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Taylor-Dunn SC-011-59, Operation, T Roubleshooting And Replacement Parts Manual

The Taylor-Dunn SC-011-59 manual is a comprehensive guide for operation, troubleshooting, and replacement parts. This valuable manual can be downloaded for free from our website, ensuring easy access and convenience for users. Explore the features and functionality of Taylor-Dunn SC-011-59 with this essential manual, available for download at manualshive.com.

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Illustrated Parts

Parts

 

 

Page 17

16920

 

79

-309

-20

 

48LC25

-8ET

 

230/50/na

 

48/25

 

Built

-In

 

- 

S/O

 

79

-808

-20

 

79

-902

-00

 

79

-749

-13

 

S/O

 

N/A

 

79

-831

-00

 

79

-530

-00

 

- 

- 

- 

N/A

 

22620

 

79

-303

-25

 

48LC25

-8ET

 

115/60/15

 

48/25

 

Built

-In

 

- 

79

-805

-68

 

79

-808

-20

 

79

-902

-00

 

79

-749

-13

 

79

-603

-10

 

- 

79

-831

-00

 

79

-530

-00

 

- 

- 

79

-809

-50

 

76

-200

-00

 

16910

 

79

-309

-10

 

48LC25

-8ET

 

115/60/15

 

48/25

 

Built

-In

 

- 

79

-805

-68

 

79

-808

-20

 

79

-902

-00

 

79

-749

-13

 

S/O

 

- 

79

-831

-00

 

79

-530

-00

 

- 

- 

- 

76

-200

-00

 

9475

-31

 

79

-306

-21

 

36LC40

-8ET

 

115/60/17

 

36/40

 

Portab

le

 

79

-852

-00

 

79

-805

-67

 

79

-808

-00

 

79

-902

-00

 

79

-749

-10

 

S/O

 

79

-575

-10

 

79

-831

-00

 

79

-530

-00

 

79

-531

-00

 

S/O

 

- 

76

-200

-00

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9695

 

79

-309

-00

 

48LC25

-8ET

 

115/60/15

 

48/25

 

Portable

 

79

-851

-10

 

79

-805

-65

 

79

-808

-20

 

79

-902

-00

 

79

-749

-13

 

S/O

 

79

-575

-10

 

79

-8

31

-00

 

79

-730

-00

 

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

-902

-00

 

79

-749

-13

 

S/O

 

S/O

 

79

-831

-00

 

79

-531

-00

 

79

-530

-00

 

79

-566

-10

 

- 

76

-2

00

-00

 

Charger Model #

 

Charger Part #

 

22740

 

79

-303

-15

 

36LC25

-8ET

 

115/60/12

 

36/25

 

Built

-In

 

- 

79

-805

-67

 

79

-808

-00

 

79

-902

-00

 

79

-749

-13

 

79

-644

-31

 

- 

79

-831

-00

 

79

-530

-00

 

- 

- 

79

-809

-60

 

76

-200

-00

 

DESCRIPTION

 

Charger Type

 

AC Voltage/Amps 

 

DC Voltage/Amps 

 

Style

 

Ammeter

 

Timer Assembly

 

Relay f

or #2

 

Capacitor

 

Diode Assembly

 

Transformer

 

AC Cord

 

Fuse Assembly

 

Strain Relief

 

Strain Relief

 

DC Cord

 

Interlock Relay Assy.

 

Replacement AC Plug

 

CHARGERS

 

ITEM #

 

 

 

 

 

1 

2 

 

3 

4 

5 

6 

7 

8 

9 

10

 

11

 

- 

 
 

Summary of Contents for SC-011-59

Page 1: ... Best Way To Go About Your B u s i n e s s Serial Number Starting 98509 MANUAL MA 159 05 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded SC 011 59 SC 159 AN 011 71 AN 171 Revision G ...

Page 2: ......

Page 3: ...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 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: ...0 Industrial Charger Operation 10 Charging Time 11 Storing and Returning to Service 11 Storing Your Vehicle 11 Returning to Service 11 Periodic Maintenance Checklist 12 Daily Visual inspection 13 Maintenance Guidelines for Severe Duty Applications 13 General Maintenance 1 Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Front Axle Service 1 Inspect the Front Wheel Bearings 2 Ad...

Page 6: ...e 9 Electrical Troubleshooting Symptoms 2 Main Troubleshooting Sequence 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 4 Special Troubleshooting Guide PMC CONTROL 2 PLUGGING DIODE 4 FREEWHEEL DIODE 5 ISO 6 SOLENOIDS 8 MOTOR 11 Lestronic II Charger Troubleshooting Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Tr...

Page 7: ...anel standard 34 Control Panel 40 bed 36 Instruments 38 Gauges 38 Batteries 40 Decals 42 Decals AN 43 Miscellaneous Frame and Body SC 44 Miscellaneous Frame and Body AN 46 Appendixes Appendix A Special Tools 2 Appendix B Suggested 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 Suggest...

Page 8: ...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 9: ...troduction Vehicles shown with optional equipment About this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 ...

Page 10: ...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 11: ...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 12: ...ted 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 to 10 mph...

Page 13: ...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 14: ...TAYLOR DUNN ...

Page 15: ...ake Treadle AN 171 6 Steering SC 159 6 Steering AN 171 6 Walk along Handle AN 171 6 Foot Interlock Switch SC 159 optional 7 Charger Interlock 7 Parking brake 7 Vehicle Operational Guidelines 8 Safety Guidelines 8 Starting 8 While driving 8 Loading and Unloading 8 Towing Loads 8 Parking 9 Towing This Vehicle 9 Charging your vehicle 10 New Battery Break in 10 Signet Charger Operation 10 Lestronic II...

Page 16: ...rol 275 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC SC 159 3 35 kW 4 5 Horse Power Intermittant duty Series Wound AN 171 4 99 kW 6 7 Horse Power Intermittant duty Brakes Drive Shaft Brake Through Differential Automaitc Mechanical Park Brake Steering SC 159 Clover Leaf Steering Wheel AN 171 Tiller Tires SC 159 4 80 x 8 Load Range B AN 171 5 70 x 8 Load Range ...

Page 17: ...h 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 th...

Page 18: ...ngage the reverse direction DO NOT SWITCH from forward to reverse or vice versa while the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward off reverse switch should be in the center OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle 1 Horn Switch The horn switch is located on the right side of the steerin...

Page 19: ... indicator is located to the left of the hour meter The battery status indicator has a LED bar graph that indicates the relative state of charge of the battery The top LED will light only when connected to a fully charged battery or after completing a charging cycle Successive lower LED s will light as the battery charge diminishes When the second from the bottom LED flashes the battery energy sta...

Page 20: ...e allow operation of the vehicle while standing on the right side of the vehicle Push forward onthe handle to start and pull back to stop Accelerator Brake Treadle SC 159 The accelerator and brake are operated by the treadle on the right side of the floorboard to be operated by the operators right foot Press the front of the treadle down to increase speed release the treadle to slow down Press the...

Page 21: ...a functioning power source NOTE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger Foot Interlock Switch SC 159 optional A switch or pedal located under the driver s left foot disables the power to the vehicle when it is released The switch or pedal must be depressed for the vehicle to operate Whenever the driver leaves the vehicle th...

Page 22: ...ar of the treadle to set the parking brake 3 Rotate the ON OFF switch to the ON position 4 Place the forward off reverse switch in the desired direction of travel 7 Slowly depress the front of the treadle 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 prohibit...

Page 23: ...cle is equipped with an automatic electric brake do not tow the vehicle with the drive wheels on the ground Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible this vehicle should be placed on a carrier...

Page 24: ...lly charged Refer to the data plate on the charger for the voltage and type power required for the charger There is a series of LED s on the faceplate of the charger that serve two functions 1 Status of charge The LED s will display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition All three LED s flashing is an indication of a charging problem c...

Page 25: ...ies before they are completely discharged we recommend waiting until they are discharged a minimum of 25 to reduce the possibility of overcharging Refer to Vehicle Controls in this section for information on how to read the BSI Do not discharge the batteries beyond a normal discharge as indicated on the BSI Refer to Vehicle Controls in this section for information on how to read the BSI Check the ...

Page 26: ...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 27: ... inclusive of a severe duty application Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Daily Visual i...

Page 28: ...TAYLOR DUNN ...

Page 29: ...le of Contents General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor Illustrations of other popular Taylor Dunn vehicles ...

Page 30: ...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 31: ...king Brakes Dragging Batteries Discharged or Defective Worn Drive Gears 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 Low Brake Worn 1 16 Wear Limit Brakes Out of Adjustment Braking Power Low Brake Worn 1 16 Wear ...

Page 32: ...eneral Purpose Grease 4 Steering Shaft 2 General Purpose Grease 5 Steering Shaft Gears 1 General Purpose Grease 6 Steering Chain 2 General Purpose Grease 7 Drive Fill Plug 1 SAE 140 API GL 5 Hypoid Gear Oil 8 Drive Level Plug 1 9 Drive Drain Plug 1 10 Chain Case Fill Plug 1 SAE 140 API GL 5 Hypoid Gear Oil 11 Chain Case Drain Plug 1 12 Control Linkage Collars 2 General Purpose Grease 13 Throttle S...

Page 33: ...TABLE OF CONTENTS Inspect the Front Wheel Bearings 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 4 Replace Front Wheel Bearings 5 Front Axle Service ...

Page 34: ...o the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings 9 Spin the wheel s and listen for any grinding noise Any noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 10 Lower the vehicle 11 Reconnect the main positive and ne...

Page 35: ...tands Installation 1 Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub 2 Assemble the bearing spacers into the front wheel hub and place the front wheel s into the fork 3 Insert the axle into the front fork 4 Install the axle nut s Refer to Adjust Front Wheel Bearings section for information regarding tightening the front axle NOTE If your vehic...

Page 36: ...n section for information regarding installing the axle 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehicle Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load...

Page 37: ...er the Steering Wheel 2 Inspect the Steering Components 4 Steering Wheel and Bushings 4 Steering Chain 4 Pillow Blocks 5 Fork Bearings 5 Adjust the Steering Shaft 6 Replace the Steering Wheel 6 Replace the Front Fork 7 Steering Component Service ...

Page 38: ...ft should be level If it is not level then perform the following A Raise the front wheel approximately 1 inch off of the ground B Remove the fork spindle bearing cap C Loosen the fork nut until the steering shaft can be rotated without rotating the fork D Position the flat top of the half gear so that it is level E With the front wheel pointing straight ahead lower the front end and tighten the fo...

Page 39: ...ten the turnbuckles to remove all play from the steering chain 14 Install new safety wire and tie off as shown in the illustration 15 Untie the front fork 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the parking brake and test drive the vehicle ...

Page 40: ...corners should be 90 degrees with a small radius If the corners are excessively rounded or the sides are tapered then the steering wheel should be replaced Insert the steering shaft back into the collar and check for lateral play as shown to the right If the lateral play exceeds 0 010 inches then the bushings should be replaced Steering shaft and sprocket Steering Chain The steering chains are ver...

Page 41: ... the main positive and negative cables at the batteries Front pillow block FORK BEARINGS 6 Raise the front of the vehicle and support with jack stands 7 Inspect for lateral play by attempting to move the fork to the left and right not rotating There should be no noticeable play 8 If there is any play in the fork bearings refer to section Replace the Front Fork for information regarding adjusting t...

Page 42: ...rse 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 ADJUST THE STEERING SHAFT The steering shaft is adjustable by means of a collar at the rear of the shaft This adjustment controls the gear lash of the half gears on the shaft and front fork 6 Loosen the set ...

Page 43: ...e 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 9 Thoroughly clean all parts and install in reverse order Tighten the fork spindle nut to remove all play in the fork beari...

Page 44: ...TAYLOR DUNN ...

Page 45: ...TABLE OF CONTENTS Inspect the Service Brake 2 Adjust the Service Brake 2 Adjust the Brake Linkages 3 Replace the Brake Lining 4 Replace Brake Drum 6 Replacing the Treadle Linkage 7 Brake Service ...

Page 46: ...from behind the wheels 8 Test drive the vehicle ADJUST THE SERVICE BRAKE 6 Raise the drive wheels off of the ground 7 Loosen the brake bolt jam nut 8 Depress the treadle until the throttle linkage is 0 125 away from the accelerator module slip joint Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket parts containing...

Page 47: ...sted incorrectly 6 Loosen the brake linkage jam nut 7 Remove the clevis pin from the brake arm 8 Depress the treadle until the front of the treadle is level with the floorboard 9 Hold the brake arm up against the front of the chain case housing 10 Adjust the brake linkage so that the clevis pin can be inserted into the brake arm while it is against the chain case housing NOTE When adjusted correct...

Page 48: ...for this procedure If the brake drum must be removed refer to ReplaceThe Brake Drum for this procedure 6 Release the park brake 7 Disconnect the parking brake cable and return spring from the brake arm 8 Loosen the bolt s 1 on the brake band alignment bracket s 9 and pivot them out of the way 9 Remove the bolts 5 holding the brake band assembly to the front of the chain housing 16 and remove the b...

Page 49: ...olts 5 18 Position the brake band alignment bracket s 9 so that the inner arm 14 is 0 100 away from the brake drum 8 Make certain that the alignment bracket does not come into contact with the brake drum 19 Adjust the alignment bracket adjusting bolt s 10 to 0 050 0 100 away from the brake band and tighten the jam nuts 12 20 Connect the brake cable or linkage to the brake arm and adjust the cable ...

Page 50: ...ke drum Make certain that the alignment bracket does not come into contact with the brake drum 13 Adjust the alignment bracket adjusting bolt s to 0 050 0 100 away from the brake band and tighten the jam nuts 14 Adjust the park brake Refer to Adjust the BandBrake section for information regarding adjusting the park brake 15 Set the park brake 16 Reconnect the main positive and negative cables at t...

Page 51: ...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 7 Inspect the holes for the clevis pins in the treadle and bell crank If the holes are worn elongated then the treadle and or bell crank should be repaired or replaced before continuing 8 Disconnect the brake linkage from the brake arm 9 Position the ...

Page 52: ...TAYLOR DUNN ...

Page 53: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Throttle Linkage ...

Page 54: ... ADJUSTMENTS The throttle linkage is coupled with the brake linkage There are no adjustments that are specific to the throttle linkage Refer to the Brake Section for linkage adjustments or replacement of the treadle linkage Accelerator Module Arm Bell Crank Treadle Linkage ...

Page 55: ...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 56: ... 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 57: ... 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 58: ... 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 59: ... 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 60: ... 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 61: ...e 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 2 625 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 ...

Page 62: ...TAYLOR DUNN ...

Page 63: ...5 Drive Motor 6 Remove 6 Install 6 Rear Axle 7 Remove and Install 7 Replace the Axle Bearing 8 Transmission Assembly 9 Remove and Install 9 Chain Case 10 Disassemble 10 Assemble 12 Differential Assembly 3rd Member 14 Disassemble 14 Assemble 16 Re shimming the Pinion Housing 18 Exploded View 20 ...

Page 64: ...lace blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 9 Raise the drive wheels off of the ground 10 Tie the vehicle in p...

Page 65: ... replacing the drive chain Rotating parts keep hands and loose clothing clear of all moving parts Failure to keep clear of moving parts may result in severe bodily injury and or property damage 14 Release the accelerator pedal place the forward off reverse switch in off turn the key off and disconnect the batteries 15 Untie the vehicle 16 Tighten the adjustment screw jam nut and motor mounting nut...

Page 66: ...ent 5 Disconnect the main positive and negative cables at the batteries 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 ...

Page 67: ...w all of the oil to drain from the housing and then reinstall the drain plug 10 Remove the chain case fill plug and add 1 pint of oil 11 Remove the drive housing fill plug and add 2 quarts of oil NOTE Refer to the Lubrication Chart for information regarding the type of oil 12 Replace all fill plugs NOTE Dispose of waste oil in accordance with your local regulations 13 Reconnect the main positive a...

Page 68: ...ce blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Install 1 Tie the chain up in position with mechanics wire as shown 2 Slip the motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove wire s holding the chain 3 Install the motor mounting hardware but do not...

Page 69: ...itive and negative at the batteries remove the blocks from the wheels and test drive 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 h...

Page 70: ...on resulting in severe bodily injury or property damage 1 Place the axle in a press and remove the bearing and bearing retainer 2 Lightly lubricate the axle shaft 3 Install a new bearing and bearing retainer and press into place NOTE Some axle configurations have an o ring around the axle bearing The bearing should be orientated so that the o ring is farthest away from the axle hub See the illustr...

Page 71: ...in reverse order 15 Check brake adjustment and adjust as needed Refer to Adjust the Brakes for information regarding adjusting the brakes 16 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive 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...

Page 72: ...rom 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 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 ...

Page 73: ...Remove the drive chain motor nut and sprocket and the drive sprocket 16 If the backing plate must be removed from the 3rd member first remove the motor from the backing plate then remove the backing plate from the 3rd member Washer Mounting Plate Woodruf Key Adjusting screw Nut Motor Nut Bolt O Ring 24 Backing Plate Bolt Drive Sprocket Spacer Nut Motor Sprocket Drive Chain Nut Pinion Seal Chain Ca...

Page 74: ...hain case housing 7 Install the chain case centering tool refer to Appendix A into the pinion seal bore in the chain case housing 8 Install the chain case housing onto the pinion shaft and tighten the pinion nut to 75 ft lbs 9 Install and tighten the three nuts and washers to the threaded studs and the housing bolts that are not used for the brake mounting bracket or alignment brackets 10 Remove t...

Page 75: ...ting bolts 15 Adjust the brake Refer to section Brake Service Adjust the Brakes for information regarding adjusting the brakes 16 Adjust the drive chain Refer to section Adjust the Drive Chain for information regarding adjusting the drive chain T A Y L OR DUN N T h e B e s t W a y To Go About Yo u r B u s i n e s s R ...

Page 76: ...ar axle assemblies Refer to section Rear Axle Remove and Install for information regarding removing the axles 4 Remove the chain case and backing plate from the 3rd member Refer to section Chain Case Disassemble for information regarding removing the chain case 5 Remove the nuts holding the 3rd member to the axle housing and remove the 3rd member from the housing 6 Install a spacer on the pinion s...

Page 77: ...rd member assembly must be replaced 13 Remove the differential bearing caps bearing adjusting nuts and races 14 Remove the differential assembly from the 3rd member 15 Mark the ring gear and differential housing so that the ring gear can be reinstalled in the same orientation 16 Remove the bearings from the differential housing and discard NOTE Removing the bearings will damage the bearings Do not...

Page 78: ...teeth marked on the ring gear and one tooth marked on the pinion gear The one tooth on the pinion gear must be installed so that it is between the two teeth on the ring gear The gear ratios are 2 50 2 70 2 75 3 25 and 3 00 Pinion housing 1 If the rear pinion bearing was removed install a new bearing 2 Install the bearing races into the pinion housing 3 Place the pinion gear into the 3rd member 4 I...

Page 79: ... races 17 Install the bearing caps in their original locations and torque the bolts to 12 15 ft lbs making sure that the adjusting nuts still turn freely NOTE In the following procedure Left adjusting nut refers to the nut on the ring gear side of the differential assembly Right adjusting nut refers to the nut on the pinion gear side of the differential assembly The differential bearing preload is...

Page 80: ... amount 22 Apply gear marking compound on both sides of 7 to 10 teeth on the ring gear 23 While applying resistance to the pinion shaft rotate the ring gear back and forth not full revolutions until a clear contact pattern is shown Compare the contact pattern to the illustration on the following page and reshim the pinion housing or adjust the backlash as indicated on the illustration If the pinio...

Page 81: ...Transmission Transmission Page 19 ...

Page 82: ...Transmission Transmission Page 20 EXPLODED VIEW ...

Page 83: ...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 Tires and Wheels ...

Page 84: ... 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 85: ... 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 86: ...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 87: ...ABLE OF CONTENTS Battery Service 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 88: ...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 89: ...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 90: ...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 91: ...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 92: ... 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 93: ...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 94: ...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 95: ...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 96: ...TAYLOR DUNN ...

Page 97: ...Table of Contents Symptoms 2 Main Troubleshooting Sequence 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 4 REV B ...

Page 98: ...nt in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low Full speed only Does not run in either direction plus there is noise from moto...

Page 99: ...oting guide is not written to be able to locate a problem if there are multiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT start in the middle of this troubleshooting guide Start at the beginning and complete each test in the order that they are written Do not skip any test unless instr...

Page 100: ...the accelerator 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 th...

Page 101: ...move 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 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...

Page 102: ... the drive wheels to the ground 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 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...

Page 103: ... the voltage is not between 11 0 and 11 5 volts then go to the Accelerator sequence Connect voltmeter across the PMC KSI terminal and battery negative With the pedal still fully depressed If the voltage is not at battery volts then go to the Key Switch sequence If the voltage is at battery volts then continue with the next test Negative Main Battery B M A2 B 2 KSI _ The voltage shown is for illust...

Page 104: ...the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground 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 The rear drive wheels may rotate during some of the following t...

Page 105: ...ve 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 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 b...

Page 106: ...ore testing can continue 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 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 vehicl...

Page 107: ...st harness Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal to engage MS 1 only If the voltage is not at battery volts then the accelerator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground If the voltage at pin 5 is good but the test at t...

Page 108: ...rator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Now Depress the accelerator module fully If the voltage is not between 11 0 and 11 5 volts then the accelerator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely ...

Page 109: ... the key switch and battery positive 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 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 1 Make sure the key switch is in the OFF positio...

Page 110: ...is completed completely retest the vehicle before lowering the drive wheels to the ground For your reference shown at the right are the Forward and Reverse switch wire connections for a typical control system Connect a voltmeter across the HOT terminal of the KSI side of the F R switch and battery negative Turn the key switch ON If the voltage is not at battery volts then go to the Accelerator seq...

Page 111: ...nd repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground F R switch The COLD terminal is the Violet Black wire on either end of the switch Battery Negative Or 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 un...

Page 112: ...d 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 forward Depress the accelerator pedal fully 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 completely retest the vehicle before lowering...

Page 113: ...p ahead to the test sequence Forward does not run in reverse If the vehicle runs in reverse only then skip ahead to the test sequence Reverse does not run in forward The REVERSE terminal is diagonally opposite the reverse side of the rocker on the switch Battery Negative A OFF mV V V Hz FLUKE 79 SERIES II MULTIMETER F R switch seen from the rear F R switch seen from the side depressed in the REVER...

Page 114: ...ry volts then check the wiring to battery positive and the main 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 Forward does not run in reverse Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place t...

Page 115: ...ross the Normally Closed contacts of the Forward solenoid Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in Reverse 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 com...

Page 116: ...tch sequence Connect a voltmeter across the Forward Solenoid coil terminals Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in forward Depress the accelerator pedal fully If the voltage is not at battery volts then go to the F R Switch sequence Set the test light voltage to the same ...

Page 117: ... truck may be different FWD REV Set the test light voltage to the same voltage as the battery volts Connect the test light across the Normally Closed contacts of the Reverse solenoid Refer to your vehicles wiring diagram to identify the position of the Reverse solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator pedal fully If the...

Page 118: ...TAYLOR DUNN ...

Page 119: ...ly and exceeds 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 h...

Page 120: ...ive B M A2 B 2 KSI _ The voltage shown is for illustration only The actual voltage 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 vehicle movement 5 Disconnect the main positive and negative cables at the batteries The rear drive wheels...

Page 121: ...r pedal to engage the first micro switch only creep speed then perform the following tests The meter reading should not be equal to the battery voltage If you have full battery voltage then the PMC control is shorted and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherw...

Page 122: ... without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated 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 w...

Page 123: ...It is important 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 pre...

Page 124: ...t 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive...

Page 125: ... need to be repeated 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 repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reading is plus or m...

Page 126: ... following has occurred A The reverse solenoid is shorted B The wire connected to the motor S1 terminal is shorted to the wire connected to the motor A2 terminal C The wire connected to the motor S1 terminal is shorted to the wire connected to the PMC A2 terminal 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 Se...

Page 127: ...ed 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 depress the accelerator pedal and perform the following tests Check continuity from the wire that was connected to the PMC M terminal to the wire that was connected to the motor S2 terminal If you do not know how to test for cont...

Page 128: ...d A The reverse 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 p...

Page 129: ...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 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 m...

Page 130: ...dark brown to black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the next test 4 Perform a continuity test around the armature commutator Place one of the test leads on a single commutator segment While holding the first test lead on the segment check the continuity to th...

Page 131: ...g 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 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 132: ...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 133: ...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 134: ... 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 of...

Page 135: ...or has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Connect the charger to the AC source 8 Test the voltage across the two 14 gauge wires This voltage should be the same as the voltage at the AC receptacle rated voltage of the charger If the voltage is l...

Page 136: ...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 HighVoltageinsidethecharger Donottouchanyinternalcomponents while the charger is plugged in Failure to do so may result in serious bodilyinjury Fuse Li...

Page 137: ...imer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the timer relay is bad Stop...

Page 138: ...oblem 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 ...

Page 139: ...of the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC 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 c...

Page 140: ...p here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirmed that the AC power source is working The DMM should indicate an open...

Page 141: ...rging Cycle 3 Test 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 G ...

Page 142: ...reases 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 ...

Page 143: ...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 144: ...s in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries 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 se...

Page 145: ...nnections broken wires and proper connection to the batteries 2 AC line voltate too high or too low Check the input voltage It must be within 96 132VAC or 196 266VAC 3 Charger overheated Wait for charger to cool the charger will automaticaly restart Inspect for dirt or debris on the charger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this...

Page 146: ...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 147: ...TABLE OF CONTENTS Wire Diagrams Complete Vehicle Standard Bed 2 Complete Vehicle Short Bed or Lift Out Battery Box 3 Complete Vehicle AN 4 ...

Page 148: ...Tail Brake Light L optional Brown White R optional Head Light L Green LIGHT Red LIGHT SW STOP SW LIGHT SW ROT Red Red White Brown optional optional HM Black optional HM DI I F R CB ACCELERATOR 9 PCB MS3 MS1 5 8 4 2 1 0 5v 6 11v B In B In Strobe Light Violet black Violet black Black Black Green Black Orange Black Green Black Violet black 10 15 White White Red Black White Red Red Blue Green Green Vi...

Page 149: ...OR LIFT OUT BATTERY BOX Wiring is the same as the standard bed with the exception of Harness is wired direct to the solenoids and controller there is no connector Built In charger is not available Charger interlock if equipped is located in the charging receptacle ...

Page 150: ...TAYLOR DUNN ...

Page 151: ...14 Lester Chargers Page 1 16 Lester Chargers Page 2 18 Signet Charger 20 Motors 22 Power Traction 24 Differential 26 Brake 28 Rear Axle 30 Rear Tires 32 Control Panel standard 34 Control Panel 40 bed 36 Instruments 38 Gauges 38 Batteries 40 Decals 42 Decals AN 43 Miscellaneous Frame and Body SC 44 Miscellaneous Frame and Body AN 46 Illustrated Parts ...

Page 152: ...Illustrated Parts Parts Page 2 Front Axle ...

Page 153: ...ated Parts Parts Page 3 FRONT AXLE Item No Part No Description Qty 1 88 229 81 Locknut 3 4NC 2 2 88 228 61 Washer 3 4 SAE 2 3 15 010 00 Front Axle 1 4 16 010 00 Spacer 4 5 15 011 00 Front Axle Dual optional 1 ...

Page 154: ...Illustrated Parts Parts Page 4 Front Tire ...

Page 155: ...00 Wheel 2 50 5 hole Split Rim 1 9 10 075 00 Tire 4 80 x 8 LR B 1 11 030 00 Tube 4 80 x 8 1 7 13 734 40 Tire Wheel Assy 4 80 x 8 Split Rim Man Toter SC only 1 8 12 042 00 Wheel 3 75 5 hole Split Rim 1 9 10 074 00 Tire 4 80 x 8 Man Toter 1 7 13 734 41 Tire Wheel Assy 4 80 x 8 Split Rim non marking SC only 1 8 12 042 00 Wheel 3 75 5 hole Split Rim 1 9 10 074 10 Tire 4 80 x 8 non marking 1 7 13 954 1...

Page 156: ...Illustrated Parts Parts Page 6 Front Fork 7 10 Fork Collar in frame 1 2 4 5 5 4 3 6 ...

Page 157: ... 4 Cut 1 3 45 307 00 Oil Seal 1 1 2 ID 1 4 80 011 10 Bearing Tapered Roller 1 1 4 ID 2 5 80 102 00 Bearing Race 2 6 14 030 10 Front Fork Assembly 1 7 92 105 00 Dust Cap 1 8 16 410 00 Spacer Fork Spindle 020 Thick Qty may vary 1 9 16 400 00 Spacer Fork Spindle 125 Thick Qty may vary 2 10 14 032 10 Front Fork Dual optional 1 ...

Page 158: ...Illustrated Parts Parts Page 8 Steering Linkage SC ...

Page 159: ...ssembly 40 Frame 1 2 84 005 00 Pillow Block 2 3 30 223 00 Steering Chain 1 4 19 008 00 Steering Wheel Shaft and Sprocket 1 5 32 032 10 Bushing 3 4 2 6 88 048 63 Washer 1 x 755 x 030 1 7 88 840 09 Snap Ring External 1 8 96 900 00 Turnbuckle Steering Chain 2 9 88 080 15 Bolt 5 16NC x 1 3 4 Hex Hd 4 10 88 089 81 Locknut 5 16NC 4 11 88 088 61 Washer 5 16 SAE 4 ...

Page 160: ...Illustrated Parts Parts Page 10 Steering Linkage AN ...

Page 161: ... Item No Part No Description Qty 1 20 026 10 Steering Shaft Assembly 1 2 84 005 00 Pillow Block 2 3 95 500 00 Steering Handle 1 4 98 350 00 Hand Grip 1 5 88 080 15 Bolt 5 16NC x 1 3 4 Hex Hd 4 6 88 089 81 Locknut 5 16NC 4 7 88 088 61 Washer 5 16 SAE 4 ...

Page 162: ...Illustrated Parts Parts Page 12 Mechanical Control Linkage 6 4 5 1 3 7 8 8 7 8 4 8 7 7 See Note On Following Page Brake Arm Ref 9 10 Collars welded to frame ...

Page 163: ...n Qty 1 50 429 00 Connecting Strap 1 2 85 281 00 Link Extension Spring 1 3 85 280 00 Spring Extension 1 3 8 OD x 7 3 4 1 4 96 762 00 Clevis 3 8 2 5 88 119 80 Nut 3 8NF 1 6 50 026 00 Rod 3 8NF x 3 Long Full Thread 1 7 96 772 00 Pin Clevis 3 8 x 1 Long 4 8 88 517 11 Cotter Pin 3 32 x 1 4 ...

Page 164: ...Illustrated Parts Parts Page 14 Throttle Linkage 3 1 2 4 5 6 6 6 7 8 8 9 10 9 10 ...

Page 165: ...ng Bracket 1 2 62 033 00 Accelerator Module 1 3 02 150 11 Lever Accelerator Extension 1 4 50 123 21 Rod Accelerator Linkage 1 5 50 481 00 Connector Park Brake Slip 1 6 88 108 61 Washer 3 8 SAE 3 7 88 109 81 Locknut 3 8NC 1 8 88 527 11 Cotter Pin 1 8 x 1 2 9 88 060 09 Bolt 1 4NC x 3 4 Hex Hd 6 10 88 069 81 Locknut 1 4NC 6 ...

Page 166: ...Illustrated Parts Parts Page 16 Lester Chargers Page 1 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 167: ... 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 168: ...Illustrated Parts Parts Page 18 Lester Chargers Page 2 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 169: ...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 170: ...net Charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector Typical Charger 8actual appearance varies ...

Page 171: ...rts Page 21 Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the charger ...

Page 172: ...Illustrated Parts Parts Page 22 Motors 9 12 13 9 5 3 4 2 1 14 10 11 7 16 17 6 8 15 Typical GE Motor ...

Page 173: ... 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 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 Spe...

Page 174: ...Illustrated Parts Parts Page 24 Power Traction ...

Page 175: ...l on SC 1 10 16 415 00 Spacer 1 11 30 092 00 Pinion Sprocket standard on model SC 1 11 30 093 00 Pinion Sprocket standard on AN optional on SC 1 12 30 507 20 Drive Chain standard on model SC 1 12 30 508 20 Drive Chain standard on AN optional on SC 1 13 44 352 53 Backing Plate 1 14 88 101 13 Bolt 3 8NC x 1 1 4 Hex Hd 5 15 88 080 19 Bolt 5 16NC x 2 3 4 Hex Hd 9 16 41 989 00 Drain and Fill Plugs 2 17...

Page 176: ...Illustrated Parts Parts Page 26 Differential ...

Page 177: ...and Pinion Gear Set 2 75 1 7 41 997 00 Oil Plugs 2 8 41 290 00 Differential Housing 1 9 80 555 00 Rear Pinion Bearing 1 10 80 554 00 Front Pinion Bearings 2 11 41 711 00 Pinion Housing Shim 1 12 80 702 00 O Ring 1 13 44 340 90 Pinion Housing w Races 1 14 16 419 00 Shim 002 as required 14 16 420 00 Shim 010 as required 14 16 411 00 Shim 005 as required 15 16 415 00 Spacer 1 16 80 125 00 Pinion Bear...

Page 178: ...Illustrated Parts Parts Page 28 Brake ...

Page 179: ...7 1 4 85 060 20 Spring 1 5 41 372 10 Bracket Brake Mounting 1 6 88 159 82 Nut 1 2NF Jam 1 7 88 159 84 Locknut 1 2NF 1 8 88 109 81 Locknut 3 8NC 1 9 88 108 61 Washer 3 8 2 10 88 517 11 Cotter Pin 1 11 96 771 00 Clevis Pin 1 12 50 656 02 Brake Arm 1 13 88 101 13 Bolt 3 8NC Hex Hd Grade 5 1 14 41 371 10 Bracket Brake Alignment 2 15 88 080 13 Bolt 5 16NC x 1 1 4 Hex Hd 2 16 88 089 91 Nut 5 16NC Jam 4 ...

Page 180: ...Illustrated Parts Parts Page 30 Rear Axle ...

Page 181: ...asket Axle Bearing 2 8 32 512 0 Spacer 2 9 88 101 13 Bolt 3 8NC x 1 Hex Hd 8 10 88 109 81 Locknut 3 8NC 8 REAR AXLE serial numbers after 135706 Item No Part No Description Qty 1 97 236 00 Wheel Lug Nut 10 2 96 329 10 Wheel Bolt 10 3 41 162 05 Axle 10 11 16 Large Bearing Right 1 3 41 163 05 Axle 13 1 8 Large Bearing Left not shown 1 4 32 514 00 Plate Axle Retainer 2 5 80 503 00 Axle Bearing Ball Ty...

Page 182: ...Illustrated Parts Parts Page 32 Rear Tires 10 Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 ...

Page 183: ...sembly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 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 11 040 00 5 70 x 8 Tube 11 030 00 4 80 x 8 T...

Page 184: ...Illustrated Parts Parts Page 34 Control Panel standard ...

Page 185: ...ker 135 amp 1 9 73 004 20 Horn 12 V 1 10 88 089 80 Nut 5 16NC 4 11 88 088 62 Lock washer 5 16 4 12 88 080 11 Bolt 5 16NC x 1 Hex Hd 4 13 61 838 41 Bus Bar 5 8 x 1 1 2 Hole Centers 2 14 61 838 42 Bus Bar 3 8 x 2 5 8 Hole Centers 2 15 88 099 91 Nut 5 16NF Thin Pattern 10 16 88 088 63 Lock washer 5 16 Internal Tooth 10 17 88 049 80 Nut 10 32 5 18 88 048 62 Lock washer 10 5 19 88 817 09 Sheet Metal Sc...

Page 186: ...Illustrated Parts Parts Page 36 Control Panel 40 bed ...

Page 187: ...x 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 Lock washer 5 16 Internal Tooth 10 16 88 049 80 Nut 10 32 5 17 88 048 62 Lock washer 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 72 560 80 Solenoid Panel Assembly 24V 21 72 560 55 Panel Solenoid Mounti...

Page 188: ...Illustrated Parts Parts Page 38 Instruments Gauges Model SC shwon Model SC shwon ...

Page 189: ...n switch 1 2 71 120 00 Key switch 1 3 71 039 10 F R switch 1 4 71 100 00 Accessory switch optional 5 71 100 00 Accessory switch optional Gauges Item No Part No Description Qty 1 74 000 00 Hour meter optional 2 74 009 10 Battery Status 24v analog 1 74 009 12 Battery status 24v digital optional ...

Page 190: ...Illustrated Parts Parts Page 40 Batteries Main positive Main negative 1 1 1 2 2 3 3 3 4 5 6 7 ...

Page 191: ...069 81 Locknut 1 4NC 3 5 88 081 12 Bolt 5 16NC Square Hd Tin Lead 8 6 88 089 80 Nut 5 16NC Tin Lead 8 7 77 042 00 Battery 6 Volt 217 amp hour standard 4 7 77 044 00 Battery 6 Volt 230 amp hour optional 4 7 77 047 00 Battery 6 Volt 244 amp hour optional 4 7 77 042 80 Battery 6 Volt 217 amp hour optional export SC only 4 7 77 047 80 Battery 6 Volt 244 amp hour optional export SC only 4 ...

Page 192: ...Illustrated Parts Parts Page 42 Decals ...

Page 193: ...Not a motor vehicle 1 2 94 313 20 Safety warning 1 3 94 384 14 Leaving vehicle 1 4 94 382 00 Treadle 1 5 94 313 00 Battery warning 1 6 94 319 00 Battery disconnect 1 7 91 301 43 Arms and legs 1 8 94 333 00 FM 1 9 94 373 10 Vehicle data 1 Decals AN Illustration not available at time of printing ...

Page 194: ...Illustrated Parts Parts Page 44 Miscellaneous Frame and Body SC 5 1 2 3 14 6 17 18 19 4 7 15 16 ...

Page 195: ... Built in Charger 1 5 88 838 06 Sheet Metal Screw 14 x 1 2 2 6 71 501 00 Horn Button 1 7 30 702 00 Steering Chain Guard 1 14 88 837 11 Screw 14 x 1 Phillips Hd 2 15 88 060 18 Bolt 1 4NC x 2 1 2 Hex Hd 1 16 88 069 81 Locknut 1 4NC 1 17 88 025 10 Screw 8 32 x 7 8 Truss Hd 2 18 88 028 62 Lock washer 8 2 19 88 029 80 Nut 8 32 2 Not Shown 01 159 10 01 159 20 Comfort kit knee pad Comfort kit floorboard ...

Page 196: ...Illustrated Parts Parts Page 46 Miscellaneous Frame and Body AN ...

Page 197: ...ANEOUS PARTS Model AN Item No Part No Description Qty 1 90 406 00 Deckboard 30 3 4 x 53 1 4 1 2 71 599 00 Console Cover 1 3 90 160 01 Tractor Seat 1 4 90 160 10 Seat Support 1 5 98 350 00 Hand Grip 1 12 88 838 06 Sheet Metal Screw 14 x 1 2 2 ...

Page 198: ...TAYLOR DUNN ...

Page 199: ...ted 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 critical hardware 5 Appendix C Brake Lining Handling Precautions 7 REV B ...

Page 200: ...intenance is completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with 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...

Page 201: ... 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 202: ...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 203: ... 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 204: ... 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 205: ...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 206: ...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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