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  5. Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn B 2-48 Operation, T Roubleshooting And Replacement Parts Manual - Replace The Wheel Cylinder

Manual is about: EQUIPPED WITH GT-DRIVE SYSTEM

Summary of B 2-48

  • 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: 171000 manual mb-248-11 operation, troubleshooting and replacement parts manual models inlcuded: b0-248-48ac (b 2-48) b0-254-48ac (b 2-54) published: 11/14/2006 revision: d equipped with ac motor speed control.

  • Page 3

    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...

  • Page 4

    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 transaxle service 7 suspension 8 tires and wheels 9 battery service 10 wire diagram 11 control system troubleshooting 12 chargers illustrate...

  • Page 6

    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 7: Introduction

    Introduction about this manual ......................................... 2 who should read this manual .................... 3 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 themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the...

  • 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...

  • Page 14

    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 15: Safety Rules and Operating

    Table of contents safety rules and operating instructions standard specifications* ............................... 2 safety rules and guidelines ......................... 3 driver training program ................................ 4 driver qualifications. ................................................

  • Page 16: Standard Specifications*

    Safety rules and operating instructions safety rules page 2 standard specifications* item model specification min/max battery 169 kg to 261 kg (372 lbs to 576 lbs) weights transmission helical gear, oil bath, automotive type hypoid differential brakes four wheel hydraulic disc, automaticaly applied ...

  • Page 17

    Safety rules page 3 safety rules and operating instructions 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. Disco...

  • Page 18: Driver Training Program

    Safety rules and operating instructions safety rules page 4 driver training program according to 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 p...

  • Page 19: Vehicle Controls

    Safety rules page 5 safety rules and operating instructions vehicle controls 6) 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 20

    Safety rules and operating instructions safety rules page 6 dash starting serial #1795002 4) forward-off-reverse switch the forward-off-reverse switch, located on the right side of the instrument panel, determines the direction of travel of the vehicle. Push the top of the switch to engage the forwa...

  • Page 21

    Safety rules page 7 safety rules and operating instructions combination display the gauge on the dash has many functions. The display will cycle through the functions while the vehicle is in operation. Some functions may not be displayed depending on the current situation of the vehicle. Battery sta...

  • Page 22

    Safety rules and operating instructions safety rules page 8 accelerator pedal the accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the ped...

  • Page 23

    Safety rules page 9 safety rules and operating instructions electrolyte alarm (optional) the electrolyte alarm is located in the battery area, in the 4th battery cell from the main battery positive cable. The electrolyte alarm is activated when the battery cell fluid level falls below the level of t...

  • Page 24: Vehicle Operational

    Safety rules and operating instructions safety rules page 10 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 25

    Safety rules page 11 safety rules and operating instructions loading and unloading • do not carry more than the maximum number of passengers allowed for this vehicle. • do not exceed the cargo load capacity. • do not load cargo that can fall off. • be careful when handling cargo that is longer, wide...

  • Page 26

    Safety rules and operating instructions safety rules page 12 model # b 2-48 equipped with 18:1 drive ratio aceleration parameters (normal mode) function value unit description fwdas ls 3.5 s time to accelerate to ~15% of full speed fwdac hs 4.0 s time to accelerate to full speed revac ls 10.0 s time...

  • Page 27

    Safety rules page 13 safety rules and operating instructions model # b 2-48 / b 2-54 equipped with 30:1 drive ratio aceleration parameters (normal mode) function value unit description fwdas ls 2.6 s time to accelerate to ~15% of full speed fwdac hs 4.0 s time to accelerate to full speed revac ls 8....

  • Page 28: Charging Your Vehicle

    Safety rules and operating instructions safety rules page 14 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 29

    Safety rules page 15 safety rules and operating instructions lestronic ii ® charger operation the lestronic ii ® charger is a semiautomatic charging system. The charger will turn itself on when the ac power cord is connected to the ac power source and turn itself off when the batteries are fully cha...

  • Page 30

    Safety rules and operating instructions safety rules page 16 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 31

    Safety rules page 17 safety rules and operating instructions 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 32: Maintenance Guidelines For

    Safety rules and operating instructions safety rules page 18 maintenance guidelines for severe duty applications 1. This maintenance checklist is based on the average application. If the vehicle is operated under “severe conditions”, service procedures should be conducted more frequently than specif...

  • Page 33: General Maintenance

    Table of contents general maintenance maintenance guidelines ............................... 2 troubleshooting guide ................................ 3 lubrication chart .......................................... 4.

  • Page 34: 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 35: Troubleshooting Guide

    Maintenance, service and repair maintenance page 3 troubleshooting guide symptom probable cause steering pulls in o ne 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 b...

  • Page 36: Lubrication Chart

    Maintenance, service and repair maintenance page 4 lubrication chart # description locations lubricant type 1 ball joints 4 general purpose grease 2 pedal linkages 3 general purpose grease 3 front wheel bearings 2 high temperature wheel bearing grease 4 king pin 2 general purpose grease 7 drive drai...

  • Page 37: 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 install...

  • Page 38

    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 the...

  • Page 39

    Maintenance, service, and repair front axle page 3 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to prev...

  • 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to prev...

  • 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to prev...

  • Page 42: Front Axle Disassembly

    Maintenance, service, and repair front axle page 6 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 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to prev...

  • Page 44

    Maintenance, service, and repair front axle page 8 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Note: refer to the brakes section for information regarding the installation of the brake body. 15. Lower the vehicle. 16. Reconnect the main positive and negati...

  • Page 45

    Maintenance, service, and repair front axle page 9 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 46

    Maintenance, service, and repair front axle page 10 failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and/or property damage. 7. Remove the steering knuckle. Refer to replace the steering knuckle for ...

  • Page 47: Replace The Steering Knuckle

    Maintenance, service, and repair front axle page 11 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. Hub with dust cap removed replace the st...

  • Page 48

    Maintenance, service, and repair front axle page 12 12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings. Note: both the left and right side bushings and thrust bearings should be replaced as a set. 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. 15. ...

  • Page 49: Steering Component Service

    Table of contents steering component service front end alignment ..................................... 2 inspect ball joints ......................................... 6 inspect rod ends .......................................... 7 adjust the steering gear ............................... 8 replace th...

  • Page 50: 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 51

    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 52

    Maintenance, service, and repair steering 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to preven...

  • Page 53

    Maintenance, service, and repair steering page 5 rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not contact any other component. Clamps positioned so that they contact other components may result in steering failure and loss of contro...

  • Page 54: Inspect Ball Joints

    Maintenance, service, and repair steering 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to preven...

  • Page 55: Inspect Rod Ends

    Maintenance, service, and repair steering page 7 inspect rod ends 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. Visually inspect each rod end for any signs of play between the ball and the n...

  • Page 56: Adjust The Steering Gear

    Maintenance, service, and repair steering 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to preven...

  • Page 57

    Maintenance, service, and repair steering page 9 13. While rotating the input shaft back and forth through its centered position, adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position. 14. While holding the gear lash adjusti...

  • Page 58: Replace The Steering Shaft

    Maintenance, service, and repair steering page 10 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the front wheels to prev...

  • Page 59

    Maintenance, service, and repair steering page 11 do not use the original pinch bolt and nut. Failure to replace the pinch bolt and nut may result in failure of the steering causing loss of control of the vehicle. This could lead to property damage and/or severe bodily injury. Make sure that the pin...

  • Page 60: Replace The Steering Wheel

    Maintenance, service, and repair steering page 12 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the front wheels to prev...

  • Page 61: Replace The Steering Gear

    Maintenance, service, and repair steering 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the rear wheels to preve...

  • Page 62

    Maintenance, service, and repair steering page 14 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 63

    Maintenance, service, and repair steering page 15 10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time. 11. Install the rod end into the steering arm. Tighten the...

  • Page 64

    Maintenance, service, and repair steering page 16 12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. And install a new cotter pin. 13. Realign the front wheels. Note: refer to the steering section for information regarding realignment of the front wheels. 1...

  • Page 65

    Maintenance, service, and repair steering page 17 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13. Remove the blocks from behind the wheels. 14. Release the park brake and test drive the vehicle. Replacing the tie rod the tie rod is the linkage that co...

  • Page 66: Center The Steering Gear

    Maintenance, service, and repair steering page 18 center the steering gear 1. Remove the pitman arm. 2. Rotate the input shaft clockwise until it stops. 3. While counting the rotations, rotate the input shaft counter clockwise until it stops. 4. Rotate the input shaft clockwise 1/2 the rotations cou...

  • Page 67: Repair The Steering Gear

    Maintenance, service, and repair steering page 19 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 68

    Maintenance, service, and repair steering page 20 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 69

    Maintenance, service, and repair steering page 21 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 70

    Maintenance, service, and repair steering page 22 exploded view of steering gear.

  • Page 71: Brake Service

    Table of contents inspect the service brake ............................. 2 disc brake pads ....................................................... 2 disc brake rotor ...................................................... 3 inspect the automatic parking brake .......... 4 adjust the automatic parkin...

  • Page 72: Inspect The Service Brake

    Maintenance, service, and repair brakes page 2 disc brake pads note: the brake pad must be removed to accurately measure the lining thickness. Refer to replace the front or rear brake pads section for information on removing the brake pads. Measure the brake pad lining at the thinnest point on the p...

  • Page 73

    Maintenance, service, and repair brakes page 3 rotor removed for clarity. The rotor does not have to be removed for this procedure. Do not use a rotor that is worn beyond its service limits. A rotor worn beyond its service limits could fail and cause loss of brakes resulting in severe bodily injury ...

  • Page 74: Adjust The Service Brakes

    Maintenance, service, and repair brakes page 4 adjust the service brakes the hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • brake fluid level low in the master cylinder. See check the master cylinder fluid section. • air in the...

  • Page 75: 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 76: Bleed The Brake System

    Maintenance, service, and repair brakes page 6 bleed the brake system note: start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. 6. Thoroughly clean the area around the master cylinder cap and remove the cap. Do not ingest br...

  • Page 77

    Maintenance, service, and repair brakes page 7 7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the master cylinder chamber. 8. The master cylinder fluid level will drop as the brakes are bled. Periodically check and fill the master cylinder during ...

  • Page 78: Flush The Brake System

    Maintenance, service, and repair brakes page 8 flush the brake system 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the ...

  • Page 79

    Maintenance, service, and repair brakes page 9 replace front disc brake pads note: it is recommended that both the left and right brake pads be replaced as a set. 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” positi...

  • Page 80

    Maintenance, service, and repair brakes page 10 note: refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. 12. Inspect...

  • Page 81: Replace Rear Brake Pads

    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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the front wheels to preven...

  • Page 82

    Maintenance, service, and repair brakes page 12 9. Remove the tire/wheel assembly. Note: refer to tires and wheels section for information on removing the tire and wheel assembly. 10. Release the park brake (wheel brake only). 11. Remove the brake body bolts and discard the lock nuts and brake pads....

  • Page 83: Replace The Wheel Cylinder

    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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under the wheels to prevent vehi...

  • Page 84

    Maintenance, service, and repair brakes page 14 8. Remove the tire/wheel assembly. Refer to tires and wheels section for information on removing the tire and wheel assembly. 9. Thoroughly clean the area around the brake body. 10. Remove the brake body bolts and discard the lock nuts. 11. Inspect the...

  • Page 85: Replace The Master Cylinder

    Maintenance, service, and repair brakes page 15 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 required. 6. If required, raise the vehicle and support with jack stands. 7. Place a drain pa...

  • Page 86

    Maintenance, service, and repair brakes page 16 10. Install in reverse order. 11. Adjust the master cylinder push rod so that it is approximately 1/8 inch away from the master cylinder plunger when the brake pedal is up. 12. Fill the master cylinder with brake fluid from a sealed container. 13. Pump...

  • Page 87: Repair The Master Cylinder

    Maintenance, service, and repair brakes page 17 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 88: Taylor -Dunn

    Taylor -dunn.

  • Page 89: Transmission

    Table of contents gt transmission assembly with disc brakes transmission check oil level ............................................. 2 change oil ..................................................... 3 motor removal and installation ................... 4 rear hub or rotor ............................

  • Page 90: Check Oil Level

    Maintenance, service, and repair transmission page 2 check oil level the oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 1. Make sure the key-switch is in...

  • Page 91: Change Oil

    Maintenance, service, and repair transmission page 3 change oil 6. Raise the rear of the vehicle and support with jack stands. 7. Place a four quart drain pan under the drive assembly. 8. Remove the drain plugs from the differential case and gear case. 9. Once the oil has drained, replace the drain ...

  • Page 92

    Maintenance, service, and repair transmission page 4 motor removal and installation note: some applications will require removing the drive assembly from the vehicle to remove the motor. Refer to removing and installing the drive assembly for information on removing the drive assembly. Some vehicles...

  • Page 93: Rear Hub Or Rotor

    Maintenance, service, and repair transmission page 5 rear hub or rotor note: the torque specification for the axle hub bolt is 275 ft-lbs. An impact wrench will be required to remove the bolt. Note: the axle hub bolt has a special thread locking compound applied to the threads. If this bolt is remov...

  • Page 94: (Disc Brakes)

    Maintenance, service, and repair transmission page 6 removing and installing the rear axles (disc brakes) the oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flang...

  • Page 95

    Maintenance, service, and repair transmission page 7 11. Remove the axle retaining plate and brake body assembly as one unit. 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14. Inspect all bearings for roughness or play, replace as nee...

  • Page 96: Transmission Assembly

    Maintenance, service, and repair transmission page 8 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. If equipped with a hand operated park brake, set the brake. 4. Place blocks under...

  • Page 97: Reduction Gear Case

    Maintenance, service, and repair transmission page 9 disassembly and reassembly of the primary reduction gear case 6. Raise the rear of the vehicle and support with jack stands. Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use l...

  • Page 98

    Maintenance, service, and repair transmission page 10 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/ bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the...

  • Page 99

    Maintenance, service, and repair transmission page 11 19. Assemble the gear case in reverse order. Note: torque the drain plug to 21-25 foot-pounds. Note: torque the gear case to 3rd member retaining bolts to 18-20 foot- pounds. Note: torque the pinion nut to 154-169 foot-pounds. Note: apply gasket ...

  • Page 100: Disassembling The 3Rd Member

    Maintenance, service, and repair transmission page 12 disassembling the 3rd member 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. If equipped with a hand operated park brake, set the brake. 4. Place bloc...

  • Page 101

    Maintenance, service, and repair transmission page 13 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race from the side plate. 15. Remove the differential assembly from the 3rd member housing. 1...

  • Page 102

    Maintenance, service, and repair transmission page 14 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the front bearing from the input shaft. Note: the input shaft may have to be driven out to perform this procedure. 19. Remove the input shaft’s shims and spacer. 20. Remo...

  • Page 103: Assembling The 3Rd Member

    Maintenance, service, and repair transmission page 15 assembling the 3rd member 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. 3. Install the carrier bearing races into the housing and cover. Cover housing cover h...

  • Page 104

    Maintenance, service, and repair transmission page 16 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. 12. Install the p...

  • Page 105

    Maintenance, service, and repair transmission page 17 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the ...

  • Page 106

    Maintenance, service, and repair transmission page 18 pinion bearing preload note: the pinion gear depth must be set before the preload. Refer to setting the pinion gear depth . 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3. Install the main g...

  • Page 107

    Maintenance, service, and repair transmission page 19 pinion gear shimming instructions note: this procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. Note: to perform this procedure, all parts must be clean and the bearings lightly lub...

  • Page 108

    Maintenance, service, and repair transmission page 20 note: values shown are for reference only c d.

  • Page 109: Suspension

    Table of contents suspension replace the rear springs ............................. 2 replace the front springs ............................ 3 replace the spring bushings ....................... 4 replace the shocks ...................................... 5.

  • Page 110: Replace The Rear Springs

    Maintenance, service, and repair suspension page 2 replace the rear springs 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 mo...

  • Page 111: Replace The Front Springs

    Maintenance, service, and repair suspension page 3 damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch ...

  • Page 112: Replace The Spring Bushings

    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 113: Replace The Shocks

    Maintenance, service, and repair suspension page 5 replace the shocks it is recommended to replace all 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 regarding removing...

  • Page 114: Taylor -Dunn

    Taylor -dunn.

  • Page 115: Tires and Wheels

    Table of contents tire inflation .................................................. 2 tire inspection .............................................. 2 replace the tire/wheel ................................. 3 repair the tire (pneumatic) ......................... 4 replace the tire (pneumatic) ........

  • Page 116: 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 117: Replace The 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 118

    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 119

    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...

  • Page 120: Taylor -Dunn

    Taylor -dunn.

  • Page 121: Battery Service

    Table of contents cleaning ........................................................ 2 testing ........................................................... 3 watering ........................................................ 5 charging ........................................................ 6 replacin...

  • Page 122: 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 123: 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 (6-volt batteries only) note: the batteries must be fully charged before performing this test. 1. ...

  • Page 124

    Maintenance, service, and repair batteries page 4 typical hydrometer float 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 readin...

  • Page 125: 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 126: Charging

    Maintenance, service, and repair batteries 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. 5. Disconnect the ...

  • Page 127

    Maintenance, service, and repair batteries page 7 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 the key-swi...

  • Page 128

    Maintenance, service, and repair batteries page 8 do not leave cables on batteries that have been removed from the vehicle. Cables left on batteries could cause a short circuit resulting in battery explosion, severe bodily injury and/or property damage. When torquing battery hardware, use a backup w...

  • Page 129

    Maintenance, service, and repair batteries 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. 5. Disconnect the ...

  • Page 130

    Maintenance, service, and repair batteries page 10 if the batteries are removed from the vehicle, do not place them directly on the ground, concrete or solid metal surface. It is recommended to store them on a wooden pallet or equivalent. Storing on the ground, concrete or solid metal surface will c...

  • Page 131

    Maintenance, service, and repair batteries 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...

  • Page 132: Taylor -Dunn

    Taylor -dunn.

  • Page 133: Wire Diagrams

    Wire diagrams the vehicle wiring diagram is too large to be legible when printed at this size. A full size diagram (22 x 16) is included on the cd in pdf format. You can access the diagram from a button on the cd menu. The diagram # is: sch-00007 for vehicles with 12 volt accessory tap. Sch-00008 fo...

  • Page 134: Taylor -Dunn

    Taylor -dunn.

  • Page 135: Control System Diagnostics

    Control system diagnostics table of contents test equipment required: ...................... 2 important notes and instructions ........... 2 status led code table .......................... 3 throttle module test ............................. 6 rev c.

  • Page 136

    Electrical troubleshooting troubleshooting page 2 test equipment required: • user level maintenance handset part number 62-027-64 the maintenance handset can view current faults, fault history, monitor all controller inputs and outputs and monitor the current status of the controller, motor, battery...

  • Page 137

    Electrical troubleshooting troubleshooting page 3 status led code table the status led’s on the speed controller can be used to give you an idea of where the problem may be. During normal operation (no faults) the yellow led will be flashing steady. When the controller senses a fault the two led’s c...

  • Page 138

    Electrical troubleshooting troubleshooting page 4 code handset display effect of fault possible cause note 24 overvoltage cutback reduced brake torque. 1. Battery failure. 2. High voltage generated during normal regen. 25 +5-volt supply failure none. 1. Faulty motor encoder. 2. Faulty wiring +5-volt...

  • Page 139

    Electrical troubleshooting troubleshooting page 5 code handset display effect of fault possible cause note 44 brake wiper low full brake. 1. See note, voltage too low on pin-17 not used – if fault occurs then check controller connector for contamination 45 pot low overcurrent shutdown throttle; full...

  • Page 140

    Electrical troubleshooting troubleshooting page 6 throttle module test with the power switch off, connect the throttle module to the analyzer. Position the power switch to the 0-5 volt range. All but the power lamp should be off. If the fs-1, fs-3 or ov lamp (over voltage) are on, then the module is...

  • Page 141: 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 142

    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 143: 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 144

    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 145

    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 146

    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 147

    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 148

    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 149: 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 150: 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 151

    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 152

    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 153: 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 154

    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 155: 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 156: 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 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: Illustrated Parts

    Table of contents front axle .................................................... 2 steering knuckle ......................................... 4 steering linkage ......................................... 6 steering column .......................................... 8 front suspension ...................

  • Page 164: Front Axle

    Illustrated parts parts page 2 front axle.

  • Page 165

    Illustrated parts parts page 3 front axle item # part # description qty - 15-049-71 axle beam, b 2-48, bt 2-48, b 2-54 1 15-050-76 complete axle assembly 1 see following pages for component breakdowns.

  • Page 166: Steering Knuckle

    Illustrated parts parts page 4 steering knuckle.

  • Page 167

    Illustrated parts parts page 5 steering knuckle item # part # description qty - - - 4 88-239-86 3/4-nf hex slotted nut 2 5 88-228-60 3/4 cut flat washer 2 6 98-603-07 rubber bushing 2 7 01-220-99 washer 2 8 32-240-44 bushing 2 9 32-240-43 bushing 2 10 80-309-12 thrust bearing 2 11 45-338-00 grease s...

  • Page 168: Steering Linkage

    Illustrated parts parts page 6 steering linkage.

  • Page 169

    Illustrated parts parts page 7 steering linkage item # part # description qty 1 18-041-05 tie rod, b 2-48, b 2-54, bt 2-48 1 2 86-510-00 ball joing clamp 4 3 86-501-98 ball joing (left) 2 4 86-501-99 ball joint (right) 2 5 88-527-11 1/8 x 1 cotter pin 4 6 18-057-11 drag link 1 7 88-159-85 1/2nf cast...

  • Page 170: Steering Column

    Illustrated parts parts page 8 steering column ref., steering gear 8 9 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. 7 4 3 6 { 5 2 1.

  • Page 171

    Illustrated parts parts page 9 steering column item # part # description qty 1 88-199-82 5/8nf hex nut 1 2 19-011-20 steering wheel 1 3 88-081-14 5/16nf x 1-1/2 hex bolt, grade 8 1 4 88-089-84 5/16nf hex lock nut, grade c 1 5 32-248-10 upper bushing 1 6 20-031-65 steering shaft assembly (incl. 3 and...

  • Page 172: Steering Gear

    Illustrated parts parts page 10 steering gear 1 2 3 4 7 8 front axle (ref) 5 9 1 0 1 5 1 3 1 7 1 2 1 1 2 3 1 4 1 6 4 1 6 8 7 5 front suspension.

  • Page 173

    Illustrated parts parts page 11 steering gear 18-308-21 item # part # description qty 1 18-308-70 locknut 1 2 18-308-71 adjuster assembly 1 3 18-308-72 worm assenbly 1 4 18-308-23 upper worm bearing 1 5 18-308-22 upper worm bearing race 1 6 18-308-77 housing 1 7 18-308-78 seal, pitman shaft 1 8 18-3...

  • Page 174: Rear Suspension

    Illustrated parts parts page 12 rear suspension view from rear.

  • Page 175

    Illustrated parts parts page 13 rear suspension item # part # description qty not shown 96-240-00 1/2nc x 4 spring bolt (front of the leaf spring) 2 32-214-50 spring bushing (front of the leaf spring) 4 14 85-510-17 leaf spring 2 15 16-861-46 spring mounting plate (left) 1 16-861-47 spring mounting ...

  • Page 176: Transmission Gear Case

    Illustrated parts parts page 14 transmission gear case.

  • Page 177

    Illustrated parts parts page 15 transmission gear case item # part # description qty 1 gt-71682 m8 x 60 bolt 12 2 gt-3287563 gear case cover 1 3 gt-71259 bearing 1 4 gt-3287513 input shaft, 30:1 0 or 1 gt-3287523 input shaft, 24:1 0 or 1 gt-3287533 input shaft, 18:1 0 or 1 5 gt-71982 o-ring 1 6 gt-3...

  • Page 178: Rear Axle

    Illustrated parts parts page 16 transmission differential case rear axle inner bearing on optional double bearing axle does not have an oil seal or o-ring. Orientation of bearing should have o-ring groove adjacent to o-ring on outer bearing. Axle shaft inner bearing (no o-ring) outer bearing o-ring ...

  • Page 179

    Illustrated parts parts page 17 transmission differential case item # part # description qty 9 gt-70302 m10 x 30 bolt 12 13 gt-3287183 ring and pinion gear set 1 14 gt-3297193 differential case cover 1 15 gt-3287133 adjusting ring 2 16 gt-70417 fill/level plug 1 17 gt-3287113 differential housing 1 ...

  • Page 180: Rear Brakes

    Illustrated parts parts page 18 rear brakes front brakes.

  • Page 181

    Illustrated parts parts page 19 rear brakes item # part # description qty 1 - - - 2 99-588-00 bleeder valve 2 99-588-01 bleeder adaptor 2 3 - - - 4 - - - 5 41-348-70 brake pad 4 6 - brake body assembly (not available as a replcement component) - 7 32-240-41 bushing 4 8 41-348-57 spacer 4 9 88-067-21...

  • Page 182: Brake Lines

    Illustrated parts parts page 20 brake lines master cylinder.

  • Page 183

    Illustrated parts parts page 21 brake lines item# part # description qty 1 99-609-61 brake line, front brakes 1 2 99-603-73 brake line, regen switch to brake switch 1 3 99-606-51 brake line, front right 1 4 99-603-72 brake line, brake switch to rear brakes 1 5 99-603-70 brake line, rear right 1 6 99...

  • Page 184: Motor

    Illustrated parts parts page 22 motor.

  • Page 185

    Illustrated parts parts page 23 70-059-41 motor spec # zfb40so/4 df100l-4 item # part # description qty 1a 41-354-05 brake 1 9 70-400-14 snap ring 1 14 70-400-12 fan shroud 1 15 70-400-11 fan 1 39 70-400-15 o-ring 1 41 70-400-16 key 1 42 70-400-17 snap ring 1 52 70-400-21 key 1 96 70-400-18 snap rin...

  • Page 186: Motor Mount

    Illustrated parts parts page 24 motor mount apply 94-421-34 grease to inside of motor coupler.

  • Page 187

    Illustrated parts parts page 25 motor mount item # part # description qty 1 see motor motor 1 2 96-114-12 u-bolt 1 3 80-714-05 o-ring 1 4 88-068-62 1/4 split lock wahser 4 5 89-060-11 6mm x 1.0 x 50 hex bolt 3 6 89-111-27 10mm x 1.5 x 20 hex bolt 2 7 88-128-62 7/16 split lock washer 2 8 70-456-03 mo...

  • Page 188: Wheels and Tires

    Illustrated parts parts page 26 wheels and tires ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9 10

  • Page 189

    Illustrated parts parts page 27 wheels and tires item # part # description 94-423-20 flat out,tire seal,pt botl 1 wheels 12-012-00 5 x 8" tubeless 12-020-00 8.5 x 8 tubeless 12-050-00 12-1/8 diameter cast iron 2 tires 10-083-00 5.70 x 8 lr c 10-092-00 8.50 x 8 lr c 10-260-00 18 x 5 x 12 1/8 solid ru...

  • Page 190

    Illustrated parts parts page 28 instrument panel up to serial # 179501 instrument panel starting serial # 179502.

  • Page 191

    Illustrated parts parts page 29 instrument panel up to serial # 179501 item # part # description qty 1 71-102-15 horn switch 1 2 71-039-02 f&r switch 1 3a 71-039-11 light switch 1 3b high / low speed switch 1 4 74-010-20 gauge, spy glass 1 5 71-100-00 auxiliary switchs 0, 1, 2 6 71-120-00 start swit...

  • Page 192: Speed Control Panel

    Illustrated parts parts page 30 speed control panel b 2-48 shown wire harnesses part # description qty 75-153-08 dash harness 1 75-153-04 cable, spy glass 75-153-07 main control h1arness 1 75-153-05-60 control panel 1 75-153-06 power 1.

  • Page 193

    Illustrated parts parts page 31 speed control panel item # part # description qty 1 73-005-01 motion alarm 1 2 62-400-35* motor speed control, b 2-48 1 62-400-11* motor speed control, b 2-54 1 3 89-080-16 8mm x 1.25 x 16mm hex bolt 5 89-060-17 8mm lock washer 5 4 02-425-17 controller base, 1/4 plate...

  • Page 194: Miscellaneous Electrical

    Illustrated parts parts page 32 miscellaneous electrical 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 195

    Illustrated parts parts page 33 miscellaneous electrical item # part # description qty not shown 98-599-15 plastic grommet for 1.75 hole 98-599-20 plastic grommet for 2.5 hole 75-107-10 potratble charger harness 1 jf3-86181-00-00 portable charger receptacle 1 72-015-00 dome light (optional) 1 78-321...

  • Page 196: Lighting

    Illustrated parts parts page 34 lighting stobe light 4 1 2 3 5 6 7.

  • Page 197

    Illustrated parts parts page 35 strobe light item # part # description qty 1 88-029-80 8-32 hex nut 3 2 88-028-62 #8 lock washer 3 3 88-025-06 8-32 x 1/2 machine screw 3 4 72-023-20 strobe assembly (amber) 1 5 * mounting pole or mounting plate 1 6 * harness 1 7 72-023-22 amber lens 1 72-023-23 red l...

  • Page 198: Lestronic® Charger (Page 1)

    Illustrated parts parts page 36 lestronic® charger (page 1) 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 199

    Illustrated parts parts page 37 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 200: Lestronic® Charger (Page 2)

    Illustrated parts parts page 38 lestronic® charger (page 2) 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 201

    Illustrated parts parts page 39 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 202: Signet® Charger

    Illustrated parts parts page 40 signet® charger 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 charg...

  • Page 203: Portable Charger Wiring

    Illustrated parts parts page 41 portable charger wiring part # description qty 75-107-10 hrnss,portable/less chrger 1 jf3-86181-00-00 receptacle, w/interlock 1 90157-05m19-00 mounting hardware for receptacle 2 92907-05100-00 4 92907-05600-00 4 98507-05035-00 2.

  • Page 204: Batteries

    Illustrated parts parts page 42 batteries neg pos neg pos 3 4 5 6 7 8 1 neg pos neg pos neg pos neg pos neg pos neg pos 12 volt negative tap main positive main negative 1 2.

  • Page 205

    Illustrated parts parts page 43 batteries item # part # description qty 1 75-237-00 batteru jumper * 2 77-042-00 217ah, t-105 * 77-042-50 217ah, td-217 * 77-042-80 217ah, t-105 moist charge (dry) * 77-044-00 230ah, t-125 * 77-044-10 195ah, mainenance free (note: requires special charger) * 77-047-00...

  • Page 206: Seat Cushions and Deck

    Illustrated parts parts page 44 seat cushions and deck.

  • Page 207

    Illustrated parts parts page 45 seats and deck item # part # description qty 1 90-148-00 passenger seat cushion (standard) 1 90-172-00 passenger seat cushion (with steel cab) 1 2 90-140-00 seat back (standard) 1 90-179-00 seat back (with steel cab) 1 90-142-00 seat back (1/2 cowl frame) 1 3 90-148-0...

  • Page 208: Mirrors

    Illustrated parts parts page 46 mirrors 92-202-00 assembly miscellaneous frame components.

  • Page 209

    Illustrated parts parts page 47 mirrors item # part # description qty - 92-201-00 mirror, rectangular, 4-1/2 x 8-1/2 (side view) - 92-202-12 mounting bracket, left - 92-202-13 mounting bracket, right - 91-814-16 hinge, left (used with 92-202-12) - 91-814-17 hinge, right (used with 92-202-13 - 92-202...

  • Page 210: Decals

    Illustrated parts parts page 48 decals.

  • Page 211

    Illustrated parts parts page 49 decals item # part # description qty 1 94-319-00 battery disconnect 1 or 2 2 94-313-00 battery warning 1 or 2 3 94-373-10 vehicle identification 1 4 94-384-21 brake warning 1 5 94-313-20 safety warning 1 6 94-384-01 not a motor vehicle 1 7 94-384-14 when leaving vehic...

  • Page 212: Cab Options

    Illustrated parts parts page 50 cab options steel cab fiberglass cab.

  • Page 213

    Illustrated parts parts page 51 steel cab item # part # description qty - 91-012-00 steel cab (unpainted) 1 - 90-852-30 front windshield 1 - 90-850-10 rear window 1 - 98-310-00 rubber windshield gasket (by the foort) - fiberglass cab item # part # description qty - 91-000-00 fiberglass cab 1 - 90-80...

  • Page 214: Door Options, Steel Cab

    Illustrated parts parts page 52 door options, steel cab 1 2 4 5 6,7 8,9 10 11,12 14 15 16 16 17 18 19 20 21 22 23 25 26 27 28 note: left door shown 24 3 13 steel door detail door restraint 16 13 door frame cab door frame 10 29,12.

  • Page 215

    Illustrated parts parts page 53 cab doors naugahyde (steel cab) item # part # description qty 1 90-923-98 door frame, left 1 not shown 90-923-99 door frame, right 1 2 90-924-98 side curtain, left 1 not shown 90-924-99 side curtain right 1 3 97-315-53 handle assembly, outer 2 4 97-315-51 door latch 2...

  • Page 216: Door Options, Fiberglass Cab

    Illustrated parts parts page 54 3 8,9 6,7 5 4 2 1 typical door assembly door options, fiberglass cab.

  • Page 217

    Illustrated parts parts page 55 cab doors naugahyde (fiberglass cab) item # part # description qty 1 90-921-98 door frame, left 1 90-921-99 door frame, right 1 98-451-11 weather seal tape (by the foot) - 2 90-908-98 side curtain, left 1 90-908-99 side curtain right 1 3 97-315-53 handle assembly, out...

  • Page 218: Hydraulic Dump Body Option

    Illustrated parts parts page 56 hydraulic dump body option.

  • Page 219

    Illustrated parts parts page 57 dump bed option item # part # description qty 1 21-018-00 cylinder pin 1 2 88-060-11 bolt, 1/4 x 1-1/4" nc, hex head 6 3 88-069-81 locknut, 1/4" nc 6 4 21-019-00 shaft, dump bed pivot 2 5 17-112-00 collar, shaft 2 6 99-524-00 hydraulic cylinder 1 7 99-957-00 hydraulic...

  • Page 220: Rear Cargo Box

    Illustrated parts parts page 58 rear cargo box 1 2 3 4 5 6 5 top covers.

  • Page 221

    Illustrated parts parts page 59 rear cargo box item # part # description qty 1 91-333-02 cargo box (unpainted) 1 2 90-471-00 front deck board 1 3 90-472-00 rear deeck board 1 4 90-850-10 front window 1 5 98-310-00 ruber window gasket (by the foor) - 6 90-851-00 rear window 2 not shown 94-320-10 load...

  • Page 222: Hitches

    Illustrated parts parts page 60 hitches.

  • Page 223

    Illustrated parts parts page 61 trailer hitches item # part # description qty 97-811-00 1-7/8 inch ball 97-821-00 2-inch ball 88-140-14 1/2nc x 1-1/2 hex bolt 4 88-149-80 1/2nc hex nut 4 88-148-62 1/2 split lock washer 4 note: replacement parts only. Ladder rack cannot be added to an existing vehicl...

  • Page 224: Taylor -Dunn

    Taylor -dunn.

  • Page 225: 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 226: Appendix A: Special Tools

    Appendixes appendixes appendix a page 2 appendix a: special tools description purpose part # 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 module p...

  • Page 227: 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 228

    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 229

    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 230: 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 231

    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 ...

  • Page 232

    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.