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Taylor Dunn B-100 Manual

1. Seat Cushions Deck and Lights ITEM PART DESCRIPTION QTY 1 94 035 01 Trim strip 7 2 90 147 10 Seat cushion black 0 or 1 2b 90 147 20 Seat cushion tan 0 or 1 3 90 411 25 Deck board 1 4a 90 147 10 Seat cushion black 0 or 1 4b 90 147 20 Seat cushion tan 0 or 1 5 94 035 01 Trim strip 11 6 94 201 00 T D Emblem 1 Notshown 88 567 91 Push clips for 6 3 7 98 240 04 Anti skid tape 16 8a 90 179 10 Seat back tan 0 orl 86 90 179 00 Seat back black or 1 9 94 035 01 Trim strip T 10a 90 179 10 Seat back tan or 1 105 90 179 00 Seat back black 1 90 134 10 Bench seat Tan 0 or 1 116 90 134 05 Bench seat black or 1 12 01 110 16 Cover plate 1 Not shown 88 837 09 Seat back screws 6 or 12 13 72 005 00 Headlight assembly includes a b c d e and bracket 1 13a 88 089 80 5 16NC Hex nut 2 136 88 088 62 5 16 Split lock washer 2 13c 88 080 16 5 16NC x 2 Hex bolt 1 13d 88 082 09 5 16NC x 5 8 Carraige bolt 1 13e 72 072 00 Replacement bulb 1 14 72 022 00 Tail light includes 15 and 16 1 15 72 022 51 Tail light gasket 1 N
2. FWD REV Curtis PMC Troubleshooting Connect the test light across the Normally Closed contacts of the Forward solenoid Refer to your vehicles wiring FWD REV 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 e f light comes on then the Forward 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 So lenoiduateshown t eot to the ground The type and position of the forward solenoid in your truck may be 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 Reverse does not run in forward The voltage shown is for illustration Connect a voltmeter across the PMC KSI terminal and batte only The actual voltage may vary negative Close all interlock switches turn the Key Switch ON and place
3. ITEM PART DESCRIPTION QTY 1 88 060 11 x 1 Hex bolt 8 2 88 060 15 1 4NC x 1 3 4 Hex bolt 4 3 88 060 18 x 2 1 2 Hex bolt 4 4 88 068 60 1 4 Cut flast washer 16 5 88 069 81 Nylon lock nut 8 6 91 028 73 Front 1 7 91 028 75 Spacer 2 8 91 110 00 Sun top 1 9 97 211 20 U nut 8 10a 91 028 10 Rear support B 125 0 or 1 10b 91 028 73 Rear support B 100 0 or 1 88 080 11 5 16NC x 1 Hex bolt B 125 8 12 88 080 60 5 16 Cut flat washer B 125 8 13 88 089 81 5 16NC Lock nut B 125 8 14 90 825 71 Windshield includes plastic brackets 1 15 90 547 12 Windshield frame 1 16 90 810 07 Windshield frame brackets 4 17 88 060 09 x 3 4 Hex bolt 4 18 88 828 09 10 x 3 4 Sheet metal screw holds plastic bracket to windshield frame 2 19 98 454 00 Foam Tape pus SECTION 5 PAGE 43 MB 100 00 Mirrors Windshield Frame ref oo Front Cowl ref SECTION 5 PAGE 44 MB 100 00 Mirrors ITEM PART DESCRIPTIO
4. D Section 3 Page 15 MB 100 00 Front Axle Removal and Installation 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING _ tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Remove both front wheels Remove the tie rod from the steering yokes Remove the bolts holding the leaf springs to the Steering Yoke frame NOTE Support the axle with additional stands 10 Remove the axle from the vehicle NOTE If the leaf sorings were removed from the axle be sure to leave the u bolts loose until the axle is mounted to the frame Ball Joint 11 Install in
5. Strobe Light ITEM PART DESCRIPTION QTY 1 98 603 00 Grommet 1 2 96 624 00 Wire clip 2 Notshown 88 737 09 Pop rivet for 2 2 3 72 023 20 Strobe light assembly includes 9 and 711 1 Not shown 72 023 21 Flash tube for 3 Not shown 72 023 22 Amber lens for 3 Not shown 72 023 23 Red lense for 3 4 75 110 10 Harness 1 5 91 028 67 Pole 1 6 88 065 13 x 1 1 4 Phillips head truss screw 4 7 88 069 82 NC lock nut 4 8 88 025 08 8 32 x 5 8 Machine screw 3 9 Included in 3 Gasket 10 88 028 62 8 Split lock washer 3 1 Included in 3 Metal ring I2 88 029 80 8 Hex nut 3 13 88 065 08 1 4NC x 5 8 Phillips Truss head screw 4 14 88 068 61 1 4 SAE flat washer 4 15 88 068 62 1 4 Split lock waser 4 16 88 069 83 1 4NC Acorn nut 4 17 72 023 27 Mounting bracket for sun top 1 Seal 1 4 hardware with 94 400 02 sealant to prevent leaks through the sun top SECTION 5 PAGE 41 MB 100 00 sun Top and Windshield 3 4 5 14 11 12 15 1 4 9 Windshield mounting bracket 1 of 4 Top left shown SECTION 5 PAGE 42 MB 100 00 sun Top and Windshield
6. 8 Towing This Vehicle 8 Charging your vehicle 9 Signet Charger Operation Model HB Series 9 Signet Charger Operation Model HBS series 9 Lestronic II Charger Operation 10 New Battery 10 Charging 10 Storing Returning to Service 10 Storme Your Vehicle 10 to Service ior E VR MEUM 10 Periodic Maintenance Checklist 11 Daily Visual inspection 12 Maintenance Guidelines for Severe Duty Applications 12 Un E NEN SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM Occupancy Dimensions Turning Radius Dry Weight no batteries Min Max Battery Weights Maximum Load Deck dimensions Electrical System Transmission Motor DC Brakes Steering Tires Frame Instrumentation Light Accessories Charger Specifications are subject to change without notice MODEL B 1 00 B 1 25 SPECIFICATION Driver 3 passengers Driver 1 passenger 241L x 112W centimeters 94 875L x 44 25W inches 335 Centimeters 132 Inches 336 kg 741 Ibs 334 kg 737 Ibs 174 kg to 195 kg 384 105 to 432 Ibs 363 kg 800 Ibs none 110 5W x 121 9L Centimeters 43 5W x 48L Inches Six 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 275 Amp Helical Gear Cil Bath
7. SECTION 5 PAGE 47 MB 100 00 Tool Box B 100 SECTION 5 PAGE 48 MB 100 00 Tool Box B 1 00 ITEM PART DESCRIPTION QTY 1 71 040 95 Lock assembly 1 2 90 547 14 Tool box 1 Not shown 88 065 13 x 1 1 4 Phillpips truss head screw 4 Not shown 97 211 20 1 4NC U nut 4 SECTION 5 PAGE 49 MB 100 00 Signet Charger Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART Z DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector SECTION 5 PAGE 50 Contents Appendix A Special Tools 2 Appendix B Suggested Torque Limits for Standard Hardware 3 Hardware Identification 3 Standard Head Markings
8. low It must be within 85 137VAC or 170 264VAC Extremely discharged battery defective battery miswired battery When this fault occurs the charger will operate in a low current mode untill the battery voltage 15 built up This fault will reset once the battery 6 Low battery voltage voltage is normal If the battery voltage does not come up gt Test the batteries gt Check battery wiring These faults will be accompanied by an audible beep and indicates that the charge cycle was termintated before completion nu A CE signet Charger Troubleshooting Page 5 Electrical Troubleshooting TROUBLESHOOTING NOTE There are no internally serviceable components in the charger Totest charger operation Connect a DC volt meter to the main battery positive and negative terminals Attach a clamp on DC Ammeter to one of the charger DC output wires Plug the charger into an AC outlet Wait for charger to start up to 15 seconds the ammeter should display the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals V1 When the batte
9. replaced The presence of solder in either of 13 Spin the bearing by hand If any vibration the two areas indicates that the armature was or roughness Is felt it must be replaced overheated 14 Reassemble the motor in reverse order 10 Inspect the armature for grooves 15 Install the motor Note If the armature is grooved then the grooves may be removed with the use of a lathe Hacksaw blade Incorrect v Insulation Undercut for 0 049 00 and 0 054 00 Motors Undercut Figure The left side shows how to properly cut the mica using a hacksaw blade The right side of the figure shows the minimum diameter of the commutator and the proper mica depth Section 3 Page 38 MB 100 00 Replacing the Brushes 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the armature Hemove the four cover retaining screws 8 Remove the end cap from the motor revealing the brush holder and brushes 9 Unfasten the brush holder retainer screws and remove the brush holder NOTE Be sure to remember the position of the crossov
10. 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 AWARNING 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 Page 11 SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection Tire condition and pressure External frame damage body Operation of all lights and warning alarms and or horns omooth and proper operation of all controls such as but not limited to Accelerator pedal Brake pedal Steering Parking 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 FOH 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
11. The service personnel are responsible for the service and maintenance of the vehicle At no time should a service person allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training At no time should an untrained individual be allowed to service or repair a vehicle without supervision This manual is not a training guide Of the Passengers The passengers are responsible to remain fully seated keeping their hands arms and legs inside the vehicle at all times Each passenger should be fully aware of the vehicle s operation All forms of recklessness are to be avoided Do not engage in horseplay 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 section describes how to use this service manual and how to identify your vehicle Safety Rules and Operating Instructions This section outlines the safety and operational issues location and operation of controls and the operational checks that are to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific information on the servicing of the vehicle and a schedule
12. dec Description Lubricant Type Front Leaf Springs General Purpose Grease 2 King Pin General Purpose Grease 3 Ball Joints General Purpose Grease 4 Front Wheel Bearings High Temperature W heel Bearing Grease 5 Rear Leaf Springs General Purpose Grease 6 Drive Drain Plug 10 oz 30 wt Motor Oil Section 3 Page 4 MB 100 00 TROUBLESHOOTING GUIDE 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 Steer Gear Needs Adjusting Steer Gear Needs To Be Replaced Excessive Steering Play Worn Ball Joints Mis Adjusted or Worn Steering Gear Loose Steering Linkage Steer Gear Needs Adjusting Steer Gear Needs To Be Replaced Lack of Power or Slow Operation Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Defective Speed Control or Motor Defective Batteries or Charger Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Moto
13. Control Wire Inputs The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause A WARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive The voltage shown 15 for illustration If the voltage is not at battery volts then check the only The actual voltage may vary wiring to battery negative and the negative circuit breaker Stop trouble shooting here and repair the 3400 Solenoids are shown for reference problem When the repair is completed completely only The type of solenoid in your retest the vehicle before lowering the drive wheels to the ground Positive Connect a voltmeter across the ISO solenoid coil terminals Close all interlock switch
14. MB 100 00 10 Reinstall the steering gear by performing this procedure in reverse order Always use new locknuts Locknuts become less effective if used more A WARNING than once Failure to replace the locknuts may result in the locknuts or bolts coming loose causing property damage and or severe bodily 11 Using the appropriate procedure center the steering gear 12 Check the front wheels to be sure that they are straight and realign as necessary 13 Lower the vehicle 14 Reconnect the main positive and negative at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle E pr AX Steering Wheel Dust Washer Bearing Steering Column Steering Shaft Shaft Collar Pinch Bolt Steering Gear 7 Lock Washer NOTE he steering column is welded to the frame Joint Clamp NS Ball Joint EY Drag Link Section 3 Page 24 MB 100 00 STEERING ADJUSTMENT Worm Shaft Jam Nut Gear Lash Juster Worm Bearing Adjuster Input Shaft Endplay 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables a
15. 13 Reconnect the main positive and negative at Front Measurement _ the batteries 14 Remove the blocks from behind the wheels Tie Rod 15 Release the park brake and test drive the vehicle Ball Joints Rear Measure Section 3 Page 17 MB 100 00 Centering the Steering Gear 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Turn the steering gear all the way to the left 8 Turn the steering gear back three turns and secure it so it can not move 9 order to align the wheels adjust the drag link 10 Lower the vehicle 11 Reconnect the main positive and negative at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle Typical steering gear and pitman
16. B 1 25 Models Inlcuded The Best Way B0 011 00 B 1 00 Tour Master To Go B0 011 25 B 1 25 Carry Master About Your Business MANUAL MB 100 00 Operation Troubleshooting and Replacement Parts Manual Published 12 15 2003 Revision E Serial number Starting 142833 Taylor Dunn Contact information Service Parts Sales Taylor Dunn has a network of dealers distributed around the globe to support our vehicles Information regarding vehicle sales replacement parts or service should be obtained through your local dealer A dealer locator can be found on the Taylor Dunn website at www taylor dunn com If you do not have access to the internet you can call the factory direct at 01 714 956 4040 Feedback regarding this or any Taylor Dunn vehicle manual can be sent to Taylor Dunn Manufacturing Attn Tech Writer 2114 West Ball Road Anaheim CA 92804 B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides P2 50 30 000 Pound Tow Tractor ET 3000 50 Full Size Truck Section Index Model B0 01 1 00 and 0 01 1 25 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions Lubrication Brakes Service Steering Front Axle Transaxle Service Motor Service Battery Service Control System Troubleshooting O uo od Wire diagram Chargers Illustrated Parts 11 Appendix A Special Tools
17. Other nuts used by Taylor Dunn should be treated as S A E grade A Appendixes Appendix B Page 4 Suggested Torque Values non critical hardware Diameter Grade2 Grade 5 Grade 8 L 9 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque ft lb ft lb ft lb ft lb 1 4 20 4 7 7 10 10 14 11 1 4 28 5 8 8 12 11 16 12 5 16 18 19 14 14 21 20 29 22 5 16 24 10 15 15 23 22 33 25 3 8 16 16 24 25 27 35 52 40 3 8 24 18 27 28 42 40 59 45 7 16 14 26 38 40 59 56 84 65 7 16 20 29 43 44 66 62 93 70 1 2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 138 207 213 319 301 451 350 3 4 16 154 231 238 357 336 504 390 7 8 9 222 334 344 515 485 728 565 7 8 14 245 367 379 568 534 802 625 1 8 333 500 515 773 727 1091 850 1 14 373 560 577 866 815 1222 1930 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
18. 5 is located 10 in the top of the steering column tube Ref Steering Gear SECTION 5 PAGE 6 MB 100 00 Steering Column ITEM PART DESCRIPTION QTY 1 88 199 82 5 8 NF Hex Jam Nut 1 2 19 011 30 Steering Wheel 1 3 88 081 14 Bolt Plated grade 8 1 4 88 089 84 Nut Plated grade 8 1 5 80 400 10 Bushing 1 6 20 031 63 Steering shaft includes 3 4 1 7 19 011 35 Steering Wheel Cover 1 8 88 128 62 7 16 Split Lock Washer 3 9 88 120 11 7 16 NC x 1 Hex Bolt Grade 5 3 10 97 200 00 Dust Washer 1 Not Shown 01 200 84 Steering Column Cover 1 SECTION 5 PAGE 7 MB 100 00 Steering Gear See steering linkage SECTION 5 PAGE 8 MB 100 00 Steering Gear ITEM PART DESCRIPTION QTY 18 308 21 Steeering Gear Assembly 1 1 18 308 70 Locking Ring 1 2 18 308 71 Adjuster 1 3 18 308 72 Wo
19. EY Sy Q O KEY SWITCH COLD Violet Wires s QO C bv Red wire s BATTERY MAIN NEGATIVE Page 11 Curtis PMC Troubleshooting Forward and Reverse Side For your reference shown at the right are the Forward and KSI Side NEUE Reverse switch wire connections for a typical control system Violet Black Green Black Do CM 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 The HOT terminal is the Violet Black side of the F amp R switch and battery 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 Connect a voltmeter across one of the COLD terminals of the KSI side of the F amp R switch and battery negative E EN ENT Close all interlock switches turn the Key Switch ON Nolet Black wire ou either and place the F amp R Switch in Forward a end of the switch e 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 completely retest the vehicle before lowering the drive wheels to the ground e f the voltage is at battery volts and the test at the PMC KSI termin
20. Forward Reverse Switch The forward reverse switch located on the instrument panel determines the direction of travel of the vehicle Push the top of the switch to make the vehicle travel forward Push the bottom of the switch to travel in reverse DO NOT SHIFT from forward to reverse or vice versa while the vehicle is in motion Make sure the vehicle is completely stopped before shifting The forward reverse switch should be in the center off position with key switch off and the park brake set whenever the operator leaves the driver s seat Accelerator Pedal The accelerator pedal is located to the right of the brake pedal It controls the speed of the vehicle and operates the same way as the accelerator pedal in an automobile Depress the pedal to increase speed and release the pedal to decrease speed Seat Interlock Switch A switch located under the driver s seat disables the vehicle when the driver leaves the seat The driver must be seated for the vehicle to operate The switch is a part of the vehicle safety system It should not be relied upon as the sole safety feature used to disable or disengage this vehicle Whenever the driver leaves the seat they should turn the key switch off place the forward reverse switch in the center off position and set the park brake safety Rules Page 4 SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system is an automotive type To turn rig
21. J wepo SWITCH L LH STROBE SWITCH z 5 Brown White 5 ea E 5 425 ocz 75 5 ea Control Panel Brown White m NOTE CHARGER I ISOLATOR COIL CORD F FORWARD COIL REVERSE BSI BATTERY STATUS INDICATOR OPTIONAL ACCESSORIES 12V Control Panel ccessory negative re Black White White White S N Green Control Panel Wire Diagrams e Page 2 Blue Black Gray White REVERSE ALARM Blue White NP HORN Control Panel White Typical wiring diagram for model B 1 00 and B 1 25 TABLE OF CONTENTS Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Troubleshooting Lestronic 1
22. M 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 the 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 otop here and repair the problem otherwise continue with the 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
23. Safety Rules and Guidelines Operational Information Operator Responsibilities 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 responsible for the overall maintenance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance performed on the vehicle OSHA Regulation 29 CFR 1910 178 Powered Industrial Truck Operator Training Of the Operator The operator is responsible for the safe operation of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel
24. 10 Programmer used on early model C4 25 Huskey GE 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 kets f AMP Pin Removing sed to remove pins and sockets from connectors 75440 55 Used i kets f MOLEX i Pin Removing Tool sed to remove pins and sockets from MO connectors 75442 55 Used to check th ifi 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 Plate Depressor the steering gear on trucks equipped with the tilt steering 96 500 39 Fork Collar Weld Jig _ en replacing the fork collar on models MX 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 Used to solder the aluminum field wire to the field stud For Solder K
25. 14 Hear SUSPENSION e iate 16 RUE RES UE ORT ERE 18 Brake Accelerator Linkage 20 Wheels and Tires 22 Instrument Panel 24 Speed Control Panel 26 Miscellaneous Electrical 28 Lester Charger 30 SONETON GET ove oeste deer Pei 32 INS SIENTO 34 Seat Cushions Lights and Deck 36 Decal Uie ri t 38 SOS IGE oca iE na nn n 40 Sun Top and Windshield 42 qe 44 B 125 Stake Sides B 100 Luggage Rack 46 TOOL BOX 100 48 50 MB 100 00 Front Axle and Steering Knuckle SECTION 5 PAGE2 MB 100 00 Front Axle and Steering ITEM PART DESCRIPTION QTY 1 15 210 00 Axle beam 1 2 14 210 98 Left side yoke 1 3 14 210 99 Right side yoke 1 4 88 527 11 Cotter pin 2 5 92 104 00 Bearing cap 2 6 32
26. 240 55 King pin bushing 4 y 97 180 55 Thrust washer 4 8 21 020 15 King pin 2 9 88 189 81 Nut 2 10 11 12 13 14 15 12 124 00 Hub includes 16 18 and one 17 2 16 45 338 00 Grease seal 2 17 80 017 00 Bearing 4 18 80 103 00 Race 4 19 88 228 61 3 4 SAE Flat washer 2 20 88 239 85 3 ANF Castle nut 2 SECTION 5 PAGE 3 MB 100 00 Steering Linkage SECTION 5 PAGE 4 MB 100 00 Steering Linkage ITEM PART DESCRIPTION QTY 1 18 308 21 Steering gear box 1 2 88 279 82 7 8NF Hex nut 1 3 88 268 62 7 8 Split lock washer 1 4 5 01 110 21 Drag link 1 6 See Steering Column 3 7 86 501 98 Ball joint 2 8 86 510 00 Ball joint clamp 4 9 86 501 99 Ball joint 2 10 18 111 30 Pitman arm 1 11 See Steering Column 3 12 See amp 5 13 88 159 85 1 2 Castle nut 4 14 88 527 11 Cotter pin 4 15 18 041 00 Stering linkage 1 SECTION 5 5 MB 100 00 Steering Column The steering column 15 an integral part of the frame and 15 not shown Part
27. 5 27 2 Motor mounting GT Dana 6 5 7 78 84 8 8 9 5 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 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 However there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as if they do contain asbestos Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to m
28. 993 1489 1610 2414 3330 Appendixes Appendixes Appendix B Page 5 Appendixes Suggested Torque Values critical hardware Torque Table Torque Range Group Description Ft Lbs In Lbs Nm Brakes Brake bolt disc brake body 11 11 132 132 15 15 Brake line tube nut fittings 12 13 144 156 16 3 17 7 Brake spider bolts Dana 160mm hyd brakes 25 35 300 420 34 47 6 Brake spider bolts Dana 160mm mech brakes 15 19 180 228 20 4 25 8 Brake spider bolts Dana 7x1 3 4 brakes 16 20 192 240 21 8 27 2 Electrical Battery terminals 8 9 96 108 10 9 122 Front Axle Front spindle nut Note Refer to maintenance section in the service manual King pin Note Refer to maintenance section in the service manual Rear Axle Transmission 3rd member Gear case cover GT drive 45 50 540 600 61 2 68 Axle bolt GT drive 275 275 3300 3300 3 4 374 Axle hub nut Dana 95 115 1140 1380 129 2 156 4 Axle tube to center section Dana 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
29. AC wires from the circuit board to the AC plug If you find an open circuit in any one of the three wires then the AC cord or plug has been damaged Stop here and repair the problem 11 Install the charger end cap where the AC wires enter Wires from the AC cord If both the AC and DC tests are good then the charger has failed There are no internally serviceable components in the charger If the charger has failed then it must be replaced signet Charger Troubleshooting Page 6 Rev Charger Models HBS 600 HBS 1000 TABLE OF CONTENTS 2 2 2 Test Equipment Required for Troubleshooting 2 Important Notes and Instructions 2 Operating Instructions and Theory of Operation 3 Testing the Charging Cycle 4 Status Light Error Code Table 5 Troubleshooting 6 ACAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries Signet Charger Troubleshooting Electrical Troubleshooting DE
30. Automotive Type Hypoid Differential 4 47 kW 6 Horse Power intermittant duty Rear Wheel Mechanical Drum Hand Operated Park Brake Automotive Steering 24 1 5 70 x 8 Load Range B Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Key Switch Horn Button Forward Reverse Switch Brake Lights Built In 1kKW dual voltage 110 220 vac 15 Amp This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 safety Rules SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDELINES Itis the responsibility of the owner of this vehicle to assure that the 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 8 and listed below These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks and resorts They are not to be driven on public highways A WARNING This vehicle is not designed to be driven on public roads or highways It is available in maximum designed speed of 12 mph Do not exceed the maximum designed
31. DC output wires Plug the charger into an AC outlet Wait for charger to start up to15 seconds the ammeter should display the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals 2 55 VPC When the battery voltage equals 2 55 VPC the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on Make sure key switch is in the OFF position then remove the key AW ARNI N G 2 Placethe forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the charger from the AC source 6 Remove the charger end cap where the DC wires enter 7 Test the voltage across the Battery Positive red and Battery Negative black wires at the lower left of the charger circuit board This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires to the batteries have been damaged Stop here and repair the problem 8 Reinstall the charger end cap where the DC wires enter 9 Remove the charger end cap where the AC wires enter 10 Test the continuity of all three
32. 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 Key Switch A key switch located at the front of the instrument panel turns on the vehicle Rotate the key clockwise to turn the vehicle counterclockwise to turn the vehicle off ai POWER X The key switch should be in the off position whenever the operator leaves the driver s seat 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
33. arm Section 3 Page 18 MB 100 00 REPAIRING THE FRONT AXLE Steering Yoke Bushings 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING 1 toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 While supporting the yoke remove the king pin nut king pin and thrust washers Remove the yoke from the axle 9 Clean and or replace all bearings nuts washers and bushings NOTE Bushings must be reamed NOTE Both the left and right side bearings should be replaced as a set 10 Using new cotter pins install in reverse order 11 Lower the vehicle 12 Reconnect the main positive and negative at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Flange Bushing Bearing Pack Bushing Lug Nut Bearing MB 100 00 Ball Joints It is recommended to replace the left and right side ball joints as a set 1 Make sure the key switch is in the OF
34. 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 TABLE OF CONTENTS c otandard Specifications 2 c safety Rules and Guidelines 3 Driver Training Program 3 Driver Qualifications o ERR 3 Vehicle Controls 4 Er Key Switch 22 rtr dade 4 Forward Reverse Switch 4 Accelerator Pedal 4 Seat Interlock 4 Un E 5 Foot Brake Pedal 5 Park Brake ERRLR 3 Horn Button EUER 5 Charger Interlock 5 Headlights and Accessories optional 6 Hour Meter 2 optional 6 Battery Status Indicator 1 optional 6 Lu Vehicle Operational Guidelines 7 Safety Ciuldelies iiimmm 7 Stanin errin eaa T TE IEIET anana 7 While driving 7 Loading and Unloading 7 Un Towing Lods esiste Rae t RED 7 I
35. 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 e Conventions oymbols 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 4 above denotes 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 Warning and the symbol 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 denotes 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
36. ft Ibs to seat the bearings c Back off spindle nut one flat until the hub turns but is not loose then install a new cotter pin 13 Install the dust cap 14 Reinstall the brake bodies and the tire wheel assembly 15 Lower the vehicle 16 Reconnect the main positive and negative at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Section 3 C Page 22 MB 100 00 Removal and Installation of the Steering Gear Assembly 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Remove the pinch bolt Pinch 8 Disconnect the drag link from the pitman arm Bolt 4 T7 E Steering Gear Input Shaft Drag Link 9 Remove the three bolts connecting the steering gear to the steering column and remove the steering column from the vehicle Pitman Arm Section 3 Page 23
37. 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 only The actual voltage may vary Main Battery Positive Connect voltmeter across the PMC B terminal and the PMC B terminal Close all interlock switches turn the Key Switch ON The voltage shown is for illustration and place the F amp R Switch in Forward IMS only The actual voltage may vary Depress the accelerator pedal to engage MS 1 only i e 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 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 Page 8 Curtis PMC Troubleshooting Motor The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause A WARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms
38. is in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting e Battery volts Full voltage available at the batteries at the time of the test being performed There are no internally serviceable components in the charger If the charger has failed then it must be replaced This charger is rated for 115 VAC or 230 VAC operation When switching from one input voltage to the other wait until all three status LED s CAUTION are off Switching voltage when any of the LED s are on will result in damage to the charger signet Charger Troubleshooting Page 4 Electrical Troubleshooting 24 STATUS LED ERROR CODE TABLE There are three status lights LED s on the charger name plate These LED s normally indicate the current operating state of the charger If all three LED s are flashing it indicate an error has occurred in the charging cycle See the table below for an explanation of the error codes Note If only the 100 LED 15 flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of Defective battery or batteries Excessively discharged batteries Oversize batteries Desc
39. jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING 1 _ tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Release the park brake Loosen the jam nut on the brake linkage 9 Tighten the adjusting bolt until most of the slack is removed from the cables Jam Nut NOTE There should be some slack in the brake cables Do not overtighten the brake cables Overtightening of the adjusting bolt and the Adjusting cables will result in brake drag and premature Bolt failure of the brake shoes 10 Tighten the jam nut against the clevis and lower the vehicle 11 Check the brake pedal to see that the park brake lock engages with medium pressure on the lower half of the pedal 12 Check the travel of the brake pedal It should have about 1 2 of travel before it engages the brakes 13 Lower the vehicle 14 Set the park brake 15 Reconnect the main positive and negative at the batteries 16 Remove the blocks from behind the wheels 17 Test drive the vehicle Section 3 Page 14 MB 100 00 AXLE AND STEERING LEFT SIDE SHOWN fo Leaf Axle Weld Right Front Axle Yoke Left Front __ Axle Yoke B un _ 2 4 PS ig
40. 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 here should be continuity on each commutator segment If an open Hold this lead segment is found the armature is bad in place CN 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 completely retest the vehicle before lowering the drive wheels to the ground Commutator STOP otop 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 Page 30 e Wire Diagrams NOTE The interlock relay may be external of the charger cabinet Green 2 Charger Interlock Relay Contacts Le V D Violet Black Green Black Violet Black Blue Black CHARGER L al d gt W hite Green Black 2 Control Panel 5 O MT ET 8 ES L A SEAT Violet Black ZB KSI Red White Violet Black METER a g Red White Red White 2 SWITCH Violet Black a A Red Red LIGHT K
41. on the PMC control and tape it off to prevent electrical contact Connect a volt meter across the PMC 2 voltage shown is for illustration terminal and battery negative Turn the key switch on close all interlock switches if equipped depress the AAN accelerator pedal to engage the first micro only The actual voltage may vary switch only creep speed then perform the E following tests AM TEE The meter reading should be between 6 CERE B and 6 5 volts e f the voltage at pin 2 is not 6 to 6 5 volts A2 then go to the ACCELERATOR sequence Main Battery Negative in the Main Troubleshooting Sequence otherwise continue with the next test Page 20 Curtis PMC Troubleshooting Connect a volt meter across the and Ux rece M terminals jh 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 he meter reading should not be equal to the battery voltage 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 sh
42. printing SECTION 5 1222 PAGE 15 MB 100 00 Rear Suspension SECTION 5 PAGE 16 MB 100 00 Rear Suspension ITEM PART DESCRIPTION QTY 1 96 248 00 9 16NF x 3 Bolt 2 2 88 169 82 9 16NF Hex lock nut grade 2 3 88 149 81 1 2NC Hex lock nut 4 4 96 120 00 1 2NC x 1 7 8 x 2 U bolt 2 5 88 149 81 1 2NC Hex lock nut 4 6 85 506 15 Leaf spring 2 7 01 110 32 Spacer 2 8 88 140 25 1 2NC x 4 1 2 Hex bolt 4 9 32 213 00 Spring eye bushing 2 SECTION 5 PAGE 17 MB 100 00 Motor SECTION 5 PAGE 18 MB 100 00 Motor GE 5BC58JBS6129A ITEM PART DESCRIPTION QTY 70 049 05 Complete motor assembly does not include 11 1 70 201 15 Field coils mounted in motor housing 1 2 70 210 51 Inulator 2 3 85 412 00 Brush spring 4 4 70 172 15 Brush holder includes 3 1 5 70 104 15 Motor brush 2 2 6 70 210 51 Insulator 2 d 32 508 15 Bearing retainer 1 8 80 209 00 Bearing 1 9 88 089 91 5 16NC Jam nut 4 10 88 088 61 5 16 SA
43. than 12 hours if he vehicle is equipped with batteries larger than 220 Amp hour capacity The charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger One or more defective cells in the battery pack A brownout drop in AC line voltage during the charging cycle electrically noisy charging environment NOTE This charger has a maintenance mode that will restart the charger if the battery voltage drops below a threshold after the charge cycle is complete In some cases it may appear that the charger 15 not turning off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but still show symptoms of overcharging if he electrolyte in the batteries is too high boil over he electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and charging current during the charging cycle as indicated below Using a digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 1096 of the DC output current see previous page until the battery voltage reaches V1 When the voltage reaches V1 the charging current will dr
44. the charger to the AC source Insert the DC charger plug into the DC receptacle and perform the following tests High Voltage inside the charger Do not touch any internal components AW ARN NG while the charger is plugged in Failure to do so may result in serious bodily injury e Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the DC cord is bad Stop here and repair the problem Test the voltage across the white and black wires that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the AC cord is bad Stop here and repair the problem e f the timer relay does not pickup click within 5 seconds of connecting the DC charger plug then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem Testthe AC voltage across the transformer primary circuit This voltage should be the same as the rated AC voltage of the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Transformer Secondary Circuit Test the AC voltage across the transformer secondary circuit The voltage here will vary depending on the state of charge in the batteries The voltage should be b
45. 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 A WARNING The park brake should be disabled for servicing or towing procedures only Do not operate the vehicle while the automatic park brake is disabled Operating the vehicle with the automatic park brake disabled could lead to severe bodily injury and or property damage 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 Signet Charger Operation Model HB Series The Signet HB series chargers use a semi automatic charging system The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Refer to the data plate on the charger for the voltage and type power required for the charg
46. turn the Key Switch ON Depress the accelerator pedal fully If 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 If 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 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 Solenoids are shown for reference only The type of solenoid in your truck may look different CN GLR 920 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 15 Curtis PMC Troubleshooting 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 e f the voltage is not at battery volts then go to the Key Switch sequence Connect a voltmeter across the Reverse Solenoid coil te
47. 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 A1 to the frame of the Motor shown for reference only motor Terminal positions on your motor AEN may not be in the same location If you do not know how to test for continuity refer test to a qualified technician e his should be an open circuit If there is 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 Page 29 Curtis PMC Troubleshooting Check continuity from SI to the frame of the motor
48. 0 Mounting plate nut 2 SECTION 5 PAGE 25 V MB 100 00 Speed Control Panel 14 3 17 15 16 17 C ZTE oe or Ee A FN ur Q Solenoid end view from side closest to PMC End view of PMC 5 19 20 21 SECTION 5 e PAGE 26 MB 100 00 Speed Control Panel gom 75 224 10 Jumper with diode EE SECTION 5 1222 PAGE 27 MB 100 00 Miscellaneous Electrical SECTION 5 PAGE 28 Accelerator Module S 5 z Floorboard Horn Switch Mounted Under Floorboard Mechanical Brake Light Switch Mounted Under Floorboard MB 100 00 Miscellaneous Electrical ITEM PART DESCRIPTION QTY Not Shown 75 148 06 Chassie vontrol harness 1 Not Shown 75 149 85 Power harness Not Shown 98 599 15 Plastic grommet fo
49. 1 Charger RevE Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic I chargers are designed as semiautomatic chargers The Lestronic II charger turns itself on when the built in charger is plugged into the wall outlet or when the portable charger is plugged into the batteries As the battery charges the battery voltage rises The charger periodically checks the battery voltage and compares it to the previous reading When the battery voltage stops rising a predetermined amount then the batteries are no longer accepting a charge and the charger shuts off The charger will not start again unless the AC cord on a built in charger is disconnected from the wall outlet or the DC plug on a portable charger is disconnected from the batteries The charger does not check the current state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200 as indicated on a hydrometer before connecting the charger If the charger is connected before the batteries are discharged 50 the batteries may enter an overcharge state before the charger can sense that the batteries are no longer accepting a charge This could result in overcharging and damaging the batteries The relay that operates the charger is powered by the batteries being charged If the voltage on the batteries to be
50. 12 Appendix B Suggested Torque Values 13 Appendix C Brake Lining Handling Precautions 14 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 Table of Contents About this manual 2 Who Should Read This Manual 2 Responsibilities 2 How To Use This Manual 3 Conventions How to Identify Your Vehicle 4 Taking Delivery of Your Vehicle 5 Introduction B 1 00 shown with optional luggage rack 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 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
51. 2 READ THIS FIBST 3 West Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 POG IBILODS 3 SYMPTOM TROUBLESHOOTING 19 20 PEUGGOING DIODE icio oe E 22 FREEWHEEL teneis 23 DO di Datus uus RENE 24 SOLENOIDS 26 MOTOR 1 uci aeu 29 REV Electrical Troubleshooting Curtis PMC Troubleshooting Note Vehicles with Dana H12 transmission Forward solenoid is in the center Solenoids Circuit Breaker PMC Speed Control O Typical Control Panel SYMPTOMS If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Symptom Troubleshooting later in this section 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 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 w
52. 3 Bex Le 3 Hex Lock Nuts stover oiii ete anos 4 Other 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 Used for testing electrical circuits Powered by the truck Test Light batteries switchable for 12 24 36 and 48 volts 62 027 00 Used to test the solid state accellerator module part number Accelerator Test Harness serias 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
53. 31 Removing the Rear Axles 31 Theory of Operation 7 Servicing the Differential 32 Inspecting the Auto Adjuster 8 Changing the Differential 35 Replacing the Brake 10 Motor Removal 37 Replacement and Inspection of Park Brake Lock 12 Armature INSpection uec eiie Sois 38 Brake Pedal Linkage 13 Replacing the Brushes 39 Adjusting the Brake Pedal Linkage 14 Inspecting the Motor Brushes 41 Front Axle and Steering 15 Baltery inse recolere fepe ore errr rr 42 Front Axle Removal and Installation 16 2 M 42 Aligning the Front End 17 te C S 43 Adjusting the Toe In uss is 17 Battery Storage 44 Centering Steering Gear 18 Repairing the Front Axle 19 Steering Yoke Bushings 19 Ball 20 Wheel 21 Removal and Installation of th
54. 8 jiffy clip SECTION 5 PAGE 29 MB 100 00 Lester Charger Typical Built In charger ay 77777 N NN f WH 5 Typical Portable charger SECTION 5 PAGE 30 MB 100 00 42p4Q 1012946 0 8 01 6FL 6L os I 6FL 6L OT 6VL 6L IT 60L 6L I 6FL 6L I 6FL 6L K quiessy oporq EN 1c 90 6L 86 LOE 6L 00 60 lt 6 02 lt 0 lt 6 HS9 r0 61 02 lt 0 lt 6 SI 0 6L NOLLdTSIOSHG 16 6 6 02821 6696 Or9TZ 09811 ZE OTLL OFLCC Weg PIY i 9po A Syp SeIHDeI VHO SECTION 5 PAGE 31 MB 100 00 Model HBS series charger shown Signet Charger Model HBS for Flooded Batteries Model HB for Flooded Batteries DESCRIPTION 24 volt Charger Assembly see note 36 volt Charger assembly see note 48 volt charger assembly see note Model HB for GEL Batteries DESCRIPTION 24 volt Charger Assembly see note 36 volt C
55. B While counting the rotation turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction Worm Bearing Adjuster 2 Remove the worm bearing adjuster locking ring and the worm bearing adjuster Side Cover 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing NOTE The side cover pitman shaft assembly normally does not have to be disassembled Section 3 Page 27 MB 100 00 10 Remove the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion Remove the worm shaft and ball nut assembly from the bottom of the housing Worm Shaft Ball Remove the worm shaft seal Nut Assembly Remove the pitman shaft seal Remove the upper worm bearing and bearing cup from the housing The ball nut assembly consists of two sets of ball bearings that recirculate in two channels in the ball nut housing These bearings may fall out once the bearing guides are removed Be careful not to lose any of these bearings Bearings Ball Guides Remove the ball guide clamps ball guides and all of the ball bearings Ball Guide damage or wear and replace as required Clamp Housing Reassembly 1 Lightly lubricate all parts before reassembly 2 nstall a new worm shaft seal and pitman shaft seal into the housing 3
56. E Flat washer 4 11 70 049 06 Bushing spacer 1 NOTE The armature is not available seperatly SECTION 5 PAGE 19 V 100 00 Brake Accelerator Linkage Left rear axle ref Accelerator Pedal 24 Floorboard Accelerator Module Frame ref SECTION 5 e PAGE 20 MB 100 00 Brake Accelerator Linkage ITEM PART DESCRIPTION QTY 88 517 11 3 32 x 1 cotter pin 4 2 96 72 00 3 8 x 1 1 8 Clevis pin 1 3 88 106 61 3 8 SAE Flat washer 1 4 85 233 00 Spring 1 5 96 820 01 Cable 1 6 Included with 8 Hex nut 1 7 01 110 22 Equilizer 1 amp 96 826 12 Brake cable 2 9 88 847 06 E Ring 2 10 Included with 8 Clevis 1 11 98 200 00 Brake pedal pad 1 12 02 536 09 Brake pedal 13 88 847 08 5 8 E Ring 2 14 96 754 00 Clevis 2 15 96 826 09 Cable lock 2 16 96 73 00 5 16 x 1 Clevis pin 2 17 98 451 11 Foam tape 2x 6 18 01 110 33 Brake cable bracket 2 19 01 110 34 Brake cable mount support 2 20 98 753 05 Rubber bumper B1 00 only 0
57. F position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Loosen the ball joint clamp NOTE Remember its position on the sleeve 8 Remove the ball joint nut then remove the ball joint NOTE Count the number of turns while removing the ball joint from the drag link Joint or tie rod 9 Install a new ball joint into the tie rod NOTE Lightly lubricate the threads on the new ball joint NOTE Count the same number of turns as when removed Tie Rod 10 Install the ball joint into the steering arm 11 Lube the new ball joint 12 Realign the front wheels Tighten the ball joint clamps 13 Tighten the ball joint clamps Typical drag link assembly NOTE Make sure the clamps are in their original position noted above Turn the steering all the way from left to right to make sure there is no interference 14 Lower the vehicle 15 Reconnect the main positive and negative at the batteries 16 Rem
58. FINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 volt battery has 3 cells Tem Value _ Condition V1 Voltages are temperature compensated V1 See Chart Flooded batteries relative to the temperature of the charger at the 2 383 Volts Per Cell Gel Batteries time the charge cycle is started V2 2 08 Volts Per Cell All batteries 2104 Amps All batteries Staring Temperature Per Cell All voltages are nominal Less than 4 2 64 4 to 2 2 61 2108 2 59 81014 2 56 14 to 21 2 54 ACAUTION ACAUTION This charger is rated for 115 VAC or 230 GEL batteries must be charged with a VAC operation nominal When switching charger configured for GEL batteries Use from one input voltage to the other wait of any other charger will result in damage until all LED s are off Switching voltage to the batteries and premature failure of when any of the LED s are on will result in the batteries damage to the charger TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM calibrated and accurate down to 0 00001 volts Clamp on DC ammeter to measure up to 20 Amps Important Notes and Instructions This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that the AC electrical socket th
59. Install the upper worm bearing cup 4 Divide the ball bearing into two equal groups 5 Position the ball nut onto the worm as shaft as shown in the illustration 6 Insert the ball guides into the ball nut 7 Insert each group of bearings into the ball guides NOTE Do not rotate the worm shaft while installing the bearings This may cause one or more of the bearings to enter the crossover passage in the ball nut causing improper operation 8 Install the ball guide clamp Section 3 Page 28 MB 100 00 9 Place the upper worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 10 Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft Worm Bearing Adjuster 11 Install but do not tighten the worm bearing adjuster lock nut 12 Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bolts 14 Pack the steering gear with grease through the open side cover bolt hole and then install the bolt 15 Adjust the steering gear NOTE Refer to Steering Gear Adjustment section for information regarding adjusting the steering gear 16 Once the adjustments are completed make sure that the locking ring and jam nut are tig
60. N QTY 1 92 207 02 Multi panel mirror 1 2 88 828 09 10 x 3 4 self drilling screw 4 9 92 201 00 Side mirror includes 7 6 2 4 88 069 61 Nylon lock nut 4 5 92 202 00 Mirror bracket includes 8 and 9 2 6 Included with 3 gt I Included with 3 8 Included with 5 9 Included with 5 10 88 065 08 x 5 8 Hex bolt 4 SECTION 5 PAGE 45 MB 100 00 B 125 Stake Sides B 100 Luggage Rack SECTION 5 PAGE 46 MB 100 00 Stake Sides ITEM PART DESCRIPTION QTY 1 90 547 08 Stake side right 1 2 90 547 10 Rear gate 1 3 90 547 06 Stake side left 1 88 065 13 1 4NC x 1 1 4 Truss head bolt 24 88 069 83 1 4NC Acorn nut 24 5 90 547 04 Gate hook rear gate 2 90 547 02 Gate hook rear left 1 90 547 03 Gate hook rear right 1 7 90 547 00 Gate hook front 2 Luggage Rack ITEM PART DESCRIPTION QTY 8 90 547 11 Luggage rack 1 Not shown 88 065 13 1 4NC x 1 1 4 Phillips truss head bolt 2 Not shown 97 211 20 1 4NC U nut 2
61. ads 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 Parking Before leaving the vehicle e Set the parking brake Set the forward off reverse switch to the OFF position Rotate the start switch to the OFF position In addition f parking this vehicle on an incline turn the wheels to the curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Towing This Vehicle ACAUTION This vehicle is equipped with regenerative braking Follow these steps before towing this vehicle 1 To tow this vehicle the start switch must be in the OFF position 2 Place the forward reverse switch in the center OFF position Failure to follow these instructions may result in damage to the 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
62. al 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 Page 12 Curtis PMC Troubleshooting F R switch The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause A WARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Connect a voltmeter across the Solenoid Negative Buss Bar The voltage shown is for illustration and battery positive only The actual voltage may vary NOTE You may skip this test if it was completed in a Solenoids are shown for reference only previous section SS The type of s
63. all a new pedal and park brake lock assembly Always use new locknuts Locknuts become less effective if used more AWARNING than once Failure to replace the locknuts may result in the locknuts or bolts coming loose causing property damage and or severe bodily 10 Lower the vehicle 11 Reconnect the main positive and negative at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle Wear Limits If the park brake lock does not catch or it slips easily it must be replaced Press on the lower half of the pedal If the park brake lock engages with little effort on the upper most notch check the linkage adjustments and adjust as needed Section 3 Page 12 MB 100 00 BRAKE PEDAL LINKAGE C lt lt a e e D ELD PEDAL amp LOCK WE ADJUSTING CABL EQUALIZER BRAKE 1 2 INCH RETAINER Section 3 Page 13 MB 100 00 Adjusting the Brake Pedal Linkage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with
64. and both intermediate bearing Input Shaft bores Inspect all parts for signs of wear or damage Note Bearing seal and gear surfaces Input Shaft Bearing should be inspected for pitting Ly i wear overheating or scoring lt Snap Ring Replace these parts as needed Reinstall or replace all parts using this Asse procedure in reverse order NOTE Be sure to pre lube all of the bearings with 30 weight motor oil Fill the differential with oil Adjust the brakes Lower the vehicle Reconnect the main positive and negative at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Section 3 Page 34 MB 100 00 Changing the Differential Oil 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Place a drain pan under the center of the drive assembly that is capable of holding 2 pints of oil Remov
65. ansmission Dana Spec 012AJ308 1 ITEM PART DESCRIPTION QTY 4C 100 00 Complete Transmission Assembly Including Brakes 1 Special order Housing 1 2 Carrior bearing cap inculded with 1 2 3 96 330 10 Carrior bearing cap bolt 4 4 66 610 04 Carrior assembly 1 5 Final Gear 6 Final gear bolt i 2 Final gear nut 4 8 80 480 00 Carrior bearing 2 9 Intermeadiate shaft 1 10 80 715 00 O ring 2 11 66 610 35 Intermeadiate shaft bearing 2 12 T Input shaft 1 13 80 480 10 Input shaft bearing 1 14 80 715 10 O ring 1 15 80 480 15 Input shaft bearing 1 16 88 840 12 Snap ring 17 41 973 00 Bore plug 1 18 TEN Cover plate 1 19 41 127 94 plug 1 20 66 610 68 Cover screw 10 Gear kit includes 5 9 and 12 41 127 64 Cover plate kit includes 18 and 19 Not available at time of printing SECTION 5 PAGE 13 MB 100 00 Rear Axle and Brakes SECTION 5 PAGE 14 MB 100 00 e Rear axle and Brakes Dana 012A308 1 Brake spring Kit Not available at time of
66. ause the battery to explode resulting in property damage and or bodily injury Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the battery CAUTION electrolyte comes in contact with Failure to clean may result in property damage Cleaning 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 at the batteries Dry dirt can be readily blown off with low pressure air or brushed off Qd ur OU due cB o Due ues Wetness or wet dirt on the batteries indicates battery acid Using a nonmetallic brush with flexible bristles wash it off with a strong solution of baking soda and hot water 1 Ib of soda to gallon of water Continue until all fizzling 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 Section 3 Page 42 MB 100 00 Servicing 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at th
67. be charged as follows Returning to Service Charging Interval Temperature th e Check the F months battery s state of charge and Over 60 1 charge if Between 40 and 60 2 required Perform ALL 18044 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 PERIODIC MAINTENANCE CHECKLIST Maintenance Iten Weekly 20hrs Monthly SOhrs Quaterly 250hrs Semi Annual 500hrs Annualy 1000hrs Check Condition of Tires and Tire Pressure Check All Lights Horns Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks Lubricate Vehicle Clean and Tighten Wire Connections Wash and Service Batteries Check Park Brake Check Motor Brushes and Blow Out Motor Check Front Wheel Bearings Check Rear Axle Oil Change Rear Axle Oil Check and Tighten all Nuts and Bolts
68. cedures Keep the vehicle in clean condition to minimize fire hazards Be sure to detect any loose or defective parts Severe Duty Guidelines If the vehicle is operated under severe conditions service procedures should be conducted more frequently than specified in the Periodic Maintenance Checklist 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 n extreme temperature bumpy dusty or ill maintained roads n excessively wet areas n corrosive or contaminated areas Frequent loading of vehicle at near capacity On multiple shifts Section 3 Page 3 MB 100 00 LUBRICATION CHART 3 3 2 2 ON m 3 H 3 4 4 3 LL Ll m RR 2 CENE 6 NE CN E
69. ch of the diodes using the diode test function of your meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Bi Diode 1 Common 5 Reconnect the lead to the diode 6 Reconnect the charger to the vehicle s harness and slide the wiring insulators back into place Connect the charger to the AC source and perform the following tests B Diode 2 High Voltage inside the charger Do not touch any internal components AW ARNI NG while the charger is plugged in Failure to do so may result in serious bodily injury Charger Troubleshooting el Page 6 Electrical Troubleshooting Testthe voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wires from the harness connectors to the charger are bad Stop here and repair the problem est the voltage across the white and black wires that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the wires from the harness connectors to the charger are bad Stop here and repair the problem If the timer relay does not pickup click when the AC source is connected then the timer control circuit or the relay is bad refer to Timer Relay Test Stop here and repair the problem Test th
70. charged is less than approximately 6596 of the rated charger DC voltage the relay will not pick up and the charger will not turn on In this situation a manual charger would have to be used to bring the battery voltage up so that the Lestronic charger can sense that they are connected and turn itself on IH Transformer T Diode 2n gt Black Black B Tan White Diode Capacitor Not all chargers are equipped with the lockout relay Violet Black T Charger Interlock purpim bik Interlock Relay Ammeter optional Black To Battery Red Typical Charger Internal Wire Diagram Charger Troubleshooting Page2 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started A charger could remain on for longer than 12 hours if The charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger A brownout drop in AC line voltage during the charging cycle An electrically noisy charging environment A charger could turn off in less than 12 hours but still show symptoms of overcharging if The batteries were not discharged to 5096 before connecting the charger he electrolyte in the batteries is too high boil over he electrolyt
71. 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 2 terminals on the PMC control and perform the following test rue 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 2 on the PMC control If you do not know how to test for a diode refer test to a qualified technician e 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 this point The tests may need to be repeated Page 22 Curtis PMC Troubleshooting FREEWHEEL DIODE Make sure the key switch is in the OFF position then remove the key AW ARNIN 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 bat
72. d technician his 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 wire connected to the 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 otop 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 Page 28 Curtis PMC Troubleshooting MOTOR High motor current in both the field and the armature accompanied with a lack of power would indicate a shorted armature 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 ARNIN G Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front
73. d that the AC power source is working The DMM should indicate an open circuit If it still indicates a closed circuit then the relay or the wires to the relay have failed Stop here and repair the problem e Ifthe DMM indicates an open circuit then the interlock relay is functioning normally Charger Troubleshooting el Page 10 TABLE OF CONTENTS Operating Instructions and Theory of m 2 HB PT and GEL Indicator Lamps 3 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code Table 5 Troubleshooting 6 A CAUTION Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Rev H Signet Charger Troubleshooting Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Charger The model HB600W and HB1000W chargers Svstem are designed as semiautomatic chargers The AC Input iode charger turns itself on when it is plugged into the Voltage Range wall outlet and turns off when the batteries are fully charged Both the HB600W and HB1000W two stage chargers The first stage is a constant current a mode It Maintain
74. depressed the auto adjuster indexes the star wheel adjuster causing a click Auto adjustor 12 Lower the vehicle 13 Reconnect the main positive and negative at the pE 3 batteries DB A UY 14 Remove the blocks from behind the wheels 15 Test drive the vehicle Brake assembly Section 3 Page 8 MB 100 00 This page intentionaly left blank Section 3 Page 9 MB 100 00 Replacing the Brake Shoes 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Using the appropriate procedure remove the brake p a drum Lever Spring 8 Release the park brake 9 Remove the tension springs 10 Remove the hold down springs 11 Remove the auto adjust lever spring Hold Dawn 12 Apply this procedure in reverse order to install the Springs new brake shoes NOTE Be sure all the parts are thoroughly cleaned NOTE Be sure that the a
75. e Steering Gear Assembly 23 MB 100 00 MAINTENANCE GUIDELINES Allow only qualified and authorized personnel to maintain repair adjust or inspect the vehicle e Before starting any repairs or maintenance immobilize the vehicle e Turn the key switch off and remove the key e Set the park brake e Place the forward reverse switch in the center off postion Disconnect both of the main battery leads before working on or disconnecting any electrical component or wire e Block the chassis with jack stands before working under a raised vehicle Conduct vehicle performance checks in an authorized area where safe clearance exists Tighten all nuts and bolts in accordance with the Hecommended Torque Values Chart found in Appendix C Avoid fire hazards and have fire protection equipment present in the work area 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 e Ventilate the work area properly Section 3 Page 2 MB 100 00 Brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices should be regularly inspected and maintained nspect and maintain battery limit switches protective devices electrical conductors and connections in conformance with Taylor Dunn s recommended pro
76. e AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board This voltage should be the same as the rated AC voltage of the charger If the voltage is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer low voltage secondary circuit The transformer low voltage secondary circuit can be tested at the two solid wires with the brown fiber insulator that are connected to the anodes on the two diodes The voltage here will vary depending on the state of charge in the batteries The voltage should be between 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 25096 of the rated DC voltage of the charger the transformer is bad and must be replaced Stop here and repair the problem Charger Troubleshooting Page 7 Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries 1 Test the voltage from the positive terminal on the vehicles DC receptacle to main battery negative This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then this wire is broken or has a bad connection Stop here and repair the problem 2 lest the voltage from the positive terminal on the DC rece
77. e batteries 6 Clean the battery 7 Check the electrolyte level in all batteries If low fill with distilled water up to the correct level using 77 201 00 battery filler Filler neck ax water ROK 22 evel 2000 Plat ate 72 inside battery QUU KN On OU AAT KRG Oy 2 COMO ANA Battery QU VU UU 4 cutaway Battery Fill Level This figure shows the proper fill 8 Clean the cell posts connectors and battery box with water 9 Reconnect the main positive and negative at the batteries 10 Remove the blocks from behind the wheels 11 Release the park brake and test drive the vehicle Section 3 Page 43 MB 100 00 Battery Storage The following pointers will help extend the life of the battery when storing the vehicle for the winter season e Clean and check the electrolyte level and charge level of the battery e Do not store a battery low in electrolyte or in a low state of charge e Recharge a battery in accordance to the chart found in section 2 Storing and Returning to Service e f possible store the vehicle in a cool dry place If the batteries are removed from the vehicle do not place them directly on the ground concrete or solid metal surface It is recommended to store them on a wooden pallet or equivalent Section 3 Page 44 Table of Contents SYMPTOMS uino d Eus dU
78. e charger is plugged into is in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition e If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting here are no internally serviceable components in the charger If the charger has failed then it must be replaced ESE Signet Charger Troubleshooting Page 2 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION AC input Voltage Range DC output MODEL 51000 36 Charger Model System Voltage PART No 79 303 40 AUTO SELECTABLE DUAL AC INPUT 100 240V 50 60Hz 13A OUTPUT 36V 20 1000W Manufacturer SIGNET SYSTEMS INC INPUT Typical specification plate reference only specifications will vary for different chargers The model HBS 600W and HBS 1000W chargers are designed as automatic chargers The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged Once the charging cycle is complete the charger will monitor the battery voltage If the battery voltage drops below a specific value V2 the charger will turn on again for a short cycle Both the HBS 600W and HBS 1000W are two stage chargers The first stage is a constant current mode It Maintains a constant current until the battery reaches a te
79. e in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and the electrolyte specific gravity during the charging cycle as indicated below Specific Gravity Using a hydrometer take the specific gravity reading of several cells at 1 hour intervals while charging If the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not shut off then the charger is running too long Battery Voltage Using an accurate 5 1 2 digit digital voltmeter monitor the battery voltage during the charging cycle Take readings every 30 minutes If the battery voltage does not increase 0 012 volts in two consecutive readings then the charger is running too long Charger Troubleshooting ez Page 3 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM with diode and capacitor test function FLUKE 799 model shown at right and in the troubleshooting illustrations Important Notes and Instructions his troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that the AC electrical socket the charger is plugged into is in good working condition Make sure that the AC voltage at the e
80. e 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 start in the middle of this troubleshooting guide 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 This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor Dunn Throttle Module Analyzer Troubleshooting CANNOT be completed without these tools 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 Page 3 Curtis PMC Troubleshooting Page 4 Definitions e MS 1 The first switch in the accelerator module Battery volts 2 The voltage at the batteries at the time the test is completed e Pick up Energizing a solenoid or contactor e F amp R Forward and Reverse e ISO Isolator e Battery negative Ma
81. e the differential case cover from the differential case and let the oil run into the drain pan 9 Clean all of the old sealant from the cover 10 Apply new sealant and reinstall the cover 11 Open the fill plug and fill the differential with 10 oz of SAE 30 motor oil 12 Replace the fill plug 13 Lower the vehicle 14 Reconnect the main positive and negative at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test drive the vehicle Section 3 Page 35 MB 100 00 Differential Assembly O Ring snap Ring Bearing Input Shaft x Differential ae a O ring Drive Gear V 0 Carrior Bearing nap Ring Intermediate Shaft Assembly Bearing Cap Cover Plate Section 3 Page 36 MB 100 00 Motor Removal NOTE It is not necessary to remove the drive assembly to perform this procedure in most cases However if the vehicle is equipped with an optional cargo box it may be necessary to lower the drive assembly in order to access the motor 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the motor NOTE Label the wires connec
82. els 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 51 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 e Check continuity from the motor 2 terminal to the wire that was connected to the motor S1 terminal DO NOT make this test to the 51 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 A The reverse solenoid is shorted B The wire connected to the motor S1 terminal is shorted to the
83. en the switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the Mob drive wheels to the ground 2 eR Battery Negative from the rear Connect a voltmeter across the reverse terminal of the forward and reverse side of the F amp R switch and battery negative The REVERSE terminal is diagonally opposite the reverse side of the Close all interlock switches turn the Key Switch ON rocker on the switch and place the F amp R Switch in reverse Depress the accelerator pedal fully F amp R switch seen from e f the voltage is not at battery volts then the F amp R E 2 switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground e f all tests in this section were good then check the wiring from the F amp R switch to the Forward and Battery Negative the rear 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 Page 14 Curtis PMC Troubleshooting Solenoids AWARNING A WARNING The rear drive wheels may ro
84. epaired or 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 f the test light did not come on during either test E Motor shown for reference only Terminal positions then go to the Switch sequence on your motor may not be in the same location Page 9 Curtis PMC Troubleshooting Accelerator The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause A WARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement With the power switch OFF connect a throttle module to the analyzer Position the power switch to the 6 11 volt range but the power lamp should be OFF If the FS 1 5 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the m
85. er There is a series of LED s on the faceplate of the charger that serve two functions 1 Status of charge The LED s will display an approximate percent of charge during the charging cycle Refer to the table below Typical Signet Built In 2 Error condition All three LED s flashing is an indication of a charging problem charger will also be beeping Refer to the Charger Troubleshooting section for information on error codes Sitetas LED s Charging State LED2 LED3 0 to 50 Blinking OFF OFF 50 to 75 ON Blinking OFF 75 to 100 ON ON Blinking Cycle complete ON ON ON 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 Signet Charger Operation Model HBS series The Signet HBS series chargers are fully automatic The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Once the charge cycle is comp
86. er wires Section 3 Page 39 MB 100 00 10 Push the brushes out of the holder until the torsion spring snaps out of position and pull the brush out of the holder 11 Install the new brushes into the brush holder NOTE Do not insert the brush all the way into the holder 12 Install the brush holder 13 Reassemble the motor 14 Install the motor Section 3 Page 40 MB 100 00 Inspecting the Motor Brushes 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries General Electric Motors NOTE Some motors may not have the brush inspection holes In this case the motor must be disassembled to inspect the brushes For future inspections holes msy be drilled into the motor housing after it has been disassembled Minimum brush length is 0 75 inches 19 05 mm 6 Inserta 0 035 diameter wire through the brush inspection hole above each brush until it contacts the top of the brush 7 Mark the wire to indicate how it was inserted into the motor housing Remove the wire and measure how far into the motor the wire was inserted If any one wire insertion length exceeds 1 5 inches 38 1 mm then all four brushes should be replaced Refer t
87. es This voltage should be the same as the voltage at the AC receptacle rated voltage of the charger If the voltage is less than the rated AC voltage of the charger then the 14 gauge white or black wire s is broken or has a bad connection between the charger connectors and the AC plug Stop here and repair the problem Charger Troubleshooting ez Page 5 Electrical Troubleshooting Disconnect the charger from the AC source Disconnect the batteries Disconnect the charger from the vehicle s harness e Remove the charger from the vehicle HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNING terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one transformer lead from the capacitor Test the capacitor using the capacitor test function of the meter It is a 6 microfarad capacitor If the capacitor is bad it must be replaced Stop here and repair the problem Capacitor 4 Reconnect the transformer lead to the capacitor and disconnect one transformer lead from one of the diodes Test ea
88. es and turn the Key Switch The voltage shown is for illustration ON only The actual voltage may vary Depress the accelerator pedal to engage MS 1 only e f the voltage is not at battery volts then go to the only The type of solenoid in your Key Switch sequence IM truck may look different e 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 Solenoids are shown for reference Note Vehicles with Dana H12 transmission Forward solenoid is in the center Page 6 Curtis PMC Troubleshooting Connect a voltmeter across the PMC 2 terminal 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 to engage MS 1 only e f the voltage is not between 6 0 and 6 5 volts then go to the Accelerator sequence Depress the pedal fully e voltage is not between 11 0 and 11 5 volts then go to the Accelerator sequence 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 e f the voltage is at battery volts then co
89. es are discharged beyond 50 or the batteries may be overcharged 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 To obtain the maximum battery life Charge the batteries only after they reach a normal discharge as indicated on the Battery Status Indicator BSI Failure to follow this guideline could result in the batteries entering an overcharge state which will reduce the life of the batteries If you find it necessary to charge the batteries before they are completely discharged we recommend waiting until they are discharged a minimum of 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 i
90. etween 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the charge s rated DC voltage the transformer is bad and must be replaced Stop here and repair the problem TESTING THE RELAY Test 1 1 Connect the batteries to the charger 2 Plug the charger into the AC source 3 Wait 5 seconds then test the voltage at the timer relay coil terminals NOTE This voltage should be close to the battery volts f the voltage is close to the battery volts then skip to test 2 e f the voltage is not close to the battery volts then the timer control circuit has failed and the timer must be replaced Test 2 1 Disconnect the batteries 2 Unplug the charger from the AC source 3 Discharge the capacitor see warning on previous page Charger Troubleshooting 9 Electrical Troubleshooting 4 Disconnect the wires from the contact terminals on the timer relay 5 Heconnect the batteries 6 Wait 5 seconds then test the continuity across the timer relay contact terminals f this is a closed circuit then the timer start up circuit is functioning normally e f there is an open circuit then the timer relay has failed and the relay must be replaced TESTING THE INTERLOCK RELAY Operation The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC power source When the charger is plugged in the relay contacts open a
91. f in less than 12 hours but still show symptoms of overcharging if he electrolyte in the batteries is too high boil over he electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if itis turning off correctly monitor the battery voltage and charging current during the charging cycle as indicated below Using a digit digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current should remain within 1096 of the DC output current see previous page until the battery voltage reaches 2 55 volts per cell When the voltage reaches 2 55 volts per cell the charging current will drop significantly and slowly taper off voltage will remain constant The charger should turn off within 2 to 4 hours after entering the second stage signet Charger Troubleshooting Page 3 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter DMM FLUKE 799 model shown at right and in the troubleshooting illustrations Clamp on DC ammeter to measure up to 20 Amps Important Notes and Instructions This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If not familiar with any part of these tests refer testing to a qualified technician Make sure that the AC electrical socket the charger is plugged into
92. ground other wise continue to the next test FWD REV Page 24 Curtis PMC Troubleshooting Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure Reading is plus or minus 10 Its resistance 35H ISO solenoid is shown for reference The meter reading should be 250 Oh ms only The type of solenoid in your truck 10 If it is not 250 ohms 10 may look different then replace the resistor Stop trouble EN i shooting here and repair the problem When the repair is completed completely z 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 Itis important to review the trouble shooting steps that have led to this point The tests may need to be repeated Page 25 Curtis PMC Troubleshooting 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 Place the forward reverse switch in the center OFF position A WARNING i Set the park brake Place blocks under the front whe
93. harger assembly see note PART DESCRIPTION PART 24 volt Charger Assembly see note 79 302 20 79 303 41 36 volt Charger assembly see note 79 303 40 79 309 42 48 volt charger assembly see note 79 309 40 Model HBS for GEL Batteries PART DESCRIPTION PART 24 volt Charger Assembly see note 79 303 42 36 volt Charger assembly see note K4G CH 003 79 309 43 48 volt charger assembly see note 79 309 41 48 volt charger assembly see note Not available at time of printing NOTE There are no user serviceable components inside the charger NOTE The charger AC cord is an intergral part of the charger When replacing the charger do not cut and splice the AC cord Cutting the AC cord will void the charger warranty NOTE The Signet model HBS series charger replaces all previous Signet models SECTION 5 PAGE 32 MB 100 00 Charger Model NOTE The harness connectors and AC plug are not included with the charger b Ce 1000 36 QTY PART DESCRIPTION sa AUTO SELECTABLE DUAL AC INPUT 2 75 318 20 Butt splice 100 240 12 04 2 75 320 51 Knife connector 1 76 200 00 AC plug 115v domes
94. he brake by means of the brake cables as this will cause misoperation of the brakes If you hear a single clunking noise while braking it may be due to misadjustment of the brake cables or linkage Refer to Replace Brake linkages Cables for information regarding proper adjustment of the cables and linkages Adjusting the brakes by means of the brake cables could cause a AW ARNING hard brake pedal with little or no braking power This could cause loss of control of the vehicle resulting in severe bodily injury and or property damage Section 3 Page 7 MB 100 00 Inspecting the Auto Adiuster 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Using the appropriate procedure remove the brake drum 8 Release the park brake 9 Back off the auto adjuster star wheel one or two turns 10 Reinstall the brake drum and depress the bake pedal 11 As the brake pedal is
95. hours If the HB PT lamp is flashing then the charging time has exceeded 18 hours time is limited to 18 hours If any of the status lamps are flashing then the charge cycle did not complete Gas T GEL lam SIGNET SYSTEMS INC This LED will only be ON if the charger is configured for GEL batteries Using a GEL charger with non GEL batteries may result Typical Charger Data Plate in an incomplete charge or long charge times your data plate may vary ACAUTION GEL batteries must be charged with a charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries TESTING THE CHARGING CYCLE In typical installations the charger will remain on for up to 12 hours depending on the state of charge of the batteries when the charge cycle was started NOTE Charging time is limited to 18 hours max An error occurs if charging time exceeds 18 hours See table on previous page A charger could remain on for longer than 12 hours if The vehicle is equipped with batteries larger than 220 Amp hour capacity charging cycle is interrupted at any time during the charging cycle Defective batteries causing a fluctuating DC voltage that confuses the charger One or more defective cells in the battery pack A brownout drop in AC line voltage during the charging cycle An electrically noisy charging environment A charger could turn of
96. housing 12 Dispose of the old oil in accordance with local regulations Cover Plate Assembly Section 3 Page 32 MB 100 00 13 Remove the bearing cap screws and bearing caps NOTE Bearing caps are marked for Differential Case identification During reassembly Drive Gear make sure they are put back in their original position 14 Remove the differential case assembly from the housing 15 Remove the differential bearings from each side of the differential case 16 Remove the drive gear from the differential case Differential Case Assembly 17 Punch or drill a 1 8 hole in the center of each bearing bore plug 18 Insert a 10 x 1 25 sheet metal screw into the hole until the bore plug is forced out of the bearing bore 19 Remove the snap ring from each bearing bore Shaping 7 20 Drive the intermediate shaft from the flange side of the housing Intermediate Shaft 21 Remove the intermediate shaft bearings gs Intermediate Shaft Bearing from the housing Intermediate Shaft Assembly 22 Remove the O rings from the intermediate shaft 23 Remove the snap ring from the input shaft bore plug 24 Pull the input shaft assembly from the housing Section 3 Page 33 MB 100 00 25 26 27 28 29 30 31 32 33 34 the bearings from the input shaft Input Shaft Bearing Hemove the O rings from the outer input bearing bore
97. ht Section 3 Page 29 MB 100 00 Exploded View of Steering Gear Locking Ring Side Cover Worm Bearing Adjuster Gear Lash and Lower Adjuster and Shim Ball Nut Housing Worm Shaft Pitman Shaft Qo Bearings Ball Guides LV Upper Bearing 0 Ball Guide Clamp Pitman Shaft Seal 77587 gt Worm Shaft Seal Section 3 Page 30 MB 100 00 DRIVE SERVICE Removing the Rear Axles NOTE This procedure does not require that the rear end or drive assembly be removed from the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Remove the tire and wheel assembly Disconnect the brake cable Remove the four bolts holding the brake backing plate to the housing 10 Remove the outer circlip from the housing and pull the axle out of the housing If the bearings are removed from the axle the axle retainer and bea
98. ht turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise Foot Brake Pedal The foot brake pedal located to the right of the steering column is for operation with the right foot only It works the same as the brake in an automobile Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied Relieving pressure from the pedal releases the braking action Park Brake The parking brake is part of the foot brake pedal To set the parking brake push down on the lower half of the brake pedal until the pedal locks in the down position To release the park brake apply pressure on the upper half of the brake pedal until the pedal disengages from the lock position Horn Button The horn button is located on the floor to the left of the steering column Depress the button to sound the horn release it to turn it off Charger Interlock The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source NOTE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger safety Rules Page 5 SAFETY RULES AND OPERATING INSTRUCTIONS Headlights and Accessories optional The headlight switch is located to the rear of the instrument panel between the seats An accessory switch if any is adjacent and to the of left
99. in a caution Note Alerts the reader to additional information about a subject 9 Model 2 46 equipped with the Dump Bed option Page 3 e INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks 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 speed of 12 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 This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 The locations of the model and serial numbers are illustrated below The location of the data plate will be in one of two locations Data Plate Location Frame Serial 34 Number Location Page 4 INTRODUCTION e TAKING DELIVERY OF YOUR VEHICLE What To Do Problem is Found If the
100. in negative battery post e Battery positive Main positive battery post e PMC Speed control module black box e HOT terminal The side of a switch or solenoid that is connect to the power source e COLD terminal The side of a switch or solenoid that power is switched to DURING ALL TESTS A WARNING AWARNING AWARNING AWARNING START After any repairs are made completely retest the vehicle before 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 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 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 before disconnecting any electrical component or wire Failure to do so may cause severe bodily injury and or property damage Head 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
101. inimize the hazard caused by airborne asbestos fibers and brake dust A WARNING Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Always wear protective clothing and a respirator when working on the brake pads shoes or their associated components Inhaled asbestos fibers have been found to cause cancer and respiratory diseases Do not drive the vehicle if any worn or broken part is detected in any part of the brake system The cause of the damage must be repaired immediately Appendixes Appendix C Page 7 Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 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
102. irm that there are no shorts in the vehicle wiring or components Installing a replacement module in a vehicle with faulty wiring will burn out the new module Page 10 Curtis PMC Troubleshooting Key Switch AWARNING The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Test all interlock switches and or interlock relays if equipped for 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 yo
103. ise continue with the next test With the key switch on and the 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 S2 terminal If you do not know how to test for continuity refer test to a qualified technician e 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 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 Motor shown for reference only Terminal positions on your motor may not be in the same location Page 27 Curtis PMC Troubleshooting With the key switch on and 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 S1 Motor shown for reference only 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 qualifie
104. it For Field Stud use on motors with soldered connections only 70 210 63 Used to align the Pini 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 Markings NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads Hex Bolts S A E Grade 2 S A E Grade 5 52 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 N gt p on 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 locknuts would be the equivelent of Grade 2 hex nuts Grade as Grade 5 and Grade as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A 5 S ety or v or or Nd kar sA S A E Grade S A E Grade Grade L 9 Other Nuts
105. ith 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 battery 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 Page 2 Curtis PMC Troubleshooting READ THIS FIRST 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 Throttle Module Analyzer Taylor Dunn 62 027 32 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 vehicl
106. lectrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition and no less than 8096 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC voltage the charger will not turn on e If the charger exhibits intermittent problems it must be in the failed mode for troubleshooting Battery volts Full voltage available atthe batteries at the time of the test being performed his test procedure must be performed in the order it was written If starting in the middle or skipping sections when not instructed to do so the proper results will not occur If the test result is good then proceed to the next test or go to the next section if instructed to do so During Tests The charger cabinet must remain electrically grounded Disconnect AW ARNING both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire Failure to do so may result in serious bodily injury Charger Troubleshooting el Page4 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT IN CHARGER the key switch is in the OFF position then remove the key Placethe forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the f
107. legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement the test light voltage to the same voltage as the battery volts Connect the test light across the motor 1 and 2 Wiring to motor omitted for clarity Do not terminals disconnect the motor wires for this test Close all interlock switches turn the Key Switch ON and place the Switch in Forward Depress the accelerator fully e f 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 Connect the test light across the motor 517 and S2 terminals Wiring to motor omitted for clarity Do not Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator fully e f the light comes on then the motor field windings are open and the motor must be r
108. lete the charger will continue to monitor the batteries If the battery voltage Typical Signet HBS drops during storage the charger will start a new cycle to keep the batteries fully charged NOTE If the charger restarts during a short time period of storage then it would be an indication of faulty batteries Refer to the data plate on the charger for the voltage and type power required for the charger There is a series of LED s on the faceplate of the charger that serve two functions 1 Status of charge The STATUS LED s will display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition The FAULT LED flashing is an indication of a charging problem charger may also be beeping Refer to Charger Troubleshooting section for information on error codes Status Light Panel Safety Rules Page 9 SAFETY RULES AND OPERATING INSTRUCTIONS Lestronic Charger Operation The Lestronic II charger is semi automatic charging system The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged Refer to the data plate on the charger for the voltage and type power required for the charger When plugged in the charger assumes that the batteries require charging and will charger for a minimum of approximately 4 hours This charger should not be plugged in until the batteri
109. n 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 10 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 Charging time is limited to 20 hours HBS or 18 hours HB A fault will occur if the charging time exceeds the 20 hour limit STORING RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel Storing Your Vehicle Cleanthe 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 ground If stored for a prolonged period the batteries should
110. nchor points on the brake shoes are given a light coat of hi temp grease 13 Lower the vehicle 14 Reconnect the main positive and negative at the batteries 15 Remove the blocks from behind the wheels TI 16 Test drive the vehicle JI WM Tension Springs Do not allow grease to contact any of the braking surfaces Braking surfaces A WARNING contaminated with grease k iriki may cause the brakes to fail resulting in property damage and or severe bodily injury Section 3 Page 10 MB 100 00 This page intentionaly left blank Section 3 Page 11 MB 100 00 Replacement and Inspection of Park Brake Lock 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING 1 _ tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 With the brake pedal in its fully extended position remove the 1 2 bolt and locknut from under the pedal 8 Remove the pedal and park brake lock assembly from the brake arm 9 Inst
111. nd break the Key Switch connection to the speed controller The Interlock Relay is available for built in chargers only Not all built in chargers are equipped with this relay To identify chargers that are equipped with the Interlock Relay Inspect the charger wire harness where it enters the charger cabinet for two Violet Black wires If these wires are present then the charger is equipped with the Interlock Relay Testing the key switch is in the OFF position then remove the key Placethe forward reverse switch in the center OFF position AWARNING Setthe park brake Place blocks under the front wheels to prevent vehicle movement Disconnectthe main positive and negative cables at the batteries Disconnect the charger from the AC power source Disconnect the two Violet Black wires at the charger harness knife connectors Set the DMM to check for continuity and connect the DMM leads to the wires going into the charger The DMM should indicate a closed circuit If the DMM indicates an open circuit then the relay or the wires to the relay have failed Stop here and repair the problem E oM 9 Connect the charger to a working AC power source e The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the AC wiring to the charger Refer to the beginning of this section for charger troubleshooting DO NOT continue until you have confirme
112. none of the three solenoids pick up click when the accelerator pedal is depressed then go to the Forward amp Reverse Switch sequence Curtis PMC Troubleshooting Power Output Test The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause A WARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Set the test light voltage to the same voltage as the battery volts Connect the test light from the PMC Terminal to battery Test Light positive Face of Controller Close all interlock switches turn the Key Switch ON and place the F amp R Switch in Forward Depress the accelerator pedal fully e light comes ON then go to the Motor sequence Ifthe light does not come ON then continue with the Main Battery Positive next test Page 5 Curtis PMC Troubleshooting
113. ntinue with the next test The voltage shown is for illustration only The actual voltage may vary f E O ote B O ES 2 I ol Battery Negative FLUKE 79 emen The voltage shown is for illustration only The actual voltage may vary NEN 2 Main Battery A2 Negative Page 7 Curtis PMC Troubleshooting Power Wire Inputs The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause AWARNING severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Connect a voltmeter to the PMC B terminal and battery positive e f the voltage is not the same as battery volts then there
114. o Replacing the Brushes section for information regarding replacing the motor brushes 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels release the park brake and test drive Advanced DC Motors The enclosed Advanced DC motors must be disassembled to inspect the motor brushes Refer to Motor Inspection tor information regarding disassembling the motor Minimum brush length is 0 62 inches 16 mm Section 3 Page 41 MB 100 00 BATTERY Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks A WARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves A WARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A WARNING Aconductive object that comes in contact with the battery terminals Will initiate a short circuit of the battery This could c
115. odule The FS 1 lamp should be ON with no more that a few degrees of rotation If the FS 1 lamp does not come on then the module is faulty see note2 below The voltage on the digital display should vary with the position of the module arm starting at approximately 6 FS 3 volts and ending at approximately 1 1 volts 52 Low Battery If the module is equipped with the FS 3 switch the FS NE lamp should come ON when the module arm is rotated 1 git Not Sye 1 the full speed position If the lamp does not come ON th OFF uw the module is faulty 0 5 SY A Note1 Current versions of the throttle module do not have SS additional switched output FS 3 fully depressed 220 1 additional switched output was only used on cc Module eet 62 0273 systems and Power Tron 240 350 or 480 systems that xayior Dunn Pa equipped with the Power Plus module If the OV lamp comes ON at any time then the module is If the Low battery lamp is ON then the analyzer battery be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer DO 1 10 53 If the module functions correctly with the analyzer but not on the vehicle it is likely that there is a fault in the vehicle wiring NOTE2 Failures of the FS 1 circuit indicate a possible vehicle wiring fault that has resulted in a short circuit across 5 1 BEFORE HEPLACING THE MODULE Conf
116. 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 e 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 Section 3 Maintainance and Repair TABLE OF CONTENTS Maintenance Guidelines 2 Steering Gear Adjustment 25 Severe Duty Guidelines 3 Input Shaft 25 Lubrication Chart 4 Gea NE 26 Troubleshooting Guide 5 Steering Gear Disassembly and Repair 27 Mechanical Drum 6 Exploded View of Steering 30 Auto Adjust Brake Mechanism Drive Service M M
117. of the light switch gt POWER e 4 POWER 7 e Accessory switch location Hour Meter 2 optional The hour meter is located below the battery status indicator This tracks the number of hours the vehicle has been in operation Battery Status Indicator 1 optional The battery status indicator is located above the hour meter The normal operating range is in the green zone The vehicle needs charging if it is in the yellow zone If it is in the red zone the vehicle should be taken out of service immediately to be charged 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 at intersections blind spots or other dangerous locations Do not drive over loose objects h
118. oint The tests may need to be repeated Page 23 Curtis PMC Troubleshooting ISO Make sure the key switch is in the OFF position then remove the key AW ARNING Place the forward reverse switch in the center OFF position 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 and the resistor from the ISO solenoid and perform the following tests Test continuity across the ISO power contacts If you do not know how to test for continuity refer test to a qualified technician This should be an open circuit If it is not di an open circuit then the contactor should one e 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
119. olenoid in your truck may look different Main Battery If the voltage is not at battery volts then check the Positive wiring to battery negative and the negative circuit E breaker Stop trouble shooting here and repair the i a problem When the repair is completed completely one 920 exe retest the vehicle before lowering the drive wheels the ground FWD REV Connect a voltmeter across the center terminal of the forward and reverse side of the F amp R switch and battery negative The CENTER terminal is the Green Black wire 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 O Battery Negative Page 13 Curtis PMC Troubleshooting Connect a voltmeter across the forward terminal of the The FORWARD terminal is forward and reverse side of the F amp R switch and battery diagonally opposite the forward side ne gativ e of the rocker on the switch Close all interlock switches turn the Key Switch ON ETET TEN TN and place the F amp R Switch in forward _ die side depressed in Depress the accelerator pedal fully Y the FORWARD gear e If the voltage is not at battery volts th
120. oles or bumps Yield right of way to pedestrians and emergencies vehicles otay 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 DX Oe Lodo Make sure the forward off reverse witch is in the center OFF position Set the parking brake Hold down the foot brake Rotate the ON OFF switch to the ON position Release the parking brake Release the foot brake Slowly depress the accelerator pedal 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 Do not carry more than the maximum number of passengers allowed for this vehicle Do not exceed the cargo load capacity Do not load cargo that can fall off Be careful when handling cargo that is longer wider or higher than this vehicle be sure to properly secure all loads 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 lo
121. ooting steps that have led to this point The tests may need to be repeated Page 18 Curtis PMC Troubleshooting SYMPTOM 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 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 both directions plus high armature current in both directions 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 Accelerates slowly and exceeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS gt Full speed only PMC CONTROL Does not run in either direction plus there is noise from motor hum or whine PLUGGING DIODE with high field current and low armature current gt Excessive spark
122. op significantly and slowly taper off voltage will remain constant The charger should turn off within 2 to 4 hours after entering the second stage when the charginc current is down to A1 GEL batteries must be charged with charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries signet Charger Troubleshooting Page 4 Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing it indicates a problem has occured during the charging cycle If the light is flashing it will flash from 2 to 6 times before a pause This is the fault code Refer to the table below Status Light Panel Fault Description Action Required Code 4 1 Charge cycle time exceeded the time Test batteries for possible Time out no flash defictive cells Open circuit or reverse polarity to Check battery wiring battery Wrong voltage charger or batteries installed 24v charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 3 Battery voltage too high Inspect for dirt or debris on the charger cooling fins and clean as 4 Overheated i required AC line voltate too high or too Check the input voltage
123. or 1 21 88 109 81 3 8NC lock nut B 1 00 only Oor 1 27 96 71 00 3 8 x 3 4 clevis pin 1 23 01 110 20 Accelerator pedal 1 24 88 069 8 1 I ANC Nylon lock nut 2 25 88 065 09 x 3 4 Hex bolt 2 26 88 065 12 x 3 4 Truss head bolt 2 SECTION 5 21 MB 100 00 Wheels and Tires wheel hub Ref SECTION 5 PAGE 22 MB 100 00 Wheels and Tires ITEM PART DESCRIPTION QTY 1 Tubeless Wheels 12 012 00 5 x 8 Tubeless standard 4 12 020 00 8 5 x 8 Tubeless 4 2 Tires 10 081 00 5 70 x 8 standard 4 10 082 00 5 70 x 8 Extra Grip 4 10 083 00 5 70 x 8LR C 4 10 093 00 8 50 x 8 LR B 4 10 091 10 8 50 x 8 Knobby 4 10 092 00 8 50 x 8 LR C 4 10 086 00 5 00 x 8 Man Toterswith lugs soft solid 4 Split Rim Wheels 3 12 041 12 Inner Wheel 2 5 bead 4 4 12 041 13 Outer Wheel 2 5 bead 4 5 12 041 00 Wheel Assembly 2 5 bead wid
124. ot shown 72 022 52 Tail light pigtail 1 SECTION 5 PAGE 37 MB 100 00 Front Cowl Decals Left Rear Wheel Well SECTION 5 PAGE 38 MB 100 00 Decals ITEM PART DESCRIPTION QTY 1 94 313 20 Safety warnings 1 2 94 301 42 Keep arms and legs inside 1 3 94 384 00 Apply park brake 1 4 94 373 10 Vehicle data plate 1 5 94 333 00 FM approved 1 6 94 309 00 Brake warning 1 7 94 384 14 Turn keu off 1 amp 94 384 01 Not a motor vehicle 1 9 1 10 94 319 00 Battery disconnect 1 11 94 313 00 Battery warning 1 Not shown 94 301 50 Cary Master decal B 1 25 only 2 SECTION 5 PAGE 39 MB 100 00 Strobe Light 4 1 2 Nu is SS 15 wa 16 10 t Mg Mount for Strobe Light on Sun Top SECTION 5 PAGE 40 MB 100 00
125. ove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Section 3 Page 20 MB 100 00 Seal Bearing Hub Tapered Bearing Tapered Bearing Race Bearing Cotter Pin s 9 Washer Spindle Nut Dust Cap Wheel Bearings 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Remove the tire wheel assembly 8 Remove the dust cap and spindle nut 9 Remove the hub from the axle yoke NOTE Catch the outer bearing as it falls out Section 3 Page 21 MB 100 00 10 Clean all grease from the inside of the hub and bearings 11 Inspect and replace the races and bearings as a set NOTE It is recommended to replace both the left and right wheel bearings at the same time 12 Assemble in reverse order using new grease seals a Pack inner and outer bearings with grease b While rotating the hub tighten the spindle nut to 30
126. own is for illustration only The actual voltage may vary 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 otop 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 Page 21 Curtis PMC Troubleshooting PLUGGING DIODE Make sure the key switch is in the OFF position then remove the key AW ARNIN 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 AWARNING legs and loose
127. ptacle to the negative terminal on the DC receptacle This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wire on the negative terminal of the DC receptacle is broken or has a bad connection Stop here and repair the problem Remove the charger cover and perform the following tests HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNI NG terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one lead from the capacitor Test the capacitor using the capacitor test function on the meter If the capacitor is bad it must be replaced Stop here and repair the problem Capacitor Test 4 Reconnect the lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the diodes using the diode test function on the meter If either one of Diode 1 the diodes are bad replace the diode B assembly Stop here and repair the problem r Diode 2 Charger Troubleshooting el Page 8 Electrical Troubleshooting 5 Reconnect the lead to the diode 6 Connect
128. r 1 75 hole Not Shown 98 599 20 Plastic grommet for 2 5 hole Not Shown 95 917 00 Plastic plug for 7 8 hole Not Shown 75 166 36 Headlight harness 1 Not shown 98 603 00 Rubber grommet 3 8 ID for 1 2 to 9 16 hole Not Shown 75 107 10 Potratble charger harness 1 Not Shown 76 013 00 Portable charger receptacle 1 Not shown 79 306 23 Charger interlock module 230 volt 0 or 1 la 73 005 05 Reverse warning alarm 0 or 1 15 73 005 01 Reverse warning alarm 0 or 1 2 96 650 01 Wire harness clip stick on 3 96 642 00 Wire harness clip push mount 4 62 033 00 Accelerator module 1 5 71 122 20 Horn switch 1 6 88 065 06 1 4 NC x 21 2 Phillips truss headsScrew horn switch 2 7 88 069 81 1 4 NC Hex nylon locknut horn switch 2 8 71 111 00 Brake light switch 1 9 88 045 06 10 32 x 1 2 Machine screw 2 9a 88 048 62 10 Split lock washer 2 10 71 102 10 Seat interlock switch 1 11 85 030 00 Spring 2 12 96 773 10 Clevis pin 2 13 02 610 18 Mounting plate 1 14 88 527 11 2 15 96 640 00 Clamp 3 16 push mount 96 629 80 not shown Clamp rubber lined 3 16 ID 96 630 00 not shown Clamp Rubber lined 5 8 ID 96 630 50 not shown Clamp Rubber lined 5 8 ID 265 mounting hole 7 96 631 00 not shown Clamp Rubber lined 3 4 ID 96 631 10 shown Clamp Rubber lined 1 0 ID 96 631 15 not shown Clamp Rubber lined 1 1 2 ID 96 624 00 Clamp 1 4 jiffy clip 96 625 00 not shown Clamp 5 16 jiffy clip 18 96 626 00 Clamp 7
129. r Bearings Worn Oil Leak in Rear Bearing Area Rear Wheel Bearing and or Gasket Failed Drive Over Filled 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 Section 3 Page 5 MB 100 00 MECHANICAL AWARNING DRUM BRAKES ENSION SPRINGS RETRACTING SP DJUSTING DJUSTING SCR Taylor Dunn does not currently supply asbestos fiber brake pads shoes with any vehicle However there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as if they do contain asbestos Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Alwa
130. re 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 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 e 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 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
131. reverse order 12 Lower the vehicle 13 Reconnect the main positive and negative at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehicle Section 3 Page 16 MB 100 00 ALIGNING THE END Adjusting the Toe In 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING 1 toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 With a piece of chalk mark a line around the center of both tires 8 Loosen the ball joint clamps at each end of the tie rod so the adjusting sleeve can be turned 9 With the wheels in the straightforward direction measure the distance between chalk lines at the front and the rear of the tires 10 Adjust the tie rod until the distance from mark to mark across the front of the tires is the same as the distance from mark to mark across the rear Refer to the illustration below 11 Tighten the ball joint clamp 12 Lower the vehicle
132. rings must be replaced with new ones Failure to replace the A WARNING bearings and retainer could result in the axle coming out of the vehicle while driving causing severe bodily injury and or property damage 11 Inspect all bearings for roughness or play 12 Install in reverse order 13 Adjust the brakes 14 Lower the vehicle 15 Reconnect the main positive and negative at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Section 3 Page 31 MB 100 00 Servicing the Differential 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AW ARNING to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Remove the complete drive from the vehicle Remove the motor Drain the oil from the differential into the appropriate receptacle 10 Remove the axle shafts from the differential 11 Remove the cover plate from the differential and let the remaining oil drain from the
133. ription Action Required Reverse polarity or open circuit to Check wiring for corrosion loose connections broken wires and the batteries proper connection to the batteries AC voltate too high or too Check the input voltage low It must be within 96 132VAC or 196 266VAC Wait for charger to cool the charger will automaticaly restart Inspect for dirt or debris the charger cooling fins and clean as required Input or Output over current Charger will automaticaly correct for this condition and restart n many cases fault 1 will only be displayed for a short amount of time and then the charger will attempt to restart Typically the fault will repeat 8 times and then the charger will start the boot up process with the 50 light on If the charger cannot restart then the fault loop will start again repeating the fault 1 This fault could be a result of an open connection between the charger and batteries an open connection on one or more of the battery cables or an open connection internal of the charger Before replacing the charger confirm all battery wiring 1s good Status LED s SIGNET SYSTEMS INC Tvpical Charger Data Plate vour data plate may vary Signet Charger Troubleshooting Page 5 Electrical Troubleshooting TROUBLESHOOTING To test charger operation Connect a DC volt meter to the main battery positive and negative terminals Attach a clamp on DC Ammeter to one of the charger
134. rm Shaft Ball Nut Assembly 1 4 18 308 23 Upper Worm Shaft Bearing 1 5 18 308 22 Upper Worm Shaft Cup 1 6 18 308 77 Housing 1 7 18 308 78 Pinion Shaft Seal 1 8 9 2 10 18 308 79 Worm Shaft Seal 1 11 18 308 82 Gasket 1 12 18 308 76 Pinion Shaft 1 13 18 308 75 Gear Lash Adjuster 1 14 18 308 84 Side Cover 1 15 18 308 86 Lock Nut 1 16 18 308 83 Side Cover Screws 3 17 18 308 85 Shim Kit 1 SECTION 5 PAGE 9 MB 100 00 Front Suspension lt a e LEFT SIDE SHOWN NO 7 SECTION 5 PAGE 10 MB 100 00 Front Suspension ITEM PART DESCRIPTION QTY 1 85 506 05 Spring 2 2 50 460 00 Strap 2 3 32 213 00 Spring eye bushing 2 4 96 243 10 9 16NF x 3 1 2 Hex bolt grade 5 2 5 88 169 82 9 16NF Hex nut grade C 2 6 96 123 00 3 8 NC x 2 06 x 4 U bolt 4 7 88 109 82 3 8NC Hex lock nut grade 8 8 16 865 02 Spring plate 2 9 96 120 00 1 2NC x 1 7 8 x 2 U bolt 2 10 01 110 32 Spring mount pad 2 11 88 149 81 1 2NC Hex lock nut 4 SECTION 5 PAGE 11 MB 100 00 Transmission Differential Case SECTION 5 PAGE 12 MB 100 00 Tr
135. rminal voltage V1 and then switches to the second stage constant voltage At the second stage the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On the charger face plate there is a status light panel that displays the current status of the charger The first light POWER should be ON when the AC cord is connected to a proper AC power source The three STATUS lights will indicate the current charging condition as follows Left Charge cycle is ON and is in constant current mode Left amp Middle 8096 Charge cycle is ON and is in constant voltage mode Right 10096 Charge cycle completed The FAULT light will turn ON and flash a fault code only when an abnormal charging condition has occurred Refer to the fault code table for more information NOTE Critical faults will be accompanied with an audible beeping Status Light Panel signet Charger Troubleshooting Page3 Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started NOTE The charge cycle time is limited to 20 hours max A fault will occur if charging time exceeds the time limit Refer to the fault code table for more information A charger could remain on for longer
136. rminals Refer to your vehicles wiring diagram to identify the position of the reverse solenoid Close all interlock switches turn the Key Switch ON and place F amp R Switch in reverse Depress the accelerator pedal fully f the voltage is not at battery volts then go to the F Switch sequence the test light voltage to the same voltage as the battery volts Connect the test light across the normally open contacts of the reverse solenoid Refer to your vehicles wiring diagram to identify the position of the reverse solenoid Close all interlock switches turn the Key Switch ON and place F amp R Switch in reverse Depress the accelerator pedal fully e 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 Page 16 The voltage shown is for illustration only The actual voltage may vary The voltage shown is for illustration only The actual voltage may vary Solenoids are shown for reference only The type and position of the reverse solenoid in your truck may be different FWD REV Solenoids are shown for reference only The type and position of the reverse solenoid in your truck may be different
137. ront wheels to prevent vehicle movement 5 Disconnect the charger from the AC source Locate the charger harness connectors where the charger harness is connected to the vehicle s control harness There will be two 10 gauge and two 14 gauge wires olide the insulators off the connectors on the two 10 gauge wires and perform the following tests Make sure that these two wires do not come into electrical contact CAUTION with any other object 6 Test the voltage from the red wire to the main battery negative This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then this wire is broken or has a bad connection Stop here and repair the problem lest the voltage from the red 10 gauge wire to the other 10 gauge wire white or black depending on model This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the white or black wire is broken or has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires olide the insulators off the connectors on the two 14 gauge wires High Voltage Do not touch the 14 gauge wires and make sure these A WARNING two wires do not come into electrical contact with any other object Failure to do so may result in serious bodily injury Re Connect the charger to the AC source 8 Test the voltage across the two 14 gauge wir
138. ry voltage equals V1 the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the POWER light is ON then the charger has failed and must be replaced If the POWER light is OFF then check the AC power source AC power cable and connections If the source cable and connections are good then the charger has failed and must be replaced The charger comes equipped with a long fully insulated AC cord that can be cut to length as needed for the vehicle application Do not cut the AC cord and splice to the existing AC cord in the vehicle Cutting and splicing the AC cord will void the charger warranty GEL batteries must be charged with charger configured for GEL batteries Use of any other charger will result in damage to the batteries and premature failure of the batteries signet Charger Troubleshooting Page 6 Illustrated Parts TABLE OF CONTENTS Front Axle and Steering Knuckle 2 steenndg LINKAGE 4 Steering Gola 6 Oed E Veces 8 Front Suspension 10 Transmission Differential Case 12 Rear Axle and
139. s a constant current until the HB1000 36 battery reaches a terminal voltage and then switches to the second stage constant voltage At the second stage the charger decreases the AUTO SELECTABLE DUAL AG INPUT charger current while holding the batteries at the 100 240V 50 S0Hz 12 04 terminal voltage until the charging cycle is MAX 454V SOUWATT complete The charger faceplate has three status LED s that SYSTEMS INC monitor the charging status Refer to the chart and illustration below for the function of these LED s If an error occurs during charging the charger will beep and display an error code by flashing the status LED s Refer to the Status LED error code table later in this section 7596 1009 complete Error refer to FLASHING FLASHING FLASHING troubleshooting SIGNET SYSTEMS INC Charger Time O ut Tvpical Charger Data Plate vour data plate may vary signet Charger Troubleshooting Page 2 Electrical Troubleshooting 24 HB PT AND GEL INDICATOR LAMPS NOTE Your charger may not be equipped with these lamps GEL HB PT Lamp If the HB PT lamp is ON then the charger has overheated and has entered a proportionally reduced output The charging cycle INDUSTRIAL will terminate if the temperature continues to rise If the charging cycle is terminated the charger will automatically restart once it has cooled o oO The charging cycle is limited to 18
140. 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 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 PROGHAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for those claiming to have previous vehicle operation experience Successful completion of the Operator Training program shall be required for all personnel who operate this vehicle The Operator Training program shall include the following Operation of this vehicle under circumstances normally associated with your particular environment Emphasis on the safety of cargo
141. t in serious bodily injury Using the appropriate procedure remove the steering gear Remove the drag link from the pitman arm Loosen the jam nut for the gear lash adjuster To adjust the gear lash loosen or tighten the setscrew NOTE there should be a slight drag when the steering gear passes through the center of its travel Tighten the jam nut NOTE Do not allow the setscrew to turn while tightening Install the drag link 13 14 15 Using the appropriate procedure reinstall the steering gear Lower the vehicle Reconnect the main positive and negative at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Section 3 Page 26 2 IE Gear Lash Adjuster S Worm Bearing Adjuster MB 100 00 STEERING GEAR DISASSEMBLY AND REPAIR Disassembly NOTE The steering gear must be removed from the vehicle for this procedure Refer to Removal and Installation of the Steering Gear Assembly section for information regarding removing the steering gear NOTE The steering gear is packed with grease Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled Refer to illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction
142. t the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING 1 toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 7 Using the appropriate procedure remove the steering gear Worm Bearing 8 Loosen the worm bearing adjuster locknut Adjuster 9 Tighten the worm bearing adjuster so that there is no endplay or wobble in the input shaft 10 Using the appropriate procedure reinstall the steering gear 11 Lower the vehicle 12 Reconnect the main positive and negative at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Section 3 Page 25 MB 100 00 Gear Lash 6 AWARNING 11 12 16 17 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands 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 resul
143. tate during some of the following tests Block the front wheels raise the rear drive wheels off the ground and support the vehicle with jack stands Failure to do so may cause the vehicle to move and cause severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key 3 Set the park brake 2 Place the forward reverse switch in the center OFF position 4 Place blocks under the front wheels to prevent vehicle movement 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 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 is 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
144. ted to the motor to insure that they are returned to their proper location on the motor during reassembly 7 Remove the motor mounting bolts from the drive and slide the motor off of the input shaft 8 Install the new motor or reassemble in reverse order NOTE Apply grease to the input shaft Section 3 Page 37 MB 100 00 Armature Inspection 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the motor from the drive 11 Measure the diameter of the commutator 7 Remove the two armature retaining screws from Note The wear limit of the commutator is 2 625 the rear cover inches If the commutator is less then 2 625 inches then it is worn out and the motor 8 Pull the armature out from the open end of the must be replaced motor housing 12 Measure the undercut depth on the 9 Check the inside of the motor housing and around commutator the commutator for bits of solder Note The undercut depth is 025 inches If the Note If there are signs of solder either around the undercut depth is less then 025 inches the inside of the motor housing or the mica can be recut to the proper depth commutator then the motor must be
145. tely retest the vehicle before lowering the drive wheels to the ground Set the test light voltage to the same voltage as the battery volts 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 solenoid Close all interlock switches turn the Key Switch ON and place the Switch in Forward Depress the accelerator pedal fully e Ifthe 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 STOP Solenoids are shown for reference only The type and position of the forward solenoid in your truck may be different 2 FWD REV FWD REV Solenoids are shown for reference only The type and position of the reverse solenoid in your truck may be different otop 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 sh
146. teries 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 gt on PMC control Refer to Diode Figure 2 If you do not know how to test for a diode refer test to a qualified technician e 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 Itis important to review the trouble shooting steps that have led to this p
147. th includes 3 4 6 7 8 4 3a 12 042 12 Inner Wheel 12 bolt 4 4a 12 042 13 Outer Wheel 12 bolt 4 5a 12 042 00 Wheel Assembly 3 75 bead width includes 4 6 7 8 4 6 88 110 09 3 8 x 3 4 NF Hex Bolt grade 5 4 7 88 109 62 3 8 Split Lock Washer 4 8 88 119 80 3 8 4 9 97 236 00 Wheel Nut 20 Not Shown 13 989 00 Valve stem tubless tire only Not Shown 11 041 00 8 50 x 8 Tube Not Shown 11 040 00 5 70 x 8 Tube Tire and Wheel Assemblies 13 742 00 5 70 x 8 standard 4 13 742 40 5 70 x 8 Man Toter 13 742 11 5 70 x 8 Split Rim 13 746 10 8 50x 8 10 16 051 00 Spacer used on rear 8 50 x 8 and split rim wheels only 0 or 2 SECTION 5 PAGE 23 MB 100 00 Instrument Panel SECTION 5 PAGE 24 MB 100 00 Instrument Panel ITEM PART DESCRIPTION QTY 1 74 009 00 Battery status indicator 1 2 74 000 00 Hour meter 1 3 71 100 00 Accessory switch 1 4 71 100 00 Accessory switch 1 5 71 039 02 Forward and reverse switch 1 6 71 120 10 Key switch 1 01 110 30 Mounting plate 1 94 386 03 Mounting plate decal 1 Not shown 88 065 09 x 3 4 Phillips truss head bolt Mounting plate bolt 2 Not shown 97 211 2
148. the Switch in forward f the voltage is not at battery volts then to the Key Switch sequence E B MM I ol Main Battery Negative Connect a voltmeter across the Forward Solenoid coil terminals Refer to your vehicles wiring diagram to identify The voltage shown is for illustration the position of the forward solenoid only The actual voltage may vary Close all interlock switches turn the Key Switch ON Solenoids are shown for reference only and place the F amp R Switch in forward m z The type and position of the forward Depress the accelerator pedal fully solenoid in your truck may be different If the voltage is not at battery volts then go to the F i Switch sequence ero FWD REV Page 17 Curtis PMC Troubleshooting Set the test light voltage to the same voltage as the battery volts Connect the test light across the Normally Open 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 e If the light comes on then the Forward solenoid has failed Stop trouble shooting here and repair the problem When the repair is completed comple
149. tic SYSTEMS INC Typical Data Plate vour data plate may be different SECTION 5 PAGE 33 MB 100 00 Batteries 5 QO Oro 2 2 Negative Tap lt FRONT Main Positive SECTION 5 PAGE 34 MB 100 00 Batteries ITEM PART DESCRIPTION QTY 1 75 231 00 Jumper cable 5 2 71 042 80 1105 Battery 0 or 6 2 71 042 50 TD 217 Battery 0 or 6 2 77 047 50 TD 250 Battery 0 or 6 2 77 047 00 T145 Battery 0 or 6 3 50 250 00 Bat Loc battery hold down 3 4 88 088 66 5 16 x 1 5OD Tin lead plated flat washer 3 5a 50 243 10 Battery rod 3 5b 88 069 81 1 4NC Nylon lock nut 3 6 88 081 12 5 16NC x 1 Hex head bolt stainless stel 12 T 88 089 80 5 16NC Hex nut stainless steel 12 8 77 055 01 Low water level alarm 0 or 1 SECTION 5 PAGE 35 MB 100 00 Seat Cushions Lights and Deck 10 1 11 Model B 1 00 light on rear panel 13 Headlight assembly Model B 1 25 SECTION 5 PAGE 36 MB 100 00
150. ur 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 If the voltage is not at battery volts then check the wire between the key switch and battery positive 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 COLD terminal of the key switch and battery negative Turn the key switch ON If the voltage is not at battery volts then the key switch has failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground If 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 View of the terminals of a typical Key Switch KEY SWITCH COLD Violet Wire s Q gt N onda Red wire s BATTERY MAIN NEGATIVE View of the terminals of a 0000 typical Key Switch Hz
151. when connecting battery ISO Does not run or runs very slow with low motor current and high battery current FREEWHEEL DIODE gt Jumps into high speed when direction is selected after depressing the accelerator HPD pedal Special Troubleshooting Table of Contents PMC CONTRO crane 22 PEGGING DIODB 29 DRBEWEEELDIODE 26 cse 27 SOLENOIDS E 29 MOTOR ee eee 92 Page 19 Curtis PMC Troubleshooting PMC CONTROL Make sure the key switch is in the OFF position then remove the key AW ARNIN 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 wire from the M terminal
152. wire connected to the motor A2 terminal C The wire connected to the motor S1 Motor shown for reference only Terminal positions on your motor may not be in the same location terminal is shorted to the wire connected to the PMC A2 terminal Page 26 Curtis PMC Troubleshooting 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 e 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 B The wire connected to the motor S2 terminal is shorted to the wire connected to the motor A2 terminal C The wire connected to the motor S2 Motor shown for reference only Terminal positions on your motor may not be in the same location 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 otherw
153. ys 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 Section 3 Page 6 MB 100 00 AUTO ADJUST BRAKE MECHANISM THEORY OF OPERATION The auto adjust mechanism is located on the bottom of the brake assembly and accessible through the oval slot in the brake drum As the brake pad material wears down the distance the brake shoes travel to engage the brake drum becomes longer When the travel becomes long enough the brake lever engages the auto adjust lever and causes it to index a tooth on the star wheel adjuster This rotates the adjuster which decreases the travel needed for the brake shoes to engage the brake drum NOTE The only time the brakes should be manually adjusted is when an internal component of the braking system has been removed NOTE The brakes will not require manual adjustment if any part of the external mechanical linkages or cables have been removed NOTE The symptom of a low brake pedal may indicate that the auto adjuster is not working or the brake cable is not adjusted properly the vehicle from service and repair the brakes NOTE The brake adjustment is inside of the left and right brake Do not adjust t

Taylor Dunn B-100 Manual

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