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Taylor-Dunn B0-254-48, Operation, T Roubleshooting And Replacement Parts Manual

The Taylor-Dunn B0-254-48 Operation, Troubleshooting And Replacement Parts Manual is your go-to guide for maintaining and operating your vehicle. This comprehensive manual covers all the essential information you need to keep your Taylor-Dunn running smoothly. Download it for free from manualshive.com today.

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TABLE OF CONTENTS

Standard Specifications ............................... 2
Safety Rules and Guidelines ........................ 3
Driver Training Program ............................... 4

Driver Qualifications. ................................................. 4
Key-Switch ................................................................ 4
Forward-Off-Reverse Switch .................................... 4
Horn Switch .............................................................. 4

Vehicle Controls ............................................ 5

Hi-Low Switch (optional) ........................................... 5
Accelerator Pedal ...................................................... 7
Foot Brake Pedal ...................................................... 7
Headlight Switch ....................................................... 7
Accessory Switch (Optional) ..................................... 7
Smart View Display ................................................... 7
Directional Signals (Optional) ................................... 8
Steering ..................................................................... 8
Hazard Light Switch (Optional) ................................. 8
Charger Interlock ...................................................... 10
Electrolyte Alarm (Optional) ...................................... 10
Seat Interlock Switch ................................................ 10
Park Brake ................................................................ 10

Safety Rules and Operating

Instructions

Vehicle Operational Guidelines ................... 11

Safety Guidelines ...................................................... 11
Starting: ..................................................................... 11
While driving: ............................................................ 12
Loading and Unloading ............................................. 12
Parking ...................................................................... 12
Towing ....................................................................... 12

Charging your vehicle .................................. 13

New Battery Break in ................................................ 13
Signet® HB-xxxx Charger Operation ........................ 13
Industrial Charger Operation ..................................... 14
Charging Time .......................................................... 14
Lestronic II® Charger Operation ............................... 15
Returning to Service ................................................. 15

Storing and Returning  to Service ............... 15

Storing Your Vehicle .................................................. 15

Periodic Maintenance Checklist .................. 16
Standard Periodic Maintenance Schedule

for the Smart View Display ..................... 17

Daily Visual inspection: ............................................. 18

Maintenance Guidelines for

Severe Duty Applications ....................... 18

Summary of Contents for B0-254-48

Page 1: ...B u s i n e s s Serial number range 165448 170871 Revision C EQUIPPED WITH GT DRIVE SYSTEM GT Drive Models Inlcuded B0 254 48 B 2 54 MANUAL MB 254 02 Operation Troubleshooting and Replacement Parts Ma...

Page 2: ......

Page 3: ...nn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or...

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: ...tch 5 Accelerator Pedal 6 Foot Brake Pedal 6 Headlight Switch 6 Accessory Switch Optional 6 Smart View Display 7 Directional Signals Optional 9 Steering 9 Hazard Light Switch Optional 9 Electrolyte Al...

Page 6: ...Removal and Installation 4 Removal 4 Installation 5 Front Axle Disassembly 6 Replace Front Wheel Bearings 7 Replace the King Pins and Bushings 9 Replace the Steering Knuckle 11 Steering Component Ser...

Page 7: ...stem 9 Flush the Brake System 11 Replace the Parking Brake Lining electric motor brake 12 Inspection 14 Replace Front Disc Brake Pads 15 Replace Rear Brake Pads 17 Hydraulic Disc 17 Replace the Wheel...

Page 8: ...inion Bearing Preload 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth 19 Suspension 1 Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace...

Page 9: ...The Timer Relay 9 Testing the Interlock Relay 10 Signet Charger Troubleshooting 1 Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshoot...

Page 10: ...Hardware Suggested Torque Limits 1 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 har...

Page 11: ...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 7 Contents...

Page 12: ...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 13: ...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 14: ...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 15: ...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 16: ...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 The...

Page 17: ...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 18: ...TAYLOR DUNN...

Page 19: ...l 10 Seat Interlock Switch 10 Park Brake 10 Safety Rules and Operating Instructions Vehicle Operational Guidelines 11 Safety Guidelines 11 Starting 11 While driving 12 Loading and Unloading 12 Parking...

Page 20: ...ifferential Brakes Optional 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Smart Vi...

Page 21: ...s Do not tow this vehicle at more than 5 mph SAFETY RULES AND GUIDELINES It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operatin...

Page 22: ...ual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive...

Page 23: ...brake set whenever the operator leaves the vehicle Key Switch A key switch located on the right center side of the instrument panel turns on the vehicle Rotate the key clockwise to turn the vehicle p...

Page 24: ...vehicle is equipped with windshield wipers and one or more accessories the windshield wipers are controlled from this switch Other accessories are controlled from the auxiliary switch Foot Brake Pedal...

Page 25: ...n as possible At 90 all segments will flash and the vehicles speed will be reduced At this time the vehicle should be removed from service for charging Discharging beyond 90 will result in damage to t...

Page 26: ...witch Reset switches and start again 02001 Defective wiring Refer to troubleshooting 04003 Start up switches not operated in the correct order or a defective switch Reset switches and start again 0400...

Page 27: ...itor optional Operation The SMD notifies the operator 10 hours standard before a scheduled maintenance is due During this warning period the meter will continue to alert the operator This should allow...

Page 28: ...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 29: ...n at high speeds Observe all traffic regulations and speed limits Keep all body parts head arms legs inside this vehicle while it is moving Keep the vehicle under control at all times Yield right of w...

Page 30: ...ch to the OFF position Turn the key switch to the OFF position and remove the key In addition If parking this vehicle on an incline turn the wheels to the curb or block the wheels Do not block fire ai...

Page 31: ...tem Charging State LED1 LED2 LED3 0 to 50 Blinking OFF OFF 50 to 75 ON Blinking OFF 75 to 100 ON ON Blinking Cycle complete ON ON ON Signet HB xxxx Charger Operation The Signet HB 600 and HB 1000 char...

Page 32: ...ation Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interrupting the charging cycle could lead to overcharging or discharging the batteri...

Page 33: ...ires to proper pressure if applicable For extended storage the vehicle should be elevated so that the tires do not touch the ground If stored for a prolonged period the batteries should be charged as...

Page 34: ...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 35: ...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 c...

Page 36: ...ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on multiple shifts 2 Any deficiencies found during an inspection should corr...

Page 37: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...Maintenance Service and Repair Steering Page 22 Exploded View of Steering Gear...

Page 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 l...

Page 95: ...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 96: ...ging off of the end of the piston 14 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake b...

Page 97: ...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 98: ...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 99: ...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 100: ...TAYLOR DUNN...

Page 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...ove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and nega...

Page 115: ...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 116: ...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 117: ...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 118: ...wiring from the motor 9 Disconnect the hydraulic brake lines from the left and right brake bodies 13 Reinstall the drive in reverse order NOTE Lubricate the transmission input shaft with a small amou...

Page 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...Maintenance Service and Repair Transmission Page 20 NOTE Values shown are for reference only C D...

Page 131: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5...

Page 132: ...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 133: ...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 134: ...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 135: ...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 136: ...TAYLOR DUNN...

Page 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...TAYLOR DUNN...

Page 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...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 154: ...TAYLOR DUNN...

Page 155: ...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 156: ...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 157: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...

Page 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...TAYLOR DUNN...

Page 177: ...g 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 Turn the Key switch OFFBEF...

Page 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...Transmission Differential Case 16 Rear Brakes 18 Master Cylinder 20 Brake linkage 20 Brake Lines 22 Rear Suspension 24 Motor 26 Rear Motor Mount 26 Instrument Panel dash 28 Resetting the Smart View Di...

Page 194: ...Illustrated Parts Parts Page 2 Steering Knuckle...

Page 195: ...g 2 9 32 240 43 Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13...

Page 196: ...Illustrated Parts Parts Page 4 Front Brakes Brake body 9 above...

Page 197: ...4 5 32 240 41 Bearing TeflonR Coated 4 6 99 588 00 Bleeder screw 2 7 99 588 01 Bleeder screw adapter 2 8 88 069 82 Locknut 1 4 NC Gr 8 Do Not Reuse 4 9 41 350 30 Brake Body Assembly see below for com...

Page 198: ...Illustrated Parts Parts Page 6 Steering Linkage...

Page 199: ...TEM PART DESCRIPTION QTY 1 18 057 00 Tie rod 1 2 86 510 00 Ball joing clamp 4 3 86 501 98 Ball joing left 2 4 86 501 99 Ball joint right 2 5 88 527 11 1 8 x 1 Cotter pin 4 6 K1 157 99 Drag link 1 7 88...

Page 200: ...rated Parts Parts Page 8 Steering Column Ref Steering Gear 8 9 The steering column is an integral part of the frame and is not shown Part ID 5 is located in the top of the steering column tube 7 4 3 6...

Page 201: ...8 1 4 88 089 84 5 16NF Hex lock nut grade C 1 5 32 248 10 Upper bushing 1 6 20 031 65 Steering shaft assembly incl 3 and 4 1 7 19 011 25 Steering wheel cap 1 8 88 128 62 7 16 Split lock washer 3 9 88...

Page 202: ...Illustrated Parts Parts Page 10 Steering Gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16 Exploded Steering Gear dwg...

Page 203: ...orm 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 Seal input shaft 1 11 18...

Page 204: ...Illustrated Parts Parts Page 12 Front Suspension 1 2 3 4 7 8 Front axle ref 5 Wheels and Tires Illustration not available...

Page 205: ...olt 4 2 85 486 00 Leaf spring 2 3 32 214 50 Bushing 12 4 96 240 00 1 2NC x 4 Hex bolt 6 5 88 149 81 1 2NC Lock nut 8 6 7 88 149 81 1 2NC Lock nut 6 8 16 872 00 Spring hanger 4 Wheels and Tires ITEM PA...

Page 206: ...Illustrated Parts Parts Page 14 Transmission Gear Case...

Page 207: ...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 3287473 Output gear 18 1 1 25 GT 328 Spacer 46 100mm 1 GT 328 Spacer 46 100mm 0 or 1 GT...

Page 208: ...al Case Rear Axle Inner bearing on optional double bearing axle does not have an oil seal or o ring Orientation of bearing should have o ring groove adjacent to o ring on outer bearing Axle Shaft Inne...

Page 209: ...Bolt 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GT 71881 Seal 1 32 GT 70052 Vent 1 Rear Axle ITEM PART DESCRIPTION QTY 1 41 154 25 Axle shaft 2 2 80 505 20 Bearing 2 2a 80 505 30...

Page 210: ...Illustrated Parts Parts Page 18 Rear Brakes Brake body 8 above...

Page 211: ...ow for components 2 9 88 840 11 Retaining ring 2 10 99 588 00 Brake bleeder 2 99 588 01 Bleeder adaptor 2 11 32 220 03 Bushing 2 12 41 350 56 Park brake pin 2 13 41 350 12 Park brake lever bracket 2 1...

Page 212: ...Illustrated Parts Parts Page 20 Master Cylinder Brake linkage Linkage at the brake caliper...

Page 213: ...otter Pin 1 8 X 1 Steel 2 5 96 771 00 Clevis Pin 3 8 x 3 4 1 6 96 773 00 Clevis Pin 5 16 x 1 1 7 96 820 25 Adjusting Brake Cable Assembly 1 8 01 204 32 Brake Equalizer 1 9 88 089 81 Locknut 5 16 2 10...

Page 214: ...Illustrated Parts Parts Page 22 Brake Lines...

Page 215: ...r Right 1 6 99 604 56 Brake Line Rear Left 1 7 99 580 20 Brake Hose Rear 2 8 99 580 10 Brake Hose Front 2 9 99 564 00 T Fitting 1 10 99 575 10 Adaptor 3 16T X 1 8P 2 11 99 576 00 Hose Clip 4 12 99 591...

Page 216: ...Illustrated Parts Parts Page 24 Rear Suspension View from rear...

Page 217: ...14 85 510 17 Leaf spring 2 15 16 861 40 Spring mounting plate left 1 16 861 41 Spring mounting plate right 1 16 96 114 00 U bolt 4 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2 20 88 149 8...

Page 218: ...Illustrated Parts Parts Page 26 Motor Rear Motor Mount...

Page 219: ...40 Brush cover 1 11 95 930 00 Dust cap 1 Not Shown 88 067 17 1 1 8 long Grade 8 mounting bolt 88 067 22 2 long Grade 8 mounting bolt REAR MOTOR MOUNT ITEM PART DESCRIPTION QTY 1 88 067 22 Bolt 1 4 X...

Page 220: ...Illustrated Parts Parts Page 28 Instrument Panel dash...

Page 221: ...nce has been performed Taylor Dunn part number 62 027 40 Hand set available with instructions as part number 62 027 61 must be used to reset the meter Refer to the handset instructions D0 100 08 for i...

Page 222: ...Illustrated Parts Parts Page 30 Speed Control Panel Components located under the driver seat cushion 2 5 11 9 8 13 6 4 11 1 14 12 7...

Page 223: ...ER 4 88 069 81 1 4NC NYL INS LOCKNUT PLTD 4 8 79 840 00 10 Amp circuit breaker 1 9 79 840 20 20 Amp circuit breaker 1 10 79 840 20 20 Amp circuit breaker 1 11 88 818 06 8 x 1 2 Sheet metal screw 8 12...

Page 224: ...Illustrated Parts Parts Page 32 Miscellaneous Electrical Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1b 1a Motion Alarms Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4...

Page 225: ...8 DC converter line contactor 1 1a 73 005 01 Motion Alarm 1b 73 005 00 2 96 650 01 Wire Harness Clip stick on 3 96 642 00 Wire harness Clip push mount 4 62 033 48 Accelerator Module 1 10 71 102 10 Sea...

Page 226: ...ts Parts Page 34 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 Butt splice 75 320 51...

Page 227: ...QTY 79 309 40 Charger 48 volt Replacement cover with AC cord and gasket 79 851 10 Ammeter 1 K7 145 29 AC cord 1 K4 081 78 AC Receptacle 1 Note Ther are no user serviceable components inside the charg...

Page 228: ...Illustrated Parts Parts Page 36 Batteries Roll Out Battery Box 7 8 1 1b NEG POS NEG POS NEG POS NEG POS NEG POS NEG POS 12 Volt Negative tap Main Positive Main Negative 1a 2...

Page 229: ...5 16NC Hex nut stainless stell Quantities depend on voltage configuration of vehicle Roll Out Battery Box ITEM PART DESCRIPTION QTY 30 172 05 ROLLER ASMBLY PRSS ROBB 2 0 OD with bushing 2 30 172 20 R...

Page 230: ...PART DESCRIPTION QTY 1 90 175 06 Seat cushion 1 2 K6 602 39 Seat back 1 Illustration not available Decals Decals ITEM PART DESCRIPTION QTY 1 94 319 00 Battery disconnect 1 or 2 2 94 313 00 Battery wa...

Page 231: ...Illustrated Parts Parts Page 39 Miscellaneous ITEM PART DESCRIPTION QTY 98 200 00 Braked pedal pad 1 71 040 95 Compartment lock 1 01 110 20 Accelerator pedal 1 Miscellaneous Illustration not available...

Page 232: ...TAYLOR DUNN...

Page 233: ...APPENDIX A Special Tools...

Page 234: ...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 235: ...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 236: ...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 237: ...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 238: ...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 239: ...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 240: ...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 241: ...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 242: ...Model B 1 00...

Page 243: ......

Page 244: ...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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