Page 1 EQUIPPED WITH GT-DRIVE SYSTEM T h e B e s t W a y Models Inlcuded: T o G o B0-248-36 (B 2-48, 36-volt) A b o u t Y o u r B0-248-48 (B 2-48, 48-volt) B0-254-36 (B 2-54)
Page 3 Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement 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.
Page 4 Table of Contents ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...
Page 5: Table Of Contents
Section Index Taylor-Dunn ® Models B0-248-36, B0-248-48, B0-254-36, BT-248-36, BT-248-48, BT-280-36, BT-280-48 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transaxle Service Tires and Wheels...
Page 7 Introduction Contents 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 ....8...
Page 8: About This Manual
Please continue to read this manual and enjoy this high quality Taylor-Dunn ® vehicle. This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn ® vehicles and is not intended as a training guide. Taylor-Dunn ®...
Page 9: Who Should Read This Manual
Of the Service Personnel... The service personnel are responsible for the service and maintenance of the vehicle. At no time should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn ® vehicle. For the purposes of training, a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training.
Page 10: How To Use This Manual
INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections: INTRODUCTION This section describes how to use this service manual and how to identify your vehicle. Safety Rules and Operating Instructions This section outlines the safety and operational issues, location and operation of controls, and the operational checks that are to be performed on this vehicle.
Page 11: Conventions
INTRODUCTION Conventions Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: A shaded box with the word “Warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others.
Page 12: 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. They are not to be driven on public highways.
Page 13 INTRODUCTION Vehicles manufactured before 2007 and up to March, 2007 B 2-48 and B 2-54 Under deck on deck rail BT 2-48 Under front left passenger cushion BT 2-80 Introduction Page-7...
Page 14: Taking Delivery Of Your Vehicle
® distributor and report the problem. The report must be made within 24 hours of receiving the vehicle and its accessories. The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn ® vehicle is a factory authorized service technician.
Page 15 TABLE OF CONTENTS Standard Specifications* (Common) ... 2 Standard Specifications* (Model B 2-48/2-54) 3 Standard Specifications* (Model BT 2-48) Standard Specifications* (Model BT 2-80) Safety Rules and Guidelines ....6 Driver Training Program ..... 6 Driver Qualifications........... 6 Vehicle Controls ........ 7 Dash up to Serial # 179669 ....
Page 16: Standard Specifications* (Common)
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* (COMMON) ITEM VOLTAGE SPECIFICATION Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs) Weights Transmission Helical Gear, Oil Bath, Automotive Type Hypoid Differential Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake, or Optional 4 Wheel Hydraulic Disc, Hand Operated Park Brake Steering...
Page 17: Standard Specifications* (Model B 2-48/2-54)
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* (MODEL B 2-48/2-54) ITEM MODEL VOLTAGE SPECIFICATION Occupancy B 2-48, B 2-54 2 Passenger Electrical System B 2-48 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries, Solid State Speed Control, 400 Amp B 2-48 48 Volt 8-250 Amp Hour, 6 Volt, Lead Acid Batteries,...
Page 18: Standard Specifications* (Model Bt 2-48)
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* (MODEL BT 2-48) ITEM VOLTAGE SPECIFICATION Occupancy Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries, Solid State Speed Control, 500 Amp 48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries, Solid State Speed Control, 500 Amp Dimensions 307L X 162W X 117H Centimeters...
Page 19: Standard Specifications* (Model Bt 2-80)
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* (MODEL BT 2-80) ITEM VOLTAGE SPECIFICATION Occupancy Eight Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries, Solid State Speed Control, 500 Amp 48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries, Solid State Speed Control, 500 Amp Dimensions 330 L X 127 W X 112 H Centimeters...
Page 20: Safety Rules And Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND DRIVER TRAINING PROGRAM GUIDELINES 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 21: Vehicle Controls
SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS DASH UP TO SERIAL # 179669 1) Accessory Switch (Optional) The accessory switch is located on the left side of the instrument panel and to the right of the headlight switch. Push the top of the switch to turn on the accessory. Push the bottom of switch to turn off the accessory.
Page 22: Dash Starting Serial #179670
SAFETY RULES AND OPERATING INSTRUCTIONS DASH STARTING SERIAL #179670 1) Headlight Switch The headlight switch is located on the top left of the instrument panel. Push the right side of the switch to turn the lights on. Push the left side of the switch to turn the light off.
Page 23: Directional Signals (Optional)
SAFETY RULES AND OPERATING INSTRUCTIONS Accelerator Pedal The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.
Page 24: Charger Interlock
SAFETY RULES AND OPERATING INSTRUCTIONS Seat Interlock Switch A switch located under the driver's seat disables the power to the vehicle when the driver leaves the seat. The driver must be seated for the vehicle to operate. Whenever the driver leaves the vehicle, the driver should turn the key-switch off, place the forward-off-reverse switch in the center “OFF”...
Page 25: Trailer Brake Module (Optional)
SAFETY RULES AND OPERATING INSTRUCTIONS Trailer Brake Module (optional) The trailer brake module controls the braking functions of a trailer equipped with electric brakes. There have been many styles of brake modules used. All of the brake modules that have been used function the same other than that the location of the manual adjustment controls may vary.
Page 26: Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is described below.
Page 27 SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance Monitor: NOTE: The Maintenance Monitor function is optional. The Maintenance Monitor function can be turned ON or OFF by your dealer. Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator.
Page 28: Fault Code Tables
SAFETY RULES AND OPERATING INSTRUCTIONS Fault Code Tables NOTE: Most faults are a result of a fault in the control Level 5 Faults system that will require service by a qualified Fault Code Description What to do technician. These faults are shown here for F05000 Contactor Over Current Refer to service technician...
Page 29: Vehicle Operation Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATION GUIDELINES Safety Guidelines While driving: • • Only qualified and trained operators may drive this Slow down and sound the horn to warn pedestrians vehicle. or when approaching a corner or other intersection. •...
Page 30: Parking
SAFETY RULES AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle: • Set the parking brake. • Set the forward-off-reverse switch to the ` “OFF” position. • Rotate the start switch to the “OFF” position. In addition: • If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.
Page 31: Dump Bed (Optional)
SAFETY RULES AND OPERATING INSTRUCTIONS DUMP BED (OPTIONAL) There are numerous variations of the dump bed options that are available for the Model B series vehicles. Although the physical design of the dump bed varies, the operation is basically the same. Refer to the original vehicle sales order for specific information regarding the dump bed option used.
Page 32: Lowering The Dump Manually
SAFETY RULES AND OPERATING INSTRUCTIONS Manual Release Lowering the Dump Manually Do not place any body part underneath a raised bed unless the bed prop rod is in place. Severe There is a manually operated valve located on the left bodily injury will result if the bed lowers side of the hydraulic pump assembly (see illustration).
Page 33: Hydraulic Pump Exploded View
SAFETY RULES AND OPERATING INSTRUCTIONS HYDRAULIC PUMP EXPLODED VIEW This view is provided by the manufacturer of the pump and should only be used as a reference. Refer to the pump manufacturere web site for current detailed information: http://www.monarchhyd.com/. The pump model # is M-303. Safety Rules Page 19...
Page 34: 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 not work with or charge battery in an area contact with skin eyes or clothing.
Page 35: 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 36: Periodic Maintenance Checklist
SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi - Weekly Monthly Quaterly Annualy Maintenance Item 2, 3 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 37: Standard Periodic Maintenance Schedule For The Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY NOTE: The maintenance function is optional. Your vehicle may be equipped with a customized maintenance schedule PREVENTATIVE MAINTENANCE SCHEDULE MAINTENANCE HOUR MAINTENANCE TO BE PERFORMED LEVEL INTERVAL Inspect the brake system including the park brake and mounting harware...
Page 38: 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 39: General Maintenance
General Maintenance TABLE OF CONTENTS Maintenance Guidelines ....... 2 Troubleshooting Guide ......... 3 Lubrication Chart .......... 4...
Page 40 • Inspect and maintain battery limit switches, protective devices, electrical conductors, and ® connections in conformance with Taylor-Dunn’s recommended procedures. • Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.
Page 41: Troubleshooting Guide
Maintenance, Service and Repair TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment Steering Pulls in O ne Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged King P in/Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis-Adjusted or Worn Steering Gear Loose Steering Linkage...
Page 42: Lubrication Chart
Maintenance, Service and Repair LUBRICATION CHART Rear Axle Lubrication Front End Lubrication Description Locations Lubricant Type Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease King Pin General Purpose Grease Drive Drain Plug Drive Level Plug Drive Fill Plug SAE 80W90 Gear Oil...
Page 43: Front Axle Service
Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin ........... 2 Adjust Front Wheel Bearings ....... 3 Front Axle Removal and Installation .... 4 Removal ..............4 Installation ..............5 Front Axle Disassembly ........ 6 Replace Front Wheel Bearings .....
Page 44: Inspect The Front Wheel Bearings And King Pin
Maintenance, Service, and Repair INSPECT THE FRONT WHEEL BEARINGS AND KING PIN 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.
Page 45: Adjust Front Wheel Bearings
Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS 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 rear wheels to prevent vehicle movement. 5.
Page 46: Front Axle Removal And Installation
Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 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 rear wheels to prevent vehicle movement. 5.
Page 47: Installation
Maintenance, Service, and Repair Installation 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 rear wheels to prevent vehicle movement. 5.
Page 48: Front Axle Disassembly
Maintenance, Service, and Repair FRONT AXLE DISASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: Replace the Steering Knuckle Replace the King Pins and Bushings NOTE: The front axle does not have to be removed unless the axle beam Front Axle Removal and must be replaced.
Page 49: Replace Front Wheel Bearings
Maintenance, Service, and Repair REPLACE FRONT WHEEL BEARINGS 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 rear wheels to prevent vehicle movement. 5.
Page 50 Maintenance, Service, and Repair 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Brakes NOTE: Refer to the section for information regarding the installation of the brake body. 15. Lower the vehicle. 16. Reconnect the main positive and negative cables at the batteries. 17.
Page 51: Replace The King Pins And Bushings
Maintenance, Service, and Repair REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle. • Bronze bushings in the axle beam. • Bronze bushings in the steering knuckle. • Metal backed teflon bushings in the axle beam or suspension arm.
Page 52 Maintenance, Service, and Repair Replace the Steering Knuckle 7. Remove the steering knuckle. Refer to for information regarding removing 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, steering knuckle or suspension arm. 9.
Page 53: Replace The Steering Knuckle
Maintenance, Service, and Repair REPLACE THE STEERING KNUCKLE 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 rear wheels to prevent vehicle movement. 5.
Page 54 Maintenance, Service, and Repair 12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings. NOTE: Both the left and right side bushings and thrust bearings should be replaced as a set. 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. 15.
Page 55 Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Inspect Ball Joints ......... 6 Inspect Rod Ends .......... 7 Adjust the Steering Gear ....... 8 Replace the Steering Shaft ......10 Replace the Steering Wheel ......12 Replace the Steering Gear ......13 Replace the Ball Joints, Tie Rods, and Drag Link ............
Page 56: Front End Alignment
Maintenance, Service, and Repair FRONT END ALIGNMENT This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is fitted to the steering arm or pitman arm. The second type cannot be greased and has a straight shaft.
Page 57 Maintenance, Service, and Repair 10. At this point both the steering wheel and the front wheels should be tied up and held in position. If one or the other is not tied up then you must start from the beginning. Do not drive the vehicle while the steering wheel or front wheels are tied in position.
Page 58 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front Center the Steering wheels. Refer to the section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 59 Maintenance, Service, and Repair 11. Measure the distance between the lines at the front Front Measurement of the tires. 12. Measure the distance between the lines at the rear of the tires. Sleeve Clamps 13. Adjust the tie rod so that the distance at the front and rear of the tires is the same.
Page 60: Inspect Ball Joints
Maintenance, Service, and Repair INSPECT BALL JOINTS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.
Page 61: Inspect Rod Ends
Maintenance, Service, and Repair INSPECT ROD ENDS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.
Page 62: Adjust The Steering Gear
Maintenance, Service, and Repair ADJUST THE STEERING GEAR NOTE: In some vehicle configurations it may be necessary to remove the Replace the steering gear to perform this procedure. Refer to Steering Gear for information regarding removing the steering gear. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 63 Maintenance, Service, and Repair 13. While rotating the input shaft back and forth through its centered position, adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position. 14.
Page 64: Replace The Steering Shaft
Maintenance, Service, and Repair REPLACE THE STEERING SHAFT 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 65 Maintenance, Service, and Repair 11. Remove the steering shaft from the vehicle. 12. Lightly grease the input shaft splines, steering wheel splines and the upper steering shaft bushing. 13. Install the steering shaft in reverse order using a new pinch bolt. Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft.
Page 66: Replace The Steering Wheel
Maintenance, Service, and Repair REPLACE THE STEERING WHEEL 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 67: Replace The Steering Gear
Maintenance, Service, and Repair REPLACE THE STEERING GEAR 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 rear wheels to prevent vehicle movement. 5.
Page 68: Replace The Ball Joints, Tie Rods, And Drag Link
Maintenance, Service, and Repair REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second Rod End cannot be greased and has a straight shaft.
Page 69 Maintenance, Service, and Repair 10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time. 11.
Page 70: Replacing The Drag Link
Maintenance, Service, and Repair 12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. and install a new cotter pin. 13. Realign the front wheels. Steering NOTE: Refer to the section for information regarding realignment of the front wheels.
Page 71: Replacing The Tie Rod
Maintenance, Service, and Repair 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13. Remove the blocks from behind the wheels. 14. Release the park brake and test drive the vehicle. Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together.
Page 72: Center The Steering Gear
Maintenance, Service, and Repair CENTER THE STEERING GEAR 1. Remove the pitman arm. 2. Rotate the input shaft clockwise until it stops. 3. While counting the rotations, rotate the input shaft counter clockwise until it stops. 4. Rotate the input shaft clockwise 1/2 the rotations counted in the previous step. 5.
Page 73: Repair The Steering Gear
Maintenance, Service, and Repair REPAIR THE STEERING GEAR Disassembly NOTE: The steering gear must be removed from the vehicle for this procedure. Refer to Replace the Steering Gear section for information regarding removing the steering gear. NOTE: The steering gear is packed with grease. Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled.
Page 74 Maintenance, Service, and Repair 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing.
Page 75 Maintenance, Service, and Repair 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft.
Page 76: Exploded View Of Steering Gear
Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 22...
Page 77: Brakes Service
Brake Service TABLE OF CONTENTS Inspect the Service Brake ......2 Disc Brake Pads ............2 Disc Brake Rotor ............. 3 Inspect the Parking brake ......4 Wheel Park Brake (hydraulic disc) ......4 Electric Motor Brake ..........5 Adjust the Service Brakes ......6 Two or Four Wheel Hydraulic Disc Brakes ....
Page 78: Inspect The Service Brake
Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads 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.
Page 79: Disc Brake Rotor
Maintenance, Service, and Repair Disc Brake Rotor 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 80: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake (hydraulic disc) NOTE: The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 81: Electric Motor Brake
Maintenance, Service, and Repair Electric Motor Brake A variable power supply capable of supplying 0-volts to 24-volts DC at 2-Amps will be required to perform the testing. The brake does not have to be removed from the transmission for this test. 1.
Page 82: Adjust The Service Brakes
Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Two or Four Wheel Hydraulic Disc Brakes The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • Check the Master Cylinder Fluid Brake fluid level low in the master cylinder.
Page 83: Adjust The Parking Brake
Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake (hydraulic disc) The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 84: Check Master Cylinder Fluid
Maintenance, Service, and Repair CHECK MASTER CYLINDER FLUID Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 85: Bleed The Brake System
Maintenance, Service, and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 86 Maintenance, Service, and Repair 7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the master cylinder chamber. • Only use DOT 3 brake fluid from a new sealed container. •...
Page 87: Flush The Brake System
Maintenance, Service, and Repair FLUSH THE BRAKE SYSTEM 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 88: Replace The Parking Brake Lining (Electric Motor Brake)
Maintenance, Service, and Repair REPLACE THE PARKING BRAKE LINING (ELECTRIC MOTOR 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.
Page 89 Maintenance, Service, and Repair 6. Mark the orientation of the inner contact plate in relation to the magnet. 7. Remove the smaller bearing circlip. 8. Using a soft hammer, drive out the center hub and remove the inner contact plate and six springs. 9.
Page 90: Inspection
Maintenance, Service, and Repair Electric motor brake exploded Inspection: Note: There are no repairable parts in this assembly. The parts must be replaced if any damage or wear is found. 1. Measure the free length of the five springs. Minimum length =0.713” 2.
Page 91: Replace Front Disc Brake Pads
REPLACE FRONT DISC BRAKE PADS NOTE: It is recommended that both the left and right brake pads be replaced as a set. Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos.
Page 92 Maintenance, Service, and Repair NOTE: Refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. Inspect the Service Brakes 12.
Page 93: Replace Rear Brake Pads
Maintenance, Service, and Repair REPLACE REAR BRAKE PADS Hydraulic Disc 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.
Page 94 Maintenance, Service, and Repair 9. Remove the tire/wheel assembly. Tires and Wheels NOTE: Refer to section for information on removing the tire and wheel assembly. 10. Release the park brake (wheel brake only). 11. Remove the brake body bolts and discard the lock nuts and brake pads. 12.
Page 95: Replace The Wheel Cylinder
Maintenance, Service, and Repair REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly (front or rear) 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.
Page 96 Maintenance, Service, and Repair Tires and Wheels 8. Remove the tire/wheel assembly. Refer to section for information on removing the tire and wheel assembly. 9. Thoroughly clean the area around the brake body. 10. Remove the brake body bolts and discard the lock nuts.
Page 97: Repair The Brake Body
Maintenance, Service, and Repair REPAIR THE BRAKE BODY Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Any debris or contaminates left in the brake system could lead to brake failure and result in property damage and/or severe bodily injury.
Page 98 Maintenance, Service, and Repair 11. Lubricate the brake parts with clean brake fluid from a sealed container. 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. NOTE: There are two different brake assemblies.
Page 99: Replace The Master Cylinder
Maintenance, Service, and Repair REPLACE THE MASTER CYLINDER Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
Page 100 Maintenance, Service, and Repair 10. Install in reverse order. 11. Adjust the master cylinder push rod so that it is Plunger approximately 1/8 inch away from the master cylinder plunger when the brake pedal is up. 12. Fill the master cylinder with brake fluid from a sealed container.
Page 101: Repair The Master Cylinder
Maintenance, Service, and Repair REPAIR THE MASTER CYLINDER NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See Replace the Master Cylinder section . Drain all fluid from the master cylinder and discard.
Page 103: Motor Service
Motor Service TABLE OF CONTENTS Inspecting the Motor Brushes ...... 2 Motors with internal cooling fans ....... 2 Motor Removal and Installation ....3 Motor Inspection ........... 3 Replacing the Brushes or Armature Bearing ........7 Repairing the Commutator......8 Service Limits ..........
Page 104: Inspecting The Motor Brushes
Motor Service INSPECTING THE MOTOR BRUSHES Motors with internal cooling fans NOTE: There are four brushes in the motor. The brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time.
Page 105: Motor Removal And Installation
Motor Service MOTOR REMOVAL AND INSTALLATION Transmission See the section for information on removing or installing the motor. MOTOR INSPECTION Disassembly Transmission 1. Remove the motor from the vehicle. See the section for information on removing the motor. 2. Remove the brush cover and pull the brushes out away from the commutator. 3.
Page 106 Motor Service 2. Measure the diameter of the commutator. • If the commutator is less than the minimum Service Limits diameter specified in section then the motor must be replaced. 3. Measure the commutator undercut depth in 5-places around the commutator. Undercut •...
Page 107 Motor Service 7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted armature. • If the insulation is cracked or burnt, then it is recommend that the armature or motor be replaced.
Page 108 Motor Service Assembly 1. Press a new bearing into the motor housing and install the circlip. 2. Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator.
Page 109: Replacing The Brushes Or Armature Bearing
Motor Service REPLACING THE BRUSHES OR ARMATURE BEARING NOTE: It is recommended that all four brushes be replaced as a set. NOTE: The motor must be disassembled to replace the brushes or the Motor Inspection-Disassembly bearing. Refer to section for information on taking the motor apart.
Page 110: Repairing The Commutator
Motor Service REPAIRING THE COMMUTATOR Transmission 1. The motor must be removed from the vehicle for this procedure. Refer to Service section for information on removing the motor. Motor Inspection- 2. The armature must be removed from the motor for this procedure. Refer to Disassembly section for information on taking the motor apart.
Page 111 Motor Service Undercutting the commutator Undercut 1. Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer Hacksaw blade Armature to undercut depth in Service Limits. Incorrect Correct Insulation 2. Once all segments have been properly undercut, mount the armature in a lathe and smooth the commutator with fine emery cloth.
Page 112: Service Limits
Motor Service SERVICE LIMITS Commutator Diameter Brush Length Resistance Undercut Depth Motor Specification (min) (min) (Ohms@75º F) Number inches inches inches Armature Field 70-054-40 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20 (XP-1672 or DV1-4002) 70-054-41 0.635 0.025 69.85 2.75 15.87 0.625 0.011...
Page 113 Transmission TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor Removal and Installation ....4 Rear 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 ......
Page 114: Check Oil Level
Maintenance, Service, and Repair CHECK OIL LEVEL The oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 1.
Page 115: Change Oil
Maintenance, Service, and Repair CHANGE OIL 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 116: Motor Removal And Installation
Maintenance, Service, and Repair MOTOR REMOVAL AND INSTALLATION NOTE: Some applications will require removing the drive assembly from Removing and the vehicle to remove the motor. Refer to Installing the Drive Assembly for information on removing the drive assembly. Some vehicles are equipped with an automatic electric brake. The automatic electric brake is sandwiched between the drive motor and the gear case.
Page 117: Rear Hub Or Rotor
Maintenance, Service, and Repair REAR HUB OR ROTOR NOTE: The torque specification for the axle hub bolt is 275 ft-lbs. An impact wrench will be required to remove the bolt. NOTE: The axle hub bolt has a special thread locking compound applied to the threads.
Page 118: Removing And Installing The Rear Axles (Disc Brakes)
Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES (DISC BRAKES) The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange.
Page 119 Maintenance, Service, and Repair 11. Remove the axle retaining plate and brake body assembly as one unit. 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14.
Page 120: 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. 5.
Page 121: Disassembly And Reassembly Of The Primary Reduction Gear Case
Maintenance, Service, and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 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.
Page 122 Maintenance, Service, and Repair 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/ bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the pinion shaft.
Page 123 Maintenance, Service, and Repair Lubricate all parts with gear oil before installation. Failure to pre-lube the parts may result in premature failure. 19. Assemble the gear case in reverse order. NOTE: Torque the drain plug to 21-25 foot-pounds. NOTE: Torque the gear case to 3rd member retaining bolts to 18-20 foot- pounds.
Page 124: Disassembling The 3Rd Member
Maintenance, Service, and Repair DISASSEMBLING THE 3RD MEMBER 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 125 Maintenance, Service, and Repair 13. Remove the carrier bearing adjusting nut roll pin and 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.
Page 126 Maintenance, Service, and Repair 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the 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.
Page 127: Assembling The 3Rd Member
Maintenance, Service, and Repair ASSEMBLING THE 3RD MEMBER 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. Cover Housing 3. Install the carrier bearing races into the housing and cover. Cover Housing 4.
Page 128 Maintenance, Service, and Repair 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. If the ring and pinion gears or bearings are replaced then the pinion gear must be re-shimmed.
Page 129 Maintenance, Service, and Repair 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the vehicle.
Page 130: Pinion Bearing Preload
Maintenance, Service, and Repair Pinion Bearing Preload NOTE: The pinion gear depth must be set before the preload. Refer to Setting the Pinion Gear Depth 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3.
Page 131: Pinion Gear Shimming Instructions
Maintenance, Service, and Repair PINION GEAR SHIMMING INSTRUCTIONS NOTE: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. NOTE: To perform this procedure, all parts must be clean and the bearings lightly lubricated.
Page 132 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 20...
Page 133 Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Replace the Front Springs ......3 Replace the Spring Bushings ....... 4 Replace the Shocks ........5...
Page 134: Replace The Rear Springs
Maintenance, Service, and Repair REPLACE THE REAR SPRINGS If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 135: Replace The Front Springs
Maintenance, Service, and Repair REPLACE THE FRONT SPRINGS If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 136: Replace The Spring Bushings
Maintenance, Service, and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): •...
Page 137: Replace The Shocks
Maintenance, Service, and Repair REPLACE THE SHOCKS It is recommended to replace all shocks as a set. NOTE: On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the front wheels.
Page 139 Tires and Wheels TABLE OF CONTENTS Tire Inflation ..........2 Tire Inspection ..........2 Replace the Tire/Wheel ......... 3 Repair the Tire (pneumatic) ......4 Replace the Tire (pneumatic) ....... 5...
Page 140: Tire Inflation
Maintenance, Service, and Repair TIRE INFLATION 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 141: Replace The Tire/Wheel
Maintenance, Service, and Repair 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. NOTE: Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment.
Page 142: 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 143: Replace The Tire (Pneumatic)
Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly must be removed from Replace the Tire/Wheel the vehicle. Refer to section for information on removing the tire/wheel assembly. Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel.
Page 145: Battery Service
Battery Service TABLE OF CONTENTS Cleaning ............2 Testing ............3 Watering ............5 Charging ............6 Replacing (6-volt batteries only) ....7 Moist Charge Batteries ..........9 Storage and Returning to Service ....10 Storage ..............10 Returning to Service ..........11...
Page 146: Cleaning
Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with 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 where batteries are being charged.
Page 147: Testing
Maintenance, Service, and Repair TESTING NOTE: A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with 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.
Page 148 Maintenance, Service, and Repair Specific Gravity Test NOTE: The batteries must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see the illustration to the right).
Page 149: Watering
Maintenance, Service, and Repair WATERING NOTE: The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete.
Page 150: Charging
Maintenance, Service, and Repair 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 151: Replacing (6-Volt Batteries Only)
Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with 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.
Page 152 Maintenance, Service, and Repair 7. Remove the battery hold downs. 8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced. 9. Remove all battery jumpers from both posts of the battery or batteries being replaced. NOTE: It is recommended to replace the battery jumpers when replacing the batteries.
Page 153: Moist Charge Batteries
Maintenance, Service, and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with 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.
Page 154: Storage And Returning To Service
Maintenance, Service, and Repair 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the Cleaning the batteries or the ground. Refer to Batteries for information on cleaning the batteries. 8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.
Page 155: Returning To Service
Maintenance, Service, and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with 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.
Page 157: Control System Troubleshooting
Sevcon Control System Troubleshooting Includes Power Pak and Micro Pak controllers TABLE OF CONTENTS Test Equipment Required: ...... 2 Definitions: ..........2 Terminology used: ........2 Important Notes and Instructions ... 2 Identifying Your Controller ..... 3 Start Troubleshooting Here ....4 Test 8.
Page 158: Test Equipment Required
• Digital multimeter (DMM) with diode test • This troubleshooting procedure is for the function, FLUKE 79 model shown. Sevcon Power Pak and Micro Pak motor • Throttle Module Analyzer, Taylor-Dunn part speed controllers as equipped in standard number 62-027-32 vehicles. Troubleshooting may not be valid for vehicles equipped with special order speed control options.
Page 159: Identifying Your Controller
Electrical Troubleshooting Identifying Your Controller Sevcon Troubleshooting Page 3...
Page 160: Start Troubleshooting Here
Electrical Troubleshooting START TROUBLESHOOTING HERE If your vehicles is equipped with an electric motor brake, the motor brake system must be checked to be sure it is working properly before continuing with this troubleshooting. Operating the speed control when the motor brake has not disengaged may result in damage to Test 9: Electric Motor the motor or speed control system.
Page 161 Electrical Troubleshooting Test 1. CHECKING THE CONTROL LOGIC TEST 1.3: INPUTS Test the voltage at pin #6 on the 12-pin logic card connector. Close the seat switch. Place the high/low switch in the HIGH position. If the voltage is low, then skip ahead to Test #1.4.
Page 162 Electrical Troubleshooting TEST 1.5: Test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to Test #1.6. If the voltage is low, then skip ahead to Test TEST 1.6: Test the voltage at pin #7 on the 12-pin logic card connector.
Page 163 Electrical Troubleshooting Test 2. TESTING THE MOTOR 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. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
Page 164 Electrical Troubleshooting TEST 2.3: Test the continuity from the motor A1 terminal 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 motor.
Page 165 Electrical Troubleshooting Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3.1: TEST 3.5 Close the seat switch, turn the key switch ON and Disconnect the batteries and remove wires from wait 1-second until the Isolator contactor closes. the B-, F1, and F2 terminals on the controller. If the vehicle runs in reverse only then skip Using the diode test function on your meter, connect ahead to test #3.3.
Page 166 Electrical Troubleshooting Test 4. KEY FAULT TEST 4.1: TEST 4.3: Turn the key switch ON and place the forward and Test the voltage at the cold side (violet/black wire) reverse switch in the center OFF position of the key switch. If the voltage equals battery volts, then skip Perform the following tests: ahead to test #4.4.
Page 167 Electrical Troubleshooting Test 5. CONTACTOR COIL FAULT Disconnect the 12-pin logic card connector from the Sevcon power unit. Turn the key switch ON and perform the following tests: TEST 5.1: Check the voltage on the positive coil terminal of the ISO solenoid (violet wire).
Page 168 Electrical Troubleshooting Test 6. ACCELERATOR MODULE FAULT 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. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
Page 169 Electrical Troubleshooting Test 7. FORWARD AND REVERSE SWITCH FAULT Turn the key switch ON, place the forward and reverse switch in the center OFF position and perform the following tests: TEST 7.1: Referencing battery positive, test the voltage on the center terminal of the F&R switch (Black wire).
Page 170 Electrical Troubleshooting TEST 7.3: If the vehicle does not travel in forward, skip ahead to test #7.4. Place the forward and reverse switch in the REVERSE position. Referencing battery positive, test the voltage at the White/Black wire on the F&R switch. If the voltage equals battery volts, skip ahead to test #7.4.
Page 171: Test 8. Anti-Rolloff Fault
Electrical Troubleshooting Test 8. ANTI-ROLLOFF FAULT The Sevcon Controller is equipped with a feature called Anti-Rolloff. Anti-Rolloff will automatically slow the vehicle if it starts to roll. Anti-Rolloff is active when the key switch has been left in the “ON” position and the accelerator pedal is not depressed. Anti-Rolloff is deactivated when the key switch is in the “OFF”...
Page 172: Test 9. Electric Motor Brake
Electrical Troubleshooting Test 9. ELECTRIC MOTOR BRAKE Description: The electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what times the brake is applied or released is dependent on the controller programing and will vary depending on the model vehicle.
Page 173 Electrical Troubleshooting Connect a volt meter across the Violet/Black wire at the electric brake harness plug and Pin #9 at the logic card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts after about 0.5 seconds. If the test is good then: •...
Page 174: Logic Voltage Reference Table
Electrical Troubleshooting Logic Voltage Reference Table Pin# Condition Volts* Key switch off 0.0 volts Key switch on Battery volts F&R in forward F&R in neutral High F&R in reverse F&R in reverse F&R in neutral High F&R in forward Accelerator pedal up High Accelerator pedal down Seat switch closed (depressed)
Page 175: Status Led Code Table
Electrical Troubleshooting Status LED Code Table The status LED on the Sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component.
Page 176: Smart View Fault Codes
Electrical Troubleshooting Smart View Fault Codes Level 5 Faults (F05xxx) Level 4 Faults (F04xxx) F05000 “Contactor Over Current” F04001: “Contactor Welded” High voltage at power up to the controller B+ terminal. This faut occurs when too much current is going into Check wiring, contactor, and pre-charge resistor on the the line contactor coil circuit.
Page 177 Electrical Troubleshooting Level 2 Faults (F02xxx) Level 1 Faults (F01xxx) F02000: “Accelerator” Most Level 1 faults are a result of operator error or Wiring to throttle module is open or faulty throttle operation of the vehicle. module. F01000: “Power Steer Overheat” F02001: “Accelerator (power up)”...
Page 179: Turn The Key Switch Off Before Disconnecting The Batteries
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 180: Charger 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 181 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 182 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 183 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 184 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 185 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 186 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 187 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 188 Electrical Troubleshooting 4. Disconnect the wires from the contact terminals on the timer relay. 5. 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 189 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 190 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 191 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 192 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 193 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 194 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 195 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 196: 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 197 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 198 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 199 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 200 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 201: Wire Diagram
Wire Diagrams TABLE OF CONTENTS Complete Vehicle ..........2 Dash ..............3 Control Panel ........... 4 Accelerator Module Detail ......5 Lighting ............6 Trailer Brake Module and Receptacle ... 7 Hydrualic Dump Option ......... 8...
Page 202: Complete Vehicle
Wire Diagrams COMPLETE VEHICLE Brown White White White Green/Black Green/Black Brown White Green/Black Black Black Blue/White Violet/Black White Blue White HORN Black/White Violet/Black Wire Diagrams Page 2...
Page 203: Dash
Wire Diagrams DASH DASH PANEL HORN BUTTON Blue/White LIGHT SWITCH Brown Brown SWITCH Special order accesories may be wired to this terminal SWITCH Harness Connector Violet/ Black HOUR METER View from pin side BATTERY STATUS F&R Switch SWITCH Gray/White Gray/White White/Black Push for Forward...
Page 204: Control Panel
Wire Diagrams CONTROL PANEL BATTERY POSITIVE Black BATTERY NEGATIVE Blue 12V NEGATIVE TAP Black Yellow Green MOTOR White Blue White White White CONTROL Violet/Black White PANEL Blue/White Violet/Black Blue/Black Blue/Black White/Black Gray/Black White/Black Green/Black Gray/Black Yellow Green/Black Blue Yellow Red/White Blue Red/White BLACK...
Page 205: Accelerator Module Detail
Wire Diagrams ACCELERATOR MODULE DETAIL B- Out B- In B- In PC Board B+ In 0-5V Out ACCELERATOR Wire Diagrams Page 5...
Page 206: Lighting
Wire Diagrams LIGHTING Brown White White White Brown White White Wire Diagrams Page 6...
Page 207: Trailer Brake Module And Receptacle
Wire Diagrams TRAILER BRAKE MODULE AND RECEPTACLE RED (speaker) BLACK (speaker) GREEN [R.TURN] YELLOW [L.TURN] BROWN [TAIL] BLUE [ELECTRIC BRAKE] WHITE Wire Diagrams Page 7...
Page 208 Wire Diagrams HYDRAULIC DUMP OPTION CIRCUIT BREAKER SEE NOTE Yellow Yellow BATTERY POSITIVE TAP - 12V BATTERY NEGATIVE TAP - 12V Black LOWER RAISE SWITCH SWITCH White HYDRAULIC PUMP ASSEMBLY Green Hydraulic pump assembly must be insulated from the Black frame of the vehicle Circuit Breaker Note: Serial number up to 175999 used two breakers...
Page 209: Illustrated Parts
Illustrated Parts TABLE OF CONTENTS Front Axle ............ 2 Wheels and Tires ........36 Steering Knuckle ......... 4 Instrument Panel Up To S/N 179669 .... 38 Front Brakes ..........6 Instrument Panel Starting S/N 179670 ..38 Steering Linkage ......... 8 Resetting the Smart View Display ......
Page 210 Illustrated Parts Front Axle Parts Page 2 * - Part number not available at time of printing...
Page 211: Front Axle
Illustrated Parts Front Axle ITEM # PART # DESCRIPTION 15-049-71 Axle Beam, B 2-48, BT 2-48, B 2-54 15-049-77 Axle beam, BT 2-80 See following pages for component breakdowns Parts Page 3 * - Part number not available at time of printing...
Page 212 Illustrated Parts Steering Knuckle Parts Page 4 * - Part number not available at time of printing...
Page 213: Steering Knuckle
Illustrated Parts Steering Knuckle ITEM # PART # DESCRIPTION 88-239-86 3/4-NF Hex Slotted Nut 88-228-60 3/4 Cut Flat Washer 98-603-07 Rubber Bushing 01-220-99 Washer 32-240-44 Bushing 32-240-43 Bushing 80-309-12 Thrust Bearing 45-338-00 Grease Seal 80-017-00 Tapered Bearing 80-103-00 Tapered Bearing Race 12-158-10 Wheel Hub W/Rotor (incl 1-#12, 1-#11, 1-#13) 12-124-00...
Page 214: Front Brakes
Illustrated Parts Front Brakes Parts Page 6 * - Part number not available at time of printing...
Page 215: Front Brake
Illustrated Parts Front Brake ITEM # PART # DESCRIPTION 88-067-29 1/4 Hex bolt, grade 8 41-350-91 Plate, Secondary, Hydraulic Disc See kit below Pad, Disc Brake, outer See kit below Pad, Disc Brake, inner 41-348-58 Spacer, Disc Brake (included in rebuild kit) 32-208-01 Bushing (included in rebuild kit) 99-588-00...
Page 216 Illustrated Parts Steering Linkage Parts Page 8 * - Part number not available at time of printing...
Page 217: Steering Linkage
Illustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 18-041-05 Tie rod, B 2-48, B 2-54, BT 2-48 18-057-00 Tie rod, BT 2-80 86-510-00 Ball joing clamp 86-501-98 Ball joing (left) 86-501-99 Ball joint (right) 88-527-11 1/8 x 1 Cotter pin 18-057-11 Drag link 88-159-85...
Page 218: Steering Column
Illustrated Parts Steering Column The steering column is an integral part of the frame and is not shown. Part ID# 5 is located in the top of the steering column tube. Ref., Steering Gear Parts Page 10 * - Part number not available at time of printing...
Page 219 Illustrated Parts Steering Column ITEM # PART # DESCRIPTION 88-199-82 5/8NF Hex nut 19-011-20 Steering wheel 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 88-089-84 5/16NF Hex lock nut, grade C 32-248-10 Upper bushing 20-031-65 Steering shaft assembly (incl. 3 and 4) 19-011-25 Steering wheel cap 88-128-62...
Page 220 Illustrated Parts Steering Gear Exploded Steering Gear.dwg Parts Page 12 * - Part number not available at time of printing...
Page 221: Steering Gear
Illustrated Parts Steering Gear 18-308-21 ITEM # PART # DESCRIPTION 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assenbly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft 18-308-81 Lock washer 18-308-79 Seal, input shaft 18-308-82...
Page 222: Front Suspension
Illustrated Parts Front Suspension Front axle (ref) Parts Page 14 * - Part number not available at time of printing...
Page 223 Illustrated Parts Front Suspension ITEM # PART # DESCRIPTION 96-121-00 U-bolt 85-498-00 Leaf spring, B 2-48, BT 2-48, BT 2--80 85-486-00 Leaf spring, B 2-54 32-214-50 Bushing 96-240-00 1/2NC x 4 Hex bolt 88-149-81 1/2NC Lock nut 88-149-81 1/2NC Lock nut 16-872-00 Spring hanger Parts...
Page 224: Transmission Gear Case
Illustrated Parts Transmission Gear Case Parts Page 16 * - Part number not available at time of printing...
Page 225 Illustrated Parts Transmission Gear Case ITEM # PART # DESCRIPTION GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1 GT-3287543 Input shaft, 12:1 0 or 1...
Page 226: Rear Axle
Illustrated Parts Rear Axle Outer Bearing Inner Bearing (no o-ring) Axle Shaft O-Ring O-Ring Groove Inner bearing on optional double bearing axle does not have an oil seal or o-ring. Orientation of bearing should have o-ring groove adjacent to o-ring on outer bearing.
Page 227 Illustrated Parts Rear Axle ITEM # PART # DESCRIPTION 41-154-10 Axle shaft, BT 2-80 41-154-20 Axle shaft, B 2-48, BT 2-48, B 2-54 (single bearing) 41-154-25* *Axle shaft, B 2-54 80-505-20 Bearing 80-505-30* *Bearing 41-490-11 Disc brake rotor 41-172-21 88-268-63 Flat washer 88-268-30 7/8-14 x 1.5 Bolt, grade 5...
Page 228 Illustrated Parts Rear Brakes Parts Page 20 * - Part number not available at time of printing...
Page 229: Rear Brakes
Illustrated Parts Rear Brakes ITEM # PART # DESCRIPTION 1/4 x 3-3/4 Hex bolt, grade 8 88-069-82 1/4NC locknut, grade C (included in rebuild kit) 41-350-91 Secondary plate See kit below Brake pad, Inner See kit below Brake pad, Outer 41-348-58 Spacer (included in rebuild kit) 32-208-01...
Page 230 Illustrated Parts Brake linkage Parts Page 22 * - Part number not available at time of printing...
Page 231: Brake Linkage
Illustrated Parts BRAKE LINKAGE ITEM # PART # DESCRIPTION 88-080-11 Bolt, 5/16 x 1", Hex Head 51-344-80 Park Brake Handle 88-088-61 Washer, 5/16" 88-089-81 Locknut, 5/16" 96-813-00 Adjusting Brake Cable Assembly, B 2-48, BT 2-48, B 2-54 96-820-20 Adjusting Brake Cable Assembly, BT 2-80 96-771-00 Clevis Pin, 3/8 x 3/4"...
Page 232: Rear Suspension
Illustrated Parts Rear Suspension View from rear Parts Page 24 * - Part number not available at time of printing...
Page 233 Illustrated Parts Rear Suspension ITEM # PART # DESCRIPTION 96-240-00 1/2NC x 4 Spring bolt (front of the leaf spring) Not shown 32-214-50 Spring bushing (front of the leaf spring) 85-510-17 Leaf spring 16-861-44 Spring mounting plate (left) 16-861-45 Spring mounting plate (right) 96-114-00 U-bolt 88-159-84...
Page 234: Motor
Illustrated Parts Motor Parts Page 26 * - Part number not available at time of printing...
Page 235 Illustrated Parts Parts Page 27 * - Part number not available at time of printing...
Page 236: Electric Brake And Rear Motor Mount
Illustrated Parts Electric Brake and Rear Motor Mount Parts Page 28 * - Part number not available at time of printing...
Page 237 Illustrated Parts ELECTRIC BRAKE AND REAR MOTOR MOUNT ITEM # PART # DESCRIPTION 88-067-22 Bolt,1/4 X 2" NC, Grade (no brake option) 88-067-29 Bolt,1/4 X 4-1/4" NC, Grade 8 (brake option only) 41-355-00 Automatic Electric Brake Unit See Motor Motor (Typical) 96-114-10 U-Bolt, 5/16"...
Page 238: Master Cylinder
Illustrated Parts Master Cylinder Dual Reservoir Single Reservoir Parts Page 30 * - Part number not available at time of printing...
Page 239 Illustrated Parts Dual Reservoir Master Cylinder ITEM # PART # DESCRIPTION 88-080-14 Bolt, 5/16" X 1-1/2" NC, Hex Head See Usage Table Master Cylinder (includes item #3) 99-511-52 Cap Seal, Master Cylinder 99-511-53 Cap, Master Cylinder 88-088-61 Washer, 5/16" 88-089-81 Locknut, 5/16"...
Page 240: Brake Lines With Dual Master Cylinder
Illustrated Parts Brake Lines with dual master cylinder Parts Page 32 * - Part number not available at time of printing...
Page 241 Illustrated Parts Brake Lines with Dual Reservoir Master Cylinder ITEM# PART # DESCRIPTION 99-609-61 Brake Line, Front 99-607-59 Brake Line, Rear 99-606-51 Brake Line, Front Right 99-607-62 Brake Line, Rear, B 2-48, B 2-54, BT 2-48 99-608-58 Brake Line, Rear, BT 2-80 99-603-68 Brake Line, Rear Right, B 2-48, B 2-54, BT 2-48 99-608-56...
Page 242: With Single Master Cylinder
Illustrated Parts Brake Lines with single master cylinder Parts Page 34 * - Part number not available at time of printing...
Page 243 Illustrated Parts Brake Lines with Single Reservoir Master Cylinder ITEM# PART # DESCRIPTION 71-110-00 Brake Light Switch (optional) 99-591-00 Brake light switch adaptor (optional) 99-576-00 Hose Clip 99-608-58 Brake Line, Rear, BT 2-80 99-607-62 Brake Line, Rear, B 2-48, B 2-54, BT 2-48 99-604-56 Brake Line, Rear Right, BT 2-80 99-603-68...
Page 244: Wheels And Tires
Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) Parts Page 36 * - Part number not available at time of printing...
Page 245 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-020-00 8.5 x 8 Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-081-00 5.70 x 8 LR B Pneumatic 10-082-00...
Page 246: Instrument Panel Up To S/N 179669
Instrument Panel Starting S/N 179670 Resetting the Smart View Display The meter should only be reset after the preventative maintenance has been performed. Taylor-Dunn ® part number 62-027-40 Hand set (available with instructions as part number 62-027-61) must be used to reset the meter.
Page 247 To reprogram the Sevcon speed control, the speed control must be returned to the factory. Contact your local ® Taylor-Dunn distributor for more information. The Smart View Display will only work with the Sevcon control system.
Page 248: Speed Control Panel
Illustrated Parts Speed Control Panel Use 94-422-21 between item #1 and item #14 Refer to the serial number data plate on the controller base to determine which controller (400A or 500A) is on your vehicle. 632S45617 = 400 Amp controller 632S15622 = 500 Amp controller ** - Early models were equipped with the above solenoid.
Page 249 Depending on the model and serial number of the vehicle, item #4 will be a circuit breaker or a fuse. Model # Serial # range Description Part # B0-248-36 146189 to current production Circuit Breaker 79-844-20 B0-248-48 146189 to 173490, and 173625, 173671...
Page 250: Miscellaneous Electrical
Illustrated Parts Miscellaneous Electrical Accelerator Module Seat Frame Motion Alarms Seat Interlock Switch Miscellaneous Wire Harness Clamps Parts Page 42 * - Part number not available at time of printing...
Page 251 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION 75-152-80 Chassie Control Harness, BT 2-80 75-152-03 Chassie Control Harness, BT 2-48, B 2-48, B 2-54 75-152-13 Control panel harness 75-152-81 Power Harness, BT 2-80 75-152-11 Power Harness, BT 2-48, B 2-54 75-152-02 Power Harness, B 2-48 Not Shown...
Page 252: Lighting
Illustrated Parts Lighting Stobe Light Parts Page 44 * - Part number not available at time of printing...
Page 253 Red lens Not shown 72-023-21 Replacement bulb ** -There are many special order types of mounting pole configurations. Contact your Taylor-Dunn distributor with the serial number of the vehcle for more information. Head and Tail Lights ITEM # PART #...
Page 254: Lestronic® Charger
Illustrated Parts Lestronic® Charger (page 1) Parts Page 46 * - Part number not available at time of printing...
Page 255 Illustrated Parts Parts Page 47 * - Part number not available at time of printing...
Page 256 Illustrated Parts Lestronic® Charger (page 2) Parts Page 48 * - Part number not available at time of printing...
Page 257 Illustrated Parts Parts Page 49 * - Part number not available at time of printing...
Page 258: Signet® Charger
Illustrated Parts Signet® Charger NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector Parts Page 50 * - Part number not available at time of printing...
Page 259 Illustrated Parts Signet® Charger ITEM # PART # DESCRIPTION 79-303-40 Charger assembly (see note on facing page) 79-575-60 Replacement cover w/AC cord and gasket Note: There are no user serviceable components inside the charger AC wire connections on PC board Parts Page 51 * - Part number not available at time of printing...
Page 260: Batteries
Illustrated Parts Batteries Depending on the configuration of your Main Positive vehicle, the batteries may be wired as shown in these two illustrations. Main Negative 12 Volt Negative tap Main Negative Main Positive 12 Volt Negative tap Parts Page 52 * - Part number not available at time of printing...
Page 261 Illustrated Parts Batteries ITEM # PART # DESCRIPTION Batteru jumper 77-042-00 217AH, T-105 77-042-50 217AH, TD-217 77-042-80 217AH, T-105 Moist charge (dry) 77-044-00 230AH, T-125 77-044-10 195AH, Mainenance free (Note: requires special charger) 77-047-00 244AH, T-145 77-047-50 250AH, TD-250 77-047-80 244AH, T-145 Moist charge (dry) 77-048-00 250AH, J-250...
Page 262: Seat Cushions And Deck, B 2-48 And
Illustrated Parts Seat Cushions and Deck, B 2-48 and B 2-54 Parts Page 54 * - Part number not available at time of printing...
Page 263 Illustrated Parts B 2-48 and B 2-54 Seats and Deck ITEM # PART # DESCRIPTION 90-148-00 Passenger seat cushion (standard) 90-172-00 Passenger seat cushion (with steel cab) 90-140-00 Seat back (standard) 90-179-00 Seat back (with steel cab) 90-148-00 Driver seat cushion (standard) 90-172-00 Driver seat cushion (with steel cab) 90-444-00...
Page 264: Seat Cushions Bt 2-48
Illustrated Parts Seat Cushions BT 2-48 Seat Cushions BT 2-80 Parts Page 56 * - Part number not available at time of printing...
Page 265 Illustrated Parts BT 2-48 Seats (black) ITEM # PART # DESCRIPTION 90-195-00 Rear seat back 02-203-14 Seat back mounting plate 88-837-11 #14 x 1 Sheet metal screw 90-194-00 Rear seat cushion 90-140-00 Front seat back 90-148-00 Front seat cushion BT 2-80 Seat Cushions (black) ITEM # PART # DESCRIPTION...
Page 266: Decals
Illustrated Parts Decals Between seats BT 2-80 under 2nd seat B 2-48 and B 2-54 BT 2-80 electronics compartment Parts Page 58 * - Part number not available at time of printing...
Page 267 Illustrated Parts Decals ITEM # PART # DESCRIPTION 94-319-00 Battery disconnect 1 or 2 94-313-00 Battery warning 1 or 2 94-373-10 Vehicle identification 94-309-00 Brake warning 94-313-20 Safety warning 94-384-01 Not a motor vehicle 94-384-14 When leaving vehicle warning 94-301-41 Brake fluid 94-384-17 Do not wash...
Page 268: Cab Options
Illustrated Parts Cab Options Steel Cab Fiberglass cab Parts Page 60 * - Part number not available at time of printing...
Page 269 Illustrated Parts Steel Cab ITEM # PART # DESCRIPTION 91-012-00 Steel cab (unpainted) 90-852-30 Front windshield 90-850-10 Rear window 98-310-00 Rubber windshield gasket (by the foort) Fiberglass Cab ITEM # PART # DESCRIPTION 91-000-00 Fiberglass cab 90-800-00 Front windshield 90-850-00 Rear window 98-310-10 Rubber windshiel gasket (by the foot)
Page 270: Door Options, Steel Cab
Illustrated Parts Door Options, Steel Cab 29,12 11,12 Steel door detail Note: Left Door Shown Door frame Door frame Door Restraint Parts Page 62 * - Part number not available at time of printing...
Page 271 Illustrated Parts Cab Doors Naugahyde (Steel cab) ITEM # PART # DESCRIPTION 90-923-98 Door Frame, Left Not shown 90-923-99 Door Frame, Right 90-924-98 Side Curtain, Left Not shown 90-924-99 Side Curtain Right 97-315-53 Handle Assembly, Outer 97-315-51 Door Latch 97-315-54 Handle Assembly Inside 97-303-03 Snap Fastner...
Page 272: Door Options, Fiberglass Cab
Illustrated Parts Door Options, Fiberglass Cab Typical door assembly Parts Page 64 * - Part number not available at time of printing...
Page 273 Illustrated Parts Cab Doors Naugahyde (fiberglass cab) ITEM # PART # DESCRIPTION 90-921-98 Door Frame, Left 90-921-99 Door Frame, Right 98-451-11 Weather seal tape (by the foot) 90-908-98 Side Curtain, Left 90-908-99 Side Curtain Right 97-315-53 Handle Assembly, Outer 97-315-51 Door Latch 97-315-54 Handle Assembly Inside...
Page 274: Hydraulic Dump Body Option
Illustrated Parts Hydraulic Dump Body Option 22 (rubber cap) 22 (plastic housing) Parts Page 66 * - Part number not available at time of printing...
Page 275 Illustrated Parts Dump Bed Option Item No. Part No. Description 21-018-00 Cylinder Pin 88-060-11 Bolt, 1/4 X 1-1/4"" NC, Hex Head 88-069-81 Locknut, 1/4"" NC 21-019-00 Shaft, Dump Bed Pivot 17-112-00 Collar, Shaft 99-524-00 Hydraulic Cylinder 99-957-00 Hydraulic Pump and Motor 99-597-09 Bracket, Hydraulic Pump 88-100-11...
Page 276: Rear Cargo Box
Illustrated Parts Rear Cargo Box Parts Page 68 * - Part number not available at time of printing...
Page 277 Illustrated Parts Rear Cargo Box ITEM # PART # DESCRIPTION 91-333-02 Cargo box (unpainted) 90-471-00 Front deck board 90-472-00 Rear deeck board 90-850-10 Front window 98-310-00 Ruber window gasket (by the foor) 90-851-00 Rear window Not shown 94-320-10 Load line decal 00-210-23 Deck support angle Parts...
Page 278: Hitches
Illustrated Parts Hitches Parts Page 70 * - Part number not available at time of printing...
Page 279 Illustrated Parts Parts Page 71 * - Part number not available at time of printing...
Page 280 Illustrated Parts Parts Page 72 * - Part number not available at time of printing...
Page 281 APPENDIX A-Special Tools...
Page 282 Special Tools Special Tools DESCRIPTION PURPOSE PART NUMBER Used to install the pinion seal on all chain drive trucks with Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43-201-50 cover. Used to center the chain case on the pinion shaft on all chain Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41-532-50...
Page 283 Appendix B: Standard Hardware Suggested Torque Limits TABLE OF CONTENTS Hardware Identification ......... 2 Standard Head Markings ......... 2 Hex Bolts ..............2 Other Bolts ............... 2 Hex Nuts ..............3 Hex Lock Nuts (stover) ..........3 Other Nuts ..............3 Suggested Torque Values (non-critical hardware) ......
Page 284: Hardware Identification
Appendix B 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. Hex Bolts S.A.E.
Page 285: Hex Nuts
‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’. 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 Appendix B Page-3...
Page 286: Suggested Torque Values
Appendix B 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...
Page 287: Suggested Torque Values
Appendix B 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...
Page 288 Appendix B ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...
Page 289: Brake Lining Handling Precautions
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 290 Model B 1-00...
Page 292 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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B 2-48 B0-254-36 B0-248-48 B 2-54 Bt-248-36 Bt-248-48 ... Show all

Taylor-Dunn B0-248-36 Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn

Table of Contents

Front Axle Service

Steering Component Service

Brake Service

Motor Service

Transmission

Suspension

Tires and Wheels

Battery Service

Sevcon Control System Troubleshooting

Electrical Troubleshooting

Wire Diagrams

Illustrated Parts

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Taylor-Dunn B0-248-36