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The Best Way To Go About Your Business MANUAL - Taylor-Dunn

1. Batteries ITEM PART DESCRIPTION QTY 71 042 00 217AH T 105 0 or 6 71 042 50 217AH TD 217 0 or 6 77 042 80 217AH T 105 Moist charge dry 0 or 6 71 044 00 230AH T 125 0 or 6 77 044 10 195AH Mainenance free Note requires special charger O or 6 71 047 00 244AH T 145 0 or 6 71 04 50 250AH TD 250 0 or 6 77 047 80 244AH T 145 Moist charge dry 0 or 6 71 048 00 250AH J 250 0 or 6 77 048 80 250AH J 250 Moist charge dry 0 or 6 77 05 1 00 160AH Gell Note requires special charger 0 or 6 75 233 00 JUMPER BATT 10 1 4 4 GA 5 75 234 00 JUMPER BATT 22 4 GA 75 238 00 JUMPER BATT 31 4 GA 04 380 11 Battery stop 50 243 10 Battery rod 3 50 250 00 Battery hold down 3 88 088 66 5 16WASHERX1 5 OD TIN LEAD 3 88 088 66 Flat washer tin lead plated 3 88 069 8 1 1 4NC Nylon lock nut 3 88 081 12 5 16NC x 1 Hex bolt stainless steel 12 88 089 80 5 16NC Hex nut stainless steel 12 88 089 70 5 16 Split lock washer stainless steel 12 Parts Page 45 lllustrated Parts Decals
2. FOLD DOWN REAR SEAT ITEM PART DESCRIPTION QTY 90 109 63 Fold Down Rear Seat Kit 1 1 90 000 00 6 X 34 Backrest 2 90 177 00 Seat Cushion 1 3 88 837 11 14 X 1 Phillips Sheet Metal Screw 8 4 00 380 67 Rear Flip Up Deck 1 5 88 065 09 A NC X 3 4 Phillips Truss Head Screw 6 6 88 068 61 1 4 SAE Washer 6 7 88 069 81 1 4 NC Locknut 6 PIPE SIDE RAILS 8 00 680 22 Left Handrail 1 9 00 680 23 Right Handrail 1 10 88 065 09 1 4 NC X 3 4 Phillips Truss Head Screw 10 1 88 068 61 1 4 SAE Washer 10 12 88 069 8 1 1 4 NC Locknut 10 REAR GATE 13 00 680 24 Rear Gate 1 DECK PLATES 14 02 380 76 Rear Stationary Deck 1 00 380 58 Rear Diamond Deck l E 00 380 67 Rear Flip Up Deck 1 SIDE RAILS 00 680 20 Rear 1 Not Shown 00 680 21 Left or night 2 02 680 20 Support rear 1 TOOL BOX nde 00 380 71 Tool box door right 00 380 70 Tool box door left CARGO BOX 91 322 20 45 High with locking doors and windows 90 85 1 00 Door window 2 90 850 10 Windoe front of box 98 3 10 00 Window gasket by the foot 94 320 10 Load line decal 91 320 20 24 high cargo box Par
3. ITEM PART DESCRIPTION QTY 1 88 067 21 Hex bolt grade 8 4 2 41 350 51 Secondary plate 2 3 41 348 70 Brake pad 4 4 41 348 52 61 Spacer kit includes spacers 4 and bushings 5 for 1 wheel 4 5 41 348 52 61 Bushing kit includes spacers 4 and bushings 5 for 1 wheel 4 6 41 350 28 Mounting bracket 2 7 See Rear Axle Hex bolt with thread locking compund 8 8 See Brake Body Brake body assembly 2 9 88 840 11 Retaining ring 2 10 See below Brake bleeder 2 11 32 220 03 Bushing 2 12 41 350 56 Park brake pin 2 13 41 350 12 Park brake lever bracket 2 41 350 52 Clevis pin 2 14 88 100 00 Washer 4 88 840 11 Retaining clip 2 15 41 350 53 Brake arm 2 Not shown 41 350 59 Extension brake arm 2 16 88 069 82 1 4NC locknut grade 8 4 Front Brake ITEM PART DESCRIPTION QTY 88 069 82 Locknut 1 4 NC Gr 8 Do Not Reuse 4 2 Bleeder screw 2 See Brake Body 3 Bleeder screw adapter 2 4 41 350 70 Assembly Front Hydraulic Brake Body 2 5 See Steering Knuckle Mounting bracket 6 41 348 52 61 Bushing kit includes spacers 4 and bushings 5 for 1 wheel 4 7 41 348 52 61 Spacer kit includes spacers 4 and bushings 5 for 1 wheel 4 8 41 348 70 Pad Disc Brake 4 9 41 350 51 Plate Secondary Hydraulic Disc 2 10 88
4. CAB DOORS ITEM PART DESCRIPTION QTY 90 924 60 Left Door Kit 1 90 924 61 Right Door Kit 1 90 923 98 Left Door Frame 1 i 90 923 99 Right Door Frame 1 90 924 98 Left Side Curtain 1 90 924 99 Right Side Curtain 1 3 97 315 53 Outer Handle Assembly 1 4 97 315 51 Door Latch 9 97 315 54 Inner Handle 1 6 97 303 03 Snap Fastener Female 7 7 88 727 06 5 13 X 1 2 Rivit 7 8 88 025 08 8 32 X 5 8 Truss Head Screw 2 9 88 029 86 8 32 Locknut 2 91 814 10 Left Hinge Female 2 l 91 814 11 Right Hinge Female 2 11 88 082 09 5 16 NC X 5 8 Carriage Bolt 4 12 88 089 81 5 16 NC Locknut 4 91 011 66 Metal Cab Door Kit Left Specify Color Inclds 10 11 12 1 91 011 68 Metal Cab Door Kit Left Orange Incld 10 11 12 1 91 011 67 Metal Cab Door Kit Right Specify Color Inclds 10 11 12 1 91 011 69 Metal Cab Door Kit Right Orange Inclds 10 11 12 1 90 853 10 Left Window 1 T 90 853 11 Right Window 1 15 97 315 58 Inner Door Handle 1 16 91 012 12 Connecting Bar i 17 16 510 00 Spacer 1 18 88 065 06 1 4 NC X 1 2 Phillips Truss Head Screw 1 19 88 045 08 10 32 X 5 8 Truss Head Screw l 20 88 049 06 3110 32 Locknut 1 21 88 045 11 110 32 X 1 Truss Head Screw 2 22 88 048 62 10 Lockwasher 2 23 88 049 80 1110 32 Nut 2 24 91 012 45 Door Reatraint Strap 1 25 88 082 11 5 16 NC X 1 Carriage Bolt 1 26 88 088 60 5 16 Washer 1 21 88 088 62 5 16 Lockwasher 28 88 089 83 5 16 Acorn Nut 1 91
5. Steering Gear ITEM PART DESCRIPTION QTY 1 18 308 70 Locknut 2 18 308 71 Adjuster assembly 1 3 18 308 72 Worm assenbly 1 4 18 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input shaft 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 13 18 308 75 Gear lash adjuster 14 18 308 85 Shim kit 1 15 18 308 84 Side cover 1 16 18 308 86 Jam nut 1 17 18 308 83 Bolt side cover 3 Parts Page 7 Illustrated Parts Front Suspension 10 jen v MA ZA W z A A QN GG A V Ox oD j om JR oOo BBB M Z 2 AW DACH ko ro rp AME TO Parts Page 8 Front Suspension Item Part 1 88 119 80 2 86 006 01 3 86 006 00 4 See Front Axle 5 88 121 19 6 85 506 01 7 01 680 61 8 88 109 81 9 88 129 81 10 88 100 15 11 02 380 50 Description 3 8 NF Hex Head Nut Shock Mounting Hardware Shock Absorber Axle Beam 7 16 X 2 3 4 NC Hex Cap Screw GR5 2 Leaf Spring Spring Pad 3 8 Nc Locknut 7 16 NC Lcoknut 3 8 X 1 3 4 NC Hex Head Screw Spring Pad Parts Page 9 Illustrated Parts QTY 16 16 Illustrated Part
6. 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 DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 volt battery has 3 cells Tem Vaue 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 Ai 2104 Amps All batteries Staring LEVOS l Temperature C Per Cell All voltages are nominal Less than 4 2 64 4 to 2 2 61 2108 2 59 8to 14 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 r
7. Parts Page 49 Illustrated Parts Strobe Light amp Other Front End Options 2o AGNI uu ss 7 24 25 2 fbi ae Parts Page 50 Illustrated Parts STROBE LIGHT DIRECTIONAL SIGNALS amp HEADLIGHT OPTIONS ITEM PART DESCRIPTION QTY 75 141 22 Turn Signal Switch 1 98 330 50 Insulator 1 2 76 352 00 Flasher Recptacle 3 71 900 05 12Volt Flasher 1 4 72 082 10 12Volt Turn signal Bulb 2 5 72 082 20 Turn Signal socket 2 6 7 8 9 10 72 023 20 Strobe Light Amber 1 11 72 023 25 Mounting Pole for Strobe Light 1 12 88 025 06 8 32 X 1 2 Truss Head Screw 3 13 88 028 62 8 Lockwasher 3 14 88 029 80 8 32 Nut 3 15 88 817 09 8 X 3 4 Phillips Head Sheet Metal Screw 2 16 88 065 08 1 4 NC X 5 8 Phillips Truss Head Screw 4 17 88 068 62 1 4 Lockwasher 4 18 88 069 83 1 4 NC Acorn Nut 4 71 100 00 Toggle Switch 1 Not Shown 75 115 17 Wire Harnes for Stobe Light Parts Page 51 Illustrated Parts Cab amp Cowl With Windshield Options if oa
8. 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 ww System are designed as semiautomatic chargers The AC Input Model pr charger turns itself on when it is plugged into the Voltage Range Voltage wall outlet and turns off when the batteries are fully charged Both the HB600W and HB1000W are two stage chargers The first stage is a constant current mode It Maintains a constant current until the battery reaches a terminal voltage and then switches to the second stage constant voltage At the second stage the charger decreases the AUTO SELECTABLE DUAL MC INPUT charger current while holding the batteries at the 100 240 asi 12 04 terminal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to the chart and illustration below for the function of these LED s Data Plate Details If an error OCCUIS 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
9. Cutaway of typical master cylinder showing the push rod clearance Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes regulations Dispose of brake fluid in accordance with local state and federal Read and follow all warnings on the brake fluid container Brakes Page 24 Maintenance Service and Repair REPAIR THE MASTER CYLINDER NOTE Hydraulic brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake fluid spills Remove the master cylinder from the vehicle See Replace the Master Cylinder section Drain all fluid from the master cylinder and discard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts as required If any damage is found in the bore of the master cylinder then it must be replaced Lubricate all parts with clean brake fluid from a sealed container Reassemble in reverse order If the master cylinder is not to be immediately installed onto a vehicle plug the brake line fitting hole to prevent any contaminates from entering the master cylinder Brakes Page 25 NN C SO TAV L TABLE OF CONTENTS Inspecting the Motor Brushes 2 Motors with internal cooling fans 2 Mo
10. 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 Clean the batteries then fill and charge before putting the vehicle in storage Do not store batteries in a discharged condition e Lube all grease fittings Clean dry and check all exposed electrical connections e Inflate tires to proper pressure if applicable e 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 be charged as follows Returning to 7 i torage Service Charging Interval Temperature Check the F months battery s state of charge and Over 60 l cha rg if Between 40 and 60 2 required Perform ALL 2 B maintenance checks in the periodic checklist e 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 Taylor Dunn Preventative Maintenance Schedule for GT Drive with DC Motor Date Model Hour Meter Inspected By Serial
11. Serviced Hy Umt DF EL Tumas pneumatic tires o Bre read o a rupe m tail brake warning a and TET all hardware Erst 500 hours aniy then 1000 bous and every 1000 hoars Ps Inspect suspension bushings spring shock po spect suspension bumpers po Replace brake pedal treadie rerum spring I rs Notes 1 and 2 Maintenance Guidelines for Severe Duty in the vehicles service manual Form PM 0001 GT Driva DC Motor Kavision B O6 20 2007 NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Safety Rules Documentation CD under the Misc sub folder Page 15 SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY NOTE The maintenance function is optional Your vehicle may be equipped with a customized maintenance schedule PREVENTATIVE MAINTENANCE SCHEDULE MAINTENANCE LEVEL HOUR INTERVAL MAINTENANCE TO BE PERFORMED 500 Inspect the brake system including the park brake and mounting harware Inspect the steering system tighten the steering shaft coupler on the steering gear input shaft Lubricate the vehicle check for leaks Inspect safety interlocks Inspect front and rear wheel bearings Inspect and adjust fork collar bearings 3 wheel trucks only Inspect and tighten all nu
12. 6 Clean the batteries Refer to Cleaning the Filler neck Batteries section for information on cleaning the batteries fae 7 Check the electrolyte level in all battery cells If x toy Ss mde water low fill to the correct level with distilled water using part number 77 201 00 battery filler never add additional battery electrolyte to the batteries CS inside battery 8 Reconnect the batteries remove the blocks from the wheels and test drive Battery cutaway CHARGING Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions Batteries Page 6 Maintenance Service and Repair REPLACING 6 VOLT BATTERIES ONLY Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks A WARNING cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not
13. Dual Brake Lights Lighting Accessories Motor DC RE 380 36 36 Volt RE 380 48 48 volt Maximum RE 380 36 36 Volt Recommended RE 380 48 48 Volt Brakes R E 380 36 36 Volt R E 380 48 48 Volt Steering Tires Frame Instrumentation Charger RE 380 36 36 Volt RE 380 48 48 Volt 115v 12 Amp 60Hz AC 25 Amp DC Built In Automatic Multi Volt input 100 240AC 9 4 5 Amp 50 60Hz AC 1kW DC Built In 3 Stage Automatic Specifications are subject to change without notice 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 It isthe 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 AWARNING These vehicles are not designed to be
14. Failure to support the steering gear will result in the steering gear falling out A WARNING of tne vehicle and could cause property damage and or severe bodily injury 10 Remove the bolts holding the steering gear to the Steering Gear with Pitman Arm vehicle frame and remove the steering gear from the vehicle 11 Install in reverse order Torque the pitman arm nut to 75 100 ft lbs 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the parking brake and test drive the vehicle Steering Page 10 Maintenance Service and Repair REPAIR THE STEERING GEAR Disassembly NOTE The steering gear must be removed from the vehicle for this procedure Refer to Replace the Steering Gear section for information regarding removing the steering gear NOTE The steering gear is packed with grease Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled Refer to the illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counting the rotation turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction 2 Remove the worm bearing adjuster locking
15. Lower the wheel to the ground Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle Tires and Wheels Page 3 Maintenance Service and Repair 8 Bolt Pattern 4 Bolt Pattern 5 Bolt Pattern Pattern for tightening the wheel nuts Re torque all wheel nuts to their final value after 1 week 20 hours of operation Failure to re torque the wheel nuts may result in the A WARNING wheel coming off of the vehicle causing severe bodily injury and or property damage HEPAIR THE TIRE PNEUMATIC Do not attempt to repair a tire with a damaged side wall or a slice in A WARNING thetread This type of repair could fail prematurely resulting in severe bodily injury and or property damage NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the type of repair equipment or repair components used Refer to the instructions provided with your equipment or repair components Tires and Wheels Page 4 Maintenance Service and Repair REPLACE THE TIRE PNEUMATIC NOTE To replace the tire the tire wheel assembly must be remove
16. QTY 3 1 2008 Part numbers 41 350 72 bracket and 41 350 73 plastic trim were added to support the parking brake arm on the rear calipers The bracket is mounted under the arm retained by one of the drive mounting u bolts Refer to bulletin BUL 08 01 001 for details The addition of the bracket helps reduce brake noises This is a temporary revision and will be in use until the brake body is updated to provide additional support A copy of the bulletin is included on the CD provided with the vehicle If you do not have the CD a copy of the bulletin may be obtained through your dealer or by contacting Taylor Dunn Parts Page 27 Illustrated Parts Wheels and Tires Ref wheel hub VO XA D oo e a p Parts Page 28 Illustrated Parts Wheels and Tires ITEM PART DESCRIPTION QTY l Tubeless Wheels 12 012 00 5 x 8 Tubeless standard 4 12 020 00 8 5 x 8 Tubeless 4
17. Tires and Wheels a e Battery Service N Control System Troubleshooting Go Battery Chargers Ja Wire diagram illustrated Parts o Appendix A Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Handling Precautions 18 This quick reference section index guide will assist you in locating a desired topic or procedure Refer to each sectional Table of Contents for the page number location for specific topics or procedures Introduction Contents About this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 COHVentlofs scen E EE recusa od ceto l usus 5 How to Identify Your Vehicle 6 Taking Delivery of Your Vehicle 7 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 ma
18. 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 Saee Capacitor Test JU Fuse Links 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 FW Diode 1 the diodes are bad replace the diode re Common assembly Stop here and repair the problem amp Diode 2 Charger Troubleshooting ez Page 8 Electrical Troubleshooting 5 Reconnect the lead to the diode 6 Connect the charger to the AC source Insert the DC charger plug into the DC receptacle and perform the following tests High Voltage inside the charger Do nottouch any internal components AW ARN I NG while the charger is plugged in Failure to do so may result in serious bodily injury e Test the voltage from the fuse assembly to the diode block This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the DC cord is bad Stop here and repair the problem e Test the voltage across the white and black wires that are connected to the timer board This voltage should be the same as the rated
19. 13 Release the parking brake and test drive the vehicle OOS Brakes Page 5 Maintenance Service and Repair ADJUST THE SERVICE BRAKES Two or Four Wheel Hydraulic Disc Brakes The hydraulic disc brake system is automatically adjusted A low brake pedal or lack of braking power could be caused by Brake fluid level low in the master cylinder See Check the Master Cylinder Fluid section Air in the brake lines See Bleed the Brakes section Worn brake pads See Inspect the Service Brake section Worn brake rotor See Inspect the Service Brake section e Binding brake pedal linkage If you are experiencing a low brake pedal or lack of braking power the entire brake system should be inspected Brakes Page 6 Maintenance Service and Repair ADJUST THE PARKING BRAKE Wheel Park Brake hydraulic disc The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles Park Brake Brake Arm Pin Extension 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 Release the park brake 7 Loosen the jam nuts on the Primary Adjustment Rod 8 Tighten the Primary Adjustment Rod until it i
20. 8 Fault Code Tables 10 Vehicle Operation Guidelines 11 Safety Guidelines 11 Starting MM 11 While driving 11 Loading and Unloading 11 Towing Loads 11 jewsaj Parking 12 Draw Bar Pull DBP definition 12 Automatic Electric Park Brake 12 Towing This Vehicle 12 Charging your vehicle 13 Signet Charger Operation Model HB Series 13 Signet Charger Operation Model HBS series 13 Lestronic II Charger Operation 14 New Battery Break in 14 Charging Time 14 Storing Returning to Service 14 Eo Storing Your Vehicle 14 Returning to Service 14 Periodic Maintenance Checklist 15 Standard Periodic Maintenance Schedule for the Smart View Display 16 Daily Visual inspection 17 Maintenance Guidelines for Severe
21. 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 Page 6 3 1 es e a Blue White Oren Green e Red ln O o R TURN 6 o
22. Check the wires from the F amp R switch to the logic card connector for continuity STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit A WARNING ACAUTION After any repairs are made completely retest This troubleshooting guide is written in the vehicle before lowering the drive wheels to sequential order All tests must be performedin the ground Failure to retest the vehicle could the order that they are written Starting in the result in unexpected movement of the vehicle middle or skipping sections when not instructed resulting in injury or property damage to do so may lead to invalid test results RI MIKE Sevcon Troubleshooting Page 14 Electrical Troubleshooting Test 8 ANTI ROLLOFF FAULT The Sevcon Controller is equipped with a feature called Anti Rolloff Anti Rolloff will automatically slow the vehicle if it starts to roll Anti Rolloff is active when the key switch has been left in the ON position and the accelerator pedal is not depressed Anti Rolloff is deactivated when the key switch is in the OFF position When the key switch is in the ON position and the truck is stationary the controller supplies a small current to the field This current is used to sense if the armature is rotating As the armature begins to rotate the controller
23. Models Inlcuded RE 380 36 R 380 36 RE 380 48 R 380 48 Equipped with the GT Drive System The Best Way To Go About Your Business Typical GT Drive MANUAL MR 380 28 Operation Troubleshooting and Replacement Parts Manual Published 1 6 2005 Revision D serial number Starting 155932 TAYLOR DUNN 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 Appendix B B 2 48 36 Equipped with optional B 1 00 Personnel carrier hydraulic dump bed MX 1600 Equipped with optional ladder rack and weld tanks Appendix B Page 6 C 4 25 Huskey tow tractor Section Index Taylor Dunn Model RE 380 36 RE 380 48 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Motor Service Transaxle Service O O N oO Q hb WO N Suspension
24. oja White gt Ea ooo R TAIL LIGHT 5 7 9 E of View from pin side White A E e 2 Brown gt gt dd L TAIL LIGHT 5 ti T VIEW FROM HEAD LIGHTS d 2 Z2 HARNESS SIDE e e e cA cA cA 9 Pin AMP VIEW FROM af Blue White Red HARNESS SIDE Brown 5 Blue 4 Green 16 Pin AMP m Green 6 Black iS lt ZA 2 o d 2 9 E Red 2 Gray 7 Black Gray lt lt S S R a Gra L TURN Blue BRAKE LIGHT Yellow 1 ray White gt White YELLOW Red 8 Black GREEN GRAY 3 o Red x STROBE LIGHT GRY BLK a eee i Q pal pee FLASHER BLACK Cj ste O 1r pn Blue White Blue White RED 2 E 680 Ohm Yellow se i Green o Q 9 White 2 E x 5 Watt COO N m Brown SWITCH 3 l l MOTOR 2 1 Red a l Red T Red oN Brown ii e 3 ISO l S Black x Violet Blue A2 Al White A Brown White meg i i a a VioleuBlack m gt SWITCH E l I L White White I l Red Red 13 l Z E l CONTROL l I l Black Whit E Red F z White y White c ridi SINE I PANEL O SMART VIEW Red Blue White 54 Blue White l 3 L l 4 J a ga Red Red l 3 Z y Il l a m Red pp Red d S e Interlock relay located in the To AC input l o 3 aa O l of E battery charger i for charger Violet Black E e j I E N 9 gt Violet Black l y Violet Black 8 Q rZ I O a Blue Black woe i l E 73 FIR z 5 7N S 1 SWITCH amp E 3 I 6 E i IO pi
25. 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Front Axle Page 11 Maintenance Service and Repair 7 Remove the ball joints or rod ends from the steering knuckles NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends Steering Knuckle Remove the tie rod as an assembly Install in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of sha dent BUS 9 9 Typical Front Axle Assembly 11 Lower the vehicle 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle HEPLACE THE KING PINS AND BUSHINGS There are different types of king pin bushings depending on the configuration of your vehicle Bronze bushings in the axle beam e Bronze bushings in the steering knuckle Metal backed teflon bushings in the axle beam The bronze bushings must be reamed or broached to the proper diameter after
26. 62 027 61 and 62 Sevcon System Handset Diagnostics and adjustments 62 only of the Sevcon Power Pak and Micro Pak control systems 43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor 62 027 64 and 65 Curtis AC System Handset Diagnostics and adjustments 65 only of the Curtis AC control system 75 089 00 Throttle Module Test Harness Used in conjunction with a volt meter to test the throttle module The module must be installed in a working control system Note Part 62 027 31 includes instructions 62 027 00 Test Light Used for testing electrical circuits Switchable for 12 24 36 48 volt systems Required to complete troubleshooting provided in the vehicle service manuals 96 500 43 PMT C Meter Reset Module Required to reset the PMT C maintenance meter special order option Appendixes Appendix A Page 2 Appendixes A APPENDIX A SPECIAL TOOLS 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors 41 350 13 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 77 200 00 Hydrometer Used for testing battery electrolyte Illustration is of a typical hydrometer actual hydrometer type may vary Molex 062 pin 11 0300 02 Molex 11 300 02 Pin Re
27. As the batteries are used segments will turn off in the order of right to left When the batteries are discharged to 75 the last three segments will flash indicating that you are approaching the end of the battery cycle At this time the vehicle s batteries should be charged as soon as possible At 90 all segments will flash and the vehicles speed will be reduced At this time the vehicle should be removed from service for charging Discharging beyond 90 will result in damage to the batteries that will shorten the battery life span NOTE The battery status gauge as well as any faults indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle Safety Rules Page 8 HM Depending on the revision level of the controller there are one or two hour meter functions Key Hours and Run Time Hours see note below Key Hours is the accumulated length of time in hours that the key switch is in the ON position Run Time Hours is the accumulated length of time that the vehicles has been in operation Time is accumulated when the FS 1 switch in the accelerator module is closed One of the Hours functions is being displayed whenever the either of the Hours Indicators are visible at the right side of the display NOTE The Key Hours function was discontinued starting with revision K controllers shipped in 2007 Key Hours When the display is turned on the Key Hours will be
28. Relieving pressure from the pedal releases the braking action Safety Rules Page 4 SAFETY RULES AND OPERATING INSTRUCTIONS Park Brake Ww The parking brake is actuated with a hand lever which is located between the driver and passenger seats To set the parking brake push down on the brake pedal and pull the lever up until it locks To release the park brake depress the foot brake pedal pull up on the park brake handle push the release button and lower the handle Horn Switch The horn switch is located to the left of the steering column Depress the switch with your left foot to sound the horn release it to turn it off Seat Interlock Switch A switch located under the driver s seat disables the power to the vehicle when the driver leaves the seat The driver must be seated for the vehicle to operate Whenever the driver leaves the seat they should turn the key switch off place the forward reverse switch in the center OFF position and set the park brake The seat interlock switch is only one part of the vehicle safety system The interlock switch should not be relied upon as the only safety AWARNING feature used to disable or disengage this vehicle Doing so could result in unexpected movement of the vehicle causing severe bodily injury and or property damage Charger Interlock The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functionin
29. Sevcon Troubleshooting Page 21 NN C SO TAV L 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 II 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 bui
30. driven on public roads or highways They are available in maximum designed speeds ranging from 7 to 15 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow this vehicle at more than 5 mph Refer to Vehicle Operational Guidelines Safety Guidelines section for important safety information regarding operating this vehicle AWARNING Read and follow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property damage Before working A WARNING on a vehicle Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries DRIVER TRAINING 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 follo
31. making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake body making sure that the boot seats properly into the upper groove on the piston 16 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 17 If the brake body assembly is not to be immediately installed onto a vehicle plug the brake hose fitting hole to prevent any contaminates from entering the brake bogy Brakes Page 22 Maintenance Service and Repair REPLACE THE MASTER CYLINDER Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately A WARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE Most vehicle configurations do not require lifting the vehicle to remove the master cylinder Lifting the vehi
32. 00 1 25 1 00 1 25 1 50 1 25 1 50 1 75 1 50 2 00 1 50 2 00 1 50 2 00 2 50 1 50 2 00 2 50 1 50 2 00 2 50 2 00 3 00 3 00 3 00 2 00 3 50 4 6 0 51 0 95 2 28 3 92 9 48 Grade N m 8 8 3 1 6 1 10 4 2 0 25 0 5 0 54 0 51 0 96 0 92 0 87 0 150 140 215 Not available at time of printing 10 9 12 9 Dia o o Co 20 22 24 27 30 Pitch 0 50 0 70 0 80 1 00 1 00 1 25 1 00 1 25 1 50 1 25 1 50 1 75 1 50 2 00 1 50 2 00 1 50 2 00 2 50 1 50 2 00 2 50 1 50 2 00 2 50 2 00 3 00 3 00 3 00 2 00 3 50 4 6 0 38 0 7 1 7 2 9 7 Metric Foot Pounds Grade N m 8 8 10 9 2 3 i 4 5 2 7 7 11 4 19 9 18 4 27 3 42 i 40 38 55 71 68 64 118 111 103 151 158 229 221 317 si 428 i 524 12 9 Appendixes Appendix B Page 7 Appendixes APPENDIX C BRAKE LINING HANDLING PRECAUTIONS Taylor Dunn does not currently supply asbestos fiber brake pads shoes with any vehicle However there is the possibility that the original brake pads shoes were replaced with aftermarket pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as if they do contain asbestos Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard cau
33. 00 10 88 119 80 11 50 009 00 12 88 100 09 13 17 104 00 14 99 510 02 15 88 100 09 16 88 527 11 17 88 101 20 18 00 380 79 Description Brake Rod 3 8NC Lock Nut 3 8 SAE Flat Washer Spring 3 8 Clevis Pin Support Plate Bushing Bellcrank 3 8 Clevis 3 8NF Hex Nut Push Rod 3 8NC x 3 4 Hex Bolt 3 8 Collar Master Cylinder 3 8NC x 3 4 Hex Bolt 1 8 x 1 Cotter Pin 3 8NC x 3 Hex Bolt Grade 5 Support Plate Master Cylinder Components 1 Bore ltem Part 1 See Above Listing 8 99 510 52 9 99 510 61 10 99 510 51 11 99 510 53 Description Master Cylinder Cap Rebuild Kit Rubber Boot Gasket Parts Page 23 Illustrated Parts QTY Illustrated Parts Brake Lines 10 FRONT BRAKES optional FRAME REF TO MASTER MASTER CYLINDER CYLINDER BOLT Qe REF 11 T fitting NU d p Qo TO MASTER CYLINDER FITTING 13 master cylinder fitting 15 master cylinder bolt Zing Z nen REAR BRAKES NOTE 1 Rear brakes only connect to adaptor then to master cylinder bolt Front brake option connect to T fitting then to master cylinder bolt g e d Parts Page 24 Brake Lines and Hoses ltem 1 2 Part 99 604 70 99 604 71 99 605 78 99 605 9 99 607 10 99 604 12 99 580 20 99 576 00 99 575 00 99 564 00 99 559 00 99 571 00 99 566 00 99 5 2 00 99 578 00 99
34. 011 31 Left Door Weldment Unpainted 1 91 011 32 Right Door Weldment Unpainted 1 Parts Page 57 Illustrated Parts A f lt SS Optional Top Cover Illustrated Parts SURREY TOP COVER ITEM PART DESCRIPTION QTY 91 120 62 Surrey Top Cover Kit l 1 91 038 00 Tubular Frame l 2 91 038 07 Left and Right Rear Support Post for Frame 2 3 91 038 08 Front Left Support Post for Frame l 4 91 038 09 Front Right Support Post for Frame 1 5 88 102 11 3 8 NC X 1 Carriage Bolt 16 6 88 109 81 3 8 NC Locknut 16 7 88 108 61 3 8 SAE Washer 4 8 91 038 10 Surrey Top White 1 9 95 911 00 Plastic Cap Square 8 en 91 110 00 Hard top l 91 038 20 Cross support for hard top 2 Parts Page 59 Illustrated Parts Rear Seat Rear Gate and Rear Deck Parts Page 60 lllustrated Parts REAR SEAT REAR GATE amp PIPE RAILS
35. 06 8 x 1 2 Sheet metal screw 8 12 73 005 01 Reverse Motion alarm 13 61 838 43 Buss bar 1 Not shown 69 068 55 Resistor across 5 power terminals 1 Replacement control must be factory programmed Supply serial number of vehicle when ordering Apply 94 427 21 heat sink paste prior to installation Parts Page 33 Illustrated Parts Miscellaneous Electrical Miscellaneous Frame Parts Page 34 Illustrated Parts Miscellaneous Electrical Hlem Part Description QTY 79 575 25 Charger cord AC 14 with terminals 79 575 30 Charger cord AC 8 with terminals 79 530 00 Strain releif AC cord SR 7W 2 75 107 10 Harness portable charger JF3 86181 00 00 Receptacle portable charger 75 120 40 Harness portable chager with SB plug 75 152 30 Harness electric deadman brake 75 152 90 Harness Smart View display 75 152 55 Harness main control 5 152 48 Harness control panel 5 152 07 Harness power 75 152 04 Harness dash 75 115 18 Harness strobe light on cab 71 122 00 Horn switch floor 71 501 00 Horn switch dash 71 102 10 Seat interlock switch 85 030 00 Spring for seat interlock switch 62 033 48 Throttle module under floorboard Miscellaneous Frame ltem Part Description QTY 98 254 10 Throttle pedal 98 200 00 Rubber brake pedal pad 01 680 58 Steering column cover 01 432 98 Weldment brake pedal 04 380 36 Brake pedal shaft 80 410 2
36. 067 21 Bolt 1 4 X 3 3 4 NC Hex Head Gr 8 4 Brake Body ITEM PART DESCRIPTION QTY 1 99 588 00 Bleeder screw 2 2 99 588 01 Bleeder adapter 2 41 350 43 Brake body left rear 1 3 41 350 44 Brake body right rear 1 41 350 42 Brake body front 2 4 80 713 00 O ring 4 5 41 350 09 Boot 4 6 41 350 10 Piston 4 Parts Page 15 Illustrated Parts Rear Suspension A NUN O A Ce NK X Parts Page 16 Rear Suspension ltem 1 2 Not Shown Part 85 507 00 16 870 10 32 213 00 96 248 00 88 169 81 96 114 00 88 159 84 16 861 42 16 861 43 01 380 86 86 000 00 86 602 26 Description Spring Spring hanger Bushing Hex bolt Hex lock nut U bolt Hex lock nut Spring plate left Spring plate right Upper shock mount optional Rear shock optional Lower Shock mount optional Parts Page 17 Illustrated Parts QTY n5 n5 9 Illustrated Parts 5 lt o qaaa Parts Page 18 w Illustrated Parts oz SUIUIUuIeIS04d o1 10 1o o 3uoo ou Surujor UO SIP 107 Surmjoegnue A uun T 10 Ae L 32e3uoo oseo d Jo o 3u09 uooAoS I ojur pourure130Jd oq jsnur s1ojoureqed MoU 10 0UI 7560 07 IP Jo o ueunojrod poseorour oq jo o3ejueApe nj dye o L p ods do ur uononpor 956 e 3noqe savy TEM IOA OY JOAIM
37. 14 240 08 14 380 92 14 380 85 2 15 380 33 15 380 31 3 80 309 10 4 88 289 81 5 80 103 00 6 88 239 85 7 92 104 00 92 104 01 8 88 527 11 9 80 017 00 10 12 124 00 11 45 338 00 12 14 380 81 14 380 93 14 240 07 14 380 86 13 21 009 10 14 12 158 10 15 32 200 00 16 32 204 00 Illustrated Parts Description Yoke Left Side Without Brakes After Serial 124156 Yoke Left Side Use with Disc Brakes After Serial 124156 Yoke Left Side Without Brakes Up to Serial 124156 Yoke Left Side Use with Disc Brakes Up to Serial 124156 Front Axle Beam After Serial 124156 Front Axle Beam Up to Serial 124156 Bearing Pack Nut Bearing Race 3 4 NF Slotted Nut Dust Cap With Grease Fitting Dust Cap Without Grease Fitting Use with Disc Brakes 1 8 X 1 Steel Cotter Pin 1 Bearing Hub W O Disc Standard Axle W O Brakes Seal Yoke Right Side Without Brakes After Serial 124156 Yoke Right Side Without Brakes Up to Serial 124156 Yoke Right Side Use with Disc Brakes After Serial 124156 Yoke Right Side Use with Disc Brakes Up to Serial 124156 King Pin Hub Use with Disc Brakes King Pin Bushing King Pin Bushing Parts Page 3 QTY a ol Illustrated Parts Steering Linkage C0 a JASLE Steering Assembly Ges w o 47 4o e 7 9 g S SS JR s amp a Parts Page 4 Steering Lin
38. 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 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 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 C Charger Models HBS 600 HBS 1000 TABLE OF CONTENTS Definitions 2 Test Equipment Required for Troubleshooting 2 Important Notes and Instructions 2 Operating Instructions and Theory of Operation
39. 79 303 40 SELECTABLE DUAL AC INPUT 100 240V 50 60Hz 134 OUTPUT 36V 20A 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 terminal 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 O
40. 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 between 208 and 250 of the rated DC voltage of the charger If the voltage is not between 208 and 250 of the charge s rated DC voltage the transformer is bad and must be replaced Stop here and repair the problem TESTING THE TIMER RELAY Test 1 1 Connect the batteries to the charger 2 Plug the charger into the AC source 3 Wait 5 seconds then test the voltage at the timer relay coil terminals NOTE This voltage should be close to the battery volts e 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 repl
41. Bolt 1 4 X 4 1 4 NC Grade 8 brake option only 3 2 41 355 00 Automatic Electric Brake Unit 1 3 See Motor Motor Typical 1 4 96 114 10 U Bolt 5 16 NF Motor Support 1 70 456 10 Motor Support Bracket 1 K66 600 03 Motor Support Bracket 45 1 6 88 128 62 Lockwasher 7 16 2 7 89 111 27 Bolt 10m X 1 5 X 20 Hex Head 2 8 88 088 62 Lockwasher 5 16 A 9 88 099 80 Nut 5 16 NF 2 io 88 067 17 Bolt 1 4 X 1 1 8 NC Grade no brake option 88 067 29 Bolt 1 4 X 4 1 4 NC Grade 8 brake option only 1 11 96 500 04 Tool Electric Brake Manual Release 2 12 3 Magnet and Coil Sub Assembly 1 13 Hub 1 14 3 Armature i 15 P Friction Plate 1 16 2 Mounting Plate 17 ii Hex Head Bolt Spacer 1 18 2d Locknut 1 19 T Screw Socket Head Cap 3 20 d Dowel Pin 3 21 Ball Bearing Deep Groove 1 22 External Circlip l 23 Internal Circlip 1 24 5 Coil Compression Spring 6 Not Shown Wiring Harness Part number not available at time of printing Parts Page 21 Illustrated Parts Master Cylinder Linkage 2 s E 17 14 15 EQ RM N G N p lt N Q S c N See Brake Lines Master Cylinder Components All n S 8 T Parts Page 22 Master Cylinder Linkage Item Part QTY 1 00 380 90 2 88 109 81 3 88 108 61 4 85 270 00 5 96 772 00 6 01 380 76 7 32 215 00 8 00 380 77 9 96 762
42. DD 9 Parts Page 52 lllustrated Parts CAB amp COWL WITH WINDSHIELD OPTIONS ITEM PART DESCRIPTION QTY 90 825 62 Windshield Kit 1 1 90 825 20 Plexiglass Windshield 1 2 90 825 06 Right Windshield Mounting Bracket 1 3 90 825 05 Left Windshield Mounting Bracket 1 4 88 060 09 1 4 NC X 3 4 HEX Head Bolt 4 5 88 068 62 1 4 Lockwasher 12 6 88 069 83 1 4 NC Acorn Nut 12 7 88 065 08 1 4 NC X 5 8 Phillips Head Truss Screw 8 8 88 068 61 1 4 SAE Washer 8 9 91 011 40 Cab Unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Rubber Channel for Windshield 1 12 90 850 10 Rear Window 1 13 88 065 09 1 4 NC X 3 4 Phillips Head Truss Screw 18 14 88 068 62 1 4 Lockwasher 13 15 88 069 83 1 4 NC Acorn Nut 13 16 88 069 8 1 1 4 NC Locknut 5 17 74 050 00 Windshield Wiper Motor 18 74 051 00 Windshiled Wiper Arm 1 19 74 052 00 Windshield Wiper Balde 1 20 88 065 11 1 4 X 1 Phillips Truss Head Screw 1 21 88 068 61 1 4 SAE Washer 2 22 88 069 83 1 4 NC Acorn Nut 1 23 98 603 00 3 8 ID Grommet 1 24 98 618 00 3 4 ID Gro
43. Duty Applications 17 Lu SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM MODEL VOLTAGE SPECIFICATION Occupancy 1 Driver 1 Passenger Dimensions 243 8L X 112 4W X 118 1H Centimeters 96L X 44 25X 46 5H Inches 284 Centimeters 112 inches Turning Radius Dry Weight RE 380 36 405 kg 894 lbs 434 kg 958 Ibs Without Batteries RE 380 48 Min Max Battery 166 kg to 261 kg 366 Ibs to 576 Ibs Weights Maximum Load 522 kg 1150 Ibs Towing Capacity Draw Bar Pull Trailing Load max level surface 45 4 kg 100 Ib 2268 kg 5 000 Ibs 377 8 kg 833 Ibs Trailing Load max 10 grade Electrical System RE 380 36 36 Volt RE 380 48 48 Volt 6 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp 8 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential 2 72 kw 3 65 hp 2335 RPM for 60 min 3 68 kw 4 94 hp 3525 RPM for 60 min 19 3 kph 12 mph 24 1 kph 15 mph with Front Disc Brakes Speed Hydraulic Rear Disc Hand Operated Park Brake 4 Wheel Hydraulic Disc Hand Operated Park Brake Automotive Steering 24 1 ratio 5 70 X 8 Load Range B Steel Unitized Body Heavy Duty 16 Gauge Steel Diamond Plate Battery Status Indicator Hour Meter System Status Monitor Key Switch Horn Button Forward Reverse Switch
44. GT 3287143 Differential case 1 20 GT 72013 O ring 1 22 GT 71896 MIO x 25 Bolt 12 29 GI 71978 Bearing and race 2 30 GI 70299 10mm Washer 12 31 GI 71881 Seal 1 32 GT 70052 Vent 1 Rear Axle ITEM PART DESCRIPTION QTY 1 41 154 20 Axle shaft 2 2 80 505 20 Bearing 2 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub 2 5 88 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5 2 7 96 329 10 Wheel stud 10 92 104 10 Hub cover 2 41 290 43 Axle housing Right 1 Not shown 41 290 40 Axle housing left 2 89 113 30 M12 x 1 75 x 30mm Hex bolt axle housing to center section 6 89 113 60 M12 Split lock washer axle housing to center section 6 Parts Page 13 Illustrated Parts Rear Brakes Brake Body Front Brakes optional I gt n 23 M VAY JS 6 a ui I uo NR 7 p ntm 6 Parts Page 14 Illustrated Parts Rear Brakes
45. Housing uc Transmission Page 20 Suspension TABLE OF CONTENTS Replace the Rear Springs 2 OAT 2 Replace the Front Springs 3 LOAN Mc 3 Replace the Spring Bushings 5 Replace the Shocks 6 Frontor Real g yu au a ar DELL 6 Maintenance Service and Repair REPLACE THE REAR SPRINGS Leaf If a spring has failed or is fatigued then it is recommended that both rear springs are replaced as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Tie up or support the rear axle so it cannot fall out of the vehicle 8 Remove the nuts from the u bolts holding the spring to the axle tube 9 Support the spring so that it cannot
46. Low switch is optional and the vehicle may not have this option If the vehicle is not equipped with option then there is a jumper bypass installed in place of the switch in the dash Check the jumper to be sure it is still connected 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 TEST 1 4 Test the voltage at pin 45 on the 12 pin logic card connector If the voltage is low then skip ahead to Test 341 5 If the voltage is high then e Check the seat switch for open contacts e Check that the seat switch is engaging the seat correctly e Check the wire from the pin 5 to the seat switch for open circuits e Check the wire from the seat switch to B for open circuits If all of the above is in working order then the logic card may have failed Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit Sevcon Troubleshooting Page 5 Electrical Troubleshooting TEST 1 5 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is high then skip ahead to Test 1
47. See dealer Startup switches not Reset tne switches and start over Refer 2 Sequence fault operated in the correct l to Vehicle Operating order Instuctions 3 MSEE OF nos Burned Motor Repair as required short 4 Contactor fault or Contactor Failure Check contactor and open motor Open Circuit motor 5 Not used Accelerator module EDI SWITCH Failure Check accelerator 6 Faulty Wiring fault l module inputs Accelerator Failure Check battery and 7 Discharged battery d battery Md connections to oose connections controller 8 Controller Overloaded ira k Wait for controller to overheated cool Check coil continuity 9 ISO coil shorted ISO Coil Short Circuit and replace as required Check wiring If Fault in the Wiring to the vehicle is not dash display or a faulty equipped with a 12 Can Buss Fault Dash Display dash display check NOTE The Dash Display is for debris in the 6 Optional pin connector on the logic card CE HERE AE WE EE TU On mO E Y J Wa Be R B F Powerpak SEVCOMN Sevcon Troubleshooting Page 19 Electrical Troubleshooting Smart View Fault Codes Level 5 Faults F05xxx F05004 VA Fail This is a result of a low voltage on an internal voltage regulator Can also be caused by a low key switch input voltage If the key switch input is within specifications then replace the controller F05006 MOSFET Short Circuit Also can be a resul
48. 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 battery 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
49. a Rod End Center the Steering 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Turn the front wheels so that they are in the straight ahead position and then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball joint or rod end from the drag link 9 Center the steering gear and tie off the steering wheel so that it cannot rotate NOTE Refer to Adjust the Steering Gear section for information regarding centering of the steering gear Steering Page 2 Maintenance Service and Repair 10 At this point both the steering wheel and the front wheels should be tied up and held in position If one or the other is not tied up then you must start from the beginning Do not drive the vehicle while the steerin
50. brake to a 24 volt source This should release the brake and allow you to troubleshoot the vehicles control system Return to the beginning of the troubleshooting section and continue If the brake does not release then he electric brake has failed Remove the brake and repair or replace the brake as required otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground A WARNING ACAUTION After any repairs are made completely retest This troubleshooting guide is written in the vehicle before lowering the drive wheels to sequential order All tests must be performedin the ground Failure to retest the vehicle could the order that they are written Starting in the result in unexpected movement of the vehicle middle or skipping sections when not instructed resulting in injury or property damage to do so may lead to invalid test results Sevcon Troubleshooting Page 17 Electrical Troubleshooting Loqic Voltaqe Reference Table Pin Condition Volts Key switch off 0 0 volts Key switch on Battery volts F
51. continuity of all wires from the controller to the motor Repair any open wires then test drive the vehicle otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground A WARNING ACAUTION After any repairs are made completely retest This troubleshooting guide is written in the vehicle before lowering the drive wheels to sequential order All tests must be performed in the ground Failure to retest the vehicle could the order that they are written Starting in the result in unexpected movement of the vehicle middle or skipping sections when not instructed resulting in injury or property damage to do so may lead to invalid test results OO ALLIILcULELLLSOLALLAL CULLLe OAOAAGIGAm IIIlUx II Sai Sevcon Troubleshooting Page 8 Electrical Troubleshooting Test 9 THE VEHICLE RUNS IN ONE DIRECTION ONLY Test 3 1 Close the seat switch turn the key switch ON and wait 1 second until the Isolator contactor closes If the vehicle runs in reverse only then skip ahead to test 3 3 Place the forward and reverse switch in the FORWARD direction Test the voltage at pin 2 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 2 If the voltage is high then skip ahead to Test 7 TEST 3 2 Test the voltage at pin 3 on the 12 pin logic card connector If the voltage is high then skip ahead to t
52. correctly before replacing the Sevcon power unit A WARNING 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 injury or property damage Sevcon Troubleshooting Page 10 Electrical Troubleshooting Test 5 CONTACTOR COIL FAULT Disconnect the 12 pin logic card connector from the Sevcon power unit Turn the key switch ON and perform the following tests TEST 5 1 Check the voltage on the positive coil terminal of the ISO solenoid violet wire If the voltage is within approximately 1 volt of the battery voltage then skip ahead to test 75 2 If the voltage is not within approximately 1 volt of the battery voltage then check the diode in the positive wire to the ISO solenoid otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before NOTE This is typical ISO snlennid Main Battery Negative lowering the drive wheels to the ground TEST 5 2 Check the voltage on the negative coil terminal of the contactor coil If the voltage is not within 1 volt of battery voltage then the contactor is bad and must be replaced NOTE An open contactor coil should be accompanied by a 4 flash code from the logic LED If the voltage is within 1 volt then one of the four E E Ga M id following fa
53. current should drop down below the value specified in the Motor Specification table This indicates that the Anti Rolloff feature is operating normally If the current does not rise then the Anti Rolloff feature has failed or has been turned off The status of the Anti Rolloff feature can be checked with the hand held calibrator If the Anti Rolloff feature is on and the field current did not rise then the controller has failed and must be replaced If the Anti Rolloff feature is off then the controller logic must be reprogrammed Contact your dealer III II IIS Sevcon Troubleshooting Page 15 Electrical Troubleshooting Test 9 ELECTRIC MOTOR BRAKE Description The electric motor brake is a 24 volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case The brake is controlled by the speed controller logic At what times the brake is applied or released is dependent on the controller programing and will vary depending on the model vehicle Operation B is supplied to the brake when the key switch is turned on When the control logic determines that it is time to start it provides B at 24 volts through pin 9 on the logic card connector Testing Place the forward and reverse switch in the OFF position turn the key switch OFF Rotate the drive wheels to confirm the brake is engaged If the brake is engaged then skip ahead to 9 1 If the brake is not engaged then Disco
54. displayed for approximately 5 seconds as indicated by the Key Hours Indicator located at the lower left of the display The icon represents the silhouette of a key Run Time Hours After the initial 5 seconds the Run Time Hours will be displayed as indicated by the Run Time Hours Indicator located at the left of the display The icon represents a motor symbol with a T in the center SAFETY RULES AND OPERATING INSTRUCTIONS Display showing Maintenance and Wrench icons Maintenance Monitor NOTE The Maintenance Monitor function is optional The Maintenance Monitor function can be turned ON or OFF by your dealer Operation The SMD notifies the operator 10 hours standard before a scheduled maintenance is due During this warning period the meter will continue to alert the operator This should allow sufficient time for the operator to schedule the maintenance that is due with minimal down time If the scheduled maintenance is not performed before the warning period elapses then the vehicles maximum speed will be significantly reduced Warning period The warning starts when the Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenance Due Once the warning has expired and the maintenance is due the Wrench icon will stop flashing and remain ON Additionally the vehicles maximum speed will be significantly reduced until the
55. fluid level in the master cylinder to drop too low as this will allow air into the brake lines 9 Attach a clear hose to the bleeder valve on the brake cylinder that is to be bled Route the hose into a clear container for waste brake fluid 10 Pump the brake pedal a few times and then press and hold light pressure to the brake pedal 11 Open the bleeder valve on the hydraulic brake body 12 Depress the foot pedal to the floor and then close the bleeder valve Do not release pressure on the brake pedal until the bleeder valve is closed 13 Slowly release the foot pedal allowing it to return to its released position Typical bleeder valve NOTE Check and fill the master cylinder frequently during the bleeding process Do not allow the fluid level in the master cylinder to drop low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning Always use brake fluid from a new sealed container Never reuse any brake fluid that has been removed from the brake system Use of AWARNING contaminated brake fluid will degrade the braking performance and may cause property damage or severe bodily injury 14 Repeat the above steps until you are sure that all of the air is expelled from the brake line Any air bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is still air in the brake lines 1
56. for information on proper tire inflation or front end wheel alignment Inspect the inner and outer side walls for cracks If any cracks are seen then the tire should be replaced Refer to Replace the Tire section for information regarding replacing the tire Inspect the valve stem for cracks If any cracks are seen then the valve stem should be replaced It is also recommended that the valve stem be replaced whenever the tire is replaced NOTE Refer to Replace the Tire section for information regarding replacing the valve stem Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak REPLACE THE TIRE WHEEL 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake ego o 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the wheel to be replaced off of the ground and support with jack stands Remove the 4 or 5 wheel nuts and remove the wheel Install in reverse order Following the pattern shown on the following page cross tighten the wheel nuts in two stages as follows 1st stage to approximately 20 ft lbs 2nd stage to 80 90 ft Ibs Reconnect the main positive and negative cables at the batteries
57. from the 3rd member housing 18 Inspect all parts for signs of wear or damage Transmission Page 10 Maintenance Service and Repair Lubricate all parts with gear oil before installation Failure to pre lube ACAUTION the parts may result in premature failure 19 Assemble the gear case in reverse order NOTE Torque the drain plug to 21 25 foot pounds NOTE Torque the gear case to 3rd member retaining bolts to 18 20 foot pounds NOTE Torque the pinion nut to 154 169 foot pounds NOTE Apply gasket sealer 94 430 05 to the front flange on the 3rd member and gear case cover NOTE Pack the motor seal with non acetic based grease 20 Fill the differential with oil NOTE Refer to Changing the Differential Oil for information on filling the drive with oil 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Transmission Page 11 Maintenance Service and Repair DISASSEMBLING THE 3RD MEMBER 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Al
58. in this section complete EXD0P Teler to FLASHING FLASHING FLASHING troubleshooting HR F a LM SIGNET SYSTEMS INC Tvpical Charger Data Plate vour data plate may vary Signet Charger Troubleshooting Page 2 Electrical Troubleshooting za HB PT AND GEL INDICATOR LAMPS NOTE Your charger may not be equipped with these lamps HB PT Lamp If the HB PT lamp is ON then the charger has overheated and 2 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 Q e The charging cycle is limited to 18 hours If the HB PT lamp is flashing then the charging time has exceeded 18 hours time is limited to 18 hours If any of the status lamps are flashing then i a the charge cycle did not complete amp E ni Ww ELEXILILLELI GEL lam SIGNET SYSTEMS INC This LED will only be ON if the charger is configured for GEL VE 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 install
59. is installed on the steering arm or pitman arm The second cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your vehicle it may be equipped one or both types of ball joints Rod End In this text The first type will be referred to as a Ball Joint The second type will be referred to as a Rod End NOTE If a rod end or ball joint is worn out we recommend replacing all of the ball joints and or rod ends as a Set Ball Joint Replacing a Rod End 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Front Axle Page 8 Maintenance Service and Repair 10 11 12 13 14 15 16 Loosen the rod end jam nut or clamp on the steering sleeve Remove the rod end nut Remove the rod end from the steering arm p HINT Count the number of turns required to Steering remove the rod end from
60. is the fault code Refer to the table below Status Light Panel Fault Description Action Required Code P 4 Il Charge cycle time exceeded the time limit Test batteries for possible Time out no flash defictive cells Open circuit or reverse polarity to battery Check battery wiring 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 37 Battery voltage too high Inspect for dirt or debris on the charger cooling fins and clean as 4 Overheated required AC line voltate too high or too Check the input voltage x low It must be within 85 137VAC or 170 264 VAC Extremely discharged battery defective battery miswired battery When this fault occurs the charger will operate in a low current mode untill the battery voltage is built up This fault will reset once the battery 6 Low battery voltage voltage is normal If the battery voltage does not come up Test the batteries Check battery wiring These faults will be accompanied by an audible beep and indicates that the charge cycle was termintated before completion Ir r mr a Signet Charger Troubleshooting Page 5 Electrical
61. park brake and test drive the vehicle Transmission Page 5 Maintenance Service and Repair REMOVING AND INSTALLING THE REAR AXLES DISC BRAKES The oil level in the housing is above the bottom of the axle flange To minimize oil spills raise the side ofthe vehicle high enough so that the oillevelis below the bottom of the axle flange If both axles are to be removed you must drain all of the oil from the housing Height of oil in housing on level surface NOTE This procedure does not require that the rear end or drive assembly be removed from the vehicle NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced Cil Level Raise the wheel off of the ground high enough so that the oil level is below the axle housing flange 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse 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 Ifrequired drain the oil from the 3rd member 7 Raise the rear of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARN
62. q 06 90 6L 09 r0 6L S0 0 6L SI ZOE 6L OI ZOE 6L 0T IO ASS 00 6L 0S 00 6L OS ZO 6L NOLLdI9IOSHG WALI STECI OCOL 0 LCC OOLET I 156 OITET OSLCI 10 SOTL 1 00FF1 Weg 19816uO 9po N PS EYD SelHDeI V HO 00 808 6L 00 808 6L 01 808 6L 01 808 6L 01 808 6L 01 808 6L 01 808 6L 01 808 6L 01 808 6L TO REON Parts Page 41 Illustrated Parts Charger Signet NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector Parts Page 42 illustrated Parts Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page l 79 575 60 Replacement cover w AC cord and gasket l Note There are no user serviceable components Inside the charger AC Wire Connections Parts Page 43 Illustrated Parts Batteries 36 Volt 48 Volt Parts Page 44 Illustrated Parts
63. remove the steering wheel Position the front wheels in the straight ahead position Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration to the right Reinstall the horn switch if equipped Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the parking brake and test drive the vehicle Steering Page 9 Maintenance Service and Repair REPLACE THE STEERING GEAR 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the steering wheel NOTE Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 7 Remove the steering shaft NOTE Refer to Replace the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a pickle fork NOTE On some vehicle configurations it may be required to remove the drag link from the pitman arm Hefer to Replace the Ball Joints section for information regarding removing the ball joint from the pitman arm 9 Support the steering gear so that it cannot fall out of the vehicle
64. result in damage to the charger Signet Charger Troubleshooting Page 4 Electrical Troubleshooting 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 10096 LED is flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged This could be a result of Defective battery or batteries Excessively discharged batteries Oversize batteries Description 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 line 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 C o for dirt or debris on 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 proc
65. ring and the worm bearing adjuster Worm Bearing Adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling Side Cover the assembly out of the housing NOTE The side cover pitman shaft assembly normally does not have to be disassembled Steering Page 11 Maintenance Service and Repair 4 Remove the worm shaft and ball nut assembly from the bottom of the housing Worm Shaft Ball Hemove the worm shaft seal Nut Assembly Remove the pitman shaft seal Remove the upper worm bearing and bearing cup from the housing 8 The ball nut assembly consists of two sets of ball bearings that recirculate in two channels in the ball nut housing The bearings may fall out once the bearing guides are removed Be careful not to lose any of the bearings Bearings Ball Guides 9 Remove the ball guide clamps ball guides and all of the ball bearings 10 Remove the ball nut from the worm shaft Ball Guide 11 Thoroughly clean and inspect all parts for signs of Clamp Housing corrosion damage or wear and replace as required Reassembly Lightly lubricate all parts before reassembly Install a new worm shaft seal and pitman shaft seal into the housing Install the upper worm bearing cup Divide the ball bearing into two equal groups oF ge ON x Position the ball nut onto the worm as shaft as shown in the illustration D Insert the ball g
66. senses a fault condition and then supplies current to the field opposing the armature rotation slowing the vehicle Refer to Motor Specifications Table for information on the maximum allowable field current when the Anti Rolloff feature is active To test the Anti rolloff feature Park the vehicle on a flat level surface turn the key switch OFF and apply the parking brake Connect an analog Ammeter in series with the motor field windings or a clamp on Ammeter on one of the field wires that is capable of reading up to 25 Amps Place the forward and reverse switch in the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Motor Service section for specifications then the Anti Rolloff feature has failed Check the status of the Anti Rolloff feature using the hand held calibrator 62 027 61 TEST 78 2 While monitoring the motor field current release the park brake and push the vehicle The surface must be level for this test Do not attempt to test the A WARNING Anti Rolloff by pushing up or down an incline Testing by pushing up or down an incline could result in injury or property damage Within approximately 10 feet the field current should rise dramatically and the vehicle should become difficult to push Now stop pushing the vehicle and allow it to come to a complete stop The field
67. switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries TIRE INSPECTION AWARNING 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 f Check the tire pressure Refer to Tire Inflation section for information on checking the tire pressure Inspect the tire tread depth Minimum recommended tread depth is 1 16 inch There are a series of tread depth wear indicators around the circumference of the tire They will appear as 1 2 inch bands across the tread as the tire approaches its wear limit see illustration to the right Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section for information regarding replacing the tire Tires and Wheels Page 2 Maintenance Service and Repair 8 9 10 11 Inspectfor uneven tire wear on the front tires Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end NOTE Refer to Tire Inflation section or Steering Component Service section
68. the carrier bearing race from the 3rd member housing 18 Remove the front bearing from the input shaft NOTE The input shaft may have to be driven out to perform this procedure 19 Remove the input shaft s shims and spacer 20 Remove the pinion shaft from the 3rd member 21 Remove the front and rear pinion bearing races 22 Inspect all parts for signs of wear or damage 23 Thoroughly clean all parts Transmission Page 14 Maintenance Service and Repair ASSEMBLING THE 3RD MEMBER 1 Temporarily install the pinion gear hand tighten only 2 Install the carrier bearing race ring nuts into the housing and cover 3 Install the carrier bearing races into the housing and cover Cover 4 Place the differential assembly into the housing 5 Tighten the housing carrier bearing race ring nut so that the ring gear is not in binding against the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembly 8 Install the cover onto the housing using 4 bolts ina cross pattern and torque to 45 50 ft lbs 9 Pre set the carrier bearing preload by tightening the housing carrier bearing race ring nut until it requires 1 5 to 3 3 ft lbs to rotate the differential assembly NOTE Rotate the carrier assembly whenever adjusting the ring nuts Transmission Page 15 Maintenance Service and Repai
69. the hub from the steering knuckle NOTE Fora front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body NOTE Catch the outer bearing as it falls out 10 Thoroughly clean all grease from the inside of the hub and the bearings 11 Inspect and replace the races and bearings as a set NOTE It is recommended to replace all four bearings and races in the left and right wheels as a set 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 ft lbs This seats the bearings c Back off the spindle nut one flat until the hub turns but is not loose d Install a new cotter pin Hub with Dust Cap Removed Front Axle Page 7 Maintenance Service and Repair 13 Install the hub dust cap 14 Reinstall the brake body and the tire wheel assembly NOTE Refer to the Brakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle REPLACE THE BALL JOINTS TIE RODS AND DRAG LINK This section will refer to two different types of ball joints One type is has a grease fitting and a tapered shaft where it
70. the key is turned ON then drop to approximately 15 volts after about 0 5 seconds If the test is good then skip ahead to test 7 1 2 If the voltage starts high drops to 15 volts and then drops to 0 volts then it indicates an open circuit to the main battery positive Check the continuity of the ISO solenoid contacts the main circuit breaker and the wiring to the main battery positive post If the voltage is starts at 24 volts but the solenoid does not pick up then skip ahead toTest 5 If the voltage does not start at 24 volts then go to Test 4 TEST 1 2 Test the voltage from B to B on the Controller If the voltage equals battery volts then go to Test 1 3 If the voltage does not equal battery volts then e Check the main positive wire to the circuit breaker for open circuits e Check the wire from the circuit breaker to battery positive e Check the wire from the contactor to B on the controller for open circuits e Check the wire from B to battery negative on the controller for open circuits Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 1 3 Test the voltage at pin 6 on the 12 pin logic card connector If the voltage is low then skip ahead to Test 311 4 If the voltage is high then check the wire to the High Low switch and the High Low switch for open circuits NOTE The High
71. the rear of the vehicle and support with jack stands Place a four quart drain pan under the drive assembly Remove the drain plugs from the differential case and gear case Once the oil has drained replace the drain plugs and lower the vehicle to the ground Remove the fill level plug and fill the differential up to the bottom of the level plug opening Refer to the Lube Chart section for information regarding type of oil Replace the fill plug o Reconnect the main positive and negative cables at the batteries Drain Plug E Remove the blocks from the wheels Release the park brake and test drive the vehicle Transmission Page 3 Maintenance Service and Repair MOTOR REMOVAL AND INSTALLATION NOTE Some applications will require removing the drive assembly from the vehicle to remove the motor Refer to Removing and Installing the Drive Assembly for information on removing the drive assembly Some vehicles are equipped with an automatic electric brake The automatic electric brake is sandwiched between the drive motor and the gear case The electric brake is retained by the drive motor mounting screws Once the motor is removed the electric brake will no longer be retained by any hardware 1 Make sure the key switch is in the OFF position then remove 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 wh
72. the steering i Sleeve sleeve This will make it easier to realign the wheels Jam Nut Install the new rod end into the steering sleeve Rod End Nut Screw it into the sleeve the same number of turns s counted in the previous step Do not tighten the Steering Arm rod end clamp or jam nut at this time Install the rod end into the steering arm Tighten the rod end nut to 20 25 ft Ibs Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels Lower the vehicle Heconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Replacing a Ball Joint 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 6 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist 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 severe bodily injury Front Axle Page 9 Maintenance Service and Repair Loosen the ball joint clamp on the steering sleeve Re
73. 0 Bearing for brake pedal shaft 17 110 00 Collar for brake pedal shaft Parts Page 35 Illustrated Parts Seat Cushions and Lights Seat Cushions and Lights ltem 2 9a 9b Part 90 198 03 90 179 00 90 198 03 72 025 00 72 022 51 00 210 04 94 201 10 04 380 25 04 380 24 94 050 11 94 050 10 72 072 15 71 072 11 Description Front Seat Cushion Front Backrest Front Seat Cushion Oval Tail Stop and Turn Light Gasket for 4 Seat Frame Name Plate Headlight Mounting Panel Front nose panel no headlights Right Headlight Assembly Left Headlight Assembly Headlight Bulb Socket for 8 and 9 Parts Page 37 Illustrated Parts QTY Illustrated Parts Lestronic Pg 1 Charger Typical Built In charger eco MU SX MMMM N Wh Yt 2 NNN S Typical Portable charger 10 Parts Page 38 Illustrated Parts ET 00 00c 9L 00 00c 9L 00 00c 9L x o 00 00c 9L 00 00c 9L NU 00 00c 9L 00 00c 9L Sn d OV 3ueuroov dos WOANMQIEI II 0S 609 6 c 90t 6L L 09 608 6L Assy Avpoy xooproqu L w I 6FL 6L r PLGL T 6VL 6L I 6VrL 6L 01 6t L 6L IT 6PL 6ZL Cl 6VL 6L eT OrL oL K quiessy porq 00 T 8 6Z 00 1 8 6L 00 1 8 6L 00 1 8 6L NEN 007 c06 6L 00 c06 6L 00 c06 6L 00 c
74. 00mm 0 or 1 25 GI 328 Spacer 46 125mm O or 1 GI 328 Spacer 46 150mm O or 1 GI 328 Spacer 46 175mm O or 1 GI 3287903 Shim 0 100mm Oor 1 GI 3287883 Shim 0 400mm Oor 1 GT 3287893 Shim 0 500mm O or 1 i GI 3287853 Shim 0 600mm 0 or 1 GT 3287863 Shim 0 700mm O or 1 GI 3287873 Shim 0 800mm O or 1 27 GI 71068 Bearing 1 28 GI 72022 Bearing 1 30 GI 70299 10mm Washer 6 257 GI 3252633 Dowel pin 2 GI 71804 Drain plug 1 Not shown GT 71755 Drain plug gasket 1 Parts Page 11 Illustrated Parts Transmission secondary reduction Rear Axle Parts Page 12 Illustrated Parts Transmission Differential Case ITEM PART DESCRIPTION QTY 9 GI 70302 MIO x 30 Bolt 12 13 GI 3287183 Ring and pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug 1 17 GT 3287113 Differential housing 1 19
75. 06 6L LM 00 06 6 00 06 6 00 06 6 00 06 6 00 06 6 o aede 01 6FL 6L 0c 808 6L 0c 808 6L 0c 808 6L 00 808 6L 0c 808 6L 00 808 6L 00 808 6L 00 808 6L 00 808 6L W OIRLIPD os 89 S0876L 89 S08 6L L9 S08 6L S9 S08 6L L9 S08 6L CL S08 6L 69 S08 6L L9 S08 6L A quiossW Jour T C xasscone LH8 SCO I8P LH8 SCO I8P LH8 070 T9 LH8 SCO T8P LA8 070 T9 LH8 SCOT9E LH8 SCOT9E LH8 SCOT9E BEETEZH 0c 60 6L ST7 0 6L O1 60 6L 17Z 90 6L 00 60 6L 0C 0 6L HS9 r0 6L 0c S0 6L ST 0 6L NOLLdIsOSHG WALI 02691 0294 IS S LT6 696 OTOCC ZE OILL OPLZC Weg 1981007 9po A 19516uO SelHDeIVHO Sc 8t Sc 8t Sc 8t 0r 9c Parts Page 39 Illustrated Parts Lestronic Pg 2 Charger Typical Built In charger T gt MOON S N N Wh Yh f WK A Typical Portable charger 10 Parts Page 40 Illustrated Parts Lees orteses orteee orreee orteses ooreo orteses ovtepe orteses Amm 01 6rL 6L 1 6VrL 6L 1 6FL 6L 1 6FL 6L 1 6FL 6L O S 1 6VL 6L l 6vL 6L O S K quiessy opoiq V F 00 06 6 00 06 6 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L 00 c06 6L o deer II I quiossy jouir eters aura 55094 955094 sosa wesw orsec mw os T0 6L
76. 11 6 If the voltage is low then skip ahead to Test 6 TEST 1 6 Test the voltage at pin 7 on the 12 pin logic card connector NOTE Pin 7 is for a parking brake interlock switch This switch is not available for all vehicles and may not be used If the voltage is high then skip ahead to Test 1 7 If the voltage is low then e Check the park brake switch for shorted contacts e Check the wire to the park brake switch for short circuits to B Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 1 7 Depress the accelerator pedal to engage FS 1 only creep speed Perform the following tests Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is below 0 3 volts then skip ahead to Test 1 8 If the voltage is above 0 3 volts then skip ahead to Test 6 ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results MicroPak Logic Connectors Pow erPak Lo gic Conne ctor TEST 1 8 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is low then skip ahead to Test 1 9 If the voltage is high then skip ahead to Test 6 TEST 1 9 Depress the accelerato
77. 2 29 8 24 125 19 0 24 16 9 25 8 3 8 16 20 30 43 40 3 8 16 27 1 41 58 54 24 225 33 50 45 24 30 5 45 68 61 716 14 27 50 70 65 7 16 14 37 68 95 88 20 36 55 2 70 20 49 75 104 95 1 2 13 49 75 106 95 1 2 13 66 102 144 129 20 55 85 120 110 20 75 115 163 149 946 12 70 109 153 140 9 6 12 95 148 614 190 18 78 121 171 160 18 106 164 232 217 5 8 1 97 150 212 195 5 8 1 132 203 287 264 18 110 170 240 225 18 149 230 325 305 3 4 10 172 275 376 350 3 4 10 233 373 510 475 16 192 297 420 390 16 260 403 569 529 7 8 9 278 429 593 565 7 8 9 377 582 804 766 14 306 473 818 625 14 45 641 1109 847 1 8 416 644 909 850 1 8 564 873 1232 1152 14 46 721 1018 930 14 632 978 1380 1261 1 1 8 7 590 794 1287 1700 1 1 8 7 800 1076 1744 2304 12 662 891 1444 1850 12 897 1208 2364 2508 1 1 4 7 832 1120 1817 2950 1 1 4 7 1128 1518 2463 4000 12 922 1241 2012 3330 12 1250 1682 2727 4514 Conversion Formulas Foot Pounds Newton Meters x 0 737562149 Newton meters Foot Pounds x 1 355817948 Appendixes Not available at time of printing Appendix B Page 6 Appendixes All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification Reduce torque approximately 10 1596 for lubricated threads Refer to the service section assembly procedure for critical torque values Dia o o o CO 12 14 16 18 20 22 24 27 30 Metric Newton Meters Pitch 0 50 0 70 0 80 1 00 1
78. 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 width 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 3a 4a 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 NF Hex Nut 4 9 97 236 00 Wheel Nut 20 10 16 051 00 Spacer used with 8 50 x 8 wheel only 2 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 13 742 50 5 00 x 8 Soft Solid Non Marking Parts Page 29 Illustrated Parts Instrument Panel dash ending s n 179484 Parts Page 30 Instrument Panel ending s n 179484 ltem Part 1 71 100 00 2 71 039 11 3 71 039 11 4 74 010 00 5 71 039 02 6 71 501 00 7 71 120 10 71 121 20 71 119 99 71 120 90 Description Accessory Switch Rocker Switch Rocker Switch Smar
79. 3 88 108 61 3 8 SAE Flat washer 4 4 88 100 11 3 8 NC x 1 Hex bolt 4 5 88 080 09 5 16 x 3 4 Hex bolt 4 6 04 380 23 Splash pan 1 7 88 089 8 1 5 16 NC Lock nut 4 8 9 Parts Page 65 NN C SO TAV L Contents Appendix A Special Tools 2 Appendix B Suggested Torque Limits for Standard Hardware 4 Hardware Identification 4 Standard Head Markings 4 Hex BOllS i as cale ER RR sa 4 UICE DOS ac c ua 4 lul asini cde 4 Hex Lock Nuts stover 4 COUIGTETNULS 2e un o ER a REED LUE CER RR ERR 4 Suggested Torque Values non critical hardware 6 Suggested Torque Values critical hardware 7 Appendix C Brake Lining Handling Precautions ukuy veneto ax rd vds da 8 Appendixes REVD endixes z A APPENDIX A SPECIAL TOOLS Note This is a listing of all tools available Not all tools would be required for all vehicles Refer to the Maintenance Repair and Troubleshooting sections for information on tools required 62 027 32 Throttle Module Analyzer Tests the throttle module in or out of the vehicle 41 532 50 Chain Case Centering Tool Used to center the chain case cover on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor Includes instructions
80. 4 15 88 069 83 1 4 NC Acorn Nut 2 or 4 16 92 206 00 Inside Mirror 1 17 02 210 70 Inside Mirror Bracket 1 92 207 00 Mirror multi panel 1 Not Shown 91 810 00 Mounting bracket for multi panel mirror 2 18 88 065 09 1 4 X 3 4 Phillips Truss Head Screw 2 19 88 068 67 1 4 Internal Toothed Lockwasher 2 20 88 069 80 1 4 NC Nut 2 Parts Page 55 Illustrated Parts Note Left Cab Door Options vf TIZ I Door Shown Parts Page 56 Illustrated Parts
81. 5 Repeat this process with each of the other wheels NOTE When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information on filling the master cylinder 16 Reconnect the main positive and negative cables at the batteries 17 Remove the blocks from behind the wheels 18 Release the park brake and test drive the vehicle Brakes Page 10 Maintenance Service and Repair FLUSH THE BRAKE SYSTEM 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 6 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the rear wheels off of the ground and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices 10 11 12 13 14 19 16 17 18 of rated load capacity may result in severe bodily injury If equipped with front brakes raise the front wheels off of the ground and support with jack stands Release the park brake Remove both rear wheels and if equipped with front brakes the front wheels Refer to Tires and Wheels section for information regarding removing the wheels Remove the wheel cylinders from each axle Refer to Rep
82. 5 5 10 88 069 81 99 585 50 88 060 09 Description Brake Line Right Front Brake Line Left Front Brake Line Right Rear Brake Line Left Rear Brake line1 front Brake line2 front Brake hose Front or Rear Hose clip Coupler T Fitting female T Fitting 2 female 1 male Copper Washer 0 500 ID Banjo fitting Copper washer 0 564 ID Master cylinder bolt 1 8 pipe to 3 16 flared tube adaptor 1 4NC Nylon Lock Nut Brake Hose Bracket Front 1 ANC x 1 1 8 Hex Bolt Parts Page 25 Illustrated Parts QTY lllustrated Parts Park Brake Linkage Parts Page 26 Parking Brake Linkage Items Part 1 51 344 80 2 88 080 11 3 96 826 08 4 88 089 81 5 88 088 61 6 96 826 09 7 04 380 49 8 88 527 11 9 96 773 00 10 96 763 00 11 88 099 80 12 00 200 48 13 04 380 13 14 80 410 20 15 88 100 09 88 109 81 16 04 380 50 17 96 763 00 18 88 099 81 19 96 343 00 20 88 099 80 21 96 765 00 22 96 754 00 Description Park brake lever 5 16NV x 1 Hex bolt Brake cable 5 16NV Hex lock nut 5 16 SAE Flat washer Cable lock Extension brake handle Cotter pin Clevis pin Clevis 5 16NF Hex nut Park brake linkage handle to equalizer Brake cross shaft Bearing Hex bolt 3 8NC Hex lock nut Equalizer Clevis 5 16NF Hex nut left hand thread Rod linkage 5 16NF Hex nut Clevis Clevis formed Illustrated Parts
83. 5 Stack Corrupt Refer to service technician F04004 F amp R Fault Bajanio senjica technician F05046 Open Contactor Refer to service technician F04005 F amp R Fault Direction was selected before start switch was Level 2 Faults closed Place direction T Fault Code Description What to do P nM OFF position F02000 Throttle Fault Occurs if throttle control F04006 Interlock Fault iid den interlock switch aie l A F04007 Inch Switch Fault F amp R switch NOT in neutral wa poca was E epressed when the F 04008 Steer Fault Refer to service technician 3 start switch was closed F04009 Low Battery Volts Extreme low battery voltage at the controller May be a n Me Peder wee not i depressed then refer to resu obsevere y qualified service discharged battery or technician wrong battery installed F02001 Throttle Fault Confirm that the correct F02002 Belly Switch Fault Refer to service technician dt aliens and FO2003 Open Field Refer to service technician FO4010 Highbatler Vols Heferiosericeiechniian nr Open Field L E ed nm F04011 Out of Range Fault Refer to service technician asa Suku pisi F04012 CRC Fault Refer to service technician F04013 Capacitor Fault Refer to service technician Safety Rules Page 10 SAFETY RULES AND OPERATING INSTRUCTIONS While drivinq VEHICLE OPERATION 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 t
84. E Refer to Charger Troubleshooting for information on checking the charging system The highest reading will be the cell that is accepting the most charge This reading will be used to gauge all other cells Compare the specific gravity readings to the highest reading if the difference between any of the cells is more than 30 points then that battery should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a set Heconnect the batteries remove the blocks from the wheels and test drive Typical Hydrometer Float Batteries Page 4 Maintenance Service and Repair WATERING NOTE The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the batteries at the end of a charging cycle If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete Explosive mixtures of Hydrogen gas are present 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 bodily injury and or property damage Battery electrolyte is poison
85. E The front brake rotor is an integral part of the front hub If the brake rotor is worn beyond its service limits then the front hub must be replaced Refer to Front Axle Service for information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be an integral part of the rear axle If the brake rotor is worn beyond its service limits then the rear axle must be replaced Refer to Transmission section for information regarding replacing the rear axle NOTE The wheel must be removed to accurately measure the rotor thickness Refer to Tires and Wheels section for information on removing the wheel 1 Measure the run out of the rotor at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its service limits NOTE A bent axle or damaged rear axle could cause excessive brake rotor run out Shown with the brake removed for clarity 2 Measure the thickness of the brake rotor in 3 places If the brake rotor thickness is less than 0 20 inches then the rotor must be replaced pion rios E ACA HL ACTA s m Do not use a rotor that is worn beyond its service limits A rotor worn beyond its service limits could fail AWARNING and cause loss of brakes resulting in severe bodily injury and or property damage Rotor removed for clarity The rotor does not have to be removed for this procedure Brakes Page 3 Ma
86. 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 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 when the charginc current is down to A1 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 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
87. ING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 8 Release the park brake Wheel Hub Brake Body 9 Remove the tire and wheel assembly Refer to section Tires and Wheels for information regarding removing the tire and wheel assembly a If the axle shaft hub or bearing is to be replaced then remove the hub bolt wheel hub and disc rotor at this time 10 Remove the four bolts attached to the axle retaining plate Axle Retaining Disc Rotor Plate Transmission Page 6 Maintenance Service and Repair 11 Remove the axle retaining plate and brake body assembly as one unit 12 Secure the brake body assembly do not let it hang by the brake hose 13 Pull the axle out of the housing 14 Inspect all bearings for roughness or play replace as needed 15 Install in reverse order lubricate the o ring NOTE Be sure not to damage the o ring 16 Use new bolts for the axle retaining plate The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes A WARNING resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt 17 If the wheel hub was removed install the hub and rotor Torque the hub bolt to 275 ft lb
88. N 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 than 12 hours if he vehicle is equipped with batteries larger than 220 Amp hour capacity e 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 e An 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 1s not turning off due to that the charger has restarted
89. NTS Inspect the Front Wheel Bearings ana ID Pill u ein a am sm RR a 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 REMOVA zit dried ricarica Pop Dod 4 IriStallatlOlt a otia eO eode oret DEO et 5 Front Axle Remosval 6 Front Axle Disassembly 8 Replace Front Wheel Bearings 10 Replace the Ball Joints Tie Rods and Drag LIDK i rrr einn SG 11 Replacing the Drag Link 13 Replacing the Tie Rod 14 Replace the King pins and Bushings 15 Replace the Steering Knuckle 17 Maintenance Service and Repair INSPECT THE FRONT WHEEL BEARINGS AND KIN PIN 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Grab the top an
90. OY I9 O 9UOO uooA9S IY ur s1ojoure ed peursro ou qr urojred qp 103001 rt 0 0 Su INOW rS0 0 IP YIM pooerdor Apop oq ueo 1070W Qp p60 0Z PUL nbio1 2p amod orou APYSIs seu 1olour I r 0 0 ML F r 0 0 Aq peoe dou useq seu 3 penunuoosip u q sey 0r r 0 0 Jequinu ped Japun poprAoud 1070W BUISTIO oU Sururd Jo oum W o qereA JON j oq Sununoui C L90 98 C L90 98 C L90 99 C L90 99 8 IPLI ST Z LI L90 88 LI L90 88 LI L90 88 LI L90 88 8 opes S S T T _ ERE NN Iv CLO OL Or CS 0 0L O0r LS0 0L Iv v 90 0L 0F FS0 0 NOLLdIMOSACd WALI VOcC81dX 10 T00r IcC 0C poor edd 10 98L1 dx cOOr TAd IO00PCAG JO 68L1 dX C00T LACI Weg 1010 A dads 1OJOIN PRIA powoxy Ajayeredas sio0Jo x Parts ey Page 19 lllustrated Parts Deadman Seat Brake Internal Components of 2 Above Parts Page 20 Illustrated Parts AUTOMATIC DRIVER SEAT BRAKE ITEM PART DESCRIPTION QTY i 88 067 22 Bolt 1 4 X 2 NC Grade no brake option 3 88 067 29
91. WARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury 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 f connected to the AC power source and turn itself OFF when the batteries are fully charged Once the charge cycle is complete the charger will continue to monitor the batteries If the battery Typical Signet HBS voltage 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 charg
92. aced 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 ez Page 9 Electrical Troubleshooting 4 Disconnect the wires from the contact terminals on the timer relay 5 Reconnect the batteries 6 Wait 5 seconds then test the continuity across the timer relay contact terminals e 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 and break the Key Switch connection to the speed controller The Interlock Relay is available for built in chargers only Not all built in chargers are equipped with this relay To identify chargers that are equipped with the Interlock Relay Inspect the charger wire harness where it enters the charger cabinet for two Violet Black wires If these wires are present then the charger is equipped with the Interlock Relay Testing Make sure the key switch is in the OFF position then remove the key Placethe forward reverse switch in the center OFF position AWARNING Setthe park brake Place blocks under the front wheels to prevent vehicle mov
93. adings 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 79 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 electrical 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 startin
94. age available at the batteries at the time of test e High Greater than 44 5 volts e Low Less than 1 8 volts Terminology used The HOT side of a switch is the terminal that the power is connected to e The COLD side of a switch is the terminal that the power is switched to e FS 1 Micro switch in the accelerator module DURING ALL TESTS e After any repairs are made completely retest vehicle before lowering the drive wheels to the ground 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 AWARNING Turn the Key switch OFF then 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 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 property damage and or serious bodily injury Important Notes and Instructions e This troubleshooting procedure is for the oevcon Power Pak and Micro Pak motor speed controllers as equipped in standard vehicles Troubleshooting may not be valid for vehicles equipped with
95. amp R in forward Low 2 F amp R in neutral High F amp R in reverse F amp R in reverse Low 3 F amp R in neutral High F amp R in forward Accelerator pedal up High Accelerator pedal down Low Seat switch closed depressed Low gt Seat switch open High High low switch in high Low High low Switch in low High Hand brake switch closed Low Hand brake switch open High Key switch on ref battery positive Key switch off ref battery positive Battery volts System off ref battery positive O volts 2 System on ref battery positive Accelerator pedal up 0 0 0 3 volts M Accelerator pedal down 4 8 5 0 volts 11 Not used 12 Notused All voltages made referencing main negative unless specified otherwise The voltage should start at approximately 24 volts then drop to approximately 15 volts after about 0 5 seconds SSS III I lliE ZI Sevcon Troubleshooting Page 18 Electrical Troubleshooting Status LED Code Table The status LED on the Sevcon power unit logic card can be used to give you an idea of where the problem may be It is recommended that you complete the troubleshooting procedure to confirm failure of any component Number of Fault Description Possible Cause Actions Flashes Personality fault
96. and or Gasket Failed Oil Leak in Rear Bearing Area Drive Over Filled Brake Pedal Soft or Spongy Air in Brake Lines Brake Worn 1 16 Wear Limit Brake Pedal Low Brake Fluid Low Brakes Out of Adjustment Brake Worn 1 16 Wear Limit Brake Pads Contaminated with Fluid Braking Power Low Brake Pedal Linkage Binding Brakes Out of Adjustment Air in Brake Lines Maintenance Page 3 Maintenance Service and Repair LUBRICATION CHART E CA 7 Ti gt a LHA RN Drive N Descnption Locations Lubricant Type I 2 King Pin 2 General Purpose Grease 3 Ball Joints 6 General Purpose Grease 4 5 Font Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Dnve Drain Plug 1 8 Dive Level Plug 1 9 Drive Hill Plug SAE 80W90 Gear Oil Maintenance Page 4 Front Axle Service TABLE OF CONTE
97. ations 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 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 An electrically noisy charging environment 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 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 an
98. ator Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted armature e f the insulation is cracked or burnt then it is recommend that the armature or motor be replaced NOTE If the armature has been burnt then there is a 8 9 10 11 good possibility that the field windings may also be burnt Symptoms indicating a shorted field include high motor current lack of power and possibly excessive speed Using a growler test the armature for shorts e Ifthe armature is shorted then we recommend that the armature or motor be replaced Using the continuity function of digital multi meter check the continuity around the entire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity around the entire commutator If any segment indicates an open circuit then the motor must be replaced Using the continuity function of digital multi meter check the continuity from any one of the commutator segments and the armature frame If it is not an open circuit then the armature is shorted and the motor must be replaced Measure the armatur
99. 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 wires This voltage should be the same as the voltage at the AC receptacle rated voltage of the charger If the voltage is less than the rated AC voltage of the charger then the 14 gauge white or black wire s is broken or has a bad connection between the charger connectors and the AC plug Stop here and repair the problem Charger Troubleshooting el 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 2
100. 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 ez 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 receptacle to the negative terminal on the DC receptacle This voltage should be equal to the battery voltage If the voltage is less than the battery voltage then the wire on the negative terminal of the DC receptacle is broken or has a bad connection Stop here and repair the problem Remove the charger cover and perform the following tests HIGH VOLTAGE may be stored in the capacitor Discharge the capacitor before continuing Connect a 2k ohm resistor across the capacitor AW ARNI NG terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers Failure to do so may cause serious bodily injury
101. cle may not be required 6 If required raise the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Place a drain pan under the master cylinder 8 Disconnect the brake line s to the master cylinder and pump out the fluid in the master cylinder by depressing the pedal several times 9 Remove the master cylinder bolts and remove the master cylinder from the vehicle Brakes Page 23 Maintenance Service and Repair 10 11 12 13 14 15 16 17 18 A WARNING Install in reverse order Adjust the master cylinder push rod so that it is approximately 1 8 inch away from the master cylinder plunger when the brake pedal is up Fill the master cylinder with brake fluid from a sealed container Pump the brake pedal a short distance of one to two inches until no bubbles are seen coming from the inlet ports inside of the master cylinder chamber If the vehicle was raised lower it to the ground Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle
102. conditions the parking brake will be applied when the start switch is turned off or the operator leaves the driver seat It will also be applied if the control system loses power such as when the emergency battery disconnect switch if equipped is activated NOTE The vehicle will come to an abrupt stop if the Start switch is turned off or the operator leaves the driver seat while the vehicle is in motion The parking brake is powered by the vehicle battery It will be applied whenever the batteries are disconnected It may be applied if the batteries are severely discharged If the vehicle power system fails and applies the brake the can be released by disconnecting the electric brake from the control system and connecting a 20 to 24 volt DC source 1 5A to the electric brake Towing This Vehicle To tow this vehicle attach a tow strap to the front bumper tow bar NOTE If the vehicle is equipped with the automatic electric park brake do not tow the vehicle with the drive wheels on the ground Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible this vehicle should be placed on a carrier rather than towing SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE AWARNING Explosive mixtures of Hydrogen gas are
103. connect 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 severe bodily injury 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle beam 9 Support the spring so that it cannot fall out of the vehicle 10 Remove the remaining hardware retaining the spring to the frame 11 Remove the spring from the vehicle Suspension Page 3 Maintenance Service and Repair 12 Inspect the spring bolts and spring hangers for signs of wear or damage If any wear or damage is found then they must be replaced Damaged or worn spring bolts or hangers could result in sudden failure A WARNING of the suspension causing severe bodily injury or property damage 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the spring 15 Tighten the spring hanger bolts securely but not so tight as to bind the spring 16 Lower the vehicle 17 Reconnect the main positive and negative cables at the batteries 18 Remove the blocks from behind the wheels 19 Release the parking brake and test drive the vehicle Su
104. d bottom of the tire wheel assembly Feel for any movement or play while pulling and pushing on the top and bottom of the tire Any movement or play is indication of loose wheel bearings or king pin NOTE Refer to the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings NOTE If the king pin is loose then refer to Replace the King Pins and Bushings for information regarding replacing the king pin bushings There are no adjustments for the king pin or bushings 8 Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 9 Lower the vehicle 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Front Axle Page 2 Maintenance Service and Repair ADJUST FRONT WHEEL BEARINGS 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 6 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands Alway
105. d from the vehicle Refer to Replace the Tire Wheel section for information on removing the tire wheel assembly Explosion Hazard Fully deflate the tire before attempting to remove the tire from the wheel Do not over inflate the tire when seating the AW ARNING bead Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death Tire replacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire Remove the tire from the wheel Cut the old valve stem off of the wheel Remove the valve stem cap from the new valve stem Lubricate the valve stem with liquid soap Install a new valve stem using a valve stem tool NOTE The valve stem tool is available at most auto repair shops Gro oo ques 6 Install the tire onto the wheel following the instructions provided with your tire replacement equipment 7 Inflate the tire to the proper pressure and check for leaks 8 Install the valve stem cap Tires and Wheels Page 5 NN C SO TAV L Battery Service TABLE OF CONTENTS CIGGning S no nosivvivesdvcudveviuxivav voe usudvev i iube Da 2 Te lig EE DLL 3 Watering u uu saa s 5 CONAN GING nett 6 Replacing 6 volt batteries on
106. d in the operator and service training program Maintenance Service and Repair This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks Electrical and Charger Troubleshooting This section identifies the troubleshooting procedures for testing the electrical system and battery charger Illustrated Parts This section provides an illustrated view of various assemblies The illustrations are accompanied by tables identifying the parts Introduction Page 4 INTRODUCTION Conventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual A WARNING A shaded box with the word Warning on its left denotes a warning A warning alerts the reader of a hazard that may result in injury to Or themselves or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the ZNNARNING task The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property ACAUTION damage may occur Be sure to exercise special care and follow any instructions contained with in a caution NOTE Alerts the reader to additional information about a subject Introduction Page 5 INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the fr
107. d 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 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 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
108. de every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are e Vehicle Description e Safety Rules and Guidelines Operational Information Operator Responsibilities Owner Responsibilities e Control Operation and Location Information Maintenance and Troubleshooting Information e Standard Parts List Before servicing operating training or performing maintenance on this or any other Taylor Dunn vehicle read the appropriate Taylor Dunn manual Each Taylor Dunn manual references the applicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual Introduction Page 2 INTRODUCTION WHO SHOULD READ THIS MANUAL This manual is intended for use by anyone who is going to operate own perform maintenance on service or order parts for this Taylor Dunn vehicle Each person should be familiar with the parts of this manual that apply to their use of this vehicle RESPONSIBILITIES Of the Owner The owner of this or any Taylor Dunn vehicle is responsible for the overall maintenance and repairs of the vehicle as well as the training of operators Owners should keep a record of conducted training and maintenance performed on the vehicle OSHA Regulation 29 CFR 1910 178 Powered Industrial Truck Operator Training Of the Operator The operator i
109. drop any tool or conductive object onto the battery A WARNINGI Aconductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in property damage and or bodily injury 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries NOTE If the batteries are over one year old it is recommended to replace them as a Set 6 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the A CAUTION battery electrolyte comes in contact with Failure to clean may result in property damage Batteries Page 7 Maintenance Service and Repair Remove the battery hold downs Inspect the battery hold downs for corrosion If any signs of corrosion are seen then the battery hold downs should be replaced 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batt
110. e 15 Maintenance Service and Repair 10 11 12 NOTE Refer to the illustration above for the following steps Remove the brake body bolts 10 and discard the lock nuts 1 and brake pads 8 Remove the spacer bushings 6 from the mounting bracket 5 and discard the bushings Inspect the brake rotor See Inspect the Service Brakes section for information regarding inspecting the brake rotor Inspect the spacers 7 and replace if any wear or damage is found Install new spacer bushings in the mounting bracket Install new brake pads in reverse order Torque the mounting bolts to 11 ft Ibs Repeat this procedure for the other wheel Install the tire wheel assembly and lower the vehicle to the ground Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information on the proper master cylinder fluid level Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Brakes Page 16 Maintenance Service and Repair REPLACE REAR BRAKE PADS Hydraulic Disc Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recomme
111. e and field resistance refer to Service Limits table at end of this section If the armature of field resistance is not within specification then the motor must be repaired or replaced Typical burn mark on a shorted armature Motor Service Page 3 Maintenance Service and Repair Assembly 1 Press a new bearing into the motor housing and Install the circlip 2 Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator See the illustration to the right Install the rear motor housing to the stator housing 4 Lightly grease the inside diameter of the armature bearing 5 Carefully insert the armature through the stator housing and onto the motor bearing in the rear housing 6 While supporting the inner race of the bearing press the armature into the bearing 7 Push the motor brushes into the brush holder until the brush spring snaps into place Be certain that the spring does not rest up against the brush wire See the illustrations below 8 Install the brush cover REPLACING THE BRUSHES OR ARMATURE BEARING NOTE It is recommended that all four brushes be replaced as a set NOTE The motor must be disassembled to replace the brushes or the bearing Refer to Motor Inspection Disassembly section for information on taking the motor apart NOTE The motor must be removed from the vehicle for this
112. e of the steering column Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal Hazard Light Switch Optional The hazard light switch is located on the left side of the steering column The switch is a small tab To activate the hazard lights pull the tab out To R turn the hazard lights off push forward or pull back the directional signal h lever Safety Rules Page 6 SAFETY RULES AND OPERATING INSTRUCTIONS p 2 Battery Status Indicator Analoq The battery status indicator is located to the left of the hour meter The normal operating range is in the green zone Park the vehicle for a few minutes for an accurate reading The vehicle needs charging if it is in the 9 T lt yellow zone During and immediately following charging the needle will be ff in the red zone to the right The needle will move through the green zone toward the yellow zone as the batteries discharge Charge the batteries when the needle is in the yellow zone If it is in the red zone to the left the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries Battery Status Indicator Digital Bargraph The battery status indicator is located to the left of the hour meter The battery status indicator has a LED bar graph that indicates the relative state of charge of the battery The top LED will light only when connected to a fully charg
113. e 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 AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in serious bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery AWARNING Aconductive object that comes in contact with the battery terminals Will initiate a short circuit of the battery This could cause the battery to explode resulting in property damage and or bodily injury Moist charged batteries are shipped without battery electrolyte This allows for a much greater shelf life of the battery Moist charged batteries must be filled with electrolyte and charged before putting into service Battery electrolyte is a solution of acid and water that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and AC AUTION charged Operating or charging moist charged batteries before
114. e that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove the drive assembly from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 9 Remove the motor only if the entire drive is to be disassembled NOTE Hefer to Motor Removal and Installation for information on removing the motor 10 Remove the cover retaining bolts 11 Remove the cover plate from the differential and let the remaining oil drain from the housing Be careful not to damage the sealing surfaces on the housings Damage to ACAUTIONI the sealing surface may lead to an oil leak resulting in damage to the internal parts of the drive Transmission Page 9 Maintenance Service and Repair 12 Remove the circlip from the idler gear 13 Remove the input shaft bearing assembly and idler gear bearing assembly from the gear case cover at the same time 14 Remove the pinion nut from the output gear and remove the output gear from the pinion shaft NOTE If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 16 Remove the six retaining bolts holding the gear case to the 3rd member housing NOTE Make note of the angle of the gear case 17 Remove the gear case housing
115. ecommended handling precautions Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately A WARNING i EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Release the park brake 7 Raise the wheel off of the ground and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING _tolift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Brakes Page 19 Maintenance Service and Repair 8 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 9 Thoroughly clean the area around the brake body 10 Remove the brake body bolts and discard the lock Lock Nuts Bushings nuts 11 Inspect the b
116. ecommended that both the left and right brake pads be replaced as a set Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full 8 Raise the front of the vehicle and support with jack stands 36v Located between the batteries shown 48v Located on the right side panel 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 severe bodily injury 9 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly Brakes Pag
117. ect the Service Brake section for information regarding inspecting the brake rotor 14 Inspect the spacers and replace if any wear or i damage is found lt i i c 15 Install new spacer bushings in the mounting bracket Mounting Bracket Spacers Bolts Lock Nuts Bushings ai An 16 Back off the parking brake adjustment wheel park brake only 17 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 18 Repeat this procedure for the other wheel 19 Install the tire wheel assembly and lower the vehicle to the ground 20 Fill the master cylinder to the proper level Refer to Check Master Cylinder Fluid section for information regarding the correct master cylinder fluid level 21 Adjust the parking brake wheel park brake only Refer to Adjust the Parking Brake section 22 Set the park brake 23 Reconnect the main positive and negative cables at the batteries 24 Remove the blocks from behind the wheels 25 Release the park brake and test drive the vehicle Brakes Page 18 Maintenance Service and Repair REPLACE THE WHEEL CYLINDER Disc Brake Bodv Assemblv front or rear Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for r
118. ection for information regarding removing the motor brushes 7 If any one brush is less than or equal to the service limit specified in Service Limits then all four brushes should be replaced 8 Reconnect the main positive and negative cables at the batteries 9 Remove the blocks from behind the wheels release the park brake and test drive Motor Service Page 2 MOTOR REMOVAL AND INSTALLATION See the Transmission section for information on removing or installing the motor MOTOR INSPECTION Disassembly 1 Remove the motor from the vehicle See the Transmission section for information on removing the motor 2 Remove the brush cover and pull the brushes out away from the commutator Remove the dust cap from the rear motor housing Place the motor in a press and press the armature out of the rear bearing NOTE Removing the armature will damage the motor bearing The motor bearing should be replaced whenever the armature is removed 5 Remove the housing screws from the rear motor housing and remove the housing from the motor 6 Remove the nuts from the armature studs and remove the two brush assemblies 7 Remove the bearing circlip and press the motor bearing out of the housing and discard Inspection 1 Measure the length of each motor brush e f any one brush is less than or equal to the service limit specified in section Service Limits then all four brushes should be replaced m Refer
119. ed battery or after completing a charging cycle Successive lower LED s will light as the battery charge diminishes When the second from the bottom LED flashes the battery energy status is in energy reserve and should be placed on charge as soon as possible When the two bottom LED s are alternately flashing the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries The BSI will reset to fully charged only after a complete charge cycle is completed A complete charge cycle is defined as battery voltage exceeding 2 35 volts per cell for a minimum of 6 minutes Hour Meter Optional The hour meter is located to the right of the battery status indicator It records the number of hours the vehicle has been in operation Safety Rules Page 7 SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Displa Maintenance Indicator Run Time Hours Indicator Key Hours Indicator AYLOR DN battery Status Wrench Hour Indicator Hour Meter Status Display The Smart View Display SVD functions as a Battery Status Indicator BSI Hour Meter HM speed controller status monitor and as an optional maintenance monitor feature The operation of each of these functions is described below BSI A bar graph representing the current state of charge is located across the top of the display When the batteries are fully charged all segments of the bar graph will be on
120. eels 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 motor wires with the number of the motor terminal before they are removed from the motor 7 f equipped remove the motor support bracket u bolt only used on larger motors 8 Remove the motor mounting bolts and slide the motor off of the input shaft 9 Install the motor in reverse order NOTE Apply a light coating of 94 421 34 grease to the splines on the transmission input shaft only Support bracket u bolt 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Transmission Page 4 Maintenance Service and Repair REAR HUB OR ROTOR NOTE The torque specification for the axle hub bolt is 275 ft Ibs An impact wrench will be required to remove the bolt NOTE The axle hub bolt has a special thread locking compound applied to the threads If this bolt is removed it must be replaced 1 Make sure the 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 wheel off of the grou
121. ement 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 e The DMM should indicate a closed circuit If the DMM indicates an open circuit then the relay or the wires to the relay have failed Stop here and repair the problem 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 confirmed that the AC power source is working e The DMM should indicate an open circuit If it still indicates a closed circuit then the relay or the wires to the relay have failed Stop here and repair the problem e f the 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 ODAeTratlof ua L u a QQ 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
122. en e Check wiring to the key switch and continue troubleshooting at test 4 2 If the voltage equals battery volts then Connect a volt meter across the Violet Black wire and the Blue wire at the electric brake harness plug The voltage should start at approximately 24 volts then drop to approximately 15 volts after about 0 5 seconds If the test is good then e he pigtail harness to the electric brake is broken or the electric brake has failed Remove the brake and repair or replace as required If the test is bad then Sevcon Troubleshooting Page 16 Electrical Troubleshooting Connect a volt meter across the Violet Black wire at the electric brake harness plug and Pin 9 at the logic card connector The voltage should start at approximately 24 volts then drop to approximately 15 volts after about 0 5 seconds If the test is good then e he blue wire from the electric brake harness plug to pin 9 on the logic card connector is broken Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground If the test is bad then helogic card is not releasing the brake This could be a result of Improper operation of the vehicle fault in the vehicles wiring or switches A fault in the speed controller Incorrect programming A failed speed controller Disconnect the electric brake harness connector and connect the electric
123. eplace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Hefer to Front Axle Removal and Installation for information regarding removing the front axle Bushing King Pin Steer Knuckle R Axle Beam Seal ES Inner Bearing Juter Bearin i Thrust Bearing Cotter Pi w A D ace n ER King Pin Nut Thrust Bearing Detail Large Cup QE Too e Steel Washer Castle Nut ee ae ronze Wasner e Steel Washer Bearing Cap Bottom Small Cup Front Axle Page 6 Maintenance Service and Repair REPLACE FRONT WHEEL BEARINGS 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity AWARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly from the hub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle Remove the hub dust cap cotter pin and spindle nut Remove
124. er may also be beeping Refer to the Charger Troubleshooting section for information on error codes Status Light Panel Safety Rules Page 13 SAFETY RULES AND OPERATING INSTRUCTIONS Lestronic II Charqer Operation The Lestronic II charger is 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 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 batteries 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 ov
125. ercharging Refer to Vehicle Controls in this section for information on how to read the BSI Do not discharge the batteries beyond a normal discharge as indicated on the BSI Refer to Vehicle Controls in this section for information on how to read the BSI Check the battery electrolyte once a week Do not charge the batteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their life span Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep Both circumstances will shorten the life of the batteries Safety Rules Page 14 Charging Time Average charging time is 8 to 10 hours The time required to fully charge your batteries will vary depending on e Capacity of the batteries higher capacity requires longer charge time e Output of the charger higher output requires less charge time e 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
126. eries 10 Remove the batteries from the vehicle Do not leave cables on batteries that have been removed from the A WARNING vehicle Cables left on batteries could cause a short circuit resulting in battery explosion severe bodily injury and or property damage 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and repainted 13 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery compartment 14 Inspect the main positive and negative cables and terminals charger cables and terminals and 12 volt tap wiring If any of the terminals or wires show signs of corrosion then they must be repaired or replaced 15 Install the batteries in reverse order Refer to the Illustrated Parts List for battery cable routing 16 It is recommended to replace the battery terminal hardware when replacing the batteries 17 Torque the terminal hardware to 7 8 ft lbs 18 Tighten the hold downs so that the batteries are secure but not so tight as to deform the batteries When torquing battery hardware use a backup wrench on the battery AC AUTION bolt and tighten the nut Failure to use a backup wrench may damage the battery post 19 Remove the blocks from the wheels and test drive Batteries Page 8 Main
127. erty damage Unauthorized repairs may also void the vehicles warranty Introduction Page 7 NN C SO TAV L TABLE OF CONTENTS c Standard Specifications 2 c Safety Rules and Guidelines 3 Driver Training Program 3 Driver Qualifications 3 Vehicle Controls 4 E KEVAS WIC heee e EE EEEa 4 Forward Off Reverse Switch 4 Accelerator Pedal 4 DICE t u e AERE RRR 4 Foot Brake Pedal 4 Seat Interlock Switch 5 Charger Interlock 5 Park Brake 5 Horn SWiteh ecenin 5 Reverse or Motion Alarm Optional 6 T Directional Signals Optional 6 Hazard Light Switch Optional 6 Lu Electrolyte Alarm Optional 6 Headlight Switch 6 Battery Status Indicator Analog 7 miss Battery Status Indicator Digital Bareraph 7 Hour Meter Optional 7 Smart View Display
128. ess 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 is good Status LED s 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 DC output wires Plug the charger into an AC outlet Wait for charger to start up to15 seconds the ammeter should display the DC Amp rating of the charger plus or minus 10 indicating that the charger is on constant current mode The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals 2 55 VPC When the battery voltage equals 2 55 VPC the charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on Make sure the key switch is in the OFF position then remove the key AW ARNI N G 2 Placethe forward reverse switch in the center OFF position
129. est 3 3 If the voltage is low then skip ahead to Test 7 TEST 3 3 Place the forward and reverse switch in the REVERSE direction Test the voltage at pin 3 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 4 If the voltage is high then skip ahead to Test 7 TEST 3 4 Test the voltage at pin 2 on the 12 pin logic card connector If the voltage is high then it is likely that the internal directional control transistors have failed test the transistors at Test 3 5 and 3 6 If the voltage is low then skip ahead to Test 7 TEST 3 5 Disconnect the batteries and remove wires from the B Fl and F2 terminals on the controller Using the diode test function on your meter connect the positive lead to the B terminal on the controller Connect the negative lead to the F1 terminal on the controller The test should show the presence of a diode approx 0 5v If the test is good then skip ahead to test 3 6 If the test is open or shorted then one or both directional FET s are shorted and the controller must be replaced TEST 3 6 Disconnect the batteries and remove wires from the B F1 and F2 terminals on the controller Using the diode test function on your meter connect the positive lead to the B terminal on the controller Connect the negative lead to the F2 terminal on the controller The test should show the presence of a diode approx 0 5v If the test is
130. esult 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 the 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 U REESE r1 ii Signet Charger Troubleshooting Page 2 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION AC input Voltage Range DC output Charger Model System Voltage MODEL HBS1000 36 PART No 4
131. evere bodily injury and or property damage 20 Reconnect the main positive and negative cables at the batteries 21 Remove the blocks from behind the wheels 22 Release the parking brake and test drive the vehicle Tie Rod Drag Link Ball Joint Clamp Steering Page 5 Maintenance Service and Repair ADJUST THE STEERING GEAR SAGINAW NOTE In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure Refer to Replace the Steering Gear for information regarding removing the steering gear 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity 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 Disconnect the drag link from the pitman arm NOTE Refer to Replace the Ball Joints section for information regarding removing the ball joint from the drag link 8 Loosen the gear lash jam nut and the worm bearing adjuster jam nut 9 Unscrew the gear lash adjuster all of the way to t
132. fall out of the vehicle 10 Remove the lower bolt from the spring hanger 11 Remove the spring bolt from the other end of the spring and remove the spring from the vehicle 12 Inspect the spring bolts and spring hangers for signs of wear or damage If any wear or damage is found then they must be replaced 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the spring Typical Spring hanger Damaged or worn spring bolts or hangers could result in sudden failure A WARNING z ie 7 of the suspension causing severe bodily injury or property damage 15 Torque the spring hanger bolts to 20 ft lbs 16 Lower the vehicle 17 Reconnect the main positive and negative cables at the batteries 18 Remove the blocks from behind the wheels 19 Release the parking brake and test drive the vehicle Suspension Page 2 Maintenance Service and Repair REPLACE THE FRONT SPRINGS Leaf If a spring has failed or is fatigued then it is recommended that both front springs are replaced as a set HINT In most vehicles it will be easier if the springs are replaced one at a time 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Dis
133. filling and charging will damage the batteries resulting in premature failure of the batteries 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Batteries Page 10 Maintenance Service and Repair 6 Fill all battery cells with electrolyte to the proper Filler neck level 7 Thoroughly clean any spilled electrolyte from the Lu batteries or the ground Refer to Cleaning the qe uem Batteries for information on cleaning the TM batteries Plate inside battery 8 Reconnect the battery cables connect the batteries to the charger and allow the charger to complete es lt Z one charging cycle OI I UT Id RRS Battery 9 Remove the blocks from the wheels and test drive OKO SOS cutaway The batteries are now ready to be put into service Battery electrolyte will stain and corrode most surfaces Immediately A C AUTI ON and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with Failure to clean may result in property damage STORAGE AND RETURNING TO SERVICE Storage If the batteries are removed from the vehicle do not place them directly on the ground concrete or
134. formed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Electric motor brake If the Battery Status Indicator does not show a charged battery check the following The batteries e The wiring from the battery status indicator to the batteries for open circuits e he battery status indicator e he positive and negative circuit breaker e The main circuit breaker for open circuits Do not continue unless the indicator shows a charged battery If the vehicle runs in one direction only then skip ahead to test 3 If the vehicle runs slow in forward but otherwise runs normal then skip ahead to test 1 3 A WARNING 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 injury or property damage Sevcon Troubleshooting Page 4 Electrical Troubleshooting Test 1 CHECKING THE CONTROL LOQIC INPUTS Close the seat switch Place the high low switch in the HIGH position Connect a voltmeter across the ISO solenoid coil terminals and carefully monitor the voltage as the key switch is turned on Turn the key switch ON and wait 1 second until the Isolator contactor closes Perform the following tests TEST 1 1 The coil voltage should start at approximately 24 volts when
135. g hangers remove the spring hanger bolt from the vehicles Typical Spring frame Hanger 9 Remove the spring bushing s e For internal bushing press the spring bushings out of the two spring eyes and from the mounting eye on the vehicles frame For external bushing Remove the bushings from the spring eye 10 Install the new bushings in reverse order Suspension Page 5 Maintenance Service and Repair REPLACE THE SHOCKS Front or Rear It is recommended to replace both front shocks as a set NOTE On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts Refer to Tires and Wheels section for information regarding removing the front wheels 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 or rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Some vehicles may require that the wheels be lifted off of the ground and supported with jack stands to replace the shocks Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily 7 Remove the upper and lower shock bolts 8 Remove
136. g in the middle or skipping sections when not instructed to do so the proper results will not occur If the test result is good then proceed to the next test or go to the next section if instructed to do so During All Tests The charger cabinet must remain electrically grounded Disconnect AW ARNING both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire Failure to do so may result in serious bodily injury Charger Troubleshooting ez Page4 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT IN CHARGER Make sure 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 front wheels to prevent vehicle movement 5 Disconnect the charger from the AC source Locate the charger harness connectors where the charger harness is connected to the vehicle s control harness There will be two 10 gauge and two 14 gauge wires 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 Testthe voltage from the red wire to the main battery negative his 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
137. g 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 11 SAFETY RULES AND OPERATING INSTRUCTIONS Parkinq Before leaving the vehicle e Set the parking brake e Set the forward off reverse switch to the OFF position e Rotate the start switch to the OFF position In addition e f parking this vehicle on an incline turn the wheels to the curb or block the wheels e Do not block fire aisles emergency equipment stairways or exits Draw Bar Pull DBP definition DBP is a measure of pulling force required to move a load The load may bea trailing load or a pushed load It is normally expressed in pounds or Newtons The DBP of a tow tractor is the horizontal force exerted on a load at its coupler while towing or pushing a load To measure the DBP a scale would be connected in line with the tractor coupler and the load The scale will directly read the DBP as the tractor tows the load Tow tractor DBP specifications definition Normal DBP Highest DBP that can be sustained for a given duty cycle Ultimate DBP Also referred to a Maximum DBP Highest DBP achieved while travailing at a minimum speed of approx
138. g 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 Headlight Switch The headlight switch is located on the far left side of the instrument panel Push the top of the switch to turn the lighs on Push the bottom of the switch to turn the light off Reverse or Motion Alarm Optional The reverse alarm is located in the electronics compartment mounted on the speed control panel or on the rear panel of the vehicle The reverse alarm is activated when the Key switch is in the ON position and the Forward Reverse switch is in the reverse position The alarm makes a repeated audible sound Electrolyte Alarm Optional The Electrolyte Alarm is located in the battery area in the 4th battery cell from the main battery positive cable The Electrolyte alarm is activated when the battery cell fluid level falls below the level of the probe The alarm is an audible continuous sound along with a bi color indicator lamp Inspect the fluid level in all battery cells when the alarm sounds or the bi color lamp turns from its green color to red The vehicle batteries should then be filled and or charged With the fluid level at a normal operating level and or the batteries charged the alarm and light will reset Directional Signals Optional The turn signal lever is located on the left sid
139. g wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front AWARNING wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 11 Loosen the ball joint clamps or the rod end jam nuts on the drag link Ball Joint NOTE Remember the position and orientation Clamp of the clamps 12 Adjust the drag link so that it can be easily inserted into the pitman arm 13 Tighten the ball joint or rod end nut as specified below Ball joint 40 45 ft Ibs Rod End Rod end 20 25 ft lbs Jam Nut 14 If equipped with ball joints position the ball joint clamps in their original location and orientation 15 Tighten the ball joint clamps or the rod end jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not contact any other component If the clamps are positioned so that they contact other components A WARNING it may result in steering failure and loss of control of the vehicle causing property damage and or severe bodily injury 19 Remove the blocks from behind the wheels 20 Release the parking brake and test drive the vehicle Steering Page 3 Maintenance Service and Repair Front wheel aliqnme
140. h is also designed to secure and disable the vehicle The key can only be removed when the key switch is in the OFF position Forward Off Reverse Switch The forward Off reverse switch located on the right side of the instrument panel determines the direction of travel of the vehicle Push the top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT 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 similar to the accelerator pedal in an automobile Depress the pedal to increase speed and release the pedal to decrease speed Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise Foot Brake Pedal The foot brake pedal is located to the right of the steering column it is for operation with the right foot only It works similar to the brake in an automobile Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied
141. h jack stands 1 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 severe bodily injury 12 Install in reverse order 13 Bleed the brake system Refer to Bleed the Brakes in the Brake Service section for information regarding bleeding the brake system 14 Check brake adjustment and adjust as needed Refer to Adjust the Brakes in the Brake Service section for information regarding adjusting the brakes 15 Reconnect the main positive and negative at the batteries remove the blocks from the wheels and test drive Transmission Page 8 Maintenance Service and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY HEDUCTION GEAR CASE 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Place a drain pan under the gear cas
142. h or skin irritation develops get medical attention immediately A WARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately NOTE Start this procedure at the wheel furthest from the master cylinder then work toward the wheel closest to the master cylinder 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Thoroughly clean the area around the master cylinder cap and remove the cap 36v Located between the batteries shown 46v Located on the right side panel Brakes Page 9 Maintenance Service and Repair 7 Add brake fluid from a new sealed container to the master cylinder Fill to 1 4 from the top of the master cylinder chamber Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes A WARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container 8 The master cylinder fluid level will drop as the brakes are bled Periodically check and fill the master cylinder during this procedure Do not allow the
143. han 10 5 6 degrees Drive slowly when making a turn especially if the ground is wet or when driving on an incline This vehicle may overturn easily if turned sharply or when driven at high speeds Observe all traffic regulations and speed limits Keep all body parts head arms legs inside this vehicle while it is moving Keep the vehicle under control at all times Yield right of way to pedestrians ambulances fire trucks or other vehicles in emergencies Do not overtake another vehicle atintersections blind spots or other dangerous locations Do not drive over loose objects holes or bumps Yield right of way to pedestrians and emergencies vehicles Stay in your driving lane under normal conditions maintaining a safe distance from all objects Keep a clear view ahead at all times Starting Perform all necessary vehicle preparation steps inspections or maintenance before operating this vehicle NOTE The vehicle is equipped with a seat or foot interlock switch This switch must be closed BEFORE the throttle is depressed Make sure the forward off reverse switch is in the center OFF position 2 If equipped with a manual park brake set the parking brake Hold down the foot brake Rotate the ON OFF switch to the ON position 5 Wait 1 second then place the forward off reverse switch in the desired direction of travel Release the parking brake Helease the foot brake 8 Slowly de
144. he stop 10 Loosen the worm bearing adjuster and then tighten just enough to remove all end play from the input shaft and then an additional 1 8 turn more 11 While holding the worm bearing adjuster so that it T MEE Gear Lash cannot turn tighten the worm bearing adjuster jam nut FA N n Adjuster 12 Find the center position of the steering shaft ON la s Worm Bearing Adjuster A Turn the steering shaft all of the way in one direction B While counting the rotations turn the steering shaft all of the way in the opposite direction C Turn the steering shaft 1 2 the number of turns in the original direction 13 While rotating the input shaft back and forth through its centered position adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels release the parking brake and test drive the vehicle Steering Page 6 Maintenance Service and Repair REPLACE THE STEERING SHAFT NON TILT STEERING 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks under the fro
145. he 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 Thoroughly clean the area around the master cylinder cap 7 Remove the master cylinder cap 8 If the fluid in the master cylinder is contaminated then the entire brake system must be flushed Refer to Bleed the Brakes for information regarding flushing the brake system 9 Fill with brake fluid from a new sealed container to within 1 4 inch of the top of the master cylinder chamber and reinstall the cap 10 Reconnect the main positive and negative cables at the batteries 11 Remove blocks from behind the wheels 36v Located between the batteries shown 12 Release the parking brake and test drive the vehicle 48v Located on the right side panel Only use DOT 3 brake fluid from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes AWARNING Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings on the brake fluid container Brakes Page 8 Maintenance Service and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a ras
146. hout upsetting the bearing preload If the ring A CAUTION nuts are not turned the same amount then the bearing preload will no longer be correct and will result in drive noise and premature failure Transmission Page 16 Maintenance Service and Repair 17 Install the locking roll pins into the housing and cover to lock the ring nuts in place 18 Remove the pinion gear holding tool 19 Install the primary reduction gear case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil section for information regarding the proper oil level 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Transmission Page 17 Maintenance Service and Repair Pinion Bearing Preload NOTE The pinion gear depth must be set before the preload Refer to Setting the Pinion Gear Depth Install the pinion gear spacer and shims into the housing Install the outer pinion bearing Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft Ibs Measure the torque required to rotate the pinion shaft in the housing Uomo Oe qe The torque required to rotate the pinion shaft should be between 1 1 and 2 9 ft Ibs If the torque is not within specificati
147. ian F01000 P S Motor Overheated Stop the vehicle and allow F05009 Wiring Motor Short Refer to service technician the system to cool down F05010 Power Up Fault Refer to service technician F01001 Motor Brush Fault Refer to service technician F05011 Drive 0 ON Refer to service technician F01002 Pump Motor Brush Fault Refer to service technician F05012 Drive 1 ON Refer to service technician F01003 P S motor Brush Fault Refer to service technician F05013 Drive 0 OFF Refer to service technician F01004 Low Battery Volts Batteries are empty and F05014 Drive 1 OFF Refer to service technician require charging If this F05015 Drv 0 MOSFET Trip Refer to service technician fault does not reset after the F05016 Drv 1 MOSFET Trip Refer to service technician charge cycle is complete F05017 Traction ON Refer to service technician then there may be a F05018 Traction OFF Refer to service technician problem with the charger or F05019 MOSFET Short L Refer to service technician batteries F05020 Power Up Fault Refer to service technician Refer to qualified service F05021 Traction Welded Refer to service technician technician F05022 Traction MOSFET Refer to service technician F01005 Controller Overheated Stop the vehicle and allow F05023 Auto Zero Refer to service technician the system to cool This 05024 Drive 0 ON L Refer to service technician could be a result of an F05025 Drive 1 ON L Refer to service technician overloaded vehicle F05026 Drive 0 OFF L Refer to service techn
148. iately and thoroughly clean any surface outside of the battery that the CAUTION battery electrolyte comes in contact with Failure to clean may result in property damage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Dry dirt can be readily blown off with low pressure air or brushed off 7 Wetness or wet dirt on the batteries indicates battery acid Using a nonmetallic brush with flexible bristles wash the batteries off with a strong solution of baking soda and hot water 1 Ib of soda to a gallon of water Continue until all fizzing stops which indicates that the acid has been neutralized Then rinse thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive Batteries Page 2 Maintenance Service and Repair TESTING NOTE A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots spa
149. ician F01006 Traction Motor Hot Stop the vehicle and allow F05027 Drive 1 OFF L Refer to service technician the system to cool down F05028 0 MOSFET trip L Refer to service technician This could be a result of an F05029 1 MOSFET trip L Refer to service technician overloaded vehicle F05030 Traction ON L Refer to service technician F01007 Pump Motor Overheated Stop the vehicle and allow F05031 Traction OFF L Refer to service technician the system to cool down F05032 MOSFET Short R Refer to service technician F01008 Wiring fault Refer to service technician F05033 Power Up Fault Refer to service technician F05034 Traction Welded Refer to service technician F05035 Traction MOSFET Refer to service technician Level 4 Faults F05036 Auto Zero R Refer to service technician Fault Code Description What to do F 05037 Drive 0 ON R Refer to service technician F04000 Open Contactor Refer to service technician F05038 Drive 1 On R Refer to service technician F04001 Contactor Welded Refer to service technician F05039 Drive 0 OFF R Refer to service technician F04002 Steer POT Fault N A F 05040 Drive 1 OFF R Refer to service technician F04003 Sequence Fault Start up switches were not F05041 0 MOSFET Trip R Refer to service technician operated in the correct F05042 1 MOSFET Trip R Refer to service technician order Refer to Vehicle F05043 Traction ON R Refer to service technician Operation Guidelines for F05044 Traction OFF R Refer to service technician correct sequence F0504
150. ignment of the front wheels 18 Lower the vehicle 19 Reconnect the main positive and negative cables at the batteries 20 Remove the blocks from behind the wheels 21 Release the park brake and test drive the vehicle Axle Beam ee 156 72 VISUAL GAP Thrust Bearing Front Axle Page 15 NN C SO TAV L Steering Component Service TABLE OF CONTENTS Front End Alignment 2 Adjust the Steering Gear Saginaw 6 Replace the Steering Shaft non tilt steering 7 Replace the Steering Wheel 9 Replace the Steering Gear 10 Repair the Steering Gear 11 Exploded View of Steering Gear 14 Maintenance Service and Repair FRONT END ALIGNMENT This section will refer to two different types of ball joints One type is has a grease fitting and a tapered shaft where it is fitted to the steering arm or pitman arm The second type cannot be greased and has a straight shaft See the illustrations to the right Depending on the configuration of your truck it may be equipped with one or both types of Ball Joint ball joints In this text The first type has a grease fitting and will be referred to as a Ball Joint The second type has no grease fitting and will be referred to as
151. ilable at time of printing Appendix B Page 4 Appendixes Hex Nuts Nuts with no markings are to be treated as S A E Grade 2 AN SN en KK A NDA a Us BY WI S A E Grade 5 S A E Grade 8 5 8 Metric Nuts Hex Lock Nuts stover Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A C Or Or S A E Grade B Or or t S A E Grade C Grade L 9 Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Not available at time of printing Appendixes Appendix B Page 5 Appendixes Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification Reduce torque approximately 10 15 for lubricated threads Refer to the service section assembly procedure for critical torque values Imperial inch Foot Pounds Imperial inch Newton Meters Grade SAE Grade SAE Dia Pich 2 5 8 9 Dia Pich 2 5 8 L9 4 40 i i i 4 40 i i i H6 32 H6 32 8 32 8 32 10 32 i i I 10 32 i 12 32 i 12 32 i i i 1 4 20 55 85 12 5 11 1 4 20 74 11 5 16 9 14 9 28 65 10 5 28 88 14 2 516 18 12 0 17 5 24 5 22 516 18 162 23 7 33
152. imately 0 5 mph 0 8 kph for a minimum of 30 seconds This specification is used in calculations for getting a load moving Notes Tow tractor DBP specifications are based on e Road surface consisting of level dry clean asphalt brushed concrete or equivalent e Maximum battery weight installed per tow tractor battery specification Towing a load up any grade will significantly affect the DBP required Most paved roads and parking lots have a drainage grade to allow water to run off When operating a tow tractor at or near its maximum capacity this drainage grade will greatly affect DBP required to pull the load and may exceed the tractor specifications Safety Rules Page 12 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 AWARNING 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 Automatic Electric Park Brake This vehicle may be equipped with an automatically applied electric parking brake Under normal driving
153. ing lining up the marks made when it was removed Tighten the three Allen head socket screws in a cross pattern evenly so that the internal spring pressure is increased gradually Turn each screw no more than two turns at a time Final torque 10 ft Ibs 2p D X Friction plate Inner contact T E Mul vs ues SANT Wa x Brakes Page 13 Maintenance Service and Repair Large Circlip Small Circlip 75 a a xy Ir Magnet P ani P put Contact Plate F aua Plate Housing Electric motor brake exploded Inspection Note There are no repairable parts in this assembly The parts must be replaced if any damage or wear is found Measure the free length of the five springs Minimum length 20 713 Inspect the splines on the hub and the friction plate for damage Inspect the inner contact plate and the outer housing where they come into contact with the friction plate for wear or damage 4 nspectthe three dowel pins and their corresponding holes in the inner contact plate The dowel pins Powel Pin 7 Spring should be straight and the holes should be round gt 5 Inspect the bearing for excessive play or roughness when rotated 6 Inspect the contact surfaces of the magnet and inner contact plate for damage and flatness IE N Magnet surface Brakes Page 14 Maintenance Service and Repair REPLACE FRONT DISC BRAKE PADS NOTE ltis r
154. intenance Service and Repair INSPECT THE PARKING BRAKE Wheel Park Brake hydraulic disc NOTE The parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles 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 Release the park brake Inspect the brake pads Refer to Inspect the Service Brake section to inspect the brake pads 8 Inspectthe park brake pin and bushing for any signs of damage or corrosion NOTE The park brake pin is inside of the brake body Refer to Repair the Brake Body for information on removing the park brake pin au 9 Inspect all brake cables and linkages for any signs of damage wear or missing cotter pins 10 Inspect the brake handle locking mechanism for any signs of damage NOTE Refer to Adjust the Parking Brake section for information regarding Park Brake adjusting the parking brake Ratchet If any sign of damage or wear is found on the locking mechanism cables or linkages then they must be repaired or replaced A WARNINGI immediately Failure to repair or replace any damaged component could result in failure of the park brake causing property da
155. 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 i Uo A 1LLw L LL LA isi Sevcon Troubleshooting Page 12 Electrical Troubleshooting Test 7 FORWARD AND REVERSE SWITCH FAULT Turn the key switch ON place the forward and reverse switch in the center OFF position and perform the following tests TEST 7 1 Referencing battery positive test the voltage on the center terminal of the F amp R switch Black wire If the voltage equals battery volts then skip ahead to test 777 2 If the voltage does not equal battery volts then check the wire from the F amp R switch to the battery voltage circuit breaker otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 7 2 If the vehicle does not travel in reverse skip ahead to test 717 3 Place the forward and reverse switch in the FORWARD position Referencing battery positive test the voltage at the Blue Black wire on the F amp R switch If the voltage equals battery volts skip ahead to test 47 4 If the voltage does not equal battery volts then the F amp H switch has failed otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground NOTE The
156. is based on the average application If the vehicle is operated under severe conditions service procedures should be conducted more frequently than specified The frequency of service under severe conditions is determined by the use of the vehicle The owner operator must evaluate the operating environment to determine the increase in maintenance frequency In addition the whole vehicle should be inspected monthly for signs of damage The damage must be repaired immediately The following list is meant as a guide and is not all inclusive of a severe duty application e Extreme temperature e Bumpy dusty or ill maintained roads 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 17 NN C SO TAV L General Maintenance TABLE OF CONTENTS Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Maintenance Service and Repair MAINTENANCE GUIDELINES Periodic maintenance and service must be performed on this vehicle Failure to complete these scheduled maintenance and service procedures can result in AWARNI NG severe bodil
157. k 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 4 Reconnect the transformer lead to the capacitor and disconnect one transformer lead from one of the diodes Test each of the diodes using the diode test function of your meter If either one of the diodes are bad replace the diode assembly Stop here and repair the problem Diode 1 E 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 f 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 fr
158. kage ltem 1 2 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Not Shown Part 19 011 25 88 199 82 19 011 20 97 200 00 32 248 10 00 680 15 88 100 11 88 108 62 88 108 62 97 211 30 20 031 64 18 308 21 88 128 62 88 120 11 00 680 13 50 002 07 88 159 85 88 140 32 88 527 11 32 215 00 88 149 81 88 148 61 00 680 12 90 002 08 86 501 98 86 501 99 86 510 00 Description Steering Wheel Cover 5 8 NF Hex Head Jam Nut Steering Wheel 3 Spoke Dust Washer 3 4 ID Bushing Steering Column 3 8 X 1 NC Hex Head Screw 3 8 Lockwasher 3 8 Cut Washer 3 8 U Nut Steering Shaft Steering Gear 7 16 Lockwasher 7 16 X1 Hex Head Cap Screw Pitman Arm Steering Sleeve Assembly 1 2 20 NF Hex Sloted Nut 1 2 X7 NC Hex Head Bolt 1 8 X 1 Steel Cotter Pin Bearing 1 2 NC Locknut 1 2 SAE Washer Steering Arm Steering Sleeve Assembly Drag Link Ball Joint Left Thread Ball Joint Right Thread Clamp Ball Joint Parts Page 5 Illustrated Parts QTY O CO CO Illustrated Parts Steering Gear Parts Page 6 Illustrated Parts
159. l m White Black White Black I 2 W L 171 Gray White EIES 12 I 9 p G oN I SS lo EE 5 ea F E Gray black Gray black l T I 2 m l G I ue Blac 7 2 E 3 Green Black Green Black l p Ex I x 0 L 3 White Black 2 i Yellow LO l Q WG l ius 8 ellow Yellow l S ad l OQ Violet Black 6 zr 3 t n Bd x Red White Red White Blue Blue I Lr m _ I ES RS T z Black use i i 16 I MOTION O l C Gray black Gray black Red White D n ALARM Green l Y 12 SEAT A T l Gray White AN ea I A 9 Gray White Gray White Black x om HIGH LOW DASH Black gt l I SS CN gt S z SWITCH PANEL Black l Black 6 9 I lt S m 16 Pin AMP l Black I E ACCELERATOR E Ed bisa Se oe ee u S gt uum gt 5 MS3 b oo Black S T e ps Black Blue Blue AUTOMATIC S O c Black HAND BRAKE ELECTRIC s SWITCH Violet Black Blue BRAKE So WY Q ellow option option S QO im adl 9 Pin AMP a S E uum Q CAN COMMUNICATION BUS E 8 e Q Je ons n a em O Sou s lt Illustrated Parts TABLE OF CONTENTS FEO A O u 2225522522 nat 2 Speed Control Panel R 3 80 36 32 Steering Linkage sessirnar 4 Miscellaneous Electrical 34 Steering GEI aana P rtu 6 Miscellaneous Frame 34 Front Suspension eirioes 8 Seat Cushions and Lights 36 Transmission p
160. lace the Wheel Cylinder section for information regarding removing the wheel cylinder Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into a container for waste brake fluid Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all bleeder screws Pump the master cylinder until all fluid has been pumped from the brake lines and all wheel cylinders Close all bleeder screws Fill the master cylinder with fluid Open one of the bleeder screws and pump the master cylinder until all fluid has been pumped from the master cylinder and close the bleeder screw Hepeat the above two steps for each wheel cylinder Reinstall the wheel cylinders and bleed the brakes Refer to Bleed the Brakes for information regarding bleeding the brakes oet the park brake Install the wheels and lower the vehicle to the ground Reconnect the main positive and negative cables at the batteries Release the park brake and test drive the vehicle Brakes Page 11 Maintenance Service and Repair REPLACE THE PARKING BRAKE LINING OPTIONAL MOTOR BRAKE Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautio
161. ler parameter sets are available from Taylor Dunn Individual parameters cannot be changed ACAUTION This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Sevcon Troubleshooting Page 2 Electrical Troubleshooting Identifying Your Controller ce mmm awa pamm Ei a x masa jis a PowerPak Co ntroller MicroPak Logic Connectors T PowerPak Logic Connector i NAaA OoOBoL OLLO L DA11 U AL1U A O L L L L1 A OAAA LAL Sevcon Troubleshooting Page 3 Electrical Troubleshooting START TROUBLESHOOTING HERE If your vehicles is equipped with an electric motor brake the motor brake system must be checked to be sure it is working properly before AC AUTION continuing with this troubleshooting Operating the speed control when the motor brake has not disengaged may result in damage to the motor or speed control system Refer to Test 9 Electric Motor Brake for information regarding testing the motor brake system The electric motor brake is mounted between the drive motor and the primary reduction gear case An illustration of the motor brake is shown to the left ACAUTION This troubleshooting guide is written in sequential order All tests must be per
162. llustration to the right Make sure that the pinch bolt is not aligned with the flat on the steering shaft Aligning the bolt with the flat could result in failure of the steering and loss of control of the AS Steering Gear vehicle This could lead to Input Shaft property damage and or severe bodily injury Do not use the original pinch bolt and nut Failure to replace the pinch AW ARNING bolt and nut may result in failure of the steering causing loss of control of the vehicle This could lead to property damage and or severe bodily injury 14 Tighten the pinch bolt to 24 26 ft lbs 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the parking brake and test drive the vehicle Steering Page 8 Maintenance Service and Repair REPLACE THE STEERING WHEEL 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 10 11 14 15 Tighten the steering wheel nut to 50 60 ft lbs 12 13 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries If equipped with a horn switch in the steering wheel remove the switch and disconnect the wires from the switch Remove the steering wheel nut Using a steering wheel puller
163. lt 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 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 i Red Black Black ae r i gt nAlal Tan i White Diode Capacitor Not all chargers are equipped Interlock purple bik with the lockout relay Violet Black 1 Y Y J Charger aum Interlock Relay Ammeter optional Black E 3 To Battery 4 lt 4 Red Typical Charger Internal Wire Diagram Charge
164. ly 7 Battery Removal 48 volt system 9 Moist Charge Batteries 10 Storage and Returning to Service 11 NIS TES 0 ROREM PATENT EM ET ND MU NM DN UE POPE 11 Returning tO SEVICE u L te a eni 12 Maintenance Service and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks 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 bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A WARNING Aconductive object that comes in contact with the battery terminals Will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte will stain and corrode most surfaces Immed
165. mage and or severe bodily injury Brakes Page 4 Maintenance Service and Repair INSPECT THE PARKING BRAKE Motor Brake optional A variable power supply capable of supplying 0 volts to 24 volts DC at 2 Amps will be required to perform the testing The brake does not have to be removed from the transmission for this test 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 If equipped with a hand or foot park brake 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 Disconnect the electric brake connector from the vehicles harness Adjust the power supply to zero volts Connect the power supply to the electric brake Slowly increase the voltage until you hear a click from the brake The click is the brake releasing The motor should now be free to rotate limited by the gear train and parking brake a If the brake does not release until the voltage exceeds 18 volts then the friction plate has worn beyond its service limits and must be replaced b If the brake does not release at all then the brake electromagnet has failed and must be replaced 10 Reconnect the electric brake 11 Reconnect the main positive and negative cables at the batteries 12 Remove blocks from behind the wheels
166. maintenance is performed and the display is reset The display should only be reset by an authorized technician Refer to the Illustrated parts section for information regarding tools required to reset the Smart View Display Speed controller status The display will indicate a fault code whenever the control system logic detects a problem with the control system A fault code is being displayed whenever the Fault Code Indicator the letter F is visible at the left of the numeric display Refer to the fault code table in this section for a summery description of the fault codes Safety Rules Page 9 SAFETY RULES AND OPERATING INSTRUCTIONS Fault Code Tables NOTE Most faults are a result of a fault in the control Level 5 Faults system that will require service by a qualified Fault Code Description What to do technician These faults are shown here for FO5000 Contactor Over Current Refer to service technician FO5001 Controller Fault Refer to service technician reference ony j F05002 Configuration Error Refer to service technician Operator correctable faults are shown in F05003 Internal Fault Refer to service technician bold and underlined F05004 VA Fail Refer to service technician ee F05005 Data Layer Fault Refer to service technician FO5006 MOSFET Short Refer to service technician Level 1 Faults F05007 Power Up Fault Refer to service technician Fault Code Description What to do F05008 Line Contactor Short Refer to service technic
167. move the cotter pin and ball joint nut f Cotter Pin 8 Ball Joint Nut 9 Using a pickle fork remove the ball joint from the steering arm Z ST HINT Count the number of turns required to remove the ball joint from the sleeve NA Steering Arm This will make it easier to realign the k N Ball Joint wheels Clamp 10 Remove the ball joint from the steering sleeve 1 Install the new ball joint into the steering sleeve Screw it into the sleeve the same number of turns counted in the previous step Do not tighten the l ball joint clamp at this time Steering Sleeve 12 Install the ball joint into the steering arm Tighten the ball joint nut to 40 45 ft lbs and install a new cotter pin 13 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 14 Lower the vehicle 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Replacing the Drag Link The Drag Link is the linkage that connects the steering gear pitman arm to the steering knuckle Refer to the illustration on the following page 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to preve
168. moving Tool Removes 0 062 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor 72 201 00 Battery Filler Used to safely add water to batteries Equipped with splash guard and auto shutoff when cell is full Molex 093 pin 11 0300 06 Molex 11 300 06 Pin Removing Tool Removes 0 093 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor 70 440 55 Pin Removing Tool Removes pin from Amp circular harness connectors illustration Not Available 96 500 40 Fork Collar Weld jig Used to properly align the front fork collar when replacing the collar in the frame SS 536 and MX 600 only Appendixes Appendix A Page 3 Appendixes APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markinqs NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads The grade of a metric bolt is cast directctly on the head Below is an example of a 10 9 the location and style of the text will vary p x Hex Bolts S A E Grade 2 S A E Grade 5 S A E Grade 8 Other Bolts Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Appendixes Not ava
169. n testing the batteries 9 The batteries are now ready to be put back into service Batteries Page 12 Sevcon Control System Troubleshooting Includes Power Pak and Micro Pak controllers TABLE OF CONTENTS Test Equipment Required 2 D olinilions essa a 2 Terminology used 2 Important Notes and Instructions 2 Identifying Your Controller 3 Start Troubleshooting Here 4 Test 8 Anti Rolloff Fault 15 Test 9 Electric Motor Brake 16 Logic Voltage Reference Table 18 Status LED Code Table 19 Smart View Fault Codes 20 Turn the Key switch OFF BEFORE disconnecting the batteries ACAUTION Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table This troubleshooting guide is written in sequential order All tests A C AUTION must be performed in the order that they are written Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results Rev R Electrical Troubleshooting Test Equipment Required Digital multimeter DMM with diode test function FLUKE 79 model shown e Throttle Module Analyzer Taylor Dunn part number 62 027 32 Definitions Battery volts full volt
170. nd Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the rotor 11 Install in reverse order a Lightly grease the axle splines b Refer to section Brake Service for information regarding installing the brake pads c Thoroughly clean the threads in the axle shaft d Using a new bolt torque the axle hub bolt to 275 ft lbs The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes A WARNING resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt e Refer to Tires and Wheels section for information regarding installing the tire wheel assembly 12 Lower the wheel to the ground 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels release the
171. nded handling precautions NOTE It is recommended that both the left and right brake pads be replaced as a set 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 NOTE Installing new brake pads will raise the brake fluid level in the master cylinder 6 Thoroughly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full 8 Raise the rear of the vehicle and support with jack I stands 36v Located between the batteries shown 46v Located on the right side panel 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 severe bodily injury Brakes Page 17 Maintenance Service and Repair 9 Remove the tire wheel assembly NOTE Refer to Tires and Wheels section for information on removing the tire and wheel assembly 10 Release the park brake wheel brake only 11 Remove the brake body bolts and discard the lock nuts and brake pads 12 Remove the spacer bushings from the mounting bracket and discard 13 Inspect the brake rotor Refer to Insp
172. nnect the electric brake harness connector and repeat the test If the brake is still not engaged then e Remove the brake and repair or replace the brake as required 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 brake engaged after the harness was disconnected then Inspect the harness for shorts Stop troubleshooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground A WARNING The electric brake is part of the vehicle braking system Do not operate a vehicle with the electric brake bypassed or disabled unless the system is being tested for faults Operating a vehicle with the brake bypassed or disabled may result in severe personal injury or property damage Test 9 1 Close the seat switch turn the key switch ON place the forward and reverse switch in the FORWARD position depress the accelerator pedal to engage FS 1 only creep speed Rotate the drive wheels to confirm the brake has released If the brake released then the brake system is working and no further testing of the brake Is required If the brake did not release then perform the following tests Connect a volt meter from battery negative to the Violet Black wire at the electric brake harness plug If the voltage is less than battery volts th
173. ns 1 Remove the electric brake assembly from the drive Refer to Motor Removal and Installation in the Transmission section for information regarding removing the brake 2 Place the brake assembly on flat surface with the shaft pointing up 3 Mark the orientation of the outer housing and magnet This mark will be used to correctly align the housing during reassembly Example of marked housing 4 Remove the three Allen head socket screws evenly so that the internal spring pressure is reduced gradually Turn each screw no more than two turns at a time 5 Remove the outer housing and friction plate Brakes Page 12 Maintenance Service and Repair 6 Mark the orientation of the inner contact plate in relation to the magnet Mark gt orientation 7 Remove the smaller bearing circlip 8 Using a soft hammer drive out the center hub and remove the inner contact plate and six springs 9 f required remove the larger bearing circlip and press out the bearing If the bearing is removed it must be replaced 10 Thoroughly clean all parts 11 Inspect all parts for damage or wear 12 Reassemble in reverse order Small circlip Reassembly Notes a Orientate the inner contact plate lining up the marks made when removed and so that the notches face away from the magnet see illustration below b Orientate the friction plate so that the cutout faces the inner contact plate Orientate the outer hous
174. ns battery cables and other electrical connections are secure e Check battery cells to be sure they are filled e Check the tire pressure tightness of lug nuts and for any signs of damage Check the operation of each of the following controls e Accelerator Brake e Parking Brake Key Switch Forward Reverse Switch e Reverse Beeper if equipped Front Headlight Switch e Steering Wheel e Horn What To Do If a Problem is Found If there is a problem or damage as a result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also notify your Taylor Dunn dealer of the claim If there is a problem with the operation of the vehicle DO NOT OPERATE THE VEHICLE Immediately contact your local Taylor Dunn distributor and report the problem The report must be made within 24 hours of receiving the vehicle and its accessories The only personnel authorized to repair modify or adjust any part of this or any Taylor Dunn vehicle is a factory authorized service technician The only personnel authorized to repair modify or adjust any part of this or any Taylor Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in AWARNING damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and or prop
175. nt NOTE It is recommended to center the steering before aligning the front wheels Refer to the Center the Steering section for information 1 Make sure the key switch is in the 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 rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Position the steering wheel in the straight ahead position and tie off the steering wheel so that it cannot rotate Do not drive the vehicle while the steering wheel or front wheels are tied in position Driving the vehicle while the steering wheel or front A WARNING wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 8 Loosen the ball joint clamps on the drag link NOTE Remember the position and orientation of the ball joint clamps 9 Agjust the drag link so that the center steering linkage pivot arm is vertical 10 Position the ball joint clamps in their original location and orientation and tighten the ball joi
176. nt clamps 11 Using a piece of chalk mark a line around the center of both front tires HINT Hold the chalk on the center of the tire and rotate the tire to mark the line 12 Loosen the ball joint clamps on the left and right tie rods NOTE Remember the position and orientation of the ball joint clamps 13 Lower the front wheels to the ground and push the vehicle back and forth a few feet to settle the suspension Steering Page 4 Maintenance Service and Repair 14 Adjust the right side tie rod so that the right wheel is positioned pointing straight ahead Front Measurement 15 Measure the distance between the lines at the front of the tires 16 Measure the distance between the lines at the rear d Sleeve Clamps of the tires 17 Adjust the left side tie rod so that the distance at Tie R d the front and rear of the tires is the same 18 Position the ball joint clamps in their original location Rear Measurement and orientation and tighten the ball joint clamps Example of toe in measurement 19 Untie the steering wheel Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not contact any other A WARNING component Clamps positioned so that they contact other components may result in steering failure and loss of control of the vehicle causing s
177. nt 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 WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Front Axle Page 10 Maintenance Service and Repair 7 Remove the ball joints or rod ends from the steering knuckle and pitman arm NOTE Hefer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends Drag Link Pitman Arm N Sa ul lt Remove the drag link as an assembly Install in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels Steering Knuckle 11 Lower the vehicle Typical Drag Link 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together Refer to the illustration on the following page 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake
178. nt wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 If equipped with a horn switch in the steering wheel remove the switch disconnect the wires from the Horn Switch switch and cut the terminals off of the wires W 7 Remove the steering wheel NOTE Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 8 Remove the upper steering shaft bushing or bearing from the steering column 9 Remove the steering gear access cover from the steering column if equipped Wi Nw 2 Steering Shaft Bushing 10 Remove and discard the pinch bolt and nut from the steering shaft coupler NOTE Most vehicle configurations will now allow the steering shaft to slide off of the steering gear input shaft and then back down out of the steering column If there is not enough clearance for this procedure then the steering gear must be removed Hefer to Replace the Steering Gear for information regarding removing the steering gear Steering Page 7 Maintenance Service and Repair 11 Remove the steering shaft from the vehicle 12 Lightly grease the input shaft splines steering wheel splines and the upper steering shaft bushing 13 Install the steering shaft in reverse order using a Coupler new pinch bolt Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft oee the i
179. ntain battery limit switches protective devices electrical conductors and connections in conformance with Taylor Dunn s recommended procedures e Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Maintenance Page 2 Maintenance Service and Repair TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged King Pin Ball Joint Low Tire Pressure Worn Ball Joints Excessive Steering Play Mis Adjusted or Worn Steering Gear Loose Steering Linkage Brakes or Parking Brakes Dragging Worn Drive Gears Lack of Power or Slow Operation Front End Out of Alignment Defective Speed Control Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Abnormal Noise Loose Lug Nuts Motor Bearings Worn Rear Wheel Bearing
180. om 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 Testthe 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
181. ommet 1 EN 75 114 16 Wiper and Light Wiring Harness 71 039 10 Wiper Switch 1 Parts Page 53 Illustrated Parts Optional Cab Accessories is 12 OPINS 4 DWC 10 Ta Parts Page 54 lllustrated Parts OPTIONAL CAB ACCESSORIES ITEM PART DESCRIPTION QTY 1 72 023 20 Strobe Light Amber 1 2 88 025 06 8 32 X 1 2 Truss Head Screw 3 3 88 028 62 8 Lockwasher 3 4 88 029 80 8 32 Nut 3 5 98 606 00 3 16 ID Grommet 1 Not Shown 75 114 16 Wiring Harnes for Wiper and Light 1 6 92 201 00 4 1 2 X 8 1 2 Mirror 1 or 2 92 202 12 Left Mounting Bracket 1 I 92 202 13 Right Mounting Bracket 1 8 92 202 15 Spacer for Mounting Bracket 1 or 2 91 814 16 Left Hinge Female 1 i 91 814 17 Right Hinge Female I 10 88 069 81 1 4 NC Locknut 2 11 88 060 22 1 4 NC X 3 1 2 HEX Head Bolt 12 88 068 61 1 4 SAE Washer 2 or 4 13 88 065 09 1 4 NC X 3 4 Phillips Truss Head Screw 2 or 4 14 88 068 62 1 4 Lockwasher 2 or
182. ons then add or subtract from the total shim thickness and repeat this procedure until the proper preload is obtained NOTE Add shims to decrease torque Pinion Gear Bearings Transmission Page 18 Maintenance Service and Repair PINION GEAR SHIMMING INSTRUCTIONS NOTE This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears NOTE To perform this procedure all parts must be clean and the bearings lightly lubricated Setting the Pinion Gear Depth This formula is used to calculate the amount of shims that are required C B A DV Pinion Shim mm where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the edge of the differential side plate closest to the input shaft see next page D The number on the edge of the differential side plate farthest from the input shaft see next page E The distance in millimeters from the rear of the drive housing to the face of the pinion gear see next page Once a shim has been selected and the pinion gear is Face of pinion gear installed confirm that E D B DV NS Number on face of pinion gear Transmission Page 19 Maintenance Service and Repair NOTE Values shown are for reference only Pinion Gear Drive
183. ont 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 This vehicle is not designed to be driven on public roads or highways Itis available in maximum designed speeds ranging from 7 to 15 mph AW ARNING Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow at more than 5 mph This vehicle conforms to requirements for Type E vehicles as described 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 WI s Serial Number b o Frame SANE x pF i Serial Number Data Plate Vinyl Data Plate Metal Tag Introduction Page 6 INTRODUCTION TAKING DELIVERY OF YOUR VEHICLE 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 e Check that all wire connectio
184. open or shorted then one or both directional FET s are shorted and the controller must be replaced STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit PowerPak Logic Connector Sevcon Troubleshooting Page 9 Electrical Troubleshooting Test 4 KEY FAULT TEST 4 1 Turn the key switch ON and place the forward and reverse switch in the center OFF position Perform the following tests Test the voltage at pin 1 on the 12 pin logic card connector If the voltage equals battery volts then skip ahead to Test 5 Test the voltage on both terminals of the battery voltage positive circuit breaker see below If the voltage on both terminals equals battery volts then skip ahead to test 4 2 If the voltage on both terminals does not equal battery volts then check the circuit breaker and wiringto the main circuit breaker and to the batteries for open circuits Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 4 2 Test the voltage at the hot terminal red wire on the key switch If the voltage equals battery volts then skip ahead to test 44 3 If the voltage does not equal battery volts then check the wiring from the key s
185. or wear is noted then the king pin must be replaced Reassemble in reverse order NOTE Refer to Replace the Steering Knuckle for information on installing the steering knuckle NOTE It is recommended that the thrust washers or bearing be replaced whenever replacing the king pin bushings Refer to the Replacement Parts section for the orientation of the bearing or washers in your vehicle Grease the bushings bronze only 13 14 15 16 Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Front Axle Page 13 Maintenance Service and Repair REPLACE THE STEERING KNUCKLE 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembl
186. ormation on testing the armature NOTE Copper debris in the undercut area can give a reading of a shorted armature Properly undercut and cleaned commutator segments Hacksaw blade Incorrect Correct Commutator Motor Service Page 5 Maintenance Service and Repair Und Depth Commutator Diameter Brush Length Resistance Motor Specification ndercut Dept min min Ohms 75 P Number mm inches mm inches mm Inches Armature Field 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 245 15 87 0 625 0116 1 20 70 054 41 XP 1789 or DY2 4001 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 057 40 XP 1673 or DV1 4003 0 635 0 025 69 85 2 429 15 87 0 625 0 008 0 58 70 052 40 XP 1876 or DD3 4004 0 635 0 025 69 85 2 15 15 87 0 625 0 011 0 73 70 072 41 XP 1820A 0 635 0 025 69 85 2 75 15 2 0 6 0 0052 0 79 70 061 40 XP 1765A 0 889 0 035 69 85 2 75 15 87 0 625 0 011 0 71 Not available at time of printing NOTE Special and expensive motor testing equipment is required in order to accurately measure motor armature or field resistance In most cases this equipment is not required in order to determine if a motor is faulty The majority of moto
187. ous 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 severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A WARNING Aconductive object that comes in contact with the battery terminals Will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Do not overfill the batteries Over filling the batteries may cause the A WARNING batteries to boil over and result in severe bodily injury or property damage Batteries Page 5 Maintenance Service and Repair 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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
188. ove 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 Disconnect both of the battery leads during any maintenance or A WARNING before disconnecting any electrical component or wire Failure to do so may cause property damage and or serious bodily injury With the power switch OFF connect the throttle module to the analyzer Position the power switch to the 0 5 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp 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 note below The voltage on the digital display should vary with the position of the module arm starting at O volts and ending at approximately 5 volts If the OV lamp comes ON at any time then the module is faulty If the Low battery lamp is ON then the analyzer battery should be replaced Additional information regarding the analyzer can be found in the instructions provided with the analyzer DO 110 53 ON ood kos Battery r FS 64 volt systems 1 OFF NOTE Failures of the FS 1 circuit indicate a possible vehicle wiring fault that has resulted in a short circuit across FS 1 BEFOHE HEPLACING THE MODULE Conf
189. 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 charger 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 Status LED s Charging State LED1 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 A
190. press the throttle pedal e Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection e No reckless driving e Do not drive this vehicle on steep inclines or where prohibited e Immediately report any accidents or vehicle problems to a supervisor NOTE This vehicle is equipped with regenerative NOTE motor braking When the throttle pedal is released the motor is converted into a generator This will slow the vehicle and return this energy to the battery To disable the motor braking action and allow the vehicle to coast hold slight pressure on the throttle pedal If the operator leaves the driver seat while in motion the vehicle will come to an abrupt stop Loading and Unloading e Do not carry more than the maximum number of passengers allowed for this vehicle e Do not exceed the cargo load capacity Do not load cargo that can fall off e Be careful when handling cargo that is longer wider or higher than this vehicle be sure to properly secure all loads Towing Loads Do not exceed the DBP towing capacity of the tractor oee vehicle specifications and DBP definition Do not exceed the load capacity of the trailer Refer to documentation supplied with your trailer for information regarding load capacity of the trailer Make sure all loads are securely tied down Refer to documentation supplied with your trailer for information regarding attachin
191. procedure Refer to Transmission Service section for information on removing the motor Motor Service Page 4 Maintenance Service and Repair REPAIRING THE COMMUTATOR 1 The motor must be removed from the vehicle for this procedure Refer to Transmission Service section for information on removing the motor The armature must be removed from the motor for this procedure Refer to Motor Inspection Disassembly section for information on taking the motor apart Using a lathe cut the armature just enough to remove all grooves depressions or ridges Measure the diameter of the commutator If the commutator is less than the minimum diameter specified in Service Limits then the motor must be replaced Thoroughly clean all copper debris from between the commutator segments Measure the commutator undercut depth in 5 places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut While still in the lathe smooth the commutator with fine emery cloth Undercutting the commutator 1 Using a small straight cut saw blade cut the commutator insulation to the proper depth Refer to undercut depth in Service Limits Once all segments have been properly undercut mount the armature in a lathe and smooth the commutator with fine emery cloth Inspect the armature for shorts Refer to Motor Inspection section for inf
192. r 10 Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly do not allow the ring nuts to rotate 11 Install the pinion gear Re shim if required If the ring and pinion gears or bearings are replaced then the pinion gear must be re shimmed Improper ACAUTION pinion gear shims will result in drive noise and premature failure Refer to Pinion Gear Shimming Instructions 12 Install the pinion gear holding tool 96 500 42 and tighten the pinion nut enough to keep the pinion gear from rotating 13 Install the differential assembly 14 Install the cover and all of the cover bolts Torque to 45 50 ft lbs 15 Check the gear lash between the ring and pinion gears The gear lash should be 005 to 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nuts The two ring nuts must be turned equally in opposite directions NOTE To move the ring gear closer to the pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing race ring nut equally NOTE To move the ring gear away from the pinion Loosen the cover carrier bearing race ring nut and tighten the housing carrier race ring nut equally The two ring nuts must be turned the same amount in opposite directions This allows the carrier assembly to be positioned with the proper gear lash wit
193. r Troubleshooting ez 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 he 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 electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is turning off correctly monitor the battery voltage and the electrolyte specific gravity during the charging cycle as indicated below Specific Gravity Using a hydrometer take the specific gravity reading of several cells at 1 hour intervals while charging If the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not shut off then the charger is running too long Battery Voltage Using an accurate 5 1 2 digit digital voltmeter monitor the battery voltage during the charging cycle Take re
194. r failures are due to an open circuit in the field or armature windings If the symptom of the vehicle is not running with NO motor current then a simple continuity test of each winding is all that is required to determine if the motor is at fault Motor Service Page 6 Transmission TABLE OF CONTENTS Check Oil Level 2 Change Oil 3 Motor Removal and Installation 4 Rear Hub or Rotor 5 Removing and Installing the Rear Axles Disc Brakes 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3rd Member 12 Assembling the 3rd Member 15 Pinion Bearing Preload 18 Pinion Gear Shimming Instructions 19 Setting the Pinion Gear Depth 19 GT Transmission Assembly With Disc Brakes Maintenance Service and Repair CHECK OIL LEVEL The oil flows freely between the main gear case 3rd member and the primary reduction gear case It is only necessary to check the oil level of the 3rd member Park the vehicle on a level s
195. r pedal fully Test the voltage at pin 10 on the 12 pin logic card connector If the voltage is between 4 8 and 5 1 volts then skip ahead to Test 72 If the voltage is notbetween 4 8 and 5 1 volts then skip ahead to Test 6 Sevcon Troubleshooting Page 6 Electrical Troubleshooting Test 2 TESTING 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 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement A WARNING Disconnect both of the battery leads during any maintenance or AWARNING before disconnecting any electrical component or wire Failure to do so may cause property damage and or serious bodily injury NOTE Special and expensive motor testing equipment is required in order to accurately measure motor armature or field resistance In most cases this equipment is not required in order to determine if a motor is faulty The majority of motor failures are due to an open circuit in the field or armature windings If the symptom of the vehicle is not running with NO motor current then a simple continuity test of each winding is all that is required to determine if the motor is at fault TEST 2 1 Check the motor field continuity from the motor F1 to the motor F2 terminals If the resistance is close to values given in the motor specification table then skip ahead
196. rake rotor Refer to Inspect the Service Brake section for information regarding inspecting the brake rotor Ar 12 Disconnect the brake hose from the brake body b 14 ig E 13 Install the new brake body assembly in reverse Mounting aa Bracket Spacers e Use teflon tape thread sealant on the brake hose pact Bolts fitting e Torque the brake body bolts to 11 ft lbs 14 Bleed the brakes Refer to Bleed the Brakes section for information regarding bleeding the brakes 15 Set the park brake 16 Reconnect the main positive and negative cables at the batteries 17 Lower the wheel to the ground 18 Remove the blocks from behind the wheels 19 Release the park brake and test drive the vehicle Brakes Page 20 Maintenance Service and Repair REPAIR THE BRAKE BODY Hydraulic brake system components must be kept clean Make sure your work area is free from dirt and debris and will contain any brake A WARNINGI fluid spills Any debris or contaminates left in the brake system could lead to brake failure and result in property damage and or severe bodily injury Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately A WARNING i EYE CONTACT Immediately flush the eye
197. rating sequence of switches F04004 Two Directions Selected Both Forward and Heverse selected at the same time Check F amp R switch and wiring F04005 SRO Start up switches not operated in the correct order or fault in start up switches or wiring Refer to operator section for correct sequence of switches Normally a result of F amp R selected before start switch is turned on F04006 Traction Seat Seat or foot interlock switch open Check interlock switch wiring F04007 Inch Switch Inch switch ON at power up both switches selected at same time inching attempted with seat interlock F amp R switch or FS 1 closed FO4008 Steer Steer Function currently not used and this fault should not occur Check wiring F04009 Low Battery Low voltage at Pin 1 of controller connector Normally a result of discharged batteries Check wiring start switch interlock switches batteries F04010 High Battery High voltage at Pin 1 of controller connector Check for correct voltage battery installed check controller parameters F04011 Personality Range One or more controller personalities are out of range Correct parameters must be uploaded to the controller F04012 Personality CRC Controller personalities are corrupted Could be a result of a damaged logic card Attempt uploading new parameters If upload fails then controller must be replaced F04013 Capacitor high Sevcon Trouble
198. ric 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 cause the battery to explode resulting in property damage and or bodily injury 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface outside of the battery that the ACAUTION battery electrolyte comes in contact with Failure to clean may result in property damage 7 Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level 8 Test the batteries Refer to Testing section for information o
199. rimary reduction 10 Charger Lestronic Pg 1 38 Transmission secondary reduction 12 Charger Lestronic Pg 2 40 RETANO 12 Gliarger olglelb sss b secs us es 42 Brake BOOY T 14 F lO O duisi MUI TECH UE 44 Hear BIaKeSs udis aba daga tna rada d 14 DOGCAIS eM T 46 Front Brakes optional 14 TANG FANG uy yuuk eet 48 Rear Suspension sees 16 Strobe Light amp Other Front End Options 50 MOTOT NE RR E 18 Cab amp Cowl With Windshield Options 52 Deadman Seat Brake 20 Optional Cab Accessories 54 Master Cylinder Linkage 22 Cab Door Options 56 Master Cylinder Components All 22 Optional Top Gover uis cae c ele ds 58 Brake LINGS ioco remet er un inb en imd 24 Rear Seat Rear Gate and Rear Deck 60 Park Brake Linkage 26 9 Side Panels nette ex nex cux tee xen 62 Wheels and ires 28 Front Bumper and Splash Pan 64 Instrument Panel dash ending s n 179484 30 Instrument Panel dash starting s n 179485 30 Illustrated Parts Front Axle Bottom 3 Thrust Bearing Detail Parts Page 2 Front Axle Item Part 1 14 380 80
200. rks A WARNINGI cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves AWARNING and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A WARNING Aconductive object that comes in contact with the battery terminals Will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 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 Load Test 6 volt batteries only NOTE The batteries must be fully charged before performing this test 1 Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries 2 Load test each battery using a battery load test meter available at most auto pa
201. rts distributors Follow the instructions provided with the test meter e f any battery fails the load test then it should be replaced NOTE If the batteries are over one year old it is recommended to replace them as a set f all batteries fail the test you should check the charging system before replacing the batteries Refer to Charger Troubleshooting section for information on checking the charging system Batteries Page 3 Maintenance Service and Repair Specific Gravity Test NOTE The batteries must be fully charged before performing this test The specific gravity of a cell is an indication of the actual state of charge of the cell A fully charged cell should have a reading of 1275 to 1300 see the illustration to the right A discharged battery will read 1100 Ideally all cells in a battery pack will have the same reading Any cells in a battery pack that vary by more than 30 points may be an indication of a bad cell Clean the batteries Refer to Cleaning the Batteries section for information on cleaning the batteries Using part number 77 200 00 hydrometer check and record the specific gravity of each cell in the battery pack If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced x ki amp 1 rm al 1 gt NOT
202. s Transmission primary reduction Parts Page 10 Illustrated Parts Transmission Gear Case ITEM PART DESCRIPTION QTY 1 GI 71682 M8 x 60 bolt 12 2 GT 3287563 Gear case cover 3 GI 71259 Bearing 1 GI 3287513 Input shaft 30 1 O or 1 GT 3287523 Input shaft 24 1 Oor 1 GT 3287533 Input shaft 18 1 O or 1 GT 3287543 Input shaft 12 1 Oor 1 2 GI 71982 O ring 1 6 GT 3287503 Eccentric shaft 1 7 GT 72005 Bearing 2 8 GT 3287493 Idler gear 1 9 GT 70302 M10 x 30 Bolt 6 10 GT 71715 Snap ring l 11 GT 3287553 Gear case housing 12 GI 72019 Seal 1 18 GT 71979 Bearing 1 21 GI 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 GI 3287453 Output gear 30 1 O or 1 GT 3287463 Output gear 24 1 O or 1 a GT 3287473 Output gear 18 1 Oor 1 GT 3287483 Output gear 12 1 O or 1 GI 328 Spacer 46 100mm 1 GI 328 Spacer 46 1
203. s 17 Fill with oil to the level of the fill plug threads Refer to Changing the Differential Oil 18 Lower the vehicle 19 Set the park brake 20 Reconnect the main positive and negative cables at the batteries 21 Remove the blocks from behind the wheels 22 Release the park brake and test drive the vehicle Transmission Page 7 Maintenance Service and Repair TRANSMISSION ASSEMBLY NOTE The transmission assembly will be removed with the springs attached Refer to Suspension section for information regarding removing the springs Remove and Install 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 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 wires Disconnect the left and right mechanical parking brake linkage from the brake arms and the cable mounting brackets 8 Disconnect the hydraulic brake hoses from the rear brake calipers 9 Remove the nuts from the rear spring hangers and the front frame mount Do not remove the bolts at this time 10 Lift the rear of the vehicle just enough to allow the removal of the spring mounting bolts and remove the bolts Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle and support wit
204. s difficult to rotate the brake arm clevis pin on both wheels 9 Loosen the Primary adjustment rod one to two turns so that both wheels rotate whith no brake drag The threaded rod must be 3 8 Min screwed into the clevis with at least 3 8 of threads Less than J A WARNING 3 8 of threads in a clevis cou JS cede bodily inju B snd or E property damage Cutaway of Clevis and Threaded Rod NOTE If there is no adjustment left in the Primary Adjustment Rod then the Brake Arm Extension must be rotated to engage the next hole in the arm 10 Tighten the jam nuts on the park brake linkage 11 Set the park brake 12 Reconnect the main positive and negative cables at the batteries 13 Remove blocks from behind the wheels 14 Release the park brake and test drive the vehicle Brakes Page 7 Maintenance Service and Repair CHECK MASTER CYLINDER FLUID Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately A WARNING EYE CONTACT Immediately flush the eye with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in t
205. s responsible for the safe operation of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible for the service and maintenance of the vehicle At no time should a service person allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training At no time should an untrained individual be allowed to service or repair a vehicle without supervision This manual is not a training guide Of the Passengers The passengers are responsible to remain fully seated keeping their hands arms and legs inside the vehicle at all times Each passenger should be fully aware of the vehicle s operation All forms of recklessness are to be avoided Do not engage in horseplay Introduction Page 3 INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections INTRODUCTION This section describes how to use this service manual and how to identify your vehicle Safety Rules and Operating Instructions This section outlines the safety and operational issues location and operation of controls and the operational checks that are to be performed on this vehicle It also includes various subjects that should be include
206. s use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices 10 11 12 13 14 15 16 of rated load capacity may result in severe bodily injury Remove the hub dust cap and cotter pin While rotating the hub tighten the spindle nut to 28 30 ft lbs This seats the bearings ur i Spindle Nut Flat of Nut gt Back off the spindle nut one flat until the hub turns but is not loose Spin the wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings l Hub with Dust Cap Removed Install a new cotter pin Install the dust cap Lower the vehicle Reconnect the main positive and negative cables at the batteries Remove the blocks from behind the wheels Release the park brake and test drive the vehicle Front Axle Page 3 Maintenance Service and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise
207. sc Brake Body Assembly front or rear 19 Repair the Brake Body 21 Replace the Master Cylinder 23 Repair the Master Cylinder 25 Maintenance Service and Repair INSPECT THE SERVICE BRAKE Disc Brake Pads Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions NOTE The brake pad must be removed to accurately measure the lining thickness Refer to Replace the Front or Rear Brake Pads section for information on removing the brake pads Measure the brake pad lining at the thinnest point on the pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Brakes Page 2 Maintenance Service and Repair Disc Brake Rotor Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket AW ARNING parts containing asbestos Since this possibility exists all brake parts should be handled as if they contain asbestos Refer to Appendix C for recommended handling precautions NOT
208. sed by airborne asbestos fibers and brake dust AWARNI NG 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 8
209. sh qnd Lower Bearg Adjuster and Shim Ball Nut Housing Worm Shaft Pitman Shaft a Qo Bearings Ball Guides LV Upper Bearing 0 Ball Guide Clamp Pitman Shaft Seal Em Worm Shaft Seal Steering Page 14 Brake Service TABLE OF CONTENTS Inspect the Service Brake 2 Disc Brake Pads 2 Disc Brake Rotor 3 Inspect the Parking brake 4 Wheel Park Brake hydraulic disc 4 Inspect the Parking brake 5 Motor Brake optional 5 Adjust the Service Brakes 6 Two or Four Wheel Hydraulic Disc Brakes 6 Adjust the Parking Brake 7 Wheel Park Brake hydraulic disc 7 Check Master Cylinder Fluid 8 Bleed the Brake System 9 Flush the Brake System 11 Replace the Parking Brake Lining optional motor brake 12 IMS HECO gems Rm rr 14 Replace Front Disc Brake Pads 15 Replace Rear Brake Pads 17 Hydraulic DISC e Lapointe ea ee en einen 17 Replace the Wheel Cylinder 19 Di
210. shooting Page 20 Electrical Troubleshooting Level 2 Faults F02xxx F02000 Accelerator Wiring to throttle module is open or faulty throttle module F02001 Accelerator power up Throttle module FS 1 switch is closed pedal depressed or wiring shorted when start switch is turned on Throttle module output high when start switch is turned on F02002 Belly Switch Belly Switch currently not used and this fault should not occur Check wiring F02003 Open Field Not used F02004 Open Field L Not used F02005 Open Field R Not used Level 1 Faults F01xxx Most Level 1 faults are a result of operator error or operation of the vehicle F01000 Power Steer Overheat Not used F01001 Traction Motor Brush Wear Not used F01002 Pump Motor Brush Wear Not used F01003 Power Steer Motor Brush Wear Not used F01004 BDI Cutout Low voltage at Pin 1 of controller connector Normally a result of discharged batteries Check wiring start switch interlock switches batteries NOTE Fault will not reset until batteries successfully complete a charge cycle and battery voltage is above reset threshold F01005 Traction Block Overheat Controller has overheated Allow controller to cool off F01006 Traction Motor Hot Not used F01007 Pump Motor Hot Not used F01008 Encoder Wiring Motor speed encoder faulty faulty wiring or incorrect controller parameters
211. solid metal surface It is AC AUTION recommended to store them on a wooden pallet or equivalent Storing on the ground concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level Store the vehicle or batteries in a cool dry well ventilated area If storing for more than one month the batteries should be charged as follows Storage Charging Interval Temperature months F Over 60 1 Between 40 and 60 2 Below 40 6 Batteries Page 11 Maintenance Service and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks 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 sulfu
212. special order speed control options For additional troubleshooting information use the handheld system anylizer part number 62 027 61 or the computer system anylizer PCpak part number 62 027 63 See note below e This troubleshooting guide assumes a familiarity with the use of a digital multimeter including voltage tests continuity tests and diode testing If you are not familiar with these types of tests then refer testing to a qualified technician These tests are not intended to locate a problem on an incorrectly wired vehicle e Make sure the batteries are in good condition and fully charged before performing any tests e Ifthe vehicle exhibits intermittent problems it must be in the failed mode for troubleshooting If it is running normally when the testing is done then the problem will not be identified e Some tests refer to a High Low switch The High Low switch is optional and the vehicle may not be equipped with this option If the vehicle is without this option there is a jumper bypass installed in place of the switch in the dash All voltage tests are done referenced to battery negative unless otherwise specified e At the start of each test sequence you will be instructed on how to place the control switches While testing do not change the position of any switches unless instructed to do so Note The PCpak application is also capable of uploading new controller parameters to the controller Control
213. spension Page 4 Maintenance Service and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set BUSHING TYPES Your vehicle will be equipped with one of two types of spring bushings internal and external see illustration to the right e he internal bushing is a plastic insert that is pressed into the spring eye There are one of these bushings for each spring eye Internal e he external bushing consists of two plastic bushings on each end of the spring eye External Refer to the parts list to identify the bushings used in your vehicle 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 Set the park brake Place blocks under the front rear wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Raise the frontor rear of the vehicle depending on which spring is to be removed and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNING toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily 7 Remove the spring from the vehicle NOTE Refer to Replace the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with sprin
214. t of an open motor armature circuit Confirm the motor armature and wires to the motor are good If motor and wires are good then replace the controller F05008 Power Up Traction Welded Normaly due to line contactor welded closed resulting in a high voltage at B This fault is generated when the differential voltage between the key switch input and the B terminal is less than approximatly 6 volts F05009 Shorted MOSFET Normaly due to interal short in controller Also could be result of shorted motor or wiring Remove the wire from the controller terminal S If fault clears then the short is in the motor or wiring F05046 Line Contactor Did Not Close Normaly due to open circuit to the controller B terminal Check wiring contactor main Circuit Breaker NOTE Controller B terminal must be within 1 5 volts of Pin 1 after contactor closes All other level 5 faults are a result of an internal failure in the Sevcon controller and cannot be repaired The controller must be replaced Level 4 Faults F04xxx F04001 Contactor Welded High voltage at power up to the controller B terminal Check wiring contactor and pre charge resistor on the contactor F04002 Steer Pot Steer Pot currently not used and this fault should not occur Check wiring F04003 Sequence Fault Start up switches not operated in the correct order or fault in start up switches or wiring Refer to operator section for correct ope
215. t view display Foward Reverse Switch Horn switch Key Switch keyed alike Key Switch keyed unalike Spacer Keys Instrument Panel starting s n 179485 ltem Part 1 771 039 11 2 71 039 11 3 71 039 1 1 4 71 039 02 5 71 039 1 1 6 74 010 00 7 71 039 35 8 71 120 10 71 121 20 71 120 90 9 10 88 607 06 11 94 303 91 Description Rocker Switch Rocker Switch Rocker Switch Foward Reverse Switch High Low speed switch optional Smart view display Horn switch optional on dash Key Switch keyed alike Key Switch keyed unalike Keys Rivit Dash Panel Parts Page 31 Illustrated Parts QTY QTY Illustrated Parts Speed Control Panel R 3 80 36 13 M NA 2 2 Parts Page 32 Illustrated Parts Speed Control Panel ITEM PART DESCRIPTION QTY 62 400 05 Speed controller 1 2 01 200 07 Mounting panel 1 3 73 004 20 Horn 1 4 79 844 00 Main circuit breaker 1 5 72 501 42 ISO solenoid 6 88 838 06 14 x 1 2 Sheet metal screw 4 7 88 060 09 ANC x 3 4 Hex bolt 4 8 79 840 00 10 Amp circuit breaker 1 9 79 840 20 20 Amp circuit breaker 1 10 79 840 20 20 Amp circuit breaker 1 11 88 818
216. tenance Service and Repair Battery Removal 48 volt system The illustration to the right shows the left bank of a typical battery installation in a model R 380 48 with the cable removed Some components have been omitted for clarity Note The charger may have to be removed to provide clearance A WARNING Do not leave cables on batteries that have been removed from the vehicle Cables left on batteries could cause a short circuit resulting in battery explosion severe bodily injury and or property damage 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 all of the battery cables from the batteries 7 Remove the battery hold downs 8 Lift the rear battery at an angle as shown 9 Lift the front battery at an angle as shown and remove the battery from the vehicle 10 The remaining batteries can now be removed 11 Repeat the same procedure for the four batteries on the right side Batteries Page 9 Maintenance Service and Repair Moist Charqe Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge battery in an area where open flames including gas furnac
217. the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove both front wheels Refer to Tires and Wheels section for information regarding removing the front wheels 8 ie up or support the front axle so it can not fall out of the vehicle 9 Disconnect the drag link ball joint or rod end from the steering knuckle or the steering gear pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 10 If equipped with front brakes disconnect the hydraulic brake lines from the brake bodies 11 Disconnect the front axle beam from the front springs and remove the axle from the vehicle NOTE In some configurations the front springs and or shocks will have to be removed in order to remove the axle beam Hefer to section Front Suspension for information g regarding removing the springs and w shocks An Axle Beam a Shown with steering linkages removed for clarity Front Axle Page 4 Maintenance Service and Repair Installation 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 4 Place blocks
218. the shock from the vehicle NOTE If the shock that was removed is to be reinstalled A Inspect the shaft where it enters the shock body for any signs of leakage If any sign of leakage is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse order 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle Suspension Page 6 Tires and Wheels TABLE OF CONTENTS TIPO MHAOIN cc 2c uuu nuusan eee ooa acct Tire Inspection Replace the Front Tire Wheel Replace the Rear Tire Wheel Repair the Tire pneumatic Replace the Tire pneumatic Maintenance Service and Repair TIRE INFLATION A WARNING There are many tire options available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall information on a tire Tire pressures must be checked when the tire is cold 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse
219. they are pressed into the axle beam or steering knuckle A WARNING I Failure to broach or ream the bushings may result in steering dificulty and loss of control of the vehicle causing severe bodily injury and or property damage Refer to the illustration below for the type of bushing in your vehicle Axle End with Metal Backed Teflon Axle End with Bushings Bronze Bushings Front Axle Page 12 Maintenance Service and Repair 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 6 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI toliftand support the vehicle Failure to use lifting and support devices 11 12 of rated load capacity may result in severe bodily injury Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle NOTE It is not necessary to remove the tie rod or drag link for this procedure Press the king pin bushings out from the axle or steering knuckle Press new bushings into the axle or steering knuckle Inspect the king pin for damage or wear If any damage
220. to Replacing the Brushes section for information regarding replacing the motor brushes 2 Measure the diameter of the commutator e f the commutator is less than the minimum diameter specified in section Service Limits then the motor must be replaced Maintenance Service and Repair 3 Measure the commutator undercut depth in 5 4 5 6 places around the commutator e If any one of the measurements is less than the minimum undercut depth specified in Service Limits at the end of this section then the commutator must be undercut Refer to Repair Commutator section for information regarding undercutting the commutator Inspect the commutator for groves e f the commutator is grooved then it must be machined on a lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator Inspect the commutator for burn marks e Burn marks and or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature A tool called a growler is required to reliably test for a shorted armature Inspect the commutator for raised segments Raised segments could be a result of a stalled motor or shorted armature A tool called a growler is required to reliably test for a shorted armature e If the armature is not shorted then the raised segments can be removed by machining the commut
221. to test 72 2 The motor specification table can be found in the Motor Service section If the test indicates an open circuit then repair or replace the motor Test continuity from F1 to the frame of the motor Any reading other than an open circuit indicates a short in the motor 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 TEST 2 2 Check the continuity from the motor Al to the A2 terminals If the resistance is close to values given in the motor specification table then go to test 42 3 If the test indicates high resistance or an open circuit then repair or replace the motor 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 Motor shown in illustrations is typical of a standard motor The terminal configuration of your motor may be different Sevcon Troubleshooting Page 7 Electrical Troubleshooting TEST 2 3 Test the continuity from the motor Al terminal to the frame on the motor and from F1 to Al for open circuits Any reading other than an open circuit indicate a short in the motor If there is a short in the motor stop here and repair or replace the motor STOP TEST 2 4 Reaching this point indicates an open circuit in the motor wiring Check the
222. tor Removal and Installation 2 Motor Inspection 2 Replacing the Brushes or Armature Bearing 4 Repairing the Commutator 5 Service LIMIS eccidi 6 Rear Housing Circlip Motor Service Brush Spring Stator Field Front Housing Brush Cover Bearing Brush Dust Cap Brush Holder Armature Maintenance Service and Repair INSPECTING THE MOTOR BRUSHES Motors with internal cooling fans Typical motor with cooling fan indicated by the arrow NOTE There are four brushes in the motor The brushes will not wear at the same rate It is recommended that all four brushes are inspected at the same time NOTE In some vehicle configurations it may not be possible to inspect all four brushes while the motor is in the vehicle Hefer to Transmission Service section for information on removing the motor A WARNING Make sure the key switch is in the OFF position then remove the key Place the forward reverse switch in the center OFF position Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement Disconnect the main positive and negative cables at the batteries 6 Look through the brush cover and compare the top of the brush to the top of the brush holder If it is even with or below the top of the brush holder then the brushes should be removed and measured Refer to Replacing the Brushes s
223. ts Page 61 Illustrated Parts 9 Side Panels Parts Page 62 Illustrated Parts 9 SIDE PANELS amp TAILGATE ITEM PART DESCRIPTION QTY 91 281 64 9 Side Panels Kit with Tailgate Orange 1 91 281 66 9 Side Panels Kit with Tailgate Specify Color 1 1 03 380 38 Left Side Panel 1 2 03 380 37 Right Side Panel 3 88 065 09 A NC X 3 4 Phillips Truss Head Screw 13 4 88 068 61 1 4 SAE Washer 13 5 88 069 81 1 4 NC Locknut 13 6 00 380 85 Tailgate 1 7 00 380 86 Right Tailgate Pivot 1 8 88 082 09 5 16 NC X 5 8 Carriage Bolt 4 9 88 089 81 5 16 NC Locknut 4 10 00 210 77 Rear Deck Angel 1 11 30 550 50 Tailgate Chain 2 12 30 551 00 S Hook 2 13 30 551 10 Tail Gate Chain 2 Parts Page 63 Illustrated Parts Front Bumper and Splash Pan Parts Page 64 Illustrated Parts FRONT BUMPER AND SPLASH PAN ITEM PART DESCRIPTION QTY 1 01 380 18 Bumper 1 2 88 109 81 3 8 NC Hex nut 4
224. ts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire connections Inspect the motor brushes and commutator Inspect the king pin bushings Check front end alignment 3 2000 Change oil in the drive and rear axle Flush hydraulic brake system Inspect suspension bushings Replace brake pedal treadle return spring Inspect frame for damage 1 2 3 See notes on following pages Safety Rules Page 16 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 FOR SEVERE DUTY APPLICATIONS 1 This maintenance checklist
225. uides 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 Steering Page 12 Maintenance Service and Repair 9 Place the upper worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 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 Hefer to Adjust the Steering gear section for information regarding adjusting the steering gear 16 Once the adjustments are completed make sure that the locking ring and jam nut are tight Steering Page 13 Maintenance Service and Repair Exploded View of Steering Gear Locking Ring Side Cover Worm Bearing Adjuster Gear La
226. ults may have occurred Broken Wire Check the wire from pin 8 in the 12 Main Battery Megative pin logic card connector to the contactor coil negative terminal for open circuits Welded Solenoid Contacts Test the solenoid for welded contact tips There are two methods for checking the contacts 1 Disconnect the batteries and test the continuity across the contacts If there is continuity then the contact tips are welded 2 With the key switch OFF check the voltage at the B terminal on the Sevcon control see illustration on following page If the voltage at the B terminal is at full battery voltage then the contact tips are welded NOTE Welded tips should be accompanied by a 4 flash code from the logic LED Shorted Solenoid Coil Disconnect the logic card connector and measure the resistance across the solenoid coil Depending on the solenoid or contactor you vehicle is equipped with the resistance should be 25 ohms or higher nominal A reading less than 25 ohms may indicate a shorted coil The control logic may have failed STOP Stop do not continue Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed correctly before replacing the Sevcon power unit Sevcon Troubleshooting Page 11 Electrical Troubleshooting Test 6 ACCELERATOR MODULE FAULT 1 Make sure the key switch is in the OFF position then rem
227. under the rear wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Raise the front of the vehicle and support with jack stands Always use a lifting strap hoist and jack stands of adequate capacity A WARNINGI tofliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Install the front axle in reverse order of removal NOTE Use all new cotter pins NOTE Refer to the Replacing the Ball Joints section for information regarding the installing the ball joints or rod ends NOTE Refer to Tires and Wheels section for information regarding removing the front wheels 8 Realign the front wheels Refer to Steering Component Service section for information regarding realigning the front wheels 9 If equipped with front brakes bleed the brakes Refer to Brake Service section for information regarding bleeding the brakes 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle Front Axle Page 5 Maintenance Service and Repair FRONT AXLE DISASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings Refer to the following sections for information regarding these procedures R
228. urface 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 Place an oil drain pan underneath the 3rd member Hemowve the fill level plug 8 The oil level should be very close to the bottom of the level plug opening a If the oil level is below the bottom of the opening add oil as required until level with the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes out of the opening allow to drain until level with the bottom of the opening TAM 9 Replace the fill level plug Drain Plug SS 10 Reconnect the main positive and negative cables N P at the batteries 11 Remove the blocks from the wheels 12 Release the park brake and test drive the vehicle Transmission Page 2 Maintenance Service and Repair CHANGE OIL 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position A WARNING 3 Set the park brake 10 11 12 13 14 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Raise
229. v emm de ARNING Front Cowl Tray KW N E Fa TAYLOR DUN n TD 21 s N kas _ MI 4 NEN ONE gt j iL Battery Compartment Parts Page 46 Decals ltem Part 1 94 384 01 2 94 309 00 3 94 384 14 4 94 301 42 5 94 313 20 6 94 373 10 7 94 333 00 8 94 313 00 9 94 301 41 10 94 319 00 Not shown 88 069 81 Description Not a Motor Vehicle Apply Hand Brake Turn Key Off Arms and Legs Safety Warning Data and Serial Number FM Battery Waring Brake Fluid Disconnect Batteries Do not Spray Wash Parts Page 47 illustrated Parts QTY Illustrated Parts Trailer Hitch Auto Coupling Hitch Pintle Hitch with Bracket Parts Page 48 Illustrated Parts Trailer Hitches ITEM PART DESCRIPTION QTY 97 808 00 Automatic Coupling hitch 97 804 01 Pintle hitch 97 811 00 1 7 8 Ball hitch 97 805 00 Mounting brakcket 97 821 00 2 Ball hitch 97 807 00 Mounting bracket 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 140 11 1 2NC x 1 Hex bolt 2 88 149 80 1 2NC Hax nut 6 88 148 62 1 2 Split lock washer 6 97 835 00 Weldment Angle for Mounting Bracket 1 97 835 10 Welment Plate for Mounting Bracket 1
230. ways use a lifting strap hoist and jack stands of adequate capacity A WARNING J toliftand support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 7 Remove the complete drive from the vehicle NOTE Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tube 11 Remove the primary reduction gear case Refer to Disassembly and reassembly of the Primary Reduction Gear Case for information on removing the gear case 12 Remove the 12 side plate bolts then remove the side plate Transmission Page 12 Maintenance Service and Repair 13 Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate 14 Turn the side plate over and remove the carrier bearing race from the side plate 15 Remove the differential assembly from the 3rd member housing 16 Remove the carrier bearing adjusting nut roll pin from the ard member housing then remove the carrier adjusting nut Transmission Page 13 Maintenance Service and Repair 17 Remove
231. wing Operation of this vehicle under circumstances normally associated with your particular environment e Emphasis on the safety of cargo and personnel All safety rules contained within this manual Proper operation of all vehicle controls e A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Training program are authorized to drive this vehicle Operators must possess the visual auditory physical and mental ability to safely operate this vehicle as specified in the American National Standards Institute Controlled Personnel and Burden Carriers ANSI B56 8 The following are minimum requirements necessary to qualify as an operator of this vehicle 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 on the right side of the instrument panel turns on the vehicle Rotate the key clockwise to turn the vehicle power on counterclockwise to turn the vehicle power off The key switch should be in the OFF position whenever the operator leaves the driver s seat This switc
232. wires are disconnected for reference only The test must be done with the wires connected to the switch NOTE The wires are disconnected for reference only The test must be done with the wires connected to the switch A CAUTION A WARNING This troubleshooting guide is written in After any repairs are made completely retest sequential order All tests must be performed in the vehicle before lowering the drive wheels to the order that they are written Starting in the the ground Failure to retest the vehicle could middle or skipping sections when not instructed result in unexpected movement of the vehicle to do so may lead to invalid test results resulting in injury or property damage Sevcon Troubleshooting Page 13 Electrical Troubleshooting TEST 7 3 If the vehicle does not travel in forward skip ahead to test 777 4 Place the forward and reverse switch in the REVERSE position Referencing battery positive test the voltage at the White Black wire on the F amp R switch If the voltage equals battery volts skip ahead to test 37 4 If the voltage does not equal battery volts then the F amp H switch has failed otop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before NOTE The wires are disconnected for lowering the drive wheels to the ground reference only The test must be done with the wires connected to the switch TEST 7 4
233. witch to the battery voltage positive 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 Typical Circuit Breaker TEST 4 3 Test the voltage at the cold side violet black wire of the key switch If the voltage equals battery volts then skip ahead to test 44 4 If the voltage does not equal battery volts then replace the key switch Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 4 4 Check the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector for open circuits NOTE Your vehicle may be equipped with a charger interlock relay The charger interlock relay disables the control system when the charger is connected to its power source The interlock relay contacts are in series with the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector The relay is located in the charger cabinet 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 Reaching this point indicates a failure in the Sevcon power unit or an error was made during testing Confirm all previous tests were performed
234. with water for 15 minutes and call physician INGESTION Get medical attention immediately 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position AWARNING 3 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 brake body from the vehicle NOTE Refer to Replace the Brake Body Assembly front or rear section for information on removing the brake body 7 Pull the pistons out of the brake body The pistons are very fragile If the piston is damaged it must be A WARNING replaced Failure to replace a damaged piston could lead to brake failure and result in property damage and or severe bodily injury 8 Remove the piston rubber boot 9 Remove the piston o ring from inside of the brake body 10 Inspect and replace parts as required Brakes Page 21 Maintenance Service and Repair 11 Lubricate the brake parts with clean brake fluid from a sealed container 12 Install the o rings into the brake body Make sure thatthe o rings are installed into the second groove O and that they are not twisted ring groove 13 Using tool 41 350 13 slide the rubber boots onto the pistons as shown The boot should be hanging off of the end of the piston 14 Insert the rubber boot piston into the brake body
235. y 8 Remove the hub bearing cap cotter pin and nut then remove the hub from the steering knuckle NOTE Fora front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then it will be necessary to bleed the brakes NOTE Catch the outer bearing as it falls out Hub with Dust Cap Removed 9 Remove the drag link and or tie rod from the steering knuckle Refer to Replace the Ball Joints Tie Rods Drag Link in this section for information regarding removal of the drag link or tie rod 10 While supporting the knuckle remove the king pin and thrust bearing 11 Remove the knuckle from the axle Front Axle Page 14 Maintenance Service and Repair 12 Thoroughly clean and or replace all bearings nuts washers and bushings NOTE Both the left and right side bushings and thrust bearings should be replaced as a Set 13 Assemble in reverse order 14 Pack the thrust bearing with grease 15 Tighten the king pin nut until there is 0 156 to 0 172 inch clearance as shown in the illustration below NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Realign the wheels NOTE Refer to the Steering section for information regarding real
236. y injury and or property damage It is the owner and or operators responsibility to insure that proper service and maintenance is performed on the vehicle described in this manual 1 Make sure the key switch is in the OFF position then remove the key AW ARNING 2 Place the forward reverse switch in the center OFF position 3 Set the park brake Before starti ng 4 Place blocks under the front wheels to prevent vehicle movement any repa ifs 5 Disconnect the main positive and negative cables at the batteries Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting A C AUTION the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 refer to fault table Read and follow all of the guidelines listed below Failure to follow these AWARNI NG guidelines may result in severe bodily injury and or property damage Avoid fire hazards and have fire protection equipment present in the work area Conduct vehicle performance checks in an authorized area where safe clearance exists Before starting the vehicle follow the recommended safety procedures in Section 2 Safety Rules and Operational Information e Ventilate the work area properly e Regularly inspect and maintain in a safe working condition brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices nspect and mai

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