Taylor-Dunn C0-425-36 Manual

The Best Way
To Go
About Your
Business
®
Serial number Starting: 150774
MANUAL MC-425-02
Operation, Troubleshooting and
Replacement Parts Manual
Models Inlcuded:
C0-425-36 (C 4-25-36)
C0-425-48 (C 4-25-48)
Revision: C

TAYLOR-DUNN SERVICE CENTER
For more information about this and other Taylor-Dunn®manuals, please write Taylor-Dunn®:
Taylor-Dunn®Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn®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 retrieval
system without prior written permission of Taylor-Dunn®Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn®Mfg., 2114 W. Ball Road, Anaheim, CA 92804

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

Table of Contents
Contents
Introduction............................................................ 1
About this manual..................................................................... 2
Who Should Read This Manual................................................ 3
Responsibilities ........................................................................ 3
How To Use This Manual.......................................................... 4
Conventions .......................................................................................................................5
How to Identify Your Vehicle .................................................... 6
Taking Delivery of Your Vehicle ............................................... 7
Safety Rules and Operating Instructions ............. 1
Standard Specifications Tow Tractor ...................................... 2
Safety Rules and Guidelines.................................................... 3
Driver Training Program ........................................................... 4
Driver Qualifications. .........................................................................................................4
Key-Switch ........................................................................................................................5
Forward-Off-Reverse Switch .............................................................................................5
Horn Switch ....................................................................................................................... 5
Headlight Switch................................................................................................................5
Hi-Low Switch....................................................................................................................6
Accessory Switch (Optional) ............................................................................................. 6
Hour Meter/ Battery Status Indicator (BSI).........................................................................6
Steering .............................................................................................................................7
Hazard Light Switch (Optional) ..........................................................................................7
Directional Signals ............................................................................................................. 7
Accelerator Pedal .............................................................................................................. 8
Foot Brake Pedal ...............................................................................................................8
Battery Disconnect Switch.................................................................................................8
Park Brake......................................................................................................................... 8
Reverse or Motion Alarm (Optional)................................................................................... 9
Seat Interlock Switch .........................................................................................................9
Smart View Display............................................................................................................10
Vehicle Operational Guidelines ............................................... 13
Safety Guidelines ..............................................................................................................13
Starting: .............................................................................................................................13
While driving:..................................................................................................................... 14
Loading and Unloading ......................................................................................................14
Parking ..............................................................................................................................14
Towing ...............................................................................................................................14
Charging your vehicle............................................................... 15
Operation of the Charger ................................................................................................... 15
New Battery Break in ......................................................................................................... 15
Storing and Returning to Service ........................................... 16
Storing Your Vehicle...........................................................................................................16
Returning To Service .........................................................................................................16
Periodic Maintenance Checklist .............................................. 17
Standard Periodic Maintenance Schedule
for the Smart View Display.................................................. 18
Daily Visual Inspection ............................................................. 19
Maintenance Schedule for Sever Duty Applications .............. 19

Table of Contents
General Maintenance ...............................................1
Maintenance Guidelines ........................................................... 2
Maintenance Guidelines for Vehicles Used in
Severe Conditions .................................................................... 3
Troubleshooting Guide............................................................. 4
Lubrication Chart ...................................................................... 5
Front Axle Service ....................................................1
Inspect the Front Wheel Bearings and King Pin .................... 2
Adjust Front Wheel Bearings .................................................. 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
Replace the Pivot Pin and Bushings....................................... 10
Replace the Steering Knuckle.................................................. 11
Steering Component Service ..................................1
Front End Alignment................................................................. 2
Inspect Ball Joints .................................................................... 5
Adjust the Steering Gear (Saginaw) ........................................ 6
Replace the Tilt Steering Assembly......................................... 8
Steering Column ....................................................................... 9
Disassemble...............................................................................................................9
Assemble....................................................................................................................10
Replace the Steering Gear ....................................................... 11
Center the Steering Gear.......................................................... 12
Pitman Shaft Alignment............................................................ 12
Replace the Ball Joints, Tie Rods, and Drag Link.................. 13
Replacing the Drag Link .............................................................................................14
Replacing the Tie Rod ................................................................................................15
Repair the Steering Gear .......................................................... 16
Exploded View of Steering Gear ................................................................................19

Table of Contents
Brake Service............................................................1
Inspect the Service Brake ........................................................ 2
Disc Brake Pads .........................................................................................................2
Disc Brake Rotor ........................................................................................................3
Inspect the Parking brake ........................................................ 4
Wheel Park Brake ......................................................................................................4
Adjust the Service Brakes ........................................................ 5
Two or Four Wheel Hydraulic Disc Brakes .................................................................5
Adjust the Brake Linkage ......................................................... 5
Adjust the Parking Brake ......................................................... 7
Wheel Park Brake ......................................................................................................7
Check Master Cylinder Fluid.................................................... 8
Bleed the Brakes ....................................................................... 9
Flush the Brake System ........................................................... 11
Replace the Parking Brake Lining ........................................... 12
Wheel Park Brake ......................................................................................................12
Replace Front Brake Pads........................................................ 13
Replace Rear Brake Pads......................................................... 15
Hydraulic Disc.............................................................................................................15
Replace the Wheel Cylinder ..................................................... 17
Disc Brake Body Assembly (front or rear) ...................................................................17
Repair the Brake Body.............................................................. 19
Replace the Master Cylinder .................................................... 21
Repair the Master Cylinder....................................................... 23
Throttle Linkage .......................................................1
Throttle Linkage Adjustments .................................................. 2
Motor Service............................................................1
Inspecting the Motor Brushes ................................................. 2
Motors with internal cooling fans ................................................................................2
Motor Removal and Installation ............................................... 3
Motor Inspection ....................................................................... 3
Replacing the Brushes or Armature Bearing.......................... 7
Repairing the Commutator ....................................................... 8
Service Limits............................................................................ 10
Transmission ............................................................1
Check Oil Level ......................................................................... 2
Change Oil ................................................................................. 3
Motor Removal and Installation ............................................... 4
Rear Hub or Rotor ..................................................................... 5
Removing and Installing the Rear Axles ................................. 6
Transmission Assembly ........................................................... 8
Remove and Install .....................................................................................................8

Table of Contents
Disassembly and Reassembly of the
Primary Reduction Gear Case ................................................. 10
Disassembling the 3rd Member ............................................... 13
Assembling the 3rd Member .................................................... 16
Pinion Bearing Preload ...............................................................................................19
Pinion Gear Shimming Instructions ........................................ 20
Setting the Pinion Gear Depth ...................................................................................20
Suspension...............................................................1
Replace the Rear Springs......................................................... 2
Replace the Front Springs ....................................................... 3
Replace the Shocks .................................................................. 4
Front or Rear ..............................................................................................................4
Tires and Wheels......................................................1
Tire Inflation .............................................................................. 2
Tire Inspection .......................................................................... 2
Replace the Rear Tire/Wheel.................................................... 3
Repair the Tire (pneumatic)..................................................... 4
Replace the Tire (pneumatic) .................................................. 5
Battery Service .........................................................1
Cleaning..................................................................................... 2
Testing ....................................................................................... 3
Watering..................................................................................... 5
Charging .................................................................................... 6
Replacing (6-volt batteries only).............................................. 7
Moist Charge Batteries ...............................................................................................9
Storage and Returning to Service ........................................... 10
Storage .......................................................................................................................10
Returning to Service ...................................................................................................11
Sevcon Control System Troubleshooting..............1
Test Equipment Required: ..........................................................................................2
Important Notes and Instructions ................................................................................2
Definitions:..................................................................................................................2
Terminology used: ......................................................................................................2
Start Troubleshooting Here .........................................................................................3
Test 8. Anti-Rolloff Fault..............................................................................................21
Sevcon Logic Voltage Reference Table ......................................................................22
Status LED Code Table...............................................................................................23
Charger Troubleshooting ........................................1

Table of Contents
Wire Diagrams........................................................ 1
Dash ........................................................................................... 2
Control Panel............................................................................. 3
Illustrated Parts...................................................... 1
Front Axle, Steering and Brakes ........................ 2
Steering Column ............................................... 4
Steering Gear .................................................... 6
Front Suspension ............................................... 8
Transmission Assembly ..................................... 10
Transmission Gear Case .................................... 12
Transmission Differential Case.......................... 14
Rear Axle .......................................................... 14
Rear Brakes....................................................... 16
Brake Body Assembly........................................ 16
Rear Suspension ................................................ 18
Motor ................................................................ 20
Master Cylinder ................................................ 20
Automatic Electric Brake .................................. 22
Brake Lines ....................................................... 24
Brake linkage (parking brake) ........................... 26
Brake linkage (foot brake) ................................. 28
Throttle linkage ................................................ 30
Wheels and Tires............................................... 32
Instrument Panel (dash) .................................... 34
Resetting the Smart View Display ..................... 35
Speed Control Panel .......................................... 36
Miscellaneous Electrical.................................... 38
Lighting System ................................................ 40
Seat Cushions and Deck .................................... 42
Decals ............................................................... 44
Frame Components ........................................... 46
Side Battery Extract Option ............................... 46
Front Push Plate Option .................................... 48
Hitches .............................................................. 48
Charger ............................................................. 50
Batteries ............................................................ 50
APPENDIX A-Special Tools.................................... A-1
APPENDIX B-Torque Values.................................. B-1
Appendix C............................................................. 1
Brake Lining Handling Precautions......................................... 2

TAYLOR -DUNN

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

INTRODUCTION
Introduction Page-2
ABOUT THIS MANUAL
The purchase of this vehicle shows a belief in high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be
sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this
high quality Taylor-Dunn®vehicle.
This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn®vehicles and is
not intended as a training guide. Taylor-Dunn®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 Guidelines
•Operational Information
•Operator Responsibilities
•Owner Responsibilities
•Control Operation and Location Information
•Maintenance and Troubleshooting Information
•Standard Parts List
Beforeservicing,operating, trainingorperformingmaintenance onthisorany otherTaylor-Dunn®vehicle,
read the appropriate Taylor-Dunn®manual.
Each Taylor-Dunn®manual references the applicable models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

INTRODUCTION
Introduction Page-3
WHO SHOULD READ THIS MANUAL
This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn®vehicle. Each person
shouldbe familiarwith theparts of thismanual thatapply
to their use of this vehicle.
RESPONSIBILITIES
Of the Owner...
The owner of this or any Taylor-Dunn®vehicle is responsible for the overall maintenance and repairs of
the vehicle, as well as the training of operators. Owners should keep a record of conducted training and
maintenance performed on the vehicle. (OSHA Regulation, 29 CFR 1910.178 Powered Industrial Truck
Operator Training).
Of the Operator...
The operator is responsible for the safe operation 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 for the service and maintenance of the vehicle. At no time
should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn®
vehicle. For the purposes of training, a qualified service person may oversee the repairs or services
being made to a vehicle by an individual in training. At no time should an untrained individual be
allowed to service or repair a vehicle without supervision. This manual is not a training guide.
Of the Passengers ...
The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside the
vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of
recklessness are to be avoided. Do not engage in horseplay.

INTRODUCTION
Introduction Page-4
HOW TO USE THIS MANUAL
This manual is organized into five main sections:
INTRODUCTION
This section describes how to use this service manual and how to identify your vehicle.
Safety Rules and Operating Instructions
This section outlines the safety and operational issues, location and operation of controls, and the
operational checks that are to be performed on this vehicle. It also includes various subjects that should
be included in the operator and service training program.
Maintenance Service and Repair
This section gives specific information on the servicing of the vehicle and a schedule for maintenance
checks.
Electrical and Charger Troubleshooting
Thissection identifies thetroubleshooting procedures fortesting the electricalsystem and batterycharger.
Illustrated Parts
This section provides an illustrated view of various assemblies. The illustrations are accompanied by
tables identifying the parts.

INTRODUCTION
Introduction Page-5
A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to
themselves or others. Be sure to follow any instructions contained
within a warning and exercise extreme 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 exercise special care and follow any
instructions contained with in a caution.
NOTE: Alerts the reader to additional information about a subject.
Conventions
Symbolsand/or wordsthat areused to definewarnings, cautions,instructions, ornotes found throughout
this manual:

INTRODUCTION
Introduction Page-6
HOW TO IDENTIFY YOUR VEHICLE
This manual applies to vehicles with the same model and serial numbers listed on the front cover.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.
The locations of the model and serial numbers are illustrated below:
This vehicle is not designed to be driven on public roads or highways.
It is available in maximum designed speeds ranging from 7 to 9 mph.
Do not exceed the maximum designed speed. Exceeding the maximum
designed speed may result in steering difficulty, motor damage, and/
or loss of control. Do not exceed locally imposed speed limits. Do not
tow this vehicle at more than 5 mph.

INTRODUCTION
Introduction Page-7
The only personnel authorized to repair, modify, or adjust any part
of this or any Taylor-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 bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.
TAKING DELIVERYOF YOUR VEHICLE
Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious
problems:
•Examine the contents of all packages and accessories that may have come in separate
packages with the vehicle.
•Make sure everything listed on the packing slip is there.
•Check that all wire connections, battery cables, and other electrical connections are secure.
•Check battery cells to be sure they are filled.
•Check the tire pressure, tightness of lug nuts, and for any signs of damage.
Check the operation of each of the following controls:
•Accelerator
•Brake
•Parking Brake
•Key-Switch
•Forward/Reverse Switch
•Reverse Beeper (if equipped)
•Front Headlight Switch
•Steering Wheel
•Horn
What To Do If a Problem is Found
If there is a problem or damage as a 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, notify your Taylor-Dunn®dealer of the claim.
If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately
contact your local Taylor-Dunn®distributor and report the problem. The report must be made within 24
hours of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn®vehicle is
a factory authorized service technician.

TAYLOR -DUNN

TABLE OF CONTENTS
Standard Specifications Tow Tractor............2
Safety Rules and Guidelines .........................3
Driver Training Program................................4
Driver Qualifications. ...............................................4
Key-Switch ...............................................................5
Forward-Off-Reverse Switch ................................... 5
Horn Switch..............................................................5
Headlight Switch ...................................................... 5
Hi-Low Switch ..........................................................6
Accessory Switch (Optional) ................................... 6
Hour Meter/ Battery Status Indicator (BSI) .............6
Steering ....................................................................7
Hazard Light Switch (Optional) ...............................7
Directional Signals ...................................................7
Accelerator Pedal ....................................................8
Foot Brake Pedal .....................................................8
Battery Disconnect Switch ......................................8
Park Brake ...............................................................8
Reverse or Motion Alarm (Optional) ....................... 9
Seat Interlock Switch...............................................9
Smart View Display .................................................10
Vehicle Operational Guidelines.....................13
Safety Guidelines .................................................... 13
Starting: ....................................................................13
While driving: ........................................................... 14
Loading and Unloading............................................14
Parking .....................................................................14
Towing ......................................................................14
Charging your vehicle ...................................15
Operation of the Charger.........................................15
New Battery Break in...............................................15
Storing and Returning to Service ................16
Storing Your Vehicle.................................................16
Returning To Service ............................................... 16
Periodic Maintenance Checklist ...................17
Standard Periodic Maintenance Schedule
for the Smart View Display .....................18
Daily Visual inspection: ........................................... 19
Maintenance Guidelines for
SevereDutyApplications........................19
Safety Rules and Operating
Instructions

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 2
STANDARD SPECIFICATIONS TOW TRACTOR
ITEM Volts SPECIFICATION
Occupancy Driver only, no passengers
Dimensions 1994 L x 965 W x 1422 H Millimeters
78.50 L x 38.00 W x 56.00 H Inches
Turning Radius 1752 Millimeters (69 inches)
Dry Weight (Without Battery) 748 kg (1650 lbs)
Battery Compartment Dimensions 420 L x 812 W x 610 H Millimeters
16.5 L x 32 W x 24 H inches
Battery Specifications:
Min/Max Battery Weight 453.5 kg to 635 kg (1000 lbs to 1400 lbs)
Voltage 36 or 48
Connector SB 350 Blue
Lead Length 762 millimeters (30 inches)
Position A
Cover No
Maximum Towed Load 48 136 kg (300 lb) Draw Bar Pull @ 14.5 kph (9 mph)
36 113 kg (250 lb) Draw Bar Pull @ 11.3 kph (7 mph)
Electrical System Solid State Speed Control, 500 Amp
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid Differential
Motor, DC 48 12 kW (16.3 Horse Power) for 5 min
Separately Excited Field 36 8.5 kW (11.5 Horse Power) for 5 minutes
Maximum 14.5 kph (9 mph)
Recommended Speed
Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake
Steering Automotive Steering 24:1
Tires 4.80 X 8 Pneumatic Load Rang C, Split Rims
Instrumentation Battery Discharge Indicator, Key Switch, Horn Button,
Forward/Reverse Switch, Headlight Switch, Hour
Meter, Battery Disconnect Switch, Hi-Low Speed Switch
Light Accessories Headlight, Tail/Brake/Reverse Light, Turn Signals
Thisvehicleconforms to requirementsforTypeE vehiclesasdescribedin O.S.H.A. StandardSection1910.178
(Powered Industrial Trucks) and with all applicable portions of the American National Standard for Operator
Controlled Industrial Tow Tractors (ANSI B56.9).