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Taylor-Dunn B0-248-TT Operation, T Roubleshooting And Replacement Parts Manual Download Page 66

Maintenance, Service, and Repair

Brakes
Page 14

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from

dirt and debris and will contain any brake fluid spills.

Remove the master cylinder from the vehicle. See 

Replace the Master Cylinder

 section .

Drain all fluid from the master cylinder and discard.

Remove the rubber boot.

Depress the plunger and remove the plunger spring clip retainer.

Pull the plunger and all seals out of the master cylinder bore.

Thoroughly clean, inspect and replace parts as required.

If any damage is found in the bore of the master cylinder then it must be replaced.

Lubricate all parts with clean brake fluid from a sealed container.

Reassemble in reverse order.

If the master cylinder is not to be immediately installed onto a vehicle, plug the brake line fitting hole to
prevent any contaminates from entering the master cylinder.

Summary of Contents for B0-248-TT

Page 1: ...Go About Your B u s i n e s s TAYLOR DUNN Serial Number Range 116303 through 156630 MANUAL MB T48 00 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 248 TT T48 Published 2 19...

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

Page 5: ...isc Brake Body Assembly front or rear 10 Repair the Brake Body 11 Replace the Master Cylinder 13 Repair the Master Cylinder 14 Introduction About this manual 2 Who Should Read This Manual 2 Responsibi...

Page 6: ...Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Battery Service Cleaning 2 Testing 3 Charging 4 Watering 5 Replacing 6 volt batteries on...

Page 7: ...smission Differential Case 14 Rear Axle 16 Rear Brakes 16 Parking Brake 18 Rear Suspension 18 Motor page 1 20 Motor page 2 22 Master Cylinder 24 Brake Lines 26 Parking Brake Linkage 28 Wheels and Tire...

Page 8: ...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 9: ...2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 Shown with fiberglass steel cab options Show...

Page 10: ...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 11: ...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 12: ...ill be in one of two locations as shown This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applic...

Page 13: ...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 14: ...TAYLOR DUNN...

Page 15: ...Indicator Digital Bargraph optional 5 Directional Signals Optional 6 Hazard Light Switch Optional 6 Charger Interlock 6 Seat Interlock Switch 6 Vehicle Operational Guidelines 7 Safety Guidelines 7 St...

Page 16: ...otive Type Hypoid Differential Motor DC Series Wound 11 1 kW 15 Horse Power 1 400 RPM Brakes 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Tires 20 5 x 8 x 10 Load...

Page 17: ...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 18: ...ped with windshield wipers and one or more accessories the windshield wipers are controlled from this switch Other accessories are controlled from the auxiliary switch Steering The steering wheel and...

Page 19: ...and operates similar to the accelerator pedal in an automobile Depress the pedal to increase speed and release the pedal to decrease speed Battery Status Indicator Digital Bargraph optional The batte...

Page 20: ...rd lights pull the tab out To turn the hazard lights off push forward or pull back the directional signal lever Seat Interlock Switch A switch located under the driver s seat disables the power to the...

Page 21: ...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 22: ...tructions may result in damage to the vehicle The park brake should be disabled for servicing or towing proceduresonly Do not operate the vehicle while the automatic park brake is disabled Operating t...

Page 23: ...n 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 to...

Page 24: ...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 25: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 11 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Page 26: ...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 27: ...Table of Contents General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor Examples of Taylor Dunn Tow Tractors...

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: ...1 Ball Joints 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 5 6 Chain Case Drai...

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: ...s in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicl...

Page 33: ...turns but is not loose 10 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings sec...

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: ...eering knuckles and 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 doe...

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: ...4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands 7 R...

Page 38: ...hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 1 Make sure the key swi...

Page 39: ...5 Adjust the 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...

Page 40: ...nds 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 i...

Page 41: ...jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a...

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: ...orward 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 c...

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: ...E Most vehicle configurations will now allow the steering shaft to slide off of the steering gear input shaft and then back down out of the steering column If there is not enough clearance for this pr...

Page 46: ...ng wheel remove the switch and disconnect the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straigh...

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: ...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 51: ...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 52: ...Maintenance Service and Repair Steering Page 14 Exploded View of Steering Gear...

Page 53: ...Repair the Brake Body 11 Replace the Master Cylinder 13 Repair the Master Cylinder 14 Brake Service Brake fluid specifications Vehicles up to serial number 151284 were shipped with DOT 5 brake fluid...

Page 54: ...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 55: ...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 56: ...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 57: ...g and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately E...

Page 58: ...epress the foot pedal to the floor and then close the bleeder valve Do not release pressure on the brake pedal until the bleeder valve is closed 13 Slowly release the foot pedal allowing it to return...

Page 59: ...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 60: ...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 61: ...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 62: ...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 63: ...damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT F...

Page 64: ...brake body making sure that the boot seats properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 17 If t...

Page 65: ...use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Do n...

Page 66: ...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 67: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Magnetic Module 2 Pot Box module 3 Throttle Linkage...

Page 68: ...he standard throttle position sensor consists of two micro switches and a magnetic sensor that detects the position of the throttle pedal Switch FS 3 is a normally open switch that is held closed by t...

Page 69: ...le is used on vehicles that are to be 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 o...

Page 70: ...TAYLOR DUNN...

Page 71: ...3 Change the Oil 3 Drive Motor 4 Remove 4 Install 4 Rear Axle 5 Remove and Install 5 Replace the Axle Bearing 5 Chain Case 6 Disassemble 6 Assemble 6 Differential Assembly 3rd Member 8 Disassemble 8 A...

Page 72: ...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 73: ...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 74: ...ounting 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 75: ...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 76: ...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 77: ...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 78: ...inion 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 pini...

Page 79: ...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 80: ...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 81: ...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 82: ...Maintenance Service and Repair F2 F3 Transmission Page 12 EXPLODED VIEW...

Page 83: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Leaf 2 Replace the Front Springs 3 Leaf 3 Replace the Spring Bushings 4 Replace the Shocks 5 Front 5...

Page 84: ...use lifting and support devices of rated load capacity may result in severe bodily injury 8 Unbolt the spring from the axle housing 9 Support the spring so that it cannot fall out of the vehicle 10 R...

Page 85: ...the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle m...

Page 86: ...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 87: ...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 88: ...TAYLOR DUNN...

Page 89: ...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 90: ...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 91: ...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 s...

Page 92: ...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 93: ...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 94: ...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 95: ...75 38 1 1 5 5BC58JBS6129B 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129C 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC49JB399C 0 635 0 025 78 97 3 109 19 05 0 75 5BC58JBS6110C 0 635 0 02...

Page 96: ...TAYLOR DUNN...

Page 97: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels...

Page 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...TAYLOR DUNN...

Page 111: ...ontrollerSmallSignalInput 6 Forward ReverseSwitch ModelET 150 74 72 volt system 6 Forward Reverse Switch 48 Volt System 7 Throttle Module using test harness 8 Throttle Module using analyser 9 MotorWin...

Page 112: ...ite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus high armature current NO...

Page 113: ...middle of this troubleshooting guide Start at the beginning and complete each test in the order that they are written Do not skip any test unless instructed to do so Once a problem is found stop test...

Page 114: ...epairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily...

Page 115: ...ould be full battery voltage If correct go to Controller Output If test failed go to Contactors ISO Contactor test Controller Output Connect the test light to the controller M and controller B termina...

Page 116: ...l system During this procedure voltages will be measured at F R switch Green Black wire White Black wire cathode of D4 NO terminal of reverse switch Turn the key switch ON select FORWARD direction and...

Page 117: ...tch in the center OFF position and depress the throttle pedal Green Black wire should be Control Volts Violet Black wire on common a should be Control Volts All others should be LOW If Green Black wir...

Page 118: ...shows the test end of the harness and the orientation of the terminals The terminal numbers shown are exactly as on the test harness NOTE Perform the test for Pin 9 first then use pin 9 as the batter...

Page 119: ...then the module is faulty see note2 below The voltage on the digital display should vary with the position of the module arm starting at approximately 6 volts and ending at approximately 11 volts If...

Page 120: ...dition will also have open armature windings Clicking noise from motor Most likely due to one or more raised commutator segments This could be a result of a damage due to a stalled condition If not ac...

Page 121: ...NO and Normally Closed NC When a direction is selected and one of the contactors picks up current will pass through the NO contacts on the energized contactor and the NC contacts on the other contacto...

Page 122: ...USE TWO TEST LIGHTS Close the seat interlock switch and turn the key switch ON The test light connected to the contactor negative buss should be ON If the control system is working the test light con...

Page 123: ...direction CONTACTORS P 13 Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low CONTACTORS P 13 Does not run in either direction...

Page 124: ...prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear d...

Page 125: ...d loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Contactors There have been a few isolated instances of a specific failure of a...

Page 126: ...TAYLOR DUNN...

Page 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...ing Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 Rev B Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the contro...

Page 134: ...hooting There are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example...

Page 135: ...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 136: ...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 137: ...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 138: ...V1 When the battery voltage equals V1 the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged T...

Page 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 diagrams are SCH 00018 Equipped with 2...

Page 150: ...R SW BL WHT ORG GRN HORN HORN BUTTON TAIL STOP LIGHT BATTERY FLASHER BL THESE WIRES NOT USED WHEN DIRECTIONAL SIGNAL OPTION IS INSTALLED DASHED WIRING IS OPTIONAL GRN YEL BL BRN WHT GRN YEL GRN INDIC...

Page 151: ...ORG GRN HORN HORN BUTTON TAIL STOP LIGHT BATTERY THESE WIRES NOT USED WHEN DIRECTIONAL SIGNAL OPTION IS INSTALLED DASHED WIRING IS OPTIONAL GRN YEL BL BRN WHT GRN YEL GRN INDICATOR BATTERY STATUS F Y...

Page 152: ...TAYLOR DUNN...

Page 153: ...ifferential Case 14 Rear Axle 16 Rear Brakes 16 Parking Brake 18 Rear Suspension 18 Motor page 1 20 Motor page 2 22 Illustrated Parts Master Cylinder 24 Brake Lines 26 Parking Brake Linkage 28 Wheels...

Page 154: ...Illustrated Parts Parts Page 2 Front Axle...

Page 155: ...eel bearing cap 2 11 88 527 11 Cotter pin 2 12 88 239 85 Wheel bearing nut 2 13 80 017 00 Inner Outer wheel bearing 4 14 12 158 10 Front hub w rotor inner bearing races and seal Note rotor N A separat...

Page 156: ...Illustrated Parts Parts Page 4 Front Brakes Steering Linkage Drag Link...

Page 157: ...bleeder fitting 2 8 99 588 00 Brake bleeder valve 2 9 88 069 82 Brake body nut grade 8 DO NOT REUSE 4 10 12 158 10 Front hub w rotor inner bearing races and seal Note rotor N A separately 2 11 41 350...

Page 158: ...Illustrated Parts Parts Page 6...

Page 159: ...Illustrated Parts Parts Page 7...

Page 160: ...Illustrated Parts Parts Page 8 Steering Column...

Page 161: ...er steering shaft bushing 1 5 20 031 65 Steering shaft includes pinch bolt and nut 1 6 7 18 308 21 Steering gear 1 8 88 128 62 7 16 split lock washer 3 9 88 120 15 7 16 x 1 NC hex bolt 3 10 88 279 82...

Page 162: ...Illustrated Parts Parts Page 10 Steering Gear 1 4 6 8 7 5 12 11 10 17 13 2 3 14 15 16 9 Front Suspension...

Page 163: ...itman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 1 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side co...

Page 164: ...Illustrated Parts Parts Page 12 Transmission Chain or Gear Case...

Page 165: ...00 Spacer 1 11 30 093 00 Pinion sprocket 1 12 30 508 20 Drive chain 1 13 44 352 53 Backing plate 1 14 88 101 13 3 8 x 1 1 4 NC hex bolt 5 15 88 080 20 5 16 x 3 NC hex bolt 9 16 41 989 00 Drain and fil...

Page 166: ...Illustrated Parts Parts Page 14 Transmission Differential Case...

Page 167: ...D 2 5 80 513 00 Carrier bearing LM 102949 1 7812 ID 2 6 31 235 00 Ring and pinion gear set 2 75 1 7 41 997 00 Oil plugs 1 8 pipe plug 3 8 41 291 32 Rear end housing 1 9 80 555 00 Rear pinion bearing 1...

Page 168: ...Illustrated Parts Parts Page 16 Rear Axle Rear Brakes...

Page 169: ...00 Axle mounting bolt DO NOT REUSE 8 REAR BRAKES ITEM PART DESCRIPTION QTY 1 96 327 00 Axle mounting bolt 8 2 41 350 05 Locking tab 4 3 41 961 01 Spacer 4 4 32 240 40 Bushing 4 5 41 348 52 Spacer 4 6...

Page 170: ...Illustrated Parts Parts Page 18 Parking Brake Rear Suspension...

Page 171: ...e 5 hex bolt 1 16 85 270 00 Return spring 1 17 88 080 13 5 16 x 1 1 4 hex bolt 2 18 41 371 10 Alignment bracket 2 19 88 089 91 5 16 NC hex jam nut 4 REAR SUSPENSION ITEM PART DESCRIPTION QTY 1 17 106...

Page 172: ...Illustrated Parts Parts Page 20 Motor page 1 16 17 6 8 15 Typical GE Motor 9 12 13 9 5 3 4 2 1 14 10 11 7...

Page 173: ...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 174: ...Illustrated Parts Parts Page 22 Motor page 2 16 17 6 8 15 Typical GE Motor 9 12 13 9 5 3 4 2 1 14 10 11 7...

Page 175: ...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 176: ...Illustrated Parts Parts Page 24 Master Cylinder...

Page 177: ...1 Cotter pin 1 5 88 119 80 3 8 NF nut 1 6 50 009 00 Push rod 1 7 17 104 00 Collar 1 8 99 510 52 Master cylinder cap 1 9 99 510 61 Rebuild kit 1 10 99 510 51 Rubber boot 1 11 88 101 20 3 8 NC Hex bolt...

Page 178: ...Illustrated Parts Parts Page 26 Brake Lines...

Page 179: ...2 6 99 648 53 Brake line 1 7 99 510 02 Master cylinder 1 8 99 648 52 Brake line front right 1 9 99 604 56 Brake line rear right 1 10 99 604 57 Brake line rear left 1 11 99 648 51 Brake line front left...

Page 180: ...Illustrated Parts Parts Page 28 Parking Brake Linkage...

Page 181: ...6 SAE flat washer 4 5 88 080 16 5 16 x 2 NC Hex bolt 2 6 Spacer part of 1 7 96 762 00 3 8 Clevis 1 8 88 119 80 3 8 NF hex nut 1 9 96 773 10 5 16 x 1 1 8 Clevis pin 1 10 96 773 00 5 16 x 1 Clevis pin 1...

Page 182: ...Illustrated Parts Parts Page 30 Wheels and Tires Ref wheel hub 1 2 3...

Page 183: ...heels and Tires ITEM PART DESCRIPTION 1 Wheels 12 025 00 8 x 10 Tubeless 2 Tires 10 264 00 20 x 8 x 10 LR E 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only Tire and Wheel Assemb...

Page 184: ...Illustrated Parts Parts Page 32 Speed Control Panel Instrument Panel dash...

Page 185: ...nut 4 17 88 068 61 1 4 SAE flat washer 4 18 89 080 25 8 x 1 25 Metric hex head bolt 8 19 89 040 12 4 x 7 Metric Phillips head screw 6 Not Shown K1 072 77 Additional harness 1 21 K1 114 06 Additional...

Page 186: ...Illustrated Parts Parts Page 34 Miscellaneous Frame and Body...

Page 187: ...plate screw 6 94 201 11 Name plate fastener plastic 2 6 94 050 10 Left headlight 1 7 00 248 32 Front cowl weldment not painted 1 8 K6 006 95 Driver Passenger seat cushion 2 9 90 140 00 Seat back cush...

Page 188: ...Illustrated Parts Parts Page 36 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 189: ...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 190: ...Illustrated Parts Parts Page 38 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 191: ...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 192: ...Illustrated Parts Parts Page 40 Batteries 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 NEG POS NEG POS...

Page 193: ...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 special charger 3 50 243 1...

Page 194: ...DOT 3 BRAKE FLUID 94 301 42 DECAL ARMS LEGS INSIDE 4 WHEEL 94 304 11 PANEL INSTRUMENT TD LOGO 94 309 00 DECAL BRAKE WARNING 94 313 00 DECAL BATTERY WARNING 94 313 20 DECAL SAFETY WARN 94 319 00 DECAL...

Page 195: ...10 00 Brake light switch 1 71 102 10 Seat switch 1 75 149 19 Truck control harness 1 72 082 01 Headlight bulb 2 72 082 10 Front turn signal bulb optional 2 72 082 20 Turn signal bulb socket optional 2...

Page 196: ...TAYLOR DUNN...

Page 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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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