Taylor-Dunn C0-014-32 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn C0-014-32 Operation, T Roubleshooting And Replacement Parts Manual

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Models Inlcuded:
C0-014-32
C0-014-33
T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
MANUAL MC-432-05
Operation, Troubleshooting and
Replacement Parts Manual
Revision: C
Serial Number Starting: 151285

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  • Page 1 Models Inlcuded: C0-014-32 C0-014-33 T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s MANUAL MC-432-05 Operation, Troubleshooting and...
  • Page 3 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...
  • Page 4 Address inquiries to Reference Permissions, Taylor-Dunn Mfg., 2114 W. Ball Road, Anaheim, CA 92804 ® TAYLOR-DUNN SERVICE CENTER For more information about this and other Taylor-Dunn manuals, please write Taylor-Dunn ® ® Taylor-Dunn Mfg.

  • Page 5: Table Of Contents

    Section Index Taylor-Dunn “Mule” Model C0-014-32 and C0-014-33 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transmission Service Tires and Wheels Battery Service Electrical Troubleshooting...
  • Page 6 SC1-00 Stock Chaser B2-48 With Stake Side Dump Bed Option E4-55 Sit Down Tow Tractor C4-25 Sit Down Tow Tractor...
  • Page 7 Table of Contents About this manual .......... 2 Who Should Read This Manual ....2 Responsibilities ..........2 How To Use This Manual ....... 3 Conventions ............3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ....5 R 3-80 shown with extended steel cab and doors options...

  • Page 8: About This Manual

    ABOUT THIS MANUAL RESPONSIBILITIES The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. The owner of this or any Taylor-Dunn ® vehicle is Taylor-Dunn ® , a leading manufacturer of electric...

  • Page 9: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL Conventions This manual is organized into five main sections: Symbols and/or words that are used to define warnings, cautions, instructions, or notes found INTRODUCTION throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 10: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts.

  • Page 11: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery ® adjust any part of this or any Taylor-Dunn vehicle is cables, and other electrical connections are a factory authorized service technician. secure.
  • Page 13 TABLE OF CONTENTS Standard Specifications Burden Carrier ..2 Safety Rules and Guidelines ......3 Driver Training Program ........ 3 Driver Qualifications..........3 Vehicle Controls ..........4 Accessory Switch (Optional) ........4 Key-Switch ............4 Forward-Off-Reverse Switch ........4 Horn Switch ............

  • Page 14: Standard Specifications Burden Carrier

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS BURDEN CARRIER ITEM MODEL VOLTAGE SPECIFICATION Occupancy Driver only Dimensions 200.6L X 74.9W X 101.6H Centimeters 79L X 29.5X 40H Inches Turning Radius 177.8Centimeters (70 Inches) Dry Weight C 4-32 258 kg (570 lbs) (less batteries) C 4-33 269 kg (594 lbs)

  • Page 15: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDE- DRIVER TRAINING PROGRAM LINES According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who It is the responsibility of the owner of this vehicle to assure will be operating this vehicle.

  • Page 16: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key-Switch A key-switch, located on the right side of the dash, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off. The key-switch should be in the “OFF” position whenever the operator leaves the vehicle.

  • Page 17: Battery Status Indicator, Analog

    SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Analog The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading.

  • Page 18: Charger Interlock

    SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter-clockwise. If equipped with tilt steering, the release lever is located on the lower left of the steering column.

  • Page 19: Vehicle Operational Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES • Do not drive this vehicle on steep inclines or where Safety Guidelines prohibited. • Only qualified and trained operators may drive this • Immediately report any accidents or vehicle vehicle. problems to a supervisor. •...

  • Page 20: Charging Your Vehicle

    SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Explosive mixtures of Hydrogen gas are Battery electrolyte is poisonous and present within battery cells at all times. Do dangerous. It contains sulfuric acid. Avoid contact with skin eyes or clothing. Wear not work with or charge battery in an area where open flames (including gas furnace rubber gloves and safety glasses while...

  • Page 21: New Battery Break In

    SAFETY RULES AND OPERATING INSTRUCTIONS Lestronic II Charger Operation Charging Time ® The Lestronic II charger is a semi-automatic charging Average charging time is 8 to 10-hours. The time required system. The charger will turn itself ON when the AC to fully charge your batteries will vary depending on: power cord is connected to the AC power source and •...

  • Page 22: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi - Weekly Monthly Quaterly Annualy Maintenance Item Annual (20hrs) (80hrs) (250hrs) (1000hrs) (500hrs) Check Condition of Tires and Tire Pressure Check All Lights, Horns, Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks...

  • Page 23: Daily Visual Inspection

    SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to: • Accelerator pedal, Brake pedal, Steering, Parking brake, etc. •...
  • Page 25 Table of Contents Maintenance Guidelines ........ 2 Troubleshooting Guide ........3 Lubrication Chart ..........4 Model C 4-25 Tow Tractor Model E 4-55 Tow Tractor...
  • Page 26 Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices. • Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in conformance with Taylor-Dunn’s ® recommended procedures. •...

  • Page 27: Troubleshooting Guide

    Maintenance, Service and Repair Troubleshooting Guide Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged King Pin/Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis-Adjusted or Worn Steering Gear Loose Steering Linkage...

  • Page 28: Lubrication Chart

    Maintenance, Service and Repair Lubrication Chart Above Front Fork Rear Axle Assembly (side view) Description Locations Lubricant Type 1 Steering Chain Chain Lube Front Axle Bearings General Purpose Grease Fork Bearings General Purpose Grease Drive Drain Plug Drive Level Plug SAE 140 API GL-5 Gear Oil Drive Fill Plug Page 4...
  • Page 29 TABLE OF CONTENTS Inspect/Adjust Front Wheel Bearings 2 Replace Front Wheel Bearings ..2 Front Axle Removal and Installation .. 3 Removal ............3 Installation ............3...

  • Page 30: Replace Front Wheel Bearings

    Maintenance, Service, and Repair INSPECT/ADJUST FRONT REPLACE FRONT WHEEL WHEEL BEARINGS BEARINGS 1. Make sure the key-switch is in the “OFF” 1. Make sure the key-switch is in the “OFF” position, then remove the key. position, then remove the key. 2.

  • Page 31: Front Axle Removal And Installation

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal Installation 1. Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub. 1. Make sure the key-switch is in the “OFF” 2.
  • Page 33 TABLE OF CONTENTS Front End Alignment ......2 Replace the Front Fork ...... 3 Adjust Steering Chains ...... 4...

  • Page 34: Front End Alignment

    Maintenance, Service, and Repair FRONT END ALIGNMENT 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 under the front wheels to prevent vehicle movement.

  • Page 35: Front Axle Service

    Maintenance, Service, and Repair 10. While supporting the front fork so that it cannot REPLACE THE FRONT FORK fall out of the vehicle, remove the fork spindle nut and remove the fork from the vehicle. 11. Thoroughly clean all parts and install in reverse order.
  • Page 36 Maintenance, Service, and Repair 11. Reconnect the main positive and negative cables ADJUST STEERING CHAINS at the batteries. There are two steering chains. One is at the bottom of 12. Remove the blocks from behind the wheels. the steering column under the floorboard, the other is at 13.
  • Page 37 TABLE OF CONTENTS Inspect the Service/Parking brake ..2 Adjust the Parking Brake ....3 Adjust the Service Brake ....3 Replace the Brake Lining ....4 Band Park Brake ..........4 Replace the Brake Drum ....6...

  • Page 38: Inspect The Service/Parking Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE/PARKING BRAKE Current Taylor-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 should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.

  • Page 39: Adjust The Parking Brake

    Maintenance, Service, and Repair ADJUST THE PARKING BRAKE ADJUST THE SERVICE BRAKE Primary Adjustment NOTE: If there is no adjustment left in the park brak Do not adjust the service brake with the handle, than the service brake must be brake cable.

  • Page 40: Replace The Brake Lining

    (3) from the assembly. 12. Inspect the brake arm pivot bolt for signs of wear. If any signs of wear are seen then the pivot bolt Current Taylor-Dunn brakes are asbestos ® must be replaced.
  • Page 41 Maintenance, Service, and Repair 19. Adjust the alignment bracket adjusting bolt(s) (10) 22. Adjust the brake band adjusting bolt (4) so that to 0.050-0.100" away from the brake band and there is no brake drag when the brake is off. It tighten the jam nuts (12).

  • Page 42: Replace The Brake Drum

    12. Position the brake band alignment bracket(s) so that the inner arm is 0.100” away from the brake drum. Make certain that the alignment bracket Current Taylor-Dunn brakes are asbestos ® does not come into contact with the brake drum.
  • Page 43 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ......2 Enclosed Motors (GE, no cooling fan) ....2 Motor Removal and Installation ..3 Motor Inspection ........ 3 Replacing the Brushes....... 5 Replacing the Bearings ..... 6 Repairing the Commutator ....

  • Page 44: Inspecting The Motor Brushes

    Motor Service INSPECTING THE MOTOR BRUSHES Typical brush and brush holder Enclosed Motors (GE, no cooling fan) Typical motor with cooling fan indicated by the arrow Motors with internal cooling fans General Electric Motors NOTE: There are four brushes in the motor. The brushes will not wear at the same rate.

  • Page 45: Motor Removal And Installation

    Motor Service Advanced DC Motors Inspection The enclosed Advanced DC motors must be 1. Measure the length of each motor brush. disassembled to inspect the motor brushes. Refer to • If any one brush is less than or equal to the Motor Inspection for information regarding Service...
  • Page 46 Motor Service 5. Inspect the commutator for burn marks. commutator segments and the armature frame. If it is not an open circuit, then the armature is • Burn marks and/or raised commutator segments shorted and the motor must be replaced. 90 or 180 degrees apart is evidence of a shorted armature.

  • Page 47: Replacing The Brushes

    Motor Service Brush Spring Orientation 3. Install the new brushes in reverse order. REPLACING THE BRUSHES 4. Be certain that the brush springs do not rest up NOTE: It is recommended that all four brushes be against the brush wires. Refer to illustrations in replaced as a set.

  • Page 48: Replacing The Bearings

    Motor Service 6. Measure the commutator undercut depth in 5- REPLACING THE BEARINGS places around the commutator. If any one of the measurements is less than the minimum undercut 1. The motor must be removed from the vehicle for Service Limits depth specified in , then the this procedure.

  • Page 49: Service Limits

    Motor Service SERVICE LIMITS Commutator Diameter Brush Length Wire Depth Undercut Depth Motor Specification (min) (min) (max) Number inches inches inches inches 5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129C 0.635 0.025 66.75 2.625...
  • Page 51 TABLE OF CONTENTS Adjust the Drive Chain ....... 2 Check the Oil Level ......3 Change the Oil ........3 Drive Motor ........4 Remove .............. 4 Install ..............4 Rear Axle ........... 5 Remove and Install ..........5 Replace the Axle Bearing ........5 Transmission Assembly .....

  • Page 52: Adjust The Drive Chain

    Maintenance, Service, and Repair ADJUST THE DRIVE CHAIN NOTE: A small amount of oil may come out when the Tie the vehicle to an immovable object to drive motor mounting bolts are loosened. prevent the vehicle from moving in forward or reverse.

  • Page 53: Check The Oil Level

    Maintenance, Service, and Repair CHECK THE OIL LEVEL CHANGE THE OIL NOTE: The oil level in the chain case is maintained by the transmission. Oil is pumped from the 3rd member into the chain case housing. It Wear protective gloves when working with is not necessary to check the oil level in the petroleum lubricants.

  • Page 54: Drive Motor

    Maintenance, Service, and Repair 3. Install the motor mounting hardware but do not DRIVE MOTOR tighten until the chain adjustment is complete. Adjust the Drive 4. Adjust the drive chain. Refer to Chain Remove for information regarding adjusting the drive chain. NOTE: In most cases it is not necessary to 5.

  • Page 55: Rear Axle

    Maintenance, Service, and Repair Replace the Axle Bearing REAR AXLE NOTE: The axle must be removed from the vehicle to replace the axle bearing. Refer to section Remove and Install Rear Axle: Remove and Install for information regarding removing the axle. NOTE: A 10-ton press is required to replace the axle bearing.

  • Page 56: Transmission Assembly

    Maintenance, Service, and Repair TRANSMISSION ASSEMBLY Remove and Install 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 under the front wheels to prevent vehicle movement.

  • Page 57: Chain Case

    Maintenance, Service, and Repair CHAIN CASE NOTE: Some vehicle configurations may require that the transmission be removed to disassemble chain case. Refer section Transmission Assembly for information on removing the transmission. Disassemble 1. Make sure the key-switch is in the “OFF” Typical Chain Case position, then remove the key.
  • Page 58 Maintenance, Service, and Repair Motor Woodruf Key Adjusting screw Bolt 3rd Member O-Ring Motor Sprocket Washer Mounting Plate Spacer Drive Sprocket Backing Plate Drive Chain Bolt Washer Bolt Chain Case Housing Drain Plug Pinion Seal Brake Assembly Pinion Nut 8. Install the chain case housing onto the pinion shaft 10.

  • Page 59: Differential Assembly (3Rd Member)

    Maintenance, Service, and Repair 7. While rotating the pinion shaft, tighten the pinion DIFFERENTIAL ASSEMBLY (3 nut to 100 ft-lbs. MEMBER) 8. Measure and record the ring and pinion gear backlash. This setting will be used during reassembly. Disassemble 9. Remove the pinion housing and pinion gear from the 3rd member.

  • Page 60: Assemble

    Maintenance, Service, and Repair Assemble NOTE: Thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. NOTE: Depending on your vehicle config-uration, the rear pinion pilot bearing is not required and may not be installed.
  • Page 61 Maintenance, Service, and Repair NOTE: Be sure to continually rotate the ring gear while adjusting the bearings. This makes sure that the bearings and races remain seated Cross threading the nuts will damage the correctly. 3rd member housing and bearing caps. If NOTE: One hole on adjusting nut = approximately the housing and/or nuts are damaged, the 0.003"...

  • Page 62: Re-Shimming The Pinion Housing

    Maintenance, Service, and Repair RE-SHIMMING THE PINION HOUSING The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced. Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear.

  • Page 63: Exploded View

    Maintenance, Service, and Repair EXPLODED VIEW F2/F3 Transmission Page 13...
  • Page 65 TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Replace the Front Tire/Wheel .... 3 Replace the Rear Tire/Wheel .... 3 Replace the Tire (pneumatic) ... 3 Repair the Tire (pneumatic) ....4...

  • Page 66: Tire Inflation

    Maintenance, Service, and Repair TIRE INFLATION TIRE INSPECTION 6. Check the tire pressure. Refer to Tire Inflation section for information on checking the tire pressure. 1. Make sure the key-switch is in the “OFF” 7. Inspect the tire tread depth. Minimum position, then remove the key.

  • Page 67: Replace The Front Tire/Wheel

    Maintenance, Service, and Repair REPLACE THE FRONT TIRE/ REPLACE THE TIRE WHEEL (PNEUMATIC) Front Axle Service NOTE; To replace the tire, the tire/wheel assembly Refer to for information on must be removed from the vehicle. Refer to removing the front wheel. Replace the Tire/Wheel section for information on removing the tire/wheel...

  • Page 68: Repair The Tire (Pneumatic)

    Maintenance, Service, and Repair 4-Bolt Pattern 5-Bolt Pattern 8-Bolt Pattern Pattern for tightening the wheel nuts Re-torque all wheel nuts to their final value after 1-week (20-hours) of operation. Failure to re-torque the wheel nuts may result in the wheel coming off of the vehicle causing severe bodily injury and/or property damage.
  • Page 69 TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Charging ..........4 Watering ..........5 Replacing (6-volt batteries only) ..6 Moist Charge Batteries ........7 Storage and Returning to Service ..8 Storage ............... 8 Returning to Service ........... 9...

  • Page 70: Cleaning

    Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 71: Testing

    Maintenance, Service, and Repair TESTING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 72: Charging

    Maintenance, Service, and Repair Cleaning the Batteries Clean the batteries. Refer to section for information on cleaning the batteries. Using part number 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 the charging system.

  • Page 73: Watering

    Maintenance, Service, and Repair WATERING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 74: Replacing (6-Volt Batteries Only)

    Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) NOTE: If the batteries are over one year old, it is recommended to replace them as a set. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area 1.

  • Page 75: Moist Charge Batteries

    Maintenance, Service, and Repair 15. Install the batteries in reverse order. Refer to the Illustrated Parts List for battery cable routing. 16. It is recommended to replace the battery terminal Battery electrolyte is poisonous and dangerous. It contains sulfuric acid. Avoid hardware when replacing the batteries.

  • Page 76: Storage And Returning To Service

    Maintenance, Service, and Repair STORAGE AND RETURNING TO SERVICE Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 77: Returning To Service

    Maintenance, Service, and Repair Returning to Service 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 under the front wheels to prevent vehicle movement.
  • Page 79 Table of Contents SYMPTOMS: ........2 READ THIS FIRST ......3 Test Equipment Required: ............3 IMPORTANT NOTES and INSTRUCTIONS ...... 3 Definitions: ................3 SYMPTOM TROUBLESHOOTING GUIDE ..........19 PMC CONTROL ..............20 PLUGGING DIODE .............. 22 FREEWHEEL DIODE ............23 ISO ................... 24 SOLENOIDS ................

  • Page 80: Symptoms

    Curtis PMC Troubleshooting Note: Vehicles with Dana H12 transmission, Solenoids Forward solenoid is in the center. Circuit Breaker PMC Speed Control Typical Control Panel SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Symptom Troubleshooting later in this section. •...

  • Page 81: Read This First

    • This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Throttle Module Analyzer. Troubleshooting CANNOT be completed without these tools. These test procedures must be performed in the order they were written.

  • Page 82: Definitions

    Curtis PMC Troubleshooting Definitions: • “MS-1” = The first switch in the accelerator module. • “Battery volts” = The voltage at the batteries at the time the test is completed. • “Pick up” = Energizing a solenoid or contactor. • “F&R”...
  • Page 83 Curtis PMC Troubleshooting Power Output Test The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 84 Curtis PMC Troubleshooting Control Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 85 Curtis PMC Troubleshooting Connect a voltmeter across the PMC #2 terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and The voltage shown is for illustration place the F&R Switch in Forward. only. The actual voltage may vary. Depress the accelerator pedal to engage MS-1 only.
  • Page 86 Curtis PMC Troubleshooting Power Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 87 Curtis PMC Troubleshooting Motor The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 88 Curtis PMC Troubleshooting Accelerator The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 89 Refer to the option list for your truck or ® contact your Taylor-Dunn Representative for more information. If you do not know how to test for continuity, refer test to a qualified technician.
  • Page 90 Curtis PMC Troubleshooting Forward and Reverse Side For your reference, shown at the right are the Forward and KSI Side White/Black Reverse switch wire connections for a typical control system. Violet/Black Green/Black Blue/Black Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back Connect a voltmeter across the HOT terminal of the KSI...
  • Page 91 Curtis PMC Troubleshooting F/R switch The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 92 Curtis PMC Troubleshooting Connect a voltmeter across the forward terminal of the The FORWARD terminal is forward and reverse side of the F&R switch and battery diagonally opposite the forward side of the rocker on the switch negative. FLUKE 79 SERIES II MULTIMETER Close all interlock switches, turn the Key Switch ON, F&R switch seen from...
  • Page 93 Curtis PMC Troubleshooting Solenoids The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 94 Curtis PMC Troubleshooting Forward (does not run in reverse) The voltage shown is for illustration Connect a voltmeter across the PMC KSI terminal and battery only. The actual voltage may vary. negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in reverse.
  • Page 95 Curtis PMC Troubleshooting Connect the test light across the Normally Closed contacts of the Forward solenoid. Refer to your vehicles wiring FWD/REV diagram to identify the position of the forward solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Reverse.
  • Page 96 Curtis PMC Troubleshooting Set the test light voltage to the same voltage as the battery volts. Solenoids are shown for reference only. The type and position of the forward Connect the test light across the Normally Open contacts solenoid in your truck may be different of the Forward solenoid.

  • Page 97: Symptom Troubleshooting Guide

    Curtis PMC Troubleshooting SYMPTOM TROUBLESHOOTING GUIDE This section is specific to the symptoms listed below. Each troubleshooting sequence assumes that all listed symptoms are present. Do not use this section unless the truck has all listed symptoms. SYMPTOMS GO TO Ø...
  • Page 98 Curtis PMC Troubleshooting PMC CONTROL 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 under the front wheels to prevent vehicle movement. 5.
  • Page 99 Curtis PMC Troubleshooting Connect a volt meter across the PMC B+ and PMC M- terminals. The voltage shown is for illustration Turn the key-switch on, close all interlock only. The actual voltage may vary. switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests: •...
  • Page 100 Curtis PMC Troubleshooting PLUGGING DIODE 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 under the front wheels to prevent vehicle movement. 5.
  • Page 101 Curtis PMC Troubleshooting FREEWHEEL DIODE 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 under the front wheels to prevent vehicle movement. 5.
  • Page 102 Curtis PMC Troubleshooting 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 under the front wheels to prevent vehicle movement. 5.
  • Page 103 Curtis PMC Troubleshooting Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure Reading is plus or minus 10% its resistance. ISO solenoid is shown for reference • The meter reading should be 250 Ohms only.
  • Page 104 Curtis PMC Troubleshooting SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms. Perform the tests covered in the MOTOR section first. If the motor is OK, continue with the following tests. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
  • Page 105 Curtis PMC Troubleshooting 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, otherwise continue with the next test. • Check continuity from the motor ‘A2’ terminal to the wire that was connected to the motor ‘S2’...
  • Page 106 Curtis PMC Troubleshooting With the key-switch on and the F&R switch in reverse, depress the accelerator pedal and perform the following tests: • Check continuity from the wire that was connected to the PMC ‘M-’ terminal to the Motor shown for reference only. wire that was connected to the motor ‘S1’...
  • Page 107 Curtis PMC Troubleshooting MOTOR High motor current in both the field and the armature, accompanied with a lack of power, would indicate a shorted armature and\or field. Another symptom that may exist is jumping or stuttering at low speeds and/or the motor will not run unless the armature is manually rotated.
  • Page 108 Curtis PMC Troubleshooting Check continuity from ‘S1’ to the frame of the motor. Motor shown for reference only. If you do not know how to test for continuity, Terminal positions on your motor may not be in the same location. refer test to a qualified technician.
  • Page 109 TABLE OF CONTENTS Operating Instructions and Theory of Operation ......2 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting ......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 BEFORE disconnecting the batteries.

  • Page 110: Electrical Troubleshooting

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION ® ® The Lestronic II chargers are designed as semiautomatic chargers. The Lestronic II charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged into the batteries.
  • Page 111 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: •...
  • Page 112 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING ® Digital Multi Meter (DMM) with diode and capacitor test function, FLUKE 79 model shown at right and in the troubleshooting illustrations. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
  • Page 113 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT-IN CHARGER 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 under the front wheels to prevent vehicle movement. 5.
  • Page 114 Electrical Troubleshooting • Disconnect the charger from the AC source. • Disconnect the batteries. • Disconnect the charger from the vehicle’s harness. • Remove the charger from the vehicle. HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor before continuing.
  • Page 115 Electrical Troubleshooting • Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad.
  • Page 116 Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles DC receptacle to main battery negative. This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage then this wire is broken or has a bad connection.
  • Page 117 Electrical Troubleshooting 5. Reconnect the lead to the diode. 6. Connect the charger to the AC source. Insert the DC charger plug into the DC receptacle and perform the following tests: High Voltage inside the charger. Do not touch any internal components while the charger is plugged in.
  • Page 118 Electrical Troubleshooting Disconnect the wires from the contact terminals on the timer relay. Reconnect the batteries. 6. Wait 5 seconds, then test the continuity across the timer relay contact terminals. • If this is a closed circuit, then the timer start up circuit is functioning normally. •...
  • Page 119 TABLE OF CONTENTS Operating Instructions and Theory of Operation ........2 HB/PT and GEL Indicator Lamps ...3 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting .......4 Important Notes and Instructions Status LED Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 120: Signet Charger Troubleshooting

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION ® ® The model HB600W and HB1000W chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.
  • Page 121 Electrical Troubleshooting HB/PT AND GEL INDICATOR LAMPS NOTE: Your charger may not be equipped with these lamps. HB/PT Lamp If the HB/PT lamp is “ON”, then the charger has overheated and has entered a proportionally reduced output. The charging cycle will terminate if the temperature continues to rise.
  • Page 122 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING ® Digital Multi Meter (DMM), FLUKE 79 model shown at right and in the troubleshooting illustrations. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
  • Page 123 Electrical Troubleshooting STATUS LED ERROR CODE TABLE There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in the charging cycle.
  • Page 124 Electrical Troubleshooting TROUBLESHOOTING To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet. Wait for charger to start (up to15 seconds), the ammeter should display the DC Amp rating of the charger (plus or minus 10%) indicating that the charger is on (constant current mode).
  • Page 125 Charger Models: HBS 600 HBS 1000 TABLE OF CONTENTS Definitions: ..........2 Test Equipment Required for Troubleshooting .......2 Important Notes and Instructions Operating Instructions and Theory of Operation ........3 Testing the Charging Cycle ....4 Status Light Error Code Table....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 126: Clamp On Dc Ammeter To Measure Up To 20-Amps

    Electrical Troubleshooting DEFINITIONS: Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells. Term Value Condition V1: Voltages are temperature compensated See Chart Flooded batteries relative to the temperature of the charger at the 2.383 Volts Per Cell Gel Batteries time the charge cycle is started.

  • Page 127: Operating Instructions And Theory Of Operation

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Typical specification plate (reference only, specifications will vary for different chargers) ® ® The model HBS 600W and HBS 1000W chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once the charging cycle is complete, the charger will monitor the battery voltage.
  • Page 128 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit.
  • Page 129 Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.
  • Page 130 Electrical Troubleshooting TROUBLESHOOTING NOTE: There are no internally serviceable components in the charger. To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet.

  • Page 132: Wire Diagram

    Wire Diagrams Charger AC Cords: If you are not familiar with standard AC power wiring, then refer repair to a qualified licenced electrician. Charger AC power source is High Voltage. Only personnel qualified for work high voltage AC power lines should repair the charger AC power cord. Improper repair or incorrect wiring may result in an electrical shock hazard causing severe bodily injury or electrocution.
  • Page 133 TABLE OF CONTENTS Front Axle ............2 Front Fork ............. 4 Steering Linkage ........... 6 Transmission Chain or Gear Case ....8 Transmission Differential Case ..... 10 Rear Brakes ..........12 Rear Axle ............12 Motor ............. 14 Brake linkage ..........16 Wheels and Tires ..........

  • Page 134: Front Axle

    Illustrated Parts Front Axle Parts Page 2...
  • Page 135 Illustrated Parts FRONT AXLE Item No. Part No. Description 88-229-81 Locknut, 3/4NC 88-228-60 Washer, 3/4” Cut 15-010-00 Front Axle 16-010-00 Spacer 14-082-10 Front Fork Assembly Parts Page 3...

  • Page 136: Front Fork

    Illustrated Parts Front Fork Parts Page 4...
  • Page 137 Illustrated Parts FRONT FORK Item No. Part No. Description 88-229-81 Locknut, 3/4NC 88-228-60 Washer, 3/4” Cut 45-307-00 Oil Seal, 1-1/2” ID 80-011-00 Bearing, Tapered Roller, 1-1/4” ID 80-102-00 Bearing Race 14-082-10 Front Fork Assembly 92-105-00 Dust Cap Parts Page 5...

  • Page 138: Steering Linkage

    Illustrated Parts Steering Linkage Parts Page 6...
  • Page 139 Illustrated Parts STEERING Item No. Part No. Description 95-915-20 Steering Wheel Cap 88-199-82 Nut, 5/8NF Jam 19-007-20 Steering Wheel 80-400-10 Ball Bearing, Sealed, 3/4” 20-010-00 Shaft, Steering Column 97-100-00 Woodruff Key, 3/16” 16-405-00 Spacer, 3/4” ID x 1/8” Thick 30-002-00 Sprocket, 11 Tooth, #40 Chain, 3/4”...

  • Page 140: Transmission Chain Or Gear Case

    Illustrated Parts Transmission Chain or Gear Case Motor 3rd Member Brake Assembly Parts Page 8...
  • Page 141 Illustrated Parts Transmission Chain Case ITEM# PART # DESCRIPTION 88-109-61 3/8" SAE Flat Washer 97-100-00 Woodruff Key 88-087-11 Chain Adjusting Screw 88-069-80 5/16" NC Hex Nut 88-103-09 Motor Mounting Screw, 3/8" X 3/4" NC 80-703-00 O-Ring, 4-1/2" ID X 5" OD 70-454-00 Motor Mounting Plate 88-109-87...

  • Page 142: Transmission Differential Case

    Illustrated Parts Transmission Differential Case Parts Page 10...
  • Page 143 Illustrated Parts Transmission Differential Case ITEM# PART # DESCRIPTION 41-179-00 3rd member Housing (1.628 ID Carrier Bearing) 0 or 1 41-710-00 3rd member Housing (1.784 ID Carrier Bearing) 0 or 1 88-119-80 3/8" NF Nut 41-712-00 Differential Assembly (1.628 ID Carrier Bearing) 0 or 1 41-713-00 Differential Assembly (1.784 ID Carrier Bearing)

  • Page 144: Rear Brakes

    Illustrated Parts Rear Brakes Rear Axle Axle tube Parts Page 12...
  • Page 145 Illustrated Parts Rear Bakes ITEM # PART # DESCRIPTION 45-331-00 Pinion Seal 41-352-00 Brake Drum 96-245-10 Brake Adjusting Bolt 41-661-60 Brake Band Kit (Incl. #'s 3, 5, 7, 8, 9, 12, 13) 85-060-20 2-1/2" Long Spring 41-372-10 Mounting Bracket 88-159-84 1/2"-20 NF Lock Nut 88-159-82 1/2"...

  • Page 146: Motor

    Illustrated Parts Motor Parts Page 14...
  • Page 147 Illustrated Parts Parts Page 15...

  • Page 148: Brake Linkage

    Illustrated Parts Brake linkage Parts Page 16...
  • Page 149 Illustrated Parts PARK & FOOT BRAKE LINKAGE Item No. Part No. Description 51-340-00 Park Brake Lever Spacer-included with lever 88-109-81 Locknut, 3/8NC 88-108-60 Washer, 3/8 SAE 88-101-16 Bolt, 3/8NC x 2” Hex Hd. 98-200-00 Brake Pedal Pad, Rubber 01-432-98 Brake Pedal Bracket (painted black) 01-432-70 Brake Shaft Weldment (painted black) 88-111-32...

  • Page 150: Wheels And Tires

    Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) Parts Page 18...
  • Page 151 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-054-00 11-1/4 Cast iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-074-10 400 x 8 Soft solid, non-marking, ribbed 10-074-00 400 x 8 Soft solid, ribbed 10-261-00...

  • Page 152: Instrument Panel (Dash)

    Illustrated Parts Instrument Panel (dash) Parts Page 20...
  • Page 153 Illustrated Parts INSTRUMENTATION Item No. Part No. Description 71-120-00 Ignition Switch, Keyed Alike 71-121-00 Ignition Switch, Keyed Unalike (optional) 71-039-00 Switch, Forward/Off/Reverse 94-312-00 Label, Forward/Off/Reverse 88-727-06 Pop Rivit, 5/32” x 1/2” 00-432-29 Cover Plate, Dash 74-009-10 Charge Indicator, 24 Volt 74-009-00 Charge Indicator, 36 Volt 74-000-00...

  • Page 154: Speed Control Panel

    Illustrated Parts Speed Control Panel Parts Page 22...
  • Page 155 Illustrated Parts Speed Control Panel Item No. Part No. Description 72-501-42 Forward or Reverse Solenoid, 24V, 200A (C4-33) 72-501-39 Forward or Reverse Solenoid, 36V, 200A (C4-32) 88-838-06 Sheet Metal Screw, #14 x 1/2” 62-205-00 Speed Controller, 400A 72-501-43 ISO Solenoid, 24V, 200A (C4-33) 72-501-38 ISO Solenoid, 36V, 200A (C4-32) 88-818-06...

  • Page 156: Lester Charger P1

    Illustrated Parts Lester Charger P1 Parts Page 24...
  • Page 157 Illustrated Parts Parts Page 25...

  • Page 158: Lester Charger P2

    Illustrated Parts Lester Charger P2 Parts Page 26...
  • Page 159 Illustrated Parts Parts Page 27...

  • Page 160: Signet Charger

    Illustrated Parts Signet Charger Model HBS series charger shown Parts Page 28...
  • Page 161 Illustrated Parts Model HBS for Flooded Batteries Model HB for Flooded Batteries PART # DESCRIPTION PART # DESCRIPTION 24 volt Charger Assembly (see note) 79-302-20 24 volt Charger Assembly (see note) 79-303-41 36 volt Charger assembly (see note) 79-303-40 36 volt Charger assembly (see note) 79-309-42 48 volt charger assembly (see note) 79-309-40...

  • Page 162: Batteries

    Illustrated Parts Batteries Parts Page 30...
  • Page 163 Illustrated Parts BATTERIES Item No. Part No. Description 75-231-00 Jumper, Battery, 10-1/4” long 01-423-79 Angle, Battery Hold 50-227-00 Battery Rod 88-069-81 Locknut, 1/4NC 88-081-12 Bolt, 5/16NC Square Hd, Tin-Lead 8 or 12 88-089-80 Nut, 5/16NC, Tin-Lead 8 or 12 77-042-00 Battery, 6 Volt, 217 amp hour (standard) 4 or 6 .

  • Page 164: Seat Cushions And Deck

    Illustrated Parts Seat Cushions and Deck Parts Page 32...
  • Page 165 Illustrated Parts Seat Cushions and Deck Item No. Part No. Description 90-001-00 Seat Cushion 90-000-00 Backrest 90-100-00 Seat Frame 90-100-51 Support Rod 90-420-00 Deckboard, 29-1/8” x 48” Not Shown 88-837-11* Screw, #14 x 1” Phillips Metal Not Shown 88-107-09** Screw, 3/8NC x 3/4”...

  • Page 166: Decals

    Illustrated Parts Decals Parts Page 34...
  • Page 167 Decal Brake Warning 94-384-01 Decal, Not a Motor Vehicle 94-373-10 Decal, Vehicle Data 94-333-00 Decal, FM 94-313-00 Decal, Battery Warning 94-319-00 Decal, Battery Disconnect 94-201-00 Taylor-Dunn Emblem (on front cowl) Shown 88-567-91 Fastener, Push On (for TD Emblem) Parts Page 35...

  • Page 168: Optional Equipment

    Illustrated Parts Optional Equipment Parts Page 36...
  • Page 169 Illustrated Parts OPTIONAL PARTS Wheel Covers Item No. Part No. Description 92-000-00 Chrome Wheel Cover, 8” 92-001-00 Chrome Wheel Cover, 6” Diamond Plate Deck Cover 90-420-40 Deck, Diamond Plate, 29-1/8” x 48”, Black 88-607-09 Rivet, 1/4” x 1/2” Starpin 90-420-60 Kit, Diamond Deck Cover, Black Reverse Warning Beeper 73-005-05...

  • Page 170: Stake Sides

    Illustrated Parts Stake Sides Parts Page 38...
  • Page 171 Illustrated Parts Stake Sides Item No. Part No. Description 90-550-03 Side Gate, Left 90-550-02 Side Gate, Right 90-550-01 End Gate 90-544-00 Stake Pocket, Outer (painted black) 90-544-10 Stake Pocket, Inner (painted black) 88-065-11 Screw, 1/4NC x 1” Phillips Truss Hd 88-069-81 Locknut, 1/4NC Parts...

  • Page 172: Fiberglass Cab And Doors P1

    Illustrated Parts Fiberglass Cab and Doors P1 Parts Page 40...
  • Page 173 Illustrated Parts Cab, Fiberglass, w/Safety Glass Item No. Part No. Description 91-005-00 Cab, Fiberglass 90-811-00 Windshield, Front 90-851-00 Rear Window 98-310-10 Window Channel, Rubber 13 ft 88-065-08 Screw, 1/4NC x 5/8” Phillips Truss Hd 88-068-62 Lockwasher, 1/4” 88-069-83 Acorn Nut, 1/4NC 91-005-10 Kit, Fiberglass Cab Doors, Naugahyde...

  • Page 174: Mirrors, Windshield Wiper, Brake Light

    Illustrated Parts Mirrors, Windshield Wiper, Brake Light Parts Page 42...
  • Page 175 Illustrated Parts Mirrors, Windshield Wiper Item No. Part No. Description 92-201-00 Mirror, 4-1/2” x 8-1/2” 92-202-00 Bracket, Mirror Mounting 88-065-08 Screw, 1/4NC x 5/8” Phillips Truss Hd 88-069-81 Locknut, 1/4NC 88-068-62 Lockwasher, 1/4” 88-069-83 Acorn Nut, 1/4NC 88-060-09 Bolt, 1/4NC x 3/4” Hex Hd Windshield Wipers 74-050-00 Windshield Wiper Motor...

  • Page 177: Brake Lining Handling Precautions

    Contents Appendix A: Special Tools ....2 Appendix B: Suggested Torque Limits for Standard Hardware ..3 Hardware Identification ...... 3 Standard Head Markings ........3 Hex Bolts ............3 Other Bolts ............3 Hex Nuts ............4 Hex Lock Nuts (stover) ........4 Other Nuts ............

  • Page 178: Appendix A: Special Tools

    Appendixes APPENDIX A: SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used for testing electrical circuits. Powered by the truck Test Light 62-027-00 batteries, switchable for 12, 24, 36, and 48 volts. Used to test the solid state accellerator module part number Accelerator Test Harness 62-027-31 series 62-033-XX.

  • Page 179: Appendix B: Suggested Torque Limits For Standard Hardware

    Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings 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.

  • Page 180: Hex Nuts

    NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts ® Other nuts used by Taylor-Dunn should be treated as S.A.E. grade A Appendixes Appendix B Page 4...

  • Page 181: Suggested Torque Values (Non-Critical Hardware)

    Appendixes Suggested Torque Values (non-critical hardware) Diameter Grade 2 Grade 5 Grade 8 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque (ft-lb) (ft-lb) (ft-lb) (ft-lb) 1/4-20 7-10 10-14 1/4-28 8-12 11-16 5/16-18 9-14 14-21 20-29 5/16-24 10-15 15-23 22-33 3/8-16 16-24...
  • Page 182 Appendixes Suggested Torque Values (critical hardware) Torque Table Torque Range Group Description Ft-Lbs In-Lbs Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15...

  • Page 183: Appendix C: Brake Lining Handling Precautions

    Appendixes APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS Taylor-Dunn does not currently supply asbestos fiber-brake pads/ shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the brake pads/ shoes should be handled as if they do contain asbestos.
  • Page 186 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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