Taylor-Dunn B0-015-00 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn B0-015-00 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: 11/26/2002
Revision: C
Models Inlcuded:
B0-015-00 (B 1-50) Load Master
MX-016-00 (MX 1600) Maintenance Expediter
MANUAL MB-150-02
Operation, Troubleshooting and
Replacement Parts Manual
Serial number Starting: 136914
B0-015-00
MX-016-00

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  • Page 1 T h e B e s t W a y Models Inlcuded: T o G o B0-015-00 (B 1-50) Load Master MX-016-00 (MX 1600) Maintenance Expediter A b o u t Y o u r B u s i n e s s...
  • 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 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 5: Table Of Contents

    Section Index Taylor-Dunn ® Model B0-015-00, MX-016-00 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 Suspension Battery Service Tires and Wheels Control System Troubleshooting...
  • Page 7 Introduction Contents About this manual ......... 2 Who Should Read This Manual ....2 Responsibilities ..........3 How To Use This Manual ......4 Conventions .............. 4 How to Identify Your Vehicle ......6 Taking Delivery of Your Vehicle ....7...

  • 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 themself 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 Model B 1-00...
  • Page 15 Safety Rules and Operating Instructions TABLE OF CONTENTS Standard Specifications ........ 2 Vehicle Operational Guidelines..... 10 Safety Rules and Guidelines ......3 Driving ..............10 Loading and Unloading ..........10 Driver Training Program ........ 4 Parking ..............10 Driver Qualifications..........4 Towing ..............

  • Page 16: Standard Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM MODEL VOLTAGE SPECIFICATION Occupancy Driver and one passenger Dimensions B 1-50 274.2L X 112.5W X 120.7H Centimeters 107.95L X 44.29 X 47.5H Inches MX 1600 274.2L X 112.5W X 207.6H Centimeters 107.95L X 44.29 X 81.75H Inches Turning Radius 279.4 Centimeters (110 inches) Dry Weight...

  • 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. As well as, obeying the following safety rules and guidelines (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 As per 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 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”...

  • Page 20: Foot Brake Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS 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.

  • Page 21: Headlight Switch

    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. Hour Meter (Optional) The hour meter is located to the right of the battery status indicator.

  • Page 22: Battery Status Indicator, Digital Bargraph

    SAFETY RULES AND OPERATING INSTRUCTIONS 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 charged battery or after completing a charging cycle.

  • Page 23: Hazard Light Switch (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Hazard Light Switch (Optional) The hazard light switch is located on the left side of the steering column. The switch is a small tab. To activate the hazard lights, pull the tab out. To turn the hazard lights off, push forward or pull back the directional signal lever.

  • Page 24: Vehicle Operational Guidelines

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

  • Page 25: 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 26: Lestronic Ii Charger Operation

    SAFETY RULES AND OPERATING INSTRUCTIONS Charging Time Lestronic II Charger Operation Average charging time is 8 to 10-hours. The time The Lestronic II ® charger is a semi-automatic required to fully charge your batteries will vary charging system. The charger will turn itself ON when depending on: the AC power cord is connected to the AC power •...

  • Page 27: Storing And Returning To Service

    SAFETY RULES AND OPERATING INSTRUCTIONS STORING AND RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing your Vehicle • Clean the batteries, then fill and charge before putting the vehicle in storage. Do not store batteries in a discharged condition.

  • Page 28: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Safety Rules NOTE: A full page copy of the Periodic Maintenance Page 14 Checklist is on the Vehicle Documentation CD under the [Misc] sub folder.

  • Page 29: Daily Visual Inspection

    SAFETY RULES AND OPERATING INSTRUCTIONS Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle. Repairs or maintenance by improperly trained or unauthorized personnel could cause improper operation of the vehicle or premature failure of components resulting in severe bodily injury and/or property damage.

  • Page 31: General Maintenance

    General Maintenance TABLE OF CONTENTS 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 Description Locations Lubricant Type Front Leaf Springs General Purpose Grease King Pin General Purpose Grease Ball Joints General Purpose Grease Front Wheel Bearings High Temperature Wheel Bearing Grease Rear Leaf Springs General Purpose Grease Drive Fill Plug 11 oz.

  • Page 37: Front Axle Service

    Front Axle Service TABLE OF CONTENTS Inspect the Front Wheel Bearings and Kin Pin ..........2 Adjust Front Wheel Bearings ...... 3 Front Axle Removal and Installation .... 4 Removal ..............4 Installation ..............5 Front Axle Disassembly and Assembly ..6 Replace Front Wheel Bearings .....

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

    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. 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 Axle Removal And Installation

    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. 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: Front Axle Disassembly And Assembly

    Maintenance, Service, and Repair FRONT AXLE DISASSEMBLY AND ASSEMBLY Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: Replace the Steering Knuckle Replace the King Pins and Bushings NOTE: The front axle does not have to be removed unless the axle beam Front Axle Removal and...

  • Page 43: 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 44: Replace The Ball Joints, Tie Rods, And Drag Link

    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 45 Maintenance, Service, and Repair 7. Loosen the rod end jam nut or clamp on the steering Rod End sleeve. 8. Remove the rod end nut. 9. Remove the rod end from the steering arm. Steering HINT: Count the number of turns required to Sleeve remove the rod end from the steering sleeve.

  • Page 46: Replacing The Drag Link

    Maintenance, Service, and Repair 7. Loosen the ball joint clamp on the steering sleeve. Cotter Pin 8. Remove the cotter pin and ball joint nut. Ball Joint Nut 9. Using a pickle fork, remove the ball joint from the steering arm. 10.

  • Page 47: Replacing The Tie Rod

    Maintenance, Service, and Repair 7. Remove the ball joints or rod ends from the steering Pitman Arm knuckle and pitman arm. Replacing the Ball NOTE: Refer to the Drag Link Joints section for information regarding the removal of the ball joints or rod ends.

  • Page 48: Replace The King Pins And Bushings

    Maintenance, Service, and Repair 7. Remove the ball joints or rod ends from the steering knuckles. Steering Knuckle Replacing the Ball NOTE: Refer to the Joints section for information regarding the removal of the ball joints or rod ends. 8. Remove the tie rod as an assembly. 9.
  • Page 49 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 rear wheels to prevent vehicle movement. 5.

  • Page 50: Replace The Steering Knuckle

    Maintenance, Service, and Repair 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. REPLACE THE STEERING KNUCKLE 1.
  • Page 51 Maintenance, Service, and Repair 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. Replacement Parts NOTE: Refer to the section for the orientation of the thrust bearing or washers in your vehicle. 15. Tighten the king pin nut until there is 0.1 to 0.123 inches clearance as shown in the illustration below.
  • Page 53 Steering Component Service TABLE OF CONTENTS Front End Alignment ........2 Adjust the Steering gear (Saginaw) ..... 5 Replace the Steering Shaft (Saginaw, non-tilt steering) ....7 Replace the Steering Wheel (Saginaw, non-tilt steering) ....9 Replace the Steering Gear (Saginaw) ..10 Repair the Steering Gear ......

  • Page 54: Front End Alignment

    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.
  • Page 55 Maintenance, Service, and Repair 10. At this point both the steering wheel and the front wheels should be tied up and held in position. If one or the other is not tied up then you must start from the beginning. Do not drive the vehicle while the steering wheel or front wheels are tied in position.
  • Page 56 Maintenance, Service, and Repair Front wheel alignment NOTE: It is recommended to center the steering before aligning the front Center the Steering wheels. Refer to the section for information. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 57: Adjust The Steering Gear (Saginaw)

    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 58 Maintenance, Service, and Repair 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.

  • Page 59: Replace The Steering Shaft (Saginaw, Non-Tilt Steering)

    Maintenance, Service, and Repair REPLACE THE STEERING SHAFT 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 60 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 new pinch bolt. Orientate the shaft so that the pinch bolt is opposite the flat in the steering gear shaft.

  • Page 61: Replace The Steering Wheel (Saginaw, Non-Tilt Steering)

    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 62: Replace The Steering Gear (Saginaw)

    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 63: Repair The Steering Gear

    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.
  • Page 64 Maintenance, Service, and Repair 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing.
  • Page 65 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.

  • Page 66: Exploded View Of Steering Gear

    Maintenance, Service, and Repair Exploded View of Steering Gear Steering Page 14...
  • Page 67 TABLE OF CONTENTS Inspect the Service Brake ....2 Front Disc Brake Pads .......... 2 Front Disc Brake Rotor ........2 Rear Brake Shoes ..........2 Rear Brake Drum ..........3 Inspect the Parking brake ....3 Adjust the Service Brakes ....4 Mechanical and Hydraulic Drum Brakes ....

  • Page 68: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE NOTE: Front brakes are optional Front Disc Brake Pads Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos.

  • Page 69: Rear Brake Drum

    Maintenance, Service, and Repair Rear Brake Drum INSPECT THE PARKING BRAKE Current Taylor-Dunn brakes are asbestos ® free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. 1. Make sure the key-switch is in the “OFF”...

  • Page 70: Adjust The Service Brakes

    Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Mechanical and Hydraulic Drum Brakes The mechanical and hydraulic brake assemblies are identical except for hydraulic fittings. The adjustment procedure is the same for both the mechanical and hydraulic brakes. NOTE: The brake adjustment is inside of the left and right brake. Do not adjust the brake by means of the brake cables as this will cause mis-operation of the brakes.

  • Page 71: Adjust The Mechanical Brake Linkages

    Maintenance, Service, and Repair Adjust the Mechanical Brake Linkages Adjusting the brakes by means of the brake cables could cause a hard brake pedal with little or no braking power. This could cause loss of control of the vehicle resulting in severe bodily injury and/or property damage.

  • Page 72: Adjust The Parking Brake

    Maintenance, Service, and Repair ADJUST THE PARKING BRAKE Wheel Park Brake (mechanical drum standard) Trucks equipped with mechanical drum brakes do not have a separate adjustment for the parking brake. If the Adjust the parking brake requires adjustment, then the entire brake system is in need of adjustment. Refer to Service Brake section for information regarding adjusting the brakes.

  • Page 73: Check Master Cylinder Fluid

    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.

  • Page 74: Bleed The Brake System

    Maintenance, Service, and Repair BLEED THE BRAKE SYSTEM Do not ingest brake fluid or allow contact • Only use DOT 3 brake fluid from a new with skin or eyes. Always wear protective sealed container. clothing and a face shield when working with or around brake fluid.

  • Page 75: Flush The Brake System

    Maintenance, Service, and Repair FLUSH THE BRAKE SYSTEM • Do not ingest brake fluid or allow contact Only use DOT 3 brake fluid from a new with skin or eyes. Always wear protective sealed container. clothing and a face shield when working •...

  • Page 76: Replace Front Disc Brake Pads

    Maintenance, Service, and Repair REPLACE FRONT DISC BRAKE PADS 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.

  • Page 77: Replace Rear Brake Shoes

    Maintenance, Service, and Repair REPLACE REAR 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 78: Replace The Front Cylinder

    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” Current Taylor-Dunn brakes are asbestos ® position, then remove the key. free. However, there is the possibility that the original brakes were replaced with 2.

  • Page 79: Repair The Brake Body

    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 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.
  • Page 80 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 that the o-rings are installed into the second groove and that they are not twisted. 13.

  • Page 81: Replace The Master Cylinder

    Maintenance, Service, and Repair REPLACE THE MASTER CYLINDER Do not ingest brake fluid or allow contact • Only use DOT 3 brake fluid from a new with skin or eyes. Always wear protective sealed container. clothing and a face shield when working •...

  • Page 82: Repair The Master Cylinder

    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.
  • Page 83 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 84: 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 85: 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 86 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 87: 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 88: 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 89: 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 91 Transmission Service TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............. 3 Motor ............. 4 Removal ..............4 Installation ..............4 Rear Hub with Brake Drum ......5 Rear Axle ............6 Replace the Axle Bearing .......... 8 Transmission ..........

  • Page 92: 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 93: Change Oil

    Maintenance, Service, and Repair CHANGE OIL Changing the transmission oil requires removal of the transmission cover. Refer to transmission disassembly later in this section. Transmission Page 3...

  • Page 94: 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 95: 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 96: 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 97 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 98: Replace The Axle Bearing

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

  • Page 99: Transmission

    Maintenance, Service, and Repair TRANSMISSION 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 front wheels to prevent vehicle movement. 5.

  • Page 100: Remove

    Maintenance, Service, and Repair DIFFERENTIAL CASE Disassemble Transmission-Removal 1. Remove the transmission from the vehicle. Refer to 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 101 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 102 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 103: 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 104 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 support in place. 6. Insert the flanged side bearing into the bearing bore. Press in just past the snap ring grove and install the snap ring.

  • Page 105: Suspension

    Suspension TABLE OF CONTENTS Replace the Rear Springs ......2 Leaf ................2 Replace the Front Springs ......4 Leaf ................4 Replace the Spring Bushings ...... 6 Replace the Shocks ........7 Front ................. 7...

  • Page 106: Replace The Rear Springs

    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.
  • Page 107 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 of the suspension causing severe bodily injury or property damage.

  • Page 108: Replace The Front Springs

    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.
  • Page 109 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 of the suspension causing severe bodily injury or property damage.

  • Page 110: Replace The Spring Bushings

    Maintenance, Service, and Repair REPLACE THE SPRING BUSHINGS It is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): •...

  • Page 111: Replace The Shocks

    Maintenance, Service, and Repair 10. Install the new bushings in reverse order. HINT: Apply a light coating of grease to the bushing before pressing into the spring eye. 11. Install the spring onto the vehicle. Replace the Front Springs NOTE: Refer to section for information regarding installing the front springs.
  • Page 112 Maintenance, Service, and Repair 8. Remove 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.

  • Page 113: Battery Service

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

  • Page 114: 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 115: 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 116 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 117: 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 118: 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 119: Replacing

    Maintenance, Service, and Repair REPLACING 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 120 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 121: 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 122: 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 bat t er i es or t he gr ound. Ref er t o Batteries for information on cleaning the batteries.

  • Page 123: 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 125: Tires And Wheels

    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 ..........4 Replace the Tire ..........5...

  • Page 126: 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 127 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 128 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 129 Maintenance, Service, and Repair REPLACE THE TIRE 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 131 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 132: 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 133: 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 134: 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 135 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 136 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 137 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 138 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 139 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 140 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 141: 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 142 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 143 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 144 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 negative. FLUKE 79 SERIES II MULTIMETER Close all interlock switches, turn the Key Switch ON, F&R switch seen from...
  • Page 145 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 146 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 147 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 148 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 149: 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 150 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 151 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 152 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 153 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 154 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 155 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 156 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 157 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 158 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 159 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 160 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 161 Wire Diagrams...
  • Page 162 Wire Diagrams Orange Brown Green/Black Violet/Black Orange/Black Blue Violet/Black Violet/Black Violet/Black Green Green Green Violet/Black Orange/Black Black White Black Black Black White Green Horn White White Brown Black Orange Wire Diagrams Page 2...

  • Page 163: Chargers

    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 164 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 165 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 166: Test Equipment Required For Troubleshooting

    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 167 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 168 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 169 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 170 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 171 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 172 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 173 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 174 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 175 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 176 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 177 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 178 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 179: Important Notes And Instructions

    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 180: 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 181 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 182 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 183 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 184 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 185: Illustrated Parts

    Illustrated Parts NOTE: Parts lists are for both the MX 1600 and B 1-50 unless otherwise specified. TABLE OF CONTENTS Front Axle/Steering Knuckle ......2 Speed Control Panel ........26 Steering Linkage ......... 4 Miscellaneous Electrical ......28 Steering Column .......... 6 Charger, Lestronic ........

  • Page 186: Front Axle/Steering Knuckle

    Illustrated Parts Front Axle/Steering Knuckle Large Cup Steel Washer Bronze washer Steel Washer Small Cup PARTS PAGE 2...
  • Page 187 Illustrated Parts Front Axle/Steering Knuckle ITEM # PART # DESCRIPTION 15-200-40 Complete Front Axle Assembly. Includes Hubs, Tire Rod and Spring (no brakes) 00-240-21 Complete Front Axle Assembly. Includes Hubs, Tire Rod and Spring (Disc brakes) 14-240-06 Left Steer Knuckle, no brake 14-240-04 Left Steer Knuckle, disc brake 21-009-10...

  • Page 188: Steering Linkage

    Illustrated Parts Steering Linkage Ref., Arm on Left Steering knuckle Ref., Stering Gear Ref., Arm on Right Steering knuckle PARTS PAGE 4...
  • Page 189 Illustrated Parts Steering Linkage ITEM # PART # DESCRIPTION 86-518-01 Rod end (LH) 86-510-00 Ball Joint Clamp 50-002-03 Drag Link 88-119-81 3/8-NF Hex Locknut 88-159-85 1/2-NF Hex Castle Nut 86-501-98 Ball Joint (left thread) 18-041-05 Tie Rod Sleeve (18-057-20 assembled with ball jointsand clamps) 86-501-99 Ball Joint (right thread) 86-518-00...

  • Page 190: Steering Column

    Illustrated Parts Steering Column The steering column is an integral part of the frame and is not shown. Part ID# 5 is located in the top of the steering column tube. Ref., Steering Gear PARTS PAGE 6...
  • Page 191 Illustrated Parts Steering Column ITEM # PART # DESCRIPTION 88-199-82 5/8-NF Hex Jam Nut 19-011-20 Steering Wheel 88-081-14 Bolt, Plated (grade 8) 88-089-84 Nut, Plated (grade 8) 80-400-10 Bushing 20-031-64 Steering shaft (includes #3, #4) 19-011-25 Steering Wheel Cover 88-128-62 7/16 Split Lock Washer 88-120-15 7/16-NC x 1-1/2 Hex Bolt, Grade 5...

  • Page 192: Steering Gear

    Illustrated Parts Steering Gear See steering linkage PARTS PAGE 8...
  • Page 193 Illustrated Parts Steering Gear ITEM # PART # DESCRIPTION 18-308-21 Steeering Gear Assembly 18-308-70 Locking Ring 18-308-71 Adjuster 18-308-72 Worm Shaft/Ball Nut Assembly 18-308-23 Upper Worm Shaft Bearing 18-308-22 Upper Worm Shaft Cup 18-308-77 Housing 18-308-78 Pinion Shaft Seal 18-308-79 Worm Shaft Seal 18-308-82 Gasket...

  • Page 194: Front Suspension

    Illustrated Parts Front Suspension PARTS PAGE 10...
  • Page 195 Illustrated Parts Front Suspension ITEM # PART # DESCRIPTION 87-074-00 Grease Fitting 96-248-01 Spring Eye Bolt (includes #1) 32-213-00 Spring Eye Bushing 88-169-82 9/16-NF Lock nut, Grade C 85-506-05 Leaf Spring (includes #3) 96-118-00 1/2-NC x 1.87 x 6.5L U-bolt 96-123-00 3/8-NC x 2.06 x 4L U-bolt 88-149-81...

  • Page 196: Transmission Differential Case

    Illustrated Parts Transmission Differential Case PARTS PAGE 12...
  • Page 197 Illustrated Parts Transmission (Dana Spec# 012AJ310-1) ITEM # PART # DESCRIPTION 4C-150-00 Complete Transmission Assembly Including Mechanical Brakes 4C-150-10 Complete Transmission Assembly Including Hydraulic Brakes Special order Housing 80-480-10 Inner Input Shaft Bearing 31-265-00 Gear set 80-480-15 Outer Input Shaft Bearing 88-840-12 Snap Ring Special order...

  • Page 198: Rear Axle And Brakes

    Illustrated Parts Rear Axle and Brakes Ref., Transmission housing PARTS PAGE 14...
  • Page 199 Illustrated Parts Rear Axle and Brakes ITEM # PART # DESCRIPTION 41-347-98 Complete Brake Assembly (left), includes 1, 5, 7, 9, 10, 11, 12, 16 41-347-99 Complete Brake Assembly (right), includes 1, 5, 7, 9, 10, 11, 12, 16 41-347-15 Brake Arm 45-303-00 Seal...

  • Page 200: Rear Suspension

    Illustrated Parts Rear Suspension Ref., Frame Ref., Transmission axle tube PARTS PAGE 16...
  • Page 201 Illustrated Parts Rear Suspension ITEM # PART # DESCRIPTION 88-140-17 Bolt 85-506-10 Leaf Spring (includes #7) 96-118-00 U-bolt 88-149-81 96-248-01 Spring Bolt 01-200-62 Spring Support 32-213-00 Spring Eye Bushing 88-169-82 PARTS PAGE 17...

  • Page 202: Motor

    Illustrated Parts Motor Armature PARTS PAGE 18...
  • Page 203 Illustrated Parts Motor GE spec#BC58JBS6129A ITEM # PART # DESCRIPTION 70-049-05 Complete Motor Assembly 70-201-15 Field Coil/Stator Assembly 70-210-51 Insulator 85-412-00 Brush Spring 70-172-15 Brush Holder (includes #3) 70-104-15 Brush Pair 70-210-51 Insulator 32-508-15 Bearing Retainer 80-209-00 Bearing 70-049-06 Rubber Bushing Not Shown 88-060-12 1/4-NC x 1-1/8 Motor Mounting Bolt...
  • Page 204 Illustrated Parts Brake and Accelerator Pedal and Linkage 19, 10 Transmission Accelerator Module Arm Ref., frame Crosshaft Arm 'A' Ref., frame PARTS PAGE 20...
  • Page 205 Illustrated Parts Brake and Accelerator Pedal and Linkage ITEM # PART # DESCRIPTION 98-200-00 Brake Pedal Pad 01-432-98 Brake Pedal 88-089-81 88-080-11 Bolt 00-200-45 Brake Pedal Arm 80-410-20 Bushing 88-109-81 88-100-09 Bolt 01-200-49 Brake Cable Mounting Bracket 88-517-11 Cotter Pin 96-818-10 Brake Cable 85-250-00...
  • Page 206 Illustrated Parts Wheels and Tires Ref., wheel hub 5 (assembly) PARTS PAGE 22...
  • Page 207 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Tubeless Wheels 12-012-00 5 x 8" Tubeless (standard) 12-020-00 8.5 x 8 Tubeless Tires 10-081-00 5.70 x 8 (standard) 10-082-00 5.70 x 8 Extra Grip 10-083-00 5.70 x 8 LR C 10-093-00 8.50 x 8 LR B 10-091-10...
  • Page 208 Illustrated Parts Instrument Panel (dash) PARTS PAGE 24...
  • Page 209 Illustrated Parts Instument Panel (dash) ITEM # PART # DESCRIPTION 95-913-00 Hole Plug 71-100-00 Toggle Switch Option 71-039-11 Rocker Switch (ON-OFF) 88-817-08 Screw 74-000-00 Hour Meter 01-200-75 Dash Housing 74-009-00 Battery Status Meter 94-304-10 Dash Plate 71-039-02 F&R Switch 71-120-00 Key Switch, keyed alike (standard) 71-121-00 Key Switch, keyed unalike...

  • Page 210: Speed Control Panel

    Illustrated Parts Speed Control Panel Typical Control Panel The control panel in your vehicle may be layed out differently PARTS PAGE 26...
  • Page 211 Illustrated Parts Speed Control Panel ITEM # PART # DESCRIPTION 62-019-00 Complete Control Panel Assembly 88-838-06 #14 x 1/2 Pan Head Screw Type D Thread 62-204-00 PMC Speed control 72-501-39 Solenoid (forward or reverse) 61-838-41 Bus Bar 88-088-62 5/16 Split Lock washer 88-099-91 5/16-NF Thin Pattern Nut 88-048-62...

  • Page 212: 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 28...
  • Page 213 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION Not Shown 75-148-79 Chassie Control Harness Not Shown 75-149-79 Power Harness, B 1-50 Not Shown 75-149-82 Power Harness, MX 1600 Not Shown 98-599-15 Plastic grommet for 1.75 hole Not Shown 98-599-20 Plastic Grommet for 2.5 hole Not Shown 75-114-20...

  • Page 214: Charger, Lestronic

    Illustrated Parts Charger, Lestronic BI_CHARGER W-INTERLOCK.DWG Charger Identification PARTS PAGE 30...
  • Page 215 Illustrated Parts Charger Lester Model# 22740 ITEM # PART # DESCRIPTION 79-303-15 Complete Charger Assembly 79-805-67 Timer Assembly 79-808-00 Timer Relay (not shown) 79-902-00 Capacitor 79-749-13 Diode Assembly 79-644-31 Transformer AC cord Strain Releif 79-831-00 Fuse 79-530-00 Strain Releif 79-809-60 Interlock Relay Charger Lester Model# 11860-225(export) ITEM #...

  • Page 216: Charger, Signet

    Illustrated Parts Charger, Signet Charger, Signet 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...
  • Page 217 Illustrated Parts This page intentionaly left blank PARTS PAGE 33...

  • Page 218: Batteries

    Illustrated Parts Batteries Main battery negative 12v tap Main battery 6 and 7 (hardware) positive PARTS PAGE 34...
  • Page 219 Illustrated Parts Batteries ITEM # PART # DESCRIPTION 50-243-10 Battery Hold Down Rod 50-250-00 Bat-Lok 88-088-66 Flat Washer 88-069-81 75-235-08 Battery Jumper 88-081-12 Bolt 88-089-80 77-042-00 T 105, 217AH Battery (standard) 77-042-50 TD217, 217AH Battery 77-042-80* 217AH Moist Charge 77-044-00 T 125, 230AH Battery 77-047-00 T 145, 244AH Battery...

  • Page 220: Seat Cushions, Deck And Lights, B 1-50

    Illustrated Parts Seat Cushions, Deck and Lights, B 1-50 PARTS PAGE 36...
  • Page 221 Illustrated Parts Seat Cushions, Deck and Lights, B 1-50 ITEM # PART # DESCRIPTION 72-005-00 Head Light Assembly 72-072-00 Replacement Bulb only Not Shown 98-603-00 Wiring Grommet 94-201-00 T/D Emblem 88-567-91 Emblem Mounting Clips 94-035-01 Cowl Moulding 90-147-00 Seat Cushion 90-179-00 Seat Backrest Not Shown...

  • Page 222: Seat Cushions, Deck And Lights, Mx 1600

    Illustrated Parts Seat Cushions, Deck and Lights, MX 1600 PARTS PAGE 38...
  • Page 223 Illustrated Parts Seat Cushions, Deck and Lights, MX 1600 ITEM # PART # DESCRIPTION See B 1-50 Head Light Assembly See B 1-50 Replacement Bulb only Not Shown See B 1-50 Wiring Grommet See B 1-50 T/D Emblem See B 1-50 Emblem Mounting Clips See B 1-50 Cowl Moulding...

  • Page 224: Decals, B 1-50

    Illustrated Parts Decals, B 1-50 VIEW FROM INSIDE OF COWL PARTS PAGE 40...
  • Page 225 Illustrated Parts Decals, B 1-50 ITEM # PART # DESCRIPTION 94-333-00 94-313-20 Safety Warning 94-384-01 Not a Motor Vehicle 94-309-00 Park Brake 94-384-14 Leaving Vehicle 94-373-10 Vinyl Data Plate 94-373-70 Metal Data Plate 94-301-42 Arms and Legs 94-319-00 Battery Disconnect 94-313-00 Battery Warning PARTS...

  • Page 226: Fiberglass Cab, Doors, Mirrors

    Illustrated Parts Fiberglass Cab, Doors, Mirrors PARTS PAGE 42...
  • Page 227 Illustrated Parts Fiberglass Cab, Doors, Mirrors ITEM # PART # DESCRIPTION 90-852-30 Front Windshield 98-310-10 Windshield Gasket (by the foot) 74-050-00 Windshield Wiper Motor 74-051-00 Windshield Wiper Arm 74-052-00 Windshield Wiper Blade 91-008-00 Fiberglass Cab, B 1-50 91-008-20 Fiberglass Cab, MX 1600 98-310-10 Rear Window Gasket (by the foot) 90-850-10...

  • Page 228: Strobe Light

    Illustrated Parts Strobe Light Strobe mounted on fiberglass cab Apply silicon sealer around each mounting screw to prevent leakage Seat Back Strobe mounted on pole PARTS PAGE 44...
  • Page 229 Illustrated Parts Strobe Light ITEM # PART # DESCRIPTION 72-023-20 Strobe Light 72-023-21 Replacement Bulb 72-023-22 Replacement lens (amber) 72-023-24 Replacement Lens (red) 88-029-80 88-028-62 Flat Washer 88-025-08 Screw 88-048-61 Washer 72-023-41 Mounting Pole 98-603-00 Rubber Grommet 88-108-60 Flat Washer 88-101-16 Bolt 17-104-00...

  • Page 230: Stake Sides, B 1-50

    Illustrated Parts Stake Sides, B 1-50 PARTS PAGE 46...
  • Page 231 Illustrated Parts Stake Sides, B 1-50 ITEM # PART # DESCRIPTION 90-542-20 Side Gate 90-542-22 End Gate 90-542-20 Side Gate 90-540-00 Gate Hook 90-540-00 Gate Hook 88-065-13 Bolt 88-069-81 90-543-00 Mounting Channel PARTS PAGE 47...

  • Page 232: Hydraulic Brake Lines And Fittings (Optional)

    Illustrated Parts Hydraulic Brake Lines and Fittings (optional) Illustration not available REAR BRAKES 50-009-00 PUSH ROD, MASTER CYLINDER 96-762-00 3/8 IN.CLEVIS CAST 96-772-00 PIN,CLEVIS,3/8 X 1 1/8 IN. 99-510-02 MASTER CYLINDER 99-564-00 UNION T, 3/16 INV FLARE 99-566-00 BANJO FITTING, MASTER CYLINDER 99-571-00 COPPER GASKET, 0.813OD, 0.500ID 99-572-00...

  • Page 233: Brake Lining Handling Precautions

    Contents Appendix A: Special Tools ....2 Appendix B: Suggested Torque Limits for Standard Hardware ..3 Hardware Identification ...... 3 Standard Head Markings ........3 Hex Bolts .............. 3 Other Bolts ............3 Hex Nuts ............... 4 Hex Lock Nuts (stover) ........4 Other Nuts .............

  • Page 234: Appendix A: Special Tools

    Appendixes APPENDIX A: SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used for testing electrical circuits. Powered by the truck Test Light 62-027-00 batteries, switchable for 12, 24, 36, and 48 volts. Used to test the solid state accellerator module part number Accelerator Test Harness 62-027-31 series 62-033-XX.

  • Page 235: Appendix B: Suggested Torque Limits For Standard Hardware

    Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. NOTE: Toque values specified are for clean dry threads.

  • Page 236: Hex Nuts

    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 ® Appendixes Appendix B Page 4...

  • Page 237: Suggested Torque Values (Non-Critical Hardware)

    Appendixes 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 16-24...
  • Page 238 Appendixes 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 15 - 15...

  • Page 239: Appendix C: Brake Lining Handling Precautions

    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.
  • Page 240 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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B 1-50Mx-016-00Mx 1600Maintenance expediterLoad master

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