Taylor-Dunn B0-T48-48 Taylor Truck T48, Manual

Page 1: ...The Best Way To Go About Your B u s i n e s s Serial Number 171239 MANUAL MB T48 99 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 T48 48 Revision A...

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Page 3: ...nn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or...

Page 4: ...B2 48 With Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor...

Page 5: ...Visual inspection 15 Maintenance Guidelines for Severe Duty Applications 15 General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Front Axle Service Inspect the Fron...

Page 6: ...le Test 6 Lestronic II Charger Troubleshooting Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructi...

Page 7: ...t 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 B 2 48 and B 2 54 6 BT 2 48 7 BT 2 80 7 Taking Delivery of Your V...

Page 8: ...de Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules and Gui...

Page 9: ...of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible fo...

Page 10: ...to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific inform...

Page 11: ...treme care while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure to exe...

Page 12: ...es as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 Theese ve...

Page 13: ...result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also...

Page 14: ...TAYLOR DUNN...

Page 15: ...dal 7 Steering 7 Directional Signals Optional 7 Hazard Light Switch Optional 7 Charger Interlock 8 Seat Interlock Switch 8 Electrolyte Alarm Optional 8 Vehicle Operational Guidelines 9 Safety Guidelin...

Page 16: ...Built In 25 Amp DC 230 VAC 60 Hertz 13 Amps Occupancy 4 Passenger Electrical System 12 244 Amp Hour 6 Volt Lead Acid Batteries 550 Amp Solid State Self Diagnostic AC Speed Control Dimensions 259 7 L...

Page 17: ...w this vehicle at more than 5 mph 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 character...

Page 18: ...ual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive...

Page 19: ...top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT SWITCH from forward to reverse or vice versa while the vehicle is in motion Make...

Page 20: ...y charged Speedometer Indicates the vehicles current rate of travel in miles per hour Hour Meter Displays total time whole hours vehicle has been in operation Time is accumulated only while the vehicl...

Page 21: ...ases the braking action 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 clockw...

Page 22: ...the alarm and light will reset Charger Interlock The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source The sea...

Page 23: ...ey switch while the vehicle is in motion unless the vehicle must be stopped in an emergency Turning the key switch off will immediately apply the park brake stopping the vehicle The abrupt stopping of...

Page 24: ...ed when the vehicle is stopped There is a parking brake bypass switch located under the rear passenger seat see illustration Place this switch in the UP position to tow the vehicle see note below This...

Page 25: ...g is ON when battery is discharged below this level BDI Reset 80 Battery must be discharged below this value before the BDI will be allowed to reset Reset Volts 2 10 V Battery voltage must be above th...

Page 26: ...t have their full capacity during this break in period and may require longer charging times Charging Time Average charging time is 8 to 12 hours The time required to fully charge your batteries will...

Page 27: ...to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interrupting...

Page 28: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 14 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Page 29: ...Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Daily Vi...

Page 30: ...TAYLOR DUNN...

Page 31: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4...

Page 32: ...Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should p...

Page 33: ...trol System Fault Speed Control System Overheated High Low Speed Switch in Low or wiring to the Switch is Faulty Low Speed Cutback Due to Maintenance Meter Trip optional Abnormal Noise Worn Drive Gear...

Page 34: ...2 Pedal Linkages 3 General Purpose Grease 3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 4 King Pin 2 General Purpose Grease 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug...

Page 35: ...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 7 Replace the King Pins and Bushings 9...

Page 36: ...rinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel be...

Page 37: ...RINGS 6 Raise the front of the vehicle and support with jack stands 7 Remove the hub dust cap and cotter pin 8 While rotating the hub tighten the spindle nut to 30 ft lbs This seats the bearings 9 Bac...

Page 38: ...vehicle and support with jack stands 7 Remove both front wheels Refer to Tires and Wheels section for information regarding removing the front wheels 8 Tie up or support the front axle so it can not f...

Page 39: ...upport with jack stands 7 Install the front axle in reverse order of removal NOTE Use all new cotter pins NOTE Refer to the Replacing the Ball Joints section for information regarding the installing t...

Page 40: ...d 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 r...

Page 41: ...assembly from the hub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 8 Remove the hub dust cap cotter pin and spindle nut 9 Remove the hub from the stee...

Page 42: ...to the Brakes 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 Remove the blocks from b...

Page 43: ...ehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Failure to correctly broach or ream bronze bushings may result in steering difficulty and lo...

Page 44: ...teering knuckle or suspension arm Ream or broach bronze bushings to 1 25 0 001 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be replaced 11 Reassembl...

Page 45: ...to the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then it will be necessary to bleed...

Page 46: ...y The rubber washer must compress slightly to create a seal for the grease NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cott...

Page 47: ...eering 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 14 Replacing the Drag Link 16 Replacing the Tie Ro...

Page 48: ...heels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball...

Page 49: ...on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a full right...

Page 50: ...g wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage Front wheel alignment NOTE It is recommended to center th...

Page 51: ...between the lines at the front of the tires 12 Measure the distance between the lines at the rear of the tires 13 Adjust the tie rod so that the distance at the front and rear of the tires is the same...

Page 52: ...hicle resulting in severe bodily injury and or property damage Typical Ball Joint 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 en...

Page 53: ...he blocks from behind the wheels 10 Release the parking brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the...

Page 54: ...ar for information regarding removing the steering gear 6 Raise the front of the vehicle and support with jack stands 7 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Join...

Page 55: ...ng gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut 15 Reconnect the main positive and...

Page 56: ...rminals off of the wires 7 Remove the steering wheel NOTE Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 8 Remove the upper steering shaft bushing or...

Page 57: ...d to property damage and or severe bodily injury 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...

Page 58: ...itch and disconnect the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straight ahead position 10 Li...

Page 59: ...e the steering shaft Refer to Replace the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a pickle fork NOTE On some vehicle configurations i...

Page 60: ...ront of the vehicle and support with jack stands 7 Loosen the rod end jam nut or clamp on the steering sleeve 8 Remove the rod end nut 9 Remove the rod end from the steering arm HINT Count the number...

Page 61: ...pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve HINT Count the number of turns required to remove the ball joint from the sleeve This will ma...

Page 62: ...ends from the steering knuckle and pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Remove the drag link as an asse...

Page 63: ...ign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and negative cables at the batteri...

Page 64: ...and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehi...

Page 65: ...fer to the illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counti...

Page 66: ...10 Remove the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Reassembly 1 Lightly lubricate all parts before reass...

Page 67: ...Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bo...

Page 68: ...Maintenance Service and Repair Steering Page 22 Exploded View of Steering Gear...

Page 69: ...he Service Brakes 4 Two or Four Wheel Hydraulic Disc Brakes 4 Check Master Cylinder Fluid 5 Bleed the Brake System 6 Flush the Brake System 8 Replace Front Disc Brake Pads 9 Replace Rear Brake Pads 11...

Page 70: ...pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Current Taylor Dunn brakes are asbestos f...

Page 71: ...d its service limits then the front hub must be replaced Refer to Front Axle Servicefor information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be...

Page 72: ...experiencing a low brake pedal or lack of braking power the entire brake system should be inspected INSPECT THE AUTOMATIC PARKING BRAKE The parking brake is located inside of the motor and is electrom...

Page 73: ...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 EYE CONTACT I...

Page 74: ...area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minutes and call physic...

Page 75: ...low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning 14 Repeat the above steps until you are...

Page 76: ...regarding removing the wheels 10 Remove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder 11 Attach a clear hose to...

Page 77: ...ining asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new brake pads will...

Page 78: ...s found 14 Install new spacer bushings in the mounting bracket 15 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 16 Repeat this procedure for the other wheel 17 Install...

Page 79: ...arts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions Always use a lifting strap hoist and jack stands of adequate capacity to lift and support th...

Page 80: ...ound 15 Install new spacer bushings in the mounting bracket 16 Back off the parking brake adjustment wheel park brake only 17 Install new brake pads in reverse order Torque the mounting bolts to 11 ft...

Page 81: ...t 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...

Page 82: ...12 Disconnect the brake hose from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting Torque the brake body bolts to 11 ft...

Page 83: ...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 EYE CONTACT I...

Page 84: ...Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind t...

Page 85: ...scard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts a...

Page 86: ...TAYLOR DUNN...

Page 87: ...ear 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 9 Disassembling the 3...

Page 88: ...th the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes out of the opening allow to drain until level with the bottom of the opening 9 Replace...

Page 89: ...of the level plug opening Refer to the Lube Chart section for information regarding type of oil 11 Replace the fill plug 12 Reconnect the main positive and negative cables at the batteries 13 Remove t...

Page 90: ...hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the...

Page 91: ...the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake...

Page 92: ...e batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe...

Page 93: ...They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage Refer to sectio...

Page 94: ...ables from the spring axle mounting brackets and brake arms 7 Disconnect the wiring from the motor 8 Disconnect the hydraulic brake lines from the left and right brake bodies 12 Reinstall the drive in...

Page 95: ...5 Disconnect the main positive and negative cables at the batteries 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8...

Page 96: ...the output gear from the pinion shaft NOTE If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be r...

Page 97: ...the front flange on the 3rd member and gear case cover NOTE Pack the motor seal with non acetic based grease 20 Fill the differential with oil NOTE Refer to Changing the Differential Oil for informati...

Page 98: ...on on removing the drive from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3r...

Page 99: ...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 16 Remove the carr...

Page 100: ...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 Remove the pinion shaft from the 3rd member...

Page 101: ...carrier bearing race ring nut so that the ring gear is not in binding against the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut to rotate 7 Remove the pinion gear and...

Page 102: ...ions 15 Check the gear lash between the ring and pinion gears The gear lash should be 0 005 to 0 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring n...

Page 103: ...gear case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil...

Page 104: ...inion bearing 3 Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft lbs 4 Measure the torque required to rotate the pinion shaft in the housing 5 The torque required to...

Page 105: ...him mm where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the...

Page 106: ...Maintenance Service and Repair Transmission Page 20 NOTE Values shown are for reference only C D...

Page 107: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5...

Page 108: ...d as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 6 Raise the rear of the vehicle and support with jack stands 7 Tie up or support the rear axle so it cannot...

Page 109: ...replaced one at a time 6 Raise the front of the vehicle and support with jack stands 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle bea...

Page 110: ...he Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles frame 9 Remove the spring...

Page 111: ...e is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse order 10 L...

Page 112: ...TAYLOR DUNN...

Page 113: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Tires and Wheels...

Page 114: ...tions available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall...

Page 115: ...em 11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak 1 Make sure the key switch i...

Page 116: ...severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on r...

Page 117: ...eplacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions pro...

Page 118: ...TAYLOR DUNN...

Page 119: ...BLE OF CONTENTS Cleaning 2 Testing 3 Watering 5 Charging 5 Replacing 6 volt batteries only 6 Moist Charge Batteries 8 Storage and Returning to Service 9 Storage 9 Returning to Service 10 Battery Servi...

Page 120: ...rinse thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive Explosive mixtures of Hydrogen gas ar...

Page 121: ...h 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...

Page 122: ...mber77 200 00 hydrometer check and record the specific gravity of each cell in the battery pack If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the...

Page 123: ...e disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the batte...

Page 124: ...tion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source...

Page 125: ...icle 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and re...

Page 126: ...n rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not dro...

Page 127: ...E AND RETURNING TO SERVICE Storage Thoroughly clean the batteries and battery compartment Refer toCleaning in this section for information regarding cleaning the batteries Check the electrolyte level...

Page 128: ...that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in property damage and or bodily injury Battery electro...

Page 129: ...ehicle wiring diagram is too large to be legible when printed at this size A full size diagram 22 x 16 is inculded on the CD in PDF format You can access the diagram from a button on the CD menu The d...

Page 130: ...TAYLOR DUNN...

Page 131: ...Control System Diagnostics TABLE OF CONTENTS Test Equipment Required 2 Important Notes and Instructions 2 Status LED Code Table 3 Throttle Module Test 6 Rev B...

Page 132: ...hibits intermittent problems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified DURING ALL TESTS or REPAIRS Tu...

Page 133: ...Failed Shutdown of main contactor Shutdown of motor Shutdown of EM brake 1 External load attached to controller B terminal Possible non factory installed device 15 Controller Severe Undertemp Shutdow...

Page 134: ...ng 32 EM Brake Open Short Shutdown Driver 2 Shutdown Throttle Full brake 3 Faulty motor brake 4 Faulty wiring 33 Coil3 Driver Open Short Shutdown driver 3 1 See note Not used If fault occurs then chec...

Page 135: ...down EM bake 1 May occur when adjusting parameters Cycle key switch to clear fault 68 VCL Runtime Error Shutdown main contactor Shutdown motor Shutdown EM bake Shutdown Throttle Shutdown interlock Shu...

Page 136: ...o the connector as shown in the illustration INTO THE HARNESS PLUG THIS END INTO THE MODULE PLUG THIS END FOR TESTING USE THIS END 9 6 7 4 3 1 The 75 089 00 Throttle Module Test harness The rear drive...

Page 137: ...ly retest the vehicle before lowering the drive wheels to the ground TEST 2 Accelerator pedal released Test the voltage from pin 9 to pin 8 If the voltage equals battery volts then skip ahead to test...

Page 138: ...erator pedal released If the voltage is low then skip ahead to test 5b If the voltage is high then then the module has failed Stop trouble shooting here and repair the problem When the repair is compl...

Page 139: ...If the voltage is between 4 8 and 5 1 volts then skip ahead to test 7 If the voltage is not between 4 8 and 5 1 volts then the module has failed and must be replaced Stop trouble shooting here and rep...

Page 140: ...TAYLOR DUNN...

Page 141: ...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 BEF...

Page 142: ...urrent state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200...

Page 143: ...efore connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is tu...

Page 144: ...than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC vo...

Page 145: ...r has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Con...

Page 146: ...re continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers F...

Page 147: ...mer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that a...

Page 148: ...blem Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconn...

Page 149: ...f the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The volta...

Page 150: ...here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the A...

Page 151: ...4 Rear Axle 16 Transmission Differential Case 16 Rear Brakes 18 Front Brakes 18 Brake Lines and Master Cylinder 20 Motor 22 Motor Mount 24 Wheels and Tires 26 Lighting 27 Instrument Panel dash 28 Wire...

Page 152: ...Illustrated Parts Parts Page 2 Front Axle...

Page 153: ...Illustrated Parts Parts Page 3 Front Axle ITEM PART DESCRIPTION QTY 15 210 70 Axle Beam 1 15 049 15 Complete axle assembly 1 See following pages for component breakdowns...

Page 154: ...Illustrated Parts Parts Page 4 Steering Knuckle...

Page 155: ...43 Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13 2 15 88 228...

Page 156: ...Illustrated Parts Parts Page 6 Steering Linkage...

Page 157: ...EM PART DESCRIPTION QTY 1 18 041 05 Tie rod 1 2 86 510 00 Ball joing clamp 4 3 86 501 98 Ball joing left 2 4 86 501 99 Ball joint right 2 5 88 527 11 1 8 x 1 Cotter pin 4 6 K49 700 74 Drag link 1 7 88...

Page 158: ...rated Parts Parts Page 8 Steering Column Ref Steering Gear 8 9 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 7 4 3 6...

Page 159: ...2 Hex bolt grade 8 1 4 88 089 84 5 16NF Hex lock nut grade C 1 5 32 248 10 Upper bushing 1 6 20 031 65 Steering shaft assembly incl 3 and 4 1 7 19 011 25 Steering wheel cap 1 8 88 128 62 7 16 Split l...

Page 160: ...Illustrated Parts Parts Page 10 Steering Gear 1 2 3 4 7 8 Front axle ref 5 9 1 0 1 5 1 3 1 7 1 2 1 1 2 3 1 4 1 6 4 1 6 8 7 5 Front Suspension...

Page 161: ...aft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 1 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side cover 1 16...

Page 162: ...Illustrated Parts Parts Page 12 Rear Suspension View from rear...

Page 163: ...f spring 4 14 85 510 17 Leaf spring 2 15 16 861 46 Spring mounting plate left 1 16 861 47 Spring mounting plate right 1 16 96 114 00 U bolt 4 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2...

Page 164: ...Illustrated Parts Parts Page 14 Transmission Gear Case...

Page 165: ...1 12 GT 72019 Seal 1 18 GT 71979 Bearing 1 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 24 GT 3287453 Output gear 30 1 0 or 1 25 GT 328 Spacer 46 100mm 1 GT 328 Spacer 46 100mm 0 or...

Page 166: ...rential Case Rear Axle Inner bearing on 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 Axle Shaft Inner Be...

Page 167: ...t 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GT 71881 Seal 1 32 GT 70052 Vent 1 Rear Axle ITEM PART DESCRIPTION QTY 1 41 154 15 Axle shaft 2 2 80 505 20 Bearing 2 2a 80 505 30 Bea...

Page 168: ...Illustrated Parts Parts Page 18 Rear Brakes Front Brakes...

Page 169: ...PLUG 1 8 PIPE HEX SOCKET 2 Not available seperatly order complete caliper assembly Front Brake ITEM PART DESCRIPTION QTY 1 88 067 21 Bolt 1 4 X 3 3 4 NC Hex Head Gr 8 4 2 41 350 51 Plate Secondary Hy...

Page 170: ...Illustrated Parts Parts Page 20 Brake Lines and Master Cylinder...

Page 171: ...14 5 16 X 1 1 2 NC Hex Bolt 2 13 88 088 61 5 16 Washer 4 14 88 089 81 5 16 Lock Nut 2 15 99 511 20 Master Cylinder 1 16 99 605 77 Brake Line 1 17 99 605 76 Brake Line up to serial 158863 1 99 607 59...

Page 172: ...Illustrated Parts Parts Page 22 Motor...

Page 173: ...15 O ring 1 41 70 400 16 Key 1 42 70 400 17 Snap ring 1 52 70 400 21 Key 1 96 70 400 18 Snap ring 1 98 70 400 19 Snap ring 1 203 70 400 13 Seal 1 224 70 400 09 Rubber Grommet 2 206 70 260 00 Terminal...

Page 174: ...Illustrated Parts Parts Page 24 Motor Mount Apply 94 421 34 grease to inside of motor coupler...

Page 175: ...88 068 62 1 4 Split lock wahser 4 5 89 060 11 6mm x 1 0 x 50 Hex bolt 3 6 89 111 27 10mm x 1 5 x 20 Hex bolt 2 7 88 128 62 7 16 Split lock washer 2 8 70 456 03 Mounting bracket 1 9 88 067 17 1 4NC x 1...

Page 176: ...els and Tires Wheels and Tires ITEM PART DESCRIPTION 1 Wheels 12 025 00 8 x 10 2 Tires 10 264 00 20 5 x 8 x 10 load range E Not Shown 13 989 00 Valve stem tubless tire only Tire and Wheel Assemblies 1...

Page 177: ...ular light right 1 72 082 01 Replacement bulb 2 94 201 10 Name plate front cowling 1 K4G LI 001 Tail light 2 K4G LI 003 Reverse light 2 Turn Signals ITEM PART DESCRIPTION QTY 72 082 10 Front bulb 2 72...

Page 178: ...n of the Reverse Alarm Disable Switch the standard dash harness must be modified as follows 1 Locate the Red wire that connects the F R Switch to the Key Switch Remove the wire from the Key Switch and...

Page 179: ...igh Low speed switch 1 4 74 010 20 Gauge Spy Glass 1 5 71 100 00 Auxiliary switchs 0 1 2 6 71 120 00 Start switch standard 1 71 119 99 Spacer 1 71 121 20 Start switch keyed unalike optional 1 7 71 120...

Page 180: ...Illustrated Parts Parts Page 30 Speed Control Panel Illustration not available at time of printing...

Page 181: ...78 301 00 RESISTOR 25 OHM 50 WATT 1 10 79 829 05 FUSE LINK 425A 80V 1 11 79 840 30 STANDOFF FUSE MOUNTING 2 12 79 840 00 CIRCUIT BREAKER 10 AMP AUTO 1 13 79 840 20 CIRCUIT BREAKER 20A AUTO RESET 2 14...

Page 182: ...Illustrated Parts Parts Page 32 Miscellaneous Electrical Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1 2 Motion Alarms Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4...

Page 183: ...h 2 7 88 069 81 1 4 NC Hex Nylon Locknut Horn Switch 2 8 71 111 00 Brake Light Switch 1 9 88 045 06 10 32 x 1 2 Machine Screw brake light switch 2 10 71 102 10 Seat interlock Switch 1 11 85 030 00 Spr...

Page 184: ...16340 ITEM PART DESCRIPTION QTY 79 315 00 Charger assembly 1 79 902 00 Capacitor 1 79 802 00 Timer 1 79 849 00 Ammeter 1 79 531 00 Bushing AC cord 1 79 530 00 Bushing DC cord 1 79 576 00 AC cord 1 79...

Page 185: ...ont 1 90 000 00 Seat back rear 2 90 178 00 Seat cushion rear 1 K49 400 04 Deck board 1 Miscellaneous Frame Components Miscellaneous Frame Components PART DESCRIPTION QTY 79 511 00 Charger AC cord hold...

Page 186: ...Illustrated Parts Parts Page 36 Batteries FRONT OF VEHICLE...

Page 187: ...hold down 6 5 88 088 66 Flat washer tin lead plated 6 6 88 069 81 1 4NC Nylon lock nut 6 7 88 081 12 5 16NC x 1 Hex bolt stainless steel 24 8 88 089 80 5 16NC Hex nut stainless steel 24 9 88 089 70 5...

Page 188: ...TAYLOR DUNN...

Page 189: ...ed Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex Bolts 3 Other Bolts 3 Hex Nuts 4 Hex Lock Nuts stover 4 Other Nuts 4 Suggested Torque Values non critica...

Page 190: ...set the Smart View display maintenance meter includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adjust Capability Same as 62 027 61 above plus allows a limited range of speed adjustmen...

Page 191: ...Carriage Bolt grade 2 unless marked as above Other Bolts 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 Toq...

Page 192: ...as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no marki...

Page 193: ...2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 1...

Page 194: ...center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Dra...

Page 195: ...um cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause u...

Page 196: ...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...