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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
Revision: B
Models Inlcuded:
ET-015-00 72, Volt Direct Drive
ET-015-72 72, Volt Direct Drive
ET-015-74 72, Volt Chain Drive
ET-015-48, 48 Volt Chain Drive
MANUAL MZ-150-05
Operation, Troubleshooting and
Replacement Parts Manual
Serial Number Coverage:
Model
Starting - Ending
ET-015-00
103847 - 108472
ET-015-72
109240 - 134256
ET-015-74
118001 - Current Production
ET-015-48
108591 - Current Production
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Troubleshooting
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Related Manuals for Taylor-Dunn ET-015-00
Summary of Contents for Taylor-Dunn ET-015-00
- Page 1 Models Inlcuded: ET-015-00 72, Volt Direct Drive ET-015-72 72, Volt Direct Drive ET-015-74 72, Volt Chain Drive ET-015-48, 48 Volt Chain Drive T h e B e s t W a y T o G o A b o u t Y o u r...
- Page 3 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 4 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...
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Page 5: Table Of Contents
Table of Contents Contents Introduction General Maintenance About this manual ........2 Maintenance Guidelines ......2 Who Should Read This Manual ....2 Troubleshooting Guide ......3 Responsibilities ........2 Lubrication Chart ........4 How To Use This Manual ......3 Front Axle Service Conventions ............ - Page 6 Table of Contents Brake Service Electrical Troubleshooting Inspect the Service Brake ......2 Symptoms: ..........2 READ THIS FIRST ........3 Front Disc Brake Pads ........... 2 Disc Brake Rotor ............ 2 Test Equipment Required: ........3 Brake Shoes ............3 IMPORTANT NOTES and INSTRUCTIONS ..
- Page 7 Table of Contents Appendixes 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) ...........
- Page 8 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 9 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 Shown with optional stake sides...
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Page 10: Introduction
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 responsible for the overall maintenance and repairs burden and personnel carriers since 1949, wants to of the vehicle, as well as the training of operators. -
Page 11: 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 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. -
Page 13: 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. - Page 15 TABLE OF CONTENTS Standard Specifications* ....2 Safety Rules and Guidelines ..... 3 Driver Training Program ....3 Driver Qualifications..........3 Vehicle Controls ........ 4 1) Light Switch ............. 4 2) Windshield Wiper Switch......... 4 3) Hour Meter............4 4) Battery Status Gauge ........
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Page 16: Safety Rules And Operating Instructions
Maximum Load 682 kg (1,500 lbs) Deck dimensions 157.5 W x 223.5 L Centimeters (62 W x 88 L Inches) Electrical System ET-015-00 72 Volt Twelve 220 Ah, 6 Volt, Lead Acid Batteries,Solid State Speed Control ET-015-48 48 Volt Eight 220 Ah, 6 Volt, Lead Acid Batteries,Solid State Speed Control... -
Page 17: 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 18: Vehicle Controls
SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1) Light Switch 6) Hazard Lights. The headlight switch is located on the left dash panel. The hazard light switch is located on the left side of the Push the top of the switch to turn the lights on. Push the steering column. -
Page 19: Odometer / Trip Odometer
SAFETY RULES AND OPERATING INSTRUCTIONS Shift Lever The forward and reverse shift lever is located between the seats. Push the shift lever forward to engage the forward direction. Pull the lever back to engage the reverse direction. DO NOT SWITCH from forward to reverse or vice-versa while the vehicle is in motion. -
Page 20: Steering
SAFETY RULES AND OPERATING INSTRUCTIONS 1) 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 21: Vehicle Operational Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS While driving: VEHICLE OPERATIONAL • Slow down and sound the horn to warn pedestrians GUIDELINES or when approaching a corner or other intersection. • No reckless driving. Safety Guidelines • Do not drive this vehicle on steep inclines or where prohibited. -
Page 22: 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 23: Fuse Panel
SAFETY RULES AND OPERATING INSTRUCTIONS FUSE PANEL The fuse panel is located under the dash to the left of the steering column. Fuse Panel Standard fuses shown. Other fuses may be installed depending on options installed on vehicle. 20A headlights 15A Wiper and Horn Safety Rules Page 9... -
Page 24: 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 25: 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 26: Periodic Maintenance Checklist
SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Safety Rules NOTE: A full page copy of the Periodic Maintenance Checklist is on the Page 12 Vehicle Documentation CD under the [Misc] sub folder. -
Page 27: 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 29 Table of Contents Maintenance Guidelines ....... 2 Troubleshooting Guide ........ 3 Lubrication Chart .......... 4 Model C 4-25 Tow Tractor Model E 4-55 Tow Tractor...
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Page 30: Maintenance Guidelines
• 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 31: 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 32: Lubrication Chart
Maintenance, Service and Repair Lubrication Chart Front Axle Rear Axle Note: Drive shaft only on model ET-150-00 Description Locations Lubricant Type Steering Pivot General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease Ball Joints General Purpose Grease Leaf Springs General Purpose Grease Drive Shaft universal Joint General Purpose Grease (see note) -
Page 33: Inspect The Front Wheel Bearings And King Pin
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 ............4... -
Page 34: Inspect The Front Wheel Bearings And King Pin
Maintenance, Service, and Repair Replace Front Wheel NOTE: Refer to the INSPECT THE FRONT WHEEL Bearings section for information regarding BEARINGS AND KING PIN the replacement of the wheel bearings. 9. Lower the vehicle. 10. Reconnect the main positive and negative cables at the batteries. -
Page 35: 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. Confirm the electric park brake is set. 4. -
Page 36: Front Axle Removal And Installation
Maintenance, Service, and Repair Installation FRONT AXLE REMOVAL AND INSTALLATION 1. Make sure the key-switch is in the “OFF” position, then remove the key. Removal 2. Place the forward-reverse switch in the center “OFF” position. 3. Confirm the electric park brake is set. 1. - Page 37 TABLE OF CONTENTS Front End Alignment ......2 Inspect Ball Joints ......5 Adjust the Steering Gear ....6 Replace the Ball Joints, Tie Rods, and Drag Link ........ 7 Replacing the Drag Link ........8 Replacing the Tie Rod .......... 9 Center the Steering Gear ....
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Page 38: 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 39 Maintenance, Service, and Repair 12. Adjust the drag link so that it can be easily inserted into the pitman arm. 13. Tighten the ball joint or rod end nut as specified below: Ball joint - 40-45 ft-lbs. Rod end - 20-25 ft-lbs. 14.
- Page 40 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front wheels. Refer to the Center the Steering section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2.
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Page 41: 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. -
Page 42: Adjust The Steering Gear
Maintenance, Service, and Repair ADJUST THE STEERING GEAR NOTE: In some vehicle configurations it may be necessary to remove the steering gear to Replace perform this procedure. Refer to the 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 43: 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 cannot be greased and has a straight shaft. -
Page 44: Replacing The Drag Link
Maintenance, Service, and Repair Replacing a Ball Joint 11. Install the new ball joint into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the ball joint clamp at this time. 1. -
Page 45: Replacing The Tie Rod
Maintenance, Service, and Repair 9. Install in reverse order. 11. Lower the vehicle. 10. Realign the front wheels. 12. Reconnect the main positive and negative cables at the batteries. Steering NOTE: Refer to the section for information 13. Remove the blocks from behind the wheels. regarding realignment of the front wheels. -
Page 46: 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 47 Maintenance, Service, and Repair Reassembly 1. Lightly lubricate all parts before reassembly. 2. Install a new worm shaft seal and pitman shaft seal into the housing. 3. Install the upper worm bearing cup. 4. Divide the ball bearing into two equal groups. 5.
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Page 48: Exploded View Of Steering Gear
Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 12... - Page 49 Differential Assembly (3rd Member) .. 8 Disassemble ............8 Assemble ............... 9 Re-shimming the Pinion Housing ..11 Exploded View ........12 NOTE: The model ET-015-00 and ET-015-72 has a direct drive input to the rear axle. There is no drive chain primary reduction.
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Page 50: 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 prevent the vehicle from moving in forward drive motor mounting bolts are loosened. or reverse. -
Page 51: Check The Oil Level
Typical location of oil plugs. The actual location of the level plug will vary depending on your vehicles configuration. The model ET-015-00 and ET-015-72 does not have a chain case. An additional fill plug is located on top of the drive housing. NOTE: This illustration shows a pinion parking brake, the ET-150 is not equipped with this brake. -
Page 52: Drive Motor, Chain Drive
Maintenance, Service, and Repair Install DRIVE MOTOR, CHAIN DRIVE Remove Do not allow the wheels to rotate after the NOTE: In most cases it is not necessary to motor has been removed. Allowing the disassemble the chain case to remove the wheels to rotate may result in the drive motor. -
Page 53: 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 54: 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 55 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 8. Install the chain case housing onto the pinion shaft 10.
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Page 56: 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 57: 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 58 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"...
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Page 59: 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 60: Exploded View
Maintenance, Service, and Repair EXPLODED VIEW F2/F3 Transmission Page 12... - Page 61 TABLE OF CONTENTS Inspect the Service Brake ....2 Front Disc Brake Pads .......... 2 Disc Brake Rotor ..........2 Brake Shoes ............3 Brake Drum ............3 Inspect the Parking brake ....4 Adjust the Service Brakes ....4 Adjust the Parking Brake ....
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Page 62: Inspect The Service Brake
Front Disc Brake Pads Disc Brake Rotor Rotor Service Limit = The minimum rotor thickness will be stamped in the rotor. See example below. Current Taylor-Dunn brakes are asbestos ® NOTE: The front brake rotor is an integral part of the free. -
Page 63: Brake Shoes
Brake Drum Drum Service Limit = The minimum drum inner diameter will be stamped in the drum. See example below. Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that NOTE: The wheel must be removed to accurately the original brakes were replaced with measure the brake drum. -
Page 64: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING ADJUST THE SERVICE BRAKE BRAKES The brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • Brake fluid level low in the master cylinder. See 1. -
Page 65: Adjust The Parking Brake
Maintenance, Service, and Repair ADJUST THE PARKING BRAKE There are two adjustments for the park brake system: 1. Primary. 2. Secondary. This adjustment should only be performed when the primary adjustment is beyond its limits or any rear brake components have been replaced. Primary Adjustment Secondary Adjustment 1. -
Page 66: 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 67: 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 68 Maintenance, Service, and Repair 13. Slowly release the foot pedal, allowing it to return to its released position. NOTE: Check and fill the master cylinder frequently during the bleeding process. Do not allow the fluid level in the master cylinder to drop low enough to allow air to enter the brake lines. If air enters the brake lines during the bleeding process, then you will have to start again from the beginning.
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Page 69: 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 70: Replace Rear Brake Shoes
Maintenance, Service, and Repair REPLACE REAR BRAKE SHOES 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 71 Maintenance, Service, and Repair Rear Brake (left side shown) Brakes Page 11...
- Page 73 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motor Inspection ........ 2 Motor Removal and Installation ..4 Replacing the Brushes....... 5 Replacing the Bearings ..... 6 Repairing the Commutator ....6 Service Limits ........7 Typical Exploded Motor...
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Page 74: Motor Service
Motor Service INSPECTING THE MOTOR BRUSHES Typical brush and brush holder Typical motor with cooling fan indicated by the arrow NOTE: There are four brushes in the motor. The MOTOR INSPECTION brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time. - Page 75 Motor Service Inspection 5. Inspect the commutator for burn marks. • Burn marks and/or raised commutator segments 1. Measure the length of each motor brush. 90 or 180 degrees apart is evidence of a shorted • If any one brush is less than or equal to the armature.
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Page 76: Motor Removal And Installation
Motor Service 10. Using the continuity function of digital multi meter, check the continuity from any one of the MOTOR REMOVAL AND commutator segments and the armature frame. If INSTALLATION it is not an open circuit, then the armature is shorted and the motor must be replaced. -
Page 77: Replacing The Brushes
Motor Service Brush Spring Orientation REPLACING THE BRUSHES NOTE: It is recommended that all four brushes be replaced as a set. NOTE: Motors without removable brush covers must be disassembled to replace the brushes. Refer to Motor Inspection- Disassembly section for information on taking the motor apart. NOTE: Some motors are equipped with brush pairs. -
Page 78: 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 79: 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 81 TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Charging ........... 4 Watering ........... 5 Single Point Battery Watering System ....5 Replacing (6-volt batteries only) ..6 Moist Charge Batteries ......... 7 Storage and Returning to Service ..8 Storage ..............
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Page 82: 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 83: 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 84: 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 85: 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 86: 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 87: Moist Charge Batteries
Maintenance, Service, and Repair 15. Install the batteries in reverse order. Refer to the Illustrated Parts List for battery cable routing. Battery electrolyte is poisonous and 16. It is recommended to replace the battery terminal dangerous. It contains sulfuric acid. Avoid hardware when replacing the batteries. -
Page 88: 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 89: 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 91 TABLE OF CONTENTS Throttle Linkage Adjustments .... 2 Magnetic Module ..........2 Pot Box module ............ 3...
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Page 92: Throttle Linkage Adjustments
Maintenance, Service, and Repair THROTTLE LINKAGE ADJUSTMENTS Magnetic Module The standard magnitic throttle module should not be used in areas that contain large magnetic fields. Large magnitic fields may effect the operation of the module resulting in unexpected movement of the vehicle. The throttle pedal is attached directly to the throttle module. -
Page 93: Pot Box Module
Maintenance, Service, and Repair Pot Box module The pot box module is used on vehicles that are to be operated in areas with large magnetic fields. The linkage to the pot box should be adjusted so that the FS-1 switch closes just as the pedal is depressed and the output is at 5K with the pedal fully depressed. - Page 95 TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Replace the Tire/Wheel ..... 3 Replace the Tire (pneumatic) ... 3 Repair the Tire (pneumatic) ....4 Replace the Tire (pneumatic) ... 5...
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Page 96: 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 97: Tires And Wheels
Maintenance, Service, and Repair REPLACE THE TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly 1. Make sure the key-switch is in the “OFF” must be removed from the vehicle. Refer to position, then remove the key. Replace the Tire/Wheel section for information on removing the tire/wheel... -
Page 98: 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 99: Replace The Tire (Pneumatic)
Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) Replace NOTE; To replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to the Tire/Wheel 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 101 Table of Contents SYMPTOMS: ........2 READ THIS FIRST ......3 Test Equipment Required: ............3 IMPORTANT NOTES and INSTRUCTIONS ...... 3 Definitions: ................4 Forward/Reverse Switch: ............6 Throttle Module: ..............7 Motor Windings ............... 8 Contactors ................9 Contactor Negative Return ............. 10 UNUSUAL SYMPTOM TROUBLESHOOTING GUIDE ..11 PLUGGING DIODE ..............
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Page 102: Electrical Troubleshooting
Maintenance, Service, and Repair SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Unusual Symptom Troubleshooting later in this section. • Runs slow in both directions plus high armature and field current in both directions. NOTE: Armature and field current should be equal. -
Page 103: 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 Accelerator Module Test Harness. Troubleshooting CANNOT be completed without these tools. If, during any test involving a test light where the light is... -
Page 104: Definitions
Maintenance, Service, and Repair START: Definitions: • “FS-1” = Start switch in the throttle module. • “Battery volts” = The voltage at the batteries at the time the test is performed. • “Pick up” = Energizing a solenoid or contactor. •... - Page 105 Maintenance, Service, and Repair 1. Make sure the start 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. The rear drive wheels may rotate during some of the following tests.
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Page 106: Forward/Reverse Switch
Maintenance, Service, and Repair Controller Small Signal Input: During this procedure, voltages will be measured at the controller terminals #1, #2, #6, and #7. Close the seat interlock switch, turn the key switch ON, select a direction and fully depress the throttle pedal. -
Page 107: Throttle Module
Maintenance, Service, and Repair Throttle Module: The throttle module is located under the floorboard and functions as a throttle position sensor. The throttle module has two output signals, one is a varying voltage relative to the pedal position and the other is a fixed voltage indicating that the pedal is depressed. -
Page 108: Motor Windings
Maintenance, Service, and Repair Motor Windings Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause severe bodily injury and/or property damage. The test equipment required to fully test a motor is very expensive. The test procedure provided here will be able to diagnose the most common motor failure modes. -
Page 109: Contactors
Maintenance, Service, and Repair Contactors Troubleshooting in the procedure assumes that the control These test procedures must be system is functioning (output from M- on controller) and performed in the order they were that the motor has tested good. written. If the test result is good, then proceed to the next test or go Both the forward and the reverse contactors pass current to the next section. -
Page 110: Contactor Negative Return
Maintenance, Service, and Repair Contactor Negative Return The forward and reverse contactors coils use a common negative return that is provided by the controller from Pin #3. The negative output from Pin #3 is part of a fault monitoring circuit in the controller. -
Page 111: Unusual Symptom Troubleshooting Guide
Maintenance, Service, and Repair UNUSUAL 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 vehicle is exhibiting has all listed symptoms. -
Page 112: Plugging Diode
Maintenance, Service, and Repair 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 113: Iso
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 115 The vehicle wiring diagram is too large to be legible when printed at this size. A full size diagram (22 x 16) is included on the CD in PDF format. You can access the diagram from a button on the CD menu. The diagram # is SCH-00022...
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Page 117: Illustrated Parts
Illustrated Parts TABLE OF CONTENTS Front Axle and Brake ........2 Steering Linkage ......... 4 Steering Gear ..........6 Steering Column ......... 6 Front Suspension ........8 Transmission Chain Case ......10 Transmission Differential Case ....12 Rear Axle ............ 14 Rear Brakes .......... -
Page 118: Front Axle And Brake
Illustrated Parts Front Axle and Brake 1 (Use red Loctite) Align flat spot 27 (King pin) with the set screw #25 27 (Cup washer) 27 (Felt washer) 27 (Bushing) 25 (Use red Loctite) 27 (Shims) 27 (Thrust Bearing) 27 (Bushing) Parts Page 2... - Page 119 Illustrated Parts Front Axle and Brake Item No. Part No. Description 15-150-15 Axle assembly, with brakes 88-130-20 Hex bolt 88-130-25 Hex bolt Steer arm 88-157-13 Bolt 41-349-22 Spindle kit, left and right, includes #27 Bolt 41-349-01 Brake bracket, left 41-349-02 Brake bracket, right 41-239-00 Brake assembly...
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Page 120: Steering Linkage
Illustrated Parts Steering Linkage Parts Page 4... - Page 121 Illustrated Parts Steering Linkage Item No. Part No. Description 88-159-85 Castle nut 86-501-98 Ball joint, left 18-045-00 Steering link, left 86-510-00 Ball joint clamp 86-501-99 Ball joint, right 18-045-00 Steering link, right 88-527-14 Cotter pin 21-009-15 Pivot bolt 18-104-31 Steering pivot 20-031-55 Steering shaft 18-308-21...
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Page 122: Steering Gear
Illustrated Parts Steering Gear Steering Column Parts Page 6... - Page 123 Illustrated Parts Steering Gear 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 Gasket...
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Page 124: Front Suspension
Illustrated Parts Front Suspension Parts Page 8... - Page 125 Illustrated Parts Front Suspension Item No. Part No. Description 88-189-81 Hex nut 88-188-61 Flat washer 86-000-00 Shock 88-189-81 Hex nut 88-180-18 Hex bolt 88-180-31 Hex bolt 00-243-11 Spring plate 88-109-81 Hex nut 96-248-01 Spring bolt 32-213-00 Bushing 88-169-82 Hex nut 85-512-50 Spring 16-870-10...
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Page 126: Transmission Chain Case
Illustrated Parts Transmission Chain Case Motor ET-015-48 and ET-015-74 only 3rd Member Seal with 94-430-03 RTV SILICON GSKT SLR, BLUE Parts Page 10... - Page 127 Illustrated Parts Transmission Chain Case ITEM# PART # DESCRIPTION 88-108-60 3/8" SAE Flat Washer 97-100-00 Woodruff Key 88-087-11 Chain Adjusting Screw 88-089-80 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...
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Page 128: Transmission Differential Case
Illustrated Parts Transmission Differential Case Seal with 94-430-03 RTV SILICON GSKT SLR, BLUE Parts Page 12... - Page 129 Illustrated Parts Transmission Differential Case ITEM# PART # DESCRIPTION 41-179-00 3rd member Housing (1.628 ID Carrier Bearing), ET-015-48, ET-015-74 41-710-00 3rd member Housing (1.784 ID Carrier Bearing), ET-015-48, ET-015-74 41-710-05 3rd member Housing, ET-150-72 88-119-80 3/8" NF Nut 41-712-00 Differential Assembly (1.628 ID Carrier Bearing) 41-713-00 Differential Assembly (1.784 ID Carrier Bearing) 80-127-00...
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Page 130: Rear Axle
Illustrated Parts Rear Axle Axle tube Rear Brakes Parts Page 14... - Page 131 Illustrated Parts Rear Axle Item No. Part No. Description 45-301-00 Seal 32-515-00 Bearing retainer Wheel stud 41-168-10 Axle, includes bearing 32-514-02 Retaining plate 80-503-00 Bearing Rear Brakes Item No. Part No. Description 41-312-88 Brake Assembly, left 41-312-89 Brake assembly, right 41-533-00 Brake drum Spring...
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Page 132: Rear Suspension
Illustrated Parts Rear Suspension Drive Shaft Parts Page 16... - Page 133 Illustrated Parts Rear Suspension Item No. Part No. Description 88-180-31 Hex bolt 86-000-00 Shock 88-188-61 Flat washer 88-109-80 Hex nut 98-753-05 Bump stop 96-122-00 U-bolt 88-169-82 Hex nut 16-871-02 Spring hanger 32-213-00 Bushing 96-248-01 Spring bolt 00-243-06 Spring plate 88-159-84 Hex nut 88-189-81 Hex nut...
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Page 134: Motor (Direct Drive)
Illustrated Parts Motor (direct drive) Motor Mount (direct drive) Parts Page 18... - Page 135 Illustrated Parts Motor, direct drive Item No. Part No. Description 70-175-00 Brush holder 70-127-00 Brush 85-402-00 Brush spring 70-208-00 Field coil 80-210-00 Rear bearing 70-072-10 Armature 80-211-00 Front bearing Motor Mount, direct drive Item No. Part No. Description 88-080-10 Bolt 88-088-32 Lock washer 02-155-03...
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Page 136: Motor (Chain Drive)
Illustrated Parts Motor (chain drive) 70-055-00 SPEC #- 5BT1326B262A 70-061-00 SPEC #- 5BT1326B96 7006100.DWG Parts Page 20... - Page 137 Illustrated Parts Motor, Chain Drive (spec 5BT1326B262A) Item No. Part No. Description 70-210-64 Terminal 85-402-02 Brush spring 70-175-02 Brush holder 70-123-00 Brush 70-209-20 Field coil 80-504-05 Bearing, rear 97-100-00 Woodruff key 80-206-00 Bearing, front 45-507-00 Seal Cross over Parts Page 21...
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Page 138: Brake Lines
Illustrated Parts Brake Lines To brake hose Rear Brakes To rear brakes Front Brakes Parts Page 22... - Page 139 Illustrated Parts Brake Lines Item No. Part No. Description 99-580-30 Brake hose 99-605-72 Brake line, formed 99-605-71 Brake line, formed 99-576-00 Clip, brake hose 99-600-55 Brake line, formed 99-573-00 Washer, gasket 99-580-31 Bolt, banjo 99-607-57 Brake line, formed 99-575-20 Adaptor 99-511-50 Master cylinder 88-109-81...
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Page 140: Brake Linkage (Parking Brake)
Illustrated Parts Brake linkage (parking brake) Spacer Included with #1 Parts Page 24... - Page 141 Illustrated Parts Brake Linkage (parking brake) Item No. Part No. Description 51-340-00 Brake handle 88-109-81 Hex nut 88-108-60 Washer 88-100-15 Hex bolt 88-527-14 Cotter pin 96-820-01 Brake cable 96-773-00 Clevis pin 00-243-03 Equilizer 96-826-14 Brake cable Parts Page 25...
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Page 142: Instrument Panel (Dash)
Illustrated Parts Instrument Panel (dash) Parts Page 26... - Page 143 Illustrated Parts Instrument Panel Item No. Part No. Description 94-303-10 Left dash assembly (complete) 94-303-12 Right dash assembly (complete) 71-038-10 Switch 71-038-10 Switch 74-000-72 Hour meter 74-009-48 Battery status gauge 71-141-20 Turn switch 74-020-00 Speedometer 71-121-10 Key switch 72-028-25 Power light Heater timer (optional) Heater switch (optional) Parts...
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Page 144: Speed Control Panel
Illustrated Parts Speed Control Panel Parts Page 28... - Page 145 Illustrated Parts Speed Control Panel Item No. Part No. Description 88-060-13 88-069-81 79-840-20 Circuit breaker, 20A 88-818-06 #8 X 1/2 PAN HD SCR TYPE B THD 79-840-00 Circuit breaker, 10A 88-818-06 #8 X 1/2 PAN HD SCR TYPE B THD 88-067-12 1/4NC X 1 HEX TAP SCREW 71-300-01...
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Page 146: F&R Switch Assembly
Illustrated Parts F&R Switch Assembly * - Concave side of belleville washer #6 faces #14 Parts Page 30... - Page 147 Illustrated Parts F&R Switch Assembly Item No. Part No. Description 95-907-00 Knob 88-119-80 88-109-81 Lock Nut 88-019-86 88-014-13 Screw 97-183-00 Washer, beleville 88-100-14 Bolt 88-108-61 Washer 32-207-00 Bushing 88-517-11 Cotter pin 96-773-10 Clevis pin 85-030-00 Spring 00-155-34 Lever 00-155-33 Shift cam 71-130-01 Switch 88-108-61...
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Page 148: Miscellaneous Electrical
Illustrated Parts Miscellaneous Electrical Item No. Part No. Description 73-005-10 Reverse alarm (optional), BULLARD MPA-II, 97DB 71-124-00 Switch, battery disconnect 78-010-30 Fuse panel 79-820-05 FUSE,ATO,15 AMP 79-820-06 FUSE,ATO,20 AMP 75-148-93 Harness, control 75-149-97 Harness, power 71-900-05 Flasher, turn signal 73-004-20 Horn 62-033-56 Throttle module assembly (includes #11) -
Page 149: Miscellaneous Frame And Body
Illustrated Parts Miscellaneous Frame and Body Item No. Part No. Description 13-770-00 Tire and wheel,P195/75R14 97-236-00 Wheel nut 91-408-00 Glove box 00-155-39 Box, charger cord 00-155-41 Cover, charger cord box 71-040-95 Lock, charger cord box 76-002-01 AC pluv PLUG,3 PRONG,30A,NEMA 6-30 79-575-20 AC cord, export 79-575-25... -
Page 150: Doors
Illustrated Parts Doors Included with window Inside part of Window Frame. Door striker on cab Parts Page 34... - Page 151 Illustrated Parts Doors Item No. Part No. Description 90-855-05 Plexiglass window 90-855-00 Window, right 90-855-10 Window, left 91-015-66 Door, right 91-015-81 Door, left 98-310-00 Window gasket (order by the foot) 97-318-70 Handle 97-318-71 Gasket 97-318-72 Gasket 89-060-13 M6 X 1.0 X 25 HEX HEAD SCREW 91-015-80 PUSH PLATE, DOOR LOCK 89-060-12...
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Page 152: Charger
Illustrated Parts Charger Parts Page 36... - Page 153 Illustrated Parts Charger Description 79-303-25 79-315-00 79-315-10 79-309-20 Spec # > 22620 16340 16780 16920 Timer assy 79-805-68 79-802-00 79-902-00 79-805-75 Capacitor 79-902-00 79-902-00 79-902-00 79-902-00 Fuse assy 79-831-00 79-831-00 79-831-00 79-831-00 Diode assy 79-749-13 79-749-13 79-749-13 79-749-13 Transformer 79-603-10 Mounting plate 01-155-57 01-155-57...
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Page 154: Batteries
Illustrated Parts Batteries 12v Tap Main Positive Main Negative 72 Volt battery configuraation Main Negative Main Positive 48 Volt battery 12v Tap configuraation Parts Page 38... - Page 155 Illustrated Parts Batteries Item No. Part No. Description 77-047-00 Battery, 244 Ah 77-042-00 Battery, T 217 Ah 50-243-10 Battery rod 50-250-00 Clamp, Bat Loc 75-237-00 Jumper, 9” 75-149-99 Harness for 48v, dual pack 03-155-10 Locator, rear battery pack, 48 volt 88-089-80 Nut, battery terminal 88-089-70...
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Page 156: Decals
Illustrated Parts Decals Parts Page 40... - Page 157 Illustrated Parts Decals Item No. Part No. Description 94-201-00 TAYLOR-DUNN EMBLEM 94-301-01 DECAL, "TAYLOR-DUNN",WHITE 94-301-02 DECAL, "ELECTRUCK" 2.262LH 94-313-00 DECAL, BATTERY WARNING 94-313-20 DECAL, SAFETY WARN 94-376-00 DECAL, KILL SWITCH 94-384-01 DECAL, NOT MOTOR VEHICLE 94-384-08 DECAL, DANGER, HIGH VOLTAGE...
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Page 158: Seat Cushions And Deck
Illustrated Parts Seat Cushions and Deck Item No. Part No. Description 90-160-50 Driver seat 90-160-51 Passenger seat 90-199-10 Seat belt 02-155-79 Angle, seat mount 00-243-41 Deck frame, standard 00-155-65 Deck frame, stake side pockets 02-155-45 Deck frame support, right 02-155-46 Deck frame support, left 02-155-55 DECK, PLYWOOD 42.000 X 61.000... - Page 159 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 .............
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Page 160: Appendix A: Special Tools
Appendixes APPENDIX A: 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 161: Hex Bolts
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 162: 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 163: 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 164: Suggested Torque Values (Critical Hardware)
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 165: 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 166 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Visit our Website: www.taylor-dunn.com...
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