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Electrical Troubleshooting

Charger Troubleshooting

Page 5

TROUBLESHOOTING FOR BUILT-IN CHARGER

5. Disconnect the charger from the AC source.

Locate the charger harness connectors where the charger harness is connected to the vehicle’s control

harness. There will be two 10 gauge and two 14 gauge wires.
Slide the insulators off the connectors on the two 10 gauge wires and perform the following tests:

6. Test the voltage from the red wire to the main battery negative. This voltage should

be equal to the battery voltage. If the voltage is less than the battery voltage, then

this wire is broken or has a bad connection.

Stop here and repair the problem.

7. Test the voltage from the red 10 gauge wire (+) to the other 10 gauge wire (white

or black depending on model). This voltage should be equal to the battery voltage.

If the voltage is less than the battery voltage, then the white (or black) wire is

broken or has a bad connection.

Stop here and repair the problem.

Slide the insulators back onto the connectors on the two 10 gauge wires.
Slide the insulators off the connectors on the two 14 gauge wires.

Re-Connect the charger to the AC source.

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

as the voltage at the AC receptacle (rated voltage of the charger). If the voltage is

less than the rated AC voltage of the charger then the 14 gauge white or black

wire(s) is broken or has a bad connection between the charger connectors and

the AC plug.

Stop here and repair the problem.

1. Make sure the key-switch is in the “OFF” position, then remove the

key.

2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

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

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

Failure to do so may result in serious bodily injury.

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

with any other object.

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Содержание AN 171

Страница 1: ...ing 94562 Ending 167016 Note Other controllers used up to serial number 95754 use manual MA 159 04 MANUAL MA 159 05 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded SC 001 59 SC...

Страница 2: ......

Страница 3: ...nn 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...

Страница 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...

Страница 5: ...ervice 11 Control System Troubleshooting 12 Charger Troubleshooting 13 Wire diagram 14 Illustrated Parts 15 Appendix A Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Ha...

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

Страница 7: ...roduction 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 Deliv...

Страница 8: ...pplicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any T...

Страница 9: ...entions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information a...

Страница 10: ...ed below This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American N...

Страница 11: ...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...

Страница 12: ...TAYLOR DUNN...

Страница 13: ...ke 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 G...

Страница 14: ...ol 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 dut...

Страница 15: ...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 P...

Страница 16: ...gage 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...

Страница 17: ...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 connecte...

Страница 18: ...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...

Страница 19: ...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 peda...

Страница 20: ...r 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 trea...

Страница 21: ...le 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...

Страница 22: ...ly 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 o...

Страница 23: ...es 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 informat...

Страница 24: ...h and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l C...

Страница 25: ...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...

Страница 26: ...TAYLOR DUNN...

Страница 27: ...e 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 vehi...

Страница 28: ...or 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 c...

Страница 29: ...ing 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 W...

Страница 30: ...neral 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 Gea...

Страница 31: ...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...

Страница 32: ...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 d...

Страница 33: ...ands 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 w...

Страница 34: ...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 t...

Страница 35: ...r 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...

Страница 36: ...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 st...

Страница 37: ...en 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 ca...

Страница 38: ...orners 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 colla...

Страница 39: ...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 t...

Страница 40: ...se 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 T...

Страница 41: ...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...

Страница 42: ...TAYLOR DUNN...

Страница 43: ...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...

Страница 44: ...rom 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...

Страница 45: ...ted 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...

Страница 46: ...or 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...

Страница 47: ...lts 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 dr...

Страница 48: ...e 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 j...

Страница 49: ...he 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 tread...

Страница 50: ...TAYLOR DUNN...

Страница 51: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Throttle Linkage...

Страница 52: ...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...

Страница 53: ...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...

Страница 54: ...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...

Страница 55: ...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...

Страница 56: ...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...

Страница 57: ...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...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...TAYLOR DUNN...

Страница 61: ...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 Assembl...

Страница 62: ...ace 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...

Страница 63: ...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 Rele...

Страница 64: ...nt 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...

Страница 65: ...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...

Страница 66: ...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 S...

Страница 67: ...tive 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 cent...

Страница 68: ...n 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 re...

Страница 69: ...n 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 re...

Страница 70: ...om the housing and then reinstall the drain plug 8 Remove the brake drum Refer to sectionBrakes Replace the Brake Drum for information regarding removing the brake drum 9 Remove the nuts from the thre...

Страница 71: ...emove 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 pl...

Страница 72: ...ain 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...

Страница 73: ...ting bolts 15 Adjust the brake Refer to sectionBrake Service Adjust the Brakes for information regarding adjusting the brakes 16 Adjust the drive chain Refer to sectionAdjust the Drive Chain for infor...

Страница 74: ...r 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 D...

Страница 75: ...d 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 differenti...

Страница 76: ...eeth 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...

Страница 77: ...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...

Страница 78: ...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...

Страница 79: ...Transmission Transmission Page 19...

Страница 80: ...Transmission Transmission Page 20 EXPLODED VIEW...

Страница 81: ...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...

Страница 82: ...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 Ti...

Страница 83: ...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...

Страница 84: ...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 r...

Страница 85: ...BLE 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...

Страница 86: ...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...

Страница 87: ...ctrolyte 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...

Страница 88: ...ger 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 char...

Страница 89: ...n 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 i...

Страница 90: ...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 bat...

Страница 91: ...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...

Страница 92: ...l 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...

Страница 93: ...tion 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 s...

Страница 94: ...TAYLOR DUNN...

Страница 95: ...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...

Страница 96: ...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...

Страница 97: ...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...

Страница 98: ...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...

Страница 99: ...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...

Страница 100: ...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...

Страница 101: ...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...

Страница 102: ...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...

Страница 103: ...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...

Страница 104: ...ion the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp...

Страница 105: ...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...

Страница 106: ...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...

Страница 107: ...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...

Страница 108: ...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...

Страница 109: ...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...

Страница 110: ...y volts then go to theF 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...

Страница 111: ...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 n...

Страница 112: ...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...

Страница 113: ...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...

Страница 114: ...n 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...

Страница 115: ...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...

Страница 116: ...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...

Страница 117: ...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...

Страница 118: ...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...

Страница 119: ...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...

Страница 120: ...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...

Страница 121: ...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...

Страница 122: ...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...

Страница 123: ...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...

Страница 124: ...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...

Страница 125: ...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...

Страница 126: ...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...

Страница 127: ...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...

Страница 128: ...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...

Страница 129: ...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...

Страница 130: ...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...

Страница 131: ...RelayTest 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 co...

Страница 132: ...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...

Страница 133: ...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...

Страница 134: ...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...

Страница 135: ...st Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error CodeTable 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting t...

Страница 136: ...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...

Страница 137: ...eter and clamp on DC ammete r 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 batter...

Страница 138: ...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...

Страница 139: ...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...

Страница 140: ...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...

Страница 141: ...ing Cycle 4 Status Light Error CodeTable 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 control...

Страница 142: ...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...

Страница 143: ...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...

Страница 144: ...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...

Страница 145: ...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...

Страница 146: ...be reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the...

Страница 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...

Страница 148: ...ail 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 MS...

Страница 149: ...R 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 Char...

Страница 150: ...TAYLOR DUNN...

Страница 151: ...4 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 3...

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

Страница 153: ...ted 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 opt...

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

Страница 155: ...0 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...

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

Страница 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 Spindl...

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

Страница 159: ......

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

Страница 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...

Страница 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...

Страница 163: ...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...

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

Страница 165: ...g 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 1...

Страница 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...

Страница 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...

Страница 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...

Страница 169: ...31 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 7...

Страница 170: ...et 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 Typic...

Страница 171: ...ts 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 component...

Страница 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...

Страница 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...

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

Страница 175: ...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 50...

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

Страница 177: ...nd 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...

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

Страница 179: ...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 9...

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

Страница 181: ...sket 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...

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

Страница 183: ...embly 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...

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

Страница 185: ...er 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 Ba...

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

Страница 187: ...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...

Страница 188: ...Illustrated Parts Parts Page 38 Instruments Gauges Model SC VKRZQ Model SC VKRZQ...

Страница 189: ...switch 1 2 71 120 00 Key switch 1 3 71 039 02 F R switch 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 opti...

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

Страница 191: ...69 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...

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

Страница 193: ...ot 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 33...

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

Страница 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...

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

Страница 197: ...NEOUS 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 1...

Страница 198: ...TAYLOR DUNN...

Страница 199: ...ed Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex Bolts 3 Other Bolts 3 Hex Nuts 4 Hex Lock Nuts stover 4 Other Nuts 4 Suggested Torque Values non critica...

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

Страница 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 Toq...

Страница 202: ...as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no marki...

Страница 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 1...

Страница 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 Dra...

Страница 205: ...um cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause u...

Страница 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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