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  4. ET-015-00
  5. Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn ET-015-00 Operation, T Roubleshooting And Replacement Parts Manual

Manual is about: MZ-150-05

Summary of ET-015-00

  • Page 1

    T h e b e s t w a y to go a b o u t your b u s i n e s s ® serial number coverage: model starting - ending et-015-00 103847 - 108472 et-015-72 109240 - 134256 et-015-74 118001 - current production et-015-48 108591 - current production manual mz-150-05 operation, troubleshooting and replacement parts...

  • Page 3

    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...

  • Page 4

    B2-48 with dump bed option b2-10 ambulance b2-48 with steel cab, foldaway 4-passenger seat and stake sides et 3000 et1-50 full size truck p2-50 30,000 pound tow tractor.

  • Page 5: Contents

    Table of contents contents introduction about this manual .................................... 2 who should read this manual ............... 2 responsibilities ........................................ 2 how to use this manual .......................... 3 conventions ....................................

  • Page 6

    Table of contents brake service inspect the service brake ........................ 2 front disc brake pads ........................................... 2 disc brake rotor .................................................... 2 brake shoes ........................................................... 3 b...

  • Page 7

    Table of contents appendixes appendix a: special tools ....................... 2 appendix b: suggested torque limits for standard hardware ............................. 3 hardware identification ............................ 3 standard head markings ........................................ 3 hex bolt...

  • Page 8

    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 9: Table of Contents

    Table of contents introduction about this manual ......................................... 2 who should read this manual .................... 2 responsibilities ............................................ 2 how to use this manual .............................. 3 conventions ...........................

  • Page 10

    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...

  • Page 11

    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 ...

  • Page 12

    Introduction page-4 how to identify your vehicle this manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile ho...

  • Page 13

    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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  • Page 15: Safety Rules and

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

  • Page 16: Standard Specifications*

    Safety rules and operating instructions safety rules page 2 standard specifications* item model voltage specification occupancy driver + 1-passenger dimensions 417 l x 157.5 w x 193 h centimeters (164 l x 62 x 76 h inches) turning radius 534 centimeters (210 inches) dry weight et-150-00 1,045 kg (2,...

  • Page 17: 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 18: Vehicle Controls

    Safety rules and operating instructions safety rules page 4 vehicle controls 1) light switch the headlight switch is located on the left dash panel. Push the top of the switch to turn the lights on. Push the bottom of the switch to turn the lights off. 2) windshield wiper switch. The windshield wipe...

  • Page 19

    Safety rules and operating instructions safety rules page 5 shift lever the forward and reverse shift lever is located between the seats. Push the shift lever forward to engage the forward direction. Pull the lever back to engage the reverse direction. Do not switch from forward to reverse or vice-v...

  • Page 20

    Safety rules and operating instructions safety rules page 6 steering the steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter- clockwise. If equipped with tilt steering, the release lever is l...

  • Page 21: Vehicle Operational

    Safety rules and operating instructions safety rules page 7 vehicle operational guidelines safety guidelines • only qualified and trained operators may drive this vehicle. • drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees). • drive slowly when making a ...

  • Page 22

    Safety rules and operating instructions safety rules page 8 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 wheel...

  • Page 23: Fuse Panel

    Safety rules and operating instructions safety rules page 9 fuse panel the fuse panel is located under the dash to the left of the steering column. Fuse panel standard fuses shown. Other fuses may be installed depending on options installed on vehicle. 20a headlights 15a wiper and horn.

  • Page 24: Charging Your Vehicle

    Safety rules and operating instructions safety rules page 10 charging your vehicle 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 ...

  • Page 25: Storing / Returning  To

    Safety rules and operating instructions safety rules page 11 storing / returning to service both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing your vehicle • clean the batteries, then fill and charge before putting the vehicle in storage. ...

  • Page 26

    Safety rules and operating instructions safety rules page 12 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 27: Maintenance Guidelines For

    Safety rules and operating instructions safety rules page 13 t a y l or - du n n th e b e st w ay to go about yo ur bu si n e s s r maintenance guidelines for severe duty applications 1. This maintenance checklist is based on the average application. If the vehicle is operated under “severe conditio...

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  • Page 29: 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.

  • Page 30: 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 31: 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 32: Lubrication Chart

    Maintenance, service and repair page 4 lubrication chart # description locations lubricant type 1 steering pivot 1 general purpose grease 2 front wheel bearings 2 high temperature wheel bearing grease 3 ball joints 6 general purpose grease 4 leaf springs 8 general purpose grease 5 drive shaft univer...

  • Page 33: 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 34: Inspect The Front Wheel

    Maintenance, service, and repair front axle page 2 inspect the front wheel bearings and king pin 6. Raise the front of the vehicle and support with jack stands. 7. Grab the top and bottom of the tire/ wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of th...

  • Page 35: Adjust Front  Wheel

    Maintenance, service, and repair front axle page 3 adjust front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the hub dust cap and cotter pin. 8. While rotating the hub, tighten the spindle nut to 30 ft-lbs. This seats the bearings. 9. Back off the spindle ...

  • Page 36: 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 37: Steering Component Service

    Table of contents steering component service front end alignment .......................... 2 inspect ball joints ............................. 5 adjust the steering gear ................... 6 replace the ball joints, tie rods, and drag link ................................ 7 replacing the drag link...

  • Page 38: 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 39

    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 40

    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 41: 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 42: 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 43

    Maintenance, service, and repair steering page 7 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 44

    Maintenance, service, and repair steering page 8 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 45: Center The Steering Gear

    Maintenance, service, and repair steering page 9 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 46: Repair The Steering Gear

    Maintenance, service, and repair steering page 10 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 47

    Maintenance, service, and repair steering page 11 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 48

    Maintenance, service, and repair steering page 12 exploded view of steering gear.

  • Page 49: Transmission/rear Axle

    Table of contents transmission/rear axle service adjust the drive chain ...................... 2 check the oil level ........................... 3 change the oil .................................. 3 drive motor, chain drive ................... 4 remove ..................................................

  • Page 50: Adjust The Drive Chain

    Maintenance, service, and repair f2/f3 transmission page 2 adjust the drive chain note: a small amount of oil may come out when the drive motor mounting bolts are loosened. 6. Place a small oil drain pan under the chain case. 7. Loosen but do not remove the three drive motor mounting nuts. 8. Loosen...

  • Page 51: Change The Oil

    Maintenance, service, and repair f2/f3 transmission page 3 change the oil 6. Place a large drain pan under the chain housing. 7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug 8. Place the drain pan under the drive housing. 9. Re...

  • Page 52: Drive Motor, Chain Drive

    Maintenance, service, and repair f2/f3 transmission page 4 drive motor, chain drive remove note: in most cases it is not necessary to disassemble the chain case to remove the motor. If you find it necessary to disassemble the chain case, refer to transmission section for information regarding disass...

  • Page 53: Rear Axle

    Maintenance, service, and repair f2/f3 transmission page 5 replace the axle bearing note: the axle must be removed from the vehicle to replace the axle bearing. Refer to section rear axle: remove and install for information regarding removing the axle. Note: a 10-ton press is required to replace the...

  • Page 54: Chain Case

    Maintenance, service, and repair f2/f3 transmission page 6 assemble 1. Thoroughly clean all gasket surfaces. 2. Apply a 1/8” bead of 94-430-03 gasket sealer to the face of the 3rd member. 3. Install the backing plate to the 3rd member. Torque to 30-45 ft-lbs. 4. Install the motor to the backing plat...

  • Page 55

    Maintenance, service, and repair f2/f3 transmission page 7 8. Install the chain case housing onto the pinion shaft and tighten the pinion nut to 75 ft-lbs. 9. Install and tighten the three nuts and washers to the threaded studs and the housing bolts that are not used for the brake mounting bracket o...

  • Page 56: Differential Assembly (3

    Maintenance, service, and repair f2/f3 transmission page 8 differential assembly (3 rd member) disassemble note: bearings and races must be replaced as a set. If any one bearing or race is worn, its mate must also be replaced. It is recommended to replace all bearings and races in the 3rd member as ...

  • Page 57

    Maintenance, service, and repair f2/f3 transmission page 9 assemble note: thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. Note: depending on your vehicle config-uration, the rear pinion pilot bearing is n...

  • Page 58

    Maintenance, service, and repair f2/f3 transmission page 10 17. Install the bearing caps in their original locations and torque the bolts to 12-15 ft-lbs. Making sure that the adjusting nuts still turn freely. Note: in the following procedure, "left adjusting nut" refers to the nut on the ring gear ...

  • Page 59

    Maintenance, service, and repair f2/f3 transmission page 11 re-shimming the pinion housing the pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced. Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number pr...

  • Page 60: Exploded View

    Maintenance, service, and repair f2/f3 transmission page 12 exploded view.

  • Page 61: Brake Service

    Table of contents inspect the service brake ................. 2 front disc brake pads .......................................... 2 disc brake rotor .................................................. 2 brake shoes .......................................................... 3 brake drum ..................

  • Page 62: Inspect The Service Brake

    Maintenance, service, and repair brakes page 2 disc brake rotor rotor service limit = the minimum rotor thickness will be stamped in the rotor. See example below. 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 hu...

  • Page 63

    Maintenance, service, and repair brakes page 3 brake shoes note: the wheel must be removed to accurately measure the brake shoes. Refer to tires and wheels section for information on removing the wheel. Measure the brake shoe lining at the thinnest point on the shoe. If this is 1/16-inch or less the...

  • Page 64: Adjust The Service

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

  • Page 65: Adjust The Parking Brake

    Maintenance, service, and repair brakes page 5 adjust the parking brake primary adjustment 6. Release the park brake 7. Rotate the knob on the end of the park brake handle until the parking brake holds firm when applied. 8. Set the park brake. 9. Reconnect the main positive and negative cables at th...

  • Page 66: Check Master Cylinder Fluid

    Maintenance, service, and repair brakes page 6 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 67: Bleed The Brake System

    Maintenance, service, and repair brakes page 7 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 68

    Maintenance, service, and repair brakes page 8 13. Slowly release the foot pedal, allowing it to return to its released position. Note: check and fill the master cylinder frequently during the bleeding process. Do not allow the fluid level in the master cylinder to drop low enough to allow air to en...

  • Page 69: Flush The Brake System

    Maintenance, service, and repair brakes page 9 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 movement...

  • Page 70: Replace Rear Brake Shoes

    Maintenance, service, and repair brakes page 10 replace rear brake shoes 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. Confirm the electric park brake is set. 4. Place blocks under the front wheels to p...

  • Page 71

    Maintenance, service, and repair brakes page 11 rear brake (left side shown).

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  • Page 73: Motor Service

    Table of contents inspecting the motor brushes ............ 2 motor inspection ................................ 2 motor removal and installation ......... 4 replacing the brushes....................... 5 replacing the bearings ..................... 6 repairing the commutator ................ 6 servi...

  • Page 74: Inspecting The Motor Brushes

    Motor service motor page 2 inspecting the motor brushes 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. Disconnec...

  • Page 75

    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 76: Motor Removal And

    Motor service motor page 4 10. Using the continuity function of digital multi meter, check the continuity from any one of the commutator segments and the armature frame. If it is not an open circuit, then the armature is shorted and the motor must be replaced. 11. Rotate the motor bearing(s) by hand...

  • Page 77: 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 78: 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 79: 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 81: Battery Service

    Table of contents battery service cleaning ............................................ 2 testing .............................................. 3 charging ........................................... 4 watering ........................................... 5 single point battery watering system .........

  • Page 82: 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 83: 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 84: 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 85: 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 86

    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 87

    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 88

    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 89

    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 91: Throttle Linkage

    Table of contents throttle linkage adjustments ............ 2 magnetic module .................................................. 2 pot box module .................................................... 3 throttle linkage.

  • Page 92

    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 93

    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 95: 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 replace the tire (pneumatic) ...........

  • Page 96: 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 97: 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 98

    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 99

    Maintenance, service, and repair tires and wheels page 5 explosion hazard. Fully deflate the tire before attempting to remove the tire from the wheel. Do not over inflate the tire when seating the bead. Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failu...

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  • Page 101: Electrical

    Table of contents electrical troubleshooting symptoms: .....................................2 read this first ............................3 test equipment required: ....................................................... 3 important notes and instructions ...................... 3 definitions: .........

  • Page 102: Symptoms:

    Maintenance, service, and repair electrical troubleshooting page 2 symptoms: if your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to unusual symptom troubleshooting later in this section. • runs slow in both directions plus high armature and ...

  • Page 103: Read This First

    Maintenance, service, and repair electrical troubleshooting page 3 read this first test equipment required: • digital multimeter (dmm) with diode test function, • shunt or clamp-on dc ammeter to measure up to 400 amps. • test light with a rated voltage equal to or exceeds maximum battery voltage. • ...

  • Page 104

    Maintenance, service, and repair electrical troubleshooting page 4 start: definitions: • “fs-1” = start switch in the throttle module. • “battery volts” = the voltage at the batteries at the time the test is performed. • “pick up” = energizing a solenoid or contactor. • “f/r” = forward and reverse. ...

  • Page 105

    Maintenance, service, and repair electrical troubleshooting page 5 1. Make sure the start 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....

  • Page 106

    Maintenance, service, and repair electrical troubleshooting page 6 controller small signal input: during this procedure, voltages will be measured at the controller terminals #1, #2, #6, and #7. Close the seat interlock switch, turn the key switch on, select a direction and fully depress the throttl...

  • Page 107

    Maintenance, service, and repair electrical troubleshooting page 7 throttle module: the throttle module is located under the floorboard and functions as a throttle position sensor. The throttle module has two output signals, one is a varying voltage relative to the pedal position and the other is a ...

  • Page 108

    Maintenance, service, and repair electrical troubleshooting page 8 motor windings disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause severe bodily injury and/or property damage. The test equipment required ...

  • Page 109

    Maintenance, service, and repair electrical troubleshooting page 9 contactors troubleshooting in the procedure assumes that the control system is functioning (output from m- on controller) and that the motor has tested good. Both the forward and the reverse contactors pass current in both directions...

  • Page 110

    Maintenance, service, and repair electrical troubleshooting page 10 contactor negative return the forward and reverse contactors coils use a common negative return that is provided by the controller from pin #3. The negative output from pin #3 is part of a fault monitoring circuit in the controller....

  • Page 111

    Maintenance, service, and repair electrical troubleshooting page 11 symptoms go to Ø runs slow in both directions plus high armature current in both directions. Note: field current will be very low. Contactors, p 13 Ø runs normal in one direction only plus runs slow or lacks power in the opposite di...

  • Page 112

    Maintenance, service, and repair electrical troubleshooting page 12 freewheel diode remove the wires from the ‘b+’ and ‘m-’ terminals on the controller and perform the following test: using the diode test function on the dmm check for the presence of a diode across the ‘b+’ and ‘m-’ terminals on the...

  • Page 113

    Maintenance, service, and repair electrical troubleshooting page 13 iso remove the wires and the resistor from the iso contactor and perform the following tests: test continuity across the power contacts. • this should be an open circuit. If it is not an open circuit then the contactor should be rep...

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  • Page 115: Wire Diagrams

    Wire diagrams the vehicle wiring diagram is too large to be legible when printed at this size. A full size diagram (22 x 16) is included on the cd in pdf format. You can access the diagram from a button on the cd menu. The diagram # is sch-00022.

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  • Page 117: Illustrated Parts

    Table of contents illustrated parts front axle and brake .................................. 2 steering linkage ......................................... 4 steering gear .............................................. 6 steering column ......................................... 6 front suspension ........

  • Page 118: Front Axle and Brake

    Illustrated parts parts page 2 front axle and brake 9 10 20 21 22 23 24 27 (felt washer) 27 (bushing) 27 (bushing) 27 (shims) 27 (thrust bearing) 25 (use red loctite) 17 18 19 7 align flat spot with the set screw #25 27 (king pin) 27 (cup washer) 26 1 (use red loctite) 2 3 4 5 6 8 11 12 13 14 15 16.

  • Page 119

    Illustrated parts parts page 3 front axle and brake item no. Part no. Description qty 15-150-15 axle assembly, with brakes 2 1 88-130-20 hex bolt 2 2 88-130-25 hex bolt 2 3 * steer arm 4 4 88-157-13 bolt 2 5 41-349-22 spindle kit, left and right, includes #27 2 6 n/a bolt 4 7 41-349-01 brake bracket...

  • Page 120: Steering Linkage

    Illustrated parts parts page 4 steering linkage 1 2 2 2 3 4 5 5 6 4 1 7 8 9 1 1 7 7 18 4 1 1 10 11 12 13 14 15 16 17.

  • Page 121

    Illustrated parts parts page 5 steering linkage item no. Part no. Description qty 1 88-159-85 castle nut 6 2 86-501-98 ball joint, left 3 3 18-045-00 steering link, left 1 4 86-510-00 ball joint clamp 6 5 86-501-99 ball joint, right 3 6 18-045-00 steering link, right 1 7 88-527-14 cotter pin 6 8 21-...

  • Page 122: Steering Gear

    Illustrated parts parts page 6 steering gear 10 9 17 16 2 3 14 15 12 11 13 6 8 7 5 4 1 steering column.

  • Page 123

    Illustrated parts 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 18-308-80 nut, ...

  • Page 124: Front Suspension

    Illustrated parts parts page 8 front suspension 1 2 2 3 4 5 5 4 6 6 7 7 8 8 9 10 11 12 10 9 9 10 13 11 14 14 9 13 10 13 11.

  • Page 125

    Illustrated parts parts page 9 front suspension item no. Part no. Description qty 1 88-189-81 hex nut 2 2 88-188-61 flat washer 4 3 86-000-00 shock 2 4 88-189-81 hex nut 2 5 88-180-18 hex bolt 2 6 88-180-31 hex bolt 2 7 00-243-11 spring plate 2 8 88-109-81 hex nut 8 9 96-248-01 spring bolt 6 10 32-2...

  • Page 126: Transmission Chain Case

    Illustrated parts parts page 10 transmission chain case 27 28 26 21 motor 2 3 4 6 7 9 13 14 15 16 17 20 22 23 24 1 25 10 11 12 8 5 3rd member et-015-48 and et-015-74 only seal with 94-430-03 rtv silicon gskt slr, blue.

  • Page 127

    Illustrated parts parts page 11 transmission chain case item# part # description qty 1 88-108-60 3/8" sae flat washer 3 2 97-100-00 woodruff key 1 3 88-087-11 chain adjusting screw 1 4 88-089-80 5/16" nc hex nut 1 5 88-103-09 motor mounting screw, 3/8" x 3/4" nc 4 6 80-703-00 o-ring, 4-1/2" id x 5" ...

  • Page 128

    Illustrated parts parts page 12 transmission differential case seal with 94-430-03 rtv silicon gskt slr, blue.

  • Page 129

    Illustrated parts parts page 13 transmission differential case item# part # description qty 1 41-179-00 3rd member housing (1.628 id carrier bearing), et-015-48, et-015-74 1 41-710-00 3rd member housing (1.784 id carrier bearing), et-015-48, et-015-74 1 41-710-05 3rd member housing, et-150-72 1 2 88...

  • Page 130: Rear Axle

    Illustrated parts parts page 14 rear axle axle tube 4 5 6 7 3 2 rear brakes.

  • Page 131

    Illustrated parts parts page 15 rear axle item no. Part no. Description qty 1 - - 2 45-301-00 seal 2 3 32-515-00 bearing retainer 2 4 n/a wheel stud 10 5 41-168-10 axle, includes bearing 2 6 32-514-02 retaining plate 2 7 80-503-00 bearing 2 8 - - - 9 - - rear brakes item no. Part no. Description qty...

  • Page 132: Rear Suspension

    Illustrated parts parts page 16 rear suspension 1 2 3 4 5 6 7 8 9 10 11 12 13 14 drive shaft.

  • Page 133

    Illustrated parts parts page 17 rear suspension item no. Part no. Description qty 1 88-180-31 hex bolt 4 2 86-000-00 shock 2 3 88-188-61 flat washer 4 4 88-109-80 hex nut 2 5 98-753-05 bump stop 2 6 96-122-00 u-bolt 4 7 88-169-82 hex nut 6 8 16-871-02 spring hanger 4 9 32-213-00 bushing 6 10 96-248-...

  • Page 134: Motor (Direct Drive)

    Illustrated parts parts page 18 motor (direct drive) motor mount (direct drive).

  • Page 135

    Illustrated parts parts page 19 motor, direct drive item no. Part no. Description qty 1 70-175-00 brush holder 1 2 70-127-00 brush 4 3 85-402-00 brush spring 8 4 70-208-00 field coil 1 5 80-210-00 rear bearing 1 6 70-072-10 armature 1 7 80-211-00 front bearing 1 motor mount, direct drive item no. Pa...

  • Page 136: Motor (Chain Drive)

    Illustrated parts parts page 20 motor (chain drive) 1 2 3 4 5 7 8 9 7006100.Dwg 70-055-00 spec #- 5bt1326b262a 70-061-00 spec #- 5bt1326b96 11 10 6.

  • Page 137

    Illustrated parts parts page 21 motor, chain drive (spec 5bt1326b262a) item no. Part no. Description qty 1 70-210-64 terminal 2 2 85-402-02 brush spring 4 3 70-175-02 brush holder 1 4 70-123-00 brush 4 5 70-209-20 field coil 1 6 80-504-05 bearing, rear 1 7 97-100-00 woodruff key 1 8 80-206-00 bearin...

  • Page 138: Brake Lines

    Illustrated parts parts page 22 brake lines 1 2 3 4 5 1 6 7 6 7 6 6 front brakes rear brakes to rear brakes 8 9 10 11 12 13 14 15 4 16 to brake hose 17 18 19 20 21 19.

  • Page 139

    Illustrated parts parts page 23 brake lines item no. Part no. Description qty 1 99-580-30 brake hose 2 2 99-605-72 brake line, formed 1 3 99-605-71 brake line, formed 1 4 99-576-00 clip, brake hose 4 5 99-600-55 brake line, formed 1 6 99-573-00 washer, gasket 4 7 99-580-31 bolt, banjo 2 8 99-607-57 ...

  • Page 140

    Illustrated parts parts page 24 brake linkage (parking brake) 1 2 3 4 5 6 7 8 9 spacer included with #1.

  • Page 141

    Illustrated parts parts page 25 brake linkage (parking brake) item no. Part no. Description qty 1 51-340-00 brake handle 1 2 88-109-81 hex nut 2 3 88-108-60 washer 4 4 88-100-15 hex bolt 2 5 88-527-14 cotter pin 1 6 96-820-01 brake cable 1 7 96-773-00 clevis pin 1 8 00-243-03 equilizer 1 9 96-826-14...

  • Page 142: Instrument Panel (Dash)

    Illustrated parts parts page 26 instrument panel (dash).

  • Page 143

    Illustrated parts parts page 27 instrument panel item no. Part no. Description qty 94-303-10 left dash assembly (complete) 1 94-303-12 right dash assembly (complete) 1 1 71-038-10 switch 1 2 71-038-10 switch 1 3 74-000-72 hour meter 1 4 74-009-48 battery status gauge 1 5 71-141-20 turn switch 1 6 - ...

  • Page 144: Speed Control Panel

    Illustrated parts parts page 28 speed control panel 1 2 3 4 5 6 7 8 9 10 11 12 4.

  • Page 145

    Illustrated parts parts page 29 speed control panel item no. Part no. Description qty 1 88-060-13 6 88-069-81 6 2 79-840-20 circuit breaker, 20a 2 88-818-06 #8 x 1/2 pan hd scr type b thd 4 3 79-840-00 circuit breaker, 10a 1 88-818-06 #8 x 1/2 pan hd scr type b thd 2 4 88-067-12 1/4nc x 1 hex tap sc...

  • Page 146: F&r Switch Assembly

    Illustrated parts parts page 30 11 12 13 7 8 5 15 4 16 6* 14 9 10 1 2 3 17 * - concave side of belleville washer #6 faces #14 f&r switch assembly.

  • Page 147

    Illustrated parts parts page 31 f&r switch assembly item no. Part no. Description qty 1 95-907-00 knob 1 2 88-119-80 nut 1 3 88-109-81 lock nut 1 4 88-019-86 nut 4 5 88-014-13 screw 4 6 97-183-00 washer, beleville 1 7 88-100-14 bolt 1 8 88-108-61 washer 1 9 32-207-00 bushing 1 10 88-517-11 cotter pi...

  • Page 148: Miscellaneous Electrical

    Illustrated parts parts page 32 miscellaneous electrical item no. Part no. Description qty 1 73-005-10 reverse alarm (optional), bullard mpa-ii, 97db 2 71-124-00 switch, battery disconnect 1 3 78-010-30 fuse panel 1 4 79-820-05 fuse,ato,15 amp 5 79-820-06 fuse,ato,20 amp 6 75-148-93 harness, control...

  • Page 149: Miscellaneous Frame and Body

    Illustrated parts parts page 33 miscellaneous frame and body item no. Part no. Description qty 1 13-770-00 tire and wheel,p195/75r14 4 2 97-236-00 wheel nut 20 3 91-408-00 glove box 1 4 00-155-39 box, charger cord 1 5 00-155-41 cover, charger cord box 1 6 71-040-95 lock, charger cord box 1 7 76-002-...

  • Page 150: Doors

    Illustrated parts parts page 34 doors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 inside part of window frame. Included with window 21 22 23 24 door striker on cab.

  • Page 151

    Illustrated parts parts page 35 doors item no. Part no. Description qty 1 90-855-05 plexiglass window 2 2 90-855-00 window, right 1 90-855-10 window, left 1 3 91-015-66 door, right 1 91-015-81 door, left 1 4 98-310-00 window gasket (order by the foot) 5 97-318-70 handle 2 6 97-318-71 gasket 2 7 97-3...

  • Page 152: Charger

    Illustrated parts parts page 36 charger 2 1 15 12 11 4 3 5 8 10 6 7 9 13 14 16.

  • Page 153

    Illustrated parts parts page 37 charger # description 79-303-25 79-315-00 79-315-10 79-309-20 spec # > 22620 16340 16780 16920 1 timer assy 79-805-68 79-802-00 79-902-00 79-805-75 2 capacitor 79-902-00 79-902-00 79-902-00 79-902-00 3 fuse assy 79-831-00 79-831-00 79-831-00 79-831-00 4 diode assy 79-...

  • Page 154: Batteries

    Illustrated parts parts page 38 batteries main negative main positive 12v tap 72 volt battery configuraation main negative main positive 12v tap 48 volt battery configuraation.

  • Page 155

    Illustrated parts parts page 39 48 volt dual battery configuraation main negative main positive 12v tap batteries item no. Part no. Description qty 77-047-00 battery, 244 ah 77-042-00 battery, t 217 ah 50-243-10 battery rod 50-250-00 clamp, bat loc 75-237-00 jumper, 9” 75-149-99 harness for 48v, dua...

  • Page 156: Decals

    Illustrated parts parts page 40 decals.

  • Page 157

    Illustrated parts parts page 41 decals item no. Part no. Description qty 1 94-201-00 taylor-dunn emblem 1 2 94-301-01 decal, "taylor-dunn",white 2 3 94-301-02 decal, "electruck" 2.262lh 1 4 94-313-00 decal, battery warning 3 5 94-313-20 decal, safety warn 1 6 94-376-00 decal, kill switch 1 7 94-384-...

  • Page 158: Seat Cushions and Deck

    Illustrated parts parts page 42 seat cushions and deck item no. Part no. Description qty 1 90-160-50 driver seat 1 2 90-160-51 passenger seat 1 3 90-199-10 seat belt 2 4 02-155-79 angle, seat mount 2 5 00-243-41 deck frame, standard 1 00-155-65 deck frame, stake side pockets 1 6 02-155-45 deck frame...

  • Page 159: 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 160: Appendix A: Special Tools

    Appendixes appendixes appendix a page 2 appendix a: special tools description purpose part number pinion seal installation tool used to install the pinion seal on all chain drive trucks with the band style brake or the speed sensor on the chain case cover. 43-201-50 chain case centering tool used to...

  • Page 161: Hardware Identification

    Appendixes appendix b page 3 appendixes hardware identification standard head markings s.A.E. Grade 2 s.A.E. Grade 5 truss head, grade 2 carriage bolt, grade 2 (unless marked as above) other bolts note: torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grad...

  • Page 162

    Appendixes appendixes appendix b page 4 hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) c or, or, b or, or, nuts with no markings are to be treated as s.A.E. Grade 2 lock nuts use a letter to indicate the grade of the nut. Grade a’ locknuts would be the equivelent of grade ‘2’ hex nuts...

  • Page 163

    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 164: Torque Table

    Appendixes appendixes appendix b page 6 suggested torque values (critical hardware) torque table torque range group description ft-lbs in-lbs nm brakes - - - - - - - - - - - - - - - - - - - - - - - - brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 brake line tube nut fittings 12 - 13 144 - 15...

  • Page 165

    Appendixes appendix c page 7 appendixes taylor-dunn does not currently supply asbestos fiber-brake pads/ shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the ...

  • Page 166

    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.