312257
3 * RH MID UPRIGHT, TOP 1 312258
4** * POWDERCOATED BRACKET CAB FRONT 1 511225W
5 * WHITE, FRONT PANEL, TOP 1 515911W
6 * WHITE, RH PANEL, TOP 1 515912W
7 * WHITE, LH PANEL, TOP 1 515913W
8 * BRACKET, TOP SUPPORT RH 1 516235
9 * BRACKET, TOP SUPPORT LH 1 516236
10 58901-11 WEATHER STRIPPING, SELF-SEALING, 126 LG " 1 719163
11 11433 CAPLUG, FP-165, 1 SQ X .063 WALL " 4 719526
13 5449-BS SCREW, 5/16-1/ X 1-1/2 CARRIAGE, GR 5, PLTD 8 719750
14 5452-BS BOLT, 5/16-18 X 5/8, CARRIAGE, GRADE 5 10 719751
17 7750 LOCKNUT, 5/16-18 HX FLNG 2-WAY CNTR 18 719897
18 58022-12 WINDSHIELD, GLASS, FR - MVP 1 760450
- 89008-14 KIT, OPERATOR ROOF (Includes above) 1 192751U
* SPECIAL ORDER
** NOT SHOWN
6-39
OPERATOR ROOF W/RACK– BC-L
6-40
OPERATOR ROOF W/RACK– BC-L (Cont.)
6-41
OPERATOR ROOF W/RACK– BC-L (Cont.)

2 * BLACK, ROOF PANEL,TOP 1 312256B
5 * POWDERCOATED BRACKET CAB FRONT 1 511225W
9 * BRACKET, REAR UPRIGHT, TOP 2 515918
10 * TUBE, REAR UPRIGHT, TOP 2 515919
11 * BRACKET, RACK MOUNTING 2 515922
12 * BRACKET, TOP SUPPORT RH 1 516235
13 * BRACKET, TOP SUPPORT LH 1 516236
14 58901-11 WEATHER STRIPPING, SELF-SEALING, 126" LONG 1 719163
17 4086 SCREW, 5/16-18 X 3.00" LG HEX CAP HD 4 719654
18 5207-BS SCREW, 5/16-18X2 PPH M/S 12 719730
19 52329-85 WASHER, FLAT DELRIN 4 719737
23 6702-B WASHER, 5/16, 24 719810
28 58022-12 WINDSHIELD GLASS 1 760450
- 89010-14 KIT, OPERATOR TOP WITH RACK 1 192762U
* SPECIAL ORDER
6-42
FULL LENGTH ROOF– BC-L
6-43
FULL LENGTH ROOF – BC-L (Cont.)
6-44
FULL LENGTH ROOF – BC-L (Cont.)

1 * ROOF PANEL 1 312256B
4 * BLACK, EXT ROOF PANEL, TOP 1 312259B
7** * WHITE, RH PANEL, TOP 1 515912W
10 * TUBE, REAR UPRIGHT, TOP 2 515919B
11 * TUBE, EXT ROOF, TOP 2 515921B
12 * BRACKET TOP SUPPORT RH 1 516235
13** * BRACKET TOP SUPPORT LH 1 516236
14 3925 SCREW, 5/16-18 X 1-3/4 HHCS, G8, YLZN 4 708746
20 6000-B WASHER,5/16,USS/STD,F/W, BLK MAX 8 719771
- 89009-14 KIT, FULL TOP (Includes above) 1 192752U
* SPECIAL ORDER
** NOT SHOWN
6-45
FULL LENGTH ROOF W/RACK– BC-L
6-46
FULL LENGTH ROOF W/RACK– BC-L (Cont.)
6-47
FULL LENGTH ROOF W/RACK– BC-L (Cont.)

2 * BLACK, ROOF PANEL, TOP 1 312256B
5 * BLACK, EXT ROOF PANEL, TOP 1 312259B
11 * TUBE, REAR UPRIGHT, TOP 2 515919
12 * TUBE, EXT ROOF, TOP 2 515921
13 BRACKET RACK 2 515922
14 BRACKET TOP SUPPORT RH 1 516235
15 BRACKET TOP SUPPORT LH 1 516236
19 4086 SCREW, 5/16-18 X 3.00" LG HEX CAP HD 4 719654
20 5207-BS SCREW, 5/16-18 X2 PPH M/S 12 719730
21 52329-85 WASHER FLAT BLK DELRIN .375X1.5X.5 4 719737
25 6702-B WASHER,5/16 24 719810
- 89007-14 KIT, FULL TOP WITH RACK (Includes above) 1 192753U
* SPECIAL ORDER
6-48
ROOF PANEL AMBER STROBE– BC
ITEM 3

1 11416 GROMMET, 3/8 X 7/8 2 2 719522
2 68029-06 STROBE LIGHT (AMBER) 1 467408
3 69258-13 HARNESS, CAB STROBE LIGHT 1 467410
4 10020 CABLE TIE MOUNTING BRACKET 4A 3 719503
5 2339 SCREW, #10-24 X 3/4" HEX HD MACH 3 719551
7* 3380 CLAMP, 5/8" NYLON BLACK HEYCO 3380 4 719604
8* 24010-ZZ LOOM, .413 X .594, SPLIT 2.5’ 719557
KIT, ROOF PANEL AMBER STROBE (Includes above
9 67705-14 1 192758U
items)
* NOT SHOWN
6-49
SIDE TOOL RACK– BC
TEM CPC P/N DESCRIPTION QTY SEATS P/N

1 N/A SIDE TOOL RACK - Special Order SP 1323 1 N/A
NOTE: Installation instructions for this assembly is located on the ParCar web site.
6-50
1115 Commercial Avenue • Reedsburg, WI 53959
Phone: (608) 524-8888 • Fax: (608) 524-8380
(800) 222-4653 • Web: www.parcar.com

CPC - Manual - Parts - BC - Rev49

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Parts Manual

BC2, BC3, BC4

1115 Commercial Avenue • Reedsburg, WI 53959

SECTION 1 Accelerator and Brake Linkage

SECTION 2 Steering, Front Suspension and Wheels

SECTION 3 Rear Axle, Brakes and Suspension

SECTION 4 Seats, Decks and Dash

SECTION 5 Electrical Systems

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

NOTE: To secure pedal pad.

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

*NOTE: QUANTITIES AS REQUIRED PER YOUR VEHICLE

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

Steering, Front Suspension and Wheels

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

USE PUNCH TO CREATE SPURS INSIDE

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

NOTE: WHEN TIGHTENED, NUT IS FLUSH WITH BOTTOM OF KING PIN.

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

* QTY PER HUB ASSEMBLY

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

Note: Must be purchased locally.

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

Rear Axle, Brakes and Suspension

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

See NOTE page 3-17

See NOTE page 3-17

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

* SEE GEAR SETS PAGE 3-18

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY** SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

** POSITIONS WILL VARY FOR LEFT & RIGHT HAND CALIPERS

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

Seats, Decks and Dash

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

* NOT SHOWN ** Include VIN for proper color

ITEM CPC P/N DESCRIPTION QTY SEATS P/N

NOTE: SEE SERVICE BULLETIN SB11-004 IF REPLACING A NON-LED CHARGER.