Taylor-Dunn B0-248-36, B 2-48, B0-254-36, B0-248-48, B 2-54 Operation, T Roubleshooting And Replacement Parts Manual

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Models Inlcuded:

B0-248-36 (B 2-48, 36-volt) B0-248-48 (B 2-48, 48-volt) B0-254-36 (B 2-54) BT-248-36 (36-volt Back to Back Tram)

BT-248-48 (48-volt Back to Back Tram) BT-280-36 (36-volt 10-passenger Tram) BT-280-48 (48-volt 10-passenger Tram)

MANUAL MB-248-12

Operation, Troubleshooting and

Replacement Parts Manual

Published 7/7/2008 Revision: B

Serial Number Starting 177127

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Taylor-Dunn Contact information

Service, Parts, Sales:

Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.

If you do not have access to the internet, you can call the factory direct at:

01 (714) 956-4040

Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:

Taylor-Dunn Manufacturing Attn: Tech Writer 2114 West Ball Road Anaheim, CA 92804

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Table of Contents

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

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Section Index

Taylor-Dunn

Models B0-248-36, B0-248-48, B0-254-36,

BT-248-36, BT-248-48, BT-280-36, BT-280-48

Operator and Service Manual Section Index

Introduction 1

Safety Rules and Operating Instructions 2

General Maintenance 3

Front Axle Service 4

Steering Component Service 5

Brakes Service 6

Motor Service 7

Transaxle Service 8

Tires and Wheels 9

Battery Service 10

Control System Troubleshooting 11

Charger Troubleshooting 12

Wire diagram 13

Illustrated Parts 14

Appendix A Special Tools 15

Appendix B Suggested Torque Values 16

Appendix C Brake Lining Handling Precautions 17

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

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

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TAYLOR -DUNN

Page 7

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 ...................8

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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

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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

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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

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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

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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 locations of the model and serial numbers are illustrated as follows: Starting early in 2007, the data plate and serial number fame stamp

is in the same location for all four models covered in this manual (refer to the illustrations below). For older vehicles, the location of the data plate and frame stamp is illustrated on the following pages.

Typical BT 2-48 shown with

optional equipment

Typical B 2-48 or B 2-54

Introduction Page-6

Typical BT 2-80 shown with

optional equipment

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INTRODUCTION

Vehicles manufactured before 2007 and up to March, 2007

B 2-48 and B 2-54

Under deck on deck rail

BT 2-48

BT 2-80

Under front left passenger cushion

Introduction Page-7

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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-8

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TABLE OF CONTENTS

Standard Specifications* (Common)...2 Standard Specifications* (Model B 2-48/2-54) 3 Standard Specifications* (Model BT 2-48) 4 Standard Specifications* (Model BT 2-80) 5

Safety Rules and Guidelines ..............6

Driver Training Program.....................6

Driver Qualifications. .......................................... 6

Vehicle Controls ................................7

Dash up to Serial # 179669................7

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

2) Headlight Switch ............................................. 7

3) Hi-Low Switch (optional) ............................... 7

4) Smart View Display ........................................ 7

5) Forward-Off-Reverse Switch .......................... 7

6) Horn Switch ..................................................... 7

7) Key-Switch ...................................................... 7

Dash Starting Serial #179670.............8

1) Headlight Switch ............................................. 8

2) Wiper Switch (Optional) ................................. 8

3) Strobe Switch (Optional) ................................ 8

4) Forward-Off-Reverse Switch .......................... 8

5) Hi-Low Switch (optional) ............................... 8

6) Smart View Display ........................................ 8

7) Horn Switch ..................................................... 8

8) Key-Switch ...................................................... 8

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

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

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

Accelerator Pedal ................................................. 9

Foot Brake Pedal .................................................. 9

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

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

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

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

Trailer Brake Module (optional) ......................... 11

Smart View Display ............................................. 12

Fault Code Tables ................................................ 14

Vehicle Operation Guidelines .............15

Safety Guidelines ................................................. 15

Starting: ................................................................ 15

While driving: ...................................................... 15

Loading and Unloading ....................................... 15

Towing Loads: ...................................................... 15

Parking .................................................................. 16

Automatic Electric Park Brake ........................... 16

Towing This Vehicle ............................................ 16

Dump Bed (optional)..........................17

Operation .............................................................. 17

Service .................................................................. 17

Lowering the Dump Manually ............................ 18

Lubrication ........................................................... 18

Hydraulic Pump Exploded View..........19

Charging your vehicle ........................20

Signet Charger Operation, Model HB Series ..... 20

Signet Charger Operation, Model HBS series ... 20

Lestronic II® Charger Operation ........................ 21

New Battery Break in .......................................... 21

Charging Time ...................................................... 21

Storing / Returning to Service............21

Storing Your Vehicle ............................................ 21

Returning to Service ............................................ 21

Periodic Maintenance Checklist .........22

Standard Periodic Maintenance Schedule

for the Smart View Display .............23

Daily Visual inspection: ...................................... 24

Maintenance Guidelines for

Severe Duty Applications ...............24

Safety Rules and

Operating Instructions

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICATIONS* (COMMON)

ITEM VOLTAGE SPECIFICATION

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

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid

Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake, or

Steering Automotive Steering 24:1

Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Smart View Display (Battery Status Indicator, Hour

Light Accessories Headlight, Dual Tail/Brake Lights

Charger 36 Volt 115v AC/12A, 60Hz, 25 Amp DC, Built-In, Automatic

48 Volt 115v AC/15A, 60Hz, 25 Amp DC, Built-In, Automatic

Differential

Optional 4 Wheel Hydraulic Disc, Hand Operated Park Brake

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).

* - Specifications are subject to change without notice.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICA TIONS* (MODEL B 2-48/2-54)

ITEM MODEL VOLTAGE SPECIFICATION

Occupancy B 2-48, B 2-54 2 Passenger

Electrical System B 2-48 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,

B 2-48 48 Volt 8-250 Amp Hour, 6 Volt, Lead Acid Batteries, B 2-54 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,

Dimensions B 2-48, B 2-54 307 L X 114 W X 114 H Centimeters Deck dimensions 104.4 W x 191 L Centimeters (41.25 W x 75.25 L Inches)

Turning Radius B 2-48, B 2-54 350 Centimeters (138 Inches)

Tires B 2-48 5.70 x 8 Load Range B

B 2-54 18 x 5 x 14 Solid Extra Cushion

Dry Weight B 2-48 542 kg (1194 lbs) Without Batteries B 2-54 693 kg (1528 lbs)

Maximum Load B 2-48 1360 kg (3000 lbs)

B 2-54 2268 kg (5000 lbs)

Motor, DC B 2-48 36 Volt 3.2 kW, (4.4 hp) for 60 min, 5.1 kW, (6.9 hp) for 5 min Separately Excited B 2-48 48 Volt 4.4 kW, (5.9 hp) for 60 min, 7.2 kW, (9.6 hp) for 5 min Field B 2-54 36 Volt 4.5 kW, (6.0 hp) for 60 min, 8.6 kW, (11.5 hp) for 5 min

Solid State Speed Control, 400 Amp Solid State Speed Control, 400 Amp Solid State Speed Control, 500 Amp

121 L X 45 X 45 H Inches

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).

* - Specifications are subject to change without notice.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICA TIONS* (MODEL BT 2-48)

ITEM VOLTAGE SPECIFICATION

Occupancy 10

Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,

48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries,

Dimensions 307L X 162W X 117H Centimeters

Turning Radius 363 Centimeters (143 Inches)

Tires 5.70 x 8 Load Range B

Dry Weight 695 kg (1,533 lbs) Without Batteries

Maximum Load 1360 kg (3,000 lbs)

Motor, DC 36 Volt 4.5 kW, (6.0 Horse Power) for 60 min Separately Excited Field 8.6 kW, (11.5 Horse Power) for 5 min

48 Volt 6.0 kW, (8.0 Horse Power) for 60 min

Solid State Speed Control, 500 Amp Solid State Speed Control, 500 Amp

121L X 64X 46H Inches

12.2 kW, (16.3 Horse Power) for 5 min

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).

* - Specifications are subject to change without notice.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICA TIONS* (MODEL BT 2-80)

ITEM VOLTAGE SPECIFICATION

Occupancy Eight

Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,

48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries,

Dimensions 330 L X 127 W X 112 H Centimeters

Turning Radius 406 Centimeters (160 Inches)

Tires 5.70 x 8 Load Range B

Dry Weight 503 kg (1,110 lbs) Without Batteries

Maximum Load 1,361 kg (3,000 lbs)

Motor, DC 36 Volt 4.5 kW, (6.0 Horse Power) for 60 min Separately Excited Field 8.6 kW, (11.5 Horse Power) for 5 min

48 Volt 6.0 kW, (8.0 Horse Power) for 60 min

Solid State Speed Control, 500 Amp Solid State Speed Control, 500 Amp

130 L X 50 X 44 H Inches

12.2 kW, (16.3 Horse Power) for 5 min

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).

* - Specifications are subject to change without notice.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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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.

Refer to Vehicle Operational Guidelines, Safety

Guidelines section for important safety information

regarding operating this vehicle.

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:

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

Before working on a 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 front wheels to prevent vehicle movement.

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

• 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.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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VEHICLE CONTROLS DASH UP TO SERIAL # 179669

1) 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.

2) 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.

3) 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.

4) Smart View Display

Refer to details later in this chapter.

5) Forward-Off-Reverse Switch

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.

6) 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.

7) Key-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.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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DASH STARTING SERIAL #179670

1) 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.

2) Wiper Switch (Optional)

The wiper 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 wiper. Push the bottom of switch to turn off the wiper. The wiper can be turned on with the key switch in the “OFF” position.

3) Strobe Switch (Optional)

The strobe switch is located on the left side of the instrument panel and to the right of the wiper switch. Push the top of the switch to turn on the strobe. Push the bottom of switch to turn off the strobe. The strobe can be turned on with the key switch in the “OFF” position.

4) Forward-Off-Reverse Switch

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.

5) 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.

6) Smart View Display

Refer to details later in this chapter.

7) 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.

8) Key-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.

in the “OFF” position.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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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.

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

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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 key-switch 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.

Electrolyte Alarm (Optional)

Charger Interlock

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

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.

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

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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Trailer Brake Module (optional)

The trailer brake module controls the braking functions of a trailer equipped with electric brakes. There have been many styles of brake modules used. All of the brake modules that have been used function the same other than that the location of the manual adjustment controls may vary.

The brake module will be located under the dash tray to the left of the steering column. It has a red indicator light (LED), a Thumb wheel braking force adjustor, a Pendulum level adjustment lever, and a Manual Braking lever.

As the vehicle slows during braking, the brake module sends a signal to the trailer energizing the trailer brakes. This signal is proportional depending on how fast the vehicle is stopping.

LED: The LED’s brightness is related to the braking force at the trailer, dim with little or no signal to bright at maximum braking force. Once the vehicles has stopped, the LED will remain at it’s dimmest intensity as long as the brake pedal is depressed.

Thumb wheel: The thumb wheel is used to adjust how much braking force is sent to the trailer brakes. Rotate the thumb wheel upward towards the top of the housing to increase the braking force.

Pendulum Lever: The brake sensor inside the module must be level for it to function correctly. The pendulum lever is used to level the internal brake sensor. Perform the following steps to adjust the sensor:

1 This adjustment must be done with the trailer disconnected from the vehicle. 2 Stop the vehicle on a level surface but do not release the brake pedal. 3 Adjust the thumb wheel to its minimum position downward towards the bottom of the module case. 4 Pull the pendulum towards the front of the module case. The LED should be at it’s maximum intensity. 5 Slowly push the pendulum towards the rear of the module case and stop when the LED just reaches

its minimum intensity. The pendulum should be very close to vertical.

6 Repeat the previous two steps a few times to be sure that the pendulum is at the correct position.

Manual Braking Lever: The manual braking lever can be used to manually apply the trailer brakes. Slide the lever to the left to apply the brakes. The braking force is proportional depending on how far the lever is moved.

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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 described 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.

NOTE: The battery status gauge as well as any faults

indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle.

HM: Depending on the revision level of the controller, there are one or two hour meter functions, Key Hours and Run Time Hours (see note below).

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.

NOTE: The Key Hours function was discontinued

starting with revision K controllers shipped in 2007.

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.

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.

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Display showing Maintenance and

Wrench icons

Maintenance Monitor:

NOTE: The Maintenance Monitor function is optional.

The Maintenance Monitor function can be turned ON or OFF by your dealer.

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 only be reset by an authorized technician. Refer to the Illustrated parts section for information regarding tools required to reset the Smart View Display.

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 fault code table in this section for a summery description of the fault codes.

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Fault Code Tables

NOTE: Most faults are a result of a fault in the control

system that will require service by a qualified technician. These faults are shown here for reference only.

Operator correctable faults are shown in bold and underlined.

Level 1 Faults

Fault Code Description What to do

F01000 P/S Motor Overheated Stop the vehicle and allow

the system to cool down.

F01001 Motor Brush Fault Refer to service technician F01002 Pump Motor Brush Fault Refer to service technician F01003 P/S motor Brush Fault Refer to service technician

F01004 Low Battery Volts Batteries are empty and

require charging. If this fault does not reset after the charge cycle is complete then there may be a problem with the charger or batteries. Refer to qualified service technician.

F01005 Controller Overheated Stop the vehicle and allow

the system to cool. This could be a result of an overloaded vehicle.

F01006 Traction Motor Hot Stop the vehicle and allow

the system to cool down. This could be a result of an overloaded vehicle

F01007 Pump Motor Overheated Stop the vehicle and allow

the system to cool down.

F01008 Wiring fault Refer to service technician

Level 4 Faults

Fault Code Description What to do

F04000 Open Contactor Refer to service technician F04001 Contactor Welded Refer to service technician F04002 Steer POT Fault N/A

F04003 Sequence Fault Start up switches were not

operated in the correct order. Refer to Vehicle Operation Guidelines for correct sequence.

F04004 F&R Fault Refer to service technician

F04005 F&R Fault Direction was selected

before start switch was closed. Place direction selector in the OFF position and restart.

F04006 Interlock Fault Seat or foot interlock switch

not closed.

F04007 Inch Switch Fault F&R switch NOT in neutral.

F04008 Steer Fault Refer to service technician

F04009 Low Battery Volts Extreme low battery voltage

at the controller. May be a result of severely discharged battery or wrong battery installed. Confirm that the correct battery is installed and charge the battery.

F04010 High battery Volts Refer to service technician F04011 Out of Range Fault Refer to service technician F04012 CRC Fault Refer to service technician F04013 Capacitor Fault Refer to service technician

Level 5 Faults

Fault Code Description What to do

F05000 Contactor Over Current Refer to service technician F05001 Controller Fault Refer to service technician F05002 Configuration Error Refer to service technician F05003 Internal Fault Refer to service technician F05004 VA Fail Refer to service technician F05005 Data Layer Fault Refer to service technician F05006 MOSFET Short Refer to service technician F05007 Power Up Fault Refer to service technician F05008 Line Contactor Short Refer to service technician F05009 Wiring/Motor Short Refer to service technician F05010 Power Up Fault Refer to service technician F05011 Drive 0 ON Refer to service technician F05012 Drive 1 ON Refer to service technician F05013 Drive 0 OFF Refer to service technician F05014 Drive 1 OFF Refer to service technician F05015 Drv 0 MOSFET Trip Refer to service technician F05016 Drv 1 MOSFET Trip Refer to service technician F05017 Traction ON Refer to service technician F05018 Traction OFF Refer to service technician F05019 MOSFET Short_L Refer to service technician F05020 Power Up Fault Refer to service technician F05021 Traction Welded Refer to service technician F05022 Traction MOSFET Refer to service technician F05023 Auto Zero Refer to service technician F05024 Drive 0 ON L Refer to service technician F05025 Drive 1 ON L Refer to service technician F05026 Drive 0 OFF L Refer to service technician F05027 Drive 1 OFF L Refer to service technician F05028 0 MOSFET trip L Refer to service technician F05029 1 MOSFET trip L Refer to service technician F05030 Traction ON L Refer to service technician F05031 Traction OFF L Refer to service technician F05032 MOSFET Short R Refer to service technician F05033 Power Up Fault Refer to service technician F05034 Traction Welded Refer to service technician F05035 Traction MOSFET Refer to service technician F05036 Auto Zero R Refer to service technician F05037 Drive 0 ON R Refer to service technician F05038 Drive 1 On R Refer to service technician F05039 Drive 0 OFF R Refer to service technician F05040 Drive 1 OFF R Refer to service technician F05041 0 MOSFET Trip R Refer to service technician F05042 1 MOSFET Trip R Refer to service technician F05043 Traction ON R Refer to service technician F05044 Traction OFF R Refer to service technician F05045 Stack Corrupt Refer to service technician F05046 Open Contactor Refer to service technician

Level 2 Faults

Fault Code Description What to do

F02000 Throttle Fault Occurs if throttle control

F02001 Throttle Fault F02002 Belly Switch Fault Refer to service technician F02003 Open Field Refer to service technician F02004 Open Field L Refer to service technician F02005 Open Field R Refer to service technician

voltage is high at start up indicating that the throttle pedal was depressed when the start switch was closed. If the pedal was not depressed, then refer to qualified service technician.

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SAFETY RULES AND OPERATING INSTRUCTIONS

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VEHICLE OPERATION GUIDELINES

Safety Guidelines

• Only qualified and trained operators may drive this

vehicle.

• Drive only on level surfaces or on surfaces having

an incline of no more than 10% (5.6 degrees).

• Drive slowly when making a turn, especially if the

ground is wet or when driving on an incline.

• This vehicle may overturn easily if turned sharply or

when driven at high speeds.

• Observe all traffic regulations and speed limits.

• Keep all body parts (head, arms, legs) inside this

vehicle while it is moving.

• Keep the vehicle under control at all times.

• Yield right of way to pedestrians, ambulances, fire

trucks, or other vehicles in emergencies.

• Do not overtake another vehicle at intersections, blind

spots, or other dangerous locations.

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

• Yield right of way to pedestrians and emergencies

vehicles.

• Stay in your driving lane under normal conditions,

maintaining a safe distance from all objects.

• Keep a clear view ahead at all times.

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.

NOTE: This vehicle is equipped with regenerative

motor braking. When the throttle pedal is released, the motor is converted into a generator. This will slow the vehicle and return this energy to the battery. To disable the motor braking action and allow the vehicle to coast, hold slight pressure on the throttle pedal.

NOTE: If the operator leaves the driver seat while in

motion, the vehicle will come to an abrupt stop.

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.

Starting:

Perform all necessary vehicle preparation steps, inspections, or maintenance before operating this vehicle.

NOTE: The vehicle is equipped with a seat or foot

interlock switch. This switch must be closed BEFORE the throttle is depressed.

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

2. If equipped with a manual park brake, set the parking brake.

3. Hold down the foot brake.

4. Rotate the ON-OFF switch 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 throttle pedal.

• Be careful when handling cargo that is longer, wider,

or higher than this vehicle, be sure to properly secure all loads.

Towing Loads:

• Do not exceed the towing capacity of the tractor.

• Do not exceed the load capacity of the trailer. Refer to documentation supplied with your trailer for information regarding load capacity of the trailer.

• Make sure all loads are securely tied down. Refer to documentation supplied with your trailer for information regarding attaching loads to the trailer.

• Do not back up when towing more than one trailer.

• Drive slowly when towing loads with a high center of gravity.

• When turning, be sure to allow for “corner cutting” of the trailer.

• Allow for longer stopping distances when towing heavy loads.

• Allow for longer stopping distances when driving down a grade.

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Parking

Before leaving the vehicle:

• Set the parking brake.

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

position.

• Rotate the start switch to the “OFF” position.

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.

Automatic Electric Park Brake

This vehicle may be equipped with an automatically applied electric parking brake. Under normal driving conditions, the parking brake will be applied when the start switch is turned off or the operator leaves the driver seat. It will also be applied if the control system loses power such as when the emergency battery disconnect switch (if equipped) is activated.

NOTE: The vehicle will come to an abrupt stop if the

start switch is turned off or the operator leaves the driver seat while the vehicle is in motion.

The parking brake is powered by the vehicle battery. It will be applied whenever the batteries are disconnected. It may be applied if the batteries are severely discharged.

If the vehicle power system fails and applies the brake, the can be released by disconnecting the electric brake from the control system and connecting a 20 to 24 volt DC source (1.5A) to the electric brake.

The automatic park brake should be disabled for servicing or towing procedures only. Do not operate the vehicle while the automatic park brake is disabled. Operating the vehicle with the automatic park brake disabled could lead to severe bodily injury and/or property damage.

Towing This Vehicle

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

NOTE: If the vehicle is equipped with the automatic

electric park 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

This vehicle is equipped with regenerative braking. Follow these steps before towing this vehicle.

1. To tow this vehicle the start switch must be in the “OFF” position.

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

Failure to follow these instructions may result in damage to the vehicle.

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DUMP BED (OPTIONAL)

There are numerous variations of the dump bed options that are available for the Model B series vehicles. Although the physical design of the dump bed varies, the operation is basically the same. Refer to the original vehicle sales order for specific information regarding the dump bed option used.

NOTE: The dump bed option must be installed at the factory; field kits are not available.

Before operating the dump bed, place the forward/reverse switch in the center (OFF) position, turn the key switch OFF and set the parking brake.

Do not operate the dump bed while parked sideways across a grade.

Do not operate the vehicle unless the dump bed is in its fully lowered position.

Failure to comply with these restrictions could result in severe bodily injury and/or property damage.

Operation

Before operating the dump bed, confirm that there is enough vertical clearance above the vehicle.

Do not operate the dump bed while underneath electrical wires. Contact with electrical wires may result in serious injury or death.

The dump bed is operated hydraulically through two push button switches.

The actual location of these switches will vary depending on the type of dump bed. The switches will be located at the rear of the vehicle on the left or right side.

Do not place any body part underneath a raised bed unless the bed prop rod is in place. Severe bodily injury will result if the bed lowers unexpectedly.

Press the top button to raise the bed. The bed should remain in the raised position when the button is released. If the bed does not hold its position, then the hydraulic system should be serviced.

Press the bottom button to lower the bed. The bed should come down within 3 to 15 seconds. If the bed does not lower, or lowers slowly then the hydraulic system should be serviced.

Service

Service should only be performed by qualified technicians familiar with hydraulic systems.

If the lowering rate of the dump bed has deminished, it may be a result of a clogged filter or plugged restricted flow fitting. The filter is internal of the pump and the pump must be disassembled to clean the filter (item # 18 on the exploded part diagram). The restricted flow fitting is installed at the cylinder, the hydraulic hose is attached to this fitting. Remove the hose and fitting to make sure nothing has plugged the hole in the fitting.

The restricted flow fitting controls the lowering rate of the dump. Do not modify the restricted flow fitting or remove it from the system as this will result in rapid falling of the dump and may cause severe bodily injury and/or property damage.

There is an internal high pressure relief valve in the pump. This valve must be readjusted whenever the pump is disassembled. To adjust the valve:

1. Raise the dump to its fully extended position and tie or block it in place.

2. Press the lowering button to relieve back pressure.

3. Install a pressure gauge (3,000 pound) in line with the high pressure hose to the cylinder.

4. Press the raise button and read the maximum pressure on the gauge. Maximum pressure should be approximately 2,000 pounds. Adjust the relief valve as required.

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Manual Release

Lowering the Dump Manually

There is a manually operated valve located on the left side of the hydraulic pump assembly (see illustration). This valve should only be used if the dump fails to lower by pressing the lowering button. The valve is covered by an Allen screw. Remove the Allen screw to access the valve then turn the internal screw clockwise to lower the dump.

Lubrication

Under normal conditions, all of the pivot points should be lubricated with chassis grease every 3months. This includes the upper and lower hydraulic cylinder pivots and the dump bed pivot points. Depending on the type of dump bed, there may be more than one grease fitting for the bed pivots. If grease fittings are not provided, then the pins must be removed to apply grease.

The hydraulic fluid level of the tank should be inspected weekly and filled as required (see illustration).

Use only use Dextron automatic transmission fluid. Using any other fluid may result in damage to the hydraulic pump. The tank must be filled only when the dump is in its fully lowered position. Fill the tank to within appriximatly 1-1/2 to 2-1/2 inches from the filler hole.

Do not place any body part underneath a raised bed unless the bed prop rod is in place. Severe bodily injury will result if the bed lowers unexpectedly.

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HYDRAULIC PUMP EXPLODED VIEW

This view is provided by the manufacturer of the pump and should only be used as a reference. Refer to the pump manufacturere web site for current detailed information: http://www.monarchhyd.com/. The pump model # is M-303.

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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.

Signet Charger Operation, Model HB Series

The Signet® HB series chargers use a semiautomatic 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 (charger will also be beeping). Refer to the

Charger Troubleshooting

section for information on error codes.

Typical Signet® Built In

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.

Signet Charger Operation, Model HBS series

The Signet® HBS series chargers are fully automatic. 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. Once the charge cycle is complete, the charger will continue to monitor the batteries. If the battery voltage drops during storage, the charger will start a new cycle to keep the batteries fully charged.

NOTE: If the charger restarts during a short time

period of storage, then it would be an indication of faulty batteries.

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

Typical Signet® HBS

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

Cycle complete ON ON ON

LED1 LED2 LED3

Safety Rules

2. Error condition. The FAULT LED flashing is an indication of a charging problem (charger may also be beeping). Refer to the Charger Troubleshooting section for information on error codes.

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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. When plugged in, the charger assumes that the batteries require charging and will charger for a minimum of approximately 4-hours. This charger should not be plugged in until the batteries are discharged beyond 50% or the batteries may be overcharged..

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.

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.

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.

Charging time is limited to 20-hours (HBS) or 18-hours (HB). A fault will occur if the charging time exceeds the 20-hour limit.

STORING / 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:

Returning to Service

• Check the

battery’s state of charge and charge if required.

• Perform ALL

maintenance checks in the periodic checklist.

Storage

Temperature

(F)

Over 60 1

Between 40 and 60 2

Below 40 6

Charging Interval

(months)

• 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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PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

2, 3

Check Condition of Tires and

Tire Pressure

Check All Lights, Horns,

Beepers and Warning Devises

Weekly

(20hrs)

Monthly

(80hrs)

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

Annual

(500hrs)

Semi -

(1000hrs)

Annualy

Check Park Brake l

Check Motor Brushes and

Blow Out Motor

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.

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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

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

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

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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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General Maintenance

TABLE OF CONTENTS

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

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

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

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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

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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

Page 42

Maintenance, Service and Repair

LUBRICATION CHART

FRONT

Rear Axle Lubrication

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

Page 43

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

Page 44

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

Page 45

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.

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

Front Axle Page 3

Page 46

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.

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

Page 47

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.

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.

Front Axle Page 5

Page 48

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

Page 49

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.

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.

Front Axle Page 7

Hub with Dust Cap Removed

Page 50

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.

Front Axle Page 8

Page 51

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.

Front Axle Page 9

Page 52

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

Page 53

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.

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

Page 54

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.

Front Axle Page 12

Page 55

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

Page 56

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.

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

Page 57

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.

Steering Page 3

Page 58

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.

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.

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

Page 59

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

Steering Page 5

Page 60

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

Page 61

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.

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

Page 62

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.

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

Page 63

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.

Steering Page 9

Page 64

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

Page 65

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.

Steering Page 11

Page 66

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.

Steering Page 12

Page 67

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

Page 68

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.

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.

Steering Page 14

Rod End

Steering Sleeve

Jam Nut

Rod End Nut

Steering Arm

Page 69

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.

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.

Steering Page 15

Clamp

Ball Joint

Steering Sleeve

Page 70

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.

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

Page 71

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.

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

Page 72

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.

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

Page 73

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

Page 74

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

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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.

Steering Page 21

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Maintenance, Service, and Repair

Exploded View of Steering Gear

Steering Page 22

Page 77

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

Page 78

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

Page 79

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

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

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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.

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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.

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.

Brakes Page 6

Page 83

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

Page 84

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

Page 85

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.

Brakes Page 9

Single reservoir master cylinder

Page 86

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

Page 87

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.

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

Page 88

Maintenance, Service, and Repair

REPLACE THE PARKING BRAKE LINING (ELECTRIC MOTOR BRAKE)

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

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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

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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

Page 91

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.

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.

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

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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.

Brakes Page 16

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Maintenance, Service, and Repair

REPLACE REAR BRAKE PADS

Hydraulic Disc

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.

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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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Maintenance, Service, and Repair

REPLACE THE WHEEL CYLINDER

Disc Brake Body Assembly (front or rear)

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.

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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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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.

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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.

NOTE: There are two different brake assemblies. One has a

standard o-ring with a round cross section, the other has a square cross section. The two o-rings are not interchangeable. The square o-ring is not available as a replacement part. If the square o-ring is damaged, the entire brake assembly must be replaced.

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.

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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.

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.

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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.

Brakes Page 24