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- B0-T48-48 Taylor Truck T48
- Operation, T Roubleshooting And Replacement Parts Manual
Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation, T Roubleshooting And Replacement Parts Manual
Summary of B0-T48-48 Taylor Truck T48
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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: 150778 manual mb-t48-01 operation, troubleshooting and re- placement parts manual models inlcuded: b0-t48-48 taylor truck (t48) et-030-48 (et 3000) published: 3/28/2002 revision: k, 8/9/2011 taylor truck et 3000
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Taylor-dunn contact information service, parts, sales: taylor-dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the tayl...
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B2-48 with dump bed option b2-10 ambulance b2-48 with steel cab, foldaway 4-passenger seat and stake sides et 3000 et1-50 full size truck p2-50 30,000 pound tow tractor.
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Section index introduction safety rules and operating instructions general maintenance front axle service steering component service brakes service throttle linkage transaxle service suspension motor service tires and wheels battery service control system troubleshooting chargers wire diagram illust...
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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 equipped with optional ladder rack and weld tanks.
Page 7: Table of Contents
Table of contents introduction about this manual ......................................... 2 who should read this manual .................... 2 responsibilities ............................................ 2 how to use this manual .............................. 3 conventions ...........................
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Introduction page-2 who should read this manual this manual is intended for use by anyone who is going to operate, own, perform maintenance on, service, or order parts for this taylor-dunn ® vehicle. Each person should be familiar with the parts of this manual that apply to their use of this vehicle...
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Introduction page-3 how to use this manual this manual is organized into five main sections: introduction this section describes how to use this service manual and how to identify your vehicle. Safety rules and operating instructions this section outlines the safety and operational issues, location ...
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Introduction page-4 how to identify your vehicle this manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile ho...
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Introduction page-5 taking delivery of your vehicle inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems: • examine the contents of all packages and accessories that may have come in separate packages with the vehicle. • make sure everyth...
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Model b 1-00
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Table of contents standard specifications* ........................ 2 safety rules and guidelines .................. 3 driver training program ......................... 3 driver qualifications. ........................................... 3 vehicle controls ..................................... 4 das...
Page 14: Standard Specifications*
Safety rules and operating instructions safety rules page 2 standard specifications* item specification occupancy driver, one passenger dimensions taylor truck 318 l x 127 w x 119 h centimeters 125 l x 50 x 47h inches et 3000 325 l x 127 w x 119 h centimeters 128 l x 50 x 47h inches turning radius 3...
Page 15: Safety Rules And
Safety rules and operating instructions safety rules page 3 safety rules and guidelines it is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the american national standards ins...
Page 16: Vehicle Controls
Safety rules and operating instructions safety rules page 4 vehicle controls dash (up to s/n 179999) 1) key-switch a key-switch, located on the right center side of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle...
Page 17: Dash (Starting S/n 180000)
Safety rules and operating instructions safety rules page 5 dash (starting s/n 180000) 1) headlight switch the headlight switch is located on the left sideof the instrument panel. Push the top of the switch to turn the lights on. Push the bottom of the switch to turn the lights off. 2) wiper switch ...
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Safety rules and operating instructions safety rules page 6 foot brake pedal the foot brake pedal, is located to the right of the steering column, it is for operation with the right foot only. It works similar to the brake in an automobile. Applying pressure to the brake pedal slows the vehicle acco...
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Safety rules and operating instructions safety rules page 7 directional signals (optional) the turn signal lever is located on the left side of the steering column. Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal. Hazard light switch ...
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Safety rules and operating instructions safety rules page 8 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 lis...
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Safety rules and operating instructions safety rules page 9 speed controller status: the display will indicate a fault code whenever the control system logic detects a problem with the control system. A fault code is being displayed whenever the fault code indicator (the letter ‘f’) is visible at th...
Page 22: 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...
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Safety rules and operating instructions safety rules page 11 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 24: Charging Your Vehicle
Safety rules and operating instructions safety rules page 12 charging your vehicle explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge a battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, o...
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Safety rules and operating instructions safety rules page 13 signet charger operation, model hbs series the signet ® hbs series chargers are fully automatic. 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 ch...
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Safety rules and operating instructions safety rules page 14 lestronic ii charger operation the lestronic ii ® charger is a semi-automatic 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 char...
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Safety rules and operating instructions safety rules page 15 the signet and x-series chargers are for lead acid batteries only. Charging other types of batteries may cause the battery to burst or explode causing severe personal injury and/or property damage. Warning do not attempt to operate the veh...
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Safety rules and operating instructions safety rules page 16 self diagnosis procedure if you suspect a battery charging problem press the self diagnostic switch to start the charger self diagnostic procedure. Any faults found by the procedure will be displayed by the two led’s. Refer to the table be...
Page 29: Storing / Returning To
Safety rules and operating instructions safety rules page 17 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 30
Safety rules and operating instructions safety rules page 18 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 31: For The Smart View Display
Safety rules and operating instructions safety rules page 19 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 32: Maintenance Guidelines For
Safety rules and operating instructions safety rules page 20 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: Table of Contents
Table of contents general maintenance maintenance guidelines ............................... 2 troubleshooting guide ................................ 3 lubrication chart .......................................... 4 model e 4-55 tow tractor model c 4-25 tow tractor examples of taylor-dunn tow tractor...
Page 34: Maintenance Guidelines
Maintenance, service and repair page 2 maintenance guidelines • avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle performance checks in an authorized area where safe clearance exists. • before starting the vehicle, follow the recommended safety procedure...
Page 35: Troubleshooting Guide
Maintenance, service and repair page 3 troubleshooting guide symptom probable cause steering pulls in one direction front end out of alignment low tire pressure hard steering dry lube points in steering linkage damaged king pin/ball joint low tire pressure excessive steering play worn ball joints mi...
Page 36: Lubrication Chart
Maintenance, service and repair 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 5 - - - 6 - - 7 drive dr...
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 installation ........................
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 adjust front wheel bearings 11. Install a new cotter pin. 12. Install the dust cap. 13. Lower the vehicle. 14. Reconnect the main positive and negative cables at the batteries. 15. Remove the blocks from behind the wheels. 16. Release the park brake...
Page 40: Front Axle Removal And
Maintenance, service, and repair front axle page 4 front axle removal and installation removal 6. Raise the front of the vehicle and support with jack stands. 7. Remove both front wheels. Refer to tires and wheels section for information regarding removing the front wheels. 8. Tie up or support the ...
Page 41: Front Axle Disassembly
Maintenance, service, and repair front axle page 5 front axle disassembly disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: replace the steering knuckl...
Page 42: Replace Front Wheel
Maintenance, service, and repair front axle page 6 replace front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly from the hub. Refer to tires and wheels for information regarding removing the wheel assembly. 8. Remove the hub dust cap,...
Page 43: Replace The King Pins And
Maintenance, service, and repair front axle page 7 replace the king pins and bushings there are different types of king pin bushings depending on the configuration of your vehicle. • bronze bushings in the axle beam. • bronze bushings in the steering knuckle. • metal backed teflon bushings in the ax...
Page 44: Replace The Steering
Maintenance, service, and repair front axle page 8 replace the steering knuckle 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly. Refer to tires and wheels section for information regarding removing the tire/wheel assembly. 8. Remove the hub bearing c...
Page 45: Steering Component Service
Table of contents steering component service front end alignment .......................... 2 inspect ball joints ............................. 5 inspect rod ends .............................. 5 adjust the steering gear ................... 6 replace the steering shaft ................ 7 replace the...
Page 46: 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 47
Maintenance, service, and repair steering page 3 if the clamps are positioned so that they contact other components, it may result in steering failure and loss of control of the vehicle causing property damage and/or severe bodily injury. 12. Adjust the drag link so that it can be easily inserted in...
Page 48
Maintenance, service, and repair steering page 4 front wheel alignment note: it is recommended to center the steering before aligning the front wheels. Refer to the center the steering section for information. 6. Raise the front of the vehicle and support with jack stands. 7. Turn the front wheels s...
Page 49: Inspect Ball Joints
Maintenance, service, and repair steering page 5 inspect ball joints note: a set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 6. Raise the front of the vehicle and support with jack stands. 7. Tie off the...
Page 50: Adjust The Steering Gear
Maintenance, service, and repair steering page 6 adjust the steering gear note: in some vehicle configurations it may be necessary to remove the steering gear to perform this procedure. Refer to replace the steering gear for information regarding removing the steering gear. 6. Raise the front of the...
Page 51: Replace The Steering
Maintenance, service, and repair steering page 7 replace the steering shaft 6. If equipped with a horn switch in the steering wheel, remove the switch, disconnect the wires from the switch and cut the terminals off of the wires. 7. Remove the steering wheel. Note: refer to replace the steering wheel...
Page 52: Replace The Steering
Maintenance, service, and repair steering page 8 replace the steering gear 6. Remove the steering wheel. Refer to replace the steering wheel section for information regarding removing the steering wheel. 7. Remove the steering shaft. Refer to replace the steering shaft section for information regard...
Page 53
Maintenance, service, and repair steering page 9 replace the ball joints, tie rods, and drag link this section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second cannot be greased ...
Page 54
Maintenance, service, and repair steering page 10 replacing a ball joint 6. Raise the front of the vehicle and support with jack stands. 7. Loosen the ball joint clamp on the steering sleeve. 8. Remove the cotter pin and ball joint nut. 9. Using a pickle fork, remove the ball joint from the steering...
Page 55: Center The Steering Gear
Maintenance, service, and repair steering page 11 9. Install in reverse order. 10. Realign the front wheels. Note: refer to the steering section for information regarding realignment of the front wheels. 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13....
Page 56: Repair The Steering Gear
Maintenance, service, and repair steering page 12 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 57
Maintenance, service, and repair steering page 13 reassembly 1. Lightly lubricate all parts before reassembly. 2. Install a new worm shaft seal and pitman shaft seal into the housing. 3. Install the upper worm bearing cup. 4. Divide the ball bearing into two equal groups. 5. Position the ball nut on...
Page 58
Maintenance, service, and repair steering page 14 exploded view of steering gear.
Page 59: Brake Service
Table of contents inspect the service brake ................. 2 disc brake pads .................................................... 2 disc brake rotor .................................................. 2 inspect the parking brake .................. 3 adjust the service brakes ................. 3 tw...
Page 60: Inspect The Service Brake
Maintenance, service, and repair brakes page 2 disc brake rotor note: the front brake rotor is an integral part of the front hub. If the brake rotor is worn beyond its service limits, then the front hub must be replaced. Refer to front axle service for information on replacing the front hub. Note: d...
Page 61: Inspect The Parking
Maintenance, service, and repair brakes page 3 inspect the parking brake note: the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Inspect the brake pads. Refer to inspect the service brake section to inspec...
Page 62: Adjust The Parking Brake
Maintenance, service, and repair brakes page 4 adjust the parking brake wheel park brake the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Loosen the jam nuts on the park brake linkage that is connected to...
Page 63: 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 64: 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. 7. Add brake flu...
Page 65: Flush The Brake System
Maintenance, service, and repair brakes page 7 flush the brake system 6. Raise the rear wheels off of the ground and support with jack stands. 7. If equipped with front brakes, raise the front wheels off of the ground and support with jack stands. 8. Release the park brake. 9. Remove both rear wheel...
Page 66: Replace Front Disc Brake
Maintenance, service, and repair brakes page 8 6. Thoroughly clean the area around the master cylinder cap. 7. Remove fluid from the master cylinder until it is 1/ 2 full. 8. Raise the front of the vehicle and support with jack stands. 9. Remove the tire/wheel assembly. Refer to tires and wheels sec...
Page 67
Maintenance, service, and repair brakes page 9 note: it is recommended that both the left and right brake pads be replaced as a set. Note: installing new brake pads will raise the brake fluid level in the master cylinder. 6. Thoroughly clean the area around the master cylinder cap. 7. Remove fluid f...
Page 68: Replace The Wheel
Maintenance, service, and repair brakes page 10 replace the wheel cylinder disc brake body assembly (front or rear) 6. Release the park brake. 7. Raise the wheel off of the ground and support with jack stands. 8. Remove the tire/wheel assembly. Refer to tires and wheels section for information on re...
Page 69: Repair The Brake Body
Maintenance, service, and repair brakes page 11 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 70
Maintenance, service, and repair brakes page 12 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. 13. Using tool #41-350-13, slide the rubber boots onto the pistons as shown. The boot should be hanging off of t...
Page 71: Replace The Master
Maintenance, service, and repair brakes page 13 push rod plunger master cylinder 1/8" cutaway of typical master cylinder showing the push rod replace the master cylinder note: most vehicle configurations do not require lifting the vehicle to remove the master cylinder. Lifting the vehicle may not be...
Page 72: Repair The Master Cylinder
Maintenance, service, and repair brakes page 14 repair the master cylinder note: hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See replace the master cy...
Page 73: Throttle Linkage
Table of contents throttle linkage adjustments ............ 2 magnetic module .................................................. 2 pot box module .................................................... 3 throttle linkage.
Page 74
Maintenance, service, and repair front axle page 2 throttle linkage adjustments magnetic module throttle module the standard magnitic throttle module should not be used in areas that contain large magnetic fields. Large magnitic fields may effect the operation of the module resulting in unexpected m...
Page 75
Maintenance, service, and repair front axle page 3 pot box module the pot box module is used on vehicles that are to be operated in areas with large magnetic fields. The linkage to the pot box should be adjusted so that the fs-1 switch closes just as the pedal is depressed and the output is at 5k wi...
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Page 77: Transmission
Table of contents gt transmission assembly with disc brakes transmission check oil level ......................................... 2 change oil ................................................ 2 motor removal and installation ................. 3 rear hub or rotor .......................................
Page 78: 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 an oil drain pan underne...
Page 79: Motor Removal And
Maintenance, service, and repair transmission page 3 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 80: Removing And Installing
Maintenance, service, and repair transmission page 4 removing and installing the rear axles 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 flange. If both axl...
Page 81
Maintenance, service, and repair transmission page 5 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 needed. 15. Install in reverse order, lubricate the o-ring. Note: be sure no...
Page 82: Disassembly And
Maintenance, service, and repair transmission page 6 disassembly and reassembly of the primary reduction gear case 6. Raise the rear of the vehicle and support with jack stands. 7. Place a drain pan under the gear case that is capable o f holding four quarts of oil and drain the oil from the front g...
Page 83
Maintenance, service, and repair transmission page 7 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 se...
Page 84: Disassembling The 3Rd
Maintenance, service, and repair transmission page 8 disassembling the 3rd member 6. Raise the rear of the vehicle and support with jack stands. 7. Remove the complete drive from the vehicle. Note: refer to removing and installing the drive assembly for information on removing the drive from the veh...
Page 85: Assembling The 3Rd
Maintenance, service, and repair transmission page 9 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. Remov...
Page 86
Maintenance, service, and repair transmission page 10 9. Pre set the carrier bearing preload by tightening the housing carrier bearing race ring nut until it requires 1.5 to 3.3 ft-lbs to rotate the differential assembly. Note: rotate the carrier assembly whenever adjusting the ring nuts. 10. Mark t...
Page 87: Pinion Gear Shimming
Maintenance, service, and repair transmission page 11 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 88
Maintenance, service, and repair transmission page 12 figreu 1a figure 2 figreu 1b figure 4 figure 3 note: values shown are for reference only d c.
Page 89: Suspension
Table of contents suspension replace the rear springs .................. 2 leaf ....................................................................... 2 replace the front springs ................. 3 leaf ....................................................................... 3 replace the spring bu...
Page 90: Replace The Rear Springs
Maintenance, service, and repair suspension page 2 replace the rear springs leaf if a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. Hint : in most vehicles it will be easier if the springs are replaced one at a time. 6. Raise the rear of the v...
Page 91: Replace The Front
Maintenance, service, and repair suspension page 3 leaf if a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. Hint : in most vehicles it will be easier if the springs are replaced one at a time. 6. Raise the front of the vehicle and support with...
Page 92: Replace The Spring
Maintenance, service, and repair suspension page 4 replace the spring bushings it is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): • the internal bushing...
Page 93: Replace The Shocks
Maintenance, service, and repair suspension page 5 replace the shocks front it is recommended to replace both front shocks as a set. Note: on some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for information regar...
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Page 95: Motor Service
Table of contents inspecting the motor brushes ............ 2 motors with internal cooling fans ......................... 2 enclosed motors (ge, no cooling fan) ................. 2 motor removal and installation ......... 3 motor inspection ................................ 3 replacing the brushes......
Page 96: Inspecting The Motor Brushes
Motor service motor page 2 enclosed motors (ge, no cooling fan) general electric motors note: some motors may not have the brush inspection holes. In this case, the motor must be disassembled to inspect the brushes. For future inspections, holes msy be drilled into the motor housing after it has bee...
Page 97: Motor Removal And
Motor service motor page 3 advanced dc motors the enclosed advanced dc motors must be disassembled to inspect the motor brushes. Refer to motor inspection for information regarding disassembling the motor. Motor removal and installation see the transmission section for information on removing or ins...
Page 98
Motor service motor page 4 5. Inspect the commutator for burn marks. • burn marks and/or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature. A tool called a growler is required to reliably test for a shorted armature. 6. Inspect the commutator for raised segments. R...
Page 99: Replacing The Brushes
Motor service motor page 5 replacing the brushes note: it is recommended that all four brushes be replaced as a set. Note: motors without removable brush covers must be disassembled to replace the brushes. Refer to motor inspection-disassembly section for information on taking the motor apart. Note:...
Page 100: Replacing The Bearings
Motor service motor page 6 replacing the bearings 1. The motor must be removed from the vehicle for this procedure. Refer to transmission service section for information on removing the motor. 2. Remove the armature. Refer to motor inspection- disassembly section for information on taking the motor ...
Page 101: Service Limits
Motor service motor page 7 service limits motor specification number undercut depth commutator diameter (min) brush length (min) wire depth (max) mm inches mm inches mm inches mm inches 5bc58jbs6129a 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5 5bc58jbs6129b 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1....
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Page 103: Tires and Wheels
Table of contents tire inflation ...................................... 2 tire inspection ................................... 2 replace the tire/wheel ..................... 3 replace the tire (pneumatic) ........... 3 repair the tire (pneumatic) .............. 4 tires and wheels.
Page 104: Tire Inflation
Maintenance, service, and repair tires and wheels page 2 tire inflation there are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires. The illustration to the right is an example of the side wall info...
Page 105: Replace The Tire/wheel
Maintenance, service, and repair tires and wheels page 3 replace the tire/wheel 6. Raise the wheel to be replaced off of the ground and support with jack stands. 7. Remove the 4 or 5 wheel nuts and remove the wheel. 8. Install in reverse order. 9. Following the pattern shown on the following page, c...
Page 106
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 107: Battery Service
Table of contents battery service cleaning ............................................ 2 testing .............................................. 3 charging ........................................... 4 watering ........................................... 5 replacing (6-volt batteries only) ........ ...
Page 108: Cleaning
Maintenance, service, and repair batteries page 2 cleaning 6. Dry dirt can be readily blown off with low-pressure air or brushed off. 7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with flexible bristles, wash the batteries off with a strong solution of bak...
Page 109: Testing
Maintenance, service, and repair batteries page 3 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 110: Charging
Maintenance, service, and repair batteries page 4 typical hydrometer float clean the batteries. Refer to cleaning the batteries section for information on cleaning the batteries. Using part number 77-200-00 hydrometer, check and record the specific gravity of each cell in the battery pack. If, after...
Page 111: Watering
Maintenance, service, and repair batteries page 5 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 112
Maintenance, service, and repair batteries page 6 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion a...
Page 113
Maintenance, service, and repair batteries page 7 a battery is a live electrical source. It cannot be disconnected or neutralized. Do not drop any tool or conductive object onto the battery. A conductive object that comes in contact with the battery terminals will initiate a short circuit of the bat...
Page 114
Maintenance, service, and repair batteries page 8 storage temperature (f) charging interval (months) over 60 1 between 40 and 60 2 below 40 6 storage and returning to service explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an ar...
Page 115
Maintenance, service, and repair batteries page 9 returning to service 6. Thoroughly clean the batteries and battery compartment. Refer to cleaning in this section for information regarding cleaning the batteries. 7. Check the electrolyte level and charge the batteries. Refer to watering in this sec...
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Page 117
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 118
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 119
Sevcon troubleshooting page 3 electrical troubleshooting identifying your controller.
Page 120
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 121
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 122
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 123
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 124
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 125
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 126
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 127
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 128
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 129
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 130
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 131
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 132
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 133
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 134
Sevcon troubleshooting page 18 electrical troubleshooting pin # condition volts* 1 key switch off 0 volts key switch on battery volts 2 f&r in forward low f&r in neutral high f&r in reverse high 3 f&r in reverse low f&r in neutral high f&r in forward high 4 accelerator pedal up high accelerator peda...
Page 135
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. # of ...
Page 136
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 137
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 138
Sevcon troubleshooting page 22 electrical troubleshooting.
Page 139
Table of contents chapter - glossary: ........................................................... 1 lester x-series charger .................... 2 test equipment required for troubleshooting . 2 important notes and instructions ...................... 2 theory of operation ..............................
Page 140: Lester X-Series Charger
Battery charger page 2 mn-402-000 built-in model shown lester x-series charger test equipment required for troubleshooting • digital multi meter (dmm). • clamp on dc ammeter to measure up to 20-amps. • small 12 volt battery. • 12 volt test light. • 300 ohm resistor. Important notes and instructions ...
Page 141
Battery charger page 3 mn-402-000 fault and diagnostic error code table fault chart b = blinking, s = solid, o = off led 4 led 2 fault o o ok b b battery voltage out of range or battery capacity is too high s o control board faulty b s current sensor faulty s b ac voltage incorrect s s dc current ou...
Page 142
Battery charger page 4 mn-402-000 testing the charging cycle before starting this procedure: • confirm that the battery voltage is above 1.7 x number of cells (36 volts = 18 cells = 1.7 x 18 = 30.6 volts). If the battery voltage is low, the charger may have to be started manually by pressing the low...
Page 143: Troubleshooting
Battery charger page 5 mn-402-000 troubleshooting scr assembly test: perform the test setup before starting this procedure. 1. The test light should be off. If the light is on then one of the scr’s is shorted. Skip ahead to gate test. 2. Momentarily touch the resistor to one of the gate terminals. 3...
Page 144
Battery charger page 6 mn-402-000 lock out relay before continuing, refer to testing the interlock relay procedure in this section. This is an external test to confirm if the relay is functioning properly. This test should only be performed if it has been determined that the relay is not closing by ...
Page 145
Battery charger page 7 mn-402-000 relay board assembly this test proceedure was not available at the time of printing. While connected to an ac outlet, the charger cabinet must remain electrically grounded. Disconnect both of the battery leads and unplug the charger from the ac source before disconn...
Page 146: Profile Setting
Battery charger page 8 mn-402-000 profile setting this charger can be set for wet/fla or sla/agm type batteries. The program setting is determined by the location of the program jumper as shown in the illustration. The type of charger is indicated on the charger specification plate on the charger co...
Page 147: Signet Hbs Charger
Battery charger page 9 mn-402-000 signet hbs charger test equipment required for troubleshooting • digital multi meter (dmm). • clamp on dc ammeter to measure up to 20-amps. Important notes and instructions • this troubleshooting guide assumes a familiarity with the use of a digital multimeter inclu...
Page 148
Battery charger page 10 mn-402-000 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 fully charged. Once the chargin...
Page 149
Battery charger page 11 mn-402-000 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-hours (max). A fault will occu...
Page 150
Battery charger page 12 mn-402-000 status light error code table if the fault light is on or flashing, it indicates a problem has occurred 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 to the table below. Fault code...
Page 151
Battery charger page 13 mn-402-000 troubleshooting note: there are no internally serviceable components in the charger. To test charger operation: 1. Connect a dc volt meter to the main battery positive and negative terminals. 2. Attach a clamp on dc ammeter to one of the charger dc output wires. 3....
Page 152: Lestronic II Charger
Battery charger page 14 mn-402-000 lestronic ii charger sla batteries must be charged with a charger configured for sla batteries. Use of any other charger will result in damage to the batteries and premature failure of the batteries. Built-in portable test equipment required for troubleshooting • d...
Page 153
Battery charger page 15 mn-402-000 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” charger is plugged int...
Page 154
Battery charger page 16 mn-402-000 troubleshooting, built-in charger 5. Disconnect the charger from the ac power source. 6. 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 or four 14 gauge wires. 7. Sli...
Page 155
Battery charger page 17 mn-402-000 • test the ac voltage across the transformer primary circuit. The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board. This voltage should be the same as the rated ac voltage of the charger. If th...
Page 156
Battery charger page 18 mn-402-000 while connected to an ac outlet, the charger cabinet must remain electrically grounded. Disconnect both of the battery leads and unplug the charger from the ac source before disconnecting any electrical component or wire. Failure to do so may result in serious bodi...
Page 157: Testing The Interlock
Battery charger page 19 mn-402-000 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 connection to the speed cont...
Page 158
Battery charger page 20 mn-402-000
Page 159
The vehicle wiring diaram is too large to be legible when printed at this size. A full size diagram (22 x 16) is inculded on the cd in pdf format. You can access the diagram from a button on the cd menu. The t48 diagram # is: sch-00004 (12v battery tap) sch-00042 (12v dc-dc converter) the et 3000 di...
Page 160
Wire diagrams wire diagrams page 2 sch-00004, 6/20/2007, revision b b0-t48-48 taylor truck with the sevcon control system head lights r. Tail light battery status light switch brake light high/low switch button horn 1 2 dash panel black blue switch key f/r switch seat accelerator ms3 5 1 9 ms1 r. Tu...
Page 161
Wire diagrams wire diagrams page 3.
Page 162
Wire diagrams wire diagrams page 4 can communication bus smart view gauge black black lights black red f yellow blue 5 4 6 7 1 3 8 gray white green red black black/gray black flasher red green blue/white white gray charger ac charger cord charger interlock white ground green battery positive battery...
Page 163: Illustrated Parts
Table of contents front axle .................................................... 2 front brakes ............................................... 4 steering linkage ......................................... 6 steering column .......................................... 8 steering gear ....................
Page 164: Front Axle
Illustrated parts parts page 2 front axle bushings (#8 and #9) must be broached or reamed to a final diameter of 1.25” +/- 0.001” after pressing into the axle. 11 17 15 16 18 12 12 14 13 13 2 1 3 10 9 8 7 6 5 4 19 bushings (#8 and #9) must be broached or reamed to a final diameter of 1.25” +/- 0.001...
Page 165
Illustrated parts parts page 3 front axle assembly 15-049-15 item # part # description qty 1 15-210-70 front axle weldment 1 2 21-020-17 steering yoke, left 1 3 21-020-18 steering yoke, right 1 4 88-239-86 lock nut 3/4" n/c 2 5 88-228-60 washer 3/4" 2 6 98-603-07 washer, rubber 2 7 01-220-99 washer,...
Page 166: Front Brakes
Illustrated parts parts page 4 front brakes.
Page 167
Illustrated parts parts page 5 front hydraulic disc brakes 24 41-348-70 pad, disc brake 4 25 41-348-52 spacer, disc brakeplate, secondary, hydraulic disc 2 26 32-240-40 bushing mounting bracket 4 27 88-067-21 brake body bolt 4 28 41-350-30 hydraulic brake body assembly 2 28a 41-350-09 boot, hydrauli...
Page 168: Steering Linkage
Illustrated parts parts page 6 steering linkage.
Page 169
Illustrated parts parts page 7 s t e e r i n g s l e e v e a s s e m b l y 1 8 - 0 5 7 - 0 0 item # part # description qty 1 86-501-98 ball joint, f1 & p2, left w/zerk fitting 1 86-501-99 ball joint, f1 & p2, right w/zerk fitting 1 2 88-159-85 1/2-20 nf slotted hex nut 2 3 86-510-00 ball joint clamp...
Page 170: Steering Column
Illustrated parts parts page 8 steering column 1 2 3 4 5 6 7 9 8 12 10 11 13 14.
Page 171
Illustrated parts parts page 9 steering column assembly item # part # description qty 1 19-011-25 steering wheel cap 1 2 88-199-82 5/8" nf jam nut 1 3 19-011-20 steering wheel 1 4 32-248-10 steering shaft bearing 1 5 20-031-63 kit, steering shaft w/clamp 1 6 18-308-45 assembly, steering, clamp (incl...
Page 172: Steering Gear
Illustrated parts parts page 10 steering gear 9 15 16 10 2 3 14 17 12 11 13 6 8 7 5 1 4.
Page 173
Illustrated parts parts page 11 steering gear 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 18-308-80 nut,...
Page 174: Front Suspension
Illustrated parts parts page 12 front suspension.
Page 175
Illustrated parts parts page 13 front suspension item # part # description qty 1 96-103-00 u-bolt length 3-1/2" 4 2 85-498-00 85-486-00 leaf spring taylor truck leaf spring et 3000 2 2 3 32-214-50 spring bushing 12 4 96-240-00 shackle bolt 6 5 88-149-81 1/2 nc lock nut 14 6 16-872-00 spring shackle ...
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 gt-3287543 input shaft, 12...
Page 178
Illustrated parts parts page 16 transmission differential case.
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 Axle
Illustrated parts parts page 18 rear axle axle shaft inner bearing (no o-ring) outer bearing o-ring o-ring groove 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..
Page 181
Illustrated parts parts page 19 rear axle item # part # description qty 1 41-154-10* *axle shaft, single bearing (see usage below) 2* 41-154-15* *axle shaft, double bearing (see usage below) 2* 2 80-505-20 bearing 2 2a 80-505-30* *bearing 2* 3 41-490-11 disc brake rotor 2 4 41-172-21 hub 2 5 88-268-...
Page 182: Rear Brakes
Illustrated parts parts page 20 rear brakes brake body.
Page 183
Illustrated parts parts page 21 rear brakes item # part # description qty 1 88-067-21 hex bolt, grade 8 4 2 41-350-51 secondary plate 2 3 41-348-70 brake pad 4 4 41-348-52-61 spacer (kit, includes spacers #4, and bushings #5 for 1 wheel) 4 5 41-348-52-61 bushing (kit, includes spacers #4, and bushin...
Page 184: Rear Suspension
Illustrated parts parts page 22 rear suspension 1 2 3 5 6 5 forward forward 4 7 8 9 10 11 12 4 13 14 15 16 17 18 left side suspension overload spring bushing.
Page 185
Illustrated parts parts page 23 drive assembly item # part # description qty. 1 4gt-0151-1033 drive standard 1 2 70-057-40 dc motor 1 3 96-826-12 park brake cable assembly rear 2 4 85-510-17 leaf springs rear, heavy duty 2 5 99-580-20 brake hose 2 6 88-159-84 1/2 nf nylock locknut 8 7 41-350-78 hydr...
Page 186: Motor
Illustrated parts parts page 24 motor.
Page 187
Illustrated parts parts page 25 203 -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 -421 -00 95 -930 -00 88 -067 -17 88 -067 -22 dv1 -40...
Page 188: Electric Brake
Illustrated parts parts page 26 electric brake 1 2 3 4 5 7 8 9 10 6 11 automatic electric brake component view.
Page 189
Illustrated parts parts page 27 automatic electric brake system item # part # description qty 1 88-067-29 bolt,1/4 x 4-1/4" nc, grade 8 3 2 41-355-00 automatic electric brake unit 1 3 motor (typical) 1 4 96-114-10 u-bolt, 5/16" nf, motor support 1 5 70-456-10 motor, support bracket 1 6 88-128-62 loc...
Page 190: Master Cylinder
Illustrated parts parts page 28 master cylinder 2 3 4 1 5 6 7 8.
Page 191
Illustrated parts parts page 29 master cylinder 99-511-20 item # part # description qty 1 88-080-14 5/16" x 1-1/2" nc hex bolt 2 2 88-088-61 5/16" washer 4 3 88-089-81 5/16" lock nut 2 4 99-511-20 master cylinder 1 5 99-511-51 rubber boot, master cylinder 1 6 99-511-52 cap seal, master cylinder 1 7 ...
Page 192: Brake Lines
Illustrated parts parts page 30 brake lines.
Page 193
Illustrated parts parts page 31 master cylinder and brake hardware item # part # description qty 1 99-648-52 brake line formed, front, right 1 2 99-648-51 brake line formed, front, left 1 3 99-564-00 3/16" union tee fitting 3 4 99-580-10 brake hose flexible 2 5 99-576-00 brake hose clip 4 6 88-527-1...
Page 194
Illustrated parts parts page 32 brake linkage (parking brake).
Page 195
Illustrated parts parts page 33 park brake linkage item # part # description qty 1 88-080-11 5/16 x 1 hex head screw 2 2 88-088-61 5/16 washer 4 3 51-344-80 park brake 1 4 88-089-81 5/16 locknut 2 5 96-813-00 adjusting brake cable assembly 1 6 96-771-00 3/8 x 3/4 clevis pin 1 7 01-204-32 brake equal...
Page 196: Wheels and Tires
Illustrated parts parts page 34 wheels and tires ref., wheel hub 1 2 3.
Page 197
Illustrated parts parts page 35 wheels and tires item # part # description 1 wheels 12-025-00 8 x 10 tubeless 2 tires 10-264-00 20 x 8 x 10 lr e 9 97-236-00 wheel nut not shown 13-989-00 valve stem, tubless tire only tire and wheel assemblies 13-746-15 20 x 8 x 10 8-ply.
Page 198
Illustrated parts parts page 36 instrument panel (up to s/n 179999) resetting the smart view display the meter should only be reset after the preventative maintenance has been performed. Taylor-dunn ® part number 62-027-40 hand set (available with instructions as part number 62-027-61) must be used ...
Page 199
Illustrated parts parts page 37 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 the maintenance feature turned on, then the sevcon s...
Page 200: Speed Control Panel
Illustrated parts parts page 38 speed control panel.
Page 201
Illustrated parts parts page 39 c o n t r o l p a n e l a s s e m b l y 6 2 - 0 1 6 - 4 0 item # part # description qty 1 72-501-50 solenoid, spst 24 volt, 220 amp 1 2 62-400-15 powerpak controller (see note below) 1 3 79-840-00 circuit breaker, 10 amp 1 4 79-840-20 circuit breaker, 20 amp 2 5 73-00...
Page 202: Miscellaneous Frame and Body
Illustrated parts parts page 40 miscellaneous frame and body.
Page 203
Illustrated parts parts page 41 frame item # part # description qty 1 72-025-00 tail light 2 2 see battery battery jumper 7 3 94-050-11 right headlight 1 4 90-444-00 deckboard (standard) 1 5 94-201-10 taylor-dunn name plate 1 not shown 88-817-07 name plate screw 6 94-201-11 name plate fastener (plas...
Page 204: Charger, Lestronic
Illustrated parts parts page 42 charger, lestronic 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 205
Illustrated parts parts page 43 chargers charger model # charger part # item # description 9695 79-309-00 16910 79-309-10 22620 79-303-25 16920 79-309-20 charger type 48lc25-8et 48lc25-8et 48lc25-8et 48lc25-8et ac voltage/amps 115/60/15 115/60/15 115/60/15 230/50/na dc voltage/amps 48/25 48/25 48/25...
Page 206: Charger, Signet
Illustrated parts parts page 44 charger, signet signet® charger model voltage battery type part # hb1000 24 flooded 79-302-20 hb1000 36 flooded 79-303-40 hb1000 36 flooded 79-303-41 hb1000 36 gel 79-303-42 hb1000 36 gel k4g-ch-003 hb1000 48 flooded 79-309-40 hb1000 48 gel 79-309-41 hb1000 48 flooded...
Page 207: Miscellaneous Electrical
Illustrated parts parts page 45 miscellaneous electrical item no. Part no. Description qty 1 75-152-11 harness, power cable 2 75-152-03 harness, chassie control 3 75-152-00 harness, control panel, used up to 10/4/2000 75-152-13 harness, control panel, used starting 10/5/2000 4 75-152-12 2gauge link ...
Page 208: Batteries
Illustrated parts parts page 46 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.
Page 209
Illustrated parts parts page 47 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 (note: requires special charger) * 77-047-00 244ah, t-...
Page 210: Decals
Illustrated parts parts page 48 decals 1 2 4 3 5 6 7.
Page 211
Illustrated parts parts page 49 decals item # part # description qty 1 94-319-00 battery disconnect decal 1 2 94-313-00 battery warning decal 1 3 94-373-10 vehicle identification decal 1 4 94-309-00 brake warning decal 1 5 94-313-20 safety warning decal 1 6 94-384-01 not a motor vehicle decal 1 7 94...
Page 212: Strobe Light
Illustrated parts parts page 50 strobe light.
Page 213
Illustrated parts parts page 51 optional parts item # part # description qty directional signals 71-141-61 kit, directional signals, standard cowl and steel cab 1 1 75-141-20 turn signal switch 1 2 76-352-00 flasher receptacle 1 3 71-900-05 flasher, 12v 1 4 72-082-10 turn signal bulb, 12v 2 5 72-082...
Page 214: Steel Cab (T48) Page 1
Illustrated parts parts page 52 steel cab (t48) page 1.
Page 215
Illustrated parts parts page 53 optional parts table item # part # description qty cowl w/windshield 91-013-64 kit, windshield, orange (requires fiberglass or surrey top cover) 1 91-013-65 kit, windshield, specify color (requires fiberglass or surrey top cover) 1 1 91-010-77 cowl w/windshield (unpai...
Page 216: Steel Cab (T48) Page 2
Illustrated parts parts page 54 steel cab (t48) page 2.
Page 217
Illustrated parts parts page 55 optional parts item # part # description qty. Strobe light on steel cab 1 72-023-20 strobe, light, amber 1 2 88-025-06 screw, #8-32 x 1/2" truss head 3 3 88-028-62 lockwasher, #8 3 4 88-029-80 nut, #8-32 3 5 98-603-00 grommet, 3/8" id 1 75-152-10 wiring harness (not s...
Page 218: Tops (T48)
Illustrated parts parts page 56 tops (t48).
Page 219
Illustrated parts parts page 57 o p t i o n a l p a r t s t a b l e i t e m # p a r t # d e s c r i p t i o n q t y . S u r r e y t o p c o v e r 1 0 0 - 2 4 8 - 3 6 t u b u l a r t o p f r a m e 1 2 0 0 - 2 4 8 - 3 5 p o s t , t o p f r a m e 4 3 8 8 - 1 0 2 - 1 1 b o l t , 3 / 8 n c x 1 " c a r r ...
Page 220: Doors (T48)
Illustrated parts parts page 58 doors (t48).
Page 221
Illustrated parts parts page 59 o p t i o n a l p a r t s t a b l e i t e m # p a r t # d e s c r i p t i o n q t y . C a b d o o r s n a u g a h y d e 9 0 - 9 2 4 - 6 0 k i t , n a u g a h y d e d o o r , l e f t 1 9 0 - 9 2 4 - 6 1 k i t , n a u g a h y d e d o o r , r i g h t 1 1 9 0 - 9 2 3 - 9 ...
Page 222: Optional Deckboards (T48)
Illustrated parts parts page 60 optional deckboards (t48).
Page 223: Watering System
Illustrated parts parts page 61 deck board table item # part # description qty. Deck cover, diamond plate 2 pc., std. Bed 90-440-45 kit, diamond cover, std bed, black (does not include 1 and 2) 1 1 90-444-20 deckboard, 41 x 38-1/2 x 5/8" 1 2 90-444-30 deckboard, 41 x 36-5/8 x 5/8" 1 3 90-440-46 deck...
Page 224: Cargo Box
Illustrated parts parts page 62 cargo box.
Page 225
Illustrated parts parts page 63 box, double doors, side & rear windows item # part # description qty. 91-333-60 kit, box, doors left & rear, w/glass, orange 1 91-333-61 kit, box, doors left & rear, w/glass, specify colors 1 1 91-333-02 box, doors left & rear, glass front & rear (unpainted) 1 2 90-47...
Page 226: Stake Sides
Illustrated parts parts page 64 stake sides.
Page 227
Illustrated parts parts page 65 stake sides table item # part # description qty. 1 90-542-01 end gate, black 1 2 90-540-00 gate hook 2 3 88-065-13 screw, 1/4 nc x 1-1/4" phillips truss head 4 4 88-069-87 nut, 1/4 nc keps 4 5 90-542-05 side gate, left black 1 6 90-542-06 side gate, right black 1 7 90...
Page 228: Cab, Deck (Et 3000)
Illustrated parts parts page 66 1 2 7, 8 3 4 5, 5a 9 11, 12 13, 14 16 10 6 18 17 15 cab, deck (et 3000).
Page 229
Illustrated parts parts page 67 standard parts et 3000 item # part # description qty 1 91-017-60 et 3000 cab std. 1 2 90-852-50 windshield 1 3 74-015-16 windshield wiper blade 1 4 74-015-15 windshield wiper arm (includes hose) 1 5 74-015-11 windshield wiper, plate support 1 5a 74-015-10 windshield w...
Page 230: Cab Components (Et 3000)
Illustrated parts parts page 68 3 4 5, 6 1, 2 door latch 9 8 7 cab components (et 3000).
Page 231
Illustrated parts parts page 69 standard parts item # part # description qty 1 90-854-10 window, door, left, 3 pieces 1 2 90-854-20 window, door, right, 3 pieces 1 3 90-854-01 latch, window, door 1 4 91-017-02 strap, door, brackets included 1 5 91-017-31 handle, inside, door, left 1 6 91-017-32 hand...
Page 232: Misc Frame (Et 3000)
Illustrated parts parts page 70 misc frame (et 3000) 1 2 10 11 19 27 26 23,24, 25 9 20 18 17 16 15 21,22 12,13 14,15 5, 6 3, 4 7.
Page 233
Illustrated parts parts page 71 s t a n d a r d p a r t s item # part # d e s c r i p t i o n qty 1 90-854-50 w indow , re a r 1 2 98-319-00 m o l d i n g , w i n d o w , r e a r 1 3 91-017-11 mirror, door, left 1 4 91-017-12 mirror, door, right 1 5 91-017-33 handle, outside, door, left 1 6 91-017-3...
Page 234: Taylor -Dunn
Taylor -dunn.
Page 235: 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 236: Appendix A: Special Tools
Appendixes appendixes appendix a page 2 appendix a: special tools description purpose part number test light used for testing electrical circuits. Powered by the truck batteries, switchable for 12, 24, 36, and 48 volts. 62-027-00 accelerator test harness used to test the solid state accellerator mod...
Page 237: Hardware Identification
Appendixes appendix b page 3 appendixes hardware identification standard head markings s.A.E. Grade 2 s.A.E. Grade 5 truss head, grade 2 carriage bolt, grade 2 (unless marked as above) other bolts note: torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grad...
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Appendixes appendixes appendix b page 4 hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) c or, or, b or, or, nuts with no markings are to be treated as s.A.E. Grade 2 lock nuts use a letter to indicate the grade of the nut. Grade a’ locknuts would be the equivelent of grade ‘2’ hex nuts...
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Appendixes appendix b page 5 appendixes diameter and tpi grade 2 tightening torque (ft-lb) grade 5 tightening torque (ft-lb) grade 8 tightening torque (ft-lb) l'9 tightening torque (ft-lb) 1/4-20 4-7 7-10 10-14 11 1/4-28 5-8 8-12 11-16 12 5/16-18 9-14 14-21 20-29 22 5/16-24 10-15 15-23 22-33 25 3/8-...
Page 240: Torque Table
Appendixes appendixes appendix b page 6 suggested torque values (critical hardware) torque table torque range group description ft-lbs in-lbs nm brakes - - - - - - - - - - - - - - - - - - - - - - - - brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 brake line tube nut fittings 12 - 13 144 - 15...
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Appendixes appendix c page 7 appendixes taylor-dunn does not currently supply asbestos fiber-brake pads/ shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the ...
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Taylor-dunn ® mfg. 2114 w. Ball rd. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 (fax) (714) 956-0504 visit our website: www.Taylor-dunn.Com.