Taylor-Dunn B0-254-48 Operation, T Roubleshooting And Replacement Parts Manual

®

Lavatory Service Vehicle

GT Drive

The Best Way

To Go

About Your

Business

EQUIPPED WITH GT-DRIVE SYSTEM

Models Inlcuded:

B0-254-48 (B 2-54)

MANUAL MB-254-02

Operation, Troubleshooting and

Replacement Parts Manual

Revision: C

Serial number range: 165448 - 170871

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

For more information about this and other Taylor-Dunn® manuals, please write Taylor-Dunn®:

TAYLOR-DUNN SERVICE CENTER

Taylor-Dunn® Mfg.

2114 W. Ball Road

Anaheim, CA 92804

(Attn: Technical Writer)

Table of Contents

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A small sample of the many types of vehicles offered by Taylor-Dunn

B 2-48-36 Equipped with optional

hydraulic dump bed

BT 2-80 Eight passenger tram

B 1-00 Personnel carrier

®

MX 1600 Equipped with optional

ladder rack and weld tanks

C 4-25 Huskey tow tractor

Table of Contents

Contents

Introduction............................................................ 1

About this manual..................................................................... 2

Who Should Read This Manual ............................................... 3

Responsibilities ........................................................................ 3

How To Use This Manual.......................................................... 4

Conventions......................................................................................................................5

How to Identify Your Vehicle .................................................... 6

Taking Delivery of Your Vehicle ............................................... 7

Safety Rules and Operating Instructions.............. 1

Standard Specifications ........................................................... 2

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

Driver Training Program ........................................................... 4

Driver Qualifications. ......................................................................................................... 4

Vehicle Controls........................................................................ 5

Hi-Low Switch (optional) ....................................................................................................5

Key-Switch ........................................................................................................................5

Horn Switch .......................................................................................................................5

Forward-Off-Reverse Switch .............................................................................................5

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

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

Headlight Switch................................................................................................................ 6

Accessory Switch (Optional) .............................................................................................6

Smart View Display............................................................................................................ 7

Directional Signals (Optional) ............................................................................................ 9

Steering .............................................................................................................................9

Hazard Light Switch (Optional) ..........................................................................................9

Electrolyte Alarm (Optional) ............................................................................................... 10

Seat Interlock Switch .........................................................................................................10

Park Brake......................................................................................................................... 10

Charger Interlock ...............................................................................................................10

Vehicle Operational Guidelines ............................................... 11

Safety Guidelines ..............................................................................................................11

Starting: .............................................................................................................................11

While driving:..................................................................................................................... 12

Loading and Unloading ......................................................................................................12

Parking ..............................................................................................................................12

Towing ...............................................................................................................................12

Charging your vehicle .............................................................. 13

New Battery Break in ......................................................................................................... 13

Signet® HB-xxxx Charger Operation .................................................................................13

Industrial Charger Operation ............................................................................................. 14

Charging Time ...................................................................................................................14

Lestronic II® Charger Operation ........................................................................................14

Storing and Returning to Service ........................................... 15

Storing Your Vehicle........................................................................................................... 15

Returning to Service ..........................................................................................................15

Table of Contents

Periodic Maintenance Checklist .............................................. 16

Standard Periodic Maintenance Schedule

for the Smart View Display ................................................. 17

Daily Visual Inspection ...................................................................................................... 18

Maintenance Guidelines for

Severe Duty Applications ......................................................... 18

General Maintenance ............................................. 1

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

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

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

Front Axle Service.................................................. 1

Inspect the Front Wheel Bearings and King Pin.................... 2

Adjust Front Wheel Bearings.................................................. 3

Front Axle Removal and Installation ....................................... 4

Removal............................................................................................................................ 4

Installation ........................................................................................................................ 5

Front Axle Disassembly ........................................................... 6

Replace Front Wheel Bearings ................................................ 7

Replace the King Pins and Bushings ..................................... 9

Replace the Steering Knuckle ................................................. 11

Steering Component Service ................................ 1

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

Inspect Ball Joints .................................................................... 6

Inspect Rod Ends...................................................................... 7

Adjust the Steering Gear .......................................................... 8

Replace the Steering Shaft....................................................... 10

Replace the Steering Wheel..................................................... 12

Replace the Steering Gear ....................................................... 13

Replace the Ball Joints, Tie Rods, and Drag Link.................. 14

Replacing the Drag Link ...................................................................................................16

Replacing the Tie Rod ......................................................................................................17

Center the Steering Gear.......................................................... 18

Pitman Shaft Alignment ............................................................ 18

Repair the Steering Gear .......................................................... 19

Exploded View of Steering Gear .......................................................................................22

Table of Contents

Brake Service ......................................................... 1

Inspect the Service Brake ........................................................ 2

Disc Brake Pads................................................................................................................ 2

Disc Brake Rotor ...............................................................................................................3

Inspect the Parking brake ........................................................ 4

Wheel Park Brake (hydraulic disc) ..................................................................................4

Electric Motor Brake .........................................................................................................5

Adjust the Service Brakes........................................................ 6

Two or Four Wheel Hydraulic Disc Brakes .....................................................................6

Adjust the Parking Brake ......................................................... 7

Wheel Park Brake (hydraulic disc) ..................................................................................7

Check Master Cylinder Fluid.................................................... 8

Bleed the Brake System ........................................................... 9

Flush the Brake System ........................................................... 11

Replace the Parking Brake Lining

(electric motor brake) ............................................................... 12

Inspection: ........................................................................................................................ 14

Replace Front Disc Brake Pads............................................... 15

Replace Rear Brake Pads ........................................................ 17

Hydraulic Disc ...................................................................................................................17

Replace the Wheel Cylinder..................................................... 19

Disc Brake Body Assembly (front or rear) ....................................................................... 19

Repair the Brake Body.............................................................. 21

Replace the Master Cylinder.................................................... 23

Repair the Master Cylinder....................................................... 25

Motor Service ......................................................... 1

Inspecting the Motor Brushes ................................................. 2

Motors with internal cooling fans ..................................................................................... 2

Motor Removal and Installation............................................... 3

Motor Inspection ....................................................................... 3

Replacing the Brushes or Armature Bearing ......................... 7

Repairing the Commutator....................................................... 8

Service Limits............................................................................ 10

Table of Contents

Transmission.......................................................... 1

Check Oil Level ......................................................................... 2

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

Motor Removal and Installation............................................... 4

Rear Hub or Rotor..................................................................... 5

Removing and Installing the Rear Axles

(Disc Brakes) ............................................................................. 6

Transmission Assembly ........................................................... 8

Remove and Install .......................................................................................................... 8

Disassembly and Reassembly of the

Primary Reduction Gear Case ............................................ 9

Disassembling the 3rd Member ............................................... 12

Assembling the 3rd Member.................................................... 15

Pinion Bearing Preload ....................................................................................................18

Pinion Gear Shimming Instructions ........................................ 19

Setting the Pinion Gear Depth .......................................................................................... 19

Suspension ............................................................ 1

Replace the Rear Springs ........................................................ 2

Replace the Front Springs ....................................................... 3

Replace the Spring Bushings .................................................. 4

Replace the Shocks .................................................................. 5

Tires and Wheels ................................................... 1

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

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

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

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

Replace the Tire (pneumatic).................................................. 5

Battery Service....................................................... 1

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

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

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

Charging .................................................................................... 6

Replacing (6-volt batteries only).............................................. 7

Moist Charge Batteries ....................................................................................................9

Storage and Returning to Service ........................................... 10

Storage .............................................................................................................................10

Returning to Service .........................................................................................................11

Table of Contents

Sevcon Control System Troubleshooting ............ 1

Test Equipment Required: ...............................................................................................2

Important Notes and Instructions ....................................................................................2

Definitions:........................................................................................................................ 2

Terminology used: ............................................................................................................ 2

Start Troubleshooting Here ................................................................................................3

Test 8. Anti-Rolloff Fault .................................................................................................... 22

Test 9. Electric Motor Brake ..............................................................................................23

Sevcon Logic Voltage Reference Table .............................................................................25

Status LED Code Table .....................................................................................................26

Lestronic II® Charger Troubleshooting................ 1

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

Signet® Charger Troubleshooting ........................ 1

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

Illustrated Parts...................................................... 1

Steering Knuckle............................................... 2

Front Brakes ..................................................... 4

Steering Linkage ............................................... 6

Steering Column ............................................... 8

Steering Gear .................................................... 10

Front Suspension............................................... 12

Wheels and Tires............................................... 12

Transmission Gear Case .................................... 14

Rear Axle .......................................................... 16

Transmission Differential Case.......................... 16

Rear Brakes....................................................... 18

Master Cylinder ................................................20

Brake linkage.................................................... 20

Brake Lines....................................................... 22

Rear Suspension ................................................ 24

Motor ................................................................ 26

Rear Motor Mount ............................................ 26

Instrument Panel (dash) .................................... 28

Speed Control Panel .......................................... 30

Miscellaneous Electrical.................................... 32

Signet® Charger ............................................... 34

Batteries

Roll Out Battery Box .................................. 36

Seat Cushions ................................................... 38

Decals ............................................................... 38

Miscellaneous ................................................... 39

Table of Contents

APPENDIX A-Special Tools.................................... A-1

Appendix B: Standard Hardware Suggested

Torque Limits ..................................................... 1

Hardware Identification ............................................................ 2

Standard Head Markings ................................................................................................. 2

Hex Bolts .......................................................................................................................... 2

Other Bolts ........................................................................................................................ 2

Hex Nuts ...........................................................................................................................3

Hex Lock Nuts (stover) .................................................................................................... 3

Other Nuts ........................................................................................................................ 3

Suggested Torque Values (non-critical hardware) ................ 4

Suggested Torque Values (critical hardware) ........................ 5

Appendix C............................................................. C-1

Introduction

Contents

About this manual ........................................2

Who Should Read This Manual ...................3

Responsibilities ............................................3

How To Use This Manual..............................4

Conventions .............................................................. 5

How to Identify Your Vehicle ........................6

Taking Delivery of Your Vehicle ...................7

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.

Introduction Page-2

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.

RESPONSIBILITIES

INTRODUCTION

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.

Introduction Page-3

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.

Introduction Page-4

INTRODUCTION

Conventions

Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout
this manual:

A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to

or,

themselves or others. Be sure to follow any instructions contained
within a warning and exercise extreme care while performing the
task.

The symbol at the left and the bold text contained within a box
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.

Introduction Page-5

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 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).

Theese vehicles are not designed to be driven on public roads or
highways. They are available in maximum designed speeds ranging
from 6 to 16 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.

The location of the serial number is illustrated as follows:

Introduction Page-6

INTRODUCTION

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

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.

Introduction Page-7

TAYLOR -DUNN

Safety Rules and Operating
Instructions

TABLE OF CONTENTS

Standard Specifications ...............................2

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

Driver Training Program ...............................4

Driver Qualifications..................................................4

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

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

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

Vehicle Controls ............................................ 5

Hi-Low Switch (optional) ........................................... 5

Accelerator Pedal...................................................... 7

Foot Brake Pedal ...................................................... 7

Headlight Switch .......................................................7

Accessory Switch (Optional).....................................7

Smart View Display ...................................................7

Directional Signals (Optional) ...................................8

Steering.....................................................................8

Hazard Light Switch (Optional) ................................. 8

Charger Interlock ......................................................10

Electrolyte Alarm (Optional) ......................................10

Seat Interlock Switch ................................................ 10

Park Brake ................................................................10

Vehicle Operational Guidelines ...................11

Safety Guidelines ...................................................... 11

Starting:.....................................................................11

While driving: ............................................................ 12

Loading and Unloading .............................................12

Parking......................................................................12

Towing.......................................................................12

Charging your vehicle ..................................13

New Battery Break in ................................................13

Signet® HB-xxxx Charger Operation ........................13

Industrial Charger Operation .....................................14

Charging Time ..........................................................14

Lestronic II® Charger Operation ............................... 15

Returning to Service .................................................15

Storing and Returning to Service ...............15

Storing Your Vehicle ..................................................15

Periodic Maintenance Checklist ..................16

Standard Periodic Maintenance Schedule

for the Smart View Display.....................17

Daily Visual inspection: ............................................. 18

Maintenance Guidelines for

Severe Duty Applications.......................18

SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS

ITEM VOLTAGE SPECIFICATION

Occupancy Driver only

Electrical System 48 Volt 6-165 Amp Hour, 8 Volt, Lead Acid Batteries,

Dimensions 467.36L x 149.86W x ?? H Centimeters

Turning Radius ??? Centimeters (??? Inches)

Tires 600 x 9 Softuff

Dry Weight ???? kg (???? lbs)
Without Batteries

Maximum Load ???? kg (???? lbs)

Motor, DC 48 Volt 4.4 kW, (5.9 hp) for 60 min, 7.2 kW, (9.6 hp) for 5 min
Separately Excited Field

Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs)
Weights

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid

Brakes Optional 4 Wheel Hydraulic Disc, Hand Operated Park

Steering Automotive Steering 24:1

Solid State Speed Control, 500 Amp

184L x 59W x ?? H Inches

Differential

Brake

Not available at
time of printing

Not available at
time of printing

Not available at
time of printing

Not available at
time of printing

Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Smart View Display (Battery Status Indicator, Hour

Light Accessories Dual Headlight, Tail/Brake Lights

Charger 48 Volt 100/240 VAC, 13/6.5 Amps (50/60Hz), 17 Amp DC

Diamond Plate

Meter, System Status Monitor), Key Switch, Horn Button,
Forward/Reverse Switch, Headlight Switch

These vehicles conform 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 OPERATING INSTRUCTIONS

SAFETY RULES AND GUIDELINES

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 6 to 16 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.

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

Refer to Vehicle Operational Guidelines, Safety Guidelines section for important safety information
regarding operating this vehicle.

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.

Before working
on a vehicle:

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

SAFETY RULES AND OPERATING INSTRUCTIONS

DRIVER TRAINING PROGRAM

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.

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.

• 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.

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Safety Rules Page 4

SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE CONTROLS

Key-Switch

Forward-Off-Reverse Switch

A key-switch, located on the right center side of the instrument panel,
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.

The forward-off-reverse switch, located on the right side of the instrument
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.

Hi-Low Switch (optional)

The high-low switch is located on the lower left of the instrument panel.
Toggle the switch lever up for normal speed. Toggle the switch lever
down for slow speed.

Horn Switch

The horn switch is located on the right side of the instrument panel.
Depress the switch to sound the horn, release it to turn it off.

Safety Rules Page 5

SAFETY RULES AND OPERATING INSTRUCTIONS

Headlight Switch

The headlight switch is located on the top left of the instrument panel.
Push the right side of the switch to turn the lights on. Push the left side
of the switch to turn the light off.

Accessory Switch (Optional)

The accessory switch is located on the left side of the instrument
panel and to the right of the headlight switch. Push the top of the
switch to turn on the accessory. Push the bottom of switch 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.

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.

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.

Safety Rules Page 6

SAFETY RULES AND OPERATING INSTRUCTIONS

Smart View Display

The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed
controller status monitor, and as an optional maintenance monitor feature. The operation of each of
these functions is listed below.

BSI: A bar graph representing the current state of charge is located across the top of the display. When
the batteries are fully charged, all segments of the bar graph will be on. As the batteries are used,
segments will turn off in the order of right to left.

When the batteries are discharged to 75%, the last three segments will flash indicating that you are
approaching the end of the battery cycle. At this time, the vehicle’s batteries should be charged as soon
as possible.

At 90%, all segments will flash and the vehicles speed will be reduced. At this time, the vehicle should be
removed from service for charging. Discharging beyond 90% will result in damage to the batteries that
will shorten the battery life-span.

HM: There are two hour meter functions, Key Hours and Run Time Hours.
Key Hours is the accumulated length of time in hours that the key switch is in the “ON” position.
Run Time Hours is the accumulated length of time that the vehicles has been in operation. Time is

accumulated when the FS-1 switch in the accelerator module is closed.
One of the Hours functions is being displayed whenever the either of the Hours Indicators are visible at

the right side of the display.

Key Hours: When the display is turned on,
the Key Hours will be displayed for
approximately 5-seconds as indicated by the
Key Hours Indicator located at the lower left
of the display. The icon represents the
silhouette of a key.

Key Hours icon

Safety Rules Page 7

SAFETY RULES AND OPERATING INSTRUCTIONS

Run Time Hours: After the initial 5-seconds,
the Run Time Hours will be displayed as
indicated by the Run Time Hours Indicator
located at the left of the display. The icon
represents a motor symbol with a “T” in the
center.

Run Time Hours icon

Speed controller status: The display will indicate
a fault code whenever the control system logic
detects a problem with the control system. A fault
code is being displayed whenever the Fault Code
Indicator (the letter ‘F’) is visible at the left of the
numeric display. Refer to the table below for a
list of fault codes and their descriptions.

Display showing a fault code

Fault Code Description Corrective action
01004 Discharged battery or defective wiring. Charge the battery. If the battery is

good, check wiring to the controller.

01005 Speed control overheated. Allow the controller to cool off. May be

the result of an overloaded vehicle or an
obstruction to the controller heat sink.

01008 Optional speed encoder or speed encoder

wiring defective

02000 Start up switches not operated in the correct

order or a defective switch.
02001 Defective wiring Refer to troubleshooting
04003 Start up switches not operated in the correct

order or a defective switch.
04004 Both the forward and reverse directions are

selected at the same time
04005 Start up switches not operated in the correct

order or a defective switch.
04006 Accelerator pedal depressed before the seat

interlock switch is closed
04007 - Defective wiring
04009 Discharged battery or defective wiring. Charge the battery. If the battery is

04010 Battery voltage too high Incorrect battery installed.
04011 Personality fault Reprogram the controller
04012 Personality fault Reprogram the controller
04013 Defective wiring or batteries Refer to troubleshooting
05000 Line contactor coil or wiring shorted Replace contactor or repair wiring
05006 MOSFET shorted Refer to troubleshooting
05008 Line contactor welded contacts or wiring

shorted
05009 MOSFET shorted Refer to troubleshooting
05046 Line contactor contacts open or defective

wiring

Repair as required

Reset switches and start again.

Reset switches and start again.

Check the forward/ switch and wiring
for shorts.
Reset switches and start again.

Recycle start up switches and try again.
Possible defective seat switch.

good, check wiring to the controller.

Replace contactor or repair wiring

Replace contactor or repair wiring.
Could also be result of open circuit
breaker

Safety Rules Page 8

SAFETY RULES AND OPERATING INSTRUCTIONS

Maintenance monitor (optional):

Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due.
During this warning period, the meter will continue to alert the operator. This should allow sufficient time
for the operator to schedule the maintenance that is due, with minimal down time. If the scheduled
maintenance is not performed before the warning period elapses, then the vehicles maximum speed
will be significantly reduced.

Warning period: The warning starts when the Maintenance Indicator
is ON and the Wrench icon is flashing. The Wrench icon will continue
to flash until the warning time has expired.

Maintenance Due: Once the warning has expired and the maintenance
is due, the Wrench icon will stop flashing and remain ON. Additionally,
the vehicles maximum speed will be significantly reduced until the
maintenance is performed and the display is reset. The display should

Display showing Maintenance and

Wrench icons

only be reset by an authorized technician. Refer to the Illustrated

parts section for information regarding tools required to reset the Smart

View Display.

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.

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.

Safety Rules Page 9

SAFETY RULES AND OPERATING INSTRUCTIONS

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 bi­color 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.

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.

Seat Interlock Switch

A switch located under the driver's seat disables the power to the vehicle
when the driver leaves the seat. The driver must be seated for the vehicle
to operate.

Whenever the driver leaves the vehicle, the driver should turn the key­switch off, place the forward-off-reverse switch in the center “OFF” position,
and set the park brake.

The seat interlock switch is only one part of the vehicle safety system.
The interlock switch should not be relied upon as the only safety
feature used to disable or disengage this vehicle. Doing so could result
in unexpected movement of the vehicle causing severe bodily injury
and/or property damage.

Safety Rules Page 10

SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

• Do not operate this vehicle while using any substance such

as medication, drugs, or alcohol that may impair your judgment,
reaction times, or driving ability.

• 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.

• While the vehicle is in motion, all occupants must be seated in

an assigned seating position. Do not exceed maximum passenger
capacity (count) or maximum load (weight) specification of the vehicle.

• 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. Wait 1-second then place the forward-off-reverse switch in the desired direction of travel.

6. Release the parking brake.

7. Release the foot brake.

8. Slowly depress the accelerator pedal.

Safety Rules Page 11

SAFETY RULES AND OPERATING INSTRUCTIONS

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

The key switch must be in the “OFF” position while being towed.
Towing the vehicle with the key switch “ON” may result in damage
to the vehicles electrical system.

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 12

SAFETY RULES AND OPERATING INSTRUCTIONS

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.

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.

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® HB-xxxx 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 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.

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

Typical Signet® Built In Charger

LED1 LED2 LED3

75% to 100% ON ON Blinking

Cycle complete ON ON ON

Safety Rules Page 13

SAFETY RULES AND OPERATING INSTRUCTIONS

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

Industrial Charger Operation

If equipped with an industrial charger, it is either specified by or provided by the end user. Refer to the
operating instruction supplied with your charger or contact the charger manufacturer for more information.

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.

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.

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.

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 14

SAFETY RULES AND OPERATING INSTRUCTIONS

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

Between 40 and 60 2

Below 40 6

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.

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Safety Rules Page 15

SAFETY RULES AND OPERATING INSTRUCTIONS

PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

2, 3

Check Condition of Tires and

Tire Pressure

Check All Lights, Horns,

Beepers and Warning Devises

Weekly

(20hrs)

l

l

1

Monthly

(80hrs)

1

Quaterly

(250hrs)

Check and Fill Batteries l
Check Brake System l
Check Steering System l
Check for Fluid Leaks l

Lubricate Vehicle l

Clean and Tighten All Wire
Connections

Wash and Service Batteries l

l

1

Annual

(500hrs)

Semi -

1

(1000hrs)

Annualy

1

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

Clean and Repack Front Wheel

Bearings

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

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.

l

l

Safety Rules Page 16

SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD PERIODIC MAINTENANCE SCHEDULE
FOR THE SMART VIEW DISPLAY

NOTE: The maintenance function is optional. Your vehicle may be equipped

with a customized maintenance schedule

PREVENTATIVE MAINTENANCE SCHEDULE

MAINTENANCE

LEVEL

1 500

2 1000

HOUR

INTERVAL

1

Inspect the brake system including the park brake and mounting
harware

Inspect the steering system, tighten the steering shaft coupler on

the steering gear input shaft

Lubricate the vehicle, check for leaks

Inspect safety interlocks

Inspect front and rear wheel bearings

Inspect and adjust fork collar bearings (3-wheel trucks only)

Inspect and tighten all nuts and bolts. First 500 hours and then

every 1000 hours.

Inspect and tighten all nuts and bolts

Clean and repack front wheel bearings

Inspect and tighten all wire connections

Inspect the motor brushes and commutator

MAINTENANCE TO BE PERFORMED

2

3 2000

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

Inspect the king pin bushings

Check front end alignment

Change oil in the drive and rear axle

Flush hydraulic brake system

Inspect suspension bushings

Replace brake pedal/treadle return spring

Inspect frame for damage

Safety Rules Page 17

SAFETY RULES AND OPERATING INSTRUCTIONS

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.

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Safety Rules Page 18

General Maintenance

TABLE OF CONTENTS

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

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

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

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.

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.

Before start­ing any re­pairs:

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

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

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.

Maintenance Page 2

Maintenance, Service and Repair

TROUBLESHOOTING GUIDE

Symptom Probable Cause

Steering Pulls in One Direction

Hard Steering

Excessive Steering Play

Lack of Power or Slow Operation

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
Worn Drive Gears

Front End Out of Alignment
Speed Control System Fault
Speed Control System Overheated

High/Low Speed Switch in Low or wiring to the Switch is Faulty

Low Speed Cutback Due to Maintenance Meter Trip (optional)

Worn Drive Gears or Bearings

Abnormal Noise

Oil Leak in Rear Bearing Area

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Pedal Low

Braking Power Low

Worn Front /Rear Axle Bearings

Loose Lug Nuts

Motor Bearings Worn

Rear Wheel Bearing and/or Gasket Failed

Drive Over Filled

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

Trailer Brake System Faulty (optional)

Maintenance Page 3

Maintenance, Service and Repair

LUBRICATION CHART

3

2

FRONT

4

1

2

3

4

Rear Axle Lubrication

1

Front End Lubrication

# Description Locations Lubricant Type

1 Ball Joints 4 General Purpose Grease
2 Pedal Linkages 3 General Purpose Grease
3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease

4 King Pin 2 General Purpose Grease

7 Drive Drain Plug 1
8 Drive Level Plug 1
9 Drive Fill Plug 1 SAE 80W90 Gear Oil

Maintenance Page 4

Front Axle Service

TABLE OF CONTENTS

Inspect the Front Wheel Bearings

and King Pin...........................................2

Adjust Front Wheel Bearings.......................3

Front Axle Removal and Installation ............4

Removal ................................................................... 4

Installation ................................................................5

Front Axle Disassembly ................................6

Replace Front Wheel Bearings .....................7

Replace the King Pins and Bushings...........9

Replace the Steering Knuckle ......................11

Maintenance, Service, and Repair

INSPECT THE FRONT WHEEL BEARINGS AND KING PIN

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Grab the top and bottom of the tire/wheel assembly.
Feel for any movement or play while pulling and
pushing on the top and bottom of the tire. Any
movement or play is an indication of loose wheel
bearings or king pin.

NOTE: Refer to the Adjust Front Wheel

Bearings section for information

regarding the adjustment of the wheel
bearings.

NOTE: If the king pin is loose, then refer to

Replace the King Pins and
Bushings for information regarding

replacing the king pin bushings. There
are no adjustments for the king pin or
bushings.

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.

Front Axle Page 2

Maintenance, Service, and Repair

ADJUST FRONT WHEEL BEARINGS

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove the hub dust cap and cotter pin.

8. While rotating the hub, tighten the spindle nut to
30 ft-lbs. This seats the bearings.

9. Back off the spindle nut one flat until the hub turns,
but is not loose.

10. 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.

11. Install a new cotter pin.

12. Install the dust cap.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Hub with Dust Cap Removed

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Front Axle Page 3

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Maintenance, Service, and Repair

FRONT AXLE REMOVAL AND INSTALLATION

Removal

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove both front wheels. Refer to Tires and Wheels section for information regarding

removing the front wheels.

8. Tie up or support the front axle so it can not fall out of the vehicle.

9. Disconnect the drag link ball joint or rod end from the steering knuckle or the steering gear
pitman arm.

NOTE: Refer to the Replacing the Ball Joints section for information

regarding the removal of the ball joints or rod ends.

10. If equipped with front brakes, disconnect the
hydraulic brake lines from the brake bodies.

11. Disconnect the front axle beam from the front
springs and remove the axle from the vehicle.

NOTE: In some configurations the front

springs and or shocks will have to be
removed in order to remove the axle
beam. Refer to section Front

Suspension for information

regarding removing the springs and
shocks.

Front Axle Page 4

Installation

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

Maintenance, Service, and Repair

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 rear 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
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury.

7. Install the front axle in reverse order of removal.

NOTE: Use all new cotter pins.
NOTE: Refer to the Replacing the Ball Joints section for information

regarding the installing the ball joints or rod ends.

NOTE: Refer to Tires and Wheels section for information regarding

removing the front wheels.

8. Realign the front wheels. Refer to Steering Component Service section for information

regarding realigning the front wheels.

9. If equipped with front brakes, bleed the brakes. Refer to Brake Service section for information

regarding bleeding the brakes.

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

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Front Axle Page 5

Maintenance, Service, and Repair

FRONT AXLE DISASSEMBLY

Disassembling and reassembling involves removing and replacing the left and right steering knuckles
and king pin bushings. Refer to the following sections for information regarding these procedures:

Replace the Steering Knuckle
Replace the King Pins and Bushings

NOTE: The front axle does not have to be removed unless the axle beam

must be replaced. Refer to Front Axle Removal and

Installation for information regarding removing the front axle.

Axle with integral king pin shown

Front Axle Page 6

Maintenance, Service, and Repair

REPLACE FRONT WHEEL BEARINGS

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove the tire/wheel assembly from the hub. Refer to Replace the Steering Knuckle for

information regarding removing the steering knuckle.

8. Remove the hub dust cap, cotter pin, and spindle nut.

9. Remove the hub from the steering knuckle.

NOTE: For a front disc brake option you must

remove the brake body before
removing the hub. Refer to the

Brakes section for information

regarding the removal of the brake
body.

NOTE: Catch the outer bearing as it falls out.

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

11. Inspect and replace the races and bearings as a
set.

NOTE: It is recommended to replace all four

bearings and races in the left and right
wheels as a set.

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

a. Pack inner and outer bearings with grease.

Hub with Dust Cap Removed

b. While rotating the hub, tighten the spindle nut to

30 ft-lbs. This seats the bearings.

c. Back off the spindle nut one flat until the hub

turns, but is not loose.

d. Install a new cotter pin.

Hub with Dust Cap Removed

Front Axle Page 7

Maintenance, Service, and Repair

13. Install the hub dust cap.

14. Reinstall the brake body and the tire/wheel assembly.

NOTE: Refer to the Brakes section for information regarding the

installation of the brake body.

15. Lower the vehicle.

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

17. Remove the blocks from behind the wheels.

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

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Front Axle Page 8

Maintenance, Service, and Repair

REPLACE THE KING PINS AND BUSHINGS

There are different types of king pin bushings depending on the configuration of your vehicle.

• Bronze bushings in the axle beam.

• Bronze bushings in the steering knuckle.

• Metal backed teflon bushings in the axle beam or suspension arm.

NOTE: Bronze bushings must be reamed or broached to the proper

diameter after they are pressed into the axle beam or steering
knuckle.

Failure to correctly broach or ream bronze bushings may result in
steering difficulty and loss of control of the vehicle causing severe
bodily injury and /or property damage.

Refer to the illustration below for the type of bushing in your vehicle.

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 rear wheels to prevent vehicle movement.

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

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

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.

Front Axle Page 9

Maintenance, Service, and Repair

7. Remove the steering knuckle. Refer to Replace the Steering Knuckle for information

regarding removing the steering knuckle.

NOTE: It is not necessary to remove the tie rod or drag link for this

procedure.

8. Press the king pin bushings out from the axle, steering knuckle or suspension arm.

9. Press new bushings into the axle, steering knuckle or suspension arm.
a) Yoke with integral king pin: Ream or broach bronze bushings to 1.25” +/- 0.001”.
b) Yoke without king pin: Ream or broach bronze bushings to 0.880” +/- 0.001”.

Tpical Yoke without king pin Typical yoke with integral

king pin

Failure to correctly broach or ream bronze bushings may result in
steering difficulty and loss of control of the vehicle causing severe
bodily injury and/or property damage.

10.Inspect the king pin for damage or wear. If any damage or wear is noted then the king pin must
be replaced.

11. Reassemble in reverse order.

NOTE: Refer to Replace the Steering Knuckle for information on installing

the steering knuckle.

NOTE: It is recommended that the thrust washers or bearing be replaced

whenever replacing the king pin bushings. Refer to the

Replacement Parts section for the orientation of the bearing or

washers in your vehicle.

12.Grease the bushings (bronze only).

13.Lower the vehicle.

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

15.Remove the blocks from behind the wheels.

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

Front Axle Page 10

Maintenance, Service, and Repair

REPLACE THE STEERING KNUCKLE

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information regarding
removing the tire/wheel assembly.

8. Remove the hub bearing cap, cotter pin and nut,
then remove the hub from the steering knuckle.

NOTE: For a front disc brake option you must

remove the brake body before
removing the hub. Refer to the

Brakes section for information

regarding the removal of the brake
body. Do not remove the hydraulic
brake line from the brake body. If the
brake line is removed then it will be
necessary to bleed the brakes.

NOTE: Catch the outer bearing as it falls out.

9. Remove the drag link and/or tie rod from the
steering knuckle. Refer to Replace the Ball Joints, Tie Rods, Drag Link in this section for
information regarding removal of the drag link or tie rod.

10. While supporting the knuckle, remove the king pin and thrust bearing.

11. Remove the knuckle from the axle.

Hub with Dust Cap Removed

Front Axle Page 11

Maintenance, Service, and Repair

12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings.

NOTE: Both the left and right side bushings and thrust bearings should be

replaced as a set.

13. Assemble in reverse order.

14. Pack the thrust bearing with grease.

15. Tighen the king pin nut as follows:
a) Yoke with integral king pin: Tighten the king pin nut until all of the up and down play is

removed and the yoke rotates freely. The rubber washer must compress slightly to create a seal
for the grease.

b) Yoke without king pin: tighten the king pin nut until all of the up and down play is removed
and the yoke rotates freely.

NOTE: Refer to Replace Front Wheel Bearings for information

regarding proper tightening of the spindle nut

16. Install new cotter pins.

17. Realign the wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

18. Lower the vehicle.

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

20. Remove the blocks from behind the wheels.

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

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Front Axle Page 12

Steering Component Service

TABLE OF CONTENTS

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

Inspect Ball Joints.........................................6

Inspect Rod Ends..........................................7

Adjust the Steering Gear...............................8

Replace the Steering Shaft ...........................10

Replace the Steering Wheel..........................12

Replace the Steering Gear ............................13

Replace the Ball Joints, Tie Rods, and Drag

Link..........................................................14

Replacing the Drag Link ..........................................16

Replacing the Tie Rod ............................................. 17

Center the Steering Gear ..............................18

Pitman Shaft Alignment ................................18

Repair the Steering Gear...............................19

Exploded View of Steering Gear ............................ 22

Maintenance, Service, and Repair

FRONT END ALIGNMENT

This section will refer to two different types of ball joints.
One type is has a grease fitting and a tapered shaft where
it is fitted to the steering arm or pitman arm. The second
type cannot be greased and has a straight shaft. See the
illustrations to the right. Depending on the configuration of
your truck, it may be equipped with one or both types of
ball joints.

In this text:
The first type has a grease fitting and will be referred to as
a “Ball Joint.”
The second type has no grease fitting and will be referred
to as a “Rod End.”

Center the Steering

1. Make sure the key-switch is in the “OFF” position, then remove
the key.

Ball Joint

Rod End

2. Place the forward-reverse switch in the center “OFF” position.

3. Set the park brake.

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

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

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

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.

7. Turn the front wheels so that they are in the straight ahead position and then tie off the wheels
so that they cannot turn from the straight ahead position.

8. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section for information

regarding removing the ball joint or rod end from the drag link.

9. Center the steering gear and tie off the steering wheel so that it cannot rotate.

NOTE: Refer to Center the Steering Gear section for information

regarding centering of the steering gear.

Steering Page 2

Maintenance, Service, and Repair

10. At this point both the steering wheel and the front wheels should be tied up and held in position.
If one or the other is not tied up then you must start from the beginning.

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 the position may cause loss of control of the vehicle
resulting in severe bodily injury and/or property damage.

11. Loosen the ball joint clamps or the rod end jam nuts
on the drag link.

NOTE: Remember the position and orientation

of the clamps.

12. Adjust the drag link so that it can be easily inserted
into the pitman arm.

13. Tighten the ball joint or rod end nut as specified
below:

Ball joint - 40-45 ft-lbs.
Rod end - 20-25 ft-lbs.

14. If equipped with ball joints, position the ball joint
clamps in their original location and orientation.

15. Tighten the ball joint clamps (28-32 ft. lbs.) or the rod end jam nuts on the drag link.

16. Untie the steering wheel and the front wheels.

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

18. Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint
clamps do not contact any other component.

If the clamps are positioned so that they contact other components,
it may result in steering failure and loss of control of the vehicle
causing property damage and/or severe bodily injury.

19. Remove the blocks from behind the wheels.

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

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Steering Page 3

Maintenance, Service, and Repair

Front wheel alignment

NOTE: It is recommended to center the steering before aligning the front

wheels. Refer to the Center the Steering section for information.

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Turn the front wheels so that they are in the straight ahead position and tie off the steering wheel
so that it cannot rotate.

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 the position may cause loss of control of the vehicle
resulting in severe bodily injury and/or property damage.

8. Using a piece of chalk, mark a line around the center
of both front tires.

HINT: Hold the chalk on the center of the tire

and rotate the tire to mark the line.

9. Loosen the ball joint clamps or the rod end jam
nuts on the tie rod.

NOTE: Remember the position and orientation

of the ball joint clamps.

10. Lower the front wheels to the ground and push the
vehicle back and forth a few feet to settle the
suspension.

Steering Page 4

Maintenance, Service, and Repair

11. Measure the distance between the lines at the front
of the tires.

12. Measure the distance between the lines at the rear
of the tires.

13. Adjust the tie rod so that the distance at the front
and rear of the tires is the same.

14. If equipped with ball joints, position the ball joint
clamps in their original location and orientation.

15. Tighten the ball joint clamps (28-32 ft. lbs.) or the
rod end jam nuts.

16. Untie the steering wheel.

Rotate the steering wheel from a full left turn to a full right turn and
make sure that the ball joint clamps do not contact any other
component. Clamps positioned so that they contact other components
may result in steering failure and loss of control of the vehicle causing
severe bodily injury and/or property damage.

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

18. Remove the blocks from behind the wheels.

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

Front Measurement

Sleeve Clamps

Tie Rod

Rear Measurement

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Steering Page 5

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Maintenance, Service, and Repair

INSPECT BALL JOINTS

NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a

ball joint and or rod end is worn out, then all should be replaced as
a set.

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 rear wheels to prevent vehicle movement.

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

6. Tie off the front wheels so that they cannot turn.

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.

7. While watching the ball joints, rapidly rotate the
steering wheel to the left and right.

8. If the ball joint housing moves up or down then the
ball joint is worn out and should be replaced. Refer
to section Replacing a Ball Joint for information
regarding replacing ball joints.

9. Untie the front wheels.

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

11. Remove the blocks from behind the wheels.

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

Typical Ball Joint

Steering Page 6

INSPECT ROD ENDS

NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a

ball joint and or rod end is worn out, then all should be replaced as
a set.

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 rear wheels to prevent vehicle movement.

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

6. Visually inspect each rod end for any signs of play between the ball and the nylon or brass
bushing in the housing.

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.

Maintenance, Service, and Repair

7. If any play is evident, then the rod end is worn out
and should be replaced. Refer to section Replace

the Ball Joints, Tie Rods, and Drag Link for

information regarding replacing ball joints.

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

9. Remove the blocks from behind the wheels.

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

< Stud

Typical rod end. Studded rod end shown, your
vehicle may be equipped with spherical rod
ends that do not have a stud.

Steering Page 7

Maintenance, Service, and Repair

ADJUST THE STEERING GEAR

NOTE: In some vehicle configurations it may be necessary to remove the

steering gear to perform this procedure. Refer to Replace the

Steering Gear for information regarding removing the steering

gear.

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 rear wheels to prevent vehicle movement.

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

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

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 serious bodily injury.

7. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints

section for information regarding
removing the ball joint from the drag
link.

8. Loosen the gear lash jam nut and the worm bearing
adjuster jam nut.

9. Unscrew the gear lash adjuster all of the way to the
stop.

10. Loosen the worm bearing adjuster and then tighten
just enough to remove all end play from the input
shaft and then an additional 1/8 turn more.

11. While holding the worm bearing adjuster so that it cannot turn, tighten the worm bearing adjuster
jam nut.

12. Find the center position of the steering shaft:

A. Turn the steering shaft all of the way in one direction.
B. While counting the rotations, turn the steering shaft all of the way in the opposite direction.
C. Turn the steering shaft 1/2 the number of turns in the original direction.

Steering Page 8

Maintenance, Service, and Repair

13. While rotating the input shaft back and forth through its centered position, adjust the gear lash
adjusting screw so that there is a slight drag as the steering gear is rotated through its centered
position.

14. While holding the gear lash adjusting screw so that it cannot turn, tighten the gear lash adjusting
screw jam nut.

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

16. Remove the blocks from behind the wheels.

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

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Steering Page 9

Maintenance, Service, and Repair

REPLACE THE STEERING SHAFT

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.

6. If equipped with a horn switch in the steering wheel, remove the switch, disconnect the wires
from the switch and cut the terminals off of the wires.

7. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel

section for information regarding
removing the steering wheel.

8. Remove the upper steering shaft bushing or bearing
from the steering column.

9. Remove the steering gear access cover from the
steering column (if equipped).

10. Remove and discard the pinch bolt and nut from
the steering shaft coupler.

NOTE Most vehicle configurations will now allow the

steering shaft to slide off of the steering gear
input shaft and then back down out of the
steering column. If there is not enough
clearance for this procedure then the steering
gear must be removed. Refer to Replace the
Steering Gear for information regarding
removing the steering gear.

Steering Page 10

Maintenance, Service, and Repair

11. Remove the steering shaft from the vehicle.

12. Lightly grease the input shaft splines, steering wheel
splines and the upper steering shaft bushing.

13. Install the steering shaft in reverse order using a
new pinch bolt. Orientate the shaft so that the pinch
bolt is opposite the flat in the steering gear shaft.
See the illustration to the right.

Make sure that the pinch bolt
is not aligned with the flat on
the steering shaft. Aligning
the bolt with the flat could
result in failure of the steering
and loss of control of the
vehicle. This could lead to
property damage and/or
severe bodily injury.

Do not use the original pinch bolt and nut. Failure to replace the pinch
bolt and nut may result in failure of the steering causing loss of control
of the vehicle. This could lead to property damage and/or severe bodily
injury.

14. Tighten the pinch bolt to 24-26 ft-lbs.

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

16. Remove the blocks from behind the wheels.

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

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Steering Page 11

Maintenance, Service, and Repair

REPLACE THE STEERING WHEEL

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.

6. If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires
from the switch.

7. Remove the steering wheel nut.

8. Using a steering wheel puller, remove the steering
wheel.

9. Position the front wheels in the straight ahead
position.

10. Lightly grease the steering wheel splines and install
the replacement steering wheel orientated as shown
in the illustration to the right.

11. Tighten the steering wheel nut to 28-32 ft lbs.

12. Reinstall the horn switch (if equipped).

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

14. Remove the blocks from behind the wheels.

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

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Steering Page 12

Maintenance, Service, and Repair

REPLACE THE STEERING GEAR

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 rear wheels to prevent vehicle movement.

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

6. Remove the steering wheel. Refer to Replace the Steering Wheel section for information

regarding removing the steering wheel.

7. Remove the steering shaft. Refer to Replace the Steering Shaft section for information

regarding removing the steering shaft.

8. Remove the pitman arm using a pickle fork.

NOTE: On some vehicle configurations it may

be required to remove the drag link
from the pitman arm. Refer to Replace
the Ball Joints section for information
regarding removing the ball joint from
the pitman arm.

9. Support the steering gear so that it cannot fall out
of the vehicle.

10. Remove the bolts holding the steering gear to the
vehicle frame and remove the steering gear from
the vehicle.

Failure to support the
steering gear will result in
the steering gear falling out
of the vehicle and could
cause property damage and/
or severe bodily injury.

11. Center the steering gear. Refer to Center the Steering Gear section for information regarding
centering the steering gear.

12. Install in reverse order. Torque the pitman arm nut to 75-100 ft-lbs.

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

14. Remove the blocks from behind the wheels.

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

Steering Gear with Pitman Arm

Steering Page 13

Maintenance, Service, and Repair

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

This section will refer to two different types of ball joints. One
type is has a grease fitting and a tapered shaft where it is
installed on the steering arm or pitman arm. The second
cannot be greased and has a straight shaft. See the
illustrations to the right. Depending on the configuration of
your vehicle, it may be equipped one or both types of ball
joints.

Rod End

In this text:
The first type will be referred to as a “Ball Joint.”
The second type will be referred to as a “Rod End.”

NOTE: If a rod end or ball joint is worn out, we

recommend replacing all of the ball joints
and/or rod ends as a set.

Replacing a Rod End

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 rear wheels to prevent vehicle movement.

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

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

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.

Ball Joint

7. Loosen the rod end jam nut or clamp on the steering
sleeve.

8. Remove the rod end nut.

9. Remove the rod end from the steering arm.

HINT: Count the number of turns required to

remove the rod end from the steering
sleeve. This will make it easier to
realign the wheels.

Rod End

Steering
Sleeve

Jam Nut

Rod End Nut

Steering Arm

Steering Page 14

10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of
turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time.

11. Install the rod end into the steering arm. Tighten the rod end nut to 20-25 ft-lbs.

12. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Replacing a Ball Joint

1. Make sure the key-switch is in the “OFF” position, then remove the

Maintenance, Service, and Repair

key.

2. Place the forward-reverse switch in the center “OFF” position.

3. Set the park brake.

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

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

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

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.

7. Loosen the ball joint clamp on the steering sleeve.

8. Remove the cotter pin and ball joint nut.

9. Using a pickle fork, remove the ball joint from the
steering arm.

10. Remove the ball joint from the steering sleeve.

HINT: Count the number of turns required to

remove the ball joint from the sleeve.
This will make it easier to realign the
wheels.

Cotter Pin

Ball Joint Nut

Steering Arm

11. Install the new ball joint into the steering sleeve.
Screw it into the sleeve the same number of turns
counted in the previous step. Do not tighten the ball
joint clamp at this time.

Clamp

Ball Joint

Steering Sleeve

Steering Page 15

Maintenance, Service, and Repair

Pitman Arm

12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. and install a new
cotter pin.

13. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

14. Lower the vehicle.

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

16. Remove the blocks from behind the wheels.

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

Replacing the Drag Link

The Drag Link is the linkage that connects the steering gear pitman arm to the steering knuckle. Refer to
the illustration on the following page.

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove the ball joints or rod ends from the steering
knuckle and pitman arm.

NOTE: Refer to the Replacing the Ball

Joints section for information

regarding the removal of the ball joints
or rod ends.

8. Remove the drag link as an assembly.

9. Install in reverse order.

Drag Link

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of
the front wheels.

Steering Knuckle

Typical Drag Link

Steering Page 16

Maintenance, Service, and Repair

Tie Rod

11. Lower the vehicle.

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

13. Remove the blocks from behind the wheels.

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

Replacing the Tie Rod

The Tie Rod is the linkage that connects the two steering knuckles together. Refer to the illustration
below..

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Remove the ball joints or rod ends from the steering
knuckles.

NOTE: Refer to the Replacing the Ball

Steering Knuckle

Joints section for information

regarding the removal of the ball joints
or rod ends.

8. Remove the tie rod as an assembly.

9. Install in reverse order.

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of
the front wheels.

11. Lower the vehicle.

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

Typical Front Axle Assembly

13. Remove the blocks from behind the wheels.

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

Steering Page 17

Maintenance, Service, and Repair

CENTER THE STEERING GEAR

1. Remove the pitman arm.

2. Rotate the input shaft clockwise until it stops.

3. While counting the rotations, rotate the input shaft counter clockwise until it stops.

4. Rotate the input shaft clockwise 1/2 the rotations counted in the previous step.

5. Mark the steering gear input shaft and pitman shaft in relation to the housing for reference.

PITMAN SHAFT ALIGNMENT

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 rear wheels to prevent vehicle movement.

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

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

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.

7. Center the steering gear. Refer to Center the Steering Gear section for information regarding

centering the steering gear.

8. Screw both steering stops all of the way in.

9. Install the pitman arm so that it is centered between the steering stops.

10. Realign the front wheels. Refer to Front End Alignment section for information regarding

aligning the front wheels.

11. Adjust the steering stops so that the front wheels do not contact any part of the frame, suspension
or steering linkages and the left and right turning radiuses are equal.

12. Tighten the steering stop jam nuts.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Steering Page 18

Maintenance, Service, and Repair

REPAIR THE STEERING GEAR

Disassembly

NOTE: The steering gear must be removed from the vehicle for this

procedure. Refer to Replace the Steering Gear section for
information regarding removing the steering gear.

NOTE: The steering gear is packed with grease. Only perform maintenance

on the steering gear in an area that will contain any grease that
may spill out of the steering gear when it is disassembled.

Refer to the illustration at the end of this section for a blown up view of the steering gear assembly.

1. Center the steering gear.

A. Turn the steering shaft all of the way in one direction.
B. While counting the rotation, turn the steering shaft all of the way in the opposite direction.
C. Turn the steering shaft 1/2 the number of turns in the original direction.

2. Remove the worm bearing adjuster locking ring and
the worm bearing adjuster.

3. Remove the side cover/pitman shaft assembly by
removing the three side cover bolts and then pulling
the assembly out of the housing.

NOTE: The side cover/pitman shaft assembly

normally does not have to be
disassembled.

Steering Page 19

Maintenance, Service, and Repair

4. Remove the worm shaft and ball nut assembly from
the bottom of the housing.

5. Remove the worm shaft seal.

6. Remove the pitman shaft seal.

7. Remove the upper worm bearing and bearing cup
from the housing.

8. The ball nut assembly consists of two sets of ball
bearings that recirculate in two channels in the ball
nut housing. The bearings may fall out once the
bearing guides are removed. Be careful not to lose
any of the bearings.

9. Remove the ball guide clamps, ball guides and all
of the ball bearings.

10. Remove the ball nut from the worm shaft.

11. Thoroughly clean and inspect all parts for signs of
corrosion, damage or wear and replace as required.

Reassembly

1. Lightly lubricate all parts before reassembly.

2. Install a new worm shaft seal and pitman shaft seal into the housing.

3. Install the upper worm bearing cup.

4. Divide the ball bearing into two equal groups.

5. Position the ball nut onto the worm as shaft as shown in the illustration.

6. Insert the ball guides into the ball nut.

7. Insert each group of bearings into the ball guides.

NOTE: Do not rotate the worm shaft while

installing the bearings. This may
cause one or more of the bearings to
enter the crossover passage in the
ball nut, causing improper operation.

8. Install the ball guide clamp.

Steering Page 20

Maintenance, Service, and Repair

9. Place the upper worm bearing on the worm shaft
and install the worm shaft/ball nut assembly into
the housing being careful not to damage the worm
shaft seal.

10. Install the assembled worm bearing adjuster into
the housing and tighten just enough to remove all
play in the worm shaft.

11. Install, but do not tighten the worm bearing adjuster
lock nut.

12. Rotate the worm shaft to center the ball nut in the
housing.

13. Place a new gasket onto the housing and install
the assembled pitman shaft/side cover onto the
housing using two of the three mounting bolts.

14. Pack the steering gear with grease through the open
side cover bolt hole and then install the bolt.

15. Adjust the steering gear.

NOTE: Refer to Adjust the Steering gear

section for information regarding
adjusting the steering gear.

16. Once the adjustments are completed, make sure that the locking ring and jam nut are tight.

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Steering Page 21

Maintenance, Service, and Repair

Exploded View of Steering Gear

Steering Page 22

Brake Service

TABLE OF CONTENTS

Inspect the Service Brake .............................2

Disc Brake Pads ...................................................... 2

Disc Brake Rotor ..................................................... 3

Inspect the Parking brake .............................4

Wheel Park Brake (hydraulic disc) .........................4

Electric Motor Brake ................................................5

Adjust the Service Brakes ............................6

Two or Four Wheel Hydraulic Disc Brakes ............6

Adjust the Parking Brake ..............................7

Wheel Park Brake (hydraulic disc) .........................7

Check Master Cylinder Fluid ........................8

Bleed the Brake System................................9

Flush the Brake System ................................11

Replace the Parking Brake Lining

(electric motor brake) .............................12

Inspection:................................................................14

Replace Front Disc Brake Pads....................15

Replace Rear Brake Pads .............................17

Hydraulic Disc ..........................................................17

Replace the Wheel Cylinder..........................19

Disc Brake Body Assembly (front or rear) .............. 19

Repair the Brake Body ..................................21

Replace the Master Cylinder.........................23

Repair the Master Cylinder ...........................25

Maintenance, Service, and Repair

INSPECT THE SERVICE BRAKE

Disc Brake Pads

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.

NOTE: The brake pad must be removed to accurately measure the lining

thickness. Refer to Replace the Front or Rear Brake Pads section
for information on removing the brake pads.

Measure the brake pad lining at the thinnest point on the pad. If the brake pad lining is 1/16-inch or less
then the brake pad must be replaced.

It is recommended to replace the left and right side brake pads as a set.

Brakes Page 2

Disc Brake Rotor

NOTE: The front brake rotor is an integral part of the front hub. If the brake

NOTE: Depending on the rear axle configuration, the rear brake rotor may

NOTE: The wheel must be removed to accurately measure the rotor

Maintenance, Service, and Repair

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.

rotor is worn beyond its service limits, then the front hub must be
replaced. Refer to Front Axle Service for information on replacing
the front hub.

be an integral part of the rear axle. If the brake rotor is worn beyond
its service limits, then the rear axle must be replaced. Refer to

Transmission section for information regarding replacing the rear

axle

thickness. Refer to Tires and Wheels section for information on
removing the wheel.

1. Measure the run out of the rotor at its maximum
diameter. If the run out exceeds 0.005, then the rotor
must be machined. Do not machine the rotor beyond
its service limits.

NOTE: A bent axle or damaged rear axle could

cause excessive brake rotor run out.

2. Measure the thickness of the brake rotor in 3 places.
If the brake rotor thickness is less than 0.20-inches,
then the rotor must be replaced.

Do not use a rotor that is
worn beyond its service
limits. A rotor worn beyond
its service limits could fail
and cause loss of brakes
resulting in severe bodily
injury and/or property
damage.

Rotor removed for clarity. The rotor does not
have to be removed for this procedure.

Brakes Page 3

Maintenance, Service, and Repair

INSPECT THE PARKING BRAKE

Wheel Park Brake (hydraulic disc)

NOTE: The parking brake is actuated through a pin in the center of the

rear left and right brake body on the rear axles.

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.

6. Release the park brake.

7. Inspect the brake pads. Refer to Inspect the
Service Brake section to inspect the brake pads.

8. Inspect the park brake pin and bushing for any signs
of damage or corrosion.

NOTE: The park brake pin is inside of the

brake body. Refer to Repair the Brake
Body for information on removing the
park brake pin.

9. Inspect all brake cables and linkages for any signs
of damage, wear, or missing cotter pins.

10. Inspect the brake handle locking mechanism for any
signs of damage.

NOTE: Refer to Adjust the Parking Brake

section for information regarding
adjusting the parking brake.

If any sign of damage or wear is found on the locking mechanism,
cables, or linkages then they must be repaired or replaced
immediately. Failure to repair or replace any damaged component
could result in failure of the park brake causing property damage
and/or severe bodily injury.

Brakes Page 4

Maintenance, Service, and Repair

Electric Motor Brake

A variable power supply capable of supplying 0-volts to 24-volts DC at 2-Amps will be required to perform
the testing.

The brake does not have to be removed from the transmission for this test.

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. If equipped with a hand or foot park brake, 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.

6. Disconnect the electric brake connector from the vehicles harness.

7. Adjust the power supply to zero volts.

8. Connect the power supply to the electric brake.

9. Slowly increase the voltage until you hear a ‘click’ from the brake. The ‘click’ is the brake releasing.
The motor should now be free to rotate limited by the gear train and parking brake).

a) If the brake does not release until the voltage exceeds 18-volts, then the friction plate has

worn beyond its service limits and must be replaced.

b) If the brake does not release at all, then the brake electromagnet has failed and must be

replaced.

10.Reconnect the electric brake.

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

12.Remove blocks from behind the wheels.

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

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Brakes Page 5

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Maintenance, Service, and Repair

ADJUST THE SERVICE BRAKES

Two or Four Wheel Hydraulic Disc Brakes

The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power
could be caused by:

• Brake fluid level low in the master cylinder. See Check the Master Cylinder Fluid section.

• Air in the brake lines. See Bleed the Brakes section.

• Worn brake pads. See Inspect the Service Brake section.

• Worn brake rotor. See Inspect the Service Brake section.

• Binding brake pedal linkage.

If you are experiencing a low brake pedal or lack of braking power, the entire brake system should be
inspected.

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Brakes Page 6

Maintenance, Service, and Repair

3/8 Min.

ADJUST THE PARKING BRAKE

Wheel Park Brake (hydraulic disc)

The parking brake is actuated through a pin in the center of
the rear left and right brake body on the rear axles.

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.

6. Release the park brake.

7. Loosen the jam nuts on the Primary Adjustment Rod.

8. Tighten the Primary Adjustment Rod until it is difficult to rotate the brake arm clevis pin on both
wheels.

9. Loosen the Primary adjustment rod one to two turns so that both wheels rotate whith no brake
drag.

The threaded rod must be
screwed into the clevis with at
least 3/8” of threads. Less than
3/8” of threads in a clevis could
result in brake failure causing
severe bodily injury and/or
property damage.

Cutaway of Clevis and Threaded Rod

NOTE: If there is no adjustment left in the Primary Adjustment Rod, then

the Brake Arm Extension must be rotated to engage the next hole
in the arm.

10.Tighten the jam nuts on the park brake linkage.

11. Set the park brake.

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

13.Remove blocks from behind the wheels.

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

Brakes Page 7

Maintenance, Service, and Repair

CHECK MASTER CYLINDER FLUID

Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.

EYE CONTACT

Immediately flush the eye with water for 15 minutes and call
physician.

INGESTION

Get medical attention immediately.

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.

6. Thoroughly clean the area around the master cylinder cap.

7. Remove the master cylinder cap.

8. If the fluid in the master cylinder is contaminated then the entire brake system must be flushed.
Refer to Bleed the Brakes for information regarding flushing the brake system.

9. Fill with brake fluid from a new sealed container to within 1/4-inch of the top of the master
cylinder chamber and reinstall the cap.

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

11. Remove blocks from behind the wheels.

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

• Only use DOT 3 brake fluid from a new sealed container.

• DOT 3 brake fluid is corrosive and will damage paint finishes.

• Dispose of brake fluid in accordance with local state and federal

regulations.

• Read and follow all warnings on the brake fluid container.

Brakes Page 8

Maintenance, Service, and Repair

BLEED THE BRAKE SYSTEM

Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.

EYE CONTACT

Immediately flush the eye with water for 15 minutes and call
physician.

INGESTION

Get medical attention immediately.

NOTE: Start this procedure at the wheel furthest from the master cylinder,

then work toward the wheel closest to the master cylinder.

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.

6. Thoroughly clean the area around the master cylinder cap and remove the cap.

Master cylinder is located between the front

seats. Dual reservoir shown.

Single reservoir master cylinder

Brakes Page 9

Maintenance, Service, and Repair

7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the
master cylinder chamber.

• Only use DOT 3 brake fluid from a new sealed container.

• DOT 3 brake fluid is corrosive and will damage paint finishes.

• Dispose of brake fluid in accordance with local state and federal

regulations.

• Read and follow all warnings on the brake fluid container.

8. The master cylinder fluid level will drop as the brakes are bled. Periodically check and fill the
master cylinder during this procedure. Do not allow the fluid level in the master cylinder to drop
too low as this will allow air into the brake lines.

9. Attach a clear hose to the bleeder valve on the brake
cylinder that is to be bled. Route the hose into a
clear container for waste brake fluid.

10. Pump the brake pedal a few times and then press
and hold light pressure to the brake pedal.

11. Open the bleeder valve on the hydraulic brake body.

12. Depress the foot pedal to the floor and then close
the bleeder valve. Do not release pressure on the
brake pedal until the bleeder valve is closed.

13. Slowly release the foot pedal, allowing it to return
to its released position.

Bleeder valve with hose attached

NOTE: Check and fill the master cylinder frequently during the bleeding

process. Do not allow the fluid level in the master cylinder to drop
low enough to allow air to enter the brake lines. If air enters the
brake lines during the bleeding process, then you will have to start
again from the beginning.

Always use brake fluid from a new sealed container. Never reuse any
brake fluid that has been removed from the brake system. Use of
contaminated brake fluid will degrade the braking performance and
may cause property damage or severe bodily injury.

14. Repeat the above steps until you are sure that all of the air is expelled from the brake line. Any air
bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is
still air in the brake lines.

15. Repeat this process with each of the other wheels.

NOTE: When finished, top off the master cylinder with fluid. See Check

Master Cylinder Fluid for information on filling the master

cylinder.

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

17. Remove the blocks from behind the wheels.

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

Brakes Page 10

Maintenance, Service, and Repair

FLUSH THE BRAKE SYSTEM

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.

6. Raise the rear wheels off of the ground and support with jack stands.

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.

7. If equipped with front brakes, raise the front wheels off of the ground and support with jack
stands.

8. Release the park brake.

9. Remove both rear wheels and, if equipped with front brakes, the front wheels. Refer to Tires

and Wheels section for information regarding removing the wheels.

10. Remove the wheel cylinders from each axle. Refer to Replace the Wheel Cylinder section
for information regarding removing the wheel cylinder.

11. Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into
a container for waste brake fluid.

12. Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all
bleeder screws.

13. Pump the master cylinder until all fluid has been pumped from the brake lines and all wheel
cylinders.

14. Close all bleeder screws.

15. Fill the master cylinder with fluid.

16. Open one of the bleeder screws and pump the master cylinder until all fluid has been pumped
from the master cylinder and close the bleeder screw.

17. Repeat the above two steps for each wheel cylinder.

18. Reinstall the wheel cylinders and bleed the brakes. Refer to Bleed the Brakes for information
regarding bleeding the brakes.

19. Set the park brake.

20. Install the wheels and lower the vehicle to the ground.

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

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

Brakes Page 11

Maintenance, Service, and Repair

REPLACE THE PARKING BRAKE LINING
(ELECTRIC MOTOR 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.

1. Remove the electric brake assembly from the drive. Refer to Motor Removal and Installation
in the Transmission section for information regarding removing the brake.

2. Place the brake assembly on flat surface with the shaft pointing up.

3. Mark the orientation of the outer housing and
magnet. This mark will be used to correctly align
the housing during reassembly

4. Remove the three Allen head socket screws evenly
so that the internal spring pressure is reduced
gradually. Turn each screw no more than two turns
at a time.

5. Remove the outer housing and friction plate.

Brakes Page 12

Maintenance, Service, and Repair

6. Mark the orientation of the inner contact plate in
relation to the magnet.

7. Remove the smaller bearing circlip.

8. Using a soft hammer, drive out the center hub and
remove the inner contact plate and six springs.

9. If required, remove the larger bearing circlip and
press out the bearing. If the bearing is removed it
must be replaced.

10. Thoroughly clean all parts.

11. Inspect all parts for damage or wear.

12. Reassemble in reverse order.

Reassembly Notes

a. Orientate the inner contact plate lining up the marks made when removed and so that the notches

face away from the magnet (see illustration below).

b. Orientate the friction plate so that the cutout faces the inner contact plate.
c. Orientate the outer housing lining up the marks made when it was removed.
d. Tighten the three Allen head socket screws in a cross pattern evenly so that the internal spring

pressure is increased gradually. Turn each screw no more than two turns at a time. Final torque­10 ft-lbs.

Brakes Page 13

Maintenance, Service, and Repair

Inspection:

1. Measure the free length of the five springs. Minimum length =0.713”

2. Inspect the splines on the hub and the friction plate for damage.

3. Inspect the inner contact plate and the outer housing where they come into contact with the
friction plate for wear or damage.

4. Inspect the three dowel pins and their corresponding
holes in the inner contact plate. The dowel pins
should be straight and the holes should be round.

5. Inspect the bearing for excessive play or roughness
when rotated.

6. Inspect the contact surfaces of the magnet and inner
contact plate for damage and flatness.

Electric motor brake exploded

Note: There are no repairable parts in this assembly. The parts must be

replaced if any damage or wear is found.

Brakes Page 14

Maintenance, Service, and Repair

REPLACE FRONT DISC BRAKE PADS

NOTE: It is recommended that both the left and right brake pads be replaced

as a set.

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.

NOTE: Installing new brake pads will raise the brake fluid level in the master

cylinder.

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 rear wheels to prevent vehicle movement.

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

6. Thoroughly clean the area around the master
cylinder cap.

7. Remove fluid from the master cylinder until it is 1/2
full.

Master cylinder is located between the front

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

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.

seats. Dual reservoir shown.

9. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing
the tire and wheel assembly.

Brakes Page 15

Maintenance, Service, and Repair

NOTE: Refer to the illustration above for the following steps.

10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8).

11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings.

12. Inspect the brake rotor. See Inspect the Service Brakes section for information regarding
inspecting the brake rotor.

13. Inspect the spacers (7) and replace if any wear or damage is found.

14. Install new spacer bushings in the mounting bracket.

15. Install new brake pads in reverse order. Torque the mounting bolts to 11 ft-lbs.

16. Repeat this procedure for the other wheel.

17. Install the tire/wheel assembly and lower the vehicle to the ground.

18. Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section
for information on the proper master cylinder fluid level.

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

20. Remove the blocks from behind the wheels.

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

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Maintenance, Service, and Repair

REPLACE REAR BRAKE PADS

Hydraulic Disc

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.

NOTE: It is recommended that both the left and right brake pads be replaced

as a set.

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.

NOTE: Installing new brake pads will raise the brake fluid level in the master

cylinder.

6. Thoroughly clean the area around the master
cylinder cap.

7. Remove fluid from the master cylinder until it is
1/2 full.

8. Raise the rear of the vehicle and support with jack
stands.

Master cylinder is located between the front

seats. Dual reservoir shown.

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.

Brakes Page 17

Maintenance, Service, and Repair

9. Remove the tire/wheel assembly.

NOTE: Refer to Tires and Wheels section for information on removing

the tire and wheel assembly.

10. Release the park brake (wheel brake only).

11. Remove the brake body bolts and discard the lock nuts and brake pads.

12. Remove the spacer bushings from the mounting
bracket and discard.

13. Inspect the brake rotor. Refer to Inspect the

Service Brake section for information regarding

inspecting the brake rotor.

14. Inspect the spacers and replace if any wear or
damage is found.

15. Install new spacer bushings in the mounting bracket.

16. Back off the parking brake adjustment (wheel park
brake only).

17. Install new brake pads in reverse order. Torque the mounting bolts to 11 ft-lbs.

18. Repeat this procedure for the other wheel.

19. Install the tire/wheel assembly and lower the vehicle to the ground.

20. Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section for
information regarding the correct master cylinder fluid level.

21. Adjust the parking brake (wheel park brake only). Refer to Adjust the Parking Brake section.

22. Set the park brake.

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

24. Remove the blocks from behind the wheels.

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

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Brakes Page 18

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Maintenance, Service, and Repair

REPLACE THE WHEEL CYLINDER

Disc Brake Body Assembly (front or rear)

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.

Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.

EYE CONTACT

Immediately flush the eye with water for 15 minutes and call
physician.

INGESTION

Get medical attention immediately.

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 wheels to prevent vehicle movement.

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

6. Release the park brake.

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

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.

Brakes Page 19

Maintenance, Service, and Repair

8. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing

the tire and wheel assembly.

9. Thoroughly clean the area around the brake body.

10. Remove the brake body bolts and discard the lock
nuts.

11. Inspect the brake rotor. Refer to Inspect the

Service Brake section for information regarding

inspecting the brake rotor.

12. Disconnect the brake hose from the brake body.

13. Install the new brake body assembly in reverse
order.

• Use teflon tape thread sealant on the brake hose

fitting.

• Torque the brake body bolts to 11 ft-lbs.

14. Bleed the brakes. Refer to Bleed the Brakes section for information regarding bleeding the
brakes.

15. Set the park brake.

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

17. Lower the wheel to the ground.

18. Remove the blocks from behind the wheels.

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

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Brakes Page 20

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Maintenance, Service, and Repair

REPAIR THE BRAKE BODY

Hydraulic brake system components must be kept clean. Make sure
your work area is free from dirt and debris and will contain any brake
fluid spills. Any debris or contaminates left in the brake system could
lead to brake failure and result in property damage and/or severe
bodily injury.

Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.

EYE CONTACT

Immediately flush the eye with water for 15 minutes and call
physician.

INGESTION

Get medical attention immediately.

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.

6. Remove the brake body from the vehicle.

NOTE: Refer to Replace the Brake Body Assembly (front or rear)

section for information on removing the brake body.

7. Pull the pistons out of the brake body.

The pistons are very fragile. If the piston is damaged it must be
replaced. Failure to replace a damaged piston could lead to brake
failure and result in property damage and/or severe bodily injury.

8. Remove the piston rubber boot.

9. Remove the piston o-ring from inside of the brake body.

10. Inspect and replace parts as required.

Brakes Page 21

Maintenance, Service, and Repair

11. Lubricate the brake parts with clean brake fluid from a sealed container.

12. Install the o-rings into the brake body. Make sure
that the o-rings are installed into the second groove
and that they are not twisted.

13. Using tool #41-350-13, slide the rubber boots onto
the pistons as shown. The boot should be hanging
off of the end of the piston.

14. Insert the rubber boot/piston into the brake body
making sure that the boot is properly seated in the
groove.

15. Press the pistons all the way down into the brake
body making sure that the boot seats properly into
the upper groove on the piston.

16. Install any fittings or plugs that were removed from
the brake body using teflon tape thread sealant.

17. If the brake body assembly is not to be immediately
installed onto a vehicle, plug the brake hose fitting
hole to prevent any contaminates from entering the
brake body.

Brakes Page 22

Maintenance, Service, and Repair

REPLACE THE MASTER CYLINDER

Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.

EYE CONTACT

Immediately flush the eye with water for 15 minutes and call
physician.

INGESTION

Get medical attention immediately.

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 rear wheels to prevent vehicle movement.

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

NOTE: Most vehicle configurations do not require lifting the vehicle to

remove the master cylinder. Lifting the vehicle may not be required.

6. If required, raise the vehicle and support with jack stands.

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.

7. Place a drain pan under the master cylinder.

8. Disconnect the brake line(s) to the master cylinder and pump out the fluid in the master cylinder
by depressing the pedal several times.

9. Remove the master cylinder bolts and remove the master cylinder from the vehicle.

Brakes Page 23

Maintenance, Service, and Repair

1/8"

10. Install in reverse order.

11. Adjust the master cylinder push rod so that it is
approximately 1/8 inch away from the master
cylinder plunger when the brake pedal is up.

12. Fill the master cylinder with brake fluid from a sealed
container.

13. Pump the brake pedal a short distance of one to
two inches until no bubbles are seen coming from
the inlet ports inside of the master cylinder chamber.

14. If the vehicle was raised, lower it to the ground.

15. Bleed the brakes. refer to Bleed the Brakes section
for information regarding bleeding the brakes.

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

17. Remove the blocks from behind the wheels.

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

Plunger

Push Rod

Master Cylinder

Cutaway of typical master cylinder showing

the push rod clearance

• Only use DOT 3 brake fluid from a new sealed container.

• DOT 3 brake fluid is corrosive and will damage paint finishes.

• Dispose of brake fluid in accordance with local state and federal

regulations.

• Read and follow all warnings on the brake fluid container.

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Brakes Page 24

Maintenance, Service, and Repair

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make

sure your work area is free from dirt and debris and will contain
any brake fluid spills.

Remove the master cylinder from the vehicle. See Replace the Master Cylinder section .
Drain all fluid from the master cylinder and discard.
Remove the rubber boot.
Depress the plunger and remove the plunger spring clip retainer.
Pull the plunger and all seals out of the master cylinder bore.
Thoroughly clean, inspect and replace parts as required.
If any damage is found in the bore of the master cylinder then it must be replaced.
Lubricate all parts with clean brake fluid from a sealed container.
Reassemble in reverse order.
If the master cylinder is not to be immediately installed onto a vehicle, plug the brake line fitting hole to

prevent any contaminates from entering the master cylinder.

Brakes Page 25

TAYLOR -DUNN