Taylor-Dunn MB-238-00 Operation, T Roubleshooting And Replacement Parts Manual
  1. Manuals
  2. Brands
  3. Taylor-Dunn Manuals
  4. Electric Vehicles
  5. MB-238-00
  6. Operation, t roubleshooting and replacement parts manual
Taylor-Dunn MB-238-00 Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn MB-238-00 Operation, T Roubleshooting And Replacement Parts Manual

3-whell rr special
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Models Inlcuded:
B0-012-38 3-wheel RR Special
T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
MANUAL MB-238-00
Operation, Troubleshooting and
Replacement Parts Manual
Revision: A
Serial Number Starting: 164954

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MB-238-00 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Taylor-Dunn MB-238-00

Summary of Contents for Taylor-Dunn MB-238-00

  • Page 1 T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s MANUAL MB-238-00 Operation, Troubleshooting and Replacement Parts Manual Revision: A...
  • 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...
  • Page 5 Section Index Taylor-Dunn Model B0-012-38 Railroad Special Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transmission Service Suspension Tires and Wheels Battery Service Lestronic II Charger Troubleshooting...

  • Page 7: Table Of Contents

    Table of Contents About this manual ......... 2 Who Should Read This Manual ....2 Responsibilities ..........2 How To Use This Manual ......3 Conventions .............. 3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ....5 R 3-80 shown with extended steel cab and doors options...

  • Page 8: About This Manual

    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 9: How To Use This Manual

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

  • Page 10: How To Identify Your Vehicle

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

  • Page 11: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery adjust any part of this or any Taylor-Dunn ® vehicle is cables, and other electrical connections are a factory authorized service technician.
  • Page 12 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 13 TABLE OF CONTENTS Standard Specifications Burden Carrier Safety Rules and Guidelines ..... 3 Driver Training Program ....3 Driver Qualifications..........3 Vehicle Controls ........ 4 1) Key switch ............4 2) Smart View Display ......... 4 3) Forward-Off-Reverse Switch ......4 4) Horn switch ............

  • Page 14: Standard Specifications Burden Carrier

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS BURDEN CARRIER ITEM VOLTAGE SPECIFICATION Occupancy Driver only Dimensions 262.9 L X 106.7 W X 129.5 H Centimeters 103.5 L X 42 W X 51 H Inches Turning Radius 393.7 Centimeters (155 Inches) Dry Weight 612.3 kg (1350 lbs) Without Batteries...

  • Page 15: 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 16: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1) Key switch A key-switch, located on the right center side of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off. The key-switch should be in the “OFF”...

  • Page 17: Headlight Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS 1) Headlight switch 2) Front Side Lights 3) Rear Side Lights All lights switches operate the same. Toggle the switch to the UP position to turn the light on, toggle it to the DOWN position to turn the light off. Switches in the left column control the lights on the left side of the vehicle.

  • Page 18: Steering

    SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter- clockwise. If equipped with tilt steering, the release lever is located on the lower left of the steering column.
  • Page 19 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 listed below.
  • Page 20 SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display Fault Codes Example of Fault Code 4003 displayed on the SVD Fault Code Description Corrective action 01004 Discharged battery or defective wiring. Charge the battery. If the battery is good, check wiring to the controller. (note 2) 01005 Speed control overheated.

  • 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: Charging Your Vehicle

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

  • Page 24: Charging Time

    SAFETY RULES AND OPERATING INSTRUCTIONS Charging Time STORING AND RETURNING TO Average charging time is 8 to 10-hours. The time required SERVICE to fully charge your batteries will vary depending on: Both storing your vehicle and returning it to service •...

  • Page 25: Periodic Maintenance Checklist

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

  • Page 26: 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 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...
  • Page 30 • 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 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 Fork Barings/Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis-Adjusted or Worn Steering Gear Loose Steering Linkage...
  • Page 32 Maintenance, Service and Repair Lubrication Chart Description Locations Lubricant Type Fork Bearings General Purpose Grease Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings Wheel Bearing Grease Drive Drain Plug Drive Level Plug Drive Fill Plug SAE 80W90 Hypoid Gear Oil 10 - Page 4...
  • Page 33 TABLE OF CONTENTS Inspect the Front Wheel Bearings..2 Adjust Front Wheel Bearings .... 3 Front Axle Removal and Installation .. 4 Removal ..............4 Installation ............4 Replace Front Wheel Bearings ..5...

  • Page 34: Inspect The Front Wheel Bearings

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

  • Page 35: Front Axle Removal And Installation

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal Installation 1. Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub. 2. Assemble the bearing spacers into the front wheel 1.

  • Page 36: 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.
  • Page 37 TABLE OF CONTENTS Front End Alignment ......2 Center the Steering Wheel ........2 Inspect the Steering Components ..3 Ball Joints ............. 3 Fork Bearings ............3 Adjust the Steering Gear ....4 Center the Steering Gear ....4 Replace the Steering Gear ....

  • Page 38: Front End Alignment

    Maintenance, Service, and Repair 13. Repeat the previous step for a left turn. FRONT END ALIGNMENT 14. Tighten all jam nuts. 15. Check the turning radius in both the left and right turn. Repeat this procedure if not within specifications. Do not drive the vehicle while the steering wheel or front fork is tied in position.

  • Page 39: Inspect The Steering Components

    Maintenance, Service, and Repair INSPECT THE STEERING COMPONENTS Ball Joints Fork Bearings 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 1.

  • Page 40: Adjust The Steering Gear

    Maintenance, Service, and Repair 10. Loosen the worm bearing adjuster and then tighten ADJUST THE STEERING GEAR just enough to remove all end play from the input shaft and then an additional 1/8 turn more. 11. While holding the worm bearing adjuster so that it cannot turn, tighten the worm bearing adjuster jam nut.

  • Page 41: Replace The Steering Gear

    Maintenance, Service, and Repair REPLACE THE STEERING REPLACE THE BALL JOINTS GEAR NOTE: If a ball joint is worn out, we recommend replacing all of the ball joints as a set. 1. Make sure the key-switch is in the “OFF” 1.

  • Page 42: 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...
  • Page 43 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.

  • Page 44: Exploded View Of Steering Gear

    Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 8...
  • Page 45 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 Adjust the Service Brakes ......5 Adjust the Parking Linkage ......

  • Page 46: 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 47: 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 48: 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 49: Adjust The Service Brakes

    Maintenance, Service, and Repair ADJUST THE SERVICE 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. See section.

  • Page 50: Adjust The Parking Linkage

    Maintenance, Service, and Repair ADJUST THE PARKING LINKAGE 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 51: 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 52: 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 53 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 54: 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 55: 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 56 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 57: Replace The Wheel Cylinder

    Maintenance, Service, and Repair REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly 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 58 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 59: 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 60 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. 13.

  • Page 61: 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 62 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 63: 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. 1. Remove the master cylinder from the vehicle. See Replace the Master Cylinder section . 2.
  • Page 65 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 66: 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 67: 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 68 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 69 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 70 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 71: 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 72: 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 73 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 74: 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 75 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 76: 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 77: 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 78: 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 79: 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 80: 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 81 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 82: 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 83: 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 84 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 85 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 86: 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 87 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 88 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 89: 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 90 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 91 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 92: 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 93: 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 94 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 20...
  • Page 95 TABLE OF CONTENTS Replace the Rear Springs ....2 Replace the Front Springs ....2 Replace the Spring Bushings (rear only) ....... 5 Replace the Shocks ......6 Front ..............6 Rear ............... 6...

  • Page 96: Replace The Rear Springs

    Maintenance, Service, and Repair REPLACE THE REAR SPRINGS REPLACE THE FRONT SPRINGS It is recommended that both left and right side springs are replaced as a set. The front springs are an integral part of the front shock and cannot be replaced. Complete the procedure for one side before replacing the opposite side spring.

  • Page 97: Replace The Spring Bushings (Rear Only)

    Maintenance, Service, and Repair 12. Lower the vehicle. REPLACE THE SPRING 13. Reconnect the main positive and negative cables BUSHINGS (REAR ONLY) at the batteries. 14. Remove the blocks from behind the wheels. It is recommended that both left and right side spring bushings are replaced as a set.

  • Page 98: Replace The Shocks

    Maintenance, Service, and Repair 9. Install the shock in reverse order. REPLACE THE SHOCKS 10. Lower the vehicle. 11. Reconnect the main positive and negative cables Front at the batteries. 12. Remove the blocks from behind the wheels. It is recommended to replace both front shocks as a set. 13.
  • Page 99 TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Replace the Front Tire/Wheel .... 3 Replace the Rear Tire/Wheel .... 3 Replace the Tire (pneumatic) ... 3 Repair the Tire (pneumatic) ....4...

  • Page 100: 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 101: Replace The Front Tire/Wheel

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

  • Page 102: 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 103 TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Charging ........... 4 Watering ........... 5 Replacing (6-volt batteries only) ..6 Moist Charge Batteries ......... 7 Storage and Returning to Service ..8 Storage ..............8 Returning to Service ..........9...

  • Page 104: 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 105: 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 106: 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 107: 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 108: 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 109: 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 110: 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 111: 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 113 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 114: Operating Instructions And Theory Of Operation

    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 115: Testing The Charging Cycle

    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 116: Test Equipment Required For Troubleshooting

    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 117: Troubleshooting For Built-In Charger

    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 118 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 119 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 120: Troubleshooting For Portable Charger

    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 121: Testing The Timer Relay

    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 122: Testing The Interlock Relay

    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 123 Sevcon Control System Troubleshooting TABLE OF CONTENTS Test Equipment Required:....... 2 Important Notes and Instructions ... 2 Definitions: ..........2 Terminology used: ........2 Start Troubleshooting Here ..... 3 Test 8. Anti-Rolloff Fault ......22 Test 9. Electric Motor Brake ....23 Sevcon Logic Voltage Reference Table ...
  • Page 124 Electrical Troubleshooting Test Equipment Required: • Digital multimeter (DMM) with diode test function, FLUKE 79 model shown. • Test harness, Taylor-Dunn #75-089-00 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 125 Electrical Troubleshooting START TROUBLESHOOTING HERE This troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results.
  • Page 126 Electrical Troubleshooting Test 1. CHECKING THE CONTROL LOGIC INPUTS Close the seat switch. Place the high/low switch in the HIGH position. Connect a voltmeter across the ISO solenoid coil terminals and carefully monitor the voltage as the key switch is turned on. Turn the key switch ON and wait 1-second until the Isolator contactor closes.
  • Page 127 Electrical Troubleshooting TEST 1.3: Test the voltage at pin #6 on the 12-pin logic card connector. If the voltage is low, then skip ahead to test #1.4. If the voltage is high, then check the wire to the High/Low switch and the High/Low switch for open circuits.
  • Page 128 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 #6. TEST 1.6: Test the voltage at pin #7 on the 12-pin logic card connector.
  • Page 129 Electrical Troubleshooting TEST 1.7: Depress the accelerator pedal to engage FS-1 only (creep speed). Perform the following tests: Test the voltage at pin #10 on the 12-pin logic card connector. If the voltage is below 0.3 volts, then skip ahead to test #1.8.
  • Page 130 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 131 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 132 Electrical Troubleshooting Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3.1: Close the seat switch, turn the key switch ON and wait 1-second until the Isolator contactor closes. If the vehicle runs in reverse only then skip ahead to test #3.3.
  • Page 133 Electrical Troubleshooting TEST 3.3: Place the forward and reverse switch in the REVERSE direction. Test the voltage at pin #3 on the 12 pin logic card connector. If the voltage is low, then skip ahead to test #3.4. If the voltage is high, then skip ahead to Test #7. TEST 3.4: Test the voltage at pin #2 on the 12 pin logic card connector.
  • Page 134 STOP Stop, do not continue. Reaching this point indicates an unanticipated failure or an error was made during testing. Confirm all previous tests were performed correctly and contact your Taylor-Dunn ® represetative for assistatnce. After any repairs are made, completely retest the vehicle before lowering the drive wheels to the ground.
  • Page 135 Electrical Troubleshooting Test 4. KEY FAULT TEST 4.1: Turn the key switch ON and place the forward and reverse switch in the center OFF position Perform the following tests: Test the voltage at pin #1 on the 12 pin logic card connector.
  • Page 136 Electrical Troubleshooting TEST 4.3: Test the voltage at the cold side (violet/black wire) of the key switch. If the voltage equals battery volts, then skip ahead to test #4.4. If the voltage does not equal battery volts, then replace the key switch. Stop trouble shooting here and repair the problem.
  • Page 137 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 138 Electrical Troubleshooting B+ Terminal on the Sevcon controller Shorted Solenoid Coil: Disconnect the logic card connector and measure the resistance across the solenoid coil. Depending on the solenoid or contactor you vehicle is equipped with, the resistance should be 25 ohms or higher (nominal). A reading less than 25 ohms may indicate a shorted coil.
  • Page 139 Electrical Troubleshooting Test 6. ACCELERATOR MODULE FAULT Disconnect the truck harness from the accelerator module. Connect the plug on the short end of the 75-089-00 test harness to the accelerator module. Connect the receptacle on the short end of the test harness to the vehicles control harness. The long end of the harness will be used for testing.
  • Page 140 Electrical Troubleshooting TEST 6.2: Accelerator pedal released. Test the voltage from pin #9 to pin #8. If the voltage equals battery volts, then skip ahead to test #6.3. If the voltage does not equal battery volts, then check the wire from pin #8 to the key switch. Stop trouble shooting here and repair the problem.
  • Page 141 Electrical Troubleshooting TEST 6.5a: Test the voltage from pin #5 to pin #8. Accelerator pedal released. If the voltage is low then skip ahead to test 6.5b. If the voltage is high then then the module has failed. Stop trouble shooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground.
  • Page 142 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 143 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 144 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 145 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 146 Electrical Troubleshooting Connect a volt meter from battery negative to the Violet/Black wire at the electric brake harness plug. If the voltage is less than battery volts then: • Check wiring to the key switch and continue troubleshooting at test #4.2. If the voltage equals battery volts then: Connect a volt meter across the Violet/Black wire and the Blue wire at the electric brake harness plug.
  • Page 147 Electrical Troubleshooting Sevcon 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...
  • Page 148 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 149 TABLE OF CONTENTS Complete Vehicle ......2...
  • Page 150 Black Green/Black White Gray/White Brown Brown White White White Black White White Blue/White Black/White Violet/Black...
  • Page 151 Illustrated Parts TABLE OF CONTENTS Lestronic® Charger (page 2) ....... 28 Illustrated Parts Batteries ............. 30 Signet® Charger ......... 30 Front Fork Assembly ........2 Seat Cushions Deck and Lights ....32 Steering Linkage ......... 4 Frame ............32 Steering Gear ..........6 Need Parts>>>>>>>>>>>>>>>...

  • Page 152: Illustrated Parts

    Illustrated Parts Front Fork Assembly See Tires and Wheels Parts Page 2...
  • Page 153 Illustrated Parts Front Fork Assembly ITEM # PART # DESCRIPTION 92-105-00 88-229-81 3/4 NC LOCK NUT 88-228-60 3/4 CUT WASHER 80-011-10 Bearing 80-011-00 Bearing 80-102-00 Race 45-304-00 Grease seal 86-006-00 Shock, with spring and upper mounting hardware K47-100-34 Fork Frame fork collar (ref) K1-158-08 Bushing 98-753-12...
  • Page 154 Illustrated Parts Steering Linkage Cowling removed for clarity Parts Page 4...

  • Page 155: Steering Linkage

    Illustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 19-011-25 Cover, steering wheel 19-011-20 Steering wheel K47-100-20 Steering column 96-123-45 U-BOLT,3/8 X 2 X 2-5/8 80-400-10 Bearing K47-100-22 Steering shaft 18-308-21 Steering gear 88-120-15 7/16 X 1 1/2 NC HEX HD,GR 5 K1-153-65 Pitman arm 86-501-98...
  • Page 156 Illustrated Parts Steering Gear Exploded Steering Gear.dwg Parts Page 6...

  • Page 157: 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 158: Transmission Gear Case

    Illustrated Parts Transmission Gear Case Parts Page 8...
  • Page 159 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 160: 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 161 Illustrated Parts Rear Axle ITEM # PART # DESCRIPTION 41-154-25 Axle shaft, 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 96-329-10 Wheel stud 92-104-10 Hub cover 41-290-78 Axle housing (L) Not shown 41-290-79 Axle housing (R)

  • Page 162: Rear Brakes

    Illustrated Parts Rear Brakes Brake Body Assembly Parts Page 12...
  • Page 163 Illustrated Parts Rear Brakes ITEM # PART # DESCRIPTION 88-067-21 Hex bolt, grade 8 41-350-51 Secondary plate 41-348-70 Brake pad 41-348-57 Spacer 32-240-41 Bushing 41-350-28 Mounting bracket See Rear Axle Hex bolt with thread locking compund See below Brake body assembly 88-840-11 Retaining ring See below...
  • Page 164 Illustrated Parts Master Cylinder Brake linkage 2, 3 14, 3 10, 11, 12 5, 6, 7 2, 3 Floorboard remoed for clarity Brake Cross Shaft Parts Page 14...

  • Page 165: Brake Linkage

    Illustrated Parts Master Cylinder ITEM # PART # DESCRIPTION 99-511.00 Master cylinder assembly 88-101-20 Hex bolt 99-579-00 Fitting, bolt 99-572-00 Washer 99-566-00 Fitting 99-571-00 Washer 88-109-81 Hex lock nut 99-510-52 99-510-62 Rebuild kit 99-511-51 Boot 99-510-53 Gasket 88-108-60 flat washer BRAKE LINKAGE ITEM # PART #...
  • Page 166 Illustrated Parts Brake Lines Illustration not available Parts Page 16...

  • Page 167: Brake Lines

    Illustrated Parts Brake Lines ITEM # PART # DESCRIPTION K47-600-01 Brake line, Master cylinder to brake switch K47-600-02 Brake line, Brake switch to rear t-fitting 99-603-68 Brake line, Left side to brake hose 99-603-68 Brake line, Right side to brake hose 99-564-00 T-fitting (rear) 71-110-00...

  • Page 168: Motor

    Illustrated Parts Motor Parts Page 18...
  • Page 169 Illustrated Parts Parts Page 19...

  • Page 170: Wheels And Tires

    Illustrated Parts Wheels and Tires Ref., wheel hub Rear Suspension Parts Page 20...
  • Page 171 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-020-00 Wheel, 5.50 x 8 Tires 10-092-00 18.5 x 8.50 x 8 LR C Pneumatic 97-236-00 Wheel Nut Not Shown 13-989-00 Valve stem, tubless tire only Not Shown 11-041-00 8.50 x 8 Tube Tire and Wheel Assemblies 13-746-13...

  • Page 172: Speed Control Panel

    Illustrated Parts Speed Control Panel Instrument Panel (dash) Parts Page 22...

  • Page 173: Resetting The Smart View Display Maintenance Meter

    Rivet Resetting the Smart View Display Maintenance Meter (optional) 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 174 Illustrated Parts Miscellaneous Electrical Miscellaneous Wire Harness Clamps Parts Page 24...

  • Page 175: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION K47-300-01 Chassie Control Harness 75-152-04 Dash harness 75-152-00 Control panel harness K47-300-02 Power Harness Not Shown K1-153-68 Battery Connector 73-002-00 Horn 98-599-15 Plastic grommet for 1.75 hole 98-599-20 Plastic Grommet for 2.5 hole 96-650-01 Wire Harness Clip, stick on 96-642-00...

  • Page 176: Lestronic® Charger

    Illustrated Parts Lestronic® Charger (page 1) Use K1-156-44 for complete portabel charger assembly with modified charger cord Parts Page 26...
  • Page 177 Illustrated Parts Parts Page 27...

  • Page 178: Lestronic® Charger

    Illustrated Parts Lestronic® Charger (page 2) Parts Page 28...
  • Page 179 Illustrated Parts Parts Page 29...

  • Page 180: Batteries

    Illustrated Parts Batteries Illustration not available 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 30...

  • Page 181: Signet® Charger

    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 182: Seat Cushions Deck And Lights

    Illustrated Parts Seat Cushions Deck and Lights Frame Illustration not available Parts Page 32...

  • Page 183: Need Parts

    Need Parts Illustrated Parts Seat Cushions, Deck and Lights ITEM # PART # DESCRIPTION 90-160-70 Seat assembly K4L-000-11 Light Deckboard, rear Steel overlay Deckboard, front Steel overlay Not shown 88-607-09 Rivet, steel deck K47-100-02 Mounting plate 90-160-71 Spacer 88-080-13 Seat mounting bolt 88-080-11 Mounting plate bolts Not shown...

  • Page 184: Decals

    Illustrated Parts Decals Parts Page 34...
  • Page 185 Illustrated Parts Decals ITEM # PART # DESCRIPTION 94-384-14 When leaving vehicle warning 94-309-00 Brake warning 94-384-01 Not a motor vehicle 94-373-10 Vehicle identification 94-301-42 Arms and legs 94-313-20 Safety warning 94-301-41 Brake fluid 94-384-17 Do not wash 94-313-00 Battery warning 94-319-00 Battery disconnect Not shown...

  • Page 186: Hitches

    Illustrated Parts Hitches Parts Page 36...
  • Page 187 Contents Appendix A: Special Tools ....2 Appendix B: Suggested Torque Limits for Standard Hardware ..3 Hardware Identification ...... 3 Standard Head Markings ........3 Hex Bolts .............. 3 Other Bolts ............3 Hex Nuts ............... 4 Hex Lock Nuts (stover) ........4 Other Nuts .............

  • Page 188: Appendix A: Special Tools

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

  • Page 189: Appendix B: Suggested Torque Limits For Standard Hardware

    Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. NOTE: Toque values specified are for clean dry threads.

  • Page 190: 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 191: 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 192 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 193: 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 194 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...

Table of Contents