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Taylor-Dunn BurdenMaster B 2-00 Operation, T Roubleshooting And Replacement Parts Manual Download Page 227

Illustrated Parts

Illustrated Parts

  

 

Page 47

Miscellaneous Electrical

ITEM #

PART #

DESCRIPTION

QTY

Not Shown

75-152-03

Chassie Control Harness

1

75-152-46

Power Harness

1

75-152-47

Control Panel Harness

1

75-152-04

Dash Harness

1

75-152-90

Smart view gauge cable

1

98-599-15

Plastic grommet for 1.75 hole

98-599-20

Plastic Grommet for 2.5 hole

Harness for Pole Mounted Strobe Light

1

75-152-06

Potratble Charger Harness

1

JF3-86181-00-00

Portable Charger Receptacle

1

2

96-650-01

Wire Harness Clip, stick on

3

96-642-00

Wire ahrness Clip, push mount

4

62-033-48

Accelerator Module

1

5

79-575-25

AC Cord (Built in charger)

1

6

88-565-06

1/4NC x 1/2 Phillips truss head screw

2

88-068-61

1/4 SAE flat washer

2

88-069-81

1/4NC lock nut

2

7

79-511-00

AC cord holder

1

8

79-530-00

Bushing

1

9

10

71-102-10

Seat interlock Switch

1

11

85-030-00

Spring

2

12

96-773-00

Clevis Pin

2

13

02-610-18

Mounting Plate

1

14

88-527-11

Cotter Pin

2

15

96-640-00

Clamp, 3/16 Push Mount

16

96-629-80 (not shown)

Clamp, Rubber Lined 3/16 ID

96-630-00 (not shown

Clamp, Rubber Lined 5/8 ID

96-630-50 (not shown

Clamp, Rubber Lined 5/8 ID (.265 mounting hole)

96-631-00 (not shown

Clamp, Rubber Lined 3/4 ID

96-631-10 (shown)

Clamp, Rubber Lined 1.0 ID

96-631-15 (not shown

Clamp, Rubber Lined 1-1/2 ID

17

96-624-00

Clamp, 1/4 Jiffy Clip

96-625-00 (not shown)

Clamp, 5/16 Jiffy Clip

18

96-626-00

Clamp, 7/8 Jiffy Clip

19

20

74-009-02

Digital Battery Status Meter, 36 volt

21

74-018-00

PMT/C Maintenance Hour Meter

22

Summary of Contents for BurdenMaster B 2-00

Page 1: ...ber Starting 147865 MANUAL MB 210 07 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 200 00 BurdenMaster B 2 00 B0 210 36 BurdenMaster B 2 10 B0 210 36 AMB Ambulance B0 210 4...

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: ...d Control 12 Chargers Wire diagram 13 Illustrated Parts 14 Appendix A Special Tools 15 Appendix B Suggested Torque Values 16 Appendix C Brake Lining Handling Precautions 17 Model B0 200 00 B0 210 36 B...

Page 6: ...TAYLOR DUNN...

Page 7: ...t this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 Various versions of the model B...

Page 8: ...pplicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any T...

Page 9: ...entions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information a...

Page 10: ...H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 This vehicle is not desig...

Page 11: ...Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe...

Page 12: ...B2 48 With Stake Side Dump Bed Option SC1 00 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor...

Page 13: ...rgraph 6 Directional Signals Optional 6 Hazard Light Switch Optional 6 Accelerator Pedal 7 Foot Brake Pedal 7 Park Brake 7 Charger Interlock 7 Seat Interlock Switch 7 Steering 8 Reverse or Motion Alar...

Page 14: ...bs B 2 00 907 kg 2 000 pounds Deck dimensions 109 W 190 5 L Centimeters 43 W x 75 L Inches Electrical System B 2 10 36 Volt Six 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Am...

Page 15: ...in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries DRIVER TRAINING P...

Page 16: ...iliary switchs located on the left side of the instrument panel and to the leftof the headlight switch Push the switch handle up turn on the accessory Push the switch handle down turn off the accessor...

Page 17: ...removed when the key switch is in the OFF position 5 Hi Low Switch optional The high low switch is located on the lower left of the instrument panel Toggle the switch lever up for normal speed Toggle...

Page 18: ...e yellow zone as the batteries discharge Charge the batteries when the needle is in the yellow zone If it is in the red zone to the left the batteries are empty and the truck should be taken out of se...

Page 19: ...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 Charger In...

Page 20: ...e position The alarm makes a repeated audible sound The motion alarm is the same alarm that is used for the reverse alarm only it operates in both the forward and reverse directions Steering The steer...

Page 21: ...fe span NOTE The battery status gauge as well as any faults indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle HM Depending on the revision...

Page 22: ...e Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenance Due Once the warning has expired and the maintenance...

Page 23: ...ce technician F05043 Traction ON R Refer to service technician F05044 Traction OFF R Refer to service technician F05045 Stack Corrupt Refer to service technician F05046 Open Contactor Refer to service...

Page 24: ...turning be sure to allow for corner cutting of the trailer Allow for longer stopping distances when towing heavy loads Allow for longer stopping distances when driving down a grade Safety Guidelines...

Page 25: ...hicle power system fails and applies the brake the can be released by disconnecting the electric brake from the control system and connecting a 20 to 24 volt DC source 1 5A to the electric brake Towin...

Page 26: ...0 ON ON Blinking Cycle complete ON ON ON Typical Signet HB Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safe...

Page 27: ...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 28: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 16 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Page 29: ...only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire...

Page 30: ...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 31: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4...

Page 32: ...s Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should...

Page 33: ...peration Brakes or Parking Brakes Dragging Worn 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...

Page 34: ...Ball Joints 4 General Purpose Grease 4 Pedal Linkages 1 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill...

Page 35: ...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 36: ...d 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 replaceme...

Page 37: ...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 38: ...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 39: ...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 40: ...regarding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Refer to Front Axle Rem...

Page 41: ...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 42: ...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 43: ...orward 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 the batteri...

Page 44: ...he king pin must be replaced 11 Reassemble in reverse order NOTE Refer to Replace the Steering Knuckle for information on installing the steering knuckle NOTE It is recommended that the thrust washers...

Page 45: ...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 steer...

Page 46: ...ten the king pin nut until it contacts the bottom of the knuckle Do not tighen so much as to squeeze the legs of the knuckle together NOTE Refer to Replace Front Wheel Bearings for information regardi...

Page 47: ...haft 9 Replace the Steering Wheel 11 Replace the Steering Gear 12 Replace the Ball Joints Tie Rods and Drag Link 13 Replacing the Drag Link 15 Replacing the Tie Rod 16 Center the Steering Gear 17 Pitm...

Page 48: ...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 49: ...teering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a full right turn and make sure that the ba...

Page 50: ...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 51: ...urement Rear Measurement 11 Measure the distance 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 distan...

Page 52: ...n severe bodily injury and or property damage Typical Ball Joint INSPECT BALL JOINTS NOTE A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end is worn out the...

Page 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 d...

Page 62: ...verse 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 ca...

Page 63: ...e 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 the...

Page 64: ...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 65: ...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 66: ...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 67: ...Maintenance Service and Repair Steering Page 21 Exploded View of Steering Gear...

Page 68: ...TAYLOR DUNN...

Page 69: ...Adjust the Parking Brake 7 Wheel Park Brake B 2 00 7 Wheel Park Brake B 2 10 8 Check Master Cylinder Fluid 10 Bleed the Brakes 11 Flush the Brake System 13 Replace the Parking Brake Lining 14 Wheel P...

Page 70: ...pad lining at the thinnest point on the 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 C...

Page 71: ...ut of the rotor at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its service limits NOTE A bent axle or damaged rear axle could caus...

Page 72: ...kages 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...

Page 73: ...aster 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 Inspect the Se...

Page 74: ...verse switch in the center OFF position 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...

Page 75: ...d 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 movement 5 Disconnect the main positive and negative cable...

Page 76: ...il 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 rod must be screwe...

Page 77: ...ut Nut Return spring bracket Cross shaft Clevis pin Jam nut Clevis pin Park brake handle linkage Bushing Clevis Cotter pin Park brake handle Clevis pin Equalizer Return spring Cotter pin Primary adjus...

Page 78: ...yes 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 g...

Page 79: ...working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately fl...

Page 80: ...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 81: ...emove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder 11 Attach a clear hose to the bleeder valve on each of the wh...

Page 82: ...kes were replaced with aftermarket parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling pr...

Page 83: ...ket parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new b...

Page 84: ...7 and replace if any wear or damage is found 14 Install new spacer bushings in the mounting bracket 15 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 16 Repeat this pro...

Page 85: ...s containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE It is recommended that b...

Page 86: ...ction for information regarding the correct master cylinder fluid level 21 Adjust the parking brake wheel park brake only Refer to Adjust the Parking Brake section 22 Set the park brake 23 Reconnect t...

Page 87: ...rease to the adjustor screw threads 15 Install in reverse order 16 Repeat for the opposite side 17 Adjust the brakes See Adjust the Service Brakes section for information regarding adjusting the brake...

Page 88: ...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 89: ...from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting Torque the brake body bolts to 11 ft lbs 14 Bleed the brakes Refer...

Page 90: ...fluid 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 s...

Page 91: ...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 92: ...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 93: ...was raised lower it to the ground 15 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 batteri...

Page 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...Table of Contents Charger Charger Remove Install 2 Troubleshooting 2 Programming 3 Delta Q 3 Signet 4 Delta Q IC650 5...

Page 106: ...horized Taylor Dunn distributor or can be downloaded from the Taylor Dunn web site HIGH VOLTAGE Disconnect the batteries and make sure that the AC power cord has been unplugged before disconnecting an...

Page 107: ...algorithm code will be displayed for 11 seconds The following is the list of algorithms available in Taylor Dunn chargers Contact Delta Q for any additional detail or for information on codes not lis...

Page 108: ...Disconnect the AC power source for a minimum of 20 seconds 11 Reconnect the charger positive battery lead and confirm all connections are secure Changing the Active Profile PC The charging profile ca...

Page 109: ...til the Fault Indicator is on solid and the Charging Output Indicator is flashing then release the button 3 The Error display will flash a code for the currently selected profile Press and release the...

Page 110: ...Chargers Page 6 Notes...

Page 111: ...10 Disassembling the 3rd Member 13 Assembling the 3rd Member 16 Pinion Bearing Preload 19 Pinion Gear Shimming Instructions 20 Setting the Pinion Gear Depth 20 Note Special Washers The washers for the...

Page 112: ...uired until level with the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes out of the opening allow to drain until level with the bottom of t...

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: ...ed load capacity may result in severe bodily injury 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the axle hub...

Page 116: ...ain 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 Failure to use lifting and support devices of ra...

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: ...t there is no tension on the spring hanger bolts Do not remove the bolts at this time 12 Remove the four u bolts holding the spring to the axle tubes 13 Remove the two lower spring hanger bolts and ra...

Page 119: ...Maintenance Service and Repair Transmission Page 9 Rear Suspension...

Page 120: ...ain 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...

Page 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...ctions 15 Check the gear lash between the ring and pinion gears The gear lash should be 005 to 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nut...

Page 128: ...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 129: ...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 130: ...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 131: ...Maintenance Service and Repair Transmission Page 21 NOTE Values shown are for reference only C D...

Page 132: ...TAYLOR DUNN...

Page 133: ...Oil 3 Motor 4 Removal 4 Installation 4 Rear Hub with Brake Drum 5 Removal and Installation 5 Rear Axle 6 Replace the Axle Bearing 8 Transmission 9 Removal 9 Installation 10 Differential Case 12 Disass...

Page 134: ...oil to drain into the drain pan and then reinstall the level plug 10 Reconnect the main positive and negative cables at the batteries 11 Remove blocks from behind the wheels 12 Test drive the vehicle...

Page 135: ...se lifting and support devices of rated load capacity may result in severe bodily injury CHANGE OIL Park the vehicle on a level surface 6 Place a drain pan that can hold a minimum of 2 quarts of oil u...

Page 136: ...be removed to allow clearance to remove the motor Refer to Transmission section for information on removing the transmission assembly from the vehicle 6 Remove the motor wires from the motor HINT Tag...

Page 137: ...tallation NOTE Some vehicle configurations do not have a removable hub The hub is an integral part of the rear axle See the illustrations to the right to identify the hub on your vehicle 6 Remove the...

Page 138: ...to identify the type of hub on your vehicle NOTE The tire wheel assembly must be removed for these procedures Refer to Tires and Wheels section for information on removing the tire and wheel assembly...

Page 139: ...rake drum 8 Remove the mechanical brake linkage from the brake arm 9 If equipped with hydraulic brakes disconnect the brake line from the wheel cylinder 10 Remove the four bolts holding the axle brake...

Page 140: ...m for information regarding removing the hub 2 Press the axle bearing off of the axle shaft and discard 3 Press a new bearing onto the axle shaft 4 If the axle is not to be immediately installed into...

Page 141: ...r deck access plate 7 Disconnect the motor wires from the motor 8 Remove the clevis pins from the brake cables left side shown 9 Remove the brake cable from the mounting bracket 10 If equipped with hy...

Page 142: ...he left and right spring hangers 14 Lift the rear of the vehicle high enough to roll the transmission out from under the vehicle 15 Place the frame of the vehicle on jack stands 1 Make sure the key sw...

Page 143: ...l the brake cable Use a new cotter pin 12 Adjust the brakes Refer to the Brake Service section for information regarding adjusting the brakes 13 Adjust the mechanical brake linkages Refer to the Brake...

Page 144: ...ion for information on removing the axles 4 Suspend the differential case over a drain pan that can hold a minimum of 2 quarts of oil 5 Remove the differential case cover being careful not to bend or...

Page 145: ...ate shaft bore plugs 10 Thread a sheet metal screw into each plug until the bore plug is forced out 11 Remove both snap rings from the intermediate shaft bore 12 Using a soft metal or hard wood dowel...

Page 146: ...ar teeth 13 Remove the intermediate bearing with an ID bearing puller 14 While supporting the shaft and gear assembly repeat steps 12 and 13 for the opposite side bearing and remove the intermediate s...

Page 147: ...t tightly into their grooves If a snap ring is loose then it must be replaced NOTE All internal components should fit easily together Do not hit any shaft or component with a hard metal hammer or punc...

Page 148: ...dowel the same diameter as the bearing bore to drive the bearing into place Do not drive against the inner race as this will damage the bearing 4 Install the input shaft into the housing and install...

Page 149: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Leaf elliptical 2 Leaf elliptical 3 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5 Front 5...

Page 150: ...ie up or support the rear axle so it cannot fall out of the vehicle 8 Remove the nuts from the u bolts holding the spring to the axle tube 9 Support the spring so that it cannot fall out of the vehicl...

Page 151: ...port with jack stands 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle beam 9 Support the spring so that it cannot fall out of the vehicl...

Page 152: ...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 153: ...leakage 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 orde...

Page 154: ...TAYLOR DUNN...

Page 155: ...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 156: ...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 157: ...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 158: ...nuts may result in the wheel coming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from t...

Page 159: ...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 160: ...TAYLOR DUNN...

Page 161: ...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 162: ...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 163: ...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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ...TAYLOR DUNN...

Page 173: ...le of Contents Motor Controller Motor Controller Remove Install 2 Inspect 2 Receptacles 2 Base Plate 2 Terminal Ends 2 R Terminal 2 Repair Programming 3 Programming 3 Troubleshooting 3 Hardware Torque...

Page 174: ...clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the controller base and heat sink 3 Install the controller to the mounting plate 4 Attach the wires to the s...

Page 175: ...troller will void the controller warranty Programming Taylor Dunn does not support field modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploa...

Page 176: ...Motor Controller Page 4 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal stud 38 44 4 29 4 97 Notes...

Page 177: ...to be legible when printed at this size A full size diagram 22 x 16 is inculded on the CD in PDF format You can access the diagram from a button on the CD menu The diagram s are B 2 10 SCH 00009 B 2...

Page 178: ...lled Special order electrical components are not included View from pin side 7 9 4 6 3 1 View from pin side 7 6 9 3 4 1 F R Switch Violet Black Gray White Gray White Black White Black Blue Black Push...

Page 179: ...h Violet Black Gray White Gray White Black White Black Blue Black Push for Forward View from Rear ACCELERATOR 9 PCB MS3 MS1 5 8 4 2 1 0 5v 6 11v B In B In SCH 00009 01 10 2007 Black MOTION ALARM AUTOM...

Page 180: ...TAYLOR DUNN...

Page 181: ...ing brake B 2 00 34 Wheels and Tires 36 Instrument Panel Up To Serial Number 179666 38 Instrument Panel Starting Serial Number 179667 38 Resetting the Smart View Display 38 Speed Control Panel 40 Char...

Page 182: ...Illustrated Parts Illustrated Parts Page 2 Front Axle...

Page 183: ...Bushing Metal Backed Teflon 4 7 97 180 55 Thrust Washer Metal Backed Teflon 5 8 4 8 21 020 15 King Pin 2 9 88 189 81 Lock Nut 5 8 N C 2 10 12 124 00 Hub Wheel 5 Stud Includes 11 12 13 2 11 45 338 00...

Page 184: ...Illustrated Parts Illustrated Parts Page 4 Front Brakes 5 Brake Body Assembly...

Page 185: ...Brake Body Bolt 4 5 41 350 70 Hydraulic Brake Body 2 6 99 588 01 Bleeder Screw Adapter 2 7 99 588 00 Bleeder Screw 2 8 88 069 82 1 4 NC Locknut Gr 8 Do Not Reuse 4 9 41 350 51 Plate Secondary Hydrauli...

Page 186: ...Illustrated Parts Illustrated Parts Page 6 Steering Linkage 7 Pitman arm see steering gear 6 4 4 1 4 5 1 2 3 5 1 3 5 1 2 FORWARD 8...

Page 187: ...age ITEM PART DESCRIPTION QTY 1 86 510 00 Clamp 4 2 86 501 98 Ball joint left 2 3 86 501 99 Ball joint right 2 4 88 159 85 Hex castle nut 4 5 88 527 11 1 8 x 1 Cotter pin 4 6 18 057 11 Drag link 1 7 8...

Page 188: ...Illustrated Parts Illustrated Parts Page 8 FLOOR BOARD 14 1 3 4 13 15 16 17 18 15 19 20 17 18 Steering Column 3 4 5 8 7 2 1 11 12 10 9 6...

Page 189: ...6NF Hex locknut grade 8 Pinch bolt nut 1 7 18 308 21 Steering gear assembly 1 8 88 128 62 7 16 Split lock washer 3 9 88 120 15 7 16NC x 1 Hex bolt 3 10 88 279 82 7 8NF Thin pattern hex nut 1 11 88 268...

Page 190: ...Illustrated Parts Illustrated Parts Page 10 Steering Gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16 Front Suspension...

Page 191: ...Lock washer 1 10 18 308 79 Seal input shaft 1 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side cover 1 16 18 308 86 Jam nut...

Page 192: ...Illustrated Parts Illustrated Parts Page 12 Rear Suspension B 2 10 Rear Suspension B 2 00 8 5 5 6 4 3 4 2 1 1a 1b...

Page 193: ...248 00 Hex bolt 6 5 88 169 82 Hex nut 6 6 96 114 00 U bolt 4 7 88 159 84 Hex nut 8 8 16 861 43 Spring plate right 2 16 861 42 Spring plate left 1 Rear Suspension ITEM PART DESCRIPTION QTY 1a 96 123 5...

Page 194: ...Illustrated Parts Illustrated Parts Page 14 1 Front Axle Ref Frame Channels Ref 2 3 2 3 4 5 Front Shocks Option...

Page 195: ...strated Parts Page 15 Front Shocks ITEM PART DESCRIPTION QTY 1 86 602 00 Shock 2 2 88 128 60 7 16 Flat washer 4 3 88 129 81 7 16NC Hex lock nut 4 4 86 602 13 Lower bracket 2 5 86 602 25 Upper bracket...

Page 196: ...Illustrated Parts Illustrated Parts Page 16 Transmission B 2 00...

Page 197: ...ring 3 15 80 480 10 Bearing 1 16 88 840 12 Snap ring 3 Not 45 100 00 Input shaft seal 1 Shown 17 41 973 00 Plug 2 18 66 611 15 Cover 1 19 41 127 94 Plug 1 20 66 610 68 Screw 10 21 94 430 04 Sealer 22...

Page 198: ...ote 1 Spacer 23 is available in increments of 05mm starting at 3 9mm 3 9mm spacer is part number GT 3287213 Add 10 to the part number for every 0 05mm over 3 9 For example if 4 55mm is needed 4 55 3 9...

Page 199: ...using 1 12 GT 72019 Seal 1 18 GT 71979 Bearing 1 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 24 GT 3287453 Output gear 30 1 0 or 1 GT 3287463 Output gear 24 1 0 or 1 GT 3287473 Out...

Page 200: ...Illustrated Parts Illustrated Parts Page 20 Transmission Differential Case B 2 10...

Page 201: ...ing and pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug 1 17 GT 3287113 Differential housing 1 19 GT 3287143 Differential case 1 20...

Page 202: ...Illustrated Parts Illustrated Parts Page 22 Rear Axle B 2 10 Rear Axle and Brakes B 2 00 Ref Transmission housing 2 3 4 1 5 7 10 6 11 15 9 12 8 13 14 16 18 19 17...

Page 203: ...kes B 2 00 Transmission Spec 012AJ309 1 Item No Part No Description Qty 1 41 347 15 Actuator park brake 2 2 45 303 00 Seal 2 3 32 509 10 Bearing retainer 2 4 80 505 10 Bearing race assembly 2 5 41 347...

Page 204: ...Illustrated Parts Illustrated Parts Page 24 Rear Brakes B 2 10 8 Brake Body Assembly...

Page 205: ...x bolt grade 8 4 2 41 350 51 Secondary plate 2 3 41 348 70 Brake pad 4 4 41 348 57 Spacer 4 5 32 240 41 Bushing 4 6 41 350 28 Mounting bracket 2 7 96 327 10 Hex bolt with thread locking compund 8 8 41...

Page 206: ...Illustrated Parts Illustrated Parts Page 26 Motor...

Page 207: ...at time of printing The original motor provided under part number 70 054 40 has been discontinued It has been replaced by 70 054 41 The 70 054 41 motor has slightly more power torque The 70 054 40 mot...

Page 208: ...Illustrated Parts Illustrated Parts Page 28 Master Cylinder and Linkage...

Page 209: ...52 Cap 1 9 99 510 61 Rebuild kit for 1 bore 1 10 99 510 51 Boot 1 11 99 510 53 Gasket 1 12 88 108 60 flat washer 2 13 1 14 05 210 97 Brake pedal 1 15 00 210 21 Mounting bracket 1 16 00 210 08 Master c...

Page 210: ...Illustrated Parts Illustrated Parts Page 30 Hydraulic Brake Lines Master Cylinder 14 13 12 11 10 9 8 7 1 6 FRAME Frame 1 3 7 1 6 5 15 4 3 2 1 1...

Page 211: ...ight 1 3 99 603 53 Brake line front left 1 4 99 603 54 Brake line front 1 5 99 605 55 Brake line rear left 1 6 99 605 56 Brake line rear right 1 7 99 576 00 Hose clip 4 8 99 564 00 T fitting 2 9 71 11...

Page 212: ...Illustrated Parts Illustrated Parts Page 32 Brake linkage parking brake B 2 10...

Page 213: ...96 772 00 Clevis Pin 3 8 1 11 02 210 72 Bracket Return Spring 1 12 80 410 20 Bolt Flange Brake Shaft 2 13 88 069 81 1 4 NC Lock Nut 2 14 88 060 14 1 4 X 1 1 2 NC Bolt 2 15 00 210 05 Brake Rod Rotor 2...

Page 214: ...Illustrated Parts Illustrated Parts Page 34 Brake linkage parking brake B 2 00 8 1 4 3 5 9 10 2 7 6 Frame Frame...

Page 215: ...5 96 772 00 Clevis pin 1 6 88 088 61 Washer 2 7 88 089 81 Nut 2 8 96 772 00 Clevis pin 1 9 88 517 09 Cotter pin 1 10 01 204 32 Equilzer 1 11 96 826 12 Cable 2 12 88 140 11 Bolt 4 13 96 773 00 Clevis...

Page 216: ...Illustrated Parts Illustrated Parts Page 36 Wheels and Tires...

Page 217: ...ead 5 12 041 00 Wheel Assembly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88...

Page 218: ...rt View Display The meter should only be reset after the preventative maintenance has been performed Taylor Dunn part number 62 027 40 Hand set available with instructions as part number 62 027 61 mus...

Page 219: ...o 179666 Item No Part No Description Qty 1 71 100 00 Auxiliary switches 0 1 2 2 71 039 11 Auxiliary switches 0 1 2 3 88 817 07 Screw 6 4 5 01 200 09 Console 1 6 74 010 00 Smart View gauge shoen 0 1 74...

Page 220: ...x 1 2 Sheet metal screw 4 7 88 060 09 1 4NC x 3 4 Hex bolt 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...

Page 221: ...9 305 20 79 309 50 Lester X Series 115 vac 79 303 36 79 303 48 79 303 37 N A Lester Summit 79 306 37 79 309 46 79 306 39 N A Delta Q QuiQ 79 306 32 79 309 49 79 306 36 79 306 48 Chargers sealed batter...

Page 222: ...Illustrated Parts Illustrated Parts Page 42...

Page 223: ...Illustrated Parts Illustrated Parts Page 43...

Page 224: ...Illustrated Parts Illustrated Parts Page 44...

Page 225: ...Illustrated Parts Illustrated Parts Page 45...

Page 226: ...llustrated Parts Illustrated Parts Page 46 Miscellaneous Electrical Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4 Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 20 21 5 6 7 8...

Page 227: ...4NC x 1 2 Phillips truss head screw 2 88 068 61 1 4 SAE flat washer 2 88 069 81 1 4NC lock nut 2 7 79 511 00 AC cord holder 1 8 79 530 00 Bushing 1 9 10 71 102 10 Seat interlock Switch 1 11 85 030 00...

Page 228: ...Illustrated Parts Illustrated Parts Page 48 Batteries...

Page 229: ...3 4 50 250 00 Battery hold down 3 5 88 088 66 Flat washer tin lead plated 3 6 88 069 81 1 2NC Nylon lock nut 3 7 88 081 12 5 16NC x 1 Hex bolt stainless steel 12 8 88 089 80 5 16NC Hex nut stainless s...

Page 230: ...Illustrated Parts Illustrated Parts Page 50 Seat Cushions Lights Deck and Frame 19 18...

Page 231: ...te 1 00 610 08 Front cowl smooth 1 See Cab and Cowl Windshield Frame Option Front cowl with windshield cutout 1 9 00 210 22 Headlight cover 1 10 00 210 25 Wire harness cover 1 11 94 050 11 Right headl...

Page 232: ...Illustrated Parts Illustrated Parts Page 52 Decals...

Page 233: ...leaving the vehicle 1 2 94 309 00 Apply hand brake 1 3 94 384 01 Not a motor vehicle 1 4 94 301 42 Arms and legs inside 1 5 94 313 20 General safety warning 1 6 94 319 00 Battery disconnect 1 7 94 31...

Page 234: ...Illustrated Parts Illustrated Parts Page 54 Fixed 2nd and 3rd Seat Option Hitches...

Page 235: ...mounting 3 16 Hitches ITEM PART DESCRIPTION QTY 97 804 01 Pintle hitch 97 808 00 Automatic coupling hitch 97 811 00 1 7 8 Ball hitch 97 805 00 Mounting bracket for 1 7 8 ball 97 821 00 2 Ball hitch 9...

Page 236: ...Illustrated Parts Illustrated Parts Page 56 Cab and Cowl Windshield Frame Option 1 2 3 10 11 12 11 13 14 15 16 9 4 17 19 18 5 6 Tubular Top Frame 7 8...

Page 237: ...oot 4 88 102 15 3 8NC x 1 3 4 Carriage bolt 4 5 88 108 60 3 8 Cut flat washer 4 6 88 109 87 3 8NC KEPS nut 4 7 96 124 00 U bolt 1 8 88 069 83 1 4NC Acorn nut 2 9 91 012 00 Cab 1 10 Same as 2 11 Same a...

Page 238: ...ted Parts Illustrated Parts Page 58 Windshield Wiper Option Illustration not available Dome Light Option Illustration not available Foldaway 2nd Seat Option DECK ANGLE REF 13 14 15 6 5 12 3 11 2 1 7 8...

Page 239: ...d Seat Option ITEM PART DESCRIPTION QTY 1 90 179 00 Seat backrest 1 2 00 210 95 Seat back weldment 1 3 00 210 97 Pivot plate 2 4 00 210 94 Seat base weldment 1 5 90 178 00 Seat cushion 1 6 See deck op...

Page 240: ...arts Illustrated Parts Page 60 Cab Doors 1 2 4 5 6 7 8 9 10 11 12 14 15 16 16 17 18 19 20 21 22 23 25 26 27 28 Note Left Door Shown 24 3 13 Steel door detail Door Restraint 16 13 Door frame Cab Door f...

Page 241: ...t 8 13 91 011 31 Steel door left unpainted 1 91 011 32 Steel door right unpainted 1 14 90 853 10 Left window assembly 1 90 853 11 Right window assembly 1 15 97 315 58 Inner Handle 2 16 91 012 12 Latch...

Page 242: ...Illustrated Parts Illustrated Parts Page 62 Mirrors Strobe Light 6 7 8 9 10 11 12 10 13 14 15 16 17 18 19 20 21 22 23 28 24 26 25 27 1 2 3 4 1 5 3 2 Multi Panel mirror option 29 31 30...

Page 243: ...ex bolt 2 12 88 068 61 1 4 SAE Flat washer 2 13 88 065 09 1 4NC x 3 4 Truss head bolt 4 14 88 068 62 1 4 Split lock washer 4 15 88 069 87 1 4NC Acorn nut 4 16 92 206 00 Mirror 1 17 00 210 70 Mounting...

Page 244: ...Illustrated Parts Illustrated Parts Page 64 Sun Tops 2 3 4 5 6 1 7 8 9 9 10 11 12...

Page 245: ...ulance 1 Not shown K1 123 09 Ambulance mountin pole spacer 0 4 as needed 3 88 102 11 3 8NC x 1 Carraige bolt 32 4 88 109 81 3 8NC Hax lock nut 32 5 91 151 00 Fiberglass top 1 6 91 101 00 Surry top 1 7...

Page 246: ...Illustrated Parts Illustrated Parts Page 66 Automatic Driver Seat Brake B 2 10...

Page 247: ...10m X 1 5 X 20 Hex Head 2 8 88 088 62 Lockwasher 5 16 2 9 88 099 80 Nut 5 16 NF 2 10 88 067 29 Bolt 1 4 X 4 1 4 NC Grade 8 1 11 96 500 04 Tool Electric Brake Manual Release 2 12 Magnet and Coil Sub As...

Page 248: ...Illustrated Parts Illustrated Parts Page 68 Optional Deckboards Illustration not available...

Page 249: ...upport angle 1 90 471 00 Deck board front 1 90 472 00 Deck board rear 1 Fixed 2nd seat 00 210 23 Center deck support angle 1 00 210 45 Left deck rail 1 00 210 46 Right deck rail 1 90 444 20 Deck board...

Page 250: ...Illustrated Parts Illustrated Parts Page 70 Tool Box Doors Option 1 2 3 5 6 7 8 9 10 4 8 10 11 12 13 14 15 16 17 Deck board...

Page 251: ...rew 16 9 88 068 61 1 4 SAE Flat washer 4 10 88 067 87 1 4NC KEPS nut 16 11 02 210 21 Rear left door 1 12 02 210 64 Rear right door 1 13 02 210 62 Rear top 1 14 Same as 4 4 15 88 065 09 1 4NC x 3 4 Tru...

Page 252: ...Illustrated Parts Illustrated Parts Page 72 Stake Side Options 1 1 1 2 3 4 5 6 7 8 9 10 10 10 Foldaway 2nd Seat Fixed 2nd Seat Flat Bed...

Page 253: ...e standard 3 90 545 02 Right side standard 4 90 545 03 Left side fixed 2nd seat 5 90 545 04 Right side fixed 2nd seat 6 90 545 14 Left side rear foldaway 2nd seat 7 90 545 12 Left side front foldaway...

Page 254: ...Illustrated Parts Illustrated Parts Page 74 1 4 3 2 3 Cargo Box Option 7 8 9 10 12 16 17 18 13 14 12 Side Panel Option...

Page 255: ...10 Front window 1 Not shown 94 320 10 Load height limit decal 1 12 Side Panels ITEM PART DESCRIPTION QTY 1 2 3 4 5 6 7 00 210 38 Left panel 1 8 00 210 37 Right panel 1 9 00 210 58 Tail gate 1 10 00 21...

Page 256: ...Illustrated Parts Illustrated Parts Page 76 Ambulance Deck and Top 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 257: ...10 05 Right side deck rail 1 8 90 440 72 Rear deck board galvanized 1 90 440 70 Front deck board galvanized 1 9 K1 111 22 Rear deck board white laminate 1 K1 111 21 Front deck board white laminate 1 1...

Page 258: ...TAYLOR DUNN...

Page 259: ...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 260: ...set the Smart View display maintenance meter includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adjust Capability Same as 62 027 61 above plus allows a limited range of speed adjustmen...

Page 261: ...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 262: ...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 263: ...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 264: ...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 265: ...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 266: ...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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