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B2-48_SN# 171000 & UP (AC DRIVE)

1. ITEM PART DESCRIPTION QTY i 90 923 98 Door Frame Left 1 Not shown 90 923 99 Door Frame Right 1 2 90 924 98 Side Curtain Left 1 Not shown 90 924 99 Side Curtain Right i 3 97 315 53 Handle Assembly Outer 2 4 97 315 51 Door Latch 2 5 97 315 54 Handle Assembly Inside 2 6 97 303 03 Snap Fastner 14 7 88 727 06 Rivet 5 32 X 5 8 14 8 88 025 08 Screw 8 32 X 5 8 Truss Head 4 9 88 029 86 Locknut 8 32 4 10 91 814 10 Hinge Female Left naugahyde and steel doors 2 Not shown 91 814 11 Hinge Female Right naugahyde and steel doors 2 11 88 082 09 Bolt 5 16 X 5 8 Carriage 8 12 88 089 81 Locknut 5 16 NC 8 Cab Doors Steel Steel cab ITEM PART DESCRIPTION QTY 91 011 66 Kit Cab Door Left Specify Color includes 10 11 12 l 91 011 68 Kit Cab Door Left Orange includes 10 11 12 1 Not Shown 91 011 67 Kit Cab D
2. Transmission Gear Case ITEM PART DESCRIPTION QTY l GT 71682 M8 x 60 bolt 12 2 GT 3287563 Gear case cover l 3 GT 71259 Bearing i GT 3287513 Input shaft 30 1 0 or 1 4 GI 3287523 Input shaft 24 1 0 or GT 3287533 Input shaft 18 1 0 or 5 GT 71982 O ring l 6 GT 3287503 Eccentric shaft l 7 GT 72005 Bearing 2 8 GT 3287493 Idler gear i 9 GT 70302 M10 x 30 Bolt 6 10 GT 71715 Snap ring i 11 GT 3287553 Gear case housing i 12 GT 72019 Seal l 18 GT 71979 Bearing i 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer i GT 3287453 Output gear 30 1 0 or 24 GI 3287463 Output gear 24 1 0 or GI 3287473 Output gear 18 1 0 or GI 328 Spacer 46 100mm i GT 328 Spacer 46 100mm Oorl 25 GT 328 Spacer 46 125mm Oorl GT 328 Spacer 46 150mm Oorl GT 328 Spacer 46 175mm 0 or GT 3287903 Shim 0 100mm 0 or 1 GT 3287883 Shim 0 400mm 0 or 1 GT 3287893 Shim 0 500mm 0 or 1 i GT 3287853 Shim 0 600mm 0 or 1 GT 3287863 Shim 0 700mm 0 or 1 GT 3287873 Shim 0 800mm 0
3. ITEM PART DESCRIPTION 94 423 20 FLAT OUT TIRE SEAL PT BOTL 1 Wheels 12 012 00 5 x 8 Tubeless 12 020 00 8 5 x 8 Tubeless 12 050 00 12 1 8 Diameter Cast Iron 2 Tires 10 083 00 5 70 x 8 LRC 10 092 00 8 50 x 8 LRC 10 260 00 18 X 5 X 12 1 8 Solid rubber Split Rim Wheels 3 12 041 12 Inner Wheel 2 5 bead 4 12 041 13 Outer Wheel 2 5 bead 5 12 041 00 Wheel 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 Hex Bolt grade 5 zi 88 109 62 3 8 Split Lock Washer 8 88 119 80 3 8 NF Hex Nut 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only Not Shown 11 041 00 8 50 x 8 Tube Not Shown 11 040 00 5 70 x 8 Tube Tire and Wheel Assemblies 13 955 10 18 x 5 x 12 1 8 Solid rubber 13 742 13 5 70 x 8 LR C Pneumatic 13 742 35 5 00 x 8 MONOMATIC SOLID 13 742 12 5 70 x 8 Split Rim LR C 13 746 10 8 50 x 8 Pneumatic 13 746 13 18 5 x 8 50 x 8 LR C 13 742 50 5 x 8 Sof
4. ITEM PART DESCRIPTION QTY 90 148 00 Passenger seat cushion standard l 90 172 00 Passenger seat cushion with steel cab l 90 140 00 Seat back standard l 2 90 179 00 Seat back with steel cab 1 90 142 00 Seat back 1 2 cowl frame i 90 148 00 Driver seat cushion standard l 90 172 00 Driver seat cushion with steel cab 1 90 444 00 Deckboard 75 1 4 x 41 standard bed 1 90 466 10 Deckboard 19 1 2 x 41 1 90 467 10 Deckboard 55 3 4 x 41 l 90 466 00 Deckboard 21 3 4 x 41 fold away seat option l 90 468 00 Deckboard 32 3 4 x 41 fold away seat option l 90 469 00 Deckboard 19 11 16 x 41 oldaway seat option 1 90 464 00 Deckboard 55 x 41 fold away seat option 1 4 90 441 00 Deckboard 37 1 2 x 41 1 90 440 43 Diamond plate deck cover 32 3 4 x 41 1 90 440 50 Diamond plate deck cover 19 1 2 x 41 1 90 440 54 Diamond plate deck cover 55 3 4 x 41 1 90 440 53 Diamond plate deck cover 19 11 16 x 40 1 2 90 440 56 Diamond plate deck cover 21 750 x 41 1 88 607 09 Rivet diamond plate deck 95 530 10 Handle fold away seat 1 90 140 00 Se
5. Speed Control Panel ITEM PART DESCRIPTION QTY l 73 005 01 Motion alarm l 62 400 35 Motor speed control B 2 48 i i 62 400 11 Motor speed control B 2 54 i 89 080 16 8mm x 1 25 x 16mm Hex bolt 5 i 89 060 17 8mm Lock washer 5 02 425 17 Controller base 1 4 plate 1 i 02 425 18 Mounting panel l 5 79 844 20 Circuit breaker Main 200A l 6 78 307 25 Resistor included with harness 2 7 73 004 20 Horn l 8 88 838 06 14 x 1 2 Screw 4 9 79 840 20 Circuit breaker 12 volt 20A 1 10 79 840 00 Circuit breaker B 10A 1 72 501 42 Line contactor B 2 48 1 i 71 210 13 Line contactor B 2 54 1 12 79 840 20 Circuit breaker B 20A 1 13 88 818 06 8 x 1 2 Screw 10 88 060 14 1 4 X 1 1 2 NC HEX HD SCR 4 14 88 069 81 Hex nut 4 88 068 61 1 4 SAE Flat washer 4 15 96 650 02 Clip 2 16 71 120 30 Brake bypass switch included with harness Not shown 75 442 64 Support Harness connector i Use 94 422 21 Heat sink paste on base of controller and controller base Resetting the Maintenance Meter Function NOTE The Main
6. ITEM PART DESCRIPTION QTY i 5 99 588 00 Bleeder valve 2 99 588 01 Bleeder adaptor 2 3 4 E R 5 41 348 70 Brake pad 4 6 41 351 30 Brake body assembly includes 3 4 5 8 9 10 2 7 32 240 41 Bushing 4 8 41 348 57 Spacer 4 88 067 21 Bolt 4 88 069 82 Nut 4 10 97 126 05 Flat Washer 4 1 41 350 28 Mounting bracket 2 96 327 10 3 8X3 4 NF 2A THD GRDS LOC brake bracket to drive 8 Not Shown 41 886 00 PLUG 1 8 PIPE HEX SOCKET 3 _ Not available seperatly order complete caliper assembly Front Brake ITEM PART DESCRIPTION QTY 1 88 067 21 Bolt 1 4 X 3 3 4 NC Hex Head Gr 8 4 2 41 350 51 Plate Secondary Hydraulic Disc 2 3 41 348 70 Pad Disc Brake 4 4 41 348 52 Spacer Disc Brake 4 5 32 240 41 Bearing Teflon Coated 4 6 99 588 00 Bleeder screw 2 7 99 588 01 Bleeder screw adapter 2 8 88 069 82 Locknut 1 4 NC Gr 8 Do Not Reuse 4 9 41 351 30 Hydraulic Brake Body Front Assembly 2 10 See Brake Lines Brake hose Not See Steering Knuckle Front hub and rotor shown 88 109 81 41 886 00 2 NOTE Brake Body 9 has no internally serviceable parts Parts Page 19 I
7. Rear Cargo Box ITEM PART DESCRIPTION QTY l 91 333 02 Cargo box unpainted l 2 90 471 00 Front deck board 1 3 90 472 00 Rear deeck board l 4 90 850 10 Front window l 5 98 310 00 Ruber window gasket by the foor 6 90 851 00 Rear window 2 Not shown 94 320 10 Load line decal l 00 210 23 Deck support angle i Top Covers ITEM PART DESCRIPTION QTY 91 151 00 Fiberglass top l 94 035 01 PLASTIC TRIM STRIP SNAP ON 29 91 028 25 Z BRACKET 6 96 124 00 U BOLT 1 75L X 1W X 1 4NC 6 97 176 00 WASHER NEOPRENE 3 8X3 4X3 12 98 451 00 TAPE WEATHER STRIP 2 91 101 00 Surry top Parts Page 59 Illustrated Parts Hitches 97 804 01 Pintle Hitch 97 209 00 97 808 00 Automatic Coupling Hitch Hook Pin and Eye Hitch 4 i nass 5 250 97 006 i0 97 806 10 Pin and Clevis Hitch Ball Hitch Mount 97 805 00 1 7 8 97 807 00 2 Parts Page 60 Illustrated Parts Trailer Hitches ITEM PART DESCRIPTION QTY 97 811 00 1 7 8 inch Ball 97 821 00 2 inch Ball 88 140 14 1 2NC x 1 1 2 Hex bo
8. Steering Linkage ITEM PART DESCRIPTION QTY l 18 041 05 Tie rod B 2 48 B 2 54 BT 2 48 1 2 86 510 00 Ball joing clamp 4 3 86 501 98 Ball joing left 2 4 86 501 99 Ball joint right 2 5 88 527 11 1 8 x 1 Cotter pin 4 6 18 057 11 Drag link 1 7 88 159 85 1 2NF Castle nut 4 18 104 00 Pitman Arm 1 Parts Page 7 Illustrated Parts Steering Column The steering column is an integral part of the frame and is not shown Part ID 5 is located in the top of the steering column tube a Ref Steering Gear DN Parts Page 8 Illustrated Parts Steering Column ITEM PART DESCRIPTION QTY l 88 199 82 5 8NF Hex nut l 2 19 011 20 Steering wheel i 3 88 081 14 5 16NF x 1 1 2 Hex bolt grade 8 i 4 88 089 84 5 16NF Hex lock nut grade C l 5 32 248 10 Upper bushing l 6 20 031 65 Steering shaft assembly incl 3 and 4 l 7 19 011 25 Steering wheel cap l 8 88 128 62 7 16 Split lock washer 3 9 88 120 15 7 16 x 1 Hex bolt 3 88 279 82 7 8NF Thin pattern hex nut Pitman shaft 1 Not Shown 88 268 62 7 8 Split lock washer pitman
9. Parts Page 57 Illustrated Parts Rear Cargo Box Top Covers Af iOT 0O4 i i Taywes 4 hy o2 6 00 ee J iz gy ae SESE eg j h T m a ee lt __ MMM a f F i ics DDN oa me _ ee ee E7 oe i e ia __ a ama 4 00to CO me a 1 ay Ne 1 02 B SI 41 023 98 et es ees oY 2 065 D4 APLCS b i fa PLCS EEEO A eee ua AUT BB OBO 1 A A Cle tics i le this m i ae AOLA i 7 aa CHB lot Y ae as oaa J acs BB Don OB ar 3 j a Fi PLCS Be 061 81 a Qrucs i i a I pe b ay hgt a rl lh p _ eh SI Ls NY a eS acs p z a acl i i gs pn a a e n l ua q nn r ar a h i a q1 028 08 If T oe LEFT STIFRENER O i eo re J oon ie G 026 0F E PTGHT STEFFENER oTHER SFPE j s p T 2 i L A yorga feres j AKTEN CEWL l BB a602 08 ff PARTON j ly lt Je j KY a TEREA 88 0o61 8 L i youe 5 pics on wm Cemiens HF bey pA mo i PARTEN DEWA 4 FI CS Parts Page 58 Illustrated Parts
10. Parts Page 35 Illustrated Parts Lestronic Charger page 1 Typical Built In charger WL i Vly Wh WHA Va Wi a Typical Portable charger Parts Page 36 Illustrated Parts ii 00 00 92 00 00 92 00 00 92 00 00 92 00 00 92 ewosoez suosstr suovstr aoon osii assi suvea l LASSTOTSP LAH8 SCO T8P sas sconsr 148 0079 LAH8 SCO T8P LH8 OVOT9E LAH8 SCTOT9IE LAH8 SCOT9IE LA8 SCOT9IE os 07 60 6L ST 0 6L 01 60 6L 17Z 90 6L 00 60 6L O7 0 6L AS9 p0E 6L 07 SOE 6L ST 0 6L NOILdIA OSAA WALI OZ69T OZCOTZ OT69T IE SLY6 5696 OVOZZ O98TI ZE OILL OPLET Weg JosieyD Opoy Josey SUHDaAVHO 0S 608 62 c 90 6L 09 608 6L Assy Avpoy Joou Il lt 00 00 92 00 00 92 Snid OV Jouroe doy a 01 99S 62L 00 0 2L 6L 00 0 2L 62 00 0 S 62 00 0 S 62 00 1 8 62 OT IE8 64 00 T 8 62 OI SLS 6L 1 6PL 6L erorL oL A quiossy porq t 00 808 64 00 808 6L a a O S O S O S tl 6vL 6L OT 6rL 6L Il 6 L 6L 00 706 62 00 c06 6L 00 c06 62 0c 808 62 00 808 62 00 808 62 9 S08 6L L9 S08 62L CL S08 6L 69 S08 6L L9 S08 6L A quiossy JOU T ST 9 ST 9 sdury eseyoA Od Lo OT IS8 6L 00 cS8 6L OT IS8 6L aqeod umg umg ST 8F OV 9E ST 9 S1 09 STT 91 09 0S1 Bu 0S 0ET Parts By Page 37 Il
11. Decals ITEM PART DESCRIPTION QTY 1 94 319 00 Battery disconnect 1 or 2 2 94 313 00 Battery warning 1 or 2 3 94 373 10 Vehicle identification l 4 94 384 21 Brake warning i 5 94 313 20 Safety warning 1 6 94 384 01 Not a motor vehicle l 7 94 384 14 When leaving vehicle warning i 8 94 301 41 Brake fluid l 9 94 384 17 Do not wash l 10 94 301 42 Arms and legs i l1 94 384 24 Emergency stop l 12 94 384 15 Low speed 13 94 384 06 Emergency brake bypass switch i Parts Page 49 Illustrated Parts Cab Options Steel Cab Fiberglass cab Parts Page 50 Illustrated Parts Steel Cab ITEM PART DESCRIPTION QTY 91 012 00 Steel cab unpainted l 90 852 30 Front windshield 1 90 850 10 Rear window 1
12. speed FwdAc HS 5 5 S Time to accelerate to full speed RevAc LS 8 0 s Te to accelerate to from FwdAC LS RevAc HS 7 0 S Time to accelerate to full speed Deceleration Settings Brake regen multiplier is activated by FwdAS LS 4 0 S Time to accelerate to 15 of full P add ay the brake switch Normal Decl HS 8 0 S o gt A to 0 when above Normal Decl LS 10 0 S atte aed when below 20 Tow Decl HS 8 5 S Fo X a to 0 when above Tow Decl LS 8 0 S eel when below 20 Maintenance Meter Function eee ee 0 H Refer to Maintenance Meter supplementary manual Speed Limits Max 6 250 RPM Governed speed see formula below P t fM hen T Tow optional 60 Percentage of Max speed when Tow Percentage of Max speed when in Rev 45 reverse Percentage of Max speed when low Low Batt 40 7 battery warning is O Percentage of Max speed when Service Due 20 service is due See maintenance Meter Function Batery Characteristics Battery must exceed this voltage to be Full Volts 2 165 V considered fully charged Empty Volts 1 730 V Voltage of a fully discharged battery BDI Level for Batt Spd 15
13. Typical Charger Data Plate vour data plate may vary a ee Signet Charger Troubleshooting Page 2 Electrical Troubleshooting HB PT AND GEL INDICATOR LAMPS NOTE Your charger may not be equipped with these lamps HB PT Lamp If the HB PT lamp is ON then the charger has overheated and has entered a proportionally reduced output The charging cycle will terminate if the temperature continues to rise If the charging cycle is terminated the charger will automatically restart once it has cooled The charging cycle is limited to 18 hours If the HB PT lamp is flashing then the charging time has exceeded 18 hours time is limited to 18 hours If any of the status lamps are flashing then the charge cycle did not complete S i GEL lam SIGNET SYSTEMS INC This LED will only be ON if the charger is configured for GEL batteries Using a GEL charger with non GEL batteries may result Typical Charger Data Plate in an incomplete charge or long charge times your data plate may vary ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the batteries when the charge cycle was started NOTE Charging time is
14. Storage e Charging Interval Temperature months F Over 60 1 Between 40 and 60 2 Below 40 6 Batteries Page 10 Maintenance Service and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion 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 Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING 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 property damage and or 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 AWARNING 3 Set the park brake
15. cccceeeees 4 Status LED Error Code Table 5 Troubleshooting ssassnnsnnnnnnnnnnnnnnnnnnnnnnnn 6 Illustrated Parts ccsccesessseesseeeeeees 1 FOOT AX O an vase vaus vast yaneyausvasbuaveeasae 2 Steering Knuckle ccccceceeeeeeeeeeeeeeeeeees 4 Steering Linkage ccseccseeeceeeeeeeseeeeeeees 6 Steering COLUMN ccceccseceeeeeeeeeeeeeeeeeees 8 FONE SUSPENSION seisyshohslobsbaia oust busbos ene nas 10 Steering Gear isiuiakiiwhudwbuinisawbeieluiebunadweehaeake 10 Rear Suspension ccccceeceeeeeeeeeceeeeeeeeaes 12 Transmission Gear Case cccccceeeeeeeeees 14 BECA E A A E E S 16 Transmission Differential Case 0 16 Rear BAKOS seuadaudaviadenocsondadeduseusdedsuedspadcaasat 18 Front Brakes ccccceccecceceeeeeeeeeeeeeeseeeeeeees 18 Brake LINES gis sean nnahouavauasaussouaunvabouavuuasausouent 20 Master Cylinder ccccccccceeeeeeeseeeseeeeeees 20 IVI OOM wecrcctetasts a e 22 Motor Mount ccceccecseeeeeeeeeeeeeseeseeeeees 24 Wheels and Tires cccceccecceeceeeeeeseeseeees 26 Instrument Panel dash cccceceeeees 28 Wire Harnesses ccsecsecceeceeeeeeeeeeeeseeees 28 Speed Control Panel ccccceeceeeeeeeeees 30 Resetting the Maintenance Meter Function 31 Miscellaneous Electrical ccccccseeeeeeees 32 Ealain oe PAAA T 34 Lestronic Charger
16. ITEM PART DESCRIPTION QTY 90 921 98 Door Frame Left l l 90 921 99 Door Frame Right 1 98 451 11 Weather seal tape by the foot 90 908 98 Side Curtain Left l 90 908 99 Side Curtain Right 1 3 97 315 53 Handle Assembly Outer 2 4 97 315 51 Door Latch 2 5 97 315 54 Handle Assembly Inside 2 6 97 304 50 Snap Fastner 12 7 88 737 08 Rivet 5 32 X 5 8 14 8 88 029 86 Locknut 8 32 4 9 88 025 08 Screw 8 32 X 5 8 Truss Head 4 10 11 12 13 s l 14 94 036 00 Drip moulding 1 91 810 00 Lower hinge 2 a 17 104 00 Collar 2 16 91 809 10 Upper hinge 2 Parts Page 55 Illustrated Parts Hydraulic Dump Body Option 23 21 22 7 8 9 10 11 PFN 13 14 15 16 17 Parts Page 56 Illustrated Parts Dump Bed Option ITEM PART DESCRIPTION OTY l 21 018 00 Cylinder Pin l 2 88 060 11 Bolt 1 4 X 1 1 4 NC Hex Head 6 3 88 069 8 1 Locknut 1 4 NC 6 4 21 019 00 Shaft Dump Bed Pivot 2 5 17 112 00 Collar Shaft 2 6 99 524 00 Hyd
17. Reconnect the main positive and negative cables 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the rear of the vehicle and support with jack stands Place a four quart drain pan under the drive assembly Remove the drain plugs from the differential case and gear case and lower the vehicle to the ground b 3 as a ay Remove the fill level plug and fill the differential up y Fill Level Plug to the bottom of the level plug opening Refer to ng i the Lube Chart section for information regarding n type of oil x ag Replace the fill plug h at the batteries Remove the blocks from the wheels Release the park brake and test drive the vehicle Transmission Page 3 Maintenance Service and Repair MOTOR REMOVAL AND INSTALLATION NOTE Some applications will require removing the drive assembly from the vehicle to remove the motor Refer to Removing and Installing the Drive Assembly for information on removing the drive assembly Some vehicles are equipped with an automatic electric brake The automatic electric brake is sandwiched between the drive motor and the gear case The electric brake is retained by the drive motor mounting SCrews Once the motor is removed the electric brake will no longer be retained by any hardware 1 Make sure the key switch is in the OFF position then remove
18. 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the ACAUTION battery electrolyte comes in contact with Failure to clean may result in property damage 7 Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level 8 Test the batteries Refer to Testing section for information on testing the batteries 9 The batteries are now ready to be put back into service Batteries Page 11 NNNG dO TAVL Control System Diagnostics TABLE OF CONTENTS Test Equipment Required 0066 2 Important Notes and Instructions 2 Status LED Code Table ee 3 Throttle Module Test ceecceeeeeees 6 RevB Electrical Troubleshooting Test Equipment Required e User Level Maintenance Handset 62 027 64 The Maintenance Handset can view current faults fault history monitor all controller inputs and outputs and monitor the current status of the controller motor battery and vehicle operation Instruction for using the handset are includ
19. STATUS LED ERROR CODE TABLE There are three status lights LED s on the charger name plate These LED s normally indicate the current operating state of the charger If all three LED s are flashing it indicate an error has occurred in the charging cycle See the table below for an explanation of the error codes Note If only the 100 LED is flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of e Defective battery or batteries e Excessively discharged batteries e Oversize batteries Error Code Description Action Required Reverse polarity or open circuit to the batteries Check wiring for corrosion loose connections broken wires and proper connection to the batteries AC line voltate too high or too Check the input voltage e low It must be within 96 132VAC or 196 266VAC Wait for charger to cool the charger will automaticaly restart Inspect i ae vere for dirt or debris on the charger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Status LED s SIGNET SYSTEMS INC Typical Charger Data Plate vour data plate may vary Signet Charger Troubleshooting Page 5 E
20. cccseeeees 10 Replace the Steering Wheel 2 000 12 Replace the Steering Gear sscssseseeeeees 13 Replace the Ball Joints Tie Rods and Drag EIK secaatecsarecscececanectacuacacasvcscetecnaaenantnceseere 14 Replacing the Drag Link cccccceeeeeeeeeeeeeeeees 16 Replacing the Tie Rod ornen eais 17 Center the Steering Gear ccceseeeeeeeeeees 18 Pitman Shaft Alignment cscceeeeeeenees 18 Repair the Steering Gear cc sseceeeeeeeeees 19 Exploded View of Steering Gear cccccccccceceeeeees 22 Maintenance Service and Repair FRONT END ALIGNMENT This section will refer to two different types of ball joints One type is has a grease fitting and a tapered shaft where it is fitted to the steering arm or pitman arm The second type cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your truck it may be equipped with one or both types of 3 Ball Joint ball joints In this text The first type has a grease fitting and will be referred to as a Ball Joint The second type has no grease fitting and will be referred to as a Rod End Rod End Center the Steering 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 AWARNING 3 If equipped with a hand operated park brake
21. Hour Meter Inspected By Serial Serviced By Unit ID Interval Inspected Service Item Description hours p Re uired Complete j P _ Master inde udial nd Parking brake for secure hold _Battery 3 water lew el Ti ire re inflation pneumatic ires Operator Daily Checklist Inspect front fork collar beanngs for play and noise 3 wheel vehicle only Inspect and tighten all hardware first 500 hours zony ihen 1000 hours and every 1000 hours eel a ae Replace brake pedal treadle retum spring Eas Inspect irame for damage Notes 1 and 2 Refer to Maintenance Guidelines for Severe Duty in the vehicles service manual Form PM 0002 GT Drive AC Motor Revision B OF25 2006 NOTE A full page copy of the Periodic Maintenance Sate Sues meget Checklist is on the Vehicle Documentation CD under the Miscl sub folder SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection Tire condition and pressure External frame damage body Operation of all lights and warning alarms and or horns Smooth and proper operation of all controls such as but not limited to e Accelerator pedal Brake pedal Steering Parking brake etc e Proper operation of all locking devises such as but not limited to Tool box Removable battery trays Cargo box Cab doors etc e Proper operation of all interlocking switches such as but not limited to e Key switch Seat interlock switc
22. The Best Way To Go About Your Business Revision A Models Inlcuded B0 248 45AC B 2 48 BO0 254 45AC B 2 54 Equipped with AC Motor Speed Control MANUAL MB 248 11 Operation Troubleshooting and Replacement Parts Manual Serial number Starting 171000 COPYRIGHT NOTICE Copyright 2001 by Taylor Dunn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or retrieval system without prior written permission of Taylor Dunn Mfg unless such copying is expressly permitted by federal copyright law Address inquiries to Reference Permissions Taylor Dunn Mfg 2114 W Ball Road Anaheim CA 92804 TAYLOR DUNN SERVICE CENTER For more information about this and other Taylor Dunn manuals please write Taylor Dunn Taylor Dunn Mfg 2114 W Ball Roa Anaheim CA 92804 Attn Technical Writer j 6 l l B2 10 Ambulance B2 48 With Dump Bed Option B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides P2 50 30 000 Pound Tow Tractor ET1 50 Full Size Truck Table of Contents Eq Contents General Maintenance c ccscssseseees 1 INTFOGUCUION I N 1 Maintenance Guidelines cssseesees 2 About this manual ccsseceeeeeeeeeeee 2 Troubleshooting Guide ss eseeees 3 Who Should Read This Manu
23. 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Place an oil drain pan underneath the 3rd member 7 Remove the fill level plug 8 The oil level should be very close to the bottom of the level plug opening a If the oil level is below the bottom of the opening add oil as required until level with the bottom of E ail the opening Refer to the Lube Chart section for Ne i dada information regarding type of oil Py Fill Level Plug b If oil comes out of the opening allow to drain until oF level with the bottom of the opening 9 Replace the fill level plug 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from the wheels 12 Release the park brake and test drive the vehicle Transmission Page 2 Maintenance Service and Repair CHANGE OIL 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 AWARNING 3 If equipped with a hand operated park brake set the brake 10 11 12 13 14 Once the oil has drained replace the drain plugs
24. OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand 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 in the straight ahead position and tie off the steering wheel so that it cannot rotate Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front AWARNING wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 8 Using apiece of chalk mark a line around the center of both front tires HINT Hold the chalk on the center of the tire and rotate the tire to mark the line 9 Loosen the ball joint clamps or the rod end jam nuts on the tie rod NOTE Remember the position and orientation of the ball joint clamps 10 Lower the front wheels to the ground and push the vehicle back and forth a few feet to settle the Suspension Stee
25. and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Center the steering gear Refer to Center the Steering Gear section for information regarding centering the steering gear 8 Screw both steering stops all of the way in 10 11 12 13 14 T9 16 Install the pitman arm so that it is centered between the steering stops Realign the front wheels Refer to Front End Alignment section for information regarding aligning the front wheels Adjust the steering stops so that the front wheels do not contact any part of the frame suspension or steering linkages and the left and right turning radiuses are equal Tighten the steering stop jam nuts Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Steering Page 18 Maintenance Service and Repair REPAIR THE STEERING GEAR Disassembly NOTE The steering gear must be removed from the vehicle for this procedure Refer to Replace the Steering Gear section for information regarding removing the steering gear NOTE The steering gear is packed with grease Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled
26. applied when the vehicle is stopped There is a parking brake bypass switch located on the right side of the control box see illustration Place this switch in the UP position to tow the vehicle see note below This switch should be in the UP position only while towing the vehicle The switch should be placed in the DOWN position immediately after the towing is completed Leaving the switch in the UP position will discharge the battery To tow this vehicle attach a tow strap to the front bumper tow bar Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible this vehicle should be placed on a Carrier rather than towing NOTE The automatic electric brake is powered by the vehicles battery The brake may not disengage if the battery is severely discharged A battery must be installed to tow the vehicle Location of Parking Brake Bypass switch Safety Rules Page 10 SAFETY RULES AND OPERATING INSTRUCTIONS Adjustable Controller Parameters Model B 2 48 equipped with 18 1 drive ratio A W AR N j NG Aceleration Parameters normal mode Function Value Unit Description Improper programming may cause unexpected FwdA
27. checks Electrical and Charger Troubleshooting This section identifies the troubleshooting procedures for testing the electrical system and battery charger Illustrated Parts This section provides an illustrated view of various assemblies The illustrations are accompanied by tables identifying the parts Introduction Page 4 INTRODUCTION Conventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual AWARNING A shaded box with the word Warning on its left denotes a warning A warning alerts the reader of a hazard that may result in injury to Or themselves or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the A WARNING task 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 ACAUTION damage may occur Be sure to exercise special care and follow any instructions contained with in a caution NOTE Alerts the reader to additional information about a subject Introduction Page 5 INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks an
28. set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand 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 in the straight ahead position and then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball joint or rod end from the drag link 9 Center the steering gear and tie off the steering wheel so that it cannot rotate NOTE Refer to Center the Steering Gear section for information regarding centering of the steering gear Steering Page 2 Maintenance Service and Repair 10 At this point both the steering wheel and the front wheels should be tied up and held in position If one or the other is not tied up then you must start from the beginning Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front AWARNING wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily
29. t4e ede eae tae y Vehicle Controls ssccsseceseceeeeeeeeeees 5 Adjust the Steering Gear seseeees 8 6 Key SWItCh ccccccccosssssessssssssseesscssssssessesssssveseesee 5 Replace the Steering Shaft 010 10 7 Emergency Stop Switch cece 5 Replace the Steering Wheel 12 Combination Display 0sseeseseeeeeeeeeeees 6 Replace the Steering GRAM ceccccccccccccceccucecs 13 E E A Pedal srenti n O O 7 Replace the Ball Joints Tie Rods and t Brake Pedal osano 7 Drag Link 44 DLC CHING secarete ca te ansncaenanesocusae E Fe ES LS SS ee Se ee see Directional Signals Optional 0 cccceeeeeeee 7 Replacing the Drag LINK ssssssrrriisrnnsssssssnnrnnnnnns 16 Hazard Light Switch Optional cseeee 7 Replacing the Tie Rod ccccccccccsscccscceeseeeeeeeeees 17 Charger IMTCHOCK arcs yra n n 8 Center the Steering Gear csceeeseeeeees 18 Sa ae signee Dama care aoeeaoonaaetane agen ans Pitman Shaft Alignment A eRe Ree Renee 18 ectrolyte Ar ptiona SER A R h Talo Gez en 1 Vehicle Operational Guidelines 9 ae renee Safety Guidelines sataa anse a a a ge The DOW Dat now aura Te 3 Starting pd eel ed UO aad E a eho 2 Set Ne bd id a 9 Brake Service See Beet ee area 1 WEGIG iea aE EEEE RARR 9 Loading and Unloading sccccei a eect eet 10 pie ec ee Brake ssscceseeesseeees 2 Tidal C A cae ret nen ry ener re nent re er tone
30. 00 17 Table of Contents Transmission cccecececeeeeeeeeeeceeeeeeeneeeenes 1 Check Oil Level cccccsecesseceeceeeecueeeeanes 2 Change Olllissaccccatecanetecucctevecec a 3 Motor Removal and Installation 4 Rear Hub or Rotor cccccsssececseseceseeeceeas 5 Removing and Installing the Rear Axles Disc Brakes ccccccecacssrtcceternecsccctneticss 6 Transmission Assembly ccecceeeeeeeeeeees 8 Remove and Install oo ccc ceccceesseeesseeeeeeeeeeeneees 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3rd Member 12 Assembling the 3rd Member 15 Pinion Bearing Preload ccccccccsssssseeeeeeeeeeeeeeeeees 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth eeeeeeeee 19 SUSPENSION aso 1 Replace the Rear SpringS ssssssessee 2 Replace the Front Springs sssese0 3 Replace the Spring Bushings 4 Replace the SHOCKS ccesseseeseeeeneees 5 Tires and Wheels c ceseeseeeeeeees 1 Hre Mhaois 2 TIRE INS DO CHO aae 2 Replace the Tire Wheel cssseeeseeeees 3 Repair the Tire pneumatic 00 4 Replace the Tire pneumatic 5 Battery Service cccsscceseeseeseeeeeees 1 Gleann Rererrererr errr reer rrr AENA 2 NES UNO Peeeere peer erre rece rr creer errerrrrer errr Eaa 3
31. 10 ISG Brake PACS et cheetah nice A dated dae odie 2 Towing IEIET A EE TE Saas eae 10 Disc Brake ROtO sessisisogasees anada 3 Adjustable Controller Parameters ccccceeeees 11 Inspect the Automatic Parking Brake 4 Charging your vehicle sccesseesseeeees 13 Adjust the Automatic Parking brake 4 New Battery Break in cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 13 Adjust the Service Brakes ccccccccccccccceces 4 Charging ARa e E E E E E 13 Check Master C linder Fluid 5 Industrial Charger Operation cccccsccccessseeeeees 13 ee ree Signet HB xxxx Charger Operation c ceeeee 14 Bleed the Brake System cssee 6 Lestronic II Charger Operation c ccccceereeeees 14 Flush the Brake System 000000 8 Storing and Returning to Service 15 Replace Front Disc Brake Pads 9 Storing Your Vehicle ccccccccecceeeeeeeeeeeeeeeeeeeeeeeeeees 15 Replace Rear Brake Pad cececccccccaccccuccuccccs 11 Returning to Service see PATEE 15 Hydraulic D SC cis tects terse nla ate tensioste theca 11 Periodic Maintenance Checklist 16 Replace the Wheel Cylinder 0 0 13 Daily Visual inspection neMindase paneer E r E EEA 17 Disc Brake Body Assembly front or rear TE 13 Maintenance Guidelines for Replace the Master Cylinder 200 15 Severe Duty Applications 17 Repair the Master Cylinder 00
32. 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
33. A E Grade 8 Other Bolts Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Appendixes Appendix B Page 3 Appendixes Hex Nuts Nuts with no markings are to be treated as S A E Grade 2 fA te tae 6 es ee N fo eed S A E Grade 5 S A E Grade 8 Hex Lock Nuts stover Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A pay Fae O Z a o a S N or or 2 or or Nd Saxe 7 aera S A E Grade B S A E Grade C Grade L 9 Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Appendixes Appendix B Page 4 Suggested Torque Values non critical hardware Diameter Grade 2 Grade5_ Grade 8 L 9 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque ft lb ft lb ft lb ft lb 1 4 20 4 7 7 10 10 14 11 1 4 2
34. Connect the charger to a working AC power source e he charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirmed that the AC power source is working e The DMM should indicate an open circuit If it still indicates a closed circuit then the relay or the wires to the relay have failed Stop here and repair the problem e Ifthe DMM indicates an open circuit then the interlock relay is functioning normally Charger Troubleshooting zj Page 10 TABLE OF CONTENTS Operating Instructions and Theory of ODS NAL ON siszssavesnccatacovcnsessaxcsanaeasace 2 HB PT and GEL Indicator Lamps 3 Testing the Charging Cycle 06 3 Test Equipment Required for Troubleshooting ceeeeseeeeeeeeeeees 4 Important Notes and Instructions 4 status LED Error Code Table 5 Troubleshooting seccceeeeceeeeceeeeseeees 6 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Signet Charger Troubleshooting RevG Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Charger The model HB600W and HB1000W charge
35. Low ites warning is ON when battery is discharged below this level Battery must be discharged below this BDI Reset 80 value before the BDI will be allowed to reset Battery voltage must be above this Reset Volts 2 1 V value to reset the BDI Modified by the BDI Reset above Discharge Time 60 M Estimated battery discharge rate Miscellaneous Motor must be below this RPM to SRO Min Speed 3 000 RPM change directions with the throttle pedal depressed Safety Rules A Page 12 SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury The key switch must be in the OFF position when charg
36. Page 4 Maintenance Service and Repair Installation 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Install the front axle in reverse order of removal NOTE Use all new cotter pins NOTE Refer to the Replacing the Ball Joints section for information regarding the installing the ball joints or rod ends NOTE Refer to Tires and Wheels section for information regarding removing the front wheels 8 Realign the front wheels Refer to Steering Component Service section for information regarding realigning the front wheels 9 If equipped with front brakes bleed the brakes Refer to Brake Service section for information regarding bleeding the brakes 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test driv
37. Relay 08 10 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Troubleshooting Lestronic II Charger RevE Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic II chargers are designed as semiautomatic chargers The Lestronic II charger turns itself on when the built in charger is plugged into the wall outlet or when the portable charger is plugged into the batteries As the battery charges the battery voltage rises The charger periodically checks the battery voltage and compares it to the previous reading When the battery voltage stops rising a predetermined amount then the batteries are no longer accepting a charge and the charger shuts off The charger will not start again unless the AC cord on a built in charger is disconnected from the wall outlet or the DC plug on a portable charger is disconnected from the batteries The charger 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 approximately 50 1175 1200 as indicated on a hydrometer before connecting the charger If the charger is connected before the batteries are discharged 50 the batt
38. Switch The key switch should be in the OFF position whenever the operator leaves the vehicle This switch is also designed to secure and disable the vehicle The key can only be removed when the key switch is in the OFF position 7 Emergency Stop Switch The emergency stop switch will immediately and abruptly stop the vehicle The high low switch is located on the lower left of the instrument panel Toggle the switch lever up for normal speed Toggle the switch lever down for slow The Emergency Stop Switch will stop the vehicle but will still allow some functions to work such as the parking brake bypass switch speed 4 Combination Display Functions for the Combination display are listed on the following pages 5 Accessory Switches optional The optional accessory switches are located on the left side of the instrument panel The function of the optional accessory switches will vary depending how the vehicle is equipped AWARNING Do not depress the Emergency Disconnect Switch while the vehicle is in motion unless the vehicle must be stopped in an emergency Depressing the switch will immediately apply the park brake stopping the vehicle The abrupt stopping of the vehicle may result in severe bodily injury Safety Rules Page 5 SAFETY RULES AND OPERATING INSTRUCTIONS Combination Displa The gauge on the dash has many functions The display will cycle through the functions while t
39. THE AUTOMATIC PARKING BRAKE The parking brake is located inside of the motor and is electromagnetically operated To inspect operation of the parking brake disconnect the harness to the parking brake and push the vehicle to confirm that the brake is applied The rubber band dust seal should fit snug around the brake Inspect the seal for any indications of cracking or fatigue ADJUST THE AUTOMATIC PARKING BRAKE The parking brake is electromagnetically operated and is either fully applied or off there are no adjustments The brake is OFF when power is applied to the brake ADJUST THE SERVICE BRAKES The hydraulic disc brake system is automatically adjusted A low brake pedal or lack of braking power could be caused by e Brake fluid level low in the master cylinder See Check the Master Cylinder Fluid section e Air in the brake lines See Bleed the Brakes section e Worn brake pads See Inspect the Service Brake section e Worn brake rotor See Inspect the Service Brake section e Binding brake pedal linkage If you are experiencing a low brake pedal or lack of braking power the entire brake system should be inspected Brakes Page 4 Maintenance Service and Repair CHECK MASTER CYLINDER FLUID 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 Flush area immediately with water for several minutes
40. Throttle module 72 volt system l 5 71 122 20 Horn Switch l 6 88 065 06 1 4 NC x 21 2 Phillips Truss Head Screw Horn Switch 2 7 88 069 8 1 1 4 NC Hex Nylon Locknut Horn Switch 2 8 71 111 00 Brake Light Switch l 9 88 045 06 10 32 x 1 2 Machine Screw brake light switch 2 10 71 102 10 Seat interlock Switch l 11 85 030 00 Spring 2 12 96 773 10 Clevis Pin 2 13 02 610 18 Mounting Plate l 14 88 527 11 Cotter Pin 2 15 96 640 00 Clamp 3 16 Push Mount 96 629 80 not shown Clamp Rubber Lined 3 16 ID 96 630 00 not shown Clamp Rubber Lined 5 8 ID 96 630 50 not shown Clamp Rubber Lined 5 8 ID 265 mounting hole i 96 63 1 00 not shown Clamp Rubber Lined 3 4 ID 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 631 15 not shown Clamp Rubber Lined 1 1 2 ID 96 624 00 Clamp 1 4 Jiffy Clip 96 625 00 not shown Clamp 5 16 Jiffy Clip 18 96 626 00 Clamp 7 8 Jiffy Clip 73 005 10 ALARM REV BULLARD MPA II 97DB optional 77 055 01 Low battery water level alarm optional Parts Page 33 Illustrated Parts Lighting Parts Page 34 Illustrated Parts Strobe Light ITEM PART DESCRIPTION QTY l 88 029 80 8 32 Hex nut 3 2 88 028 62 8 lock washer 3 3 88 025 06 8 32 x 1 2 Machine screw 3 4 72 023 20 Strobe assembly amber i 5 i Mounting
41. Wateringen 5 Charging sssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 6 Replacing 6 volt batteries only 7 Moist Charge Batteries ccccccccccccssccscssseeeeeees 9 Storage and Returning to Service 10 AS 1 0 516 ene eee i i ei en Pe nN 10 Returning to Service ccccccccccccececeeeeeeeeeeeeeeeeeeeeeess 11 Control System Diagnostics 1 Test Equipment Required ssessseeeeeeeeeeeeees 2 Important Notes and Instructions cccceeee 2 Status LED Code Table riisi hiaai ia 3 Throttle Module Test ccccccssssseeeeeeeeesseeeeeeeeeees 6 Lestronic II Charger Troubleshooting 2ccceeseeeeeeeeeeees 1 Operating Instructions and Theory of Opera OM iiaiai aida 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting ccceeeceeeeeeeeeeeeees 4 Important Notes and Instructions cceeeeeee 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay csscesseeeees 9 Testing the Interlock Relay asnasan 10 Signet Charger Troubleshooting 1 Operating Instructions and Theory of Opera NON erudician 2 HB PT and GEL Indicator Lamps 3 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting ccceeseeeeeeeeeeeeees 4 Important Notes and Instructions
42. bodily injury 9 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly Brakes Page 9 Maintenance Service and Repair 10 11 12 NOTE Refer to the illustration above for the following steps Remove the brake body bolts 10 and discard the lock nuts 1 and brake pads 8 Remove the spacer bushings 6 from the mounting bracket 5 and discard the bushings Inspect the brake rotor See Inspect the Service Brakes section for information regarding inspecting the brake rotor Inspect the spacers 7 and replace if any wear or damage is found Install new spacer bushings in the mounting bracket Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs Repeat this procedure for the other wheel Install the tire wheel assembly and lower the vehicle to the ground Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information on the proper master cylinder fluid level Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Brakes Page 10 Maintenance Service and Repair REPLACE REAR BRAKE PADS Hydraulic Disc Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarke
43. comes in contact with Failure to clean may result in property damage Batteries Page 7 Maintenance Service and Repair Remove the battery hold downs Inspect the battery hold downs for corrosion If any signs of corrosion are seen then the battery hold downs should be replaced 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batteries 10 Remove the batteries from the vehicle Do not leave cables on batteries that have been removed from the AWARNING vehicle Cables left on batteries could cause a short circuit resulting in battery explosion severe bodily injury and or property damage 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 repainted 13 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery compartment 14 Inspect the main positive and negative cables and terminals charger cables and terminals and 12 volt tap wiring If any of the terminals or wires show signs of corrosion then they must be repaired or replaced 15 Install the batteries in reverse order Refer to the Illustrated Parts List for battery cable routing 16 It is recommended to replace
44. filled and or charged With the fluid level at a normal operating level and or the batteries charged the alarm and light will reset The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source AWARNING Seat Interlock Switch A switch located under the driver s seat disables the power to the vehicle when the driver leaves the seat The driver must be seated for the vehicle to operate Whenever the driver leaves the vehicle the driver should turn the key switch off place the forward off reverse switch in the center OFF position and set the park brake The seat interlock switch is only one part of the vehicle safety system The interlock switch should not be relied upon as the only safety feature used to disable or disengage this vehicle Doing so could result in unexpected movement of the vehicle causing severe bodily injury and or property damage Safety Rules Page 8 SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines e Only qualified and trained operators may drive this vehicle e Drive only on level surfaces or on surfaces having an incline of no more than 10 5 6 degrees e Drive slowly when making a turn especially if the ground is wet or when driving on an incline e This vehicle may overturn easily if turned sharply or when driven at high speeds e Observe all traf
45. is an integral part of the front hub If the brake rotor is worn beyond its service limits then the front hub must be replaced Refer to Front Axle Service for information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be an integral part of the rear axle If the brake rotor is worn beyond its service limits then the rear axle must be replaced Refer to Transmission section for information regarding replacing the rear axle NOTE The wheel must be removed to accurately measure the rotor thickness Refer to Tires and Wheels section for information on removing the wheel 1 Measure the run out of the rotor at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its service limits NOTE A bent axle or damaged rear axle could cause excessive brake rotor run out Shown with the brake removed for clarity 2 Measure the thickness of the brake rotor in 3 places lf the brake rotor thickness is less than 0 20 inches ee then the rotor must be replaced mg a ME Do not use a rotor that is worn beyond its service limits A rotor worn beyond its service limits could fail AWARNING and cause loss of brakes resulting in severe bodily injury and or property damage Rotor removed for clarity The rotor does not have to be removed for this procedure Brakes Page 3 Maintenance Service and Repair INSPECT
46. or 1 27 GT 71068 Bearing i 28 GT 72022 Bearing l 30 GT 70299 10mm Washer 6 37 GT 3252633 Dowel pin 2 Parts Page 15 Illustrated Parts Rear Axle Outer Bearing Inner Bearing no o ring f Axle Shaft l l 2a 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 groove adjacent to o ring on outer bearing Transmission Differential Case 13 Parts Page 16 Illustrated Parts Rear Axle ITEM PART DESCRIPTION QTY 41 154 20 Axle shaft single bearing 2 i 41 154 25 Axle shaft double bearing 2 2 80 505 20 Bearing 2 2a 80 505 30 Bearing for double bearing axle ar 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub
47. pole or mounting plate l 6 Harness l 72 023 22 Amber lens l 72 023 23 Red lens l Not shown 72 023 21 Replacement bulb l There are many special order types of mounting configurations Contact your Taylor Dunn distributor with the serial number of the vehcle for more information Head and Tail Lights ITEM PART DESCRIPTION QTY 72 005 00 5 Round head light 1 or 2 72 072 00 Replacement bulb 1 or 2 94 050 10 Rectangular light left steel cab 1 2 94 050 11 Rectangular light right steel cab l 72 082 01 Replacement bulb 2 3 94 201 10 Name plate i 72 022 00 Tail light lor2 4 72 022 51 Tail ligh rubber grommet lor2 72 022 52 Tail light pigtail Turn Signals ITEM PART DESCRIPTION QTY 72 051 00 Front lights standard cowl 2 72 082 10 Front bulb steel cab 2 72 082 20 Light socket steel cab 2 71 141 22 Turn signal switch includes flasher l 98 330 50 Insulator for turn signal switch 1 71 900 05 Flasher 1 72 405 00 Front light guard standard cowl 1
48. shaft 1 Parts Page 9 Illustrated Parts Steering Gear Front Suspension Front axle ref Parts Page 10 Illustrated Parts Steering Gear 18 308 21 ITEM PART DESCRIPTION QTY l 18 308 70 Locknut 1 2 18 308 71 Adjuster assembly 1 3 18 308 72 Worm assenbly 1 4 18 308 23 Upper worm bearing i 5 18 308 22 Upper worm bearing race i 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 l 10 18 308 79 Seal input shaft i 11 18 308 82 Gasket l 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side cover l 16 18 308 86 Jam nut l 17 18 308 83 Bolt side cover 3 Front Suspension ITEM PART DESCRIPTION QTY l 96 121 00 U bolt 4 85 498 00 Leaf spring B 2 48 2 85 486 00 Leaf spr
49. switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 6 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Tie off the front wheels so that they cannot turn Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front AWARNING wheels tied in position may cause loss of control of the vehicle 11 12 Reconnect the main positive and negative cables resulting in severe bodily injury and or property damage While watching the ball joints rapidly rotate the steering wheel to the left and right If the ball joint housing moves up or down then the ball joint is worn out and should be replaced Refer to section Replacing a Ball Joint for information EE regarding replacing ball joints Typical Ball Joint Untie the front wheels RHYL iii at the batteries Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle Steering Page 6 Maintenance Service and Repair INSPECT ROD ENDS 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 replaced as a Set 1 Make sure the key s
50. the battery terminal hardware when replacing the batteries 17 Torque the terminal hardware to 7 8 ft lbs 18 Tighten the hold downs so that the batteries are secure but not so tight as to deform the batteries When torquing battery hardware use a backup wrench on the battery AC AUTION bolt and tighten the nut Failure to use a backup wrench may damage the battery post 19 Remove the blocks from the wheels and test drive Batteries Page 8 Maintenance Service and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion 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 Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING Aconductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This cou
51. the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 10 11 12 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Remove the wires from the motor NOTE Label the motor wires with the number of the motor terminal before they are removed from the motor If equipped remove the motor support bracket u bolt only used on larger motors Remove the motor mounting bolts and slide the motor off of the input shaft Install the motor in reverse order Make sure that the motor coupler o ring is properly installed on the transmission input shaft NOTE Apply a light coating of part number Support bracket u bolt 94 421 34 moly paste grease to the splines on the transmission input shaft only Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Transmission input shaft Transmission Page 4 Maintenance Service and Repair REAR HUB OR ROTOR NOTE The torque specification for the axle hub bolt is 275 ft lbs An impact wrench will be required to remove the bolt NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced 1 Make sure the
52. the various controls and operating characteristics of this vehicle extracted from the American National Standards Institute Personnel and Burden Carriers ANSI B56 8 As well as following the safety rules and guidelines outlined in ANSI B56 8 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 to be driven on public highways These vehicles are not designed to be driven on public roads or highways They are available in maximum designed speeds ranging AW ARNING from 6 to 16 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow this vehicle at more than 5 mph AWARNING Read and follow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property Refer to Vehicle Operational Guidelines Safety Guidelines section for important safety information regarding operating this vehicle 1 Make sure the key switch is in the OFF position then remove the key AWARNING 2 Place the forward reverse switch in the center OFF position Before working 3 Set the park brake on a vehicle 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnec
53. under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Load Test 6 volt batteries only NOTE The batteries must be fully charged before performing this test 1 Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries 2 Load test each battery using a battery load test meter available at most auto parts distributors Follow the instructions provided with the test meter e If any battery fails the load test then it should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a Set e f all batteries fail the test you should check the charging system before replacing the batteries Refer to Charger Troubleshooting section for information on checking the charging system Batteries Page 3 Maintenance Service and Repair Specific Gravity Test NOTE The batteries must be fully charged before performing this test The specific gravity of a cell is an indication of the actual state of charge of the cell A fully charged cell should have a reading of 1275 to 1300 see the illustration to the right A discharged battery will read 1100 Ideally all cells in a battery pack will have the same reading Any cells in a battery pack that vary by more than 30 points may be an indication of a bad cell Clean the batteries Refer to Cleaning the Batteries section for inform
54. voltage equals battery volts then skip ahead to test 3 If the voltage does not equal battery volts then check the wire from pin 8 to the ON OFF switch 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 3 Accelerator pedal released Test the voltage from pin 9 to pin 4 If the voltage equals battery volts then skip ahead to test 4 If the voltage does not equal battery volts then check the wire from pin 4 to the start switch 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 Troubleshooting Page 7 Electrical Troubleshooting TEST 4 Accelerator pedal released Test the voltage from pin 9 to pin 1 If the voltage is below 0 3 volts then skip ahead to test 5 If the voltage is above 0 3 volts then the module has failed and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 5a Test the voltage from pin 5 to pin 9 Accelerator pedal released If the voltage is low then skip ahead to test 5b If the voltage is high then then the module has failed Stop trouble shooting here and repair the problem When the repair is completed co
55. 0 217AH T 105 Moist charge dry si 77 044 00 230AH T 125 77 044 10 195AH Mainenance free Note requires special charger i 2 77 047 00 244AH T 145 i 77 047 50 250AH TD 250 77 047 80 244AH T 145 Moist charge dry 77 048 00 250AH J 250 x 77 048 80 250AH J 250 Moist charge dry is 77 051 00 160AH Gell Note requires special charger i 3 50 243 10 Battery rod i 4 50 250 00 Battery hold down i 5 88 088 66 Flat washer tin lead plated 7 6 88 069 81 1 2NC Nylon lock nut T 7 88 081 12 5 16NC x 1 Hex bolt stainless steel 8 88 089 80 5 16NC Hex nut stainless steel i 9 88 089 70 5 16 Split lock washer stainless steel 77 055 15 Battery wattering system for Trojan batteries optional 77 055 12 Battery wattering system for Exide or Taylor Dunn batteries optional Not shown 77 055 13 BATTERY FILLING GUN used with watering systems optional 01 534 43 Battery locator angle in bottom of battery box i Quantities depend on voltage configuration of vehicle Parts Page 43 Illustrated Parts Seat Cushions and Deck Optional _ rear seat 11 Optional fold down seat and stake sides Parts Page 44 Illustrated Parts Seats and Deck
56. 0 ft lbs 16 If the spring bolts are equipped with grease fittings lube them at this time 17 Lower the vehicle 18 Reconnect the main positive and negative cables at the batteries 19 Remove the blocks from behind the wheels 20 Release the parking brake and test drive the vehicle N Damaged or worn spring bolts or hangers could result in sudden failure AWARNING of the suspension causing severe bodily injury or property damage Suspension Page 3 Maintenance Service and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set BUSHING TYPES Your vehicle will be equipped with one of two types of spring bushings internal and external see illustration to the right e The internal bushing is a plastic insert that is pressed into the spring eye There are one of these bushings for each spring eye Internal e The external bushing consists of two plastic bushings on each end of the spring eye External e Refer to the parts list to identify the bushings used in your vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front or
57. 2 Parts Page 40 Illustrated Parts Signet Charger ITEM PART DESCRIPTION QTY 79 309 40 Charger assembly incudes AC cord with out plug see note below i Note There are no user serviceable components inside the 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 Parts Page 41 Illustrated Parts Batteries Main Negative Main Positive 12 Volt Negative tap Parts Page 42 Illustrated Parts Batteries ITEM PART DESCRIPTION QTY l 75 237 00 Batteru jumper T 77 042 00 217AH T 105 j 77 042 50 217AH TD 217 7 77 042 8
58. 2 5 88 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5 2 7 96 329 10 Wheel stud 10 92 104 10 Hub cover 2 41 290 40 Axle housing left single bearing l 41 290 43 Axle housing right single bearing l Not shown 41 290 78 Axle housing left double bearing i 41 290 79 Axle housing right double bearing 1 89 113 30 M12 x 1 75 x 30mm Hex bolt axle housing to center section 6 89 113 60 M12 Split lock washer axle housing to center section 6 B 2 54 optional double bearing axle Transmission Differential Case ITEM PART DESCRIPTION QTY 9 GT 70302 M10 x 30 Bolt 12 13 GI 3287183 Ring and pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug i 17 GT 3287113 Differential housing l 19 GT 3287143 Differential case l 20 GT 72013 O ring l 22 GT 71896 M10 x 25 Bolt 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GI 71881 Seal 1 32 GT 70052 Vent l Parts Page 17 Illustrated Parts Rear Brakes Front Brakes Hoe Parts Page 18 Illustrated Parts Rear Brakes
59. 2 336 384 38 1 43 5 Steering wheel nut 18 308 25 steering gear 72 86 864 1032 97 9 117 Suspension Leaf spring hangers Note Refer to maintenance section in the service manual Appendixes Appendix B Page 6 Appendixes APPENDIX C BRAKE LINING HANDLING PRECAUTIONS Taylor Dunn does not currently supply asbestos fiber brake pads shoes with any vehicle However there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as if they do contain asbestos Never use compressed air or dry brush to clean the brake 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 AWARNING Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Always wear protective clothing and a respirator when working on the brake pads shoes or their associated components Inhaled asbestos fibers have been found to cause cancer and respiratory diseases Do not drive the vehicle if any worn or broken part is detected in any part of the brake system The cause of the damage must be repaired immediately Appendixes Appendix C Page 7 Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804
60. 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices 10 11 12 13 14 15 16 of rated load capacity may result in severe bodily injury Remove the hub dust cap and cotter pin While rotating the hub tighten the spindle nut to Pa 30 ft lbs This seats the bearings a Back off the spindle nut one flat until the hub turns but is not loose k Pi E q oN 5 A ae 4 am P boamp ae N Ta a P oe gt Laa Spindle Nut p of Nut 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 section for information regarding the replacement of the wheel bearings l Hub with Dust Cap Removed Install a new cotter pin Install the dust cap Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Front Axle Page 3 Maintenance Service and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 1 Make sure the key switch is in the OFF posi
61. 5 Sit Down Tow Tractor Safety Rules and Operating Instructions TABLE OF CONTENTS Standard Specifications ccsceeeeeeeeees 2 Safety Rules and Guidelines 0ss00 3 Driver Training Program cccsssceeseseeeeeees 4 Driver Qualifications esnan A 4 Ea ARE eA e EEEE TT 5 2 Forward Off Reverse Switch cccccceeeeeeeeeeeeeeeees 5 3a LON OWIE eere a a a a a a a 5 BO MILOW SWIC aes a 5 4 Combination Display cccccccceceeeeeeeeeeeeeeeeeeeeeees 5 5 Accessory Switches optional ceeeee 5 Vehicle CONIIOIS wiscscdiccssececciccnenmecsvecnivecceveccans 5 6 KOY SWIIGH isdssnseldeeseinisrsinicisivieisinieisivaiasieiens 5 7 Emergency Stop Switch eeeeeeeeeeeeees 5 Combination Display 00 00000eeeeeeeeeeeeeeeeeeeeees 6 ACCeleralor Peal vecerscewsasissassadvesacnadvesevecesveuedunsenans 7 Foot Brake Pedal techies deceased ceeds ntcoctey 7 EONO rte Be A Be BR A has 7 Directional Signals Optional ccccssseeeeeeeees 7 Hazard Light Switch Optional ssssssssssees 7 charger InlenOCk 2 it wi te es 8 Seat Interlock SWIC ietis 8 Electrolyte Alarm Optional ccccccccccscssssseeeeees 8 Vehicle Operational Guidelines 9 Safety Guidelines 0seeeeeeeeeeeeeeeeeeseeseeeeeeeeees 9 O a a a ener meee 9 WAS OVO a a raa ihe E 9 Loading and Unloading sseeeeeeeeeeeeeeeeeee
62. 8 5 8 8 12 11 16 12 5 16 18 9 14 14 21 20 29 22 5 16 24 10 15 15 23 22 33 25 3 8 16 16 24 25 37 35 52 40 3 8 24 18 27 28 42 40 59 45 7 16 14 26 38 40 59 56 84 65 7 16 20 29 43 44 66 62 93 70 1 2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 138 207 213 319 301 451 350 3 4 16 154 231 238 357 336 504 390 7 8 9 222 334 344 515 485 728 565 7 8 14 245 367 379 568 534 802 625 1 8 333 500 515 773 727 1091 850 1 14 373 560 577 866 815 1222 930 1 125 7 472 708 635 953 1030 1545 1700 1 125 12 530 794 713 1069 1156 1733 1850 1 25 7 666 999 896 1344 1454 2180 2950 1 25 12 738 1107 993 1489 1610 2414 3330 Appendixes Appendixes Appendix B Page 5 Appendixes Suggested Torque Values critical hardware Torque Table Torque Range Group Description Ft Lbs In Lbs Nm Brakes Brake bolt disc brake body 11 11 132 132 15 15 Brake line tube nut fittings 12 13 144 156 16 3 17 7 Brake spider bolts Dana 160mm hyd brakes 25 35 300 420 34 47 6 Brake spider bolts Dana 160mm mech brakes 15 19 180 228 20 4 25 8 Brake spider bolts Dana 7x1 3 4 brakes 16 20 192 240 21 8 27 2 Electrical Bat
63. 98 310 00 Rubber windshield gasket by the foort Fiberglass Cab ITEM PART DESCRIPTION QTY 91 000 00 Fiberglass cab i 90 800 00 Front windshield l 90 850 00 Rear window l 98 310 10 Rubber windshiel gasket by the foot 94 035 01 Plastic door trim by the foot 90 908 50 Filler panel 2 Fiberglass Windshield Frame illustration not available ITEM PART DESCRIPTION QTY 90 800 00 Windshield 1 91 006 00 Fiberglass frame l 91 029 00 Support bracket 2 98 310 10 Rubber channel 10 Windshield Wiper illustration not available ITEM PART DESCRIPTION QTY 74 050 00 Wiper motor l 74 051 00 Wiper arm 1 74 052 00 Wiper blade l 75 152 09 Harness l Parts Page 51 Illustrated Parts Door Options Steel Cab Steel door detail Note Left Door Shown ec va Door frame Pa 24 26 LL Door Restraint 16 Parts Page 52 Illustrated Parts Cab Doors Naugahyde Steel cab
64. If a rash or skin irritation develops get medical attention immediately AWARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap 7 Remove the master cylinder cap 8 If the fluid in the master cylinder is contaminated then the entire brake system must be flushed Refer to Bleed the Brakes for information regarding flushing the brake system 9 Fill with brake fluid from a new sealed container to within 1 4 inch of the top of the master cylinder chamber and reinstall the cap 10 Reconnect the main positive and negative cables at the batteries 11 Remove blocks from behind the wheels 12 Release the parking brake and test drive the vehicle Master cylinder is located between the front seats Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes A WARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow
65. KLE Make sure the ON OFF switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING If equipped with a hand operated park brake set the brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting 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 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding fe aoe Spindle Nut removing the tire wheel assembly t E Ere N 8 Remove the hub bearing cap cotter pin and nut then remove the hub from the steering knuckle NOTE For a front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then it will be necessary to bleed the brakes Hub with Dust Cap Removed NOTE Catch the outer bearing as it falls out 9 Remove the drag link and or tie rod from the steering knuckle Refer to Replace the Ball Joints Tie Rods Drag Linkin this section for information reg
66. Mounting bracket nght 91 814 16 Hinge left used with 92 202 12 91 814 17 Hinge right used with 92 202 13 92 202 15 Spacer used with 92 202 12 and 13 92 207 00 Mirror multi panel inside cab 91 810 00 Mounting tab for multi panel mirrir 2 97 176 00 Washer Neoprene 2 92 206 00 Mirror rectangular 5 1 2 x 8 inside cab 02 210 70 Bracket for 92 206 00 92 202 00 Mirror mountingr bracket assembly 1 92 202 21 Arm 1 2 92 202 23 Bracket 2 3 92 202 22 Joint l 4 88 080 14 5 16NC x 1 1 2 Hex bolt l 5 88 088 61 5 16 SAE flat washer 4 6 88 089 8 1 5 16NC Lock nut 1 T 88 088 62 5 16 Split lock washer 1 8 88 089 80 5 16NC Hex nut 1 9 88 080 14 5 16NC x 1 1 2 Hex bolt 1 Miscellaneous Frame Components ITEM PART DESCRIPTION QTY 1 79 511 00 Charger AC cord holder 1 2 79 530 00 Charger AC cord strain releif 1 3 79 575 25 Charger cord Lester charger only 1 4 30 807 00 COVER STEERING GEAR SUPT l 5 94 201 00 TAYLOR DUNN EMBLEM 1 6 88 567 91 Clip for TD Emblem 3 7 01 110 20 Throttle pedal i 8 98 200 00 Rubber brake pedal pad i Parts Page 47 Illustrated Parts Decals a 7 4 w Bi E Tiie Parts Page 48 Illustrated Parts
67. ON PURPOSE PART Used for testing electrical circuits Powered by the Test Light truck batteries switchable for 12 24 36 and 48 62 027 00 volts Used to test the solid state accellerator module Accelerator Test Harness part number series 62 033 XX 62 027 31 User level maintenance Used for diagnostics of the AC motor speed 62 027 64 Dealer level maintenance Used for diagnostics and adjusting of the AC Start switch handset motor speed control system standard Disc Brake Boot Installation Used to install the rubber boot on all disc brake 41 350 13 Tool bodies Pin Removing Tool Used to remove pins and sockets from AMP 75_4A0 55 connectors Pin Removing Tool Used to remove pins and sockets from MOLEX 75_442 55 connectors Hydrometer Used to check the specific gravity of battery 77 2000 00 electrolyte Battery Filler Used to safely add water to batteries 77 201 00 Appendixes Appendix A Page 2 Appendixes APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads Hex Bolts S A E Grade 2 S A E Grade 5 3 S
68. Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE Most vehicle configurations do not require lifting the vehicle to remove the master cylinder Lifting the vehicle may not be required 6 If required raise the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Place a drain pan under the master cylinder 8 Disconnect the brake line s to the master cylinder and pump out the fluid in the master cylinder by depressing the pedal several times 9 Remove the master cylinder bolts and remove the master cylinder from the vehicle Brakes Page 15 Maintenance Service and Repair 10 Install in reverse order 11 Adjust the master cylinder push rod so that it is approximately 1 8 inch away from the master cylinder plunger when the brake pedal is up 12 Fill the master cylinder with brake fluid from a sealed container 13 Pump the brake pedal a short distance of one to two inches until no bubbles are seen coming from the inlet ports inside of the master cylinder chamber 14 If the vehicle
69. Refer to the illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counting the rotation turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction 2 Remove the worm bearing adjuster locking ring and the worm bearing adjuster Worm Bearing Adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing NOTE The side cover pitman shaft assembly normally does not have to be disassembled Steering Page 19 Maintenance Service and Repair 4 Remove the worm shaft and ball nut assembly from the bottom of the housing Worm Shaft Ball Remove the worm shaft seal Nut Assembly Remove the pitman shaft seal Remove the upper worm bearing and bearing cup from the housing 8 The ball nut assembly consists of two sets of ball bearings that recirculate in two channels in the ball Bearings nut housing The bearings may fall out once the Ball Guides bearing guides are removed Be careful not to lose any of the bearings 9 Remove the ball guide clamps ball guides and all of the ball bearings 10 Remove the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of a Rall Guide corrosio
70. Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle Replacing a Ball Joint 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 A WARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Loosen the ball joint clamp on the steering sleeve Cotter Pin 8 Remove the cotter pin and ball joint nut l Ball 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 sleeve NA This will make it easier to realign the A O Arm Ball Joint wheels Clamp 11 Install the new ball joint into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the ball joint clamp at this time Steering Sleeve Steering Page 15 Maintenance Se
71. S LS 3 5 s oi accelerate to 15 of full operation of the vehicle and or damage the FwdAc HS 4 0 S Time to accelerate to full speed electrical components This could result in F PVE E RevAc LS 10 0 S ime to accelerate to from FwdAC LS severe bodily injury and or property damage to full RevAc HS 8 0 S Time to accelerate to full speed A limited number of controller parameters can be Aceleration Parameters low speed mode adjusted by your dealer The values of these parameters Time to accelerate to 15 of full FwdAS LS 4 0 S will vary depending on the vehicle model and or speed configuration FwdAc HS 5 5 S Time to accelerate to full speed Time to accelerate to from FwdAC LS er RevAc LS 10 0 S A list of the adjustable parameters and their function is to full listed on the following pages along with their typical RevAc HS 10 0 S Time to accelerate to full speed default factory settings Deceleration Settings Brak Itiplier is activated b Default factory settings are subject to change without Brake Multplier A0 We Ngee E ATS notice It is highly recommended that you record current Normal Dec HS 9 0 S A f filled eet 0 O spee settings in the controller before making any adjustments ee acl lt Time to decelerate hen below O o spee i The Mainte
72. Stop here and repair the problem 8 Reinstall the charger end cap where the DC wires enter 9 Remove the charger end cap where the AC wires enter 10 Test the continuity of all three AC wires from the circuit board to the AC plug If you find an open circuit in any one of the three wires then the AC cord or plug has been damaged Stop here and repair the problem 11 Install the charger end cap where the AC wires enter Wires from the AC cord If both the AC and DC tests are good then the charger has failed There are no internally serviceable components in the charger If the charger has failed then it must be replaced Signet Charger Troubleshooting Page 6 Illustrated Parts TABLE OF CONTENTS FOIL Fl a daca dacicane dace AA 2 Miscellaneous Electrical c ccceeeeeeeees 32 Steering Knuckle ccceceeeeseeeeeeeeeeeeeeeees 4 KORNO are nee T a a eee 34 Steering LINKAGE aranean naaa 6 Lestronic Charger page 1 c seeee 36 Steering CONUN rriren 8 Lestronic Charger page 2 ss sssessessnenn 38 Front SUSPENSION 0 c ceccseeeeseeeesceeees 10 SIQGNet CharGer ersehen neeaaeia 40 STEEVING GOAL e A 10 Portable Charger Wiring ccccseeceseeeees 40 Rear SUSDS SION aana aaa 12 Batten S saca ae aa 42 Transmission Gear Case eeeeeeeeeeeeees 14 Seat Cushions and Deck cccceeeeeeees 44 REIA aniona aea 16 WIKONS vrsio aa R ERE EEEREN 46 T
73. Test drive the vehicle Transmission Page 11 Maintenance Service and Repair DISASSEMBLING THE 3RD MEMBER 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 AWARNING 3 If equipped with a hand operated park brake set the brake 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 rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING J toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the complete drive from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tube 11 Remove the primary reduction gear case Refer to Disassembly and reassembly of the Primary Reduction Gear Case for information on removing the gear case 12 Remove the 12 side plate
74. Ventilate the work area properly Regularly inspect and maintain in a safe working condition brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices Inspect and maintain battery limit switches protective devices electrical conductors and connections in conformance with Taylor Dunn s recommended procedures Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts 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 perform maintenance or repairs to this vehicle Maintenance Page 2 Maintenance Service and Repair TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged King Pin Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis Adjusted or Worn Steering Gear Loose Steering Linkage Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Lack of Power or Slow Operation Speed Control Sys
75. WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Grab the top and bottom of the tire wheel assembly Feel for any movement or play while pulling and pushing on the top and bottom of the tire Any movement or play is an indication of loose wheel bearings or king pin NOTE Refer to the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings NOTE If the king pin is loose then refer to Replace the King Pins and Bushings for information regarding replacing the king pin bushings There are no adjustments for the king pin or bushings 8 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 section for information regarding the replacement of the wheel bearings 9 Lower the vehicle 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Front Axle Page 2 Maintenance Service and Repair ADJUST FRONT WHEEL BEARINGS 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 AWARNING 3 If equipped with a hand operated park brake set the brake 6
76. a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes AWARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container 8 The master cylinder fluid level will drop as the brakes are bled Periodically check and fill the master cylinder during this procedure Do not allow the fluid level in the master cylinder to drop too low as this will allow air into the brake lines 9 Attach aclear hose to the bleeder valve on the brake ee Bleeder cylinder that is to be bled Route the hose into a clear container for waste brake fluid 10 Pump the brake pedal a few times and then press and hold light pressure to the brake pedal 11 Open the bleeder valve on the hydraulic brake body 12 Depress 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 to its released position Bleeder valve with hose attached NOTE Check and fill the master cylinder frequently during the bleeding process Do not allow the fluid level in the master cylinder to drop low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning Always use brake fluid from a new sealed container Never reuse any brake fluid t
77. a qualified technician After a charging cycle if the LED s are flashing then the charger found a fault during the charging cycle Refer testing of the charging system to a qualified technician Typical charging times are eight to twelve hours depending on the how deep the batteries are discharged The charger has an internal timer that will terminate the charge cycle if the batteries are not fully charged within a preset time limit If this occurs the charger will report a fault of running too long The most likely cause of this fault is defective batteries Refer testing of the batteries to a qualified technician Lestronic lIe Charger Operation The Lestronic II charger is a semiautomatic 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 plate on the charger for the voltage and type power required for the charger When the charger is plugged in it should turn on within a few seconds To determine if the charger is on listen for a humming sound from the charger If the charger does not turn on then there may be a fault in the AC line voltage or in the charger Refer troubleshooting to a qualified technician Typical Lestronic IT Built In Charger Typical charging times are eight to twelve hours depending on the how deep the batteries are discharged Charging times exceeding 16 hours may be a resu
78. al 3 Lubrication Cart isco sete ceietecsescsiccesacstaszias 4 Responsibilities ccceeceeeeeeeeeeeeeeeeeeeenees 3 i Hov To Use This MaLa 4 Front Axle Service coeeeeanseeanaee 1 CONVENTIONS calteccsnncsseiedtensaes crevinseecranereiess 5 Inspect the Front Wheel Bearings and How to Identify Your Vehicle 00 6 King Pin sateneaeaeeneneaeananeneaeananenentaneneneatay 2 Taking Delivery of Your Vehicle 7 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Safety Rules and Operating PSO UA o a faeces kere eect 4 i MSAA a rencrtri tere ncnrnare ec naretre 5 alae a OE Front Axle Dassen 6 Safety R ae and Gui delines D 3 Replace Front Wheel Bearings 7 aaa de loa ease E 4 Replace the King Pins and Bushings 9 ae ga aa pare E crea Replace the Steering Knuckle 11 river Qualifications cc ccccceececccesseeeeeeeeeeeeeueeeees 4 DROM SWITCH oes arte ra cece nec aed nets cota nedu cede atte aedlee 5 2 Forward Off Reverse Switch ccccssssscssseesssseeee 5 Steering Component Service 1 Bay Light Swit h nea ia a ELERA 5 Front End Alignment cesceseeeeeees 2 a He one eee wee ee Inspect Ball Joints ccceeeseeeeeeeeeeeeeeees 6 ombination Display 0 sseeeeeeeeeeeeeees 5 Accessory Switches optional e 5 Inspect Rod Ends E S E eae
79. al Purpose Grease 3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 4 King Pin 2 General Purpose Grease 7 Drive Drain Plug l 8 Drive Level Plug l 9 Drive Fill Plug l SAE 80W90 Gear Oil 10 Motor Coupler Part Number 94 421 34 Moly Paste Grease Maintenance Page 4 Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and KUNG PIN wrekceicicdeeteicncieeceseesecacecaied Adjust Front Wheel BearingS 000 Front Axle Removal and Installation POMOVAl e paanan ea aai r EN 4 mstallatiom aa sei Ea a 5 Front Axle Disassembly cccsseeeseeeeeeeeees Replace Front Wheel Bearings 00000 Replace the King Pins and Bushings Replace the Steering Knuckle Maintenance Service and Repair INSPECT THE FRONT WHEEL BEARINGS AND KING PIN 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity A
80. all Joints section for information regarding the removal of the ball joints or rod ends Steering Knuckle Remove the tie rod as an assembly Install in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels Typical Front Axle Assembly 11 Lower the vehicle 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Steering Page 17 Maintenance Service and Repair CENTER THE STEERING GEAR 1 Remove the pitman arm 2 Rotate the input shaft clockwise until it stops 3 While counting the rotations rotate the input shaft counter clockwise until it stops 4 Rotate the input shaft clockwise 1 2 the rotations counted in the previous step 5 Mark the steering gear input shaft and pitman shaft in relation to the housing for reference PITMAN SHAFT ALIGNMENT 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 AWARNING 3 If equipped with a hand operated park brake set the brake 6 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist
81. all warnings on the brake fluid container Brakes Page 5 Maintenance Service and Repair BLEED THE BRAKE SYSTEM 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 Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately AWARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately NOTE Start this procedure at the wheel furthest from the master cylinder then work toward the wheel closest to the master cylinder 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap and remove the cap Master cylinder is located between the front seats Dual reservoir shown Brakes Page 6 Maintenance Service and Repair 7 Add brake fluid from a new sealed container to the master cylinder Fill to 1 4 from the top of the master cylinder chamber Only use DOT 3 brake fluid from
82. and Repair REPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle e Bronze bushings in the axle beam e Bronze bushings in the steering knuckle e Metal backed teflon bushings in the axle beam or Suspension arm NOTE Bronze bushings must be reamed or broached to the proper diameter after they are pressed into the axle beam or steering knuckle Failure to correctly broach or ream bronze bushings may result in AWARNING steering difficulty and loss of control of the vehicle causing severe bodily injury and or property damage Refer to the illustration below for the type of bushing in your vehicle Make sure the ON OFF switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING If equipped with a hand operated park brake set the brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Steering Knuckle with 7 Bronze Bushings Axle End with Metal Backed Teflon Axle End with Bushings Bronze Bushing
83. and support devices of recommended load capacity may result in severe bodily injury After any repairs are made completely retest the vehicle before AW ARNIN G lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and or property damage Troubleshooting kd Page 2 Electrical Troubleshooting Status LED Code Table The status LED s on the speed controller can be used to give you an idea of where the problem may be During normal operation no faults the yellow LED will be flashing steady When the controller senses a fault the two LED s can be used to determine the fault code The fault code will be a two digit code The red LED signifies which digit and the yellow LED signifies the fault code For example When the red LED flashes once the yellow LED will be flashing the first digit When the red LED flashes twice the yellow LED will be flashing the second digit The fault code will repeat until the fault is corrected Handset Display Possible Cause Effect of Fault Controller Overcurent External short in motor wiring Shutdown of main contactor Defective controller Shutdown of motor Faulty wiring Shutdown of EM brake Current Sensor Fault Short or leakage to frame from motor Shutdown of main contactor windings or wiring Shutdown of motor Controller defective Shutdown of EM brake Precharge Fai
84. arding removal of the drag link or tie rod 10 While supporting the knuckle remove the king pin and thrust bearing 11 Remove the knuckle from the axle Front Axle Page 11 Maintenance Service and Repair 12 Thoroughly clean and or replace all bearings nuts washers and bushings NOTE Both the left and right side bushings and thrust bearings should be replaced as a set 13 Assemble in reverse order 14 Pack the thrust bearing with grease 15 Tighten the king pin nut until all of the up and down play is removed and the yoke rotates freely The rubber washer must compress slightly to create a seal for the grease NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign the wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 18 Lower the vehicle 19 Reconnect the main positive and negative cables at the batteries 20 Remove the blocks from behind the wheels 21 Release the park brake and test drive the vehicle Front Axle Page 12 Steering Component Service TABLE OF CONTENTS Front End Alignment cccssceeseeeeeeeeeeeeenees 2 Inspect Ball Joints ccccceeeeeeeeeeeeeeeeneeeneees 6 Inspect Rod Ends cssscseseeseeeeesseeeeeeeeeeaes 7 Adjust the Steering Gear cccsseceeseeeeees 8 Replace the Steering Shaft
85. assembly i See following pages for component breakdowns Parts Page 3 Illustrated Parts Steering Knuckle Parts Page 4 Illustrated Parts Steering Knuckle ITEM PART DESCRIPTION QTY 4 88 239 86 3 4 NF Hex Slotted Nut 2 5 88 228 60 3 4 Cut Flat Washer 2 6 98 603 07 Rubber Bushing 2 7 01 220 99 Washer 2 8 32 240 44 Bushing 2 9 32 240 43 Bushing 2 10 80 309 12 Thrust Bearing 2 1 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13 2 15 88 228 61 3 4 SAE Flat Washer 2 16 88 527 14 1 8 x 1 1 2 Cotter Pin 2 17 88 239 85 3 4 NF Hex Slotted Nut 2 18 92 104 01 Bearing cap 2 21 020 20 Right Steering knuckle 1 i 21 020 21 Left Steering Knuckle 1 20 96 329 00 Wheel stud 10 Parts Page 5 Illustrated Parts Steering Linkage Parts Page 6 Illustrated Parts
86. aster Cylinder ITEM PART DESCRIPTION OTY l 88 080 14 Bolt 5 16 X 1 1 2 NC Hex Head 2 2 99 511 20 Master Cylinder includes item 3 99 511 52 Cap Seal Master Cylinder i 99 511 53 Cap Master Cylinder 1 4 88 088 61 Washer 5 16 4 5 88 089 81 Locknut 5 16 2 99 511 51 Rubber Boot Master Cylinder 1 50 009 05 Master cylinder push rod 1 Not Shown 17 104 00 Collar for push rod 1 96 762 00 Clevis for push rod 1 85 250 00 Brake pedal return spring 1 Parts Page 21 Illustrated Parts Motor 203 298 297 293 297 292 255 294 2706 5 39 3900 58 LL pa A 41 42 ia 52 96 Parts Page 22 Illustrated Parts 70 059 41 Motor Spec ZFB40SO 4 DF100L 4 ITEM PART DESCRIPTION QTY la 41 354 05 Brake i 9 70 400 14 Snap ring i 14 70 400 12 Fan Shroud 1 15 70 400 11 Fan 1 39 70 400 15 O ring 1 Al 70 400 16 Key 42 70 400 17 Snap ring i 52 70 400 21 Key 1 96 70 400 18 Snap ring 1 98 70 400 19 Snap ring 1 203 70 400 13 Seal l 224 70 400 09 Rubber Grommet 2 206 Te
87. at back l 90 107 01 Seat frame l 6 90 134 00 Seat cushion l 7 90 108 20 Rerar step 1 90 134 00 Seat cushion fold away seat i j 90 149 00 Seat cushion fixed seat 9 90 140 00 Back rest l 90 542 01 End gate l 90 542 06 Left gate 75 i 90 542 05 Right gate 75 1 10 90 542 03 Left gate 37 1 4 1 90 542 02 Right gate 37 1 4 i 90 542 04 Left gate 37 1 2 l 90 542 07 Right gate 37 1 2 1 90 101 50 Seat frame lower unpainted 1 j 90 101 51 Seat frame upper unpainted i Parts Page 45 Illustrated Parts Mirrors 92 202 00 Assembly Miscellaneous Frame Components Parts Page 46 Illustrated Parts Mirrors ITEM PART DESCRIPTION QTY 92 201 00 Mirror rectangular 4 1 2 x 8 1 2 side view 92 202 12 Mounting bracket left 92 202 13
88. ation on cleaning the batteries Using part number 77 200 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 charging system If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced NOTE Refer to Charger Troubleshooting for information on checking the charging system The highest reading will be the cell that is accepting the most charge This reading will be used to gauge all other cells Typical Hyd ter Float Compare the specific gravity readings to the highest reading if the difference Ue sve cu meena Sete between any of the cells is more than 30 points then that battery should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a Set Reconnect the batteries remove the blocks from the wheels and test drive Batteries Page 4 Maintenance Service and Repair WATERING NOTE The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the batteries at the end of a charging cycle If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete Explosive mixtures of Hydrogen gas are present withi
89. axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes A WARNING resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt 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 level of the fill plug threads Refer to Changing the Differential Oil 18 Lower the vehicle 19 If equipped with a hand operated park brake set the brake 20 Reconnect the main positive and negative cables at the batteries 21 Remove the blocks from behind the wheels 22 Release the park brake and test drive the vehicle Transmission Page 7 Maintenance Service and Repair TRANSMISSION ASSEMBLY Remove and Install 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 If equipped with a hand operated park brake release the brake and remove the park brake cables from the spring axle mounting brackets and brake arms Disconnect the wiring f
90. bolts then remove the side plate Transmission Page 12 Maintenance Service and Repair 13 Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate 14 Turn the side plate over and remove the carrier bearing race from the side plate 15 Remove the differential assembly from the 3rd member housing 16 Remove the carrier bearing adjusting nut roll pin from the 3rd member housing then remove the carrier adjusting nut Roll Pin Transmission Page 13 Maintenance Service and Repair 17 Remove the carrier bearing race from the 3rd member housing 18 Remove the front bearing from the input shaft NOTE The input shaft may have to be driven out to perform this procedure 19 Remove the input shaft s shims and spacer 20 Remove the pinion shaft from the 3rd member 21 Remove the front and rear pinion bearing races 22 Inspect all parts for signs of wear or damage 23 Thoroughly clean all parts Transmission Page 14 Maintenance Service and Repair 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 3 Install the carrier bearing races into the housing and cover Cover 4 Place the differential assembly into the housing 5 Tighten the housing carrier bearing race ring nut so that the ring gear is not in binding against
91. connecting Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries STORING AND RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel Storing Your Vehicle e Clean the batteries then fill and charge before putting the vehicle in storage Do not store batteries in a discharged condition e Lube all grease fittings Storage e Clean dry and check all exposed electrical Temperature Saale ee connections F months e Inflate tires to proper pressure if applicable Over 0 j e For extended storage the vehicle should be elevated so that the tires do not touch the ground Between 40 and 60 2 lf stored for a prolonged period the batteries should be charged Below 40 6 per the table to the right Returning to Service e Check the battery s state of charge and charge if required e Perform ALL maintenance checks in the periodic checklist e Remove any blocks from the vehicle and or place the vehicle down on to the ground e Test drive before putting into normal service Safety Rules Page 15 SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Taylor Dunn Preventative Maintenance Schedule for GT Drive with AC Motor Date Model
92. d resorts They are not to be driven on public highways This vehicle conforms to requirements for 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 B56 8 Theese vehicles are not designed to be driven on public roads or highways They are available in maximum designed speeds ranging AW ARNING from 6 to 16 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow at more than 5 mph The locations of the model and serial numbers are illustrated as follows gt Location of Data Plate on Cowl Location of Data Plate on Kick Panel Introduction Bf Page 6 INTRODUCTION TAKING DELIVERY OF YOUR VEHICLE Inspect the vehicle immediately after delivery Use the following guidelines to help identify any obvious problems e Examine the contents of all packages and accessories that may have come in separate packages with the vehicle e Make sure everything listed on the packing slip is there e Check that all wire connections battery cables and other electrical connections are secure e Check battery cells to be sure they are filled e Check the tire pressure tightness of lug nuts and for any signs of damage Check the operati
93. d support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property AWARNING damage Use lifting and support devices with a minimum capacity of twice the gross weight of your vehicle Failure to use lifting and support devices of recommended load capacity may result in severe bodily injury After any repairs are made completely retest the vehicle before AW ARNIN G lowering the drive wheels to the ground Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and or property damage Troubleshooting kd Page 6 Electrical Troubleshooting All tests performed with the ON OFF Switch switch in the ON position Accelerator pedal depressed meas to depress the accelerator pedal fully full soeed Accelerator pedal released means to completely release the accelerator pedal off TEST 1 Accelerator pedal released Test the voltage from pin 9 to battery positive If the voltage equals battery volts then skip ahead to test 2 If the voltage does not equal battery volts then check the wire from pin 9 to the battery voltage negative circuit breaker Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 2 Accelerator pedal released Test the voltage from pin 9 to pin 8 If the
94. d test drive the vehicle Brakes Page 8 Maintenance Service and Repair REPLACE FRONT DISC BRAKE PADS NOTE It is recommended that both the left and right brake pads be replaced as a set Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full Master cylinder is located between the front seats Dual reservoir shown 8 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe
95. damage Batteries Page 5 Maintenance Service and Repair 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 AWARNING 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 6 Clean the batteries Refer to Cleaning the Filler neck Batteries section for information on cleaning the Pa batteries Pei 7 Check the electrolyte level in all battery cells If i toy ON s Max water low fill to the correct level with distilled water using part number 77 201 00 battery filler never add additional battery electrolyte to the batteries Rue inside battery 8 Reconnect the batteries remove the blocks from the wheels and test dri ESE e wheels and test drive SERINE SRILA Battery 209 OSIM cutaway CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions Batteries Page 6 Maintenance Service and Repair REPLACING 6 VOLT BATTERIES ONLY Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks A WARNING cigarettes or any other sources of combustion are present Always provide ampl
96. de plate closest to the input shaft see next page D The number on the edge of the differential side plate farthest from the input shaft see next page E The distance in millimeters from the rear of the drive housing to the face of the pinion gear see next page Once a shim has been selected and the pinion gear is Face of pinion gear installed confirm that E D B DV Number on face of pinion gear Transmission Page 19 Maintenance Service and Repair NOTE Values shown are for reference only Pinion Gear RSs x Drive Housing TE Transmission Page 20 Suspension TABLE OF CONTENTS Replace the Rear Springs cssseseseee 2 Replace the Front Springs sesesee 3 Replace the Spring Bushings 0000 4 Replace the ShOcKS cesseeesseeeeseeeeneees 5 Maintenance Service and Repair REPLACE THE REAR SPRINGS If a spring has failed or is fatigued then it is recommended that both rear springs are replaced as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 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 AWARNING 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 batte
97. de the insulators off the connectors on the two 14 gauge wires High Voltage Do not touch the 14 gauge wires and make sure these A WARNING two wires do not come into electrical contact with any other object Failure to do so may result in serious bodily injury 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 Charger Troubleshooting zj Page 5 Electrical Troubleshooting e Disconnect the charger from the AC source e Disconnect the batteries e Disconnect the charger from the vehicle s harness e Remove the charger from the vehicle HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNING terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury 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 Discon
98. delines e Operational Information e Operator Responsibilities e Owner Responsibilities e Control Operation and Location Information e Maintenance and Troubleshooting Information e Standard Parts List Before servicing operating training or performing maintenance on this or any other Taylor Dunn vehicle read the appropriate Taylor Dunn manual Each Taylor Dunn manual references the applicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual Introduction 2 Page 2 INTRODUCTION WHO SHOULD READ THIS MANUAL This manual is intended for use by anyone who is going to operate own perform maintenance on service or order parts for this Taylor Dunn vehicle Each person should be familiar with the parts of this manual that apply to their use of this vehicle RESPONSIBILITIES Of the Owner The owner of this or any Taylor Dunn vehicle is responsible for the overall maintenance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance performed on the vehicle OSHA Regulation 29 CFR 1910 178 Powered Industrial Truck Operator Training Of the Operator The operator is responsible for the safe operation of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Se
99. diodes using the diode test function on the meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Diode 1 PE Common Diode 2 Charger Troubleshooting zj Page 8 Electrical Troubleshooting 5 Reconnect the lead to the diode 6 Connect the charger to the AC source Insert the DC charger plug into the DC receptacle and perform the following tests High Voltage inside the charger Do not touch any internal components ANW ARN I NG while the charger is plugged in Failure to do so may result in serious bodily injury e Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the DC cord is bad Stop here and repair the problem e Test the voltage across the white and black wires 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 AC cord is bad Stop here and repair the problem e If the timer relay does not pickup click within 5 seconds of connecting the DC charger plug then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem e Test the AC voltage across the transformer primary circuit This voltage should be the same as the rated AC voltage of the charger If it is
100. e carrier 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 tighten the cover carrier bearing race ring nut equally NOTE To move the ring gear away from the pinion Loosen the cover carrier bearing race ring nut and tighten the housing carrier race ring nut equally The two ring nuts must be turned the same amount in opposite directions This allows the carrier assembly to be positioned with the proper gear lash without upsetting the bearing preload If the ring A CAUTION nuts are not turned the same amount then the bearing preload will no longer be correct and will result in drive noise and premature failure Transmission Page 16 Maintenance Service and Repair 17 Install the locking roll pins into the housing and cover to lock the ring nuts in place 18 Remove the pinion gear holding tool 19 Install the primary reduction gear case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil section for information regarding the proper oil level 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Transmis
101. e the vehicle Front Axle Page 5 Maintenance Service and Repair FRONT AXLE DISASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering 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 does not have to be removed unless the axle beam must be replaced Refer to Front Axle Removal and Installation for information regarding removing the front axle Axle with integral king pin shown a Front Axle Page 6 Maintenance Service and Repair REPLACE FRONT WHEEL BEARINGS 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly from the hub Refer to Replace the Steering Knuckle for information regarding
102. e ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING Aconductive 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 property damage and or 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 AWARNING 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 NOTE If the batteries are over one year old it is recommended to replace them as a Set 6 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the A CAUTION battery electrolyte
103. eck controller Full brake connector for contamination 46 EEPROM Failure Controller parameters corrupted Controller must be Shutdown main contactor returned to factory for Shutdown motor reprogramming Shutdown EM bake Shutdown Throttle Shutdown interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD Full brake 1 Startup switches not operated in the Refer to operator section Shutdown throttle correct order for correct startup 2 Faulty wiring or switches sequence 49 Parameter Change Fault May occur when adjusting parameters Cycle key switch to clear Shutdown main contactor fault Shutdown motor Shutdown EM bake VCL Runtime Error Controller parameters corrupted Controller must be Shutdown main contactor returned to factory for Shutdown motor reprogramming Shutdown EM bake Shutdown Throttle Shutdown interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD Full brake None 2 Faulty motor encoder current into pin 26 and 3 Faulty dash display pin 25 71 OS General Internal controller fault If cycle key switch does not Shutdown main contactor clear fault controller may Shutdown motor have failed Shutdown EM bake Shutdown Throttle Shutdown interlock Shutdown Driver 1 Shutdown Driver 2 Shutdown Driver 3 Shutdown Driver 4 Shutdown PD Full brake TA PDO Timeout Internal controller fault Cycle key switch t
104. ect the main positive and negative cables at the batteries Raise the wheel to be replaced off of the ground and support with jack stands Remove the 4 or 5 wheel nuts and remove the wheel Install in reverse order Following the pattern shown on the following page cross tighten the wheel nuts in two stages as follows 1st stage to approximately 20 ft lbs 2nd stage to 80 90 ft lbs 10 Reconnect the main positive and negative cables at the batteries 11 Lower the wheel to the ground 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Oo on Oe Tires and Wheels Page 3 Maintenance Service and Repair 8 Bolt Pattern 4 Bolt Pattern 5 Bolt Pattern Pattern for tightening the wheel nuts Re torque all wheel nuts to their final value after 1 week 20 hours of operation Failure to re torque the wheel nuts may result in the AWARNING wheel coming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC Do not attempt to repair a tire with a damaged side wall or a slice in AWARNING thetread This type of repair could fail prematurely resulting in severe bodily injury and or property damage NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repai
105. ed with the handset e Throttle module test harness 75 089 00 Important Notes and Instructions e Troubleshooting this vehicle requires proficiency in the use of standard test equipment such as Volt meters Ammeters Ohm meters etc Troubleshooting this vehicle requires proficiency in testing relating to the continuity of switches connectors wiring etc If the technician working on this vehicle is not proficient in any of the above diagnostics should be referred to a qualified technician e Make sure the batteries are in good condition and fully charged before performing any tests e Ifthe vehicle exhibits intermittent problems 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 DURING ALL TESTS or REPAIRS Turn the ON OFF switch OFF then disconnect both of the battery leads during any maintenance or before disconnecting any electrical AWARNING component or wire Failure to do so may cause severe bodily injury and or property damage The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property AWARNING damage Use lifting and support devices with a minimum capacity of twice the gross weight of your vehicle Failure to use lifting
106. eees 10 elanla o ster st EE eases hice AO eA eke eA oe 10 TONI sist Stes chek ctaca et a aks ahead Ooh 10 Adjustable Controller Parameters ccccceeeeeees 11 Charging your vehicle cscsceeeeeeeeeeeeeeeeees 13 New Battery Break in cccssssssssseeeeeeeeeeeeeseeeeeeees 13 harding Time 4 4 ae ee a ee 13 Industrial Charger Operation cccccccccccccceeeeeeeeeeees 13 Signet HB xxxx Charger Operation 00008 14 Lestronic II Charger Operation 00ee 14 Storing and Returning to Service 15 Storing Your Vehicle ccccscceccceeeeeeeessesssstseeeeees 15 Returning to Service ccccccccccccceeceeeeeeeeeeeeeeeeeeeeeetess 15 Periodic Maintenance Checklist 16 Daily Visual inspection voles tavesshedices wtsadeleedscesieceres 17 Maintenance Guidelines for Severe Duty Applications 000 17 SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM Model SPECIFICATION Min Max Battery 169 kg to 261 kg 872 lbs to 576 Ibs Weights Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Brakes Four Wheel Hydraulic Disc Automaticaly Applied Park Brake Steering Automotive Steering 24 1 Frame Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Instrumentation Combination Display Battery Status Indicator Hour Meter System Status Monitor Key Switch Horn Button Speed se
107. eries may enter an overcharge state before the charger can sense that the batteries are no longer accepting a charge This could result in overcharging and damaging the batteries The relay that operates the charger is powered by the batteries being charged If the voltage on the batteries to be charged is less than approximately 65 of the rated charger DC voltage the relay will not pick up and the charger will not turn on In this situation a manual charger would have to be used to bring the battery voltage up so that the Lestronic charger can sense that they are connected and turn itself on Red Diode P I lk Transformer Tan Black 1 ft i i Black R Green E FIS AC Input a 2 Pm Tan Diode __ Capacitor Not all chargers are equipped with the lockout relay White Violet Black T T Charger Interlock purple blk Interlock Relay Ammeter optional Black To Battery Red af f Typical Charger Internal Wire Diagram Charger Troubleshooting zj Page 2 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started A charger could remain on for longer than 12 hours if e The charging cycle is interrupted at any time during the charging cycle e Defective batteries causing a fluctuating DC voltage that confuses the char
108. esult in serious bodily injury Charger Troubleshooting zj Page 4 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT IN CHARGER Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 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 Make sure that these two wires do not come into electrical contact A CAUTION with any other object 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 Sli
109. fic regulations and speed limits e Keep all body parts head arms legs inside this vehicle while it is moving e Keep the vehicle under control at all times e Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle at intersections blind spots or other dangerous locations e Do not drive over loose objects holes or bumps e Yield right of way to pedestrians and emergencies vehicles e Stay in your driving lane under normal conditions maintaining a safe distance from all objects e Keep a clear view ahead at all times AWARNING Do not get off of the seat while the vehicle Is in motion Getting off of the seat will activate the seat interlock rapidly slowing the vehicle and applying the park brake The abrupt slowing of the vehicle may result in severe bodily injury Starting 1 Make sure the forward off reverse witch is in the center OFF position 2 Hold down the foot brake 3 Insert the key and turn it to the ON position 4 Wait 1 second then place the forward off reverse switch in the desired direction of travel 5 Release the foot brake 6 Slowly depress the accelerator pedal While driving Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection e No reckless driving e Do not drive this vehicle on steep inclines or where prohibited e Im
110. fluid from a sealed container Reassemble in reverse order If the master cylinder is not to be immediately installed onto a vehicle plug the brake line fitting hole to prevent any contaminates from entering the master cylinder Brakes Page 17 NNNG dO TAVL Transmission TABLE OF CONTENTS Check Oil Level cccesseeeseeeeeeeeeeeeeeeeaes 2 Change Ol cccccsseccsseeceseseeseeceneeceneseenenes 3 Motor Removal and Installation 4 Rear Hub or Rotor ccscceseesseeseeeeeeeesenees 5 Removing and Installing the Rear Axles Disc Brakes c cccsccseesseeeeeesenseneeeeeees 6 Transmission Assembly sssasasnnnnnnnnnnnnnnnnnnn 8 Remove and Install ccccccccssssssssssssseeeeeeeeeeeeees 8 Disassembly and Reassembly of the Primary Reduction Gear Case cssssesesseseeees 9 Disassembling the 3rd Member 12 Assembling the 3rd Member 005 15 Pinion Bearing Preload cccccecccssssessssseeeeeeeeeeeeeees 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth cceeeeeeeeeees 19 GT Transmission Assembly With Disc Brakes Maintenance Service and Repair CHECK OIL LEVEL The oil flows freely between the main gear case 8rd member and the primary reduction gear case It is only necessary to check the oil level of the 3rd member Park the vehicle on a level surface
111. g adjuster jam nut 12 Find the center position of the steering shaft A Turn the steering shaft all of the way in one direction B While counting the rotations turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction Steering Page 8 Maintenance Service and Repair 13 While rotating the input shaft back and forth through its centered position adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the parking brake and test drive the vehicle Steering Page 9 Maintenance Service and Repair REPLACE THE STEERING SHAFT 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 If equipped with a horn switch in the steering wheel remove the switch disconnect the wires from the switch and cut the termi
112. ger e A brownout drop in AC line voltage during the charging cycle e An electrically noisy charging environment A charger could turn off in less than 12 hours but still show symptoms of overcharging if e The batteries were not discharged to 50 before connecting the charger e The electrolyte in the batteries is too high boil over e The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and the electrolyte specific gravity during the charging cycle as indicated below Specific Gravity Using a hydrometer take the specific gravity reading of several cells at 1 hour intervals while charging If the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not shut off then the charger is running too long Battery Voltage Using an accurate 5 1 2 digit digital voltmeter monitor the battery voltage during the charging cycle Take readings every 30 minutes If the battery voltage does not increase 0 012 volts in two consecutive readings then the charger is running too long Charger Troubleshooting zj Page 3 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM with diode and capacitor test function FLUKE 79 model shown at right and in the troubleshooting illustrations Important Notes and Instructions e This troublesh
113. h Charger interlock switch etc Inspect for leaking fluids or grease MAINTENANCE GUIDELINES FOR SEVERE DUTY APPLICATIONS 1 This maintenance checklist is based on the average application If the vehicle is operated under severe conditions service procedures should be conducted more frequently than specified The frequency of service under severe conditions is determined by the use of the vehicle The owner operator must evaluate the operating environment to determine the increase in maintenance frequency In addition the whole vehicle should be inspected monthly for signs of damage The damage must be repaired immediately The following list is meant as a guide and is not all inclusive of a severe duty application e Extreme temperature e Bumpy dusty or ill maintained roads e Excessively wet areas e Corrosive or contaminated areas e Frequent loading of vehicle at near capacity e Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Repairs or maintenance by AW ARNING improperly trained or unauthorized personnel could cause improper operation of the vehicle or premature failure of components resulting in severe bodily injury and or property damage Safety Rule
114. h a hand operated park brake set the brake 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 rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove the drive assembly from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 9 Remove the motor only if the entire drive is to be disassembled NOTE Refer to Motor Removal and Installation for information on removing the motor 10 Remove the cover retaining bolts 11 Remove the cover plate from the differential and let the remaining oil drain from the housing Be careful not to damage the sealing surfaces on the housings Damage to ACAUTION the sealing surface may lead to an oil leak resulting in damage to the internal parts of the drive Transmission Page 9 Maintenance Service and Repair 12 Remove the circlip from the idler gear 13 Remove the input shaft bearing assembly and idler gear bearing assembly fro
115. hat has been removed from the brake system Use of AWARNING contaminated brake fluid will degrade the braking performance and may cause property damage or severe bodily injury 14 Repeat the above steps until you are sure that all of the air is expelled from the brake line Any air bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is still air in the brake lines 15 Repeat this process with each of the other wheels NOTE When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information on filling the master cylinder 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Brakes Page 7 Maintenance Service and Repair FLUSH THE BRAKE SYSTEM 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 A WARNING 3 If equipped with a hand operated park brake set the brake 6 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the rear wheels off of the ground and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and supp
116. he vehicle is in operation Some functions may not be displayed depending on the current situation of the vehicle as i Eeee Hour Meter Battery Status Speedometer Battery Status Indicator bar graph Hour Meter There are five LED s at the bottom of the gauge Displays total time whole hours vehicle has been Each LED represents an approximate state of charge in operation Time is accumulated only while the as listed below vehicle is moving The example to the right indicates 5 far right LED green When on that the vehicle has been in operation for 2 114 hours represents 84 to 100 charge remaining 4 LED green When on represents 68 84 charge remaining System Fault Monitor 3 LED green When on represents 52 a 67 charge remaining The gauge has an alpha numeric display that 2 LED vellow When on represents 36 monitors the system status If the system detects a 52 rt eb j fault an abbreviated fault message will be displayed 1 LED red When on represents charge Refer to the table below for the abbreviated fault 20 36 remaining When flashing MESAJE AN E CNPNON represents 0 20 charge remaining Fault Code Description Ifthe 1 LED is flashing the vehicle or battery should CNTL TEMP Speed controller overheated be immediately removed from service to be LOW V Low battery voltage recharged Discharging beyond 20 will damage the HIGH V High battery voltage battery CNTL FLT Speed contro
117. ies Plate x OG S50 a inside battery 8 Reconnect the battery cables connect the batteries to the charger and allow the charger to complete Cees one charging cycle OPO ROO 9 Remove the blocks from the wheels and test drive OKO SON cutaway The batteries are now ready to be put into service Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the A CAUTION battery electrolyte comes in contact with Failure to clean may result in property damage STORAGE AND RETURNING TO SERVICE Storage If the batteries are removed from the vehicle do not place them directly on the ground concrete or solid metal surface It is AC AUTION recommended to store them on a wooden pallet or equivalent Storing on the ground concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level Store the vehicle or batteries in a cool dry well ventilated area If storing for more than one month the batteries should be charged as follows
118. inder 05 13 Disc Brake Body Assembly front or rear 13 Replace the Master Cylinder 00000 15 Repair the Master Cylinder cseseees 17 Maintenance Service and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions NOTE The brake pad must be removed to accurately measure the lining thickness Refer to Replace the Front or Rear Brake Pads section for information on removing the brake pads Measure the brake pad lining at the thinnest point on the pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Brakes Page 2 Maintenance Service and Repair Disc Brake Rotor Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions NOTE The front brake rotor
119. indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section for information regarding replacing the tire Tires and Wheels Page 2 Maintenance Service and Repair 8 Inspect for uneven tire wear on the front tires Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end NOTE Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment 9 Inspect the inner and outer side walls for cracks If any cracks are seen then the tire should be replaced Refer to Replace the Tire section for information regarding replacing the tire 10 Inspect the valve stem for cracks If any cracks are seen then the valve stem should be replaced It is also recommended that the valve stem be replaced whenever the tire is replaced NOTE Refer to Replace the Tire section for information regarding replacing the valve stem 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 REPLACE THE TIRE WHEEL 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconn
120. ing B 2 54 2 3 32 214 50 Bushing 12 4 96 240 00 1 2NC x 4 Hex bolt 6 5 88 149 81 1 2NC Lock nut 8 6 Z T 88 149 81 1 2NC Lock nut 6 8 16 872 00 Spring hanger 4 Parts Page 11 Illustrated Parts Rear Suspension Parts Page 12 Illustrated Parts Rear Suspension ITEM PART DESCRIPTION QTY 96 240 00 1 2NC x 4 Spring bolt front of the leaf spring 2 Not shown 32 2 14 50 Spring bushing front of the leaf spring 4 14 85 510 17 Leaf spring 2 16 861 46 Spring mounting plate left l j 16 861 47 Spring mounting plate right i 96 114 00 U bolt 4 7 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2 20 88 149 81 1 2NC Lock nut 4 21 50 460 00 Strap 2 22 98 002 00 Rubber overload spring optional 2 23 86 602 00 Shock 2 88 120 17 T 16NC x 2 1 4 Hex bolt 2 24 88 129 81 T 16NC Lock nut 2 88 128 60 7 16 Flat washer 2 Parts Page 13 Illustrated Parts Transmission Gear Case Parts Page 14 Illustrated Parts
121. ing Precautions icsccicctinanicteccte cite 7 SC1 00 Stock Chaser B2 48 With Stake Side Dump Bed Option E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor Introduction Contents About this manual 2 2cccecececececececececeeeees Who Should Read This Manual Responsibilities cccceeeeeeeeeeeeeeeneeeeeeneeenees How To Use This Manual ccscscsceeeeeeees CONVENTIONS 0 0 20 ceeeeeeeeeecceeeeceseeeceeeeeneeeceueeeneeeeneeess 5 How to Identify Your Vehicle ssc0000 B 2 48 and B 2 54 oo cecceccccesscceseccecsaceccateccateseareseacess 6 BT PAG S E 7 BT 280 etc cscs e ei iE irn iinis 7 Taking Delivery of Your Vehicle 0 INTRODUCTION ABOUT THIS MANUAL The purchase of this vehicle shows a belief in high quality products manufactured in the USA Taylor Dunn a leading manufacturer of electric burden and personnel carriers since 1949 wants to be sure this vehicle provides years of reliable service Please continue to read this manual and enjoy this high quality Taylor Dunn vehicle This manual is to serve as a guide for the service repair and operation of Taylor Dunn vehicles and is not intended as a training guide 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 e Vehicle Description e Safety Rules and Gui
122. ing the AC AUTION batteries Failure to turn the key switch OFF may result in damage to the vehicles electrical system New Battery Break in New 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 Charging Time Average charging time is 8 to 12 hours The time required to fully charge your batteries will vary depending on e Capacity of the batteries higher capacity requires longer charge time e Output of the charger higher output requires less charge time Depth of discharge the deeper a battery is discharged the longer it takes to charge e Temperature low temperatures require longer charge time It is not unusual for charge times to exceed 15 hours especially with new batteries Industrial Charger Operation If equipped with an industrial charger it is either specified by or provided by the end user Refer to the operating instruction supplied with your charger or contact the charger manufacturer for more information Safety Rules Page 13 SAFETY RULES AND OPERATING INSTRUCTIONS Signet HB xxxx Charger Operation The Signet HB 600 and HB 1000 chargers use a semiautomatic 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 plate on the charger for the vo
123. injury and or property damage 11 Loosen the ball joint clamps or the rod end jam nuts on the drag link Ball Joint NOTE Remember the position and orientation a7 lt Clamp of the clamps _ i 12 Adjust the drag link so that it can be easily inserted into the pitman arm 13 Tighten the ball joint or rod end nut as specified below Ball joint 40 45 ft lbs j Rod End Rod end 20 25 ft lbs Jam Nut 14 If equipped with ball joints position the ball joint clamps in their original location and orientation 15 Tighten the ball joint clamps 28 32 ft Ibs or the rod end 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 full right turn and make sure that the ball joint clamps do not contact any other component If the clamps are positioned so that they contact other components AWARNING it may result in steering failure and loss of control of the vehicle causing property damage and or severe bodily injury 19 Remove the blocks from behind the wheels 20 Release the parking brake and test drive the vehicle Maintenance Service and Repair Front wheel alignment NOTE It is recommended to center the steering before aligning the front wheels Refer to the Center the Steering section for information 1 Make sure the key switch is in the
124. ke only 11 Remove the brake body bolts and discard the lock nuts and brake pads 12 Remove the spacer bushings from the mounting bracket and discard k Nuts Bushings 13 Inspect the brake rotor Refer to Inspect the Service Brake section for information regarding T Pads inspecting the brake rotor 14 Inspect the spacers and replace if any wear or s l damage is found kis 15 Install new spacer bushings in the mounting P iiis bracket Mounting fa 16 Back off the parking brake adjustment wheel park Bracket Spacers Bolts brake only 17 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 18 Repeat this procedure for the other wheel 19 Install the tire wheel assembly and lower the vehicle to the ground 20 Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information regarding the correct master cylinder fluid level 21 Set the park brake 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Release the park brake and test drive the vehicle Brakes Page 12 Maintenance Service and Repair REPLACE THE WHEEL CYLINDER Disc Brake Body Assembly front or rear Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exist
125. key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 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 wheel off of the ground Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the rotor 11 Install in reverse order a Lightly grease the axle splines b Refer to section Brake Service for information regarding installing the brake pads c Thoroughly clean the threads in the axle shaft d Using a new bolt torque the axle hub bolt to 275 ft lbs The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes AWARNING resulting in se
126. ld cause the battery to explode resulting in property damage and or bodily injury Moist charged batteries are shipped without battery electrolyte This allows for a much greater shelf life of the battery Moist charged batteries must be filled with electrolyte and charged before putting into service Battery electrolyte is a solution of acid and water that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and AC AUTION charged Operating or charging moist charged batteries before filling and charging will damage the batteries resulting in premature failure of the batteries 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 AWARNING 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 Batteries Page 9 Maintenance Service and Repair 6 Fill all battery cells with electrolyte to the proper Filler neck level a T74 7 Thoroughly clean any spilled electrolyte trom the SS batteries or the ground Refer to Cleaning the q A i K 7 Max water Batteries for information on cleaning the cal batter
127. lect Switch Forward Reverse Switch Headlight Switch Emergency Stop Switch Light Accessories Headlight Dual Tail Brake Lights Charger Built In 1kKW Automatic AC voltage adjust 120 240 VAC 13 6 5 Amp 50 or 60 Hz Occupancy 2 Passenger Electrical System Eight 244 Amp Hour 6 Volt Lead Acid Batteries B 2 48 350 Amp Solid State Self Diagnostic AC Speed Control B 2 54 450 Amp Solid State Self Diagnostic AC Speed Control Dimensions 307 LX 114 W X 114 H Centimeters 121 L X 45 X 45 H Inches Deck dimensions 104 4 W x 191 L Centimeters 41 25 W x 75 25 L Inches Turning Radius 350 Centimeters 138 Inches Tires B 2 48 5 70 x 8 Load Range C B 2 54 18 x 5 x 14 Solid Extra Cushion Dry Weight 542 kg 1 194 Ibs Without Batteries Maximum Load B 2 48 1 360 kg 3 000 pounds B 2 54 2 268 kg 5 000 pounds Speed Limit B 2 48 25 kph 16 mph depends on gear ratio installed B 2 54 13 kph 8 mph Motor AC 3 2 kW 4 4 hp for 60 min 5 1 kW 6 9 hp for 5 min Specifications are subject to change without notice These vehicles conform to requirements for 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 B56 8 Safety Rules Page 2 SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDELINES It is the responsibility of the owner of this vehicle to assure that the operator understands
128. lectrical Troubleshooting TROUBLESHOOTING To test charger operation Connect a DC volt meter to the main battery positive and negative terminals Attach a clamp on DC Ammeter to one of the charger DC output wires Plug the charger into an AC outlet Wait for charger to start up to15 seconds the ammeter should display the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals 2 55 VPC When the battery voltage equals 2 55 VPC the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on Make sure the key switch is in the OFF position then remove the key AW ARNING Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the charger from the AC source 6 Remove the charger end cap where the DC wires enter 7 Test the voltage across the Battery Positive red and Battery Negative black wires at the lower left of the charger circuit board This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires to the batteries have been damaged
129. led External load attached to controller Possible non factory Shutdown of main contactor B terminal installed device Shutdown of motor Shutdown of EM brake Controller Severe Undertemp Vehicle operated in temperatures Shutdown of main contactor below 40 C Shutdown of motor Shutdown of EM brake Shutdown throttle Full Brake k Controller Severe Overtemp Vehicle operated in extreme high Controller overheated 12 13 14 15 16 l Shutdown of main contactor ambient temperatures 95 C 17 18 21 22 3 Shutdown of motor Vehicle overloaded Shutdown of EM brake Controller not properly mounted Shutdown throttle Full Brake Severe Undervoltage 1 Blown circuit breaker Reduced drive torque 2 Battery failure while in operation severe Overvoltage Blown circuit breaker during regen Shutdown of main contactor Battery failure during regen Shutdown of motor Shutdown of EM brake Shutdown throttle Full Brake Controller Undertemp Cutback 1 Controller operated in temperatures Controller output is Reduced motor torque below 25 C reduced below 25 C Controller Overtemp Cutback 1 Vehicle operated in extreme high Controller overheated Reduced drive and brake torque ambient temperatures 485 C 2 Vehicle overloaded 3 Controller not properly mounted 2 Undervoltage Cutback 1 Batteries discharged Reduced drive torque 2 Battery failure Troubleshooting Page 3 Electrical Troub
130. leshooting Handset Display Possible Cause Effect of Fault 24 Overvoltage Cutback l Reduced brake torque 2 25 o gt VOLG Supply Failure 1 Faulty motor encoder 5 volt supply at Pin None 2 Faulty wiring 26 is too low l 28 Motor Temp Hot CUEDaCk Reduced drive torque NO O ki pd Digital Out 6 Overcurrent Digital output 6 will not turn on Digital Out 7 Overcurrent Digital output 7 will not turn on Motor Temp Sensor Fault MaxSpeed reduced Limited Operating Strategy LOS and motor temperature cutback disabled Main Open Short Shutdown Driver 1 Shutdown of motor Shutdown of EM brake EM Brake Open Short Shutdown Driver 2 Shutdown Throttle Full brake Coit Driver Opens Snort Shutdown driver 3 PD Open Short Shutdown PD Encoder Fault Control mode changed to Limited Operating Strategy LOS Motor Open Shutdown main contactor Shutdown motor Shutdown EM bake Main Contactor Welded Shutdown main contactor Shutdown motor Shutdown EM bake Main Contactor Did Not Close Shutdown main contactor Shutdown motor Shutdown EM bake Battery failure High voltage generated during normal regen Load on output 6 exceeded 0 015 Amps Not used If fault occurs then check controller connector for contamination Not used If fault occurs then check controller connector for contamination Load on output 7 exceeded 0 015 Amps 1 Vehicle operated in extreme Mot
131. less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Transformer Secondary Circuit e Test the AC voltage across the transformer secondary circuit The voltage here will vary depending on the state of charge in the batteries The voltage should be between 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the charge s rated DC voltage the transformer is bad and must be replaced Stop here and repair the problem TESTING THE TIMER RELAY Test 1 1 Connect the batteries to the charger 2 Plug the charger into the AC source 3 Wait 5 seconds then test the voltage at the timer relay coil terminals NOTE This voltage should be close to the battery volts e If the voltage is close to the battery volts then skip to test 2 e If the voltage is not close to the battery volts then the timer control circuit has failed and the timer must be replaced Test 2 1 Disconnect the batteries 2 Unplug the charger from the AC source 3 Discharge the capacitor See warning on previous page Charger Troubleshooting zj Page 9 Electrical Troubleshooting 4 Disconnect the wires from the contact terminals on the timer relay 5 Reconnect the batteries 6 Wait 5 seconds then test the continuity across the timer relay contact terminals e If this is a closed circuit then the timer start up circuit is functioning normally e If the
132. limited to 18 hours max An error occurs if charging time exceeds 18 hours See table on previous page A charger could remain on for longer than 12 hours if e The vehicle is equipped with batteries larger than 220 Amp hour capacity e The charging cycle is interrupted at any time during the charging cycle e Defective batteries causing a fluctuating DC voltage that confuses the charger e One or more defective cells in the battery pack e A brownout drop in AC line voltage during the charging cycle e An electrically noisy charging environment A charger could turn off in less than 12 hours but still show symptoms of overcharging if e The electrolyte in the batteries is too high boil over e The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and charging current during the charging cycle as indicated below Using a digit digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 10 of the DC output current see previous page until the battery voltage reaches 2 55 volts per cell When the voltage reaches 2 55 volts per cell the charging current will drop significantly and slowly taper off voltage will remain constant The charger should turn off within 2 to 4 hours after entering the second stage a a ee eee Signet Charger Tro
133. ller internal fault or wiring fault MOTORTEMP Motor overheated Battery Status Indicator digital MOTR FLT Faulty motor or wiring EB FAULT Electric brake fault Displays total charge remaining in percent The SRO Operator error example to the right indicates that the vehicle has STALL Motor stalled 100 charge remaining fully charged l 1 Refer repair to a qualified technician 2 Switched used to operate vehicle may have been selected in the incorrect sequence Refer to operator instructions in this Speedometer een Indicates the vehicles current rate of travel in miles 3 Wait for component to cool Vehicle may be overloaded per hour 4 Vehicle overloaded faulty motor or possible locked up brakes or transmission If vehicle is not overloaded Refer repair to a qualified technician Safety Rules Page 6 SAFETY RULES AND OPERATING INSTRUCTIONS D Accelerator Pedal The accelerator pedal is located to the right of the brake pedal It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile Depress the pedal to increase speed and release the pedal to decrease speed Foot Brake Pedal The foot brake pedal is located to the right of the steering column it is for operation with the right foot only It works similar to the brake in an automobile Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied Relieving pressure fr
134. llustrated Parts Brake Lines 11 IANS Kw NO ee e LA ATTAN Eig oe 13 Sa 4 n L ag Sa SE I V7 on ey a L S57 Parts Page 20 Illustrated Parts Brake Lines ITEM PART DESCRIPTION QTY l 99 609 61 Brake Line front brakes l 2 99 603 73 Brake Line regen switch to brake switch 1 3 99 606 51 Brake Line Front Right 1 4 99 603 72 Brake Line brake switch to rear brakes l 5 99 603 70 Brake Line Rear Right 1 6 99 603 71 Brake Line Rear Left 1 7 99 580 20 Brake Hose Rear 2 8 99 580 10 Brake Hose Front 2 9 99 564 00 T Fitting 1 10 99 575 10 Adaptor 3 16T X 1 8P 2 11 99 576 00 Hose Clip 4 12a 99 591 00 Brake light switch regen switch adaptor 2 13 71 110 00 Brake Light Switch l 14 99 575 32 Adaptor 3 16T x M10 1 0 2 15 99 559 00 T Fitting Single Male Flare to 2 Female Flare 3 16 Tube 1 16 99 603 74 Brake line MS to regen switch 1 Regen switch l M
135. lt 15 Adjust the steering gear NOTE Refer to Adjust the Steering gear section for information regarding adjusting the steering gear 16 Once the adjustments are completed make sure that the locking ring and jam nut are tight Steering Page 21 Maintenance Service and Repair Exploded View of Steering Gear Side Cover p A Locking Ring Worm Bearing Adjuster Gear Lash and Lower Bearing Adjuster and Shim Ball Nut Housing Worm Shaft ff Pitman Shafi ii i Bearings Ball Guides LY Upper Bearing Ball Guide Clamp Pitman Shaft Seal gt Worm Shaft Seal Steering Page 22 Brake Service TABLE OF CONTENTS Inspect the Service Brake ssesesseee 2 Disc Brake Pads ccccccceceeeeeeeseeeesesseeeeeeeeeeeeeees 2 Disc Brake Rotor ccccccccccesssseeeeeeceeseeeeesseeaeeees 3 Inspect the Automatic Parking Brake 4 Adjust the Automatic Parking brake 4 Adjust the Service Brakes s e0s000 4 Two or Four Wheel Hydraulic Disc Brakes 4 Check Master Cylinder Fluid 00000 5 Bleed the Brake System ecssseeeeeeees 6 Flush the Brake System c ssecssseeeeeeees 8 Replace Front Disc Brake Pads 9 Replace Rear Brake Pads sscseseeeeeeees 11 Hydraulic DISC cies cock bach tnst tacece aed atte been elt Stn tetas 11 Replace the Wheel Cyl
136. lt 4 88 149 80 1 2NC Hax nut 4 88 148 62 1 2 Split lock washer 4 Ladder Rack Option B2 004 66 and B2 006 78 NOTE Replacement parts only Ladder rack cannot be added to an existing vehicle PART DESCRIPTION QTY 00 201 44 Ladder rack l 00 201 49 Ladder rack with stake side pockets l 88 102 11 3 8 X 1 NC CARRIAGE BOLT 14 88 108 62 3 8 LOCK WASHER 14 88 109 81 3 8 NC LOCK NUT1 14 90 473 00 Deckboard 52 375 x 40 375 1 90 473 10 Deckboard 22 0 x 40 375 l Parts Page 61 NNNG dO TAVL Contents Appendix A Special Tools 2 Appendix B Suggested Torque Limits for Standard Hardware 3 Hardware Identification 08 3 Standard Head Markings ccccccssceeseeeeteeeees 3 cif o gt eb Le i AA AASIAS 3 Hex Lock Nuts StoVEr csosssssererseenesserssasansbsreahonis 4 Other NUS oiner abatere a taaah 4 Suggested Torque Values non critical hardware 5 Appendix C Brake Lining Handling Precautions 7 Appendixes REV C Appendixes APPENDIX A SPECIAL TOOLS handset control system DESCRIPTI
137. lt of faulty batteries faulty charger noisy or fluctuating AC line voltage or momentarily interrupting the charging cycle Refer troubleshooting to a qualified technician Safety Rules Page 14 SAFETY RULES AND OPERATING INSTRUCTIONS To obtain the maximum battery life Charge the batteries only after they reach a normal discharge 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 find it necessary to charge the batteries before they are completely discharged we recommend waiting until they are discharged a minimum of 25 to reduce the possibility of overcharging Refer to Vehicle Controls in this section for information on how to read the BSI Do not discharge the batteries beyond a normal discharge as indicated on the BSI Refer to Vehicle Controls in this section for information on how to read the BSI Check the 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 authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before dis
138. ltage and power type required for the charger The charger has a series of LED s on the face plate that will display the current status of the charger and charging cycle The location and layout of the status LED s will vary depending on Typical Signet Built In Charger age of the charger Flashing LED s and a beeping sound from the charger indicate a fault in the charging system sing Stte LEDI LED2 LED3 See below 0 to 50 FLASHING OFF OFF When the charger is plugged in the charger status LED s will go through a start up sequence During the start up asad aa inci a the charger is performing a self test and system voltage 750 to 100 ON ON FLASHING check After about 10 seconds the charger will start and the LED s will display the current charging status Do Cycle complete ON ON ON not disconnect the charger during the start up pi oosid period os OFF OFF FLASHING If the LED s do not turn on when the charger is plugged TER a FLASHING FLASHING FLASHING in then there may be a problem with the AC line voltage 00 some or the charger has failed Refer testing of the charging system to a qualified technician After the start up sequence if all the LED s are flashing then the charger has found a fault in the charging system Refer testing of the charging system to
139. lure to support the steering gear will result in the steering gear falling out am ae h Pitman A AWARNING of the vehicle and could a cause property damage and or severe bodily injury 11 Center the steering gear Refer to Center the Steering Gear section for information regarding centering the steering gear 12 Install in reverse order Torque the pitman arm nut to 75 100 ft lbs 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the parking brake and test drive the vehicle Steering Page 13 Maintenance Service and Repair REPLACE THE BALL JOINTS TIE RODS AND DRAG LINK This section will refer to two different types of ball joints One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm The second cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your vehicle it may be equipped one or both types of ball joints Rod End In this text The first type will be referred to as a Ball Joint py Ball Joint The second type will be referred to as a Rod End NOTE If a rod end or ball joint is worn out we recommend replacing all of the ball joints and or rod ends as a Set Replacing a Rod End 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse
140. lustrated Parts Lestronic Charger page 2 Typical Built In charger WL i Vly Wh WHA Va Wi a Typical Portable charger Parts Page 38 Illustrated Parts ii Snid OV Wowdoedoy 00 00c 92 00 00 92 00 00 92 09 608 62 OI L9S 6L O S 00 0 S 6L 00 0 S 6L 00 TES 6L 00 TES 6L 00 IES 64 00 IES 6L 00 IES 6L 00 T 8 62 00 1 8 6L OI T 8 6L OI T 8 62 OL IE8 6L O S O S O S A quiossy porq OT 6PL 6L Cl 6rL 6L Cl 6PL 6L Cl 6rL 6L Cl 6PL 6L O S et ors oL e1 orl oL v 00 06 62 00 706 6L 00 06 62 00 706 6L 00 706 6L 00 808 62 00 808 62 01 808 62 6L SI COE 6L A8 SZ 06 90 6L 09 P0 6L S0 0 7OE OI ZOE 6L OI 10 6L ASS O0 6L 0S 00 6L 0S ZOE 6L NOLLdrdosdd WALI STEZT OCOL OELTZ O9LET TE E1S6 TO SOTL Te O00rbT Weg PIY Opoy Josreq7a SUHDaAVHDO 01 808 62 01 808 62 99 S08 6L 9 S08 6L ATquiossy JOUIL Parts By Page 39 Illustrated Parts Signet Charger Portable Charger Wiring 98507 05035 00 PART DESCRIPTION QTY 75 107 10 HRNSS PORTABLE LESS CHRGER 1 JF3 86181 00 00 RECEPTACLE W INTERLOCK 1 90157 05M19 00 2 92907 05100 00 4 Mounting hardware for receptacle 92907 05600 00 4
141. m the gear case cover at the same time 14 Remove the pinion nut from the output gear and remove the output gear from the pinion shaft NOTE If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 16 Remove the six retaining bolts holding the gear case to the 3rd member housing NOTE Make note of the angle of the gear case 17 Remove the gear case housing from the 3rd member housing 18 Inspect all parts for signs of wear or damage Transmission Page 10 Maintenance Service and Repair Lubricate all parts with gear oil before installation Failure to pre lube ACAUTION the parts may result in premature failure 19 Assemble the gear case in reverse order NOTE Torque the drain plug to 21 25 foot pounds NOTE Torque the gear case to 3rd member retaining bolts to 18 20 foot pounds NOTE Torque the pinion nut to 154 169 foot pounds NOTE Apply gasket sealer 94 430 05 to 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 information on filling the drive with oil 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24
142. mediately report any accidents or vehicle problems to a supervisor e Use the low speed model while towing heavy loads While towing heavy loads the low speed mode will increase the efficiency of the system and extend running time between charges AWARNING Do not turn off the key switch while the vehicle is in motion unless the vehicle must be stopped in an emergency Turning the key switch off will immediately apply the park brake stopping the vehicle The abrupt stopping of the vehicle may result in severe bodily injury Safety Rules Page 9 SAFETY RULES AND OPERATING INSTRUCTIONS Loading and Unloadin e Do not carry more than the maximum number of passengers allowed for this vehicle e Do not exceed the cargo load capacity e Do not load cargo that can fall off e Be careful when handling cargo that is longer wider or higher than this vehicle be sure to properly secure all loads Parking Before leaving the vehicle e Set the forward off reverse switch to the OFF position e Turn the key switch to the OFF position and remove the key e f equipped with optional hand parking brake set the park brake In addition e If parking this vehicle on an incline turn the wheels to the curb or block the wheels e Do not block fire aisles emergency equipment stairways or exits Towin This vehicle is equipped with a standard automatic electric parking brake The brake is automatically
143. mpletely retest the vehicle before lowering the drive wheels to the ground TEST 5b Accelerator pedal depressed If the voltage equals battery volts then skip ahead to test 6 If the voltage does not equal battery volts then the module has failed or the accelerator pedal return spring on the module is broken 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 Troubleshooting zd Page 8 Electrical Troubleshooting TEST 6 Accelerator pedal depressed Test the voltage from pin 9 to pin 1 If the voltage is between 4 8 and 5 1 volts then skip ahead to test 7 If the voltage is not between 4 8 and 5 1 volts then the module has failed and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Troubleshooting Page 9 NNNG dO TAVL TABLE OF CONTENTS Operating Instructions and Theory of Operation cccceeceeees 2 Testing the Charging Cycle 0 3 Test Equipment Required for Troubleshooting cccseeeeeeeeeees 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 0cc008 9 Testing the Interlock
144. n damage or wear and replace as required cy Clamp Housing Reassembly Lightly lubricate all parts before reassembly Install a new worm shaft seal and pitman shaft seal into the housing Install the upper worm bearing cup Divide the ball bearing into two equal groups Position the ball nut onto the worm as shaft as shown in the illustration Insert the ball guides into the ball nut o o o e w w Insert each group of bearings into the ball guides NOTE Do not rotate the worm shaft while installing the bearings This may cause one or more of the bearings to enter the crossover passage in the ball nut causing improper operation 8 Install the ball guide clamp Steering Page 20 Maintenance Service and Repair 9 Place the upper 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 Bearing 10 Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft Worm Bearing Adjuster 11 Install but do not tighten the worm bearing adjuster lock nut 12 Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bolts 14 Pack the steering gear with grease through the open side cover bolt hole and then install the bo
145. n Drag Link regarding the removal of the ball joints or rod ends Remove the drag link as an assembly Install in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of l the front wheels Steering Knuckle Typical Drag Link Steering Page 16 Maintenance Service and Repair 11 Lower the vehicle 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together Refer to the illustration below 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the ball joints or rod ends from the steering knuckles NOTE Refer to the Replacing the B
146. n battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage 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 AWARNING 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 Do not overfill the batteries Over filling the batteries may cause the AWARNING batteries to boil over and result in severe bodily injury or property
147. n positive and negative cables at the batteries 6 Some vehicles may require that the wheels be lifted off of the ground and supported with jack stands to replace the shocks Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily 7 Remove the upper and lower shock bolts 8 Remove the shock from the vehicle on dM Bushing NOTE If the shock that was removed is to be A hi reinstalled 5 _ Shaft A Inspect the shaft where it enters the shock body for any signs of leakage If any sign of leakage 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 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Suspension Page 5 NNNG dO TAVL Tires and Wheels TABLE OF CONTENTS Gl cca lait Lic 0 geeerreerrrrrreecrerreer E Tire Inspection siicencttcacecccnassecevoceseancocnecceeanecues Replace the Tire Wheel cssscsssseseeeseenees Repair the Tire pneumatic ccceeee Replace the Tire pneumatic ccccseeeees Maintenance Ser
148. nals off of the wires 7 Remove the steering wheel Horn Switch NOTE Refer to Replace the Steering Wheel iff section for information regarding removing the steering wheel 8 Remove the upper steering shaft bushing or bearing from the steering column 9 Remove the steering gear access cover from the steering column if equipped 10 Remove and discard the pinch bolt and nut from the steering shaft coupler Steering Shaft Bushing NOTE 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 procedure then the steering Steering Gear gear must be removed Refer to Replace the Input Shaft Steering Gear for information regarding removing the steering gear Steering Page 10 Maintenance Service and Repair 11 Remove the steering shaft from the vehicle 12 Lightly grease the input shaft splines steering wheel splines and the upper steering shaft bushing 13 Install the steering shaft in reverse order using a Coupler new pinch bolt Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft See the illustration to the right Make sure that the pinch bolt is not aligned with the flat on the steering shaft Aligning the bolt with the flat could AWARNING resultin failure of the steering and loss of control of the i
149. nance Meter Function is optional When ae 5 Time to decelerate to 0 when above equipped the Maintenance Meter Function will notify i e a speed the operator when a scheculed maintenance is due Tow Decl LS S0 38 Weenie Refer to the supplementary Maintenance Meter manual Maintenance Meter Function for more information Service Timer 0 H Refer to Maintenance Meter supplementary manual Speed Limits Speed Calculation Formulas z Max see warning 6 250 RPM Governed speed see formula RPM 20172 T MPH 60 R Tow optional 62 rene A Max speed when Tow RPM 31837 T KPH 60 R S Rev 45 ercentage of Max speed when in Wh reverse ere Low Batt 40 Percentage of Max speed when low RPM motor RPM battery warning is O _ T Percentage of Max speed when Tj Tire diameter I nches or cm Service Due 20 service is due See maintenance Meter MPH Miles Per Hour Function KPH Kilometers per hour Batery Characteristics i Battery must exceed this voltage to be R Rear axle ratio Full Volts 2 165 V considered fully charged Empty Volts 1 730 V Voltage of a fully discharged battery AWARNING Low battery warning is ON when BDI Level for Batt Spd 15 7 battery is Aa belo
150. nect one transformer lead from the capacitor Test the capacitor using the capacitor test function of the meter It is a 6 microfarad capacitor If the Capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the transformer lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the diodes using the diode test function of your meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Diode 1 Comman 5 Reconnect the lead to the diode 6 Reconnect the charger to the vehicle s harness and slide the wiring insulators back into place Connect the charger to the AC source and perform the following tests P Diode 2 High Voltage inside the charger Do not touch any internal components AW ARNI NG while the charger is plugged in Failure to do so may result in serious bodily injury Charger Troubleshooting zj Page 6 Electrical Troubleshooting e Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires from the harness connectors to the charger are bad Stop here and repair the problem e Test the voltage across the white and black wires 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
151. o clear Shutdown interlock fault CAN NMT State set to Pre operational Stall Detect Stalled motor Encoder power supply is Control mode changed to LOS Faulty motor encoder provided by pin 26 from Faulty wiring to encoder controller Encoder power supply fault Troubleshooting Page 5 Electrical Troubleshooting THROTTLE MODULE TEST Disconnect the truck harness from the throttle module Connect the plug on the short end of the 75 089 00 test harness to the throttle module Connect the receptacle on the short end of the test harness to the vehicles control harness The long end of the harness will be used for testing Refer to the illustration below Testing must be performed in the order shown This testing cannot be completed without the 75 089 00 test harness Unless specified otherwise all references to a pin is referring the connector on the long end of the test harness Refer to the illustration for the pin locations in the connector The pin numbers are cast into the connector as shown in the illustration PLUG THIS END INTO THE HARNESS The 75 089 00 Throttle Module Test harness USE THIS END FOR TESTING PLUG THIS END INTO THE MODULE The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground an
152. o repair shops Ot Oly 6 Install the tire onto the wheel following the instructions provided with your tire replacement equipment 7 Inflate the tire to the proper pressure and check for leaks 8 Install the valve stem cap Tires and Wheels Page 5 NNNG dO TAVL Battery Service TABLE OF CONTENTS CIC ANNA aininn inini 2 TESUNO aA 3 WENNO eae avewatenstenelanetexetanetanelarclersiasetennee te 5 CONAN LING esses essere EA 6 Replacing 6 volt batteries only 000 7 Moist Charge Batteries ccccccccccscccscscceseeeeeeeeeees 9 Storage and Returning to Service 10 BS 0 6 meee ma me ne en en cE en Te ee ec nO ce 10 Returning to SGIVIGE menais ene a 11 Maintenance Service and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A batter
153. om the pedal releases the braking action Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise If equipped with tilt steering the release lever is located on the lower left of the steering column Pull the lever up to reposition the steering wheel irectional Signals Optional The turn signal lever is located on the left side of the steering column Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal Hazard Light Switch Optional The hazard light switch is located on the left side of the steering column The switch is a small tab To activate the hazard lights pull the tab out To turn the hazard lights off push forward or pull back the directional signal lever Safety Rules A Page 7 SAFETY RULES AND OPERATING INSTRUCTIONS Charger Interlock Electrolyte Alarm Optional The Electrolyte Alarm is located in the battery area in the 4th battery cell from the main battery positive cable The Electrolyte alarm is activated when the battery cell fluid level falls below the level of the probe The alarm is an audible continuous sound along with a bi color indicator lamp Inspect the fluid level in all battery cells when the alarm sounds or the bi color lamp turns from its green color to red The vehicle batteries should then be
154. on of each of the following controls e Accelerator e Brake e Parking Brake e Key Switch e Forward Reverse Switch e Reverse Beeper if equipped e Front Headlight Switch e Steering Wheel e Horn What To Do If a Problem is Found If there is a problem or damage as a 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 notify your Taylor Dunn dealer of the claim If there is a problem with the operation of the vehicle DO NOT OPERATE THE VEHICLE Immediately contact your local Taylor Dunn distributor and report the problem The report must be made within 24 hours of receiving the vehicle and its accessories The only personnel authorized to repair modify or adjust any part of this or any Taylor Dunn vehicle is a factory authorized service technician The only personnel authorized to repair modify or adjust any part of this or any Taylor Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in AWARNING damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and or property damage Unauthorized repairs may also void the vehicles warranty Introduction Page 7 SC1 00 Stock Chaser B2 48 With Stake Side Dump Bed Option E4 55 Sit Down Tow Tractor C4 2
155. oor Right Specify Color includes 10 11 12 1 91 011 69 Kit Cab Door Right Specify Color includes 10 11 12 1 14 90 853 10 Window Left l Not Shown 90 853 11 Window Right 1 15 97 315 58 Door Handle Inner 2 16 91 012 12 Connecting Bar 2 17 16 510 00 Spacer 2 18 88 065 06 Screw 1 4 X 1 2 NC Phillips Truss Head 2 19 88 045 08 Screw 10 32 X 5 8 Truss Head 2 20 88 049 86 Locknut 10 32 2 21 88 045 11 Screw 10 32 X 1 Truss Head 4 22 88 048 62 Lock Washer 10 4 23 88 049 80 Nut 10 32 2 24 91 012 45 Strap Door Restraint 2 25 88 082 11 Bolt 5 16 NC X 1 Carriagee 2 26 88 088 60 Washer 5 16 Cut 2 27 88 088 62 Lock Washer 5 16 2 28 88 089 83 Acorn Nut 5 16 NC 2 29 91 011 31 Door Weldment Left unpainted l 91 011 32 Door Weldment Right unpainted 1 Not Shown 98 454 00 Weatherstrip by the foot 27 Parts Page 53 Illustrated Parts Door Options Fiberglass Cab 8 9 a 15 Items 1 through 13 Parts Page 54 Illustrated Parts Cab Doors Naugahyde fiberglass cab
156. ooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician e Make sure that the AC electrical socket the charger is plugged into is in good working condition e Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate e Make sure the batteries are in good condition and no less than 80 discharged as per hydrometer reading e The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC voltage the charger will not turn on e If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting e Battery volts Full voltage available at the batteries at the time of the test being performed e This test procedure must be performed in the order it was written If starting in the middle or skipping sections when not instructed to do so the proper results will not occur If the test result is good then proceed to the next test or go to the next section if instructed to do so During All Tests The charger cabinet must remain electrically grounded Disconnect AW ARNING 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 r
157. or overheated high ambient temperatures 2 Vehicle overloaded l l 2 Motor temperature sensor fault Wiring Fault Faulty main contactor coil Faulty wiring Faulty motor brake Faulty wiring Not used If fault occurs then check controller connector for contamination Not used If fault occurs then check controller connector for contamination Faulty motor encoder Faulty wiring Open motor windings Faulty wiring Main contactor welded Motor phase U open circuit Short to B controller terminal Faulty wiring Faulty main contactor Faulty wiring B Circuit breaker blown 41 Throttle Wiper High 1 Faulty throttle module Voltage from throttle Shutdown throttle 2 Faulty wiring module too high 42 Throttle Wiper Low 1 Faulty throttle module Voltage from throttle Shutdown throttle 2 Faulty wiring module too low See note voltage too high on pin 17 D 09 Brake Wiper high Full brake Not used If fault occurs then check controller connector for contamination Troubleshooting kd Page 4 Electrical Troubleshooting Handset Display Possible Cause Note Effect of fault 44 Brake Wiper Low See note voltage too low on pin 17 Not used If fault occurs Full brake then check controller connector for contamination 45 Pot Low Overcurrent Current into pin 18 exceeded 0 010A Not used If fault occurs Shutdown throttle then ch
158. ort devices 10 11 12 13 14 15 16 17 18 of rated load capacity may result in severe bodily injury If equipped with front brakes raise the front wheels off of the ground and support with jack stands Release the park brake Remove both rear wheels and if equipped with front brakes the front wheels Refer to Tires and Wheels section for information regarding removing the wheels Remove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into a container for waste brake fluid Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all bleeder screws Pump the master cylinder until all fluid has been pumped from the brake lines and all wheel cylinders Close all bleeder screws Fill the master cylinder with fluid Open one of the bleeder screws and pump the master cylinder until all fluid has been pumped from the master cylinder and close the bleeder screw Repeat the above two steps for each wheel cylinder Reinstall the wheel cylinders and bleed the brakes Refer to Bleed the Brakes for information regarding bleeding the brakes Set the park brake Install the wheels and lower the vehicle to the ground Reconnect the main positive and negative cables at the batteries Release the park brake an
159. p Steering Gear vehicle This could lead to Input Shaft property damage and or severe bodily injury Do not use the original pinch bolt and nut Failure to replace the pinch AW ARNING bolt and nut may result in failure of the steering causing loss of control of the vehicle This could lead to property damage and or severe bodily injury 14 Tighten the pinch bolt to 24 26 ft lbs 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the parking brake and test drive the vehicle Steering Page 11 Maintenance Service and Repair REPLACE THE STEERING WHEEL 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 AWARNING 3 If equipped with a hand operated park brake set the brake 10 11 12 14 15 Reinstall the horn switch if equipped 13 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries If equipped with a horn switch in the steering wheel remove the switch and disconnect the wires from the switch Remove the steering wheel nut Horn Switch Using a steering wheel puller remove the steering g wheel Position the front wheels in the straight ahead position Lightly grease the steering wheel splines and install the replacemen
160. page 1 n0nn0nnannnan 36 Lestronic Charger page 2 scccseeeeeees 38 Signet Charger apohstsersbanto yaya pasuiesb yal ouee 40 Portable Charger Wiring ccc secceseeeees 40 Table of Contents Eq BIENES enaa aiiai aidai 42 Seat Cushions and Deck ascese 44 GONG a aa eas sae aaa aa 46 Miscellaneous Frame Components 46 DECAS raidir aaa fade cade sete a aaa da n stage 48 caD ODIONS mrn a a A 50 Door Options Steel Cab nonnnennennennennnnnn 52 Door Options Fiberglass Cab 00 54 Hydraulic Dump Body Option 0006 56 Rear Cargo Box 58 TOP COVES annann naaa aa 58 PONO S eE EE E E E 60 Ladder Rack Option B2 004 66 and B2 006 79 eee ENARN 61 ADDENOIXES virona 1 Appendix A Special Tools 00000 2 Appendix B Suggested Torque Limits for Standard Hardware 0c000000 3 Hardware Identification c ccccsssseseee 3 Standard Head Markings ccccccccseeeesesssesseees 3 Hex 9 oe oe ee ee ne et ere ene nee OraP Pe ee ee 3 Other Bolts cet eg ence csecsereceseuectecamactesaecusessstuenecameae 3 Hex Nuts ett hatte a dees eeeeeuceeeciea eens eanecuseseeecess 4 Hex Lock Nuts stover cccccccescsssseeseeeseeeeeeees 4 Other Nuts sett eee an tices ecenuacuncanetueanieckansrinese 4 Suggested Torque Values non critical hardware 5 Suggested Torque Values critical hardware 6 Appendix C Brake Lining Handl
161. r a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the type of repair equipment or repair components used Refer to the instructions provided with your equipment or repair components Tires and Wheels Page 4 Maintenance Service and Repair REPLACE THE TIRE PNEUMATIC NOTE 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 Explosion Hazard Fully deflate the tire before attempting to remove the tire from the wheel Do not over inflate the tire when seating the AW ARNING bead Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death Tire replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire Remove the tire from the wheel Cut the old valve stem off of the wheel Remove the valve stem cap from the new valve stem Lubricate the valve stem with liquid soap Install a new valve stem using a valve stem tool NOTE The valve stem tool is available at most aut
162. ransmission Differential Case 000 16 Miscellaneous Frame Components 46 Rear Brakes ccccscccecceeceeeseeeceeeeeeseeenees 18 Bieler Cerner rere are Tyrer mers cner irene ner er 48 FON BAKES ach edchaticdcticnctiatetiehedicuatetetenctianetecetes 18 Cab OOS se zstoiecorascicatecieciadesetosostasostoaeceaesesecs 50 Brake WINGS cesaria araa a 20 Door Options Steel Cab cccceeceeeeees 52 Master Cylinder ccccccccseeeeseeeeseeeeneeeees 20 Door Options Fiberglass Cab 00 54 WO OIF Enan 22 Hydraulic Dump Body Option 005 56 MOTO MOUN xctctccscrdicestcnstceatcenteneteastcastetetcee 24 Rear Cargo Os catesieostonesemoasnseasnnooaasssanoncanine 58 Wheels and Tires cccseccceeeseeeeeeeeeeaeees 26 TOP GOVENS cacesieiiodecedecctecetetdekotetdseedeset sistas 58 Instrument Panel dash cccceeeeeeeeees 28 Bc ok ante eet een ene enon nn een ae ee 60 WIRE Harness ES aona eannan aa 28 Ladder Rack Option B2 004 66 and Speed Control Panel ccccceeeceeeeeeeeees 30 B2 006 78 scissiinsskdsvieedosanevawnnsdeceiadeines 61 Resetting the Maintenance Meter Function 31 Illustrated Parts Front Axle Parts Page 2 Illustrated Parts Front Axle ITEM PART DESCRIPTION QTY 15 049 71 Axle Beam B 2 48 BT 2 48 B 2 54 1 15 050 76 Complete axle
163. raulic Cylinder 1 7 99 957 00 Hydraulic Pump and Motor 1 8 99 597 09 Bracket Hydraulic Pump l 9 88 100 11 Bolt 3 8 X 1 NC Hex Head 3 10 88 109 81 Locknut 3 8 NC 3 11 98 753 08 Isolator Mount Rubber 3 12 91 286 01 Carrier Frame Dump Bed i 13 91 285 11 Safety Prop Rod i 14 98 754 00 Rubber Bumper Safety Prop Rod i 15 91 285 10 Bracket Safety Prop Rod i 16 96 244 00 Bolt 1 2 NC Hex Head with Grease Fitting 1 17 88 149 81 Locknut 1 2 NC Hex Head l 18 19 20 21 72 022 51 Rubber Mounting Ring l 22 71 102 15 Switch Dump Bed i 23 91 285 01 Dump Bed 1 90 442 00 Deckboard l AA 000 11 Fluid Hydraulic Dextron 2 Quart 1 75 124 00 Wire Harness 1 78 106 00 Buss Bar Circuit Breaker 1 79 843 00 Circuit Breaker 100 AMP 2 Pole 1 71 610 02 Circuit breaker mounting plate l 99 526 11 Fitting Adapter 3 8 X 3 8 NPTF i 99 527 01 Fitting Adapter 90 2 Not shown 99 597 50 Bracket Hydraulic Pump I 99 597 51 Hose Assemble 24 i 77 980 00 BATT BOX BOLT IN MODEL B 1 77 869 00 BAR BAT HOLD DOWN 2 50 240 00 ROD BATTERY 1 4X36 3 8PLTD 3 50 241 00 COVER TUBE BATTERY ROD 1 01 220 82 SPLASH PAN CHARGER DUMP BODY l 94 379 00 TAG CAPACITY D BODY 1000LB l M6 001 00 Manual Supplement Dump Body 1
164. re is an open circuit then the timer relay has failed and the relay must be replaced TESTING THE INTERLOCK RELAY Operation The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC power source When the charger is plugged in the relay contacts open and break the Key Switch connection to the speed controller The Interlock Relay is available for built in chargers only Not all built in chargers are equipped with this relay To identify chargers that are equipped with the Interlock Relay Inspect the charger wire harness where it enters the charger cabinet for two Violet Black wires If these wires are present then the charger is equipped with the Interlock Relay Testing Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position AWARNING Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Disconnect the charger from the AC power source Disconnect the two Violet Black wires at the charger harness knife connectors Set the DMM to check for continuity and connect the DMM leads to the wires going into the charger e The DMM should indicate a closed circuit If the DMM indicates an open circuit then the relay or the wires to the relay have failed Stop here and repair the problem TER 9
165. rear of the vehicle depending on which spring is to be removed and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily 7 Remove the spring from the vehicle NOTE Refer to Replace the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles Typical Spring frame 9 Remove the spring bushing s e For internal bushing press the spring bushings out of the two spring eyes and from the mounting eye on the vehicles frame e For external bushing Remove the bushings from the spring eye 10 Install the new bushings in reverse order Suspension Page 4 Maintenance Service and Repair REPLACE THE SHOCKS lt is recommended to replace all shocks as a set NOTE On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts Refer to Tires and Wheels section for information regarding removing the front wheels 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 AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the mai
166. removing the steering knuckle Remove the hub dust cap cotter pin and spindle nut Remove the hub from the steering knuckle NOTE Fora front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body NOTE Catch the outer bearing as it falls out 10 Thoroughly clean all grease from the inside of the hub and the bearings 11 Inspect and replace the races and bearings as a set NOTE It is recommended to replace all four Me m bearings and races in the left and right F lat of ut e wheels as a set w o 12 Assemble in reverse order using new grease seals of a Pack inner and outer bearings with grease b While rotating the hub tighten the spindle nut to 30 ft lbs This seats the bearings c Back off the spindle nut one flat until the hub turns but is not loose d Install a new cotter pin Hub with Dust Cap Removed Front Axle Page 7 Maintenance Service and Repair 13 Install the hub dust cap 14 Reinstall the brake body and the tire wheel assembly NOTE Refer 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 behind the wheels 18 Release the park brake and test drive the vehicle Front Axle Page 8 Maintenance Service
167. ries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Tie up or support the rear axle so it cannot fall out of the vehicle 8 Unbolt the spring from the axle housing 9 Support the spring so that it cannot fall out of the vehicle 10 Remove the remaining hardware retaining the spring to the frame 11 Remove the spring from the vehicle 12 Inspect the spring bolts and spring hangers for signs of wear or damage If any wear or damage is found then they must be replaced Damaged or worn spring bolts or hangers could result in sudden failure AWARNING of the suspension causing severe bodily injury or property damage 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the spring 15 Tighten the spring hanger bolts securely but not so tight as to bind the spring 16 Lower the vehicle 17 Reconnect the main positive and negative cables at the batteries 18 Remove the blocks from behind the wheels 19 Release the parking brake and test drive the vehicle Suspension Page 2 Maintenance Service and Repair REPLACE THE FRONT SPRINGS If a spring has failed or is fatigued then i
168. ring Page 4 Maintenance Service and Repair 11 Measure the distance between the lines at the front ae eee of the tires WN 12 Measure the distance between the lines at the rear of the tires 13 Adjust the tie rod so that the distance at the front i Sleeve Clamps and rear of the tires is the same 14 If equipped with ball joints position the ball joint Tie Rod clamps in their original location and orientation 15 Tighten the ball joint clamps 28 32 ft lbs or the Rear Measurement rod end jam nuts 16 Untie the steering wheel Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not contact any other AWARNI NG component Clamps positioned so that they contact other components may result in steering failure and loss of control of the vehicle causing severe bodily injury and or property damage 17 Reconnect the main positive and negative cables at the batteries 18 Remove the blocks from behind the wheels 19 Release the parking brake and test drive the vehicle Steering Page 5 Maintenance Service and Repair 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 replaced as a set 1 Make sure the key
169. rminal stud 3 291 Hex nut 3 292 Washer 3 293 Washer 3 294 70 260 00 O ring 3 295 Hex nut 3 296 Washer 3 297 Lock washer 3 298 hex nut 3 3900 80 216 05 Sensor bearing i Not Shown 45 308 30 Rubber seal around brake l Parts Page 23 Illustrated Parts Motor Mount Apply 94 421 34 grease to inside of motor coupler Parts Page 24 Illustrated Parts MOTOR MOUNT ITEM PART DESCRIPTION OTY l See Motor Motor l 2 96 114 12 U bolt l 3 80 714 05 O ring 1 4 88 068 62 1 4 Split lock wahser 4 5 89 060 11 6mm x 1 0 x 50 Hex bolt 3 6 89 111 27 10mm x 1 5 x 20 Hex bolt 2 7 88 128 62 7 16 Split lock washer 2 8 70 456 03 Mounting bracket l 9 88 067 17 1 4NC x 1 1 4 Hex bolt 1 10 88 099 80 5 16NF hex nut 2 11 88 088 62 5 16 Split lock washer 2 Parts Page 25 Apply 94 421 34 grease to inside of motor coupler Illustrated Parts Wheels and Tires Ref wheel hub tia Se 5 assembly Parts Page 26 Illustrated Parts Wheels and Tires
170. rom the motor Disconnect the hydraulic brake lines from the left and VF o right brake bodies af Lan a i Park Brake Brake Arm Pin Extension 9 Remove the u bolts holding the leaf springs to the frame as shown in the illustration to the right Do not remove the u bolts on the axle housing 10 Remove the lower shock mounting bolts and the front spring mounting bolts 11 Raise the rear of the vehicle lifting the frame up and off of the drive assembly Support the rear of the vehicle with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 12 Reinstall the drive in reverse order 13 Bleed the brake system Refer to Bleed the Brake System for information regarding bleeding the brakes 14 If equipped with a hand operated park brake set the brake 15 Lower the vehicle 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from the wheels release the park brake and test drive the vehicle Transmission Page 8 Maintenance Service and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION 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 AWARNING 3 If equipped wit
171. rs Model System are designed as semiautomatic chargers The a pal ais s z a charger turns itself on when it is plugged into the Voltage Range Voltage wall outlet and turns off when the batteries are y f fully charged Both the HB600W and HB1000W2 are two stage chargers The first stage is a constant current mode It Maintains a constant current until the battery reaches a terminal voltage and then switches to the second stage constant voltage At the second stage the charger decreases the AITO SELECTABLE DUAL AC INPUT charger current while holding the batteries at the 100 240 BUEH 12 04 terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to the chart and illustration below for the function of these LED s Data Plate Details If an error occurs during charging the charger will beep and display an error code by flashing the status LED s Refer to the Status LED error code table later in this section 715 50 100 Charging Status Left 50 M iddle 75 Right 100 0 50 FLASHING OFF OFF 50 75 ON FLASHING OFF 75 100 ON ON FLASHING Charging Cycle ON ON ON complete mre waaa m n aan FLASHING FLASHING FLASHING SIGNET SYSTEMS INC ieee Charger Time Out OFF OFF FLASHING
172. rvice and Repair 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 for information regarding realignment of the front wheels 14 Lower the vehicle 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Replacing the Drag Link The Drag Link is the linkage that connects the steering gear pitman arm to the steering knuckle Refer to the illustration on the following page 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the ball joints or rod ends from the steering knuckle and pitman arm Pitman Arm NOTE Refer to the Replacing the Ball N K Joints section for informatio
173. rvice Personnel The service personnel are responsible for the service and maintenance of the vehicle At no time should a service person allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training At no time should an untrained individual be allowed to service or repair a vehicle without supervision This manual is not a training guide Of the Passengers The passengers are responsible to remain fully seated keeping their hands arms and legs inside the vehicle at all times Each passenger should be fully aware of the vehicle s operation All forms of recklessness are to be avoided Do not engage in horseplay Introduction Page 3 INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections INTRODUCTION This section describes how to use this service manual and how to identify your vehicle Safety Rules and Operating Instructions This section outlines the safety and operational issues location and operation of controls and the operational checks that are 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 information on the servicing of the vehicle and a schedule for maintenance
174. s Front Axle Page 9 Maintenance Service and Repair 7 Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle NOTE It is not necessary to remove the tie rod or drag link for this procedure Press the king pin bushings out from the axle steering knuckle or suspension arm Press new bushings into the axle steering Knuckle or Suspension arm Ream or broach bronze bushings to 1 25 0 001 Failure to correctly broach or ream bronze bushings may result in AWARNING steering difficulty and loss of control of the vehicle causing severe bodily injury and or property damage 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 Knuckle for information on installing the steering knuckle NOTE It is recommended that the thrust washers or bearing be replaced whenever replacing the king pin bushings Refer to the Replacement Parts section for the orientation of the bearing or washers in your vehicle 12 Grease the bushings bronze only 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle Front Axle Page 10 Maintenance Service and Repair REPLACE THE STEERING KNUC
175. s all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions 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 Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately A WARNING i EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Raise the wheel off of the ground and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING _tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Brakes Page 13 Maintenance Service and Repair 11 12 13 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly Thoro
176. s Page 17 NNNG dO TAVL General Maintenance TABLE OF CONTENTS Maintenance Guidelines ccsccsscssssseeees 2 Troubleshooting Guide sccseseeeeeeeeeees 3 Lubrication Chart siunaus 4 Maintenance Service and Repair MAINTENANCE GUIDELINES Periodic maintenance and service must be performed on this vehicle Failure to complete these scheduled maintenance and service procedures can result in AWARNING severe bodily injury and or property damage It is the owner and or operators responsibility to insure that proper service and maintenance is performed on the vehicle described in this manual 1 Make sure the key switch is in the OFF position then remove the key AWARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake Before start 4 Place blocks under the front wheels to prevent vehicle movement ing any re 5 Disconnect the main positive and negative cables at the batteries palrsS Read and follow all of the guidelines listed below Failure to follow these AWARNING guidelines may result in severe bodily injury and or property damage Avoid fire hazards and have fire protection equipment present in the work area Conduct vehicle performance checks in an authorized area where safe clearance exists Before starting the vehicle follow the recommended safety procedures in Section 2 Safety Rules and Operational Information
177. s and test drive Batteries Page 2 Maintenance Service and Repair TESTING NOTE A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks AWARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING Aconductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage 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 AWARNING 3 Set the park brake 4 Place blocks
178. sion Page 17 Maintenance Service and Repair Pinion Bearing Preload NOTE The pinion gear depth must be set before the preload Refer to Setting the Pinion Gear Depth Install the pinion gear spacer and shims into the housing Install the outer pinion bearing Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft Ibs Measure the torque required to rotate the pinion shaft in the housing The torque required to rotate the pinion shaft should be between 1 1 and 2 9 ft lbs If the torque is not within specifications then add or subtract from the total shim thickness and repeat this procedure until the proper preload is obtained oo W i S NOTE Add shims to decrease torque Pinion Gear Bearings Transmission Page 18 Maintenance Service and Repair PINION GEAR SHIMMING INSTRUCTIONS NOTE 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 lubricated Setting the Pinion Gear Depth This formula is used to calculate the amount of shims that are required C B A DV Pinion Shim mm where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the edge of the differential si
179. switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 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 Steering remove the rod end from the steering Sleeve This will make it easier to realign the wheels Sleeve Jam Nut hina Rod End Nut Steering Arm Steering Page 14 Maintenance Service and Repair 10 Install the new rod end into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the rod end clamp or jam nut at this time 11 Install the rod end into the steering arm Tighten the rod end nut to 20 25 ft lbs 12 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15
180. t AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE It is recommended that both the left and right brake pads be replaced as a Set 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full 8 Raise the rear of the vehicle and support with jack stands Master cylinder is located between the front seats Dual reservoir shown Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Brakes Page 11 Maintenance Service and Repair 9 Remove the tire wheel assembly NOTE Refer to Tires and Wheels section for information on removing the tire and wheel assembly 10 Release the park brake wheel bra
181. t is recommended that both front springs are replaced as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 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 AWARNING 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 the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Tie up or support the front axle so it cannot fall out of the vehicle Unbolt the spring from the front axle beam Support the spring so that it cannot fall out of the vehicle Remove the lower bolt from the spring hanger Remove the spring bolt from the other end of the Typical Spring spring and remove the spring from the vehicle Hanger 12 Inspect the spring bolts and spring hangers for signs y of wear or damage If any wear or damage is found then they must be replaced 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the spring 15 Torque the spring hanger bolts to 2
182. t steering wheel orientated as shown in the illustration to the right Tighten the steering wheel nut to 28 32 ft Ibs Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle Steering Page 12 Maintenance Service and Repair REPLACE THE STEERING GEAR 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the steering wheel Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 7 Remove the steering shaft Refer to Replace the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a pickle fork NOTE On some vehicle configurations it may be required to remove the drag link from the pitman arm Refer to Replace the Ball Joints section for information regarding removing the ball joint from the pitman arm 9 Support the steering gear so that it cannot fall out of the vehicle 10 Remove the bolts holding the steering gear to the vehicle frame and remove the steering gear from the vehicle Fai
183. t the main positive and negative cables at the batteries Safety Rules A Page 3 SAFETY RULES AND OPERATING INSTRUCTIONS DRIVER TRAINING PROGRAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for those claiming to have previous vehicle operation experience Successful completion of the Operator Training program shall be required for all personnel who operate this vehicle The Operator Training program shall include the following e Operation of this vehicle under circumstances normally associated with your particular environment e Emphasis on the safety of cargo and personnel e All safety rules contained within this manual e Proper operation of all vehicle controls e A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive this vehicle Operators must possess the visual auditory physical and mental ability to safely operate this vehicle as specified in the American National Standards Institute Controlled Personnel and Burden Carriers ANSI B56 8 The following are minimum requirements necessary to qualify as an operator of this vehicle e Demonstrate a working knowledge of each control e Understand all safety rules and guidelines as presented in this manual e Know how to properl
184. tch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 If required drain the oil from the 3rd member 7 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 8 Release the park brake _ Brake Bod 9 Remove the tire and wheel assembly Refer to section Tires and Wheels for information regarding removing the tire and wheel assembly a If the axle shaft hub or bearing is to be replaced then remove the hub bolt wheel hub and disc rotor at this time 10 Remove the four bolts attached to the axle retaining plate _ R Axle Retaining Disc Rotor Plate Transmission Page 6 Maintenance Service and Repair 11 Remove the axle retaining plate and brake body assembly as one unit 12 Secure the brake body assembly do not let it hang by the brake hose 13 Pull the axle out of the housing 14 Inspect all bearings for roughness or play replace as needed 15 Install in reverse order lubricate the o ring NOTE Be sure not to damage the o ring 16 Use new bolts for the axle retaining plate The
185. tem Fault Speed Control System Overheated High Low Speed Switch in Low or wiring to the Switch is Faulty Low Speed Cutback Due to Maintenance Meter Trip optional Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Abnormal Noise Loose Lug Nuts Motor Bearings Worn Rear Wheel Bearing and or Gasket Failed Oil Leak in Rear Bearing Area Drive Over Filled Brake Pedal Soft or Spongy Air in Brake Lines Brake Worn 1 16 Wear Limit Brake Pedal Low Brake Fluid Low Brakes Out of Adjustment Brake Worn 1 16 Wear Limit Brake Pads Contaminated with Fluid Brake Pedal Linkage Binding Braking Power Low Brakes Out of Adjustment Air in Brake Lines Trailer Brake System Faulty optional Maintenance Page 3 Maintenance Service and Repair LUBRICATION CHART NO LINO Rear Axle Lubrication Front End Lubrication Description Locations Lubricant Type 1 Ball Joints 4 General Purpose Grease 2 Pedal Linkages 3 Gener
186. tenance meter function is optional The controller handset is required to reset the Maintenance meter Refer to the Appendix for the part number of the handset Parts Page 31 Illustrated Parts Miscellaneous Electrical Accelerator Module Seat Interlock Switch Miscellaneous Wire Harness Clamps Parts Page 32 Illustrated Parts Miscellaneous Electrical ITEM PART DESCRIPTION QTY 98 599 15 Plastic grommet for 1 75 hole 98 599 20 Plastic Grommet for 2 5 hole 75 107 10 Potratble Charger Harness l Not Shown 76 013 00 Portable Charger Receptacle 1 72 015 00 Dome light optional i 78 321 10 optional 1 75 105 25 Harness Dome light 1 1 73 005 05 Reverse Warning alarm 1 2 96 650 01 Wire Harness Clip stick on 3 96 642 00 Wire ahrness Clip push mount 62 033 48 Throttle Module 48 volt system 1 i 62 033 47
187. tery terminals 8 9 96 108 10 9 12 2 Front Axle Front spindle nut Note Refer to maintenance section in the service manual King pin Note Refer to maintenance section in the service manual Rear Axle Transmission 3rd member Gear case cover GT drive 45 50 540 600 61 2 68 Axle bolt GT drive 275 275 3300 3300 374 374 Axle hub nut Dana 95 115 1140 1380 129 2 156 4 Axle tube to center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Drain plug GT drive 21 25 252 300 28 6 34 Gear case to 3rd member GT drive 18 20 216 240 24 5 27 2 Motor mounting GT Dana 6 5 7 78 84 8 8 9 5 Pinion nut F2 F3 175 175 2100 2100 238 238 Pinion nut GT drive 154 169 1848 2028 209 4 229 8 Ring gear Dana 35 45 420 540 47 6 61 2 Wheel lug nut 75 90 900 1080 102 122 4 Steering Ball joint clamp 28 32 336 384 38 1 43 5 Ball joint nut 40 45 480 540 54 4 61 2 Pitman nut 18 308 21 steering gear 75 100 900 1200 102 136 Pitman nut 18 308 25 steering gear 181 217 2172 2604 246 2 295 1 Rod end nut 20 25 240 300 27 2 34 Steering shaft pinch bolt 24 26 288 312 32 6 35 4 Steering wheel nut 18 308 21 steering gear 28 3
188. the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembly 8 Install the cover onto the housing using 4 bolts ina cross pattern and torque to 45 50 ft lbs 9 Pre set the carrier bearing preload by tightening the housing carrier bearing race ring nut until it requires 1 5 to 3 3 ft lbs to rotate the differential assembly NOTE Rotate the carrier assembly whenever adjusting the ring nuts Transmission Page 15 Maintenance Service and Repair 10 Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly do not allow the ring nuts to rotate 11 Install the pinion gear Re shim if required If the ring and pinion gears or bearings are replaced then the pinion gear must be re shimmed Improper ACAUTION pinion gear shims will result in drive noise and premature failure Refer to Pinion Gear Shimming Instructions 12 Install the pinion gear holding tool 96 500 42 and tighten the pinion nut enough to keep the pinion gear from rotating 13 Install the differential assembly 14 Install the cover and all of the cover bolts Torque to 45 50 ft lbs 15 Check the gear lash between the ring and pinion gears The gear lash should be 0 005 to 0 007 inches 16 Adjust the gear lash if needed by tightening or loosening th
189. the rated AC voltage of the charger then the wires from the harness connectors to the charger are bad Stop here and repair the problem e If the timer relay does not pickup click when the AC source is connected then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem e 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 e 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 Charger Troubleshooting zj Page 7 Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries 1 Test
190. the voltage from the positive terminal on the vehicles DC receptacle to 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 2 Test the voltage from the positive terminal on the DC receptacle to the negative terminal on the DC receptacle This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wire on the negative terminal of the DC receptacle is broken or has a bad connection Stop here and repair the problem Remove the charger cover and perform the following tests HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNI NG terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one lead from the capacitor Test the capacitor using the capacitor test function on the meter If the capacitor is bad it must be replaced Stop here and repair the problem 4 Reconnect the lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the
191. tion then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove both front wheels Refer to Tires and Wheels section for information regarding removing the front wheels 8 Tie up or support the front axle so it can not fall out of the vehicle 9 Disconnect the drag link ball joint or rod end from the steering Knuckle or the steering gear pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 10 If equipped with front brakes disconnect the hydraulic brake lines from the brake bodies Axle Beam 11 Disconnect the front axle beam from the front springs and remove the axle from the vehicle NOTE In some configurations the front springs and or shocks will have to be removed in order to remove the axle beam Refer to section Front Suspension for information regarding removing the springs and shocks Front Axle
192. tions it may be necessary to remove the steering gear to perform this procedure Refer to Replace the Steering Gear for information regarding removing the steering gear 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 AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear 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 Always use a lifting strap hoist and jack stands of adequate capacity AWARNING J toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball joint from the drag amp a link ai OAY 8 Loosen the gear lash jam nut and the worm bearing i wey Gear Lash adjuster jam nut Ni Adjuster 9 Unscrew the gear lash adjuster all of the way to the 4 stop Worm Bearing 10 Loosen the worm bearing adjuster and then tighten Adjuster just enough to remove all end play from the input shaft and then an additional 1 8 turn more 11 While holding the worm bearing adjuster so that it cannot turn tighten the worm bearin
193. tshoe Non marking Parts Page 27 Illustrated Parts Instrument Panel dash Wire Harnesses PART DESCRIPTION QTY 75 153 08 Dash harness l 75 153 04 Cable Spy Glass 75 153 07 Main control hlarness l 75 153 05 60 Control panel 1 75 153 06 Power l Parts Page 28 Illustrated Parts Instrument Panel ITEM PART DESCRIPTION QTY i 71 102 15 Horn switch i 2 71 039 02 F amp R switch 1 3a Light switch 1 71 039 11 3b High Low speed switch 1 4 74 010 20 Gauge Spy Glass 1 5 71 100 00 Auxiliary switchs 0 1 2 71 120 00 Start switch standard 1 71 119 99 Spacer 1 71 121 20 Start switch keyed unalike optional i 7 71 120 14 Emergency stop switch l 8 94 304 11 Dash panel i 9 88 817 07 Screw 6 10 02 546 02 Dash housing i 97 211 20 U Nut 2 Not shown 97 211 20 Plug 1 2 hole 0 1 2 Parts Page 29 Illustrated Parts Speed Control Panel B 2 48 shown Parts Page 30 Illustrated Parts
194. ubleshooting Page 3 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM FLUKE 79 model shown at right and in the troubleshooting illustrations Clamp on DC ammeter to measure up to 20 Amps Important Notes and Instructions e This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician e Make sure that the AC electrical socket the charger is plugged into is in good working condition e Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate e Make sure the batteries are in good condition e If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting e Battery volts Full voltage available at the batteries at the time of the test being performed e There are no internally serviceable components in the charger If the charger has failed then it must be replaced This charger is rated for 115 VAC or 230 VAC operation When switching from one input voltage to the other wait until all three status LED s A CAUTION are off Switching voltage when any of the LED s are on will result in damage to the charger aS ee eee S 333 3 Signet Charger Troubleshooting Page 4 Electrical Troubleshooting
195. ughly clean the area around the brake body Remove the brake body bolts and discard the lock bak Nuts Bushings MRi nuts Inspect the brake rotor Refer to Inspect the Service Brake section for information regarding inspecting the brake rotor Disconnect the brake hose from the brake body Install the new brake body assembly in reverse order e Use teflon tape thread sealant on the brake hose Bracket Spacers Bolts fitting e Torque the brake body bolts to 11 ft lbs Brake Pads Bleed the brakes Refer to Bleed the Brakes section for information regarding bleeding the brakes Set the park brake Reconnect the main positive and negative cables at the batteries Lower the wheel to the ground Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Brakes Page 14 Maintenance Service and Repair REPLACE THE MASTER CYLINDER 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 Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately AWARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2
196. vere bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt e Ref amp rto Tires and Wheels section for information regarding installing the tire wheel assembly 12 Lower the wheel to the ground 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels release the park brake and test drive the vehicle Transmission Page 5 Maintenance Service and Repair REMOVING AND INSTALLING THE REAR AXLES DISC BRAKES The oil level in the housing is above the bottom of the axle flange To minimize oil spills raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange If both axles are to be removed you must drain all of the oil from the housing Height of oil in housing on level surface NOTE This procedure does not require that the rear end or drive assembly be removed from the vehicle NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced Oil Level Raise the wheel off of the ground high enough so that the oil level is below the axle housing flange 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse swi
197. vice and Repair TIRE INFLATION AWARNING There are many tire options 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 information on a tire Tire pressures must be checked when the tire is cold 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries TIRE INSPECTION AWARNING 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 7 Check the tire pressure Refer to Tire Inflation section for information on checking the tire pressure Inspect the tire tread depth Minimum recommended tread depth is 1 16 inch There are a series of tread depth wear indicators around the circumference of the tire They will appear as 1 2 inch bands across the tread as the tire approaches its wear limit see illustration to the right Replace the tire if any tread depth
198. w this level Do not increase the governed speed RPM Pary must be discharged below this BDI Reset 80 value before the BDI will be allowed beyond the maximum recommended speed of to reset i i i Battery voltage must be above this the vehicle Exceedi Le the JUG 2 U A Reset Volts 2 10 V ale E BDI Modified by recommended speed of the vehicle may result the BDI Reset above in loss of control and severe bodily injury or Discharge Time 60 M Estimated battery discharge rate property damage Miscellaneous E T P Motor must be below this RPM to Refer to Vehicle Specifications for vehicle SRO Min Speed 3 000 RPM change directions with the throttle speed limit pedal depressed Safety Rules Page 11 SAFETY RULES AND OPERATING INSTRUCTIONS Model B 2 48 B 2 54 equipped with 30 1 drive ratio Aceleration Parameters normal mode Function Value Unit Description Time to accelerate to 15 of full FwdAS LS 2 6 S speed FwdAc HS 4 0 S Time to accelerate to full speed RevAcTS 8 0 S Time to accelerate to from FwdAC LS to full RevAc HS 7 0 S Time to accelerate to full speed Aceleration Parameters low speed mode
199. was raised lower it to the ground 15 Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables at the batteries Master Cylinder 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Push Rod Cutaway of typical master cylinder showing the push rod clearance Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes AWARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Brakes Page 16 Maintenance Service and Repair REPAIR THE MASTER CYLINDER NOTE Hydraulic brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake fluid spills Remove the master cylinder from the vehicle See Replace the Master Cylinder section Drain all fluid from the master cylinder and discard 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 as required If any damage is found in the bore of the master cylinder then it must be replaced Lubricate all parts with clean brake
200. witch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 If equipped with a hand operated park brake set the brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Visually inspect each rod end for any signs of play between the ball and the nylon or brass bushing in the housing Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front A WARN NG wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 7 If any play is evident then the rod end is worn out and should be replaced Refer to section Replace the Ball Joints Tie Rods and Drag Link for information regarding replacing ball joints 8 Reconnect the main positive and negative cables at the batteries a k z a j ki 9 Remove the blocks from behind the wheels 10 Release the parking brake and test drive the vehicle I i a r 7 a 7 sN z p Typical rod end Studded rod end shown your vehicle may be equipped with spherical rod ends that do not have a stud Steering Page 7 Maintenance Service and Repair ADJUST THE STEERING GEAR NOTE In some vehicle configura
201. y is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING Aconductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the A CAUTION battery electrolyte comes in contact with Failure to clean may result in property damage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 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 6 Dry dirt can be readily blown off with low pressure air or brushed off 7 Wetness or wet dirt on the batteries indicates battery acid Using a nonmetallic brush with flexible bristles wash the batteries off with a strong solution of baking soda and hot water 1 lb of soda to a gallon of water Continue until all fizzing stops which indicates that the acid has been neutralized Then 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 wheel
202. y load and unload cargo e Know how to properly park this vehicle e Recognize an improperly maintained vehicle e Demonstrate ability to handle this vehicle in all conditions Safety Rules Page 4 SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1 Horn Switch The horn switch is located on the right side of the instrument panel Depress the switch to sound the horn release it to turn it off 2 Forward Off Reverse Switch The forward off reverse switch located on the right side of the instrument panel determines the direction of travel of the vehicle Push the top of the switch to engage the forward direction Push the bottom of the switch to engage 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 6 Key Switch A key switch located on the right center side of the instrument panel turns on the vehicle Rotate the key clockwise to turn the vehicle power on The forward off reverse switch should be in the center counterclockwise to turn the vehicle power off OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle 3a Light Switch The headlight switch is located on the top left of the instrument panel Push the right side of the switch to turn the lights on Push the left side of the switch to turn the light off 3b Hi Low

B2-48_SN# 171000 & UP (AC DRIVE)

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B2-48_SN# 171000 &amp; UP (AC DRIVE)

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B2-48_SN# 171000 & UP (AC DRIVE)