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Taylor-Dunn B 2-48, Operation, T Roubleshooting And Replacement Parts Manual

The Taylor-Dunn B 2-48 Operation, Troubleshooting, and Replacement Parts Manual is a comprehensive guide for users of this versatile electric vehicle. This essential manual covers everything from operation instructions to troubleshooting tips and is available for free download on our website. Get your copy and unleash the full potential of your Taylor-Dunn B 2-48!

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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

. Stop here and repair the

problem.

• Test the voltage across the white and black wires 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 wires from the harness connectors to the charger are bad.

 Stop here

and repair the problem.

• If the timer relay does not pickup (click) when the AC source is connected, then the timer control circuit

or the relay is bad (refer to Timer Relay Test). 

 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 and repair the problem.

• Test the AC voltage across the transformer low voltage secondary

circuit. The transformer low voltage secondary circuit can be
tested at the two solid wires with the brown fiber insulator that
are connected to the anodes on the two diodes. 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 rated DC voltage of the charger, the transformer
is bad and must be replaced. 

Stop here and repair the

problem

.

Summary of Contents for B 2-48

Page 1: ...s i n e s s Serial number Starting 171000 MANUAL MB 248 11 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 248 48AC B 2 48 B0 254 48AC B 2 54 Published 11 14 2006 Revision D Equipped with AC Motor Speed Control ...

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 Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor ...

Page 5: ...System Troubleshooting 12 Chargers Illustrated Parts 13 Appendix A Special Tools 14 Appendix B Suggested Torque Values 15 Appendix C Brake Lining Handling Precautions 16 Taylor Dunn Model B0 248 48AC B0 254 48AC 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 Contents for th...

Page 6: ...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 7: ...ut this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 Conventions 5 How to Identify Your Vehicle 6 B 2 48 and B 2 54 6 BT 2 48 7 BT 2 80 7 Taking Delivery of Your Vehicle 8 Contents ...

Page 8: ...ide Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules and Guidelines Operational Information Operator Responsibilities Owner Responsibilities Control Operation and Location Information Maintenance and Troubleshooting Information Standard Parts List Before serv...

Page 9: ...n of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible for the service and maintenance of the vehicle At no time should a service person allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a quali...

Page 10: ... to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks Electrical and Charger Troubleshooting This section identifies the troubleshooting procedures for testing the electrical sy...

Page 11: ...xtreme care while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure to exercise special care and follow any instructions contained with in a caution NOTE Alerts the reader to additional information about a subject Conventions Symbols and or words that are used to define wa...

Page 12: ...les 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 ANSI B56 8 Theese vehicles are not designed to be driven on public roads or highways They are available in maximum designed speeds ranging from 6 to 16 mph Do not exceed the maximum designed speed Exceeding the maximum ...

Page 13: ...a result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also notify your Taylor Dunn dealer of the claim If there is a problem with the operation of the vehicle DO NOT OPERATE THE VEHICLE Immediately contact your local Taylor Dunn distributor and report the p...

Page 14: ...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 15: ...95002 6 Combination Display 7 Seat Interlock Switch 8 Electrolyte Alarm Optional 8 Accelerator Pedal 9 Foot Brake Pedal 9 Steering 9 Directional Signals Optional 9 Hazard Light Switch Optional 9 Charger Interlock 9 Vehicle Operational Guidelines 10 Safety Guidelines 10 Starting 10 While driving 10 Loading and Unloading 11 Parking 11 Towing 11 Adjustable Controller Parameters 12 Charging your vehic...

Page 16: ...id Batteries B 2 48 350 Amp Solid State Self Diagnostic AC Speed Control B 2 54 450 Amp Solid State Self Diagnostic AC Speed Control Dimensions 307 L X 114 W X 114 H Centimeters 121 L X 45 X 45 H Inches Deck dimensions 104 4 W x 191 L Centimeters 41 25 W x 75 25 L Inches Turning Radius 350 Centimeters 138 Inches Tires B 2 48 5 70 x 8 Load Range C B 2 54 18 x 5 x 14 Solid Extra Cushion Dry Weight 5...

Page 17: ...ts Do not tow this vehicle at more than 5 mph 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 Institute Personnel and Burden Carriers ANSI B56 8 As well as following the safety rules and guidelines outlined in AN...

Page 18: ...nual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive this vehicle Operators must possess the visual auditory physical and mental ability to safely operate this vehicle as specified in the American National Standards Institute Controlled Personnel and ...

Page 19: ...itch to engage the reverse direction DO NOT SWITCH from forward to reverse or vice versa while the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward off reverse switch should be in the center OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle 3a Light Switch The headlight switch is located on the top left ...

Page 20: ...he 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 1 Headlight Switch The headlight switch is located on the top left of the instrument panel Push the right side of the switch to turn the lights on Push the left side of the switch to turn the light off 2 Wiper Switch Optional The wiper switch is located on the left sid...

Page 21: ...f travel in miles per hour Hour Meter Displays total time whole hours vehicle has been in operation Time is accumulated only while the vehicle is moving The example to the right indicates that the vehicle has been in operation for 2 114 hours Hour Meter Battery Status Speedometer System Fault Monitor The gauge has an alpha numeric display that monitors the system status If the system detects a fau...

Page 22: ...eases the braking action Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise If equipped with tilt steering the release lever is located on the lower left of the steering column Pull the lever up to reposition the steering wheel Hazard Light Switch Optional The hazard lig...

Page 23: ... the alarm and light will reset Charger Interlock The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source 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 res...

Page 24: ...key switch while the vehicle is in motion unless the vehicle must be stopped in an emergency Turning the key switch off will immediately apply the park brake stopping the vehicle The abrupt stopping of the vehicle may result in severe bodily injury Do not get off of the seat while the vehicle is in motion Getting off of the seat will activate the seat interlock rapidly slowing the vehicle and appl...

Page 25: ...y applied when the vehicle is stopped There is a parking brake bypass switch located on the right side of the control box see illustration Place this switch in the UP position to tow the vehicle see note below This switch should be in the UP position only while towing the vehicle The switch should be placed in the DOWN position immediately after the towing is completed Leaving the switch in the UP...

Page 26: ...Spd 15 Low battery warning is ON when battery is discharged below this level BDI Reset 80 Battery must be discharged below this value before the BDI will be allowed to reset Reset Volts 2 10 V Battery voltage must be above this value to reset the BDI Modified by the BDI Reset above Discharge Time 60 M Estimated battery discharge rate Miscellaneous SRO Min Speed 3 000 RPM Motor must be below this R...

Page 27: ...l speed Tow Decl LS 8 0 S Time to decelerate when below 20 of full speed Maintenance Meter Function Service Timer 0 H Refer to Maintenance Meter supplementary manual Speed Limits Max see warning 6 250 RPM Governed speed see formula Tow optional 60 Percentage of Max speed when Tow Switch is ON Rev 45 Percentage of Max speed when in reverse Low Batt 40 Percentage of Max speed when low battery warnin...

Page 28: ...e to turn the key switch OFF may result in damage to the vehicles electrical system New Battery Break in New batteries require a break in period of up to 40 cycles The batteries will not have their full capacity during this break in period and may require longer charging times Charging Time Average charging time is 8 to 12 hours The time required to fully charge your batteries will vary depending ...

Page 29: ...harger There is a series of LED s on the faceplate of the charger that serve two functions 1 Status of charge The LED s will display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition All three LED s flashing is an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error co...

Page 30: ... to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries STORING AND RETURNING TO SERVICE Both storing your vehicl...

Page 31: ...y Rules Page 17 SAFETY RULES AND OPERATING INSTRUCTIONS 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 32: ...y 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 inspection Tire condition and pressure External frame damage body Operation of all lights and warning alarms and or horns Smooth and proper operation of all controls such as but not limited to A...

Page 33: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 ...

Page 34: ...s Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids 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 s...

Page 35: ...ntrol System Fault Speed Control System Overheated High Low Speed Switch in Low or wiring to the Switch is Faulty Low Speed Cutback Due to Maintenance Meter Trip optional 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 i...

Page 36: ... 2 Pedal Linkages 3 General Purpose Grease 3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 4 King Pin 2 General Purpose Grease 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug 1 SAE 80W90 Gear Oil 10 Motor Coupler Part Number 94 421 34 Moly Paste Grease 1 2 3 4 2 3 1 4 FRONT Front End Lubrication Rear Axle Lubrication ...

Page 37: ... and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 5 Front Axle Disassembly 6 Replace Front Wheel Bearings 7 Replace the King Pins and Bushings 9 Replace the Steering Knuckle 11 Front Axle Service ...

Page 38: ...grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 9 Lower the vehicle 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle 1 Make ...

Page 39: ...ARINGS 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 nut one flat until the hub turns but is not loose 10 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE ...

Page 40: ... 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 front axle so it can not fall out of the vehicle 9 Disconnect the drag link ball joint or rod end from the steering knuckle or the steering gear pitman arm NOTE Refer to the Replacing the Ball Joints section for information r...

Page 41: ...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 installing the ball joints or rod ends NOTE Refer to Tires and Wheels section for information regarding removing the front wheels 8 Realign the front wheels Refer to Steering Component Service section for inform...

Page 42: ...nd king pin bushings Refer to the following sections for information 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 Front Axle Removal and Installation for information regarding removing the front axle Axle with integral king pin shown ...

Page 43: ...l assembly from the hub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 8 Remove the hub dust cap cotter pin and spindle nut 9 Remove the hub from the steering knuckle NOTE For a front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body NOTE Catch t...

Page 44: ...r to the Brakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle T A Y L OR DUN N T h e B e s t W a y To Go About Yo u r B u s i n e s s R ...

Page 45: ...vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and or property damage Refer to the illustration below for the type of bushing in your vehicle 6 Raise the front of the vehicle and support w...

Page 46: ...steering knuckle or suspension arm Ream or broach bronze bushings to 1 25 0 001 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be replaced 11 Reassemble in reverse order NOTE Refer to Replace the Steering Knuckle for information on installing the steering knuckle NOTE It is recommended that the thrust washers or bearing be replaced whenever replaci...

Page 47: ... to the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then it will be necessary to bleed the brakes NOTE Catch the outer bearing as it falls out 9 Remove the drag link and or tie rod from the steering knuckle Refer to Replace the Ball Joints Tie Rods Drag Link in this section for inform...

Page 48: ...ly The rubber washer must compress slightly to create a seal for the grease NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign the wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 18 Lower the vehicle 19 Reconnect the main positive and negative cables at t...

Page 49: ...teering Gear 8 Replace the Steering Shaft 10 Replace the Steering Wheel 12 Replace the Steering Gear 13 Replace the Ball Joints Tie Rods and Drag Link 14 Replacing the Drag Link 16 Replacing the Tie Rod 17 Center the Steering Gear 18 Pitman Shaft Alignment 18 Repair the Steering Gear 19 Exploded View of Steering Gear 22 ...

Page 50: ...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 Joints section for information regarding removing the ball joint or rod end from the drag link 9 Center the steering gear and tie off the steering wheel so that it cannot rotate NOTE Refer to Center the Steering Gear section for information regarding center...

Page 51: ... 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 Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the ...

Page 52: ...ng wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage Front wheel alignment NOTE It is recommended to center the steering before aligning the front wheels Refer to the Center the Steering section for information 6 Raise the front of the vehicle and support with jack stands 7 Turn the front wheels so that they...

Page 53: ... between the lines at the front of the tires 12 Measure the distance between the lines at the rear of the tires 13 Adjust the tie rod so that the distance at the front and rear of the tires is the same 14 If equipped with ball joints position the ball joint clamps in their original location and orientation 15 Tighten the ball joint clamps 28 32 ft lbs or the rod end jam nuts 16 Untie the steering ...

Page 54: ...ehicle resulting in severe bodily injury and or property damage Typical Ball Joint INSPECT BALL JOINTS NOTE A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end is worn out then all should be replaced as a set 6 Tie off the front wheels so that they cannot turn 7 While watching the ball joints rapidly rotate the steering wheel to the left and right 8 If th...

Page 55: ...the blocks from behind the wheels 10 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 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at...

Page 56: ...ear for information regarding removing the steering gear 6 Raise the front of the vehicle and support with jack stands 7 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball joint from the drag link 8 Loosen the gear lash jam nut and the worm bearing adjuster jam nut 9 Unscrew the gear lash adjuster all of the way to...

Page 57: ...ing gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the parking brake and test drive the vehicle T A Y L OR DUN N T h e B e s t W a y To Go About Yo u r B u s i n ...

Page 58: ...erminals off of the wires 7 Remove the steering wheel NOTE Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 8 Remove the upper steering shaft bushing or bearing from the steering column 9 Remove the steering gear access cover from the steering column if equipped 10 Remove and discard the pinch bolt and nut from the steering shaft coupler NOTE Most v...

Page 59: ...ad to property damage and or severe bodily injury 11 Remove the steering shaft from the vehicle 12 Lightly grease the input shaft splines steering wheel splines and the upper steering shaft bushing 13 Install the steering shaft in reverse order using a new pinch bolt Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft See the illustration to the right 14 Tigh...

Page 60: ...witch 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 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 nut to 28 32 ft lbs 12 Reinstall ...

Page 61: ...ve the steering shaft Refer to Replace the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a pickle fork NOTE On some vehicle configurations it may be required to remove the drag link from the pitman arm Refer to Replace the Ball Joints section for information regarding removing the ball joint from the pitman arm 9 Support the steering gea...

Page 62: ...front of the vehicle and support with jack stands 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 to realign the wheels Rod End Ball Joint 1 Make sure the key switch is in the OFF position then remove the ke...

Page 63: ...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 turns required to remove the ball joint from the sleeve This will make it easier to realign the wheels 11 Install the new ball joint into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the ball joint ...

Page 64: ... 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 Install in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels Always use a lifting strap hoist and jack stan...

Page 65: ...lign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and negative cables at the batteries 13 Remove the 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 forward reverse s...

Page 66: ...t 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 6 Raise the front of the vehicle and support with jack stands 7 Center the steering gear Refer to Center the Steering Gear section for information regarding centering the steering gear 8 Screw both steering stops all of the way ...

Page 67: ...efer to the illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counting the rotation turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction 2 Remove the worm bearing adjuster locking...

Page 68: ... 10 Remove the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Reassembly 1 Lightly lubricate all parts before reassembly 2 Install a new worm shaft seal and pitman shaft seal into the housing 3 Install the upper worm bearing cup 4 Divide the ball bearing into two equal groups 5 Position the ball nut onto the worm...

Page 69: ... Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bolts 14 Pack the steering gear with grease through the open side cover bolt hole and then install the bolt 15 Adjust the steering gear NOTE Refer to Adjust the Steering gear section for information re...

Page 70: ...Maintenance Service and Repair Steering Page 22 Exploded View of Steering Gear ...

Page 71: ...the Service Brakes 4 Two or Four Wheel Hydraulic Disc Brakes 4 Check Master Cylinder Fluid 5 Bleed the Brake System 6 Flush the Brake System 8 Replace Front Disc Brake Pads 9 Replace Rear Brake Pads 11 Hydraulic Disc 11 Replace the Wheel Cylinder 13 Disc Brake Body Assembly front or rear 13 Replace the Master Cylinder 15 Repair the Master Cylinder 17 Brake Service ...

Page 72: ...e pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set 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 conta...

Page 73: ...nd its service limits then the front hub must be replaced Refer to Front Axle Servicefor information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be an integral part of the rear axle If the brake rotor is worn beyond its service limits then the rear axle must be replaced Refer to Transmission section for information regarding replacing the rear ...

Page 74: ...r lack of braking power the entire brake system should be inspected INSPECT THE AUTOMATIC PARKING BRAKE The parking brake is located inside of the motor and is electromagnetically operated To inspect operation of the parking brake disconnect the harness to the parking brake and push the vehicle to confirm that the brake is applied The rubber band dust seal should fit snug around the brake Inspect ...

Page 75: ...e 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 EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the for...

Page 76: ...h area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 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 If equipped with ...

Page 77: ... low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning 14 Repeat the above steps until you are sure that all of the air is expelled from the brake line Any air bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is still air in the brake lines 15 Repe...

Page 78: ...n regarding removing the wheels 10 Remove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder 11 Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into a container for waste brake fluid 12 Position the wheel cylinders so that the bleeder screw is pointing to the ground and ope...

Page 79: ...aining asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full Always use a lifting strap h...

Page 80: ...is found 14 Install new spacer bushings in the mounting bracket 15 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 16 Repeat this procedure for the other wheel 17 Install the tire wheel assembly and lower the vehicle to the ground 18 Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information on the proper master cylinder...

Page 81: ...parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions 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 Hydraulic Disc NOTE It is recommended that both the left and right brake pads be replace...

Page 82: ...found 15 Install new spacer bushings in the mounting bracket 16 Back off the parking brake adjustment wheel park brake only 17 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 18 Repeat this procedure for the other wheel 19 Install the tire wheel assembly and lower the vehicle to the ground 20 Fill the master cylinder to the proper level Refer to Check Master Cylinder...

Page 83: ...nt or rear 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 asbestos Refer to appendix C for recommended handling precautions Do not ingest brake fluid or allow contact with skin or eyes Always wear protect...

Page 84: ...r 12 Disconnect the brake hose from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting Torque the brake body bolts to 11 ft lbs 14 Bleed the brakes Refer to Bleed the Brakes section for information regarding bleeding the brakes 15 Set the park brake 16 Reconnect the main positive and negative cables at the batteries 17 Lo...

Page 85: ...e 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 EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the for...

Page 86: ...5 Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Push Rod Plunger Master Cylinder 1 8 Cutaway of typical master cylinder showing the push rod clearance Only use DOT 3 brake fluid from a...

Page 87: ...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 88: ...TAYLOR DUNN ...

Page 89: ...Rear Hub or Rotor 5 Removing and Installing the Rear Axles Disc Brakes 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3rd Member 12 Assembling the 3rd Member 15 Pinion Bearing Preload 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth 19 ...

Page 90: ...ort the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Place a level on top of the motor Raise the rear of the vehicle until the level indicates that the drive is level with the ground 7 Place an oil drain pan underneath the 3rd member 8 Remove the fill level plug 9 The oil level should be very close to the bottom of the level plug op...

Page 91: ... of the level plug opening Refer to the Lube Chart section for information regarding type of oil 11 Replace the fill plug 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from 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 forward reverse switch in the center O...

Page 92: ... hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the motor NOTE Label the motor wires with the number of the motor terminal before they are removed from the motor 7 If equipped remove the motor support bracket u bolt only used on larger motors 8 Remov...

Page 93: ...g the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the rotor 11 Install in reverse order a Lightly grease the axle splines b Refer to section Brake Service for information regarding installing the brake pads c Thoroughly clean the thr...

Page 94: ...he 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 This procedure does not require that the rear end or drive assembly be removed from the vehicle NOTE The axle hub bolt has a special thread locking compound applied to the threads...

Page 95: ...d They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage Refer to sectionRear Brakes in Illustrated Parts for the part number of the bolt 17 If the wheel hub was removed install the hub and rotor Torque the hub bolt to 275 ft lbs 17 Fill with oil to the level of the fill...

Page 96: ...cables from the spring axle mounting brackets and brake arms 7 Disconnect the wiring from the motor 8 Disconnect the hydraulic brake lines from the left and right brake bodies 12 Reinstall the drive in reverse order 13 Bleed the brake system Refer to Bleed the Brake System for information regarding bleeding the brakes 14 If equipped with a hand operated park brake set the brake 15 Lower the vehicl...

Page 97: ...t 5 Disconnect the main positive and negative cables at the batteries 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove the drive assembly from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 9 Remove the motor only if the e...

Page 98: ... the output gear from the pinion shaft NOTE If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 16 Remove the six retaining bolts holding the gear case to the 3rd member housing NOTE Make note of the angle of the gear case 17 Remove the gear case housing from the...

Page 99: ... the front flange on the 3rd member and gear case cover NOTE Pack the motor seal with non acetic based grease 20 Fill the differential with oil NOTE Refer to Changing the Differential Oil for information on filling the drive with oil 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Lubrica...

Page 100: ...ion on removing the drive from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tube 11 Remove the primary reduction ge...

Page 101: ... 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 16 Remove the carrier bearing adjusting nut roll pin from the 3rd member housing then remove the carrier adjusting nut Roll Pin ...

Page 102: ... 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 Remove the pinion shaft from the 3rd member 21 Remove the front and rear pinion bearing races 22 Inspect all parts for signs of wear or damage 23 Thoroughly clean all parts ...

Page 103: ...g carrier bearing race ring nut so that the ring gear is not in binding against the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembly 8 Install the cover onto the housing using 4 bolts in a cross pattern and torque to 45 50 ft lbs 9 Pre set the carrier bearing preload by tightening the housi...

Page 104: ...tions 15 Check the gear lash between the ring and pinion gears The gear lash should be 0 005 to 0 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nuts The two ring nuts must be turned equally in opposite directions NOTE To move the ring gear closer to the pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bea...

Page 105: ...n gear case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil section for information regarding the proper oil level 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test dr...

Page 106: ...pinion bearing 3 Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft lbs 4 Measure the torque required to rotate the pinion shaft in the housing 5 The torque required to rotate the pinion shaft should be between 1 1 and 2 9 ft lbs If the torque is not within specifications then add or subtract from the total shim thickness and repeat this procedure until the proper ...

Page 107: ...Shim mm where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the edge of the differential side plate closest to the input shaft see next page D The number on the edge of the differential side plate farthest from the input shaft see next page E The distance in mill...

Page 108: ...Maintenance Service and Repair Transmission Page 20 NOTE Values shown are for reference only C D ...

Page 109: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5 ...

Page 110: ...ed as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 6 Raise the rear of the vehicle and support with jack stands 7 Tie up or support the rear axle so it cannot fall out of the vehicle 8 Unbolt the spring from the axle housing 9 Support the spring so that it cannot fall out of the vehicle 10 Remove the remaining hardware retaining the spring to the frame 11...

Page 111: ... replaced one at a time 6 Raise the front of the vehicle and support with jack stands 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle beam 9 Support the spring so that it cannot fall out of the vehicle 10 Remove the lower bolt from the spring hanger 11 Remove the spring bolt from the other end of the spring and remove the spring from ...

Page 112: ...the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles frame 9 Remove the spring bushing s For internal bushing press the spring bushings out of the two spring eyes and from the mounting eye on the vehicles frame For external bushing Remove the bushings from the spring eye 10 In...

Page 113: ...ge 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 1 Make sure th...

Page 114: ...TAYLOR DUNN ...

Page 115: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Tires and Wheels ...

Page 116: ...ptions available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall information on a tire Tire pressures must be checked when the tire is cold TIRE INSPECTION 6 Check the tire pressure Refer to Tire Inflation section for information on checking the tire pressure 7 In...

Page 117: ...tem 11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak 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 Discon...

Page 118: ...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 119: ...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 120: ...TAYLOR DUNN ...

Page 121: ...BLE OF CONTENTS Cleaning 2 Testing 3 Watering 5 Charging 6 Replacing 6 volt batteries only 7 Moist Charge Batteries 9 Storage and Returning to Service 10 Storage 10 Returning to Service 11 Battery Service ...

Page 122: ... rinse thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive 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 comb...

Page 123: ...th or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact wi...

Page 124: ...umber77 200 00 hydrometer check and record the specific gravity of each cell in the battery pack If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced NOTE Refer to Charger Troubleshooting for information on checking the char...

Page 125: ...bject 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 contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicin...

Page 126: ...gative cables at the batteries CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions 6 Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries 7 Check the electrolyte level in all battery cells If low fill to the correct level with distilled water using part number 77 201 00 battery filler never add additional batte...

Page 127: ...stion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit ...

Page 128: ...hicle 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 compartment prepped and repainted 13 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery compartment 14 Inspect the main positive and negat...

Page 129: ...in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to expl...

Page 130: ...GE AND RETURNING TO SERVICE Storage Thoroughly clean the batteries and battery compartment Refer toCleaning in this section for information regarding cleaning the batteries Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level Store the vehicle or batteries in a cool dry well ventilated area If storing for mo...

Page 131: ...t 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 property damage and or bodily injury 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 ser...

Page 132: ...TAYLOR DUNN ...

Page 133: ...ble when printed at this size A full size diagram 22 x 16 is included on the CD in PDF format You can access the diagram from a button on the CD menu The diagram is SCH 00007 for vehicles with 12 volt accessory tap SCH 00008 for vehicles with 12 volt DC DC converter ...

Page 134: ...TAYLOR DUNN ...

Page 135: ...Control System Diagnostics TABLE OF CONTENTS Test Equipment Required 2 Important Notes and Instructions 2 Status LED Code Table 3 Throttle Module Test 6 Rev C ...

Page 136: ... vehicle exhibits intermittent problems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified DURING ALL TESTS or REPAIRS Turn the ON OFF switch OFF then disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire Failure to do so may cause severe bodily i...

Page 137: ...e Failed Shutdown of main contactor Shutdown of motor Shutdown of EM brake 1 External load attached to controller B terminal Possible non factory installed device 15 Controller Severe Undertemp Shutdown of main contactor Shutdown of motor Shutdown of EM brake Shutdown throttle Full Brake 1 Vehicle operated in temperatures below 40ºC 16 Controller Severe Overtemp Shutdown of main contactor Shutdown...

Page 138: ...ing 32 EM Brake Open Short Shutdown Driver 2 Shutdown Throttle Full brake 3 Faulty motor brake 4 Faulty wiring 33 Coil3 Driver Open Short Shutdown driver 3 1 See note Not used If fault occurs then check controller connector for contamination 35 PD Open Short Shutdown PD 1 See note Not used If fault occurs then check controller connector for contamination 36 Encoder Fault Control mode changed to Li...

Page 139: ...tdown EM bake 1 May occur when adjusting parameters Cycle key switch to clear fault 68 VCL Runtime Error Shutdown main contactor Shutdown motor Shutdown EM bake Shutdown Throttle Shutdown interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD Full brake 1 Controller parameters corrupted Controller must be returned to factory for reprogramming 69 External Supp...

Page 140: ...ry lamp is ON then the analyzer battery should be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer D0 110 53 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 1 Make sure the key switch is in the...

Page 141: ...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 142: ...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 143: ...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 144: ... 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 145: ...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 146: ...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 147: ...imer Relay Test 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...

Page 148: ...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 149: ...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 150: ...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 151: ...est Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 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 152: ...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 153: ...meter and clamp on DC ammeter 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 tur...

Page 154: ...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 155: ...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 156: ...ng 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 t...

Page 157: ...ging Cycle 4 Status Light Error Code Table 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 batte...

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: ...strument Panel Starting Serial 179502 28 Speed Control Panel 30 Wire Harnesses 30 Resetting the Maintenance Meter Function 31 Miscellaneous Electrical 32 Lighting 34 Lestronic Charger page 1 36 Lestronic Charger page 2 38 Signet Charger 40 Portable Charger Wiring 41 Batteries 42 Seat Cushions and Deck 44 Mirrors 46 Miscellaneous Frame Components 46 Decals 48 Cab Options 50 Door Options Steel Cab 5...

Page 164: ...Illustrated Parts Parts Page 2 Front Axle ...

Page 165: ...Illustrated Parts Parts Page 3 Front Axle ITEM PART DESCRIPTION QTY 15 049 71 Axle Beam B 2 48 BT 2 48 B 2 54 1 15 050 76 Complete axle assembly 1 See following pages for component breakdowns ...

Page 166: ...Illustrated Parts Parts Page 4 Steering Knuckle ...

Page 167: ... 43 Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13 2 15 88 228 61 3 4 SAE Flat Washer 2 16 88 527 14 1 8 x 1 1 2 Cotter Pin 2 17 88 239 85 3 4 NF Hex Slotted Nut 2 18 92 104 01 Bearing cap 2 19 21 020 20 Right Steering knuckle 1 21 020 21 Left Steering Knuckle 1...

Page 168: ...Illustrated Parts Parts Page 6 Steering Linkage ...

Page 169: ...ESCRIPTION QTY 1 18 041 05 Tie rod B 2 48 B 2 54 BT 2 48 1 2 86 510 00 Ball joing clamp 4 3 86 501 98 Ball joing left 2 4 86 501 99 Ball joint right 2 5 88 527 11 1 8 x 1 Cotter pin 4 6 18 057 11 Drag link 1 7 88 159 85 1 2NF Castle nut 4 18 104 00 Pitman Arm 1 ...

Page 170: ...trated Parts Parts Page 8 Steering Column Ref Steering Gear 8 9 The steering column is an integral part of the frame and is not shown Part ID 5 is located in the top of the steering column tube 7 4 3 6 5 2 1 ...

Page 171: ...1 2 Hex bolt grade 8 1 4 88 089 84 5 16NF Hex lock nut grade C 1 5 32 248 10 Upper bushing 1 6 20 031 65 Steering shaft assembly incl 3 and 4 1 7 19 011 25 Steering wheel cap 1 8 88 128 62 7 16 Split lock washer 3 9 88 120 15 7 16 x 1 Hex bolt 3 Not Shown 88 279 82 7 8NF Thin pattern hex nut Pitman shaft 1 88 268 62 7 8 Split lock washer pitman shaft 1 ...

Page 172: ...Illustrated Parts Parts Page 10 Steering Gear 1 2 3 4 7 8 Front axle ref 5 9 1 0 1 5 1 3 1 7 1 2 1 1 2 3 1 4 1 6 4 1 6 8 7 5 Front Suspension ...

Page 173: ...1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 1 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side cover 1 16 18 308 86 Jam nut 1 17 18 308 83 Bolt side cover 3 Front Suspension ITEM PART DESCRIPTION QTY 1 96 121 00 U bolt 4 2 85 498 00 Leaf spring B 2 48 2 85 486 00 Leaf spring B 2 54 2 3 32 214 50 Bushing 12 4...

Page 174: ...Illustrated Parts Parts Page 12 Rear Suspension View from rear ...

Page 175: ...85 510 17 Leaf spring 2 15 16 861 46 Spring mounting plate left 1 16 861 47 Spring mounting plate right 1 16 96 114 00 U bolt 4 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2 20 88 149 81 1 2NC Lock nut 4 21 50 460 00 Strap 2 22 98 002 00 Rubber overload spring optional 2 23 86 602 00 Shock 2 24 88 120 17 7 16NC x 2 1 4 Hex bolt 2 88 129 81 7 16NC Lock nut 2 88 128 60 7 16 Flat washer 2...

Page 176: ...Illustrated Parts Parts Page 14 Transmission Gear Case ...

Page 177: ... 1 12 GT 72019 Seal 1 18 GT 71979 Bearing 1 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 24 GT 3287453 Output gear 30 1 0 or 1 GT 3287463 Output gear 24 1 0 or 1 GT 3287473 Output gear 18 1 0 or 1 25 GT 328 Spacer 46 100mm 1 GT 328 Spacer 46 100mm 0 or 1 GT 328 Spacer 46 125mm 0 or 1 GT 328 Spacer 46 150mm 0 or 1 GT 328 Spacer 46 175mm 0 or 1 26 GT 3287903 Shim 0 100mm 0 or 1 GT...

Page 178: ...ial Case Rear Axle Inner bearing on optional double bearing axle does not have an oil seal or o ring Orientation of bearing should have o ring groove adjacent to o ring on outer bearing Axle Shaft Inner Bearing no o ring Outer Bearing O Ring O Ring Groove ...

Page 179: ...PART DESCRIPTION QTY 1 41 154 20 Axle shaft single bearing 2 41 154 25 Axle shaft double bearing 2 2 80 505 20 Bearing 2 2a 80 505 30 Bearing for double bearing axle 2 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub 2 5 88 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5 2 7 96 329 10 Wheel stud 10 Not shown 92 104 10 Hub cover 2 41 290 40 Axle housing left single bearing 1 41 290 43 Axle...

Page 180: ...Illustrated Parts Parts Page 18 Rear Brakes Front Brakes ...

Page 181: ... Brake 4 4 41 348 52 Spacer Disc Brake 4 5 32 240 41 Bearing TeflonR Coated 4 6 99 588 00 Bleeder screw 2 7 99 588 01 Bleeder screw adapter 2 8 88 069 82 Locknut 1 4 NC Gr 8 Do Not Reuse 4 9 41 351 30 Hydraulic Brake Body Front Assembly 2 10 See Brake Lines Brake hose Not shown See Steering Knuckle Front hub and rotor 88 109 81 41 886 00 2 NOTE Brake Body 9 has no internally serviceable parts For ...

Page 182: ...Illustrated Parts Parts Page 20 Brake Lines Master Cylinder ...

Page 183: ...ke light switch regen switch adaptor 2 13 71 110 00 Brake Light Switch 1 14 99 575 32 Adaptor 3 16T x M10 1 0 2 15 99 559 00 T Fitting Single Male Flare to 2 Female Flare 3 16 Tube 1 16 99 603 74 Brake line MS to regen switch 1 Regen switch 1 Master Cylinder ITEM PART DESCRIPTION QTY 1 88 080 14 Bolt 5 16 X 1 1 2 NC Hex Head 2 2 99 511 20 Master Cylinder includes item 3 1 3 99 511 52 Cap Seal Mast...

Page 184: ...Illustrated Parts Parts Page 22 Motor ...

Page 185: ...O ring 1 41 70 400 16 Key 1 42 70 400 17 Snap ring 1 52 70 400 21 Key 1 96 70 400 18 Snap ring 1 98 70 400 19 Snap ring 1 203 70 400 13 Seal 1 224 70 400 09 Rubber Grommet 2 206 70 260 00 Terminal stud 3 291 Hex nut 3 292 Washer 3 293 Washer 3 294 O ring 3 295 Hex nut 3 296 Washer 3 297 Lock washer 3 298 hex nut 3 3900 80 216 05 Sensor bearing assembly 1 Not Shown 45 308 30 Rubber seal around brak...

Page 186: ...Illustrated Parts Parts Page 24 Motor Mount Apply 94 421 34 grease to inside of motor coupler ...

Page 187: ... 88 068 62 1 4 Split lock wahser 4 5 89 060 11 6mm x 1 0 x 50 Hex bolt 3 6 89 111 27 10mm x 1 5 x 20 Hex bolt 2 7 88 128 62 7 16 Split lock washer 2 8 70 456 03 Mounting bracket 1 9 88 067 17 1 4NC x 1 1 4 Hex bolt 1 10 88 099 80 5 16NF hex nut 2 11 88 088 62 5 16 Split lock washer 2 Apply 94 421 34 grease to inside of motor coupler ...

Page 188: ...Illustrated Parts Parts Page 26 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10 ...

Page 189: ...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 11 041 00 8 50 x 8 Tube Not Shown 11 040 00 5 70 x 8 Tube Tire and Wheel Assembli...

Page 190: ...Illustrated Parts Parts Page 28 Instrument Panel Up To Serial 179501 Instrument Panel Starting Serial 179502 ...

Page 191: ...Emergency stop switch 1 8 94 304 11 Dash panel 1 9 88 817 07 Screw 6 10 02 546 02 Dash housing 1 Not shown 97 211 20 U Nut 2 95 313 00 Plug 1 2 hole 0 1 2 Instrument Panel Starting Serial 179502 ITEM PART DESCRIPTION QTY 1 71 039 11 Light Switch 1 2 71 039 11 Wiper Switch 1 3 71 039 11 Strobe Switch 1 4 71 039 02 Forward Reverse Switch 1 5 71 039 11 High Low Speed Switch 1 6 74 010 20 Combination ...

Page 192: ...ts Parts Page 30 Speed Control Panel B 2 48 shown Wire Harnesses PART DESCRIPTION QTY 75 153 08 Dash harness 1 75 153 04 Cable Spy Glass 75 153 07 Main control h1arness 1 75 153 05 60 Control panel 1 75 153 06 Power 1 ...

Page 193: ... Circuit breaker B 10A 1 11 72 501 42 Line contactor B 2 48 1 71 210 13 Line contactor B 2 54 1 12 79 840 20 Circuit breaker B 20A 1 13 88 818 06 8 x 1 2 Screw 10 14 88 060 14 1 4 X 1 1 2 NC HEX HD SCR 4 88 069 81 Hex nut 4 88 068 61 1 4 SAE Flat washer 4 15 96 650 02 Clip 2 16 71 120 30 Brake bypass switch included with harness Not shown 75 442 64 Support Harness connector 1 73 012 33 12v DC DC c...

Page 194: ...Illustrated Parts Parts Page 32 Miscellaneous Electrical Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1 2 Motion Alarms Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4 ...

Page 195: ...witch 2 7 88 069 81 1 4 NC Hex Nylon Locknut Horn Switch 2 8 71 111 00 Brake Light Switch 1 9 88 045 06 10 32 x 1 2 Machine Screw brake light switch 2 10 71 102 10 Seat interlock Switch 1 11 85 030 00 Spring 2 12 96 773 10 Clevis Pin 2 13 02 610 18 Mounting Plate 1 14 88 527 11 Cotter Pin 2 15 96 640 00 Clamp 3 16 Push Mount 16 96 629 80 not shown Clamp Rubber Lined 3 16 ID 96 630 00 not shown Cla...

Page 196: ...Illustrated Parts Parts Page 34 Lighting Stobe Light 4 1 2 3 5 6 7 ...

Page 197: ...information Head and Tail Lights ITEM PART DESCRIPTION QTY 1 72 005 00 5 Round head light 1 or 2 72 072 00 Replacement bulb 1 or 2 2 94 050 10 Rectangular light left steel cab 1 94 050 11 Rectangular light right steel cab 1 72 082 01 Replacement bulb 2 3 94 201 10 Name plate 1 4 72 022 00 Tail light 1 or 2 72 022 51 Tail ligh rubber grommet 1 or 2 72 022 52 Tail light pigtail Turn Signals ITEM PAR...

Page 198: ...Illustrated Parts Parts Page 36 Lestronic Charger page 1 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 199: ... 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 200: ...Illustrated Parts Parts Page 38 Lestronic Charger page 2 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 201: ...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 202: ...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 203: ... 41 Portable Charger Wiring PART DESCRIPTION QTY 75 107 10 HRNSS PORTABLE LESS CHRGER 1 JF3 86181 00 00 RECEPTACLE W INTERLOCK 1 90157 05M19 00 Mounting hardware for receptacle 2 92907 05100 00 4 92907 05600 00 4 98507 05035 00 2 ...

Page 204: ...Illustrated Parts Parts Page 42 Batteries NEG POS NEG POS 3 4 5 6 7 8 1 NEG POS NEG POS NEG POS NEG POS NEG POS NEG POS 12 Volt Negative tap Main Positive Main Negative 1 2 ...

Page 205: ...ote requires special charger 3 50 243 10 Battery rod 4 50 250 00 Battery hold down 5 88 088 66 Flat washer tin lead plated 6 88 069 81 1 4NC Nylon lock nut 7 88 081 12 5 16NC x 1 Square bolt stainless steel 8 88 089 80 5 16NC Hex nut stainless steel 9 88 089 70 5 16 Split lock washer stainless steel Not shown 77 055 15 Battery wattering system for Trojan batteries optional 77 055 12 Battery watter...

Page 206: ...Illustrated Parts Parts Page 44 Seat Cushions and Deck ...

Page 207: ...ckboard 55 x 41 fold away seat option 1 90 441 00 Deckboard 37 1 2 x 41 1 90 440 43 Diamond plate deck cover 32 3 4 x 41 1 90 440 50 Diamond plate deck cover 19 1 2 x 41 1 90 440 54 Diamond plate deck cover 55 3 4 x 41 1 90 440 53 Diamond plate deck cover 19 11 16 x 40 1 2 1 90 440 56 Diamond plate deck cover 21 750 x 41 1 88 607 09 Rivet diamond plate deck 95 530 10 Handle fold away seat 1 5 90 1...

Page 208: ...Illustrated Parts Parts Page 46 Mirrors 92 202 00 Assembly Miscellaneous Frame Components ...

Page 209: ...Bracket for 92 206 00 92 202 00 Mirror mountingr bracket assembly 1 92 202 21 Arm 1 2 92 202 23 Bracket 2 3 92 202 22 Joint 1 4 88 080 14 5 16NC x 1 1 2 Hex bolt 1 5 88 088 61 5 16 SAE flat washer 4 6 88 089 81 5 16NC Lock nut 1 7 88 088 62 5 16 Split lock washer 1 8 88 089 80 5 16NC Hex nut 1 9 88 080 14 5 16NC x 1 1 2 Hex bolt 1 Miscellaneous Frame Components ITEM PART DESCRIPTION QTY 1 79 511 0...

Page 210: ...Illustrated Parts Parts Page 48 Decals ...

Page 211: ...373 10 Vehicle identification 1 4 94 384 21 Brake warning 1 5 94 313 20 Safety warning 1 6 94 384 01 Not a motor vehicle 1 7 94 384 14 When leaving vehicle warning 1 8 94 301 41 Brake fluid 1 9 94 384 17 Do not wash 1 10 94 301 42 Arms and legs 1 11 94 384 24 Emergency stop 1 12 94 384 15 Low speed 13 94 384 06 Emergency brake bypass switch 1 ...

Page 212: ...Illustrated Parts Parts Page 50 Cab Options Steel Cab Fiberglass cab ...

Page 213: ...hield 1 90 850 00 Rear window 1 98 310 10 Rubber windshiel gasket by the foot 94 035 01 Plastic door trim by the foot 90 908 50 Filler panel 2 Fiberglass Windshield Frame illustration not available ITEM PART DESCRIPTION QTY 90 800 00 Windshield 1 91 006 00 Fiberglass frame 1 91 029 00 Support bracket 2 98 310 10 Rubber channel 10 Windshield Wiper illustration not available ITEM PART DESCRIPTION QT...

Page 214: ...arts Parts Page 52 Door Options Steel Cab 1 2 4 5 6 7 8 9 10 11 12 14 15 16 16 17 18 19 20 21 22 23 25 26 27 28 Note Left Door Shown 24 3 13 Steel door detail Door Restraint 16 13 Door frame Cab Door frame 10 29 12 ...

Page 215: ... 011 66 Kit Cab Door Left Specify Color includes 10 11 12 1 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 Specify Color includes 10 11 12 1 14 90 853 10 Window Left 1 Not Shown 90 853 11 Window Right 1 15 97 315 58 Door Handle Inner 2 16 91 012 12 Connecting Bar 2 17 16 510 00 Spacer 2 18 88 065 06...

Page 216: ...Illustrated Parts Parts Page 54 3 8 9 6 7 5 4 2 1 Typical door assembly Door Options Fiberglass Cab ...

Page 217: ...908 98 Side Curtain Left 1 90 908 99 Side Curtain Right 1 3 97 315 53 Handle Assembly Outer 2 4 97 315 51 Door Latch 2 5 97 315 54 Handle Assembly Inside 2 6 97 304 50 Snap Fastner 12 7 88 737 08 Rivet 5 32 X 5 8 14 8 88 029 86 Locknut 8 32 4 9 88 025 08 Screw 8 32 X 5 8 Truss Head 4 10 11 12 13 14 94 036 00 Drip moulding 1 15 91 810 00 Lower hinge 2 17 104 00 Collar 2 16 91 809 10 Upper hinge 2 ...

Page 218: ...Illustrated Parts Parts Page 56 Hydraulic Dump Body Option ...

Page 219: ... 1 17 88 149 81 Locknut 1 2 NC Hex Head 1 18 19 20 21 72 022 51 Rubber Mounting Ring 1 22 71 102 15 Switch Dump Bed 1 23 91 285 01 Dump Bed 1 Not shown 90 442 00 Deckboard 1 AA 000 11 Fluid Hydraulic Dextron 2 Quart 1 75 124 00 Wire Harness 1 78 106 00 Buss Bar Circuit Breaker up to S N 1 79 843 00 Circuit Breaker 100 AMP 2 Pole up to S N175999 1 71 610 02 Circuit breaker mounting plate unp to S N...

Page 220: ...Illustrated Parts Parts Page 58 Rear Cargo Box 1 2 3 4 5 6 5 Top Covers ...

Page 221: ... 1 5 98 310 00 Ruber window gasket by the foor 6 90 851 00 Rear window 2 Not shown 94 320 10 Load line decal 1 00 210 23 Deck support angle 1 Top Covers ITEM PART DESCRIPTION QTY 91 151 00 Fiberglass top 1 94 035 01 PLASTIC TRIM STRIP SNAP ON 29 91 028 25 Z BRACKET 6 96 124 00 U BOLT 1 75L X 1W X 1 4NC 6 97 176 00 WASHER NEOPRENE 3 8X3 4X3 12 98 451 00 TAPE WEATHER STRIP 2 91 101 00 Surry top ...

Page 222: ...Illustrated Parts Parts Page 60 Hitches ...

Page 223: ...it lock washer 4 NOTE Replacement parts only Ladder rack cannot be added to an existing vehicle PART DESCRIPTION QTY 00 201 44 Ladder rack 1 00 201 49 Ladder rack with stake side pockets 1 88 102 11 3 8 X 1 NC CARRIAGE BOLT 14 88 108 62 3 8 LOCK WASHER 14 88 109 81 3 8 NC LOCK NUT1 14 90 473 00 Deckboard 52 375 x 40 375 1 90 473 10 Deckboard 22 0 x 40 375 1 Ladder Rack Option B2 004 66 and B2 006 ...

Page 224: ...TAYLOR DUNN ...

Page 225: ...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 C ...

Page 226: ...s of the AC motor speed control system 62 027 64 Dealer level maintenance handset Used for diagnostics and adjusting of the AC motor speed control system Start switch standard Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41 350 13 Pin Removing Tool Used to remove pins and sockets from AMP connectors 75 440 55 Pin Removing Tool Used to remove pins and s...

Page 227: ... 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 228: ...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 229: ... 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 230: ... 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 231: ...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 232: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com ...

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