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Taylor-Dunn RE-380-48 User Manual

Taylor-Dunn RE-380-48
260 pages
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Serial number Starting: 155932
MANUAL MR-380-28
Operation, Troubleshooting 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

Table of Contents

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Questions and Answers:

Taylor-Dunn RE-380-48 Specifications

General IconGeneral
BrandTaylor-Dunn
ModelRE-380-48
CategoryUtility Vehicle
LanguageEnglish

Summary

Introduction

About This Manual

Provides an overview of the manual's purpose and content.

Vehicle Identification and Delivery

Details how to identify the vehicle model and serial numbers, and delivery inspection procedures.

Safety Rules and Operating Instructions

Standard Specifications

Lists the technical specifications for the vehicle models covered in the manual.

Safety Rules and Driver Training

Outlines critical safety guidelines and requirements for operator training and qualifications.

Vehicle Controls and Operation

Explains the function and operation of all vehicle controls and driving guidelines.

Maintenance and Charging Procedures

Covers vehicle charging methods, periodic maintenance schedules, and inspection guidelines.

General Maintenance

Maintenance Guidelines

Details the schedule and procedures for performing regular vehicle maintenance.

Troubleshooting Guide

Provides a systematic approach to diagnosing and resolving common vehicle issues.

Lubrication Chart

Specifies lubrication points, intervals, and lubricant types for vehicle components.

Front Axle Service

Inspect and Adjust Wheel Bearings

Describes the process for checking wheel bearing play and adjusting them for proper function.

Front Axle Removal and Installation

Provides step-by-step instructions for removing and reinstalling the front axle assembly.

Front Axle Component Replacement

Details procedures for replacing key front axle components like ball joints and king pins.

Steering Component Service

Front End Alignment

Explains how to perform front wheel alignment for optimal steering and tire wear.

Adjust and Replace Steering Gear Components

Covers adjusting the steering gear and replacing components like the steering shaft.

Steering Gear Replacement and Repair

Outlines the steps for replacing or repairing the main steering gear assembly.

Brake Service

Inspect and Adjust Brakes

Details procedures for inspecting brake pads, rotors, and adjusting the system.

Master Cylinder and Brake System Maintenance

Covers checking brake fluid, bleeding, and flushing the hydraulic brake system.

Brake Component Replacement

Provides instructions for replacing brake pads, wheel cylinders, and brake bodies.

Motor Service

Motor Inspection and Removal

Explains how to inspect motor brushes, commutator, and perform motor removal.

Motor Brush and Bearing Replacement

Details the process for replacing worn motor brushes or bearings.

Commutator Repair and Service Limits

Covers commutator repair procedures and essential service limit specifications.

Transmission

Check and Change Oil

Instructions for checking and changing the transmission fluid in the differential and gear cases.

Motor and Drive Assembly Service

Covers motor removal/installation and servicing of rear axles and hubs.

Transmission Assembly and Disassembly

Provides detailed procedures for disassembling and reassembling the transmission.

Pinion Gear Shimming and Preload

Explains how to set pinion gear depth, preload, and mesh for proper operation.

Suspension

Spring and Bushing Replacement

Details procedures for replacing leaf springs and spring bushings.

Shock Absorber Replacement

Instructions for removing and installing front or rear shock absorbers.

Tires and Wheels

Tire Inflation and Inspection

Covers checking tire pressure and inspecting tread depth and wear indicators.

Tire and Wheel Replacement

Provides steps for removing and installing tire and wheel assemblies.

Tire Repair and Replacement

Outlines procedures for repairing punctures and replacing pneumatic tires.

Battery Service

Battery Cleaning and Testing

Details methods for cleaning battery terminals and performing load and specific gravity tests.

Battery Watering and Charging

Covers procedures for checking electrolyte levels and charging the batteries.

Battery Replacement and Storage

Provides instructions for replacing batteries and proper storage procedures.

Sevcon Control System Troubleshooting

Test Equipment and Important Notes

Lists necessary test equipment and provides crucial notes for troubleshooting procedures.

Controller, Motor, and Switch Testing

Guides on identifying controllers and testing logic inputs, motor circuits, and switches.

Brake and Fault Code Troubleshooting

Details testing the electric motor brake and interpreting various system fault codes.

Lestronic II Charger Troubleshooting

Operating Instructions and Charging Cycle Testing

Explains the charger's operation, theory, and methods for testing the charging cycle.

Charger Troubleshooting Procedures

Provides systematic troubleshooting steps for built-in and portable Lestronic II chargers.

Signet Charger Troubleshooting

Operating Instructions and Charging Cycle Testing

Details the Signet charger's operation, theory, and how to test its charging cycle.

Status LED Error Codes and Troubleshooting

Explains error codes indicated by charger status LEDs and outlines troubleshooting steps.

Wire Diagrams

Complete Vehicle Wiring Diagram

Presents a detailed wiring diagram illustrating the complete electrical system of the vehicle.

Illustrated Parts

Front Axle and Steering Components

Exploded views and part numbers for front axle and steering system components.

Brake, Suspension, and Wheel Parts

Illustrated parts lists for brake systems, suspension components, and wheels/tires.

Motor, Transmission, and Charger Parts

Exploded views and part numbers for motor, transmission, and charger assemblies.

Cab, Chassis, and Optional Accessories

Illustrated parts for cab options, decals, trailer hitches, and other vehicle accessories.

Appendixes

Appendix A: Special Tools

Lists specialized tools required for vehicle maintenance, repair, and troubleshooting tasks.

Appendix B: Suggested Torque Limits

Provides torque specifications for standard hardware used in vehicle assembly.

Appendix C: Brake Lining Handling Precautions

Details safety precautions for handling brake lining materials, including potential asbestos exposure.

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