Taylor-Dunn B0-015-00, B 1-50, MX-016-00, MX 1600, MAINTENANCE EXPEDITER Operation, T Roubleshooting And Replacement Parts Manual

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Page 1

B0-015-00

The Best Way

To Go

About Your

Business

MX-016-00

Models Inlcuded:

B0-015-00 (B 1-50) Load Master MX-016-00 (MX 1600) Maintenance Expediter

MANUAL MB-150-02

Operation, Troubleshooting and

Replacement Parts Manual

Published: 11/26/2002 Revision: C

Serial number Starting: 136914

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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

Model B0-015-00, MX-016-00

Operator and Service Manual Section Index

Introduction 1

Safety Rules and Operating Instructions 2

General Maintenance 3

Front Axle Service 4

Steering Component Service 5

Brakes Service 6

Motor Service 7

Transaxle Service 8

Suspension 9

Battery Service 10

Tires and Wheels 11

Control System Troubleshooting 12

Wire diagram 13

Chargers 14

Illustrated Parts 15

Appendix A Special Tools 16

Appendix B Suggested Torque Values 17

Appendix C Brake Lining Handling Precautions 18

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

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

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TAYLOR -DUNN

Page 7

Introduction

Contents

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

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

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

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

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

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

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

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INTRODUCTION

ABOUT THIS MANUAL

The purchase of this vehicle shows a belief in high quality products manufactured in the USA. Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this high quality Taylor-Dunn® vehicle.

This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn® vehicles and is not intended as a training guide. Taylor-Dunn® has made every effort to include as much information as possible about the operation and maintenance of this vehicle.

Included in this manual are:

• Vehicle Description

• Safety Rules and Guidelines

• Operational Information

• Operator Responsibilities

• Owner Responsibilities

• Control Operation and Location Information

• Maintenance and Troubleshooting Information

• Standard Parts List

Before servicing, operating, training or performing maintenance on this or any other Taylor-Dunn® vehicle, read the appropriate Taylor-Dunn® manual.

Each Taylor-Dunn® manual references the applicable models and serial numbers on the front cover. Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

Introduction Page-2

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WHO SHOULD READ THIS MANUAL

This manual is intended for use by anyone who is going to operate, own, perform maintenance on, service, or order parts for this Taylor-Dunn® vehicle. Each person should be familiar with the parts of this manual that apply to their use of this vehicle.

RESPONSIBILITIES

INTRODUCTION

Of the Owner...

The owner of this or any Taylor-Dunn® vehicle is responsible for the overall maintenance and repairs of the vehicle, as well as the training of operators. Owners should keep a record of conducted training and maintenance performed on the vehicle. (OSHA Regulation, 29 CFR 1910.178 Powered Industrial Truck Operator Training).

Of the Operator...

The operator is responsible for the safe operation of the vehicle, preoperational and operational checks on the vehicle, and the reporting of any problems to service and repair personnel.

Of the Service Personnel...

The service personnel are responsible for the service and maintenance of the vehicle. At no time should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn vehicle. For the purposes of training, a qualified service person may oversee the repairs or services being made to a vehicle by an individual in training. At no time should an untrained individual be allowed to service or repair a vehicle without supervision. This manual is not a training guide.

Of the Passengers ...

The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside the vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of recklessness are to be avoided. Do not engage in horseplay.

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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.

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INTRODUCTION

Conventions

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

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

or,

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

The symbol at the left and the bold text contained within a box denotes a “Caution” and is used to inform the reader that property damage may occur. Be sure to exercise special care and follow any instructions contained with in a caution.

NOTE: Alerts the reader to additional information about a subject.

Introduction Page-5

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INTRODUCTION

HOW TO IDENTIFY YOUR VEHICLE

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

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

This vehicle is not designed to be driven on public roads or highways. It is available in maximum designed speeds ranging from 7 to 15 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

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:

B 1-50 and MX

1600

B 1-50 and MX 1600

MX 1600B 1-50

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INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

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

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

packages with the vehicle.

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

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

• Check battery cells to be sure they are filled.

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

Check the operation of each of the following controls:

• Accelerator

• Brake

• Parking Brake

• Key-Switch

• Forward/Reverse Switch

• Reverse Beeper (if equipped)

• Front Headlight Switch

• Steering Wheel

• Horn

What To Do If a Problem is Found

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

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

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

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

Introduction Page-7

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Model B 1-00

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Safety Rules and Operating Instructions

TABLE OF CONTENTS

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

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

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

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

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

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

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

Accelerator Pedal ....................................................5

Steering .................................................................... 5

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

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

Horn Switch ..............................................................6

Seat Interlock Switch ............................................... 6

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

Hour Meter (Optional) .............................................. 7

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

Battery Status Indicator, Analog .............................. 7

Battery Status Indicator, Digital Bargraph ............... 8

Reverse or Motion Alarm (Optional) .......................8

Electrolyte Alarm (Optional) ....................................8

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

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

Accessory Switch (Optional) ................................... 9

Auxiliary Switch (Optional) ......................................9

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

Driving ......................................................................10

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

Parking ..................................................................... 10

Towing ...................................................................... 10

Charging your vehicle...................................11

Signet Charger Operation, Model HB Series ......... 11

Signet Charger Operation, Model HBS series ........ 11

Lestronic II Charger Operation ................................ 12

New Battery Break in ............................................... 12

Charging Time ..........................................................12

Storing and Returning to Service ................13

Storing your Vehicle ................................................. 13

Returning To Service ............................................... 13

Periodic Maintenance Checklist ...................14

Daily Visual inspection: ............................................15

Maintenance Guidelines for

Severe Duty Applications........................15

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SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS

ITEM MODEL VOLTAGE SPECIFICATION

Occupancy Driver and one passenger

Dimensions B 1-50 274.2L X 112.5W X 120.7H Centimeters

MX 1600 274.2L X 112.5W X 207.6H Centimeters

Turning Radius 279.4 Centimeters (110 inches)

Dry Weight B 1-50 376.5 kg (830 lbs) Without Batteries MX 1600 469.9 kg (1036 lbs)

Min/Max Battery 166 kg to 212 kg (366 lbs to 468 lbs) Weights

Maximum Load B 1-50 726 kg (1600 lbs)

MX 1600 454 kg (1000 lbs)

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

Transmission Helical Gear, Oil Bath, Direct Drive

Motor, DC Series Wound 36 volt 6 hp @1200 RPM for 5 minutes

Maximum Recommended 19.3 kph (12 mph) Speed

Brakes Rear Wheel Mechanical Drum, Foot Operated Park Brake

Steering Automotive Steering 24:1

107.95L X 44.29 X 47.5H Inches

107.95L X 44.29 X 81.75H Inches

Solid State Speed Control, 275 Amp

2 hp @ 2800 RPM for 60 min

Tires 5.70 X 8 Load Range B, Tire Pressure 60 psi max

Frame B 1-50 Steel Unitized Body, Heavy Duty 16 Gauge Steel,

MX 1600 Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Battery Status Indicator, Key Switch, Horn Button,

Light Accessories B 1-50 12 Volt Brake Light

MX 1600 12 Volt Headlight, Tail/Brake Light

Charger 36 Volt 110 Volt 12 Amp AC, 25 Amp DC, Built-In, Automatic with

Diamond Plate Tool Box, Ladder Rack, Vise, Work Bench,

Gas Weld Tank Compartment

Forward/Reverse Switch, Brake Light

Control system Interlock Relay

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SAFETY RULES AND OPERATING INSTRUCTIONS

SAFETY RULES AND GUIDELINES

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

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.

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

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

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

• Drive slowly when making a turn especially if the ground is wet, slippery or when driving on an

incline.

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

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

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

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

• Keep to the right under normal conditions.

• Maintain a safe distance from all objects.

• Keep the vehicle under control at all times.

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

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

• Keep a clear view ahead at all times.

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

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

Before working on a vehicle:

3. Set the park brake.

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

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

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

DRIVER TRAINING PROGRAM

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

The Operator Training program shall include the following:

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

environment.

• Emphasis on the safety of cargo and personnel.

• All safety rules contained within this manual.

• Proper operation of all vehicle controls.

• A vehicle operation and driving test.

Driver Qualifications.

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

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

• Demonstrate a working knowledge of each control.

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

• Know how to properly load and unload cargo.

• Know how to properly park this vehicle.

• Recognize an improperly maintained vehicle.

• Demonstrate ability to handle this vehicle in all conditions.

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SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE CONTROLS

Key-Switch

A key-switch, located on the right 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 driver's seat.

This switch is also designed to secure and disable the vehicle. The key can only be removed when the key-switch is in the “OFF” position.

Forward-Off-Reverse Switch

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

Accelerator Pedal

Steering

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

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

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.

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.

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SAFETY RULES AND OPERATING INSTRUCTIONS

Foot Brake Pedal

The foot brake pedal, is located to the right of the steering column, it is for operation with the right foot only. It works similar to the brake in an automobile. Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied. Relieving pressure from the pedal releases the braking action.

Park Brake

The parking brake is actuated with a hand lever, which is located between the driver and passenger seats. 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.

Horn Switch

Seat Interlock Switch

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

The horn switch is located to the left of the steering column. Depress the switch with your left foot to sound the horn, release it to turn it off.

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 seat, they should turn the key-switch off, place the forward-reverse switch in the center “OFF” position, and set the park brake.

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SAFETY RULES AND OPERATING INSTRUCTIONS

Headlight Switch

Hour Meter (Optional)

The headlight switch is located on the far left side of the instrument panel. Push the top of the switch to turn the lighs on. Push the bottom of the switch to turn the light off.

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.

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.

NOTE: The interlock shown is mounted external of the charger. Some vehicles may have the interlock built into the charger.

Battery Status Indicator, Analog

The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading. The vehicle needs charging if it is in the yellow zone. During and immediately following charging, the needle will be in the red zone to the right. The needle will move through the green zone toward the yellow zone as the batteries discharge. Charge the batteries when the needle is in the yellow zone. If it is in the red zone to the left, the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries.

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SAFETY RULES AND OPERATING INSTRUCTIONS

Battery Status Indicator, Digital Bargraph

The battery status indicator is located to the left of the hour meter. The battery status indicator has a LED bar graph that indicates the relative state of charge of the battery. The top LED will light only when connected to a fully charged battery or after completing a charging cycle. Successive lower LED’s will light as the battery charge diminishes. When the second from the bottom LED flashes the battery energy status is in energy reserve and should be placed on charge as soon as possible. When the two bottom LED’s are alternately flashing the batteries are empty and the truck should be taken out of service and charged to avoid damaging the batteries.

Reverse or Motion Alarm (Optional)

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

Electrolyte Alarm (Optional)

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

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.

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SAFETY RULES AND OPERATING INSTRUCTIONS

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.

Accessory Switch (Optional)

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

Auxiliary Switch (Optional)

The auxiliary switch is located on the left side of the instrument panel and to the left of the headlight switch. Push the switch up to turn on an accessory. Push the switch down 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 auxiliary switch will control the other accessories.

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SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE OPERATIONAL GUIDELINES

Driving

• Slow down and sound the horn to warn pedestrians or when

approaching a corner or other blind intersection.

• No reckless driving.

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

• Immediately report any accidents or vehicle problems to a

supervisor.

Loading and Unloading

• Do not carry more than the maximum number of passengers

allowed for this vehicle.

• Do not exceed the cargo load capacity.

• Do not load cargo that can fall off.

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

properly secure all loads.

Parking

Before leaving the vehicle:

• Set the parking brake.

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

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

In addition:

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

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

Towing

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

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

tow the vehicle with the drive wheels on the ground.

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

CHARGING YOUR VEHICLE

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

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.

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

LED1 LED2 LED3

Typical Signet® Built In

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

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

Signet Charger Operation, Model HBS series

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

NOTE: If the charger restarts during a short time period of

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

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

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

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

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

Cycle complete ON ON ON

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SAFETY RULES AND OPERATING INSTRUCTIONS

Lestronic II Charger Operation

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

New Battery Break in

New batteries require a break in period of up to 40cycles. 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.

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 18hours (HB). A fault will occur if the charging time exceeds the 20-hour limit.

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.

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SAFETY RULES AND OPERATING INSTRUCTIONS

STORING AND RETURNING TO SERVICE

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

Storing your Vehicle

• Clean the batteries, then fill and charge before putting the vehicle in storage. Do not store

batteries in a discharged condition.

• Lube all grease fittings.

• Clean, dry, and check all exposed electrical connections.

• Inflate tires to proper pressure (if applicable).

• For extended storage, the vehicle should be elevated so that the tires do not touch the ground.

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

Storage

Temperature

(F)

Over 60 1

Between 40 and 60 2

Below 40 6

Charging Interval

(months)

Returning To Service

• Check the battery’s state of charge and charge if required.

• Perform ALL maintenance checks in the periodic checklist.

• Remove any blocks from the vehicle and/or place the vehicle down on to the ground.

• Test drive before putting into normal service.

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SAFETY RULES AND OPERATING INSTRUCTIONS

under the [Misc] sub folder.

PERIODIC MAINTENANCE CHECKLIST

Safety Rules Page 14

NOTE: A full page copy of the Periodic Maintenance

Checklist is on the Vehicle Documentation CD

Page 29

SAFETY RULES AND OPERATING INSTRUCTIONS

Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle. Repairs or maintenance by improperly trained or unauthorized personnel could cause improper operation of the vehicle or premature failure of components resulting in severe bodily injury and/or property damage.

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 15

Page 30

TAYLOR -DUNN

Page 31

General Maintenance

TABLE OF CONTENTS

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

Maintenance Guidelines for

Vehicles Used in Severe Conditions .....3

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

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

Page 32

Maintenance, Service and Repair

MAINTENANCE GUIDELINES

Periodic maintenance and service must be performed on this vehicle. Failure to complete these scheduled maintenance and service procedures can result in severe bodily injury and/or property damage. It is the owner and/or operators responsibility to insure that proper service and maintenance is performed on the vehicle, described in this manual.

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

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

3. Set the park brake.

Before starting any repairs:

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

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

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

• Avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle

performance checks in an authorized area where safe clearance exists.

• Before starting the vehicle, follow the recommended safety procedures in Section 2, “Safety

Rules and Operational Information.”

• Ventilate the work area properly.

• Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed

and directional control mechanisms, warning devices, lights, governors, guards, and safety devices.

• Inspect and maintain battery limit switches, protective devices, electrical conductors, and

connections in conformance with Taylor-Dunn’s recommended procedures.

• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or

defective parts.

• Do not use an open flame to check level or leakage of battery electrolyte.

• Do not use open pans of fuel or flammable fluids for cleaning parts.

• Only properly trained and authorized technicians should perform maintenance or repairs to this

vehicle.

Maintenance Page 2

Page 33

Maintenance, Service and Repair

MAINTENANCE GUIDELINES FOR VEHICLES USED IN SEVERE CONDITIONS

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

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

• In extreme temperatures

• On bumpy, dusty, or poorly maintained roads

• In excessively wet areas

• In corrosive or contaminated areas

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

• On multiple shifts

Maintenance Page 3

Page 34

Maintenance, Service and Repair

TROUBLESHOOTING GUIDE

Symptom Probable Cause

Front End Out of Alignment

Steering Pulls in One Direction

Low Tire Pressure

Dry Lube Points in Steering Linkage

Hard Steering

Excessive Steering Play

Lack of Power or Slow Operation

Abnormal Noise

Oil Leak in Rear Bearing Area

Damaged King Pin/Ball Joint

Low Tire Pressure

Worn Ball Joints

Mis-Adjusted or Worn Steering Gear

Loose Steering Linkage

Brakes or Parking Brakes Dragging

Worn Drive Gears

Front End Out of Alignment

Defective Speed Control

Worn Drive Gears or Bearings

Worn Front /Rear Axle Bearings

Loose Lug Nuts

Motor Bearings Worn

Rear Wheel Bearing and/or Gasket Failed

Drive Over Filled

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Worn (1/16" Wear Limit)

Brake Pedal Low

Braking Power Low

Brake Fluid Low

Brakes Out of Adjustment

Brake Worn (1/16" Wear Limit)

Brake Pads Contaminated with Fluid

Brake Pedal Linkage Binding

Brakes Out of Adjustment

Air in Brake Lines

Maintenance Page 4

Page 35

LUBRICATION CHART

Maintenance, Service and Repair

# Description Locations Lubricant Type

1 Front Leaf Springs General Purpose Grease

2 King Pin General Purpose Grease

3 Ball Joints General Purpose Grease

5 Front Wheel Bearings High Temperature Wheel Bearing Grease

6 Rear Leaf Springs General Purpose Grease

9 Drive Fill Plug 11 oz. 30 wt Motor Oil

Maintenance Page 5

Page 36

TAYLOR -DUNN

Page 37

Front Axle Service

TABLE OF CONTENTS

Inspect the Front Wheel Bearings

and Kin Pin ............................................2

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

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

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

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

Front Axle Disassembly and Assembly .......6

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

Replace the Ball Joints, Tie Rods,

and Drag Link .........................................8

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

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

Replace the King Pins and Bushings ..........12

Replace the Steering Knuckle ......................14

Page 38

Maintenance, Service, and Repair

INSPECT THE FRONT WHEEL BEARINGS AND KIN PIN

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

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

3. Set the park brake.

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

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

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

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

7. Grab the top and bottom of the tire/wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of the tire. Any movement or play is 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. Set the park brake.

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

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

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

7. Remove the hub dust cap and cotter pin.

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

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

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

NOTE: Refer to the Replace Front Wheel

Bearings section for information

regarding the replacement of the wheel bearings.

11. Install a new cotter pin.

12. Install the dust cap.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Hub with Dust Cap Removed

Front Axle Page 3

Page 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. Set the park brake.

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

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

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

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

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

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

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

regarding the removal of the ball joints or rod ends.

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

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

NOTE: In some configurations the front

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

Suspension for information

regarding removing the springs and shocks.

Front Axle Page 4

Page 41

Installation

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

Maintenance, Service, and Repair

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

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

3. Set the park brake.

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

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

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

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

regarding the installation of the ball joints or rod ends.

NOTE: Refer to Tires and Wheels section for information regarding

removing the front wheels.

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

regarding realigning the front wheels.

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

regarding bleeding the brakes.

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

Front Axle Page 5

Page 42

Maintenance, Service, and Repair

FRONT AXLE DISASSEMBLY AND ASSEMBLY

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.

King Pin

Upper Bushing

Cotter Pin

Lower Bushing

Yoke

Castle Nut

Bearing Cap

Thrust

Washer

Outer Bearing

Flat Washer

{

Large Cup Steel Washer Bronze washer Steel Washer Small Cup

King Pin Nut

Front Axle Page 6

Page 43

Maintenance, Service, and Repair

REPLACE FRONT WHEEL BEARINGS

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

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

3. Set the park brake.

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

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

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

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

information regarding removing the steering knuckle.

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

9. Remove the hub from the steering knuckle.

NOTE: For a front disc brake option you must

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

Brakes section for information

regarding the removal of the brake body.

NOTE: Catch the outer bearing as it falls out.

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

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

NOTE: It is recommended to replace all four

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

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

a. Pack inner and outer bearings with grease.

Hub with Dust Cap Removed

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

30 ft-lbs. This seats the bearings.

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

turns, but is not loose.

d. Install a new cotter pin.

Front Axle Page 7

Hub with Dust Cap Removed

Page 44

Maintenance, Service, and Repair

13. Install the hub dust cap.

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

NOTE: Refer to the Brakes section for information regarding the

installation of the brake body.

15. Lower the vehicle.

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

17. Remove the blocks from behind the wheels.

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

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

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

Rod End

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

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

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

Replacing a Rod End

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

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

3. Set the park brake.

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

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

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

Ball Joint

Front Axle Page 8

Page 45

Maintenance, Service, and Repair

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

8. Remove the rod end nut.

9. Remove the rod end from the steering arm.

Rod End

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.

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

12. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Replacing a Ball Joint

Steering Sleeve

Jam Nut

Rod End Nut

Steering Arm

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

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

3. Set the park brake.

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

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

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

Front Axle Page 9

Page 46

Maintenance, Service, and Repair

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

8. Remove the cotter pin and ball joint nut.

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

10. Remove the ball joint from the steering sleeve.

HINT: Count the number of turns required to

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

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

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

13. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

14. Lower the vehicle.

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

Steering Sleeve

Cotter Pin

Ball Joint Nut

Steering Arm

Ball Joint

Clamp

16. Remove the blocks from behind the wheels.

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

Replacing the Drag Link

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

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

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

3. Set the park brake.

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

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

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

Front Axle Page 10

Page 47

Maintenance, Service, and Repair

Pitman Arm

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

NOTE: Refer to the Replacing the Ball

Joints section for information

regarding the removal of the ball joints or rod ends.

8. Remove the drag link as an assembly.

9. Install in reverse order.

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of the front wheels.

11. Lower the vehicle.

12. Reconnect the main 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.

Drag Link

Steering Knuckle

Typical Drag Link

Replacing the Tie Rod

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

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

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

3. Set the park brake.

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

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

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

Front Axle Page 11

Page 48

Maintenance, Service, and Repair

Tie Rod

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

NOTE: Refer to the Replacing the Ball

Joints section for information

regarding the removal of the ball joints or rod ends.

8. Remove the tie rod as an assembly.

9. Install in reverse order.

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of the front wheels.

11. Lower the vehicle.

12. Reconnect the main 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.

Typical Front Axle Assembly

Steering Knuckle

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.

The bronze bushings must be reamed or broached to the proper diameter after they are pressed into the axle beam or steering knuckle. Failure to broach or ream the bushings may result in steering dificulty and loss of control of the vehicle causing severe bodily injury and /or property damage.

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

Front Axle Page 12

Page 49

Maintenance, Service, and Repair

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

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

3. Set the park brake.

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

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

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

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

regarding removing the steering knuckle.

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

procedure.

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

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

10. Ream or broach the bronze bushings to 0.878 ± 0.001 inches.

The bronze bushings must be reamed or broached to the proper diameter after they are pressed in to the axle beam or steering knuckle. Failure to broach or ream the bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and/or property damage.

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

12. Reassemble in reverse order.

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

the steering knuckle.

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

whenever replacing the king pin bushings. Refer to the

Replacement Parts section for the orientation of the bearing or

washers in your vehicle.

13. Grease the bushings (bronze only).

Front Axle Page 13

Page 50

Maintenance, Service, and Repair

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.

REPLACE THE STEERING KNUCKLE

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

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

3. Set the park brake.

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

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

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

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

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

NOTE: For a front disc brake option you must

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

Brakes section for information

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

NOTE: Catch the outer bearing as it falls out.

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

tie rod.

Hub with Dust Cap Removed

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 14

Page 51

Maintenance, Service, and Repair

13. Assemble in reverse order.

14. Pack the thrust bearing with grease.

NOTE: Refer to the Replacement Parts section for the orientation of

the thrust bearing or washers in your vehicle.

15. Tighten the king pin nut until there is 0.1 to 0.123 inches clearance as shown in the illustration below.

NOTE: Refer to Replace Front Wheel Bearings for information

regarding proper tightening of the spindle nut

16. Install new cotter pins.

17. Realign the wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

18. Lower the vehicle.

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

20. Remove the blocks from behind the wheels.

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

.100 .123

Yoke clearance after tightening the king pin

Front Axle Page 15

Page 52

TAYLOR -DUNN

Page 53

Steering Component Service

TABLE OF CONTENTS

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

Adjust the Steering gear (Saginaw) .............5

Replace the Steering Shaft

(Saginaw, non-tilt steering)....................7

Replace the Steering Wheel

(Saginaw, non-tilt steering)....................9

Replace the Steering Gear (Saginaw) ..........10

Repair the Steering Gear ..............................11

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

Page 54

Maintenance, Service, and Repair

FRONT END ALIGNMENT

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

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

Center the Steering

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

Ball Joint

Rod End

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

3. Set the park brake.

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

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

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

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

8. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section for information

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

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

NOTE: Refer to Adjust the Steering Gear section for information

regarding centering of the steering gear.

Steering Page 2

Page 55

Maintenance, Service, and Repair

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

Do not drive the vehicle while the steering wheel or front wheels are tied in position. Driving the vehicle while the steering wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and/or property damage.

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

NOTE: Remember the position and orientation

of the clamps.

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

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

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

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

15. Tighten the ball joint clamps or the rod end jam nuts on the drag link.

16. Untie the steering wheel and the front wheels.

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

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

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

19. Remove the blocks from behind the wheels.

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

Steering Page 3

Page 56

Maintenance, Service, and Repair

Front wheel alignment

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

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

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

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

3. Set the park brake.

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

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

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

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

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

HINT: Hold the chalk on the center of the tire

and rotate the tire to mark the line.

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

NOTE: Remember the position and orientation

of the ball joint clamps.

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

Steering Page 4

Page 57

Maintenance, Service, and Repair

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

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

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

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

15. Tighten the ball joint clamps or the rod end jam nuts.

16. Untie the steering wheel.

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

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

18. Remove the blocks from behind the wheels.

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

Front Measurement

Sleeve Clamps

Tie Rod

Rear Measurement

ADJUST THE STEERING GEAR

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

steering gear to perform this procedure. Refer to Replace the

Steering Gear for information regarding removing the steering

gear.

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

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

3. Set the park brake.

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

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

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

Steering Page 5

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Maintenance, Service, and Repair

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.

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

Steering Page 6

Page 59

Maintenance, Service, and Repair

REPLACE THE STEERING SHAFT

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

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

3. Set the park brake.

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

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

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

7. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel

section for information regarding removing the steering wheel.

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

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

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

NOTE Most vehicle configurations will now allow

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

Steering Page 7

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Maintenance, Service, and Repair

11. Remove the steering shaft from the vehicle.

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

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

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

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

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

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

16. Remove the blocks from behind the wheels.

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

Steering Page 8

Page 61

Maintenance, Service, and Repair

REPLACE THE STEERING WHEEL

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

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

3. Set the park brake.

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

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

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

7. Remove the steering wheel nut.

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

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

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

11. Tighten the steering wheel nut to 50-60 ft-lbs

12. Reinstall the horn switch (if equipped).

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

14. Remove the blocks from behind the wheels.

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

Steering Page 9

Page 62

Maintenance, Service, and Repair

REPLACE THE STEERING GEAR

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

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

3. Set the park brake.

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

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

6. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel section for information

regarding removing the steering wheel.

7. Remove the steering shaft.

NOTE: Refer to Replace the Steering Shaft section for information

regarding removing the steering shaft.

8. Remove the pitman arm using a pickle fork.

NOTE: On some vehicle configurations it may

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

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

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.

Steering Gear with Pitman Arm

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

11. Install in reverse order. Torque the pitman arm nut to75-100 ft-lbs.

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

13. Remove the blocks from behind the wheels.

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

Steering Page 10

Page 63

Maintenance, Service, and Repair

REPAIR THE STEERING GEAR

Disassembly

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

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

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

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

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

1. Center the steering gear.

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

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

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

NOTE: The side cover/pitman shaft assembly

normally does not have to be disassembled.

Steering Page 11

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Maintenance, Service, and Repair

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

5. Remove the worm shaft seal.

6. Remove the pitman shaft seal.

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

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

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

10. Remove the ball nut from the worm shaft.

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

Reassembly

1. Lightly lubricate all parts before reassembly.

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

3. Install the upper worm bearing cup.

4. Divide the ball bearing into two equal groups.

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

6. Insert the ball guides into the ball nut.

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

NOTE: Do not rotate the worm shaft while

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

8. Install the ball guide clamp.

Steering Page 12

Page 65

Maintenance, Service, and Repair

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

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

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

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

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

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

15. Adjust the steering gear.

NOTE: Refer to Adjust the Steering gear

section for information regarding adjusting the steering gear.

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

Steering Page 13

Page 66

Maintenance, Service, and Repair

Exploded View of Steering Gear

Steering Page 14

Page 67

TABLE OF CONTENTS

Brake Service

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

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

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

Rear Brake Shoes ................................................. 2

Rear Brake Drum ................................................. 3

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

Adjust the Service Brakes .................4

Mechanical and Hydraulic Drum Brakes ............ 4

Adjust the Mechanical Brake Linkages ............... 5

Adjust the Parking Brake ...................6

Wheel Park Brake (mechanical drum standard) .. 6

Wheel Park Brake (hydraulic drum) .................... 6

Check Master Cylinder Fluid .............7

Bleed the Brake System ....................8

Flush the Brake System ....................9

Replace Front Disc Brake Pads.........10

Replace Rear Brake Shoes ...............11

Replace the Front Cylinder................12

Repair the Brake Body ......................13

Replace the Master Cylinder .............15

Repair the Master Cylinder ................16

Page 68

Maintenance, Service, and Repair

INSPECT THE SERVICE BRAKE

NOTE: Front brakes are optional

Front 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 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.

Front Disc Brake Rotor

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.

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: 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.

Measuring pad thickness

Rear Brake Shoes

NOTE: The wheel must be removed to accurately

measure the brake shoes. Refer to Tires and Wheels section for information on removing the wheel.

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

NOTE: If this is a riveted lining, then the measurement

must be to the top of the rivets.

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

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.

Brakes Page 2

Measuring lining thickness

Page 69

Maintenance, Service, and Repair

Rear Brake Drum

NOTE: The wheel must be removed to accurately

measure the brake drum. Refer to Tires and Wheels section for information on removing the wheel.

The service limit for the inside diameter of the brake drum is 7.060 inches.

If the brake drum is grooved or worn beyond the service limit then the brake drum must be replaced.

Measure the inside diameter of the brake drum in 3places.

If the difference between any of the measurements exceeds 0.010-inches then the brake drum must be replaced.

INSPECT THE PARKING BRAKE

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 shoes. The parking brake shoes are the same as the service brake shoes. Refer to Inspect the Service Brake section to inspect the brake shoes.

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

9. Inspect the park brake ratchet for any signs of damage or wear.

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

10. Set the park brake.

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

12. Remove the blocks from the wheels

Brakes

Page 3

Page 70

Maintenance, Service, and Repair

ADJUST THE SERVICE BRAKES

Mechanical and Hydraulic Drum Brakes

The mechanical and hydraulic brake assemblies are identical except for hydraulic fittings. The adjustment procedure is the same for both the mechanical and hydraulic brakes.

NOTE: The brake adjustment is inside of the left and right brake. Do not adjust the brake by means of the

brake cables as this will cause mis-operation of the brakes. If you hear a single “clunking” noise while braking it may be due to mis-adjustment of the brake cables or linkage. Refer to Replace Brake Linkages/Cables for information regarding proper adjustment of the cables and linkages.

Adjusting the brakes by means of the brake cables could cause a hard brake pedal with little or no braking power. This could cause loss of control of the vehicle resulting in property damage and/or severe bodily injury.

11. Back off the star wheel just enough so that the brake drum rotates freely.

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 wheel off of the ground and support with jack stands.

7. Release the park brake.

12. Install the tire/wheel assembly.

13. Repeat this procedure for the opposite side brake.

14. Set the park brake.

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

16. Remove blocks from behind the wheels.

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

8. Remove the tire/wheel assembly.

NOTE: Refer to Tires and Wheels section for

information on removing the wheel.

9. Align the adjusting access slot in the brake drum with the adjusting star wheel at the bottom of the brake.

10.While rotating the brake drum back and forth, rotate the brake adjuster star wheel until the brake is tight enough so that brake drum cannot be rotated.

Brakes Page 4

Brake drum shown with the access slot aligned with the adjusting star wheel .

Page 71

Maintenance, Service, and Repair

Adjust the Mechanical Brake Linkages

Adjusting the brakes by means of the brake cables could cause a hard brake pedal with little or no braking power. This could cause loss of control of the vehicle resulting in severe bodily injury and/or property damage.

Do not use this procedure to adjust the brakes. This procedure should only be performed when replacing any of the mechanical brake linkages or cables or it is found that the cables or linkages have been adjusted incorrectly.

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 clevis jam nuts on the main brake cable and connecting rod (refer to illustration on previous page.

8. Loosen the brake cable and connecting rod.

9. Adjust the park brake linkage so that the angle between the connecting rod and the cross shaft tab is at 60 degrees.

10. Tighten the brake cable so that all slack is removed from the cable, but not so much so that the cross shaft rotates.

11. Tighten the connecting rod so that all slack is removed from the brake cables, but not so much as to actuate the brakes.

12. Tighten the jam nuts on the brake cable, connecting rod, and park brake linkage.

13. Set the park brake.

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

Brake linkage with protractor in place

at 60 degrees

15. Remove blocks from behind the wheels.

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

Brakes

Page 5

Page 72

Maintenance, Service, and Repair

ADJUST THE PARKING BRAKE

Wheel Park Brake (mechanical drum standard)

Trucks equipped with mechanical drum brakes do not have a separate adjustment for the parking brake. If the parking brake requires adjustment, then the entire brake system is in need of adjustment. Refer to Adjust the

Service Brake section for information regarding adjusting the brakes.

Wheel Park Brake (hydraulic drum)

NOTE: Hydraulic brakes are optional. The service

brake must be properly adjusted before attempting to adjust the parking brake. Refer to Adjust the Service Brakes for information regarding adjusting the service brakes.

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 clevis jam nuts on the connecting rod (refer to illustration on next page).

8. Loosen the connecting rod.

9. Adjust the park brake linkage so that the angle between the connecting rod and the cross shaft tab is at 60 degrees.

10.Tighten the connecting rod so that all slack is removed from the brake cables, but not so much as to actuate the brakes.

11. Tighten the jam nuts on the connecting rod and park brake linkage.

12.Set the park brake.

Brake linkage with protractor in place

at 60 degrees

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

14.Remove blocks from behind the wheels.

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

Brakes Page 6

Page 73

Maintenance, Service, and Repair

CHECK MASTER CYLINDER FLUID

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

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

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

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

regulations.

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

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

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

3. Set the park brake.

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

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

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

7. Remove the master cylinder cap.

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

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

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

11. Remove blocks from behind the wheels.

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

Brakes

Page 7

Page 74

Maintenance, Service, and Repair

BLEED THE BRAKE SYSTEM

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

NOTE: Hydraulic brakes are optional. Start this

procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder.

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.

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

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

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

• Only use DOT 3 brake fluid from a new

sealed container.

• DOT 3 brake fluid is corrosive and will

damage paint finishes.

• Dispose of brake fluid in accordance with

local state and federal regulations.

• Read and follow all warnings on the

brake fluid container.

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.

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

Brakes Page 8

Typical bleeder valve

Page 75

FLUSH THE BRAKE SYSTEM

Maintenance, Service, and Repair

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

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

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

3. Confirm the electric park brake is set.

• Only use DOT 3 brake fluid from a new

sealed container.

• DOT 3 brake fluid is corrosive and will

damage paint finishes.

• Dispose of brake fluid in accordance with

local state and federal regulations.

• Read and follow all warnings on the

brake fluid container.

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.

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

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

NOTE: Hydraulic brakes are optional.

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

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

8. Release the park brake.

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

14. Close all bleeder screws.

15. Fill the master cylinder with fluid.

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

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

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

19. Set the park brake.

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

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

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

Brakes

Page 9

Page 76

Maintenance, Service, and Repair

REPLACE FRONT DISC BRAKE PADS

NOTE: Front brakes are optional. 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.

NOTE: Refer to the illustration above for the following

steps.

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

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

12. Inspect the brake rotor. See Inspect the Service

Brakes section for information regarding

inspecting the brake rotor.

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

14. Install new spacer bushings in the mounting bracket.

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

16. Repeat this procedure for the other wheel.

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

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

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

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

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

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

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

and Wheels section for information on removing

the tire and wheel assembly.

Brakes Page 10

20. Remove the blocks from behind the wheels.

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

Page 77

Maintenance, Service, and Repair

REPLACE REAR BRAKE SHOES

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: It is recommended that both the left and right

brake pads be replaced as a set.

6. Release the park brake.

Do not allow grease to contact any of the braking surfaces. Braking surfaces contaminated with grease may cause the brakes to fail resulting in property damage and/or severe bodily injury.

14.

Apply a

grease to the adjustor screw threads.

15. Install in reverse order.

16. Repeat for the opposite side.

17. Adjust the brakes. See Adjust the Service

very light coating of high temperature

Brakes section for information regarding

adjusting the brakes.

18. Set the park brake.

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

20. Lower the wheels to the ground.

21. Remove the blocks from behind the wheels.

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

7. Raise the rear wheels 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 wheel.

9. Remove and inspect the brake drum. Refer to

Inspect the Service Brake section for

information regarding inspecting the brake drum.

10. Remove the retracting springs and torsion springs from the brake shoes.

11. Remove the hair pin clips from the actuating arms and discard.

12. Remove the brake shoes and brake adjustor assembly from the backing plate.

13. Thoroughly clean and inspect the adjustor assembly. Replace parts as required.

Brake Adjuster Assembly

Brakes

Page 11

Page 78

Maintenance, Service, and Repair

REPLACE THE FRONT CYLINDER

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

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

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

3. 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: Front brakes are optional.

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.

12. Disconnect the brake hose from the brake body.

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

• Use teflon tape thread sealant on the brake hose

fitting.

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

14. Bleed the brakes. Refer to Bleed the Brakes

section for information regarding bleeding the brakes.

15. Set the park brake.

16. Reconnect the main positive and negative cables

at the batteries.

17. Lower the wheel to the ground.

18. Remove the blocks from behind the wheels.

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

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.

Brakes Page 12

Page 79

REPAIR THE BRAKE BODY

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

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

SKIN CONTACT

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

EYE CONTACT

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

INGESTION

Get medical attention immediately.

Maintenance, Service, and Repair

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

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

3. Set the park brake.

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

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

6. Remove the brake body from the vehicle.

NOTE: Refer to Replace the Brake Body

Assembly (front or rear) section for

information on removing the brake body.

7. Pull the pistons out of the brake body.

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.

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.

Brakes

Page 13

Page 80

Maintenance, Service, and Repair

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

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

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

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

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

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

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

Brakes Page 14

Page 81

Maintenance, Service, and Repair

1/8"

REPLACE THE MASTER CYLINDER

• Only use DOT 3 brake fluid from a new

sealed container.

• DOT 3 brake fluid is corrosive and will

damage paint finishes.

• Dispose of brake fluid in accordance with

local state and federal regulations.

• Read and follow all warnings on the

brake fluid container.

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.

INGESTION

Get medical attention immediately.

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

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

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

NOTE: Most vehicle configurations do not require

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

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

7. Place a drain pan under the master cylinder.

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

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

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.

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

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

17. Remove the blocks from behind the wheels.

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

Plunger

Push Rod

Master Cylinder

Cutaway of typical master cylinder showing

the push rod clearance

Brakes

Page 15

Page 82

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 16

Page 83

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 84

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 85

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

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

Correct

Insulation

Commutator

Repair Commutator section for information

regarding machining the commutator.

Undercut

Armature

Min. OD

Motor

Page 86

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 87

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 88

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

Page 89

SERVICE LIMITS

Motor Service

Motor Specification

Undercut Depth

Commutator Diameter

(min)

Brush Length

(min)

Wire Depth

(max)

Number

mm inches mm inches mm inches mm inches

5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC58JBS6129C 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC49JB399C 0.635 0.025 78.97 3.109 19.05 0.75 - -

5BC58JBS6110C 0.635 0.025 78.97 3.109 19.05 0.75 38.1 1.5

Motor

Page 90

TAYLOR -DUNN

Page 91

Transmission Service

TABLE OF CONTENTS

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

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

Motor .............................................................4

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

Installation ................................................................. 4

Rear Hub with Brake Drum...........................5

Rear Axle .......................................................6

Replace the Axle Bearing ..........................................8

Transmission.................................................9

Remove.....................................................................9

Install ........................................................................9

Differential Case............................................10

Disassemble .............................................................10

Assemble .................................................................. 13

Page 92

Maintenance, Service, and Repair

CHECK OIL LEVEL

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 a drain pan that can hold a minimum of 2-quarts of oil under the transmission level plug.

7. Remove the level plug. When the plug is removed, a small amount of oil should come out. This indicates that the transmission has the correct amount of oil.

8. If no oil comes out, then add oil as required through the level plug hole.

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

10. Remove blocks from behind the wheels.

11. Test drive the vehicle

Transmission Oil Level Plug

Transmission Page 2

Page 93

Maintenance, Service, and Repair

CHANGE OIL

Changing the transmission oil requires removal of the transmission cover. Refer to transmission disassembly later in this section.

Transmission Page 3

Page 94

Maintenance, Service, and Repair

MOTOR

Removal

NOTE: In some vehicle configurations the transmission assembly will have

to be removed to allow clearance to remove the motor. Refer to

Transmission section for information on removing the

transmission assembly from the vehicle.

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

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

3. Set the park brake.

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

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

6. Remove the motor wires from the motor.

7. Remove the bolts holding the motor to the transmission housing (see illustration).

8. Slide the motor off of the transmission input shaft.

Installation

1. Remove the rubber bushing from inside of the motor armature coupling.

2. Thoroughly clean all grease from the transmission input shaft, rubber bushing and the motor armature coupling.

3. Install the rubber bushing back into the motor armature coupling.

4. Lightly grease the transmission input shaft only (see caution below).

5. Install the motor in reverse order.

6. Torque the motor mounting bolts to 6-8 ft-lbs.

HINT: Tag each wire with the number of the

terminal it was removed from.

Do not apply grease to the armature coupler, rubber bushing or the end of the transmission input shaft. Grease applied to these areas may result in premature failure of the armature bearing.

Transmission Page 4

Page 95

Maintenance, Service, and Repair

REAR HUB WITH BRAKE DRUM

Removal and Installation

NOTE: Some vehicle configurations do

not have a removable hub. The hub is an integral part of the rear axle. See the illustrations to the right to identify the hub on 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.

Integral hub Removable hub

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 rear wheel. Refer to Replace the

Rear Tire/Wheel section for information regarding

removing the rear wheel.

7. Remove the cotter pin from the axle shaft.

8. Remove the hub retaining nut and remove the hub from the axle shaft.

9. Install in reverse order.

10. Lightly grease the axle shaft splines.

Too much grease on the axle splines could contaminate the braking surfaces resulting in loss of braking power. This could lead to severe bodily injury and/or property damage.

11. Tighten the axle hub retaining nut to 95-115 ft-lbs.

12. Install the wheel. Refer to Replace the Rear Tire/Wheel section for information regarding installing the rear wheel.

13. Reconnect the main positive and negative cables at the batteries, remove the blocks from the wheels, and test drive.

Transmission Page 5

Page 96

Maintenance, Service, and Repair

REAR AXLE

Your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axle and the other is an integral part of the rear axle. The service of both of these axles is addressed in this section as follows:

The removable hub will be referred to as “Removable Hub.” The non-removable hub will be referred to as “Non-Removable Hub.”

Refer to the illustrations on the previous page to identify the type of hub on your vehicle.

NOTE: The tire/wheel assembly must be removed for these procedures.

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

Remove and Install Axle - Removable Hub

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 rear wheel. Refer to Replace the Rear Tire/Wheel section for information regarding

removing the rear wheel.

7. Remove the axle hub. Refer to Rear Hub/Brake

Drum section for information on removing the hub.

8. Remove the outer snap ring from the axle housing.

9. Remove the axle from the transmission assembly.

HINT: Use a slide hammer threaded onto the

end of the axle shaft.

10. Remove the inner snap ring.

11. Remove the axle seal from the axle housing.

12. Install the axle in reverse order using a new axle seal.

13. Refer to Rear Hub/Brake Drum section for information on installing the hub.

14. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels, and test drive.

Transmission Page 6

Page 97

Maintenance, Service, and Repair

Remove and Install Axle - Non - Removable Hub

NOTE: The brake assembly is retained by the axle bearing and must be

removed along with the axle assembly.

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

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

3. Set the park brake.

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

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

6. Remove the rear wheel. Refer to Replace the Rear Tire/Wheel section for information

regarding removing the rear wheel.

7. Remove the brake drum.

8. Remove the mechanical brake linkage from the brake arm.

9. If equipped with hydraulic brakes, disconnect the brake line from the wheel cylinder.

10. Remove the four bolts holding the axle/brake assembly to the axle housing.

11. Remove the axle/brake assembly from the transmission assembly.

HINT: Use a slide hammer threaded onto one

of the wheel studs.

12. If the axle bearing is to be replaced, remove the bearing race from inside of the axle housing.

13. Remove the axle seal from the axle housing and discard.

14. Install in reverse order using a new axle seal.

15. If equipped with hydraulic brakes, bleed the brakes. Refer to Brake Service-Bleed the Brakes section for information on bleeding the brake system.

16. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels, and test drive.

Transmission Page 7

Page 98

Maintenance, Service, and Repair

Replace the Axle Bearing

NOTE: The axle must be removed from the transmission for this procedure.

Refer to Remove and Install Axle for information regarding removing the rear axle.

Removable Hub:

1. Remove the hub from the axle shaft. Refer to Rear Hub/Brake Drum for information regarding removing the hub.

2. Press the axle bearing off of the axle shaft and discard.

3. Press a new bearing onto the axle shaft.

4. If the axle is not to be immediately installed into a vehicle, pack the bearing with grease and wrap it in plastic to prevent corrosion.

Non-Removable Hub

1. Drill a 1/4” hole to a depth of approximately 3/4 the thickness of the retaining ring.

Do not drill all of the way through the retainer into the axle shaft. Drilling into the axle shaft will weaken the axle shaft and could cause the axle to fail resulting in severe bodily injury and/or property damage.

2. Use a chisel to split the retainer and remove the retainer from the axle shaft.

3. Press the bearing and brake assembly off of the axle shaft.

4. Press a new bearing/race assembly onto the axle shaft.

5. If the axle is not to be immediately installed into a vehicle, pack the bearing with grease and wrap it in plastic to prevent corrosion.

Transmission Page 8

Page 99

TRANSMISSION

Removal

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

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 motor from the transmission. Refer to Remove Motor section for information regarding removing the motor.

7. Disconnect the brake cables from the left and right brake arm and cable mounting bracket.

Maintenance, Service, and Repair

the key.

8. Support the frame of the vehicle so it will not drop.

9. Remove the bolts and nuts holding the transmission to the springs.

10. Lift the vehicle frame and remove the transmission out from under the vehicle.

Installation

Do not let the vehicle hang from a hoist or leave the vehicle supported only by the lifting device. Once the transmission is removed, support the vehicle frame with jackstands of adequate capacity. Failure to use lifting and support devices of rated load capacity may result in severe bodily injury.

1. Install in reverse order.

2. Adjust the brakes. Refer to Adjust the Service Brakes section for information regarding adjusting the brakes.

3. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels, and test drive.

Transmission Page 9

Page 100

Maintenance, Service, and Repair

DIFFERENTIAL CASE

Disassemble

1. Remove the transmission from the vehicle. Refer to Transmission-Removal section for information on removing the transmission.

2. Thoroughly clean the transmission assembly before disassembly.

3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.

4. Suspend the differential case over a drain pan that can hold a minimum of 2-quarts of oil.

5. Remove the differential case cover being careful not to bend or damage the case cover flange or the sealing surface of the differential case.

6. Remove the differential bearing caps and remove the differential assembly from the housing.

NOTE: The bearing caps are marked for

identification. When the transmission is reassembled they must be installed in their original position.

7. Remove both bearings from the differential case.

Transmission Page 10

Taylor-Dunn B0-015-00, B 1-50, MX-016-00, MX 1600, MAINTENANCE EXPEDITER Operation, T Roubleshooting And Replacement Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Rules

VEHICLE CONTROLS

MOTOR INSPECTION

SERVICE LIMITS

CHANGE OIL