Taylor-Dunn B0-011-00 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn B0-011-00 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: 12/15/2003
Revision: E
Models Inlcuded:
B0-011-00 (B 1-00) Tour Master
B0-011-25 (B 1-25) Carry Master
MANUAL MB-100-00
Operation, Troubleshooting and
Replacement Parts Manual
Serial number Starting: 142833
B 1-00
B 1-25

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Summary of Contents for Taylor-Dunn B0-011-00

  • Page 1 B 1-00 B 1-25 Models Inlcuded: T h e B e s t W a y B0-011-00 (B 1-00) Tour Master T o G o B0-011-25 (B 1-25) Carry Master 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 Section Index Taylor-Dunn ® Model B0-011-00 and B0-011-25 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions Lubrication Brakes Service Steering/Front Axle Transaxle Service Motor Service Battery Service Control System Troubleshooting Wire diagram Chargers Illustrated Parts Appendix A...

  • Page 6: Table Of Contents

    Table of Contents About this manual ......... 2 Who Should Read This Manual ....2 Responsibilities ..........2 How To Use This Manual ......3 Conventions .............. 3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ....5 B 1-00 shown with optional luggage rack...

  • Page 7: About This Manual

    The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. ® ® The owner of this or any Taylor-Dunn vehicle is Taylor-Dunn , a leading manufacturer of electric responsible for the overall maintenance and repairs burden and personnel carriers since 1949, wants to of the vehicle, as well as the training of operators.

  • Page 8: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL Conventions This manual is organized into five main sections: Symbols and/or words that are used to define warnings, cautions, instructions, or notes found INTRODUCTION throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 9: 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.

  • Page 10: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery adjust any part of this or any Taylor-Dunn ® vehicle is cables, and other electrical connections are a factory authorized service technician.
  • Page 11 TABLE OF CONTENTS Standard* Specifications ....2 Safety Rules and Guidelines ....3 Driver Training Program ..... 3 Driver Qualifications........... 3 Vehicle Controls ........ 4 Key-Switch ............4 Forward-Reverse Switch ........4 Accelerator Pedal ..........4 Seat Interlock Switch ........... 4 Steering ..............

  • Page 12: Standard* Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD* SPECIFICATIONS ITEM MODEL SPECIFICATION Occupancy B 1-00 Driver + 3-passengers B 1-25 Driver + 1-passenger Dimensions 241L x 112W centimeters (94.875L x 44.25W inches) Turning Radius 335 Centimeters (132 Inches) Dry Weight (no batteries) B 1-00 336 kg (741 lbs) B 1-25...

  • Page 13: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND DRIVER TRAINING PROGRAM GUIDELINES According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who It is the responsibility of the owner of this vehicle to assure will be operating this vehicle.

  • Page 14: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key-Switch A key-switch, located at the front of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle on, counterclockwise to turn the vehicle off. The key-switch should be in the “off” position whenever the operator leaves the driver's seat.

  • Page 15: Steering

    SAFETY RULES AND OPERATING INSTRUCTIONS Steering The steering wheel and steering system is an automotive type. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter clockwise. Foot Brake Pedal The foot brake pedal, located to the right of the steering column, is for operation with the right foot only.

  • Page 16: Headlights And Accessories (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Headlights and Accessories (optional) The headlight switch is located to the rear of the instrument panel, between the seats. An accessory switch, if any, is adjacent and to the left of the light switch. Head light switch location Accessory switch location Hour Meter (2) (optional) The hour meter is located below the battery status indicator.

  • Page 17: Vehicle Operational Guidelines

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

  • Page 18: Parking

    SAFETY RULES AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle: • Set the parking brake. • Set the forward-off-reverse switch to the ` “OFF” position. • Rotate the start switch to the “OFF” position. In addition: • If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.

  • Page 19: 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 20: Lestronic Ii Charger Operation

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

  • Page 21: 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 22: Daily Visual Inspection

    SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to: • Accelerator pedal, Brake pedal, Steering, Parking brake, etc. •...
  • Page 23 Section 3 - Maintainance and Repair TABLE OF CONTENTS Maintenance Guidelines ....... 2 Steering Gear Adjustment ......25 Severe Duty Guidelines ..........3 Input Shaft Endplay ........... 25 Lubrication Chart .......... 4 Gear Lash ..............26 Steering Gear Disassembly and Repair ..27 Troubleshooting Guide ........

  • Page 24: Maintenance Guidelines

    MB-100-00 MAINTENANCE GUIDELINES Allow only qualified and authorized personnel to maintain, repair, adjust, or inspect the vehicle. • Before starting any repairs or maintenance, immobilize the vehicle. • Turn the key switch “off” and remove the key. • Set the park brake. •...

  • Page 25: Severe Duty 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. Be sure to detect any loose or defective parts.

  • Page 26: Lubrication Chart

    MB-100-00 LUBRICATION CHART Descriptio n Lubricant Type Front Leaf Springs General P urpose Grease K ing Pin General P urpose Grease Ball Joints General P urpose Grease Front W heel Bearings H igh Temperature W heel Bearing Grease Rear Leaf Springs General P urpose Grease Drive Drain Plug 10 oz.

  • Page 27: Troubleshooting Guide

    MB-100-00 TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Damaged King Pin/Ball Joint Hard Steering Low Tire Pressure Steer Gear Needs Adjusting Steer Gear Needs To Be Replaced Worn Ball Joints Mis-Adjusted or Worn Steering Gear Excessive Steering Play...

  • Page 28: Mechanical Drum Brakes

    MB-100-00 MECHANICAL DRUM BRAKES 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 29: Auto-Adjust Brake Mechanism Theory Of Operation

    MB-100-00 AUTO-ADJUST BRAKE MECHANISM THEORY OF OPERATION The auto-adjust mechanism is located on the bottom of the brake assembly and accessible through the oval slot in the brake drum. As the brake pad material wears down, the distance the brake shoes travel to engage the brake drum becomes longer.

  • Page 30: Inspecting The Auto Adjuster

    MB-100-00 Inspecting the Auto Adjuster 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 31 MB-100-00 This page intentionaly left blank Section 3 Page 9...

  • Page 32: Replacing The Brake Shoes

    MB-100-00 Replacing the Brake Shoes 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 33 MB-100-00 This page intentionaly left blank Section 3 Page 11...

  • Page 34: Replacement And Inspection Of Park Brake Lock

    MB-100-00 Replacement and Inspection of Park Brake Lock 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 35: Brake Pedal Linkage

    MB-100-00 BRAKE PEDAL LINKAGE Section 3 Page 13...

  • Page 36: Adjusting The Brake Pedal Linkage

    MB-100-00 Adjusting the Brake Pedal Linkage 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 37: Front Axle And Steering

    MB-100-00 FRONT AXLE AND STEERING Front Axle (ref) LEFT SIDE SHOWN Spring Leaf Axle Weld Right Front Axle Yoke Left Front Axle Spring Axle Yoke Plate Tie Rod Section 3 Page 15...

  • Page 38: Front Axle Removal And Installation

    MB-100-00 Front Axle Removal and Installation 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 39: Aligning The Front End

    MB-100-00 ALIGNING THE FRONT END Adjusting the Toe-In 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 40: Centering The Steering Gear

    MB-100-00 Centering the Steering Gear 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 41: Repairing The Front Axle

    MB-100-00 REPAIRING THE FRONT AXLE Steering Yoke/Bushings 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 42: Ball Joints

    MB-100-00 Ball Joints It is recommended to replace the left and right side ball joints as a set. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3.

  • Page 43: Wheel Bearings

    MB-100-00 Seal Bearing Tapered Bearing Race Tapered Bearing Race Bearing Cotter Pin Washer Spindle Nut Dust Cap Wheel Bearings 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3.
  • Page 44 MB-100-00 10. Clean all grease from the inside of the hub and bearings. 11. Inspect and replace the races and bearings as a set. NOTE: It is recommended to replace both the left and right wheel bearings at the same time. 12.

  • Page 45: Removal And Installation Of The Steering Gear Assembly

    MB-100-00 Removal and Installation of the Steering Gear Assembly 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 46 MB-100-00 10. Reinstall the steering gear by performing this procedure in reverse order. Always use new locknuts. Locknuts become less effective if used more than once. Failure to replace the locknuts may result in the locknuts or bolts coming loose causing property damage and/or severe bodily 11.

  • Page 47: Steering Gear Adjustment

    MB-100-00 STEERING GEAR ADJUSTMENT Worm Shaft Jam Nut Gear Lash Ad- juster Worm Bearing Adjuster Input Shaft Endplay 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3.

  • Page 48: Gear Lash

    MB-100-00 Gear Lash 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 49: Steering Gear Disassembly And Repair

    MB-100-00 STEERING GEAR DISASSEMBLY AND REPAIR Disassembly NOTE: The steering gear must be removed from the vehicle for this procedure. Refer to Removal and Installation of the Steering Gear Assembly section for information regarding removing the steering gear. NOTE: The steering gear is packed with grease. Only perform maintenance on the steering gear in an area that will contain any grease that may spill out of the steering gear when it is disassembled.
  • Page 50 MB-100-00 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. 8.
  • Page 51 MB-100-00 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in the worm shaft.

  • Page 52: Exploded View Of Steering Gear

    MB-100-00 Exploded View of Steering Gear Section 3 Page 30...

  • Page 53: Drive Service

    MB-100-00 DRIVE SERVICE Removing the Rear Axles NOTE: This procedure does not require that the rear end or drive assembly be removed from the vehicle. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3.

  • Page 54: Servicing The Differential

    MB-100-00 Servicing the Differential 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 55 MB-100-00 13. Remove the bearing cap screws and bearing caps. NOTE: Bearing caps are marked for identification. During reassembly, Differential Case make sure they are put back in their Drive Gear original position. 14. Remove the differential case assembly from the housing.
  • Page 56 MB-100-00 25. Remove the bearings from the input shaft. Input Shaft Bearing 26. Remove the O-rings from the outer input bearing bore and both intermediate bearing Input Shaft bores. 27. Inspect all parts for signs of wear or damage. Note: Bearing, seal and gear surfaces Input Shaft Bearing should be inspected for pitting, wear, overheating or scoring.

  • Page 57: Changing The Differential Oil

    MB-100-00 Changing the Differential Oil 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 58 MB-100-00 Differential Assembly O-Ring Snap Ring Bearing Input Shaft Intermediate Shaft Bearing Bore Plug Differential O-ring Drive Gear Snap Ring Intermediate Shaft Assembly Carrior Bearing Bearing Cap Oil Level Plug Cover Plate Section 3 Page 36...

  • Page 59: Motor Removal

    MB-100-00 Motor Removal NOTE: It is not necessary to remove the drive assembly to perform this procedure in most cases. However, if the vehicle is equipped with an optional cargo box, it may be necessary to lower the drive assembly in order to access the motor.

  • Page 60: Armature Inspection

    MB-100-00 Armature Inspection 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 61: Replacing The Brushes

    MB-100-00 Replacing the Brushes 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 62 MB-100-00 10. Push the brushes out of the holder until the torsion spring snaps out of position and pull the brush out of the holder. 11. Install the new brushes into the brush holder. NOTE: Do not insert the brush all the way into the holder.

  • Page 63: Inspecting The Motor Brushes

    MB-100-00 Inspecting the Motor Brushes 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 64: Battery

    MB-100-00 BATTERY Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.

  • Page 65: Servicing

    MB-100-00 Servicing 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.

  • Page 66: Battery Storage

    MB-100-00 Battery Storage The following pointers will help extend the life of the battery when storing the vehicle for the winter season: • Clean and check the electrolyte level and charge level of the battery. • Do not store a battery low in electrolyte or in a low state of charge. •...
  • Page 67 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 68: 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 69: 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 70: 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85: 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 86: Pmc Control

    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 87 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 88: Plugging Diode

    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 89: Freewheel Diode

    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 90: Iso

    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 91 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 92: Solenoids

    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 93 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 94 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 95: Motor

    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 96 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 97 Wire Diagrams...
  • Page 98 Wire Diagrams Green/Black Brown Brown White Black White White Violet/Black Blue/White HORN SWITCH Black Control Panel -12V TAP Blue Green White White Black Black Black/White Black Black White White Green Control Panel Wire Diagrams Page 2...
  • Page 99 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 100: Operating Instructions And Theory Of Operation

    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 101: Testing The Charging Cycle

    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 102: 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 103: Troubleshooting For Built-In Charger

    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 104 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 105 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 106: Troubleshooting For Portable Charger

    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 107: Testing The Timer Relay

    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 108: Testing The Interlock Relay

    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 109 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 110: Operating Instructions And Theory Of Operation

    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 111: Hb/Pt And Gel Indicator Lamps

    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 112 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 113: Status Led Error Code Table

    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 114: Troubleshooting

    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 115 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 116: 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 117: Operating Instructions And Theory Of Operation

    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 118: Testing The Charging Cycle

    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 119: Status Light Error Code Table

    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 120: Troubleshooting

    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 121 Illustrated Parts TABLE OF CONTENTS Front Axle and Steering Knuckle ....2 Steering Linkage ......... 4 Steering Column .......... 6 Steering Gear ..........8 Front Suspension ........10 Transmission Differential Case ....12 Rear Axle and Brakes ........14 Rear Suspension ......... 16 Motor ............

  • Page 122: Front Axle And Steering Knuckle

    MB-100-00 Front Axle and Steering Knuckle SECTION 5 PAGE 2...
  • Page 123 MB-100-00 Front Axle and Steering ITEM # PART # DESCRIPTION 15-210-00 Axle beam 14-210-98 Left side yoke 14-210-99 Right side yoke 88-527-11 Cotter pin 92-104-00 Bearing cap 32-240-55 King pin bushing 97-180-55 Thrust washer 21-020-15 King pin 88-189-81 12-124-00 Hub (includes #16, 18 and one of #17) 45-338-00 Grease seal 80-017-00...

  • Page 124: Steering Linkage

    MB-100-00 Steering Linkage Steering Knuckle (ref) SECTION 5 PAGE 4...
  • Page 125 MB-100-00 Steering Linkage ITEM # PART # DESCRIPTION 18-308-21 Steering gear box 88-279-82 7/8NF Hex nut 88-268-62 7/8 Split lock washer 01-110-21 Drag link See Steering Column 86-501-98 Ball joint 86-510-00 Ball joint clamp 86-501-99 Ball joint 18-111-30 Pitman arm See Steering Column See #8 88-159-85...

  • Page 126: Steering Column

    MB-100-00 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 SECTION 5 PAGE 6...
  • Page 127 MB-100-00 Steering Column ITEM # PART # DESCRIPTION 88-199-82 5/8-NF Hex Jam Nut 19-011-30 Steering Wheel 88-081-14 Bolt, Plated (grade 8) 88-089-84 Nut, Plated (grade 8) 80-400-10 Bushing 20-031-63 Steering shaft (includes #3, #4) 19-011-35 Steering Wheel Cover 88-128-62 7/16 Split Lock Washer 88-120-11 7/16-NC x 1 Hex Bolt, Grade 5 97-200-00...

  • Page 128: Steering Gear

    MB-100-00 Steering Gear See steering linkage SECTION 5 PAGE 8...
  • Page 129 MB-100-00 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 18-308-76...

  • Page 130: Front Suspension

    MB-100-00 Front Suspension Front Axle (ref) LEFT SIDE SHOWN SECTION 5 PAGE 10...
  • Page 131 MB-100-00 Front Suspension ITEM # PART # DESCRIPTION 85-506-05 Spring 50-460-00 Strap 32-213-00 Spring eye bushing 96-243-10 9/16NF x 3-1/2 Hex bolt, grade 5 88-169-82 9/16NF Hex nut, grade C 96-123-00 3/8 NC x 2.06 x 4 U-bolt 88-109-82 3/8NC Hex lock nut, grade C 16-865-02 Spring plate 96-120-00...

  • Page 132: Transmission Differential Case

    MB-100-00 Transmission Differential Case SECTION 5 PAGE 12...
  • Page 133 MB-100-00 Transmission (Dana Spec# 012AJ308-1) ITEM # PART # DESCRIPTION 4C-100-00 Complete Transmission Assembly Including Brakes Special order Housing Carrior bearing cap, inculded with #1 96-330-10 Carrior bearing cap bolt 66-610-04 Carrior assembly Final Gear Final gear bolt Final gear nut 80-480-00 Carrior bearing Intermeadiate shaft...

  • Page 134: Rear Axle And Brakes

    MB-100-00 Rear Axle and Brakes SECTION 5 PAGE 14...
  • Page 135 MB-100-00 Rear axle and Brakes (Dana Spec# 012AJ308-1) 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 41-344-98 Brake assembly (L) 41-344-99 Brake assembly (R) 66-611-14 Wheel stud 41-126-96...

  • Page 136: Rear Suspension

    MB-100-00 Rear Suspension SECTION 5 PAGE 16...
  • Page 137 MB-100-00 Rear Suspension ITEM # PART # DESCRIPTION 96-248-00 9/16NF x 3 Bolt 88-169-82 9/16NF Hex lock nut, grade C 88-149-81 1/2NC Hex lock nut 96-120-00 1/2NC x 1-7/8 x 2 U-bolt 88-149-81 1/2NC Hex lock nut 85-506-15 Leaf spring 01-110-32 Spacer 88-140-25...

  • Page 138: Motor

    MB-100-00 Motor Armature SECTION 5 PAGE 18...
  • Page 139 MB-100-00 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 Bearing retainer...

  • Page 140: Brake/Accelerator Linkage

    MB-100-00 Brake/Accelerator Linkage Frame (ref) Frame (ref) Floorboard Accelerator Module Accelerator Pedal Left rear axle (ref) SECTION 5 PAGE 20...
  • Page 141 MB-100-00 Brake/Accelerator Linkage ITEM # PART # DESCRIPTION 88-517-11 3/32 x 1 cotter pin 96-772-00 3/8 x 1-1/8 Clevis pin 88-106-61 3/8 SAE Flat washer 85-233-00 Spring 96-820-01 Cable Included with #8 Hex nut 01-110-22 Equilizer 96-826-12 Brake cable 88-847-06 E-Ring Included with #8 Clevis...

  • Page 142: Wheels And Tires

    MB-100-00 Wheels and Tires Ref., wheel hub 5 (assembly) SECTION 5 PAGE 22...
  • Page 143 MB-100-00 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 144: Instrument Panel

    MB-100-00 Instrument Panel SECTION 5 PAGE 24...
  • Page 145 MB-100-00 Instrument Panel ITEM # PART # DESCRIPTION 74-009-00 Battery status indicator 74-000-00 Hour meter 71-100-00 Accessory switch 71-100-00 Accessory switch 71-039-02 Forward and reverse switch 71-120-10 Key switch 01-110-30 Mounting plate 94-386-03 Mounting plate decal Not shown 88-065-09 1/4NC x 3/4 Phillips truss head bolt (Mounting plate bolt) Not shown 97-211-20 Mounting plate nut...

  • Page 146: Speed Control Panel

    MB-100-00 Speed Control Panel Solenoid end view from side closest to PMC End view of PMC (#5) SECTION 5 PAGE 26...
  • Page 147 MB-100-00 Speed Control Panel ITEM # PART # DESCRIPTION 79-844-00 Circuit breaker 88-818-06 #8 x 1/2 Pan head screw, type B thread 79-840-00 Circuit breaker 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...

  • Page 148: Miscellaneous Electrical

    MB-100-00 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 SECTION 5 PAGE 28...
  • Page 149 MB-100-00 Miscellaneous Electrical ITEM # PART # DESCRIPTION Not Shown 75-148-06 Chassie vontrol harness Not Shown 75-149-85 Power harness Not Shown 98-599-15 Plastic grommet for 1.75 hole Not Shown 98-599-20 Plastic grommet for 2.5 hole Not Shown 95-917-00 Plastic plug for 7/8 hole Not Shown 75-166-36 Headlight harness...

  • Page 150: Lester Charger

    MB-100-00 Lester Charger Typical Built In charger Typical Portable charger CHARGERS.DWG SECTION 5 PAGE 30...
  • Page 151 MB-100-00 SECTION 5 PAGE 31...

  • Page 152: Signet Charger

    MB-100-00 Signet Charger 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) 79-309-42...
  • Page 153 MB-100-00 NOTE: The harness connectors and AC plug are not included with the charger. PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector 76-200-00 AC plug, 115v domestic SECTION 5 PAGE 33...

  • Page 154: Batteries

    MB-100-00 Batteries Main Negative 12-v Negative Tap #8 Optional Low water level alarm Main Positive SECTION 5 PAGE 34...
  • Page 155 MB-100-00 Batteries ITEM # PART # DESCRIPTION 75-231-00 Jumper cable 77-042-80 T105 Battery 0 or 6 77-042-50 TD 217 Battery 0 or 6 77-047-50 TD 250 Battery 0 or 6 77-047-00 T145 Battery 0 or 6 50-250-00 Bat-Loc battery hold down 88-088-66 5/16 x 1.5OD Tin/lead plated flat washer 50-243-10...

  • Page 156: Seat Cushions, Lights And Deck

    MB-100-00 Seat Cushions, Lights and Deck Model B 1-00 Tail light on rear panel #13 Headlight assembly Model B 1-25 SECTION 5 PAGE 36...
  • Page 157 MB-100-00 Seat Cushions, Deck and Lights ITEM # PART # DESCRIPTION 94-035-01 Trim strip 90-147-10 Seat cushion, black 0 or 1 90-147-20 Seat cushion, tan 0 or 1 90-411-25 Deck board 90-147-10 Seat cushion, black 0 or 1 90-147-20 Seat cushion, tan 0 or 1 94-035-01 Trim strip...

  • Page 158: Decals

    MB-100-00 Decals Front Cowl Decals Left Rear Wheel Well SECTION 5 PAGE 38...
  • Page 159 MB-100-00 Decals ITEM # PART # DESCRIPTION 94-313-20 Safety warnings 94-301-42 Keep arms and legs inside 94-384-00 Apply park brake * 94-373-10 Vehicle data plate 94-333-00 FM approved 94-309-00 Brake warning 94-384-14 Turn keu off 94-384-01 Not a motor vehicle 94-319-00 Battery disconnect 94-313-00...

  • Page 160: Strobe Light

    MB-100-00 Strobe Light Mount for Strobe Light on Sun Top SECTION 5 PAGE 40...
  • Page 161 MB-100-00 Strobe Light ITEM # PART # DESCRIPTION 98-603-00 Grommet 96-624-00 Wire clip Not shown 88-737-09 Pop rivet for #2 72-023-20 Strobe light assembly (includes #9 and #11) Not shown 72-023-21 Flash tube for #3 Not shown 72-023-22 Amber lens for #3 Not shown 72-023-23 Red lense for #3...

  • Page 162: Sun Top And Windshield

    MB-100-00 Sun Top and Windshield Windshield mounting bracket (1 of 4) Top left shown SECTION 5 PAGE 42...
  • Page 163 MB-100-00 Sun Top and Windshield ITEM # PART # DESCRIPTION 88-060-11 1/4NC x 1 Hex bolt 88-060-15 1/4NC x 1-3/4 Hex bolt 88-060-18 1/4NC x 2-1/2 Hex bolt 88-068-60 1/4 Cut flast washer 88-069-81 1/4NC Nylon lock nut 91-028-73 Front 91-028-75 Spacer 91-110-00...

  • Page 164: Mirrors

    MB-100-00 Mirrors Windshield Frame (ref) Front Cowl (ref) SECTION 5 PAGE 44...
  • Page 165 MB-100-00 Mirrors ITEM # PART # DESCRIPTION 92-207-02 Multi panel mirror 88-828-09 #10 x 3/4 self drilling screw 92-201-00 Side mirror (includes #7, #6) 88-069-61 1/4NC Nylon lock nut 92-202-00 Mirror bracket (includes #8 and #9) Included with #3 Included with #3 Included with #5 Included with #5 88-065-08...

  • Page 166: B 125 Stake Sides/B 100 Luggage Rack

    MB-100-00 B 125 Stake Sides/B 100 Luggage Rack SECTION 5 PAGE 46...
  • Page 167 MB-100-00 Stake Sides ITEM # PART # DESCRIPTION 90-547-08 Stake side, right 90-547-10 Rear gate 90-547-06 Stake side, left 88-065-13 1/4NC x 1-1/4 Truss head bolt 88-069-83 1/4NC Acorn nut 90-547-04 Gate hook, rear gate 90-547-02 Gate hook, rear left 90-547-03 Gate hook, rear right 90-547-00...

  • Page 168: Tool Box B 100

    MB-100-00 Tool Box B 100 SECTION 5 PAGE 48...
  • Page 169 MB-100-00 Tool Box (B 1-00) ITEM # PART # DESCRIPTION 71-040-95 Lock assembly 90-547-14 Tool box Not shown 88-065-13 1/4NC x 1-1/4 Phillpips truss head screw Not shown 97-211-20 1/4NC U-nut SECTION 5 PAGE 49...

  • Page 170: Signet Charger

    MB-100-00 Signet Charger Signet® Charger ITEM # PART # DESCRIPTION 79-303-40 Charger assembly (see note on facing page) 79-575-60 Replacement cover w/AC cord and gasket Note: There are no user serviceable components inside the charger NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION...
  • Page 171 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 172: Appendix A: Special Tools

    Appendixes APPENDIX A: SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used to install the pinion seal on all chain drive trucks with Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43-201-50 cover. Used to center the chain case on the pinion shaft on all chain Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41-532-50...

  • Page 173: Hardware Identification

    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 174: 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 175: 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 176 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 177: 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 178 Model B 1-00...
  • Page 180 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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B0-011-25B 1-00B 1-05

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