Taylor-Dunn C0-425-36 Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual Download

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Maintenance, Service, and Repair

Brakes

Page 23

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make

sure your work area is free from dirt and debris and will contain
any brake fluid spills.

Remove the master cylinder from the vehicle. See

Replace the Master Cylinder

section .

Drain all fluid from the master cylinder and discard.

Remove the rubber boot.

Depress the plunger and remove the plunger spring clip retainer.

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

Thoroughly clean, inspect and replace parts as required.

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

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

Reassemble in reverse order.

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

Summary of Contents for C0-425-36

Page 1: ...t Way To Go About Your B u s i n e s s Serial number Starting 150774 MANUAL MC 425 02 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded C0 425 36 C 4 25 36 C0 425 48 C 4 25 48 Rev...

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: ...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: ...us Indicator BSI 6 Steering 7 Hazard Light Switch Optional 7 Directional Signals 7 Accelerator Pedal 8 Foot Brake Pedal 8 Battery Disconnect Switch 8 Park Brake 8 Reverse or Motion Alarm Optional 9 Se...

Page 6: ...Front Wheel Bearings 7 Replace the King Pins and Bushings 9 Replace the Pivot Pin and Bushings 10 Replace the Steering Knuckle 11 Steering Component Service 1 Front End Alignment 2 Inspect Ball Joint...

Page 7: ...Rear Brake Pads 15 Hydraulic Disc 15 Replace the Wheel Cylinder 17 Disc Brake Body Assembly front or rear 17 Repair the Brake Body 19 Replace the Master Cylinder 21 Repair the Master Cylinder 23 Thro...

Page 8: ...Tire Inspection 2 Replace the Rear Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Battery Service 1 Cleaning 2 Testing 3 Watering 5 Charging 6 Replacing 6 volt batteries only 7...

Page 9: ...inder 20 Automatic Electric Brake 22 Brake Lines 24 Brake linkage parking brake 26 Brake linkage foot brake 28 Throttle linkage 30 Wheels and Tires 32 Instrument Panel dash 34 Resetting the Smart View...

Page 10: ...TAYLOR DUNN...

Page 11: ...Introduction About this manual 2 Who Should Read This Manual 2 Responsibilities 3 How To Use This Manual 4 Conventions 4 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: ...home parks and resorts They are not to be driven on public highways The locations of the model and serial numbers are illustrated below This vehicle is not designed to be driven on public roads or hig...

Page 17: ...e Check battery cells to be sure they are filled Check the tire pressure tightness of lug nuts and for any signs of damage Check the operation of each of the following controls Accelerator Brake Parki...

Page 18: ...TAYLOR DUNN...

Page 19: ...Switch 8 Park Brake 8 Reverse or Motion Alarm Optional 9 Seat Interlock Switch 9 Smart View Display 10 Vehicle Operational Guidelines 13 Safety Guidelines 13 Starting 13 While driving 14 Loading and U...

Page 20: ...ph Electrical System Solid State Speed Control 500 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC 48 12 kW 16 3 Horse Power for 5 min Separately Excited Field 36 8...

Page 21: ...It is available in maximum designed speeds ranging from 5 to 9 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or l...

Page 22: ...safety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Tr...

Page 23: ...ines the direction of travel of the vehicle Push the top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT SWITCH from forward to rever...

Page 24: ...in operation The battery status indicator located on the top of the display has a LED bar graph that indicates the relative state of charge of the battery The right LED will light only when connected...

Page 25: ...steering column Pull the lever up to reposition the steering wheel Directional Signals The turn signal lever is located on the left side of the steering column Push the lever forward to activate the r...

Page 26: ...pressure to the brake pedal slows the vehicle according to the amount of pressure applied Relieving pressure from the pedal releases the braking action Park Brake The parking brake is actuated with a...

Page 27: ...es the seat The driver must be seated for the vehicle to operate Whenever the driver leaves the vehicle the driver should turn the key switch off place the forward off reverse switch in the center OFF...

Page 28: ...e charged as soon 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 resul...

Page 29: ...switch 04007 Defective wiring 04009 Discharged battery or defective wiring Charge the battery If the battery is good check wiring to the controller 04010 Battery voltage too high Incorrect battery in...

Page 30: ...eriod elapses then the vehicles maximum speed will be significantly reduced Warning period The warning starts when the Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will...

Page 31: ...all times Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle at intersections blind spots or other dangerous locations Do not dr...

Page 32: ...fore leaving the vehicle Set the parking brake Set the forward off reverse switch to the OFF position Turn the key switch to the OFF position and remove the key In addition If parking this vehicle on...

Page 33: ...e a week Do not charge the batteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their lifespan Only authorized personnel should perfor...

Page 34: ...h and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l C...

Page 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...

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 Maintenance Guidelines for Vehicles Used in Severe Conditions 3 Troubleshooting Guide 4 Lubrication Chart 5...

Page 38: ...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 39: ...ition the entire vehicle should be inspected monthly for signs of damage If any damage is found the vehicle should be immediately removed from service and repaired The following list is meant as a gui...

Page 40: ...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 41: ...2 King Pin 2 General Purpose Grease 3 Ball Joints 6 General Purpose Grease 4 Idler Pivot 1 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Drive Drain Plug 1...

Page 42: ...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 43: ...st 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 Replace the Pivot...

Page 44: ...r bushings 8 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for infor...

Page 45: ...the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding...

Page 46: ...l out of the vehicle 9 Disconnect the drag link ball joint or rod end from the steering pivot on the front axle assembly NOTE Refer to the Replacing the Ball Joints section for information regarding t...

Page 47: ...ation regarding removing the front wheels 8 Realign the front wheels Refer to Steering Component Service section for information regarding realigning the front wheels 9 If equipped with front brakes b...

Page 48: ...nuckles and king pin bushings Refer to the following sections for information regarding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not ha...

Page 49: ...ving the hub Refer to the Brakes section for information regarding the removal of the brake body NOTE Catch the outer bearing as it falls out 10 Thoroughly clean all grease from the inside of the hub...

Page 50: ...tall the hub dust cap 14 Reinstall the brake body and the tire wheel assembly NOTE Refer to the Brakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reco...

Page 51: ...icle Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily...

Page 52: ...iculty and loss of control of the vehicle causing severe bodily injury and or property damage 12 Reassemble in reverse order NOTE Refer to Replace the Steering Knuckle for information on installing th...

Page 53: ...e body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is remov...

Page 54: ...er arm of the axle beam NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign the wheels NOTE Refer to the Ste...

Page 55: ...place the Tilt Steering Assembly 8 Steering Column 9 Disassemble 9 Assemble 10 Replace the Steering Gear 11 Center the Steering Gear 12 Pitman Shaft Alignment 12 Replace the Ball Joints Tie Rods and D...

Page 56: ...o that the distance is between 10 1 8 to 10 3 8 inches NOTE The difference between the left and right measurement should be no more than 1 8 inch 8 Measure the distances from the rear of the upper axl...

Page 57: ...n position Driving the vehicle while the steering wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 14 Loosen...

Page 58: ...tioned so that they contact other components may result in steering failure and loss of control of the vehicle causing severe bodily injury and or property damage 21 Reconnect the main battery connect...

Page 59: ...tching the ball joints rapidly rotate the steering wheel to the left and right 8 If the ball joint housing moves up or down then the ball joint is worn out and should be replaced Refer to section Repl...

Page 60: ...ion for information regarding removing the ball joint from the drag link 8 Loosen the gear lash jam nut and the worm bearing adjuster jam nut 9 Unscrew the gear lash adjuster all of the way to the sto...

Page 61: ...he steering shaft 1 2 the number of turns in the original direction 13 While rotating the input shaft back and forth through its centered position adjust the gear lash adjusting screw so that there is...

Page 62: ...f the screws must be removed the other only needs to be loosened Refer to the illustration Loosen the jam nuts and and remove loosen the screws 7 Disconnect the harness from the steering column 8 Loos...

Page 63: ...irclip Steering wheel adaptor 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks un...

Page 64: ...e bearings remove the inner race from the steering shaft and outer races from the tilt housing 20 Remove the roll pin from the lower bushing and the lower bushing from the column Assemble Assemble in...

Page 65: ...may result in severe bodily injury Failure to support the steering gear will result in the steering gear falling out of the vehicle and could cause property damage and or severe bodily injury 1 Make s...

Page 66: ...ate the input shaft clockwise 1 2 the rotations counted in the previous step 4 Mark the input and pitman shaft in relation to the housing PITMAN SHAFT ALIGNMENT 1 Center the steering gear Refer to Cen...

Page 67: ...s required to remove the ball joint from the sleeve This will make it easier to realign the wheels 11 Install the new ball joint into the steering sleeve Screw it into the sleeve the same number of tu...

Page 68: ...stands 7 Remove the 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...

Page 69: ...stands 7 Remove the ball joints or rod ends from the steering knuckles NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Remove...

Page 70: ...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 71: ...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 72: ...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 73: ...Maintenance Service and Repair Steering Page 19 Exploded View of Steering Gear...

Page 74: ...TAYLOR DUNN...

Page 75: ...5 Adjust the Parking Brake 7 Wheel Park Brake 7 Check Master Cylinder Fluid 8 Bleed the Brakes 9 Flush the Brake System 11 Replace the Parking Brake Lining 12 Wheel Park Brake 12 Replace Front Brake...

Page 76: ...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 Current Taylor...

Page 77: ...r 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 cause excessive br...

Page 78: ...and bushing for any signs of damage or corrosion NOTE The park brake pin is inside of the brake body Refer to Repair the Brake Body for information on removing the park brake pin 9 Inspect all brake...

Page 79: ...nding brake pedal linkage If you are experiencing a low brake pedal or lack of braking power the entire brake system should be inspected ADJUST THE BRAKE LINKAGE 6 Tighten the master cylinder push rod...

Page 80: ...ivot bolt so that the brake pedal moves freely with no side play 9 Reconnect the main battery connector 10 Remove blocks from behind the wheels 11 Release the park brake and test drive the vehicle T A...

Page 81: ...ADJUST THE PARKING BRAKE Wheel Park Brake The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles 6 Release the park brake 7 Loosen the jam nu...

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: ...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 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: ...rts 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 Wheel Park Brake The parkin...

Page 87: ...et 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 br...

Page 88: ...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 89: ...ning 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 both the...

Page 90: ...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 91: ...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 92: ...12 Disconnect the brake hose from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting Torque the brake body bolts to 11 ft...

Page 93: ...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 94: ...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 95: ...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 96: ...arding bleeding the brakes 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Push Rod...

Page 97: ...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 98: ...TAYLOR DUNN...

Page 99: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Throttle Linkage...

Page 100: ...al arm pivot nut so that there is 0 005 clearance between the nut and flat washer 7 Make sure the accelerator pedal arm is in the fully released position See arrow 1 in the illustration 8 Adjust the t...

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: ...en 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: ...a t s i s e R F 5 7 s m h O m m s e h c n i m m s e h c n i m m s e h c n i e r u t a m r A d l e i F 2 7 6 1 P X 0 4 4 5 0 0 7 5 3 6 0 5 2 0 0 5 8 9 6 5 7 2 7 8 5 1 5 2 6 0 6 1 1 0 0 2 1 9 8 7 1 P X...

Page 111: ...Hub or Rotor 5 Removing and Installing the Rear Axles 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 10 Disassembling the 3rd Member 13 A...

Page 112: ...l level of the 3rd member Park the vehicle on a level surface 6 Place an oil drain pan underneath the 3rd member 7 Remove the fill level plug 8 The oil level should be very close to the bottom of the...

Page 113: ...support with jack stands 7 Place a four quart drain pan under the drive assembly 8 Remove the drain plugs from the differential case and gear case 9 Once the oil has drained replace the drain plugs an...

Page 114: ...tic electric brake is sandwiched between the drive motor and the gear case The electric brake is retained by the drive motor mounting screws Once the motor is removed the electric brake will no longer...

Page 115: ...remove the bolt 6 Raise the wheel off of the ground 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: ...housing is above the bottom of the axle flange To minimize oil spills raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange If both axles are to be re...

Page 117: ...e body assembly do not let it hang by the brake hose 13 Pull the axle out of the housing 14 Inspect all bearings for roughness or play replace as needed 15 Install in reverse order lubricate the o rin...

Page 118: ...osition 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 TRANSMISSION ASSEMBLY Remove and Inst...

Page 119: ...the rear wheels come off of the ground 11 Remove the swing arm pivot bolts and roll the transmission assembly out from under the vehicle 12 Install the transmission assembly in reverse order of remov...

Page 120: ...ngs Damage to the sealing surface may lead to an oil leak resulting in damage to the internal parts of the drive DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 6 Raise the rear of the v...

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: ...bolts to 18 20 foot pounds NOTE Torque the pinion nut to 154 169 foot pounds NOTE Apply gasket sealer 94 430 05 to the front flange on the 3rd member and gear case cover NOTE Pack the motor seal with...

Page 123: ...MEMBER 6 Raise the rear of the vehicle and support with jack stands 7 Remove the complete drive from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing th...

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: ...move the differential assembly do not allow the ring nuts to rotate 11 Install the pinion gear Re shim if required 12 Install the pinion gear holding tool 96 500 42 and tighten the pinion nut enough t...

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: ...ed C B A DV Pinion Shim 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...

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

Page 132: ...TAYLOR DUNN...

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

Page 134: ...use lifting and support devices of rated load capacity may result in severe bodily injury If a spring has failed or is fatigued then it is recommended that both springs are replaced as a set 6 Remove...

Page 135: ...bolt Wheel removed for illustration only Front spring 6 Remove the lower shock mounting bolt from the front shocks 7 Raise the front wheels off of the ground just enough so that the springs can be rem...

Page 136: ...igns of leakage If any sign of 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 In...

Page 137: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Rear 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: ...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 is...

Page 140: ...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 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: ...mber 77 200 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 th...

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: ...t in property damage STORAGE AND RETURNING TO SERVICE Storage Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries...

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: ...BLE OF CONTENTS Test Equipment Required 2 Important Notes and Instructions 2 Definitions 2 Terminology used 2 Start Troubleshooting Here 3 Test 8 Anti Rolloff Fault 22 Test 9 Electric Motor Brake 23 S...

Page 156: ...the start of each test sequence you will be instructed on how to place the control switches While testing do not change the position of any switches unless instructed to do so DURING ALL TESTS After...

Page 157: ...uits Do not continue unless the indicator shows a charged battery If the vehicle runs in one direction only then skip ahead to test 3 If the vehicle runs slow in forward but otherwise runs normal then...

Page 158: ...ad to section 5 If the voltage does not start at 24 volts then go to section 4 TEST 1 2 Test the voltage from B to B on the Controller If the voltage equals battery volts then go to test 1 3 If the vo...

Page 159: ...e drive wheels to the ground TEST 1 4 Test the voltage at pin 5 on the 12 pin logic card connector If the voltage is low then skip ahead to test 1 5 If the voltage is high then Check the seat switch f...

Page 160: ...ke switch for shorted contacts Check the wire to the park brake switch for short circuits to B Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehi...

Page 161: ...the voltage is above 0 3 volts then skip ahead to Test 6 TEST 1 8 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is low then skip ahead to test 1 9 If the voltage is high...

Page 162: ...vehicle before lowering the drive wheels to the ground TEST 2 2 Check the resistance from the motor A1 to the A2 terminals If the resistance is less than 1 Ohm then go to test 2 3 If the resistance i...

Page 163: ...ult in unexpected movement of the vehicle resulting in injury or property damage This troubleshooting guide is written in sequential order All tests must be performed in the order that they are writte...

Page 164: ...tage at pin 2 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 2 If the voltage is high then skip ahead to Test 7 TEST 3 2 Test the voltage at pin 3 on the 12 pin log...

Page 165: ...voltage at pin 3 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 4 If the voltage is high then skip ahead to Test 7 TEST 3 4 Test the voltage at pin 2 on the 12 pin...

Page 166: ...the controller Connect the negative lead to the F2 terminal on the controller The test should show the presence of a diode approx 0 5v If the test is open or shorted then one or both directional FET...

Page 167: ...r 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 4 2 Test the voltage at...

Page 168: ...th the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector The relay is located in the charger cabinet Stop trouble shooting here and repair the problem When the repa...

Page 169: ...actor coil If the voltage is not within 1 volt of battery voltage then the contactor is bad and must be replaced NOTE An open contactor coil should be accompanied by a 4 flash code from the logic LED...

Page 170: ...t of the vehicle resulting in injury or property damage B Terminal on the Sevcon controller This troubleshooting guide is written in sequential order All tests must be performed in the order that they...

Page 171: ...in numbers are cast into the connector as shown in the illustration TEST 6 1 Accelerator pedal released Test the voltage from pin 9 to battery positive If the voltage equals battery volts then skip ah...

Page 172: ...quals battery volts then skip ahead to test 6 4 If the voltage does not equal battery volts then check the wire from pin 4 to the battery voltage negative circuit breaker Stop trouble shooting here an...

Page 173: ...een 4 8 and 5 1 volts then the module has failed and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the d...

Page 174: ...e circuit breaker 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 7 2 If the vehicle do...

Page 175: ...e at the White Black wire on the F R switch If the voltage equals battery volts skip ahead to test 7 4 If the voltage does not equal battery volts then the F R switch has failed Stop trouble shooting...

Page 176: ...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 Drive Mo...

Page 177: ...f the brake is not engaged then Disconnect the electric brake harness connector and repeat the test If the brake is still not engaged then Remove the brake and repair or replace the brake as required...

Page 178: ...rd connector is broken 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 If the test is bad th...

Page 179: ...igh 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 off ref b...

Page 180: ...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 Accelera...

Page 181: ...er Refer to the documentation supplied with the charger or contact the charger manufacturer for more information Turn the Key switch OFFBEFORE disconnectingthebatteries Disconnecting the batteries wit...

Page 182: ...TAYLOR DUNN...

Page 183: ...TABLE OF CONTENTS Wire Diagrams Dash 2 Control Panel 3...

Page 184: ...15A 10A Red Black Red Black Red Black Violet Black 12 Black White Gray Red Black Green Brown 16 14 15 13 Red Black Yellow White White Blue White 11 23 22 21 Violet Black Red Black Red Gray Black 18 1...

Page 185: ...hite Violet Black Blue Black 4 8 3 5 Black White Black 2 1 Yellow Blk Red Blue White 20A 48v CB Black Red 200A CB 12V HORN White White 12v CB Red Red Black Red Black Red Black Red Black DISCONNECT MAI...

Page 186: ...TAYLOR DUNN...

Page 187: ...r 20 Master Cylinder 20 Automatic Electric Brake 22 Brake Lines 24 Brake linkage parking brake 26 Brake linkage foot brake 28 Throttle linkage 30 Wheels and Tires 32 Instrument Panel dash 34 Resetting...

Page 188: ...Illustrated Parts Illustrated Parts Page 2 Front Axle Steering and Brakes 7 8 35 34 33 32 12 30 29 28 27 26 25 24 23 22 21 20 19 18 16 15 14 2 13 12 11 10 9 5 7 6 5 4 3 2 1 36 31 17...

Page 189: ...nd thread 3 17 87 074 00 Grease fiting 6 18 18 020 30 Steeing link 2 19 32 200 00 Bushing 2 20 86 510 00 Ball joint clamp 6 21 14 425 07 Steering pivot 1 22 86 501 99 Ball joint right hand thread 3 23...

Page 190: ...Illustrated Parts Illustrated Parts Page 4 Steering Column 1 2 3 4 5 6 7 8 9 Use LockTite on mounting hardware...

Page 191: ...hex nut 1 4 88 262 62 7 8 Split lock washer 1 5 18 108 00 Pitman arm 1 6 18 308 21 Steering gear 1 7 88 128 62 7 16 Split lock washer 3 8 88 120 15 7 16 NC x 1 1 2 Hex bolt 3 9 18 308 04 Universal jo...

Page 192: ...Illustrated Parts Illustrated Parts Page 6 Steering Gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16...

Page 193: ...worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 1 11 1...

Page 194: ...Illustrated Parts Illustrated Parts Page 8 Front Suspension...

Page 195: ...140 22 1 2 NC x 3 1 2 Hex bolt 2 8 88 149 81 1 2 NC Lock nut 3 9 88 189 82 5 8 NC Then pattern lock nut 4 10 88 101 16 3 8 NC x 2 Hex bolt grade 5 4 11 88 109 81 3 8 NC Hex lock nut 4 12 86 007 00 Sh...

Page 196: ...Illustrated Parts Illustrated Parts Page 10 Transmission Assembly 5 7 6 8 9...

Page 197: ...Split lock washer 12 3 4 41 290 60 Axle tube 2 5 88 099 80 5 16 NF Hex nut 2 6 88 088 62 5 16 Split lock washer 2 7 88 128 62 7 16 Split lock washer 2 8 89 111 27 10 x 1 5 x 30mm Hex bolt 2 9 70 456 1...

Page 198: ...Illustrated Parts Illustrated Parts Page 12 Transmission Gear Case...

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 14 Transmission Differential Case Rear Axle...

Page 201: ...7 GT 3287113 Differential housing 1 19 GT 3287143 Differential case 1 20 GT 72013 O ring 1 22 GT 71896 M10 x 25 Bolt 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GT 71881 Seal 1 32...

Page 202: ...Illustrated Parts Illustrated Parts Page 16 Rear Brakes Brake Body Assembly...

Page 203: ...assembly 2 9 88 840 11 Retaining ring 2 10 See Brake Body Assembly Bleeder 2 11 32 220 03 Bushing 2 12 41 350 52 Park brake pin 2 13 41 350 12 Park brake lever mounting bracket 2 14 41 350 52 Clevis...

Page 204: ...Illustrated Parts Illustrated Parts Page 18 Rear Suspension 12 FRONT 11 1 5 4 2 17 6 Frame 7 7...

Page 205: ...omplete drive assembly includes 1 10 32 207 10 Busjing 4 11 17 108 00 Spacer 1 12 16 857 10 Spring mount left 1 13 96 240 00 1 2NC x 4 Hex bolt 2 14 88 149 81 1 2NC Lock nut 2 15 86 007 00 Shock 2 16...

Page 206: ...Illustrated Parts Illustrated Parts Page 20 Motor Master Cylinder 13...

Page 207: ...r housing 1 10 70 421 40 Brush cover 1 11 95 930 00 Dust cap 1 Master Cylinder ITEM PART DESCRIPTION QTY 1 99 510 02 Master cylinder assembly incl 8 9 10 11 1 2 See Brake Linkage Bolt 2 3 99 578 00 Hy...

Page 208: ...Illustrated Parts Illustrated Parts Page 22 Automatic Electric Brake...

Page 209: ...2 7 89 111 27 Bolt 10m X 1 5 X 20 Hex Head 2 8 88 088 62 Lockwasher 5 16 2 9 88 099 80 Nut 5 16 NF 2 10 88 067 17 Bolt 1 4 X 1 1 8 NC Grade 8 no brake option 88 067 29 Bolt 1 4 X 4 1 4 NC Grade 8 bra...

Page 210: ...Illustrated Parts Illustrated Parts Page 24 Brake Lines 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4 4 Master Cylinder ref Cowl view from rear 2 Use thread sealant...

Page 211: ...00 Coupler 3 5 71 110 00 Brake light switch 1 6 99 591 00 Brake light switch adaptor 1 7 99 559 00 T fitting 1 8 99 604 66 Brake line 1 9 99 600 58 Brake line 1 10 99 605 74 Brake line 1 11 99 609 57...

Page 212: ...Illustrated Parts Illustrated Parts Page 26 Brake linkage parking brake Cable lock Cable clevis 6...

Page 213: ...t hand thread 1 2 88 099 81 5 16NF Hex nut left hand thread 1 3 88 099 80 5 16NF Hex nut 1 4 96 343 00 Link 1 5 96 763 00 Clevis right hand thread 1 6 96 754 00 Clevis 2 7 96 773 00 Clevis pin 4 8 96...

Page 214: ...Illustrated Parts Illustrated Parts Page 28 Brake linkage foot brake 1 2 3 4 5 8 23 7 4 4 22 3 2 1 6 9 9 10 11 12 13 14 15 16 17 18 19 20 21...

Page 215: ...t 1 8 88 100 15 3 8NC x 1 3 4 Hex bolt 1 9 97 211 30 Blind nut 6 10 88 148 61 1 2 SAE Flat washer 2 11 32 215 00 Bushing 2 12 00 425 06 Mounting plate 2 13 See Master Cylinder Master cylinder 1 14 98...

Page 216: ...Illustrated Parts Illustrated Parts Page 30 Throttle linkage 15 14 7 3 13 9 8 5 6 2 12 17 10 16 17 1 11 14 13 14...

Page 217: ...ead 1 6 97 211 00 1 4NF Hex nut left hand thread 1 7 86 503 99 Rod end right hand thread 1 8 88 079 80 1 4NF Hex nut 1 9 50 002 13 Link 1 10 32 215 00 Bushing 2 11 62 033 48 Accelerator module 1 12 88...

Page 218: ...Illustrated Parts Illustrated Parts Page 32 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 219: ...4 x 12 Solid rubber Split Rim Wheels 3 12 042 12 Inner Wheel 12 bolt 4 12 042 13 Outer Wheel 12 bolt 5 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF Hex Bolt...

Page 220: ...Illustrated Parts Illustrated Parts Page 34 Instrument Panel dash 2 Smart View Display...

Page 221: ...d 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 information on the pro...

Page 222: ...nk 13 4Vdc 300W DC DC CONVERTER F2 0A Part Serial No 622 11088 Input 36 48V battery IN I N O U T O U T 18 Install around entire perimeter of lip 19 2 plcs 13 into harness connectors Install 94 422 10...

Page 223: ...at washer 4 88 069 81 1 4NC Nylon lock nut 4 9 73 004 20 Horn 1 10 88 838 06 14 x 1 2 Pan head sheet metal screw 2 11 98 603 00 Grommet 1 12 62 400 10 Sevon controller 1 13 73 005 04 Reverse beeper 1...

Page 224: ...Illustrated Parts Illustrated Parts Page 38 Miscellaneous Electrical 9 Seat switch Miscellaneous Wire Harness Clamps 2 3 7 4 6 8 Horn switch mounted on the dash...

Page 225: ...al PMT C Maintenance Hour Meter 1 73 005 05 Reverse Warning alarm 1 2 96 650 01 Wire Harness Clip stick on 3 96 642 00 Wire ahrness Clip push mount 4 96 629 80 not shown Clamp Rubber Lined 3 16 ID 96...

Page 226: ...Illustrated Parts Illustrated Parts Page 40 Lighting System...

Page 227: ...15 Tailight mounting screw 4 88 034 13 Tailight mounting nut 4 Taillight Brake light bulb 1157 2 72 082 00 Back up Turn signal bulb 4 72 028 30 Front turn signal 2 72 028 32 Wiring pigtail for turn si...

Page 228: ...Illustrated Parts Illustrated Parts Page 42 Seat Cushions and Deck...

Page 229: ...ery disconnect switch 1 2 51 344 80 Park brake handle 1 3 95 512 00 Deck handle 2 4 90 160 70 Seat assembly 1 5 90 160 60 Arm rest kit 1 6 00 425 13 Deck cover 1 7 90 160 71 Seat spacer 2 8 88 080 13...

Page 230: ...Illustrated Parts Illustrated Parts Page 44 Decals...

Page 231: ...ata plate decal 1 94 373 09 Data plate metal 1 4 94 313 20 Safety waring 1 5 94 313 00 Explosive gases 1 6 94 309 00 Park brake warning 1 7 94 384 01 Not a motor vehicle 1 8 94 384 14 When leaving veh...

Page 232: ...Illustrated Parts Illustrated Parts Page 46 Frame Components 6 14 20 6 Side Battery Extract Option Illustration not available...

Page 233: ...crew 4 13 88 100 14 3 8NC x 1 1 2 Hex bolt 10 14 88 106 62 3 8 Split lock washer 10 15 88 108 61 3 8 SAE Flat washer 10 16 98 017 95 Floor mat 1 17 00 425 18 Floorboard 1 98 451 20 Foam tape 13 18 94...

Page 234: ...Illustrated Parts Illustrated Parts Page 48 1 2 3 4 5 4 5 4 3 4 6 4 Front Push Plate Option Hitches...

Page 235: ...5 22 Push plate 1 3 88 140 16 1 2NC x 2 Hex bolt 6 4 88 148 61 1 2 SAE Flat washer 36 5 88 149 81 1 2NC Hex lock nut 18 6 88 140 22 1 2NC x 3 1 2 Hax bolt 12 Hitches ITEM PART DESCRIPTION QTY 97 804 0...

Page 236: ...e end user Refer to the documentation supplied with the charger or contact the charger manufacturer for more information Batteries The battery supplied with this vehicle is either specified or provide...

Page 237: ...APPENDIX A Special Tools...

Page 238: ...l C4 25 Huskey 62 027 10 GE EV1 Analyzer Used to test the GE EV1 speed control 62 027 20 Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41 350 13 Pin Removi...

Page 239: ...APPENDIX B Torque Values...

Page 240: ...4 110 9 16 12 5 6 8 4 8 7 1 3 1 1 2 3 1 8 4 1 4 0 9 16 18 6 3 9 4 9 7 1 4 6 1 3 7 2 0 6 1 6 0 5 8 11 7 8 117 1 2 0 1 8 0 1 7 0 2 5 4 1 9 5 5 8 18 8 8 1 3 2 1 3 6 2 0 4 1 9 2 2 8 8 2 2 5 3 4 10 1 3 8...

Page 241: ...NDIX B PAGE 3 Torque Values L 9 Head Markings S A E Grade 2 S A E Grade 5 S A E Grade 8 L 9 Truss Head 1 4 20 Carriage Bolt 5 16 18 3 8 16 The following bolts are in accordance with Grade 2 torque val...

Page 242: ...TAYLOR DUNN...

Page 243: ...Appendix C...

Page 244: ...brake assemblies 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 chise...

Page 245: ......

Page 246: ...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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