- DL manuals
- Taylor-Dunn
- Utility Vehicle
- B 2-10
- Operation, T Roubleshooting And Replacement Parts Manual
Taylor-Dunn B 2-10 Operation, T Roubleshooting And Replacement Parts Manual
Summary of B 2-10
Page 1
T h e b e s t w a y to go a b o u t your b u s i n e s s ® serial number starting: 151285 manual mb-210-08 operation, troubleshooting and replacement parts manual models inlcuded: b0-012-10 ( b 2-10) published: 3/27/2002 revision: d, 7/23/2013 shown with optional steel cab and doors.
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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 stake side dump bed option sc1-00 stock chaser e4-55 sit down tow tractor c4-25 sit down tow tractor.
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Section index introduction 1 safety rules and operating instructions 2 general maintenance 3 front axle service 4 steering component service 5 brakes service 6 throttle linkage 7 transaxle service 8 motor service 9 suspension 10 tires and wheels 11 battery service 12 control system troubleshooting 1...
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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 7: Table Of Contents
Table of contents introduction about this manual ......................................... 2 who should read this manual .................... 2 responsibilities ............................................ 2 how to use this manual .............................. 3 conventions ...........................
Page 8
Introduction page-2 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 this vehicle...
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Introduction page-3 how to use this manual this manual is organized into five main sections: introduction this section describes how to use this service manual and how to identify your vehicle. Safety rules and operating instructions this section outlines the safety and operational issues, location ...
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Introduction page-4 how to identify your vehicle this manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile ho...
Page 11
Introduction page-5 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 sure everyth...
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B2-48 with stake side dump bed option sc1-00 stock chaser e4-55 sit down tow tractor c4-25 sit down tow tractor.
Page 13: Safety Rules and
Table of contents safety rules and operating instructions standard specifications* .................... 2 safety rules and guidelines ............. 3 driver training program .................... 3 driver qualifications. ..................................................... 3 vehicle controls ..........
Page 14: Standard Specifications*
Safety rules and operating instructions safety rules page 2 standard specifications* item specification occupancy driver, 1-passenger dimensions 302l x 114w x 122h centimeters 119l x 45w x 48h inches turning radius 317 centimeters (125 inches) dry weight 301 kg (665 lbs) without batteries min/max ba...
Page 15: Safety Rules And
Safety rules and operating instructions safety rules page 3 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 (extracted from the american national standards ins...
Page 16: Vehicle Controls
Safety rules and operating instructions safety rules page 4 vehicle controls 1) key-switch a key-switch, located on the right center 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-swit...
Page 17
Safety rules and operating instructions safety rules page 5 steering the steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter-clockwise. If equipped with tilt steering, the release lever is lo...
Page 18
Safety rules and operating instructions safety rules page 6 seat interlock switch a switch located under the driver's seat disables the power to the vehicle when the driver leaves the seat. The driver must be seated for the vehicle to operate. Whenever the driver leaves the vehicle, the driver shoul...
Page 19
Safety rules and operating instructions safety rules page 7 battery status indicator, digital bargraph (optional) 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 to...
Page 20: Vehicle Operational
Safety rules and operating instructions safety rules page 8 vehicle operational guidelines safety guidelines • only qualified and trained operators may drive this vehicle. • drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees). • drive slowly when making a ...
Page 21
Safety rules and operating instructions safety rules page 9 parking before leaving the vehicle: • set the parking brake. • set the forward-of f-reverse switch to the ` “off” position. • rotate the start switch to the “off” position. In addition: • if parking this vehicle on an incline, turn the whee...
Page 22: Charging Your Vehicle
Safety rules and operating instructions safety rules page 10 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of c...
Page 23: Storing / Returning To
Safety rules and operating instructions safety rules page 11 storing / 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 24
Safety rules and operating instructions safety rules page 12 maintenance item 2,3 weekly (20hrs) monthly (80hrs) quaterly (250hrs) semi - annual (500hrs) annualy (1000hrs) check condition of tires and tire pressure l check all lights, horns, beepers and warning devises l check and fill batteries l c...
Page 25: Maintenance Guidelines For
Safety rules and operating instructions safety rules page 13 t a y l or - du n n th e b e st w ay to go about yo ur bu si n e s s r maintenance guidelines for severe duty applications 1. This maintenance checklist is based on the average application. If the vehicle is operated under “severe conditio...
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Page 27: Table Of Contents
Table of contents general maintenance maintenance guidelines ............................... 2 troubleshooting guide ................................ 3 lubrication chart .......................................... 4 model e 4-55 tow tractor model c 4-25 tow tractor shown here are two of the many tayl...
Page 28: Maintenance Guidelines
Maintenance, service and repair 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 safety procedure...
Page 29: Troubleshooting Guide
Maintenance, service and repair page 3 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 ball joints mi...
Page 30: Lubrication Chart
Maintenance, service and repair page 4 lubrication chart # description locations lubricant type 1 - general purpose grease 2 king pin 2 general purpose grease 3 ball joints 4 general purpose grease 4 pedal linkages 1 general purpose grease 5 front wheel bearings 2 high temperature wheel bearing grea...
Page 31: Front Axle Service
Table of contents inspect the front wheel bearings and king pin......................................... 2 adjust front wheel bearings ............ 3 front axle removal and installation .. 4 removal ................................................................ 4 installation ........................
Page 32: Inspect The Front Wheel
Maintenance, service, and repair front axle page 2 inspect the front wheel bearings and king 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 th...
Page 33: Adjust Front Wheel
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 34: Front Axle Removal And
Maintenance, service, and repair front axle page 4 front axle removal and installation removal 6. Raise the front of the vehicle and support with jack stands. 7. Remove both front wheels. Refer to tires and wheels section for information regarding removing the front wheels. 8. Tie up or support the ...
Page 35: Front Axle Disassembly
Maintenance, service, and repair front axle page 5 front axle disassembly disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: replace the steering knuckl...
Page 36: Replace Front Wheel
Maintenance, service, and repair front axle page 6 replace front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly from the hub. Refer to tires and wheels for information regarding removing the wheel assembly. 8. Remove the hub dust cap,...
Page 37: Replace The King Pins And
Maintenance, service, and repair front axle page 7 replace the king pins and bushings there are different types of king pin bushings depending on the configuration of your vehicle. • bronze bushings in the axle beam. • bronze bushings in the steering knuckle. • metal backed teflon bushings in the ax...
Page 38: Replace The Steering
Maintenance, service, and repair front axle page 8 replace the steering knuckle 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly. Refer to tires and wheels section for information regarding removing the tire/wheel assembly. 8. Remove the hub bearing c...
Page 39: Steering Component Service
Table of contents steering component service front end alignment .......................... 2 inspect ball joints ............................. 5 inspect rod ends .............................. 5 adjust the steering gear ................... 6 replace the steering shaft ................ 7 replace the...
Page 40: 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 41
Maintenance, service, and repair steering page 3 if the clamps are positioned so that they contact other components, it may result in steering failure and loss of control of the vehicle causing property damage and/or severe bodily injury. 12. Adjust the drag link so that it can be easily inserted in...
Page 42
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 43: Inspect Ball Joints
Maintenance, service, and repair steering page 5 inspect ball joints note: a set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 6. Raise the front of the vehicle and support with jack stands. 7. Tie off the...
Page 44: Adjust The Steering Gear
Maintenance, service, and repair steering page 6 adjust the steering gear note: in some vehicle configurations it may be necessary to remove the steering gear to perform this procedure. Refer to replace the steering gear for information regarding removing the steering gear. 6. Raise the front of the...
Page 45: Replace The Steering
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 46: Replace The Steering
Maintenance, service, and repair steering page 8 replace the steering gear 6. Remove the steering wheel. Refer to replace the steering wheel section for information regarding removing the steering wheel. 7. Remove the steering shaft. Refer to replace the steering shaft section for information regard...
Page 47
Maintenance, service, and repair steering page 9 replace the ball joints, tie rods, and drag link 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 installed on the steering arm or pitman arm. The second cannot be greased ...
Page 48
Maintenance, service, and repair steering page 10 replacing a ball joint 6. Raise the front of the vehicle and support with jack stands. 7. Loosen the ball joint clamp on the steering sleeve. 8. Remove the cotter pin and ball joint nut. 9. Using a pickle fork, remove the ball joint from the steering...
Page 49: Center The Steering Gear
Maintenance, service, and repair steering page 11 9. Install in reverse order. 10. Realign the front wheels. Note: refer to the steering section for information regarding realignment of the front wheels. 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13....
Page 50: Pitman Shaft Alignment
Maintenance, service, and repair steering page 12 pitman shaft alignment 6. Center the steering gear. Refer to center the steering gear section for information regarding centering the steering gear. 7. Tie the steering wheel in position so that it cannot rotate. 8. Install the pitman shaft on the st...
Page 51: Repair The Steering Gear
Maintenance, service, and repair steering page 13 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 52
Maintenance, service, and repair steering page 14 reassembly 1. Lightly lubricate all parts before reassembly. 2. Install a new worm shaft seal and pitman shaft seal into the housing. 3. Install the upper worm bearing cup. 4. Divide the ball bearing into two equal groups. 5. Position the ball nut on...
Page 53
Maintenance, service, and repair steering page 15 exploded view of steering gear.
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Page 55: Brake Service
Table of contents inspect the service brake ................. 2 disc brake pads .................................................... 2 disc brake rotor .................................................. 2 inspect the parking brake .................. 3 adjust the service brakes ................. 3 tw...
Page 56: Inspect The Service Brake
Maintenance, service, and repair brakes page 2 disc brake rotor note: the front brake rotor is an integral part of the front hub. If the brake rotor is worn beyond its service limits, then the front hub must be replaced. Refer to front axle service for information on replacing the front hub. Note: d...
Page 57: Inspect The Parking
Maintenance, service, and repair brakes page 3 inspect the parking brake note: the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Inspect the brake pads. Refer to inspect the service brake section to inspec...
Page 58: Adjust The Parking Brake
Maintenance, service, and repair brakes page 4 adjust the parking brake wheel park brake the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Loosen the jam nuts on the park brake linkage that is connected to...
Page 59: Check Master Cylinder Fluid
Maintenance, service, and repair brakes page 5 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 60: Bleed The Brake System
Maintenance, service, and repair brakes page 6 • only use dot 3 brake fluid from a new sealed container. • dot 3 brake fluid is corrosive and will damage paint finishes. • dispose of brake fluid in accordance with local state and federal regulations. • read and follow all warnings on the brake fluid...
Page 61: Flush The Brake System
Maintenance, service, and repair brakes page 7 flush the brake system 6. Raise the rear wheels off of the ground and support with jack stands. 7. If equipped with front brakes, raise the front wheels off of the ground and support with jack stands. 8. Release the park brake. 9. Remove both rear wheel...
Page 62: Replace Front Disc Brake
Maintenance, service, and repair brakes page 8 6. Thoroughly clean the area around the master cylinder cap. 7. Remove fluid from the master cylinder until it is 1/ 2 full. 8. Raise the front of the vehicle and support with jack stands. 9. Remove the tire/wheel assembly. Refer to tires and wheels sec...
Page 63
Maintenance, service, and repair brakes page 9 note: it is recommended that both the left and right brake pads be replaced as a set. Note: installing new brake pads will raise the brake fluid level in the master cylinder. 6. Thoroughly clean the area around the master cylinder cap. 7. Remove fluid f...
Page 64: Replace The Wheel
Maintenance, service, and repair brakes page 10 replace the wheel cylinder disc brake body assembly (front or rear) 6. Release the park brake. 7. Raise the wheel off of the ground and support with jack stands. 8. Remove the tire/wheel assembly. Refer to tires and wheels section for information on re...
Page 65: Repair The Brake Body
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. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 66
Maintenance, service, and repair brakes page 12 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 the rubber boots onto the pistons as shown. The boot should be hanging off of t...
Page 67: Replace The Master
Maintenance, service, and repair brakes page 13 push rod plunger master cylinder 1/8" cutaway of typical master cylinder showing the push rod replace the master cylinder note: most vehicle configurations do not require lifting the vehicle to remove the master cylinder. Lifting the vehicle may not be...
Page 68: Repair The Master Cylinder
Maintenance, service, and repair brakes page 14 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 69: Throttle Linkage
Table of contents throttle linkage adjustments ............ 2 magnetic sensor module ...................................... 2 pot box module .................................................... 3 throttle linkage.
Page 70
Maintenance, service, and repair front axle page 2 throttle linkage adjustments magnetic sensor module throttle module the standard magnitic throttle module should not be used in areas that contain large magnetic fields. Large magnitic fields may effect the operation of the module resulting in unexp...
Page 71
Maintenance, service, and repair front axle page 3 pot box module the pot box module is used on vehicles that are to be operated in areas with large magnetic fields. The linkage to the pot box should be adjusted so that the fs-1 switch closes just as the pedal is depressed and the output is at 5k wi...
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Page 73: F2/f3 Transmission
Table of contents f2/f3 transmission service adjust the drive chain ...................... 2 check the oil level ........................... 3 change the oil .................................. 3 drive motor ....................................... 4 remove ...............................................
Page 74: Adjust The Drive Chain
Maintenance, service, and repair f2/f3 transmission page 2 adjust the drive chain note: a small amount of oil may come out when the drive motor mounting bolts are loosened. 6. Place a small oil drain pan under the chain case. 7. Loosen but do not remove the three drive motor mounting nuts. 8. Loosen...
Page 75: Change The Oil
Maintenance, service, and repair f2/f3 transmission page 3 change the oil 6. Place a large drain pan under the chain housing. 7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug 8. Place the drain pan under the drive housing. 9. Re...
Page 76: Drive Motor
Maintenance, service, and repair f2/f3 transmission page 4 drive motor remove note: in most cases it is not necessary to disassemble the chain case to remove the motor. If you find it necessary to disassemble the chain case, refer to transmission section for information regarding disassembly of the ...
Page 77: Rear Axle
Maintenance, service, and repair f2/f3 transmission page 5 replace the axle bearing note: the axle must be removed from the vehicle to replace the axle bearing. Refer to section rear axle: remove and install for information regarding removing the axle. Note: a 10-ton press is required to replace the...
Page 78: Transmission Assembly
Maintenance, service, and repair f2/f3 transmission page 6 remove and install transmission assembly 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 whee...
Page 79: Chain Case
Maintenance, service, and repair f2/f3 transmission page 7 assemble 1. Thoroughly clean all gasket surfaces. 2. Apply a 1/8” bead of 94-430-03 gasket sealer to the face of the 3rd member. 3. Install the backing plate to the 3rd member. Torque to 30-45 ft-lbs. 4. Install the motor to the backing plat...
Page 80
Maintenance, service, and repair f2/f3 transmission page 8 washer mounting plate woodruf key adjusting screw nut motor nut bolt o-ring 24 backing plate bolt drive sprocket spacer nut motor sprocket drive chain nut pinion seal chain case housing washer bolt drain plug pinion nut brake assembly 3rd me...
Page 81: Differential Assembly (3
Maintenance, service, and repair f2/f3 transmission page 9 differential assembly (3 rd member) disassemble note: bearings and races must be replaced as a set. If any one bearing or race is worn, its mate must also be replaced. It is recommended to replace all bearings and races in the 3rd member as ...
Page 82
Maintenance, service, and repair f2/f3 transmission page 10 assemble note: thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. Note: depending on your vehicle config-uration, the rear pinion pilot bearing is ...
Page 83
Maintenance, service, and repair f2/f3 transmission page 11 17. Install the bearing caps in their original locations and torque the bolts to 12-15 ft-lbs. Making sure that the adjusting nuts still turn freely. Note: in the following procedure, "left adjusting nut" refers to the nut on the ring gear ...
Page 84
Maintenance, service, and repair f2/f3 transmission page 12 re-shimming the pinion housing the pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced. Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number pr...
Page 85: Exploded View
Maintenance, service, and repair f2/f3 transmission page 13 exploded view.
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Page 87: 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 88: 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 89: 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 90
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 91: 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 92: 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 93: 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 95: Suspension
Table of contents suspension replace the rear springs .................. 2 replace the front springs ................. 3 replace the spring bushings ............. 4 replace the shocks .......................... 5 front ...................................................................... 5.
Page 96: Replace The Rear Springs
Maintenance, service, and repair suspension page 2 replace the rear springs if a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. Hint : i n most vehicles it will be easier if the springs are replaced one at a time. 6. Raise the rear of the vehic...
Page 97: Replace The Front
Maintenance, service, and repair suspension page 3 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 the vehicle and support with jack...
Page 98: Replace The Spring
Maintenance, service, and repair suspension page 4 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 99: Replace The Shocks
Maintenance, service, and repair suspension page 5 replace the shocks front it is recommended to replace both front shocks as a set. Note: on some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for information regar...
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Page 101: Tires and Wheels
Table of contents tire inflation ...................................... 2 tire inspection ................................... 2 replace the front tire/wheel ............ 3 replace the rear tire/wheel ............ 3 replace the tire (pneumatic) ........... 3 repair the tire (pneumatic) .................
Page 102: Tire Inflation
Maintenance, service, and repair tires and wheels page 2 tire inflation there are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires. The illustration to the right is an example of the side wall info...
Page 103: Replace The Tire/wheel
Maintenance, service, and repair tires and wheels page 3 replace the tire/wheel 6. Raise the wheel to be replaced off of the ground and support with jack stands. 7. Remove the 4 or 5 wheel nuts and remove the wheel. 8. Install in reverse order. 9. Following the pattern shown on the following page, c...
Page 104
Maintenance, service, and repair tires and wheels page 4 pattern for tightening the wheel nuts do not attempt to repair a tire with a damaged side wall or a slice in the tread. This type of repair could fail prematurely resulting in severe bodily injury and/or property damage. Re-torque all wheel nu...
Page 105
Maintenance, service, and repair tires and wheels page 5 explosion hazard. Fully deflate the tire before attempting to remove the tire from the wheel. Do not over inflate the tire when seating the bead. Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failu...
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Page 107: Battery Service
Table of contents battery service cleaning ............................................ 2 testing .............................................. 3 charging ........................................... 4 watering ........................................... 5 replacing (6-volt batteries only) ........ ...
Page 108: Cleaning
Maintenance, service, and repair batteries page 2 cleaning 6. Dry dirt can be readily blown off with low-pressure air or brushed off. 7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with flexible bristles, wash the batteries off with a strong solution of bak...
Page 109: Testing
Maintenance, service, and repair batteries page 3 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 110: Charging
Maintenance, service, and repair batteries page 4 typical hydrometer float clean the batteries. Refer to cleaning the batteries section for information on cleaning the batteries. Using part number 77-200-00 hydrometer, check and record the specific gravity of each cell in the battery pack. If, after...
Page 111: Watering
Maintenance, service, and repair batteries page 5 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 112
Maintenance, service, and repair batteries page 6 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 113
Maintenance, service, and repair batteries page 7 a battery is a live electrical source. It cannot be disconnected or neutralized. Do not drop any tool or conductive object onto the battery. A conductive object that comes in contact with the battery terminals will initiate a short circuit of the bat...
Page 114
Maintenance, service, and repair batteries page 8 storage temperature (f) charging interval (months) over 60 1 between 40 and 60 2 below 40 6 storage and returning to service explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an ar...
Page 115
Maintenance, service, and repair batteries page 9 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 sec...
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Page 117: Electrical
Table of contents electrical troubleshooting symptoms: .....................................2 read this first ............................3 test equipment required: ....................................................... 3 important notes and instructions ...................... 3 definitions: .........
Page 118: 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 119: 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 120
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 121
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 122
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 123
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 124
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 125
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 126
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 127
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 128
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 129
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 130
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 131
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 132
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 133
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 134
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 135: 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 136
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 137
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 138
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 139
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 140
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 141
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 142
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 143
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 144
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 145
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 146
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 147: 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 148
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 149: 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 150
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 151
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 152
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 153
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 . St...
Page 154
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 155: 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 156: 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 157: 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 158: 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 159
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 160: 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 161
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 162: 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 163
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 inst...
Page 164
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 165: 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 166
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 167: 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 charge r. If all three led’s are flashing, it indicate an error has occurred ...
Page 168: 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 169: Wire Diagrams
Wire diagrams the vehicle wiring diaram is too large to be legible when printed at this size. A full size diagram (22 x 16) is inculded on the cd in pdf format. You can access the diagram from a button on the cd menu. The diagram # is sch-00017.
Page 170
Attach to body of directional switch (optional) strobe light v* #4 wire #10 wire grn= green brn= brown blk= black #16 wire cb = circuit breaker r = reverse f = forward i = isolator org= orange yel= yellow wht= white v = violet #12 wire a2 blk grn grn pos neg pos neg ksi #2 b- m- b+ a2 control bl wht...
Page 171: Illustrated Parts
Table of contents front axle ................................................... 2 front suspension ........................................ 4 front shocks (optional) ........................ 5 steering ................................................. 6 steering gear ..................................
Page 172: Front Axle
Illustrated parts parts page 2 front axle.
Page 173
Illustrated parts parts page 3 front axle item no. Part no. Description qty 1 15-210-00 front axle 1 2 14-210-98 axle yoke, left 1 3 14-210-99 axle yoke, right 1 4 14-210-88 axle yoke, hydraulic disc, left (optional) 1 5 14-210-89 axle yoke, hydraulic disc, right (optional) 1 6 32-240-55 bushing, me...
Page 174: Front Suspension
Illustrated parts parts page 4 front suspension item no. Part no. Description qty 1 85-512-10 leaf spring, 1-3/4” x 27-3/8” 2 2 16-870-10 spring link 4 3 32-213-00 bushing, 3/4” od x 1.656” long 6 4 96-248-00 bolt, 9/16nf x 3” 12 5 88-169-82 locknut, 9/16nf, grade c 12 6 96-123-00 u-bolt, 3/8nc x 2”...
Page 175: Front Shocks (Optional)
Illustrated parts parts page 5 front shocks (optional) front shocks (optional) item no. Part no. Description qty 1 86-602-00 shock absorber 2 2 88-128-60 washer, 7/16 4 3 88-129-81 locknut, 7/16nc 4 4 86-602-13 lower shock mount 2 5 86-602-25 upper shock mount (bolt on) 1 86-602-61 kit, front shocks...
Page 176: Steering
Illustrated parts parts page 6 steering.
Page 177
Illustrated parts parts page 7 steering item no. Part no. Description qty 1 18-308-21 steering gear 1 2 21-031-13 steering shaft, 17.938” long 1 3 17-110-00 collar, 3/4” shaft 1 4 88-080-04 bolt, 5/16nc x 3/8” hex hd 1 5 80-400-10 sealed bearing, 3/4” (up to 4/1/2002) 1 32-248-10 bushing, plastic (a...
Page 178: Steering Gear
Illustrated parts parts page 8 steering gear.
Page 179
Illustrated parts parts page 9 steering gear (18-308-21) item no. Part no. Description qty 1 18-308-70 locknut, worm bearing adjuster 1 2 18-308-71 adjuster assembly 1 3 18-308-72 worm assembly 1 4 18-308-23 upper worm bearing 1 5 18-308-22 upper worm bearing race 1 6 18-308-77 housing, steering gea...
Page 180: Park Brake
Illustrated parts parts page 10 park brake.
Page 181
Illustrated parts parts page 11 park brake item no. Part no. Description qty 1 51-344-10 lever, park brake, w/tab 1 2 05-210-86 hand brake bar 1 3 96-763-00 clevis, 5/16” 3 4 96-773-00 clevis pin, 5/16” x 1” long 3 5 88-517-09 cotter pin, 3/32” x 3/4” long 6 6 80-410-20 bearing, brake shaft 2 7 00-2...
Page 182
Illustrated parts parts page 12 deadman seat brake (optional).
Page 183
Illustrated parts parts page 13 deadman seat brake item no. Part no. Description qty 1 00-210-24 brake push rod 1 2 02-210-50 seat brake link 1 3 02-210-60 seat link arm 1 4 85-123-00 spring, deadman seat 1 5 00-210-03 seat frame 1 6 96-773-00 clevis pin, 5/16” x 1” long 2 7 88-517-09 cotter pin, 3/...
Page 184
Illustrated parts parts page 14 master cylinder & brake linkage.
Page 185
Illustrated parts parts page 15 master cylinder & brake linkage item no. Part no. Description qty 1 05-210-97 brake pedal 1 2 00-210-21 mount, brake pedal 1 3 00-210-08 rod, hydraulic brake 1 4 85-233-00 spring, extension, 1” od x 5-1/2” 1 5 96-772-00 clevis pin, 3/8” x 1” 1 6 88-527-11 cotter pin, ...
Page 186: Hydraulic Brake Lines
Illustrated parts parts page 16 hydraulic brake lines.
Page 187
Illustrated parts parts page 17 hydraulic brake lines rear item no. Part no. Description qty 1 99-607-51 brake line, 51 long 1 2 99-605-55 brake line, left 1 3 99-605-56 brake line, right 1 4 99-564-00 t-fitting 1 5 99-580-20 brake hose 2 6 99-576-00 clip, brake hose 2 front (optional) 7 99-607-51 b...
Page 188: Front Brakes (Optional)
Illustrated parts parts page 18 front brakes (optional) rear brakes.
Page 189
Illustrated parts parts page 19 front brakes (optional) item no. Part no. Description qty* 1 41-348-70 pad, disc brake 2 2 41-348-52 spacer, disc brake 2 3 32-240-40 bushing, mounting bracket 2 4 88-067-21 brake body bolt 2 5 41-350-70 hydraulic brake body, lt or rt 1 6 99-588-01 bleeder fitting 1 7...
Page 190: Chargers, Lestronic (P1)
Illustrated parts parts page 20 chargers, lestronic (p1) 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 typical built in charger typical portable charger.
Page 191
Illustrated parts parts page 21 16920 79 -309 -20 48lc25 -8et 230/50/na 48/25 built -in - s/o 79 -808 -20 79 -902 -00 79 -749 -13 s/o n/a 79 -831 -00 79 -530 -00 - - - n/a 22620 79 -303 -25 48lc25 -8et 115/60/15 48/25 built -in - 79 -805 -68 79 -808 -20 79 -902 -00 79 -749 -13 79 -603 -10 - 79 -831 ...
Page 192: Chargers, Lestronic (P2)
Illustrated parts parts page 22 chargers, lestronic (p2) 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 typical built in charger typical portable charger.
Page 193
Illustrated parts parts page 23 12315 79 -306 -90 36lc40 -8et 230/50/8 36/40 portable 79 -852 -00 k4 -071 -87 79 -808 -00 79 -902 -00 79 -749 -10 s/o s/o 79 -831 -00 79 -532 -00 79 -530 -00 79 -567 -10 - - 7030 79 -304 -60 36lc25 -8et 230/50/7 3625 portable 79 -851 -10 k4 -071 -87 79 -808 -00 79 -90...
Page 194: Chargers, Signet
Illustrated parts parts page 24 chargers, 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 * 24 volt char...
Page 195
Illustrated parts parts page 25 this page intentionally left blank.
Page 196: Motors (P1)
Illustrated parts parts page 26 motors (p1) 16 17 6 8 15 typical ge motor 9 12 13 9 5 3 4 2 1 14 10 11 7.
Page 197
Illustrated parts parts page 27 l94 -4006 70 -074 -00 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 5bt1344b185 70 -072 -00 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 5bc49jb3043b 70 -061 -00 n/a n/a n/a n/a n/a n/a n/a n...
Page 198: Motors (P2)
Illustrated parts parts page 28 16 17 6 8 15 typical ge motor 9 12 13 9 5 3 4 2 1 14 10 11 7 motors (p2).
Page 199
Illustrated parts parts page 29 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/ a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a...
Page 200: Rear Axle
Illustrated parts parts page 30 rear axle item no. Part no. Description qty 1 97-236-00 wheel lug nut 10 2 wheel bolt 10 3 41-152-00 axle (includes #2) 2 4 80-503-00 axle bearing, ball type 2 5 32-515-00 bearing retainer 2 6 45-301-00 seal, rear axle 2 rear axle.
Page 201: Belt Drive
Illustrated parts parts page 31 belt drive item no. Part no. Description qty 1 30-121-10 pulley, 4 belt, 10.6” od 1 2 30-158-00 pulley, 4 belt, 2.43” od (used on 10.5 mph drive) 1 2a 30-159-00 pulley, 4 belt, 3.00” od (used on 12.0 mph drive) 1 3 30-620-00 belt, 3v x 400, r-edge 4 4 88-239-82 nut, m...
Page 202: Power Traction Drive
Illustrated parts parts page 32 power traction drive.
Page 203
Illustrated parts parts page 33 power traction drive item no. Part no. Description qty 1 70-049-00 motor, dc, 4.5/6.0 hp 1 1a 70-054-00 motor, dc, 6.7/10.0 hp 1 1b 70-054-20 motor, dc, 6.7/10.0 hp 1 2 97-100-00 woodruff key 1 3 88-087-11 chain adjusting screw 1 4 88-069-80 nut, 5/16nc 1 5 88-103-09 ...
Page 204: Rear Differential
Illustrated parts parts page 34 rear differential.
Page 205
Illustrated parts parts page 35 rear differential item no. Part no. Description qty 44-340-10 3rd member-complete, 2.69/2.70/2.75 ratio 1 44-340-12 3rd member-complete, 3.00 ratio 1 1 41-709-00 3rd member housing (small carrier bearing, 1.628”id) 1 1a 41-710-00 3rd member housing (large carrier bear...
Page 206: Rear Suspension
Illustrated parts parts page 36 rear suspension item no. Part no. Description qty 1 85-513-10 leaf spring 2 2 16-861-00 spring pad 2 3 88-101-18 bolt, 3/8nc x 2-1/2” hex hd, grade 5 8 4 88-109-81 locknut, 3/8nc 8 5 16-870-10 spring link 4 6 32-213-00 bushing, 3/4” od x 1.656” long 6 7 96-248-00 bolt...
Page 207: Batteries
Illustrated parts parts page 37 batteries item no. Part no. Description qty 1 75-231-00 jumper, battery, 10-1/4” long 5 2 50-250-00 clamp, battery hold down 2 3 50-243-10 battery rod 2 4 88-069-81 locknut, 1/4nc 2 5 88-088-60 washer, 5/16” cut 2 6 88-081-12 bolt, 5/16nc square hd, tin-lead 12 7 88-0...
Page 208: Tires/wheels
Illustrated parts parts page 38 tires/wheels 10 ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9.
Page 209
Illustrated parts parts page 39 wheels and tires item # part # description 1 wheels 12-012-00 5 x 8" tubeless 12-020-00 8.5 x 8 tubeless 2 tires 10-081-00 5.70 x 8 lr b pneumatic 10-082-00 5.70 x 8 extra grip 10-083-00 5.70 x 8 lr c 10-093-00 8.50 x 8 lr b 10-091-10 8.50 x 8 knobby 10-092-00 8.50 x ...
Page 210: Control Panel
Illustrated parts parts page 40 control panel.
Page 211
Illustrated parts parts page 41 control panel item no. Part no. Description qty 1 72-501-39 forward or reverse solenoid 2 2 88-838-06 sheet metal screw, #14 x 1/2” 10 3 01-534-80 panel, control mounting 1 4 62-204-40 speed controller, 275 plus 400 1 4a 62-205-00 speed controller, 400a, 24/36v (optio...
Page 212: Control Panel-Ee
Illustrated parts parts page 42 control panel-ee.
Page 213
Illustrated parts parts page 43 control panel-ee item no. Part no. Description qty 1 72-501-39 forward or reverse solenoid 2 2 88-838-06 sheet metal screw, #14 x 1/2” 8 3 04-210-20 panel, control box floor 1 4 62-205-00 speed controller, 400 amp 1 5 72-501-38 iso solenoid 1 6 88-818-06 sheet metal s...
Page 214: Accelerator Module
Illustrated parts parts page 44 accelerator module item no. Part no. Description qty 1 98-254-00 accelerator pedal, aluminum 1 2 98-254-25 mount, accelerator pedal 1 3 03-210-96 mounting plate, accelerator 1 4 62-033-00 accelerator module 1 5 88-060-09 bolt, 1/4nc x 3/4” hex hd. 2 6 88-065-08 screw,...
Page 215: Instrumentation
Illustrated parts parts page 45 instrumentation item no. Part no. Description qty 1 71-120-00 ignition switch, keyed alike 1 1a 71-121-00 ignition switch, keyed unalike (optional) 1 2 71-039-00 switch, forward/reverse 1 3 74-009-00 battery status indicator 1 4 74-000-00 hourmeter (optional) 1 5 71-0...
Page 216
Illustrated parts parts page 46 decals & miscellaneous standard parts.
Page 217
Illustrated parts parts page 47 decals & miscellaneous standard parts item no. Part no. Description qty 1 94-373-10 decal, vehicle data 1 2 94-319-00 decal, battery disconnect 1 3 94-313-00 decal, battery warning 1 4 94-313-20 decal, safety warning 1 5 94-309-00 decal, brake warning 1 6 94-384-01 de...
Page 218
Illustrated parts parts page 48 miscellaneous standard parts-cont’d.
Page 219
Illustrated parts parts page 49 miscellaneous standard parts-cont’d item no. Part no. Description qty 1 94-050-10 headlight, left 1 2 94-050-11 headlight, right 1 72-082-01 bulb, headlight 2 3 94-201-10 taylor-dunnâ name plate 1 4 94-201-11 fastener strip, plastic 2 5 88-817-07 screw, #8 x 1/2” self...
Page 220: Options
Illustrated parts parts page 50 options.
Page 221
Illustrated parts parts page 51 directional signals item no. Part no. Description qty 1 75-141-20 turn signal switch 1 2 76-352-00 flasher receptacle 1 3 71-900-05 flasher, 12v 1 4 72-082-10 turn signal bulb, 12v 2 5 72-082-20 socket, turn signal 2 seat belts 6 90-199-10 seat belt, black 1 7 88-151-...
Page 222
Illustrated parts parts page 52.
Page 223
Illustrated parts parts page 53 cowl w/windshield item no. Part no. Description qty 91-013-64 kit, windshield, orange (requires fiberglass or surrey top cover) 1 91-013-65 kit, windshield, specify color (requires fiberglass or surrey top cover) 1 1 91-010-77 cowl w/windshield (unpainted) 1 2 90-852-...
Page 224
Illustrated parts parts page 54.
Page 225
Illustrated parts parts page 55 strobe light on cab item no. Part no. Description qty 1 72-023-20 strobe light, amber 1 2 88-025-06 screw, #8-32 x 1/2” truss hd 3 3 88-028-62 lockwasher, #8 3 4 88-029-80 nut, #8-32 3 5 98-606-00 grommet, 3/16” id 1 * 75-114-15 harness, wiper & light 1 * 71-100-00 to...
Page 226
Illustrated parts parts page 56.
Page 227
Illustrated parts parts page 57 cab doors, naugahyde item no. Part no. Description qty 90-924-60 kit, naugahyde door, left 1 90-924-61 kit, naugahyde door, right 1 1 90-923-98 door frame, left 1 ** 90-923-99 door frame, right 1 2 90-924-98 side curtain, left 1 ** 90-924-99 side curtain, right 1 3 97...
Page 228
Illustrated parts parts page 58.
Page 229
Illustrated parts parts page 59 surrey top cover item no. Part no. Description qty 91-101-61 kit, surrey top cover 1 1 91-028-20 tubular top frame 1 2 91-028-24 post, top frame 4 3 88-102-11 bolt, 3/8nc x 1” carriage 32 4 88-109-81 locknut, 3/8nc 32 6 91-101-00 surrey top, white 1 fiberglass top cov...
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Illustrated parts parts page 60
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Illustrated parts parts page 61 fixed 2nd seat item no. Part no. Description qty 90-010-61 kit, 2nd seat, orange 1 90-010-64 kit, 2nd seat, specify color 1 1 00-210-01 seat bulkhead (unpainted) 1 2 90-175-00 seat cushion, black 1 3 90-179-00 seatback, black 1 4 88-837-09 screw, #14 x 3/4” phillips s...
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Illustrated parts parts page 62.
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Illustrated parts parts page 63 deck cover, diamond plate, 2 pc., std. Bed item no. Part no. Description qty 90-440-45 kit, diamond cover, std bed, black (does not include #1 & 2) 1 1 90-444-20 deckboard, 41” x 38-1/2” x 5/8” 1 2 90-444-30 deckboard, 41” x 36-5/8” x 5/8” 1 3 90-440-46 deck cover, di...
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Illustrated parts parts page 64.
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Illustrated parts parts page 65 foldaway 2nd seat item no. Part no. Description qty 90-010-59 kit, foldaway 2nd seat, specify color 1 90-010-60 kit, foldaway 2nd seat, black 1 1 00-210-92 seat base frame 1 2 00-210-93 seat back frame 1 3 00-210-91 seat pivot plate 2 4 90-179-00 backrest, black 1 5 8...
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Illustrated parts parts page 66 deckboard, lockable, 2 piece item no. Part no. Description qty 1 90-444-20 deckboard, 41” x 38-1/2”, black 1 2 90-444-30 deckboard, 41” x 36-5/8”, black 1 3 03-210-25 plate, deck side lock 2 4 03-210-24 plate, deck center lock 1 5 88-082-13 bolt, 5/16nc x 1-1/4” carri...
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Illustrated parts parts page 67 box, double doors, side & rear windows item no. Part no. Description 91-333-60 kit, box, doors lt & rr, w/glass, orange 1 91-333-61 kit, box, doors lt & rr, w/glass, specify color 1 1 90-333-02 box, doors left & rear, glass front & rear (unpainted) 1 2 90-471-00 deckb...
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Illustrated parts parts page 68.
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Illustrated parts parts page 69 tools box doors, side item no. Part no. Description 91-340-62 kit, side tool box doors, orange 1 91-340-64 kit, side tool box doors, specify color 1 1 02-210-12 tool box door, left (unpainted) 1 2 02-210-13 tool box door, right (unpainted) 1 3 02-210-15 tool box top, ...
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Illustrated parts parts page 70 stake sides, standard bed item no. Part no. Description 90-545-61 kit, stake sides, 2 passenger, std bed 1 1 90-545-02 side gate, black 1 2 90-545-01 end gate, black 1 3 90-540-00 gate hook 2 4 88-065-08 screw, 1/4nc x 5/8” phillips truss hd 4 5 88-069-87 nut, 1/4nc k...
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Illustrated parts parts page 71 stake sides, fixed 2nd seat item no. Part no. Description 90-545-62 kit, stake sides, 4 passenger 1 1 90-545-03 side gate, left, black 1 2 90-545-04 side gate, right, black 1 3 90-545-01 end gate, black 1 4 90-540-00 gate hook 2 5 88-065-08 screw, 1/4nc x 5/8” phillip...
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Illustrated parts parts page 72 stake sides, foldaway 2nd seat item no. Part no. Description 1 90-545-12 side gate, front left, black 1 2 90-545-13 side gate, front right, black 1 3 90-545-14 side gate, rear left, black 1 4 90-545-15 side gate, rear right, black 1 5 90-545-01 end gate, black 1 6 90-...
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Illustrated parts parts page 73 reverse warning/motion beeper item no. Part no. Description qty 1 73-005-05 alarm, pulsating 1 hitches 2 97-804-01 hitch, pintle type 1 3 97-808-00 hitch, automatic coupling 1 4 88-140-14 bolt, 1/2nc x 1-1/2” hex hd 4 5 88-148-62 lockwasher, 1/2” 6 6 88-149-80 nut, 1/...
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Illustrated parts parts page 74.
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Illustrated parts parts page 75 nurse’s seat, black cushions item no. Part no. Description 1 00-210-51 nurse’s seat frame (unpainted) 1 2 90-000-00 backrest, 6-1/8” x 16-3/4”, black 1 3 88-837-13 screw, #14 x 1-1/4” phillips sheet metal 4 4 90-191-00 seat cushion, 17” x 18”, black 1 *** 88-065-08* s...
Page 246: Taylor -Dunn
Taylor -dunn.
Page 247: 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 248: Appendix A: Special Tools
Appendixes appendixes appendix a page 2 appendix a: special tools description purpose part number pinion seal installation tool used to install the pinion seal on all chain drive trucks with the band style brake or the speed sensor on the chain case cover. 43-201-50 chain case centering tool used to...
Page 249: 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...
Page 250
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...
Page 251
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 252: 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...
Page 253
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 visit our website: www.Taylor-dunn.Com.