Taylor-Dunn B0-050-00 Operation, T Roubleshooting And Replacement Parts Manual Download

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Serial number Starting: 157300

MANUAL MB-050-00

Operation, Troubleshooting and

Replacement Parts Manual

Models Included:
B0-050-00 (B 50) Shuttle Master

Published: 12/16/2003
Revision: C

Summary of Contents for B0-050-00

Page 1: ...To Go About Your B u s i n e s s Serial number Starting 157300 MANUAL MB 050 00 Operation Troubleshooting and Replacement Parts Manual Models Included B0 050 00 B 50 Shuttle Master Published 12 16 200...

Page 2: ......

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

Page 4: ...B2 48 With Stake Side Dump Bed Option SC1 59 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor...

Page 5: ...ubleshooting 11 Chargers 12 Wire diagram 13 Illustrated Parts 14 Appendix A Special Tools 15 Appendix B Suggested Torque Values 16 Appendix C Brake Lining Handling Precautions 17 Taylor Dunn Model B0...

Page 6: ...TAYLOR DUNN...

Page 7: ...ONTENTS Introduction About this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 Conventions 5 How to Identify Your Vehicle 6 Taking Delivery of Your Vehicle 7 Add fi...

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

Page 9: ...of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible fo...

Page 10: ...to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific inform...

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

Page 12: ...Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B...

Page 13: ...result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also...

Page 14: ...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 15: ...ional 8 Directional Signals Optional 9 Hazard Light Switch Optional 9 Accelerator Pedal 9 Reverse or Motion Alarm Optional 9 Park Brake 9 Seat Interlock Switch 10 Vehicle Operational Guidelines 11 Saf...

Page 16: ...275 Amp Transmission Direct Drive Oil Bath Motor DC 36 Volt 1 5kW 2 hp 2400 RPM for 60 min Series Wound Field Brakes Rear Wheel Mechanical Drum Hand Operated Park Brake Steering Automotive Steering T...

Page 17: ...and listed below These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks and resorts They are not...

Page 18: ...afety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Tra...

Page 19: ...The forward off reverse switch located behind the key switch on the console between the seats determines the direction of travel of the vehicle Push the top of the switch to engage the forward direct...

Page 20: ...Charge the batteries when the needle is in the yellow zone If it is in the red zone to the left the batteries are empty and the truck should be taken out of service and charged to avoid damaging the...

Page 21: ...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 botto...

Page 22: ...e left side of the steering column The switch is a small tab To activate the hazard lights pull the tab out To turn the hazard lights off push forward or pull back the directional signal lever Acceler...

Page 23: ...l and or the batteries charged the alarm and light will reset Reverse or Motion Alarm Optional The reverse alarm is located in the electronics compartment mounted in the speed control panel enclosure...

Page 24: ...so could result in unexpected movement of the vehicle causing severe bodily injury and or property damage Seat Interlock Switch A switch located under the driver s seat disables the power to the vehic...

Page 25: ...it is moving Keep the vehicle under control at all times Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle at intersections bli...

Page 26: ...fore leaving the vehicle Set the parking brake Set the forward off reverse switch to the OFF position Turn the key switch to the OFF position and remove the key In addition If parking this vehicle on...

Page 27: ...e a semi automatic charging system The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Refer to the data...

Page 28: ...ew batteries require a break in period of up to 40 cycles The batteries will not have their full capacity during this break in period and may require longer charging times Lestronic II Charger Operati...

Page 29: ...charge as indicated on the Battery Status Indicator BSI Failure to follow this guideline could result in the batteries entering an overcharge state which will reduce the life of the batteries If you f...

Page 30: ...onnections l Wash 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 Nu...

Page 31: ...TABLE OF CONTENTS General Maintenance General Maintenance 1 Maintenance Guidelines 2 Maintenance Guidelines for Vehicles Used in Severe Conditions 3 Troubleshooting Guide 4 Lubrication Chart 5...

Page 32: ...s Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should...

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

Page 34: ...Power or Slow Operation Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings...

Page 35: ...Grease 3 Ball Joints 2 General Purpose Grease 4 Pedal Linkages 2 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Dri...

Page 36: ...TAYLOR DUNN...

Page 37: ...el Bearings and King Pin 2 Adjust Front Wheel Bearings 3 Front A Arm Removal and Installation 4 Removal 4 Installation 5 Replace Front Wheel Bearings 6 Replace the King Pins and Bushings 8 Replace the...

Page 38: ...d listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replaceme...

Page 39: ...ront of the vehicle and support with jack stands 7 Remove the hub dust cap and cotter pin 8 While rotating the hub tighten the spindle nut to 30 ft lbs This seats the bearings 9 Back off the spindle n...

Page 40: ...ck 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 FRONT A ARM REMOVAL AND INSTALLATION...

Page 41: ...vere bodily injury 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 Installation 6 Raise the front of the vehicle and support with jack stands 7 Install the A arm in reverse o...

Page 42: ...ub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 8 Remove the hub dust cap cotter pin and spindle nut 9 Remove the hub from the steering knuckle NOTE Fo...

Page 43: ...to the Brakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from b...

Page 44: ...ace the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at th...

Page 45: ...nuckle or suspension arm 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be replaced 11 Reassemble in reverse order NOTE Refer to Replace the Steering...

Page 46: ...ult in severe bodily injury Hub with Dust Cap Removed REPLACE THE STEERING KNUCKLE 6 Raise the front of the vehicle and support with jack stands 7 Remove the tire wheel assembly Refer to Tires and Whe...

Page 47: ...Do not tighten so much as to squeeze the legs of the knuckle together NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter p...

Page 48: ...Maintenance Service and Repair Front Axle Page 12 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 49: ...Steering Wheel 9 Replace the Steering Gear 10 Replace the Ball Joints Tie Rods and Drag Link 11 Replacing a Rod End 11 Replacing a Ball Joint 12 Replacing the Drag Link 13 Replacing the Tie Rod 14 Ce...

Page 50: ...y switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement...

Page 51: ...he ball joint clamps in their original location and orientation If the clamps are positioned so that they contact other components it may result in steering failure and loss of control of the vehicle...

Page 52: ...vehicle while the steering wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage Front wheel alignment 6 Raise t...

Page 53: ...e tie rod so that the distance at the front and rear of the tires is the same 14 If equipped with ball joints position the ball joint clamps in their original location and orientation 15 Tighten the b...

Page 54: ...injury and or property damage Typical Ball Joint INSPECT BALL JOINTS NOTE A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end is worn out then all should be...

Page 55: ...atteries 9 Remove the blocks from behind the wheels 10 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 re...

Page 56: ...information regarding removing the ball joint from the drag link 8 Loosen the gear lash jam nut 9 Find the center position of the steering shaft A Turn the steering shaft all of the way in one direct...

Page 57: ...the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straight ahead position 10 Lightly grease the ste...

Page 58: ...steering gear so that it cannot fall out of the vehicle Failure to support the steering gear will result in the steering gear falling out of the vehicle and could cause property damage and or severe...

Page 59: ...Loosen the rod end jam nut or clamp on the steering sleeve 8 Remove the rod end nut 9 Remove the rod end from the steering arm HINT Count the number of turns required to remove the rod end from the s...

Page 60: ...joint nut 9 Using a pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve HINT Count the number of turns required to remove the ball joint from the...

Page 61: ...ball joints or rod ends from the steering knuckle and pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Remove the d...

Page 62: ...verse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and negative ca...

Page 63: ...cannot rotate 8 Install the pitman shaft on the steering gear so that it is as close as possible to perpendicular to the ground Torque the pitman arm nut to 181 217 ft lbs 10 Untie the steering wheel...

Page 64: ...the input shaft 8 Remove the upper bearing race from the housing 9 Remove the jam nut from the gear lash adjustor and separate the housing cover from the output shaft 10 Remove the output shaft oil s...

Page 65: ...Maintenance Service and Repair Steering Page 17 Steering Gear Exploded...

Page 66: ...TAYLOR DUNN...

Page 67: ...ke Mechanism Operation 2 Inspecting the Auto Adjust Brake Mechanism 3 Brake Shoes 4 Brake Drum Dana 4 Inspect the Park Brake 5 Inspection and Replacement of Park Brake Pedal Lock 5 Rear Brake Linkage...

Page 68: ...anual adjustment if any part of the external mechanical linkages or cables have been removed NOTE The symptom of a low brake pedal may indicate that the auto adjuster is not working or the brake cable...

Page 69: ...ad capacity may result in serious bodily injury Inspecting the Auto Adjust Brake Mechanism 6 Raise the rear of the vehicle and support with jack stands 7 Using the appropriate procedure remove the bra...

Page 70: ...Refer to appendix C for recommended handling precautions Brake Drum Dana NOTE The wheel must be removed to accurately measure the brake drum Refer to Tires and Wheels section for information on remov...

Page 71: ...to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Park Brake Lock Brake Arm Brake Pedal 1 2 Bolt Always use new lock...

Page 72: ...both clevis jam nuts and back off the brake rod adjustment so that the brake pedal falls 2 inches 12 Temporarily install the brake pedal return spring in the clevis pin and stretch approximately 1 5 i...

Page 73: ...and or severe bodily injury 7 Using the appropriate procedure remove the brake drum 8 Release the park brake 9 Remove the tension springs 10 Remove the hold down springs 11 Remove the auto adjust lev...

Page 74: ...TAYLOR DUNN...

Page 75: ...tors with internal cooling fans 2 Enclosed Motors GE no cooling fan 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes 5 Replacing the Bearings 6 Repairing the Commutator 6 Se...

Page 76: ...Disconnect the main positive and negative cables at the batteries Typical motor with cooling fan indicated by the arrow Typical brush and brush holder Motors with internal cooling fans NOTE There are...

Page 77: ...the length of each motor brush If any one brush is less than or equal to the service limit specified in section Service Limits then all four brushes should be replaced Refer to Replacing the Brushes s...

Page 78: ...of digital multi meter check the continuity from any one of the commutator segments and the armature frame If it is not an open circuit then the armature is shorted and the motor must be replaced 11 R...

Page 79: ...Remove the brush covers 2 Loosen the brush wire retaining screw and remove the brush from the brush holder Be careful with the brush spring and do not let it slip off of the spring mount If the spring...

Page 80: ...Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Do not press against the outer race of the bearing Pressing against the outer race will...

Page 81: ...Depth max mm inches mm inches mm inches mm inches 5BC58JBS6129A 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129B 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129C 0 635 0 025 66 75 2...

Page 82: ...TAYLOR DUNN...

Page 83: ...r 4 Removal 4 Installation 4 Rear Hub with Brake Drum 5 Removal and Installation 5 Rear Axle 6 Replace the Axle Bearing 8 Transmission 9 Removal and Installation 9 Differential Case 10 Disassemble 10...

Page 84: ...oil to drain into the drain pan and then reinstall the level plug 10 Reconnect the main positive and negative cables at the batteries 11 Remove blocks from behind the wheels 12 Test drive the vehicle...

Page 85: ...se lifting and support devices of rated load capacity may result in severe bodily injury CHANGE OIL Park the vehicle on a level surface 6 Place a drain pan that can hold a minimum of 2 quarts of oil u...

Page 86: ...be removed to allow clearance to remove the motor Refer to Transmission section for information on removing the transmission assembly from the vehicle 6 Remove the motor wires from the motor HINT Tag...

Page 87: ...tallation NOTE Some vehicle configurations do not have a removable hub The hub is an integral part of the rear axle See the illustrations to the right to identify the hub on your vehicle 6 Remove the...

Page 88: ...to identify the type of hub on your vehicle NOTE The tire wheel assembly must be removed for these procedures Refer to Tires and Wheels section for information on removing the tire and wheel assembly...

Page 89: ...rake drum 8 Remove the mechanical brake linkage from the brake arm 9 If equipped with hydraulic brakes disconnect the brake line from the wheel cylinder 10 Remove the four bolts holding the axle brake...

Page 90: ...m for information regarding removing the hub 2 Press the axle bearing off of the axle shaft and discard 3 Press a new bearing onto the axle shaft 4 If the axle is not to be immediately installed into...

Page 91: ...Support the rear of the vehicle with a lifting device but do not raise the rear wheels off of the ground 10 Remove the lower shock bolts and compress the shocks to get them out of the way Always use...

Page 92: ...ion for information on removing the axles 4 Suspend the differential case over a drain pan that can hold a minimum of 2 quarts of oil 5 Remove the differential case cover being careful not to bend or...

Page 93: ...ate shaft bore plugs 10 Thread a sheet metal screw into each plug until the bore plug is forced out 11 Remove both snap rings from the intermediate shaft bore 12 Using a soft metal or hard wood dowel...

Page 94: ...ar teeth 13 Remove the intermediate bearing with an ID bearing puller 14 While supporting the shaft and gear assembly repeat steps 12 and 13 for the opposite side bearing and remove the intermediate s...

Page 95: ...t tightly into their grooves If a snap ring is loose then it must be replaced NOTE All internal components should fit easily together Do not hit any shaft or component with a hard metal hammer or punc...

Page 96: ...dowel the same diameter as the bearing bore to drive the bearing into place Do not drive against the inner race as this will damage the bearing 4 Install the input shaft into the housing and install...

Page 97: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Spring 3 Replace the Shocks 4...

Page 98: ...nds of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Remove the lower shock bolt on the same...

Page 99: ...g and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehicle and support with jack stands 7 Tie up or support the left and right side front wheel so...

Page 100: ...kage is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse order 1...

Page 101: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Tires and Wheels...

Page 102: ...tions available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall...

Page 103: ...em 11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak 1 Make sure the key switch i...

Page 104: ...nuts may result in the wheel coming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from t...

Page 105: ...eplacement 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 pro...

Page 106: ...TAYLOR DUNN...

Page 107: ...LE OF CONTENTS Cleaning 2 Testing 3 Watering 5 Charging 6 Replacing 6 volt batteries only 7 Moist Charge Batteries 9 Storage and Returning to Service 10 Storage 10 Returning to Service 11 Battery Serv...

Page 108: ...rinse thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive Explosive mixtures of Hydrogen gas ar...

Page 109: ...h or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms...

Page 110: ...mber77 200 00 hydrometer check and record the specific gravity of each cell in the battery pack If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the...

Page 111: ...ject 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 bodi...

Page 112: ...ative cables at the batteries CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions 6 Clean the batteries Refer to Cleaning the Batteries section for information o...

Page 113: ...tion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source...

Page 114: ...icle 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 compartment prepped and re...

Page 115: ...n rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not dro...

Page 116: ...E AND RETURNING TO SERVICE Storage Thoroughly clean the batteries and battery compartment Refer toCleaning in this section for information regarding cleaning the batteries Check the electrolyte level...

Page 117: ...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 property damage and or bodily injury Battery electro...

Page 118: ...TAYLOR DUNN...

Page 119: ...leshooting SYMPTOMS 2 READ THIS FIRST 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 3 SYMPTOM TROUBLESHOOTING GUIDE 19 PMC CONTROL 20 PLUGGING DIODE 22 FREEWHEEL DIODE 23...

Page 120: ...mal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus hi...

Page 121: ...iple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT start in the middle of this troubleshoo...

Page 122: ...lerator pedal is depressed then go to the Forward Reverse Switch sequence After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the...

Page 123: ...key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some o...

Page 124: ...k brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the...

Page 125: ...all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator pedal to engage MS 1 only If the voltage is not between 6 0 and 6 5 volts then go to the Accel...

Page 126: ...ositive If the voltage is not the same as battery volts then there is an open circuit in the wire from B to the battery Stop troubleshooting here and repair the problem When the repair is completed co...

Page 127: ...motor may not be in the same location S2 A1 A2 S1 Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Motor Set the test light voltage to the same voltage as the batter...

Page 128: ...on the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp...

Page 129: ...Representative for more information If you do not know how to test for continuity refer test to a qualified technician COLD Violet Wire s HOT Red wire s BATTERY MAIN NEGATIVE KEY SWITCH View of the t...

Page 130: ...at battery volts then go to the Accelerator sequence Connect a voltmeter across one of the COLD terminals of the KSI side of the F R switch and battery negative Close all interlock switches turn the K...

Page 131: ...ve NOTE You may skip this test if it was completed in a previous section If the voltage is not at battery volts then check the wiring to battery negative and the negative circuit breaker Stop trouble...

Page 132: ...ttery volts then the F R switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground C...

Page 133: ...may vary Battery Negative FWD REV Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal f...

Page 134: ...volts then go to the F R Switch sequence Set the test light voltage to the same voltage as the battery volts Connect the test light across the normally open contacts of the reverse solenoid Refer to...

Page 135: ...When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery ne...

Page 136: ...e position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F R Switch in forward Depress the accelerator pedal fully If the light comes on then the Forward so...

Page 137: ...eeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL Does not run in either direction plus there is noise from moto...

Page 138: ...in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnec...

Page 139: ...drive wheels to the ground otherwise continue with the next test If the voltage at pin 2 is correct and the voltage at M is correct then there is a short in the harness between the wire connected to...

Page 140: ...ution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated...

Page 141: ...ant to review the trouble shooting steps that have led to this point The tests may need to be repeated B M A2 B 2 KSI _ The reading shown is for illustration only The actual reading may vary 1 Make su...

Page 142: ...re bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do s...

Page 143: ...repeated Reading is plus or minus 10 ISO solenoid is shown for reference only The type of solenoid in your truck may look different _ Connect the meter to each end of the resistor that was removed fro...

Page 144: ...is a very slight possibility that a failure in the motor could cause these symptoms Perform the tests covered in the MOTOR section first If the motor is OK continue with the following tests Remove the...

Page 145: ...the wire connected to the motor A2 terminal C The wire connected to the motor S2 terminal is shorted to the wire connected to the PMC A2 terminal Stop trouble shooting here and repair the problem Whe...

Page 146: ...se solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S1 terminal Stop trouble shooting here and repair the problem When the repair is complet...

Page 147: ...ing here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test 1 Make sure the key swit...

Page 148: ...black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the next test 4 Perf...

Page 149: ...4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 Turn the Key switch OFF BEF...

Page 150: ...urrent state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200...

Page 151: ...efore connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is tu...

Page 152: ...than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC vo...

Page 153: ...r has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Con...

Page 154: ...re continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers F...

Page 155: ...mer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that a...

Page 156: ...blem Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconn...

Page 157: ...f the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The volta...

Page 158: ...here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the A...

Page 159: ...st Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting...

Page 160: ...ses the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to...

Page 161: ...eter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery...

Page 162: ...od working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger exhibits...

Page 163: ...arger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Note If only the 100 LED is flashing and all others are OFF the...

Page 164: ...g current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charge...

Page 165: ...ing Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 Rev C Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the contro...

Page 166: ...here are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 vol...

Page 167: ...ge the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On t...

Page 168: ...ng off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but stil...

Page 169: ...charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the c...

Page 170: ...e reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the P...

Page 171: ...TABLE OF CONTENTS Wire Diagrams Complete Vehicle 2 Dash 3 Control Panel 4 Accelerator Module Detail 5 Lights 6...

Page 172: ...verse solenoid coil STROBE Brown STROBE White _ Brown White Black HM _ BSI Black _ SWITCH STOP Gray Violet Black Red Brown LIGHT D1 KEY Red Red SEAT SWITCH YELLOW Violet Black Black Yellow F Violet Bl...

Page 173: ...Black BSI Red LIGHT Red KEY Red Red Red Violet Black Violet Black Violet Black Black R Black Yellow Violet Black Green Black Fowrard and Reverse Switch Accelerator Module Plug R Reverse solenoid coil...

Page 174: ...Black D1 Red R1 S1 Red CB 20A Red Black White Black White White MOTOR Black SPEED CONTROL KSI Violet Black Yellow 2 B Black B A2 Blue A Charging Recptacle Black Red Main battery negative Main battery...

Page 175: ...ge 5 ACCELERATOR MODULE DETAIL Black Yellow Violet Black Green Black MS2 Micro switch 2 MS1 Micro switch 1 Internal components are illustrated for reference only There are no user serviceable parts in...

Page 176: ...HEAD LIGHTS Brown Turn Lights White Left Right Brown White To 12v Brown Brown White White STROBE _ Red Brown D1 LIGHT STROBE KEY Red Red Red To B 4 4 OFF RIGHT 4W AY LEFT White 3 3 Black FLASHER 9 9...

Page 177: ...ar Suspension 12 Motor 14 Brake linkage 16 Wheels and Tires 18 Instrument Panel Console 20 Speed Control Panel 22 Miscellaneous Electrical 24 Miscellaneous Frame and Body 26 Charger Page 1 28 Charger...

Page 178: ...Illustrated Parts Parts Page 2 Front Axle and Suspension...

Page 179: ...eft 1 9 88 189 81 5 8NC Hex lock nut 2 10 97 180 55 Thrust washer 4 11 32 240 55 Bushing 4 12 21 020 15 King pin 2 13 88 119 81 3 8NC hex lock nut 2 14 14 110 17 Bushing 2 15 88 111 22 3 8NC x 3 1 2 H...

Page 180: ...Illustrated Parts Parts Page 4 Steering Linkage...

Page 181: ...d 1 7 86 519 10 Rod end right thread 1 8 86 519 11 Rod end left thread 1 9 50 002 20 Drag link 1 10 88 119 50 3 8NF Hex nut 1 11 97 202 50 Jam nut left thread 1 12 88 100 15 3 8NC x 1 3 4 Hex bolt 2 1...

Page 182: ...Illustrated Parts Parts Page 6 Steering Gear...

Page 183: ...ck washer 1 7 Oil seal 1 8 Lower worm bearing and race 1 9 Shim 0 10 mm As needed Shim 0 15 mm Shim 0 30 mm 10 Gasket 1 11 Housing 1 12 Housing cover 1 13 Screw 4 14 Gasket 1 15 Output gear shaft 1 16...

Page 184: ...Illustrated Parts Parts Page 8 Transmission Differential Case 1 2 3b 4 5 6 7 6 5 8 3c 9 3d 9 8 5 6 7 15 10 16 10 3a 14 11 11 17 12 13...

Page 185: ...r 1 3d See kit below Intermediate shaft 1 4 80 480 15 Input shaft bearing 1 5 88 840 12 Snap ring 1 6 80 715 10 O ring 1 7 41 973 00 Bore plug 1 8 66 610 35 Intermeadiate shaft bearing 2 9 80 715 00 O...

Page 186: ...Illustrated Parts Parts Page 10 Rear Axle and Brakes...

Page 187: ...28 66 611 11 Retaining ring 2 29 66 611 12 Axle bearing 2 30 66 611 13 Snap ring 4 31 Brake assembly L 1 32 Brake assembly R 1 33 66 611 14 Wheel stud 10 35 41 126 96 Axle shaft L 1 36 41 126 97 Axle...

Page 188: ...Illustrated Parts Parts Page 12 Rear Suspension...

Page 189: ...32 249 00 Bushing assembly 3 6 85 140 00 Spring 2 7 86 602 00 Shock 2 8 17 106 00 Spacer 2 9 01 110 83 Spring mount left 1 01 110 84 Spring mount right 1 10 01 110 80 Swing arm 1 11 00 255 02 Track a...

Page 190: ...Illustrated Parts Parts Page 14 Motor 2 3 5 6 4 7 8 1 9 10 Armature 12...

Page 191: ...70 201 15 Field coils mounted in motor housing 1 2 70 210 51 Inulator 2 3 85 412 00 Brush spring 4 4 70 172 15 Brush holder includes 3 1 5 70 104 15 Motor brush 2 2 6 70 210 51 Insulator 2 7 32 508 1...

Page 192: ...Illustrated Parts Parts Page 16 Brake linkage...

Page 193: ...4 7 88 517 11 1 8 x 1 Cotter pin 4 8 50 002 17 Brake rod 1 9 88 099 80 5 16 Hex nut 1 10 96 763 00 Clevis 1 11 01 204 32 Brake cable eqalizer 1 12 96 754 00 Clevis 2 13 96 826 12 Brake cable 2 14 96...

Page 194: ...Illustrated Parts Parts Page 18 Wheels and Tires Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9 10...

Page 195: ...l Assembly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF...

Page 196: ...Illustrated Parts Parts Page 20 Instrument Panel Console...

Page 197: ...nt Panel ITEM PART DESCRIPTION QTY 1 71 120 10 Key switch 1 2 71 100 00 Light switches 2 3 74 009 00 Battery status meter 1 4 71 039 02 Forward and reverse switch 1 5 94 386 03 Console decal 1 6 00 11...

Page 198: ...Illustrated Parts Parts Page 22 Speed Control Panel 4 6 7 5 21 20 19 13 10 REV FWD ISO 8 8 1 2 11 12 14 15 16 Solenoid end view from side closest to PMC 9 17 17 18 End view of PMC 5...

Page 199: ...D thread 8 9 73 004 20 Horn 1 10 01 110 35 Mounting panel 1 11 97 211 20 14NC U nut 4 12 88 838 06 14 x 1 2 Pan head screw type D thread 2 13 88 817 09 8 x 3 4 Phillips head sheet metal screw 2 14 61...

Page 200: ...s Electrical Horn Switch Mounted 5 7 6 Floorboard Mechanical Brake Light Switch Mounted Under Floorboard 8 9 Seat Interlock Switch Accelerator Module 10 14 13 11 12 Seat Frame 1 Motion Alarms Miscella...

Page 201: ...065 06 1 4 NC x 21 2 Phillips Truss Head Screw Horn Switch 2 7 88 069 81 1 4 NC Hex Nylon Locknut Horn Switch 2 8 71 111 00 Brake Light Switch 1 9 88 045 06 10 32 x 1 2 Machine Screw brake light switc...

Page 202: ...Illustrated Parts Parts Page 26 Miscellaneous Frame and Body...

Page 203: ...90 147 30 Passenger seat cushion 1 3 90 179 10 Seat back 1 4 01 110 16 Deck lid 1 5 94 035 01 Seat trim 7 feet 6 98 455 50 Heat shrink tube 6 inches 7 01 110 20 Accelerator pedal 1 8 See Brake Linkag...

Page 204: ...Illustrated Parts Parts Page 28 Charger Page 1 CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 205: ...9 730 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 8...

Page 206: ...Illustrated Parts Parts Page 30 CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger Charger Page 2...

Page 207: ...1 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...

Page 208: ...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 model...

Page 209: ...M PART DESCRIPTION QTY 94 050 10 Headlight left 1 94 050 11 Headlight right 1 94 050 04 Headlight retainer 4 00 110 02 Headlight panel 1 72 022 00 Tailight 1 or 2 72 022 51 Tailight gasket 1 or 2 72 0...

Page 210: ...Illustrated Parts Parts Page 34 Batteries POS POS POS POS POS POS NEG NEG NEG NEG NEG 1 2 7 8 NEG Main Positive 12 v Negative Tap Main Negative 6 5 4 3...

Page 211: ...charger 0 or 6 77 047 00 244AH T 145 0 or 6 77 047 50 250AH TD 250 0 or 6 77 047 80 244AH T 145 Moist charge dry 0 or 6 77 048 00 250AH J 250 0 or 6 77 048 80 250AH J 250 Moist charge dry 0 or 6 77 0...

Page 212: ...Illustrated Parts Parts Page 36 Decals...

Page 213: ...4 01 Not a motor vehicle 0 or 1 94 384 04 Not a motor vehicle Export vehicles 0 or 1 5 94 313 00 Battery warning 1 6 94 319 00 Dissconnect battery 1 7 See Instument Panel Console decal 8 94 313 20 Saf...

Page 214: ...Illustrated Parts Parts Page 38 Sun Top and Windshield...

Page 215: ...eld 1 7 98 314 01 Gasket 1 8 98 603 00 Grommet 8 9 88 065 11 1 4NC x 1 Truss head bolt 8 10 88 068 60 1 4 Cut flat washer 8 11 88 080 11 5 16NC x 1 Hex bolt 4 12 88 089 81 5 16NC Lock nut 4 13 88 069...

Page 216: ...Illustrated Parts Parts Page 40 Mirrors Multi Panel mirror Side mirror 9 11 2 1 2 5 4 6 7 3...

Page 217: ...M PART DESCRIPTION QTY 1 92 201 00 Mirror 1 or 2 2 92 202 12 Mounting bracket left 1 3 88 088 61 5 16 SAE flat washer 2 4 88 080 09 5 16NC x 3 4 Hex bolt 1 5 88 088 62 5 16 Split lock washer 1 6 88 06...

Page 218: ...Illustrated Parts Parts Page 42 Tool Box Luggage Rack 2 1 3 Tool box Luggage rack...

Page 219: ...Ilustrated Parts Parts Page 43 Tool Box Luggage Rack ITEM PART DESCRIPTION QTY 1 71 040 95 Lock 1 2 90 547 14 Tool box 1 3 90 547 11 Luggage rack 1...

Page 220: ...Illustrated Parts Parts Page 44...

Page 221: ...TAYLOR DUNN...

Page 222: ...APPENDIX A Special Tools...

Page 223: ...l C4 25 Huskey 62 027 10 GE EV1 Analyzer Used to test the GE EV1 speed control 62 027 20 Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41 350 13 Pin Removi...

Page 224: ...are Suggested Torque Limits Hardware Identification 2 Standard Head Markings 2 Hex Bolts 2 Other Bolts 2 Hex Nuts 3 Hex Lock Nuts stover 3 Other Nuts 3 Suggested Torque Values non critical hardware 4...

Page 225: ...e 5 Truss Head grade 2 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...

Page 226: ...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 ar...

Page 227: ...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 20...

Page 228: ...r 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 pl...

Page 229: ...TAYLOR DUNN...

Page 230: ...Appendix C...

Page 231: ...rake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel...

Page 232: ......

Page 233: ...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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