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Battery Charger

Page 17

MN-402-000

• 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 here and repair the
problem.

• Test the AC voltage across the transformer low voltage

secondary circuit. The transformer low voltage secondary
circuit can be tested at the two solid wires with the brown
fiber insulator that are connected to the anodes on the two
diodes. 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 rated DC voltage of
the charger, the transformer is bad and must be replaced. Stop
here and repair the problem.

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Содержание B0-T48-48 Taylor Truck T48

Страница 1: ...i n e s s Serial number Starting 150778 MANUAL MB T48 01 Operation Troubleshooting and Re placement Parts Manual Models Inlcuded B0 T48 48 Taylor Truck T48 ET 030 48 ET 3000 Published 3 28 2002 Revis...

Страница 2: ......

Страница 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...

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: ...ice Control System Troubleshooting Chargers Wire diagram Illustrated Parts Appendix A Special Tools Appendix B Suggested Torque Values Appendix C Brake Lining Handling Precautions Taylor Dunn Operator...

Страница 6: ...pes of vehicles offered by Taylor Dunn B 2 48 36 Equipped with optional hydraulic dump bed BT 2 80 Eight passenger tram B 1 00 Personnel carrier C 4 25 Huskey tow tractor MX 1600 Equipped with optiona...

Страница 7: ...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 Shown with fiberglass steel cab options Show...

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: ...ill be in one of two locations as shown 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 applic...

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: ...Model B 1 00...

Страница 13: ...irectional Signals Optional 7 Hazard Light Switch Optional 7 Charger Interlock 7 Seat Interlock Switch 7 Smart View Display 8 Vehicle Operational Guidelines 10 Safety Guidelines 10 Starting 10 While d...

Страница 14: ...tive Type Hypoid Differential Motor DC Seperatly Excited Field 5 9 kW 7 9 Horse Power for 60 minutes Brakes 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Tires 20 5...

Страница 15: ...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...

Страница 16: ...trical options are installed see above Toggle the switch lever up for normal speed Toggle the switch lever down for slow speed 5 Accessory Switch Optional The accessory switch is located on the left s...

Страница 17: ...he key clockwise to turn the vehicle power on counterclockwise to turn the vehicle power off The key switch should be in the OFF position whenever the operator leaves the vehicle This switch is also d...

Страница 18: ...pull the lever up until it locks To release the park brake depress the foot brake pedal pull up on the park brake handle push the release button and lower the handle Accelerator Pedal The accelerator...

Страница 19: ...rd lights pull the tab out To turn the hazard lights off push forward or pull back the directional signal lever Seat Interlock Switch A switch located under the driver s seat disables the power to the...

Страница 20: ...emoved from service for charging Discharging beyond 90 will result in damage to the batteries that will shorten the battery life span HM There are two hour meter functions Key Hours and Run Time Hours...

Страница 21: ...wiring to the controller 01005 Speed control overheated Allow the controller to cool off May be the result of an overloaded vehicle or an obstruction to the controller heat sink 01008 Optional speed e...

Страница 22: ...parking brake 3 Hold down the foot brake 4 Rotate the Start switch to the ON position and wait 1 second 5 Release the parking brake 6 Release the foot brake 7 Slowly depress the accelerator pedal Whi...

Страница 23: ...parking brake will be applied when the start switch is turned off or the operator leaves the driver seat It will also be applied if the control system loses power such as when the emergency battery d...

Страница 24: ...d technician Incorrect repair or reassembly of the charger can result in an explosion electric shock or fire Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with...

Страница 25: ...roperty damage WARNING Do not attempt to operate the vehicle while charging the battery Operating the charger and vehicle at the same time may lead to damage to the charger and or the vehicle resultin...

Страница 26: ...y or death WARNING WARNING DO NOT disassemble the charger There are no user serviceable components in the charger Refer all repairs to a qualified technician Incorrect repair or reassembly of the char...

Страница 27: ...n in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage WARNING This charger is rated for 115 VAC or 230 VAC operation nominal Confirm t...

Страница 28: ...ds If the charger does not remain ON after releasing the switch then try again If the charger refuses to start then have the batteries and charger tested by an qualified technician Fault LED Status LE...

Страница 29: ...the battery electrolyte once a week Do not charge the batteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their life span Only autho...

Страница 30: ...RULES AND OPERATING INSTRUCTIONS Safety Rules Page 18 PERIODIC MAINTENANCE CHECKLIST NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub...

Страница 31: ...only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire...

Страница 32: ...n 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 f...

Страница 33: ...Table 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 Examples of Taylor Dunn Tow Tractors...

Страница 34: ...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 35: ...n Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Oil Leak in Rear Bearing A...

Страница 36: ...pe 1 Ball Joints 4 General Purpose Grease 2 Pedal Linkages 3 General Purpose Grease 3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 4 King Pin 2 General Purpose Grease 5 6 7 Drive Drain...

Страница 37: ...and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 4 Front Axle Disassembly 5 Replace Front Wheel Bearings 6 Replace the King Pins and Bushings 7...

Страница 38: ...s in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicl...

Страница 39: ...turns but is not loose 10 Spin the wheel and 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 sec...

Страница 40: ...ion 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Installation 6 Raise...

Страница 41: ...eering knuckles and king pin bushings Refer to the following sections for information regarding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle doe...

Страница 42: ...ys 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 1...

Страница 43: ...4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands 7 R...

Страница 44: ...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 1 Make sure the key swi...

Страница 45: ...5 Adjust the Steering Gear 6 Replace the Steering Shaft 7 Replace the Steering Wheel 8 Replace the Steering Gear 8 Replace the Ball Joints Tie Rods and Drag Link 9 Replacing the Drag Link 10 Replacing...

Страница 46: ...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 7 Turn the front wheels so that they are i...

Страница 47: ...jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a...

Страница 48: ...evices of rated load capacity may result in severe bodily injury 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 C...

Страница 49: ...orward reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative c...

Страница 50: ...ailure to use lifting and support devices of rated load capacity may result in severe bodily injury 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse sw...

Страница 51: ...E Most vehicle configurations will now allow the steering shaft to slide off of the steering gear input shaft and then back down out of the steering column If there is not enough clearance for this pr...

Страница 52: ...ng wheel remove the switch and disconnect 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 straigh...

Страница 53: ...ns required to remove the rod end from the steering sleeve This will make it easier to realign the wheels 10 Install the new rod end into the steering sleeve Screw it into the sleeve the same number o...

Страница 54: ...amp at this time 12 Install the ball joint into the steering arm Tighten the ball joint nut to 40 45 ft lbs and install a new cotter pin 13 Realign the front wheels NOTE Refer to the Steering section...

Страница 55: ...st 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 1 Make sure the key switch...

Страница 56: ...of turns in the original direction 2 Remove the worm bearing adjuster locking ring and the worm bearing adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts an...

Страница 57: ...r worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 10 Install the assembled worm bearing adjuster into the h...

Страница 58: ...Maintenance Service and Repair Steering Page 14 Exploded View of Steering Gear...

Страница 59: ...Repair the Brake Body 11 Replace the Master Cylinder 13 Repair the Master Cylinder 14 Brake Service Brake fluid specifications Vehicles up to serial number 151284 were shipped with DOT 5 brake fluid...

Страница 60: ...could cause excessive brake rotor run out 2 Measure the thickness of the brake rotor in 3 places If the brake rotor thickness is less than 0 20 inches then the rotor must be replaced Disc Brake Pads...

Страница 61: ...the brake body Refer to Repair the Brake Body for information on removing the park brake pin 9 Inspect all brake cables and linkages for any signs of damage wear or missing cotter pins 10 Inspect the...

Страница 62: ...nd then loosen the linkage 1 turn 9 Tighten the jam nuts on the park brake linkage 10 Repeat this procedure for both rear wheels 11 Set the park brake 12 Reconnect the main positive and negative cable...

Страница 63: ...g and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately E...

Страница 64: ...epress the foot pedal to the floor and then close the bleeder valve Do not release pressure on the brake pedal until the bleeder valve is closed 13 Slowly release the foot pedal allowing it to return...

Страница 65: ...e OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Confirm the electric park brake is set 4 Place blocks under the front wheels to prevent vehicle movem...

Страница 66: ...o 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 Fai...

Страница 67: ...handling precautions 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 Confirm the electric park brake is set 4 Pla...

Страница 68: ...parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward...

Страница 69: ...damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT F...

Страница 70: ...brake body making sure that the boot seats properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 17 If t...

Страница 71: ...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 Do n...

Страница 72: ...scard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts a...

Страница 73: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Magnetic Module 2 Pot Box module 3 Throttle Linkage...

Страница 74: ...he standard throttle position sensor consists of two micro switches and a magnetic sensor that detects the position of the throttle pedal Switch FS 3 is a normally open switch that is held closed by t...

Страница 75: ...le is used on vehicles that are to be operated in areas with large magnetic fields The linkage to the pot box should be adjusted so that the FS 1 switch closes just as the pedal is depressed and the o...

Страница 76: ...TAYLOR DUNN...

Страница 77: ...r Removal and Installation 3 Rear Hub or Rotor 3 Removing and Installing the Rear Axles 4 Disassembly and Reassembly of the Primary Reduction Gear Case 6 Disassembling the 3rd Member 8 Assembling the...

Страница 78: ...ack stands 7 Place a four quart drain pan under the drive assembly 8 Remove the drain plugs from the differential case and gear case 9 Once the oil has drained replace the drain plugs and lower the ve...

Страница 79: ...olt 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 pr...

Страница 80: ...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 t...

Страница 81: ...E Be sure not to damage the o ring 16 Use new bolts for the axle retaining plate 17 If the wheel hub was removed install the hub and rotor Torque the hub bolt to 275 ft lbs 17 Fill with oil to the lev...

Страница 82: ...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 moveme...

Страница 83: ...the front flange on the 3rd member and gear case cover NOTE Pack the motor seal with non acetic based grease 20 Fill the differential with oil NOTE Refer to Changing the Differential Oil for informati...

Страница 84: ...on on removing the gear case 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 und...

Страница 85: ...ASSEMBLING THE 3RD MEMBER 1 Temporarily install the pinion gear hand tighten only 2 Install the carrier bearing race ring nuts into the housing and cover Cover Housing 3 Install the carrier bearing r...

Страница 86: ...arrier bearing race ring nuts The two ring nuts must be turned equally in opposite directions NOTE To move the ring gear closer to the pinion Loosen the housing carrier bearing race ring nuts and tigh...

Страница 87: ...This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears NOTE To perform this procedure all parts must be clean and the bearings lightly...

Страница 88: ...Maintenance Service and Repair Transmission Page 12 Figreu 1a Figure 2 Figreu 1b Figure 4 Figure 3 NOTE Values shown are for reference only D C...

Страница 89: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Leaf 2 Replace the Front Springs 3 Leaf 3 Replace the Spring Bushings 4 Replace the Shocks 5 Front 5...

Страница 90: ...use lifting and support devices of rated load capacity may result in severe bodily injury 8 Unbolt the spring from the axle housing 9 Support the spring so that it cannot fall out of the vehicle 10 R...

Страница 91: ...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 92: ...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 inj...

Страница 93: ...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...

Страница 94: ...TAYLOR DUNN...

Страница 95: ...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 96: ...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 97: ...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...

Страница 98: ...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 99: ...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 100: ...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 101: ...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 02...

Страница 102: ...TAYLOR DUNN...

Страница 103: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels...

Страница 104: ...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 105: ...emoved 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 T...

Страница 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...TAYLOR DUNN...

Страница 117: ...itions 2 Terminology used 2 Important Notes and Instructions 2 Identifying Your Controller 3 Start Troubleshooting Here 4 Test 8 Anti Rolloff Fault 15 Test 9 Electric Motor Brake 16 Logic Voltage Refe...

Страница 118: ...ems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified Some tests refer to a High Low switch The High Low swit...

Страница 119: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...

Страница 120: ...battery check the following The batteries The wiring from the battery status indicator to the batteries for open circuits The battery status indicator The positive and negative circuit breaker The ma...

Страница 121: ...r for open circuits 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 TEST 1 3 Test the voltag...

Страница 122: ...to the ground TEST 1 7 Depress the accelerator pedal to engage FS 1 only creep speed Perform the following tests Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is below...

Страница 123: ...fication table can be found in the Motor Service section If the test indicates an open circuit then repair or replace the motor Test continuity from F1 to the frame of the motor Any reading other than...

Страница 124: ...to the frame on the motor and from F1 to A1 for open circuits Any reading other than an open circuit indicate a short in the motor If there is a short in the motor stop here and repair or replace the...

Страница 125: ...at switch turn the key switch ON and wait 1 second until the Isolator contactor closes If the vehicle runs in reverse only then skip ahead to test 3 3 Place the forward and reverse switch in the FORWA...

Страница 126: ...movement of the vehicle resulting in injury or property damage Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all pr...

Страница 127: ...ults may have occurred Broken Wire Check the wire from pin 8 in the 12 Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm...

Страница 128: ...Low battery lamp is ON then the analyzer battery should be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer D0 110 53 Disconnect both...

Страница 129: ...se skip ahead to test 7 3 Place the forward and reverse switch in the FORWARD position Referencing battery positive test the voltage at the Blue Black wire on the F R switch If the voltage equals batt...

Страница 130: ...ground TEST 7 4 Check the wires from the F R switch to the logic card connector for continuity After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground F...

Страница 131: ...tch in the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor...

Страница 132: ...ere and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Test 9 1 Close the seat switch turn the key switch ON place the for...

Страница 133: ...eed controller Disconnect the electric brake harness connector and connect the electric brake to a 24 volt source This should release the brake and allow you to troubleshoot the vehicles control syste...

Страница 134: ...low switch in high Low High low Switch in low High 7 Hand brake switch closed Low Hand brake switch open High 8 Key switch on ref battery positive Key switch off ref battery positive Battery Volts 9 S...

Страница 135: ...te 4 Line contactor fault or open motor Contactor failure Open motor circuit Check contactor and motor 5 Not used 6 Throttle fault FS 1 switch failure Faulty wiring Throttle module Failure Check throt...

Страница 136: ...d Level 4 Faults F04xxx F04001 Contactor Welded High voltage at power up to the controller B terminal Check wiring contactor and pre charge resistor on the contactor F04002 Steer Pot Steer Pot current...

Страница 137: ...1 faults are a result of operator error or operation of the vehicle F01000 Power Steer Overheat Not used F01001 Traction Motor Brush Wear Not used F01002 Pump Motor Brush Wear Not used F01003 Power St...

Страница 138: ...Sevcon Troubleshooting Page 22 Electrical Troubleshooting...

Страница 139: ...g 19 Replacing the Charger 19 12 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 fau...

Страница 140: ...fully automatic microprocessor controlled SCR switching charger The charger turns itself on when it is plugged into the AC electrical outlet and turns off when the batteries are fully charged Once the...

Страница 141: ...ff LED 4 LED 2 Fault O O OK B B Battery voltage out of range or battery capacity is too high S O Control Board faulty B S Current Sensor faulty S B AC voltage incorrect S S DC current out of range B O...

Страница 142: ...the charger to the AC power source 2 The charger should automatically start as indicated by the flashing Status LED If the charger does not start try pressing the Low Voltage Start switch for 10 seco...

Страница 143: ...nd 15 meg Ohms 4 If the reading is low then the gate is shorted If the gate has shorted on either SCR then it is likely that the control board has been damaged and must also be replaced Note Both SCR...

Страница 144: ...in electrically grounded Disconnect both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire Failure to do so may result in serious bod...

Страница 145: ...ecting any electrical component or wire Failure to do so may result in serious bodily injury Control Board Assembly There is no test for the control board assembly Test all other components and confir...

Страница 146: ...d for Full River VRLA AGM DC Series batteries SLA batteries must be charged with a charger configured for SLA batteries Use of any other charger will result in damage to the batteries and premature fa...

Страница 147: ...in the charger If the charger has failed then it must be replaced SLA batteries must be charged with a charger configured for SLA batteries Use of any other charger will result in damage to the batter...

Страница 148: ...decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On the charger fac...

Страница 149: ...harger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but still show symptoms of overc...

Страница 150: ...y voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the charger cooling...

Страница 151: ...per off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 6 If the charger does not turn on there are no faults and the POWER light is ON th...

Страница 152: ...ure that the AC electrical outlet is in good working condition Make sure that the AC voltage at the electrical outlet is the same as the AC voltage on the charger nameplate Make sure the batteries are...

Страница 153: ...ger does not check the 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 ap...

Страница 154: ...ire Failure to do so may result in serious bodily injury 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...

Страница 155: ...op here and repair the problem Test the AC voltage across the transformer low voltage secondary circuit The transformer low voltage secondary circuit can be tested at the two solid wires with the brow...

Страница 156: ...on the meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem 3 Reconnect the lead to the diode 4 Connect the charger to the AC source Insert the DC cha...

Страница 157: ...re and repair the problem If the DMM indicates an open circuit then the interlock relay is functioning normally 1 Make sure the start switch is in the OFF position then remove the key 2 Place the forw...

Страница 158: ...Battery Charger Page 20 MN 402 000...

Страница 159: ...when printed at this size A full size diagram 22 x 16 is inculded on the CD in PDF format You can access the diagram from a button on the CD menu The T48 diagram is SCH 00004 12v battery tap SCH 00042...

Страница 160: ...UND GREEN CHARGER Blue MOTOR F2 Yellow F1 Green AC CHARGER CORD CHARGER INTERLOCK WHITE GROUND GREEN Blue Blue 2 1 Black Gray White Red White Blue Yellow Green Black Gray Black White Black Blue Black...

Страница 161: ...Wire Diagrams Wire Diagrams Page 3...

Страница 162: ...TURN L TURN 8 ISO NEG HORN BLACK BLACK BLACK BLACK BLACK BLACK BLUE Black White Yellow Blue Black Blue Black Green Brown Brown Brown Brown Brown Brown Red Yellow Gray Gray black Gray black Blue Green...

Страница 163: ...ls and Tires 34 Instrument Panel up to S N 179999 36 Instrument Panel starting S N 180000 36 Resetting the Smart View Display 36 Illustrated Parts Speed Control Panel 38 Miscellaneous Frame and Body 4...

Страница 164: ...d 9 must be broached or reamed to a final diameter of 1 25 0 001 after pressing into the axle 11 17 15 16 18 12 12 14 13 13 2 1 3 10 9 8 7 6 5 4 19 Bushings 8 and 9 must be broached or reamed to a fin...

Страница 165: ...240 43 Sleeve Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 1 ID Tapered Bearing 4 13 80 103 00 Race Tapered Bearing 4 14 12 158 10 Hub Disc Wheel 5 Stud Includes 11...

Страница 166: ...Illustrated Parts Parts Page 4 Front Brakes...

Страница 167: ...7 88 067 21 Brake Body Bolt 4 28 41 350 30 Hydraulic Brake Body Assembly 2 28a 41 350 09 Boot Hydraulic Brake Body Not Shown 2 28b 41 350 10 Piston Hydraulic Brake Body Not Shown 2 28c 80 713 00 O Rin...

Страница 168: ...Illustrated Parts Parts Page 6 Steering Linkage...

Страница 169: ...2 88 159 85 1 2 20 NF Slotted Hex Nut 2 3 86 510 00 Ball Joint Clamp Assembly 2 4 18 057 00 Sleeve Steering Adjust 26 1 5 88 527 11 1 8 X 1 Steel Cotter Pin 2 DRAG LINK 18 037 10 ITEM PART DESCRIPTION...

Страница 170: ...Illustrated Parts Parts Page 8 Steering Column 1 2 3 4 5 6 7 9 8 12 10 11 13 14...

Страница 171: ...ering Shaft Bearing 1 5 20 031 63 Kit Steering Shaft w Clamp 1 6 18 308 45 Assembly Steering Clamp Includes s 5 7 1 7 18 308 21 Steering Gear 1 8 88 128 62 7 16 Split Lock Washer 3 9 88 120 15 7 16 X...

Страница 172: ...Illustrated Parts Parts Page 10 Steering Gear 9 15 16 10 2 3 14 17 12 11 13 6 8 7 5 1 4...

Страница 173: ...earing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 1 11 18 308...

Страница 174: ...Illustrated Parts Parts Page 12 Front Suspension...

Страница 175: ...ITEM PART DESCRIPTION QTY 1 96 103 00 U Bolt Length 3 1 2 4 2 85 498 00 85 486 00 Leaf Spring Taylor Truck Leaf Spring ET 3000 2 2 3 32 214 50 Spring Bushing 12 4 96 240 00 Shackle Bolt 6 5 88 149 81...

Страница 176: ...Illustrated Parts Parts Page 14 Transmission Gear Case...

Страница 177: ...79 Bearing 1 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 24 GT 3287453 Output gear 30 1 0 or 1 GT 3287463 Output gear 24 1 0 or 1 GT 3287473 Output gear 18 1 0 or 1 GT 3287483 Outp...

Страница 178: ...Illustrated Parts Parts Page 16 Transmission Differential Case...

Страница 179: ...d pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug 1 17 GT 3287113 Differential housing 1 19 GT 3287143 Differential case 1 20 GT 72...

Страница 180: ...le Axle Shaft Inner Bearing no o ring Outer Bearing O Ring O Ring Groove Inner bearing on optional double bearing axle does not have an oil seal or o ring Orientation of bearing should have o ring gro...

Страница 181: ...used during the transition between the single bearing axles and the double bearing axles Use the following lists to determine what parts were used on vehicles manufactured during this transition Mode...

Страница 182: ...Illustrated Parts Parts Page 20 Rear Brakes Brake Body...

Страница 183: ...m 2 16 88 069 82 1 4NC locknut grade 8 4 Brake Body ITEM PART DESCRIPTION QTY 1 99 588 00 Bleeder screw 2 2 99 588 01 Bleeder adapter 2 3 41 350 43 Brake body left 1 41 350 44 Brake body right 1 4 80...

Страница 184: ...Illustrated Parts Parts Page 22 Rear Suspension 1 2 3 5 6 5 FORWARD FORWARD 4 7 8 9 10 11 12 4 13 14 15 16 17 18 Left Side Suspension Overload Spring Bushing...

Страница 185: ...ing 1 41 290 67 Axle Tube Left double bearing 1 11 96 114 00 U Bolt single axle bearing 4 12 16 861 44 Spring Axle Mount Bracket Left 1 13 16 861 45 Spring Axle Mount Bracket Right 1 14 89 113 30 Bolt...

Страница 186: ...Illustrated Parts Parts Page 24 Motor...

Страница 187: ...at time of printing The original motor provided under part number 70 054 40 has been discontinued It has been replaced by 70 054 41 The 70 054 41 motor has slightly more power torque The 70 054 40 mo...

Страница 188: ...Illustrated Parts Parts Page 26 Electric Brake 1 2 3 4 5 7 8 9 10 6 11 Automatic Electric Brake Component View...

Страница 189: ...4 NC Grade 8 1 11 96 500 04 Tool Manual Auto Electric Brake Release 2 75 152 30 Wiring Harness Not Shown 1 AUTOMATIC ELECTRIC BRAKE PARTS SPECIAL ORDER 1 Magnet and Coil Sub Assembly 1 2 Hub 1 3 Arma...

Страница 190: ...Illustrated Parts Parts Page 28 Master Cylinder 2 3 4 1 5 6 7 8...

Страница 191: ...QTY 1 88 080 14 5 16 X 1 1 2 NC Hex Bolt 2 2 88 088 61 5 16 Washer 4 3 88 089 81 5 16 Lock Nut 2 4 99 511 20 Master Cylinder 1 5 99 511 51 Rubber Boot Master Cylinder 1 6 99 511 52 Cap Seal Master Cy...

Страница 192: ...Illustrated Parts Parts Page 30 Brake Lines...

Страница 193: ...ex Bolt 2 13 88 088 61 5 16 Washer 4 14 88 089 81 5 16 Lock Nut 2 15 99 511 20 Master Cylinder 1 16 99 605 77 Brake Line 1 17 99 605 76 Brake Line up to serial 158863 1 99 607 59 Brake Line starting s...

Страница 194: ...Illustrated Parts Parts Page 32 Brake Linkage parking brake...

Страница 195: ...88 61 5 16 Washer 4 3 51 344 80 Park Brake 1 4 88 089 81 5 16 Locknut 2 5 96 813 00 Adjusting Brake Cable Assembly 1 6 96 771 00 3 8 x 3 4 Clevis Pin 1 7 01 204 32 Brake Equalizer 1 8 96 760 00 Brake...

Страница 196: ...Illustrated Parts Parts Page 34 Wheels and Tires Ref wheel hub 1 2 3...

Страница 197: ...heels and Tires ITEM PART DESCRIPTION 1 Wheels 12 025 00 8 x 10 Tubeless 2 Tires 10 264 00 20 x 8 x 10 LR E 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only Tire and Wheel Assemb...

Страница 198: ...reset after the preventative maintenance has been performed Taylor Dunn part number 62 027 40 Hand set available with instructions as part number 62 027 61 must be used to reset the meter Refer to th...

Страница 199: ...99 Item No Part No Description Qty 1 71 100 00 Auxiliary switches 0 1 2 2 71 039 11 Auxiliary switches 0 1 2 3 88 817 07 Screw 6 4 5 01 200 09 Console 1 6 74 010 00 Smart View gauge shoen 0 1 74 009 4...

Страница 200: ...Illustrated Parts Parts Page 38 Speed Control Panel...

Страница 201: ...eaker 10 amp 1 4 79 840 20 Circuit Breaker 20 amp 2 5 73 005 01 Alarm 1 6 73 004 20 Horn 1 7 79 844 20 Circuit Breaker 200 amp 1 8 62 400 11 Controller Heatsink 1 01 200 08 Control Panel Not Shown 1 6...

Страница 202: ...Illustrated Parts Parts Page 40 Miscellaneous Frame and Body...

Страница 203: ...88 817 07 Name plate screw 6 94 201 11 Name plate fastener plastic 2 6 94 050 10 Left headlight 1 7 00 248 32 Front cowl weldment not painted 1 8 K6 006 95 Driver Passenger seat cushion 2 9 90 140 00...

Страница 204: ...Illustrated Parts Parts Page 42 Charger Lestronic 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 205: ...n 1 Ammeter 79 851 10 2 Timer Assembly 79 805 65 79 805 68 79 805 68 S O Relay for 2 79 808 20 79 808 20 79 808 20 79 808 20 3 Capacitor 79 902 00 79 902 00 79 902 00 79 902 00 4 Diode Assembly 79 749...

Страница 206: ...HB1000 48 Flooded 79 309 42 HB1000 48 GEL 79 309 43 Notes There are no user serviceable components inside the charger The AC cord is included with the charger Cutting the AC cord will void the charge...

Страница 207: ...Harness Chassie control 3 75 152 00 Harness Control panel used up to 10 4 2000 75 152 13 Harness Control panel used starting 10 5 2000 4 75 152 12 2Gauge link wire for control panel 5 10 5 62 033 48 T...

Страница 208: ...Illustrated Parts Parts Page 46 Batteries NEG POS NEG POS NEG POS NEG POS NEG POS NEG POS 12 Volt Negative tap Main Positive Main Negative 1 2 3 4 5 6 7 8 1 NEG POS NEG POS...

Страница 209: ...00 244AH T 145 77 047 50 250AH TD 250 77 047 80 244AH T 145 Moist charge dry 77 048 00 250AH J 250 77 048 80 250AH J 250 Moist charge dry 77 051 00 160AH Gell Note requires special charger 3 50 243 1...

Страница 210: ...Illustrated Parts Parts Page 48 Decals 1 2 4 3 5 6 7...

Страница 211: ...ect Decal 1 2 94 313 00 Battery Warning Decal 1 3 94 373 10 Vehicle Identification Decal 1 4 94 309 00 Brake Warning Decal 1 5 94 313 20 Safety Warning Decal 1 6 94 384 01 Not A Motor Vehicle Decal 1...

Страница 212: ...Illustrated Parts Parts Page 50 Strobe Light...

Страница 213: ...1 4 72 082 10 Turn Signal Bulb 12V 2 5 72 082 20 Socket Turn Signal 2 STROBE LIGHT COMPONENTS 6 72 023 20 Strobe Light Amber 1 7 72 023 30 Pole Mount 1 8 88 025 06 Screw 8 32 X 1 2 Phillips Head 3 9...

Страница 214: ...Illustrated Parts Parts Page 52 Steel Cab T48 Page 1...

Страница 215: ...n Nut 1 4 NC 2 CAB 91 012 62 Kit Cab Orange 1 91 012 63 Kit Cab Specify Color 1 9 91 012 00 Cab unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Window Channel Rubber 20 ft 12 90 850 10 Rear Window...

Страница 216: ...Illustrated Parts Parts Page 54 Steel Cab T48 Page 2...

Страница 217: ...emale Right 1 10 88 069 81 Locknut 1 4 NC 2 11 88 060 22 Bolt 1 4NC X 3 4 Hex Head 1 12 88 068 61 Washer 1 4 SAE 1 13 88 065 09 Screw 1 4NC X 3 4 Phillips Truss Head 2 14 88 068 62 Lockwasher 1 4 2 15...

Страница 218: ...Illustrated Parts Parts Page 56 Tops T48...

Страница 219: ...e 1 F I B E R G L A S S T O P C O V E R 1 0 0 2 4 8 3 6 T u b u l a r T o p F r a m e 1 2 0 0 2 4 8 3 5 P o s t T o p F r a m e 4 3 8 8 1 0 2 1 1 B o l t 3 8 N C X 1 C a r r i a g e 3 2 4 8 8 1 0 9 8...

Страница 220: ...Illustrated Parts Parts Page 58 Doors T48...

Страница 221: ...0 1 1 1 2 1 1 3 9 1 0 1 1 6 8 K i t C a b D o o r L e f t O r a n g e i n c l u d e s 1 0 1 1 1 2 1 9 1 0 1 1 6 7 K i t C a b D o o r R i g h t S p e c i f y C o l o r i n c l u d e s 1 0 1 1 1 2 1 9...

Страница 222: ...Illustrated Parts Parts Page 60 Optional Deckboards T48...

Страница 223: ...065 08 Screw 1 4 NC X 5 8 Phillips Truss Head Not Shown 3 88 069 87 Nut 1 4 NC Keps Not Shown 3 WATERING SYSTEM 48 VOLT NOT SHOWN 77 201 60 Kit Watering System 48 Volt 1 77 201 40 Flow Indicator Water...

Страница 224: ...Illustrated Parts Parts Page 62 Cargo Box...

Страница 225: ...Front Rear unpainted 1 2 90 471 00 Deckboard Front 40 X 35 1 2 1 3 90 472 00 Deckboard Rear 40 X 38 3 4 1 4 90 850 10 Window 13 7 8 X 31 7 8 1 5 98 310 00 Window Channel Rubber 19 6 90 851 00 Window R...

Страница 226: ...Illustrated Parts Parts Page 64 Stake Sides...

Страница 227: ...3 88 065 13 Screw 1 4 NC X 1 1 4 Phillips Truss Head 4 4 88 069 87 Nut 1 4 NC Keps 4 5 90 542 05 Side Gate Left Black 1 6 90 542 06 Side Gate Right Black 1 7 90 544 20 Pocket Outer Weld on 8 8 90 544...

Страница 228: ...Illustrated Parts Parts Page 66 1 2 7 8 3 4 5 5a 9 11 12 13 14 16 10 6 18 17 15 Cab Deck ET 3000...

Страница 229: ...nt headlight bulb 2 9 91 017 65 Front Bumper 1 88 103 09 Screw Socket Head 3 8 X 3 4 Front Bumper Hardware 2 88 109 81 Locknut 3 8 Front Bumper Hardware 2 10 72 005 21 Headlight Support 1 11 72 052 00...

Страница 230: ...Illustrated Parts Parts Page 68 3 4 5 6 1 2 Door Latch 9 8 7 Cab Components ET 3000...

Страница 231: ...0 Window Door Right 3 Pieces 1 3 90 854 01 Latch Window Door 1 4 91 017 02 Strap Door Brackets Included 1 5 91 017 31 Handle Inside Door Left 1 6 91 017 32 Handle Inside Door Right 1 7 72 015 10 Light...

Страница 232: ...Illustrated Parts Parts Page 70 Misc Frame ET 3000 1 2 10 11 19 27 26 23 24 25 9 20 18 17 16 15 21 22 12 13 14 15 5 6 3 4 7...

Страница 233: ...Post Left Side Panel 2 17 Header Rear Right 1 18 Latch 4 19 89 080 16 Bolt 8mm X 16 1 2 2 0 H i n g e A l u m i n u m 6 2 1 A l u m i n u m T H i n g e 6 22 P l a t e T h r e a d e d 8 m m 6 23 88 081...

Страница 234: ...TAYLOR DUNN...

Страница 235: ...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 236: ...set the Smart View display maintenance meter 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 adjustmen...

Страница 237: ...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 238: ...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 239: ...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 240: ...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 241: ...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 242: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Visit our Website www taylor dunn com...

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