Table of Contents
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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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Chapters
Table of Contents
Troubleshooting
Related Manuals for Taylor-Dunn B 1-50
Summarization of Contents
Introduction
About this manual
Explains the purpose and content of the manual for the Taylor-Dunn vehicle.
Who Should Read This Manual
Identifies intended users of the manual, covering operators, owners, and service personnel.
Responsibilities
Outlines responsibilities for owners, operators, service personnel, and passengers.
How To Use This Manual
Describes the organization of the manual into five main sections.
How to Identify Your Vehicle
Details how to identify vehicle models and serial numbers, and clarifies intended use.
Taking Delivery of Your Vehicle
Provides guidelines for inspecting the vehicle upon delivery and handling problems.
Safety Rules and Operating Instructions
Standard Specifications
Lists detailed technical specifications for the vehicle models.
Safety Rules and Guidelines
Provides essential safety rules and guidelines for operating the vehicle.
Driver Training Program
Details the required operator training program and qualifications.
Vehicle Controls
Explains the function and operation of various vehicle controls.
Vehicle Operational Guidelines
Provides guidelines for driving, loading, parking, and towing the vehicle.
Storing and Returning to Service
Outlines procedures for storing the vehicle and returning it to service.
Periodic Maintenance Checklist
Provides a checklist for regular preventative maintenance tasks.
Maintenance Guidelines for Severe Duty Applications
Specifies increased maintenance frequency for vehicles used in severe conditions.
General Maintenance
Maintenance Guidelines
Provides general maintenance guidelines, safety precautions, and service responsibilities.
Troubleshooting Guide
Lists common symptoms and their probable causes for troubleshooting.
Lubrication Chart
Provides a chart detailing lubrication points and lubricant types for maintenance.
Front Axle Service
Inspect the Front Wheel Bearings and Kin Pin
Describes how to inspect front wheel bearings and king pins for wear or looseness.
Adjust Front Wheel Bearings
Provides step-by-step instructions for adjusting front wheel bearings.
Front Axle Removal and Installation
Details the procedure for removing and installing the front axle assembly.
Replace Front Wheel Bearings
Provides instructions for replacing front wheel bearings.
Replace the Ball Joints, Tie Rods, and Drag Link
Details the process for replacing steering linkage components.
Replace the King Pins and Bushings
Describes how to replace king pins and their associated bushings.
Replace the Steering Knuckle
Provides instructions for replacing the steering knuckle.
Steering Component Service
Front End Alignment
Explains how to perform front-end alignment on the vehicle.
Adjust the Steering Gear (Saginaw)
Provides instructions for adjusting the steering gear lash and center position.
Replace the Steering Shaft (Saginaw, non-tilt steering)
Details the procedure for replacing the steering shaft.
Replace the Steering Gear (Saginaw)
Details the procedure for removing and replacing the steering gear.
Repair the Steering Gear
Explains the disassembly and reassembly process for repairing the steering gear.
Brake Service
Inspect the Service Brake
Describes how to inspect front disc brake pads, rotor, rear brake shoes, and drum.
Inspect the Parking Brake
Outlines procedures for inspecting the parking brake system components.
Adjust the Service Brakes
Provides instructions for adjusting mechanical and hydraulic drum service brakes.
Bleed the Brake System
Provides step-by-step instructions for bleeding the hydraulic brake system.
Replace Front Disc Brake Pads
Provides instructions for replacing front disc brake pads.
Replace Rear Brake Shoes
Details the procedure for replacing rear brake shoes.
Replace the Master Cylinder
Provides instructions for removing and replacing the master cylinder.
Motor Service
Inspecting the Motor Brushes
Describes how to inspect motor brushes for wear.
Motor Removal and Installation
Provides instructions for removing and installing the motor.
Replacing the Brushes
Provides instructions for replacing motor brushes.
Replacing the Bearings
Details how to replace motor bearings.
Repairing the Commutator
Explains how to repair the motor commutator.
Transmission Service
Check Oil Level
Provides instructions for checking the transmission oil level.
Rear Hub with Brake Drum
Provides instructions for removing and installing the rear hub with brake drum.
Rear Axle
Details the removal and installation of rear axles, distinguishing between hub types.
Transmission
Details the removal and installation procedures for the transmission assembly.
Differential Case
Explains the disassembly process for the differential case.
Suspension
Replace the Rear Springs
Details the procedure for replacing rear leaf springs.
Replace the Front Springs
Provides instructions for replacing front leaf springs.
Replace the Shocks
Details the procedure for replacing front shocks.
Battery Service
Testing
Details load testing and specific gravity testing for batteries.
Replacing
Provides instructions for replacing batteries and related hardware.
Storage and Returning to Service
Details procedures for storing batteries and returning them to service.
Tires and Wheels
Tire Inspection
Details how to inspect tire tread depth, wear indicators, and sidewalls.
Replace Tire/Wheel
Provides instructions for replacing a tire and wheel assembly.
Replace the Tire
Details the procedure for replacing a tire on the wheel.
Electrical Troubleshooting
Symptoms
Lists common vehicle symptoms related to the electrical system.
Read This First
Important notes, instructions, and required test equipment for troubleshooting.
Power Output Test
Describes how to test the power output of the PMC controller.
Control Wire Inputs
Details testing control wire inputs to the PMC and solenoids.
Power Wire Inputs
Details testing power wire inputs to the PMC controller.
Motor
Describes how to test motor windings for continuity and potential issues.
Accelerator
Details testing the accelerator module using an analyzer.
Key Switch
Explains how to test the key switch for proper operation.
F/R switch
Details testing the forward/reverse switch for correct voltage output.
Solenoids
Covers testing solenoids for proper operation and wiring.
Symptom Troubleshooting Guide
Guides troubleshooting based on specific vehicle symptoms.
PMC Control
Details testing the PMC control module for proper voltage output.
Plugging Diode
Explains how to test the plugging diode on the PMC control.
Freewheel Diode
Describes how to test the freewheel diode on the PMC control.
ISO
Details testing the ISO solenoid and its power contacts.
Motor Inspection
Guides inspection of motor components like brushes, commutator, and windings.
Lestronic II® Charger Troubleshooting
Testing the Charging Cycle
Details how to test the charger's charging cycle and identify issues.
Troubleshooting for Built-in Charger
Provides troubleshooting steps for built-in Lestronic II chargers.
Troubleshooting for Portable Charger
Offers troubleshooting steps for portable Lestronic II chargers.
Signet® Charger Troubleshooting
Operating Instructions and Theory of Operation
Explains Signet charger operation and charging stages.
Testing the Charging Cycle
Details how to test the Signet charger's charging cycle.
Status LED Error Code Table
Explains error codes indicated by the charger's status LEDs.
Troubleshooting
Provides steps to diagnose issues when the Signet charger does not turn on.
Illustrated Parts
Front Axle/Steering Knuckle
Lists illustrated parts for the front axle and steering knuckle.
Steering Gear
Illustrates and lists parts for the steering gear assembly.
Rear Axle and Brakes
Illustrates and lists parts for the rear axle and brake assembly.
Motor
Illustrates and lists parts for the motor assembly.
Brake and Accelerator Pedal and Linkage
Illustrates and lists parts for the brake and accelerator pedal systems.
Wheels and Tires
Illustrates and lists parts for wheels and tires.
Speed Control Panel
Illustrates and lists parts for the speed control panel.
Batteries
Illustrates and lists battery components and related hardware.
Appendixes
Appendix A: Special Tools
Lists special tools required for maintenance and troubleshooting.
Appendix B: Suggested Torque Limits for Standard Hardware
Provides torque specifications for standard hardware.
Appendix C: Brake Lining Handling Precautions
Outlines precautions for handling brake lining materials safely.
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