6pr Sport Parts Diagram - Bintelli Electric Vehicles · 2015. 12. 6. · 2 Frame Assembly Item Part No Description Qty Remark 1 5101100-110 Left Beam (hydraulic brake) 1 2 5101200-110

Service Parts Manual For

6pr Sport Golf Cart

620 Dobbin Rd.

Charleston, SC 29414

(843) 531-6833 Phone

(843) 556-4080 Fax

www.citEcarEV.com

Index

1.Frame ................................................................................................................................................................1

1-1 Frame Assembly ....................................................................................................................................1

2. Brake and Drive System ..................................................................................................................................3

2-1 Brake System, Hydraulic .......................................................................................................................3

2-1-1 Reservoir Assembly and Brake Pipe ..........................................................................................3

2-1-2 Braking Pedal & Bracket Assembly ...........................................................................................5

2-1-3 Brake Assembly Rear .................................................................................................................8

2-1-4 Brake Assembly Rear .................................................................................................................9

2-2 Parking Brake System .........................................................................................................................10

2-2-1 EM Brake .................................................................................................................................10

2-2-2 Parking Brake Handle .............................................................................................................. 11

2-3 Brake system, mechanical ...................................................................................................................12

2-3-1 Braking Pedal & Bracket Assembly, mechanical .....................................................................12

2-3-2 Brake Assembly Rear ...............................................................................................................14

3. Suspension .....................................................................................................................................................16

3-1 Front Suspension, Hydraulic Brake .....................................................................................................16

3-2 Front Suspension, Mechanical Brake, Optional ..................................................................................19

3-3 Front Hub .............................................................................................................................................20

3-4 Front Suspension .................................................................................................................................21

3-5 Rear Suspension ..................................................................................................................................23

3-6 Rear Shock Absorber ...........................................................................................................................25

4 .Rear Axle .......................................................................................................................................................27

4-1 Rear axle assembly ..............................................................................................................................27

4-2 Half Axle Assembly .............................................................................................................................28

4-3 Retarder Assembly ...............................................................................................................................29

4-4 Differential ...........................................................................................................................................31

5. Steering System..............................................................................................................................................33

5-1 Steering Wheel Assembly ....................................................................................................................33

5-2 Steering Shaft Assembly ......................................................................................................................35

5-3 Steering Gear Assembly ......................................................................................................................37

6. Wheel .............................................................................................................................................................39

6-1 Tires .....................................................................................................................................................39

7. Body Parts ......................................................................................................................................................40

7-1 Floor .....................................................................................................................................................40

7-2 Front Cover，Instrument Board ..........................................................................................................42

7-3 Front Windshield .................................................................................................................................44

7-4 Rear Body ............................................................................................................................................46

7-5 Cushion ..............................................................................................................................................48

7-6 Front Seat Compartment ......................................................................................................................50

7-7 Front Seat Cushion, Backrest ..............................................................................................................51

7-8 Bracket Under Rear Seat Cushion .......................................................................................................53

7-9 Main Bracket of Seat ...........................................................................................................................54

7-10 Bracket of Front Backrest and Rear Backrest ...................................................................................55

7-11 Rear Top Supports..............................................................................................................................56

7-12 Front Backrest ....................................................................................................................................57

7-13 Rear Backrest .....................................................................................................................................58

7-14 Caddy Handle ....................................................................................................................................59

7-15 Upper Bracket ....................................................................................................................................60

7-16 Canopy ...............................................................................................................................................61

7-17 Footrest Bottom .................................................................................................................................62

7-18 Footrest Bottom Bracket ....................................................................................................................63

7-19 Aluminum Plate Under Cushion & Turnover Bracket Aluminum Board and Bracket .....................64

7-20 Seat Cushion ......................................................................................................................................65

7-21 Armrest and Seat Cushion Bracket ....................................................................................................66

7-22 Footrest Handrail ...............................................................................................................................67

7-23 Front Bumper .....................................................................................................................................68

7-24 Combination Switch Cover ...............................................................................................................69

8. Electrical System ...........................................................................................................................................71

8-1 204AKSZ .............................................................................................................................................71

8-1-1 Motor Assembly .......................................................................................................................71

8-1-2 Motor Assembly .......................................................................................................................73

8-2 204AKSZ .............................................................................................................................................75

8-2-1 Electronic Controller Assembly ...............................................................................................75

8-2-2 Electronic Controller Assembly ...............................................................................................78

8-3 Battery .................................................................................................................................................81

8-3-1 EG204AKSZ T105 Batteries & Connect Wire .....................................................................81

8-3-2 EG204AKSZ Batteries & Connect Wire ...............................................................................82

9. Instrument Panel，Ignition Key ....................................................................................................................84

10. Combination Switch，Loud Speaker，Backup Buzzer，Electronic Flasher，Auxiliary Relay ...............88

11. Lighting System ...........................................................................................................................................90

12. DC Converter ...............................................................................................................................................91

13.Combination Instrument ...............................................................................................................................92

1

1. Frame

1-1 Frame Assembly

2

Frame Assembly

Item Part No Description Qty Remark

1 5101100-110 Left Beam (hydraulic brake) 1

2 5101200-110 Right Beam (hydraulic brake) 1

3 5101311-097 Central Beam (hydraulic brake without hand

park brake)

1

4 5101300-110 Central Beam (hydraulic brake with hand park

brake)

1

5 5101400-097 Rear Beam 1

6 Q150B08100 zinc hexagon bolt M8×100 4

Q40108 Black nickel washer M8 4 Must purchase full assembly

7 Q150B0825 Hex head bolt M8×25 8

Q40308 Black nickel Spring washer M8 8

8

Q40108 Black nickel washer M8 16



9

Q340B08-304H Black nickel hex head nut M8 4

Q150B0870 Out hexad bolt, color zinc 2



10 5101511-110 Reinforce on the beam 2

11 5101311-098 Central Beam (Mechanical brake) 1

12 5101100-111 Left Beam (Mechanical brake) 1

11

3

12

3

2. Brake and Drive System

2-1 Brake System , Hydraulic

2-1-1 Reservoir Assembly and Brake Pipe

21

22

4

Reservoir Assembly and Brake Pipe


1 2801100-009 Front brake assembly LH 1 180

2 2801200-009 Front brake assembly RH 1 180

3 2805030-018 Brake pipe (550mm) 2 550mm

4 2805020-026 Brake pipe (857mm) 1 857mm

5

2804100-004 Master cylinder 1

2805020-027 Brake pipe 1 808mm

2802100-009 Rear brake assembly LH 1 180

8 2802200-009 Rear brake assembly RH 1 180

2805030-019 Brake pipe (250mm) 1 250mm

10

2805020-023 Brake pipe (120mm) 1 120mm

2805020-024 Brake pipe (840mm) 1 840mm

2805014-001 Tri-connector 2

13

Tri-connector bracket 1 Must purchase full assembly

Tri-connector bracket 1 Must purchase full assembly

Brake pipe bracket 1 Must purchase full assembly

16 Q353C16 Hexad nut M6 1

17 Q150B0830 Bolt M8×30 1



18 Q150B0840 Bolt M8×40 1


19 Q40308 Black nickel Spring washer M8 1



20

2805040-004 Reservoir Assembly 1

Q67518 Wire clip 4

2805012-002 Rubber tube 2

5

2-1-2 Braking Pedal & Bracket Assembly

6

Braking Pedal & Bracket Assembly


1 2803114-107 Brake pedal 1

2 2803112-107 Brake pedal support 1

3 2803115-107 Brake pedal pad, upper 1

4 2803116-107 Brake pedal pad, low 1

5

Q150B0618 Out hexad bolt M6x18 2



6 2803113-107 Accelerator pedal block 1

7 2803124-107 Return spring of accelerator pedal 1

8 2803111-107 Accelerator pedal 1

9 2803117-107 Low pin shaft of brake pedal 1

10 2803123-107 Return spring of brake pedal 1

11 2803118-107 Low pin shaft bushing of brake pedal 1

12 2803121-107 Low pin shaft bushing of accelerator pedal 1

13 2803122-107 Spring pin 1 M5 L27

14 2803119-107 Low pin shaft of accelerator pedal 1

15 Q430114 Stretchable block ring ￠14 4

16 Q2739116 Cross slot round head self tap screw M4x16 4

17 2803100-107 Pedal assembly 1

18 Q2610630 Hexad self tap screw M6x30 4

19 Pin shaft of master cylinder shaft 1

20 Q40108 Black nickel washer M8 1

21 Q5000225 Split pin Φ2×25 1

22 Fork of master cylinder shaft 1

23 5111012-097 Block of brake light switch 1

24 Q340B08-304H Black nickel hex head nut M8 1

25 5111011-097 Brake light switch bracket 1

7

26 Q350B08 Hexad nut M8 2

27 3127011-001 Brake light switch 1

28

Q150B1060 Bolt M1×6 2

Q40310 Spring washer M10 2

Q40110 Flat washer M10 2

29


Q340B10 Nut M10 2

30 5111030-097 Master cylinder bracket 1

31

Q150B0825 Hex head bolt M8×25 2



32




33 5101311-097 Central Beam (hydraulic brake without hand

parking brake)

1

8

2-1-3 Brake Assembly Rear

Brake Assembly Rear


1 2801100-007 Front arrester, LH 1

2801200-007 Front arrester, RH 1

2 2801110-007 Brake shoe assembly 4

3 2801130-007 Front wheel cylinder 2

4 Chassis base assembly 2 Must purchase full assembly

3

2

2

4

1

9


Brake Assembly Rear


1

2802200-006 Rear arrester, RH 1

2802100-006 Rear arrester, LH 1

2 2802310-006 Rear brake drum 2

3 2802110-006 Left brake caliper 4

4 2802130-006 Rear Wheel cylinder,LH 2

5

Motherboard 2 Must purchase full assembly

10

2-2 Parking Brake System

2-2-1EM Brake

EM Brake Item Part No Description Qty Remark

1 2400000-038 Rear axle assembly 1

2 Q43130 Stretchable block ring ￠20 2

3 Q5510618 Flat key 6x6x18 1

4 2806131-004 Spline 1

5 2806120-004 Spline housing 1

6

2806110-004 EM brake, 48V 1 48V

2806110-003 EM brake, 36V 1 36V

7

Q150B0625 Bolt M6×25 3

Q40306 Black nickel gasket spring M6 3

Q40106 Black nickel gasket M6 3

11

2-2-2 Parking Brake Handle

Parking Brake Handle


1 2807100-002 Parking brake control handle 1

2

Parking brake lever bolt 2 Must purchase full assembly

3 2807200-015 Parking brake cable assembly 1 1

4 2807111-005 Cable split retaining ring 1 1

5

Cable clutch pin 1 1 Must purchase full assembly

6 2803114-037 Cable return spring 1

7 2807300-012 Parking brake cable assembly 2 1

8 3127010-001 Park Brake light switch 1

2-3 Brake System, Mechanical

12

2-3-1 Brake Pedal & Bracket Assembly, Mechanical

13

Braking Pedal & Bracket Assembly


1 2803100-107 Pedal assembly 1

2 Q5100825 Pin M8×25 1

3 Q40108 Gasket M8 1

4 Q5000225 Split pin Φ2×25 1

5 2803122-036 Bumper head of compensator for braking 2

6 2803121-036 Balance bracket 1

7 2803125-036 Thickening nut M8 1

8 2807320-018 Braking cable assembly 1

9 2807310-018 Braking cable assembly 1

10 Q5100825 Pin M8×25 1

11 Q40108 Gasket M8 1

12 Q5000225 Split pin Φ2×25 1

13 2802100-007 Assembly of brake 1

14 Q340B08 Hex head nut M8 1


16 Q40208 Black nickel big washer M8 1

17 2803116-036 Compression spring 1

18 2803118-036 Limit retainer of balancer 1

19 2803119-036 Protection cover 1

20 2803117-108 Brake bolt 1

21 2803115-036 Furcated arm 1



23 5111011-098 Brake light bracket 1

24




25 3127010-001 Brake light switch 1

26 Q350B08 Hexad nut M8 2

14

2 3 4

6

7

8

11

9

12

10

14

15

13

16

1


15

Brake Assembly Rear


1

2802200-017 Rear Brake assembly RH (include

item 3-16)

1

2802100-017 Rear Brake assembly LH (include

item 3-16)

1

2 2802210-007 Brake drum 2

3 2802110-007 Brake shoe assembly 2

4

Motherboard assembly 2 Must purchase full assembly

6 Adjusting screw 1 Must purchase full assembly

Adjusting screw 1 Must purchase full assembly

7 Ratchet wheel 1 Must purchase full assembly

Ratchet wheel 1 Must purchase full assembly

8

Mandril head 2 Must purchase full assembly

9 Q150B0825 Bolt M8×25 8

10 Q32608 Self-lock nut M8 8

11

Bearing peg 4 Must purchase full assembly

12 HX8060A-35072001 Spring and cuppy restrainer 4

13

Upside return spring 2 Must purchase full assembly

14

Underside return spring 2 Must purchase full assembly

15

Adjusting spring 2 Must purchase full assembly

16 Dialing clip 1 Must purchase full assembly

Dialing clip 1 Must purchase full assembly

16

3. Suspension

3-1 Front suspension, Hydraulic Brake

17

Front Suspension, Hydraulic Brake


1 2500100-107 Front suspension frame assembly 1

2 2503200-107 Front upper swing arm, RH 1

3 2503400-107 Front lower swing arm, RH 1

4 2302112-029 Lower support of front shock absorber 2

5 2302120-029 Main pin shaft 2

6 2302211-029 Steering knuckle, RH 1

7 2302113-029 Copper bushing 4

4,5,6,7 2302200-029 Steering knuckle, RH 1

8 2503422-107 Bushing of front swing arm 8

9

2503423-107 Bolt of front swing arm 4 M10 P1.25 L171


10


Q33210 Hexad lock nut M10 6

11


Black nickel flat washer M10 2 Must purchase full assembly

12 Q32012 Hexad flange nut M12 2

13 Q150B1080 Out hexad bolt M10x80 1


14 2503100-107 Front upper swing arm, LH 1

15 2503300-107 Front lower swing arm, LH 1

16 2302111-029 Steering knuckle, LH 1

4,5,16,7 2302100-029 Steering knuckle, LH 1

18

3-2 Front Suspension, Mechanical Brake, Optional

19

3-2 Front Suspension, Mechanical Brake, Optional



2 2503200-107 Front upper swing arm, RH 1

3 2503400-107 Front lower swing arm, RH 1


5 2302120-029 Main pin shaft 2

6 2302211-030 Steering knuckle, RH 1

7 2302113-029 Copper bushing 4

4,5,6,7 2302200-030 Steering knuckle, RH 1

8 2503422-107 Bushing of front swing arm 8

9

2503423-107 Bolt of front swing arm 4 M10 P1.25 L171

Q40110 Black nickel flat washer M10 4

10


Q33210 Hexad lock nut M10 6


Black nickel flat washer M10 2 Must purchase full assembly

12 Q32012 Hexad flange nut M12 2

13




15 2503300-107 Front lower swing arm, LH 1

16 2302111-030 Steering knuckle, LH 1

4,5,16,7 2302100-030 Steering knuckle, LH 1

20

3-3 Front Hub

Front Hub


1 2600111-036 Front hub 2

2 L44643 Bearing assembly 4

6 Q38324 Slotted nut M24 2

7 2600114-036 Hub cap (for aluminum rim) 4

8 2600113-036 Oil seal 2

9 2302111-030 Spindle assembly (driver side) 1

2302211-030 Spindle assembly (passenger side) 1

10 2600011-012 Tire bolt M12×45 8

3-4 Front Suspension

21

22

Front Suspension


1 5301100-107 Front trim bracket 1

2 5101610-097 Front trim bracket support 1


4 2501000-018 Front helix spring with shock absorber 2



2503210-107 Front upper swing arm, RH 1

7 5101000-097 Frame assembly 1



9


Q40310-304 Gasket spring M8 4

Q40110-304H Black nickel flat washer 4



11 Q33210 Hexad lock nut M10 2




13

Q340B10 Nut M10 8



23

3-5 Rear Suspension

24

Rear Suspension




3 2508000-027 Rear leaf spring 2

4 2509111-107 U bolt for rear leaf spring 4

5 2509120-107 Rear support of rear leaf spring 2

6 2509112-036 Flange bolt M10 4

7 2509115-036 Bush 8

8 2509113-107 Bushing 4

9



Q340B10 Nut M10 8

10

Q150B1070 Flange bolt M10x70 2


11 2509131-107 Bush (short) 4

12 2509132-107 Bushing 2

25

3-6 Rear Shock Absorber

26

Rear Shock Absorber Item Part No Description Qty Remark


2 2511100-007 Rear shock absorber 2


4 Nut M10 4 Must purchase full assembly

5 Inner retainer（2） 2 Must purchase full assembly

6 Upper cushion 4 Must purchase full assembly

7 Inner retainer（2） 2 Must purchase full assembly

8 Q150B1055 Zinc hexagon bolt M8×2 2


9

Q340B10 Nut M10 2



27

4. Rear Axle

4-1 Rear Axle Assembly

Rear Axle Assembly


1 2403100-038 Reducer assembly 1

2 2402200-038 Half shaft, RH 1

3 2402100-038 Half shaft, LH 1

4 2401100-038 Rear axle shell 1




5

1

2 3

4

6 7

28

4-2 Half Axle Assembly

Half Axle Assembly


1 2402100-008 Left half axle 1

2402200-008 Right half axle 1

2 Tire bolt M12×45 8 Must purchase full assembly

3 2401009-EG2024-000 Bearing capping 2

4 9010007-06206-001 Inner shield ring 2

5 6206 Bearing 6206-Z 2

6 9010007-06206-000 Outer shield ring 2

1

2

3

4 5

6

29

4-3 Retarder Assembly

30

Retarder Assembly


1 Q218B0830 Hexad column head screw M8x30 5

2 Q40308 Black nickel gasket spring M8 5

3 Flange 1 Must purchase full assembly

4 Oil seal 25x40 1 Must purchase full assembly

5 Bearing 6205 1 Must purchase full assembly

6 2403112-038 Gear shaft I 1 12.76

2403112-040 Gear shaft I 1 10.26

7 Block 1 Must purchase full assembly

8 Block ring 40 2 Must purchase full assembly


10 2403114-033 Gear shaft II 1 12.76

2403114-034 Gear shaft II 1 10.26

11 Key 6x16 1 Must purchase full assembly

12 Reducer housing 1 Must purchase full assembly

13 Gear of shaft II 1 Must purchase full assembly

14 Gasket spring of shaft II 1 Must purchase full assembly



17 Oil seal 20x40 1 Must purchase full assembly

18 Connecting flange 1 Must purchase full assembly

19 Q218B0820 Inner hexad column head screw M8x20 3

20 2403200-033 Differential assembly 1


22 Differential support bearing cover 2 Must purchase full assembly

23 Q218B0845 Inner hexad column head screw M8x45

31

4-4 Differential

13

32

Differential


1 Differential housing 1 Must purchase full assembly

2 Spheroidal thrust washer 1 Must purchase full assembly

3 Planetary gear 2 Must purchase full assembly

4 Axle shaft gear 2 Must purchase full assembly

5 Planetary gear shaft 1 Must purchase full assembly

6 Adjusting gasket 2 Must purchase full assembly

9 Pin 5×45 1 Must purchase full assembly

10 Washer 2 Must purchase full assembly

11 Driving bevel gear screw 6 Must purchase full assembly


13 Big gear 1 Must purchase full assembly

14 2403200-033 Differential assembly 1

Rear Axle Assembly


1 2400000-038 Rear axle assembly, 12.76:1, hydraulic, with EM brake 1

2 2400000-039 Rear axle assembly, 12.76:1, mechanic, with EM brake 1

3 2400000-040 Rear axle assembly, 10.26, hydraulic, with EM brake 1

4 2400000-041 Rear axle assembly, 10.26, mechanic, with EM brake 1

33

3

4

5

6

7

1

8

5. Steering System

5-1 Steering Wheel Assembly

8

34

Steering Wheel Assembly


1

2702100-007 Steering wheel assembly (plastic) 1

2702100-006 Steering wheel assembly (timber) 1

3 Steering wheel cover 1 Must purchase full assembly

4 Score board folder 1 Must purchase full assembly

5 Self-tapping screw 2 Must purchase full assembly

6 Gasket 2 Must purchase full assembly

7 Spring 2 Must purchase full assembly

8 Score board folder assembly 1 Must purchase full assembly

35

5-2 Steering Shaft Assembly

36

Steering Shaft Assembly


1 2705010-006 Ignition support base 1

2 2702200-107 Upper steering column 1

3 2702310-107 Bracket for upper steering column 1

4 5301100-107 Front trim bracket 1

5 2702324-107 Adjust handle 1

6 2702330-107 Steering column adjust handle 1

7 2702322-107 Pin shaft 1

8 2702323-107 Separator 1

9 Q33206 Hexad lock nut 1

10 2702325-107 Firmware 1

11 Q2140508 Cross recessed pan head tapping screw, color zinc 1

12 Q32624 Hex head lock nut M24 1

13 Q218B0825 Inner hexad column head screw M8 4



15 Q2540616 Cross slot deep head color zinc bolt M6x16 2

16



Q340B06-304H Hex head nut M6 1

17 2702321-107 Flange bolt 1

18 Q32608 Black nickel hex head lock nut M8 1

19

Q150B0860 zinc hexagon bolt M8×60 4





37

5-3 Steering Gear Assembly

25

38

Steering Gear Assembly


1 2704300-019 Lower steering column 1

2 Housing 1 Must purchase full assembly

3 Rack 1 Must purchase full assembly

4 Gasket ring 2 Must purchase full assembly

5 2701120-015 Steering drag rod 2

6 Hexad nut M12x1.25 2 Must purchase full assembly

7 Hoop 35-51 2 Must purchase full assembly

8 2701111-015 Dustproof cover of steering box 2

9 Hoop 18-28 2

10 2701130-015 Ball head of steering drag rod 2

11 Q381C12 Slotted nut M12 2

12 Q5000225 Split pin Φ2×25 2

13 Q150B1250 zinc hexagon bolt M8×2 2


14 Dustproof cover 1 Must purchase full assembly

15 Oil seal 35x15x7 1 Must purchase full assembly

16 Block ring ￠15 1 Must purchase full assembly

17 6202RS Bearing 1

18 Pinion 1 Must purchase full assembly

19 gear bearing 1 Must purchase full assembly

20 rack support 1 Must purchase full assembly

21 Spring 1 Must purchase full assembly

22 Adjust block 1 Must purchase full assembly

23 Lock nut 1 Must purchase full assembly

24 rack bushing 1 Must purchase full assembly

25 2701100-017 Redirector 1

39

6. Wheel

6-1 Aluminum Rim and Tire

Aluminum Rim and Tire


1 2602011-013-01 Tire 205/50-10 4

2 2600114-036 Hub cap (for aluminum rim) 4

3 2601100-016 Aluminum rim 4

4 2601210-004 Tire valve 4

5 2600012-012 Lug Nut 16

1

2

3

4

5

40

7. Body Parts

7-1 Floor, Side Board

41

Floor, Side Board


1 5101100-110 Left beam 1

5101200-110 Right beam 1

2 5102020-107 Rear base 1

3 5102031-107 Rear base support 2

4 5102032-107 Block of rear base support 6

5 5102033-107 Fasten piece of rear base support 2

6 5102010-107 Front base 1

7 5103011-107 Front base support 1

8 5109012-107 Floor mat rear pressing bar 1

9 5107010-107 Floor mat 1

10 Q150B0825-304H Hex head bolt M8x25 4

11 Q37208-304H Rivet nut 2

12

Q40308-304H Black nickel Spring washer M8 4

Q40108-304H Black nickel flat washer M8 4

Q2700640-304H Hexad flange self-tapping screw M6x40 9

13 Q2140620-304H Stainless steel cross slot pan head bolt M6×20 2

14 Q40206-304H Black nickel big washer M6 2

15 5102020-107 Rear base 1

16 5103021-107 Middle base support 1

17 5502110-107 Front side trim, LH 1

5602110-107 Front side trim, RH 1

18 AIC-JL-001 Button 2

19

5109013-107 Floor mat pressing bar, LH 1

5109014-107 Floor mat pressing bar, RH 1

20 5109013-107 Floor mat pressing bar, LH 1

5109014-107 Floor mat pressing bar, RH 1

21 9021011-107 Plastic self-tap screw, I type 6

22 5502130-107 Rear side trim, LH 1

5602130-107 Rear side trim, RH 1


24 Q218B0520 Inner hexad pan head bolt M5x20, black nickel 2

25 Q40205-304H washer 2

26 9021010-092 Rubber expansion nut M5 2

42

7-2 Front Cover，，，，Instrument Board

1

2

3

7

5

6

4

10,11

9

8

12

13

43

Front Cover, Instrument Board


1 5302020-107 Front body 1

2 5302031-107 Front body insert 1

3 5305110-023 Upper instrument panel 1

4 5305210-023 Lower instrument panel 1

5 5305121-023 Cup holder 2

6 5302010-107 Front trim 1

7

5108011-107 Access board of left headlight 1

5108012-107 Access board of right headlight 1

8 9021010-092 Rubber expansion nut M5 11



11 Q40205-304H Washer 3



44

7-3 Front Windshield

45

Front Windshield


1 5701011-107 Front bracket left 1

2 5303010-039 Front Windshield 1

3 5303021-038 Sash for one-piece windshield 2

4 5303022-011 Holding block 2

5 Q3720615 Flat head rivet nut M6 2

6 Q 40108-304H Washer M8 2

7 Q40308-304H Black nickel Spring washer M8 2

8 Q218B0845-304H Inner hexad bolt M8x45 2

9

5708011-107 Rubber ring of front bracket, LH 1

5708012-107 Rubber ring of front bracket, RH 1

46

7-4 Rear Body

3

16,17 17,18,19

9

21

12,13,20

1

5

6

7

14

9

8

4

3

11，12,13

15

10

47

Rear Body


1 5102020-107 Rear base 1


5101000-098 Frame assembly 1

3 5402041-107 Rear small wheel fender, LH 1

5402042-107 Rear small wheel fender, RH 1

4 5402031-107 Rear big wheel fender, LH 1

5402032-107 Rear big wheel fender, RH 1

5 5402010-107 Rear cover 1

6 5108013-107 Battery access panel 1

7 5109011-107 Bag well liner 1

8 5108014-107 Motor access panel 1

9 5406110-025 Rear bumper 1


11 Q150B0635-304H Hexagon bolt M6×35 4


13 Q40108-304H Black nickel flat washer M8 6


15 AIC-JL-001 Button 5

16 Q150B0616-304H Hexad bolt M6×16 4



19 Q340B06 Black stainless steel hex head nut M6 4

20 Q150B0860-304H Hexad bolt M8×60 2


48

7-5 Cushion

1

2

3

4,5

6

2

7

49

Lazyback, Cushion


1 7101100-107 Seat cushion 2

2 7101110-107 Seat cover 2

3

7109010-107 Arm rest left 2

7109020-107 Arm rest right 2




7 5402010-107 Rear cover 1

8

1101013-011 Battery box 6P 1

1101013-009 Battery box 4P 1

9

7107231-002 Upper piece of gemel 2

7107232-002 Lower piece of hinge 2

6 5

9 7

8 2

50

7-6 Front Seat Compartment

Front seat compartment


1 5302041-111 Front seat compartment 1

2 5103021-107 Middle base support 1

3 5102020-107 Rear base 1



51

7-7 Front Seat Cushion, Backrest

52

Front Seat Cushion, Backrest


1 7106121-111 Seat back support, LH 1

7106122-111 Seat back support, RH 1

2 5302041-111 Front seat compartment 1

3 7107211-002 Seat ball 2 2048



6 Q2140625-304H Black nickel cross slot pan head bolt M6×25 2




10 Must purchase full assembly Rubber blanket 4 2048

11 7106100-036 Seat back cushion 1

12 Q2140660-304H Black nickel bolt M8×60 2

13 7101110-107 Seat cover 1

14 7107212-002 Seat ball socket 2 2048

15 Q23704825 Cross slot deep head selt tapping screw M4.8x25 4 4

53

7-8 Bracket Under Rear Seat Cushion

Bracket Under Rear Seat Cushion


1 5102020-107 Rear base 1

2 5101000-097 Bracket under rear seat cushion 1




54

7-9 Main Bracket of Seat

Main Bracket of Seat


1 5402010-107 Rear cover 1

2 5401110-108 Master bracket of seat, LH 1

3 5401120-108 Master bracket of seat, RH 1

4 Q150B0640-304H Hex head bolt M6×40 4






10 Q394B08-304H Black nickel operculiform nut M8 2

55

7-10 Bracket of Front Backrest and Rear Backrest

Bracket of Front Backrest and Rear Backrest


1 5402010-107 Rear cover 1

2 7107012-108 Front backrest bracket, RH 2

3 7107011-108 Front backrest bracket, LH 2

4 5401110-108 Master bracket of seat 2





56

7-11 Rear Top Supports

Rear Top Supports


2 5701021-108 Rear bracket 2



5 5401110-108 Master bracket of seat, LH 2

6 Q150B0840-304H Black nickel bolt M8×40 4




57

7-12 Front Backrest

Front Backrest


1 5402010-107 Rear cover 1





6 Q2140630-304H Cross recessed pan head tapping screw, black STS M6×30 4


58

7-13 Rear Backrest

Rear Backrest


1 5402010-107 Rear cover 1





6 Q2140630-304H Cross recessed pan head tapping screw, black

STS M6×30

4


59

7-14 Caddy Handle

Caddy Handle


1 5701031-108 Caddy handle 1

2 5701041-036 #1 jacket for caddy handle 2 pairs

3 5701021-108 Rear bracket, LH 2

4 Q2140650-304H Black nickel cross slot pan head bolt M6X50 4




60

7-15 Upper Bracket

Upper Bracket


1 5701061-112 Upper bracket 1

2 5701010-108 Front bracket 1

3 5701021-108 Rear bracket, LH 1

5701022-108 Rear bracket right 1

4 Q150B0840-304H Black nickel bolt M8×40 3

5 Q150B0865-304H Black nickel hex head bolt M8×65 4




61

7-16 Canopy

Canopy


1 5702010-112 Roof 1

2 5701061-112 Upper bracket 1

3 Q150B0860-304H Hexad bolt M8×60 6


5 2024-5601002 Cushion board 18




62

7-17 Footrest Bottom

Footrest Bottom


1 5402211-108 Footrest bottom 1

2 5402212-108 Footrest board 1


63

7-18 Footrest Bottom Bracket

Footrest Bottom Bracket


1 5101111-110 Left beam 1

5101211-110 Right beam 1

2 5402110-108 Footrest bottom bracket 2

3 Q150B01070 Hex head bolt M10x70 4

4 Q402010-304H big gasket M10 8

5 Q326010 2 type hex head lock nut M10 4




9 Q150B1025 Hex head bolt M10x25 4

10 Q40110 Flat washer M10 8

11 Q40310 Spring washer M10 4

12 Q340B10 Nut M10 4

64

7-19 Aluminum Plate Under Cushion & Turnover Bracket Aluminum Board and

Bracket

Aluminum Plate Under Cushion & Turnover Bracket Aluminum Board and Bracket


1 5401181-037 Aluminum plate under cushion 1

2 7101110-107 Seat cover 1

3 5401161-037 Turnover bracket aluminum board 1

4 5401150-037 Turnover bracket 1

5 Q2140630-304H Cross recessed pan head tapping screw, black

STS 8




9 Q150B1030 Black nickel hex head bolt M10×30 2

10 2042-7102048 Copper sleeve 2

11 Q32610 Hex head lock nut M10 2

65

7-20 Seat Cushion

Seat Cushion


1 5401150-037 Turnover bracket 1

2 5401161-037 Turnover bracket aluminum board 1

3 7101100-107 Seat cushion 1

4 Q2710635 Cross slot pan head rivet M6x35 6

66

7-21 Armrest and Seat Cushion Bracket

Armrest and Seat Cushion Bracket


1 5401110-108 Aluminum board 2

2 5401141-109 Side armrest 2

3 Q150B0845-304H Hex head bolt M8X45 4




7 7101110-107 Seat cover 1




11 Q32608 Black nickel hex head lock nut M8

4

Black nickel hex head lock nut M8

67

7-22 Footrest handrail

Footrest handrail


1 7202010-109 Footrest handrail 1



4 Q150B0850-304H Bolt 2


6 Q32608 Black nickel hex head lock nut M8 4

Black nickel hex head lock nut M8

7 7202010-037 Caddy standing board armrest assembly 1


9 Q32606 Self-lock nut M6

2

Self-lock nut M6

68

7-23 Front Bumper

Front Bumper


1 5307110-021 Front bumper 1


5101000-098 Frame assembly 1

3 5307121-021 Front bumper frame left 1

5307122-021 Front bumper frame right 1

4 Q150B0816-304H Hexad bolt M8×16 4

5 Q150B0820-304H Hexad bolt M8x20, black STS 2




1

3

2

4,6,

5,6,7

6,7,8

69

7-24 Combination Switch Cover

1

4

3

2

5

1

6

7

70

Combination Switch Cover


1 5305141-023 Combination Switch upper cover 1

5305142-023 Combination Switch lower cover 1

2 Steering column assembly 1 Must purchase full assembly

3 5305151-023 Combination switch bracket 2

4 Q2710416-304H Black nickel cross recessed pan head tapping

screws 5

5 Q340B06 Black stainless steel hex head nut M6 2

6 Q31205 Spring nut M5 2

7 Q218B0520 Inner hexad pan head bolt M5x20, black

nickel 2

8 2702330-107 Steering column adjust handle 1

9 Q2780616 Cross recessed countersunk head screws

M6x16 2



9

8

10 11

71

8. Electric system

8-1 Motor

8-1-1 Motor 48V/3.8KW

1

2 3

4

2

7

8 9

10

11 12

13

14

15

16

72

Motor 48V/3.8KW Item No Part No Description Qty Remark

1 1003000-017 Motor assembly 1

2 Commutator end of cover 1 Must purchase full assembly

3 Bolt 2 Must purchase full assembly

4 Gasket spring 2 Must purchase full assembly

7 Bearing 1 Must purchase full assembly

8 Gland ring 1 Must purchase full assembly

9 Armature binding post 2 Must purchase full assembly

10 Brush spring 4 Must purchase full assembly

11 1003010-007 Carbon brush 4


13 Motor case 1 Must purchase full assembly

14 1003050-017 Field coil kit 4

15 Pole core 4 Must purchase full assembly

16 1003040-017 Armature 1

73

8-1-2 Motor 48V/5KW AC

74

Motor 48V/5KW AC

Item No Part No Description Qty/car Remark

1 1003000-039 Motor assembly 3KW, 48V, AC 1 48V/3KW

2 Temperature sensor 1 Must purchase full assembly

3 Connection base 1 Must purchase full assembly


5 Rotor 1 Must purchase full assembly



8 Front cover 1 Must purchase full assembly

9 Rear cover 2 Must purchase full assembly

10 Motor case 4 Must purchase full assembly

11 1003060-012 Encoder 1

75

8-2 Controller and harness

8-2-1 Zapi ACE2 controller

76

Zapi ACE2 Controller


1 1005100-024 ZAPI ACE0 Controller(48V/280A) 1

2 1005022-014 Conflux plate 1 1

3 1005200-004 Main contactor 1

4 1005023-014 Conflux plate 2 1

5 1005013-003 Main contactor bracket 1

6 1005520-001 Fuse holder 1

7 1005510-004 Main fuse 1

8 1005021-021 Heat diffusion plate 1

9 5111040-098 Controller bracket 1

Harness of Zapi ACE2

77

Harness of Zapi ACE2


1

To left taillight 1 Must purchase full assembly

2

To EM brake 1 Must purchase full assembly

3

To speed sensor 1 Must purchase full assembly

4

To reverse buzzer 1 Must purchase full assembly

5

To right taillight 1 Must purchase full assembly

6

To fuse 1 Must purchase full assembly

7

To DC/DC input 1 Must purchase full assembly

8

To park brake switch 1 Must purchase full assembly

9

To DC/DC output 1 Must purchase full assembly

10

To controller 1 Must purchase full assembly

11

To function switch 1 1 Must purchase full assembly

12

To function switch 2 1 Must purchase full assembly

13

3308000-119 Chassis harness (without meter) 1

3308000-108 Chassis harness (with meter) 1

14

To combination switch 1 Must purchase full assembly

15

To ignition key 1 Must purchase full assembly

16

To meter 1 Must purchase full assembly

17

To left headlight 1 Must purchase full assembly

18

To front left turning light 1 Must purchase full assembly

19

To battery power meter 1 Must purchase full assembly

20

To F/R switch 1 Must purchase full assembly

21

To emergency warning light switch 1 Must purchase full assembly

22 Cabin harness（without meter) 1 Must purchase full assembly

3302000-107 Cabin harness (with meter) 1

23

To accelerator 1 Must purchase full assembly

24

3307200-013 Controller harness （with 6pcs

batteries) 1

3307200-022 Controller harness （with 8pcs

batteries) 1

25

To brake light switch 1 Must purchase full assembly

26

To right headlight 1 Must purchase full assembly

27

To front right turning light 1 Must purchase full assembly

28

To horn 1 Must purchase full assembly

78

8-2-2 Curtis 1268 Controller

Curtis 1268 Controller

Item No Part No Description Qty. Remark

1 1005100-007 Controller 1268 1

2 2044-3018027 Connect wire 2 Black & red each one


6 3308000-058 Chassis harness 1

7 1005200-004 Main contactor 1

8 Q2140412 Cross slot pan head bolt M4×12 2

9 1005510-003 Main fuse 1 425A

10 Q40208 Black nickel big washer M8 2




14 5111040-097 bracket for controller 1 1268, 1244

15 1005021-025 Heat diffusion plate 1

18 2024-3018301E Motor cable 4 48V

79

Harness For Curtis 1268 Controller

80

Harness For Curtis 1268 Controller

Item No Part No Description Qty Remark

1 To left taillight 1 Must purchase full assembly

2 To EM brake 1 Must purchase full assembly

3 To speed sensor 1 Must purchase full assembly

4 To reverse buzzer 1 Must purchase full assembly

5 To right taillight 1 Must purchase full assembly

6 To fuse 1 Must purchase full assembly

7 To DC/DC input 1 Must purchase full assembly

8 To park brake switch 1 Must purchase full assembly

9 To DC/DC output 1 Must purchase full assembly

10 To controller 1 Must purchase full assembly

11 To function switch 1 1 Must purchase full assembly

12 To function switch 2 1 Must purchase full assembly

13 3308000-120 Chassis harness (without meter) 1

3308000-109 Chassis harness (with meter) 1

14 To combination switch 1 Must purchase full assembly

15 To ignition key 1 Must purchase full assembly

16 To meter 1 Must purchase full assembly

17 To left headlight 1 Must purchase full assembly

18 To front left turning light 1 Must purchase full assembly

19 To battery power meter 1 Must purchase full assembly

20 To F/R switch 1 Must purchase full assembly

21 To emergency warning light switch 1 Must purchase full assembly

22 3302000-106 Cabin harness （with meter) 1

Cabin harness （without meter) 1 Must purchase full assembly

23 To accelerator 1

24 3307200-014 Controller harness （6pcs batteries) 1

3307200-023 Controller harness （8pcs batteries) 1

25 To brake light switch 1 Must purchase full assembly

26 To right headlight 1 Must purchase full assembly

27 To front right turning light 1 Must purchase full assembly

28 To horn 1 Must purchase full assembly

81

8-3 Battery

8-3-1 8xT105 Batteries & Connect Wire

8xT105 Batteries & Connect Wire Item New Part No Description Qty Remark

1 1101100-002 Battery（T-105） 8 6V×8

2 3313010-002 Connect wire 4 252×180mm

3 3313010-003 Connect wire 1 252×200mm

3313010-005 Connect wire 1 252×300mm

5 3313010-016 Connect wire 1 252×380mm

6 3049120-010 Charger harness assembly 1

7 3049110-004 Charger receptacle 1

8 1101012-002 Battery impact block 2

9 1101011-005 Battery dead lever 2

10 FB01009 British system nut 12 5/16-8

11 Q40308-304 Spring washer M8 12

12 1101013-002 Battery box 1

13 1101012-003 Battery impact block 2


15 1101011-004 Battery Dead Lever 4

16 2024-3022002 Press plate for receptacle

82

8-3-2 6xT-875 Batteries & Connect Wire

6xT875 Batteries & Connect Wire

83


1 T-875 Battery（T-875） 6 8V×6

2 1101014-002 Battery cable jacket 12

3 3313010-001 Connect wire 4 252 ×130mm

4 3313010-016 Connect wire 1 252 ×380mm

5 3049120-016 AC receptacle with cable 900mm 1

6 5111060-097 Charger bracket 1

7 1103100-058 Eagle Charger (on-body use,48V-22A) 1 EAGLE 48V-22A

8 1101012-001 Batteries pressure block 2


10 FB01009 British system nut 12 5/16-8

11 Q40308-304 Spring washer M8 12

12 1101013-011 Battery box 6P 1

84

9. Instrument Panel，，，，Ignition Key

9-1 Instrument Panel, Ignition Key, Standard Configuration Without Meter

1 2

3 4

5

6

85

Instrument Panel, Ignition Key, Standard Configuration Without Meter


1 2026-3004014 Panel (one round hole) 1

3212051-002 Panel (two round hole) 1

2 Q2730416-304H Self-tapping screw M4×16 4

3 3217010-001 Battery power meter 36V 1

3217010-002 Battery power meter 48V

4 3032010-001 F/R switch 1

5

3001010-002 Start key (include item 6) 1

3001010-003 Universal Start key (include item 6) 1

6 6042-3001011 Key 2

86

9-2 Instrument Panel, Ignition Key, Optional Configuration With Meter

（1）

（2）（3）

（4）（5）

87

（6）

9-2 Instrument Panel, Ignition Key, optional configuration with meter


1 3212051-008 Instrument panel, 4 holes 1

3212051-009 Instrument panel, 3 holes 1

2 3217010-001 Battery power meter 36V 1 36V

3217010-002 Battery power meter 48V 1 48V

3 3032010-001 F/R switch 1

4 3032010-002 Alarm switch 1

5 3032010-019 Park Switch 1

6 3001010-004 Start key 1

88

10. Combination Switch，，，，Loud Speaker，，，，Backup Buzzer，，，，Electronic Flasher，，，，

Auxiliary Relay

（1）

（2）

89

（3）（4）（5）

Combination Switch，，，，Loud Speaker，，，，Backup Buzzer，，，，

Electronic Flasher，，，， Auxiliary Relay


1 3024100-005 Combination switch 1 Standard

3024100-007 Combination switch 1 Optional

2 3004010-002 Electric horn 1 12V

3 3211010-003 Reverse buzzer 1

4 3040010-006 Auxiliary relay 2

5 3129010-002 Electronic flasher 1

90

11. Lighting System

Lighting System


1 3117100-007 Headlight，RH 1

2 3117200-007 Headlight，LH 2

3 3101141-017 Headlight bulb, low beam 2

4 3101131-017 Headlight bulb, high beam 2

5 3126100-006 Taillight, LH 1

6 3126200-006 Taillight, RH 2

91

12. DC Converter

48V/12V DC

48V/12V（（（（DC Converter））））


1 3048100-003 DC converter 1

2 To 48V out 1 Must purchase full assembly

3 To 12V in 1 Must purchase full assembly

92

13. Combination Instrument


1 3212100-093 Digital meter, AC system 1

2 3212100-094 Digital meter, DC system 1

Documents

6pr Sport Parts Diagram - Bintelli Electric Vehicles · 2015. 12. 6. · 2 Frame Assembly Item Part No Description Qty Remark 1 5101100-110 Left Beam (hydraulic brake) 1 2 5101200-110