Taylor-Dunn B0-050-00, Shuttle Master, B 50 Operation, T Roubleshooting And Replacement Parts Manual

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Models Included: B0-050-00 (B 50) Shuttle Master

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MANUAL MB-050-00

Operation, Troubleshooting and

Replacement Parts Manual

Published: 12/16/2003 Revision: C

Serial number Starting: 157300

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Taylor-Dunn Contact information

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

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

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

01 (714) 956-4040

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

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

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B2-48 With Stake Side Dump Bed Option

SC1-59 Stock Chaser

E4-55 Sit Down Tow Tractor

C4-25 Sit Down Tow Tractor

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Section Index

Taylor-Dunn

Model B0-050-00 Operator and Service Manual Section Index

Introduction 1

Safety Rules and Operating Instructions 2

General Maintenance 3

Front Axle Service 4

Steering Component Service 5

Brakes Service 6

Motor Service 7

Transaxle Service 8

Tires and Wheels 9

Battery Service 10

Control System Troubleshooting 11

Chargers 12

Wire diagram 13

Illustrated Parts 14

Appendix A Special Tools 15

Appendix B Suggested Torque Values 16

Appendix C Brake Lining Handling Precautions 17

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

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

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TAYLOR -DUNN

Page 7

Introduction

TABLE OF CONTENTS

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

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

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

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

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

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

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

Add fill page...................................................8

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INTRODUCTION

ABOUT THIS MANUAL

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

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

Included in this manual are:

• Vehicle Description

• Safety Rules and Guidelines

• Operational Information

• Operator Responsibilities

• Owner Responsibilities

• Control Operation and Location Information

• Maintenance and Troubleshooting Information

• Standard Parts List

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

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

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WHO SHOULD READ THIS MANUAL

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

RESPONSIBILITIES

INTRODUCTION

Of the Owner...

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

Of the Operator...

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

Of the Service Personnel...

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

Of the Passengers ...

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

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INTRODUCTION

HOW TO USE THIS MANUAL

This manual is organized into five main sections:

INTRODUCTION

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

Safety Rules and Operating Instructions

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

Maintenance Service and Repair

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

Electrical and Charger Troubleshooting

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

Illustrated Parts

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

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INTRODUCTION

Conventions

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

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

or,

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

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

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

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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 speed of 12 mph. Do not exceed the maximum designed speed. Exceeding the maximum designed speed may result in steering difficulty, motor damage, and/or loss of control. Do not exceed locally imposed speed limits. Do not tow at more than 5 mph.

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

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

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

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INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

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

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

packages with the vehicle.

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

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

• Check battery cells to be sure they are filled.

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

Check the operation of each of the following controls:

• Accelerator

• Brake

• Parking Brake

• Key-Switch

• Forward/Reverse Switch

• Reverse Beeper (if equipped)

• Front Headlight Switch

• Steering Wheel

• Horn

What To Do If a Problem is Found

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

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

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

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

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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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Safety Rules and Operating Instructions

TABLE OF CONTENTS

Standard Specifications Personnel Carrier ..2

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

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

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

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

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

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

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

Headlight Switch ...................................................... 6

Strobe Light Switch (Optional) .................................6

Battery Status Indicator, Analog (Optional) ............. 6

Battery Status Indicator,

Digital Bargraph (optional) .............................. 6

Hour Meter (optional) ............................................... 7

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

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

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

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

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

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

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

Park Brake ...............................................................9

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

Vehicle Operational Guidelines.....................11

Safety Guidelines ..................................................... 11

Starting: .................................................................... 11

While driving: ........................................................... 12

Loading and Unloading ............................................12

Parking ..................................................................... 12

Towing ......................................................................12

Charging your vehicle...................................13

Signet Charger Operation, Model HB Series .........13

Signet Charger Operation, Model HBS series ........ 14

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

New Battery Break in ............................................... 14

Charging Time ..........................................................14

Storing / Returning to Service .....................15

Storing Your Vehicle .................................................15

Returning to Service ................................................ 15

Periodic Maintenance Checklist ...................16

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SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS PERSONNEL CARRIER

ITEM VOLTAGE SPECIFICATION

Occupancy 2-Passenger

Dimensions 199L X 112W X 120.6H Centimeters

Turning Radius 366 Centimeters (144 inches)

Dry Weight 322 kg (710 lbs) Without Batteries

Min/Max Battery 174 kg to 212 kg (384 lbs to 468 lbs) Weights

Maximum Load 227 kg (500 lbs)

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

Transmission Direct Drive, Oil Bath

Motor, DC 36 Volt 1.5kW, (2 hp) @ 2400 RPM for 60 min Series Wound Field

Brakes Rear Wheel Mechanical Drum, Hand Operated Park Brake

Steering Automotive Steering

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

Frame Steel Unitized Body, Heavy Duty 14 Gauge Steel

Instrumentation Key Switch, Horn Button, Forward/Reverse Switch

78.5L X 44.25 X 47.5H Inches

Solid State Speed Control, 275 Amp

Light Accessories Single Brake Light

Charger 36 Volt 25 Amp, Portable, Automatic

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).

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SAFETY RULES AND OPERATING INSTRUCTIONS

SAFETY RULES AND GUIDELINES

It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle (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.

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

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

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

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

• Drive slowly when driving on an incline.

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

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

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

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

• Keep to the right under normal conditions.

• Maintain a safe distance from all objects.

• Keep the vehicle under control at all times.

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

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

• Keep a clear view ahead at all times.

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

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

Before working on a vehicle:

3. Set the park brake.

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

DRIVER TRAINING PROGRAM

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

The Operator Training program shall include the following:

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

environment.

• Emphasis on the safety of cargo and personnel.

• All safety rules contained within this manual.

• Proper operation of all vehicle controls.

• A vehicle operation and driving test.

Driver Qualifications.

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

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

• Demonstrate a working knowledge of each control.

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

• Know how to properly load and unload cargo.

• Know how to properly park this vehicle.

• Recognize an improperly maintained vehicle.

• Demonstrate ability to handle this vehicle in all conditions.

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SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE CONTROLS

Key-Switch

Forward-Off-Reverse Switch

A key-switch, located to the front of the consol between the seats, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off.

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

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

The forward-off-reverse switch, located behind the key-switch on the console between the seats, 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.

Horn Switch

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

Headlight Switch

The headlight switch is located behind and to the right of the forwardoff-reverse switch on the center console between the seats. Push the right side of the switch to turn the lights on. Push the left side of the switch to turn the light off.

Strobe Light Switch (Optional)

The strobe light switch is located behind the forward-off-reverse switch on the center console between the seats. Toggle the switch forward to turn on the strobe light. Toggle the switch backward to turn off the accessory.

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.

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SAFETY RULES AND OPERATING INSTRUCTIONS

Battery Status Indicator, Digital Bargraph (optional)

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.

Hour Meter (optional)

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

Steering

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

Directional Signals (Optional)

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

Hazard Light Switch (Optional)

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

Accelerator Pedal

The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.

Foot Brake Pedal

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

Park Brake

The parking brake is part of the foot brake pedal. To set the parking brake, push down on the lower half of the brake pedal until the pedal locks in the down position. To release the park brake, apply pressure on the upper half of the brake pedal until the pedal disengages from the locked position.

Electrolyte Alarm (Optional)

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

Reverse or Motion Alarm (Optional)

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

Seat Interlock Switch

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

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE OPERATIONAL GUIDELINES

Safety Guidelines

• Only qualified and trained operators may drive this vehicle.

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

no more than 10% (5.6 degrees).

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

or when driving on an incline.

• This vehicle may overturn easily if turned sharply or when

driven at high speeds.

• Observe all traffic regulations and speed limits.

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

it is moving.

• Keep the vehicle under control at all times.

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

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

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

• Yield right of way to pedestrians and emergencies vehicles.

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

• Keep a clear view ahead at all times.

Starting:

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

2. Set the parking brake.

3. Hold down the foot brake.

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

5. Release the parking brake.

6. Release the foot brake.

7. Slowly depress the accelerator pedal.

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SAFETY RULES AND OPERATING INSTRUCTIONS

While driving:

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

intersection.

• No reckless driving.

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

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

Loading and Unloading

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

• Do not exceed the cargo load capacity.

• Do not load cargo that can fall off.

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

properly secure all loads.

Parking

Before leaving the vehicle:

• Set the parking brake.

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

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

In addition:

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

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

Towing

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

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

tow the vehicle with the drive wheels on the ground.

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

CHARGING YOUR VEHICLE

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

Signet Charger Operation, Model HB Series

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

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

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

Typical Signet® Built In

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

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

Charging State

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

Cycle complete ON ON ON

LED1 LED2 LED3

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.

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SAFETY RULES AND OPERATING INSTRUCTIONS

Signet Charger Operation, Model HBS series

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

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

it would be an indication of faulty batteries.

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

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

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

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

Typical Signet® HBS

Lestronic II Charger Operation

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

New Battery Break in

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

Charging Time

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

• Capacity of the batteries, higher capacity

requires longer charge time.

• Output of the charger, higher output requires

less charge time.

• Depth of discharge, the deeper a battery is

discharged, the longer it takes to charge.

• Temperature, low temperatures require longer

charge time.

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

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

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SAFETY RULES AND OPERATING INSTRUCTIONS

To obtain the maximum battery life:

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

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

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

Service and Repair for battery maintenance

information.

STORING / RETURNING TO SERVICE

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

Storing Your Vehicle

• Clean the batteries, then fill and charge before

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

• Lube all grease fittings.

• Clean, dry, and check all exposed electrical

connections.

• Inflate tires to proper pressure (if applicable).

• For extended storage, the vehicle should be

elevated so that the tires do not touch the ground.

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

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.

Returning to Service

• Check the battery’s state of charge and charge

if required.

• Perform ALL maintenance checks in the

periodic checklist.

• Remove any blocks from the vehicle and/or

place the vehicle down on to the ground.

• Test drive before putting into normal service.

Storage

Temperature

(F)

Over 60 1

Between 40 and 60 2

Below 40 6

Charging Interval

(months)

Safety Rules Page 15

Page 30

SAFETY RULES AND OPERATING INSTRUCTIONS

PERIODIC MAINTENANCE CHECKLIST

Maintenance Item

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

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 16

Page 31

General Maintenance

TABLE OF CONTENTS

General Maintenance 1

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

Maintenance Guidelines for Vehicles Used in

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

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

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

Page 32

Maintenance, Service and Repair

MAINTENANCE GUIDELINES

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

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

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

3. Set the park brake.

Before starting any repairs:

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

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

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

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

performance checks in an authorized area where safe clearance exists.

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

Rules and Operational Information.”

• Ventilate the work area properly.

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

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

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

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

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

defective parts.

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

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

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

vehicle.

Maintenance Page 2

Page 33

Maintenance, Service and Repair

MAINTENANCE GUIDELINES FOR VEHICLES USED IN SEVERE CONDITIONS

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

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

• In extreme temperatures

• On bumpy, dusty, or poorly maintained roads

• In excessively wet areas

• In corrosive or contaminated areas

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

• On multiple shifts

Maintenance Page 3

Page 34

Maintenance, Service and Repair

TROUBLESHOOTING GUIDE

Symptom Probable Cause

Front End Out of Alignment

Steering Pulls in One Direction

Low Tire Pressure Dry Lube Points in Steering Linkage

Hard Steering

Excessive Steering Play

Lack of Power or Slow Operation

Abnormal Noise

Oil Leak in Rear Bearing Area

Damaged King Pin/Ball Joint Low Tire Pressure Worn Ball Joints Mis-Adjusted or Worn Steering Gear Loose Steering Linkage Brakes or Parking Brakes Dragging Worn Drive Gears Front End Out of Alignment Defective Speed Control Worn Drive Gears or Bearings Worn Front /Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Rear Wheel Bearing and/or Gasket Failed Drive Over Filled

Brake Pedal Soft or Spongy Brakes Out of Adjustment

Brake Pedal Low

Braking Power Low

Brake Worn (1/16" Wear Limit) Brakes Out of Adjustment Brake Worn (1/16" Wear Limit) Brake Pads Contaminated with Fluid Brake Pedal Linkage Binding Brakes Out of Adjustment

Maintenance Page 4

Page 35

LUBRICATION CHART

Viewd from the front

Maintenance, Service and Repair

RIGHT

FRONT

Viewed from underneath the chassie

# Description Locations Lubricant Type

7, 8, 9

1 2 King Pin 2 General Purpose Grease

3 Ball Joints 2 General Purpose Grease 4 Pedal Linkages 2 General Purpose Grease 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug 1 10 oz. 30 wt. motor oil

Maintenance Page 5

Page 36

TAYLOR -DUNN

Page 37

Front Axle Service

TABLE OF CONTENTS

Inspect the Front Wheel

Bearings and King Pin ............................2

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

Front A-Arm Removal and Installation .........4

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

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

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

Replace the King Pins and Bushings...........8

Replace the Steering Knuckle ......................10

Page 38

Maintenance, Service, and Repair

INSPECT THE FRONT WHEEL BEARINGS AND KING PIN

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

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

3. Set the park brake.

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

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

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

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

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

NOTE: Refer to the Adjust Front Wheel

Bearings section for information

regarding the adjustment of the wheel bearings.

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

Replace the King Pins and Bushings for information regarding

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

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

NOTE: Refer to the Replace Front Wheel Bearings section for

information regarding the replacement of the wheel bearings.

9. Lower the vehicle.

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

11. Remove the blocks from behind the wheels.

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

Front Axle Page 2

Page 39

Maintenance, Service, and Repair

ADJUST FRONT WHEEL BEARINGS

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

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

3. Set the park brake.

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

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

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

7. Remove the hub dust cap and cotter pin.

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

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

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

NOTE: Refer to the Replace Front Wheel

Bearings section for information

regarding the replacement of the wheel bearings.

11. Install a new cotter pin.

12. Install the dust cap.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Hub with Dust Cap Removed

Front Axle Page 3

Page 40

Maintenance, Service, and Repair

FRONT A-ARM REMOVAL AND INSTALLATION

Removal

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

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

3. Set the park brake.

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

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

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

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

the front wheel.

8. Remove the king pin. Refer to Replace King Pins and Bushings section for information

regarding removing the king pin.

9. Remove the A-arm bolt where it attaches to the frame.

10. Remove the A-arm.

Front Axle Page 4

Page 41

Installation

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

Maintenance, Service, and Repair

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

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

3. Set the park brake.

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

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

7. Install the A-arm in reverse order of removal.

NOTE: Refer to Tires and Wheels section for information regarding

removing the front wheels.

NOTE: Refer to Replace King Pins and Bushings section for

information regarding installing the king pin.

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

regarding realigning the front wheels.

9. Lower the vehicle.

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

11. Remove the blocks from behind the wheels.

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

Front Axle Page 5

Page 42

Maintenance, Service, and Repair

REPLACE FRONT WHEEL BEARINGS

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

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

3. Set the park brake.

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

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

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

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

information regarding removing the steering knuckle.

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

9. Remove the hub from the steering knuckle.

NOTE: For a front disc brake option you must

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

Brakes section for information

regarding the removal of the brake body.

NOTE: Catch the outer bearing as it falls out.

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

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

NOTE: It is recommended to replace all four

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

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

a. Pack inner and outer bearings with grease.

Hub with Dust Cap Removed

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

30 ft-lbs. This seats the bearings.

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

turns, but is not loose.

d. Install a new cotter pin.

Hub with Dust Cap Removed

Front Axle Page 6

Page 43

Maintenance, Service, and Repair

13. Install the hub dust cap.

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

NOTE: Refer to the Brakes section for information regarding the

installation of the brake body.

15. Lower the vehicle.

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

17. Remove the blocks from behind the wheels.

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

Front Axle Page 7

Page 44

Maintenance, Service, and Repair

REPLACE THE KING PINS AND BUSHINGS

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

• Bronze bushings in the axle beam.

• Bronze bushings in the steering knuckle.

• Metal backed teflon bushings in the axle beam or suspension arm.

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

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

Failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and /or property damage.

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

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

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

3. Set the park brake.

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

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

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

Front Axle Page 8

Page 45

Maintenance, Service, and Repair

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

regarding removing the steering knuckle.

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

procedure.

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

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

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

Failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and /or property damage.

11. Reassemble in reverse order.

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

the steering knuckle.

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

whenever replacing the king pin bushings. Refer to the

Replacement Parts section for the orientation of the bearing or

washers in your vehicle.

12. Grease the bushings.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Front Axle Page 9

Page 46

Maintenance, Service, and Repair

REPLACE THE STEERING KNUCKLE

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

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

3. Set the park brake.

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

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

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

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

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

NOTE: Catch the outer bearing as it falls out.

9. Remove the drag link and/or tie rod from the steering knuckle. Refer to Replace the Ball Joints, Tie

Rods, Drag Link in this section for information

regarding removal of the drag link or tie rod.

10. While supporting the knuckle, remove the king pin and thrust bearing.

11. Remove the knuckle from the axle.

Hub with Dust Cap Removed

Front Axle Page 10

Page 47

Maintenance, Service, and Repair

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

NOTE: Both the left and right side bushings and thrust bearings should be

replaced as a set.

13. Assemble in reverse order.

14. Pack the thrust bearing with grease.

15. Install the king pin and tighten the king pin nut until it contacts the bottom of the knuckle. Do not tighten so much as to squeeze the legs of the knuckle together.

NOTE: Refer to Replace Front Wheel

Bearings for information regarding

proper tightening of the spindle nut

16. Install new cotter pins.

17. Realign the wheels.

NOTE: Refer to the Steering section for

information regarding realignment of the front wheels.

18. Lower the vehicle.

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

20. Remove the blocks from behind the wheels.

21. Release the park brake and test drive the vehicle

Front Axle Page 11

Page 48

Maintenance, Service, and Repair

Front Axle Page 12

Page 49

Steering Component Service

TABLE OF CONTENTS

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

Inspect Ball Joints.........................................6

Inspect Rod Ends..........................................7

Adjust the Steering Gear...............................8

Replace the Steering Wheel..........................9

Replace the Steering Gear ............................10

Replace the Ball Joints, Tie Rods,

and Drag Link..........................................11

Replacing a Rod End ...............................................11

Replacing a Ball Joint .............................................. 12

Replacing the Drag Link .......................................... 13

Replacing the Tie Rod .............................................14

Center the Steering Gear ..............................15

Pitman Shaft Alignment ................................15

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

Assembly ................................................................. 16

Page 50

Maintenance, Service, and Repair

FRONT END ALIGNMENT

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

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

Center the Steering

NOTE: It is recommended that the front wheel toe in is set properly before

performing this procedure. Refer to Front Wheel Alignment section for information regarding Adjusting the toe in.

Ball Joint

Rod End

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

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

3. Set the park brake.

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

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

6. Position the front wheels in the straight ahead position and tie off so that the front wheels cannot turn.

7. Remove the drag ling from the pitman arm.

NOTE: Refer to Replace the Ball Joints section for information regarding

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

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

NOTE: Refer to Center the Steering Gear section for information

regarding centering of the steering gear.

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

Steering Page 2

Page 51

Maintenance, Service, and Repair

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

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

NOTE: Remember the position and orientation

of the clamps.

11. Adjust the drag link so that it can be easily reinserted into the pitman arm.

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

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

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

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

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

15. Untie the steering wheel and the front wheels.

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

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

18. Remove the blocks from behind the wheels.

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

Steering Page 3

Page 52

Maintenance, Service, and Repair

Front wheel alignment

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

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

3. Set the park brake.

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

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

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

7. Turn the steering wheel so that the driver side (left) wheel is in the straight ahead position and then tie off the steering wheel and left wheel so that they cannot rotate.

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

HINT: Hold the chalk on the center of the tire

and rotate the tire to mark the line.

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

NOTE: Remember the position and orientation

of the ball joint clamps.

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

Steering Page 4

Page 53

Maintenance, Service, and Repair

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

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

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

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

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

16. Untie the steering wheel.

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

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

18. Remove the blocks from behind the wheels.

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

Front Measurement

Sleeve Clamps

Tie Rod

Rear Measurement

NOTE: After completing this procedure, inspect the position of the pitman

arm while the wheels are in the straight ahead position. If the pitman arm is not perpendicular to the ground then refer to Center the

Steering section to center the steering.

Steering Page 5

Page 54

Maintenance, Service, and Repair

INSPECT BALL JOINTS

NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a

ball joint and or rod end is worn out, then all should be replaced as a set.

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

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

3. Set the park brake.

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

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

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

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

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

8. If the ball joint housing moves up or down, then the ball joint is worn out and should be replaced. Refer to section Replace the Ball Joints, Tie Rods,

and Drag Link for information regarding replacing

ball joints.

9. Untie the front wheels.

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

11. Remove the blocks from behind the wheels.

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

Typical Ball Joint

Steering Page 6

Page 55

INSPECT ROD ENDS

NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a

ball joint and or rod end is worn out, then all should be replaced as a set.

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

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

3. Set the park brake.

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

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

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

Maintenance, Service, and Repair

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

the Ball Joints, Tie Rods, and Drag Link for

information regarding replacing ball joints.

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

9. Remove the blocks from behind the wheels.

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

< Stud

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

Steering Page 7

Page 56

Maintenance, Service, and Repair

ADJUST THE STEERING GEAR

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

steering gear to perform this procedure. Refer to Replace the

Steering Gear for information regarding removing the steering

gear.

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

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

3. Set the park brake.

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

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

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

7. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints

section for information regarding removing the ball joint from the drag link.

8. Loosen the gear lash jam nut.

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

direction.

B. While counting the rotations, turn the steering

shaft all of the way in the opposite direction.

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

10. While rotating the input shaft through its centered position, adjust the gear lash adjusting screw

so that the torque required to rotate the shaft through the center position is between 11.3 in-lbs to

17.1 in-lbs.

NOTE: The torque to rotate the input shaft when out of the centered position

should be between 2.17 in-lbs and 4.34 in-lbs.

11. While holding the gear lash adjusting screw so that it cannot turn, tighten the gear lash adjusting

screw jam nut.

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

13. Remove the blocks from behind the wheels, release the parking brake and test drive the vehicle.

Steering Page 8

Page 57

Maintenance, Service, and Repair

REPLACE THE STEERING WHEEL

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

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

3. Set the park brake.

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

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

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

7. Remove the steering wheel nut.

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

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

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

11. Tighten the steering wheel nut to 72-86 ft lbs.

12. Reinstall the horn switch (if equipped).

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

14. Remove the blocks from behind the wheels.

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

Steering Page 9

Page 58

Maintenance, Service, and Repair

REPLACE THE STEERING GEAR

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

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

3. Set the park brake.

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

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

6. Remove the steering wheel. Refer to Replace the Steering Wheel section for information

regarding removing the steering wheel.

7. Remove the pitman arm from the steering gear.

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

Failure to support the steering gear will result in the steering gear falling out of the vehicle and could cause property damage and/or severe bodily injury.

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

10. Install in reverse order. Torque the pitman arm nut to 181-217 ft-lbs.

NOTE: Replacement steering gears are not lubed. The steering gear must

be lubed before putting into service.

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.

Steering Page 10

Page 59

Maintenance, Service, and Repair

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

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

Studded Rod End

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

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

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

Replacing a Rod End

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

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

3. Set the park brake.

4. Place blocks under the 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.

Ball Joint

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

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

8. Remove the rod end nut.

9. Remove the rod end from the steering arm.

HINT: Count the number of turns required to

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

Rod End

Steering Sleeve

Jam Nut

Rod End Nut

Steering Arm

Steering Page 11

Page 60

Maintenance, Service, and Repair

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

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

12. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

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

Replacing a Ball Joint

1. Make sure the key-switch is in the “OFF” position, then remove the 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. Loosen the ball joint clamp on the steering sleeve.

8. Remove the cotter pin and ball joint nut.

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

10. Remove the ball joint from the steering sleeve.

HINT: Count the number of turns required to

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

Cotter Pin

Ball Joint Nut

Steering Arm

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

Clamp

Ball Joint

Steering Sleeve

Steering Page 12

Page 61

Maintenance, Service, and Repair

Pitman Arm

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

13. Realign the front wheels.

NOTE: Refer to the Steering section for information regarding realignment

of the front wheels.

14. Lower the vehicle.

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

16. Remove the blocks from behind the wheels.

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

Replacing the Drag Link

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

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

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

3. Set the park brake.

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

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

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

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

NOTE: Refer to the Replacing the Ball

Joints section for information

regarding the removal of the ball joints or rod ends.

8. Remove the drag link as an assembly.

9. Install in reverse order.

Drag Link

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of the front wheels.

Steering Knuckle

Typical Drag Link

Steering Page 13

Page 62

Maintenance, Service, and Repair

Tie Rod

11. Lower the vehicle.

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

13. Remove the blocks from behind the wheels.

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

Replacing the Tie Rod

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

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

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

3. Set the park brake.

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

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

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

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

NOTE: Refer to the Replacing the Ball

Steering Knuckle

Joints section for information

regarding the removal of the ball joints or rod ends.

8. Remove the tie rod as an assembly.

9. Install in reverse order.

10. Realign the front wheels.

NOTE: Refer to the Steering section for

information regarding realignment of the front wheels.

11. Lower the vehicle.

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

Typical Front Axle Assembly

13. Remove the blocks from behind the wheels.

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

Steering Page 14

Page 63

Maintenance, Service, and Repair

CENTER THE STEERING GEAR

NOTE: The drag link must be disconnected from the pitman arm or the

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

1. Rotate the input shaft clockwise until it stops.

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

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

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

PITMAN SHAFT ALIGNMENT

1. 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. Center the steering gear. Refer to Center the Steering Gear section for information regarding

centering the steering gear.

7. Tie the steering wheel in position so that it cannot rotate.

8. Install the pitman shaft on the steering gear so that it is as close as possible to perpendicular to the ground. Torque the pitman arm nut to 181-217 ft-lbs.

10. Untie the steering wheel.

11. If required, remove and reposition the steering wheel. Refer to Replace the Steering Wheel section for information regarding repositioning the steering wheel.

13. Realign the front wheels. Refer to Front End Alignment for information regarding realigning the front wheels.

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 15

Page 64

Maintenance, Service, and Repair

REPAIR THE STEERING GEAR

Disassembly

For this procedure, the steering gear assembly must be removed from the vehicle. Refer to Replace

the Steering Gear section for information regarding removing the steering gear from the vehicle.

1. Center the steering gear.

2. Remove the four bolts to the output shaft housing cover.

3. Remove the output shaft and cover as an assembly.

4. Remove the four bolts to the input shaft housing cover and remove the cover.

5. Pull the input shaft out from the bottom of the housing.

6. Remove the upper column bushing from the housing.

7. Remove the bearings from the input shaft.

8. Remove the upper bearing race from the housing.

9. Remove the jam nut from the gear lash adjustor and separate the housing cover from the output shaft.

10. Remove the output shaft oil seal.

Assembly

1. Thoroughly clean all components.

2. Assemble in reverse order of disassembly using new gaskets and seals.

3. Torque the housing cover bolts to 18-21 ft-lbs.

4. Fill the gear with general purpose grease.

5. Adjust the gear lash. Refer to Adjust the Steering Gear section for information regarding adjusting

NOTE: If the input shaft or bearings were replaced then the shaft must be

re-shimmed. Shims are available in 0.10, 0.15, and 0.30 mm thickness. Add or subtract shims as required so that the minimum torque required to rotate the shaft meets the requirements specified in section Adjust the Steering Gear.

the steering gear.

Steering Page 16

Page 65

Maintenance, Service, and Repair

Steering Gear Exploded

Steering Page 17

Page 66

TAYLOR -DUNN

Page 67

Brake Service

TABLE OF CONTENTS

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

Auto-Adjust Brake Mechanism Operation ..............2

Inspecting the Auto-Adjust Brake Mechanism .......3

Brake Shoes ............................................................ 4

Brake Drum (Dana) .................................................4

Inspect the Park Brake..................................5

Inspection and Replacement of Park Brake Pedal Lock 5

Rear Brake Linkage Adjustment .............................6

Replace Rear Brake Pads or Shoes..............7

Page 68

Maintenance, Service, and Repair

INSPECT THE SERVICE BRAKE

Auto-Adjust Brake Mechanism Operation

The auto-adjust mechanism is located on the bottom of the brake assembly and accessible through the oval slot in the brake drum. As the brake pad material wears down, the distance the brake shoes travel to engage the brake drum becomes longer. When the travel becomes long enough, the brake lever engages the auto-adjust lever and causes it to index a tooth on the star wheel adjuster. This rotates the adjuster, which decreases the travel needed for the brake shoes to engage the brake drum.

NOTE: The only time the brakes should be manually adjusted is when an

internal component of the braking system has been removed.

NOTE: The brakes will not require manual adjustment if any part of the

external mechanical linkages or cables have been removed.

NOTE: The symptom of a low brake pedal may indicate that the auto

adjuster is not working or the brake cable is not adjusted properly. Remove the vehicle from service and repair the brakes.

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

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

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

Brakes Page 2

Page 69

Maintenance, Service, and Repair

Inspecting the Auto-Adjust Brake Mechanism

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

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

3. Set the park brake.

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

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

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

7. Using the appropriate procedure, remove the brake drum.

8. Release the park brake.

9. Back off the auto adjuster star wheel one or two turns.

10. Reinstall the brake drum and depress the brake pedal.

11. As the brake pedal is depressed, the auto adjuster indexes the star wheel adjuster causing a click.

12. Lower the vehicle.

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

14. Remove the blocks from behind the wheels.

15. Test drive the vehicle

Brake assembly

Brakes Page 3

Page 70

Maintenance, Service, and Repair

Brake Shoes

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

NOTE: The wheel must be removed to accurately measure the brake shoes.

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

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

NOTE: If this is a riveted lining, then the

measurement must be to the top of the rivets.

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

Brake Drum (Dana)

NOTE: The wheel must be removed to accurately measure the brake drum.

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

The service limit for the inside diameter of the brake drum is 6.330 inches. If the brake drum is grooved or worn beyond the service limit then the brake drum must be replaced. Measure the inside diameter of the brake drum in 3-places. If the difference between any of the measurements exceeds 0.010-inches then the brake drum must be

replaced.

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

Brakes Page 4

Page 71

Maintenance, Service, and Repair

INSPECT THE PARK BRAKE

Inspection and Replacement of Park Brake Pedal Lock

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

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

3. Set the park brake.

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

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

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

7. With the brake pedal in its fully extended position, remove the 1/2” bolt and locknut from under the pedal.

8. Remove the pedal and park brake lock assembly from the brake arm.

9. Install a new pedal and park brake lock assembly.

Always use new locknuts. Locknuts become less effective if used more than once. Failure to replace the locknuts may result in the locknuts or bolts coming loose causing property damage and/or severe bodily

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

Park Brake Lock

Wear Limits:

Brake Pedal

Brake Arm

1/2” Bolt

If the park brake lock does not catch, or it slips easily, it must be replaced. Press on the lower half of the pedal. If the park brake lock engages with little effort on the upper

most notch, check the linkage adjustments and adjust as needed.

Brakes Page 5

Page 72

Maintenance, Service, and Repair

Rear Brake Linkage Adjustment

NOTE: This vehicle is equipped with self-adjusting brakes. The need to

adjust the brakes manually may be an indication that the autoadjust mechanism is not functioning properly. Refer to Inspecting

the Auto-Adjust Brake Mechanism for information on the auto-

adjust mechanism.

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

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

3. Set the park brake.

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

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

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

7. Release the park brake.

8. Remove the two coil springs from the brake cables and reinstall the cable onto the brake arm. Do not insert a cotter pin at this time.

9. Remove the brake pedal return spring.

10. Remove the cotter pin from the brake rod clevis where it attaches to the equalizer.

11. Loosen both clevis jam nuts and back off the brake rod adjustment so that the brake pedal falls 2 inches.

12. Temporarily install the brake pedal return spring in the clevis pin and stretch approximately 1.5 inches and tie off.

13. Tighten the brake rod until the brake pedal returns to within 1/4 inch of the floorboard.

14. Remove the brake pedal return spring from the clevis pin and reinstall in its normal position.

15. Install a new cotter pin in the clevis pin.

16. Tighten the brake rod jam nuts.

17. Reinstall the two coil springs removed from the brake cables and reinstall the cable onto the brake arm using new cotter pins.

18. Pump the brake pedal to actuate the automatic adjusters inside the brakes until the brake is working properly.

19. Lower the vehicle.

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

21. Remove the blocks from behind the wheels.

22. Test drive the vehicle.

Spring position for adjusting the brake

linkage. The bracket used to hold the

spring is for reference only.

Brakes Page 6

Page 73

Maintenance, Service, and Repair

REPLACE REAR BRAKE PADS OR SHOES

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

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

3. Set the park brake.

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

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

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

7. Using the appropriate procedure, remove the brake drum.

8. Release the park brake.

9. Remove the tension springs.

10. Remove the hold down springs.

11. Remove the auto-adjust lever spring.

12. Apply this procedure in reverse order to install the new brake shoes.

NOTE: Be sure all the parts are thoroughly

cleaned.

NOTE: Be sure that the anchor points on the

brake shoes are given a light coat of hitemp grease.

13. Lower the vehicle.

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

15. Remove the blocks from behind the wheels.

16. Test drive the vehicle.

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

Brakes Page 7

Page 74

TAYLOR -DUNN

Page 75

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 76

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 77

Motor Service

Advanced DC Motors

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

Motor Inspection for information regarding

disassembling the motor.

MOTOR REMOVAL AND INSTALLATION

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

MOTOR INSPECTION

Disassembly

1. Remove the motor from the vehicle. See the

Transmission section for information on

removing the motor.

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

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

Inspection

1. Measure the length of each motor brush.

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

service limit specified in section Service

Limits, then all four brushes should be

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

2. Measure the diameter of the commutator.

• If the commutator is less than the minimum

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

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

• If any one of the measurements is less than the

minimum undercut depth specified in Service

Limits above, then the commutator must be

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

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

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

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

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

Hacksaw blade

Incorrect

Correct

Insulation

Commutator

4. Inspect the commutator for grooves.

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

Repair Commutator section for information

regarding machining the commutator.

Undercut

Armature

Min. OD

Motor

Page 78

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 79

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 80

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 81

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 82

TAYLOR -DUNN

Page 83

Transmission Service

TABLE OF CONTENTS

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

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

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

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

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

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

Removal and Installation ......................................... 5

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

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

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

Removal and Installation ......................................... 9

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

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

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

Typical Transmission

Page 84

Maintenance, Service, and Repair

CHECK OIL LEVEL

Park the vehicle on a level surface.

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

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

3. Set the park brake.

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

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

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

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

8. If no oil comes out, then lift the side of the vehicle with the level plug and add 11-ounces of oil through the level plug hole. See the illustration below.

9. Lower the vehicle, allow any excess oil to drain into the drain pan, and then reinstall the level plug.

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

11. Remove blocks from behind the wheels.

12. Test drive the vehicle

Level Plug viewed from in front of the right rear wheel

Transmission Page 2

Page 85

CHANGE OIL

Park the vehicle on a level surface.

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

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

3. Set the park brake.

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

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

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

Maintenance, Service, and Repair

Level Plug viewed from in front of the right rear wheel

7. Remove the level plug then lift the side of the vehicle without the level plug and allow the oil to drain out.

8. Lower the vehicle and now lift the side of the vehicle with the level plug and add 11-ounces of oil (see illustration on preceding page).

9. Lower the vehicle, allow any excess oil to drain into the drain pan, and then reinstall the level plug.

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

11. Remove blocks from behind the wheels.

12. Test drive the vehicle

Transmission Page 3

Page 86

Maintenance, Service, and Repair

MOTOR

Removal

NOTE: In some vehicle configurations the transmission assembly will have

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

Transmission section for information on removing the

transmission assembly from the vehicle.

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

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

3. Set the park brake.

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

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

6. Remove the motor wires from the motor.

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

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

Installation

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

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

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

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

5. Install the motor in reverse order.

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

HINT: Tag each wire with the number of the

terminal it was removed from.

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

Transmission Page 4

Page 87

Maintenance, Service, and Repair

REAR HUB WITH BRAKE DRUM

Removal and Installation

NOTE: Some vehicle configurations do

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

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

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

Integral hub Removable hub

3. Set the park brake.

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

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

6. Remove the rear wheel. Refer to Replace the

Rear Tire/Wheel section for information regarding

removing the rear wheel.

7. Remove the cotter pin from the axle shaft.

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

9. Install in reverse order.

10. Lightly grease the axle shaft splines.

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

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

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

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

Transmission Page 5

Page 88

Maintenance, Service, and Repair

REAR AXLE

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

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

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

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

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

Remove and Install Axle - Removable Hub

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

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

3. Set the park brake.

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

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

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

removing the rear wheel.

7. Remove the axle hub. Refer to Rear Hub/Brake Drum section for information on removing the hub.

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

9. Remove the axle from the transmission assembly.

HINT: Use a slide hammer threaded onto the

end of the axle shaft.

10. Remove the inner snap ring.

11. Remove the axle seal from the axle housing.

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

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

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

Transmission Page 6

Page 89

Maintenance, Service, and Repair

Remove and Install Axle - Non - Removable Hub

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

removed along with the axle assembly.

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

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

3. Set the park brake.

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

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

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

7. Remove the brake drum.

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

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

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

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

HINT: Use a slide hammer threaded onto one

of the wheel studs.

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

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

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

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

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

Transmission Page 7

Page 90

Maintenance, Service, and Repair

Replace the Axle Bearing

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

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

Removable Hub:

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

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

3. Press a new bearing onto the axle shaft.

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

Non-Removable Hub

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

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

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

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

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

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

Transmission Page 8

Page 91

TRANSMISSION

Removal and Installation

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

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

3. Set the park brake.

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

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

6. Remove the rear deck access plate.

7. Disconnect the motor wires from the motor.

8. Remove the clevis pins from the brake cables (right side shown).

Maintenance, Service, and Repair

9. Support the rear of the vehicle with a lifting device but do not raise the rear wheels off of the ground.

10.Remove the lower shock bolts and compress the shocks to get them out of the way..

11. Lift the rear of the vehicle just high enough to remove the coil springs and place the frame of the vehicle on jack stands

12. Remove the springs and spring mounting plates from the axle tubes.

13. Remove the bolts holding the swing arm to the axle tubes and roll the transmission out from the vehicle.

14. Install in reverse order.

Transmission Page 9

Page 92

Maintenance, Service, and Repair

DIFFERENTIAL CASE

Disassemble

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

2. Thoroughly clean the transmission assembly before disassembly.

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

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

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

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

NOTE: The bearing caps are marked for

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

7. Remove both bearings from the differential case.

Transmission Page 10

Page 93

Maintenance, Service, and Repair

8. Remove the final drive gear from the differential housing.

9. Punch or drill a small hole into the center of both of the intermediate shaft bore plugs.

10. Thread a sheet metal screw into each plug until the bore plug is forced out.

11. Remove both snap rings from the intermediate shaft bore.

12. Using a soft metal or hard wood dowel, drive the intermediate shaft through the bearing just enough to allow clearance for an ID bearing puller. Do not attempt to drive the shaft out of the opposite end of the transmission.

Transmission Page 11

Page 94

Maintenance, Service, and Repair

13. Remove the intermediate bearing with an ID bearing puller.

The shaft and gear assembly must be supported by hand during the next step. Failure to properly support the shaft and gear assembly could result in damage to the gear teeth.

14. While supporting the shaft and gear assembly, repeat steps #12 and #13 for the opposite side bearing and remove the intermediate shaft from the housing.

15. Remove the o-rings from each end of the intermediate shaft.

16. Remove the circlip from the input shaft.

17. Remove the input shaft from the housing.

18. Press the bearings off of the input shaft.

Transmission Page 12

Page 95

19. Remove the o-rings from both sides of the

Assemble

Maintenance, Service, and Repair

intermediate shaft bore and the input shaft bore and discard the o-rings.

NOTE: When pressing bearings, do not press against or support the outer

race as this will damage the bearing.

NOTE: All snap rings should fit tightly into their grooves. If a snap ring is

loose, then it must be replaced.

NOTE: All internal components should fit easily together. Do not hit any

shaft or component with a hard metal hammer or punch.

NOTE: Pre-lube all bearings, seals and o-rings before assembly.

1. Thoroughly clean all components as well as the inside of the housing.

2. Press new bearings onto the input shaft and differential case.

3. Insert new o-rings into both sides of the intermediate shaft bore, the input shaft bore and the intermediate shafts.

Transmission Page 13

Page 96

Maintenance, Service, and Repair

4. Install the input shaft into the housing and install the snap ring.

5. Insert the intermediate shaft into the housing and

Use a hard wood dowel the same diameter as the bearing bore to drive the bearing into place. Do not drive against the inner race as this will damage the bearing.

Transmission Page 14

Page 97

Suspension

TABLE OF CONTENTS

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

Replace the Front Spring ..............................3

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

Page 98

Maintenance, Service, and Repair

REPLACE THE REAR SPRINGS

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 lower shock bolt on the same side of the vehicle as the spring to be replaced.

7. Raise the side of the vehicle just enough so that the spring clears the upper spring guide and support with jack stands.

8. Remove the spring.

9. Install the new spring in reverse order.

Pinch point. Do not place any part of your body between the spring and the vehicles frame, spring mounts or between the spring coils. This could result in severe bodily injury.

Suspension Page 2

Page 99

Maintenance, Service, and Repair

REPLACE THE FRONT SPRING

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

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

3. Set the park brake.

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

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

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

7. Tie up or support the left and right side front wheel so they cannot pivot down.

8. Remove the two u-bolts holding the spring to the center frame member.

9. Slide the spring out from under the A-arm spring bushings.

10. It is recommended that the A-arm spring bushings be replaced any time the spring is replaced.

11. Install the new spring in reverse order.

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 parking brake and test drive the vehicle.

Suspension Page 3

Page 100

Maintenance, Service, and Repair

REPLACE THE SHOCKS

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

NOTE: On some vehicles it may be required to remove the front wheel to

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

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

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

3. Set the park brake.

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

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

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

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

7. Remove the upper and lower shock bolts.

8. Remove the shock from the vehicle.

NOTE: If the shock that was removed is to be reinstalled:

A. Inspect the shaft where it enters the shock

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

B. Inspect the upper and lower shock

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

9. Install the shock in reverse order.

10. Lower the vehicle.

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

12. Remove the blocks from behind the wheels.

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

Suspension Page 4

Taylor-Dunn B0-050-00, Shuttle Master, B 50 Operation, T Roubleshooting And Replacement Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual