Taylor-Dunn SC-011-59, SC 159, AN-011-71, AN 171 Operation, T Roubleshooting And Replacement Parts Manual

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Models Inlcuded: SC-011-59 (SC 159) AN-011-71 (AN 171)

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MANUAL MA-159-05

Operation, Troubleshooting and

Replacement Parts Manual

Revision: G

Serial Number Starting: 98509

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

TAYLOR-DUNN SERVICE CENTER

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

Taylor-Dunn® Mfg.

2114 W. Ball Road

Anaheim, CA 92804

(Attn: Technical Writer)

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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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Contents

Introduction

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

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

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

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

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

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

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

Safety Rules and Operating Instructions

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

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

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

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

2 - Start Switch ....................................................... 4

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

1 - Horn Switch....................................................... 4

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

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

5 - Headlight Switch (optional) ................................ 4

2 - Battery Status Indicator, Digital Bargraph .......... 5

1 - Hour Meter (optional)......................................... 5

2 - Battery Status Indicator, Analog (optional) ......... 5

Accelerator / Brake Treadle, SC 159 ...................... 6

Accelerator / Brake Treadle, AN 171 ...................... 6

Steering, SC 159 .................................................... 6

Steering, AN 171 .................................................... 6

Walk-along Handle, AN 171 ................................... 6

Foot Interlock Switch, SC 159 (optional) ................ 7

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

Parking brake ......................................................... 7

Vehicle Operational Guidelines ............... 8

Safety Guidelines ................................................... 8

Starting: .................................................................. 8

While driving:.......................................................... 8

Loading and Unloading ........................................... 8

Towing Loads:......................................................... 8

Parking ................................................................... 9

Towing This Vehicle................................................ 9

Charging your vehicle .............................. 10

New Battery Break in .............................................. 10

Signet® Charger Operation .................................... 10

Lestronic II® Charger Operation ............................. 10

Industrial Charger Operation .................................. 10

Charging Time ........................................................ 11

Storing and Returning to Service ........... 11

Storing Your Vehicle................................................ 11

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

Periodic Maintenance Checklist .............. 12

Daily Visual inspection:........................................... 13

Maintenance Guidelines for

Severe Duty Applications................... 13

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

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

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

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

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

Inspect the Front Wheel Bearings ........... 2

Adjust Front Wheel Bearings.................. 2

Front Axle Removal and Installation ....... 3

Removal.................................................................. 3

Installation .............................................................. 3

Replace Front Wheel Bearings ................ 4

Steering Component Service

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

Center the Steering Wheel ..................................... 2

Inspect the Steering Components ........... 4

Steering Wheel and Bushings ................................ 4

Steering Chain ........................................................ 4

Pillow Blocks .......................................................... 5

Fork Bearings ........................................... 5

Adjust the Steering Shaft ......................... 6

Replace the Steering Wheel ..................... 6

Replace the Front Fork............................. 7

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

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

Adjust the Service Brake .......................... 2

Adjust the Brake Linkages ...................................... 3

Replace the Brake Lining ......................... 4

Replace Brake Drum................................ 6

Replacing the Treadle Linkage ................ 7

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

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

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

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

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Table of Contents

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

Adjust the Drive Chain ............................. 2

Check the Oil Level................................... 4

Change the Oil .......................................... 5

Drive Motor ............................................... 6

Remove .................................................................. 6

Install ...................................................................... 6

Rear Axle ................................................... 7

Remove and Install ................................................. 7

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

Transmission Assembly ........................... 9

Remove and Install ................................................. 9

Chain Case ................................................ 10

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

Assemble................................................................ 12

Differential Assembly (3rd Member) ........ 14

Disassemble........................................................... 14

Assemble................................................................ 16

Re-shimming the Pinion Housing............ 18

Exploded View .......................................... 20

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

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

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

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

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

Replace the Tire (pneumatic) .................. 3

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

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

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

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

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

Charging ................................................... 4

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

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

Moist Charge Batteries ........................................... 7

Storage and Returning to Service ........... 8

Storage ................................................................... 8

Returning to Service ............................................... 9

Special Troubleshooting Guide

PMC CONTROL .................................................... 2

PLUGGING DIODE ............................................... 4

FREEWHEEL DIODE ............................................ 5

ISO ......................................................................... 6

SOLENOIDS .......................................................... 8

MOTOR.................................................................. 11

Lestronic II® Charger Troubleshooting

Operating Instructions and

Theory of Operation ........................... 2

Testing the Charging Cycle...................... 3

Test Equipment Required for

Troubleshooting ................................. 4

Important Notes and Instructions ............................ 4

Troubleshooting for Built-in Charger ...... 5

Troubleshooting for Portable Charger .... 8

Testing The Timer Relay .......................... 9

Testing the Interlock Relay ...................... 10

Signet® Charger Troubleshooting

Operating Instructions and

Theory of Operation ........................... 2

HB/PT and GEL Indicator Lamps ............. 3

Testing the Charging Cycle...................... 3

Test Equipment Required for

Troubleshooting ................................. 4

Important Notes and Instructions ............................ 4

Status LED Error Code Table ................... 5

Troubleshooting ....................................... 6

Wire Diagrams

Complete Vehicle, Standard Bed ............. 2

Complete Vehicle, Short Bed or Lift Out

Battery Box ......................................... 3

Complete Vehicle, AN ............................... 4

Electrical Troubleshooting

Symptoms: ................................................ 2

Main Troubleshooting Sequence............. 3

Test Equipment Required: ...................................... 3

IMPORTANT NOTES and INSTRUCTIONS......... 3

Definitions:.............................................................. 4

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Table of Contents

Illustrated Parts

Front Axle ................................................... 2

Front Tire.................................................... 4

Front Fork................................................... 6

Steering Linkage SC ................................... 8

Steering Linkage AN ................................... 10

Mechanical Control Linkage ........................ 12

Throttle Linkage.......................................... 14

Lester Chargers, Page 1 ............................. 16

Lester Chargers, Page 2 ............................. 18

Signet Charger............................................ 20

Motors ........................................................ 22

Power Traction............................................ 24

Differential .................................................. 26

Brake.......................................................... 28

Rear Axle.................................................... 30

Rear Tires................................................... 32

Control Panel (standard) ............................. 34

Control Panel (40” bed)............................... 36

Instruments................................................. 38

Gauges....................................................... 38

Batteries ..................................................... 40

Decals ........................................................ 42

Decals, AN.................................................. 43

Miscellaneous Frame and Body, SC............ 44

Miscellaneous Frame and Body, AN............ 46

Appendixes

Appendix A: Special Tools ....................... 2

Appendix B: Suggested Torque

Limits for Standard Hardware ............ 3

Hardware Identification ............................ 3

Standard Head Markings ........................................ 3

Hex Bolts ................................................................ 3

Other Bolts ............................................................. 3

Hex Nuts................................................................. 4

Hex Lock Nuts (stover) ........................................... 4

Other Nuts .............................................................. 4

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

Suggested Torque Values (critical hardware) ......... 6

Appendix C: Brake Lining Handling

Precautions......................................... 7

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B2-48 With Stake Side Dump Bed Option

SC1-00 Stock Chaser

E4-55 Sit Down Tow Tractor

C4-25 Sit Down Tow Tractor

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Table of Contents

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

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

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

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

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

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

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

Vehicles shown with optional equipment

Introduction

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INTRODUCTION

ABOUT THIS MANUAL

RESPONSIBILITIES

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

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

Included in this manual are:

• Vehicle Description

• Safety Rules and Guidelines

• Operational Information

• Operator Responsibilities

• Owner Responsibilities

• Control Operation and Location Information

• Maintenance and Troubleshooting Information

• Standard Parts List

Of the Owner...

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

Of the Operator...

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

Of the Service Personnel...

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

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

Each Taylor-Dunn® manual references the applicable models and serial numbers on the front cover.

Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

WHO SHOULD READ THIS MANUAL

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

Of the Passengers ...

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

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

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INTRODUCTION

HOW TO USE THIS MANUAL

This manual is organized into five main sections:

INTRODUCTION

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

Safety Rules and Operating Instructions

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

Maintenance Service and Repair

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

Electrical and Charger Troubleshooting

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

Illustrated Parts

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

Conventions

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

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

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

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

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

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

A box with the word “CAUTION” and the symbol above denotes a caution and is used to inform the reader that property

damage may occur. Be sure to exercise special care and follow any instructions contained with in a caution.

Note: Alerts the reader to additional

information about a subject.

Model B 2-48 equipped with the Dump Bed option

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INTRODUCTION

HOW TO IDENTIFY YOUR VEHICLE

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

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

This vehicle is not designed to be driven on public roads or highways. It is available in maximum designed speeds ranging from 4 to 10 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow at more than 5 mph.

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

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

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

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INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

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

• Examine the contents of all packages and

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

• Make sure everything listed on the packing

slip is there.

• Check that all wire connections, battery

cables, and other electrical connections are secure.

• Check battery cells to be sure they are filled.

• Check the tire pressure, tightness of lug nuts,

and for any signs of damage.

Check the operation of each of the following controls:

• Accelerator

• Brake

• Parking Brake

• Key-Switch

• Forward/Reverse Switch

What To Do If a Problem is Found

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

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

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

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

• Reverse Beeper (if equipped)

• Front Headlight Switch

• Steering Wheel

• Horn

Model B 2-10 Ambulance

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TAYLOR -DUNN

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TABLE OF CONTENTS

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

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

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

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

2 - Start Switch ..................................................... 4

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

1 - Horn Switch ..................................................... 4

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

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

5 - Headlight Switch (optional) ............................ 4

2 - Battery Status Indicator, Digital Bargraph ..... 5

1 - Hour Meter (optional) ..................................... 5

2 - Battery Status Indicator, Analog (optional) .... 5

Accelerator / Brake Treadle, SC 159 ................... 6

Accelerator / Brake Treadle, AN 171 ................... 6

Steering, SC 159 ................................................... 6

Steering, AN 171 .................................................. 6

Walk-along Handle, AN 171 ................................ 6

Foot Interlock Switch, SC 159 (optional) ............ 7

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

Parking brake ........................................................ 7

Vehicle Operational Guidelines..........8

Safety Guidelines .................................................. 8

Starting: ................................................................. 8

While driving: ....................................................... 8

Loading and Unloading ........................................ 8

Towing Loads: ...................................................... 8

Parking .................................................................. 9

Towing This Vehicle ............................................. 9

Charging your vehicle........................10

New Battery Break in ........................................... 10

Signet® Charger Operation .................................. 10

Lestronic II® Charger Operation ......................... 10

Industrial Charger Operation ................................ 10

Charging Time ...................................................... 11

Storing and Returning to Service ......11

Storing Your Vehicle ............................................. 11

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

Periodic Maintenance Checklist.........12

Daily Visual inspection: ........................................ 13

Maintenance Guidelines for

Severe Duty Applications...............13

Safety Rules and

Operating Instructions

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SAFETY RULES AND OPERATING INSTRUCTIONS

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STANDARD SPECIFICATIONS*

ITEM MODEL SPECIFICATION

Occupancy Driver only

Dimensions SC 159 213L x 78W x 119H Centimeters (84L x 31 x 47H Inches)

Turning Radius SC 159 160 Centimeters (63 Inches)

Dry Weight SC 159 262 kg (578 lbs) Without Batteries AN 171 323 kg (714 lbs)

Min/Max Battery 105 kg to 195 kg (232 lbs to 432 lbs) Weights

Maximum Load 453 kg (1,000 lbs) Deck dimensions 74.9W x 121.9L Centimeters (29.5W x 48 L Inches)

Electrical System Four 217 Amp Hour, 6 Volt, Lead Acid Batteries,

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid Differential.

Motor, DC SC 159 3.35 kW, (4.5 Horse Power) Intermittant duty Series Wound AN 171 4.99 kW, (6.7 Horse Power) Intermittant duty

Brakes Drive Shaft Brake Through Differential,

Steering SC 159 Clover Leaf Steering Wheel

Tires SC 159 4.80 x 8 Load Range B

AN 171 267l x 78W x 126H Centimeters (105L x 31 x 49.5H Inches)

AN 171 188 Centimeters (74 Inches)

Solid State Speed Control, 275 Amp

Automaitc Mechanical Park Brake

AN 171 Tiller

AN 171 5.70 x 8 Load Range B

Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Key Switch, Horn Button, Forward/Reverse Switch

Charger 25 Amp, Built-In, Automatic

* - Specifications subject to change without notice

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).

Safety Rules

Diamond Plate

Page 17

SAFETY RULES AND OPERATING INSTRUCTIONS

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SAFETY RULES AND GUIDELINES

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

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

These vehicles are not designed to be driven on public roads or highways. They are available in maximum designed speeds ranging from 4 to 10 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/ or loss of control. Do not exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

Refer to Vehicle Operational Guidelines, Safety

Guidelines section for important safety information

regarding operating this vehicle.

DRIVER TRAINING PROGRAM

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

The Operator Training program shall include the following:

• Operation of this vehicle under circumstances

normally associated with your particular environment.

• Emphasis on the safety of cargo and personnel.

• All safety rules contained within this manual.

• Proper operation of all vehicle controls.

• A vehicle operation and driving test.

Driver Qualifications.

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

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

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

Before working on a vehicle:

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

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

3. Set the park brake.

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

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

• Demonstrate a working knowledge of each control.

• Understand all safety rules and guidelines as

presented in this manual.

• Know how to properly load and unload cargo.

• Know how to properly park this vehicle.

• Recognize an improperly maintained vehicle.

• Demonstrate ability to handle this vehicle in all

conditions.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 4

VEHICLE CONTROLS

1 - Horn Switch

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

2 - Start Switch

The start-switch turns on the vehicle control system. Rotate the switch clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off.

The switch should be in the “OFF” position whenever the operator leaves the vehicle.

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

3 - Forward-Off-Reverse Switch

The forward-off-reverse switch determines the direction of travel of the vehicle. Push the top of the switch to engage the forward direction. Push the bottom of the switch to engage the reverse direction.

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

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

Accessory Switch (Optional)

Push switch forward to turn on the accessory. Pull the switch back to turn off the accessory. The accessory can be turned on with the key switch in the “OFF” position.

The actual function of this switch depends on what accessories are installed on the vehicle.

5 - Headlight Switch (optional)

Push switch forward to turn the lights on. Pull the switch back to turn the lights off.

Safety Rules

Page 19

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 5

1 - Hour Meter (optional)

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.

2 - Battery Status Indicator, Analog (optional)

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.

2 - 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. The BSI will reset to fully charged only after a complete charge cycle is completed. A complete charge cycle is defined as battery voltage exceeding 2.35 volts per cell for a minimum of 6 minutes.

Safety Rules

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SAFETY RULES AND OPERATING INSTRUCTIONS

Page 6

Steering, SC 159

The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counterclockwise.

Steering, AN 171

The AN 171 uses a tiller for steering.

While sitting:

To turn right, move the tiller to the right. To turn left, move the tiller to the left.

While standing:

While holding the grab rail with both hands with the tiller between your legs, lean to the right to turn right and lean to the left to turn left.

Accelerator / Brake Treadle, SC 159

The accelerator and brake are operated by the treadle on the right side of the floorboard to be operated by the operators right foot..

Press the front of the treadle down to increase speed, release the treadle to slow down.

Press the rear of the treadle to apply the brake.

Accelerator / Brake Treadle, AN 171

The treadle for the AN 171 functions the same as the SC 159 with the exception that it is operated by both feet.

Walk-along Handle, AN 171

The walkalon handle allow operation of the vehicle while standing on the right side of the vehicle. Push forward onthe handle to start and pull back to stop.

The walk-along feature should only be used in the forward direction and the vehicle should be in a track to control steering. Failure to observe these guidlines may result in severe bodily injury and/or property damage.

Safety Rules

Page 21

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 7

Foot Interlock Switch, SC 159 (optional)

A switch or pedal located under the driver's left foot disables the power to the vehicle when it is released. The switch or pedal must be depressed for the vehicle to operate. Whenever the driver leaves the vehicle, the driver should turn the key-switch off, place the forwardoff-reverse switch in the center “OFF” position, and set the park brake.

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.

Parking brake

The parking brake functions the same on boththe SC 159 and AN 171. Depress the rear of the treadle to set the brake.

Safety Rules

Page 22

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 8

VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

• Only qualified and trained operators may drive this

vehicle.

• Drive only on level surfaces or on surfaces having

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

• Drive slowly when making a turn, especially if the

ground is wet or when driving on an incline.

• This vehicle may overturn easily if turned sharply or

when driven at high speeds.

• Observe all traffic regulations and speed limits.

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

vehicle while it is moving.

• Keep the vehicle under control at all times.

• Yield right of way to pedestrians, ambulances, fire

trucks, or other vehicles in emergencies.

• Do not overtake another vehicle at intersections, blind

spots, or other dangerous locations.

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

• Yield right of way to pedestrians and emergencies

vehicles.

• Stay in your driving lane under normal conditions,

maintaining a safe distance from all objects.

• Keep a clear view ahead at all times.

Starting:

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

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

2. Depress the rear of the treadle to set the parking brake.

While driving:

• Slow down and sound the horn to warn pedestrians

or when approaching a corner or other intersection.

• No reckless driving.

• Do not drive this vehicle on steep inclines or where

prohibited.

• Immediately report any accidents or vehicle problems

to a supervisor.

Loading and Unloading

• Do not carry more than the maximum number of

passengers allowed for this vehicle.

• Do not exceed the cargo load capacity.

• Do not load cargo that can fall off.

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

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

Towing Loads:

• Do not exceed the towing capacity of the tractor.

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

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

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

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

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

• Allow for longer stopping distances when towing heavy loads.

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

3. Rotate the ON-OFF switch to the “ON” position.

4. Place the forward-off-reverse switch in the desired direction of travel.

7. Slowly depress the front of the treadle.

Safety Rules

Page 23

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 9

Parking

Before leaving the vehicle:

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

position.

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

In addition:

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

to the curb, or block the wheels.

• Do not block fire aisles, emergency equipment,

stairways, or exits.

Towing This Vehicle

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

NOTE: If the vehicle is equipped with an automatic

electric brake, do not tow the vehicle with the drive wheels on the ground.

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

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

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

Safety Rules

Page 24

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 10

CHARGING YOUR VEHICLE

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

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

New Battery Break in

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

Signet® Charger Operation

The Signet® HB-600 and HB-1000 chargers use a semi-automatic charging system. The charger will turn itself ON when the AC power cord is connected to the AC power source and turn itself OFF when the batteries are fully charged. Refer to the data plate on the charger for the voltage and type power required for the charger.

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

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

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

Charger Troubleshooting

section for information on error codes.

Typical Signet® Built In

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.

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..

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

Cycle complete ON ON ON

Safety Rules

LED1 LED2 LED3

Typical Lestronic II® Built In Charger

Industrial Charger Operation

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

Page 25

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 11

Charging Time

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

• Capacity of the batteries, higher capacity requires

longer charge time.

• Output of the charger, higher output requires less

charge time.

• Depth of discharge, the deeper a battery is

discharged, the longer it takes to charge.

• Temperature, low temperatures require longer charge

time.

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

To obtain the maximum battery life:

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

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:

Returning to Service

Storage

Temperature

(F)

Charging Interval

(months)

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.

Over 60 1

Between 40 and 60 2

Below 40 6

• 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.

Safety Rules

Page 26

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 12

PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

2,3

Check Condition of Tires and

Tire Pressure

Check All Lights, Horns,

Beepers and Warning Devises

Weekly

(20hrs)

Monthly

(80hrs)

Quaterly (250hrs)

Check and Fill Batteries l

Check Brake System l

Check Steering System l

Check for Fluid Leaks l

Lubricate Vehicle l

Clean and Tighten All Wire Connections

Wash and Service Batteries l

Semi -

Annual

(500hrs)

Annualy

(1000hrs)

Check Park Brake l

Check Motor Brushes and

Blow Out Motor

Check Front Wheel Bearings l

Check Rear Axle Oil l

Change Rear Axle Oil l

Check and Tighten all Nuts and

Bolts

Clean and Repack Front Wheel

Bearings

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

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

Safety Rules

Page 27

SAFETY RULES AND OPERATING INSTRUCTIONS

Page 13

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 28

TAYLOR -DUNN

Page 29

Table of Contents

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

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

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

Model C 4-25 Tow Tractor

Illustrations of other popular Taylor-Dunn vehicles

Model E 4-55 Tow Tractor

General Maintenance

Page 30

Maintenance, Service and Repair

Maintenance Guidelines

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

Before starting any repairs:

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

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

3. Set the park brake.

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

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

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

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

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

performance checks in an authorized area where safe clearance exists.

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

Operational Information.”

• Ventilate the work area properly.

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

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

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

conformance with Taylor-Dunn’s® recommended procedures.

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

parts.

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

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

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

Page 2

Page 31

Maintenance, Service and Repair

Troubleshooting Guide

Symptom Probable Cause

Steering Pulls in One Direction Front End Out of Alignment , Frame or Fork bent

Dry Lube Points in Steering Linkage

Damaged Fork Bearings

Hard Steering

Damaged Steering Chains

Low Tire Pressure

Loose Steering Chains

Excessive Steering Play

Lack of Power or Slow Operation

Abnormal Noise

Oil Leak in Rear Bearing Area

Brake Pedal Low

Loose Steering Linkage

Worn Shaft Gears

Brakes or Parking Brakes Dragging

Batteries Discharged or Defective

Worn Drive Gears

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 Worn (1/16" Wear Limit)

Brakes Out of Adjustment

Braking Power Low

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

symptom.

Brake Worn (1/16" Wear Limit)

Brake Pads Contaminated with Fluid

Brake Pedal Linkage Binding

Brakes Out of Adjustment

Page 3

Page 32

Maintenance, Service and Repair

Lubrication Chart

Page 4

# Description Locations Lubricant Type

1 Treadle Bushings 3 General Purpose Grease

2 Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease

3 Fork Spindle Bearings 1 General Purpose Grease

4 Steering Shaft 2 General Purpose Grease

5 Steering Shaft Gears 1 General Purpose Grease

6 Steering Chain 2 General Purpose Grease

7 Drive Fill Plug 1 SAE 140 API GL-5 Hypoid Gear Oil

8 Drive Level Plug 1 -

9 Drive Drain Plug 1 -

10 Chain Case Fill Plug 1 SAE 140 API GL-5 Hypoid Gear Oil

11 Chain Case Drain Plug 1 -

12 Control Linkage Collars 2 General Purpose Grease

13 Throttle Slip Joint 1 General Purpose Grease

Page 33

TABLE OF CONTENTS

Inspect the Front Wheel Bearings .....2

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

Front Axle Removal and Installation ..4

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

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

Replace Front Wheel Bearings..........5

Front Axle Service

Page 34

Maintenance, Service, and Repair

Page 2

INSPECT THE 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 front wheels to prevent vehicle movement.

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

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

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 front wheels to prevent vehicle movement.

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

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

7. 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.

8. Spin the front wheel(s) by hand. The wheel should stop spinning in no more than 2-revolutions. A wheel that continues to spin freely is an indication of a loose wheel bearing.

NOTE: Refer to the Adjust Front Wheel Bearings

section for information regarding the adjustment of the wheel bearings.

9. Spin the wheel(s) and listen for any grinding noise. Any 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.

10.Lower the vehicle.

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

6. Raise the front wheel(s) off of the ground and support with jack stands.

7. Tighten the front axle until the wheel(s) do not spin freely. To test, spin the front wheel by hand. The wheel should stop spinning in no more than 2revolutions. If the wheel continues to spin, tighten the axle nut and repeat the test.

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.

12.Remove the blocks from behind the wheels.

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

Front Axle

Page 35

Maintenance, Service, and Repair

Page 3

FRONT AXLE REMOV AL 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 front wheels to prevent vehicle movement.

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

Installation

1. Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub.

2. Assemble the bearing spacers into the front wheel hub and place the front wheel(s) into the fork.

3. Insert the axle into the front fork.

4. Install the axle nut(s). Refer to Adjust Front

Wheel Bearings section for information

regarding tightening the front axle.

NOTE: If your vehicle is equipped with two axle nuts,

the nuts should be tightened equally so that the same number of axle threads are visible on both ends.

5. Lower the vehicle.

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

7. Remove the blocks from behind the wheels.

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

6. Remove the front axle nut.

7. Slowly raise the front of the vehicle until the axle can slide freely out of the fork. The front wheel(s) should still be resting on the ground.

8. Remove the front axle from the fork and support the vehicle with jack stands.

Fork (single)

Axle

Spacer

Seal

Bearing

Race

Typical fork illustrated. Your fork may be different.

Front Axle

Page 36

Maintenance, Service, and Repair

Page 4

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 front wheels to prevent vehicle movement.

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

6. Remove the front axle and wheel(s). Refer to

Front Axle Removal and Installation section

for information regarding removing the axle.

7. Remove the spacers, seals and bearings from the hub

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

9. Drive the races out from the hub.

10.Press new races into the hub.

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

a. Pack bearings with grease. b. Refer to Front Axle Removal and

Installation section for information regarding

installing the axle.

12.Lower the vehicle.

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

14.Remove the blocks from behind the wheels.

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

Front Axle

Page 37

TABLE OF CONTENTS

Service

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

Center the Steering Wheel .................................... 2

Inspect the Steering Components ......4

Steering Wheel and Bushings ............................... 4

Steering Chain ....................................................... 4

Pillow Blocks ........................................................ 5

Fork Bearings....................................5

Adjust the Steering Shaft ...................6

Replace the Steering Wheel ..............6

Replace the Front Fork......................7

Steering Component

Page 38

Maintenance, Service, and Repair

FRONT END ALIGNMENT

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

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

3. Set the park brake.

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

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

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

8. Center the steering wheel. Refer to section Center

the Steering Wheel for information regarding

centering the steering wheel.

9. Untie the front fork.

10. Adjust the steering shaft. Refer to section Adjust

the Steering Shaft for information regarding

adjusting the steering shaft.

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

12. Remove the blocks from behind the wheels.

13. Test drive the vehicle.

Center 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.

6. Position the front fork so that it is in the straight ahead position and tie it off so that it cannot rotate.

7. The flat top of the half gear on the steering shaft should be level. If it is not level then perform the following:

A)Raise the front wheel approximately 1 inch off

of the ground. B)Remove the fork spindle bearing cap. C)Loosen the fork nut until the steering shaft can

be rotated without rotating the fork. D)Position the flat top of the half gear so that it is

level. E)With the front wheel pointing straight ahead,

lower the front end and tighten the fork spindle

nut. Refer to section Replace the Front Fork

for information regarding tightening the spindle

nut.

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

6. Position the front fork in the straight ahead position and tie it off so that it cannot rotate.

7. Remove the steering chain access plate.

8. Remove the safety wire from the turn buckles and discard.

9. Loosen the turn buckles just enough to remove the chain from the lower sprocket

10. Center the steering wheel as shown in the illustration and tie it off so that it cannot rotate.

Steering Page 2

Front fork and shaft shown outside of the vehicle

11. Position the chains so that the turnbuckles are an equivalent distance from the steering wheel sprocket. See illustration to the right.

Page 39

Maintenance, Service, and Repair

12. Install the chain on the lower sprocket.

13. Tighten the turnbuckles to remove all play from the steering chain.

14. Install new safety wire and tie off as shown in the illustration.

15. Untie the front fork.

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

17. Remove the blocks from behind the wheels.

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

Step #10

Step #11

Step #14

Steering

Page 3

Page 40

Maintenance, Service, and Repair

INSPECT THE STEERING COMPONENTS

Steering Wheel and Bushings

After the steering wheel has been removed, thoroughly

clean the steering wheel shaft and bushings.

Measure the diameter of the steering shaft.

• If the shaft diameter is not between 0.745” and

0.0750” then the steering wheel should be replaced.

Inspect the surface of the shaft for unusual signs of

wear.

• The surface should be smooth with no pits or

grooves. If any unusual signs of wear are present, then the steering wheel should be replaced.

Inspect the slot for the retaining ring.

• The retaining ring slot corners should be 90

degrees with a small radius. If the corners are excessively rounded or the sides are tapered, then the steering wheel should be replaced.

Insert the steering shaft back into the collar and check

for lateral play as shown to the right.

Steering shaft and sprocket

• If the lateral play exceeds 0.010 inches then the

bushings should be replaced.

Steering Chain

The steering chains are very durable and, properly lubricated, will last the lifetime of the vehicle. Inspect the chains for corrosion. Any sign of corrosion is evidence of an improperly lubricated chain and the chain

should be replaced. Inspect each link in the chains for binding. If any binding is found, remove the chain and soak it in 30 wt. motor oil

overnight and reinspect the links. Replace the chain if the binding is not corrected.

Steering Page 4

Page 41

Maintenance, Service, and Repair

Pillow Blocks

Front pillow block

NOTE: The two pillow blocks will wear at the same

rate. If one is worn out, then both blocks should be replaced as a set.

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

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

3. Set the park brake.

FORK 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 front wheels to prevent vehicle movement.

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

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

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

6. Tie off the front fork so that it cannot turn.

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

8. There should not be any discernible play between the steering shaft and the pillow blocks. Any play indicates that the pillow block is worn out and should be replaced.

9. Untie the front fork.

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

11. Remove the blocks from behind the wheels.

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

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

7. Inspect for lateral play by attempting to move the fork to the left and right (not rotating), There should be no noticeable play.

8. If there is any play in the fork bearings, refer to section Replace the Front Fork for information regarding adjusting the fork bearings.

9. Lower the front end to the ground.

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

11. Remove the blocks from behind the wheels.

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

Steering

Page 5

Page 42

Maintenance, Service, and Repair

ADJUST THE STEERING SHAFT

The steering shaft is adjustable by means of a collar at the rear of the shaft. This adjustment controls the gear lash of the half gears on the shaft and front fork.

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. Loosen the set screw on the collar.

7. Push the steering shaft half gear up against the half gear on the fork.

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. Cut the safety wire from the turn buckles and discard.

7. Remove the retaining clip and washer(s) from the steering wheel shaft.

8. While lightly holding the two gears together, push the collar up against the rear pillow block and tighten the set screw.

1 - Rear pillow block 2-Adjustable collar

9. Rotate the steering wheel from left to right. Any roughness is an indication of being too tight. Repeat the procedure and hold less tension on the gears while setting the collar.

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

11. Remove the blocks from behind the wheels.

12 Release the parking brake and test drive the

vehicle.

Clip partially removed

NOTE: The retaining clip goes completely around the

shaft two times. Locate the end of the clip and lift the end of the clip out of the groove with a small screwdriver. The clip can then easily be removed by rotating it around the shaft. See the illustration to the right.

8. Loosen the turn buckles so that the steering chain can be lifted off of the steering wheel sprocket.

9. Remove the steering wheel.

10. Install the steering wheel in reverse order.

NOTE: Lightly lubricate the steering wheel shaft.

11. Align the steering. Refer to section Front End

Alignment for information regarding aligning the

steering.

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 6

Page 43

Maintenance, Service, and Repair

REPLACE THE FRONT FORK

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.

9. Thoroughly clean all parts and install in reverse order.

• Tighten the fork spindle nut to remove all play

in the fork bearings and then an additional 1/4 turn.

• Refer to section Front Axle Removal and

Installation in Front Axle Service for

information regarding installing the front axle.

• If the fork was replaced with a new fork the front

end should be realigned. Refer to section Front

End Alignment for information regarding

aligning the front end.

10. Lower the wheels to the ground.

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

12. Remove the blocks from behind the wheels.

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

Bearing cap

Spindle nut

Washer

Bearing

Race

Single fork

Fork Collar (in frame)

Dual fork (optional)

Race

Bearing

Grease seal

6. Remove the front axle. Refer to section Front

Axle Removal and Installation in Front Axle Service for information regarding removing the

front axle.

7. Remove the fork bearing cap.

8. While supporting the front fork so that it cannot fall out of the vehicle, remove the fork spindle nut and remove the fork from the vehicle.

Steering

Page 7

Page 44

TAYLOR -DUNN

Page 45

TABLE OF CONTENTS

Brake Service

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

Adjust the Service Brake ...................2

Adjust the Brake Linkages ................................... 3

Replace the Brake Lining ..................4

Replace Brake Drum ........................6

Replacing the Treadle Linkage ..........7

Page 46

Maintenance, Service, and Repair

Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.

INSPECT THE SERVICE BRAKE

The band parking brake is located on the front of the drive chain case housing, it must be removed to accurately measure the lining thickness. Refer to

Replace the Parking Brake Lining for information

on removing the band park brake.

1. Measure the thickness of the brake lining at its thinnest point. If it is 1/16-inch or less, then the brake band must be replaced.

2. Measure the run out of the brake drum. If it is more than 0.010-inches then it must be machined or replaced. Do not machine the brake drum beyond its service limits.

ADJUST THE SERVICE 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. Raise the drive wheels off of the ground.

7. Loosen the brake bolt jam nut.

8. Depress the treadle until the throttle linkage is

0.125” away from the accelerator module slip joint.

3. Measure the diameter of the brake drum. If it is less than 5.85inches then the brake drum must be replaced.

4. Inspect all brake cables and linkages for any signs of damage or wear.

5. Inspect the park brake ratchet for any signs of damage.

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

7. Remove blocks from behind the wheels.

8. Test drive the vehicle.

Brakes Page 2

9. While rotating the brake drum, tighten the brake bolt until the brake just starts to drag.

10. Tighten the jam nut.

11. Reconnect the main positive and negative at the batteries, lower the wheels to the ground, remove the blocks from the wheels, and test drive.

Page 47

Maintenance, Service, and Repair

Adjust the Brake Linkages

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. Loosen the brake linkage jam nut.

7. Remove the clevis pin from the brake arm.

8. Depress the treadle until the front of the treadle is level with the floorboard.

9. Hold the brake arm up against the front of the chain case housing.

10. Adjust the brake linkage so that the clevis pin can be inserted into the brake arm while it is against the chain case housing.

NOTE: When adjusted correctly, the brake arm will

contact the chain case when the front of the treadle is level with the floorboard.

11.Install a new cotter pin into the clevis pin and tighten the brake linkage jam nut.

Step #8 - Level with floorboard

12.Reconnect the main positive and negative at the batteries, lower the wheels to the ground, remove the blocks from the wheels, and test drive.

Brake arm against housing

Brakes

Page 3

Page 48

Maintenance, Service, and Repair

REPLACE THE BRAKE LINING

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.

The brake band bolt, spring, lock nut, jam nut, clevis pin, and cotter pin must be replaced with new parts whenever the brake band is replaced. Failure to replace these components could cause the parking brake to fail resulting in severe bodily injury and/or property damage.

NOTE: Some vehicle configurations do not allow

clearance to remove the brake band while the drive is in the vehicle. In this case the drive must be removed to replace the brake band. Refer to Transmission Section for information on removing the drive from the vehicle.

NOTE: Refer to the illustration on the previous page

for locations of the components.

NOTE: On most vehicle configurations, the brake

drum does not have to be removed for this procedure. If the brake drum must be removed, refer to ReplaceThe Brake

Drum for this procedure.

6. Release the park brake.

7. Disconnect the parking brake cable and return spring from the brake arm.

8. Loosen the bolt(s) (1) on the brake band alignment bracket(s) (9) and pivot them out of the way.

9. Remove the bolts (5) holding the brake band assembly to the front of the chain housing (16) and remove the brake band assembly from the drive.

Brakes Page 4

Page 49

Maintenance, Service, and Repair

10. Remove the brake band bolt (4).

11. Remove the clevis pin (11) from the brake band anchor and remove the brake band (3) from the assembly.

12. Inspect the brake arm pivot bolt for signs of wear. If any signs of wear are seen then the pivot bolt must be replaced.

13. Tighten the brake band pivot bolt and then back off just enough so that the brake arm (15) pivots freely.

14. Install the new brake band using new hardware.

15. Install the brake band assembly onto the drive. Tighten the mounting bolts (5) just enough to keep the mounting bracket (13) against the chain case (16) but still allowing the bracket to move.

16. Tighten the brake band bolt (4) to 50 ft-lbs.

17. Tighten the brake band bracket mounting bolts (5).

18. Position the brake band alignment bracket(s) (9) so that the inner arm (14) is 0.100” away from the brake drum (8). Make certain that the alignment bracket does not come into contact with the brake drum.

19. Adjust the alignment bracket adjusting bolt(s) (10) to 0.050-0.100" away from the brake band and tighten the jam nuts (12).

20. Connect the brake cable or linkage to the brake arm and adjust the cable so that the brake arm is 1/4” away from the chain case when the parking brake is off.

21. Loosen the brake band adjusting bolt (4) and adjust so that there is no brake drag when the brake is off. It may be necessary to readjust the alignment bracket adjusting bolt(s) (10) for optimum brake alignment and operation.

22. Tighten the brake band bolt jam nut (7).

23. Set the park brake.

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

25. Remove the blocks from behind the wheels.

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

Brakes

Page 5

Page 50

Maintenance, Service, and Repair

REPLACE BRAKE DRUM

Inspect the pinion seal for any signs of misalignment. A misaligned pinion seal could cause premature failure of the pinion seal and an oil leak. This could result in property damage and/or severe bodily injury.

NOTE: Some vehicle configurations do not allow

clearance to remove the brake drum while the drive is in the vehicle. In this case the drive must be removed to replace the brake drum. Refer to Transmission Section for information on removing the drive from the vehicle.

6. Release the park brake.

7. Loosen the bolt(s) on the brake band alignment bracket(s) and pivot them out of the way.

8. Remove the pinion nut and slide the brake drum off of the pinion shaft.

9. Remove the pinion seal.

10.Lightly grease the new pinion seal and install using the pinion seal installation tool (see appendix C).

11. Install the brake drum using a new pinion nut. Torque the pinion nut to 170 ft-lbs.

12.Position the brake band alignment bracket(s) so that the inner arm is 0.100” away from the brake drum. Make certain that the alignment bracket does not come into contact with the brake drum.

13.Adjust the alignment bracket adjusting bolt(s) to

0.050-0.100" away from the brake band and tighten the jam nuts.

14.Adjust the park brake. Refer to Adjust the

BandBrake section for information regarding

adjusting the park brake.

15.Set the park brake.

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

17.Remove the blocks from behind the wheels.

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

Brakes Page 6

Page 51

Maintenance, Service, and Repair

REPLACING THE TREADLE LINKAGE

Due to variations in the length of the frame, the treadle linkage must be individually fitted to each vehicle. The hole for the treadle clevis pin is pre-punched. The hole for the bell crank must be match drilled.

6. Remove the treadle linkage

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

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

3. Set the park brake.

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

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

Accelerator Module Arm

Bell Crank

Treadle (depressed to floorboard)

Treadle Linkage

Match Drill Hole

7. Inspect the holes for the clevis pins in the treadle and bell crank. If the holes are worn (elongated), then the treadle and/or bell crank should be repaired or replaced before continuing.

8. Disconnect the brake linkage from the brake arm.

9. Position the treadle so that the front of the treadle is level with the floorboard and lock it in place so that it cannot move.

Treadle shown depressed to the floorboard

Brakes

Page 7

Page 52

TAYLOR -DUNN

Page 53

TABLE OF CONTENTS

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

Throttle Linkage

Page 54

Maintenance, Service, and Repair

Page 2

THROTTLE LINKAGE ADJUSTMENTS

The throttle linkage is coupled with the brake linkage. There are no adjustments that are specific to the throttle linkage. Refer to the Brake Section for linkage adjustments or replacement of the treadle linkage.

Accelerator Module Arm

Bell Crank

Treadle Linkage

Throttle Linkage

Page 55

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 56

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 57

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 58

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 59

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 60

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 61

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 62

TAYLOR -DUNN

Page 63

Transmission

TABLE OF CONTENTS

Adjust the Drive Chain..................................2

Check the Oil Level .......................................4

Change the Oil ..............................................5

Drive Motor....................................................6

Remove.....................................................................6

Install ........................................................................ 6

Rear Axle .......................................................7

Remove and Install ...................................................7

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

Transmission Assembly ...............................9

Remove and Install ...................................................9

Chain Case ....................................................10

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

Assemble .................................................................. 12

Differential Assembly (3rd Member).............14

Disassemble .............................................................14

Assemble .................................................................. 16

Re-shimming the Pinion Housing................18

Exploded View ..............................................20

Page 64

Transmission

ADJUST THE DRIVE CHAIN

NOTE: A small amount of oil may come out when the drive motor mounting

bolts are loosened.

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 small oil drain pan under the chain case.

7. Loosen but do not remove the three drive motor mounting nuts.

8. Loosen the adjusting screw jam nut.

9. Raise the drive wheels off of the ground.

10. Tie the vehicle in place so that it cannot move.

Tie the vehicle to an immovable object to prevent the vehicle from moving in forward or reverse. Failure to securely tie the vehicle may result in unexpected vehicle movement resulting in severe bodily injury or property damage.

Transmission Page 2

Page 65

Transmission

11. Reconnect the batteries.

Rotating parts, keep hands and loose clothing clear of all moving parts. Failure to keep clear of moving parts may result in severe bodily injury and/or property damage.

12. Close all safety interlock switches, turn the key On, place the forward-off-reverse switch in forward and fully depress the accelerator pedal.

13. Tighten or loosen the adjustment screw to obtain the minimum noise level.

NOTE: If there is less than 1/16” of threads

left on the adjustment screw then the drive chain has stretched beyond service limits and should be replaced. Refer to section Chain Case for information regarding replacing the drive chain.

14. Release the accelerator pedal, place the forward-off-reverse switch in off, turn the key off and disconnect the batteries.

15. Untie the vehicle.

16. Tighten the adjustment screw jam nut and motor mounting nuts.

17. Wipe off any oil that may have come from behind the motor.

18. Lower the drive wheels to the ground.

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

Transmission Page 3

Page 66

Transmission

CHECK THE OIL LEVEL

NOTE: The oil level in the chain case is maintained by the transmission.

Oil is pumped from the 3rd member into the chain case housing. It is not necessary to check the oil level in the chain case.

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

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

3. Set the park brake.

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

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

6. Park the vehicle on a level surface.

7. Place a small oil drain pan under the drive housing.

8. Remove the drive housing level plug.

9. A small amount of oil should come out. This indicates the correct oil level.

NOTE: If a large amount of oil comes out, then

let it drain to the proper level and replace the level plug.

If no oil comes out, then fill the drive to the proper level and replace the level plug.

Typical location of oil plugs. The actual location of the level plug will vary depending on your vehicles configuration.

Transmission Page 4

Page 67

CHANGE THE OIL

Wear protective gloves when working with petroleum lubricants. Repeated contact with petroleum lubricants can result in skin disorders.

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 large drain pan under the chain housing.

Transmission

7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

8. Place the drain pan under the drive housing.

9. Remove the drive housing drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

10. Remove the chain case fill plug and add 1-pint of oil.

11. Remove the drive housing fill plug and add 2-quarts of oil.

NOTE: Refer to the Lubrication Chart for

information regarding the type of oil.

Typical location of oil plugs. The actual location of the plugs will vary depending on your vehicles configuration.

12. Replace all fill plugs.

NOTE: Dispose of waste oil in accordance with your local regulations.

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

Transmission Page 5

Page 68

Transmission

DRIVE MOTOR

Remove

NOTE: In most cases it is not necessary to disassemble the chain case to

remove the motor. If you find it necessary to disassemble the chain case, refer to Transmission section for information regarding disassembly of the chain case.

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

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

3. Set the park brake.

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

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

Install

6. Remove the four motor wires.

7. Loosen the drive chain adjusting screw.

8. Remove the hardware holding the motor to the chain case backing plate.

9. Lift the rear of the motor and rotate the motor so that the motor mounting plate clears the two threaded studs on the chain case backing plate and remove the motor from the drive.

Do not allow the wheels to rotate after the motor has been removed. Allowing the wheels to rotate may result in the drive chain getting bound up with the drive sprocket, locking up the transmission. Should this happen, the chain may have to be disassembled to free up the chain.

1. Tie the chain up in position with mechanics wire as shown.

2. Slip the motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove wire(s) holding the chain.

3. Install the motor mounting hardware but do not tighten until the chain adjustment is complete.

4. Adjust the drive chain. Refer to Adjust the Drive

Chain for information regarding adjusting the drive

chain.

5. Connect the motor wires.

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

Transmission Page 6

Page 69

REAR AXLE

Remove and Install

6. Raise the drive wheel off of the ground.

Transmission

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.

7. Remove the wheel assembly.

8. Place a small oil drain pan under the end of the axle housing.

9. Remove the four axle retaining bolts.

10. Using a slide hammer, remove the axle from the axle housing.

11. Remove the bearing gasket and axle seal from the housing.

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

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

Transmission Page 7

Page 70

Transmission

REPLACE THE AXLE BEARING

NOTE: The axle must be removed from the vehicle to replace the axle

bearing. Refer to section Rear Axle: Remove and Install for

information regarding removing the axle. NOTE: A 10-ton press is required to replace the axle bearing. NOTE: The axle bearing will be damaged when it is removed.

The axle bearing retainer will be damaged when it is removed. Do not reuse the axle bearing retainer. Reinstalling the original bearing retainer may result in the axle falling out of the transmission resulting in severe bodily injury or property damage.

Old axle bearings may explode while being removed. Place a cage around the axle bearing that will contain all debris if the bearing explodes. Failure to place a cage around the axle bearing could result in severe bodily injury or property damage.

1. Place the axle in a press and remove the bearing and bearing retainer.

2. Lightly lubricate the axle shaft.

3. Install a new bearing and bearing retainer and press into place.

NOTE: Some axle configurations have an

o-ring around the axle bearing. The

bearing should be orientated so that

the o-ring is farthest away from the axle

hub. See the illustration to the right.

Transmission Page 8

Page 71

TRANSMISSION ASSEMBLY

Remove and Install

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.

7. Disconnect the brake linkage from the brake arm.

8. Remove the treadle linkage.

Transmission

9. Remove the nuts from the four transmission mounting bolts. Do not remove the bolts at this time.

10. Place jack stands under the left and right side of the front cowling.

11. Lift the rear of the vehicle just enough to allow the removal of the mounting bolts and remove the bolts.

12. Raise the rear of the vehicle high enough to roll the transmission out from under the vehicle.

13. Lower the rear of the vehicle to the ground.

14. Install in reverse order.

15. Check brake adjustment and adjust as needed. Refer to Adjust the Brakes for information regarding adjusting the brakes.

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

Transmission Page 9

Page 72

Transmission

CHAIN CASE

NOTE: Some vehicle configurations may require that the transmission be

Disassemble

removed to disassemble the chain case. Refer to section

Transmission Assembly for information on removing the

transmission.

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

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

3. Set the park brake.

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

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

6. Place an oil drain pan under the chain case.

7. Remove the chain case drain plug and allow all of the oil to drain from the housing and then reinstall the drain plug

8. Remove the brake drum. Refer to section Brakes:

Replace the Brake Drum for information

regarding removing the brake drum.

9. Remove the nuts from the three threaded studs at the small end of the chain case housing.

Typical Chain Case

Transmission Page 10

Page 73

10. Remove the chain case housing bolts, brake assembly, and alignment brackets.

11. Remove the chain case housing from the backing plate.

12. Remove the pinion seal from the chain case housing.

13. Loosen the motor mounting bolts.

14. Loosen the chain adjuster.

15. Remove the drive chain, motor nut and sprocket and the drive sprocket.

16. If the backing plate must be removed from the 3rd member, first remove the motor from the backing plate then remove the backing plate from the 3rd member.

Transmission

Woodruf Key

Adjusting screw

3rd Member

Nut

Washer

Mounting Plate

Washer

Motor

Nut

Backing Plate

Nut

Typical Chain Case

Bolt

O-Ring

Motor Sprocket

Nut

Spacer

Drive Sprocket

Drive Chain

Bolt

Chain Case Housing

Transmission Page 11

Drain Plug

Pinion Seal

Brake Assembly

Pinion Nut

Page 74

Transmission

Assemble

1. Thoroughly clean all gasket surfaces.

2. Apply a 1/8” bead of 94-430-03 gasket sealer to the face of the 3rd member.

3. Install the backing plate to the 3rd member. Torque to 30-45 ft-lbs.

4. Install the motor to the backing plate. Do not fully tighten the mounting hardware at this time.

5. Install the motor sprocket, drive sprocket and chain. Do not adjust the chain tension at this time.

6. Apply a 1/8” bead of 94-430-03 gasket sealer to the chain case housing.

7. Install the chain case centering tool (refer to Appendix A) into the pinion seal bore in the chain case housing.

8. Install the chain case housing onto the pinion shaft and tighten the pinion nut to 75 ft-lbs.

Apply sealer around the ID of the holes

9. Install and tighten the three nuts and washers to the threaded studs and the housing bolts that are not used for the brake mounting bracket or alignment brackets.

10. Remove the centering tool and install a new pinion seal. Lightly lubricate the pinion seal lip.

11. Install the brake assembly and the brake band alignment bracket(s). Do not tighten the bolts at this time.

12. Install the brake drum. Torque to 175 ft-lbs.

Transmission Page 12

Page 75

13. Tighten the brake adjusting bolt to 25 ft-lbs.

14. Tighten the brake assembly mounting bolts.

15. Adjust the brake. Refer to section Brake Service:

Adjust the Brakes for information regarding

adjusting the brakes.

16. Adjust the drive chain. Refer to section Adjust the

Drive Chain for information regarding adjusting

the drive chain.

Transmission

Transmission Page 13

Page 76

Transmission

DIFFERENTIAL ASSEMBLY (3RD MEMBER)

Disassemble

NOTE: Bearings and races must be replaced as a set. If any one bearing

or race is worn, its mate must also be replaced. It is recommended to replace all bearings and races in the 3rd member as a set.

1. Drain the oil from the differential housing and chain case. Refer to section Change the Oil for information regarding draining the oil.

2. Remove the transmission assembly from the vehicle. Refer to Transmission Assembly:

Remove and Install for information regarding removing the transmission.

3. Remove both rear axle assemblies. Refer to section Rear Axle: Remove and Install for information regarding removing the axles.

4. Remove the chain case and backing plate from the 3rd member. Refer to section Chain Case:

Disassemble for information regarding removing the chain case.

5. Remove the nuts holding the 3rd member to the axle housing and remove the 3rd member from the housing.

6. Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened.

7. While rotating the pinion shaft, tighten the pinion nut to 100 ft-lbs.

8. Measure and record the ring and pinion gear backlash. This setting will be used during reassembly.

9. Remove the pinion housing and pinion gear from the 3rd member.

NOTE: Do not lose the spacers and shims in the pinion housing or the

pinion housing shim(s).

Transmission Page 14

Page 77

Transmission

10. If required, remove the rear tapered bearing from the pinion shaft and discard.

NOTE: Do not remove the bearing unless it requires replacement.

Removing the rear bearing will damage the bearing. Replacing this bearing will require re-shimming of the pinion shaft.

11. If required, remove the bearing races from the pinion housing.

12. Mark the differential bearing caps and 3rd member housing so that they can be reassembled in their original location. Refer to illustration at end of section.

NOTE: The caps cannot be interchanged or replaced. If the caps are lost

or damaged then the entire 3rd member assembly must be replaced.

13. Remove the differential bearing caps, bearing adjusting nuts and races.

14. Remove the differential assembly from the 3rd member.

15. Mark the ring gear and differential housing so that the ring gear can be reinstalled in the same orientation.

16. Remove the bearings from the differential housing and discard.

NOTE: Removing the bearings will damage the bearings. Do not remove

the bearings unless they require replacement.

17. Remove the ring gear from the differential housing.

18. Remove the differential shaft locking roll pin.

19. Split the 2-piece differential housing.

20. Drive the differential pinion shaft out of the housing with a brass drift punch.

21. Remove the differential gears, axle gears, and thrust washers.

Transmission Page 15

Page 78

Transmission

Assemble

NOTE: Thoroughly clean and inspect all parts

before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly.

NOTE: Depending on your vehicle config-

uration, the rear pinion pilot bearing is not required and may not be installed.

NOTE: If the ring and pinion gear set is to be

replaced then the shims for the pinion housing may have to be adjusted. Refer to section Selecting the

Pinion Housing Shim for

information on adjusting the shim.

NOTE: Most of our gear sets are non-hunting

or semi-hunting gears. With this type of gear the pinion and ring gears must be aligned correctly. There will be two teeth marked on the ring gear and one tooth marked on the pinion gear. The one tooth on the pinion gear must be installed so that it is between the two teeth on the ring gear. The gear ratios are; 2.50, 2.70, 2.75, 3.25 and 3.00.

Pinion housing

1. If the rear pinion bearing was removed, install a new bearing.

2. Install the bearing races into the pinion housing.

3. Place the pinion gear into the 3rd member.

4. Install the pinion housing onto the 3rd member.

5. Install the pinion bearing spacers, shims and front bearing.

6. Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened.

7. While rotating the pinion shaft, tighten the pinion nut to 100 ft-lbs.

8. Check the torque required to rotate the shaft. If the torque is not between 6 -10 in-lbs. then the bearings must be re-shimmed. Add or subtract shims as required until the torque is within specifications.

Transmission Page 16

Page 79

Differential Assembly

9. Reassemble the differential housing in reverse order.

10. Place the ring gear onto the differential housing matching the mark made during disassembly.

11. Install two of the ring gear bolts finger tight to align the gear.

12. Press the ring gear onto the differential housing.

13. Install the ring gear bolts and cross tighten to 65-80 ft-lbs.

14. If the differential bearings were removed, install new bearings.

15. Place races onto the differential bearings and place the differential assembly onto the 3rd member. Position the assembly so that it is just touching the pinion gear.

16. Install the bearing adjusting nuts making sure that the nuts are not cross threaded. Position the nuts so they are in contact with the bearing races.

Cross threading the nuts will damage the 3rd member housing and bearing caps. If the housing and/or nuts are damaged, the entire 3rd member assembly may have to be replaced.

17. Install the bearing caps in their original locations and torque the bolts to 12-15 ft-lbs. making sure that the adjusting nuts still turn freely.

Transmission

NOTE: In the following procedure, "Left

adjusting nut" refers to the nut on the ring gear side of the differential assembly. "Right adjusting nut" refers to the nut on the pinion gear side of the differential assembly.

The differential bearing preload is set by measuring the case spread of the 3rd member housing. As the bearing adjusting nuts are tightened, the two differential bearing caps will be pushed (spread) away from each other. A dial indicator must be used to measure the case spread as the nuts are tightened. Mount the dial indicator so that it is 4 inches above the top of the bearing caps and parallel to the center line of the carrier bearings.

Transmission Page 17

Page 80

Transmission

NOTE: Be sure to continually rotate the ring gear while adjusting the

bearings. This makes sure that the bearings and races remain seated correctly.

NOTE: One hole on adjusting nut = approximately 0.003" change in

backlash. Left and right nuts MUST be turned the same amount AND in the same direction. The final direction of rotation MUST be in the tightening direction, to loosen a nut 1-hole, back off 2-holes and then tighten 1 hole. The ring gear should be rotated any time the nuts are being adjusted.

18. Loosen the right side nut.

19. Tighten the left nut until all backlash is removed from the ring and pinion gear.

20. Tighten the right nut until a case spread of 0.010” is indicated on the dial indicator.

NOTE: If new ring and pinion gears are used, refer to the recommended

backlash that is supplied with the gear set

21. Measure the backlash. If the backlash is not within 0.002” of the original measurement taken on disassembly or the recommended setting for new gears, then readjust the bearings as follows:

To increase backlash, loosen the left spanner nut and then tighten the right spanner nut the same amount.

To decrease backlash, loosen the right spanner nut and then tighten the left spanner nut the same amount.

22. Apply gear marking compound on both sides of 7 to 10 teeth on the ring gear.

23. While applying resistance to the pinion shaft, rotate the ring gear back and forth (not full revolutions) until a clear contact pattern is shown. Compare the contact pattern to the illustration on the following page and reshim the pinion housing or adjust the backlash as indicated on the illustration . If the pinion housing is reshimed the backlash must be reset. Go back and repeat ALL procedures in setting the backlash.

24. Tighten the bearing cap bolts to 70-85 ft/lbs (F2 drive), 55-70 ft/lbs (F3 drive) and install the spanner nut locks. Tighten the spanner nut lock bolts to 12-25 ft/lbs.

NOTE: Final pinion nut torque on completely assembled drive, 175 ft/lbs.

RE-SHIMMING THE PINION HOUSING

The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced.

Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear. It should be a number ranging from -5 to +5. This is the amount in 0.001” increments to add to the “standard” shim. For example, if the number on the shaft is ‘-3’ then the standard shim (0.015) plus ‘-3’ equals 0.012. The correct shim would be 0.012”.

If you cannot locate the number on the shaft, start with the standard shim and adjust as required per the contact pattern chart on the following page.

Transmission Page 18

Page 81

Transmission

Transmission Page 19

Page 82

Transmission

EXPLODED VIEW

Transmission Page 20

Page 83

TABLE OF CONTENTS

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

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

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

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

Replace the Tire (pneumatic) ...........3

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

Tires and Wheels

Page 84

Maintenance, Service, and Repair

TIRE INFLATION

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.

There are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires.

The illustration to the right is an example of the side wall information on a tire.

Tire pressures must be checked when the tire is cold.

TIRE INSPECTION

6. Check the tire pressure. Refer to Tire Inflation section for information on checking the tire pressure.

7. Inspect the tire tread depth. Minimum recommended tread depth is 1/16-inch. There are a series of tread depth wear indicators around the circumference of the tire. They will appear as 1/2-inch bands across the tread as the tire approaches its wear limit (see illustration below). Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1/16inch or less. Refer to Replace the Tire section for information regarding replacing the tire.

8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end.

NOTE: Refer to Tire Inflation section or Steering

Component Service section for information

on proper tire inflation or front end wheel alignment.

9. Inspect the inner and outer side walls for cracks. If any cracks are seen, then the tire should be replaced. Refer to Replace the Tire section for information regarding replacing the tire.

10. Inspect the valve stem for cracks. If any cracks are seen, then the valve stem should be replaced. It is also recommended that the valve stem be replaced whenever the tire is replaced.

NOTE: Refer to Replace the Tire section for

information regarding replacing the valve stem.

11. Inspect the tread and side walls for debris in the rubber that could lead to a puncture. If any debris is found it should be removed and the tire inspected for a leak.

Tires and Wheels Page 2

Page 85

Maintenance, Service, and Repair

Page 3

REPLACE THE FRONT TIRE/ WHEEL

Refer to Front Axle Service for information on removing the front wheel.

REPLACE THE REAR TIRE/ 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. Raise the wheel to be replaced off of the ground and support with jack stands.

7. Remove the 4 or 5 wheel nuts and remove the wheel.

8. Install in reverse order.

9. Following the pattern shown on the following page, cross tighten the wheel nuts in two stages as follows:

1st stage to approximately 20 ft-lbs. 2nd stage to 80-90 ft-lbs.

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

REPLACE THE TIRE (PNEUMATIC)

NOTE; To replace the tire, the tire/wheel assembly

must be removed from the vehicle. Refer to

Replace the Tire/Wheel section for

information on removing the tire/wheel assembly.

Tire replacement should only be performed by personnel trained in tire replacement.

The tire replacement procedure will be unique to the type of replacement equipment being used. Refer to the instructions provided with your equipment.

Always use a new valve stem when replacing a tire.

Explosion Hazard. Fully deflate the tire before attempting to remove the tire from the wheel. Do not over inflate the tire when seating the bead. Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failure of the tire resulting in severe bodily injury or death.

1. Remove the tire from the wheel.

2. Cut the old valve stem off of the wheel.

3. Remove the valve stem cap from the new valve stem.

4. Lubricate the valve stem with liquid soap.

5. Install a new valve stem using a valve stem tool.

NOTE: The valve stem tool is available at most auto

repair shops.

6. Install the tire onto the wheel following the instructions provided with your tire replacement equipment.

7. Inflate the tire to the proper pressure and check for leaks.

8. Install the valve stem cap.

11. Lower the wheel to the ground.

12. Remove the blocks from behind the wheels.

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

Tires and Wheels

Page 86

Maintenance, Service, and Repair

4 1

4-Bolt Pattern

5-Bolt Pattern

Pattern for tightening the wheel nuts

Re-torque all wheel nuts to their final value after 1-week (20-hours) of operation. Failure to re-torque the wheel nuts may result in the wheel coming off of the vehicle causing severe bodily injury and/or property damage.

REPAIR THE TIRE (PNEUMATIC)

8-Bolt Pattern

Do not attempt to repair a tire with a damaged side wall or a slice in the tread. This type of repair could fail prematurely resulting in severe bodily injury and/or property damage.

NOTE: To properly repair a puncture, the tire must be removed from the wheel. Refer to Replace the

Tire section for information on removing the tire from the wheel.

It is recommended to repair a tire with a combination vulcanized plug and internal patch. Tire repairs should only be performed by personnel trained in tire repair. The tire repair procedure will be unique to the type of repair equipment or repair components used. Refer to

the instructions provided with your equipment or repair components.

Tires and Wheels Page 4

Page 87

TABLE OF CONTENTS

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

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

Charging ...........................................4

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

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

Moist Charge Batteries ......................................... 7

Storage and Returning to Service ......8

Storage .................................................................. 8

Returning to Service ............................................. 9

Battery Service

Page 88

Maintenance, Service, and Repair

CLEANING

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. Dry dirt can be readily blown off with low-pressure air or brushed off.

7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with flexible bristles, wash the batteries off with a strong solution of baking soda and hot water (1 lb. of soda to a gallon of water). Continue until all fizzing stops, which indicates that the acid has been neutralized. Then rinse thoroughly with clear water. DO NOT get any of the solution into the battery cells.

8. Reconnect the batteries, remove the blocks from the wheels and test drive.

A battery is a live electrical source. It cannot be disconnected or neutralized. Do not drop any tool or conductive object onto the battery. A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery. This could cause the battery to explode resulting in severe bodily injury and/or property damage.

Battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage.

Batteries Page 2

Page 89

TESTING

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.

NOTE: A combination of the Load Test and Specific

Gravity Test should be used to accurately determine the condition of the batteries.

Load Test (6-volt batteries only)

NOTE: The batteries must be fully charged before

performing this test.

1. Clean the batteries. Refer to Cleaning the

Batteries section for information on cleaning the

batteries.

2. Load test each battery using a battery load test meter (available at most auto parts distributors). Follow the instructions provided with the test meter.

• If any battery fails the load test, then it should be replaced.

NOTE: If the batteries are over one year old, it is

recommended to replace them as a set.

• If all batteries fail the test you should check the charging system before replacing the batteries. Refer to Charger Troubleshooting section for information on checking the charging system.

Specific Gravity Test

NOTE: The batteries must be fully charged before

performing this test.

The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see the illustration to the right). A discharged battery will read 1100. Ideally, all cells in a battery pack will have the same reading. Any cells in a battery pack that vary by more than 30points may be an indication of a bad cell.

Batteries

Page 3

Page 90

Maintenance, Service, and Repair

Clean the batteries. Refer to Cleaning the Batteries section for information on cleaning the batteries.

Using part number 77-200-00 hydrometer, check and record the specific gravity of each cell in the battery pack.

If, after charging, none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system. If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced.

NOTE: Refer to Charger Troubleshooting for

information on checking the charging system.

The highest reading will be the cell that is accepting the most charge. This reading will be used to gauge all other cells.

Compare the specific gravity readings to the highest reading, if the difference between any of the cells is more than 30-points, then that battery should be replaced.

NOTE: If the batteries are over one year old, it is

recommended to replace them as a set.

Reconnect the batteries, remove the blocks from the wheels and test drive.

Typical Hydrometer Float

CHARGING

Refer to Charging Your Vehicle in section Safety

Rules and Operating Instructions.

Batteries Page 4

Page 91

WATERING

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.

NOTE: The electrolyte level in a battery rises while

charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete.

6. Clean the batteries. Refer to Cleaning the Batteries section for information on cleaning the

batteries.

7. Check the electrolyte level in all battery cells. If low, fill to the correct level with distilled water using part number 77-201-00 battery filler, never add additional battery electrolyte to the batteries.

8. Reconnect the batteries, remove the blocks from the wheels and test drive.

Do not overfill the batteries. Over filling the batteries may cause the battery electrolyte to boil out of the battery and result in severe bodily injury or property damage.

Batteries

Page 5

Page 92

Maintenance, Service, and Repair

REPLACING (6-VOLT BATTERIES ONLY)

NOTE: If the batteries are over one year old, it is

recommended to replace them as a set.

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

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

3. Set the park brake.

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

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

6. Thoroughly clean the batteries and battery

compartment. Refer to Cleaning in this section for information regarding cleaning the batteries.

7. Remove the battery hold downs.

8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced.

Do not leave cables on batteries that have been removed from the vehicle. Cables left on batteries could cause a short circuit resulting in battery explosion, severe bodily injury and/or property damage.

9. Remove all battery jumpers from both posts of the battery or batteries being replaced.

NOTE: It is recommended to replace the battery

jumpers when replacing the batteries.

10. Remove the batteries from the vehicle.

11. Inspect the battery compartment for signs of corrosion.

12. If minimal signs of corrosion are seen, then the damaged paint should be stripped off and the entire battery compartment prepped and repainted.

13. If there are excessive signs of corrosion, then it may be necessary to replace some of the frame members or completely rebuild the battery compartment.

Batteries Page 6

14. Inspect the main positive and negative cables and terminals, charger cables and terminals and 12volt tap wiring. If any of the terminals or wires show signs of corrosion, then they must be repaired or replaced.

Page 93

Maintenance, Service, and Repair

15. Install the batteries in reverse order. Refer to the Illustrated Parts List for battery cable routing.

16. It is recommended to replace the battery terminal hardware when replacing the batteries.

When torquing battery hardware, use a backup wrench on the battery bolt and tighten the nut. Failure to use a backup wrench may damage the battery post.

17. Torque the terminal hardware to 7-8 ft.-lbs.

18. Tighten the hold downs so that the batteries are secure but not so tight as to deform the batteries.

19. Remove the blocks from the wheels and test drive.

Moist Charge Batteries

Moist charged batteries are shipped without battery electrolyte. This allows for a much greater shelf life of the battery. Moist charged batteries must be filled with electrolyte and charged before putting into service. Battery electrolyte is a solution of acid and water that is formulated to be used in wet lead acid batteries and is available at most automotive parts distributors that carry batteries.

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.

Do not operate or charge a vehicle equipped with moist charged batteries until the batteries have been filled with electrolyte and charged. Operating or charging moist charged batteries before filling and charging will damage the batteries resulting in premature failure of the batteries.

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. Fill all battery cells with electrolyte to the proper level.

7. Thoroughly clean any spilled electrolyte from the batteries or the ground. Refer to Cleaning the

Batteries for information on cleaning the

batteries.

8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.

9. Remove the blocks from the wheels and test drive. The batteries are now ready to be put into service.

Batteries

Page 7

Page 94

Maintenance, Service, and Repair

STORAGE AND RETURNING TO SERVICE

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.

If the batteries are removed from the vehicle, do not place them directly on the ground, concrete or solid metal surface. It is recommended to store them on a wooden pallet or equivalent. Storing on the ground, concrete or solid metal surface will cause the batteries to discharge and may result in premature failure of the batteries.

Storage

Thoroughly clean the batteries and battery compartment. Refer to Cleaning in this section for information regarding cleaning the batteries.

Check the electrolyte level and charge the batteries. Refer to Watering in this section for information regarding checking the electrolyte level.

Store the vehicle or batteries in a cool, dry, well ventilated area.

If storing for more than one month, the batteries should be charged as follows:

Storage

Temperature

(F)

Over 60 1

Between 40 and 60 2

Below 40 6

Charging Interval

(months)

Batteries Page 8

Page 95

Returning to Service

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 batteries and battery compartment. Refer to Cleaning in this section for information regarding cleaning the batteries.

7. Check the electrolyte level and charge the batteries. Refer to Watering in this section for information regarding checking the electrolyte level.

Maintenance, Service, and Repair

8. Test the batteries. Refer to Testing section for information on testing the batteries.

9. The batteries are now ready to be put back into service.

Batteries

Page 9

Page 96

TAYLOR -DUNN

Page 97

Table of Contents

Symptoms:............................................2

Main Troubleshooting Sequence..........3

Test Equipment Required:.................................................... 3

IMPORTANT NOTES and INSTRUCTIONS .................... 3

Definitions: ......................................................................... 4

REV B

Page 98

Electrical Troubleshooting

Solenoids

Circuit Breaker

FWD

REV

ISO

PMC Speed Control

Typical Control Panel

SYMPTOMS:

If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to troubleshooting sequence.

• Runs slow in both directions plus high armature and field current in both directions. NOTE: Armature and field current should be equal.

•

Runs slow in both directions plus high armature current in both directions. NOTE: Field current will be very low.

•

Runs normal in one direction only plus runs slow or lacks power in the opposite direction with high armature current in the opposite direction or;

•

Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only. NOTE: Field current will be very low in the opposite direction.

•

Accelerates slowly and exceeds normal speed in both directions plus high armature current. NOTE: Field current will be very low.

•

Full speed only.

• Does not run in either direction plus there is noise from motor (hum or whine) with high field current and low armature current.

•

Jumps into high speed when direction is selected after depressing the accelerator pedal. Excessive spark when connecting battery

•

Does not run or runs very slow with low motor current and high battery current.

•

Jumps into high speed when direction is selected after depressing the accelerator pedal.

If your vehicle does not exhibits any of the above symptoms then continue with the main troubleshooting sequence on the following pages.

Special Troubleshooting

in Section 4 at the end of the main

Main Sequence Page 2

Page 99

Electrical Troubleshooting

MAIN TROUBLESHOOTING SEQUENCE

Test Equipment Required:

•

Digital multimeter (DMM) with diode test function, FLUKE 79 model used in illustrations.

•

Shunt or clamp-on DC Ammeter to measure up to 400 amps.

•

Test light with a rated voltage equal to or exceeds maximum battery voltage or TaylorDunn test light part number #62-027-00 for systems up to 48 volts.

•

Test harness, Taylor-Dunn #62-027-31. This troubleshooting guide assumes that the vehicle is wired correctly. It is not intended to diagnose a vehicle that is not wired correctly.

•

These tools are available through your local Taylor-Dunn parts distributor.

IMPORTANT NOTES and INSTRUCTIONS

•

This troubleshooting guide assumes that the vehicle is wired correctly. It is not intended to diagnose a vehicle that is not wired correctly.

•

This troubleshooting guide is not written to be able to locate a problem if there are multiple component failures.

•

This troubleshooting guide assumes the batteries are good. Charge and test the batteries before troubleshooting the control system.

•

DO NOT start in the middle of this troubleshooting guide. Start at the beginning and complete each test in the order that they are written. Do not skip any test unless instructed to do so. Once a problem is found, stop testing and repair the indicated problem. When the repair is completed it is recommended that the control system be retested before lowering the drive wheels to the ground.

These test procedures must be performed in the order they were written. If the test result is good, then proceed to the next test or go to the next section. Failure to do so may result in incorrect test results.

•

This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Accelerator Module Test Harness. Troubleshooting CANNOT be completed without these tools.

Main Sequence Page 3

Page 100

Electrical Troubleshooting

Definitions:

•

“MS-1” = The first switch in the accelerator module.

•

“Battery volts” = The voltage at the batteries at the time the test is completed.

•

“Pick up” = Energizing a solenoid or contactor.

•

“F&R” = Forward and Reverse.

•

“ISO” = Isolator.

•

“Battery negative” = Main negative battery post.

•

“Battery positive” = Main positive battery post.

•

“PMC” = Speed control module (black box).

•

“HOT terminal” = The side of a switch or solenoid that is connect to the power source.

•

“COLD terminal” = The side of a switch or solenoid that power is switched to.

DURING ALL TESTS

After any repairs are made, completely retest the vehicle before lowering the drive wheels to the ground. Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and/or property damage.

The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.

Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and loose clothing away from the rear drive wheels while conducting tests. Failure to do so may cause serious bodily injury.

Disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause severe bodily injury and/or property damage.

START:

Read all warnings above before continuing. If the vehicle runs normal in one direction but does not run in the opposite direction then go to

the

Solenoids

If none of the three solenoids pick up (click) when the accelerator pedal is depressed then go to the

Forward & Reverse Switch

sequence.

Main Sequence Page 4

Taylor-Dunn SC-011-59, SC 159, AN-011-71, AN 171 Operation, T Roubleshooting And Replacement Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Introduction

Operating Instructions

VEHICLE CONTROLS

General Maintenance

ADJUST FRONT WHEEL BEARINGS

Front Axle

REPLACE FRONT WHEEL BEARINGS

Steering Chain

FORK BEARINGS

SERVICE LIMITS

Transmission

DRIVE MOTOR

Remove

Install

REAR AXLE

Transmission

Assemble

Assemble

CLEANING

TESTING

WATERING