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RE-380-36
Taylor-Dunn RE-380-36 User Manual
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Serial number Starting: 155932
MANUAL MR-380-28
Operation,
T
roubleshooting and
Replacement Parts Manual
Models Inlcuded:
RE-380-36 (R 380-36)
RE-380-48 (R 380-48)
Equipped with the GT Drive System
Published: 1/6/2005
Revision: D
Typical GT Drive
2
Table of Contents
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
Signet Charger Operation, Model HB Series
25
Signet Charger Operation, Model HBS Series
25
Lestronic II Charger Operation
26
New Battery Break in
26
Charging Time
26
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
Front End Alignment
52
Adjust the Steering Gear (Saginaw)
56
Replace the Steering Shaft (Non-Tilt Steering)
57
Replace the Steering Wheel
59
Replace the Steering Gear
60
Repair the Steering Gear
61
Exploded View of Steering Gear
64
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
Clamp on DC Ammeter to Measure up to 20-Amps
180
Damage to the Charger
180
Definitions
180
If the Charger Exhibits Intermittent Problems, It Must be in the Failed Mode for Troubleshooting
180
Make Sure that the AC Electrical Socket the Charger Is Plugged into Is in Good
180
Make Sure that the AC Voltage at the Electrical Socket Is the same as the AC
180
Make Sure the Batteries Are in Good Condition
180
Test Equipment Required for Troubleshooting
180
There Are no Internally Serviceable Components in the Charger. if the Charger Has Failed then It Must be
180
This Troubleshooting Guide Assumes a Familiarity with the Use of a Digital Multimeter
180
Operating Instructions and Theory of Operation
181
Testing the Charging Cycle
182
Status Light Error Code Table
183
Troubleshooting
184
Illustrated Parts
187
Default Chapter
188
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
Other manuals for Taylor-Dunn RE-380-36
Service And Replacement Parts Manual
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Taylor-Dunn RE-380-36 Specifications
General
Brand
Taylor-Dunn
Model
RE-380-36
Category
Utility Vehicle
Language
English
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