Page 1 Models Inlcuded: B0-200-00 BurdenMaster (B 2-00) B0-210-36 BurdenMaster (B 2-10) B0-210-36 AMB Ambulance B0-210-48 BurdenMaster (B 2-10) 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-210-07 Operation, Troubleshooting and...
Page 3 Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.
Page 4 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  ® Model B0-200-00, B0-210-36, B0-210-36AMB Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transaxle Service Suspension Tires and Wheels Battery Service Motor Speed Control Chargers Wire diagram...
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 Various versions of the model B 2-10 with optional equipment added...
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 Dash EndingSerial #179666 ....4 1) Key-Switch ............4 2) Horn Switch ............. 4 4) Battery Gauge / Smart View ......
Page 14: Standard Specifications Burden Carrier
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS BURDEN CARRIER ITEM MODEL VOLTAGE SPECIFICATION Occupancy 2-Passenger (standard) Dimensions 302.3L X 114.3 W X 122 H Centimeters 119 L X 45 W X 48 H Inches Turning Radius 317.5 Centimeters (125 inches) Dry Weight B 2-10 529 kg (1,166 pounds)
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 DASH ENDINGSERIAL #179666 1) Key-Switch A key-switch, located on the right 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.
Page 17: Dash Starting Serial #179667
SAFETY RULES AND OPERATING INSTRUCTIONS DASH STARTING SERIAL #179667 1) Headlight Switch The headlight switch is located on the top left of the instrument panel. Push the right side of the switch to turn the lights on. Push the left side of the switch to turn the light off.
Page 18: Battery Status Indicator, Analog
SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Analog The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading. The vehicle needs charging if it is in the yellow zone.
Page 19: Accelerator Pedal
SAFETY RULES AND OPERATING INSTRUCTIONS Accelerator Pedal The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.
Page 20: 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 21: Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is described below.
Page 22 SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance Monitor: NOTE: The Maintenance Monitor function is optional. The Maintenance Monitor function can be turned ON or OFF by your dealer. Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator.
Page 23: Fault Code Tables
SAFETY RULES AND OPERATING INSTRUCTIONS Fault Code Tables NOTE: Most faults are a result of a fault in the control Level 5 Faults system that will require service by a qualified Fault Code Description What to do technician. These faults are shown here for F05000 Contactor Over Current Refer to service technician...
Page 24: Vehicle Operation Guidelines
SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATION GUIDELINES Safety Guidelines While driving: • • Only qualified and trained operators may drive this Slow down and sound the horn to warn pedestrians vehicle. or when approaching a corner or other intersection. •...
Page 25: 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 26: 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 27: 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 28: 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 Vehicle Page 16 Documentation CD under the [Misc] sub folder.
Page 29: 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 30: 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 31 General Maintenance TABLE OF CONTENTS Maintenance Guidelines ....... 2 Troubleshooting Guide ........ 3 Lubrication Chart .......... 4...
Page 32 • 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 33 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 34 Maintenance, Service and Repair LUBRICATION CHART Transmission, B 2-10 Front end Transmission, B 2-00 Description Locations Lubricant Type King Pin General Purpose Grease Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease Drive Drain Plug Drive Level Plug Drive Fill Plug, B 2-10...
Page 35 Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin ........... 2 Adjust Front Wheel Bearings ....... 3 Front Axle Removal and Installation .... 4 Removal ..............4 Installation ..............5 Front Axle Disassembly ........ 6 Replace Front Wheel Bearings .....
Page 36: Inspect The Front Wheel Bearings And King Pin
Maintenance, Service, and Repair INSPECT THE FRONT WHEEL BEARINGS AND KING PIN 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.
Page 37: Adjust Front Wheel Bearings
Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 38: Front Axle Removal And Installation
Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 39: Installation
Maintenance, Service, and Repair Installation 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 40: Front Axle Disassembly
Maintenance, Service, and Repair FRONT AXLE DISASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: Replace the Steering Knuckle Replace the King Pins and Bushings NOTE: The front axle does not have to be removed unless the axle beam Front Axle Removal and must be replaced.
Page 41: Replace Front Wheel Bearings
Maintenance, Service, and Repair REPLACE FRONT WHEEL BEARINGS 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 42 Maintenance, Service, and Repair 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Brakes NOTE: Refer to the section for information regarding the installation of the brake body. 15. Lower the vehicle. 16. Reconnect the main positive and negative cables at the batteries. 17.
Page 43: Replace The King Pins And Bushings
Maintenance, Service, and Repair REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle. • Bronze bushings in the axle beam. • Bronze bushings in the steering knuckle. • Metal backed teflon bushings in the axle beam.
Page 44 Maintenance, Service, and Repair Replace the Steering Knuckle Rem ove t he st eer i ng knuckl e. Ref er t o for information regarding removing the steering knuckle. NOTE: It is not necessary to remove the tie rod or drag link for this procedure.
Page 45: Replace The Steering Knuckle
Maintenance, Service, and Repair REPLACE THE STEERING KNUCKLE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 46 Maintenance, Service, and Repair 12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings. NOTE: Both the left and right side bushings and thrust bearings should be replaced as a set. 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. 15.
Page 47 Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Inspect Ball Joints ......... 6 Adjust the Steering Gear ....... 7 Replace the Steering Shaft ......9 Replace the Steering Wheel ......11 Replace the Steering Gear ......12 Replace the Ball Joints, Tie Rods, and Drag Link ............
Page 48: 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 49 Maintenance, Service, and Repair 10. At this point both the steering wheel and the front wheels should be tied up and held in position. If one or the other is not tied up then you must start from the beginning. Do not drive the vehicle while the steering wheel or front wheels are tied in position.
Page 50 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front Center the Steering wheels. Refer to the section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 51 Maintenance, Service, and Repair 11. Measure the distance between the lines at the front Front Measurement of the tires. 12. Measure the distance between the lines at the rear of the tires. Sleeve Clamps 13. Adjust the tie rod so that the distance at the front and rear of the tires is the same.
Page 52: Inspect Ball Joints
Maintenance, Service, and Repair INSPECT BALL JOINTS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.
Page 53: Adjust The Steering Gear
Maintenance, Service, and Repair ADJUST THE STEERING GEAR NOTE: In some vehicle configurations it may be necessary to remove the Replace the steering gear to perform this procedure. Refer to Steering Gear for information regarding removing the steering gear. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 54 Maintenance, Service, and Repair 13. While rotating the input shaft back and forth through its centered position, adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position. 14.
Page 55: Replace The Steering Shaft
Maintenance, Service, and Repair REPLACE THE STEERING SHAFT 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 56 Maintenance, Service, and Repair 11. Remove the steering shaft from the vehicle. 12. Lightly grease the input shaft splines, steering wheel splines and the upper steering shaft bushing. 13. Install the steering shaft in reverse order using a new pinch bolt. Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft.
Page 57: Replace The Steering Wheel
Maintenance, Service, and Repair REPLACE THE STEERING WHEEL 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 58: Replace The Steering Gear
Maintenance, Service, and Repair REPLACE THE STEERING GEAR 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
Page 59: Replace The Ball Joints, Tie Rods, And Drag Link
Maintenance, Service, and Repair REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second Rod End cannot be greased and has a straight shaft.
Page 60 Maintenance, Service, and Repair 10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time. 11.
Page 61: Replacing The Drag Link
Maintenance, Service, and Repair 12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. and install a new cotter pin. 13. Realign the front wheels. Steering NOTE: Refer to the section for information regarding realignment of the front wheels.
Page 62: Replacing The Tie Rod
Maintenance, Service, and Repair 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13. Remove the blocks from behind the wheels. 14. Release the park brake and test drive the vehicle. Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together.
Page 63: Center The Steering Gear
Maintenance, Service, and Repair CENTER THE STEERING GEAR This procedure should only be performed with the steering gear removed from the vehicle. 1. Rotate the input shaft clockwise until it stops. 2. While counting the rotations, rotate the input shaft counter clockwise until it stops. 3.
Page 64: 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 65 Maintenance, Service, and Repair 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing.
Page 66 Maintenance, Service, and Repair 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft.
Page 67: Exploded View Of Steering Gear
Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 21...
Page 69 Brake Service TABLE OF CONTENTS Inspect the Service Brake ......2 Disc Brake Pads (B 2-10, front B 2-00 optional) ..2 Disc Brake Rotor (B 2-10, front B 2-00 optional) ..3 Inspect the Parking brake ......4 Wheel Park Brake ............. 4 Adjust the Service Brakes, B 2-10 ....
Page 70: Inspect The Service Brake
Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads (B 2-10, front B 2-00 optional) 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: Disc Brake Rotor (B 2-10, Front B 2-00 Optional)
Maintenance, Service, and Repair Disc Brake Rotor (B 2-10, front B 2-00 optional) 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 72: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake 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 73: Adjust The Service Brakes, B 2-10
Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES, B 2-10 Two or Four Wheel Hydraulic Disc Brakes The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • Check the Master Cylinder Fluid Brake fluid level low in the master cylinder.
Page 74: Adjust The Service Brakes, B 2-00
Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES, B 2-00 NOTE: The brake adjustment is inside of the left and right brake. Do not adjust the brake by means of the brake cables as this will cause mis-operation of the brakes. If you hear a single “clunking” noise while braking it may be due to mis-adjustment of the brake cables or linkage.
Page 75: Adjust The Parking Brake
Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake, B 2-00 NOTE: The service brake must be properly adjusted before attempting to adjust the parking brake. Refer to Adjust the Service Brakes for information regarding adjusting the service brakes. Do not use this procedure to adjust the brakes.
Page 76: Wheel Park Brake, B 2-10
Maintenance, Service, and Repair Wheel Park Brake, B 2-10 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 77 Maintenance, Service, and Repair Park brake handle Cotter pin Clevis Park brake handle linkage Clevis pin Bushing Jam nut Clevis pin Cross shaft Bolt Collar Cotter pin Return spring Primary adjustment rod Return spring bracket Clevis pin Cotter pin Jam nut Clevis Equalizer Park Brake Linkage, B 210...
Page 78: 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 79: Bleed The Brakes
Maintenance, Service, and Repair BLEED THE BRAKES 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 80 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 81: 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 82: Replace The Parking Brake Lining
Maintenance, Service, and Repair REPLACE THE PARKING BRAKE LINING 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 83: Replace Front Brake Pads
REPLACE FRONT BRAKE PADS NOTE: It is recommended that both the left and right brake pads be replaced as a set. Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos.
Page 84 Maintenance, Service, and Repair NOTE: Refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. Inspect the Service Brakes 12.
Page 85: Replace Rear Brake Pads Or Shoes
Maintenance, Service, and Repair REPLACE REAR BRAKE PADS OR SHOES Hydraulic Disc, B 2-10 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 86: Rear Drum Brakes, B 2-00
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 87 Maintenance, Service, and Repair 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 88: Replace The Wheel Cylinder
Maintenance, Service, and Repair REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly (front or rear) Current Taylor-Dunn brakes are asbestos free. However, there is ® the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
Page 89: Torque Spider. B 2-00
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 90: Repair The Disc Brake Body
Maintenance, Service, and Repair REPAIR THE DISC 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 91 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 92: 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 93 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 94: Repair The Master Cylinder
Maintenance, Service, and Repair REPAIR THE MASTER CYLINDER NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See Replace the Master Cylinder section . Drain all fluid from the master cylinder and discard.
Page 95 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 96: 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 97: 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 98 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 99 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 100 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 101: 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 102: 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 103 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 104: 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 105 Table of Contents Charger Remove/Install ..........2 Troubleshooting ..........2 Programming ...........3 Delta-Q ..............3 Signet ..............4 Delta-Q IC650 ............5...
Page 106: Remove/Install
CD. A hard copy can be purchased Failure to follow this instruction may result in serious from your authorized Taylor-Dunn distributor or can be injury due to electric shock and/or property damage. downloaded from the Taylor-Dunn web site.
Page 107: Programming
The algorithm code will be displayed for 11 seconds. The following is the list of algorithms available in Taylor-Dunn chargers. Contact Delta-Q for any additional detail or for information on codes not listed.
Page 108: Signet
This application will also allow viewing the charging history to aid in troubleshooting or uploading other algorithms. Instructions for using the application are included with the application or contact Delta-Q. Taylor-Dunn does not offer 3rd party computer application support, contact Delta-Q for assistance in using the application.
Page 109: Delta-Q Ic650
Your charger was configured for use with the batteries originally installed in your vehicle from the factory. The IC650 charger can store up to 25 different profiles in its internal memory. The list of available profiles is listed below. Contact your Taylor-Dunn dealer for information regarding batteries not listed. Profile Mfg...
Page 110 Notes Chargers Page 6...
Page 111 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 ..6 Transmission Assembly .........8 Remove and Install ..........8 Disassembly and Reassembly of the Primary Reduction Gear Case ........10 Disassembling the 3rd Member .....13 Assembling the 3rd Member ......16...
Page 112: 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 113: 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 114: 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 115: 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. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 116: Removing And Installing The Rear Axles
Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES 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 117 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 118: 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 119 Maintenance, Service, and Repair Rear Suspension Transmission Page 9...
Page 120: 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 121 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 122 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 123: 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 124 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 125 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 126: 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 127 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 128 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 129: 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 130: 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 131 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 21...
Page 133 Transmission 2 (B 2-00) TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor ............. 4 Removal ..............4 Installation ..............4 Rear Hub with Brake Drum ......5 Removal and Installation ........... 5 Rear Axle ............6 Replace the Axle Bearing ..........
Page 134: Check Oil Level
Maintenance, Service, and Repair CHECK OIL LEVEL Park the vehicle on a level surface. 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 135: Change Oil
Maintenance, Service, and Repair CHANGE OIL Park the vehicle on a level surface. 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 136: Motor
Maintenance, Service, and Repair MOTOR Removal NOTE: In some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor. Refer to Transmission section for information on removing the transmission assembly from the vehicle. 1.
Page 137: Rear Hub With Brake Drum
Maintenance, Service, and Repair REAR HUB WITH BRAKE DRUM Removal and Installation NOTE: Some vehicle configurations do not have a removable hub. The hub is an integral part of the rear axle. See the illustrations to the right to identify the hub on your vehicle.
Page 138: Rear Axle
Maintenance, Service, and Repair REAR AXLE Your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axle and the other is an integral part of the rear axle. The service of both of these axles is addressed in this section as follows: The removable hub will be referred to as “Removable Hub.”...
Page 139 Maintenance, Service, and Repair Remove and Install Axle - Non - Removable Hub NOTE: The brake assembly is retained by the axle bearing and must be removed along with the axle assembly. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 140: Replace The Axle Bearing
Maintenance, Service, and Repair Replace the Axle Bearing NOTE: The axle must be removed from the transmission for this procedure. Refer to Remove and Install Axle for information regarding removing the rear axle. Removable Hub: 1. Remove the hub from the axle shaft. Refer to Rear Hub/Brake Drum for information regarding removing the hub.
Page 141: Transmission
Maintenance, Service, and Repair TRANSMISSION Removal 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 142: Installation
Maintenance, Service, and Repair 12. Remove the four u-bolts holding the transmission to the left and right springs. 13. Remove the lower bolt from the left and right spring hangers. 14. Lift the rear of the vehicle high enough to roll the transmission out from under the vehicle.
Page 143 Maintenance, Service, and Repair 7. Place the transmission on to the locating pins on each leaf spring. 8. Install the four u-bolts so that the u-bolt nuts are tight enough to hold the springs on the locating pins but not so tight as to keep the springs from moving. 9.
Page 144: Differential Case
Maintenance, Service, and Repair DIFFERENTIAL CASE Disassemble 1. Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2. Thoroughly clean the transmission assembly before disassembly. 3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.
Page 145 Maintenance, Service, and Repair 8. Remove the final drive gear from the differential housing. 9. Punch or drill a small hole into the center of both of the intermediate shaft bore plugs. 10. Thread a sheet metal screw into each plug until the bore plug is forced out.
Page 146 Maintenance, Service, and Repair 13. Remove the intermediate bearing with an ID bearing puller. The shaft and gear assembly must be supported by hand during the next step. Failure to properly support the shaft and gear assembly could result in damage to the gear teeth. 14.
Page 147: Assemble
Maintenance, Service, and Repair 19. Remove the o-rings from both sides of the intermediate shaft bore and the input shaft bore and discard the o-rings. Assemble NOTE: When pressing bearings, do not press against or support the outer race as this will damage the bearing. NOTE: All snap rings should fit tightly into their grooves.
Page 148 Maintenance, Service, and Repair 4. Install the input shaft into the housing and install the snap ring. 5. Insert the intermediate shaft into the housing and Use a hard wood dowel the same diameter as the bearing bore to drive the bearing into place.
Page 149 Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Leaf (elliptical) ............2 Leaf (elliptical) ............3 Replace the Front Springs ......3 Replace the Spring Bushings ....... 4 Replace the Shocks ........5 Front ................. 5...
Page 150: Replace The Rear Springs
Maintenance, Service, and Repair REPLACE THE REAR SPRINGS Leaf (elliptical) If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 151: Leaf (Elliptical)
Maintenance, Service, and Repair REPLACE THE FRONT SPRINGS Leaf (elliptical) If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.
Page 152: Replace The Spring Bushings
Maintenance, Service, and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): •...
Page 153: Replace The Shocks
Maintenance, Service, and Repair REPLACE THE SHOCKS Front It is recommended to replace both front shocks as a set. NOTE: On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the front wheels.
Page 155 Tires and Wheels TABLE OF CONTENTS Tire Inflation ..........2 Tire Inspection ..........2 Replace the Tire/Wheel ......... 3 Repair the Tire (pneumatic) ......4 Replace the Tire (pneumatic) ....... 5...
Page 156: Tire Inflation
Maintenance, Service, and Repair TIRE INFLATION 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 157: Replace The Tire/Wheel
Maintenance, Service, and Repair 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. NOTE: Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment.
Page 158: Repair The Tire (Pneumatic)
Maintenance, Service, and Repair 4-Bolt Pattern 5-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 159: Replace The Tire (Pneumatic)
Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly must be removed from Replace the Tire/Wheel the vehicle. Refer to section for information on removing the tire/wheel assembly. Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel.
Page 161 Battery Service TABLE OF CONTENTS Cleaning ............2 Testing ............3 Watering ............5 Charging ............6 Replacing (6-volt batteries only) ....7 Moist Charge Batteries ..........9 Storage and Returning to Service ....10 Storage ..............10 Returning to Service ..........11...
Page 162: Cleaning
Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.
Page 163: Testing
Maintenance, Service, and Repair TESTING NOTE: A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 164 Maintenance, Service, and Repair Specific Gravity Test NOTE: The batteries must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see the illustration to the right).
Page 165: Watering
Maintenance, Service, and Repair WATERING NOTE: The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete.
Page 166: Charging
Maintenance, Service, and Repair 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
Page 167: Replacing (6-Volt Batteries Only)
Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 168 Maintenance, Service, and Repair 7. Remove the battery hold downs. 8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced. 9. Remove all battery jumpers from both posts of the battery or batteries being replaced. NOTE: It is recommended to replace the battery jumpers when replacing the batteries.
Page 169: Moist Charge Batteries
Maintenance, Service, and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 170: Storage And Returning To Service
Maintenance, Service, and Repair 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the Cleaning the batteries or the ground. Refer to Batteries for information on cleaning the batteries. 8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.
Page 171: Returning To Service
Maintenance, Service, and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 173 Table of Contents Motor Controller Remove/Install ..........2 Inspect ..............2 Receptacles .............2 Base Plate ...............2 Terminal Ends ............2 ’R’ Terminal ..............2 Repair/Programming ........3 Programming ............3 Troubleshooting ..........3 Hardware Torque ..........4...
Page 174 Motor Controller REMOVE/INSTALL INSPECT NOTICE Receptacles The inside of each receptacle should be clean and free Do not allow the wires to rotate while removing of any debris. Use aerosol electrical cleaner if required. terminal hardware. Base Plate Internal electrical connection will be damaged if the terminal stud rotates.
Page 175 Repairs A hard copy can be purchased from your authorized There are no internally serviceable components in the Taylor-Dunn distributor or can be downloaded from the motor speed controllers. If a controller is faulty then it Taylor-Dunn web site. must be replaced.
Page 176 Motor Controller HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the Notes appendix. Description Inch Pounds Newton Meters Terminal stud 38-44 4.29-4.97 Page 4...
Page 177 The vehicle wiring diaram is too large to be legible when printed at this size. A full size diagram (22 x 16) is inculded on the CD in PDF format. You can access the diagram from a button on the CD menu. The diagram #’s are: B 2-10: SCH-00009 B 2-00: SCH-00010...
Page 178 Wire Diagrams Brown White White White Green/Black Green/Black Brown White Black Black Blue/White Violet/Black White Blue White HORN Black/White Connector A Violet/Black Blue White Black Yellow Wire Diagrams Page 2...
Page 179 Wire Diagrams 4 2 1 Wire Diagrams Page 3...
Page 181 Illustrated Parts TABLE OF CONTENTS Front Axle ............2 Chargers ............41 Front Brakes ..........4 Miscellaneous Electrical ........46 Steering Linkage..........6 Batteries ............48 Steering Column ..........8 Seat Cushions, Lights, Deck and Frame ..50 Steering Gear ..........10 Decals............52 Front Suspension ..........10 Fixed 2nd and 3rd Seat Option......54 Rear Suspension, B 2-10 ......12 Hitches............54 Rear Suspension, B 2-00 ......12...
Page 182: Front Axle
Illustrated Parts Front Axle Illustrated Parts Page 2...
Page 183 Illustrated Parts Axle Assembly, Front Item No. Part No. Description 15-210-00 Front Axle Beam 14-210-98 Steering Yoke, Left 14-210-99 Steering Yoke, Right 14-210-88 Steering Yoke, Hydraulic Disc, Left (Optional) 14-210-89 Steering Yoke, Hydraulic Disc, Right (Optional) 32-240-55 Bushing Metal Backed Teflon 97-180-55 Thrust Washer, Metal Backed Teflon, 5/8” 21-020-15 King Pin 88-189-81...
Page 184: Front Brakes
Illustrated Parts Front Brakes #5 - Brake Body Assembly Illustrated Parts Page 4...
Page 185 Illustrated Parts FRONT BRAKES ITEM # PART # DESCRIPTION 41-348-70 Pad, Disc Brake 41-348-57 Spacer, Disc BrakePlate, Secondary, Hydraulic Disc 32-240-41 Bushing Mounting Bracket 88-067-21 Brake Body Bolt 41-350-70 Hydraulic Brake Body 99-588-01 Bleeder Screw Adapter 99-588-00 Bleeder Screw 88-069-82 1/4 NC Locknut Gr.
Page 186: Steering Linkage
Illustrated Parts Steering Linkage Pitman arm (see steering gear) FORWARD Illustrated Parts Page 6...
Page 187 Illustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 86-510-00 Clamp 86-501-98 Ball joint, left 86-501-99 Ball joint, right 88-159-85 Hex castle nut 88-527-11 1/8 x 1 Cotter pin 18-057-11 Drag link 87-074-00 Grease fitting 18-041-00 Steering linkage Illustrated Parts Page 7...
Page 188: Steering Column
Illustrated Parts Steering Column FLOOR BOARD Illustrated Parts Page 8...
Page 189 Illustrated Parts Steering Column ITEM # PART # DESCRIPTION 88-199-82 5/8NF Hex nut 19-011-25 Steering wheel cap 19-011-20 Steering wheel 80-400-10 Upper column bushing, used before April, 2002 32-248-10 Upper column bushing, used after April, 2002 20-031-63 Steering shaft (incle 6a and 6b) 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 (Pinch bolt) 88-089-84...
Page 190: Steering Gear
Illustrated Parts Steering Gear Front Suspension Illustrated Parts Page 10...
Page 191 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...
Page 192: Rear Suspension, B 2-10
Illustrated Parts Rear Suspension, B 2-10 Rear Suspension, B 2-00 Illustrated Parts Page 12...
Page 193 Illustrated Parts Rear Suspension, B 2-10 ITEM # PART # DESCRIPTION 85-513-10 Spring 16-871-02 Spring hanger 32-213-00 Spring bushing 96-248-00 Hex bolt 88-169-82 Hex nut 96-114-00 U-bolt 88-159-84 Hex nut 16-861-43 Spring plate, right 16-861-42 Spring plate, left Rear Suspension ITEM # PART # DESCRIPTION...
Page 194: Front Shocks Option
Illustrated Parts Front Shocks Option Frame Channels Ref. Front Axle Ref. Illustrated Parts Page 14...
Page 195 Illustrated Parts Front Shocks ITEM # PART # DESCRIPTION 86-602-00 Shock 88-128-60 7/16 Flat washer 88-129-81 7/16NC Hex lock nut 86-602-13 Lower bracket 86-602-25 Upper bracket (bolt on replacement) Illustrated Parts Page 15...
Page 196 Illustrated Parts Transmission, B 2-00 Illustrated Parts Page 16...
Page 197 Illustrated Parts Illustrated Parts Transmission, Spec #012AJ309-1 Item No. Part No. Description Housing Bearing cap (included with #1) 96-330-10 Bolt Carrier assembly Final gear Bolt 80-480-00 Bearing Shaft and gear assembly 80-715-00 O-ring 66-610-35 Bearing Input shaft 80-480-15 Bearing 80-715-10 O-ring 80-480-10 Bearing...
Page 198: Transmission Primary Gear Case, B 2-10
Illustrated Parts Transmission Primary Gear Case, B 2-10 Note 1: Spacer 23 is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number GT- 3287213. Add 10 to the part number for every 0.05mm over 3.9. For example, if 4.55mm is needed: 4.55-3.9 = .65mm over, 0.65/.05 = 13, 13*10 = 130.
Page 199 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 200: Transmission Differential Case, B 2-10
Illustrated Parts Transmission Differential Case, B 2-10 Illustrated Parts Page 20...
Page 201 Illustrated Parts Transmission Differential Case ITEM # PART # DESCRIPTION GT-70302 M10 x 30 Bolt GT-3287183 Ring and pinion gear set GT-3297193 Differential case cover GT-3287133 Adjusting ring GT-70417 Fill/Level plug GT-3287113 Differential housing GT-3287143 Differential case GT-72013 O-ring GT-71896 M10 x 25 Bolt GT-71978 Bearing and race...
Page 202 Illustrated Parts Rear Axle, B 2-10 Rear Axle and Brakes, B 2-00 Ref., Transmission housing Illustrated Parts Page 22...
Page 203: Rear Axle, B 2-10
Illustrated Parts Rear Axle, B 2-10 Item No. Part No. Description 41-154-20 Axle shaft 80-505-20 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 Not shown 92-104-10 Hub cover 41-290-44 Axle housing 89-113-30 M12 x 1.75 x 30mm Hex bolt (axle housing to center section) 6...
Page 204: Rear Brakes, B 2-10
Illustrated Parts Rear Brakes, B 2-10 #8 - Brake Body Assembly Illustrated Parts Page 24...
Page 205 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 96-327-10 Hex bolt with thread locking compund 41-350-68 Brake body assembly 88-840-11 Retaining ring See below Brake bleeder 32-220-03...
Page 206: Motor
Illustrated Parts Motor Illustrated Parts Page 26...
Page 207 Illustrated Parts Illustrated Parts Page 27...
Page 208: Master Cylinder And Linkage
Illustrated Parts Master Cylinder and Linkage Illustrated Parts Page 28...
Page 209 Illustrated Parts Master Cylinder and Linkage ITEM # PART # DESCRIPTION 99-510-02 Master cylinder assembly 88-101-20 Hex bolt See brake lines Fitting See brake lines Washer See brake lines Fitting See brake lines Washer 88-109-81 Hex lock nut 99-510-52 99-510-61 Rebuild kit for 1"...
Page 210: Hydraulic Brake Lines
Illustrated Parts Hydraulic Brake Lines Master Cylinder Frame FRAME Illustrated Parts Page 30...
Page 211 Illustrated Parts Hydraulic Brake Lines ITEM # PART # DESCRIPTION 99-580-20 Brake hose, B 2-10 front and rear, B 2-00 front 2 or 4 99-580-10 Brake hose, B 2-00 rear 99-603-53 Brake line, front right 99-603-53 Brake line, front left 99-603-54 Brake line, front 99-605-55...
Page 212: Brake Linkage (Parking Brake), B 2-10
Illustrated Parts Brake linkage (parking brake), B 2-10 Illustrated Parts Page 32...
Page 213 Illustrated Parts PARK BRAKE LINKAGE ITEM # PART # DESCRIPTION 51-344-80 Park Brake 88-517-09 Cotter Pin 96-773-00 Clevis Pin, 5/16 96-763-00 Clevis 88-089-80 5/16 Hex Nut 05-210-86 Hand Brake Bar 88-100-09 3/8 X 3/4 NC Bolt 88-109-81 3/8 NC Hex Lock Nut 06-210-11 Brake Cross Shaft 96-772-00...
Page 214: Brake Linkage (Parking Brake), B 2-00
Illustrated Parts Brake linkage (parking brake), B 2-00 Frame Frame Illustrated Parts Page 34...
Page 215 Illustrated Parts Brake Linkage, B 2-00 ITEM # PART # DESCRIPTION 51-344-80 park brake handle 88-080-11 Bolt 88-517-09 Cotter pin 96-813-00 Cable 96-772-00 Clevis pin 88-088-61 Washer 88-089-81 96-772-00 Clevis pin 88-517-09 Cotter pin 01-204-32 Equilzer 96-826-12 Cable 88-140-11 Bolt 96-773-00 Clevis pin 01-200-49...
Page 216: Wheels And Tires
Illustrated Parts Wheels and Tires Illustrated Parts Page 36...
Page 217 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-020-00 8.5 x 8 Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-081-00 5.70 x 8 LR B Pneumatic 10-082-00...
Page 218: Instrument Panel Up To Serial Number 179666
Instrument Panel Starting Serial Number 179667 Resetting the Smart View Display The meter should only be reset after the preventative maintenance has been performed. Taylor-Dunn ® part number 62-027-40 Hand set (available with instructions as part number 62-027-61) must be used to reset the meter.
Page 219 To reprogram the Sevcon speed control, the speed control must be returned to the factory. Contact your local ® Taylor-Dunn distributor for more information. The Smart View Display will only work with the Sevcon control system.
Page 220: Speed Control Panel
Illustrated Parts Speed Control Panel B 2-10 panel shown Speed Control Panel I T E M # PART # D E S C R I P T I O N 6 2 - 4 0 0 - 0 5 * Speed controller, PowerrPak B 2-10 6 2 - 4 0 0 - 3 1 Speed controller, MicroPak B 2-00...
Page 221: Chargers
Illustrated Parts Chargers (flooded batteries) Charger 36v Built In 48v Built In 36v Portable 48v Portable Signet HB (115/230 vac) 79-303-40 79-309-40 Signet HBS (115/230 vac) 79-303-41 79-309-42 Lester Lestronic II (115 vac) 79-303-15 79-303-25 79-305-20 79-309-50 Lester X-Series (115 vac) 79-303-36 79-303-48 79-303-37...
Page 222 Illustrated Parts Illustrated Parts Page 42...
Page 223 Illustrated Parts Illustrated Parts Page 43...
Page 224 Illustrated Parts Illustrated Parts Page 44...
Page 225 Illustrated Parts Illustrated Parts Page 45...
Page 226: Miscellaneous Electrical
Illustrated Parts Miscellaneous Electrical Accelerator Module Miscellaneous Wire Harness Clamps Seat Frame Seat Interlock Switch Illustrated Parts Page 46...
Page 227 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION 75-152-03 Chassie Control Harness 75-152-46 Power Harness 75-152-47 Control Panel Harness 75-152-04 Dash Harness 75-152-90 Smart view gauge cable Not Shown 98-599-15 Plastic grommet for 1.75 hole 98-599-20 Plastic Grommet for 2.5 hole Harness for Pole Mounted Strobe Light 75-152-06 Potratble Charger Harness...
Page 228 Illustrated Parts Batteries Illustrated Parts Page 48...
Page 229: Batteries
Illustrated Parts Batteries Item No. Part No. Description Battery Jumper 5 or 7 77-043-00 210AH, T-605 77-042-00 225AH, T-105 77-047-00 260AH, T-145 50-243-10 Battery rod 50-250-00 Battery hold down 88-088-66 Flat washer, tin/lead plated 88-069-81 1/2NC Nylon lock nut 88-081-12 5/16NC x 1 Hex bolt, stainless steel 88-089-80 5/16NC Hex nut, stainless stell...
Page 230: Seat Cushions, Lights, Deck And Frame
Illustrated Parts Seat Cushions, Lights, Deck and Frame Illustrated Parts Page 50...
Page 231 Front cowl with windshield cutout Frame Option 00-210-22 Headlight cover 00-210-25 Wire harness cover 94-050-11 Right headlight assembly 94-201-10 "TAYLOR-DUNN" name plate 94-050-10 Left headlight assembly 72-082-01 Replacement headlight bulb 72-072-11 Replacement headlight socket 94-050-04 Retainer for #11and 13 94-201-11...
Page 232: Decals
Illustrated Parts Decals Illustrated Parts Page 52...
Page 233 Illustrated Parts Decals ITEM # PART # DESCRIPTION 94-384-14 "When leaving the vehicle" 94-309-00 Apply hand brake 94-384-01 "Not a motor vehicle" 94-301-42 Arms and legs inside 94-313-20 General safety warning 94-319-00 Battery disconnect 94-313-00 Battery warning 94-301-41 DOT 3 brake fluid Not shown 94-384-17 Do not spray wash...
Page 234: Fixed 2Nd And 3Rd Seat Option
Illustrated Parts Fixed 2nd and 3rd Seat Option Hitches Illustrated Parts Page 54...
Page 235: Hitches
Illustrated Parts Fixed 2nd Seat Option ITEM # PART # DESCRIPTION 02-680-39 Seat bulkhead 90-175-00 Seat cushion 90-179-00 Backrest 88-065-09 1/4NC x 3/4 Hex bolt for mounting #1 88-068-60 1/4 Cut washer Not Shown 88-069-81 1/4NC Lock nut for mounting #1 88-867-09 #14 x 3/4 screw for mounting #3 Hitches...
Page 236: Cab And Cowl Windshield Frame Option
Illustrated Parts Cab and Cowl Windshield Frame Option Tubular Top Frame Illustrated Parts Page 56...
Page 237 Illustrated Parts Cab and Cowl Windshield Frame Option ITEM # PART # DESCRIPTION 91-010-77 Cowl and windshield frame 90-852-30 Windshield 98-310-000 Window gasket (by the foot) 88-102-15 3/8NC x 1-3/4 Carriage bolt 88-108-60 3/8 Cut flat washer 88-109-87 3/8NC KEPS nut 96-124-00 U-bolt 88-069-83...
Page 238: Foldaway 2Nd Seat Option
Illustrated Parts Windshield Wiper Option Illustration not available Dome Light Option Illustration not available Foldaway 2nd Seat Option DECK ANGLE REF. Illustrated Parts Page 58...
Page 239 Illustrated Parts Windshield Wiper ITEM # PART # DESCRIPTION 74-050-00 Wiper motor 74-051-00 Wiper arm 74-052-00 Wiper blade 75-152-09 Wiring harness 98-615-00 Motor insulating grommet, 3/4 ID 98-615-00 Motor insulationg grommet, 5/8 ID Dome Light ITEM # PART # DESCRIPTION 72-015-00 Dome light 75-105-25...
Page 240: Cab Doors
Illustrated Parts Cab Doors 29,12 11,12 Steel door detail Note: Left Door Shown Door frame Door frame Door Restraint Illustrated Parts Page 60...
Page 241 Illustrated Parts Cab Doors ITEM # PART # DESCRIPTION 90-923-98 Door frame, left 90-923-99 Door frame, right 90-924-98 Naugahyde door cover, left 90-924-99 Naugahyde door cover, right 97-315-53 Outer handle 97-315-51 Door latch 97-315-54 Inner handle 97-303-03 Snap fastener 88-727-06 Pop rivet for #6 88-825-08 8-32 x 5/8 Truss head machine screw...
Page 242: Mirrors
Illustrated Parts Mirrors Strobe Light Multi-Panel mirror option Illustrated Parts Page 62...
Page 243 Illustrated Parts Mirrors and Strobe Light ITEM # PART # DESCRIPTION 72-023-20 Strobe light 88-029-80 8-32 Hex nut 88-028-62 #8 Split lock washer 88-025-06 8-32 x 1/2 Truss head machine screw 75-152-10 Harness for cab 92-201-00 Mirror 92-202-13 Mounting bracket, right 92-202-12 Mounting bracket, left 92-202-15...
Page 244: Sun Tops
Illustrated Parts Sun Tops Illustrated Parts Page 64...
Page 245 Illustrated Parts Sun Tops ITEM # PART # DESCRIPTION 91-028-20 Top frame, standard K1-103-79 Top frame, ambulance 91-028-24 Mounting pole, standard 91-028-24 Mounting pole, ambulance K1-177-60 Mounting pile, ambulance 0-4 as Not shown K1-123-09 Ambulance mountin pole spacer needed 88-102-11 3/8NC x 1 Carraige bolt 88-109-81 3/8NC Hax lock nut...
Page 246 Illustrated Parts Automatic Driver Seat Brake, B 2-10 Illustrated Parts Page 66...
Page 247 Illustrated Parts AUTOMATIC DRIVER SEAT BRAKE ITEM # PART # DESCRIPTION 88-067-29 Bolt,1/4 X 4-1/4" NC, Grade 8 41-355-00 Automatic Electric Brake Unit See Motor Motor (Typical) 96-114-10 U-Bolt, 5/16" NF, Motor Support 70-456-10 Motor, Support Bracket 88-128-62 Lockwasher, 7/16" 89-111-27 Bolt, 10m X 1.5 X 20 Hex Head 88-088-62...
Page 248: Optional Deckboards
Illustrated Parts Optional Deckboards Illustration not available Illustrated Parts Page 68...
Page 249 Illustrated Parts Deckboard Options ITEM # PART # DESCRIPTION 2-Piece Deck option 00-210-23 Center deck support angle 88-607-09 Rivet 90-440-46 Steel deck cover, 38-1/2 long 90-440-47 Steel deck cover, 36-5/8 long 90-444-20 Deck board, 38-1/2 long 90-444-30 Deck board, 36-5/8 long Uses standard deck rails, see Seat Cushions, Lights, Deck and Frame Cargo Box 00-210-23...
Page 250: Tool Box Doors Option
Illustrated Parts Tool Box Doors Option Deck board 7,8,9,10 8,10 15,16 Illustrated Parts Page 70...
Page 251: Rear Shocks (Optional)
Illustrated Parts Tool Box Doors ITEM # PART # DESCRIPTION 02-210-12 Left side door 02-210-13 Right side door 02-210-15 Front top 88-737-08 Pop rivet 02-210-14 Front door stop 88-837-09 #14 x 3/4 Sheet metal screw 02-210-16 Door catch 88-065-08 1/4NC x 5/8 Truss head screw 88-068-61 1/4 SAE Flat washer 88-067-87...
Page 252: Stake Side Options
Illustrated Parts Stake Side Options Foldaway 2nd Seat Fixed 2nd Seat Flat Bed Illustrated Parts Page 72...
Page 253 Illustrated Parts Stake Sides ITEM # PART # DESCRIPTION 90-545-01 End gate 90-545-02 Left side, standard 90-545-02 Right side, standard 90-545-03 Left side, fixed 2nd seat 90-545-04 Right side, fixed 2nd seat 90-545-14 Left side rear, foldaway 2nd seat 90-545-12 Left side front, foldaway 2nd seat 90-545-15 Right side rear, foldawy 2nd seat...
Page 254: Cargo Box Option
Illustrated Parts Cargo Box Option 12” Side Panel Option 16,17,18 Illustrated Parts Page 74...
Page 255 Illustrated Parts Cargo Box ITEM # PART # DESCRIPTION 91-333-02 Cargo box 90-851-00 Rear window 98-310-00 Window gasket (by the foot) 90-850-10 Front window Not shown 94-320-10 Load height limit decal 12" Side Panels ITEM # PART # DESCRIPTION 00-210-38 Left panel 00-210-37 Right panel...
Page 256: Ambulance Deck And Top
Illustrated Parts Ambulance Deck and Top 13,14 Illustrated Parts Page 76...
Page 257 Illustrated Parts Ambulance Deck ITEM # PART # DESCRIPTION 00-210-51 Seat frame (un painted) 90-000-00 Seat backrest cushion 88-837-11 #14 x 1 Screw 90-191-00 Seat chshion 00-610-07 Left side deck rail 00-610-06 Rear deck rail 00-610-05 Right side deck rail 90-440-72 Rear deck board, galvanized 90-440-70...
Page 259 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 260: 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 261: 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 262: 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 263: 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 264 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 265: 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 266 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...

This manual is also suitable for:

Burdenmaster b 2-10 Amb ambulance B0-200-00 B0-210-36 B0-210-48

Taylor-Dunn BurdenMaster B 2-00 Operation, T Roubleshooting And Replacement Parts Manual

Table of Contents

Sc1-00 Stock Chaser B2-48 with Stake Side Dump Bed Option

Standard Specifications Burden Carrier

Safety Rules and Guidelines

Driver Training Program

Vehicle Controls

Dash Endingserial #179666

Dash Starting Serial #179667

Vehicle Operation Guidelines

Charging Your Vehicle

Storing / Returning to Service

Periodic Maintenance Checklist

Standard Periodic Maintenance Schedule for the Smart View Display

Maintenance Guidelines for Severe Duty Applications

Front Axle Service

Steering Component Service

Brake Service

Inspect the Service Brake

Inspect the Parking Brake

Adjust the Service Brakes, B 2-10

Adjust the Service Brakes, B 2-00

Adjust the Parking Brake

Check Master Cylinder Fluid

Bleed the Brakes

Flush the Brake System

Replace the Parking Brake Lining

Replace Front Brake Pads

Replace Rear Brake Pads or Shoes

Replace the Wheel Cylinder

Repair the Disc Brake Body

Replace the Master Cylinder

Repair the Master Cylinder

Motor Service

Table of Contents

Troubleshooting

Remove/Install

Programming

Transmission

Transmission 2 (B 2-00)

Check Oil Level

Change Oil

Motor

Rear Hub with Brake Drum

Rear Axle

Transmission

Differential Case

Suspension

Replace the Rear Springs

Replace the Front Springs

Replace the Spring Bushings

Replace the Shocks

Tires and Wheels

Battery Service

Illustrated Parts

Appendix A: Special Tools

Appendix B: Suggested Torque

Appendix C: Brake Lining Handling Precautions

Quick Links

Chapters

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Summary of Contents for Taylor-Dunn BurdenMaster B 2-00