1. DL manuals
  2. Taylor-Dunn
  3. Utility Vehicle
  4. B0-248-36
  5. Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn B0-248-36 Operation, T Roubleshooting And Replacement Parts Manual

Other manuals for B0-248-36: Service Replacement Parts
Manual is about: EQUIPPED WITH GT-DRIVE SYSTEM

Summary of B0-248-36

  • 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 177127 manual mb-248-12 operation, troubleshooting and replacement parts manual published 7/7/2008 revision: b equipped with gt-drive system gt drive models inlcuded: b0-248-36 (b 2-48, 36-volt) b0-248-48 (b 2-48, 48-v...

  • 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

    Table of contents t a y l or - dun n th e b e st w ay to go about yo ur bu si n e ss r a small sample of the many types of vehicles offered by taylor-dunn ® b 2-48-36 equipped with optional hydraulic dump bed bt 2-80 eight passenger tram b 1-00 personnel carrier c 4-25 huskey tow tractor mx 1600 equ...

  • Page 5: Taylor-Dunn

    Section index introduction 1 safety rules and operating instructions 2 general maintenance 3 front axle service 4 steering component service 5 brakes service 6 motor service 7 transaxle service 8 tires and wheels 9 battery service 10 control system troubleshooting 11 charger troubleshooting 12 wire ...

  • Page 6: Taylor -Dunn

    Taylor -dunn.

  • 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 b 2-48 and b 2-54 vehicles manufactured before 2007 and up to march, 2007 bt 2-48 bt 2-80 under front left passenger cushion under deck on deck rail.

  • Page 14

    Introduction introduction page-8 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 15: Safety Rules and

    Table of contents safety rules and operating instructions standard specifications* (common) ... 2 standard specifications* (model b 2-48/2-54) 3 standard specifications* (model bt 2-48) 4 standard specifications* (model bt 2-80) 5 safety rules and guidelines .............. 6 driver training program ...

  • Page 16

    Safety rules and operating instructions safety rules page 2 * - specifications are subject to change without notice. Standard specifications* (common) item voltage specification min/max battery 169 kg to 261 kg (372 lbs to 576 lbs) weights transmission helical gear, oil bath, automotive type hypoid ...

  • Page 17

    Safety rules and operating instructions safety rules page 3 these vehicles conform to requirements for type e vehicles as described in o.S.H.A. Standard section 1910.178 (powered industrial trucks) and with all applicable portions of the american national standard for personnel and burden carriers (...

  • Page 18

    Safety rules and operating instructions safety rules page 4 standard specifications* (model bt 2-48) item voltage specification occupancy 10 electrical system 36 volt six 217 amp hour, 6 volt, lead acid batteries, solid state speed control, 500 amp 48 volt eight 250 amp hour, 6 volt, lead acid batte...

  • Page 19

    Safety rules and operating instructions safety rules page 5 standard specifications* (model bt 2-80) item voltage specification occupancy eight electrical system 36 volt six 217 amp hour, 6 volt, lead acid batteries, solid state speed control, 500 amp 48 volt eight 250 amp hour, 6 volt, lead acid ba...

  • Page 20: Safety Rules And

    Safety rules and operating instructions safety rules page 6 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 21: Vehicle Controls

    Safety rules and operating instructions safety rules page 7 vehicle controls dash up to serial # 179669 5) 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 en...

  • Page 22

    Safety rules and operating instructions safety rules page 8 dash starting serial #179670 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 forwar...

  • Page 23

    Safety rules and operating instructions safety rules page 9 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 24

    Safety rules and operating instructions safety rules page 10 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 ...

  • Page 25

    Safety rules and operating instructions safety rules page 11 trailer brake module (optional) the trailer brake module controls the braking functions of a trailer equipped with electric brakes. There have been many styles of brake modules used. All of the brake modules that have been used function th...

  • Page 26

    Safety rules and operating instructions safety rules page 12 smart view display the smart view display (svd) functions as a battery status indicator (bsi), hour meter (hm), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is de...

  • Page 27

    Safety rules and operating instructions safety rules page 13 display showing maintenance and wrench icons maintenance monitor: note: the maintenance monitor function is optional. The maintenance monitor function can be turned on or off by your dealer. Operation: the smd notifies the operator 10-hour...

  • Page 28

    Safety rules and operating instructions safety rules page 14 note: most faults are a result of a fault in the control system that will require service by a qualified technician. These faults are shown here for reference only. Operator correctable faults are shown in bold and underlined. Fault code t...

  • Page 29: Vehicle Operation Guidelines

    Safety rules and operating instructions safety rules page 15 vehicle operation guidelines while driving: • slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection. • no reckless driving. • do not drive this vehicle on steep inclines or where prohibited. • ...

  • Page 30

    Safety rules and operating instructions safety rules page 16 parking before leaving the vehicle: • set the parking brake. • set the forward-off-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 31: Dump Bed (Optional)

    Safety rules and operating instructions safety rules page 17 dump bed (optional) there are numerous variations of the dump bed options that are available for the model b series vehicles. Although the physical design of the dump bed varies, the operation is basically the same. Refer to the original v...

  • Page 32

    Safety rules and operating instructions safety rules page 18 manual release lowering the dump manually there is a manually operated valve located on the left side of the hydraulic pump assembly (see illustration). This valve should only be used if the dump fails to lower by pressing the lowering but...

  • Page 33: Hydraulic Pump Exploded View

    Safety rules and operating instructions safety rules page 19 hydraulic pump exploded view this view is provided by the manufacturer of the pump and should only be used as a reference. Refer to the pump manufacturere web site for current detailed information: http://www.Monarchhyd.Com/. The pump mode...

  • Page 34: Charging Your Vehicle

    Safety rules and operating instructions safety rules page 20 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 35: Storing / Returning  To

    Safety rules and operating instructions safety rules page 21 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 36

    Safety rules and operating instructions safety rules page 22 maintenance item 2, 3 weekly 1 (20hrs) monthly 1 (80hrs) quaterly 1 (250hrs) semi - annual 1 (500hrs) annualy 1 (1000hrs) check condition of tires and tire pressure l check all lights, horns, beepers and warning devises l check and fill ba...

  • Page 37: For The Smart View Display

    Safety rules and operating instructions safety rules page 23 preventative maintenance schedule maintenance level hour interval 1 maintenance to be performed 2,3 1 500 inspect the brake system including the park brake and mounting harware inspect the steering system, tighten the steering shaft couple...

  • Page 38: Maintenance Guidelines For

    Safety rules and operating instructions safety rules page 24 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...

  • Page 39: General Maintenance

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

  • Page 40: 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 41: 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 p in/ball joint low tire pressure excessive steering play worn ...

  • Page 42: 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 43: 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 44

    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 45

    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. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 46

    Maintenance, service, and repair front axle page 4 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 47

    Maintenance, service, and repair front axle page 5 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 48: 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 49: Replace Front Wheel Bearings

    Maintenance, service, and repair front axle page 7 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 50

    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 51

    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 52

    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 53: Replace The Steering Knuckle

    Maintenance, service, and repair front axle 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 rear wheels to prevent vehicle movement. 5. Disconnect the...

  • Page 54

    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 55: 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 56: 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 57

    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 58

    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. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 59

    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 60: 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. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 61: 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 62: 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. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 63

    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 64: 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. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 65

    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 66: 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. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...

  • Page 67: 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. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the m...

  • Page 68

    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 69

    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 70

    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 71

    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 72: 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 73: 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 74

    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 75

    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 76

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

  • Page 77: Brake Service

    Table of contents inspect the service brake ............................. 2 disc brake pads ...................................................... 2 disc brake rotor ..................................................... 3 inspect the parking brake ............................. 4 wheel park brake (hy...

  • Page 78: 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 79

    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 80: Inspect The Parking Brake

    Maintenance, service, and repair brakes page 4 inspect the parking brake wheel park brake (hydraulic disc) 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 t...

  • Page 81

    Maintenance, service, and repair brakes page 5 electric motor brake a variable power supply capable of supplying 0-volts to 24-volts dc at 2-amps will be required to perform the testing. The brake does not have to be removed from the transmission for this test. 6. Disconnect the electric brake conne...

  • Page 82: Adjust The Service Brakes

    Maintenance, service, and repair brakes page 6 adjust the service brakes two or four wheel hydraulic disc 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 mas...

  • Page 83: Adjust The Parking Brake

    Maintenance, service, and repair brakes page 7 adjust the parking brake wheel park brake (hydraulic disc) the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. P...

  • Page 84: Check Master Cylinder Fluid

    Maintenance, service, and repair brakes page 8 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 85: Bleed The Brake System

    Maintenance, service, and repair brakes page 9 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 86

    Maintenance, service, and repair brakes page 10 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 87: Flush The Brake System

    Maintenance, service, and repair brakes page 11 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. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movemen...

  • Page 88: (Electric Motor Brake)

    Maintenance, service, and repair brakes page 12 current taylor-dunn ® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asb...

  • Page 89

    Maintenance, service, and repair brakes page 13 6. Mark the orientation of the inner contact plate in relation to the magnet. 7. Remove the smaller bearing circlip. 8. Using a soft hammer, drive out the center hub and remove the inner contact plate and six springs. 9. If required, remove the larger ...

  • Page 90

    Maintenance, service, and repair brakes page 14 electric motor brake exploded inspection: note: there are no repairable parts in this assembly. The parts must be replaced if any damage or wear is found. 1. Measure the free length of the five springs. Minimum length =0.713” 2. Inspect the splines on ...

  • Page 91

    Maintenance, service, and repair brakes page 15 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” posit...

  • Page 92

    Maintenance, service, and repair brakes page 16 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 93: Replace Rear Brake Pads

    Maintenance, service, and repair brakes page 17 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 94

    Maintenance, service, and repair brakes page 18 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 95: Replace The Wheel Cylinder

    Maintenance, service, and repair brakes page 19 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 wheels to prevent vehicle movement. 5. Disconnect the main pos...

  • Page 96

    Maintenance, service, and repair brakes page 20 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 97: Repair The Brake Body

    Maintenance, service, and repair brakes page 21 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 98

    Maintenance, service, and repair brakes page 22 11. Lubricate the brake parts with clean brake fluid from a sealed container. 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. 13. Using tool #41-350-13, slide t...

  • Page 99: Replace The Master Cylinder

    Maintenance, service, and repair brakes page 23 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 100

    Maintenance, service, and repair brakes page 24 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 101: Repair The Master Cylinder

    Maintenance, service, and repair brakes page 25 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 102: Taylor -Dunn

    Taylor -dunn.

  • Page 103: Motor Service

    Table of contents inspecting the motor brushes ...................... 2 motors with internal cooling fans ............................... 2 motor removal and installation ................... 3 motor inspection ........................................... 3 replacing the brushes or armature bearing .....

  • Page 104: Inspecting The Motor Brushes

    Motor service motor page 2 inspecting the motor brushes motors with internal cooling fans note: there are four brushes in the motor. The brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time. Note: in some vehicle configurations it may not be ...

  • Page 105: Motor Inspection

    Motor service motor page 3 inspection 1. Measure the length of each motor brush. • if any one brush is less than or equal to the service limit specified in section service limits , then all four brushes should be replaced. Refer to replacing the brushes section for information regarding replacing th...

  • Page 106

    Motor service motor page 4 insulation commutator incorrect hacksaw blade correct min. Od armature undercut typical burn mark on a shorted armature 2. Measure the diameter of the commutator. • if the commutator is less than the minimum diameter specified in section service limits , then the motor mus...

  • Page 107

    Motor service motor page 5 check each segment all of the way around the commutator hold this lead in place commutator 7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted armature. • if the insulation is ...

  • Page 108

    Motor service motor page 6 assembly 1. Press a new bearing into the motor housing and install the circlip. 2. Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator. See the illustration t...

  • Page 109

    Motor service motor page 7 replacing the brushes or armature bearing note: it is recommended that all four brushes be replaced as a set. Note: the motor must be disassembled to replace the brushes or the bearing. Refer to motor inspection-disassembly section for information on taking the motor apart...

  • Page 110: Repairing The Commutator

    Motor service motor page 8 example of freshly cut commutator properly undercut and cleaned commutator segments repairing the commutator 1. The motor must be removed from the vehicle for this procedure. Refer to transmission service section for information on removing the motor. 2. The armature must ...

  • Page 111

    Motor service motor page 9 insulation commutator incorrect hacksaw blade correct min. Od armature undercut example of freshly cut commutator undercutting the commutator 1. Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer to undercut depth in service limi...

  • Page 112: Service Limits

    Motor service motor page 10 service limits motor specification number undercut depth commutator diameter (min) brush length (min) resistance (ohms@75º f) mm inches mm inches mm inches armature field 70-054-40 (xp-1672 or dv1-4002) 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20 70-054-41 (xp-1789 or d...

  • Page 113: 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 114: 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. 6. Place a level on the top of th...

  • Page 115: 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 116

    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 117: 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 118: (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 119

    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 120: 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. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle mov...

  • Page 121: 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 122

    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 123

    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 124: 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. Set the park brake. 4. Place blocks under the front wheels to prevent veh...

  • Page 125

    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 126

    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 127: 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 128

    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 129

    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 130

    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 131

    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 132

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

  • Page 133: 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 134: 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 135: 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 136: 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 137: 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 138: Taylor -Dunn

    Taylor -dunn.

  • Page 139: 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 140: 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 141: 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 142

    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 143

    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 144: Taylor -Dunn

    Taylor -dunn.

  • Page 145: Battery Service

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

  • Page 146: 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 147: 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 148

    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 149: 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 150: 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 151

    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 152

    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 153

    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 154

    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 155

    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 156: Taylor -Dunn

    Taylor -dunn.

  • Page 157

    Sevcon control system troubleshooting this troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results. Table of contents test equipment...

  • Page 158

    Sevcon troubleshooting page 2 electrical troubleshooting test equipment required: • digital multimeter (dmm) with diode test function, fluke 79 model shown. • throttle module analyzer, taylor-dunn part number 62-027-32 definitions: • battery volts = full voltage available at the batteries at the tim...

  • Page 159

    Sevcon troubleshooting page 3 electrical troubleshooting identifying your controller.

  • Page 160

    Sevcon troubleshooting page 4 electrical troubleshooting if your vehicles is equipped with an electric motor brake, the motor brake system must be checked to be sure it is working properly before continuing with this troubleshooting. Operating the speed control when the motor brake has not disengage...

  • Page 161

    Sevcon troubleshooting page 5 electrical troubleshooting test 1. Checking the control logic inputs close the seat switch. Place the high/low switch in the high position. Connect a voltmeter across the iso solenoid coil terminals and carefully monitor the voltage as the key switch is turned on. Turn ...

  • Page 162

    Sevcon troubleshooting page 6 electrical troubleshooting test 1.5: test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to test #1.6. If the voltage is low, then skip ahead to test #6. Test 1.6: test the voltage at pin #7 on the 12-pin logic card con...

  • Page 163

    Sevcon troubleshooting page 7 electrical troubleshooting test 2. Testing the motor disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause property damage and/or serious bodily injury. Note: special and expensiv...

  • Page 164

    Sevcon troubleshooting page 8 electrical troubleshooting test 2.4: reaching this point indicates an open circuit in the motor wiring. Check the continuity of all wires from the controller to the motor. Repair any open wires then test drive the vehicle. Stop trouble shooting here and repair the probl...

  • Page 165

    Sevcon troubleshooting page 9 electrical troubleshooting test 3. The vehicle runs in one direction only test 3.5 disconnect the batteries and remove wires from the b-, f1, and f2 terminals on the controller. Using the diode test function on your meter, connect the positive lead to the b- terminal on...

  • Page 166

    Sevcon troubleshooting page 10 electrical troubleshooting test 4. Key fault test 4.3: test the voltage at the cold side (violet/black wire) of the key switch. If the voltage equals battery volts, then skip ahead to test #4.4. If the voltage does not equal battery volts, then replace the key switch. ...

  • Page 167

    Sevcon troubleshooting page 11 electrical troubleshooting test 5. Contactor coil fault disconnect the 12-pin logic card connector from the sevcon power unit. Turn the key switch on and perform the following tests: test 5.1: check the voltage on the positive coil terminal of the iso solenoid (violet ...

  • Page 168

    Sevcon troubleshooting page 12 electrical troubleshooting test 6. Accelerator module fault 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...

  • Page 169

    Sevcon troubleshooting page 13 electrical troubleshooting test 7. Forward and reverse switch fault turn the key switch on, place the forward and reverse switch in the center off position and perform the following tests: test 7.1: referencing battery positive, test the voltage on the center terminal ...

  • Page 170

    Sevcon troubleshooting page 14 electrical troubleshooting test 7.3: if the vehicle does not travel in forward, skip ahead to test #7.4. Place the forward and reverse switch in the reverse position. Referencing battery positive, test the voltage at the white/black wire on the f&r switch. If the volta...

  • Page 171

    Sevcon troubleshooting page 15 electrical troubleshooting test 8. Anti-rolloff fault the sevcon controller is equipped with a feature called anti-rolloff. Anti-rolloff will automatically slow the vehicle if it starts to roll. Anti-rolloff is active when the key switch has been left in the “on” posit...

  • Page 172

    Sevcon troubleshooting page 16 electrical troubleshooting test 9. Electric motor brake description: the electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what tim...

  • Page 173

    Sevcon troubleshooting page 17 electrical troubleshooting connect a volt meter across the violet/black wire at the electric brake harness plug and pin #9 at the logic card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts after about 0.5 seconds. If t...

  • Page 174

    Sevcon troubleshooting page 18 electrical troubleshooting pin# condition volts* 1 key switch off 0.0 volts key switch on battery volts 2 f&r in forward low f&r in neutral high f&r in reverse 3 f&r in reverse low f&r in neutral high f&r in forward 4 accelerator pedal up high accelerator pedal down lo...

  • Page 175

    Sevcon troubleshooting page 19 electrical troubleshooting status led code table the status led on the sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component. Numbe...

  • Page 176

    Sevcon troubleshooting page 20 electrical troubleshooting smart view fault codes level 5 faults (f05xxx) f05000 “contactor over current” this faut occurs when too much current is going into the line contactor coil circuit. This could be a result of a shorted contactor coil, short in the wiring, or f...

  • Page 177

    Sevcon troubleshooting page 21 electrical troubleshooting level 2 faults (f02xxx) f02000: “accelerator” wiring to throttle module is open or faulty throttle module. F02001: “accelerator (power up)” throttle module fs-1 switch is closed (pedal depressed) or wiring shorted when start switch is turned ...

  • Page 178: Taylor -Dunn

    Taylor -dunn.

  • Page 179: 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 180

    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 181: 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 182

    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 183

    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 184

    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 185

    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 186

    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 187: 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 188: 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 189

    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 190

    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 191: 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 192

    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 193: 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 194: 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 195: 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 196: 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 197

    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 198: 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 199

    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 200: 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 201: Wire Diagrams

    Table of contents wire diagrams complete vehicle ............................................ 2 dash ................................................................. 3 control panel ................................................... 4 accelerator module detail .............................. 5 ligh...

  • Page 202: Complete Vehicle

    Wire diagrams wire diagrams page 2 complete vehicle green gray yellow diagram inculdes options that may not be installed on your vehicle white violet/black violet/black black view from pin side 4 8 9 1 5 accelerator ms3 ms1 gray/black high/low black violet/black yellow 0-5v green/black black 2 switc...

  • Page 203: Dash

    Wire diagrams wire diagrams page 3 dash switch red gray/white white/black violet/black red gray/black blue/black high/low 2 switch black black 2 1 f 7 battery status violet/ black meter hour dash panel 12 3 8 switch f/r 14 5 red red 6 1 blue/white red special order accesories may be wired to this te...

  • Page 204: Control Panel

    Wire diagrams wire diagrams page 4 control panel white motion alarm 14 view from pin side 14 16 6 10 2 11 15 3 7 1 black 2 black red/white gray/white 16 yellow blue 6 10 white/black gray/black green/black 7 12 3 5 red 11 violet/black blue/black 8 red 1 blue/white white 4 9 white 13 white/black blue ...

  • Page 205: Accelerator Module Detail

    Wire diagrams wire diagrams page 5 accelerator module detail accelerator 8 1 0-5v out 9 5 4 ms3 ms1 b- in b- out b- in b+ in pc board.

  • Page 206: Lighting

    Wire diagrams wire diagrams page 6 lighting red red green r. Tail light white black black brown red white brown yellow 13 white white white white green white white 1 4 3 6 blue/white r. Turn 9 7 view from pin side red green blue 5 blue/white black white gray green white yellow 7 1 6 black red 8 3 gr...

  • Page 207

    Wire diagrams wire diagrams page 7 trailer brake module and receptacle dash panel brown 8 10 11 red red red key switch light switch red red 1 6 13 headlights left turn right turn blue/white blue blue/white yellow red blue/white horn button brake light red gray white brown black white red green blue ...

  • Page 208: Hydraulic Dump Option

    Wire diagrams wire diagrams page 8 hydraulic dump option red black m switch lower battery positive tap - 12v battery negative tap - 12v circuit breaker see note hydraulic pump assembly hydraulic pump assembly must be insulated from the frame of the vehicle circuit breaker note: serial number up to 1...

  • Page 209: Illustrated Parts

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

  • Page 210: Front Axle

    Illustrated parts parts page 2 * - part number not available at time of printing front axle.

  • Page 211

    Illustrated parts parts page 3 * - part number not available at time of printing front axle item # part # description qty - 15-049-71 axle beam, b 2-48, bt 2-48, b 2-54 1 - 15-049-77 axle beam, bt 2-80 1 see following pages for component breakdowns.

  • Page 212: Steering Knuckle

    Illustrated parts parts page 4 * - part number not available at time of printing steering knuckle.

  • Page 213

    Illustrated parts parts page 5 * - part number not available at time of printing 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 1...

  • Page 214: Front Brakes

    Illustrated parts parts page 6 * - part number not available at time of printing front brakes.

  • Page 215

    Illustrated parts parts page 7 * - part number not available at time of printing front brake item # part # description qty 1 88-067-29 1/4 hex bolt, grade 8 4 2 41-350-91 plate, secondary, hydraulic disc 2 3 see kit below pad, disc brake, outer 2 see kit below pad, disc brake, inner 2 4 41-348-58 sp...

  • Page 216: Steering Linkage

    Illustrated parts parts page 8 * - part number not available at time of printing steering linkage.

  • Page 217

    Illustrated parts parts page 9 * - part number not available at time of printing steering linkage item # part # description qty 1 18-041-05 tie rod, b 2-48, b 2-54, bt 2-48 1 18-057-00 tie rod, bt 2-80 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 ...

  • Page 218: Steering Column

    Illustrated parts parts page 10 * - part number not available at time of printing 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 219

    Illustrated parts parts page 11 * - part number not available at time of printing 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...

  • Page 220: Steering Gear

    Illustrated parts parts page 12 * - part number not available at time of printing steering gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16 exploded steering gear.Dwg.

  • Page 221

    Illustrated parts parts page 13 * - part number not available at time of printing 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...

  • Page 222: Front Suspension

    Illustrated parts parts page 14 * - part number not available at time of printing front suspension 1 2 3 4 7 8 front axle (ref) 5.

  • Page 223

    Illustrated parts parts page 15 * - part number not available at time of printing front suspension item # part # description qty 1 96-121-00 u-bolt 4 2 85-498-00 leaf spring, b 2-48, bt 2-48, bt 2--80 2 85-486-00 leaf spring, b 2-54 2 3 32-214-50 bushing 12 4 96-240-00 1/2nc x 4 hex bolt 6 5 88-149-...

  • Page 224: Transmission Gear Case

    Illustrated parts parts page 16 * - part number not available at time of printing transmission gear case.

  • Page 225

    Illustrated parts parts page 17 * - part number not available at time of printing 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 i...

  • Page 226: Rear Axle

    Illustrated parts parts page 18 * - part number not available at time of printing 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 sha...

  • Page 227

    Illustrated parts parts page 19 * - part number not available at time of printing 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/...

  • Page 228: Rear Brakes

    Illustrated parts parts page 20 * - part number not available at time of printing rear brakes.

  • Page 229

    Illustrated parts parts page 21 * - part number not available at time of printing rear brakes item # part # description qty 1 1/4 x 3-3/4 hex bolt, grade 8 4 88-069-82 1/4nc locknut, grade c (included in rebuild kit) 4 2 41-350-91 secondary plate 2 3 see kit below brake pad, inner 2 see kit below br...

  • Page 230: Brake Linkage

    Illustrated parts parts page 22 * - part number not available at time of printing brake linkage.

  • Page 231

    Illustrated parts parts page 23 * - part number not available at time of printing brake linkage item # part # description qty 1 88-080-11 bolt, 5/16 x 1", hex head 2 2 51-344-80 park brake handle 1 3 88-088-61 washer, 5/16" 4 4 88-089-81 locknut, 5/16" 2 5 96-813-00 adjusting brake cable assembly, b...

  • Page 232: Rear Suspension

    Illustrated parts parts page 24 * - part number not available at time of printing rear suspension view from rear.

  • Page 233

    Illustrated parts parts page 25 * - part number not available at time of printing 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 16-861-44 spring ...

  • Page 234: Motor

    Illustrated parts parts page 26 * - part number not available at time of printing motor.

  • Page 235

    Illustrated parts parts page 27 * - part number not available at time of printing 203 -21 -4001 or xp1820a 70 -072 -41 * * * 85 -403 -00 70 -173 -00 70 -170 -10 (1) * * * * - - - xp -1786 or dd3 -4004 70 -052 -40 * * * 70 -412 -20 70 -170 -00 70 -109 -00 (2) 70 -417 -00 80 -212 -00 70 -421 -20 70 -4...

  • Page 236

    Illustrated parts parts page 28 * - part number not available at time of printing electric brake and rear motor mount.

  • Page 237

    Illustrated parts parts page 29 * - part number not available at time of printing electric brake and rear motor mount item # part # description qty 1 88-067-22 bolt,1/4 x 2" nc, grade (no brake option) 3 88-067-29 bolt,1/4 x 4-1/4" nc, grade 8 (brake option only) 3 2 41-355-00 automatic electric bra...

  • Page 238: Master Cylinder

    Illustrated parts parts page 30 * - part number not available at time of printing master cylinder single reservoir dual reservoir.

  • Page 239

    Illustrated parts parts page 31 * - part number not available at time of printing single reservoir master cylinder item # part # description qty 1 99-511.00 master cylinder assembly 1 2 88-101-20 hex bolt 2 3 99-579-00 fitting, bolt 1 4 99-572-00 washer 1 5 99-566-00 fitting 1 6 99-571-00 washer 1 7...

  • Page 240: Brake Lines

    Illustrated parts parts page 32 * - part number not available at time of printing brake lines with dual master cylinder.

  • Page 241

    Illustrated parts parts page 33 * - part number not available at time of printing brake lines with dual reservoir master cylinder item# part # description qty 1 99-609-61 brake line, front 1 2 99-607-59 brake line, rear 1 3 99-606-51 brake line, front right 1 4 99-607-62 brake line, rear, b 2-48, b ...

  • Page 242: Brake Lines

    Illustrated parts parts page 34 * - part number not available at time of printing brake lines with single master cylinder.

  • Page 243

    Illustrated parts parts page 35 * - part number not available at time of printing brake lines with single reservoir master cylinder item# part # description qty 1 71-110-00 brake light switch (optional) 1 2 99-591-00 brake light switch adaptor (optional) 1 3 99-576-00 hose clip 2 4 99-608-58 brake l...

  • Page 244: Wheels and Tires

    Illustrated parts parts page 36 * - part number not available at time of printing wheels and tires ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9 10

  • Page 245

    Illustrated parts parts page 37 * - part number not available at time of printing wheels and tires item # part # description 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 10-075-00 4.80 x 8 lr b pneumatic 10-076-00 4.80 x 8 lr c pneumatic 1...

  • Page 246

    Illustrated parts parts page 38 * - part number not available at time of printing instrument panel up to s/n 179669 #6 bargraph battery status indicator #6 analog battery status indicator resetting the smart view display the meter should only be reset after the preventative maintenance has been perf...

  • Page 247

    Illustrated parts parts page 39 * - part number not available at time of printing note: if your vehicle was not originally equipped with the smart view display, then the sevcon speed control must be reprogrammed before the display will function. If you have the smart view display and wish to have th...

  • Page 248: Speed Control Panel

    Illustrated parts parts page 40 * - part number not available at time of printing speed control panel 9 3 4 6 5 2 12 11 10 8 7 1 13 14 use 94-422-21 between item #1 and item #14 refer to the serial number data plate on the controller base to determine which controller (400a or 500a) is on your vehic...

  • Page 249

    Illustrated parts parts page 41 * - part number not available at time of printing speed control panel item # part # description qty 1 62-400-05 (see note) speed controller, 400 amp 1 62-400-15 (see note) speed controller, 500 amp 2 01-200-06 mounting panel 1 3 73-004-20 horn 1 4 see below see below ...

  • Page 250: Miscellaneous Electrical

    Illustrated parts parts page 42 * - part number not available at time of printing 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 251

    Illustrated parts parts page 43 * - part number not available at time of printing miscellaneous electrical item # part # description qty not shown 75-152-80 chassie control harness, bt 2-80 1 75-152-03 chassie control harness, bt 2-48, b 2-48, b 2-54 1 75-152-13 control panel harness 1 75-152-81 pow...

  • Page 252: Lighting

    Illustrated parts parts page 44 * - part number not available at time of printing lighting stobe light 4 1 2 3 5 6 7.

  • Page 253

    Illustrated parts parts page 45 * - part number not available at time of printing 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 1 6 ** harness 1 7 72-0...

  • Page 254: Lestronic® Charger (Page 1)

    Illustrated parts parts page 46 * - part number not available at time of printing 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 255

    Illustrated parts parts page 47 * - part number not available at time of printing 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 ...

  • Page 256: Lestronic® Charger (Page 2)

    Illustrated parts parts page 48 * - part number not available at time of printing 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 257

    Illustrated parts parts page 49 * - part number not available at time of printing 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 p...

  • Page 258: Signet® Charger

    Illustrated parts parts page 50 * - part number not available at time of printing signet® charger note: the harness connectors are not included with the charger. When replacing the charger order 2 each of the following: part # description 75-318-20 butt splice 75-320-51 knife connector.

  • Page 259

    Illustrated parts parts page 51 * - part number not available at time of printing signet® charger item # part # description qty 79-303-40 charger assembly (see note on facing page) 1 79-575-60 replacement cover w/ac cord and gasket 1 note: there are no user serviceable components inside the charger ...

  • Page 260: Batteries

    Illustrated parts parts page 52 * - part number not available at time of printing batteries neg pos neg pos neg pos neg pos neg pos neg pos 12 volt negative tap main positive main negative 1 2 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 negat...

  • Page 261

    Illustrated parts parts page 53 * - part number not available at time of printing batteries item # part # description qty 1 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...

  • Page 262

    Illustrated parts parts page 54 * - part number not available at time of printing seat cushions and deck, b 2-48 and b 2-54.

  • Page 263

    Illustrated parts parts page 55 * - part number not available at time of printing b 2-48 and b 2-54 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 ...

  • Page 264: Seat Cushions Bt 2-48

    Illustrated parts parts page 56 * - part number not available at time of printing seat cushions bt 2-48 seat cushions bt 2-80

  • Page 265

    Illustrated parts parts page 57 * - part number not available at time of printing bt 2-48 seats (black) item # part # description qty 1 90-195-00 rear seat back 4 02-203-14 seat back mounting plate 4 88-837-11 #14 x 1 sheet metal screw 30 2 90-194-00 rear seat cushion 4 3 90-140-00 front seat back 1...

  • Page 266: Decals

    Illustrated parts parts page 58 * - part number not available at time of printing decals between seats bt 2-80 under 2nd seat b 2-48 and b 2-54 bt 2-80 electronics compartment.

  • Page 267

    Illustrated parts parts page 59 * - part number not available at time of printing 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 94-309-00 brake warning 1 5 94-313-20 safety warning 1 6 94-384-01 no...

  • Page 268: Cab Options

    Illustrated parts parts page 60 * - part number not available at time of printing cab options steel cab fiberglass cab.

  • Page 269

    Illustrated parts parts page 61 * - part number not available at time of printing 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 # de...

  • Page 270: Door Options, Steel Cab

    Illustrated parts parts page 62 * - part number not available at time of printing 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 271

    Illustrated parts parts page 63 * - part number not available at time of printing 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...

  • Page 272: Door Options, Fiberglass Cab

    Illustrated parts parts page 64 * - part number not available at time of printing 3 8,9 6,7 5 4 2 1 typical door assembly door options, fiberglass cab.

  • Page 273

    Illustrated parts parts page 65 * - part number not available at time of printing 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 sid...

  • Page 274: Hydraulic Dump Body Option

    Illustrated parts parts page 66 * - part number not available at time of printing hydraulic dump body option 22 (rubber cap) 22 (plastic housing).

  • Page 275

    Illustrated parts parts page 67 * - part number not available at time of printing circuit breaker usage: up to serial number 175999 use: 79-843-00 circuit breaker 1 each 78-106-00 buss bar 2 each 71-610-02 mounting bracket 1 each starting with serial number 176000 use: 79-843-01 circuit breaker 1 ea...

  • Page 276: Rear Cargo Box

    Illustrated parts parts page 68 * - part number not available at time of printing rear cargo box 1 2 3 4 5 6 5.

  • Page 277

    Illustrated parts parts page 69 * - part number not available at time of printing 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) - ...

  • Page 278: Hitches

    Illustrated parts parts page 70 * - part number not available at time of printing hitches.

  • Page 279

    Illustrated parts parts page 71 * - part number not available at time of printing.

  • Page 280

    Illustrated parts parts page 72 * - part number not available at time of printing.

  • Page 281: Appendix A-Special Tools

    Appendix a-special tools.

  • Page 282: Special Tools

    Appendix a page 2 special tools 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 center the chain ca...

  • Page 283: Appendix B:

    Table of contents appendix b: standard hardware suggested torque limits hardware identification ................................. 2 standard head markings ......................................... 2 hex bolts .................................................................. 2 other bolts .............

  • Page 284: Hardware Identification

    Appendix b appendix b page-2 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 grade 8 bolt, u...

  • Page 285

    Appendix b appendix b page-3 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, grade ‘b’...

  • Page 286: Suggested Torque Values

    Appendix b appendix b page-4 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 3/8-16 16-24 25...

  • Page 287: Suggested Torque Values

    Appendix b appendix b page-5 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 - 156 16.3 - 17...

  • Page 288

    Appendix b appendix b page-6 t a y l or - du n n t h e b e st w ay to go about yo ur b u si n e s s r a small sample of the many types of vehicles offered by taylor-dunn ® b 2-48-36 equipped with optional hydraulic dump bed bt 2-80 eight passenger tram b 1-00 personnel carrier c 4-25 huskey tow trac...

  • Page 289: Appendix C

    Appendix c brake lining handling precautions 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, ...

  • Page 290

    Model b 1-00

  • Page 292

    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.