- DL manuals
- Taylor-Dunn
- Utility Vehicle
- C0-425-36
- Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual
Taylor-Dunn C0-425-36 Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual
Summary of C0-425-36
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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: 150774 manual mc-425-02 operation, troubleshooting and replacement parts manual models inlcuded: c0-425-36 (c 4-25-36) c0-425-48 (c 4-25-48) revision: c.
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Taylor-dunn service center for more information about this and other taylor-dunn ® manuals, please write taylor-dunn ® : taylor-dunn ® mfg. 2114 w. Ball road anaheim, ca 92804 (attn: technical writer) copyright notice copyright © 2001 by taylor-dunn ® mfg. All rights reserved. No part of this work m...
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B2-48 with dump bed option b2-10 ambulance b2-48 with steel cab, foldaway 4-passenger seat and stake sides et 3000 et1-50 full size truck p2-50 30,000 pound tow tractor.
Page 5: Contents
Table of contents contents introduction ............................................................ 1 about this manual ..................................................................... 2 who should read this manual ................................................ 3 responsibilities ..............
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Table of contents general maintenance ...............................................1 maintenance guidelines ........................................................... 2 maintenance guidelines for vehicles used in severe conditions .....................................................................
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Table of contents brake service............................................................1 inspect the service brake ........................................................ 2 disc brake pads ......................................................................................................... ...
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Table of contents disassembly and reassembly of the primary reduction gear case ................................................. 10 disassembling the 3rd member ............................................... 13 assembling the 3rd member .................................................... 16 pinio...
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Table of contents wire diagrams........................................................ 1 dash ........................................................................................... 2 control panel ............................................................................. 3 illustrated parts...
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Taylor -dunn.
Page 11: Introduction
Introduction about this manual .......................................... 2 who should read this manual .................... 2 responsibilities .............................................. 3 how to use this manual ............................... 4 conventions .........................................
Page 12: 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 13: 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 14: 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...
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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...
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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...
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Introduction introduction page-7 the only personnel authorized to repair, modify, or adjust any part of this or any taylor-dunn ® vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe cond...
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Taylor -dunn.
Page 19: Safety Rules and Operating
Table of contents standard specifications tow tractor ............ 2 safety rules and guidelines ......................... 3 driver training program ................................ 4 driver qualifications. ............................................... 4 key-switch ...................................
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Safety rules and operating instructions safety rules page 2 standard specifications tow tractor item volts specification occupancy driver only, no passengers dimensions 1994 l x 965 w x 1422 h millimeters 78.50 l x 38.00 w x 56.00 h inches turning radius 1752 millimeters (69 inches) dry weight (with...
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Safety rules page 3 safety rules and operating instructions 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disco...
Page 22: Driver Training Program
Safety rules and operating instructions safety rules page 4 driver training program according to ansi b56.8, the owner of this vehicle shall conduct an operator training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have p...
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Safety rules page 5 safety rules and operating instructions key-switch a key-switch, located on the right center side of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off. The key-switch should be in the ...
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Safety rules and operating instructions safety rules page 6 battery status indicator hour meter accessory switch (optional) the accessory switch is located on the left side of the instrument panel and to the right of the headlight switch. Push the top of the switch to turn on the accessory. Push the...
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Safety rules page 7 safety rules and operating instructions tilt lever 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...
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Safety rules and operating instructions safety rules page 8 accelerator pedal the accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the ped...
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Safety rules page 9 safety rules and operating instructions the seat interlock switch is only one part of the vehicle safety system. The interlock switch should not be relied upon as the only safety feature used to disable or disengage this vehicle. Doing so could result in unexpected movement of th...
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Safety rules and operating instructions safety rules page 10 smart view display key hours icon 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 ...
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Safety rules page 11 safety rules and operating instructions run time hours icon fault code description corrective action 01004 discharged battery or defective wiring. Charge the battery. If the battery is good, check wiring to the controller. 01005 speed control overheated. Allow the controller to ...
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Safety rules and operating instructions safety rules page 12 display showing maintenance and wrench icons maintenance monitor: operation: the smd notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator...
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Safety rules page 13 safety rules and operating instructions 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 14 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. • immediately report any accide...
Page 33: Charging Your Vehicle
Safety rules page 15 safety rules and operating instructions charging your vehicle operation of the charger the charger supplied with this vehicle is either specified by or provided by the end user. Refer to the operating instruction supplied with your charger or contact the charger manufacturer for...
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Safety rules page 17 safety rules and operating instructions maintenance item 2,3 weekly (20hrs) monthly (80hrs) quaterly (250hrs) semi - annual (500hrs) annualy (1000hrs) check condition of tires and tire pressure l check all lights, horns, beepers and warning devises l check and fill batteries l c...
Page 35: For The Smart View Display
Safety rules and operating instructions safety rules page 18 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 36: Maintenance Guidelines For
Safety rules page 19 safety rules and operating instructions 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 37: General Maintenance
Table of contents general maintenance maintenance guidelines ............................... 2 maintenance guidelines for vehicles used in severe conditions .................................. 3 troubleshooting guide ................................ 4 lubrication chart ..................................
Page 38: 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 39: Severe Conditions
Maintenance, service and repair maintenance page 3 maintenance guidelines for vehicles used in severe conditions if this vehicle is operated in severe conditions all maintenance items listed in the periodic maintenance table should be carried out twice as often as stated. In addition, the entire veh...
Page 40: Troubleshooting Guide
Maintenance, service and repair maintenance page 4 troubleshooting guide symptom probable cause steering pulls in one direction front end out of alignment low tire pressure hard steering dry lube points in steering linkage damaged king pin/ball joint low tire pressure excessive steering play worn ba...
Page 41: Lubrication Chart
Maintenance, service and repair maintenance page 5 front end 3 5 5 (from bottom) 3 2 3 3 4 3 lubrication chart # description locations lubricant type 1 - - - 2 king pin 2 general purpose grease 3 ball joints 6 general purpose grease 4 idler pivot 1 general purpose grease 5 front wheel bearings 2 hig...
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B2-48 with stake side dump bed option sc1-00 stock chaser e4-55 sit down tow tractor c4-25 sit down tow tractor.
Page 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 installa...
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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...
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Maintenance, service, and repair front axle page 3 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. Hub with dust cap removed adjust front wh...
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Maintenance, service, and repair front axle page 4 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. Front axle removal and installation remov...
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Maintenance, service, and repair front axle page 5 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. Installation 6. Raise the front of the ve...
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 hub with dust cap removed always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. Hub with dust c...
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Maintenance, service, and repair front axle page 8 t a y l or - du n n t he b e st w ay to go about yo ur bu si n e s s r 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 ...
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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...
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Maintenance, service, and repair front axle page 10 7. Remove the steering knuckle. Refer to replace the steering knuckle for information regarding removing the steering knuckle. Note: it is not necessary to remove the tie rod or drag link for this procedure. 8. Press the king pin bushings out from ...
Page 53: Replace The Steering Knuckle
Maintenance, service, and repair front axle page 11 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. Hub with dust cap removed replace the st...
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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 .......................................... 5 adjust the steering gear (saginaw) ............. 6 replace the tilt steering assembly .............. 8 steering column .............
Page 56: Front End Alignment
Maintenance, service, and repair steering page 2 front end alignment inspection, axle centers always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury...
Page 57
Maintenance, service, and repair steering page 3 center the wheels 9. Center the steering gear and tie it off so that it cannot rotate. Note: refer to center the steering gear section for information regarding centering of the steering gear. 11. Loosen the ball joint clamps on the drag link. 12. Adj...
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Maintenance, service, and repair steering page 4 19. Adjust the left side tie rod so that the distance at the front and rear of the tires is the same. 20. Position the ball joint clamps as shown and tighten to 28-32 ft lbs. 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 cla...
Page 59: Inspect Ball Joints
Maintenance, service, and repair steering page 5 do not drive the vehicle while the steering wheel or front wheels are tied in position. Driving the vehicle while the steering wheel or front wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and/or pro...
Page 60
Maintenance, service, and repair steering page 6 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in serious bodily injury. Adjust the steering gear (saginaw) note: i...
Page 61
Maintenance, service, and repair steering page 7 t a y l or - du n n t h e b e st w ay to go about yo ur bu si n e s s r 12. Find the center position of the steering shaft: a. Turn the steering shaft all of the way in one direction. B. While counting the rotations, turn the steering shaft all of the...
Page 62
Maintenance, service, and repair steering page 8 replace the tilt steering 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 rear wheels to prevent veh...
Page 63: Steering Column
Maintenance, service, and repair steering page 9 steering column note: the steering column does not have to be removed from the vehicle unless the lower steering shaft or bushing is to be replaced. Refer to replace the tilt steering assembly section for information regarding removing the steering co...
Page 64
Maintenance, service, and repair steering page 10 12. Depress and turn the tilt spring about 30º and remove the retainer, tilt spring and the spring guide. 13. Thread an 8-32 machine screw into the pivot pins and pull them out. 14. Install the tilt lever and pull it up to release the tilt housing fr...
Page 65: Replace The Steering Gear
Maintenance, service, and repair steering page 11 replace the steering gear 6. Raise the front of the vehicle and support with jack stands. 7. There are two allen head set screws holding the steering shaft to the universal joint. Only one of the screws must be removed, the other only needs to be loo...
Page 66: Center The Steering Gear
Maintenance, service, and repair steering page 12 center the steering gear 1. Rotate the input shaft clockwise until it stops. 2. While counting the rotations, rotate the input shaft counter clockwise until it stops. 3. Rotate the input shaft clockwise 1/2 the rotations counted in the previous step....
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Maintenance, service, and repair steering page 13 replace the ball joints, tie rods, and drag link note: if a rod end or ball joint is worn out, we recommend replacing all of the ball joints and/or rod ends as a set. Replacing a ball joint ball joint cotter pin clamp steering arm ball joint nut stee...
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Maintenance, service, and repair steering page 14 replacing the drag link the drag link is the linkage that connects the steering gear pitman arm to the steering knuckle. Refer to the illustration on the following page. Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift...
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Maintenance, service, and repair steering page 15 replacing the tie rod the tie rod is the linkage that connects the two steering knuckles together. Refer to the illustration on the following page. Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehic...
Page 70: Repair The Steering Gear
Maintenance, service, and repair steering page 16 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 71
Maintenance, service, and repair steering page 17 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...
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Maintenance, service, and repair steering page 18 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 ...
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Maintenance, service, and repair steering page 19 exploded view of steering gear.
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Page 75: 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 ....
Page 76: Inspect The Service Brake
Maintenance, service, and repair brakes page 2 inspect the service brake 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 t...
Page 77
Maintenance, service, and repair brakes page 3 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 78: Inspect The Parking Brake
Maintenance, service, and repair brakes page 4 inspect the parking brake wheel park 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. If any sign of damage or wear is found on the locking mechanism, cables, or linkages then...
Page 79: Adjust The Service Brakes
Maintenance, service, and repair brakes page 5 pivot bolt push rod 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 cylinde...
Page 80
Maintenance, service, and repair brakes page 6 8. Tight the brake pedal pivot bolt so that the brake pedal moves freely with no side play. 9. Reconnect the main battery connector. 10. Remove blocks from behind the wheels. 11. Release the park brake and test drive the vehicle. T a y l or - du n n t h...
Page 81: Adjust The Parking Brake
Maintenance, service, and repair brakes 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. Unplug the main bat...
Page 82: 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 83: Bleed The Brakes
Maintenance, service, and repair brakes page 9 bleed the brakes 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 brake fl...
Page 84
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 85: 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 86
Maintenance, service, and repair brakes page 12 replace the parking brake lining 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 ...
Page 87: Replace Front Brake Pads
Maintenance, service, and repair brakes page 13 replace front 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” position. ...
Page 88
Maintenance, service, and repair brakes page 14 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 89: Replace Rear Brake Pads
Maintenance, service, and repair brakes page 15 replace rear brake pads hydraulic disc 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...
Page 90
Maintenance, service, and repair brakes page 16 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 91: Replace The Wheel Cylinder
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 wheels to prevent vehicle movement. 5. Disconnect the main pos...
Page 92
Maintenance, service, and repair brakes page 18 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 93: Repair The Brake Body
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 front wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 94
Maintenance, service, and repair brakes page 20 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 95: Replace The Master Cylinder
Maintenance, service, and repair brakes page 21 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 96
Maintenance, service, and repair brakes page 22 10. Install in reverse order. 11. Fill the master cylinder with brake fluid from a sealed container. 12. Pump the brake pedal a short distance of one to two inches until no bubbles are seen coming from the inlet ports inside of the master cylinder cham...
Page 97: Repair The Master Cylinder
Maintenance, service, and repair brakes page 23 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...
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Taylor -dunn.
Page 99: Throttle Linkage
Table of contents throttle linkage adjustments ...................... 2 throttle linkage.
Page 100
Maintenance, service, and repair throttle linkage page 2 throttle linkage adjustments 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 v...
Page 101: 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 102: 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 103: 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 104
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 105
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 106
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 107
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 108: 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 109
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 110: Service Limits
Motor service motor page 10 n o it a c if i c e p s r o t o m r e b m u n h t p e d t u c r e d n u r e t e m a i d r o t a t u m m o c ) n i m ( h t g n e l h s u r b ) n i m ( e c n a t s i s e r ) f º 5 7 @ s m h o ( m m s e h c n i m m s e h c n i m m s e h c n i e r u t a m r a d l e i f ) 2 7 ...
Page 111: Transmission
Table of contents gt transmission assembly transmission check oil level ............................................. 2 change oil ..................................................... 3 motor removal and installation ................... 4 rear hub or rotor ......................................... ...
Page 112: Check Oil Level
Maintenance, service, and repair transmission page 2 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 t...
Page 113: Change Oil
Maintenance, service, and repair transmission 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 front wheels to prevent vehicle movement. 5. Disconnect t...
Page 114
Maintenance, service, and repair transmission 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 front wheels to prevent vehicle movement. 5. Disconnect t...
Page 115: Rear Hub Or Rotor
Maintenance, service, and repair transmission 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 front wheels to prevent vehicle movement. 5. Disconnect t...
Page 116
Maintenance, service, and repair transmission 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 t...
Page 117
Maintenance, service, and repair transmission page 7 the axle retaining plate bolts have a pre-applied thread locking compound. They are intended for one time use only. If removed they must be replaced. Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and/or pr...
Page 118: Transmission Assembly
Maintenance, service, and repair transmission page 8 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect t...
Page 119
Maintenance, service, and repair transmission page 9 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. 9. Remove the nuts from the rear suspen...
Page 120: Reduction Gear Case
Maintenance, service, and repair transmission page 10 always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury. 1. Make sure the key-switch is in the ...
Page 121
Maintenance, service, and repair transmission page 11 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 122
Maintenance, service, and repair transmission page 12 lubricate all parts with gear oil before installation. Failure to pre- lube the parts may result in premature failure. 19. Assemble the gear case in reverse order. Note: torque the drain plug to 21-25 foot-pounds. Note: torque the gear case to 3r...
Page 123: Disassembling The 3Rd Member
Maintenance, service, and repair transmission page 13 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect ...
Page 124
Maintenance, service, and repair transmission page 14 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 125
Maintenance, service, and repair transmission page 15 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 126: Assembling The 3Rd Member
Maintenance, service, and repair transmission page 16 cover housing cover housing 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 ...
Page 127
Maintenance, service, and repair transmission page 17 if the ring and pinion gears or bearings are replaced then the pinion gear must be re-shimmed. Improper pinion gear shims will result in drive noise and premature failure. Refer to pinion gear shimming instructions. The two ring nuts must be turn...
Page 128
Maintenance, service, and repair transmission page 18 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 129
Maintenance, service, and repair transmission page 19 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 130
Maintenance, service, and repair transmission page 20 face of pinion gear 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 ...
Page 131
Maintenance, service, and repair transmission page 21 note: values shown are for reference only c d.
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Page 133: Suspension
Table of contents suspension replace the rear springs .............................. 2 replace the front springs ............................. 3 replace the shocks ........................................ 4 front or rear ......................................................... 4.
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 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. Unplug the batt...
Page 136: Replace The Shocks
Maintenance, service, and repair suspension page 4 replace the shocks front or rear it is recommended to replace all four front shock as a set. Note: on some vehicles it may be required to remove the wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for information ...
Page 137: Tires and Wheels
Table of contents tire inflation ................................................... 2 tire inspection ............................................... 2 replace the rear tire/wheel ......................... 3 repair the tire (pneumatic) .......................... 4 replace the tire (pneumatic) ........
Page 138: 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 139: Replace The Rear 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 140
Maintenance, service, and repair tires and wheels page 4 1 2 3 4 5 3 4 2 1 4-bolt pattern 5-bolt pattern 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 injur...
Page 141
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 142: Taylor -Dunn
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Page 143: Battery Service
Table of contents cleaning .......................................................... 2 testing ............................................................ 3 watering .......................................................... 5 charging ......................................................... 6 re...
Page 144: 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 145: 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 146
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 147: 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 148: 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 149
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 150
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 151
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 152
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 153
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...
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Page 155
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 156
Electrical troubleshooting troubleshooting page 2 test equipment required: • digital multimeter (dmm) with diode test function, fluke 79 model shown. • test harness, taylor-dunn #75-089-00 important notes and instructions • this troubleshooting guide assumes a familiarity with the use of a digital m...
Page 157
Electrical troubleshooting troubleshooting page 3 start troubleshooting here 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 re...
Page 158
Electrical troubleshooting troubleshooting page 4 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 the key...
Page 159
Electrical troubleshooting troubleshooting page 5 test 1.3: test the voltage at pin #6 on the 12-pin logic card connector. If the voltage is low, then skip ahead to test #1.4. If the voltage is high, then check the wire to the high/low switch and the high/low switch for open circuits. Note: the high...
Page 160
Electrical troubleshooting troubleshooting page 6 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 connector....
Page 161
Electrical troubleshooting troubleshooting page 7 test 1.7: depress the accelerator pedal to engage fs-1 only (creep speed). Perform the following tests: test the voltage at pin #10 on the 12-pin logic card connector. If the voltage is below 0.3 volts, then skip ahead to test #1.8. If the voltage is...
Page 162
Electrical troubleshooting troubleshooting page 8 test 2. Testing the motor test 2.1: check the motor field resistance from the motor f1 to the motor f2 terminals. If the resistance is within the values given in the motor specification table, then skip ahead to test #2.2. (the motor specification ca...
Page 163
Electrical troubleshooting troubleshooting page 9 test 2.3: test the continuity from the motor a1 terminal to the frame on the motor and from f1 to a1 for open circuits. Any reading other than an open circuit indicate a short in the motor. If there is a short in the motor, stop here and repair or re...
Page 164
Electrical troubleshooting troubleshooting page 10 test 3. The vehicle runs in one direction only test 3.1: close the seat switch, turn the key switch on and wait 1-second until the isolator contactor closes. If the vehicle runs in reverse only then skip ahead to test #3.3. Place the forward and rev...
Page 165
Electrical troubleshooting troubleshooting page 11 test 3.3: place the forward and reverse switch in the reverse direction. Test the voltage at pin #3 on the 12 pin logic card connector. If the voltage is low, then skip ahead to test #3.4. If the voltage is high, then skip ahead to test #7. Test 3.4...
Page 166
Electrical troubleshooting troubleshooting page 12 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 the controller. Connect the negative lead to the f1 ...
Page 167
Electrical troubleshooting troubleshooting page 13 test 4. Key fault test 4.1: turn the key switch on and place the forward and reverse switch in the center off position perform the following tests: test the voltage at pin #1 on the 12 pin logic card connector. If the voltage equals battery volts, t...
Page 168
Electrical troubleshooting troubleshooting page 14 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. Stop trouble shooting her...
Page 169
Electrical troubleshooting troubleshooting page 15 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 wire). ...
Page 170
Electrical troubleshooting troubleshooting page 16 stop stop, do not continue. Reaching this point indicates a failure in the sevcon power unit or an error was made during testing. Confirm all previous tests were performed correctly before replacing the sevcon power unit. After any repairs are made,...
Page 171
Electrical troubleshooting troubleshooting page 17 test 6. Accelerator module fault disconnect the truck harness from the accelerator module. Connect the plug on the short end of the 75-089-00 test harness to the accelerator module. Connect the receptacle on the short end of the test harness to the ...
Page 172
Electrical troubleshooting troubleshooting page 18 test 6.4: accelerator pedal released. Test the voltage from pin #9 to pin #1. If the voltage is below 0.3 volts, then skip ahead to test #6.5. If the voltage is above 0.3 volts, then the module has failed and must be replaced. Stop trouble shooting ...
Page 173
Electrical troubleshooting troubleshooting page 19 test 6.7: if the test at pin #4 on the 12-pin logic card connector failed, but the test at pin #5 at the accelerator module was good (#6.5), then check the wire from pin #5 (module) to pin #4 (logic card). If the test at pin #10 on the 12-pin logic ...
Page 174
Electrical troubleshooting troubleshooting page 20 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 of the ...
Page 175
Electrical troubleshooting troubleshooting page 21 stop stop, do not continue. Reaching this point indicates a failure in the sevcon power unit or an error was made during testing. Confirm all previous tests were performed correctly before replacing the sevcon power unit. Test 7.3: if the vehicle do...
Page 176
Electrical troubleshooting troubleshooting page 22 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” position and...
Page 177
Electrical troubleshooting troubleshooting page 23 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 times the ...
Page 178
Electrical troubleshooting troubleshooting page 24 connect a volt meter from battery negative to the violet/black wire at the electric brake harness plug. If the voltage is less than battery volts then: • check wiring to the key switch and continue troubleshooting at test #4.2. If the voltage equals...
Page 179
Electrical troubleshooting troubleshooting page 25 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 low 5 sea...
Page 180
Electrical troubleshooting troubleshooting page 26 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. Led status l...
Page 181: Charger Troubleshooting
Charger troubleshooting the charger supplied with this vehicle is either specified or provided by the end user. Refer to the documentation supplied with the charger or contact the charger manufacturer for more information. Turn the key switch off before disconnecting the batteries. Disconnecting the...
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Page 183: Wire Diagrams
Table of contents wire diagrams dash ................................................................ 2 control panel .................................................. 3.
Page 184: Dash
Wire diagrams wire diagrams page 2 dash sc re w ed to ste er in g c olu m n f us e l oc ati on s f u se p a n e l b lu e/w hit e(r f) g re en (r r ) y ell ow (l r ) b lu e(l f) v io le t/b la ck h o r n s w it c h c o n n e c t o r # 3 g t u r n l ig h t b lu e n m j k l h r ed r ed h e a d l ig h t...
Page 185: Control Panel
Wire diagrams wire diagrams page 3 control panel 16 gauge 10 gauge 14 gauge 4 gauge connector #1 right tail left tail c o n t r o l p a n e l b o x connector #2 14 control panel box 15 16 connector #2 11 13 12 b la ck 3 white light switch brake red/white black r ed /w hi te 1 2 seat switch w hi te b...
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Page 187: Illustrated Parts
Table of contents front axle, steering and brakes .................. 2 steering column ......................................... 4 steering gear .............................................. 6 front suspension ........................................ 8 transmission assembly ...........................
Page 188
Illustrated parts illustrated parts page 2 front axle, steering and brakes 7 8 35 34 33 32 12 30 29 28 27 26 25 24 23 22 21 20 19 18 16 15 14 2 13 12 11 10 9 5 7 6 5 4 3 2 1 36 31 17.
Page 189
Illustrated parts illustrated parts page 3 front axle, steering and brakes item # part # description qty 1 92-104-014 bearing cap 2 2 88-527-14 cotter pin 8 3 88-239-85 3/4 nf hex slotted nut 2 4 88-228-61 3/4 sae flat washer 2 5 80-017-00 bearing 4 6 12-158-10 wheel hub 2 7 80-103-00 race 4 8 88-26...
Page 190: Steering Column
Illustrated parts illustrated parts page 4 steering column 1 2 3 4 5 6 7 8 9 use locktite on mounting hardware.
Page 191
Illustrated parts illustrated parts page 5 steering column item # part # description qty 1 18-414-32 tilt steering column assembly 1 2 19-005-17 stereing wheel 1 3 88-279-82 7/8 nf thin pattern hex nut 1 4 88-262-62 7/8 split lock washer 1 5 18-108-00 pitman arm 1 6 18-308-21 steering gear 1 7 88-12...
Page 192: Steering Gear
Illustrated parts illustrated parts page 6 steering gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16.
Page 193
Illustrated parts illustrated parts page 7 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-...
Page 194: Front Suspension
Illustrated parts illustrated parts page 8 front suspension.
Page 195
Illustrated parts illustrated parts page 9 front suspension item # part # description qty 1 32-214-50 bushing 6 2 00-425-00 wishbone link 1 3 86-521-99 rod end 4 4 see front axle axle beam 1 5 85-142-00 spring 2 6 96-240-00 1/2 nc x 4 hex bolt 1 7 88-140-22 1/2 nc x 3-1/2 hex bolt 2 8 88-149-81 1/2 ...
Page 196: Transmission Assembly
Illustrated parts illustrated parts page 10 transmission assembly 5 7 6 8 9.
Page 197
Illustrated parts illustrated parts page 11 transmission assembly item # part # description qty 1 89-113-30 12 x 1.75 x 30mm hex bolt, class 8.8 12 2 89-113-60 12mm split lock washer 12 3 - - - 4 41-290-60 axle tube 2 5 88-099-80 5/16 nf hex nut 2 6 88-088-62 5/16 split lock washer 2 7 88-128-62 7/1...
Page 198: Transmission Gear Case
Illustrated parts illustrated parts page 12 transmission gear case.
Page 199
Illustrated parts illustrated parts page 13 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 inp...
Page 200: Rear Axle
Illustrated parts illustrated parts page 14 transmission differential case rear axle.
Page 201
Illustrated parts illustrated parts page 15 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 differentia...
Page 202: Rear Brakes
Illustrated parts illustrated parts page 16 rear brakes brake body assembly.
Page 203
Illustrated parts illustrated parts page 17 rear brakes item # part # description qty 1 88-067-21 1/4 nc x 3-3/4 hex bolt, grade 8 4 2 41-350-51 secondary plate 2 3 41-348-70 brake pad 4 4 41-348-57 spacer 4 5 32-240-41 bushing 4 6 41-350-28 mounting bracket 2 7 96-327-10 3/8 x 3/4 nf hex bolt, grad...
Page 204: Rear Suspension
Illustrated parts illustrated parts page 18 rear suspension 12 front 11 1 5 4 2 17 6 frame 7 7.
Page 205
Illustrated parts illustrated parts page 19 rear suspension item # part # description qty 1 88-189-82 5/8nc thin pattern lock nut 2 2 88-188-61 5/8 sae flat washer 1 3 85-142-00 spring 2 4 86-510-00 ball joint clamp 2 5 86-521-98 rod end (left) 1 6 86-521-99 rod end (right) 1 7 88-180-15 5/8nc x 1-3...
Page 206: Motor
Illustrated parts illustrated parts page 20 motor master cylinder 13.
Page 207
Illustrated parts illustrated parts page 21 70-057-40 motor spec # dv1-4003 item # part # description qty 1 70-421-10 front housing 1 2 70-400-10 armature 1 3 70-209-40 field assembly 1 4 85-403-00 brush spring 4 5 70-173-00 brush holder 1 6 70-170-10 brush pair 2 7 70-417-00 bearing retainer 1 8 80...
Page 208: Automatic Electric Brake
Illustrated parts illustrated parts page 22 automatic electric brake.
Page 209
Illustrated parts illustrated parts page 23 automatic electric brake 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 brake unit 1 3 see motor motor (typical) 1 4 96-114-...
Page 210: Brake Lines
Illustrated parts illustrated parts page 24 brake lines 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4 4 master cylinder (ref) cowl view from rear 2 use thread sealant.
Page 211
Illustrated parts illustrated parts page 25 brake lines item # part # description qty 1 99-564-00 t-fitting 1 2 see front axle front brake hose 2 3 99-576-00 brake hose clip 4 4 99-575-00 coupler 3 5 71-110-00 brake light switch 1 6 99-591-00 brake light switch adaptor 1 7 99-559-00 t-fitting 1 8 99...
Page 212
Illustrated parts illustrated parts page 26 brake linkage (parking brake) cable lock cable clevis 6.
Page 213
Illustrated parts illustrated parts page 27 brake linkage item # part # description qty 1 96-765-00 clevis, left hand thread 1 2 88-099-81 5/16nf hex nut, left hand thread 1 3 88-099-80 5-16nf hex nut 1 4 96-343-00 link 1 5 96-763-00 clevis, right hand thread 1 6 96-754-00 clevis 2 7 96-773-00 clevi...
Page 214: Brake Linkage (Foot Brake)
Illustrated parts illustrated parts page 28 brake linkage (foot brake) 1 2 3 4 5 8, 23 7 4 4 22 3 2 1 6 9 9 10 11 12 13 14 15 16 17 18 19 20 21.
Page 215
Illustrated parts illustrated parts page 29 brake linkage item # part # description qty 1 88-108-61 3/8 sae flat washer 6 2 88-108-62 3/8 split lock washer 6 3 88-101-13 3/8nc x 1-1/4 hex bolt, grade 5 6 4 88-101-21 3/8nc x 3 hex bolt 4 5 88-140-22 1/2nc x 3 hex bolt 1 6 88-109-81 3/8nc hex lock nut...
Page 216: Throttle Linkage
Illustrated parts illustrated parts page 30 throttle linkage 15 14 7 3 13 9 8 5 6 2 12 17 10 16 17 1 11 14 13 14.
Page 217
Illustrated parts illustrated parts page 31 throttle linkage item # part # description qty 1 00-425-21 mounting bracket 1 2 00-425-09 accelerator pedal 1 3 01-110-20 accelerator pedal pad 1 4 - - - 5 86-503-98 rod end, left hand thread 1 6 97-211-00 1/4nf hex nut, left hand thread 1 7 86-503-99 rod ...
Page 218: Wheels and Tires
Illustrated parts illustrated parts page 32 wheels and tires ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9 10
Page 219
Illustrated parts illustrated parts page 33 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 10-076-00 4.80 x 8 lr c pneumatic 10-250-00 16 x 4 x 12 solid rubber split rim wheels 3 12-042-12 inner whe...
Page 220: Instrument Panel (Dash)
Illustrated parts illustrated parts page 34 instrument panel (dash) #2 smart view display.
Page 221
Illustrated parts illustrated parts page 35 instrument panel item # part # description qty 1 71-039-11 light switch 1 2 74-009-49 hour meter/battery status meter 1 74-010-00* smart view display* 1 3 71-039-02 forward and reverse switch 1 4 71-120-10 key switch 1 5 71-120-90 key 1 6 94-304-23 dash pa...
Page 222: Speed Control Panel
Illustrated parts illustrated parts page 36 speed control panel use heatsink grease between controller and heatsink 13.4vdc 300w dc/dc converter f20a part/serial no:622/11088 input: 36/48v battery +in -in + ou t -out 18 install around entire perimeter of lip 19 (2 plcs) 13 into harness connectors in...
Page 223
Illustrated parts illustrated parts page 37 speed control panel item # part # description qty 1 98-599-20 grommet 1 2 88-838-06 #14 x 1/2 pan head sheet metal screw 4 3 88-818-02 #8 x 1/4 pan head sheet metal screw 4 4 88-818-02 #8 x 1/4 pan head sheet metal screw 4 5 79-844-20 200a circuit breaker ...
Page 224: Miscellaneous Electrical
Illustrated parts illustrated parts page 38 miscellaneous electrical 9 - seat switch miscellaneous wire harness clamps 2 3 7 4 6 8 horn switch mounted on the dash.
Page 225
Illustrated parts illustrated parts page 39 miscellaneous electrical item # part # description qty not shown 75-152-42 chassie control harness 1 75-152-41 dash harness 1 75-152-43 tail light harness 1 75-152-40 control panel harness 1 94-422-10 dielectric grease for harness connectors 75-152-91 smar...
Page 226: Lighting System
Illustrated parts illustrated parts page 40 lighting system.
Page 227
Illustrated parts illustrated parts page 41 lighting system item # part # description qty - 72-025-03 headllight 1 - 72-082-01 head light bulb 1 - 72-025-20 taillight 1 - 97-211-15 tailight mounting screw 4 - 88-034-13 tailight mounting nut 4 - taillight/brake light bulb (1157) 2 - 72-082-00 back up...
Page 228: Seat Cushions and Deck
Illustrated parts illustrated parts page 42 seat cushions and deck.
Page 229
Illustrated parts illustrated parts page 43 seat cushions and deck item # part # description qty 1 71-124-00 battery disconnect switch 1 2 51-344-80 park brake handle 1 3 95-512-00 deck handle 2 4 90-160-70 seat assembly 1 5 90-160-60 arm rest kit 1 6 00-425-13 deck cover 1 7 90-160-71 seat spacer 2...
Page 230: Decals
Illustrated parts illustrated parts page 44 decals.
Page 231
Illustrated parts illustrated parts page 45 decals item # part # description qty 1 94-319-00 disconnect the battery 1 2 94-376-00 battery disconnect switch 1 3 94-373-12 data plate (decal) 1 94-373-09 data plate (metal) 1 4 94-313-20 safety waring 1 5 94-313-00 explosive gases 1 6 94-309-00 park bra...
Page 232: Frame Components
Illustrated parts illustrated parts page 46 frame components 6 } 14 20 6 side battery extract option illustration not available..
Page 233
Illustrated parts illustrated parts page 47 frame components item # part # description qty 1 00-425-30 battery cover (not painted) 1 2 88-100-14 3/8 x 1-1/2 hex bolt 4 3 88-108-62 3/8 split lock washer 4 4 32-214-50 bushing 4 5 00-425-16 mounting bracket (not painted) 1 6 97-211-30 3/8 blind nut 18 ...
Page 234: Front Push Plate Option
Illustrated parts illustrated parts page 48 1 2 3 4 5 4 5 4 3 4 6 4 front push plate option hitches.
Page 235
Illustrated parts illustrated parts page 49 front push plate option item # part # description qty 1 98-757-02 bumper 6 2 00-425-22 push plate 1 3 88-140-16 1/2nc x 2 hex bolt 6 4 88-148-61 1/2 sae flat washer 36 5 88-149-81 1/2nc hex lock nut 18 6 88-140-22 1/2nc x 3-1/2 hax bolt 12 hitches item # p...
Page 236: Charger
Illustrated parts illustrated parts page 50 charger the charger supplied with this vehicle is either specified or provided by the end user. Refer to the documentation supplied with the charger or contact the charger manufacturer for more information. Batteries the battery supplied with this vehicle ...
Page 237: Appendix A-
Appendix a- special tools.
Page 238: Special Tools
Appendix a page 2 special tools special tools d e s c r i p t i o n p u r p o s e p a r t n u m b e r 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 use...
Page 239: Appendix B-Torque Values
Appendix b-torque values.
Page 240: Torque Values
Appendix b page 2 torque values recommended torque values chart d ia m e t e r a n d t p i g r a d e 2 tightening torque (ft- lb ) g r a d e 5 tightening to rq ue (ft- lb ) g r a d e 8 tightening to rque (ft- lb ) l'9 tightening to rq ue (ft- lb ) 1 /4 - 2 0 4 - 7 7 - 1 0 1 0 - 1 4 11 1 /4 - 2 8 5 -...
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Appendix b page 3 torque values l’9 head markings s.A.E. Grade 2 s.A.E. Grade 5 s.A.E. Grade 8 l’9 truss head 1/4-20 carriage bolt 5/16-18 & 3/8-16 the following bolts are in accordance with grade 2 torque values.
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Taylor -dunn.
Page 243: Appendix C
Appendix c.
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Section description section description page 2 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....
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Taylor-dunn ® mfg. 2114 w. Ball rd. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 (fax) (714) 956-0504 mailing address: p.O. Box 4240 anaheim, california 92803 visit our website: www.Taylor-dunn.Com.