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®

Serial Number Starting: 97370

MANUAL MB-240-00

Operation, Troubleshooting andReplacement Parts Manual

Models Inlcuded:Aristocrat

FT-012-40 (FT-240)FT-012-80 (FT-280)

Revision: B

FT-240

FT-280

TAYLOR-DUNN SERVICE CENTER

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

Taylor-Dunn® Mfg.2114 W. Ball Road

Anaheim, CA 92804(Attn: Technical Writer)

COPYRIGHT NOTICE

Copyright © 2001 by Taylor-Dunn® Mfg. All rights reserved.

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

B2-48 With Dump Bed OptionB2-10 Ambulance

B2-48 with Steel Cab, Foldaway4-Passenger Seat and Stake Sides

ET 3000

ET1-50 Full Size Truck

P2-50 30,000 Pound Tow Tractor

Table of Contents

ContentsIntroduction

About this manual .................................... 2Who Should Read This Manual ............... 2Responsibilities ........................................ 2How To Use This Manual .......................... 3

Conventions ............................................................ 3How to Identify Your Vehicle .................... 4Taking Delivery of Your Vehicle ............... 5

Safety Rules and Operating InstructionsStandard Specifications* .......................... 2Safety Rules and Guidelines .................... 3Driver Training Program ........................... 3

Driver Qualifications. .............................................. 3Vehicle Controls ....................................... 4

1) Headlight Switch ................................................ 42) Hi-Low Switch (optional) ..................................... 42) Accessory Switch (Optional) .............................. 43) Battery Status Indicator, Analog .......................... 44) Hour Meter (optional) .......................................... 45) Forward-Off-Reverse Switch .............................. 46) Horn Switch ........................................................ 47) Key-Switch ......................................................... 4Accelerator Pedal ................................................... 5Foot Brake Pedal .................................................... 5Park Brake .............................................................. 5Steering .................................................................. 5Battery Status Indicator, Digital Bargraph (optional) 5Directional Signals (Optional) ................................. 6Hazard Light Switch (Optional) ............................... 6Seat Interlock Switch .............................................. 6Charger Interlock .................................................... 6

Vehicle Operational Guidelines ............... 7Safety Guidelines ................................................... 7Starting: .................................................................. 7While driving: .......................................................... 7Loading and Unloading ........................................... 7Towing Loads:......................................................... 7Parking ................................................................... 8Towing This Vehicle ................................................ 8

Charging your vehicle .............................. 9Signet® Charger Operation, Model HB Series ....... 9Signet® Charger Operation, Model HBS series ..... 9Lestronic II® Charger Operation ............................. 10New Battery Break in .............................................. 10Charging Time ........................................................ 10

Storing / Returning to Service ................ 10Storing Your Vehicle ................................................ 10Returning to Service ............................................... 10

Periodic Maintenance Checklist .............. 11Daily Visual inspection: ........................................... 12

Maintenance Guidelines forSevere Duty Applications ................... 12

General MaintenanceMaintenance Guidelines ........................... 2Troubleshooting Guide ............................ 3Lubrication Chart ...................................... 4

Front Axle ServiceInspect the Front Wheel Bearings and

King Pin ............................................. 2Adjust Front Wheel Bearings .................. 3Front Axle Removal and Installation ....... 4

Removal .................................................................. 4Installation .............................................................. 4

Front Axle Disassembly............................ 5Replace Front Wheel Bearings ................ 6Replace the King Pins and Bushings ...... 7Replace the Steering Knuckle .................. 8

Steering ServiceFront End Alignment ................................ 2Inspect Ball Joints .................................... 5Inspect Rod Ends ..................................... 5Adjust the Steering Gear .......................... 6Replace the Steering Shaft ....................... 7Replace the Steering Wheel ..................... 8Replace the Steering Gear ....................... 8Replace the Ball Joints, Tie Rods, and

Drag Link ............................................ 9Replacing the Drag Link ......................................... 10Replacing the Tie Rod ............................................ 11

Center the Steering Gear .......................... 11Repair the Steering Gear .......................... 12

Brake ServiceInspect the Service Brake ........................ 2

Brake Shoes ........................................................... 2Brake Drum ............................................................ 2

Inspect the Parking brake ........................ 3Adjust the Parking Brake ......................... 3

Wheel Park Brake (mechanical drum) .................... 3Adjust the Service Brakes ........................ 4

............................................................................... 4Replace Rear Brake Shoes ....................... 5

Table of Contents

Transmission ServiceCheck Oil Level ......................................... 2Change Oil ................................................ 3Motor ......................................................... 4

Removal .................................................................. 4Installation .............................................................. 4

Rear Hub with Brake Drum....................... 5Removal and Installation ......................................... 5

Rear Axle ................................................... 6Replace the Axle Bearing ........................................ 8

Transmission ............................................ 9Removal .................................................................. 9Installation .............................................................. 10

Differential Case ....................................... 12Disassemble ........................................................... 12Assemble................................................................ 15

SuspensionReplace the Rear Springs......................... 2Replace the Front Springs ....................... 3Replace the Spring Bushings .................. 4

Tires and WheelsTire Inflation .............................................. 2Tire Inspection .......................................... 2Replace the Tire/Wheel ............................. 3Replace the Tire (pneumatic) .................. 3Repair the Tire (pneumatic) ..................... 4

Motor ServiceInspecting the Motor Brushes ................. 2

Motors with internal cooling fans ............................ 2Enclosed Motors (GE, no cooling fan) .................... 2

Motor Removal and Installation ............... 3Motor Inspection....................................... 3Replacing the Brushes ............................. 5Replacing the Bearings ............................ 6Repairing the Commutator ....................... 6Service Limits ........................................... 7

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

Magnetic Module .................................................... 2Pot Box module ...................................................... 3

Battery ServiceCleaning .................................................... 2Testing....................................................... 3Charging ................................................... 4Watering .................................................... 5Replacing (6-volt batteries only) .............. 6

Moist Charge Batteries ........................................... 7Storage and Returning to Service ........... 8

Storage ................................................................... 8Returning to Service ............................................... 9

Electrical TroubleshootingSymptoms: ................................................ 2READ THIS FIRST ..................................... 3

Test Equipment Required: ...................................... 3IMPORTANT NOTES and INSTRUCTIONS ......... 3Definitions: .............................................................. 4

Symptom Troubleshooting Guide ........... 22PMC CONTROL .................................................... 23PLUGGING DIODE ............................................... 25FREEWHEEL DIODE ............................................ 26ISO ......................................................................... 27SOLENOIDS .......................................................... 29MOTOR .................................................................. 32

Lestronic II® Charger TroubleshootingOperating Instructions and

Theory of Operation ........................... 2Testing the Charging Cycle ...................... 3Test Equipment Required for

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

Troubleshooting for Built-in Charger ...... 5Troubleshooting for Portable Charger .... 8Testing The Timer Relay .......................... 9Testing the Interlock Relay ...................... 10

Signet® Charger TroubleshootingOperating Instructions and

Theory of Operation ........................... 2HB/PT and GEL Indicator Lamps ............. 3Testing the Charging Cycle ...................... 3Test Equipment Required for


Status LED Error Code Table ................... 5Troubleshooting ....................................... 6

Signet® Charger TroubleshootingDefinitions: ................................................ 2Test Equipment Required for


Operating Instructions andTheory of Operation ........................... 3

Testing the Charging Cycle ...................... 4Status Light Error Code Table ................. 5Troubleshooting ....................................... 6

Wire Diagrams

Table of Contents

Illustrated PartsFront Axle ................................................... 2Steering Gear, TRW .................................... 4Steering Gear ............................................. 6Steering Column ......................................... 7Front Suspension ........................................ 8Transmission Differential Case ................... 10Rear Axle .................................................... 12Rear Brakes................................................ 14Rear Suspension ........................................ 16Motor, Page 1 ............................................. 18Motor, Page 2 ............................................. 20Brake linkage (parking brake) ..................... 22Instrument Panel (dash) .............................. 24Speed Control Panel ................................... 26Miscellaneous Frame and Body .................. 28Charger, Lester Page 1 ............................... 30Charger, Lester Page 2 ............................... 32Charger, Signet ........................................... 34Decals ........................................................ 35Batteries ..................................................... 36

AppendixesAppendix A: Special Tools ....................... 2Appendix B: Suggested Torque Limits for

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

Standard Head Markings ........................................ 3Hex Bolts ................................................................ 3Other Bolts ............................................................. 3Hex Nuts ................................................................. 4Hex Lock Nuts (stover) ........................................... 4Other Nuts .............................................................. 4Suggested Torque Values (non-critical hardware) .. 5Suggested Torque Values (critical hardware) ......... 6

Appendix C: Brake Lining HandlingPrecautions......................................... 7

B2-48 With Stake Side Dump Bed Option

SC1-00 Stock Chaser

E4-55 Sit Down Tow Tractor

C4-25 Sit Down Tow Tractor

Table of Contents

Intr

od

uct

ion

About this manual ......................................... 2Who Should Read This Manual .................... 2Responsibilities ............................................ 2How To Use This Manual .............................. 3

Conventions .............................................................. 3How to Identify Your Vehicle ........................ 4Taking Delivery of Your Vehicle ................... 5

FT-240

FT-280

INTRODUCTION

Page-2

WHO SHOULD READ THIS MANUAL

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

ABOUT THIS MANUAL

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

This manual is to serve as a guide for the service,repair, and operation of Taylor-Dunn® vehicles and isnot intended as a training guide. Taylor-Dunn® hasmade every effort to include as much information aspossible about the operation and maintenance of thisvehicle.

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 performingmaintenance on this or any other Taylor-Dunn® vehicle,read the appropriate Taylor-Dunn® manual.

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

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

RESPONSIBILITIES

Of the Owner...The owner of this or any Taylor-Dunn® vehicle isresponsible for the overall maintenance and repairsof the vehicle, as well as the training of operators.Owners should keep a record of conducted trainingand maintenance performed on the vehicle. (OSHARegulation, 29 CFR 1910.178 Powered IndustrialTruck Operator Training).

Of the Operator...The operator is responsible for the safe operation ofthe vehicle, preoperational and operational checkson the vehicle, and the reporting of any problems toservice and repair personnel.

Of the Service Personnel...The service personnel are responsible for the serviceand maintenance of the vehicle. At no time should aservice person allow any untrained personnel toservice or repair this or any Taylor-Dunn® vehicle.For the purposes of training, a qualified serviceperson may oversee the repairs or services beingmade to a vehicle by an individual in training. At notime should an untrained individual be allowed toservice or repair a vehicle without supervision. Thismanual is not a training guide.

Of the Passengers ...The passengers are responsible to remain fullyseated, keeping their hands, arms, and legs insidethe vehicle at all times. Each passenger should befully aware of the vehicle’s operation. All forms ofrecklessness are to be avoided. Do not engage inhorseplay.

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

INTRODUCTION

Page-3

HOW TO USE THIS MANUAL

This manual is organized into five main sections:

INTRODUCTIONThis section describes how to use this service manualand how to identify your vehicle.

Safety Rules and Operating InstructionsThis section outlines the safety and operational issues,location and operation of controls, and the operationalchecks that are to be performed on this vehicle. Italso includes various subjects that should be includedin the operator and service training program.

Maintenance Service and RepairThis section gives specific information on the servicingof the vehicle and a schedule for maintenance checks.

Electrical and Charger TroubleshootingThis section identifies the troubleshooting proceduresfor testing the electrical system and battery charger.

Illustrated PartsThis section provides an illustrated view of variousassemblies. The illustrations are accompanied bytables identifying the parts.

Conventions

Symbols and/or words that are used to definewarnings, cautions, instructions, or notes foundthroughout this manual. Refer to the examples below.

Note: Alerts the reader to additionalinformation about a subject.

Model B 2-48 equippedwith the Dump Bed option

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

A shaded box with and the word “Warning”and the symbol above denotes awarning. This warning alerts the reader ofa high voltage hazard that may result ininjury to themselves or others. Be sure tofollow any instructions contained within awarning and exercise extreme care whileperforming the task.

A shaded box with the word “Warning” andthe symbol above denotes a warning. Awarning alerts the reader of a hazard thatmay result in injury to themselves orothers. Be sure to follow any instructionscontained within a warning and exerciseextreme care while performing the task.

A box with the word “CAUTION” and thesymbol above denotes a caution and isused to inform the reader that propertydamage may occur. Be sure to exercisespecial care and follow any instructionscontained with in a caution.

INTRODUCTION

Page-4

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.

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

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section 29 CFR1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard forPersonnel and Burden Carriers (ANSI B56.8).

This vehicle is not designed to be driven on public roads or highways. It is available in maximumdesigned speed of 12 mph. Do not exceed the maximum designed speed. Exceeding the maximumdesigned speed may result in steering difficulty, motor damage, and/or loss of control. Do notexceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

INTRODUCTION

Page-5

TAKING DELIVERY OF YOURVEHICLE

Inspect the vehicle immediately after delivery. Usethe following guidelines to help identify any obviousproblems:

• Examine the contents of all packages andaccessories that may have come in separatepackages with the vehicle.

• Make sure everything listed on the packingslip is there.

• Check that all wire connections, batterycables, and other electrical connections aresecure.

• 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

The only personnel authorized to repair,modify, or adjust any part of this or anyTaylor-Dunn® vehicle is a factoryauthorized service technician. Repairsmade by unauthorized personnel mayresult in damage to the vehicles systemswhich could lead to an unsafe conditionresulting in severe bodily injury and/orproperty damage. Unauthorized repairsmay also void the vehicles warranty.

What To Do If a Problem is FoundIf there is a problem or damage as a result of shipping,note the damage or problem on the bill of lading andfile a claim with the freight carrier. The claim must befiled within 48 hours of receiving the vehicle and itsaccessories. Also, notify your Taylor-Dunn® dealer ofthe claim.

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

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

Model B 2-10 Ambulance

TAYL

OR -

DUNN

TABLE OF CONTENTS

Saf

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Ru

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and

Op

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In

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Standard Specifications* .................... 2Safety Rules and Guidelines ............. 3Driver Training Program .................... 3

Driver Qualifications. ........................................... 3Vehicle Controls ................................ 4

1) Headlight Switch .............................................. 42) Hi-Low Switch (optional) ................................ 42) Accessory Switch (Optional) ............................ 43) Battery Status Indicator, Analog ...................... 44) Hour Meter (optional) ...................................... 45) Forward-Off-Reverse Switch ........................... 46) Horn Switch ...................................................... 47) Key-Switch ....................................................... 4Accelerator Pedal .................................................. 4Foot Brake Pedal .................................................. 4Park Brake ............................................................ 4Steering ................................................................. 5Battery Status Indicator,

Digital Bargraph (optional) ............................... 5Directional Signals (Optional) ............................. 6Hazard Light Switch (Optional) ........................... 6Seat Interlock Switch ............................................ 6Charger Interlock .................................................. 6

Vehicle Operational Guidelines.......... 7Safety Guidelines .................................................. 7Starting: ................................................................. 7While driving: ....................................................... 7Loading and Unloading ........................................ 7Towing Loads: ...................................................... 7Parking .................................................................. 8Towing This Vehicle ............................................. 8

Charging your vehicle........................ 9Signet® Charger Operation, Model HB Series .... 9Signet® Charger Operation, Model HBS series .. 9Lestronic II® Charger Operation ......................... 10New Battery Break in ........................................... 10Charging Time ...................................................... 10

Storing / Returning to Service ........... 10Storing Your Vehicle ............................................. 10Returning to Service ............................................. 10

Periodic Maintenance Checklist ......... 11Daily Visual inspection: ........................................ 12

Maintenance Guidelines forSevere Duty Applications ............... 12

SAFETY RULES AND OPERATING INSTRUCTIONS

Safety RulesPage 2

STANDARD SPECIFICATIONS*ITEM MODEL SPECIFICATION

Occupancy FT-240 Driver + 3 passengersFT-280 Driver + 5 passengers

Dimensions FT-240 292 L x 120 W x 114 H Centimeters115 L x 46.75 W x 45 H Inches

FT-280

Turning Radius 335 Centimeters (132 Inches)

Dry Weight FT-240 414 kg (912 lbs)Without Batteries FT-280 500 kg (1,102 lbs)

Min/Max Battery 158 kg to 190 kg (348 lbs to 420 lbs)Weights

Maximum Load FT-240 545 kg (1,200 lbs)FT-280 726 kg (1,600 lbs)

Deck dimensions 76 W x 104 L Centimeters (30 W x 41 L Inches)

Electrical System Six 220 Amp Hour, 6 Volt, Lead Acid Batteries,Solid State Speed Control, 275 Amp

Transmission Helical Gear, Oil Bath, Automotive Type HypoidDifferential.

Motor, DC 4.5kW (6 Horse Power) @ 1400 RPMSeries Wound 1.5 kW, (2 Horse Power) @ 2800 RPM

Brakes Rear Wheel Mechanical Drum, Hand Operated Park Brake

Steering Automotive Steering 24:1

Tires 18 x 8.50 x 8 Load Range B

Frame Fiberglass Body Over Steel Unitized Frame

Instrumentation Battery Status Gauge, Key Switch, Horn Button,Forward/Reverse Switch, Headlight Switch

Light Accessories Dual Headlights and Tail Lights

Charger 120/240 volt, 12/6 Amp, 50/60 Hz AC, 20 Amp DC

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard forPersonnel and Burden Carriers (ANSI B56.8).

* - Specifications are subject to change without notice.


Safety RulesPage 3

SAFETY RULES ANDGUIDELINESIt is the responsibility of the owner of this vehicle to assurethat the operator understands the various controls andoperating characteristics of this vehicle (extracted fromthe American National Standards Institute Personnel andBurden Carriers ANSI B56.8). As well as, following thesafety rules and guidelines outlined in ANSI B56.8 andlisted below.

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

Refer to Vehicle Operational Guidelines, SafetyGuidelines section for important safety informationregarding operating this vehicle.

Read and follow all of the guidelines listedbelow. Failure to follow these guidelinesmay result in severe bodily injury and/orproperty damage.

These vehicles are not designed to bedriven on public roads or highways. Theyare available in maximum designed speedof 12 mph. Do not exceed the maximumdesigned speed. Exceeding the maximumdesigned speed may result in steeringdifficulty, motor damage, and/or loss ofcontrol. Do not exceed locally imposedspeed limits. Do not tow this vehicle atmore than 5 mph.

Before workingon a vehicle:

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

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

3. Set the park brake.

4. Place blocks under the front wheels toprevent vehicle movement.

5. Disconnect the main positive andnegative cables at the batteries.

DRIVER TRAINING PROGRAMAccording to ANSI B56.8, the owner of this vehicle shallconduct an Operator Training program for all those whowill be operating this vehicle. The training program shallnot be condensed for those claiming to have previousvehicle operation experience. Successful completion ofthe Operator Training program shall be required for allpersonnel who operate this vehicle.

The Operator Training program shall include thefollowing:

• Operation of this vehicle under circumstancesnormally 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 theOperator Training program are authorized to drive thisvehicle. Operators must possess the visual, auditory,physical, and mental ability to safely operate this vehicleas specified in the American National Standards InstituteControlled Personnel and Burden Carriers ANSI B56.8.

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

• Demonstrate a working knowledge of each control.

• Understand all safety rules and guidelines aspresented 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 allconditions.


Safety RulesPage 4

VEHICLE CONTROLS

1) Headlight Switch

The headlight switch is located on the left side of theinstrument panel. Push the top of the switch to turn thelights on. Push the bottom of the switch to turn the lightsoff.

2) Hi-Low Switch (optional)

The high-low switch is located on the lower left of theinstrument panel. Toggle the switch lever up for normalspeed. Toggle the switch lever down for slow speed.

2) Accessory Switch (Optional)

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

3) Battery Status Indicator, Analog

The battery status indicator is located to the left of thehour meter. The normal operating range is in the greenzone. Park the vehicle for a few minutes for an accuratereading. The vehicle needs charging if it is in the yellowzone. During and immediately following charging, theneedle will be in the red zone to the right. The needlewill move through the green zone toward the yellow zoneas the batteries discharge. Charge the batteries whenthe needle is in the yellow zone. If it is in the red zone tothe left, the batteries are empty and the truck should betaken out of service and charged to avoid damaging thebatteries.

4) Hour Meter (optional)

The hour meter is located to the right of the battery statusindicator. It records the number of hours the vehicle hasbeen in operation.

5) Forward-Off-Reverse Switch

The forward-off-reverse switch, located on the right sideof the instrument panel, determines the direction of travelof the vehicle. Push the top of the switch to engage theforward direction. Push the bottom of the switch toengage the reverse direction.

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

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

6) Horn Switch

The horn switch is located to the left of the steeringcolumn. Depress the switch to sound the horn, release itto turn it off.

7) Key-Switch

A key-switch, located below and to the right r side of theinstrument panel, turns on the vehicle. Rotate the keyclockwise to turn the vehicle power on, counterclockwiseto turn the vehicle power off.

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

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


Safety RulesPage 5

Battery Status Indicator, Digital Bargraph(optional)

The battery status indicator is located to the left of thehour meter. The battery status indicator has a LED bargraph that indicates the relative state of charge of thebattery. The top LED will light only when connected to afully charged battery or after completing a charging cycle.Successive lower LED’s will light as the battery chargediminishes. When the second from the bottom LEDflashes the battery energy status is in energy reserveand should be placed on charge as soon as possible.When the two bottom LED’s are alternately flashing thebatteries are empty and the truck should be taken out ofservice and charged to avoid damaging the batteries.The BSI will reset to fully charged only after a completecharge cycle is completed. A complete charge cycle isdefined as battery voltage exceeding 2.35 volts per cellfor a minimum of 6 minutes.

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 onthe lower left of the steering column. Pull the lever up to reposition the steering wheel.

Accelerator Pedal

The accelerator pedal is located to the right of the brakepedal. It controls the speed of the vehicle and operatessimilar to the accelerator pedal in an automobile. Depressthe pedal to increase speed and release the pedal todecrease speed.

Foot Brake Pedal

The foot brake pedal, is located to the right of the steeringcolumn, it is for operation with the right foot only. It workssimilar to the brake in an automobile. Applying pressureto the brake pedal slows the vehicle according to theamount of pressure applied. Relieving pressure from thepedal releases the braking action.

Park Brake

The parking brake is actuated with a hand lever, whichis located to the right of the driver. To set the parkingbrake, push down on the brake pedal and pull the leverup until it locks. To release the park brake, depress thefoot brake pedal, pull up on the park brake handle, pushthe release button, and lower the handle.


Safety RulesPage 6

Seat Interlock Switch

A switch located under the driver's seat disables theengines ignition system when the driver leaves the seat.The driver must be seated for the engine to run.

Whenever the driver leaves the vehicle, the driver shouldturn the ignition switch off and set the park brake andplace the shift lever in the neutral position.

Directional Signals (Optional)

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

Hazard Light Switch (Optional)

The hazard light switch is located on the left side of thesteering column. The switch is a small tab. To activatethe hazard lights, pull the tab out. To turn the hazardlights off, push forward or pull back the directional signallever.

Charger Interlock

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

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

The seat interlock switch is only one part of thevehicle safety system. The interlock switchshould not be relied upon as the only safetyfeature used to disable or disengage thisvehicle. Doing so could result in unexpectedmovement of the vehicle causing severe bodilyinjury and/or property damage.


Safety RulesPage 7

VEHICLE OPERATIONALGUIDELINES

Safety Guidelines

• Only qualified and trained operators may drive thisvehicle.

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

• Drive slowly when making a turn, especially if theground is wet or when driving on an incline.

• This vehicle may overturn easily if turned sharply orwhen driven at high speeds.

• Observe all traffic regulations and speed limits.

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

• Keep the vehicle under control at all times.

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

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

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

• Yield right of way to pedestrians and emergenciesvehicles.

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

• Keep a clear view ahead at all times.

Starting:

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

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

2. Set the parking brake.

3. Hold down the foot brake.

4. Rotate the Start switch to the “ON” position.

5. Release the parking brake.

6. Release the foot brake.

7. Slowly depress the accelerator pedal.

While driving:

• Slow down and sound the horn to warn pedestriansor when approaching a corner or other intersection.

• No reckless driving.

• Do not drive this vehicle on steep inclines or whereprohibited.

• Immediately report any accidents or vehicle problemsto a supervisor.

Loading and Unloading

• Do not carry more than the maximum number ofpassengers 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 secureall loads.

Towing Loads:

• Do not exceed the towing capacity of the tractor.

• Do not exceed the load capacity of the trailer. Referto documentation supplied with your trailer forinformation regarding load capacity of the trailer.

• Make sure all loads are securely tied down. Refer todocumentation supplied with your trailer forinformation regarding attaching loads to the trailer.

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

• Drive slowly when towing loads with a high center ofgravity.

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

• Allow for longer stopping distances when towingheavy loads.

• Allow for longer stopping distances when drivingdown a grade.


Safety RulesPage 8

Parking

Before leaving the vehicle:

• Set the parking brake.

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

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

In addition:

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

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

Towing This Vehicle

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

NOTE: If the vehicle is equipped with an automaticelectric brake, do not tow the vehicle withthe drive wheels on the ground.

Use another driver to steer this vehicle while it is beingtowed. Be sure the driver uses the brakes when thetowing vehicle slows or stops. Do not tow the vehiclefaster 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.

This vehicle is equipped with regenerativebraking. Follow these steps before towingthis vehicle.

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

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

Failure to follow these instructions mayresult in damage to the vehicle.

The park brake should be disabled forservicing or towing procedures only. Do notoperate the vehicle while the automaticpark brake is disabled. Operating thevehicle with the automatic park brakedisabled could lead to severe bodily injuryand/or property damage.


Safety RulesPage 9

Explosive mixtures of Hydrogen gas arepresent within battery cells at all times. Donot work with or charge battery in an areawhere open flames (including gas furnaceor water heater pilots), sparks, cigarettes,or any other sources of combustion arepresent. Always provide ample ventilationin rooms where batteries are beingcharged. Failure to do so may result insevere bodily injury and/or propertydamage.

CHARGING YOUR VEHICLE

Battery electrolyte is poisonous anddangerous. It contains sulfuric acid. Avoidcontact with skin eyes or clothing. Wearrubber gloves and safety glasses whileservicing batteries. DO NOT INGEST! Thismay result in severe bodily injury.

Signet® Charger Operation, Model HB Series

The Signet® HB serieschargers use a semi-automatic charging system.The charger will turn itselfON when the AC power cordis connected to the ACpower source and turn itselfOFF when the batteries arefully charged. Refer to the data plate on the charger forthe voltage and type power required for the charger.

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

1. Status of charge. The LED’s will display anapproximate percent of charge during the chargingcycle. Refer to the table below.

2. Error condition. All threeLED’s flashing is anindication of a chargingproblem (charger will alsobe beeping). Refer to theCharger Troubleshootingsection for information onerror codes.

Charging State LED1 LED2 LED3

0 to 50% Blinking OFF OFF

50% to 75% ON Blinking OFF

75% to 100% ON ON Blinking

Cycle complete ON ON ON

Typical Signet® Built In

Signet® Charger Operation, Model HBSseries

The Signet® HBS serieschargers are fully automatic.The charger will turn itself ONwhen the AC power cord isconnected to the AC powersource and turn itself OFFwhen the batteries are fullycharged. Once the chargecycle is complete, the chargerwill continue to monitor thebatteries. If the batteryvoltage drops during storage,the charger will start a new cycle to keep the batteriesfully charged.

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

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

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

2. Error condition. The FAULT LED flashing is anindication of a charging problem (charger may alsobe beeping). Refer to the ChargerTroubleshooting section for information on errorcodes.

Typical Signet® HBS

The key switch must be in the “OFF” positionwhen charging the batteries. Failure to turnthe key switch “OFF” may result in damage tothe vehicles electrical system.


Safety RulesPage 10

STORING / RETURNING TOSERVICEBoth storing your vehicle and returning it to serviceshould only be performed by authorized personnel.

Storing Your Vehicle

• Clean the batteries, then fill and charge beforeputting the vehicle in storage. Do not store batteriesin a discharged condition.

• Lube all grease fittings.

• Clean, dry, and check all exposed electricalconnections.

• Inflate tires to proper pressure (if applicable).

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

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

Returning toService

• Check thebattery’s stateof charge andcharge ifrequired.

• Perform ALLmaintenance checks in the periodic checklist.

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

• Test drive before putting into normal service.

StorageTemperature

(F)

Charging Interval(months)

Over 60 1

Between 40 and 60 2

Below 40 6

To obtain the maximum battery life:

Charge the batteries only after they reach a normaldischarge as indicated on the Battery Status Indicator(BSI). Failure to follow this guideline could result in thebatteries entering an overcharge state, which will reducethe life of the batteries. If you find it necessary to chargethe batteries before they are completely discharged werecommend waiting until they are discharged a minimumof 25% to reduce the possibility of overcharging. Referto Vehicle Controls in this section for information on howto read the BSI.

Do not discharge the batteries beyond a normaldischarge as indicated on the BSI. Refer to VehicleControls in this section for information on how to readthe BSI.

Check the battery electrolyte once a week. Do not chargethe batteries if the battery electrolyte is low. Chargingwhen the electrolyte is low will damage the batteries andshorten their life-span. Only authorized personnel shouldperform battery maintenance including maintaining thebattery electrolyte level. Refer to Section Maintenance,Service and Repair for battery maintenanceinformation.

Do not interrupt the charging cycle. When the charger isplugged in, allow it to turn off before disconnecting.Interrupting the charging cycle could lead to overchargingor discharging the batteries too deep. Both circumstanceswill shorten the life of the batteries.

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 thisbreak in period and may require longer charging times.

Lestronic II® Charger Operation

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

Charging Time

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

• Capacity of the batteries, higher capacity requireslonger charge time.

• Output of the charger, higher output requires lesscharge time.

• Depth of discharge, the deeper a battery isdischarged, the longer it takes to charge.

• Temperature, low temperatures require longer chargetime.

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

Charging time is limited to 20-hours (HBS) or 18-hours(HB). A fault will occur if the charging time exceeds the20-hour limit.


Safety RulesPage 11

PERIODIC MAINTENANCE CHECKLIST

NOTE: A full page copy of the Periodic Maintenance Checklist is on theVehicle Documentation CD under the [Misc] sub folder.


Safety RulesPage 12

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MAINTENANCE GUIDELINES FORSEVERE DUTY APPLICATIONS

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

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

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

• Extreme temperature.

• Bumpy, dusty, or ill maintained roads.

• Excessively wet areas.

• Corrosive or contaminated areas.

• Frequent loading of vehicle at/near capacity.

• Use on multiple shifts.

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

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

Daily Visual inspection:

Tire condition and pressure.

External frame damage (body).

Operation of all lights and warning alarms and/or horns.

Smooth and proper operation of all controls such as but not limited to:

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

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

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

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

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

Inspect for leaking fluids or grease.

Table of Contents

Gen

eral

Mai

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ceMaintenance Guidelines ............................... 2Troubleshooting Guide ................................ 3Lubrication Chart .......................................... 4

Model E 4-55 Tow Tractor

Model C 4-25 Tow Tractor

Maintenance, Service and Repair

Page 2

Maintenance Guidelines

• Avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicleperformance checks in an authorized area where safe clearance exists.

• Before starting the vehicle, follow the recommended safety procedures in Section 2, “Safety Rules andOperational Information.”

• Ventilate the work area properly.

• Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed anddirectional control mechanisms, warning devices, lights, governors, guards, and safety devices.

• Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections inconformance with Taylor-Dunn’s® recommended procedures.

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

• 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.

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

Before starting any repairs:

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

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


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

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

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

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


Page 3

Troubleshooting Guide

Symptom Probable Cause

Steering Pulls in One DirectionFront End Out of Alignment

Low Tire Pressure

Hard Steering

Dry Lube Points in Steering Linkage

Damaged King Pin/Ball Joint

Low Tire Pressure

Excessive Steering Play

Worn Ball Joints

Mis-Adjusted or Worn Steering Gear

Loose Steering Linkage

Lack of Power or Slow Operation

Brakes or Parking Brakes Dragging

Batteries Discharged or Defective

Worn Drive Gears

Front End Out of Alignment

Defective Speed Control

Abnormal Noise

Worn Drive Gears or Bearings

Worn Front /Rear Axle Bearings

Loose Lug Nuts

Motor Bearings Worn

Oil Leak in Rear Bearing AreaRear Wheel Bearing and/or Gasket Failed

Drive Over Filled

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Pedal Low

Brake Worn (1/16" Wear Limit)

Brake Fluid Low

Brakes Out of Adjustment

Braking Power Low

Brake Worn (1/16" Wear Limit)

Brake Pads Contaminated with Fluid

Brake Pedal Linkage Binding

Brakes Out of Adjustment

Air in Brake Lines

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


Page 4

Lubrication Chart

# Description Locations Lubricant Type

1 Front Leaf Springs General Purpose Grease

2 King Pin General Purpose Grease

3 Ball Joints General Purpose Grease

4 - - -

5 Front Wheel Bearings High Temperature Wheel Bearing Grease

6 Rear Leaf Springs General Purpose Grease

7 Drive Drain Plug - -

8 Drive Level Plug - -

9 Drive Fill Plug 1 30 wt Motor Oil

11

2

2

3

5

5

66

9

Drive as viewedfrom rear

TABLE OF CONTENTS

Fro

nt

Axl

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Inspect the Front Wheel Bearings andKing Pin......................................... 2

Adjust Front Wheel Bearings ............ 3Front Axle Removal and Installation .. 4

Removal ................................................................ 4Installation ............................................................ 4

Front Axle Disassembly ..................... 5Replace Front Wheel Bearings .......... 6Replace the King Pins and Bushings . 7Replace the Steering Knuckle ............ 8

Maintenance, Service, and Repair

Front AxlePage 2

INSPECT THE FRONT WHEEL BEARINGS AND KING PIN



3. Confirm the electric park brake is set.



Always use a lifting strap, hoist, and jackstands, of adequate capacity to lift andsupport the vehicle. Failure to use liftingand support devices of rated load capacitymay result in severe bodily injury.

8. Spin the wheel and listen for any grinding noise. Anygrinding noise may be an indication of worn ordamaged wheel bearings.

NOTE: Refer to the Replace Front WheelBearings section for information regardingthe replacement of the wheel bearings.

9. Lower the vehicle.

10. Reconnect the main positive and negative cablesat the batteries.

11. Remove the blocks from behind the wheels.

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

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6. Raise the front of the vehicle and support with jackstands.

7. Grab the top and bottomof the tire/wheelassembly. Feel for anymovement or play whilepulling and pushing onthe top and bottom of thetire. Any movement orplay is an indication ofloose wheel bearings orking pin.

NOTE: Refer to the Adjust Front Wheel Bearingssection for information regarding theadjustment of the wheel bearings.

NOTE: If the king pin is loose, then refer to Replacethe King Pins and Bushings forinformation regarding replacing the king pinbushings. There are no adjustments for theking pin or bushings.


Front AxlePage 3

ADJUST FRONT WHEELBEARINGS


7. Remove the hub dust cap and cotter pin.

8. While rotating the hub, tighten the spindle nut to30 ft-lbs. This seats the bearings.

9. Back off the spindle nutone flat until the hubturns, but is not loose.

10. Spin the wheel andlisten for any grindingnoise. Any grindingnoise may be anindication of worn ordamaged wheelbearings.

NOTE: Refer to the Replace Front WheelBearings section for information regardingthe replacement of the wheel bearings.

11. Install a new cotter pin.

12. Install the dust cap.











Hub with Dust CapRemoved

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Front AxlePage 4

FRONT AXLE REMOVAL AND INSTALLATION







Installation


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

NOTE: Use all new cotter pins.

NOTE: Refer to the Replacing the Ball Jointssection for information regarding the installingthe ball joints or rod ends.

NOTE: Refer to Tires and Wheels section forinformation regarding removing the frontwheels.

8. Realign the front wheels. Refer to SteeringComponent Service section for informationregarding realigning the front wheels.

9. If equipped with front brakes, bleed the brakes. Referto Brake Service section for information regardingbleeding the brakes.











Removal


7. Remove both front wheels. Refer to Tires andWheels section for information regarding removingthe front wheels.

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

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

NOTE: Refer to the Replacing the Ball Jointssection for information regarding the removalof the ball joints or rod ends.

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

11. Disconnect the front axle beam from the front springsand remove the axle from the vehicle.

NOTE: In some configurations the front springs andor shocks will have to be removed in order toremove the axle beam. Refer to section FrontSuspension for information regardingremoving the springs and shocks.


Front AxlePage 5

FRONT AXLE DISASSEMBLY

Disassembling and reassembling involves removing and replacing the left and right steering knuckles and kingpin bushings. Refer to the following sections for information regarding these procedures:

Replace the Steering Knuckle

Replace the King Pins and Bushings

NOTE: The front axle does not have to be removed unless the axle beam must be replaced. Refer to Front AxleRemoval and Installation for information regarding removing the front axle.

Yoke

Lower Bushing

King Pin Nut

Cotter Pin

Outer Bearing

Bearing CapCastle Nut

Flat Washer

Steel WasherBronze washerSteel Washer

Small Cup

Large Cup

Upper Bushing

King Pin

ThrustWasher


Front AxlePage 6

REPLACE FRONT WHEEL BEARINGS







13. Install the hub dust cap.

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

NOTE: Refer to the Brakes for information regardingthe installation of the brake body.





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7. Remove the tire/wheel assembly from the hub. Referto Tires and Wheels for information regardingremoving the wheel assembly.

8. Remove the hub dust cap, cotter pin, and spindlenut.

9. Remove the hub from the steering knuckle.

NOTE: For a front disc brake option you must removethe brake body before removing the hub.Refer to the Brakes section for informationregarding the removal of the brake body.

NOTE: Catch the outer bearing as it falls out.

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

11. Inspect and replace the races, bearings, and seals.

NOTE: It is recommended to replace all four bearingsand races in the left and right wheels as aset.

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

NOTE: Refer to Adjust Wheel Bearings forinformation regarding proper tightening of thespindle nut


Front AxlePage 7

REPLACE THE KING PINS ANDBUSHINGS

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

• Bronze bushings in the axle beam.

• Bronze bushings in the steering knuckle.

• Metal backed teflon bushings in the axlebeam or suspension arm.

NOTE: Bronze bushings must be reamed or broachedto the proper diameter after they are pressedinto the axle beam or steering knuckle.







Refer to the illustration below for the type of bushingin your vehicle.


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

NOTE: It is not necessary to remove the tie rod ordrag 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 knuckleor suspension arm.

a) Ream or broach bronze bushings to 0.878 +/-0.001 inches.

10. Inspect the king pin for damage or wear. If anydamage or wear is noted then the king pin must bereplaced.

11. Reassemble in reverse order.

NOTE: Refer to Replace the Steering Knuckle forinformation on installing the steering knuckle.

NOTE: It is recommended that the thrust washers orbearing be replaced whenever replacing theking pin bushings. Refer to theReplacement Parts section for theorientation of the bearing or washers in yourvehicle.

12. Grease the bushings (bronze only).





Failure to correctly broach or ream bronzebushings may result in steering difficulty andloss of control of the vehicle causing severebodily injury and /or property damage.


Front AxlePage 8

REPLACE THE STEERING KNUCKLE







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

14. Pack the thrust bearing with grease.

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

NOTE: Refer to Adjust Wheel Bearings forinformation regarding proper tightening of thespindle nut

16. Install new cotter pins.

17. Realign the wheels.

NOTE: Refer to the Steering section for informationregarding realignment of the front wheels.






7. Remove the tire/wheel assembly. Refer to Tires andWheels section for information regarding removingthe tire/wheel assembly.

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

NOTE: For a front disc brake option you must removethe brake body before removing the hub.Refer to the Brakes section for informationregarding the removal of the brake body. Donot remove the hydraulic brake line from thebrake body. If the brake line is removed thenit will be necessary to bleed the brakes.

NOTE: Catch the outer bearing as it falls out.

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

10. While supporting the knuckle, remove the king pinand thrust bearing.

11. Remove the knuckle from the axle.

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

NOTE: Both the left and right side bushings and thrustbearings should be replaced as a set.

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TABLE OF CONTENTS

Ste

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Front End Alignment .......................... 2Inspect Ball Joints ............................. 5Inspect Rod Ends .............................. 5Adjust the Steering Gear ................... 6Replace the Steering Shaft ................ 7Replace the Steering Wheel .............. 8Replace the Steering Gear ................ 8Replace the Ball Joints, Tie Rods,

and Drag Link ................................ 9Replacing the Drag Link ...................................... 10Replacing the Tie Rod .......................................... 11

Center the Steering Gear ................... 11Repair the Steering Gear ................... 12


SteeringPage 2

FRONT END ALIGNMENT

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

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

Center the Steering


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

8. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section forinformation regarding removing the ball jointor rod end from the drag link.

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

Ball Joint

Rod End






NOTE: Refer to Center the Steering Gear sectionfor information regarding centering of thesteering gear.

10. At this point both the steering wheel and the frontwheels should be tied up and held in position. Ifone or the other is not tied up then you must startfrom the beginning.

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

NOTE: Remember the position and orientation of theclamps.

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

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

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

Always use a lifting strap, hoist, and jackstands, of adequate capacity to lift andsupport the vehicle. Failure to use lifting andsupport devices of rated load capacity mayresult in severe bodily injury.

Do not drive the vehicle while the steeringwheel or front wheels are tied in position.Driving the vehicle while the steering wheelor front wheels tied in the position may causeloss of control of the vehicle resulting insevere bodily injury and/or property damage.

If the clamps are positioned so that theycontact other components, it may result insteering failure and loss of control of thevehicle causing property damage and/orsevere bodily injury.


SteeringPage 3

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

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

16. Untie the steering wheel and the front wheels.


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


20. Release the parking brake and test drive thevehicle.


SteeringPage 4

Front wheel alignment

NOTE: It is recommended to center the steering beforealigning the front wheels. Refer to the Centerthe Steering section for information.


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

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

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

NOTE: Remember the position and orientation of theball joint clamps.

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

11. Measure the distance between the lines at the frontof the tires.

Tie Rod

Sleeve Clamps

Front Measurement

Rear Measurement







12. Measure the distance between the lines at the rearof the tires.

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

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

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

16. Untie the steering wheel.




Rotate the steering wheel from a full left turnto a full right turn and make sure that the balljoint clamps do not contact any othercomponent. Clamps positioned so that theycontact other components may result insteering failure and loss of control of thevehicle causing severe bodily injury and/orproperty damage.



SteeringPage 5

Typical Ball Joint

INSPECT BALL JOINTS

NOTE: A set of ball joints and/or rod ends will wear atthe same rate. If a ball joint and or rod end isworn out, then all should be replaced as aset.

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

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

8. If the ball joint housing moves up or down then theball joint is worn out and should be replaced. Referto section Replacing a Ball Joint for informationregarding replacing ball joints.

9. Untie the front wheels.










INSPECT ROD ENDS

NOTE: A set of ball joints and/or rod ends will wear atthe same rate. If a ball joint and or rod end isworn out, then all should be replaced as aset.

6. Visually inspect each rod end for any signs of playbetween the ball and the nylon or brass bushing inthe housing.

7. If any play is evident, then the rod end is worn outand should be replaced. Refer to section Replacethe Ball Joints, Tie Rods, and Drag Link forinformation regarding replacing ball joints.










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

< Stud


SteeringPage 6

ADJUST THE STEERING GEAR

NOTE: In some vehicle configurations it may benecessary to remove the steering gear toperform this procedure. Refer to Replace theSteering Gear for information regardingremoving the steering gear.


7. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section forinformation regarding removing the ball jointfrom the drag link.

8. Loosen the gear lash jam nut and the worm bearingadjuster jam nut.

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

10. Loosen the worm bearing adjuster and then tightenjust enough to remove all end play from the inputshaft and then an additional 1/8 turn more.

11. While holding the worm bearing adjuster so that itcannot turn, tighten the worm bearing adjuster jamnut.







12. Find the center position of the steering shaft:

A. Turn the steering shaft all of the way in onedirection.

B. While counting the rotations, turn the steeringshaft all of the way in the opposite direction.

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

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

14. While holding the gear lash adjusting screw so thatit cannot turn, tighten the gear lash adjusting screwjam nut.





SteeringPage 7

REPLACE THE STEERINGSHAFT

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

7. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel sectionfor information regarding removing thesteering wheel.

8. Remove the upper steering shaft bushing or bearingfrom the steering column.

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

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

NOTE Most vehicle configurations will now allow thesteering shaft to slide off of the steering gearinput shaft and then back down out of thesteering column. If there is not enoughclearance for this procedure then the steeringgear must be removed. Refer to Replace theSteering Gear for information regardingremoving the steering gear.






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

Make sure that the pinch bolt is not alignedwith the flat on the steering shaft. Aligningthe bolt with the flat could result in failure ofthe steering and loss of control of the vehicle.This could lead to property damage and/orsevere bodily injury.

11. Remove the steering shaft from the vehicle.

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

13. Install the steering shaft in reverse order using anew pinch bolt. Orientate the shaft so that the pinchbolt is opposite the flat in the steering gear shaft.See the illustration below.

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





SteeringPage 8

REPLACE THE STEERINGGEAR

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

7. Remove the steering shaft. Refer to Replace theSteering Shaft section for information regardingremoving the steering shaft.

8. Remove the pitman arm using a pickle fork.

NOTE: On some vehicle configurations it may berequired to remove the drag link from thepitman arm. Refer to Replace the Ball Jointssection for information regarding removing theball joint from the pitman arm.

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

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

11. Center the steering gear. Refer to Center theSteering Gear section for information regardingcentering the steering gear.

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









Failure to support the steering gear will resultin the steering gear falling out of the vehicleand could cause property damage and/orsevere bodily injury.

REPLACE THE STEERINGWHEEL

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

7. Remove the steering wheel nut.

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

9. Position the front wheels in the straight aheadposition.

10. Lightly grease the steering wheel splines and installthe replacement steering wheel orientated asshown in the illustration to the right.

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

12. Reinstall the horn switch (if equipped).










SteeringPage 9

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

Rod End

Ball Joint

Rod End Nut

Rod End

Jam Nut

SteeringSleeve

Steering Arm

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

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

NOTE: If a rod end or ball joint is worn out, werecommend replacing all of the ball joints and/or rod ends as a set.

Replacing a Rod End


7. Loosen the rod end jam nut or clamp on the steeringsleeve.

8. Remove the rod end nut.

9. Remove the rod end from the steering arm..

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

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







12. Realign the front wheels.



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


16. Release the park brake and test drive thevehicle.


SteeringPage 10

Replacing a Ball Joint


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 thesteering arm.

10. Remove the ball joint from the steering sleeve.

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

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













Replacing the Drag Link

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


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

NOTE: Refer to the Replacing the Ball Joints sectionfor information regarding the removal of theball joints or rod ends.

8. Remove the drag link as an assembly.

9. Install in reverse order.














SteeringPage 11

Replacing the Tie Rod

The Tie Rod is the linkage that connects the twosteering knuckles together. Refer to the illustrationbelow..


7. Remove the ball joints or rod ends from the steeringknuckles.

NOTE: Refer to the Replacing the Ball Joints sectionfor information regarding the removal of theball joints or rod ends.

8. Remove the tie rod as an assembly.














CENTER THE STEERING GEAR

NOTE: The drag link must be disconnected from thepitman arm or the pitman arm removed fromthe steering gear to perform this procedure.Refer to the appropriat section for details.

1. Remove the pitman arm.

2. Rotate the input shaft clockwise until it stops.

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

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

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


SteeringPage 12

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

5. Remove the worm shaft seal.

6. Remove the pitman shaft seal.

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

REPAIR THE STEERING GEAR

Disassembly

NOTE: The steering gear must be removed from the vehicle for thisprocedure. Refer to Replace the Steering Gear section forinformation regarding removing the steering gear.

NOTE: The steering gear is packed with grease. Only perform maintenanceon the steering gear in an area that will contain any grease thatmay spill out of the steering gear when it is disassembled.

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

3. Remove the side cover/pitman shaftassembly by removing the three side coverbolts and then pulling the assembly out ofthe housing.

NOTE: The side cover/pitman shaftassembly normally does nothave to be disassembled.

1. Center the steering gear.

A. Turn the steering shaft all of the way inone direction.

B. While counting the rotation, turn thesteering shaft all of the way in the oppositedirection.

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

2. Remove the worm bearing adjuster lockingring and the worm bearing adjuster.


SteeringPage 13

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

9. Remove the ball guide clamps, ball guides and allof the ball bearings.

10. Remove the ball nut from the worm shaft.

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

Reassembly

1. Lightly lubricate all parts before reassembly.

2. Install a new worm shaft seal and pitman shaft seal into thehousing.

3. Install the upper worm bearing cup.

4. Divide the ball bearing into two equal groups.

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

6. Insert the ball guides into the ball nut.

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

NOTE: Do not rotate the worm shaft while installing the bearings.This may cause one or more of the bearings to enter thecrossover passage in the ball nut, causing improperoperation.

8. Install the ball guide clamp.

9. Place the upper worm bearing on the worm shaft and installthe worm shaft/ball nut assembly into the housing being carefulnot to damage the worm shaft seal.

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

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

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

13. Place a new gasket onto the housing and install the assembledpitman shaft/side cover onto the housing using two of the threemounting bolts.

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

15. Adjust the steering gear.

NOTE: Refer to Adjust the Steering gear section for informationregarding adjusting the steering gear.

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

Installing Bearings

Installing Worm Shaft into housing

TAYL

OR -

DUNN

TABLE OF CONTENTS

Inspect the Service Brake ................. 2Brake Shoes .......................................................... 2Brake Drum .......................................................... 2

Inspect the Parking brake .................. 3Adjust the Parking Brake ................... 3

Wheel Park Brake (mechanical drum) ................. 3Adjust the Service Brakes ................. 4

............................................................................... 4Replace Rear Brake Shoes ............... 5

Bra

ke S

ervi

ce


BrakesPage 2

Brake Shoes

NOTE: The wheel must be removed to accuratelymeasure the brake shoes. Refer to Tires andWheels section for information on removingthe wheel.

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

NOTE: If this is a riveted lining, then the measurementmust be to the top of the rivets.

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

Current Taylor-Dunn® brakes are asbestosfree. However, there is the possibility thatthe original brakes were replaced withaftermarket parts containing asbestos.Since this possibility exists, all brake partsshould be handled as if they containasbestos. Refer to Appendix C forrecommended handling precautions.

Brake Drum

NOTE: The wheel must be removed to accuratelymeasure the brake drum. Refer to Tires andWheels section for information on removingthe wheel.

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

If the brake drum is grooved or worn beyond the servicelimit 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 measurementsexceeds 0.010-inches then the brake drum must bereplaced.

Current Taylor-Dunn® brakes are asbestosfree. However, there is the possibility thatthe original brakes were replaced withaftermarket parts containing asbestos.Since this possibility exists, all brake partsshould be handled as if they containasbestos. Refer to Appendix C forrecommended handling precautions.

Do not use a brake drum that is wornbeyond its service limits. A drum wornbeyond its service limits could fail andcause loss of brakes resulting in severebodily injury and/or property damage.

INSPECT THE SERVICE BRAKE


BrakesPage 3

INSPECT THE PARKINGBRAKE

6. Release the park brake.

7. Inspect the brake shoes. The parking brake shoesare the same as the service brake shoes. Refer toInspect the Service Brake section to inspect thebrake shoes.

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

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



12. Remove the blocks from the wheels






ADJUST THE PARKING BRAKE

Wheel Park Brake (mechanical drum)

Trucks equipped with mechanical drum brakes do nothave a separate adjustment for the parking brake. If theparking brake requires adjustment, then the entire brakesystem is in need of adjustment. Refer to Adjust theService Brake section for information regardingadjusting the brakes.


BrakesPage 4

6. Raise the wheel off of the ground and support withjack stands.


8. Remove the tire/wheel assembly.

NOTE: Refer to Tires and Wheels section forinformation on removing the wheel.

9. Align the adjusting access slot in the brake drumwith the adjusting star wheel at the bottom of thebrake.

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

Brake drum shown with the access slotaligned with the adjusting star wheel .

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

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

NOTE: The brake adjustment is inside of the left and right brake. Do not adjust the brake by means of thebrake cables as this will cause mis-operation of the brakes. If you hear a single “clunking” noisewhile braking it may be due to mis-adjustment of the brake cables or linkage. Refer to ReplaceBrake Linkages/Cables for information regarding proper adjustment of the cables and linkages.

ADJUST THE SERVICE BRAKES







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

12. Install the tire/wheel assembly.

13. Repeat this procedure for the opposite side brake.



16. Remove blocks from behind the wheels.



BrakesPage 5







Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the originalbrakes 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 forrecommended handling precautions.

NOTE: It is recommended that both the left and rightbrake pads be replaced as a set.


7. Raise the rear wheels off of the ground and supportwith jack stands.

8. Remove the tire/wheel assembly. Refer to Tiresand Wheels section for information on removingthe wheel.

9. Remove and inspect the brake drum. Refer toInspect the Service Brake section forinformation regarding inspecting the brake drum.

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

11. Remove the hair pin clips from the actuating armsand discard.

12. Remove the brake shoes and brake adjustorassembly from the backing plate.

13. Thoroughly clean and inspect the adjustorassembly. Replace parts as required.

14. Apply a very light coating of high temperaturegrease to the adjustor screw threads.


16. Repeat for the opposite side.

17. Adjust the brakes. See Adjust the ServiceBrakes section for information regardingadjusting the brakes.


19. Reconnect the main positive and negative at thebatteries.

20. Lower the wheels to the ground.



REPLACE REAR BRAKE SHOES

Do not allow grease to contact any of thebraking surfaces. Braking surfacescontaminated with grease may cause thebrakes to fail resulting in property damageand/or severe bodily injury.

Brake Adjuster Assembly

TAYL

OR -

DUNN

TABLE OF CONTENTS

Check Oil Level ............................................. 2Change Oil ..................................................... 3Motor ............................................................. 4

Removal .................................................................... 4Installation ................................................................. 4

Rear Hub with Brake Drum ........................... 5Removal and Installation ........................................... 5

Rear Axle ....................................................... 6Replace the Axle Bearing .......................................... 8

Transmission................................................. 9Removal .................................................................... 9Installation ................................................................. 10

Differential Case ............................................ 12Disassemble ............................................................. 12Assemble .................................................................. 15

Transmission Service

Typical Transmission


Transmission Page 2

CHECK OIL LEVEL

Park the vehicle on a level surface.

6. Place a drain pan that can hold a minimum of2-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. Thisindicates that the transmission has the correctamount of oil.

8. If no oil comes out, then lift the side of the vehiclewith the level plug and add 11-ounces of oil throughthe 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 levelplug.

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


12. Test drive the vehicle

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



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


Level Plug viewed from in front ofthe right rear wheel

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


Transmission Page 3

Level Plug viewed from in front ofthe right rear wheel






Always use a lifting strap,hoist, and jack stands, ofadequate capacity to lift andsupport the vehicle. Failureto use lifting and supportdevices of rated load capacitymay result in severe bodilyinjury.

CHANGE OIL

Park the vehicle on a level surface.

6. Place a drain pan that can hold a minimum of2-quarts of oil under the transmission.

7. Remove the level plug then lift the side of the vehiclewithout 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 levelplug.

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


12. Test drive the vehicle


Transmission Page 4






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

MOTOR

Removal

NOTE: In some vehicle configurations the transmission assembly will haveto be removed to allow clearance to remove the motor. Refer toTransmission section for information on removing thetransmission assembly from the vehicle.

6. Remove the motor wires from the motor.

HINT: Tag each wire with the number of theterminal it was removed from.

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

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

Installation

1. Remove the rubber bushing from inside of the motorarmature coupling.

2. Thoroughly clean all grease from the transmissioninput shaft, rubber bushing and the motor armaturecoupling.

3. Install the rubber bushing back into the motorarmature coupling.

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

5. Install the motor in reverse order.

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


Transmission Page 5






Too much grease on the axlesplines could contaminate thebraking surfaces resulting inloss of braking power. Thiscould lead to severe bodilyinjury and/or propertydamage.

Integral hub Removable hub

REAR HUB WITH BRAKE DRUM

Removal and Installation

NOTE: Some vehicle configurations donot have a removable hub. Thehub is an integral part of the rearaxle. See the illustrations to theright to identify the hub on yourvehicle.

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

7. Remove the cotter pin from the axle shaft.

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


10. Lightly grease the axle shaft splines.

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 regardinginstalling the rear wheel.

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


Transmission Page 6






REAR AXLE

Your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axleand the other is an integral part of the rear axle. The service of both of these axles is addressed in thissection 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 removingthe tire and wheel assembly.

Remove and Install Axle - Removable Hub

6. Remove the rear wheel. Refer to Replace the RearTire/Wheel section for information regardingremoving the rear wheel.

7. Remove the axle hub. Refer to Rear Hub/BrakeDrum 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 theend 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 7






Remove and Install Axle - Non - Removable Hub

NOTE: The brake assembly is retained by the axle bearing and must beremoved along with the axle assembly.

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

7. Remove the brake drum.

8. Remove the mechanical brake linkage from thebrake arm.

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

10. Remove the four bolts holding the axle/brakeassembly to the axle housing.

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

HINT: Use a slide hammer threaded onto oneof the wheel studs.

12. If the axle bearing is to be replaced, remove thebearing 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 Brakessection for information on bleeding the brake system.



Transmission Page 8

Do not drill all of the waythrough the retainer into theaxle shaft. Drilling into theaxle shaft will weaken theaxle shaft and could cause theaxle to fail resulting in severebodily injury and/or propertydamage.

Replace the Axle Bearing

NOTE: The axle must be removed from the transmission for this procedure.Refer to Remove and Install Axle for information regardingremoving the rear axle.

Removable Hub:

1. Remove the hub from the axle shaft. Refer to Rear Hub/Brake Drum for information regardingremoving 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 andwrap it in plastic to prevent corrosion.

Non-Removable Hub

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

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

3. Press the bearing and brake assembly off of theaxle 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 toprevent corrosion.


Transmission Page 9






TRANSMISSION

Removal

6. Remove the rear deck access plate.

7. Disconnect the motor wires from the motor.

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

9. Remove the brake cable from the mounting bracket.

10. If equipped with hydraulic brakes, disconnect thebrake line from the wheel cylinder.

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



Transmission Page 10

Installation

6. Lift the rear of the vehicle high enough to roll the transmission under the vehicle.

Always use a lifting strap,hoist, and jack stands, ofadequate capacity to lift andsupport the vehicle. Failure touse lifting and support devicesof rated load capacity mayresult in severe bodily injury.

12. Remove the four u-bolts holding the transmissionto the left and right springs.

13. Remove the lower bolt from the left and right springhangers.

14. Lift the rear of the vehicle high enough to roll thetransmission out from under the vehicle.

15. Place the frame of the vehicle on jack stands.









7. Place the transmission on to the locating pins oneach leaf spring.

8. Install the four u-bolts so that the u-bolt nuts aretight enough to hold the springs on the locating pinsbut not so tight as to keep the springs from moving.

9. Install the lower spring hanger bolts. Torque to 20ft-lbs.

10. Tighten the u-bolt nuts.

11. Install the brake cable. Use a new cotter pin.

12. Adjust the brakes. Refer to the Brake Servicesection for information regarding adjusting thebrakes.

13. Adjust the mechanical brake linkages. Refer to theBrake Service section for information regardingadjusting the brake linkages.

14. If equipped with hydraulic brakes, install the brake line and bleed the brakes. Refer to theBrake Service section for information regarding bleeding the brakes.

15. Connect the wires to the motor.




DIFFERENTIAL CASE

Disassemble

1. Remove the transmission from the vehicle. Refer to Transmission-Remove section forinformation 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 forinformation 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 carefulnot to bend or damage the case cover flange or thesealing surface of the differential case.

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

NOTE: The bearing caps are marked foridentification. When the transmission isreassembled they must be installed intheir original position.

7. Remove both bearings from the differential case.



8. Remove the final drive gear from the differentialhousing.

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

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

11. Remove both snap rings from the intermediate shaftbore.

12. Using a soft metal or hard wood dowel, drive theintermediate shaft through the bearing just enoughto allow clearance for an ID bearing puller. Do notattempt to drive the shaft out of the opposite end ofthe transmission.



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

13. Remove the intermediate bearing with an ID bearingpuller.

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

15. Remove the o-rings from each end of theintermediate 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.



19. Remove the o-rings from both sides of theintermediate shaft bore and the input shaft boreand discard the o-rings.

Assemble

NOTE: When pressing bearings, do not press against or support the outerrace as this will damage the bearing.

NOTE: All snap rings should fit tightly into their grooves. If a snap ring isloose, then it must be replaced.

NOTE: All internal components should fit easily together. Do not hit anyshaft 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 theinside of the housing.

2. Press new bearings onto the input shaft anddifferential case.

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



Use a hard wood dowel thesame diameter as the bearingbore to drive the bearing intoplace. Do not drive against theinner race as this will damagethe bearing.

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

5. Insert the intermediate shaft into the housing and

TABLE OF CONTENTS

Su

spen

sio

n

Replace the Rear Springs .................. 2Replace the Front Springs ................. 3Replace the Spring Bushings ............. 4


SuspensionPage 2

REPLACE THE REAR SPRINGS

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

HINT : In most vehicles it will be easier if the springsare replaced one at a time.

6. Raise the rear of the vehicle and support with jackstands.

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

8. Unbolt the spring from the axle housing.







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

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

11. Remove the spring from the vehicle.

12. Inspect the spring bolts and spring hangers for

signs of wear or damage. If any wear or damageis found, then they must be replaced.

13. Install the new spring in reverse order.

14. If the spring hanger bolts do not have a greasefitting, lube the spring bushings before installingthe spring.

15. Tighten the spring hanger bolts securely, but notso tight as to bind the spring.





Damaged or worn spring bolts or hangerscould result in sudden failure of thesuspension causing severe bodily injury orproperty damage.


SuspensionPage 3

REPLACE THE FRONTSPRINGS

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

HINT : In most vehicles it will be easier if the springsare replaced one at a time.

6. Raise the front of the vehicle and support withjack stands.

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

8. Unbolt the spring from the front axle beam.

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







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


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

13. Install the new spring in reverse order.

14. If the spring hanger bolts do not have a greasefitting, lube the spring bushings before installingthe spring.

15. Tighten the spring hanger bolts securely, but notso tight as to bind the spring.





Damaged or worn spring bolts or hangerscould result in sudden failure of thesuspension causing severe bodily injury orproperty damage.


SuspensionPage 4

REPLACE THE SPRINGBUSHINGS

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

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

• The internal bushing is a plastic insert that is pressedinto the spring eye. There are one of these bushingsfor each spring eye.

• The external bushing consists of two plastic bushingson each end of the spring eye.

• Refer to the parts list to identify the bushings used inyour vehicle.

6. Raise the front or rear of the vehicle dependingon which spring is to be removed and support withjack stands.








NOTE: Refer to Replace the Front Springssection for information regarding removingthe front springs.

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

9. Remove the spring bushing(s):

• For internal bushing, press the spring bushingsout of the two spring eyes and from the mountingeye on the vehicles frame.

• For external bushing, Remove the bushingsfrom the spring eye.

10. Install the new bushings in reverse order.

HINT: Apply a light coating of grease to the bushingbefore pressing into the spring eye.

11. Install the spring onto the vehicle.

NOTE: Refer to Replace the Front Springssection for information regarding installing thefront springs.

12. Repeat for the other spring.





TABLE OF CONTENTS

Tire Inflation ...................................... 2Tire Inspection ................................... 2Replace the Tire/Wheel ..................... 3Replace the Tire (pneumatic) ........... 3Repair the Tire (pneumatic) .............. 4

Tir

es a

nd

Wh

eels


Tires and WheelsPage 2

TIRE INFLATION

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

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

Tire pressures must be checked when the tire is cold.






TIRE INSPECTION6. Check the tire pressure. Refer to Tire Inflation

section for information on checking the tirepressure.

7. Inspect the tire tread depth. Minimumrecommended tread depth is 1/16-inch. There area series of tread depth wear indicators aroundthe circumference of the tire. They will appear as1/2-inch bands across the tread as the tireapproaches its wear limit (see illustration below).Replace the tire if any tread depth indicator canbe seen or any part of the tread depth is 1/16-inch or less. Refer to Replace the Tire sectionfor information regarding replacing the tire.

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

NOTE: Refer to Tire Inflation section or SteeringComponent Service section for informationon proper tire inflation or front end wheelalignment.

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

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

NOTE: Refer to Replace the Tire section forinformation regarding replacing the valvestem.

11. Inspect the tread and side walls for debris in therubber that could lead to a puncture. If any debrisis found it should be removed and the tireinspected for a leak.



REPLACE THE TIRE/WHEEL

6. Raise the wheel to be replaced off of the groundand support with jack stands.

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


9. Following the pattern shown on the followingpage, cross tighten the wheel nuts in two stagesas follows:

1st stage to approximately 20 ft-lbs.

2nd stage to 80-90 ft-lbs.


11. Lower the wheel to the ground.








REPLACE THE TIRE(PNEUMATIC)NOTE; To replace the tire, the tire/wheel assembly

must be removed from the vehicle. Refer toReplace the Tire/Wheel section forinformation on removing the tire/wheelassembly.

Tire replacement should only be performed by personneltrained in tire replacement.

The tire replacement procedure will be unique to thetype of replacement equipment being used. Refer to theinstructions provided with your equipment.

Always use a new valve stem when replacing a tire.

1. Remove the tire from the wheel.

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

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

4. Lubricate the valve stem with liquid soap.

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

NOTE: The valve stem tool is available at most autorepair shops.

6. Install the tire onto the wheel following theinstructions provided with your tire replacementequipment.

7. Inflate the tire to the proper pressure and checkfor leaks.

8. Install the valve stem cap.

Explosion Hazard. Fully deflate the tirebefore attempting to remove the tire fromthe wheel. Do not over inflate the tire whenseating the bead. Failure to deflate the tireor over inflating the tire to seat the beadmay cause explosive failure of the tireresulting in severe bodily injury or death.



Pattern for tightening the wheel nuts

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

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

REPAIR THE TIRE (PNEUMATIC)

NOTE: To properly repair a puncture, the tire must be removed from the wheel. Refer to Replace theTire section for information on removing the tire from the wheel.

It is recommended to repair a tire with a combination vulcanized plug and internal patch.

Tire repairs should only be performed by personnel trained in tire repair.

The tire repair procedure will be unique to the type of repair equipment or repair components used. Refer tothe instructions provided with your equipment or repair components.

1

4-Bolt Pattern

3

2

5-Bolt Pattern

3

52

4 14

8-Bolt Pattern

18

3

52

7

4

6

TABLE OF CONTENTS

Inspecting the Motor Brushes ............ 2Motors with internal cooling fans ......................... 2Enclosed Motors (GE, no cooling fan) ................. 2

Motor Removal and Installation ......... 3Motor Inspection ................................ 3Replacing the Brushes....................... 5Replacing the Bearings ..................... 6Repairing the Commutator ................ 6Service Limits ................................... 7

Mo

tor

Ser

vice

Typical Exploded Motor

Motor Service

MotorPage 2

Enclosed Motors (GE, no cooling fan)

General Electric Motors

NOTE: Some motors may not have the brushinspection holes. In this case, the motor mustbe disassembled to inspect the brushes. Forfuture inspections, holes msy be drilled intothe motor housing after it has beendisassembled.

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

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

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

9. If any one wire insertion length exceeds the lengthspecified in Service Limits, then all four brushesshould be replaced. Refer to Replacing theBrushes section for information regardingreplacing the motor brushes.


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

INSPECTING THE MOTOR BRUSHES






Typical motor with cooling fan indicated bythe arrow

Typical brush and brush holder

Motors with internal cooling fans

NOTE: There are four brushes in the motor. Thebrushes will not wear at the same rate. It isrecommended that all four brushes areinspected at the same time.

NOTE: In some vehicle configurations it may not bepossible to inspect all four brushes while themotor is in the vehicle. Refer toTransmission Service section forinformation on removing the motor.

6. Look through the brush cover and compare thetop of the brush to the top of the brush holder. If itis even with or below the top of the brush holderthen the brushes should be removed andmeasured. Refer to Replacing the Brushessection for information regarding removing themotor brushes.

7. If any one brush is less than or equal to the servicelimit specified in Service Limits, then all fourbrushes should be replaced.


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






Motor Service

MotorPage 3

Advanced DC Motors

The enclosed Advanced DC motors must bedisassembled to inspect the motor brushes. Refer toMotor Inspection for information regardingdisassembling the motor.

MOTOR REMOVAL ANDINSTALLATIONSee the Transmission section for information onremoving or installing the motor.

MOTOR INSPECTION

Disassembly

1. Remove the motor from the vehicle. See theTransmission section for information onremoving the motor.

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

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

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

5. Pull the armature out of the front end of the motorhousing.

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

7. Remove the rear motor housing being careful notto damage the field coil wires.

Inspection

1. Measure the length of each motor brush.

• If any one brush is less than or equal to theservice limit specified in section ServiceLimits, then all four brushes should bereplaced. Refer to Replacing the Brushessection for information regarding replacing themotor brushes.

2. Measure the diameter of the commutator.

• If the commutator is less than the minimumdiameter specified in section Service Limits,then the motor must be replaced.

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

• If any one of the measurements is less than theminimum undercut depth specified in ServiceLimits above, then the commutator must beundercut. Refer to Repair Commutatorsection for information regarding undercuttingthe commutator.

4. Inspect the commutator for grooves.

• If the commutator is groved then it must bemachined on a lathe. Do not machine thecommutator past the minimum diameterspecified in Service Limits section. Refer toRepair Commutator section for informationregarding machining the commutator.

Insulation

Commutator

Incorrect

Hacksaw blade

Correct

Min. OD

Armature

Undercut

Motor Service

MotorPage 4

5. Inspect the commutator for burn marks.

• Burn marks and/or raised commutator segments90 or 180 degrees apart is evidence of a shortedarmature. A tool called a growler is required toreliably test for a shorted armature.

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

• If the armature is not shorted then the raisedsegments can be removed by machining thecommutator. Do not machine the commutatorpast the minimum diameter specified inService Limits section. Refer to RepairCommutator section for information regardingmachining the commutator.

7. Visually inspect the armature windings for burntinsulation. Burnt insulation is a direct result ofmotor overheating and could lead to a shortedarmature.

• If the insulation is cracked or burnt, then it isrecommend that the armature or motor bereplaced.

NOTE: If the armature has been burnt then there is agood possibility that the field windings mayalso be burnt. Symptoms indicating a shortedfield include high motor current, lack of powerand 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 commutatorby placing one test lead against one of thecommutator segments and the other test leadagainst all of the other segments one at a time.There should be continuity around the entirecommutator. If any segment indicates an opencircuit, then the motor must be replaced.

10. Using the continuity function of digital multi meter,check the continuity from any one of thecommutator segments and the armature frame. Ifit is not an open circuit, then the armature isshorted and the motor must be replaced.

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

• The bearing should not ‘freewheel’ but shouldcome to a smooth stop when rapidly spun byhand. If the bearing freewheels, then grease isno longer present in the bearing and it must bereplaced. Refer to Replacing the Bearingssection for information regarding replacing thearmature bearings.

• Feel for any roughness when the bearing isrotated. If any roughness or grinding is noticedthen the bearing must be replaced. Refer toReplacing the Bearings section forinformation regarding replacing the armaturebearings.

Assembly

NOTE: If this is an enclosed motor on a vehicle witha Power Traction primary reduction, then itis recommended to replace the armatureshaft seal any time the motor isdisassembled.

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

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

3. Lightly grease the outside diameter of the armaturebearings.

4. Insert the armature through the stator housing andseat the bearing into the rear housing.

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

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

NOTE: If the vehicle is equipped with a belt typeprimary reduction then the spring on themotor seal should be removed. Failure toremove the spring may result in a high pitchedsqueal from the seal.

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

Typical burn mark on a shorted armature

Motor Service

MotorPage 5

REPLACING THE BRUSHESNOTE: It is recommended that all four brushes be

replaced as a set.

NOTE: Motors without removable brush covers mustbe disassembled to replace the brushes.Refer to Motor Inspection-Disassemblysection for information on taking the motorapart.

NOTE: Some motors are equipped with brush pairs.These motors must be disassembled toreplace the brushes. Refer to MotorInspection-Disassembly section forinformation on taking the motor apart. Referto the Motor Parts List for your vehiclesbrush configuration.

NOTE: Some motors have brush leads that are routedthrough or behind the brush holder assembly.In this case, the brush holder assembly mustbe removed to replace the brushes.

NOTE: The motor must be removed from the vehiclefor this procedure. Refer to TransmissionService section for information on removingthe motor.

Motors with brush covers and brushes withtermination screws

1. Remove the brush covers.

2. Loosen the brush wire retaining screw and removethe brush from the brush holder. Be careful withthe brush spring and do not let it slip off of thespring mount. If the spring comes off, then themotor must be disassembled. Refer to MotorInspection-Disassembly section forinformation on taking the motor apart.

3. Install the new brushes in reverse order.

4. Be certain that the brush springs do not rest upagainst the brush wires. Refer to illustrations inMotor Inspection-Assembly for proper brushspring position.

Motors with brush pairs or not equippedwith brush covers

1. Disassemble the motor. Refer to MotorInspection-Disassembly section for informationon taking the motor apart.

2. Remove the brush holder.

Note: Remember the position and routing of the brushcrossover leads. They must be reinstalled inthe same position.

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

4. Install the new brushes in reverse order.

5. Reassemble the motor. Refer to MotorInspection-Assembly for information regardingreassembling the motor.

Brush Spring Orientation

Motor Service

MotorPage 6

REPLACING THE BEARINGS1. The motor must be removed from the vehicle for

this procedure. Refer to Transmission Servicesection for information on removing the motor.

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

3. Press the armature bearing(s) off of the armatureshaft.

4. Press new bearing(s) onto the shaft.

5. Reassemble the motor.

REPAIRING THE COMMUTATOR1. The motor must be removed from the vehicle for

this procedure. Refer to Transmission Servicesection for information on removing the motor.

2. The armature must be removed from the motorfor this procedure. Refer to Motor Inspection-Disassembly section for information on takingthe motor apart.

3. Using a lathe, cut the armature just enough toremove all grooves, depressions or ridges.

4. Measure the diameter of the commutator. If thecommutator is less than the minimum diameterspecified in Service Limits, then the motor mustbe replaced.

5. Thoroughly clean all copper debris from betweenthe commutator segments.

Do not press against the outer race of thebearing. Pressing against the outer racewill damage the bearing and may result inpremature failure of the bearing. See theillustration below

Example of freshly cut commutator

Properly undercut and cleanedcommutator segments

6. Measure the commutator undercut depth in 5-places around the commutator. If any one of themeasurements is less than the minimum undercutdepth specified in Service Limits, then thecommutator must be undercut.

7. While still in the lathe, smooth the commutatorwith fine emery cloth.

Undercutting the commutator

1. Using a small straight cut saw blade, cut thecommutator insulation to the proper depth. Referto undercut depth in Service Limits.

2. Once all segments have been properly undercut,mount the armature in a lathe and smooth thecommutator with fine emery cloth.

3. Inspect the armature for shorts. Refer to MotorInspection section for information on testing thearmature.

NOTE: Copper debris in the undercut area can givea reading of a shorted armature.

Motor Service

MotorPage 7

SERVICE LIMITS

Motor SpecificationNumber

Undercut Depth Commutator Diameter(min)

Brush Length(min)

Wire Depth(max)

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

5BT1326B262A 0.635 0.025 78.97 3.109 19.05 0.75 - -

A02-4011 1.0 .04 69.9 2.75 16 0.62 - -

ER5-4001XP-2023 1.0 .04 69.9 2.75 16 0.62 - -

ER5-4002 1.0 .04 69.9 2.75 16 0.62 - -

BP5-4002 1.0 .04 69.9 2.75 16 0.62 - -

TAYL

OR -

DUNN

TABLE OF CONTENTS

Throttle Linkage Adjustments ............ 2Magnetic Module .................................................. 2Pot Box module .................................................... 3

Th

rott

le L

inka

ge


Front AxlePage 2

THROTTLE LINKAGE ADJUSTMENTS

Magnetic Module

Throttle Module

The standard magnitic throttle module shouldnot be used in areas that contain largemagnetic fields. Large magnitic fields mayeffect the operation of the module resultingin unexpected movement of the vehicle.

FS-1

FS-3

B+ Input

B- Input

6-11 Volt output

0-5 Volt output

5

98

4

21

Throttle Module Internal Wiring

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

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

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

Switch FS-1 closes just as the throttle pedal is depressed.

Depending on the control system in the vehicle, the throttleposition output is obtained from pin #1 (0-5v) or pin #2 (6-11v).

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

Note: Pin 1 output exists on module manufactured after 2/16/2001.Pin 1 output not used on the Curtis control systems.


Front AxlePage 3

Pot Box module

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

The linkage to the pot box should be adjusted so that the FS-1switch closes just as the pedal is depressed and the output is at5K with the pedal fully depressed.

FS-15

98

4

21

5K

Pot Box Module

TAYL

OR -

DUNN

TABLE OF CONTENTS

Bat

tery

Ser

viceCleaning ............................................ 2

Testing .............................................. 3Charging ........................................... 4Watering ........................................... 5Replacing (6-volt batteries only) ........ 6

Moist Charge Batteries ......................................... 7Storage and Returning to Service ...... 8

Storage .................................................................. 8Returning to Service ............................................. 9


BatteriesPage 2

CLEANING

6. Dry dirt can be readily blown off with low-pressureair or brushed off.

7. Wetness or wet dirt on the batteries indicatesbattery acid. Using a nonmetallic brush with flexiblebristles, wash the batteries off with a strong solutionof baking soda and hot water (1 lb. of soda to agallon of water). Continue until all fizzing stops,which indicates that the acid has been neutralized.Then rinse thoroughly with clear water. DO NOTget any of the solution into the battery cells.

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


Battery electrolyte will stain and corrodemost surfaces. Immediately andthoroughly clean any surface outside of thebattery that the battery electrolyte comesin contact with. Failure to clean may resultin property damage.






A battery is a live electrical source. Itcannot be disconnected or neutralized. Donot drop any tool or conductive object ontothe battery. A conductive object that comesin contact with the battery terminals willinitiate a short circuit of the battery. Thiscould cause the battery to exploderesulting in severe bodily injury and/orproperty damage.



BatteriesPage 3










TESTING

NOTE: A combination of the Load Test and SpecificGravity Test should be used to accuratelydetermine the condition of the batteries.

Load Test (6-volt batteries only)

NOTE: The batteries must be fully charged beforeperforming this test.

1. Clean the batteries. Refer to Cleaning theBatteries section for information on cleaning thebatteries.

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

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

NOTE: If the batteries are over one year old, it isrecommended to replace them as a set.

• If all batteries fail the test you shouldcheck the charging system beforereplacing the batteries. Refer toCharger Troubleshooting section forinformation on checking the chargingsystem.

Specific Gravity Test

NOTE: The batteries must be fully charged beforeperforming this test.

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


BatteriesPage 4

Typical Hydrometer Float

Clean the batteries. Refer to Cleaning the Batteriessection for information on cleaning the batteries.

Using part number 77-200-00 hydrometer, check andrecord the specific gravity of each cell in the batterypack.

If, after charging, none of the cells exceed a hydrometerreading of 1250 then there may be a fault in the chargingsystem. If the charging system checks OK then thebatteries are no longer accepting a charge and shouldbe replaced.

NOTE: Refer to Charger Troubleshooting forinformation on checking the charging system.

The highest reading will be the cell that is accepting themost charge. This reading will be used to gauge all othercells.

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

NOTE: If the batteries are over one year old, it isrecommended to replace them as a set.

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

CHARGINGRefer to Charging Your Vehicle in section SafetyRules and Operating Instructions.


BatteriesPage 5










Do not overfill the batteries. Over filling thebatteries may cause the battery electrolyteto boil out of the battery and result insevere bodily injury or property damage.

WATERING

NOTE: The electrolyte level in a battery rises whilecharging and will be close to its highest levelafter the end of a charging cycle. It isrecommended to fill the batteries at the endof a charging cycle. If the electrolyte is belowthe top of the battery plates then fill justenough to cover the plates and then top offwhen the charging cycle is complete.

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

7. Check the electrolyte level in all battery cells. Iflow, fill to the correct level with distilled water usingpart number 77-201-00 battery filler, never addadditional battery electrolyte to the batteries.

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


BatteriesPage 6








REPLACING (6-VOLT BATTERIES ONLY)NOTE: If the batteries are over one year old, it is

recommended to replace them as a set.

6. Thoroughly clean the batteries and batterycompartment. Refer to Cleaning in this sectionfor information regarding cleaning the batteries.

7. Remove the battery hold downs.

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

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

NOTE: It is recommended to replace the batteryjumpers when replacing the batteries.

10. Remove the batteries from the vehicle.

11. Inspect the battery compartment for signs ofcorrosion.

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

13. If there are excessive signs of corrosion, then itmay be necessary to replace some of the framemembers or completely rebuild the batterycompartment.

14. Inspect the main positive and negative cables andterminals, charger cables and terminals and 12-volt tap wiring. If any of the terminals or wires showsigns of corrosion, then they must be repaired orreplaced.

Do not leave cables on batteries that havebeen removed from the vehicle. Cables lefton batteries could cause a short circuitresulting in battery explosion, severebodily injury and/or property damage.




BatteriesPage 7



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

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

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

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

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

Moist Charge Batteries

Moist charged batteries are shipped without batteryelectrolyte. This allows for a much greater shelf life ofthe battery. Moist charged batteries must be filled withelectrolyte and charged before putting into service.Battery electrolyte is a solution of acid and water that isformulated to be used in wet lead acid batteries and isavailable at most automotive parts distributors that carrybatteries.

When torquing battery hardware, use abackup wrench on the battery bolt andtighten the nut. Failure to use a backupwrench may damage the battery post.






Do not operate or charge a vehicleequipped with moist charged batteries untilthe batteries have been filled withelectrolyte and charged. Operating orcharging moist charged batteries beforefilling and charging will damage thebatteries resulting in premature failure ofthe batteries.


6. Fill all battery cells with electrolyte to the properlevel.

7. Thoroughly clean any spilled electrolyte from thebatteries or the ground. Refer to Cleaning theBatteries for information on cleaning thebatteries.

8. Reconnect the battery cables, connect thebatteries to the charger and allow the charger tocomplete one charging cycle.

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


BatteriesPage 8

StorageTemperature

(F)

Charging Interval(months)

Over 60 1

Between 40 and 60 2

Below 40 6

STORAGE AND RETURNING TO SERVICE










Storage

Thoroughly clean the batteries and battery compartment.Refer to Cleaning in this section for informationregarding cleaning the batteries.

Check the electrolyte level and charge the batteries.Refer to Watering in this section for informationregarding checking the electrolyte level.

Store the vehicle or batteries in a cool, dry, well ventilatedarea.

If storing for more than one month, the batteries shouldbe charged as follows:

If the batteries are removed from thevehicle, do not place them directly on theground, concrete or solid metal surface. Itis recommended to store them on a woodenpallet or equivalent. Storing on the ground,concrete or solid metal surface will causethe batteries to discharge and may resultin premature failure of the batteries.


BatteriesPage 9

Returning to Service

6. Thoroughly clean the batteries and batterycompartment. Refer to Cleaning in this sectionfor information regarding cleaning the batteries.

7. Check the electrolyte level and charge thebatteries. Refer to Watering in this section forinformation regarding checking the electrolytelevel.

8. Test the batteries. Refer to Testing section forinformation on testing the batteries.

9. The batteries are now ready to be put back intoservice.






TAYL

OR -

DUNN

Table of Contents

Ele

ctri

cal

Trou

bles

hoot

ing

SYMPTOMS: .....................................2READ THIS FIRST ............................3

Test Equipment Required: ....................................................... 3IMPORTANT NOTES and INSTRUCTIONS ...................... 3Definitions: .............................................................................. 4

SYMPTOM TROUBLESHOOTINGGUIDE..........................................22

PMC CONTROL .................................................................... 23PLUGGING DIODE .............................................................. 25FREEWHEEL DIODE ........................................................... 26ISO ........................................................................................... 27SOLENOIDS .......................................................................... 29MOTOR .................................................................................. 32

REV C

Electrical Troubleshooting

Troubleshooting Page 2

RE

V

FWD

Solenoids

PMC Speed Control

Circuit Breaker

ISO

Typical Control Panel

SYMPTOMS:

If your vehicle exhibits any of the following symptoms then skip the main troubleshootingsequence and proceed to Symptom Troubleshooting later in this section.

• Runs slow in both directions plus high armature and field current in both directions. NOTE:Armature and field current should be equal.

• Runs slow in both directions plus high armature current in both directions. NOTE: Fieldcurrent will be very low.

• Runs normal in one direction only plus runs slow or lacks power in the opposite directionwith high armature current in the opposite direction or;

• Accelerates slowly and exceeds normal speed in the opposite direction with high armaturecurrent only. NOTE: Field current will be very low in the opposite direction.

• Accelerates slowly and exceeds normal speed in both directions plus high armature current.NOTE: Field current will be very low.

• Full speed only.• Does not run in either direction plus there is noise from motor (hum or whine) with high

field current and low armature current.• Jumps into high speed when direction is selected after depressing the accelerator pedal.

Excessive spark when connecting battery• Does not run or runs very slow with low motor current and high battery current.• Jumps into high speed when direction is selected after depressing the accelerator pedal.

If your vehicle does not exhibits any of the above symptoms then continue with the maintroubleshooting sequence on the following pages.


Main Sequence Page 3

READ THIS FIRST

Test Equipment Required:

• Digital multimeter (DMM) with diode test function, FLUKE 79 model used in illustrations.• Shunt or clamp-on DC Ammeter to measure up to 400 amps.• Test light with a rated voltage equal to or exceeds maximum battery voltage or Taylor-

Dunn test light part number #62-027-00 for systems up to 48 volts.• Test harness, Taylor-Dunn #62-027-31. This troubleshooting guide assumes that the

vehicle is wired correctly. It is not intended to diagnose a vehicle that is not wired correctly.• These tools are available through your local Taylor-Dunn parts distributor.

IMPORTANT NOTES and INSTRUCTIONS

• This troubleshooting guide assumes that the vehicle is wired correctly. It is not intendedto diagnose a vehicle that is not wired correctly.

• This troubleshooting guide is not written to be able to locate a problem if there are multiplecomponent failures.

• This troubleshooting guide assumes the batteries are good. Charge and test the batteriesbefore troubleshooting the control system.

• DO NOT start in the middle of this troubleshooting guide. Start at the beginning andcomplete each test in the order that they are written. Do not skip any test unless instructedto do so. Once a problem is found, stop testing and repair the indicated problem. Whenthe repair is completed it is recommended that the control system be retested beforelowering the drive wheels to the ground.

• This troubleshooting guide requires the use of a test light rated at the battery voltage ofthe truck and the Taylor-Dunn Accelerator Module Test Harness. Troubleshooting CANNOTbe completed without these tools.

These test procedures must be performed in the order they werewritten. If the test result is good, then proceed to the next test orgo to the next section. Failure to do so may result in incorrect testresults.



Definitions:

• “MS-1” = The first switch in the accelerator module.• “Battery volts” = The voltage at the batteries at the time the test is completed.• “Pick up” = Energizing a solenoid or contactor.• “F&R” = Forward and Reverse.• “ISO” = Isolator.• “Battery negative” = Main negative battery post.• “Battery positive” = Main positive battery post.• “PMC” = Speed control module (black box).• “HOT terminal” = The side of a switch or solenoid that is connect to the power source.• “COLD terminal” = The side of a switch or solenoid that power is switched to.

DURING ALL TESTS

START:

Read all warnings above before continuing.

If the vehicle runs normal in one direction but does not run in the opposite direction then go tothe Solenoids sequence.

If none of the three solenoids pick up (click) when the accelerator pedal is depressed then goto the Forward & Reverse Switch sequence.

After any repairs are made, completely retest the vehicle beforelowering the drive wheels to the ground. Failure to retest the vehiclecould result in unexpected movement of the vehicle resulting insevere bodily injury and/or property damage.

The rear drive wheels may rotate during some of the following tests.Block the front wheels, raise the rear drive wheels off the ground,and support the vehicle with jack stands. Failure to do so may causethe vehicle to move and cause severe bodily injury and/or propertydamage.

Rotating rear drive wheels are a potential hazard. Keep hands, arms,legs and loose clothing away from the rear drive wheels whileconducting tests. Failure to do so may cause serious bodily injury.

Disconnect both of the battery leads during any maintenance orbefore disconnecting any electrical component or wire. Failure to doso may cause severe bodily injury and/or property damage.



Power Output Test

Set the test light voltage to the same voltage as thebattery volts.

Connect the test light from the PMC ‘M-’ Terminalto battery positive.

Close all interlock switches, turn the Key SwitchON, and place the F&R Switch in Forward.

Depress the accelerator pedal fully.• If the light comes ON then go to the Motor

sequence.• If the light does not come ON then continue

with the next test.


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.



Main Battery Positive

Test Light

Face of Controller

B-

M-A2

B+#2

KSI



Control Wire inputs Test

Connect a voltmeter across the SolenoidNegative Buss Bar and battery positive.

• If the voltage is not at battery volts thencheck the wiring to battery negative andthe negative circuit breaker. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

Connect a voltmeter across the ISO solenoid coilterminals.

Close all interlock switches and turn theKey Switch ON.Depress the accelerator pedal to engageMS-1 only.

• If the voltage is not at battery volts thengo to the Key Switch sequence.

• If the voltage is at battery volts and theISO solenoid does not pick up (click) thenthe ISO solenoid has failed. Stop troubleshooting here and repair the problem.When the repair is completed, completelyretest the vehicle before lowering thedrive wheels to the ground.





The voltage shown is for illustration only. The actual voltage may vary.

_+

PositiveMain Battery

Solenoids are shown for reference only. The type of solenoid in your truck may look different

REVFWD ISO

ISOFWD REV_+





Control Wire inputs (continued)

Connect a voltmeter across the PMC #2 terminaland battery negative.

Close all interlock switches, turn the Key SwitchON, and place the F&R Switch in Forward.

Depress the accelerator pedal to engageMS-1 only.

• If the voltage is not between 6.0 and 6.5volts then go to the Acceleratorsequence.

Depress the pedal fully.• If the voltage is not between 11.0 and

11.5 volts then go to the Acceleratorsequence.

Connect voltmeter across the PMC KSI terminaland battery negative.

With the pedal still fully depressed:• If the voltage is not at battery volts thengo to the Key Switch sequence.

• If the voltage is at battery volts thencontinue with the next test.

NegativeMain Battery

B-

M-A2

B+#2

KSI

_+


NegativeMain Battery

B-

M-A2

B+#2

KSI

FLUKE 79

OFF V

Hz

SERIES II MULTIMETER

+−

A

Ω

mV

V




Power Wire Inputs

Connect a voltmeter to the PMC ‘B-’ terminaland battery positive.

• If the voltage is not the same as batteryvolts then there is an open circuit in thewire from ‘B-’ to the battery. Stoptroubleshooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

Connect a voltmeter across the PMC ‘B-’terminal and the PMC ‘B+’ terminal.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.Depress the accelerator pedal to engageMS-1 only.

• If the voltage is not the same as batteryvolts then go to the Solenoids sequence.

• If the voltage is the same as battery voltsthen the PMC controller has failed. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.





B-

M-A2

B+#2

KSI

_+



B-

M-A2

B+#2

KSI

_+




Motor

Set the test light voltage to the same voltage asthe battery volts.

Connect the test light across the motor ‘A1’ and‘A2’ terminals.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.Depress the accelerator fully.

• If the light comes on then the motorarmature windings are open and themotor must be repaired or replaced. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely test the vehicle beforelowering the drive wheels to the ground.





Motor shown for reference only. Terminal positions on your motor may not be in the same location.

S2

A1

A2S1

Wiring to motor omitted for clarity. Do not disconnect the motor wires for this test.



Connect the test light across the motor ‘S1’ and‘S2’ terminals.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.Depress the accelerator fully.

• If the light comes on then the motor fieldwindings are open and the motor mustbe repaired or replaced. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the test light did not come on duringeither test then go to the F/R Switchsequence.

Accelerator

This is the accelerator module testharness part number 62-027-31. It willbe used in the following tests. Thesetests cannot be completed without thisharness. If you do not have this harness,one must be obtained before testing cancontinue.






S2

A1

A2S1

Wiring to motor omitted for clarity. Do not disconnect the motor wires for this test.

INTO THE HARNESSPLUG THIS END

INTO THE MODULEPLUG THIS END

FOR TESTINGUSE THIS END

9

6

7

4

3 1



Connect the accelerator module test harness tothe accelerator module.

Connect a voltmeter between pin #9 in the testharness and battery positive.

• If the voltage is not at battery volts thenthe wiring between pin #9 in the harnessand battery negative is open. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

Connect a voltmeter negative probe to Pin #9(-) in the test harness. Connect the positiveprobe to:24 or 36 volt truck - Pin #448 volt truck - Pin #7

Close all interlock switches and turn theKey Switch ON.


Connect a voltmeter between pin #9 (-) and pin#5 (+) in the test harness.

Close all interlock switches and turn theKey Switch ON.Depress the accelerator pedal to engageMS-1 only.

• If the voltage is not at battery volts thenthe accelerator module has failed. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the voltage at pin #5 is good but thetest at the center terminal of the forwardand reverse side of the F&R switch inthe Key Switch Section failed then check the wire between the accelerator module pin #5and the F&R switch. Stop trouble shooting here and repair the problem. When the repairis completed, completely retest the vehicle before lowering the drive wheels to the ground.


+

-


+

-


24-36-volt

48-volt

+

-




Connect a voltmeter between pin #9 (-) and pin#2 (+) in the test harness.

Depress the accelerator pedal to engageMS-1 only.

• If the voltage is between 6.0 and 6.5 voltsand the test at the PMC #2 terminal inthe Control Wire Input section failed thenthe wire or interlock switches betweenthe accelerator module pin #2 and thePMC pin #2 is open. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the voltage is not between 6.0 and 6.5volts then the accelerator module has failed. Stop trouble shooting here and repair theproblem. When the repair is completed, completely retest the vehicle before lowering thedrive wheels to the ground.

Now Depress the accelerator module fully.• If the voltage is not between 11.0 and 11.5 volts then the accelerator module has failed.

Stop trouble shooting here and repair the problem. When the repair is completed,completely retest the vehicle before lowering the drive wheels to the ground.

+

-


STOPStop, do not continue. If you reached this point without a solution, then you may have anunanticipated problem or have made an error during testing. It is important to review thetrouble shooting steps that have led to this point. The tests may need to be repeated.



Key Switch

Test all interlock switches and/or interlock relays (if equipped) for continuity. Depending on themodel of your vehicle, it may have a seat interlock, Foot interlock, Charger interlock, specialorder interlock or any combination of the above. Refer to the wire diagram at the end of thissection for location of the interlocks.

NOTE: Due to the many different configurations possible for special orderinterlocks, they will not be included in this text. Refer to the optionlist for your truck or contact your Taylor-Dunn® Representative formore information.

If you do not know how to test for continuity,refer test to a qualified technician.

Connect a voltmeter across the HOT terminal ofthe key switch and battery negative.

• If the voltage is not at battery volts thencheck the wire between the key switchand battery positive. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

"COLD, Violet Wire(s)"

"HOT, Red wire(s)"

BATTERY MAIN NEGATIVE

KEY SWITCH

View of the terminals of a typical Key Switch

A

OFF

mV

V

V

Hz

FLUKE 79 SERIES II MULTIMETER







Connect a voltmeter across the COLD terminalof the key switch and battery negative.

Turn the key switch ON.• If the voltage is not at battery volts then

the key switch has failed. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the voltage is at battery volts but theprevious test at pin #4 in the Acceleratorsection failed then check the wire fromthe key switch to pin #4 at the acceleratormodule. Stop trouble shooting here andrepair the problem. When the repair iscompleted, completely retest the vehiclebefore lowering the drive wheels to theground.

For your reference, shown at the right are theForward and Reverse switch wire connectionsfor a typical control system.

Connect a voltmeter across the HOT terminal ofthe KSI side of the F&R switch and batterynegative.

Turn the key switch ON.• If the voltage is not at battery volts then

go to the Accelerator sequence.

The HOT terminal is the Violet/Black wire on the center terminal

Battery Negative

"COLD, Violet Wires(s)"

"HOT, Red wire(s)"

BATTERY MAIN NEGATIVE

KEY SWITCH

View of the terminals of a typical Key Switch

A

OFF

mV

V

V

Hz


Violet/Black

Forward and Reverse Side

Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back

KSI Side

Blue/Black

Green/Black

White/Black



Connect a voltmeter across one of the COLDterminals of the KSI side of the F&R switch andbattery negative.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.

• If the voltage is not at battery volts thenthe F&R switch has failed. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the voltage is at battery volts and thetest at the PMC KSI terminal in theControl Wire Inputs section failed thencheck the wiring between COLD terminals of the KSI side of the F&R switch and the PMCKSI terminal. Stop trouble shooting here and repair the problem. When the repair iscompleted, completely retest the vehicle before lowering the drive wheels to the ground.

F/R switch

The COLD terminal is the Violet/Black wire on either end of the switch

Battery Negative

Or,







Connect a voltmeter across the SolenoidNegative Buss Bar and battery positive.

NOTE: You may skip this test if it wascompleted in a previous section

• If the voltage is not at battery volts thencheck the wiring to battery negative andthe negative circuit breaker. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

Connect a voltmeter across the center terminalof the forward and reverse side of the F&R switchand battery negative.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.Depress the accelerator pedal fully.

• If the voltage is not at battery volts thengo to the Accelerator sequence.

Connect a voltmeter across the forward terminalof the forward and reverse side of the F&R switchand battery negative.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inforward.Depress the accelerator pedal fully.


ISO

FWD/REV

Solenoids are shown for reference only. The type of solenoid in your truck may look different Main Battery

Positive


A

OFF

FLUKE 79

-+

SERIES II MULTIMETER

Hz

V

mV

V

The CENTER terminal is the Green/Black wire

Battery Negative

A

OFF

mV

V

V

Hz


The FORWARD terminal is diagonally opposite the forward side of the rocker on the switch

Battery Negative

A

OFF

mV

V

V

Hz


F&R switch seen from the rear

F&R switch seen from the side depressed in the FORWARD gear



Connect a voltmeter across the reverse terminalof the forward and reverse side of the F&R switchand battery negative.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inreverse.Depress the accelerator pedal fully.


• If all tests in this section were good thencheck the wiring from the F&R switch tothe Forward and Reverse solenoids and both the forward and reverse solenoid coils.Stop trouble shooting here and repair the problem. When the repair is completed,completely retest the vehicle before lowering the drive wheels to the ground.

Solenoids

If the vehicle runs in forward only then skip ahead to the test sequence Forward (does notrun in reverse).

If the vehicle runs in reverse only then skip ahead to the test sequence Reverse (does notrun in forward).

The REVERSE terminal is diagonally opposite the reverse side of the rocker on the switch

Battery Negative

A

OFF

mV

V

V

Hz


F&R switch seen from the rear

F&R switch seen from the side depressed in the REVERSE gear







Connect a voltmeter across the ISO solenoidCOLD terminal and battery negative.

Close all interlock switches and turn theKey Switch ON.Depress the accelerator pedal fully.

• If the voltage is at battery volts thenthe wire from the ISO solenoid to thePMC is bad. Stop trouble shootinghere and repair the problem. Whenthe repair is completed, completelyretest the vehicle before lowering thedrive wheels to the ground.

Connect a voltmeter across the ISO solenoidHOT terminal and battery negative.

Close all interlock switches and turn theKey Switch ON.Depress the accelerator pedal fully.

• If the voltage is at battery volts then theISO solenoid has failed. Stop troubleshooting here and repair the problem.When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

• If the voltage is not at battery volts thencheck the wiring to battery positive andthe main circuit breaker. Stop troubleshooting here and repair the problem.When the repair is completed, completely retest the vehicle before lowering the drivewheels to the ground.

Forward (does not run in reverse)

Connect a voltmeter across the PMC KSIterminal and battery negative.

Close all interlock switches, turn theKey Switch ON, and place the F&RSwitch in reverse.

• If the voltage is not at battery voltsthen go to the Key Switch sequence.


V

VOFF

Hz

mV

A


ISO_+


Battery NegativeFWD/REV


V

VOFF

Hz

mV

A


ISO_+


Battery NegativeFWD/REV

Main Battery Negative

B-

M-A2

B+#2

KSI

_+




Connect a voltmeter across the Reverse Solenoidcoil terminals. Refer to your vehicles wiringdiagram to identify the position of the reversesolenoid.


• If the voltage is not at battery volts thengo to the F/R Switch sequence.


Connect the test light across the normally opencontacts of the reverse solenoid. Refer to yourvehicles wiring diagram to identify the positionof the reverse solenoid.


• If the light comes on then the Reversesolenoid has failed. Stop trouble shootinghere and repair the problem. When therepair is completed, completely retest thevehicle before lowering the drive wheelsto the ground.

Connect the test light across the Normally Closedcontacts of the Forward solenoid. Refer to yourvehicles wiring diagram to identify the positionof the forward solenoid.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inReverse.Depress the accelerator pedal fully.

• If the light comes on then the Forwardsolenoid has failed. Stop trouble shootinghere and repair the problem. When therepair is completed, completely retest thevehicle before lowering the drive wheelsto the ground.


Solenoids are shown for reference only. The type and position of the reverse solenoid in your truck may be different

ISO_+


FWD/REV


FWD/REV

Solenoids are shown for reference only. The type and position of the forward solenoid in your truck may be different

FWD/REV




B-

M-A2

B+#2

KSI

_+



ISO_+


FWD/REV


FWD/REV

Reverse (does not run in forward)

Connect a voltmeter across the PMC KSIterminal and battery negative.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inforward.


Connect a voltmeter across the Forward Solenoidcoil terminals. Refer to your vehicles wiringdiagram to identify the position of the forwardsolenoid.


• If the voltage is not at battery volts thengo to the F/R Switch sequence.


Connect the test light across the Normally Opencontacts of the Forward solenoid. Refer to yourvehicles wiring diagram to identify the positionof the forward solenoid.


• If the light comes on then the Forwardsolenoid has failed. Stop trouble shootinghere and repair the problem. When therepair is completed, completely retest thevehicle before lowering the drive wheelsto the ground.





FWD/REV


Connect the test light across the Normally Closedcontacts of the Reverse solenoid. Refer to yourvehicles wiring diagram to identify the positionof the Reverse solenoid.

Close all interlock switches, turn the KeySwitch ON, and place the F&R Switch inForward.Depress the accelerator pedal fully.

• If the light comes on then the Reversesolenoid has failed. Stop trouble shootinghere and repair the problem. When therepair is completed, completely retest thevehicle before lowering the drive wheels to the ground.



SYMPTOMS GO TO

Ø Runs slow in both directions plus high armature and field current in bothdirections. NOTE: Armature and field current should be equal. MOTOR

Ø Runs slow in both directions plus high armature current in both directions.NOTE: Field current will be very low. SOLENOIDS

Ø

Ø

Runs normal in one direction only plus runs slow or lacks power in the oppositedirection with high armature current in the opposite direction or;

Accelerates slowly and exceeds normal speed in the opposite direction with higharmature current only. NOTE: Field current will be very low in the oppositedirection.

SOLENOIDS

Ø Accelerates slowly and exceeds normal speed in both directions plus higharmature current. NOTE: Field current will be very low. SOLENOIDS

Ø Full speed only. PMC CONTROL

Ø Does not run in either direction plus there is noise from motor (hum or whine)with high field current and low armature current. PLUGGING DIODE

Ø Excessive spark when connecting battery ISO

Ø Does not run or runs very slow with low motor current and high battery current. FREEWHEEL DIODE

Ø Jumps into high speed when direction is selected after depressing the acceleratorpedal. HPD

SYMPTOM TROUBLESHOOTING GUIDE

This section is specific to the symptoms listed below. Each troubleshooting sequence assumesthat all listed symptoms are present. Do not use this section unless the truck has all listedsymptoms.

Special TroubleshootingTable of Contents

PMC CONTROL .................................................................... 22PLUGGING DIODE .............................................................. 25FREEWHEEL DIODE ........................................................... 26ISO ........................................................................................... 27SOLENOIDS .......................................................................... 29MOTOR .................................................................................. 32



PMC CONTROL

Disconnect the wire from the ‘M-’ terminal on thePMC control and tape it off to prevent electricalcontact. Connect a volt meter across the PMC #2terminal and battery negative.

Turn the key-switch on, close all interlockswitches (if equipped), depress theaccelerator pedal to engage the first microswitch only (creep speed), then perform thefollowing tests:

• The meter reading should be between 6and 6.5 volts.

• If the voltage at pin #2 is not 6 to 6.5 volts,then go to the ACCELERATOR sequencein the Main Troubleshooting Sequence,otherwise continue with the next test.


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.




B-

M-A2

B+#2

KSI

_+




Connect a volt meter across the PMC B+ and PMCM- terminals.

Turn the key-switch on, close all interlockswitches (if equipped), depress theaccelerator pedal to engage the first microswitch only (creep speed), then perform thefollowing tests:

• The meter reading should not be equal tothe battery voltage.

• If you have full battery voltage then thePMC control is shorted and must bereplaced. Stop trouble shooting here andrepair the problem. When the repair iscompleted, completely retest the vehiclebefore lowering the drive wheels to theground, otherwise continue with the nexttest.

If the voltage at pin #2 is correct and the voltage at ‘M-’ is correct, then there is a short in theharness between the wire connected to the PMC ‘M-’ and main battery negative. Stop troubleshooting here and repair the problem. When the repair is completed, completely retest thevehicle before lowering the drive wheels to the ground.

B-

M-A2

B+#2

KSI

_+





PLUGGING DIODE

Remove the wires from the ‘B+’ and ‘A2’terminals on the PMC control and perform thefollowing test:

Using the diode test function on the DMM checkfor the presence of a diode across ‘B+’ and ‘A2’on the PMC control..

If you do not know how to test for a diode, refertest to a qualified technician.

• If the diode is open or shorted, then thePMC control must be replaced. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.

Ω

A

Hz

OFF V

mV

V

SERIES II MULTIMETERFLUKE 79

+− B

M A2

B#2

KSI − +−

The reading shown is for illustration only. The actual reading may vary.








FREEWHEEL DIODE

Remove the wires from the ‘B+’ and ‘M-’terminals on the PMC control and perform thefollowing test:

Using the diode test function on the DMM checkfor the presence of a diode across ‘B+’ and ‘M-’ on the PMC control. Refer to Diode Figure 2.

If you do not know how to test for a diode, refertest to a qualified technician.

• If the diode is open or shorted, then thePMC control must be replaced. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.


B-

M-A2

B+#2

KSI

_+

The reading shown is for illustration only. The actual reading may vary.











ISO

+-

FWD/REV

ISO

Remove the wires and the resistor from the ISOsolenoid and perform the following tests:

Test continuity across the ISO power contacts.


• This should be an open circuit. If it is notan open circuit then the contactor shouldbe replaced. Stop trouble shooting hereand repair the problem. When the repairis completed, completely retest thevehicle before lowering the drive wheelsto the ground, other wise continue to thenext test.




Reading is plus or minus 10%

ISO solenoid is shown for reference only. The type of solenoid in your truck may look different

_+

Connect the meter to each end of the resistor thatwas removed from the ISO solenoid and measureits resistance.

• The meter reading should be 250 Ohms(+/-10%). If it is not 250 ohms (+/-10%),then replace the resistor. Stop troubleshooting here and repair the problem.When the repair is completed, completelyretest the vehicle before lowering thedrive wheels to the ground.








S2

A1

A2S1

_+

SOLENOIDS

There is a very slight possibility that a failure in the motor could cause these symptoms.Perform the tests covered in the MOTOR section first. If the motor is OK, continue with thefollowing tests.

Remove the wires from the ‘S1’ and ‘S2’ terminals on the motor. Remove the wire from the‘M-’ terminal on the PMC control. Make sure none of these wires can come into electrical contactwith the frame or any other wire.

Reconnect the batteries.With the key-switch on and the forward and reverse switch in neutral, perform thefollowing tests:

• Check continuity from the motor ‘A2’terminal to the wire that was connectedto the motor ‘S1’ terminal. DO NOT makethis test to the ‘S1” terminal, just the wire.Refer to Solenoid Figure 1.


• This should be an open circuit, if it readsas a short, then one of the following hasoccurred:

A) The reverse solenoid is shorted.B) The wire connected to the motor ‘S1’

terminal is shorted to the wire connectedto the motor ‘A2’ terminal.

C) The wire connected to the motor ‘S1’terminal is shorted to the wire connected to the PMC ‘A2’ terminal.




S2

A1

A2S1

_+

B-

M-A2

B+#2

KSI


S2

A1

A2S1

_+

Stop trouble shooting here and repair the problem. When the repair is completed, completelyretest the vehicle before lowering the drive wheels to the ground, otherwise continue with thenext test.

• Check continuity from the motor ‘A2’terminal to the wire that was connectedto the motor ‘S2’ terminal. DO NOT makethis test to the ‘S2” terminal, just the wire.


• This should read as an open circuit. If itreads as a short then one of the followinghas occurred:

A) The forward solenoid is shorted.B) The wire connected to the motor ‘S2’

terminal is shorted to the wire connectedto the motor ‘A2’ terminal.

C) The wire connected to the motor ‘S2’terminal is shorted to the wire connected to the PMC ‘A2’ terminal.

Stop trouble shooting here and repair the problem. When the repair is completed, completelyretest the vehicle before lowering the drive wheels to the ground, otherwise continue with thenext test.

With the key-switch on and the F&R switch in forward, depress the accelerator pedaland perform the following tests:

Check continuity from the wire that wasconnected to the PMC ‘M-’ terminal tothe wire that was connected to the motor‘S2’ terminal.


• This should read as an open circuit. If itreads as a short, then one of thefollowing has occurred:

A) The forward solenoid is shorted.B) The wire connected to the PMC ‘M-’

terminal is shorted to the wire connectedto the motor ‘S2’ terminal.

Stop trouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle before loweringthe drive wheels to the ground, otherwisecontinue with the next test.



With the key-switch on and the F&R switch in reverse, depress the accelerator pedaland perform the following tests:

• Check continuity from the wire that wasconnected to the PMC ‘M-’ terminal to thewire that was connected to the motor ‘S1’terminal.

If you do not know how to test for continuity, refertest to a qualified technician.

• This should read as an open circuit. If itreads as a short, then one of the followinghas occurred:

A) The reverse solenoid is shorted.B) The wire connected to the PMC ‘M-’

terminal is shorted to the wire connectedto the motor ‘S1’ terminal.

Stop trouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle before loweringthe drive wheels to the ground


B-

M-A2

B+#2

KSI


S2

A1

A2S1

_+



MOTOR

High motor current in both the field and the armature, accompanied with a lack of power,would indicate a shorted armature and\or field.

Another symptom that may exist is jumping or stuttering at low speeds and/or the motor willnot run unless the armature is manually rotated. If this symptom exists, it indicates that theremay be open segments in the armature. Visually inspect the brushes, if they are OK, continuewith the testing below.

Disconnect the four motor wires and perform thefollowing tests:

Check continuity from ‘A1’ to the frame of themotor..

If you do not know how to test for continuity, refertest to a qualified technician.

• This should be an open circuit. If there iscontinuity from ‘A1’ to the frame of themotor, then the motor armature orarmature circuit (brushes) are shorted.

Stop trouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle before loweringthe drive wheels to the ground, otherwisecontinue with the next test.






A1

S2

S1A2

_+



Check continuity from ‘S1’ to the frame of themotor.


This should be an open circuit. If there iscontinuity from ‘S1’ to the frame of themotor, then the motor field is shorted.Stop trouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground,otherwise continue to Motor Inspection.

Motor Inspection

1.Remove and disassemble the motor.2.Visually inspect the inside of the brush end housing. If there are any silver specs of metal

around the inside of the housing, it indicates that the armature has overheated and meltedthe solder around the commutator. The armature is bad and the motor must be replaced.Stop here and repair the problem, otherwise continue with the next test.

3.Visually inspect the armature wires where they loop around at the shaft end of the armature.The insulation should be a light to medium reddish brown color. If the insulation is darkbrown to black or the insulation is cracked and peeling, then the armature has beenoverheated and burnt. The motor must be replaced. Stop here and repair the problem,otherwise continue with the next test.

4.Perform a continuity test around the armature commutator. Place one of the test leads ona single commutator segment. While holding the first test lead on the segment, check thecontinuity to the other segments around the commutator.


• There should be continuity on eachcommutator segment. If an opensegment is found, the armature is badand the motor must be replaced. Stoptrouble shooting here and repair theproblem. When the repair is completed,completely retest the vehicle beforelowering the drive wheels to the ground.



A1

S2

S1A2

_+

Check each segmentall of the way around

the commutator

Hold this leadin place

Commutator

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TABLE OF CONTENTS

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Operating Instructions andTheory of Operation .........................2

Testing the Charging Cycle ....................3Test Equipment Required for

Troubleshooting ..............................4Important Notes and Instructions -------------------- 4

Troubleshooting for Built-in Charger .......5Troubleshooting for Portable Charger ....8Testing The Timer Relay ........................9Testing the Interlock Relay .....................10

Turn the Key switch OFF BEFOREdisconnecting the batteries. Disconnectingthe batteries with the key switch ON maycorrupt the controller programmingresulting in a fault code 1 (refer to faulttable).

Rev E


Charger Troubleshooting Page 2

OPERATING INSTRUCTIONS AND THEORY OF OPERATION

The Lestronic II® chargers are designed as semiautomatic chargers. The Lestronic II® charger turns itselfon when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged intothe batteries. As the battery charges, the battery voltage rises. The charger periodically checks the batteryvoltage and compares it to the previous reading. When the battery voltage stops rising a predeterminedamount, then the batteries are no longer accepting a charge and the charger shuts off. The charger will notstart again unless the AC cord on a “built-in” charger is disconnected from the wall outlet, or the DC plug ona portable charger is disconnected from the batteries.

The charger does not check the current state of charge when it is plugged in, it assumes that the batteriesrequire charging when it is connected. For this reason, it is recommended to discharge the batteriesapproximately 50% (1175-1200 as indicated on a hydrometer) before connecting the charger. If the chargeris connected before the batteries are discharged 50%, the batteries may enter an overcharge state beforethe charger can sense that the batteries are no longer accepting a charge. This could result in overchargingand damaging the batteries.

The relay that operates the charger is powered by the batteries being charged. If the voltage on thebatteries to be charged is less than approximately 65% of the rated charger DC voltage, the relay will notpick up and the charger will not turn on. In this situation, a manual charger would have to be used to bringthe battery voltage up so that the Lestronic® charger can sense that they are connected and turn itself on.

Typical Charger Internal Wire Diagram

Not all chargers are equippedwith the lockout relay



TESTING THE CHARGING CYCLE

In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of thebattery when the charge cycle was started.

A charger could remain on for longer than 12 hours if:

• The charging cycle is interrupted at any time during the charging cycle.• Defective batteries causing a fluctuating DC voltage that confuses the charger.• A brownout (drop in AC line voltage) during the charging cycle.• An electrically noisy charging environment.

A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:

• The batteries were not discharged to 50% before connecting the charger.• The electrolyte in the batteries is too high (boil over).• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).

To test the charger to see if it is turning off correctly, monitor the batteryvoltage and the electrolyte specific gravity during the charging cycle asindicated below.

Specific GravityUsing a hydrometer take the specific gravity reading of several cells, at 1 hour intervals while charging. Ifthe specific gravity of the electrolyte does not rise for three consecutive readings and the charger does notshut off, then the charger is running too long.

Battery VoltageUsing an accurate 5-1/2 digit digital voltmeter, monitor the battery voltage during the charging cycle. Takereadings every 30 minutes. If the battery voltage does not increase 0.012 volts in two consecutive readings,then the charger is running too long.



TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING

Digital Multi Meter (DMM) with diode and capacitor test function, FLUKE 79® modelshown at right and in the troubleshooting illustrations.

Important Notes and Instructions• This troubleshooting guide assumes a familiarity with the use of a digital multimeter

including, voltage tests, continuity tests and diode testing. If not familiar withany part of these tests, refer testing to a qualified technician.

• Make sure that the AC electrical socket the charger is plugged into is in goodworking condition.

• Make sure that the AC voltage at the electrical socket is the same as the ACvoltage on the charger nameplate.

• Make sure the batteries are in good condition and no less than 80% dischargedas per hydrometer reading.

• The battery voltage must be above approximately 65% of the chargers rated DC voltage. If the batteriesare below approximately 65% of the chargers rated DC voltage, the charger will not turn on.

• If the charger exhibits intermittent problems, it must be in the failed mode for troubleshooting.• Battery volts = Full voltage available at the batteries at the time of the test being performed.• This test procedure must be performed in the order it was written. If starting in the middle or skipping

sections when not instructed to do so, the proper results will not occur. If the test result is good, thenproceed to the next test or go to the next section if instructed to do so.

During All Tests

The charger cabinet must remain electrically grounded. Disconnectboth of the battery leads and unplug the charger from the AC sourcebefore disconnecting any electrical component or wire. Failure to doso may result in serious bodily injury.



TROUBLESHOOTING FOR BUILT-IN CHARGER

5. Disconnect the charger from the AC source.Locate the charger harness connectors where the charger harness is connected to the vehicle’s controlharness. There will be two 10 gauge and two 14 gauge wires.

Slide the insulators off the connectors on the two 10 gauge wires and perform the following tests:

6. Test the voltage from the red wire to the main battery negative. This voltage shouldbe equal to the battery voltage. If the voltage is less than the battery voltage, thenthis wire is broken or has a bad connection. Stop here and repair the problem.

7. Test the voltage from the red 10 gauge wire (+) to the other 10 gauge wire (whiteor black depending on model). This voltage should be equal to the battery voltage.If the voltage is less than the battery voltage, then the white (or black) wire isbroken or has a bad connection. Stop here and repair the problem.

Slide the insulators back onto the connectors on the two 10 gauge wires.

Slide the insulators off the connectors on the two 14 gauge wires.

Re-Connect the charger to the AC source.

8. Test the voltage across the two 14 gauge wires. This voltage should be the sameas the voltage at the AC receptacle (rated voltage of the charger). If the voltage isless than the rated AC voltage of the charger then the 14 gauge white or blackwire(s) is broken or has a bad connection between the charger connectors andthe AC plug. Stop here and repair the problem.

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




High Voltage. Do not touch the 14-gauge wires and make sure thesetwo wires do not come into electrical contact with any other object.Failure to do so may result in serious bodily injury.

Make sure that these two wires do not come into electrical contactwith any other object.



• Disconnect the charger from the AC source.• Disconnect the batteries.• Disconnect the charger from the vehicle’s harness.• Remove the charger from the vehicle.

Remove the charger cover and perform the following tests:1. Inspect the internal wiring of the charger and repair as required.2. Check the continuity of both fuse links and replace if bad.3. Disconnect one transformer lead from the capacitor. Test the capacitor using the

capacitor test function of the meter. It is a 6 microfarad capacitor. If the capacitoris bad, it must be replaced. Stop here and repair the problem.

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitorbefore continuing. Connect a 2k ohm resistor across the capacitorterminals for 10 seconds. Do not touch the capacitor terminals withyour hands. The resistor should be held with a pair of insulated pliers.Failure to do so may cause serious bodily injury

High Voltage inside the charger. Do not touch any internal componentswhile the charger is plugged in. Failure to do so may result in seriousbodily injury.

Fuse LinksCapacitor

4. Reconnect the transformer lead to the capacitorand disconnect one transformer lead from oneof the diodes. Test each of the diodes usingthe diode test function of your meter. If eitherone of the diodes are bad, replace the diodeassembly. Stop here and repair the problem.

5. Reconnect the lead to the diode.6. Reconnect the charger to the vehicle’s harness

and slide the wiring insulators back into place.Connect the charger to the AC source andperform the following tests:



• Test the voltage from the fuse assembly (-) to the diode block (+).This voltage should be equal to the battery voltage. If the voltageis less than the battery voltage, then the wires from the harnessconnectors to the charger are bad. Stop here and repair theproblem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltageshould be the same as the rated AC voltage of the charger. If the voltage is less than the rated ACvoltage of the charger, then the wires from the harness connectors to the charger are bad. Stop hereand repair the problem.

• If the timer relay does not pickup (click) when the AC source is connected, then the timer control circuitor the relay is bad (refer to Timer Relay Test). Stop here and repair the problem.

• Test the AC voltage across the transformer primary circuit. The transformer primary consists of the twosolid wires with the brown fiber insulator that are connected to the timer board. This voltage should bethe same as the rated AC voltage of the charger. If the voltage is less than the rated AC voltage of thecharger, then the timer relay is bad. Stop here and repair the problem.

• Test the AC voltage across the transformer low voltage secondarycircuit. The transformer low voltage secondary circuit can betested at the two solid wires with the brown fiber insulator thatare connected to the anodes on the two diodes. The voltagehere will vary depending on the state of charge in the batteries.The voltage should be between 208% and 250% of the ratedDC voltage of the charger. If the voltage is not between 208%and 250% of the rated DC voltage of the charger, the transformeris bad and must be replaced. Stop here and repair theproblem.



TROUBLESHOOTING FOR PORTABLE CHARGER

Disconnect the charger from the AC outlet and the batteries.

1. Test the voltage from the positive terminal on the vehicles DC receptacle to mainbattery negative. This voltage should be equal to the battery voltage. If the voltageis less than the battery voltage then this wire is broken or has a bad connection.Stop here and repair the problem.

2. Test the voltage from the positive terminal on the DC receptacle to the negativeterminal on the DC receptacle. This voltage should be equal to the battery voltage.If the voltage is less than the battery voltage, then the wire on the negative terminalof the DC receptacle is broken or has a bad connection. Stop here and repair theproblem.

Remove the charger cover and perform the following tests:

1. Inspect the internal wiring of the charger and repair as required.2. Check the continuity of both fuse links and replace if bad.3. Disconnect one lead from the capacitor. Test the capacitor using the capacitor

test function on the meter. If the capacitor is bad, it must be replaced. Stop hereand repair the problem.

4. Reconnect the lead to the capacitor anddisconnect one transformer lead from one ofthe diodes. Test each of the diodes using thediode test function on the meter. If either one ofthe diodes are bad, replace the diodeassembly. Stop here and repair the problem.

Fuse LinksCapacitor Test

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitorbefore continuing. Connect a 2k ohm resistor across the capacitorterminals for 10 seconds. Do not touch the capacitor terminals withyour hands. The resistor should be held with a pair of insulated pliers.Failure to do so may cause serious bodily injury



5. Reconnect the lead to the diode.6. Connect the charger to the AC source. Insert the DC charger plug into the DC

receptacle and perform the following tests:

• Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to thebattery voltage. If the voltage is less than the battery voltage, then the DC cord is bad. Stop here andrepair the problem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltageshould be the same as the rated AC voltage of the charger. If the voltageis less than the rated AC voltage of the charger then the AC cord isbad. Stop here and repair the problem.

• If the timer relay does not pickup (click) within 5 seconds of connectingthe DC charger plug, then the timer control circuit or the relay is bad(refer to Timer Relay Test). Stop here and repair the problem.

• Test the AC voltage across the transformer primary circuit. This voltageshould be the same as the rated AC voltage of the charger. If it is lessthan the rated AC voltage of the charger, then the timer relay is bad.Stop here and repair the problem.

• Test the AC voltage across the transformer secondary circuit. The voltage here will vary depending onthe state of charge in the batteries. The voltage should be between 208% and 250% of the rated DCvoltage of the charger. If the voltage is not between 208% and 250% of the charge’s rated DC voltage,the transformer is bad and must be replaced. Stop here and repair the problem.

Transformer Secondary Circuit

TESTING THE TIMER RELAY

Test 1:1. Connect the batteries to the charger.2. Plug the charger into the AC source.3. Wait 5 seconds, then test the voltage at the timer relay coil terminals.

NOTE: This voltage should be close to the battery volts.• If the voltage is close to the battery volts, then skip to test 2.• If the voltage is not close to the battery volts, then the timer control circuit has failed and the timer must

be replaced.Test 2:

1. Disconnect the batteries.2. Unplug the charger from the AC source.3. Discharge the capacitor (see warning on previous page).

High Voltage inside the charger. Do not touch any internal componentswhile the charger is plugged in. Failure to do so may result in seriousbodily injury.



TESTING THE INTERLOCK RELAY

OperationThe Interlock Relay disables the vehicle from running whenever the charger is connected to a working ACpower source. When the charger is plugged in, the relay contacts open and break the Key Switch connectionto the speed controller. The Interlock Relay is available for built-in chargers only. Not all built-in chargersare equipped with this relay. To identify chargers that are equipped with the Interlock Relay:

Inspect the charger wire harness where it enters the charger cabinet for two Violet/Blackwires. If these wires are present then the charger is equipped with the Interlock Relay.

Testing

6. Disconnect the charger from the AC power source.7. Disconnect the two Violet/Black wires at the charger harness knife connectors.8. Set the DMM to check for continuity and connect the DMM leads to the wires

going into the charger.• The DMM should indicate a closed circuit. If the DMM indicates an open circuit, then the relay

or the wires to the relay have failed. Stop here and repair the problem.

9. Connect the charger to a working AC power source.• The charger should turn on. If the charger does not turn on then their may be a problem with the

AC power source or the AC wiring to the charger. Refer to the beginning of this section forcharger troubleshooting. DO NOT continue until you have confirmed that the AC power source isworking.

• The DMM should indicate an open circuit. If it still indicates a closed circuit, then the relay or thewires to the relay have failed. Stop here and repair the problem.

• If the DMM indicates an open circuit then the interlock relay is functioning normally.






4. Disconnect the wires from the contact terminals on the timer relay.5. Reconnect the batteries.6. Wait 5 seconds, then test the continuity across the timer relay contact terminals.

• If this is a closed circuit, then the timer start up circuit is functioning normally.• If there is an open circuit, then the timer relay has failed and the relay must be replaced.

TABLE OF CONTENTS

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Operating Instructions and Theory ofOperation ........................................2

HB/PT and GEL Indicator Lamps ...........3Testing the Charging Cycle ....................3Test Equipment Required for

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

Status LED Error Code Table ................5Troubleshooting .....................................6


Rev G


Signet Charger TroubleshootingPage 2


The model HB600W® and HB1000W® chargersare designed as semiautomatic chargers. Thecharger turns itself on when it is plugged into thewall outlet and turns off when the batteries arefully charged.

Both the HB600W® and HB1000W® are two stagechargers. The first stage is a constant currentmode. It Maintains a constant current until thebattery reaches a terminal voltage and thenswitches to the second stage, constant voltage.At the second stage the charger decreases thecharger current while holding the batteries at theterminal voltage until the charging cycle iscomplete.

The charger faceplate has three status LED’s thatmonitor the charging status. Refer to the chartand illustration below for the function of theseLED’s.

If an error occurs during charging, the chargerwill beep, and display an error code by flashingthe status LED’s. Refer to the Status LED errorcode table later in this section.

C h a r g ing S ta tus L e ft (5 0 % ) M id d le ( 7 5 % ) R ig h t ( 1 0 0 % )

0 - 5 0 % F L A S H I N G O F F O F F

5 0 % - 7 5 % O N F L A S H I N G O F F

7 5 % - 1 0 0 % O N O N F L A S H I N G

C h a r g ing C y c lec o m p lete

O N O N O N

Error , re fer tot r o u b le s h o o t ing

F L A S H I N G F L A S H I N G F L A S H I N G

C harge r T im e O ut O F F O F F F L A S H I N G




In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of thebatteries when the charge cycle was started.

NOTE: Charging time is limited to 18-hours (max). An error occurs if charging time exceeds 18-hours. See tableon previous page.

A charger could remain on for longer than 12 hours if:• The vehicle is equipped with batteries larger than 220 Amp hour capacity.• The charging cycle is interrupted at any time during the charging cycle.• Defective batteries causing a fluctuating DC voltage that confuses the charger.• One or more defective cells in the battery pack.• A brownout (drop in AC line voltage) during the charging cycle.• An electrically noisy charging environment.

A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:• The electrolyte in the batteries is too high (boil over).• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).

To test the charger to see if it is turning off correctly, monitor the battery voltage and charging current duringthe charging cycle as indicated below.

Using a digit digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during thecharging cycle. The charging current should remain within 10% of the DC output current (see previouspage) until the battery voltage reaches 2.55 volts per cell. When the voltage reaches 2.55 volts per cell, thecharging current will drop significantly and slowly taper off (voltage will remain constant). The chargershould turn off within 2 to 4 hours after entering the second stage.

HB/PT AND GEL INDICATOR LAMPS

NOTE: Your charger may not be equipped with these lamps.

HB/PT LampIf the HB/PT lamp is “ON”, then the charger has overheated andhas entered a proportionally reduced output. The charging cyclewill terminate if the temperature continues to rise. If the chargingcycle is terminated, the charger will automatically restart once ithas cooled.

The charging cycle is limited to 18-hours. If the HB/PT lamp isflashing, then the charging time has exceeded 18-hours (time islimited to 18-hours). If any of the status lamps are flashing, thenthe charge cycle did not complete.

GEL lampThis LED will only be “ON” if the charger is configured for GELbatteries. Using a GEL charger with non-GEL batteries may resultin an incomplete charge or long charge times.

GEL batteries must be charged with a charger configured forGEL batteries. Use of any other charger will result in damageto the batteries and premature failure of the batteries.




Digital Multi Meter (DMM), FLUKE 79® model shown at right and in the troubleshootingillustrations.

Clamp on DC ammeter to measure up to 20-Amps.

Important Notes and Instructions• This troubleshooting guide assumes a familiarity with the use of a digital multimeter

including, voltage tests, continuity tests and diode testing. If not familiar withany part of these tests, refer testing to a qualified technician.

• Make sure that the AC electrical socket the charger is plugged into is in goodworking condition.

• Make sure that the AC voltage at the electrical socket is the same as the ACvoltage on the charger nameplate.

• Make sure the batteries are in good condition.• If the charger exhibits intermittent problems, it must be in the failed mode for troubleshooting.• Battery volts = Full voltage available at the batteries at the time of the test being performed.• There are no internally serviceable components in the charger. If the charger has failed then it must be

replaced.

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This charger is rated for 115 VAC or 230 VAC operation. When switchingfrom one input voltage to the other, wait until all three status LED’sare off. Switching voltage when any of the LED’s are on will result indamage to the charger.



STATUS LED ERROR CODE TABLE

There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the currentoperating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in thecharging cycle. See the table below for an explanation of the error codes:

ErrorCode Description Action Required

1 Reverse polarity or open circuit tothe batteries

Check wiring for corrosion, loose connections. broken wires andproper connection to the batteries

2 AC line voltate too high or toolow

Check the input voltage.It must be within 96-132VAC or 196-266VAC

3 Charger overheated Wait for charger to cool, the charger will automaticaly restart. Inspectfor dirt or debris on the charger cooling fins and clean as required.

4 Input or Output over current Charger will automaticaly correct for this condition and restart

Note: If only the 100% LED is flashing and all others are OFF then the charger has exceeded its maximum chargingtime and shut off before the batteries were fully charged.This could be a result of:• Defective battery or batteries• Excessively discharged batteries• Oversize batteries







TROUBLESHOOTING

To test charger operation:

Connect a DC volt meter to the main battery positive and negative terminals.Attach a clamp on DC Ammeter to one of the charger DC output wires.Plug the charger into an AC outlet.Wait for charger to start (up to15 seconds), the ammeter should display the DC Amp rating of the charger

(plus or minus 10%) indicating that the charger is on (constant current mode).The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals

2.55 VPC. When the battery voltage equals 2.55 VPC the charger will switch to the constant voltagemode. At this point the charging current will be reduced and will taper off until the batteries are fullycharged.

Perform the following if the charger does not turn on:

5. Disconnect the charger from the AC source.6. Remove the charger end cap where the DC

wires enter.7. Test the voltage across the Battery Positive

(red) and Battery Negative (black) wires atthe lower left of the charger circuit board.This voltage should be equal to the batteryvoltage. If the voltage is less than the batteryvoltage, then the wires to the batteries havebeen damaged. Stop here and repair theproblem.

8. Reinstall the charger end cap where the DCwires enter.

9. Remove the charger end cap where the ACwires enter.

10.Test the continuity of all three AC wires fromthe circuit board to the AC plug. If you findan open circuit in any one of the three wiresthen the AC cord or plug has beendamaged. Stop here and repair the problem.

11.Install the charger end cap where the ACwires enter.

If both the AC and DC tests are good then the charger has failed. There are no internally serviceablecomponents in the charger. If the charger has failed then it must be replaced.

TABLE OF CONTENTS

Charger Models:HBS 600HBS 1000

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Definitions: ............................................2Test Equipment Required for

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

Operating Instructions and Theory ofOperation ........................................3

Testing the Charging Cycle ....................4Status Light Error Code Table................5Troubleshooting .....................................6

Rev A






Digital Multi Meter (DMM), calibrated and accurate down to 0.00001 volts.

Clamp on DC ammeter to measure up to 20-Amps.

Important Notes and Instructions• This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage

tests, continuity tests and diode testing. If not familiar with any part of these tests, refer testing to aqualified technician.

• Make sure that the AC electrical socket the charger is plugged into is in good working condition.• Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger

nameplate.• Make sure the batteries are in good condition.• If the charger exhibits intermittent problems, it must be in the failed mode for troubleshooting.• There are no internally serviceable components in the charger. If the charger has failed then it must be

replaced.

DEFINITIONS:

Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells.

Term Value ConditionV1: 2.47 Volts Per Cell Flooded batteries at 80F ambient temperature*.

2.39 Volts Per Cell Gel Batteries at 80F ambient temperature*.

V2: 2.08 Volts Per Cell All batteries

A1: 5 Amps (+/- 1 Amp) All batteries

All voltages are nominal.

* - Voltages are temperature compensated.Actual V1 = V1 + ((80 - TA) • TC) where:

TA = Current ambient temperature.TC = 0.0028 for flooded batteries or 0.00375 for gel batteries


This charger is rated for 115 VAC or 230 VAC operation(nominal). When switching from one input voltage to the other,wait until all LED’s are off. Switching voltage when any of theLED’s are on will result in damage to the charger.




The model HBS 600W® and HBS 1000W® chargers are designed as automatic chargers. The charger turnsitself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once thecharging cycle is complete, the charger will monitor the battery voltage. If the battery voltage drops below aspecific value (V2), the charger will turn on again for a short cycle.

Both the HBS 600W® and HBS 1000W® are two stage chargers. The first stage is a constant current mode. ItMaintains a constant current until the battery reaches a terminal voltage (V1) and then switches to the secondstage, constant voltage. At the second stage the charger decreases the charger current while holding thebatteries at the terminal voltage until the charging cycle is complete. The charging cycle is complete when thecurrent is down to A1

On the charger face plate, there is a status light panel that displays the current status of the charger.The first light (POWER) should be ON when the AC cord is connected to a proper AC power source.The three STATUS lights will indicate the current charging condition as follows:

Left: Charge cycle is ON and is in constant current mode.Left & Middle (80%): Charge cycle is ON and is in constant voltage mode.Right (100%): Charge cycle completed.

The FAULT light will turn ON and flash a fault code only when an abnormal charging condition has occurred.Refer to the fault code table for more information.

NOTE: Critical faults will be accompanied with an audible beeping.

Typical specification plate(reference only, specifications will vary for different chargers)




In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state ofcharge of the batteries when the charge cycle was started.

NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the timelimit. Refer to the fault code table for more information.

A charger could remain on for longer than 12 hours if:• The vehicle is equipped with batteries larger than 220 Amp hour capacity.• The charging cycle is interrupted at any time during the charging cycle.• Defective batteries causing a fluctuating DC voltage that confuses the charger.• One or more defective cells in the battery pack.• A brownout (drop in AC line voltage) during the charging cycle.• An electrically noisy charging environment.

A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:• The electrolyte in the batteries is too high (boil over).• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).

To test the charger to see if it is turning off correctly, monitor the battery voltage and charging current duringthe charging cycle as indicated below.

Using a digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during thecharging cycle. The charging current should remain within 10% of the DC output current (see previouspage) until the battery voltage reaches V1. When the voltage reaches V1, the charging current will dropsignificantly and slowly taper off (voltage will remain constant). The charger should turn off within 2 to 4hours after entering the second stage when the charginc current is down to A1.

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STATUS LIGHT ERROR CODE TABLE

If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the lightis flashing, it will flash from 2 to 6 times before a pause. This is the fault code.

Refer to the table below.

FaultCode

Description Action Required

1(no flash)

Time out Charge cycle time exceeded the time limit. Test batteries for possibledefictive cells.

2*Open circuit or reverse polarity tobattery Check battery wiring.

3* Battery voltage too high

Wrong voltage charger or batteries installed.24v charger: Battery voltage must be less than 33.7v36v charger: Battery voltage must be less than 43.2v48v charger: Battery voltage must be less than 57.6v

4 Overheated Inspect for dirt or debris on the charger cooling fins and clean asrequired.

5*AC line voltate too high or toolow

Check the input voltage.It must be within 85-137VAC or 170-264VAC

6 Low battery voltage

Extremely discharged battery, defective battery, miswired battery.When this fault occurs, the charger will operate in a low current modeuntill the battery voltage is built up. This fault will reset once the batteryvoltage is normal.If the battery voltage does not come up:> Test the batteries> Check battery wiring

*These faults will be accompanied by an audible beep and indicates that the charge cycle was termintatedbefore completion.



TROUBLESHOOTING

NOTE: There are no internally serviceable components in the charger.

To test charger operation:

Connect a DC volt meter to the main battery positive and negative terminals.Attach a clamp on DC Ammeter to one of the charger DC output wires.Plug the charger into an AC outlet.Wait for charger to start (up to 15 seconds), the ammeter should display the DC Amp rating of the

charger (plus or minus 10%) indicating that the charger is on (constant current mode).The ammeter should continue to display the DC Amp rating of the charger until the battery voltage equals

V1. When the battery voltage equals V1 the charger will switch to the constant voltage mode. At thispoint, the charging current will be reduced and will taper off until the batteries are fully charged. Thebatteries are fully charged when the charging current is down to A1.

If the charger does not turn on, there are no faults and the POWER light is ON, then the charger hasfailed and must be replaced.

If the POWER light is OFF, then check the AC power source, AC power cable and connections. If thesource, cable and connections are good, then the charger has failed and must be replaced.

T

A Y L OR - DUNN

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Wire Diagrams

Wire Diagrams Page 2

95

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TABLE OF CONTENTS

Illustrated Parts

Front Axle ................................................... 2Steering Gear, TRW .................................... 4Steering Gear .............................................. 6Steering Column ......................................... 7Front Suspension ........................................ 8Transmission Differential Case .................... 10Rear Axle .................................................... 12Rear Brakes ................................................ 14Rear Suspension ......................................... 16Motor, Page 1 ............................................. 18Motor, Page 2 ............................................. 20

Brake linkage (parking brake) ...................... 22Instrument Panel (dash) .............................. 24Speed Control Panel ................................... 26Miscellaneous Frame and Body .................. 28Charger, Lester Page 1 ............................... 30Charger, Lester Page 2 ............................... 32Charger, Signet ........................................... 34Decals......................................................... 35Batteries ..................................................... 36

Illustrated Parts

Parts Page 2

Front Axle

Illustrated Parts

Parts Page 3

Illustrated Parts

Parts Page 4

Steering Gear, TRWThis steering gear is obsolete and isshown here for reference only.There is no direct replacement forthis steering gear. Refer to servicebulletin BUL-98-09-011.

Illustrated Parts

Parts Page 5

OBSOLE

TE

Illustrated Parts

Parts Page 6

Steering Gear

6

8

7

5

17

12

11

132

3

14

9

1

410

16

15

Illustrated Parts

Parts Page 7

Steering Gear - 18-308-44ITEM # PART # DESCRIPTION QTY

1 18-308-70 Locknut 1

2 18-308-71 Adjuster assembly 1

3 18-308-72 Worm assenbly 1

4 18-308-23 Upper worm bearing 1

5 18-308-22 Upper worm bearing race 1

6 18-308-77 Housing 1

7 18-308-78 Seal, pitman shaft 1

8 18-308-80 Nut, pitman shaft 1

9 18-308-81 Lock washer 1

10 18-308-79 Seal, input shaft 1

11 18-308-82 Gasket 1

12 18-308-76 Pitman shaft 1

13 18-308-75 Gear lash adjuster 1

14 18-308-85 Shim kit 1

15 18-308-84 Side cover 1

16 18-308-86 Jam nut 1

17 18-308-83 Bolt, side cover 3

Steering Column

Item No. Part No. Description Qty

- 00-240-18 Column 1

- 01-240-04 Support 1

- 96-102-00 U-bolt 1

Illustrated Parts

Parts Page 8

Front Suspension

Illustrated Parts

Parts Page 9

Illustrated Parts

Parts Page 10

Transmission Differential Case

Illustrated Parts

Parts Page 11

Illustrated Parts

Parts Page 12

Rear Axle

Illustrated Parts

Parts Page 13

Illustrated Parts

Parts Page 14

Rear Brakes

Illustrated Parts

Parts Page 15

Illustrated Parts

Parts Page 16

Rear Suspension

Illustrated Parts

Parts Page 17

Illustrated Parts

Parts Page 18

Motor, Page 1

10 11 7 9 12

13

9

5

3

4

2

1

14

16

17

6

8

15

Typ

ical

GE

Mot

or

Illustrated Parts

Parts Page 19

L94

-400

6 70

-074

-00

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5BT

1344

B18

5 70

-072

-00

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5BC

49JB

3043

B

70-0

61-0

0

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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N/A

N/A

N/A

N/A

N/A

N/A

N/A

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9475

-31

70-0

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0

N/A

N/A

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N/A

N/A

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N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5BC

49JB

249A

70

-057

-10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5BT

1326

B26

2A

70-0

55-0

0

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

XP1

706A

70

-054

-05

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5BC

49JB

399C

70

-054

-00

45-5

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0

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0

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0

97-1

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0

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0

-

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22-0

0

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23-0

0

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0

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0

-

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2

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95-1

0

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0

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12-0

0

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0

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0

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0

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N/A

N/A

5BC

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S612

9B

70-0

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5

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88-0

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Mot

or S

pec

# M

otor

Par

t #

5BC

58JB

S611

0C

70-0

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0

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97-1

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0

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5

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1

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70-2

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-

N/A

- -

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0

-

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0

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0

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N/A

N/A

DE

SCR

IPT

ION

Oil

seal

Fron

t bea

ring

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r bea

ring

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druf

f key

Fiel

d w

indi

ng

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lato

r

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hing

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lato

r

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lato

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t C

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over

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sh s

prin

g

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sh c

over

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sh

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ring

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5/16

NC

Jam

nut

5/16

SA

E Fl

at

was

her

Mot

ors,

Ser

ies

Wou

nd F

ield

ITE

M #

1 2 3 4 5 6 7 8 9 10

11

- 12

13

14

15

16

17

18

19

20

Illustrated Parts

Parts Page 20

Motor, Page 2

10 11 7 9 12

13

9

5

3

4

2

1

14

16

17

6

8

15

Typ

ical

GE

Mot

or

Illustrated Parts

Parts Page 21

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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N/A

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N/A

N/A

N/A

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N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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N/A

N/A

N/A

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N/A

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N/A

N/A

N/A

N/A

N/A

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N/A

N/A

N/A

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N/A

N/A

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N/A

N/A

N/A

N/A

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N/A

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N/A

N/A

BP5

-400

2 70

-054

-00

45-5

09-0

0

80-2

12-0

0

80-2

12-0

0

97-1

00-0

0

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

70-1

70-3

0

85-4

03-0

0

70-4

21-0

0

70-1

70-1

0

70-1

80-0

1

70-4

17-0

0

88-0

89-9

1

88-0

88-6

1

A02

-401

1 70

-049

-40

- -

80-2

12-0

0

-

N/A

- - - - - - - - -

70-4

12-2

0

N/A

70-1

09-0

0

70-1

80-0

0

70-4

17-0

0

88-0

89-9

1

88-0

88-6

1

ER

5-40

01

70-0

49-0

5 - -

80-2

12-0

0

-

N/A

- - - - - - - - -

70-4

12-2

0

N/A

70-1

09-0

0

70-1

80-0

0

70-4

17-0

0

88-0

89-9

1

88-0

88-6

1

Mot

or S

pec

# M

otor

Par

t #

5BC

49JB

430

70-0

54-2

0

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

DE

SCR

IPT

ION

Oil

seal

Fron

t bea

ring

Rea

r bea

ring

Woo

druf

f key

Fiel

d w

indi

ng

Insu

lato

r

Bus

hing

Bus

hing

Insu

lato

r

Insu

lato

r

Insu

lato

r

Insu

lato

r/Bus

hing

ki

t C

ross

over

Cro

ssov

er

Bru

sh s

prin

g

Bru

sh c

over

Bru

sh

Bru

sh h

olde

r

Bea

ring

Ret

aine

r

5/16

NC

Jam

nut

5/16

SA

E F

lat

was

her

Mot

ors,

Ser

ies

Wou

nd F

ield

ITE

M #

1 2 3 4 5 6 7 8 9 10

11

- 12

13

14

15

16

17

18

19

20

Illustrated Parts

Parts Page 22

Brake linkage (parking brake)

Illustrated Parts

Parts Page 23

Illustrated Parts

Parts Page 24

Instrument Panel (dash)

Illustrated Parts

Parts Page 25

Illustrated Parts

Parts Page 26

Speed Control Panel

Illustrated Parts

Parts Page 27

Illustrated Parts

Parts Page 28

Miscellaneous Frame and Body

Illustrated Parts

Parts Page 29

Illustrated Parts

Parts Page 30

Charger, Lester Page 16

85

4

3

711 1

28

34

5

10

76

2

1

8

9

Typ

ical

Bui

lt In

cha

rger

Typ

ical

Por

tabl

e ch

arge

r

Illustrated Parts

Parts Page 31

1692

0 79

-309

-20

48L

C25

-8E

T

230/

50/n

a

48/2

5

Bui

lt-I

n

-

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79-8

08-2

0

79-9

02-0

0

79-7

49-1

3

S/O

N/A

79-8

31-0

0

79-5

30-0

0

- - -

N/A

2262

0 79

-303

-25

48L

C25

-8E

T

115/

60/1

5

48/2

5

Bui

lt-In

-

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8

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0

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3

79-6

03-1

0

-

79-8

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0

79-5

30-0

0

- -

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0

76-2

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0

1691

0 79

-309

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C25

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5

48/2

5

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8

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0

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0

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0

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-31

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1

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7

36/4

0

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0

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0

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0

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79-5

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0

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31-0

0

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0

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79

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5

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0

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79-8

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79-5

75-1

0

79-8

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0

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0

79-7

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0

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0 79

-303

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-

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0

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0

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0

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SCR

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Cha

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Typ

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AC

Vol

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ps

DC

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ps

Styl

e

Am

met

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ssem

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Rel

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ssem

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Cor

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M #

1 2 3 4 5 6 7 8 9 10

11

-

Illustrated Parts

Parts Page 32

Charger, Lester Page 26

85

4

3

711 1

28

34

5

10

76

2

1

8

9

Typ

ical

Bui

lt In

cha

rger

Typ

ical

Por

tabl

e ch

arge

r

Illustrated Parts

Parts Page 33

1231

5 79

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T

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36/4

0

Por

tabl

e

79-8

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0

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87

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0

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0

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0

S/O

S/O

79-8

31-0

0

79-5

32-0

0

79-5

30-0

0

79-5

67-1

0

- -

7030

79

-304

-60

36L

C25

-8E

T

230/

50/7

3625

Por

tabl

e

79-8

51-1

0

K4-

071-

87

79-8

08-0

0

79-9

02-0

0

79-7

49-1

3

S/O

S/O

79-8

31-0

0

79-5

32-0

0

79-5

30-0

0

S/O

- -

2273

0 79

-303

-05

24L

C25

-8E

T

115/

60/8

24/2

5

Bui

lt-I

n

-

79-8

05-6

6

79-8

08-1

0

79-9

02-0

0

79-7

49-1

3

S/O

-

79-8

31-1

0

79-5

31-0

0

- -

79-8

09-6

0

76-2

00-0

0

1376

0 79

-302

-15

24L

C40

-8E

T

115/

60/1

3

24/4

0

Bui

lt-I

n

-

79-8

05-6

6

79-8

08-1

0

79-9

02-0

0

79-7

49-1

3

S/O

-

79-8

31-1

0

79-5

31-0

0

- - -

76-2

00-0

0

9513

-31

79-3

02-1

0

24L

C40

-8E

T

115/

60/1

3

24/4

0

Por

tabl

e

79-8

52-0

0

79-8

05-6

4

79-8

08-1

0

79-9

02-0

0

79-7

49-1

3

S/O

79-5

75-1

0

79-8

31-1

0

79-5

31-0

0

79-5

30-0

0

S/O

-

76-2

00-0

0

1311

0 79

-301

-10

24L

C25

-8E

T

115/

60/9

24/2

5

Por

tabl

e

79-8

51-1

0

79-8

05-6

4

79-8

08-1

0

79-9

02-0

0

S/O

S/O

S/O

79-8

31-0

0

79-5

32-0

0

79-5

30-0

0

79-5

66-1

0

-

76-2

00-0

0

1275

0 79

-300

-55E

24L

C25

-8E

T

230/

50/4

24/2

5

Bui

lt-I

n

-

79-8

05-7

0

79-8

08-1

0

79-9

02-0

0

79-7

49-1

3

79-6

44-0

8

-

79-8

31-0

0

79-5

30-0

0

- -

79-3

06-2

3

-

7105

-01

79-3

00-5

0

24L

C25

-8E

T

230/

50/4

24/2

5

Por

tabl

e

79-8

51-1

0

79-8

05-6

4

79-8

08-1

0

79-9

02-0

0

79-7

49-1

3

S/O

S/O

79-8

31-0

0

79-5

32-0

0

79-5

30-0

0

79-5

66-1

0

- -

Cha

rger

Mod

el #

C

harg

er P

art #

1440

0-31

79

-302

-50

24L

C40

-8E

T

230/

50/7

24/4

0

Por

tabl

e

79-8

52-0

0

S/O

79-8

08-1

0

79-9

02-0

0

S/O

S/O

S/O

79-8

31-1

0

S/O

S/O

79-5

67-1

0

- -

DE

SCR

IPT

ION

Cha

rger

Typ

e

AC

Vol

tage

/Hz/

Am

ps

DC

Vol

tage

/Am

ps

Styl

e

Am

met

er

Tim

er A

ssem

bly

Rel

ay fo

r #2

Cap

acito

r

Dio

de A

ssem

bly

Tra

nsfo

rmer

AC

Cor

d

Fuse

Ass

embl

y

Stra

in R

elie

f

Stra

in R

elie

f

DC

Cor

d

Inte

rloc

k R

elay

Ass

y.

Rep

lace

men

t AC

Plu

g

CH

AR

GER

S

ITEM

#

1 2 3 4 5 6 7 8 9 10

11

-

Illustrated Parts

Parts Page 34

Charger, Signet

NOTE: The harness connectors and AC plug are not includedwith the charger.

QTY PART # DESCRIPTION

2 75-318-20 Butt splice

2 75-320-51 Knife connector

1 76-200-00 AC plug, 115v domestic

Model HBS for Flooded BatteriesPART # DESCRIPTION

* 24 volt Charger Assembly (see note)

79-303-41 36 volt Charger assembly (see note)

79-309-42 48 volt charger assembly (see note)

* - Not available at time of printing

NOTE: There are no user serviceable components inside the charger

NOTE: The charger AC cord is an intergral part of the charger. Whenreplacing the charger, do not cut and splice the AC cord. Cuttingthe AC cord will void the charger warranty.

NOTE: The Signet model HBS series charger replaces all previous Signetmodels.

Model HBS series charger shown

Model HBS for GEL BatteriesPART # DESCRIPTION


* 36 volt Charger assembly (see note)

* 48 volt charger assembly (see note)

Model HB for Flooded BatteriesPART # DESCRIPTION

79-302-20 24 volt Charger Assembly (see note)

79-303-40 36 volt Charger assembly (see note)


Model HB for GEL BatteriesPART # DESCRIPTION


K4G-CH-003 36 volt Charger assembly (see note)


Illustrated Parts

Parts Page 35

Decals

Item No. Part No. Description Qty

1 94-384-04 Traffic standards 1

2 94-333-00 FM 1

3 94-309-00 Set park brake 1

4 94-384-14 When leaving vehicle 1

5 94-301-42 Amrs and legs 1

6 94-313-20 Safety 1

7 94-319-00 Battery disconnect 1

8 94-313-00 Battery gasses 1

Illustrated Parts

Parts Page 36

Batteries

3

456

NE

G

POSN

EG

POS

NE

G

POSN

EG

POS

7

8

1

1b

NEG

POS

NEG

POS

NEG

POS

NEG

POS

12 VoltNegative tap

Main Positive

Main Negative

1a2

Illustrated Parts

Parts Page 37

BatteriesITEM # PART # DESCRIPTION QTY

1a 75-235-00 Battery jumper 4

1b N/A Battery jumper, 43" long, 6 gauge 1

2

77-042-00 217AH, T-105 *

77-042-50 217AH, TD-217 *

77-042-80 217AH, T-105 Moist charge (dry) *

77-044-00 230AH, T-125 *

77-044-10 195AH, Mainenance free (Note: requires special charger) *

77-047-00 244AH, T-145 *

77-047-50 250AH, TD-250 *

77-047-80 244AH, T-145 Moist charge (dry) *

77-048-00 250AH, J-250 *

77-048-80 250AH, J-250 Moist charge (dry) *

77-051-00 160AH Gell (Note: requires special charger) *

3 50-243-10 Battery rod 2

4 50-250-00 Battery hold down (front) 2

Not shown 00-240-06 Battery hold down (rear) 1

5 88-088-66 Flat washer, tin/lead plated 2

6 88-069-81 1/2NC Nylon lock nut 4

7 88-081-12 5/16NC x 1 Hex bolt, stainless steel 12

8 88-089-80 5/16NC Hex nut, stainless stell 12

TAYL

OR -

DUNN

Ap

pen

dix

esContentsAppendix A: Special Tools ................. 2Appendix B: Suggested Torque

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

Standard Head Markings ...................................... 3Hex Bolts .............................................................. 3Other Bolts ............................................................ 3Hex Nuts ............................................................... 4Hex Lock Nuts (stover) ........................................ 4Other Nuts ............................................................. 4Suggested Torque Values (non-critical hardware) 5

Appendix C: Brake Lining Handling Precautions .................... 7

REV B

Appendixes

AppendixesAppendix APage 2

APPENDIX A: SPECIAL TOOLS

DESCRIPTION PURPOSE PART NUMBER

Test Light Used for testing electrical circuits. Powered by the truckbatteries, switchable for 12, 24, 36, and 48 volts. 62-027-00

Accelerator Test Harness Used to test the solid state accellerator module part numberseries 62-033-XX. 62-027-31

PMC Test KitIncludes 62-027-00, 62-027-31, and supplementarytroubleshooting manual M3-001-06. For controllersequipped with pins labeled KSI and #2 only.

62-027-60

Curtis® PMC HandheldProgrammer

Used to test and program the 62-215-00 PMC speed controlused on early model C4-25 Huskey. 62-027-10

PMT/C Meter Reset Module Used to reset the PMT/C maintenance meter after amaintenance is completed. 96-500-43

Disc Brake Boot InstallationTool

Used to install the rubber boot on all disc brake bodies. 41-350-13

Pin Removing Tool Used to remove pins and sockets from AMP connectors. 75-440-55

Pin Removing Tool Used to remove pins and sockets from MOLEX connectors. 75-442-55

Hydrometer Used to check the specific gravity of battery electrolyte. 77-200-00

Battery Filler Used to safely add water to batteries. 77-201-00

Solder Kit For Field Stud Used to solder the aluminum field wire to the field stud. Foruse on motors with soldered connections only. 70-210-63

AppendixesAppendix B

Page 3

Appendixes

HARDWARE IDENTIFICATIONStandard Head Markings

S.A.E. Grade 2 S.A.E. Grade 5

Truss Head, grade 2 Carriage Bolt, grade 2(unless marked as above)

Other Bolts

NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on agrade 8 bolt, use grade 2 torque value.

NOTE: Toque values specified are for clean dry threads.

Hex Bolts

S.A.E. Grade 8

L’9

L’9

APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARDHARDWARE

Appendixes

AppendixesAppendix BPage 4

Hex Nuts

S.A.E. Grade 5 S.A.E. Grade 8

Hex Lock Nuts (stover)

Cor, or,

Bor, or,

Nuts with no markings are to be treated as S.A.E. Grade 2

Lock nuts use a letter to indicate the grade of the nut. Grade A’ locknuts would be the equivelent of Grade ‘2’hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’.

NOTE: Nuts with no markings are to be treated as S.A.E. Grade A

S.A.E. Grade B S.A.E. Grade C

Other Nuts

Other nuts used by Taylor-Dunn® should be treated as S.A.E. grade A

Grade L’9

AppendixesAppendix B

Page 5

Appendixes

Diameterand TPI

Grade 2TighteningTorque(ft-lb)



L'9TighteningTorque(ft-lb)

1/4-20 4-7 7-10 10-14 11

1/4-28 5-8 8-12 11-16 12

5/16-18 9-14 14-21 20-29 22

5/16-24 10-15 15-23 22-33 25

3/8-16 16-24 25-37 35-52 40

3/8-24 18-27 28-42 40-59 45

7/16-14 26-38 40-59 56-84 65

7/16-20 29-43 44-66 62-93 70

1/2-13 39-59 60-90 85-128 95

1/2-20 44-66 68-102 96-144 110

9/16-12 56-84 87-131 123-184 140

9/16-18 63-94 97-146 137-206 160

5/8-11 78-117 120-180 170-254 195

5/8-18 88-132 136-204 192-288 225

3/4-10 138-207 213-319 301-451 350

3/4-16 154-231 238-357 336-504 390

7/8-9 222-334 344-515 485-728 565

7/8-14 245-367 379-568 534-802 625

1-8 333-500 515-773 727-1091 850

1-14 373-560 577-866 815-1222 930

1.125-7 472-708 635-953 1030-1545 1700

1.125-12 530-794 713-1069 1156-1733 1850

1.25-7 666-999 896-1344 1454-2180 2950

1.25-12 738-1107 993-1489 1610-2414 3330

Suggested Torque Values (non-critical hardware)

Appendixes

AppendixesAppendix BPage 6

Suggested Torque Values (critical hardware)

Torque Table Torque Range Group Description Ft-Lbs In-Lbs Nm Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 Brake line tube nut fittings 12 - 13 144 - 156 16.3 - 17.7 Brake spider bolts (Dana 160mm hyd brakes) 25 - 35 300 - 420 34 - 47.6 Brake spider bolts (Dana 160mm mech brakes) 15 - 19 180 - 228 20.4 - 25.8 Brake spider bolts (Dana 7x1-3/4 brakes) 16 - 20 192 - 240 21.8 - 27.2 Electrical - - - - - - - - - - - - - - - - - - - - - - - - Battery terminals 8 - 9 96 - 108 10.9 - 12.2 Front Axle - - - - - - - - - - - - - - - - - - - - - - - - Front spindle nut - - - Note: Refer to maintenance section in the service manual King pin - - - Note: Refer to maintenance section in the service manual Rear Axle/Transmission - - - - - - - - - - - - - - - - - - - - - - - - 3rd member Gear case cover (GT drive) 45 - 50 540 - 600 61.2 - 68 Axle bolt (GT drive) 275 - 275 3300 - 3300 374 - 374 Axle hub nut (Dana) 95 - 115 1140 - 1380 129.2 - 156.4 Axle tube to center section (Dana F-N-R) 25 - 35 300 - 420 34 - 47.6 Carrier cap bolts (Dana) 100 - 120 1200 - 1440 136 - 163.2 Differential Cover plate (Dana H12) 18 - 25 216 - 300 24.5 - 34 Drain plug (Dana H12) 25 - 40 300 - 480 34 - 54.4 Drain plug (GT drive) 21 - 25 252 - 300 28.6 - 34 Gear case to 3rd member (GT drive) 18 - 20 216 - 240 24.5 - 27.2 Motor mounting (GT/Dana) 6.5 - 7 78 - 84 8.8 - 9.5 Pinion nut (F2/F3) 175 - 175 2100 - 2100 238 - 238 Pinion nut (GT drive) 154 - 169 1848 - 2028 209.4 - 229.8 Ring gear (Dana) 35 - 45 420 - 540 47.6 - 61.2 Wheel lug nut 75 - 90 900 - 1080 102 - 122.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - Ball joint clamp 28 - 32 336 - 384 38.1 - 43.5 Ball joint nut 40 - 45 480 - 540 54.4 - 61.2 Pitman nut (18-308-21 steering gear) 75 - 100 900 - 1200 102 - 136 Pitman nut (18-308-25 steering gear) 181 - 217 2172 - 2604 246.2 - 295.1 Rod end nut 20 - 25 240 - 300 27.2 - 34 Steering shaft pinch bolt 24 - 26 288 - 312 32.6 - 35.4 Steering wheel nut (18-308-21 steering gear) 28 - 32 336 - 384 38.1 - 43.5 Steering wheel nut (18-308-25 steering gear) 72 - 86 864 - 1032 97.9 - 117 Suspension - - - - - - - - - - - - - - - - - - - - - - - - Leaf spring hangers - - - Note: Refer to maintenance section in the service manual

AppendixesAppendix C

Page 7

Appendixes

Taylor-Dunn does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that theoriginal brake pads/shoes were replaced with aftermarket pads/shoescontaining asbestos. Since this possibility does exist, the brake pads/shoes should be handled as if they do contain asbestos.

Never use compressed air or dry brush to clean the brake assemblies.Use an OSHA approved vacuum cleaner or any alternate methodapproved by OSHA to minimize the hazard caused by airborneasbestos fibers and brake dust.

Do not grind, sand, break, or chisel the brake pads/shoes, as this willcause unnecessary dust, possibly releasing asbestos fibers in the air.

Always wear protective clothing and a respirator when working onthe brake pads/shoes or their associated components.

Inhaled asbestos fibers have been found to cause cancer andrespiratory diseases.

Do not drive the vehicle if any worn or broken part is detected in anypart of the brake system. The cause of the damage must be repairedimmediately.

APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS

Taylor-Dunn® Mfg.2114 W. Ball Rd.Anaheim, CA 92804(800)-688-8680(714) 956-4040(FAX) (714) 956-0504

Visit our Website:www.taylor-dunn.com

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