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- Taylor-Dunn
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- B 1-50
- Operation, T Roubleshooting And Replacement Parts Manual
Taylor-Dunn B 1-50 Operation, T Roubleshooting And Replacement Parts Manual
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
®
Serial number Starting: 136914
MANUAL MB-150-02
Operation, Troubleshooting and
Replacement Parts Manual
Published: 11/26/2002
Revision: C
B0-015-00
MX-016-00
Models Inlcuded:
B0-015-00 (B 1-50) Load Master
MX-016-00 (MX 1600) Maintenance Expediter
Summary of B 1-50
Page 1
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 ® serial number starting: 136914 manual mb-150-02 operation, troubleshooting and replacement parts manual published: 11/26/2002 revision: c b0-015-00 mx-016-00 models inlcuded: b0-015-00 (b 1-50) load master mx-016-00 (mx 1600) maintenanc...
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Taylor-dunn contact information service, parts, sales: taylor-dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the tayl...
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B2-48 with dump bed option b2-10 ambulance b2-48 with steel cab, foldaway 4-passenger seat and stake sides et 3000 et1-50 full size truck p2-50 30,000 pound tow tractor.
Page 5: Taylor-Dunn
Section index introduction 1 safety rules and operating instructions 2 general maintenance 3 front axle service 4 steering component service 5 brakes service 6 motor service 7 transaxle service 8 suspension 9 battery service 10 tires and wheels 11 control system troubleshooting 12 wire diagram 13 ch...
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Page 7: Introduction
Introduction about this manual ......................................... 2 who should read this manual .................... 2 responsibilities ............................................ 3 how to use this manual .............................. 4 conventions .............................................
Page 8: About This Manual
Introduction introduction page-2 about this manual the purchase of this vehicle shows a belief in high quality products manufactured in the usa. Taylor-dunn ® , a leading manufacturer of electric burden and personnel carriers since 1949, wants to be sure this vehicle provides years of reliable servi...
Page 9: Who Should Read This Manual
Introduction introduction page-3 who should read this manual this manual is intended for use by anyone who is going to operate, own, perform maintenance on, service, or order parts for this taylor-dunn ® vehicle. Each person should be familiar with the parts of this manual that apply to their use of...
Page 10: How to Use This Manual
Introduction introduction page-4 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 issu...
Page 11
Introduction introduction page-5 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 themself or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the t...
Page 12
Introduction introduction page-6 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, mote...
Page 13
Introduction introduction page-7 taking delivery of your vehicle inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems: • examine the contents of all packages and accessories that may have come in separate packages with the vehicle. • make...
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Model b 1-00
Page 15: Safety Rules and Operating
Table of contents standard specifications ................................ 2 safety rules and guidelines ......................... 3 driver training program ................................ 4 driver qualifications. ............................................... 4 vehicle controls .....................
Page 16: Standard Specifications
Safety rules and operating instructions safety rules page 2 standard specifications item model voltage specification occupancy driver and one passenger dimensions b 1-50 274.2l x 112.5w x 120.7h centimeters 107.95l x 44.29 x 47.5h inches mx 1600 274.2l x 112.5w x 207.6h centimeters 107.95l x 44.29 x...
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Safety rules page 3 safety rules and operating instructions safety rules and guidelines it is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle. As well as, obeying the following safety rules and...
Page 18: Driver Training Program
Safety rules and operating instructions safety rules page 4 driver training program as per ansi b56.8, the owner of this vehicle shall conduct an operator training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have previou...
Page 19: Vehicle Controls
Safety rules page 5 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 ...
Page 20
Safety rules and operating instructions safety rules page 6 foot brake pedal the foot brake pedal, is located to the right of the steering column, it is for operation with the right foot only. It works similar to the brake in an automobile. Applying pressure to the brake pedal slows the vehicle acco...
Page 21
Safety rules page 7 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. Hour meter (optional) the hour meter is loc...
Page 22
Safety rules and operating instructions safety rules page 8 battery status indicator, digital bargraph the battery status indicator is located to the left of the hour meter. The battery status indicator has a led bar graph that indicates the relative state of charge of the battery. The top led will ...
Page 23
Safety rules page 9 safety rules and operating instructions hazard light switch (optional) the hazard light switch is located on the left side of the steering column. The switch is a small tab. To activate the hazard lights, pull the tab out. To turn the hazard lights off, push forward or pull back ...
Page 24
Safety rules and operating instructions safety rules page 10 vehicle operational guidelines driving • slow down and sound the horn to warn pedestrians or when approaching a corner or other blind intersection. • no reckless driving. • do not drive this vehicle on steep inclines or where prohibited. •...
Page 25: Charging Your Vehicle
Safety rules page 11 safety rules and operating instructions charging your vehicle battery electrolyte is poisonous and dangerous. It contains sulfuric acid. Avoid contact with skin eyes or clothing. Wear rubber gloves and safety glasses while servicing batteries. Do not ingest! This may result in s...
Page 26
Safety rules and operating instructions safety rules page 12 to obtain the maximum battery life: charge the batteries only after they reach a normal discharge as indicated on the battery status indicator (bsi). Failure to follow this guideline could result in the batteries entering an overcharge sta...
Page 27
Safety rules page 13 safety rules and operating instructions storing and returning to service both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing your vehicle • clean the batteries, then fill and charge before putting the vehicle in storage...
Page 28
Safety rules and operating instructions safety rules page 14 periodic maintenance checklist note: a full page copy of the periodic maintenance checklist is on the vehicle documentation cd under the [misc] sub folder..
Page 29: Maintenance Guidelines For
Safety rules page 15 safety rules and operating instructions only properly trained and authorized technicians should perform maintenance or repairs to this vehicle. Repairs or maintenance by improperly trained or unauthorized personnel could cause improper operation of the vehicle or premature failu...
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Page 31: General Maintenance
Table of contents general maintenance maintenance guidelines ............................... 2 maintenance guidelines for vehicles used in severe conditions ..... 3 troubleshooting guide ................................ 4 lubrication chart .......................................... 5.
Page 32: Maintenance Guidelines
Maintenance, service and repair maintenance page 2 maintenance guidelines • avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle performance checks in an authorized area where safe clearance exists. • before starting the vehicle, follow the recommended safe...
Page 33: Severe Conditions
Maintenance, service and repair maintenance page 3 maintenance guidelines for vehicles used in severe conditions if this vehicle is operated in severe conditions all maintenance items listed in the periodic maintenance table should be carried out twice as often as stated. In addition, the entire veh...
Page 34: Troubleshooting Guide
Maintenance, service and repair maintenance page 4 troubleshooting guide symptom probable cause steering pulls in one direction front end out of alignment low tire pressure hard steering dry lube points in steering linkage damaged king pin/ball joint low tire pressure excessive steering play worn ba...
Page 35: Lubrication Chart
Maintenance, service and repair maintenance page 5 lubrication chart # description locations lubricant type 1 front leaf springs general purpose grease 2 king pin general purpose grease 3 ball joints general purpose grease 5 front wheel bearings high temperature wheel bearing grease 6 rear leaf spri...
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Page 37: 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 install...
Page 38
Maintenance, service, and repair front axle page 2 inspect the front wheel bearings and kin pin 6. Raise the front of the vehicle and support with jack stands. 7. Grab the top and bottom of the tire/wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of the ...
Page 39
Maintenance, service, and repair front axle page 3 adjust front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the hub dust cap and cotter pin. 8. While rotating the hub, tighten the spindle nut to 30 ft-lbs. This seats the bearings. 9. Back off the spindle ...
Page 40
Maintenance, service, and repair front axle page 4 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. Disconnect the ...
Page 41
Maintenance, service, and repair front axle page 5 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. Disconnect the ...
Page 42
Maintenance, service, and repair front axle page 6 front axle disassembly and assembly 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 st...
Page 43: Replace Front Wheel Bearings
Maintenance, service, and repair front axle page 7 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. Disconnect the ...
Page 44
Maintenance, service, and repair front axle page 8 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. Disconnect the ...
Page 45
Maintenance, service, and repair front axle page 9 rod end nut rod end jam nut steering sleeve steering arm 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 re...
Page 46
Maintenance, service, and repair front axle page 10 steering sleeve clamp ball joint steering arm cotter pin ball joint nut 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 blo...
Page 47
Maintenance, service, and repair front axle page 11 pitman arm drag link steering knuckle typical drag link 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 re...
Page 48
Maintenance, service, and repair front axle page 12 the bronze bushings must be reamed or broached to the proper diameter after they are pressed into the axle beam or steering knuckle. Failure to broach or ream the bushings may result in steering dificulty and loss of control of the vehicle causing ...
Page 49
Maintenance, service, and repair front axle page 13 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. 1. Make sure the key-switch is in the “o...
Page 50: Replace The Steering Knuckle
Maintenance, service, and repair front axle page 14 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. Disconnect the...
Page 51
Maintenance, service, and repair front axle page 15 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. Note: refer to the replacement parts section for the orientation of the thrust bearing or washers in your vehicle. 15. Tighten the king pin nut until there is 0.1 to 0.123 inch...
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Page 53: Steering Component Service
Table of contents front end alignment .................................... 2 adjust the steering gear (saginaw) ............. 5 replace the steering shaft (saginaw, non-tilt steering) .................... 7 replace the steering wheel (saginaw, non-tilt steering) .................... 9 replace the st...
Page 54: Front End Alignment
Maintenance, service, and repair steering page 2 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. S...
Page 55
Maintenance, service, and repair steering page 3 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. 11. Loosen the ball joint clamps or the rod end jam nuts on the drag link...
Page 56
Maintenance, service, and repair steering page 4 front wheel alignment note: it is recommended to center the steering before aligning the front wheels. Refer to the center the steering section for information. 6. Raise the front of the vehicle and support with jack stands. 7. Turn the front wheels s...
Page 57: Adjust The Steering Gear
Maintenance, service, and repair steering page 5 11. Measure the distance between the lines at the front of the tires. 12. Measure the distance between the lines at the rear of the tires. 13. Adjust the tie rod so that the distance at the front and rear of the tires is the same. 14. If equipped with...
Page 58
Maintenance, service, and repair steering page 6 7. Disconnect the drag link from the pitman arm. Note: refer to replace the ball joints section for information regarding removing the ball joint from the drag link. 8. Loosen the gear lash jam nut and the worm bearing adjuster jam nut. 9. Unscrew the...
Page 59: Replace The Steering Shaft
Maintenance, service, and repair steering page 7 replace the steering shaft 6. If equipped with a horn switch in the steering wheel, remove the switch, disconnect the wires from the switch and cut the terminals off of the wires. 7. Remove the steering wheel. Note: refer to replace the steering wheel...
Page 60
Maintenance, service, and repair steering page 8 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 tha...
Page 61: Replace The Steering Wheel
Maintenance, service, and repair steering page 9 replace the steering wheel 6. If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch. 7. Remove the steering wheel nut. 8. Using a steering wheel puller, remove the steering wheel. 9. Position ...
Page 62: Replace The Steering Gear
Maintenance, service, and repair steering page 10 replace the steering gear 6. Remove the steering wheel. Note: refer to replace the steering wheel section for information regarding removing the steering wheel. 7. Remove the steering shaft. Note: refer to replace the steering shaft section for infor...
Page 63: Repair The Steering Gear
Maintenance, service, and repair steering page 11 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 ...
Page 64
Maintenance, service, and repair steering page 12 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. 8. The ball nut assembly consists of two...
Page 65
Maintenance, service, and repair steering page 13 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 ...
Page 66
Maintenance, service, and repair steering page 14 exploded view of steering gear.
Page 67: Brake Service
Table of contents inspect the service brake ................. 2 front disc brake pads .......................................... 2 front disc brake rotor ........................................ 2 rear brake shoes ................................................. 2 rear brake drum .....................
Page 68: Inspect The Service Brake
Maintenance, service, and repair brakes page 2 rear brake shoes note: the wheel must be removed to accurately measure the brake shoes. Refer to tires and wheels section for information on removing the wheel. Measure the brake shoe lining at the thinnest point on the shoe. If this is 1/16-inch or les...
Page 69: Inspect The Parking
Maintenance, service, and repair brakes page 3 rear brake drum note: the wheel must be removed to accurately measure the brake drum. Refer to tires and wheels section for information on removing the wheel. The service limit for the inside diameter of the brake drum is 7.060 inches. If the brake drum...
Page 70: Adjust The Service Brakes
Maintenance, service, and repair brakes page 4 6. Raise the wheel off of the ground and support with jack stands. 7. Release the park brake. 8. Remove the tire/wheel assembly. Note: refer to tires and wheels section for information on removing the wheel. 9. Align the adjusting access slot in the bra...
Page 71
Maintenance, service, and repair brakes page 5 adjusting the brakes by means of the brake cables could cause a hard brake pedal with little or no braking power. This could cause loss of control of the vehicle resulting in severe bodily injury and/or property damage. Brake linkage with protractor in ...
Page 72: Adjust The Parking Brake
Maintenance, service, and repair brakes page 6 adjust the parking brake wheel park brake (hydraulic drum) note: hydraulic brakes are optional. The service brake must be properly adjusted before attempting to adjust the parking brake. Refer to adjust the service brakes for information regarding adjus...
Page 73: Check Master Cylinder Fluid
Maintenance, service, and repair brakes page 7 check master cylinder fluid 6. Thoroughly clean the area around the master cylinder cap. 7. Remove the master cylinder cap. 8. If the fluid in the master cylinder is contaminated then the entire brake system must be flushed. Refer to bleed the brakes fo...
Page 74: Bleed The Brake System
Maintenance, service, and repair brakes page 8 typical bleeder valve 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 seve...
Page 75: Flush The Brake System
Maintenance, service, and repair brakes page 9 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 dev...
Page 76
Maintenance, service, and repair brakes page 10 replace front 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 ...
Page 77: Replace Rear Brake Shoes
Maintenance, service, and repair brakes page 11 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. Confirm the electric park brake is set. 4. Place blocks under the front wheels to prevent vehicle movement. ...
Page 78: Replace The Front Cylinder
Maintenance, service, and repair brakes page 12 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 de...
Page 79: Repair The Brake Body
Maintenance, service, and repair brakes page 13 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. Disconnect the ma...
Page 80
Maintenance, service, and repair brakes page 14 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. Using tool #41-350-13, slide t...
Page 81: Replace The Master Cylinder
Maintenance, service, and repair brakes page 15 push rod plunger master cylinder 1/8" cutaway of typical master cylinder showing the push rod clearance replace the master cylinder always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use...
Page 82: Repair The Master Cylinder
Maintenance, service, and repair brakes page 16 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 cy...
Page 83: Motor Service
Table of contents inspecting the motor brushes ............ 2 motors with internal cooling fans ......................... 2 enclosed motors (ge, no cooling fan) ................. 2 motor removal and installation ......... 3 motor inspection ................................ 3 replacing the brushes......
Page 84: Inspecting The Motor Brushes
Motor service motor page 2 enclosed motors (ge, no cooling fan) general electric motors note: some motors may not have the brush inspection holes. In this case, the motor must be disassembled to inspect the brushes. For future inspections, holes msy be drilled into the motor housing after it has bee...
Page 85: Motor Removal And
Motor service motor page 3 advanced dc motors the enclosed advanced dc motors must be disassembled to inspect the motor brushes. Refer to motor inspection for information regarding disassembling the motor. Motor removal and installation see the transmission section for information on removing or ins...
Page 86
Motor service motor page 4 5. Inspect the commutator for burn marks. • burn marks and/or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature. A tool called a growler is required to reliably test for a shorted armature. 6. Inspect the commutator for raised segments. R...
Page 87: Replacing The Brushes
Motor service motor page 5 replacing the brushes note: it is recommended that all four brushes be replaced as a set. Note: motors without removable brush covers must be disassembled to replace the brushes. Refer to motor inspection-disassembly section for information on taking the motor apart. Note:...
Page 88: Replacing The Bearings
Motor service motor page 6 replacing the bearings 1. The motor must be removed from the vehicle for this procedure. Refer to transmission service section for information on removing the motor. 2. Remove the armature. Refer to motor inspection- disassembly section for information on taking the motor ...
Page 89: Service Limits
Motor service motor page 7 service limits motor specification number undercut depth commutator diameter (min) brush length (min) wire depth (max) mm inches mm inches mm inches mm inches 5bc58jbs6129a 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5 5bc58jbs6129b 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1....
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Page 91: Transmission Service
Table of contents check oil level ............................................. 2 change oil ..................................................... 3 motor ............................................................. 4 removal .................................................................... 4 in...
Page 92: Check Oil Level
Maintenance, service, and repair transmission page 2 check oil level park the vehicle on a level surface. 6. Place a drain pan that can hold a minimum of 2-quarts of oil under the transmission level plug. 7. Remove the level plug. When the plug is removed, a small amount of oil should come out. This...
Page 93: Change Oil
Maintenance, service, and repair transmission page 3 change oil changing the transmission oil requires removal of the transmission cover. Refer to transmission disassembly later in this section..
Page 94: Motor
Maintenance, service, and repair transmission page 4 motor removal note: in some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor. Refer to transmission section for information on removing the transmission assembly from the vehicle. 1. M...
Page 95: Rear Hub With Brake Drum
Maintenance, service, and repair transmission page 5 rear hub with brake drum removal and installation note: some vehicle configurations do not have a removable hub. The hub is an integral part of the rear axle. See the illustrations to the right to identify the hub on your vehicle. 1. Make sure the...
Page 96: Rear Axle
Maintenance, service, and repair transmission page 6 rear axle your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axle and the other is an integral part of the rear axle. The service of both of these axles is addressed in this section as follows: the remo...
Page 97
Maintenance, service, and repair transmission page 7 remove and install axle - non - removable hub note: the brake assembly is retained by the axle bearing and must be removed along with the axle assembly. 6. Remove the rear wheel. Refer to replace the rear tire/wheel section for information regardi...
Page 98
Maintenance, service, and repair transmission page 8 replace the axle bearing note: the axle must be removed from the transmission for this procedure. Refer to remove and install axle for information regarding removing the rear axle. Removable hub: 1. Remove the hub from the axle shaft. Refer to rea...
Page 99: Transmission
Maintenance, service, and repair transmission page 9 transmission removal 6. Remove the motor from the transmission. Refer to remove motor section for information regarding removing the motor. 7. Disconnect the brake cables from the left and right brake arm and cable mounting bracket. 8. Support the...
Page 100: Differential Case
Maintenance, service, and repair transmission page 10 differential case disassemble 1. Remove the transmission from the vehicle. Refer to transmission-removal section for information on removing the transmission. 2. Thoroughly clean the transmission assembly before disassembly. 3. Remove the left an...
Page 101
Maintenance, service, and repair transmission page 11 8. Remove the final drive gear from the differential housing. 9. Punch or drill a small hole into the center of both of the intermediate shaft bore plugs. 10. Thread a sheet metal screw into each plug until the bore plug is forced out. 11. Remove...
Page 102
Maintenance, service, and repair transmission page 12 13. Remove the intermediate bearing with an id bearing puller. 14. While supporting the shaft and gear assembly, repeat steps #12 and #13 for the opposite side bearing and remove the intermediate shaft from the housing. 15. Remove the o-rings fro...
Page 103
Maintenance, service, and repair transmission page 13 19. Remove the o-rings from both sides of the intermediate shaft bore and the input shaft bore and discard the o-rings. Assemble note: when pressing bearings, do not press against or support the outer race as this will damage the bearing. Note: a...
Page 104
Maintenance, service, and repair transmission page 14 4. Install the input shaft into the housing and install the snap ring. 5. Insert the intermediate shaft into the housing and support in place. 6. Insert the flanged side bearing into the bearing bore. Press in just past the snap ring grove and in...
Page 105: Suspension
Table of contents suspension replace the rear springs ............................. 2 leaf ........................................................................... 2 replace the front springs ........................... 4 leaf .........................................................................
Page 106: Replace The Rear Springs
Maintenance, service, and repair suspension page 2 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. 6. Raise the rear of the v...
Page 107
Maintenance, service, and repair suspension page 3 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 i...
Page 108: Replace The Front Springs
Maintenance, service, and repair suspension page 4 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. 6. Raise the front of th...
Page 109
Maintenance, service, and repair suspension page 5 damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage. 12. Inspect the spring bolts and spring hangers for signs of wear or damage. If any wear or damage is found, th...
Page 110: Replace The Spring Bushings
Maintenance, service, and repair suspension page 6 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): • the internal bushing...
Page 111: Replace The Shocks
Maintenance, service, and repair suspension page 7 10. Install the new bushings in reverse order. Hint: apply a light coating of grease to the bushing before pressing into the spring eye. 11. Install the spring onto the vehicle. Note: refer to replace the front springs section for information regard...
Page 112
Maintenance, service, and repair suspension page 8 8. Remove the shock from the vehicle. Note: if the shock that was removed is to be reinstalled: a. Inspect the shaft where it enters the shock body for any signs of leakage. If any sign of leakage is seen, then the shock must be replaced. B. Inspect...
Page 113: Battery Service
Table of contents cleaning ........................................................ 2 testing ........................................................... 3 watering ........................................................ 5 charging ........................................................ 6 replacin...
Page 114: Cleaning
Maintenance, service, and repair batteries page 2 cleaning battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage. 1. Make sure th...
Page 115: Testing
Maintenance, service, and repair batteries page 3 testing note: a combination of the load test and specific gravity test should be used to accurately determine the condition of the batteries. Load test note: the batteries must be fully charged before performing this test. 1. Clean the batteries. Ref...
Page 116
Maintenance, service, and repair batteries page 4 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 th...
Page 117: Watering
Maintenance, service, and repair batteries page 5 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 t...
Page 118: Charging
Maintenance, service, and repair batteries page 6 6. Clean the batteries. Refer to cleaning the batteries section for information on cleaning the batteries. 7. Check the electrolyte level in all battery cells. If low, fill to the correct level with distilled water using part number 77-201-00 battery...
Page 119: Replacing
Maintenance, service, and repair batteries page 7 replacing battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage. Note: if the b...
Page 120
Maintenance, service, and repair batteries page 8 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 repl...
Page 121
Maintenance, service, and repair batteries page 9 moist charge batteries 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 movem...
Page 122
Maintenance, service, and repair batteries page 10 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the batteries or the ground. Refer to cleaning the batteries for information on cleaning the batteries. 8. Reconnect the battery cables,...
Page 123
Maintenance, service, and repair batteries page 11 returning to service 6. Thoroughly clean the batteries and battery compartment. Refer to cleaning in this section for information regarding cleaning the batteries. 7. Check the electrolyte level and charge the batteries. Refer to watering in this se...
Page 124: Taylor -Dunn
Taylor -dunn.
Page 125: 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 ..........................
Page 126: Tire Inflation
Maintenance, service, and repair tires and wheels page 2 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 moveme...
Page 127: Replace Tire/wheel
Maintenance, service, and repair tires and wheels page 3 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 informa...
Page 128: Repair The Tire
Maintenance, service, and repair tires and wheels page 4 repair the tire note: to properly repair a puncture, the tire must be removed from the wheel. Refer to replace the tire section for information on removing the tire from the wheel. It is recommended to repair a tire with a combination vulcaniz...
Page 129: Replace The Tire
Maintenance, service, and repair tires and wheels page 5 replace the tire note; to replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to replace the tire/wheel section for information on removing the tire/wheel assembly. Tire replacement should only be performed by per...
Page 130: Taylor -Dunn
Taylor -dunn.
Page 131: Electrical
Table of contents electrical troubleshooting symptoms: .....................................2 read this first ............................3 test equipment required: ....................................................... 3 important notes and instructions ...................... 3 definitions: .........
Page 132: Symptoms:
Curtis pmc troubleshooting page 2 rev fwd solenoids pmc speed control circuit breaker iso typical control panel symptoms: if your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to symptom troubleshooting later in this section. • runs slow in bo...
Page 133: Read This First
Curtis pmc troubleshooting page 3 read this first test equipment required: • digital multimeter (dmm) with diode test function, fluke 79 model used in illustrations. • shunt or clamp-on dc ammeter to measure up to 400 amps. • test light with a rated voltage equal to or exceeds maximum battery voltag...
Page 134
Curtis pmc troubleshooting page 4 definitions: • “ms-1” = the first switch in the accelerator module. • “battery volts” = the voltage at the batteries at the time the test is completed. • “pick up” = energizing a solenoid or contactor. • “f&r” = forward and reverse. • “iso” = isolator. • “battery ne...
Page 135
Curtis pmc troubleshooting page 5 power output test set the test light voltage to the same voltage as the battery volts. Connect the test light from the pmc ‘m-’ terminal to battery positive. Close all interlock switches, turn the key switch on, and place the f&r switch in forward. Depress the accel...
Page 136
Curtis pmc troubleshooting page 6 control wire inputs the voltage shown is for illustration only. The actual voltage may vary. _ + positive main battery solenoids are shown for reference only. The type of solenoid in your truck may look different rev fwd iso iso fwd rev _ + solenoids are shown for r...
Page 137
Curtis pmc troubleshooting page 7 negative main battery b- m- a2 b+ #2 ksi fluke 79 off v hz series ii multimeter + − a Ω mv v the voltage shown is for illustration only. The actual voltage may vary. Negative main battery b- m- a2 b+ #2 ksi _ + the voltage shown is for illustration only. The actual ...
Page 138
Curtis pmc troubleshooting page 8 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. The rear drive wheels may rotate d...
Page 139
Curtis pmc troubleshooting page 9 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. The rear drive wheels may rotate d...
Page 140
Curtis pmc troubleshooting page 10 accelerator 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. The rear drive wheels...
Page 141
Curtis pmc troubleshooting page 11 key switch 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. The rear drive wheels ...
Page 142
Curtis pmc troubleshooting page 12 the cold terminal is the violet/black wire on either end of the switch battery negative or, the hot terminal is the violet/black wire on the center terminal battery negative violet/black forward and reverse side typical configuration of the terminals on a forward a...
Page 143
Curtis pmc troubleshooting page 13 f/r switch 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. The rear drive wheels ...
Page 144
Curtis pmc troubleshooting page 14 the reverse terminal is diagonally opposite the reverse side of the rocker on the switch battery negative a off mv v v hz fluke 79 series ii multimeter f&r switch seen from the rear f&r switch seen from the side depressed in the reverse gear the forward terminal is...
Page 145
Curtis pmc troubleshooting page 15 solenoids 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. The rear drive wheels m...
Page 146
Curtis pmc troubleshooting page 16 solenoids are shown for reference only. The type and position of the reverse solenoid in your truck may be different fwd/rev forward (does not run in reverse) connect a voltmeter across the pmc ksi terminal and battery negative. Close all interlock switches, turn t...
Page 147
Curtis pmc troubleshooting page 17 stop stop, do not continue. If you reached this point without a solution, then you may have an unanticipated problem or have made an error during testing. It is important to review the trouble shooting steps that have led to this point. The tests may need to be rep...
Page 148
Curtis pmc troubleshooting page 18 stop stop, do not continue. If you reached this point without a solution, then you may have an unanticipated problem or have made an error during testing. It is important to review the trouble shooting steps that have led to this point. The tests may need to be rep...
Page 149: Special Troubleshooting
Curtis pmc troubleshooting page 19 symptoms go to Ø runs slow in both directions plus high armature and field current in both directions. Note: armature and field current should be equal. Motor Ø runs slow in both directions plus high armature current in both directions. Note: field current will be ...
Page 150
Curtis pmc troubleshooting page 20 pmc control disconnect the wire from the ‘m-’ terminal on the pmc control and tape it off to prevent electrical contact. Connect a volt meter across the pmc #2 terminal and battery negative. Turn the key-switch on, close all interlock switches (if equipped), depres...
Page 151
Curtis pmc troubleshooting page 21 connect a volt meter across the pmc b+ and pmc m- terminals. Turn the key-switch on, close all interlock switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests: • the meter reading...
Page 152
Curtis pmc troubleshooting page 22 plugging diode remove the wires from the ‘b+’ and ‘a2’ terminals on the pmc control and perform the following test: using the diode test function on the dmm check for the presence of a diode across ‘b+’ and ‘a2’ on the pmc control.. If you do not know how to test f...
Page 153
Curtis pmc troubleshooting page 23 freewheel diode remove the wires from the ‘b+’ and ‘m-’ terminals on the pmc control and perform the following test: using the diode test function on the dmm check for the presence of a diode across ‘b+’ and ‘m- ’ on the pmc control. Refer to diode figure 2. If you...
Page 154
Curtis pmc troubleshooting page 24 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. Disconnect the main positive a...
Page 155
Curtis pmc troubleshooting page 25 stop stop, do not continue. If you reached this point without a solution, then you may have an unanticipated problem or have made an error during testing. It is important to review the trouble shooting steps that have led to this point. The tests may need to be rep...
Page 156
Curtis pmc troubleshooting page 26 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. Disconnect the main positive a...
Page 157
Curtis pmc troubleshooting page 27 motor shown for reference only. Terminal positions on your motor may not be in the same location. S2 a1 a2 s1 _ + b- m- a2 b+ #2 ksi motor shown for reference only. Terminal positions on your motor may not be in the same location. S2 a1 a2 s1 _ + stop trouble shoot...
Page 158
Curtis pmc troubleshooting page 28 with the key-switch on and the f&r switch in reverse, depress the accelerator pedal and perform the following tests: • check continuity from the wire that was connected to the pmc ‘m-’ terminal to the wire that was connected to the motor ‘s1’ terminal. If you do no...
Page 159
Curtis pmc troubleshooting page 29 motor high motor current in both the field and the armature, accompanied with a lack of power, would indicate a shorted armature and\or field. Another symptom that may exist is jumping or stuttering at low speeds and/or the motor will not run unless the armature is...
Page 160
Curtis pmc troubleshooting page 30 check continuity from ‘s1’ to the frame of the motor. If you do not know how to test for continuity, refer test to a qualified technician. This should be an open circuit. If there is continuity from ‘s1’ to the frame of the motor, then the motor field is shorted. S...
Page 161: Wire Diagrams
Wire diagrams.
Page 162
Wire diagrams wire diagrams page 2 r1=250 ohms 5w resistor cb = circuit breaker isolator solenoid or contactor coil brown red bsi head light a motor s1 s2 a2 bl f r i a1 blue green yellow green ksi b- b+ a2 m- white cb 135a black red red forward/reverse switch blue/black white/black orange/black gre...
Page 163: Lestronic II
Table of contents lestronic ii ® charger troubleshooting operating instructions and theory of operation .........................2 testing the charging cycle ....................3 test equipment required for troubleshooting ..............................4 important notes and instructions -----------...
Page 164
Electrical troubleshooting charger troubleshooting page 2 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”...
Page 165: Testing The Charging Cycle
Electrical troubleshooting charger troubleshooting page 3 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: • the...
Page 166
Electrical troubleshooting charger troubleshooting page 4 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 gu...
Page 167
Electrical troubleshooting charger troubleshooting page 5 troubleshooting for built-in charger 5. Disconnect the charger from the ac source. Locate the charger harness connectors where the charger harness is connected to the vehicle’s control harness. There will be two 10 gauge and two 14 gauge wire...
Page 168
Electrical troubleshooting charger troubleshooting page 6 • disconnect the charger from the ac source. • disconnect the batteries. • disconnect the charger from the vehicle’s harness. • remove the charger from the vehicle. Remove the charger cover and perform the following tests: 1. Inspect the inte...
Page 169
Electrical troubleshooting charger troubleshooting page 7 • 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. Sto...
Page 170
Electrical troubleshooting charger troubleshooting page 8 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 batte...
Page 171: Testing The Timer Relay
Electrical troubleshooting charger troubleshooting page 9 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: • test the voltage from the fuse assembly (-) to the diode block (+). This voltage...
Page 172: Testing The Interlock Relay
Electrical troubleshooting charger troubleshooting page 10 testing the interlock relay operation the interlock relay disables the vehicle from running whenever the charger is connected to a working ac power source. When the charger is plugged in, the relay contacts open and break the key switch conn...
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 in...
Page 174
Electrical troubleshooting signet charger troubleshooting page 2 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 f...
Page 175: Testing The Charging Cycle
Electrical troubleshooting signet charger troubleshooting page 3 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 batteries when the charge cycle was started. Note: charging time is limited to 18-hours (max). A...
Page 176
Electrical troubleshooting signet charger troubleshooting page 4 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 trou...
Page 177: Status Led Error Code Table
Electrical troubleshooting signet charger troubleshooting page 5 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 i...
Page 178: Troubleshooting
Electrical troubleshooting signet charger troubleshooting page 6 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. Tro...
Page 179: Charger Models:
Table of contents charger models: hbs 600 hbs 1000 signet ® charger troubleshooting definitions: ............................................2 test equipment required for troubleshooting ...............................2 important notes and instructions 2 operating instructions and theory of operatio...
Page 180: Definitions:
Electrical troubleshooting signet charger troubleshooting page 2 test equipment required for troubleshooting digital multi meter (dmm), calibrated and accurate down to 0.00001 volts. Clamp on dc ammeter to measure up to 20-amps. Important notes and instructions • this troubleshooting guide assumes a...
Page 181
Electrical troubleshooting signet charger troubleshooting page 3 operating instructions and theory of operation 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 f...
Page 182: Testing The Charging Cycle
Electrical troubleshooting signet charger troubleshooting page 4 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-...
Page 183
Electrical troubleshooting signet charger troubleshooting page 5 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 t...
Page 184: Troubleshooting
Electrical troubleshooting signet charger troubleshooting page 6 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 cha...
Page 185: Illustrated Parts
Table of contents front axle/steering knuckle ......................... 2 steering linkage ......................................... 4 steering column .......................................... 6 steering gear .............................................. 8 front suspension ...........................
Page 186: Front Axle/steering Knuckle
Illustrated parts parts page 2 front axle/steering knuckle 19 1 18 14 13 16 15 11 10 12 10 17 9 12 } small cup large cup bronze washer steel washer steel washer 8 20 2 4 3 7.
Page 187
Illustrated parts parts page 3 front axle/steering knuckle item # part # description qty 15-200-40 complete front axle assembly. Includes hubs, tire rod and spring (no brakes) 00-240-21 complete front axle assembly. Includes hubs, tire rod and spring (disc brakes) 1 14-240-06 left steer knuckle, no ...
Page 188: Steering Linkage
Illustrated parts parts page 4 steering linkage 10 3 9 3 8 ref., arm on right steering knuckle ref., arm on left steering knuckle 6 15 7 ref., stering gear 7 15 11 17 5 16 12 14 6 13 1.
Page 189
Illustrated parts parts page 5 steering linkage item # part # description qty 1 86-518-01 rod end (lh) 1 2 -- - - 3 86-510-00 ball joint clamp 2 4 - - - 5 50-002-03 drag link 1 6 88-119-81 3/8-nf hex locknut 2 7 88-159-85 1/2-nf hex castle nut 2 8 86-501-98 ball joint (left thread) 1 9 18-041-05 tie...
Page 190: Steering Column
Illustrated parts parts page 6 steering column 1 2 5 6 3 4 7 the steering column is an integral part of the frame and is not shown. Part id# 5 is located in the top of the steering column tube. 9 8 ref., steering gear 10
Page 191
Illustrated parts parts page 7 steering column item # part # description qty 1 88-199-82 5/8-nf hex jam nut 1 2 19-011-20 steering wheel 1 3 88-081-14 bolt, plated (grade 8) 1 4 88-089-84 nut, plated (grade 8) 1 5 80-400-10 bushing 1 6 20-031-64 steering shaft (includes #3, #4) 1 7 19-011-25 steerin...
Page 192: Steering Gear
Illustrated parts parts page 8 steering gear 5 4 2 1 6 see steering linkage 7 10 15 17 3 11 12 13 14 16.
Page 193
Illustrated parts parts page 9 steering gear item # part # description qty 18-308-21 steeering gear assembly 1 1 18-308-70 locking ring 1 2 18-308-71 adjuster 1 3 18-308-72 worm shaft/ball nut assembly 1 4 18-308-23 upper worm shaft bearing 1 5 18-308-22 upper worm shaft cup 1 6 18-308-77 housing 1 ...
Page 194: Front Suspension
Illustrated parts parts page 10 front suspension 4 3 2 1 5 10 6 8 9 7 11 12.
Page 195
Illustrated parts parts page 11 front suspension item # part # description qty 1 87-074-00 grease fitting 2 2 96-248-01 spring eye bolt (includes #1) 2 3 32-213-00 spring eye bushing 2 4 88-169-82 9/16-nf lock nut, grade c 2 5 85-506-05 leaf spring (includes #3) 2 6 96-118-00 1/2-nc x 1.87 x 6.5l u-...
Page 196
Illustrated parts parts page 12 transmission differential case 1 2 3 4 5 6 7 6 5 8 3 9 3 9 8 5 6 7 15 10 16 10 3 14 11 11 17 12 13.
Page 197
Illustrated parts parts page 13 transmission (dana spec# 012aj310-1) item # part # description qty 4c-150-00 complete transmission assembly including mechanical brakes 4c-150-10 complete transmission assembly including hydraulic brakes 1 special order housing 1 2 80-480-10 inner input shaft bearing ...
Page 198: Rear Axle and Brakes
Illustrated parts parts page 14 rear axle and brakes ref., transmission housing 2 3 4 1 5 7 10 6 11 15 9 12 8 13 14 16 18 19 17.
Page 199
Illustrated parts parts page 15 rear axle and brakes item # part # description qty 41-347-98 complete brake assembly (left), includes 1, 5, 7, 9, 10, 11, 12, 16 1 41-347-99 complete brake assembly (right), includes 1, 5, 7, 9, 10, 11, 12, 16 1 1 41-347-15 brake arm 2 2 45-303-00 seal 2 3 32-509-10 b...
Page 200: Rear Suspension
Illustrated parts parts page 16 rear suspension 5 7 8 3 4 ref., frame 2 6 4 1 ref., transmission axle tube.
Page 201
Illustrated parts parts page 17 rear suspension item # part # description qty 1 88-140-17 bolt 4 2 85-506-10 leaf spring (includes #7) 2 3 96-118-00 u-bolt 2 4 88-149-81 nut 8 5 96-248-01 spring bolt 2 6 01-200-62 spring support 2 7 32-213-00 spring eye bushing 2 8 88-169-82 nut 2.
Page 202: Motor
Illustrated parts parts page 18 motor 2 3 5 6 4 7 8 1 9 10 armature 9.
Page 203
Illustrated parts parts page 19 motor ge spec#bc58jbs6129a item # part # description qty 70-049-05 complete motor assembly 1 70-201-15 field coil/stator assembly 1 2 70-210-51 insulator 2 3 85-412-00 brush spring 4 4 70-172-15 brush holder (includes #3) 1 5 70-104-15 brush pair 2 6 70-210-51 insulat...
Page 204
Illustrated parts parts page 20 brake and accelerator pedal and linkage 1 2 3 4 5 6 7 8 7 19 10 11 12 10 19 7 8 19 10 13 8 6 6 6 7 14 22 transmission ref., frame 29 18 17 18 19 29 19 20 19 10 10 19 ref., frame 21 22 23 24 10 crosshaft arm 'a' to crosshaft arm 'a' 14 18 29 19 10 25 26 27 28 24 19, 10...
Page 205
Illustrated parts parts page 21 brake and accelerator pedal and linkage item # part # description qty 1 98-200-00 brake pedal pad 1 2 01-432-98 brake pedal 1 3 88-089-81 nut 1 4 88-080-11 bolt 1 5 00-200-45 brake pedal arm 1 6 80-410-20 bushing 4 7 88-109-81 nut 8 8 88-100-09 bolt 8 9 01-200-49 brak...
Page 206: Wheels and Tires
Illustrated parts parts page 22 wheels and tires ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9.
Page 207
Illustrated parts parts page 23 wheels and tires item # part # description qty 1 tubeless wheels 12-012-00 5 x 8" tubeless (standard) 4 12-020-00 8.5 x 8 tubeless 4 2 tires 10-081-00 5.70 x 8 (standard) 4 10-082-00 5.70 x 8 extra grip 4 10-083-00 5.70 x 8 lr c 4 10-093-00 8.50 x 8 lr b 4 10-091-10 8...
Page 208: Instrument Panel (Dash)
Illustrated parts parts page 24 instrument panel (dash).
Page 209
Illustrated parts parts page 25 instument panel (dash) item # part # description qty 1a 95-913-00 hole plug 1 1b 71-100-00 toggle switch option 2 71-039-11 rocker switch (on-off) 1 3 88-817-08 screw 8 4 74-000-00 hour meter 1 5 01-200-75 dash housing 1 6 74-009-00 battery status meter 1 7 94-304-10 ...
Page 210: Speed Control Panel
Illustrated parts parts page 26 speed control panel 3 4 5 6 2 7 8 9 10 1 1 11 12 14 18 17 16 1 13 15 typical control panel the control panel in your vehicle may be layed out differently 20
Page 211
Illustrated parts parts page 27 speed control panel item # part # description qty 62-019-00 complete control panel assembly 1 1 88-838-06 #14 x 1/2 pan head screw type d thread 10 2 62-204-00 pmc speed control 1 3 72-501-39 solenoid (forward or reverse) 2 4 61-838-41 bus bar 2 5 88-088-62 5/16 split...
Page 212: Miscellaneous Electrical
Illustrated parts parts page 28 miscellaneous electrical horn switch mounted 5 7 6 floorboard mechanical brake light switch mounted under floorboard 8 9 seat interlock switch accelerator module 10 14 13 11 12 seat frame 1 2 motion alarms miscellaneous wire harness clamps 2 3 17 16 15 18 4.
Page 213
Illustrated parts parts page 29 miscellaneous electrical item # part # description qty not shown 75-148-79 chassie control harness 1 not shown 75-149-79 power harness, b 1-50 1 not shown 75-149-82 power harness, mx 1600 1 not shown 98-599-15 plastic grommet for 1.75 hole not shown 98-599-20 plastic ...
Page 214: Charger, Lestronic
Illustrated parts parts page 30 charger, lestronic 1 2 3 4 8 7 5 6 11 bi_charger w-interlock.Dwg charger identification.
Page 215
Illustrated parts parts page 31 charger lester model# 22740 item # part # description qty 79-303-15 complete charger assembly 1 79-805-67 timer assembly 1 1a 79-808-00 timer relay (not shown) 2 79-902-00 capacitor 1 3 79-749-13 diode assembly 1 4 79-644-31 transformer 1 5 * ac cord 6 * strain releif...
Page 216: Charger, Signet
Illustrated parts parts page 32 charger, signet charger, signet note: the harness connectors and ac plug are not included with the charger. Qty part # description 2 75-318-20 butt splice 2 75-320-51 knife connector 1 76-200-00 ac plug, 115v domestic model hbs for flooded batteries part # description...
Page 217
Illustrated parts parts page 33 this page intentionaly left blank.
Page 218: Batteries
Illustrated parts parts page 34 batteries 9 6 and 7 (hardware) 5 4 3 2 1 main battery negative neg pos neg neg pos pos 12v tap main battery positive neg neg pos pos neg pos.
Page 219
Illustrated parts parts page 35 batteries item # part # description qty 1 50-243-10 battery hold down rod 3 2 50-250-00 bat-lok 3 3 88-088-66 flat washer 3 4 88-069-81 nut 3 5 75-235-08 battery jumper 5 6 88-081-12 bolt 12 7 88-089-80 nut 12 8 - - 9 77-042-00 t 105, 217ah battery (standard) 6 77-042...
Page 220
Illustrated parts parts page 36 seat cushions, deck and lights, b 1-50
Page 221
Illustrated parts parts page 37 seat cushions, deck and lights, b 1-50 item # part # description qty 1 72-005-00 head light assembly 1 1a 72-072-00 replacement bulb only 1 not shown 98-603-00 wiring grommet 1 2 94-201-00 t/d emblem 1 2a 88-567-91 emblem mounting clips 3 3 94-035-01 cowl moulding 8' ...
Page 222
Illustrated parts parts page 38 seat cushions, deck and lights, mx 1600
Page 223
Illustrated parts parts page 39 seat cushions, deck and lights, mx 1600 item # part # description qty 1 see b 1-50 head light assembly 1 1a see b 1-50 replacement bulb only 1 not shown see b 1-50 wiring grommet 1 2 see b 1-50 t/d emblem 1 2a see b 1-50 emblem mounting clips 3 3 see b 1-50 cowl mould...
Page 224: Decals, B 1-50
Illustrated parts parts page 40 decals, b 1-50 view from inside of cowl 1 2 3 4 5 6 7 8 9.
Page 225
Illustrated parts parts page 41 decals, b 1-50 item # part # description qty 1 94-333-00 fm 1 2 94-313-20 safety warning 1 3 94-384-01 not a motor vehicle 1 4 94-309-00 park brake 1 5 94-384-14 leaving vehicle 1 6 94-373-10 vinyl data plate 1 94-373-70 metal data plate 1 7 94-301-42 arms and legs 1 ...
Page 226
Illustrated parts parts page 42 fiberglass cab, doors, mirrors 1 2 4 3 5 6 7 8 9 10 11 12 13 17 18 19 20 21 23a 24 25 23b 16 15 14 26.
Page 227
Illustrated parts parts page 43 fiberglass cab, doors, mirrors item # part # description qty 1 90-852-30 front windshield 1 2 98-310-10 windshield gasket (by the foot) 3 74-050-00 windshield wiper motor 1 4 74-051-00 windshield wiper arm 1 5 74-052-00 windshield wiper blade 1 6 91-008-00 fiberglass ...
Page 228: Strobe Light
Illustrated parts parts page 44 strobe light strobe mounted on fiberglass cab strobe mounted on pole apply silicon sealer around each mounting screw to prevent leakage 2 3 4 4 2 1 3 5 6 7 7 8 9 10 11 12 1 seat back.
Page 229
Illustrated parts parts page 45 strobe light item # part # description qty 1a 72-023-20 strobe light 1 1b 72-023-21 replacement bulb 1 1c 72-023-22 replacement lens (amber) 1 1d 72-023-24 replacement lens (red) 1 2 88-029-80 nut 3 3 88-028-62 flat washer 3 4 88-025-08 screw 4 5 88-048-61 washer 3 6 ...
Page 230: Stake Sides, B 1-50
Illustrated parts parts page 46 stake sides, b 1-50 1 2 3 4 5 6 7 8.
Page 231
Illustrated parts parts page 47 stake sides, b 1-50 item # part # description qty 1 90-542-20 side gate 1 2 90-542-22 end gate 1 3 90-542-20 side gate 1 4 90-540-00 gate hook 6 5 90-540-00 gate hook 6 6 88-065-13 bolt 44 7 88-069-81 nut 44 8 90-543-00 mounting channel 8.
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Illustrated parts parts page 48 hydraulic brake lines and fittings (optional) rear brakes 50-009-00 push rod, master cylinder 96-762-00 3/8 in.Clevis cast 96-772-00 pin,clevis,3/8 x 1 1/8 in. 99-510-02 master cylinder 99-564-00 union t, 3/16 inv flare 99-566-00 banjo fitting, master cylinder 99-571-...
Page 233: Appendixes
Appendixes contents appendix a: special tools ................. 2 appendix b: suggested torque limits for standard hardware ......... 3 hardware identification ...................... 3 standard head markings ...................................... 3 hex bolts ............................................
Page 234: Appendix A: Special Tools
Appendixes appendixes appendix a page 2 appendix a: special tools description purpose part number test light used for testing electrical circuits. Powered by the truck batteries, switchable for 12, 24, 36, and 48 volts. 62-027-00 accelerator test harness used to test the solid state accellerator mod...
Page 235: Hardware Identification
Appendixes appendix b page 3 appendixes hardware identification standard head markings s.A.E. Grade 2 s.A.E. Grade 5 truss head, grade 2 carriage bolt, grade 2 (unless marked as above) other bolts note: torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grad...
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Appendixes appendixes appendix b page 4 hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) c or, or, b or, or, nuts with no markings are to be treated as s.A.E. Grade 2 lock nuts use a letter to indicate the grade of the nut. Grade a’ locknuts would be the equivelent of grade ‘2’ hex nuts...
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Appendixes appendix b page 5 appendixes diameter and tpi grade 2 tightening torque (ft-lb) grade 5 tightening torque (ft-lb) grade 8 tightening torque (ft-lb) l'9 tightening torque (ft-lb) 1/4-20 4-7 7-10 10-14 11 1/4-28 5-8 8-12 11-16 12 5/16-18 9-14 14-21 20-29 22 5/16-24 10-15 15-23 22-33 25 3/8-...
Page 238: Torque Table
Appendixes appendixes appendix b page 6 suggested torque values (critical hardware) torque table torque range group description ft-lbs in-lbs nm brakes - - - - - - - - - - - - - - - - - - - - - - - - brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 brake line tube nut fittings 12 - 13 144 - 15...
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Appendixes appendix c page 7 appendixes 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 ...
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Taylor-dunn ® mfg. 2114 w. Ball rd. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 (fax) (714) 956-0504 mailing address: p.O. Box 4240 anaheim, california 92803 visit our website: www.Taylor-dunn.Com.