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troubleshooting - Taylor-Dunn

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1. White Brown Front left B Brown El em Brown g CHARGER 5 INTERLOCK a Black Rear Left Rear Right e 53 C 5 Red L Black AC peri 2 3 White White 5 White White White 9 9 White Green F White Green GROUND 2 White i White GROUND DASH PANEL White NOTE The charger interlock may 1 Switch 5 Backup Light be located in the charger cabinet Front er rown 3I mgh Red Gray Gray Bur VR IM Oe Ean e E NOTE Charger wire r Front eft 7 Brown 32 routing may vary 2 i Red 2 Gray Red FronvRight L o Brown 33 BATTERY POSITIVE Brown Black H HORN BATTERY NEGATIV i Rear Right lo Brown 43 Tail Lights i i Rear Left Brown 42 2 E 4 Brown 11 Brown E z Horn E 2 Switch 1 i 1 Blue White Blue White Red 9 i l E 1 Yellow 2 i Red i Red i 5 Red Red Black __ 1 White 8 1 1 Sle m White B White 3 1 4 2 i CONTROL Key Switch White White Violet Black 4 A E Red Red Blue White Blue White E a Viole gt gt 6 e White 8
2. Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 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 AWARNING 3 Set the park brake 9 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap 7 8 Remove the master cylinder cap If the fluid in the master cylinder is contaminated then the entire brake system must be flushed Refer to Bleed the Brakes for information regarding flushing the brake system Fill with brake fluid from a new sealed container to within 1 4 inch of the top of the master cylinder chamber and reinstall the cap 10 Reconnect the main positive and negative cables at the batteries 11 Remove blocks from behind the wheels 12 Release the parking brake and test drive the vehicle Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes AWARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Brakes 27 Page 7 Maintenance Service and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact w
3. 5 16 96 631 15 not shown Clamp Rubber Lined 1 1 2 ID 7 96 624 00 Clamp 1 4 Jiffy Clip 1 96 625 00 not shown Clamp 5 16 Jiffy Clip 96 626 00 Clamp 7 8 Jiffy Clip Parts 27 Page 25 Illustrated Parts Lestronic Charger page 1 Use K1 156 44 for complete portabel charger assembly with modified charger cord 11 1 Typical Built In charger Boe EM Typical Portable charger Parts gy Page 26 2 5 in V N 00 00c 9L 00 00c 9L 00 00c 9L 00 00c 9L 00 00c 9L 00 00 94 00 00 94 1uourooe dos 5 0 lt 608 6 0 lt 608 6 ET 90 6L z 09 608 6L Assy epy xoo ro1ug II 7 7 O S 01 995 61 01 99 lt 6 s Od 01 g 00 1 S 6L 00 0 2 6L 00 0 s 6L Py ureng 6 00 0 S 6L 00 0 S 6L 00 0 S 6L 00 0 S 6L 00 0 2 6L 00 0 S 6L 00 0 S 6L 00 1 S 6L 00 0 S 6L jenes WENS 8 00 1 8 6L 00 1 8 6L 00 1 8 6L 00 1 8 6L 00 1 8 6L 01 1 8 6L 00 1 8 6L 00 1 8 6L 00 1 8 6L Ayquiassy 5 4 L V N 01 48 64 01 88 64 2 O S p100 OV 9 O S 01 09 6L O S O S O S O S O S O S Te rvr9 6L JOWIOJSULI L S 6 2 64 I 6FL 6L T 6bL 6L OT 6bL 6L ET 6bL 6L OT 6bL 6L IT 6 L 6L ET 6bL 6L ET 6bL 6L porq v 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06
4. Best Way About Your Business TAYLOR DUNN _ Revision B 2 10 2011 Models Inlcuded 0 012 38 3 wheel RR Special MANUAL MB 238 00 Operation Troubleshooting and Replacement Parts Manual Serial Number Starting 164954 COPYRIGHT NOTICE Copyright 2001 by Taylor Dunn Mfg 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 TAYLOR DUNN SERVICE CENTER For more information about this and other Taylor Dunn manuals please write Taylor Dunn Mfg 2114 W Ball Roa Anaheim CA 92804 Attn Technical Writer B2 10 Ambulance B2 48 With Dump Bed Option B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides P2 50 30 000 Pound Tow Tractor ET 3000 50 Full Size Truck Section Index Taylor Dunn Model 0 012 38 Railroad Special Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transmission Service
5. Sevcon Troubleshooting Page 2 Electrical Troubleshooting Identifying Your Controller MicroPak Logic Connectors ween PowerPak Logic Connector NENNEN Sevcon Troubleshooting Page 3 Electrical Troubleshooting START TROUBLESHOOTING HERE If your vehicles is equipped with an electric motor brake the motor brake system must be checked to be sure it is working properly before AC AUTION continuing with this troubleshooting Operating the speed control when the motor brake has not disengaged may result in damage to the motor or speed control system Refer to Test 9 Electric Motor Brake for information regarding testing the motor brake system The electric motor brake is mounted between the drive motor and the primary reduction gear case An illustration of the motor brake is shown to the left ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Electric motor brake If the Battery Status Indicator does not show a charged 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 main circuit breaker for open circuits Do not continue unless the indicator sh
6. sss 6 Instrument Panel dash 22 Transmission Gear Case 8 Resetting the Smart View Display Maintenance Meter Rear 10 EE 23 Transmission Differential 10 Miscellaneous Electrical oeron 24 Rear Brakes 4 2 422 12 Lestronic amp Charger page 1 26 Brake Body Assembly 12 Lestronic Charger 2 28 Brake 14 2 hi HORE D nr 122 d ich VUE VERI M A IR 2 Master Cylinder sss 14 eat Cushions Deck and Lights MMC 16 Frame 32 Decals dede ee pepe 34 pP 18 Hitches 36 Rear 205 Signet 37 Illustrated Parts Front Fork Assembly See Tires and Wheels Parts el Page 2 Illustrated Parts Front Fork Assembly PART DESCRIPTION QT C 1 ITEM 12 88 109 80 3 8 NC HEX HD NUT 13 86 006 00 Shock with spring and upper mounting hardware 14 97 229 00 NUT 1 14NS NYLON INSERT 15 88 130 20 7 16 NF X 3 HEX HD GR 5 16 88 130 86 7 16NF FIB INSERT L
7. 2 Identifying Your Controller 3 Start Troubleshooting 4 Test 8 Anti Rolloff Fault 15 Test 9 Electric Motor Brake 16 Logic Voltage Reference Table 18 Status LED Code Table 19 Smart View Fault Codes 20 Turn the Key switch OFF BEFORE disconnecting the batteries ACAUTION Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table This troubleshooting guide is written in sequential order All tests AC AUTI ON must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Rev S Electrical Troubleshooting Test Equipment Required Digital multimeter DMM with diode test function FLUKE 79 model shown Throttle Module Analyzer Taylor Dunn part number 62 027 32 Definitions Battery volts full voltage available at the batteries at the time of test High Greater than 4 5 volts Low Less than 1 8 volts Terminology used The HOT side of a switch is the terminal that the power is connected to The COLD side of a switch 15 the terminal that the power is switched to FS 1 Micro switch in the accelerator modu
8. Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehicle and support with jack stands 7 Grab the top and bottom of the tire wheel assembly Feel for any movement or play while pulling and pushing on the top and bottom of the tire Any movement or play is indication of loose wheel bearings or king pin 8 Spin the front wheel 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
9. 01 99s 6L i 01 99 lt 6 01 98 64 p100 Od 01 00 0 lt lt 6 00 0 S 6L 00 08 64 00 05 64 00 08 64 O S PY 6 00 lt 6 00 lt 6 00 1 6 00 1 S 6L 00 lt 6 00 c s 6L 00 0 S 6L 00 ccs 6L O S PPY ureng 8 00 1 8 6L 00 1 8 6L 01 1 8 6L 01 1 8 6L 01 1 8 6L 00 1 8 6L 00 1 8 6L 00 1 8 6L 01 1 8 6L L O S O S s OT SLS 6L O S O S O S PIOD OV 9 O S O S O S O S O S O S 80 9 64 O S O S JOULI0JSUUI L 01 62 62 1 6FL 6L I 6PL 6L 6 2 62 6 2 62 O S T 6bL 6L 6 2 62 O S A quiessy oporq v 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L p 00 808 6L 00 808 6L 01 808 6L 01 808 6 01 808 6 01 808 6L 01 808 6L 01 808 6 01 808 6 TH 103 L8 TL0 YA L8 TL0 YA 99 S08 6L 99 S08 6L 9 lt 08 64 79 lt 08 6 0L S08 6L P9 S08 6L O S 00 8 62 017 188 642 s 5 00 lt 8 6 01 1 lt 8 6 OT TS8 6L 00 cs8 6L 1 91993104 9 qe 10d umg umg 91467104 91993104 91983104 91993104 1415 9 Sco Scivc Or rc Or rc Scivc Scc ST bT Or vc Od 8 0S 0ET LIOS OET 8 09 lt 6 09 lt 09 lt 6 09 lt F 0s 0 c F 0s 0 c LIOS OET sdury zg oSeoA 188 072196 188502196 188500790 1 8 0 188090190 188500190 188600790 188 0070 1 8 0 ed T 19349 06 90 6L 09 P0E 6L S0 0 6
10. Inspect the charger wire harness where it enters the charger cabinet for two Violet Black wires If these wires are present then the charger is equipped with the Interlock Relay Testing Make sure the key switch is in the OFF position then remove the key Placethe forward reverse switch in the center OFF position A WARNING Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Disconnect the charger from the AC power source Disconnect the two Violet Black wires at the charger harness knife connectors Set the DMM to check for continuity and connect the DMM leads to the wires going into the charger The DMM should indicate a closed circuit If the DMM indicates an open circuit then the relay or the wires to the relay have failed Stop here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirmed that the AC power source is working The DMM should indicate an open circuit If it still indicates a closed circuit then the relay or the wires to the relay have failed Stop here and repair the problem Ifthe DMM indicates
11. position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A CAUTION If the batteries are removed from the vehicle do not place them directly on the ground concrete or solid metal surface It is recommended to store them on a wooden pallet or equivalent Storing on the ground concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries AWARNING A battery is a live electrical source It Storage cannot be disconnected or neutralized Do Thoroughly clean the batteries and battery compartment not drop any tool or conductive object onto Refer to Cleaning in this section for information the battery A conductive object that comes regarding cleaning the batteries in contact with the battery terminals will Check the electrolyte level and charge the batteries initiate a short circuit of the battery This Refer to Watering in this section for information could cause the battery to explode s red regarding checking the electrolyte level resulting in severe bodily injury and or property damage Store the vehicle or batteries in a cool dry well ventilate area If storing for more than one month the batteries should be charged as follows ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately
12. 00 066 56 00 066 56 00 0 6 S6 00 0 6 86 deo jsnq 00 2 0 0 00 122 0 00 Ict 0L 19400 snug 01 Oc Ic 0L 0 ICt 0L Oc Tct 0L Oc IC 0L way 6 00 212 08 00 212 08 00 212 08 00 212 08 Suuvog 8 00 1 0 00 1 0 00 13 0 00 LIP OL Suto g L D 01 041 0 c 00 601 0L 8 01 041 0 c 00 601 0 c 00 601 0 ysnig 9 00 ELT OL 00 0 1 0 00 L1 0L 00 OLT OL 00 0 1 0 usnzq s 00 0 lt 8 02 1 04 00 0 lt 8 02 14 01 02 61 04 qsnig 0 602 0 0 60 0 Ayquiosse 01 00 0 00 00 0 00 00t 0L c OT ICt 0L OI TCt 0L OT ICt 0L 30014 1 It CL0 0L Ov ZS0 0L 0 lt 0 0 50 0 109 80 01 VOC8IdX 10 1007 12 02 POOP EAC 20 98 1 4 00t TAG TOOFCAG 20 68LTdX c00f TAG PPL s4030 A Parts 27 Page 19 Illustrated Parts Wheels and Tires Ref wheel hub Ec Ys Rear Suspension Parts Page 20 Illustrated Parts Wheels and Tires p 12 020 00 Wheel 5 50 x 8 10 092 00 18 5 x 8 50 x 8 LR C Pneumatic ewe 0000 CS ITEM PART 96 240 00 Not shown 32 214 50 85 510 17 16 861 40 16 861 41 96 114 00 88 159 84 8 19 96 103 00 20 88 149 81 21 50 460 00 2 86 602 00 88 120 17 88 129 81 88 128 60 Rear Suspension DESCRIPTION 1 2N
13. 18 Remove the front bearing from the input shaft NOTE The input shaft may have to be driven out to perform this procedure 19 Remove the input shaft s shims and spacer 20 Remove the pinion shaft from the 3rd member 21 Remove the front and rear pinion bearing races 22 Inspect all parts for signs of wear or damage 23 Thoroughly clean all parts Transmission Page 14 Maintenance Service and Repair ASSEMBLING THE 3RD MEMBER 1 Temporarily install the pinion gear hand tighten only 2 Install the carrier bearing race ring nuts into the housing and cover Cover 3 Install the carrier bearing races into the housing and cover Cover Housing 4 Place the differential assembly into the housing 5 Tighten the housing carrier bearing race ring nut so that the ring gear is not in binding against the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembly 8 Install the cover onto the housing using 4 bolts in a cross pattern and torque to 45 50 ft lbs 9 Pre set the carrier bearing preload by tightening the housing carrier bearing race ring nut until it requires 1 5 to 3 3 ft lbs to rotate the differential assembly NOTE Rotate the carrier assembly whenever adjusting the ring nuts Transmission Page 15 Maintenance Service and Repair 10
14. Illustrated Parts n M RN NT T fitting brake switch 99 564 00 T fitting rear Parts 27 Page 17 Illustrated Parts Motor C Qe oo Parts Page 18 2 5 in Surumure1801d o1 10 uo 10 Suumjoejnue A uunqp I0 L JORJUOS uooAos ojur oq snu s1ojoure red MOU 60 0 99 Jo Jo o3ejuvApe OL poods do ur uoronpor v jnoqe TIM 5 BUISTIO YM uuojred IOJOW p p60 07 94 JOIOW p PS0 OL Apop 0 0 24 1010 A 82245 1010 JA anbio X 5114915 seq 10101 0 0 PUL Tt 60 07 Aq peoerder seq 1 penunuoosrp sey 60 0 qumu wed eUISTIO oq 1 Sunund jo oum o qe reAe JON 109 CC L90 88 CC L90 88 CC L90 88 CC L90 88 8 8 Sununop umoys L1 L90 88 L1 L90 88 L1 L90 88 L1 L90 88 8 8 S 8 1 1
15. Make sure the batteries in good condition f the charger exhibits intermittent problems it must be in the failed mode for troubleshooting There are no internally serviceable components in the charger If the charger has failed then it must be replaced N Signet Charger Troubleshooting Page 2 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION AC input Voltage Range DC output System Voltage Charger Model HBS1000 36 PART No 79 303 40 AUTO SELECTABLE DUAL AC INPUT 100 240V 50 60Hz 13A OUTPUT 36V 20A 1000W Manufacturer SIGNET SYSTEMS INC Typical specification plate reference only specifications will vary for different chargers The model HBS 600W and HBS 1000W chargers are designed as automatic chargers The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged Once the charging cycle is complete the charger will monitor the battery voltage If the battery voltage drops below a specific value V2 the charger will turn on again for a short cycle Both the HBS 600W and HBS 1000W are two stage chargers The first stage is a constant current mode It Maintains a constant current until the battery reaches a terminal voltage V1 and then switches to the second stage constant voltage At the second stage the charger decreases the charger current while holding the batteries at the terminal volt
16. Suspension Tires and Wheels Battery Service Electrical Troubleshooting Lestronic Charger Troubleshooting Signet HB Charger Troubleshooting Signet HBS Charger Troubleshooting Wire diagram Illustrated Parts Appendix A Special Tools Appendix B Suggested Torque Values Appendix C Brake Lining Handling Precautions This quick reference section index guide will assist you in locating a desired topic or procedure Refer to each sectional Table of Contents for the page number location for specific topics or procedures Table of Contents About this 2 Who Should Read This 2 Responsibilities ee 2 How Use This Manual 3 CONVOMUIONS M 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 Introduction R 3 80 shown with extended steel cab and doors options INTRODUCTION ABOUT THIS MANUAL RESPONSIBILITIES 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
17. Black or Red Ground Green MODEL 1000 36 AUTO SELECTABLE DUAL INPUT 100 240 5060Hz 120 454V ITT 20 0 0 SYSTEMS INC IEC Europe and United Kingdom Neutral Blue Hot Brown Ground Green Yellow Typical Data Plate your data plate may be different Parts Page 37 TAYLOR DUNN NI EE UFACTURING Wo Greens Since 1949 Contents Appendix A Special Tools Appendix B Suggested Torque Limits for Standard Hardware Hardware Identification Standard Head Markings Hex Bolts inertes Other Bolts HEX Nuts isnt Hex Lock Nuts stover 2 2 Other Nuts rete rrt Suggested Torque Values non critical hardware 6 Suggested Torque Values critical hardware 7 Appendix C Brake Lining Handling Precautions Appendixes APPENDIX SPECIAL TOOLS Note This is a listing of all tools available Not all tools would be required for all vehicles Refer to the Maintenance Repair and Troubleshooting sections for information on tools required 41 532 50 Chain Case Centering Tool Used to center the chain case cover on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor Includes instructions 62 027 61 and 62 Sevcon System Handset
18. SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines Only qualified and trained operators may drive this vehicle Drive only on level surfaces or on surfaces having an incline of no more than 10 5 6 degrees Drive slowly when making a turn especially if the ground is wet or when driving on an incline This vehicle may overturn easily if turned sharply or when driven at high speeds Observe all traffic regulations and speed limits Keep all body parts head arms legs inside this vehicle while it is moving Keep the vehicle under control at all times Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle at intersections blind spots or other dangerous locations Do not drive over loose objects holes or bumps Yield right of way to pedestrians and emergencies vehicles Stay in your driving lane under normal conditions maintaining a safe distance from all objects Keep clear view ahead at all times Starting Perform all necessary vehicle preparation steps inspections or maintenance before operating this ve hicle 1 Make sure the forward off reverse witch is in the center OFF position Set the parking brake Hold down the foot brake Rotate the ON OFF switch to the ON position Wait 1 second then place the forward off reverse switch in the desired direction of
19. 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 Before servicing operating training or performing maintenance on this or any other Taylor 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 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 should be familiar with the parts of this manual that apply to their use of this vehicle Page 2 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 t
20. charger is plugged into the wall outlet or when the portable charger is plugged into the batteries As the battery charges the battery voltage rises The charger periodically checks the battery voltage and compares it to the previous reading When the battery voltage stops rising a predetermined amount then the batteries are no longer accepting a charge and the charger shuts off The charger will not start again unless the AC cord on a built in charger is disconnected from the wall outlet or the DC plug on a portable charger is disconnected from the batteries The charger does not check the current state of charge when it is plugged it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 5096 1175 1200 as indicated on a hydrometer before connecting the charger If the charger is connected before the batteries are discharged 50 the batteries may enter an overcharge state before the charger can sense that the batteries are no longer accepting a charge This could result in overcharging and damaging the batteries The relay that operates the charger is powered by the batteries being charged If the voltage on the batteries to be charged is less than approximately 6596 of the rated charger DC voltage the relay will not pick up and the charger will not turn on In this situation a manual charger would have to be used to bring the battery voltage
21. motor Remove the nuts from the armature studs and remove the two brush assemblies Remove the bearing circlip and press the motor bearing out of the housing and discard Inspection 1 Measure the length of each motor brush If any one brush is less than or equal to the service limit specified in section Service Limits then all four brushes should be replaced Refer to Replacing the Brushes section for information regarding replacing the motor brushes Rear Housing Circlip Brush Spring Stator Field Brush Cover Bearing Dust Cap Brush Holder Brush Armature Motor 3 4 Motor Service 2 Measure the diameter of the commutator f the commutator is less than the minimum diameter specified in section Service Limits then the motor must be replaced 3 Measure the commutator 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 at the end of this section then the commutator must be undercut Refer to Repair Commutator section for information regarding undercutting the commutator 4 Inspect the commutator for groves Hacksaw blade Incorrect Correct f the commutator is grooved then it must be machined on a lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for inform
22. the vehicle before lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in injury or property damage ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Sevcon Troubleshooting Page 14 Electrical Troubleshooting Test 8 ANTI ROLLOFF FAULT The Sevcon Controller is equipped with a feature called Anti Rolloff Anti Rolloff will automatically slow the vehicle if it starts to roll Anti Rolloff is active when the key switch has been left in the ON position and the accelerator pedal is not depressed Anti Rolloff is deactivated when the key switch is in the OFF position When the key switch is in the ON position and the truck is stationary the controller supplies a small current to the field This current is used to sense if the armature is rotating As the armature begins to rotate the controller senses a fault condition and then supplies current to the field opposing the armature rotation slowing the vehicle Refer to Motor Specifications Table for information on the maximum allowable field current when the Anti Rolloff feature is active To test the Anti rolloff feature Park the vehicle on a flat level surface turn the key switch OFF and apply the parking
23. 30 M12 1 75 x 30mm Hex bolt axle housing to center section 89 113 60 M12 Split lock washer axle housing to center section Transmission Differential Case ITEM DESCRIPTION MIO x 30 13 Ring and pinion gear set 14 Differential case cover 17 Differential housing 19 Differential case 2 MIO x25 Bok 29 Bearing and race 30 10mm Washer s Parts 27 Page 11 4 Illustrated Parts Rear Brakes 15 16 14 t 1 Brake Body Assembly sid Parts Page 12 Illustrated Parts Zu am See below Brake bleeder 41 350 56 Park brake pin 41 350 12 Park brake lever bracket 88 069 82 locknut grade 8 See below Brake body assembly 728 41 350 09 Boot 41 350 10 Piston Parts 27 Page 13 v2 Illustrated Parts Master Cylinder Floorboard remoed for clarity Brake Cross Shaft Parts 14 Illustrated Parts Master Cylinder a nn LLL Y 1 2 1 1 1 1 2 1 1 1 1 2 BRAKE LINKAGE 1 88 119 80 3 8 Hex nut 96 773 00 Clevis 5 16 88 119 80 3 8 NF Hex nut 50 028 10 Threaded rod 1 2 3 4 5 7 10 11 12 13 14 ot K1 154 58 Push rod master cylinder 17 104 00 3 8 collar for push rod N shown Parts 27 Page 15 Illustrated Parts Brake Lines Illustration not available Parts 27 Page 16
24. 6L 00 c06 6L 0c 808 6L 0c 808 6L 0c 808 6L 00 808 6L 0c 808 6L 00 808 6L 00 808 6L 00 808 6L 00 808 6L TH O S 89 S08 6L 89 S08 6L L9 S08 6L S9 S08 6L L9 S08 6L CL S08 6L 69 S08 6L L9 S08 6L A quioss y 19W11 00 258 61 OT TS8 6L 00 258 61 OT TS8 62 01 188 64 1 umg umg 91483104 91993104 91993104 eias sc 8t sc 8st Sc 8t 0r 9 Sc 8t Or 9E 5 96 5 96 596 8 Od u 0s 0tc ST 09 STI ST 09 STI LV 09 STI ST 09 STT 91 09 0ST u 0s 0tc lt 1 09 lt lt 1 09 lt sdury oSeyoA 198 0018 188 0187 189 lt 0018 198 0079 1488 lt lt 0187 1 8 0 148 lt 00196 188500196 198 0019 19349 07 60E 6L SC 0 6L 01 60 6 IZ 90E 6L 00 60 6L O 0E 6L AS9 POE 6L 0 SOE 6L SI 0 6L WALI 00691 OcZ 01691 TE SLP6 5696 07922 09811 2650111 0 ued Josey PPO 1581942 S IHOVHO Parts 27 Page 27 Illustrated Parts Lestronic Charger page 2 11 1 Typical Built In charger 72722 Typical Portable charger Parts Page 28 2 5 in 2 00 00 94 00 00 94 00 00 94 00 00 94 7 09 608 6L 5 5 7 90 6L Assy Kepoy Yop 01 98 64 O S d
25. AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle Set the parking brake Set the forward off reverse switch to the OFF position Rotate the start switch to the OFF position In addition f parking this vehicle on an incline turn the wheels to the curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Towing This Vehicle A CAUTION This vehicle is equipped with regenerative braking Follow these steps before towing this vehicle 1 To tow this vehicle the start switch must be in the OFF position 2 Place the forward reverse switch in the center OFF position Failure to follow these instructions may result in damage to the vehicle Totow this vehicle attach a tow strap to the front bumper tow bar NOTE If the vehicle is equipped with an automatic electric brake do not tow the vehicle with the drive wheels on the ground Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible this vehicle should be placed on a carrier rather than towing Safety Rules Page 10 SAFETY RULES AND OPERATING INSTRUCTIONS 22 CHARGING YOUR VEHICLE AWARNING Explosive mixtures of Hydrogen gas are present within battery cells at all time
26. BSI Check the battery electrolyte once a week Do not charge the batteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their life span Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries Safety Rules Page 12 gt SAFETY RULES AND OPERATING INSTRUCTIONS Charging Time Average charging time is 8 to 10 hours The time required to fully charge your batteries will vary depending on Capacity of the batteries higher capacity requires longer charge time Output of the charger higher output requires less charge time Depth of discharge the deeper a battery is discharged the longer it takes to charge Temperature low temperatures require longer charge time It is not unusual for charge times to exceed 15 hours especially with new batteries Charging time is limited to 20 hours HBS or 18 hours HB A fault will occur if the charging time exceeds the 20 hour limit STORING RETURNING TO SERVICE Both storing your vehicle and returning itt
27. Black 2 E RS gt F amp R i Switch 1 i 6 Violet Black 97 5 7 oi mO Gray White Gray White 1 Viole Black Violet Black Blue Black Blue Black Blue Black z Blue Black Blue Black White Black White Black White Black White Black Gray Black 3 5 Violet Black i Violet Black 4 Gray Black T Gray Black Green Black High Low Green Black gt Green Black mellow 10 21 Switch xu Blue 3ray blac Yellow ellow mg Graylblack 12 Sraylblack 10 Red White Black 17 Black Blue z Blue Red White Red White L Green Black 16 The Smart View 17 Gray Whit Gray Whit ray White Display is wired 1 287 MOTION A V iew through a cable to Black Black ALARM Can Buss Connector Display the Can Buss E 2 Black Black connector on the 8 Black speed control 2 DASH PANEL 6 Yellow View from side ELECTRIC output BRAKE Violet Black Blue Blue Input 1 Kk y s uos Viole Black 5 1 Blue Black View from pin side Green Black 4 le Module Illustrated Parts TABLE OF CONTENTS Front Fork 2 Wheels and 20 Steering Linkage 4 Speed Control 22 Steering Gear
28. Grade 8 L 9 Other Bolts Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Appendixes available at time of printing Appendix B Page 4 Appendixes Hex Nuts Nuts with no markings are to be treated as S A E Grade 2 we oN off i 57 P E P en g x f A RON Y N x N 1 4 S A E Grade 5 S A E Grade 8 5 8 Metric Nuts Hex Lock Nuts stover 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 markings are to be treated as S A E Grade 7 nN f lt 7 V P NL P i N un A PES ZEN ZON Or or V 4 N Du cad To Pv 2 Z N NN Ney weed S A E Grade B S A E Grade C Grade L 9 Other Nuts Other nuts used by Taylor D unn should be treated as S A E grade A Not available at time of printing Appendixes Appendix B Page 5 A Appendixes Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification Reduce torque approximately 10 15 for lubricated threads Refer to the service section assembly procedure for critical to
29. Test 1 5 If the voltage is high then Check the seat switch for open contacts Check that the seat switch is engaging the seat correctly Check the wire from the pin 5 to the seat switch for open circuits Check the wire from the seat switch to B for open circuits If all of the above is in working order then the logic card may have failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit Sevcon Troubleshooting Page 5 Electrical Troubleshooting TEST 1 5 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is high then skip ahead to Test 1 6 If the voltage is low then skip ahead to Test 6 TEST 1 6 Test the voltage at pin 7 on the 12 pin logic card connector NOTE Pin 7 is for a parking brake interlock switch This switch is not available for all vehicles and may not be used If the voltage is high then skip ahead to Test 1 7 If the voltage is low then Check the park brake switch for shorted contacts Check the wire to the park brake switch for short circuits to B Stop trouble shooting here and repair the problem W
30. Tires and Wheels section for information on removing the tire and wheel assembly 9 Thoroughly clean the area around the brake body 10 Remove the brake body bolts and discard the lock Lock Nuts Bushings nuts 11 Inspect the brake rotor Refer to Inspect the Brake Pads Service Brake section for information regarding E 7 inspecting the brake rotor 3 12 Disconnect brake hose from the brake body Hn 2 3 13 Install the new brake body assembly reverse Mounting 4 order Use teflon tape thread sealant on the brake hose Bracket Spacers Bolts fitting Torque the brake body bolts to 11 ft lbs 14 Bleed the brakes Refer to Bleed the Brakes section for information regarding bleeding the brakes 15 Set the park brake 16 Reconnect the main positive and negative cables at the batteries 17 Lower the wheel to the ground 18 Remove the blocks from behind the wheels 19 Release the park brake and test drive the vehicle Brakes e Page 14 Maintenance Service and Repair REPAIR THE BRAKE BODY AWARNING AWARNING AWARNING Hydraulic brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake fluid spills Any debris or contaminates left in the brake system could lead to brake failure and result in property damage and or severe bodily injury Do not ingest brake fluid or allow contact with s
31. Worn Ball Joints Excessive Steering Play Mis Adjusted or Worn Steering Gear Loose Steering Linkage Brakes or Parking Brakes Dragging Batteries Discharged or Defective Front End Out of Alignment Defective Speed Control Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Abnormal Noise Loose Lug Nuts Motor Bearings Worn Rear Wheel Bearing and or Gasket Failed Oil Leak in Rear Bearing Area Drive Over Filled Brake Pedal Soft or Spongy Air in Brake Lines Brake Worn 1 16 Wear Limit Brake Pedal Low Brake Fluid Low Brakes Out of Adjustment Brake Worn 1 16 Wear Limit ping Pover Lon Air in Brake Lines Note This list is provided as a guide only It is not all inclusive of causes that may result in a specific symptom Page 3 Maintenance Service and Repair Lubrication Chart Page 4 STEERING TRANSAXLE eC ______ _____ a 7 422 C perum 2 seriei TABLE OF CONTENTS Inspect the Front Wheel Bearings 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 REMOVAL M 4 nrbem 4 Replace Front Wheel Bearings 5 Front Axle Service Maintenance Service and Repair INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS BEARINGS AWARNING AWARNING Make sure the key switch is in the OFF position then remove the key
32. an open circuit then the interlock relay is functioning normally Charger Troubleshooting Page 10 TABLE OF CONTENTS Operating Instructions and Theory of Operation 2 HB PT and GEL Indicator Lamps 3 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 A CAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Rev Signet Charger Troubleshooting Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Charger The model HB600W and HB1000W chargers 3 System are designed as semiautomatic chargers The AC Input Model charger turns itself on when it is plugged into the Voltage Range Voltage wall outlet and turns off when the batteries are fully charged DC Output Both the HB600W and HB1000W are two stage chargers The first stage is a constant current mode It Maintains a constant current until the battery reaches a terminal voltage and then Switches to the second stage constant voltage _ At the second stage the charger decreases the A
33. batteries proper connection to the batteries AC voltate too high or too Check the input voltage low It must be within 96 132V AC or 196 266VAC Wait for charger to cool the charger will automaticaly restart Inspect for dirt debris on the charger cooling fins and clean as required Input or Output over current Charger will automaticaly correct for this condition and restart In many cases fault 1 will only be displayed for a short amount of time and then the charger will attempt to restart Typically the fault will repeat 8 times and then the charger will start the boot up process with the 50 light on If the charger cannot restart then the fault loop will start again repeating the fault 1 This fault could be a result of an open connection between the charger and batteries an open connection on one or more of the battery cables or an open connection internal of the charger Before replacing the charger confirm all battery wiring is good Status LED s SIGNET SYSTEMS INC Typical Charger Data Plate your data plate may vary Signet Charger Troubleshooting Page 5 Electrical Troubleshooting TROUBLESHOOTING To test charger operation Connect a DC volt meter to the main battery positive and negative terminals Attach a clamp on DC Ammeter to one of the charger DC output wires Plug the charger into an AC outlet Wait for charger to start up to15 seconds the ammeter should dis
34. conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage Batteries Page 2 Maintenance Service and Repair TESTING AWARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury AWARNING A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the b
35. is for left turns 9 Inspect the position of the pitman arm It should be close to centered between the two steering stops If the pitman arm is significantly off center then remove and reinstall the pitman arm so that itis centered Torque the pitman arm nut to 75 100 ft lbs 10 Untie the steering wheel 11 Reconnect the batteries and remove the blocks from the wheels AWARNING Disconnect the batteries set the park brake and block the wheels before making any adjustments 12 Drive the vehicle in a right turn until the turning radius is at 155 inches Stop and adjust the right turn steering stop until it touches the pitman arm Steering Page 2 Maintenance Service and Repair FRONT END ALIGNMENT 13 Repeat the previous step for a left turn 14 Tighten all jam nuts 15 Check the turning radius in both the left and right turn Repeat this procedure if not within specifications Center the Steering Wheel AWARNING Do not drive the vehicle while the steering wheel or front fork is tied in position Driving the vehicle while the steering wheel or front fork tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 1 Inspect the steering alignment and adjust as required Refer to Front End Alignment for information regarding aligning the steering 2 Drive the vehicle in a straight line and stop AWARNING Make sure the key
36. level of the 3rd member Park the vehicle on a level surface 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Place an oil drain pan underneath the 3rd member Remove the fill level plug 8 The oil level should be very close to the bottom of the level plug opening a If the oil level is below the bottom of the opening add oil as required until level with the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes out of the opening allow to drain until level with the bottom of the opening 9 Replace the fill level plug 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from the wheels 12 Release the park brake and test drive the vehicle Transmission Maintenance Service and Repair CHANGE OIL 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 10 11 12 13 14 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative
37. normal If the battery voltage does not come up gt Test the batteries gt Check battery wiring These faults will be accompanied by an audible beep and indicates that the charge cycle was termintated before completion Signet Charger Troubleshooting Page 5 Electrical Troubleshooting TROUBLESHOOTING NOTE There are no internally serviceable components in the charger To test charger operation Connect a DC volt meter to the main battery positive and negative terminals Attach a clamp on DC Ammeter to one of the charger DC output wires Plug the charger into an AC outlet Wait for charger to start up to 15 seconds the ammeter should display the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals 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 The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there no faults and the POWER light is ON then the charger has failed and must be replaced If the POWER light is OFF then check the AC power source AC power cable and connections If the source cable and connections are good then the charger has faile
38. not start at 24 volts then go to Test 4 TEST 1 2 Test the voltage from B to B on the Controller If the voltage equals battery volts then go to Test 41 3 If the voltage does not equal battery volts then Check the main positive wire to the circuit breaker for open circuits Check the wire from the circuit breaker to battery positive Check the wire from the contactor to on the controller for open circuits Check the wire from B to battery negative on the controller 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 voltage at pin 6 on the 12 pin logic card connector If the voltage is low then skip ahead to Test 111 4 If the voltage is high then check the wire to the High Low switch and the High Low switch for open circuits NOTE The High Low switch is optional and the vehicle may not have this option If the vehicle is not equipped with option then there is a jumper bypass installed in place of the switch in the dash Check the jumper to be sure it is still connected 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 STOP TEST 1 4 Test the voltage at pin 5 on the 12 pin logic card connector If the voltage is low then skip ahead to
39. or plug has been damaged Stop here and repair the problem 11 Install the charger end cap where the AC wires enter Wires from the AC cord If both the AC and DC tests are good then the charger has failed There are no internally serviceable components in the charger If the charger has failed then it must be replaced Signet Charger Troubleshooting Page 6 Charger odels HBS 600 HBS 1000 TABLE OF CONTENTS 2 Test Equipment Required for Troubleshooting 2 Important Notes and Instructions 2 Operating Instructions and Theory of Operation RR 3 Testing the Charging Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries Troubleshooting Electrical Troubleshooting DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 volt battery has 3 cells Term Value Condition V1 See Chart Flooded batteries V1 Voltages are temperatur
40. pressure Refer to Tire Inflation section for information on checking the tire pressure 7 Inspect the tire tread depth Minimum recommended tread depth is 1 16 inch There are a series of tread depth wear indicators around the circumference of the tire They will appear as 1 2 inch bands across the tread as the tire approaches its wear limit see illustration below Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section for information regarding replacing the tire 8 Inspect for uneven tire wear the front tires Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end NOTE Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment 9 Inspect the inner and outer side walls for cracks If any cracks are seen then the tire should be replaced Refer to Replace the Tire section for information regarding replacing the tire 10 Inspect the valve stem for cracks If any cracks are seen then the valve stem should be replaced It is also recommended that the valve stem be replaced whenever the tire is replaced NOTE Refer to Replace the Tire section for information regarding replacing the valve stem 11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture I
41. recommended to replace the left and right side brake pads as a set Brakes gp Page 2 Maintenance Service and Repair Disc Brake Rotor Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions 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 to Front Axle Service for information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be an integral part of the rear axle If the brake rotor is worn beyond its service limits then the rear axle must be replaced Refer to Transmission section for information regarding replacing the rear axle NOTE The wheel must be removed to accurately measure the rotor thickness Refer to Tires and Wheels section for information on removing the wheel 1 Measure the run out of the rotor at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its service limits NOTE A bent axle or damaged rear axle could cause excessive brake rotor run out 2 Measure the thickness of the brake rotor in 3 places If
42. right to left When the batteries are discharged to 75 the last three segments will flash indicating that you are approaching the end of the battery cycle At this time the vehicle s batteries should be charged as soon as possible At 90 all segments will flash and the vehicles speed will be reduced At this time the vehicle should be removed from service for charging Discharging beyond 90 will result in damage to the batteries that will shorten the battery life span HM There are three hour meter functions Key Hours Run Time Hours and Pump Hours Key Hours Accumulated length of time in hours that the key switch is in the ON position When the display is turned on the Key Hours will be displayed for approximately 5 seconds as indicated by the Key Hours Indicator located at the lower left of the display The icon represents the silhouette of a key Pump hours Accumulated length of time the hydraulic pump has been in operation This is an optional feature After the Key Hours the Pump Hours will be displayed for approximately 5 seconds as indicated by the Pump Hours Indicator located at the lower left of the display The icon represents a motor symbol with a P in the center Run Time Hours Accumulated length of time that the vehicles has been in operation Time is accumulated when the FS 1 switch in the accelerator module is closed After the Pump Hours the Run Time Hours will be displayed as indicated by
43. s is broken or has a bad connection between the charger connectors and the AC plug Stop here and repair the problem Charger Troubleshooting gl Page 5 Electrical Troubleshooting Disconnect the charger from the AC source Disconnect the batteries Disconnect the charger from the vehicle s harness Remove the charger from the vehicle HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNI NG terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one transformer lead from the capacitor Test the capacitor using the capacitor test function of the meter It is a 6 microfarad capacitor If the capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the transformer lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the diodes using the diode test function of your meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Diode 1 Common 5 Reconnect the lead
44. tests and diode testing If you are not familiar with these types of tests then refer testing to a qualified technician These tests are not intended to locate a problem on an incorrectly wired vehicle Make sure the batteries are in good condition and fully charged before performing any tests Ifthe vehicle exhibits intermittent problems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified Some tests refer to a High Low switch The High Low switch is optional and the vehicle may not be equipped with this option If the vehicle is without this option there is a jumper bypass installed in place of the switch in the dash All voltage tests are done referenced to battery negative unless otherwise specified At the start of each test sequence you will be instructed on how to place the control switches While testing do not change the position of any switches unless instructed to do so Note The application is also capable of uploading new controller parameters to the controller Controller parameter sets are available from Taylor Dunn Individual parameters cannot be changed ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results
45. that the armature or motor be replaced Using the continuity function of digital multi meter check the continuity around the entire commutator by placing one test lead against one of the commutator segments and the other test lead Check each segment against all of the other segments one at a time all of the way around There should be continuity around the entire the commutator commutator If any segment indicates an open circuit then the motor must be replaced Hold this lead in place Using the continuity function of digital multi meter check the continuity from any one of the commutator segments and the armature frame If itis not an open circuit then the armature is shorted and the motor must be replaced Measure the armature and field resistance refer to Service Limits table at end of this section If the armature of field resistance is not within specification then the motor must be repaired or replaced Rear Housing Circlip Brush Spring Stator Field ex Front Housing Brush Cover Bearing Brush Dust Brush Holder Armature Motor 5 4 Motor Service a ss Assembly 1 Press a new bearing into the motor housing and install the circlip Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator See the illustrat
46. the Run Time Hours Indicator located at the left of the display The icon represents a motor symbol with a T in the center Speed controller status The display will indicate a fault code whenever the control system logic detects a problem with the control system A fault code is being displayed whenever the Fault Code Indicator the letter is visible at the left of the numeric display Refer to the table on the following page for a list of fault codes and their descriptions Maintenance monitor optional Operation The SVD notifies the operator 10 hours standard before a scheduled maintenance is due During this warning period the meter will continue to alert the operator This should allow sufficient time for the operator to schedule the maintenance that is due with minimal down time If the scheduled maintenance is not performed before the warning period elapses then the vehicles maximum speed will be significantly reduced Warning period The warning period starts when the Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenance Due Once the warning period has expired and the maintenance is due the Wrench icon will stop flashing and remain ON Additionally the vehicles maximum speed will be significantly reduced until the maintenance is performed and the display is reset The display should only be reset by an authorize
47. the brake rotor thickness is less than 0 20 inches iv then the rotor must be replaced i yt panes g o c Do not use rotor that is worn beyond its service limits A rotor worn beyond its service limits could fail AWARNING and cause loss of brakes resulting in severe bodily injury and or property damage Rotor removed for clarity The rotor does not have to be removed for this procedure Brakes Maintenance Service and Repair INSPECT THE PARKING BRAKE Wheel Park Brake hydraulic disc NOTE The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Release the park brake Inspect the brake pads Refer to Inspect the Service Brake section to inspect the brake pads Inspect the park brake pin and bushing for any signs of damage or corrosion NOTE The park brake pin is inside of the brake body Refer to Repair the Brake Body for information on removing the park brake pin 9 Inspect all brake cables a
48. the spring from the vehicle Inspect the spring hardware for signs of wear or damage If any wear or damage is found then the hardware must be replaced Install the new spring in reverse order Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle Suspension Page 2 REPLACE THE FRONT SPRINGS The front springs are an integral part of the front shock and cannot be replaced Refer to Replace The Front Shocks Maintenance Service and Repair REPLACE THE SPRING BUSHINGS REAR ONLY It is recommended that both left and right side spring bushings are replaced as a set Complete the procedure for one side before replacing the opposite side bushings AWARNING 1 Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheel to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Remove the spring eye bolt and spring u bolt A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Raise the rear lef
49. there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately AWARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 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 A WARNING 3 Set the park brake 4 Place blocks under the wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Raise the wheel off of the ground and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Brakes 27 Page 13 Maintenance Service and Repair 8 Remove the tire wheel assembly Refer to
50. travel Release the parking brake Release the foot brake 8 Slowly depress the accelerator pedal 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 Immediately report any accidents or vehicle problems to a supervisor Loading and Unloading Do not carry more than the maximum number of passengers allowed for this vehicle Do not exceed the cargo load capacity Do not load cargo that can fall off Be careful when handling cargo that is longer wider or higher than this vehicle be sure to properly secure all loads Towing Loads Do not exceed the towing capacity of the tractor Do not exceed the load capacity of the trailer Refer to documentation supplied with your trailer for information regarding load capacity of the trailer Make sure all loads are securely tied down Refer to documentation supplied with your trailer for information regarding attaching loads to the trailer Do not back up when towing more than one trailer Drive slowly when towing loads with a high center of gravity When turning be sure to allow for corner cutting of the trailer Allow for longer stopping distances when towing heavy loads Allow for longer stopping distances when driving down a grade Safety Rules Page 9 SAFETY RULES
51. up so that the Lestronic charger can sense that they are connected and turn itself on Red Transformer T Diode Black mm 1 L Diode White Capacitor Violet Black T 1 Charger Not all chargers are equipped Interlock pyrple bik with the lockout relay Black Interlock Relay Ammeter optional Black To Battery Red Typical Charger Internal Wire Diagram Charger Troubleshooting 27 Page 2 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started Acharger could remain on for longer than 12 hours if charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger brownout drop in AC line voltage during the charging cycle electrically noisy charging environment Acharger could turn off in less than 12 hours but still show symptoms of overcharging if batteries were not discharged to 50 before connecting the charger electrolyte in the batteries is too high boil over electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and the electrolyte specific gravity during the chargin
52. vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 9 Remove the motor only if the entire drive is to be disassembled NOTE Refer to Motor Removal and Installation for information on removing the motor 10 Remove the cover retaining bolts 11 Remove the cover plate from the differential and let the remaining oil drain from the housing Be careful not to damage the sealing surfaces on the housings Damage to ACAUTION the sealing surface may lead to an oil leak resulting in damage to the internal parts of the drive Transmission A Page 9 4 Maintenance Service and Repair 12 Remove the circlip from the idler gear 13 Remove the input shaft bearing assembly and idler gear bearing assembly from the gear case cover at the same time 14 Remove the pinion nut from the output gear and remove the output gear from the pinion shaft NOTE If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 16 Remove the six retaining bolts holding the gear case to the 3rd member housing NOTE Make note of the angle of the gear case 17 Remove the gear case housing from the 3rd member housing 18 Inspect all parts for signs of wear or damage Transmission Page 10 Maintenan
53. 01 Contactor Welded High voltage at power up to the controller B terminal Check 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 operated in the correct order or fault in start up switches or wiring Refer to operator section for correct operating sequence of switches F04004 Two Directions Selected Both Forward and Reverse selected at the same time Check F amp R switch and wiring F04005 SRO Start up switches not operated in the correct order or fault in start up switches or wiring Refer to operator section for correct sequence of switches Normally a result of F amp R selected before start switch is turned on F04006 Traction Seat Seat or foot interlock switch open Check interlock Switch wiring F04007 Inch Switch Inch switch ON at power up both switches selected at same time inching attempted with seat interlock F amp R switch or FS 1 closed F04008 Steer Steer Function currently not used and this fault should not occur Check wiring F04009 Low Battery Low voltage at Pin 1 of controller connector Normally a result of discharged batteries Check wiring start switch interlock switches batteries F04010 High Battery High voltage at Pin 1 of controller connector Check for correct voltage battery installed check controller
54. 7903 GT 3287883 GT 3287893 GT 3287853 GT 3287863 GT 3287873 27 GT 71068 28 GT 72022 30 GT 70299 Transmission Gear Case DESCRIPTION 8 x 60 bolt Gear case cover Bearing Input shaft 30 1 Input shaft 24 1 Input shaft 18 1 Input shaft 12 1 O ring Eccentric shaft Bearing Idler gear M10 x 30 Bolt Snap ring Gear case housing Seal Bearing Pinion nut Spacer Output gear 30 1 Output gear 24 1 Output gear 18 1 Output gear 12 1 Spacer 46 100mm Spacer 46 100mm Spacer 46 125mm Spacer 46 150mm Spacer 46 175mm Shim 0 100mm Shim 0 400mm Shim 0 500mm Shim 0 600mm Shim 0 700mm Shim 0 800mm Bearing Bearing 10mm Washer Illustrated Parts Parts Page 9 Illustrated Parts Rear Axle Outer Bearing Inner Bearing no o ring Axle Shaft 1 O Ring O Ring Groove Inner bearing on optional double bearing axle does not have an oil seal or o ring Orientation of bearing should have o ring groove adjacent to o ring on outer bearing Transmission Differential Case 13 Parts Page 10 Illustrated Parts Rear Axle ITEM PART DESCRIPTION 41 154 25 Axle shaft 80 505 20 Bearing 80 505 30 Bearing 41 490 11 Disc brake rotor 41 172 21 Hub 88 268 63 Flat washer 88 268 30 7 8 14 x 1 5 Bolt grade 5 96 329 10 Wheel stud 92 104 10 Hub cover 41 290 78 Axle housing L Not shown 41 290 79 Axle housing R 89 113
55. C x 4 Spring bolt front of the leaf spring Spring bushing front of the leaf spring Leaf spring Spring mounting plate left Spring mounting plate right U bolt 1 2NC Nylon lock nut U bolt 1 2NC Lock nut Strap Shock 7 16NC x 2 1 4 Hex bolt 7 16NC Lock nut 7 16 Flat washer Not Shown 98 753 05 Rubber bump stop Parts Page 21 t 2 5 in a Speed Control Panel A gt NN SAN y Instrument Panel dash dah FORWARD N on e gt A yX x TAYLOR DUNN Illustrated Parts Speed Control Panel ITEM PART DESCRIPTION 62 400 05 Speed controller 400 Amp 01 200 05 Mounting panel 79 844 20 Main circuit breaker 71 300 02 Line contactor 71 300 01 Mounting bracket 88 838 06 14 x 1 2 Sheet metal screw 88 067 15 1 4NC X 1 75 OVAL PHLP HD SCR 88 068 61 88 068 61 88 069 81 1 4NC NYLINS LOCKNUTPLTD 79 840 00 10 Amp circuit breaker 79 840 20 20 Amp circuit breaker 10 79 840 20 20 Amp circuit breaker 88 818 06 8 x 1 2 Sheet metal screw 12 73 005 01 Reverse Motion alarm 13 88 8 18 06 8 x 1 2 Sheet metal screw Not shown 69 068 55 Resistor across 5 power terminals 94 422 21 HEATSINK 340 PASTE 13 50Z NOTE To order part number 62 400 05 you will need to provide the vehicle serial number The controller will be programmed to match the ve
56. Diagnostics and adjustments 62 only of the Sevcon Power Pak and Micro Pak control systems 62 027 32 Throttle Module Analyzer Tests the throttle module in or out of the vehicle 43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor 62 027 64 and 65 Curtis AC System Handset Diagnostics and adjustments 65 only of the Curtis AC control system 75 089 00 Throttle Module Test Harness Used in conjunction with a volt meter to test the throttle module The module must be installed in a working control system Note Part 62 027 31 includes instructions 62 027 00 Test Light Used for testing electrical circuits Switchable for 12 24 36 48 volt systems Required to complete troubleshooting provided in the vehicle service manuals 96 500 43 PMT C Meter Reset Module Required to reset the PMT C maintenance meter special order option Appendixes Appendix A Page 2 APPENDIX SPECIAL TOOLS 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors 77 200 00 Hydrometer Used for testing battery electrolyte Illustration is of a typical hydrometer actual hydrometer type may vary Molex 062 pin 11 0300 02 Molex 11 300 02 Pin Removing Tool Removes 0 062 diameter pins from Molex rectangular harness connectors
57. EST 7 1 Referencing battery positive test the voltage on the center terminal of the F amp R switch Black wire If the voltage equals battery volts then skip ahead to test 7 2 If the voltage does not equal battery volts then check the wire from the F amp R switch to the battery voltage circuit breaker 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 7 2 If the vehicle does not travel in reverse 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 amp R switch If the voltage equals battery volts skip ahead to test 7 4 If the voltage does not equal battery volts then the F amp R switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Main Battery Positive y NOTE The wires are disconnected for reference only The test must be done with the wires connected to the switch Main Battery Positive NOTE The wires are disconnected for reference only The test must be done with the wires connected to the switch ACAUTION AWARNING This troubleshooting guide is written in After any repairs are made completely retest sequential order All tests must be perfo
58. HE TIRE PNEUMATIC Do not attempt to repair a tire with a damaged side wall or a slice in AWARNING the tread This type of repair could fail prematurely resulting in severe bodily injury and or property damage NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the type of repair equipment or repair components used Refer to the instructions provided with your equipment or repair components Tires and Wheels Page 4 TABLE CONTENTS 2 Testing 2 3 4 Wate ning 5 Replacing 6 volt batteries only 6 Moist Charge Batteries 7 Storage and Returning to Service 8 DIOLA BE DR Ga 8 Returning to Service see 9 Battery Service Maintenance Service and Repair CLEANING AWARNING AWARNING Explosive mixtures of Hydrogen gas are Make sure the key switch is in the OFF present within battery cells at all times Do position then remove the key not work with or charge battery in an are
59. IMER RELAY Test 1 1 Connect the batteries to the charger 2 Plug the charger into the AC source 3 Wait 5 seconds then test the voltage at the timer relay coil terminals NOTE This voltage should be close to the battery volts f the voltage is close to the battery volts then skip to test 2 If the voltage is not close to the battery volts then the timer control circuit has failed and the timer must be replaced Test 2 1 Disconnect the batteries 2 Unplug the charger from the AC source 3 Discharge the capacitor see warning on previous page Charger Troubleshooting 27 Page 9 Electrical Troubleshooting 4 Disconnect the wires from the contact terminals on the timer relay 5 Reconnect the batteries 6 Wait 5 seconds then test the continuity across the timer relay contact terminals e If this is a closed circuit then the timer start up circuit is functioning normally f there is an open circuit then the timer relay has failed and the relay must be replaced TESTING THE INTERLOCK RELAY Operation The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC power source When the charger is plugged in the relay contacts open and break the Key Switch connection to the speed controller The Interlock Relay is available for built in chargers only Not all built in chargers are equipped with this relay To identify chargers that are equipped with the Interlock Relay
60. ION The key switch must be in the OFF position when charging the batteries Failure to turn the key switch OFF may result in damage to the vehicles electrical system Siqnet Charger Operation Model HBS series The Signet HBS series chargers are fully automatic The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Once the charge cycle is complete the charger will continue to monitor the batteries If the battery voltage Typical Signet HBS drops during storage the charger will start a new cycle to keep the batteries fully charged NOTE If the charger restarts during a short time period of storage then it would be an indication of faulty batteries Refer to the data plate on the charger for the voltage and type power required for the charger There is a series of LED s on the faceplate of the charger that serve two functions 1 Status of charge The STATUS LED s will display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition The FAULT LED flashing is an indication of a charging problem charger may also be beeping Refer to the Charger Troubleshooting section for information on error codes POWER STATUS FAULT 5225 Status Light Panel Safety Rules Page 11 e Lestronic Charger Operation The Lestronic II cha
61. L ST COE 6L 01 20 64 01 10 6 ASS O0E 6L 0S 00 6L OS ZOE 6L WALT OCOL DOELT 09261 TE ETS6 OTTET 05721 TO SOTL IYO PPO 1981200 S IHO VHO Parts 27 Page 29 3 Illustrated Parts n s me Batteries Illustration not available Illustrated Parts 22 ms 88 089 80 5 16NC Hex nut stainless stell battery post 12 Quantities depend on voltage configuration of vehicle lt Parts Page 31 4 Illustrated Parts Seat Cushions Deck and Lights ae Frame Illustration not available Parts 32 Need Parts Illustrated Parts Seat Cushions Deck and Lights PART DESCRIPTION 90 160 70 Seat assembly K4L 000 11 Light 6 1 Deckboard rear 88 607 09 Rivet steel deck 14 1 5 K47 100 02 Mounting plate 90 160 71 Spacer 2 Steel overlay i Em Oooo EC 1 _____________ ___________ overiny LIT 2 fe 1 2 X 3 5 88 080 13 Seat mounting bolt 4 88 080 11 Mounting plate bolts Er Notshown 97 211 25 U Nut mounting plate 6 88 088 60 5 16 WASHER 88 089 81 5 16 NC LOCK NUT 72 034 10 Tail light Frame waas COVER COWLBOLT ON SUPPORT STEERING COLUMN 992000 R
62. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly do not allow the ring nuts to rotate 11 Install the pinion gear Re shim if required If the ring and pinion gears or bearings are replaced then the pinion gear must be re shimmed Improper ACAUTION pinion gear shims will result in drive noise and premature failure Refer to Pinion Gear Shimming Instructions 12 Install the pinion gear holding tool 96 500 42 and tighten the pinion nut enough to keep the pinion gear from rotating 13 Install the differential assembly 14 Install the cover and all of the cover bolts Torque to 45 50 ft lbs 15 Check the gear lash between the ring and pinion gears The gear lash should be 0 005 to 0 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring 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 tighten the cover carrier bearing race ring nut equally NOTE To move the ring gear away from the pinion Loosen the cover carrier bearing race ring nut and tighten the housing carrier race ring nut equally The two ring nuts must be turned the same amount in opposite directions This allows the carrier assembly to be positioned with the proper gear lash without upset
63. Not available from Taylor Dunn Purchase from any local electronics distributor vN 41 350 13 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 4 72 201 00 Battery Filler Used to safely add water to batteries Equipped with splash guard and auto shutoff when cell is full 70 440 55 Pin Removing Tool Removes pin from Amp circular harness connectors Extension Not Included 96 500 48 GT Drive Oil Fill Plug Tool Used to remove the oil fil plug on GT drives It is used with a 3 8 drive extension not included Molex 093 pin 11 0300 06 Molex 1 1 300 06 Pin Removing Tool Removes 0 093 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor Appendixes Appendix A Page 3 APPENDIX SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used ona grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads Hex Bolts Zo ant The grade of a metric bolt is cast directctly on the 77 N head Below is an example of a 10 9 the location and style of the text will vary S A E Grade 2 S A E Grade 5 BN P NI E S m Le S A E
64. OCK NUT 17 18 K1 159 02 Fork Arm right K1 159 03 Fork Arm left 19 21 22 23 24 25 26 88 128 60 7 16 WASHER 3 side 4 on inside both shocks 96 243 10 BOLT 9 16 X 3 1 2 GR 5 88 169 82 LOCK NUT 9 16 NF GRADE C 1 1 1 1 1 2 1 2 1 1 1 2 1 1 1 4 27 2 2 28 Parts eb Page 3 v2 Illustrated Parts Steering Linkage Cowling removed for clarity Parts 27 4 Illustrated Parts SOO _ __ ______ _ 3 4 5 7 10 12 13 14 88 120 15 7 16 X 1 1 2 NC HEX HD GR 5 86 510 00 Clamp ball joint 86 501 98 Ball joint left 14 86 501 99 Ball joint right ooo pissa Seines s 1 E CHE Oooo ia Parts eb Page 5 Illustrated Parts Steering Gear Parts Page 6 Illustrated Parts _ _ 10 18 308 79 Seal input shaft 1 E I I 17 Bolt side cover i Parts el Page 7 2 4 Illustrated Parts Transmission Gear Case Parts Page 8 ITEM PART GT 71682 GT 3287563 GT 71259 GT 3287513 GT 3287523 GT 3287533 GT 3287543 GT 71982 GT 3287503 GT 72005 GT 3287493 GT 70302 GT 71715 GT 3287553 GT 72019 GT 71979 GT 3273633 See Note 1 previous page GT 3287453 GT 3287463 GT 3287473 GT 3287483 GT 328 GT 328 GT 328 GT 328 GT 328 GT 328
65. RNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE Most vehicle configurations do not require lifting the vehicle to remove the master cylinder Lifting the vehicle may not be required 6 If required raise the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Place a drain pan under the master cylinder Disconnect the brake line s to the master cylinder and pump out the fluid in the master cylinder by depressing the pedal several times 9 Remove the master cylinder bolts and remove the master cylinder from the vehicle Brakes 27 Page 17 Maintenance Service and Repair 10 Install in reverse order 11 Adjust the master cylinder push rod so that it is approximately 1 8 inch away from the master Finger cylinder plunger when the brake pedal is up 12 Fill the master cylinder with brake fluid from a sealed NN container 13 Pump the brake pedal a short distance of one to two inches until no bubbles are seen coming from the inlet ports inside of the master cylinder chamber 14 If the vehicle was raised lower it to the ground 15 Bleed the brakes refer to Bleed the Brakes sect
66. Refer to the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings 9 Spin the wheel and listen for any grinding noise Any noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle Front Axle Page 2 6 Raisethe front wheel off of the ground and support with jack stands 7 Tighten the front axle until the wheel does not spin freely To test spin the front wheel by hand The wheel should stop spinning in no more than 2 revolutions If the wheel continues to spin tighten the axle nut and repeat the test 8 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Hefer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 9 Lower the vehicle 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Maintenance Service and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal Installation 1 Raise the fro
67. Release the park brake and test drive the vehicle Front Axle Page 4 TABLE OF CONTENTS Front End Alignment 2 Center the Steering Wheel 2 Inspect the Steering Components 3 3 Fork Bearings eere 3 Adjust the Steering Gear 4 Center the Steering Gear 4 Replace the Steering Gear 5 Replace the Ball Joints 5 Repair the Steering Gear 6 Exploded View of Steering Gear 8 Steering Component Service AWARNING Do not drive the vehicle while the steering wheel or front fork is tied in position Driving the vehicle while the steering wheel or front fork tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Center the steering gear 7 Tie off the steering wheel so that it cannot rotate 8 Adjust both steering stops to their shortest lengths NOTE The front steering stop is for right turns the rear steering stop
68. TEST 3 5 Disconnect the batteries and remove wires from the B Fl and F2 terminals on the controller Using the diode test function on your meter connect the positive lead to the B terminal on the controller Connect the negative lead to the F1 terminal on the controller The test should show the presence of a diode approx 0 5 If the test is good then skip ahead to test 23 6 If the test is open or shorted then one or both directional FET s are shorted and the controller must be replaced TEST 3 6 Disconnect the batteries and remove wires from the B Fl and F2 terminals on the controller Using the diode test function on your meter connect the positive lead to the B terminal on the controller Connect the negative lead to the F2 terminal on the controller The test should show the presence of a diode approx 0 5 If the test is open or shorted then one or both directional FET s are shorted and the controller must be replaced STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit PowerPak Logic Connector Sevcon Troubleshooting Page 9 Electrical Troubleshooting Test 4 KEY FAULT TEST 4 1 Turn the key switch ON and place the forward and reverse switch in the center OFF position Perform the following tests T
69. UBBER BRAKE PEDAL PAD T DLOGO eas Pada ACCEL WDM o 4 10050 SPACER ACCEL PADEL Ed E NE EER sl Parts el Page 33 4 Illustrated Parts Decals REAR under deck Parts Page 34 Illustrated Parts e onsen tg ing 2 94 373 10 Vehicle identification Parts e Page 35 Illustrated Parts Hitches 97 804 01 4 97 808 00 Pintle Hitch rage ee a Eye Hitch Automatic Coupling Hitch 1 Pin om co D 52 DT 97 806 10 Pin Clevis Hitch 97 805 00 H Ball Hitch Mount Parts Page 36 Illustrated Parts Signet Charger Model HBS series charger shown Model HBS for Flooded Batteries NOTE The harness connectors and AC plug are not included with the charger Model HB for Flooded Batteries 36 volt Charger assembly see note Model HB for GEL Batteries PART DESCRIPTION PART DESCRIPTION 24 volt Charger Assembly see note 2 318 MU K4G CH 003 36 volt Charger assembly see note 79 309 41 48 volt charger assembly see note 76 200 00 AC plug 115v domestic Model HBS for GEL Batteries Standard Single Phase AC wire Color Codes as of 2010 Older systems may use a alternate color code Refer high voltage wiring repairs to a qualified technician Charger United States Canada Model Neutral White Hot
70. UTO SELECTABLE DUAL AC INPUT charger current while holding the batteries at the terminal voltage until the charging cycle is T compete The charger faceplate has three status LED s that monitor the charging status Refer to the chart SYSTEMS INC and illustration below for the function of these LED s Data Plate Details If an error occurs during charging the charger will beep and display an error code by flashing the status LED s Refer to the Status LED error code table later in this section 75 50 100 NDUS uO 21034 200 22 complete Error refer to FLASHING FLASHING FLASHING troubleshooting Charger Time Out Typical Charger Data Plate your data plate may vary Signet Charger Troubleshooting Page 2 Electrical Troubleshooting HB PT AND GEL INDICATOR LAMPS NOTE Your charger may not be equipped with these lamps GEL HB PT Lamp If the HB PT lamp is ON then the charger has overheated and p has entered a proportionally reduced output The charging cycle INDUSTRIAL 6 Ln will terminate if the temperature continues to rise If the charging BATTERY CHARGER cycle is terminated the charger will automatically restart once it 9 has cooled The charging cycle is limited to 18 hours If the HB PT lamp is flashing then the charging time has exceeded 18 hours time is limited to 18 hours If any of the status lamps are flashing then t
71. a where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are Set the park brake present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property Disconnect the main positive and damage negative cables at the batteries Place the forward reverse switch in the center OFF position Place blocks under the front wheels to prevent vehicle movement 6 Dry dirt can be readily blown off with low pressure AWARNING air or brushed off 7 Wetness or wet dirt on the batteries indicates battery acid Using a nonmetallic brush with flexible bristles wash the batteries off with a strong solution of baking soda and hot water 1 Ib of soda to a gallon of water Continue until all fizzing stops which indicates that the acid has been neutralized Then rinse thoroughly with clear water DO NOT get any of the solution into the battery cells Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury 8 Reconnect the batteries remove the blocks from A WARNING the wheels and test drive A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or
72. age until the charging cycle is complete The charging cycle is complete when the current is down to A1 On the charger face plate there is a status light panel that displays the current status of the charger The first light POWER should be ON when the AC cord is connected to a proper AC power source The three STATUS lights will indicate the current charging condition as follows Left Charge cycle is ON and is in constant current mode Left amp Middle 80 Charge cycle is ON and is in constant voltage mode Right 100 Charge cycle completed The FAULT light will turn ON and flash a fault code only when an abnormal charging condition has occurred Refer to the fault code table for more information NOTE Critical faults will be accompanied with an audible beeping Status Light Panel Signet Charger Troubleshooting Page 3 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started NOTE The charge cycle time is limited to 20 hours max A fault will occur if charging time exceeds the time limit Refer to the fault code table for more information Acharger could remain on for longer than 12 hours if vehicle is equipped with batteries larger than 220 Amp hour capacity charging cycle is interrupted at any time during the charging cycle Defect
73. all of the air is expelled from the brake line Any air bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is still air in the brake lines 15 Repeat this process with each of the other wheels NOTE When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information on filling the master cylinder 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Brakes Maintenance Service and Repair FLUSH THE BRAKE SYSTEM 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 6 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the rear wheels off of the ground and support with jack stands Always use lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices 10 11 12 13 14 15 16 17 18 19 20 22 of rated load capacity may result in severe bodily injury If equipped with front brakes raise the front wheels off of the ground and support with jack stands Release the park brake Remov
74. and thoroughly clean any surface outside of the Storage Temperature F Over 60 Charging Interval months battery that the battery electrolyte comes in contact with Failure to clean may result in property damage Between 40 and 60 Below 40 Batteries Page 8 Maintenance Service and Repair Returning to Service AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries 7 Check the electrolyte level and charge the batteries Refer to Watering in this section for information 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 Batteries Page 9 Sevcon Control System Troubleshooting Includes Power Pak and Micro Pak controllers TABLE OF CONTENTS Test Equipment Required 2 Defnitiols 2 Terminology used 22 2 Important Notes and Instructions
75. and proper operation of all controls such as but not limited to Accelerator pedal Brake pedal Steering Parking brake etc Proper operation of all locking devises such as but not limited to Tool box Removable battery trays Cargo box Cab doors etc Proper operation of all interlocking switches such as but not limited to Key switch Seat interlock switch Charger interlock switch etc Inspect for leaking fluids or grease MAINTENANCE GUIDELINES FOR SEVERE DUTY APPLICATIONS 1 This maintenance checklist is based on the average application If the vehicle is operated under severe conditions service procedures should be conducted more frequently than specified The frequency of service under severe conditions is determined by the use of the vehicle The owner operator must evaluate the operating environment to determine the increase in maintenance frequency In addition the whole vehicle should be inspected monthly for signs of damage The damage must be repaired immediately The following list is meant as a guide and is not all 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 multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water
76. arger nameplate Make sure the batteries are in good condition If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting Battery volts Full voltage available atthe batteries at the time of the test being performed There are no internally serviceable components in the charger If the charger has failed then it must be replaced This charger is rated for 115 VAC or 230 VAC operation When switching from one input voltage to the other wait until all three status LED s ACAUTION are off Switching voltage when any of the LED s are on will result in damage to the charger Signet Charger Troubleshooting Page 4 Electrical Troubleshooting STATUS LED ERROR CODE TABLE There are three status lights LED s on the charger name plate These LED s normally indicate the current operating state of the charger If all three LED s are flashing it indicate an error has occurred in the charging cycle See the table below for an explanation of the error codes Note If only the 10096 LED is flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of Defective battery or batteries Excessively discharged batteries Oversize batteries Description Action Required Reverse polarity or open circuit to Check wiring for corrosion loose connections broken wires and the
77. ark the input shaft and pitman shaft in relation to the housing Maintenance Service and Repair REPLACE THE STEERING REPLACE THE BALL JOINTS GEAR NOTE If a ball joint is worn out we recommend replacing all of the ball joints as a set AWARNING AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Remove the steering wheel 7 Remove the steering shaft 8 Remove the pitman arm NOTE On some vehicle configurations it may be required to remove the drag link from the pitman arm Refer to Replace the Ball Joints section for information regarding removing the ball joint from the pitman arm A WARNING Failure to support the steering gear will result in the steering gear falling out of the vehicle and could cause severe bodily injury and or property damage 9 Support the steering gear so that it cannot fall out of the vehicle 10 Remove the bolts holding the steering gear to the vehicle frame and remove the steering gear from the vehicle 11 Install in reverse order Torque the pitman arm nut to 75 100 ft Ibs NOTE Refer to section Front End Alignment for information regarding the correct position of the pitman arm 12 Reconne
78. as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer low voltage secondary circuit The transformer low voltage secondary circuit can be tested at the two solid wires with the brown fiber insulator that are connected to the anodes on the two diodes The voltage here will vary depending on the state of charge in the batteries The voltage should be between 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the rated DC voltage of the charger the transformer is bad and must be replaced Stop here and repair the problem Charger Troubleshooting 7 Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries 1 Test the voltage from the positive terminal on the vehicles DC receptacle to main battery negative This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then this wire is broken or has a bad connection Stop here and repair the problem 2 Test the voltage from the positive terminal on the DC receptacle to the negative terminal on the DC receptacle This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wire on the negative terminal of the DC r
79. ash adjuster all of the way to the stop Steering Page 4 Maintenance Service and Repair ADJUST THE STEERING GEAR 10 14 16 17 Loosen the worm bearing adjuster and then tighten just enough to remove all end play from the input shaft and then an additional 1 8 turn more While holding the worm bearing adjuster so that it cannot turn tighten the worm bearing adjuster jam nut Find the center position of the steering shaft A Turn the steering shaft all of the way in one direction B While counting the rotations turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction While rotating the input shaft back and forth through its centered position adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle CENTER THE STEERING GEAR Rotate the input shaft clockwise until it stops While counting the rotations rotate the input shaft counter clockwise until it stops Rotate the input shaft clockwise 1 2 the rotations counted in the previous step M
80. ation regarding machining the commutator 5 Inspect the commutator for burn marks Commutator marks and or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature A tool called a growler is required to reliably test for a shorted armature 6 Inspect the commutator for raised segments Raised segments could be a result of a stalled motor or shorted armature A tool called a growler is required to reliably test for a shorted armature e lf the armature is not shorted then the raised segments can be removed by machining the commutator Do not machine the commutator past the minimum diameter specified in Service Typical burn mark shorted armature Limits section Refer to Repair Commutator section for information regarding machining the commutator Motor Page 4 Motor Service 7 10 11 Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted armature f the insulation is cracked or burnt then it is recommend that the armature or motor be replaced NOTE If the armature has been burnt then there is good possibility that the field windings may also be burnt Symptoms indicating a shorted field include high motor current lack of power and possibly excessive speed Using a growler test the armature for shorts f the armature is shorted then we recommend
81. ations then add or subtract from the total shim thickness and repeat this procedure until the proper preload is obtained NOTE Add shims to decrease torque Pinion Gear Bearings Transmission 18 Maintenance Service and Repair PINION GEAR SHIMMING INSTRUCTIONS NOTE This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears NOTE To perform this procedure all parts must be clean and the bearings lightly lubricated Setting the Pinion Gear Depth This formula is used to calculate the amount of shims that are required C B A DV Pinion Shim mm where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the edge of the differential side plate closest to the input shaft see next page D The number on the edge of the differential side plate farthest from the input shaft see next page E The distance in millimeters from the rear of the drive housing to the face of the pinion gear see next page Once a shim has been selected and the pinion gear is installed confirm that DV Number on face of pinion gear Transmission Page 19 4 Maintenance Service and Repair NOTE Values shown are for reference only Pinion Gear Drive Housing Trans
82. atteries 11 Remove the blocks from behind the wheels release the park brake and test drive the vehicle Transmission Maintenance Service and Repair REMOVING AND INSTALLING THE REAR AXLES DISC BRAKES The oil level in the housing is above the bottom of the axle flange To minimize oil spills raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange If both axles are to be removed you must drain all of the oil from the housing Height of oil in housing on level surface NOTE This procedure does not require that the rear end or drive assembly be removed from the vehicle NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced Oil Level Raise the wheel off of the ground high enough so that the oil level is below the axle housing flange 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 If required drain the oil from the 3rd member 7 Raise the rear of the vehicle and support with jack stands Always use lifting strap hoist and jack stands of ade
83. attery 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 ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries NOTE A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries Load Test 6 volt batteries only NOTE The batteries must be fully charged before 1 performing this test Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries Load test each battery using a battery load test meter available at most auto parts distributors Follow the instructions provided with the test meter If any battery fails the load test then it should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a set If all batteries fail the test you sho
84. bout 0 5 seconds Sevcon Troubleshooting Page 18 Electrical Troubleshooting Status LED Code Table The status LED on the Sevcon power unit logic card can be used to give you an idea of where the problem may be It is recommended that you complete the troubleshooting procedure to confirm failure of any component Fault Description Possible Cause Actions Flashes Reset the switches and start over Refer to Vehicle Operating Instuctions MOSFET motor Burned Motor Repair as required short Contactor fault or Contactor Failure Check contactor and a motor Circuit Not Notused Startup switches not Sequence fault operated in the correct order FS 1 Micro Failure Faulty Wiring Accelerator Failure Check accelerator module inputs Accelerator module Check battery and connections to controller Discharged battery or loose connections Wait for controller to cool Check coil continuity and replace as required Check wiring If Fault in the Wiring to the vehicle is not dash display or a faulty equipped witha Dash Display dash display check NOTE The Dash Display is for debris in the 6 Optional pin connector on the logic card PowerPak ener Sevcon Troubleshooting Page 19 Electrical Troubleshooting Smart View Fault Codes Level 5 Faults F05xxx 05000 Contactor Over Current This faut occurs when too much current is going into the l
85. brake Connect an analog Ammeter in series with the motor field windings or a clamp on Ammeter on one of the field wires that is capable of reading up to 25 Amps Place the forward and reverse switch in the center OFF position and turn the key switch ON TEST 48 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor Service section for specifications then the Anti Rolloff feature has failed Check the status of the Anti Rolloff feature using the hand held calibrator 62 027 61 TEST 48 2 While monitoring the motor field current release the park brake and push the vehicle The surface must be level for this test Do not attempt to test the A WARNING Anti Rolloff by pushing up or down an incline Testing by pushing up or down an incline could result in injury or property damage Within approximately 10 feet the field current should rise dramatically and the vehicle should become difficult to push Now stop pushing the vehicle and allow it to come to a complete stop The field current should drop down below the value specified in the Motor Specification table This indicates that the Anti Rolloff feature is operating normally If the current does not rise then the Anti Rolloff feature has failed or has been turned off status of the Anti Rolloff feature can be checked with the hand held calibrator If the Anti Rolloff feature is on a
86. cables at the batteries Raise the rear of the vehicle and support with jack stands Place a four quart drain pan under the drive assembly Remove the drain plugs from the differential case and gear case Once the oil has drained replace the drain plugs gt and lower the vehicle to the ground e Remove the fill level plug and fill the differential up Fill Level Plug to the bottom of the level plug opening Refer to ae a the Lube Chart section for information regarding Ee type of oil run Flug gt Replace the fill plug Reconnect the main positive and negative cables at the batteries Remove the blocks from the wheels Release the park brake and test drive the vehicle Transmission Maintenance Service and Repair MOTOR REMOVAL AND INSTALLATION NOTE Some applications will require removing the drive assembly from the vehicle to remove the motor Refer to Removing and Installing the Drive Assembly for information on removing the drive assembly Some vehicles are equipped with an automatic electric brake The automatic electric brake is sandwiched between the drive motor and the gear case The electric brake is retained by the drive motor mounting screws Once the motor is removed the electric brake will no longer be retained by any hardware 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 positi
87. ce Service and Repair Lubricate all parts with gear oil before installation Failure to pre lube ACAUTION the parts may result in premature failure 19 Assemble the gear case in reverse order NOTE Torque the drain plug to 21 25 foot pounds NOTE Torque the gear case to 3rd member retaining bolts to 18 20 foot pounds NOTE Torque the pinion nut to 154 169 foot pounds NOTE Apply gasket sealer 94 430 05 to 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 information on filling the drive with oil 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Transmission el Page 11 Maintenance Service and Repair DISASSEMBLING THE 3RD MEMBER 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Fai
88. ct the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the parking brake and test drive the vehicle Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Remove the front access cover Loosen the ball joint clamp on the steering sleeve Remove the cotter pin and ball joint nut Using a pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve HINT Count the number of turns required to remove the ball joint from the sleeve This will make it easier to realign the wheels 11 Install the new ball joint into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the ball joint clamp at this time 12 Install the ball joint into the steering arm Tighten the ball joint nut to 40 45 ft lbs and install a new cotter pin 13 Realign the front end Refer to the Front End Alignment section for information regarding realignment of the front wheel 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brak
89. d and must be replaced The charger comes equipped with a long fully insulated AC cord that can be cut to length as needed for the vehicle application Do not cut the AC cord and splice to the existing AC cord in the vehicle Cutting and splicing the AC cord will void the charger warranty ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries Signet Charger Troubleshooting Page 6 sweibeig TABLE OF CONTENTS Front Light B 2 38 RR Special Sevcon control system no 12 volt tap Diagram inculdes options that may not be installed on your vehicle
90. d technician Refer to the Illustrated parts section for information regarding tools required to reset the Smart View Display Display showing Maintenance and Wrench icons Safety Rules Page 7 SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display Fault Codes Example of Fault Code 4003 displayed on the SVD Fault Code Description Corrective action 01004 Discharged battery or defective wiring Charge the battery If the battery is good check wiring to the controller note 2 01005 Speed control overheated Allow the controller to cool off May be the result of an overloaded vehicle or an obstruction to the controller heat sink 01008 Optional speed encoder defective or speed Repair as required encoder wiring defective 02000 Start up switches not operated in the correct Reset switches and start again note 1 order or a defective switch 02001 Defective wiring Refer to troubleshooting 04003 Start up switches not operated in the correct Reset switches and start again note 1 order or a defective switch 04004 Both the forward and reverse directions are Check the forward switch and wiring selected at the same time for shorts 04005 Start up switches not operated in the correct Reset switches and start again note 1 order or a defective switch 04006 Accelerator pedal depressed before the seat Recycle start up switches and try again in
91. distributors that carry batteries ACAUTION Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and charged Operating or charging moist charged batteries before filling and charging will damage the batteries resulting in premature failure of the batteries ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury AWARNING A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle move
92. do so may result in serious bodily injury Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the DC cord is bad Stop here and repair the problem Test the voltage across the white and black wires that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the AC cord is bad Stop here and repair the problem If the timer relay does not pickup click within 5 seconds of connecting the DC charger plug then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit This voltage should be the same as the rated AC voltage of the charger If itis less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Transformer Secondary Circuit Test the AC voltage across the transformer secondary circuit The voltage here will vary depending the state of charge in the batteries The voltage should be between 20896 and 25096 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the charge s rated DC voltage the transformer is bad and must be replaced Stop here and repair the problem TESTING THE T
93. draulic disc 4 Adjust the Service Brakes 5 Adjust the Parking Linkage 6 Check Master Cylinder Fluid 7 Bleed the Brake System 8 Flush the Brake System 10 Replace Rear Brake Pads 11 Hydraulic Dise ce ott cte 11 Replace the Wheel Cylinder 13 Disc Brake Body Assembly 13 Repair the Brake Body 15 Replace the Master Cylinder 17 Repair the Master Cylinder 19 Maintenance Service and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions NOTE The brake pad must be removed to accurately measure the lining thickness Refer to Replace the Front or Rear Brake Pads section for information on removing the brake pads Measure the brake pad lining at the thinnest point on the pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is
94. ds of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 13 Reinstall the drive in reverse order 14 Bleed the brake system Refer to Bleed the Brake System for information regarding bleeding the brakes 15 Set the park brake 16 Lower the vehicle 17 Reconnect the main positive and negative cables at the batteries 18 Remove the blocks from the wheels release the park brake and test drive the vehicle Transmission A Page 8 Maintenance Service and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Place drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove the drive assembly from the
95. e battery compartment prepped and repainted 13 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery compartment 14 Inspect the main positive and negative cables and terminals charger cables and terminals and 12 volt tap wiring If any ofthe terminals or wires show signs of corrosion then they must be repaired or replaced Batteries Page 6 Maintenance Service and Repair 15 Install the batteries in reverse order Refer to the Illustrated Parts List for battery cable routing 16 It is recommended to replace the battery terminal hardware when replacing the batteries ACAUTION When torquing battery hardware use a backup wrench on the battery bolt and tighten the nut Failure to use a backup wrench may damage the battery post 17 Torque the terminal hardware to 7 8 1 105 18 Tighten the hold downs so that the batteries are secure but not so tight as to deform the batteries 19 Remove the blocks from the wheels and test drive Moist Charge Batteries Moist charged batteries are shipped without battery electrolyte This allows for a much greater shelf life of the battery Moist charged batteries must be filled with electrolyte and charged before putting into service Battery electrolyte is a solution of acid and water that is formulated to be used in wet lead acid batteries and is available at most automotive parts
96. e pedal to decrease speed Safety Rules Page 5 SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise If equipped with tilt steering the release lever is located on the lower left of the steering column Pull the lever up to reposition the steering wheel Charger Interlock built in charger The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source NOTE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger Safety Rules Page 6 SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display Maintenance Indicator Pump Time Hours Indicator Key Hours Indicator Battery Status The Smart View Display SVD functions as a Battery Status Indicator BSI Hour Meter HM speed controller status monitor and as an optional maintenance monitor feature The operation of each of these functions is listed below Hour Indicator Hour Meter Status Display BSI A bar graph representing the current state of charge is located across the top of the display When the batteries are fully charged all segments of the bar graph will be on As the batteries are used segments will turn off in the order of
97. e and test drive the vehicle Steering Page 5 REPAIR THE STEERING GEAR Maintenance Service and Repair Disassembly NOTE The steering gear must be removed from the vehicle for this procedure Refer to Replace the Steering Gear section for information regarding removing the steering gear NOTE The steering gear is packed with grease Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled Refer to the illustration at the end of this section for a blown up view of the steering gear assembly Center the steering gear A Turn the steering shaft all of the way in one direction B While counting the rotation turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction Remove the worm bearing adjuster locking ring and the worm bearing adjuster Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing NOTE The side cover pitman shaft assembly 4 normally does not have to be disassembled Remove the worm shaft and ball nut assembly from the bottom of the housing 5 Remove the worm shaft seal 6 Remove the pitman shaft seal 7 Remove the upper worm bearing and bearing cup 10 11 from the housing The ball nut assembly consists of two s
98. e both rear wheels and if equipped with front brakes the front wheels Refer to Tires and Wheels section for information regarding removing the wheels Remove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into a container for waste brake fluid Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all bleeder screws Pump the master cylinder until all fluid has been pumped from the brake lines and all wheel cylinders Close all bleeder screws Fill the master cylinder with fluid Open one of the bleeder screws and pump the master cylinder until all fluid has been pumped from the master cylinder and close the bleeder screw Repeat the above two steps for each wheel cylinder Reinstall the wheel cylinders and bleed the brakes Refer to Bleed the Brakes for information regarding bleeding the brakes Set the park brake Install the wheels and lower the vehicle to the ground Reconnect the main positive and negative cables at the batteries Release the park brake and test drive the vehicle Brakes 27 Page 10 Maintenance Service and Repair REPLACE REAR BRAKE PADS Hydraulic Disc Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with af
99. e cells is more than 30 points then that battery should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a set Reconnect the batteries remove the blocks from the wheels and test drive Typical Hydrometer Float CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions Batteries Page 4 Maintenance Service and Repair WATERING AWARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage AWARNING A battery is a live electrical source It cannot be disconnected or neutrali
100. e compensated relative to the temperature of the charger at the 2 383 Volts Per Cell Gel Batteries V2 2 08 Volts Per Cell X All batteries A1 2 to 4 Amps All batteries All voltages are nominal ACAUTION This charger is rated for 115 VAC or 230 VAC operation nominal When switching from one input voltage to the other wait until all LED s are off Switching voltage when any of the LED s are on will result in time the charge cycle is started Starting V1 Volts Temperature Per Cell Less than 4 2 64 4to2 2 61 2108 2 59 81014 2 56 141021 2 54 ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries damage to the charger TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM calibrated and accurate down to 0 00001 volts Clamp on DC ammeter to measure up to 20 Amps Important Notes and Instructions This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that AC electrical socket the charger is plugged into is 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
101. e 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 AWARNING 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 Model B 2 10 Ambulance Page 5 SC1 00 Stock Chaser B2 48 With Stake Side Dump Bed Option E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor TABLE OF CONTENTS Standard Specifications 2 Safety Rules and Guidelines 2 39 Driver Training Program 3 Driver 22 2 3 Vehicle Controls 4 Ly Key seite eres 4 2 Smart View Display eee 4 3 Forward Off Reverse Switch 4 4 Horn switch m 1 Headlight switch eee 5 2 Front Side Lights esse 5 3 Rear Side Lights Park Brake 1 Foot Brake Pedal 2 Accelerator Steenin D Charger Interl
102. eakage If any sign of 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 Reconnect the main positive and negative cables at the batteries 10 Remove the blocks from behind the wheels 11 Release the parking brake and test drive the vehicle TABLE OF CONTENTS Tire Inflation 2 Tire 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 Maintenance Service and Repair TIRE INSPECTION AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries There are many tire options available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall information on a tire Tire pressures must be checked when the tire is cold Tires and Wheels Page 2 6 Check the tire
103. eceptacle is broken or has a bad connection Stop here and repair the problem Remove the charger cover and perform the following tests HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNI NG terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one lead from the capacitor Test the capacitor using the capacitor test function on the meter If the capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the diodes using the diode test function on the meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Diode 1 Common Diode 2 Charger Troubleshooting Page 8 Electrical Troubleshooting 5 Reconnect the lead to the diode 6 Connect the charger to the AC source Insert the DC charger plug into the DC receptacle and perform the following tests High Voltage inside the charger Do not touch any internal components AW ARNING while the charger is plugged in Failure to
104. er If the master cylinder is not to be immediately installed onto a vehicle plug the brake line fitting hole to prevent any contaminates from entering the master cylinder Brakes 27 Page 19 Motor Service TABLE OF CONTENTS Inspecting the Motor Brushes 2 Motors with internal cooling fans 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes or Armature Bearing 7 Repairing the 8 Service 21 10 Motor Service INSPECTING THE MOTOR BRUSHES Motors with internal cooling fans NOTE There are four brushes in the motor The brushes will not wear at the same rate It is recommended that all four brushes are inspected at the same time NOTE In some vehicle configurations it may not be possible to inspect all four brushes while the motor is in the Typical motor with cooling fan indicated by vehicle Refer to Transmission the arrow Service section for information on removing the motor 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front w
105. es at the batteries 6 Raise the wheel off of the ground Always use lifting strap hoist and jack stands of adequate capacity AWARNING tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the rotor 11 Install in reverse order a Lightly grease the axle splines b Refer to section Brake Service for information regarding installing the brake pads c Thoroughly clean the threads in the axle shaft d Using new bolt torque the axle hub bolt to 275 ft lbs The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes AWARNING resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt Refer to Tires Wheels section for information regarding installing the tire wheel assembly 12 Lower the wheel to the ground 10 Reconnect the main positive and negative cables at the b
106. est the voltage at pin 1 on the 12 pin logic card connector If the voltage equals battery volts then skip ahead to Test 5 Test the voltage on both terminals of the battery voltage positive circuit breaker see below If the voltage on both terminals equals battery volts then skip ahead to test 4 2 If the voltage on both terminals does not equal battery volts then check the circuit breaker and wiring to the main circuit breaker and to the batteries 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 4 2 Test the voltage at the hot terminal red wire on the key switch If the voltage equals battery volts then skip ahead to test 4 3 If the voltage does not equal battery volts then check the wiring from the key switch to the battery voltage positive circuit breaker 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 Typical Circuit Breaker TEST 4 3 Test the voltage at the cold side violet black wire of the key switch If the voltage equals battery volts then skip ahead to test 44 4 If the voltage does not equal battery volts then replace the key switch Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehic
107. esult in severe bodily injury 6 Raisethe front of the vehicle so that the front wheel just touches the ground and support with jack stands 7 Remove the upper and lower shock bolts 8 Remove the shock from the vehicle NOTE If the shock that was removed is to be reinstalled A Inspect the shaft where it enters the shock body for any signs of leakage If any sign of 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 Suspension Page 4 Maintenance Service and Repair REPLACE THE SHOCKS 9 Install the shock in reverse order 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Rear A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheel to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Remove the upper and lower shock mounting bolts 7 Remove the shock 8 Install the shock in reverse order NOTE If the shock that was removed is to be reinstalled A Inspect the shaft where it enters the shock body for any signs of l
108. ets of ball bearings that recirculate in two channels in the ball nut housing The bearings may fall out once the bearing guides are removed Be careful not to lose any of the bearings Remove the ball guide clamps ball guides and all of the ball bearings Remove the ball nut from the worm shaft Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Steering Page 6 Worm Bearing Adjuster Side Cover Worm Shaft Ball Nut Assembly Bearings Ball Guides Ball Guide 1 Clamp Housing Maintenance Service and Repair Reassembly 6 7 Lightly lubricate all parts before reassembly Install a new worm shaft seal and pitman shaft seal into the housing Install the upper worm bearing cup Divide the ball bearing into two equal groups Position the ball nut onto the worm as shaft as shown in the illustration Insert the ball guides into the ball nut Insert each group of bearings into the ball guides NOTE Do not rotate the worm shaft while installing 14 15 the bearings This cause or more of the bearings to enter the crossover passage in the ball nut causing improper operation Install the ball guide clamp Place the upper worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal Install the assembled worm bearing adjuster into t
109. f any debris is found it should be removed and the tire inspected for a leak Maintenance Service and Repair REPLACE THE FRONT TIRE WHEEL REPLACE THE TIRE PNEUMATIC Refer to Front Axle Service for information on removing the front wheel REPLACE THE REAR TIRE WHEEL AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Raise the wheel to be replaced off of the ground and support with jack stands 7 Remove the 4 or 5 wheel nuts and remove the wheel Install in reverse order Following the pattern shown on the following page cross tighten the wheel nuts in two stages as follows 1st stage to approximately 20 ft lbs 2nd stage to 80 90 ft lbs 10 Reconnect the main positive and negative cables at the batteries 11 Lower the wheel to the ground 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle NOTE To replace the tire the tire wheel assembly must be removed from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assembly Tire replacement should only be performed by personnel trained in tire replacement The
110. front axle from the fork and support the vehicle with jack stands Typical fork illustrated Your fork may be different Front Axle Page 3 Maintenance Service and Repair REPLACE FRONT WHEEL BEARINGS AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Remove the front axle and wheel Refer to Front Axle Removal and Installation section for information regarding removing the axle 7 Remove the spacers seals and bearings from the hub 8 Thoroughly clean all grease from the inside of the hub and the bearings 9 Drive the races out of the hub 10 Press new races into the hub 11 Assemble in reverse order using new grease seals a Pack bearings with grease b Refer to Front Axle Removal and Installation 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
111. g 372 105 to 432 Ibs Weights Maximum Load Deck dimensions 952 5 kg 2 100 Ibs 105 4 W x 109 2 L Centimeters 41 5 W x 43 L Inches Electrical System 36 Volt Six 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 400 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC 36 Volt 3 2 kW 4 4 Horse Power for 60 min Separately Excited 5 1 kW 6 9 Horse Power for 5 min Field Brakes Rear Wheel Hydraulic Disc Hand Operated Park Brake 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Tires 18 5 x 8 50 x 8 Load Range C Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Smart View Display Battery Status Indicator Hour Meter System Status Monitor Key Switch Horn Button Forward Reverse Switch Headlight Switch Light Accessories Headlight Side and Rear Utility Lights Dual Tail Brake Lights Specifications are subject to change without notice This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 Safety Rules SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDELINES It is the responsibility of the owner of this vehicle to assure that the operator unders
112. g Appendix B Page 6 Appendixes All torque values for clean dry zinc plated threads noncritical steel assemblies of the same hardess specification Reduce torque approximately 10 15 for lubricated threads Refer to the service section assembly procedure for critical torque values Dia oO 12 14 16 18 20 22 24 27 30 available at time of printing Pitch 0 50 0 70 0 80 1 1 2 2 00 00 25 50 2 50 1 50 2 00 2 50 2 00 3 00 3 00 3 00 2 00 3 50 4 6 0 51 0 95 2 28 3 92 9 48 Metric Newton Meters Grade N m 8 8 3 1 6 1 10 4 27 0 25 0 57 0 54 0 51 0 10 9 12 9 Dia Jo 20 22 24 27 30 1 50 2 50 1 50 2 00 2 50 2 00 3 00 3 00 3 00 2 00 3 50 4 6 0 38 0 7 1 7 2 9 Metric Foot Pounds Grade N m 8 8 2 3 4 5 7 7 19 9 18 4 42 40 38 71 68 64 111 10 9 11 4 27 3 12 9 Appendixes Appendix B Page 7 A Appendixes APPENDIX C BRAKE LINING HANDLING PRECAUTIONS Taylor Dunn does not currently supply asbestos fiber brake pads shoes with any vehicle However there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as
113. g cycle as indicated below Specific Gravity Using a hydrometer take the specific gravity reading of several cells at 1 hour intervals while charging If the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not shut off then the charger is running too long Battery Voltage Using an accurate 5 1 2 digit digital voltmeter monitor the battery voltage during the charging cycle Take readings every 30 minutes If the battery voltage does not increase 0 012 volts in two consecutive readings then the charger is running too long Charger Troubleshooting 27 Page 3 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM with diode and capacitor test function FLUKE 79 model shown at right and in the troubleshooting illustrations Important Notes and Instructions This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that the AC electrical socket the charger is plugged into is 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 in good condition and no less than 80 discharged as per hydrometer reading The battery v
114. good then The pigtail harness to the electric brake is broken or the electric brake has failed Remove the brake and repair or replace as required If the test is bad then Sevcon Troubleshooting Page 16 Electrical Troubleshooting Connect a volt meter across the Violet Black wire at the electric brake harness plug and Pin 9 at the logic card connector The voltage should start at approximately 24 volts then drop to approximately 15 volts after about 0 5 seconds If the test is good then The blue wire from the electric brake harness plug to pin 9 on the logic card connector is broken 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 If the test is bad then The logic card is not releasing the brake This could be a result of Improper operation of the vehicle fault in the vehicles wiring or switches A fault in the speed controller Incorrect programming A failed speed 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 system Return to the beginning of the troubleshooting section and continue If the brake does not release then The electric brake has failed Remove the brake and repair or replace the brake as required Stop trouble shooting here and repair the p
115. gs Check Rear Axle Oil Change Rear Axle Oil Check and Tighten all Nuts and Bolts Clean and Repack Front Wheel Bearings 1 2 3 See notes on following pages Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Repairs or maintenance by AWARNING improperly trained or unauthorized personnel could cause improper operation of the vehicle or premature failure of components resulting in severe bodily injury and or property damage Safety Rules Page 13 SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY NOTE The maintenance function is optional Your vehicle may be equipped with a customized maintenance schedule PREVENTATIVE MAINTENANCE SCHEDULE MAINTENANCE HOUR MAINTENANCE TO BE PERFORMED Inspect the brake system including the park brake and mounting harware Inspect the steering system tighten the steering shaft coupler on the steering gear input shaft Lubricate the vehicle check for leaks 500 Inspect safety interlocks Inspect front and rear wheel bearings Inspect and adjust fork collar bearings 3 wheel trucks only every 1000 hours 1 2 3 See notes on following pages Safety Rules Page 14 SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection Tire condition and pressure External frame damage body Operation of all lights and warning alarms and or horns Smooth
116. he charge cycle did not complete GEL lamp SIGNET SYSTEMS INC This LED will only be ON if the charger is configured for GEL batteries Using a GEL charger with non GEL batteries may result Charger Data Plate in an incomplete charge or long charge times your data plate may vary ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the batteries when the charge cycle was started NOTE Charging time is limited to 18 hours max An error occurs if charging time exceeds 18 hours See table on previous page Acharger could remain on for longer than 12 hours if vehicle is equipped with batteries larger than 220 Amp hour capacity charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger One or more defective cells in the battery pack brownout drop in AC line voltage during the charging cycle electrically noisy charging environment A charger could turn off in less than 12 hours but still show symptoms of overcharging if The electrolyte in the batteries is too high boil over The electrolyte in the batteries
117. he housing and tighten just enough to remove all play in the worm shaft Install but do not tighten the worm bearing adjuster lock nut Rotate the worm shaft to center the ball nut in the housing Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bolts Pack the steering gear with grease through the open side cover bolt hole and then install the bolt Adjust the steering gear NOTE Refer to Adjust the Steering gear section 16 for information regarding adjusting the steering gear Once the adjustments are completed make sure that the locking ring and jam nut are tight Worm Bearing Adjuster Steering Page 7 Maintenance Service and Repair Exploded View_of Steering Gear Side Cover 9 Locking Ring Worm Bearing Adjuster Gear Lash p and Lower Bearing Adjuster and Shim Ball Nut Housing Worm Shaft Pitman Shaft 9 ET e Bearings Ball Guides 0 Upper Bearing Ball Guide Clamp Pitman Shaft Seal Worm Shaft Seal Steering Page 8 Brake Service TABLE OF CONTENTS Inspect the Service Brake 2 Disc Brake Pads 2 2 4 00 2 Disc Brake Rotor 3 Inspect the Parking brake 4 Wheel Park Brake hy
118. he 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 Model B 2 10 shown withstake sides and steel cab with doors options HOW 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 is
119. heels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Look through the brush cover and compare the top of the brush to the top of the brush holder If it is even with or below the top of the brush holder then the brushes should be removed and measured Refer to Replacing the Brushes section for information regarding removing the motor brushes 7 lf any one brush is less than or equal to the service limit specified in Service Limits then all four brushes should be replaced 8 Reconnect the main positive and negative cables at the batteries Typical brush and brush holder 9 Remove the blocks from behind the wheels release the park brake and test drive Motor Page 2 Motor Service MOTOR REMOVAL AND INSTALLATION See the Transmission section for information on removing or installing the motor MOTOR INSPECTION Disassembly 1 Remove the motor from the vehicle See the Transmission section for information on removing the motor Remove the brush cover and pull the brushes out away from the commutator Remove the dust cap from the rear motor housing Place the motor in a press and press the armature out of the rear bearing NOTE Removing the armature will damage the motor bearing The motor bearing should be replaced whenever the armature is removed 5 Remove the housing screws from the rear motor housing and remove the housing from the
120. hen the repair is completed completely retest the vehicle before lowering the drive wheels 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 0 3 volts then skip ahead to Test 41 8 If the voltage is above 0 3 volts then skip ahead to Test 6 ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results PowerPak Logic Connector TEST 1 8 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is low then skip ahead to Test 1 9 If the voltage is high then skip ahead to Test 6 TEST 1 9 Depress the accelerator pedal fully Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is between 4 8 and 5 1 volts then skip ahead to Test 2 If the voltage is not between 4 8 and 5 1 volts then skip ahead to Test 6 Sevcon Troubleshooting Page 6 Electrical Troubleshooting Test 2 TESTING THE MOTOR 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels
121. hicle as originally manufactured Instrument Panel ITEM DESCRIPTION Smart view display see information below Spacer key switch Sheet metal screw Resetting the Smart View Display Maintenance Meter optional The meter should only be reset after the preventative maintenance has been performed Taylor Dunn part number 62 027 40 Hand set available with instructions as part number 62 027 61 must be used to reset the meter Refer to the handset instructions DO 100 08 for information on the procedure to reset the display Parts 27 Page 23 Illustrated Parts Miscellaneous Electrical Miscellaneous Wire Harness Clamps Parts gp Page 24 Illustrated Parts Miscellaneous Electrical ITEM PART DESCRIPTION K47 300 01 Chassie Control Harness 75 152 04 Dash harness 75 152 00 Control panel harness K47 300 02 Power Harness Not Shown K1 153 68 Battery Connector 73 002 00 Horn 98 599 15 Plastic grommet for 1 75 hole 98 599 20 Plastic Grommet for 2 5 hole 1 lt 2 96 650 01 Wire Harness Clip stick on 3 96 642 00 Wire ahrness Clip push mount 4 62 033 48 Accelerator Module 1 96 640 00 Clamp 3 16 Push Mount 96 629 80 not shown Clamp Rubber Lined 3 16 ID 96 630 00 not shown Clamp Rubber Lined 5 8 ID 96 630 50 not shown Clamp Rubber Lined 5 8 ID 265 mounting hole 96 631 00 not shown Clamp Rubber Lined 3 4 ID 96 631 10 shown Clamp Rubber Lined 1 0 ID
122. if they do contain asbestos Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust AWARNING Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Always wear protective clothing and a respirator when working on the brake pads shoes or their associated components Inhaled asbestos fibers have been found to cause cancer and respiratory diseases Do not drive the vehicle if any worn or broken part is detected in any part of the brake system The cause of the damage must be repaired immediately Appendixes Appendix C Page 8 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
123. ine contactor coil circuit This could be a result of a shorted contactor coil short in the wiring or faulty logic card 05004 VA Fail This is a result of a low voltage on an internal voltage regulator Can also be caused by a low key switch input voltage If the key switch input is within specifications then replace the controller FO5006 MOSFET Short Circuit Also can be a result of an open motor armature circuit Confirm the motor armature and wires to the motor are good If motor and wires are good then replace the controller F05008 Power Up Traction Welded Normaly due to line contactor welded closed resulting in a high voltage at B This fault is generated when the differential voltage between the key switch input and the B terminal is less than approximatly 6 volts F05009 Shorted MOSFET Normaly due to interal short in controller Also could be result of shorted motor or wiring Remove the wire from the controller terminal S If fault clears then the short is in the motor or wiring F05046 Line Contactor Did Not Close Normaly due to open circuit to the controller B terminal Check wiring contactor main Circuit Breaker NOTE Controller B terminal must be within 1 5 volts of Pin 1 after contactor closes All other level 5 faults are a result of an internal failure in the Sevcon controller and cannot be repaired The controller must be replaced Level 4 Faults 04 F040
124. ion for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables i at the batteries Master Cylinder 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Push Rod Cutaway of typical master cylinder showing the push rod clearance Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes A WARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Brakes 27 Page 18 Maintenance Service and Repair REPAIR THE MASTER CYLINDER NOTE Hydraulic brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake fluid spills Remove the master cylinder from the vehicle See Replace the Master Cylinder section Drain all fluid from the master cylinder and discard 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 as required If any damage is found in the bore of the master cylinder then it must be replaced Lubricate all parts with clean brake fluid from a sealed container Reassemble in reverse ord
125. ion to the right Install the rear motor housing to the stator housing Lightly grease the inside diameter of the armature bearing Carefully insert the armature through the stator housing and onto the motor bearing in the rear housing While supporting the inner race of the bearing press the armature into the bearing Push the motor brushes into the brush holder until the brush spring snaps into place Be certain that the spring does not rest up against the brush wire See the illustrations below Install the brush cover Motor Page 6 Motor Service REPLACING THE BRUSHES OR ARMATURE BEARING NOTE It is recommended that all four brushes be replaced as a set NOTE The motor must be disassembled to replace the brushes or the bearing Refer to Motor Inspection Disassembly section for information on taking the motor apart NOTE The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor Motor Page 7 4 Motor Service REPAIRING THE COMMUTATOR While still in the lathe smooth the commutator with The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor The armature must be removed from the motor for this procedure Refer to Motor Inspection Disassembly section for information on taking the motor apart Using a la
126. is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and charging current during the charging cycle as indicated below Using a digit digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 1096 of the DC output current see previous page until the battery voltage reaches 2 55 volts per cell When the voltage reaches 2 55 volts per cell the charging current will drop significantly and slowly taper off voltage will remain constant The charger should turn off within 2 to 4 hours after entering the second stage EE EE EE i Signet Charger Troubleshooting Page3 4 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM FLUKE 799 model shown at right and in the troubleshooting illustrations Clamp on DC ammeter to measure up to 20 Amps Important Notes and Instructions This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that the AC electrical socket the charger is plugged into is in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the ch
127. ith skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately AWARNING 1 EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately NOTE Start this procedure at the wheel furthest from the master cylinder then work toward the wheel closest to the master cylinder 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 A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap and remove the cap Master cylinder is located under the floorboard by the throttle pedal Brakes 27 Page 8 Maintenance Service and Repair 7 Add brake fluid from a new sealed container to the master cylinder Fill to 1 4 from the top of the master cylinder chamber Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes AWARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fl
128. ive batteries causing a fluctuating DC voltage that confuses the charger One or more defective cells in the battery pack brownout drop in AC line voltage during the charging cycle electrically noisy charging environment NOTE This charger has a maintenance mode that will restart the charger if the battery voltage drops below a threshold after the charge cycle is complete In some cases it may appear that the charger is not turning 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 Acharger could turn off in less than 12 hours but still show symptoms of overcharging if electrolyte in the batteries is too high boil over electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if itis turning off correctly monitor the battery voltage and charging current during the charging cycle as indicated below Using a digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 1096 of the DC output current see previous page until the battery voltage reaches V1 When the voltage reaches V1 the charging current will drop significantly and slowly taper off voltage will remain constant The charger should turn off within 2 to 4 hours after entering the second stage when the charginc cu
129. ke body bolts and discard the lock nuts and brake pads 12 Remove the spacer bushings from the mounting bracket and discard ie Nuts Bushings 13 Inspect the brake rotor Refer to Inspect the _ Service Brake section for information regarding Brake Pads inspecting the brake rotor e 14 Inspect the spacers and replace if wear or 3 gt damage is found b 2 6 4 15 Install new spacer bushings the mounting bracket Mounting m 16 Back off the parking brake adjustment wheel park Bracket S brake only pacers Bolts 17 Install new brake pads in reverse order Torque the mounting bolts to 11 ft Ibs 18 Repeat this procedure for the other wheel 19 Install the tire wheel assembly and lower the vehicle to the ground 20 Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information regarding the correct master cylinder fluid level 21 Adjust the parking brake wheel park brake only Refer to Adjust the Parking Brake section 22 Set the park brake 23 Reconnect the main positive and negative cables at the batteries 24 Remove the blocks from behind the wheels 25 Release the park brake and test drive the vehicle Brakes 27 Page 12 Maintenance Service and Repair ______________ ___ __ ____ _ _________ __ _ __ _ REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly Current Taylor Dunn brakes are asbestos free However
130. kin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the brake body from the vehicle NOTE Refer to Replace the Brake Body Assembly section for information on removing the brake body 7 Pull the pistons out of the brake body AWARNING The pistons are very fragile If the piston is damaged it must be replaced Failure to replace a damaged piston could lead to brake failure and result in property damage and or severe bodily injury 8 Remove the piston rubber boot 9 Remove the piston o ring from inside of the brake body 10 Inspect and replace parts as required Brakes 27 Page 15 4 Maintenance Service and Repair 11 Lubricate the brake parts with clean brake fluid from a sealed container 12 Install the o rings into the brake body Make sure that the o ring
131. l batteries successfully complete a charge cycle and battery voltage is above reset threshold F01005 Traction Block Overheat Controller has overheated Allow controller to cool off F01006 Traction Motor Hot Not used F01007 Pump Motor Hot Not used F01008 Encoder Wiring Motor speed encoder faulty faulty wiring or incorrect controller parameters Sevcon Troubleshooting Page 21 TAYLOR DUNN NI EE UFACTURING Wo Greens Since 1949 5 Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Troubleshooting Lestronic II Charger RevE Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic II chargers are designed as semiautomatic chargers The Lestronic II charger turns itself on when the built in
132. l of the ISO solenoid violet wire If the voltage is within approximately 1 volt of the battery voltage then skip ahead to test 5 2 If the voltage is not within approximately 1 volt of the battery voltage then check the diode in the positive wire to the ISO solenoid NOTE This is a typical ISO solenoid 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 Main Battery Negative TEST 5 2 Check the voltage on the negative coil terminal of the contactor coil If the voltage is not within 1 volt of battery voltage then the contactor is bad and must be replaced NOTE An open contactor coil should be accompanied by a 4 flash code from the logic LED NOTE This is a If the voltage is within 1 volt then one of the four typical ISO solenoid following faults may have occurred Broken Wire Check the wire from pin 8 in the 12 Main Battery Negative pin logic card connector to the contactor coil negative terminal for open circuits Welded Solenoid Contacts Test the solenoid for welded contact tips There are two methods for checking the contacts 1 Disconnect the batteries and test the continuity across the contacts If there is continuity then the contact tips are welded 2 With the key switch OFF check the voltage at the B terminal on the Sevcon control see illustration on following page If the voltage a
133. lbs 17 Fill with oil to the level of the fill plug threads Refer to Changing the Differential Oil 18 Lower the vehicle 19 Set the park brake 20 Reconnect the main positive and negative cables at the batteries 21 Remove the blocks from behind the wheels 22 Release the park brake and test drive the vehicle Transmission 27 Page 7 Maintenance Service and Repair eee TRANSMISSION ASSEMBLY Remove and Install 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Release the park brake Remove the park brake cables from the spring axle mounting brackets and brake arms Disconnect the wiring from the motor 9 Disconnect the hydraulic brake lines from the left and right brake bodies Park Brake Brake Arm Pin Extension 10 Remove the u bolts holding the leaf springs to the frame as shown in the illustration to the right Do not remove the u bolts on the axle housing 11 Remove the lower shock mounting bolts and the front spring mounting bolts 12 Raise the rear of the vehicle lifting the frame up and off of the drive assembly Support the rear of the vehicle with jack stands Always use lifting strap hoist and jack stan
134. le DURING ALL TESTS After any repairs are made completely retest vehicle before lowering the drive wheels to the ground ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table AWARNING Turn the Key switch OFF then disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire Failure to do so may cause severe bodily injury and or property damage A WARNING The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause property damage and or serious bodily injury Important Notes and Instructions This troubleshooting procedure is for the Sevcon Power Pak and Micro Pak motor speed controllers as equipped in standard vehicles Troubleshooting may not be valid for vehicles equipped with special order speed control options For additional troubleshooting information use the handheld system anylizer part number 62 027 61 or the computer system anylizer PCpaK part number 62 027 63 See note below This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity
135. le before lowering the drive wheels to the ground TEST 4 4 Check the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector for open circuits NOTE Your vehicle may be equipped with a charger interlock relay The charger interlock relay disables the control system when the charger is connected to its power source The interlock relay contacts are in series with the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector The relay is located in the charger cabinet 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 STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit A WARNING After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in injury or property damage Sevcon Troubleshooting Page 10 Electrical Troubleshooting Test 5 CONTACTOR COIL FAULT Disconnect the 12 pin logic card connector from the Sevcon power unit Turn the key switch ON and perform the following tests TEST 5 1 Check the voltage on the positive coil termina
136. level should be inspected on a weekly schedule Safety Rules Page 15 Table of Contents Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication 4 Model 4 25 Tow Tractor Model E 4 55 Tow Tractor General Maintenance el Maintenance Service and Repair Maintenance Guidelines A WARNING Periodic maintenance and service must be performed on this vehicle Failure to complete these scheduled maintenance and service procedures can result in severe bodily injury and or property damage It is the owner and or operators responsibility to insure that proper service and maintenance is performed on the vehicle described in this manual A WARNING Before starting any repairs 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front or rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to the fault table in the troubleshooting section AWARNING Read and fo
137. llow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property damage Avoid fire hazards and have fire protection equipment present in the work area Conduct vehicle performance checks in an authorized area where safe clearance exists Before starting the vehicle follow the recommended safety procedures in Section 2 Safety Rules and Operational Information Ventilate the work area properly Regularly inspect and maintain in a safe working condition brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices Inspect and maintain battery limit switches protective devices electrical conductors and connections in conformance with Taylor Dunn s recommended procedures Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Page 2 Maintenance Service and Repair gg Troubleshooting Guide Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Dry Lube Points in Steering Linkage Hard Steering Damaged Fork Barings Ball Joint
138. lure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the complete drive from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 8 Place drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from 558 g the 3rd member by removing the six axle tube flange Axle Tube bolts on each axle tube Flange Bolts 11 Remove the primary reduction gear case Refer to Disassembly and reassembly of the Primary Reduction Gear Case for information on removing the gear case 12 Remove the 12 side plate bolts then remove the side plate Transmission Maintenance Service and Repair 13 Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate 14 Turn the side plate over and remove the carrier bearing race from the side plate 15 Remove the differential assembly from the 3rd member housing 16 Remove the carrier bearing adjusting nut roll pin from the 3rd member housing then remove the carrier adjusting nut Roll Pin Transmission Page 13 4 Maintenance Service and Repair 17 Remove the carrier bearing race from the 3rd member housing
139. ment Disconnect the main positive and negative cables at the batteries 6 Fill all battery cells with electrolyte to the proper level 7 Thoroughly clean any spilled electrolyte from the batteries or the ground Refer to Cleaning the Batteries for information on cleaning the batteries 8 Reconnect the battery cables connect the batteries to the charger and allow the charger to complete one charging cycle 9 Remove the blocks from the wheels and test drive The batteries are now ready to be put into service Batteries Page 7 Maintenance Service and Repair STORAGE AND RETURNING TO SERVICE AWARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF
140. mission Page 20 TABLE CONTENTS Replace the Rear Springs 2 Replace the Front Springs 2 Replace the Spring Bushings rear only 5 Replace the Shocks 6 nanninannan Raui 6 PROBE 6 Suspension Maintenance Service and Repair REPLACE THE REAR SPRINGS It is recommended that both left and right side springs are replaced as a set Complete the procedure for one side before replacing the opposite side spring AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Raise the rear left or right side of the vehicle depending on which side spring is to be replaced and support with jack stands Tie up or support the rear axle so it cannot fall down to the ground 8 Unbolt the spring from the axle housing 9 Remove the spring u 11 12 13 14 15 16 bolt and eye bolt and remove
141. nd linkages for any signs a __ Park Brake of damage wear or missing cotter pins Pin 10 Inspect the brake handle locking mechanism for any signs of damage NOTE Refer to Adjust the Parking Brake section for information regarding Park Brake adjusting the parking brake Ratchet If any sign of damage or wear is found on the locking mechanism cables or linkages then they must be repaired or replaced AWARNING immediately Failure to repair or replace any damaged component could result in failure of the park brake causing property damage and or severe bodily injury Brakes Page 4 Maintenance Service and Repair ADJUST THE SERVICE BRAKES The hydraulic disc brake system is automatically adjusted A low brake pedal or lack of braking power could be caused by Brake fluid level low in the master cylinder See Check the Master Cylinder Fluid section e Air in the brake lines See Bleed the Brakes section Worn brake pads See Inspect the Service Brake section Worn brake rotor See Inspect the Service Brake section Binding brake pedal linkage If you are experiencing a low brake pedal or lack of braking power the entire brake system should be inspected Brakes 27 Page 5 4 Maintenance Service and Repair _1 ADJUST THE PARKING LINKAGE 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward
142. nd the field current did not rise then the controller has failed and must be replaced If the Anti Rolloff feature is off then the controller logic must be reprogrammed Contact your dealer T 41 L9 Sevcon Troubleshooting Page 15 Electrical Troubleshooting Test 9 ELECTRIC MOTOR BRAKE Description The electric motor brake is a 24 volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case The brake is controlled by the speed controller logic At what times the brake is applied or released is dependent on the controller programing and will vary depending on the model vehicle Operation B is supplied to the brake when the key switch is turned on When the control logic determines that it is time to start it provides B at 24 volts through pin 9 on the logic card connector Testing Place the forward and reverse switch in the OFF position turn the key switch OFF Rotate the drive wheels to confirm the brake is engaged If the brake is engaged then skip ahead to 9 1 If the brake is not engaged then Disconnect the electric brake harness connector and repeat the test If the brake is still not engaged then Remove the brake and repair or replace the brake as required 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 If the brake engaged afte
143. nt of the vehicle so that the hole for AWARNING the axle is the same height as the front wheel hub 2 Assemble the bearing spacers into the front wheel Make sure the key switch is in the OFF hub and place the front wheel into the fork position remove key Insert the axle into the front fork Place the forward reverse switch in the center OFF position 4 Install the axle nut s Refer to Adjust Front Wheel Bearings section for information Set the park brake regarding tightening the front axle Place blocks under the rear wheels to NOTE If your vehicle is equipped with two axle nuts prevent vehicle movement the nuts should be tightened equally so that the Disconnect the main positive and a number of axle threads are visible on both negative cables at the batteries 5 Lower the vehicle 6 Reconnect the main positive and negative cables AWARNING at the batteries _ Remove the blocks from behind the wheels Always use a lifting strap hoist and jack stands of adequate capacity to lift and 8 Release the park brake and test drive the vehicle support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Remove the front axle nut Fork single 7 Slowly raise the front of the vehicle until the axle can slide freely out of the fork The front wheel should still be resting on the ground 8 Remove the
144. o service should only be performed by authorized personnel Storing Your Vehicle Cleanthe batteries then fill and charge before putting the vehicle in storage Do not store batteries in a discharged condition Lube all grease fittings Clean dry and check all exposed electrical connections Inflate tires to proper pressure if applicable For extended storage the vehicle should be elevated so that the tires do not touch the ground If stored for a prolonged period the batteries should be charged as follows Returning to Service Charging Interval Temperature th Check the F months battery s state of charge and uc required ___ Perform ALL maintenance checks in the periodic checklist Remove any blocks from the vehicle and or place the vehicle down on to the ground Test drive before putting into normal service SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi Annual 500hrs Monthly Quaterly 80hrs 250hrs Annualy 2 3 Maintenance Item 1000hrs Check Condition of Tires and Tire Pressure Check All Lights Horns Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks Lubricate Vehicle Clean and Tighten All Wire Connections Wash and Service Batteries Check Park Brake Check Motor Brushes and Blow Out Motor Check Front Wheel Bearin
145. ocations of the model and serial numbers are illustrated below Location of Serial Number Stamped in the Frame Data Plate Page 4 INTRODUCTION el TAKING DELIVERY OF YOUR VEHICLE What To Do Problem is Found If there is a problem or damage as a result of shipping 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 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 mad
146. ock built in charger As Smart View Display eee Smart View Display Fault Codes 8 Vehicle Operational Guidelines 9 Safety Guidelines 9 9 While driving 9 Loading and Unloading Towing Loads eene 9 Parking Wet eec 10 Towing This Vehicle sees 10 Charging your vehicle 11 Signet Charger Operation Model HB Series 11 Signet Charger Operation Model HBS series 11 Lestronic II Charger Operation 12 New Battery Break in ee 12 Charging Time ete tte eet 12 Storing Returning to Service 12 Storing Your Vehicle sss 12 Returning to Service 12 Periodic Maintenance Checklist 13 Standard Periodic Maintenance Schedule for the Smart View Display 14 Daily Visual inspection 1 0 22 15 Maintenance Guidelines for Severe Duty Applications 15 Safety Rules and Operating Instructions z SAFETY RULES OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM VOLTAGE SPECIFICATION Occupancy Driver only Dimensions 262 9 L X 106 7 W X 129 5 H Centimeters 103 5 L X 42 W X 51 H Inches Turning Radius 393 7 Centimeters 155 Inches Dry Weight 612 3 kg 1350 Ibs Without Batteries Min Max Battery 169 kg to 196 k
147. oltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 6596 of the chargers rated DC voltage the charger will not turn on If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting Battery volts Full voltage available at the batteries at the time of the test being performed This test procedure must be performed in the order it was written If starting in the middle or skipping sections when not instructed to do so the proper results will not occur If the test result is good then proceed to the next test or go to the next section if instructed to do so During All Tests The charger cabinet must remain electrically grounded Disconnect AW ARNING both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire Failure to do so may result in serious bodily injury Charger Troubleshooting Page 4 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT INCHARGER Make sure the key switch is in the OFF position then remove the key Placethe forward reverse switch in the center OFF position AWARNING 3 Setthe park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the charger from the AC source Locate the charger harness connectors where the charger harness is connected to the vehicle s control harness The
148. on AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the motor NOTE Label the motor wires with the number of the motor terminal before they are removed from the motor 7 equipped remove the motor support bracket u bolt only used on larger motors 8 Remove the motor mounting bolts and slide the motor off of the input shaft 9 Install the motor in reverse order NOTE Apply a light coating of grease to the splines on the transmission input shaft only Support bracket u bolt 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Transmission Maintenance Service and Repair REAR HUB OR ROTOR NOTE The torque specification for the axle hub bolt is 275 ft lbs An impact wrench will be required to remove the bolt NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cabl
149. on regarding replacing ball joints 11 Remove the blocks from behind the wheels 9 Untie the front fork 12 Release the parking brake and test drive the 10 Reconnect the main positive and negative cables vehicle at the batteries 11 Remove the blocks from behind the wheels 12 Release the parking brake and test drive the vehicle Steering Page 3 NOTE In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure Refer to Replace the Steering Gear for information regarding removing the steering gear AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehicle and support with jack stands 7 Disconnect the drag link from the pitman arm NOTE Refer to section Replace the Ball Joints for information regarding removing the ball joint from the arag link 8 Loosen the gear lash jam nut and the worm bearing adjuster jam nut 9 Unscrew the gear l
150. ows a charged battery If the vehicle runs in one direction only then skip ahead to test 3 If the vehicle runs slow in forward but otherwise runs normal then skip ahead to test 441 3 A WARNING After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in injury or property damage Sevcon Troubleshooting Page 4 Electrical Troubleshooting Test 1 CHECKING THE CONTROL LOGIC INPUTS Close the seat switch Place the high low switch in the HIGH position Connect a voltmeter across the ISO solenoid coil terminals and carefully monitor the voltage as the key switch is turned on Turn the key switch ON and wait 1 second until the Isolator contactor closes Perform the following tests TEST 1 1 The coil voltage should start at approximately 24 volts when the key is turned ON then drop to approximately 15 volts after about 0 5 seconds If the test is good then skip ahead to test 1 2 If the voltage starts high drops to 15 volts and then drops to O volts then it indicates an open circuit to the main battery positive Check the continuity of the ISO solenoid contacts the main circuit breaker and the wiring to the main battery positive post If the voltage is starts at 24 volts but the solenoid does not pick up then skip ahead toTest 5 If the voltage does
151. parameters F04011 Personality Range One or more controller personalities are out of range Correct parameters must be uploaded to the controller F04012 Personality CRC Controller personalities are corrupted Could be a result of a damaged logic card Attempt uploading new parameters If upload fails then controller must be replaced F04013 Capacitor high Sevcon Troubleshooting Page 20 Electrical Troubleshooting Level 2 Faults F02xxx F02000 Accelerator Wiring to throttle module is open or faulty throttle module F02001 Accelerator power up Throttle module FS 1 switch is closed pedal depressed or wiring shorted when start switch is turned on Throttle module output high when start switch is turned on F02002 Belly Switch Belly Switch currently not used and this fault should not occur Check wiring F02003 Open Field Not used F02004 Open Field L Not used F02005 Open Field R Not used Level 1 Faults F01xxx Most Level 1 faults are a result of operator 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 F01004 BDI Cutout Low voltage at Pin 1 of controller connector Normally a result of discharged batteries Check wiring start switch interlock switches batteries NOTE Fault will not reset unti
152. pecification Number E inches Armature Held 0 625 1 20 0 625 0 43 0 625 0 58 0 625 0 73 8 15 87 15 87 15 87 70 052 40 1876 DD3 4004 0 635 0 025 69 85 70 072 41 18204 0 635 0 025 69 85 0 0052 0 79 70 061 40 1765 0 889 0 035 69 85 15 87 0 625 0 011 0 71 Not available at time of printing 15 2 Motor Page 10 Transmission TABLE OF CONTENTS Check Oil Level rs 2 Change 3 Motor Removal and Installation 4 Rear Hub or Rotor 5 Removing and Installing the Rear Axles Disc Brakes ee 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3rd Member 12 Assembling the 3rd Member 15 Pinion Bearing Preload 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth 19 GT Transmission Assembly With Disc Brakes Maintenance Service and Repair CHECK OIL LEVEL The oil flows freely between the main gear case 3rd member and the primary reduction gear case It is only necessary to check the oil
153. play the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals 2 55 VPC When the battery voltage equals 2 55 VPC 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 Perform the following if the charger does not turn on Make sure the key switch is in the OFF position then remove the key AW ARNI NG 2 Place the forward reverse switch in the center OFF position 3 Set the park brake Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the charger from the AC source 6 Remove the charger end cap where the 21 wires enter B 7 Test the voltage across the Battery Positive red and Battery Negative black wires at the lower left of the charger circuit board This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires to the batteries have been damaged Stop here and repair the problem 8 Reinstall the charger end cap where the DC wires enter 9 Remove the charger end cap where the AC wires enter 10 Test the continuity of all three AC wires from the circuit board to the AC plug If you find an open circuit in any one of the three wires then the AC cord
154. quate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 8 Release the park brake 9 Remove the tire and wheel assembly Refer to section Tires and Wheels for information regarding removing the tire and wheel assembly a If the axle shaft hub or bearing is to be replaced then remove the hub bolt wheel hub and disc rotor at this time 10 Remove the four bolts attached to the axle retaining plate Axle Retaining Disc Rotor Plate Transmission Maintenance Service and Repair 11 Remove the axle retaining plate and brake body assembly as one unit 12 Secure the brake body assembly do not let it hang by the brake hose 13 Pull the axle out of the housing 14 Inspect all bearings for roughness or play replace as needed 15 Install in reverse order lubricate the o ring NOTE Be sure not to damage the o ring 16 Use new bolts for the axle retaining plate The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes AWARNING resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt 17 If the wheel hub was removed install the hub and rotor Torque the hub bolt to 275 ft
155. r the harness was disconnected then Inspect the harness for shorts Stop troubleshooting here and repair the problem When the repair 15 completed completely retest the vehicle before lowering the drive wheels to the ground A WARNING The electric brake is part of the vehicle braking system Do not operate a vehicle with the electric brake bypassed or disabled unless the system is being tested for faults Operating a vehicle with the brake bypassed or disabled may result in severe personal injury or property damage Test 9 1 Close the seat switch turn the key switch ON place the forward and reverse switch in the FORWARD position depress the accelerator pedal to engage FS 1 only creep speed Rotate the drive wheels to confirm the brake has released If the brake released then the brake system is working and no further testing of the brake is required If the brake did not release then perform the following tests Connect a volt meter from battery negative to the Violet Black wire at the electric brake harness plug If the voltage is less than battery volts then Check wiring to the key switch and continue troubleshooting at test 4 2 If the voltage equals battery volts then Connect a volt meter across the Violet Black wire and the Blue wire at the electric brake harness plug The voltage should start at approximately 24 volts then drop to approximately 15 volts after about 0 5 seconds If the test is
156. re will be two 10 gauge and two 14 gauge wires Slide the insulators off the connectors on the two 10 gauge wires and perform the following tests Make sure that these two wires do not come into electrical contact A CAUTION with any other object 6 Test the voltage from the red wire to the main battery negative This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then this wire is broken or has a bad connection Stop here and repair the problem 7 Test the voltage from the red 10 gauge wire to the other 10 gauge wire white or black depending on model This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the white or black wire is broken or has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires High Voltage Do not touch the 14 gauge wires and make sure these A W ARNING two wires do not come into electrical contact with any other object Failure to do so may result in serious bodily injury Re Connect the charger to the AC source 8 Test the voltage across the two 14 gauge wires This voltage should be the same as the voltage at the AC receptacle rated voltage of the charger If the voltage is less than the rated AC voltage of the charger then the 14 gauge white or black wire
157. reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Disconnect the linkage to the park brake handle by removing the clevis pin at the handle 8 While pulling on the cross shaft to take up all of the cable slack adjust the center linkage so that the cross shaft tab is vertical 9 Adjust the side linkage so that clevis pin can be easily inserted into the handle tab 10 Install new cotter pins and tighten all jam nuts 11 Set the park brake 12 Reconnect the main positive and negative cables Park Brake Brake Arm at the batteries Pin Extension 13 Remove blocks from behind the wheels 14 Release the park brake and test drive the vehicle NOTE If there is no adjustment left in the linkages then the Brake Arm Extension must be rotated to engage the next hole in the arm Center Linkage Side Linkage Brakes Page 6 Maintenance Service and Repair CHECK MASTER CYLINDER FLUID Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately AWARNING
158. rger is a semi automatic charging system The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Refer to the data plate on the charger for the voltage and type power required for the charger When plugged in the charger assumes that the batteries require charging and will charger for a minimum of approximately 4 hours This charger should not be plugged in until the batteries are discharged beyond 5096 or the batteries may be overcharged New Battery Break in New batteries require a break in period of up to 40 cycles The batteries will not have their full capacity during this break in period and may require longer charging times To obtain the maximum battery life Charge the batteries only after they reach a normal discharge as indicated on the Battery Status Indicator BSI Failure to follow this guideline could result in the batteries entering an overcharge state which will reduce the life of the batteries If you find it necessary to charge the batteries before they are completely discharged we recommend waiting until they are discharged a minimum of 2596 to reduce the possibility of overcharging Refer to Vehicle Controls in this section for information on how to read the BSI Do not discharge the batteries beyond a normal discharge as indicated on the BSI Refer to Vehicle Controls in this section for information on how to read the
159. rmed in the vehicle before lowering the drive wheels to the order that they are written Starting in the the ground Failure to retest the vehicle could middle or skipping sections when not instructed result in unexpected movement of the vehicle to do so may lead to invalid test results resulting in injury or property damage Sevcon Troubleshooting Page 13 Electrical Troubleshooting TEST 7 3 If the vehicle does not travel in forward skip ahead to test 7 4 Place the forward and reverse switch in the REVERSE position Referencing battery positive test the voltage at the White Black wire on the F amp R switch If the voltage equals battery volts skip ahead to test 117 4 If the voltage does not equal battery volts then the F amp R switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 7 4 NOTE The wires are disconnected for reference only The test must be done with the wires connected to the switch Check the wires from the F amp R switch to the logic card connector for continuity STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit A WARNING After any repairs are made completely retest
160. roblem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground A WARNING ACAUTION After any repairs are made completely retest This troubleshooting guide is written in the vehicle before lowering the drive wheels to sequential order All tests must be performed in the ground Failure to retest the vehicle could the order that they are written Starting in the result in unexpected movement of the vehicle middle or skipping sections when not instructed resulting in injury or property damage to do so may lead to invalid test results Sevcon Troubleshooting Page 17 Electrical Troubleshooting Logic Voltage Reference Table Key switch off Key switch on F amp R in forward F amp R in neutral 5 5 F amp R reverse F amp R in reverse F amp R in neutral F amp R in forward Accelerator pedal up Accelerator pedal down Seat switch closed depressed Seat switch open High low switch in high High low Switch in low Hand brake switch closed Hand brake switch open Key switch on ref battery positive Key switch off ref battery positive System off ref battery positive System on ref battery positive Accelerator pedal up Accelerator pedal down 12 Not used All voltages made referencing main negative unless specified otherwise The voltage should start at approximately 24 volts then drop to approximately 15 volts after a
161. rque values Imperial inch Foot Pounds Imperial inch Newton Meters Grade SAE Grade SAE Dia Pith 2 5 8 L Pith 2 5 8 L9 4 40 5 i i 4 40 s 6 32 6 32 8 32 8 32 10 32 i 10 32 j 12 32 112 32 2 1 4 20 5 5 8 5 12 5 11 1 4 20 7 4 11 5 16 9 14 9 28 65 10 5 28 88 142 5 16 18 12 0 17 5 24 5 22 5 16 18 16 2 23 7 33 2 29 8 24 12 5 19 0 24 16 9 25 8 3 8 16 20 30 43 40 3 8 16 274 4 58 54 24 225 33 50 45 24 30 5 45 68 61 716 14 27 50 70 65 7 16 14 37 68 95 88 20 36 55 77 70 20 49 75 104 95 1 2 13 49 75 106 95 1 2 13 66 102 144 129 20 55 85 120 110 20 75 115 163 149 916 12 70 109 153 140 9 16 12 95 148 614 190 18 78 121 171 160 18 106 164 232 217 5 8 11 97 150 212 195 5 8 11 132 203 287 264 18 110 170 240 225 18 149 230 325 305 3 4 10 172 275 376 350 34 10 233 373 510 475 16 192 297 420 390 16 260 403 569 529 7 8 9 278 429 593 565 7 8 9 377 582 804 766 14 306 473 818 625 14 415 641 1109 847 1 8 416 644 909 850 1 8 564 873 1232 1152 14 466 721 1018 930 14 632 978 1380 1261 1 1 8 7 590 794 1287 1700 1 1 8 7 800 1076 1744 2304 12 662 891 1444 1850 12 897 1208 2364 2508 1 14 7 832 1120 1817 2950 1 1 4 7 1128 1518 2463 4000 12 922 1241 2012 3330 12 1250 1682 2727 4514 Conversion Formulas Foot Pounds Newton Meters x 0 737562149 Newton meters Foot Pounds x 1 355817948 Appendixes available at time of printin
162. rrent is down to A1 ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries Signet Charger Troubleshooting Page 4 Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing it indicates a problem has occured during the charging cycle If the light is flashing it will flash from 2 to 6 times before a pause This is the fault code Refer to the table below Status Light Panel Fault Description Action Required 1 Time out Charge cycle time exceeded the time limit Test batteries for possible no flash defictive cells Open circuit or reverse polarity to ad battery Check battery wiring Wrong voltage charger or batteries installed 2 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 Inspect for dirt or debris on the charger cooling fins and clean as required 5 AC line voltate too high or too Check the input voltage low It must be within 85 137VAC or 170 264VAC Battery voltage too high Extremely discharged battery defective battery miswired battery When this fault occurs the charger will operate in a low current mode untill the battery voltage is built up This fault will reset once the battery Low battery voltage voltage is
163. s Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Signet Charger Operation Model HB Series The Signet HB series chargers use semi automatic charging system The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Refer to the data plate on the charger for the voltage and type power required for the charger There is a series of LED s on the faceplate of the charger that serve two functions Typical Signet Built In 1 Status of charge The LED s will display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition All three LED s flashing is an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes LED1 LED2 LED3 AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury ACAUT
164. s are installed into the second groove O and that they are not twisted ring groove 13 Using tool 41 350 13 slide the rubber boots onto the pistons as shown The boot should be hanging off of the end of the piston 14 Insert 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 properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 17 If the brake body assembly is not to be immediately installed onto a vehicle plug the brake hose fitting hole to prevent any contaminates from entering the brake body Brakes Page 16 Maintenance Service and Repair REPLACE THE MASTER CYLINDER Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately AWARNING 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 AWA
165. s to the ground STOP TEST 2 2 Check the continuity from the motor A1 to the A2 terminals If the resistance is close to values given in the motor specification table then go to test 312 3 If the test indicates high resistance or an open circuit then repair or replace the motor 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 STOP Sevcon Troubleshooting Page 7 Electrical Troubleshooting TEST 2 3 Test the continuity from the motor Al terminal to the frame on the motor and from F1 to A1 for open circuits Any reading other than an open circuit indicate a short in the motor If there is a short in the motor stop here and repair or replace the motor STOP TEST 2 4 Reaching this point indicates an open circuit in the motor wiring Check the continuity of all wires from the controller to the motor Repair any open wires then test drive the vehicle 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 AWARNING ACAUTION After any repairs are made completely retest This troubleshooting guide is written in the vehicle before lowering the drive wheels to Sequential order All tests must be performed in the ground Failure to retest the vehicle could the order that they are wri
166. sues 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 This section identifies the troubleshooting procedures for testing the electrical system and battery charger Illustrated Parts This section provides an illustrated view of various assemblies The illustrations are accompanied by tables identifying the parts Model R 3 80 shown equiped with a cargo box and steel cab with doors options INTRODUCTION Conventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below AWARNING Ashaded box with the word Warning and the symbol 4 above denotes a warning 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 A WARNING Ashaded box with and the word Warning and the symbol above denotes a warning This warning alerts the reader of a high voltage hazard that may result in injury to themselves or others Be sure to follow an
167. switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 6 Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 8 Tie off the front fork so that it cannot turn Remove and reinstall the steering wheel orientated as shown in the illustration with one spoke pointing straight up Tighten the steering wheel nut to 50 60 ft Ibs 10 Untie the front fork 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Maintenance Service and Repair INSPECT THE STEERING COMPONENTS Ball Joints NOTE A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end is worn out then all should be replaced as a set AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Fork Bearings A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positi
168. t Disconnect the main positive and negative cables at the batteries DRIVER TRAINING PROGRAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for those claiming to have previous vehicle operation experience Successful completion of the Operator Training program shall be required for all personnel who operate this vehicle The Operator Training program shall include the following Operation of this vehicle under circumstances normally associated with your particular environment e Emphasis on the safety of cargo and personnel All safety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive this vehicle Operators must possess the visual auditory physical and mental ability to safely operate this vehicle as specified in the American National Standards Institute Controlled Personnel and Burden Carriers ANSI B56 8 The following are minimum requirements necessary to qualify as an operator of this vehicle Demonstrate a working knowledge of each control Understand all safety rules and guidelines as presented in this manual Know how to properly load and unload cargo Know how
169. t or right side of the vehicle depending on which side bushings are to be replaced and support with jack stands 8 Ifthe spring eye did not fall out of the frame tabs pry the spring out of the frame with a pry bar 9 Remove the spring bushings 10 Install the new bushings in reverse order HINT Apply a light coating of grease to the bushing before pressing into the spring eye 11 Install the spring eye bolt and u bolt 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the parking brake and test drive the vehicle Suspension Page 3 Front It is recommended to replace both front shocks as a set NOTE On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts Refer to Tires and Wheels section for information regarding removing the front wheels AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries A WARNING 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 r
170. t the B terminal is at full battery voltage then the contact tips are welded NOTE Welded tips should be accompanied by a 4 flash code from the logic LED Shorted Solenoid Coil Disconnect the logic card connector and measure the resistance across the solenoid coil Depending on the solenoid or contactor you vehicle is equipped with the resistance should be 25 ohms or higher nominal A reading less than 25 ohms may indicate a shorted coil The control logic may have failed STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit Sevcon Troubleshooting Page 11 Electrical Troubleshooting Test 6 ACCELERATOR MODULE FAULT 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect both of the battery leads during any maintenance or AWARNING before disconnecting any electrical component or wire Failure to do 50 may cause property damage and or serious bodily injury With the power switch OFF connect the throttle module to the analyzer Position the power switch to the 0 5 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp O
171. tands the various controls and operating characteristics of this vehicle extracted from the American National Standards Institute Personnel and Burden Carriers ANSI B56 8 As well as following the safety rules and guidelines outlined in ANSI B56 8 and listed below 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 AWARNING These vehicles are not designed to be driven on public roads or highways They are available in maximum designed speed of 10 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 Refer to Vehicle Operational Guidelines Safety Guidelines section for important safety information regarding operating this vehicle A WARNING Read and follow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property damage Before working AWARNING vehicle Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movemen
172. terlock switch is closed Possible defective seat switch 04007 Defective wiring 04009 Discharged battery or defective wiring Charge the battery 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 Personality fault Reprogram or replace the controller note 3 04013 Defective wiring or batteries Refer to troubleshooting 05000 Line contactor coil or wiring shorted Replace contactor or repair wiring 05006 MOSFET shorted Refer to troubleshooting 05008 Line contactor welded contacts or wiring Replace contactor or repair wiring shorted 05009 MOSFET shorted Refer to troubleshooting 05046 Line contactor contacts open or defective Replace contactor or repair wiring wiring Could also be result of open circuit breaker refer to troubleshooting Note 1 The start up switches include the following and must be operated in the order listed F amp R OFF Seat Interlock ON Key ON F amp R Direction forward or reverse Accelerator FS 1 ON Note 2 A Low Battery Fault occurs when the system voltage drops below a preset value The fault will not reset until the batteries are fully charged or the problem that caused the fault is repaired Note 3 A personality fault occurs when the parameters set in the controller logic is corrupted This can occur if the Safety Rules Page 8
173. termarket AWARNING containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE It is recommended that both the left and right brake pad s be replaced as a set 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is1 2 full 8 Raise the rear of the vehicle and support with jack stands Master cylinder is located under the floorboard by the throttle pedal Always use lifting strap hoist and jack stands of adequate capacity AWARNING support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Brakes Maintenance Service and Repair 9 Remove the tire wheel assembly NOTE Refer to Tires and Wheels section for information on removing the tire and wheel assembly 10 Release the park brake wheel brake only 11 Remove the bra
174. the cut the armature just enough to remove all grooves depressions or ridges Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in Service Limits then the motor must be replaced Thoroughly clean all copper debris from between the commutator segments Measure the commutator 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 fine emery cloth Properly undercut and cleaned commutator segments Motor Page 8 Motor Service Undercutting the commutator 1 Using a small straight cut saw blade cut the commutator insulation to the proper depth Refer to undercut depth in Service Limits Hacksaw blade Incorrect Correct dusulation 2 Once all segments have been properly undercut mount the armature a lathe and smooth the commutator with fine emery cloth Commutator 3 Inspect the armature for shorts Refer to Motor Inspection section for information on testing the armature NOTE Copper debris in the undercut area can give a reading of a shorted armature Example of freshly cut commutator Motor Page 9 Motor Service SERVICE LIMITS Commutator Diameter Brush Length Resistance min i Ohms 75 F sri am CMM M 75 Undercut Depth Motor S
175. the battery This could cause the battery to explode resulting in severe bodily injury and or property damage NOTE If the batteries are over one year old it is recommended to replace them as a set AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Remove the battery hold downs Inspect the battery hold downs for corrosion If any signs of corrosion are seen then the battery hold downs should be replaced A WARNING Do not leave cables on batteries that have been removed from the vehicle Cables left on batteries could cause a short circuit resulting in battery explosion severe bodily injury and or property damage 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batteries 10 Remove the batteries from the vehicle 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entir
176. ting the bearing preload If the ring ACAUTION nuts are not turned the same amount then the bearing preload will no longer be correct and will result in drive noise and premature failure Transmission Page 16 Maintenance Service and Repair 17 Install the locking roll pins into the housing and cover to lock the ring nuts in place 18 Remove the pinion gear holding tool 19 Install the primary reduction gear case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil section for information regarding the proper oil level 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Transmission 27 Page 17 Maintenance Service and Repair Pinion Bearing Preload NOTE The pinion gear depth must be set before the preload Refer to Setting the Pinion Gear Depth Install the pinion gear spacer and shims into the housing Install the outer pinion bearing Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft Ibs Measure the torque required to rotate the pinion shaft in the housing a amp OND gt The torque required to rotate the pinion shaft should be between 1 1 and 2 9 ft lbs If the torque is not within specific
177. tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire AWARNING Explosion Hazard Fully deflate the tire before attempting to remove the tire from the wheel Do not over inflate the tire when seating the bead Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death 1 Remove the tire from the wheel 2 Cut old valve stem off of the wheel 3 Remove the valve stem cap from the new valve stem 4 Lubricate the valve stem with liquid soap 5 Install a new valve stem using a valve stem tool NOTE The valve stem tool is available at most auto repair shops 6 Install the tire onto the wheel following the instructions provided with your tire replacement equipment 7 Inflate the tire to the proper pressure and check for leaks 8 Install the valve stem cap Tires and Wheels Page 3 Maintenance Service and Repair 4 Bolt Pattern 5 Bolt Pattern 8 Bolt Pattern Pattern for tightening the wheel nuts Re torque all wheel nuts to their final value after 1 week 20 hours AW ARNING of operation Failure to re torque the wheel nuts may result in the wheel coming off of the vehicle causing severe bodily injury and or property damage REPAIR T
178. to prevent vehicle movement Disconnect both of the battery leads during any maintenance or AWARNING before disconnecting any electrical component or wire Failure to do 5 may cause property damage and or serious bodily injury NOTE Special and expensive motor testing equipment is required in order to accurately measure motor armature or field resistance In most cases this equipment is not required in order to determine if a motor is faulty The majority of motor failures are due to an open circuit in the field or armature windings If the symptom of the vehicle is not running with NO motor current then a simple continuity test of each winding is all that is required to determine if the motor is at fault TEST 2 1 Check the motor field continuity from the motor F1 to the motor F2 terminals If the resistance is close to values given in the motor specification table then skip ahead to test 42 2 The motor specification 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 an open circuit indicates a short in the motor Stop trouble shooting here and repair the Motor shown in illustrations is typical of a standard motor problem When the repair is completed The terminal configuration of your motor may be different completely retest the vehicle before lowering the drive wheel
179. to properly park this vehicle Recognize an improperly maintained vehicle Demonstrate ability to handle this vehicle in all conditions Safety Rules Page 3 SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1 Key switch A key switch located on the right center side of the instrument panel turns on the vehicle Rotate the key clockwise to turn the vehicle power on counterclockwise to turn the vehicle power off The key switch should be in the OFF position whenever the operator leaves the vehicle This switch is also designed to secure and disable the vehicle The key can only be removed when the key switch is in the OFF position 2 Smart View Display Refer to the end of this section for information on the operation of the Smart View Display 3 Forward Off Reverse Switch The forward off reverse switch located to the left of the key switch determines the direction of travel of the vehicle Push the top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT SWITCH from forward to reverse or vice versa while the vehicle is in motion Make 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 and the park brake set whenever the operator leaves the vehicle 4 Horn switch The horn switch is located on the upper right side of the instr
180. to the diode 6 Reconnect the charger to the vehicle s harness and slide the wiring insulators back into place Connect the charger to the AC source and perform the following tests Diode 2 High Voltage inside the charger Do not touch any internal components AW ARNING while the charger is plugged in Failure to do so may result in serious bodily injury Charger Troubleshooting Page 6 Electrical Troubleshooting Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires from the harness connectors to the charger are bad Stop here and repair the problem Test the voltage across the white and black wires that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the wires from the harness connectors to the charger are bad Stop here and repair the problem If the timer relay does not pickup click when the AC source is connected then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board This voltage should be the same
181. tten Starting in the result in unexpected movement of the vehicle middle or skipping sections when not instructed resulting in injury or property damage to do so may lead to invalid test results NENNEN Sevcon Troubleshooting Page 8 Electrical Troubleshooting Test 3 THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3 1 Close the seat switch turn the key switch ON and wait 1 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 FORWARD direction Test the voltage at pin 2 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 2 If the voltage is high then skip ahead to Test 7 TEST 3 2 Test the voltage at pin 3 on the 12 pin logic card connector If the voltage is high then skip ahead to test 3 3 If the voltage is low then skip ahead to Test 7 TEST 3 3 Place the forward and reverse switch in the REVERSE direction Test the voltage at pin 3 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 4 If the voltage is high then skip ahead to Test 7 TEST 3 4 Test the voltage at pin 2 on the 12 pin logic card connector If the voltage is high then it is likely that the internal directional control transistors have failed test the transistors at Test 3 5 and 3 6 If the voltage is low then skip ahead to Test 7
182. uid container 8 The master cylinder fluid level will drop as the brakes are bled Periodically check and fill the master cylinder during this procedure Do not allow the fluid level in the master cylinder to drop too low as this will allow air into the brake lines 9 Attach a clear hose to the bleeder valve 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 11 Open the bleeder valve on the hydraulic brake body 12 Depress the foot pedal to the floor and then close the bleeder valve Do not release pressure on the brake pedal until the bleeder valve is closed 13 Slowly release the foot pedal allowing it to return to its released position Bleeder valve with hose attached NOTE Check and fill the master cylinder frequently during the bleeding process Do not allow the fluid level in the master cylinder to drop low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning Always use brake fluid from a new sealed container Never reuse any brake fluid that has been removed from the brake system Use of AWARNING contaminated brake fluid will degrade the braking performance and may cause property damage or severe bodily injury 14 Repeat the above steps until you are sure that
183. uld check the charging system before replacing the batteries Refer to Charger Troubleshooting section for information on checking the charging system Specific Gravity Test NOTE The batteries must be fully charged before performing this test The specific gravity of a cell is an indication of the actual state of charge of the cell A fully charged cell should have a reading of 1275 to 1300 see the illustration to the right A discharged battery will read 1100 Ideally all cells in a battery pack will have the same reading Any cells in a battery pack that vary by more than 30 points may be an indication of a bad cell Batteries Page 3 Maintenance Service and Repair Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries Using part number 77 200 00 hydrometer check and record the specific gravity of each cell in the battery pack If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system If the charging system checks OK then the batteries are no longer accepting 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 reading will be used to gauge all other cells Compare the specific gravity readings to the highest reading if the difference between any of th
184. ument panel Depress the switch to sound the horn release it to turn it off Safety Rules Page 4 SAFETY RULES AND OPERATING INSTRUCTIONS 1 Headlight switch 2 Front Side Lights 3 Rear Side Lights All lights switches operate the same Toggle the switch to the UP position to turn the light on toggle it to the DOWN position to turn the light off Switches in the left column control the lights on the left side of the vehicle Switches in the right column control the lights on the right side of the vehicle Park Brake The parking brake is actuated with a hand lever which is located to the left of the driver seat To set the parking brake push down on the brake pedal and pull the lever up until it locks To release the park brake depress the foot brake pedal pull up on the park brake handle push the release button and lower the handle 1 Foot Brake Pedal The foot brake pedal is located to the right of the steering column it is for operation with the right foot 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 braking action 2 Accelerator Pedal The accelerator pedal is located to the right of the brake pedal It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile Depress the pedal to increase speed and release th
185. ve and negative cables at the batteries Place blocks under the front wheels to prevent vehicle movement A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting Disconnect the main positive and negative cables at the batteries A WARNING Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front wheels tied in position may and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehicle and support with jack stands cause loss of control of the vehicle resulting in severe bodily injury and or property damage 7 Inspect for lateral play by attempting to move the fork to the left and right not rotating There should be no noticeable play 8 If there is any play in the fork bearings refer to section Replace the Front Fork for information regarding adjusting the fork bearings 6 Tie off the front fork so that it cannot turn 7 While watching the ball joints rapidly rotate the steering wheel to the left and right bes 9 Lower the front end to the ground 8 If the ball joint housing moves up or down then the ball joint is worn out and should be replaced 10 Reconnect the main positive and negative cables Refer to section Replacing a Ball Joint for at the batteries informati
186. ver Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp should be ON with no more that a few degrees of rotation If the FS 1 lamp does not come on then the module is faulty see note below The voltage on the digital display should vary with the position of the module arm starting at O volts and ending at approximately 5 volts If the OV lamp comes ON at any time then the module is faulty If the Low battery lamp is ON then the analyzer battery should be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer DO 110 53 NOTE Failures of the FS 1 circuit indicate a possible vehicle wiring fault that has resulted in a short circuit across FS 1 BEFORE REPLACING THE MODULE Confirm that there are no shorts in the vehicle wiring or components Installing a replacement module in a vehicle with faulty wiring will burn out the new module EEEEEEEEEIIISIGIIIICIGOIU ICLELESLI IL US ISVAS EQIULLIRILLLLIOLLO G bE SCOSOEOUDPEK O LGL LOSE GIILOISCLCOCULUOILLIISBLEOCLOIXANA UULLUALSL DOGCGD BCCOILLLEDILCGLLL LLULLLILEIRICeAGRSUSCDALLOLLZO SUOLLLL L LLE EIRwdLEDCOA L ILUILIPOLLIBOULLLLLIU LALA eoQPA Sevcon Troubleshooting Page 12 Electrical Troubleshooting Test 7 FORWARD AND REVERSE SWITCH FAULT Turn the key switch ON place the forward and reverse switch in the center OFF position and perform the following tests T
187. y instructions contained within a warning and exercise extreme care while performing the task ACAUTION A box with the word CAUTION and the symbol 4 above 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 with the Dump Bed option Page 3 INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks and resorts They are not to be driven on public highways A WARNING This vehicle is not designed to be driven on public roads or highways It is available in maximum designed speed of 10 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 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 National Standard for Personnel and Burden Carriers ANSI B56 8 The l
188. yte to the batteries 8 Reconnect the batteries remove the blocks from the wheels and test drive Plate inside battery Battery cutaway Batteries Page 5 Maintenance Service and Repair REPLACING 6 VOLT BATTERIES ONLY AWARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage AWARNING A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of
189. zed Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage AWARNING Do not overfill the batteries Over filling the batteries may cause the battery electrolyte to boil out of the battery and result in severe bodily injury or property damage AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries NOTE The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the batteries at the end of a charging cycle If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete 6 Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries 7 Check the electrolyte level in all battery cells If low fill to the correct level with distilled water using part number 77 201 00 battery filler never add additional battery electrol

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