Taylor-Dunn B0-254-48 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn B0-254-48 Operation, T Roubleshooting And Replacement Parts Manual

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Lavatory Service Vehicle
GT Drive
EQUIPPED WITH GT-DRIVE SYSTEM
T h e B e s t W a y
T o G o
Models Inlcuded:
A b o u t Y o u r
B0-254-48 (B 2-54)
B u s i n e s s
MANUAL MB-254-02
Operation, Troubleshooting and
Replacement Parts Manual
Revision: C
Serial number range: 165448 - 170871

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Summary of Contents for Taylor-Dunn B0-254-48

  • Page 1 T h e B e s t W a y T o G o Models Inlcuded: A b o u t Y o u r B0-254-48 (B 2-54) B u s i n e s s MANUAL MB-254-02 Operation, Troubleshooting and...
  • Page 3 Address inquiries to Reference Permissions, ® Taylor-Dunn Mfg., 2114 W. Ball Road, Anaheim, CA 92804 TAYLOR-DUNN SERVICE CENTER For more information about this and other Taylor-Dunn ® manuals, please write Taylor-Dunn ® ® Taylor-Dunn Mfg.
  • Page 4 Table of Contents ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...

  • Page 5: Table Of Contents

    Table of Contents Contents Introduction ............1 About this manual ..............2 Who Should Read This Manual ..........3 Responsibilities ................ 3 How To Use This Manual ............4 Conventions ........................5 How to Identify Your Vehicle ............ 6 Taking Delivery of Your Vehicle ..........7 Safety Rules and Operating Instructions....
  • Page 6 Table of Contents Periodic Maintenance Checklist ..........16 Standard Periodic Maintenance Schedule for the Smart View Display ..........17 Daily Visual Inspection ...................... 18 Maintenance Guidelines for Severe Duty Applications ............18 General Maintenance ..........1 Maintenance Guidelines ............2 Troubleshooting Guide .............
  • Page 7 Table of Contents Brake Service ............1 Inspect the Service Brake ............2 Disc Brake Pads ........................ 2 Disc Brake Rotor ....................... 3 Inspect the Parking brake ............4 Wheel Park Brake (hydraulic disc) .................. 4 Electric Motor Brake ......................5 Adjust the Service Brakes ............
  • Page 8 Table of Contents Transmission............1 Check Oil Level ................. 2 Change Oil ................. 3 Motor Removal and Installation ..........4 Rear Hub or Rotor ..............5 Removing and Installing the Rear Axles (Disc Brakes) ................6 Transmission Assembly ............8 Remove and Install ......................
  • Page 9 Table of Contents Sevcon Control System Troubleshooting .... 1 Test Equipment Required: ....................2 Important Notes and Instructions ..................2 Definitions: ........................2 Terminology used: ......................2 Start Troubleshooting Here ....................3 Test 8. Anti-Rolloff Fault ....................22 Test 9. Electric Motor Brake ....................23 Sevcon Logic Voltage Reference Table ................
  • Page 10 Table of Contents APPENDIX A-Special Tools........A-1 Appendix B: Standard Hardware Suggested Torque Limits ............. 1 Hardware Identification ............2 Standard Head Markings ....................2 Hex Bolts .......................... 2 Other Bolts ........................2 Hex Nuts ........................... 3 Hex Lock Nuts (stover) ....................3 Other Nuts ........................

  • Page 11: Introduction

    Introduction Contents About this manual ........2 Who Should Read This Manual ....3 Responsibilities ..........3 How To Use This Manual ......4 Conventions .............. 5 How to Identify Your Vehicle ......6 Taking Delivery of Your Vehicle ....7...

  • Page 12: Introduction

    Please continue to read this manual and enjoy this high quality Taylor-Dunn ® vehicle. This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn ® vehicles and is not intended as a training guide. Taylor-Dunn ®...

  • Page 13: Who Should Read This Manual

    Of the Service Personnel... The service personnel are responsible for the service and maintenance of the vehicle. At no time should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn ® vehicle. For the purposes of training, a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training.

  • Page 14: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections: INTRODUCTION This section describes how to use this service manual and how to identify your vehicle. Safety Rules and Operating Instructions This section outlines the safety and operational issues, location and operation of controls, and the operational checks that are to be performed on this vehicle.

  • Page 15: Conventions

    INTRODUCTION Conventions Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: A shaded box with the word “Warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others.

  • Page 16: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on public highways.

  • Page 17: Taking Delivery Of Your Vehicle

    ® distributor and report the problem. The report must be made within 24 hours of receiving the vehicle and its accessories. The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn ® vehicle is a factory authorized service technician.

  • Page 19: Safety Rules And Operating Instructions

    Safety Rules and Operating Instructions TABLE OF CONTENTS Standard Specifications ....... 2 Vehicle Operational Guidelines ....11 Safety Rules and Guidelines ......3 Safety Guidelines ............11 Starting: ..............11 Driver Training Program ....... 4 While driving: ............12 Driver Qualifications..........4 Loading and Unloading ..........

  • Page 20: Safety Rules And Operating Instructions

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM VOLTAGE SPECIFICATION Occupancy Driver only Electrical System 48 Volt 6-165 Amp Hour, 8 Volt, Lead Acid Batteries, Solid State Speed Control, 500 Amp Not available at Dimensions 467.36L x 149.86W x ?? H Centimeters time of printing 184L x 59W x ?? H Inches Not available at...

  • Page 21: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDELINES It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the American National Standards Institute Personnel and Burden Carriers ANSI B56.8).

  • Page 22: Driver Training Program

    SAFETY RULES AND OPERATING INSTRUCTIONS DRIVER TRAINING PROGRAM According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have previous vehicle operation experience.

  • Page 23: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 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 24: Accelerator Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS 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. Accessory Switch (Optional) The accessory switch is located on the left side of the instrument panel and to the right of the headlight switch.

  • Page 25: 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 listed below. BSI: A bar graph representing the current state of charge is located across the top of the display.
  • Page 26 SAFETY RULES AND OPERATING INSTRUCTIONS Run Time Hours: After the initial 5-seconds, the Run Time Hours will be displayed as indicated by the Run Time Hours Indicator located at the left of the display. The icon represents a motor symbol with a “T” in the center.

  • Page 27: Directional Signals (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance monitor (optional): 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. This should allow sufficient time for the operator to schedule the maintenance that is due, with minimal down time. If the scheduled maintenance is not performed before the warning period elapses, then the vehicles maximum speed will be significantly reduced.

  • Page 28: Electrolyte Alarm (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Electrolyte Alarm (Optional) The Electrolyte Alarm is located in the battery area, in the 4th battery cell from the main battery positive cable. The Electrolyte alarm is activated when the battery cell fluid level falls below the level of the probe. The alarm is an audible continuous sound along with a bi-color indicator lamp.

  • Page 29: Vehicle Operational Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines • Do not operate this vehicle while using any substance such as medication, drugs, or alcohol that may impair your judgment, reaction times, or driving ability. • Only qualified and trained operators may drive this vehicle. •...

  • Page 30: While Driving

    SAFETY RULES AND OPERATING INSTRUCTIONS While driving: • Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection. • No reckless driving. • Do not drive this vehicle on steep inclines or where prohibited. •...

  • Page 31: Charging Your Vehicle

    SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do 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 32: Industrial Charger Operation

    SAFETY RULES AND OPERATING INSTRUCTIONS ® Lestronic II Charger Operation The Lestronic II ® charger is a semi-automatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged.

  • Page 33: Storing And Returning To Service

    SAFETY RULES AND OPERATING INSTRUCTIONS STORING AND RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing Your Vehicle • Clean the batteries, then fill and charge before putting the vehicle in storage. Do not store batteries in a discharged condition.

  • Page 34: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi - Weekly Monthly Quaterly Annualy 2, 3 Maintenance Item Annual (20hrs) (80hrs) (250hrs) (1000hrs) (500hrs) Check Condition of Tires and Tire Pressure Check All Lights, Horns, Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks...

  • Page 35: 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 36: 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 37: General Maintenance

    General Maintenance TABLE OF CONTENTS Maintenance Guidelines ....... 2 Troubleshooting Guide ......... 3 Lubrication Chart .......... 4...

  • Page 38: 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 39: Troubleshooting Guide

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

  • Page 40: Lubrication Chart

    Maintenance, Service and Repair LUBRICATION CHART Rear Axle Lubrication Front End Lubrication Description Locations Lubricant Type Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease King Pin General Purpose Grease Drive Drain Plug Drive Level Plug Drive Fill Plug SAE 80W90 Gear Oil...

  • Page 41: Front Axle Service

    Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin ........... 2 Adjust Front Wheel Bearings ....... 3 Front Axle Removal and Installation .... 4 Removal ..............4 Installation ..............5 Front Axle Disassembly ........ 6 Replace Front Wheel Bearings .....

  • Page 42: 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 43: 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 44: 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 45: 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 46: 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 47: 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 48 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 49: Replace The King Pins And Bushings

    Maintenance, Service, and Repair REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle. • Bronze bushings in the axle beam. • Bronze bushings in the steering knuckle. • Metal backed teflon bushings in the axle beam or suspension arm.
  • Page 50 Maintenance, Service, and Repair Replace the Steering Knuckle 7. Remove the steering knuckle. Refer to for information regarding removing the steering knuckle. NOTE: It is not necessary to remove the tie rod or drag link for this procedure. 8. Press the king pin bushings out from the axle, steering knuckle or suspension arm. 9.

  • Page 51: 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 52 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 53: Steering Component Service

    Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Inspect Ball Joints ......... 6 Inspect Rod Ends .......... 7 Adjust the Steering Gear ....... 8 Replace the Steering Shaft ......10 Replace the Steering Wheel ......12 Replace the Steering Gear ......13 Replace the Ball Joints, Tie Rods, and Drag Link ............

  • Page 54: 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 55 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 56 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 57 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 58: 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 59: Inspect Rod Ends

    Maintenance, Service, and Repair INSPECT ROD ENDS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.

  • Page 60: 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 61 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 62: 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 63 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 64: 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 65: 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 66: 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 67 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 68: 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 69: 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 70: Center The Steering Gear

    Maintenance, Service, and Repair CENTER THE STEERING GEAR 1. Remove the pitman arm. 2. Rotate the input shaft clockwise until it stops. 3. While counting the rotations, rotate the input shaft counter clockwise until it stops. 4. Rotate the input shaft clockwise 1/2 the rotations counted in the previous step. 5.

  • Page 71: 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 72 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 73 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 74: Exploded View Of Steering Gear

    Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 22...

  • Page 75: Brake Service

    Brake Service TABLE OF CONTENTS Inspect the Service Brake ......2 Disc Brake Pads ............2 Disc Brake Rotor ............. 3 Inspect the Parking brake ......4 Wheel Park Brake (hydraulic disc) ......4 Electric Motor Brake ..........5 Adjust the Service Brakes ......6 Two or Four Wheel Hydraulic Disc Brakes ....

  • Page 76: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 77: Disc Brake Rotor

    Maintenance, Service, and Repair Disc Brake Rotor Current Taylor-Dunn brakes are asbestos free. However, there is ® the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.

  • Page 78: Inspect The Parking Brake

    Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake (hydraulic disc) NOTE: The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 79: Electric Motor Brake

    Maintenance, Service, and Repair Electric Motor Brake A variable power supply capable of supplying 0-volts to 24-volts DC at 2-Amps will be required to perform the testing. The brake does not have to be removed from the transmission for this test. 1.

  • Page 80: Adjust The Service Brakes

    Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Two or Four Wheel Hydraulic Disc Brakes The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • Check the Master Cylinder Fluid Brake fluid level low in the master cylinder.

  • Page 81: Adjust The Parking Brake

    Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake (hydraulic disc) The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 82: 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 83: Bleed The Brake System

    Maintenance, Service, and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
  • Page 84 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 85: 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 86: Replace The Parking Brake Lining (Electric Motor Brake)

    Maintenance, Service, and Repair REPLACE THE PARKING BRAKE LINING (ELECTRIC MOTOR BRAKE) Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
  • Page 87 Maintenance, Service, and Repair 6. Mark the orientation of the inner contact plate in relation to the magnet. 7. Remove the smaller bearing circlip. 8. Using a soft hammer, drive out the center hub and remove the inner contact plate and six springs. 9.

  • Page 88: Inspection

    Maintenance, Service, and Repair Electric motor brake exploded Inspection: Note: There are no repairable parts in this assembly. The parts must be replaced if any damage or wear is found. 1. Measure the free length of the five springs. Minimum length =0.713” 2.

  • Page 89: Replace Front Disc Brake Pads

    REPLACE FRONT DISC BRAKE PADS NOTE: It is recommended that both the left and right brake pads be replaced as a set. Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos.
  • Page 90 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 91: Replace Rear Brake Pads

    Maintenance, Service, and Repair REPLACE REAR BRAKE PADS Hydraulic Disc Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.
  • Page 92 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 93: 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 94 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 95: 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 96 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 97: 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 98 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 99: 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 101: Motor Service

    Motor Service TABLE OF CONTENTS Inspecting the Motor Brushes ...... 2 Motors with internal cooling fans ....... 2 Motor Removal and Installation ....3 Motor Inspection ........... 3 Replacing the Brushes or Armature Bearing ........7 Repairing the Commutator......8 Service Limits ..........

  • Page 102: Transmission

    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 103: 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 104 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 105 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 106 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 107: 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 108: 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 109 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 110: 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 111: Check Oil Level

    Transmission TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor Removal and Installation ....4 Rear Hub or Rotor ......... 5 Removing and Installing the Rear Axles (Disc Brakes) ........... 6 Transmission Assembly ........ 8 Remove and Install ..........8 Disassembly and Reassembly of the Primary Reduction Gear Case ......

  • Page 112: Transmission

    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. NOTE: The axle hub bolt has a special thread locking compound applied to the threads.

  • Page 116: Removing And Installing The Rear Axles (Disc Brakes)

    Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES (DISC BRAKES) The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange.
  • Page 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: 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 120 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 121 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 122: 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 123 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 124 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 125: 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 126 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 127 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 128: 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 129: 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 130 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 20...
  • Page 131 Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Replace the Front Springs ......3 Replace the Spring Bushings ....... 4 Replace the Shocks ........5...

  • Page 132: Suspension

    Maintenance, Service, and Repair REPLACE THE REAR SPRINGS If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.

  • Page 133: Replace The Front Springs

    Maintenance, Service, and Repair REPLACE THE FRONT SPRINGS If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. HINT : In most vehicles it will be easier if the springs are replaced one at a time.

  • Page 134: 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 135: Replace The Shocks

    Maintenance, Service, and Repair REPLACE THE SHOCKS It is recommended to replace all shocks as a set. NOTE: On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the front wheels.
  • Page 137 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 138: Tires And Wheels

    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 139: 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 140: 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 141: 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 143: Battery Service

    Battery Service TABLE OF CONTENTS Cleaning ............2 Testing ............3 Watering ............5 Charging ............6 Replacing (6-volt batteries only) ....7 Moist Charge Batteries ..........9 Storage and Returning to Service ....10 Storage ..............10 Returning to Service ..........11...

  • Page 144: 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 145: 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 146 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 147: 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 148: 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 149: 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 150 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 151: 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 152: 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 153: 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 155: Sevcon Control System Troubleshooting

    Sevcon Control System Troubleshooting Includes Power Pak and Micro Pak controllers TABLE OF CONTENTS Test Equipment Required: ...... 2 Definitions: ..........2 Terminology used: ........2 Important Notes and Instructions ... 2 Identifying Your Controller ..... 3 Start Troubleshooting Here ....4 Test 8.

  • Page 156: Test Equipment Required

    • Digital multimeter (DMM) with diode test • This troubleshooting procedure is for the function, FLUKE 79 model shown. Sevcon Power Pak and Micro Pak motor • Throttle Module Analyzer, Taylor-Dunn part speed controllers as equipped in standard number 62-027-32 vehicles. Troubleshooting may not be valid for vehicles equipped with special order speed control options.

  • Page 157: Identifying Your Controller

    Electrical Troubleshooting Identifying Your Controller Sevcon Troubleshooting Page 3...

  • Page 158: Start Troubleshooting Here

    Electrical Troubleshooting START TROUBLESHOOTING HERE If your vehicles is equipped with an electric motor brake, the motor brake system must be checked to be sure it is working properly before continuing with this troubleshooting. Operating the speed control when the motor brake has not disengaged may result in damage to Test 9: Electric Motor the motor or speed control system.
  • Page 159 Electrical Troubleshooting Test 1. CHECKING THE CONTROL LOGIC TEST 1.3: INPUTS Test the voltage at pin #6 on the 12-pin logic card connector. Close the seat switch. Place the high/low switch in the HIGH position. If the voltage is low, then skip ahead to Test #1.4.
  • Page 160 Electrical Troubleshooting TEST 1.5: Test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to Test #1.6. If the voltage is low, then skip ahead to Test TEST 1.6: Test the voltage at pin #7 on the 12-pin logic card connector.
  • Page 161 Electrical Troubleshooting Test 2. TESTING THE MOTOR 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
  • Page 162 Electrical Troubleshooting TEST 2.3: Test the continuity from the motor A1 terminal to the frame on the motor and from F1 to A1 for open circuits. Any reading other than an open circuit indicate a short in the motor. If there is a short in the motor, stop here and repair or replace the motor.
  • Page 163 Electrical Troubleshooting Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3.1: TEST 3.5 Close the seat switch, turn the key switch ON and Disconnect the batteries and remove wires from wait 1-second until the Isolator contactor closes. the B-, F1, and F2 terminals on the controller. If the vehicle runs in reverse only then skip Using the diode test function on your meter, connect ahead to test #3.3.
  • Page 164 Electrical Troubleshooting Test 4. KEY FAULT TEST 4.1: TEST 4.3: Turn the key switch ON and place the forward and Test the voltage at the cold side (violet/black wire) reverse switch in the center OFF position of the key switch. If the voltage equals battery volts, then skip Perform the following tests: ahead to test #4.4.
  • Page 165 Electrical Troubleshooting Test 5. CONTACTOR COIL FAULT Disconnect the 12-pin logic card connector from the Sevcon power unit. Turn the key switch ON and perform the following tests: TEST 5.1: Check the voltage on the positive coil terminal of the ISO solenoid (violet wire).
  • Page 166 Electrical Troubleshooting Test 6. ACCELERATOR MODULE FAULT 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire.
  • Page 167 Electrical Troubleshooting Test 7. FORWARD AND REVERSE SWITCH FAULT Turn the key switch ON, place the forward and reverse switch in the center OFF position and perform the following tests: TEST 7.1: Referencing battery positive, test the voltage on the center terminal of the F&R switch (Black wire).
  • Page 168 Electrical Troubleshooting TEST 7.3: If the vehicle does not travel in forward, skip ahead to test #7.4. Place the forward and reverse switch in the REVERSE position. Referencing battery positive, test the voltage at the White/Black wire on the F&R switch. If the voltage equals battery volts, skip ahead to test #7.4.

  • Page 169: Test 8. Anti-Rolloff Fault

    Electrical Troubleshooting Test 8. ANTI-ROLLOFF FAULT The Sevcon Controller is equipped with a feature called Anti-Rolloff. Anti-Rolloff will automatically slow the vehicle if it starts to roll. Anti-Rolloff is active when the key switch has been left in the “ON” position and the accelerator pedal is not depressed. Anti-Rolloff is deactivated when the key switch is in the “OFF”...

  • Page 170: Test 9. Electric Motor Brake

    Electrical Troubleshooting Test 9. ELECTRIC MOTOR BRAKE Description: The electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what times the brake is applied or released is dependent on the controller programing and will vary depending on the model vehicle.
  • Page 171 Electrical Troubleshooting Connect a volt meter across the Violet/Black wire at the electric brake harness plug and Pin #9 at the logic card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts after about 0.5 seconds. If the test is good then: •...

  • Page 172: Logic Voltage Reference Table

    Electrical Troubleshooting Logic Voltage Reference Table Pin# Condition Volts* Key switch off 0.0 volts Key switch on Battery volts F&R in forward F&R in neutral High F&R in reverse F&R in reverse F&R in neutral High F&R in forward Accelerator pedal up High Accelerator pedal down Seat switch closed (depressed)

  • Page 173: Status Led Code Table

    Electrical Troubleshooting Status LED Code Table The status LED on the Sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component.

  • Page 174: Smart View Fault Codes

    Electrical Troubleshooting Smart View Fault Codes Level 5 Faults (F05xxx) Level 4 Faults (F04xxx) F05000 “Contactor Over Current” F04001: “Contactor Welded” High voltage at power up to the controller B+ terminal. This faut occurs when too much current is going into Check wiring, contactor, and pre-charge resistor on the the line contactor coil circuit.
  • Page 175 Electrical Troubleshooting Level 2 Faults (F02xxx) Level 1 Faults (F01xxx) F02000: “Accelerator” Most Level 1 faults are a result of operator error or Wiring to throttle module is open or faulty throttle operation of the vehicle. module. F01000: “Power Steer Overheat” F02001: “Accelerator (power up)”...

  • Page 177: Operating Instructions And Theory Of Operation

    ® Lestronic II Charger Troubleshooting 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 178: 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 179: 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 180: 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 181: 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 182 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 183 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 184: 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 185: 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 186: 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 187: Important Notes And Instructions

    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 188: 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 189 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 190 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 191 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 192 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 193: Illustrated Parts

    Illustrated Parts TABLE OF CONTENTS Steering Knuckle ......... 2 Front Brakes ..........4 Steering Linkage ......... 6 Steering Column ......... 8 Steering Gear ..........10 Front Suspension ........12 Wheels and Tires ........12 Transmission Gear Case ......14 Rear Axle ............ 16 Transmission Differential Case ....

  • Page 194: Steering Knuckle

    Illustrated Parts Steering Knuckle Parts Page 2...
  • Page 195 Illustrated Parts Steering Knuckle ITEM # PART # DESCRIPTION 15-210-70 Axle beam 88-239-86 3/4-NF Hex nylon lock nut 88-228-60 3/4 Cut Flat Washer 98-603-07 Rubber Bushing 01-220-99 Washer 32-240-44 Bushing 32-240-43 Bushing 80-309-12 Thrust Bearing 45-338-00 Grease Seal 80-017-00 Tapered Bearing 80-103-00 Tapered Bearing Race 12-158-10...

  • Page 196: Front Brakes

    Illustrated Parts Front Brakes Brake body (#9 above) Parts Page 4...

  • Page 197: Front Brake

    Illustrated Parts Front Brake ITEM # PART # DESCRIPTION 88-067-21 Bolt, 1/4 X 3-3/4" NC, Hex Head, Gr. 8 41-350-51 Plate, Secondary, Hydraulic Disc 41-348-70 Pad, Disc Brake 41-348-57 Spacer, Disc Brake 32-240-41 Bearing Teflon Coated 99-588-00 Bleeder screw 99-588-01 Bleeder screw adapter 88-069-82 Locknut, 1/4"...

  • Page 198: Steering Linkage

    Illustrated Parts Steering Linkage Parts Page 6...
  • Page 199 Illustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 18-057-00 Tie rod 86-510-00 Ball joing clamp 86-501-98 Ball joing (left) 86-501-99 Ball joint (right) 88-527-11 1/8 x 1 Cotter pin K1-157-99 Drag link 88-159-85 1/2NF Castle nut 18-104-00 Pitman arm Parts Page 7...

  • Page 200: Steering Column

    Illustrated Parts Steering Column The steering column is an integral part of the frame and is not shown. Part ID# 5 is located in the top of the steering column tube. Ref., Steering Gear Parts Page 8...
  • Page 201 Illustrated Parts Steering Column ITEM # PART # DESCRIPTION 88-199-82 5/8NF Hex nut 19-011-20 Steering wheel 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 88-089-84 5/16NF Hex lock nut, grade C 32-248-10 Upper bushing 20-031-65 Steering shaft assembly (incl. 3 and 4) 19-011-25 Steering wheel cap 88-128-62...

  • Page 202: Steering Gear

    Illustrated Parts Steering Gear Exploded Steering Gear.dwg Parts Page 10...
  • Page 203 Illustrated Parts Steering Gear 18-308-21 ITEM # PART # DESCRIPTION 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assenbly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft 18-308-81 Lock washer 18-308-79 Seal, input shaft 18-308-82...

  • Page 204: Front Suspension

    Illustrated Parts Front Suspension Front axle (ref) Wheels and Tires Illustration not available Parts Page 12...

  • Page 205: Front Suspension

    Illustrated Parts Front Suspension ITEM # PART # DESCRIPTION 96-121-00 U-bolt 85-486-00 Leaf spring 32-214-50 Bushing 96-240-00 1/2NC x 4 Hex bolt 88-149-81 1/2NC Lock nut 88-149-81 1/2NC Lock nut 16-872-00 Spring hanger Wheels and Tires ITEM # PART # DESCRIPTION K4T-600X9-EL Tire/Wheel assembly, SOFTUFF 600X9...

  • Page 206: Transmission Gear Case

    Illustrated Parts Transmission Gear Case Parts Page 14...
  • Page 207 Illustrated Parts Transmission Gear Case ITEM # PART # DESCRIPTION GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287533 Input shaft, 18:1 GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing GT-3287493 Idler gear GT-70302 M10 x 30 Bolt GT-71715 Snap ring GT-3287553...

  • Page 208: Rear Axle

    Illustrated Parts Rear Axle Outer Bearing Inner Bearing (no o-ring) Axle Shaft O-Ring O-Ring Groove Inner bearing on optional double bearing axle does not have an oil seal or o-ring. Orientation of bearing should have o-ring groove adjacent to o-ring on outer bearing.
  • Page 209 Illustrated Parts Rear Axle ITEM # PART # DESCRIPTION 41-154-25 Axle shaft, 80-505-20 Bearing 80-505-30 Bearing 41-490-11 Disc brake rotor 41-172-21 88-268-63 Flat washer 88-268-30 7/8-14 x 1.5 Bolt, grade 5 96-329-10 Wheel stud 92-104-10 Hub cover 41-290-78 Axle housing (L) Not shown 41-290-79 Axle housing (R)

  • Page 210: Rear Brakes

    Illustrated Parts Rear Brakes Brake body (#8 above) Parts Page 18...
  • Page 211 Illustrated Parts Rear Brakes ITEM # PART # DESCRIPTION 88-067-21 Hex bolt, grade 8 41-350-51 Secondary plate 41-348-70 Brake pad 41-348-57 Spacer 32-240-41 Bushing 41-350-28 Mounting bracket See Rear Axle Hex bolt with thread locking compund Brake body assembly (see below for components) 88-840-11 Retaining ring 99-588-00...

  • Page 212: Master Cylinder

    Illustrated Parts Master Cylinder Brake linkage Linkage at the brake caliper Parts Page 20...
  • Page 213 Illustrated Parts Dual Reservoir Master Cylinder ITEM # PART # DESCRIPTION 88-080-14 Bolt, 5/16" X 1-1/2" NC, Hex Head 99-511-20 Master Cylinder (includes item #3) 99-511-52 Cap Seal, Master Cylinder 99-511-53 Cap, Master Cylinder 88-088-61 Washer, 5/16" 88-089-81 Locknut, 5/16" Not Shown 99-510-51 Rubber Boot, Master Cylinder...

  • Page 214: Brake Lines

    Illustrated Parts Brake Lines Parts Page 22...
  • Page 215 Illustrated Parts Brake Lines with Dual Reservoir Master Cylinder ITEM# PART # DESCRIPTION 99-648-54 Brake Line, Front K54-700-01 Brake Line, Rear 99-648-57 Brake Line, Front Right 99-648-56 Brake Line, Rear, 99-604-57 Brake Line, Rear Right, 99-604-56 Brake Line, Rear Left, 99-580-20 Brake Hose, Rear 99-580-10...

  • Page 216: Rear Suspension

    Illustrated Parts Rear Suspension View from rear Parts Page 24...
  • Page 217 Illustrated Parts Rear Suspension ITEM # PART # DESCRIPTION 96-240-00 1/2NC x 4 Spring bolt (front of the leaf spring) Not shown 32-214-50 Spring bushing (front of the leaf spring) 85-510-17 Leaf spring 16-861-40 Spring mounting plate (left) 16-861-41 Spring mounting plate (right) 96-114-00 U-bolt 88-159-84...

  • Page 218: Motor

    Illustrated Parts Motor Rear Motor Mount Parts Page 26...
  • Page 219 Illustrated Parts Motor 70-057-40 (DV1-4003) ITEM # PART # DESCRIPTION 70-421-10 Front housing 70-400-10 Armature 70-209-40 Field assembly 85-403-00 Brush spring 70-173-00 Brush holder 70-170-10 Brush 70-417-00 Bearing retainer 80-212-00 Bearing 70-421-30 Rear housing 70-421-40 Brush cover 95-930-00 Dust cap 88-067-17 1-1/8"...

  • Page 220: Instrument Panel (Dash)

    Illustrated Parts Instrument Panel (dash) Parts Page 28...

  • Page 221: Resetting The Smart View Display

    The Smart View Display will only work with the Sevcon control system. 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 222: Speed Control Panel

    Illustrated Parts Speed Control Panel Components located under the driver seat cushion Parts Page 30...
  • Page 223 Illustrated Parts Speed Control Panel ITEM # PART # DESCRIPTION 62-400-15* Speed controller, 500 Amp K54-300-01 Mounting panel 73-004-20 Horn 79-844-20 Main circuit breaker 71-300-02 Line contactor 71-300-01 Mounting bracket 88-838-06 #14 x 1/2 Sheet metal screw 88-060-13 1/4 X 1-1/4 NC HEX HD SCR 88-068-61 1/4 SAE WASHER 88-069-81...

  • Page 224: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical Accelerator Module Seat Frame Motion Alarms Seat Interlock Switch Miscellaneous Wire Harness Clamps Parts Page 32...
  • Page 225 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION 75-152-82 Chassie Control Harness 75-152-13 Control panel harness K54-300-00 Power Harness Not Shown 75-152-83 Dash harness 98-599-15 Plastic grommet for 1.75 hole 98-599-20 Plastic Grommet for 2.5 hole 75-152-90 Harness, Smart View display 73-012-30 DC-DC converter 73-005-26...

  • Page 226: Signet® Charger

    Illustrated Parts Signet® Charger NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector Parts Page 34...
  • Page 227 Illustrated Parts Signet® Charger ITEM # PART # DESCRIPTION 79-309-40 Charger, 48 volt Replacement cover with AC cord and gasket 79-851-10 Ammeter K7-145-29 AC cord K4-081-78 AC Receptacle Note: Ther are no user serviceable components inside the charger. * - Not available at time of printing AC wire connections on PC board Parts Page 35...

  • Page 228: Batteries Roll Out Battery Box

    Illustrated Parts Batteries Roll Out Battery Box Main Positive Main Negative 12 Volt Negative tap Parts Page 36...

  • Page 229: Roll Out Battery Box

    Illustrated Parts Batteries ITEM # PART # DESCRIPTION 75-237-00 Battery jumper, 9" long K1-153-99 Battery jumper, 18" long 77-052-00 Battery, 8-volt, 165AH 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 Quantities depend on voltage configuration of vehicle.

  • Page 230: Lighting

    Illustrated Parts Lighting Illustration not available Head and Tail Lights ITEM # PART # DESCRIPTION K4L-000-00 Headlight (includes 2 headlights) 72-022-00 Tail light 1 or 2 72-022-51 Tail ligh rubber grommet 1 or 2 72-022-52 Tail light pigtail Seat Cushions Illustration not available Seat Cushions ITEM #...

  • Page 231: Miscellaneous

    Illustrated Parts Miscellaneous Illustration not available Miscellaneous ITEM # PART # DESCRIPTION 98-200-00 Braked pedal pad 71-040-95 Compartment lock 01-110-20 Accelerator pedal Parts Page 39...

  • Page 233: Appendix A-Special Tools

    APPENDIX A-Special Tools...

  • Page 234: Special Tools

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

  • Page 235: Hardware Identification

    Appendix B: Standard Hardware Suggested Torque Limits TABLE OF CONTENTS Hardware Identification ......... 2 Standard Head Markings ......... 2 Hex Bolts ..............2 Other Bolts ............... 2 Hex Nuts ..............3 Hex Lock Nuts (stover) ..........3 Other Nuts ..............3 Suggested Torque Values (non-critical hardware) ......

  • Page 236: Hardware Identification

    Appendix B HARDWARE IDENTIFICATION Standard Head Markings NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. NOTE: Toque values specified are for clean dry threads. Hex Bolts S.A.E.

  • Page 237: Hex Nuts

    ‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’. NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts ® Other nuts used by Taylor-Dunn should be treated as S.A.E. grade A Appendix B Page-3...

  • Page 238: Suggested Torque Values

    Appendix B SUGGESTED TORQUE VALUES (non-critical hardware) Diameter Grade 2 Grade 5 Grade 8 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque (ft-lb) (ft-lb) (ft-lb) (ft-lb) 1/4-20 7-10 10-14 1/4-28 8-12 11-16 5/16-18 9-14 14-21 20-29 5/16-24 10-15 15-23 22-33 3/8-16...

  • Page 239: Suggested Torque Values

    Appendix B SUGGESTED TORQUE VALUES (critical hardware) Torque Table Torque Range Group Description Ft-Lbs In-Lbs Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132...
  • Page 240 Appendix B ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...

  • Page 241: Appendix C

    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 242 Model B 1-00...
  • Page 244 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Mailing Address: P.O. Box 4240 Anaheim, California 92803 Visit our Website: www.taylor-dunn.com...

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