Taylor-Dunn C0-425-36 Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual
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Taylor-Dunn C0-425-36 Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual

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Models Inlcuded:
C0-425-36 (C 4-25-36)
C0-425-48 (C 4-25-48)
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 MC-425-02
Operation, Troubleshooting and
Replacement Parts Manual
Revision: C
Serial number Starting: 150774

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Summary of Contents for Taylor-Dunn C0-425-36

  • Page 1 Models Inlcuded: C0-425-36 (C 4-25-36) C0-425-48 (C 4-25-48) 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 MC-425-02...
  • Page 3 Address inquiries to Reference Permissions, Taylor-Dunn Mfg., 2114 W. Ball Road, Anaheim, CA 92804 ® TAYLOR-DUNN SERVICE CENTER For more information about this and other Taylor-Dunn manuals, please write Taylor-Dunn ® ® Taylor-Dunn Mfg.
  • Page 4 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...

  • Page 5: 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 General Maintenance ..........1 Maintenance Guidelines ............2 Maintenance Guidelines for Vehicles Used in Severe Conditions ..............3 Troubleshooting Guide ............. 4 Lubrication Chart ..............5 Front Axle Service ............1 Inspect the Front Wheel Bearings and King Pin ....2 Adjust Front Wheel Bearings ..........
  • 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 ...................... 4 Adjust the Service Brakes ............5 Two or Four Wheel Hydraulic Disc Brakes ..............5 Adjust the Brake Linkage ............
  • Page 8 Table of Contents Disassembly and Reassembly of the Primary Reduction Gear Case ..........10 Disassembling the 3rd Member ..........13 Assembling the 3rd Member ............ 16 Pinion Bearing Preload ....................19 Pinion Gear Shimming Instructions ........20 Setting the Pinion Gear Depth ................... 20 Suspension ...............1 Replace the Rear Springs ............
  • Page 9 Table of Contents Wire Diagrams............1 Dash ................... 2 Control Panel ................3 Illustrated Parts ............1 Front Axle, Steering and Brakes ......2 Steering Column ..........4 Steering Gear ............ 6 Front Suspension ..........8 Transmission Assembly ........10 Transmission Gear Case ........

  • Page 11: Introduction

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

  • Page 12: About This Manual

    ® 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 has made every effort to include as much information as possible about the operation and maintenance of this vehicle.

  • Page 13: Who Should Read This Manual

    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

    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 Tow Tractor .... 2 Vehicle Operational Guidelines..... 13 Safety Rules and Guidelines ......3 Safety Guidelines ............ 13 Starting: ..............13 Driver Training Program ........ 4 While driving: ............14 Driver Qualifications.

  • Page 20: Standard Specifications Tow Tractor

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS TOW TRACTOR ITEM Volts SPECIFICATION Occupancy Driver only, no passengers Dimensions 1994 L x 965 W x 1422 H Millimeters 78.50 L x 38.00 W x 56.00 H Inches Turning Radius 1752 Millimeters (69 inches) Dry Weight (Without Battery) 748 kg (1650 lbs) Battery Compartment Dimensions...

  • 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 while also obeying he following safety rules and guidelines (reference American National Standards Institute Operator Controlled Industrial Tow Tractors ANSI B56.9).

  • 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: Key-Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS 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” position whenever the operator leaves the vehicle.

  • Page 24: Hi-Low Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS Hi-Low Switch The high-low switch is located on the lower left of the instrument panel. Push on the left side of the switch (turtle) for slow speed. Push on the right side of the switch (rabbit) for normal speed. 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: Steering

    SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter- clockwise. If equipped with tilt steering, the release lever is located on the lower left of the steering column.

  • Page 26: Accelerator Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS Accelerator Pedal The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.

  • Page 27: Reverse Or Motion Alarm (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Seat Interlock Switch A switch located under the driver's seat disables the power to the vehicle when the driver leaves the seat. The driver must be seated for the vehicle to operate. Whenever the driver leaves the vehicle, the driver should turn the key-switch off, place the forward-off-reverse switch in the center “OFF”...

  • Page 28: 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 29 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 30 SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance monitor: 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 31: Vehicle Operational Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines • Only qualified and trained operators may drive this vehicle. • Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees). • Drive slowly when making a turn, especially if the ground is wet or when driving on an incline.

  • Page 32: 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 33: 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 34: Periodic Maintenance Checklist

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

  • Page 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 Maintenance Guidelines for Vehicles Used in Severe Conditions ........3 Troubleshooting Guide ........ 4 Lubrication Chart .......... 5...

  • 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: Maintenance Guidelines For Vehicles Used In Severe Conditions

    Maintenance, Service and Repair MAINTENANCE GUIDELINES FOR VEHICLES USED IN SEVERE CONDITIONS If this vehicle is operated in severe conditions all maintenance items listed in the Periodic Maintenance Table should be carried out twice as often as stated. In addition, the entire vehicle should be inspected monthly for signs of damage.

  • Page 40: 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 41: Lubrication Chart

    Maintenance, Service and Repair LUBRICATION CHART Front end (from bottom) GT Drive, center section Description Locations Lubricant Type King Pin General Purpose Grease Ball Joints General Purpose Grease Idler Pivot General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease Drive Drain Plug SAE 80W90 Hypoid Gear Oil Drive Level Plug...
  • Page 42 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 43: 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: 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 50 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 battery connector. 17.

  • Page 51: Replace The King Pins And Bushings

    Maintenance, Service, and Repair REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle. • Bronze bushings in the axle beam. • Bronze bushings in the steering knuckle. • Metal backed teflon bushings in the axle beam.

  • Page 52: Replace The Pivot Pin And Bushings

    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 or steering knuckle. 9.

  • Page 53: 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 54 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. Upper arm of axle beam 15.

  • Page 55: Steering Component Service

    Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Inspect Ball Joints .......... 5 Adjust the Steering Gear (Saginaw) ..... 6 Replace the Tilt Steering Assembly ....8 Steering Column ..........9 Disassemble ............9 Assemble .............. 10 Replace the Steering Gear ......

  • Page 56: Front End Alignment

    Maintenance, Service, and Repair FRONT END ALIGNMENT Inspection, Axle Centers 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 57 Maintenance, Service, and Repair Center the Wheels 9. Center the steering gear and tie it off so that it cannot rotate. Center the Steering Gear NOTE: Refer to section for information regarding centering of the steering gear. Do not drive the vehicle while the steering wheel or front wheels are tied in position.
  • Page 58 Maintenance, Service, and Repair 19. Adjust the left side tie rod so that the distance at the front and rear of the tires is the same. 20. Position the ball joint clamps as shown and tighten Clamp to 28-32 ft lbs. LEFT RIGHT FORWARD...

  • Page 59: 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 60: Adjust The Steering Gear (Saginaw)

    Maintenance, Service, and Repair ADJUST THE STEERING GEAR (SAGINAW) 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.
  • Page 61 Maintenance, Service, and Repair 12. Find the center position of the steering shaft: A. Turn the steering shaft all of the way in one direction. B. While counting the rotations, turn the steering shaft all of the way in the opposite direction. C.

  • Page 62: Replace The Tilt Steering Assembly

    Maintenance, Service, and Repair REPLACE THE TILT STEERING ASSEMBLY 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 63: Steering Column

    Maintenance, Service, and Repair STEERING COLUMN NOTE: The steering column does not have to be removed from the vehicle unless the lower steering shaft Replace the Tilt Steering Assembly or bushing is to be replaced. Refer to section for information regarding removing the steering column.

  • Page 64: Assemble

    Maintenance, Service, and Repair 12. Depress and turn the tilt spring about 30º and remove the retainer, tilt spring and the spring guide. 13. Thread an 8-32 machine screw into the pivot pins and pull them out. 14. Install the tilt lever and pull it up to release the tilt housing from the column. 15.

  • 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: Center The Steering Gear

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

  • Page 67: Replace The Ball Joints, Tie Rods, And Drag Link

    Maintenance, Service, and Repair REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK NOTE: If a rod end or ball joint is worn out, we recommend replacing all of the ball joints and/or rod ends as a set. Replacing a Ball Joint 1.

  • Page 68: Replacing The Drag Link

    Maintenance, Service, and Repair Replacing the Drag Link The Drag Link is the linkage that connects the steering gear pitman arm to the steering knuckle. Refer to the illustration on the following page. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 69: Replacing The Tie Rod

    Maintenance, Service, and Repair Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together. Refer to the illustration on the following page. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 70: 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 71 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 72 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 73: Exploded View Of Steering Gear

    Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 19...

  • 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 ............. 4 Adjust the Service Brakes ......5 Two or Four Wheel Hydraulic Disc Brakes ....5 Adjust the Brake Linkage ......

  • 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 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: 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 80 Maintenance, Service, and Repair 8. Tight the brake pedal pivot bolt so that the brake pedal moves freely with no side play. 9. Reconnect the main battery connector. 10. Remove blocks from behind the wheels. 11. Release the park brake and test drive the vehicle. Brakes Page 6...

  • Page 81: 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 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 Brakes

    Maintenance, Service, and Repair BLEED THE BRAKES Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing and a face shield when working with or around brake fluid. SKIN CONTACT Flush area immediately with water for several minutes. If a rash or skin irritation develops, get medical attention immediately.
  • Page 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

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

  • Page 87: Replace Front Brake Pads

    REPLACE FRONT BRAKE PADS NOTE: It is recommended that both the left and right brake pads be replaced as a set. Current Taylor-Dunn brakes are asbestos free. However, there is ® the possibility that the original brakes were replaced with aftermarket parts containing asbestos.
  • Page 88 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 89: 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 90 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 91: 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 92 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 93: 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 94 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 95: 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 96 Maintenance, Service, and Repair 10. Install in reverse order. 11. Fill the master cylinder with brake fluid from a sealed Plunger container. 12. Pump the brake pedal a short distance of one to two inches until no bubbles are seen coming from the inlet ports inside of the master cylinder chamber.

  • Page 97: 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 99: Throttle Linkage

    Throttle Linkage TABLE OF CONTENTS Throttle Linkage Adjustments ...... 2...

  • Page 100: Throttle Linkage Adjustments

    Maintenance, Service, and Repair THROTTLE LINKAGE ADJUSTMENTS 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 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: Inspecting The Motor Brushes

    Motor Service INSPECTING THE MOTOR BRUSHES Motors with internal cooling fans NOTE: There are four brushes in the motor. The brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time.

  • Page 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 t a t r e t t s i c i f i t a ) n i ) n i º 5 Motor Page 10...
  • Page 111 Transmission TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor Removal and Installation ....4 Rear Hub or Rotor ......... 5 Removing and Installing the Rear Axles ..6 Transmission Assembly ....... 8 Remove and Install ........... 8 Disassembly and Reassembly of the Primary Reduction Gear Case ......

  • 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. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 116: Removing And Installing The Rear Axles

    Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange.
  • Page 117 Maintenance, Service, and Repair 11. Remove the axle retaining plate and brake body assembly as one unit. 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14.

  • Page 118: Transmission Assembly

    Maintenance, Service, and Repair TRANSMISSION ASSEMBLY Remove and Install 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 119 Maintenance, Service, and Repair 9. Remove the nuts from the rear suspension bushing bolts. 10. Raise the rear of the vehicle and support with jack stands. NOTE: Do not raise the vehicle so high to where the rear wheels come off of the ground.

  • Page 120: Disassembly And Reassembly Of The Primary Reduction Gear Case

    Maintenance, Service, and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.
  • Page 121 Maintenance, Service, and Repair 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/ bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the pinion shaft.
  • Page 122 Maintenance, Service, and Repair Lubricate all parts with gear oil before installation. Failure to pre- lube the parts may result in premature failure. 19. Assemble the gear case in reverse order. NOTE: Torque the drain plug to 21-25 foot-pounds. NOTE: Torque the gear case to 3rd member retaining bolts to 18-20 foot- pounds.

  • Page 123: Disassembling The 3Rd Member

    Maintenance, Service, and Repair DISASSEMBLING THE 3RD MEMBER 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 124 Maintenance, Service, and Repair 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race from the side plate. 15. Remove the differential assembly from the 3rd member housing.
  • Page 125 Maintenance, Service, and Repair 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the front bearing from the input shaft. NOTE: The input shaft may have to be driven out to perform this procedure. 19. Remove the input shaft’s shims and spacer. 20.

  • Page 126: Assembling The 3Rd Member

    Maintenance, Service, and Repair ASSEMBLING THE 3RD MEMBER 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. Cover Housing 3. Install the carrier bearing races into the housing and cover. Cover Housing 4.
  • Page 127 Maintenance, Service, and Repair 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. If the ring and pinion gears or bearings are replaced then the pinion gear must be re-shimmed.
  • Page 128 Maintenance, Service, and Repair 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the vehicle.

  • Page 129: Pinion Bearing Preload

    Maintenance, Service, and Repair Pinion Bearing Preload NOTE: The pinion gear depth must be set before the preload. Refer to Setting the Pinion Gear Depth 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3.

  • Page 130: Pinion Gear Shimming Instructions

    Maintenance, Service, and Repair PINION GEAR SHIMMING INSTRUCTIONS NOTE: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. NOTE: To perform this procedure, all parts must be clean and the bearings lightly lubricated.
  • Page 131 Maintenance, Service, and Repair NOTE: Values shown are for reference only Transmission Page 21...

  • Page 133: Suspension

    Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Replace the Front Springs ......3 Replace the Shocks ........4 Front or Rear ............4...

  • Page 134: Replace The Rear Springs

    Maintenance, Service, and Repair REPLACE THE REAR SPRINGS If a spring has failed or is fatigued, then it is recommended that both springs are replaced as a set. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 135: 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 springs are replaced as a set. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 136: Replace The Shocks

    Maintenance, Service, and Repair REPLACE THE SHOCKS Front or Rear It is recommended to replace all four front shock as a set. NOTE: On some vehicles it may be required to remove the wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the wheels.
  • Page 137 Tires and Wheels TABLE OF CONTENTS Tire Inflation ........... 2 Tire Inspection ..........2 Replace the Rear 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 Rear 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 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 TABLE OF CONTENTS Test Equipment Required: ...... 2 Important Notes and Instructions ... 2 Definitions: ..........2 Terminology used: ........2 Start Troubleshooting Here ....3 Test 8. Anti-Rolloff Fault ......22 Test 9. Electric Motor Brake ....23 Sevcon Logic Voltage Reference Table ...

  • Page 156: Test Equipment Required

    Electrical Troubleshooting Test Equipment Required: • Digital multimeter (DMM) with diode test function, FLUKE 79 model shown. • Test harness, Taylor-Dunn #75-089-00 Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests, and diode testing.

  • Page 157: Start Troubleshooting Here

    Electrical Troubleshooting START TROUBLESHOOTING HERE This troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results.
  • Page 158 Electrical Troubleshooting Test 1. CHECKING THE CONTROL LOGIC INPUTS Close the seat switch. Place the high/low switch in the HIGH position. Connect a voltmeter across the ISO solenoid coil terminals and carefully monitor the voltage as the key switch is turned on. Turn the key switch ON and wait 1-second until the Isolator contactor closes.
  • Page 159 Electrical Troubleshooting TEST 1.3: Test the voltage at pin #6 on the 12-pin logic card connector. If the voltage is low, then skip ahead to test #1.4. If the voltage is high, then check the wire to the High/Low switch and the High/Low switch for open circuits.
  • Page 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 #6. TEST 1.6: Test the voltage at pin #7 on the 12-pin logic card connector.
  • Page 161 Electrical Troubleshooting TEST 1.7: Depress the accelerator pedal to engage FS-1 only (creep speed). Perform the following tests: Test the voltage at pin #10 on the 12-pin logic card connector. If the voltage is below 0.3 volts, then skip ahead to test #1.8.
  • Page 162 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 163 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 164 Electrical Troubleshooting Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3.1: Close the seat switch, turn the key switch ON and wait 1-second until the Isolator contactor closes. If the vehicle runs in reverse only then skip ahead to test #3.3.
  • Page 165 Electrical Troubleshooting TEST 3.3: Place the forward and reverse switch in the REVERSE direction. Test the voltage at pin #3 on the 12 pin logic card connector. If the voltage is low, then skip ahead to test #3.4. If the voltage is high, then skip ahead to Test #7. TEST 3.4: Test the voltage at pin #2 on the 12 pin logic card connector.
  • Page 166 Stop, do not continue. Reaching this point indicates an unanticipated failure or an error was made during testing. Confirm all previous tests were performed correctly and contact ® your Taylor-Dunn represetative for assistatnce. After any repairs are made, completely retest the vehicle before lowering the drive wheels to the ground.
  • Page 167 Electrical Troubleshooting Test 4. KEY FAULT TEST 4.1: Turn the key switch ON and place the forward and reverse switch in the center OFF position Perform the following tests: Test the voltage at pin #1 on the 12 pin logic card connector.
  • Page 168 Electrical Troubleshooting TEST 4.3: Test the voltage at the cold side (violet/black wire) of the key switch. If the voltage equals battery volts, then skip ahead to test #4.4. If the voltage does not equal battery volts, then replace the key switch. Stop trouble shooting here and repair the problem.
  • Page 169 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 170 Electrical Troubleshooting B+ Terminal on the Sevcon controller Shorted Solenoid Coil: Disconnect the logic card connector and measure the resistance across the solenoid coil. Depending on the solenoid or contactor you vehicle is equipped with, the resistance should be 25 ohms or higher (nominal). A reading less than 25 ohms may indicate a shorted coil.
  • Page 171 Electrical Troubleshooting Test 6. ACCELERATOR MODULE FAULT Disconnect the truck harness from the accelerator module. Connect the plug on the short end of the 75-089-00 test harness to the accelerator module. Connect the receptacle on the short end of the test harness to the vehicles control harness. The long end of the harness will be used for testing.
  • Page 172 Electrical Troubleshooting TEST 6.2: Accelerator pedal released. Test the voltage from pin #9 to pin #8. If the voltage equals battery volts, then skip ahead to test #6.3. If the voltage does not equal battery volts, then check the wire from pin #8 to the key switch. Stop trouble shooting here and repair the problem.
  • Page 173 Electrical Troubleshooting TEST 6.5a: Test the voltage from pin #5 to pin #8. Accelerator pedal released. If the voltage is low then skip ahead to test 6.5b. If the voltage is high then then the module has failed. Stop trouble shooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground.
  • Page 174 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 175 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 176 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 177 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 178 Electrical Troubleshooting Connect a volt meter from battery negative to the Violet/Black wire at the electric brake harness plug. If the voltage is less than battery volts then: • Check wiring to the key switch and continue troubleshooting at test #4.2. If the voltage equals battery volts then: Connect a volt meter across the Violet/Black wire and the Blue wire at the electric brake harness plug.
  • Page 179 Electrical Troubleshooting Sevcon Logic Voltage Reference Table Pin# Condition Volts* Key switch off 0.0 volts Key switch on Battery volts F&R in forward F&R in neutral High F&R in reverse F&R in reverse F&R in neutral High F&R in forward Accelerator pedal up High Accelerator pedal down...

  • Page 180: 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 181 Charger Troubleshooting The charger supplied with this vehicle is either specified or provided by the end user. Refer to the documentation supplied with the charger or contact the charger manufacturer for more information. Turn the Key switch OFF BEFORE disconnecting the batteries. Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 (refer to fault table).
  • Page 183 Wire Diagrams TABLE OF CONTENTS Dash ..............2 Control Panel ..........3...
  • Page 184 Wire Diagrams DASH Brown Brown Red/Black Red/Black Red/Black Violet/Black Blue/White Violet/Black Violet/Black Black Violet/Black Green/Black Black Red/Black Black Wire Diagrams Page 2...

  • Page 185: Control Panel

    Wire Diagrams CONTROL PANEL Yellow Green MOTOR Blue White CONNECTOR #2 200A CB Black Violet MAIN BATTERY 48v CB DISCONNECT (if equipped) Black/White ISO NEG White/Black REVERSE-1 Blue/Black FORWARD Gray/black Green/Black Yellow/Blk Yellow/Blk Black HANDBRAKE White/Black Red/White SEATSWITCH Blue/Black CONNECTOR #3 Gray/Black Violet/Black Green/Black...
  • Page 187 Illustrated Parts TABLE OF CONTENTS Front Axle, Steering and Brakes ....2 Brake linkage (foot brake) ......28 Steering Column ......... 4 Throttle linkage ........... 30 Steering Gear ..........6 Wheels and Tires ........32 Front Suspension ........8 Instrument Panel (dash) ......34 Transmission Assembly .......

  • Page 188: Front Axle, Steering And Brakes

    Illustrated Parts Front Axle, Steering and Brakes Illustrated Parts Page 2...
  • Page 189 Illustrated Parts Front Axle, Steering and Brakes ITEM # PART # DESCRIPTION 92-104-014 Bearing cap 88-527-14 Cotter pin 88-239-85 3/4 NF Hex slotted nut 88-228-61 3/4 SAE Flat washer 80-017-00 Bearing 12-158-10 Wheel hub 80-103-00 Race 88-268-61 7/8 Flat washer 45-338-00 Grease seal 21-015-15...

  • Page 190: Steering Column

    Illustrated Parts Steering Column Use LockTite on mounting hardware Illustrated Parts Page 4...
  • Page 191 Illustrated Parts Steering Column ITEM # PART # DESCRIPTION 18-414-32 Tilt steering column assembly 19-005-17 Stereing wheel 88-279-82 7/8 NF Thin pattern hex nut 88-262-62 7/8 Split lock washer 18-108-00 Pitman arm 18-308-21 Steering gear 88-128-62 7/16 Split lock washer 88-120-15 7/16 NC x 1-1/2 Hex bolt 18-308-04...

  • Page 192: Steering Gear

    Illustrated Parts Steering Gear Illustrated Parts Page 6...
  • Page 193 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 194: Front Suspension

    Illustrated Parts Front Suspension Illustrated Parts Page 8...

  • Page 195: Front Suspension

    Illustrated Parts Front Suspension ITEM # PART # DESCRIPTION 32-214-50 Bushing 00-425-00 Wishbone link 86-521-99 Rod end See Front Axle Axle beam 85-142-00 Spring 96-240-00 1/2 NC x 4 Hex bolt 88-140-22 1/2 NC x 3-1/2 Hex bolt 88-149-81 1/2 NC Lock nut 88-189-82 5/8 NC Then pattern lock nut 88-101-16...

  • Page 196: Transmission Assembly

    Illustrated Parts Transmission Assembly Illustrated Parts Page 10...
  • Page 197 Illustrated Parts Transmission Assembly ITEM # PART # DESCRIPTION 89-113-30 12 x 1.75 x 30mm Hex bolt, class 8.8 89-113-60 12mm Split lock washer 41-290-60 Axle tube 88-099-80 5/16 NF Hex nut 88-088-62 5/16 Split lock washer 88-128-62 7/16 Split lock washer 89-111-27 10 x 1.5 x 30mm Hex bolt 70-456-10...

  • Page 198: Transmission Gear Case

    Illustrated Parts Transmission Gear Case Illustrated Parts Page 12...
  • Page 199 Illustrated Parts Transmission Gear Case ITEM # PART # DESCRIPTION GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1 GT-3287543 Input shaft, 12:1 0 or 1...

  • Page 200: Transmission Differential Case

    Illustrated Parts Transmission Differential Case Rear Axle Illustrated Parts Page 14...
  • Page 201 Illustrated Parts Transmission Differential Case ITEM # PART # DESCRIPTION GT-70302 M10 x 30 Bolt GT-3287183 Ring and pinion gear set GT-3297193 Differential case cover GT-3287133 Adjusting ring GT-70417 Fill/Level plug GT-3287113 Differential housing GT-3287143 Differential case GT-72013 O-ring GT-71896 M10 x 25 Bolt GT-71978 Bearing and race...

  • Page 202: Rear Brakes

    Illustrated Parts Rear Brakes Brake Body Assembly Illustrated Parts Page 16...
  • Page 203 Illustrated Parts Rear Brakes ITEM # PART # DESCRIPTION 88-067-21 1/4 NC x 3-3/4 Hex bolt, grade 8 41-350-51 Secondary plate 41-348-70 Brake pad 41-348-57 Spacer 32-240-41 Bushing 41-350-28 Mounting bracket 96-327-10 3/8 x 3/4 NF Hex bolt, grade 5 with thread locking compound 41-350-68 Brake body assembly 88-840-11...

  • Page 204: Rear Suspension

    Illustrated Parts Rear Suspension Frame Illustrated Parts Page 18...
  • Page 205 Illustrated Parts Rear Suspension ITEM # PART # DESCRIPTION 88-189-82 5/8NC Thin pattern lock nut 88-188-61 5/8 SAE Flat washer 85-142-00 Spring 86-510-00 Ball joint clamp 86-521-98 Rod end (left) 86-521-99 Rod end (right) 88-180-15 5/8NC x 1-3/4 Hex bolt 88-100-15 3/8NC x 1-3/4 Hex bolt 4GT-0261-1211...

  • Page 206: Motor

    Illustrated Parts Motor Master Cylinder Illustrated Parts Page 20...
  • Page 207 Illustrated Parts 70-057-40 Motor Spec # 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 pair 70-417-00 Bearing retainer 80-212-00 Bearing 70-421-30 Rear housing 70-421-40 Brush cover 95-930-00 Dust cap Master Cylinder...
  • Page 208 Illustrated Parts Automatic Electric Brake Illustrated Parts Page 22...
  • Page 209 Illustrated Parts AUTOMATIC ELECTRIC BRAKE ITEM # PART # DESCRIPTION 88-067-22 Bolt,1/4 X 2" NC, Grade (no brake option) 88-067-29 Bolt,1/4 X 4-1/4" NC, Grade 8 (brake option only) 41-355-00 Automatic Electric Brake Unit See Motor Motor (Typical) 96-114-10 U-Bolt, 5/16" NF, Motor Support 70-456-10 Motor, Support Bracket K66-600-03...

  • Page 210: Master Cylinder

    Illustrated Parts Brake Lines Use thread sealant Master Cylinder (ref) Cowl view from rear Illustrated Parts Page 24...
  • Page 211 Illustrated Parts Brake Lines ITEM # PART # DESCRIPTION 99-564-00 T-fitting See front axle Front brake hose 99-576-00 Brake hose clip 99-575-00 Coupler 71-110-00 Brake light switch 99-591-00 Brake light switch adaptor 99-559-00 T-fitting 99-604-66 Brake line 99-600-58 Brake line 99-605-74 Brake line 99-609-57...

  • Page 212: Brake Linkage (Parking Brake)

    Illustrated Parts Brake linkage (parking brake) Cable lock Cable clevis Illustrated Parts Page 26...
  • Page 213 Illustrated Parts Brake Linkage ITEM # PART # DESCRIPTION 96-765-00 Clevis, left hand thread 88-099-81 5/16NF Hex nut, left hand thread 88-099-80 5-16NF Hex nut 96-343-00 Link 96-763-00 Clevis, right hand thread 96-754-00 Clevis 96-773-00 Clevis pin 96-827-17 Brake cable 04-380-08 Equalizer 88-517-11...

  • Page 214: Brake Linkage (Foot Brake)

    Illustrated Parts Brake linkage (foot brake) 8, 23 Illustrated Parts Page 28...
  • Page 215 Illustrated Parts Brake Linkage ITEM # PART # DESCRIPTION 88-108-61 3/8 SAE Flat washer 88-108-62 3/8 Split lock washer 88-101-13 3/8NC x 1-1/4 Hex bolt, Grade 5 88-101-21 3/8NC x 3 Hex bolt 88-140-22 1/2NC x 3 Hex bolt 88-109-81 3/8NC Hex lock nut 88-149-81 1/2NC Hex lock nut...

  • Page 216: Throttle Linkage

    Illustrated Parts Throttle linkage Illustrated Parts Page 30...
  • Page 217 Illustrated Parts Throttle Linkage ITEM # PART # DESCRIPTION 00-425-21 Mounting bracket 00-425-09 Accelerator pedal 01-110-20 Accelerator pedal pad 86-503-98 Rod end, left hand thread 97-211-00 1/4NF Hex nut, left hand thread 86-503-99 Rod end, right hand thread 88-079-80 1/4NF Hex nut 50-002-13 Link 32-215-00...

  • Page 218: Wheels And Tires

    Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) Illustrated Parts Page 32...
  • Page 219 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-020-00 8.5 x 8 Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-076-00 4.80 x 8 LR C Pneumatic 10-250-00 16 x 4 x 12 Solid rubber Split Rim Wheels 12-042-12 Inner Wheel (12-bolt)

  • Page 220: Instrument Panel (Dash)

    Illustrated Parts Instrument Panel (dash) #2 Smart View Display Illustrated Parts Page 34...

  • 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 (4 plcs) Use Heatsink Grease between Controller and Heatsink (4 plcs) Install 94-422-10 (silicon) into harness connectors (2 plcs) Base of 00-425-05 (ref) Install around entire perimeter of lip Illustrated Parts Page 36...
  • Page 223 Illustrated Parts Speed Control Panel ITEM # PART # DESCRIPTION 98-599-20 Grommet 88-838-06 #14 x 1/2 Pan head sheet metal screw 88-818-02 #8 x 1/4 Pan head sheet metal screw 88-818-02 #8 x 1/4 Pan head sheet metal screw 79-844-20 200A Circuit breaker 88-818-06 #8 x 1/2 Pan head sheet metal screw...

  • Page 224: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical 9 - Seat switch Miscellaneous Wire Harness Clamps Horn switch mounted on the dash Illustrated Parts Page 38...
  • Page 225 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION 75-152-42 Chassie Control Harness 75-152-41 Dash Harness 75-152-43 Tail light harness 75-152-40 Control Panel Harness 94-422-10 Dielectric grease for harness connectors Not Shown 75-152-91 Smart view display cable 75-152-44 Power harness 98-599-15 Plastic grommet for 1.75 hole 98-599-20...

  • Page 226: Lighting System

    Illustrated Parts Lighting System Illustrated Parts Page 40...
  • Page 227 Illustrated Parts Lighting System ITEM # PART # DESCRIPTION 72-025-03 Headllight 72-082-01 Head light bulb 72-025-20 Taillight 97-211-15 Tailight mounting screw 88-034-13 Tailight mounting nut Taillight/Brake light bulb (1157) 72-082-00 Back up/Turn signal bulb 72-028-30 Front turn signal 72-028-32 Wiring pigtail for turn signal light 72-028-31 Gromment for turn signal light 71-900-05...

  • Page 228: Seat Cushions And Deck

    Illustrated Parts Seat Cushions and Deck Illustrated Parts Page 42...
  • Page 229 Illustrated Parts Seat Cushions and Deck ITEM # PART # DESCRIPTION 71-124-00 Battery disconnect switch 51-344-80 Park brake handle 95-512-00 Deck handle 90-160-70 Seat assembly 90-160-60 Arm rest kit 00-425-13 Deck cover 90-160-71 Seat spacer 88-080-13 5/16NC x 1-1/4 Hex bolt 88-089-81 5/16NC Lock nut 88-088-60...

  • Page 230: Decals

    Illustrated Parts Decals Illustrated Parts Page 44...
  • Page 231 Illustrated Parts Decals ITEM # PART # DESCRIPTION 94-319-00 Disconnect the battery 94-376-00 Battery disconnect switch 94-373-12 Data plate (decal) 94-373-09 Data plate (metal) 94-313-20 Safety waring 94-313-00 Explosive gases 94-309-00 Park brake warning 94-384-01 Not a motor vehicle 94-384-14 When leaving vehicle 94-301-44 Keep arms and legs inside...

  • Page 232: Frame Components

    Illustrated Parts Frame Components Side Battery Extract Option Illustration not available. Illustrated Parts Page 46...
  • Page 233 Illustrated Parts Frame Components ITEM # PART # DESCRIPTION 00-425-30 Battery cover (not painted) 88-100-14 3/8 x 1-1/2 Hex bolt 88-108-62 3/8 Split lock washer 32-214-50 Bushing 00-425-16 Mounting bracket (not painted) 97-211-30 3/8 blind nut 96-240-00 1/2NC x 4 Hex bolt 88-149-81 1/2NC lock nut 88-089-81...

  • Page 234: Hitches

    Illustrated Parts Front Push Plate Option Hitches Illustrated Parts Page 48...
  • Page 235 Illustrated Parts Front Push Plate Option ITEM # PART # DESCRIPTION 98-757-02 Bumper 00-425-22 Push plate 88-140-16 1/2NC x 2 Hex bolt 88-148-61 1/2 SAE Flat washer 88-149-81 1/2NC Hex lock nut 88-140-22 1/2NC x 3-1/2 Hax bolt Hitches ITEM # PART # DESCRIPTION 97-804-01...

  • Page 236: Batteries

    Illustrated Parts Charger The charger supplied with this vehicle is either specified or provided by the end user. Refer to the documentation supplied with the charger or contact the charger manufacturer for more information. Batteries The battery supplied with this vehicle is either specified or provided by the end user. Refer to the documentation supplied with the battery or contact the battery manufacturer for more information.
  • Page 237 APPENDIX A- Special Tools...

  • Page 238: Special Tools

    Special Tools Special Tools D E S C R I P T I O N P U R P O S E P A R T N U M B E R Used to install the pinion seal on all chain drive trucks Pinion Seal Installation Tool w i t h t h e b a n d s t y l e b r a k e o r t h e s p e e d s e n s o r o n t h e 43-201-50...
  • Page 239 APPENDIX B-Torque Values...

  • Page 240: Torque Values

    Torque Values Recommended Torque Values Chart D ia m e t e r G r a d e 2 G r a d e 5 G r a d e 8 a n d T P I Tightening Tightening Tighte n ing Tightening Torque To rq ue...
  • Page 241 Torque Values Head Markings S.A.E. Grade 2 S.A.E. Grade 5 L’9 S.A.E. Grade 8 L’9 The following bolts are in accordance with Grade 2 torque values Carriage Bolt Truss Head 5/16-18 & 3/8-16 1/4-20 APPENDIX B PAGE 3...
  • Page 243 Appendix C...

  • Page 244: Brake Lining Handling Precautions

    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 246 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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C0-425-38

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