User Manuals: Taylor-Dunn LOAD MASTER Utility Vehicle

Manuals and User Guides for Taylor-Dunn LOAD MASTER Utility Vehicle. We have 1 Taylor-Dunn LOAD MASTER Utility Vehicle manual available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn LOAD MASTER Operation, T Roubleshooting And Replacement Parts Manual (240 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 22 MB

Taylor-Dunn

5
- Table of Contents
  5
- About this Manual
  8
- Introduction
  8
- Responsibilities
  9
- Who Should Read this Manual
  9
- How to Use this Manual
  10
- Safety Rules and Operating Instructions
  10
- Conventions
  11
- How to Identify Your Vehicle
  12
- Taking Delivery of Your Vehicle
  13
Safety Rules and Operating Instructions

15
- Standard Specifications
  
  16
- Safety Rules and Guidelines
  
  17
- Driver Training Program
  
  18
  - Driver Qualifications
    18
- Vehicle Controls
  
  19
  - Key-Switch
    19
  - Forward-Off-Reverse Switch
    19
  - Accelerator Pedal
    19
  - Steering
    19
  - Foot Brake Pedal
    20
  - Park Brake
    20
  - Horn Switch
    20
  - Seat Interlock Switch
    20
  - Headlight Switch
    21
  - Hour Meter (Optional)
    21
  - Charger Interlock
    21
  - Battery Status Indicator, Analog
    21
  - Battery Status Indicator, Digital Bargraph
    22
  - Reverse or Motion Alarm (Optional)
    22
  - Electrolyte Alarm (Optional)
    22
  - Directional Signals (Optional)
    22
  - Hazard Light Switch (Optional)
    23
  - Accessory Switch (Optional)
    23
  - Auxiliary Switch (Optional)
    23
- Vehicle Operational Guidelines
  
  24
  - Driving
    24
  - Loading and Unloading
    24
  - Parking
    24
  - Towing
    24
- Charging Your Vehicle
  
  25
- Storing and Returning to Service
  
  27
  - Storing Your Vehicle
    27
  - Returning to Service
    27
- Periodic Maintenance Checklist
  
  28
  - Daily Visual Inspection
    29
- Maintenance Guidelines for Severe Duty Applications
  
  29
General Maintenance

31
Front Axle Service

37
Steering Component Service

53
Maintenance, Service, and Repair

67
- Inspect the Service Brake
  68
  - Front Disc Brake Pads
    68
  - Front Disc Brake Rotor
    68
  - Rear Brake Shoes
    68
  - Rear Brake Drum
    69
- Inspect the Parking Brake
  69
- Adjust the Service Brakes
  70
  - Mechanical and Hydraulic Drum Brakes
    70
  - Adjust the Mechanical Brake Linkages
    71
- Adjust the Parking Brake
  72
  - Wheel Park Brake (Mechanical Drum Standard)
    72
  - Wheel Park Brake (Hydraulic Drum)
    72
- Check Master Cylinder Fluid
  73
- Bleed the Brake System
  74
- Flush the Brake System
  75
- Replace Front Disc Brake Pads
  76
- Replace Rear Brake Shoes
  77
- Replace the Front Cylinder
  78
- Repair the Brake Body
  79
- Replace the Master Cylinder
  81
- Repair the Master Cylinder
  82
Table of Contents

83
- Inspecting the Motor Brushes
  84
- Motor Inspection
  85
- Motor Removal and Installation
  85
- Replacing the Brushes
  87
- Repairing the Commutator
  88
- Replacing the Bearings
  88
- Service Limits
  89
Transmission Service

91
- Check Oil Level
  
  92
- Change Oil
  
  93
- Motor
  
  94
  - Removal
    94
  - Installation
    94
- Rear Hub with Brake Drum
  
  95
- Rear Axle
  
  96
  - Replace the Axle Bearing
    98
- Transmission
  
  99
  - Remove
    100
- Differential Case
  
  100
  - Disassemble
    100
  - Assemble
    103
Suspension

105
- Replace the Rear Springs
  
  106
  - Leaf
    106
- Replace the Front Springs
  
  108
  - Leaf
    108
- Replace the Spring Bushings
  
  110
- Replace the Shocks
  
  111
  - Front
    111
Battery Service

113
- Cleaning
  114
- Testing
  115
- Watering
  117
- Charging
  118
- Replacing
  119
  - Moist Charge Batteries
    121
- Storage and Returning to Service
  122
  - Returning to Service
    123
- Tires and Wheels
  125
  - Tire Inflation
    126
  - Tire Inspection
    126
Table of Contents

131
- Symptoms
  
  132
- Read this First
  
  133
  - Test Equipment Required
    133
  - IMPORTANT NOTES and INSTRUCTIONS
    133
  - Definitions
    134
  - Wire Diagram
    141
- Symptom Troubleshooting Guide
  
  149
  - Pmc Control
    149
  - Plugging Diode
    149
  - Freewheel Diode
    149
  - Iso
    149
  - Solenoids
    149
  - Motor
    149
  - Chargers
    163
  - Test Equipment Required for Troubleshooting
    166
    
    Including, Voltage Tests, Continuity Tests and Diode Testing. if Not Familiar with
    166
    
    Any Part of These Tests, Refer Testing to a Qualified Technician
    166
    
    Working Condition
    166
    
    Voltage on the Charger Nameplate
    166
    
    Battery Volts = Full Voltage Available at the Batteries at the Time of the Test Being Performed
    166
Electrical Troubleshooting

176
Illustrated Parts

185
- Front Axle/Steering Knuckle
  186
- Steering Linkage
  188
- Steering Column
  190
- Steering Gear
  192
- Front Suspension
  194
- Transmission Differential Case
  196
- Rear Axle and Brakes
  198
- Rear Suspension
  200
- Motor
  202
- Speed Control Panel
  210
- Miscellaneous Electrical
  212
- Charger, Lestronic
  214
- Charger, Signet
  216
- Batteries
  218
- Seat Cushions, Deck and Lights, B 1-50
  220
- Seat Cushions, Deck and Lights, MX 1600
  222
- Decals, B 1-50
  224
- Fiberglass Cab, Doors, Mirrors
  226
- Strobe Light
  228
- Stake Sides, B 1-50
  230
- Hydraulic Brake Lines and Fittings (Optional)
  232
  - Brake Lining Handling Precautions
    233
- Appendix A: Special Tools
  
  234
- Appendix B: Suggested Torque Limits for Standard Hardware
  
  235
  - Hex Bolts
    235
  - Other Bolts
    235
  - Hardware Identification
    235
  - Hex Nuts
    236
  - Hex Lock Nuts (Stover)
    236
  - Other Nuts
    236
  - Suggested Torque Values (Non-Critical Hardware)
    237
- Appendix C: Brake Lining Handling Precautions
  
  239

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Utility Vehicle Electric Vehicles Trucks Tractor Automobile

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User Manuals: Taylor-Dunn LOAD MASTER Utility Vehicle

Taylor-Dunn LOAD MASTER Operation, T Roubleshooting And Replacement Parts Manual (240 pages)

Table of Contents

Taylor-Dunn

Safety Rules and Operating Instructions

Standard Specifications

Safety Rules and Guidelines

Driver Training Program

Vehicle Controls

Vehicle Operational Guidelines

Charging Your Vehicle

Storing and Returning to Service

Periodic Maintenance Checklist

Maintenance Guidelines for Severe Duty Applications

General Maintenance

Front Axle Service

Steering Component Service

Maintenance, Service, and Repair

Table of Contents

Transmission Service

Check Oil Level

Change Oil

Motor

Rear Hub with Brake Drum

Rear Axle

Transmission

Differential Case

Suspension

Replace the Rear Springs

Replace the Front Springs

Replace the Spring Bushings

Replace the Shocks

Battery Service

Table of Contents

Symptoms

Read this First

Symptom Troubleshooting Guide

Electrical Troubleshooting

Important Notes and Instructions

Are Off. Switching Voltage When any of the Led's Are on will Result in

From One Input Voltage to the Other, Wait until All Three Status Led's

This Charger Is Rated for 115 VAC or 230 VAC Operation. When Switching

Damage to the Charger

Illustrated Parts

Appendix A: Special Tools

Appendix B: Suggested Torque Limits for Standard Hardware

Appendix C: Brake Lining Handling Precautions

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