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

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

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T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
Published: 2/19/1996
Revision: F
Models Inlcuded:
B0-248-TT (T48)
MANUAL MB-T48-00
Operation, Troubleshooting and
Replacement Parts Manual
Serial Number Range: 116303 through 156630

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  • Page 1 Models Inlcuded: B0-248-TT (T48) 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-T48-00 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: Table Of Contents

    Table of Contents Contents Introduction General Maintenance About this manual ........2 Maintenance Guidelines ......2 Who Should Read This Manual ....2 Troubleshooting Guide ......3 Responsibilities ........2 Lubrication Chart ........4 How To Use This Manual ......3 Front Axle Service Conventions ............
  • Page 6 Table of Contents Throttle Linkage Battery Service Throttle Linkage Adjustments ....2 Cleaning ............ 2 Testing ............3 Magnetic Module ............ 2 Pot Box module ............3 Charging ........... 4 Watering ............ 5 F2/F3 Transmission Service Replacing (6-volt batteries only) ....6 Adjust the Drive Chain ......
  • Page 7 Table of Contents Lestronic II® Charger Troubleshooting Appendixes Operating Instructions and Theory of Appendix A: Special Tools ....... 2 Operation ..........2 Appendix B: Suggested Torque Limits for Testing the Charging Cycle ...... 3 Standard Hardware ......3 Test Equipment Required for Hardware Identification ......
  • Page 8 SC1-00 Stock Chaser B2-48 With Stake Side Dump Bed Option E4-55 Sit Down Tow Tractor C4-25 Sit Down Tow Tractor...
  • Page 9 Table of Contents About this manual ......... 2 Who Should Read This Manual ....2 Responsibilities ..........2 How To Use This Manual ......3 Conventions .............. 3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ....5 Shown with fiberglass steel cab options Shown with extended steel cab...

  • Page 10: Introduction

    The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. ® ® The owner of this or any Taylor-Dunn vehicle is Taylor-Dunn , a leading manufacturer of electric responsible for the overall maintenance and repairs burden and personnel carriers since 1949, wants to of the vehicle, as well as the training of operators.

  • Page 11: How To Use This Manual

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

  • Page 12: How To Identify Your Vehicle

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

  • Page 13: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery adjust any part of this or any Taylor-Dunn ® vehicle is cables, and other electrical connections are a factory authorized service technician.
  • Page 15 TABLE OF CONTENTS Standard Specifications* ......2 Safety Rules and Guidelines ....3 Driver Training Program ......3 Driver Qualifications..........3 Vehicle Controls ........4 1) Key-Switch ............4 2) Forward-Off-Reverse Switch ....... 4 3) Hour Meter ............4 4) Battery Status Indicator, Analog ......

  • Page 16: Safety Rules And Operating Instructions

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* ITEM SPECIFICATION Occupancy Driver, one passenger Dimensions 325 L x 127 W x 119 H Centimeters 128 L x 50 x 47H Inches Turning Radius 368 Centimeters (145 Inches) Dry Weight 691 kg (1,524 lbs) With out Batteries Min/Max Battery 158 kg to 181 kg (350 lbs to 400 lbs)

  • Page 17: Safety Rules And Guidelines

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

  • Page 18: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1) 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 19: Foot Brake Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Digital Bargraph (optional) The battery status indicator is located to the left of the hour meter. The battery status indicator has a LED bar graph that indicates the relative state of charge of the battery.

  • Page 20: Directional Signals (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Directional Signals (Optional) The turn signal lever is located on the left side of the steering column. Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal. Hazard Light Switch (Optional) The hazard light switch is located on the left side of the steering column.

  • 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 Towing This Vehicle Before leaving the vehicle: • Set the parking brake. This vehicle is equipped with regenerative • Set the forward-off-reverse switch to the ` “OFF” braking. Follow these steps before towing position. this vehicle.

  • Page 23: 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 24: 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 25: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST NOTE: A full page copy of the Periodic Maintenance Checklist is on Safety Rules the Vehicle Documentation CD under the [Misc] sub folder. Page 11...

  • Page 26: 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 27 Table of Contents Maintenance Guidelines ....... 2 Troubleshooting Guide ........ 3 Lubrication Chart .......... 4 Model C 4-25 Tow Tractor Examples of Taylor-Dunn Tow Tractors Model E 4-55 Tow Tractor...

  • Page 28: Maintenance Guidelines

    • Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in ® conformance with Taylor-Dunn’s recommended procedures. • Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

  • Page 29: Troubleshooting Guide

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

  • Page 30: Lubrication Chart

    Maintenance, Service and Repair Lubrication Chart Description Locations Lubricant Type Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease King Pin General Purpose Grease Chain Case Drain plug Drive Drain Plug Drive Level Plug Fill Plug 140 API GL5 hypoid Gear Oil...
  • Page 31 TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin........2 Adjust Front Wheel Bearings .... 3 Front Axle Removal and Installation .. 4 Removal ..............4 Installation ............4 Front Axle Disassembly ..... 5 Replace Front Wheel Bearings ..6 Replace the King Pins and Bushings .

  • Page 32: 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. Confirm the electric park brake is set. 4.

  • Page 33: Adjust Front Wheel Bearings

    Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Confirm the electric park brake is set. 4.

  • Page 34: Front Axle Removal And Installation

    Maintenance, Service, and Repair Installation FRONT AXLE REMOVAL AND INSTALLATION 1. Make sure the key-switch is in the “OFF” position, then remove the key. Removal 2. Place the forward-reverse switch in the center “OFF” position. 3. Confirm the electric park brake is set. 1.

  • Page 35: 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 Front Axle NOTE: The front axle does not have to be removed unless the axle beam must be replaced.

  • Page 36: Replace Front Wheel Bearings

    Maintenance, Service, and Repair 12. Assemble in reverse order, using new grease REPLACE FRONT WHEEL seals. BEARINGS NOTE: Refer to Adjust Wheel Bearings for information regarding proper tightening of the spindle nut 13. Install the hub dust cap. 1. Make sure the key-switch is in the “OFF” 14.

  • Page 37: Replace The King Pins And Bushings

    Maintenance, Service, and Repair REPLACE THE KING PINS AND BUSHINGS Failure to correctly broach or ream bronze bushings may result in steering difficulty There are different types of king pin bushings depending and loss of control of the vehicle causing on the configuration of your vehicle.

  • Page 38: Replace The Steering Knuckle

    Maintenance, Service, and Repair NOTE: Both the left and right side bushings and thrust REPLACE THE STEERING bearings should be replaced as a set. KNUCKLE 13. Assemble in reverse order. Refer to the illustratinon below for orientation of the thrust bearing.
  • Page 39 TABLE OF CONTENTS Front End Alignment ......2 Inspect Ball Joints ......5 Inspect Rod Ends ......5 Adjust the Steering Gear ....6 Replace the Steering Shaft ....7 Replace the Steering Wheel ....8 Replace the Steering Gear ....8 Replace the Ball Joints, Tie Rods, and Drag Link ..........

  • Page 40: 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 41 Maintenance, Service, and Repair 12. Adjust the drag link so that it can be easily inserted into the pitman arm. 13. Tighten the ball joint or rod end nut as specified below: Ball joint - 40-45 ft-lbs. Rod end - 20-25 ft-lbs. 14.
  • Page 42 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front wheels. Refer to the Center the Steering section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2.

  • Page 43: Inspect Ball Joints

    Maintenance, Service, and Repair INSPECT BALL JOINTS INSPECT ROD ENDS NOTE: A set of ball joints and/or rod ends will wear NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end at the same rate.

  • Page 44: Adjust The Steering Gear

    Maintenance, Service, and Repair ADJUST THE STEERING GEAR NOTE: In some vehicle configurations it may be necessary to remove the steering gear to Replace perform this procedure. Refer to the Steering Gear for information regarding removing the steering gear. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 45: 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. Confirm the electric park brake is set. 4.

  • Page 46: Replace The Steering Wheel

    Maintenance, Service, and Repair REPLACE THE STEERING REPLACE THE STEERING WHEEL GEAR 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 47: Replace The Ball Joints, Tie Rods, And Drag Link

    Maintenance, Service, and Repair REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second cannot be greased and has a straight shaft.

  • Page 48: Replacing The Drag Link

    Maintenance, Service, and Repair Replacing a Ball Joint 11. Install the new ball joint into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the ball joint clamp at this time. 1.

  • Page 49: Replacing The Tie Rod

    Maintenance, Service, and Repair 9. Install in reverse order. 11. Lower the vehicle. 10. Realign the front wheels. 12. Reconnect the main positive and negative cables at the batteries. Steering NOTE: Refer to the section for information 13. Remove the blocks from behind the wheels. regarding realignment of the front wheels.

  • Page 50: 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 51 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 52: Exploded View Of Steering Gear

    Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 14...
  • Page 53 TABLE OF CONTENTS Inspect the Service Brake ....2 Disc Brake Pads ............ 2 Disc Brake Rotor ..........2 Inspect the Parking brake ....3 Adjust the Service Brakes ....3 Two or Four Wheel Hydraulic Disc Brakes ..3 Adjust the Parking Brake ....

  • Page 54: Inspect The Service Brake

    Disc Brake Pads Disc Brake Rotor NOTE: The front brake rotor is an integral part of the front hub. If the brake rotor is worn beyond Current Taylor-Dunn brakes are asbestos ® its service limits, then the front hub must be free.

  • Page 55: Inspect The Parking Brake

    Maintenance, Service, and Repair INSPECT THE PARKING ADJUST THE SERVICE BRAKE BRAKES Two or Four Wheel Hydraulic Disc Brakes NOTE: The parking brake is actuated through a pin in the center of the rear left and right brake The hydraulic disc brake system is automatically body on the rear axles.

  • Page 56: Adjust The Parking Brake

    Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake 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 57: Check Master Cylinder Fluid

    Maintenance, Service, and Repair CHECK MASTER CYLINDER FLUID Do not ingest brake fluid or allow contact 1. Make sure the key-switch is in the “OFF” with skin or eyes. Always wear protective position, then remove the key. clothing and a face shield when working 2.

  • Page 58: Bleed The Brake System

    Maintenance, Service, and Repair BLEED THE BRAKE SYSTEM Always use brake fluid from a new sealed NOTE: Start this procedure at the wheel furthest from container. Never reuse any brake fluid that the master cylinder, then work toward the has been removed from the brake system. wheel closest to the master cylinder.

  • Page 59: Flush The Brake System

    7. If equipped with front brakes, raise the front wheels off of the ground and support with jack stands. 8. Release the park brake. Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that 9.

  • Page 60: Replace Front Disc Brake Pads

    Maintenance, Service, and Repair REPLACE FRONT DISC BRAKE PADS Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that NOTE: It is recommended that both the left and right the original brakes were replaced with brake pads be replaced as a set.

  • Page 61: Replace Rear Brake Pads Or Shoes

    Maintenance, Service, and Repair REPLACE REAR BRAKE PADS OR SHOES NOTE: It is recommended that both the left and right Current Taylor-Dunn brakes are asbestos ® brake pads be replaced as a set. free. However, there is the possibility that...

  • Page 62: Replace The Wheel Cylinder

    Maintenance, Service, and Repair REPLACE THE WHEEL CYLINDER Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that the original brakes were replaced with Disc Brake Body Assembly (front or rear) aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 63: 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 64 Maintenance, Service, and Repair 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. NOTE: There are two different brake assemblies. One has a standard o-ring with a round cross section, the other has a square cross section.

  • Page 65: 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 NOTE: Most vehicle configurations do not require clothing and a face shield when working lifting the vehicle to remove the master with or around brake fluid.

  • Page 66: 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 67 TABLE OF CONTENTS Throttle Linkage Adjustments .... 2 Magnetic Module ..........2 Pot Box module ............ 3...

  • Page 68: Throttle Linkage Adjustments

    Maintenance, Service, and Repair THROTTLE LINKAGE ADJUSTMENTS Magnetic Module The standard magnitic throttle module should not be used in areas that contain large magnetic fields. Large magnitic fields may effect the operation of the module resulting in unexpected movement of the vehicle. The throttle pedal is attached directly to the throttle module.

  • Page 69: Pot Box Module

    Maintenance, Service, and Repair Pot Box module The pot box module is used on vehicles that are to be operated in areas with large magnetic fields. The linkage to the pot box should be adjusted so that the FS-1 switch closes just as the pedal is depressed and the output is at 5K with the pedal fully depressed.
  • Page 71 TABLE OF CONTENTS Adjust the Drive Chain ...... 2 Check the Oil Level ......3 Change the Oil ........3 Drive Motor ........4 Remove ..............4 Install ..............4 Rear Axle .......... 5 Remove and Install ..........5 Replace the Axle Bearing ........5 Chain Case ........

  • Page 72: Adjust The Drive Chain

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

  • Page 73: Check The Oil Level

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

  • Page 74: Drive Motor

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

  • Page 75: Rear Axle

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

  • Page 76: Chain Case

    Maintenance, Service, and Repair CHAIN CASE NOTE: Some vehicle configurations may require that the transmission be removed to disassemble the chain case. Refer to section Transmission Assembly for information on removing the transmission. Disassemble 1. Make sure the key-switch is in the “OFF” Typical Chain Case position, then remove the key.
  • Page 77 Maintenance, Service, and Repair Motor Woodruf Key Adjusting screw Bolt 3rd Member O-Ring Motor Sprocket Washer Mounting Plate Spacer Drive Sprocket Backing Plate Drive Chain Bolt Washer Bolt Chain Case Housing Drain Plug Pinion Seal Brake Assembly Pinion Nut 8. Install the chain case housing onto the pinion shaft 10.

  • Page 78: Differential Assembly (3Rd Member)

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

  • Page 79: Assemble

    Maintenance, Service, and Repair Assemble NOTE: Thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. NOTE: Depending on your vehicle config-uration, the rear pinion pilot bearing is not required and may not be installed.
  • Page 80 Maintenance, Service, and Repair NOTE: Be sure to continually rotate the ring gear while adjusting the bearings. This makes sure that the bearings and races remain seated Cross threading the nuts will damage the correctly. 3rd member housing and bearing caps. If NOTE: One hole on adjusting nut = approximately the housing and/or nuts are damaged, the 0.003"...

  • Page 81: Re-Shimming The Pinion Housing

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

  • Page 82: Exploded View

    Maintenance, Service, and Repair EXPLODED VIEW F2/F3 Transmission Page 12...
  • Page 83 TABLE OF CONTENTS Replace the Rear Springs ....2 Leaf ............... 2 Replace the Front Springs ....3 Leaf ............... 3 Replace the Spring Bushings ..... 4 Replace the Shocks ......5 Front ..............5...

  • Page 84: Suspension

    Maintenance, Service, and Repair 8. Unbolt the spring from the axle housing. REPLACE THE REAR SPRINGS 9. Support the spring so that it cannot fall out of the vehicle. 10. Remove the remaining hardware retaining the Leaf spring to the frame. If a spring has failed or is fatigued, then it is 11.

  • Page 85: Replace The Front Springs

    Maintenance, Service, and Repair REPLACE THE FRONT SPRINGS Damaged or worn spring bolts or hangers could result in sudden failure of the Leaf suspension causing severe bodily injury or If a spring has failed or is fatigued, then it is property damage.

  • Page 86: Replace The Spring Bushings

    Maintenance, Service, and Repair 7. Remove the spring from the vehicle. REPLACE THE SPRING Replace the Front Springs NOTE: Refer to BUSHINGS section for information regarding removing the front springs. It is recommended that all front spring bushings are 8. If the vehicle is equipped with spring hangers, replaced as a set.

  • Page 87: Replace The Shocks

    Maintenance, Service, and Repair 7. Remove the upper and lower shock bolts. REPLACE THE SHOCKS 8. Remove the shock from the vehicle. NOTE: If the shock that was removed is to be reinstalled: A. Inspect the shaft where it enters the shock body for any signs of leakage.
  • Page 89 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ......2 Enclosed Motors (GE, no cooling fan) ....2 Motor Removal and Installation ..3 Motor Inspection ........ 3 Replacing the Brushes....... 5 Replacing the Bearings ..... 6 Repairing the Commutator ....

  • Page 90: Motor Service

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

  • Page 91: Motor Removal And Installation

    Motor Service Advanced DC Motors Inspection The enclosed Advanced DC motors must be 1. Measure the length of each motor brush. disassembled to inspect the motor brushes. Refer to • If any one brush is less than or equal to the Motor Inspection for information regarding Service...
  • Page 92 Motor Service 5. Inspect the commutator for burn marks. commutator segments and the armature frame. If it is not an open circuit, then the armature is • Burn marks and/or raised commutator segments shorted and the motor must be replaced. 90 or 180 degrees apart is evidence of a shorted armature.

  • Page 93: Replacing The Brushes

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

  • Page 94: Replacing The Bearings

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

  • Page 95: Service Limits

    Motor Service SERVICE LIMITS Commutator Diameter Brush Length Wire Depth Undercut Depth Motor Specification (min) (min) (max) Number inches inches inches inches 5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129C 0.635 0.025 66.75 2.625...
  • Page 97 TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Replace the Tire/Wheel ..... 3 Replace the Tire (pneumatic) ... 3 Repair the Tire (pneumatic) ....4...

  • Page 98: Tires And Wheels

    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 99: Replace The Tire/Wheel

    Maintenance, Service, and Repair REPLACE THE TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly 1. Make sure the key-switch is in the “OFF” must be removed from the vehicle. Refer to position, then remove the key. Replace the Tire/Wheel section for information on removing the tire/wheel...

  • Page 100: 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 101 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 102: 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 103: 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 104: 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 105: 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 106: 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 107: 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 108: 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 109: 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 111 Table of Contents SYMPTOMS:........2 READ THIS FIRST ......3 Test Equipment Required ............3 IMPORTANT NOTES and INSTRUCTIONS ...... 3 START HERE: ................ 4 Definitions: ................4 Controller Small Signal Input ..........6 Forward/Reverse Switch, Model ET -150-74 (72 volt system) 6 Forward/Reverse Switch (48 Volt System) ......

  • Page 112: Electrical Troubleshooting

    Maintenance, Service, and Repair This troubleshooting procedure is for systems equiped with this type speed control only SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Unusual Symptom Troubleshooting later in this section. •...

  • Page 113: Read This First

    This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Accelerator Module Test Harness. Troubleshooting CANNOT be completed without these tools. If, during any test involving a test light where the light is...

  • Page 114: Definitions

    Maintenance, Service, and Repair START HERE: Definitions: • “FS-1” = Start switch in the throttle module. • “Battery volts” = The voltage of the batteries at the time the test is performed. • “Control volts” = Battery Volts (48v system) or 12 Volts (72 volt system). •...
  • Page 115 Maintenance, Service, and Repair 1. Make sure the start switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. The rear drive wheels may rotate during some of the following tests.

  • Page 116: Controller Small Signal Input

    Maintenance, Service, and Repair Controller Small Signal Input During this procedure, voltages will be measured at the controller terminals #1, #2, #6, and #7. Close the seat interlock switch, turn the key switch ON, select a direction and fully depress the throttle pedal.

  • Page 117: Forward/Reverse Switch

    Maintenance, Service, and Repair Forward/Reverse Switch (48 Volt System) The forward\reverse switch (F/R) is a double pole double throw center off switch (DPDT). One pole controls the direction of the vehicle and the other pole provides the Key Switch Input (KSI) to the speed controller. These two poles have different functions and are isolated but a failure in either pole can result in similar symptoms.

  • Page 118: Throttle Module

    Maintenance, Service, and Repair Throttle Module (using test harness): The throttle module is located under the floorboard and functions as a throttle position sensor. The throttle module has two output signals, one is a varying voltage relative to the pedal position and the other is a fixed voltage indicating that the pedal is depressed.

  • Page 119: Throttle Module (Using Analyser)

    Maintenance, Service, and Repair Throttle Module (using analyser): The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.

  • Page 120: Motor Windings

    Maintenance, Service, and Repair Motor Windings Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause severe bodily injury and/or property damage. The test equipment required to fully test a motor is very expensive. The test procedure provided here will be able to diagnose the most common motor failure modes.

  • Page 121: Contactors

    Maintenance, Service, and Repair Contactors Troubleshooting in the procedure assumes that the control These test procedures must be system is functioning (output from M- on controller) and performed in the order they were that the motor has tested good. written. If the test result is good, then proceed to the next test or go Both the forward and the reverse contactors pass current to the next section.

  • Page 122: Contactor Negative Return

    Maintenance, Service, and Repair Contactor Negative Return The forward and reverse contactors coils use a common negative return that is provided by the controller from Pin #3. The negative output from Pin #3 is part of a fault monitoring circuit in the controller.

  • Page 123: Unusual Symptom Troubleshooting Guide

    Maintenance, Service, and Repair UNUSUAL SYMPTOM TROUBLESHOOTING GUIDE This section is specific to the symptoms listed below. Each troubleshooting sequence assumes that all listed symptoms are present. Do not use this section unless the vehicle is exhibiting has all listed symptoms.

  • Page 124: Plugging Diode

    Maintenance, Service, and Repair PLUGGING DIODE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 125: Iso

    Maintenance, Service, and Repair 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 127 TABLE OF CONTENTS Operating Instructions and Theory of Operation ........2 HB/PT and GEL Indicator Lamps ...3 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting .......4 Important Notes and Instructions Status LED Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 128: Signet Charger Troubleshooting

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION ® ® The model HB600W and HB1000W chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.

  • Page 129: Hb/Pt And Gel Indicator Lamps

    Electrical Troubleshooting HB/PT AND GEL INDICATOR LAMPS NOTE: Your charger may not be equipped with these lamps. HB/PT Lamp If the HB/PT lamp is “ON”, then the charger has overheated and has entered a proportionally reduced output. The charging cycle will terminate if the temperature continues to rise.
  • Page 130 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING ® Digital Multi Meter (DMM), FLUKE 79 model shown at right and in the troubleshooting illustrations. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.

  • Page 131: Status Led Error Code Table

    Electrical Troubleshooting STATUS LED ERROR CODE TABLE There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in the charging cycle.
  • Page 132 Electrical Troubleshooting TROUBLESHOOTING To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet. Wait for charger to start (up to15 seconds), the ammeter should display the DC Amp rating of the charger (plus or minus 10%) indicating that the charger is on (constant current mode).
  • Page 133 Charger Models: HBS 600 HBS 1000 TABLE OF CONTENTS Definitions: ..........2 Test Equipment Required for Troubleshooting .......2 Important Notes and Instructions Operating Instructions and Theory of Operation ........3 Testing the Charging Cycle ....4 Status Light Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 134: Definitions

    Electrical Troubleshooting DEFINITIONS: Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells. Term Value Condition 2.47 Volts Per Cell Flooded batteries at 80F ambient temperature*. 2.39 Volts Per Cell Gel Batteries at 80F ambient temperature*. 2.08 Volts Per Cell All batteries 5 Amps (+/- 1 Amp)

  • Page 135: Operating Instructions And Theory Of Operation

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Typical specification plate (reference only, specifications will vary for different chargers) The model HBS 600W ® and HBS 1000W ® chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once the charging cycle is complete, the charger will monitor the battery voltage.

  • Page 136: Testing The Charging Cycle

    Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit.

  • Page 137: Status Light Error Code Table

    Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.

  • Page 138: Troubleshooting

    Electrical Troubleshooting TROUBLESHOOTING NOTE: There are no internally serviceable components in the charger. To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet.
  • Page 139 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 140: 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 141: 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 142: 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 143: 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 144 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 145 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 146: 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 147: 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 148: 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 149 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 diagrams # are SCH-00018: Equipped with 2-piece charger SCH-00019: Equipped with 1- piece charger...

  • Page 150: Wire Diagrams

    Wire Diagrams THESE WIRES NOT USED WHEN DIRECTIONAL SIGNAL OPTION IS INSTALLED Wire Diagrams Page 2...
  • Page 151 Wire Diagrams HORN Wire Diagrams Page 3...

  • Page 153: Illustrated Parts

    Illustrated Parts TABLE OF CONTENTS Front Axle ........... 2 Master Cylinder ........... 24 Front Brakes ..........4 Brake Lines ..........26 Steering Linkage Drag Link ......4 Parking Brake Linkage ........ 28 Steering Column ......... 8 Wheels and Tires ........30 Steering Gear ..........

  • Page 154: Front Axle

    Illustrated Parts Front Axle Parts Page 2...
  • Page 155 Illustrated Parts FRONT AXLE Item # Part # Description 88-239-86 King pin nut 88-228-60 Flat washer 98-603-07 Rubber washer 97-180-21 Thrust washer 32-240-44 Upper king pin bushing 15-210-70 Axle beam 32-240-43 Lower king pin bushing 80-309-12 Thrust bearing 21-020-18 Right steering yoke 92-104-00 Wheel bearing cap 88-527-11...

  • Page 156: Front Brakes

    Illustrated Parts Front Brakes Steering Linkage Drag Link Parts Page 4...
  • Page 157 Illustrated Parts FRONT BRAKES ITEM # PART # DESCRIPTION 41-348-70 Brake pad 41-348-52 Spacer 32-240-40 Bushing 88-067-21 Brake body bolt (grade 8) 41-350-70 Brake body (Rebuild kit 41-350-66) 99-580-10 Brake hose 99-588-01 Brake bleeder fitting 99-588-00 Brake bleeder valve 88-069-82 Brake body nut (grade 8) DO NOT REUSE! 12-158-10 Front hub (w/rotor, inner bearing, races and seal),Note:...
  • Page 158 Illustrated Parts Parts Page 6...
  • Page 159 Illustrated Parts Parts Page 7...

  • Page 160: Steering Column

    Illustrated Parts Steering Column Parts Page 8...
  • Page 161 Illustrated Parts S T E E R I N G G E A R I T E M # P A R T # D E S C R I P T I O N Q T Y 8 8 -1 5 9 -8 2 1 / 2 N F j a m n u t 1 9 -0 1 1 -2 5 C a p...

  • Page 162: Steering Gear

    Illustrated Parts Steering Gear Front Suspension Parts Page 10...
  • Page 163 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 164: Transmission Chain Or Gear Case

    Illustrated Parts Transmission Chain or Gear Case Parts Page 12...
  • Page 165 Illustrated Parts POWER TRACTION 70-061-00 Motor 97-100-00 Woodruff key 88-087-11 Chain adjusting screw 88-069-80 5/16 NC hex nut 88-103-09 Motor mounting screw 80-703-00 O-ring 70-454-00 Motor mounting plate 88-109-87 3/8 KEPS nut (intergral lockwasher) 30-080-00 Motor sprocket 16-417-00 Spacer 30-093-00 Pinion sprocket 30-508-20 Drive chain...

  • Page 166: Transmission Differential Case

    Illustrated Parts Transmission Differential Case Parts Page 14...
  • Page 167 Illustrated Parts 3rd MEMBER 41-709-00 3rd member housing (Small carrier bearing, 1.628 ID) 41-710-00 3rd member housing (Large carrier bearing, 1.784 ID) 88-119-80 3/8 NF nut 41-712-00 Differential assembly (Small carrier bearing 1.628 ID) 41-713-00 Differential assembly (Largecarrier bearing 1.784 ID) 80-127-00 Carrior bearing race (80-511-00 bearing)) 80-128-00...

  • Page 168: Rear Axle

    Illustrated Parts Rear Axle Rear Brakes Parts Page 16...
  • Page 169 Illustrated Parts REAR AXLE Item # Part # Description 97-236-00 Wheel nut 12-025-00 Wheel 10-264-00 Tire 13-746-14 Tire/wheel assembly (#2 and 3) 96-340-60 Replacement wheel stud kit 41-152-41 Rear axle (left/right) 41-350-08 Axle retaining bracket 80-503-00 Bearing 32-515-00 Bearing retainer 45-301-00 Seal 96-327-00...

  • Page 170: Parking Brake

    Illustrated Parts Parking Brake Rear Suspension Parts Page 18...
  • Page 171 Illustrated Parts PARKING BRAKE 45-331-00 Pinion seal 45-532-00 Brake drum 96-245-10 Brake adjusting bolt 41-661-60 Brake band kit (incl. 3, 5, 7, 8, 9, 12, 13) 85-060-20 Spring 41-370-10 Mounting bracket 88-159-82 1/2 NF hex jam nut 88-159-84 1/2 NF lock nut 97-250-00 Pinion nut 88-109-81...

  • Page 172: Motor

    Illustrated Parts Motor (page 1) Parts Page 20...
  • Page 173 Illustrated Parts Parts Page 21...
  • Page 174 Illustrated Parts Motor (page 2) Parts Page 22...
  • Page 175 Illustrated Parts Parts Page 23...

  • Page 176: Master Cylinder

    Illustrated Parts Master Cylinder Parts Page 24...
  • Page 177 Illustrated Parts FOOT BRAKE LINKAGE ITEM # PART # DESCRIPTION 99-510-02 Master cylinder (incl. parts 8, 9, 12) 96-762-00 Clevis 96-772-00 Clevis pin 88-527-11 Cotter pin 88-119-80 3/8 NF nut 50-009-00 Push rod 17-104-00 Collar 99-510-52 Master cylinder cap 99-510-61 Rebuild kit 99-510-51 Rubber boot...

  • Page 178: Brake Lines

    Illustrated Parts Brake Lines Parts Page 26...
  • Page 179 Illustrated Parts BRAKE LINES AND HOSES ITEM # PART # DESCRIPTION K1-118-98 Brake line 99-564-00 T-Fitting 71-110-00 Brake light switch 99-576-00 Hose retaining clip 99-580-10 Front brake hose 99-648-53 Brake line 99-510-02 Master cylinder 99-648-52 Brake line (front right) 99-604-56 Brake line (rear right) 99-604-57 Brake line (rear left)

  • Page 180: Parking Brake Linkage

    Illustrated Parts Parking Brake Linkage Parts Page 28...
  • Page 181 Illustrated Parts PARKING BRAKE LINKAGE ITEM # PART # DESCRIPTION 51-340-00 Park brake lever ----- Spacer (part of #1) 88-089-81 5/16 NC Hex lock nut 88-088-61 5/16 SAE flat washer 88-080-16 5/16 x 2 NC Hex bolt ----- Spacer (part of #1) 96-762-00 3/8 Clevis 88-119-80...

  • Page 182: Wheels And Tires

    Illustrated Parts Wheels and Tires Ref., wheel hub Parts Page 30...
  • Page 183 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-025-00 8 x 10 Tubeless Tires 10-264-00 20 x 8 x 10 LR E 97-236-00 Wheel Nut Not Shown 13-989-00 Valve stem, tubless tire only Tire and Wheel Assemblies 13-746-15 20 x 8 x 10 8-ply Parts...

  • Page 184: Speed Control Panel

    Illustrated Parts Speed Control Panel Instrument Panel (dash) Parts Page 32...
  • Page 185 Illustrated Parts CONTROL PANEL (62-016-15) ITEM# PART # DESCRIPTION 88-838-06 Screw 71-306-70 Forward and reverse contactor 78-302-50 250 ohm 5W resistor 71-306-72 ISO contactor 88-818-06 Screw 88-065-13 1/4 x 1-1/4 Truss head bolt 62-209-70 PMC speed control 79-844-20 200A circuit breaker 75-224-15 Diode 62-209-71...

  • Page 186: Miscellaneous Frame And Body

    Illustrated Parts Miscellaneous Frame and Body Parts Page 34...
  • Page 187 PART # DESCRIPTION 72-025-00 Tail light See battery Battery jumper 94-050-11 Right headlight 90-444-00 Deckboard (standard) 94-201-10 TAYLOR-DUNN name plate 88-817-07 Name plate screw SHOWN 94-201-11 Name plate fastener (plastic) 94-050-10 Left headlight 00-248-32 Front cowl weldment (not painted) K6-006-95...

  • Page 188: Charger

    Illustrated Parts Charger (page 1) Parts Page 36...
  • Page 189 Illustrated Parts Parts Page 37...
  • Page 190 Illustrated Parts Charger (page 2) Parts Page 38...
  • Page 191 Illustrated Parts Parts Page 39...

  • Page 192: Batteries

    Illustrated Parts Batteries Main Negative Main Positive 12 Volt Negative tap Parts Page 40...
  • Page 193 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 194: Decals

    Illustrated Parts Decals Item No. Part No. Description 94-301-04 DECAL "TAYLOR TRUCK",BLK,3"HI 94-301-41 DECAL,DOT 3 BRAKE FLUID 94-301-42 DECAL,ARMS/LEGS INSIDE,4 WHEEL 94-304-11 PANEL, INSTRUMENT, TD LOGO 94-309-00 DECAL-BRAKE WARNING 94-313-00 DECAL, BATTERY WARNING 94-313-20 DECAL, SAFETY WARN 94-319-00 DECAL,BATTERY DISCONNECT 94-373-10 DECAL, VEHICLE DATA 94-384-01...

  • Page 195: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical ELECTRICAL SYSTEM (FRAME) PART # DESCRIPTION 71-110-00 Brake light switch 71-102-10 Seat switch` 75-149-19 Truck control harness 72-082-01 Headlight bulb 72-082-10 Front turn signal bulb (optional) 72-082-20 Turn signal bulb socket (optional) 71-900-05 Signal flasher (optional) 71-141-20 Turn signal switch (optional) 71-501-00...
  • Page 197 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 198: Appendixes

    Appendixes APPENDIX A: SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used to install the pinion seal on all chain drive trucks with Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43-201-50 cover. Used to center the chain case on the pinion shaft on all chain Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41-532-50...

  • Page 199: 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 200: 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 201: 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 202: Suggested Torque Values (Critical Hardware)

    Appendixes Suggested Torque Values (critical hardware) Torque Table Torque Range Group Description Ft-Lbs In-Lbs Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15...

  • Page 203: 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 204 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Visit our Website: www.taylor-dunn.com...

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