Page 1 Models Inlcuded: RE-380-36 (R 380-36) RE-380-48 (R 380-48) Equipped with the GT Drive System 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...
Page 2 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 3 Appendix B ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...
Page 4 Section Index Taylor-Dunn ® Model RE-380-36, RE-380-48 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transaxle Service Suspension Tires and Wheels Battery Service Control System Troubleshooting...
Page 5: Table Of Contents
Introduction Contents About this manual ......... 2 Who Should Read This Manual ....3 Responsibilities ..........3 How To Use This Manual ......4 Conventions ............. 5 How to Identify Your Vehicle ......6 Taking Delivery of Your Vehicle ....7...
Page 6: Introduction
Please continue to read this manual and enjoy this high quality Taylor-Dunn ® vehicle. This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn ® vehicles and is not intended as a training guide. Taylor-Dunn ®...
Page 7: Who Should Read This Manual
Of the Service Personnel... The service personnel are responsible for the service and maintenance of the vehicle. At no time should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn ® vehicle. For the purposes of training, a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training.
Page 8: Safety Rules And Operating Instructions
INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections: INTRODUCTION This section describes how to use this service manual and how to identify your vehicle. Safety Rules and Operating Instructions This section outlines the safety and operational issues, location and operation of controls, and the operational checks that are to be performed on this vehicle.
Page 9: Conventions
INTRODUCTION Conventions Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: A shaded box with the word “Warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others.
Page 10: How To Identify Your Vehicle
INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on public highways.
Page 11: Taking Delivery Of Your Vehicle
® distributor and report the problem. The report must be made within 24 hours of receiving the vehicle and its accessories. The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn ® vehicle is a factory authorized service technician.
Page 13 TABLE OF CONTENTS Standard Specifications ..... 2 Safety Rules and Guidelines ..... 3 Driver Training Program ....3 Driver Qualifications..........3 Vehicle Controls ........ 4 Key-Switch ............4 Forward-Off-Reverse Switch ........ 4 Accelerator Pedal ..........4 Steering ..............4 Foot Brake Pedal ..........
Page 14: Standard Specifications
Dimensions 243.8L X 112.4W X 118.1H Centimeters 96L X 44.25X 46.5H Inches Turning Radius 284 Centimeters (112 inches) Dry Weight RE-380-36 405 kg (894 lbs) Without Batteries RE-380-48 434 kg (958 lbs) Min/Max Battery 166 kg to 261 kg (366 lbs to 576 lbs)
Page 15: Safety Rules And Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND DRIVER TRAINING PROGRAM GUIDELINES According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who It is the responsibility of the owner of this vehicle to assure will be operating this vehicle.
Page 16: Vehicle Controls
SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key-Switch A key-switch, located on the right side of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off. The key-switch should be in the “OFF”...
Page 17: Seat Interlock Switch
SAFETY RULES AND OPERATING INSTRUCTIONS Park Brake The parking brake is actuated with a hand lever, which is located between the driver and passenger seats. To set the parking brake, push down on the brake pedal and pull the lever up until it locks. To release the park brake, depress the foot brake pedal, pull up on the park brake handle, push the release button, and lower the handle.
Page 18: Reverse Or Motion Alarm (Optional)
SAFETY RULES AND OPERATING INSTRUCTIONS Headlight Switch The headlight switch is located on the far left side of the instrument panel. Push the top of the switch to turn the lighs on. Push the bottom of the switch to turn the light off. Reverse or Motion Alarm (Optional) The reverse alarm is located in the electronics compartment mounted on the speed control panel or on the rear panel of the vehicle.
Page 19: Battery Status Indicator, Analog
SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Analog The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading. The vehicle needs charging if it is in the yellow zone.
Page 20: Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is described below.
Page 21 SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance Monitor: NOTE: The Maintenance Monitor function is optional. The Maintenance Monitor function can be turned ON or OFF by your dealer. Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator.
Page 22: Fault Code Tables
SAFETY RULES AND OPERATING INSTRUCTIONS Fault Code Tables NOTE: Most faults are a result of a fault in the control Level 5 Faults system that will require service by a qualified Fault Code Description What to do technician. These faults are shown here for F05000 Contactor Over Current Refer to service technician...
Page 23: Vehicle Operation Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS While driving: VEHICLE OPERATION • Slow down and sound the horn to warn pedestrians GUIDELINES or when approaching a corner or other intersection. Safety Guidelines • No reckless driving. • Do not drive this vehicle on steep inclines or where •...
Page 24: Parking
SAFETY RULES AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle: This vehicle is equipped with regenerative braking. Follow these steps before towing this • Set the parking brake. vehicle. • Set the forward-off-reverse switch to the ` “OFF” 1. To tow this vehicle the start switch must be position.
Page 25: Charging Your Vehicle
SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Explosive mixtures of Hydrogen gas are Battery electrolyte is poisonous and present within battery cells at all times. Do dangerous. It contains sulfuric acid. Avoid not work with or charge battery in an area contact with skin eyes or clothing.
Page 26: Lestronic Ii Charger Operation
SAFETY RULES AND OPERATING INSTRUCTIONS Lestronic II Charger Operation Charging Time ® The Lestronic II charger is a semi-automatic charging Average charging time is 8 to 10-hours. The time required system. The charger will turn itself ON when the AC to fully charge your batteries will vary depending on: power cord is connected to the AC power source and •...
Page 27: Periodic Maintenance Checklist
SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST NOTE: A full page copy of the Periodic Maintenance Checklist is on the Vehicle Safety Rules Documentation CD under the [Misc] sub folder. Page 15...
Page 28: Standard Periodic Maintenance Schedule For The Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY NOTE: The maintenance function is optional. Your vehicle may be equipped with a customized maintenance schedule PREVENTATIVE MAINTENANCE SCHEDULE MAINTENANCE HOUR MAINTENANCE TO BE PERFORMED LEVEL INTERVAL Inspect the brake system including the park brake and mounting harware...
Page 29: Daily Visual Inspection
SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to: • Accelerator pedal, Brake pedal, Steering, Parking brake, etc. •...
Page 31: General Maintenance
General Maintenance TABLE OF CONTENTS Maintenance Guidelines ....... 2 Troubleshooting Guide ......... 3 Lubrication Chart .......... 4...
Page 32 • Inspect and maintain battery limit switches, protective devices, electrical conductors, and ® connections in conformance with Taylor-Dunn’s recommended procedures. • Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.
Page 33: Troubleshooting Guide
Maintenance, Service and Repair TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged King Pin/Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis-Adjusted or Worn Steering Gear Loose Steering Linkage...
Page 34: Lubrication Chart
Maintenance, Service and Repair LUBRICATION CHART Drive Description Locations Lubricant Type 2 King Pin General Purpose Grease 3 Ball Joints General Purpose Grease 5 Front Wheel Bearings High Temperature Wheel Bearing Grease 7 Drive Drain Plug 8 Drive Level Plug 9 Drive Fill Plug SAE 80W90 Gear Oil Maintenance...
Page 35: Front Axle Service
Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and Kin Pin ..........2 Adjust Front Wheel Bearings ...... 3 Front Axle Removal and Installation .... 4 Removal ..............4 Installation ..............5 Front Axle Removal ........6 Front Axle Disassembly ........
Page 36: Inspect The Front Wheel Bearings And Kin Pin
Maintenance, Service, and Repair INSPECT THE FRONT WHEEL BEARINGS AND KIN PIN 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.
Page 37: Adjust Front Wheel Bearings
Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 38: Front Axle Removal And Installation
Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 39: Installation
Maintenance, Service, and Repair Installation 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 40: Front Axle Removal
Maintenance, Service, and Repair FRONT AXLE DISASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: Replace the Steering Knuckle Replace the King Pins and Bushings NOTE: The front axle does not have to be removed unless the axle beam Front Axle Removal and must be replaced.
Page 41: Replace Front Wheel Bearings
Maintenance, Service, and Repair REPLACE FRONT WHEEL BEARINGS 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 42: Replace The Ball Joints, Tie Rods, And Drag Link
Maintenance, Service, and Repair 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Brakes NOTE: Refer to the section for information regarding the installation of the brake body. 15. Lower the vehicle. 16. Reconnect the main positive and negative cables at the batteries. 17.
Page 43 Maintenance, Service, and Repair 7. Loosen the rod end jam nut or clamp on the steering sleeve. Rod End 8. Remove the rod end nut. 9. Remove the rod end from the steering arm. HINT: Count the number of turns required to Steering remove the rod end from the steering Sleeve...
Page 44: Replacing The Drag Link
Maintenance, Service, and Repair 7. Loosen the ball joint clamp on the steering sleeve. Cotter Pin 8. Remove the cotter pin and ball joint nut. Ball Joint Nut 9. Using a pickle fork, remove the ball joint from the steering arm. 10.
Page 45: Replacing The Tie Rod
Maintenance, Service, and Repair 7. Remove the ball joints or rod ends from the steering Pitman Arm knuckle and pitman arm. Replacing the Ball NOTE: Refer to the Drag Link Joints section for information regarding the removal of the ball joints or rod ends.
Page 46: Replace The King Pins And Bushings
Maintenance, Service, and Repair 7. Remove the ball joints or rod ends from the steering knuckles. Steering Knuckle Replacing the Ball NOTE: Refer to the Joints section for information regarding the removal of the ball joints or rod ends. 8. Remove the tie rod as an assembly. 9.
Page 47 Maintenance, Service, and Repair 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 48: Replace The Steering Knuckle
Maintenance, Service, and Repair REPLACE THE STEERING KNUCKLE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 49 Maintenance, Service, and Repair 12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings. NOTE: Both the left and right side bushings and thrust bearings should be replaced as a set. 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. 15.
Page 51 Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Adjust the Steering Gear (Saginaw) ..... 6 Replace the Steering Shaft (non-tilt steering) ........7 Replace the Steering Wheel ......9 Replace the Steering Gear ......10 Repair the Steering Gear ......11 Exploded View of Steering Gear ......
Page 52: Front End Alignment
Maintenance, Service, and Repair FRONT END ALIGNMENT This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is fitted to the steering arm or pitman arm. The second type cannot be greased and has a straight shaft.
Page 53 Maintenance, Service, and Repair 10. At this point both the steering wheel and the front wheels should be tied up and held in position. If one or the other is not tied up then you must start from the beginning. Do not drive the vehicle while the steering wheel or front wheels are tied in position.
Page 54 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front Center the Steering wheels. Refer to the section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 55 Maintenance, Service, and Repair 14. Adjust the right side tie rod so that the right wheel Front Measurement is positioned pointing straight ahead. 15. Measure the distance between the lines at the front of the tires. Sleeve Clamps 16. Measure the distance between the lines at the rear of the tires.
Page 56: Adjust The Steering Gear (Saginaw)
Maintenance, Service, and Repair ADJUST THE STEERING GEAR (SAGINAW) NOTE: In some vehicle configurations it may be necessary to remove the Replace the steering gear to perform this procedure. Refer to Steering Gear for information regarding removing the steering gear. 1.
Page 57: Replace The Steering Shaft (Non-Tilt Steering)
Maintenance, Service, and Repair REPLACE THE STEERING SHAFT (NON-TILT STEERING) 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 58 Maintenance, Service, and Repair 11. Remove the steering shaft from the vehicle. 12. Lightly grease the input shaft splines, steering wheel splines and the upper steering shaft bushing. 13. Install the steering shaft in reverse order using a new pinch bolt. Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft.
Page 59: Replace The Steering Wheel
Maintenance, Service, and Repair REPLACE THE STEERING WHEEL 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 60: Replace The Steering Gear
Maintenance, Service, and Repair REPLACE THE STEERING GEAR 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 61: Repair The Steering Gear
Maintenance, Service, and Repair REPAIR THE STEERING GEAR Disassembly NOTE: The steering gear must be removed from the vehicle for this procedure. Refer to Replace the Steering Gear section for information regarding removing the steering gear. NOTE: The steering gear is packed with grease. Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled.
Page 62 Maintenance, Service, and Repair 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing.
Page 63 Maintenance, Service, and Repair 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft.
Page 64: Exploded View Of Steering Gear
Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 14...
Page 65 Brake Service TABLE OF CONTENTS Inspect the Service Brake ......2 Disc Brake Pads ............2 Disc Brake Rotor ............. 3 Inspect the Parking brake ......4 Wheel Park Brake (hydraulic disc) ......4 Inspect the Parking brake ......5 Motor Brake (optional) ..........
Page 66: Inspect The Service Brake
Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
Page 67: Disc Brake Rotor
Maintenance, Service, and Repair Disc Brake Rotor Current Taylor-Dunn brakes are asbestos free. However, there is ® the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.
Page 68: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake (hydraulic disc) NOTE: The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 69: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Motor Brake (optional) A variable power supply capable of supplying 0-volts to 24-volts DC at 2-Amps will be required to perform the testing. The brake does not have to be removed from the transmission for this test. 1.
Page 70: Adjust The Service Brakes
Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Two or Four Wheel Hydraulic Disc Brakes The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • Check the Master Cylinder Fluid Brake fluid level low in the master cylinder.
Page 71: Adjust The Parking Brake
Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake (hydraulic disc) The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 72: Check Master Cylinder Fluid
Maintenance, Service, and Repair CHECK MASTER CYLINDER FLUID Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 73: Bleed The Brake System
Maintenance, Service, and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 74 Maintenance, Service, and Repair 7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the master cylinder chamber. • Only use DOT 3 brake fluid from a new sealed container. •...
Page 75: Flush The Brake System
Maintenance, Service, and Repair FLUSH THE BRAKE SYSTEM 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 76: Replace The Parking Brake Lining (Optional Motor Brake)
Maintenance, Service, and Repair REPLACE THE PARKING BRAKE LINING (OPTIONAL MOTOR BRAKE) Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
Page 77 Maintenance, Service, and Repair 6. Mark the orientation of the inner contact plate in relation to the magnet. 7. Remove the smaller bearing circlip. 8. Using a soft hammer, drive out the center hub and remove the inner contact plate and six springs. 9.
Page 78: Inspection
Maintenance, Service, and Repair Electric motor brake exploded Inspection: Note: There are no repairable parts in this assembly. The parts must be replaced if any damage or wear is found. 1. Measure the free length of the five springs. Minimum length =0.713” 2.
Page 79: Replace Front Disc Brake Pads
REPLACE FRONT DISC BRAKE PADS NOTE: It is recommended that both the left and right brake pads be replaced as a set. Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos.
Page 80 Maintenance, Service, and Repair NOTE: Refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. Inspect the Service Brakes 12.
Page 81: Replace Rear Brake Pads
Maintenance, Service, and Repair REPLACE REAR BRAKE PADS Hydraulic Disc Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
Page 82 Maintenance, Service, and Repair 9. Remove the tire/wheel assembly. Tires and Wheels NOTE: Refer to section for information on removing the tire and wheel assembly. 10. Release the park brake (wheel brake only). 11. Remove the brake body bolts and discard the lock nuts and brake pads. 12.
Page 83: Replace The Wheel Cylinder
Maintenance, Service, and Repair REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly (front or rear) Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
Page 84 Maintenance, Service, and Repair Tires and Wheels 8. Remove the tire/wheel assembly. Refer to section for information on removing the tire and wheel assembly. 9. Thoroughly clean the area around the brake body. 10. Remove the brake body bolts and discard the lock nuts.
Page 85: Repair The Brake Body
Maintenance, Service, and Repair REPAIR THE BRAKE BODY Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Any debris or contaminates left in the brake system could lead to brake failure and result in property damage and/or severe bodily injury.
Page 86 Maintenance, Service, and Repair 11. Lubricate the brake parts with clean brake fluid from a sealed container. 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. 13.
Page 87: Replace The Master Cylinder
Maintenance, Service, and Repair REPLACE THE MASTER CYLINDER Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 88 Maintenance, Service, and Repair 10. Install in reverse order. 11. Adjust the master cylinder push rod so that it is Plunger approximately 1/8 inch away from the master cylinder plunger when the brake pedal is up. 12. Fill the master cylinder with brake fluid from a sealed container.
Page 89: Repair The Master Cylinder
Maintenance, Service, and Repair REPAIR THE MASTER CYLINDER NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See Replace the Master Cylinder section . Drain all fluid from the master cylinder and discard.
Page 91 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ......2 Motor Removal and Installation ..2 Motor Inspection ........ 2 Replacing the Brushes or Armature Bearing Repairing the Commutator ....5 Service Limits ........6...
Page 92: Motor Service
Maintenance, Service, and Repair INSPECTING THE MOTOR MOTOR REMOVAL AND BRUSHES INSTALLATION Transmission See the section for information on removing or installing the motor. Motors with internal cooling fans MOTOR INSPECTION Disassembly 1. Remove the motor from the vehicle. See the Transmission section for information on removing the motor.
Page 93 Maintenance, Service, and Repair 3. Measure the commutator undercut depth in 5- NOTE: If the armature has been burnt then there is a places around the commutator. good possibility that the field windings may also be burnt. Symptoms indicating a shorted •...
Page 94: Replacing The Brushes Or Armature Bearing
Maintenance, Service, and Repair Assembly 1. Press a new bearing into the motor housing and install the circlip. 2. Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator.
Page 95: Repairing The Commutator
Maintenance, Service, and Repair REPAIRING THE COMMUTATOR 1. The motor must be removed from the vehicle for Transmission Service this procedure. Refer to section for information on removing the motor. 2. The armature must be removed from the motor Motor Inspection- for this procedure.
Page 96: Service Limits
Maintenance, Service, and Repair SERVICE LIMITS Commutator Diameter Brush Length Resistance Undercut Depth Motor Specification (min) (min) (Ohms@75º F) Number inches inches inches Armature Field 70-054-40 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20 (XP-1672 or DV1-4002) 70-054-41 0.635 0.025 69.85 2.75 15.87...
Page 97 Transmission TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor Removal and Installation ....4 Rear Hub or Rotor ......... 5 Removing and Installing the Rear Axles (Disc Brakes) ........... 6 Transmission Assembly ........ 8 Remove and Install ..........8 Disassembly and Reassembly of the Primary Reduction Gear Case ......
Page 98: Check Oil Level
Maintenance, Service, and Repair CHECK OIL LEVEL The oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 1.
Page 99: Change Oil
Maintenance, Service, and Repair CHANGE OIL 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 100: Motor Removal And Installation
Maintenance, Service, and Repair MOTOR REMOVAL AND INSTALLATION NOTE: Some applications will require removing the drive assembly from Removing and the vehicle to remove the motor. Refer to Installing the Drive Assembly for information on removing the drive assembly. Some vehicles are equipped with an automatic electric brake. The automatic electric brake is sandwiched between the drive motor and the gear case.
Page 101: Rear Hub Or Rotor
Maintenance, Service, and Repair REAR HUB OR ROTOR NOTE: The torque specification for the axle hub bolt is 275 ft-lbs. An impact wrench will be required to remove the bolt. NOTE: The axle hub bolt has a special thread locking compound applied to the threads.
Page 102: Removing And Installing The Rear Axles (Disc Brakes)
Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES (DISC BRAKES) The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange.
Page 103 Maintenance, Service, and Repair 11. Remove the axle retaining plate and brake body assembly as one unit. 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14.
Page 104: Suspension
Maintenance, Service, and Repair TRANSMISSION ASSEMBLY NOTE: The transmission assembly will be removed with the springs Suspension attached. Refer to section for information regarding removing the springs. Remove and Install 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 105: Disassembly And Reassembly Of The Primary Reduction Gear Case
Maintenance, Service, and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.
Page 106 Maintenance, Service, and Repair 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/ bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the pinion shaft.
Page 107 Maintenance, Service, and Repair Lubricate all parts with gear oil before installation. Failure to pre-lube the parts may result in premature failure. 19. Assemble the gear case in reverse order. NOTE: Torque the drain plug to 21-25 foot-pounds. NOTE: Torque the gear case to 3rd member retaining bolts to 18-20 foot- pounds.
Page 108: Disassembling The 3Rd Member
Maintenance, Service, and Repair DISASSEMBLING THE 3RD MEMBER 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 109 Maintenance, Service, and Repair 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race from the side plate. 15. Remove the differential assembly from the 3rd member housing.
Page 110 Maintenance, Service, and Repair 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the front bearing from the input shaft. NOTE: The input shaft may have to be driven out to perform this procedure. 19. Remove the input shaft’s shims and spacer. 20.
Page 111: Assembling The 3Rd Member
Maintenance, Service, and Repair ASSEMBLING THE 3RD MEMBER 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. Cover Housing 3. Install the carrier bearing races into the housing and cover. Cover Housing 4.
Page 112 Maintenance, Service, and Repair 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. If the ring and pinion gears or bearings are replaced then the pinion gear must be re-shimmed.
Page 113 Maintenance, Service, and Repair 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the vehicle.
Page 114: Pinion Bearing Preload
Maintenance, Service, and Repair Pinion Bearing Preload NOTE: The pinion gear depth must be set before the preload. Refer to Setting the Pinion Gear Depth 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3.
Page 115: Pinion Gear Shimming Instructions
Maintenance, Service, and Repair 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. NOTE: To perform this procedure, all parts must be clean and the bearings lightly lubricated.
Page 116 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 20...
Page 117 Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Leaf ................2 Replace the Front Springs ......3 Leaf ................3 Replace the Spring Bushings ...... 5 Replace the Shocks ........6 Front or Rear ............. 6...
Page 118: Replace The Rear Springs
Maintenance, Service, and Repair REPLACE THE REAR SPRINGS Leaf If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 119: Replace The Front Springs
Maintenance, Service, and Repair REPLACE THE FRONT SPRINGS Leaf If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 120 Maintenance, Service, and Repair 12. Inspect the spring bolts and spring hangers for signs of wear or damage. If any wear or damage is found, then they must be replaced. Damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage.
Page 121: Replace The Spring Bushings
Maintenance, Service, and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): •...
Page 122: Replace The Shocks
Maintenance, Service, and Repair REPLACE THE SHOCKS Front or Rear It is recommended to replace both front shocks as a set. NOTE: On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the front wheels.
Page 123 Tires and Wheels TABLE OF CONTENTS Tire Inflation ..........2 Tire Inspection ..........2 Replace the Front Tire/Wheel ....... 3 Replace the Rear Tire/Wheel ......3 Repair the Tire (pneumatic) ......4 Replace the Tire (pneumatic) ...... 5...
Page 124: Tire Inflation
Maintenance, Service, and Repair TIRE INFLATION 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 125 Maintenance, Service, and Repair 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. NOTE: Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment.
Page 126: Repair The Tire (Pneumatic)
Maintenance, Service, and Repair 4-Bolt Pattern 5-Bolt Pattern 8-Bolt Pattern Pattern for tightening the wheel nuts Re-torque all wheel nuts to their final value after 1-week (20-hours) of operation. Failure to re-torque the wheel nuts may result in the wheel coming off of the vehicle causing severe bodily injury and/or property damage.
Page 127: Replace The Tire (Pneumatic)
Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly must be removed from Replace the Tire/Wheel the vehicle. Refer to section for information on removing the tire/wheel assembly. Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel.
Page 129: Battery Service
Battery Service TABLE OF CONTENTS Cleaning ............2 Testing ............3 Watering ............5 Charging ............6 Replacing (6-volt batteries only) ....7 Battery Removal (48 volt system) ......9 Moist Charge Batteries ..........10 Storage and Returning to Service ....11 Storage ..............
Page 130: Cleaning
Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.
Page 131: Testing
Maintenance, Service, and Repair TESTING NOTE: A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 132 Maintenance, Service, and Repair Specific Gravity Test NOTE: The batteries must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see the illustration to the right).
Page 133: Watering
Maintenance, Service, and Repair WATERING NOTE: The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete.
Page 134: Charging
Maintenance, Service, and Repair 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 135: Replacing (6-Volt Batteries Only)
Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 136 Maintenance, Service, and Repair 7. Remove the battery hold downs. 8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced. 9. Remove all battery jumpers from both posts of the battery or batteries being replaced. NOTE: It is recommended to replace the battery jumpers when replacing the batteries.
Page 137: Battery Removal (48 Volt System)
Maintenance, Service, and Repair Battery Removal (48 volt system) The illustration to the right shows the left bank of a typical battery installation in a model R 380-48 with the cable removed. Some components have been omitted for clarity Note: The charger may have to be removed to provide clearance.
Page 138: Moist Charge Batteries
Maintenance, Service, and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 139: Storage And Returning To Service
Maintenance, Service, and Repair 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the Cleaning the batteries or the ground. Refer to Batteries for information on cleaning the batteries. 8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.
Page 140: Returning To Service
Maintenance, Service, and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 141: Control System Troubleshooting
Sevcon Control System Troubleshooting Includes Power Pak and Micro Pak controllers TABLE OF CONTENTS Test Equipment Required: ...... 2 Definitions: ..........2 Terminology used: ........2 Important Notes and Instructions ... 2 Identifying Your Controller ..... 3 Start Troubleshooting Here ....4 Test 8.
Page 142: Test Equipment Required
• Digital multimeter (DMM) with diode test • This troubleshooting procedure is for the function, FLUKE 79 model shown. Sevcon Power Pak and Micro Pak motor • Throttle Module Analyzer, Taylor-Dunn part speed controllers as equipped in standard number 62-027-32 vehicles. Troubleshooting may not be valid for vehicles equipped with special order speed control options.
Page 143: Identifying Your Controller
Electrical Troubleshooting Identifying Your Controller Sevcon Troubleshooting Page 3...
Page 144: Start Troubleshooting Here
Electrical Troubleshooting START TROUBLESHOOTING HERE If your vehicles is equipped with an electric motor brake, the motor brake system must be checked to be sure it is working properly before continuing with this troubleshooting. Operating the speed control when the motor brake has not disengaged may result in damage to Test 9: Electric Motor the motor or speed control system.
Page 145 Electrical Troubleshooting Test 1. CHECKING THE CONTROL LOGIC TEST 1.3: INPUTS Test the voltage at pin #6 on the 12-pin logic card connector. Close the seat switch. Place the high/low switch in the HIGH position. If the voltage is low, then skip ahead to Test #1.4.
Page 146 Electrical Troubleshooting TEST 1.5: Test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to Test #1.6. If the voltage is low, then skip ahead to Test TEST 1.6: Test the voltage at pin #7 on the 12-pin logic card connector.
Page 147 Electrical Troubleshooting Test 2. TESTING THE MOTOR 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
Page 148 Electrical Troubleshooting TEST 2.3: Test the continuity from the motor A1 terminal to the frame on the motor and from F1 to A1 for open circuits. Any reading other than an open circuit indicate a short in the motor. If there is a short in the motor, stop here and repair or replace the motor.
Page 149 Electrical Troubleshooting Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3.1: TEST 3.5 Close the seat switch, turn the key switch ON and Disconnect the batteries and remove wires from wait 1-second until the Isolator contactor closes. the B-, F1, and F2 terminals on the controller. If the vehicle runs in reverse only then skip Using the diode test function on your meter, connect ahead to test #3.3.
Page 150 Electrical Troubleshooting Test 4. KEY FAULT TEST 4.1: TEST 4.3: Turn the key switch ON and place the forward and Test the voltage at the cold side (violet/black wire) reverse switch in the center OFF position of the key switch. If the voltage equals battery volts, then skip Perform the following tests: ahead to test #4.4.
Page 151 Electrical Troubleshooting Test 5. CONTACTOR COIL FAULT Disconnect the 12-pin logic card connector from the Sevcon power unit. Turn the key switch ON and perform the following tests: TEST 5.1: Check the voltage on the positive coil terminal of the ISO solenoid (violet wire).
Page 152 Electrical Troubleshooting Test 6. ACCELERATOR MODULE FAULT 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
Page 153 Electrical Troubleshooting Test 7. FORWARD AND REVERSE SWITCH FAULT Turn the key switch ON, place the forward and reverse switch in the center OFF position and perform the following tests: TEST 7.1: Referencing battery positive, test the voltage on the center terminal of the F&R switch (Black wire).
Page 154 Electrical Troubleshooting TEST 7.3: If the vehicle does not travel in forward, skip ahead to test #7.4. Place the forward and reverse switch in the REVERSE position. Referencing battery positive, test the voltage at the White/Black wire on the F&R switch. If the voltage equals battery volts, skip ahead to test #7.4.
Page 155: Test 8. Anti-Rolloff Fault
Electrical Troubleshooting Test 8. ANTI-ROLLOFF FAULT The Sevcon Controller is equipped with a feature called Anti-Rolloff. Anti-Rolloff will automatically slow the vehicle if it starts to roll. Anti-Rolloff is active when the key switch has been left in the “ON” position and the accelerator pedal is not depressed. Anti-Rolloff is deactivated when the key switch is in the “OFF”...
Page 156: Test 9. Electric Motor Brake
Electrical Troubleshooting Test 9. ELECTRIC MOTOR BRAKE Description: The electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what times the brake is applied or released is dependent on the controller programing and will vary depending on the model vehicle.
Page 157 Electrical Troubleshooting Connect a volt meter across the Violet/Black wire at the electric brake harness plug and Pin #9 at the logic card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts after about 0.5 seconds. If the test is good then: •...
Page 158: Logic Voltage Reference Table
Electrical Troubleshooting Logic Voltage Reference Table Pin# Condition Volts* Key switch off 0.0 volts Key switch on Battery volts F&R in forward F&R in neutral High F&R in reverse F&R in reverse F&R in neutral High F&R in forward Accelerator pedal up High Accelerator pedal down Seat switch closed (depressed)
Page 159: Status Led Code Table
Electrical Troubleshooting Status LED Code Table The status LED on the Sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component.
Page 160: Smart View Fault Codes
Electrical Troubleshooting Smart View Fault Codes Level 5 Faults (F05xxx) Level 4 Faults (F04xxx) F05004: “VA Fail” F04001: “Contactor Welded” This is a result of a low voltage on an internal voltage High voltage at power up to the controller B+ terminal. regulator.
Page 161 Electrical Troubleshooting Level 2 Faults (F02xxx) Level 1 Faults (F01xxx) F02000: “Accelerator” Most Level 1 faults are a result of operator error or Wiring to throttle module is open or faulty throttle operation of the vehicle. module. F01000: “Power Steer Overheat” F02001: “Accelerator (power up)”...
Page 163: Turn The Key Switch Off Before Disconnecting The Batteries
TABLE OF CONTENTS Operating Instructions and Theory of Operation ......2 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting ......4 Important Notes and Instructions -------------------- 4 Troubleshooting for Built-in Charger ..5 Troubleshooting for Portable Charger ..8 Testing The Timer Relay ......9 Testing the Interlock Relay .....10 Turn the Key switch OFF BEFORE disconnecting the batteries.
Page 164: Operating Instructions And Theory Of Operation
Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic II ® chargers are designed as semiautomatic chargers. The Lestronic II ® charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged into the batteries.
Page 165: Testing The Charging Cycle
Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: •...
Page 166: Test Equipment Required For Troubleshooting
Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter (DMM) with diode and capacitor test function, FLUKE 79 ® model shown at right and in the troubleshooting illustrations. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
Page 167: Troubleshooting For Built-In Charger
Electrical Troubleshooting TROUBLESHOOTING FOR BUILT-IN CHARGER 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 168 Electrical Troubleshooting • Disconnect the charger from the AC source. • Disconnect the batteries. • Disconnect the charger from the vehicle’s harness. • Remove the charger from the vehicle. HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor before continuing.
Page 169 Electrical Troubleshooting • Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad.
Page 170: Troubleshooting For Portable Charger
Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles DC receptacle to main battery negative. This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage then this wire is broken or has a bad connection.
Page 171: Testing The Timer Relay
Electrical Troubleshooting 5. Reconnect the lead to the diode. 6. Connect the charger to the AC source. Insert the DC charger plug into the DC receptacle and perform the following tests: High Voltage inside the charger. Do not touch any internal components while the charger is plugged in.
Page 172: Testing The Interlock Relay
Electrical Troubleshooting 4. Disconnect the wires from the contact terminals on the timer relay. 5. Reconnect the batteries. 6. Wait 5 seconds, then test the continuity across the timer relay contact terminals. • If this is a closed circuit, then the timer start up circuit is functioning normally. •...
Page 173 TABLE OF CONTENTS Operating Instructions and Theory of Operation ........2 HB/PT and GEL Indicator Lamps ...3 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting .......4 Important Notes and Instructions Status LED Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.
Page 174: Operating Instructions And Theory Of Operation
Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION ® ® The model HB600W and HB1000W chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.
Page 175: Hb/Pt And Gel Indicator Lamps
Electrical Troubleshooting HB/PT AND GEL INDICATOR LAMPS NOTE: Your charger may not be equipped with these lamps. HB/PT Lamp If the HB/PT lamp is “ON”, then the charger has overheated and has entered a proportionally reduced output. The charging cycle will terminate if the temperature continues to rise.
Page 176 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING ® Digital Multi Meter (DMM), FLUKE 79 model shown at right and in the troubleshooting illustrations. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
Page 177: Status Led Error Code Table
Electrical Troubleshooting STATUS LED ERROR CODE TABLE There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in the charging cycle.
Page 178: Troubleshooting
Electrical Troubleshooting TROUBLESHOOTING To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet. Wait for charger to start (up to15 seconds), the ammeter should display the DC Amp rating of the charger (plus or minus 10%) indicating that the charger is on (constant current mode).
Page 179 Charger Models: HBS 600 HBS 1000 TABLE OF CONTENTS Definitions: ..........2 Test Equipment Required for Troubleshooting .......2 Important Notes and Instructions Operating Instructions and Theory of Operation ........3 Testing the Charging Cycle ....4 Status Light Error Code Table....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.
Page 180: Clamp On Dc Ammeter To Measure Up To 20-Amps
Electrical Troubleshooting DEFINITIONS: Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells. Term Value Condition V1: Voltages are temperature compensated See Chart Flooded batteries relative to the temperature of the charger at the 2.383 Volts Per Cell Gel Batteries time the charge cycle is started.
Page 181: Operating Instructions And Theory Of Operation
Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Typical specification plate (reference only, specifications will vary for different chargers) ® ® The model HBS 600W and HBS 1000W chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once the charging cycle is complete, the charger will monitor the battery voltage.
Page 182: Testing The Charging Cycle
Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit.
Page 183: Status Light Error Code Table
Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.
Page 184: Troubleshooting
Electrical Troubleshooting TROUBLESHOOTING NOTE: There are no internally serviceable components in the charger. To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet.
Page 185 Wire Diagrams...
Page 186 Wire Diagrams COMPLETE VEHICLE Violet/Black Brown Green/Black Green/Black White White White White Brown Green/Black Violet/Black Black Black Gray/White Blue/Black White/Black Violet/Black White White Black White Brown White Blue White Blue Battery 12-volt tap HORN Battery positive Black Battery negative Violet/Black Violet/Black Yellow Blue...
Page 187 Illustrated Parts TABLE OF CONTENTS Front Axle ........... 2 Speed Control Panel, R 3-80-36 ....32 Steering Linkage ......... 4 Miscellaneous Electrical ......34 Steering Gear ..........6 Miscellaneous Frame ........34 Front Suspension ........8 Seat Cushions and Lights ......36 Transmission (primary reduction) ....
Page 188: Front Axle
Illustrated Parts Front Axle Bottom Thrust Bearing Detail Parts Page 2...
Page 189 Illustrated Parts Front Axle Item # Part# Description 14-380-80 Yoke, Left Side, Without Brakes After Serial # 124156 14-240-08 Yoke, Left Side, Use with Disc Brakes After Serial # 124156 14-380-92 Yoke, Left Side, Without Brakes Up to Serial # 124156 14-380-85 Yoke, Left Side, Use with Disc Brakes Up to Serial # 124156 15-380-33...
Page 190: Steering Linkage
Illustrated Parts Steering Linkage Parts Page 4...
Page 191 Illustrated Parts Steering Linkage Item# Part# 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 192 Illustrated Parts Steering Gear Parts Page 6...
Page 193: Steering Gear
Illustrated Parts Steering Gear ITEM # PART # DESCRIPTION 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assenbly 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 Seal, input shaft 18-308-82 Gasket...
Page 194: Front Suspension
Illustrated Parts Front Suspension Parts Page 8...
Page 195 Illustrated Parts Front Suspension Item# Part# Description 88-119-80 3/8” NF Hex Head Nut 86-006-01 Shock Mounting Hardware 86-006-00 Shock Absorber See Front Axle Beam Axle 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 88-109-81 3/8”Nc Locknut 88-129-81...
Page 196: Transmission (Primary Reduction)
Illustrated Parts Transmission (primary reduction) Parts Page 10...
Page 197 Illustrated Parts Transmission Gear Case ITEM # PART # DESCRIPTION GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1 GT-3287543 Input shaft, 12:1 0 or 1...
Page 198: Transmission (Secondary Reduction)
Illustrated Parts Transmission (secondary reduction) Rear Axle Parts Page 12...
Page 199: Rear Axle
Illustrated Parts Transmission Differential Case ITEM # PART # DESCRIPTION GT-70302 M10 x 30 Bolt GT-3287183 Ring and pinion gear set GT-3297193 Differential case cover GT-3287133 Adjusting ring GT-70417 Fill/Level plug GT-3287113 Differential housing GT-3287143 Differential case GT-72013 O-ring GT-71896 M10 x 25 Bolt GT-71978 Bearing and race...
Page 200 Illustrated Parts Rear Brakes Brake Body Front Brakes (optional) Parts Page 14...
Page 201: Brake Body
Illustrated Parts Rear Brakes ITEM # PART # DESCRIPTION 88-067-21 Hex bolt, grade 8 41-350-51 Secondary plate 41-348-70 Brake pad 41-348-52-61 Spacer (kit, includes spacers #4, and bushings #5 for 1 wheel) 41-348-52-61 Bushing (kit, includes spacers #4, and bushings #5 for 1 wheel) 41-350-28 Mounting bracket See Rear Axle...
Page 202: Rear Suspension
Illustrated Parts Rear Suspension Parts Page 16...
Page 203 Illustrated Parts Rear Suspension Item# Part# 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 01-380-86 Upper shock mount (optional) Shown 86-000-00 Rear shock (optional) 86-602-26...
Page 204: Motor
Illustrated Parts Motor Parts Page 18...
Page 205 Illustrated Parts Parts Page 19...
Page 206: Deadman Seat Brake
Illustrated Parts Deadman Seat Brake Parts Page 20...
Page 207 Illustrated Parts AUTOMATIC DRIVER SEAT BRAKE ITEM # PART # DESCRIPTION 88-067-22 Bolt,1/4 X 2" NC, Grade (no brake option) 88-067-29 Bolt,1/4 X 4-1/4" NC, Grade 8 (brake option only) 41-355-00 Automatic Electric Brake Unit See Motor Motor (Typical) 96-114-10 U-Bolt, 5/16"...
Page 208: Master Cylinder Linkage
Illustrated Parts Master Cylinder Linkage See Brake Lines Master Cylinder Components (All) Parts Page 22...
Page 209 Illustrated Parts Master Cylinder Linkage Item# Part# 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 3/8 Clevis 88-119-80 3/8NF Hex Nut 50-009-00 Push Rod 88-100-09...
Page 210: Brake Lines
Illustrated Parts Brake Lines FRONT BRAKES (optional) FRAME REF. FRAME, REF. FRAME, FRAME, REF. REF. TO MASTER CYLINDER BOLT MASTER CYLINDER REF. SEE NOTE 1 11 (T-fitting) 16 (adaptor) TO MASTER CYLINDER FITTING 13 (master cylinder fitting) 15 (master cylinder bolt) REAR BRAKES NOTE 1: Rear brakes only, connect to adaptor then to master cylinder bolt Front brake option, connect to T-fitting then to master cylinder bolt...
Page 211 Illustrated Parts Brake Lines and Hoses Item# Part# 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 line1, front 99-604-12 Brake line2, front 99-580-20 Brake hose, Front or Rear 99-576-00 Hose clip 99-575-00...
Page 212: Park Brake Linkage
Illustrated Parts Park Brake Linkage Frame Frame Parts Page 26...
Page 213 *-A copy of the bulletin is included on the CD provided with the vehicle. If you do not have the CD, a copy of the bulletin may be obtained through your dealer or by contacting Taylor-Dunn. Parts...
Page 214: Wheels And Tires
Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) Parts Page 28...
Page 215 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Tubeless Wheels 12-012-00 5 x 8" Tubeless (standard) 12-020-00 8.5 x 8 Tubeless Tires 10-081-00 5.70 x 8 (standard) 10-082-00 5.70 x 8 Extra Grip 10-083-00 5.70 x 8 LR C 10-093-00 8.50 x 8 LR B 10-091-10...
Page 216: Instrument Panel (Dash) Ending S/N 179484
Illustrated Parts Instrument Panel (dash) ending s/n 179484 Instrument Panel (dash) starting s/n 179485 Parts Page 30...
Page 217 Illustrated Parts Instrument Panel (ending s/n 179484) Item# Part# Description 71-100-00 Accessory Switch 71-039-11 Rocker Switch 71-039-11 Rocker Switch 74-010-00 Smart view display 71-039-02 Foward/Reverse Switch 71-501-00 Horn switch 71-120-10 Key Switch (keyed alike) 71-121-20 Key Switch (keyed unalike) 71-119-99 Spacer 71-120-90 Keys...
Page 218: Speed Control Panel, R 3-80-36
Illustrated Parts Speed Control Panel, R 3-80-36 Parts Page 32...
Page 219 Illustrated Parts Speed Control Panel ITEM # PART # 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 88-060-09 1/4NC x 3/4 Hex bolt 79-840-00 10 Amp circuit breaker 79-840-20 20 Amp circuit breaker 79-840-20...
Page 220: Miscellaneous Electrical
Illustrated Parts Miscellaneous Electrical Miscellaneous Frame Parts Page 34...
Page 221 Illustrated Parts Miscellaneous Electrical Item# Part# Description 79-575-25 Charger cord, AC 14’ with terminals 79-575-30 Charger cord, AC 8’ with terminals 79-530-00 Strain releif, AC cord (SR 7W-2) 75-107-10 Harness, portable charger JF3-86181-00-00 Receptacle, portable charger 75-120-40 Harness, portable chager with SB plug 75-152-30 Harness, electric deadman brake 75-152-90...
Page 222: Seat Cushions And Lights
Illustrated Parts Seat Cushions and Lights Parts Page 36...
Page 223 Illustrated Parts Seat Cushions and Lights Item# Part# Description 90-198-03 Front Seat Cushion 90-179-00 Front Backrest 90-198-03 Front Seat Cushion 72-025-00 Oval Tail, Stop and Turn Light 72-022-51 Gasket for #4 00-210-04 Seat Frame 94-201-10 Name Plate 04-380-25 Headlight Mounting Panel 04-380-24 Front nose panel (no headlights) 94-050-11...
Page 224: Charger, Lestronic
Illustrated Parts Charger, Lestronic (Pg. 1) Typical Built In charger Typical Portable charger CHARGERS.DWG Parts Page 38...
Page 225 Illustrated Parts Parts Page 39...
Page 226 Illustrated Parts Charger, Lestronic (Pg. 2) Typical Built In charger Typical Portable charger CHARGERS.DWG Parts Page 40...
Page 227 Illustrated Parts Parts Page 41...
Page 228: Charger, Signet
Illustrated Parts Charger, Signet NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector Parts Page 42...
Page 229 Illustrated Parts Signet® Charger ITEM # PART # DESCRIPTION 79-303-40 Charger assembly (see note on facing page) 79-575-60 Replacement cover w/AC cord and gasket Note: There are no user serviceable components inside the charger AC Wire Connections Parts Page 43...
Page 230 Illustrated Parts Batteries 36-Volt 48-Volt Parts Page 44...
Page 231: Batteries
Illustrated Parts Batteries ITEM # PART # DESCRIPTION 77-042-00 217AH, T-105 0 or 6 77-042-50 217AH, TD-217 0 or 6 77-042-80 217AH, T-105 Moist charge (dry) 0 or 6 77-044-00 230AH, T-125 0 or 6 77-044-10 195AH, Mainenance free (Note: requires special charger) 0 or 6 77-047-00 244AH, T-145...
Page 232: Decals
Illustrated Parts Decals Front Cowl Tray Battery Compartment Parts Page 46...
Page 233 Illustrated Parts Decals Item# Part# Description 94-384-01 Not a Motor Vehicle 94-309-00 Apply Hand Brake 94-384-14 Turn Key Off 94-301-42 Arms and Legs 94-313-20 Safety Warning 94-373-10 Data and Serial Number 94-333-00 94-313-00 Battery Waring 94-301-41 Brake Fluid 94-319-00 Disconnect Batteries shown 88-069-81 Do not Spray Wash Parts...
Page 234: Trailer Hitch
Illustrated Parts Trailer Hitch Parts Page 48...
Page 235 Illustrated Parts Trailer Hitches ITEM # PART # DESCRIPTION 97-808-00 Automatic Coupling hitch 97-804-01 Pintle hitch 97-811-00 1-7/8" Ball hitch 97-805-00 Mounting brakcket 97-821-00 2" Ball hitch 97-807-00 Mounting bracket 88-140-14 1/2NC x 1-1/2 Hex bolt 88-140-11 1/2NC x 1 Hex bolt 88-149-80 1/2NC Hax nut 88-148-62...
Page 236: Strobe Light & Other Front End Options
Illustrated Parts Strobe Light & Other Front End Options Parts Page 50...
Page 237 Illustrated Parts STROBE LIGHT, DIRECTIONAL SIGNALS & HEADLIGHT OPTIONS ITEM# PART # DESCRIPTION 75-141-22 Turn Signal Switch 98-330-50 Insulator 76-352-00 Flasher Recptacle 71-900-05 12Volt Flasher 72-082-10 12Volt Turn signal Bulb 72-082-20 Turn Signal socket 72-023-20 Strobe Light, Amber 72-023-25 Mounting Pole for Strobe Light 88-025-06 #8-32 X 1/2"...
Page 238: Cab & Cowl With Windshield Options
Illustrated Parts Cab & Cowl With Windshield Options Parts Page 52...
Page 239 Illustrated Parts CAB & COWL WITH WINDSHIELD OPTIONS ITEM# PART # DESCRIPTION 90-825-62 Windshield Kit 90-825-20 Plexiglass 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" Lockwasher 88-069-83 1/4"NC Acorn Nut 88-065-08 1/4"NC X 5/8"...
Page 240: Optional Cab Accessories
Illustrated Parts Optional Cab Accessories Parts Page 54...
Page 241 Illustrated Parts OPTIONAL CAB ACCESSORIES ITEM# PART # DESCRIPTION 72-023-20 Strobe Light, Amber 88-025-06 #8-32 X 1/2" Truss Head Screw 88-028-62 #8 Lockwasher 88-029-80 #8-32 Nut 98-606-00 3/16" ID Grommet Not Shown 75-114-16 Wiring Harnes for Wiper and Light 92-201-00 4-1/2"...
Page 242: Cab Door Options
Illustrated Parts Cab Door Options Parts Page 56...
Page 243 Illustrated Parts CAB DOORS ITEM# PART # 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 Door Latch 97-315-54 Inner Handle 97-303-03 Snap Fastener, Female...
Page 244: Optional Top Cover
Illustrated Parts Optional Top Cover Parts Page 58...
Page 245 Illustrated Parts S U R R E Y TOP COVER ITEM# PART # DESCRIPTION 91-120-62 Surrey Top Cover Kit 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 246: Rear Seat, Rear Gate And Rear Deck
Illustrated Parts Rear Seat, Rear Gate and Rear Deck Parts Page 60...
Page 247 Illustrated Parts REAR SEAT, REAR GATE & PIPE RAILS FOLD DOWN REAR SEAT ITEM# PART # DESCRIPTION 90-109-63 Fold Down Rear Seat Kit 90-000-00 6" X 34" Backrest 90-177-00 Seat Cushion 88-837-11 #14 X 1" Phillips Sheet Metal Screw 00-380-67 Rear Flip Up Deck 88-065-09 1/4"NC X 3/4"...
Page 248: 9" Side Panels
Illustrated Parts 9” Side Panels Parts Page 62...
Page 249 Illustrated Parts 9" SIDE PANELS & TAILGATE ITEM# PART # DESCRIPTION 91-281-64 9" Side Panels Kit with Tailgate, Orange 91-281-66 9" Side Panels Kit with Tailgate, Specify Color 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...
Page 250: Front Bumper And Splash Pan
Illustrated Parts Front Bumper and Splash Pan Parts Page 64...
Page 251 Illustrated Parts FRONT BUMPER AND SPLASH PAN ITEM# PART # 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 Parts Page 65...
Page 253: Brake Lining Handling Precautions
Contents Appendix A: Special Tools ....2 Appendix B: Suggested Torque Limits for Standard Hardware ....4 Hardware Identification ...... 4 Standard Head Markings ........4 Hex Bolts .............. 4 Other Bolts ............4 Hex Nuts ............... 4 Hex Lock Nuts (stover) ........4 Other Nuts .............
Page 254: Appendix A: Special Tools
Appendixes APPENDIX A: SPECIAL TOOLS Note: This is a listing of all tools available. Not all tools would be required for all vehicles. Refer to the Maintenance, Repair, and Troubleshooting sections for information on tools required. 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness Used in conjunction with a volt meter to test Tests the throttle module in or out of the vehicle...
Page 255 Molex # 11-300-06: Pin Removing Tool Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not available rectangular harness connectors. Not available from Taylor-Dunn. Purchase from any local from Taylor-Dunn. Purchase from any local electronics distributor. electronics distributor. Appendixes...
Page 256: Appendix B: Suggested Torque Limits For Standard Hardware
Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings 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. NOTE: Toque values specified are for clean dry threads.
Page 257: Hex Nuts
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 Appendixes *Not available at time of printing Appendix B Page 5...
Page 258 Appendixes Generic Torque Values 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. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
Page 259 Appendixes 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 Grade, N-m...
Page 260: Appendix C: Brake Lining Handling Precautions
Appendixes APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS Taylor-Dunn does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the brake pads/ shoes should be handled as if they do contain asbestos.

This manual is also suitable for:

Re-380-48 R 380-36 R 380-48

Taylor-Dunn RE-380-36 Operator's And Service Manual

Introduction

Table of Contents

Standard Specifications

Driver Training Program

Safety Rules and Guidelines

Vehicle Controls

Vehicle Operation Guidelines

Charging Your Vehicle

Storing / Returning to Service

Periodic Maintenance Checklist

Standard Periodic Maintenance Schedule for the Smart View Display

Maintenance Guidelines for Severe Duty Applications

Front Axle Service

Steering Component Service

Brake Service

Table of Contents

Transmission

Suspension

Replace the Rear Springs

Replace the Front Springs

Replace the Spring Bushings

Replace the Shocks

Tires and Wheels

Battery Service

Sevcon Control System Troubleshooting

Turn the Key Switch off before Disconnecting the Batteries

Table of Contents

Charger Models: Hbs 600 Hbs 1000

Illustrated Parts

Appendix A: Special Tools

Appendix B: Suggested Torque Limits for Standard Hardware

Appendix C: Brake Lining Handling Precautions

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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