Taylor-Dunn TT-316-36, Operation, T Roubleshooting And Replacement Parts Manual

Page 1: ...The Best Way To Go About Your B u s i n e s s Serial Number Starting 166099 MANUAL MT 316 00 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded TT 316 36 TT3 16 Revision C...

Page 2: ......

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: ...12 Signet Charger Troubleshooting 13 Wire diagram 14 Illustrated Parts 15 Appendix Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Handling Precautions 18 Taylor Dunn El...

Page 6: ...TAYLOR DUNN...

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

Page 8: ...pplicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any T...

Page 9: ...entions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information a...

Page 10: ...ated below This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American...

Page 11: ...Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe...

Page 12: ...TAYLOR DUNN...

Page 13: ...Codes 8 Vehicle Operational Guidelines 9 Safety Guidelines 9 Starting 9 While driving 9 Loading and Unloading 9 Towing Loads 9 Parking 10 Draw Bar Pull DBP definition 10 Towing This Vehicle 10 Chargi...

Page 14: ...inition Ultimate 2 000 pounds Draw bar Pull 8 896 Newtons Tongue weight max 22 kg 50 lbs Electrical System Solid State Speed Control 400 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid D...

Page 15: ...those who will be operating this vehicle The training program shall not be condensed for those claiming to have previous vehicle operation experience Successful completion of the Operator Training pr...

Page 16: ...while the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward off reverse switch should be in the center OFF position with the key switch off whenever the oper...

Page 17: ...ot only It works similar to the brake in an automobile Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied Relieving pressure from the pedal releases the...

Page 18: ...uous sound along with a bi color indicator lamp Inspect the fluid level in all battery cells when the alarm sounds or the bi color lamp turns from its green color to red The vehicle batteries should t...

Page 19: ...he accelerator module is closed After the Pump Hours 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 sy...

Page 20: ...attery If the battery is good check wiring to the controller note 2 04010 Battery voltage too high Incorrect battery installed 04011 Personality fault Reprogram or replace the controller note 3 04012...

Page 21: ...al 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 22: ...possible this vehicle should be placed on a carrier rather than towing Draw Bar Pull DBP definition DBP is a measure of pulling force required to move a load The load may be a trailing load or a pushe...

Page 23: ...an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes Charging State LED1 LED2 LED3 0 to 50 Blinking OFF OFF 50 t...

Page 24: ...eir life span Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to SectionMaintenance Service and Repair for battery maintenance in...

Page 25: ...h and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l C...

Page 26: ...only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire...

Page 27: ...inclusive of a severe duty application Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on...

Page 28: ...TAYLOR DUNN...

Page 29: ...Table of Contents General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor...

Page 30: ...parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Periodic maintenance and service must be performed on this vehicle Failure to complete thes...

Page 31: ...n Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Oil Leak in Rear Bearing A...

Page 32: ...e 2 Front Fork Bearings 1 General Purpose Grease 3 Steering Gear 1 General Purpose Grease 4 Pedal Linkages 2 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 Ste...

Page 33: ...TABLE OF CONTENTS Inspect the Front Wheel Bearings 2 Adjust Front Wheel Bearings 2 Front Axle Removal and Installation 3 Removal 3 Installation 3 Replace Front Wheel Bearings 4 Front Axle Service...

Page 34: ...el s by hand The wheel should stop spinning in no more than 2 revolutions A wheel that continues to spin freely is an indication of a loose wheel bearing NOTE Refer to the Adjust Front Wheel Bearings...

Page 35: ...ust Front Wheel Bearings section for information regarding tightening the front axle 5 Lower the vehicle 6 Reconnect the main positive and negative cables at the batteries 7 Remove the blocks from beh...

Page 36: ...on section for information regarding installing the axle 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Test dr...

Page 37: ...d Alignment 2 Inspect the Steering Gear 2 Fork Bearings 2 Inspection 2 Steering Gear and Column Assembly 3 Disassemble 3 Inspection 3 Assemble 3 Replace the Front Fork 4 Steering Component Service MX...

Page 38: ...ted to Broken or fatigued fork spring Bent fork Bent frame Dragging rear brake Seized rear wheel bearing INSPECT THE STEERING GEAR Tie the front fork so that it cannot rotate Rotate the steering wheel...

Page 39: ...a fine tooth single draw file or fine Arkansas stone Insert the counter gear into each of the bronze bushings The gear should rotate freely with no noticeable lateral play If the gear binds or has exc...

Page 40: ...ront springs 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 sever...

Page 41: ...e Brake System 5 Flush the Brake System 6 Replace the Parking Brake Lining 7 Inspection 8 Replace Front Disc Brake Pads 9 Replace Rear Brake Pads 10 Replace the Wheel Cylinder 11 Rear Disc Brake Body...

Page 42: ...NSPECT THE SERVICE BRAKE Disc Brake Rotor NOTE The front brake rotor is an integral part of the front hub If the brake rotor is worn beyond its service limits then the front hub must be replaced Refer...

Page 43: ...and must be replaced 10 Reconnect the electric brake 11 Reconnect the main positive and negative cables at the batteries 12 Remove blocks from behind the wheels 13 Test drive the vehicle ADJUST THE S...

Page 44: ...ow all warnings on the brake fluid container Always use brake fluid from a new sealed container Never reuse any brake fluid that has been removed from the brake system Use of contaminated brake fluid...

Page 45: ...on the brake cylinder that is to be bled Route the hose into a clear container for waste brake fluid 10 Pump the brake pedal a few times and then press and hold light pressure to the brake pedal Typi...

Page 46: ...ach axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder 11 Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hose...

Page 47: ...s 9 If required remove the larger bearing circlip and press out the bearing If the bearing is removed it must be replaced 10 Thoroughly clean all parts 11 Inspect all parts for damage or wear 12 Reass...

Page 48: ...on the hub and the friction plate for damage 3 Inspect the inner contact plate and the outer housing where they come into contact with the friction plate for wear or damage 4 Inspect the three dowel p...

Page 49: ...10 Remove the wheel from the front hub and push it away from the brake NOTE Refer to the illustration below for the following steps 11 Remove the brake body bolts 10 and discard the lock nuts 1 and b...

Page 50: ...le Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Current Taylor Dunn brakes are asbestos free However there is the possibility that the original...

Page 51: ...ain 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 the vehicle Failure to use lifting and s...

Page 52: ...estos Refer to appendix C for recommended handling precautions Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support...

Page 53: ...ntaminates left in the brake system could lead to brake failure and result in property damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin or eyes Always wear prote...

Page 54: ...nsert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake body making sure that the boot seats pr...

Page 55: ...sh 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 phys...

Page 56: ...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 57: ...tor 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 10 Motor Ser...

Page 58: ...motor from the vehicle See the Transmission section for information on removing the motor 2 Remove the brush cover and pull the brushes out away from the commutator 3 Remove the dust cap from the rea...

Page 59: ...or information regarding machining the commutator 7 Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted arm...

Page 60: ...ring in the rear housing 6 While supporting the inner race of the bearing press the armature into the bearing 7 Push the motor brushes into the brush holder until the brush spring snaps into place Be...

Page 61: ...mmutator undercut depth in 5 places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut 7 Whil...

Page 62: ...e Field 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0116 1 20 70 054 41 XP 1789 or DY2 4001 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 057 40 XP 1673 or DV1 4003 0 635 0 025...

Page 63: ...ation 3 Rear Hub or Rotor 3 Removing and Installing the Rear Axles 4 Transmission Assembly 6 Remove and Install 6 Disassembly and Reassembly of the Primary Reduction Gear Case 7 Disassembling the 3rd...

Page 64: ...r quart drain pan under the drive assembly 8 Remove the drain plugs from the differential case and gear case 9 Once the oil has drained replace the drain plugs and lower the vehicle to the ground 10 R...

Page 65: ...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 bodily injury REAR HUB OR ROTOR NOTE...

Page 66: ...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 The axle retaining plate bolts...

Page 67: ...he o ring NOTE Be sure not to damage the o ring 16 Use new bolts for the axle retaining plate 17 If the wheel hub was removed install the hub and rotor Torque the hub bolt to 275 ft lbs 17 Fill with o...

Page 68: ...en raising more than one wheel off of the ground a vehicle lift system capable of raising the entire vehicle must be used Raising only the 2 rear wheels will result in instabilty of the raised vehicle...

Page 69: ...oist 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 12 Remove the circlip fro...

Page 70: ...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 71: ...ng the gear case 12 Remove the 12 side plate bolts then remove the side plate Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifti...

Page 72: ...s 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...

Page 73: ...arrier bearing race ring nuts The two ring nuts must be turned equally in opposite directions NOTE To move the ring gear closer to the pinion Loosen the housing carrier bearing race ring nuts and tigh...

Page 74: ...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...

Page 75: ...Maintenance Service and Repair Transmission Page 13 Figreu 1a Figure 2 Figreu 1b Figure 4 Figure 3 NOTE Values shown are for reference only D C...

Page 76: ...TAYLOR DUNN...

Page 77: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 5 Front 5 Taylor Dunn also manufactures People Movers...

Page 78: ...ifting 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 bodily injury Damaged or...

Page 79: ...at the batteries 11 Remove the blocks from behind the wheels 12 Test drive the vehicle Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to...

Page 80: ...tion 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 bushing s For inter...

Page 81: ...leakage 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 orde...

Page 82: ...TAYLOR DUNN...

Page 83: ...Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels The Taylor Dunn line of small personnel carrie...

Page 84: ...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...

Page 85: ...eplacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire 1 Remove the tire from the wheel 2 Cut the old valve stem off o...

Page 86: ...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 87: ...rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage A battery is a live electrical source It cannot be disconnected or neutralized Do not...

Page 88: ...O NOT get any of the solution into the battery cells 8 Reconnect the battery remove the blocks from the wheels and test drive CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operat...

Page 89: ...pting a charge and should be replaced NOTE Refer to Charger Troubleshooting for information on checking the charging system The highest reading will be the cell that is accepting the most charge This...

Page 90: ...istilled water using part number 77 201 00 battery filler never add additional battery electrolyte to the batteries 8 Reconnect the battery remove the blocks from the wheels and test drive Do not over...

Page 91: ...ns of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and repainted 13 If there are excessive signs of corrosion then it may be necessary to...

Page 92: ...mulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries When torquing battery hardware use a backup wrench on the battery bolt and tig...

Page 93: ...the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte is poisonous an...

Page 94: ...ure failure of the batteries 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Confirm the electric park brake is ap...

Page 95: ...ormation regarding checking the electrolyte level 8 Test the batteries Refer to Testing section for information on testing the batteries 9 The batteries are now ready to be put back into service 1 Mak...

Page 96: ...TAYLOR DUNN...

Page 97: ...itions 2 Terminology used 2 Important Notes and Instructions 2 Identifying Your Controller 3 Start Troubleshooting Here 4 Test 8 Anti Rolloff Fault 17 Test 9 Electric Motor Brake 18 Logic Voltage Refe...

Page 98: ...be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified Some tests refer to a High Low switch The High Low switch is option...

Page 99: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...

Page 100: ...battery check the following The batteries The wiring from the battery status indicator to the batteries for open circuits The battery status indicator The positive and negative circuit breaker The ma...

Page 101: ...r for open circuits 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 TEST 1 3 Test the voltag...

Page 102: ...to the ground 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...

Page 103: ...fication table can be found in the Motor Service section If the test indicates an open circuit then repair or replace the motor Test continuity from F1 to the frame of the motor Any reading other than...

Page 104: ...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...

Page 105: ...at 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 Place the forward and reverse switch in the FORWA...

Page 106: ...d movement of the vehicle resulting in injury or property damage Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all p...

Page 107: ...ults may have occurred Broken Wire Check the wire from pin 8 in the 12 Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm...

Page 108: ...e pin numbers are cast into the connector as shown in the illustration TEST 6 1 Accelerator pedal released Test the voltage from pin 9 to battery positive If the voltage equals battery volts then skip...

Page 109: ...ge equals battery volts then skip ahead to test 6 4 If the voltage does not equal battery volts then check the wire from pin 4 to the battery voltage negative circuit breaker Stop trouble shooting her...

Page 110: ...between 4 8 and 5 1 volts then the module has failed and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering t...

Page 111: ...se skip ahead to test 7 3 Place the forward and reverse switch in the FORWARD position Referencing battery positive test the voltage at the Blue Black wire on the F R switch If the voltage equals batt...

Page 112: ...ground TEST 7 4 Check the wires from the F R switch to the logic card connector for continuity After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground F...

Page 113: ...tch in the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor...

Page 114: ...ere and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Test 9 1 Close the seat switch turn the key switch ON place the for...

Page 115: ...eed controller Disconnect the electric brake harness connector and connect the electric brake to a 24 volt source This should release the brake and allow you to troubleshoot the vehicles control syste...

Page 116: ...ch in high Low High low Switch in low High 7 Hand brake switch closed Low Hand brake switch open High 8 Key switch on ref battery positive Key switch off ref battery positive Battery volts 9 System of...

Page 117: ...Burned Motor Repair as required 4 Contactor fault or open motor Contactor Failure Open Circuit Check contactor and motor 5 Not used 6 Accelerator module fault FS 1 Micro Switch Failure Faulty Wiring A...

Page 118: ...eck wiring contactor and pre charge resistor on the contactor F04002 Steer Pot Steer Pot currently not used and this fault should not occur Check wiring F04003 Sequence Fault Start up switches not ope...

Page 119: ...ator error or operation of the vehicle F01000 Power Steer Overheat Not used F01001 Traction Motor Brush Wear Not used F01002 Pump Motor Brush Wear Not used F01003 Power Steer Motor Brush Wear Not used...

Page 120: ...TAYLOR DUNN...

Page 121: ...ging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries...

Page 122: ...eases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer t...

Page 123: ...eter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery...

Page 124: ...in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger ex...

Page 125: ...nections broken wires and proper connection to the batteries 2 AC line voltate too high or too low Check the input voltage It must be within 96 132VAC or 196 266VAC 3 Charger overheated Wait for charg...

Page 126: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charge...

Page 127: ...ing Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 Rev B Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the contro...

Page 128: ...hooting There are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example...

Page 129: ...ge the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On t...

Page 130: ...ng off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but stil...

Page 131: ...charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the c...

Page 132: ...V1 When the battery voltage equals V1 the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged T...

Page 133: ...end user Refer to the documentation supplied with the charger or contact the charger manufacturer for more information Turn the Key switch OFFBEFORE disconnectingthebatteries Disconnecting the batteri...

Page 134: ...TAYLOR DUNN...

Page 135: ...ehicle wiring diagram is too large to be legible when printed at this size A full size diagram 22 x 16 is included on the CD in PDF format You can access the diagram from a button on the CD menu The d...

Page 136: ...White Black Blue Black Violet Black Red Red Blue White White White Black Gray White Red White Blue Yellow Green Black Gray Black White Black Blue Black Violet Black Red Red Blue White White White Red...

Page 137: ...Cylinder 12 Rear Suspension 14 Motor 16 Electric Parking Brake 18 Motor Mount 18 Brake Lines 20 Wheels and Tires 22 Instrument Panel 24 Resetting the Smart View Display 25 Speed Control Panel 26 Misc...

Page 138: ...Illustrated Parts Page 2 Front Fork...

Page 139: ...5 142 00 Spring 10 15 003 02 Axle 11 45 338 00 Seal 12 80 017 00 Bearing 13 80 103 00 Race 14 12 158 11 Hub with rotor and races 15 14 090 04 Spacer right Not shown 14 090 02 Spacer right used up to s...

Page 140: ...Illustrated Parts Page 4 Front Brakes...

Page 141: ...3 41 348 70 Brake pad 4 41 348 57 Spacer 5 See Front Fork Rotor part of front hub 6 32 240 41 Bushing 7 41 350 10 Piston 8 41 350 09 Rubber boot 9 41 350 42 Brake body 10 88 069 82 1 4 NC HEX LOCKNUT...

Page 142: ...Illustrated Parts Page 6 Tilt Steering Column and Gear...

Page 143: ...8 148 61 1 2 SAE WASHER 4 18 18 308 65 PLATE SPRING STRNG TILT ADJSTR 1 19 97 211 20 U NUT 1 4 20 4 20 18 308 57 HANDLE TILT STEERING LOCKER 1 21 88 065 06 1 4 X 1 2 PHILLIPS TR HD 4 22 88 065 09 1 4...

Page 144: ...s available in increments of 05mm starting at 3 9mm 3 9mm spacer is part number GT 3287213 Add 10 to the part number for every 0 05mm over 3 9 For example if 4 55mm is needed 4 55 3 9 65mm over 0 65 0...

Page 145: ...earing 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 GT 3287463 Output gear 24 1 0 or 1 GT 3287473 Output gear 18 1 0 or 1 GT 3287483 Output g...

Page 146: ...Illustrated Parts Page 10 Transmission Differential Case Rear Axle...

Page 147: ...1 22 GT 71896 M10 x 25 Bolt 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 30 Axle shaft 2 2 80 505 20...

Page 148: ...Illustrated Parts Page 12 Rear Brakes Master Cylinder 8 Brake Body...

Page 149: ...grade 8 4 Brake Body ITEM PART DESCRIPTION QTY 1 99 588 00 Bleeder screw 2 2 99 588 01 Bleeder adapter 2 3 41 350 43 Brake body left 1 41 350 44 Brake body right 1 4 80 713 00 O ring 4 5 41 350 09 Boo...

Page 150: ...Illustrated Parts Page 14 Rear Suspension...

Page 151: ...Description Qty 1 88 101 18 3 8 X 2 1 2 NC HEX SCR GRADE 5 2 88 169 82 LOCK NUT 9 16 NF GRADE C 3 16 871 03 Spring hanger 4 32 213 00 Bushing 5 96 248 00 BOLT SHACKLE 9 16 DIA X 3 6 16 861 00 Spring p...

Page 152: ...Illustrated Parts Page 16 Motor...

Page 153: ...20 70 421 00 98 930 00 88 067 17 88 067 22 Not available at time of printing The original motor provided under part number 70 054 40 has been discontinued It has been replaced by 70 054 41 The 70 054...

Page 154: ...Illustrated Parts Page 18 Electric Parking Brake Motor Mount Up to serial number 173289 Up to serial number 173289...

Page 155: ...er 5 16 2 9 88 099 80 Nut 5 16 NF 2 10 88 067 17 Bolt 1 4 X 1 1 8 NC Grade 8 no brake option 88 067 29 Bolt 1 4 X 4 1 4 NC Grade 8 brake option only 1 11 96 500 04 Tool Electric Brake Manual Release 2...

Page 156: ...Illustrated Parts Page 20 Brake Lines...

Page 157: ...line rear 2 1 6 99 600 02 Formed brake line rear 3 1 7 99 603 03 Formed brake line rear 4 1 8 99 580 20 Hose rear 2 9 99 564 00 T fitting 3 16 tube 1 10 99 578 00 Bolt master cylinder fillting 1 11 9...

Page 158: ...Illustrated Parts Page 22 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 159: ...bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF Hex Bolt grad...

Page 160: ...Illustrated Parts Page 24 Instrument Panel Control console is located to the right side of the driver seat cushion 4 5 3 2 1 6 7 8...

Page 161: ...ed before the display will function If you have the Smart View display and wish to have the maintenance feature turned on then the Sevcon speed control must be reprogrammed To reprogram the Sevcon spe...

Page 162: ...arts Page 26 Speed Control Panel 9 3 4 6 5 2 12 11 10 8 7 1 13 14 Use 94 422 21 between item 1 and item 14 CONTROLLER TORQUE SETTINGS FOR M6 BOLTS 38 44 inch Ibs Miscellaneous Electrical Illustration...

Page 163: ...Motion alarm 13 88 818 06 screw 14 62 400 13 Heat sink Not Shown 69 068 55 Resistor contactor 75 152 13 Harness control wires 75 152 02 Power wires to motor 75 152 01 Link wires power Miscellaneous El...

Page 164: ...Illustrated Parts Page 28 Miscellaneous Frame and Body...

Page 165: ...1 2 SAE WASHER 4 88 148 62 1 2 IN LOCK WASHER 4 6 01 440 26 Floor Mat includes adhesive backing 1 7 01 440 56 Battery door right 8 88 140 15 1 2 X 1 3 4 NC HEX HD SCR 10 88 149 81 1 2 NC LOCK NUT 10 9...

Page 166: ...ed Parts Page 30 Charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife c...

Page 167: ...ignet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the...

Page 168: ...Illustrated Parts Page 32 Decals...

Page 169: ...43 Arma Legs Inside 1 4 94 373 10 Vehicle Data 1 5 94 384 21 Auto Park Brake 1 6 94 313 20 Safety Warning 1 7 See instrument Panel 8 94 319 00 Battery Disconnect 1 9 94 313 00 Battery Warning 1 10 94...

Page 170: ...EX HD NUT 2 7 88 099 81 5 16 NF NUT L H THREAD 2 8 88 109 80 3 8 NC HEX HD NUT 2 9 88 111 28 3 8 X 6 NF HD CAP SCREW 1 10 88 119 80 3 8 NF HEX HD NUT 1 11 88 140 23 1 2X3 1 2NC HEX HD SCR GR5 4 12 88...

Page 171: ...6 X 1 3 4NC HEX HD SCR 2 9 88 088 61 5 16 SAE WASHER 2 10 88 089 81 5 16 NC LOCK NUT 2 11 88 100 15 3 8X1 3 4 NC HEX HD SCR 1 12 88 108 61 3 8 SAE WASHER 1 13 88 109 80 3 8 NC HEX HD NUT 1 14 88 109 8...

Page 172: ...TAYLOR DUNN...

Page 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...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...