Home

The Best Way To Go About Your Business MANUAL MC-432-05

1. Clean and Tighten All Wire Connections Wash and Wash and Service Batteries Batteries ILE Park Brake Cosh Pk re Motor Brushes and Blow Out Motor Check Front Wheel Bearings Front Wheel Check Front Wheel Bearings Change Rear Axle Ol Rear Axle Change Rear Axle Ol 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 10 SAFETY RULES AND OPERATING INSTRUCTIONS e Daily Visual inspection Tire condition and pressure External frame damage body Operation of all lights and warning alarms and or horns Smooth 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 flui
2. Commutator commutator segment If an open Hold this lead segment is found the armature is bad inplace and the motor must be replaced Stop i Check each segment trouble shooting here and repair the all ofthe way around lt problem When the repair is completed the commutator completely retest the vehicle before lowering the drive wheels to the ground Aj STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing Itis important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting TABLE OF CONTENTS 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
3. H iX Speed Control Panel Item No Part No Description Qty 1 72 501 42 Forward or Reverse Solenoid 24V 200A C4 33 2 1a 72 501 39 Forward or Reverse Solenoid 36V 200A C4 32 2 2 88 838 06 Sheet Metal Screw 14 x 1 2 4 3 62 205 00 Speed Controller 400A 1 4 72 501 43 ISO Solenoid 24V 200A C4 33 1 4a 72 501 38 ISO Solenoid 36V 200A C4 32 1 5 88 818 06 Sheet Metal Screw 8 x 1 2 2 6 79 840 00 Circuit Breaker 10 amp 1 7 79 844 00 Circuit Breaker 135 amp 1 8 73 004 10 Horn 12 V 1 9 88 089 80 Nut 5 16NC 4 10 88 088 63 Lockwasher 5 16 4 11 88 080 11 Bolt 5 16NC x 1 Hex Hd 4 12 61 838 41 Bus Bar 5 8 x 1 1 2 Hole Centers 2 13 61 838 42 Bus Bar 3 8 x 2 5 8 Hole Centers 2 14 88 099 91 Nut 5 16NF Thin Pattern 10 15 88 088 63 Lockwasher 5 16 Internal Tooth 10 16 88 049 80 Nut 10 32 5 17 88 048 62 Lockwasher 10 5 18 88 045 11 Screw 10 32 x 1 Truss 2 19 78 302 50 Resistor 250 ohm 5 watt 1 20 62 021 00 Solenoid Panel Assembly 24V C4 33 1 20a 62 023 00 Solenoid Panel Assembly 36V C4 32 1 21 01 432 26 Panel Solenoid Mounting painted black 1 22 75 235 26 Jumper 4 Ga 6 Long 2 23 88 065 09 Bolt 1 4NC x 3 4 Truss Hd 4 24 88 060 09 Bolt 1 4NC x 3 4 Hex Hd 2 25 88 069 81 Locknut 1 4NC 6 Not 75 149 28 Harness Power Control Assembly Shown 75 148 23 Harness Control Vehicle 1 Pa
4. Special Troubleshooting If you do not know how to test for continuity refer test to a qualified technician If you do not know how to test for continuity refer test to a qualified technician ELECTRICAL TROUBLESHOOTING amp 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 otherwise continue with the next test Check continuity from the motor A2 terminal to the wire that was connected to the motor S2 terminal DO NOT make this test to the S2 terminal just the wire This should read as an open circuit If it reads as a short then one of the following has occurred A The forward solenoid is shorted CE aly B The wire connected to the motor S2 terminal positions on your motor terminal is shorted to the wire connected may not be in the same location to the motor A2 terminal C The wire connected to the motor S2 terminal is shorted to the wire connected to the PMC A2 terminal 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 otherwise continue with the next test With the key switch on and the F amp R switch in forward depress the accelerator pedal and perform the following tests Check continuity from the wire that was connected
5. uam 2106 Sc 8t Sc 8t Sc 8t 0 9 lt Sc 8t 0r 9 Sc 9 Sc 9 ST 9E Od u 0s 0 c ST 09 SIT SI 09 SYI LVWO09 SIT SL 09 STI 91 09 0671 u 0s 0 c CI 09 SIT ZI 09 STT 188500187 198 6078 198 08 Las oroT9 IH amp SCOISP 188090796 198 9 198 9 1 8 500796 od L 1931040 OT 60 6L ST E0 6L OT 60 6L 1906 64 00 60 6 02 0 6 989 0 6 0 506 6 ST 0 6L Oda DU 02691 0292 07697 TESL 6 5696 OTZ 09811 20111 OPLET Meg 198107 PPOW 190 S HO VHO o qeu110q Lester Charger P2 2 4 4 42 2 5 Illustrated Parts 3 00 00c 9L 00 00c 9L 00 00c 9L 00 00 94 x 5 5 3 09 608 6L E 7 90 6L 5 Assy 01 95 64 O S O S 01 995 64 5 01 995 64 01 95 64 P109 Od 01 00 0 S 6L 00 0 S 6L gt 00 0 S 6L 00 05 64 00 05 64 O S PPA wrens 6 00 85 64 00 CES 6L 00 TEs 6L 00 TES 6L 00 TES 6L 00 c s 6L 00 0 S 6L 00 CES 6L O S PA wrens 8 00 1 8 6L 00 TE8 6L OT TE8 6L OT TE8 6L OT TE8 6L 00 TE8 6L 00 TE8 6L 00 TE8 6L 01 1 8 6L A quiassy osny L O S O S OT SLS 6L O S 5 O S O S p100 OV 9 O S O S O S O S O S O S 80 9 6 O S O S T9ULIOJSUUI S OT 6bL 6L 6 2 64 6 2 64 6 2 64 6 2 6 6 76
6. FRONT AXLE Item No Part No Description Qty 1 88 229 81 Locknut 3 4NC 2 2 88 228 60 Washer 3 4 Cut 2 3 15 010 00 Front Axle 1 4 16 010 00 Spacer 4 5 14 082 10 Front Fork Assembly 1 Illustrated Parts Front Fork Fork Collar Ref part of frame Parts Page 4 Illustrated Parts lm S 2 FRONT FORK Item No Part No Description Qty 1 88 229 81 Locknut 3 4NC 1 2 88 228 60 Washer 3 4 Cut 1 3 45 307 00 Oil Seal 1 1 2 ID 1 4 80 011 00 Bearing Tapered Roller 1 1 4 ID 2 5 80 102 00 Bearing Race 2 6 14 082 10 Front Fork Assembly 1 7 92 105 00 Dust Cap 1 Illustrated Parts Steering Linkage Steering Column Tube Ref part of frame N V Steering Tube Ref part of frame Illustrated Parts M 2 22 SSS STEERING Item No Part No Description Qty 1 95 915 20 Steering Wheel Cap 1 2 88 199 82 Nut 5 8NF Jam 1 3 19 007 20 Steering Wheel 1 4 80 400 10 Ball Bearing Sealed 3 4 4 5 20 010 00 Shaft Steering Column 1 6 97 100 00 Woodruff Key 3 16 4 7 16 405 00 Spacer 3 4 ID x 1 8 Thick 4 8 30 002 00 Sprocket 11 Tooth 40 Chain 3 4 Bore 2 9 88 229 81 Locknut 3 4NC 3 10 30 400 00 Master Link 40 Chain 4 11
7. The 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 charging 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 gl Page 3 Z Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM with diode and capacitor test function FLUKE 799 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 th
8. 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 front axle from the fork and support the vehicle with jack stands 1 Installation Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub Assemble the bearing spacers into the front wheel hub and place the front wheel into the fork 3 Insert the axle into the front fork Install the axle nut s Refer to Adjust Front Wheel Bearings section for information regarding tightening the front axle NOTE If your vehicle is equipped with two axle nuts the nuts should be tightened equally so that the same number of axle threads are visible on both ends Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Fork single Seal Race Typical fork illustrated Your fork may be different Front Axle Page 3 HO lAV L TABLE OF CONTENTS Front End Alignment 2 Replace the Front Fork 3 Adjust Steering Chains 4 Steering Component Service A Maintenance Service and Repair FRONT END ALIGNMENT AWARNING Make sure the key switch is in the OFF pos
9. 9 01 04 9 01 04 1 055012 Surgsn gi1om nsug Joye nsuy 00 6L1 L6 05 01 04 Joye nsuy 00 8L1 L6 Ts 01c 0L Joye nsuy 00 79 86 surysng 00 cc9 86 90 6 0 0 surysng Ts 01c 0L Ts 01c 0L Joyensuy 01 lt 0 0 61 10 04 61 10 04 Surpurm 00 001 26 00 001 L6 Kex JJNIPOO AA V N V N V N V N V N V N V N 00 00 08 00 70 08 00 60 08 00 60 08 00 05 08 Surreoq 1894 Surreoq 30014 VIN VIN VIN VIN VIN VIN VIN 00 S0S St 00 90S St Teas 00 7L0 0L 00 CLO OL 00 190 0 OC LSO OL OI LS0 0L 00 lt lt 0 0 50 750 04 00 750 0 S0 670 0L 00 60 02 9007 7611 68187761186 derocdforo gs Tt eLv6 V6vcatovode VC9CHOCEILES 2946 1010 q V90LIdX 26664167246 86019541852 5 2011959185096 NOLLdT3OSHG PPL PUNOM SIHIS SIJON Illustrated Parts Brake linkage Illustrated Parts MH nn PARK amp FOOT BRAKE LINKAGE Item No Part No Description Qty 1 51 340 00 Park Brake Lever 1 1a n a Spacer included with lever 2 2 88 109 81 Locknut 3 8NC 6 3 88 108 60 Washer 3 8 SAE 12 4 88 101 16 Bolt 3 8NC x 2 Hex Hd 2 5 98 200 00 Brake Pedal Pad Rubber 1 6 01 4
10. Attach a clamp on DC Ammeter to one of the charger DC output wires Plug the charger into an AC outlet After 5 or 6 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 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 A W ARNI NG 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 charger from the AC source 6 Remove the charger end cap where the DC wires enter 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
11. Round Hd 2 88 019 80 Nut 6 32 2 88 045 06 Screw 10 32 x 1 2 Truss Hd Machine 2 88 048 62 Lockwasher 10 4 88 101 18 Bolt 3 8NC x 2 1 2 Hex Hd Grade 5 2 88 108 60 Washer 3 8 Cut 1 Parts e Page 43 HO lAV L Contents Appendix A Special Tools 2 Appendix B Suggested Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex ROHS oeque ases ora SPERO RI 3 Other Bolts merenti 3 Nuts 4 Hex Lock Nuts stover sese 4 Other Nuts creto 4 Suggested Torque Values non critical hardware 5 Appendix C Brake Lining Handling Precautions 7 Appendixes Appendixes APPENDIX A SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used for testing electrical circuits Powered by the truck batteries switchable for 12 24 36 and 48 volts Used to test the solid state accellerator module part number Accelerator Test Harness series 62 033 XX 62 027 31 Sevcon Handset Analyzer Used to test the Sevcon 8 control systems and reset the 62 027 61 read only Smart View display includes instructions gt 7 Sevcon Handset Analyzer Same as 62 027 61 above plus allows a limited range of 62 027 62 with Speed Adjust Capability adjustment
12. Set the park brake Place blocks under the front wheels to prevent vehicle movement 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 severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury This is the accelerator module test harness part number 62 027 31 It will be used in the following tests These tests cannot be completed without this harness If you do not have this harness one must be obtained before testing can continue PLUG THIS END INTO THE HARNESS il NS TZ USE THIS END FOR TESTING PLUG THIS END INTO THE MODULE Main Sequence Connect the accelerator module test harness to the accelerator module The voltage shown is for illustration only The actual voltage may vary Connect a voltmeter between pin 9 in the test harness and battery positive If the voltage is not at battery volts then the wiring between pin 9 in the harness and battery negative is open Stop trouble shooting here and
13. 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 any 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 Model B 2 48 equipped with the Dump Bed option Page 3 e 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 speeds ranging from 4 5 to 9 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow at more than 5 mph This vehicle conforms to requirements for Type E vehicles as described
14. 10 If required remove the rear tapered bearing from the pinion shaft and discard NOTE Do not remove the bearing unless it requires replacement Removing the rear bearing will damage the bearing Replacing this bearing will require re shimming of the pinion shatt 11 If required remove the bearing races from the pinion housing 12 Mark the differential bearing caps and 3rd member housing so that they can be reassembled in their original location Refer to illustration at end of section NOTE The caps cannot be interchanged or replaced Ifthe caps are lost or damaged then the entire 3rd member assembly must be replaced 13 Remove the differential bearing caps bearing adjusting nuts and races 14 Remove the differential assembly from the 3rd member 15 Mark the ring gear and differential housing so that the ring gear can be reinstalled in the same orientation 16 Remove the bearings from the differential housing and discard NOTE Hemoving the bearings will damage the bearings Do not remove the bearings unless they require replacement 17 Remove the ring gear from the differential housing 18 Remove the differential shaft locking roll pin 19 8plit the 2 piece differential housing 20 Drive the differential pinion shaft out of the housing with a brass drift punch 21 Remove the differential gears axle gears and thrust washers DIFFERENTIAL PINION SHAFT F2 F3 Transmission
15. AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires from the 1 and S2 terminals on the motor Remove the wire from the M terminal on the PMC control Make sure none of these wires can come into electrical contact with the frame or any other wire Reconnect the batteries With the key switch on and the forward and reverse switch in neutral perform the following tests Check continuity from the motor A2 terminal to the wire that was connected to the motor S1 terminal DO NOT make this test to the S1 terminal just the wire Refer to Solenoid Figure 1 If you do not know how to test for continuity refer test to a qualified technician This should be an open circuit if it reads as a short then one of the following has 0 Motor shown for reference A The reverse solenoid is shorted only on B The wire connected to the motor St 29 oeaan o O terminal is shorted to the wire connected to the motor A2 terminal C The wire connected to the motor S1 terminal is shorted to the wire connected to the PMC A2 terminal
16. Depress the accelerator fully f the light comes on then the motor armature windings are open and the motor must be repaired or replaced Stop trouble shooting here and repair the problem When the repair is completed completely test the vehicle before D the heels to th d Motor shown for reference only Terminal positions OwWenng HDEREVEDESISTOTBSS Qredgnes on your motor may not be in the same location Page 9 Main Sequence Connect the test light across the motor 517 and 52 terminals Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator fully Electrical Troubleshooting Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Ifthe light comes on then the motor field windings are open and the motor must be repaired or replaced 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 f the test light did not come on during either test then go to the F R Switch Motor shown for reference Terminal positions on your motor may not be in the same location sequence Accelerator AWARNING 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
17. HO lAV L TABLE OF CONTENTS Front AXIO Te 2 FrODb ROK d o 4 Steering Linkage 6 Transmission Chain or Gear Case 8 Transmission Differential Case 10 12 Rear Axle aeo eter doe Galata 12 edidere perum tbt uda Pet 14 Brake linkage 16 Wheels and Tires 18 Instrument Panel dash 20 Speed Control 22 Lester Charger 1 24 Lester Charger 2 26 Signet 28 vs crecen bebe 30 Seat Cushions and Deck 32 Decals atii sette ide a epo E 34 Optional Equipment 36 Stake Sides i diese d 38 Fiberglass Cab and Doors P1 40 Mirrors Windshield Wiper Brake Light 42 Illustrated Parts Illustrated Parts Front Axle Parts Page 2 Illustrated Parts lm S 2
18. The Best Way About Your Business TAYLOR DUNN Models Inlcuded 0 014 32 0 014 33 MANUAL 432 05 Operation Troubleshooting and Replacement Parts Manual Serial Number Starting 151285 47 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 ET1 50 Full Size Truck COPYRIGHT NOTICE Copyright 2001 by Taylor Dunn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or retrieval system without prior written permission of Taylor Dunn Mfg unless such copying is expressly permitted by federal copyright law Address inquiries to Reference Permissions Taylor Dunn Mfg 2114 W Ball Road Anaheim CA 92804 TAYLOR DUNN SERVICE CENTER For more information about this and other Taylor Dunn manuals please write Taylor Dunn Taylor Dunn Mfg 2114 W Ball Roa Anaheim CA 92804 Attn Technical Writer Section Index i Taylor Dunn Mule Model 0 014 32 C0 014 33 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 O Ui BP WYN H T
19. 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 HO lAV L Table of Contents SYMP OM Si eisien enia Ee ERR enini LES 2 Main Troubleshooting Sequence 3 Test Equipment Required 2 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions teet e e e REGIA 4 REVB Electrical Troubleshooting Electrical Troubleshooting Solenoids es _ Circuit Breaker 9 _ PMC Speed Control Typical Control Panel SYMPTOMS If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence
20. Chain tied with mechanics wire 5 Disconnect the main positive and negative cables at the batteries 6 Remove the four motor wires 7 Loosen the drive chain adjusting screw 8 Remove the hardware holding the motor to the chain case backing plate 9 Lift the rear of the motor and rotate the motor so that the motor mounting plate clears the two threaded studs on the chain case backing plate and remove the motor from the drive Install ACAUTION Do not allow the wheels to rotate after the motor has been removed Allowing the wheels to rotate may result in the drive chain getting bound up with the drive sprocket locking up the transmission Should this happen the chain may have to 1 Tie the chain up in position with mechanics wire as shown 2 Slip the motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove wire s holding the chain F2 F3 Transmission Page 4 Maintenance Service and Repair Replace the Axle Bearing NOTE The axle must be removed from the vehicle to replace the axle bearing Refer to section Rear Axle Remove and Install for information regarding removing the axle REAR AXLE Remove and Install AWARNING NOTE A 10 ton press is required to replace the axle Make sure the key switch is in the OFF bearing position then remove the key NOTE The axle bearing will be damaged when it is removed Pl
21. OFF position then remove the key AW ARNING 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires and the resistor from the ISO solenoid and perform the following tests Test continuity across the ISO power contacts If you do not know how to test for continuity refer test to a qualified technician This should be an open circuit If itis not an open circuit then the contactor should be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the FWD REV vehicle before lowering the drive wheels to the ground other wise continue to the next test Special Troubleshooting Connect the meter to each end of the resistor
22. 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 A WARNING 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 I NGEST 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 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 p
23. regarding operating this vehicle AWARNING 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 4 Place blocks under the front wheels to prevent vehicle movement 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 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 Operato
24. the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Set the test light voltage to the same voltage as the battery volts Connect the test light from the PMC M Terminal SE to battery positive est Light Close all interlock switches turn the Key Switch Face of Controller ON and place the F amp R Switch in Forward AGERE aes Depress the accelerator pedal fully S B e If the light comes ON then go to the Motor M sequence wll Main Battery Positive e Ifthe light does not come ON then continue with the next test Page 5 Main Sequence Electrical Troubleshooting Control Wire inputs Test Make sure the key switch is in the OFF position then remove the key AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating r
25. whichever is lower If at all possible this vehicle should be placed on a carrier rather than towing Safety Rules Page 7 CHARGING YOUR VEHICLE ge SAFETY RULES AND OPERATING INSTRUCTIONS A WARNING 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 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 Signet Charger Operation The Signet HB 600 and HB 1000 chargers use 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 Typical Signet Built In There is a series of LED s on the faceplate of the charger that serve two functions 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
26. x 48 Black 1 3 88 607 09 Rivet 1 4 x 1 2 Starpin 6 90 420 60 Kit Diamond Deck Cover Black 1 Reverse Warning Beeper 4 73 005 05 Alarm Pulsating 10V to 48V 1 No Headlight No Taillight gt gt gt gt 5 72 022 51 Mounting Ring Rubber 2 6 30 805 00 Plate Hole Cover 2 Headlight amp Taillight 6 72 022 00 Taillight Assembly 12V 1 7 72 005 00 Headlight Assembly 12V 1 Not Shown 72 005 05 Headlight Mount 1 8 88 102 11 Bolt 3 8NC x 1 Carriage 1 9 88 108 60 Washer 3 8 Cut 1 10 88 109 81 Locknut 3 8NC 1 Hitches 11 97 804 01 Hitch Pintle Type 1 12 97 808 00 Hitch Automatic Coupling 1 13 97 806 10 Hitch Pin and Clevis 1 14 02 432 00 Plate Hitch Mounting Lowered 1 15 88 140 14 Bolt 1 2NC x 1 1 2 Hex Hd 40r8 16 88 148 62 Lockwasher 1 2 4or8 17 88 149 80 Nut 1 2NC 40r8 Bulkhead Bolt On 18 01 432 90 Bulkhead unpainted 1 19 88 065 09 Screw 1 ANC x 3 4 Phillips Truss Hd 4 20 88 068 62 Lockwasher 1 4 4 21 88 069 80 Nut 1 4NC 4 Parts e Page 37 Illustrated Parts Stake Sides Illustrated Parts lm S 2 Stake Sides Item No Part No Description Qty 1 90 550 03 Side Gate Left 1 2 90 550 02 Side Gate Right 1 3 90 550 01 End Gate 1 4 90 544 00 Stake Pocket Outer painted black 6 5 90 544 10 Stake Pocket Inner painted black 6 6
27. 010 is indicated on the dial indicator NOTE If new ring and pinion gears are used refer to 21 22 23 24 the recommended backlash that is supplied with the gear set Measure the backlash If the backlash is not within 0 002 of the original measurement taken on disassembly or the recommended setting for new gears then readjust the bearings as follows To increase backlash loosen the left spanner nut and then tighten the right spanner nut the same amount To decrease backlash loosen the right spanner nut and then tighten the left spanner nut the same amount Apply gear marking compound on both sides of 7 to 10 teeth on the ring gear While applying resistance to the pinion shaft rotate the ring gear back and forth not full revolutions until a clear contact pattern is shown Compare the contact pattern to the illustration on the following page and reshim the pinion housing or adjust the backlash as indicated on the illustration If the pinion housing is reshimed the backlash must be reset Go back and repeat ALL procedures in setting the backlash Tighten the bearing cap bolts to 70 85 ft lbs F2 drive 55 70 ft Ibs drive and install the spanner nut locks Tighten the spanner nut lock bolts to 12 25 ft lbs NOTE Final pinion nut torque on completely assembled drive 175 ft Ibs F2 F3 Transmission Page 11 A Maintenance Service and Repair RE SHIMMING THE PINION HOUSING The pinion h
28. 10 While supporting the front fork so that it cannot REPLACE THE FRONT FORK fall out of the vehicle remove the fork spindle nut and remove the fork from the vehicle A WARNING 11 Thoroughly clean all parts and install in reverse order Make sure the key switch is in the OFF position then remove the key Tighten the fork spindle nut to remove all play 3 in the fork bearings and then an additional Place the forward reverse switch in the Tap turn cemer OERE positon e Refer to section Front Axle Removal and Set the park brake Installation in Front Axle Service for Place blocks under the front wheels to information regarding installing the front axle prevent vehicle movement Refer to section Front End Alignment for m information regarding installing the upper Disconnect the main positive and steering chain negative cables at the batteries 12 Lower the wheels to the ground 13 Reconnect the main positive and negative cables AWARNING at the batteries PA i 14 Remove the blocks from behind the wheels 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 15 Release the parking brake and test drive the vehicle Locknut Washer Tapered Bearing Bearing Race lt 2 Collar SR Bearing Race Tapered Bearing Spind
29. 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 There 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 CAUTI 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 AW 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 vo
30. 88 065 11 Screw 1 ANC x 1 Phillips Truss Hd 24 7 88 069 81 Locknut 1 4NC 24 Parts e Page 39 Illustrated Parts Fiberglass Cab and Doors P1 12 25 24 Illustrated Parts M M PH SSS Cab Fiberglass w Safety Glass Item No Part No Description Qty 1 91 005 00 Cab Fiberglass 1 2 90 811 00 Windshield Front 1 3 90 851 00 Rear Window 1 4 98 310 10 Window Channel Rubber 13 ft 5 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 8 6 88 068 62 Lockwasher 1 4 8 7 88 069 83 Acorn Nut 1 4NC 8 91 005 10 Kit Fiberglass Cab 1 Doors Naugahyde 8 90 903 98 Side Curtain Left 1 8 90 903 99 Side Curtain Right 1 9 90 913 98 Frame Side Curtain Left 1 9a 90 913 99 Frame Side Curtain Right 1 10 91 809 10 Hinge Door Frame 1 11 91 810 01 Angle Lower Hinge 1 12 17 104 00 Collar 3 8 1 13 97 315 53 Handle Door Outer 1 14 97 315 54 Handle Door Inner 1 15 97 315 51 Latch Door Handle 1 16 88 727 06 Rivit 5 32 x 1 2 16 17 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 2 18 88 068 61 Washer 1 4 SAE 2 19 88 068 62 Lockwasher 1 4 4 20 88 069 83 Acorn Nut 1 4NC 4 21 88 065 06 Screw 1 4NC x 1 2 Phillips Truss Hd 2 22 94 011 00 Rail Trim Drip 1 23 88 025 08 Screw 8 32 x 5 8 Truss Hd Machine 2 24 88 029 86 Locknut 8 32
31. By WATERING A WARNING A WARNING Explosive mixtures of Hydrogen gas are 1 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 area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are 3 Set the park brake 2 Place the forward reverse switch in the center OFF position 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 5 Disconnect the main positive and damage negative cables at the batteries 4 Place blocks under the front wheels to prevent vehicle movement AW ARNING 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 Batter lectrolyte i i dm OG et E Pe ESIC recommended to fill the batteries at the end dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear of a charging cycle If the electrolyte is below rubber gloves and safety glasses while the top of the battery plates then fill just servicing batteries DO NOT INGEST This enough TO COVEI ie p lares MEN TOP O may result in severe bodily injury when the charging cycle is complete 6 Clean the batteries Refer to Cleaning the Batteries s
32. Charger Rev E 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 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 in itassumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 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 batter
33. 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 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 Testthe AC voltage across the transformer primary circuit This voltage should be the same as the rated AC voltage of the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Transformer Secondary Circuit Testthe AC voltage across the transformer secondary circuit The voltage here will vary depending on the state of charge in the batteries The voltage should
34. Maintenance Service and Repair DIFFERENTIAL ASSEMBLY 3 MEMBER Disassemble NOTE Bearings and races must be replaced as a set If any one bearing or race is worn its mate must also be replaced It is recommended to replace all bearings and races in the 3rd member as a set 1 Drain the oil from the differential housing and chain case Refer to section Change the Oil tor information regarding draining the oil 2 Remove the transmission assembly from the vehicle Refer to Transmission Assembly Remove and Install for information regarding removing the transmission 3 Remove both rear axle assemblies Refer to section Rear Axle Remove and Install for information regarding removing the axles 4 Remove the chain case and backing plate from the 3rd member Refer to section Chain Case Disassemble for information regarding removing the chain case 5 Remove the nuts holding the 3rd member to the axle housing and remove the 3rd member from the housing 6 Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened Measuring backlash 7 While rotating the pinion shaft tighten the pinion nut to 100 ft lbs 8 Measure and record the ring and pinion gear backlash This setting will be used during reassembly 9 Remove the pinion housing and pinion gear from the 3rd member NOTE Do not lose the spacers and shims in the pinion housing or the pinion housing shim s
35. Nut Not Shown Valve stem tubless tire only Not Shown 8 50 x 8 Tube Not Shown 11 040 00 5 70 x 8 Tube 11 030 00 Tire and Wheel Assemblies 4 80 x 8 LR B Pneumatic 4 80 x 8 LR B Split Rim Pneumatic 4 80 x 8 LR C Split Rim Pneumatic 400 x 8 Soft solid non marking ribed 400 x 8 Soft solid 16 1 4 x 11 1 4 Solid rubber 4 80 x 8 Tube e Page 19 Parts Illustrated Parts Instrument Panel dash Parts Page 20 Illustrated Parts V Y M ing INSTRUMENTATION Item No Part No Description Qty 1 71 120 00 Ignition Switch Keyed Alike 1 1 71 121 00 Ignition Switch Keyed Unalike optional 1 2 71 039 00 Switch Forward Off Reverse 1 3 94 312 00 Label Forward Off Reverse 1 4 88 727 06 Pop Rivit 5 32 x 1 2 2 5 00 432 29 Cover Plate Dash 1 6 74 009 10 Charge Indicator 24 Volt 1 6 74 009 00 Charge Indicator 36 Volt 1 7 74 000 00 Hourmeter 12 48 Volts optional 1 8 71 501 00 Horn Button 1 9 71 100 00 Toggle Switch with optional light 1 10 88 025 06 Screw 8 32 x 1 2 Truss Hd 2 11 88 028 62 Lockwasher 8 2 12 88 029 80 Nut 8 32 2 13 88 065 06 Screw 1 4NC x 1 2 Truss Hd 4 14 88 069 81 Locknut 1 4NC 4 15 94 304 00 Label Console Switches 1 Not Shown 73 004 10 Horn 1 Parts e Page 21 Illustrated Parts Speed Control Panel Illustrated Parts P
36. WARNING 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 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 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 Dry dirt can be readily blown off with low pressure air or brushed off 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 Reconnect th
37. and proceed to Special Troubleshooting in Section 4 at the end of the main troubleshooting sequence Runs slow in both directions plus high armature and field current in both directions NOTE Armature and field current should be equal Runs slow in both directions plus high armature current in both directions NOTE Field current will be very low Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low Full speed only Does not run in either direction plus there is noise from motor hum or whine with high field current and low armature current Jumps into high speed when direction is selected after depressing the accelerator pedal Excessive spark when connecting battery Does not run or runs very slow with low motor current and high battery current Jumps into high speed when direction is selected after depressing the accelerator pedal If your vehicle does not exhibits any of the above symptoms then continue with the main troubleshooting sequence on the following pages Page 2 Main Sequence Electrical Troubleshooting g MAIN TROUBLESHOO
38. as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A X y f d f N oR or e aoe SOR Zl SA ee A pud pod WE S N PA N Nc Se S A E Grade B S A E Grade C Grade L 9 Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Appendixes Appendix B Page 4 A Suggested Torque Values non critical hardware Diameter Grade 2 Grade5 Grade 8 and TPI Tightening Tightening Tightening Torque Torque Torque ft Ib ft Ib ft Ib e ndixes Appendixes Appendix B Page 5 Suggested Torque Values critical hardware Torque Table Appendixes Torque Range Group Description Ft Lbs In Lbs Nm Brakes Brake bolt disc brake body 11 11 132 132 15 15 Brake line tube nut fittings 12 13 144 156 16 3 17 7 Brake spider bolts Dana 160mm hyd brakes 25 35 300 420 34 47 6 Brake spider bolts Dana 160mm mech brakes 15 19 180 228 20 4 25 8 Brake spider bolts Dana 7x1 3 4 brakes 16 20 192 240 21 8 27 2 Electrical Battery terminals 8 9 96 108 10 9 122 Front Axle Front spindle nut Note Refer to maintenance section in the service manual King pin Note Refer to maintenance secti
39. 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 fy Maintenance Service and Repair STORAGE AND RETURNING TO SERVICE A WARNING 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 A WARNING 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 I NGEST This may result in severe bodily injury 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 positive and negative cables at the batteries ACAUTION If the batteries are removed from the vehicle do not place them directly on the ground concrete or solid metal surface It is recommen
40. 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 1 j cn ET wires then the AC cord or plug has been 1 damaged Stop here and repair the problem T pa 22 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 ebeg Wd 19 dau gt 9 18 034 015 11 1 T 4 1 HOLS HC 019441422 92 ovid 7051309 MIO 31 201 H3ONVHO
41. forward side of the rocker on the switch F amp R switch seen from the side depressed in the FORWARD gear F amp R switch seen Battery Negative from the rear Main Sequence Page 16 Connect a voltmeter across the reverse terminal of the forward and reverse side of the F amp R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse Depress the accelerator pedal fully If the voltage is not at 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 f all tests in this section were good then check the wiring from the F amp R switch to the Forward and Reverse solenoids and both the forward and reverse solenoid coils 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 The REVERSE terminal is diagonally opposite the reverse side of the rocker on the switch F amp R switch seen from the side depressed in the REVERSE gear E J F amp R switch seen Battery Negative from the rear Solenoids Make sure the key switch is in the OFF position then remove
42. 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 Motor Page 4 Incorrect Brush Spring Position REPLACING THE BRUSHES NOTE It is recommended that all four brushes be replaced as a set NOTE Motors without removable brush covers must be disassembled to replace the brushes Refer to Motor Inspection Disassembly section for information on taking the motor apart NOTE Some motors are equipped with brush pairs These motors must be disassembled to replace the brushes Refer to Motor Inspection Disassembly section for information on taking the motor apart Refer to the Motor Parts List for your vehicles brush configuration NOTE Some motors have brush leads that are routed through or behind the brush holder assembly In this case the brush holder assembly must be removed to replace the brushes NOTE The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor Motors with brush covers and brushes with termination screws 1 Remove the brush covers 2 Loosen the brush wire retaining screw and remove the brush from the brush holder Be careful with the brush spring and do not let it slip off of the spring mount If the spring comes off then the motor must be disassembled Refer to Motor Inspection Disassembly section for information on tak
43. 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 locations of the model and serial numbers are illustrated below Serial Number Stamped in Frame Vehicle Data Page 4 TAKING DELIVERY OF YOUR VEHICLE Inspect the vehicle immediately after delivery Use the following guidelines to help identify any obvious problems Examine the contents of all packages and accessories that may have come in separate packages with the vehicle Make sure everything listed on the packing slip is there Check that all wire connections battery cables and other electrical connections are secure Check battery cells to be sure they are filled Check the tire pressure tightness of lug nuts and for any signs of damage Check the operation of each of the following controls Accelerator Brake Parking Brake Key Switch Forward Reverse Switch Reverse Beeper if equipped Front Headlight Switch Steering Wheel Horn INTRODUCTION What To Do If a Problem is Found If there is a problem or damage as a result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also notify your Taylor Dunn dealer of the claim If
44. possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions The band brake is located on the front of the drive chain case housing it must be removed to accurately measure the lining thickness Refer to Replace the Brake Lining for information on removing the band brake 1 Measure the thickness of the brake lining at its thinnest point If it is 1 16 inch or less then the brake band must be replaced 2 Measure the run out of the brake drum If it is more than 0 010 inches then it must be machined or replaced Do not machine the brake drum beyond its service limits 3 Measure the diameter of the brake drum If it is less than 5 85 inches then the brake drum must be replaced 4 Inspect all brake cables and linkages for any signs of damage or wear 6 Reconnect the main positive and negative cables at the batteries 7 Remove blocks from behind the wheels 8 Test drive the vehicle Brakes Page 2 Maintenance Service and Repair ADJUST THE PARKING BRAKE ADJUST THE SERVICE BRAKE Primary Adjustment ACAUTION NOTE If there is no adjustment left in the park brak adjusted Refer to Adjust the Service brake brake cable Refer to Replace the Brake for more information Lining for information regarding the proper 1 Release the park brake adjustment for the brake cable 2 Rotate the knob on the end of the park
45. result in severe bodily injury 6 10 11 12 13 14 15 Remove the front axle and wheel Refer to Front Axle Removal and Installation section for information regarding removing the axle Remove the spacers seals and bearings from the hub Thoroughly clean all grease from the inside of the hub and the bearings Drive the races out from the hub Press new races into the hub 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 Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Maintenance Service and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 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 Remove the front axle nut
46. severe bodily injury and or property damage 12 Close all safety interlock switches turn the key On place the forward off reverse switch in forward and fully depress the accelerator pedal 13 Tighten or loosen the adjustment screw to obtain the minimum noise level NOTE If there is less than 1 16 of threads left on the adjustment screw see illustration then the drive chain has stretched beyond service limits and should be replaced Hefer to section Chain Case for information regarding replacing the drive chain 14 Release the accelerator pedal place the forward off reverse switch in off turn the key off and disconnect the batteries 15 Untie the vehicle 16 Tighten the adjustment screw jam nut and motor mounting nuts 17 Wipe off any oil that may have come from behind the motor 18 Lower the drive wheels to the ground 19 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive Maintenance Service and Repair CHANGE THE OIL AWARNING Wear protective gloves when working with petroleum lubricants Repeated contact with petroleum lubricants can result in skin disorders CHECK THE OIL LEVEL NOTE The oil level in the chain case is maintained by the transmission Oil is pumped from the 3rd member into the chain case housing It is not necessary to check the oil level in the chain case AWARNING Make sure the key switch i
47. steps that have led to this point The tests may need to be repeated Page 21 Main Sequence HO lAV L ELECTRICAL TROUBLESHOOTING amp Special Troubleshooting Guide This section is specific to the symptoms listed below Each troubleshooting sequence assumes that all listed symptoms are present Do not use this section unless the truck has all listed symptoms SYMPTOMS GO TO gt Runs slow in both directions plus high armature and field current in both MOTOR directions NOTE Armature and field current should be equal gt Runs slow in both directions plus high armature current in both directions d NOTE Field current will be very low SOLENOIDS gt Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high SOLENOIDS armature current only NOTE Field current will be very low in the opposite gt direction gt Accelerates slowly and exceeds normal speed in both directions plus high A armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL gt Does not run in either direction plus there is noise from motor hum or whine A with high field current and low armature current PLUGGING DIODE gt Excessive spark when connecting battery Does not run or runs very slow with
48. that was removed from the ISO solenoid and measure its resistance ISO solenoid is shown for reference The meter reading should be 250 Ohms only The type of solenoid in your truck 10 If it is not 250 ohms 10 then replace the resistor 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing Itis important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ELECTRICAL TROUBLESHOOTING SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms Perform the tests covered in the MOTOR section first If the motor is OK continue with the following tests Make sure the key switch is in the OFF position then remove the key AW ARNIN G 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground
49. the key AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury If the vehicle runs in forward only then skip ahead to the test sequence Forward does not run in reverse If the vehicle runs in reverse only then skip ahead to the test sequence Reverse does not run in forward Page 17 Main Sequence Electrical Troubleshooting Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal fully f the voltage is at battery volts then the wire from the ISO solenoid to the PMC is bad 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 Connect a voltmeter across the ISO solenoid HOT terminal a
50. 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 voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to the chart below FLASHING FLASHING AC Input Voltage Range DC Output INDUSTRIAL BATTERY CHARGER 50 75 100 eam LISTED Signet Charger Troubleshooting Page2 Charger System Model Voltage HB600 24 AUTO SELECTABLE DUAL AC INPUT 100 240 50 60 Hz 9 0 1 5A OUTPUT 30 6V 222 18 0 550 WATT Manufacturer SIGNET SYSTEMS INC Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 14 hours depending on the state of charge of the battery when the charge cycle was started Acharger could remain on for longer than 14 hours if The vehicle is equipped with batteries larger than 220 Amp hour capacity The 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 Abrownout 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 electrol
51. three Status LED s LED s flashing is an indication of a charging problem Refer to the Charger Troubleshooting section for information on error codes Charging State LEDI LED2 Safety Rules Page 8 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 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 Lestronic II Charger Operation The Lestronic II charger 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 Typical Lestronic II Built In Charger SAFETY RULES AND OPERATING INSTRUCTIONS ge 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 th
52. to the PMC M terminal to the wire that was connected to the motor Motor shown for reference only S2 terminal Terminal positions on your motor may not be in the same location This should read as an open circuit If it reads as a short then one of the following has occurred A The forward solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S2 terminal 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 otherwise continue with the next test Special Troubleshooting ELECTRICAL TROUBLESHOOTING With the key switch on and the F amp R switch in reverse depress the accelerator pedal and perform the following tests Check continuity from the wire that was connected to the PMC M terminal to the wire that was connected to the motor S1 terminal Motor shown for reference only Terminal positions on your motor may not be in the same location If you do not know how to test for continuity refer test to a qualified technician This should read as an open circuit If it reads as a short then one of the following has occurred A The reverse solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected t
53. 2 25 97 304 50 Snap Fastener 6 26 98 451 00 Tape Weather Strip 3 ft 27 88 027 03 Screw 8 32 x 5 16 Set 1 90 903 60 Kit Side Curtain Left 1 90 903 61 Kit Side Curtain Right 1 Quantites are for one door only Not shown in illustration Parts e Page 41 Illustrated Parts Mirrors Windshield Wiper Brake Light Illustrated Parts y M M MM BHE Mirrors Windshield Wiper Item No Part No Description Qty 1 92 201 00 Mirror 4 1 2 x 8 1 2 1 2 92 202 00 Bracket Mirror Mounting 1 3 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 2 4 88 069 81 Locknut 1 4NC 1 5 88 068 62 Lockwasher 1 4 2 6 88 069 83 Acorn Nut 1 4NC 2 7 88 060 09 Bolt 1 4NC 3 4 Hex Hd 1 Windshield Wipers 8 74 050 00 Windshield Wiper Motor 1 9 74 051 00 Arm Windshield Wiper 1 10 74 052 00 Blade Windshield Wiper 1 11 88 065 08 Screw 1 4NC x 5 8 Phillips Truss Hd 1 12 88 069 87 Nut 1 4NC Keps 1 13 88 069 83 Acorn Nut 1 4NC 1 75 114 15 Harness Wiper amp Light 1 71 100 00 Switch Toggle located on the dash tray 1 Stop Light Mechanical Brake illustration not availalble 01 432 99 Support Park Brake Switch 1 17 104 00 Collar 3 8 2 71 111 00 Switch Brake Light Mechanical 1 71 135 00 Switch Micro w Formed Lever 1 75 007 02 Harness Mechanical Stop Light 1 88 014 13 Screw 6 32 x 1 1 4
54. 32 98 Brake Pedal Bracket painted black 1 7 01 432 70 Brake Shaft Weldment painted black 1 8 88 111 32 Bolt 3 8NF x 8 Hex Hd Grade 5 1 9 96 762 00 Clevis 3 8 1 10 96 813 00 Cable Assy Adjustable 1 11 96 771 00 Clevis Pin 3 4 2 12 88 517 09 Cotter Pin 3 32 x 3 4 3 13 96 772 00 Clevis Pin 1 1 14 85 270 00 Brake Return Spring 1 15 88 080 11 Bolt 5 16NC x 1 Hex Hd 1 16 80 410 20 Flanged Bearing 3 4 ID 2 17 88 102 11 Bolt 3 8 NC x 1 Carriage 4 18 88 089 81 Locknut 5 16NC 1 19 88 119 80 Nut 3 8NF 1 Parts e Page 17 Illustrated Parts Wheels and Tires Ref wheel hub _ 5 assembly Illustrated Parts eX Wheels and Tires DESCRIPTION M 1 PART Wheels 12 012 00 5 x 8 Tubeless 12 054 00 11 1 4 Cast iron Tires 10 075 00 N 4 80 x 8 LR B Pneumatic 10 076 00 4 80 x 8 LR C Pneumatic 10 074 10 400 x 8 Soft solid non marking ribbed 10 074 00 400 x 8 Soft solid ribbed 10 261 00 Split Rim Wheels 12 041 12 16 1 4 x 11 1 4 Solid rubber Inner Wheel 2 5 bead 12 041 13 Outer Wheel 2 5 bead 12 041 00 Wheel Assembly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 88 110 09 3 8 x 3 4 NF Hex Bolt grade 5 88 109 62 88 119 80 3 8 Split Lock Washer 3 8 NF Hex Nut 9 97 236 00 13 989 00 11 041 00 Wheel
55. 6 2 64 O S 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 Joyoedej 00 808 6L 00 808 6L 01 808 62 808 6 01 80876L OT 808 6L 01 808 6L 01 80876L 01 808 6L TH L8 1L0 Y3 L8 1L0 T 9 0 6 99 508 6 9 508 64 9 508 6 02 08 64 9 508 64 O S A quiossy 00 7S8 6L 01 158 64 00 58 64 01 1858 64 01 IS8 6L 00 7S8 6L I 9192 10g amg 91483104 91423100 91493104 ers 0 9 lt 5096 su om 8 8 0S 0ET 0 lt 0 seit erosti 09 lt 11 6 09 STT 0 L 0S 0 c sdury zg e3eoA DV 1 8 0 LA8 STOT9E lLHS SCO PC ILH8 OPO IPC LASOPOTHC 188500792 188520792 188500790 1 8 0 ada 19349 06 90 6L 09 P0E 6L S0 0 6L S1 CO 6L 01 06 6 01 10 6 ASS O0E 6L 0S 00 6L 05 20 6 NOL dS ac STEZI 0601 OELTZ O9LET 1 6 OTE 05101 TO SOIZ Te O0PrT ued 18107 POW 2981000 S IHOVHO Illustrated Parts Signet Charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following Parts Illustrated Parts SSS i i Note There are no user serviceable components inside the charger Parts Page 29 Illustrated Part
56. 96 900 00 Turnbuckle Steering Chain 2 12 30 241 00 Chain 40 29 1 2 Long 1 13 30 005 00 Sprocket 22 Tooth 40 Chain 3 4 Bore 1 14 20 144 00 Shaft Steering 13 1 4 Long 1 15 30 248 00 Chain 40 36 1 2 Long 1 16 14 082 10 Front Fork Assembly 1 Illustrated Parts Transmission Chain or Gear Case Illustrated Parts Transmission Chain Case PART 88 109 61 97 100 00 88 087 11 88 069 80 88 103 09 80 703 00 DESCRIPTION 3 8 SAE Flat Washer Woodruff Key Chain Adjusting Screw 5 16 NC Hex Nut Motor Mounting Screw 3 8 X 3 4 NC O Ring 4 1 2 ID X 5 OD 70 454 00 Motor Mounting Plate 88 109 87 3 8 KEPS Nut Interegral Lockwasher 30 081 00 14 Tooth Single Motor Sprocket 30 070 00 15 Tooth Double Motor Sprocket 30 080 00 15 Tooth Single Motor Sprocket 30 082 00 17 Tooth Single Motor Sprocket 16 415 00 Spacer Main Sprocket F2 Axle 440 Thick 30 091 00 42 Tooth Single Pinion Sprocket 30 092 00 59 Tooth Single Pinion Sprocket 30 070 11 60 Tooth Double Pinion Sprocke 30 070 10 81 Tooth Double Pinion Sprocket 30 093 00 81 Tooth Single Pinion Sprocket 30 320 11 Drive Chain 15 81 T Double Sprocket 30 508 20 Drive Chain 15 81 T Single Sprocket 44 352 53 88 101 13 88 080 20 41 989 00 43 201 11 45 002 00 45 021 00 45 331 00 21 97 250 00 22 88 089 81 23 88 088 61 24 88 108 63 Internal Tooth Lock Washer 25 88 239 82 Motor Nut 3 4 NF Hex Jam Nut Thin No longer used on late model
57. Directional Signals Optional Hazard Light Switch Optional Electrolyte Alarm Optional ae Park Brakes Steering Foot Brake Pedal ui Accelerator Vehicle Operational Guidelines Safety Guidelines Starting While driving Loading and Unloading Parking ate TOWING reor een eae Charging your vehicle New Battery Break in 8 Signet Charger Operation 8 Lestronic II Charger Operation 8 Charging 9 Storing and Returning to Service Storing Your Vehicle Returning to Service Periodic Maintenance Checklist Daily Visual inspection 11 Maintenance Guidelines for Severe Duty Applications Safety Rules and Operating Instructions ge SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS BURDEN CARRIER ITEM MODEL VOLTAGE
58. I NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Disconnect the four motor wires and perform the following tests Check continuity from A to the frame of the motor S Motor shown for reference only If you do not know how to test for continuity Terminal positions on yo r motor refer test to a qualified technician may not be in the same location e This should be an open circuit If there is continuity from 1 to the frame of the motor then the motor armature or armature circuit brushes are shorted 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 otherwise continue with the next test Special Troubleshooting ELECTRICAL TROUBLESHOOTING Check continuity from S1 to the frame of the motor If you do not know how to test for continuity refer test to a qualified technician This should be an open circuit If there is continuity from S1 to the frame of the motor then the motor field is shorted Stop trouble shooting here and repa
59. ID of the holes 7 Install the chain case centering tool refer to Appendix A into the pinion seal bore in the chain case housing F2 F3 Transmission Page 7 A Maintenance Service and Repair 4 SNe Ju x Md Spacer is um Backing Plate XC S uc Drive Sprocket yw eae 2 ASX Drive Chain e lt 74 N v z _ g Ny pr e lt lt gt Washer 5 4 f Nut C p K 7 7 Chain Case Housing d Pinion Seal Brake Assembly N Pur rac one Pinion Nut 8 Install the chain case housing onto the pinion shaft 10 Remove the centering tool and install a new pinion and tighten the pinion nut to 75 ft lbs seal Lightly lubricate the pinion seal lip 9 Install and tighten the three nuts and washers to 11 Install the brake assembly and the brake band the threaded studs and the housing bolts that are alignment bracket s Do not tighten the bolts at not used for the brake mounting bracket or this time alignment brackets 12 Install the brake drum Torque to 175 ft lbs Chain Case 13 Tighten the brake adjusting bolt to 25 ft lbs 14 Tighten the brake assembly mounting bolts 15 Adjust the brake Refer to section Brake Service Adjust the Brakes tor information regarding adjusting the brakes 16 Adjust the drive chain Refer to section Adjust the Drive Chain for information regarding adjusting the drive chain F2 F3 Transmission Page 8
60. In Automatic 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 Page 2 SAFETY RULES AND OPERATING INSTRUCTIONS ge SAFETY RULES AND GUIDE LINES It is the responsibility of the owner of this vehicle to assure that the operator understands 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 speeds ranging from 4 5 to 9 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow this vehicle at more than 5 mph Refer to Vehicle Operational Guidelines Safety Guidelines section for important safety information
61. Inflation 2 Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels A Maintenance Service and Repair TIRE INFLATION 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 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 i
62. Item No Part No Description Qty 1 90 001 00 Seat Cushion 1 2 90 000 00 Backrest 1 3 90 100 00 Seat Frame 1 4 90 100 51 Support Rod 2 5 90 420 00 Deckboard 29 1 8 x 48 1 Not Shown 88 837 11 Screw 14 x 1 Phillips Metal 8 Not Shown 88 107 09 Screw 3 8NC x 3 4 Square Hd Set 6 Parts e Page 33 x Illustrated Parts Parts 34 Illustrated Parts w SSS DECALS Item No Part No Description Qty 1 94 301 44 Decal Arms and Legs 1 2 94 313 20 Decal Safety Warning 1 94 312 00 Forward and Reverse Switch label 1 88 807 01 Rivet for F amp R label 2 4 94 384 14 Decal When Leaving Vehicle 1 5 94 309 00 Decal Brake Warning 1 6 94 384 01 Decal Not a Motor Vehicle 1 7 94 373 10 Decal Vehicle Data 1 8 94 333 00 Decal FM 1 9 94 313 00 Decal Battery Warning 1 10 94 319 00 Decal Battery Disconnect 1 Not 94 201 00 Taylor Dunn Emblem on front cowl 1 Shown 88 567 91 Fastener Push On for TD Emblem 3 Parts e Page 35 Illustrated Parts Optional Equipment Illustrated Parts OPTIONAL PARTS Wheel Covers Item No Part No Description Qty 1 92 000 00 Chrome Wheel Cover 8 2 la 92 001 00 Chrome Wheel Cover 6 2 Diamond Plate Deck Cover 2 90 420 40 Deck Diamond Plate 29 1 8
63. N Oa PF ON 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 Parking Before leaving the vehicle Set the parking brake Set the forward off reverse switch to the OFF position Turn the key switch to the OFF position and remove the key 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 Towin To tow 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
64. Page 9 DIFFERENTI CASE Assemble NOTE Thoroughly clean and inspect all parts before reassembly Apply a small amount of differential oil to all gears and bearings before reassembly NOTE Depending on your vehicle config uration the rear pinion pilot bearing is not required and may not be installed NOTE If the ring and pinion gear set is to be replaced then the shims for the pinion housing may have to be adjusted Refer to section Selecting the Pinion Housing Shim for information on adjusting the shim NOTE Most of our gear sets are non hunting or semi hunting gears With this type of gear the pinion and ring gears must be aligned correctly There will be two teeth marked on the ring gear and one tooth marked on the pinion gear The one tooth on the pinion gear must be installed so that it is between the two teeth on the ring gear The gear ratios are 2 50 2 70 2 75 3 25 and 3 00 Pinion housing 1 If the rear pinion bearing was removed install a new bearing Place the pinion gear into the 3rd member Install the pinion housing onto the 3rd member bearing 6 Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened 7 While rotating the pinion shaft tighten the pinion nut to 100 ft lbs 8 Check the torque required to rotate the shaft If the torque is not between 6 10 in lbs then the bearings must be re shimmed Add or subtract shims
65. SPECIFICATION Occupancy Driver only Dimensions 200 6L X 74 9W X 101 6H Centimeters 79L X 29 5X 40H Inches Turning Radius 177 8Centimeters 70 Inches Dry Weight C 4 32 258 kg 570 Ibs less batteries C 4 33 269 kg 594 Ibs Min Max Battery 92 5 kg to 156 7 kg 248 Ibs to 420 Ibs Weights Maximum Load C 4 32 635 kg 1 400lbs C 4 33 544 kg 1 200165 Deck dimensions 73 6W x 101 6L Centimeters 29W x 40L Inches Electrical System C 4 32 36 Volt Six 217Amp Hour 6 Volt Lead Acid Batteries C 4 33 24 Volt Four 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 400Amp Transmission Primary Oil Bath Chain Reduction to Automotive Type Hypoid Differential Motor DC C 4 32 1 5 kW 2 Horse Power for 60 min Series Wound 4 5 kW 6 Horse Power for 5 min C 4 33 1 1 kW 1 5 Horse Power for 60 min 3 4 kW 4 5 Horse Power for 5 min Brakes Rear Wheel Drive Line Band Brake Hand Operated Park Brake Tires 4 80 x 8 Load Range B Pneumatic Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Battery Discharge Indicator Key Switch Horn Button Forward Reverse Switch Light Accessories Optional Charger C 4 32 36 Volt Up to serial 164171 120v 12 Amp AC 25Amp DC Built In Automatic Starting Serial 164172 100 230v 12 6 Amp AC 20A DC Built In Automatic C 4 33 24 Volt Up to serial 164195 120v 8 Amp AC 25Amp DC Built In Automatic Starting Serial 164196 100 230v 9 4 5 Amp AC 18 Amp DC Built
66. TING SEQUENCE Test Equipment Required Digital multimeter DMM with diode test function FLUKE 79 model used in illustrations Shunt or clamp on DC Ammeter to measure up to 400 amps Test light with a rated voltage equal to or exceeds maximum battery voltage or Taylor Dunn test light part number 62 027 00 for systems up to 48 volts Test harness Taylor Dunn 62 027 31 This troubleshooting guide assumes that the vehicle is wired correctly It is not intended to diagnose a vehicle that is not wired correctly These tools are available through your local Taylor Dunn parts distributor IMPORTANT NOTES and INSTRUCTIONS This troubleshooting guide assumes that the vehicle is wired correctly It is not intended to diagnose a vehicle that is not wired correctly This troubleshooting guide is not written to be able to locate a problem if there are multiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT start in the middle of this troubleshooting guide Start at the beginning and complete each test in the order that they are written Do not skip any test unless instructed to do so Once a problem is found stop testing and repair the indicated problem When the repair is completed it is recommended that the control system be retested before lowering the drive wheels to the ground These test procedures must be perfor
67. Test Light 62 027 00 Disc Brake Boot Installation Used to install the rubber boot on all disc brake bodies 41 350 13 Tool Used to remove pins and sockets from AMP connectors ie EM u i paci Pin Removing Used to remove pins and sockets from MOLEX connectors 15 442 55 Hydrometer Used to check the specific gravity of battery electrolyte 11 200 00 Battery Filler Used to safely add water to batteries 77 201 00 Appendixes Appendix A Page 2 Appendixes 57 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 S A E Grade 2 S A E Grade 5 S A E Grade 8 Other Bolts Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Appendixes Appendix B Page 3 gt Appendixes Hex Nuts Nuts with no markings are to be treated as S A E Grade 2 N P FI P E E a ATN N f 3 is N N N p N N OA NNNM 2 N 52 _ J x _ 4 Xe ANNA J S A E Grade 5 S A E Grade 8 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
68. UTION 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 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 4 Place blocks under the front wheels to prevent vehicle movement 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
69. ace the forward reverse switch in the center OFF position AWARNING The axle bearing retainer will be damaged when it is removed Do not reuse the axle bearing retainer Reinstalling the original bearing retainer may result in the axle falling out of the transmission resulting in severe bodily injury or property damage 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 A WARNING Old axle bearings may explode while being removed Place a cage around the axle bearing that will contain all debris if the bearing explodes Failure to place a cage around the axle bearing could result in severe bodily injury or property damage and support devices of rated load capacity may result in severe bodily injury 6 Raise the drive wheel off of the ground 7 Remove the wheel assembly S Pape a smallgil drai pah Unger meend 1 Place the axle in a press and remove the bearing 10 11 12 13 axle housing Remove the four axle retaining bolts Secure the brake body assembly do not let it hang by the brake hose Using a slide hammer remove the axle from the axle housing Remove the bearing gasket and axle seal from the housing Install the
70. ailure to use lifting DO NOT place jack stands where the bumper is curved and support devices of rated load capacity may result in severe bodily injury 11 Lift the rear of the vehicle just enough to allow the removal of the transmission mounting bolts and remove the bolts 12 Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle and support the rear of the vehicle with jack stands 13 Install in reverse order 14 Check brake adjustment and adjust as needed Refer to Adjust the Brakes in the Brake Service section for information regarding adjusting the brakes 15 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive F2 F3 Transmission Page 6 Maintenance Service and Repair CHAIN CASE NOTE Some vehicle configurations may require that the transmission be removed to disassemble the chain case Refer to section Transmission Assembly for information on removing the transmission Disassemble 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 10 11 12 13 14 15 16 prevent vehicle movement Disconnect the main positive and negative cables at the batteries Place an oil drain pan under the chai
71. and If the bearing freewheels then grease is no longer present in the bearing and it must be replaced Refer to Replacing the Bearings section for information regarding replacing the armature bearings Feel for any roughness when the bearing is rotated If any roughness or grinding is noticed then the bearing must be replaced Refer to Replacing the Bearings section for information regarding replacing the armature bearings Assembly NOTE If this is an enclosed motor on a vehicle with a Power Traction primary reduction then it is recommended to replace the armature shaft seal any time the motor is disassembled 1 Push the motor brushes just far enough out of the brush holder so that the brush springs hold them in place away from the commutator See the illustration to the right Install the rear motor housing to the stator housing 3 Lightly grease the outside diameter of the armature bearings 4 Insertthe armature through the stator housing and seat the bearing into the rear housing 5 If equipped with armature retaining screws install and tighten them at this time 6 If this is an enclosed motor lightly grease the armature shaft seal and install the front motor housing NOTE If the vehicle is equipped with a belt type primary reduction then the spring on the motor seal should be removed Failure to remove the spring may result in a high pitched squeal from the seal 7 Pushthe motor brushes into the brush
72. 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 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 Place the forward reverse switch in the center OFF position AWARNI NG Setthe 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 pog 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 confir
73. armature bearing s off of the armature shaft ACAUTION Do not press against the outer race of the bearing Pressing against the outer race will damage the bearing and may result in premature failure of the bearing See the illustration below Example of freshly cut commutator 7 While still in the lathe smooth the commutator Inner race with fine emery cloth 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 2 Once all segments have been properly undercut mount the armature in a lathe and smooth the commutator with fine emery cloth 3 Inspect the armature for shorts Refer to Motor Inspection section for information on testing the 4 Press new bearing s onto the shaft armature 5 Reassemble the motor NOTE Copper debris in the undercut area can give a reading of a shorted armature REPAIRING THE COMMUTATOR 1 The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor 2 The armature must be removed from the motor for this procedure Refer to Motor Inspection Disassembly section for information on taking the motor apart 3 Using a lathe cut the armature just enough to Properly undercut and cleaned remove all grooves depressions or ridges commutator segments 4 Measure the diameter of the commutato
74. as required until the torque is within specifications F2 F3 Transmission Page 10 Install the bearing races into the pinion housing Install the pinion bearing spacers shims and front Maintenance Service and Repair PINION GEAR PILOT BEARING PAINT MARKING INDICATES POSITION IN WHICH GEARS WERE LAPPED Differential Assembly 12 13 Reassemble the differential housing in reverse order Place the ring gear onto the differential housing matching the mark made during disassembly Install two of the ring gear bolts finger tight to align the gear Press the ring gear onto the differential housing Install the ring gear bolts and cross tighten to 65 80 ft lbs If the differential bearings were removed install new bearings Place races onto the differential bearings and place the differential assembly onto the 3rd member Position the assembly so that it is just touching the pinion gear Install the bearing adjusting nuts making sure that the nuts are not cross threaded Position the nuts so they are in contact with the bearing races Maintenance Service and Repair ACAUTION Cross threading the nuts will damage the 3rd member housing and bearing caps If the housing and or nuts are damaged the entire 3rd member assembly may have to be replaced 17 Install the bearing caps in their original locations and torque the bolts to 12 15 ft lbs making sure that the adjustin
75. at the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition and no less than 8096 discharged as per hydrometer reading The battery voltage must be above approximately 6596 of the chargers rated DC voltage If the batteries are below approximately 65 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 AWARNING 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 A Page 4 Electrical Troubleshooting A TROUBLESHOOTING FOR BUILT IN CHARGER Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake
76. atteries 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 Ifany 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 9 Remove the blocks from behind the wheels release the park brake and test drive Typical brush and brush holder Enclosed Motors GE no cooling fan General Electric Motors A WARNING 6 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 Insert a 0 035 diameter wire through the brush inspection hole above each brush until it contacts the top of the brush Mark the wire to indicate how far it was inserted into the motor housing Remove the wire and measure how far into the motor the wire was inserted If any one wire insertion length exceeds the length specified in Service Limits then all four brushes should be replaced Refer to Repla
77. axle in reverse order using a new gasket and seal Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive and bearing retainer 2 Lightly lubricate the axle shaft 3 Install a new bearing and bearing retainer and press into place NOTE Some axle configurations have an o ring around the axle bearing The bearing should be orientated so that the o ring is farthest away from the axle hub See the illustration below F2 F3 Transmission Page 5 ejl Maintenance Service and Repair TRANSMISSION ASSEMBLY Remove and Install 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 If equipped with a built in charger remove the charger 7 Remove the motor wires 8 Disconnect the brake cable from the brake arm at the brake band 9 Remove the four nuts from the bolts holding the transmission assembly to the frame DO NOT remove the bolts at this time 10 Place two jack stands under the front bumper They should be located at each corner of the frame see illustration A WARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle F
78. be between 208 and 250 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 TIMER 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 f 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 gl 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 If this is a closed circuit then the timer start up circuit is functioning normally If 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
79. brake handle until the parking brake holds firm when A WARNING applied 3 Set the park brake 4 Reconnect the main positive and negative cables at the batteries 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 5 Remove the blocks from the wheels 6 Release the park brake and test drive the vehicle Adjustment Knob Disconnect the main positive and negative cables at the batteries 6 Release the park brake 77 Park Brake 7 Loosen the park brake handle adjustment until is Handle as loose as possible 8 Loosen the brake band bolt jam nut 9 Tighten the brake band bolt until the brake starts to drag and then back off two turns 10 Tighten the brake band bolt jam nut 11 Adjust the primary adjustment until the parking brake holds firm when applied 12 Set the park brake 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from the wheels 15 Release the park brake and test drive the vehicle Brake Bolt Jam Nut Brakes Page 3 Maintenance Service and Repair REPLACE THE BRAKE LINING AWARNING Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket parts
80. 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 wheel off of the ground and support with jack stands 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 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel 9 10 11 12 Bearings section for information regarding the replacement of the wheel bearings Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Front Axle Page 2 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
81. ch 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 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 should 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 d
82. cing the Brushes section for information regarding replacing the motor brushes Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels release the park brake and test drive Motor Page 2 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 housing screws from the rear and or front of the motor Remove the armature retaining screws from the rear housing if equipped Housing screws Armature retaining screws If this is an enclosed motor remove the front housing end Pull the armature out of the front end of the motor housing Remove the nuts off of all of the terminals in the rear motor housing Remove the rear motor housing being careful not to damage the field coil wires gt Motor Service gy Inspection 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 Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in section Service Limits t
83. 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 Band Park Brake NOTE The drive must be removed to replace the brake band Refer to Remove Complete Transmission Assembly for information on removing the drive from the vehicle NOTE Refer to the illustration on the following page for locations of the components NOTE On most vehicle configurations the brake drum does not have to be removed for this procedure If the brake drum must be removed refer to Replacing the Brake Drum for this procedure 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 6 Release the park brake 7 Disconnect the parking brake cable and return spring from the brake arm 11 Remove the clevis pin 11 from the brake band anchor and remove the brake band 3 from the assembly 12 Inspect the brake arm pivot bolt for signs of wear If any signs of wear are seen then the pivot bolt must be replaced 13 Tighten the brake band pivot bolt and then back off just enough so that the brake arm 15 pivots freely AWARNING The brake band bolt s
84. d adjust the cable so that the brake arm is 1 4 away from the chain case when the parking brake is off 1 4 Clearance 3 13 11 22 Adjust the brake band adjusting bolt 4 so that there is no brake drag when the brake is off It may be necessary to readjust the alignment bracket adjusting bolt s 10 for optimum brake alignment and operation 23 Tighten the brake band bolt jam nut 7 24 Set the park brake 25 Reconnect the main positive and negative cables at the batteries 26 Remove the blocks from behind the wheels 27 Release the park brake and test drive the vehicle Brakes Page 5 fj Maintenance Service and Repair REPLACE THE BRAKE DRUM A WARNING Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE The drive must be removed to replace the brake drum Refer to Remove Complete Transmission Assembly section for information on removing the drive from the vehicle 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 movemen
85. ded 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 Storage A battery is a live electrical source It 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 resulting in severe bodily injury and or daran LA Iu Store the vehicle or batteries in a cool dry well ventilated area regarding checking the electrolyte level If storing for more than one month the batteries should be charged as follows ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately 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
86. ds 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 level should be inspected on a weekly schedule Safety Rules Page 11 HO lAV L Table of Contents Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication 4 Model C 4 25 Tow Tractor Model E 4 55 Tow Tractor General Maintenance Maintenance Service and Repair Maintenance Guid
87. e batteries remove the blocks from the wheels and test drive Maintenance Service and Repair By TESTING A WARNING 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 A WARNING 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 I NGEST This may result in severe bodily injury A WARNING 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 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 swit
88. e 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 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 25 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 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
89. e problem Testthe 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 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 Testthe 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 A Page 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 term
90. e 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 Horn Switch The horn switch is located on the left side of the dash Depress the switch to sound the horn release it to turn it off Headlight Switch optional The headlight switch is located on the bottom right side of the dash Push the top of the switch forward to turn the lights on Pull the switch back to turn the lights off Accessory Switch Optional The accessory switch is located on the botom right of the dash Push the top of the switch forward to turn on the accessory Pull the switch back to turn off the accessory The accessory can be turned on with the key switch in the OFF position If a vehicle is equipped with windshield wipers and one or more accessories the windshield wipers are controlled from this switch Other accessories are controlled from the auxiliary switch Safety Rules Page 4 Battery Status Indicator Analog The battery status indicator is located to the left of the hour meter The normal operating range is in the green zone Park the vehicle for a few minutes for an accurate reading The vehicle needs charging if it is in the yellow zone During and immediately following charging the needle will be in the red zone to the right The needl
91. e will move through the green zone toward the yellow zone as the batteries discharge Charge the batteries when the needle is in the yellow zone lf it is in the red zone to the left the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries Hour Meter optional The hour meter is located to the right of the battery status indicator It records the number of hours the vehicle has been in operation Directional Signals Optional The turn signal lever is located on the left side of the steering column Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal Hazard Light Switch Optional The hazard light switch is located on the left side of the steering column The switch is a small tab To activate the hazard lights pull the tab out To turn the hazard lights off push forward or pull back the directional signal lever Electrolyte Alarm Optional The Electrolyte Alarm is located in the battery area in the 4th battery cell from the main battery positive cable The Electrolyte alarm is activated when the battery cell fluid level falls below the level of the probe The alarm is an audible continuous sound along with a bi color indicator lamp Inspect the fluid level in all battery cells when the alarm sounds or the bi color lamp turns from its green color to red The vehicle batteries should then be filled and or charged With t
92. ear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive The voltage shown is for illustration f the voltage is not at battery volts then only The actual voltage may vary check the wiring to battery negative and nem the negative circuit breaker Stop trouble nade for shooting here and repair the problem 7 MSN LOT YON 5 ERE truck may look different When the repair is completed Main Battery completely retest the vehicle before M 222 aa Qu lowering the drive wheels to the ground ae ee Connect a voltmeter across the ISO solenoid coil terminals The voltage shown is for illustration Close all interlock switches and turn the only The actual voltage may vary Key Switch ON A EPIIT Depress the accelerator pedal to engage Solenoids are shown for reference MS 1 only only The type of solenoid in your If the voltage is not at battery volts then tuckmay look detent go to the Key Switch sequence If the voltage is at battery volts and the ISO solenoid does not pick up click then the ISO solenoid has failed Stop trouble shooting here and repair the
93. ection for information on cleaning the ACAUTION batteries 7 Check the electrolyte level in all battery cells If Battery electrolyte will stain and corrode low fill to the correct level with distilled water using most surfaces Immediately and part number 77 201 00 battery filler never add thoroughly clean any surface outside of the additional battery electrolyte to the batteries battery that the battery electrolyte comes 8 Reconnect the batteries remove the blocks from in contact with Failure to clean may result the wheels and test drive in property damage AWARNING 42 Filler neck A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto x the battery A conductive object that comes 225 level in contact with the battery terminals will ORO KORO initiate a short circuit of the battery This COCO inside battery could cause the battery to explode Z resulting in severe bodily injury and or OER OO property damage Battery 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 Batteries Page 5 fy Maintenance Service and Repair REPLACING 6 VOLT BATTERIES ONLY A WARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do
94. ed 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 OF CONTENTS 2 iT sting 2 uec 3 4 2 5 Replacing 6 volt batteries only 6 Moist Charge Batteries eese 7 Storage and Returning to Service 8 Nic 8 Returning to Service 9 Battery Service Maintenance Service and Repair CLEANING AWARNING 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 6 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 I NGEST This may result in severe bodily injury A
95. efore lowering the drive wheels to the ground Main Sequence The voltage shown is for illustration only The actual voltage may vary Main Battery Positive The voltage shown is for illustration only The actual voltage may vary Page 8 Electrical Troubleshooting g Motor Make sure the key switch is in the OFF position then remove the key AW ARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AW ARNING and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Set the test light voltage to the same voltage as the battery volts connect the test light across the motor 1 and Wiring to motor omitted for clarity Do not A2 terminals disconnect the motor wires for this test Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward
96. elines AWARNING 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 AWARNING 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 follow 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 Ven
97. ent FWD REV Solenoids are shown for reference only The type and position of the forward solenoid in your truck may be different th FWD REV Main Sequence Page 20 Set the test light voltage to the same voltage as the battery volts FWD REV Connect the test light across the Normally Closed contacts of the Reverse solenoid Refer to your vehicles wiring diagram to identify the position of the Reverse solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal fully Solenoids are shown for reference only f the light comes on then the Reverse The type and position of the reverse solenoid has failed Stop trouble shooting solenoid in your truck may be different 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing Itis important to review the trouble shooting
98. er to Repair Commutator section for information regarding machining the commutator 7 Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted armature If 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 a 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 8 Using a growler test the armature for shorts Ifthe armature is shorted then we recommend that the armature or motor be replaced 9 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 against all of the other segments one at a time There should be continuity around the entire commutator If any segment indicates an open circuit then the motor must be replaced 10 Using the continuity function of digital multi meter check the continuity from any one of the commutator segments and the armature frame If it is not an open circuit then the armature is shorted and the motor must be replaced 11 Rotate the motor bearing s by hand The bearing should not freewheel but should come to a smooth stop when rapidly spun by h
99. g nuts still turn freely NOTE In the following procedure Left adjusting nut refers to the nut on the ring gear side of the differential assembly Right adjusting nut refers to the nut on the pinion gear side of the differential assembly RING GEAR PINION GEAR SIDE SIDE The differential bearing preload is set by measuring the case spread of the 3rd member housing As the bearing adjusting nuts are tightened the two differential bearing caps will be pushed spread away from each other A dial indicator must be used to measure the case spread as the nuts are tightened Mount the dial indicator so that it is 4 inches above the top of the bearing caps and parallel to the center line of the carrier bearings Dial Indicator 4 Inches NOTE Be sure to continually rotate the ring gear while adjusting the bearings This makes sure that the bearings and races remain seated correctly NOTE One hole on adjusting nut approximately 18 19 20 0 003 change in backlash Left and right nuts MUST be turned the same amount AND in the same direction The final direction of rotation MUST be in the tightening direction to loosen a nut 1 hole back off 2 holes and then tighten 1 hole The ring gear should be rotated any time the nuts are being adjusted Loosen the right side nut Tighten the left nut until all backlash is removed from the ring and pinion gear Tighten the right nut until a case spread of 0
100. ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires from the B and M terminals on the PMC control and perform the following test The reading shown is for illustration only The actual reading may vary Using the diode test function on the DMM check for the presence of a diode across and on the PMC control Refer to Diode Figure 2 If you do not know how to test for a diode refer test to a qualified technician f the diode is open or shorted then the PMC control must be replaced 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ELECTRICAL TROUBLESHOOTING ISO Make sure the key switch is in the
101. he fluid level at a normal operating level and or the batteries charged the alarm and light will reset Safety Rules Page 5 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 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 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 the pedal to decrease speed Park Brake The parking brake is actuated with a hand lever which is located to the right of the driver 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 Charger Interlock The charger interl
102. hen the motor must be replaced 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 above then the commutator must be undercut Refer to Repair Commutator section for information regarding undercutting the commutator Hacksaw blade Incorrect Correct Insulation N Commutator Inspect the commutator for grooves If the commutator is groved 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 information regarding machining the commutator Motor Page 3 el Motor Service 5 Inspect the commutator for burn marks Burn 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 Typical burn mark on 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 f 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 Limits section Ref
103. ies to be charged is less than approximately 65 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 up so that the Lestronic charger can sense that they are connected and turn itself on Red Diode Transformer Tan gt 5 4 5 6 TT CJ 7 Tan 4 White Diode Black Capacitor Violet Black Y Y Charger E Not all chargers are equipped Interlock pyrpia bik with the lockout relay Interlock Relay Ammeter optional Black C Y To Battery Red EN Typical Charger Internal Wire Diagram Charger Troubleshooting A 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 The charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger Abrownout 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 batteries were not discharged to 5096 before connecting the charger The electrolyte in the batteries is too high boil over
104. iew the trouble shooting steps that have led to this point The tests may need to be repeated Main Sequence Page 12 Electrical Troubleshooting g Key Switch Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Test all interlock switches and or interlock relays if equipped for continuity Depending on the model of your vehicle it may have a seat interlock Foot interlock Charger interlock special order interlock or any combination of the above Refer to the wire diagram at the end of this section for location of the interlocks NOTE Due to the many different configurations possible for special order interlocks they will not be included in this text Refer to the option list for your truck or contact your Taylor Dunn Represen
105. inal 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 receptacle is broken or has a bad connection Stop here and repair the problem Remove the charger cover and perform the following tests HI GH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with AWARNING 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 Capacitor Test 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 A Page 8 Electrical Troubleshooting 5 Reconnect the lead to the diode 6
106. ing the motor apart Motor Service Correct Brush Spring Position Brush Spring Orientation 3 Install the new brushes in reverse order 4 Be certain that the brush springs do not rest up against the brush wires Refer to illustrations in Motor Inspection Assembly for proper brush spring position Motors with brush pairs or not equipped with brush covers 1 Disassemble the motor Refer to Motor Inspection Disassembly section for information on taking the motor apart 2 Remove the brush holder Note Remember the position and routing of the brush crossover leads They must be reinstalled in the same position 3 Remove the brush termination screws or the armature studs and remove the brushes from the brush holder 4 Install the new brushes in reverse order 5 Reassemble the motor Refer to Motor Inspection Assembly for information regarding reassembling the motor Motor Page 5 g Motor Service 6 Measure the commutator undercut depth in 5 REPLACING THE BEARINGS places around the commutator If any one of the 1 The motor must be removed from the vehicle for measurements is less than the minimum undercut this procedure Refer to Transmission Service depth specified in Service Limits then the section for information on removing the motor commutator must be undercut 2 Remove the armature Refer to Motor Inspection Disassembly section for information on taking the motor apart 3 Press the
107. ir the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue to Motor Inspection Motor Inspection 1 Remove and disassemble the motor Motor shown for reference only Terminal positions on your motor may not be in the same location 2 Visually inspect the inside of the brush end housing If there are any silver specs of metal around the inside of the housing it indicates that the armature has overheated and melted the solder around the commutator The armature is bad and the motor must be replaced Stop here and repair the problem otherwise continue with the next test 3 Visually inspect the armature wires where they loop around at the shaft end of the armature The insulation should be a light to medium reddish brown color If the insulation is dark brown to black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the next test 4 Perform a continuity test around the armature commutator Place one of the test leads on a single commutator segment While holding the first test lead on the segment check the continuity to the other segments around the commutator If you do not know how to test for continuity refer test to a qualified technician There should be continuity on each
108. ires and Wheels Battery Service ee O Electrical Troubleshooting n N Special Troubleshooting m UJ Lestronic Charger Troubleshooting n A Signet Charger Troubleshooting m Ui Wire diagram m Illustrated Parts Appendix A Special Tools 17 Appendix B Suggested Torque Values 18 Appendix C Brake Lining Handling Precautions 19 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 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 About this manual eee 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 GOnventiOns 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 R 3 80 shown with extended steel cab and doors options Introduction e 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 carrier
109. ischarged 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 A 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 the 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 CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions Batteries Page 4 STUNT Typical Hydrometer Float Maintenance Service and Repair
110. ition 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 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 cause loss of control of the vehicle resulting in severe bodily injury and or property damage 6 Loosen the upper and lower steering chain turnbuckles and remove the chains 7 Position the steering wheel as shown in the illustration to the right and tie off so that it cannot rotate 8 Position the steening fork so that it is in the straight ahead position and tie off so that it cannot rotate 9 Install the upper and lower steeing chains so that the turn buckles are centered between the two sprockets and tighten the turn buckles to tension the chains Refer to Adjust Steering Chains for information regarding tightening the turn buckles 10 Install safety wire in each turn buckle as show in the illustration 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 Turnbuckle with Safety Wire Steering Page 2 Maintenance Service and Repair
111. ixes Appendix B Page 6 Appendixes APPENDIX BRAKE LINING HANDLING PRECAUTIONS AWARNING 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 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 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 7 HO lAV L 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
112. le Seal Front Fork Assembly 6 Remove the seat frame Remove the fork bearing cap Remove the front axle Refer to section Front Axle Removal and Installationin Front Axle Service for information regarding removing the front axle 9 Remove the upper steering chain Steering Page 3 A Maintenance Service and Repair ADJUST STEERING CHAINS There are two steering chains One is at the bottom of the steering column under the floorboard the other is at the top of the fork under the seat platform Both steering chains have an adjustable turnbuckle for setting the chain tension Before adjusting the chains be certain that the turn buckles are positioned correctly The turnbuckles should be centered between the two sprockets when the steering is positioned in the straight ahead position If the turnbuckles are not centered then remove and reposition the turnbuckles before adjusting the chains After the turnbuckles are centered rotate the steering from a full right turn to a full left turn and be certain that the turnbuckles do not contact the sprockets To adjust the steering chain tension perform the following for the upper and or lower chains 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 Disco
113. low motor current and high battery current FREEWHEEL DIODE Jumps into high speed when direction is selected after depressing the accelerator pedal Section 4 Special Troubleshooting Table of Contents PMC CONTROL 2 PEUGGING DIODE 4 FREEWHEEL DIODE 5 a ae 6 SOLENOID S LM LIES 8 ELECTRICAL TROUBLESHOOTING Make sure the key switch is in the OFF position then remove the key AW ARNIN G 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury PMC CONTROL The voltage shown is for illustration only The actual voltage may vary Disconnect
114. ltage 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 s is broken or has a bad connection between the charger connectors and the AC plug Stop here and repair the problem Charger Troubleshooting gel 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 GH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with AWARNING 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 Common 4 Reconnect the transformer lead to the capacitor and disconnect one transformer lead fro
115. ly Tire replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions 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 thetire when seating the bead Failure to deflate the tire 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 or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death 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 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 8 Install in reverse order 9 Following the pattern shown on the following page cross tighten the wheel nuts in two stages as follows 1st stage to approximately 20 ft Ibs 2nd stage to 80 90 ft Ibs 10 Reconnect the main positive and negative cables at the batteries 11 Lower the wheel to the ground 12 Remove the blocks fro
116. m behind the wheels 13 Release the parking brake and test drive the vehicle 1 Remove the tire from the wheel 2 Out the old valve stem off of the wheel 3 Remove the valve stem cap from the new valve 4 5 stem Lubricate the valve stem with liquid soap Install a new valve stem using a valve stem tool NOTE The valve stem tool is available at most auto 6 repair shops Install the tire onto the wheel following the instructions provided with your tire replacement equipment Inflate the tire to the proper pressure and check for leaks Install the valve stem cap Tires and Wheels Page 3 Maintenance Service and Repair E i L 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 THE TIRE PNEUMATIC Do not attempt to repair a tire with a damaged side wall or a slice in 1 thetread 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 recommend
117. m 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 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 AWARNING while the charger is plugged in Failure to do so may result in serious bodily injury Charger Troubleshooting A Page 6 Electrical Troubleshooting ge 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 e 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 th
118. med in the order they were A C AUTI ON written If the test result is good then proceed to the next test or go to the next section Failure to do so may result in incorrect test results This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor Dunn Accelerator Module Test Harness Troubleshooting CANNOT be completed without these tools Page 3 Main Sequence Electrical Troubleshooting Definitions MS 1 The first switch in the accelerator module Battery volts The voltage at the batteries at the time the test is completed Pick up Energizing a solenoid or contactor F amp R Forward and Reverse ISO Isolator Battery negative Main negative battery post Battery positive Main positive battery post PMC Speed control module black box HOT terminal The side of a switch or solenoid that is connect to the power source COLD terminal The side of a switch or solenoid that power is switched to DURING ALL TESTS After any repairs are made completely retest the vehicle before AW ARNI N G lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and or property damage The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive
119. med 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 e f the DMM indicates an open circuit then the interlock relay is functioning normally Charger Troubleshooting el Page 10 TABLE OF CONTENTS Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code 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 D Signet Charger Troubleshooting Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The model HB600W and HB1000W chargers are designed as semiautomatic chargers The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged 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
120. n case Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug Remove the brake drum Refer to section Brakes Replace the Brake Drum for information regarding removing the brake drum Remove the nuts from the three threaded studs at the small end of the chain case housing Remove the chain case housing bolts brake assembly and alignment brackets Remove the chain case housing from the backing plate Remove the pinion seal from the chain case housing Loosen the motor mounting bolts Loosen the chain adjuster Remove the drive chain motor nut and sprocket and the drive sprocket If the backing plate must be removed from the 3rd member first remove the motor from the backing plate then remove the backing plate from the 3rd member Small End of 2 gt Housing Chain Case gt Housing Bolts Drain Plug Typical Chain Case Assemble 1 Thoroughly clean all gasket surfaces 2 Apply a 1 8 bead of 94 430 03 gasket sealer to the face of the 3rd member 3 Install the backing plate to the 3rd member Torque to 30 45 ft Ibs 4 nstall the motor to the backing plate Do not fully tighten the motor mounting hardware at this time 5 Install the motor sprocket drive sprocket and chain Do not adjust the chain tension at this time 6 Apply a 1 8 bead of 94 430 03 gasket sealer to the chain case housing Apply sealer around the
121. nance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance performed on the vehicle OSHA Regulation 29 CFR 1910 178 Powered Industrial Truck Operator Training Of the Operator The operator is responsible for the safe operation of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible for the service and maintenance of the vehicle At no time should a service person allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training At no time should an untrained individual be allowed to service or repair a vehicle without supervision This manual is not a training guide Of the Passengers The passengers are responsible to remain fully seated keeping their hands arms and legs inside the vehicle at all times Each passenger should be fully aware of the vehicle s operation All forms of recklessness are to be avoided Do not engage in horseplay Model B 2 10 shown withstake sides and steel cab with doors options HOW TO USE THIS MANUAL This manual is organized into five main sections INTRODUCTION This section describes how t
122. nd battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal fully f the voltage is at battery volts then the ISO solenoid 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 f the voltage is not at battery volts then check the wiring to battery positive and the main circuit breaker Stop trouble shooting here and repair the problem The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different FWD REV The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Forward does not run in reverse Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse f the voltage is not at battery volts then go to the Key Switch sequence Main Battery Negative The voltage shown i
123. ndicator 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 on 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 Hefer 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 If any debris is found it should be removed and the tire inspected for a leak Maintenance Service and Repair 7 REPLACE THE FRONT TIRE REPLACE THE TIRE WHEEL PNEUMATIC Refer to Front Axle Service for information on NOTE To replace the tire the tire wheel assembly removing the front wheel must be removed from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assemb
124. ng the Motor Brushes 2 Motors with internal cooling fans 2 Enclosed Motors GE no cooling fan 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes 5 Replacing the Bearings 6 Repairing the Commutator 6 Service Limits 7 Motor Service Rear Housing Circlip Brush Spring Stator Field 4 L Front Housing Brush Cover Brush Dust Cap Brush Holder Armature Typical Exploded Motor el Motor Service INSPECTING THE MOTOR BRUSHES Typical motor with cooling fan indicated by the arrow 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 vehicle Hefer to Transmission Service section for information on removing the motor 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 positive and negative cables at the b
125. nnect 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 Cut remove and discard the safety wire from the turnbuckle DO NOT reuse the safety wire 8 Using a pull scale adjust the turnbuckle until it deflects approximately 0 25 at 20 pounds 9 Install new safety wire on the turnbuckle 10 Lower the wheels to the ground Steering Page4 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 Not to scale Turnbuckle with Safety Wire TABLE OF CONTENTS Inspect the Service Parking brake 2 Adjust the Parking Brake 3 Adjust the Service Brake 3 Replace the Brake Lining 4 Band Park 4 Replace the Brake Drum 6 Brake Service Maintenance Service and Repair INSPECT THE SERVICE PARKING BRAKE 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
126. o the motor S1 terminal 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ELECTRICAL TROUBLESHOOTING Ej MOTOR High motor current in both the field and the armature accompanied with a lack of power would indicate a shorted armature and or field Another symptom that may exist is jumping or stuttering at low speeds and or the motor will not run unless the armature is manually rotated If this symptom exists it indicates that there may be open segments in the armature Visually inspect the brushes if they are OK continue with the testing below Make sure the key switch is in the OFF position then remove the key AW ARNIN G 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARN
127. o use this service manual and how to identify your vehicle Safety Rules and Operating Instructions This section outlines the safety and operational issues location and operation of controls and the operational checks that are to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks Electrical and Charger Troubleshooting 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 A warning alerts the reader of a hazard that may result in injury to themselves or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task A WARNING Ashaded box with and the word Warning and the symbol
128. ock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source Safety Rules Page 6 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 1096 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 a clear view ahead at all times Starting 1 Make sure the forward off reverse witch is in the center OFF position Set the parking brake Hold down the foot brake Insert the key and turn it to the ON position Release the parking brake Release the foot brake
129. oltage may vary Page 11 Main Sequence Electrical Troubleshooting Connect a voltmeter between pin 9 and pin 2 in the test harness Depress the accelerator pedal to engage MS 1 only Ifthe voltage is between 6 0 and 6 5 volts and the test at the PMC 2 terminal in the Control Wire Input section failed then the wire or interlock switches between the accelerator module pin 2 and the PMC pin 2 is open 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 voltage is not between 6 0 and 6 5 The voltage shown is for illustration only The actual voltage may vary volts then the accelerator module 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 Now Depress the accelerator module fully f the voltage is not between 11 0 and 11 5 volts then the accelerator module 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 STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to rev
130. om the B and A terminals on the PMC control and perform the following test mn The reading shown is for illustration only The actual reading may vary Using the diode test function on the DMM check for the presence of a diode across and 2 on the PMC control If you do not know how to test for a diode refer test to a qualified technician f the diode is open or shorted then the PMC control must be replaced 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing Itis important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ELECTRICAL TROUBLESHOOTING E FREEWHEEL DIODE Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the
131. on Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Connect a voltmeter to the PMC B terminal and battery positive If the voltage is not the same as battery volts then there is an open circuit in the wire from B to the battery Stop troubleshooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect a voltmeter across the PMC B terminal and the PMC B terminal Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal to engage MS 1 only f the voltage is not the same as battery volts then go to the Solenoids sequence f the voltage is the same as battery volts then the PMC controller has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle b
132. on in the service manual Rear Axle Transmission 3rd member Gear case cover GT drive 45 50 540 600 61 2 68 Axle bolt GT drive 275 275 3300 3300 374 374 Axle hub nut Dana 95 115 1140 1380 129 2 156 4 Axle tube to center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Drain plug GT drive 21 25 252 300 28 6 34 Gear case to 3rd member GT drive 18 20 216 240 24 5 27 2 Motor mounting GT Dana 6 5 7 78 84 8 8 9 5 Pinion nut F2 F3 175 175 2100 2100 238 238 Pinion nut GT drive 154 169 1848 2028 209 4 229 8 Ring gear Dana 35 45 420 540 47 6 61 2 Wheel lug nut 75 90 900 1080 102 122 4 Steering Ball joint clamp 28 32 336 384 38 1 43 5 Ball joint nut 40 45 480 540 54 4 61 2 Pitman nut 18 308 21 steering gear 75 100 900 1200 102 136 Pitman nut 18 308 25 steering gear 181 217 2172 2604 246 2 295 1 Rod end nut 20 25 240 300 27 2 34 Steering shaft pinch bolt 24 26 288 312 32 6 35 4 Steering wheel nut 18 308 21 steering gear 28 32 336 384 38 1 43 5 Steering wheel nut 18 308 25 steering gear 72 86 864 1032 97 9 117 Suspension Leaf spring hangers z Note Refer to maintenance section in the service manual Append
133. osition Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries 7 Remove the battery hold downs 8 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 10 11 jumpers when replacing the batteries Remove the batteries from the vehicle Inspect the battery compartment for signs of corrosion If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and repainted 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 Inspect the main positive and negative cables and terminals charger cables and terminals and 12 volt tap wiring If any of the terminals or
134. ousing shim may require replacement if the ring and pinion gear or pinion housing is replaced Pinion housing shims are available from 0 005 to 0 021 in increments of 0 001 Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear It should be a number ranging from 5 to 5 This is the amount in 0 001 increments to add to the standard shim For example if the number on the shaft is 3 then the standard shim 0 015 plus 3 equals 0 012 The correct shim would be 0 012 If you cannot locate the number on the shaft start with the standard shim and adjust as required per the contact pattern chart below Ideal contact pattern Correct shim Correct backlash TOE TOE Backlash is correct Add 0 004 shim Backlash is correct Subtract 0 004 shim Shim is correct Decrease backlash 0 004 Shim is correct Increase backlash 0 004 F2 F3 Transmission Page 12 Maintenance Service and Repair 5 EXPLODED VIEW FLAT WASHER DIFFERENTIAL THRUST DRIVE GEAR ATTACHING BOLT SIDE GEAR ies ha DIFFERENTIAL PINION SHAFT oM 7 E 1 TP e QO DIFFERENTIAL HOUSING amp Am cnm PINION GEAR THRUST WASHER A SPANNER NUT HAT dd E PINION REAR BEARING PINION BEARING SPACER PINION FRONT BEARING DRIVE ii iml HOUSING F2 F3 Transmission Page 13 HO lAV L TABLE OF CONTENTS Tire
135. pring lock nut jam nut clevis pin and cotter pin must be replaced with new parts whenever the brake band is replaced Failure to replace these components could cause the parking brake to fail resulting in severe bodily injury and or property damage 14 Install the new brake band using new hardware 15 Install the brake band assembly onto the drive Tighten the mounting bolts 5 just enough to keep the mounting bracket 13 against the chain case 16 but still allowing the bracket to move 16 Tighten the brake band bolt 4 to 50 ft lbs 17 Tighten the brake band bracket mounting bolts 5 18 Position the brake band alignment bracket s 9 so that the inner arm 14 is 0 100 away from the brake drum 8 Make certain that the alignment bracket does not come into contact with the brake drum 0 100 Clearance 8 Loosen the bolt s 1 on the brake band alignment bracket s 9 and pivot them out of the way 9 Remove the bolts 5 holding the brake band assembly to the front of the chain housing 16 and remove the brake band assembly from the drive 10 Remove the brake band bolt 4 Brakes Page 4 Maintenance Service and Repair 14 10 16 12 15 19 Adjust the alignment bracket adjusting bolt s 10 to 0 050 0 100 away from the brake band and tighten the jam nuts 12 20 Loosen the brake band adjusting bolt 4 21 Connect the brake cable or linkage to the brake arm an
136. problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Page 6 Main Sequence Control Wire inputs continued Connect a voltmeter across the PMC 2 terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal to engage MS 1 only If the voltage is not between 6 0 and 6 5 volts then go to the Accelerator sequence Depress the pedal fully f the voltage is not between 11 0 and 11 5 volts then go to the Accelerator sequence Connect voltmeter across the PMC KSI terminal and battery negative With the pedal still fully depressed e Ifthe voltage is not at battery volts then go to the Key Switch sequence f the voltage is at battery volts then continue with the next test The voltage shown is for illustration only The actual voltage may vary Negative Main B 0 FLUKE 79 The voltage shown is for illustration only The actual voltage may vary UN x B Main dA M Negative Main Sequence Page 7 Power Wire Inputs Make sure the key switch is in the OFF position then remove the key AWARNING Place the forward reverse switch in the center OFF positi
137. r If the commutator is less than the minimum diameter specified in Service Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Motor Page 6 Motor Service SERVICE LIMITS Commutator Diameter Brush Length Wire Depth Motor Specification Undercut Depth min min max Number 5BC58JB56129A 0 635 0 025 66 75 2 625 5BC58JB56129B 0 635 0 025 66 75 2 625 EN 5BC58JB56129C 0 635 0 025 66 75 2 625 5 3079 5BC49JB399C 0 635 0 025 78 97 3 109 19 05 e 5BC58JBS6110C 0 635 0 025 78 97 3 109 19 05 TARRA Motor Page 7 HO lAV L TABLE OF CONTENTS Adjust the Drive Chain 2 Check the Oil Level 3 E Change the 3 Drive 4 400222 4 Un Remove Install cte eR E NER ERU Hear Axle ni carentem ees 5 Un Remove and 5 Replace the Axle Bearing 5 Transmission Assembly 6 Eu Remove and 6 Chain Case sse 7 IDisasse mble 5 te entente ASSEmbIG 7 Re shimming the Pinion Housing 12 Exploded View 13 Typical Transmission Assembly F2 F3 Transm Service ADJUST THE DRIVE CHAIN NOTE A
138. repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect a voltmeter negative probe to Pin 9 in the test harness Connect the positive probe to 24 or 36 volt truck Pin 4 48 volt truck Pin 7 The voltage shown is for illustration only The actual voltage may vary 24 36 volt Close all interlock switches and turn the Key Switch ON If the voltage is not at battery volts then go to the Key Switch sequence Connect a voltmeter between pin 9 and pin 5 in the test harness Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal to engage MS 1 only If the voltage is not at battery volts then the accelerator module 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 f the voltage at pin 5 is good but the test at the center terminal of the forward and reverse side of the F amp R switch in the Key Switch Section failed then check the wire between the accelerator module pin 5 and the F amp R switch 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 The voltage shown is for illustration only The actual v
139. rive wheels FWD REV to the ground Connect the test light across the Normally Closed contacts of the Forward solenoid Refer to your FWD REV vehicles wiring diagram to identify the position EUM of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Reverse Depress the accelerator pedal fully f the light comes on then the Forward solenoid has failed Stop trouble shooting here and repair the problem When the The type and position of the forward repair is completed completely retest the solenoid in your truck may be different vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing Itis important to review the trouble shooting steps that have led to this point The tests may need to be repeated Main Sequence zi Electrical Troubleshooting Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward f the vol
140. rs 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 to properly park this vehicle Recognize an improperly maintained vehicle Demonstrate ability to handle this vehicle in all conditions Safety Rules Page 3 e SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key Switch A key switch located on the right side of the dash 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 Forward Off Reverse Switch The forward off reverse switch located on the right side of the dash panel 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 vic
141. rts e Page 23 Illustrated Parts Lester Charger P1 Typical Built In charger Typical Portable charger Illustrated Parts V N 00 00 9 00 00 9 00 00 9 00 00 9 00 00 92 00 00 94 00 00 92 Snid OV 1ueuro v dost 5 x 0S 608 6L 5 0 lt 608 6 c 90 6L 09 608 6L Assy Avjoy Yop gt O S 01 99 lt 6 01 99 lt 6 p109 01 d E 00 15 64 00 02 64 00 0 lt lt 6 PPA 6 00 0 S 6L 00 0 lt lt 6 00 0 S 6L 00 0 S 6L 00 0 2 62 00 0 S 6L 00 0 S 6L 00 lt 6 00 0 S 6L PPY 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 TE8 6L 00 1 8 64 00 8 6 A quassy osn rm VIN 01 55 64 OI SLS 6L T O S p100 OV 9 O S 01 lt 09 6 O S O S O S O S O S O S 9 6 Teurmjsuel S I 6bL 6L T 6bL 6L E T 6bL 6L OT 6bL 6L T 6bL 6L 01 67 64 6 2 64 T 6bL 6L T 6bL 6L K quiessy opotq v 00 706 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 1ojpede 0c 808 6L 0 808 6 0c 808 6L 00 808 64 0c 808 6L 00 808 64 00 808 64 00 808 6 00 808 62 TH 10 O S 89 508 6 89 S08 6L L9 S08 6L S9 S08 6L L9 S08 6L TL S08 6L 69 S08 6L L9 S08 6L K quiossy 00 CS8 6L 01 1 lt 8 6 00 lt 8 6 01 158 6 01 1 lt 8 6 Tapuy I uam uam uam uam uam
142. ry negative and the negative 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 Connect a voltmeter across the center terminal of the forward and reverse side of the F amp R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal fully f the voltage is not at battery volts then go to the Accelerator sequence Connect a voltmeter across the forward terminal of the forward and reverse side of the F amp R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward Depress the accelerator pedal fully f the voltage is not at 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 The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different Main Battery Positive The CENTER terminal is the Green Black wire Battery Negative The FORWARD terminal is diagonally opposite the
143. s Batteries 4 por X PERS ON i O NEG Main negative N N Main positive t JEL 8 9 N V NEG Main negative Main positive KON No N Sy Parts Page 30 Illustrated Parts lm S 2 BATTERIES Item No Part No Description Qty 1 75 231 00 Jumper Battery 10 1 4 long 3 2 01 423 79 Angle Battery Hold 2 3 50 227 00 Battery Rod 3 4 88 069 81 Locknut 1 4NC 3 5 88 081 12 Bolt 5 1 6NC Square Hd Tin Lead 8 or 12 6 88 089 80 Nut 5 16NC Tin Lead 8 or 12 7 77 042 00 Battery 6 Volt 217 amp hour standard 4or6 7a 77 044 00 Battery 6 Volt 230 amp hour optional 4or6 7b 77 047 00 Battery 6 Volt 244 amp hour optional 4or6 7C 77 042 80 Battery 6 Volt 217 amp hour optional export 4or6 7d 77 047 80 Battery 6 Volt 244 amp hour optional export 4or6 88 100 09 Bolt 3 8NC x 3 4 Hex Hd 1 9 88 109 87 Nut 3 8NC Keps 1 Parts e Page 31 Illustrated Parts Seat Cushions and Deck Parts 32 Illustrated Parts SSS Seat Cushions and Deck
144. s for illustration only The actual voltage may vary ge a LUE B Po Main Sequence Connect a voltmeter across the Reverse Solenoid coil terminals Refer to your vehicles wiring The voltage shown is for illustration diagram to identify the position of the reverse only The actual voltage may vary solenoid Solenoids are shown for reference only Close all interlock switches turn the Key x The type and position of the reverse Switch ON and place the F amp R Switch in solenoid in your truck may be different reverse Depress the accelerator pedal fully f the voltage is not at battery volts then go to the F R Switch sequence FWD REV Set the test light voltage to the same voltage as the battery volts Connect the test light across the normally open Solenoids shown for reference only contacts of the reverse solenoid Refer to your The type and position of the reverse vehicles wiring diagram to identify the position solenoid in your truck may be different of the reverse solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse Depress the accelerator pedal fully f the light comes on then the Reverse solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the d
145. s in the OFF position then remove the key 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 4 Place blocks under the front wheels to prevent vehicle movement 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 Park the vehicle on a level surface Disconnect the main positive and negative cables at the batteries Place a small oil drain pan under the drive housing Remove the drive housing level plug ainsuntor ei should come out This 6 Place a large drain pan under the chain housing indicates the correct oil level 7 Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall NOTE If a large amount of oil comes out then let it drain to the proper level and replace the level plug If no oil comes out then fill the drive to the proper level and replace the level plug the drain plug Place the drain pan under the drive housing Remove the drive housing drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug 10 Remove the chain case fill plug and add 1 pint of oil 11 Remo
146. s since 1949 wants to be sure this vehicle provides years of reliable service Please continue to read this manual and enjoy this high quality Taylor Dunn vehicle This manual is to serve as a guide for the service repair and operation of Taylor Dunn vehicles and is not intended as a training guide Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description e 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 mainte
147. se switch wire connections for a typical control system Connect a voltmeter across the HOT terminal of the KSI side of the F amp R switch and battery negative Turn the key switch ON f the voltage is not at battery volts then go to the Accelerator sequence View of the terminals of a typical Key Switch KEY SWITCH 2 COLD Violet Wires s bw Red wire s BATTERY MAIN NEGATIVE Forward and Reverse Side KSI Side White Black 7 Violet Black a lt Green Black N Blue Black Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back The HOT terminal is the Violet Black wire on the center terminal Battery Negative Main Sequence Page 14 Connect a voltmeter across one of the COLD terminals of the KSI side of the F amp R switch and battery negative The COLD terminal is the Violet Black wire on either Close all interlock switches turn the Key end of the switch Switch ON and place the F amp R Switch in If the voltage is not at battery volts then the F amp R switch has failed Stop trouble shooting here and repair the problem When the repair is completed O a completely retest the vehicle before O Q lowering the drive wheels to the ground f the voltage is at battery vol
148. small amount of oil may come out when the drive motor mounting bolts are loosened 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 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 Place a small oil drain pan under the chain case 7 Loosen but do not remove the three drive motor mounting nuts 8 Loosen the chain adjuster jam nut hain Adjuster T 3rd nut is at the bottom of the motor 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 9 Raise the drive wheels off of the ground F2 F3 Transmission Page 2 Maintenance Service and Repair A WARNING Tie the vehicle to an immovable object to prevent the vehicle from moving in forward or reverse Failure to securely tie the vehicle may result in unexpected vehicle movement resulting in severe bodily injury or property damage 10 Tie the vehicle in place so that it cannot move 11 Reconnect the batteries A WARNING Rotating parts keep hands and loose clothing clear of all moving parts Failure to keep clear of moving parts may result in
149. t Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Loosen the bolt s on the brake band alignment bracket s and pivot them out of the way 8 Remove the pinion nut and slide the brake drum off of the pinion shaft 9 Remove the pinion seal 10 Lightly grease the new pinion seal and install using the pinion seal installation tool see appendix C A WARNING Inspect the pinion seal for any signs of misalignment A misaligned pinion seal could cause premature failure of the pinion seal and an oil leak This could result in property damage and or severe bodily injury Brakes Page 6 11 Install the brake drum using a new pinion nut Torque the pinion nut to 170 ft lbs 12 Position the brake band alignment bracket s so that the inner arm is 0 100 away from the brake drum Make certain that the alignment bracket does not come into contact with the brake drum 13 Adjust the alignment bracket adjusting bolt s to 0 050 0 100 away from the brake band and tighten the jam nuts 0 050 0 100 Clearance 14 Ad stthe park brake Ref erto Adjust the Park Brake section for information regarding adjusting the park brake 15 Set the park brake 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 TABLE OF CONTENTS Inspecti
150. t Brake Pedal Low Brake Fluid Low Brakes Out of Adjustment Brake Worn 1 16 Wear Limit 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 Above Front F ork 9 I N a Y TONS a 4 M PN Rear Axle Assembly side view IER ET Steering Chain Chain 2 Chaine 000000 Lube OO PARS ME C E 3 werosmacsaeror Dpemm a TABLE OF CONTENTS Inspect Adjust Front Wheel Bearings 2 Replace Front Wheel Bearings 2 Front Axle Removal and Installation Removal ie aee o Hb Hs 3 Installation cuc iet n eee ss 3 Front Axle Service Maintenance Service and Repair INSPECT ADJUST FRONT REPLACE FRONT WHEEL WHEEL BEARINGS BEARINGS 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 A WARNING Always use a lifting strap hoist and jack stands of adequate
151. t the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger 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 There are no internally serviceable components in the charger If the charger has failed then it must be replaced This chargeris rated for 115 VAC or 230 VAC operation When switching from one input voltage to the other Wait until all three status LED s A CAUTION 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 ge STATUS LED ERROR CODE There are three status lights LED s on the charger name plate These LED s normally indicate the current operating state of the charger All three LED s flashing indicate an error in the charger See the table below for an explanation if the error codes Error Code Description Action Required Reverse polarity or open circuit to the batteries AC line voltate too high or too low Charger overheated 4 Input or Output over current 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
152. tage is not at battery volts then go to the Key Switch sequence Connect a voltmeter across the Forward Solenoid coil terminals Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward Depress the accelerator pedal fully f the voltage is not at battery volts then go to the F R Switch sequence Set the test light voltage to the same voltage as the battery volts Connect the test light across the Normally Open contacts of the Forward solenoid Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward Depress the accelerator pedal fully f the light comes on then the Forward solenoid 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 The voltage shown is for illustration only The actual voltage may vary Ta d N Y 5 d mm in ga x1 B ane I ol Main Battery Negative The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type and position of the forward solenoid in your truck may be differ
153. tative for more information If you do not know how to test for continuity refer test to a qualified technician Connect a voltmeter across the HOT terminal of the key switch and battery negative View of the terminals of a typical Key Switch f the voltage is not at battery volts then check the wire between the key switch KEY SWITCH BEI Violet Wire s shooting here and repair the problem aa When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Red wire s BATTERY MAIN NEGATIVE Page 13 Main Sequence Electrical Troubleshooting Connect a voltmeter across the COLD terminal of the key switch and battery negative Turn the key switch ON If the voltage is not at battery volts then the key 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 f the voltage is at battery volts but the previous test at pin 4 in the Accelerator section failed then check the wire from the key switch to pin 4 at the accelerator module 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 For your reference shown at the right are the Forward and Rever
154. the wire from the M terminal on the PMC control and tape it off to prevent electrical contact Connect a volt meter across the PMC 2 terminal and battery negative Turn the key switch on close all interlock switches if equipped depress the accelerator pedal to engage the first micro switch only creep speed then perform the following tests Main Battery Negative The meter reading should be between 6 and 6 5 volts f the voltage at pin Z2 is not 6 to 6 5 volts then go to the ACCELERATOR sequence in the Main Troubleshooting Sequence otherwise continue with the next test Special Troubleshooting Connect a volt meter across the PMC and PMC M terminals Turn the key switch on close all interlock switches if equipped depress the accelerator pedal to engage the first micro switch only creep speed then perform the following tests The meter reading should not be equal to the battery voltage f you have full battery voltage then the PMC control is shorted and must be replaced 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 otherwise continue with the next test The voltage shown is for illustration only The actual voltage may vary If the voltage at pin 2 is correct and the voltage at M is correct then
155. there is a problem with the operation of the vehicle DO NOT OPERATE THE VEHICLE Immediately contact your local Taylor Dunn distributor and report the problem The report must be made within 24 hours of receiving the vehicle and its accessories The only personnel authorized to repair modify or adjust any part of this or any Taylor Dunn vehicle is a factory authorized service technician A WARNING 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 m Model B 2 10 Ambulance Page 5 HO lAV L TABLE OF CONTENTS Standard Specifications Burden Carrier Safety Rules and Guidelines Driver Training Program Driver Qualifications 29 Vehicle Controls Accessory Switch Optional Key Switch m Forward Off Reverse Switch Horn eren Headlight Switch optional Battery Status Indicator Analog m Hour Meter optional
156. there is a short in the harness between the wire connected to the PMC M and main battery negative 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 If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ELECTRICAL TROUBLESHOOTING PLUGGING DIODE Make sure the key switch is in the OFF position then remove the key AW ARNIN G 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires fr
157. tilate the work area properly e 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 Troubleshooting Guide Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Dry Lube Points in Steering Linkage Hard Steering Damaged King Pin Ball Joint 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 Limi
158. to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries STORING AND RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel Storing Your Vehicle Clean the 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 Storage Temperature F Charging Interval months Over 60 Between 40 and 60 Below 40 Returning to Service Check the battery s state of charge and charge if 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 Page 9 ge SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi Maintenance Item DO OU ewm Tire Pressure Beepers and Warming Deas Check and Fill Batteries and Fill Batteries CETT EE ee cre seve e
159. trucks Replaced with Ultra Blue RTV sealant 94 430 03 Backing Plate Gear Case 3 8 X 1 1 4 NC Hex Bolt 5 16 X 3 Hex Bolt Drain and Fill Plug Chain Cover Chain Case Gasket Backing Plate Gasket Pinion Oil Seal Gear Case Pinion Nut 5 16 NC Locknut 5 16 SAE Flat Washer Illustrated Parts Transmission Differential Case Illustrated Parts gx Transmission Differential Case mes am 3rd member Housing 1 628 ID Carrier Bearing Oorl 3rd member Housing 1 784 ID Carrier Bearing Oor 1 Differential Assembly 1 628 ID Carrier Bearing Differential Assembly 1 784 ID Carrier Bearing Carrier Bearing Race For 1 628 ID Carrier Bearing Carrier Bearing Race For 1 784 ID Carrier Bearing Carrier Bearing Race For P N 80 513 00 Carrier Bearing 1 628 ID Carrier Bearing Carrier Bearing 1 784 ID Carrier Bearing 1 2 3 80 5 13 00 Carrier Bearing 1 7812 ID Carrier Bearing 31 239 00 Ring and Pinion Gear Set 5 43 31 234 00 Ring and Pinion Gear Set 3 00 41 997 00 Oil Plug 41 291 32 Rear End Housing For B2 48 amp B2 38 41 299 20 Rear End Housing For B2 54 80 554 00 Front Pinion Bearings 41 711 00 Pinion Housing Shim 1 O z 002 Shim Add Shims As Needed 1010 Shim Add Shims As Needed 1005 Shim Add Shims As Needed Pinion Bearing Race Differential Bearing Adjuster Nut For 80 511 00 0 or 2 Differential Bearing Adjuster Nut For 80 512 00 0 or2 Differential Bearing Adjuster N
160. ts and the Battery Negative test at the PMC KSI terminal in the Control Wire Inputs section failed then check the wiring between COLD terminals of the KSI side of the F amp R switch and the PMC KSI terminal 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 F R switch Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Page 15 Main Sequence zi Electrical Troubleshooting Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive NOTE You may skip this test if it was completed in a previous section If the voltage is not at battery volts then check the wiring to batte
161. ut For 80 513 00 0 or2 5 16 X 3 8 NC Hex Bolt 2 1 2 X 2 Hex Bolt 7 16 X 7 8 Hex Bolt Locking Head 7 1 1 1 _ A 0 1 2 3 15 16 18 19 20 1 2 31 275 00 Ring and Pinion Gear Set 2 75 c Parts e Page 11 Illustrated Parts Rear Brakes Pinion Brake DWG z Axle tube Illustrated Parts Rear Bakes DESCRIPTION Brake Adjusting Bolt Ee Rear Axle Item No Part No Description Qty 1 96 330 20 3 8NF x 1 3 16 bolt 8 2 45 301 00 Seal 2 3 32 515 00 Retainer bearing 2 4 96 329 10 Lug bolt 10 5 41 162 21 Right axle assembly includes items 2 through 8 1 41 163 21 Left axle includes items 2 through 8 1 6 32 514 00 Retainer axle 2 7 80 503 00 Bearing 2 8 45 045 00 Gasket 2 9 88 119 81 3 8NF locknut 8 Parts e Page 13 Motor IQON AD 9Id T 2 4 4 42 2 5 OI Illustrated Parts W VIN VIN VIN VIN VIN VIN VIN VIN 19 880 88 VIN 0 V N V N V N V N V N V N V N V N 16 680 88 VIN mu 2391 6 61 V N VIN VIN VIN VIN VIN VIN lt 1 805 lt gt Jourejoy 8 8I VIN VIN VIN VIN VIN VIN VIN 01 01 0 ST CLT OL 00 cLT1 0L Joppoy ysg LI 00 lt 01 0 ST vOT OL 00 F01 0L ysnig 00 c08 0 00 1 08 01 lt 61 0 00 ZIP S8 00 ZIP S8 JOAOO Usnig Suuds ysnig 1 055012 01 lt 61 0
162. ve the drive housing fill plug and add 2 quarts of oil NOTE Refer to the Lubrication Chart for information regarding the type of oil 12 Replace all fill plugs NOTE Dispose of waste oil in accordance with your local regulations 13 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive Level Plug 7 Drain Plug Typical location of oil plugs The actual location of the level plug will vary depending on your vehicles configuration F2 F3 Transmission Page 3 A Maintenance Service and Repair als AAAA 3 Install the motor mounting hardware but do not DRIVE MOTOR tighten until the chain adjustment is complete 4 Adjust the drive chain Refer to Adjust the Drive Remove Chain for information regarding adjusting the drive chain NOTE In most cases it is not necessary to disassemble the chain case to remove the 5 Connect the motor wires motor If you find it necessary to disassemble 6 Reconnect the main positive and negative at the the chain case refer to Transmission batteries remove the blocks from the wheels and section for information regarding disassembly test drive of the chain case 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 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement
163. wheels off the ground AWARNI NG and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Disconnect both of the battery leads during any maintenance or A WARNING before disconnecting any electrical component or wire Failure to do so may cause severe bodily injury and or property damage START Read all warnings above before continuing If the vehicle runs normal in one direction but does not run in the opposite direction then go to the Solenoids sequence If none of the three solenoids pick up click when the accelerator pedal is depressed then go to the Forward amp Reverse Switch sequence Page 4 Main Sequence Electrical Troubleshooting g Power Output Test Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING and support the vehicle with jack stands Failure to do so may cause
164. 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 ft lbs 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 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 ACA
165. yte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is 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 2 4 hours after entering the second stage Signet Charger Troubleshooting Page 3 Z Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM with diode and capacitor test function 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 tha

The Best Way To Go About Your Business MANUAL MC-432-05

Contents

Download Pdf Manuals

Related Search

Related Contents