Taylor-Dunn B0-T48-48, ET-030-48 Operation, T Roubleshooting And Replacement Parts Manual

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Taylor Truck

ET 3000

Models Inlcuded: B0-T48-48 Taylor Truck (T48) ET-030-48 (ET 3000)

The Best Way

To Go

About Your

Business

MANUAL MB-T48-01

Operation, Troubleshooting and Re-

placement Parts Manual

Published: 3/28/2002 Revision: K, 8/9/2011

Serial number Starting: 150778

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Taylor-Dunn Contact information

Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our

vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.

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

01 (714) 956-4040

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

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

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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

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Section Index

Taylor-Dunn

Operator and Service Manual Section Index

Introduction

Safety Rules and Operating Instructions

General Maintenance

Front Axle Service

Steering Component Service

Brakes Service

Throttle Linkage

Transaxle Service

Suspension

Motor Service

Tires and Wheels

Battery Service

Control System Troubleshooting

Chargers

Wire diagram

Illustrated Parts

Appendix A Special Tools

Appendix B Suggested Torque Values

Appendix C Brake Lining Handling Precautions

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

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

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

B 2-48-36 Equipped with optional

hydraulic dump bed

MX 1600 Equipped with optional

ladder rack and weld tanks

B 1-00 Personnel carrier

BT 2-80 Eight passenger tram

C 4-25 Huskey tow tractor

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Table of Contents

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

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

Responsibilities ............................................2

How To Use This Manual ..............................3

Conventions .............................................................. 3

How to Identify Your Vehicle ........................4

Taking Delivery of Your Vehicle ...................5

Shown with fiberglass steel cab options

Introduction

Shown with extended steel cab and stake side options

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INTRODUCTION

ABOUT THIS MANUAL

RESPONSIBILITIES

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

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.

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.

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.

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.

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Model B 2-10 shown withstake sides and steel cab with doors options

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INTRODUCTION

HOW TO USE THIS MANUAL

This manual is organized into five main sections:

INTRODUCTION

This section describes how to use this service manual and how to identify your vehicle.

Safety Rules and Operating Instructions

This section outlines the safety and operational issues, location and operation of controls, and the operational checks that are to be performed on this vehicle. It also includes various subjects that should be included in the operator and service training program.

Maintenance Service and Repair

This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks.

Electrical and Charger Troubleshooting

This section identifies the troubleshooting procedures for testing the electrical system and battery charger.

Illustrated Parts

This section provides an illustrated view of various assemblies. The illustrations are accompanied by tables identifying the parts.

Conventions

Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual. Refer to the examples below.

A shaded box with the word “Warning” and the symbol above denotes a warning. A warning alerts the reader of a hazard that

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

A shaded box with and the word “Warning” and the symbol above denotes a warning. This warning alerts the reader of

a high voltage hazard that may result in injury to themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task.

Model R 3-80 shown equiped with a cargo box and steel cab with doors options

A box with the word “CAUTION” and the symbol above 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.

Model B 2-48 equipped with the Dump Bed option

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INTRODUCTION

HOW TO IDENTIFY YOUR VEHICLE

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

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

This vehicle is not designed to be driven on public roads or highways. It is available in maximum designed speeds ranging from 9 to 18 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow at more than 5 mph.

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section 29 CFR

1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for Personnel and Burden Carriers (ANSI B56.8).

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

NOTE: The frame stamp will be in one of two locations as shown.

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INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

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

• Examine the contents of all packages and

accessories that may have come in separate packages with the vehicle.

• Make sure everything listed on the packing

slip is there.

• Check that all wire connections, battery

cables, and other electrical connections are secure.

• Check battery cells to be sure they are filled.

• Check the tire pressure, tightness of lug nuts,

and for any signs of damage.

Check the operation of each of the following controls:

• Accelerator

• Brake

• Parking Brake

• Key-Switch

• Forward/Reverse Switch

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.

• Reverse Beeper (if equipped)

• Front Headlight Switch

• Steering Wheel

• Horn

Model B 2-10 Ambulance

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Model B 1-00

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TABLE OF CONTENTS

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

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

Driver Training Program ......................... 3

Driver Qualifications. ...........................................3

Vehicle Controls ..................................... 4

Dash (up to S/N 179999) ....................... 4

1) Key-Switch.......................................................4

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

3) Hour Meter ....................................................... 4

4) Battery Status Indicator, Analog.......................4

5) Accessory Switch (Optional) ............................ 4

6) Headlight Switch..............................................4

7) Auxiliary Switch (Optional) .............................4

8) Horn Switch ..................................................... 4

Hi-Low Switch (optional) ..................................... 4

2) WIper Switch (Optional) ..................................5

Dash (Starting S/N 180000) ................... 5

1) Headlight Switch..............................................5

3) Strobe Switch (Optional)..................................5

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

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

6) Smart View gauge ............................................5

7) Horn Switch ..................................................... 5

8) Key-Switch.......................................................5

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

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

Park Brake ............................................................ 6

Steering.................................................................6

Directional Signals (Optional) .............................. 7

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

Charger Interlock .................................................. 7

Seat Interlock Switch............................................7

Smart View Display..............................................8

Vehicle Operational Guidelines .............. 10

Safety Guidelines..................................................10

Starting: ................................................................10

While driving:.......................................................10

Loading and Unloading ........................................10

Towing Loads: ......................................................10

Parking ................................................................. 11

Automatic Electric Park Brake ............................. 11

Towing This Vehicle .............................................11

Charging your vehicle............................. 12

Signet Charger Operation, Model HB Series ........ 12

Signet Charger Operation, Model HBS series ......13

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

Taylor-Dunn X-Series Charger ............................. 15

Charging with the X-Series Charger ..................... 16

AC Power Source .................................................17

New Battery Break in ........................................... 17

Charging Time ...................................................... 17

Storing / Returning to Service ............... 17

Storing Your Vehicle ............................................. 17

Returning to Service ............................................. 17

Periodic Maintenance Checklist ............. 18

Standard Periodic Maintenance Schedule

for the Smart View Display .............. 19

Daily Visual inspection:........................................20

Maintenance Guidelines for

Severe Duty Applications................. 20

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICATIONS*

ITEM SPECIFICATION

Occupancy Driver, one passenger

Dimensions Taylor Truck 318 L x 127 W x 119 H Centimeters

ET 3000 325 L x 127 W x 119 H Centimeters

Turning Radius 368 Centimeters (145 Inches)

Dry Weight Taylor Truck 696 kg (1,534 lbs) With out Batteries ET 3000 856 kg (1,884 lbs)

Min/Max Battery 158 kg to 181 kg (350 lbs to 400 lbs) Weights

Maximum Load 1,360 kg (3,000 lbs) Deck Dimensions 104 W x 191 L Centimeters (41 W x 75.25 L Inches)

Electrical System Eight 244Amp Hour, 6 Volt, Lead Acid Batteries,

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid

Motor, DC, Seperatly Excited Field 5.9 kW, (7.9 Horse Power) for 60 minutes

Brakes 4 Wheel Hydraulic Disc, Hand Operated Park Brake

Steering Automotive Steering 24:1

Tires 20.5 x 8 x 10 Load Range E

125 L x 50 x 47H Inches 128 L x 50 x 47H Inches

Solid State Speed Control, 500 Amp

Differential.

Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Smart View Display (Battery Status Indicator, Hour

Light Accessories Taylor Truck Dual Headlight, Dual Tail/Brake Lights

Charger 120/240 volts AC, 50/60Hz, 13/3.6 Amp AC, 17 Amp DC

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section

1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for Personnel and Burden Carriers (ANSI B56.8).

* - Specifications are subject to change without notice.

Safety Rules

Diamond Plate

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

ET 3000 Sames as above + turn signals

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SAFETY RULES AND OPERATING INSTRUCTIONS

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SAFETY RULES AND GUIDELINES

It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (extracted from the American National Standards Institute Personnel and Burden Carriers ANSI B56.8). As well as, following the safety rules and guidelines outlined in ANSI B56.8 and listed below.

These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on public highways.

These vehicles are not designed to be driven on public roads or highways. They are available in maximum designed speeds ranging from 9 to 18 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

Refer to Vehicle Operational Guidelines, Safety

Guidelines section for important safety information

regarding operating this vehicle.

DRIVER TRAINING PROGRAM

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

The Operator Training program shall include the following:

• Operation of this vehicle under circumstances

normally associated with your particular environment.

• Emphasis on the safety of cargo and personnel.

• All safety rules contained within this manual.

• Proper operation of all vehicle controls.

• A vehicle operation and driving test.

Driver Qualifications.

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

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

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

Before working on a vehicle:

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

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

3. Set the park brake.

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

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

• Demonstrate a working knowledge of each control.

• Understand all safety rules and guidelines as

presented in this manual.

• Know how to properly load and unload cargo.

• Know how to properly park this vehicle.

• Recognize an improperly maintained vehicle.

• Demonstrate ability to handle this vehicle in all

conditions.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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VEHICLE CONTROLS DASH (UP T O S/N 179999)

1) 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 keyswitch is in the “OFF” position.

2) Forward-Off-Reverse Switch

The forward-off-reverse switch, located on the right side of the instrument panel, determines the direction of travel of the vehicle. Push the top of the switch to engage the forward direction. Push the bottom of the switch to engage the reverse direction.

DO NOT SWITCH from forward to reverse or vice-versa while the vehicle is in motion. Make sure the vehicle is completely stopped before shifting.

The forward-off-reverse switch should be in the center “OFF” position, with the key-switch off and the park brake set whenever the operator leaves the vehicle.

3) Hour Meter

The hour meter is located to the right of the battery status indicator. It records the number of hours the vehicle has been in operation.

4) Battery Status Indicator, Analog

See Smart View Display later in this section

5) Accessory Switch (Optional)

6) Headlight Switch

The headlight switch is located on the left sideof the instrument panel. Push the top of the switch to turn the lights on. Push the bottom of the switch to turn the lights off.

7) Auxiliary Switch (Optional)

Other electrical accessories are controlled from the auxiliary switch or switches. The actual function of the switch may vary depending on the electrical option installed.

8) Horn Switch

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

Hi-Low Switch (optional)

The high-low switch will be switch #5 or #7 depending on what other electrical options are installed (see above). Toggle the switch lever up for normal speed. Toggle the switch lever down for slow speed.

The accessory switch is located on the left side of the instrument panel and to the right of the headlight switch. Push the top of the switch to turn on the accessory. Push the bottom of switch to turn off the accessory. The accessory can be turned on with the key switch in the “OFF” position. If a vehicle is equipped with windshield wipers and one or more accessories, the windshield wipers are controlled from this switch. Other accessories are controlled from the auxiliary switch.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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DASH (STARTING S/N 180000)

1) Headlight Switch

The headlight switch is located on the left sideof the instrument panel. Push the top of the switch to turn the lights on. Push the bottom of the switch to turn the lights off.

2) WIper Switch (Optional)

5) Hi-Low Switch (optional)

Other electrical accessories are controlled from the auxiliary switch or switches. The actual function of the switch may vary depending on the electrical option installed.

3) Strobe Switch (Optional)

Other electrical accessories are controlled from the auxiliary switch or switches. The actual function of the switch may vary depending on the electrical option installed.

4) Forward-Off-Reverse Switch

DO NOT SWITCH from forward to reverse or vice-versa while the vehicle is in motion. Make sure the vehicle is completely stopped before shifting.

The forward-off-reverse switch should be in the center “OFF” position, with the key-switch off and the park brake set whenever the operator leaves the vehicle.

6) Smart View gauge

See Smart View Display later in this section

7) Horn Switch

Depress the switch to sound the horn, release it to turn it off.

8) Key-Switch

A key-switch, located on the lower center 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 keyswitch is in the “OFF” position.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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Steering

The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter-clockwise. If equipped with tilt steering, the release lever is located on the lower left of the steering column. Pull the lever up to reposition the steering wheel.

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.

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.

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.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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Directional Signals (Optional)

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

Hazard Light Switch (Optional)

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

Charger Interlock

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

Seat Interlock Switch

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

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

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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Smart View Display

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

Run Time Hours icon

Safety Rules

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

Key Hours icon

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

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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.

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

Display showing Maintenance and

Wrench icons

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 04001 Line contactor welded or shorted wiring Replace contactor, repair wiring 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 or shorted wiring Replace contactor, repair wiring 05009 MOSFET shorted Refer to troubleshooting 05046 Line contactor contacts open or defective

wiring

Repair as required Reset switches and start again.

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

for shorts. Reset switches and start again.

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

good, check wiring to the controller.

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

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

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VEHICLE OPERA TIONAL 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:

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

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

2. Set the parking brake.

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.

Towing Loads:

• Do not exceed the towing capacity of the tractor.

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

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

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

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

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

• Allow for longer stopping distances when towing heavy loads.

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

3. Hold down the foot brake.

4. Rotate the Start switch to the “ON” position and wait 1-second.

5. Release the parking brake.

6. Release the foot brake.

7. Slowly depress the accelerator pedal.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 11

Parking

Before leaving the vehicle:

• Set the parking brake.

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

position.

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

In addition:

• If parking this vehicle on an incline, turn the wheels

to the curb, or block the wheels.

• Do not block fire aisles, emergency equipment,

stairways, or exits.

Automatic Electric Park Brake

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

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

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

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

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

Towing This Vehicle

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

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

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

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

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.

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

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 12

CHARGING YOUR VEHICLE

WARNING

Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge a 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.

WARNING

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.

WARNING

The charger must be connected to a properly grounded AC receptacle. Improper connection will increase the risk of electric shock and can cause severe personal injury or death.

WARNING

The Signet and X-Series chargers are for lead acid batteries only. Charging other types of batteries may cause the battery to burst or explode causing severe personal injury and/or property damage.

WARNING

DO NOT disassemble the charger. There are no user serviceable components in the charger. Refer all repairs to a qualified technician. Incorrect repair or reassembly of the charger can result in an explosion, electric shock, or fire.

CAUTION

The key switch must be in the “OFF” position when charging the batteries. Failure to turn the key switch “OFF” may result in damage to the vehicles electrical system.

WARNING

This charger requires a standard household 15 Amp electrical circuit. Before plugging the charger in, confirm that your charging station is configured correctly.

DO NOT attempt to charge two vehicles on one standard household 15A circuit.

Failure to confirm the proper charging station configuration or attempting to charge two vehicles may result in fire.

Signet Charger Operation, Model HB Series

The Signet® HB series chargers use a semiautomatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Refer to the data plate on the charger for the voltage and type power required for the charger.

There is a series of LED’s on the faceplate of the charger that serve two functions:

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

2. Error condition. All three LED’s flashing is an indication of a charging problem (charger will also be beeping). Refer to the

Charger Troubleshooting

section for information on error codes.

Typical Signet® Built In

WARNING

Do not attempt to operate the vehicle while charging the battery. Operating the charger and vehicle at the same time may lead to damage to the charger and/or the vehicle resulting in personal injury and/or property damage.

Safety Rules

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

Cycle complete ON ON ON

LED1 LED2 LED3

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 13

WARNING

The charger must be connected to a properly grounded AC receptacle. Improper connection will increase the risk of electric shock and can cause severe personal injury or death.

WARNING

The Signet and X-Series chargers are for lead acid batteries only. Charging other types of batteries may cause the battery to burst or explode causing severe personal injury and/or property damage.

WARNING

CAUTION

The key switch must be in the “OFF” position when charging the batteries. Failure to turn the key switch “OFF” may result in damage to the vehicles electrical system.

WARNING

This charger requires a standard household 15 Amp electrical circuit. Before plugging the charger in, confirm that your charging station is configured correctly.

DO NOT attempt to charge two vehicles on one standard household 15A circuit.

Failure to confirm the proper charging station configuration or attempting to charge two vehicles may result in fire.

Signet Charger Operation, Model HBS series

The Signet® HBS series chargers are fully automatic. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Once the charge cycle is complete, the charger will continue to monitor the batteries. If the battery voltage drops during storage, the charger will start a new cycle to keep the batteries fully charged.

NOTE: If the charger restarts during a short time period

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

Refer to the data plate on the charger for the voltage and type power required for the charger.

There is a series of LED’s on the faceplate of the charger that serve two functions:

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

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

Typical Signet® HBS

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 14

WARNING

The charger must be connected to a properly grounded AC receptacle. Improper connection will increase the risk of electric shock and can cause severe personal injury or death.

WARNING

The Signet and X-Series chargers are for lead acid batteries only. Charging other types of batteries may cause the battery to burst or explode causing severe personal injury and/or property damage.

CAUTION

The key switch must be in the “OFF” position when charging the batteries. Failure to turn the key switch “OFF” may result in damage to the vehicles electrical system.

WARNING

This charger requires a standard household 15 Amp electrical circuit. Before plugging the charger in, confirm that your charging station is configured correctly.

DO NOT attempt to charge two vehicles on one standard household 15A circuit.

Failure to confirm the proper charging station configuration or attempting to charge two vehicles may result in fire.

Lestronic II Charger Operation

The Lestronic II® charger is a semi-automatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Refer to the data plate on the charger for the voltage and type power required for the charger. When plugged in, the charger assumes that the batteries require charging and will charger for a minimum of approximately 4-hours. This charger should not be plugged in until the batteries are discharged beyond 50% or the batteries may be overcharged.

WARNING

Safety Rules

Page 27

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 15

WARNING

The charger must be connected to a properly grounded AC receptacle. Improper connection will increase the risk of electric shock and can cause severe personal injury or death.

WARNING

The Signet and X-Series chargers are for lead acid batteries only. Charging other types of batteries may cause the battery to burst or explode causing severe personal injury and/or property damage.

WARNING

CAUTION

The key switch must be in the “OFF” position when charging the batteries. Failure to turn the key switch “OFF” may result in damage to the vehicles electrical system.

Taylor-Dunn X-Series Charger

This charger is rated for 115 VAC or 230 VAC operation (nominal). Confirm the charger installed is correct for the AC voltage power source before connecting the charger.

Sealed batteries must be charged with a charger configured for sealed batteries. Use of any other charger will result in damage to the batteries and premature failure of the batteries.

The X-Series chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.

There is a user interface on the charger. The interface consists the following:

1) Start/stop switch: When depressed, the charging cycle will be terminated or restarted.

2) Charging status light: Indicates the current status of the charging cycle. The light will start flashing when the charging cycle is started. It will stop flashing and remain ON when the cycle has completed. Also used for fault indication along with the fault light.

3) Low voltage start switch: When depressed, will start the charge cycle if the battery voltage is too low for an automatic start.

WARNING

4) Fault light.: Displays faults after self diagnosis is completed.

5) Circuit breaker.

6) Ammeter: Indicates the current flowing into the battery during the charging cycle.

7) Self diagnostic switch: Starts the charger self diagnosis procedure.

Safety Rules

Page 28

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 16

Fault LED

Status LED

Action Required

OFF OFF • No faults found.

• Battery voltage either too high or too low. Confirm that the correct

ON OFF or Dim

• *

Faulty charger

Flashing

ON • *

Faulty charger

• **AC input voltage is out of range.

Confirm that the AC outlet has

ON ON • *Faulty charger.

Flashing

OFF • ***Charger programmed incorrectly.

Refer charger repair to a qualified technician

Only a qualified

electrician should check the AC line voltage.

Continued use of the charger may damage your batteries. Refer charger repair to a

Self Diagnosis Procedure

If you suspect a battery charging problem press the self diagnostic switch to start the charger self diagnostic procedure. Any faults found by the procedure will be displayed by the two LED’s. Refer to the table below for the fault codes.

Note: To run this procedure, a battery that is not severely discharged must be connected to the charger.

Flashing Flashing

ON Flashing

***

qualified technician

battery and charger is installed in the vehicle.

• Faulty battery, will not accept a charge.

• Battery installed is too large (Amp Hours).

the correct voltage for the charger.

• *Charger circuit breaker tripped. Reset the breaker by pushing the button. If the fault reoccurs, then it indicates a faulty charger.

Charging with the X-Series Charger

Note: Opportunity charging is not recommended. For maximum battery

life, it is recommended that the batteries be discharged a minimum of 30% (7 bars showing on the BSI) before starting a charging cycle.

This charger requires a standard household electrical circuit rated at 15 to 20 Amps. Consult an authorized electrician if you do not know the configuration of your circuits. See warning to the right.

Park the vehicle at an authorized charging station. Refer to Parking in the Driving section.

Connect the charging cord to the vehicle charging port and then plug the cord into the AC power receptacle.

The charger should start automatically. If the charger does not start, then depress and hold the “Low Voltage Start”

switch for a 10-seconds. If the charger does not remain ON after releasing the switch, then try again. If the charger refuses to start, then have the batteries and charger tested by an qualified technician.

WARNING

This charger requires a standard household 15 Amp electrical circuit. Before plugging the charger in, confirm that your charging station is configured correctly.

DO NOT attempt to charge two vehicles on one standard household 15A circuit.

Failure to confirm the proper charging station configuration or attempting to charge two vehicles may result in fire.

Safety Rules

Page 29

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 17

AC Power Source

WARNING

The AC power source required by the charger will vary depending on the charger installed in the vehicle. Refer to the specifications printed on the charger for details.

Use of extension cords is not recommended. If you find it necessary to use an extension cord, make sure the extension cord power rating exceeds the power requirements of the charger.

New Battery Break in

New batteries require a break in period of up to 40-cycles. The batteries will not have their full capacity during this break in period and may require longer charging times.

To obtain the maximum battery life:

Charge the batteries only after they reach a normal discharge as indicated on the Battery Status Indicator (BSI). Failure to follow this guideline could result in the batteries entering an overcharge state, which will reduce the life of the batteries. If you find it necessary to charge the batteries before they are completely discharged we recommend waiting until they are discharged a minimum of 25% to reduce the possibility of overcharging. Refer to Vehicle Controls in this section for information on how to read the BSI.

Do not discharge the batteries beyond a normal discharge as indicated on the BSI. Refer to Vehicle Controls in this section for information on how to read the BSI.

Check the battery electrolyte once a week. Do not charge the batteries if the battery electrolyte is low. Charging when the electrolyte is low will damage the batteries and shorten their life-span. Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level. Refer to Section Maintenance,

Service and Repair for battery maintenance

information. Do not interrupt the charging cycle. When the charger is

plugged in, allow it to turn off before disconnecting. Interrupting the charging cycle could lead to overcharging or discharging the batteries too deep. Both circumstances will shorten the life of the batteries.

Use of extension cords is not recommended. Improper use of an extension cord may result in fire.

Charging Time

Average charging time is 8 to 10-hours. The time required to fully charge your batteries will vary depending on:

• Capacity of the batteries, higher capacity requires

longer charge time.

• Output of the charger, higher output requires less

charge time.

• Depth of discharge, the deeper a battery is

discharged, the longer it takes to charge.

• Temperature, low temperatures require longer charge

time.

It is not unusual for charge times to exceed 15-hours, especially with new batteries.

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

STORING / RETURNING TO SERVICE

Both storing your vehicle and returning it to service should only be performed by authorized personnel.

Storing Your Vehicle

• Clean the batteries, then fill and charge before putting

the vehicle in storage. Do not store batteries in a discharged condition.

• Lube all grease fittings.

• Clean, dry, and check all exposed electrical

connections.

• Inflate tires to proper pressure (if applicable).

• For extended storage, the vehicle should be elevated

so that the tires do not touch the ground.

If stored for a prolonged period, the batteries should be charged as follows:

Returning to Service

• Check the

battery’s state of charge and charge if required.

• Perform ALL

maintenance checks in the periodic checklist.

Storage

Temperature

(F)

Over 60 1 Between 40 and 60 2 Below 40 6

Charging Interval

(months)

• Remove any blocks from the vehicle and/or place the

vehicle down on to the ground.

• Test drive before putting into normal service.

Safety Rules

Page 30

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 18

the Vehicle Documentation CD under the [Misc] sub folder.

PERIODIC MAINTENANCE CHECKLIST

Safety Rules

NOTE: A full page copy of the Periodic Maintenance Checklist is on

Page 31

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 19

STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY

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

schedule

PREVENTATIVE MAINTENANCE SCHEDULE

MAINTENANCE

LEVEL

1 500

2 1000

HOUR

INTERVAL

Inspect the brake system including the park brake and mounting harware

Inspect the steering system, tighten the steering shaft coupler on

the steering gear input shaft

Lubricate the vehicle, check for leaks

Inspect safety interlocks

Inspect front and rear wheel bearings

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

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

every 1000 hours.

Inspect and tighten all nuts and bolts

Clean and repack front wheel bearings

Inspect and tighten all wire connections

Inspect the motor brushes and commutator

MAINTENANCE TO BE PERFORMED

2,3

3 2000

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

Inspect the king pin bushings

Check front end alignment

Change oil in the drive and rear axle

Flush hydraulic brake system

Inspect suspension bushings

Replace brake pedal/treadle return spring

Inspect frame for damage

Safety Rules

Page 32

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 20

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 33

Table of Contents

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

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

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

Model C 4-25 Tow Tractor

Examples of Taylor-Dunn Tow Tractors

Model E 4-55 Tow Tractor

General Maintenance

Page 34

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.

Before starting any repairs:

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 or rear wheels to prevent vehicle movement.

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

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 the fault table in the troubleshooting section).

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.

Page 2

Page 35

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

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 Batteries Discharged or Defective 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

Oil Leak in Rear Bearing Area

Drive Over Filled

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Worn (1/16" Wear Limit)

Brake Pedal Low

Braking Power Low

Note: This list is provided as a guide only. It is not all inclusive of causes that may result in a specific

symptom.

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

Page 3

Page 36

Maintenance, Service and Repair

Lubrication Chart

FRONT

# Description Locations Lubricant Type

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

4 King Pin 2 General Purpose Grease

5 - - 6 - -

7 Drive Drain Plug 1 -

8 Drive Level Plug 1 9 Fill Plug 2 SAE 80w90 hypoid Gear Oil

Page 4

Page 37

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

Front Axle Disassembly.....................5

Replace Front Wheel Bearings..........6

Replace the King Pins and Bushings .7

Replace the Steering Knuckle............8

Front Axle Service

Page 38

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. Confirm the electric park brake is set.

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

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

Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury.

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

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

NOTE: Refer to the Adjust Front Wheel Bearings

section for information regarding the adjustment of the wheel bearings.

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

the King Pins and Bushings for

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

8. Spin the wheel and listen for any grinding noise. Any grinding noise may be an indication of worn or damaged wheel bearings.

NOTE: Refer to the Replace Front Wheel

Bearings section for information regarding

the replacement of the wheel bearings.

9. Lower the vehicle.

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

11. Remove the blocks from behind the wheels.

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

Front Axle Page 2

Page 39

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. Confirm the electric park brake is set.

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 front of the vehicle and support with jack stands.

7. Remove the hub dust cap and cotter pin.

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

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

10. Spin the wheel and listen for any grinding noise. Any grinding noise may be an indication of worn or damaged wheel bearings.

NOTE: Refer to the Replace Front Wheel

Bearings section for information regarding

the replacement of the wheel bearings.

11. Install a new cotter pin.

12. Install the dust cap.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Hub with Dust Cap

Removed

Front Axle

Page 3

Page 40

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. Confirm the electric park brake is set.

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 front of the vehicle and support with jack stands.

7. Remove both front wheels. Refer to Tires and

Wheels section for information regarding

removing the front wheels.

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

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

NOTE: Refer to the Replacing the Ball Joints

section for information regarding the removal of the ball joints or rod ends.

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

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

Installation

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. Confirm the electric park brake is set.

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 front of the vehicle and support with jack stands.

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

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

section for information regarding the installing the ball joints or rod ends.

NOTE: Refer to Tires and Wheels section for

information regarding removing the front wheels.

8. Realign the front wheels. Refer to Steering

Component Service section for information

regarding realigning the front wheels.

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

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

NOTE: In some configurations the front springs and

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

Front Suspension for information

regarding removing the springs and shocks.

Front Axle Page 4

Page 41

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.

Front Axle

Page 5

Page 42

Maintenance, Service, and Repair

REPLACE FRONT WHEEL

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

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. Confirm the electric park brake is set.

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

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

NOTE: Refer to Adjust Wheel Bearings for

information regarding proper tightening of the spindle nut

13. Install the hub dust cap.

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

NOTE: Refer to the Brakes for information regarding

the installation of the brake body.

15. Lower the vehicle.

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

17. Remove the blocks from behind the wheels.

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

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

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

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, bearings, and seals.

NOTE: It is recommended to replace all four bearings

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

Front Axle Page 6

Page 43

Maintenance, Service, and Repair

REPLACE THE KING PINS AND BUSHINGS

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

• Bronze bushings in the axle beam.

• Bronze bushings in the steering knuckle.

• Metal backed teflon bushings in the axle beam

or suspension arm.

NOTE: Bronze bushings must be reamed or broached

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

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

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

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

3. Confirm the electric park brake is set.

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

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

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.

7. Remove the steering knuckle. Refer to Replace

the Steering Knuckle for information regarding

removing the steering knuckle.

NOTE: It is not necessary to remove the tie rod or

drag link for this procedure.

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

9. Press new bushings into the axle, steering knuckle or suspension arm.

a) Ream or broach bronze bushings to 1.128 inches.

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

11. Reassemble in reverse order.

NOTE: Refer to Replace the Steering Knuckle for

information on installing the steering knuckle.

NOTE: It is recommended that the thrust washers or

bearing be replaced whenever replacing the king pin bushings. Refer to the

Replacement Parts section for the

orientation of the bearing or washers in your vehicle.

12. Grease the bushings (bronze only).

13. Lower the vehicle.

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

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

15. Remove the blocks from behind the wheels.

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

Front Axle

Page 7

Page 44

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. Confirm the electric park brake is set.

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

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

NOTE: Both the left and right side bushings and thrust

bearings should be replaced as a set.

13. Assemble in reverse order. Refer to the illustratinon below for orientation of the thrust bearing.

14. Pack the thrust bearing with grease.

15. Tighten the king pin nut until all of the up and down play is removed and the yoke rotates freely. The rubber washer must compress slightly to create a seal for the grease.

NOTE: Refer to Adjust Wheel Bearings for

information regarding proper tightening of the spindle nut

16. Install new cotter pins.

17. Realign the wheels.

NOTE: Refer to the Steering section for information

regarding realignment of the front wheels.

18. Lower the vehicle.

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

20. Remove the blocks from behind the wheels.

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

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.

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

Front Axle Page 8

Page 45

TABLE OF CONTENTS

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

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

Inspect Rod Ends ..............................5

Adjust the Steering Gear ...................6

Replace the Steering Shaft................7

Replace the Steering Wheel ..............8

Replace the Steering Gear ................8

Replace the Ball Joints, Tie Rods, and Drag

Link ...............................................9

Replacing the Drag Link ...................................... 10

Replacing the Tie Rod .......................................... 11

Center the Steering Gear...................11

Repair the Steering Gear...................12

Exploded View of Steering Gear ......................... 14

Steering Component Service

Page 46

Maintenance, Service, and Repair

FRONT END ALIGNMENT

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

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

Center the Steering

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

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

3. Confirm the electric park brake is set.

Ball Joint

Rod End

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.

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 front of the vehicle and support with jack stands.

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

8. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section

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

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

NOTE: Refer to Center the Steering Gear section

for information regarding centering of the steering gear.

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

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

NOTE: Remember the position and orientation of the

clamps.

Steering Page 2

Page 47

Maintenance, Service, and Repair

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

13. Tighten the ball joint or rod end nut as specified below: Ball joint - 40-45 ft-lbs. Rod end - 20-25 ft-lbs.

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

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

16. Untie the steering wheel and the front wheels.

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

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

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

19. Remove the blocks from behind the wheels.

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

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

Steering

Page 3

Page 48

Maintenance, Service, and Repair

Front wheel alignment

NOTE: It is recommended to center the steering

before aligning the front wheels. Refer to the

Center the Steering section for

information.

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

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

3. Confirm the electric park brake is set.

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

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

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

HINT: Hold the chalk on the center of the tire and

rotate the tire to mark the line.

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

NOTE: Remember the position and orientation of the

ball joint clamps.

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

Front Measurement

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

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

Steering Page 4

Sleeve Clamps

Tie Rod

Rear Measurement

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

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

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

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

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

16. Untie the steering wheel.

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

18. Remove the blocks from behind the wheels.

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

Page 49

Maintenance, Service, and Repair

INSPECT BALL JOINTS

NOTE: A set of ball joints and/or rod ends will wear

at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set.

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

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

3. Confirm the electric park brake is set.

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

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

INSPECT ROD ENDS

NOTE: A set of ball joints and/or rod ends will wear

at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set.

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

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

3. Confirm the electric park brake is set.

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

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

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

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

the Ball Joints, Tie Rods, and Drag Link

for information regarding replacing ball joints.

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

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

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

9. 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.

10. Untie the front wheels.

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

12. Remove the blocks from behind the wheels.

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

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

9. Remove the blocks from behind the wheels.

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

< Stud

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

Steering

Page 5

Page 50

Maintenance, Service, and Repair

ADJUST THE STEERING GEAR

NOTE: In some vehicle configurations it may be

necessary to remove the steering gear to perform this procedure. Refer to Replace

the Steering Gear for information

regarding removing the steering gear.

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

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

3. Confirm the electric park brake is set.

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 front of the vehicle and support with jack stands.

7. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section for

information regarding removing the ball joint from the drag link.

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

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

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

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

12. Find the center position of the steering shaft: A. Turn the steering shaft all of the way in one

direction.

B. While counting the rotations, turn the steering

shaft all of the way in the opposite direction.

C. Turn the steering shaft 1/2 the number of turns

in the original direction.

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

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

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

16. Remove the blocks from behind the wheels.

Steering Page 6

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

Page 51

REPLACE THE STEERING SHAFT

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

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

3. Confirm the electric park brake is set.

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

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

Maintenance, Service, and Repair

NOTE Most vehicle configurations will now allow the

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

11. Remove the steering shaft from the vehicle.

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

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

7. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel section

for information regarding removing the steering wheel.

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

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

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

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

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

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

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

16. Remove the blocks from behind the wheels.

17. Test drive the vehicle.

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

Steering

Page 7

Page 52

Maintenance, Service, and Repair

REPLACE THE STEERING WHEEL

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

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

3. Confirm the electric park brake is set.

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

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

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

7. Remove the steering wheel nut.

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

9. Position the front wheels in the straight ahead position (see below).

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

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

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. Confirm the electric park brake is set.

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 steering wheel. Refer to Replace the

Steering Wheel section for information regarding

removing the steering wheel.

7. Remove the steering shaft. Refer to Replace the

Steering Shaft section for information regarding

removing the steering shaft.

8. Remove the pitman arm using a pickle fork.

NOTE: On some vehicle configurations it may be

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

12.Reinstall the horn switch (if equipped).

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

14.Remove the blocks from behind the wheels.

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

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.

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

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

11. Center the steering gear. Refer to Center the

Steering Gear section for information regarding

centering the steering gear.

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

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

14. Remove the blocks from behind the wheels.

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

Steering Page 8

Page 53

Maintenance, Service, and Repair

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

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

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

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

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

Replacing a Rod End

Rod End

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. Confirm the electric park brake is set.

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 front of the vehicle and support with jack stands.

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

Rod End

Steering Sleeve

Jam Nut

Rod End Nut

Steering Arm

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

12. Realign the front wheels.

NOTE: Refer to the Steering section for information

regarding realignment of the front wheels.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

8. Remove the rod end nut.

9. Remove the rod end from the steering arm.

HINT: Count the number of turns required to remove

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

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

Steering

Page 9

Page 54

Maintenance, Service, and Repair

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. Confirm the electric park brake is set.

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

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

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.

14. Lower the vehicle.

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

16. Remove the blocks from behind the wheels.

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

Replacing the Drag Link

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

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

Cotter Pin

Ball Joint Nut

Steering Arm

Ball Joint

Clamp

Steering Sleeve

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.

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. Confirm the electric park brake is set.

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 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.

Steering Page 10

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Maintenance, Service, and Repair

9. Install in reverse order.

10. Realign the front wheels.

NOTE: Refer to the Steering section for information

regarding realignment of the front wheels.

11. Lower the vehicle.

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

13. Remove the blocks from behind the wheels.

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

Replacing the Tie Rod

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

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

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

11. Lower the vehicle.

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

13. Remove the blocks from behind the wheels.

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

CENTER THE STEERING GEAR

NOTE: The drag link must be disconnected from the

pitman arm or the pitman arm removed from the steering gear to perform this procedure. Refer to the appropriat section for details.

1. Remove the pitman arm.

2. Rotate the input shaft clockwise until it stops.

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

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

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

3. Confirm the electric park brake is set.

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 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.

Steering

Page 11

Page 56

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.

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.

Steering Page 12

Page 57

Maintenance, Service, and Repair

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.

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 13

Page 58

Maintenance, Service, and Repair

Exploded View of Steering Gear

Steering Page 14

Page 59

TABLE OF CONTENTS

Brake Service

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

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

Disc Brake Rotor .................................................. 2

Inspect the Parking brake ..................3

Adjust the Service Brakes .................3

Two or Four Wheel Hydraulic Disc Brakes......... 3

Adjust the Parking Brake ...................4

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

Check Master Cylinder Fluid .............5

Bleed the Brake System ....................6

Flush the Brake System ....................7

Replace the Parking Brake Lining......7

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

Replace Front Disc Brake Pads.........8

Replace Rear Brake Pads or Shoes ..9

Replace the Wheel Cylinder ..............10

Disc Brake Body Assembly (front or rear)........... 10

Repair the Brake Body ......................11

Replace the Master Cylinder .............13

Repair the Master Cylinder ................14

Brake fluid specifications:

Vehicles up to serial number 151284, were shipped with DOT 5 brake fluid.

Starting with serial number 151285, vehicles were shipped with DOT 3 brake fluid.

The brake system is compatible with DOT 3 or DOT 5 brake fluid, see Warning.

• Only use the specified brake fluid as

indicated to the left.

• DOT 3 brake fluid is corrosive and will

damage paint finishes.

• Do not mix brake fluids. If changing

brake fluid type, the entire system must be flushed.

• Dispose of brake fluid in accordance

with local state and federal regulations.

• Read and follow all warnings on the

brake fluid container.

Page 60

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.

Disc Brake Rotor

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

front hub. If the brake 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.

NOTE: Depending on the rear axle configuration, the

rear brake rotor may 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

NOTE: The wheel must be removed to accurately

measure the rotor 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.

Brakes Page 2

Page 61

Maintenance, Service, and Repair

INSPECT THE PARKING 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. Confirm the electric park brake is set.

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

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

6. Release the park brake.

7. Inspect the brake pads. Refer to Inspect the

Service Brake section to inspect the brake pads.

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.

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.

Brakes

Page 3

Page 62

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. Confirm the electric park brake is set.

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

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

6. Release the park brake.

7. Loosen the jam nuts on the park brake linkage that is connected to the brake arm on the caliper assembly.

8. Tighten the brake linkage until it is difficult to rotate the brake arm clevis pin and then loosen the linkage 1-turn.

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

10.Repeat this procedure for both rear wheels.

11. Set the park brake.

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

13.Remove blocks from behind the wheels.

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

Brakes Page 4

Page 63

Maintenance, Service, and Repair

CHECK MASTER CYLINDER FLUID

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. Confirm the electric park brake is set.

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.

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.

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 the specified brake fluid as indicated on page 1 of this

section 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 5

Page 64

Maintenance, Service, and Repair

BLEED THE BRAKE SYSTEM

NOTE: Start this procedure at the wheel furthest from

the master cylinder, then work toward the wheel closest to the master cylinder.

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

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

3. Confirm the electric park brake is set.

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.

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.

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.

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.

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.

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.

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.

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

• Only use the specified brake fluid as indicated on page 1 of this

section 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 6

Page 65

FLUSH THE BRAKE SYSTEM

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. Confirm the electric park brake is set.

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.

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.

REPLACE THE PARKING BRAKE LINING

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.

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.

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.

Brakes

Page 7

Page 66

Maintenance, Service, and Repair

REPLACE FRONT DISC BRAKE PADS

NOTE: It is recommended that both the left and right

brake pads be replaced as a set.

NOTE: Installing new brake pads will raise the brake

fluid level in the master cylinder.

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

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

3. Confirm the electric park brake is set.

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

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

NOTE: Refer to the illustration 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.

9. Remove the tire/wheel assembly. Refer to Tires

and Wheels section for information on removing

the tire and wheel assembly.

Brakes Page 8

20. Remove the blocks from behind the wheels.

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

Page 67

Maintenance, Service, and Repair

REPLACE REAR BRAKE PADS OR SHOES

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. Confirm the electric park brake is set.

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

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

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.

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.

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.

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.

13. Inspect the brake rotor. Refer to Inspect the

Service Brake section for information regarding

inspecting the brake rotor.

Brakes

Page 9

Page 68

Maintenance, Service, and Repair

REPLACE THE WHEEL CYLINDER

Disc Brake Body Assembly (front or rear)

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. Confirm the electric park brake is set.

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

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

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.

6. Release the park brake.

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

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.

INGESTION

Get medical attention immediately.

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 10

Page 69

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

Maintenance, Service, and Repair

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.

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.

7. Pull the pistons out of the brake body.

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.

11. Lubricate the brake parts with clean DOT 5 brake fluid from a sealed container.

On systems to be filled with DOT 3 brake fluid, DOT 5 fluid is used for lubriacation only . See Brake Fluid Specification on page 1 of this section.

Brakes

Page 11

Page 70

Maintenance, Service, and Repair

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

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

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

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

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

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

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

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

Brakes Page 12

Page 71

1/8"

REPLACE THE MASTER

Maintenance, Service, and Repair

CYLINDER

NOTE: Most vehicle configurations do not require

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

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. Confirm the electric park brake is set.

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

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

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.

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.

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

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

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

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

17. Remove the blocks from behind the wheels.

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

Plunger

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

10. Install in reverse order.

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

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

• Only use the specified brake fluid as indicated on page 1 of this section 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.

Push Rod

Master Cylinder

Cutaway of typical master

cylinder showing the push rod

Brakes

Page 13

Page 72

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 14

Page 73

TABLE OF CONTENTS

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

Magnetic Module.................................................. 2

Pot Box module .................................................... 3

Throttle Linkage

Page 74

Maintenance, Service, and Repair

Page 2

THROTTLE LINKAGE ADJUSTMENTS

Magnetic Module

The standard magnitic throttle module should not be used in areas that contain large magnetic fields. Large magnitic fields may effect the operation of the module resulting in unexpected movement of the vehicle.

The throttle pedal is attached directly to the throttle module. There are no adjustments to the throttle linkage. There are no serviceable components in the throttle module.

The standard throttle position sensor consists of two micro switches and a magnetic sensor that detects the position of the throttle pedal.

Switch FS-3 is a normally open switch that is held closed by the throttle pedal return spring. The vehicle will be disabled if the throttle return spring breaks.

Switch FS-1 closes just as the throttle pedal is depressed. Depending on the control system in the vehicle, the throttle

position output is obtained from pin #1 (0-5v) or pin #2 (611v).

The start signal output is either a positive or a negative signal from pin #5. The polarity of the signal depends on the type of control system in the vehicle and will be the same as the voltage into pin #4.

0-5 Volt output

6-11 Volt output

B+ Input

B- Input

FS-1

FS-3

1 2 8 9

4 5

Front Axle

Throttle Module Internal Wiring

Note: Pin 1 output exists on module manufactured after 2/16/2001.

Pin 1 output not used on the Curtis control systems.

Throttle Module

Page 75

Maintenance, Service, and Repair

Page 3

Pot Box module

The pot box module is used on vehicles that are to be operated in areas with large magnetic fields.

The linkage to the pot box should be adjusted so that the FS-1 switch closes just as the pedal is depressed and the output is at 5K with the pedal fully depressed.

1 2

8 9

FS-1

Pot Box Module

Front Axle

Page 76

TAYLOR -DUNN

Page 77

TABLE OF CONTENTS

Transmission

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

Change Oil ................................................2

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

Rear Hub or Rotor .....................................3

Removing and Installing the Rear Axles ....4

Disassembly and Reassembly of the

Primary Reduction Gear Case ...............6

Disassembling the 3rd Member .................8

Assembling the 3rd Member......................9

Pinion Bearing Preload......................................... 11

Pinion Gear Shimming Instructions ...........11

Setting the Pinion Gear Depth ............................. 11

GT Transmission Assembly With Disc Brakes

Page 78

Maintenance, Service, and Repair

Page 2

CHECK OIL LEVEL

The oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member.

Park the vehicle on a level surface.

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. Place an oil drain pan underneath the 3rd member.

7. Remove the fill/level plug.

8. The oil level should be very close to the bottom of the level plug opening.

a. If the oil level is below the bottom of the opening,

add oil as required until level with the bottom of the opening. Refer to the Lube Chart section for information regarding type of oil.

b. If oil comes out of the opening, allow to drain

until level with the bottom of the opening.

9. Replace the fill/level plug.

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

11. Remove the blocks from the wheels.

CHANGE OIL

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 of the vehicle and support with jack stands.

7. Place a four quart drain pan under the drive assembly.

8. Remove the drain plugs from the differential case and gear case.

9. Once the oil has drained, replace the drain plugs and lower the vehicle to the ground.

10. Remove the fill/level plug and fill the differential up to the bottom of the level plug opening. Refer to the Lube Chart section for information regarding type of oil.

11. Replace the fill plug.

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

13. Remove the blocks from the wheels.

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

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

Transmission

Page 79

Maintenance, Service, and Repair

Page 3

MOTOR REMOVAL AND INSTALLATION

NOTE: Some applications will require removing the

drive assembly from the vehicle to remove the motor. Refer to Removing and

Installing the Drive Assembly for

information on removing the drive assembly.

Some vehicles are equipped with an automatic electric brake. The automatic electric brake is sandwiched between the drive motor and the gear case. The electric brake is retained by the drive motor mounting screws. Once the motor is removed the electric brake will no longer be retained by any hardware.

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 wires from the motor.

REAR HUB OR ROTOR

NOTE: The torque specification for the axle hub bolt

is 275 ft-lbs. An impact wrench will be required to remove the bolt.

NOTE: The axle hub bolt has a special thread locking

compound applied to the threads. If this bolt is removed, it must be replaced.

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: Label the motor wires with the number of the

motor terminal before they are removed from the motor.

7. If equipped, remove the motor support bracket u-bolt (only used on larger motors).

8. Remove the motor mounting bolts and slide the motor off of the input shaft.

9. Install the motor in reverse order.

NOTE: Apply a light coating of grease part number

94-421-34 to the splines on the transmission input shaft only.

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

11. Remove the blocks from behind the wheels.

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

Support bracket u-bolt

6. Raise the wheel off of the ground.

7. Remove the tire/wheel assembly, Refer to Tires

and Wheels section for information regarding

removing the tire/wheel assembly.

8. Remove the axle hub bolt and washer and remove the hub from the axle.

9. Remove the outer brake pad. Refer to section

Brake Service for information regarding

removing the brake pads.

10. Remove the rotor.

Transmission

Page 80

Maintenance, Service, and Repair

Page 4

REMOVING AND INSTALLING

The axle retaining plate bolts have a preapplied thread locking compound. They are intended for one time use only. If removed they must be replaced. Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and/or property damage.

Refer to section Rear Brakes in

Illustrated Parts for the part number of

the bolt.

11. Install in reverse order. a. Lightly grease the axle splines.

b. Refer to section Brake Service for information

regarding installing the brake pads. c. Thoroughly clean the threads in the axle shaft. d. Using a new bolt, torque the axle hub bolt to

275 ft-lbs. e. Refer to Tires and Wheels section for

information regarding installing the tire/wheel

assembly.

12.Lower the wheel to the ground.

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

THE REAR AXLES

The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange. If both axles are to be removed, you must drain all of the oil from the housing.

NOTE: This procedure does not require that the rear

end or drive assembly be removed from the vehicle.

NOTE: The axle hub bolt has a special thread locking

compound applied to the threads. If this bolt is removed, it must be replaced.

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.

11. Remove the blocks from behind the wheels, release the park brake and test drive the vehicle.

6. If required, drain the oil from the 3rd member.

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

8. Release the park brake.

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

a. If the axle shaft, hub or bearing is to be replaced

then remove the hub bolt, wheel hub and disc rotor at this time.

10. Remove the four bolts attached to the axle retaining plate.

11. Remove the axle retaining plate and brake body assembly as one unit.

Transmission

Page 81

Maintenance, Service, and Repair

Page 5

12. Secure the brake body assembly, do not let it hang by the brake hose.

13. Pull the axle out of the housing.

14. Inspect all bearings for roughness or play, replace as needed.

15. Install in reverse order, lubricate the o-ring.

NOTE: Be sure not to damage the o-ring.

16. Use new bolts for the axle retaining plate.

17. If the wheel hub was removed, install the hub and rotor. Torque the hub bolt to 275 ft-lbs.

17. Fill with oil to the level of the fill plug threads. Refer to Changing the Differential Oil.

18. Lower the vehicle.

19. Set the park brake.

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

21. Remove the blocks from behind the wheels.

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

Transmission

Page 82

Maintenance, Service, and Repair

Page 6

DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE

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.

Be careful not to damage the sealing surfaces on the housings. Damage to the sealing surface may lead to an oil leak resulting in damage to the internal parts of the drive.

11. Remove the cover plate from the differential and let the remaining oil drain from the housing.

12. Remove the circlip from the idler gear.

13. Remove the input shaft/bearing assembly and idler gear/bearing assembly from the gear case cover at the same time.

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

7. Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case.

8. If required, remove the drive assembly from the vehicle

NOTE: Refer to Removing and

Installing the Drive Assembly for

information on removing the drive from the vehicle.

9. Remove the motor only if the entire drive is to be disassembled.

NOTE: Refer to Motor Removal and Installation

for information on removing the motor.

10.Remove the cover retaining bolts.

Oil Drain Plug

14. Remove the pinion nut from the output gear and remove the output gear from the pinion shaft.

NOTE: If necessary, remove the seal from the input

shaft bore at this time.

15. Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position.

16. Remove the six retaining bolts holding the gear case to the 3rd member housing.

NOTE: Make note of the angle of the gear case.

17. Remove the gear case housing from the 3rd member housing.

18. Inspect all parts for signs of wear or damage.

Transmission

Page 83

Maintenance, Service, and Repair

Page 7

Lubricate all parts with gear oil before installation. Failure to pre-lube the parts may result in premature failure.

19. Assemble the gear case in reverse order.

NOTE: Torque the drain plug to 21-25 foot-pounds. NOTE: Torque the gear case to 3rd member retaining

bolts to 18-20 foot-pounds. NOTE: Torque the pinion nut to 154-169 foot-pounds. NOTE: Apply gasket sealer (#94-430-05) to the front

flange on the 3rd member and gear case

cover. NOTE: Pack the motor seal with non-acetic based

grease.

20. Fill the differential with oil.

NOTE: Refer to Changing the Differential Oil

for information on filling the drive with oil.

21. Lower the vehicle.

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

23. Remove the blocks from behind the wheels.

24. Test drive the vehicle.

Transmission

Page 84

Maintenance, Service, and Repair

Page 8

DISASSEMBLING THE 3RD MEMBER

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

12. Remove the 12 side plate bolts, then remove the side plate.

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 of the vehicle and support with jack stands.

7. Remove the complete drive from the vehicle.

NOTE: Refer to Removing and Installing the

Drive Assembly for information on

removing the drive from the vehicle.

8. Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member.

13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate.

14. Turn the side plate over and remove the carrier bearing race from the side plate.

15. Remove the differential assembly from the 3rd member housing.

9. Place the 3rd member on an appropriate stand.

10.Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tube.

11. Remove the primary reduction gear case. Refer to Disassembly and reassembly of the

Primary Reduction Gear Case for information

on removing the gear case.

Transmission

16. Remove the carrier bearing adjusting nut roll pin from the 3rd member housing, then remove the carrier adjusting nut.

Roll Pin

Page 85

Page 9

17. Remove the carrier bearing race from the 3rd member housing.

Maintenance, Service, and Repair

ASSEMBLING THE 3RD MEMBER

1. Temporarily install the pinion gear (hand tighten only).

18. Remove the front bearing from the input shaft.

NOTE: The input shaft may

have to be driven out to perform this procedure.

19. Remove the input shaft’s shims and spacer.

20. Remove the pinion shaft from the 3rd member.

2. Install the carrier bearing race ring nuts into the housing and cover.

Cover

Housing

3. Install the carrier bearing races into the housing and cover.

21. Remove the front and rear pinion bearing races.

22. Inspect all parts for signs of wear or damage.

23. Thoroughly clean all parts.

Cover

4. Place the differential assembly into the housing.

5. Tighten the housing carrier bearing race ring nut so that the ring gear is not in binding against the pinion gear.

6. Remove the differential assembly.

NOTE: Do not allow the ring nut to rotate.

7. Remove the pinion gear and then reinstall the differential assembly.

8. Install the cover onto the housing using 4-bolts in a cross pattern and torque to 45-50 ft-lbs.

Housing

Transmission

Page 86

Maintenance, Service, and Repair

Page 10

9. Pre set the carrier bearing preload by tightening the housing carrier bearing race ring nut until it requires 1.5 to 3.3 ft-lbs to rotate the differential assembly.

NOTE: Rotate the carrier

assembly whenever adjusting the ring nuts.

10.Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate.

11. Install the pinion gear. Re-shim if required.

16. Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nuts. The two ring nuts must be turned equally in opposite directions.

NOTE: To move the ring gear closer to the pinion:

Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing race ring nut equally.

NOTE: To move the ring gear away from the

pinion: Loosen the cover carrier bearing race ring nut and tighten the housing carrier race ring nut equally.

The two ring nuts must be turned the same amount in opposite directions. This allows the carrier assembly to be positioned with the proper gear lash without upsetting the bearing preload. If the ring nuts are not turned the same amount, then the bearing preload will no longer be correct and will result in drive noise and premature failure.

17. Install the locking roll pins into the housing and cover to lock the ring nuts in place.

If the ring and pinion gears or bearings are replaced then the pinion gear must be reshimmed. Improper pinion gear shims will result in drive noise and premature failure. Refer to Pinion Gear Shimming Instructions.

12.Install the pinion gear holding tool (96-500-

42) and tighten the pinion nut enough to keep the pinion gear from rotating.

13.Install the differential assembly.

14.Install the cover and all of the cover bolts. Torque to 45-50 ft-lbs.

15.Check the gear lash between the ring and pinion gears. The gear lash should be .005 to .007 inches.

18. Remove the pinion gear holding tool.

19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the vehicle.

20. Fill the drive with oil. Refer to the Lube Chart section for information regarding type of oil. Refer to Change Oil section for information regarding the proper oil level..

21. Lower the vehicle.

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

23. Remove the blocks from behind the wheels.

24. Test drive the vehicle.

Transmission

Page 87

Maintenance, Service, and Repair

Page 11

Pinion Bearing Preload

NOTE: The pinion gear depth must be set before the

preload. Refer to Setting the Pinion Gear

Depth.

1. Install the pinion gear, spacer, and shims into the housing.

2. Install the outer pinion bearing.

3. Install the main gear onto the pinion shaft and torque the pinion nut to 154-169 ft lbs.

4. Measure the torque required to rotate the pinion shaft in the housing.

5. The torque required to rotate the pinion shaft should be between 1.1 and 2.9 ft-lbs. If the torque is not within specifications then add or subtract from the total shim thickness and repeat this procedure until the proper preload is obtained.

NOTE: Add shims to decrease torque.

PINION GEAR SHIMMING INSTRUCTIONS

NOTE: This procedure is required only when replacing

the front or rear pinion bearings and races or the ring and pinion gears.

NOTE: To perform this procedure, all parts must be

clean and the bearings lightly lubricated.

Refer to the illustrations on the following pages.

Setting the Pinion Gear Depth

This formula is used to calculate the amount of shims that are required:

C - B - A + (DV) = Pinion Shim (mm) where,

DV = The number on the face of the pinion gear

(Figure 1). A = The distance in millimeters from the face of

the pinion gear to the top of the inner pinion bearing race (Figuer 2).

B = 54. C = The number on the edge of the differential

side plate closest to the input shaft (Figure 3). D = The number on the edge of the differential

side plate farthest from the input shaft (Figure

3). E = The distance in millimeters from the rear of

the drive housing to the face of the pinion gear (Figure 4).

Once a shim has been selected and the pinion gear is installed, confirm that: E - D = B + (DV)

Transmission

Page 88

Maintenance, Service, and Repair

Page 12

Figreu 1b

Figreu 1a

Figure 2

Figure 4

NOTE: Values shown are for reference only

Transmission

Figure 3

Page 89

TABLE OF CONTENTS

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

Leaf ....................................................................... 2

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

Leaf ....................................................................... 3

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

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

Front ...................................................................... 5

Suspension

Page 90

Maintenance, Service, and Repair

REPLACE THE REAR SPRINGS

8. Unbolt the spring from the axle housing.

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

Leaf

If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set.

HINT : In most vehicles it will be easier if the springs

are replaced one at a time.

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.

10. Remove the remaining hardware retaining the spring to the frame.

11. Remove the spring from the vehicle.

Damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage.

12. Inspect the spring bolts and spring hangers for signs of wear or damage. If any wear or damage is found, then they must be replaced.

13. Install the new spring in reverse order.

14. If the spring hanger bolts do not have a grease fitting, lube the spring bushings before installing the spring.

15. Tighten the spring hanger bolts securely, but not so tight as to bind the spring.

16. Lower the vehicle.

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

18. Remove the blocks from behind the wheels.

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

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

7. Tie up or support the rear axle so it cannot fall out of the vehicle.

Suspension Page 2

Page 91

Maintenance, Service, and Repair

REPLACE THE FRONT SPRINGS

Leaf

If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set.

HINT : In most vehicles it will be easier if the springs

are replaced one at a time.

Damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage.

14. If the spring hanger bolts do not have a grease fitting, lube the spring bushings before installing the spring.

15. Torque the spring hanger bolts to 20 ft-lbs.

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 front of the vehicle and support with jack stands.

16. If the spring bolts are equipped with grease fittings, lube them at this time.

17. Lower the vehicle.

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

19. Remove the blocks from behind the wheels.

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

7. Tie up or support the front axle so it cannot fall out of the vehicle.

8. Unbolt the spring from the front axle beam.

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

10. Remove the lower bolt from the spring hanger.

11. Remove the spring bolt from the other end of the spring and remove the spring from the vehicle.

12. Inspect the spring bolts and spring hangers for signs of wear or damage. If any wear or damage is found, then they must be replaced.

13. Install the new spring in reverse order.

Suspension

Page 3

Page 92

Maintenance, Service, and Repair

REPLACE THE SPRING BUSHINGS

7. Remove the spring from the vehicle.

NOTE: Refer to Replace the Front Springs

section for information regarding removing the front springs.

It is recommended that all front spring bushings are replaced as a set.

Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right):

• The internal bushing is a plastic insert that is pressed

into the spring eye. There are one of these bushings for each spring eye.

• The external bushing consists of two plastic bushings

on each end of the spring eye.

• Refer to the parts list to identify the bushings used in

your vehicle.

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

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

3. Set the park brake.

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

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

8. If the vehicle is equipped with spring hangers, remove the spring hanger bolt from the vehicles frame.

9. Remove the spring bushing(s):

• For internal bushing, press the spring bushings

out of the two spring eyes and from the mounting eye on the vehicles frame.

• For external bushing, Remove the bushings

from the spring eye.

10. Install the new bushings in reverse order.

HINT: Apply a light coating of grease to the bushing

before pressing into the spring eye.

11. Install the spring onto the vehicle.

NOTE: Refer to Replace the Front Springs

section for information regarding installing the front springs.

12. Repeat for the other spring.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

6. Raise the front or rear of the vehicle depending on which spring is to be removed and support with jack stands.

Suspension Page 4

Page 93

REPLACE THE SHOCKS

Front

Maintenance, Service, and Repair

7. Remove the upper and lower shock bolts.

8. Remove the shock from the vehicle.

NOTE: If the shock that was removed is to be

reinstalled:

A. Inspect the shaft where it enters the

shock body for any signs of leakage. If any sign of leakage is seen, then the shock must be replaced.

B. Inspect the upper and lower shock

bushings. If any signs of damage or wear are seen, then the shock must be replaced.

9. Install the shock in reverse order.

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

It is recommended to replace both front shocks as a set.

NOTE: On some vehicles it may be required to

remove the front wheel to gain access to the shock mounting bolts. Refer to Tires and Wheels section for information regarding removing the front wheels.

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. Some vehicles may require that the wheels be lifted off of the ground and supported with jack stands to replace the shocks.

Suspension

Page 5

Page 94

TAYLOR -DUNN

Page 95

TABLE OF CONTENTS

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

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

Enclosed Motors (GE, no cooling fan) ................. 2

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

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

Replacing the Brushes.......................5

Replacing the Bearings .....................6

Repairing the Commutator ................6

Service Limits ...................................7

Typical Exploded Motor

Motor Service

Page 96

Motor Service

INSPECTING THE MOTOR BRUSHES

Typical brush and brush holder

Typical motor with cooling fan indicated by

the arrow

Motors with internal cooling fans

NOTE: There are four brushes in the motor. The

brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time.

NOTE: In some vehicle configurations it may not be

possible to inspect all four brushes while the motor is in the vehicle. Refer to

Transmission Service section for

information on removing the motor.

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. Look through the brush cover and compare the top of the brush to the top of the brush holder. If it is even with or below the top of the brush holder then the brushes should be removed and measured. Refer to Replacing the Brushes section for information regarding removing the motor brushes.

7. If any one brush is less than or equal to the service limit specified in Service Limits, then all four brushes should be replaced.

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

9. Remove the blocks from behind the wheels, release the park brake and test drive.

Enclosed Motors (GE, no cooling fan)

General Electric Motors

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: Some motors may not have the brush

inspection holes. In this case, the motor must be disassembled to inspect the brushes. For future inspections, holes msy be drilled into the motor housing after it has been disassembled.

6. Insert a 0.035” diameter wire through the brush inspection hole above each brush until it contacts the top of the brush.

7. Mark the wire to indicate how far it was inserted into the motor housing.

8. Remove the wire and measure how far into the motor the wire was inserted.

9. If any one wire insertion length exceeds the length specified in Service Limits, then all four brushes should be replaced. Refer to Replacing the

Brushes section for information regarding

replacing the motor brushes.

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

11. Remove the blocks from behind the wheels, release the park brake and test drive.

Motor

Page 97

Motor Service

Advanced DC Motors

The enclosed Advanced DC motors must be disassembled to inspect the motor brushes. Refer to

Motor Inspection for information regarding

disassembling the motor.

MOTOR REMOVAL AND INSTALLATION

See the Transmission section for information on removing or installing the motor.

MOTOR INSPECTION

Disassembly

1. Remove the motor from the vehicle. See the

Transmission section for information on

removing the motor.

2. Remove the housing screws from the rear and/or front of the motor.

3. Remove the armature retaining screws from the rear housing (if equipped).

Inspection

1. Measure the length of each motor brush.

• If any one brush is less than or equal to the

service limit specified in section Service

Limits, then all four brushes should be

replaced. Refer to Replacing the Brushes section for information regarding replacing the motor brushes.

2. Measure the diameter of the commutator.

• If the commutator is less than the minimum

diameter specified in section Service Limits, then the motor must be replaced.

3. Measure the commutator undercut depth in 5places around the commutator.

• If any one of the measurements is less than the

minimum undercut depth specified in Service

Limits above, then the commutator must be

undercut. Refer to Repair Commutator section for information regarding undercutting the commutator.

4. If this is an enclosed motor, remove the front housing end.

5. Pull the armature out of the front end of the motor housing.

6. Remove the nuts off of all of the terminals in the rear motor housing.

7. Remove the rear motor housing being careful not to damage the field coil wires.

Hacksaw blade

Incorrect

Correct

Insulation

Commutator

4. Inspect the commutator for grooves.

• If the commutator is groved then it must be machined on a lathe. Do not machine the commutator past the minimum diameter specified in Service Limits section. Refer to

Repair Commutator section for information

regarding machining the commutator.

Undercut

Armature

Min. OD

Motor

Page 98

Motor Service

5. Inspect the commutator for burn marks.

• Burn marks and/or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature. A tool called a growler is required to reliably test for a shorted armature.

Typical burn mark on a shorted armature

6. Inspect the commutator for raised segments. Raised segments could be a result of a stalled motor or shorted armature. A tool called a growler is required to reliably test for a shorted armature.

• If the armature is not shorted then the raised

segments can be removed by machining the commutator. Do not machine the commutator past the minimum diameter specified in

Service Limits section. Refer to Repair Commutator section for information regarding

machining the commutator.

7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted armature.

• If the insulation is cracked or burnt, then it is

recommend that the armature or motor be replaced.

NOTE: If the armature has been burnt then there is a

good possibility that the field windings may also be burnt. Symptoms indicating a shorted field include high motor current, lack of power and possibly excessive speed.

8. Using a growler, test the armature for shorts.

• If the armature is shorted, then we recommend

that the armature or motor be replaced.

9. Using the continuity function of digital multi meter, check the continuity around the entire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time. There should be continuity around the entire commutator. If any segment indicates an open circuit, then the motor must be replaced.

commutator segments and the armature frame. If it is not an open circuit, then the armature is shorted and the motor must be replaced.

11. Rotate the motor bearing(s) by hand.

• The bearing should not ‘freewheel’ but should come to a smooth stop when rapidly spun by hand. If the bearing freewheels, then grease is no longer present in the bearing and it must be replaced. Refer to Replacing the Bearings section for information regarding replacing the armature bearings.

• Feel for any roughness when the bearing is rotated. If any roughness or grinding is noticed then the bearing must be replaced. Refer to

Replacing the Bearings section for

information regarding replacing the armature bearings.

Assembly

NOTE: If this is an enclosed motor on a vehicle with

a Power Traction primary reduction, then it is recommended to replace the armature shaft seal any time the motor is disassembled.

1. Push the motor brushes just far enough out of the brush holder so that the brush springs hold them in place away from the commutator. See the illustration to the right.

2. Install the rear motor housing to the stator housing.

3. Lightly grease the outside diameter of the armature bearings.

4. Insert the armature through the stator housing and seat the bearing into the rear housing.

5. If equipped with armature retaining screws, install and tighten them at this time.

6. If this is an enclosed motor, lightly grease the armature shaft seal and install the front motor housing.

NOTE: If the vehicle is equipped with a belt type

primary reduction then the spring on the motor seal should be removed. Failure to remove the spring may result in a high pitched squeal from the seal.

7. Push the motor brushes into the brush holder until the brush spring snaps into place. Be certain that the spring does not rest up against the brush wire. See the illustrations below.

10.Using the continuity function of digital multi meter, check the continuity from any one of the

Motor

Page 99

Brush Spring Orientation

REPLACING THE BRUSHES

NOTE: It is recommended that all four brushes be

replaced as a set.

NOTE: Motors without removable brush covers must

be disassembled to replace the brushes. Refer to Motor Inspection-Disassembly section for information on taking the motor apart.

NOTE: Some motors are equipped with brush pairs.

These motors must be disassembled to replace the brushes. Refer to Motor

Inspection-Disassembly section for

information on taking the motor apart. Refer to the Motor Parts List for your vehicles brush configuration.

NOTE: Some motors have brush leads that are routed

through or behind the brush holder assembly. In this case, the brush holder assembly must be removed to replace the brushes.

NOTE: The motor must be removed from the vehicle

for this procedure. Refer to Transmission

Service section for information on removing

the motor.

Motor Service

3. Install the new brushes in reverse order.

4. Be certain that the brush springs do not rest up against the brush wires. Refer to illustrations in

Motor Inspection-Assembly for proper brush

spring position.

Motors with brush pairs or not equipped with brush covers

1. Disassemble the motor. Refer to Motor Inspection-Disassembly section for information

on taking the motor apart.

2. Remove the brush holder.

Note: Remember the position and routing of the brush

crossover leads. They must be reinstalled in the same position.

3. Remove the brush termination screws or the armature studs and remove the brushes from the brush holder.

4. Install the new brushes in reverse order.

5. Reassemble the motor. Refer to Motor

Inspection-Assembly for information regarding

reassembling the motor.

Motors with brush covers and brushes with termination screws

1. Remove the brush covers.

2. Loosen the brush wire retaining screw and remove the brush from the brush holder. Be careful with the brush spring and do not let it slip off of the spring mount. If the spring comes off, then the motor must be disassembled. Refer to Motor

Inspection-Disassembly section for

information on taking the motor apart.

Motor

Page 100

Motor Service

REPLACING THE BEARINGS

1. The motor must be removed from the vehicle for this procedure. Refer to Transmission Service section for information on removing the motor.

2. Remove the armature. Refer to Motor Inspection- Disassembly section for information on taking the motor apart.

3. Press the armature bearing(s) off of the armature shaft.

Do not press against the outer race of the bearing. Pressing against the outer race will damage the bearing and may result in premature failure of the bearing. See the illustration below

6. Measure the commutator undercut depth in 5places around the commutator. If any one of the measurements is less than the minimum undercut depth specified in Service Limits, then the commutator must be undercut.

Example of freshly cut commutator

7. While still in the lathe, smooth the commutator with fine emery cloth.

4. Press new bearing(s) onto the shaft.

5. Reassemble the motor.

REPAIRING THE COMMUTATOR

1. The motor must be removed from the vehicle for

this procedure. Refer to Transmission Service section for information on removing the motor.

2. The armature must be removed from the motor

for this procedure. Refer to Motor Inspection-

Disassembly section for information on taking

the motor apart.

3. Using a lathe, cut the armature just enough to remove all grooves, depressions or ridges.

Undercutting the commutator

1. Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer to undercut depth in Service Limits.

2. Once all segments have been properly undercut, mount the armature in a lathe and smooth the commutator with fine emery cloth.

3. Inspect the armature for shorts. Refer to Motor Inspection section for information on testing the armature.

NOTE: Copper debris in the undercut area can give

a reading of a shorted armature.

Properly undercut and cleaned

commutator segments

4. Measure the diameter of the commutator. If the commutator is less than the minimum diameter specified in Service Limits, then the motor must be replaced.

5. Thoroughly clean all copper debris from between the commutator segments.

Motor