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Taylor-Dunn B0-012-10, Operation, T Roubleshooting And Replacement Parts Manual

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Taylor-Dunn B0-012-10 Operation, T Roubleshooting And Replacement Parts Manual Download Page 213

Illustrated Parts

Parts

 

 

Page 43

CONTROL PANEL-EE

Item No.

Part No.

Description

Qty

1

72-501-39

Forward or Reverse Solenoid

2

2

88-838-06

Sheet Metal Screw, #14 x 1/2”

8

3

04-210-20

Panel, Control Box Floor

1

4

62-205-00

Speed Controller, 400 amp

1

5

72-501-38

ISO Solenoid

1

6

88-818-06

Sheet Metal Screw, #8 x 1/2”

30

7

79-840-00

Circuit Breaker, 10 amp

2

8

79-844-20

Circuit Breaker, 200 amp

1

9

88-089-80

Nut, 5/16NC

4

10

88-088-62

Lockwasher, 5/16

4

11

88-080-11

Bolt, 5/16NC x 1” Hex Hd

4

12

61-838-41

Bus Bar, 5/8” x 1-1/2” Hole Centers

2

13

61-838-42

Bus Bar, 3/8” x 2-5/8” Hole Centers

2

14

88-099-91

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,FWD

1

00-210-42

PAN,SPLASH,CENTER,FWD

1

00-210-43

PAN,SPLASH,CENTER,REAR

1

00-210-44

PAN,SPLASH,REAR

1

00-210-70

ANGLE,GUARD,WIRE,FWD

1

00-210-71

ANGLE,GUARD,WIRE,CENTER

1

00-210-72

ANGLE,GUARD,WIRE,REAR

1

00-210-73

BAR,GUARD,VENT,BATTERY

2

78-321-10

STRAP,STATIC GROUND,15 IN LONG

2

94-201-20

DECAL, EE

2

94-320-21

DECAL,CHARGING WARNING, EE

1

94-373-14

DECAL,VEH ID,EE CARRIER

1

Summary of Contents for B0-012-10

Page 1: ...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 wit...

Page 2: ......

Page 3: ...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 th...

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: ...ontrol 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 Tayl...

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: ...ble 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...

Page 8: ...pplicable 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 T...

Page 9: ...entions 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 a...

Page 10: ...s 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 v...

Page 11: ...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...

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: ...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 W...

Page 14: ...d 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 Steer...

Page 15: ...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 P...

Page 16: ...f 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...

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 accele...

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 c...

Page 19: ...harging 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 char...

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 drivin...

Page 21: ...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 s...

Page 22: ...N 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 s...

Page 23: ...tteries 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 includ...

Page 24: ...h 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 C...

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...

Page 26: ...TAYLOR DUNN...

Page 27: ...nce 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...

Page 28: ...or 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 c...

Page 29: ...n 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 A...

Page 30: ...s 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...

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...

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 switc...

Page 33: ...ings 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...

Page 34: ...ion 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...

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 Remo...

Page 36: ...ys 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...

Page 37: ...ectric 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 supp...

Page 38: ...s 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 pos...

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...

Page 40: ...ands 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...

Page 41: ...nt 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 steer...

Page 42: ...evices 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 C...

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...

Page 44: ...ailure 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 sw...

Page 45: ...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 pro...

Page 46: ...g 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...

Page 47: ...ns 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 o...

Page 48: ...amp 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...

Page 49: ...st 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...

Page 50: ...teering 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 Rele...

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 an...

Page 52: ...r 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 h...

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...

Page 56: ...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...

Page 57: ...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...

Page 58: ...nd 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 cable...

Page 59: ...luid 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 b...

Page 60: ...t 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 se...

Page 61: ...e 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 movem...

Page 62: ...o 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 Fai...

Page 63: ...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 Pla...

Page 64: ...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...

Page 65: ...eft 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 clothi...

Page 66: ...nsert 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 pr...

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 s...

Page 68: ...scard 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 a...

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

Page 70: ...nts 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...

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 de...

Page 72: ...TAYLOR DUNN...

Page 73: ...e 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 Me...

Page 74: ...ement 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...

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...

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...

Page 77: ...e 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...

Page 78: ...lts 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 s...

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...

Page 80: ...nd 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...

Page 81: ...ion 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...

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 pin...

Page 83: ...ion 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...

Page 84: ...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 standa...

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

Page 86: ...TAYLOR DUNN...

Page 87: ...tors 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 Se...

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...

Page 89: ...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...

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 R...

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...

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...

Page 93: ...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...

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: ...ey switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movemen...

Page 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...

Page 98: ...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 inj...

Page 99: ...kage 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 1...

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 Ti...

Page 103: ...emoved 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 T...

Page 104: ...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 r...

Page 105: ...eplacement 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 pro...

Page 106: ...TAYLOR DUNN...

Page 107: ...BLE 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...

Page 108: ...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...

Page 109: ...ctrolyte 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...

Page 110: ...ger 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 char...

Page 111: ...n 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 i...

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 bat...

Page 113: ...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...

Page 114: ...l 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...

Page 115: ...tion 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 s...

Page 116: ...TAYLOR DUNN...

Page 117: ...leshooting 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...

Page 118: ...mal 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 hi...

Page 119: ...iple 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 troubleshoo...

Page 120: ...lerator 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...

Page 121: ...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 o...

Page 122: ...k 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...

Page 123: ...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 Accel...

Page 124: ...ositive 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 co...

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 batter...

Page 126: ...ion 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...

Page 127: ...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 t...

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 K...

Page 129: ...ve 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...

Page 130: ...ttery 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 C...

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 f...

Page 132: ...y 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...

Page 133: ...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 n...

Page 134: ...e 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 so...

Page 135: ...eeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL Does not run in either direction plus there is noise from moto...

Page 136: ...n the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect...

Page 137: ...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...

Page 138: ...ution 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...

Page 139: ...ant 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 su...

Page 140: ...re 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 s...

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 fro...

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...

Page 143: ...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 Whe...

Page 144: ...se 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 complet...

Page 145: ...ing 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 swit...

Page 146: ...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 Perf...

Page 147: ...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 BEF...

Page 148: ...urrent 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...

Page 149: ...efore 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 tu...

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 vo...

Page 151: ...r 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 Con...

Page 152: ...re 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 F...

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 co...

Page 154: ...blem 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 Disconn...

Page 155: ...f 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 volta...

Page 156: ...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 A...

Page 157: ...ing 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 control...

Page 158: ...here 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 vol...

Page 159: ...ge 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 t...

Page 160: ...ng 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 stil...

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 c...

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...

Page 163: ...st 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 t...

Page 164: ...ses 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...

Page 165: ...eter 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 batter...

Page 166: ...od 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...

Page 167: ...arger 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 the...

Page 168: ...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...

Page 169: ...ehicle 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 di...

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...

Page 171: ...ted 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...

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...

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 8...

Page 175: ...ONT 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 bo...

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

Page 177: ...shing 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...

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

Page 179: ...ring 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...

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

Page 181: ...n 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 Ro...

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...

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

Page 185: ...d 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...

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

Page 187: ...e 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...

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...

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...

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: ...31 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 7...

Page 194: ...al 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 Si...

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...

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 0...

Page 200: ...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...

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...

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...

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

Page 205: ...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 Ho...

Page 206: ...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...

Page 207: ...1 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 Vol...

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: ...ter 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 3...

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

Page 211: ...er 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 4...

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

Page 213: ...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...

Page 214: ...y 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 06...

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...

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

Page 217: ...l 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...

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

Page 219: ...tainer 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 Phillip...

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

Page 221: ...be 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 Tru...

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

Page 223: ...2 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...

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

Page 225: ...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 W...

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

Page 227: ...t 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 include...

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

Page 229: ...ass 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 Fibergla...

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

Page 231: ...uss 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...

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

Page 233: ...e 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...

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

Page 235: ...8 082 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...

Page 236: ...lack 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 Forwa...

Page 237: ...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 08...

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 Doo...

Page 240: ...ndard 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 P...

Page 241: ...o 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 Sc...

Page 242: ...0 545 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 0...

Page 243: ...ch 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...

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

Page 245: ...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...

Page 246: ...TAYLOR DUNN...

Page 247: ...ed 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 critica...

Page 248: ...ntenance 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...

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 Toq...

Page 250: ...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 marki...

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 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 Dra...

Page 253: ...um 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 u...

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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