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Taylor-Dunn RE-380-36, Operator'S And Service Manual

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Taylor-Dunn RE-380-36 Operator'S And Service Manual Download Page 186

Wire Diagrams

Wire Diagrams

  Page 2

COMPLETE VEHICLE

Battery positive

HORN

4

STROBE LIGHT 

[option]

SWITCH

Blue/Black

White/Black

Gray/White

Black

9-Pin AMP

9

Yellow

Brown/White

ACCELERATOR

MS3

MS1

5

4

8

Green/Black

Violet/Black

Black

Black

HIGH/LOW

Black

SWITCH

2

Black

Gray/black

Violet/Black

Green/Black

Green/Black

Violet/Black

2

1

7

HAND BRAKE 

SWITCH

[option]

1

1

2

Blue

Red/White

To AC input

for charger

Black

DASH

PANEL

12

8

3

Black

Gray/White

Red/White

Green/Black

SEAT

Violet/Black

Interlock relay located in the 

battery charger

14

5

F/R

Red

Red

6

White/Black

Gray/black

Violet/Black

Blue/White

7

Green/Black

Gray/White

16-Pin AMP

Violet/Black

Black

2

Blue

Red/White

14

16

Yellow

10

6

Black

Blue

Gray/White

Blue/Black

Gray/black

White/Black

Violet/Black

Blue/White

12

3

5

8

Red

1

Red

9

11

Blue/White

Gray

BRAKE LIGHT

Blue

Brown

Violet/Black

Brown

Red

KEY

SWITCH

8

11

Red

BUTTON

LIGHT

SWITCH

Brown

10

HORN

Blue/White

L. TURN

White

White

Blue

Red

Blue/White

White

HEAD LIGHTS

White

Brown

R. TURN

White

Battery 12-volt tap

Red

Yellow

White

13

Red

1

Red

White

9

Red

White

FLASHER

Black/Gray

Gray

Yellow

Red

White

Black

3

8

1

Green

Black

6

7

4

Red

5

White

White

White

13

White

White

Red

Blue

Red

Red

White

Red

White

Green

Green

Brown

White

R. TAIL LIGHT

Red

Brown

BLACK

BLACK

White

PANEL

Violet/Black

Violet/Black

AUTOMATIC

ELECTRIC

BRAKE

[option]

Yellow

MOTION 

ALARM

5

9

Black

Black

Green

4

10

6

3

2

1

8

Red

Blue

Black

Battery negative

16-Pin AMP

HARNESS SIDE

VIEW FROM

CONTROL

White

Green

Red

Red

Black/White

Violet

ISO

680  Ohm 

5 Watt

Blue

A

A2

A1

Yellow

MOTOR

F2

F1

HARNESS SIDE

9-Pin AMP

Black

VIEW FROM

4

7

1

6

9

3

15

11

3

7

1

10

16

14

6

2

2

GAUGE

SMART VIEW

CAN COMMUNICATION BUS

White

Brown

Red

Black

Black

White

White

Red

Red

Blue

Blue

Yellow

Blue/Black

Gray/black

Violet/Black

White/Black

Blue/Black

Gray/White

Blue/White

Red

Blue

Red

F

A full size wire diagram for this vehicle is located on
the CD, file name SCH-00002.PDF.

Summary of Contents for RE-380-36

Page 1: ...s s Serial number Starting 155932 MANUAL MR 380 28 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded RE 380 36 R 380 36 RE 380 48 R 380 48 Equipped with the GT Drive System Publi...

Page 2: ...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 3: ...u r B u s i n e s s R A small sample of the many types of vehicles offered by Taylor Dunn B 2 48 36 Equipped with optional hydraulic dump bed BT 2 80 Eight passenger tram B 1 00 Personnel carrier C 4...

Page 4: ...leshooting 12 Battery Chargers 13 Wire diagram 14 Illustrated Parts 15 Appendix A Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Handling Precautions 18 Taylor Dunn Mod...

Page 5: ...Introduction About this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 Conventions 5 How to Identify Your Vehicle 6 Taking Delivery of Your Vehicle 7 Contents...

Page 6: ...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 7: ...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 8: ...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 9: ...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 10: ...ghways It is available in maximum designed speeds ranging from 7 to 15 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage...

Page 11: ...result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also...

Page 12: ...TAYLOR DUNN...

Page 13: ...tal Bargraph 7 Hour Meter Optional 7 Smart View Display 8 Fault Code Tables 10 Vehicle Operation Guidelines 11 Safety Guidelines 11 Starting 11 While driving 11 Loading and Unloading 11 Towing Loads 1...

Page 14: ...36 36 Volt 6 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp RE 380 48 48 Volt 8 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp Transmission Helic...

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: ...rsa while the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward reverse switch should be in the center OFF position with key switch off and the park brake se...

Page 17: ...ark brake handle push the release button and lower the handle Horn Switch The horn switch is located to the left of the steering column Depress the switch with your left foot to sound the horn release...

Page 18: ...rolyte alarm is activated when the battery cell fluid level falls below the level of the probe The alarm is an audible continuous sound along with a bi color indicator lamp Inspect the fluid level in...

Page 19: ...and the truck should be taken out of service and charged to avoid damaging the batteries Battery Status Indicator Digital Bargraph The battery status indicator is located to the left of the hour meter...

Page 20: ...ery status gauge as well as any faults indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle HM Depending on the revision level of the controll...

Page 21: ...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 22: ...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 23: ...gh center of gravity When 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...

Page 24: ...ic brake from the control system and connecting a 20 to 24 volt DC source 1 5A to the electric brake Towing This Vehicle To tow this vehicle attach a tow strap to the front bumper tow bar NOTE If the...

Page 25: ...an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes Charging State LED1 LED2 LED3 0 to 50 Blinking OFF OFF 50 t...

Page 26: ...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 27: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 15 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Page 28: ...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 29: ...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 30: ...TAYLOR DUNN...

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

Page 32: ...the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Avoid fire hazards and have fire protection equipment present in the work a...

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: ...2 3 3 7 5 3 Drive Description Locations Lubricant Type 1 2 KingPin 2 General Purpose Grease 3 Ball Joints 6 General Purpose Grease 4 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7...

Page 35: ...Front Axle Removal and Installation 4 Removal 4 Installation 5 Front Axle Removal 6 Front Axle Disassembly 8 Replace Front Wheel Bearings 10 Replace the Ball Joints Tie Rods and Drag Link 11 Replacin...

Page 36: ...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 replacemen...

Page 37: ...wheel bearings 11 Install a new cotter pin 12 Install the dust cap 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels...

Page 38: ...ke bodies 11 Disconnect the front axle beam from the front springs and remove the axle from the vehicle NOTE In some configurations the front springs and or shocks will have to be removed in order to...

Page 39: ...es bleed the brakes Refer to Brake Service section for information regarding bleeding the brakes 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the...

Page 40: ...uckle 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 Removal and Installation for information regarding re...

Page 41: ...NOTE It is recommended to replace all four bearings and races in the left and right wheels as a set 12 Assemble in reverse order using new grease seals a Pack inner and outer bearings with grease b W...

Page 42: ...t Depending on the configuration of your vehicle it may be equipped one or both types of ball joints In this text The first type will be referred to as a Ball Joint The second type will be referred to...

Page 43: ...on regarding realignment of the front wheels 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels 16 Release the park br...

Page 44: ...f the front wheels 14 Lower the vehicle 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 veh...

Page 45: ...brake and test drive the vehicle Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together Refer to the illustration on the following page 6 Raise the front of...

Page 46: ...behind the wheels 14 Release the park brake and test drive the vehicle REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle...

Page 47: ...moving the steering knuckle NOTE It is not necessary to remove the tie rod or drag link for this procedure 8 Press the king pin bushings out from the axle or steering knuckle 9 Press new bushings into...

Page 48: ...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 49: ...0 172 inch clearance as shown in the illustration below NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign...

Page 50: ...TAYLOR DUNN...

Page 51: ...ent 2 Adjust the Steering Gear Saginaw 6 Replace the Steering Shaft non tilt steering 7 Replace the Steering Wheel 9 Replace the Steering Gear 10 Repair the Steering Gear 11 Exploded View of Steering...

Page 52: ...nd type cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your truck it may be equipped with one or both types of ball joints In this text...

Page 53: ...beginning 11 Loosen the ball joint clamps or the rod end jam nuts on the drag link NOTE Remember the position and orientation of the clamps 12 Adjust the drag link so that it can be easily inserted in...

Page 54: ...NOTE It is recommended to center the steering before aligning the front wheels Refer to the Center the Steering section for information 6 Raise the front of the vehicle and support with jack stands 7...

Page 55: ...de tie rod so that the right wheel is positioned pointing straight ahead 15 Measure the distance between the lines at the front of the tires 16 Measure the distance between the lines at the rear of th...

Page 56: ...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 stop 10 Loosen the worm bearing adjuster and then tighte...

Page 57: ...of the wires 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 fr...

Page 58: ...ontrol of the vehicle This could lead 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...

Page 59: ...eel remove the switch and disconnect the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straight ahe...

Page 60: ...garding removing the steering wheel 7 Remove the steering shaft NOTE Refer to Replace the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a p...

Page 61: ...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 62: ...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 63: ...he worm bearing adjuster lock nut 12 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 housi...

Page 64: ...Maintenance Service and Repair Steering Page 14 Exploded View of Steering Gear...

Page 65: ...c Disc Brakes 6 Adjust the Parking Brake 7 Wheel Park Brake hydraulic disc 7 Check Master Cylinder Fluid 8 Bleed the Brake System 9 Flush the Brake System 11 Replace the Parking Brake Lining optional...

Page 66: ...pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Current Taylor Dunn brakes are asbestos f...

Page 67: ...d its service limits then the front hub must be replaced Refer to Front Axle Servicefor information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be...

Page 68: ...for any signs of damage wear or missing cotter pins If any sign of damage or wear is found on the locking mechanism cables or linkages then they must be repaired or replaced immediately Failure to rep...

Page 69: ...r train and parking brake a If the brake does not release until the voltage exceeds 18 volts then the friction plate has worn beyond its service limits and must be replaced b If the brake does not rel...

Page 70: ...r could be caused by Brake fluid level low in the master cylinder See Check the Master Cylinder Fluid section Air in the brake lines See Bleed the Brakes section Worn brake pads See Inspect the Servic...

Page 71: ...justment Rod until it is difficult to rotate the brake arm clevis pin on both wheels 9 Loosen the Primary adjustment rod one to two turns so that both wheels rotate whith no brake drag The threaded ro...

Page 72: ...a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CO...

Page 73: ...SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minut...

Page 74: ...drop 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 yo...

Page 75: ...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 76: ...OPTIONAL MOTOR BRAKE 1 Remove the electric brake assembly from the drive Refer to Motor Removal and Installation in the Transmission section for information regarding removing the brake 2 Place the b...

Page 77: ...parts 11 Inspect all parts for damage or wear 12 Reassemble in reverse order Reassembly Notes a Orientate the inner contact plate lining up the marks made when removed and so that the notches face aw...

Page 78: ...on the hub and the friction plate for damage 3 Inspect the inner contact plate and the outer housing where they come into contact with the friction plate for wear or damage 4 Inspect the three dowel...

Page 79: ...his possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new brake pads will raise the brake fluid...

Page 80: ...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 81: ...as if they contain asbestos Refer to appendix C for recommended handling precautions Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to u...

Page 82: ...nstall new spacer bushings in the mounting 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 R...

Page 83: ...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 84: ...regarding inspecting the brake rotor 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 T...

Page 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...TAYLOR DUNN...

Page 91: ...nspecting the Motor Brushes 2 Motors with internal cooling fans 2 Motor Removal and Installation 2 Motor Inspection 2 Replacing the Brushes or Armature Bearing 4 Repairing the Commutator 5 Service Lim...

Page 92: ...ed in Service Limits then all four brushes should be replaced 8 Reconnect the main positive and negative cables at the batteries 9 Remove the blocks from behind the wheels release the park brake and t...

Page 93: ...or information regarding machining the commutator 7 Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted arm...

Page 94: ...ring in the rear housing 6 While supporting the inner race of the bearing press the armature into the bearing 7 Push the motor brushes into the brush holder until the brush spring snaps into place Be...

Page 95: ...mmutator undercut depth in 5 places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut 7 Whil...

Page 96: ...inding is all that is required to determine if the motor is at fault Motor Specification Number Undercut Depth Commutator Diameter min Brush Length min Resistance Ohms 75 F mm inches mm inches mm inch...

Page 97: ...ear Hub or Rotor 5 Removing and Installing the Rear Axles Disc Brakes 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3...

Page 98: ...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 99: ...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 100: ...he key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative...

Page 101: ...embly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the...

Page 102: ...se a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury NOTE...

Page 103: ...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 104: ...Disconnect the left and right mechanical parking brake linkage from the brake arms and the cable mounting brackets 8 Disconnect the hydraulic brake hoses from the rear brake calipers 9 Remove the nut...

Page 105: ...in positive and negative cables at the batteries 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove t...

Page 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...Maintenance Service and Repair Transmission Page 20 NOTE Values shown are for reference only C D...

Page 117: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Leaf 2 Replace the Front Springs 3 Leaf 3 Replace the Spring Bushings 5 Replace the Shocks 6 Front or Rear 6...

Page 118: ...s a set HINT In most vehicles it will be easier if the springs are replaced one at a time 6 Raise the rear of the vehicle and support with jack stands 7 Tie up or support the rear axle so it cannot fa...

Page 119: ...F 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 batteries Always use a lifting strap hoist an...

Page 120: ...or damage is found then they must be replaced 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the sprin...

Page 121: ...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 122: ...shock bolts 8 Remove the shock from the vehicle NOTE If the shock that was removed is to be reinstalled A Inspect the shaft where it enters the shock body for any signs of leakage If any sign of leak...

Page 123: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Tires and Wheels...

Page 124: ...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 125: ...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 126: ...severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on r...

Page 127: ...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 128: ...TAYLOR DUNN...

Page 129: ...eaning 2 Testing 3 Watering 5 Charging 6 Replacing 6 volt batteries only 7 Battery Removal 48 volt system 9 Moist Charge Batteries 10 Storage and Returning to Service 11 Storage 11 Returning to Servic...

Page 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...48 with the cable removed Some components have been omitted for clarity Note The charger may have to be removed to provide clearance 6 Remove all of the battery cables from the batteries 7 Remove the...

Page 138: ...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 It cannot be disconnected or neutralized Do not dr...

Page 139: ...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 140: ...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 141: ...itions 2 Terminology used 2 Important Notes and Instructions 2 Identifying Your Controller 3 Start Troubleshooting Here 4 Test 8 Anti Rolloff Fault 15 Test 9 Electric Motor Brake 16 Logic Voltage Refe...

Page 142: ...ems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified Some tests refer to a High Low switch The High Low swit...

Page 143: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...

Page 144: ...battery check the following The batteries The wiring from the battery status indicator to the batteries for open circuits The battery status indicator The positive and negative circuit breaker The ma...

Page 145: ...r for open circuits Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 1 3 Test the voltag...

Page 146: ...to the ground TEST 1 7 Depress the accelerator pedal to engage FS 1 only creep speed Perform the following tests Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is below...

Page 147: ...fication table can be found in the Motor Service section If the test indicates an open circuit then repair or replace the motor Test continuity from F1 to the frame of the motor Any reading other than...

Page 148: ...to the frame on the motor and from F1 to A1 for open circuits Any reading other than an open circuit indicate a short in the motor If there is a short in the motor stop here and repair or replace the...

Page 149: ...at switch turn the key switch ON and wait 1 second until the Isolator contactor closes If the vehicle runs in reverse only then skip ahead to test 3 3 Place the forward and reverse switch in the FORWA...

Page 150: ...d movement of the vehicle resulting in injury or property damage Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all p...

Page 151: ...ults may have occurred Broken Wire Check the wire from pin 8 in the 12 Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm...

Page 152: ...Low battery lamp is ON then the analyzer battery should be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer D0 110 53 Disconnect both...

Page 153: ...se skip ahead to test 7 3 Place the forward and reverse switch in the FORWARD position Referencing battery positive test the voltage at the Blue Black wire on the F R switch If the voltage equals batt...

Page 154: ...ground TEST 7 4 Check the wires from the F R switch to the logic card connector for continuity After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground F...

Page 155: ...tch in the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor...

Page 156: ...ere and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Test 9 1 Close the seat switch turn the key switch ON place the for...

Page 157: ...eed controller Disconnect the electric brake harness connector and connect the electric brake to a 24 volt source This should release the brake and allow you to troubleshoot the vehicles control syste...

Page 158: ...ch in high Low High low Switch in low High 7 Hand brake switch closed Low Hand brake switch open High 8 Key switch on ref battery positive Key switch off ref battery positive Battery volts 9 System of...

Page 159: ...Burned Motor Repair as required 4 Contactor fault or open motor Contactor Failure Open Circuit Check contactor and motor 5 Not used 6 Accelerator module fault FS 1 Micro Switch Failure Faulty Wiring A...

Page 160: ...eck wiring contactor and pre charge resistor on the contactor F04002 Steer Pot Steer Pot currently not used and this fault should not occur Check wiring F04003 Sequence Fault Start up switches not ope...

Page 161: ...1 faults are a result of operator error or operation of the vehicle F01000 Power Steer Overheat Not used F01001 Traction Motor Brush Wear Not used F01002 Pump Motor Brush Wear Not used F01003 Power St...

Page 162: ...TAYLOR DUNN...

Page 163: ...4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 Turn the Key switch OFF BEF...

Page 164: ...urrent state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200...

Page 165: ...efore connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is tu...

Page 166: ...than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC vo...

Page 167: ...r has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Con...

Page 168: ...re continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers F...

Page 169: ...mer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that a...

Page 170: ...blem Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconn...

Page 171: ...f the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The volta...

Page 172: ...here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the A...

Page 173: ...st Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting...

Page 174: ...ses the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to...

Page 175: ...eter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery...

Page 176: ...od working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger exhibits...

Page 177: ...arger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Note If only the 100 LED is flashing and all others are OFF the...

Page 178: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charge...

Page 179: ...ing Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 Rev C Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the contro...

Page 180: ...here are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 vol...

Page 181: ...ge the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On t...

Page 182: ...ng off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but stil...

Page 183: ...charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the c...

Page 184: ...e reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the P...

Page 185: ...Wire Diagrams...

Page 186: ...H 8 11 Red BUTTON LIGHT SWITCH Brown 10 HORN Blue White L TURN White White Blue Red Blue White White HEAD LIGHTS White Brown R TURN White Battery 12 volt tap Red Yellow White 13 Red 1 Red White 9 Red...

Page 187: ...ls and Tires 28 Instrument Panel dash ending s n 179484 30 Instrument Panel dash starting s n 179485 30 Illustrated Parts Speed Control Panel R 3 80 36 32 Miscellaneous Electrical 34 Miscellaneous Fra...

Page 188: ...Illustrated Parts Parts Page 2 Front Axle FWD 1 2 3 4 5 6 7 8 9 5 12 13 12 14 10 9 11 Thrust Bearing Detail Top Bottom 3 15 16...

Page 189: ...earing Race 2 6 88 239 85 3 4 NF Slotted Nut 2 7 92 104 00 Dust Cap With Grease Fitting 2 92 104 01 Dust Cap Without Grease Fitting Use with Disc Brakes 2 8 88 527 11 1 8 X 1 Steel Cotter Pin 2 9 80 0...

Page 190: ...Illustrated Parts Parts Page 4 Steering Linkage...

Page 191: ...4 11 20 031 64 Steering Shaft 1 12 18 308 21 Steering Gear 1 13 88 128 62 7 16 Lockwasher 3 14 88 120 11 7 16 X1 Hex Head Cap Screw 3 15 00 680 13 Pitman Arm 1 16 50 002 07 Steering Sleeve Assembly 2...

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

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

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

Page 195: ...01 Shock Mounting Hardware 2 3 86 006 00 Shock Absorber 2 4 See Front Axle Beam Axle 5 88 121 19 7 16 X 2 3 4 NC Hex Cap Screw GR5 2 6 85 506 01 2 Leaf Spring 2 7 01 680 61 Spring Pad 4 8 88 109 81 3...

Page 196: ...Illustrated Parts Parts Page 10 Transmission primary reduction...

Page 197: ...79 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 Output gear 18 1 0 or 1 GT 3287483 Outp...

Page 198: ...Illustrated Parts Parts Page 12 Transmission secondary reduction Rear Axle...

Page 199: ...10 x 25 Bolt 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GT 71881 Seal 1 32 GT 70052 Vent 1 Rear Axle ITEM PART DESCRIPTION QTY 1 41 154 20 Axle shaft 2 2 80 505 20 Bearing 2 3 41...

Page 200: ...Illustrated Parts Parts Page 14 Rear Brakes Front Brakes optional Brake Body...

Page 201: ...350 53 Brake arm 2 Not shown 41 350 59 Extension brake arm 2 16 88 069 82 1 4NC locknut grade 8 4 Front Brake ITEM PART DESCRIPTION QTY 1 88 069 82 Locknut 1 4 NC Gr 8 Do Not Reuse 4 2 See Brake Body...

Page 202: ...Illustrated Parts Parts Page 16 Rear Suspension...

Page 203: ...hanger 4 3 32 213 00 Bushing 6 4 96 248 00 Hex bolt 6 5 88 169 81 Hex lock nut 6 6 96 114 00 U bolt 4 7 88 159 84 Hex lock nut 8 8 16 861 42 Spring plate left 1 16 861 43 Spring plate right 1 Not 01...

Page 204: ...Illustrated Parts Parts Page 18 Motor...

Page 205: ...e 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 motor can...

Page 206: ...Illustrated Parts Parts Page 20 Deadman Seat Brake...

Page 207: ...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 brake o...

Page 208: ...Illustrated Parts Parts Page 22 16 5 18 15 17 3 15 14 13 12 11 10 9 7 8 7 See Brake Lines 6 5 2 4 2 2 3 3 2 1 Master Cylinder Linkage Master Cylinder Components All...

Page 209: ...762 00 3 8 Clevis 1 10 88 119 80 3 8NF Hex Nut 1 11 50 009 00 Push Rod 1 12 88 100 09 3 8NC x 3 4 Hex Bolt 2 13 17 104 00 3 8 Collar 1 14 99 510 02 Master Cylinder 1 15 88 100 09 3 8NC x 3 4 Hex Bolt...

Page 210: ...8 12 13 master cylinder fitting 14 15 master cylinder bolt 16 adaptor 11 T fitting FRAME REF TO MASTER CYLINDER BOLT SEE NOTE 1 TO MASTER CYLINDER FITTING NOTE 1 Rear brakes only connect to adaptor th...

Page 211: ...ne2 front 1 7 99 580 20 Brake hose Front or Rear 2 8 99 576 00 Hose clip 4 9 99 575 00 Coupler 1 10 99 564 00 T Fitting female 1 11 99 559 00 T Fitting 2 female 1 male 1 12 99 571 00 Copper Washer 0 5...

Page 212: ...Illustrated Parts Parts Page 26 Park Brake Linkage FRONT 1 2 2 4 4 5 5 7 8 8 8 9 9 9 9 9 8 10 11 12 13 14 15 16 17 18 19 20 21 22 3 3 Frame 6 14 Frame...

Page 213: ...er 1 17 96 763 00 Clevis 1 18 88 099 81 5 16NF Hex nut left hand thread 1 19 96 343 00 Rod linkage 1 20 88 099 80 5 16NF Hex nut 1 21 96 765 00 Clevis 1 22 96 754 00 Clevis formed 2 3 1 2008 Part numb...

Page 214: ...Illustrated Parts Parts Page 28 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 215: ...12 041 00 Wheel Assembly 2 5 bead width includes 3 4 6 7 8 4 3a 12 042 12 Inner Wheel 12 bolt 4 4a 12 042 13 Outer Wheel 12 bolt 4 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 4 6...

Page 216: ...Illustrated Parts Parts Page 30 Instrument Panel dash ending s n 179484 Instrument Panel dash starting s n 179485...

Page 217: ...71 121 20 Key Switch keyed unalike 71 119 99 Spacer 1 71 120 90 Keys Instrument Panel starting s n 179485 Item Part Description QTY 1 771 039 11 Rocker Switch 1 2 71 039 11 Rocker Switch 1 3 71 039 1...

Page 218: ...Illustrated Parts Parts Page 32 Speed Control Panel R 3 80 36 1 2 4 5 6 6 7 8 3 9 10 11 12 13...

Page 219: ...ew 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 metal screw 8 12 73 0...

Page 220: ...Illustrated Parts Parts Page 34 Miscellaneous Electrical Miscellaneous Frame...

Page 221: ...w display 75 152 55 Harness main control 75 152 48 Harness control panel 75 152 07 Harness power 75 152 04 Harness dash 75 115 18 Harness strobe light on cab 71 122 00 Horn switch floor 71 501 00 Horn...

Page 222: ...Illustrated Parts Parts Page 36 Seat Cushions and Lights 1 2 3 4 5 6 7 8 9...

Page 223: ...Seat Cushion 1 4 72 025 00 Oval Tail Stop and Turn Light 2 4a 72 022 51 Gasket for 4 2 5 00 210 04 Seat Frame 1 6 94 201 10 Name Plate 1 7 04 380 25 Headlight Mounting Panel 1 7 04 380 24 Front nose...

Page 224: ...Illustrated Parts Parts Page 38 Charger Lestronic Pg 1 CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 225: ...79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25...

Page 226: ...Illustrated Parts Parts Page 40 Charger Lestronic Pg 2 CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 227: ...31 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 7...

Page 228: ...ts Parts Page 42 Charger Signet NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51...

Page 229: ...Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside t...

Page 230: ...Illustrated Parts Parts Page 44 Batteries 36 Volt 48 Volt...

Page 231: ...0 or 6 77 048 00 250AH J 250 0 or 6 77 048 80 250AH J 250 Moist charge dry 0 or 6 77 051 00 160AH Gell Note requires special charger 0 or 6 75 233 00 JUMPER BATT 10 1 4 4 GA 5 75 234 00 JUMPER BATT 2...

Page 232: ...Illustrated Parts Parts Page 46 Decals Front Cowl Tray Battery Compartment...

Page 233: ...2 94 309 00 Apply Hand Brake 1 3 94 384 14 Turn Key Off 1 4 94 301 42 Arms and Legs 1 5 94 313 20 Safety Warning 1 6 94 373 10 Data and Serial Number 1 7 94 333 00 FM 1 8 94 313 00 Battery Waring 1 9...

Page 234: ...Illustrated Parts Parts Page 48 Trailer Hitch...

Page 235: ...ch 97 811 00 1 7 8 Ball hitch 97 805 00 Mounting brakcket 97 821 00 2 Ball hitch 97 807 00 Mounting bracket 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 140 11 1 2NC x 1 Hex bolt 2 88 149 80 1 2NC Hax nut 6...

Page 236: ...Illustrated Parts Parts Page 50 Strobe Light Other Front End Options...

Page 237: ...5 72 082 20 Turn Signal socket 2 6 7 8 9 10 72 023 20 Strobe Light Amber 1 11 72 023 25 Mounting Pole for Strobe Light 1 12 88 025 06 8 32 X 1 2 Truss Head Screw 3 13 88 028 62 8 Lockwasher 3 14 88 02...

Page 238: ...Illustrated Parts Parts Page 52 Cab Cowl With Windshield Options...

Page 239: ...91 011 40 Cab Unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Rubber Channel for Windshield 1 12 90 850 10 Rear Window 1 13 88 065 09 1 4 NC X 3 4 Phillips Head Truss Screw 18 14 88 068 62 1 4 Loc...

Page 240: ...Illustrated Parts Parts Page 54 Optional Cab Accessories...

Page 241: ...acer for Mounting Bracket 1 or 2 9 91 814 16 Left Hinge Female 1 91 814 17 Right Hinge Female 1 10 88 069 81 1 4 NC Locknut 2 11 88 060 22 1 4 NC X 3 1 2 HEX Head Bolt 1 12 88 068 61 1 4 SAE Washer 2...

Page 242: ...Illustrated Parts Parts Page 56 Cab Door Options...

Page 243: ...t Left Specify Color Inclds 10 11 12 1 91 011 68 Metal Cab Door Kit Left Orange Incld 10 11 12 1 91 011 67 Metal Cab Door Kit Right Specify Color Inclds 10 11 12 1 91 011 69 Metal Cab Door Kit Right O...

Page 244: ...Illustrated Parts Parts Page 58 Optional Top Cover...

Page 245: ...t Rear Support Post for Frame 2 3 91 038 08 Front Left Support Post for Frame 1 4 91 038 09 Front Right Support Post for Frame 1 5 88 102 11 3 8 NC X 1 Carriage Bolt 16 6 88 109 81 3 8 NC Locknut 16 7...

Page 246: ...Illustrated Parts Parts Page 60 Rear Seat Rear Gate and Rear Deck...

Page 247: ...Right Handrail 1 10 88 065 09 1 4 NC X 3 4 Phillips Truss Head Screw 10 11 88 068 61 1 4 SAE Washer 10 12 88 069 81 1 4 NC Locknut 10 REAR GATE 13 00 680 24 Rear Gate 1 DECK PLATES 14 02 380 76 Rear S...

Page 248: ...Illustrated Parts Parts Page 62 9 Side Panels...

Page 249: ...ft Side Panel 1 2 03 380 37 Right Side Panel 1 3 88 065 09 1 4 NC X 3 4 Phillips Truss Head Screw 13 4 88 068 61 1 4 SAE Washer 13 5 88 069 81 1 4 NC Locknut 13 6 00 380 85 Tailgate 1 7 00 380 86 Righ...

Page 250: ...Illustrated Parts Parts Page 64 Front Bumper and Splash Pan...

Page 251: ...SPLASH PAN ITEM PART DESCRIPTION QTY 1 01 380 18 Bumper 1 2 88 109 81 3 8 NC Hex nut 4 3 88 108 61 3 8 SAE Flat washer 4 4 88 100 11 3 8 NC x 1 Hex bolt 4 5 88 080 09 5 16 x 3 4 Hex bolt 4 6 04 380 23...

Page 252: ...TAYLOR DUNN...

Page 253: ...for Standard Hardware 4 Hardware Identification 4 Standard Head Markings 4 Hex Bolts 4 Other Bolts 4 Hex Nuts 4 Hex Lock Nuts stover 4 Other Nuts 4 Suggested Torque Values non critical hardware 6 Sug...

Page 254: ...43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor 41 532 50 Chain Case Cente...

Page 255: ...3 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors 96 500 40 Fork Coll...

Page 256: ...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 Toque values specified are for clean dry threads Hex...

Page 257: ...ed 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 mar...

Page 258: ...plated threads in noncritical steel assemblies of the same hardess specification Reduce torque approximately 10 15 for lubricated threads Refer to the service section assembly procedure for critical...

Page 259: ...00 398 30 2 00 3 50 540 Metric Foot Pounds Grade N m Dia Pitch 4 6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14...

Page 260: ...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...

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