Taylor-Dunn B0-050-00 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn B0-050-00 Operation, T Roubleshooting And Replacement Parts Manual

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T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
Published: 12/16/2003
Revision: C
Models Included:
B0-050-00 (B 50) Shuttle Master
MANUAL MB-050-00
Operation, Troubleshooting and
Replacement Parts Manual
Serial number Starting: 157300

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  • Page 1 Models Included: B0-050-00 (B 50) Shuttle Master T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s MANUAL MB-050-00...
  • Page 3 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.
  • Page 4 SC1-59 Stock Chaser B2-48 With Stake Side Dump Bed Option E4-55 Sit Down Tow Tractor C4-25 Sit Down Tow Tractor...

  • Page 5: Table Of Contents

    Section Index Taylor-Dunn ® Model B0-050-00 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 Tires and Wheels Battery Service Control System Troubleshooting...
  • Page 7 Introduction TABLE OF CONTENTS About this manual ......... 2 Who Should Read This Manual ....3 Responsibilities ..........3 How To Use This Manual ......4 Conventions ............. 5 How to Identify Your Vehicle ......6 Taking Delivery of Your Vehicle ....7 Add fill page...........

  • Page 8: About This Manual

    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 ®...

  • Page 9: Who Should Read This Manual

    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.

  • Page 10: How To Use This Manual

    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.

  • Page 11: Conventions

    INTRODUCTION Conventions Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: 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 themselves or others.

  • Page 12: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on public highways.

  • Page 13: Taking Delivery Of Your Vehicle

    ® 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.
  • Page 14 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...
  • Page 15 Safety Rules and Operating Instructions TABLE OF CONTENTS Standard Specifications Personnel Carrier .. 2 Vehicle Operational Guidelines..... 11 Safety Rules and Guidelines ......3 Safety Guidelines ............. 11 Starting: ..............11 Driver Training Program ........ 4 While driving: ............12 Driver Qualifications.

  • Page 16: Standard Specifications Personnel Carrier

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS PERSONNEL CARRIER ITEM VOLTAGE SPECIFICATION Occupancy 2-Passenger Dimensions 199L X 112W X 120.6H Centimeters 78.5L X 44.25 X 47.5H Inches Turning Radius 366 Centimeters (144 inches) Dry Weight 322 kg (710 lbs) Without Batteries Min/Max Battery 174 kg to 212 kg (384 lbs to 468 lbs) Weights...

  • Page 17: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDELINES It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the American National Standards Institute Personnel and Burden Carriers ANSI B56.8).

  • Page 18: Driver Training Program

    SAFETY RULES AND OPERATING INSTRUCTIONS DRIVER TRAINING PROGRAM According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have previous vehicle operation experience.

  • Page 19: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key-Switch A key-switch, located to the front of the consol between the seats, 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”...

  • Page 20: Headlight Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS Headlight Switch The headlight switch is located behind and to the right of the forward- off-reverse switch on the center console between the seats. Push the right side of the switch to turn the lights on. Push the left side of the switch to turn the light off.

  • Page 21: Battery Status Indicator

    SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Digital Bargraph (optional) 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 charged battery or after completing a charging cycle.

  • Page 22: Foot Brake Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS Directional Signals (Optional) The turn signal lever is located on the left side of the steering column. Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal. Hazard Light Switch (Optional) The hazard light switch is located on the left side of the steering column.

  • Page 23: Reverse Or Motion Alarm (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Park Brake The parking brake is part of the foot brake pedal. To set the parking brake, push down on the lower half of the brake pedal until the pedal locks in the down position. To release the park brake, apply pressure on the upper half of the brake pedal until the pedal disengages from the locked position.

  • Page 24: Seat Interlock Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS Seat Interlock Switch A switch located under the driver's seat disables the power to the vehicle when the driver leaves the seat. The driver must be seated for the vehicle to operate. Whenever the driver leaves the vehicle, the driver should turn the key- switch off, place the forward-off-reverse switch in the center “OFF”...

  • Page 25: Vehicle Operational Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines • Only qualified and trained operators may drive this vehicle. • Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees). • Drive slowly when making a turn, especially if the ground is wet or when driving on an incline.

  • Page 26: While Driving

    SAFETY RULES AND OPERATING INSTRUCTIONS While driving: • Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection. • No reckless driving. • Do not drive this vehicle on steep inclines or where prohibited. •...

  • Page 27: Charging Your Vehicle

    SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Explosive mixtures of Hydrogen gas are Battery electrolyte is poisonous and present within battery cells at all times. Do dangerous. It contains sulfuric acid. Avoid not work with or charge battery in an area contact with skin eyes or clothing.

  • Page 28: Signet Charger Operation, Model Hbs Series

    SAFETY RULES AND OPERATING INSTRUCTIONS Signet Charger Operation, Model HBS series The Signet ® HBS series chargers are fully automatic. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Once the charge cycle is complete, the charger will continue to monitor the batteries.

  • Page 29: Storing / Returning To Service

    SAFETY RULES AND OPERATING INSTRUCTIONS To obtain the maximum battery life: STORING / RETURNING TO SERVICE Charge the batteries only after they reach a normal discharge as indicated on the Battery Status Indicator (BSI). Failure to follow this Both storing your vehicle and returning it to service guideline could result in the batteries entering an should only be performed by authorized personnel.

  • Page 30: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi - Weekly Monthly Quaterly Annualy Maintenance Item Annual (20hrs) (80hrs) (250hrs) (1000hrs) (500hrs) Check Condition of Tires and Tire Pressure Check All Lights, Horns, Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks...

  • Page 31: General Maintenance

    General Maintenance TABLE OF CONTENTS General Maintenance Maintenance Guidelines ....... 2 Maintenance Guidelines for Vehicles Used in Severe Conditions ........3 Troubleshooting Guide ......... 4 Lubrication Chart .......... 5...

  • Page 32: Maintenance Guidelines

    • Inspect and maintain battery limit switches, protective devices, electrical conductors, and ® connections in conformance with Taylor-Dunn’s recommended procedures. • Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

  • Page 33: Maintenance Guidelines For Vehicles Used In Severe Conditions

    Maintenance, Service and Repair MAINTENANCE GUIDELINES FOR VEHICLES USED IN SEVERE CONDITIONS If this vehicle is operated in severe conditions all maintenance items listed in the Periodic Maintenance Table should be carried out twice as often as stated. In addition, the entire vehicle should be inspected monthly for signs of damage.

  • Page 34: Troubleshooting Guide

    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...

  • Page 35: Lubrication Chart

    Maintenance, Service and Repair LUBRICATION CHART Viewd from the front RIGHT 7, 8, 9 Viewed from underneath the chassie 7, 8, 9 Description Locations Lubricant Type King Pin General Purpose Grease Ball Joints General Purpose Grease Pedal Linkages General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease Drive Drain Plug...

  • Page 37: Front Axle Service

    Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin ......2 Adjust Front Wheel Bearings ....... 3 Front A-Arm Removal and Installation ..4 Removal ..............4 Installation ..............5 Replace Front Wheel Bearings ..... 6 Replace the King Pins and Bushings ...

  • Page 38: Inspect The Front Wheel Bearings And King Pin

    Maintenance, Service, and Repair INSPECT THE FRONT WHEEL BEARINGS AND KING PIN 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.

  • Page 39: Adjust Front Wheel Bearings

    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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.

  • Page 40: Front A-Arm Removal And Installation

    Maintenance, Service, and Repair FRONT A-ARM 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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.

  • Page 41: Installation

    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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.

  • Page 42: Replace Front Wheel Bearings

    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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
  • Page 43 Maintenance, Service, and Repair 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Brakes NOTE: Refer to the 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.

  • Page 44: Replace The King Pins And Bushings

    Maintenance, Service, and Repair REPLACE 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. • Bronze bushings in the steering knuckle. • Metal backed teflon bushings in the axle beam or suspension arm.
  • Page 45 Maintenance, Service, and Repair Replace the Steering Knuckle 7. Remove the steering knuckle. Refer to for information regarding removing the steering knuckle. NOTE: It is not necessary to remove the tie rod or drag link for this procedure. 8. Press the king pin bushings out from the axle, steering knuckle or suspension arm. 9.

  • Page 46: Replace The Steering Knuckle

    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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
  • Page 47 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.
  • Page 48 Maintenance, Service, and Repair Front Axle Page 12...
  • Page 49 Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Inspect Ball Joints ......... 6 Inspect Rod Ends .......... 7 Adjust the Steering Gear ....... 8 Replace the Steering Wheel ......9 Replace the Steering Gear ......10 Replace the Ball Joints, Tie Rods, and Drag Link ..........

  • Page 50: Front End Alignment

    Maintenance, Service, and Repair FRONT END ALIGNMENT This section will refer to two different types of ball joints. One type 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.
  • Page 51 Maintenance, Service, and Repair 9. 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. 10.
  • Page 52 Maintenance, Service, and Repair Front wheel alignment 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.
  • Page 53 Maintenance, Service, and Repair 11. Measure the distance between the lines at the front Front Measurement of the tires. 12. Measure the distance between the lines at the rear of the tires. Sleeve Clamps 13. Adjust the tie rod so that the distance at the front and rear of the tires is the same.

  • Page 54: Inspect Ball Joints

    Maintenance, Service, and Repair INSPECT BALL JOINTS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.

  • Page 55: Inspect Rod Ends

    Maintenance, Service, and Repair INSPECT ROD ENDS NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1.

  • Page 56: Adjust The Steering Gear

    Maintenance, Service, and Repair ADJUST THE STEERING GEAR NOTE: In some vehicle configurations it may be necessary to remove the Replace the steering gear to perform this procedure. Refer to Steering Gear for information regarding removing the steering gear. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 57: Replace The Steering Wheel

    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. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 58: Replace The Steering Gear

    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. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5.

  • Page 59: Replace The Ball Joints, Tie Rods, And Drag Link

    Maintenance, Service, and Repair REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK This section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second Studded Rod cannot be greased and has a straight shaft.

  • Page 60: Replacing A Ball Joint

    Maintenance, Service, and Repair 10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time. 11.

  • Page 61: Replacing The Drag Link

    Maintenance, Service, and Repair 12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. and install a new cotter pin. 13. Realign the front wheels. Steering NOTE: Refer to the section for information regarding realignment of the front wheels.

  • Page 62: Replacing The Tie Rod

    Maintenance, Service, and Repair 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13. Remove the blocks from behind the wheels. 14. Release the park brake and test drive the vehicle. Replacing the Tie Rod The Tie Rod is the linkage that connects the two steering knuckles together.

  • Page 63: Center The Steering Gear

    Maintenance, Service, and Repair CENTER THE STEERING GEAR NOTE: The drag link must be disconnected from the pitman arm or the pitman arm removed from the steering gear to perform this procedure. Refer to the appropriate section for details. 1. Rotate the input shaft clockwise until it stops. 2.

  • Page 64: Repair The Steering Gear

    Maintenance, Service, and Repair REPAIR THE STEERING GEAR Disassembly Replace For this procedure, the steering gear assembly must be removed from the vehicle. Refer to the Steering Gear section for information regarding removing the steering gear from the vehicle. 1. Center the steering gear. 2.
  • Page 65 Maintenance, Service, and Repair Steering Gear Exploded Steering Page 17...

  • Page 67: Brakes Service

    Brake Service TABLE OF CONTENTS Inspect the Service Brake ......2 Auto-Adjust Brake Mechanism Operation ....2 Inspecting the Auto-Adjust Brake Mechanism ..3 Brake Shoes ............4 Brake Drum (Dana) ..........4 Inspect the Park Brake ........5 Inspection and Replacement of Park Brake Pedal Lock Rear Brake Linkage Adjustment ......

  • Page 68: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Auto-Adjust Brake Mechanism Operation The auto-adjust mechanism is located on the bottom of the brake assembly and accessible through the oval slot in the brake drum. As the brake pad material wears down, the distance the brake shoes travel to engage the brake drum becomes longer.

  • Page 69: Inspecting The Auto-Adjust Brake Mechanism

    Maintenance, Service, and Repair Inspecting the Auto-Adjust Brake Mechanism 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.

  • Page 70: Brake Shoes

    Maintenance, Service, and Repair Brake Shoes Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket 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.

  • Page 71: Inspect The Park Brake

    Maintenance, Service, and Repair INSPECT THE PARK BRAKE Inspection and Replacement of Park Brake Pedal Lock 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3.

  • Page 72: Rear Brake Linkage Adjustment

    Maintenance, Service, and Repair Rear Brake Linkage Adjustment NOTE: This vehicle is equipped with self-adjusting brakes. The need to adjust the brakes manually may be an indication that the auto- Inspecting adjust mechanism is not functioning properly. Refer to the Auto-Adjust Brake Mechanism for information on the auto- adjust mechanism.

  • Page 73: Replace Rear Brake Pads Or Shoes

    Maintenance, Service, and Repair REPLACE REAR BRAKE PADS OR SHOES 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 75 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ......2 Enclosed Motors (GE, no cooling fan) ....2 Motor Removal and Installation ..3 Motor Inspection ........ 3 Replacing the Brushes....... 5 Replacing the Bearings ..... 6 Repairing the Commutator ....

  • Page 76: Inspecting The Motor Brushes

    Motor Service INSPECTING THE MOTOR BRUSHES Typical brush and brush holder Enclosed Motors (GE, no cooling fan) Typical motor with cooling fan indicated by the arrow Motors with internal cooling fans General Electric Motors NOTE: There are four brushes in the motor. The brushes will not wear at the same rate.

  • Page 77: Motor Removal And Installation

    Motor Service Advanced DC Motors Inspection The enclosed Advanced DC motors must be 1. Measure the length of each motor brush. disassembled to inspect the motor brushes. Refer to • If any one brush is less than or equal to the Motor Inspection for information regarding Service...
  • Page 78 Motor Service 5. Inspect the commutator for burn marks. commutator segments and the armature frame. If it is not an open circuit, then the armature is • Burn marks and/or raised commutator segments shorted and the motor must be replaced. 90 or 180 degrees apart is evidence of a shorted armature.

  • Page 79: Replacing The Brushes

    Motor Service Brush Spring Orientation 3. Install the new brushes in reverse order. REPLACING THE BRUSHES 4. Be certain that the brush springs do not rest up NOTE: It is recommended that all four brushes be against the brush wires. Refer to illustrations in replaced as a set.

  • Page 80: Replacing The Bearings

    Motor Service 6. Measure the commutator undercut depth in 5- REPLACING THE BEARINGS places around the commutator. If any one of the measurements is less than the minimum undercut 1. The motor must be removed from the vehicle for Service Limits depth specified in , then the this procedure.

  • Page 81: Service Limits

    Motor Service SERVICE LIMITS Commutator Diameter Brush Length Wire Depth Undercut Depth Motor Specification (min) (min) (max) Number inches inches inches inches 5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129C 0.635 0.025 66.75 2.625...
  • Page 83 Transmission Service TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor ............. 4 Removal ..............4 Installation ..............4 Rear Hub with Brake Drum ......5 Removal and Installation ......... 5 Rear Axle ............6 Replace the Axle Bearing ........8 Transmission ..........

  • Page 84: Check Oil Level

    Maintenance, Service, and Repair CHECK OIL LEVEL Park the vehicle on a level surface. 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.

  • Page 85: Change Oil

    Maintenance, Service, and Repair CHANGE OIL Park the vehicle on a level surface. 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.

  • Page 86: Motor

    Maintenance, Service, and Repair MOTOR Removal NOTE: In some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor. Refer to Transmission section for information on removing the transmission assembly from the vehicle. 1.

  • Page 87: Rear Hub With Brake Drum

    Maintenance, Service, and Repair REAR HUB WITH BRAKE DRUM Removal and Installation NOTE: Some vehicle configurations do not have a removable hub. The hub is an integral part of the rear axle. See the illustrations to the right to identify the hub on your vehicle.

  • Page 88: Rear Axle

    Maintenance, Service, and Repair REAR AXLE Your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axle and the other is an integral part of the rear axle. The service of both of these axles is addressed in this section as follows: The removable hub will be referred to as “Removable Hub.”...
  • Page 89 Maintenance, Service, and Repair Remove and Install Axle - Non - Removable Hub NOTE: The brake assembly is retained by the axle bearing and must be removed along with the axle assembly. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 90: Replace The Axle Bearing

    Maintenance, Service, and Repair Replace the Axle Bearing NOTE: The axle must be removed from the transmission for this procedure. Refer to Remove and Install Axle for information regarding removing the rear axle. Removable Hub: 1. Remove the hub from the axle shaft. Refer to Rear Hub/Brake Drum for information regarding removing the hub.

  • Page 91: Transmission

    Maintenance, Service, and Repair TRANSMISSION Removal and Installation 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 92: Differential Case

    Maintenance, Service, and Repair DIFFERENTIAL CASE Disassemble 1. Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2. Thoroughly clean the transmission assembly before disassembly. 3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.
  • Page 93 Maintenance, Service, and Repair 8. Remove the final drive gear from the differential housing. 9. Punch or drill a small hole into the center of both of the intermediate shaft bore plugs. 10. Thread a sheet metal screw into each plug until the bore plug is forced out.
  • Page 94 Maintenance, Service, and Repair 13. Remove the intermediate bearing with an ID bearing puller. The shaft and gear assembly must be supported by hand during the next step. Failure to properly support the shaft and gear assembly could result in damage to the gear teeth. 14.

  • Page 95: Assemble

    Maintenance, Service, and Repair 19. Remove the o-rings from both sides of the intermediate shaft bore and the input shaft bore and discard the o-rings. Assemble NOTE: When pressing bearings, do not press against or support the outer race as this will damage the bearing. NOTE: All snap rings should fit tightly into their grooves.
  • Page 96 Maintenance, Service, and Repair 4. Install the input shaft into the housing and install the snap ring. 5. Insert the intermediate shaft into the housing and Use a hard wood dowel the same diameter as the bearing bore to drive the bearing into place.
  • Page 97 Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Replace the Front Spring ......3 Replace the Shocks ........4...
  • Page 98 Maintenance, Service, and Repair REPLACE THE REAR SPRINGS 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.
  • Page 99 Maintenance, Service, and Repair REPLACE THE FRONT SPRING 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 rear wheels to prevent vehicle movement. 5.

  • Page 100: Replace The Shocks

    Maintenance, Service, and Repair REPLACE THE SHOCKS 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.
  • Page 101 Tires and Wheels TABLE OF CONTENTS Tire Inflation ..........2 Tire Inspection ..........2 Replace the Front Tire/Wheel ....... 3 Replace the Rear Tire/Wheel ......3 Repair the Tire (pneumatic) ......4 Replace the Tire (pneumatic) ...... 5...

  • Page 102: Tire Inflation

    Maintenance, Service, and Repair TIRE INFLATION 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.

  • Page 103: Replace The Front Tire/Wheel

    Maintenance, Service, and Repair 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. NOTE: Refer to Tire Inflation section or Steering Component Service section for information on proper tire inflation or front end wheel alignment.

  • Page 104: Repair The Tire (Pneumatic)

    Maintenance, Service, and Repair 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 wheel coming off of the vehicle causing severe bodily injury and/or property damage.

  • Page 105: Replace The Tire (Pneumatic)

    Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) NOTE; To replace the tire, the tire/wheel assembly must be removed from Replace the Tire/Wheel the vehicle. Refer to section for information on removing the tire/wheel assembly. Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel.

  • Page 107: Battery Service

    Battery Service TABLE OF CONTENTS Cleaning ............2 Testing ............3 Watering ............5 Charging ............6 Replacing (6-volt batteries only) ....7 Moist Charge Batteries ..........9 Storage and Returning to Service ....10 Storage ..............10 Returning to Service ..........11...

  • Page 108: Cleaning

    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, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.

  • Page 109: Testing

    Maintenance, Service, and Repair TESTING NOTE: A combination of the Load Test and Specific Gravity Test should be used to accurately determine the condition of the batteries. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
  • Page 110 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).

  • Page 111: Watering

    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.

  • Page 112: Charging

    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. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 113: Replacing (6-Volt Batteries Only)

    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, cigarettes, or any other sources of combustion are present.
  • Page 114 Maintenance, Service, and Repair 7. Remove the battery hold downs. 8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced. 9. Remove all battery jumpers from both posts of the battery or batteries being replaced. NOTE: It is recommended to replace the battery jumpers when replacing the batteries.

  • Page 115: Moist Charge Batteries

    Maintenance, Service, and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.

  • Page 116: Storage And Returning To Service

    Maintenance, Service, and Repair 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the Cleaning the batteries or the ground. Refer to Batteries for information on cleaning the batteries. 8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.

  • Page 117: Returning To Service

    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, cigarettes, or any other sources of combustion are present.
  • Page 119 Table of Contents SYMPTOMS: ........2 READ THIS FIRST ......3 Test Equipment Required: ............3 IMPORTANT NOTES and INSTRUCTIONS ...... 3 Definitions: ................3 SYMPTOM TROUBLESHOOTING GUIDE ..........19 PMC CONTROL ..............20 PLUGGING DIODE .............. 22 FREEWHEEL DIODE ............23 ISO ................... 24 SOLENOIDS ................

  • Page 120: Symptoms

    Curtis PMC Troubleshooting Note: Vehicles with Dana H12 transmission, Solenoids Forward solenoid is in the center. Circuit Breaker PMC Speed Control Typical Control Panel SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Symptom Troubleshooting later in this section. •...

  • Page 121: Read This First

    • This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Throttle Module Analyzer. Troubleshooting CANNOT be completed without these tools. These test procedures must be performed in the order they were written.

  • Page 122: Definitions

    Curtis PMC Troubleshooting Definitions: • “MS-1” = The first switch in the accelerator module. • “Battery volts” = The voltage at the batteries at the time the test is completed. • “Pick up” = Energizing a solenoid or contactor. • “F&R”...
  • Page 123 Curtis PMC Troubleshooting Power Output Test The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 124 Curtis PMC Troubleshooting Control Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 125 Curtis PMC Troubleshooting Connect a voltmeter across the PMC #2 terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and The voltage shown is for illustration place the F&R Switch in Forward. only. The actual voltage may vary. Depress the accelerator pedal to engage MS-1 only.
  • Page 126 Curtis PMC Troubleshooting Power Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 127 Curtis PMC Troubleshooting Motor The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 128 Curtis PMC Troubleshooting Accelerator The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.

  • Page 129: Wire Diagram

    Refer to the option list for your truck or ® contact your Taylor-Dunn Representative for more information. If you do not know how to test for continuity, refer test to a qualified technician.
  • Page 130 Curtis PMC Troubleshooting Forward and Reverse Side For your reference, shown at the right are the Forward and KSI Side White/Black Reverse switch wire connections for a typical control system. Violet/Black Green/Black Blue/Black Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back Connect a voltmeter across the HOT terminal of the KSI...
  • Page 131 Curtis PMC Troubleshooting F/R switch The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 132 Curtis PMC Troubleshooting Connect a voltmeter across the forward terminal of the The FORWARD terminal is forward and reverse side of the F&R switch and battery diagonally opposite the forward side of the rocker on the switch FLUKE 79 SERIES II MULTIMETER negative.
  • Page 133 Curtis PMC Troubleshooting Solenoids The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 134 Curtis PMC Troubleshooting Forward (does not run in reverse) The voltage shown is for illustration Connect a voltmeter across the PMC KSI terminal and battery only. The actual voltage may vary. negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in reverse.
  • Page 135 Curtis PMC Troubleshooting Connect the test light across the Normally Closed contacts of the Forward solenoid. Refer to your vehicles wiring FWD/REV diagram to identify the position of the forward solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Reverse.
  • Page 136 Curtis PMC Troubleshooting Set the test light voltage to the same voltage as the battery volts. Solenoids are shown for reference only. The type and position of the forward Connect the test light across the Normally Open contacts solenoid in your truck may be different of the Forward solenoid.

  • Page 137: Symptom Troubleshooting Guide

    Curtis PMC Troubleshooting SYMPTOM TROUBLESHOOTING GUIDE This section is specific to the symptoms listed below. Each troubleshooting sequence assumes that all listed symptoms are present. Do not use this section unless the truck has all listed symptoms. SYMPTOMS GO TO Ø...
  • Page 138 Curtis PMC Troubleshooting PMC CONTROL 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.
  • Page 139 Curtis PMC Troubleshooting Connect a volt meter across the PMC B+ and PMC M- terminals. The voltage shown is for illustration Turn the key-switch on, close all interlock only. The actual voltage may vary. switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests: •...
  • Page 140 Curtis PMC Troubleshooting PLUGGING DIODE 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.
  • Page 141 Curtis PMC Troubleshooting FREEWHEEL DIODE 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.
  • Page 142 Curtis PMC Troubleshooting 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.
  • Page 143 Curtis PMC Troubleshooting Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure Reading is plus or minus 10% its resistance. ISO solenoid is shown for reference • The meter reading should be 250 Ohms only.
  • Page 144 Curtis PMC Troubleshooting SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms. Perform the tests covered in the MOTOR section first. If the motor is OK, continue with the following tests. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
  • Page 145 Curtis PMC Troubleshooting Stop trouble shooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground, otherwise continue with the next test. • Check continuity from the motor ‘A2’ terminal to the wire that was connected to the motor ‘S2’...
  • Page 146 Curtis PMC Troubleshooting With the key-switch on and the F&R switch in reverse, depress the accelerator pedal and perform the following tests: • Check continuity from the wire that was connected to the PMC ‘M-’ terminal to the Motor shown for reference only. wire that was connected to the motor ‘S1’...
  • Page 147 Curtis PMC Troubleshooting MOTOR High motor current in both the field and the armature, accompanied with a lack of power, would indicate a shorted armature and\or field. Another symptom that may exist is jumping or stuttering at low speeds and/or the motor will not run unless the armature is manually rotated.
  • Page 148 Curtis PMC Troubleshooting Check continuity from ‘S1’ to the frame of the motor. Motor shown for reference only. If you do not know how to test for continuity, Terminal positions on your motor may not be in the same location. refer test to a qualified technician.
  • Page 149 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 Turn the Key switch OFF BEFORE disconnecting the batteries.
  • Page 150 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic II ® chargers are designed as semiautomatic chargers. The Lestronic II ® charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged into the batteries.
  • Page 151 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: •...
  • Page 152 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 • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
  • Page 153 Electrical Troubleshooting TROUBLESHOOTING FOR BUILT-IN CHARGER 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.
  • Page 154 Electrical Troubleshooting • Disconnect the charger from the AC source. • Disconnect the batteries. • Disconnect the charger from the vehicle’s harness. • Remove the charger from the vehicle. HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor before continuing.
  • Page 155 Electrical Troubleshooting • Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad.
  • Page 156 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.
  • Page 157 Electrical Troubleshooting 5. Reconnect the lead to the diode. 6. Connect the charger to the AC source. Insert the DC charger plug into the DC receptacle and perform the following tests: High Voltage inside the charger. Do not touch any internal components while the charger is plugged in.
  • Page 158 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. • If this is a closed circuit, then the timer start up circuit is functioning normally. •...
  • Page 159 TABLE OF CONTENTS Operating Instructions and Theory of Operation ........2 HB/PT and GEL Indicator Lamps ...3 Testing the Charging Cycle ....3 Test Equipment Required for Troubleshooting .......4 Important Notes and Instructions Status LED Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.
  • Page 160 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION ® ® The model HB600W and HB1000W chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.
  • Page 161 Electrical Troubleshooting HB/PT AND GEL INDICATOR LAMPS NOTE: Your charger may not be equipped with these lamps. HB/PT Lamp If the HB/PT lamp is “ON”, then the charger has overheated and has entered a proportionally reduced output. The charging cycle will terminate if the temperature continues to rise.
  • Page 162 Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING ® Digital Multi Meter (DMM), FLUKE 79 model shown at right and in the troubleshooting illustrations. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.
  • Page 163 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.
  • Page 164 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).
  • Page 165 Charger Models: HBS 600 HBS 1000 TABLE OF CONTENTS Definitions: ..........2 Test Equipment Required for Troubleshooting .......2 Important Notes and Instructions Operating Instructions and Theory of Operation ........3 Testing the Charging Cycle ....4 Status Light Error Code Table....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 166: Clamp On Dc Ammeter To Measure Up To 20-Amps

    Electrical Troubleshooting DEFINITIONS: Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells. Term Value Condition V1: Voltages are temperature compensated 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.
  • Page 167 Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION 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.
  • Page 168 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.
  • Page 169 Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.
  • Page 170 Electrical Troubleshooting TROUBLESHOOTING NOTE: There are no internally serviceable components in the charger. 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.
  • Page 171 Wire Diagrams TABLE OF CONTENTS Complete Vehicle .......... 2 Dash ............... 3 Control Panel ..........4 Accelerator Module Detail ......5 Lights ............. 6...

  • Page 172: Complete Vehicle

    Wire Diagrams COMPLETE VEHICLE Brown Black White Black White Blue Brown Brown/White White Brown White White Black Yellow Violet/Black Blue Green White Black Black Black Black White White White White Wire Diagrams Page 2...

  • Page 173: Dash

    Wire Diagrams DASH Green/Black Fowrard and Violet/Black Reverse Switch Black Yellow Blue/Black Black White/Black Green/Black Violet/Black Accelerator Module Violet/Black Plug Violet/Black STOP SWITCH Violet/Black Gray LIGHT Brown STROBE Black STROBE White F = Forward solenoid coil MS1 = Micro switch 1 R = Reverse solenoid coil MS2 = Micro switch 2 I = Isolator (ISO) solenoid coil...

  • Page 174: Control Panel

    Wire Diagrams CONTROL PANEL Black Main battery negative Black Main battery positive Black 12v negative tap White Charging Recptacle Black White SPEED CONTROL Violet/Black MOTOR Yellow 135A Yellow Blue Green Connect to R+ (coil) for Black reverse alarm or I+ (coil) for motion alarm Motion/Reverse Alarm...

  • Page 175: Accelerator Module Detail

    Wire Diagrams ACCELERATOR MODULE DETAIL MS1 = Micro switch 1 MS2 = Micro switch 2 Internal components are illustrated for reference only. There are no user serviceable parts inside of the accelerator module. Wire Diagrams Page 5...

  • Page 176: Lights

    Wire Diagrams LIGHTS STOP SWITCH To B+ Gray Violet/Black LIGHT Brown STROBE VIEW FROM WIRE END STROBE White Green Yellow Green Gray Right Ft Gray GREEN Left Ft Blue Black GRAY Gray Left Rr Gray/Black GRY/BLK Stop In Blue Black BLACK Right Rr White...
  • Page 177 Illustrated Parts TABLE OF CONTENTS Front Axle and Suspension ......2 Steering Linkage ......... 4 Steering Gear ..........6 Transmission Differential Case ....8 Rear Axle and Brakes ........10 Rear Suspension ......... 12 Motor ............14 Brake linkage ..........16 Wheels and Tires ........

  • Page 178: Front Axle And Suspension

    Illustrated Parts Front Axle and Suspension Parts Page 2...
  • Page 179 Ilustrated Parts Front Axle and Suspension ITEM # PART # DESCRIPTION 92-104-00 Beatring cap 88-239-85 Castle nut 88-228-61 3/4 SAE Flat washer 80-017-00 Bearing 80-103-00 Race 12.124-00 45-308-00 Grease seal 14-110-25 Steer knuckle, right 14-110-20 Steer knuckle, left 88-189-81 5/8NC Hex lock nut 97-180-55 Thrust washer 32-240-55...

  • Page 180: Steering Linkage

    Illustrated Parts Steering Linkage Parts Page 4...
  • Page 181 Ilustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 88-159-85 1/2NF Castle Nut 88-527-11 1/8 x 1 Cotter pin 86-501-98 Ball joint (left thread) 86-510-00 Ball joint clamp 18-041-01 Tie rod 86-501-99 Ball joint (right thread) 86-519-10 Rod end (right thread) 86-519-11 Rod end (left thread) 50-002-20...

  • Page 182: Steering Gear

    Illustrated Parts Steering Gear Parts Page 6...
  • Page 183 Ilustrated Parts Steering Gear (18-308-30) ITEM # PART # DESCRIPTION Steering wheel nut Upper column bearing Worm shaft Upper worm bearing and race Output shaft nut Split lock washer Oil seal Lower worm bearing and race Shim, 0.10 mm Shim, 0.15 mm needed Shim, 0.30 mm Gasket...

  • Page 184: Transmission Differential Case

    Illustrated Parts Transmission Differential Case Parts Page 8...
  • Page 185 Ilustrated Parts Transmission (Dana Spec# 012AJ308-1) ITEM # PART # DESCRIPTION 4C-100-00 Complete Transmission Assembly Including Brakes Special order Housing Carrier bearing cap (included with #1) 80-480-10 Input shaft bearing ** See kit below Final Gear ** See kit below Input shaft ** See kit below Intermediate gear...

  • Page 186: Rear Axle And Brakes

    Illustrated Parts Rear Axle and Brakes Parts Page 10...
  • Page 187 Ilustrated Parts Rear axle and Brakes ITEM # PART # DESCRIPTION 66-611-00 Axle bolt 66-610-97 Axle nut 66-611-10 Retaining ring 45-303-40 Oil seal 66-611-11 Retaining ring 66-611-12 Axle bearing 66-611-13 Snap ring Brake assembly (L) Brake assembly (R) 66-611-14 Wheel stud 41-126-96 Axle shaft (L) 41-126-97...

  • Page 188: Rear Suspension

    Illustrated Parts Rear Suspension Parts Page 12...
  • Page 189 Ilustrated Parts Rear Suspension ITEM # PART # DESCRIPTION 88-149-81 1/2 NC Lock nut 96-248-01 Bolt with grease fitting 88-169-82 9/16NF Lock nut, grade C 32-249-00 Bushing assembly 85-140-00 Spring 86-602-00 Shock 17-106-00 Spacer 01-110-83 Spring mount (left) 01-110-84 Spring mount (right) 01-110-80 Swing arm 00-255-02...

  • Page 190: Motor

    Illustrated Parts Motor Armature Parts Page 14...
  • Page 191 Ilustrated Parts Motor GE spec# 5BC58JBS6129A ITEM # PART # DESCRIPTION 70-049-05 Complete motor assembly (does not include #11) 70-201-15 Field coils (mounted in motor housing) 70-210-51 Inulator 85-412-00 Brush spring 70-172-15 Brush holder (includes #3) 70-104-15 Motor brush (2) 70-210-51 Insulator 32-508-15...

  • Page 192: Brake Linkage

    Illustrated Parts Brake linkage Parts Page 16...
  • Page 193 Ilustrated Parts Brake Linkage ITEM # PART # DESCRIPTION 88-140-13 1/2 NC x 1-1/4 Hex bolt 02-536-09 Brake pedal 88-149-81 Brake pedal shaft weldment 32-033-00 Collar 96-773-00 5/16 x 1 Clevis pin 88-517-11 1/8 x 1 Cotter pin 50-002-17 Brake rod 88-099-80 5/16 Hex nut 96-763-00...

  • Page 194: Wheels And Tires

    Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) Parts Page 18...
  • Page 195 Ilustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-020-00 8.5 x 8 Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-081-00 5.70 x 8 LR B Pneumatic 10-082-00...

  • Page 196: Instrument Panel Console

    Illustrated Parts Instrument Panel Console Parts Page 20...
  • Page 197 Ilustrated Parts Instrument Panel ITEM # PART # DESCRIPTION 71-120-10 Key switch 71-100-00 Light switches 74-009-00 Battery status meter 71-039-02 Forward and reverse switch 94-386-03 Console decal 00-110-01 Console 74-000-00 Hour meter Parts Page 21...

  • Page 198: Speed Control Panel

    Illustrated Parts Speed Control Panel Solenoid end view from side closest to PMC End view of PMC (#5) Parts Page 22...
  • Page 199 Ilustrated Parts Speed Control Panel ITEM # PART # DESCRIPTION 79-844-00 Circuit breaker 88-818-06 #8 x 1/2 Pan head screw, type B thread 79-840-20 Circuit breaker 62-204-00 PMC speed control 72-501-36 ISO Solenoid (SPST), includes #15, 16 and 18 72-501-37 Forward or Reverse solenoid (SPDT, includes #15, 16 and 18 88-838-06 #14 x 1/2 Pan head screw, type D thread...

  • Page 200: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical Accelerator Module Seat Frame Motion Alarms Seat Interlock Switch Floorboard Horn Switch Mounted Miscellaneous Wire Harness Clamps Mechanical Brake Light Switch Mounted Under Floorboard Parts Page 24...
  • Page 201 Ilustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION Not Shown 75-152-70 Chassie Control Harness Not Shown 75-149-85 Power Harness Not Shown Not Shown 98-599-15 Plastic grommet for 1.75 hole Not Shown 98-599-20 Plastic Grommet for 2.5 hole Not Shown Not Shown Not Shown 75-148-80...

  • Page 202: Miscellaneous Frame And Body

    Illustrated Parts Miscellaneous Frame and Body Parts Page 26...
  • Page 203 90-179-10 Seat back 01-110-16 Deck lid 94-035-01 Seat trim 7 feet 98-455-50 Heat shrink tube 6 inches 01-110-20 Accelerator pedal See Brake Linkage Brake pedal pad 00-110-03 Front bulkhead (no lights) 98-757-01 Front bumper 94-201-10 Taylor-Dunn Emblem Parts Page 27...

  • Page 204: Charger

    Illustrated Parts Charger Page 1 Typical Built In charger Typical Portable charger CHARGERS.DWG Parts Page 28...
  • Page 205 Ilustrated Parts Parts Page 29...
  • Page 206 Illustrated Parts Charger Page 2 Typical Built In charger Typical Portable charger CHARGERS.DWG Parts Page 30...
  • Page 207 Ilustrated Parts Parts Page 31...

  • Page 208: Charger

    Illustrated Parts Charger Page 3 Model HBS series charger shown Model HBS for Flooded Batteries Model HB for Flooded Batteries PART # DESCRIPTION PART # DESCRIPTION 24 volt Charger Assembly (see note) 79-302-20 24 volt Charger Assembly (see note) 79-303-41 36 volt Charger assembly (see note) 79-303-40 36 volt Charger assembly (see note)

  • Page 209: Lights

    Ilustrated Parts Lights Illustration not available Lights ITEM # PART # DESCRIPTION 94-050-10 Headlight, left 94-050-11 Headlight, right 94-050-04 Headlight retainer 00-110-02 Headlight panel 72-022-00 Tailight 1 or 2 72-022-51 Tailight gasket 1 or 2 72-023-20 Strobe light Parts Page 33...
  • Page 210 Illustrated Parts Batteries Main Negative 12-v Negative Tap Main Positive Parts Page 34...

  • Page 211: Batteries

    Ilustrated Parts Batteries ITEM # PART # DESCRIPTION 75-231-00 Battery jumper 77-042-00 217AH, T-105 0 or 6 77-042-50 217AH, TD-217 0 or 6 77-042-80 217AH, T-105 Moist charge (dry) 0 or 6 77-044-00 230AH, T-125 0 or 6 77-044-10 195AH, Mainenance free (Note: requires special charger) 0 or 6 77-047-00 244AH, T-145...

  • Page 212: Decals

    Illustrated Parts Decals Parts Page 36...
  • Page 213 Not a motor vehicle (Export vehicles) 0 or 1 94-313-00 Battery warning 94-319-00 Dissconnect battery See Instument Panel Console decal 94-313-20 Safety warning 94-301-51 Shuttle Master See Misc Frame Parts Taylor-Dunn Emblem Not shown 94-201-11 Fastener for #10 94-373-10 Vehicle data decal Parts Page 37...

  • Page 214: Sun Top And Windshield

    Illustrated Parts Sun Top and Windshield Parts Page 38...
  • Page 215 Ilustrated Parts Sun Top and Windshield ITEM # PART # DESCRIPTION 91-046-00 Sun top 91-028-88 Rear suport 90-825-06 Right post 90-825-05 Left post 91-028-90 Upper support 90-825-20 Windshield 98-314-01 Gasket 98-603-00 Grommet 88-065-11 1/4NC x 1 Truss head bolt 88-068-60 1/4 Cut flat washer 88-080-11 5/16NC x 1 Hex bolt...

  • Page 216: Mirrors

    Illustrated Parts Mirrors Multi-Panel mirror Side mirror Parts Page 40...
  • Page 217 Ilustrated Parts Multi-Panel Mirror ITEM # PART # DESCRIPTION 92-207-00 Mirror 01-110-95 Mounting bracket Side Mirror ITEM # PART # DESCRIPTION 92-201-00 Mirror 1 or 2 92-202-12 Mounting bracket (left) 88-088-61 5/16 SAE flat washer 88-080-09 5/16NC x 3/4 Hex bolt 88-088-62 5/16 Split lock washer 88-069-81...

  • Page 218: Tool Box / Luggage Rack

    Illustrated Parts Tool Box / Luggage Rack Luggage rack Tool box Parts Page 42...
  • Page 219 Ilustrated Parts Tool Box / Luggage Rack ITEM # PART # DESCRIPTION 71-040-95 Lock 90-547-14 Tool box 90-547-11 Luggage rack Parts Page 43...
  • Page 220 Illustrated Parts Parts Page 44...
  • Page 222 APPENDIX A-Special Tools...
  • Page 223 Special Tools Special Tools D E S C R I P T I O N P U R P O S E P A R T N U M B E R Used to install the pinion seal on all chain drive trucks Pinion Seal Installation Tool w i t h t h e b a n d s t y l e b r a k e o r t h e s p e e d s e n s o r o n t h e 43-201-50...
  • Page 224 Appendix B: Standard Hardware Suggested Torque Limits TABLE OF CONTENTS Hardware Identification ......... 2 Standard Head Markings ......... 2 Hex Bolts ..............2 Other Bolts ............... 2 Hex Nuts ..............3 Hex Lock Nuts (stover) ..........3 Other Nuts ..............3 Suggested Torque Values (non-critical hardware) ......

  • Page 225: Hardware Identification

    Appendix B HARDWARE IDENTIFICATION Standard Head Markings NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. NOTE: Toque values specified are for clean dry threads. Hex Bolts S.A.E.

  • Page 226: Hex Nuts

    ‘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 S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts ® Other nuts used by Taylor-Dunn should be treated as S.A.E. grade A Appendix B Page-3...

  • Page 227: Suggested Torque Values

    Appendix B SUGGESTED TORQUE VALUES (non-critical hardware) Diameter Grade 2 Grade 5 Grade 8 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque (ft-lb) (ft-lb) (ft-lb) (ft-lb) 1/4-20 7-10 10-14 1/4-28 8-12 11-16 5/16-18 9-14 14-21 20-29 5/16-24 10-15 15-23 22-33 3/8-16...

  • Page 228: Suggested Torque Values

    Appendix B SUGGESTED TORQUE VALUES (critical hardware) Torque Table Torque Range Group Description Ft-Lbs In-Lbs Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132...
  • Page 230 Appendix C...

  • Page 231: Brake Lining Handling Precautions

    Brake Lining Precautions 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.
  • Page 233 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Mailing Address: P.O. Box 4240 Anaheim, California 92803 Visit our Website: www.taylor-dunn.com...

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