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Taylor-Dunn B 2-10, Operation, T Roubleshooting And Replacement Parts Manual

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Taylor-Dunn B 2-10 Operation, T Roubleshooting And Replacement Parts Manual Download Page 154

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 battery voltage. If the voltage

is less than the battery voltage then this wire is broken or has a bad connection.

Stop here and repair the problem.

2. Test the voltage from the positive terminal on the DC receptacle to the negative

terminal on the DC receptacle. This voltage should be equal to the battery voltage.

If the voltage is less than the battery voltage, then the wire on the negative terminal

of the DC receptacle is broken or has a bad connection.  

Stop here and repair the

problem.

Remove the charger cover and perform the following tests:

1. Inspect the internal wiring of the charger and repair as required.

2. Check the continuity of both fuse links and replace if bad.

3. Disconnect  one lead from the capacitor.  Test  the capacitor using the capacitor

test function on the meter. If the capacitor is bad, it must be replaced.  

Stop here

and repair the problem.

4. Reconnect  the lead to the capacitor and

disconnect  one transformer lead from one of

the diodes. Test  each of the diodes using the

diode test function on the meter. If either one of

the  diodes are bad, replace the diode

assembly.  

Stop here and repair the problem.

Fuse Links

Capacitor Test

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor

before continuing. Connect a 2k ohm resistor across the capacitor

terminals for 10 seconds. Do not touch the capacitor terminals with

your hands.  The resistor should be held with a pair of insulated pliers.

Failure to do so may cause serious bodily injury

Summary of Contents for B 2-10

Page 1: ...B u s i n e s s Serial Number Starting 151285 MANUAL MB 210 08 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 012 10 B 2 10 Published 3 27 2002 Revision D 7 23 2013 Shown with optional steel cab and doors ...

Page 2: ......

Page 3: ...t parts or service should be obtained through your local dealer A dealer locator can be found on the Taylor Dunn website at www taylor dunn com If you do not have access to the internet you can call the factory direct at 01 714 956 4040 Feedback regarding this or any Taylor Dunn vehicle manual can be sent to Taylor Dunn Manufacturing Attn Tech Writer 2114 West Ball Road Anaheim CA92804 ...

Page 4: ...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 5: ...Control System Troubleshooting 13 Chargers 14 Wire diagram 15 Illustrated Parts 16 Appendix A Special Tools 17 Appendix B Suggested Torque Values 18 Appendix C Brake Lining Handling Precautions 19 Taylor Dunn Model B0 012 10 Operator and Service Manual Section Index This quick reference section index guide will assist you in locating a desired topic or procedure Refer to each sectional Table of Co...

Page 6: ...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 7: ...able of Contents Introduction About this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 ...

Page 8: ...applicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any Taylor Dunn vehicle is responsible for the overall maintenance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance perform...

Page 9: ...ventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information about a subject Model B 2 48 equipped with the Dump Bed option Model R 3 80 shown equiped with a cargo box and steel cab with doors options A shaded box with and the word Warning and the symbol above ...

Page 10: ...as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 This vehicle is not designed to be driven on public roads or highways It is available in maximum designed speeds ranging from 7 to 16 mph Do not exceed the maximum designed speed Exceeding the maximum desi...

Page 11: ...r Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and or property damage Unauthorized repairs may also void the vehicles warranty What To Do If a Problem is Found If there is a problem or damage as a result of shipping note the damage...

Page 12: ...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 13: ...t Interlock Switch 6 Directional Signals Optional 6 Hazard Light Switch Optional 6 Battery Status Indicator Digital Bargraph optional 7 Vehicle Operational Guidelines 8 Safety Guidelines 8 Starting 8 While driving 8 Loading and Unloading 8 Towing Loads 8 Parking 9 Towing This Vehicle 9 Charging your vehicle 10 Signet Charger Operation Model HB Series 10 Signet Charger Operation Model HBS series 10...

Page 14: ...id Differential Motor DC Series Wound 4 47 kW 6 Horse Power 1 400 RPM Brakes Rear Wheel Hydraulic Disc Hand Operated Park Brake 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Tires 5 70 x 8 Load Range B Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Battery Status Indicator Key Switch Horn Button Forward Reverse Switch Headlight...

Page 15: ...h in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries DRIVER TRAINING PROGRAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for th...

Page 16: ...If a vehicle is equipped with windshield wipers and one or more accessories the windshield wipers are controlled from this switch Other accessories are controlled from the auxiliary switch Horn Switch The horn switch is located on the right side of the instrument panel Depress the switch to sound the horn release it to turn it off 3 Hour Meter optional The hour meter is located to the right of the...

Page 17: ... automobile Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied Relieving pressure from the pedal releases the braking action Accelerator Pedal The accelerator pedal is located to the right of the brake pedal It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile Depress the pedal to increase speed and rele...

Page 18: ... from being driven while the AC charger cord is plugged into a functioning power source NOTE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger Directional Signals Optional The turn signal lever is located on the left side of the steering column Push the lever forward to activate the right turn signal and pull the lever back to activa...

Page 19: ...charging cycle Successive lower LED s will light as the battery charge diminishes When the second from the bottom LED flashes the battery energy status is in energy reserve and should be placed on charge as soon as possible When the two bottom LED s are alternately flashing the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries The BSI will...

Page 20: ... 2 Set the parking brake 3 Hold down the foot brake 4 Rotate the start switch to the ON position 5 Release the parking brake 6 Release the foot brake 7 Slowly depress the accelerator pedal While driving Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection No reckless driving Do not drive this vehicle on steep inclines or where prohibited Immediately r...

Page 21: ...e curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Towing This Vehicle To tow this vehicle attach a tow strap to the front bumper tow bar Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever ...

Page 22: ...ON ON Blinking Cycle complete ON ON ON Typical Signet Built In Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury Signet Charger Operation Model HBS series The Signet HBS series chargers are fully automatic The charger ...

Page 23: ...atteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their life span Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to SectionMaintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in all...

Page 24: ...sh and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l Clean and Repack Front Wheel Bearings l Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Repairs or maintenance by improperly trained or unauthori...

Page 25: ... inclusive of a severe duty application Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Daily Visual i...

Page 26: ...TAYLOR DUNN ...

Page 27: ...ance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor Shown here are two of the many Taylor Dunn tow tractors available Contact you distributor for more information ...

Page 28: ...for cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle 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 operators responsibility to insure that proper service and ...

Page 29: ...rn Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Oil Leak in Rear Bearing Area Rear Wheel Bearing and or Gasket Failed Drive Over Filled Brake Pedal Soft or Spongy Air in Brake Lines Brake Pedal Low Brake Worn 1 16 Wear Limit Brake Fluid Low Brakes Out of Adjustment Braking...

Page 30: ...ts 4 General Purpose Grease 4 Pedal Linkages 1 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 Chain Case Drain Plug 1 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug 1 SAE 140 API GL5 Hypoid Gear Oil 10 3 3 3 5 2 5 3 2 4 8 6 7 9 9 Drive view from left side Note 9 and 6 on chain case is not included on belt drives ...

Page 31: ... and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 4 Front Axle Disassembly 5 Replace Front Wheel Bearings 6 Replace the King Pins and Bushings 7 Replace the Steering Knuckle 8 Front Axle Service ...

Page 32: ... for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings 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 prevent vehicle movement 5 Disconnect the main positive and negative cables at the batte...

Page 33: ...rings 11 Install a new cotter pin 12 Install the dust cap 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle 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 p...

Page 34: ...tion 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 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 informa...

Page 35: ... regarding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Refer to FrontAxle Removal and Installation for information regarding removing the front axle King Pin Locknut Dust Cap Hub Disc Brake Assembly optional Yoke Steering Adjustment Sleeve Drag Link Leaf Spring Spring Plate U ...

Page 36: ...ays 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 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 fr...

Page 37: ...lectric park brake is set 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands 7 Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle NOTE It is not necessary to remove the tie rod or drag...

Page 38: ...ds 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 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 prevent vehicle movement 5 Di...

Page 39: ... Steering Gear 6 Replace the Steering Shaft 7 Replace the Steering Wheel 8 Replace the Steering Gear 8 Replace the Ball Joints Tie Rods and Drag Link 9 Replacing the Drag Link 10 Replacing the Tie Rod 11 Center the Steering Gear 11 Pitman Shaft Alignment 12 Repair the Steering Gear 13 Exploded View of Steering Gear 15 ...

Page 40: ...tands 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 7 Turn the front wheels so that they are in the straight ahead position and then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Join...

Page 41: ...int clamps 28 32 ft lbs or the rod end jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 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 19 Remove the blocks from behind the wheels 20 Release the parking bra...

Page 42: ...devices of rated load capacity may result in severe bodily injury 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 rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 8 Using a piece of chalk mar...

Page 43: ... forward reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries INSPECT ROD ENDS NOTE A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end is worn out then all should be replaced as a set 6 Visuall...

Page 44: ...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 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 prevent vehicle movement 5 Disconnect the main positive and negative cables at the ba...

Page 45: ...E Most vehicle configurations will now allow the steering shaft to slide off of the steering gear input shaft and then back down out of the steering column If there is not enough clearance for this procedure then the steering gear must be removed Refer to Replace the Steering Gear for information regarding removing the steering gear 11 Remove the steering shaft from the vehicle 12 Lightly grease t...

Page 46: ...ng wheel remove the switch and disconnect the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straight ahead position see below 10 Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration to the right 11 Tighten the steering wheel nu...

Page 47: ...rns required to remove the rod end from the steering sleeve This will make it easier to realign the wheels 10 Install the new rod end into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the rod end clamp or jam nut at this time 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch ...

Page 48: ...lamp at this time 12 Install the ball joint into the steering arm Tighten the ball joint nut to 40 45 ft lbs and install a new cotter pin 13 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 14 Lower the vehicle 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Relea...

Page 49: ...ist 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 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 prevent vehi...

Page 50: ...Steering Wheel section for information regarding repositioning the steering wheel 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the parking brake and test drive the vehicle 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 elec...

Page 51: ... of turns in the original direction 2 Remove the worm bearing adjuster locking ring and the worm bearing adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing NOTE The side cover pitman shaft assembly normally does not have to be disassembled 4 Remove the worm shaft and ball nut assembly from the bottom of the...

Page 52: ...er 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 to remove all play in the worm shaft 11 Install but do not tighten the worm bearing adjuster lock nut 12 Rotate the worm shaft to center the ball nut in the housing 13 ...

Page 53: ...Maintenance Service and Repair Steering Page 15 Exploded View of Steering Gear ...

Page 54: ...TAYLOR DUNN ...

Page 55: ... Brake 4 Wheel Park Brake 4 Check Master Cylinder Fluid 5 Bleed the Brake System 6 Flush the Brake System 7 Replace the Parking Brake Lining 7 Wheel Park Brake 7 Replace Front Disc Brake Pads 8 Replace Rear Brake Pads or Shoes 9 Replace the Wheel Cylinder 10 Disc Brake Body Assembly front or rear 10 Repair the Brake Body 12 Replace the Master Cylinder 14 Repair the Master Cylinder 15 Brake Service...

Page 56: ...e could cause excessive brake rotor run out 2 Measure the thickness of the brake rotor in 3 places If the brake rotor thickness is less than 0 20 inches then the rotor must be replaced 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 li...

Page 57: ...f the brake body Refer to Repair the Brake Body for information on removing the park brake pin 9 Inspect all brake cables and linkages for any signs of damage wear or missing cotter pins 10 Inspect the brake handle locking mechanism for any signs of damage NOTE Refer to Adjust the Parking Brake section for information regarding adjusting the parking brake Two or Four Wheel Hydraulic Disc Brakes Th...

Page 58: ...and then loosen the linkage 1 turn 9 Tighten the jam nuts on the park brake linkage 10 Repeat this procedure for both rear wheels 11 Set the park brake 12 Reconnect the main positive and negative cables at the batteries 13 Remove blocks from behind the wheels 14 Release the park brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forwa...

Page 59: ...fluid is corrosive and will damage paint finishes Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minu...

Page 60: ...at the batteries 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 11 Open the bleeder valve on the hydraulic brake body 12 Depress the foot pedal to the floor and then close the bleeder valve Do not release pressure on the brake pedal until the b...

Page 61: ...he 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 prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting an...

Page 62: ...to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 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 NOTE Refer to the illustration for the following steps 10 Remove the brake body bolts 10 and discard ...

Page 63: ...d handling precautions 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 prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity ...

Page 64: ...e parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions 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 prevent vehicle movement 5 Disconnect the main positive and negative cables...

Page 65: ...left in the brake system could lead to brake failure and result in property damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately...

Page 66: ...Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake body making sure that the boot seats properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 17 If the brake body assembly is not to be immediate...

Page 67: ... at the batteries 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 Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area imme...

Page 68: ...iscard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts as required If any damage is found in the bore of the master cylinder then it must be replaced Lubricate all parts with clean brake fluid from a sealed container Reassemble in reverse order If the mas...

Page 69: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Magnetic Sensor Module 2 Pot Box module 3 Throttle Linkage ...

Page 70: ...ents in the throttle module The standard throttle module consists of two micro switches and a magnetic sensor that detects the position of the throttle pedal Switch FS 3 is a normally open switch that is held closed by the throttle pedal return spring The vehicle will be disabled if the throttle return spring breaks Switch FS 1 closes just as the throttle pedal is depressed Depending on the contro...

Page 71: ... 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 with the pedal fully depressed FS 1 5 9 8 4 2 1 5K Pot Box Module NOTE The magnetic sensor module and pot box module are not interchangeable ...

Page 72: ...TAYLOR DUNN ...

Page 73: ...ve Motor 4 Remove 4 Install 4 Rear Axle 5 Remove and Install 5 Replace the Axle Bearing 5 Transmission Assembly 6 Remove and Install 6 Chain Case 7 Disassemble 7 Assemble 7 Differential Assembly 3rd Member 9 Disassemble 9 Assemble 10 Re shimming the Pinion Housing 12 Exploded View 13 Typical Transmission Assembly ...

Page 74: ...vement 5 Disconnect the main positive and negative cables at the batteries 10 Tie the vehicle in place so that it cannot move 11 Reconnect the batteries 12 Close all safety interlock switches turn the key On place the forward off reverse switch in forward and fully depress the accelerator pedal 13 Tighten or loosen the adjustment screw to obtain the minimum noise level NOTE If there is less than 1...

Page 75: ... 6 Park the vehicle on a level surface 7 Place a small oil drain pan under the drive housing 8 Remove the drive housing level plug 9 A small amount of oil should come out This indicates the correct oil level NOTE If a large amount of oil comes out then let it drain to the proper level and replace the level plug If no oil comes out then fill the drive to the proper level and replace the level plug ...

Page 76: ... mounting plate goes into the threaded studs and remove wire s holding the chain Do not allow the wheels to rotate after the motor has been removed Allowing the wheels to rotate may result in the drive chain getting bound up with the drive sprocket locking up the transmission Should this happen the chain may have to 1 Make sure the key switch is in the OFF position then remove the key 2 Place the ...

Page 77: ...se the axle bearing retainer Reinstalling the original bearing retainer may result in the axle falling out of the transmission resulting in severe bodily injury or property damage REAR AXLE Remove and Install 6 Raise the drive wheel off of the ground 7 Remove the wheel assembly 8 Place a small oil drain pan under the end of the axle housing 9 Remove the four axle retaining bolts Secure the brake b...

Page 78: ...olts at this time 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 11 Lift the rear of the vehicle just enough to allow the removal of the rear spring hanger bolts and remove the bolts 12 Raise the rear of the vehicle high enough to roll the tran...

Page 79: ... plug and allow all of the oil to drain from the housing and then reinstall the drain plug 8 Remove the brake drum Refer to section Brakes Replace the Brake Drum for information regarding removing the brake drum 9 Remove the nuts from the three threaded studs at the small end of the chain case housing 10 Remove the chain case housing bolts brake assembly and alignment brackets 11 Remove the chain ...

Page 80: ...and the housing bolts that are not used for the brake mounting bracket or alignment brackets 10 Remove the centering tool and install a new pinion seal Lightly lubricate the pinion seal lip 11 Install the brake assembly and the brake band alignment bracket s Do not tighten the bolts at this time 12 Install the brake drum Torque to 175 ft lbs 13 Tighten the brake adjusting bolt to 25 ft lbs 14 Tigh...

Page 81: ...nion housing and pinion gear from the 3rd member NOTE Do not lose the spacers and shims in the pinion housing or the pinion housing shim s 10 If required remove the rear tapered bearing from the pinion shaft and discard NOTE Do not remove the bearing unless it requires replacement Removing the rear bearing will damage the bearing Replacing this bearing will require re shimming of the pinion shaft ...

Page 82: ... the pinion gear into the 3rd member 4 Install the pinion housing onto the 3rd member 5 Install the pinion bearing spacers shims and front bearing 6 Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened 7 While rotating the pinion shaft tighten the pinion nut to 100 ft lbs 8 Check the torque required to rotate the shaft If the torque is not between 6 10 in lbs ...

Page 83: ...tion to loosen a nut 1 hole back off 2 holes and then tighten 1 hole The ring gear should be rotated any time the nuts are being adjusted 18 Loosen the right side nut 19 Tighten the left nut until all backlash is removed from the ring and pinion gear 20 Tighten the right nut until a case spread of 0 010 is indicated on the dial indicator NOTE If new ring and pinion gears are used refer to the reco...

Page 84: ...f 0 001 Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear It should be a number ranging from 5 to 5 This is the amount in 0 001 increments to add to the standard shim For example if the number on the shaft is 3 then the standard shim 0 015 plus 3 equals 0 012 The correct shim would be 0 012 If you cannot locate the number on the shaft start with the standa...

Page 85: ...Maintenance Service and Repair F2 F3 Transmission Page 13 EXPLODED VIEW ...

Page 86: ...TAYLOR DUNN ...

Page 87: ...otors with internal cooling fans 2 Enclosed Motors GE no cooling fan 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes 5 Replacing the Bearings 6 Repairing the Commutator 6 Service Limits 7 Motor Service Typical Exploded Motor ...

Page 88: ... Disconnect the main positive and negative cables at the batteries Typical motor with cooling fan indicated by the arrow Typical brush and brush holder Motors with internal cooling fans NOTE There are four brushes in the motor The brushes will not wear at the same rate It is recommended that all four brushes are inspected at the same time NOTE In some vehicle configurations it may not be possible ...

Page 89: ...e 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 the motor brushes 2 Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in sectionService Limits then the ...

Page 90: ... 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 The bearing should not freewheel but should come to a smooth stop when rapidly spun by hand If the bearing freewheels then grease is no longer present in the bearing...

Page 91: ... Remove the brush covers 2 Loosen the brush wire retaining screw and remove the brush from the brush holder Be careful with the brush spring and do not let it slip off of the spring mount If the spring comes off then the motor must be disassembled Refer to Motor Inspection Disassembly section for information on taking the motor apart 3 Install the new brushes in reverse order 4 Be certain that the...

Page 92: ... Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Do not press against the outer race of the bearing Pressing against the outer race will damage the bearing and may result in premature failure of the bearing See the illustration below Example of freshly cut commutator Properly undercut and cleaned commutator segments 6 Measure the com...

Page 93: ...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 5 5BC58JBS6129C 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC49JB399C 0 635 0 025 78 97 3 109 19 05 0 75 5BC58JBS6110C 0 635 0 025 78 97 3 109 19 05 0 75 38 1 1 5 A02 4011 1 0 04 69 9 2 75 16 0 62 ER5 4001 XP 2023 1 0 04 69 9 2 75 16 0 62 ER5 4002 1 0 04 69 9 2 75 16 0 62 BP5 4002 1 0 04 69 9 2 75 16 0 ...

Page 94: ...TAYLOR DUNN ...

Page 95: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5 Front 5 ...

Page 96: ...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 main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and ...

Page 97: ... 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 Damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage 10 Remove the lower bolt from the spring hanger 11 Remove the spring bolt from the other end of the spring a...

Page 98: ...s 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 7 Remove the spring from the vehicle NOTE Refer to Replace the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove t...

Page 99: ...akage is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse order 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Always use ...

Page 100: ...TAYLOR DUNN ...

Page 101: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels ...

Page 102: ... tread as the tire approaches its wear limit see illustration below Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section for information regarding replacing the tire 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 ...

Page 103: ...removed from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assembly Tire replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire 1...

Page 104: ...g severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The ...

Page 105: ...replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire 1 Remove the tire from the wheel 2 Cut the old valve stem off of the wheel 3 Remove the valve stem cap from the new valve s...

Page 106: ...TAYLOR DUNN ...

Page 107: ...ABLE OF CONTENTS Battery Service Cleaning 2 Testing 3 Charging 4 Watering 5 Replacing 6 volt batteries only 6 Moist Charge Batteries 7 Storage and Returning to Service 8 Storage 8 Returning to Service 9 ...

Page 108: ...o may result in severe bodily injury and or property damage 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 switch is in the OFF position then remove the key 2 Place the forward reverse switch in the cente...

Page 109: ...ectrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury 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 T...

Page 110: ...nger accepting a charge and should be replaced NOTE Refer to Charger Troubleshooting for information on checking the charging system The highest reading will be the cell that is accepting the most charge This reading will be used to gauge all other cells Compare the specific gravity readings to the highest reading if the difference between any of the cells is more than 30 points then that battery ...

Page 111: ...in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bo...

Page 112: ... be replaced 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batteries 10 Remove the batteries from the vehicle 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compar...

Page 113: ...r that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries When torquing battery hardware use a backup wrench on the battery bolt and tighten the nut Failure to use a backup wrench may damage the battery post 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the cen...

Page 114: ...al 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 battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid ...

Page 115: ...ction for information regarding checking the electrolyte level 8 Test the batteries Refer to Testing section for information on testing the batteries 9 The batteries are now ready to be put back into service 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 t...

Page 116: ...TAYLOR DUNN ...

Page 117: ...bleshooting SYMPTOMS 2 READ THIS FIRST 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 3 SYMPTOM TROUBLESHOOTING GUIDE 19 PMC CONTROL 20 PLUGGING DIODE 22 FREEWHEEL DIODE 23 ISO 24 SOLENOIDS 26 MOTOR 29 REV F ...

Page 118: ...rmal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low Full speed only Does not run in either direction plus there is noise from motor hum or whine with high field current and low armature current J...

Page 119: ...tiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT start in the middle of this troubleshooting guide Start at the beginning and complete each test in the order that they are written DO NOT skip any test unless instructed to do so Once a problem is found stop testing and repair the indicat...

Page 120: ...elerator pedal is depressed then go to the Forward Reverse Switch sequence After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and or property damage The rear drive wheels may rotate during some of the following tests Block the front...

Page 121: ...e 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily...

Page 122: ...rk brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard...

Page 123: ...e all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator pedal to engage MS 1 only If the voltage is not between 6 0 and 6 5 volts then go to the Accelerator sequence Depress the pedal fully If the voltage is not between 11 0 and 11 5 volts then go to the Accelerator sequence Connect voltmeter across the PMC KSI terminal and battery negative With ...

Page 124: ...positive If the voltage is not the same as battery volts then there is an open circuit in the wire from B to the battery Stop troubleshooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground B M A2 B 2 KSI _ Main Battery Positive The voltage shown is for illustration only The actual voltage may vary B M A2 B 2 KSI...

Page 125: ... motor may not be in the same location S2 A1 A2 S1 Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Motor Set the test light voltage to the same voltage as the battery volts Connect the test light across the motor A1 and A2 terminals Close all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator fully If the light ...

Page 126: ...tion the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp should be ON with no more that a few degrees of rotation If the FS 1 lamp does not come on then the module is faulty see note2 below The voltage on the digital display should vary with the position ...

Page 127: ...n Representative for more information If you do not know how to test for continuity refer test to a qualified technician COLD Violet Wire s HOT Red wire s BATTERY MAIN NEGATIVE KEY SWITCH View of the terminals of a typical Key Switch A OFF mV V V Hz FLUKE 79 SERIES II MULTIMETER Connect a voltmeter across the HOT terminal of the key switch and battery negative If the voltage is not at battery volt...

Page 128: ... at battery volts then go to the Accelerator sequence Connect a voltmeter across one of the COLD terminals of the KSI side of the F R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F R Switch in Forward If the voltage is not at battery volts then the F R switch has failed Stop trouble shooting here and repair the problem When the repair is completed c...

Page 129: ...ive NOTE You may skip this test if it was completed in a previous section If the voltage is not at battery volts then check the wiring to battery negative and the negative circuit breaker Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect a voltmeter across the center terminal of the fo...

Page 130: ...attery volts then the F R switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect a voltmeter across the reverse terminal of the forward and reverse side of the F R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F R Switch in r...

Page 131: ... may vary Battery Negative FWD REV Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal fully If the voltage is at battery volts then the wire from the ISO solenoid to the PMC is bad Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehi...

Page 132: ...ry volts then go to theF R Switch sequence Set the test light voltage to the same voltage as the battery volts Connect the test light across the normally open contacts of the reverse solenoid Refer to your vehicles wiring diagram to identify the position of the reverse solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in reverse Depress the accelerator pedal ful...

Page 133: ...m When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F R Switch in forward If the voltage is not at battery volts then go to the Key Switch sequence Connect a voltmeter across th...

Page 134: ...he position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in forward Depress the accelerator pedal fully If the light comes on then the Forward solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Set the test light voltag...

Page 135: ...ceeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Ø Full speed only PMC CONTROL Ø Does not run in either direction plus there is noise from motor hum or whine with high field current and low armature current PLUGGING DIODE Ø Excessive spark when connecting battery ISO Ø Does not run or runs very slow with low motor current and high batte...

Page 136: ...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 main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and suppo...

Page 137: ...e drive wheels to the ground otherwise continue with the next test If the voltage at pin 2 is correct and the voltage at M is correct then there is a short in the harness between the wire connected to the PMC M and main battery negative Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground B M A2 ...

Page 138: ...olution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated 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 pre...

Page 139: ...tant to review the trouble shooting steps that have led to this point The tests may need to be repeated B M A2 B 2 KSI _ The reading shown is for illustration only The actual reading may vary 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 vehicl...

Page 140: ...ere bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury ISO FWD REV ISO Remove the wires and the resistor from the ISO solenoid and perform the following tests Test continuity across the ISO power contacts If you do not k...

Page 141: ... repeated Reading is plus or minus 10 ISO solenoid is shown for reference only The type of solenoid in your truck may look different _ Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure its resistance The meter reading should be 250 Ohms 10 If it is not 250 ohms 10 then replace the resistor Stop trouble shooting here and repair the problem When the rep...

Page 142: ... is a very slight possibility that a failure in the motor could cause these symptoms Perform the tests covered in the MOTOR section first If the motor is OK continue with the following tests Remove the wires from the S1 and S2 terminals on the motor Remove the wire from the M terminal on the PMC control Make sure none of these wires can come into electrical contact with the frame or any other wire...

Page 143: ...o the wire connected to the motor A2 terminal C The wire connected to the motor S2 terminal is shorted to the wire connected to the PMC A2 terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test With the key switch on and the F R switch in forward depre...

Page 144: ...rse solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S1 terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or ha...

Page 145: ...ting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test 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 Di...

Page 146: ...o black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the next test 4 Perform a continuity test around the armature commutator Place one of the test leads on a single commutator segment While holding the first test lead on the segment check the continuity to the other segm...

Page 147: ...g 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Rev E ...

Page 148: ...current state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200 as indicated on a hydrometer before connecting the charger If the charger is connected before the batteries are discharged 50 the batteries may enter an overcharge state before the charger can sense...

Page 149: ...before connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and the electrolyte specific gravity during the charging cycle as indicated below Specific Gravity Using a hydrometer take the specific gravity reading...

Page 150: ... than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC voltage the charger will not turn on If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting Battery volts Full voltage available at the batteries at the time of...

Page 151: ...or has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Connect the charger to the AC source 8 Test the voltage across the two 14 gauge wires This voltage should be the same as the voltage at the AC receptacle rated voltage of the charger If the voltage is l...

Page 152: ...ore continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury HighVoltageinsidethecharger Donottouchanyinternalcomponents while the charger is plugged in Failure to do so may result in serious bodilyinjury Fuse Li...

Page 153: ... RelayTest Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the timer relay is bad Stop here...

Page 154: ...oblem Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one lead from the capacitor Test the capacitor using the capacitor test function on the meter If the capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the lead to ...

Page 155: ...of the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The voltage here will vary depending on the state of charge in the batteries The voltage should be between 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the c...

Page 156: ...p here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirmed that the AC power source is working The DMM should indicate an open...

Page 157: ...ging Cycle 4 Status Light Error CodeTable 5 Troubleshooting 6 Rev C Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batter...

Page 158: ...There are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 volt battery has 3 cells This charger is rated for 115 VAC or 230 VAC operation nominal When switching from one input voltage to the other wait until all LED s are off Switching voltage when any of the ...

Page 159: ...age the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On the charger face plate there is a status light panel that displays the current status of the charger The first light POWER should be ON when the AC cord is connected to a proper AC power source The th...

Page 160: ...ing off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but still show symptoms of overcharging if The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if i...

Page 161: ... charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the charger cooling fins and clean as required 5 AC line voltate too high or too low Check the input voltage It must be within 85 137VAC or 170 264VAC 6 Low battery voltage Extremely discharged battery de...

Page 162: ... be reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the POWER light is ON then the charger has failed and must be replaced If the POWER light is OFF then check the AC power source AC power cable and connections If the source cable and connections are good...

Page 163: ...est Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error CodeTable 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Rev H ...

Page 164: ...ases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to the chart and illustration below for the function of these LED s If an error occurs during charging the charger will beep and display an error code by flashing the status LED s Refer to the Status LE...

Page 165: ...meter and clamp on DC ammete r monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery voltage reaches 2 55 volts per cell When the voltage reaches 2 55 volts per cell the charging current will drop significantly and slowly taper off voltage will remain constant The charger should tu...

Page 166: ...ood working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting Battery volts Full voltage available at the batteries at the time of the test being performed There are no internally servicea...

Page 167: ...harger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Note If only the 100 LED is flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of Defective battery or batteries Excessively discharged batteries Ove...

Page 168: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charger end cap where the DC wires enter 7 Test the voltage across the Battery Positive red and Battery Negative black wires at the lower left of the charger circuit board This voltage should be equal to th...

Page 169: ...vehicle wiring diaram is too large to be legible when printed at this size A full size diagram 22 x 16 is inculded on the CD in PDF format You can access the diagram from a button on the CD menu The diagram is SCH 00017 ...

Page 170: ... wires removed when dir signals are installed KEY DASHED WIRES INCUDED WITH ORANGE BLACK RED GREEN GRAY SPLICE WHT GRN BRAKE LIGHT SWITCH F R SW V V FLASHER switch OPTIONAL Directional BLACK GREEN RED GRAY ORANGE BLACK GRAY YELLOW BLUE GRN R WHITE BL WHT HM OPTIONAL GRN V DI Signal lights optional GRAY BLACK BLK WHT LEFT BL WHT GRN 10 ORG V 15 ORG 8 V WHT BL GRN R 5 6 7 1 R YEL S2 GRN F INTERCONNE...

Page 171: ...nted Strobe Light 51 Cowl Mounted Emergency Light 51 Cowl w Windshield 53 Cab 53 Windshield Wipers 53 Strobe Light On Cab 55 Mirrors Cowl Cab or Door Mounted 55 Mirror Inside Cab 55 Mirror Winks Inside Cab 55 Cab Doors Naugahyde 57 Cab Doors Metal 57 Surrey Top Cover 59 Fiberglass Top Cover 59 Fixed 2nd Seat 61 Deck Fixed 2nd Seat 61 Deck Cover Diamond Plate Fixed 2nd Seat 61 Fixed 3rd Seat 61 Dec...

Page 172: ...Illustrated Parts Parts Page 2 Front Axle ...

Page 173: ... 8 x 1 1 4 w fitting 2 9 88 189 81 Locknut 5 8NC 2 10 18 041 00 Steering Sleeve 22 1 2 1 11 86 501 98 Ball Joint Left 1 12 86 501 99 Ball Joint Right 1 13 86 510 00 Ball Joint Clamp 2 14 88 159 85 Nut Slotted 1 2NF 2 15 12 124 00 Hub 5 Stud 1 Bearing includes 16 17 18 2 16 45 338 00 Seal 1 1 4 ID 2 17 80 017 00 Bearing Tapered 1 ID 2 18 80 103 00 Race Tapered Bearing 2 19 88 228 61 Washer 3 4 SAE ...

Page 174: ... 1 85 512 10 Leaf Spring 1 3 4 x 27 3 8 2 2 16 870 10 Spring Link 4 3 32 213 00 Bushing 3 4 OD x 1 656 Long 6 4 96 248 00 Bolt 9 16NF x 3 12 5 88 169 82 Locknut 9 16NF Grade C 12 6 96 123 00 U Bolt 3 8NC x 2 4 7 88 109 81 Locknut 3 8NC 8 8 16 865 02 Spring Plate 2 Front Suspension ...

Page 175: ...RONT SHOCKS optional Item No Part No Description Qty 1 86 602 00 Shock Absorber 2 2 88 128 60 Washer 7 16 4 3 88 129 81 Locknut 7 16NC 4 4 86 602 13 Lower Shock Mount 2 5 86 602 25 Upper Shock Mount bolt on 1 86 602 61 Kit Front Shocks includes 1 2 3 4 5 1 ...

Page 176: ...Illustrated Parts Parts Page 6 STEERING ...

Page 177: ...ushing plastic after 4 1 2002 1 6 19 011 20 Steering Wheel 1 7 88 199 82 Jam Nut 5 8NF 1 8 19 011 25 Cover Steering Wheel 1 9 00 210 17 Steering Column Weldment 1 10 18 111 30 Pitman Arm 1 11 88 268 62 Lock Washer 7 8 1 12 88 279 82 Jam Nut 7 8NF 1 13 88 128 62 Lock Washer 7 16 3 14 88 120 15 Bolt 7 16NC x 1 Hex Hd 3 15 18 057 11 Sleeve Drag Link 1 16 86 501 98 Ball Joint Left 1 17 86 501 99 Ball ...

Page 178: ...Illustrated Parts Parts Page 8 STEERING GEAR ...

Page 179: ...aring 1 5 18 308 22 Upper Worm Bearing Race 1 6 18 308 77 Housing Steering Gear 1 7 18 308 78 Seal Pitman Shaft 1 8 18 308 80 Nut Pitman Shaft 1 9 18 308 81 Lock Washer Pitman Shaft 1 10 18 308 79 Seal Worm Shaft 1 11 18 308 82 Gasket Side Cover 1 12 18 308 76 Pitman Shaft 1 13 18 308 75 Lash Adjuster 1 14 18 308 85 Shim Kit 1 15 18 308 84 Side Cover 1 16 18 308 86 Nut Lash Adjuster 1 17 18 308 83...

Page 180: ...Illustrated Parts Parts Page 10 PARK BRAKE ...

Page 181: ...in 3 32 x 3 4 Long 6 6 80 410 20 Bearing Brake Shaft 2 7 00 210 05 Rotor Brake Rod 2 8 06 210 11 Brake Cross Shaft 1 9 02 210 72 Spring Link 1 10 85 295 00 Spring Extension 1 11 02 210 01 Park Brake Rod 2 12 96 343 00 Screw Brake Adjusting 2 13 88 099 80 Nut 5 16NF 2 14 88 089 80 Nut 5 16NC 1 15 88 060 14 Bolt 1 4NC x 1 1 2 Hex Hd 2 16 88 069 81 Nut 1 4NC 2 17 88 108 60 Washer 3 8 Cut 2 18 96 772 ...

Page 182: ...Illustrated Parts Parts Page 12 DEADMAN SEAT BRAKE optional ...

Page 183: ... 8NC x 3 4 Hex Hd 2 12 88 109 81 Locknut 3 8NC 2 13 85 234 00 Spring Extension 1 OD x 5 1 2 1 14 71 135 01 Seat Switch 1 15 88 014 13 Screw 6 32 x 1 1 4 Round Hd 2 16 88 019 86 Locknut 6 32 2 17 00 210 31 Mount Seat Shock 1 18 86 007 00 Shock Absorber 1 19 02 210 91 U Mount Seat Shock 1 20 32 207 10 Bushing Rubber 3 8 x 5 8 x 1 Long 2 21 88 080 15 Bolt 5 16NC x 1 3 4 Hex Hd 2 22 88 089 81 Locknut ...

Page 184: ...Illustrated Parts Parts Page 14 MASTER CYLINDER BRAKE LINKAGE ...

Page 185: ...od Master Cylinder Push 1 12 17 104 00 Collar 3 8 ID 1 13 99 510 61 Master Cylinder Rebuild Kit 1 14 99 510 51 Rubber Boot 1 15 99 510 52 Cap Master Cylinder 1 16 99 510 53 Gasket Master Cylinder Cap 1 17 99 510 02 Master Cylinder includes 13 15 16 1 18 88 101 20 Bolt 3 8NC x 3 Hex Hd Grade 5 2 19 99 572 00 Washer Small Dia 1 20 99 565 00 Y Fitting 1 21 99 571 00 Washer Large Dia 1 22 99 578 00 Bo...

Page 186: ...Illustrated Parts Parts Page 16 HYDRAULIC BRAKE LINES ...

Page 187: ...ne 51 Long 1 2 99 605 55 Brake Line Left 1 3 99 605 56 Brake Line Right 1 4 99 564 00 T Fitting 1 5 99 580 20 Brake Hose 2 6 99 576 00 Clip Brake Hose 2 Front optional 7 99 607 51 Brake Line 51 Long 1 8 99 603 53 Brake Line Front 2 9 99 580 20 Brake Hose 2 10 99 576 00 Clip Brake Hose 2 11 99 564 00 T Fitting 1 ...

Page 188: ...Illustrated Parts Parts Page 18 FRONT BRAKES optional REAR BRAKES ...

Page 189: ... Assembly Right 1 1 41 348 70 Pad Disc Brake 2 2 41 348 57 Spacer Disc Brake 2 3 32 240 40 Bushing Mounting Bracket 2 4 88 067 21 Brake Body Bolt 2 5 41 350 70 Hydraulic Brake Body Lt or Rt 1 6 99 588 01 Bleeder Fitting 1 7 99 588 00 Bleeder Valve 1 8 88 069 82 Locknut 1 4NC Grade 8 DO NOT REUSE 2 9 41 350 51 Secondary Plate 1 10 41 350 08 Bracket Hydraulic Disc Brake 1 11 41 350 05 Clip Bolt Lock...

Page 190: ...Illustrated Parts Parts Page 20 Chargers Lestronic P1 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 191: ... 79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25 8ET 230 50 na 36 25 Built In 79 851 10 79 805 72 79 808 00 79 902 00 79 749 11 S O 79 831 00 79 530 00 79 306 23 7710 32 79 305 20 36LC25 8ET 115 60 12 36 25 Portable 79 851 10 79 805 69 79 808 00 79...

Page 192: ...Illustrated Parts Parts Page 22 Chargers Lestronic P2 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 193: ...831 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 79 300 55E 24LC25 8ET 230 50 4 24 25 Built In 79 805 70 79 808 10 79 902 00 79 749 13 79 644 08 79 831 00 79 530 00 79 306 23 7105 01 79 300 50 24LC25 8ET 230 50 4 24 25 Portable 79 851 10 79 805 64 7...

Page 194: ...ral part of the charger When replacing the charger do not cut and splice the AC cord Cutting the AC cord will void the charger warranty NOTE The Signet model HBS series charger replaces all previous Signet models Model HBS series charger shown Model HBS for GEL Batteries PART DESCRIPTION 24 volt Charger Assembly see note 36 volt Charger assembly see note 48 volt charger assembly see note Model HB ...

Page 195: ...Illustrated Parts Parts Page 25 This page intentionally left blank ...

Page 196: ...Illustrated Parts Parts Page 26 Motors P1 16 17 6 8 15 Typical GE Motor 9 12 13 9 5 3 4 2 1 14 10 11 7 ...

Page 197: ... A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 5BC49JB399C 70 054 00 45 508 00 80 504 00 80 200 00 97 100 00 70 203 10 98 622 00 98 623 00 97 178 00 97 179 00 70 210 62 70 195 10 70 195 10 80 412 00 30 802 00 70 105 00 70 104 10 N A N A 5BC58JBS6129B 70 049 05 80 209 00 70 201 15 70 210 51 70 049 06 70 210 51 85 412 00 70 104 15 70 172 15 32 508 15 88 089 91 88 088 61 Motor Spe...

Page 198: ...Illustrated Parts Parts Page 28 16 17 6 8 15 Typical GE Motor 9 12 13 9 5 3 4 2 1 14 10 11 7 Motors P2 ...

Page 199: ... 00 N A N A N A N A N A N A N A N A N A 70 170 30 85 403 00 70 421 00 70 170 10 70 180 01 70 417 00 88 089 91 88 088 61 A02 4011 70 049 40 80 212 00 N A 70 412 20 N A 70 109 00 70 180 00 70 417 00 88 089 91 88 088 61 ER5 4001 70 049 05 80 212 00 N A 70 412 20 N A 70 109 00 70 180 00 70 417 00 88 089 91 88 088 61 Motor Spec Motor Part 5BC49JB430 70 054 20 N A N A N A N A N A N A N A N A N A N A N A...

Page 200: ...e 30 REAR AXLE Item No Part No Description Qty 1 97 236 00 Wheel Lug Nut 10 2 Wheel Bolt 10 3 41 152 00 Axle includes 2 2 4 80 503 00 Axle Bearing Ball Type 2 5 32 515 00 Bearing Retainer 2 6 45 301 00 Seal Rear Axle 2 REAR AXLE ...

Page 201: ... 00 Pulley 4 Belt 3 00 OD used on 12 0 mph drive 1 3 30 620 00 Belt 3V x 400 R Edge 4 4 88 239 82 Nut Motor 3 4NF Jam 1 5 97 250 00 Nut Pinion 3 4NF 1 6 00 380 96 Motor Mount 1 7 88 100 11 Bolt 3 8NC x 1 Hex Hd 4 8 70 422 00 Strap Motor Mount 2 9 88 109 87 Nut Keps 3 8NC 4 10 41 381 10 Motor Adjuster 1 11 96 316 00 Bolt All Thread 1 2NC x 3 1 12 88 149 80 Nut 1 2NC 1 BELT DRIVE ...

Page 202: ...Illustrated Parts Parts Page 32 POWER TRACTION DRIVE ...

Page 203: ... 3 9 30 081 00 Motor Sprocket 14 Tooth 1 10 16 415 00 Spacer 1 11 30 093 00 Pinion Sprocket 81 Tooth 1 12 30 508 20 Drive Chain SSG 1 13 44 352 53 Backing Plate 1 14 88 101 13 Bolt 3 8NC x 1 1 4 Hex Hd 5 15 88 080 19 Bolt 5 16NC x 2 3 4 Hex Hd 9 16 41 989 00 Drain and Fill Plugs 2 17 43 201 30 Chain Cover 1 18 45 002 00 Chain Case Gasket 1 19 45 021 00 Backing Plate Gasket 1 20 88 089 81 Locknut 5...

Page 204: ...Illustrated Parts Parts Page 34 REAR DIFFERENTIAL ...

Page 205: ...5 1 6a 31 234 00 Ring and Pinion Gear Set 3 00 1 7 41 997 00 Oil Plugs 2 8 41 291 51 Differential Housing 1 9 80 555 00 Rear Pinion Bearing 1 10 80 554 00 Front Pinion Bearings 2 11 41 711 00 Pinion Housing Shim 1 12 80 702 00 O Ring 1 13 44 340 90 Pinion Housing w Races 1 14 16 419 00 Shim 002 as req d 14a 16 420 00 Shim 010 as req d 14b 16 411 00 Shim 005 as req d 15 16 415 00 Spacer 1 16 80 125...

Page 206: ...y 1 85 513 10 Leaf Spring 2 2 16 861 00 Spring Pad 2 3 88 101 18 Bolt 3 8NC x 2 1 2 Hex Hd Grade 5 8 4 88 109 81 Locknut 3 8NC 8 5 16 870 10 Spring Link 4 6 32 213 00 Bushing 3 4 OD x 1 656 Long 6 7 96 248 00 Bolt 9 16NF x 3 6 8 88 169 82 Locknut 9 16NF Grade C 6 REAR SUSPENSION ...

Page 207: ...81 12 Bolt 5 16NC Square Hd Tin Lead 12 7 88 089 80 Nut 5 16NC Tin Lead 12 8 01 534 43 Battery Box Angle 1 9 88 060 09 Bolt 1 4NC x 3 4 Hex Hd 1 10 88 069 87 Nut 1 4NC Keps 1 11 77 042 00 Battery 6 Volt 217 amp hour standard 6 11 77 044 00 Battery 6 Volt 230 amp hour optional 6 11 77 047 00 Battery 6 Volt 244 amp hour optional 6 11 77 042 80 Battery 6 Volt 217 amp hour optional 6 11 77 047 80 Batt...

Page 208: ...Illustrated Parts Parts Page 38 Tires Wheels 10 Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 ...

Page 209: ...uter Wheel 2 5 bead 5 12 041 00 Wheel Assembly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF Hex Bolt grade 5 7 88 109 62 3 8 Split Lock Washer 8 88 119 80 3 8 NF Hex Nut 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only Not Shown 11 0...

Page 210: ...Illustrated Parts Parts Page 40 CONTROL PANEL ...

Page 211: ...ker 135 amp 1 8 79 844 20 Circuit Breaker 200 amp optional used w 4a 1 9 73 004 20 Horn 12 V 1 10 88 089 80 Nut 5 16NC 4 11 88 088 62 Lockwasher 5 16 4 12 88 080 11 Bolt 5 16NC x 1 Hex Hd 4 13 61 838 41 Bus Bar 5 8 x 1 1 2 Hole Centers 2 14 61 838 42 Bus Bar 3 8 x 2 5 8 Hole Centers 2 15 88 099 91 Nut 5 16NF Thin Pattern 10 16 88 088 63 Lockwasher 5 16 Internal Tooth 10 17 88 049 80 Nut 10 32 6 18...

Page 212: ...Illustrated Parts Parts Page 42 CONTROL PANEL EE ...

Page 213: ...8 099 91 Nut 5 16NF Thin Pattern 10 15 88 088 63 Lockwasher 5 16 Internal Tooth 10 16 88 049 80 Nut 10 32 6 17 88 048 62 Lockwasher 10 6 18 78 302 50 Resistor 250 ohm 5 watt 1 19 00 210 02 Control Box 1 20 04 210 23 Lid Control Box 1 21 98 451 20 Foam Tape 1 8 x 1 2 Wide 8ft Not 75 146 71 Harness Control Box 1 Shown 75 149 60 Harness Power 1 75 146 70 Harness Control Vehicle 1 00 210 41 PAN SPLASH...

Page 214: ...ty 1 98 254 00 Accelerator Pedal Aluminum 1 2 98 254 25 Mount Accelerator Pedal 1 3 03 210 96 Mounting Plate Accelerator 1 4 62 033 00 Accelerator Module 1 5 88 060 09 Bolt 1 4NC x 3 4 Hex Hd 2 6 88 065 08 Screw 1 4NC x 5 8 Truss Hd 6 7 88 069 81 Locknut 1 4NC 10 ACCELERATOR MODULE ...

Page 215: ... 00 Switch Forward Reverse 1 3 74 009 00 Battery Status Indicator 1 4 74 000 00 Hourmeter optional 1 5 71 039 10 Headlight Switch 1 6 94 304 10 Instrument Panel 1 7 88 817 07 Screw 8 x 1 2 Tapping 6 8 71 039 20 Plug Rocker Switch Hole 1 8a 71 039 10 Rocker Switch On Off optional 1 9 00 610 01 Instrument Console painted black 1 10 88 817 07 Screw 8 x 1 2 Self Tapping 6 INSTRUMENTATION ...

Page 216: ...Illustrated Parts Parts Page 46 DECALS MISCELLANEOUS STANDARD PARTS ...

Page 217: ...al Vehicle Data 1 2 94 319 00 Decal Battery Disconnect 1 3 94 313 00 Decal Battery Warning 1 4 94 313 20 Decal Safety Warning 1 5 94 309 00 Decal Brake Warning 1 6 94 384 01 Decal Not Motor Vehicle 1 7 71 501 00 Horn Button 1 8 88 025 06 Screw 8 32 x 1 2 Truss Hd 2 9 88 028 62 Lockwasher 8 2 10 88 029 80 Nut 8 32 2 ...

Page 218: ...Illustrated Parts Parts Page 48 MISCELLANEOUS STANDARD PARTS Cont d ...

Page 219: ...Retainer Headlight 4 7 90 444 00 Deckboard 75 1 4 x 41 1 8 90 179 00 Backrest 1 9 90 174 00 Seat Cushion 17 x 19 1 2 1 10 90 173 00 Seat Cushion 17 x 18 1 11 88 837 09 Screw Sheet Metal 14 x 3 4 Phillips Truss Hd 12 12 02 210 25 Angle Wire Cover 1 13 91 513 00 S Clip 2 14 00 210 22 Light Guard 1 15 88 065 06 Screw 1 4NC x 1 2 Phillips Truss Hd 6 16 88 069 81 Locknut 1 4NC 6 17 72 025 00 Light Stop...

Page 220: ...Illustrated Parts Parts Page 50 Options ...

Page 221: ...obe Light 1 12 88 025 06 Screw 8 32 x 1 2 Truss Hd 3 13 88 028 62 Lockwasher 8 3 14 88 029 80 Nut 8 32 3 15 88 817 09 Screw Sheet Metal 8 x 3 4 Phillips Hd 2 16 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 4 17 88 068 62 Lockwasher 1 4 4 18 88 069 83 Acorn Nut 1 4NC 4 71 100 00 Toggle Switch 1 75 106 10 Harness Strobe On Pole 1 Cowl Mounted Emergency Light 19 72 023 15 Light Emergency Red 1 20 72...

Page 222: ...Illustrated Parts Parts Page 52 ...

Page 223: ...12 00 Cab unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Window Channel Rubber 20 ft 12 90 850 10 Rear Window 1 13 05 210 87 Floor Pan 1 14 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 4 15 88 068 61 Washer 1 4 SAE 4 16 88 069 81 Locknut 1 4NC 4 17 88 102 13 Bolt 3 8NC x 1 1 4 Carriage 4 18 88 108 60 Washer 3 8 4 19 88 109 87 Nut 3 8NC Keps 4 Windshield Wipers 20 74 050 00 Windshield Wiper Mo...

Page 224: ...Illustrated Parts Parts Page 54 ...

Page 225: ...t Right 1 8 92 202 15 Spacer Mirror Bracket 1 or 2 9 91 814 16 Hinge Female Left 1 9a 91 814 17 Hinge Female Right 1 10 88 069 81 Locknut 1 4NC 2 11 88 060 22 Bolt 1 4NC x 3 1 2 Hex Hd 1 12 88 068 61 Washer 1 4 SAE 1 13 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 2 or 4 14 88 068 62 Lockwasher 1 4 2 or 4 15 88 069 83 Acorn Nut 1 4NC 2 or 4 Mirror Inside Cab 16 92 206 00 Mirror Inside 1 17 02 210...

Page 226: ...Illustrated Parts Parts Page 56 ...

Page 227: ...ft Specify Color includes 10 11 12 1 13 91 011 68 Kit Cab Door Left Orange includes 10 11 12 1 91 011 67 Kit Cab Door Right Specify Color includes 10 11 12 1 91 011 69 Kit Cab Door Right Orange includes 10 11 12 1 14 90 853 10 Window Left 1 90 853 11 Window Right 1 15 97 315 58 Door Handle Inner 1 16 91 012 12 Connecting Bar 1 17 16 510 00 Spacer 1 18 88 065 06 Screw 1 4NC x 1 2 Phillups Truss Hd ...

Page 228: ...Illustrated Parts Parts Page 58 ...

Page 229: ...lass Top Cover 91 151 61 Kit Fiberglass Top Cover 1 1 91 028 20 Tubular Top Frame 1 2 91 028 24 Post Top Frame 4 3 88 102 11 Bolt 3 8NC x 1 Carriage 32 4 88 109 81 Locknut 3 8NC 32 5 91 151 00 Fiberglass Top White 1 7 91 028 25 Z Bracket 6 8 96 124 00 U Bolt 1 4NC x 1 3 4 6 9 88 069 81 Locknut 1 4NC 24 10 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 12 11 97 176 00 Washer Neoprene 12 12 88 068 60...

Page 230: ...Illustrated Parts Parts Page 60 ...

Page 231: ...russ Hd 11 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 8 88 068 61 Washer 1 4 SAE 16 88 069 87 Nut 1 4NC Keps 19 Deck Cover Diamond Plate Fixed 2nd Seat 11 90 440 46 Deck Cover Diamond Plate Black 1 12 88 607 09 Rivet 1 4 x 1 2 Starpin 8 Fixed 3rd Seat 90 010 62 Kit 2nd 3rd Seat Orange 1 90 010 65 Kit 2nd 3rd Seat Specify Color 1 13 00 210 01 Seat Bulkhead unpainted 1 14 90 175 00 Seat Cushion B...

Page 232: ...Illustrated Parts Parts Page 62 ...

Page 233: ...te Orange 1 90 545 64 Kit 12 Side Panels Tailgate Specify Color 1 7 00 210 38 Side Panel Left 12 unpainted 1 8 00 210 37 Side Panel Right 12 unpainted 1 9 00 210 58 Tailgate 12 unpainted 1 10 00 210 78 Deck Angle Lower Rear unpainted 1 11 00 210 77 Deck Angle Top Rear unpainted 1 12 30 550 55 Chain 12 1 4 Long 2 13 30 551 00 S Hook 2 14 30 551 10 Hook Tailgate Chain 2 15 00 210 39 Tailgate Pivot 2...

Page 234: ...Illustrated Parts Parts Page 64 ...

Page 235: ...88 082 11 Bolt 5 16NC x 1 Carriage 4 11 88 088 82 Lockwasher 5 16 4 12 88 089 80 Nut 5 16NC 4 Deckboard Foldaway 2nd Seat 13 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 17 14 88 069 88 T Nut 1 4NC x 5 16 4 Prong 3 15 90 440 36 Deckboard Foldaway 2nd Seat 1 16 03 210 21 Side Rail Left unpainted 1 17 03 210 20 Side Rail Right unpainted 1 18 00 210 15 Rear Rail unpainted 1 19 90 440 37 Deckboard Fo...

Page 236: ...Black 1 3 03 210 25 Plate Deck Side Lock 2 4 03 210 24 Plate Deck Center Lock 1 5 88 082 13 Bolt 5 16NC x 1 1 4 Carriage 7 6 88 088 62 Lockwasher 5 16 7 7 88 089 80 Nut 5 16NC 7 8 03 210 23 Angle Forward Deck Lock 1 9 88 737 08 Rivet 3 16 x 5 8 3 10 03 210 28 Deck Lock Rear 1 11 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 2 12 88 069 88 T Nut 1 4NC x 5 16 4 Prong 2 ...

Page 237: ...1 2 90 471 00 Deckboard Front 40 x 35 1 2 1 3 90 472 00 Deckboard Rear 40 x 38 3 4 1 4 90 850 10 Window 13 7 8 x 31 7 8 1 5 98 310 00 Window Channel Rubber 19 ft 6 90 851 00 Window Rear 12 x 18 2 88 080 11 Bolt 5 16NC x 1 Hex Hd 6 88 088 62 Lockwasher 5 16 6 88 089 80 Nut 5 16NC 6 00 210 23 Angle Deck Support 1 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 3 88 069 87 Nut 1 4NC Keps 3 Hardware use...

Page 238: ...Illustrated Parts Parts Page 68 ...

Page 239: ... 6 7 02 210 16 Catch Door Latch 2 8 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 8 9 88 068 61 Washer 1 4 SAE 2 10 88 069 87 Nut 1 4NC Keps 8 98 451 10 Tape Weather Strip 3 4 x 9 16 5 ft Tools Box Doors Rear 91 340 61 Kit Tool Box Doors Rear Orange 1 91 340 65 Kit Tool Box Doors Rear Specify Color 1 11 02 210 21 Tool Box Door Rear Left unpainted 1 12 02 210 64 Tool Box Door Rear Right unpainted 1...

Page 240: ...andard Bed Item No Part No Description 90 545 61 Kit Stake Sides 2 Passenger Std Bed 1 1 90 545 02 Side Gate Black 1 2 90 545 01 End Gate Black 1 3 90 540 00 Gate Hook 2 4 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 4 5 88 069 87 Nut 1 4NC Keps 4 ...

Page 241: ...No Part No Description 90 545 62 Kit Stake Sides 4 Passenger 1 1 90 545 03 Side Gate Left Black 1 2 90 545 04 Side Gate Right Black 1 3 90 545 01 End Gate Black 1 4 90 540 00 Gate Hook 2 5 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 4 6 88 069 87 Nut 1 4NC Keps 4 ...

Page 242: ...90 545 12 Side Gate Front Left Black 1 2 90 545 13 Side Gate Front Right Black 1 3 90 545 14 Side Gate Rear Left Black 1 4 90 545 15 Side Gate Rear Right Black 1 5 90 545 01 End Gate Black 1 6 90 540 00 Gate Hook 4 7 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 8 8 88 069 87 Nut 1 4NC Keps 8 ...

Page 243: ...tch Automatic Coupling 1 4 88 140 14 Bolt 1 2NC x 1 1 2 Hex Hd 4 5 88 148 62 Lockwasher 1 2 6 6 88 149 80 Nut 1 2NC 6 7 88 140 11 Bolt 1 2NC x 1 Hex Hd 2 8 97 835 10 Plate Hitch Mounting 1 9 97 835 00 Angle Hitch Mounting 1 10 97 805 00 Bracket Ball Hitch Mounting 1 7 8 1 10a 97 807 00 Bracket Ball Hitch Mounting 2 1 11 97 811 00 Hitch 1 7 8 Ball 1 11a 97 821 00 Hitch 2 Ball 1 ...

Page 244: ...Illustrated Parts Parts Page 74 ...

Page 245: ...d 1 8 90 440 72 Deckboard Galvenized Rear 1 9 90 440 70 Deckboard Galvenized Front 1 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 13 88 065 09 Screw 1 4NC x 3 4 Phillips Truss Hd 4 88 069 87 Nut 1 4NC Keps 17 Ambulance Safety Panels 10 00 201 77 Safety Panel Right unpainted 1 11 00 201 78 Safety Panel Rear unpainted 1 12 00 210 53 Panel Right Side 1 13 88 065 08 Screw 1 4NC x 5 8 Phillips Truss H...

Page 246: ...TAYLOR DUNN ...

Page 247: ...ted Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex Bolts 3 Other Bolts 3 Hex Nuts 4 Hex Lock Nuts stover 4 Other Nuts 4 Suggested Torque Values non critical hardware 5 Appendix C Brake Lining Handling Precautions 7 REV B ...

Page 248: ...intenance is completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adjust Capability Same as 62 027 61 above plus allows a limited range of speed adjustment 62 027 62 Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41...

Page 249: ... Carriage Bolt grade 2 unless marked as above Other Bolts NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads Hex Bolts S A E Grade 8 L 9 L 9 APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE ...

Page 250: ...d as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A S A E Grade B S A E Grade C Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Grade L 9 ...

Page 251: ... 2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 138 207 213 319 301 451 350 3 4 16 154 231 238 357 336 504 390 7 8 9 222 334 344 515 485 728 565 7 8 14 245 367 379 568 534 802 625 1 8 333 500 515 773 727 1091 850 1 14 373 560 577 866 815 1222 930 1...

Page 252: ... center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Drain plug GT drive 21 25 252 300 28 6 34 Gear case to 3rd member GT drive 18 20 216 240 24 5 27 2 Motor mounting GT Dana 6 5 7 78 84 8 8 9 5 Pinion nut F2 F3 175 175 2100 2100 238 238 Pinion nut GT dri...

Page 253: ...uum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Always wear protective clothing and a respirator when working on the brake pads shoes or their associated components Inhaled asbestos fib...

Page 254: ...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 ...

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