Taylor-Dunn AN 171, Operation, T Roubleshooting And Replacement Parts Manual

Page 1: ...ing 94562 Ending 167016 Note Other controllers used up to serial number 95754 use manual MA 159 04 MANUAL MA 159 05 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded SC 001 59 SC...

Page 2: ......

Page 3: ...nn 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...

Page 4: ...B2 48 With Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor...

Page 5: ...ervice 11 Control System Troubleshooting 12 Charger Troubleshooting 13 Wire diagram 14 Illustrated Parts 15 Appendix A Special Tools 16 Appendix B Suggested Torque Values 17 Appendix C Brake Lining Ha...

Page 6: ...B2 48 With Stake Side Dump Bed Option SC1 00 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor...

Page 7: ...roduction Vehicles shown with optional equipment 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 Deliv...

Page 8: ...pplicable 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 T...

Page 9: ...entions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information a...

Page 10: ...ed below 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 N...

Page 11: ...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...

Page 12: ...TAYLOR DUNN...

Page 13: ...ke Treadle AN 171 6 Steering SC 159 6 Steering AN 171 6 Walk along Handle AN 171 6 Foot Interlock Switch SC 159 optional 7 Charger Interlock 7 Parking brake 7 Vehicle Operational Guidelines 8 Safety G...

Page 14: ...ol 275 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC SC 159 3 35 kW 4 5 Horse Power Intermittant duty Series Wound AN 171 4 99 kW 6 7 Horse Power Intermittant dut...

Page 15: ...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 DRIVER TRAINING P...

Page 16: ...gage 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...

Page 17: ...indicator is located to the left of the hour meter The battery status indicator has a LED bar graph that indicates the relative state of charge of the battery The top LED will light only when connecte...

Page 18: ...allow operation of the vehicle while standing on the right side of the vehicle Push forward onthe handle to start and pull back to stop Accelerator Brake Treadle SC 159 The accelerator and brake are...

Page 19: ...functioning power source NOTE The interlock shown is mounted external of the charger Some vehicles may have the interlock built into the charger Foot Interlock Switch SC 159 optional A switch or peda...

Page 20: ...r of the treadle to set the parking brake 3 Rotate the ON OFF switch to the ON position 4 Place the forward off reverse switch in the desired direction of travel 7 Slowly depress the front of the trea...

Page 21: ...le 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...

Page 22: ...ly 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 o...

Page 23: ...es 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 informat...

Page 24: ...h and Service Batteries l Check Park Brake l Check Motor Brushes and Blow Out Motor l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l C...

Page 25: ...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...

Page 26: ...TAYLOR DUNN...

Page 27: ...e of Contents General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 Model E 4 55 Tow Tractor Model C 4 25 Tow Tractor Illustrations of other popular Taylor Dunn vehi...

Page 28: ...or cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Periodic maintenance and service must be performed on this vehicle Failure to c...

Page 29: ...ing Brakes Dragging Batteries Discharged or Defective Worn Drive Gears Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings W...

Page 30: ...neral Purpose Grease 4 Steering Shaft 2 General Purpose Grease 5 Steering Shaft Gears 1 General Purpose Grease 6 Steering Chain 2 General Purpose Grease 7 Drive Fill Plug 1 SAE 140 API GL 5 Hypoid Gea...

Page 31: ...TABLE OF CONTENTS Inspect the Front Wheel Bearings 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 4 Replace Front Wheel Bearings 5 Front Axle Service...

Page 32: ...the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings 9 Spin the wheel s and listen for any grinding noise Any noise may be an indication of worn or d...

Page 33: ...ands 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 w...

Page 34: ...section for information regarding installing the axle 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release t...

Page 35: ...r the Steering Wheel 2 Inspect the Steering Components 4 Steering Wheel and Bushings 4 Steering Chain 4 Pillow Blocks 5 Fork Bearings 5 Adjust the Steering Shaft 6 Replace the Steering Wheel 6 Replace...

Page 36: ...ft should be level If it is not level then perform the following A Raise the front wheel approximately 1 inch off of the ground B Remove the fork spindle bearing cap C Loosen the fork nut until the st...

Page 37: ...en the turnbuckles to remove all play from the steering chain 14 Install new safety wire and tie off as shown in the illustration 15 Untie the front fork 16 Reconnect the main positive and negative ca...

Page 38: ...orners should be 90 degrees with a small radius If the corners are excessively rounded or the sides are tapered then the steering wheel should be replaced Insert the steering shaft back into the colla...

Page 39: ...the main positive and negative cables at the batteries Front pillow block FORK BEARINGS 6 Raise the front of the vehicle and support with jack stands 7 Inspect for lateral play by attempting to move t...

Page 40: ...se 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 ADJUST T...

Page 41: ...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 m...

Page 42: ...TAYLOR DUNN...

Page 43: ...TABLE OF CONTENTS Inspect the Service Brake 2 Adjust the Service Brake 2 Adjust the Brake Linkages 3 Replace the Brake Lining 4 Replace Brake Drum 6 Replacing the Treadle Linkage 7 Brake Service...

Page 44: ...rom behind the wheels 8 Test drive the vehicle ADJUST THE SERVICE BRAKE 6 Raise the drive wheels off of the ground 7 Loosen the brake bolt jam nut 8 Depress the treadle until the throttle linkage is 0...

Page 45: ...ted incorrectly 6 Loosen the brake linkage jam nut 7 Remove the clevis pin from the brake arm 8 Depress the treadle until the front of the treadle is level with the floorboard 9 Hold the brake arm up...

Page 46: ...or this procedure If the brake drum must be removed refer to ReplaceThe Brake Drum for this procedure 6 Release the park brake 7 Disconnect the parking brake cable and return spring from the brake arm...

Page 47: ...lts 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 dr...

Page 48: ...e drum Make certain that the alignment bracket does not come into contact with the brake drum 13 Adjust the alignment bracket adjusting bolt s to 0 050 0 100 away from the brake band and tighten the j...

Page 49: ...he park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 7 Inspect the holes for the clevis pins in the tread...

Page 50: ...TAYLOR DUNN...

Page 51: ...TABLE OF CONTENTS Throttle Linkage Adjustments 2 Throttle Linkage...

Page 52: ...ADJUSTMENTS The throttle linkage is coupled with the brake linkage There are no adjustments that are specific to the throttle linkage Refer to the Brake Section for linkage adjustments or replacement...

Page 53: ...tors 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 Se...

Page 54: ...Disconnect the main positive and negative cables at the batteries Typical motor with cooling fan indicated by the arrow Typical brush and brush holder Motors with internal cooling fans NOTE There are...

Page 55: ...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...

Page 56: ...of digital multi meter check the continuity from any one of the 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 R...

Page 57: ...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...

Page 58: ...Limits then the motor must be replaced 5 Thoroughly clean all copper debris from between the commutator segments Do not press against the outer race of the bearing Pressing against the outer race will...

Page 59: ...Depth max mm inches mm inches mm inches mm inches 5BC58JBS6129A 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129B 0 635 0 025 66 75 2 625 19 05 0 75 38 1 1 5 5BC58JBS6129C 0 635 0 025 66 75 2...

Page 60: ...TAYLOR DUNN...

Page 61: ...Drive Motor 6 Remove 6 Install 6 Rear Axle 7 Remove and Install 7 Replace the Axle Bearing 8 Transmission Assembly 9 Remove and Install 9 Chain Case 10 Disassemble 10 Assemble 12 Differential Assembl...

Page 62: ...ace blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity...

Page 63: ...replacing the drive chain 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 14 Rele...

Page 64: ...nt 5 Disconnect the main positive and negative cables at the batteries 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...

Page 65: ...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 2 quarts of oil NOTE...

Page 66: ...ce blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Install 1 Tie the chain up in position with mechanics wire as shown 2 S...

Page 67: ...tive and negative at the batteries remove the blocks from the wheels and test drive 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the cent...

Page 68: ...n resulting 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 re...

Page 69: ...n reverse order 15 Check brake adjustment and adjust as needed Refer to Adjust the Brakes for information regarding adjusting the brakes 16 Reconnect the main positive and negative at the batteries re...

Page 70: ...om the housing and then reinstall the drain plug 8 Remove the brake drum Refer to sectionBrakes Replace the Brake Drum for information regarding removing the brake drum 9 Remove the nuts from the thre...

Page 71: ...emove 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 pl...

Page 72: ...ain case housing 7 Install the chain case centering tool refer to Appendix A into the pinion seal bore in the chain case housing 8 Install the chain case housing onto the pinion shaft and tighten the...

Page 73: ...ting bolts 15 Adjust the brake Refer to sectionBrake Service Adjust the Brakes for information regarding adjusting the brakes 16 Adjust the drive chain Refer to sectionAdjust the Drive Chain for infor...

Page 74: ...r 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 D...

Page 75: ...d 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 differenti...

Page 76: ...eeth 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...

Page 77: ...races 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...

Page 78: ...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...

Page 79: ...Transmission Transmission Page 19...

Page 80: ...Transmission Transmission Page 20 EXPLODED VIEW...

Page 81: ...TABLE OF CONTENTS 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 Tires and Wheels...

Page 82: ...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 16 inch or less Refer to Replace the Ti...

Page 83: ...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...

Page 84: ...severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on r...

Page 85: ...BLE OF CONTENTS Battery Service 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...

Page 86: ...may result 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...

Page 87: ...ctrolyte 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...

Page 88: ...ger 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 char...

Page 89: ...n 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 i...

Page 90: ...be replaced 9 Remove all battery jumpers from both posts of the battery or batteries being replaced NOTE It is recommended to replace the battery jumpers when replacing the batteries 10 Remove the bat...

Page 91: ...that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries When torquing battery hardware use a backup wrench on the battery...

Page 92: ...l 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...

Page 93: ...tion 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 s...

Page 94: ...TAYLOR DUNN...

Page 95: ...leshooting SYMPTOMS 2 READ THIS FIRST 3 Test Equipment Required 3 IMPORTANT NOTES and INSTRUCTIONS 3 Definitions 3 SYMPTOM TROUBLESHOOTING GUIDE 19 PMC CONTROL 20 PLUGGING DIODE 22 FREEWHEEL DIODE 23...

Page 96: ...mal 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 hi...

Page 97: ...iple 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 troubleshoo...

Page 98: ...lerator pedal is depressed then go to the Forward Reverse Switch sequence After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the...

Page 99: ...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 The rear drive wheels may rotate during some o...

Page 100: ...k brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate during some of the following tests Block the front wheels raise the rear drive wheels off the...

Page 101: ...all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator pedal to engage MS 1 only If the voltage is not between 6 0 and 6 5 volts then go to the Accel...

Page 102: ...ositive 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 co...

Page 103: ...motor may not be in the same location S2 A1 A2 S1 Wiring to motor omitted for clarity Do not disconnect the motor wires for this test Motor Set the test light voltage to the same voltage as the batter...

Page 104: ...ion the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp...

Page 105: ...Representative for more information If you do not know how to test for continuity refer test to a qualified technician COLD Violet Wire s HOT Red wire s BATTERY MAIN NEGATIVE KEY SWITCH View of the t...

Page 106: ...at battery volts then go to the Accelerator sequence Connect a voltmeter across one of the COLD terminals of the KSI side of the F R switch and battery negative Close all interlock switches turn the K...

Page 107: ...ve 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...

Page 108: ...ttery volts then the F R switch 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 C...

Page 109: ...may vary Battery Negative FWD REV Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal f...

Page 110: ...y volts then go to theF R Switch sequence Set the test light voltage to the same voltage as the battery volts Connect the test light across the normally open contacts of the reverse solenoid Refer to...

Page 111: ...When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground Reverse does not run in forward Connect a voltmeter across the PMC KSI terminal and battery n...

Page 112: ...e position of the forward solenoid 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 the Forward so...

Page 113: ...eeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL Does not run in either direction plus there is noise from moto...

Page 114: ...n 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...

Page 115: ...drive wheels to the ground otherwise continue with the next test 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...

Page 116: ...ution 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...

Page 117: ...ant to review the trouble shooting steps that have led to this point The tests may need to be repeated B M A2 B 2 KSI _ The reading shown is for illustration only The actual reading may vary 1 Make su...

Page 118: ...re 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 s...

Page 119: ...repeated Reading is plus or minus 10 ISO solenoid is shown for reference only The type of solenoid in your truck may look different _ Connect the meter to each end of the resistor that was removed fro...

Page 120: ...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...

Page 121: ...the wire connected to the motor A2 terminal C The wire connected to the motor S2 terminal is shorted to the wire connected to the PMC A2 terminal Stop trouble shooting here and repair the problem Whe...

Page 122: ...se 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 complet...

Page 123: ...ing 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 1 Make sure the key swit...

Page 124: ...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 Perf...

Page 125: ...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 BEF...

Page 126: ...urrent 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...

Page 127: ...efore 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 tu...

Page 128: ...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 vo...

Page 129: ...r 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 Re Con...

Page 130: ...re 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 F...

Page 131: ...RelayTest 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 co...

Page 132: ...blem 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 Disconn...

Page 133: ...f 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 Test the AC voltage across the transformer secondary circuit The volta...

Page 134: ...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 A...

Page 135: ...st Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error CodeTable 5 Troubleshooting 6 Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting t...

Page 136: ...ses 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...

Page 137: ...eter and clamp on DC ammete r 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 batter...

Page 138: ...od 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...

Page 139: ...arger cooling fins and clean as required 4 Input or Output over current Charger will automaticaly correct for this condition and restart Note If only the 100 LED is flashing and all others are OFF the...

Page 140: ...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...

Page 141: ...ing Cycle 4 Status Light Error CodeTable 5 Troubleshooting 6 Rev C Turn the Key switch OFF BEFORE disconnecting the batteries Disconnecting the batteries with the key switch ON may corrupt the control...

Page 142: ...here are no internally serviceable components in the charger If the charger has failed then it must be replaced DEFINITIONS Volts Per Cell Voltage for each cell in a battery pack for example one 6 vol...

Page 143: ...ge the charger decreases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On t...

Page 144: ...ng off due to that the charger has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but stil...

Page 145: ...charger Battery voltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the c...

Page 146: ...be reduced and will taper off until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 If the charger does not turn on there are no faults and the...

Page 147: ...TABLE OF CONTENTS Wire Diagrams Complete Vehicle Standard Bed 2 Complete Vehicle Short Bed or Lift Out Battery Box 3 Complete Vehicle AN 4...

Page 148: ...ail Brake Light L optional Brown White R optional Head Light L Green LIGHT Red LIGHT SW STOP SW LIGHT SW ROT Red Red White Brown optional optional HM Black optional HM DI I F R CB ACCELERATOR 9 PCB MS...

Page 149: ...R LIFT OUT BATTERY BOX Wiring is the same as the standard bed with the exception of Harness is wired direct to the solenoids and controller there is no connector Built In charger is not available Char...

Page 150: ...TAYLOR DUNN...

Page 151: ...4 Lester Chargers Page 1 16 Lester Chargers Page 2 18 Signet Charger 20 Motors 22 Power Traction 24 Differential 26 Brake 28 Rear Axle 30 Rear Tires 32 Control Panel standard 34 Control Panel 40 bed 3...

Page 152: ...Illustrated Parts Parts Page 2 Front Axle...

Page 153: ...ted Parts Parts Page 3 FRONT AXLE Item No Part No Description Qty 1 88 229 81 Locknut 3 4NC 2 2 88 228 61 Washer 3 4 SAE 2 3 15 010 00 Front Axle 1 4 16 010 00 Spacer 4 5 15 011 00 Front Axle Dual opt...

Page 154: ...Illustrated Parts Parts Page 4 Front Tire...

Page 155: ...0 Wheel 2 50 5 hole Split Rim 1 9 10 075 00 Tire 4 80 x 8 LR B 1 11 030 00 Tube 4 80 x 8 1 7 13 734 40 Tire Wheel Assy 4 80 x 8 Split Rim Man Toter SC only 1 8 12 042 00 Wheel 3 75 5 hole Split Rim 1...

Page 156: ...Illustrated Parts Parts Page 6 Front Fork 7 10 Fork Collar in frame 1 2 4 5 5 4 3 6...

Page 157: ...4 Cut 1 3 45 307 00 Oil Seal 1 1 2 ID 1 4 80 011 10 Bearing Tapered Roller 1 1 4 ID 2 5 80 102 00 Bearing Race 2 6 14 030 10 Front Fork Assembly 1 7 92 105 00 Dust Cap 1 8 16 410 00 Spacer Fork Spindl...

Page 158: ...Illustrated Parts Parts Page 8 Steering Linkage SC...

Page 159: ......

Page 160: ...Illustrated Parts Parts Page 10 Steering Linkage AN...

Page 161: ...Item No Part No Description Qty 1 20 026 10 Steering Shaft Assembly 1 2 84 005 00 Pillow Block 2 3 95 500 00 Steering Handle 1 4 98 350 00 Hand Grip 1 5 88 080 15 Bolt 5 16NC x 1 3 4 Hex Hd 4 6 88 089...

Page 162: ...Illustrated Parts Parts Page 12 Mechanical Control Linkage 6 4 5 1 3 7 8 8 7 8 4 8 7 7 See Note On Following Page Brake Arm Ref 9 10 Collars welded to frame...

Page 163: ...Qty 1 50 429 00 Connecting Strap 1 2 85 281 00 Link Extension Spring 1 3 85 280 00 Spring Extension 1 3 8 OD x 7 3 4 1 4 96 762 00 Clevis 3 8 2 5 88 119 80 Nut 3 8NF 1 6 50 026 00 Rod 3 8NF x 3 Long...

Page 164: ...Illustrated Parts Parts Page 14 Throttle Linkage 3 1 2 4 5 6 6 6 7 8 8 9 10 9 10...

Page 165: ...g Bracket 1 2 62 033 00 Accelerator Module 1 3 02 150 11 Lever Accelerator Extension 1 4 50 123 21 Rod Accelerator Linkage 1 5 50 481 00 Connector Park Brake Slip 1 6 88 108 61 Washer 3 8 SAE 3 7 88 1...

Page 166: ...Illustrated Parts Parts Page 16 Lester Chargers Page 1 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 167: ...79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25...

Page 168: ...Illustrated Parts Parts Page 18 Lester Chargers Page 2 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 169: ...31 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 7...

Page 170: ...et Charger NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector Typic...

Page 171: ...ts Page 21 Signet Charger ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable component...

Page 172: ...Illustrated Parts Parts Page 22 Motors 9 12 13 9 5 3 4 2 1 14 10 11 7 16 17 6 8 15 Typical GE Motor...

Page 173: ...A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 5BC49JB399C 70 054 00 45 508 00 80 504 00 80 200 00 97 100 00 70 203 10 98 622 00 98 623 00 97 178 00 97 179 00 70 210 62 70 195 10 70...

Page 174: ...Illustrated Parts Parts Page 24 Power Traction...

Page 175: ...on SC 1 10 16 415 00 Spacer 1 11 30 092 00 Pinion Sprocket standard on model SC 1 11 30 093 00 Pinion Sprocket standard on AN optional on SC 1 12 30 507 20 Drive Chain standard on model SC 1 12 30 50...

Page 176: ...Illustrated Parts Parts Page 26 Differential...

Page 177: ...nd Pinion Gear Set 2 75 1 7 41 997 00 Oil Plugs 2 8 41 290 00 Differential Housing 1 9 80 555 00 Rear Pinion Bearing 1 10 80 554 00 Front Pinion Bearings 2 11 41 711 00 Pinion Housing Shim 1 12 80 702...

Page 178: ...Illustrated Parts Parts Page 28 Brake...

Page 179: ...1 4 85 060 20 Spring 1 5 41 372 10 Bracket Brake Mounting 1 6 88 159 82 Nut 1 2NF Jam 1 7 88 159 84 Locknut 1 2NF 1 8 88 109 81 Locknut 3 8NC 1 9 88 108 61 Washer 3 8 2 10 88 517 11 Cotter Pin 1 11 9...

Page 180: ...Illustrated Parts Parts Page 30 Rear Axle...

Page 181: ...sket Axle Bearing 2 8 32 512 0 Spacer 2 9 88 101 13 Bolt 3 8NC x 1 Hex Hd 8 10 88 109 81 Locknut 3 8NC 8 REAR AXLE serial numbers after 135706 Item No Part No Description Qty 1 97 236 00 Wheel Lug Nut...

Page 182: ...Illustrated Parts Parts Page 32 Rear Tires 10 Ref wheel hub 1 2 5 assembly 4 3 6 7 8 9...

Page 183: ...embly 2 5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 00 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF Hex...

Page 184: ...Illustrated Parts Parts Page 34 Control Panel standard...

Page 185: ...er 135 amp 1 9 73 004 20 Horn 12 V 1 10 88 089 80 Nut 5 16NC 4 11 88 088 62 Lock washer 5 16 4 12 88 080 11 Bolt 5 16NC x 1 Hex Hd 4 13 61 838 41 Bus Bar 5 8 x 1 1 2 Hole Centers 2 14 61 838 42 Bus Ba...

Page 186: ...Illustrated Parts Parts Page 36 Control Panel 40 bed...

Page 187: ...Hd 4 12 61 838 41 Bus Bar 5 8 x 1 1 2 Hole Centers 2 13 61 838 42 Bus Bar 3 8 x 2 5 8 Hole Centers 2 14 88 099 91 Nut 5 16NF Thin Pattern 10 15 88 088 63 Lock washer 5 16 Internal Tooth 10 16 88 049...

Page 188: ...Illustrated Parts Parts Page 38 Instruments Gauges Model SC VKRZQ Model SC VKRZQ...

Page 189: ...switch 1 2 71 120 00 Key switch 1 3 71 039 02 F R switch 4 71 100 00 Accessory switch optional 5 71 100 00 Accessory switch optional Gauges Item No Part No Description Qty 1 74 000 00 Hour meter opti...

Page 190: ...Illustrated Parts Parts Page 40 Batteries Main positive Main negative 1 1 1 2 2 3 3 3 4 5 6 7...

Page 191: ...69 81 Locknut 1 4NC 3 5 88 081 12 Bolt 5 16NC Square Hd Tin Lead 8 6 88 089 80 Nut 5 16NC Tin Lead 8 7 77 042 00 Battery 6 Volt 217 amp hour standard 4 7 77 044 00 Battery 6 Volt 230 amp hour optional...

Page 192: ...Illustrated Parts Parts Page 42 Decals...

Page 193: ...ot a motor vehicle 1 2 94 313 20 Safety warning 1 3 94 384 14 Leaving vehicle 1 4 94 382 00 Treadle 1 5 94 313 00 Battery warning 1 6 94 319 00 Battery disconnect 1 7 91 301 43 Arms and legs 1 8 94 33...

Page 194: ...Illustrated Parts Parts Page 44 Miscellaneous Frame and Body SC 5 1 2 3 14 6 17 18 19 4 7 15 16...

Page 195: ...Built in Charger 1 5 88 838 06 Sheet Metal Screw 14 x 1 2 2 6 71 501 00 Horn Button 1 7 30 702 00 Steering Chain Guard 1 14 88 837 11 Screw 14 x 1 Phillips Hd 2 15 88 060 18 Bolt 1 4NC x 2 1 2 Hex Hd...

Page 196: ...Illustrated Parts Parts Page 46 Miscellaneous Frame and Body AN...

Page 197: ...NEOUS PARTS Model AN Item No Part No Description Qty 1 90 406 00 Deckboard 30 3 4 x 53 1 4 1 2 71 599 00 Console Cover 1 3 90 160 01 Tractor Seat 1 4 90 160 10 Seat Support 1 5 98 350 00 Hand Grip 1 1...

Page 198: ...TAYLOR DUNN...

Page 199: ...ed 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 critica...

Page 200: ...ntenance is completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with...

Page 201: ...Carriage Bolt grade 2 unless marked as above Other Bolts 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 Toq...

Page 202: ...as S A E Grade 2 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 marki...

Page 203: ...2 13 39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 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 1...

Page 204: ...center section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Dra...

Page 205: ...um 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 u...

Page 206: ...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...