Taylor-Dunn B0-248-36 Operation, T Roubleshooting And Replacement Parts Manual Download | Manualshive

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SAFETY RULES AND OPERATING INSTRUCTIONS

Safety Rules
Page 4

STANDARD SPECIFICATIONS* (MODEL BT 2-48)

ITEM

VOLTAGE

SPECIFICATION

Occupancy

10

Electrical System

36 Volt

Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp

48 Volt

Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp

Dimensions

307L X 162W X 117H Centimeters
121L X 64X 46H Inches

Turning Radius

363 Centimeters (143 Inches)

Tires

5.70 x 8 Load Range B

Dry Weight

695 kg (1,533 lbs)

Without Batteries

Maximum Load

1360 kg (3,000 lbs)

Motor, DC

36 Volt

4.5 kW, (6.0 Horse Power) for 60 min

Separately Excited Field

8.6 kW, (11.5 Horse Power) for 5 min

48 Volt

6.0 kW, (8.0 Horse Power) for 60 min
12.2 kW, (16.3 Horse Power) for 5 min

These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).

* - Specifications are subject to change without notice.

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Summary of Contents for B0-248-36

Page 1: ...anual Published 7 7 2008 Revision B EQUIPPED WITH GT DRIVE SYSTEM GT Drive Models Inlcuded B0 248 36 B 2 48 36 volt B0 248 48 B 2 48 48 volt B0 254 36 B 2 54 BT 248 36 36 volt Back to Back Tram BT 248...

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: ...u s i n e s s R A small sample of the many types of vehicles offered by Taylor Dunn B 2 48 36 Equipped with optional hydraulic dump bed BT 2 80 Eight passenger tram B 1 00 Personnel carrier C 4 25 Hu...

Page 5: ...g 12 Wire diagram 13 Illustrated Parts 14 Appendix A Special Tools 15 Appendix B Suggested Torque Values 16 Appendix C Brake Lining Handling Precautions 17 Taylor Dunn Models B0 248 36 B0 248 48 B0 25...

Page 6: ...TAYLOR DUNN...

Page 7: ...Introduction About 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 Taking Delivery of Your Vehicle 8 Contents...

Page 8: ...de 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 Gui...

Page 9: ...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 fo...

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 inform...

Page 11: ...treme 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 exe...

Page 12: ...ese 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 max...

Page 13: ...INTRODUCTION Introduction Page 7 B 2 48 and B 2 54 Vehicles manufactured before 2007 and up to March 2007 BT 2 48 BT 2 80 Under front left passenger cushion Under deck on deck rail...

Page 14: ...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...

Page 15: ...Optional 9 Accelerator Pedal 9 Foot Brake Pedal 9 Charger Interlock 10 Seat Interlock Switch 10 Electrolyte Alarm Optional 10 Park Brake 10 Trailer Brake Module optional 11 Smart View Display 12 Fault...

Page 16: ...ing 24 1 Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Smart View Display Battery Status Indicator Hour Meter System Status Monitor Key Switch Horn Button Forward R...

Page 17: ...ontrol 400 Amp B 2 54 36 Volt 6 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 500 Amp Dimensions B 2 48 B 2 54 307 L X 114 W X 114 H Centimeters 121 L X 45 X 45 H Inches Deck dimen...

Page 18: ...Centimeters 143 Inches Tires 5 70 x 8 Load Range B Dry Weight 695 kg 1 533 lbs Without Batteries Maximum Load 1360 kg 3 000 lbs Motor DC 36 Volt 4 5 kW 6 0 Horse Power for 60 min Separately Excited Fi...

Page 19: ...406 Centimeters 160 Inches Tires 5 70 x 8 Load Range B Dry Weight 503 kg 1 110 lbs Without Batteries Maximum Load 1 361 kg 3 000 lbs Motor DC 36 Volt 4 5 kW 6 0 Horse Power for 60 min Separately Excit...

Page 20: ...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 21: ...o secure and disable the vehicle The key can only be removed when the key switch is in the OFF position 3 Hi Low Switch optional The high low switch is located on the lower left of the instrument pane...

Page 22: ...removed when the key switch is in the OFF position 5 Hi Low Switch optional The high low switch is located on the lower left of the instrument panel Toggle the switch lever up for normal speed Toggle...

Page 23: ...nal The hazard light switch is located on the left side of the steering column The switch is a small tab To activate the hazard lights pull the tab out To turn the hazard lights off push forward or pu...

Page 24: ...down on the brake pedal and pull the lever up until it locks To release the park brake depress the foot brake pedal pull up on the park brake handle push the release button and lower the handle Charg...

Page 25: ...sed Thumb wheel The thumb wheel is used to adjust how much braking force is sent to the trailer brakes Rotate the thumb wheel upward towards the top of the housing to increase the braking force Pendul...

Page 26: ...ery status gauge as well as any faults indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle HM Depending on the revision level of the controll...

Page 27: ...e Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenance Due Once the warning has expired and the maintenance...

Page 28: ...ce technician F05043 Traction ON R Refer to service technician F05044 Traction OFF R Refer to service technician F05045 Stack Corrupt Refer to service technician F05046 Open Contactor Refer to service...

Page 29: ...turning be sure to allow for corner cutting of the trailer Allow for longer stopping distances when towing heavy loads Allow for longer stopping distances when driving down a grade Safety Guidelines...

Page 30: ...hicle power system fails and applies the brake the can be released by disconnecting the electric brake from the control system and connecting a 20 to 24 volt DC source 1 5A to the electric brake Towin...

Page 31: ...technicians familiar with hydraulic systems If the lowering rate of the dump bed has deminished it may be a result of a clogged filter or plugged restricted flow fitting The filter is internal of the...

Page 32: ...rs unexpectedly Lubrication Under normal conditions all of the pivot points should be lubricated with chassis grease every 3 months This includes the upper and lower hydraulic cylinder pivots and the...

Page 33: ...Page 19 HYDRAULIC PUMP EXPLODED VIEW This view is provided by the manufacturer of the pump and should only be used as a reference Refer to the pump manufacturere web site for current detailed informa...

Page 34: ...an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes Charging State LED1 LED2 LED3 0 to 50 Blinking OFF OFF 50 t...

Page 35: ...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 36: ...Wash 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...

Page 37: ...only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire...

Page 38: ...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 39: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4...

Page 40: ...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 p...

Page 41: ...trol 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 Gear...

Page 42: ...ts 4 General Purpose Grease 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 Le...

Page 43: ...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...

Page 44: ...nd listen for any 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 replacem...

Page 45: ...ront 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 n...

Page 46: ...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 vehi...

Page 47: ...nds 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 ro...

Page 48: ...d 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 r...

Page 49: ...ub 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 Fo...

Page 50: ...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 b...

Page 51: ...ace the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at th...

Page 52: ...ze bushings to 1 25 0 001 b Yoke without king pin Ream or broach bronze bushings to 0 880 0 001 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be repl...

Page 53: ...the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the hub bearing cap cotter pin and nut then remove the hub from the steeri...

Page 54: ...ress slightly to create a seal for the grease b Yoke without king pin tighten the king pin nut until all of the up and down play is removed and the yoke rotates freely NOTE Refer to Replace Front Whee...

Page 55: ...eering 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 Ro...

Page 56: ...d then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regardi...

Page 57: ...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...

Page 58: ...eels 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 a...

Page 59: ...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...

Page 60: ...evere 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 a...

Page 61: ...atteries 9 Remove 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 re...

Page 62: ...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 info...

Page 63: ...ng 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...

Page 64: ...ires 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 st...

Page 65: ...d 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...

Page 66: ...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 st...

Page 67: ...t 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 t...

Page 68: ...d End 6 Raise the 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 HIN...

Page 69: ...joint nut 9 Using a pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve HINT Count the number of turns required to remove the ball joint from the...

Page 70: ...ball joints or rod ends from the steering knuckle and pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Remove the...

Page 71: ...everse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and negative c...

Page 72: ...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 wit...

Page 73: ...fer 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 counti...

Page 74: ...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 reass...

Page 75: ...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 bo...

Page 76: ...Maintenance Service and Repair Steering Page 22 Exploded View of Steering Gear...

Page 77: ...arking Brake 7 Wheel Park Brake hydraulic disc 7 Check Master Cylinder Fluid 8 Bleed the Brake System 9 Flush the Brake System 11 Replace the Parking Brake Lining electric motor brake 12 Inspection 14...

Page 78: ...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 f...

Page 79: ...d 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...

Page 80: ...for any signs of damage wear or missing cotter pins If any sign of damage or wear is found on the locking mechanism cables or linkages then they must be repaired or replaced immediately Failure to rep...

Page 81: ...release until the voltage exceeds 18 volts then the friction plate has worn beyond its service limits and must be replaced b If the brake does not release at all then the brake electromagnet has faile...

Page 82: ...l low in the master cylinder See Check the Master Cylinder Fluid section Air in the brake lines See Bleed the Brakes section Worn brake pads See Inspect the Service Brake section Worn brake rotor See...

Page 83: ...justment Rod until it is difficult to rotate the brake arm clevis pin on both wheels 9 Loosen the Primary adjustment rod one to two turns so that both wheels rotate whith no brake drag The threaded ro...

Page 84: ...es Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops ge...

Page 85: ...ush 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 phy...

Page 86: ...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...

Page 87: ...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 o...

Page 88: ...ELECTRIC MOTOR BRAKE 1 Remove the electric brake assembly from the drive Refer to Motor Removal and Installation in the Transmission section for information regarding removing the brake 2 Place the b...

Page 89: ...parts 11 Inspect all parts for damage or wear 12 Reassemble in reverse order Reassembly Notes a Orientate the inner contact plate lining up the marks made when removed and so that the notches face aw...

Page 90: ...on the hub and the friction plate for damage 3 Inspect the inner contact plate and the outer housing where they come into contact with the friction plate for wear or damage 4 Inspect the three dowel...

Page 91: ...e 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 flu...

Page 92: ...s 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...

Page 93: ...ed 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...

Page 94: ...nting 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 wh...

Page 95: ...ylor 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 shou...

Page 96: ...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...

Page 97: ...id spills Any debris or contaminates left in the brake system could lead to brake failure and result in property damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin...

Page 98: ...the pistons all the way down into the brake body making sure that the boot seats properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body us...

Page 99: ...clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immed...

Page 100: ...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 t...

Page 101: ...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 102: ...TAYLOR DUNN...

Page 103: ...specting the Motor Brushes 2 Motors with internal cooling fans 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes or Armature Bearing 7 Repairing the Commutator 8 Service Limi...

Page 104: ...then the brushes should be removed and measured Refer to Replacing the Brushes section for information regarding removing the motor brushes 7 If any one brush is less than or equal to the service lim...

Page 105: ...out away from the commutator 3 Remove the dust cap from the rear motor housing 4 Place the motor in a press and press the armature out of the rear bearing NOTE Removing the armature will damage the mo...

Page 106: ...n it must be machined on a lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the...

Page 107: ...then we recommend that the armature or motor be replaced 9 Using the continuity function of digital multi meter check the continuity around the entire commutator by placing one test lead against one...

Page 108: ...nstall the rear motor housing to the stator housing 4 Lightly grease the inside diameter of the armature bearing 5 Carefully insert the armature through the stator housing and onto the motor bearing i...

Page 109: ...laced as a set NOTE The motor must be disassembled to replace the brushes or the bearing Refer to Motor Inspection Disassembly section for information on taking the motor apart NOTE The motor must be...

Page 110: ...the motor apart 3 Using a lathe cut the armature just enough to remove all grooves depressions or ridges 4 Measure the diameter of the commutator If the commutator is less than the minimum diameter sp...

Page 111: ...cut the commutator insulation to the proper depth Refer to undercut depth in Service Limits 2 Once all segments have been properly undercut mount the armature in a lathe and smooth the commutator with...

Page 112: ...mm inches mm inches mm inches Armature Field 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0116 1 20 70 054 41 XP 1789 or DY2 4001 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 0...

Page 113: ...ear 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 3...

Page 114: ...If the oil level is below the bottom of the opening add oil as required until level with the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes...

Page 115: ...al up to the bottom 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 b...

Page 116: ...he key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative...

Page 117: ...ls section for information regarding removing 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...

Page 118: ...se 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...

Page 119: ...ead locking compound 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 da...

Page 120: ...axle mounting brackets and brake arms 8 Disconnect the wiring from the motor 9 Disconnect the hydraulic brake lines from the left and right brake bodies 13 Reinstall the drive in reverse order 14 Ble...

Page 121: ...in 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 t...

Page 122: ...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 r...

Page 123: ...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 informati...

Page 124: ...rive 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 appro...

Page 125: ...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 carr...

Page 126: ...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...

Page 127: ...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...

Page 128: ...ions 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 n...

Page 129: ...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...

Page 130: ...inion 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...

Page 131: ...him 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...

Page 132: ...Maintenance Service and Repair Transmission Page 20 NOTE Values shown are for reference only C D...

Page 133: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5...

Page 134: ...d 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...

Page 135: ...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 bea...

Page 136: ...he 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...

Page 137: ...e 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 L...

Page 138: ...TAYLOR DUNN...

Page 139: ...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 140: ...tions 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...

Page 141: ...em 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 i...

Page 142: ...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 143: ...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 144: ...TAYLOR DUNN...

Page 145: ...LE 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 Serv...

Page 146: ...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 ar...

Page 147: ...h 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...

Page 148: ...mber77 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...

Page 149: ...ject 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 bodi...

Page 150: ...ative 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 o...

Page 151: ...tion 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...

Page 152: ...icle 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 re...

Page 153: ...n 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 dro...

Page 154: ...E 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...

Page 155: ...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 electro...

Page 156: ...TAYLOR DUNN...

Page 157: ...itions 2 Terminology used 2 Important Notes and Instructions 2 Identifying Your Controller 3 Start Troubleshooting Here 4 Test 8 Anti Rolloff Fault 15 Test 9 Electric Motor Brake 16 Logic Voltage Refe...

Page 158: ...ems 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 Some tests refer to a High Low switch The High Low swit...

Page 159: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...

Page 160: ...battery check the following The batteries The wiring from the battery status indicator to the batteries for open circuits The battery status indicator The positive and negative circuit breaker The ma...

Page 161: ...r for open circuits 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 TEST 1 3 Test the voltag...

Page 162: ...to the ground TEST 1 7 Depress the accelerator pedal to engage FS 1 only creep speed Perform the following tests Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is below...

Page 163: ...fication table can be found in the Motor Service section If the test indicates an open circuit then repair or replace the motor Test continuity from F1 to the frame of the motor Any reading other than...

Page 164: ...to the frame on the motor and from F1 to A1 for open circuits Any reading other than an open circuit indicate a short in the motor If there is a short in the motor stop here and repair or replace the...

Page 165: ...at switch turn the key switch ON and wait 1 second until the Isolator contactor closes If the vehicle runs in reverse only then skip ahead to test 3 3 Place the forward and reverse switch in the FORWA...

Page 166: ...d movement of the vehicle resulting in injury or property damage Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all p...

Page 167: ...ults may have occurred Broken Wire Check the wire from pin 8 in the 12 Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm...

Page 168: ...Low battery 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...

Page 169: ...se skip ahead to test 7 3 Place the forward and reverse switch in the FORWARD position Referencing battery positive test the voltage at the Blue Black wire on the F R switch If the voltage equals batt...

Page 170: ...ground TEST 7 4 Check the wires from the F R switch to the logic card connector for continuity After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground F...

Page 171: ...tch in the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor...

Page 172: ...ere and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Test 9 1 Close the seat switch turn the key switch ON place the for...

Page 173: ...eed controller Disconnect the electric brake harness connector and connect the electric brake to a 24 volt source This should release the brake and allow you to troubleshoot the vehicles control syste...

Page 174: ...ch in high Low High low Switch in low High 7 Hand brake switch closed Low Hand brake switch open High 8 Key switch on ref battery positive Key switch off ref battery positive Battery volts 9 System of...

Page 175: ...Burned Motor Repair as required 4 Contactor fault or open motor Contactor Failure Open Circuit Check contactor and motor 5 Not used 6 Accelerator module fault FS 1 Micro Switch Failure Faulty Wiring A...

Page 176: ...d Level 4 Faults F04xxx F04001 Contactor Welded High voltage at power up to the controller B terminal Check wiring contactor and pre charge resistor on the contactor F04002 Steer Pot Steer Pot current...

Page 177: ...1 faults are a result of operator error or operation of the vehicle F01000 Power Steer Overheat Not used F01001 Traction Motor Brush Wear Not used F01002 Pump Motor Brush Wear Not used F01003 Power St...

Page 178: ...TAYLOR DUNN...

Page 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...mer 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 a...

Page 186: ...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 187: ...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 188: ...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 189: ...st 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...

Page 190: ...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 191: ...eter 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...

Page 192: ...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 193: ...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 194: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charge...

Page 195: ...ing 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 contro...

Page 196: ...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 197: ...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 198: ...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 199: ...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 200: ...e 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 P...

Page 201: ...TABLE OF CONTENTS Wire Diagrams Complete Vehicle 2 Dash 3 Control Panel 4 Accelerator Module Detail 5 Lighting 6 Trailer Brake Module and Receptacle 7 Hydrualic Dump Option 8...

Page 202: ...lue Blue 1 2 Red White Gray White Black 14 2 16 AUTOMATIC ELECTRIC BRAKE MOTION ALARM Black Violet Black White Violet Black Blue Black White Black Gray Black Green Black Yellow Blue 10 12 7 5 3 8 Blue...

Page 203: ...ER HOUR DASH PANEL 12 3 8 SWITCH F R 14 5 Red Red 6 1 Blue White Red Special order accesories may be wired to this terminal ACC 16 KEY SWITCH 11 Brown Brown 10 SWITCH LIGHT HORN BUTTON 9 Red Red Red 1...

Page 204: ...7 12 3 5 Red 11 Violet Black Blue Black 8 Red 1 Blue White White 4 9 White 13 White Black Blue 9 Red White 5 Gray Black Green Black Yellow 10 4 6 3 HORN Black White Blue Black 2 8 1 Violet Black Blac...

Page 205: ...Wire Diagrams Wire Diagrams Page 5 ACCELERATOR MODULE DETAIL ACCELERATOR 8 1 0 5V Out 9 5 4 MS3 MS1 B In B Out B In B In PC Board...

Page 206: ...side Red Green Blue 5 Blue White Black White Gray Green White Yellow 7 1 6 Black Red 8 3 Gray Red 4 Brown White White Brown Red White Blue White BRAKE LIGHT Red 9 DASH PANEL Red 13 Red Red 1 BUTTON H...

Page 207: ...Green Blue FLASHER Red 9 Black Black Black Gray 1 8 3 Gray Green 7 4 6 Gray White 5 Red Red Green Blue Yellow Brown White Yellow Brown Green TRAILER BRAKE MODULE OPTION Brown BLACK White Red White Re...

Page 208: ...ATTERY NEGATIVE TAP 12V CIRCUIT BREAKER SEE NOTE HYDRAULIC PUMP ASSEMBLY Hydraulic pump assembly must be insulated from the frame of the vehicle Circuit Breaker Note Serial number up to 175999 used tw...

Page 209: ...ke Lines with single master cylinder 34 Wheels and Tires 36 Instrument Panel Up To S N 179669 38 Instrument Panel Starting S N 179670 38 Resetting the Smart View Display 38 Speed Control Panel 40 Misc...

Page 210: ...Illustrated Parts Parts Page 2 Part number not available at time of printing Front Axle...

Page 211: ...s Parts Page 3 Part number not available at time of printing Front Axle ITEM PART DESCRIPTION QTY 15 049 71 Axle Beam B 2 48 BT 2 48 B 2 54 1 15 049 77 Axle beam BT 2 80 1 See following pages for comp...

Page 212: ...Illustrated Parts Parts Page 4 Part number not available at time of printing Steering Knuckle...

Page 213: ...rease 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 12 124 00 Wheel Hub no rotor incl 1 12 1 11 1 13 2 15 88 228 61 3 4...

Page 214: ...Illustrated Parts Parts Page 6 Part number not available at time of printing Front Brakes...

Page 215: ...kit below Pad Disc Brake inner 2 4 41 348 58 Spacer Disc Brake included in rebuild kit 4 5 32 208 01 Bushing included in rebuild kit 4 6 99 588 00 Bleeder valve 2 7 99 588 01 Bleeder screw adapter 2...

Page 216: ...Illustrated Parts Parts Page 8 Part number not available at time of printing Steering Linkage...

Page 217: ...Linkage ITEM PART DESCRIPTION QTY 1 18 041 05 Tie rod B 2 48 B 2 54 BT 2 48 1 18 057 00 Tie rod BT 2 80 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...

Page 218: ...0 Part number not available at time of printing 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 steer...

Page 219: ...3 88 081 14 5 16NF x 1 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...

Page 220: ...Illustrated Parts Parts Page 12 Part number not available at time of printing Steering Gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16 Exploded Steering Gear dwg...

Page 221: ...y 1 4 18 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 S...

Page 222: ...Illustrated Parts Parts Page 14 Part number not available at time of printing Front Suspension 1 2 3 4 7 8 Front axle ref 5...

Page 223: ...Suspension ITEM PART DESCRIPTION QTY 1 96 121 00 U bolt 4 2 85 498 00 Leaf spring B 2 48 BT 2 48 BT 2 80 2 85 486 00 Leaf spring B 2 54 2 3 32 214 50 Bushing 12 4 96 240 00 1 2NC x 4 Hex bolt 6 5 88...

Page 224: ...Illustrated Parts Parts Page 16 Part number not available at time of printing Transmission Gear Case...

Page 225: ...7553 Gear case housing 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...

Page 226: ...Transmission Differential 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...

Page 227: ...BT 2 80 2 41 154 20 Axle shaft B 2 48 BT 2 48 B 2 54 single bearing 2 41 154 25 Axle shaft B 2 54 2 2 80 505 20 Bearing 2 2a 80 505 30 Bearing 2 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub 2 5 88 2...

Page 228: ...Illustrated Parts Parts Page 20 Part number not available at time of printing Rear Brakes...

Page 229: ...0 28 1 Mounting bracket 2 8 41 350 39 Brake body assembly 2 9 88 840 11 Retaining ring 2 41 350 52 Clevis pin 2 10a 99 588 00 Brake bleeder 2 10b 99 588 01 Adapter brake bleeder 2 11 41 350 56 Park br...

Page 230: ...Illustrated Parts Parts Page 22 Part number not available at time of printing Brake linkage...

Page 231: ...71 00 Clevis Pin 3 8 x 3 4 1 7 01 204 32 Brake Equalizer 1 8 96 760 00 Brake Cable Clevis 1 9 88 099 80 Nut 5 16 Hex Head 2 10 96 773 00 Clevis Pin 5 16 x 1 1 11 88 527 11 Cotter Pin 1 8 X 1 Steel 2 N...

Page 232: ...Illustrated Parts Parts Page 24 Part number not available at time of printing Rear Suspension View from rear...

Page 233: ...t of the leaf spring 4 14 85 510 17 Leaf spring 2 15 16 861 44 Spring mounting plate left 1 16 861 45 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...

Page 234: ...Illustrated Parts Parts Page 26 Part number not available at time of printing Motor...

Page 235: ...88 067 22 Not available at time of printing The original motor provided under part number 70 054 40 has been discontinued It has been replaced by 70 054 41 The 70 054 41 motor has slightly more power...

Page 236: ...Illustrated Parts Parts Page 28 Part number not available at time of printing Electric Brake and Rear Motor Mount...

Page 237: ...6 88 128 62 Lockwasher 7 16 2 7 89 111 27 Bolt 10m X 1 5 X 20 Hex Head 2 8 88 088 62 Lockwasher 5 16 2 9 88 099 80 Nut 5 16 NF 2 10 88 067 17 Bolt 1 4 X 1 1 8 NC Grade 8 no brake option 88 067 29 Bolt...

Page 238: ...Illustrated Parts Parts Page 30 Part number not available at time of printing Master Cylinder Single Reservoir Dual Reservoir...

Page 239: ...QTY 1 88 080 14 Bolt 5 16 X 1 1 2 NC Hex Head 2 2 See Usage Table Master Cylinder includes item 3 1 3 99 511 52 Cap Seal Master Cylinder 1 99 511 53 Cap Master Cylinder 1 4 88 088 61 Washer 5 16 4 5...

Page 240: ...Illustrated Parts Parts Page 32 Part number not available at time of printing Brake Lines with dual master cylinder...

Page 241: ...8 Brake Line Rear Right B 2 48 B 2 54 BT 2 48 1 99 608 56 Brake Line Rear Right BT 280 1 6 99 603 68 Brake Line Rear Left B 2 48 B 2 54 BT 2 48 1 99 608 57 Brake Line Rear Left BT 2 80 1 7 99 580 20 B...

Page 242: ...Illustrated Parts Parts Page 34 Part number not available at time of printing Brake Lines with single master cylinder...

Page 243: ...2 4 99 608 58 Brake Line Rear BT 2 80 1 99 607 62 Brake Line Rear B 2 48 B 2 54 BT 2 48 1 5 99 604 56 Brake Line Rear Right BT 2 80 1 99 603 68 Brake Line Rear Right B 2 48 B 2 54 BT 2 48 1 6 99 604 5...

Page 244: ...Illustrated Parts Parts Page 36 Part number not available at time of printing Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 245: ...Outer 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...

Page 246: ...Resetting the Smart View Display The meter should only be reset after the preventative maintenance has been performed Taylor Dunn part number 62 027 40 Hand set available with instructions as part nu...

Page 247: ...iption Qty 1 71 100 00 Auxiliary switches 0 1 2 2 71 039 11 Auxiliary switches 0 1 2 3 88 817 07 Screw 6 4 5 01 200 09 Console 1 6 74 010 00 Smart View gauge 0 1 74 009 00 Battery Gauge analog 36 volt...

Page 248: ...item 14 Refer to the serial number data plate on the controller base to determine which controller 400A or 500A is on your vehicle 632S45617 400 Amp controller 632S15622 500 Amp controller Early mode...

Page 249: ...400 05 or 62 400 15 you will need to provide the vehicle serial number The controller will be programmed to match the vehicle as originally manufactured Item 4 Depending on the model and serial numbe...

Page 250: ...rts Page 42 Part number not available at time of printing Miscellaneous Electrical Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1 2 Motion Alarms Miscellaneous Wire Harness Clamp...

Page 251: ...ick on 3 96 642 00 Wire ahrness Clip push mount 4 62 033 48 Accelerator Module 1 5 71 122 20 Horn Switch 1 6 88 065 06 1 4 NC x 21 2 Phillips Truss Head Screw Horn Switch 2 7 88 069 81 1 4 NC Hex Nylo...

Page 252: ...Illustrated Parts Parts Page 44 Part number not available at time of printing Lighting Stobe Light 4 1 2 3 5 6 7...

Page 253: ...with the serial number of the vehcle for more 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...

Page 254: ...Illustrated Parts Parts Page 46 Part number not available at time of printing 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 255: ...10 79 831 00 79 730 00 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 1...

Page 256: ...Illustrated Parts Parts Page 48 Part number not available at time of printing 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 257: ...9 13 S O 79 575 10 79 831 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 5...

Page 258: ...umber not available at time of printing Signet Charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20...

Page 259: ...time of printing Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable co...

Page 260: ...G POS NEG POS NEG POS 12 Volt Negative tap Main Positive Main Negative 1 2 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 3 4 5 6 7...

Page 261: ...special charger 77 047 00 244AH T 145 77 047 50 250AH TD 250 77 047 80 244AH T 145 Moist charge dry 77 048 00 250AH J 250 77 048 80 250AH J 250 Moist charge dry 77 051 00 160AH Gell Note requires spe...

Page 262: ...Illustrated Parts Parts Page 54 Part number not available at time of printing Seat Cushions and Deck B 2 48 and B 2 54...

Page 263: ...away seat option 1 90 469 00 Deckboard 19 11 16 x 41 f oldaway seat option 1 90 464 00 Deckboard 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...

Page 264: ...Illustrated Parts Parts Page 56 Part number not available at time of printing Seat Cushions BT 2 48 Seat Cushions BT 2 80...

Page 265: ...ng plate 4 88 837 11 14 x 1 Sheet metal screw 30 2 90 194 00 Rear seat cushion 4 3 90 140 00 Front seat back 1 4 90 148 00 Front seat cushion 2 BT 2 80 Seat Cushions black ITEM PART DESCRIPTION QTY 1...

Page 266: ...Illustrated Parts Parts Page 58 Part number not available at time of printing Decals Between seats BT 2 80 under 2nd seat B 2 48 and B 2 54 BT 2 80 electronics compartment...

Page 267: ...ery disconnect 1 or 2 2 94 313 00 Battery warning 1 or 2 3 94 373 10 Vehicle identification 1 4 94 309 00 Brake warning 1 5 94 313 20 Safety warning 1 6 94 384 01 Not a motor vehicle 1 7 94 384 14 Whe...

Page 268: ...Illustrated Parts Parts Page 60 Part number not available at time of printing Cab Options Steel Cab Fiberglass cab...

Page 269: ...nted 1 90 852 30 Front windshield 1 90 850 10 Rear window 1 98 310 00 Rubber windshield gasket by the foort Fiberglass Cab ITEM PART DESCRIPTION QTY 91 000 00 Fiberglass cab 1 90 800 00 Front windshie...

Page 270: ...number not available at time of printing 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 1...

Page 271: ...91 011 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 Not Shown 91 011 67 Kit Cab Door Right Specify Color includes 10 11 12 1 Not Shown...

Page 272: ...Illustrated Parts Parts Page 64 Part number not available at time of printing 3 8 9 6 7 5 4 2 1 Typical door assembly Door Options Fiberglass Cab...

Page 273: ...tape by the foot 2 90 908 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 Fastn...

Page 274: ...Illustrated Parts Parts Page 66 Part number not available at time of printing Hydraulic Dump Body Option 22 rubber cap 22 plastic housing...

Page 275: ...cknut 3 8 NC 11 98 753 08 Isolator Mount Rubber 12 91 286 01 Carrier Frame Dump Bed 13 91 285 11 Safety Prop Rod 14 98 754 00 Rubber Bumper Safety Prop Rod 15 91 285 10 Bracket Safety Prop Rod used up...

Page 276: ...Illustrated Parts Parts Page 68 Part number not available at time of printing Rear Cargo Box 1 2 3 4 5 6 5...

Page 277: ...ox ITEM PART DESCRIPTION QTY 1 91 333 02 Cargo box unpainted 1 2 90 471 00 Front deck board 1 3 90 472 00 Rear deeck board 1 4 90 850 10 Front window 1 5 98 310 00 Ruber window gasket by the foor 6 90...

Page 278: ...Illustrated Parts Parts Page 70 Part number not available at time of printing Hitches...

Page 279: ...Illustrated Parts Parts Page 71 Part number not available at time of printing...

Page 280: ...Illustrated Parts Parts Page 72 Part number not available at time of printing...

Page 281: ...APPENDIX A Special Tools...

Page 282: ...s completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adju...

Page 283: ...are Suggested Torque Limits Hardware Identification 2 Standard Head Markings 2 Hex Bolts 2 Other Bolts 2 Hex Nuts 3 Hex Lock Nuts stover 3 Other Nuts 3 Suggested Torque Values non critical hardware 4...

Page 284: ...e 5 Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Other Bolts NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade...

Page 285: ...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 ar...

Page 286: ...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 20...

Page 287: ...r 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 pl...

Page 288: ...u r B u s i n e s s R A small sample of the many types of vehicles offered by Taylor Dunn B 2 48 36 Equipped with optional hydraulic dump bed BT 2 80 Eight passenger tram B 1 00 Personnel carrier C 4...

Page 289: ...Use an OSHA approved vacuum 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 s...

Page 290: ...Model B 1 00...

Page 291: ......

Page 292: ...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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