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Taylor-Dunn B0-011-00, Operation, T Roubleshooting And Replacement Parts Manual

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Taylor-Dunn B0-011-00 Operation, T Roubleshooting And Replacement Parts Manual Download Page 103

Electrical Troubleshooting

Charger Troubleshooting 

  Page 5

TROUBLESHOOTING FOR BUILT-IN CHARGER

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:

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.

Re-Connect the charger to the AC source.

8. Test the voltage across the two 14 gauge wires. This voltage should be the same

as the voltage at the AC receptacle (rated voltage of the charger). If the voltage is
less than the rated AC voltage of the charger then the 14 gauge white or black
wire(s) is broken or has a bad connection between the charger connectors and
the AC plug. 

Stop here and repair the problem.

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.

High Voltage. Do not touch the 14-gauge wires and make sure these

two wires do not come into electrical contact with any other object.

Failure to do so may result in serious bodily injury.

Make sure that these two wires do not come into electrical contact

with any other object.

Summary of Contents for B0-011-00

Page 1: ...u r B u s i n e s s Serial number Starting 142833 MANUAL MB 100 00 Operation Troubleshooting and Replacement Parts Manual Published 12 15 2003 Revision E B 1 00 B 1 25 Models Inlcuded B0 011 00 B 1 00...

Page 2: ......

Page 3: ...parts or service should be obtained through your local dealer A dealer locator can be found on the Taylor Dunn website at www taylor dunn com If you do not have access to the internet you can call th...

Page 4: ...B2 48 With Dump Bed Option B2 10 Ambulance 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...

Page 5: ...argers Illustrated Parts 11 Appendix A Special Tools 12 Appendix B Suggested Torque Values 13 Appendix C Brake Lining Handling Precautions 14 Taylor Dunn Model B0 011 00 and B0 011 25 Operator and Ser...

Page 6: ...oduction About this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 B 1 00 shown with...

Page 7: ...pplicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any T...

Page 8: ...entions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information a...

Page 9: ...te will be in one of two locations This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable...

Page 10: ...Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe...

Page 11: ...ter 2 optional 6 Battery Status Indicator 1 optional 6 Vehicle Operational Guidelines 7 Safety Guidelines 7 Starting 7 While driving 7 Loading and Unloading 7 Towing Loads 7 Parking 8 Towing This Vehi...

Page 12: ...State Speed Control 275 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC 4 47 kW 6 Horse Power intermittant duty Brakes Rear Wheel Mechanical Drum Hand Operated Park...

Page 13: ...ter 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 DRIVER TRAINING PROGRAM Acco...

Page 14: ...hile the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward reverse switch should be in the center off position with key switch off and the park brake set whe...

Page 15: ...ses the braking action Park Brake The parking brake is part of the foot brake pedal To set the parking brake push down on the lower half of the brake pedal until the pedal locks in the down position T...

Page 16: ...ocation Accessory switch location Hour Meter 2 optional The hour meter is located below the battery status indicator This tracks the number of hours the vehicle has been in operation Battery Status In...

Page 17: ...Set the parking brake 3 Hold down the foot brake 4 Rotate the ON OFF switch to the ON position 5 Release the parking brake 6 Release the foot brake 7 Slowly depress the accelerator pedal While drivin...

Page 18: ...hile it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all p...

Page 19: ...n indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes Charging State LED1 LED2 LED3 0 to 50 Blinking OFF OFF 50 to...

Page 20: ...tteries 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 includ...

Page 21: ...h and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l C...

Page 22: ...inclusive of a severe duty application Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on...

Page 23: ...Installation 16 Aligning the Front End 17 Adjusting the Toe In 17 Centering the Steering Gear 18 Repairing the Front Axle 19 Steering Yoke Bushings 19 Ball Joints 20 Wheel Bearings 21 Removal and Ins...

Page 24: ...re working on or disconnecting any electrical component or wire Block the chassis with jack stands before working under a raised vehicle Conduct vehicle performance checks in an authorized area where...

Page 25: ...severe conditions service procedures should be conducted more frequently than specified in the Periodic Maintenance Checklist The frequency of service under severe conditions is determined by the use...

Page 26: ...n Lubricant Type 1 Front Leaf Springs General Purpose Grease 2 K ing Pin General Purpose Grease 3 Ball Joints General Purpose Grease 4 Front W heel Bearings High Temperature W heel Bearing Grease 5 Re...

Page 27: ...ds Adjusting Steer Gear Needs To Be Replaced Lack of Power or Slow Operation Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Defective Speed Control or Motor Defective Ba...

Page 28: ...es 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 pad...

Page 29: ...s will not require manual adjustment if any part of the external mechanical linkages or cables have been removed NOTE The symptom of a low brake pedal may indicate that the auto adjuster is not workin...

Page 30: ...Reconnect the main positive and negative at the batteries 14 Remove the blocks from behind the wheels 15 Test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2...

Page 31: ...MB 100 00 Section 3 Page 9 This page intentionaly left blank...

Page 32: ...gative at the batteries 15 Remove the blocks from behind the wheels 16 Test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch i...

Page 33: ...MB 100 00 Section 3 Page 11 This page intentionaly left blank...

Page 34: ...tion 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 Always use a lifting strap hoist and jac...

Page 35: ...MB 100 00 Section 3 Page 13 BRAKE PEDAL LINKAGE...

Page 36: ...on the lower half of the pedal 12 Check the travel of the brake pedal It should have about 1 2 of travel before it engages the brakes 13 Lower the vehicle 14 Set the park brake 15 Reconnect the main p...

Page 37: ...MB 100 00 Section 3 Page 15 FRONT AXLE AND STEERING Front Axle ref LEFT SIDE SHOWN Spring Leaf Axle Spring Plate Right Front Axle Yoke Left Front Axle Yoke Tie Rod Axle Weld...

Page 38: ...Lower the vehicle 13 Reconnect the main positive and negative at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehicle 1 Make sure the key swi...

Page 39: ...fer to the illustration below 11 Tighten the ball joint clamp 12 Lower the vehicle 13 Reconnect the main positive and negative at the batteries 14 Remove the blocks from behind the wheels 15 Release t...

Page 40: ...three turns and secure it so it can not move 9 In order to align the wheels adjust the drag link 10 Lower the vehicle 11 Reconnect the main positive and negative at the batteries 12 Remove the blocks...

Page 41: ...negative at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Plac...

Page 42: ...E Make sure the clamps are in their original position noted above Turn the steering all the way from left to right to make sure there is no interference 14 Lower the vehicle 15 Reconnect the main posi...

Page 43: ...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...

Page 44: ...Pack inner and outer bearings with grease b While rotating the hub tighten the spindle nut to 30 ft lbs to seat the bearings c Back off spindle nut one flat until the hub turns but is not loose then...

Page 45: ...use lifting and support devices of rated load capacity may result in serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in t...

Page 46: ...eries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle Always use new locknuts Locknuts become less effective if used more than once Failure to replace...

Page 47: ...he batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Always use a lifting strap hoist and jack stands of adequate capacity to lift and support...

Page 48: ...procedure reinstall the steering gear 14 Lower the vehicle 15 Reconnect the main positive and negative at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test...

Page 49: ...sassembled Refer to illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B Whi...

Page 50: ...e the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Reassembly 1 Lightly lubricate all parts before reassembly 2...

Page 51: ...aring adjuster lock nut 12 Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using t...

Page 52: ...MB 100 00 Section 3 Page 30 Exploded View of Steering Gear...

Page 53: ...locks from behind the wheels 17 Release the park brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center...

Page 54: ...e housing 12 Dispose of the old oil in accordance with local regulations 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 posi...

Page 55: ...ing bore plug Differential Case Differential Bearing Drive Gear Bearing Cap Differential Case Assembly Bore Plug O Ring Snap Ring Intermediate Shaft Intermediate Shaft Bearing Intermediate Shaft Assem...

Page 56: ...r scoring Replace these parts as needed 28 Reinstall or replace all parts using this procedure in reverse order NOTE Be sure to pre lube all of the bearings with 30 weight motor oil 29 Fill the differ...

Page 57: ...2 Replace the fill plug 13 Lower the vehicle 14 Reconnect the main positive and negative at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehic...

Page 58: ...36 Differential Assembly Cover Plate Drive Gear Carrior Bearing Differential Bearing Cap Intermediate Shaft Assembly Snap Ring O ring Bore Plug Input Shaft Bearing Snap Ring O Ring Oil Level Plug Int...

Page 59: ...insure that they are returned to their proper location on the motor during reassembly 7 Remove the motor mounting bolts from the drive and slide the motor off of the input shaft 8 Install the new moto...

Page 60: ...lace 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...

Page 61: ...everse 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 8 Re...

Page 62: ...r until the torsion spring snaps out of position and pull the brush out of the holder 11 Install the new brushes into the brush holder NOTE Do not insert the brush all the way into the holder 12 Insta...

Page 63: ...5 inches 38 1 mm then all four brushes should be replaced Refer to Replacing the Brushes section for information regarding replacing the motor brushes 10 Reconnect the main positive and negative cable...

Page 64: ...de of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage Explosive mixtures of Hydrogen gas are present within battery cells at all times Do...

Page 65: ...tors and battery box with water 9 Reconnect the main positive and negative at the batteries 10 Remove the blocks from behind the wheels 11 Release the park brake and test drive the vehicle 1 Make sure...

Page 66: ...the battery Do not store a battery low in electrolyte or in a low state of charge Recharge a battery in accordance to the chart found in section 2 Storing and Returning to Service If possible store th...

Page 67: ...leshooting SYMPTOMS 2 READ THIS FIRST 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 3 SYMPTOM TROUBLESHOOTING GUIDE 19 PMC CONTROL 20 PLUGGING DIODE 22 FREEWHEEL DIODE 23...

Page 68: ...mal 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 hi...

Page 69: ...iple 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 troubleshoo...

Page 70: ...lerator pedal is depressed then go to the Forward Reverse Switch sequence After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the...

Page 71: ...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 The rear drive wheels may rotate during some o...

Page 72: ...k brake 4 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...

Page 73: ...all interlock switches turn the Key Switch ON and place the F 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 Accel...

Page 74: ...ositive 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 co...

Page 75: ...motor may not be in the same location S2 A1 A2 S1 Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Motor Set the test light voltage to the same voltage as the batter...

Page 76: ...on the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp...

Page 77: ...Representative for more information If you do not know how to test for continuity refer test to a qualified technician COLD Violet Wire s HOT Red wire s BATTERY MAIN NEGATIVE KEY SWITCH View of the t...

Page 78: ...at battery volts then go to the Accelerator sequence Connect a voltmeter across one of the COLD terminals of the KSI side of the F R switch and battery negative Close all interlock switches turn the K...

Page 79: ...ve 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 battery negative and the negative circuit breaker Stop trouble...

Page 80: ...ttery volts then the F 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 C...

Page 81: ...may vary Battery Negative FWD REV 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 f...

Page 82: ...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 reverse solenoid Refer to...

Page 83: ...When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery ne...

Page 84: ...e position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in forward Depress the accelerator pedal fully If the light comes on then the Forward so...

Page 85: ...eeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL Does not run in either direction plus there is noise from moto...

Page 86: ...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 Disconnec...

Page 87: ...drive wheels to the ground otherwise continue with the next test If the voltage at pin 2 is correct and the voltage at M is correct then there is a short in the harness between the wire connected to...

Page 88: ...ution 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...

Page 89: ...ant to review the trouble shooting steps that have led to this point The tests may need to be repeated B M A2 B 2 KSI _ The reading shown is for illustration only The actual reading may vary 1 Make su...

Page 90: ...re 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 s...

Page 91: ...repeated Reading is plus or minus 10 ISO solenoid is shown for reference only The type of solenoid in your truck may look different _ Connect the meter to each end of the resistor that was removed fro...

Page 92: ...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 Remove the...

Page 93: ...the wire connected 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 Whe...

Page 94: ...se solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S1 terminal Stop trouble shooting here and repair the problem When the repair is complet...

Page 95: ...ing 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 1 Make sure the key swit...

Page 96: ...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 Perf...

Page 97: ...Wire Diagrams...

Page 98: ...k SWITCH BSI _ Red Red Red White Black Green Black Red White Violet Black Violet Black Violet Black SWITCH KEY SWITCH SEAT Green M Yellow Blue A2 S2 Black White SPEED CONTROL KSI 2 B B Blue A 2 BATTER...

Page 99: ...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 Turn the Key switch OFF BEF...

Page 100: ...urrent state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200...

Page 101: ...efore connecting the charger The electrolyte 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 tu...

Page 102: ...than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC vo...

Page 103: ...r 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 Re Con...

Page 104: ...re continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers F...

Page 105: ...mer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that a...

Page 106: ...blem 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 Disconn...

Page 107: ...f 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 Test the AC voltage across the transformer secondary circuit The volta...

Page 108: ...here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the A...

Page 109: ...st Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting...

Page 110: ...ses 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...

Page 111: ...eter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery...

Page 112: ...od working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger exhibits...

Page 113: ...arger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Note If only the 100 LED is flashing and all others are OFF the...

Page 114: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charge...

Page 115: ...ing Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 Rev C Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the contro...

Page 116: ...here are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 vol...

Page 117: ...ge the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On t...

Page 118: ...ng off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but stil...

Page 119: ...charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the c...

Page 120: ...e reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the P...

Page 121: ...e and Brakes 14 Rear Suspension 16 Motor 18 Brake Accelerator Linkage 20 Wheels and Tires 22 Instrument Panel 24 Speed Control Panel 26 Miscellaneous Electrical 28 Lester Charger 30 Signet Charger 32...

Page 122: ...MB 100 00 SECTION 5 PAGE 2 Front Axle and Steering Knuckle 5 20 4 17 18 15 18 17 16 19 2 1 6 6 7 7 9 3 8...

Page 123: ...ke 1 4 88 527 11 Cotter pin 2 5 92 104 00 Bearing cap 2 6 32 240 55 King pin bushing 4 7 97 180 55 Thrust washer 4 8 21 020 15 King pin 2 9 88 189 81 Nut 2 10 11 12 13 14 15 12 124 00 Hub includes 16...

Page 124: ...MB 100 00 SECTION 5 PAGE 4 Steering Linkage 1 2 3 10 11 6 12 7 9 8 5 Steering Knuckle ref 13 14 7 9 13 14 13 14 15 12...

Page 125: ...nut 1 3 88 268 62 7 8 Split lock washer 1 4 5 01 110 21 Drag link 1 6 See Steering Column 3 7 86 501 98 Ball joint 2 8 86 510 00 Ball joint clamp 4 9 86 501 99 Ball joint 2 10 18 111 30 Pitman arm 1...

Page 126: ...00 SECTION 5 PAGE 6 Steering Column 1 2 5 6 3 4 7 The steering column is an integral part of the frame and is not shown Part ID 5 is located in the top of the steering column tube 9 8 Ref Steering Ge...

Page 127: ...heel 1 3 88 081 14 Bolt Plated grade 8 1 4 88 089 84 Nut Plated grade 8 1 5 80 400 10 Bushing 1 6 20 031 63 Steering shaft includes 3 4 1 7 19 011 35 Steering Wheel Cover 1 8 88 128 62 7 16 Split Lock...

Page 128: ...MB 100 00 SECTION 5 PAGE 8 Steering Gear 5 4 2 1 6 See steering linkage 7 10 15 17 3 11 12 13 14 16...

Page 129: ...Ball Nut Assembly 1 4 18 308 23 Upper Worm Shaft Bearing 1 5 18 308 22 Upper Worm Shaft Cup 1 6 18 308 77 Housing 1 7 18 308 78 Pinion Shaft Seal 1 8 9 10 18 308 79 Worm Shaft Seal 1 11 18 308 82 Gas...

Page 130: ...MB 100 00 SECTION 5 PAGE 10 Front Suspension Front Axle ref LEFT SIDE SHOWN 4 3 5 1 2 10 9 6 7 8 11...

Page 131: ...00 Spring eye bushing 2 4 96 243 10 9 16NF x 3 1 2 Hex bolt grade 5 2 5 88 169 82 9 16NF Hex nut grade C 2 6 96 123 00 3 8 NC x 2 06 x 4 U bolt 4 7 88 109 82 3 8NC Hex lock nut grade C 8 8 16 865 02...

Page 132: ...MB 100 00 SECTION 5 PAGE 12 Transmission Differential Case...

Page 133: ...6 Final gear bolt 4 7 Final gear nut 4 8 80 480 00 Carrior bearing 2 9 Intermeadiate shaft 1 10 80 715 00 O ring 2 11 66 610 35 Intermeadiate shaft bearing 2 12 Input shaft 1 13 80 480 10 Input shaft...

Page 134: ...MB 100 00 SECTION 5 PAGE 14 Rear Axle and Brakes...

Page 135: ...8 66 611 11 Retaining ring 2 29 66 611 12 Axle bearing 2 30 66 611 13 Snap ring 4 31 41 344 98 Brake assembly L 1 32 41 344 99 Brake assembly R 1 33 66 611 14 Wheel stud 10 35 41 126 96 Axle shaft L 1...

Page 136: ...MB 100 00 SECTION 5 PAGE 16 Rear Suspension 8 6 2 4 9 1 7 5 3...

Page 137: ...9 16NF x 3 Bolt 2 2 88 169 82 9 16NF Hex lock nut grade C 2 3 88 149 81 1 2NC Hex lock nut 4 4 96 120 00 1 2NC x 1 7 8 x 2 U bolt 2 5 88 149 81 1 2NC Hex lock nut 4 6 85 506 15 Leaf spring 2 7 01 110...

Page 138: ...MB 100 00 SECTION 5 PAGE 18 Motor 4 3 2 10 9 Armature 1 5 8 7 6 11...

Page 139: ...mounted in motor housing 1 2 70 210 51 Inulator 2 3 85 412 00 Brush spring 4 4 70 172 15 Brush holder includes 3 1 5 70 104 15 Motor brush 2 2 6 70 210 51 Insulator 2 7 32 508 15 Bearing retainer 1 8...

Page 140: ...00 SECTION 5 PAGE 20 Brake Accelerator Linkage 1 2 3 4 5 6 2 1 7 8 9 10 11 12 Frame ref Frame ref 13 8 14 15 1 16 17 18 Left rear axle ref 19 20 21 Accelerator Pedal 23 24 25 26 Floorboard Accelerator...

Page 141: ...1 11 98 200 00 Brake pedal pad 1 12 02 536 09 Brake pedal 1 13 88 847 08 5 8 E Ring 2 14 96 754 00 Clevis 2 15 96 826 09 Cable lock 2 16 96 773 00 5 16 x 1 Clevis pin 2 17 98 451 11 Foam tape 2 x 6 1...

Page 142: ...MB 100 00 SECTION 5 PAGE 22 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 143: ...ad 4 5 12 041 00 Wheel Assembly 2 5 bead width includes 3 4 6 7 8 4 3a 12 042 12 Inner Wheel 12 bolt 4 4a 12 042 13 Outer Wheel 12 bolt 4 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7...

Page 144: ...MB 100 00 SECTION 5 PAGE 24 Instrument Panel...

Page 145: ...Hour meter 1 3 71 100 00 Accessory switch 1 4 71 100 00 Accessory switch 1 5 71 039 02 Forward and reverse switch 1 6 71 120 10 Key switch 1 01 110 30 Mounting plate 1 94 386 03 Mounting plate decal...

Page 146: ...MB 100 00 SECTION 5 PAGE 26 Speed Control Panel 4 6 7 5 21 20 19 13 10 FWD REV ISO 8 8 1 2 11 12 14 15 16 Solenoid end view from side closest to PMC 9 17 17 18 End view of PMC 5...

Page 147: ...Horn 1 10 01 110 35 Mounting panel 1 11 97 211 20 14NC U nut 4 12 88 838 06 14 x 1 2 Pan head screw type D thread 2 13 88 817 09 8 x 3 4 Phillips head sheet metal screw 2 14 61 838 41 Buss bar 2 15 8...

Page 148: ...ctrical Horn Switch Mounted 5 7 6 Floorboard Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1a 1b Motion Alarms Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4 Mechanical Brake...

Page 149: ...00 Wire harness clip push mount 4 62 033 00 Accelerator module 1 5 71 122 20 Horn switch 1 6 88 065 06 1 4 NC x 21 2 Phillips truss headsScrew horn switch 2 7 88 069 81 1 4 NC Hex nylon locknut horn...

Page 150: ...MB 100 00 SECTION 5 PAGE 30 Lester Charger CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 151: ...831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25 8ET 79 851 10 79 805 72 79 902 00 79 749 11 S O 79 575 26 79 831 00 79 530 00 79 306 23 7710 32 79 305 20 36LC25 8ET 79 851 10 79 805 69 79...

Page 152: ...will void the charger warranty NOTE The Signet model HBS series charger replaces all previous Signet models Model HBS series charger shown Model HBS for GEL Batteries PART DESCRIPTION 24 volt Charger...

Page 153: ...00 00 SECTION 5 PAGE 33 NOTE The harness connectors and AC plug are not included with the charger QTY PART DESCRIPTION 2 75 318 20 Butt splice 2 75 320 51 Knife connector 1 76 200 00 AC plug 115v dome...

Page 154: ...MB 100 00 SECTION 5 PAGE 34 Batteries POS POS NEG NEG POS NEG POS NEG POS NEG POS NEG 1 5 2 Main Positive 12 v Negative Tap 4 3 6 7 Main Negative 8 Optional Low water level alarm...

Page 155: ...047 50 TD 250 Battery 0 or 6 2 77 047 00 T145 Battery 0 or 6 3 50 250 00 Bat Loc battery hold down 3 4 88 088 66 5 16 x 1 5OD Tin lead plated flat washer 3 5a 50 243 10 Battery rod 3 5b 88 069 81 1 4...

Page 156: ...MB 100 00 SECTION 5 PAGE 36 Seat Cushions Lights and Deck Model B 1 00 Model B 1 25 Tail light on rear panel 13 Headlight assembly...

Page 157: ...90 179 00 Seat back black 0 or 1 9 94 035 01 Trim strip 7 10a 90 179 10 Seat back tan 0 or 1 10b 90 179 00 Seat back black 0 or 1 11a 90 134 10 Bench seat Tan 0 or 1 11b 90 134 05 Bench seat black 0 o...

Page 158: ...MB 100 00 SECTION 5 PAGE 38 Decals Front Cowl Decals Left Rear Wheel Well...

Page 159: ...d legs inside 1 3 94 384 00 Apply park brake 1 4 94 373 10 Vehicle data plate 1 5 94 333 00 FM approved 1 6 94 309 00 Brake warning 1 7 94 384 14 Turn keu off 1 8 94 384 01 Not a motor vehicle 1 9 1 1...

Page 160: ...MB 100 00 SECTION 5 PAGE 40 Strobe Light 16 15 14 13 Mount for Strobe Light on Sun Top 12 11 10 9 8 7 6 5 4 3 2 1 17...

Page 161: ...1 5 91 028 67 Pole 1 6 88 065 13 1 1NC x 1 1 4 Phillips head truss screw 4 7 88 069 82 1 4NC NC lock nut 4 8 88 025 08 8 32 x 5 8 Machine screw 3 9 Included in 3 Gasket 10 88 028 62 8 Split lock wash...

Page 162: ...MB 100 00 SECTION 5 PAGE 42 Sun Top and Windshield Windshield mounting bracket 1 of 4 Top left shown...

Page 163: ...top 1 9 97 211 20 1 4NC U nut 8 10a 91 028 10 Rear support B 125 0 or 1 10b 91 028 73 Rear support B 100 0 or 1 11 88 080 11 5 16NC x 1 Hex bolt B 125 8 12 88 080 60 5 16 Cut flat washer B 125 8 13 88...

Page 164: ...MB 100 00 SECTION 5 PAGE 44 Mirrors 1 2 Windshield Frame ref 3 4 5 6 7 8 9 10 Front Cowl ref...

Page 165: ...el mirror 1 2 88 828 09 10 x 3 4 self drilling screw 4 3 92 201 00 Side mirror includes 7 6 2 4 88 069 61 1 4NC Nylon lock nut 4 5 92 202 00 Mirror bracket includes 8 and 9 2 6 Included with 3 7 Inclu...

Page 166: ...MB 100 00 SECTION 5 PAGE 46 B 125 Stake Sides B 100 Luggage Rack 5 6 7 8 1 2 3 4...

Page 167: ...shown 97 211 20 1 4NC U nut 2 Stake Sides ITEM PART DESCRIPTION QTY 1 90 547 08 Stake side right 1 2 90 547 10 Rear gate 1 3 90 547 06 Stake side left 1 4 88 065 13 1 4NC x 1 1 4 Truss head bolt 24 8...

Page 168: ...MB 100 00 SECTION 5 PAGE 48 Tool Box B 100 1 2...

Page 169: ...SECTION 5 PAGE 49 Tool Box B 1 00 ITEM PART DESCRIPTION QTY 1 71 040 95 Lock assembly 1 2 90 547 14 Tool box 1 Not shown 88 065 13 1 4NC x 1 1 4 Phillpips truss head screw 4 Not shown 97 211 20 1 4NC...

Page 170: ...e on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the charger NOTE The harness connectors are not included with the charger Whe...

Page 171: ...ed Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex Bolts 3 Other Bolts 3 Hex Nuts 4 Hex Lock Nuts stover 4 Other Nuts 4 Suggested Torque Values non critica...

Page 172: ...ntenance is completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with...

Page 173: ...Carriage Bolt grade 2 unless marked as above Other Bolts NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toq...

Page 174: ...as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no marki...

Page 175: ...2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 1...

Page 176: ...center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Dra...

Page 177: ...um cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause u...

Page 178: ...Model B 1 00...

Page 179: ......

Page 180: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com...

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