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MX-016-00
Taylor-Dunn MX-016-00 User Manual
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Serial number Starting: 136914
MANUAL MB-150-02
Operation, Troubleshooting and
Replacement Parts Manual
Published: 11/26/2002
Revision:
C
B0-015-00
MX-016-00
Models Inlcuded:
B0-015-00 (B 1-50) Load Master
MX-016-00 (MX 1600) Maintenance Expediter
2
Table of Contents
Taylor-Dunn
5
Table of Contents
5
About this Manual
8
Introduction
8
Responsibilities
9
Who Should Read this Manual
9
How to Use this Manual
10
Safety Rules and Operating Instructions
10
Conventions
11
How to Identify Your Vehicle
12
Taking Delivery of Your Vehicle
13
Safety Rules and Operating Instructions
15
Standard Specifications
16
Safety Rules and Guidelines
17
Driver Training Program
18
Driver Qualifications
18
Vehicle Controls
19
Key-Switch
19
Forward-Off-Reverse Switch
19
Accelerator Pedal
19
Steering
19
Foot Brake Pedal
20
Park Brake
20
Horn Switch
20
Seat Interlock Switch
20
Headlight Switch
21
Hour Meter (Optional)
21
Charger Interlock
21
Battery Status Indicator, Analog
21
Battery Status Indicator, Digital Bargraph
22
Reverse or Motion Alarm (Optional)
22
Electrolyte Alarm (Optional)
22
Directional Signals (Optional)
22
Hazard Light Switch (Optional)
23
Accessory Switch (Optional)
23
Auxiliary Switch (Optional)
23
Vehicle Operational Guidelines
24
Driving
24
Loading and Unloading
24
Parking
24
Towing
24
Charging Your Vehicle
25
Signet Charger Operation, Model HB Series
25
Signet Charger Operation, Model HBS Series
25
Lestronic II Charger Operation
26
New Battery Break in
26
Charging Time
26
Storing and Returning to Service
27
Storing Your Vehicle
27
Returning to Service
27
Periodic Maintenance Checklist
28
Daily Visual Inspection
29
Maintenance Guidelines for Severe Duty Applications
29
General Maintenance
31
Maintenance Guidelines
32
Maintenance Guidelines for Vehicles Used in Severe Conditions
33
Troubleshooting Guide
34
Lubrication Chart
35
Front Axle Service
37
Inspect the Front Wheel Bearings and Kin Pin
38
Adjust Front Wheel Bearings
39
Front Axle Removal and Installation
40
Removal
40
Installation
41
Steering Component Service
41
Front Axle Disassembly and Assembly
42
Replace Front Wheel Bearings
43
Replace the Ball Joints, Tie Rods, and Drag Link
44
Replacing the Drag Link
46
Replacing the Tie Rod
47
Replace the King Pins and Bushings
48
Replace the Steering Knuckle
50
Steering Component Service
53
Front End Alignment
54
Adjust the Steering Gear (Saginaw)
57
Replace the Steering Shaft (Saginaw, Non-Tilt Steering)
59
Replace the Steering Wheel (Saginaw, Non-Tilt Steering)
61
Replace the Steering Gear (Saginaw)
62
Repair the Steering Gear
63
Exploded View of Steering Gear
66
Maintenance, Service, and Repair
67
Inspect the Service Brake
68
Front Disc Brake Pads
68
Front Disc Brake Rotor
68
Rear Brake Shoes
68
Rear Brake Drum
69
Inspect the Parking Brake
69
Adjust the Service Brakes
70
Mechanical and Hydraulic Drum Brakes
70
Adjust the Mechanical Brake Linkages
71
Adjust the Parking Brake
72
Wheel Park Brake (Mechanical Drum Standard)
72
Wheel Park Brake (Hydraulic Drum)
72
Check Master Cylinder Fluid
73
Bleed the Brake System
74
Flush the Brake System
75
Replace Front Disc Brake Pads
76
Replace Rear Brake Shoes
77
Replace the Front Cylinder
78
Repair the Brake Body
79
Replace the Master Cylinder
81
Repair the Master Cylinder
82
Table of Contents
83
Inspecting the Motor Brushes
84
Motors with Internal Cooling Fans
84
Enclosed Motors (GE, no Cooling Fan)
84
Motor Service
84
Motor Inspection
85
Motor Removal and Installation
85
Replacing the Brushes
87
Repairing the Commutator
88
Replacing the Bearings
88
Service Limits
89
Transmission Service
91
Check Oil Level
92
Change Oil
93
Motor
94
Removal
94
Installation
94
Rear Hub with Brake Drum
95
Rear Axle
96
Replace the Axle Bearing
98
Transmission
99
Remove
100
Differential Case
100
Disassemble
100
Assemble
103
Suspension
105
Replace the Rear Springs
106
Leaf
106
Replace the Front Springs
108
Leaf
108
Replace the Spring Bushings
110
Replace the Shocks
111
Front
111
Battery Service
113
Cleaning
114
Testing
115
Watering
117
Charging
118
Replacing
119
Moist Charge Batteries
121
Storage and Returning to Service
122
Returning to Service
123
Tires and Wheels
125
Tire Inflation
126
Tire Inspection
126
Table of Contents
131
Symptoms
132
Read this First
133
Test Equipment Required
133
IMPORTANT NOTES and INSTRUCTIONS
133
Definitions
134
Wire Diagram
141
Symptom Troubleshooting Guide
149
Pmc Control
149
Plugging Diode
149
Freewheel Diode
149
Iso
149
Solenoids
149
Motor
149
Chargers
163
Test Equipment Required for Troubleshooting
166
Including, Voltage Tests, Continuity Tests and Diode Testing. if Not Familiar with
166
Any Part of These Tests, Refer Testing to a Qualified Technician
166
Working Condition
166
Voltage on the Charger Nameplate
166
Battery Volts = Full Voltage Available at the Batteries at the Time of the Test Being Performed
166
Electrical Troubleshooting
176
Important Notes and Instructions
179
Are Off. Switching Voltage When any of the Led's Are on will Result in
180
From One Input Voltage to the Other, Wait until All Three Status Led's
180
This Charger Is Rated for 115 VAC or 230 VAC Operation. When Switching
180
Clamp on DC Ammeter to Measure up to 20-Amps
180
This Troubleshooting Guide Assumes a Familiarity with the Use of a Digital Multimeter
180
Make Sure that the AC Electrical Socket the Charger Is Plugged into Is in Good
180
Make Sure that the AC Voltage at the Electrical Socket Is the same as the AC
180
Make Sure the Batteries Are in Good Condition
180
If the Charger Exhibits Intermittent Problems, It Must be in the Failed Mode for Troubleshooting
180
There Are no Internally Serviceable Components in the Charger. if the Charger Has Failed then It Must be
180
Damage to the Charger
180
Illustrated Parts
185
Default Chapter
186
Front Axle/Steering Knuckle
186
Steering Linkage
188
Steering Column
190
Steering Gear
192
Front Suspension
194
Transmission Differential Case
196
Rear Axle and Brakes
198
Rear Suspension
200
Motor
202
Speed Control Panel
210
Miscellaneous Electrical
212
Charger, Lestronic
214
Charger, Signet
216
Batteries
218
Seat Cushions, Deck and Lights, B 1-50
220
Seat Cushions, Deck and Lights, MX 1600
222
Decals, B 1-50
224
Fiberglass Cab, Doors, Mirrors
226
Strobe Light
228
Stake Sides, B 1-50
230
Hydraulic Brake Lines and Fittings (Optional)
232
Brake Lining Handling Precautions
233
Appendix A: Special Tools
234
Appendix B: Suggested Torque Limits for Standard Hardware
235
Hex Bolts
235
Other Bolts
235
Hardware Identification
235
Hex Nuts
236
Hex Lock Nuts (Stover)
236
Other Nuts
236
Suggested Torque Values (Non-Critical Hardware)
237
Appendix C: Brake Lining Handling Precautions
239
Other manuals for Taylor-Dunn MX-016-00
Service And Replacement Parts Manual
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Taylor-Dunn MX-016-00 Specifications
General
Brand
Taylor-Dunn
Model
MX-016-00
Category
Utility Vehicle
Language
English
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