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E4-50_SN# 137548 & UP

1. Description Locations Lubricant Type 1 Front Fork Bearings 1 General Purpose Grease 2 3 4 Pedal Linkages 3 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 Chain Case Drain 1 7 Drive Drain Plug 1 8 Drive Level Plug 9 Drive Plue 1 SAE 140 weight API GL5 Hypoid Gear Oil TABLE OF CONTENTS Inspect the Front Wheel Bearings 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 R mova m 4 B Of 4 Replace Front Wheel Bearings 5 Front Axle Service INSPECT THE FRONT WHEEL BEARINGS Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Maintenance Service and Repair ADJUST FRONT WHEEL BEARINGS
2. Solenoids Circuit Breaker aa A O gt o o O Ha TE POG SEL B 9 5 PMC Speed Control 3 E Typical Control Panel SYMPTOMS If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Special Troubleshooting in Section 4 at the end of the main troubleshooting sequence Runs slow in both directions plus high armature and field current in both directions NOTE Armature and field current should be equal Runs slow in both directions plus high armature current in both directions NOTE Field current will be very low Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low Full speed only Does not run in either direction plus there is noise from motor hum or whine with high field current and low armature current Jumps into high speed when direction is selected after depressing the accelerator pedal Excessive spark when connecting batt
3. Solenoids shown for reference only repair is completed completely retest the solenoid in your truck may be different vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important review the trouble shooting steps that have led to this point The tests may need to be repeated Main Sequence ez Page 19 Electrical Troubleshooting Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward f the voltage is not at battery volts then go to the Key Switch sequence The voltage shown is for illustration only The actual voltage may vary Main Battery Negative Connect a voltmeter across the Forward Solenoid coil terminals Refer to your vehicles wiring The voltage shown is for illustration diagram to identify the position of the forward only The actual voltage may vary solenoid Solenoids are shown for reference only The type and position of the forward solenoid in your truck may be different Close all interlock switches turn the Key Switch ON
4. 12 Maintenance Guidelines for Severe Duty Applications 12 Un SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS TOW TRACTOR ITEM Occupancy Dimensions Turning Radius Dry Weight Without Battery Battery Compartment Dimensions Battery specifications Min Max Battery Weight Voltage Connector Lead Length Position Cover Maximum Towed Load Electrical System Transmission Motor DC Series Wound Brakes Steering Tires Instrumentation Model E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 E 4 51 E 4 57 SPECIFICATION Driver only no passengers 147L x 81W x 140H Centimeters 58L x 31 75W x 55H Inches 193L x 81W x 140H Centimeters 76L x 31 75W x 55H Inches 124 Centimeters 49 inches 171 Centimeters 67 5 inches 442 kg 975 lbs 575 kg 1 267 lbs 340L x 774W x 610H Millimeters 13 375L x 30 5W x 24H inches 670L x 774W x 610H Millimeters 26 375L x 30 5W x 24H inches 113 kg to 463 kg 250 Ibs to 1 020 Ibs 163 kg to 816 kg 360 Ibs to 1 800 Ibs 24 volts 36 volts SB 175 Gray 762 millimeters 30 inches B Yes 90 7 kg 200 Ibs Draw Bar Pull max 136 kg 300 165 Draw Bar Pull max Tongue weight max 22 kg 50 lbs Solid State Speed Control 400 Amp Helical Gear Oil Bath Automotive
5. set the test light voltage to the same voltage as the battery volts Connect the test light across the normally open Solenoids are shown for reference only contacts of the reverse solenoid Refer to your The type and position of the reverse vehicles wiring diagram to identify the position solenoid in your truck may be different of the reverse solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse Depress the accelerator pedal fully f the light comes on then the Reverse solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect the test light across the Normally Closed contacts of the Forward solenoid Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Reverse Depress the accelerator pedal fully f the light comes on then the Forward solenoid has failed Stop trouble shooting
6. 4 P Horn S WIUODE eco OOo POOL RR 4 Accelerator Brake Treadle 5 Park Brake 5 Foot Interlock Switch 5 EHE Battery Status Indicator Digital Bargraph 5 SIEGE occ ted m a 6 Electrolyte Alarm Optional 6 Vehicle Operational Guidelines 7 Safety Guidelines 7 Starting MM 7 While driving 7 Loading and Unloading 7 Towing Loads 7 Parking 8 Towing This Vehicle 8 Storing and Returning to Service 8 Storing Your Vehicle 8 Returning to Service 8 Charging your vehicle 9 ms New Battery Break in 9 Industrial Charger Operation 9 9 Periodic Maintenance Checklist 10 Standard Periodic Maintenance Schedule for the Smart View Display 11 Daily Visual inspection
7. Check Steering System Check for Fluid Leaks Lubricate Vehicle o Clean and Tighten All Wire Connections Wash and Service Batteries Check Park Brake e Check Motor Brushes and Blow Out Motor Check Front Wheel Bearings Check Rear Axle Oil e Change Rear Axle Oil e Check and Tighten all Nuts and Bolts Clean and Repack Front Wheel Bearings 1 2 3 See notes on following pages 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 Rules Paee 10 SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY The maintenance function is optional Your vehicle may be equipped with a customized maintenance schedule PREVENTATIVE SCHEDULE MAINTENANCE HOUR LEVEL INTERVAL MAINTENANCE TO BE PERFORMED Inspect the brake system
8. Parts Page 10 Illustrated Parts Rear Axle Item Part No Description Qty 1 88 100 11 3 8 X 1 NC HEX HD SCREWbolt 8 2 45 301 00 Seal large bearing axle only 2 3 32 515 00 Retainer large bearing 2 32 509 00 Retainer small bearing 2 4 96 331 00 Wheel stud 10 5 41 163 05 Axle left large bearing 2 41 162 05 Axle right large bearing 2 41 163 00 Axle left small bearing 2 41 162 00 Axle right small bearing 2 6 32 514 00 Retainer axle large bearing 2 32 511 00 Retainer axle small bearing 2 7 80 503 00 Bearing large 2 80 505 00 Bearing small 27 8 45 045 00 Gasket large bearing 2 45 044 00 Gasket small bearing early model without o ring ere 9 88 109 81 3 8 NC LOCK NUT 8 Not 32 512 00 Spacer behind axle retainer small bearing only 2 shown Large bearing is 3 15 OD Small bearing is 2 83 OD Gasket is not required on small bearings with o ring Brake ITEM PART DESCRIPTION QTY l 45 331 00 Pinion Seal l 2 41 352 00 Brake Drum 1 3 96 245 10 Brake Adjusting Bolt l 4 41 661 60 Brake Band Kit Incl 5 3 5 7 8 9 12 13 l 5 85 060 20
9. Excessive Steering Play Worn Ball Joints Worn steer shaft or jack shaft bearings Loose Steering Linkage or chain Lack of Power or Slow Operation Brakes or Parking Brakes Dragging Batteries Discharged or Defective Worn Drive Gears Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Oil Leak in Rear Bearing Area Rear Wheel Bearing and or Gasket Failed Drive Over Filled Brake Pedal Soft or Spongy Brakes Out of Adjustment Brake Pedal Low Brake Worn 1 16 Wear Limit Brakes Out of Adjustment Braking Power Low Brake Worn 1 16 Wear Limit Brake Pads Contaminated with Fluid Brake Pedal Linkage Binding Brakes Out of Adjustment Note This list is provided as a guide only It is not all inclusive of causes that may result in a specific symptom Page 3 Z Maintenance Service and Repair Lubrication Chart Page 4 Drive view from left side Ps
10. Special Troubleshooting ez Page 9 ELECIRICAL IROUBLESHOOTING With the key switch on and the F amp R switch in reverse depress the accelerator pedal and perform the following tests Check continuity from the wire that was connected to the PMC M terminal to the wire that was connected to the motor MAPA dar bs MP MR MEE Terminal positions on your motor S1 terminal may not be in the same location If you do not know how to test for continuity refer test to a qualified technician This should read as an open circuit If it reads as a short then one of the following has occurred A The reverse solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S1 terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ez Page 10 ELECIRICAL IROUBLESHOOTING MOTOR High motor current in both the field and the armature accompanied with a lack of power would indicate a shorted armatur
11. Example of freshly cut commutator 7 While still in the lathe smooth the commutator with fine emery cloth Undercutting the commutator 1 Using a small straight cut saw blade cut the commutator insulation to the proper depth Refer to undercut depth in Service Limits 2 Once all segments have been properly undercut mount the armature in a lathe and smooth the commutator with fine emery cloth 3 Inspect the armature for shorts Refer to Motor Inspection section for information on testing the armature NOTE Copper debris in the undercut area can give a reading of a shorted armature Properly undercut and cleaned commutator segments Motor Service _ h Commutator Diameter Brush Length Wire Depth Motor Specification Undercut Dept min Number mm inches mm inches mm inches mm inches 5BC58JB56129A 0 635 0 025 66 75 2 625 38 1 SBC58JBS6129B 0 635 0 025 66 75 2 625 38 1 1 5 SBCS8JBS6129C 0 635 0 025 66 75 2025 38 1 1 5 5BC49JB399C 0 635 0 025 78 97 3 109 19 05 0 75 5BC58JBS6110C 0 685 0 025 78 97 3 109 19 05 0 75 Motor Paee 7 SO TAVL TABLE OF CONTENTS Adjust
12. This should be an open circuit If there 15 continuity from A1 to the frame of the motor then the motor armature or armature circuit brushes are shorted 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 otherwise continue with the next test Special Troubleshooting ez Page 11 ELECIRICAL IROUBLESHOOTING Check continuity from S1 to the frame of the motor Motor shown for reference only If you do not know how to test for continuity Terminal positions on your motor may not be in the same location refer test to a qualified technician This should be an open circuit If there is continuity from S1 to the frame of the motor then the motor field is shorted 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 otherwise continue to Motor Inspection Motor Inspection 1 Remove and disassemble the motor 2 Visually inspect inside of the brush end housing If there are any silver specs of metal around the inside of the housing it indicates that the armature has overheated and melted the solder around the commutator The armature is bad and the motor must be replaced Stop here and repair the problem otherwise continue with the
13. Parts Page 24 Item No 1 CO O O 15 16 17 18 19 Not Shown Part No 62 205 00 62 205 40 72 501 43 72 501 39 72 501 42 72 501 38 79 840 00 88 818 06 79 844 20 88 818 06 73 002 00 88 838 06 88 838 06 01 534 80 01 534 91 88 080 11 88 088 62 88 089 80 88 838 06 75 235 26 61 838 42 61 838 41 88 099 91 88 088 63 75 148 25 78 302 50 Illustrated Parts TITLE Description Motor speed control E 4 51 Motor speed control E 4 57 Forward or Reverse solenoid E 4 51 Forward or Reverse solenoid E 4 57 ISO solenoid E 4 51 ISO solenoid E 4 57 Circuit breaker 8 X 1 2 PAN HD SCR TYPE B THD Circuit breaker 8 X 1 2 PAN HD SCR TYPE B THD Horn 24v 36v 14X1 2 PAN HD SCR TYPE D THD 14X1 2 PAN HD SCR TYPE D THD Mounting plate E 4 51 Mounting plate E 4 57 5 16 X 1 NC HEX HD CAP SCR 5 16 Split lock washer 5 16 NC HEX NUT S S 14X1 2 PAN HD SCR TYPE D THD Jumper Buss bar small Buss bar large 5 16 NF THIN PATTERN NUT 5 16 LOCK WASHER INT TOOTH Harness Resistor on ISO solenoid Parts Page 25 9 lt N o 5 N N N O Illustrated Parts Item No O O1 OW PO Item No Part No 75 149 10 75 149 09 73 005 01 75 148 13 71 122 10 62 033 48 72 023 20 Part 75 231 00 75 23
14. f you have full battery voltage then the PMC control is shorted and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test The voltage shown is for illustration only The actual voltage may vary NEN B B 2 M I l If the voltage at pin 2 is correct and the voltage at M is correct then there is a short in the harness between the wire connected to the PMC M and main battery negative Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ez Page 3 ELECIRICAL IROUBLESHOOTING PLUGGING DIODE Make sure the key switch is in the OFF position then remove the key AW ARNI N G Place the forward reverse switch in the center OFF position Set the park brake Place blocks underthe front wheels to prevent vehicle movement Disconnect the main positive and negative cables
15. only The actual voltage may vary NEM KI B 2 I M Main Battery Positive Connect a voltmeter across the PMC B terminal PMC terminal Close all interlock switches turn the Key The voltage shown is for illustration Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal to engage MS 1 only f the voltage is not the same as battery volts then go to the Solenoids sequence e f the voltage is the same as battery volts only The actual voltage may vary KSI B 2 then the PMC controller has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Main Sequence ez Page 8 I 2 Electrical Troubleshooting Motor Make sure the key switch is in the OFF position then remove the key AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING 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 damage Rot
16. 00 08 00 Ib SS 00 58 01 S61 0L 01 S61 0L c9 01c 0L c9 01c 0L 00 6L1 L6 05 01 04 15 01 04 06689167096 96195918095 301195918995 puno AA 591196 1030 Illustrated Parts Motor Page 2 Typical GE Motor Parts Page 16 Illustrated Parts V N 1104 1010 A 2915 1010 A PPL punoAA 91295 SIJON 0CtrS0 0 Otratorods Toysem WIH AVS 9
17. CHANGE THE OIL AWARNING Wear protective gloves when working with petroleum lubricants Repeated contact with petroleum lubricants can result in skin disorders AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Place a large drain pan under the chain housing Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug Place the drain pan under the drive housing Remove the drive housing drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug 10 Remove the chain case fill plug and add 1 pint of oil 11 Remove the drive housing fill plug and add 2 quarts of oil NOTE Refer to the Lubrication Chart for information regarding the type of oil 12 Replace all fill plugs NOTE Dispose of waste oil in accordance with your local regulations 13 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive F2 F3 Transmission Page 3 Maintenance Service and Repair P NON ME 7 3 Install the motor mounting hardware but do not DRIVE MOTOR tighten until the chain adjustment is complete 4
18. Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Remove the front axle and wheel s Refer to Front Axle Removal and Installation section for information regarding removing the axle 7 Remove the spacers seals and bearings from the hub 8 Thoroughly clean all grease from the inside of the hub and the bearings 9 Drive the races out from the hub 10 Press new races into the hub 11 Assemble in reverse order using new grease seals a Pack bearings with grease b Refer to Front Axle Removal and Installation section for information regarding installing the axle 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehicle Front Axle Page 4 TABLE OF CONTENTS Steering Alignment 2 Inspect the Steering Components 4 Fork Bearings 4 Steering Chalin 4 R d Bids ase era ANS 4 Adjust the Steering Chain
19. 18 Remove the differential shaft locking roll pin 19 Split the 2 piece differential housing 20 Drive the differential pinion shaft out of the housing with a brass drift punch 21 Remove the differential gears axle gears and thrust washers DIFFERENTIAL CASE Maintenance Service and Repair Assemble NOTE Thoroughly clean and inspect all parts before reassembly Apply a small amount of differential oil to all gears and bearings before reassembly NOTE Depending on your vehicle config uration the rear pinion pilot bearing is not required and may not be installed NOTE If the ring and pinion gear set is to be replaced then the shims for the pinion housing may have to be adjusted Hefer to section Selecting the Pinion Housing Shim for information on adjusting the shim NOTE Most of our gear sets are non hunting or semi hunting gears With this type of gear the pinion and ring gears must be aligned correctly There will be two teeth marked on the ring gear and one tooth marked on the pinion gear The one tooth on the pinion gear must be installed so that it is between the two teeth on the ring gear The gear ratios are 2 50 2 70 2 75 3 25 and 3 00 Pinion housing 1 OV copo TS If the rear pinion bearing was removed install a new bearing Install the bearing races into the pinion housing Place the pinion gear into the 3rd member Install the pinion housing onto the 3rd m
20. Illustrated Parts TITLE Description Bearing cap nut Washer Bearing Collar w races This is a weld on part Race Seal Fork Spacer fork Spacer wheel bearing Wheel includes bearings spacers and seals Bearing Race Seal Grease fitting 5 8 X 1 3 4 NC HEX HD SCR 5 8 NC THIN FLEXLOCK NUT Axle shaft Rod end left thread Rod end right thread Clamp Drag link E 4 51 only see following page for E 4 57 Jack shaft Spacer U bolt 5 16 LOCK WASHER 5 16 NC HEX NUT S S 1 2 NC HEX HD NUT Tube jack shaft Woodruff key Bearing Sprocket Chain Master link Sprocket Steering shaft Steering wheel 5 8 NF HEX HD JAM NUT BOLT 5 8 X 1 1 2 NC GR5 W HOLE EXTERNAL TOOTH LOCK WASHER Parts Page 3 Qty IN N lo aA a C1 PE IN IN IN Illustrated Parts Front Wheels Steering E 4 57 Steering wheel chain and jackshaft is same as E 4 51 Parts Page 4 Illustrated Parts Item No I C OO O 13 Part No 14 319 00 80 308 00 14 087 00 88 389 86 80 011 00 80 102 00 16 408 00 15 002 05 16 408 01 16 410 00 45 307 00 80 011 00 80 102 00 13 964 10 12 058 10 10 267 00 88 389 86 Not shown 18 054 00 Description Mounting plate Bearing Fork 1 1 4 NC LOCKNUT PLATED Bearing Race Spacer Axle Spacer Shims Seal Bearin
21. AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Raise the front of the vehicle and support with jack stands 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 indication of loose wheel bearings or king pin 8 Spin the front wheel s by hand The wheel should stop spinning in no more than 2 revolutions A wheel that continues to spin freely is an indication of a loose wheel bearing NOTE Refer to the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings 9 Spin the wheel s and listen for any grinding noise Any noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 10 Lower the vehicle 11 Reconnect the main positive and negative cable
22. The Best Way To Go About Your Business Revision TAYLOR DUNN E0 034 51 E0 034 57 Models Inlcuded E0 034 51 E 4 51 E0 034 57 E 4 57 MANUAL ME 450 05 Operation Troubleshooting and Replacement Parts Manual Serial Number Starting 137548 with the exception of serial numbers 140665 140666 143548 143549 143550 refer to manual ME 450 03 COPYRIGHTNOTICE Copyright 2001 by Taylor Dunn Mfg 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 1 t 8 f f B2 10 Ambulance 2 48 With Dump Bed Option B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides P2 50 30 000 Pound Tow Tractor 50 Full Size Truck Section Index Taylor Dunn Model E0 034 51 and E0 034 57 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General
23. 5 Replace the Front Fork 6 Service Steering Component STEERING ALIGNMENT A WARNING Make sure the key switch is in the OFF position then remove the key Maintenance Service and Repair Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING 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 wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 6 Remove the steering chain 7 Remove the drag link 8 Position the front fork so that it is in the full right 11 12 13 14 16 17 turn position and tie off so it cannot rotate Position the steering jack shaft arm as shown in the illustration parallel with the rear wheel Position the steering wheel so that it is centered see illustration and tie off so it cannot rotate Loosen the rod end clamps Adjust the drag link rod ends so that the drag link can be easily installed Both rod ends should have approximately the same number of threads into the drag link Install the drag link Position the rod end clamps as shown in the illustratio
24. AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Set the test light voltage to the same voltage as the battery volts Connect the test light from the PMC M Terminal to battery positive Close all interlock switches turn the Key Switch Controller ON and place the F amp R Switch in Forward Depress the accelerator pedal fully f the light comes ON then go to the Motor sequence e Ifthe light does not come ON then continue with the next test Main Battery Positive Main Sequence ez Page 5 Electrical Troubleshooting Control Wire inputs Test Make sure the key switch is in the OFF position then remove the key AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent v
25. OZ LILZ ZL6 ONISQvO SOZ ZM TIVISNI Parts Page 31 SO TAVL Contents Appendix A Special Tools 2 Appendix B Suggested Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings 3 Hex Rn 3 Hex Lock Nuts stover 4 COUIGETNULS kunun 4 Suggested Torque Values non critical hardware 5 Appendix C Brake Lining Handling Precautions 7 Appendixes REV B Appendixes APPENDIX A SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used to install the pinion seal on all chain drive trucks with Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43 201 50 cover Used to center the chain case on the pinion shaft on all chain Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41 532 50 on the chain case cover Includes instructions I Used for testing electrical circuits Powered by the truck Test Light batteries switchable for 12 24 36 an
26. PMC control 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 STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troubleshooting ez Page 5 ELECIRICAL IROUBLESHOOTING ISO Make sure the key switch is in the OFF position then remove the key AW ARNI NG Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires and the resistor from the ISO solenoid and perform the following t
27. Violet Black wire on either Close all interlock switches turn the Key bcc end of the switch Switch ON and place the F amp R Switch in 4 Forward f the voltage is not at battery volts then the F amp R switch has failed Stop trouble 5 shooting here and repair the problem Or When the repair is completed Zo lt p completely retest the vehicle before lowering the drive wheels to the ground k s f the voltage is at battery volts and the Battery Negative test at the PMC KSI terminal in the Control Wire Inputs section failed then check the wiring between COLD terminals of the KSI side of the F amp R switch and the PMC KSI terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground a F R switch Make sure the key switch is in the OFF position then remove the key AWARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING 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 damage Rotating rear drive wheels are a potential haza
28. f the voltage at pin 5 is good but the test at the center terminal of the forward and reverse side of the F amp R switch in the Key Switch Section failed then check the wire between the accelerator module pin 5 and the F amp R 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 The voltage shown is for illustration only The actual voltage may vary Main Sequence ez Page 11 Electrical Troubleshooting Connect voltmeter between pin 9 and pin 2 1 the test harness Depress the accelerator pedal to engage MS 1 only Ifthe voltage is between 6 0 and 6 5 volts and the test at the PMC 2 terminal in the Control Wire Input section failed then the wire or interlock switches between the accelerator module pin 2 and the PMC pin 2 is open 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 f the voltage is not between 6 0 and 6 5 The voltage shown is for illustration only The actual voltage may vary volts then the accelerator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Now
29. seat the bearing into the rear housing If equipped with armature retaining screws install and tighten them at this time If this is an enclosed motor lightly grease the armature shaft seal and install the front motor housing NOTE If the vehicle is equipped with a belt type primary reduction then the spring on the motor seal should be removed Failure to remove the spring may result in a high pitched squeal from the seal 7 Pushthe motor brushes into the brush holder until the brush spring snaps into place Be certain that the spring does not rest up against the brush wire See the illustrations below n b Incorrect Brush Spring Position Motor Service Brush Spring Orientation HEPLACING THE BRUSHES NOTE is recommended that all four brushes be replaced as a set NOTE Motors without removable brush covers must be disassembled to replace the brushes Refer to Motor Inspection Disassembly section for information on taking the motor apart NOTE Some motors are equipped with brush pairs These motors must be disassembled to replace the brushes Hefer to Motor Inspection Disassembly section for information on taking the motor apart Refer to the Motor Parts List for your vehicles brush configuration NOTE Some motors have brush leads that are routed through or behind the brush holder assembly In this case the brush holder assembly must be removed to replace the brushes NOTE The motor
30. 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 6 88 110 09 3 8 x 3 4 Hex Bolt grade 5 7 88 109 62 3 8 Split Lock Washer 8 88 119 80 3 8 NF Hex Nut 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only 11 030 00 4 80 x 8 Tube Tire and Wheel Assemblies 13 734 00 4 80 x 8 LR B Pneumatic E 4 51 only 13 734 11 4 80 x 8 LR B Split Rim Pneumatic E 4 51 only 13 739 10 4 80 x 8 LR C Split Rim Pneumatic 13 952 10 16 x 4 x 12 Solid Rubber Cast Iron Wheel 13 734 40 400x 8 Soft Solid man toter Parts Page 21 Illustrated Parts Instrument Panel dash Parts Page 22 Illustrated Parts No 1 2 3 CO O Part 71 039 11 71 039 11 74 009 10 74 009 00 74 000 00 71 039 02 71 120 10 71 501 00 94 304 11 88 817 06 88 025 08 88 029 86 88 048 61 Instument Panel Description Switch Switch Battery status indicator E 4 51 Battery status indicator E 4 57 Hour meter F amp R Switch Key switch Horn Switch Dash plate Screw 8 32 X5 8 TRUS HD MACH SCR 8 32 FLEXLOCK NUT WASHER 10 SAE Parts Page 23 lt N N a a Illustrated Parts Speed Control Panel 12 Face of Controller 1 17 ALL BO ere FWD REV ISO 18 Top of Solenoids
31. 2 Apply 1 8 bead of 94 430 03 gasket 10 7 the face of the member Install the backing plate to the 3rd member Torque to 30 45 ft lbs Install the motor to the backing plate Do not fully tighten the motor mounting hardware at this time Install the motor sprocket drive sprocket and chain Do not adjust the chain tension at this time Apply a 1 8 bead of 94 430 03 gasket sealer to the chain case housing Apply sealer around the ID of the holes Install the chain case centering tool refer to Appendix A into the pinion seal bore in the chain case housing Maintenance Service and Repair Pinion Seal Brake Assembly PWR_TRAC DWG 8 Install the chain case housing onto the pinion shaft and tighten the pinion nut to 75 ft lbs 9 Install and tighten the three nuts and washers to the threaded studs and the housing bolts that are not used for the brake mounting bracket or alignment brackets Chain Case Housing Bolts j Motor Sprocket d al m Spacer zw Drive Sprocket CO ss Drive Chain Nut 10 Remove the centering tool and install a new pinion seal Lightly lubricate the pinion seal lip 11 Install the brake assembly and the brake band alignment bracket s Do not tighten the bolts at this time 12 Install the brake drum Torque to 175 ft Ibs 13 Tighten the brake adjusting bolt to 25 ft Ibs 14 Tighten the brake assembly
32. 2 1 2 Long Sprine 1 6 41 372 10 Mounting Bracket 1 7 88 159 84 1 2 20 Lock Nut 1 8 88 159 82 1 2 NF Hex Jam Nut l 9 97 250 00 Pinion Nut l 10 88 109 81 3 8 Lock Nut l 11 88 108 61 3 8 Lock Washer 2 12 88 517 11 3 32 X 1 Cotter Pin l 13 96 771 00 Clevis Pin l 14 550 656 00 Brake Arm l 15 88 101 13 3 8 X 1 1 4 NC Grade 5 Hex Bolt l 16 NOT USED 17 88 080 13 5 16 X 1 1 4 Hex Bolt 2 18 41 371 10 Alignment Bracket 2 19 88 089 91 5 16 Hex Jam Nut 4 Parts Page 11 Illustrated Parts Brake linkage 4 5 9 7 2 WM k E I 6 GEO E h _ au A 4 axo T Loacted under driver platform Parts Page 12 Illustrated Parts Item No Part No 50 027 00 88 119 80 Brake Linkage Description Brake rod lt 2 8911980 ___ 38NFHEXHDNUT 1 _ 96 762 00 Clevis 4 9677200 ___ 2 _ O OI 5 09 IN 88 527 11 Clevis Cotter _____ 38NFHEXHDNUT 50 028 00 88 119 80 85 282 00 85 280 00 Spring E 4 51 Spring E 4 57 Ie 8 5064700 ___ 1 96 762 00 Bell Clevis 10 848045 5 8X1 34NCHEXHDSCR 88 180 15 88 188 64 ______ 3818864 Lockwasher 11 12 86 520 00 Hod end 12 8830015 3SBXTSANCHEXHDSCR __
33. 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 or or S A E Grade B Or Or te S A E Grade C Grade 179 Other Nuts Other nuts used by Taylor Dunn should be treated S A E grade Appendixes Appendix B Page 4 Suggested Torque Values non critical hardware Diameter Grade 2 Grade5_ Grade 8 79 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque ft Ib ft Ib ft Ib ft Ib 1 4 20 4 7 7 10 10 14 11 1 4 28 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
34. Adjustthe drive chain Refer to Adjust the Drive Remove Chain for information regarding adjusting the drive chain NOTE In most cases it is not necessary to disassemble the chain case to remove the 5 Connect motor wires motor If you find it necessary to disassemble 6 Reconnect the main positive and negative at the the chain case refer to Transmission batteries remove the blocks from the wheels and section for information regarding disassembly test drive of the chain case AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Chain tied with mechanics wire Disconnect the main positive and negative cables at the batteries 6 Remove the four motor wires 7 Loosen the drive chain adjusting screw 8 Remove the hardware holding the motor to the chain case backing plate 9 Lift the rear of the motor and rotate the motor so that the motor mounting plate clears the two threaded studs on the chain case backing plate and remove the motor from the drive Install A CAUTION Do not allow the wheels to rotate after the motor has been removed Allowing the wheels to rotate may result in the drive chain getting bound up with the drive sprocket locking up the transmission Should this happen the chain may ha
35. Before leaving the vehicle Set the parking brake e Set the forward off reverse switch to the OFF position Rotate the Key switch to the OFF position In addition f parking this vehicle on incline turn the wheels to the curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Towing This Vehicle To tow this vehicle attach a tow strap to the front bumper tow bar NOTE If the vehicle is equipped with an automatic electric brake do not tow the vehicle with the drive wheels on the ground Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible this vehicle should be placed on a carrier rather than towing Safety Rules Page 8 STORING AND RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel Storing Your Vehicle Clean the batteries then fill and charge before putting the vehicle in storage Do not store batteries in a discharged condition Lube all grease fittings Clean dry and check all exposed electrical connections Inflate tires to proper pressure if applicable For extended storage the vehicle should be elevated so that the tires do not touch the grou
36. Depress the accelerator module fully f the voltage is not between 11 0 and 11 5 volts then the accelerator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Main Sequence ez Page 12 Electrical Troubleshooting Key Switch Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Test all interlock switches and or interlock relays Gf equipped for
37. Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transmission Service Q Rh WO N Tires and Wheels Battery Service a Electrical Troubleshooting N E0 034 57 Special Troubleshooting Go Charger Troubleshooting Ja Wire diagram illustrated Parts Appendix Special Tools 16 Appendix B Suggested Torque Values 17 Appendix G Brake Lining Handling Precautions 18 This quick reference section Index guide will assist you in locating a desired topic or procedure Refer to each sectional Table of Contents for the page number location for specific topics or procedures SC1 00 Stock Chaser B2 48 With Stake Side Dump Bed Option E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor Table of Contents About this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventio Sss a T qd LA D UE NSS 3 How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 Introduction e 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
38. Taylor Dunn brakes are asbestos free However there is the possibility that 14 Remove the blocks from behind the wheels the original brakes were replaced with aftermarket parts containing asbestos 15 Release the park brake and test drive the vehicle Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Depress the treadle to release the brake Loosen the bolt s on the brake band alignment bracket s and pivot them out of the way 7 Remove the pinion nut and slide the brake drum off of the pinion shaft 8 Remove the pinion seal A WARNING Inspect the pinion seal for any signs of misalignment A misaligned pinion seal could cause premature failure of the pinion seal and an oil leak This could result in property damage and or severe bodily injury 9 Lightly grease the new pinion seal and install using the pinion seal installation tool see appendix C 10 Install the brake drum using a new pinion nut Torque the pinion nut to 170 ft Ibs 11 Adjust the park brake Refer to Adjust the Service Brake secti
39. and place the F amp R Switch in forward Depress the accelerator pedal fully f the voltage is not at battery volts then go to the F R Switch sequence FWD REV Set the test light voltage to the same voltage as the battery volts Solenoids are shown for reference only The type and position of the forward Connect the test light across the Normally Open pe solenoid in your truck may be different contacts of the Forward solenoid Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward Depress the accelerator pedal fully f the light comes on then the Forward solenoid has failed Stop trouble shooting FWD REV here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Main Sequence za Page 20 Electrical Troubleshooting Set the test light voltage to the same voltage as the battery volts FWD REV Connect the test light across the Normally Closed contacts of the Reverse solenoid Refer to your vehicles wiring diagram to identify the position of the Reverse sol
40. 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 Vehicle Description Safety Rules and Guidelines Operational Information Operator Responsibilities e Owner Responsibilities Control Operation and Location Information Maintenance and Troubleshooting Information 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 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 Page 2 RESPONSIBILITIES Of the Owner The owner of this or any Taylor Dunn vehicle is re
41. could cause the battery to explode resulting in severe bodily injury and or property damage Battery Service e Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury Maintenance Service and Repair CLEANING AWARNING e Explosive mixtures of Hydrogen gas 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 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 A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage e Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A CAUTION Batt
42. for illustration only The actual voltage may vary e f the voltage is at battery volts then continue with the next test ede Main Battery Negative Main Sequence ez Page 7 Electrical Troubleshooting Power Wire Inputs Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Connect a voltmeter to the PMC B terminal and battery positive f the voltage is not the same as battery volts then there is an open circuit in the wire from B to the battery Stop troubleshooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground The voltage shown is for illustration
43. ic i a 2 Pneumatic Tire Inspection 2 Replace the Front Tire Wheel 3 Replace the Rear Tire Wheel 3 Replace the Tire pneumatic 3 Repair the Tire pneumatic 4 Tires and Wheels Maintenance Service and Repair TIRE INFLATION PNEUMATIC TIRE INSPECTION 6 Check the tire pressure Refer to Tire Inflation TIRE INFLATION A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the rear wheels to prevent vehicle movement Disconnect the main positive and 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 below Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section negative cables at the batteries for information regarding replacing the tire 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
44. information on removing the transmission Disassemble AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Place an oil drain pan under the chain case Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug Remove the brake drum Refer to section Brakes Replace the Brake Drum for information regarding removing the brake drum Remove the nuts from the three threaded studs at the small end of the chain case housing Remove the chain case housing bolts brake assembly and alignment brackets Remove the chain case housing from the backing plate Remove the pinion seal from the chain case housing Loosen the motor mounting bolts Loosen the chain adjuster Remove the drive chain motor nut and sprocket and the drive sprocket If the backing plate must be removed from the 3rd member first remove the motor from the backing plate then remove the backing plate from the 3rd member F2 F3 Transmission Page 6 smal End of Housing Chain Case Housing Bolts Drain Plug Typical Chain Case Assemble 1 Thoroughly clean all gasket surfaces
45. 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 32 336 384 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 How
46. of 2596 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 disconnecting Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries Safety Rules Page 9 SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi Annual 500hrs Weekly Monthly Quaterly 20hrs 80hrs 250hrs Annualy 2 3 Maintenance Item 1000hrs Check Condition of Tires and o Tire Pressure Check AII Lights Horns Beepers and Warning Devises Check and Fill Batteries Check Brake System
47. 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 AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A CAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage AWARNING A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will Initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage recommended to replace them as a set AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to 6 prevent vehicle movement Disconnect the main positive and negative cables at the batteries Thorough
48. pinion shaft tighten the pinion nut to 100 ft Ibs 8 Measure and record the ring and pinion gear backlash This setting will be used during reassembly 9 Remove the pinion housing and pinion gear from the 3rd member NOTE Do not lose the spacers and shims in the pinion housing or the pinion housing shim s 10 If required remove the rear tapered bearing from the pinion shaft and discard NOTE Do not remove the bearing unless it requires replacement Removing the rear bearing will damage the bearing Replacing this bearing will require re shimming of the pinion shaft 11 If required remove the bearing races from the pinion housing 12 Mark the differential bearing caps and 3rd member housing so that they can be reassembled in their Original location Refer to illustration at end of section NOTE The caps cannot be interchanged or replaced If the caps are lost or damaged then the entire member assembly must be replaced 13 Remove the differential bearing caps bearing adjusting nuts and races 14 Remove the differential assembly from the 3rd member 15 Mark the ring gear and differential housing so that the ring gear can be reinstalled in the same orientation 16 Remove the bearings from the differential housing and discard NOTE Removing the bearings will damage the bearings Do not remove the bearings unless they require replacement 17 Remove the ring gear from the differential housing
49. 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 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 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 Model R 3 80 shown equiped with a cargo box and steel cab with doors options INTRODUCTION Z Conventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below AWARNING A shaded box with the word Warning and the symbol above denotes a warning A warning alerts the reader of a hazard that may result in injury to themselves or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task A WARNING A shaded box with and the word War
50. the drive wheels to the ground Battery Negative from the rear e f all tests in this section were good then check the wiring from the F amp R switch to the Forward and Reverse solenoids and both the forward and reverse solenoid coils 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 Solenoids Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury If the vehicle runs in forward only then skip ahead to the test sequence Forward does not run in reverse If the vehicle runs in reverse only then skip ahead to the test sequence Reverse does not run in forward Main Sequen
51. this point The tests may need to be repeated Special Troubleshooting ez Page 4 ELECIRICAL IROUBLESHOOTING FREEWHEEL DIODE Make sure the key switch is in the OFF position then remove the key AW ARNI N G Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires from the B and M terminals on the PMC control and perform the following test The reading shown is for illustration only The actual reading may vary Using the diode test function on the DMM check for the presence of a diode across B and M on the PMC control Refer to Diode Figure 2 If you do not know how to test for a diode refer test to a qualified technician f the diode is open or shorted then the
52. turns 9 Tighten the brake band bolt jam nut 10 Release the treadle 1 Measure the thickness of the brake lining at its thinnest point If it is 1 16 inch or less then the brake band must be replaced 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from the wheels 13 Release the park brake and test drive the vehicle Brake Bolt F E 2 Measure the run out of the brake drum If it is more than 0 010 inches then it must be machined Or replaced Do not machine the brake drum beyond its service limits 3 Measure the diameter of the brake drum If it is less than 5 85 inches then the brake drum must be replaced 4 Inspect all brake cables and linkages for any signs of damage or wear 5 Reconnect the main positive and negative cables at the batteries Remove blocks from behind the wheels 7 Test drive the vehicle Brakes Page 2 Maintenance Service and Repair REPLACE THE BRAKE LINING 14 5 6 13 10 1 o 15 11 8 AW ARNING NOTE Refer to the illustration above for locations of the components NOTE On most vehicle configurations the brake THO Drake nant gotb spring icar nut drum does not have to be removed for this nut clevis pin and cotter pin must be replaced with new parts whenever the procedure If the brake drum must be brake band is replaced Failure to replace removed refer to Band Br
53. 0 00 450 23 72 024 51 72 024 52 72 093 00 72 022 51 88 837 09 Not shown 77 863 00 Illustrated Parts Miscellaneous Frame and Body Description Headlight E 4 51 Headlight E 4 57 Seat back cushion Seat back suport Locking collar Knob Rear cover Front cover Interlock switch pedal bolt on black Taillight housing Plug Bulb Taillight mounting ring 14X3 4 PHILLIPS METAL SCR Batttery clamp Parts Page 29 lt Illustrated Parts Hitches 97 804 01 pain Pintle Hitch Automatic Coupling Hitch Hook Pin and Eye Hitch 97 8309 00 3 250 s Bna in 97 806 10 Pin and Clevis Hitch 97 805 00 cP Ball Mount Standard Mounting Hardware ITEM PART DESCRIPTION QTY 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 149 80 1 2NC Hax nut 4 88 148 62 1 2 Split lock washer 4 Parts Page 30 lllustrated Parts Tilt Steering Column optional S 18 qr OL O00r 08 IE EDO TEM Qv3H v 1 82714 v 60 090 88 CLAN N v 1 527 OZ 11Z ZL6 ONISQLZ ZO0Z 2ZM TIVISNI VOS SOC C VAH v 1 SOld v 60 090 88 CLAN N v 1 Sold
54. 1 5 mu wef 391 6 61 o Jeurejos SUJ ES NOLLdTI IOSHG WALI Parts Page 17 Illustrated Parts Throttle linkage Right Rear Fender Well Parts Page 18 Illustrated Parts Throttle Linkage Item Part No Description Qty 1 01 450 29 Accelerator module mounting bracket 1 2 02 150 11 Extension lever on module arm 1 50 123 23 Rod treadle arm to module 1 88 109 81 3 8 NC LOCK NUT 1 88 108 60 3 8 CUT WASHER 1 4 50 481 00 Connector slip 1 5 88 527 11 Cotter pin 1 Parts Page 19 Illustrated Parts Wheels and Tires Illustration not available Parts Page 20 Illustrated Parts Wheels and Tires ITEM PART DESCRIPTION 1 Wheels 12 050 00 12 1 8 Diameter Cast Iron 2 Tires 10 250 00 16 x 4 x 12 Solid rubber 10 074 00 400x8 Soft solid ribbed man toter 10 074 10 400x8 Soft solid ribbed non marking man toter 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
55. 207 213 319 301 451 350 3 4 16 154 231 238 357 336 504 390 718 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 Suqqested 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 Battery terminals 8 9 96 108 10 9 12 2 Front Axle Front spindle nut a a 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
56. 4 00 75 244 00 88 081 12 88 089 80 77 042 00 77 044 00 77 047 00 77 042 80 77 047 80 77 048 00 77 972 00 77 867 00 Miscellaneous Electrical Description Power harness E 4 51 Power harness E4 57 Reverse Motion alarm Control harness Foot interlock switch Accelerator module Amber Strobe light Batteries BATTERIES 6 volt golf car Description Jumper Battery 10 long Jumper Battery 22 long POWER CORD SB 175 RECEPT Bolt 5 16NC Square Hd Tin Lead Nut 5 16NC Tin Lead Battery 6 Volt 217 amp hou Battery 6 Volt 230 amp hour Battery 6 Volt 244 amp hour Battery 6 Volt 217 amp hour Battery 6 Volt 244 amp hour Battery 6 Volt 250 amp hour Lift out battery box E 4 57 Spacer battery box E 4 57 Parts Page 26 Qty eee Illustrated Parts Decals Item Part No Description Qty 1 94 201 00 TAYLOR DUNN EMBLEM 1 88 567 91 Clip 3 2 94 313 00 DECAL BATTERY WARNING 1 3 94 313 20 DECAL SAFETY WARN 1 4 94 319 00 DECAL BATTERY DISCONNECT 1 5 94 373 12 DATA PLATE 1 6 94 384 01 DECAL NOT MOTOR VEHICLE 1 7 94 382 00 DECAL TREADLE 1 8 94 384 14 DECAL WARNING WHEN LEAVING VEHICLE 1 l on front of cover Parts Page 27 Illustrated Parts Miscellaneous Frame and Body Parts Page 28 Item No 1 oO 9 Part No 72 006 00 72 007 10 90 144 00 90 159 00 17 113 00 95 901 00 71 617 00 71 618 1
57. AWARNING Rotating parts keep hands and loose clothing clear of all moving parts Failure to keep clear of moving parts may result in Disconnect the main positive and negative cables at the batteries severe bodily injury and or property damage Place a small oil drain pan under the chain case 7 Loosen but do not remove the three drive motor mounting nuts 12 Close all safety interlock switches turn the key On place the forward off reverse switch in forward 8 Loosen the chain adjuster jam nut and fully depress the accelerator pedal 13 Tighten or loosen the adjustment screw to obtain the minimum noise level NOTE If there is less than 1 16 of threads left on the adjustment screw see illustration then the drive chain has stretched beyond service limits and should be replaced Refer to section Chain Case for information regarding replacing the drive chain Chain Adjuster 3rd nut is at the bottom cof the motor Always use a lifting strap hoist and jack ai M stands of adequate capacity to lift and support the vehicle Failure to use lifting 14 Release the accelerator pedal place the forward off reverse switch in off turn the key off and disconnect the batteries 15 Untie the vehicle 16 Tighten the adjustment screw jam nut and motor mounting nuts and support devices of rated load capacity may result in severe bodily injury 9 Raise
58. Front Wheel Bearings section for information Set the park brake regarding tightening the front axle Place blocks under the front wheels to NOTE If your vehicle is equipped with two axle nuts prevent vehicle movement the nuts should be tightened equally so that the Disconnect the main positive and same number of axle threads are visible on both negative cables at the batteries enas Lower the vehicle Reconnect the main positive and negative cables 6 A WARNING at the batteries UN Remove the blocks from behind the wheels Always use a lifting strap hoist and jack stands of adequate capacity to lift and 8 Release the park brake and test drive the vehicle support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Remove the front axle nut 7 Slowly raise the front of the vehicle until the axle can slide freely out of the fork The front wheel s should still be resting on the ground 8 Remove the front axle from the fork and support the vehicle with jack stands e Seal Bearing Typical fork illustrated Your fork may be different Front Axle Page 3 Maintenance Service and Repair REPLACE FRONT WHEEL BEARINGS AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake
59. OKGOS iut LA Ee 10 Brake linkage 12 Motor Page Toe oos muses oer oo 14 Motor Page 2 16 Throttle linkage 18 Wheels and Tires 20 Instrument Panel dash 22 Speed Control Panel 24 Miscellaneous Electrical 26 Baller amp 9_ 26 e a 27 Miscellaneous Frame and 28 30 Tilt Steering Column 31 Illustrated Parts Front Wheels Steering E 4 51 Parts Page 2 Item No CO N O O JOJN 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Part No 92 105 00 88 229 81 88 228 61 80 011 00 17 001 10 80 102 00 45 307 00 14 084 10 16 406 11 Supplied with wheel 13 904 00 Supplied with wheel Supplied with wheel Supplied with wheel Supplied with wheel 88 180 15 88 189 82 15 010 20 86 521 98 86 521 99 86 510 00 18 041 52 20 146 00 16 405 00 96 102 00 88 088 62 88 089 80 88 149 80 32 047 00 97 100 00 80 400 10 30 010 00 30 246 00 30 400 00 30 002 00 20 145 00 19 007 20 88 199 82 96 317 00 88 188 64
60. Type Hypoid Differential 5 kW 6 7 Horse Power 935 RPM Intermittant Duty 7 45 kW 10 Horse Power 1 400 RPM Intermittant Duty Mechanical brake to rear differential to both rear wheels Brake operated by integrated accelerator and brake treadle Automaticaly applied Park Brake Chain and Sprocket Reduction to Front Fork Two 16 x 4 x 12 125 Solid Cushion rear Two 8 x 2 5 Solid Cushion front Two 16 x 4 x 12 125 Solid Cushion rear Two 10 x 3 5 Solid Cushion front Key Switch Horn Button Forward Reverse Switch 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 Operator Controlled Industrial Tow Tractors ANSI B56 9 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 thatthe operator understands 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 9 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 p
61. URING ALL TESTS After any repairs are made completely retest the vehicle before AW ARNI N 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 The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Disconnect both of the battery leads during any maintenance or A WARNING before disconnecting any electrical component or wire Failure to do so may cause severe bodily injury and or property damage START Read all warnings above before continuing If the vehicle runs normal in one direction but does not run in the opposite direction then go to the Solenoids sequence If none of the three solenoids pick up click when the accelerator pedal is depressed then go to the Forward amp Reverse Switch sequence Main Sequence ez Page 4 Electrical Troubleshooting Power Output Test Make sure the key switch is in the OFF position then remove the key
62. _____ 1 13 88 100 15 88 109 81 3 8 NC LOCK NUT N a 8840860 89 BCUTWASHER 2 _ 88 108 60 Parts Page 13 Illustrated Parts Motor Page 1 Typical GE Motor Parts Page 14 Illustrated Parts V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N V N 00 VL0 OL 9007 16 00 cL0 0L CST aprer Las VI 00 190702 gdEtr0tgf6rodse VI Oc LSO OL 5276 lt 2 2 lt 2 OI LSO OL Vorcdforo ds 00 SS0 0 V e9cdo9ccl 1q S Weg 1010 A SO VS0 OL V9OLTAX y 29145 IQON ISEM 19 880 88 WIH AVS 91 5 mu wef ON91 S 61 VIN 16768088 V N Suneog SI 90S N Parts Page 15 OL VOT OL 00 SOT OL ST CLT OL ST vOT OL 00 CLT OL 00 VOT OL Surgsng 1oj nsu 00 8LI L6 o oes 007v 0 0L 076T070L 00 670 0L NOLLdTI9IOSHG WHIT 00 c08 0
63. 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 AWARNING 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 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 Model B 2 10 Ambulance Page 5 SO TAVL TABLE OF CONTENTS c otandard Specifications Tow Tractor 2 c Safety Rules and Guidelines 3 Driver Training Program 3 Driver Qualifications 3 Vehicle Controls 4 Er 1 Headlight Switch 4 2 Accessory Switch Optional 4 3 Battery Status Indicator Analog 4 4 Hour Meter 4 Un 5 Forward Off Reverse Switch 4 6 Key Switch
64. age 5 SO TAVL TABLE OF CONTENTS Inspect the Service Brake 2 Adjust the Service Brake 2 Replace the Brake Lining 3 Replace the Brake Drum 5 Brake Service Maintenance Service and Repair INSPECT THE SERVICE ADJUST THE SERVICE BRAKE BRAKE AWARNING AWARNING Make sure the key switch is in the OFF position then remove the key Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos Place the forward reverse switch in the center OFF position Place blocks under the front wheels to Since this possibility exists all brake parts prevent vehicle movement should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions Disconnect the main positive and negative cables at the batteries The band brake is located on the front of the drive chain 6 Depress the accelerator treadle untill the stop nut case housing it must be removed to accurately measure on the throttle rod is in contact with the accelerator the lining thickness Refer to Replace the Brake module slip joint see below Lining for information on removing the band brake Loosen the brake band bolt jam nut 8 Tighten the brake band bolt until the brake starts to drag and then back off one
65. ailure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury PMC CONTROL The voltage shown is for illustration only The actual voltage may vary Disconnect the wire from the M terminal on the PMC control and tape it off to prevent electrical contact Connect a volt meter across the PMC 2 terminal and battery negative Turn the key switch on close all interlock switches if equipped depress the accelerator pedal to engage the first micro switch only creep speed then perform the following tests Main Battery Negative The meter reading should be between 6 and 6 5 volts If the voltage at pin 2 15 not 6 to 6 5 volts then go to the ACCELERATOR sequence in the Main Troubleshooting Sequence otherwise continue with the next test Special Troubleshooting ez Page 2 ELECIRICAL IROUBLESHOOTING Connect a volt meter across the PMC B and M terminals Turn the key switch on close all interlock switches if equipped depress the accelerator pedal to engage the first micro switch only creep speed then perform the following tests The meter reading should not be equal to the battery voltage
66. ake Drum for these components could cause the parking this procedure brake to fail resulting in severe bodily 5 Depress the treadle to release the brake injury and or property damage Disconnect the brake linkage from the brake arm 7 Loosen the bolt s 1 on the brake band alignment AW ARNING bracket s 9 and pivot them out of the way 8 Remove the bolts 5 holding the brake band 1 Make sure the key switch Is in the OFF assembly to the front of the chain housing 16 position then remove the key and remove the brake band assembly from the 2 Place the forward reverse switch in the center OFF position 9 Remove the brake band bolt 4 3 Place blocks under the front wheels to 10 Remove the clevis pin 11 from the brake band prevent vehicle movement anchor and remove the brake band 3 from the assembly 4 Disconnect the main positive and negative cables at the batteries 11 Inspect the brake arm pivot bolt for signs of wear If any signs of wear are seen then the pivot bolt must be replaced Brakes Page 3 Maintenance Service and Repair 12 Tighten the brake band pivot bolt and then back 18 Adjust the alignment bracket adjusting bolt s 10 off just enough so that the brake arm 15 pivots to 0 050 0 100 away from the brake band and freely tighten the jam nuts 12 13 Install the new brake band using new hardware 0 050 0 100 Clearance 14 Install the brake ban
67. and or property damage Page 2 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 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 Troubleshooting Guide Maintenance Service and Repair j Symptom Probable Cause Steering Pulls in One Direction Front End Out of Alignment Low Tire Pressure Hard Steering Dry Lube Points in Steering Linkage Damaged King Pin Ball Joint Low Tire Pressure
68. at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires from the B A2 terminals on the PMC control and perform the following test mun The reading shown is for illustration Hi only The actual reading may vary Using the diode test function on the DMM check for the presence of a diode across B A2 on the PMC control If you do not know how to test for a diode refer test to a qualified technician f the diode is open or shorted then the PMC control 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 STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to
69. ating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Set the test light voltage to the same voltage as the battery volts onnee the test light across the motor A 1 and Wiring to motor omitted for clarity Do not A terminals disconnect the motor wires for this test Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator fully e If the light comes on then the motor armature windings are open and the motor must be repaired or replaced Stop trouble shooting here and repair the problem When the repair is completed completely test the vehicle before lowering the drive wheels to the ground Motor shown for reference only Terminal positions on your motor may not be in the same location Main Sequence za Page 9 Electrical Troubleshooting Connect the test light across the motor S1 and 52 terminals Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator fully f the light comes on then the motor field windings are open and the motor must be repaired or replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before Motor shown for reference o
70. ble T COLD Violet Wires s shooting here and repair the problem When the repair is completed SE completely retest the vehicle before lowering the drive wheels to the ground HOT Red wire s f the voltage is at battery volts but the previous test at pin 4 in the Accelerator section failed then check the wire from the key switch to pin 4 at the accelerator module 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 BATTERY MAIN NEGATIVE For your reference shown at the right are the Forward and Reverse switch wire connections KSI Side for a typical control system Forward and Reverse Side y White Black Violet Black Green Black AA jeu Blue Black Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back Connect a voltmeter across the HOT terminal of the KSI side of the F amp R switch and battery The HOT terminal is the Violet Black negative wire on the center terminal Turn the key switch ON f the voltage is not at battery volts then go to the Accelerator sequence Main Sequence ez Page 14 Electrical Troubleshooting Connect a voltmeter across one of the COLD terminals of the KSI side of the F lt R switch and battery negative The COLD terminal is the
71. blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Remove the front axle Refer to section Front Axle Removal and Installation in Front Axle Service for information regarding removing the front axle Remove the rod end from the fork Loosen the fork spindle nut but do not remove it at this time 9 Tie up or support the front fork so that it cannot fall from the vehicle and remove the fork spindle nut 10 Remove the fork from the vehicle 11 Thoroughly clean all parts and install in reverse order e Tighten the fork spindle nut to remove all play in the fork bearings and then an additional 1 4 turn Refer to section Front Axle Removal and Installation in Front Axle Service for information regarding installing the front axle Ifthe fork was replaced with a new fork the front end should be realigned Refer to section Steering Alignmentfor information regarding aligning the front end 12 Lower the wheels to the ground 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 P
72. cables at the batteries NOTE The battery 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 cell will read 1100 Ideally all cells in a battery will have the same reading Any cells in a battery that vary by more than 30 points may be an indication of a bad cell Clean the battery Refer to Cleaning section for information on cleaning the battery Using part number 77 200 00 hydrometer check and record the specific gravity of each cell in the battery If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system the charging system checks OK then the battery is no longer accepting a charge and should be replaced NOTE Hefer to Charger Troubleshooting for information y nin Hydrometer on checking the charging system Foai The highest reading will be the cell that is accepting the most charge This reading will be used to gauge all other cells Compare the specific gravity readings to the highest reading if the difference between any of the cells is more than 30 points then that battery should be replaced NOTE Individual cells in some industrial batteries can be replaced Contact the battery manufacturer for more information Reconnect the battery r
73. ce ez Page 10 Electrical Troubleshooting Connect the accelerator module test harness to the accelerator module The voltage shown is for illustration only The actual voltage may vary Connect a voltmeter between pin 9 in the test harness and battery positive If the voltage is not at battery volts then the wiring between pin 9 the harness Main Battery Positive and battery negative is open Stop 7 trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Connect a voltmeter negative probe to Pin 9 in the test harness Connect the positive probe to 24 or 36 volt truck Pin 4 48 volt truck Pin 7 The voltage shown is for illustration only The actual voltage may vary Close all interlock switches and turn the Key Switch ON f the voltage is not at battery volts then go to the Key Switch sequence Connect a voltmeter between pin 9 and pin 5 1 the test harness Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal to engage MS 1 only f the voltage is not at battery volts then the accelerator module has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground
74. ce ez Page 17 Electrical Troubleshooting Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal fully If the voltage 15 at battery volts then the wire from the ISO solenoid to the PMC is bad 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 Connect a voltmeter across the ISO solenoid HOT terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal fully f the voltage is at battery volts then the ISO solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground f the voltage is not at battery volts then check the wiring to battery positive and the main circuit breaker Stop trouble shooting here and repair the problem Battery Negative The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different ere J 2 Nas m Battery Negative FWD REV The voltage shown is for illustration only Th
75. cluding gas furnace or water heater pilots sparks 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 A battery is live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will Initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage Specific Gravity AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Confirm the electric park brake is applied Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative
76. continuity Depending on the model of your vehicle it may have a seat interlock Foot interlock Charger interlock special order interlock or any combination of the above Refer to the wire diagram at the end of this section for location of the interlocks NOTE Due to the many different configurations possible for special order interlocks they will not be included in this text Refer to the option list for your truck or contact your Taylor Dunn Representative for more information If you do not know how to test for continuity refer test to a qualified technician Connect a voltmeter across the HOT terminal of the key switch and battery negative View of the terminals of a If the voltage is not at battery volts then Itn check the wire between the key switch KEY SWITCH and battery positive Stop trouble COLD Violet Wire s shooting here and repair the problem e When the repair is completed Q completely retest the vehicle before lowering the drive wheels to the ground HOT Red wire s BATTERY MAIN NEGATIVE Main Sequence za Page 13 Electrical Troubleshooting Connect a voltmeter across the COLD terminal of the key switch and battery negative adi o ie terminals on typical Key Switch Turn the key switch ON f the voltage is not at battery volts then KEY SWITCH the key switch has failed Stop trou
77. d 48 volts 62 027 00 Used to test the solid state accellerator module part number Accelerator Test Harness series 62 033 XX 62 027 31 Includes 62 027 00 62 027 31 and supplementary PMC Test Kit troubleshooting manual M3 001 06 For controllers 62 027 60 equipped with pins labeled KSI and 2 only Curtis PMC Handheld Used to test and program the 62 215 00 PMC speed control 62 027 10 Programmer used on early model C4 25 Huskey B GE EVI Analyzer Used to test the EVI speed control 62 027 20 Used to reset the PMT C maintenance meter after a PMT C Meter Reset Module maintenance is completed 96 500 43 Sevcon Handset Analyzer Used to test the Sevcon control systems and reset the 62 027 61 read only Smart View display includes instructions Sevcon Handset Analyzer Same as 62 027 61 above plus allows a limited range of 62 027 62 with Speed Adjust Capability speed adjustment Disc Brake Boot Installation Used to install the rubber boot on all disc brake bodies 41 350 13 Tool Used i kets f AMP Pin Removing sed to remove pins and sockets from connectors 75 440 55 Used i kets f MOLEX Pin Removing Tool sed to remove pins and sockets from MO connectors 75_442 55 Used to check th ifi i f lyte Hydrometer sed to check the specific gravity of battery electrolyte 77 200 00 Usedt fel ies Battery killer sed to safely add water to batteries 77 201 00 nm Used to hold down the retaining plate when disassembling Retaining P
78. d armature Typical burn mark on a shorted armature Inspect the commutator for raised segments Raised segments could be a result of a stalled motor or shorted armature A tool called a growler is required to reliably test for a shorted armature e f the armature is not shorted then the raised segments can be removed by machining the commutator Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted armature f the insulation is cracked or burnt then it is recommend that the armature or motor be replaced NOTE If the armature has been burnt then there is a 8 9 10 Motor good possibility that the field windings may also be burnt Symptoms indicating a shorted field include high motor current lack of power and possibly excessive speed Using a growler test the armature for shorts e armature is shorted then we recommend that the armature or motor be replaced Using the continuity function of digital multi meter check the continuity around the entire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity aro
79. d assembly onto the drive a Tighten the mounting bolts 5 just enough to keep the mounting bracket 13 against the chain case 16 but still allowing the bracket to move 15 Tighten the brake band bolt 4 to 50 ft lbs 16 Tighten the brake band bracket mounting bolts 5 17 Position the brake band alignment bracket s 9 so that the inner arm 14 is 0 100 away from the brake drum 8 Make certain that the alignment 19 Connect the brake linkage to the brake arm and bracket does not come into contact with the brake adjust the linkage so that the brake arm is drum contacting the chain case when the treadle is fully depressed level with the floorboard 20 Release the treadle and then depress the accelerator treadle untill the stop nut on the throttle rod is in contact with the accelerator module slip joint see below 21 Loosen the brake band adjusting bolt 4 and adjust so that there is a slight brake drag It may be necessary to readjust the alignment bracket adjusting bolt s 10 for optimum brake alignment and operation 22 Tighten the brake band bolt jam nut 7 23 Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels and test drive 13 10 Brakes Page 4 Maintenance Service and Repair REPLACE THE BRAKE DRUM A WARNING 12 Release the treadle 13 Reconnect the main positive and negative cables at the batteries Current
80. e 12 Install the battery in reverse order e Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury AWARNING 1 Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the Typical battery lifting beam center OFF position Confirm the electric park brake is applied Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the battery and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries 7 Using a hoist or forklift equipped with a proper battery lifting device see next page slowly raise the battery out of the vehicle 8 Inspect the battery compartment for signs of Typical forklift attachment to use with corrosion the lifting beam Batteries Page 5 Maintenance Service and Repair REPLACING 6 VOLT BATTERIES ONLY NOTE If the batteries are over one year old it is AWARNING 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 cigarettes or any
81. e Start at the beginning and complete each test in the order that they are written Do not skip any test unless instructed to do so Once a problem is found stop testing and repair the indicated problem When the repair is completed it is recommended that the control system be retested before lowering the drive wheels to the ground These test procedures must be performed in the order they were A C AUTI ON written If the test result is good then proceed to the next test or go to the next section Failure to do so may result in incorrect test results This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck andthe Taylor Dunn Accelerator Module Test Harness Troubleshooting CANNOT be completed without these tools Main Sequence ez Page 3 Electrical Troubleshooting Definitions e MS 1 The first switch in the accelerator module e Battery volts The voltage at the batteries at the time the test is completed Pick up Energizing a solenoid or contactor F amp R Forward and Reverse 150 Isolator e Battery negative Main negative battery post Battery positive Main positive battery post PMC Speed control module black box e HOT terminal The side of a switch or solenoid that is connect to the power source COLD terminal The side of a switch or solenoid that power is switched to D
82. e actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different Nas ee FWD REV 5 When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Forward does not run in reverse Connect a voltmeter across the PMC KSI terminal and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse If the voltage is not at battery volts then go to the Key Switch sequence Main Battery Negative The voltage shown is for illustration only The actual voltage may vary FE S MES B 2 I ol Main Sequence ez Page 18 Electrical Troubleshooting Connect a voltmeter across the Reverse Solenoid coil terminals Refer to your vehicles wiring The voltage shown is for illustration diagram to identify the position of the reverse only The actual voltage may vary solenoid Solenoids are shown for reference only Close all interlock switches turn the Key P The type and position of the reverse Switch ON and place the F amp R Switch in s solenoid in your truck may be different reverse Depress the accelerator pedal fully f the voltage 15 not at battery volts then go to the F R Switch sequence
83. e and measure how far into the motor the wire was inserted If any one wire insertion length exceeds the length specified in Service Limits then all four brushes should be replaced Refer to Replacing the Brushes section for information regarding replacing the motor brushes Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels release the park brake and test drive Motor Service Advanced DC Motors Inspection The enclosed Advanced DC motors must be 1 Measure the length of each motor brush disassembled to inspect the motor brushes Refer to Motor Inspection for information regarding disassembling the motor If any one brush is less than or equal to the service limit specified in section Service Limits then all four brushes should be replaced Refer to Replacing the Brushes section for information regarding replacing the motor brushes MOTOR REMOVAL AND 2 Measure the diameter of the commutator INSTALLATION See the Transmission section for information on removing or installing the motor MOTOR INSPECTION Disassembly 1 Remove the motor from the vehicle See the Transmission section for information on removing the motor e f the commutator is less than the minimum diameter specified in section Service Limits then the motor must be replaced 2 Remove the housing screws from the rear and or 3 Measure the commutator undercut depth in 5 f
84. e and or field Another symptom that may exist is jumping or stuttering at low speeds and or the motor will not run unless the armature is manually rotated If this symptom exists it indicates that there may be open segments in the armature Visually inspect the brushes if they are OK continue with the testing below Make sure the key switch is in the OFF position then remove the key AW ARNI N G Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Disconnect the four motor wires and perform the following tests Check continuity from Al to the frame of the motor Motor shown for reference only If you do not know how to test for continuity s E ns refer test to a qualified technician may not be in the same location
85. e key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position e Battery electrolyte is poisonous and Confirm the electric park brake is applied dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Clean the battery Refer to Cleaning section for ACAUTION information on cleaning the battery 7 Check the electrolyte level in all battery cells If 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 Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes 8 Reconnect the battery remove the blocks from in contact with Failure to clean may result the wheels and test drive in property damage Filler neck 1 4 Max water level Plate inside battery Battery cutaway Batteries Page 4 Maintenance Service and Repair REMOVING ACAUTION AWARNING Battery electrolyte will stain and corrode mos
86. ehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive The voltage shown is for illustration If the voltage is not at battery volts then only The actual voltage may vary check the wiring to battery negative and i the negative circuit breaker Stop trouble 3bn s E ee for shooting here and repair the problem sss Sy os truck may look different When the repair is completed Main Battery completely retest the vehicle before Positive lowering the drive wheels to the ground Connect a voltmeter across the ISO solenoid coil terminals The voltage shown is for illustration Close all interlock switches and turn the only The actual voltage may vary Key Switch ON Depress the accelerator to engage Solenoids are sho
87. ember Install the pinion bearing spacers shims and front bearing Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened While rotating the pinion shaft tighten the pinion nut to 100 ft Ibs Check the torque required to rotate the shaft If the torque is not between 6 10 in lbs then the bearings must be re shimmed Add or subtract shims as required until the torque is within specifications PAINT MARKING INDICATES POSITION IN WHICH GEARS WERE LAPPED Differential Assembly 9 10 1 12 13 14 15 16 Reassemble the differential housing in reverse order Place the ring gear onto the differential housing matching the mark made during disassembly Install two of the ring gear bolts finger tight to align the gear Press the ring gear onto the differential housing Install the ring gear bolts and cross tighten to 65 80 ft lbs If the differential bearings were removed install new bearings Place races onto the differential bearings and place the differential assembly onto the 3rd member Position the assembly so that it is just touching the pinion gear Install the bearing adjusting nuts making sure that the nuts are not cross threaded Position the nuts so they are in contact with the bearing races F2 F3 Transmission Page 9 Maintenance Service and Repair ACAUTION NOTE Be sure to continually rotate the ring gear while adjusting
88. emove the blocks from the wheels and test drive Batteries Page 3 Maintenance Service and Repair WATERING AWARNING AWARNING Do not overfill the batteries Over filling the batteries may cause the batteries to boil e 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 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 over and result in severe bodily injury or property damage 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 battery at the end of a charging cycle If the electrolyte is below the top of the battery plates then fill just A battery is a live electrical source It enough to COET the plates and then top off cannot be disconnected or neutralized Do when the charging cycle is complete not drop any tool or conductive object onto the battery A conductive object that comes AWARNI NG 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 Make sure th
89. enoid Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal fully Solenoids shown for reference only If the light comes on then the Reverse The type and position of the reverse solenoid has failed Stop trouble shooting solenoid in your truck may be different here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important review the trouble shooting steps that have led to this point The tests may need to be repeated Main Sequence ez Page 21 SO TAVL ELECIRICAL IROUBLESHOOTING Special Troubleshooting Guide This section is specific to the symptoms listed below Each troubleshooting sequence assumes that all listed symptoms are present Do not use this section unless the truck has all listed SYMPTOMS GO TO gt Runs slow in both directions plus high armature and field current in both MOTOR directions NOTE Armature and field current should be equal gt Runs slow in both di
90. ent 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 REPLACE THE REAR TIRE WHEEL AWARNING Make sure the key switch is in the OFF position then remove the key Always use a new valve stem when replacing a tire AWARNING Explosion Hazard Fully deflate the tire before attempting to remove the tire from the wheel Do not over inflate the tire when Place the forward reverse switch in the seating the bead Failure to deflate the tire center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death 1 Remove the tire from the wheel Disconnect the main positive and negative cables at the batteries 2 Cut the old valve stem off of the wheel Remove the valve stem cap from the new valve 6 Raise the wheel to be replaced off of the ground stem and support with jack stands 4 Lubricate the valve stem with liquid soap 7 Remove the 4 or 5 wheel nuts and remove the 5 Install a new valve stem using a valve stem tool wheel NOTE The valve stem tool is available at most auto Install in reverse order repair shops Following the pattern shown on t
91. ery Does not run or runs very slow with low motor current and high battery current Jumps into high speed when direction is selected after depressing the accelerator pedal If your vehicle does not exhibits any of the above symptoms then continue with the main troubleshooting sequence on the following pages Main Sequence ez Page 2 Electrical Troubleshooting MAIN TROUBLESHOOTING SEQUENCE Test Equipment Required Digital multimeter DMM with diode test function FLUKE 79 model used in illustrations Shunt or clamp on DC Ammeter to measure up to 400 amps Test light with a rated voltage equal to or exceeds maximum battery voltage or Taylor Dunn test light part number 62 027 00 for systems up to 48 volts Test harness Taylor Dunn 62 027 31 This troubleshooting guide assumes that the vehicle is wired correctly It is not intended to diagnose a vehicle that is not wired correctly These tools are available through your local Taylor Dunn parts distributor IMPORTANT NOTES and INSTRUCTIONS This troubleshooting guide assumes that the vehicle is wired correctly It is not intended to diagnose a vehicle that is not wired correctly This troubleshooting guide is not written to be able to locate a problem if there are multiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT start in the middle of this troubleshooting guid
92. ery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions Battertes Page 2 AWARNING 1 Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Confirm the electric park brake is applied Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Dry dirt can be readily blown off with low pressure air or brushed off Wetness or wet dirt on the battery indicates battery acid Using a nonmetallic brush with flexible bristles wash the battery off with a strong solution of baking soda and hot water 1 Ib 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 Reconnect the battery remove the blocks from the wheels and test drive Maintenance Service and Repair TESTING AWARNING e Explosive mixtures of Hydrogen gas present within battery cells at all times Do not work with or charge battery in an area where open flames in
93. ests Test continuity across the ISO power contacts If you do not know how to test for continuity refer test to a qualified technician e This should be an open circuit If it is not an open circuit then the contactor should be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the FWD REV vehicle before lowering the drive wheels to the ground other wise continue to the next test Special Troubleshooting ez Page 6 ELECIRICAL IROUBLESHOOTING Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure its resistance The meter reading should be 250 Ohms 10 If it is not 250 ohms 10 then replace the resistor Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reading is plus or minus 10 ISO solenoid is shown for reference only The type of solenoid in your truck may look different STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troub
94. et 1 19 45 021 00 Backing Plate Gasket 1 20 45 331 00 Pinion Oil Seal Gear Case 1 21 97 250 00 Pinion Nut 1 22 88 089 8 1 5 16 NC Locknut 12 23 88 088 61 5 16 SAE Hat Washer 3 24 88 108 63 Intemal Tooth Lock Washer 5 25 88 239 82 Motor Nut 34 NF Hex Jam Nut Thin 1 No longer used on late model trucks Replaced with Ultra Blue RIV sealant 94 430 03 Parts Page 7 Illustrated Parts Transmission Differential Case Parts Page 8 Illustrated Parts Transmission Differential Case ITEM PART DESCRIPTION QTY 41 179 00 3rd member Housing 1 628 ID Carrier Bearing O or 1 41 710 00 3rd member Housi
95. ever 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 SO TAVL Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com
96. example of the side wall information on a tire Tire pressures must be checked when the tire is cold 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 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 Tires and Wheels Page 2 Maintenance Service and Repair REPLACE THE FRONT TIRE REPLACE THE TIRE WHEEL PNEUMATIC Refer to Front Axle Service for information on NOTE To replace the tire the tire wheel assembly removing the front wheels must be removed from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assembly Tire replacem
97. g Race Tire Wheel assembly Wheel includes 10 11 Tire press on 1 1 4 NC LOCKNUT PLATED Drag Link Parts Page 5 Front Wheels and Fork E 4 57 lt L N N A Illustrated Parts Transmission Chain Case Parts Page 6 lllustrated Parts Transmission Chain Case TTEM PART DESCRIPTION 1 88 109 61 3 8 SAE Flat Washer 3 2 97 100 00 Woodruff Key 1 3 88 087 11 Chain Adjusting Screw 1 4 88 069 80 3 16 NC Hex Nut 1 5 88 103 09 Motor Mounting Screw 3 8 X NC 4 6 80 703 00 O Ring 41 2 ID X 5 OD 1 7 70 454 00 Motor Mounting Plate 8 88 109 87 3 8 KEPS Nut Interegral Lockwasher 3 9 30 070 00 15 Tooth Double Motor Sprocket 1 10 16 415 00 Spacer Sprocket F2 Axle 440 Thick 1 ii 30 070 11 60 Tooth Double Pinion Sprocke E 4 51 1 30 070 10 81 Tooth Double Pinion Sprocket E 4 51 E 4 57 i 30 320 11 Drive Chain 15 81 T Double Sprocket E 4 51 4 57 1 30 320 12 Drive Chain 15 60 T Double Sprocket E 4 51 1 13 44 352 52 Backing Plate Gear Case 1 14 88 101 13 3 8 X 1 1 4 NC Hex Bolt 5 15 88 080 20 S 16 X 3 Hex Bolt 9 16 41 989 00 Drain and Fill Plug 2 17 43 201 11 Chain Cover 1 18 45 002 00 Chain Case Gask
98. he following 6 Install the tire onto the wheel following the page cross tighten the wheel nuts in two stages instructions provided with your tire replacement as follows equipment 15 stage to approximately 20 ft lbs 7 Inflate the tire to the proper pressure and check for leaks e 2nd stage to 80 90 ft lbs 8 Install the valve stem cap 10 11 12 13 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 parking brake and test drive the vehicle Tires and Wheels Page 3 Maintenance Service and Repair 4 Bolt Pattern 5 Bolt Pattern 8 Bolt Pattern Pattern for tightening the wheel nuts Re torque all wheel nuts to their final value after 1 week 20 hours AW ARNING of operation Failure to re torque the wheel nuts may result in the 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 repair a tire with a combination vulcanized plug and i
99. including the park brake and mounting harware Inspect the steering system tighten the steering shaft coupler on the steering gear input shaft Lubricate the vehicle check for leaks 1 200 Inspect safety interlocks Inspect front and rear wheel bearings Inspect and adjust fork collar bearings 3 wheel trucks only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire connections 2 1000 Inspect the motor brushes and commutator Inspect the king pin bushings Check front end alignment Change oil in the drive and rear axle Flush hydraulic brake system 3 2000 Inspect suspension bushings Replace brake pedal treadle return spring Inspect frame for damage 1 2 3 See notes on following pages Safety Rules Paee 11 SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection Tire condition and pressure External frame body Operation of all lights and warning alarms and or horns Smooth and proper operation of all controls such as but not limited to Accelerator pedal Brake pedal Steering Parki
100. ional The accessory switch is located on the left side of the instrument panel and to the right of the headlight switch Push the top of the switch to turn on the accessory Push the bottom of switch to turn off the accessory The accessory can be turned on with the key switch in the OFF position If a vehicle is equipped with windshield wipers and one or more accessories the windshield wipers are controlled from this switch Other accessories are controlled from the auxiliary switch 3 Battery Status Indicator Analog The battery status indicator is located to the left of the hour meter The normal operating range 15 in the green zone Park the vehicle for a few minutes for an accurate reading The vehicle needs charging if it is in the yellow zone During and immediately following charging the needle will be in the red zone to the right The needle will move through the green zone toward the yellow zone as the batteries discharge Charge the batteries when the needle is in the yellow zone If itis in the red zone to the left the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries 4 Hour Meter The hour meter is located to the right of the battery status indicator It records the number of hours the vehicle has been in operation Safety Rules Page 4 5 Forward Off Reverse Switch The forward off reverse switch located on the right side of the instrument pane
101. l 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 The forward off reverse switch should be in the center OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle 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 counterclockwise to turn the vehicle power off The key switch should be in the OFF position whenever the operator leaves the vehicle This switch is also designed to secure and disable the vehicle The key can only be removed when the key switch is in the OFF position Battery Status indicator T 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 SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator Digital Bargraph The battery status indicator is located to the left of the hour meter The Full Charge Z battery status indicator has a LED bar graph that indicates the relative state of charge of the battery The top LED will light only when connected to a fully charged batte
102. l pinion nut torque on completely assembled drive 175 ft Ibs F2 F3 Transmission Page 10 Maintenance Service and Repair RE SHIMMING THE PINION HOUSING The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced Pinion housing shims are available from 0 005 to 0 021 in increments of 0 001 Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear It should be a number ranging from 5 to 5 This is the amount in 0 001 increments to add to the standard shim For example if the number on the shaft is 3 then the standard shim 0 015 plus 3 equals 0 012 The correct shim would be 0 012 If you cannot locate the number on the shaft start with the standard shim and adjust as required per the contact pattern chart below Ideal contact pattern Correct shim Correct backlash ON TOE TOE Backlash is correct Add 0 004 shim Backlash is correct Subtract 0 004 shim Shim is correct Decrease backlash 0 004 Shim is correct Increase backlash 0 004 F2 F3 Transmission Page 11 Maintenance Service and Repair FLAT WASHER m La DIFFERENTIAL PINIGN GEAR oc THRUST WASHER OQ __ SPANNER NUT DIFFERENTIAL BEARING G ssia DRIVE GEAR HOUSING PINION REAR BEARING EXPLODED VIEW F2 F3 Transmission Page 12 TABLE OF CONTENTS Tire Miiat
103. late Depressor the steering gear on trucks equipped with the tilt steering 96 500 39 h Fork Collar Weld Jig _ en replacing the fork collar models 600 and 96 500 40 Used to hold the secondary sheave pulley from turning on Secondary Sheave Holder models R6 80 and B6 10 with the Yamaha drive 96 500 14 I I Used to solder the aluminum field wire to the field stud For Solder Kit For Field Stud use on motors with soldered connections only 70 210 63 Used to align the Pini i pinon Gear Holding Tl sed to align the Pinion Gear and Case during assembly and 96 500 42 disassembly Appendixes Appendix A Page 2 Appendixes APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markinqs 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 for clean dry threads Hex Bolts S A E Grade 2 S A E Grade 5 J S 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 Ko te tae 0 2 ee N 4 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
104. leshooting ez Page 7 ELECIRICAL IROUBLESHOOTING SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms Perform the tests covered in the MOTOR section first If the motor is OK continue with the following tests Make sure the key switch is in the OFF position then remove the key AW ARNI N G Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Remove the wires from the SI and S2 terminals on the motor Remove the wire from the M terminal on the PMC control Make sure none of these wires can come into electrical contact with the frame or any other wire Reconnect the batteries With the key switch on and the forward and reverse switch in neutral perform the following tests Check contin
105. ly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries 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 AWARNING Do not leave cables on batteries that have been removed from the vehicle Cables left on batteries could cause a short circuit resulting in battery explosion severe bodily injury and or property damage 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery 10 11 14 jumpers when replacing the batteries Remove the batteries from the vehicle Inspect the battery compartment for signs of corrosion If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and epainted 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 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 Batteries Page 6 Maintenance Service and Repair 15 Install the batteries in reverse order Refer to the Illust
106. m Optional Rev Alarm wiring Charger S gt CB ea Accelerator Module Connector Interlock Relay Contacts Violet Black oO M Violet Black Key Brake Light Switch Switch Eo aa Orange g TAIL STOP Yell o Red elow E White LIGHT Brown Light Switch 8518 Yellow Black E 2 d E eal ge A m g ea 5 Black 5 E Horn Red z m Switch 4 i 518 965427 9 ZZ 5 S z om o 965427 E RI 50 ea S Du 3 S g AWWW 5 MS2 2 Diodes used on i 2 8 gt 48 volt systems e Black 5 MSI MS3 are Orange Black Orange Black only m T 6 11v out oe m T Blue Black 5 Blue Black PCB MEROE White Black_ c White Black Green Black 7 Green Black ACCELERATOR pick Red Red Black Black 2 Black SI Blue 9 Blue Red 14 Red White 4 White White Head Light 16 a 3 Whiter Black Connect to Forward or Reverse for motion alarm Black 11 2 12 Black 5 White PN White Harness Connector White Brown Brown Orange Orange Typical PMC control system Some components on diagram may not be installed on all vehicles Wire Diagrams Page 2 Illustrated Parts TABLE OF CONTENTS Front Wheels Steering E 4 51 2 Front Wheels Steering E 4 57 4 Transmission Chain Case 6 Transmission Differential Case 8 nig i E 10 RGAl BI
107. mounting bolts 15 Adjust the brake Refer to section Brake Service Adjust the Brakes for information regarding adjusting the brakes 16 Adjust the drive chain Refer to section Adjust the Drive Chain for information regarding adjusting the drive chain F2 F3 Transmission Page 7 DIFFERENTIAL ASSEMBLY 375 MEMBER Disassemble NOTE Bearings and races must be replaced as a set If any one bearing or race is worn its mate must also be replaced lt is recommended to replace all bearings and races in the 3rd member as a set 1 Drainthe oil from the differential housing and chain case Refer to section Change the Oil for information regarding draining the oil 2 Remove the transmission assembly from the vehicle Refer to Transmission Assembly Remove and Install tor information regarding removing the transmission 3 Hemove both rear axle assemblies Refer to section Rear Axle Remove and Install for information regarding removing the axles 4 Remove the chain case and backing plate from the 3rd member Refer to section Chain Case Disassemble for information regarding removing the chain case 5 Remove the nuts holding the 3rd member to the axle housing and remove the 3rd member from the housing 6 Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened Measuring backlash F2 F3 Transmission Page 8 Maintenance Service and Repair 7 While rotating the
108. must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor Motors with brush covers and brushes with termination screws 1 Remove the brush covers 2 Loosenthe brush wire retaining screw and remove the brush from the brush holder Be careful with the brush spring and do not let it slip off of the spring mount If the spring comes off then the motor must be disassembled Refer to Motor Inspection Disassembly section for information on taking the motor apart 3 Install the new brushes in reverse order 4 Be certain that the brush springs do not rest up against the brush wires Refer to illustrations in Motor Inspection Assembly for proper brush spring position Motors with brush pairs or not equipped with brush covers 1 Disassemble the motor Refer to Motor Inspection Disassembly section for information on taking the motor apart 2 Remove the brush holder Note Remember the position and routing of the brush crossover leads They must be reinstalled in the same position 3 Remove the brush termination screws or the armature studs and remove the brushes from the brush holder 4 Install the new brushes in reverse order 5 Reassemble the motor Refer to Motor Inspection Assembly for information regarding reassembling the motor Motor Page 5 Motor Service REPLACING THE BEARINGS 1 The motor must be removed from the vehicle for this p
109. n O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Operator Controlled Industrial Tow Tractors ANSI B56 9 The locations of the model and serial numbers are illustrated below Frame Stamp 4 INTRODUCTION Z TAKING DELIVERY OF YOUR VEHICLE What To Do Ita Problem is Found If there is a problem or damage as a result of shipping 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 Make sure everything listed on the packing Slip is there Check that all wire connections battery cables and other electrical connections are secure Check battery cells to be sure they are filled Check the tire pressure tightness of lug nuts and for any signs of damage Check the operation of each of the following controls Accelerator Brake Parking Brake Key Switch Forward Reverse Switch Reverse Beeper if equipped Front Headlight Switch Steering Wheel Horn 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
110. n and tighten the clamp bolts 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 2 Rear rod end Rear Rod End with Safety Wire INSPECT THE STEERING Maintenance Service and Repair 5 Fork Bearings AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 11 Raise the front of the vehicle and support with jack stands Inspect for lateral play by attempting to move the fork to the left and right not rotating There should be no noticeable play If there is any play in the fork bearings refer to section Replace the Front Fork for information regarding adjusting the fork bearings Lower the front end to the ground Reconnect the main positive and negative cables at the batteries Hemove the blocks from behind the wheels Helease the parking brake a
111. nd If stored for a prolonged period the batteries should be charged as follows Returning to Service Storage 5 Charging Interval Temperature months Over 60 1 Between 40 and 60 2 Below 40 6 Check the battery s state of charge and charge if required Perform ALL maintenance checks in the periodic checklist Remove any blocks from the vehicle and or place the vehicle down on to the ground Test drive before putting into normal service SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE AWARNING 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 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 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 Industrial Charger Operation The charger supplied with this vehicle is either specified by or provided by the end user Refer to the operating instruction supplied with
112. nd dangerous It contains sulfuric acid Avoid Between 40 and 60 2 contact with skin eyes or clothing Wear rubber gloves and safety glasses while Below 40 6 servicing batteries DO NOT INGEST This may result in severe bodily injury Batteries Page 8 Industrial Charger Troubleshooting The charger supplied with this vehicle is either specified or provided by the end user Refer to the documentation supplied with the charger or contact the charger manufacturer for more information Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting ACAUTION the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table SO TAVL Table of Contents OVITIDIOITIS so 2 22 35 d d una de 2 Main Troubleshooting Sequence 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions Sates ac cede oio 4 Electrical Troubleshooting Electrical Troubleshooting
113. nd test drive the vehicle Steering Chain The steering chains are very durable and properly lubricated will last the lifetime of the vehicle Inspect the chains for corrosion Any sign of corrosion is evidence of an improperly lubricated chain and the chain should be replaced Inspect each link in the chains for binding If any binding is found remove the chain and soak it in 30 wt motor oil overnight and reinspect the links Replace the chain if the binding is not corrected Rod Ends NOTE ends will wear at the same rate If one is worn out then all should be replaced as a set AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries AWARNING 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 wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 6 Tie off the front fork so that it cannot turn 7 While watching the rod ends rapidly rotate the steering wheel to the left and right 8 Ifthe rod end housing moves up or down then the rod end is worn out and should be replaced Steeri
114. nes 2 Troubleshooting Guide 3 Lubrication Chart 4 Model C 4 25 Tow Tractor Examples of other Taylor Dunn Tow Tractors Model E 4 55 Tow Tractor General Maintenance j Maintenance Service and Repair Maintenance Guidelines AWARNING Periodic maintenance and service must be performed on this vehicle Failure to complete these scheduled maintenance and service procedures can result in severe bodily injury and or property damage It is the owner and or operators responsibility to insure that proper service and maintenance is performed on the vehicle described in this manual AWARNING Before starting any repairs 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 or rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 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 the fault table in the troubleshooting section AWARNING Read and follow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury
115. next test 3 Visually inspect the armature wires where they loop around at the shaft end of the armature The insulation should be a light to medium reddish brown color If the insulation is dark brown to black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the next test 4 Perform a continuity test around the armature commutator Place one of the test leads on a single commutator segment While holding the first test lead on the segment check the continuity to the other segments around the commutator If you do not know how to test for continuity refer test to a qualified technician e There should be continuity on each commutator segment If an open Hold this lead segment is found the armature is bad in place and the motor must be replaced Stop Check each segment trouble shooting here and repair the all of the way around problem When the repair is completed the commutator 7 completely retest the vehicle before lowering the drive wheels to the ground Commutator STOP Stop do not continue If you reached this point without a solution then you may have an unanticipated problem or have made an error during testing It is important review the trouble shooting steps that have led to this point The tests may need to be repeated Special Troublesho
116. ng 1 784 ID Camer 2 88 119 80 3 8 NF Nut 14 41 712 00 Differential Assembly 1 628 ID Carrier Bearing O or 1 41 713 00 Differential Assembly 1 784 ID Camer Bearing O or 1 80 127 00 Carrier Bearing Race For 1 628 ID Carrier Bearing O or 2 4 80 128 00 Carrier Bearing Race For 1 784 ID Carrier Bearing O or 2 80 129 00 Carrier Bearing Race For P N 80 513 00 0 or 2 80 511 00 Carrier Bearing 1 628 ID Carrier Bearing 0 or 2 5 80 512 00 Carrier Bearing 1 784 ID Carrier Bearing 0 or 2 80 5 13 00 Carrier Bearing 1 7812 ID Carrier Bearing 6 31 239 00 Ring and Pinion Gear Set 5 43 O or 1 7 41 997 00 Oil Plue 3 41 290 13 Housing l 10 80 554 00 Front Pinion Bearings 41 711 00 Pinion Housing Shim 1 12 80 702 00 O Ring 1 13 44 340 90 Pinion Housing 1 16 419 00 002 Shim Add Shims As Needed 14 16 420 00 010 Shim Add Shims As Needed T 16 411 00 005 Shim Add Shims As Needed 15 16 415 00 Spacer 1 16 80 125 00 Pinion Bearing Race 2 41 707 00 Differential Bearing Adjuster Nut For 80 5 11 00 0 or 2 18 41 707 50 Differential Bearing Adjuster Nut For 80 512 00 0 or 2 41 708 50 Differential Bearing Adjuster Nut For 80 513 00 0 or 2 19 88 080 04 5 16 X 3 8 NC Hex Bolt 2 20 88 140 16 1 2 X 2 Hex Bolt 2 21 96 243 00 7 16 X 7 8 Hex Bolt Locking Head 10 Parts Page 9 Illustrated Parts Rear Axle Axle tube
117. ng Page 3 Maintenance Service and Repair NOTE The rear end must be secured with safety wire through holes in the bolt head and jack shaft arm see illustration Rear rod _ 9 Untie the front fork 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the parking brake and test drive the vehicle ADJUST THE STEERING CHAIN A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Loosen chain adjuster locking nuts see illustration 7 Using the chain adjuster tighten the steering so that it deflects approximatly 1 4 with 20 pounds of force see illustration 8 Tighten the chain adjuster locking nuts 9 Reconnect the main positive and negative cables at the batteries 10 Remove the blocks from behind the wheels 11 Release the parking brake and test drive the vehicle Steering Page 4 Maintenance Service and Repair REPLACE THE FRONT FORK AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place
118. ng brake etc Proper operation of all locking devises such as but not limited to Tool box Removable battery trays Cargo box Cab doors etc Proper operation of all interlocking switches such as but not limited to Key switch Seat interlock switch 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 Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Safety Rules Page 12 Table of Contents Maintenance Guideli
119. ng the drive wheels to the ground The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type of solenoid in your truck may look different Main Battery Positive f es FWD REV 920 exe The CENTER terminal is the Green Black wire A Battery Negative The FORWARD terminal is diagonally opposite the forward side of the rocker on the switch F amp R switch seen from the side depressed in the FORWARD gear F amp R switch seen Battery Negative from the rear Main Sequence ez Page 16 Electrical Troubleshooting Connect a voltmeter across the reverse terminal of the forward and reverse side of the F amp R switch The REVERSE terminal is diagonally and battery negative opposite the reverse side of the T rocker on the switch Close all interlock switches turn the Key Switch ON and place the F amp R Switch in reverse the side depressed in Depress the accelerator pedal fully the REVERSE gear f the voltage is not at battery volts then F amp R switch has failed Stop trouble shooting here and repair the problem When the repair is completed I completely retest the vehicle before PER seen lowering
120. ning and the symbol A above denotes a warning This warning alerts the reader of a high voltage hazard that may result in injury to themselves or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task A CAUTION A box with the word CAUTION and the symbol 4 above denotes a caution and is used to inform the reader that property 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 with the Dump Bed option Page 3 Z 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 5 institutions motels mobile home parks and resorts They are not to be driven on public highways AWARNING This vehicle is not designed to be driven on public roads or highways It is available in maximum designed speeds ranging from 4 5 to 6 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 This vehicle conforms to requirements for Type E vehicles as described i
121. nly Terminal positions lowering the drive wheels to the ground on your motor may not be in the same location f the test light did not come on during either test then go to the F R Switch sequence Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Accelerator Make sure the key switch is in the OFF position then remove the key A WARNING Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground A WARNING 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 damage Rotating rear drive wheels are a potential hazard Keep hands arms A WARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury This is the accelerator module test PLUG THIS END harness part number 62 027 31 It will INTO THE HARNESS be used in the following tests These tests cannot be completed without this harness If you do not have this harness 60004 one must obtained before testing can QOO continue USE THIS END FOR TESTING PLUG THIS END INTO THE MODULE Main Sequen
122. nternal 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 TABLE OF CONTENTS Cleaning 2 eurem 2 Hine t E 3 Watering 4 REMOVING 5 Replacing 6 volt batteries only 6 Moist Charge Batteries 7 Storage and Returning to Service 8 ia pu aa aaa E 8 Returning to Service 8 AWARNING e Explosive mixtures of Hydrogen gas 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 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 is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This
123. o clean may result in property damage A WARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury AWARNING A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will Initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Fill all battery cells with electrolyte to the proper level 7 Thoroughly clean any spilled electrolyte from the batteries or the ground Refer to Cleaning the Batteries for information on cleaning the batteries 8 Reconnect the battery cables connect the batteries to the charger and allow the charger to complete one charging cycle 9 Remove the blocks from the wheels and test drive The batteries are now ready to be put into service Ba
124. of the treadle to set the brake Depress the foot interlock pedal Rotate the Key switch to the ON position Place the Forward Off Reverse switch in the desired direction of travel 6 Slowly depress the front of the treadle While driving Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection No reckless driving Do not drive this vehicle on steep inclines or where prohibited Immediately report any accidents or vehicle problems to a supervisor Loading and Unloading e Do not carry any passengers e This vehicle is designed as a tow tractor only DO NOT carry any cargo on this vehicle Towing Loads Do not exceed the towing capacity of the tractor Do not exceed the load capacity of the trailer Refer to documentation supplied with your trailer for information regarding load capacity of the trailer Make sure all loads are securely tied down Refer to documentation supplied with your trailer for information regarding attaching loads to the trailer Do not back up when towing more than one trailer Drive slowly when towing loads with a high center of gravity When turning be sure to allow for corner cutting of the trailer Allow for longer stopping distances when towing heavy loads Allow for longer stopping distances when driving down a grade Safety Rules Page 7 SAFETY RULES AND OPERATING INSTRUCTIONS Parkinq
125. on for information regarding adjusting the brake Brakes Page 5 SO TAVL TABLE OF CONTENTS Inspecting the Motor Brushes 2 Motors with internal cooling fans 2 Enclosed Motors GE no cooling fan 2 Motor Removal and Installation 3 Motor Inspection 3 Replacing the Brushes 5 Replacing the Bearings 6 Repairing the Commutator 6 Service Limits 7 Motor Service Rear Housing Circlip Brush Spring Stator Field E P Z Front Housing Brush Cover Bearing Dust Cap Brush Holder irene Typical Exploded Motor Motor Service INSPECTING THE MOTOR BRUSHES Typical motor with cooling fan indicated by the arrow Motors with internal cooling fans NOTE There are four brushes in the motor The brushes will not wear at the same rate It is recommended that all four brushes are inspected at the same time NOTE In some vehicle configurations it may not be possible to inspect all four brushes while the motor is in the vehicle Refer to Transmission Service section for information on removing the motor AWARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place block
126. operate this vehicle The Operator Training program shall include the following Operation of this vehicle under circumstances normally associated with your particular environment Emphasis on the safety of cargo and personnel All safety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator 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 Demonstrate a working knowledge of each control Understand all safety rules and guidelines as presented in this manual Know how to properly load and unload cargo Know how to properly park this vehicle Recognize an improperly maintained vehicle Demonstrate ability to handle this vehicle in all conditions Safety Rules Page 3 SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1 Headlight Switch The headlight switch is located on the left side of the instrument panel Push the top of the switch to turn the lights on Push the bottom of the switch to turn the lights off 2 Accessory Switch Opt
127. oting ez Page 12 p Abelg IM BL E O F CONTEN TS Wire Diagrams COMPLETE VEHICLE Red Main Battery Positive Main Battery Negative The charger interlock is optional and may not be installed on your vehicle If equipped with the charger interlock option the interlock relay will be located in the main charger cabinet or in a seperate module external of the charger Forward Reverse Switch 1 Isolator solenoid or contactor coil Reverse solenoid or contactor coil CB CIRCUIT BREAKER Forward solenoid or contactor coil Bs Battery Status Indicator R1 250 OHMS 5W RESISTOR View from wire side Harness Connector F Blue Black O Green Black S 3 1 m R White Black 12v negative tap 6 O O O 4 Green Black m OOO KSI 9 7 Q a L e B B TA 5 2 UG CON TROE 10A P View from pin side u
128. r charged With the fluid level at normal operating level and or the batteries charged the alarm and light will reset Safety Rules 6 SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines Only qualified and trained operators may drive this vehicle Drive only on level surfaces or on surfaces having an incline of no more than 10 5 6 degrees Drive slowly when making a turn especially if the ground is wet or when driving on an incline This vehicle may overturn easily if turned sharply or when driven at high speeds Observe all traffic regulations and speed limits Keep all body parts head arms legs inside this vehicle while it is moving Keep the vehicle under control at all times Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle atintersections blind spots or other dangerous locations Do not drive over loose objects holes or bumps Yield right of way to pedestrians and emergencies vehicles Stay in your driving lane under normal conditions maintaining a safe distance from all objects Keep a clear view ahead at all times Starting Perform all necessary vehicle preparation steps inspections or maintenance before operating this vehicle 1 Make sure the forward off reverse witch is in the center OFF position 2 Set the parking brake or depress the rear
129. rated Parts List for battery cable routing 16 It is recommended to replace the battery terminal hardware when replacing the batteries A CAUTION When torquing battery hardware use a backup wrench on the battery bolt and tighten the nut Failure to use a backup wrench may damage the battery post 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 19 Remove the blocks from the wheels and test drive Moist Charge Batteries 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 A CAUTION Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and charged Operating or charging moist charged batteries before filling and charging will damage the batteries resulting in premature failure of the batteries ACAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure t
130. rd Keep hands arms AWARNING legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Main Sequence ez Page 15 Electrical Troubleshooting Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive NOTE You may skip this test if it was completed in a previous section f the voltage is not at battery volts then check the wiring to battery negative and the 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 Connect a voltmeter across the center terminal of the forward and reverse side of the F amp R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal fully f the voltage is not at battery volts then go to the Accelerator sequence Connect a voltmeter across the forward terminal of the forward and reverse side of the F amp R switch and battery negative Close all interlock switches turn the Key Switch ON and place the F amp R Switch in forward Depress the accelerator pedal fully f the voltage is not at battery volts then the F amp R switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before loweri
131. rections plus high armature current in both directions a NOTE Field current will be very low SOLENOIDS gt Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high SOLENOIDS armature current only NOTE Field current will be very low in the opposite gt direction symptoms iy sot inn quel hes i pti een M om tee in ao RENTER BODE Jumps into high speed when direction is selected after depressing the accelerator pedal Section 4 Special Troubleshooting Table of Contents PNO CONTROL ce 2 PEUGGING DIODE cece 4 FREEWHEEL DIODE 5 DS O S 6 SOLENOIDS le tm 8 11 Special Troubleshooting ez Page 1 ELECIRICAL IROUBLESHOOTING Make sure the key switch is in the OFF position then remove the key AW ARNI N G Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground AWARNING and support the vehicle with jack stands F
132. reference only B The wire connected to the motor S2 Terminal positions on your motor terminal is shorted to the wire connected may not be in the same location to the motor A2 terminal C The wire connected to the motor S2 terminal is shorted to the wire connected to the PMC A2 terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test With the key switch on and the F amp R switch in forward depress the accelerator pedal and perform the following tests Check continuity from the wire that was connected to the PMC M terminal to the wire that was connected to the motor Motor shown for reference only S2 terminal Terminal positions on your motor may not be in the same location If you do not know how to test for continuity refer test to a qualified technician his should read as an open circuit If it reads as a short then one of the following has occurred A The forward solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S2 terminal Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test
133. rocedure Refer to Transmission Service section for information on removing the motor 2 Remove the armature Refer to Motor Inspection Disassemblysection for information on taking the motor apart 3 Press the armature bearing s off of the armature shaft A CAUTION Do not press against the outer race of the bearing Pressing against the outer race will damage the bearing and may result in premature failure of the bearing See the illustration below Inner race Outer race 4 Press new bearing s onto the shaft 5 Reassemble the motor REPAIRING THE COMMUTATOR 1 The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor 2 The armature must be removed from the motor for this procedure Refer to Motor Inspection Disassembly section for information on taking the motor apart 3 Using a lathe cut the armature just enough to remove all grooves depressions or ridges 4 Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in Service Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Motor Page 6 6 Measure the commutator undercut depth in 5 places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut
134. ront of the motor 3 Remove the armature retaining screws from the rear housing if equipped Housing screws Armature retaining screws 4 f this is an enclosed motor remove the front housing end 5 the armature out of the front end of the motor housing 4 6 Remove the nuts off of all of the terminals in the rear motor housing 7 Remove the rear motor housing being careful not to damage the field coil wires places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits above then the commutator must be undercut Refer to Repair Commutator section for information regarding undercutting the commutator Undercut Hacksaw blade Armature Incorrect Correct d Insulation O Inspect the commutator for grooves Commutator If the commutator is groved then it must machined on a lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator Motor Page 3 D 6 Motor Service Inspect the commutator for burn marks Burn marks and or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature A tool called a growler is required to reliably test for a shorte
135. ry or after completing a charging cycle Successive lower LED s will light as the battery charge diminishes When Energy i a WE Fee BATTERY the second from the bottom LED flashes the battery energy status is in ecerve energy reserve and should be placed on charge as soon as possible When the two bottom LED s are alternately flashing the batteries are Empty empty and the truck should be taken out of service and charged to avoid damaging the batteries The BSI will reset to fully charged only after a complete charge cycle is completed A complete charge cycle is defined as battery voltage exceeding 2 35 volts per cell for a minimum of 6 minutes Foot Interlock Switch Accelerator Brake Treadle Accelerator Brake Treadle Accelerator The accelerator pedal is the treadle located on the right side of the floorboard positioned under the operators right foot The treadle also functions as the brake pedal Press the front of the treadle down to increase speed release the treadle to slow down Brake The brake pedal is the treadle located on the right side of the floorboard positioned under the operators right foot The treadle also functions as the accelerator pedal Press the rear of the treadle to apply the brake The brake is automatically released when accelerating Park Brake deadman The parking brake is automatically applied when the accelerator treadle is released see Accelerator and Brake above To firml
136. s at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle Front Axle Page 2 6 Raise the front wheel s off of the ground and support with jack stands 7 Tighten the front axle until the wheel s do not spin freely To test spin the front wheel by hand The wheel should stop spinning in no more than 2 revolutions If the wheel continues to spin tighten the axle nut and repeat the test 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 Maintenance Service and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal Installation 1 Raise the front of the vehicle so that the hole for AWARNING the axle is the same height as the front wheel hub ae E 5 2 Assemble the bearing spacers into the front wheel Make sure the key switch is in the OFF hub and place the front wheel s into the fork position then remove the key Insert the axle into the front fork Place the forward reverse switch in the center OFF position 4 Install the axle nut s Refer to Adjust
137. s under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Look through the brush cover and compare the top of the brush to the top of the brush holder If it is even with or below the top of the brush holder then the brushes should be removed and measured Refer to Replacing the Brushes section for information regarding removing the motor brushes 7 If any one brush is less than or equal to the service limit specified in Service Limits then all four brushes should be replaced 8 Reconnect the main positive and negative cables at the batteries 9 Remove the blocks from behind the wheels release the park brake and test drive Motor Page 2 E LE a M as pe 5 s Top of Brush Typical brush and brush holder Enclosed Motors no cooling fan General Electric Motors Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Insert a 0 035 diameter wire through the brush inspection hole above each brush until it contacts the top of the brush Mark the wire to indicate how far it was Inserted into the motor housing Remove the wir
138. sponsible 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 Service 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 forms of recklessness are to be avoided Do not engage in horseplay Model B 2 10 shown withstake sides and steel cab with doors options HOW TO USE THIS MANUAL This manual is organized into five main sections INTRODUCTION This
139. ssembly or the recommended setting for new gears then readjust the bearings as follows To increase backlash loosen the left spanner nut and then tighten the right spanner nut the same amount To decrease backlash loosen the right spanner nut and then tighten the left spanner nut the same amount The differential bearing preload is set by measuring the case spread of the 3rd member housing As the bearing adjusting nuts are tightened the two differential bearing 22 Apply gear marking compound on both sides of 7 to 10 teeth on the ring gear caps will be pushed spread away from each other A 23 While applying resistance to the pinion shaft rotate dial indicator must be used to measure the case spread the ring gear back and forth not full revolutions as the nuts are tightened Mount the dial indicator so until a clear contact pattern is shown Compare that it is 4 inches above the top of the bearing caps and the contact pattern to the illustration on the parallel to the center line of the carrier bearings following page and reshim the pinion housing or adjust the backlash as indicated on the illustration If the pinion housing is reshimed the backlash Dial Indicator must be reset Go back and repeat ALL procedures in setting the backlash 24 Tighten the bearing cap bolts to 70 85 ft lbs F2 drive 55 70 ft lbs drive and install the spanner nut locks Tighten the spanner nut lock bolts to 12 25 ft lbs NOTE Fina
140. t surfaces Immediately and thoroughly clean any surface outside of the e Explosive mixtures of Hydrogen gas 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 cigarettes or any other sources of combustion are 9 If minimal signs of corrosion are seen then the present Always provide ample ventilation damaged paint should be stripped off and the entire in rooms where batteries are being battery compartment cleaned and repainted charged Failure to do so may result in severe bodily injury and or property damage battery that the battery electrolyte comes in contact with Failure to clean may result in property damage 10 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery A battery is a live electrical source It compartment cannot be disconnected or neutralized Do 11 Inspect the battery cables and terminals If any of not drop any tool or conductive object onto the cables or terminals show signs of corrosion the battery A conductive object that comes then they must be repaired or replaced in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode 13 Remove the blocks from the wheels and test drive resulting in severe bodily injury and or property damag
141. the Drive Chain 2 Check the Oil Level 3 Change the 3 Dive MOOT RR 4 4 iisas 4 qu 5 Remove and Install 5 Replace the Axle Bearing 5 ASC 6 usa nus ans 6 cede 6 Differential Assembly 3rd Member 8 Disassemble oos ceti 9 Re shimming the Pinion Housing 11 Exploded View 12 Typical Transmission Assembly E Serv Ission Transm Maintenance Service and Repair ADJUST THE DRIVE CHAIN AWARNING NOTE A small amount of oil may come out when __ Tie the vehicle to an immovable object to drive motor mounting bolts are loosened prevent the vehicle from moving in forward or reverse Failure to securely tie the AWARNING vehicle may result in unexpected vehicle movement resulting in severe bodily injury or property damage Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the 10 Tie the vehicle in place so that it cannot move center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 11 Reconnect the batteries
142. the bearings This makes sure that the bearings and races remain seated Cross threading the nuts will damage the correctly 3rd member housing and bearing caps If the housing and or nuts are damaged the NOTE One hole on adjusting nut approximately 0 003 change in backlash Left and right nuts MUST be turned the same amount AND in the same direction The final direction of rotation MUST be in the tightening direction to loosen a nut 1 hole back off 2 holes and then tighten 1 hole The ring gear should be rotated any time the nuts are being adjusted entire 3rd member assembly may have to be replaced 17 Install the bearing caps in their original locations and torque the bolts to 12 15 ft lbs making sure that the adjusting nuts still turn freely 18 Loosen the right side nut NOTE In the following procedure Left adjusting nut 19 Tighten the left nut until all backlash is removed refers to the nut on the ring gear side of the from the ring and pinion gear differential assembly Fight adjusting nut 20 Tighten the right nut until a case spread of 0 010 refers to the nut on the pinion gear side of is indicated on the dial indicator the differential assembly NOTE If new ring pinion gears are used refer to the recommended backlash that is supplied RING GEAR PINION GEAR with the gear set SIDE 21 Measure the backlash If the backlash is not within 0 002 of the original measurement taken on disa
143. the drive wheels off of the ground 17 Wipe off any oil that may have come from behind the motor 18 Lower the drive wheels to the ground 19 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive F2 F3 Transmission Page 2 Maintenance Service and Repair CHECK THE LEVEL The oil level in the chain case is maintained by the transmission Oil is pumped from the 3rd member into the chain case housing lt 15 not necessary to check the oil level in the chain case A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries Park the vehicle on a level surface Place a small oil drain pan under the drive housing Remove the drive housing level plug O o p 9 A small amount of oil should come out This indicates the correct oil level NOTE If a large amount of oil comes out then let it drain to the proper level and replace the level plug If no oil comes out then fill the drive to the proper level and replace the level plug Level Plug Drain Plug Typical location of oil plugs The actual location of the level plug will vary depending on your vehicles configuration
144. tteries Page 7 Maintenance Service and Repair STORAGE AND RETURNING thorag Thoroughly clean the battery and battery compartment TO SERVICE Refer to Cleaning in this section for information regarding cleaning the battery Check the electrolyte level and charge the battery Refer to Watering in this section for information regarding checking the electrolyte level ACAUTION If the batteries are removed from the vehicle do not place them directly on the ground concrete or solid metal surface It 15 recommended to store them on a wooden Store the vehicle or battery if removed in a cool dry well ventilated area If storing for more than one month the battery should pallet or equivalent Storing on the ground be charged per the table ar right concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries Returning to Service AWARNING 1 Make sure the key switch is in the OFF A CAUTION Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result position then remove the key Place the forward reverse switch in the center OFF position Confirm the electric park brake is applied in property damage property 9 Place blocks under the front wheels to prevent vehicle mo
145. ublic highways A WARNING These vehicles are not designed to be driven on public roads or highways They are available in maximum designed speeds ranging from 4 5 to 6 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 Refer to Vehicle Operational Guidelines Safety Guidelines section for important safety information regarding operating this vehicle AWARNING Read and follow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property damage Before working AWARNING on a vehicle Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries DRIVER TRAINING PROGRAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for those claiming to have previous vehicle operation experience Successful completion of the Operator Training program shall be required for all personnel who
146. uity from the motor A2 terminal to the wire that was connected to the motor S1 terminal DO NOT make this test to the S1 terminal just the wire Refer to Solenoid Figure 1 If you do not know how to test for continuity refer test to a qualified technician This should be an open circuit if it reads as a Short then one of the following has occurred Motor shown for reference A The reverse solenoid is shorted only B The wire connected to the motor St terminal is shorted to the wire connected to the motor A2 terminal C The wire connected to the motor S1 terminal is shorted to the wire connected to the PMC A2 terminal Special Troubleshooting ez Page 8 ELECIRICAL IROUBLESHOOTING 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 otherwise continue with the next test Check continuity from the motor 2 terminal to the wire that was connected to the motor S2 terminal DO NOT make this test to the S2 terminal just the wire If you do not know how to test for continuity refer test to a qualified technician This should read as an open circuit If it reads as a short then one of the following has occurred A The forward solenoid is shorted Motor shown for
147. und the entire commutator If any segment indicates an open circuit then the motor must be replaced Using the continuity function of digital multi meter check the continuity from any one of the Page 4 commutator segments and the armature frame If it is not an open circuit then the armature is shorted and the motor must be replaced 11 Rotate the motor bearing s by hand The bearing should not freewheel but should come to a smooth stop when rapidly spun by hand If the bearing freewheels then grease is no longer present in the bearing and it must be replaced Refer to Replacing the Bearings section for information regarding replacing the armature bearings Feel for any roughness when the bearing is rotated If any roughness or grinding is noticed then the bearing must be replaced Refer to Replacing the Bearings section for information regarding replacing the armature bearings Assembly NOTE If this is an enclosed motor on a vehicle with a Power Traction primary reduction then it is recommended to replace the armature shaft seal any time the motor is disassembled Push the motor brushes just far enough out of the brush holder so that the brush springs hold them in place away from the commutator See the illustration to the right Install the rear motor housing to the stator housing Lightly grease the outside diameter of the armature bearings Insert the armature through the stator housing and
148. ve to 1 Tie the chain up in position with mechanics wire as shown 2 Slip the motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove wire s holding the chain F2 F3 Transmission Page 4 Maintenance Service and Repair Replace the Axle NOTE The axle must be removed from the vehicle to replace the axle bearing Refer to section Rear Axle Remove and Install for information regarding removing the axle REAR AXLE Remove and Install AWARNING NOTE A 10 ton press is required to replace the axle Make sure the key switch is in the OFF bearing position then remove the key NOTE The axle bearing will be damaged when it is removed Place the forward reverse switch in the center OFF position AW ARNING Set the park brake The axle bearing retainer will be damaged when it is removed Do not reuse the axle bearing retainer Reinstalling the original Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and d bearing retainer may result in the axle negative cables at the batteries falling out of the transmission resulting in severe bodily injury or property damage A WARNING Always use a lifting strap hoist and Jack stands of adequate capacity to lift and support the vehicle Failure to use lifting AWARNING Old axle bearings may explode while being remo
149. ved Place a cage around the axle bearing that will contain all debris if the bearing explodes Failure to place a cage around the axle bearing could result severe bodily injury or property damage and support devices of rated load capacity may result in severe bodily injury 6 Raise the drive wheel off of the ground Remove the wheel assembly La 1 Place the axle press remove the bearing 10 11 12 13 axle housing Remove the four axle retaining bolts Secure the brake body assembly do not let it hang by the brake hose Using a slide hammer remove the axle from the axle housing Remove the bearing gasket and axle seal from the housing Install the axle in reverse order using a new gasket and seal Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive and bearing retainer Lightly lubricate the axle shaft Install a new bearing and bearing retainer and press into place NOTE Some axle configurations have an o ring around the axle bearing The bearing should be orientated so that the o ring is farthest away from the axle hub See the illustration below F2 F3 Transmission Page 5 Maintenance Service and Repair CHAIN CASE NOTE Some vehicle configurations may require that the transmission be removed to disassemble the chain case Refer to section Transmission Assembly for
150. vement AWARNING e Explosive mixtures of Hydrogen gas are present within battery cells at all times Do 6 not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are 7 Checkthe electrolyte level and charge the battery present Always provide ample ventilation Refer to Watering in this section for information in rooms where batteries are being regarding checking the electrolyte level charged Failure to do so may result in 8 Test the battery Refer to Testing section for severe bodily injury and or property information on testing the battery damage Disconnect the main positive and negative cables at the batteries Thoroughly clean the battery and battery compartment Refer to Cleaning in this section for information regarding cleaning the battery 9 he battery is now ready to be put back into A battery is a live electrical source It service cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will Storage initiate a short circuit of the battery This Charging Interval could cause the battery to explode Temperature months resulting in severe bodily injury and or CF property damage Battery electrolyte is poisonous a
151. wn for reference MS 1 only only The type of solenoid in your e f the voltage is not at battery volts then truck may look different go to the Key Switch sequence f the voltage is at battery volts and the ISO solenoid does not pick up click then the ISO solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Main Sequence ez Page 6 Electrical Troubleshooting Control Wire inputs continued Connect a voltmeter across the PMC 2 terminal and battery negative Close all interlock switches turn the Key Switch Y The voltage shown is for illustration ON and place the F amp R Switch in Forward only The actual voltage may vary Depress the accelerator pedal to engage MS 1 only f the voltage is not between 6 0 and 6 5 app volts then go to the Accelerator KI B B sequence aM Depress the pedal fully M Main Battery f the voltage 15 not between 11 0 and 11 5 volts then go to the Accelerator 5 sequence FLUKE 79 semen Connect voltmeter across the PMC KSI terminal and battery negative With the pedal still fully depressed e f the voltage is not at battery volts then go to the Key Switch sequence The voltage shown is
152. y set the parking brake push down on the rear of the treadle after the vehicle has come to a complete stop The brake automatically releases when the front of the treadle is depressed Foot Interlock Switch A switch or pedal located under the driver s left foot disables the power to the vehicle when it is released The switch or pedal must be depressed for the vehicle to operate Whenever the driver leaves the vehicle the driver should turn the key switch off place the forward off reverse switch in the center OFF position and set the park brake Safety Rules Page 5 SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise 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 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 Inspectthe fluid levelin 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 filled and o
153. your charger or contact the charger manufacturer for more information Charging Time Average charging time is 8 to 10 hours The time required to fully charge your batteries will vary depending on Capacity of the batteries higher capacity requires longer charge time 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 Temperature low temperatures require longer charge time It is not unusual for charge times to exceed 15 hours especially with new batteries AWARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A CAUTION The key switch must be in the OFF position when charging the batteries Failure to turn the key switch OFF may result in damage to the vehicles electrical system 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

E4-50_SN# 137548 & UP

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E4-50_SN# 137548 &amp; UP

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E4-50_SN# 137548 & UP