Taylor-Dunn RE-380-48 Manuals

Manuals and User Guides for Taylor-Dunn RE-380-48. We have 2 Taylor-Dunn RE-380-48 manuals available for free PDF download: Operator's And Service Manual, Service And Replacement Parts Manual

Taylor-Dunn RE-380-48 Operator's And Service Manual (260 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 8.33 MB

Introduction

5
- Table of Contents
  5
- Introduction
  6
- About this Manual
  6
- Who Should Read this Manual
  7
- Responsibilities
  7
  - Safety Rules and Operating Instructions
    8
- How to Use this Manual
  8
- Conventions
  9
- How to Identify Your Vehicle
  10
- Taking Delivery of Your Vehicle
  11
Table of Contents

13
- Standard Specifications
  
  14
  - Safety Rules and Operating Instructions
    14
- Driver Training Program
  
  15
  - Driver Qualifications
    15
  - Before Working
    15
- Safety Rules and Guidelines
  
  15
- Vehicle Controls
  
  16
  - Key-Switch
    16
  - Forward-Off-Reverse Switch
    16
  - Accelerator Pedal
    16
  - Steering
    16
  - Foot Brake Pedal
    16
  - Seat Interlock Switch
    17
  - Charger Interlock
    17
  - Park Brake
    17
  - Horn Switch
    17
  - Reverse or Motion Alarm (Optional)
    18
  - Directional Signals (Optional)
    18
  - Hazard Light Switch (Optional)
    18
  - Electrolyte Alarm (Optional)
    18
  - Headlight Switch
    18
  - Battery Status Indicator, Analog
    19
  - Battery Status Indicator, Digital Bargraph
    19
  - Hour Meter (Optional)
    19
  - Smart View Display
    20
  - Fault Code Tables
    22
- Vehicle Operation Guidelines
  
  23
  - Safety Guidelines
    23
  - Starting
    23
  - While Driving
    23
  - Loading and Unloading
    23
  - Towing Loads
    23
  - Parking
    24
  - Draw Bar Pull (DBP), Definition
    24
  - Automatic Electric Park Brake
    24
  - Towing this Vehicle
    24
- Charging Your Vehicle
  
  25
- Storing / Returning to Service
  
  26
  - Storing Your Vehicle
    26
  - Returning to Service
    26
- Periodic Maintenance Checklist
  
  27
- Standard Periodic Maintenance Schedule for the Smart View Display
  
  28
  - Daily Visual Inspection
    29
- Maintenance Guidelines for Severe Duty Applications
  
  29
  - General Maintenance
    31
  - Troubleshooting Guide
    33
  - Lubrication Chart
    34
Front Axle Service

35
- Inspect the Front Wheel Bearings and Kin Pin
  36
- Adjust Front Wheel Bearings
  37
- Front Axle Removal and Installation
  38
  - Removal
    38
  - Installation
    39
  - Steering Component Service
    39
- Front Axle Disassembly
  40
- Front Axle Removal
  40
- Replace Front Wheel Bearings
  41
- Replace the Ball Joints, Tie Rods, and Drag Link
  42
  - Replacing the Drag Link
    44
  - Replacing the Tie Rod
    45
- Replace the King Pins and Bushings
  46
- Replace the Steering Knuckle
  48
Steering Component Service

51
Brake Service

65
- Inspect the Service Brake
  66
  - Disc Brake Pads
    66
  - Disc Brake Rotor
    67
- Inspect the Parking Brake
  68
  - Wheel Park Brake (Hydraulic Disc)
    68
- Inspect the Parking Brake
  69
  - Motor Brake (Optional)
    69
- Adjust the Service Brakes
  70
  - Two or Four Wheel Hydraulic Disc Brakes
    70
- Adjust the Parking Brake
  71
  - Wheel Park Brake (Hydraulic Disc)
    71
- Check Master Cylinder Fluid
  72
- Bleed the Brake System
  73
- Flush the Brake System
  75
- Replace the Parking Brake Lining (Optional Motor Brake)
  76
  - Inspection
    78
- Replace Front Disc Brake Pads
  79
- Replace Rear Brake Pads
  81
  - Hydraulic Disc
    81
- Replace the Wheel Cylinder
  83
  - Disc Brake Body Assembly (Front or Rear)
    83
- Repair the Brake Body
  85
- Replace the Master Cylinder
  87
- Repair the Master Cylinder
  89
Table of Contents

91
- Inspecting the Motor Brushes
  92
  - Motors with Internal Cooling Fans
    92
- Motor Inspection
  92
- Motor Removal and Installation
  92
- Motor Service
  92
- Replacing the Brushes or Armature Bearing
  94
- Repairing the Commutator
  95
- Service Limits
  96
Transmission

97
- Check Oil Level
  98
- Change Oil
  99
- Motor Removal and Installation
  100
- Rear Hub or Rotor
  101
- Removing and Installing the Rear Axles (Disc Brakes)
  102
  - Suspension
    104
- Transmission Assembly
  104
  - Remove and Install
    104
- Disassembly and Reassembly of the Primary Reduction Gear Case
  105
- Disassembling the 3Rd Member
  108
- Assembling the 3Rd Member
  111
  - Pinion Bearing Preload
    114
- Pinion Gear Shimming Instructions
  115
  - Setting the Pinion Gear Depth
    115
Suspension

117
- Replace the Rear Springs
  
  118
  - Leaf
    118
- Replace the Front Springs
  
  119
  - Leaf
    119
- Replace the Spring Bushings
  
  121
- Replace the Shocks
  
  122
  - Front or Rear
    122
  - Tires and Wheels
    122
Tires and Wheels

123
- Tire Inflation
  124
- Tire Inspection
  124
- Repair the Tire (Pneumatic)
  126
- Replace the Tire (Pneumatic)
  127
Battery Service

129
- Cleaning
  130
- Testing
  131
- Watering
  133
- Charging
  134
- Replacing (6-Volt Batteries Only)
  135
  - Battery Removal (48 Volt System)
    137
  - Moist Charge Batteries
    138
- Storage and Returning to Service
  139
  - Storage
    139
  - Returning to Service
    140
Sevcon Control System Troubleshooting

141
- Control System Troubleshooting
  141
- Definitions
  142
- Important Notes and Instructions
  142
- Terminology Used
  142
- Test Equipment Required
  142
- Identifying Your Controller
  143
- Start Troubleshooting here
  144
- Test 8. Anti-Rolloff Fault
  155
- Test 9. Electric Motor Brake
  156
- Logic Voltage Reference Table
  158
- Status LED Code Table
  159
- Smart View Fault Codes
  160
Turn the Key Switch off before Disconnecting the Batteries

163
- Operating Instructions and Theory of Operation
  164
- Wire Diagram
  164
- Testing the Charging Cycle
  165
- Important Notes and Instructions
  166
- Test Equipment Required for Troubleshooting
  166
- Troubleshooting for Built-In Charger
  167
- Troubleshooting for Portable Charger
  170
- Testing the Timer Relay
  171
- Testing the Interlock Relay
  172
Table of Contents

173
- Operating Instructions and Theory of Operation
  174
- HB/PT and GEL Indicator Lamps
  175
- Testing the Charging Cycle
  175
  - Troubleshooting
    175
- Status LED Error Code Table
  177
- Troubleshooting
  178
Charger Models: Hbs 600 Hbs 1000

179
Illustrated Parts

187
- Front Axle
  188
- Steering Linkage
  190
- Steering Gear
  193
- Front Suspension
  194
- Transmission (Primary Reduction)
  196
- Transmission (Secondary Reduction)
  198
- Rear Axle
  199
- Brake Body
  201
- Front Brake
  201
- Rear Brakes
  201
- Rear Suspension
  202
- Motor
  204
- Deadman Seat Brake
  206
- Master Cylinder Components (All)
  208
- Master Cylinder Linkage
  208
- Brake Lines
  210
- Park Brake Linkage
  212
- Wheels and Tires
  214
- Illustrated Parts
  216
- Instrument Panel (Dash) Ending S/N 179484
  216
- Instrument Panel (Dash) Starting S/N 179485
  216
- Speed Control Panel, R 3-80-36
  218
- Miscellaneous Electrical
  220
- Miscellaneous Frame
  220
- Seat Cushions and Lights
  222
- Charger, Lestronic
  224
- Charger, Signet
  228
- Batteries
  231
- Decals
  232
- Trailer Hitch
  234
- Strobe Light & Other Front End Options
  236
- Cab & Cowl with Windshield Options
  238
- Optional Cab Accessories
  240
- Cab Door Options
  242
- Optional Top Cover
  244
- Rear Seat, Rear Gate and Rear Deck
  246
- 9" Side Panels
  248
- Front Bumper and Splash Pan
  250
  - Brake Lining Handling Precautions
    253
- Appendix A: Special Tools
  
  254
- Appendix B: Suggested Torque Limits for Standard Hardware
  
  256
  - Standard Head Markings
    256
  - Hex Bolts
    256
  - Other Bolts
    256
  - Hex Nuts
    257
  - Hex Lock Nuts (Stover)
    257
  - Other Nuts
    257
- Appendix C: Brake Lining Handling Precautions
  
  260

Taylor-Dunn RE-380-48 Service And Replacement Parts Manual (150 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 7.2 MB

Master

5
- Table of Contents
  5
- About this Manual
  8
- How to Use this Manual
  8
- Introduction
  8
- Who Should Read this Manual
  8
- Introduction
  9
  - Conventions
    9
    
    Signal Words and Their Definitions
    9
  - Responsibilities
    10
  - How to Identify Your Vehicle
    11
  - Web Site Registration
    11
Service/Maintenance Guidelines

13
Section 3

17
- Preventative Maintenance
  17
- Daily Visual Inspection
  
  18
- Pre-Operation Inspection
  
  18
- Maintenance Schedule
  
  18
- Interlock Switch Inspection
  
  20
  - Start Switch
    20
  - Charger Interlock Switch
    20
  - High Pedal Disable (HPD)
    20
  - Operator Presence Switch
    20
  - Brake Interlock Switch
    20
  - Special Tool List
    21
  - Lubrication
    25
Section 4

29
- Front Axle
  29
  - Front Axle
    30
  - Remove
    30
  - Install
    31
  - Disassemble
    32
  - Inspect Front Wheel Bearings
    33
  - Adjust Front Wheel Bearings
    33
  - Front Wheel Alignment
    34
  - Replace Front Wheel Bearings
    35
  - Replace Steering Knuckle
    35
  - Center the Steering
    36
  - Replace King Pin/Bushings
    37
  - Service Limits and Specifications
    38
    
    King Pin Bushings
    38
    
    Toe in
    38
  - Hardware Torque
    38
Section 5

39
- Transaxle-GT
  39
  - Transaxle-GT
    40
  - Check Oil Level
    40
  - Change Oil
    40
  - Transaxle Assembly
    41
    
    Remove and Install
    41
  - Axle Shaft
    42
    
    Remove
    42
    
    Install
    42
  - Rear Hub, Rotor & Bearings
    43
  - Motor, Remove
    43
  - Primary Gear Case
    44
  - Secondary Gear Case
    45
    
    Disassemble
    45
    
    Assemble
    45
  - Pinion Bearing Preload
    47
    
    Pinion Gear Shimming Instructions
    47
    
    Set Pinion Bearing Preload
    47
  - Hardware Torque
    48
Section 6

49
- Transaxle-SD
  49
  - Transaxle-SD
    50
  - Check Oil Level
    50
  - Change Oil
    50
  - Transaxle Assembly
    51
    
    Remove and Install
    51
  - Axle Shaft
    52
    
    Remove
    52
    
    Install
    52
  - Rear Hub, Rotor & Bearings
    53
  - Motor, Remove
    53
  - Primary Reduction Gear Case
    54
  - 3Rd Member
    56
  - Hardware Torque
    56
Section 7

57
- Steering
  57
  - Inspect Ball Joints
    58
  - Inspect Rod Ends
    58
  - Adjust Steering Gear
    59
  - Front Wheel Alignment
    59
  - Replace Ball Joint
    60
  - Replace Rod End
    60
  - Replace Steering Shaft
    61
  - Replace Steering Wheel
    62
  - Steering Gear
    63
    
    Disassemble
    63
    
    Reassemble
    64
    
    Exploded View of Steering Gear
    65
  - Hardware Torque
    66
Section 8

67
- Brakes
  67
- General Guidelines and Safety
  
  68
- Front Brake
  
  69
  - Service Limits
    69
  - Inspection
    69
  - Replace Pads
    69
- Rear Brake
  
  70
  - Service Limits
    70
  - Inspection
    70
  - Replace Pads
    70
- Rebuild Disc Brake Body
  
  71
- Bleed System
  
  72
- Flush System
  
  72
- Master Cylinder
  
  73
  - Add Fluid
    73
  - Rebuild
    73
- Parking Brake
  
  74
  - Inspect
    74
  - Adjust
    74
- Pedal Linkage
  
  75
- Service Limits
  
  76
- Hardware Torque
  
  76
Section 9

77
- SEM Motor
  77
- Remove/Install
  
  78
- Disassemble
  
  78
- Inspect
  
  79
  - Brushes
    79
  - Bearing
    79
  - Commutator
    79
  - Armature Windings
    79
  - Field Windings
    80
- Repair
  
  81
- Service Limits
  
  82
Section 10

83
- Inspect
  84
  - Receptacles
    84
  - Base Plate
    84
  - Terminal Ends
    84
  - R' Terminal
    84
- Motor Controller
  84
- Remove/Install
  84
- Motor Controller
  85
  - Repair/Programming
    85
    
    Programming
    85
  - Troubleshooting
    85
  - Hardware Torque
    86
- Wire Diagram
  87
Section 11

91
- Batteries
  91
  - General Guidelines and Safety
    92
  - Cleaning
    93
  - Charging
    93
  - Watering
    93
  - Testing
    94
    
    Specific Gravity
    94
  - Storing
    94
    
    Storage
    94
    
    Returning to Service
    94
  - Remove/Install
    95
    
    Individual Batteries
    95
    
    Battery Removal, 48 Volt System
    96
  - Hardware Torque
    96
Section 12

97
- Tires & Wheels
  97
  - Tires & Wheels
    98
  - Inflation
    98
  - Air Pressure
    98
  - Tread Wear
    99
  - Rotation
    99
  - Changing Tire/Wheel Assembly
    100
  - Replace the Tire (Pneumatic)
    100
  - Repair the Tire (Pneumatic)
    100
  - Hardware Torque
    101
Section 13

103
- Hardware Information
  103
- Torque Guidelines for Standard Hardware
  
  104
  - Hardware Identification
    104
  - Hex Lock Nuts (Stover)
    105
  - Hex Nuts
    105
  - Other Nuts
    105
  - Generic Torque Values
    106
- Replacing Hardware
  
  108
Replacement Parts

109
- Replacement Parts
  110
  - Ordering Parts for Your Vehicle
    110
  - Taylor-Dunn Web Site Information
    110
- Axle Assembly, Front
  112
- Axle Shaft Assembly, Rear
  112
- GT Transaxle Assembly, Rear
  114
- SD Transaxle Assembly, Rear 3Rd Member
  116
- SD Transaxle Assembly, Rear Primary Reduction
  117
- Battery
  118
- Brakes, Brake Lines
  120
- Brakes, Front Axle
  122
- Brakes, Master Cylinder Linkage
  123
- Brakes, Park Brake Linkage
  124
- Brakes, Rear Axle
  125
- Charger, Signet
  126
- Charger, Summit
  127
- Control System, Motor Speed Control
  128
- Control System, Instrument Panel
  129
- Decals
  130
- Electrical, Miscellaneous
  131
- Frame and Body (P1)
  132
- Frame and Body (P2)
  133
- Frame and Body (P3)
  134
- Frame and Body (P4)
  135
- Frame and Body (P5)
  137
- Frame and Body (P6)
  138
- Hitches
  139
- Lights
  140
- Mirrors
  141
- Motor
  142
- Seats
  142
- Steering Gear
  143
- Steering Linkage
  144
- Suspension, Front
  146
- Suspension, Rear
  147
- Turn Signals
  148
- Wheels and Tires
  148
- Windshield Wiper
  148

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Taylor-Dunn RE-380-48 Manuals

Taylor-Dunn RE-380-48 Operator's And Service Manual (260 pages)

Table of Contents

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

Taylor-Dunn RE-380-48 Service And Replacement Parts Manual (150 pages)

Table of Contents

Master

Service/Maintenance Guidelines

Section 3

Daily Visual Inspection

Pre-Operation Inspection

Maintenance Schedule

Interlock Switch Inspection

Section 4

Section 5

Section 6

Section 7

Section 8

General Guidelines and Safety

Front Brake

Rear Brake

Rebuild Disc Brake Body

Bleed System

Flush System

Master Cylinder

Parking Brake

Pedal Linkage

Service Limits

Hardware Torque

Section 9

Remove/Install

Disassemble

Inspect

Repair

Service Limits

Section 10

Section 11

Section 12

Section 13

Torque Guidelines for Standard Hardware

Replacing Hardware

Replacement Parts

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