Taylor-Dunn B0-015-00 Operation, T Roubleshooting And Replacement Parts Manual Download

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Maintenance, Service, and Repair

Brakes
Page 16

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and

debris and will contain any brake fluid spills.

Remove the master cylinder from the vehicle. See

Replace the Master Cylinder

section .

Drain all fluid from the master cylinder and discard.

Remove the rubber boot.

Depress the plunger and remove the plunger spring clip retainer.

Pull the plunger and all seals out of the master cylinder bore.

Thoroughly clean, inspect and replace parts as required.

If any damage is found in the bore of the master cylinder then it must be replaced.

Lubricate all parts with clean brake fluid from a sealed container.

Reassemble in reverse order.

If the master cylinder is not to be immediately installed onto a vehicle, plug the brake line fitting hole to prevent any
contaminates from entering the master cylinder.

Summary of Contents for B0-015-00

Page 1: ...s i n e s s Serial number Starting 136914 MANUAL MB 150 02 Operation Troubleshooting and Replacement Parts Manual Published 11 26 2002 Revision C B0 015 00 MX 016 00 Models Inlcuded B0 015 00 B 1 50 L...

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 ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor...

Page 5: ...roubleshooting 12 Wire diagram 13 Chargers 14 Illustrated Parts 15 Appendix A Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Handling Precautions 18 Taylor Dunn Model B...

Page 6: ...TAYLOR DUNN...

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

Page 8: ...de Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules and Gui...

Page 9: ...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 fo...

Page 10: ...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 inform...

Page 11: ...reme care while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure to exer...

Page 12: ...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 The locations of the model and...

Page 13: ...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...

Page 14: ...Model B 1 00...

Page 15: ...ctrolyte Alarm Optional 8 Directional Signals Optional 8 Hazard Light Switch Optional 9 Accessory Switch Optional 9 Auxiliary Switch Optional 9 Vehicle Operational Guidelines 10 Driving 10 Loading and...

Page 16: ...lid State Speed Control 275 Amp Transmission Helical Gear Oil Bath Direct Drive Motor DC Series Wound 36 volt 6 hp 1200 RPM for 5 minutes 2 hp 2800 RPM for 60 min Maximum Recommended 19 3 kph 12 mph S...

Page 17: ...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 n...

Page 18: ...ty 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 Traini...

Page 19: ...Push the top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT SHIFT from forward to reverse or vice versa while the vehicle is in mot...

Page 20: ...p on the park brake handle push the release button and lower the handle Horn Switch The horn switch is located to the left of the steering column Depress the switch with your left foot to sound the ho...

Page 21: ...TE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger Battery Status Indicator Analog The battery status indicator is located to the lef...

Page 22: ...n the speed control panel or on the rear panel of the vehicle The reverse alarm is activated when the Key switch is in the ON position and the Forward Reverse switch is in the reverse position The ala...

Page 23: ...of switch 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 w...

Page 24: ...s Parking Before leaving the vehicle Set the parking brake Set the forward reverse switch to the center OFF position Turn the key switch to the OFF position and remove the key In addition If parking t...

Page 25: ...rn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Once the charge cycle is complete the charger will continue to monitor...

Page 26: ...ycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries New Battery Break in New batteries require a break in period of up to 40...

Page 27: ...osed 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 perio...

Page 28: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 14 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Page 29: ...ch Charger interlock switch etc Inspect for leaking fluids or grease MAINTENANCE GUIDELINES FOR SEVERE DUTY APPLICATIONS 1 This maintenance checklist is based on the average application If the vehicle...

Page 30: ...TAYLOR DUNN...

Page 31: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Maintenance Guidelines for Vehicles Used in Severe Conditions 3 Troubleshooting Guide 4 Lubrication Chart 5...

Page 32: ...s 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...

Page 33: ...ition the entire vehicle should be inspected monthly for signs of damage If any damage is found the vehicle should be immediately removed from service and repaired The following list is meant as a gui...

Page 34: ...peration Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts...

Page 35: ...bricant Type 1 Front Leaf Springs General Purpose Grease 2 King Pin General Purpose Grease 3 Ball Joints General Purpose Grease 5 Front Wheel Bearings High Temperature Wheel Bearing Grease 6 Rear Leaf...

Page 36: ...TAYLOR DUNN...

Page 37: ...moval and Installation 4 Removal 4 Installation 5 Front Axle Disassembly and Assembly 6 Replace Front Wheel Bearings 7 Replace the Ball Joints Tie Rods and Drag Link 8 Replacing the Drag Link 10 Repla...

Page 38: ...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 Bearings section for information regarding the replacemen...

Page 39: ...wheel bearings 11 Install a new cotter pin 12 Install the dust cap 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels...

Page 40: ...with jack stands 7 Remove both front wheels Refer to Tires and Wheels section for information regarding removing the front wheels 8 Tie up or support the front axle so it can not fall out of the vehi...

Page 41: ...e vehicle and support with jack stands 7 Install the front axle in reverse order of removal NOTE Use all new cotter pins NOTE Refer to the Replacing the Ball Joints section for information regarding t...

Page 42: ...arding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Refer to Front Axle Remova...

Page 43: ...ub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 8 Remove the hub dust cap cotter pin and spindle nut 9 Remove the hub from the steering knuckle NOTE Fo...

Page 44: ...where it is installed on the steering arm or pitman arm The second cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your vehicle it may...

Page 45: ...ove the rod end nut 9 Remove the rod end from the steering arm HINT Count the number of turns required to remove the rod end from the steering sleeve This will make it easier to realign the wheels 10...

Page 46: ...nt from the steering sleeve HINT Count the number of turns required to remove the ball joint from the sleeve This will make it easier to realign the wheels 11 Install the new ball joint into the steer...

Page 47: ...injury 7 Remove the ball joints or rod ends from the steering knuckle and pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or ro...

Page 48: ...ings in the axle beam Bronze bushings in the steering knuckle Metal backed teflon bushings in the axle beam Refer to the illustration below for the type of bushing in your vehicle 7 Remove the ball jo...

Page 49: ...causing severe bodily injury and or property damage 6 Raise the front of the vehicle and support with jack stands 7 Remove the steering knuckle Refer to Replace the Steering Knuckle for information re...

Page 50: ...hub bearing cap cotter pin and nut then remove the hub from the steering knuckle NOTE For a front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section f...

Page 51: ...in the illustration below NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign the wheels NOTE Refer to the S...

Page 52: ...TAYLOR DUNN...

Page 53: ...ring gear Saginaw 5 Replace the Steering Shaft Saginaw non tilt steering 7 Replace the Steering Wheel Saginaw non tilt steering 9 Replace the Steering Gear Saginaw 10 Repair the Steering Gear 11 Explo...

Page 54: ...d then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regardi...

Page 55: ...clamps or the rod end jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a...

Page 56: ...oint clamps 10 Lower the front wheels to the ground and push the vehicle back and forth a few feet to settle the suspension 1 Make sure the key switch is in the OFF position then remove the key 2 Plac...

Page 57: ...ring Gear for information regarding removing the steering gear 6 Raise the front of the vehicle and support with jack stands Rotate the steering wheel from a full left turn to a full right turn and ma...

Page 58: ...r jam nut 12 Find the center position of the steering shaft A Turn the steering shaft all of the way in one direction B While counting the rotations turn the steering shaft all of the way in the oppos...

Page 59: ...e 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 10 Remove and discard the pinch bolt and nut from the steering s...

Page 60: ...re to replace the pinch bolt and nut may result in failure of the steering causing loss of control of the vehicle This could lead to property damage and or severe bodily injury 14 Tighten the pinch bo...

Page 61: ...eering wheel orientated as shown in the illustration to the right 11 Tighten the steering wheel nut to 50 60 ft lbs 12 Reinstall the horn switch if equipped 13 Reconnect the main positive and negative...

Page 62: ...ut of 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 OFF position 3 Set the park brake 4 Place blocks under the rear...

Page 63: ...fer to the 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 While counti...

Page 64: ...10 Remove 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 reass...

Page 65: ...he worm bearing 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 housi...

Page 66: ...Maintenance Service and Repair Steering Page 14 Exploded View of Steering Gear...

Page 67: ...kes 4 Adjust the Mechanical Brake Linkages 5 Adjust the Parking Brake 6 Wheel Park Brake mechanical drum standard 6 Wheel Park Brake hydraulic drum 6 Check Master Cylinder Fluid 7 Bleed the Brake Syst...

Page 68: ...for information on removing the wheel 1 Measure the run out of the rotor at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its servi...

Page 69: ...ommended handling precautions Do not use a brake drum that is worn beyond its service limits A drum worn beyond its service limits could fail and cause loss of brakes resulting in severe bodily injury...

Page 70: ...nside of the left and right brake Do not adjust the brake by means of the brake cables as this will cause mis operation of the brakes If you hear a single clunking noise while braking it may be due to...

Page 71: ...s set 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Loosen the clevis jam nuts on the...

Page 72: ...ts on the connecting rod and park brake linkage 12 Set the park brake 13 Reconnect the main positive and negative cables at the batteries 14 Remove blocks from behind the wheels 15 Release the park br...

Page 73: ...3 brake fluid is corrosive and will damage paint finishes Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Do no...

Page 74: ...in the master cylinder to drop too low as this will allow air into the brake lines 9 Attach a clear hose to the bleeder valve on the brake cylinder that is to be bled Route the hose into a clear conta...

Page 75: ...rakes are optional 6 Raise the rear wheels off of the ground and support with jack stands 7 If equipped with front brakes raise the front wheels off of the ground and support with jack stands 8 Releas...

Page 76: ...wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly NOTE Refer to the illustration above for the following steps 10 Remove the brake body bolts 10...

Page 77: ...ands 8 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the wheel 9 Remove and inspect the brake drum Refer to Inspect the Service Brake section for informa...

Page 78: ...reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables...

Page 79: ...brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake fluid spills Any debris or contaminates left in the brake system could lead...

Page 80: ...ging off of the end of the piston 14 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake b...

Page 81: ...sh or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately NOTE Mos...

Page 82: ...scard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts a...

Page 83: ...tors 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 Se...

Page 84: ...Disconnect the main positive and negative cables at the batteries Typical motor with cooling fan indicated by the arrow Typical brush and brush holder Motors with internal cooling fans NOTE There are...

Page 85: ...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 s...

Page 86: ...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 R...

Page 87: ...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...

Page 88: ...Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Do not press against the outer race of the bearing Pressing against the outer race will...

Page 89: ...Depth max mm inches mm inches mm inches mm inches 5BC58JBS6129A 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129B 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129C 0 635 0 025 66 75 2...

Page 90: ...TAYLOR DUNN...

Page 91: ...il Level 2 Change Oil 3 Motor 4 Removal 4 Installation 4 Rear Hub with Brake Drum 5 Rear Axle 6 Replace the Axle Bearing 8 Transmission 9 Remove 9 Install 9 Differential Case 10 Disassemble 10 Assembl...

Page 92: ...the main positive and negative cables at the batteries 10 Remove blocks from behind the wheels 11 Test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place...

Page 93: ...Maintenance Service and Repair Transmission Page 3 CHANGE OIL Changing the transmission oil requires removal of the transmission cover Refer to transmission disassembly later in this section...

Page 94: ...tor HINT Tag each wire with the number of the terminal it was removed from 7 Remove the bolts holding the motor to the transmission housing see illustration 8 Slide the motor off of the transmission i...

Page 95: ...se on the axle splines could contaminate the braking surfaces resulting in loss of braking power This could lead to severe bodily injury and or property damage 6 Remove the rear wheel Refer to Replace...

Page 96: ...r Tire Wheel section for information regarding removing the rear wheel 7 Remove the axle hub Refer to Rear Hub Brake Drum section for information on removing the hub 8 Remove the outer snap ring from...

Page 97: ...assembly HINT Use a slide hammer threaded onto one of the wheel studs 12 If the axle bearing is to be replaced remove the bearing race from inside of the axle housing 13 Remove the axle seal from the...

Page 98: ...the bearing with grease and wrap it in plastic to prevent corrosion Non Removable Hub 1 Drill a 1 4 hole to a depth of approximately 3 4 the thickness of the retaining ring 2 Use a chisel to split the...

Page 99: ...nt wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the...

Page 100: ...tion for information on removing the axles 4 Suspend the differential case over a drain pan that can hold a minimum of 2 quarts of oil 5 Remove the differential case cover being careful not to bend or...

Page 101: ...ate shaft bore plugs 10 Thread a sheet metal screw into each plug until the bore plug is forced out 11 Remove both snap rings from the intermediate shaft bore 12 Using a soft metal or hard wood dowel...

Page 102: ...nd remove the intermediate shaft from the housing 15 Remove the o rings from each end of the intermediate shaft 16 Remove the circlip from the input shaft 17 Remove the input shaft from the housing 18...

Page 103: ...t tightly into their grooves If a snap ring is loose then it must be replaced NOTE All internal components should fit easily together Do not hit any shaft or component with a hard metal hammer or punc...

Page 104: ...ferential housing Torque the nuts to 35 45 ft lbs 11 Install the differential assembly into the drive housing and install the bearing caps Torque the bolts to 35 45 ft lbs NOTE The bearing caps are ma...

Page 105: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Leaf 2 Replace the Front Springs 4 Leaf 4 Replace the Spring Bushings 6 Replace the Shocks 7 Front 7...

Page 106: ...F 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 Always use a lifting strap hoist a...

Page 107: ...using severe bodily injury or property damage 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the sprin...

Page 108: ...F position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist an...

Page 109: ...or damage is found then they must be replaced 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the sprin...

Page 110: ...OTE Refer to Replace the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles fra...

Page 111: ...ome vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts Refer toTires and Wheels section for information regarding removing the front wheels 6 Some vehicle...

Page 112: ...akage If any sign of leakage is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the...

Page 113: ...TABLE OF CONTENTS Cleaning 2 Testing 3 Watering 5 Charging 6 Replacing 7 Moist Charge Batteries 9 Storage and Returning to Service 10 Returning to Service 11 Battery Service...

Page 114: ...rinse thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive Explosive mixtures of Hydrogen gas ar...

Page 115: ...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 Explosive mixtures o...

Page 116: ...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 c...

Page 117: ...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...

Page 118: ...add additional battery electrolyte to the batteries 8 Reconnect the batteries remove the blocks from the wheels and test drive CHARGING Refer to Charging Your Vehicle in section Safety Rules and Oper...

Page 119: ...batteries 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...

Page 120: ...mpartment 14 Inspect the main positive and negative cables and terminals charger cables and terminals and 12 volt tap wiring If any of the terminals or wires show signs of corrosion then they must be...

Page 121: ...er that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries Explosive mixtures of Hydrogen gas are present within battery ce...

Page 122: ...crete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries Storage Temperature F Charging Interval months Over 60 1 Between 40 and 60 2 Bel...

Page 123: ...ge 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 ba...

Page 124: ...TAYLOR DUNN...

Page 125: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Repair the Tire 4 Replace the Tire 5 Tires and Wheels...

Page 126: ...tions 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...

Page 127: ...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 REPLACE TIRE WHEEL 6 Rais...

Page 128: ...unique to the type of repair equipment or repair components used Refer to the instructions provided with your equipment or repair components 1 2 3 4 5 3 4 2 1 4 Bolt Pattern 5 Bolt Pattern Pattern fo...

Page 129: ...wheel 2 Cut the old valve stem off of the wheel 3 Remove the valve stem cap from the new valve stem 4 Lubricate the valve stem with liquid soap 5 Install a new valve stem using a valve stem tool NOTE...

Page 130: ...TAYLOR DUNN...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...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 154: ...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 155: ...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 156: ...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 157: ...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 158: ...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 159: ...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 160: ...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 161: ...Wire Diagrams...

Page 162: ...ge Black Black Black White Red Brown Orange Main Battery Positive Main Battery Negative 12v negative tap Green Black Red White CB 10A R F I Reverse solenoid or contactor coil Forward solenoid or conta...

Page 163: ...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 164: ...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 165: ...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 166: ...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 167: ...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 168: ...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 169: ...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 170: ...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 171: ...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 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...s and Tires 22 Instrument Panel dash 24 Speed Control Panel 26 Miscellaneous Electrical 28 Charger Lestronic 30 Charger Signet 32 Batteries 34 Seat Cushions Deck and Lights B 1 50 36 Seat Cushions Dec...

Page 186: ...Illustrated Parts PARTS PAGE 2 Front Axle Steering Knuckle 19 1 18 14 13 16 15 11 10 12 10 17 9 12 Small Cup Large Cup Bronze washer Steel Washer Steel Washer 8 20 2 4 3 7...

Page 187: ...Beam Includes 19 and 20 disc brakes 1 4 14 240 05 Right Steer Knuckle no brake 1 14 240 03 Right Steer Knuckle disc brake 1 5 6 7 87 074 00 Grease Fitting 2 8 80 309 10 Thrust Bearing 2 9 45 338 00 Gr...

Page 188: ...Illustrated Parts PARTS PAGE 4 Steering Linkage 10 3 9 3 8 Ref Arm on Right Steering knuckle Ref Arm on Left Steering knuckle 6 15 7 Ref Stering Gear 7 15 11 17 5 16 12 14 6 13 1...

Page 189: ...1 2 NF Hex Castle Nut 2 8 86 501 98 Ball Joint left thread 1 9 18 041 05 Tie Rod Sleeve 18 057 20 assembled with ball jointsand clamps 1 10 86 501 99 Ball Joint right thread 1 11 86 518 00 Rod End RH...

Page 190: ...ted Parts PARTS 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...

Page 191: ...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 64 Steering shaft includes 3 4 1 7 19 011 25 Steering Wheel Cover 1 8 88 128 62 7 16 Split Lock...

Page 192: ...Illustrated Parts PARTS PAGE 8 Steering Gear 5 4 2 1 6 See steering linkage 7 10 15 17 3 11 12 13 14 16...

Page 193: ...ft 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 G...

Page 194: ...Illustrated Parts PARTS PAGE 10 Front Suspension 4 3 2 1 5 10 6 8 9 7 11 12...

Page 195: ...1 2 3 32 213 00 Spring Eye Bushing 2 4 88 169 82 9 16 NF Lock nut Grade C 2 5 85 506 05 Leaf Spring includes 3 2 6 96 118 00 1 2 NC x 1 87 x 6 5L U bolt 2 7 96 123 00 3 8 NC x 2 06 x 4L U bolt 4 8 88...

Page 196: ...Illustrated Parts PARTS PAGE 12 Transmission Differential Case 1 2 3 4 5 6 7 6 5 8 3 9 3 9 8 5 6 7 15 10 16 10 3 14 11 11 17 12 13...

Page 197: ...aft Bearing 1 3 31 265 00 Gear set 1 4 80 480 15 Outer Input Shaft Bearing 1 5 88 840 12 Snap Ring 3 6 Special order O ring 3 7 Special order Bore Plug 2 8 66 610 35 Intermeadiate Shaft Bearing 2 9 80...

Page 198: ...Illustrated Parts PARTS PAGE 14 Rear Axle and Brakes Ref Transmission housing 2 3 4 1 5 7 10 6 11 15 9 12 8 13 14 16 18 19 17...

Page 199: ...6 45 303 10 Dust seal 2 7 41 347 25 Spider Mechanical Brake 2 41 347 27 Spider Hydraulic Brake 2 8a 41 171 10 Axle shaft right does not include 17 wheel stud 1 8b 41 170 10 Axle Shaft Left does not in...

Page 200: ...Illustrated Parts PARTS PAGE 16 Rear Suspension 5 7 8 3 4 Ref Frame 2 6 4 1 Ref Transmission axle tube...

Page 201: ...Suspension ITEM PART DESCRIPTION QTY 1 88 140 17 Bolt 4 2 85 506 10 Leaf Spring includes 7 2 3 96 118 00 U bolt 2 4 88 149 81 Nut 8 5 96 248 01 Spring Bolt 2 6 01 200 62 Spring Support 2 7 32 213 00 S...

Page 202: ...Illustrated Parts PARTS PAGE 18 Motor 2 3 5 6 4 7 8 1 9 10 Armature 9...

Page 203: ...l Stator Assembly 1 2 70 210 51 Insulator 2 3 85 412 00 Brush Spring 4 4 70 172 15 Brush Holder includes 3 1 5 70 104 15 Brush Pair 2 6 70 210 51 Insulator 2 7 32 508 15 Bearing Retainer 1 8 80 209 00...

Page 204: ...kage 1 2 3 4 5 6 7 8 7 19 10 11 12 10 19 7 8 19 10 13 8 6 6 6 7 14 22 Transmission Ref frame 29 18 17 18 19 29 19 20 19 10 10 19 Ref frame 21 22 23 24 10 Crosshaft Arm A To Crosshaft arm A 14 18 29 19...

Page 205: ...pring 1 13 00 200 49 Brake Cross Shaft 1 14 00 200 48 Park Brake Linkage 1 15 88 065 09 1 4 NC x 3 4 Truss Head Machine Screw 3 16 17 50 002 01 Brake Rod 1 18 88 099 80 Nut 2 19 96 773 00 5 16 x 1 Cle...

Page 206: ...Illustrated Parts PARTS PAGE 22 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9...

Page 207: ...5 bead 4 4 12 041 13 Outer Wheel 2 5 bead 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 Ass...

Page 208: ...Illustrated Parts PARTS PAGE 24 Instrument Panel dash...

Page 209: ...r Meter 1 5 01 200 75 Dash Housing 1 6 74 009 00 Battery Status Meter 1 7 94 304 10 Dash Plate 1 8 71 039 02 F R Switch 1 9 71 120 00 Key Switch keyed alike standard 1 9a 71 121 00 Key Switch keyed un...

Page 210: ...Illustrated Parts PARTS PAGE 26 Speed Control Panel 3 4 5 6 2 7 8 9 10 1 1 11 12 14 18 17 16 1 13 15 Typical Control Panel The control panel in your vehicle may be layed out differently 20...

Page 211: ...10 32 Hex Nut 3 9 61 838 42 Bus Bar 2 10 72 501 38 ISO Solenoid 1 11 79 840 00 Small Circuit Breaker 2 12 79 844 00 Large Circuit Breaker 1 13 88 080 11 5 16 NC x 1 Hex Bolt 4 14 01 534 80 Mounting P...

Page 212: ...Electrical Horn Switch Mounted 5 7 6 Floorboard Mechanical Brake Light Switch Mounted Under Floorboard 8 9 Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1 2 Motion Alarms Miscell...

Page 213: ...p 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 Head Screw Horn Switch 2 7 88 069 81 1 4 NC Hex Nylon Locknut Horn Switch 2 8 71 111 00...

Page 214: ...Illustrated Parts PARTS PAGE 30 Charger Lestronic 1 2 3 4 8 7 5 6 11 BI_CHARGER W INTERLOCK DWG Charger Identification...

Page 215: ...eleif 7 79 831 00 Fuse 1 8 79 530 00 Strain Releif 1 9 10 11 79 809 60 Interlock Relay 1 See Seat Cushions Deck and Lights Charger Lester Model 11860 225 export ITEM PART DESCRIPTION QTY 79 304 65 Com...

Page 216: ...intergral part of the charger When replacing the charger do not cut and splice the AC cord Cutting the AC cord will void the charger warranty NOTE The Signet model HBS series charger replaces all prev...

Page 217: ...Illustrated Parts PARTS PAGE 33 This page intentionaly left blank...

Page 218: ...Illustrated Parts PARTS PAGE 34 Batteries 9 6 and 7 hardware 5 4 3 2 1 Main battery negative NEG POS NEG NEG POS POS 12v tap Main battery positive NEG NEG POS POS NEG POS...

Page 219: ...t 12 8 9 77 042 00 T 105 217AH Battery standard 6 77 042 50 TD217 217AH Battery 77 042 80 217AH Moist Charge 77 044 00 T 125 230AH Battery 77 047 00 T 145 244AH Battery 77 047 50 TD 250 250AH Battery...

Page 220: ...Illustrated Parts PARTS PAGE 36 Seat Cushions Deck and Lights B 1 50...

Page 221: ...ckrest Mounting Screws 6 6 90 444 50 Deck Board standard 1 6 Deck Board Cab 1 7 94 035 01 Seat Back Moulding 7 8 79 575 30 Charger AC Cord 1 8a 79 511 00 Mounting Bracket 1 8b 88 065 06 Mounting Brack...

Page 222: ...Illustrated Parts PARTS PAGE 38 Seat Cushions Deck and Lights MX 1600...

Page 223: ...eat Back Moulding 7 8 See B 1 50 Charger AC Cord 1 8a See B 1 50 Mounting Bracket 1 8b See B 1 50 Mounting Bracket Screws 2 8c See B 1 50 Mounting Brackt Nuts 2 8e See B 1 50 AC Cord Strain Releif 1 8...

Page 224: ...Illustrated Parts PARTS PAGE 40 Decals B 1 50 VIEW FROM INSIDE OF COWL 1 2 3 4 5 6 7 8 9...

Page 225: ...3 00 FM 1 2 94 313 20 Safety Warning 1 3 94 384 01 Not a Motor Vehicle 1 4 94 309 00 Park Brake 1 5 94 384 14 Leaving Vehicle 1 6 94 373 10 Vinyl Data Plate 1 94 373 70 Metal Data Plate 1 7 94 301 42...

Page 226: ...Illustrated Parts PARTS PAGE 42 Fiberglass Cab Doors Mirrors 1 2 4 3 5 6 7 8 9 10 11 12 13 17 18 19 20 21 23a 24 25 23b 16 15 14 26...

Page 227: ...over left 1 11b 90 923 10 Door Frame left 1 11c 90 924 97 Door Cover right 1 11d 90 923 20 Door Frame right 1 12 01 200 73 Front Bumper 1 13 88 102 17 Bolt 1 14 16 206 00 Spacer 1 15 88 108 62 Split L...

Page 228: ...ated Parts PARTS PAGE 44 Strobe Light Strobe mounted on fiberglass cab Strobe mounted on pole Apply silicon sealer around each mounting screw to prevent leakage 2 3 4 4 2 1 3 5 6 7 7 8 9 10 11 12 1 Se...

Page 229: ...1c 72 023 22 Replacement lens amber 1 1d 72 023 24 Replacement Lens red 1 2 88 029 80 Nut 3 3 88 028 62 Flat Washer 3 4 88 025 08 Screw 4 5 88 048 61 Washer 3 6 72 023 41 Mounting Pole 1 7 98 603 00...

Page 230: ...Illustrated Parts PARTS PAGE 46 Stake Sides B 1 50 1 2 3 4 5 6 7 8...

Page 231: ...take Sides B 1 50 ITEM PART DESCRIPTION QTY 1 90 542 20 Side Gate 1 2 90 542 22 End Gate 1 3 90 542 20 Side Gate 1 4 90 540 00 Gate Hook 6 5 90 540 00 Gate Hook 6 6 88 065 13 Bolt 44 7 88 069 81 Nut 4...

Page 232: ...00 COPPER GASKET 0 813OD 0 500ID 99 572 00 COPPER GASKET 0 813OD 0 594ID 99 575 00 BRAKE LINE COUPLER 99 576 00 BRAKE LINE CLIP 99 579 00 BOLT MASTER CYLINDER 99 603 50 BRAKE LINE LEFT AND RIGHT REAR...

Page 233: ...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 234: ...nd program the 62 215 00 PMC speed control used on early model C4 25 Huskey 62 027 10 PMT C Meter Reset Module Used to reset the PMT C maintenance meter after a maintenance is completed 96 500 43 Disc...

Page 235: ...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 236: ...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 237: ...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 238: ...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 239: ...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 240: ...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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Taylor-Dunn B0-015-00, Operation, T Roubleshooting And Replacement Parts Manual

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