Taylor-Dunn C0-425-36, C0-425-38 Operation, Troubleshooting And Replacement Parts Manualooting And Replacement Parts Manual

Download

Page 1

Models Inlcuded: C0-425-36 (C 4-25-36) C0-425-48 (C 4-25-48)

The Best Way

To Go

About Your

Business

MANUAL MC-425-02

Operation, Troubleshooting and

Replacement Parts Manual

Revision: C

Serial number Starting: 150774

Page 2

Page 3

No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or any information storage or retrieval system without prior written permission of Taylor-Dunn® Mfg. unless such copying is expressly permitted by federal copyright law. Address inquiries to Reference Permissions, Taylor-Dunn® Mfg., 2114 W. Ball Road, Anaheim, CA 92804

TAYLOR-DUNN SERVICE CENTER

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

Taylor-Dunn® Mfg.

2114 W. Ball Road

Anaheim, CA 92804

(Attn: Technical Writer)

Page 4

B2-48 With Dump Bed Option

B2-10 Ambulance

B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides

P2-50 30,000 Pound Tow Tractor

ET 3000

ET1-50 Full Size Truck

Page 5

Contents

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

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

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

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

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

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

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

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

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

Standard Specifications Tow Tractor ...................................... 2

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

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

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

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

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

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

Headlight Switch................................................................................................................5

Hi-Low Switch....................................................................................................................6

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

Hour Meter/ Battery Status Indicator (BSI).........................................................................6

Steering ............................................................................................................................. 7

Hazard Light Switch (Optional) ..........................................................................................7

Directional Signals ............................................................................................................. 7

Accelerator Pedal .............................................................................................................. 8

Foot Brake Pedal ............................................................................................................... 8

Battery Disconnect Switch.................................................................................................8

Park Brake......................................................................................................................... 8

Reverse or Motion Alarm (Optional)................................................................................... 9

Seat Interlock Switch ......................................................................................................... 9

Smart View Display............................................................................................................10

Vehicle Operational Guidelines ............................................... 13

Safety Guidelines .............................................................................................................. 13

Starting: ............................................................................................................................. 13

While driving:..................................................................................................................... 14

Loading and Unloading ...................................................................................................... 14

Parking .............................................................................................................................. 14

Towing ............................................................................................................................... 14

Charging your vehicle............................................................... 15

Operation of the Charger ...................................................................................................15

New Battery Break in .........................................................................................................15

Storing and Returning to Service ........................................... 16

Storing Your Vehicle...........................................................................................................16

Returning To Service ......................................................................................................... 16

Periodic Maintenance Checklist .............................................. 17

Standard Periodic Maintenance Schedule

for the Smart View Display.................................................. 18

Daily Visual Inspection ............................................................. 19

Maintenance Schedule for Sever Duty Applications .............. 19

Page 6

Table of Contents

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

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

Maintenance Guidelines for Vehicles Used in

Severe Conditions .................................................................... 3

Troubleshooting Guide............................................................. 4

Lubrication Chart ...................................................................... 5

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

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

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

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

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

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

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

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

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

Replace the Pivot Pin and Bushings....................................... 10

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

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

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

Inspect Ball Joints .................................................................... 5

Adjust the Steering Gear (Saginaw) ........................................ 6

Replace the Tilt Steering Assembly......................................... 8

Steering Column ....................................................................... 9

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

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

Replace the Steering Gear ....................................................... 11

Center the Steering Gear.......................................................... 12

Pitman Shaft Alignment............................................................ 12

Replace the Ball Joints, Tie Rods, and Drag Link.................. 13

Replacing the Drag Link .............................................................................................14

Replacing the Tie Rod ................................................................................................15

Repair the Steering Gear .......................................................... 16

Exploded View of Steering Gear ................................................................................19

Page 7

Table of Contents

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

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

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

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

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

Wheel Park Brake ......................................................................................................4

Adjust the Service Brakes ........................................................ 5

Two or Four Wheel Hydraulic Disc Brakes .................................................................5

Adjust the Brake Linkage ......................................................... 5

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

Wheel Park Brake ......................................................................................................7

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

Bleed the Brakes ....................................................................... 9

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

Replace the Parking Brake Lining ........................................... 12

Wheel Park Brake ......................................................................................................12

Replace Front Brake Pads........................................................ 13

Replace Rear Brake Pads......................................................... 15

Hydraulic Disc.............................................................................................................15

Replace the Wheel Cylinder ..................................................... 17

Disc Brake Body Assembly (front or rear) ...................................................................17

Repair the Brake Body.............................................................. 19

Replace the Master Cylinder .................................................... 21

Repair the Master Cylinder....................................................... 23

Throttle Linkage .......................................................1

Throttle Linkage Adjustments .................................................. 2

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

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

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

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

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

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

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

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

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

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

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

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

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

Removing and Installing the Rear Axles ................................. 6

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

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

Page 8

Table of Contents

Disassembly and Reassembly of the

Primary Reduction Gear Case ................................................. 10

Disassembling the 3rd Member ............................................... 13

Assembling the 3rd Member .................................................... 16

Pinion Bearing Preload ...............................................................................................19

Pinion Gear Shimming Instructions ........................................ 20

Setting the Pinion Gear Depth ...................................................................................20

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

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

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

Replace the Shocks .................................................................. 4

Front or Rear ..............................................................................................................4

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Test 8. Anti-Rolloff Fault..............................................................................................21

Sevcon Logic Voltage Reference Table ......................................................................22

Status LED Code Table...............................................................................................23

Charger Troubleshooting ........................................1

Page 9

Table of Contents

Wire Diagrams........................................................ 1

Dash ........................................................................................... 2

Control Panel............................................................................. 3

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

Front Axle, Steering and Brakes ........................2

Steering Column ............................................... 4

Steering Gear .................................................... 6

Front Suspension ............................................... 8

Transmission Assembly ..................................... 10

Transmission Gear Case ....................................12

Transmission Differential Case.......................... 14

Rear Axle .......................................................... 14

Rear Brakes....................................................... 16

Brake Body Assembly........................................ 16

Rear Suspension ................................................ 18

Motor ................................................................ 20

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

Automatic Electric Brake .................................. 22

Brake Lines ....................................................... 24

Brake linkage (parking brake) ........................... 26

Brake linkage (foot brake) ................................. 28

Throttle linkage ................................................ 30

Wheels and Tires............................................... 32

Instrument Panel (dash) .................................... 34

Resetting the Smart View Display ..................... 35

Speed Control Panel .......................................... 36

Miscellaneous Electrical.................................... 38

Lighting System ................................................ 40

Seat Cushions and Deck .................................... 42

Decals ............................................................... 44

Frame Components ........................................... 46

Side Battery Extract Option ............................... 46

Front Push Plate Option .................................... 48

Hitches .............................................................. 48

Charger ............................................................. 50

Batteries ............................................................ 50

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

APPENDIX B-Torque Values.................................. B-1

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

Brake Lining Handling Precautions......................................... 2

Page 10

TAYLOR -DUNN

Page 11

Introduction

Contents

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

Who Should Read This Manual ....................2

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

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

Conventions........................................................... 4

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

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

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

INTRODUCTION

HOW TO IDENTIFY YOUR VEHICLE

This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial

plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on public highways.

This vehicle is not designed to be driven on public roads or highways. It is available in maximum designed speeds ranging from 7 to 9 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

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

Introduction Page-6

Page 17

INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

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

• Examine the contents of all packages and accessories that may have come in separate

packages with the vehicle.

• Make sure everything listed on the packing slip is there.

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

• Check battery cells to be sure they are filled.

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

Check the operation of each of the following controls:

• Accelerator

• Brake

• Parking Brake

• Key-Switch

• Forward/Reverse Switch

• Reverse Beeper (if equipped)

• Front Headlight Switch

• Steering Wheel

• Horn

What To Do If a Problem is Found

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

If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately contact your local Taylor-Dunn® distributor and report the problem. The report must be made within 24 hours of receiving the vehicle and its accessories.

The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn® vehicle is a factory authorized service technician.

The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn® vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage. Unauthorized repairs may also void the vehicles warranty.

Introduction Page-7

Page 18

TAYLOR -DUNN

Page 19

Safety Rules and Operating Instructions

TABLE OF CONTENTS

Standard Specifications Tow Tractor............2

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

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

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

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

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

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

Headlight Switch ...................................................... 5

Hi-Low Switch ..........................................................6

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

Hour Meter/ Battery Status Indicator (BSI) ............. 6

Steering .................................................................... 7

Hazard Light Switch (Optional) ............................... 7

Directional Signals ................................................... 7

Accelerator Pedal .................................................... 8

Foot Brake Pedal ..................................................... 8

Battery Disconnect Switch ......................................8

Park Brake ...............................................................8

Reverse or Motion Alarm (Optional) ....................... 9

Seat Interlock Switch ...............................................9

Smart View Display .................................................10

Vehicle Operational Guidelines.....................13

Safety Guidelines .................................................... 13

Starting: .................................................................... 13

While driving: ........................................................... 14

Loading and Unloading ............................................14

Parking ..................................................................... 14

Towing ......................................................................14

Charging your vehicle...................................15

Operation of the Charger .........................................15

New Battery Break in ............................................... 15

Storing and Returning to Service ................16

Storing Your Vehicle .................................................16

Returning To Service ............................................... 16

Periodic Maintenance Checklist ...................17

Standard Periodic Maintenance Schedule

for the Smart View Display .....................18

Daily Visual inspection: ........................................... 19

Maintenance Guidelines for

Severe Duty Applications........................19

Page 20

SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS TOW TRACTOR

ITEM Volts SPECIFICATION

Occupancy Driver only, no passengers

Dimensions 1994 L x 965 W x 1422 H Millimeters

Turning Radius 1752 Millimeters (69 inches)

Dry Weight (Without Battery) 748 kg (1650 lbs)

Battery Compartment Dimensions 420 L x 812 W x 610 H Millimeters

78.50 L x 38.00 W x 56.00 H Inches

16.5 L x 32 W x 24 H inches

Battery Specifications:

Min/Max Battery Weight 453.5 kg to 635 kg (1000 lbs to 1400 lbs) Voltage 36 or 48 Connector SB 350 Blue Lead Length 762 millimeters (30 inches) Position A Cover No

Maximum Towed Load 48 136 kg (300 lb) Draw Bar Pull @ 14.5 kph (9 mph)

Electrical System Solid State Speed Control, 500 Amp

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid Differential

Motor, DC 48 12 kW (16.3 Horse Power) for 5 min Separately Excited Field 36 8.5 kW (11.5 Horse Power) for 5 minutes

Maximum 14.5 kph (9 mph) Recommended Speed

36 113 kg (250 lb) Draw Bar Pull @ 11.3 kph (7 mph)

Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake

Steering Automotive Steering 24:1

Tires 4.80 X 8 Pneumatic Load Rang C, Split Rims

Instrumentation Battery Discharge Indicator, Key Switch, Horn Button,

Light Accessories Headlight, Tail/Brake/Reverse Light, Turn Signals

Forward/Reverse Switch, Headlight Switch, Hour Meter, Battery Disconnect Switch, Hi-Low Speed Switch

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 Operator Controlled Industrial Tow Tractors (ANSI B56.9).

Safety Rules Page 2

Page 21

SAFETY RULES AND OPERATING INSTRUCTIONS

SAFETY RULES AND GUIDELINES

It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle while also obeying he following safety rules and guidelines (reference American National Standards Institute Operator Controlled Industrial Tow Tractors ANSI B56.9).

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.

• Do not drive this vehicle unless you are a qualified and trained operator.

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

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

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

• Drive slowly when making a turn especially if the ground is wet or slippery.

• Drive slowly when driving on an incline.

• This vehicle may overturn easily if turned sharply while driven at high speeds, or on an incline.

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

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

• Observe all traffic regulations and speed limits (see speed warning above).

• Keep to the right under normal conditions.

• Maintain a safe distance from all objects.

• 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.

• Keep a clear view ahead at all times.

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

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

Before working on a vehicle:

3. Set the park brake.

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

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

Safety Rules Page 3

Page 22

SAFETY RULES AND OPERATING INSTRUCTIONS

DRIVER TRAINING PROGRAM

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

The Operator Training program shall include the following:

• Operation of this vehicle under circumstances normally associated with your particular

environment.

• Emphasis on the safety of cargo and personnel.

• All safety rules contained within this manual.

• Proper operation of all vehicle controls.

• A vehicle operation and driving test.

Driver Qualifications.

Only those who have successfully completed the Operator Training program are authorized to drive this vehicle. Operators must possess the visual, auditory, physical, and mental ability to safely operate this vehicle as specified in the American National Standards Institute Controlled Personnel and Burden Carriers ANSI B56.8.

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

• Demonstrate a working knowledge of each control.

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

• Know how to properly load and unload cargo.

• Know how to properly park this vehicle.

• Recognize an improperly maintained vehicle.

• Demonstrate ability to handle this vehicle in all conditions.

Safety Rules Page 4

Page 23

SAFETY RULES AND OPERATING INSTRUCTIONS

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.

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 key-switch off and the park brake set whenever the operator leaves the vehicle.

Horn Switch

The horn switch is located in the center of the steering wheel. Depress the switch to sound the horn, release it to turn it off.

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.

Safety Rules Page 5

Page 24

SAFETY RULES AND OPERATING INSTRUCTIONS

Hi-Low Switch

The high-low switch is located on the lower left of the instrument panel. Push on the left side of the switch (turtle) for slow speed. Push on the right side of the switch (rabbit) for normal speed.

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.

Hour Meter/ Battery Status Indicator (BSI)

The hour meter and BSI are combined into one unit and is located to the right of the headlight switch in the middle of the dash panel battery status indicator.

The hour meter, located on the bottom of the display, records the number of hours the vehicle has been in operation.

The battery status indicator, located on the top of the display, has a LED bar graph that indicates the relative state of charge of the battery. The right LED will light only when connected to a fully charged battery or after completing a charging cycle.

Hour meter

battery energy status is in energy reserve and should be placed on charge as soon as possible. When the two left LED’s are alternately flashing the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries. The BSI will reset to fully charged only after a complete charge cycle is completed. A complete charge cycle is defined as battery voltage exceeding 2.35 volts per cell for a minimum of 6 minutes.

Successive LED’s to the left will light as the battery charge diminishes. When the second from the left LED flashes the

Battery status indicator

Safety Rules Page 6

Page 25

SAFETY RULES AND OPERATING INSTRUCTIONS

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 counterclockwise. 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.

Tilt lever

Directional Signals

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

Hazard Light Switch (Optional)

The hazard light switch is located on the left side of the steering column. The switch is a small tab. To activate the hazard lights, pull the tab out. To turn the hazard lights off, push forward or pull back the directional signal lever.

Safety Rules Page 7

Page 26

SAFETY RULES AND OPERATING INSTRUCTIONS

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.

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.

Battery Disconnect Switch

The battery disconnect switch is located to the right of the driver seat (red knob). To disconnect the battery from the control system, push down on the knob. Pull up on the knob to reconnect the battery.

Safety Rules Page 8

Page 27

SAFETY RULES AND OPERATING INSTRUCTIONS

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.

Reverse or Motion Alarm (Optional)

The reverse alarm is located in the electronics compartment mounted in the speed control panel enclosure. The reverse alarm is activated when the Key switch is in the “ON” position and the Forward-Off-Reverse switch is in the reverse position. The alarm makes a repeated audible sound.

The motion alarm is the same alarm that is used for the reverse alarm, only it operates in both the forward and reverse directions.

Safety Rules Page 9

Page 28

SAFETY RULES AND OPERATING INSTRUCTIONS

Smart View Display

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

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

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

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

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

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

the right side of the display.

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

Key Hours icon

Safety Rules Page 10

Page 29

SAFETY RULES AND OPERATING INSTRUCTIONS

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

Run Time Hours icon

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

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

good, check wiring to the controller.

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

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

01008 Optional speed encoder or speed encoder

wiring defective

02000 Start up switches not operated in the correct

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

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

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

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

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

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

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

wiring

Repair as required

Reset switches and start again.

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

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

good, check wiring to the controller.

Replace contactor or repair wiring

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

Safety Rules Page 11

Page 30

SAFETY RULES AND OPERATING INSTRUCTIONS

Maintenance monitor:

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

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

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

Display showing Maintenance and

Wrench icons

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

Safety Rules Page 12

Page 31

SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

• Only qualified and trained operators may drive this vehicle.

• Drive only on level surfaces or on surfaces having an incline of

no more than 10% (5.6 degrees).

• Drive slowly when making a turn, especially if the ground is wet

or when driving on an incline.

• This vehicle may overturn easily if turned sharply or when

driven at high speeds.

• Observe all traffic regulations and speed limits.

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

it is moving.

• Keep the vehicle under control at all times.

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

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

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

• Yield right of way to pedestrians and emergencies vehicles.

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

• Keep a clear view ahead at all times.

Starting:

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

2. Set the parking brake.

3. Hold down the foot brake.

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

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

6. Release the parking brake.

7. Release the foot brake.

8. Slowly depress the accelerator pedal.

Safety Rules Page 13

Page 32

SAFETY RULES AND OPERATING INSTRUCTIONS

While driving:

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

intersection.

• No reckless driving.

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

• Immediately report any accidents or vehicle problems to a supervisor.

Loading and Unloading

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

• Do not exceed the cargo load capacity.

• Do not load cargo that can fall off.

• Be careful when handling cargo that is longer, wider, or higher than this vehicle, be sure to

properly secure all loads.

Parking

Before leaving the vehicle:

• Set the parking brake.

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

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

In addition:

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

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

Towing

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

NOTE: If the vehicle is equipped with an automatic electric brake, do not

tow the vehicle with the drive wheels on the ground.

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

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

Safety Rules Page 14

Page 33

SAFETY RULES AND OPERATING INSTRUCTIONS

CHARGING YOUR VEHICLE

Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged. Failure to do so may result in severe bodily injury and/or property damage.

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

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

Operation of the Charger

The charger supplied with this vehicle is either specified by or provided by the end user. Refer to the operating instruction supplied with your charger or contact the charger manufacturer for more information.

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 lifespan. Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level. Refer to Section 2-Maintainence, Service and Repair for battery maintenance information.

Do not interrupt the charging cycle. When the charger is plugged in, allow it to turn off before disconnecting. Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep. Both circumstances will shorten the life of the batteries.

Safety Rules Page 15

Page 34

SAFETY RULES AND OPERATING INSTRUCTIONS

PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

2,3

Check Condition of Tires and

Tire Pressure

Check All Lights, Horns,

Beepers and Warning Devises

Weekly

(20hrs)

Monthly

(80hrs)

Quaterly (250hrs)

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

Lubricate Vehicle

Clean and Tighten All Wire Connections

Wash and Service Batteries l

Semi -

Annual

(500hrs)

Annualy

(1000hrs)

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.

Safety Rules Page 17

Page 35

SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY

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

with a customized maintenance schedule

PREVENTATIVE MAINTENANCE SCHEDULE

MAINTENANCE

LEVEL

1 500

2 1000

HOUR

INTERVAL

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

Inspect the king pin bushings

Check front end alignment

Change oil in the drive and rear axle

Flush hydraulic brake system

3 2000

Inspect suspension bushings

Replace brake pedal/treadle return spring

Inspect frame for damage

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

Safety Rules Page 18

Page 36

SAFETY RULES AND OPERATING INSTRUCTIONS

Daily Visual inspection:

Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to:

• Accelerator pedal, Brake pedal, Steering, Parking brake, etc.

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

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

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

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

Inspect for leaking fluids or grease.

MAINTENANCE GUIDELINES FOR SEVERE DUTY APPLICATIONS

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

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

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

• Extreme temperature.

• Bumpy, dusty, or ill maintained roads.

• Excessively wet areas.

• Corrosive or contaminated areas.

• Frequent loading of vehicle at/near capacity.

• Use on multiple shifts.

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

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

Safety Rules Page 19

Page 37

General Maintenance

TABLE OF CONTENTS

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

Maintenance Guidelines for Vehicles Used in

Severe Conditions ..................................3

Troubleshooting Guide ................................4

Lubrication Chart ..........................................5

Page 38

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.

Before starting

3. Set the park brake.

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

Page 39

Maintenance, Service and Repair

MAINTENANCE GUIDELINES FOR VEHICLES USED IN SEVERE CONDITIONS

If this vehicle is operated in severe conditions all maintenance items listed in the Periodic Maintenance Table should be carried out twice as often as stated. In addition, the entire vehicle should be inspected monthly for signs of damage. If any damage is found, the vehicle should be immediately removed from service and repaired.

The following list is meant as a guide and is not all inclusive: SEVERE CONDITIONS refer to operation:

• In extreme temperatures

• On bumpy, dusty, or poorly maintained roads

• In excessively wet areas

• In corrosive or contaminated areas

• At or near maximum capacity for more than 50% of the operating time

• On multiple shifts

Maintenance Page 3

Page 40

Maintenance, Service and Repair

TROUBLESHOOTING GUIDE

Symptom Probable Cause

Front End Out of Alignment

Steering Pulls in One Direction

Low Tire Pressure

Dry Lube Points in Steering Linkage

Hard Steering

Excessive Steering Play

Lack of Power or Slow Operation

Abnormal Noise

Oil Leak in Rear Bearing Area

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

Defective Speed Control

Worn Drive Gears or Bearings

Worn Front /Rear Axle Bearings

Loose Lug Nuts

Motor Bearings Worn

Rear Wheel Bearing and/or Gasket Failed

Drive Over Filled

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Worn (1/16" Wear Limit)

Brake Pedal Low

Braking Power Low

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

Maintenance Page 4

Page 41

LUBRICATION CHART

Maintenance, Service and Repair

Front end (from bottom)

GT Drive, center section

# Description Locations Lubricant Type

1 - - 2 King Pin 2 General Purpose Grease

3 Ball Joints 6 General Purpose Grease 4 Idler Pivot 1 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 - - 7 Drive Drain Plug 1 SAE 80W90 Hypoid Gear Oil 8 Drive Level Plug 1 SAE 80W90 Hypoid Gear Oil 9 Drive Fill Plug 1 SAE 80W90 Hypoid Gear Oil

10 - - -

Maintenance Page 5

Page 42

B2-48 With Stake Side Dump Bed Option

SC1-00 Stock Chaser

E4-55 Sit Down Tow Tractor

C4-25 Sit Down Tow Tractor

Page 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 Pivot Pin and Bushings............ 10

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. Unplug the main battery connector.

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 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 battery connector.

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. Unplug the main battery connector.

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 battery connector.

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. Unplug the main battery connector.

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 pivot on the front axle assembly.

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

regarding the removal of the ball joints or rod ends.

10.Disconnect the hydraulic brake lines from the brake bodies.

11. Remove the three bolts holding the front axle beam to the upper wishbone and the two lower suspension links and remove the axle from the vehicle.

Viewed from front

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. Unplug the main battery connector.

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 battery connector.

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.

View from rear

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. Unplug the main battery connector.

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 battery connector.

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.

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

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

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

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.

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. Unplug the main battery connector.

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 or steering knuckle.

9. Press new bushings into the axle or steering knuckle.

10.Ream or broach bronze bushings to 0.8755 - 0.8765 inches.

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

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.

12.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.

13.Grease the bushings (bronze only).

14.Lower the vehicle.

15.Reconnect the main battery connector.

16.Remove the blocks from behind the wheels.

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

REPLACE THE PIVOT PIN AND BUSHINGS

The procedure to replace the pivot pin is the same as the king pin procedure.

Ream or broach the bronze pivot bushings to

0.878 - 0.880 inches.

King pin

Pivot pin

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. Unplug the main battery connector.

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.Tighten the king pin nut until there is 0.005” clearance between the top of the thrust bearing and the upper arm of the axle beam.

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.

0.005" clearance

Thrust bearing

Steering knuckle

Upper arm of axle beam

King pin nut

19.Reconnect the main battery connector.

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 .......................................... 5

Adjust the Steering Gear (Saginaw) .............6

Replace the Tilt Steering Assembly..............8

Steering Column ............................................. 9

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

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

Replace the Steering Gear............................. 11

Center the Steering Gear ...............................12

Pitman Shaft Alignment ................................. 12

Replace the Ball Joints, Tie Rods,

and Drag Link ........................................... 13

Replacing the Drag Link ......................................... 14

Replacing the Tie Rod ............................................ 15

Repair the Steering Gear................................16

Exploded View of Steering Gear............................. 19

Page 56

Maintenance, Service, and Repair

FRONT END ALIGNMENT

Inspection, Axle Centers

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. Unplug the main battery connector.

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

7. Measure the distances from the rear of the lower axle beam to the rear wall of the wheel well on both sides of the axle beam next to the steering knuckle. Adjust the lower suspension links so that the distance is between 10-1/8 to 10-3/8 inches.

NOTE: The difference between the left and right measurement should be

no more than 1/8 inch.

8. Measure the distances from the rear of the upper axle beam to the rear wall of the wheel well on both sides of the axle beam next to the steering knuckle. Adjust the upper wishbone link so that the distance is 1/2 inch less than the lower measurement.

NOTE: Do not continue with the front end alignment until the axle centers

are properly adjusted.

Steering Page 2

Page 57

Center the Wheels

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

NOTE: Refer to Center the Steering Gear section for information

11. Loosen the ball joint clamps on the drag link.

12.Adjust the drag link so that the steering pivot arm is parallel with the axle beam.

13.Position the ball joint clamps as shown and tighten to 28-32 ft lbs.

Maintenance, Service, and Repair

regarding centering of the steering gear.

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.

Toe In

14. Loosen the ball joint clamps on the left and right tie rods.

15.Position a straight edge along the right side of the vehicle and adjust the right side tie rod so that the front wheel is parallel with the rear wheel.

Tie rods

16.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.

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

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

Steering Page 3

Page 58

Maintenance, Service, and Repair

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

20. Position the ball joint clamps as shown and tighten to 28-32 ft lbs.

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.

21. Reconnect the main battery connector.

22. Untie the stering wheel.

23.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.

24.Remove the blocks from behind the wheels.

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

Clamp

RIGHT

LEFT

FORWARD

Steering Page 4

Page 59

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. Unplug the main battery connector.

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.

Maintenance, Service, and Repair

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 battery connector.

11. Remove the blocks from behind the wheels.

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

Typical Ball Joint

Steering Page 5

Page 60

Maintenance, Service, and Repair

ADJUST THE STEERING GEAR (SAGINAW)

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. Unplug the main battery connector.

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.

Steering Page 6

Page 61

Maintenance, Service, and Repair

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.

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 battery connector.

16.Remove the blocks from behind the wheels.

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

Steering Page 7

Page 62

Maintenance, Service, and Repair

REPLACE THE TILT STEERING ASSEMBLY

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. Unplug the main battery connector.

6. There are two allen head set screws holding the steering shaft to the universal joint. Only one of the screws must be removed, the other only needs to be loosened. Refer to the illustration. Loosen the jam nuts and and remove/loosen the screws.

7. Disconnect the harness from the steering column.

8. Loosen the upper u-bolt and slide the steering column up and out of the vehicle.

9. Install the steering column in reverse order.

10.Apply thread locking compound on the universal joint screws.

11. Tighten the upper u-bolt enough to prevent the steering column from rotating without crushing the column.

12.Reconnect the main battery connector.

13.Remove the blocks from behind the wheels.

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

Steering Page 8

Page 63

Maintenance, Service, and Repair

STEERING COLUMN

NOTE: The steering column does not have to be removed from the vehicle unless the lower steering shaft or bushing is to be replaced. Refer to Replace the Tilt Steering Assembly section for information regarding removing the steering column.

Perform the following 5 steps if the steering column is not removed from the 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. Unplug the main battery connector.

Disassemble

6. Depress the retaining plate and remove the retaining plate circlip.

7. Remove the retaining plate and the horn button contact plate and spring.

8. Remove he three button head screws holding the turn signal switch.

9. If replacing the turn switch, remove the pins from the harness connector and pull the switch out of the column.

10.Remove the upper shaft inner race and bearing #1.

11. Remove the two Torx head screws in the housing and remove the housing. Catch the flat washer as it falls out.

Steering wheel adaptor

Circlip

Retaining plate

Turn switch

Tilt spring retainer

Tilt spring

Tilt spring guide

1/4 cut flat washer

Upper bearing #1

Upper bearing #2

Upper steering shaft

Tilt housing

Pivot pin

Plastic CV bushing

Steering Page 9

Page 64

Maintenance, Service, and Repair

12.Depress and turn the tilt spring about 30º and remove the retainer, tilt spring and the spring guide.

13.Thread an 8-32 machine screw into the pivot pins and pull them out.

14.Install the tilt lever and pull it up to release the tilt housing from the column.

15.Remove the upper shaft inner race and bearing #2.

16.Remove the steering shaft.

17.Rotate the upper shaft 90º and separate it from the upper shaft

18.Rotate the plastic CV bushing 30º and remove it from the steering shaft.

19.If replacing the bearings, remove the inner race from the steering shaft and outer races from the tilt housing.

20.Remove the roll pin from the lower bushing and the lower bushing from the column.

Assemble

Assemble in reverse order. Use a soft faced hammer to install the pivot pins. a.) Pack the upper steering shaft bearings with grease. b.) Apply grease on the plastic CV bushings. c.) Lightly grease the pivot pins and pivot spring guide pivot point. d.) Lightly grease the turn signal switch contacts. e.) Use locktite on lower U-joint set screws.

Steering wheel adaptor

Circlip

Retaining plate

Turn switch

Tilt spring retainer

Tilt spring

Tilt spring guide

1/4 cut flat washer

Upper bearing #1

Upper bearing #2

Upper steering shaft

Tilt housing

Pivot pin

Plastic CV bushing

Steering Page 10

Page 65

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. Unplug the main battery connector.

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

7. There are two allen head set screws holding the steering shaft to the universal joint. Only one of the screws must be removed, the other only needs to be loosened. Refer to the illustration. Loosen the jam nuts and and remove/loosen the screws.

8. Remove the pitman arm.

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

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

11. Install in reverse order. Torque the pitman arm nut to 75-100 ft-lbs. Apply thread locking compound to the steering shaft allen head screws.

12.Reconnect the main battery connector.

13.Remove the blocks from behind the wheels.

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

Steering Page 11

Page 66

Maintenance, Service, and Repair

CENTER THE STEERING GEAR

1. Rotate the input shaft clockwise until it stops.

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

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

4. Mark the input and pitman shaft in relation to the housing.

PITMAN SHAFT ALIGNMENT

1. Center the steering gear. Refer to Center the Steeing Gear for information regarding centering the steering gear.

2. Install the pitman arm parallel with the input shaft orientated as shown in the illustration.

3. Torque the pitman arm nut to 75-100 ft-lbs

Steering Page 12

Page 67

Maintenance, Service, and Repair

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

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 Ball Joint

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. Unplug the main battery connector.

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.

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.

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.

Steering arm

Ball joint

Ball joint nut

Cotter pin

Clamp

Steering sleeve

14.Lower the vehicle.

15.Reconnect the main battery connector., remove the blocks from the wheels, and test drive.

Steering Page 13

Page 68

Maintenance, Service, and Repair

Pitman Arm

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. Unplug the main battery connector.

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.

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 battery connector.

13.Remove the blocks from behind the wheels.

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

Drag Link

Steering Knuckle

Typical Drag Link

Steering Page 14

Page 69

Maintenance, Service, and Repair

Replacing the Tie Rod

The Tie Rod is the linkage that connects the two steering knuckles together. 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. Unplug the main battery connector.

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

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 battery connector.

13.Remove the blocks from behind the wheels.

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

Tie rod

Steering knuckle

Front Axle Assembly (left side shown)

Steering Page 15

Page 70

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 16

Page 71

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 17

Page 72

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 18

Page 73

Exploded View of Steering Gear

Maintenance, Service, and Repair

Steering Page 19

Page 74

TAYLOR -DUNN

Page 75

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..................................................... 4

Adjust the Service Brakes ............................5

Two or Four Wheel Hydraulic Disc Brakes ............... 5

Adjust the Brake Linkage .............................5

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

Wheel Park Brake..................................................... 7

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

Bleed the Brakes ...........................................9

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

Replace the Parking Brake Lining ...............12

Wheel Park Brake..................................................... 12

Replace Front Brake Pads............................13

Replace Rear Brake Pads .............................15

Hydraulic Disc ..........................................................15

Replace the Wheel Cylinder .........................17

Disc Brake Body Assembly (front or rear) .................17

Repair the Brake Body..................................19

Replace the Master Cylinder ........................21

Repair the Master Cylinder ...........................23

Page 76

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 77

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

Page 78

Maintenance, Service, and Repair

INSPECT THE PARKING BRAKE

Wheel Park Brake

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 rear wheels to prevent vehicle movement.

5. Unplug the main battery connector.

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.

11. Reconnect the main battery connector.

12. Remove blocks from behind the wheels.

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

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

Brakes Page 4

Page 79

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.

ADJUST THE BRAKE LINKAGE

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. Unplug the main battery connector.

6. Tighten the master cylinder push rod pivot bolt so that the push rod may pivot freely with no side play. See the illustration to the right.

Pivot bolt

Push rod

7. Tighten the spring mounting bolt and the pedal stop bolt so that one thread shows beyond the locknut. See arrows in the illustraition to the left.

Brakes Page 5

Page 80

Maintenance, Service, and Repair

8. Tight the brake pedal pivot bolt so that the brake pedal moves freely with no side play.

9. Reconnect the main battery connector.

10. Remove blocks from behind the wheels.

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

Brakes Page 6

Page 81

Maintenance, Service, and Repair

ADJUST THE PARKING BRAKE

Wheel Park Brake

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 rear wheels to prevent vehicle movement.

5. Unplug the main battery connector.

6. Release the park brake.

7. Loosen the jam nuts on the park brake linkage.

8. Adjust the linkage to remove all slack for the park brake cables.

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

10. Set the park brake.

11. Reconnect the main battery connector.

12.Remove blocks from behind the wheels.

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

Brakes Page 7

Page 82

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 83

BLEED THE BRAKES

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.

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 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.

Brakes Page 9

Page 84

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 85

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 86

Maintenance, Service, and Repair

REPLACE THE PARKING BRAKE LINING

Wheel Park Brake

The parking brake is the same as the rear service brake. See Replace Rear Brake Pads or Shoes section for information on replacing the park brake lining.

Brakes Page 12

Page 87

Maintenance, Service, and Repair

REPLACE FRONT 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.

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

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

Brakes Page 13

Page 88

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 14

Page 89

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.

Brakes Page 15

Page 90

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.

Brakes Page 16

Page 91

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.

Brakes Page 17

Page 92

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.

Brakes Page 18

Page 93

Maintenance, Service, and Repair

REPAIR THE BRAKE BODY

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

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

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

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

3. Set the park brake.

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

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

6. Remove the brake body from the vehicle.

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

section for information on removing the brake body.

7. Pull the pistons out of the brake body.

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

8. Remove the piston rubber boot.

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

10. Inspect and replace parts as required.

Brakes Page 19

Page 94

Maintenance, Service, and Repair

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

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

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

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

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

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

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

Brakes Page 20

Page 95

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.

Brakes Page 21

Page 96

Maintenance, Service, and Repair

1/8"

10. Install in reverse order.

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

12. 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.

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

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

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.

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 22

Page 97

Maintenance, Service, and Repair

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make

sure your work area is free from dirt and debris and will contain any brake fluid spills.

Remove the master cylinder from the vehicle. See Replace the Master Cylinder section . Drain all fluid from the master cylinder and discard. Remove the rubber boot. Depress the plunger and remove the plunger spring clip retainer. Pull the plunger and all seals out of the master cylinder bore. Thoroughly clean, inspect and replace parts as required. If any damage is found in the bore of the master cylinder then it must be replaced. Lubricate all parts with clean brake fluid from a sealed container. Reassemble in reverse order. If the master cylinder is not to be immediately installed onto a vehicle, plug the brake line fitting hole to

prevent any contaminates from entering the master cylinder.

Brakes Page 23

Page 98

TAYLOR -DUNN

Page 99

Throttle Linkage

TABLE OF CONTENTS

Throttle Linkage Adjustments ......................2

Page 100

Maintenance, Service, and Repair

THROTTLE LINKAGE ADJUSTMENTS

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. Unplug the main battery connector.

6. Adjust the accelerator pedal arm pivot nut so that there is 0.005” clearance between the nut and flat washer.

7. Make sure the accelerator pedal arm is in the fully released position. See arrow 1 in the illustration.

8. Adjust the throttle rod so that the accelerator module arm has 0.010” clearance between the arm and the accelerator module bracket. See arrow 2 in the illustration.

Accelerator

Module

Pivot nut

Accelerator

Arm

9. Reconnect the main battery connector.

10. Remove the blocks from the wheels and test drive the vehicle.

2 (see magnified view at right)

0.010

Pivot nut

Throttle rod

0.005"

Throttle Linkage Page 2