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Taylor-Dunn RE-380-36 Manual

Summary of RE-380-36

  • Page 1

    T h e b e s t w a y to go a b o u t your b u s i n e s s ® serial number starting: 155932 manual mr-380-28 operation, troubleshooting and replacement parts manual models inlcuded: re-380-36 (r 380-36) re-380-48 (r 380-48) equipped with the gt drive system published: 1/6/2005 revision: d typical gt d...

  • Page 2

    Taylor-dunn contact information service, parts, sales: taylor-dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the tayl...

  • Page 3

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

  • Page 4: Taylor-Dunn

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

  • Page 5: Introduction

    Introduction about this manual ......................................... 2 who should read this manual .................... 3 responsibilities ............................................. 3 how to use this manual .............................. 4 conventions ............................................

  • Page 6: 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 7: 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 8: How to Use This Manual

    Introduction introduction page-4 how to use this manual this manual is organized into five main sections: introduction this section describes how to use this service manual and how to identify your vehicle. Safety rules and operating instructions this section outlines the safety and operational issu...

  • Page 9

    Introduction introduction page-5 a shaded box with the word “warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the...

  • Page 10

    Introduction introduction page-6 how to identify your vehicle this manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, mote...

  • Page 11

    Introduction introduction page-7 taking delivery of your vehicle inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems: • examine the contents of all packages and accessories that may have come in separate packages with the vehicle. • make...

  • Page 12: Taylor -Dunn

    Taylor -dunn.

  • Page 13: 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 14: Standard Specifications

    Safety rules and operating instructions safety rules page 2 this vehicle conforms to requirements for type e vehicles as described in o.S.H.A. Standard section 1910.178 (powered industrial trucks) and with all applicable portions of the american national standard for personnel and burden carriers (a...

  • Page 15: Safety Rules And

    Safety rules and operating instructions safety rules page 3 safety rules and guidelines it is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the american national standards ins...

  • Page 16: Vehicle Controls

    Safety rules and operating instructions safety rules page 4 vehicle controls key-switch a key-switch, located on the right 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 ...

  • Page 17

    Safety rules and operating instructions safety rules page 5 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...

  • Page 18

    Safety rules and operating instructions safety rules page 6 headlight switch the headlight switch is located on the far left side of the instrument panel. Push the top of the switch to turn the lighs on. Push the bottom of the switch to turn the light off. Reverse or motion alarm (optional) the reve...

  • Page 19

    Safety rules and operating instructions safety rules page 7 hour meter (optional) the hour meter is located to the right of the battery status indicator. It records the number of hours the vehicle has been in operation. Battery status indicator, analog the battery status indicator is located to the ...

  • Page 20

    Safety rules and operating instructions safety rules page 8 smart view display the smart view display (svd) functions as a battery status indicator (bsi), hour meter (hm), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is des...

  • Page 21

    Safety rules and operating instructions safety rules page 9 display showing maintenance and wrench icons maintenance monitor: note: the maintenance monitor function is optional. The maintenance monitor function can be turned on or off by your dealer. Operation: the smd notifies the operator 10-hours...

  • Page 22

    Safety rules and operating instructions safety rules page 10 note: most faults are a result of a fault in the control system that will require service by a qualified technician. These faults are shown here for reference only. Operator correctable faults are shown in bold and underlined. Fault code t...

  • Page 23: Vehicle Operation

    Safety rules and operating instructions safety rules page 11 vehicle operation guidelines while driving: • slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection. • no reckless driving. • do not drive this vehicle on steep inclines or where prohibited. • ...

  • Page 24

    Safety rules and operating instructions safety rules page 12 parking before leaving the vehicle: • set the parking brake. • set the forward-off-reverse switch to the ` “off” position. • rotate the start switch to the “off” position. In addition: • if parking this vehicle on an incline, turn the whee...

  • Page 25: Charging Your Vehicle

    Safety rules and operating instructions safety rules page 13 explosive mixtures of hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of c...

  • Page 26: Storing / Returning  To

    Safety rules and operating instructions safety rules page 14 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 27

    Safety rules and operating instructions safety rules page 15 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 28: For The Smart View Display

    Safety rules and operating instructions safety rules page 16 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 29: Maintenance Guidelines For

    Safety rules and operating instructions safety rules page 17 t a y l or - du n n th e b e st w ay to go about yo ur bu si n e s s r maintenance guidelines for severe duty applications 1. This maintenance checklist is based on the average application. If the vehicle is operated under “severe conditio...

  • Page 30: Taylor -Dunn

    Taylor -dunn.

  • Page 31: General Maintenance

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

  • Page 32: Maintenance Guidelines

    Maintenance, service and repair maintenance page 2 maintenance guidelines periodic maintenance and service must be performed on this vehicle. Failure to complete these scheduled maintenance and service procedures can result in severe bodily injury and/or property damage. It is the owner and/or opera...

  • Page 33: Troubleshooting Guide

    Maintenance, service and repair maintenance 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 ba...

  • Page 34: Lubrication Chart

    Maintenance, service and repair maintenance page 4 lubrication chart 3 5 2 3 3 7 5 3 drive # description locations lubricant type 1 2 king pin 2 general purpose grease 3 ball joints 6 general purpose grease 4 5 front wheel bearings 2 high temperature wheel bearing grease 6 7 drive drain plug 1 8 dri...

  • Page 35: Front Axle Service

    Front axle service table of contents inspect the front wheel bearings and kin pin ............................................. 2 adjust front wheel bearings ...................... 3 front axle removal and installation ............ 4 removal .............................................................

  • Page 36

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

  • Page 37

    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 38

    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 39

    Maintenance, service, and repair front axle page 5 installation 6. Raise the front of the vehicle and support with jack stands. 7. Install the front axle in reverse order of removal. Note: use all new cotter pins. Note: refer to the replacing the ball joints section for information regarding the ins...

  • Page 40: 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 41: Replace Front Wheel Bearings

    Maintenance, service, and repair front axle page 7 replace front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly from the hub. Refer to replace the steering knuckle for information regarding removing the steering knuckle. 8. Remove the...

  • Page 42

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

  • Page 43

    Maintenance, service, and repair front axle page 9 7. Loosen the rod end jam nut or clamp on the steering sleeve. 8. Remove the rod end nut. 9. Remove the rod end from the steering arm. Hint: count the number of turns required to remove the rod end from the steering sleeve. This will make it easier ...

  • Page 44

    Maintenance, service, and repair front axle page 10 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 arm. 10. Remove the ball joint from the steering sleeve. Hint: count the number of t...

  • Page 45

    Maintenance, service, and repair front axle page 11 7. Remove the ball joints or rod ends from the steering knuckle and pitman arm. Note: refer to the replacing the ball joints section for information regarding the removal of the ball joints or rod ends. 8. Remove the drag link as an assembly. 9. In...

  • Page 46

    Maintenance, service, and repair front axle page 12 7. Remove the ball joints or rod ends from the steering knuckles. Note: refer to the replacing the ball joints section for information regarding the removal of the ball joints or rod ends. 8. Remove the tie rod as an assembly. 9. Install in reverse...

  • Page 47

    Maintenance, service, and repair front axle page 13 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 “o...

  • Page 48: Replace The Steering Knuckle

    Maintenance, service, and repair front axle page 14 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the...

  • Page 49

    Maintenance, service, and repair front axle page 15 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 50: Taylor -Dunn

    Taylor -dunn.

  • Page 51: Steering Component Service

    Table of contents front end alignment .................................... 2 adjust the steering gear (saginaw) ............. 6 replace the steering shaft (non-tilt steering) .................................... 7 replace the steering wheel ......................... 9 replace the steering gear ........

  • Page 52: Front End Alignment

    Maintenance, service, and repair steering 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 rear wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 53

    Maintenance, service, and repair steering page 3 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 the position may cause loss of control of the vehicle resulting in severe bodily injury and/or...

  • Page 54

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

  • Page 55

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

  • Page 56

    Maintenance, service, and repair steering page 6 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 57: Replace The Steering Shaft

    Maintenance, service, and repair steering 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 front wheels to prevent vehicle movement. 5. Disconnect the m...

  • Page 58

    Maintenance, service, and repair steering page 8 do not use the original pinch bolt and nut. Failure to replace the pinch bolt and nut may result in failure of the steering causing loss of control of the vehicle. This could lead to property damage and/or severe bodily injury. Make sure that the pinc...

  • Page 59: Replace The Steering Wheel

    Maintenance, service, and repair steering 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 m...

  • Page 60: Replace The Steering Gear

    Maintenance, service, and repair steering page 10 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the m...

  • Page 61: Repair The Steering Gear

    Maintenance, service, and repair steering page 11 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 62

    Maintenance, service, and repair steering page 12 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing. 8. The ball nut assembly consists of two...

  • Page 63

    Maintenance, service, and repair steering page 13 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough ...

  • Page 64

    Maintenance, service, and repair steering page 14 exploded view of steering gear.

  • Page 65: Brake Service

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

  • Page 66: Inspect The Service Brake

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

  • Page 67

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

  • Page 68: Inspect The Parking Brake

    Maintenance, service, and repair brakes page 4 inspect the parking brake wheel park brake (hydraulic disc) note: the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Inspect the brake pads. Refer to inspect t...

  • Page 69: Inspect The Parking Brake

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

  • Page 70: Adjust The Service Brakes

    Maintenance, service, and repair brakes page 6 adjust the service brakes two or four wheel hydraulic disc brakes the hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • brake fluid level low in the master cylinder. See check the mas...

  • Page 71: Adjust The Parking Brake

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

  • Page 72: 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 73: Bleed The Brake System

    Maintenance, service, and repair brakes page 9 bleed the brake system note: start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. 6. Thoroughly clean the area around the master cylinder cap and remove the cap. Do not ingest br...

  • Page 74

    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 75: 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 76: (Optional Motor Brake)

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

  • Page 77

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

  • Page 78

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

  • Page 79

    Maintenance, service, and repair brakes page 15 replace front disc brake pads note: it is recommended that both the left and right brake pads be replaced as a set. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” posit...

  • Page 80

    Maintenance, service, and repair brakes page 16 note: refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. 12. Inspect...

  • Page 81: Replace Rear Brake Pads

    Maintenance, service, and repair brakes page 17 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 82

    Maintenance, service, and repair brakes page 18 9. Remove the tire/wheel assembly. Note: refer to tires and wheels section for information on removing the tire and wheel assembly. 10. Release the park brake (wheel brake only). 11. Remove the brake body bolts and discard the lock nuts and brake pads....

  • Page 83: Replace The Wheel Cylinder

    Maintenance, service, and repair brakes page 19 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the wheels to prevent vehicle movement. 5. Disconnect the main pos...

  • Page 84

    Maintenance, service, and repair brakes page 20 8. Remove the tire/wheel assembly. Refer to tires and wheels section for information on removing the tire and wheel assembly. 9. Thoroughly clean the area around the brake body. 10. Remove the brake body bolts and discard the lock nuts. 11. Inspect the...

  • Page 85: Repair The Brake Body

    Maintenance, service, and repair brakes page 21 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...

  • Page 86

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

  • Page 87: Replace The Master Cylinder

    Maintenance, service, and repair brakes page 23 replace the master cylinder note: most vehicle configurations do not require lifting the vehicle to remove the master cylinder. Lifting the vehicle may not be required. 6. If required, raise the vehicle and support with jack stands. 7. Place a drain pa...

  • Page 88

    Maintenance, service, and repair brakes page 24 10. Install in reverse order. 11. Adjust the master cylinder push rod so that it is approximately 1/8 inch away from the master cylinder plunger when the brake pedal is up. 12. Fill the master cylinder with brake fluid from a sealed container. 13. Pump...

  • Page 89: Repair The Master Cylinder

    Maintenance, service, and repair brakes page 25 repair the master cylinder note: hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See replace the master cy...

  • Page 90: Taylor -Dunn

    Taylor -dunn.

  • Page 91: Motor Service

    Table of contents inspecting the motor brushes ............ 2 motors with internal cooling fans ......................... 2 motor removal and installation ......... 2 motor inspection ................................ 2 replacing the brushes or armature bearing 4 repairing the commutator ...............

  • Page 92: Motor Removal And

    Maintenance, service, and repair motor service page 2 motor removal and installation see the transmission section for information on removing or installing the motor. Inspecting the motor brushes motors with internal cooling fans 1. Make sure the key-switch is in the “off” position, then remove the ...

  • Page 93

    Maintenance, service, and repair motor service page 3 3. Measure the commutator undercut depth in 5- places around the commutator. • if any one of the measurements is less than the minimum undercut depth specified in service limits at the end of this section, then the commutator must be undercut. Re...

  • Page 94

    Maintenance, service, and repair motor service page 4 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 commuta...

  • Page 95: Repairing The Commutator

    Maintenance, service, and repair motor service page 5 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 be removed from the motor for this procedure. Refer to mo...

  • Page 96: Service Limits

    Maintenance, service, and repair motor service page 6 service limits note: special and expensive motor testing equipment is required in order to accurately measure motor armature or field resistance. In most cases, this equipment is not required in order to determine if a motor is faulty. The majori...

  • Page 97: Transmission

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

  • Page 98: Check Oil Level

    Maintenance, service, and repair transmission page 2 check oil level the oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 6. Place an oil drain pan underne...

  • Page 99: Change Oil

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

  • Page 100

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

  • Page 101: Rear Hub Or Rotor

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

  • Page 102: (Disc Brakes)

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

  • Page 103

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

  • Page 104: 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 105: Reduction Gear Case

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

  • Page 106

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

  • Page 107

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

  • Page 108: Disassembling The 3Rd Member

    Maintenance, service, and repair transmission page 12 disassembling the 3rd member 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent veh...

  • Page 109

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

  • Page 110

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

  • Page 111: Assembling The 3Rd Member

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

  • Page 112

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

  • Page 113

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

  • Page 114

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

  • Page 115

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

  • Page 116

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

  • Page 117: Suspension

    Table of contents suspension replace the rear springs ............................. 2 leaf ........................................................................... 2 replace the front springs ........................... 3 leaf .........................................................................

  • Page 118: 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 119: Replace The Front Springs

    Maintenance, service, and repair suspension page 3 replace the front springs leaf if a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. Hint : in most vehicles it will be easier if the springs are replaced one at a time. 6. Raise the front of th...

  • Page 120

    Maintenance, service, and repair suspension page 4 damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage. 12. Inspect the spring bolts and spring hangers for signs of wear or damage. If any wear or damage is found, th...

  • Page 121: Replace The Spring Bushings

    Maintenance, service, and repair suspension page 5 replace the spring bushings it is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): • the internal bushing...

  • Page 122: Replace The Shocks

    Maintenance, service, and repair suspension page 6 replace the shocks front or rear it is recommended to replace both front shocks as a set. Note: on some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for informati...

  • Page 123: Tires and Wheels

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

  • Page 124: 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 125: Replace The Tire/wheel

    Maintenance, service, and repair tires and wheels page 3 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. Note: refer to tire inflation section or steering component service section for informa...

  • Page 126

    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 127

    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 128: Taylor -Dunn

    Taylor -dunn.

  • Page 129: Battery Service

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

  • Page 130: 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 131: 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 132

    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 133: 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 134: 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 135

    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 136

    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 137

    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 138

    Maintenance, service, and repair batteries page 10 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the...

  • Page 139

    Maintenance, service, and repair batteries page 11 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 140

    Maintenance, service, and repair batteries page 12 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the...

  • Page 141

    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 142

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

  • Page 143

    Sevcon troubleshooting page 3 electrical troubleshooting identifying your controller.

  • Page 144

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

  • Page 145

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

  • Page 146

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

  • Page 147

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

  • Page 148

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

  • Page 149

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

  • Page 150

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

  • Page 151

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

  • Page 152

    Sevcon troubleshooting page 12 electrical troubleshooting test 6. Accelerator module fault with the power switch off, connect the throttle module to the analyzer. Position the power switch to the 0-5 volt range. All but the power lamp should be off. If the fs-1, fs-3 or ov lamp (over voltage) are on...

  • Page 153

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

  • Page 154

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

  • Page 155

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

  • Page 156

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

  • Page 157

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

  • Page 158

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

  • Page 159

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

  • Page 160

    Sevcon troubleshooting page 20 electrical troubleshooting smart view fault codes level 5 faults (f05xxx) f05004: “va fail” this is a result of a low voltage on an internal voltage regulator. Can also be caused by a low key switch input voltage. If the key switch input is within specifications, then ...

  • Page 161

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

  • Page 162: Taylor -Dunn

    Taylor -dunn.

  • Page 163: Lestronic II

    Table of contents lestronic ii ® charger troubleshooting operating instructions and theory of operation .........................2 testing the charging cycle ....................3 test equipment required for troubleshooting ..............................4 important notes and instructions -----------...

  • Page 164

    Electrical troubleshooting charger troubleshooting page 2 operating instructions and theory of operation the lestronic ii ® chargers are designed as semiautomatic chargers. The lestronic ii ® charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable”...

  • Page 165: Testing The Charging Cycle

    Electrical troubleshooting charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: • the...

  • Page 166

    Electrical troubleshooting charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm) with diode and capacitor test function, fluke 79 ® model shown at right and in the troubleshooting illustrations. Important notes and instructions • this troubleshooting gu...

  • Page 167

    Electrical troubleshooting charger troubleshooting page 5 troubleshooting for built-in charger 5. Disconnect the charger from the ac source. Locate the charger harness connectors where the charger harness is connected to the vehicle’s control harness. There will be two 10 gauge and two 14 gauge wire...

  • Page 168

    Electrical troubleshooting charger troubleshooting page 6 • disconnect the charger from the ac source. • disconnect the batteries. • disconnect the charger from the vehicle’s harness. • remove the charger from the vehicle. Remove the charger cover and perform the following tests: 1. Inspect the inte...

  • Page 169

    Electrical troubleshooting charger troubleshooting page 7 • test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad . St...

  • Page 170

    Electrical troubleshooting charger troubleshooting page 8 troubleshooting for portable charger disconnect the charger from the ac outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles dc receptacle to main battery negative. This voltage should be equal to the batte...

  • Page 171: Testing The Timer Relay

    Electrical troubleshooting charger troubleshooting page 9 5. Reconnect the lead to the diode. 6. Connect the charger to the ac source. Insert the dc charger plug into the dc receptacle and perform the following tests: • test the voltage from the fuse assembly (-) to the diode block (+). This voltage...

  • Page 172: Testing The Interlock Relay

    Electrical troubleshooting charger troubleshooting page 10 testing the interlock relay operation the interlock relay disables the vehicle from running whenever the charger is connected to a working ac power source. When the charger is plugged in, the relay contacts open and break the key switch conn...

  • Page 173

    Table of contents ® operating instructions and theory of operation ........................................2 hb/pt and gel indicator lamps ...........3 testing the charging cycle ....................3 test equipment required for troubleshooting ...............................4 important notes and in...

  • Page 174

    Electrical troubleshooting signet charger troubleshooting page 2 operating instructions and theory of operation the model hb600w ® and hb1000w ® chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are f...

  • Page 175: Testing The Charging Cycle

    Electrical troubleshooting signet charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the batteries when the charge cycle was started. Note: charging time is limited to 18-hours (max). A...

  • Page 176

    Electrical troubleshooting signet charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm), fluke 79 ® model shown at right and in the troubleshooting illustrations. Clamp on dc ammeter to measure up to 20-amps. Important notes and instructions • this trou...

  • Page 177: Status Led Error Code Table

    Electrical troubleshooting signet charger troubleshooting page 5 status led error code table there are three status lights (led’s) on the charger name plate. These led’s normally indicate the current operating state of the charger. If all three led’s are flashing, it indicate an error has occurred i...

  • Page 178: Troubleshooting

    Electrical troubleshooting signet charger troubleshooting page 6 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Tro...

  • Page 179: Charger Models:

    Table of contents charger models: hbs 600 hbs 1000 signet ® charger troubleshooting definitions: ............................................2 test equipment required for troubleshooting ...............................2 important notes and instructions 2 operating instructions and theory of operatio...

  • Page 180: Definitions:

    Electrical troubleshooting signet charger troubleshooting page 2 test equipment required for troubleshooting digital multi meter (dmm), calibrated and accurate down to 0.00001 volts. Clamp on dc ammeter to measure up to 20-amps. Important notes and instructions • this troubleshooting guide assumes a...

  • Page 181

    Electrical troubleshooting signet charger troubleshooting page 3 operating instructions and theory of operation the model hbs 600w ® and hbs 1000w ® chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are f...

  • Page 182: Testing The Charging Cycle

    Electrical troubleshooting signet charger troubleshooting page 4 testing the charging cycle in typical installations, the charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. Note: the charge cycle time is limited to 20-...

  • Page 183

    Electrical troubleshooting signet charger troubleshooting page 5 status light error code table if the fault light is on or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer t...

  • Page 184: Troubleshooting

    Electrical troubleshooting signet charger troubleshooting page 6 troubleshooting note: there are no internally serviceable components in the charger. To test charger operation: connect a dc volt meter to the main battery positive and negative terminals. Attach a clamp on dc ammeter to one of the cha...

  • Page 185: Wire Diagrams

    Wire diagrams.

  • Page 186: Complete Vehicle

    Wire diagrams wire diagrams page 2 complete vehicle battery positive horn 4 strobe light [option] switch blue/black white/black gray/white black 9-pin amp 9 yellow brown/white accelerator ms3 ms1 5 4 8 green/black violet/black black black high/low black switch 2 black gray/black violet/black green/b...

  • Page 187: Illustrated Parts

    Table of contents front axle ................................................... 2 steering linkage ......................................... 4 steering gear ............................................. 6 front suspension ........................................ 8 transmission (primary reduction) ....

  • Page 188: Front Axle

    Illustrated parts parts page 2 front axle fwd 1 2 3 4 5 6 7 8 9 5 12 13 12 14 10 9 11 thrust bearing detail top bottom #3 15 16.

  • Page 189

    Illustrated parts parts page 3 front axle item # part# description qty 1 14-380-80 yoke, left side, without brakes after serial # 124156 1 14-240-08 yoke, left side, use with disc brakes after serial # 124156 1 14-380-92 yoke, left side, without brakes up to serial # 124156 1 14-380-85 yoke, left si...

  • Page 190: Steering Linkage

    Illustrated parts parts page 4 steering linkage.

  • Page 191

    Illustrated parts parts page 5 steering linkage item# part# description qty 1 19-011-25 steering wheel cover 1 2 88-199-82 5/8”nf hex head jam nut 1 3 19-011-20 steering wheel, 3 spoke 1 4 97-200-00 dust washer 1 5 32-248-10 3/4” id bushing 1 6 00-680-15 steering column 1 7 88-100-11 3/8” x 1” nc he...

  • Page 192: Steering Gear

    Illustrated parts 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 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 194: Front Suspension

    Illustrated parts parts page 8 front suspension.

  • Page 195

    Illustrated parts parts page 9 front suspension item# part# description qty 1 88-119-80 3/8” nf hex head nut 4 2 86-006-01 shock mounting hardware 2 3 86-006-00 shock absorber 2 4 see front axle beam axle 5 88-121-19 7/16” x 2-3/4”nc hex cap screw gr5 2 6 85-506-01 2 leaf, spring 2 7 01-680-61 sprin...

  • Page 196

    Illustrated parts parts page 10 transmission (primary reduction).

  • Page 197

    Illustrated parts parts page 11 transmission gear case item # part # description qty 1 gt-71682 m8 x 60 bolt 12 2 gt-3287563 gear case cover 1 3 gt-71259 bearing 1 4 gt-3287513 input shaft, 30:1 0 or 1 gt-3287523 input shaft, 24:1 0 or 1 gt-3287533 input shaft, 18:1 0 or 1 gt-3287543 input shaft, 12...

  • Page 198: Rear Axle

    Illustrated parts parts page 12 transmission (secondary reduction) rear axle.

  • Page 199

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

  • Page 200: Rear Brakes

    Illustrated parts parts page 14 rear brakes front brakes (optional) brake body.

  • Page 201

    Illustrated parts parts page 15 rear brakes item # part # description qty 1 88-067-21 hex bolt, grade 8 4 2 41-350-51 secondary plate 2 3 41-348-70 brake pad 4 4 41-348-52-61 spacer (kit, includes spacers #4, and bushings #5 for 1 wheel) 4 5 41-348-52-61 bushing (kit, includes spacers #4, and bushin...

  • Page 202: Rear Suspension

    Illustrated parts parts page 16 rear suspension.

  • Page 203

    Illustrated parts parts page 17 rear suspension item# part# description qty 1 85-507-00 spring 2 2 16-870-10 spring hanger 4 3 32-213-00 bushing 6 4 96-248-00 hex bolt 6 5 88-169-81 hex lock nut 6 6 96-114-00 u-bolt 4 7 88-159-84 hex lock nut 8 8 16-861-42 spring plate, left 1 16-861-43 spring plate...

  • Page 204: Motor

    Illustrated parts parts page 18 motor.

  • Page 205

    Illustrated parts parts page 19 203 -21 -4001 or xp1820a 70 -072 -41 * * * 85 -403 -00 70 -173 -00 70 -170 -10 * * * * - - - xp -1786 or dd3 -4004 70 -052 -40 * * * 70 -412 -20 70 -170 -00 70 -109 -00 70 -417 -00 80 -212 -00 70 -421 -20 70 -421 -00 95 -930 -00 88 -067 -17 88 -067 -22 dv1 -4003 70 -0...

  • Page 206: Deadman Seat Brake

    Illustrated parts parts page 20 deadman seat brake.

  • Page 207

    Illustrated parts parts page 21 automatic driver seat 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 96-114-10 u-bolt...

  • Page 208: Master Cylinder Linkage

    Illustrated parts parts page 22 16 5 18 15 17 3 15 14 13 12 11 10 9 7 8 7 see brake lines 6 5 2 ? 4 2 2 3 3 2 1 master cylinder linkage master cylinder components (all).

  • Page 209

    Illustrated parts parts page 23 master cylinder linkage item# part# description qty 1 00-380-90 brake rod 1 2 88-109-81 3/8nc lock nut 8 3 88-108-61 3/8 sae flat washer 6 4 85-270-00 spring 1 5 96-772-00 3/8 clevis pin 1 6 01-380-76 support plate 1 7 32-215-00 bushing 2 8 00-380-77 bellcrank 1 9 96-...

  • Page 210: Brake Lines

    Illustrated parts parts page 24 brake lines 2 5 10 frame, ref. Master cylinder ref. 9 6 frame, ref. 7 1 19 18 8 frame ref. 17 3 4 7 7 8 8 12 13 (master cylinder fitting) 14 15 (master cylinder bolt) 16 (adaptor) 11 (t-fitting) frame, ref. To master cylinder bolt see note 1 to master cylinder fitting...

  • Page 211

    Illustrated parts parts page 25 brake lines and hoses item# part# description qty 1 99-604-70 brake line, right front 1 2 99-604-71 brake line, left front 1 3 99-605-78 brake line, right rear 1 4 99-605-79 brake line, left rear 1 5 99-607-10 brake line1, front 1 6 99-604-12 brake line2, front 1 7 99...

  • Page 212: Park Brake Linkage

    Illustrated parts parts page 26 park brake linkage front 1 2 2 4 4 5 5 7 8 8 8 9 9 9 9 9 8 10 11 12 13 14 15 16 17 18 19 20 21 22 3 3 frame 6 14 frame.

  • Page 213

    Illustrated parts parts page 27 parking brake linkage item# part# description qty 1 51-344-80 park brake lever 1 2 88-080-11 5/16nv x 1 hex bolt 4 3 96-826-08 brake cable 2 4 88-089-81 5/16nv hex lock nut 4 5 88-088-61 5/16 sae flat washer 2 6 96-826-09 cable lock 2 7 04-380-49 extension, brake hand...

  • Page 214: Wheels and Tires

    Illustrated parts parts page 28 wheels and tires ref., wheel hub 1 2 5 (assembly) 4 3 6 7 8 9 10

  • Page 215

    Illustrated parts parts page 29 wheels and tires item # part # description qty 1 tubeless wheels 12-012-00 5 x 8" tubeless (standard) 4 12-020-00 8.5 x 8 tubeless 4 2 tires 10-081-00 5.70 x 8 (standard) 4 10-082-00 5.70 x 8 extra grip 4 10-083-00 5.70 x 8 lr c 4 10-093-00 8.50 x 8 lr b 4 10-091-10 8...

  • Page 216

    Illustrated parts parts page 30 instrument panel (dash) ending s/n 179484 instrument panel (dash) starting s/n 179485.

  • Page 217

    Illustrated parts parts page 31 instrument panel (ending s/n 179484) item# part# description qty 1 71-100-00 accessory switch 2 2 71-039-11 rocker switch 1 3 71-039-11 rocker switch 1 4 74-010-00 smart view display 1 5 71-039-02 foward/reverse switch 1 6 71-501-00 horn switch 1 7 71-120-10 key switc...

  • Page 218

    Illustrated parts parts page 32 speed control panel, r 3-80-36 1 2 4 5 6 6 7 8 3 9 10 11 12 13.

  • Page 219

    Illustrated parts parts page 33 speed control panel item # part # description qty 1 62-400-05* speed controller 1 2 01-200-07 mounting panel 1 3 73-004-20 horn 1 4 79-844-00 main circuit breaker 1 5 72-501-42 iso solenoid 1 6 88-838-06 #14 x 1/2 sheet metal screw 4 7 88-060-09 1/4nc x 3/4 hex bolt 4...

  • Page 220: Miscellaneous Electrical

    Illustrated parts parts page 34 miscellaneous electrical miscellaneous frame.

  • Page 221

    Illustrated parts parts page 35 miscellaneous electrical item# part# description qty 79-575-25 charger cord, ac 14’ with terminals 79-575-30 charger cord, ac 8’ with terminals 79-530-00 strain releif, ac cord (sr 7w-2) 75-107-10 harness, portable charger jf3-86181-00-00 receptacle, portable charger ...

  • Page 222: Seat Cushions and Lights

    Illustrated parts parts page 36 seat cushions and lights 1 2 3 4 5 6 7 8 9.

  • Page 223

    Illustrated parts parts page 37 seat cushions and lights item# part# description qty 1 90-198-03 front seat cushion 1 2 90-179-00 front backrest 1 3 90-198-03 front seat cushion 1 4 72-025-00 oval tail, stop and turn light 2 4a 72-022-51 gasket for #4 2 5 00-210-04 seat frame 1 6 94-201-10 name plat...

  • Page 224: Charger, Lestronic (Pg. 1)

    Illustrated parts parts page 38 charger, lestronic (pg. 1) chargers.Dwg 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 typical built in charger typical portable charger.

  • Page 225

    Illustrated parts parts page 39 16920 79 -309 -20 48lc25 -8et 230/50/na 48/25 built -in - s/o 79 -808 -20 79 -902 -00 79 -749 -13 s/o n/a 79 -831 -00 79 -530 -00 - - - n/a 22620 79 -303 -25 48lc25 -8et 115/60/15 48/25 built -in - 79 -805 -68 79 -808 -20 79 -902 -00 79 -749 -13 79 -603 -10 - 79 -831 ...

  • Page 226: Charger, Lestronic (Pg. 2)

    Illustrated parts parts page 40 charger, lestronic (pg. 2) chargers.Dwg 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 typical built in charger typical portable charger.

  • Page 227

    Illustrated parts parts page 41 12315 79 -306 -90 36lc40 -8et 230/50/8 36/40 portable 79 -852 -00 k4 -071 -87 79 -808 -00 79 -902 -00 79 -749 -10 s/o s/o 79 -831 -00 79 -532 -00 79 -530 -00 79 -567 -10 - - 7030 79 -304 -60 36lc25 -8et 230/50/7 3625 portable 79 -851 -10 k4 -071 -87 79 -808 -00 79 -90...

  • Page 228: Charger, Signet

    Illustrated parts parts page 42 charger, signet note: the harness connectors are not included with the charger. When replacing the charger order 2 each of the following: part # description 75-318-20 butt splice 75-320-51 knife connector.

  • Page 229

    Illustrated parts parts page 43 signet® charger item # part # description qty 79-303-40 charger assembly (see note on facing page) 1 79-575-60 replacement cover w/ac cord and gasket 1 note: there are no user serviceable components inside the charger ac wire connections.

  • Page 230: Batteries

    Illustrated parts parts page 44 batteries 36-volt 48-volt.

  • Page 231

    Illustrated parts parts page 45 batteries item # part # description qty 1 77-042-00 217ah, t-105 0 or 6 77-042-50 217ah, td-217 0 or 6 77-042-80 217ah, t-105 moist charge (dry) 0 or 6 77-044-00 230ah, t-125 0 or 6 77-044-10 195ah, mainenance free (note: requires special charger) 0 or 6 77-047-00 244...

  • Page 232: Decals

    Illustrated parts parts page 46 decals front cowl tray battery compartment.

  • Page 233

    Illustrated parts parts page 47 decals item# part# description qty 1 94-384-01 not a motor vehicle 1 2 94-309-00 apply hand brake 1 3 94-384-14 turn key off 1 4 94-301-42 arms and legs 1 5 94-313-20 safety warning 1 6 94-373-10 data and serial number 1 7 94-333-00 fm 1 8 94-313-00 battery waring 1 9...

  • Page 234: Trailer Hitch

    Illustrated parts parts page 48 trailer hitch.

  • Page 235

    Illustrated parts parts page 49 trailer hitches item # part # description qty 97-808-00 automatic coupling hitch 97-804-01 pintle hitch 97-811-00 1-7/8" ball hitch 97-805-00 mounting brakcket 97-821-00 2" ball hitch 97-807-00 mounting bracket 88-140-14 1/2nc x 1-1/2 hex bolt 4 88-140-11 1/2nc x 1 he...

  • Page 236

    Illustrated parts parts page 50 strobe light & other front end options.

  • Page 237

    Illustrated parts parts page 51 strobe light, directional signals & headlight options item# part # description qty 1 75-141-22 turn signal switch 1 98-330-50 insulator 1 2 76-352-00 flasher recptacle 1 3 71-900-05 12volt flasher 1 4 72-082-10 12volt turn signal bulb 2 5 72-082-20 turn signal socket ...

  • Page 238

    Illustrated parts parts page 52 cab & cowl with windshield options.

  • Page 239

    Illustrated parts parts page 53 cab & cowl with windshield options item# part # description qty 90-825-62 windshield kit 1 1 90-825-20 plexiglass windshield 1 2 90-825-06 right windshield mounting bracket 1 3 90-825-05 left windshield mounting bracket 1 4 88-060-09 1/4"nc x 3/4" hex head bolt 4 5 88...

  • Page 240: Optional Cab Accessories

    Illustrated parts parts page 54 optional cab accessories.

  • Page 241

    Illustrated parts parts page 55 optional cab accessories item# part # description qty 1 72-023-20 strobe light, amber 1 2 88-025-06 #8-32 x 1/2" truss head screw 3 3 88-028-62 #8 lockwasher 3 4 88-029-80 #8-32 nut 3 5 98-606-00 3/16" id grommet 1 not shown 75-114-16 wiring harnes for wiper and light...

  • Page 242: Cab Door Options

    Illustrated parts parts page 56 cab door options.

  • Page 243

    Illustrated parts parts page 57 cab doors item# part # description qty 90-924-60 left door kit 1 90-924-61 right door kit 1 1 90-923-98 left door frame 1 90-923-99 right door frame 1 2 90-924-98 left side curtain 1 90-924-99 right side curtain 1 3 97-315-53 outer handle assembly 1 4 97-315-51 door l...

  • Page 244: Optional Top Cover

    Illustrated parts parts page 58 optional top cover.

  • Page 245

    Illustrated parts parts page 59 s u r r e y top cover item# part # description qty 91-120-62 surrey top cover kit 1 1 91-038-00 tubular frame 1 2 91-038-07 left and right rear support post for frame 2 3 91-038-08 front left support post for frame 1 4 91-038-09 front right support post for frame 1 5 ...

  • Page 246

    Illustrated parts parts page 60 rear seat, rear gate and rear deck.

  • Page 247

    Illustrated parts parts page 61 rear seat, rear gate & pipe rails fold down rear seat item# part # description qty 90-109-63 fold down rear seat kit 1 1 90-000-00 6" x 34" backrest 1 2 90-177-00 seat cushion 1 3 88-837-11 #14 x 1" phillips sheet metal screw 8 4 00-380-67 rear flip up deck 1 5 88-065...

  • Page 248: 9” Side Panels

    Illustrated parts parts page 62 9” side panels.

  • Page 249

    Illustrated parts parts page 63 9" side panels & tailgate item# part # description qty 91-281-64 9" side panels kit with tailgate, orange 1 91-281-66 9" side panels kit with tailgate, specify color 1 1 03-380-38 left side panel 1 2 03-380-37 right side panel 1 3 88-065-09 1/4"nc x 3/4" phillips trus...

  • Page 250: Front Bumper and Splash Pan

    Illustrated parts parts page 64 front bumper and splash pan.

  • Page 251

    Illustrated parts parts page 65 front bumper and splash pan item# part # description qty 1 01-380-18 bumper 1 2 88-109-81 3/8-nc hex nut 4 3 88-108-61 3/8 sae flat washer 4 4 88-100-11 3/8-nc x 1 hex bolt 4 5 88-080-09 5/16 x 3/4 hex bolt 4 6 04-380-23 splash pan 1 7 88-089-81 5/16-nc lock nut 4 8 9.

  • Page 252: Taylor -Dunn

    Taylor -dunn.

  • Page 253: Appendixes

    Appendixes rev d contents appendix a: special tools ................. 2 appendix b: suggested torque limits for standard hardware .................. 4 hardware identification ...................... 4 standard head markings ...................................... 4 hex bolts .............................

  • Page 254: Appendix A: Special Tools

    Appendixes appendixes appendix a page 2 62-027-32: throttle module analyzer tests the throttle module in or out of the vehicle 75-089-00: throttle module test harness used in conjunction with a volt meter to test the throttle module. The module must be installed in a working control system. Note: pa...

  • Page 255: Appendix A: Special Tools

    Appendixes appendix a page 3 appendixes appendix a: special tools 72-201-00: battery filler used to safely add water to batteries. Equipped with splash guard and auto- shutoff when cell is full. 70-440-55: pin removing tool removes pin from amp circular harness connectors. Molex # 11-300-06: pin rem...

  • Page 256: Hardware Identification

    Appendixes appendixes appendix b page 4 *not available at time of printing 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....

  • Page 257

    Appendixes appendix b page 5 appendixes *not available at time of printing 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 t...

  • Page 258

    Appendixes appendixes appendix b page 6 *not available at time of printing generic torque values imperial (inch), foot pounds grade, sae dia. Pitch 2 5 8 l9 #4 40 * * * * #6 32 * * * * #8 32 * * * * #10 32 * * * * #12 32 * * * * 1/4 20 5.5 8.5 12.5 11 28 6.5 10.5 5/16 18 12.0 17.5 24.5 22 24 12.5 19...

  • Page 259

    Appendixes appendix b page 7 appendixes *not available at time of printing metric, newton meters grade, n-m dia. Pitch 4.6 8.8 10.9 12.9 3 0.50 0.51 * * * 4 0.70 0.95 3.1 * * 5 0.80 2.28 6.1 * * 6 1.00 3.92 10.4 15.5 * 8 1.00 * 27.0 * * 1.25 9.48 25.0 37.0 * 10 1.00 * 57.0 * * 1.25 * 54.0 * * 1.50 1...

  • Page 260

    Appendixes appendixes appendix c page 8 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 b...