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Service and Replacement
Parts Manual
MANUAL: MR-380-03
R-380 DC System
Model Numbers:
R0-380-36
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.
Starting Serial Number: 207315
Ending Serial Number: See Introduction Chapter
C
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Summary of Contents for Taylor-Dunn R0-380-36
- Page 1 Parts Manual MANUAL: MR-380-03 R-380 DC System Model Numbers: R0-380-36 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 10/15/2017 Revision C, 9/17/2018, 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.
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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 Drive Axle ............37 Steering ............45 Brakes...............55 Drive Motor ............65 Motor Controller ..........73 Wire Diagram ...........77 Batteries ............79... - 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.
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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 R-380 DC System 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 R-380 DC System Page-12 MR-380-03...
- Page 13 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...
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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: Service/Maintenance Guidelines
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 Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 Interlock Switch Inspection ......20 Start Switch ............20 High Pedal Disable (HPD) ........20 Operator Presence Switch ........20 Charger Interlock Switch .........20 WARNING This section is one section of a complete service manual.
- Page 18 PM Schedule R-380 DC System 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
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Page 19: Preventative Maintenance
PM Schedule R-380 DC System 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 PM Schedule R-380 DC System 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 Table of Contents Special Tool List Troubleshooting Guide ........23...
- Page 22 Tool List R-380 DC System 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 62-027-00: Test Light Tests the throttle module in or out of the Used in conjunction with a volt meter to test Used for testing electrical circuits.
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Page 23: Special Tool List
Tool List R-380 DC System 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. Symptom Suspect Component or System Action... - Page 24 Notes Tool List R-380 DC System Page 24 MR-380-03...
- Page 25 Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
- Page 26 Lubrication R-380 DC System LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 2: King Pin NLGI Grade 2 lithium multi-purpose grease 3: Ball Joint NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Brake Fluid: Master Cylinder DOT 3, Meets or exceeds SAE J1703...
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Page 27: Lubrication
Lubrication R-380 DC System LUBRICATION DIAGRAM MR-380-03 Page 27... - Page 28 Notes Lubrication R-380 DC System Page 28 MR-380-03...
- Page 29 Table of Contents Front Axle Remove.............30 Install ..............30 Disassemble.............31 Inspect Front Wheel Bearings ......32 Adjust Front Wheel Bearings ......32 Front Wheel Alignment ........33 Center the Steering ..........33 Front wheel alignment ..........33 Replace Front Wheel Bearings.......34 Replace Steering Knuckle ......34 Replace King Pin/Bushings ......35 Service Limits and Specifications ....36 King Pin Bushings ...........36 Toe In ...............36...
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Page 30: Front Axle
Front Axle R-380 DC System 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. 2: Remove both front wheels. -
Page 31: Front Axle
Front Axle R-380 DC System 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 32: Inspect Front Wheel Bearings
Front Axle R-380 DC System 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 33: Front Wheel Alignment
Front Axle R-380 DC System 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: Only Toe In can be set. Caster and Camber is not adjustable. Center the Steering 1: Raise the front of the vehicle and support with jack stands. -
Page 34: Replace Front Wheel Bearings
Front Axle R-380 DC System 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 35: Replace King Pin/Bushings
Front Axle R-380 DC System 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 36: Service Limits And Specifications
Front Axle R-380 DC System 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 Notes... - Page 37 Table of Contents Drive Axle Check Oil Level ..........38 Change Oil ............38 Drive Motor ............39 Remove ..............39 Install ...............39 Differential Case ..........40 Disassemble ............40 Assemble ..............42 Hardware Torque ..........43 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.
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Page 38: Drive Axle
Drive Axle R-380 DC System 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter. -
Page 39: Drive Axle
Drive Axle R-380 DC System DRIVE MOTOR 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. Remove Note: In some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor. -
Page 40: Differential Case
Drive Axle R-380 DC System DIFFERENTIAL CASE Disassemble 1: Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2: Thoroughly clean the transmission assembly before disassembly. 3: Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles. - Page 41 Drive Axle R-380 DC System 12: Using a soft metal or hard wood dowel, drive 16: Remove the circlip from the input shaft. the intermediate shaft through the bearing just 17: Remove the input shaft from the housing. enough to allow clearance for an ID bearing 18: Press the bearings off of the input shaft.
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Page 42: Assemble
Drive Axle R-380 DC System Assemble Notes: W hen pressing bearings, do not press against or support the outer race as this will damage the bearing. All snap rings should fit tightly into their grooves. If a snap ring is loose, then it must be replaced. Do not hit any shaft or component with a hard metal hammer or punch. Pre-lube all bearings, seals and o-rings before assembly. 6: Insert the flanged side bearing into the bearing bore. Press in just past the snap ring grove and install the snap ring. 1: Thoroughly clean all components as well as the 7: Repeat the above step for the opposite bearing. -
Page 43: Hardware Torque
Drive Axle R-380 DC System HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Motor terminals 7.5-9.1 10.2-12.4 Motor Mounting Bolts 8-10.5 Final Drive Gear Nuts 35-45 48-61 Differential Bearing Cap Bolts 35-45 45-61... - Page 44 Notes Drive Axle R-380 DC System Page 44 MR-380-03...
- Page 45 Table of Contents Steering Inspect Ball Joints ...........46 Inspect Rod Ends ..........46 Adjust Steering Gear ........47 Front Wheel Alignment ........47 Replace Ball Joint..........48 Replace Rod End ..........48 Replace Steering Shaft ........49 Replace Steering Wheel ........50 Steering Gear ...........51 Disassemble ............51 Reassemble ............52 Exploded View of Steering Gear ......53 Hardware Torque ..........54...
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Page 46: Inspect Ball Joints
Steering R-380 DC System 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter. -
Page 47: Steering
Steering R-380 DC System 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 48: Replace Ball Joint
Steering R-380 DC System 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. 2: Loosen the ball joint clamp on the steering sleeve. -
Page 49: Replace Steering Shaft
Steering R-380 DC System 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 warnings and instructions that are located in the failure of the steering causing loss of control of the Service Guidelines chapter. -
Page 50: Replace Steering Wheel
Steering R-380 DC System 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 51: Steering Gear
Steering R-380 DC System 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 52: Reassemble
Steering R-380 DC System 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. 16: Position the ball nut onto the worm shaft as shown in the illustration. -
Page 53: Exploded View Of Steering Gear
Steering R-380 DC System Exploded View of Steering Gear MR-380-03 Page 53... -
Page 54: Hardware Torque
Steering R-380 DC System 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 54 MR-380-03... - Page 55 Table of Contents Brakes General Guidelines and Safety.......56 Front Disc Brake ..........57 Service Limits ............57 Inspection ..............57 Replace Pads ............57 Brake Adjustment ..........58 Service Brake: Mechanical and Hydraulic ....58 Adjust the Service Brake Linkage ......58 Parking Brake, Mechanical Brakes ......59 Parking Brake, Hydraulic Brakes ......59 Rear Drum Brake, Inspect/Replace ....60 Service Limits ............60...
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Page 56: General Guidelines And Safety
R-380 DC System 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 57: Brakes
Brakes R-380 DC System FRONT DISC 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 Inspection Note: Service Limits are listed in a table at the end of this section. -
Page 58: Brake Adjustment
Brakes R-380 DC System Adjust the Service Brake Linkage BRAKE ADJUSTMENT WARNING Do not use this procedure to adjust the brakes. This procedure should only be performed when replacing any of the mechanical brake linkages or cables or it is Adjusting the brakes by means of the brake cables found that the cables or linkages have been adjusted could cause a hard brake pedal with little or no... -
Page 59: Parking Brake, Mechanical Brakes
Brakes R-380 DC System Parking Brake, Mechanical Brakes 9: Inspect the angle on the equalizer. The equalizer should be perpendicular to the brake rod. If the Trucks equipped with mechanical drum brakes do not equalizer is not perpendicular to the brake rod have a separate adjustment for the parking brake. -
Page 60: Rear Drum Brake, Inspect/Replace
Brakes R-380 DC System Replace REAR DRUM BRAKE, INSPECT/ 1: Release the park brake. REPLACE 2: Raise the rear wheels off of the ground and WARNING support with jack stands. 3: Remove the tire/wheel assembly. Refer to Tires section for information on removing This section is one section of a complete service and Wheels the wheel. -
Page 61: Rebuild Disc Brake Body
Brakes R-380 DC System 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 62: Bleed System
Brakes R-380 DC System 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 63: Master Cylinder
Brakes R-380 DC System 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 Rebuild 1: Thoroughly clean the area around the master Note: Hydraulic brake system components must cylinder cap and remove the cap. -
Page 64: Service Limits
Brakes R-380 DC System HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc pad lining minimum thickness 00625 inch 1.58 mm Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch 5.08 mm Brake Body Bolts... - Page 65 Table of Contents Drive Motor Motor Removal and Installation .....66 Disassemble.............66 Assemble............67 Inspection ............68 Brushes ..............68 Armature ..............68 Bearings ..............69 Commutator .............69 Repair ...............70 Brushes ..............70 Commutator .............70 Service Limits ..........71 WARNING This section is one section of a complete service manual.
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Page 66: Drive Motor
Drive Motor R-380 DC System MOTOR REMOVAL AND INSTALLATION See the Transmission section for information on removing or installing the motor. 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 67: Drive Motor
Drive Motor R-380 DC System ASSEMBLE 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: Lightly lubricate the bearing bore and press a new bearing into the rear end cap and install the retainer. -
Page 68: Inspection
Drive Motor R-380 DC System INSPECTION Armature WARNING 1: Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted This section is one section of a complete service armature. -
Page 69: Bearings
Drive Motor R-380 DC System Bearings Pressing the armature out of the bearings is likely to damage the bearings. Once removed the bearings should be replaced. Commutator 1: Measure the outside diameter of the commutator. • If the commutator is less than the minimum diameter specified in section Service Limits, then the motor must be replaced. -
Page 70: Repair
Drive Motor R-380 DC System 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. Brushes Note: It is recommended that all four brushes be replaced as a set. -
Page 71: Service Limits
Drive Motor R-380 DC System 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. Commutator Brush Length Resistance Undercut Depth Motor Specification Diameter (min) (min) - Page 72 Notes Drive Motor R-380 DC System Page 72 MR-380-03...
- Page 73 Table of Contents Motor Controller Remove/Install ..........74 Inspect ..............74 Troubleshooting ..........74 Repair/Adjustments.........75 Adjustments .............75 Hardware Torque ..........76 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.
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Page 74: Motor Controller
1: Thoroughly clean the controller base and vehicle documentation CD. A replacement CD or hard mounting plate. copy can be purchased from your authorized Taylor-Dunn 2: Install the controller to the mounting plate. distributor or can be downloaded from the Taylor-Dunn 3: Attach the wires to the studs and, using a backup web site. -
Page 75: Motor Controller
Motor Controller R-380 DC System REPAIR/ADJUSTMENTS 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. Repairs There are no internally serviceable components in the motor speed controller. -
Page 76: Hardware Torque
Motor Controller R-380 DC System HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal hardware 8.13 Adjustment plugs 0.90 Page 76 MR-380-03... - Page 77 Table of Contents Wire Diagram Diagram Part Numbers........78 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 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-00012 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. WIPER MOTOR Brown/Black WIPER SW.
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Page 79: Wire Diagram
Table of Contents Batteries General Guidelines and Safety.......80 Cleaning ............81 Charging ............81 Watering ............81 Testing ..............82 Specific Gravity ............82 Storing ..............82 Storage ..............82 Returning to Service ..........82 Remove/Install ..........83 Individual Batteries ..........83 Hardware Torque ..........84 WARNING This section is one section of a complete service manual. -
Page 80: General Guidelines And Safety
Batteries R-380 DC System 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 81: Batteries
Batteries R-380 DC System 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this... -
Page 82: Testing
Batteries R-380 DC System 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this... -
Page 83: Remove/Install
Batteries R-380 DC System 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 warnings and instructions that are located in the short circuit resulting severe bodily injury or damage Service Guidelines chapter and beginning of this... -
Page 84: Hardware Torque
Batteries R-380 DC System HARDWARE TORQUE WARNING If hardware is not listed here, refer to standard torque values in the appendix. Individual batteries can weight up to 80 pounds or Description Inch Pounds Newton Meters more. To avoid injury, use proper lifting techniques Battery terminal, Trojan bolt 95-105 11-12... - Page 85 Table of Contents Tires & Wheels Inflation .............86 Air pressure .............86 Tread Wear ............87 Rotation ............87 Changing Tire/Wheel Assembly .....88 Replace the Tire (pneumatic) ......88 Repair the Tire (pneumatic) ......88 Hardware Torque ..........89 WARNING This section is one section of a complete service manual.
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Page 86: Tires & Wheels
Tires & Wheels R-380 DC System 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 87: Tires & Wheels
Tires & Wheels R-380 DC System 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 warnings and instructions that are located in the in this conditions may suddenly fail at Service Guidelines chapter. -
Page 88: Changing Tire/Wheel Assembly
Tires & Wheels R-380 DC System 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 89: Hardware Torque
Tires & Wheels R-380 DC System HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MR-380-03 Page 89... - Page 90 Notes Tires & Wheels R-380 DC System Page 90 MR-380-03...
- Page 91 Table of Contents Suspension Front or Rear Springs ........92 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 92 Suspension R-380 DC System FRONT OR REAR SPRINGS 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: If a left or right side spring is replaced, it is recommended to replace the opposite side at the same time.
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Page 93: Suspension
Table of Contents Hardware Information Torque Guidelines for Standard hardware ..94 Hardware Identification ..........94 Hex Nuts ..............95 Hex Lock Nuts (stover) ..........95 Other Nuts ...............95 Generic Torque Values ..........96 Replacing Hardware ........98 WARNING This section is one section of a complete service manual. -
Page 94: Torque Guidelines For Standard Hardware
Hardware R-380 DC System 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. SAE Grade 2 Below is an example of a 10.9. -
Page 95: Hardware Information
‘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-380-03 Page 95... -
Page 96: Generic Torque Values
Hardware R-380 DC System 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. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE... - Page 97 Hardware R-380 DC System 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. Metric, Newton Meters Metric, Foot Pounds Grade, N-m...
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Page 98: Replacing Hardware
Hardware R-380 DC System 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 99 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....100 Taylor-Dunn Web Site Information ....100 Axle Assembly, Front ........102 Axle, Rear ............104 Battery ..............106 Brakes, Brake Lines ........108 Brakes, Front Axle ...........110 Brakes, Mechanical Rear ........111 Brakes, Hydraulic Rear ........112 Brakes, Master Cylinder........113...
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Page 100: 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 101: Replacement Parts
Replacement Parts R-380 DC System My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MR-380-03 * Not available at time of printing Page 101... -
Page 102: Axle Assembly, Front
Replacement Parts R-380 DC System AXLE ASSEMBLY, FRONT Page 102 MR-380-03... - Page 103 Replacement Parts R-380 DC System Axle Assembly, Front Item No. Part No. Description 14-380-80 Yoke, Left Side, w/out Brakes (Std) 14-240-08 Yoke, Left Side, W/Brakes (Optional) 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 92-104-00 Dust Cap, With Grease Fitting (STD) 92-104-01...
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Page 104: Axle, Rear
Replacement Parts R-380 DC System AXLE, REAR Page 104 MR-380-03... - Page 105 Replacement Parts R-380 DC System Axle, Rear Item No. Part No. Description 41-171-10 Rear Axle Shaft, Right 41-170-10 Rear Axle Shaft, Left Bolt 45-303-00 Oil Seal 32-509-10 Bearing Retainer 80-505-10 Bearing and Race 45-046-00 Gasket 45-303-10 Seal MR-380-03 * Not available at time of printing Page 105...
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Page 106: Battery
Replacement Parts R-380 DC System BATTERY Page 106 MR-380-03... - Page 107 Replacement Parts R-380 DC System Battery 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 50-243-10 Battery rod 50-250-00 Battery hold down 88-088-66 Flat washer, tin/lead plated 88-069-81 1/4 NC Nylon lock nut 88-081-12 5/16 NC x 1 Square bolt, stainless steel 88-089-80...
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Page 108: Brakes, Brake Lines
Replacement Parts R-380 DC System BRAKES, BRAKE LINES Page 108 MR-380-03... - Page 109 Replacement Parts R-380 DC System Brake Lines Item No. Part No. Description 99-604-70 Brake Line, Right Front 99-604-71 Brake Line, Left Front 99-605-10 Brake Line, Right Rear 99-576-00 Hose clip 99-563-00 T-Fitting with mounting hole 99-578-00 Master Cylinder Fitting 99-604-10 Brake Line, Left Rear 99-580-00 Brake hose, Rear...
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Page 110: Brakes, Front Axle
Replacement Parts R-380 DC System 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 99-588-00 Bleeder valve See rebuild kit... -
Page 111: Brakes, Mechanical Rear
Replacement Parts R-380 DC System BRAKES, MECHANICAL REAR Brake, Mechanical Rear Item No. Part No. Description 41-347-15 Brake Arm 41-347-00 Backing Plate 41-347-25 Spider w/out wheel cylinder 85-411-15 Torsion Spring 41-635-00 Brake Shoes(Set of 2) 85-215-00 Spring 41-347-33 Adjustment Body 41-347-31 Star Wheel 41-347-30... -
Page 112: Brakes, Hydraulic Rear
Replacement Parts R-380 DC System BRAKES, HYDRAULIC REAR Item No. Part No. Description 41-347-15 Brake Arm 41-347-00 Backing Plate 41-347-27 Spider with wheel cylinder 85-411-15 Torsion Spring 41-635-00 Brake Shoes(Set of 2) 85-215-00 Spring 41-347-33 Adjustment Body 41-347-31 Star Wheel 41-347-30 Socket 85-411-10... -
Page 113: Brakes, Master Cylinder
Replacement Parts R-380 DC System BRAKES, MASTER CYLINDER Item No. Part No. Description 00-380-80 Brake Rod 88-109-81 3/8 NC 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 Bell crank 96-762-00 3/8 Clevis 88-119-80... -
Page 114: Brakes, Park Brake Linkage
Replacement Parts R-380 DC System BRAKES, PARK BRAKE LINKAGE Page 114 MR-380-03... - Page 115 Replacement Parts R-380 DC System Brake, Park Brake Linkage Item No. Part No. Description 98-200-00 Rubber Pedal Pad 88-089-81 Hex Nut 88-080-11 Hex Bolt 04-380-36 Brake Pedal Arm 80-410-20 Nylon Bearing 88-527-11 Cotter Pin 96-773-00 Clevis Pin 88-109-81 Hex Nut 88-100-09 Hex Bolt 88-080-11...
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Page 116: Bumper, Front
Replacement Parts R-380 DC System BUMPER, FRONT 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 88-089-81 5/16 NC Lock nut Page 116... -
Page 117: Cab
Replacement Parts R-380 DC System Item No. Part No. Description 91-011-30 Cab, Unpainted 90-852-30 Windshield 98-310-00 Rubber Channel for Windshield 90-850-10 Rear Window 88-065-09 1/4”NC X 3/4” Phillips Head Truss Screw 88-068-62 1/4” Lock washer 88-069-83 1/4”NC Acorn Nut 88-069-81 1/4”NC Locknut 74-050-00 Windshield Wiper Motor... -
Page 118: Cab Doors
Replacement Parts R-380 DC System CAB DOORS Page 118 MR-380-03... - Page 119 Replacement Parts R-380 DC System Doors Item No. Part No. Description 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 Door Latch 97-315-54 Inner Handle 97-303-03 Snap Fastener, Female 88-727-06 5/13”...
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Page 120: Charger, Signet
Replacement Parts R-380 DC System CHARGER, SIGNET Note: The harness connectors and AC plug are not included with the charger. Model HBS Charger PART # DESCRIPTION 79-303-41 Flooded Batteries (WET, FLA) 79-303-42 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. -
Page 121: Charger, X-Series
Replacement Parts R-380 DC System CHARGER, X-SERIES Item No. Part No. Description 79-303-49 Charger Assembly, X-Series, 48 volt 79-831-00 Fuse 79-809-61 Relay board assembly Control board assembly 79-749-14 SCR assembly 79-840-02 Circuit breaker 79-849-00 Ammeter 79-810-01 Switch kit (start/stop, low voltage, self diagnostic) 79-575-41 AC cord (includes bushing) 79-566-21... -
Page 122: Charger, Lestronic Ii
Replacement Parts R-380 DC System CHARGER, LESTRONIC II Charger Model > 7710-32 22740 11860 Style > Portable Built In Built In Item # Description Part # Charger Assembly 79-305-20 79-301-15 79-304-65E Ammeter 79-851-10 79-851-10 Timer 79-805-69 79-805-67 79-805-72 Relay, Timer 79-808-00 79-808-00 79-808-00... -
Page 123: Charger, Delta Q
Replacement Parts R-380 DC System CHARGER, DELTA Q Note: There are no user serviceable components inside the charger Model QuiQ Model IC650 Item No. Part No. Description 79-306-32 Charger, QuiQ, 36 volt Trojan T105 79-306-31 Charger, QuiQ, 36 volt Full River AGM 79-306-34 Charger, IC650, 36 volt Full River AGM 79-306-33... -
Page 124: Charger, Lestronic Portable (Export)
Replacement Parts R-380 DC System CHARGER, LESTRONIC PORTABLE (EXPORT) Item No. Part No. Description 79-304-60 Charger assembly, spec 7030-01 79-851-10 Ammeter K4-071-87 Timer 79-902-00 Capacitor 79-749-13 Diode assembly Transformer Cable, AC 79-831-00 Fuse assembly 79-532-00 Grommet 79-530-00 Grommet Cable, DC JF3-86181-00-00 Receptacle Page 124... -
Page 125: Control System, Motor Speed Control
Replacement Parts R-380 DC System CONTROL SYSTEM, MOTOR SPEED CONTROL Speed Control Panel Item No. Part No. Description 01-534-80 Mounting Panel 73-004-20 Horn 79-844-00 Circuit Breaker 79-840-00 10 Amp Circuit Breaker 88-048-62 #10 Lock washer 88-049-80 10-32 Hex Head Nut 62-204-00 Controller 61-838-41... -
Page 126: Control System, Instrument Panel
Replacement Parts R-380 DC System CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 71-039-11 Switch 0 or 3 74-009-00 Battery status indicator 71-000-00 Hour meter 0 or 1 71-039-02 Switch, Direction Control 71-120-00 Switch Key Page 126 MR-380-03... -
Page 127: Decals
Replacement Parts R-380 DC System 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 94-384-14 DECAL, LEAVING VEHICLE (E) 94-301-57... -
Page 128: Deck, Rear
Replacement Parts R-380 DC System DECK, REAR Side Panels Pipe Rails Item No. Part No. Description Item No. Part No. Description 03-380-38 Left Side Panel 00-680-22 Left Pipe Rail 03-380-37 Right Side Panel 00-680-23 Right Pipe Rail 00-380-85 Tailgate 00-680-24 Tail Gate 00-380-86 Tailgate Pivot, Right... -
Page 129: Electrical, Miscellaneous
Replacement Parts R-380 DC System ELECTRICAL, MISCELLANEOUS Throttle Module 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 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID... -
Page 130: Hitches
Replacement Parts R-380 DC System 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 1/2 NC x 1-1/2 Hex bolt 88-149-80 1/2 NC Hex nut 88-148-62 1/2 Split lock washer Page 130 MR-380-03... -
Page 131: Lights
Replacement Parts R-380 DC System LIGHTS Item No. Part No. Description 94-050-11 Headlight Assembly, Right 94-050-10 Headlight Assembly, Left 72-025-00 Taillight 72-072-15 Bulb, Headlight 72-072-10 Bulb, Front turn signal 72-023-59 Strobe light 71-141-22 Turn signal switch (includes flasher) 98-330-50 Insulator for turn signal switch 71-900-05 Flasher MR-380-03... -
Page 132: Mirrors
Replacement Parts R-380 DC System MIRRORS Item No. Part No. Description See Lights See Lights See Lights See Lights See Lights 92-201-00 4-1/2” X 8-1/2” Mirror 1 or 2 92-202-12 Left Mounting Bracket 92-202-13 Right Mounting Bracket 92-202-15 Spacer for Mounting Bracket 1 or 2 91-814-16 Left Hinge, Female... -
Page 133: Motor
Replacement Parts R-380 DC System MOTOR Motor Spec # ER5-4002MX Item No. Part No. Description 70-049-05 Motor assembly Field assembly Armature 70-180-00 Brush holder 80-412-20 Brush spring 70-109-00 Brush pair 70-417-00 Bearing retainer 80-212-00 Bearing, rear End cap Brush cover MR-380-03 * Not available at time of printing Page 133... -
Page 134: Seats
Replacement Parts R-380 DC System SEATS Seats Item No. Part No. Description 90-198-03 Seat cushion, Front 90-179-00 Seat back, Front 90-000-00 Seat back, Rear fold down 90-177-00 Seat cushion, Rear fold down PKIT-00062 Switch, Operator presence Page 134 MR-380-03... -
Page 135: Steering Gear
Replacement Parts R-380 DC System 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 18-308-81 Lock washer 18-308-79... -
Page 136: Steering Linkage
Replacement Parts R-380 DC System STEERING LINKAGE Page 136 MR-380-03... - Page 137 Replacement Parts R-380 DC System Steering Linkage Item No. Part No. Description 19-011-23 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 02-380-88 Steering Column 88-100-11 3/8” X 1” NC Hex Head Screw 88-108-62 3/8”...
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Page 138: Suspension, Front
Replacement Parts R-380 DC System 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 15-380-33 Front Axle Beam 88-121-19 7/16” X 2-3/4”NC Hex Cap Screw GR5 85-506-01 2 Leaf, Spring 01-680-61 Spring Pad... -
Page 139: Suspension, Rear
Replacement Parts R-380 DC System SUSPENSION, REAR Item No. Part No. Description 96-123-52 3/8” X 2” X 4” U-Bolt (W/Bend) 16-861-00 Spring Pad (No shocks) 04-380-03 Spring pad (with shocks) 16-871-00 Shackle Strap 96-248-00 9/16” X 3” Shackle Bolt 88-109-87 3/8”... -
Page 140: Transmission
Replacement Parts R-380 DC System TRANSMISSION Item No. Part No. Description Housing Carrier bearing cap, included with #1 96-330-10 Carrier bearing cap bolt 66-610-04 Carrier assembly Final Gear Final gear bolt Final gear nut 80-480-00 Carrier bearing Intermediate shaft 80-715-00 O-ring 66-610-35 Intermediate shaft bearing... -
Page 141: Wheels And Tires
Replacement Parts R-380 DC System WHEELS AND TIRES Item No. Part No. Description 13-742-13 Tire/Wheel assembly, 5.70 x 8 LR C 13-742-12 Tire/Wheel assembly, 5.70 x 8 LR C SPLIT RIM 10-083-00 Tire, 5.70 x 8 LR C 13-746-10 Tire/Wheel assembly, 18 x 8.50 x 8 10-093-00 Tire, 18 x 8.50 x 8 13-742-41... - Page 142 Notes: Replacement Parts R-380 DC System Page 142 MR-380-03...
- Page 144 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...