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

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Enlarged version
T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
B
Service and Replacement
Parts Manual
modelnumber
Model Numbers:
RE-380-36
RE-380-48
Ending Serial Number: See Introduction Chapter
MANUAL: MR-380-05
Starting Serial Number: 207500

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Summary of Contents for Taylor-Dunn RE-380-36

  • Page 1 Service and Replacement Parts Manual MANUAL: MR-380-05 modelnumber Model Numbers: RE-380-36 RE-380-48 T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s WARNING READ THE OPERATOR’S MANUAL BEFORE OPERATING...
  • Page 2 Service Advisor at your local dealership. Taylor-Dunn has a worldwide dealer and distribution network to provide replacement 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 without notice ®...
  • Page 3 Taylor-Dunn Contact information Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement 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.
  • Page 4 Decades of experience are an 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 international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving. Tiger Tractor: Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment.

  • Page 5: Table Of Contents

    Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Preventative Maintenance ......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...
  • Page 7 Table of Contents Introduction About this manual ...........8 Who Should Read This Manual ......8 How To Use This Manual ........8 Conventions ............9 Signal Words and Their Definitions: ......9 Responsibilities ..........10 How to Identify Your Vehicle ......11 Web Site Registration ........11 WARNING This section is one section of a complete service manual.

  • Page 8: Introduction

    Taylor-Dunn is not to be held liable for errors in this manual or any consequential damage that results from the use of this manual.

  • Page 9: Introduction

    Introduction RE-380-36 & RE-380-48 Conventions Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be used elsewhere in the text of this document without being a signal word.

  • Page 10: Responsibilities

    Of the Service Personnel... WARNING The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.

  • Page 11: How To Identify Your Vehicle

    WEB SITE REGISTRATION Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor- Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside of the Taylor-Dunn corporation.
  • Page 12 Notes Introduction RE-380-36 & RE-380-48 Page-12 MR-380-05...

  • Page 13: Service/Maintenance Guidelines

    Table of Contents Service/Maintenance Guidelines READ ME FIRST-Maintenance Guidelines and General instructions .........14 Vehicle Modifications ........15 Replacement Parts ..........16 Using Non-OEM Replacement Components ...16...

  • Page 14: Service/Maintenance Guidelines

    BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the Start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Vehicle Modifications

    Contact the factory for information regarding available alternate program settings. Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle. Any other alterations to the programming ARE NOT AUTHORIZED and is at your own risk.

  • Page 16: Replacement Parts

    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-Dunn model vehicles. Only use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.

  • Page 17: Preventative Maintenance

    Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 Interlock Switch Inspection ......20 Start Switch ............20 Charger Interlock Switch .........20 High Pedal Disable (HPD) ........20 Operator Presence Switch ........20 Brake Interlock Switch ..........20 WARNING This section is one section of a complete service manual.

  • Page 18: Daily Visual Inspection

    PM Schedule RE-380-36 & RE-380-48 DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...
  • Page 19 PM Schedule RE-380-36 & RE-380-48 Every Week Every 3 Months or 300 hours • All daily items plus the following: • All monthly items plus the following: • Battery electrolyte level • Inspect/adjust brake • Check tire tread for debris •...

  • Page 20: Interlock Switch Inspection

    PM Schedule RE-380-36 & RE-380-48 INTERLOCK SWITCH INSPECTION The interlock switches should disable vehicle operation when activated. Perform the following to confirm proper operation. If any one test fails, then immediately remove the vehicle from service and refer repair to a qualified technician.

  • Page 21: Special Tool List

    Table of Contents Special Tool List Controller Programming: .........22 Troubleshooting Guide ........24...
  • Page 22 Tool List RE-380-36 & RE-380-48 Tool List The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness Tests the throttle module in or out of the...
  • Page 23 Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not rectangular harness connectors. Not available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. MR-380-05...
  • Page 24 Tool List RE-380-36 & RE-380-48 TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom.

  • Page 25: Lubrication

    Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication RE-380-36 & RE-380-48 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 3: Ball Joint NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease 2: King Pin NLGI Grade 2 lithium multi-purpose grease...
  • Page 27 Lubrication RE-380-36 & RE-380-48 LUBRICATION DIAGRAM GT Transaxle SD Transaxle MR-380-05 Page 27...
  • Page 28 Notes Lubrication RE-380-36 & RE-380-48 Page 28 MR-380-05...

  • Page 29: Front Axle

    Table of Contents 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 Bearings.......35 Replace Steering Knuckle ......35 Center the Steering .........36 Replace King Pin/Bushings ......37 Service Limits and Specifications ....38 King Pin Bushings ...........38 Toe In ...............38 Hardware Torque ..........38...

  • Page 30: Front Axle

    Front Axle RE-380-36 & RE-380-48 REMOVE WARNING 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. 1: Raise the front of the vehicle and support with jack stands.

  • Page 31: Install

    Front Axle RE-380-36 & RE-380-48 INSTALL WARNING 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. 1: Raise the front of the vehicle and support with jack stands.

  • Page 32: Disassemble

    Front Axle RE-380-36 & RE-380-48 DISASSEMBLE WARNING 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. Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings.

  • Page 33: Inspect Front Wheel Bearings

    Front Axle RE-380-36 & RE-380-48 INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 34: Front Wheel Alignment

    Front Axle RE-380-36 & RE-380-48 FRONT WHEEL ALIGNMENT WARNING 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. Note: It is recommended to center the steering before aligning the front wheels. Refer to the Center the Steering section for information.

  • Page 35: Replace Front Wheel Bearings

    Front Axle RE-380-36 & RE-380-48 REPLACE FRONT WHEEL REPLACE STEERING KNUCKLE BEARINGS WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 36: Center The Steering

    Front Axle RE-380-36 & RE-380-48 CENTER THE STEERING 1: Raise the front of the vehicle and support with jack stands. 2: Turn the front wheels so that they are in the straight ahead position and then tie off the wheels so that they cannot turn from the straight ahead position.

  • Page 37: Replace King Pin/Bushings

    Front Axle RE-380-36 & RE-380-48 REPLACE KING PIN/BUSHINGS WARNING 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. There are different types of king pin bushings depending on the configuration of your vehicle. This is a generic procedure that covers all three types of bushings.

  • Page 38: Service Limits And Specifications

    Front Axle RE-380-36 & RE-380-48 SERVICE LIMITS AND HARDWARE TORQUE SPECIFICATIONS Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 King Pin Bushings Rod End Stud Nut 20-25 27.1-33.9 Ream or broach to 0.876 ±0.001 Rod End Jam Nut 20-25 27.1-33.9...

  • Page 39: Transaxle-Gt

    Table of Contents Transaxle-GT Check Oil Level ..........40 Change Oil ............40 Transaxle Assembly ........41 Remove and Install ..........41 Axle Shaft ............42 WARNING Remove ..............42 Install ...............42 Rear Hub, Rotor & Bearings ......43 This section is one section of a complete service Motor, Remove ..........43 manual.

  • Page 40: Transaxle-Gt

    Transaxle - GT RE-380-36 & RE-380-48 CHECK OIL LEVEL CHANGE OIL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 41: Transaxle Assembly

    Transaxle - GT RE-380-36 & RE-380-48 TRANSAXLE ASSEMBLY WARNING 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. Note: The transmission assembly will be removed with the springs attached. Refer to Suspension section for information regarding removing the springs.

  • Page 42: Axle Shaft

    Transaxle - GT RE-380-36 & RE-380-48 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 43: Rear Hub, Rotor & Bearings

    Transaxle - GT RE-380-36 & RE-380-48 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications will require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and Installing This section is one section of a complete service the Drive Assembly for information on manual.

  • Page 44: Primary Gear Case

    Transaxle - GT RE-380-36 & RE-380-48 PRIMARY GEAR CASE WARNING 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. 1: Disconnect the batteries.

  • Page 45: Secondary Gear Case

    Transaxle - GT RE-380-36 & RE-380-48 SECONDARY GEAR CASE WARNING 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. Disassemble 1: Remove the transaxle assembly from the vehicle.
  • Page 46 Transaxle - GT RE-380-36 & RE-380-48 13: Install the differential assembly. 14: Install the cover and all of the cover bolts and washers. See note regarding special washers at the end of this section. Torque per torque listed in the Hardware Torque table at the end of this section.

  • Page 47: Pinion Bearing Preload

    Transaxle - GT RE-380-36 & RE-380-48 PINION BEARING PRELOAD WARNING 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. Pinion Gear Shimming Instructions Note: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears.

  • Page 48: Hardware Torque

    Transaxle - GT 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 Pinion nut 154-169 209229 Drain plug 21-25 28.4-33 Gear case to 3rd member 18-20 24.4-27...

  • Page 49: Transaxle-Sd

    Table of Contents Transaxle-SD Check Oil Level ..........50 Change Oil ............50 Transaxle Assembly ........51 Remove and Install ..........51 WARNING Axle Shaft ............52 Remove ..............52 Install ...............52 Rear Hub, Rotor & Bearings ......53 This section is one section of a complete service Motor, Remove ..........53 manual.

  • Page 50: Transaxle-Sd

    Transaxle - SD RE-380-36 & RE-380-48 CHECK OIL LEVEL CHANGE OIL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 51: Transaxle Assembly

    Transaxle - SD RE-380-36 & RE-380-48 TRANSAXLE ASSEMBLY WARNING 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. Note: The transmission assembly will be removed with the springs attached. Refer to Suspension section for information regarding removing the springs.

  • Page 52: Axle Shaft

    Transaxle - SD RE-380-36 & RE-380-48 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 53: Rear Hub, Rotor & Bearings

    Transaxle - SD RE-380-36 & RE-380-48 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications may require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and This section is one section of a complete service Installing the Drive Assembly for information manual.

  • Page 54: Primary Reduction Gear Case

    Transaxle - SD RE-380-36 & RE-380-48 PRIMARY REDUCTION GEAR CASE WARNING 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.
  • Page 55 Transaxle - SD RE-380-36 & RE-380-48 MR-380-05 Page 55...

  • Page 56: 3Rd Member

    Transaxle - SD RE-380-36 & RE-380-48 3RD MEMBER WARNING 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.

  • Page 57: Steering

    Table of Contents 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 Replace Steering Shaft ........61 Replace Steering Wheel ........62 Steering Gear ...........63 Disassemble ............63 Reassemble ............64 Exploded View of Steering Gear ......65 Hardware Torque ..........66...

  • Page 58: Inspect Ball Joints

    Steering RE-380-36 & RE-380-48 INSPECT BALL JOINTS INSPECT ROD ENDS WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 59: Adjust Steering Gear

    Steering RE-380-36 & RE-380-48 ADJUST STEERING GEAR WARNING 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. Note: In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure.

  • Page 60: Replace Ball Joint

    Steering RE-380-36 & RE-380-48 REPLACE BALL JOINT WARNING 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. 1: Raise the front of the vehicle and support with jack stands.

  • Page 61: Replace Steering Shaft

    Steering RE-380-36 & RE-380-48 REPLACE STEERING SHAFT WARNING WARNING This section is one section of a complete service Do not reuse the original pinch bolt and nut. Failure manual. Before starting any procedure, read all to replace the pinch bolt and nut may result in...

  • Page 62: Replace Steering Wheel

    Steering RE-380-36 & RE-380-48 REPLACE STEERING WHEEL WARNING 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. Note: The steering wheel is on a tapered shaft and may be damaged when it is removed. 1: If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch.

  • Page 63: Steering Gear

    Steering RE-380-36 & RE-380-48 STEERING GEAR WARNING 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. Disassemble Note: The steering gear must be removed from the vehicle for this procedure.

  • Page 64: Reassemble

    Steering RE-380-36 & RE-380-48 Reassemble 12: Lightly lubricate all parts before reassembly. 13: Install a new worm shaft seal and pitman shaft seal into the housing. 14: Install the upper worm bearing cup. 15: Divide the ball bearing into two equal groups.

  • Page 65: Exploded View Of Steering Gear

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

  • Page 66: Hardware Torque

    Steering RE-380-36 & RE-380-48 HARDWARE TORQUE Notes 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 Steering Wheel Nut 28-32 38-43...

  • Page 67: Brakes

    Table of Contents 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 Disc Brake Body ........71 Bleed System ...........72 Flush System ...........72 Master Cylinder..........73 Add Fluid ..............73 Rebuild ..............73...

  • Page 68: General Guidelines And Safety

    RE-380-36 & RE-380-48 GENERAL GUIDELINES AND SAFETY WARNING WARNING Taylor-Dunn does not currently supply asbestos This section is one section of a complete service fiber-brake pads/shoes with any vehicle. However, manual. Before starting any procedure, read all there is the possibility that the original brake pads/...

  • Page 69: Front Brake

    Brakes RE-380-36 & RE-380-48 FRONT BRAKE WARNING 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. Service Limits Refer to the table at the end of this section...

  • Page 70: Rear Brake

    Brakes RE-380-36 & RE-380-48 REAR BRAKE WARNING 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. Service Limits Refer to the table at the end of this section Note: Service Limits are listed in a table at the end of this section.

  • Page 71: Rebuild Disc Brake Body

    Brakes RE-380-36 & RE-380-48 REBUILD DISC BRAKE BODY WARNING 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. This procedure assumes that the component has been removed from the vehicle.

  • Page 72: Bleed System

    Brakes RE-380-36 & RE-380-48 FLUSH SYSTEM BLEED SYSTEM 1: Raise the rear wheels off of the ground and WARNING support with jack stands. 2: If equipped with front brakes, raise the front This section is one section of a complete service wheels off of the ground and support with jack manual.

  • Page 73: Master Cylinder

    Brakes RE-380-36 & RE-380-48 MASTER CYLINDER WARNING 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. Add Fluid 1: Thoroughly clean the area around the master cylinder cap and remove the cap.

  • Page 74: Parking Brake

    Brakes RE-380-36 & RE-380-48 PARKING BRAKE WARNING 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. The brake pads and rotor should be inspected anytime the park brake requires adjustment.

  • Page 75: Pedal Linkage

    Brakes RE-380-36 & RE-380-48 PEDAL LINKAGE The pedal linkage to the master cylinder must be adjusted 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.

  • Page 76: Service Limits

    Brakes RE-380-36 & RE-380-48 HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc brake Pad minimum lining 00625 inch 1.58 millimeter Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch...

  • Page 77: Sem Motor

    Table of Contents SEM Motor Remove/Install ..........78 Disassemble.............78 Inspect ..............79 Brushes ..............79 Bearing ..............79 Commutator .............79 Armature Windings ..........79 Field Windings ............80 Repair ...............81 Service Limits ..........82 WARNING 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 78: Remove/Install

    Motor SEM RE-380-36 & RE-380-48 REMOVE/INSTALL DISASSEMBLE WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 79: Inspect

    Motor SEM RE-380-36 & RE-380-48 INSPECT Inspect the commutator for groves. WARNING • If the commutator is grooved then it must be machined on a lathe. Do not machine the This section is one section of a complete service commutator past the minimum diameter specified manual.

  • Page 80: Field Windings

    Motor SEM RE-380-36 & RE-380-48 Inspect the armature windings where they loop back at Using the continuity function of digital multi meter, check the opposite end of the commutator. the continuity from any one of the commutator segments • If the windings show indications of expanding (see and the armature frame.

  • Page 81: Repair

    Motor SEM RE-380-36 & RE-380-48 REPAIR WARNING 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. The only recommended repair to a motor is cutting the commutator. If any other components are damaged then they should be replaced.

  • Page 82: Service Limits

    Motor SEM RE-380-36 & RE-380-48 SERVICE LIMITS WARNING 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. This is a generic section covering all currently available SEM motors at the time this manual was revised.
  • Page 83 Table of Contents Motor Controller Remove/Install ..........84 Inspect ..............84 Receptacles .............84 Base Plate ...............84 Terminal Ends ............84 ’R’ Terminal ..............84 Repair/Programming ........85 Programming ............85 Troubleshooting ..........85 Hardware Torque ..........86 WARNING 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 84: Motor Controller

    Motor Controller RE-380-36 & RE-380-48 REMOVE/INSTALL INSPECT WARNING Receptacles The inside of each receptacle should be clean and free This section is one section of a complete service of any debris. Use aerosol electrical cleaner if required. manual. Before starting any procedure, read all...

  • Page 85: Motor Controller

    This manual was provided on the original vehicle CD. A hard copy can be purchased from your authorized NOTICE Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. The controller power base and logic are a matched set. DO NOT swap logics from one base to another as this may damage the logic or power base.

  • Page 86: Hardware Torque

    Motor Controller RE-380-36 & RE-380-48 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the Notes appendix. Description Inch Pounds Newton Meters Terminal stud 38-44 4.29-4.97 Page 86 MR-380-05...

  • Page 87: Wire Diagram

    Table of Contents Wire Diagram Diagram Part Numbers........88 WARNING 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 88 Wire diagrams are too large to be legible 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 diagram as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Page 88...
  • Page 89 Wire Diagram RE-380-36 & RE-380-48 RE-380-36 & RE-380-48 Page 89...
  • Page 90 Notes Wire Diagram RE-380-36 & RE-380-48 Page 90 RE-380-36 & RE-380-48...

  • Page 91: Batteries

    Table of Contents Batteries General Guidelines and Safety.......92 Cleaning ............93 Charging ............93 Watering ............93 Testing ..............94 Specific Gravity ............94 Storing ..............94 Storage ..............94 Returning to Service ..........94 Remove/Install ..........95 Individual Batteries ..........95 Battery removal, 48 Volt System ......96 Hardware Torque ..........96 WARNING This section is one section of a complete service manual.

  • Page 92: General Guidelines And Safety

    Batteries RE-380-36 & RE-380-48 GENERAL GUIDELINES AND SAFETY WARNING NOTICE Battery electrolyte will stain and corrode most This section is one section of a complete service surfaces. Immediately and thoroughly clean any manual. Before starting any procedure, read all surface outside of the battery that the battery warnings and instructions that are located in the electrolyte comes in contact with.

  • Page 93: Cleaning

    Batteries RE-380-36 & RE-380-48 CLEANING WATERING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 94: Testing

    Batteries RE-380-36 & RE-380-48 TESTING STORING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all...

  • Page 95: Remove/Install

    Batteries RE-380-36 & RE-380-48 REMOVE/INSTALL WARNING WARNING This section is one section of a complete service Do not allow the loose battery cables to contact any manual. Before starting any procedure, read all other parts of the vehicle as this could cause in a...

  • Page 96: Battery Removal, 48 Volt System

    Batteries RE-380-36 & RE-380-48 Battery removal, 48 Volt System Batteries for the 48 volt system are packed into a small area and requires a specific procedure to get them out of the vehicle. Refer to Individual Batteries section for actual battery removal instructions for an individual battery.

  • Page 97: Tires & Wheels

    Table of Contents Tires & Wheels Inflation .............98 Air pressure .............98 Tread Wear ............99 Rotation ............99 Changing Tire/Wheel Assembly .....100 Replace the Tire (pneumatic) ......100 Repair the Tire (pneumatic) ......100 Hardware Torque ..........101 WARNING This section is one section of a complete service manual.

  • Page 98: Tires & Wheels

    Tires & Wheels RE-380-36 & RE-380-48 INFLATION WARNING WARNING Incorrect tire inflation can result in sudden failure of This section is one section of a complete service the tire and/or braking / steering problems leading manual. Before starting any procedure, read all to loss of control of the vehicle.

  • Page 99: Tread Wear

    Tires & Wheels RE-380-36 & RE-380-48 TREAD WEAR WARNING WARNING This section is one section of a complete service DO NOT operate a vehicle if the cord is manual. Before starting any procedure, read all visible on any tire (see illustration). A tire...

  • Page 100: Changing Tire/Wheel Assembly

    Tires & Wheels RE-380-36 & RE-380-48 CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) WARNING ASSEMBLY WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the This section is one section of a complete service Service Guidelines chapter.

  • Page 101: Hardware Torque

    Tires & Wheels 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 MR-380-05 Page 101...
  • Page 102 Notes Tires & Wheels RE-380-36 & RE-380-48 Page 102 MR-380-05...

  • Page 103: Hardware Information

    Table of Contents Hardware Information Torque Guidelines for Standard hardware ..104 Hardware Identification ..........104 Hex Nuts ..............105 Hex Lock Nuts (stover) ..........105 Other Nuts ...............105 Generic Torque Values ..........106 Replacing Hardware ........108 WARNING This section is one section of a complete service manual.

  • Page 104: Torque Guidelines For Standard Hardware

    Hardware RE-380-36 & RE-380-48 TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, 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 metric hex head bolt or screw is cast directly on the head.

  • Page 105: Hex Nuts

    ‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’. NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts Other nuts used by Taylor-Dunn ® should be treated as S.A.E. grade A MR-380-05 Page 105...

  • Page 106: Generic Torque Values

    Hardware RE-380-36 & RE-380-48 Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values.
  • Page 107 Hardware RE-380-36 & RE-380-48 All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values.

  • Page 108: Replacing Hardware

    Hardware RE-380-36 & RE-380-48 REPLACING HARDWARE WARNING 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 Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
  • Page 109 Replacement Parts Ordering Parts for Your Vehicle .....110 Note: Your vehicle may have been ordered with Taylor-Dunn Web Site Information ....110 special order options. These options typically Axle Assembly, Front ........112 start with the letter “K”. Refer to your vehicle sales Axle Shaft Assembly, Rear ......112...

  • Page 110: Replacement Parts

    ORDERING PARTS FOR YOUR VEHICLE WARNING The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.
  • Page 111 Replacement Parts RE-380-36 & RE-380-48 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MR-380-05 * Not available at time of printing Page 111...

  • Page 112: Axle Assembly, Front

    Replacement Parts RE-380-36 & RE-380-48 AXLE ASSEMBLY, FRONT AXLE SHAFT ASSEMBLY, REAR Page 112 MR-380-05...
  • Page 113 Replacement Parts RE-380-36 & RE-380-48 Axle Assembly, Front Item No. Part No. Description 14-380-80 Yoke, Left Side, Without Brakes 14-240-08 Yoke, Left Side, Use with Disc Brakes 15-380-33 Front Axle Beam 80-309-10 Bearing Pack 88-289-81 80-103-00 Bearing Race 88-239-85 3/4”NF, Slotted Nut...

  • Page 114: Gt Transaxle Assembly, Rear

    Replacement Parts RE-380-36 & RE-380-48 GT TRANSAXLE ASSEMBLY, REAR Page 114 MR-380-05...
  • Page 115 Replacement Parts RE-380-36 & RE-380-48 GT Axle Assembly, Rear Item No. Part No. Description GT-71682 Bolt, M8 x 60 mm GT-3287563 Gear case cover GT-71259 Bearing see gear kits below Input shaft GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing see gear kits below...

  • Page 116: Sd Transaxle Assembly, Rear 3Rd Member

    Replacement Parts RE-380-36 & RE-380-48 SD TRANSAXLE ASSEMBLY, REAR 3RD MEMBER Illustration is for reference only. This assembly as not serviceable with the exception of oil seals. Item No. Part No. Description 44-440-93 Complete 3rd member assembly Bolt N/A - Order assembly...

  • Page 117: Sd Transaxle Assembly, Rear Primary Reduction

    Replacement Parts RE-380-36 & RE-380-48 SD TRANSAXLE ASSEMBLY, REAR PRIMARY REDUCTION Item No. Part No. Description 44-440-89 Assembly, Primary reduction, 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...

  • Page 118: Battery

    Replacement Parts RE-380-36 & RE-380-48 BATTERY Page 118 MR-380-05...
  • Page 119 Replacement Parts RE-380-36 & RE-380-48 Item No. Part No. Description 77-043-00 210AH, T-605 77-042-00 225AH, T-105 77-047-00 260AH, T-145 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 50-250-00 Battery hold down...

  • Page 120: Brakes, Brake Lines

    Replacement Parts RE-380-36 & RE-380-48 BRAKES, BRAKE LINES Page 120 MR-380-05...
  • Page 121 Replacement Parts RE-380-36 & RE-380-48 Brake Lines Item No. Part No. Description 99-604-70 Brake Line, Right Front 99-604-71 Brake Line, Left Front 99-605-78 Brake Line, Right Rear 99-605-79 Brake Line, Left Rear 99-607-10 Brake line, front 99-604-12 Brake line, front...

  • Page 122: Brakes, Front Axle

    Replacement Parts RE-380-36 & RE-380-48 BRAKES, FRONT AXLE Front Brakes Item No. Part No. Description 88-067-21 Bolt 88-069-82 41-350-91 Plate, Secondary 41-348-58 Spacer 32-208-01 Bushing (included in rebuild kit) 41-351-35 Brake body assembly (no internally serviceable parts) 99-588-01 Bleeder adaptor...

  • Page 123: Brakes, Master Cylinder Linkage

    Replacement Parts RE-380-36 & RE-380-48 BRAKES, MASTER CYLINDER LINKAGE Item No. Part No. Description 00-380-90 Brake Rod 88-109-81 3/8NC Lock Nut 88-108-61 3/8 SAE Flat Washer 85-270-00 Spring 96-772-00 3/8 Clevis Pin 01-380-76 Support Plate 32-215-00 Bushing 00-380-77 Bellcrank 96-762-00...

  • Page 124: Brakes, Park Brake Linkage

    Replacement Parts RE-380-36 & RE-380-48 BRAKES, PARK BRAKE LINKAGE Item No. Part No. Description 51-344-80 Park brake lever 88-080-11 5/16NV x 1 Hex bolt 96-826-08 Brake cable 88-089-81 5/16NV Hex lock nut 88-088-61 5/16 SAE Flat washer 96-826-09 Cable lock...

  • Page 125: Brakes, Rear Axle

    Replacement Parts RE-380-36 & RE-380-48 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-351-80 (see note) Complete caliper assembly (left) 41-351-81 (see note) Complete caliper assembly (right) Brake body 32-208-01 Bushing (included in rebuild kit) 41-348-58 Spacer (included in rebuild kit)

  • Page 126: Charger, Signet

    Replacement Parts RE-380-36 & RE-380-48 CHARGER, SIGNET Note: The harness connectors and AC plug are not included with the charger. Model HBS Charger PART # DESCRIPTION 79-309-42 48 volt Flooded Batteries (WET, FLA) 79-309-43 48 volt Sealed Batteries (GEL, SLA, AGM) Note: There are no user serviceable components inside the charger Note: The charger AC cord is an integral part of the charger. When replacing the charger, do not cut...

  • Page 127: Charger, Summit

    Replacement Parts RE-380-36 & RE-380-48 CHARGER, SUMMIT Note: There are no user serviceable components inside the charger Part No. Description 79-306-37 Charger, 36 volt FLA 79-309-46 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.

  • Page 128: Control System, Motor Speed Control

    Replacement Parts RE-380-36 & RE-380-48 CONTROL SYSTEM, MOTOR SPEED CONTROL Speed Control Panel Item No. Part No. Description 62-400-05 Speed controller 01-200-07 Mounting panel 73-004-20 Horn 79-844-00 Main circuit breaker 72-501-42 ISO solenoid 88-838-06 #14 x 1/2 Sheet metal screw...

  • Page 129: Control System, Instrument Panel

    Replacement Parts RE-380-36 & RE-380-48 CONTROL SYSTEM, INSTRUMENT PANEL Item No. Part No. Description 771-039-11 Rocker Switch 71-039-11 Rocker Switch 71-039-11 Rocker Switch 71-039-02 Direction Control Switch 71-039-11 High/Low speed switch (optional) 74-010-00 Smart view display 71-039-35 Horn switch (optional on dash)

  • Page 130: Decals

    Replacement Parts RE-380-36 & RE-380-48 DECALS Item No. Part No. Description 94-301-42 DECAL, ARMS/LEGS, 2 PASS 94-319-00 DECAL, BATTERY DISCONNECT (E) 94-313-20 DECAL, SAFETY WARNING, 5X6 (E) 94-384-61 DECAL, OPS, DASH 94-313-00 DECAL, BATTERY WARNING (GASES) 94-384-17 DECAL, WARNING,DO NOT SPRAY...

  • Page 131: Electrical, Miscellaneous

    Replacement Parts RE-380-36 & RE-380-48 ELECTRICAL, MISCELLANEOUS Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01...

  • Page 132: Frame And Body (P1)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P1) Cab and Windshield Item No. Part No. Description 90-825-20 Plexiglas Windshield 90-825-06 Right Windshield Mounting Bracket 90-825-05 Left Windshield Mounting Bracket 88-060-09 1/4”NC X 3/4” HEX Head Bolt 88-068-62 1/4” Lock washer 88-069-83 1/4”NC Acorn Nut...

  • Page 133: Frame And Body (P2)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P2) Cab Accessories Item No. Part No. Description 72-023-20 Strobe Light, Amber 88-025-06 #8-32 X 1/2” Truss Head Screw 88-028-62 #8 Lock washer 88-029-80 #8-32 Nut 98-606-00 3/16” ID Grommet 92-201-00 4-1/2” X 8-1/2” Mirror...

  • Page 134: Frame And Body (P3)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P3) 9” Side Panels Item No. Part No. Description 03-380-38 Left Side Panel 03-380-37 Right Side Panel 88-065-09 1/4”NC X 3/4” Phillips Truss Head Screw 88-068-61 1/4”SAE Washer 88-069-81 1/4”NC Locknut 00-380-85...

  • Page 135: Frame And Body (P4)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P4) MR-380-05 * Not available at time of printing Page 135...
  • Page 136 Replacement Parts RE-380-36 & RE-380-48 Doors Item No. Part No. Description 90-924-60 Left Door Kit 90-924-61 Right Door Kit 90-923-98 Left Door Frame 90-923-99 Right Door Frame 90-924-98 Left Side Curtain 90-924-99 Right Side Curtain 97-315-53 Outer Handle Assembly 97-315-51...

  • Page 137: Frame And Body (P5)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P5) Item No. Part No. Description 91-038-00 Tubular Frame 91-038-07 Left and Right Rear Support Post for Frame 91-038-08 Front Left Support Post for Frame 91-038-09 Front Right Support Post for Frame 88-102-11 3/8”NC X 1”...

  • Page 138: Frame And Body (P6)

    Replacement Parts RE-380-36 & RE-380-48 FRAME AND BODY (P6) Item No. Part No. Description 01-380-18 Bumper 88-109-81 3/8-NC Hex nut 88-108-61 3/8 SAE Flat washer 88-100-11 3/8-NC x 1 Hex bolt 88-080-09 5/16 x 3/4 Hex bolt 04-380-23 Splash pan...

  • Page 139: Hitches

    Replacement Parts RE-380-36 & RE-380-48 HITCHES Mounting Hardware Item No. Part No. Description 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 88-149-80 1/2NC Hex nut 88-148-62 1/2 Split lock washer 97-835-00 Weldment, Angle for Mounting Bracket...

  • Page 140: Lights

    Replacement Parts RE-380-36 & RE-380-48 LIGHTS Item No. Part No. Description 94-050-11 Headlight assembly, Right 94-050-10 Headlight assembly, Left 72-082-01 Bulb 72-025-00 Taillight 72-023-59 Strobe light 0 or 1 72-082-10 Bulb, Front turn signal 0 or 2 71-141-22 Switch , Turn Signal...

  • Page 141: Mirrors

    Replacement Parts RE-380-36 & RE-380-48 MIRRORS Mirrors Item No. Part No. Description 92-201-00 Mirror, rectangular, 4-1/2 x 8-1/2 (side view) 92-202-12 Mounting bracket, left, Steel cab 92-202-13 Mounting bracket, right, Steel Cab 91-814-16 Hinge, left (used with 92-202-12) 91-814-17 Hinge, right (used with 92-202-13...

  • Page 142: Motor

    Replacement Parts RE-380-36 & RE-380-48 MOTOR Motor Spec # DD3-4004 Item No. Part No. Description 70-052-40 Motor Assembly Front housing Armature Field PKIT-00022 Spring (4) 70-170-00 Holder PKIT-00064 Brushes (includes springs) 70-417-00 Retainer PKIT-00011 Bearing (includes retainer) 70-421-20 Rear housing...

  • Page 143: Steering Gear

    Replacement Parts RE-380-36 & RE-380-48 STEERING GEAR Steering Gear, 18-308-21 Item No. Part No. Description 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assembly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft...

  • Page 144: Steering Linkage

    Replacement Parts RE-380-36 & RE-380-48 STEERING LINKAGE Page 144 MR-380-05...
  • Page 145 Replacement Parts RE-380-36 & RE-380-48 Steering Linkage Item No. Part No. Description 19-011-25 Steering Wheel Cover 88-199-82 5/8”NF Hex Head Jam Nut 19-011-20 Steering Wheel, 3 Spoke 97-200-00 Dust Washer 32-248-10 3/4” ID Bushing 00-680-15 Steering Column 88-100-11 3/8” X 1” NC Hex Head Screw 88-108-62 3/8”...

  • Page 146: Suspension, Front

    Replacement Parts RE-380-36 & RE-380-48 SUSPENSION, FRONT Front Suspension Item No. Part No. Description 88-119-80 3/8” NF Hex Head Nut 86-006-01 Shock Mounting Hardware 86-006-00 Shock Absorber See Front Axle Axle Beam 88-121-19 7/16” X 2-3/4”NC Hex Cap Screw GR5...

  • Page 147: Suspension, Rear

    Replacement Parts RE-380-36 & RE-380-48 SUSPENSION, REAR Item No. Part No. Description 85-507-00 Spring 16-870-10 Spring hanger 32-213-00 Bushing 96-248-00 Hex bolt 88-169-81 Hex lock nut 96-114-00 U-bolt 88-159-84 Hex lock nut 16-861-42 Spring plate, left 16-861-43 Spring plate, right...

  • Page 148: Windshield Wiper

    Replacement Parts RE-380-36 & RE-380-48 WINDSHIELD WIPER Item No. Part No. Description 74-050-00 Wiper motor 74-051-00 Wiper arm 74-052-00 Wiper blade 75-152-09 Harness TURN SIGNALS Item No. Part No. Description 72-082-10 Front bulb, T-48 steel cowl or cab 72-082-20 Light socket...
  • Page 150 For more information go to www.P65Warnings.ca.gov/ passenger-vehicle. Taylor-Dunn® Manufacturing. 2114 West Ball Road. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 FAX: (714) 956-0504 Visit our Website: www.taylor-dunn.com...

This manual is also suitable for:

Re-380-48

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