Taylor-Dunn C0-014-32, C0-014-33 Utility Vehicle Operation, Troubleshooting and Replacement Parts Manual

T h e B e s t W a y

To Go

A b o u t Your

B u s i n e s s

Models Inlcuded:

C0-014-32

C0-014-33

Revision: B

MANUAL MC-432-05

Operation, Troubleshooting and

Replacement Parts Manual

Serial Number Starting: 151285

B2-48 With Dump Bed Option

B2-48 with Steel Cab, Foldaway

4-Passenger Seat and Stake Sides

B2-10 Ambulance

ET 3000

P2-50 30,000 Pound Tow Tractor

ET1-50 Full Size Truck

COPYRIGHT NOTICE

Copyright © 2001 by Taylor-Dunn

®

Mfg. All rights reserved.

No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or any information storage or retrieval system without prior written permission of Taylor-Dunn ® Mfg. unless such copying is expressly permitted by federal copyright law. Address inquiries to Reference Permissions,

Taylor-Dunn ® Mfg., 2114 W. Ball Road, Anaheim, CA 92804

TAYLOR-DUNN SERVICE CENTER

For more information about this and other Taylor-Dunn

®

manuals, please write Taylor-Dunn

®

:

Taylor-Dunn

®

Mfg.

2114 W. Ball Road

Anaheim, CA 92804

(Attn: Technical Writer)

Section Index

Taylor-Dunn

“Mule” Model C0-014-32 and C0-014-33

Operator and Service Manual Section Index

Introduction 1

Safety Rules and Operating Instructions 2

General Maintenance

Front Axle Service

3

4

Steering Component Service

Brakes Service

Motor Service

Transmission Service

Tires and Wheels

5

6

7

8

9

Battery Service

Electrical Troubleshooting

Special Troubleshooting

Lestronic II Charger Troubleshooting

Signet Charger Troubleshooting

Wire diagram

Illustrated Parts

Appendix A

Special Tools

Appendix B

Suggested Torque Values

Appendix C

Brake Lining Handling Precautions

13

14

15

16

10

11

12

17

18

19

This quick reference section index guide will assist you in locating a desired topic or procedure.

Refer to each sectional Table of Contents for the page number location for specific topics or procedures.

B2-48 With Stake Side Dump Bed Option

E4-55 Sit Down Tow Tractor

SC1-00 Stock Chaser

C4-25 Sit Down Tow Tractor

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

R 3-80 shown with extended steel cab and doors options

INTRODUCTION

ABOUT THIS MANUAL

The purchase of this vehicle shows a belief in high quality products manufactured in the USA.

Taylor-Dunn ® , a leading manufacturer of electric burden and personnel carriers since 1949, wants to be sure this vehicle provides years of reliable service.

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 ® has made every effort to include as much information as possible about the operation and maintenance of this vehicle.

Included in this manual are:

•

Vehicle Description

•

Safety Rules and Guidelines

•

Operational Information

•

Operator Responsibilities

•

Owner Responsibilities

•

Control Operation and Location Information

•

Maintenance and Troubleshooting Information

•

Standard Parts List

Before servicing, operating, training or performing maintenance on this or any other Taylor-Dunn

®

vehicle, read the appropriate Taylor-Dunn

®

manual.

Each Taylor-Dunn ® manual references the applicable models and serial numbers on the front cover.

Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

RESPONSIBILITIES

Of the Owner...

The owner of this or any Taylor-Dunn

®

vehicle is responsible for the overall maintenance and repairs of the vehicle, as well as the training of operators.

Owners should keep a record of conducted training and maintenance performed on the vehicle. (OSHA

Regulation, 29 CFR 1910.178 Powered Industrial

Truck Operator Training).

Of the Operator...

The operator is responsible for the safe operation of the vehicle, preoperational and operational checks on the vehicle, and the reporting of any problems to service and repair personnel.

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. At no time should an untrained individual be allowed to service or repair a vehicle without supervision. This manual is not a training guide.

Of the Passengers ...

The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside the vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of recklessness are to be avoided. Do not engage in horseplay.

WHO SHOULD READ THIS MANUAL

This manual is intended for use by anyone who is going to operate, own, perform maintenance on, service, or order parts for this Taylor-Dunn

®

vehicle.

Each person should be familiar with the parts of this manual that apply to their use of this vehicle.

Model B 2-10 shown withstake sides and steel cab with doors options

Page-2

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. It also includes various subjects that should be included in the operator and service training program.

Maintenance Service and Repair

This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks.

Electrical and Charger Troubleshooting

This section identifies the troubleshooting procedures for testing the electrical system and battery charger.

Illustrated Parts

This section provides an illustrated view of various assemblies. The illustrations are accompanied by tables identifying the parts.

Conventions

Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual. Refer to the examples below.

A shaded box with the word “Warning” and the symbol above denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task.

A shaded box with and the word “Warning” and the symbol above denotes a warning. This warning alerts the reader of a high voltage hazard that may result in injury to themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task.

A box with the word “CAUTION” and the symbol above denotes a caution and is used to inform the reader that property damage may occur. Be sure to exercise special care and follow any instructions contained with in a caution.

Note: Alerts the reader to additional information about a subject.

Model R 3-80 shown equiped with a cargo box and steel cab with doors options

Model B 2-48 equipped with the Dump Bed option

Page-3

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.

This vehicle is not designed to be driven on public roads or highways. It is available in maximum designed speeds ranging from 4.5 to 9 mph. Do not exceed the maximum designed speed.

Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow at more than 5 mph.

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section 29 CFR

1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for

Personnel and Burden Carriers (ANSI B56.8).

The locations of the model and serial numbers are illustrated below:

Page-4

TAKING DELIVERY OF YOUR

VEHICLE

Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems:

•

Examine the contents of all packages and accessories that may have come in separate packages with the vehicle.

•

Make sure everything listed on the packing slip is there.

•

Check that all wire connections, battery cables, and other electrical connections are secure.

•

Check battery cells to be sure they are filled.

•

Check the tire pressure, tightness of lug nuts, and for any signs of damage.

Check the operation of each of the following controls:

•

Accelerator

•

Brake

•

Parking Brake

•

Key-Switch

•

Forward/Reverse Switch

•

Reverse Beeper (if equipped)

•

Front Headlight Switch

•

Steering Wheel

•

Horn

INTRODUCTION

What To Do If a Problem is Found

If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading and file a claim with the freight carrier. The claim must be filed within 48 hours of receiving the vehicle and its accessories. Also, notify your Taylor-Dunn ® dealer of the claim.

If there is a problem with the operation of the vehicle,

DO NOT OPERATE THE VEHICLE. Immediately contact your local Taylor-Dunn

®

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.

The only personnel authorized to repair, modify, or adjust any part of this or any

Taylor-Dunn

®

vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage. Unauthorized repairs may also void the vehicles warranty.

Model B 2-10 Ambulance

Page-5

TABLE OF CONTENTS

Standard Specifications Burden Carrier ...... 2

Safety Rules and Guidelines ......................... 3

Driver Training Program ................................ 3

Driver Qualifications. .............................................. 3

Vehicle Controls ............................................. 4

Accessory Switch (Optional) .................................. 4

Key-Switch ............................................................ 4

Forward-Off-Reverse Switch .................................. 4

Horn Switch ........................................................... 4

Headlight Switch (optional) ..................................... 4

Battery Status Indicator, Analog .............................. 5

Hour Meter (optional) ............................................. 5

Directional Signals (Optional) ................................. 5

Hazard Light Switch (Optional) ............................... 5

Electrolyte Alarm (Optional) .................................... 5

Charger Interlock ................................................... 6

Park Brake ............................................................. 6

Steering ................................................................. 6

Foot Brake Pedal ................................................... 6

Accelerator Pedal ................................................... 6

Vehicle Operational Guidelines .................... 7

Safety Guidelines ................................................... 7

Starting: ................................................................. 7

While driving: ......................................................... 7

Loading and Unloading ........................................... 7

Parking .................................................................. 7

Towing ................................................................... 7

Charging your vehicle .................................... 8

New Battery Break in .............................................. 8

Signet® Charger Operation .................................... 8

Lestronic II® Charger Operation ............................. 8

Charging Time ....................................................... 9

Storing and Returning to Service ................ 9

Storing Your Vehicle ............................................... 9

Returning to Service ............................................... 9

Periodic Maintenance Checklist ................... 10

Daily Visual inspection: .......................................... 11

Maintenance Guidelines for

Severe Duty Applications ........................ 11

SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS BURDEN CARRIER

MODEL ITEM

Occupancy

Dimensions

Turning Radius

VOLTAGE SPECIFICATION

Driver only

200.6L X 74.9W X 101.6H Centimeters

79L X 29.5X 40H Inches

177.8Centimeters (70 Inches)

Dry Weight

(less batteries)

Min/Max Battery

Weights

Maximum Load

Deck dimensions

Electrical System

C 4-32

C 4-33

C 4-32

C 4-33

C 4-32

C 4-33

36 Volt

24 Volt

258 kg (570 lbs)

269 kg (594 lbs)

92.5 kg to 156.7 kg (248 lbs to 420 lbs)

Transmission

Motor, DC

Series Wound

Brakes

Tires

Frame

Instrumentation

Light Accessories

Charger

C 4-32

C 4-33

C 4-32

C 4-33

36 Volt

24 Volt

635 kg (1,400lbs)

544 kg (1,200lbs)

73.6W x 101.6L Centimeters (29W x 40L Inches)

Six 217Amp Hour, 6 Volt, Lead Acid Batteries

Four 217 Amp Hour, 6 Volt, Lead Acid Batteries

Solid State Speed Control, 400Amp

Primary Oil Bath Chain Reduction to Automotive Type Hypoid Differential.

1.5 kW, (2 Horse Power) for 60 min

4.5 kW, (6 Horse Power) for 5 min

1.1 kW, (1.5 Horse Power) for 60 min

3.4 kW, (4.5 Horse Power) for 5 min

Rear Wheel Drive Line Band Brake, Hand Operated Park Brake

4.80 x 8 Load Range B, Pneumatic

Steel Unitized Body, Heavy Duty 16 Gauge Steel, Diamond Plate

Battery Discharge Indicator, Key Switch, Horn Button, Forward/Reverse

Switch

Optional

Up to serial # 164171: 120v, 12 Amp AC, 25Amp DC, Built-In, Automatic

Starting Serial # 164172: 100/230v, 12/6 Amp AC, 20A DC Built-In,

Automatic

Up to serial # 164195: 120v, 8 Amp AC, 25Amp DC, Built-In, Automatic

Starting Serial # 164196: 100/230v, 9/4.5 Amp AC, 18 Amp DC

Built-In, Automatic

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section

1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for

Personnel and Burden Carriers (ANSI B56.8).

Safety Rules

Page 2

SAFETY RULES AND GUIDE-

LINES


DRIVER TRAINING PROGRAM

It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the American National Standards Institute Personnel and

Burden Carriers ANSI B56.8). As well as, following the safety rules and guidelines outlined in ANSI B56.8 and listed below.

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.

These vehicles are not designed to be driven on public roads or highways. They are available in maximum designed speeds ranging from 4.5 to 9 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have previous vehicle operation experience. Successful completion of the Operator Training program shall be required for all personnel who operate this vehicle.

The Operator Training program shall include the following:

•

Operation of this vehicle under circumstances normally associated with your particular environment.

•

Emphasis on the safety of cargo and personnel.

•

All safety rules contained within this manual.

•

Proper operation of all vehicle controls.

•

A vehicle operation and driving test.

Driver Qualifications.

Refer to

Vehicle Operational Guidelines, Safety

Guidelines

section for important safety information regarding operating this vehicle.

Read and follow all of the guidelines listed below. Failure to follow these guidelines may result in severe bodily injury and/or property damage.

Only those who have successfully completed the

Operator Training program are authorized to drive this vehicle. Operators must possess the visual, auditory, physical, and mental ability to safely operate this vehicle as specified in the American National Standards Institute

Controlled Personnel and Burden Carriers ANSI B56.8.

The following are minimum requirements necessary to qualify as an operator of this vehicle:

•

Demonstrate a working knowledge of each control.

Before working on a vehicle:

•

Understand all safety rules and guidelines as presented in this manual.

•

Know how to properly load and unload cargo.

•

Know how to properly park this vehicle.

•

Recognize an improperly maintained vehicle.

•

Demonstrate ability to handle this vehicle in all conditions.

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. Disconnect the main positive and negative cables at the batteries.

Safety Rules

Page 3


VEHICLE CONTROLS

Key-Switch

A key-switch, located on the right side of the dash, 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” position whenever the operator leaves the vehicle.

This switch is also designed to secure and disable the vehicle. The key can only be removed when the key-switch is in the “OFF” position.

Forward-Off-Reverse Switch

The forward-off-reverse switch, located on the right side of the dash panel, determines the direction of travel of the vehicle. Push the top of the switch to engage the forward direction. Push the bottom of the switch to engage the reverse direction.

DO NOT SWITCH from forward to reverse or vice-versa while the vehicle is in motion. Make sure the vehicle is completely stopped before shifting.

The forward-off-reverse switch should be in the center “OFF” position, with the key-switch off and the park brake set whenever the operator leaves the vehicle.

Horn Switch

The horn switch is located on the left side of the dash. Depress the switch to sound the horn, release it to turn it off.

Headlight Switch (optional)

The headlight switch is located on the bottom right side of the dash. Push the top of the switch forward to turn the lights on. Pull the switch back to turn the lights off.

Accessory Switch (Optional)

The accessory switch is located on the botom right of the dash. Push the top of the switch forward to turn on the accessory. Pull the switch back to turn off the accessory. The accessory can be turned on with the key switch in the

“OFF” position. If a vehicle is equipped with windshield wipers and one or more accessories, the windshield wipers are controlled from this switch. Other accessories are controlled from the auxiliary switch.

Safety Rules

Page 4


Battery Status Indicator, Analog

The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading. The vehicle needs charging if it is in the yellow zone. During and immediately following charging, the needle will be in the red zone to the right. The needle will move through the green zone toward the yellow zone as the batteries discharge. Charge the batteries when the needle is in the yellow zone. If it is in the red zone to the left, the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries.

Hour Meter (optional)

The hour meter is located to the right of the battery status indicator. It records the number of hours the vehicle has been in operation.

Directional Signals (Optional)

The turn signal lever is located on the left side of the steering column. Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal.

Hazard Light Switch (Optional)

The hazard light switch is located on the left side of the steering column. 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.

Electrolyte Alarm (Optional)

The Electrolyte Alarm is located in the battery area, in the 4th battery cell from the main battery positive cable. The Electrolyte alarm is activated when the battery cell fluid level falls below the level of the probe. The alarm is an audible continuous sound along with a bi-color indicator lamp. Inspect the fluid level in all battery cells when the alarm sounds or the bi-color lamp turns from its green color to red. The vehicle batteries should then be filled and/or charged. With the fluid level at a normal operating level and/or the batteries charged the alarm and light will reset.

Safety Rules

Page 5


Steering

The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter-clockwise. If equipped with tilt steering, the release lever is located on the lower left of the steering column. Pull the lever up to reposition the steering wheel.

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. Relieving pressure from the pedal releases the braking action.

Accelerator Pedal

The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.

Park Brake

The parking brake is actuated with a hand lever, which is located to the right of the driver. To set the parking brake, push down on the brake pedal and pull the lever up until it locks. To release the park brake, depress the foot brake pedal, pull up on the park brake handle, push the release button, and lower the handle.

Charger Interlock

The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source.

Safety Rules

Page 6


VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

•

Only qualified and trained operators may drive this vehicle.

•

Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees).

•

Drive slowly when making a turn, especially if the ground is wet or when driving on an incline.

•

This vehicle may overturn easily if turned sharply or when driven at high speeds.

•

Observe all traffic regulations and speed limits.

•

Keep all body parts (head, arms, legs) inside this vehicle while it is moving.

•

Keep the vehicle under control at all times.

•

Yield right of way to pedestrians, ambulances, fire trucks, or other vehicles in emergencies.

•

Do not overtake another vehicle at intersections, blind spots, or other dangerous locations.

•

Do not drive over loose objects, holes, or bumps.

•

Yield right of way to pedestrians and emergencies vehicles.

•

Stay in your driving lane under normal conditions, maintaining a safe distance from all objects.

•

Keep a clear view ahead at all times.

Starting:

1. Make sure the forward-off-reverse witch is in the center “OFF” position.

2. Set the parking brake.

3. Hold down the foot brake.

4. Insert the key and turn it to the “ON” position.

5. Release the parking brake.

6. Release the foot brake.

7. Slowly depress the accelerator pedal.

While driving:

•

Slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection.

•

No reckless driving.

•

Do not drive this vehicle on steep inclines or where prohibited.

•

Immediately report any accidents or vehicle problems to a supervisor.

Loading and Unloading

•

Do not carry more than the maximum number of passengers allowed for this vehicle.

•

Do not exceed the cargo load capacity.

•

Do not load cargo that can fall off.

•

Be careful when handling cargo that is longer, wider, or higher than this vehicle, be sure to properly secure all loads.

Parking

Before leaving the vehicle:

•

Set the parking brake.

•

Set the forward-off-reverse switch to the ` “OFF” position.

•

Turn the key switch to the “OFF” position and remove the key.

In addition:

•

If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.

•

Do not block fire aisles, emergency equipment, stairways, or exits.

Towing

To tow this vehicle, attach a tow strap to the front bumper tow-bar.

NOTE: If the vehicle is equipped with an automatic electric brake, do not tow the vehicle with the drive wheels on the ground.

Use another driver to steer this vehicle while it is being towed. Be sure the driver uses the brakes when the towing vehicle slows or stops. Do not tow the vehicle faster than 5 m.p.h. or its maximum designed speed, whichever is lower.

If at all possible, this vehicle should be placed on a carrier, rather than towing.

Safety Rules

Page 7


CHARGING YOUR VEHICLE

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. Failure to do so may result in severe bodily injury and/or property damage.

New Battery Break in

New batteries require a break in period of up to 40-cycles.

The batteries will not have their full capacity during this break in period and may require longer charging times.

Signet

®

Charger Operation

The Signet ® HB-600 and

HB-1000 chargers use a semi-automatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself

OFF when the batteries are

Typical Signet

®

Built In

fully charged. Refer to the data plate on the charger for the voltage and type power required for the charger.

There is a series of LED’s on the faceplate of the charger that serve two functions:

1. Status of charge. The LED’s will display an approximate percent of charge during the charging cycle. Refer to the table below.

2. Error condition. All three

LED’s flashing is an indication of a charging problem. Refer to the

Charger Troubleshooting

section for information on error codes.

Battery electrolyte is poisonous and dangerous. It contains sulfuric acid. Avoid contact with skin eyes or clothing. Wear rubber gloves and safety glasses while servicing batteries. DO NOT INGEST! This may result in severe bodily injury.

The key switch must be in the “OFF” position when charging the batteries.

Failure to turn the key switch “OFF” may result in damage to the vehicles electrical system.

Lestronic II

®

Charger Operation

The Lestronic II ® charger is a semi-automatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Refer to the data plate on the charger for the voltage and type power required for the charger.

Typical Lestronic II

®

Built In

Charger

Charging State

0 to 50%

50% to 75%

75% to 100%

Cycle complete

Safety Rules

Page 8

LED1

Blinking

ON

ON

ON

LED2

OFF

Blinking

ON

ON

LED3

OFF

OFF

Blinking

ON


Charging Time

Average charging time is 8 to 10-hours. The time required to fully charge your batteries will vary depending on:

•

Capacity of the batteries, higher capacity requires longer charge time.

•

Output of the charger, higher output requires less charge time.

•

Depth of discharge, the deeper a battery is discharged, the longer it takes to charge.

•

Temperature, low temperatures require longer charge time.

It is not unusual for charge times to exceed 15-hours, especially with new batteries.

To obtain the maximum battery life:

Charge the batteries only after they reach a normal discharge as indicated on the Battery Status Indicator

(BSI). Failure to follow this guideline could result in the batteries entering an overcharge state, which will reduce the life of the batteries. If you find it necessary to charge the batteries before they are completely discharged we recommend waiting until they are discharged a minimum of 25% to reduce the possibility of overcharging. Refer to Vehicle Controls in this section for information on how to read the BSI.

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.

•

Lube all grease fittings.

•

Clean, dry, and check all exposed electrical connections.

•

Inflate tires to proper pressure (if applicable).

•

For extended storage, the vehicle should be elevated so that the tires do not touch the ground.

If stored for a prolonged period, the batteries should be charged as follows:

Storage

Temperature

(F)

Charging Interval

(months)

Over 60 1

Do not discharge the batteries beyond a normal discharge as indicated on the BSI. Refer to Vehicle

Controls in this section for information on how to read the BSI.

Between 40 and 60

Below 40

2

6

Check the battery electrolyte once a week. Do not charge the batteries if the battery electrolyte is low. Charging when the electrolyte is low will damage the batteries and shorten their life-span. Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level. Refer to Section

Maintenance,

Service and Repair

for battery maintenance information.

Returning to Service

•

Check the battery’s state of charge and charge if required.

•

Perform ALL maintenance checks in the periodic checklist.

•

Remove any blocks from the vehicle and/or place the vehicle down on to the ground.

•

Test drive before putting into normal service.

Do not interrupt the charging cycle. When the charger is plugged in, allow it to turn off before disconnecting.

Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep. Both circumstances will shorten the life of the batteries.

Safety Rules

Page 9


PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

2,3

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

Lubricate Vehicle

Clean and Tighten All Wire

Connections

Wash and Service Batteries

Check Park Brake

Check Motor Brushes and

Blow Out Motor

Check Front Wheel Bearings

Check Rear Axle Oil

Change Rear Axle Oil

Check and Tighten all Nuts and

Bolts

Clean and Repack Front Wheel

Bearings

1, 2, 3 - See notes on following pages.

Weekly

(20hrs)

Monthly

(80hrs)

Quaterly

(250hrs)

Semi -

Annual

(500hrs)

Annualy

(1000hrs) l l l l l l l l l l l l l l l l

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.

Safety Rules

Page 10


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.

Proper operation of all locking devises such as but not limited to:

•

•

Tool box, Removable battery trays, Cargo box, Cab doors, etc.

Proper operation of all interlocking switches such as but not limited to:

•

Key switch, Seat interlock switch, Charger interlock switch, etc.

Inspect for leaking fluids or grease.

MAINTENANCE GUIDELINES FOR

SEVERE DUTY APPLICATIONS

1. This maintenance checklist is based on the average application. If the vehicle is operated under

“severe conditions”, service procedures should be conducted more frequently than specified. The frequency of service under severe conditions is determined by the use of the vehicle. The owner/ operator must evaluate the operating environment to determine the increase in maintenance frequency.

In addition, the whole vehicle should be inspected monthly for signs of damage. The damage must be repaired immediately.

The following list is meant as a guide and is not all-inclusive of a “severe duty” application.

• Extreme temperature.

• Bumpy, dusty, or ill maintained roads.

• Excessively wet areas.

• Corrosive or contaminated areas.

• Frequent loading of vehicle at/near capacity.

• Use on multiple shifts.

2. Any deficiencies found during an inspection should corrected before the vehicle is returned to service.

3. Battery water level should be inspected on a weekly schedule.

T

A Y

L OR - DU N

N

Th e

B st

W ay

To

Go About

Yo ur

R

Bu si

Safety Rules

Page 11


Maintenance Guidelines ................................ 2

Troubleshooting Guide .................................. 3

Lubrication Chart ............................................ 4

Model C 4-25 Tow Tractor

Model E 4-55 Tow Tractor

Maintenance, Service and Repair

Maintenance Guidelines

Periodic maintenance and service must be performed on this vehicle. Failure to complete these scheduled maintenance and service procedures can result in severe bodily injury and/or property damage. It is the owner and/or operators responsibility to insure that proper service and maintenance is performed on the vehicle, described in this manual.

Before starting any repairs:




4. Place blocks under the front or rear wheels to prevent vehicle movement.


Turn the Key switch OFF BEFORE disconnecting the batteries. Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 (refer to the fault table in the troubleshooting section).

Read and follow all of the guidelines listed below. Failure to follow these guidelines may result in severe bodily injury and/or property damage.

•

Avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle performance checks in an authorized area where safe clearance exists.

•

Before starting the vehicle, follow the recommended safety procedures in Section 2, “Safety Rules and

Operational Information.”

•

Ventilate the work area properly.

•

Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices.

•

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.

•

Do not use an open flame to check level or leakage of battery electrolyte.

• Do not use open pans of fuel or flammable fluids for cleaning parts.

•

Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle.

Page 2


Troubleshooting Guide

Symptom

Steering Pulls in One Direction

Hard Steering

Excessive Steering Play

Lack of Power or Slow Operation

Abnormal Noise

Oil Leak in Rear Bearing Area

Brake Pedal Soft or Spongy

Brake Pedal Low

Braking Power Low

Probable Cause

Front End Out of Alignment

Low Tire Pressure

Dry Lube Points in Steering Linkage

Damaged King Pin/Ball Joint

Low Tire Pressure

Worn Ball Joints

Mis-Adjusted or Worn Steering Gear

Loose Steering Linkage

Brakes or Parking Brakes Dragging

Batteries Discharged or Defective

Worn Drive Gears

Front End Out of Alignment

Defective Speed Control

Worn Drive Gears or Bearings

Worn Front /Rear Axle Bearings

Loose Lug Nuts

Motor Bearings Worn

Rear Wheel Bearing and/or Gasket Failed

Drive Over Filled

Air in Brake Lines

Brake Worn (1/16" Wear Limit)

Brake Fluid Low

Brakes Out of Adjustment

Brake Worn (1/16" Wear Limit)

Brake Pads Contaminated with Fluid

Brake Pedal Linkage Binding

Brakes Out of Adjustment

Air in Brake Lines

Note: This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom.

Page 3


Lubrication Chart

Above Front Fork

Page 4

# Description

1 Steering Chain

2 Front Axle Bearings

3 Fork Bearings

4 -

5 -

6 -

7 Drive Drain Plug

8 Drive Level Plug

9 Drive Fill Plug

9

7

Rear Axle Assembly (side view)

8

7

9

Locations Lubricant Type

2

1

1

Chain Lube

General Purpose Grease

General Purpose Grease

2

2

1

SAE 140 API GL-5 Gear Oil


Inspect/Adjust Front Wheel Bearings 2

Replace Front Wheel Bearings .......... 2

Front Axle Removal and Installation .. 3

Removal ............................................................ 3

Installation ......................................................... 3

Maintenance, Service, and Repair

INSPECT/ADJUST FRONT

WHEEL BEARINGS

REPLACE FRONT WHEEL

BEARINGS











Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury.

6. Raise the front wheel off of the ground and support with jack stands.

7. Tighten the front axle until the wheel does not spin freely. To test, spin the front wheel by hand. The wheel should stop spinning in no more than 2revolutions. If the wheel continues to spin, tighten the axle nut and repeat the test.

8. Spin the wheel and listen for any grinding noise.

Any grinding noise may be an indication of worn or damaged wheel bearings.

NOTE: Refer to the

Replace Front Wheel

Bearings

section for information regarding the replacement of the wheel bearings.

9. Lower the vehicle.

10. Reconnect the main positive and negative cables at the batteries.

11. Remove the blocks from behind the wheels.

12. Release the park brake and test drive the vehicle.


6. Remove the front axle and wheel. Refer to

Front

Axle Removal and Installation

section for information regarding removing the axle.

7. Remove the spacers, seals and bearings from the hub

8. Thoroughly clean all grease from the inside of the hub and the bearings.

9. Drive the races out from the hub.

10. Press new races into the hub.

11. Assemble in reverse order, using new grease seals.

a. Pack bearings with grease.

b. Refer to

Front Axle Removal and

Installation

section for information regarding installing the axle.





Front Axle

Page 2


FRONT AXLE REMOVAL AND INSTALLATION

Removal







Installation

1. Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub.

2. Assemble the bearing spacers into the front wheel hub and place the front wheel into the fork.

3. Insert the axle into the front fork.

4. Install the axle nut(s). Refer to

Adjust Front

Wheel Bearings

section for information regarding tightening the front axle.

NOTE: If your vehicle is equipped with two axle nuts, the nuts should be tightened equally so that the same number of axle threads are visible on both ends.





6. Remove the front axle nut.

7. Slowly raise the front of the vehicle until the axle can slide freely out of the fork. The front wheel should still be resting on the ground.

8. Remove the front axle from the fork and support the vehicle with jack stands.

Axle

Fork (single)

Spacer

Seal

Bearing

Race

Typical fork illustrated.

Your fork may be different.

Front Axle

Page 3


Front End Alignment .......................... 2

Replace the Front Fork ...................... 3

Adjust Steering Chains ...................... 4


FRONT END ALIGNMENT






Do not drive the vehicle while the steering wheel or front wheels are tied in position.

Driving the vehicle while the steering wheel or front wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and/or property damage.

6. Loosen the upper and lower steering chain turnbuckles and remove the chains.

7. Position the steering wheel as shown in the illustration to the right, and tie off so that it cannot rotate.

8. Position the steening fork so that it is in the straight ahead position and tie off so that it cannot rotate.

9. Install the upper and lower steeing chains so that the turn buckles are centered between the two sprockets and tighten the turn buckles to tension the chains. Refer to Adjust Steering Chains for information regarding tightening the turn buckles.

10. Install safety wire in each turn buckle as show in the illustration.



13. Release the parking brake and test drive the vehicle.

Steering

Page 2

Turnbuckle with Safety Wire


REPLACE THE FRONT FORK







10. While supporting the front fork so that it cannot fall out of the vehicle, remove the fork spindle nut and remove the fork from the vehicle.

11. Thoroughly clean all parts and install in reverse order.

•

Tighten the fork spindle nut to remove all play in the fork bearings and then an additional

1/4 turn.

•

Refer to section Front Axle Removal and

Installation in Front Axle Service for information regarding installing the front axle.

•

Refer to section Front End Alignment for information regarding installing the upper steering chain.

12. Lower the wheels to the ground.




Locknut

Washer

Tapered Bearing

Bearing Race

Collar

Spindle

Front Fork Assembly

Bearing Race

Tapered Bearing

Seal

6. Remove the seat frame.

7. Remove the fork bearing cap.

8. Remove the front axle. Refer to section

Front

Axle Removal and Installation

in

Front Axle

Service

for information regarding removing the front axle.

9. Remove the upper steering chain.

Steering

Page 3


ADJUST STEERING CHAINS

There are two steering chains. One is at the bottom of the steering column under the floorboard, the other is at the top of the fork under the seat platform. Both steering chains have an adjustable turnbuckle for setting the chain tension. Before adjusting the chains, be certain that the turn buckles are positioned correctly.

The turnbuckles should be centered between the two sprockets when the steering is positioned in the straight ahead position. If the turnbuckles are not centered, then remove and reposition the turnbuckles before adjusting the chains.

After the turnbuckles are centered, rotate the steering from a full right turn to a full left turn and be certain that the turnbuckles do not contact the sprockets.

To adjust the steering chain tension, perform the following for the upper and/or lower chains:




Turnbuckle on Lower Steering




4. Place blocks under the rear wheels to prevent vehicle movement.


Upper Steering Chain


6. Raise the front of the vehicle and support with jack stands.

7. Cut, remove and discard the safety wire from the turnbuckle. DO NOT reuse the safety wire.

8. Using a pull scale, adjust the turnbuckle until it deflects approximately 0.25” at 20 pounds.

9. Install new safety wire on the turnbuckle.

10. Lower the wheels to the ground.

Turnbuckle with Safety Wire

Steering

Page 4


Inspect the Service/Parking brake ..... 2

Adjust the Parking Brake ................... 3

Adjust the Service Brake ................... 3

Replace the Brake Lining ................... 4

Band Park Brake ................................................ 4

Replace the Brake Drum ................... 6


INSPECT THE SERVICE/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. Since this possibility exists, all brake parts should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.

The band brake is located on the front of the drive chain case housing, it must be removed to accurately measure the lining thickness. Refer to

Replace the Brake

Lining

for information on removing the band brake.

1. Measure the thickness of the brake lining at its thinnest point. If it is 1/16-inch or less, then the brake band must be replaced.

2. Measure the run out of the brake drum. If it is more than 0.010-inches then it must be machined or replaced. Do not machine the brake drum beyond its service limits.

3. Measure the diameter of the brake drum. If it is less than 5.85-inches then the brake drum must be replaced.

4. Inspect all brake cables and linkages for any signs of damage or wear.


7. Remove blocks from behind the wheels.

8. Test drive the vehicle.

Brakes

Page 2


ADJUST THE PARKING BRAKE ADJUST THE SERVICE BRAKE

Primary Adjustment

NOTE: If there is no adjustment left in the park brak handle, than the service brake must be adjusted. Refer to Adjust the Service brake for more information.

1. Release the park brake

2. Rotate the knob on the end of the park brake handle until the parking brake holds firm when applied.

3. Set the park brake.


5. Remove the blocks from the wheels.


Do not adjust the service brake with the brake cable. Refer to Replace the Brake

Lining for information regarding the proper adjustment for the brake cable.






6. Release the park brake.

7. Loosen the park brake handle adjustment until is as loose as possible.

8. Loosen the brake band bolt jam nut.

9. Tighten the brake band bolt until the brake starts to drag and then back off two turns.

10. Tighten the brake band bolt jam nut.

11. Adjust the primary adjustment until the parking brake holds firm when applied.



14. Remove the blocks from the wheels.


Brakes

Page 3


REPLACE THE BRAKE LINING


®

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.

Band Park Brake

NOTE: The drive must be removed to replace the brake band. Refer to

Remove Complete

Transmission Assembly

for information on removing the drive from the vehicle.

NOTE: Refer to the illustration on the following page for locations of the components.

NOTE: On most vehicle configurations, the brake drum does not have to be removed for this procedure. If the brake drum must be removed, refer to

Replacing the Brake

Drum

for this procedure.






11. Remove the clevis pin (11) from the brake band anchor and remove the brake band (3) from the assembly.

12. Inspect the brake arm pivot bolt for signs of wear.

If any signs of wear are seen then the pivot bolt must be replaced.

13. Tighten the brake band pivot bolt and then back off just enough so that the brake arm (15) pivots freely.

The brake band bolt, spring, lock nut, jam nut, clevis pin, and cotter pin must be replaced with new parts whenever the brake band is replaced. Failure to replace these components could cause the parking brake to fail resulting in severe bodily injury and/or property damage

14. Install the new brake band using new hardware.

15. Install the brake band assembly onto the drive.

Tighten the mounting bolts (5) just enough to keep the mounting bracket (13) against the chain case

(16) but still allowing the bracket to move.

16. Tighten the brake band bolt (4) to 50 ft-lbs.

17. Tighten the brake band bracket mounting bolts (5).

18. Position the brake band alignment bracket(s) (9) so that the inner arm (14) is 0.100” away from the brake drum (8). Make certain that the alignment bracket does not come into contact with the brake drum.


7. Disconnect the parking brake cable and return spring from the brake arm.

8. Loosen the bolt(s) (1) on the brake band alignment bracket(s) (9) and pivot them out of the way.

9. Remove the bolts (5) holding the brake band assembly to the front of the chain housing (16) and remove the brake band assembly from the drive.

10. Remove the brake band bolt (4).

Brakes

Page 4


19. Adjust the alignment bracket adjusting bolt(s) (10) to 0.050-0.100" away from the brake band and tighten the jam nuts (12).

22. Adjust the brake band adjusting bolt (4) so that there is no brake drag when the brake is off. It may be necessary to readjust the alignment bracket adjusting bolt(s) (10) for optimum brake alignment and operation.

23. Tighten the brake band bolt jam nut (7).





20. Loosen the brake band adjusting bolt (4).

21. Connect the brake cable or linkage to the brake arm and adjust the cable so that the brake arm is

1/4” away from the chain case when the parking brake is off.

Brakes

Page 5


REPLACE THE BRAKE DRUM


®

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.

11. Install the brake drum using a new pinion nut.

Torque the pinion nut to 170 ft-lbs.

12. Position the brake band alignment bracket(s) so that the inner arm is 0.100” away from the brake drum. Make certain that the alignment bracket does not come into contact with the brake drum.

NOTE: The drive must be removed to replace the brake drum. Refer to

Remove Complete


section for information on removing the drive from the vehicle.

13. Adjust the alignment bracket adjusting bolt(s) to

0.050-0.100" away from the brake band and tighten the jam nuts.







7. Loosen the bolt(s) on the brake band alignment bracket(s) and pivot them out of the way.

8. Remove the pinion nut and slide the brake drum off of the pinion shaft.

9. Remove the pinion seal.

10. Lightly grease the new pinion seal and install using the pinion seal installation tool

(see appendix C).

14.

Brake

section for information regarding adjusting the park brake.





Inspect the pinion seal for any signs of misalignment. A misaligned pinion seal could cause premature failure of the pinion seal and an oil leak. This could result in property damage and/or severe bodily injury.

Brakes

Page 6


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 ................ 6

Service Limits .................................... 7

Typical Exploded Motor

Motor Service

INSPECTING THE MOTOR BRUSHES

Typical motor with cooling fan indicated by the arrow

Motors with internal cooling fans

NOTE: There are four brushes in the motor. The brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time.

NOTE: In some vehicle configurations it may not be possible to inspect all four brushes while the motor is in the vehicle. Refer to

Transmission Service

section for information on removing the motor.






6. Look through the brush cover and compare the top of the brush to the top of the brush holder. If it is even with or below the top of the brush holder then the brushes should be removed and measured. Refer to

Replacing the Brushes

section for information regarding removing the motor brushes.

7. If any one brush is less than or equal to the service limit specified in

Service Limits

, then all four brushes should be replaced.


9. Remove the blocks from behind the wheels, release the park brake and test drive.

Motor

Page 2

Typical brush and brush holder

Enclosed Motors (GE, no cooling fan)

General Electric Motors






6. Insert a 0.035” diameter wire through the brush inspection hole above each brush until it contacts the top of the brush.

7. Mark the wire to indicate how far it was inserted into the motor housing.

8. Remove the wire and measure how far into the motor the wire was inserted.

9. If any one wire insertion length exceeds the length specified in


, then all four brushes should be replaced. Refer to

Replacing the

Brushes

section for information regarding replacing the motor brushes.


11. Remove the blocks from behind the wheels, release the park brake and test drive.

MOTOR REMOVAL AND

INSTALLATION

See the

Transmission

section for information on removing or installing the motor.

MOTOR INSPECTION

Disassembly

1. Remove the motor from the vehicle. See the

Transmission

section for information on removing the motor.

2. Remove the housing screws from the rear and/or front of the motor.

3. Remove the armature retaining screws from the rear housing (if equipped).

Motor Service

Inspection

1. Measure the length of each motor brush.

• If any one brush is less than or equal to the service limit specified in section

Service

Limits

, then all four brushes should be replaced. Refer to

Replacing the Brushes

section for information regarding replacing the motor brushes.

2. Measure the diameter of the commutator.

• If the commutator is less than the minimum diameter specified in section


,

then the motor must be replaced.

4. If this is an enclosed motor, remove the front housing end.

5. Pull the armature out of the front end of the motor housing.

6. Remove the nuts off of all of the terminals in the rear motor housing.

7. Remove the rear motor housing being careful not to damage the field coil wires.

3. Measure the commutator undercut depth in 5places around the commutator.

• If any one of the measurements is less than the minimum undercut depth specified in

Service

Limits

above, then the commutator must be undercut. Refer to

Repair Commutator

section for information regarding undercutting the commutator.

Undercut

Armature Hacksaw blade

Incorrect

Correct

Insulation

Min. OD

Commutator

4. Inspect the commutator for grooves.

• If the commutator is groved then it must be machined on a lathe. Do not machine the commutator past the minimum diameter specified in


section. Refer to

Repair Commutator

section for information regarding machining the commutator.

Motor

Page 3

Motor Service

5. Inspect the commutator for burn marks.

• Burn marks and/or raised commutator segments

90 or 180 degrees apart is evidence of a shorted armature. A tool called a growler is required to reliably test for a shorted armature.

Typical burn mark on a shorted armature

6. Inspect the commutator for raised segments.

Raised segments could be a result of a stalled motor or shorted armature. A tool called a growler is required to reliably test for a shorted armature.

• If the armature is not shorted then the raised segments can be removed by machining the commutator. Do not machine the commutator past the minimum diameter specified in


section. Refer to

Repair

Commutator

section for information regarding machining the commutator.

7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted armature.

• If the insulation is cracked or burnt, then it is recommend that the armature or motor be replaced.

NOTE: If the armature has been burnt then there is a good possibility that the field windings may also be burnt. Symptoms indicating a shorted field include high motor current, lack of power and possibly excessive speed.

8. Using a growler, test the armature for shorts.

• If the armature is shorted, then we recommend that the armature or motor be replaced.

9. Using the continuity function of digital multi meter, check the continuity around the entire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time.

There should be continuity around the entire commutator. If any segment indicates an open circuit, then the motor must be replaced.

10. Using the continuity function of digital multi meter, check the continuity from any one of the

Motor

Page 4 commutator segments and the armature frame. If it is not an open circuit, then the armature is shorted and the motor must be replaced.

11. Rotate the motor bearing(s) by hand.

• The bearing should not ‘freewheel’ but should come to a smooth stop when rapidly spun by hand. If the bearing freewheels, then grease is no longer present in the bearing and it must be replaced. Refer to

Replacing the Bearings

section for information regarding replacing the armature bearings.

• Feel for any roughness when the bearing is rotated. If any roughness or grinding is noticed then the bearing must be replaced. Refer to

Replacing the Bearings

section for information regarding replacing the armature bearings.

Assembly

NOTE: If this is an enclosed motor on a vehicle with a Power Traction primary reduction, then it is recommended to replace the armature shaft seal any time the motor is disassembled.

1. Push the motor brushes just far enough out of the brush holder so that the brush springs hold them in place away from the commutator. See the illustration to the right.

2. Install the rear motor housing to the stator housing.

3. Lightly grease the outside diameter of the armature bearings.

4. Insert the armature through the stator housing and seat the bearing into the rear housing.

5. If equipped with armature retaining screws, install and tighten them at this time.

6. If this is an enclosed motor, lightly grease the armature shaft seal and install the front motor housing.

NOTE: If the vehicle is equipped with a belt type primary reduction then the spring on the motor seal should be removed. Failure to remove the spring may result in a high pitched squeal from the seal.

7. Push the motor brushes into the brush holder until the brush spring snaps into place. Be certain that the spring does not rest up against the brush wire.

See the illustrations below.

Motor Service

Brush Spring Orientation

REPLACING THE BRUSHES

NOTE: It is recommended that all four brushes be replaced as a set.

NOTE: Motors without removable brush covers must be disassembled to replace the brushes.

Refer to Motor Inspection-Disassembly

section for information on taking the motor apart.

NOTE: Some motors are equipped with brush pairs.

These motors must be disassembled to replace the brushes. Refer to

Motor

Inspection-Disassembly

section for information on taking the motor apart. Refer to the

Motor Parts List

for your vehicles brush configuration.

NOTE: Some motors have brush leads that are routed through or behind the brush holder assembly.

In this case, the brush holder assembly must be removed to replace the brushes.

NOTE: The motor must be removed from the vehicle for this procedure. Refer to

Transmission

Service

section for information on removing the motor.

3. Install the new brushes in reverse order.

4. Be certain that the brush springs do not rest up against the brush wires. Refer to illustrations in

Motor Inspection-Assembly

for proper brush spring position.

Motors with brush pairs or not equipped with brush covers

1. Disassemble the motor. Refer to Motor

Inspection-Disassembly section for information on taking the motor apart.

2. Remove the brush holder.

Note: Remember the position and routing of the brush crossover leads. They must be reinstalled in the same position.

3. Remove the brush termination screws or the armature studs and remove the brushes from the brush holder.

4. Install the new brushes in reverse order.

5. Reassemble the motor. Refer to

Motor

Inspection-Assembly

for information regarding reassembling the motor.

Motors with brush covers and brushes with termination screws

1. Remove the brush covers.

2. Loosen the brush wire retaining screw and remove the brush from the brush holder. Be careful with the brush spring and do not let it slip off of the spring mount. If the spring comes off, then the motor must be disassembled. Refer to

Motor

Inspection-Disassembly

section for information on taking the motor apart.

Motor

Page 5

Motor Service

REPLACING THE BEARINGS

1. The motor must be removed from the vehicle for this procedure. Refer to Transmission Service section for information on removing the motor.

2. Remove the armature. Refer to Motor Inspection-

Disassembly section for information on taking the motor apart.

3. Press the armature bearing(s) off of the armature shaft.

6. Measure the commutator undercut depth in 5places around the commutator. If any one of the measurements is less than the minimum undercut depth specified in


, then the commutator must be undercut.

Do not press against the outer race of the bearing. Pressing against the outer race will damage the bearing and may result in premature failure of the bearing. See the illustration below

Example of freshly cut commutator

7. While still in the lathe, smooth the commutator with fine emery cloth.

4. Press new bearing(s) onto the shaft.

5. Reassemble the motor.

REPAIRING THE COMMUTATOR

1. The motor must be removed from the vehicle for this procedure. Refer to

Transmission Service

section for information on removing the motor.

2. The armature must be removed from the motor for this procedure. Refer to

Motor Inspection-

Disassembly section for information on taking the motor apart.

3. Using a lathe, cut the armature just enough to remove all grooves, depressions or ridges.

4. Measure the diameter of the commutator. If the commutator is less than the minimum diameter specified in


, then the motor must be replaced.

5. Thoroughly clean all copper debris from between the commutator segments.

Motor

Page 6

Undercutting the commutator

1. Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer to undercut depth in Service Limits.

2. Once all segments have been properly undercut, mount the armature in a lathe and smooth the commutator with fine emery cloth.

3. Inspect the armature for shorts. Refer to Motor

Inspection section for information on testing the armature.

NOTE: Copper debris in the undercut area can give a reading of a shorted armature.

Properly undercut and cleaned commutator segments

Motor Service

SERVICE LIMITS

Motor Specification

Number

5BC58JBS6129A

5BC58JBS6129B

5BC58JBS6129C

5BC49JB399C

5BC58JBS6110C

Undercut Depth mm

0.635

0.635

0.635

0.635

0.635

inches

0.025

0.025

0.025

0.025

0.025

Commutator Diameter

(min) mm

66.75

66.75

66.75

78.97

78.97

inches

2.625

2.625

2.625

3.109

3.109

Brush Length

(min)

-

mm

-

19.05

19.05

inches

-

-

-

0.75

0.75

Wire Depth

(max) mm

38.1

38.1

38.1

-

inches

1.5

1.5

1.5

-

-

Motor

Page 7


Adjust the Drive Chain ....................... 2

Check the Oil Level ........................... 3

Change the Oil ................................... 3

Drive Motor ........................................ 4

Remove .............................................................. 4

Install ................................................................. 4

Rear Axle ........................................... 5

Remove and Install ............................................. 5

Replace the Axle Bearing ................................... 5

Transmission Assembly ..................... 6

Remove and Install ............................................. 6

Chain Case ........................................ 7

Disassemble ....................................................... 7

Assemble ........................................................... 7

Differential Assembly (3rd Member) .. 9

Disassemble ....................................................... 9

Assemble ........................................................... 10

Re-shimming the Pinion Housing ...... 12

Exploded View ................................... 13

Typical Transmission Assembly


ADJUST THE DRIVE CHAIN

NOTE: A small amount of oil may come out when the drive motor mounting bolts are loosened.

Tie the vehicle to an immovable object to prevent the vehicle from moving in forward or reverse. Failure to securely tie the vehicle may result in unexpected vehicle movement resulting in severe bodily injury or property damage.






10. Tie the vehicle in place so that it cannot move.

11. Reconnect the batteries.

Rotating parts, keep hands and loose clothing clear of all moving parts. Failure to keep clear of moving parts may result in severe bodily injury and/or property damage.

6. Place a small oil drain pan under the chain case.

7. Loosen but do not remove the three drive motor mounting nuts.

8. Loosen the chain adjuster jam nut.

12. Close all safety interlock switches, turn the key

On, place the forward-off-reverse switch in forward and fully depress the accelerator pedal.

13. Tighten or loosen the adjustment screw to obtain the minimum noise level.

NOTE: If there is less than 1/16” of threads left on the adjustment screw (see illustration) then the drive chain has stretched beyond service limits and should be replaced. Refer to section

Chain Case

for information regarding replacing the drive chain.


9. Raise the drive wheels off of the ground.

14. Release the accelerator pedal, place the forwardoff-reverse switch in off, turn the key off and disconnect the batteries.

15. Untie the vehicle.

16. Tighten the adjustment screw jam nut and motor mounting nuts.

17. Wipe off any oil that may have come from behind the motor.

18. Lower the drive wheels to the ground.

19. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels, and test drive.

F2/F3 Transmission

Page 2

CHECK THE OIL LEVEL

NOTE: The oil level in the chain case is maintained by the transmission. Oil is pumped from the

3rd member into the chain case housing. It is not necessary to check the oil level in the chain case.


CHANGE THE OIL

Wear protective gloves when working with petroleum lubricants. Repeated contact with petroleum lubricants can result in skin disorders.











6. Park the vehicle on a level surface.

7. Place a small oil drain pan under the drive housing.

8. Remove the drive housing level plug.

9. A small amount of oil should come out. This indicates the correct oil level.

NOTE: If a large amount of oil comes out, then let it drain to the proper level and replace the level plug.

If no oil comes out, then fill the drive to the proper level and replace the level plug.

6. Place a large drain pan under the chain housing.

7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

8. Place the drain pan under the drive housing.

9. Remove the drive housing drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

10. Remove the chain case fill plug and add 1-pint of oil.

11. Remove the drive housing fill plug and add 2quarts of oil.

NOTE: Refer to the Lubrication Chart for information

regarding the type of oil.

12. Replace all fill plugs.

NOTE: Dispose of waste oil in accordance with your local regulations.


Typical location of oil plugs. The actual location of the level plug will vary depending on your vehicles configuration.

F2/F3 Transmission

Page 3


DRIVE MOTOR

Remove

NOTE: In most cases it is not necessary to disassemble the chain case to remove the motor. If you find it necessary to disassemble

the chain case, refer to Transmission

section for information regarding disassembly of the chain case.

3. Install the motor mounting hardware but do not tighten until the chain adjustment is complete.

4. Adjust the drive chain. Refer to

Adjust the Drive

Chain

for information regarding adjusting the drive chain.

5. Connect the motor wires.







6. Remove the four motor wires.

7. Loosen the drive chain adjusting screw.

8. Remove the hardware holding the motor to the chain case backing plate.

9. Lift the rear of the motor and rotate the motor so that the motor mounting plate clears the two threaded studs on the chain case backing plate and remove the motor from the drive.

Install

Chain tied with mechanics wire

Do not allow the wheels to rotate after the motor has been removed. Allowing the wheels to rotate may result in the drive chain getting bound up with the drive sprocket, locking up the transmission.

Should this happen, the chain may have to

1. Tie the chain up in position with mechanics wire as shown.

2. Slip the motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove wire(s) holding the chain.

F2/F3 Transmission

Page 4

REAR AXLE

Remove and Install







Replace the Axle Bearing

NOTE: The axle must be removed from the vehicle to replace the axle bearing. Refer to section

Rear Axle: Remove and Install for

information regarding removing the axle.

NOTE: A 10-ton press is required to replace the axle bearing.

NOTE: The axle bearing will be damaged when it is removed.

The axle bearing retainer will be damaged when it is removed. Do not reuse the axle bearing retainer. Reinstalling the original bearing retainer may result in the axle falling out of the transmission resulting in severe bodily injury or property damage.


6. Raise the drive wheel off of the ground.

7. Remove the wheel assembly.

8. Place a small oil drain pan under the end of the axle housing.

9. Remove the four axle retaining bolts. Secure the brake body assembly, do not let it hang by the brake hose.

10. Using a slide hammer, remove the axle from the axle housing.

11. Remove the bearing gasket and axle seal from the housing.

12. Install the axle in reverse order using a new gasket and seal.


Old axle bearings may explode while being removed. Place a cage around the axle bearing that will contain all debris if the bearing explodes. Failure to place a cage around the axle bearing could result in severe bodily injury or property damage.

1. Place the axle in a press and remove the bearing and bearing retainer.

2. Lightly lubricate the axle shaft.

3. Install a new bearing and bearing retainer and press into place.

NOTE: Some axle configurations have an o-ring around the axle bearing. The bearing should be orientated so that the o-ring is farthest away from the axle hub. See the illustration below.

F2/F3 Transmission

Page 5


TRANSMISSION ASSEMBLY

Remove and Install






6. If equipped with a built in charger, remove the charger.

7. Remove the motor wires.

8. Disconnect the brake cable from the brake arm at the brake band.

9. Remove the four nuts from the bolts holding the transmission assembly to the frame. DO NOT remove the bolts at this time.

10. Place two jack stands under the front bumper. They should be located at each corner of the frame (see illustration).


11. Lift the rear of the vehicle just enough to allow the removal of the transmission mounting bolts and remove the bolts.

12. Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle and support the rear of the vehicle with jack stands.

13. Install in reverse order.

14. Check brake adjustment and adjust as needed.

Refer to

Adjust the Brakes

in the

Brake

Service

section for information regarding adjusting the brakes.


F2/F3 Transmission

Page 6

DO NOT place jack stands where the bumper is curved.


CHAIN CASE

NOTE: Some vehicle configurations may require that the transmission be removed to disassemble the chain case. Refer to section


for information on removing the transmission.

Disassemble






6. Place an oil drain pan under the chain case.

7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

8. Remove the brake drum. Refer to section

Brakes: Replace the Brake Drum

for information regarding removing the brake drum.

9. Remove the nuts from the three threaded studs at the small end of the chain case housing.

10. Remove the chain case housing bolts, brake assembly, and alignment brackets.

11. Remove the chain case housing from the backing plate.

12. Remove the pinion seal from the chain case housing.

13. Loosen the motor mounting bolts.

14. Loosen the chain adjuster.

15. Remove the drive chain, motor nut and sprocket and the drive sprocket.

16. If the backing plate must be removed from the

3rd member, first remove the motor from the backing plate then remove the backing plate from the 3rd member.

Typical Chain Case

Assemble

1. Thoroughly clean all gasket surfaces.

2. Apply a 1/8” bead of 94-430-03 gasket sealer to the face of the 3rd member.

3. Install the backing plate to the 3rd member. Torque to 30-45 ft-lbs.

4. Install the motor to the backing plate. Do not fully tighten the motor mounting hardware at this time.

5. Install the motor sprocket, drive sprocket and chain. Do not adjust the chain tension at this time.

6. Apply a 1/8” bead of 94-430-03 gasket sealer to the chain case housing.

Apply sealer around the ID of the holes

7. Install the chain case centering tool (refer to

Appendix A) into the pinion seal bore in the chain case housing.

F2/F3 Transmission

Page 7


Motor

Woodruf Key

Adjusting screw

Nut

3rd Member

Washer

Mounting Plate

Nut

Backing Plate

Bolt

O-Ring

Motor Sprocket

Nut

Spacer

Drive Sprocket

Drive Chain

24

Bolt

Washer

Nut

Chain Case Housing

Bolt

Drain Plug

Pinion Seal

Brake Assembly

8. Install the chain case housing onto the pinion shaft and tighten the pinion nut to 75 ft-lbs.

Pinion Nut

10. Remove the centering tool and install a new pinion seal. Lightly lubricate the pinion seal lip.

9. Install and tighten the three nuts and washers to the threaded studs and the housing bolts that are not used for the brake mounting bracket or alignment brackets.

11. Install the brake assembly and the brake band alignment bracket(s). Do not tighten the bolts at this time.

12. Install the brake drum. Torque to 175 ft-lbs.

13. Tighten the brake adjusting bolt to 25 ft-lbs.

14. Tighten the brake assembly mounting bolts.

15. Adjust the brake. Refer to section

Brake

Service: Adjust the Brakes

for information regarding adjusting the brakes.

16. Adjust the drive chain. Refer to section

Adjust the Drive Chain

for information regarding adjusting the drive chain.

F2/F3 Transmission

Page 8

DIFFERENTIAL ASSEMBLY (3

MEMBER)

Disassemble

RD

NOTE: Bearings and races must be replaced as a set. If any one bearing or race is worn, its mate must also be replaced. It is recommended to replace all bearings and races in the 3rd member as a set.

1. Drain the oil from the differential housing and chain case. Refer to section

Change the Oil

for information regarding draining the oil.

2. Remove the transmission assembly from the vehicle. Refer to

Transmission Assembly:

Remove and Install

for information regarding removing the transmission.

3. Remove both rear axle assemblies. Refer to section

Rear Axle: Remove and Install

for information regarding removing the axles.

4. Remove the chain case and backing plate from the 3rd member. Refer to section

Chain Case:

Disassemble

for information regarding removing the chain case.

5. Remove the nuts holding the 3rd member to the axle housing and remove the 3rd member from the housing.

6. Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened.

Measuring backlash


7. While rotating the pinion shaft, tighten the pinion nut to 100 ft-lbs.

8. Measure and record the ring and pinion gear backlash. This setting will be used during reassembly.

9. Remove the pinion housing and pinion gear from the 3rd member.

NOTE: Do not lose the spacers and shims in the pinion housing or the pinion housing shim(s).

10. If required, remove the rear tapered bearing from the pinion shaft and discard.

NOTE: Do not remove the bearing unless it requires replacement. Removing the rear bearing will damage the bearing. Replacing this bearing will require re-shimming of the pinion shaft.

11. If required, remove the bearing races from the pinion housing.

12. Mark the differential bearing caps and 3rd member housing so that they can be reassembled in their original location. Refer to illustration at end of section.

NOTE: The caps cannot be interchanged or replaced.

If the caps are lost or damaged then the entire

3rd member assembly must be replaced.

13. Remove the differential bearing caps, bearing adjusting nuts and races.

14. Remove the differential assembly from the 3rd member.

15. Mark the ring gear and differential housing so that the ring gear can be reinstalled in the same orientation.

16. Remove the bearings from the differential housing and discard.

NOTE: Removing the bearings will damage the bearings. Do not remove the bearings unless they require replacement.

17. Remove the ring gear from the differential housing.

18. Remove the differential shaft locking roll pin.

19. Split the 2-piece differential housing.

20. Drive the differential pinion shaft out of the housing with a brass drift punch.

21. Remove the differential gears, axle gears, and thrust washers.

F2/F3 Transmission

Page 9


Assemble

NOTE: Thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly.

NOTE: Depending on your vehicle config-uration, the rear pinion pilot bearing is not required and may not be installed.

NOTE: If the ring and pinion gear set is to be replaced then the shims for the pinion housing may have to be adjusted. Refer to section

Selecting the Pinion Housing Shim

for information on adjusting the shim.

NOTE: Most of our gear sets are non-hunting or semihunting gears. With this type of gear the pinion and ring gears must be aligned correctly. There will be two teeth marked on the ring gear and one tooth marked on the pinion gear. The one tooth on the pinion gear must be installed so that it is between the two teeth on the ring gear. The gear ratios are; 2.50, 2.70, 2.75, 3.25 and 3.00.

Pinion housing

1. If the rear pinion bearing was removed, install a new bearing.

2. Install the bearing races into the pinion housing.

3. Place the pinion gear into the 3rd member.

4. Install the pinion housing onto the 3rd member.

5. Install the pinion bearing spacers, shims and front bearing.

6. Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened.

7. While rotating the pinion shaft, tighten the pinion nut to 100 ft-lbs.

8. Check the torque required to rotate the shaft. If the torque is not between 6 -10 in-lbs. then the bearings must be re-shimmed. Add or subtract shims as required until the torque is within specifications.

Differential Assembly

9. Reassemble the differential housing in reverse order.

10. Place the ring gear onto the differential housing matching the mark made during disassembly.

11. Install two of the ring gear bolts finger tight to align the gear.

12. Press the ring gear onto the differential housing.

13. Install the ring gear bolts and cross tighten to 65-

80 ft-lbs.

14. If the differential bearings were removed, install new bearings.

15. Place races onto the differential bearings and place the differential assembly onto the 3rd member.

Position the assembly so that it is just touching the pinion gear.

16. Install the bearing adjusting nuts making sure that the nuts are not cross threaded. Position the nuts so they are in contact with the bearing races.

F2/F3 Transmission

Page 10

Cross threading the nuts will damage the

3rd member housing and bearing caps. If the housing and/or nuts are damaged, the entire 3rd member assembly may have to be replaced.

17. Install the bearing caps in their original locations and torque the bolts to 12-15 ft-lbs. making sure that the adjusting nuts still turn freely.

NOTE: In the following procedure, "Left adjusting nut" refers to the nut on the ring gear side of the differential assembly. "Right adjusting nut" refers to the nut on the pinion gear side of the differential assembly.

The differential bearing preload is set by measuring the case spread of the 3rd member housing. As the bearing adjusting nuts are tightened, the two differential bearing caps will be pushed (spread) away from each other. A dial indicator must be used to measure the case spread as the nuts are tightened. Mount the dial indicator so that it is 4 inches above the top of the bearing caps and parallel to the center line of the carrier bearings.


NOTE: Be sure to continually rotate the ring gear while adjusting the bearings. This makes sure that the bearings and races remain seated correctly.

NOTE: One hole on adjusting nut = approximately

0.003" change in backlash. Left and right nuts

MUST be turned the same amount AND in the same direction. The final direction of rotation MUST be in the tightening direction, to loosen a nut 1-hole, back off 2-holes and then tighten 1 hole. The ring gear should be rotated any time the nuts are being adjusted.

18. Loosen the right side nut.

19. Tighten the left nut until all backlash is removed from the ring and pinion gear.

20. Tighten the right nut until a case spread of 0.010” is indicated on the dial indicator.

NOTE: If new ring and pinion gears are used, refer to the recommended backlash that is supplied with the gear set

21. Measure the backlash. If the backlash is not within

0.002” of the original measurement taken on disassembly or the recommended setting for new gears, then readjust the bearings as follows:

To increase backlash, loosen the left spanner nut and then tighten the right spanner nut the same amount.

To decrease backlash, loosen the right spanner nut and then tighten the left spanner nut the same amount.

22. Apply gear marking compound on both sides of 7 to 10 teeth on the ring gear.

23. While applying resistance to the pinion shaft, rotate the ring gear back and forth (not full revolutions) until a clear contact pattern is shown. Compare the contact pattern to the illustration on the following page and reshim the pinion housing or adjust the backlash as indicated on the illustration

. If the pinion housing is reshimed the backlash must be reset. Go back and repeat ALL procedures in setting the backlash.

24. Tighten the bearing cap bolts to 70-85 ft/lbs (F2 drive), 55-70 ft/lbs (F3 drive) and install the spanner nut locks. Tighten the spanner nut lock bolts to 12-25 ft/lbs.

NOTE: Final pinion nut torque on completely assembled drive, 175 ft/lbs.

F2/F3 Transmission

Page 11


RE-SHIMMING THE PINION HOUSING

The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced.

Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear. It should be a number ranging from -5 to +5. This is the amount in 0.001” increments to add to the “standard” shim. For example, if the number on the shaft is ‘-3’ then the standard shim (0.015) plus ‘-3’ equals 0.012. The correct shim would be 0.012”.

If you cannot locate the number on the shaft, start with the standard shim and adjust as required per the contact pattern chart below.

F2/F3 Transmission

Page 12

EXPLODED VIEW


F2/F3 Transmission

Page 13


Tire Inflation ....................................... 2

Tire Inspection ................................... 2

Replace the Front Tire/Wheel ............ 3

Replace the Rear Tire/Wheel ............ 3

Replace the Tire (pneumatic) ........... 3

Repair the Tire (pneumatic) .............. 4


TIRE INFLATION






TIRE INSPECTION

6. Check the tire pressure. Refer to Tire Inflation section for information on checking the tire pressure.

7. Inspect the tire tread depth. Minimum recommended tread depth is 1/16-inch. There are a series of tread depth wear indicators around the circumference of the tire. They will appear as

1/2-inch bands across the tread as the tire approaches its wear limit (see illustration below).

Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1/16inch or less. Refer to Replace the Tire section for information regarding replacing the tire.

There are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires.

The illustration to the right is an example of the side wall information on a tire.

Tire pressures must be checked when the tire is cold.

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.

9. Inspect the inner and outer side walls for cracks.

If any cracks are seen, then the tire should be replaced. Refer to Replace the Tire section for information regarding replacing the tire.

10. Inspect the valve stem for cracks. If any cracks are seen, then the valve stem should be replaced.

It is also recommended that the valve stem be replaced whenever the tire is replaced.

NOTE: Refer to Replace the Tire section for

information regarding replacing the valve stem.

11. Inspect the tread and side walls for debris in the rubber that could lead to a puncture. If any debris is found it should be removed and the tire inspected for a leak.

Tires and Wheels

Page 2


REPLACE THE FRONT TIRE/

WHEEL

Refer to

Front Axle Service

for information on removing the front wheel.

REPLACE THE TIRE

(PNEUMATIC)

NOTE; To replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to

Replace the Tire/Wheel

section for information on removing the tire/wheel assembly.

Tire replacement should only be performed by personnel trained in tire replacement.

The tire replacement procedure will be unique to the type of replacement equipment being used. Refer to the instructions provided with your equipment.

Always use a new valve stem when replacing a tire.

REPLACE THE REAR TIRE/

WHEEL

Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel. Do not over inflate the tire when seating the bead. Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death.






6. Raise the wheel to be replaced off of the ground and support with jack stands.

7. Remove the 4 or 5 wheel nuts and remove the wheel.

8. Install in reverse order.

9. Following the pattern shown on the following page, cross tighten the wheel nuts in two stages as follows:

1st stage to approximately 20 ft-lbs.

2nd stage to 80-90 ft-lbs.


11. Lower the wheel to the ground.



1. Remove the tire from the wheel.

2. Cut the old valve stem off of the wheel.

3. Remove the valve stem cap from the new valve stem.

4. Lubricate the valve stem with liquid soap.

5. Install a new valve stem using a valve stem tool.

NOTE: The valve stem tool is available at most auto repair shops.

6. Install the tire onto the wheel following the instructions provided with your tire replacement equipment.

7. Inflate the tire to the proper pressure and check for leaks.

8. Install the valve stem cap.

Tires and Wheels

Page 3


1

4

3

2

4-Bolt Pattern

1

3

4

5

2

5-Bolt Pattern

Pattern for tightening the wheel nuts

3

8

1

5

6

2

7

4

8-Bolt Pattern

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.

REPAIR THE TIRE (PNEUMATIC)

Do not attempt to repair a tire with a damaged side wall or a slice in the tread. This type of repair could fail prematurely resulting in severe bodily injury and/or property damage.

NOTE: To properly repair a puncture, the tire must be removed from the wheel. Refer to Replace the

Tire section for information on removing the tire from the wheel.

It is recommended to repair a tire with a combination vulcanized plug and internal patch.

Tire repairs should only be performed by personnel trained in tire repair.

The tire repair procedure will be unique to the type of repair equipment or repair components used. Refer to the instructions provided with your equipment or repair components.

Tires and Wheels

Page 4


Cleaning ............................................. 2

Testing ................................................ 3

Charging ............................................. 4

Watering ............................................. 5

Replacing (6-volt batteries only) ........ 6

Moist Charge Batteries ....................................... 7

Storage and Returning to Service ..... 8

Storage ............................................................... 8

Returning to Service ........................................... 9


CLEANING








6. Dry dirt can be readily blown off with low-pressure air or brushed off.

7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with flexible bristles, wash the batteries off with a strong solution of baking soda and hot water (1 lb. of soda to a gallon of water). Continue until all fizzing stops, which indicates that the acid has been neutralized.

Then rinse thoroughly with clear water. DO NOT get any of the solution into the battery cells.

8. Reconnect the batteries, remove the blocks from the wheels and test drive.

A battery is a live electrical source. It cannot be disconnected or neutralized. Do not drop any tool or conductive object onto the battery. A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery. This could cause the battery to explode resulting in severe bodily injury and/or property damage.

Battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage.

Batteries

Page 2


TESTING










NOTE: A combination of the Load Test and Specific

Gravity Test should be used to accurately determine the condition of the batteries.

Load Test (6-volt batteries only)

NOTE: The batteries must be fully charged before performing this test.

1. Clean the batteries. Refer to

Cleaning the

Batteries

section for information on cleaning the batteries.

2. Load test each battery using a battery load test meter (available at most auto parts distributors).

Follow the instructions provided with the test meter.

• If any battery fails the load test, then it should be replaced.

NOTE: If the batteries are over one year old, it is recommended to replace them as a set.

• If all batteries fail the test you should check the charging system before replacing the batteries. Refer to

Charger Troubleshooting section for information on checking the charging system.

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). A discharged battery will read 1100. Ideally, all cells in a battery pack will have the same reading.

Any cells in a battery pack that vary by more than 30points may be an indication of a bad cell.

Batteries

Page 3


Clean the batteries. Refer to

Cleaning the Batteries

section for information on cleaning the batteries.

Using part number 77-200-00 hydrometer, check and record the specific gravity of each cell in the battery pack.

If, after charging, none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system. If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced.

NOTE: Refer to Charger Troubleshooting for

information on checking the charging system.

The highest reading will be the cell that is accepting the most charge. This reading will be used to gauge all other cells.

Compare the specific gravity readings to the highest reading, if the difference between any of the cells is more than 30-points, then that battery should be replaced.


Reconnect the batteries, remove the blocks from the wheels and test drive.

Typical Hydrometer Float

CHARGING

Refer to

Charging Your Vehicle

in section

Safety

Rules and Operating Instructions

.

Batteries

Page 4


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.

6. Clean the batteries. Refer to Cleaning the

Batteries section for information on cleaning the batteries.

7. Check the electrolyte level in all battery cells. If low, fill to the correct level with distilled water using part number 77-201-00 battery filler, never add additional battery electrolyte to the batteries.

8. Reconnect the batteries, remove the blocks from the wheels and test drive.


Do not overfill the batteries. Over filling the batteries may cause the battery electrolyte to boil out of the battery and result in severe bodily injury or property damage.

Batteries

Page 5


REPLACING (6-VOLT BATTERIES ONLY)









6. Thoroughly clean the batteries and battery compartment. Refer to

Cleaning

in this section for information regarding cleaning the batteries.

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.



Do not leave cables on batteries that have been removed from the vehicle. Cables left on batteries could cause a short circuit resulting in battery explosion, severe bodily injury and/or property damage.

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.

10. Remove the batteries from the vehicle.

11. Inspect the battery compartment for signs of corrosion.

12. If minimal signs of corrosion are seen, then the damaged paint should be stripped off and the entire battery compartment prepped and repainted.

13. If there are excessive signs of corrosion, then it may be necessary to replace some of the frame members or completely rebuild the battery compartment.

14. Inspect the main positive and negative cables and terminals, charger cables and terminals and 12volt tap wiring. If any of the terminals or wires show signs of corrosion, then they must be repaired or replaced.

Batteries

Page 6


15. Install the batteries in reverse order. Refer to the

Illustrated Parts List for battery cable routing.

16. It is recommended to replace the battery terminal hardware when replacing the batteries.


When torquing battery hardware, use a backup wrench on the battery bolt and tighten the nut. Failure to use a backup wrench may damage the battery post.

17. Torque the terminal hardware to 7-8 ft.-lbs.

18. Tighten the hold downs so that the batteries are secure but not so tight as to deform the batteries.

19. Remove the blocks from the wheels and test drive.


Moist Charge Batteries

Moist charged batteries are shipped without battery electrolyte. This allows for a much greater shelf life of the battery. Moist charged batteries must be filled with electrolyte and charged before putting into service.

Battery electrolyte is a solution of acid and water that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries.

Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and charged. Operating or charging moist charged batteries before filling and charging will damage the batteries resulting in premature failure of the batteries.







6. Fill all battery cells with electrolyte to the proper level.

7. Thoroughly clean any spilled electrolyte from the batteries or the ground. Refer to

Cleaning the

Batteries

for information on cleaning the batteries.

8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.

9. Remove the blocks from the wheels and test drive.

The batteries are now ready to be put into service.

Batteries

Page 7


STORAGE AND RETURNING TO SERVICE









If the batteries are removed from the vehicle, do not place them directly on the ground, concrete or solid metal surface. It is recommended to store them on a wooden pallet or equivalent. Storing on the ground, concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries.

Storage

Thoroughly clean the batteries and battery compartment.

Refer to

Cleaning

in this section for information regarding cleaning the batteries.

Check the electrolyte level and charge the batteries.

Refer to

Watering

in this section for information regarding checking the electrolyte level.

Store the vehicle or batteries in a cool, dry, well ventilated area.

If storing for more than one month, the batteries should be charged as follows:


Storage

Temperature

(F)

Over 60

Between 40 and 60

Below 40

Charging Interval

(months)

1

2

6

Batteries

Page 8


Returning to Service






6. Thoroughly clean the batteries and battery compartment. Refer to Cleaning in this section for information regarding cleaning the batteries.

7. Check the electrolyte level and charge the batteries. Refer to Watering in this section for information regarding checking the electrolyte level.

8. Test the batteries. Refer to Testing section for information on testing the batteries.

9. The batteries are now ready to be put back into service.

Batteries

Page 9

Table of Contents

Symptoms: ............................................2

Main Troubleshooting Sequence ..........3

Test Equipment Required: ................................................... 3

IMPORTANT NOTES and INSTRUCTIONS .................... 3

Definitions: ......................................................................... 4

REV B


Solenoids

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 Special Troubleshooting in Section 4 at the end of the main troubleshooting sequence.

• Runs slow in both directions plus high armature and field current in both directions. NOTE:

Armature and field current should be equal.

•

Runs slow in both directions plus high armature current in both directions. NOTE: Field current will be very low.

•

Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or;

•

Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only. NOTE: Field current will be very low in the opposite direction.

•

Accelerates slowly and exceeds normal speed in both directions plus high armature current.

NOTE: Field current will be very low.

•

Full speed only.

• Does not run in either direction plus there is noise from motor (hum or whine) with high field current and low armature current.

•

Jumps into high speed when direction is selected after depressing the accelerator pedal.

Excessive spark when connecting battery

•

Does not run or runs very slow with low motor current and high battery current.

•


If your vehicle does not exhibits any of the above symptoms then continue with the main troubleshooting sequence on the following pages.

Main Sequence Page 2


MAIN TROUBLESHOOTING SEQUENCE

Test Equipment Required:

•

Digital multimeter (DMM) with diode test function, FLUKE 79 model used in illustrations.

•

Shunt or clamp-on DC Ammeter to measure up to 400 amps.

•

Test light with a rated voltage equal to or exceeds maximum battery voltage or Taylor-

Dunn test light part number #62-027-00 for systems up to 48 volts.

•

Test harness, Taylor-Dunn #62-027-31. This troubleshooting guide assumes that the vehicle is wired correctly. It is not intended to diagnose a vehicle that is not wired correctly.

•

These tools are available through your local Taylor-Dunn parts distributor.

IMPORTANT NOTES and INSTRUCTIONS

•

This troubleshooting guide assumes that the vehicle is wired correctly. It is not intended to diagnose a vehicle that is not wired correctly.

•

This troubleshooting guide is not written to be able to locate a problem if there are multiple component failures.

•

This troubleshooting guide assumes the batteries are good. Charge and test the batteries before troubleshooting the control system.

•

DO NOT start in the middle of this troubleshooting guide. Start at the beginning and complete each test in the order that they are written. Do not skip any test unless instructed to do so. Once a problem is found, stop testing and repair the indicated problem. When the repair is completed it is recommended that the control system be retested before lowering the drive wheels to the ground.

These test procedures must be performed in the order they were written. If the test result is good, then proceed to the next test or go to the next section. Failure to do so may result in incorrect test results.

•

This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Accelerator Module Test Harness. Troubleshooting CANNOT be completed without these tools.



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” = Forward and Reverse.

•

“ISO” = Isolator.

•

“Battery negative” = Main negative battery post.

•

“Battery positive” = Main positive battery post.

•

“PMC” = Speed control module (black box).

•

“HOT terminal” = The side of a switch or solenoid that is connect to the power source.

•

“COLD terminal” = The side of a switch or solenoid that power is switched to.

DURING ALL TESTS

After any repairs are made, completely retest the vehicle before lowering the drive wheels to the ground. Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and/or property damage.

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.

Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and loose clothing away from the rear drive wheels while conducting tests. Failure to do so may cause serious bodily injury.

Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause severe bodily injury and/or property damage.

START:

Read all warnings above before continuing.

If the vehicle runs normal in one direction but does not run in the opposite direction then go to the Solenoids sequence.

If none of the three solenoids pick up (click) when the accelerator pedal is depressed then go to the Forward & Reverse Switch sequence.



Power Output Test








Set the test light voltage to the same voltage as the battery volts.

Connect the test light from the PMC ‘M-’ Terminal to battery positive.

Close all interlock switches, turn the Key Switch

ON, and place the F&R Switch in Forward.

Depress the accelerator pedal fully.

•

If the light comes ON then go to the Motor sequence.

•

If the light does not come ON then continue with the next test.

Test Light

Main Battery Positive

Face of Controller

KSI

#2

B-

M-

B+

A2



Control Wire inputs Test








Connect a voltmeter across the Solenoid

Negative Buss Bar and battery positive.

•

If the voltage is not at battery volts then check the wiring to battery negative and the negative circuit breaker. 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.

The voltage shown is for illustration only. The actual voltage may vary.

Solenoids are shown for reference only. The type of solenoid in your truck may look different

Main Battery

Positive

+

_

FWD REV

ISO

Connect a voltmeter across the ISO solenoid coil terminals.

Close all interlock switches and turn the

Key Switch ON.

Depress the accelerator pedal to engage

MS-1 only.

• If the voltage is not at battery volts then go to the Key Switch sequence.

• If the voltage is at battery volts and the

ISO solenoid does not pick up (click) then the ISO solenoid has failed. Stop trouble shooting here and repair the problem.



Solenoids are shown for reference only. The type of solenoid in your truck may look different

+

_

FWD

REV ISO



Control Wire inputs (continued)

Connect a voltmeter across the PMC #2 terminal and battery negative.

Close all interlock switches, turn the Key Switch

ON, and place the F&R Switch in Forward.


MS-1 only.

•

If the voltage is not between 6.0 and 6.5

volts then go to the Accelerator sequence.

Depress the pedal fully.

•

If the voltage is not between 11.0 and

11.5 volts then go to the Accelerator sequence.

Connect voltmeter across the PMC KSI terminal and battery negative.

With the pedal still fully depressed:

•

If the voltage is not at battery volts then go to the Key Switch sequence.

•

If the voltage is at battery volts then continue with the next test.

+

_

Main Battery

Negative


KSI

#2

B-

M-

B+

A2

FLUKE 79 SERIES II MULTIMETER

OFF

V

Hz

V

Ω mV

A


Main Battery

Negative

KSI

#2

B-

M-

B+

A2



Power Wire Inputs








Connect a voltmeter to the PMC ‘B-’ terminal and battery positive.

• If the voltage is not the same as battery volts then there is an open circuit in the wire from ‘B-’ to the battery. Stop troubleshooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground.

+

_


KSI

#2

B-

M-

B+

A2


Connect a voltmeter across the PMC ‘B-’ terminal and the PMC ‘B+’ terminal.

Close all interlock switches, turn the Key

Switch ON, and place the F&R Switch in

Forward.


MS-1 only.

•

If the voltage is not the same as battery volts then go to the Solenoids sequence.

•

If the voltage is the same as battery volts then the PMC controller has failed. 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.


+

_


KSI

#2

B-

M-

B+

A2


Motor









Connect the test light across the motor ‘A1’ and

‘A2’ terminals.



Forward.

Depress the accelerator fully.

•

If the light comes on then the motor armature windings are open and the motor must be repaired or replaced. Stop trouble shooting here and repair the problem. When the repair is completed, completely test the vehicle before lowering the drive wheels to the ground.

Wiring to motor omitted for clarity. Do not disconnect the motor wires for this test.

S2

A1

S1

A2

Motor shown for reference only. Terminal positions on your motor may not be in the same location.



Connect the test light across the motor ‘S1’ and

‘S2’ terminals.



Forward.

Depress the accelerator fully.

•

If the light comes on then the motor field windings are open and the motor must be repaired or replaced. Stop trouble shooting here and repair the problem.


•

If the test light did not come on during either test then go to the F/R Switch sequence.

Accelerator

Wiring to motor omitted for clarity. Do not disconnect the motor wires for this test.

S2

A1

S1

A2









This is the accelerator module test harness part number 62-027-31. It will be used in the following tests. These tests cannot be completed without this harness. If you do not have this harness, one must be obtained before testing can continue.

PLUG THIS END

INTO THE HARNESS

3 1

6

9 7

USE THIS END

FOR TESTING

4

PLUG THIS END

INTO THE MODULE



Connect the accelerator module test harness to the accelerator module.

Connect a voltmeter between pin #9 in the test harness and battery positive.

• If the voltage is not at battery volts then the wiring between pin #9 in the harness and battery negative is open. 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.

Connect a voltmeter negative probe to Pin #9

(-) in the test harness. Connect the positive probe to:

24 or 36 volt truck - Pin #4

48 volt truck - Pin #7


Key Switch ON.

•


-

+



-

+


24-36-volt

48-volt

Connect a voltmeter between pin #9 (-) and pin

#5 (+) in the test harness.


Key Switch ON.


MS-1 only.

•

If the voltage is not at battery volts then the accelerator module has failed. 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.

-

+


•

If the voltage at pin #5 is good but the test at the center terminal of the forward and reverse side of the F&R switch in the Key Switch Section failed then check the wire between the accelerator module pin #5 and the F&R switch. 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.



Connect a voltmeter between pin #9 (-) and pin

#2 (+) in the test harness.


MS-1 only.

•

If the voltage is between 6.0 and 6.5 volts and the test at the PMC #2 terminal in the Control Wire Input section failed then the wire or interlock switches between the accelerator module pin #2 and the

PMC pin #2 is open. Stop trouble shooting here and repair the problem.


-

+


•

If the voltage is not between 6.0 and 6.5

volts then the accelerator module has failed. 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.

Now Depress the accelerator module fully.

•

If the voltage is not between 11.0 and 11.5 volts then the accelerator module has failed.

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.

STOP

Stop, do not continue. If you reached this point without a solution, then you may have an unanticipated problem or have made an error during testing. It is important to review the trouble shooting steps that have led to this point. The tests may need to be repeated.



Key Switch








Test all interlock switches and/or interlock relays (if equipped) for continuity. Depending on the model of your vehicle, it may have a seat interlock, Foot interlock, Charger interlock, special order interlock or any combination of the above. Refer to the wire diagram at the end of this section for location of the interlocks.

NOTE: Due to the many different configurations possible for special order interlocks, they will not be included in this text. 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.

Connect a voltmeter across the HOT terminal of the key switch and battery negative.

•

If the voltage is not at battery volts then check the wire between the key switch and battery positive. Stop trouble shooting here and repair the problem.



OFF

V

Hz

V mV

A

View of the terminals of a typical Key Switch

KEY SWITCH

"COLD, Violet Wire(s)"

"HOT, Red wire(s)"

BATTERY MAIN NEGATIVE



Connect a voltmeter across the COLD terminal of the key switch and battery negative.

Turn the key switch ON.

•

If the voltage is not at battery volts then the key switch has failed. Stop trouble shooting here and repair the problem.


•

If the voltage is at battery volts but the previous test at pin #4 in the Accelerator section failed then check the wire from the key switch to pin #4 at the accelerator module. 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.

For your reference, shown at the right are the

Forward and Reverse switch wire connections for a typical control system.


OFF

V

Hz

V mV

A

KSI Side

View of the terminals of a typical Key Switch

KEY SWITCH

"COLD, Violet Wires(s)"

"HOT, Red wire(s)"

BATTERY MAIN NEGATIVE

Forward and Reverse Side

White/Black

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 side of the F&R switch and battery negative.

Turn the key switch ON.

•

If the voltage is not at battery volts then go to the Accelerator sequence.

The HOT terminal is the Violet/Black wire on the center terminal

Battery Negative



Connect a voltmeter across one of the COLD terminals of the KSI side of the F&R switch and battery negative.



Forward.

•

If the voltage is not at battery volts then the F&R switch has failed. Stop trouble shooting here and repair the problem.


•

If the voltage is at battery volts and the

The COLD terminal is the

Violet/Black wire on either end of the switch

Or,

Battery Negative test at the PMC KSI terminal in the

Control Wire Inputs section failed then check the wiring between COLD terminals of the KSI side of the F&R switch and the PMC

KSI terminal. 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.

F/R switch










Connect a voltmeter across the Solenoid

Negative Buss Bar and battery positive.

NOTE: You may skip this test if it was completed in a previous section

•

If the voltage is not at battery volts then check the wiring to battery negative and the negative circuit breaker. Stop trouble shooting here and repair the problem.



OFF

V

Hz

V mV


Solenoids are shown for reference only.

The type of solenoid in your truck may look different

Main Battery

Positive

A

-

+

ISO

FWD/REV

Connect a voltmeter across the center terminal of the forward and reverse side of the F&R switch and battery negative.



Forward.


•

If the voltage is not at battery volts then go to the Accelerator sequence.


The CENTER terminal is the

Green/Black wire

OFF

V

Hz

V mV

A

Battery Negative

Connect a voltmeter across the forward terminal of the forward and reverse side of the F&R switch and battery negative.


Switch ON, and place the F&R Switch in forward.


•




OFF

V

Hz

V mV

The FORWARD terminal is diagonally opposite the forward side of the rocker on the switch

F&R switch seen from the side depressed in the FORWARD gear

A

Battery Negative

F&R switch seen from the rear



Connect a voltmeter across the reverse terminal of the forward and reverse side of the F&R switch and battery negative.


Switch ON, and place the F&R Switch in reverse.


•



•

If all tests in this section were good then


OFF

A

V

Hz

V mV

The REVERSE terminal is diagonally opposite the reverse side of the rocker on the switch

Battery Negative

F&R switch seen from the side depressed in the REVERSE gear

F&R switch seen from the rear check the wiring from the F&R switch to the Forward and Reverse solenoids and both the forward and reverse solenoid coils.

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.

Solenoids








If the vehicle runs in forward only then skip ahead to the test sequence Forward (does not

run in reverse).

If the vehicle runs in reverse only then skip ahead to the test sequence Reverse (does not

run in forward).



Connect a voltmeter across the ISO solenoid

COLD terminal and battery negative.


Key Switch ON.


•

If the voltage is at battery volts then the wire from the ISO solenoid to the

PMC is bad. 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.


OFF

V

Hz

V mV

A

+

_

Battery Negative




FWD/REV

ISO

Connect a voltmeter across the ISO solenoid

HOT terminal and battery negative.



Key Switch ON.


•

If the voltage is at battery volts then the


OFF

V

Hz

V



ISO solenoid has failed. Stop trouble shooting here and repair the problem.


A

+

_ mV

ISO

•

If the voltage is not at battery volts then

Battery Negative check the wiring to battery positive and the main circuit breaker. Stop trouble

FWD/REV shooting here and repair the problem.


Forward (does not run in reverse)

Connect a voltmeter across the PMC KSI terminal and battery negative.

Close all interlock switches, turn the

Key Switch ON, and place the F&R

Switch in reverse.

•



+

_

KSI

#2

B-

M-

B+

A2

Main Battery Negative



Connect a voltmeter across the Reverse Solenoid coil terminals. Refer to your vehicles wiring diagram to identify the position of the reverse solenoid.




•

If the voltage is not at battery volts then go to the F/R Switch sequence.

+

_



The type and position of the reverse solenoid in your truck may be different

ISO

FWD/REV


Connect the test light across the normally open contacts of the reverse solenoid. Refer to your vehicles wiring diagram to identify the position of the reverse solenoid.




•

If the light comes on then the Reverse solenoid has failed. 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.

Connect the test light across the Normally Closed contacts of the Forward solenoid. Refer to your vehicles wiring diagram to identify the position of the forward solenoid.



Reverse.


•

If the light comes on then the Forward solenoid has failed. 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.



FWD/REV

FWD/REV


The type and position of the forward solenoid in your truck may be different

STOP




Reverse (does not run in forward)

Connect a voltmeter across the PMC KSI terminal and battery negative.



•



+

_


KSI

#2

B-

M-

B+

A2

Connect a voltmeter across the Forward Solenoid coil terminals. Refer to your vehicles wiring diagram to identify the position of the forward solenoid.




•

If the voltage is not at battery volts then go to the F/R Switch sequence.

+

_




ISO

FWD/REV


Connect the test light across the Normally Open contacts of the Forward solenoid. Refer to your vehicles wiring diagram to identify the position of the forward solenoid.




•

If the light comes on then the Forward solenoid has failed. 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.



FWD/REV




FWD/REV

Connect the test light across the Normally Closed contacts of the Reverse solenoid. Refer to your vehicles wiring diagram to identify the position of the Reverse solenoid.



Forward.


•

If the light comes on then the Reverse solenoid has failed. 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.



STOP



ELECTRICAL TROUBLESHOOTING

Special 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

Ø

Runs slow in both directions plus high armature and field current in both directions. NOTE: Armature and field current should be equal.

Ø

Runs slow in both directions plus high armature current in both directions.

NOTE: Field current will be very low.

Ø

Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or;

Ø

Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only. NOTE: Field current will be very low in the opposite direction.

Ø

Accelerates slowly and exceeds normal speed in both directions plus high armature current. NOTE: Field current will be very low.

Ø

Full speed only.

Ø

Does not run in either direction plus there is noise from motor (hum or whine) with high field current and low armature current.

Ø

Excessive spark when connecting battery

Ø

Does not run or runs very slow with low motor current and high battery current.

Ø


GO TO

MOTOR

SOLENOIDS

SOLENOIDS

SOLENOIDS

PMC CONTROL

PLUGGING DIODE

ISO

FREEWHEEL DIODE

HPD

Section 4, Special Troubleshooting


PMC CONTROL --------------------------------------------------- 2

PLUGGING DIODE----------------------------------------------- 4

FREEWHEEL DIODE -------------------------------------------- 5

ISO ------------------------------------------------------------------- 6

SOLENOIDS ------------------------------------------------------- 8

MOTOR ------------------------------------------------------------- 11

Special Troubleshooting Page 1










PMC CONTROL


Disconnect the wire from the ‘M-’ terminal on the PMC control and tape it off to prevent electrical contact. Connect a volt meter across the PMC #2 terminal and battery negative.

Turn the key-switch on, close all interlock switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests:

•

The meter reading should be between 6 and 6.5 volts.

•

If the voltage at pin #2 is not 6 to 6.5

volts, then go to the ACCELERATOR sequence in the Main Troubleshooting

Sequence, otherwise continue with the next test.

+

_


KSI

#2

B-

M-

B+

A2



Connect a volt meter across the PMC B+ and

PMC M- terminals.

Turn the key-switch on, close all interlock switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests:

•

The meter reading should not be equal to the battery voltage.

•

If you have full battery voltage then the

PMC control is shorted and must be replaced. 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.

+

_


KSI

#2

B-

M-

B+

A2

If the voltage at pin #2 is correct and the voltage at ‘M-’ is correct, then there is a short in the harness between the wire connected to the PMC ‘M-’ and main battery negative. 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.

STOP




PLUGGING DIODE









Remove the wires from the ‘B+’ and ‘A2’ terminals on the PMC control and perform the following test:

Using the diode test function on the DMM check for the presence of a diode across ‘B+’ and ‘A2’ on the PMC control..

If you do not know how to test for a diode, refer test to a qualified technician.

•

If the diode is open or shorted, then the

PMC control must be replaced. 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.

FLUKE 79

SERIES II MULTIMETER

The reading shown is for illustration only. The actual reading may vary.

OFF

V

Hz

V

Ω mV

A

KSI

#2

B

M

−

B

+

−

A2

STOP




FREEWHEEL DIODE









Remove the wires from the ‘B+’ and ‘M-’ terminals on the PMC control and perform the following test:

Using the diode test function on the DMM check for the presence of a diode across ‘B+’ and ‘M-

’ on the PMC control. Refer to Diode Figure 2.

If you do not know how to test for a diode, refer test to a qualified technician.

•

If the diode is open or shorted, then the

PMC control must be replaced. 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.

+

_

The reading shown is for illustration only. The actual reading may vary.

KSI

#2

B-

M-

B+

A2

STOP




ISO









Remove the wires and the resistor from the ISO solenoid and perform the following tests:

Test continuity across the ISO power contacts.


•

This should be an open circuit. If it is not an open circuit then the contactor should be replaced. 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, other wise continue to the next test.

-

+

FWD/REV

ISO



Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure its resistance.

•

The meter reading should be 250 Ohms

(+/-10%). If it is not 250 ohms (+/-10%), then replace the resistor. Stop trouble shooting here and repair the problem.


Reading is plus or minus 10%

ISO solenoid is shown for reference only. The type of solenoid in your truck may look different

+

_

STOP




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.









Remove the wires from the ‘S1’ and ‘S2’ terminals on the motor. Remove the wire from the

‘M-’ terminal on the PMC control. Make sure none of these wires can come into electrical contact with the frame or any other wire.

Reconnect the batteries.

With the key-switch on and the forward and reverse switch in neutral, perform the following tests:

•

Check continuity from the motor ‘A2’ terminal to the wire that was connected to the motor ‘S1’ terminal. DO NOT make this test to the ‘S1” terminal, just the wire.

Refer to Solenoid Figure 1.

S1

A2


S2

A1

•

This should be an open circuit, if it reads as a short, then one of the following has occurred:

A) The reverse solenoid is shorted.

B) The wire connected to the motor ‘S1’


terminal is shorted to the wire connected to the motor ‘A2’ terminal.

C) The wire connected to the motor ‘S1’ terminal is shorted to the wire connected to the PMC ‘A2’ terminal.

+

_



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’ terminal. DO NOT make this test to the ‘S2” terminal, just the wire.

If you do not know how to test for continuity,

S1

refer test to a qualified technician.

A2

S2

•

This should read as an open circuit. If it

A1 reads as a short then one of the following has occurred:

A) The forward solenoid is shorted.

B) The wire connected to the motor ‘S2’ terminal is shorted to the wire connected to the motor ‘A2’ terminal.

C) The wire connected to the motor ‘S2’ terminal is shorted to the wire connected

Motor shown for reference only.

Terminal positions on your motor may not be in the same location.

+

_ to the PMC ‘A2’ terminal.


With the key-switch on and the F&R switch in forward, depress the accelerator pedal and perform the following tests:

Check continuity from the wire that was connected to the PMC ‘M-’ terminal to the wire that was connected to the motor

‘S2’ terminal.




•

This should read as an open circuit. If it reads as a short, then one of the following has occurred:

A) The forward solenoid is shorted.

B) The wire connected to the PMC ‘M-’ terminal is shorted to the wire connected to the motor ‘S2’ terminal.


S2

A1

S1

A2

+

_

KSI

#2

B-

M-

B+

A2



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 wire that was connected to the motor

‘S1’ terminal.




S1

•

This should read as an open circuit. If it reads as a short, then one of the following has occurred:

A) The reverse solenoid is shorted.

B) The wire connected to the PMC ‘M-’ terminal is shorted to the wire connected to the motor ‘S1’ terminal.

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

S2

A1

A2

+

_

KSI

#2

B-

M-

B+

A2

STOP




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. If this symptom exists, it indicates that there may be open segments in the armature. Visually inspect the brushes, if they are OK, continue with the testing below.









Disconnect the four motor wires and perform the following tests:

Check continuity from ‘A1’ to the frame of the motor..


•

This should be an open circuit. If there is continuity from ‘A1’ to the frame of the motor, then the motor armature or armature circuit (brushes) are shorted.




S2

A1

S1

A2

+

_



Check continuity from ‘S1’ to the frame of the motor.


This should be an open circuit. If there is continuity from ‘S1’ to the frame of the motor, then the motor field is shorted.

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 to Motor Inspection.



S2

A1

S1

A2

+

_

Motor Inspection

1. Remove and disassemble the motor.

2. Visually inspect the inside of the brush end housing. If there are any silver specs of metal around the inside of the housing, it indicates that the armature has overheated and melted the solder around the commutator. The armature is bad and the motor must be replaced.

Stop here and repair the problem, otherwise continue with the next test.

3. Visually inspect the armature wires where they loop around at the shaft end of the armature.

The insulation should be a light to medium reddish brown color. If the insulation is dark brown to black or the insulation is cracked and peeling, then the armature has been overheated and burnt. The motor must be replaced. Stop here and repair the problem, otherwise continue with the next test.

4. Perform a continuity test around the armature commutator. Place one of the test leads on a single commutator segment. While holding the first test lead on the segment, check the continuity to the other segments around the commutator.


•

There should be continuity on each commutator segment. If an open segment is found, the armature is bad and the motor must be replaced. 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.

Hold this lead in place

Check each segment all of the way around the commutator

Commutator

+

_

STOP




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. Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 (refer to fault table).

Rev E


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. As the battery charges, the battery voltage rises. The charger periodically checks the battery voltage and compares it to the previous reading. When the battery voltage stops rising a predetermined amount, then the batteries are no longer accepting a charge and the charger shuts off. The charger will not start again unless the AC cord on a “built-in” charger is disconnected from the wall outlet, or the DC plug on a portable charger is disconnected from the batteries.

The charger does not check the current state of charge when it is plugged in, it assumes that the batteries require charging when it is connected. For this reason, it is recommended to discharge the batteries approximately 50% (1175-1200 as indicated on a hydrometer) before connecting the charger. If the charger is connected before the batteries are discharged 50%, the batteries may enter an overcharge state before the charger can sense that the batteries are no longer accepting a charge. This could result in overcharging and damaging the batteries.

The relay that operates the charger is powered by the batteries being charged. If the voltage on the batteries to be charged is less than approximately 65% of the rated charger DC voltage, the relay will not pick up and the charger will not turn on. In this situation, a manual charger would have to be used to bring the battery voltage up so that the Lestronic ® charger can sense that they are connected and turn itself on.

Not all chargers are equipped with the lockout relay

Charger Troubleshooting Page 2

Typical Charger Internal Wire Diagram


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:

• The charging cycle is interrupted at any time during the charging cycle.

• Defective batteries causing a fluctuating DC voltage that confuses the charger.

• A brownout (drop in AC line voltage) during the charging cycle.

• An electrically noisy charging environment.

A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:

• The batteries were not discharged to 50% before connecting the charger.

• The electrolyte in the batteries is too high (boil over).

• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).

To test the charger to see if it is turning off correctly, monitor the battery voltage and the electrolyte specific gravity during the charging cycle as indicated below.

Specific Gravity

Using a hydrometer take the specific gravity reading of several cells, at 1 hour intervals while charging. If the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not shut off, then the charger is running too long.

Battery Voltage

Using an accurate 5-1/2 digit digital voltmeter, monitor the battery voltage during the charging cycle. Take readings every 30 minutes. If the battery voltage does not increase 0.012 volts in two consecutive readings, then the charger is running too long.



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. If not familiar with any part of these tests, refer testing to a qualified technician.

• Make sure that the AC electrical socket the charger is plugged into is in good working condition.

• Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate.

• Make sure the batteries are in good condition and no less than 80% discharged as per hydrometer reading.

• The battery voltage must be above approximately 65% of the chargers rated DC voltage. If the batteries are below approximately 65% of the chargers rated DC voltage, the charger will not turn on.

• If the charger exhibits intermittent problems, it must be in the failed mode for troubleshooting.

• Battery volts = Full voltage available at the batteries at the time of the test being performed.

• This test procedure must be performed in the order it was written. If starting in the middle or skipping sections when not instructed to do so, the proper results will not occur. If the test result is good, then proceed to the next test or go to the next section if instructed to do so.

During All Tests

The charger cabinet must remain electrically grounded. Disconnect both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire. Failure to do so may result in serious bodily injury.



TROUBLESHOOTING FOR BUILT-IN CHARGER





5. Disconnect the charger from the AC source.

Locate the charger harness connectors where the charger harness is connected to the vehicle’s control harness. There will be two 10 gauge and two 14 gauge wires.

Slide the insulators off the connectors on the two 10 gauge wires and perform the following tests:

Make sure that these two wires do not come into electrical contact with any other object.

6. Test the voltage from the red wire to the 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. Stop here and repair the problem.

7. Test the voltage from the red 10 gauge wire (+) to the other 10 gauge wire (white or black depending on model). This voltage should be equal to the battery voltage.

If the voltage is less than the battery voltage, then the white (or black) wire is broken or has a bad connection. Stop here and repair the problem.

Slide the insulators back onto the connectors on the two 10 gauge wires.

Slide the insulators off the connectors on the two 14 gauge wires.

High Voltage. Do not touch the 14-gauge wires and make sure these two wires do not come into electrical contact with any other object.

Failure to do so may result in serious bodily injury.

Re-Connect the charger to the AC source.

8. Test the voltage across the two 14 gauge wires. This voltage should be the same as the voltage at the AC receptacle (rated voltage of the charger). If the voltage is less than the rated AC voltage of the charger then the 14 gauge white or black wire(s) is broken or has a bad connection between the charger connectors and the AC plug. Stop here and repair the problem.



• 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. Connect a 2k ohm resistor across the capacitor terminals for 10 seconds. Do not touch the capacitor terminals with your hands. The resistor should be held with a pair of insulated pliers.

Failure to do so may cause serious bodily injury

Remove the charger cover and perform the following tests:

1. Inspect the internal wiring of the charger and repair as required.

2. Check the continuity of both fuse links and replace if bad.

3. Disconnect one transformer lead from the capacitor. Test the capacitor using the capacitor test function of the meter. It is a 6 microfarad capacitor. If the capacitor is bad, it must be replaced. Stop here and repair the problem.

Capacitor

Fuse Links

4. Reconnect the transformer lead to the capacitor and disconnect one transformer lead from one of the diodes. Test each of the diodes using the diode test function of your meter. If either one of the diodes are bad, replace the diode assembly. Stop here and repair the problem.

5. Reconnect the lead to the diode.

6. Reconnect the charger to the vehicle’s harness and slide the wiring insulators back into place.

Connect the charger to the AC source and perform the following tests:

High Voltage inside the charger. Do not touch any internal components while the charger is plugged in. Failure to do so may result in serious bodily injury.



• 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. Stop here and repair the

problem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltage should be the same as the rated AC voltage of the charger. If the voltage is less than the rated AC voltage of the charger, then the wires from the harness connectors to the charger are bad. Stop here

and repair the problem.

• If the timer relay does not pickup (click) when the AC source is connected, then the timer control circuit or the relay is bad (refer to Timer Relay Test). Stop here and repair the problem.

• Test the AC voltage across the transformer primary circuit. The transformer primary consists of the two solid wires with the brown fiber insulator that are connected to the timer board. This voltage should be the same as the rated AC voltage of the charger. If the voltage is less than the rated AC voltage of the charger, then the timer relay is bad. Stop here and repair the problem.

• Test the AC voltage across the transformer low voltage secondary circuit. The transformer low voltage secondary circuit can be tested at the two solid wires with the brown fiber insulator that are connected to the anodes on the two diodes. The voltage here will vary depending on the state of charge in the batteries.

The voltage should be between 208% and 250% of the rated

DC voltage of the charger. If the voltage is not between 208% and 250% of the rated DC voltage of the charger, the transformer is bad and must be replaced. Stop here and repair the

problem.



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.

Stop here and repair the problem.

2. Test the voltage from the positive terminal on the DC receptacle to the negative terminal on the DC receptacle. This voltage should be equal to the battery voltage.

If the voltage is less than the battery voltage, then the wire on the negative terminal of the DC receptacle is broken or has a bad connection. Stop here and repair the

problem.

Remove the charger cover and perform the following tests:

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor before continuing. Connect a 2k ohm resistor across the capacitor terminals for 10 seconds. Do not touch the capacitor terminals with your hands. The resistor should be held with a pair of insulated pliers.

Failure to do so may cause serious bodily injury

1. Inspect the internal wiring of the charger and repair as required.

2. Check the continuity of both fuse links and replace if bad.

3. Disconnect one lead from the capacitor. Test the capacitor using the capacitor test function on the meter. If the capacitor is bad, it must be replaced. Stop here

and repair the problem.

Capacitor Test

Fuse Links

4. Reconnect the lead to the capacitor and disconnect one transformer lead from one of the diodes. Test each of the diodes using the diode test function on the meter. If either one of the diodes are bad, replace the diode assembly. Stop here and repair the problem.



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. Failure to do so may result in serious bodily injury.

• 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 DC cord is bad. Stop here and

repair the problem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltage should be the same as the rated AC voltage of the charger. If the voltage is less than the rated AC voltage of the charger then the AC cord is bad. Stop here and repair the problem.

• If the timer relay does not pickup (click) within 5 seconds of connecting the DC charger plug, then the timer control circuit or the relay is bad

(refer to Timer Relay Test). Stop here and repair the problem.

• Test the AC voltage across the transformer primary circuit. This voltage should be the same as the rated AC voltage of the charger. If it is less than the rated AC voltage of the charger, then the timer relay is bad.

Stop here and repair the problem.

Transformer Secondary Circuit

• Test the AC voltage across the transformer secondary circuit. The voltage here will vary depending on the state of charge in the batteries. The voltage should be between 208% and 250% of the rated DC voltage of the charger. If the voltage is not between 208% and 250% of the charge’s rated DC voltage, the transformer is bad and must be replaced. Stop here and repair the problem.

TESTING THE TIMER RELAY

Test 1:

1. Connect the batteries to the charger.

2. Plug the charger into the AC source.

3. Wait 5 seconds, then test the voltage at the timer relay coil terminals.

NOTE: This voltage should be close to the battery volts.

•

If the voltage is close to the battery volts, then skip to test 2.

•

If the voltage is not close to the battery volts, then the timer control circuit has failed and the timer must be replaced.

Test 2:

1. Disconnect the batteries.

2. Unplug the charger from the AC source.

3. Discharge the capacitor (see warning on previous page).



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.

•

If there is an open circuit, then the timer relay has failed and the relay must be replaced.

TESTING THE INTERLOCK RELAY

Operation

The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC power source. When the charger is plugged in, the relay contacts open and break the Key Switch connection to the speed controller. The Interlock Relay is available for built-in chargers only. Not all built-in chargers are equipped with this relay. To identify chargers that are equipped with the Interlock Relay:

Inspect the charger wire harness where it enters the charger cabinet for two Violet/Black wires. If these wires are present then the charger is equipped with the Interlock Relay.

Testing






6. Disconnect the charger from the AC power source.

7. Disconnect the two Violet/Black wires at the charger harness knife connectors.

8. Set the DMM to check for continuity and connect the DMM leads to the wires going into the charger.

•

The DMM should indicate a closed circuit. If the DMM indicates an open circuit, then the relay or the wires to the relay have failed. Stop here and repair the problem.

9. Connect the charger to a working AC power source.

•

The charger should turn on. If the charger does not turn on then their may be a problem with the

AC power source or the AC wiring to the charger. Refer to the beginning of this section for charger troubleshooting. DO NOT continue until you have confirmed that the AC power source is working.

•

The DMM should indicate an open circuit. If it still indicates a closed circuit, then the relay or the wires to the relay have failed. Stop here and repair the problem.

•

If the DMM indicates an open circuit then the interlock relay is functioning normally.



Operating Instructions and Theory of

Operation ........................................2

Testing the Charging Cycle ....................3

Test Equipment Required for

Troubleshooting ...............................4

Important Notes and Instructions 4

Status LED Error Code .........................5

Troubleshooting .....................................6

Turn the Key switch OFF BEFORE disconnecting the batteries. Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 (refer to fault table).

Rev D


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.

Both the HB600W

®

and HB1000W

®

are two stage chargers. The first stage is a constant current mode. It

Maintains a constant current until the battery reaches a terminal voltage and then switches to the second stage, constant voltage. At the second stage the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete.

The charger faceplate has three status LED’s that monitor the charging status. Refer to the chart below.

C harging S tatus

0 - 5 0 %

5 0 % - 7 5 %

7 5 % - 1 0 0 %

C harging C ycle c o m p le te

Erro r, refer to tro u b le s h o o ting

L e ft M id d le

F L A S H I N G

O N

O F F

F L A S H I N G

O N O N

R ight

O F F

O F F

F L A S H I N G

O N O N O N

F L A S H I N G F L A S H I N G F L A S H I N G


Page 2


TESTING THE CHARGING CYCLE

In typical installations, the charger will remain on for up to 14 hours depending on the state of charge of the battery when the charge cycle was started.

A charger could remain on for longer than 14 hours if:

• The vehicle is equipped with batteries larger than 220 Amp hour capacity.

• The charging cycle is interrupted at any time during the charging cycle.

• Defective batteries causing a fluctuating DC voltage that confuses the charger.

• One or more defective cells in the battery pack.

• A brownout (drop in AC line voltage) during the charging cycle.

• An electrically noisy charging environment.

A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:

• The electrolyte in the batteries is too high (boil over).

• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).

To test the charger to see if it is turning off correctly, monitor the battery voltage and charging current during the charging cycle as indicated below.

Using a digit digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during the charging cycle. The charging current should remain within 10% of the DC output current (see previous page) until the battery voltage reaches 2.55 volts per cell. When the voltage reaches 2.55 volts per cell, the charging current will drop significantly and slowly taper off (voltage will remain constant). The charger should turn off 2-4 hours after entering the second stage.

T

A Y

L OR - DUN

N h

T e

B st

W ay

To

Go About

Yo ur

R

Bu si s


Page 3


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.

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. If not familiar with any part of these tests, refer testing to a qualified technician.

• Make sure that the AC electrical socket the charger is plugged into is in good working condition.

• Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate.

• Make sure the batteries are in good condition.

• If the charger exhibits intermittent problems, it must be in the failed mode for troubleshooting.

• Battery volts = Full voltage available at the batteries at the time of the test being performed.

• There are no internally serviceable components in the charger. If the charger has failed then it must be replaced.

This charger is rated for 115 VAC or 230 VAC operation. When switching from one input voltage to the other, Wait until all three status LED’s are off. Switching voltage when any of the LED’s are on will result in damage to the charger.

T

A Y

L OR - DUN

N h

T e

B st

W ay

To

Go About

Yo ur

R

Bu si s


Page 4


STATUS LED ERROR CODE

There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. All three LED’s flashing indicate an error in the charger. See the table below for an explanation if the error codes:

Error

Code

Description

1

Action Required

Reverse polarity or open circuit to the batteries

Check wiring for corrosion, loose connections. broken wires and proper connection to the batteries

2

3

AC line voltate too high or too low

Charger overheated

Check the input voltage.

It must be within 96-132VAC or 196-266VAC

Wait for charger to cool, the charger will automaticaly restart. Inspect for dirt or debris on the charger cooling fins and clean as required.

4 Input or Output over current Charger will automaticaly correct for this condition and restart


Page 5


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.

After 5 or 6 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).

The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals

2.55 VPC. When the battery voltage equals 2.55 VPC the charger will switch to the constant voltage mode. At this point the charging current will be reduced and will taper off until the batteries are fully charged.

Perform the following if the charger does not turn on:





5. Disconnect the charger from the AC source.

6. Remove the charger end cap where the DC wires enter.

7. Test the voltage across the Battery Positive

(red) and Battery Negative (black) wires at the lower left of the charger circuit board.

This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires to the batteries have been damaged. Stop here and repair the

problem.

8. Reinstall the charger end cap where the DC wires enter.

9. Remove the charger end cap where the AC wires enter.

10.

Test the continuity of all three AC wires from the circuit board to the AC plug. If you find an open circuit in any one of the three wires then the AC cord or plug has been

11.

damaged. Stop here and repair the problem.

Install the charger end cap where the

AC wires enter.

If both the AC and DC tests are good then the charger has failed. There are no internally serviceable components in the charger. If the charger has failed then it must be replaced.


Page 6


Front Axle ...................................................... 2

Front Fork ..................................................... 4

Steering Linkage ........................................... 6

Transmission Chain or Gear Case ............... 8

Transmission Differential Case ..................... 10

Rear Brakes .................................................. 12

Rear Axle ...................................................... 12

Motor ............................................................. 14

Brake linkage ................................................ 16

Wheels and Tires .......................................... 18

Instrument Panel (dash) ............................... 20

Speed Control Panel ..................................... 22

Lester Charger P1 ......................................... 24

Lester Charger P2 ......................................... 26

Signet Charger .............................................. 28

Batteries ........................................................ 30

Seat Cushions and Deck .............................. 32

Decals ........................................................... 34

Optional Equipment ...................................... 36

Stake Sides ................................................... 38

Fiberglass Cab and Doors P1 ....................... 40

Mirrors, Windshield Wiper, Brake Light ........ 42

Illustrated Parts

Front Axle

Parts Page 2

Item No.

Part No.

1 88-229-81

2 88-228-60

3

4

5

15-010-00

16-010-00

14-082-10

FRONT AXLE

Description

Locknut, 3/4NC

Washer, 3/4” Cut

Front Axle

Spacer

Front Fork Assembly

Illustrated Parts

1

4

1

Qty

2

2

Parts Page 3

Illustrated Parts

Front Fork

Parts Page 4

Item No.

Part No.

1 88-229-81

2 88-228-60

3

4

45-307-00

80-011-00

5

6

7

80-102-00

14-082-10

92-105-00

FRONT FORK

Description

Locknut, 3/4NC

Washer, 3/4” Cut

Oil Seal, 1-1/2” ID

Bearing, Tapered Roller, 1-1/4” ID

Bearing Race

Front Fork Assembly

Dust Cap

Illustrated Parts

Qty

1

1

1

2

2

1

1

Parts Page 5

Illustrated Parts

Steering Linkage

Parts Page 6

13

14

15

16

10

11

12

5

6

7

8

9

Item No.

Part No.

1 95-915-20

2 88-199-82

3

4

19-007-20

80-400-10

20-010-00

97-100-00

16-405-00

30-002-00

88-229-81

30-400-00

96-900-00

30-241-00

30-005-00

20-144-00

30-248-00

14-082-10

Illustrated Parts

STEERING

Description

Steering Wheel Cap

Nut, 5/8NF Jam

Steering Wheel

Ball Bearing, Sealed, 3/4”

Shaft, Steering Column

Woodruff Key, 3/16”

Spacer, 3/4” ID x 1/8” Thick

Sprocket, 11 Tooth, #40 Chain, 3/4” Bore

Locknut, 3/4NC

Master Link, #40 Chain

Turnbuckle, Steering Chain

Chain, #40, 29-1/2” Long

Sprocket, 22 Tooth, #40 Chain, 3/4” Bore

Shaft, Steering, 13-1/4” Long

Chain, #40, 36-1/2” Long

Front Fork Assembly

1

4

4

2

3

Qty

1

1

1

4

1

1

1

1

4

2

1

Parts Page 7

Illustrated Parts

Transmission Chain or Gear Case

Motor

2

3rd Member

4

3

8

5

6

1

7

13

24

14

23

22

17

15

16

20

Brake Assembly

9

25

10

11

21

12

Parts Page 8

Transmission Chain Case

ITEM#

1

2

5

6

3

4

7

8

9

PART #

88-109-61

97-100-00

88-087-11

88-069-80

88-103-09

80-703-00

70-454-00

88-109-87

30-081-00

30-070-00

30-080-00

30-082-00

16-415-00

DESCRIPTION

3/8" SAE Flat Washer

Woodruff Key

Chain Adjusting Screw

5/16" NC Hex Nut

Motor Mounting Screw, 3/8" X 3/4" NC

O-Ring, 4-1/2" ID X 5" OD

Motor Mounting Plate

3/8" KEPS Nut (Interegral Lockwasher)

14 Tooth Single Motor Sprocket

15 Tooth Double Motor Sprocket



Spacer Main Sprocket, F2 Axle, .440" Thick 10

11

12

30-091-00

30-092-00

30-070-11

30-070-10

30-093-00

30-320-11

30-508-20

44-352-53

42 Tooth Single Pinion Sprocket


60 Tooth Double Pinion Sprocke

81 Tooth Double Pinion Sprocket


Drive Chain, 15-81 T Double Sprocket

Drive Chain, 15-81 T Single Sprocket

Backing Plate, Gear Case 13

14

15

16

17

18*

19*

88-101-13

88-080-20

41-989-00

43-201-11

45-002-00

45-021-00

45-331-00

97-250-00

3/8" X 1-1/4" NC Hex Bolt

5/16" X 3" Hex Bolt

Drain and Fill Plug

Chain Cover

Chain Case Gasket

Backing Plate Gasket

Pinion Oil Seal, Gear Case

Pinion Nut

20

21

22

23

24

88-089-81

88-088-61

88-108-63

5/16" NC Locknut

5/16" SAE Flat Washer

Internal Tooth Lock Washer

25 88-239-82 Motor Nut, 3/4" NF Hex Jam Nut, Thin

* - No longer used on late model trucks. Replaced with Ultra-Blue RTV sealant 94-430-03

Illustrated Parts

1

1

1

1

2

1

5

9

12

3

5

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

QTY

3

1

4

1

1

1

Parts Page 9

Illustrated Parts

Transmission Differential Case

Parts Page 10

5

14

15

16

18

19

20

21

6

7

8

10

11

12

13

ITEM#

1

2

3

4

Illustrated Parts

41-997-00

41-291-32

41-299-20

80-554-00

41-711-00

80-702-00

44-340-90

16-419-00

16-420-00

16-411-00

16-415-00

80-125-00

41-707-00

41-707-50

41-708-50

88-080-04

88-140-16

96-243-00

PART #

41-179-00

41-710-00

88-119-80

41-712-00

41-713-00

80-127-00

80-128-00

80-129-00

80-511-00

80-512-00

80-513-00

31-239-00

31-234-00

31-275-00

Transmission Differential Case

DESCRIPTION

3rd member Housing (1.628 ID Carrier Bearing)

3rd member Housing (1.784 ID Carrier Bearing)

3/8" NF Nut

Differential Assembly (1.628 ID Carrier Bearing)

Differential Assembly (1.784 ID Carrier Bearing)

Carrier Bearing Race, (For 1.628 ID Carrier Bearing)

Carrier Bearing Race, (For 1.784 ID Carrier Bearing)

Carrier Bearing Race, (For P/N 80-513-00)

Carrier Bearing (1.628 ID Carrier Bearing)



Ring and Pinion Gear Set (5.43)



Oil Plug

Rear End Housing (For B2-48 & B2-38)

Rear End Housing (For B2-54)

Front Pinion Bearings

Pinion Housing Shim

O-Ring

Pinion Housing

.002 Shim (Add Shims As Needed)



Spacer

Pinion Bearing Race

Differential Bearing Adjuster Nut (For 80-511-00)



5/16" X 3/8: NC Hex Bolt

1/2" X 2" Hex Bolt

7/16" X 7/8" Hex Bolt (Locking Head)

QTY

0 or 1

0 or 1

14

0 or 1

0 or 1

0 or 2

0 or 2

0 or 2

0 or 2

0 or 2

0 or 1

0 or 1

0 or 1

3

1

1

0 or 2

0 or 2

0 or 2

2

2

10

1

2

*

*

1

*

1

1

Parts Page 11

Illustrated Parts

Rear Brakes

5

9

6

Rear Axle

1

7

8

3

2

Axle tube

4

Parts Page 12

13

14

15

16

17

8

9

10

11

12

18

19

ITEM #

1

2

3

6

7

4

5

PART #

45-331-00

41-352-00

96-245-10

41-661-60

85-060-20

41-372-10

88-159-84

88-159-82

97-250-00

88-109-81

88-108-61

88-517-11

96-771-00

50-656-04

88-101-13

85-270-00

88-080-13

41-371-10

88-089-91

Rear Bakes

DESCRIPTION

Pinion Seal

Brake Drum

Brake Adjusting Bolt

Brake Band Kit (Incl. #'s 3, 5, 7, 8, 9, 12, 13)

2-1/2" Long Spring

Mounting Bracket

1/2"-20 NF Lock Nut

1/2" NF Hex Jam Nut

Pinion Nut

3/8" Lock Nut

3/8" Lock Washer

3/32" X 1" Cotter Pin

Clevis Pin

Brake Arm

3/8" X 1-1/4" NC Grade 5 Hex Bolt

Return Spring 4-3/8" Long

5/16" X 1-1/4" Hex Bolt

Alignment Bracket

5/16" Hex Jam Nut

Illustrated Parts

1

1

1

1

2

2

4

1

2

1

1

1

1

1

1

1

QTY

1

1

1

6

7

8

9

Item No.

Part No.

1

2

3

4

5

96-330-20

45-301-00

32-515-00

96-329-10

41-162-21

41-163-21

32-514-00

80-503-00

45-045-00

88-119-81

Rear Axle

Description

3/8NF x 1-3/16 ‘T’ bolt

Seal

Retainer, bearing

Lug bolt

Right axle assembly (includes items 2 through 8)

Left axle (includes items 2 through 8)

Retainer, axle

Bearing

Gasket

3/8NF locknut

2

2

2

8

Qty

8

2

2

10

1

1

Parts Page 13

Illustrated Parts

Motor

Parts Page 14

Parts Page 15

Illustrated Parts

Illustrated Parts

Brake linkage

Parts Page 16

Illustrated Parts

17

18

19

14

15

16

9

10

11

12

13

4

5

6

7

8

Item No.

Part No.

1 51-340-00

1a n/a

2

3

88-109-81

88-108-60

88-101-16

98-200-00

01-432-98

01-432-70

88-111-32

96-762-00

96-813-00

96-771-00

88-517-09

96-772-00

85-270-00

88-080-11

80-410-20

88-102-11

88-089-81

88-119-80

PARK & FOOT BRAKE LINKAGE

Description

Park Brake Lever

Spacer-included with lever

Locknut, 3/8NC

Washer, 3/8 SAE

Bolt, 3/8NC x 2” Hex Hd.

Brake Pedal Pad, Rubber

Brake Pedal Bracket (painted black)

Brake Shaft Weldment (painted black)

Bolt, 3/8NF x 8” Hex Hd., Grade 5

Clevis, 3/8”

Cable Assy, Adjustable

Clevis Pin, 3/4”

Cotter Pin, 3/32” x 3/4”

Clevis Pin, 1”

Brake Return Spring

Bolt, 5/16NC x 1” Hex Hd.

Flanged Bearing, 3/4” ID

Bolt, 3/8”NC x 1” Carriage

Locknut, 5/16NC

Nut, 3/8NF

4

1

1

1

1

2

1

1

2

3

1

2

1

1

1

1

Qty

1

2

6

12

Parts Page 17

2

Illustrated Parts

Wheels and Tires

9

1

Ref., wheel hub

10

3

8

7

6

4

5 (assembly)

Parts Page 18

Illustrated Parts

Wheels and Tires

DESCRIPTION ITEM #

1

2

PART #

Wheels

12-012-00

12-054-00

Tires

10-075-00

10-076-00

10-074-10

10-074-00

5 x 8" Tubeless

11-1/4 Cast iron

4.80 x 8 LR B Pneumatic

4.80 x 8 LR C Pneumatic

400 x 8 Soft solid, non-marking, ribbed

400 x 8 Soft solid, ribbed

16-1/4 x 11-1/4 Solid rubber 10-261-00

Split Rim Wheels

12-041-12 3

4

5

3a

4a

5a

6

7

8

12-041-13

12-041-00

12-042-12

12-042-13

12-042-00

88-110-09

88-109-62

88-119-80

9 97-236-00

Not Shown 13-989-00

Not Shown 11-041-00

Not Shown 11-040-00

Inner Wheel (2.5 bead)

Outer Wheel (2.5 bead)

Wheel Assembly, 2.5 bead width (includes #3, #4, #6, #7, #8)

Inner Wheel (12-bolt)

Outer Wheel (12-bolt)

Wheel Assembly, 3.75 bead width (includes #3a, #4a, #6, #7, #8

3/8 x 3/4-NF Hex Bolt, grade 5

3/8 Split Lock Washer

3/8-NF Hex Nut

Wheel Nut

Valve stem, tubless tire only

8.50 x 8 Tube

5.70 x 8 Tube

11-030-00

Tire and Wheel Assemblies

4.80 x 8 Tube

13-734-00

13-734-11

4.80 x 8 LR B Pneumatic

4.80 x 8 LR B Split Rim Pneumatic

13-739-10 4.80 x 8 LR C Split Rim Pneumatic

13-734-41

13-734-40

13-954-10

400 x 8 Soft solid, non-marking, ribed

400 x 8 Soft solid

16-1/4 x 11-1/4 Solid rubber

Parts Page 19

Illustrated Parts

Instrument Panel (dash)

Parts Page 20

13

14

15

Not

Shown

8

9

10

11

12

4

5

6

6

7

Item No.

Part No.

1 71-120-00

1 71-121-00

2

3

71-039-00

94-312-00

88-727-06

00-432-29

74-009-10

74-009-00

74-000-00

71-501-00

71-100-00

88-025-06

88-028-62

88-029-80

88-065-06

88-069-81

94-304-00

73-004-10

Illustrated Parts

INSTRUMENTATION

Description

Ignition Switch, Keyed Alike

Ignition Switch, Keyed Unalike (optional)

Switch, Forward/Off/Reverse

Label, Forward/Off/Reverse

Pop Rivit, 5/32” x 1/2”

Cover Plate, Dash

Charge Indicator, 24 Volt

Charge Indicator, 36 Volt

Hourmeter, 12-48 Volts (optional)

Horn Button

Toggle Switch (with optional light)

Screw, #8-32 x 1/2” Truss Hd

Lockwasher, #8

Nut, #8-32

Screw, 1/4NC x 1/2 Truss Hd

Locknut, 1/4NC

Label, Console Switches

Horn

1

1

2

2

2

4

4

1

2

1

1

1

1

Qty

1

1

1

1

1

Parts Page 21

Illustrated Parts

Speed Control Panel

Parts Page 22

22

23

24

25

18

19

20

20a

21

13

14

15

16

17

8

9

10

11

12

6

7

4

4a

5

Item No.

Part No.

1 72-501-42

1a 72-501-39

2

3

88-838-06

62-205-00

72-501-43

72-501-38

88-818-06

79-840-00

79-844-00

73-004-10

88-089-80

88-088-63

88-080-11

61-838-41

61-838-42

88-099-91

88-088-63

88-049-80

88-048-62

88-045-11

78-302-50

62-021-00

62-023-00

01-432-26

75-235-26

88-065-09

88-060-09

88-069-81

Not 75-149-28

Shown 75-148-23

Illustrated Parts

Speed Control Panel

Description

Forward or Reverse Solenoid, 24V, 200A (C4-33)

Forward or Reverse Solenoid, 36V, 200A (C4-32)

Sheet Metal Screw, #14 x 1/2”

Speed Controller, 400A

ISO Solenoid, 24V, 200A (C4-33)

ISO Solenoid, 36V, 200A (C4-32)

Sheet Metal Screw, #8 x 1/2”

Circuit Breaker, 10 amp

Circuit Breaker, 135 amp

Horn, 12 V

Nut, 5/16NC

Lockwasher, 5/16

Bolt, 5/16NC x 1” Hex Hd

Bus Bar, 5/8” x 1-1/2” Hole Centers

Bus Bar, 3/8” x 2-5/8” Hole Centers

Nut, 5/16NF Thin Pattern

Lockwasher, 5/16” Internal Tooth

Nut, #10-32

Lockwasher, #10

Screw, #10-32 x 1” Truss Hd

Resistor, 250 ohm, 5 watt

Solenoid Panel Assembly, 24V (C4-33)

Solenoid Panel Assembly, 36V (C4-32)

Panel, Solenoid Mounting (painted black)

Jumper, 4 Ga., 6” Long

Bolt, 1/4NC x 3/4” Truss Hd

Bolt, 1/4NC x 3/4” Hex Hd

Locknut, 1/4NC

Harness, Power, Control Assembly

Harness, Control, Vehicle

5

5

2

10

10

1

4

4

4

2

1

1

2

1

1

Qty

2

2

4

1

2

4

2

6

2

1

1

1

1

1

1

Parts Page 23

Illustrated Parts

Lester Charger P1

Parts Page 24

Parts Page 25

Illustrated Parts

Illustrated Parts

Lester Charger P2

Parts Page 26

Parts Page 27

Illustrated Parts

Illustrated Parts

Signet Charger

NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following:

PART #

75-318-20

75-320-51

DESCRIPTION

Butt splice

Knife connector

Parts Page 28

Signet® Charger

ITEM # PART #

79-202-20

79-303-40

79-575-60

DESCRIPTION

24v Charger assembly (see note on facing page)

36v Charger assembly (see note on facing page)

Replacement cover w/AC cord and gasket

Note: There are no user serviceable components inside the charger

Illustrated Parts

QTY

1

1

Parts Page 29

Illustrated Parts

Batteries

Parts Page 30

Illustrated Parts

Item No.

Part No.

1 75-231-00

BATTERIES

Description

Jumper, Battery, 10-1/4” long

Qty

3

2 01-423-79 Angle, Battery Hold 2

7c

7d

8

9

5

6

7

3

4

7a

7b

50-227-00

88-069-81

88-081-12

88-089-80

77-042-00

77-044-00

77-047-00

77-042-80

77-047-80

88-100-09

88-109-87

Battery Rod

Locknut, 1/4NC

Bolt, 5/16NC Square Hd, Tin-Lead

Nut, 5/16NC, Tin-Lead

Battery, 6 Volt, 217 amp hour (standard)

Battery, 6 Volt, 230 amp hour (optional)

Battery, 6 Volt, 244 amp hour (optional)

Battery, 6 Volt, 217 amp hour (optional, export)

Battery, 6 Volt, 244 amp hour (optional, export)


Nut, 3/8NC Keps

3

3

8 or 12

8 or 12

4 or 6 .

4 or 6 .

4 or 6 .

4 or 6 .

4 or 6 .

1

1

Parts Page 31

Illustrated Parts

Seat Cushions and Deck

Parts Page 32

Item No.

Part No.

1 90-001-00

2 90-000-00

3

4

90-100-00

90-100-51

5 90-420-00

Not Shown

#14 x 1” Phillips Metal

Not Shown

3/8NC x 3/4” Square Hd Set

Seat Cushions and Deck

Description

Seat Cushion

Backrest

Seat Frame

Support Rod

Deckboard, 29-1/8” x 48”

88-837-11*

8

88-107-09**

6

Illustrated Parts

Qty

1

1

1

2

1

Screw,

Screw,

Parts Page 33

Illustrated Parts

Decals

Parts Page 34

Item No.

Part No.

1 94-301-44

2 94-313-20

3

4

94-312-00

88-807-01

94-384-14

5

6

7

94-309-00

94-384-01

94-373-10

8

9

94-333-00

94-313-00

10 94-319-00

Not 94-201-00

Shown 88-567-91

Illustrated Parts

DECALS

Description

Decal, Arms and Legs

Decal, Safety Warning

Forward and Reverse Switch label

Rivet (for F&R label)

Decal, When Leaving Vehicle

Decal Brake Warning

Decal, Not a Motor Vehicle

Decal, Vehicle Data

Decal, FM

Decal, Battery Warning

Decal, Battery Disconnect

Taylor-Dunn Emblem (on front cowl)

Fastener, Push On (for TD Emblem)

1

1

3

1

1

1

1

1

1

2

1

Qty

1

1

Parts Page 35

Illustrated Parts

Optional Equipment

Parts Page 36

Illustrated Parts

OPTIONAL PARTS

Wheel Covers

Item No.

Part No.

1

1a

92-000-00

92-001-00

Description

Chrome Wheel Cover, 8”

Chrome Wheel Cover, 6”

Diamond Plate Deck Cover

2

3

90-420-40

88-607-09

90-420-60

Deck, Diamond Plate, 29-1/8” x 48”, Black

Rivet, 1/4” x 1/2” Starpin

Kit, Diamond Deck Cover, Black

Reverse Warning Beeper

4 73-005-05 Alarm, Pulsating, 10V to 48V

No Headlight, No Taillight >>>>

5

6

72-022-51

30-805-00

Mounting Ring, Rubber

Plate, Hole Cover

Headlight & Taillight

8

9

10

6

7

72-022-00

72-005-00

Not

Shown 72-005-05

88-102-11

88-108-60

88-109-81

Hitches

11

12

13

14

15*

16*

17*

97-804-01

97-808-00

97-806-10

02-432-00

88-140-14

88-148-62

88-149-80

Bulkhead, Bolt On

18

19

20

21

01-432-90

88-065-09

88-068-62

88-069-80

Taillight Assembly, 12V

Headlight Assembly, 12V

Headlight Mount

Bolt, 3/8NC x 1” Carriage

Washer, 3/8” Cut

Locknut, 3/8NC

Hitch, Pintle Type

Hitch, Automatic Coupling

Hitch, Pin and Clevis

Plate, Hitch Mounting, Lowered

Bolt, 1/2NC x 1-1/2” Hex Hd

Lockwasher, 1/2”

Nut, 1/2NC

Bulkhead (unpainted)

Screw, 1/4NC x 3/4” Phillips Truss Hd

Lockwasher, 1/4”

Nut, 1/4NC

Qty

2

2

1

6

1

1

2

2

1

1

1

1

1

1

1

4

4

4

1

1

1

1

4 or 8 .

4 or 8 .

4 or 8 .

Parts Page 37

Illustrated Parts

Stake Sides

Parts Page 38

Item No.

Part No.

1 90-550-03

2 90-550-02

3

4

90-550-01

90-544-00

5

6

7

90-544-10

88-065-11

88-069-81

Illustrated Parts

Stake Sides

Description

Side Gate, Left

Side Gate, Right

End Gate

Stake Pocket, Outer (painted black)

Stake Pocket, Inner (painted black)

Screw, 1/4NC x 1” Phillips Truss Hd

Locknut, 1/4NC

Qty

1

1

1

6

6

24

24

Parts Page 39

Illustrated Parts

Fiberglass Cab and Doors P1

Parts Page 40

Illustrated Parts

Item No.

Part No.

1 91-005-00

2 90-811-00

3

4

90-851-00

98-310-10

5

6

7

88-065-08

88-068-62

88-069-83

91-005-10

Doors, Naugahyde

23

24

25

26

27

18

19

20

21

22

13

14

15

16

17

8

8a**

9

9a**

10

11

12

88-068-61

88-068-62

88-069-83

88-065-06

94-011-00

88-025-08

88-029-86

97-304-50

98-451-00

88-027-03

90-903-60

90-903-61

90-903-98

90-903-99

90-913-98

90-913-99

91-809-10

91-810-01

17-104-00

97-315-53

97-315-54

97-315-51

88-727-06

88-065-08

Cab, Fiberglass, w/Safety Glass

Description

Cab, Fiberglass

Windshield, Front

Rear Window

Window Channel, Rubber


Lockwasher, 1/4”

Acorn Nut, 1/4NC

Kit, Fiberglass Cab

Side Curtain, Left

Side Curtain, Right

Frame, Side Curtain, Left

Frame, Side Curtain, Right

Hinge, Door Frame

Angle, Lower Hinge

Collar, 3/8”

Handle, Door, Outer

Handle, Door, Inner

Latch, Door Handle

Rivit, 5/32” x 1/2”


Washer, 1/4” SAE

Lockwasher, 1/4”

Acorn Nut, 1/4NC


Rail, Trim/Drip

Screw, 8-32 x 5/8” Truss Hd Machine

Locknut, 8-32

Snap Fastener

Tape, Weather Strip

Screw, 8-32 x 5/16” Set

Kit, Side Curtain, Left

Kit, Side Curtain, Right

* Quantites are for one door only.

** Not shown in illustration

2*

2*

6*

1

1

3 ft*

1*

2*

4*

4*

2*

1*

1*

1*

1*

16*

2*

1

1

1

1

1*

1*

1*

8

8

8

1

Qty

1

1

1

13 ft

Parts Page 41

Illustrated Parts

Mirrors, Windshield Wiper, Brake Light

Parts Page 42

Illustrated Parts

Windshield Wipers

8

9

10

11

12

13

Item No.

Part No.

1 92-201-00

2 92-202-00

3

4

88-065-08

88-069-81

5

6

7

88-068-62

88-069-83

88-060-09

74-050-00

74-051-00

74-052-00

88-065-08

88-069-87

88-069-83

75-114-15

71-100-00

Mirrors, Windshield Wiper

Description

Mirror, 4-1/2” x 8-1/2”

Bracket, Mirror Mounting


Locknut, 1/4NC

Lockwasher, 1/4”

Acorn Nut, 1/4NC


Windshield Wiper Motor

Arm, Windshield Wiper

Blade, Windshield Wiper


Nut, 1/4NC Keps

Acorn Nut, 1/4NC

Harness, Wiper & Light

Switch, Toggle (located on the dash tray)

Stop Light, Mechanical Brake (illustration not availalble)

01-432-99

17-104-00

71-111-00

71-135-00

75-007-02

88-014-13

88-019-80

88-045-06

88-048-62

88-101-18

88-108-60

Support, Park Brake Switch

Collar, 3/8”

Switch, Brake Light, Mechanical

Switch, Micro, w/Formed Lever

Harness, Mechanical Stop Light

Screw, 6-32 x 1-1/4” Round Hd

Nut, 6-32

Screw, 10-32 x 1/2” Truss Hd Machine

Lockwasher, #10

Bolt, 3/8NC x 2-1/2” Hex Hd, Grade 5

Washer, 3/8” Cut

1

1

1

1

1

1

1

1

Qty

1*

1*

2*

1*

2*

2*

1*

4

2

1

2

2

2

1

2

1

1

1

Parts Page 43

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 ......................................................... 4

Suggested Torque Values (non-critical hardware) 5

Appendix C: Brake Lining

Handling Precautions .................... 7

Appendixes

APPENDIX A: SPECIAL TOOLS

DESCRIPTION

Test Light

Accelerator Test Harness

Sevcon® Handset Analyzer

(read only)

Sevcon® Handset Analyzer with Speed Adjust Capability

Disc Brake Boot Installation

Tool

Pin Removing Tool

Pin Removing Tool

Hydrometer

Battery Filler

PURPOSE

Used for testing electrical circuits. Powered by the truck batteries, switchable for 12, 24, 36, and 48 volts.

Used to test the solid state accellerator module part number series 62-033-XX.

Used to test the Sevcon® control systems and reset the

Smart View display (includes instructions).

Same as 62-027-61 (above) plus allows a limited range of speed adjustment.

Used to install the rubber boot on all disc brake bodies.

PART NUMBER

62-027-00

62-027-31

62-027-61

62-027-62

41-350-13

Used to remove pins and sockets from AMP connectors.

75-440-55

Used to remove pins and sockets from MOLEX connectors.

75-442-55

Used to check the specific gravity of battery electrolyte.

77-200-00

Used to safely add water to batteries.

77-201-00

Appendixes

Appendix A

Page 2

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.

Hex Bolts

S.A.E. Grade 2

S.A.E. Grade 8

S.A.E. Grade 5

L’9

L’9

Other Bolts

Truss Head, grade 2 Carriage Bolt, grade 2

(unless marked as above)

Appendixes

Appendix B

Page 3

Appendixes

Hex Nuts

Nuts with no markings are to be treated as S.A.E. Grade 2

S.A.E. Grade 5 S.A.E. Grade 8

Hex Lock Nuts (stover)

Lock nuts use a letter to indicate the grade of the nut. Grade A’ locknuts would be the equivelent of Grade ‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’.

NOTE: Nuts with no markings are to be treated as S.A.E. Grade A

or,

B or, or,

C or,

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

Appendixes

Suggested Torque Values (non-critical hardware)

Diameter and TPI

Grade 2

Tightening

Torque

(ft-lb)

Grade 5

Tightening

Torque

(ft-lb)

Grade 8

Tightening

Torque

(ft-lb)

1/4-20 4-7

1/4-28 5-8

7-10

8-12

10-14

11-16

5/16-18 9-14

5/16-24 10-15

3/8-16 16-24

3/8-24 18-27

14-21

15-23

25-37

28-42

20-29

22-33

35-52

40-59

7/16-14 26-38

7/16-20 29-43

1/2-13 39-59

1/2-20 44-66

40-59

44-66

56-84

62-93

60-90 85-128

68-102 96-144

9/16-12 56-84

9/16-18 63-94

87-131 123-184 140

97-146 137-206 160

5/8-11 78-117 120-180 170-254 195

5/8-18 88-132 136-204 192-288 225

3/4-10 138-207 213-319 301-451 350

3/4-16 154-231 238-357 336-504 390

7/8-9 222-334 344-515 485-728 565

65

70

95

110

7/8-14 245-367 379-568 534-802 625

1-8 333-500 515-773 727-1091 850

1-14 373-560 577-866 815-1222 930

1.125-7 472-708 635-953 1030-1545 1700

1.125-12 530-794 713-1069 1156-1733 1850

1.25-7 666-999 896-1344 1454-2180 2950

1.25-12 738-1107 993-1489 1610-2414 3330

22

25

40

45

L'9

Tightening

Torque

(ft-lb)

11

12

Appendixes

Appendix B

Page 5

Appendixes

Suggested Torque Values (critical hardware)

Torque Table

Group Description Ft-Lbs

Brakes - - - - - - - - - - - - - - - - - - - - - - - -

Brake bolt (disc brake body)

Brake line tube nut fittings

Brake spider bolts (Dana 160mm hyd brakes)

Brake spider bolts (Dana 160mm mech brakes)

Brake spider bolts (Dana 7x1-3/4 brakes)

Electrical - - - - - - - - - - - - - - - - - - - - - - - -

Battery terminals

Front Axle - - - - - - - - - - - - - - - - - - - - - - - -

11 - 11

12 - 13

25 - 35

15 - 19

16 - 20

8 - 9

Front spindle nut -

Note: Refer to maintenance section in the service manual

King pin


-

Rear Axle/Transmission - - - - - - - - - - - - - - - - - - - - - - - -

3rd member Gear case cover (GT drive)

Axle bolt (GT drive)

Axle hub nut (Dana)

Axle tube to center section (Dana F-N-R)

Carrier cap bolts (Dana)

Differential Cover plate (Dana H12)

Drain plug (Dana H12)

Drain plug (GT drive)

Gear case to 3rd member (GT drive)

Motor mounting (GT/Dana)

Pinion nut (F2/F3)

Pinion nut (GT drive)

Ring gear (Dana)

Wheel lug nut

Steering - - - - - - - - - - - - - - - - - - - - - - - -

45 - 50

275 - 275

95 - 115

25 - 35

100 - 120

18 - 25

25 - 40

21 - 25

18 - 20

6.5 - 7

175 - 175

154 - 169

35 - 45

75 - 90

Ball joint clamp

Ball joint nut

Pitman nut (18-308-21 steering gear)

Pitman nut (18-308-25 steering gear)

Rod end nut

Steering shaft pinch bolt

Steering wheel nut (18-308-21 steering gear)

Steering wheel nut (18-308-25 steering gear)

28 - 32

40 - 45

75 - 100

181 - 217

20 - 25

24 - 26

28 - 32

72 - 86

Suspension - - - - - - - - - - - - - - - - - - - - - - - -

Leaf spring hangers


-

Torque Range

In-Lbs

132 - 132

144 - 156

300 - 420

180 - 228

192 - 240

96 - 108

-

-

Nm

15 - 15

16.3 - 17.7

34 - 47.6

20.4 - 25.8

21.8 - 27.2

10.9 - 12.2

-

-

540 - 600

3300 - 3300

61.2 - 68

374 - 374

1140 - 1380 129.2 - 156.4

300 - 420 34 - 47.6

1200 - 1440 136 - 163.2

216 - 300

300 - 480

252 - 300

216 - 240

24.5 - 34

34 - 54.4

28.6 - 34

24.5 - 27.2

78 - 84

2100 - 2100

900 - 1080

8.8 - 9.5

238 - 238

1848 - 2028 209.4 - 229.8

420 - 540 47.6 - 61.2

102 - 122.4

336 - 384

480 - 540

900 - 1200 102 - 136

2172 - 2604 246.2 - 295.1

240 - 300

288 - 312

38.1 - 43.5

54.4 - 61.2

27.2 - 34

32.6 - 35.4

336 - 384

864 - 1032

38.1 - 43.5

97.9 - 117

- -

Appendixes

Appendix B

Page 6

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.

Never use compressed air or dry brush to clean the brake assemblies.

Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust.

Do not grind, sand, break, or chisel the brake pads/shoes, as this will cause unnecessary dust, possibly releasing asbestos fibers in the air.

Always wear protective clothing and a respirator when working on the brake pads/shoes or their associated components.

Inhaled asbestos fibers have been found to cause cancer and respiratory diseases.

Do not drive the vehicle if any worn or broken part is detected in any part of the brake system. The cause of the damage must be repaired immediately.

Appendixes

Appendix C

Page 7

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

Taylor-Dunn C0-014-32, C0-014-33 Utility Vehicle Operation, Troubleshooting and Replacement Parts Manual

Assistant Bot

Models Inlcuded:

C0-014-32

C0-014-33

Revision: B

MANUAL MC-432-05

Operation, Troubleshooting and

Replacement Parts Manual

Serial Number Starting: 151285

Taylor-Dunn

Mfg.

2114 W. Ball Road

Anaheim, CA 92804

(Attn: Technical Writer)

Section Index

Taylor-Dunn

“Mule” Model C0-014-32 and C0-014-33

Operator and Service Manual Section Index

Table of Contents

ABOUT THIS MANUAL

RESPONSIBILITIES

Of the Owner...

Of the Operator...

Of the Service Personnel...

Of the Passengers ...

WHO SHOULD READ THIS MANUAL

HOW TO USE THIS MANUAL

INTRODUCTION

Safety Rules and Operating Instructions

Maintenance Service and Repair

Electrical and Charger Troubleshooting

Illustrated Parts

Conventions

HOW TO IDENTIFY YOUR VEHICLE

TAKING DELIVERY OF YOUR

VEHICLE

What To Do If a Problem is Found

TABLE OF CONTENTS

STANDARD SPECIFICATIONS BURDEN CARRIER

MODEL ITEM

VOLTAGE SPECIFICATION

SAFETY RULES AND GUIDE-

LINES

DRIVER TRAINING PROGRAM

Driver Qualifications.

VEHICLE CONTROLS

Key-Switch

Forward-Off-Reverse Switch

Horn Switch

Headlight Switch (optional)

Accessory Switch (Optional)

Battery Status Indicator, Analog

Hour Meter (optional)

Directional Signals (Optional)

Hazard Light Switch (Optional)

Electrolyte Alarm (Optional)

Steering

Foot Brake Pedal

Accelerator Pedal

Park Brake

Charger Interlock

VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

Starting:

While driving:

Loading and Unloading

Parking

Towing

CHARGING YOUR VEHICLE

New Battery Break in

Signet

Charger Operation

Lestronic II

Charger Operation

Charging Time

To obtain the maximum battery life:

STORING AND RETURNING TO

SERVICE

Storing Your Vehicle