Taylor-Dunn C0-014-32 Operation, T Roubleshooting And Replacement Parts Manual Download | Manualshive

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TAYLOR-DUNN SERVICE CENTER

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Summary of Contents for C0-014-32

Page 1: ...The Best Way To Go About Your B u s i n e s s Serial Number Starting 151285 MANUAL MC 432 05 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded C0 014 32 C0 014 33 Revision C ...

Page 2: ......

Page 3: ...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 4: ...unn 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 21...

Page 5: ...II Charger Troubleshooting 13 Signet Charger Troubleshooting 14 Wire diagram 15 Illustrated Parts 16 Appendix A Special Tools 17 Appendix B Suggested Torque Values 18 Appendix C Brake Lining Handling Precautions 19 Taylor Dunn Mule Model C0 014 32 and C0 014 33 Operator and Service Manual Section Index This quick reference section index guide will assist you in locating a desired topic or procedur...

Page 6: ...B2 48 With Stake Side Dump Bed Option SC1 00 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor ...

Page 7: ...t 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 R 3 80 shown with extended steel cab and doors options ...

Page 8: ...applicable 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 Taylor Dunn vehicle is responsible for the overall maintenance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance perform...

Page 9: ...ventions 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 about a subject Model B 2 48 equipped with the Dump Bed option Model R 3 80 shown equiped with a cargo box and steel cab with doors options A shaded box with and the word Warning and the symbol above ...

Page 10: ...ed below This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 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...

Page 11: ...r 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 What To Do If a Problem is Found If there is a problem or damage as a result of shipping note the damage...

Page 12: ...TAYLOR DUNN ...

Page 13: ...Switch Optional 5 ElectrolyteAlarm Optional 5 Charger Interlock 6 Park Brake 6 Steering 6 Foot Brake Pedal 6 Accelerator Pedal 6 Vehicle Operational Guidelines 7 Safety Guidelines 7 Starting 7 While driving 7 Loading and Unloading 7 Parking 7 Towing 7 Charging your vehicle 8 New Battery Break in 8 Signet Charger Operation 8 Lestronic II Charger Operation 8 Charging Time 9 Storing and Returning to ...

Page 14: ... 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 Rever...

Page 15: ...ch 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 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 t...

Page 16: ...ehicle 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 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...

Page 17: ...nal 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 haz...

Page 18: ...he amount of pressure applied Relieving pressure from the pedal releases the braking action 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 an...

Page 19: ... brake 7 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 f...

Page 20: ...an 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 75 ON Blinking OFF 75 to 100 ON ON Blinking Cycle complete ON ON ON Typical Signet Built In Signet Charger Operation Model HBS series The Signet HBS series chargers are fully automatic The charger w...

Page 21: ...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 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 all...

Page 22: ...sh 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 Clean and Repack Front Wheel Bearings l Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Repairs or maintenance by improperly trained or unauthori...

Page 23: ... 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 Daily Visual inspection Tire condition and pressure External frame damage body Operation...

Page 24: ...TAYLOR DUNN ...

Page 25: ...Table of Contents Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor ...

Page 26: ...for cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle 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 ...

Page 27: ...rn 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 Motor Bearings Worn Oil Leak in Rear Bearing Area Rear Wheel Bearing and or Gasket Failed Drive Over Filled Brake Pedal Soft or Spongy Air in Brake Lines Brake Pedal Low Brake Worn 1 16 Wear Limit Brake Fluid Low Brakes Out of Adjustment Braking...

Page 28: ...ubricant Type 1 Steering Chain 2 Chain Lube 2 Front Axle Bearings 1 General Purpose Grease 3 Fork Bearings 1 General Purpose Grease 4 5 6 7 Drive Drain Plug 2 8 Drive Level Plug 2 SAE 140 API GL 5 Gear Oil 9 Drive Fill Plug 1 Above Front Fork 8 7 7 9 9 Rear Axle Assembly side view ...

Page 29: ...TABLE OF CONTENTS Inspect Adjust Front Wheel Bearings 2 Replace Front Wheel Bearings 2 Front Axle Removal and Installation 3 Removal 3 Installation 3 ...

Page 30: ...equate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury REPLACE FRONT WHEEL BEARINGS 6 Remove the front axle and wheel Refer to Front Axle Removal and Installation section for information regarding removing the axle 7 Remove the spacers seals and bearings from the hub 8 Thoroughly clean all grease from the...

Page 31: ...ks from behind the wheels 8 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 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 Always use a lifting strap hoist an...

Page 32: ...TAYLOR DUNN ...

Page 33: ...TABLE OF CONTENTS Front End Alignment 2 Replace the Front Fork 3 Adjust Steering Chains 4 ...

Page 34: ... 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 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 bl...

Page 35: ... movement 5 Disconnect the main positive and negative cables at the batteries 10 While supporting the front fork so that it cannot fall out of the vehicle remove the fork spindle nut and remove the fork from the vehicle 11 Thoroughly clean all parts and install in reverse order Tighten the fork spindle nut to remove all play in the fork bearings and then an additional 1 4 turn Refer to section Fro...

Page 36: ...ower chains 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 Turnbuckle on Lower Steering Upper Steering Chain 1 Make sure the...

Page 37: ...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 Brake 4 Replace the Brake Drum 6 ...

Page 38: ...ce 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 I...

Page 39: ...e 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...

Page 40: ...he 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 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 ...

Page 41: ...rm is 1 4 away from the chain case when the parking brake is off 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 bat...

Page 42: ...ten the jam nuts 14 Adj ustt hepar kbr ake Ref ert oAdjust 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 1 Make sure the key switch is in the OFF position then remove the key 2 Place th...

Page 43: ...otors 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 Typical Exploded Motor ...

Page 44: ... 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 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 ...

Page 45: ... 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 2 Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in section Service Limits then the ...

Page 46: ... 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 hand If the bearing freewheels then grease is no longer present in the bearing...

Page 47: ... 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 taking the motor apart 3 Install the new brushes in reverse order 4 Be certain that the...

Page 48: ... 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 damage the bearing and may result in premature failure of the bearing See the illustration below Example of freshly cut commutator Properly undercut and cleaned commutator segments 6 Measure the com...

Page 49: ...5 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 2 625 19 05 0 75 38 1 1 5 5BC49JB399C 0 635 0 025 78 97 3 109 19 05 0 75 5BC58JBS6110C 0 635 0 025 78 97 3 109 19 05 0 75 38 1 1 5 5BT1326B262A 0 635 0 025 78 97 3 109 19 05 0 75 5BT1326B96 0 635 0 025 96 8 3 810 19 05 0 75 5BT1344B185 0 635 0 025 104 8 4 125 20 3 0 80 ...

Page 50: ...TAYLOR DUNN ...

Page 51: ...nge the Oil 3 Drive Motor 4 Remove 4 Install 4 Rear Axle 5 Remove and Install 5 Replace theAxle Bearing 5 Transmission Assembly 6 Remove and Install 6 Chain Case 7 Disassemble 7 Assemble 7 Differential Assembly 3rd Member 9 Disassemble 9 Assemble 10 Re shimming the Pinion Housing 12 Exploded View 13 ...

Page 52: ...vement 5 Disconnect the main positive and negative cables at the batteries 10 Tie the vehicle in place so that it cannot move 11 Reconnect the batteries 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...

Page 53: ... 6 Park the vehicle on a level surface 7 Place a small oil drain pan under the drive housing 8 Remove the drive housing level plug 9 A small amount of oil should come out This indicates the correct oil level 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 ...

Page 54: ...mounting plate goes into the threaded studs and remove wire s holding the chain 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 Make sure the key switch is in the OFF position then remove the key 2 Place the f...

Page 55: ...se 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 REAR AXLE Remove and Install 6 Raise the drive wheel off of the ground 7 Remove the wheel assembly 8 Place a small oil drain pan under the end of the axle housing 9 Remove the four axle retaining bolts Secure the brake b...

Page 56: ... 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 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 ...

Page 57: ... plug and allow all of the oil to drain from the housing and then reinstall the drain plug 8 Remove the brake drum Refer to section Brakes Replace the Brake Drum for information regarding removing the brake drum 9 Remove the nuts from the three threaded studs at the small end of the chain case housing 10 Remove the chain case housing bolts brake assembly and alignment brackets 11 Remove the chain ...

Page 58: ...and the housing bolts that are not used for the brake mounting bracket or alignment brackets 10 Remove the centering tool and install a new pinion seal Lightly lubricate the pinion seal lip 11 Install the brake assembly and the brake band alignment bracket s Do not tighten the bolts at this time 12 Install the brake drum Torque to 175 ft lbs 13 Tighten the brake adjusting bolt to 25 ft lbs 14 Tigh...

Page 59: ...nion 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 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 shaft ...

Page 60: ... the pinion gear into the 3rd member 4 Install the pinion housing onto the 3rd member 5 Install the pinion bearing spacers shims and front 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 ...

Page 61: ...tion 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 18 Loosen the right side nut 19 Tighten the left nut until all backlash is removed from the ring and pinion gear 20 Tighten the right nut until a case spread of 0 010 is indicated on the dial indicator NOTE If new ring and pinion gears are used refer to the reco...

Page 62: ...f 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 standa...

Page 63: ...Maintenance Service and Repair F2 F3 Transmission Page 13 EXPLODED VIEW ...

Page 64: ...TAYLOR DUNN ...

Page 65: ...TABLE OF CONTENTS Tire 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 ...

Page 66: ... tread as the tire approaches its wear limit see illustration below Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section for information regarding replacing the tire 8 Inspect for uneven tire wear on the front tires Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged ...

Page 67: ... To replace the tire the tire wheel assembly must be removed from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assembly Tire replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipmen...

Page 68: ...g severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The ...

Page 69: ...TABLE OF CONTENTS Cleaning 2 Testing 3 Charging 4 Watering 5 Replacing 6 volt batteries only 6 Moist Charge Batteries 7 Storage and Returning to Service 8 Storage 8 Returning to Service 9 ...

Page 70: ...o may result in severe bodily injury and or property damage 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 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the cente...

Page 71: ...ectrolyte 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 TESTING 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 T...

Page 72: ...nger 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 ...

Page 73: ...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 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 bo...

Page 74: ... be replaced 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batteries 10 Remove the batteries from the vehicle 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compar...

Page 75: ...r that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries 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 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the cen...

Page 76: ...al 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 Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid ...

Page 77: ...ction 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 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 t...

Page 78: ...TAYLOR DUNN ...

Page 79: ...bleshooting 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 ISO 24 SOLENOIDS 26 MOTOR 29 REV F ...

Page 80: ...rmal 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 J...

Page 81: ...tiple 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 indicat...

Page 82: ...elerator 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 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...

Page 83: ...e 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 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...

Page 84: ...rk 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 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...

Page 85: ...e 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 Accelerator sequence Depress the pedal fully If 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 ...

Page 86: ...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 B M A2 B 2 KSI _ Main Battery Positive The voltage shown is for illustration only The actual voltage may vary B M A2 B 2 KSI...

Page 87: ... 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 battery volts Connect the test light across the motor A1 and A2 terminals Close all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator fully If the light ...

Page 88: ...ion 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 should be ON with no more that a few degrees of rotation If the FS 1 lamp does not come on then the module is faulty see note2 below The voltage on the digital display should vary with the position o...

Page 89: ...n 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 terminals of a typical Key Switch A OFF mV V V Hz FLUKE 79 SERIES II MULTIMETER Connect a voltmeter across the HOT terminal of the key switch and battery negative If the voltage is not at battery volt...

Page 90: ... 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 Key Switch ON and place the F R Switch in Forward If the voltage is not at battery volts then the F R switch has failed Stop trouble shooting here and repair the problem When the repair is completed c...

Page 91: ...ive 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 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 fo...

Page 92: ...attery 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 Connect a voltmeter across the reverse terminal of the forward and reverse side of the F R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F R Switch in r...

Page 93: ... 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 fully If 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 vehi...

Page 94: ...y 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 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 R Switch in reverse Depress the accelerator pedal ful...

Page 95: ... 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 negative Close all interlock switches turn the Key Switch ON and place the F R Switch in forward If the voltage is not at battery volts then go to the Key Switch sequence Connect a voltmeter across the...

Page 96: ...he 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 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 Set the test light voltag...

Page 97: ...ceeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Ø Full speed only PMC CONTROL Ø Does not run in either direction plus there is noise from motor hum or whine with high field current and low armature current PLUGGING DIODE Ø Excessive spark when connecting battery ISO Ø Does not run or runs very slow with low motor current and high batte...

Page 98: ... 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 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 supp...

Page 99: ...e 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 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 B M A2 ...

Page 100: ...olution 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 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 pre...

Page 101: ...tant 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 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 vehicl...

Page 102: ...ere 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 ISO FWD REV ISO 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 k...

Page 103: ... 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 from the ISO solenoid and measure its resistance The meter reading should be 250 Ohms 10 If it is not 250 ohms 10 then replace the resistor Stop trouble shooting here and repair the problem When the rep...

Page 104: ... 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 wires from the S1 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...

Page 105: ...o 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 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 R switch in forward depre...

Page 106: ...rse 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 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 ha...

Page 107: ...ting 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 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 Di...

Page 108: ...o 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 segm...

Page 109: ... 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 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 E ...

Page 110: ...current 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 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...

Page 111: ...before 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 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...

Page 112: ...s 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 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 o...

Page 113: ...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 theAC 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 le...

Page 114: ...ore 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 Failure to do so may cause serious bodily injury High Voltage inside the charger Do not touch any internal components while the charger is plugged in Failure to do so may result in serious bodily inju...

Page 115: ... Relay Test Stop here and repair the problem Test theAC 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 ratedAC voltage of the charger then the timer relay is bad Stop here ...

Page 116: ...m 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 lead from the capacitor Test the capacitor using the capacitor test function on the meter If the capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the lead to the ...

Page 117: ... 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 theAC voltage across the transformer secondary circuit 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 charge s...

Page 118: ... here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirmed that theAC power source is working The DMM should indicate an open c...

Page 119: ...est 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 the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Rev H ...

Page 120: ...ases 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 and illustration below for the function of these LED s If an error occurs during charging the charger will beep and display an error code by flashing the status LED s Refer to the Status LE...

Page 121: ...meter 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 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 tur...

Page 122: ...ood 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 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 servicea...

Page 123: ...harger 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 then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of Defective battery or batteries Excessively discharged batteries Ove...

Page 124: ...ng 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 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 t...

Page 125: ...ging 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 controller programming resulting in a fault code 1 refer to fault table GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batte...

Page 126: ...There 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 volt battery has 3 cells This charger is rated for 115 VAC or 230 VAC operation nominal When switching from one input voltage to the other wait until all LED s are off Switching voltage when any of the ...

Page 127: ...age 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 the charger face plate there is a status light panel that displays the current status of the charger The first light POWER should be ON when the AC cord is connected to a proper AC power source The th...

Page 128: ...ing 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 still show symptoms of overcharging if 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 i...

Page 129: ... 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 charger cooling fins and clean as required 5 AC line voltate too high or too low Check the input voltage It must be within 85 137VAC or 170 264VAC 6 Low battery voltage Extremely discharged battery de...

Page 130: ...be reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the POWER light is ON then the charger has failed and must be replaced If the POWER light is OFF then check the AC power source AC power cable and connections If the source cable and connections are good ...

Page 131: ......

Page 132: ... used for the AC power source United States Standard 120 Volt White Neutral Black Hot Green Ground European Standard Blue Neutral Brown Hot Green Yellow Ground Charger AC power source is High Voltage Only personnel qualified for work high voltage AC power lines should repair the charger AC power cord Improper repair or incorrect wiring may result in an electrical shock hazard causing severe bodily...

Page 133: ...r Brakes 12 Rear Axle 12 Motor 14 Brake linkage 16 Wheels and Tires 18 Instrument Panel dash 20 Speed Control Panel 22 Lester Charger P1 24 Lester Charger P2 26 Signet Charger 28 Batteries 30 Seat Cushions and Deck 32 Decals 34 Optional Equipment 36 Stake Sides 38 Fiberglass Cab and Doors P1 40 Mirrors Windshield Wiper Brake Light 42 ...

Page 134: ...Illustrated Parts Parts Page 2 Front Axle ...

Page 135: ...strated Parts Parts Page 3 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 ...

Page 136: ...Illustrated Parts Parts Page 4 Front Fork ...

Page 137: ...m 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 ...

Page 138: ...Illustrated Parts Parts Page 6 Steering Linkage ...

Page 139: ...6 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 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 N...

Page 140: ...Illustrated Parts Parts Page 8 Transmission Chain or Gear Case 3rd Member Brake Assembly Motor 2 3 4 6 7 9 13 14 15 16 17 20 22 23 24 1 25 10 11 12 21 8 5 ...

Page 141: ...ion Sprocket 1 30 092 00 59 Tooth Single Pinion Sprocket 1 30 070 11 60 Tooth Double Pinion Sprocke 1 30 070 10 81 Tooth Double Pinion Sprocket 1 30 093 00 81 Tooth Single Pinion Sprocket 1 12 30 320 11 Drive Chain 15 81 T Double Sprocket 1 30 508 20 Drive Chain 15 81 T Single Sprocket 1 13 44 352 53 Backing Plate Gear Case 1 14 88 101 13 3 8 X 1 1 4 NC Hex Bolt 5 15 88 080 20 5 16 X 3 Hex Bolt 9 ...

Page 142: ...Illustrated Parts Parts Page 10 Transmission Differential Case ...

Page 143: ...earing 1 7812 ID Carrier Bearing 6 31 239 00 Ring and Pinion Gear Set 5 43 0 or 1 31 234 00 Ring and Pinion Gear Set 3 00 0 or 1 31 275 00 Ring and Pinion Gear Set 2 75 0 or 1 7 41 997 00 Oil Plug 3 8 41 291 32 Rear End Housing For B2 48 B2 38 1 41 299 20 Rear End Housing For B2 54 1 10 80 554 00 Front Pinion Bearings 11 41 711 00 Pinion Housing Shim 1 12 80 702 00 O Ring 1 13 44 340 90 Pinion Hou...

Page 144: ...Illustrated Parts Parts Page 12 Rear Brakes Axle tube 8 9 4 5 6 7 3 2 1 Rear Axle ...

Page 145: ...17 11 3 32 X 1 Cotter Pin 1 13 96 771 00 Clevis Pin 1 14 50 656 04 Brake Arm 1 15 88 101 13 3 8 X 1 1 4 NC Grade 5 Hex Bolt 1 16 85 270 00 Return Spring 4 3 8 Long 1 17 88 080 13 5 16 X 1 1 4 Hex Bolt 2 18 41 371 10 Alignment Bracket 2 19 88 089 91 5 16 Hex Jam Nut 4 Rear Axle Item No Part No Description Qty 1 96 330 20 3 8NF x 1 3 16 T bolt 8 2 45 301 00 Seal 2 3 32 515 00 Retainer bearing 2 4 96...

Page 146: ...Illustrated Parts Parts Page 14 Motor 10 11 7 9 12 13 9 5 3 4 2 1 14 16 17 6 8 15 Typical GE Motor ...

Page 147: ...N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 5BC49JB399C 70 054 00 45 508 00 80 504 00 80 200 00 97 100 00 70 203 10 98 622 00 98 623 00 97 178 00 97 179 00 70 210 62 70 195 10 70 195 10 80 412 00 30 802 00 70 105 00 70 104 10 N A N A 5BC58JBS6129B 70 049 05 80 209 00 70 201 15 70 210 51 70 049 06 70 210 51 85 412 00 70 104 15 70 172 15 32 508 15 88 089 91 88 088 61 Motor Spec M...

Page 148: ...Illustrated Parts Parts Page 16 Brake linkage ...

Page 149: ... 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...

Page 150: ...Illustrated Parts Parts Page 18 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10 ...

Page 151: ... 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 6 88 110 09 3 8 x 3 4 NF Hex Bolt grade 5 7 88 109 62 3 8 Split Lock Washer 8 88 119 80 3 8 NF Hex Nut 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only Not Shown 11 041 00 8 50 x 8 Tube Not Shown 11 040 00 5 70 x 8 Tube 11 030 00 4 80 x 8...

Page 152: ...Illustrated Parts Parts Page 20 Instrument Panel dash ...

Page 153: ...ivit 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 Locknu...

Page 154: ...Illustrated Parts Parts Page 22 Speed Control Panel ...

Page 155: ...er 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 Hd 2 19 78 302 50 Resistor 250 ohm 5 watt 1 20 62 021 00 Solenoid Panel Assembly...

Page 156: ...Illustrated Parts Parts Page 24 Lester Charger P1 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 157: ... 79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25 8ET 230 50 na 36 25 Built In 79 851 10 79 805 72 79 808 00 79 902 00 79 749 11 S O 79 831 00 79 530 00 79 306 23 7710 32 79 305 20 36LC25 8ET 115 60 12 36 25 Portable 79 851 10 79 805 69 79 808 00 79...

Page 158: ...Illustrated Parts Parts Page 26 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 Lester Charger P2 ...

Page 159: ...831 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 79 300 55E 24LC25 8ET 230 50 4 24 25 Built In 79 805 70 79 808 10 79 902 00 79 749 13 79 644 08 79 831 00 79 530 00 79 306 23 7105 01 79 300 50 24LC25 8ET 230 50 4 24 25 Portable 79 851 10 79 805 64 7...

Page 160: ...Illustrated Parts Parts Page 28 Signet Charger Model HBS series charger shown ...

Page 161: ...l 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 previous Signet models Model HBS for GEL Batteries PART DESCRIPTION 24 volt Charger Assembly see note 79 303 42 36 volt Charger assembly see note 79 309 43 48 volt charger assembly see note Model HB for Flooded B...

Page 162: ...Illustrated Parts Parts Page 30 Batteries ...

Page 163: ...uare 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 4 or 6 7a 77 044 00 Battery 6 Volt 230 amp hour optional 4 or 6 7b 77 047 00 Battery 6 Volt 244 amp hour optional 4 or 6 7c 77 042 80 Battery 6 Volt 217 amp hour optional export 4 or 6 7d 77 047 80 Battery 6 Volt 244 amp hour optional export 4 or 6 8 88 100 09 Bolt 3 8NC x 3 4 Hex Hd 1...

Page 164: ...Illustrated Parts Parts Page 32 Seat Cushions and Deck ...

Page 165: ...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 ...

Page 166: ...Illustrated Parts Parts Page 34 Decals ...

Page 167: ...bel 1 88 807 01 Rivet for F 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 ...

Page 168: ...Illustrated Parts Parts Page 36 Optional Equipment ...

Page 169: ...e Cover 2 Headlight 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 1...

Page 170: ...Illustrated Parts Parts Page 38 Stake Sides ...

Page 171: ...ription 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 88 065 11 Screw 1 4NC x 1 Phillips Truss Hd 24 7 88 069 81 Locknut 1 4NC 24 ...

Page 172: ...Illustrated Parts Parts Page 40 Fiberglass Cab and Doors P1 ...

Page 173: ...nge 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...

Page 174: ...Illustrated Parts Parts Page 42 Mirrors Windshield Wiper Brake Light ...

Page 175: ...eld 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 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 Le...

Page 176: ...TAYLOR DUNN ...

Page 177: ...d 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 TorqueValues non critical hardware 5 Appendix C Brake Lining Handling Precautions 7 ...

Page 178: ...ems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adjust Capability Same as 62 027 61 above plus allows a limited range of speed adjustment 62 027 62 Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41 350 13 Pin Removing Tool Used to remove pins and sockets from AMP connectors 75 440 55 Pin Removing To...

Page 179: ... 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 Toque values specified are for clean dry threads Hex Bolts S A E Grade 8 L 9 L 9 APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE ...

Page 180: ...d 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 markings are to be treated as S A E Grade A S A E Grade B S A E Grade C Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Grade L 9 ...

Page 181: ... 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 10 138 207 213 319 301 451 350 3 4 16 154 231 238 357 336 504 390 7 8 9 222 334 344 515 485 728 565 7 8 14 245 367 379 568 534 802 625 1 8 333 500 515 773 727 1091 850 1 14 373 560 577 866 815 1222 930 1...

Page 182: ... 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 dri...

Page 183: ...uum 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 fib...

Page 184: ...TAYLOR DUNN ...

Page 185: ......

Page 186: ...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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