Taylor-Dunn ET 1-50, Operation And Maintenance Manual

Page 1: ...P YEAR 1993 UP MANUAL NUMBER MZ 150 02 IMPORTANT READ AND FOLLOW INSTRUCTIONS GIVEN IN SAFETY OPERATIONS AND THOSE SECTIONS RELATED TO YOUR SERVICE AND REPAIR RESPONSIBILITIES II 2114 W Ball Rd Anahei...

Page 2: ...y cables disconnected Be sure that the rear wheels are clear of any foreign objects Place a 6 gauge jumper wire between the B terminal and M terminal of the PMC controller Reconnect the main traction...

Page 3: ...Front Brake Hoses Replacing the Front Brake Lines Replacing the Rear Brake Hose Replacing the Rear Brake Lines Replacing the Master Cylinder Replacing the Brake Light Switch SUSPENSION Replacing the...

Page 4: ...haft from the Differential Disengaging the Drive Shaft from the Motor Installing the Drive Shaft Replacing the Motor Removing the Motor Installing the Motor DIFFERENTIAL I REAR AXLE Rear Axle I Differ...

Page 5: ...Testing the Main Power Output Testing the Main Power Input Testing Input to the Speed Control Module Testing the Contactors Testing the Forward I Reverse Switches Testing the Accelerator Module Electr...

Page 6: ...ist Vehicle Specifications ILLUSTRATED PARTS LIST Front Brake Lines And Master Cylinder Rear Brake Lines Front Brake Assembly Rear Brake Assembly Park Brake Assembly Steering Gear And Linkages Front A...

Page 7: ...er Shaft Rear Suspension Rear Axle And Wheel Differential Seats Instrument Panel Speed Control Charger And Charger Mount TAYLOR DUNN ET 1 50 PARTS LIST 16 PARTS LIST 18 PARTS LIST 20 PARTS LIST 22 PAR...

Page 8: ...e Replacing the Rear Brake Lines Replacing the Master Cylinder Replacing the Brake Light Switch Replacing the Front Axle Suspension Springs Replacing the Front Shock Absorbers Replacing the Rear Axle...

Page 9: ...ntrol Panel Replacing the Accelerator Module Replacing the Turn Signal Pilot Bulb Replacing the Turn Signal Assembly Replacing Shift Lever Switches Shift Lever Switches Wiring Layout Motor and Motor T...

Page 10: ...ly Steering Gear And Linkages Front Axle Suspension and Wheel Motor And Motor Mounts Motor Propeller Shaft Rear Suspension Rear Axle And Wheel Differential Seats Instrument Panel Speed Control Charger...

Page 11: ...le Suspension and Wheel Motor And Motor Mounts Motor Propeller Shaft Rear Suspension Rear Axle And Wheel Differential Seats Instrument Panel Speed Control Charger And Charger Mount TAYLOR DUNN ET 1 50...

Page 12: ...Table of Contents X THIS PAGE IS INTENTIONALLY LEFT BLANK TAYLOR DUNN TAYLOR DUNN ET 1 50...

Page 13: ...IITAYLOR DUNN TAYLOR DUNN ET 1 50 SAFETY GENERAL INFORMATION SAFETY I GENERAL INFORMATION SAFETY 1...

Page 14: ...T KEEP THEIR ENTIRE BODIES AND ALL EXTREMITIES INSIDE THE VEHICLE AT ALL TIMES A DO NOT EXCEED 32 MPH 50 KPH UNDER ANY CIRCUMSTANCES DRIVE SLOWLY IN TURNS AND UP AND DOWN SLOPES A BRING THE VEHICLE TO...

Page 15: ...ising the vehicle place a piece of wood or the tire that was removed under the frame This will prevent a hand or a foot from being injured if the vehicle falls off the jack stands When servicing elect...

Page 16: ...rmation Figure A 2 Figure A 3 Axle support points use when replacing flat tires shock absorbers or leaf springs Jack stands 4 SAFETY Lift and Support Points TAYLOR DUNN T43 10 Frame support points use...

Page 17: ...tow with the rear wheels off the ground Towing with the rear wheels on the ground will cause severe damage to the differential and motor NEVER use tow chains or ropes to tow a vehicle You might not b...

Page 18: ...e is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician KEEP OUT OF REACH OF CHILDREN Battery Charging The batteries...

Page 19: ...gative battery terminals should also be washed off with warm water Checking Battery Electrolyte Level Distilled water Figure A 7 To check electrolyte level for each battery D Remove each cell cover fJ...

Page 20: ...anging tires only STAND CLEAR DO NOT GET UNDER the truck and DO NOT run the motor when the truck is supported only by the jack l I Place a jack under the axle on the side nearest the wheel you are rem...

Page 21: ...re Traction Driving on worn out or under inflated tires is very hazardous and will reduce braking effectiveness steering accuracy and traction ffliWIUffi WORN TIRES or slippery road surfaces can reduc...

Page 22: ...SAFETY I GENERAL INFORMATION IITAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 10 SAFETY TAYLOR DUNN ET 1 50...

Page 23: ...TAYLOR DUNN BRAKE SYSTEM BRAKE SYSTEM TAYLOR DUNN ET 1 50 BRAKES 1...

Page 24: ...to or loss of brakes It will also turn on your brake lights and might confuse drivers behind you Driving through deep water may affect the brakes Check by pressing the brake pedal gently If the vehic...

Page 25: ...eyes flush with water immediately for 15 minutes and call a physician right away If somebody swallows brake fluid let him drink large quantities of water or milk and follow with milk of magnesia or v...

Page 26: ...p TAYLOR DUNN NOTE Low brake fluid level may be an indication of brake pad wear or ofbrake fluid leakage Check for these items if the brake fluid level is low before refilling it If the fluid needs re...

Page 27: ...Figure B 4 Brake pedal Adjusting the Brake Pedal Free Play Loosen the adjusting nut Turn the push rod counter clockwise to reduce free play clockwise to increase free play Tighten the adjusting nut TA...

Page 28: ...erflow Discard the fluid properly Jack up and support the vehicle on the front axle see General Safety and Support Points at the beginning of this manual Remove one front wheel see Replacing Tires Rem...

Page 29: ...y airborne asbestos fibers Clean your hands thoroughly Install the retaining spring onto the new inner pad Figure B Sc Compressing the piston cup with a C clamp Use a C clamp as shown to compress the...

Page 30: ...ng the Rear Brake Shoes Jack up and support the vehicle on the front axle see General Safety at the beginning of this section Remove one rear wheel Remove the brake drum Remove the three brake springs...

Page 31: ...justing screw park brake link and link spring Disengage park brake cable from the park brake lever Remove the circlip to disengage park brake lever from the secondary shoe Installation See Replacing B...

Page 32: ...AKE SYSTEM TAYLOR DUNN I Seconda y shoe Spring washer R lnlngcUp 1JJ Figure B 6c Attach the park brake lever to the secondary shoe with the spring washer and retaining clip 10 BRAKES TAYLOR DUNN ET 1...

Page 33: ...9 TAYLOR DUNN BRAKE SYSTEM Backing plate Brake shoes Figure B 6d Install the shoes on the backing plate with the hold down springs cups and pins TAYLOR DUNN ET 1 50 BRAKES 11...

Page 34: ...Figure B 6e Install the park brake link spring and washer and connect the brake cable to the rear brake lever Install the anchor pin plate and attach the cable anchor to the pin with the crimped side...

Page 35: ...ndary shoe Route the cable around the guide making sure it is in the groove and not between the guide and shoe Connect the secondary shoe retracting spring to the anchor pin Note Make sure that the an...

Page 36: ...ttach the cable to the adjusting lever and engage the hook on the lever in the hole in the secondary shoe Connect the adjuster spring Checking the adjuster action Pull the cable between the guide and...

Page 37: ...ne to hose Remove clip Dispose of old brake hose properly Place new copper washer insert new hose end and another copper washer on brake line bolt and screw into brake caliper Mount the other end to t...

Page 38: ...catch brake fluid that may spill from the fittings Unscrew REAR connector from master cylinder Figure B sb 97TAYLOR DUNN Master cylinder Front brake hose Connector Unscrew connectors joining front bra...

Page 39: ...remaining long line for the remaining hole on the T fitting Screw the connector at the other end of the looped line onto the master cylinder the short line onto the driver s side brake hose and the re...

Page 40: ...Unscrew the rear brake hose from T fitting taking care not to drop the ferrel from inside the fitting Discard the old brake hose properly Center the ferrel in the T fitting and screw the hose end in M...

Page 41: ...n master cylinder Ifthe adapter also needs replacing unscrew the adapter from the master cylinder Brake light T fitting Figure B 10b Brake light switch Forward connector Lift up driver s seat and unsc...

Page 42: ...line connectors to rear wheels Remove the two rear wheel brake lines Install new rear wheel brake lines and T fitting as shown Install new brake lines in reverse order IITAYLOR DUNN Bleed the right r...

Page 43: ...e adapter Have somebody hold the master cylinder to prevent it from falling From inside the cab remove the two bolts holding the master cylinder to the cab wall Discard the old master cylinder properl...

Page 44: ...s seat access Disconnect two wires and unscrew brake light switch Disconnect two wires and discard old switch properly Coat the threads of the new switch with teflon tape Screw new brake light switch...

Page 45: ...IITAYLOR DUNN SUSPENSION SUSPENSION TAYLOR DUNN ET 1 50 SUSPENSION 1...

Page 46: ...front axle see Safety I General Information11 Remove front axle u bolts and spring mounting plates Remove front and rear mounting bolts nuts shackles and bushings Dispose of the old springs properly...

Page 47: ...d Replace the remaining washers with new ones on the bottom side Place a washer on the axle stud then the lower eye of the new shock absorber washer and new locknut Tighten the nut until washers touch...

Page 48: ...rubber bushings are compressed to about 11 on either side as shown Figure C 3a Replacing the Rear Axle Springs Jack up and support the truck on the rear of the frame See Lift and Support Points at th...

Page 49: ...frame with the mounting bolts as shown Tighten each nut securely then back out turn Repeat the entire procedure for the other side Note It is recommended that both springs be replaced at the same time...

Page 50: ...pacers Dispose of old shock absorbers properly Install the new ones in the following order Top Mount Bolt washer shocks washer short bushing frame nut Bottom Mount Bolt washer shocks washer long bushi...

Page 51: ...IITAYLOR DUNN STEERING STEERING TAYLOR DUNN ET 1 50 STEERING 1...

Page 52: ...lacing the Ball Joints Remove cotter pins Unscrew and remove the slotted nuts from both ball joints Note position of clamps Unscrew linkage clamps Note Half the ball joints have right hand and half ha...

Page 53: ...tighten securely Insert a cotter pin into one ball joint hole and bend one end outwards around the ball joint Repeat for the other end Tighten all clamp screws securely Align the front end for toe in...

Page 54: ...tire FRONT Figure D 2 D L RH sldem u omo should be o to more than front El Measure the distance between the marks on the rear side of the front tires l J Measure the distance between marks on the fro...

Page 55: ...NN STEERING Figure D 3a Replacing the Steering Gearbox Removing the Steering Gearbox Jack up the truck and remove the left front wheel see Changing a Flat Tire Accessories section TAYLOR DUNN ET 1 50...

Page 56: ...ng the balljoint see Replacing Ball Joints 11 this section at the top of the center pivot Remove the steering wheel shaft connector nuts one 11 and one 9 i6 and lock washers Reach from under the wheel...

Page 57: ...3c Remove the nut and lock washer from the steering arm Use a wedge fork to force the arm from the spline Set the old gearbox aside Remove the cotter pin and unscrew the slotted nut to disengage the b...

Page 58: ...tor nuts Figure D 3d Installing New Steering Gearbox Install the gearbox on the frame with the three mounting bolts Attach it to the steering shaft with the connector nuts and lock washers removed ear...

Page 59: ...e TAYLOR DUNN ET 1 50 STEERING Turn the steering wheel all the way to the right Turn it back all the way to the left counting the number of turns Turn it back half the counted number of turns approxim...

Page 60: ...3e Engage the spline on the new gearbox into the steering arm hole keeping the arm parallel to the gearbox body Note Spline can only go into the arm one way Engage lock washer and nut on the spline T...

Page 61: ...drag link to the center pivot see Replacing Ball Joints this section Place the clamps as close to the edge of the sleeve as possible Make sure clamp nuts are facing forward and up for easy servicing T...

Page 62: ...STEERING IITAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 12 STEERING TAYLOR DUNN ET 1 50...

Page 63: ...TAYLOR DUNN FRONT AXLE FRONT AXLE TAYLOR DUNN ET 1 50 FRONT AXLE 1...

Page 64: ...e Replacing the Front Axle Assembly Lift the truck up and support the forward side of the frame Support the front axle See Lift and Support Points Safety I General Information Section Remove both fron...

Page 65: ...AXLE Steering linkages Remove steering linkages from the axle see Replacing the Ball Joints 11 Steering section Remove front shock absorbers see Replacing the Front Shock Absorbers Suspension section...

Page 66: ...m II I i i i i i i TAYLOR DUNN Remove suspension springs see Replacing the Front Axle Suspension Springs Suspension section Remove the axle Install the new one in reverse order Bleed both front brake...

Page 67: ...9 TAYLOR DUNN POWER TRAIN POWER TRAIN TAYLOR DUNN ET 1 50 POWER TRAIN 1...

Page 68: ...POWER TRAIN IITAYLOR DUNN Power train Figure F 1a Please refer to Section 1 SAFETY I GENERAL INFORMATION before performing any repairs I maintenance on this vehicle 2 POWER TRAIN TAYLOR DUNN ET 1 50...

Page 69: ...ure F 1b _________ Nuts Replacing the Drive Shaft Disengaging the Drive Shaft from the Differential Disengage 2 u bolts from the rear u joint Pull the rear portion of the shaft forward and lower it sl...

Page 70: ...he set bolt Remove the set bolt Figure F 1d TAYLOR DUNN Yoke Push to disengage shaft Hold a spacer block against the mounting plate as shown Insert a metal rod in the U joint Disengage the yoke from t...

Page 71: ...igure F 1e Installing the Drive Shaft To install new one engage 2 u bolts from rear u joint Line up the motor shaft keyway Tap the drive shaft into position with a soft hammer until speedmeter ring al...

Page 72: ...ER TRAIN TAYLOR DUNN Figure F 1c Use loctite Tighten set screw Replace safety wire Figure F 1g Lubricate all grease fittings with multi purpose grease using a grease gun 6 POWER TRAIN TAYLOR DUNN ET 1...

Page 73: ...cing the Motor Removing the Motor Support the motor from below The motor weighs approximately 180 lbs and tends to roll Make sure the support will prevent it from rolling and is strong enough to bear...

Page 74: ...and nuts Disconnect power wires from motor terminals I r Front mounting bolts Front mounting plate Front plate mount nuts Loosen two front plate mount nuts to provide play for the front mounting plat...

Page 75: ...ew Motor Remove the screws that mount the original brackets to the new motor Dispose of the brackets properly Install the screws back in position and tighten securely Install the new motor in reverse...

Page 76: ...POWER TRAIN IITAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 1O POWER TRAIN TAYLOR DUNN ET 1 50...

Page 77: ...IITAYLOR DUNN TAYLOR DUNN ET 1 50 DIFFERENTIAL I REAR AXLE DIFFERENTIAL REAR AXLE DIFFERENTIAL 1...

Page 78: ...ATIONII before performing any repairs I maintenance on this vehicle Replacing the Differential Support the truck from the rear frame support points until the rear wheels clear the ground see Support P...

Page 79: ...hoes Brake System section Remove brake lines from rear wheel backing plates Unclamp right rear brake line from differential housing Tie the brake lines out of the way Note Do not kink the brake lines...

Page 80: ...oving Rear Leaf Springs 11 Suspension section Set the old differential aside Install the new differential in reverse order Adding Oil to the Differential Remove differential filler plug with a socket...

Page 81: ...ar axles The differential is shown by itselfin these illustrations solely for purposes of clarity Figure G 3b Differential assembly _ _ Rear Brake drum Remove the rear wheel see Changing a Flat Tire S...

Page 82: ...es Figure G 3c Disengage the four axle mounting nuts as shown Note Rotate the axle hub to align the access holes with each nut in turn Slide homme pulle Figure G 3d Engage a slide hammer puller to the...

Page 83: ...acking plate during this procedure to prevent it from falling and damaging the brake lines After the axle assembly comes off replace two axle nuts on the studs to hold the backing plate in place Figur...

Page 84: ...DIFFERENTIAL I REAR AXLE IITAYLOR DUNN Figure G 3g Assemble the axle plate into the axle Figure G 3h Press fit the bearing and new retaining ring onto the axle 8 DIFFERENTIAL TAYLOR DUNN ET 1 50...

Page 85: ...king plate then remove the axle nuts that hold them in place Insert the axle into the differential housing Seat it properly by rotating it by hand then push it all the way in Tap it with a heavy hamme...

Page 86: ...m the vehicle to perform this procedure Neither is it necessary to pull the axles and backing plates out of the rear end housing The rear end housing is shown bare only for purposes ofbrevity D Jack u...

Page 87: ...ually replaceable parts inside If necessary replace the entire carrier housing assembly W Remove the pinion housing assembly from the third member lfJ Remove the 0 ring from the pinion housing assembl...

Page 88: ...it is too tight or too loose adjust the fit with a new shim ErJ Install the pinion housing assembly and pinion gear into the housing cover E9 Insert housing cover bolts and tighten to 50 ft lbs of tor...

Page 89: ...standard shim is 0 01511 thick Inserting a thicker shim between the pinion retainer and the carrier moves the pinion away from the drive gear Note Matched pinions and drive gears use the same number...

Page 90: ...DIFFERENTIAL I REAR AXLE IITAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 14 DIFFERENTIAL TAYLOR DUNN ET 1 50...

Page 91: ...VOLTAGE PRESENT CAREFULLY DISCONNECT BATTERIES BEFORE SERVICING Ii BATTERY GASES ARE EXPLOSIVE KEEP SPARKS FLAMES AND LIGHTED CIGARETTES AWAY FROM BATTERIES Ii KEEP THE VEHICLE AND BATTERIES IN A WELL...

Page 92: ...UNN WIRING DIAGRAM I I I y I fz i C L 71 lJ M j s I 1u1 Ir u I 1 a 111 i _ _ I Ln lG t J r L t 11 o LC1l a a tfif M iii I I nwM e _ LIE II IE a Figure H 1a Electruck Wiring Diagram Sheet 1 of 2 2 ELEC...

Page 93: ...AL SYTEM J aj l I II P I L ii y n C I I 119 L 1 1 I I I D i __ cl I 11 a 1ll I r lll lG tj 1_ 2 l I i l Y I I 11 II I r fl I i ti l u I 1 I Figure H 1b Electruck Wiring Diagram Sheet 2 of 2 TAYLOR DUN...

Page 94: ...0 battery layout IITAYLOR DUNN r 12 Volt positive lead Black main to emergency disconnect switch FORWARD Please refer to Section 1 SAFETY I GENERAL INFORMATION before performing any repairs maintenanc...

Page 95: ...l Figure H 3a Removing the battery Indicator llght and wiper switch panel Remove four mounting screws from the front panel Figure H 3b Replacing the panel Disengage the wire harness coupling from the...

Page 96: ...ving the keyswltch I speedometer panel Remove four mounting screws from the front panel Figure H 4b Replacing the keyswltch I speedometer panel Disengage the wire harness coupling from the panel Insta...

Page 97: ...tch To replace the seat switch the driver seat must be replaced Lift up the driver s seat Remove the four mounting bolts and angle mounting bracket Note The seat belts will come off Cut the two wires...

Page 98: ...H 6a Disconnect switch mounts Disconnect switch Black from control FORWARD TOP VIEW Figure H 6b Disconnect switch wiring layout 8 ELECTRICAL TAYLOR DUNN Black from battery Mounting post Red from batt...

Page 99: ...ONTROL PANEL WIRES Black Dloeonnoctowltch Figure H 6d Replacing the disconnect switch CHARGER WIRES White Black BATTERY WIRES Note wire positions Battery and charger wires are on the rear studs the co...

Page 100: ...e charger terminals Remove two cord stopper screws from behind the charger cord box Remove the plug from the end of the cord Pull out the charger cord Support charger from below Remove four bolts at t...

Page 101: ...n Tighten securely Secure to mounting panel through the panel holes with another washer and locknut for each bolt Figure H 7c Installing the charger Position charger under frame below mounting holes H...

Page 102: ...e Speed Control Panel Pull up passenger seat Gang plug Wire harness coupling Figure H Sb Disconnecting the speed control panel Pull off the gang plug connecting the control panel wires to the motor an...

Page 103: ...oving the speed control panel Support the panel from the bottom Remove 6 nuts from under the mounting plate Lower the old panel safely Pull the new control panel up from below the frame Install in rev...

Page 104: ...phillips screws that hold the accelerator pedal to the module From under the hood disengage the wire harness coupling from the module Bolt_ N u t Accelerator module _ Figure H 9b Removing the accelera...

Page 105: ...ulb Replacing the Turn Signal Pilot Bulb Remove the two screws on the top cover of the turn signal assembly Remove top cover Pull the spring clip away from the handle Unscrew the old bulb Screw the ne...

Page 106: ...here the assembly was removed Separate the ground wire from the rest of the signal wires Dispose of the old assembly properly Take the new turn signal assembly Engage the ground wire to one screw and...

Page 107: ...anel for aesthetic purposes Cut one old wire strip off the end and fasten it to the new wire of the same color Repeat the procedure for all the wires Nut Lock washer Switch mounting screw Figure H 12a...

Page 108: ...ELECTRICAL SYSTEM TAYLOR DUNN FORWARD SELECTOR LEVER REVERSE FDR ARD GREEN BLACK TD PIN 8 Figure H 12b Wiring connection for the shift lever switches 18 ELECTRICAL TAYLOR DUNN ET 1 50...

Page 109: ...c Folowing are the steps to be taken in the event of an electrical failure Testing the Main Power Output For all of the following steps use a volt ohmmeter V O M to check voltage Note Actual readings...

Page 110: ...re and or brushes see 11 Repairing the Motor 11 this section Connect positive V O M lead to the motor A1 terminal Put Forward Reverse Selector Lever henceforth referred to as selector lever in forward...

Page 111: ...for poor contacts Note For all of the following steps when checking voltage the negative lead of the V O M should be in contact with the battery negative terminal black cable unless specified B With...

Page 112: ...ACCELERATOR 1 3 13 15 Figure H 15 Speed control module plug TESTING INPUT TO THE SPEED CONTROL MODULE Disconnect main battery positive and negative wires PANEL PLUG HARNESS PLUG Failure to disconnect...

Page 113: ...Inspect all wiring for loose or bad connections ELECTRICAL SYTEM _ _ I R v I J V _ l I g lS r IHTT l HITE 11 UE YELLCII YELLD 2UA CIRCUIT 20A AKER RED T I RED B AERREIJII RED HITE uu VIEW FROM FRONT o...

Page 114: ...correct polarity connect 12v source across both reverse and forward solenoid coils Using R x1 o if resistance across test points 1 and 2 Fig H 17 is not Oohms then F R contactor is bad STOP NOTE Diode...

Page 115: ...FORWARD ELECTRICAL SYTEM If voltage at the forward switch normally open Figure H 18 is not positive 12V then switch is bad STOP If voltage at Pin 8 on the control module plug Figure H 15 is not positi...

Page 116: ...If Pin 4 on the connector is not positive 12 15V check the key switch STOP If Pin 7 is not approximately 36V go to CONTROL MODULE Connect the V O M positive lead to the battery positive If Pin 9 is n...

Page 117: ...11 B V See Note 3 Neutral OFF Up 12 B V See Note 3 Neutral OFF Up 15 12 to 15 Volts See Note 2 Neutral OFF Depressed fully 1 12 to 15 Volts See Note 1 Neutral OFF Depressed fully 2 B V Check Circuit...

Page 118: ...ully 15 12 Volts See Note 2 Reverse Depressed fully 1 12 Volts See Note 1 Reverse Depressed fully 2 B V Check circuit breakers Reverse Depressed fully 4 12 Volts See Note 1 Reverse Depressed fully 5 1...

Page 119: ...ection at the beginning of this manual Disconnect the charger from the AC plug and DC batteries sources If the charger is built in remove the charger from the vehicle see Replacing the Charger this se...

Page 120: ...bad If AC input is bad repairs should be made by a qualified electrician The possible problems are Wiring to AC cord AC cord or plug House wiring or circuit breaker Measure AC output voltage at timer...

Page 121: ...iode block with diodes The meter should either deflect to the right side of the scale or not at all Reverse polarity on the diode test leads You should get the opposite readings from the previous step...

Page 122: ...ross one capacitor The needle should deflect to low ohms reading and slowly return to infinity left side of scale If needle stays on low ohms reading or does not deflect at all the capacitor is bad an...

Page 123: ...t the bearings by hand If they do not operate smoothly replace them with new ones Measure the length of the brushes If they are less than 0 8 replace them with new ones 411s Minimum after cutting Figu...

Page 124: ...ELECTRICAL SYSTEM IITAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 34 ELECTRICAL TAYLOR DUNN ET 1 50...

Page 125: ...IITAYLOR DUNN ACCESSORIES ACCESSORIES TAYLOR DUNN ET 1 50 ACCESSORIES 1...

Page 126: ...just the beam direction to the left turn the horizontal adjusting screw clockwise inward with the phillips screwdriver To adjust it to the right turn the adjusting screw counter clockwise outward To a...

Page 127: ...ight mounting bracket ID The headlight is now free to move Reach behind it and disengage the electrical coupling lJ Engage the electrical coupling on the new headlight l I Install the headlight mounti...

Page 128: ...s D Remove the two front park light lens mounting screws f 1 Remove the park light lens exposing the bulb EJ Unscrew the bulb IJ Screw the new bulb in 1 J Mount the lens with the two screws removed ea...

Page 129: ...h under the bumper behind the bulb to be replaced and disengage the electrical coupling from the old bulb Push the bulb towards the rear out of the rubber grommet Push the new bulb from the rear into...

Page 130: ...mum visibility replace worn or cracked wiper blades when you notice they do not wipe the windshield cleanly or smoothly Remove the screw and nut from the blade mounting bracket and remove the wiper bl...

Page 131: ...unts the wiper arm to the motor shaft then pull the arm off Gasket Wiper motor Nut Motor shaft nut Orange wire Figure l 6b Remove the nut from the motor mounting screw as shown Remove the ground white...

Page 132: ...haft as shown in previous page Tighten the nut securely Installing the Wiper Arm Turn the wiper on The motor shaft will turn one way then stop and turn the other way Turn the motor off when the shaft...

Page 133: ...7a Horn mounting screws Horn Figure l 7b Replacing the Horn Disengage the wire terminals from the horn Remove the two mounting screws Install in reverse order TAYLOR DUNN ET1 50 ACCESSORIES Horn powe...

Page 134: ...ove a side mirror unscrew four mounting screws The side mirror will come off Remove expander plugs from mounting holes To install a new one place new expander plugs in mounting holes Align gasket hole...

Page 135: ...IITAYLOR DUNN MAINTENANCE MAINTENANCE TAYLOR DUNN ET 1 50 MAINTENANCE 1...

Page 136: ...lity Note A warranty work must be done by an authorized Taylor Dunn dealer Brakes Brakes should be maintained according to the PERIODIC MAINTENANCE INSPECTION CHECKLIST this section For more detail on...

Page 137: ...s and ball joint fittings Lubricate if neces sary use wheel bearing grease Front end alignment and rod ends Suspension mounting bolts Check and fill batteries use distilled water only Wash batteries w...

Page 138: ...0 ft lbs Rear axle differential refill with SAE 90 oil Check motor brushes Repack front wheel bearings use wheel bearing grease Tighten all nuts and bolts R Replace I Relubri cate 4 800 km 10 000 km R...

Page 139: ...ti purpose Grease 2 Front Wheel Bearings 6 Wheel Bearing Grease 3 Steering Ball Joints 12 4 Suspension Bolts 1 MP Multi Purpose Grease 5 Master Cylinder 4 DOT 3 Brake Fluid 6 Kingpin Boss 2 7 Drive Sh...

Page 140: ...teering gear Lubricate steering gear Misadjusted steering gear Adjust steering gear Unlubricated king pin bushings Lubricate king pin bushings Air in brake lines Fill master cylinder and bleed brake l...

Page 141: ...pedal mount Tighten pedal mount screws Motor or solenoids Check motor and solenoids Dead battery Replace or recharge battery Loose wire connections Check wires and connections Defective accelerator m...

Page 142: ...25 Power on Light 1 6 71 038 10 Light I Windshield Wiper Switch 1 7 71 505 55 Horn Button 1 8 73 004 20 Horn 1 9 72 076 00 Headlight 1 10 72 050 00 Front Turn Indicator Lights 1 11 72 022 00 Taillight...

Page 143: ...7 5 cm 88X62 in 259 cm 102 in 1 045 Kg 2 300 lbs with Charger and Batteries 682 kg 1 500 lbs including driver passengers and accessories 534 cm 210 in 32 mph 50 kmph empty Fiberglass with front window...

Page 144: ...n rating Motor power wire 0 insulated cable Interlock driver s seat switch emergency power off button Front 11 hydraulic disc brakes Rear 11 hydraulic drum brakes 14 Highway radial tread pneumatic all...

Page 145: ...IITAYLOR DUNN ILLUSmATED PARTS UST PARTS LIST TAYLOR DUNN ET 1 50 PARTS LIST 1...

Page 146: ...ILLUSTRATED PARTS UST IITAYLOR DUNN FRONT BRAKE LINES AND MASTER CYLINDER 1 2 PARTS LIST TAYLOR DUNN ET 1 50...

Page 147: ...2 2 99 576 00 Clip Wagner 2 3 99 605 72 Brake Line Front to Master Cylinder 1 4 88 100 15 x 1 NC Hex Head Screw 2 5 99 511 50 Master Cylinder 1 6 88 109 81 NC Locknut 2 7 99 580 31 Bolt Brake 10 mm 2...

Page 148: ...ILLUSTRATED PARTS UST IITAYLOR DUNN REAR BRAKE LINES 1 11 4 PARTS LIST TAYLOR DUNN ET 1 50...

Page 149: ...1 3 99 574 00 Washer 1 4 99 603 59 Brake Line Formed Rear Left 1 5 99 580 00 Hose Brake with 24M and 3 s TF 1 6 99 576 00 Clip 1 7 99 609 56 Brake Line Formed Rear Axle to Switch 1 8 71 110 00 Brake...

Page 150: ...ILLUSTRATED PARTS UST 9 TAYLOR DUNN FRONT BRAKE ASSEMBLY 3 1 1 4 I 13 6 PARTS LIST TAYLOR DUNN ET 1 50...

Page 151: ...et Right 1 4 Caliper Bracket Bolts 4 5 Bearing Adaptor 1 6 Caliper Bracket Nuts 4 7 Grease Seal 1 8 Inner Bearing 1 9 1 nner Bearing Race 1 10 Outer Bearing Race 1 11 Outer Bearing 1 12 Spindle Washer...

Page 152: ...ILLUSTRATED PARTS LIST flTAYLOR DUNN REAR BRAKE ASSEMBLY 8 PARTS LIST TAYLOR DUNN ET 1 50...

Page 153: ...n fr t fr Hi REAR BRAKE ASSEMBL r t f L ITEM PART DESCRIPTION QTY NUMBER 1 85 205 61 Spring Kit 1 2 99 _504 00 Cylinder Wheel 2 3 41 632 00 Brake Shoes 11 Set of four 1 4 85 000 02 Park Brake Link Spr...

Page 154: ...ILLUSTRATED PARTS UST 9 TAYLOR DUNN PARK BRAKE ASSEMBLY 4 10 PARTS LIST TAYLOR DUNN ET 1 50...

Page 155: ...d Park Brake Lever 1 2 88 100 15 x 1 Hexagonal Head Screw 2 3 88 108 60 315 Washer 4 4 96 820 01 Cable Assembly Adjustable 1 5 41 311 20 Equalizer Loop Brake Cable 1 6 96 826 14 Cable Park Brake 1 7 8...

Page 156: ...ILLUSTRATED PARTS UST 8JTAYLOR DUNN STEERING GEAR AND LINKAGES 12 PARTS LIST TAYLOR DUNN ET 1 50...

Page 157: ...ing Shaft 1 8 88 289 81 7 8 NF Thin Hex Locknut 1 9 88 128 62 11 s Lock Washer 3 10 88 120 11 11 6 x 1 NC Hex Head Cap Screw 3 11 18 104 10 Lever Steering Splined 1 12 86 510 00 Clamp Assembly Ball Jo...

Page 158: ...ILLUSTRATED PARTS UST 8 TAYLOR DUNN FRONT AXLE AND SUSPENSION 1 2 11 14 PARTS LIST TAYLOR DUNN ET 1 50...

Page 159: ...F Grade C Bushing OD x 0 6 ID x 1 65 1f Tapered Lug Nuts Wheel Locknut 3 a NC Locknut Plate Spring Shock Absorber 5 a NC Nylock Hex Nut Washer SAE Plain 51a x 21f NC Hex Head Screw Spring 4 leaf Axle...

Page 160: ...ILLUSTRAiED PARTS UST 81TAYLOR DUNN MOTOR MOUNTS 16 PARTS LIST TAYLOR DUNN ET 1 50...

Page 161: ...155 03 Motor Mount Front 1 4 88 149 81 112 NC Locknut 2 5 88 148 61 112 SAE Washer 2 6 98 601 51 1 12 ID Washer Mount 2 7 98 603 10 R ubber Grommet s s ID 2 8 70 072 00 Motor 72V 9 1 9 02 155 02 Motor...

Page 162: ...ILLUSTRATED PARTS UST IITAYLOR DUNN MOTOR 18 PARTS LIST TAYLOR DUNN ET1 50...

Page 163: ...0 27 00 Brushes With Terminal 4 3 85 402 00 Brush Spring 8 4 70 208 00 Field Coil 1 5 80 210 00 Ball Bearing CE 1 6 70 072 10 Armature 1 7 80 211 00 Ball Bearing DE 1 Available from Manufacturer at ti...

Page 164: ...ILLUSTRATED PARTS UST 8 TAYLOR DUNN PROPELLER SHAFT Differential 20 PARTS LIST TAYLOR DUNN ET 1 50...

Page 165: ...i i e gqpgpggffl ft AFT _ _ _ __ t x t t r _ ITEM PART DESCRIPTION QTY NUMBER 1 88 107 10 x NC Square Head Screw Drilled 3 2 86 557 31 Drive Shaft with Speedo Gear 1 3 86 554 30 U bolt and Nut U joint...

Page 166: ...ILLUSTRATED PARTS UST REAR AXLE SUSPENSION 22 PARTS LIST 9 10 i I j i i I I I I 1 I I 1 I I 15 I TAYLOR DUNN 13 TAYLOR DUNN ET 1 50...

Page 167: ...5 16 514 10 Spacer 1 2 6 88 189 81 5 e NC Nylock Hex Nut 4 7 96 248 01 Bolt Spring with Grease Fitting 6 8 85 513 20 Spring 4 leaf 2 9 88 159 84 1 2 20 Locknut 8 10 16 867 02 Plat Spring Formed 3 Axle...

Page 168: ...ILLUSTRATED PARTS UST TAYLOR DUNN REAR AXLE AND WHEEL 24 PARTS LIST TAYLOR DUNN ET 1 50...

Page 169: ...Tapered Lug nuts 10 2 13 770 00 Wheel 2 3 41 533 02 Drum Brake 11 ID 5 x 51 211 2 4 41 168 20 Axle Rear 26 with Short Stud and Bearing 2 5 88 159 84 Locknut 112 NF 8 6 32 514 02 Plate Retainer RearAxl...

Page 170: ...ILLUSTRATED PARTS UST DIFFERENTIAL 26 PARTS LIST IITAYLOR DUNN 6 7 TAYLOR DUNN ET 1 50...

Page 171: ...Adjusting Nut Differential Bearing 2 10 41 711 00 Shim Pinion 1 3 11 80 555 00 Bearing Ball Pinion 1 12 41 714 00 Retainer Bearing 1 13 80 702 00 0 ring Pinion 1 14 44 340 91 Flange Ring Ge ar Pinion...

Page 172: ...ILLUSTRATED PARTS UST 9JTAYLOR DUNN SEATS 1 10 7 28 PARTS LIST TAYLOR DUNN ET 1 50...

Page 173: ...eat and Back with Switch 1 2 88 101 16 x 2 NC Hex Head Cap Screw Grade 5 4 3 88 108 61 Washer SAE Plain 8 4 88 140 14 x 1 NC Hex Head Screw 4 5 88 148 61 Washer SAE Plain 8 6 90 199 10 Seat Belt 2 7 9...

Page 174: ...ILLUSTRATED PARTS UST 11TAYLOR DUNN INSTRUMENT PANEL DASHBOARD 3 30 PARTS LIST TAYLOR DUNN ET 1 50...

Page 175: ...TJ ANl iP L L L Lt L ITEM PART DESCRIPTION QTY NUMBER 1 94 303 12 Assembly Dash with Speedometer and Keyswitch 1 2 8 x Pan Head Screw Type B Threaded 8 3 94 303 11 Assembly Dash with Battery Status In...

Page 176: ...ILLUSlRATED PARTS UST 8TAYLOR DUNN SPEED CONTROL 32 PARTS LIST TAYLOR DUNN ET 1 50...

Page 177: ...13 71 300 1 Contactor Forward Reverse 2 14 79 730 05 Diode Assembly with Terminals 3 15 62 209 71 Heatsink 1209 Type Control 1 16 62 209 70 Controller 400A 48 72 Volts EEC 1 17 79 840 00 Circuit Brea...

Page 178: ...ILLUSTRATED PARTS UST UJTAYLOR DUNN CHARGER AND CHARGER MOUNTS 34 PARTS LIST TAYLOR DUNN ET 1 50...

Page 179: ...t Sink Assembly with Diodes 1 6 79 831 00 Fuse Assembly 1 7 79 603 00 Transformer 1 8 79 531 00 Bushing Insulator for AC Cord 1 9 79 576 00 Cordset AC 230 15 with Plug 1 10 76 002 01 Plug 230 30 1 11...

Page 180: ...ILLUSTRATED PARTS UST m TAYLOR DUNN THIS PAGE IS INTENTIONALLY LEFT BLANK 36 PARTS LIST TAYLOR DUNN ET 1 50...