Taylor-Dunn RE-380-36, Service And Replacement Parts Manual

Page 1: ...HIS VEHICLE The operator s manual contains important information regarding the safe operation of this vehicle WARNING Starting Serial Number 207500 Ending Serial Number See Introduction Chapter Servic...

Page 2: ...acement parts and service for our vehicles Refer to our web site www taylor dunn com for a dealer lookup application Originally Published 11 6 2017 Revision B 7 13 2018 contents subject to change with...

Page 3: ...parts or service should be obtained through your local dealer A dealer locator can be found on the Taylor Dunn website at www taylor dunn com If you do not have access to the internet you can call th...

Page 4: ...n invaluable asset and it is an asset we cherish and protect Our guiding principle is to provide application specific solutions which are reliable efficient and economical Our domestic and internation...

Page 5: ...17 Special Tool List 21 Lubrication 25 Front Axle 29 Transaxle GT 39 Transaxle SD 49 Steering 57 Brakes 67 SEM Motor 77 Motor Controller 83 Wire Diagram 87 Batteries 91 Tires Wheels 97 Hardware Infor...

Page 6: ......

Page 7: ...ure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Introduction About this manual 8 Who Should Read This Manual 8 How To Use This Manual 8 Conventions 9...

Page 8: ...propriate Taylor Dunn manual Each Taylor Dunn manual references the applicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in...

Page 9: ...e NOTICE This signal word will not be accompanied by the safety alert symbol NOTICE will indicate a condition that if not avoided may result in property damage Property is defined as the vehicle compo...

Page 10: ...ce procedures and lead acid batteries Of the Operator A vehicle shall not be operated until the operator has successfully completed an operator training course provided by the owner of the vehicle The...

Page 11: ...del and serial numbers are shown in the illustrations below WEB SITE REGISTRATION Registering on the Taylor Dunn web site will give you access to a wealth of information about your vehicle and the ent...

Page 12: ...Page 12 MR 380 05 Introduction RE 380 36 RE 380 48 Notes...

Page 13: ...ts Service Maintenance Guidelines Service Maintenance Guidelines READ ME FIRST Maintenance Guidelines and General instructions 14 Vehicle Modifications 15 Replacement Parts 16 Using Non OEM Replacemen...

Page 14: ...ains attached to the left and right side of the vehicle Failure to properly support the vehicle may result in the vehicle tipping over causing severe bodily injury and or property damage WARNING The v...

Page 15: ...afe operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed accordin...

Page 16: ...nn vehicle To maintain peak performance always use original Taylor Dunn replacement parts intended for use on your vehicle Taylor Dunn components are designed and tested for use on specific Taylor Dun...

Page 17: ...rnings and instructions that are located in the Service Guidelines chapter WARNING Preventative Maintenance Daily Visual Inspection 18 Pre Operation Inspection 18 Maintenance Schedule 18 Interlock Swi...

Page 18: ...iven Rear and side view mirror adjustments Steering operation Brake operation service and park brake Tire pressure visual inspection only Proper operation of trailer hitch This section is one section...

Page 19: ...eck ball joints for play Trailer hitch operation latch wear Every 3 Months or 300 hours All monthly items plus the following Inspect adjust brake Clean battery compartment Inspect and tighten all hard...

Page 20: ...witch ON select a direction and slowly press the throttle pedal The vehicle should operate normally High Pedal Disable HPD Sit in the approved operator position turn the start switch ON Press and hold...

Page 21: ...Table of Contents Special Tool List Special Tool List Controller Programming 22 Troubleshooting Guide 24...

Page 22: ...ing control system Note Part 62 027 31 includes instructions 62 027 00 Test Light Used for testing electrical circuits Switchable for 12 24 36 48 volt systems Required to complete troubleshooting prov...

Page 23: ...rom Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors...

Page 24: ...nd or Low Brake Pedal Air in brake lines Bleed brake system Master cylinder fluid level low Fill master cylinder and bleed system Brake pedal linkage out of adjustment Adjust linkages Hard Brake Pedal...

Page 25: ...Table of Contents Lubrication Lubrication Lubrication and Fluids Chart 26 Hazardous Waste Disposal 26 Lubrication Diagram 27...

Page 26: ...r Oil 9 Fill Plug SD 1 1 4 Liters SAE 80W90 Gear Oil 10 Motor Coupler 1 Part 94 421 34 Moly Paste Grease 11 Fill Level SD Axle 1 0 75 Liters SAE 80W90 Gear Oil HAZARDOUS WASTE DISPOSAL This vehicle co...

Page 27: ...Lubrication Page 27 MR 380 05 RE 380 36 RE 380 48 LUBRICATION DIAGRAM GT Transaxle SD Transaxle...

Page 28: ...Lubrication Page 28 RE 380 36 RE 380 48 MR 380 05 Notes...

Page 29: ...he Service Guidelines chapter WARNING Front Axle Remove 30 Install 31 Disassemble 32 Inspect Front Wheel Bearings 33 Adjust Front Wheel Bearings 33 Front Wheel Alignment 34 Replace Front Wheel Bearing...

Page 30: ...s section for information regarding the removal of the ball joints or rod ends 5 If equipped with front brakes disconnect the hydraulic brake lines from the brake bodies 6 Disconnect the front axle be...

Page 31: ...3 Realign the front wheels Refer to Steering Component Service section for information regarding realigning the front wheels 4 If equipped with front brakes bleed the brakes Refer to Brake Service sec...

Page 32: ...hese procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Refer to Front Axle Removal and In...

Page 33: ...el s off of the ground and support with jack stands 2 While rotating the wheel tighten the front axle nut until the wheel is difficult to rotate 3 Continue to rotate the wheel for 5 compete revolution...

Page 34: ...ew feet to settle the suspension 9 Adjust the right side tie rod so that the right wheel is positioned pointing straight ahead 10 Measure the distance between the lines at the front of the tires 11 Me...

Page 35: ...Raise the front of the vehicle and support with jack stands 2 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 3 Remove the...

Page 36: ...Remember the position and orientation of the clamps 7 Adjust the drag link so that it can be easily inserted into the pitman arm 8 Tighten the ball joint or rod end nut to torque specified in the tabl...

Page 37: ...he front of the vehicle and support with jack stands 2 Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 3 Press the king pin bu...

Page 38: ...IMITS AND SPECIFICATIONS King Pin Bushings Ream or broach to 0 876 0 001 Toe In 0 0 25 inches 6 3 mm HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28 32 37 9 43 4 Rod End Stud...

Page 39: ...Oil 40 Transaxle Assembly 41 Remove and Install 41 Axle Shaft 42 Remove 42 Install 42 Rear Hub Rotor Bearings 43 Motor Remove 43 Primary Gear Case 44 Secondary Gear Case 45 Disassemble 45 Assemble 45...

Page 40: ...rain until level with the bottom of the opening 8 Replace the fill level plug 9 Reconnect the batteries 10 Remove the blocks from the wheels This section is one section of a complete service manual Be...

Page 41: ...gh to allow the removal of the spring mounting bolts and remove the bolts 6 Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle and support with jack stands 7...

Page 42: ...the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage WARNING Install 11 Install in reverse order or removal a Lubricate the bearing external O ring b...

Page 43: ...hind the wheels release the park brake and test drive This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the...

Page 44: ...e position in relation to the 3rd member housing so that it will be reassembled in the same position 12 Remove the six retaining bolts holding the gear case to the 3rd member housing 13 Remove the gea...

Page 45: ...Thoroughly clean all parts This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter...

Page 46: ...to the pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing race ring nut equally Note To move the ring gear away from the pinion Loosen the cover carrier be...

Page 47: ...nce in millimeters from the rear of the drive housing to the face of the pinion gear see illustration Once a shim has been selected and the pinion gear is installed confirm that E D B DV Set Pinion Be...

Page 48: ...9 Drain plug 21 25 28 4 33 Gear case to 3rd member 18 20 24 4 27 3rd Member cover bolts 40 50 54 67 5 Axle hub bolt 275 392 Note Special Washers The washers for the primary gear case housing and carri...

Page 49: ...lines chapter WARNING Transaxle SD Check Oil Level 50 Change Oil 50 Transaxle Assembly 51 Remove and Install 51 Axle Shaft 52 Remove 52 Install 52 Rear Hub Rotor Bearings 53 Motor Remove 53 Primary Re...

Page 50: ...th the bottom of the opening Refer to Lubrication section for oil specification If oil comes out of the opening allow to drain until level with the bottom of the opening 10 Reconnect the batteries and...

Page 51: ...gh to allow the removal of the spring mounting bolts and remove the bolts 6 Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle and support with jack stands 7...

Page 52: ...the axle shaft Use new bolts for the axle retaining plate If the wheel hub was removed install the hub and rotor Torque the hub bolt to the specification listed in the table at the end of this sectio...

Page 53: ...lts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily...

Page 54: ...e all bearings and gears with clean oil 6 Install new seals and wipe the seal lip with grease 7 Place the outer housing on a CLEAN flat bench 8 Brush a small amount of axle oil into the three bearing...

Page 55: ...Transaxle SD Page 55 MR 380 05 RE 380 36 RE 380 48...

Page 56: ...ation is for reference only This assembly is not serviceable with the exception of oil seals HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description...

Page 57: ...hat are located in the Service Guidelines chapter WARNING Steering Inspect Ball Joints 58 Inspect Rod Ends 58 Adjust Steering Gear 59 Front Wheel Alignment 59 Replace Ball Joint 60 Replace Rod End 60...

Page 58: ...re read all warnings and instructions that are located in the Service Guidelines chapter WARNING This section is one section of a complete service manual Before starting any procedure read all warning...

Page 59: ...ing adjuster jam nut 7 Find the center position of the steering shaft a Turn the steering shaft all of the way in one direction b While counting the rotations turn the steering shaft all of the way in...

Page 60: ...drive This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING REPLACE ROD...

Page 61: ...haft splines steering wheel splines and the upper steering shaft bushing 8 Install the steering shaft in reverse order using a new pinch bolt Orientate the shaft so that the pinch bolt is opposite the...

Page 62: ...tion 5 Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration 6 Tighten the steering wheel nut to torque listed in the Hardware To...

Page 63: ...bearing adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing Note The side cover pitman shaft assembly normall...

Page 64: ...upper worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 21 Install the assembled worm bearing adjuster into...

Page 65: ...Steering Page 65 MR 380 05 RE 380 36 RE 380 48 Exploded View of Steering Gear...

Page 66: ...MR 380 05 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28 32 37 9 43 4 Rod End Stud Nut 20 25 27 1 33 9 Rod End Jam Nut 20 25 27 1 33 9 Ball Joint Castle Nut 40 45 54 2 61 S...

Page 67: ...delines chapter WARNING Brakes General Guidelines and Safety 68 Front Brake 69 Service Limits 69 Inspection 69 Replace Pads 69 Rear Brake 70 Service Limits 70 Inspection 70 Replace Pads 70 Rebuild Dis...

Page 68: ...there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as i...

Page 69: ...move fluid from the master cylinder until it is 1 2 full 3 Raise the front of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for informatio...

Page 70: ...2 full 3 Raise the rear of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 5 Remove...

Page 71: ...f of the end of the piston Fig 2 8 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove Fig 3 9 Press the pistons all the way down into the brak...

Page 72: ...at there is still air in the brake lines 10 Repeat this process with each of the other wheels Note When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information...

Page 73: ...area is free from dirt and debris and will contain any brake fluid spills 1 Remove the master cylinder from the vehicle 2 Drain all fluid from the master cylinder and discard 3 Remove the rubber boot...

Page 74: ...the center of the rear left and right brake body on the rear axles 6 Release the park brake 7 Loosen the jam nuts on the Primary Adjustment Rod 8 Tighten the Primary Adjustment Rod until it is difficu...

Page 75: ...d so that the master cylinder push rod IS NOT in contact with the master cylinder plunger when the pedal is released The brakes may drag or lock up if the push rod is in contact with the plunger With...

Page 76: ...appendix Description Foot Pounds Newton Meters Brake Body Bolts 11 14 9 SERVICE LIMITS Description Imperial Metric Disc brake Pad minimum lining 00625 inch 1 58 millimeter Front rotor minimum thickne...

Page 77: ...l Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING SEM Motor Remove Install 78 Disassemble 78 Inspect 79 Brushes 79 Bearing 7...

Page 78: ...screws from the rear motor housing and remove the housing from the motor 6 Remove the nuts from the armature studs and remove the two brush assemblies 7 Remove the bearing circlip and press the motor...

Page 79: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Inspect the commutator for groves If the commutator is grooved then it must be machined...

Page 80: ...ntire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity around the entire co...

Page 81: ...commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut see below 6 While still in the lathe smooth the comm...

Page 82: ...es Armature Field 70 052 40 XP 1876 or DD3 4004 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 73 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0 0116 1 2 70 054 41 XP 1789 or DY2 4001...

Page 83: ...starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Controller Remove Install 84 Inspect 84 Receptacles 84 Base Plate 84 Termina...

Page 84: ...at sink is installed then these bolts may also hold the heat sink to the panel Install 1 Thoroughly clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the cont...

Page 85: ...support field modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the PCpaK application and c...

Page 86: ...ller Page 86 RE 380 36 RE 380 48 MR 380 05 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal stud 38 44 4 29...

Page 87: ...iagram This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Wire Diagram...

Page 88: ...gible when printed at this size The wire diagram for this vehicle is included on the Vehicle Documentation CD provided with the vehicle The diagram s for this vehicle are SCH 00002 This vehicle diagra...

Page 89: ...Wire Diagram Page 89 RE 380 36 RE 380 48 RE 380 36 RE 380 48...

Page 90: ...Wire Diagram Page 90 RE 380 36 RE 380 48 RE 380 36 RE 380 48 Notes...

Page 91: ...gs and instructions that are located in the Service Guidelines chapter WARNING Batteries General Guidelines and Safety 92 Cleaning 93 Charging 93 Watering 93 Testing 94 Specific Gravity 94 Storing 94...

Page 92: ...and or property damage A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in conta...

Page 93: ...olyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the battery at the end of a charging cycle If the elect...

Page 94: ...arting any procedure read all warnings and instructions that are located in the Service Guidelines chapter and beginning of this section WARNING DO NOT attempt to test the specific gravity of a sealed...

Page 95: ...parts of the vehicle as this could cause in a short circuit resulting severe bodily injury or damage to the vehicle WARNING Use the proper equipment when handling and transporting batteries Equipment...

Page 96: ...dual Batteries section for actual battery removal instructions for an individual battery The illustration to the right shows the left bank of a typical battery installation in a vehicle with the 48 vo...

Page 97: ...arting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Inflation 98 Air pressure 98 Tread Wear 99 Rotation 99 Changing Tire Whe...

Page 98: ...ing pulling to the left or right Only check the tire pressure when the tire is cold When checking tire pressure you must check all tires including your spare tire The correct tire size and pressure ca...

Page 99: ...ection of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING DO NOT operate a vehicle if the cord is...

Page 100: ...ir a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the type of repair...

Page 101: ...ires Wheels Page 101 MR 380 05 RE 380 36 RE 380 48 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters Wheel nut 85 115...

Page 102: ...Tires Wheels Page 102 RE 380 36 RE 380 48 MR 380 05 Notes...

Page 103: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Torque Guidelines for Standard hardware 104 Hardware Identificatio...

Page 104: ...olt use grade 2 torque value Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head as illustrated to the right The grade of a metri...

Page 105: ...ock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treat...

Page 106: ...50 16 192 297 420 390 7 8 9 278 429 593 565 14 306 473 818 625 1 8 416 644 909 850 14 466 721 1018 930 1 1 8 7 590 794 1287 1700 12 662 891 1444 1850 1 1 4 7 832 1120 1817 2950 12 922 1241 2012 3330 I...

Page 107: ...6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14 1 38 55 12 1 25 71 1 50 68 1 75 24 64 118 14 1 50 111 2 00 38 103...

Page 108: ...procedure for information regarding proper hardware torque All hardware should be inspected for thread damage or corrosion prior to reassembly If any evidence of damage is found then the hardware shou...

Page 109: ...ear 3rd Member 116 SD TransAxle Assembly Rear Primary Reduction 117 Battery 118 Brakes Brake Lines 120 Brakes Front Axle 122 Brakes Master Cylinder Linkage 123 Brakes Park Brake Linkage 124 Brakes Rea...

Page 110: ...not include special order options that may have been ordered for your vehicle To identify special order options refer to the original vehicle sales order Any special order options will have a K lette...

Page 111: ...Parts Page 111 Not available at time of printing MR 380 05 RE 380 36 RE 380 48 My Vehicle information Serial Number Date Purchased Date Delivered Dealer Purchased From Salesman Name My local Parts De...

Page 112: ...Replacement Parts Page 112 MR 380 05 RE 380 36 RE 380 48 AXLE ASSEMBLY FRONT AXLE SHAFT ASSEMBLY REAR...

Page 113: ...00 Hub W O Disc Standard Axle W O Brakes 2 11 45 338 00 Seal 2 12 14 380 81 Yoke Right Side Without Brakes 1 14 240 07 Yoke Right Side Use with Disc 1 13 21 009 10 King Pin 2 14 12 158 10 Hub Use with...

Page 114: ...Replacement Parts Page 114 MR 380 05 RE 380 36 RE 380 48 GT TRANSAXLE ASSEMBLY REAR...

Page 115: ...1 20 GT 72013 O ring 1 21 GT 3273633 Pinion nut 1 22 GT 71896 Bolt M10 x 25 mm 12 23 See Note Spacer 1 24 see gear kits below Output gear 1 25 PKIT 00018 Shim and spacer kit 1 26 PKIT 00018 Shim and...

Page 116: ...cer 1 7 66 610 67 Vent 1 8 41 989 02 Plug with O ring 1 9 N A Order assembly Housing 1 10 N A Order assembly Cover 1 11 N A Order assembly Gears Ring Pinion 1 12 N A Order assembly Race 1 13 N A Order...

Page 117: ...ction 15 1 0 or 1 44 440 90 Assembly Primary reduction 19 1 0 or 1 44 440 91 Assembly Primary reduction 27 1 0 or 1 44 440 92 Assembly Primary reduction 30 1 0 or 1 1 Kit B Bearing 2 2 Kit B Bearing 1...

Page 118: ...Replacement Parts Page 118 MR 380 05 RE 380 36 RE 380 48 BATTERY...

Page 119: ...75 237 00 Battery jumper 9 75 233 00 Battery jumper 10 25 75 234 00 Battery jumper 22 75 238 00 Battery jumper 31 50 243 10 Battery rod 2 50 250 00 Battery hold down 2 88 088 66 Flat washer tin lead...

Page 120: ...Replacement Parts Page 120 MR 380 05 RE 380 36 RE 380 48 BRAKES BRAKE LINES...

Page 121: ...ont 1 6 99 604 12 Brake line front 1 7 99 580 20 Brake hose Front or Rear 2 8 99 576 00 Hose clip 4 9 99 575 00 Coupler 1 10 99 564 00 T Fitting female 1 11 99 559 00 T Fitting 2 female 1 male 1 12 99...

Page 122: ...08 01 Bushing included in rebuild kit 4 5 41 351 35 Brake body assembly no internally serviceable parts 2 6 99 588 01 Bleeder adaptor 2 7 99 588 00 Bleeder valve 2 8 See rebuild kit Brake pad Inner 2...

Page 123: ...6 4 85 270 00 Spring 1 5 96 772 00 3 8 Clevis Pin 1 6 01 380 76 Support Plate 1 7 32 215 00 Bushing 2 8 00 380 77 Bellcrank 1 9 96 762 00 3 8 Clevis 1 10 88 119 80 3 8NF Hex Nut 1 11 50 009 00 Push R...

Page 124: ...4 380 49 Extension brake handle 1 8 88 527 11 Cotter pin 5 9 96 773 00 Clevis pin 5 10 96 763 00 Clevis 1 11 88 099 80 5 16NF Hex nut 1 12 00 200 48 Park brake linkage handle to equalizer 1 13 04 380...

Page 125: ...mbly right 1 1 Brake body 1 2 32 208 01 Bushing included in rebuild kit 2 3 41 348 58 Spacer included in rebuild kit 4 4 41 350 28 1 Mounting Bracket 2 5 41 350 91 Secondary Plate 2 6a 88 067 21 Bolt...

Page 126: ...er serviceable components inside the charger Note The charger AC cord is an integral part of the charger When replacing the charger do not cut and splice the AC cord Cutting the AC cord will void the...

Page 127: ...46 Charger 48 volt FLA 79 575 09 AC cord 17 foot front cord 79 575 15 Cable AC to charger 79 306 15 Module Interlock with Relay Standard Single Phase AC wire Color Codes as of 2010 Note Older systems...

Page 128: ...Horn 1 4 79 844 00 Main circuit breaker 1 5 72 501 42 ISO solenoid 1 6 88 838 06 14 x 1 2 Sheet metal screw 4 7 88 060 09 1 4NC x 3 4 Hex bolt 4 8 79 840 00 10 Amp circuit breaker 1 9 79 840 20 20 Am...

Page 129: ...1 3 71 039 11 Rocker Switch 1 4 71 039 02 Direction Control Switch 1 5 71 039 11 High Low speed switch optional 1 6 74 010 00 Smart view display 1 7 71 039 35 Horn switch optional on dash 0 or 1 8 71...

Page 130: ...0 DECAL SAFETY WARNING 5X6 E 1 4 94 384 61 DECAL OPS DASH 1 5 94 313 00 DECAL BATTERY WARNING GASES 1 6 94 384 17 DECAL WARNING DO NOT SPRAY 1 7 94 384 14 DECAL LEAVING VEHICLE E 1 8 94 301 57 Door 9...

Page 131: ...ole 96 631 00 not shown Clamp Rubber Lined 3 4 ID 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 631 15 not shown Clamp Rubber Lined 1 1 2 ID 62 033 48 Throttle Module 24 48 volt system 1 71 122 20 Horn...

Page 132: ...8 9 91 011 40 Cab Unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Rubber Channel for Windshield 1 12 90 850 10 Rear Window 1 13 88 065 09 1 4 NC X 3 4 Phillips Head Truss Screw 18 14 88 068 62 1 4...

Page 133: ...acket 1 or 2 9 91 814 16 Left Hinge Female 1 91 814 17 Right Hinge Female 1 10 88 069 81 1 4 NC Locknut 2 11 88 060 22 1 4 NC X 3 1 2 HEX Head Bolt 1 12 88 068 61 1 4 SAE Washer 2 or 4 13 88 065 09 1...

Page 134: ...ide Panel 1 3 88 065 09 1 4 NC X 3 4 Phillips Truss Head Screw 13 4 88 068 61 1 4 SAE Washer 13 5 88 069 81 1 4 NC Locknut 13 6 00 380 85 Tailgate 1 7 00 380 86 Right Tailgate Pivot 1 8 88 082 09 5 16...

Page 135: ...Replacement Parts Page 135 Not available at time of printing MR 380 05 RE 380 36 RE 380 48 FRAME AND BODY P4...

Page 136: ...l Cab Door Kit Left Specify Color Inclds 10 11 12 1 91 011 68 Metal Cab Door Kit Left Orange Incld 10 11 12 1 91 011 67 Metal Cab Door Kit Right Specify Color Inclds 10 11 12 1 91 011 69 Metal Cab Doo...

Page 137: ...07 Left and Right Rear Support Post for Frame 2 3 91 038 08 Front Left Support Post for Frame 1 4 91 038 09 Front Right Support Post for Frame 1 5 88 102 11 3 8 NC X 1 Carriage Bolt 16 6 88 109 81 3 8...

Page 138: ...FRAME AND BODY P6 Item No Part No Description Qty 1 01 380 18 Bumper 1 2 88 109 81 3 8 NC Hex nut 4 3 88 108 61 3 8 SAE Flat washer 4 4 88 100 11 3 8 NC x 1 Hex bolt 4 5 88 080 09 5 16 x 3 4 Hex bolt...

Page 139: ...CHES Mounting Hardware Item No Part No Description Qty 97 811 00 1 7 8 inch Ball 97 821 00 2 inch Ball 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 149 80 1 2NC Hex nut 4 88 148 62 1 2 Split lock washer 4 97...

Page 140: ...em No Part No Description Qty 94 050 11 Headlight assembly Right 1 94 050 10 Headlight assembly Left 1 72 082 01 Bulb 2 72 025 00 Taillight 2 72 023 59 Strobe light 0 or 1 72 082 10 Bulb Front turn si...

Page 141: ...ng bracket left Steel cab 1 92 202 13 Mounting bracket right Steel Cab 1 91 814 16 Hinge left used with 92 202 12 1 91 814 17 Hinge right used with 92 202 13 1 92 202 15 Spacer used with 92 202 12 and...

Page 142: ...70 170 00 Holder 1 6 PKIT 00064 Brushes includes springs 1 7 70 417 00 Retainer 1 8 PKIT 00011 Bearing includes retainer 1 9 70 421 20 Rear housing 1 10 70 421 00 Cover 1 11 95 930 00 Dust cap 1 SEATS...

Page 143: ...8 72 Worm assembly 1 4 18 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer...

Page 144: ...Replacement Parts Page 144 MR 380 05 RE 380 36 RE 380 48 STEERING LINKAGE...

Page 145: ...Washer 8 10 97 211 30 3 8 U Nut 4 11 20 031 64 Steering Shaft 1 12 18 308 21 Steering Gear 1 13 88 128 62 7 16 Lockwasher 3 14 88 120 11 7 16 X1 Hex Head Cap Screw 3 15 00 680 13 Pitman Arm 1 16 50 0...

Page 146: ...Hex Head Nut 4 2 86 006 01 Shock Mounting Hardware 2 3 86 006 00 Shock Absorber 2 4 See Front Axle Axle Beam 5 88 121 19 7 16 X 2 3 4 NC Hex Cap Screw GR5 2 6 85 506 01 2 Leaf Spring 2 7 01 680 61 Spr...

Page 147: ...07 00 Spring 2 2 16 870 10 Spring hanger 4 3 32 213 00 Bushing 6 4 96 248 00 Hex bolt 6 5 88 169 81 Hex lock nut 6 6 96 114 00 U bolt 4 7 88 159 84 Hex lock nut 8 8 16 861 42 Spring plate left 1 16 86...

Page 148: ...x 8 Man Toter 13 742 11 5 70 x 8 Split Rim 13 746 10 8 50 x 8 13 742 50 5 00 x 8 Soft Solid Non Marking Misc 97 236 00 Wheel Nut 13 989 00 Valve stem tubeless tire only TURN SIGNALS Item No Part No De...

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Page 150: ...other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequ...