®

B0-015-00

MX-016-00

The Best Way Models Inlcuded:

To Go B0-015-00 (B 1-50) Load Master
MX-016-00 (MX 1600) Maintenance Expediter
About Your
Business

MANUAL MB-150-02
Operation, Troubleshooting and
Replacement Parts Manual

Published: 11/26/2002 Serial number Starting: 136914

Revision: C
 Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support our
vehicles. Information regarding vehicle sales, replacement parts, or service should be
obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn
website at www.taylor-dunn.com.
If you do not have access to the internet, you can call the factory direct at:
01 (714) 956-4040
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804
 B2-10 Ambulance
B2-48 With Dump Bed Option

B2-48 with Steel Cab, Foldaway

4-Passenger Seat and Stake Sides

ET 3000
P2-50 30,000 Pound Tow Tractor

ET1-50 Full Size Truck

 Section Index

Taylor-Dunn
®

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

Operator and Service Manual Section Index

Introduction 1
Safety Rules and Operating Instructions 2
General Maintenance 3
Front Axle Service 4
Steering Component Service 5
Brakes Service 6
Motor Service 7
Transaxle Service 8
Suspension 9
Battery Service 10
Tires and Wheels 11
Control System Troubleshooting 12
Wire diagram 13
Chargers 14
Illustrated Parts 15
Appendix A
Special Tools 16
Appendix B
Suggested Torque Values 17
Appendix C
Brake Lining Handling Precautions 18

This quick reference section index guide will assist you in

locating a desired topic or procedure.
Refer to each sectional Table of Contents for the page
number location for specific topics or procedures.
TAYLOR -DUNN
Introduction

Contents
About this manual ......................................... 2
Who Should Read This Manual .................... 2
Responsibilities ............................................ 3
How To Use This Manual .............................. 4
Conventions .............................................................. 4
How to Identify Your Vehicle ........................ 6
Taking Delivery of Your Vehicle ................... 7
 INTRODUCTION

ABOUT THIS MANUAL

The purchase of this vehicle shows a belief in high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be
sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this
high quality Taylor-Dunn® vehicle.
This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn® vehicles and is
not intended as a training guide. Taylor-Dunn® has made every effort to include as much information as
possible about the operation and maintenance of this vehicle.
Included in this manual are:
• Vehicle Description
• Safety Rules and Guidelines
• Operational Information
• Operator Responsibilities
• Owner Responsibilities
• Control Operation and Location Information
• Maintenance and Troubleshooting Information
• Standard Parts List
Before servicing, operating, training or performing maintenance on this or any other Taylor-Dunn® vehicle,
read the appropriate Taylor-Dunn® manual.
Each Taylor-Dunn® manual references the applicable models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

Introduction Page-2
 INTRODUCTION

WHO SHOULD READ THIS MANUAL

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

RESPONSIBILITIES

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

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

Of the Service Personnel...

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

Of the Passengers ...

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

Introduction Page-3
 INTRODUCTION

HOW TO USE THIS MANUAL

This manual is organized into five main sections:

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

Safety Rules and Operating Instructions

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

Maintenance Service and Repair

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

Electrical and Charger Troubleshooting

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

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

Introduction Page-4
 INTRODUCTION

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

A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to
or, themself or others. Be sure to follow any instructions contained
within a warning and exercise extreme care while performing the
task.

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

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

Introduction Page-5
 INTRODUCTION

HOW TO IDENTIFY YOUR VEHICLE

This manual applies to vehicles with the same model and serial numbers listed on the front cover.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.

This vehicle is not designed to be driven on public roads or highways.

It is available in maximum designed speeds ranging from 7 to 15
mph. Do not exceed the maximum designed speed. Exceeding the
maximum designed speed may result in steering difficulty, motor
damage, and/or loss of control. Do not exceed locally imposed speed
limits. Do not tow at more than 5 mph.

This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard
for Personnel and Burden Carriers (ANSI B56.8).
The locations of the model and serial numbers are illustrated below:

B 1-50 and MX
1600
B 1-50 and MX 1600

B 1-50 MX 1600

Introduction Page-6
 INTRODUCTION

TAKING DELIVERY OF YOUR VEHICLE

Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious
problems:
• Examine the contents of all packages and accessories that may have come in separate
packages with the vehicle.
• Make sure everything listed on the packing slip is there.
• Check that all wire connections, battery cables, and other electrical connections are secure.
• Check battery cells to be sure they are filled.
• Check the tire pressure, tightness of lug nuts, and for any signs of damage.
Check the operation of each of the following controls:
• Accelerator
• Brake
• Parking Brake
• Key-Switch
• Forward/Reverse Switch
• Reverse Beeper (if equipped)
• Front Headlight Switch
• Steering Wheel
• Horn

What To Do If a Problem is Found

If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading
and file a claim with the freight carrier. The claim must be filed within 48 hours of receiving the vehicle
and its accessories. Also, notify your Taylor-Dunn® dealer of the claim.
If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately
contact your local Taylor-Dunn® distributor and report the problem. The report must be made within 24
hours of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn® vehicle is
a factory authorized service technician.

The only personnel authorized to repair, modify, or adjust any part

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

Introduction Page-7
Model B 1-00
 Safety Rules and Operating
Instructions

TABLE OF CONTENTS
Standard Specifications ................................ 2 Vehicle Operational Guidelines..................... 10
Safety Rules and Guidelines ......................... 3 Driving ...................................................................... 10
Driver Training Program ................................ 4 Loading and Unloading ............................................ 10
Parking ..................................................................... 10
Driver Qualifications. ............................................... 4
Towing ...................................................................... 10
Vehicle Controls ............................................ 5 Charging your vehicle ................................... 11
Key-Switch ............................................................... 5
Signet Charger Operation, Model HB Series ......... 11
Forward-Off-Reverse Switch ................................... 5
Signet Charger Operation, Model HBS series ........ 11
Accelerator Pedal .................................................... 5
Lestronic II Charger Operation ................................ 12
Steering .................................................................... 5
New Battery Break in ............................................... 12
Foot Brake Pedal ..................................................... 6
Charging Time.......................................................... 12
Park Brake ............................................................... 6
Horn Switch .............................................................. 6 Storing and Returning to Service ................ 13
Seat Interlock Switch ............................................... 6 Storing your Vehicle ................................................. 13
Headlight Switch ...................................................... 7 Returning To Service ............................................... 13
Hour Meter (Optional) .............................................. 7 Periodic Maintenance Checklist ................... 14
Charger Interlock ..................................................... 7 Daily Visual inspection: ............................................ 15
Battery Status Indicator, Analog .............................. 7 Maintenance Guidelines for
Battery Status Indicator, Digital Bargraph ............... 8 Severe Duty Applications........................ 15
Reverse or Motion Alarm (Optional) ....................... 8
Electrolyte Alarm (Optional) .................................... 8
Directional Signals (Optional) .................................. 8
Hazard Light Switch (Optional) ............................... 9
Accessory Switch (Optional) ................................... 9
Auxiliary Switch (Optional) ...................................... 9
 SAFETY RULES AND OPERATING INSTRUCTIONS

STANDARD SPECIFICATIONS
ITEM MODEL VOLTAGE SPECIFICATION
Occupancy Driver and one passenger

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

107.95L X 44.29 X 47.5H Inches
MX 1600 274.2L X 112.5W X 207.6H Centimeters
107.95L X 44.29 X 81.75H Inches

Turning Radius 279.4 Centimeters (110 inches)

Dry Weight B 1-50 376.5 kg (830 lbs)

Without Batteries MX 1600 469.9 kg (1036 lbs)

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

Weights

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

MX 1600 454 kg (1000 lbs)

Electrical System 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 275 Amp

Transmission Helical Gear, Oil Bath, Direct Drive

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

2 hp @ 2800 RPM for 60 min

Maximum Recommended 19.3 kph (12 mph)

Speed

Brakes Rear Wheel Mechanical Drum, Foot Operated Park Brake

Steering Automotive Steering 24:1

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

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

Diamond Plate
MX 1600 Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Tool Box, Ladder Rack, Vise, Work Bench,
Gas Weld Tank Compartment

Instrumentation Battery Status Indicator, Key Switch, Horn Button,

Forward/Reverse Switch, Brake Light

Light Accessories B 1-50 12 Volt Brake Light

MX 1600 12 Volt Headlight, Tail/Brake Light

Charger 36 Volt 110 Volt 12 Amp AC, 25 Amp DC, Built-In, Automatic with
Control system Interlock Relay

Safety Rules
Page 2
 SAFETY RULES AND OPERATING INSTRUCTIONS

SAFETY RULES AND GUIDELINES

It is the responsibility of the owner of this vehicle to assure that the operator understands the various
controls and operating characteristics of this vehicle. As well as, obeying the following safety rules and
guidelines (extracted from the American National Standards Institute Personnel and Burden Carriers
ANSI B56.8).
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.

This vehicle is not designed to be driven on public roads or highways.

It is available in maximum designed speeds ranging from 7 to 15
mph. Do not exceed the maximum designed speed. Exceeding the
maximum designed speed may result in steering difficulty, motor
damage, and/or loss of control. Do not exceed locally imposed speed
limits. Do not tow at more than 5 mph.

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

• Do not drive this vehicle unless you are a qualified and trained operator.
• Keep all body parts (head, arms’, legs’) inside the vehicle while it is moving.
• Drive slowly when making a turn especially if the ground is wet, slippery or when driving on an
incline.
• This vehicle may overturn easily if turned sharply, driven at high speeds, or when on an incline.
• Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees).
• Do not drive over loose objects, holes, or bumps.
• Observe all traffic regulations and speed limits (see speed warning above).
• Keep to the right under normal conditions.
• Maintain a safe distance from all objects.
• Keep the vehicle under control at all times.
• Yield right of way to pedestrians, ambulances, fire trucks, or other vehicles in emergencies.
• Do not overtake another vehicle at intersections, blind spots, or other dangerous locations.
• Keep a clear view ahead at all times.
1. Make sure the key-switch is in the “OFF” position, then remove
the key.
2. Place the forward-reverse switch in the center “OFF” position.
Before working 3. Set the park brake.
on a vehicle:
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

Safety Rules
Page 3
 SAFETY RULES AND OPERATING INSTRUCTIONS

DRIVER TRAINING PROGRAM

As per ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those
who will be operating this vehicle. The training program shall not be condensed for those claiming to
have previous vehicle operation experience. Successful completion of the Operator Training program
shall be required for all personnel who operate this vehicle.
The Operator Training program shall include the following:
• Operation of this vehicle under circumstances normally associated with your particular
environment.
• Emphasis on the safety of cargo and personnel.
• All safety rules contained within this manual.
• Proper operation of all vehicle controls.
• A vehicle operation and driving test.

Driver Qualifications.
Only those who have successfully completed the Operator Training program are authorized to drive this
vehicle. Operators must possess the visual, auditory, physical, and mental ability to safely operate this
vehicle as specified in the American National Standards Institute Controlled Personnel and Burden
Carriers ANSI B56.8.
The following are minimum requirements necessary to qualify as an operator of this vehicle:
• Demonstrate a working knowledge of each control.
• Understand all safety rules and guidelines as presented in this manual.
• Know how to properly load and unload cargo.
• Know how to properly park this vehicle.
• Recognize an improperly maintained vehicle.
• Demonstrate ability to handle this vehicle in all conditions.

Safety Rules
Page 4
 SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE CONTROLS

Key-Switch
A key-switch, located on the right side of the instrument panel, turns on the
vehicle. Rotate the key clockwise to turn the vehicle power on,
counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position whenever the operator
leaves the driver's seat.
This switch is also designed to secure and disable the vehicle. The key
can only be removed when the key-switch is in the “OFF” position.

Forward-Off-Reverse Switch
The forward-Off-reverse switch, located on the right side of the instrument
panel, determines the direction of travel of the vehicle. Push the top of the
switch to engage the forward direction. Push the bottom of the switch to
engage the reverse direction.
DO NOT SHIFT from forward to reverse or vice-versa while the vehicle is
in motion. Make sure the vehicle is completely stopped before shifting.
The forward-reverse switch should be in the center “OFF” position, with
key-switch off and the park brake set whenever the operator leaves the
driver's seat.

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

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.

Safety Rules
Page 5
 SAFETY RULES AND OPERATING INSTRUCTIONS

Foot Brake Pedal

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

Park Brake
The parking brake is actuated with a hand lever, which is located between
the driver and passenger seats. To set the parking brake, push down on
the brake pedal and pull the lever up until it locks. To release the park
brake, depress the foot brake pedal, pull up on the park brake handle,
push the release button, and lower the handle.

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

Seat Interlock Switch

A switch located under the driver's seat disables the power to the vehicle
when the driver leaves the seat. The driver must be seated for the vehicle
to operate.
Whenever the driver leaves the seat, they should turn the key-switch off,
place the forward-reverse switch in the center “OFF” position, and set the
park brake.

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

Safety Rules
Page 6
 SAFETY RULES AND OPERATING INSTRUCTIONS

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

Hour Meter (Optional)

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

Charger Interlock
The charger interlock is designed to disable the vehicle from being driven
while the AC charger cord is plugged into a functioning power source.
NOTE: The interlock shown is mounted external of the charger. Some
vehicles may have the interlock built into the charger.

Battery Status Indicator, Analog

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

Safety Rules
Page 7
 SAFETY RULES AND OPERATING INSTRUCTIONS

Battery Status Indicator, Digital Bargraph

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

Reverse or Motion Alarm (Optional)

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

Electrolyte Alarm (Optional)

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

Directional Signals (Optional)

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

Safety Rules
Page 8
 SAFETY RULES AND OPERATING INSTRUCTIONS

Hazard Light Switch (Optional)

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

Accessory Switch (Optional)

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

Auxiliary Switch (Optional)

The auxiliary switch is located on the left side of the instrument panel and
to the left of the headlight switch. Push the switch up to turn on an accessory.
Push the switch down to turn off the accessory. The accessory can be
turned on with the key switch in the “OFF” position. If a vehicle is equipped
with windshield wipers and one or more accessories, the auxiliary switch
will control the other accessories.

Safety Rules
Page 9
 SAFETY RULES AND OPERATING INSTRUCTIONS

VEHICLE OPERATIONAL GUIDELINES

Driving
• Slow down and sound the horn to warn pedestrians or when
approaching a corner or other blind intersection.
• No reckless driving.
• Do not drive this vehicle on steep inclines or where prohibited.
• Immediately report any accidents or vehicle problems to a
supervisor.

Loading and Unloading

• Do not carry more than the maximum number of passengers
allowed for this vehicle.
• Do not exceed the cargo load capacity.
• Do not load cargo that can fall off.
• Be careful when handling cargo that is longer, wider, or higher than this vehicle, be sure to
properly secure all loads.

Parking
Before leaving the vehicle:
• Set the parking brake.
• Set the forward-reverse switch to the center “OFF” position.
• Turn the key switch to the “OFF” position and remove the key.
In addition:
• If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.
• Do not block fire aisles, emergency equipment, stairways, or exits.

Towing
To tow this vehicle, attach a tow strap to the front bumper tow-bar.
NOTE: If the vehicle is equipped with an automatic electric brake, do not
tow the vehicle with the drive wheels on the ground.
Use another driver to steer this vehicle while it is being towed. Be sure the driver uses the brakes when
the towing vehicle slows or stops. Do not tow the vehicle faster than 5 m.p.h. or its maximum designed
speed, whichever is lower.
If at all possible, this vehicle should be placed on a carrier, rather than towing it.
Safety Rules
Page 10
 SAFETY RULES AND OPERATING INSTRUCTIONS

CHARGING YOUR VEHICLE

Explosive mixtures of Hydrogen gas are Battery electrolyte is poisonous and

present within battery cells at all times. Do dangerous. It contains sulfuric acid. Avoid
not work with or charge battery in an area contact with skin eyes or clothing. Wear
where open flames (including gas furnace rubber gloves and safety glasses while
or water heater pilots), sparks, cigarettes, servicing batteries. DO NOT INGEST! This
or any other sources of combustion are may result in severe bodily injury.
present. Always provide ample ventilation
in rooms where batteries are being charged.
Failure to do so may result in severe bodily
injury and/or property damage.
The key switch must be in the “OFF” position
when charging the batteries. Failure to turn
Signet Charger Operation, Model HB Series the key switch “OFF” may result in damage to
The Signet ® HB series chargers use a semi- the vehicles electrical system.
automatic charging system. The charger will turn itself
ON when the AC power
Signet Charger Operation, Model HBS series
cord is connected to the
AC power source and The Signet® HBS series chargers
turn itself OFF when the are fully automatic. The charger
batteries are fully will turn itself ON when the AC
charged. Refer to the power cord is connected to the
data plate on the AC power source and turn itself
Typical Signet® Built In OFF when the batteries are fully
charger for the voltage
charged. Once the charge cycle
and type power required for the charger. is complete, the charger will
There is a series of LED’s on the faceplate of the continue to monitor the batteries.
charger that serve two functions: If the battery voltage drops during
storage, the charger will start a
1. Status of charge. The LED’s will display an new cycle to keep the batteries Typical Signet® HBS
approximate percent of charge during the charging fully charged.
cycle. Refer to the table below. NOTE: If the charger restarts during a short time period of
2. Error condition. All three storage, then it would be an indication of faulty
LED’s flashing is an batteries.
indication of a charging Refer to the data plate on the charger for the voltage and type
problem (charger will also power required for the charger.
be beeping). Refer to the There is a series of LED’s on the faceplate of the charger that
Charger Troubleshooting serve two functions:
section for information on
1. Status of charge. The STATUS LED’s will display an
error codes. approximate percent of charge during the charging
cycle. Refer to the table below.
Charging State LED1 LED2 LED3 2. Error condition. The FAULT LED flashing is an indication
0 to 50% Blinking OFF OFF
of a charging problem (charger may also be beeping).
Refer to the Charger
50% to 75% ON Blinking OFF Troubleshooting
section for information
75% to 100% ON ON Blinking on error codes.

Cycle complete ON ON ON

Safety Rules
Page 11
 SAFETY RULES AND OPERATING INSTRUCTIONS

Lestronic II Charger Operation Charging Time

Average charging time is 8 to 10-hours. The time
The Lestronic II ® charger is a semi-automatic
required to fully charge your batteries will vary
charging system. The charger will turn itself ON when
depending on:
the AC power cord is connected to the AC power
source and turn itself OFF when the batteries are • Capacity of the batteries, higher capacity
fully charged. Refer to the data plate on the charger requires longer charge time.
for the voltage and type power required for the
charger. When plugged in, the charger assumes that • Output of the charger, higher output requires
the batteries require charging and will charger for a less charge time.
minimum of approximately 4-hours. This charger • Depth of discharge, the deeper a battery is
should not be plugged in until the batteries are discharged, the longer it takes to charge.
discharged beyond 50% or the batteries may be
overcharged.. • Temperature, low temperatures require longer
New Battery Break in charge time.

New batteries require a break in period of up to 40- It is not unusual for charge times to exceed 15-hours,
cycles. The batteries will not have their full capacity especially with new batteries.
during this break in period and may require longer Charging time is limited to 20-hours (HBS) or 18-
charging times. hours (HB). A fault will occur if the charging time
To obtain the maximum battery life: exceeds the 20-hour limit.

Charge the batteries only after they reach a normal

discharge as indicated on the Battery Status Indicator
(BSI). Failure to follow this guideline could result in
the batteries entering an overcharge state, which will
reduce the life of the batteries. If you find it necessary
to charge the batteries before they are completely
discharged we recommend waiting until they are
discharged a minimum of 25% to reduce the
possibility of overcharging. Refer to Vehicle Controls
in this section for information on how to read the BSI.
Do not discharge the batteries beyond a normal
discharge as indicated on the BSI. Refer to Vehicle
Controls in this section for information on how to read
the BSI.
Check the battery electrolyte once a week. Do not
charge the batteries if the battery electrolyte is low.
Charging when the electrolyte is low will damage the
batteries and shorten their life-span. Only authorized
personnel should perform battery maintenance
including maintaining the battery electrolyte level.
Refer to Section Maintenance, Service and
Repair for battery maintenance information.
Do not interrupt the charging cycle. When the charger
is plugged in, allow it to turn off before disconnecting.
Interrupting the charging cycle could lead to
overcharging or discharging the batteries too deep.
Both circumstances will shorten the life of the
batteries.

Safety Rules
Page 12
 SAFETY RULES AND OPERATING INSTRUCTIONS

STORING AND RETURNING TO SERVICE

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

Storing your Vehicle

• Clean the batteries, then fill and charge before putting the vehicle in storage. Do not store
batteries in a discharged condition.
• Lube all grease fittings.
• Clean, dry, and check all exposed electrical connections.
• Inflate tires to proper pressure (if applicable).
• For extended storage, the vehicle should be elevated so that the tires do not touch the ground.
If stored for a prolonged period, the batteries should be charged as follows:

Storage
Charging Interval
Temperature
(months)
(F)
Over 60 1

Between 40 and 60 2

Below 40 6

Returning To Service
• Check the battery’s state of charge and charge if required.
• Perform ALL maintenance checks in the periodic checklist.
• Remove any blocks from the vehicle and/or place the vehicle down on to the ground.
• Test drive before putting into normal service.

Safety Rules
Page 13
 SAFETY RULES AND OPERATING INSTRUCTIONS

PERIODIC MAINTENANCE CHECKLIST

Safety Rules NOTE: A full page copy of the Periodic Maintenance

Page 14 Checklist is on the Vehicle Documentation CD
under the [Misc] sub folder.
 SAFETY RULES AND OPERATING INSTRUCTIONS

Only properly trained and authorized technicians should perform

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

Daily Visual inspection:

Tire condition and pressure.
External frame damage (body).
Operation of all lights and warning alarms and/or horns.
Smooth and proper operation of all controls such as but not limited to:
• Accelerator pedal, Brake pedal, Steering, Parking brake, etc.
• Proper operation of all locking devises such as but not limited to:
• Tool box, Removable battery trays, Cargo box, Cab doors, etc.
• Proper operation of all interlocking switches such as but not limited to:
• Key switch, Seat interlock switch, Charger interlock switch, etc.
Inspect for leaking fluids or grease.

MAINTENANCE GUIDELINES FOR

SEVERE DUTY APPLICATIONS
1. This maintenance checklist is based on the average application. If the vehicle is operated under
“severe conditions”, service procedures should be conducted more frequently than specified. The
frequency of service under severe conditions is determined by the use of the vehicle. The owner/
operator must evaluate the operating environment to determine the increase in maintenance frequency.
In addition, the whole vehicle should be inspected monthly for signs of damage. The damage must be
repaired immediately.
The following list is meant as a guide and is not all-inclusive of a “severe duty” application.
• Extreme temperature.
• Bumpy, dusty, or ill maintained roads.
• Excessively wet areas.
• Corrosive or contaminated areas.
• Frequent loading of vehicle at/near capacity.
• Use on multiple shifts.
2. Any deficiencies found during an inspection should corrected before the vehicle is returned to service.
3. Battery water level should be inspected on a weekly schedule.

Safety Rules
Page 15
TAYLOR -DUNN
General Maintenance

TABLE OF CONTENTS

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

Maintenance Guidelines for
Vehicles Used in Severe Conditions ..... 3
Troubleshooting Guide ................................ 4
Lubrication Chart .......................................... 5
 Maintenance, Service and Repair

MAINTENANCE GUIDELINES

Periodic maintenance and service must be performed on this vehicle. Failure to

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

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
Before starting 4. Place blocks under the front wheels to prevent vehicle movement.
any repairs: 5. Disconnect the main positive and negative cables at the batteries.

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

• Avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle
performance checks in an authorized area where safe clearance exists.
• Before starting the vehicle, follow the recommended safety procedures in Section 2, “Safety
Rules and Operational Information.”
• Ventilate the work area properly.
• Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed
and directional control mechanisms, warning devices, lights, governors, guards, and safety
devices.
• Inspect and maintain battery limit switches, protective devices, electrical conductors, and
connections in conformance with Taylor-Dunn’s recommended procedures.
• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or
defective parts.
• Do not use an open flame to check level or leakage of battery electrolyte.
• Do not use open pans of fuel or flammable fluids for cleaning parts.
• Only properly trained and authorized technicians should perform maintenance or repairs to this
vehicle.

Maintenance Page 2
 Maintenance, Service and Repair

MAINTENANCE GUIDELINES FOR VEHICLES USED IN

SEVERE CONDITIONS
If this vehicle is operated in severe conditions all maintenance items listed in the Periodic Maintenance
Table should be carried out twice as often as stated. In addition, the entire vehicle should be inspected
monthly for signs of damage. If any damage is found, the vehicle should be immediately removed from
service and repaired.
The following list is meant as a guide and is not all inclusive:
SEVERE CONDITIONS refer to operation:
• In extreme temperatures
• On bumpy, dusty, or poorly maintained roads
• In excessively wet areas
• In corrosive or contaminated areas
• At or near maximum capacity for more than 50% of the operating time
• On multiple shifts

Maintenance Page 3
 Maintenance, Service and Repair

TROUBLESHOOTING GUIDE
Symptom Probable Cause
Front End Out of Alignment
Steering Pulls in One Direction
Low Tire Pressure

Dry Lube Points in Steering Linkage

Hard Steering Damaged King Pin/Ball Joint

Low Tire Pressure

Worn Ball Joints

Excessive Steering Play Mis-Adjusted or Worn Steering Gear

Loose Steering Linkage

Brakes or Parking Brakes Dragging

Worn Drive Gears

Lack of Power or Slow Operation
Front End Out of Alignment

Defective Speed Control

Worn Drive Gears or Bearings

Worn Front /Rear Axle Bearings

Abnormal Noise
Loose Lug Nuts

Motor Bearings Worn

Rear Wheel Bearing and/or Gasket Failed

Oil Leak in Rear Bearing Area
Drive Over Filled

Brake Pedal Soft or Spongy Air in Brake Lines

Brake Worn (1/16" Wear Limit)

Brake Pedal Low Brake Fluid Low

Brakes Out of Adjustment

Brake Worn (1/16" Wear Limit)

Brake Pads Contaminated with Fluid

Braking Power Low Brake Pedal Linkage Binding

Brakes Out of Adjustment

Air in Brake Lines

Maintenance Page 4
 Maintenance, Service and Repair

LUBRICATION CHART

1
1

2
5
5
2
3

6
6

# Description Locations Lubricant Type

1 Front Leaf Springs General Purpose Grease
2 King Pin General Purpose Grease
3 Ball Joints General Purpose Grease

5 Front Wheel Bearings High Temperature Wheel Bearing Grease

6 Rear Leaf Springs General Purpose Grease

9 Drive Fill Plug 11 oz. 30 wt Motor Oil

Maintenance Page 5
TAYLOR -DUNN
Front Axle Service

TABLE OF CONTENTS
Inspect the Front Wheel Bearings
and Kin Pin ............................................ 2
Adjust Front Wheel Bearings ...................... 3
Front Axle Removal and Installation ............ 4
Removal .................................................................... 4
Installation ................................................................. 5
Front Axle Disassembly and Assembly ....... 6
Replace Front Wheel Bearings ..................... 7
Replace the Ball Joints, Tie Rods,
and Drag Link ......................................... 8
Replacing the Drag Link ............................................ 10
Replacing the Tie Rod ............................................... 11
Replace the King Pins and Bushings .......... 12
Replace the Steering Knuckle ...................... 14
 Maintenance, Service, and Repair

INSPECT THE FRONT WHEEL BEARINGS AND KIN PIN

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Grab the top and bottom of the tire/wheel assembly.

Feel for any movement or play while pulling and
pushing on the top and bottom of the tire. Any
movement or play is indication of loose wheel
bearings or king pin.
NOTE: Refer to the Adjust Front Wheel
Bearings section for information
regarding the adjustment of the wheel
bearings.
NOTE: If the king pin is loose, then refer to
Replace the King Pins and
Bushings for information regarding
replacing the king pin bushings. There
are no adjustments for the king pin or
bushings.
8. Spin the wheel and listen for any grinding noise.
Any grinding noise may be an indication of worn or
damaged wheel bearings.
NOTE: Refer to the Replace Front Wheel Bearings section for
information regarding the replacement of the wheel bearings.
9. Lower the vehicle.
10. Reconnect the main positive and negative cables at the batteries.
11. Remove the blocks from behind the wheels.
12. Release the park brake and test drive the vehicle.

Front Axle Page 2

 Maintenance, Service, and Repair

ADJUST FRONT WHEEL BEARINGS

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the hub dust cap and cotter pin.

8. While rotating the hub, tighten the spindle nut to
30 ft-lbs. This seats the bearings.
9. Back off the spindle nut one flat until the hub turns,
but is not loose.
10. Spin the wheel and listen for any grinding noise.
Any grinding noise may be an indication of worn or
damaged wheel bearings.
NOTE: Refer to the Replace Front Wheel
Bearings section for information
regarding the replacement of the wheel
bearings.
Hub with Dust Cap Removed
11. Install a new cotter pin.
12. Install the dust cap.
13. Lower the vehicle.
14. Reconnect the main positive and negative cables at the batteries.
15. Remove the blocks from behind the wheels.
16. Release the park brake and test drive the vehicle.

Front Axle Page 3

 Maintenance, Service, and Repair

FRONT AXLE REMOVAL AND INSTALLATION

Removal

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove both front wheels. Refer to Tires and Wheels section for information regarding removing
the front wheels.
8. Tie up or support the front axle so it can not fall out of the vehicle.
9. Disconnect the drag link ball joint or rod end from the steering knuckle or the steering gear
pitman arm.
NOTE: Refer to the Replacing the Ball Joints section for information
regarding the removal of the ball joints or rod ends.
10. If equipped with front brakes, disconnect the
hydraulic brake lines from the brake bodies.
11. Disconnect the front axle beam from the front
springs and remove the axle from the vehicle.
NOTE: In some configurations the front
springs and or shocks will have to be
removed in order to remove the axle
beam. Refer to section Front
Suspension for information
regarding removing the springs and
shocks.

Front Axle Page 4

 Maintenance, Service, and Repair

Installation

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

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

NOTE: Use all new cotter pins.
NOTE: Refer to the Replacing the Ball Joints section for information
regarding the installation of the ball joints or rod ends.
NOTE: Refer to Tires and Wheels section for information regarding
removing the front wheels.
8. Realign the front wheels. Refer to Steering Component Service section for information
regarding realigning the front wheels.
9. If equipped with front brakes, bleed the brakes. Refer to Brake Service section for information
regarding bleeding the brakes.
10. Lower the vehicle.
11. Reconnect the main positive and negative cables at the batteries.
12. Remove the blocks from behind the wheels.
13. Release the park brake and test drive the vehicle.

Front Axle Page 5

 Maintenance, Service, and Repair

FRONT AXLE DISASSEMBLY AND ASSEMBLY

Disassembling and reassembling involves removing and replacing the left and right steering knuckles
and king pin bushings. Refer to the following sections for information regarding these procedures:
Replace the Steering Knuckle
Replace the King Pins and Bushings

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

King Pin
Upper Bushing

Lower Bushing

Yoke

Large Cup
Steel Washer

{
Cotter Pin
Bronze washer
Thrust Steel Washer
Washer Small Cup

King Pin Nut

Outer Bearing
Flat Washer
Castle Nut
Bearing Cap

Front Axle Page 6

 Maintenance, Service, and Repair

REPLACE FRONT WHEEL BEARINGS

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the tire/wheel assembly from the hub. Refer to Replace the Steering Knuckle for
information regarding removing the steering knuckle.
8. Remove the hub dust cap, cotter pin, and spindle nut.
9. Remove the hub from the steering knuckle.
NOTE: For a front disc brake option you must
remove the brake body before
removing the hub. Refer to the
Brakes section for information
regarding the removal of the brake
body.
NOTE: Catch the outer bearing as it falls out.
10. Thoroughly clean all grease from the inside of the
hub and the bearings.
11. Inspect and replace the races and bearings as a Hub with Dust Cap Removed
set.
NOTE: It is recommended to replace all four
bearings and races in the left and right
wheels as a set.
12. Assemble in reverse order, using new grease seals.
a. Pack inner and outer bearings with grease.
b. While rotating the hub, tighten the spindle nut to
30 ft-lbs. This seats the bearings.
c. Back off the spindle nut one flat until the hub
turns, but is not loose.
d. Install a new cotter pin. Hub with Dust Cap Removed

Front Axle Page 7

 Maintenance, Service, and Repair

13. Install the hub dust cap.

14. Reinstall the brake body and the tire/wheel assembly.
NOTE: Refer to the Brakes section for information regarding the
installation of the brake body.
15. Lower the vehicle.
16. Reconnect the main positive and negative cables at the batteries.
17. Remove the blocks from behind the wheels.
18. Release the park brake and test drive the vehicle.

REPLACE THE BALL JOINTS, TIE RODS, AND DRAG LINK

This section will refer to two different types of ball joints.
One type is has a grease fitting and a tapered shaft where it
is installed on the steering arm or pitman arm. The second
cannot be greased and has a straight shaft. See the Rod End
illustrations to the right. Depending on the configuration of
your vehicle, it may be equipped one or both types of ball
joints.
In this text:
The first type will be referred to as a “Ball Joint.” Ball Joint
The second type will be referred to as a “Rod End.”
NOTE: If a rod end or ball joint is worn out, we
recommend replacing all of the ball joints
and/or rod ends as a set.

Replacing a Rod End

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Front Axle Page 8

 Maintenance, Service, and Repair

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

sleeve. Rod End
8. Remove the rod end nut.
9. Remove the rod end from the steering arm.
HINT: Count the number of turns required to Steering
remove the rod end from the steering Sleeve
sleeve. This will make it easier to
realign the wheels. Jam Nut
10. Install the new rod end into the steering sleeve.
Rod End Nut
Screw it into the sleeve the same number of turns
counted in the previous step. Do not tighten the Steering Arm
rod end clamp or jam nut at this time.
11. Install the rod end into the steering arm. Tighten the rod end nut to 20-25 ft-lbs.
12. Realign the front wheels.
NOTE: Refer to the Steering section for information regarding realignment
of the front wheels.
13. Lower the vehicle.
14. Reconnect the main positive and negative cables at the batteries.
15. Remove the blocks from behind the wheels.
16. Release the park brake and test drive the vehicle.

Replacing a Ball Joint

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Front Axle Page 9

 Maintenance, Service, and Repair

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

Cotter Pin
8. Remove the cotter pin and ball joint nut.
Ball Joint Nut
9. Using a pickle fork, remove the ball joint from the
steering arm.
10. Remove the ball joint from the steering sleeve.
HINT: Count the number of turns required to
remove the ball joint from the sleeve.
This will make it easier to realign the Steering Arm
wheels.
11. Install the new ball joint into the steering sleeve.
Screw it into the sleeve the same number of turns Ball Joint
Clamp
counted in the previous step. Do not tighten the
ball joint clamp at this time. Steering Sleeve
12. Install the ball joint into the steering arm. Tighten
the ball joint nut to 40-45 ft-lbs. and install a new cotter pin.
13. Realign the front wheels.
NOTE: Refer to the Steering section for information regarding realignment
of the front wheels.
14. Lower the vehicle.
15. Reconnect the main positive and negative cables at the batteries.
16. Remove the blocks from behind the wheels.
17. Release the park brake and test drive the vehicle.

Replacing the Drag Link

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Front Axle Page 10

 Maintenance, Service, and Repair

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

Pitman Arm
knuckle and pitman arm.
NOTE: Refer to the Replacing the Ball
Joints section for information Drag Link
regarding the removal of the ball joints
or rod ends.
8. Remove the drag link as an assembly.
9. Install in reverse order.
10. Realign the front wheels.
NOTE: Refer to the Steering section for
information regarding realignment of Steering Knuckle
the front wheels.
Typical Drag Link
11. Lower the vehicle.
12. Reconnect the main positive and negative cables at the batteries.
13. Remove the blocks from behind the wheels.
14. Release the park brake and test drive the vehicle.

Replacing the Tie Rod

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Front Axle Page 11

 Maintenance, Service, and Repair

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

knuckles. Steering Knuckle
NOTE: Refer to the Replacing the Ball
Joints section for information
regarding the removal of the ball joints
or rod ends.
8. Remove the tie rod as an assembly.
9. Install in reverse order.
10. Realign the front wheels.
Tie Rod
NOTE: Refer to the Steering section for
information regarding realignment of
Typical Front Axle Assembly
the front wheels.
11. Lower the vehicle.
12. Reconnect the main positive and negative cables at the batteries.
13. Remove the blocks from behind the wheels.
14. Release the park brake and test drive the vehicle.

REPLACE THE KING PINS AND BUSHINGS

There are different types of king pin bushings depending on the configuration of your vehicle.
• Bronze bushings in the axle beam.
• Bronze bushings in the steering knuckle.
• Metal backed teflon bushings in the axle beam.

The bronze bushings must be reamed or broached to the proper

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

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

Front Axle Page 12

 Maintenance, Service, and Repair

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the steering knuckle. Refer to Replace the Steering Knuckle for information
regarding removing the steering knuckle.
NOTE: It is not necessary to remove the tie rod or drag link for this
procedure.
8. Press the king pin bushings out from the axle or steering knuckle.
9. Press new bushings into the axle or steering knuckle.
10. Ream or broach the bronze bushings to 0.878 ± 0.001 inches.

The bronze bushings must be reamed or broached to the proper

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

11. Inspect the king pin for damage or wear. If any damage or wear is noted then the king pin must
be replaced.
12. Reassemble in reverse order.
NOTE: Refer to Replace the Steering Knuckle for information on installing
the steering knuckle.
NOTE: It is recommended that the thrust washers or bearing be replaced
whenever replacing the king pin bushings. Refer to the
Replacement Parts section for the orientation of the bearing or
washers in your vehicle.
13. Grease the bushings (bronze only).

Front Axle Page 13

 Maintenance, Service, and Repair

14. Lower the vehicle.

15. Reconnect the main positive and negative cables at the batteries.
16. Remove the blocks from behind the wheels.
17. Release the park brake and test drive the vehicle.

REPLACE THE STEERING KNUCKLE

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information regarding
removing the tire/wheel assembly.
8. Remove the hub bearing cap, cotter pin and nut,
then remove the hub from the steering knuckle.
NOTE: For a front disc brake option you must
remove the brake body before
removing the hub. Refer to the
Brakes section for information
regarding the removal of the brake
body. Do not remove the hydraulic
brake line from the brake body. If the
brake line is removed then it will be
necessary to bleed the brakes.
NOTE: Catch the outer bearing as it falls out. Hub with Dust Cap Removed
9. Remove the drag link and/or tie rod from the steering knuckle. Refer to Replace the Ball
Joints, Tie Rods, Drag Link in this section for information regarding removal of the drag link or
tie rod.
10. While supporting the knuckle, remove the king pin and thrust bearing.
11. Remove the knuckle from the axle.
12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings.

Front Axle Page 14

 Maintenance, Service, and Repair

13. Assemble in reverse order.

14. Pack the thrust bearing with grease.
NOTE: Refer to the Replacement Parts section for the orientation of
the thrust bearing or washers in your vehicle.
15. Tighten the king pin nut until there is 0.1 to 0.123 inches clearance as shown in the illustration
below.
NOTE: Refer to Replace Front Wheel Bearings for information
regarding proper tightening of the spindle nut
16. Install new cotter pins.
17. Realign the wheels.
NOTE: Refer to the Steering section for information regarding realignment
of the front wheels.
18. Lower the vehicle.
19. Reconnect the main positive and negative cables at the batteries.
20. Remove the blocks from behind the wheels.
21. Release the park brake and test drive the vehicle.

.100
.123
Yoke clearance after tightening the king pin

Front Axle Page 15

TAYLOR -DUNN
Steering Component Service

TABLE OF CONTENTS

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

Adjust the Steering gear (Saginaw) ............. 5
Replace the Steering Shaft
(Saginaw, non-tilt steering) .................... 7
Replace the Steering Wheel
(Saginaw, non-tilt steering) .................... 9
Replace the Steering Gear (Saginaw) .......... 10
Repair the Steering Gear .............................. 11
Exploded View of Steering Gear .............................. 14
 Maintenance, Service, and Repair

FRONT END ALIGNMENT

This section will refer to two different types of ball joints.
One type is has a grease fitting and a tapered shaft where
it is fitted to the steering arm or pitman arm. The second
type cannot be greased and has a straight shaft. See the
illustrations to the right. Depending on the configuration of
your truck, it may be equipped with one or both types of Ball Joint
ball joints.
In this text:
The first type has a grease fitting and will be referred to as
a “Ball Joint.”
The second type has no grease fitting and will be referred
to as a “Rod End.” Rod End

Center the Steering

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Turn the front wheels so that they are in the straight ahead position and then tie off the wheels
so that they cannot turn from the straight ahead position.
8. Disconnect the drag link from the pitman arm.
NOTE: Refer to Replace the Ball Joints section for information
regarding removing the ball joint or rod end from the drag link.
9. Center the steering gear and tie off the steering wheel so that it cannot rotate.
NOTE: Refer to Adjust the Steering Gear section for information
regarding centering of the steering gear.

Steering Page 2
 Maintenance, Service, and Repair

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

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

11. Loosen the ball joint clamps or the rod end jam
nuts on the drag link.
NOTE: Remember the position and orientation
of the clamps.
12. Adjust the drag link so that it can be easily inserted
into the pitman arm.
13. Tighten the ball joint or rod end nut as specified
below:
Ball joint - 40-45 ft-lbs.
Rod end - 20-25 ft-lbs.
14. If equipped with ball joints, position the ball joint
clamps in their original location and orientation.
15. Tighten the ball joint clamps or the rod end jam nuts on the drag link.
16. Untie the steering wheel and the front wheels.
17. Reconnect the main positive and negative cables at the batteries.
18. Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint
clamps do not contact any other component.

If the clamps are positioned so that they contact other components,

it may result in steering failure and loss of control of the vehicle
causing property damage and/or severe bodily injury.

19. Remove the blocks from behind the wheels.

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

Steering Page 3
 Maintenance, Service, and Repair

Front wheel alignment

NOTE: It is recommended to center the steering before aligning the front
wheels. Refer to the Center the Steering section for information.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

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

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

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

of both front tires.
HINT: Hold the chalk on the center of the tire
and rotate the tire to mark the line.
9. Loosen the ball joint clamps or the rod end jam
nuts on the tie rod.
NOTE: Remember the position and orientation
of the ball joint clamps.
10. Lower the front wheels to the ground and push the
vehicle back and forth a few feet to settle the
suspension.

Steering Page 4
 Maintenance, Service, and Repair

11. Measure the distance between the lines at the front

Front Measurement
of the tires.
12. Measure the distance between the lines at the rear
of the tires.
13. Adjust the tie rod so that the distance at the front Sleeve Clamps
and rear of the tires is the same.
14. If equipped with ball joints, position the ball joint Tie Rod
clamps in their original location and orientation.
15. Tighten the ball joint clamps or the rod end jam Rear Measurement
nuts.
16. Untie the steering wheel.

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

17. Reconnect the main positive and negative cables at the batteries.
18. Remove the blocks from behind the wheels.
19. Release the parking brake and test drive the vehicle.

ADJUST THE STEERING GEAR

NOTE: In some vehicle configurations it may be necessary to remove the
steering gear to perform this procedure. Refer to Replace the
Steering Gear for information regarding removing the steering
gear.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Steering Page 5
Maintenance, Service, and Repair

7. Disconnect the drag link from the pitman arm.

NOTE: Refer to Replace the Ball Joints section for information regarding
removing the ball joint from the drag link.
8. Loosen the gear lash jam nut and the worm bearing
adjuster jam nut.
9. Unscrew the gear lash adjuster all of the way to the
stop.
10. Loosen the worm bearing adjuster and then tighten
just enough to remove all end play from the input
shaft and then an additional 1/8 turn more.
11. While holding the worm bearing adjuster so that it
cannot turn, tighten the worm bearing adjuster jam
nut.
12. Find the center position of the steering shaft:
A. Turn the steering shaft all of the way in one direction.
B. While counting the rotations, turn the steering shaft all of the way in the opposite direction.
C. Turn the steering shaft 1/2 the number of turns in the original direction.
13. While rotating the input shaft back and forth through its centered position, adjust the gear lash
adjusting screw so that there is a slight drag as the steering gear is rotated through its centered
position.
14. While holding the gear lash adjusting screw so that it cannot turn, tighten the gear lash adjusting
screw jam nut.
15. Reconnect the main positive and negative cables at the batteries.
16. Remove the blocks from behind the wheels.
17. Release the parking brake and test drive the vehicle.

Steering Page 6
 Maintenance, Service, and Repair

REPLACE THE STEERING SHAFT

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. If equipped with a horn switch in the steering wheel, remove the switch, disconnect the wires
from the switch and cut the terminals off of the wires.
7. Remove the steering wheel.
NOTE: Refer to Replace the Steering Wheel
section for information regarding
removing the steering wheel.

8. Remove the upper steering shaft bushing or bearing

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

10. Remove and discard the pinch bolt and nut from
the steering shaft coupler.
NOTE Most vehicle configurations will now allow
the steering shaft to slide off of the steering
gear input shaft and then back down out
of the steering column. If there is not
enough clearance for this procedure then
the steering gear must be removed. Refer
to Replace the Steering Gear for
information regarding removing the
steering gear.

Steering Page 7
Maintenance, Service, and Repair

11. Remove the steering shaft from the vehicle.

12. Lightly grease the input shaft splines, steering wheel
splines and the upper steering shaft bushing.
13. Install the steering shaft in reverse order using a
new pinch bolt. Orientate the shaft so that the pinch
bolt is opposite the flat in the steering gear shaft.
See the illustration to the right.

Make sure that the pinch bolt

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

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

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

15. Reconnect the main positive and negative cables at the batteries.
16. Remove the blocks from behind the wheels.
17. Release the parking brake and test drive the vehicle.

Steering Page 8
 Maintenance, Service, and Repair

REPLACE THE STEERING WHEEL

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires
from the switch.
7. Remove the steering wheel nut.
8. Using a steering wheel puller, remove the steering
wheel.
9. Position the front wheels in the straight ahead
position.
10. Lightly grease the steering wheel splines and install
the replacement steering wheel orientated as shown
in the illustration to the right.

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

12. Reinstall the horn switch (if equipped).
13. Reconnect the main positive and negative cables
at the batteries.
14. Remove the blocks from behind the wheels.
15. Release the parking brake and test drive the vehicle.

Steering Page 9
 Maintenance, Service, and Repair

REPLACE THE STEERING GEAR

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the steering wheel.

NOTE: Refer to Replace the Steering Wheel section for information
regarding removing the steering wheel.
7. Remove the steering shaft.
NOTE: Refer to Replace the Steering Shaft section for information
regarding removing the steering shaft.
8. Remove the pitman arm using a pickle fork.
NOTE: On some vehicle configurations it may
be required to remove the drag link
from the pitman arm. Refer to
Replace the Ball Joints section for
information regarding removing the
ball joint from the pitman arm.
9. Support the steering gear so that it cannot fall out
of the vehicle.

Failure to support the

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

Steering Gear with Pitman Arm

10. Remove the bolts holding the steering gear to the vehicle frame and remove the steering gear
from the vehicle.
11. Install in reverse order. Torque the pitman arm nut to75-100 ft-lbs.
12. Reconnect the main positive and negative cables at the batteries.
13. Remove the blocks from behind the wheels.
14. Release the parking brake and test drive the vehicle.

Steering Page 10
 Maintenance, Service, and Repair

REPAIR THE STEERING GEAR

Disassembly
NOTE: The steering gear must be removed from the vehicle for this
procedure. Refer to Replace the Steering Gear section for
information regarding removing the steering gear.
NOTE: The steering gear is packed with grease. Only perform maintenance
on the steering gear in an area that will contain any grease that
may spill out of the steering gear when it is disassembled.
Refer to the illustration at the end of this section for a blown up view of the steering gear assembly.
1. Center the steering gear.
A. Turn the steering shaft all of the way in one direction.
B. While counting the rotation, turn the steering shaft all of the way in the opposite direction.
C. Turn the steering shaft 1/2 the number of turns in the original direction.
2. Remove the worm bearing adjuster locking ring and
the worm bearing adjuster.

3. Remove the side cover/pitman shaft assembly by

removing the three side cover bolts and then pulling
the assembly out of the housing.
NOTE: The side cover/pitman shaft assembly
normally does not have to be
disassembled.

Steering Page 11
 Maintenance, Service, and Repair

4. Remove the worm shaft and ball nut assembly from

the bottom of the housing.
5. Remove the worm shaft seal.
6. Remove the pitman shaft seal.
7. Remove the upper worm bearing and bearing cup
from the housing.

8. The ball nut assembly consists of two sets of ball

bearings that recirculate in two channels in the ball
nut housing. The bearings may fall out once the
bearing guides are removed. Be careful not to lose
any of the bearings.
9. Remove the ball guide clamps, ball guides and all
of the ball bearings.
10. Remove the ball nut from the worm shaft.
11. Thoroughly clean and inspect all parts for signs of
corrosion, damage or wear and replace as required.

Reassembly
1. Lightly lubricate all parts before reassembly.
2. Install a new worm shaft seal and pitman shaft seal into the housing.
3. Install the upper worm bearing cup.
4. Divide the ball bearing into two equal groups.
5. Position the ball nut onto the worm as shaft as
shown in the illustration.
6. Insert the ball guides into the ball nut.
7. Insert each group of bearings into the ball guides.
NOTE: Do not rotate the worm shaft while
installing the bearings. This may cause
one or more of the bearings to enter
the crossover passage in the ball nut,
causing improper operation.
8. Install the ball guide clamp.

Steering Page 12
 Maintenance, Service, and Repair

9. Place the upper worm bearing on the worm shaft

and install the worm shaft/ball nut assembly into
the housing being careful not to damage the worm
shaft seal.

10. Install the assembled worm bearing adjuster into

the housing and tighten just enough to remove all
play in the worm shaft.
11. Install, but do not tighten the worm bearing adjuster
lock nut.
12. Rotate the worm shaft to center the ball nut in the
housing.
13. Place a new gasket onto the housing and install
the assembled pitman shaft/side cover onto the
housing using two of the three mounting bolts.
14. Pack the steering gear with grease through the open
side cover bolt hole and then install the bolt.
15. Adjust the steering gear.
NOTE: Refer to Adjust the Steering gear
section for information regarding
adjusting the steering gear.
16. Once the adjustments are completed, make sure that the locking ring and jam nut are tight.

Steering Page 13
 Maintenance, Service, and Repair

Exploded View of Steering Gear

Steering Page 14
 Brake Service
TABLE OF CONTENTS

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

Front Disc Brake Pads .......................................... 2
Front Disc Brake Rotor ........................................ 2
Rear Brake Shoes ................................................. 2
Rear Brake Drum ................................................. 3
Inspect the Parking brake .................. 3
Adjust the Service Brakes ................. 4
Mechanical and Hydraulic Drum Brakes ............ 4
Adjust the Mechanical Brake Linkages ............... 5
Adjust the Parking Brake ................... 6
Wheel Park Brake (mechanical drum standard) .. 6
Wheel Park Brake (hydraulic drum) .................... 6
Check Master Cylinder Fluid ............. 7
Bleed the Brake System .................... 8
Flush the Brake System .................... 9
Replace Front Disc Brake Pads ......... 10
Replace Rear Brake Shoes ............... 11
Replace the Front Cylinder ................ 12
Repair the Brake Body ...................... 13
Replace the Master Cylinder ............. 15
Repair the Master Cylinder ................ 16
 Maintenance, Service, and Repair

INSPECT THE SERVICE BRAKE

NOTE: Front brakes are optional
Front Disc Brake Pads

Current Taylor-Dunn® brakes are asbestos

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

NOTE: The brake pad must be removed to accurately

measure the lining thickness. Refer to Measuring pad thickness
Replace the Front Pads section for
information on removing the brake pads. Rear Brake Shoes
Measure the brake pad lining at the thinnest point on the
pad. If the brake pad lining is 1/16-inch or less then the
brake pad must be replaced.
Current Taylor-Dunn® brakes are asbestos
It is recommended to replace the left and right side brake
free. However, there is the possibility that
pads as a set.
the original brakes were replaced with
aftermarket parts containing asbestos.
Front Disc Brake Rotor Since this possibility exists, all brake parts
should be handled as if they contain
asbestos. Refer to Appendix C for
recommended handling precautions.
Do not use a rotor that is worn beyond its
service limits. A rotor worn beyond its NOTE: The wheel must be removed to accurately
service limits could fail and cause loss of measure the brake shoes. Refer to Tires and
brakes resulting in severe bodily injury Wheels section for information on removing
and/or property damage. the wheel.
Measure the brake shoe lining at the thinnest point on
NOTE: The front brake rotor is an integral part of the the shoe. If this is 1/16-inch or less then the brake shoe
front hub. If the brake rotor is worn beyond must be replaced.
its service limits, then the front hub must be NOTE: If this is a riveted lining, then the measurement
replaced. Refer to Front Axle Service for must be to the top of the rivets.
information on replacing the front hub.
It is recommended to replace the left and right side brake
NOTE: The wheel must be removed to accurately shoes as a set.
measure the rotor thickness. Refer to Tires
and Wheels section for information on
removing the wheel.
1. Measure the run out of the rotor at its maximum
diameter. If the run out exceeds 0.005, then the
rotor must be machined. Do not machine the rotor
beyond its service limits.
2. Measure the thickness of the brake rotor in 3
places. If the brake rotor thickness is less than
0.20-inches, then the rotor must be replaced. Measuring lining thickness

Brakes
Page 2
 Maintenance, Service, and Repair
Rear Brake Drum
INSPECT THE PARKING
BRAKE
Current Taylor-Dunn® brakes are asbestos
free. However, there is the possibility that
the original brakes were replaced with
aftermarket parts containing asbestos. 1. Make sure the key-switch is in the “OFF”
Since this possibility exists, all brake parts position, then remove the key.
should be handled as if they contain
2. Place the forward-reverse switch in the
asbestos. Refer to Appendix C for
center “OFF” position.
recommended handling precautions.
3. Confirm the electric park brake is set.

NOTE: The wheel must be removed to accurately 4. Place blocks under the front wheels to
measure the brake drum. Refer to Tires and prevent vehicle movement.
Wheels section for information on removing 5. Disconnect the main positive and
the wheel. negative cables at the batteries.
The service limit for the inside diameter of the brake
drum is 7.060 inches. 6. Release the park brake.
If the brake drum is grooved or worn beyond the service
7. Inspect the brake shoes. The parking brake shoes
limit then the brake drum must be replaced.
are the same as the service brake shoes. Refer to
Measure the inside diameter of the brake drum in 3- Inspect the Service Brake section to inspect the
places. brake shoes.
If the difference between any of the measurements 8. Inspect all brake cables and linkages for any signs
exceeds 0.010-inches then the brake drum must be of damage or missing cotter pins.
replaced.
9. Inspect the park brake ratchet for any signs of
damage or wear.
10. Set the park brake.
Do not use a brake drum that is worn
11. Reconnect the main positive and negative cables
beyond its service limits. A drum worn
at the batteries.
beyond its service limits could fail and
cause loss of brakes resulting in severe 12. Remove the blocks from the wheels
bodily injury and/or property damage.

Brakes
Page 3
 Maintenance, Service, and Repair

ADJUST THE SERVICE BRAKES

Mechanical and Hydraulic Drum Brakes
The mechanical and hydraulic brake assemblies are identical except for hydraulic fittings. The adjustment
procedure is the same for both the mechanical and hydraulic brakes.
NOTE: The brake adjustment is inside of the left and right brake. Do not adjust the brake by means of the
brake cables as this will cause mis-operation of the brakes. If you hear a single “clunking” noise
while braking it may be due to mis-adjustment of the brake cables or linkage. Refer to Replace
Brake Linkages/Cables for information regarding proper adjustment of the cables and linkages.

Adjusting the brakes by means of the brake cables could cause a

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

11. Back off the star wheel just enough so that the
brake drum rotates freely.
1. Make sure the key-switch is in the “OFF” 12. Install the tire/wheel assembly.
position, then remove the key. 13. Repeat this procedure for the opposite side brake.
2. Place the forward-reverse switch in the 14. Set the park brake.
center “OFF” position.
15. Reconnect the main positive and negative cables
3. Confirm the electric park brake is set. at the batteries.
4. Place blocks under the front wheels to 16. Remove blocks from behind the wheels.
prevent vehicle movement. 17. Release the park brake and test drive the vehicle.
5. Disconnect the main positive and
negative cables at the batteries.

Always use a lifting strap, hoist, and jack

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

6. Raise the wheel off of the ground and support with

jack stands.
7. Release the park brake.
8. Remove the tire/wheel assembly. Brake drum shown with the access slot
NOTE: Refer to Tires and Wheels section for aligned with the adjusting star wheel .
information on removing the wheel.
9. Align the adjusting access slot in the brake drum
with the adjusting star wheel at the bottom of the
brake.
10. While rotating the brake drum back and forth,
rotate the brake adjuster star wheel until the brake
is tight enough so that brake drum cannot be
rotated.

Brakes
Page 4
 Maintenance, Service, and Repair
Adjust the Mechanical Brake Linkages

Adjusting the brakes by means of the brake cables could cause a

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

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

1. Make sure the key-switch is in the “OFF”

position, then remove the key.
2. Place the forward-reverse switch in the
center “OFF” position.
3. Confirm the electric park brake is set.
4. Place blocks under the front wheels to
prevent vehicle movement.
5. Disconnect the main positive and
negative cables at the batteries.

6. Release the park brake.

7. Loosen the clevis jam nuts on the main brake cable
and connecting rod (refer to illustration on previous
page.
8. Loosen the brake cable and connecting rod.
9. Adjust the park brake linkage so that the angle
between the connecting rod and the cross shaft
tab is at 60 degrees.
10. Tighten the brake cable so that all slack is removed
Brake linkage with protractor in place
from the cable, but not so much so that the cross
at 60 degrees
shaft rotates.
11. Tighten the connecting rod so that all slack is
removed from the brake cables, but not so much
as to actuate the brakes.
12. Tighten the jam nuts on the brake cable,
connecting rod, and park brake linkage.
13. Set the park brake.
14. Reconnect the main positive and negative cables
at the batteries.
15. Remove blocks from behind the wheels.
16. Release the park brake and test drive the vehicle.

Brakes
Page 5
 Maintenance, Service, and Repair

ADJUST THE PARKING BRAKE

Wheel Park Brake (mechanical drum standard)
Trucks equipped with mechanical drum brakes do not have a separate adjustment for the parking brake. If the
parking brake requires adjustment, then the entire brake system is in need of adjustment. Refer to Adjust the
Service Brake section for information regarding adjusting the brakes.

Wheel Park Brake (hydraulic drum)

NOTE: Hydraulic brakes are optional. The service
brake must be properly adjusted before
attempting to adjust the parking brake. Refer
to Adjust the Service Brakes for
information regarding adjusting the service
brakes.

1. Make sure the key-switch is in the “OFF”

position, then remove the key.
2. Place the forward-reverse switch in the
center “OFF” position.
3. Confirm the electric park brake is set.
4. Place blocks under the front wheels to
prevent vehicle movement.
5. Disconnect the main positive and
negative cables at the batteries.

6. Release the park brake.

7. Loosen the clevis jam nuts on the connecting rod
(refer to illustration on next page).
8. Loosen the connecting rod.
9. Adjust the park brake linkage so that the angle
between the connecting rod and the cross shaft
tab is at 60 degrees.
10. Tighten the connecting rod so that all slack is
removed from the brake cables, but not so much
as to actuate the brakes.
11. Tighten the jam nuts on the connecting rod and
park brake linkage. Brake linkage with protractor in place
12. Set the park brake. at 60 degrees
13. Reconnect the main positive and negative cables
at the batteries.
14. Remove blocks from behind the wheels.
15. Release the park brake and test drive the vehicle.

Brakes
Page 6
 Maintenance, Service, and Repair

CHECK MASTER CYLINDER FLUID

Do not ingest brake fluid or allow contact with skin or eyes. Always wear
protective clothing and a face shield when working with or around brake
fluid.
SKIN CONTACT
Flush area immediately with water for several minutes. If a rash or skin
irritation develops, get medical attention immediately.
EYE CONTACT
Immediately flush the eye with water for 15 minutes and call physician.
INGESTION
Get medical attention immediately.

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

• DOT 3 brake fluid is corrosive and will damage paint finishes.
• Dispose of brake fluid in accordance with local state and federal
regulations.
• Read and follow all warnings on the brake fluid container.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

7. Remove the master cylinder cap.
8. If the fluid in the master cylinder is contaminated then the entire brake system must be flushed. Refer to
Bleed the Brakes for information regarding flushing the brake system.
9. Fill with brake fluid from a new sealed container to within 1/4-inch of the top of the master cylinder chamber
and reinstall the cap.
10. Reconnect the main positive and negative cables at the batteries.
11. Remove blocks from behind the wheels.
12. Release the parking brake and test drive the vehicle.

Brakes
Page 7
 Maintenance, Service, and Repair

BLEED THE BRAKE SYSTEM

Do not ingest brake fluid or allow contact

with skin or eyes. Always wear protective
• Only use DOT 3 brake fluid from a new
clothing and a face shield when working sealed container.
with or around brake fluid. • DOT 3 brake fluid is corrosive and will
SKIN CONTACT damage paint finishes.

Flush area immediately with water for • Dispose of brake fluid in accordance with
several minutes. If a rash or skin irritation local state and federal regulations.
develops, get medical attention
immediately. • Read and follow all warnings on the
brake fluid container.
EYE CONTACT
Immediately flush the eye with water for
15 minutes and call physician.
INGESTION
Get medical attention immediately.

NOTE: Hydraulic brakes are optional. Start this NOTE: Check and fill the master cylinder frequently
procedure at the wheel furthest from the during the bleeding process. Do not allow the
master cylinder, then work toward the wheel fluid level in the master cylinder to drop low
closest to the master cylinder. enough to allow air to enter the brake lines.
6. Thoroughly clean the area around the master If air enters the brake lines during the bleeding
cylinder cap and remove the cap. process, then you will have to start again from
the beginning.
7. Add brake fluid from a new sealed container to
the master cylinder. Fill to 1/4” from the top of the 14. Repeat the above steps until you are sure that all
master cylinder chamber. of the air is expelled from the brake line. Any air
bubbles that can be seen in the clear hose attached
8. The master cylinder fluid level will drop as the to the bleeder is an indication that there is still air
brakes are bled. Periodically check and fill the in the brake lines.
master cylinder during this procedure. Do not allow
the fluid level in the master cylinder to drop too 15. Repeat this process with each of the other wheels.
low as this will allow air into the brake lines. NOTE: When finished, top off the master cylinder
9. Attach a clear hose to the bleeder valve on the with fluid. See Check Master Cylinder
brake cylinder that is to be bled. Route the hose Fluid for information on filling the master
into a clear container for waste brake fluid. cylinder.
10. Pump the brake pedal a few times and then press 16. Reconnect the main positive and negative cables
and hold light pressure to the brake pedal. at the batteries.

11. Open the bleeder valve on the hydraulic brake 17. Remove the blocks from behind the wheels.
body. 18. Release the park brake and test drive the vehicle.
12. Depress the foot pedal to the floor and then close
the bleeder valve. Do not release pressure on the
brake pedal until the bleeder valve is closed.
13. Slowly release the foot pedal, allowing it to return Typical bleeder
to its released position. valve

Brakes
Page 8
 Maintenance, Service, and Repair

FLUSH THE BRAKE SYSTEM

Do not ingest brake fluid or allow contact • Only use DOT 3 brake fluid from a new
with skin or eyes. Always wear protective sealed container.
clothing and a face shield when working
with or around brake fluid. • DOT 3 brake fluid is corrosive and will
damage paint finishes.
SKIN CONTACT
Flush area immediately with water for
• Dispose of brake fluid in accordance with
several minutes. If a rash or skin irritation local state and federal regulations.
develops, get medical attention • Read and follow all warnings on the
immediately. brake fluid container.
EYE CONTACT
Immediately flush the eye with water for 9. Remove both rear wheels and, if equipped with
15 minutes and call physician. front brakes, the front wheels. Refer to Tires and
INGESTION Wheels section for information regarding
removing the wheels.
Get medical attention immediately.
10. Remove the wheel cylinders from each axle. Refer
to Replace the Wheel Cylinder section for
information regarding removing the wheel cylinder.

1. Make sure the key-switch is in the “OFF” 11. Attach a clear hose to the bleeder valve on each
position, then remove the key. of the wheel cylinders and route the hoses into a
container for waste brake fluid.
2. Place the forward-reverse switch in the
12. Position the wheel cylinders so that the bleeder
center “OFF” position.
screw is pointing to the ground and open all bleeder
3. Confirm the electric park brake is set. screws.
4. Place blocks under the front wheels to 13. Pump the master cylinder until all fluid has been
prevent vehicle movement. pumped from the brake lines and all wheel
cylinders.
5. Disconnect the main positive and
negative cables at the batteries. 14. Close all bleeder screws.
15. Fill the master cylinder with fluid.
16. Open one of the bleeder screws and pump the
master cylinder until all fluid has been pumped
Always use a lifting strap, hoist, and jack from the master cylinder and close the bleeder
stands, of adequate capacity to lift and screw.
support the vehicle. Failure to use lifting 17. Repeat the above two steps for each wheel
and support devices of rated load capacity cylinder.
may result in severe bodily injury.
18. Reinstall the wheel cylinders and bleed the brakes.
Refer to Bleed the Brakes for information
NOTE: Hydraulic brakes are optional. regarding bleeding the brakes.
6. Raise the rear wheels off of the ground and support 19. Set the park brake.
with jack stands.
20. Install the wheels and lower the vehicle to the
7. If equipped with front brakes, raise the front wheels ground.
off of the ground and support with jack stands.
21. Reconnect the main positive and negative cables
8. Release the park brake. at the batteries.
22. Release the park brake and test drive the vehicle.

Brakes
Page 9
 Maintenance, Service, and Repair

REPLACE FRONT DISC BRAKE PADS

Current Taylor-Dunn® brakes are asbestos

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

NOTE: Front brakes are optional. It is recommended NOTE: Refer to the illustration above for the following
that both the left and right brake pads be steps.
replaced as a set.
10. Remove the brake body bolts (10) and discard the
NOTE: Installing new brake pads will raise the brake lock nuts (1) and brake pads (8).
fluid level in the master cylinder.
11. Remove the spacer bushings (6) from the
mounting bracket (5) and discard the bushings.
12. Inspect the brake rotor. See Inspect the Service
1. Make sure the key-switch is in the “OFF” Brakes section for information regarding
position, then remove the key. inspecting the brake rotor.
2. Place the forward-reverse switch in the 13. Inspect the spacers (7) and replace if any wear or
center “OFF” position. damage is found.
3. Confirm the electric park brake is set. 14. Install new spacer bushings in the mounting
4. Place blocks under the front wheels to bracket.
prevent vehicle movement. 15. Install new brake pads in reverse order. Torque
the mounting bolts to 11 ft-lbs.
5. Disconnect the main positive and
negative cables at the batteries. 16. Repeat this procedure for the other wheel.
17. Install the tire/wheel assembly and lower the
vehicle to the ground.
18. Fill the master cylinder to the proper level. Refer
Always use a lifting strap, hoist, and jack to Check Master Cylinder Fluid section for
stands, of adequate capacity to lift and information on the proper master cylinder fluid
support the vehicle. Failure to use lifting level.
and support devices of rated load capacity 19. Reconnect the main positive and negative cables
may result in severe bodily injury. at the batteries.
20. Remove the blocks from behind the wheels.
6. Thoroughly clean the area around the master
21. Release the park brake and test drive the vehicle.
cylinder cap.
7. Remove fluid from the master cylinder until it is 1/
2 full.
8. Raise the front of the vehicle and support with
jack stands.
9. Remove the tire/wheel assembly. Refer to Tires
and Wheels section for information on removing
the tire and wheel assembly.

Brakes
Page 10
 Maintenance, Service, and Repair

REPLACE REAR BRAKE SHOES

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

1. Make sure the key-switch is in the “OFF” Do not allow grease to contact any of the
position, then remove the key. braking surfaces. Braking surfaces
contaminated with grease may cause the
2. Place the forward-reverse switch in the
brakes to fail resulting in property damage
center “OFF” position.
and/or severe bodily injury.
3. Confirm the electric park brake is set.
4. Place blocks under the front wheels to
14. Apply a very light coating of high temperature
prevent vehicle movement.
grease to the adjustor screw threads.
5. Disconnect the main positive and
15. Install in reverse order.
negative cables at the batteries.
16. Repeat for the opposite side.
17. Adjust the brakes. See Adjust the Service
Brakes section for information regarding
Always use a lifting strap, hoist, and jack adjusting the brakes.
stands, of adequate capacity to lift and 18. Set the park brake.
support the vehicle. Failure to use lifting
19. Reconnect the main positive and negative at the
and support devices of rated load capacity
batteries.
may result in severe bodily injury.
20. Lower the wheels to the ground.
21. Remove the blocks from behind the wheels.
NOTE: It is recommended that both the left and right
brake pads be replaced as a set. 22. Release the park brake and test drive the vehicle.
6. Release the park brake.
7. Raise the rear wheels off of the ground and support
with jack stands.
8. Remove the tire/wheel assembly. Refer to Tires
and Wheels section for information on removing
the wheel. Brake Adjuster Assembly
9. Remove and inspect the brake drum. Refer to
Inspect the Service Brake section for
information regarding inspecting the brake drum.
10. Remove the retracting springs and torsion springs
from the brake shoes.
11. Remove the hair pin clips from the actuating arms
and discard.
12. Remove the brake shoes and brake adjustor
assembly from the backing plate.
13. Thoroughly clean and inspect the adjustor
assembly. Replace parts as required.

Brakes
Page 11
 Maintenance, Service, and Repair

REPLACE THE FRONT CYLINDER

Do not ingest brake fluid or allow contact with skin or eyes. Always wear protective clothing
and a face shield when working with or around brake fluid.
SKIN CONTACT
Flush area immediately with water for several minutes. If a rash or skin irritation develops, get
medical attention immediately.
EYE CONTACT
Immediately flush the eye with water for 15 minutes and call physician.
INGESTION
Get medical attention immediately.

1. Make sure the key-switch is in the “OFF” Current Taylor-Dunn® brakes are asbestos
position, then remove the key. free. However, there is the possibility that
the original brakes were replaced with
2. Place the forward-reverse switch in the
aftermarket parts containing asbestos.
center “OFF” position.
Since this possibility exists, all brake parts
3. Confirm the electric park brake is set. should be handled as if they contain
asbestos. Refer to Appendix C for
4. Place blocks under the front wheels to
recommended handling precautions.
prevent vehicle movement.
5. Disconnect the main positive and
12. Disconnect the brake hose from the brake body.
negative cables at the batteries.
13. Install the new brake body assembly in reverse
order.
• Use teflon tape thread sealant on the brake hose
Always use a lifting strap, hoist, and jack fitting.
stands, of adequate capacity to lift and • Torque the brake body bolts to 11 ft-lbs.
support the vehicle. Failure to use lifting 14. Bleed the brakes. Refer to Bleed the Brakes
and support devices of rated load capacity section for information regarding bleeding the
may result in severe bodily injury. brakes.
15. Set the park brake.
NOTE: Front brakes are optional.
6. Release the park brake. 16. Reconnect the main positive and negative cables
at the batteries.
7. Raise the wheel off of the ground and support with
jack stands. 17. Lower the wheel to the ground.
18. Remove the blocks from behind the wheels.
8. Remove the tire/wheel assembly. Refer to Tires
and Wheels section for information on removing 19. Release the park brake and test drive the vehicle.
the tire and wheel assembly.
9. Thoroughly clean the area around the brake body.
10. Remove the brake body bolts and discard the lock
nuts.
11. Inspect the brake rotor. Refer to Inspect the
Service Brake section for information regarding
inspecting the brake rotor.
Brakes
Page 12
 Maintenance, Service, and Repair

REPAIR THE BRAKE BODY

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

Do not ingest brake fluid or allow contact with skin or eyes. Always wear
protective clothing and a face shield when working with or around brake
fluid.
SKIN CONTACT
Flush area immediately with water for several minutes. If a rash or skin
irritation develops, get medical attention immediately.
EYE CONTACT
Immediately flush the eye with water for 15 minutes and call physician.
INGESTION
Get medical attention immediately.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the brake body from the vehicle.

NOTE: Refer to Replace the Brake Body
Assembly (front or rear) section for
information on removing the brake body. The pistons are very fragile. If the piston is
7. Pull the pistons out of the brake body. damaged it must be replaced. Failure to
replace a damaged piston could lead to
8. Remove the piston rubber boot.
brake failure and result in property damage
9. Remove the piston o-ring from inside of the brake and/or severe bodily injury.
body.
10. Inspect and replace parts as required.

Brakes
Page 13
 Maintenance, Service, and Repair

11. Lubricate the brake parts with clean brake fluid

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

13. Using tool #41-350-13, slide the rubber boots onto

the pistons as shown. The boot should be hanging
off of the end of the piston.

14. Insert the rubber boot/piston into the brake body

making sure that the boot is properly seated in
the groove.

15. Press the pistons all the way down into the brake
body making sure that the boot seats properly into
the upper groove on the piston.
16. Install any fittings or plugs that were removed from
the brake body using teflon tape thread sealant.
17. If the brake body assembly is not to be immediately
installed onto a vehicle, plug the brake hose fitting
hole to prevent any contaminates from entering
the brake body.

Brakes
Page 14
 Maintenance, Service, and Repair

REPLACE THE MASTER CYLINDER

• Only use DOT 3 brake fluid from a new Do not ingest brake fluid or allow contact
sealed container. with skin or eyes. Always wear protective
clothing and a face shield when working
• DOT 3 brake fluid is corrosive and will with or around brake fluid.
damage paint finishes.
SKIN CONTACT
• Dispose of brake fluid in accordance with Flush area immediately with water for
local state and federal regulations. several minutes. If a rash or skin irritation
• Read and follow all warnings on the develops, get medical attention
immediately.
brake fluid container.
EYE CONTACT
Immediately flush the eye with water for
15 minutes and call physician.
1. Make sure the key-switch is in the “OFF” INGESTION
position, then remove the key.
Get medical attention immediately.
2. Place the forward-reverse switch in the
center “OFF” position.
12. Fill the master cylinder with brake fluid from a
3. Confirm the electric park brake is set. sealed container.
4. Place blocks under the front wheels to 13. Pump the brake pedal a short distance of one to
prevent vehicle movement. two inches until no bubbles are seen coming from
the inlet ports inside of the master cylinder
5. Disconnect the main positive and
chamber.
negative cables at the batteries.
14. If the vehicle was raised, lower it to the ground.
15. Bleed the brakes. refer to Bleed the Brakes
Always use a lifting strap, hoist, and jack section for information regarding bleeding the
stands, of adequate capacity to lift and brakes.
support the vehicle. Failure to use lifting 16. Reconnect the main positive and negative cables
and support devices of rated load capacity at the batteries.
may result in severe bodily injury.
17. Remove the blocks from behind the wheels.
18. Release the park brake and test drive the vehicle.
NOTE: Most vehicle configurations do not require
lifting the vehicle to remove the master
cylinder. Lifting the vehicle may not be Plunger
required.
6. If required, raise the vehicle and support with jack
stands.
7. Place a drain pan under the master cylinder.
8. Disconnect the brake line(s) to the master cylinder Push Rod
and pump out the fluid in the master cylinder by
depressing the pedal several times.
9. Remove the master cylinder bolts and remove the
master cylinder from the vehicle.
Master Cylinder
10. Install in reverse order.
11. Adjust the master cylinder push rod so that it is 1/8"
approximately 1/8 inch away from the master Cutaway of typical master cylinder showing
cylinder plunger when the brake pedal is up. the push rod clearance

Brakes
Page 15
 Maintenance, Service, and Repair

REPAIR THE MASTER CYLINDER

NOTE: Hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and
debris and will contain any brake fluid spills.
Remove the master cylinder from the vehicle. See Replace the Master Cylinder section .
Drain all fluid from the master cylinder and discard.
Remove the rubber boot.
Depress the plunger and remove the plunger spring clip retainer.
Pull the plunger and all seals out of the master cylinder bore.
Thoroughly clean, inspect and replace parts as required.
If any damage is found in the bore of the master cylinder then it must be replaced.
Lubricate all parts with clean brake fluid from a sealed container.
Reassemble in reverse order.
If the master cylinder is not to be immediately installed onto a vehicle, plug the brake line fitting hole to prevent any
contaminates from entering the master cylinder.

Brakes
Page 16
 Motor Service
TABLE OF CONTENTS

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

Motors with internal cooling fans ......................... 2
Enclosed Motors (GE, no cooling fan) ................. 2
Motor Removal and Installation ......... 3
Motor Inspection ................................ 3
Replacing the Brushes....................... 5
Replacing the Bearings ..................... 6
Repairing the Commutator ................ 6
Service Limits ................................... 7

Typical Exploded Motor

 Motor Service

INSPECTING THE MOTOR BRUSHES

Typical brush and brush holder

Typical motor with cooling fan indicated by Enclosed Motors (GE, no cooling fan)
the arrow
Motors with internal cooling fans
General Electric Motors
NOTE: There are four brushes in the motor. The
brushes will not wear at the same rate. It is
recommended that all four brushes are
inspected at the same time. 1. Make sure the key-switch is in the “OFF”
NOTE: In some vehicle configurations it may not be position, then remove the key.
possible to inspect all four brushes while the 2. Place the forward-reverse switch in the
motor is in the vehicle. Refer to center “OFF” position.
Transmission Service section for
3. Set the park brake.
information on removing the motor.
4. Place blocks under the front wheels to
prevent vehicle movement.

1. Make sure the key-switch is in the “OFF” 5. Disconnect the main positive and
position, then remove the key. negative cables at the batteries.

2. Place the forward-reverse switch in the

center “OFF” position. NOTE: Some motors may not have the brush
inspection holes. In this case, the motor must
3. Set the park brake. be disassembled to inspect the brushes. For
4. Place blocks under the front wheels to future inspections, holes msy be drilled into
prevent vehicle movement. the motor housing after it has been
disassembled.
5. Disconnect the main positive and
negative cables at the batteries. 6. Insert a 0.035” diameter wire through the brush
inspection hole above each brush until it contacts
the top of the brush.
6. Look through the brush cover and compare the
7. Mark the wire to indicate how far it was inserted
top of the brush to the top of the brush holder. If it
into the motor housing.
is even with or below the top of the brush holder
then the brushes should be removed and 8. Remove the wire and measure how far into the
measured. Refer to Replacing the Brushes motor the wire was inserted.
section for information regarding removing the 9. If any one wire insertion length exceeds the length
motor brushes. specified in Service Limits, then all four brushes
7. If any one brush is less than or equal to the service should be replaced. Refer to Replacing the
limit specified in Service Limits, then all four Brushes section for information regarding
brushes should be replaced. replacing the motor brushes.
8. Reconnect the main positive and negative cables 10. Reconnect the main positive and negative cables
at the batteries. at the batteries.
9. Remove the blocks from behind the wheels, 11. Remove the blocks from behind the wheels,
release the park brake and test drive. release the park brake and test drive.

Motor
Page 2
 Motor Service
Advanced DC Motors Inspection
The enclosed Advanced DC motors must be 1. Measure the length of each motor brush.
disassembled to inspect the motor brushes. Refer to • If any one brush is less than or equal to the
Motor Inspection for information regarding service limit specified in section Service
disassembling the motor.
Limits , then all four brushes should be
replaced. Refer to Replacing the Brushes
section for information regarding replacing the
motor brushes.
MOTOR REMOVAL AND 2. Measure the diameter of the commutator.
• If the commutator is less than the minimum
INSTALLATION diameter specified in section Service Limits,
See the Transmission section for information on then the motor must be replaced.
removing or installing the motor.

MOTOR INSPECTION

Disassembly
1. Remove the motor from the vehicle. See the
Transmission section for information on
removing the motor.
2. Remove the housing screws from the rear and/or 3. Measure the commutator undercut depth in 5-
front of the motor. places around the commutator.
3. Remove the armature retaining screws from the • If any one of the measurements is less than the
rear housing (if equipped). minimum undercut depth specified in Service
Limits above, then the commutator must be
undercut. Refer to Repair Commutator
section for information regarding undercutting
the commutator.

Undercut

Hacksaw blade Armature

Incorrect Correct
Insulation

Min. OD

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

housing end.
5. Pull the armature out of the front end of the motor Commutator
housing. 4. Inspect the commutator for grooves.
6. Remove the nuts off of all of the terminals in the • If the commutator is groved then it must be
rear motor housing. machined on a lathe. Do not machine the
7. Remove the rear motor housing being careful not commutator past the minimum diameter
to damage the field coil wires. specified in Service Limits section. Refer to
Repair Commutator section for information
regarding machining the commutator.

Motor
Page 3
 Motor Service
5. Inspect the commutator for burn marks. commutator segments and the armature frame. If
it is not an open circuit, then the armature is
• Burn marks and/or raised commutator segments
shorted and the motor must be replaced.
90 or 180 degrees apart is evidence of a shorted
armature. A tool called a growler is required to 11. Rotate the motor bearing(s) by hand.
reliably test for a shorted armature. • The bearing should not ‘freewheel’ but should
come to a smooth stop when rapidly spun by
hand. If the bearing freewheels, then grease is
no longer present in the bearing and it must be
replaced. Refer to Replacing the Bearings
section for information regarding replacing the
armature bearings.
• Feel for any roughness when the bearing is
rotated. If any roughness or grinding is noticed
then the bearing must be replaced. Refer to
Replacing the Bearings section for
information regarding replacing the armature
bearings.
Typical burn mark on a shorted armature
6. Inspect the commutator for raised segments. Assembly
Raised segments could be a result of a stalled
motor or shorted armature. A tool called a growler NOTE: If this is an enclosed motor on a vehicle with
is required to reliably test for a shorted armature. a Power Traction primary reduction, then it
is recommended to replace the armature
• If the armature is not shorted then the raised shaft seal any time the motor is
segments can be removed by machining the disassembled.
commutator. Do not machine the commutator
1. Push the motor brushes just far enough out of the
past the minimum diameter specified in
brush holder so that the brush springs hold them
Service Limits section. Refer to Repair in place away from the commutator. See the
Commutator section for information regarding illustration to the right.
machining the commutator.
7. Visually inspect the armature windings for burnt 2. Install the rear motor housing to the stator housing.
insulation. Burnt insulation is a direct result of 3. Lightly grease the outside diameter of the armature
motor overheating and could lead to a shorted bearings.
armature.
4. Insert the armature through the stator housing and
• If the insulation is cracked or burnt, then it is seat the bearing into the rear housing.
recommend that the armature or motor be
5. If equipped with armature retaining screws, install
replaced.
and tighten them at this time.
NOTE: If the armature has been burnt then there is a
good possibility that the field windings may 6. If this is an enclosed motor, lightly grease the
also be burnt. Symptoms indicating a shorted armature shaft seal and install the front motor
field include high motor current, lack of power housing.
and possibly excessive speed. NOTE: If the vehicle is equipped with a belt type
8. Using a growler, test the armature for shorts. primary reduction then the spring on the
• If the armature is shorted, then we recommend motor seal should be removed. Failure to
that the armature or motor be replaced. remove the spring may result in a high pitched
9. Using the continuity function of digital multi meter, squeal from the seal.
check the continuity around the entire commutator 7. Push the motor brushes into the brush holder until
by placing one test lead against one of the the brush spring snaps into place. Be certain that
commutator segments and the other test lead the spring does not rest up against the brush wire.
against all of the other segments one at a time. See the illustrations below.
There should be continuity around the entire
commutator. If any segment indicates an open
circuit, then the motor must be replaced.
10. Using the continuity function of digital multi meter,
check the continuity from any one of the

Motor
Page 4
 Motor Service

Brush Spring Orientation

3. Install the new brushes in reverse order.

REPLACING THE BRUSHES 4. Be certain that the brush springs do not rest up
NOTE: It is recommended that all four brushes be against the brush wires. Refer to illustrations in
replaced as a set. Motor Inspection-Assembly for proper brush
NOTE: Motors without removable brush covers must spring position.
be disassembled to replace the brushes.
Refer to Motor Inspection-Disassembly
section for information on taking the motor
Motors with brush pairs or not equipped
apart. with brush covers
NOTE: Some motors are equipped with brush pairs. 1. Disassemble the motor. Refer to Motor
These motors must be disassembled to Inspection-Disassembly section for information
replace the brushes. Refer to Motor on taking the motor apart.
Inspection-Disassembly section for 2. Remove the brush holder.
information on taking the motor apart. Refer
to the Motor Parts List for your vehicles Note: Remember the position and routing of the brush
brush configuration. crossover leads. They must be reinstalled in
the same position.
NOTE: Some motors have brush leads that are routed
through or behind the brush holder assembly. 3. Remove the brush termination screws or the
In this case, the brush holder assembly must armature studs and remove the brushes from the
be removed to replace the brushes. brush holder.
NOTE: The motor must be removed from the vehicle 4. Install the new brushes in reverse order.
for this procedure. Refer to Transmission 5. Reassemble the motor. Refer to Motor
Service section for information on removing Inspection-Assembly for information regarding
the motor. reassembling the motor.

Motors with brush covers and brushes with

termination screws
1. Remove the brush covers.
2. Loosen the brush wire retaining screw and remove
the brush from the brush holder. Be careful with
the brush spring and do not let it slip off of the
spring mount. If the spring comes off, then the
motor must be disassembled. Refer to Motor
Inspection-Disassembly section for
information on taking the motor apart.

Motor
Page 5
 Motor Service
6. Measure the commutator undercut depth in 5-
REPLACING THE BEARINGS places around the commutator. If any one of the
1. The motor must be removed from the vehicle for measurements is less than the minimum undercut
this procedure. Refer to Transmission Service depth specified in Service Limits, then the
section for information on removing the motor. commutator must be undercut.

2. Remove the armature. Refer to Motor Inspection-

Disassembly section for information on taking the
motor apart.
3. Press the armature bearing(s) off of the armature
shaft.

Do not press against the outer race of the

bearing. Pressing against the outer race
will damage the bearing and may result in
premature failure of the bearing. See the
illustration below
Example of freshly cut commutator
7. While still in the lathe, smooth the commutator
with fine emery cloth.

Undercutting the commutator

1. Using a small straight cut saw blade, cut the
commutator insulation to the proper depth. Refer
to undercut depth in Service Limits.
2. Once all segments have been properly undercut,
mount the armature in a lathe and smooth the
commutator with fine emery cloth.
3. Inspect the armature for shorts. Refer to Motor
Inspection section for information on testing the
4. Press new bearing(s) onto the shaft. armature.
5. Reassemble the motor. NOTE: Copper debris in the undercut area can give
a reading of a shorted armature.
REPAIRING THE COMMUTATOR
1. The motor must be removed from the vehicle for
this procedure. Refer to Transmission Service
section for information on removing the motor.
2. The armature must be removed from the motor
for this procedure. Refer to Motor Inspection-
Disassembly section for information on taking
the motor apart.
3. Using a lathe, cut the armature just enough to Properly undercut and cleaned
remove all grooves, depressions or ridges. commutator segments
4. Measure the diameter of the commutator. If the
commutator is less than the minimum diameter
specified in Service Limits, then the motor must
be replaced.
5. Thoroughly clean all copper debris from between
the commutator segments.

Motor
Page 6
 Motor Service

SERVICE LIMITS
Commutator Diameter Brush Length Wire Depth
Motor Specification Undercut Depth
(min) (min) (max)
Number
mm inches mm inches mm inches mm inches

5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC58JBS6129C 0.635 0.025 66.75 2.625 19.05 0.75 38.1 1.5

5BC49JB399C 0.635 0.025 78.97 3.109 19.05 0.75 - -

5BC58JBS6110C 0.635 0.025 78.97 3.109 19.05 0.75 38.1 1.5

Motor
Page 7
TAYLOR -DUNN
Transmission Service

TABLE OF CONTENTS
Check Oil Level ............................................. 2
Change Oil ..................................................... 3
Motor ............................................................. 4
Removal .................................................................... 4
Installation ................................................................. 4
Rear Hub with Brake Drum ........................... 5
Rear Axle ....................................................... 6
Replace the Axle Bearing .......................................... 8
Transmission ................................................. 9
Remove ..................................................................... 9
Install ........................................................................ 9
Differential Case ............................................ 10
Disassemble ............................................................. 10
Assemble .................................................................. 13
 Maintenance, Service, and Repair

CHECK OIL LEVEL

Park the vehicle on a level surface.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Place a drain pan that can hold a minimum of

2-quarts of oil under the transmission level plug.
7. Remove the level plug. When the plug is removed, a small amount
of oil should come out. This indicates that the transmission has
the correct amount of oil.
8. If no oil comes out, then add oil as required through the level plug
hole.
9. Reconnect the main positive and negative cables at the batteries.
10. Remove blocks from behind the wheels. Transmission Oil Level Plug

11. Test drive the vehicle

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

Transmission Page 2
 Maintenance, Service, and Repair

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

Transmission Page 3
 Maintenance, Service, and Repair

MOTOR

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the motor wires from the motor.

HINT: Tag each wire with the number of the
terminal it was removed from.
7. Remove the bolts holding the motor to the
transmission housing (see illustration).
8. Slide the motor off of the transmission input shaft.

Installation
1. Remove the rubber bushing from inside of the motor
armature coupling.
2. Thoroughly clean all grease from the transmission
input shaft, rubber bushing and the motor armature
coupling.
3. Install the rubber bushing back into the motor
armature coupling.
4. Lightly grease the transmission input shaft only (see
caution below).
5. Install the motor in reverse order.
6. Torque the motor mounting bolts to 6-8 ft-lbs.

Do not apply grease to the armature coupler, rubber bushing or the

end of the transmission input shaft. Grease applied to these areas
may result in premature failure of the armature bearing.

Transmission Page 4
 Maintenance, Service, and Repair

REAR HUB WITH BRAKE DRUM

Removal and Installation

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

Integral hub Removable hub

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the rear wheel. Refer to Replace the

Rear Tire/Wheel section for information regarding
removing the rear wheel.
7. Remove the cotter pin from the axle shaft.
8. Remove the hub retaining nut and remove the hub
from the axle shaft.
9. Install in reverse order.
10. Lightly grease the axle shaft splines.

Too much grease on the axle

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

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

12. Install the wheel. Refer to Replace the Rear Tire/Wheel section for information regarding
installing the rear wheel.
13. Reconnect the main positive and negative cables at the batteries, remove the blocks from the
wheels, and test drive.

Transmission Page 5
 Maintenance, Service, and Repair

REAR AXLE
Your vehicle is configured with one of two types of rear hubs. One can be removed from the rear axle
and the other is an integral part of the rear axle. The service of both of these axles is addressed in this
section as follows:
The removable hub will be referred to as “Removable Hub.”
The non-removable hub will be referred to as “Non-Removable Hub.”
Refer to the illustrations on the previous page to identify the type of hub on your vehicle.
NOTE: The tire/wheel assembly must be removed for these procedures.
Refer to Tires and Wheels section for information on removing
the tire and wheel assembly.

Remove and Install Axle - Removable Hub

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the rear wheel. Refer to Replace the Rear

Tire/Wheel section for information regarding
removing the rear wheel.
7. Remove the axle hub. Refer to Rear Hub/Brake
Drum section for information on removing the hub.
8. Remove the outer snap ring from the axle housing.
9. Remove the axle from the transmission assembly.
HINT: Use a slide hammer threaded onto the
end of the axle shaft.
10. Remove the inner snap ring.
11. Remove the axle seal from the axle housing.
12. Install the axle in reverse order using a new axle seal.
13. Refer to Rear Hub/Brake Drum section for information on installing the hub.
14. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels,
and test drive.

Transmission Page 6
 Maintenance, Service, and Repair

Remove and Install Axle - Non - Removable Hub

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the rear wheel. Refer to Replace the Rear Tire/Wheel section for information
regarding removing the rear wheel.
7. Remove the brake drum.
8. Remove the mechanical brake linkage from the
brake arm.
9. If equipped with hydraulic brakes, disconnect the
brake line from the wheel cylinder.
10. Remove the four bolts holding the axle/brake
assembly to the axle housing.
11. Remove the axle/brake assembly from the
transmission assembly.
HINT: Use a slide hammer threaded onto one
of the wheel studs.
12. If the axle bearing is to be replaced, remove the
bearing race from inside of the axle housing.
13. Remove the axle seal from the axle housing and discard.
14. Install in reverse order using a new axle seal.
15. If equipped with hydraulic brakes, bleed the brakes. Refer to Brake Service-Bleed the Brakes
section for information on bleeding the brake system.
16. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels,
and test drive.

Transmission Page 7
 Maintenance, Service, and Repair

Replace the Axle Bearing

NOTE: The axle must be removed from the transmission for this procedure.
Refer to Remove and Install Axle for information regarding
removing the rear axle.
Removable Hub:
1. Remove the hub from the axle shaft. Refer to Rear Hub/Brake Drum for information regarding
removing the hub.
2. Press the axle bearing off of the axle shaft and discard.
3. Press a new bearing onto the axle shaft.
4. If the axle is not to be immediately installed into a vehicle, pack the bearing with grease and
wrap it in plastic to prevent corrosion.
Non-Removable Hub
1. Drill a 1/4” hole to a depth of approximately 3/4 the
thickness of the retaining ring.

Do not drill all of the way

through the retainer into the
axle shaft. Drilling into the
axle shaft will weaken the
axle shaft and could cause the
axle to fail resulting in severe
bodily injury and/or property
damage.

2. Use a chisel to split the retainer and remove the

retainer from the axle shaft.

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

shaft.
4. Press a new bearing/race assembly onto the axle shaft.
5. If the axle is not to be immediately installed into a
vehicle, pack the bearing with grease and wrap it in
plastic to prevent corrosion.

Transmission Page 8
 Maintenance, Service, and Repair

TRANSMISSION

Removal

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Remove the motor from the transmission. Refer to Remove Motor section for information
regarding removing the motor.
7. Disconnect the brake cables from the left and right
brake arm and cable mounting bracket.
8. Support the frame of the vehicle so it will not drop.
9. Remove the bolts and nuts holding the transmission
to the springs.
10. Lift the vehicle frame and remove the transmission
out from under the vehicle.

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

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

Installation
1. Install in reverse order.
2. Adjust the brakes. Refer to Adjust the Service Brakes section for information regarding adjusting
the brakes.
3. Reconnect the main positive and negative at the batteries, remove the blocks from the wheels,
and test drive.

Transmission Page 9
 Maintenance, Service, and Repair

DIFFERENTIAL CASE

Disassemble
1. Remove the transmission from the vehicle. Refer to Transmission-Removal section for
information on removing the transmission.
2. Thoroughly clean the transmission assembly before disassembly.
3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for
information on removing the axles.
4. Suspend the differential case over a drain pan that can hold a minimum of 2-quarts of oil.
5. Remove the differential case cover being careful
not to bend or damage the case cover flange or the
sealing surface of the differential case.

6. Remove the differential bearing caps and remove

the differential assembly from the housing.
NOTE: The bearing caps are marked for
identification. When the transmission
is reassembled they must be installed
in their original position.

7. Remove both bearings from the differential case.

Transmission Page 10
 Maintenance, Service, and Repair

8. Remove the final drive gear from the differential

housing.

9. Punch or drill a small hole into the center of both of

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

11. Remove both snap rings from the intermediate shaft

bore.

12. Using a soft metal or hard wood dowel, drive the

intermediate shaft through the bearing just enough
to allow clearance for an ID bearing puller. Do not
attempt to drive the shaft out of the opposite end of
the transmission.

Transmission Page 11
Maintenance, Service, and Repair

13. Remove the intermediate bearing with an ID bearing

puller.

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

14. While supporting the shaft and gear assembly,

repeat steps #12 and #13 for the opposite side
bearing and remove the intermediate shaft from
the housing.

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

intermediate shaft.

16. Remove the circlip from the input shaft.

17. Remove the input shaft from the housing.
18. Press the bearings off of the input shaft.

Transmission Page 12
 Maintenance, Service, and Repair

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

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

Assemble
NOTE: When pressing bearings, do not press against or support the outer
race as this will damage the bearing.
NOTE: All snap rings should fit tightly into their grooves. If a snap ring is
loose, then it must be replaced.
NOTE: All internal components should fit easily together. Do not hit any
shaft or component with a hard metal hammer or punch.
NOTE: Pre-lube all bearings, seals and o-rings before assembly.
1. Thoroughly clean all components as well as the inside of the housing.
2. Press new bearings onto the input shaft and
differential case.

3. Insert new o-rings into both sides of the intermediate

shaft bore, the input shaft bore and the intermediate
shafts.

Transmission Page 13
Maintenance, Service, and Repair

4. Install the input shaft into the housing and install

the snap ring.

5. Insert the intermediate shaft into the housing and support in place.
6. Insert the flanged side bearing into the bearing bore.
Press in just past the snap ring grove and install
the snap ring.

Use a hard wood dowel the

same diameter as the bearing
bore to drive the bearing into
place. Do not drive against the
inner race as this will damage
the bearing.

7. Repeat the above step for the opposite bearing.

8. Thoroughly clean both sides of the intermediate bore. All contaminates must be removed.
9. Apply Loctite #RC 609 to both sides of the intermediate bore and install new bore plugs.
NOTE: Drive the bore plugs until they are firmly seated against the snap
rings.
10. Install the final drive gear onto the differential
housing. Torque the nuts to 35-45 ft-lbs.
11. Install the differential assembly into the drive
housing and install the bearing caps. Torque the
bolts to 35-45 ft-lbs.
NOTE: The bearing caps are marked for
identification and must be installed in
their original locations.
12. Place a small bead of non-acidic silicone sealant
to the bottom flange of the housing.
NOTE: The sealant bead should be on the
inside of the cover plate mounting holes.
13. Install the cover plate. Torque the bolts to 18-28 ft-lbs.
14. Install the axles using new axle seals. Refer to Rear Axle section for information on installing
the axles.
15. Fill with 11 ounces of oil. Refer to the Lubrication Table for the proper type of oil.

Transmission Page 14
Suspension

TABLE OF CONTENTS

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

Leaf ........................................................................... 2
Replace the Front Springs ........................... 4
Leaf ........................................................................... 4
Replace the Spring Bushings ...................... 6
Replace the Shocks ...................................... 7
Front ......................................................................... 7
 Maintenance, Service, and Repair

REPLACE THE REAR SPRINGS

Leaf
If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set.
HINT : In most vehicles it will be easier if the springs are replaced one at
a time.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Tie up or support the rear axle so it cannot fall out of the vehicle.
8. Unbolt the spring from the axle housing.
9. Support the spring so that it cannot fall out of the vehicle.
10. Remove the remaining hardware retaining the spring to the frame.
11. Remove the spring from the vehicle.

Suspension Page 2
 Maintenance, Service, and Repair

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

Damaged or worn spring bolts or hangers could result in sudden failure

of the suspension causing severe bodily injury or property damage.

13. Install the new spring in reverse order.

14. If the spring hanger bolts do not have a grease fitting, lube the spring bushings before installing
the spring.
15. Tighten the spring hanger bolts securely, but not so tight as to bind the spring.
16. Lower the vehicle.
17. Reconnect the main positive and negative cables at the batteries.
18. Remove the blocks from behind the wheels.
19. Release the parking brake and test drive the vehicle.

Suspension Page 3
 Maintenance, Service, and Repair

REPLACE THE FRONT SPRINGS

Leaf
If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set.
HINT : In most vehicles it will be easier if the springs are replaced one at
a time.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the rear wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Tie up or support the front axle so it cannot fall out of the vehicle.
8. Unbolt the spring from the front axle beam.
9. Support the spring so that it cannot fall out of the vehicle.
10. Remove the remaining hardware retaining the spring to the frame.
11. Remove the spring from the vehicle.

Suspension Page 4
 Maintenance, Service, and Repair

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

Damaged or worn spring bolts or hangers could result in sudden failure

of the suspension causing severe bodily injury or property damage.

13. Install the new spring in reverse order.

14. If the spring hanger bolts do not have a grease fitting, lube the spring bushings before installing
the spring.
15. Tighten the spring hanger bolts securely, but not so tight as to bind the spring.
16. Lower the vehicle.
17. Reconnect the main positive and negative cables at the batteries.
18. Remove the blocks from behind the wheels.
19. Release the parking brake and test drive the vehicle.

Suspension Page 5
 Maintenance, Service, and Repair

REPLACE THE SPRING BUSHINGS

It is recommended that all front spring bushings are replaced
as a set.
Your vehicle will be equipped with one of two types of spring
bushings, internal and external (see illustration to the right):
• The internal bushing is a plastic insert that is pressed
into the spring eye. There are one of these bushings
for each spring eye.
• The external bushing consists of two plastic bushings
on each end of the spring eye.
• Refer to the parts list to identify the bushings used in
your vehicle.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front/rear wheels to prevent vehicle
movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the spring from the vehicle.

NOTE: Refer to Replace the Front Springs section for information
regarding removing the front springs.
8. If the vehicle is equipped with spring hangers, remove the spring hanger bolt from the vehicles
frame.
9. Remove the spring bushing(s):
• For internal bushing, press the spring bushings
out of the two spring eyes and from the mounting
eye on the vehicles frame.
• For external bushing, Remove the bushings from
the spring eye.

Suspension Page 6
 Maintenance, Service, and Repair

10. Install the new bushings in reverse order.

HINT: Apply a light coating of grease to the bushing before pressing into
the spring eye.
11. Install the spring onto the vehicle.
NOTE: Refer to Replace the Front Springs section for information
regarding installing the front springs.
12. Repeat for the other spring.
13. Lower the vehicle.
14. Reconnect the main positive and negative cables at the batteries.
15. Remove the blocks from behind the wheels.
16. Release the parking brake and test drive the vehicle.

REPLACE THE SHOCKS

Front
It is recommended to replace both front shocks as a set.
NOTE: On some vehicles it may be required to remove the front wheel to
gain access to the shock mounting bolts. Refer to Tires and Wheels
section for information regarding removing the front wheels.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

7. Remove the upper and lower shock bolts.

Suspension Page 7
Maintenance, Service, and Repair

8. Remove the shock from the vehicle.

NOTE: If the shock that was removed is to be
reinstalled:
A. Inspect the shaft where it enters the
shock body for any signs of
leakage. If any sign of leakage is
seen, then the shock must be
replaced.
B. Inspect the upper and lower shock
bushings. If any signs of damage
or wear are seen, then the shock
must be replaced.
9. Install the shock in reverse order.
10. Lower the vehicle.
11. Reconnect the main positive and negative cables
at the batteries.
12. Remove the blocks from behind the wheels.
13. Release the parking brake and test drive the vehicle.

Suspension Page 8
Battery Service

TABLE OF CONTENTS

Cleaning ........................................................ 2
Testing ........................................................... 3
Watering ........................................................ 5
Charging ........................................................ 6
Replacing ...................................................... 7
Moist Charge Batteries ............................................. 9
Storage and Returning to Service ................ 10
Returning to Service ................................................. 11
 Maintenance, Service, and Repair

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in severe bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

Battery electrolyte will stain and corrode most surfaces. Immediately

and thoroughly clean any surface outside of the battery that the
battery electrolyte comes in contact with. Failure to clean may result
in property damage.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Dry dirt can be readily blown off with low-pressure air or brushed off.
7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with
flexible bristles, wash the batteries off with a strong solution of baking soda and hot water (1
lb. of soda to a gallon of water). Continue until all fizzing stops, which indicates that the acid
has been neutralized. Then rinse thoroughly with clear water. DO NOT get any of the solution
into the battery cells.
8. Reconnect the batteries, remove the blocks from the wheels and test drive.

Batteries Page 2
 Maintenance, Service, and Repair

TESTING
NOTE: A combination of the Load Test and Specific Gravity Test should
be used to accurately determine the condition of the batteries.

Explosive mixtures of Hydrogen gas are present within battery cells

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in severe bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

Load Test
NOTE: The batteries must be fully charged before performing this test.
1. Clean the batteries. Refer to Cleaning the Batteries section for information on cleaning the
batteries.
2. Load test each battery using a battery load test meter (available at most auto parts distributors).
Follow the instructions provided with the test meter.
• If any battery fails the load test, then it should be replaced.
NOTE: If the batteries are over one year old, it is recommended to replace
them as a set.
• If all batteries fail the test you should check the charging system before replacing the batteries.
Refer to Charger Troubleshooting section for information on checking the charging system.

Batteries Page 3
 Maintenance, Service, and Repair

Specific Gravity Test

NOTE: The batteries must be fully charged before performing this test.
The specific gravity of a cell is an indication of the actual state of charge of
the cell. A fully charged cell should have a reading of 1275 to 1300 (see the
illustration to the right). A discharged battery will read 1100. Ideally, all cells in
a battery pack will have the same reading. Any cells in a battery pack that
vary by more than 30-points may be an indication of a bad cell.
Clean the batteries. Refer to Cleaning the Batteries section for information
on cleaning the batteries.
Using part number 77-200-00 hydrometer, check and record the specific gravity
of each cell in the battery pack.
If, after charging, none of the cells exceed a hydrometer reading of 1250
then there may be a fault in the charging system. If the charging system
checks OK then the batteries are no longer accepting a charge and should be
replaced.
NOTE: Refer to Charger Troubleshooting for information on
checking the charging system.
The highest reading will be the cell that is accepting the most charge. This
reading will be used to gauge all other cells.
Typical Hydrometer Float
Compare the specific gravity readings to the highest reading, if the difference
between any of the cells is more than 30-points, then that battery should be replaced.
NOTE: If the batteries are over one year old, it is recommended to replace
them as a set.
Reconnect the batteries, remove the blocks from the wheels and test drive.

Batteries Page 4
 Maintenance, Service, and Repair

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

Explosive mixtures of Hydrogen gas are present within battery cells

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in severe bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

Batteries Page 5
 Maintenance, Service, and Repair

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Clean the batteries. Refer to Cleaning the

Batteries section for information on cleaning the
batteries.
7. Check the electrolyte level in all battery cells. If
low, fill to the correct level with distilled water using
part number 77-201-00 battery filler, never add
additional battery electrolyte to the batteries.
8. Reconnect the batteries, remove the blocks from
the wheels and test drive.

CHARGING
Refer to Charging Your Vehicle in section Safety Rules and Operating Instructions.

Batteries Page 6
 Maintenance, Service, and Repair

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in serious bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

NOTE: If the batteries are over one year old, it is recommended to replace
them as a set.
6. Thoroughly clean the batteries and battery compartment. Refer to Cleaning in this section for
information regarding cleaning the batteries.

Battery electrolyte will stain and corrode most surfaces. Immediately

and thoroughly clean any surface outside of the battery that the
battery electrolyte comes in contact with. Failure to clean may result
in property damage.

Batteries Page 7
Maintenance, Service, and Repair

7. Remove the battery hold downs.

8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the
battery hold downs should be replaced.
9. Remove all battery jumpers from both posts of the battery or batteries being replaced.
NOTE: It is recommended to replace the battery jumpers when replacing
the batteries.
10. Remove the batteries from the vehicle.

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

11. Inspect the battery compartment for signs of corrosion.

12. If minimal signs of corrosion are seen, then the damaged paint should be stripped off and the
entire battery compartment prepped and repainted.
13. If there are excessive signs of corrosion, then it may be necessary to replace some of the
frame members or completely rebuild the battery compartment.
14. Inspect the main positive and negative cables and terminals, charger cables and terminals
and 12-volt tap wiring. If any of the terminals or wires show signs of corrosion, then they must
be repaired or replaced.
15. Install the batteries in reverse order. Refer to the Illustrated Parts List for battery cable
routing.
16. It is recommended to replace the battery terminal hardware when replacing the batteries.
17. Torque the terminal hardware to 7-8 ft.-lbs.
18. Tighten the hold downs so that the batteries are secure but not so tight as to deform the
batteries.

When torquing battery hardware, use a backup wrench on the battery

bolt and tighten the nut. Failure to use a backup wrench may damage
the battery post.

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

Batteries Page 8
 Maintenance, Service, and Repair

Moist Charge Batteries

Explosive mixtures of Hydrogen gas are present within battery cells

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in serious bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

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

Do not operate or charge a vehicle equipped with moist charged

batteries until the batteries have been filled with electrolyte and
charged. Operating or charging moist charged batteries before filling
and charging will damage the batteries resulting in premature failure
of the batteries.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

Batteries Page 9
 Maintenance, Service, and Repair

6. Fill all battery cells with electrolyte to the proper

level.
7. Thoroughly clean any spilled electrolyte from the
batteries orthe ground.RefertoCleaning the
Batteries for information on cleaning the
batteries.
8. Reconnect the battery cables, connect the batteries
to the charger and allow the charger to complete
one charging cycle.
9. Remove the blocks from the wheels and test drive.
The batteries are now ready to be put into service.

Battery electrolyte will stain and corrode most surfaces. Immediately

and thoroughly clean any surface outside of the battery that the
battery electrolyte comes in contact with. Failure to clean may result
in property damage.

STORAGE AND RETURNING TO SERVICE

Storage

If the batteries are removed from the vehicle, do not place them
directly on the ground, concrete or solid metal surface. It is
recommended to store them on a wooden pallet or equivalent. Storing
on the ground, concrete or solid metal surface will cause the batteries
to discharge and may result in premature failure of the batteries.

Thoroughly clean the batteries and battery compartment. Refer to Cleaning in this section for information
regarding cleaning the batteries.
Check the electrolyte level and charge the batteries. Refer to Watering in this section for information
regarding checking the electrolyte level.
Store the vehicle or batteries in a cool, dry, well ventilated area.
If storing for more than one month, the batteries should be charged as follows:

Storage
Charging Interval
Temperature
(months)
(F)
Over 60 1

Between 40 and 60 2

Below 40 6

Batteries Page 10
 Maintenance, Service, and Repair

Returning to Service

Explosive mixtures of Hydrogen gas are present within battery cells

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

Battery electrolyte is poisonous and dangerous. It contains sulfuric

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in serious bodily injury.

A battery is a live electrical source. It cannot be disconnected or

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

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

Battery electrolyte will stain and corrode most surfaces. Immediately

and thoroughly clean any surface outside of the battery that the
battery electrolyte comes in contact with. Failure to clean may result
in property damage.

7. Check the electrolyte level and charge the batteries. Refer to Watering in this section for
information regarding checking the electrolyte level.
8. Test the batteries. Refer to Testing section for information on testing the batteries.
9. The batteries are now ready to be put back into service.

Batteries Page 11
TAYLOR -DUNN
Tires and Wheels

TABLE OF CONTENTS

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

Tire Inspection .............................................. 2
Replace the Front Tire/Wheel ....................... 3
Replace the Rear Tire/Wheel ........................ 3
Repair the Tire ............................................... 4
Replace the Tire ............................................ 5
 Maintenance, Service, and Repair

TIRE INFLATION

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

There are many tire options available with varying tire

pressures. Refer to the side wall of your tire for information
regarding the tire pressure for your tires.
The illustration to the right is an example of the side wall
information on a tire.
Tire pressures must be checked when the tire is cold.

TIRE INSPECTION

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Check the tire pressure. Refer to Tire Inflation

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

Tires and Wheels Page 2

 Maintenance, Service, and Repair

8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly
inflated tire or a misaligned or damaged front end.
NOTE: Refer to Tire Inflation section or Steering Component Service
section for information on proper tire inflation or front end wheel
alignment.
9. Inspect the inner and outer side walls for cracks. If any cracks are seen, then the tire should be
replaced. Refer to Replace the Tire section for information regarding replacing the tire.
10. Inspect the valve stem for cracks. If any cracks are seen, then the valve stem should be replaced.
It is also recommended that the valve stem be replaced whenever the tire is replaced.
NOTE: Refer to Replace the Tire section for information regarding
replacing the valve stem.
11. Inspect the tread and side walls for debris in the rubber that could lead to a puncture. If any
debris is found it should be removed and the tire inspected for a leak.

REPLACE TIRE/WHEEL

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. Raise the wheel to be replaced off of the ground and support with jack stands.
7. Remove the 4 or 5 wheel nuts and remove the wheel.
8. Install in reverse order.
9. Following the pattern shown on the following page, cross tighten the wheel nuts in two stages as
follows:
1st stage to approximatly 20 ft-lbs.
2nd stage to 80-90 ft-lbs.
10. Reconnect the main positive and negative cables at the batteries.
11. Lower the wheel to the ground.
12. Remove the blocks from behind the wheels.
13. Release the parking brake and test drive the vehicle.

Tires and Wheels Page 3

 Maintenance, Service, and Repair

4 1
4
1
3
2
2
3 5

4-Bolt Pattern 5-Bolt Pattern

Pattern for tightening the wheel nuts

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

REPAIR THE TIRE

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

NOTE: To properly repair a puncture, the tire must be removed from the
wheel. Refer to Replace the Tire section for information on
removing the tire from the wheel.
It is recommended to repair a tire with a combination vulcanized plug and internal patch.
Tire repairs should only be performed by personnel trained in tire repair.
The tire repair procedure will be unique to the type of repair equipment or repair components used.
Refer to the instructions provided with your equipment or repair components.

Tires and Wheels Page 4

 Maintenance, Service, and Repair

REPLACE THE TIRE

NOTE; To replace the tire, the tire/wheel assembly must be removed from
the vehicle. Refer to Replace the Tire/Wheel section for
information on removing the tire/wheel assembly.

Explosion Hazard. Fully deflate the tire before attempting to remove

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

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

The tire replacement procedure will be unique to the type of replacement equipment being used. Refer
to the instructions provided with your equipment.
Always use a new valve stem when replacing a tire.
1. Remove the tire from the wheel.
2. Cut the old valve stem off of the wheel.
3. Remove the valve stem cap from the new valve stem.
4. Lubricate the valve stem with liquid soap.
5. Install a new valve stem using a valve stem tool.
NOTE: The valve stem tool is available at most auto repair shops.
6. Install the tire onto the wheel following the instructions provided with your tire replacement
equipment.
7. Inflate the tire to the proper pressure and check for leaks.
8. Install the valve stem cap.

Tires and Wheels Page 5

TAYLOR -DUNN
 Troubleshooting
Electrical
Table of Contents
SYMPTOMS: .....................................2
READ THIS FIRST ............................3
Test Equipment Required: ....................................................... 3
IMPORTANT NOTES and INSTRUCTIONS ...................... 3
Definitions: .............................................................................. 3
SYMPTOM TROUBLESHOOTING
GUIDE ..........................................19
PMC CONTROL .................................................................... 20
PLUGGING DIODE .............................................................. 22
FREEWHEEL DIODE ........................................................... 23
ISO ........................................................................................... 24
SOLENOIDS .......................................................................... 26
MOTOR .................................................................................. 29

REV F
 Curtis PMC Troubleshooting

Note: Vehicles with Dana H12 transmission,

Forward solenoid is in the center. Solenoids
Circuit Breaker

FWD

REV

ISO
PMC Speed Control

Typical Control Panel

SYMPTOMS:
If your vehicle exhibits any of the following symptoms then skip the main troubleshooting
sequence and proceed to 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: Field
current will be very low.
• Runs normal in one direction only plus runs slow or lacks power in the opposite direction
with high armature current in the opposite direction or;
• Accelerates slowly and exceeds normal speed in the opposite direction with high armature
current only. NOTE: Field current will be very low in the opposite direction.
• Accelerates slowly and exceeds normal speed in both directions plus high armature current.
NOTE: Field current will be very low.
• Full speed only.
• Does not run in either direction plus there is noise from motor (hum or whine) with high
field current and low armature current.
• Jumps into high speed when direction is selected after depressing the accelerator pedal.
Excessive spark when connecting battery
• Does not run or runs very slow with low motor current and high battery current.
• Jumps into high speed when direction is selected after depressing the accelerator pedal.
If your vehicle does not exhibits any of the above symptoms then continue with the main
troubleshooting sequence on the following pages.

Page 2
 Curtis PMC Troubleshooting

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.
• Throttle Module Analyzer, Taylor-Dunn #62-027-32.
• These tools are available through your local Taylor-Dunn parts distributor.

IMPORTANT NOTES and INSTRUCTIONS

• This troubleshooting guide assumes that the vehicle is wired correctly. It is not intended to
diagnose a vehicle that is not wired correctly.
• This troubleshooting guide is not written to be able to locate a problem if there are multiple
component failures.
• This troubleshooting guide assumes the batteries are good. Charge and test the batteries
before troubleshooting the control system.
• DO NOT start in the middle of this troubleshooting guide. Start at the beginning and
complete each test in the order that they are written.DO NOT skip any test unless instructed
to do so. Once a problem is found, stop testing and repair the indicated problem. When
the repair is completed it is recommended that the control system be retested before
lowering the drive wheels to the ground.
• This troubleshooting guide requires the use of a test light rated at the battery voltage of
the truck and the Taylor-Dunn Throttle Module Analyzer. Troubleshooting CANNOT be
completed without these tools.

These test procedures must be performed in the order they were

written. If the test result is good, then proceed to the next test or
go to the next section. Failure to do so may result in incorrect test
results.

Page 3
 Curtis PMC Troubleshooting

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

DURING ALL TESTS

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

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

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

Disconnect both of the battery leads during any maintenance or

before disconnecting any electrical component or wire. Failure to do
so may cause severe bodily injury and/or property damage.

START:
Read all warnings above before continuing.
If the vehicle runs normal in one direction but does not run in the opposite direction then go to
the Solenoids sequence.
If none of the three solenoids pick up (click) when the accelerator pedal is depressed then go
to the Forward & Reverse Switch sequence.

Page 4
 Curtis PMC Troubleshooting

Power Output Test

The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Set the test light voltage to the same voltage as the battery
volts.
Connect the test light from the PMC ‘M-’ Terminal to battery Test Light
positive.
Face of Controller
Close all interlock switches, turn the Key Switch ON, and
place the F&R Switch in Forward. KSI B- B+
Depress the accelerator pedal fully. #2

• If the light comes ON then go to theMotor sequence. M-

Main Battery Positive
A2
• If the light does not come ON then continue with the
next test.

Page 5
 Curtis PMC Troubleshooting

Control Wire Inputs

The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Connect a voltmeter across the Solenoid Negative Buss Bar

and battery positive.
The voltage shown is for illustration
• If the voltage is not at battery volts then check the only. The actual voltage may vary.
wiring to battery negative and the negative circuit
breaker. Stop trouble shooting here and repair the Solenoids are shown for reference
problem. When the repair is completed, completely only. The type of solenoid in your
retest the vehicle before lowering the drive wheels truck may look different
Main Battery
to the ground. Positive

+
_
FWD REV ISO

Connect a voltmeter across the ISO solenoid coil terminals.

Close all interlock switches and turn the Key Switch The voltage shown is for illustration
only. The actual voltage may vary.
ON.
Depress the accelerator pedal to engage MS-1 only. Solenoids are shown for reference
• If the voltage is not at battery volts then go to the only. The type of solenoid in your
Key Switch sequence. truck may look different
• If the voltage is at battery volts and the ISO solenoid
does not pick up (click) then the ISO solenoid 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. FWD REV ISO

Note: Vehicles with Dana H12 transmission,

Forward solenoid is in the center.

Page 6
 Curtis PMC Troubleshooting

Connect a voltmeter across the PMC #2 terminal and battery

negative.
Close all interlock switches, turn the Key Switch ON, and The voltage shown is for illustration
place the F&R Switch in Forward. only. The actual voltage may vary.
Depress the accelerator pedal to engage MS-1 only.
• If the voltage is not between 6.0 and 6.5 volts then
go to the Accelerator sequence.
Depress the pedal fully. + KSI B- B+
• If the voltage is not between 11.0 and 11.5 volts then _ #2

go to the Accelerator sequence. M-

Main Battery A2
Negative

Connect voltmeter across the PMC KSI terminal and battery FLUKE 79 SERIES II MULTIMETER

negative.
With the pedal still fully depressed: OFF V The voltage shown is for illustration
• If the voltage is not at battery volts then go to the Hz

V
only. The actual voltage may vary.
Key Switch sequence. mV

• If the voltage is at battery volts then continue with A

Ω

the next test.

+ B- B+
−
KSI

#2
M-
Main Battery A2
Negative

Page 7
 Curtis PMC Troubleshooting

Power Wire Inputs

The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Connect a voltmeter to the PMC ‘B-’ terminal and battery

positive.
• If the voltage is not the same as battery volts then
The voltage shown is for illustration
there is an open circuit in the wire from ‘B-’ to the only. The actual voltage may vary.
battery. Stop troubleshooting here and repair the
problem. When the repair is completed, completely
retest the vehicle before lowering the drive wheels
to the ground.
+ KSI B- B+
_ #2
M-
A2

Main Battery Positive

Connect a voltmeter across the PMC ‘B-’ terminal and the

PMC ‘B+’ terminal.
Close all interlock switches, turn the Key Switch ON, The voltage shown is for illustration
and place the F&R Switch in Forward. only. The actual voltage may vary.
Depress the accelerator pedal to engage MS-1 only.
• If the voltage is not the same as battery volts then
go to the Solenoids sequence.
• If the voltage is the same as battery volts then the
+ KSI B- B+
PMC controller has failed. Stop trouble shooting _ #2
here and repair the problem. When the repair is M-
completed, completely retest the vehicle before A2
lowering the drive wheels to the ground.

Page 8
 Curtis PMC Troubleshooting

Motor
The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Set the test light voltage to the same voltage as the battery
volts.
Connect the test light across the motor ‘A1’ and ‘A2’ Wiring to motor omitted for clarity. Do not
terminals. disconnect the motor wires for this test.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in Forward.
Depress the accelerator fully.
• If the light comes on then the motor armature S1
A2
windings are open and the motor must be repaired
S2
or replaced. Stop trouble shooting here and repair
the problem. When the repair is completed, A1

completely test the vehicle before lowering the drive

wheels to the ground.
Motor shown for reference only. Terminal positions
on your motor may not be in the same location.

Connect the test light across the motor ‘S1’ and ‘S2’ terminals. Wiring to motor omitted for clarity. Do not
disconnect the motor wires for this test.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in Forward.
Depress the accelerator fully.
• If the light comes on then the motor field windings
S1
are open and the motor must be repaired or replaced. A2
Stop trouble shooting here and repair the problem. S2
When the repair is completed, completely retest the A1
vehicle before lowering the drive wheels to the
ground.
• If the test light did not come on during either test Motor shown for reference only. Terminal positions
then go to the F/R Switch sequence. on your motor may not be in the same location.

Page 9
 Curtis PMC Troubleshooting

Accelerator
The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

With the power switch OFF, connect a throttle module to the analyzer.
Position the power switch to the 6-11 volt range.
All but the power lamp should be OFF. If the FS-1, FS-3
or OV lamp (Over Voltage) are ON, then the module is
faulty.
Depress the lever on the module. The FS-1 lamp should
be ON with no more that a few degrees of rotation. If the
FS-1 lamp does not come on, then the module is faulty
(see note2 below).
The voltage on the digital display should vary with the
position of the module arm, starting at approximately 6-
volts and ending at approximately 11-volts.
If the module is equipped with the FS-3 switch, the FS-3
lamp should come ON when the module arm is rotated to
the full speed position. If the lamp does not come ON then
the module is faulty.
Note1: Current versions of the throttle module do not have the
additional switched output (FS-3 fully depressed). The
additional switched output was only used on PT-II control
systems and Power-Tron 240, 350, or 480 systems that were
equipped with the Power Plus module.
If the OV lamp comes ON at any time, then the module is faulty.
If the Low battery lamp is ON, then the analyzer battery should
be replaced.
Additional information regarding the analyzer can be found in the instructions
provided with the analyzer (D0-110-53)
If the module functions correctly with the analyzer but not on the vehicle it is likely
that there is a fault in the vehicle wiring.

NOTE2: Failures of the FS-1 circuit indicate a possible vehicle wiring fault that has resulted in
a short circuit across FS-1. BEFORE REPLACING THE MODULE: Confirm that there
are no shorts in the vehicle wiring or components. Installing a replacement module in
a vehicle with faulty wiring will burn out the new module.

Page 10
 Curtis PMC Troubleshooting

Key Switch
The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Test all interlock switches and/or interlock relays (if equipped) for continuity. Depending on the model of
your vehicle, it may have a seat interlock, Foot interlock, Charger interlock, special order interlock or any
combination of the above. Refer to the wire diagram at the end of this section for location of the interlocks.
NOTE: Due to the many different configurations possible for special order interlocks,
they will not be included in this text. Refer to the option list for your truck or
contact your Taylor-Dunn® Representative for more information.
If you do not know how to test for continuity, refer test to a qualified technician.

Connect a voltmeter across the HOT terminal of the key FLUKE 79 SERIES II MULTIMETER

View of the terminals of a

switch and battery negative. typical Key Switch
• If the voltage is not at battery volts then check the
OFF V
Hz

wire between the key switch and battery positive.

V

mV
KEY SWITCH
Stop trouble shooting here and repair the problem. A
"COLD, Violet Wire(s)"
When the repair is completed, completely retest the
vehicle before lowering the drive wheels to the
ground.
"HOT, Red wire(s)"

BATTERY MAIN NEGATIVE

Connect a voltmeter across the COLD terminal of the key
switch and battery negative.
Turn the key switch ON.
• If the voltage is not at battery volts then the key switch FLUKE 79 SERIES II MULTIMETER

View of the terminals of a

has failed. Stop trouble shooting here and repair the typical Key Switch
problem. When the repair is completed, completely OFF V
Hz

retest the vehicle before lowering the drive wheels

V

mV
KEY SWITCH
to the ground. A
"COLD, Violet Wires(s)"
• If the voltage is at battery volts but the previous test
at pin #4 in the Accelerator section failed then check
the wire from the key switch to pin #4 at the
accelerator module. Stop trouble shooting here and "HOT, Red wire(s)"
repair the problem. When the repair is completed,
completely retest the vehicle before lowering the BATTERY MAIN NEGATIVE
drive wheels to the ground.

Page 11
 Curtis PMC Troubleshooting

Forward and Reverse Side

For your reference, shown at the right are the Forward and KSI Side
White/Black
Reverse switch wire connections for a typical control system.
Violet/Black
Green/Black

Blue/Black
Typical configuration of the
terminals on a Forward and
Reverse Switch as viewed
from the back

Connect a voltmeter across the HOT terminal of the KSI The HOT terminal is the Violet/Black
side of the F&R switch and battery negative. wire on the center terminal
Turn the key switch ON.
• If the voltage is not at battery volts then go to the
Accelerator sequence.

Battery Negative

Connect a voltmeter across one of the COLD terminals of

the KSI side of the F&R switch and battery negative.
The COLD terminal is the
Close all interlock switches, turn the Key Switch ON, Violet/Black wire on either
and place the F&R Switch in Forward. end of the switch
• If the voltage is not at battery volts then the F&R
switch 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. Or,
• If the voltage is at battery volts and the test at the
PMC KSI terminal in the Control Wire Inputs section
failed then check the wiring between COLD terminals
of the KSI side of the F&R switch and the PMC KSI Battery Negative
terminal. 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.

Page 12
 Curtis PMC Troubleshooting

F/R switch
The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

Connect a voltmeter across the Solenoid Negative Buss Bar The voltage shown is for illustration
and battery positive. only. The actual voltage may vary.
FLUKE 79 SERIES II MULTIMETER

NOTE: You may skip this test if it was completed in a Solenoids are shown for reference only.
previous section OFF V The type of solenoid in your truck may
look different
Hz

Main Battery
• If the voltage is not at battery volts then check the
V

mV Positive
wiring to battery negative and the negative circuit
A

breaker. Stop trouble shooting here and repair the

problem. When the repair is completed, completely +
retest the vehicle before lowering the drive wheels - ISO
to the ground.
FWD/REV

Connect a voltmeter across the center terminal of the forward

and reverse side of the F&R switch and battery negative. The CENTER terminal is the
FLUKE 79 SERIES II MULTIMETER

Green/Black wire
Close all interlock switches, turn the Key Switch ON,
OFF
and place the F&R Switch in Forward. V
Hz

Depress the accelerator pedal fully. V

• If the voltage is not at battery volts then go to the mV

Accelerator sequence.
A

Battery Negative

Page 13
 Curtis PMC Troubleshooting

Connect a voltmeter across the forward terminal of the The FORWARD terminal is
forward and reverse side of the F&R switch and battery diagonally opposite the forward side
negative.
FLUKE 79 SERIES II MULTIMETER

of the rocker on the switch

Close all interlock switches, turn the Key Switch ON, OFF V
F&R switch seen from
and place the F&R Switch in forward. Hz

the side depressed in

V

Depress the accelerator pedal fully. the FORWARD gear

• If the voltage is not at battery volts then the F&R
mV

switch has failed. Stop trouble shooting here and A

repair the problem. When the repair is completed,

completely retest the vehicle before lowering the
drive wheels to the ground. F&R switch seen
Battery Negative from the rear

Connect a voltmeter across the reverse terminal of the

forward and reverse side of the F&R switch and battery
The REVERSE terminal is diagonally
negative. opposite the reverse side of the
Close all interlock switches, turn the Key Switch ON, FLUKE 79 SERIES II MULTIMETER

rocker on the switch

and place the F&R Switch in reverse.
Depress the accelerator pedal fully. OFF V
Hz
F&R switch seen from
the side depressed in
• If the voltage is not at battery volts then the F&R V

the REVERSE gear

switch has failed. Stop trouble shooting here and mV

repair the problem. When the repair is completed, A

completely retest the vehicle before lowering the

drive wheels to the ground.
• If all tests in this section were good then check the F&R switch seen
wiring from the F&R switch to the Forward and Battery Negative from the rear
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.

Page 14
 Curtis PMC Troubleshooting

Solenoids

The rear drive wheels may rotate during some of the following tests. Block the
front wheels, raise the rear drive wheels off the ground, and support the vehicle
with jack stands. Failure to do so may cause the vehicle to move and cause
severe bodily injury and/or property damage.
Rotating rear drive wheels are a potential hazard. Keep hands, arms, legs and
loose clothing away from the rear drive wheels while conducting tests. Failure
to do so may cause serious bodily injury.

1. Make sure the key-switch is in the “OFF” position, then remove the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

If the vehicle runs in forward only then skip ahead to the test sequence:
Forward (does not run in reverse).
If the vehicle runs in reverse only then skip ahead to the test sequence:
Reverse (does not run in forward).

Connect a voltmeter across the ISO solenoid COLD terminal

and battery negative. The voltage shown is for illustration
FLUKE 79 SERIES II MULTIMETER
only. The actual voltage may vary.
Close all interlock switches and turn the Key Switch
Solenoids are shown for reference only.
ON. OFF The type of solenoid in your truck may
V

Depress the accelerator pedal fully. Hz

look different
• If the voltage is at battery volts then the wire
V

mV

from the ISO solenoid to the PMC is bad. Stop

A

trouble shooting here and repair the problem.

When the repair is completed, completely retest +
the vehicle before lowering the drive wheels to _
ISO
the ground.
Battery Negative
FWD/REV

Connect a voltmeter across the ISO solenoid HOT terminal

and battery negative.
Close all interlock switches and turn the Key Switch
ON. The voltage shown is for illustration
Depress the accelerator pedal fully. FLUKE 79 SERIES II MULTIMETER
only. The actual voltage may vary.
• If the voltage is at battery volts then the ISO solenoid Solenoids are shown for reference only.
The type of solenoid in your truck may
has failed. Stop trouble shooting here and repair the OFF V
Hz
look different
problem. When the repair is completed, completely V

retest the vehicle before lowering the drive wheels mV

to the ground. A

• If the voltage is not at battery volts then check the +

wiring to battery positive and the main circuit breaker. _
Stop trouble shooting here and repair the problem. ISO
When the repair is completed, completely retest the Battery Negative
vehicle before lowering the drive wheels to the FWD/REV
ground.

Page 15
 Curtis PMC Troubleshooting

Forward (does not run in reverse)

The voltage shown is for illustration
Connect a voltmeter across the PMC KSI terminal and battery only. The actual voltage may vary.
negative.
Close all interlock switches, turn the Key Switch
ON, and place the F&R Switch in reverse.
• If the voltage is not at battery volts then go to
the Key Switch sequence.
+ KSI B- B+
_ #2
M-
A2
Main Battery Negative

Connect a voltmeter across the Reverse Solenoid coil

terminals. Refer to your vehicles wiring diagram to identify The voltage shown is for illustration
the position of the reverse solenoid. only. The actual voltage may vary.
Close all interlock switches, turn the Key Switch ON, Solenoids are shown for reference only.
and place the F&R Switch in reverse. The type and position of the reverse
Depress the accelerator pedal fully. solenoid in your truck may be different
• If the voltage is not at battery volts then go to the F/
R Switch sequence.
+
_
ISO

FWD/REV

Set the test light voltage to the same voltage as the battery Solenoids are shown for reference only.
volts. The type and position of the reverse
solenoid in your truck may be different
Connect the test light across the normally open contacts of
the reverse solenoid. Refer to your vehicles wiring diagram
to identify the position of the reverse solenoid.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in reverse.
Depress the accelerator pedal fully.
• If the light comes on then the Reverse solenoid 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. FWD/REV

Page 16
 Curtis PMC Troubleshooting

Connect the test light across the Normally Closed contacts

of the Forward solenoid. Refer to your vehicles wiring FWD/REV
diagram to identify the position of the forward solenoid.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in Reverse.
Depress the accelerator pedal fully.
• If the light comes on then the Forward solenoid has
failed. Stop trouble shooting here and repair the
problem. When the repair is completed, completely
retest the vehicle before lowering the drive wheels Solenoids are shown for reference only.
to the ground. The type and position of the forward
solenoid in your truck may be different

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Reverse (does not run in forward)

The voltage shown is for illustration
Connect a voltmeter across the PMC KSI terminal and battery only. The actual voltage may vary.
negative.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in forward.
• If the voltage is not at battery volts then go to the
Key Switch sequence.
+ KSI B- B+
_ #2
M-
A2
Main Battery Negative

Connect a voltmeter across the Forward Solenoid coil

terminals. Refer to your vehicles wiring diagram to identify The voltage shown is for illustration
the position of the forward solenoid. only. The actual voltage may vary.
Close all interlock switches, turn the Key Switch ON, Solenoids are shown for reference only.
and place the F&R Switch in forward. The type and position of the forward
solenoid in your truck may be different
Depress the accelerator pedal fully.
• If the voltage is not at battery volts then go to the F/
R Switch sequence.
+
_
ISO

FWD/REV

Page 17
 Curtis PMC Troubleshooting

Set the test light voltage to the same voltage as the battery
volts. Solenoids are shown for reference only.
The type and position of the forward
Connect the test light across the Normally Open contacts solenoid in your truck may be different
of the Forward solenoid. Refer to your vehicles wiring
diagram to identify the position of the forward solenoid.
Close all interlock switches, turn the Key Switch
ON, and place the F&R Switch in forward.
Depress the accelerator pedal fully.
• If the light comes on then the Forward solenoid
has failed. Stop trouble shooting here and repair
the problem. When the repair is completed,
completely retest the vehicle before lowering the FWD/REV
drive wheels to the ground.

Set the test light voltage to the same voltage as the battery
volts. FWD/REV
Connect the test light across the Normally Closed contacts
of the Reverse solenoid. Refer to your vehicles wiring
diagram to identify the position of the Reverse solenoid.
Close all interlock switches, turn the Key Switch ON,
and place the F&R Switch in Forward.
Depress the accelerator pedal fully.
• If the light comes on then the Reverse solenoid has
failed. Stop trouble shooting here and repair the
Solenoids are shown for reference only.
problem. When the repair is completed, completely The type and position of the reverse
retest the vehicle before lowering the drive wheels solenoid in your truck may be different
to the ground.

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 18
 Curtis PMC Troubleshooting

SYMPTOM TROUBLESHOOTING GUIDE

This section is specific to the symptoms listed below. Each troubleshooting sequence assumes
that all listed symptoms are present. Do not use this section unless the truck has all listed
symptoms.

SYMPTOMS GO TO
Ø Runs slow in both directions plus high armature and field current in both
directions. NOTE: Armature and field current should be equal.
MOTOR

Ø Runs slow in both directions plus high armature current in both directions.
SOLENOIDS
NOTE: Field current will be very low.

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

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

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

Ø Full speed only. PMC CONTROL

Ø Does not run in either direction plus there is noise from motor (hum or whine)
PLUGGING DIODE
with high field current and low armature current.

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 accelerator
HPD
pedal.

Special Troubleshooting
Table of Contents
PMC CONTROL .................................................................... 22
PLUGGING DIODE .............................................................. 25
FREEWHEEL DIODE ........................................................... 26
ISO ........................................................................................... 27
SOLENOIDS .......................................................................... 29
MOTOR .................................................................................. 32

Page 19
 Curtis PMC Troubleshooting

PMC CONTROL

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Disconnect the wire from the ‘M-’ terminal on the

PMC control and tape it off to prevent electrical
contact. Connect a volt meter across the PMC #2 The voltage shown is for illustration
terminal and battery negative. only. The actual voltage may vary.
Turn the key-switch on, close all interlock
switches (if equipped), depress the
accelerator pedal to engage the first micro
switch only (creep speed), then perform the
following tests:
+
• The meter reading should be between 6 _
KSI B- B+
#2
and 6.5 volts. M-
• If the voltage at pin #2 is not 6 to 6.5 volts, A2
then go to the ACCELERATOR sequence Main Battery Negative
in the Main Troubleshooting Sequence,
otherwise continue with the next test.

Page 20
 Curtis PMC Troubleshooting

Connect a volt meter across the PMC B+ and PMC

M- terminals.
The voltage shown is for illustration
Turn the key-switch on, close all interlock only. The actual voltage may vary.
switches (if equipped), depress the
accelerator pedal to engage the first micro
switch only (creep speed), then perform the
following tests:
• The meter reading should not be equal to + KSI B- B+
the battery voltage. _ #2

• If you have full battery voltage then the M-

PMC control is shorted and must be
A2
replaced. 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, otherwise continue with the next
test.

If the voltage at pin #2 is correct and the voltage at ‘M-’ is correct, then there is a short in the
harness between the wire connected to the PMC ‘M-’ and main battery negative. 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.

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 21
 Curtis PMC Troubleshooting

PLUGGING DIODE

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Remove the wires from the ‘B+’ and ‘A2’

FLUKE 79 SERIES II MULTIMETER

The reading shown is for illustration

terminals on the PMC control and perform the only. The actual reading may vary.
following test: OFF V
Hz

Using the diode test function on the DMM check V

for the presence of a diode across ‘B+’ and ‘A2’ mV

Ω
on the PMC control.. A

If you do not know how to test for a diode, refer +

test to a qualified technician. − KSI B− B +
• If the diode is open or shorted, then the #2
M − A2
PMC control must be replaced. 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.

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 22
 Curtis PMC Troubleshooting

FREEWHEEL DIODE

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Remove the wires from the ‘B+’ and ‘M-’

terminals on the PMC control and perform the
following test: The reading shown is for illustration
only. The actual reading may vary.
Using the diode test function on the DMM check
for 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, refer + KSI B- B+
test to a qualified technician. _ #2

• If the diode is open or shorted, then the M-

A2
PMC control must be replaced. 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.

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 23
 Curtis PMC Troubleshooting

ISO

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Remove the wires and the resistor from the ISO

solenoid and perform the following tests:
Test continuity across the ISO power contacts.
If you do not know how to test for continuity,
refer test to a qualified technician.
• This should be an open circuit. If it is not
an open circuit then the contactor should +
be replaced. Stop trouble shooting here -
ISO
and repair the problem. When the repair
is completed, completely retest the FWD/REV
vehicle before lowering the drive wheels
to the ground, other wise continue to the
next test.

Page 24
 Curtis PMC Troubleshooting

Connect the meter to each end of the resistor that

was removed from the ISO solenoid and measure Reading is plus or minus 10%
its resistance.
ISO solenoid is shown for reference
• The meter reading should be 250 Ohms only. The type of solenoid in your truck
(+/-10%). If it is not 250 ohms (+/-10%), may look different
then replace the resistor. 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. +
_

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 25
 Curtis PMC Troubleshooting

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 the
following tests.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

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 contact
with the frame or any other wire.
Reconnect the batteries.
With the key-switch on and the forward and reverse switch in neutral, perform the
following tests:
• Check continuity from the motor ‘A2’
terminal to the wire that was connected
to the motor ‘S1’ terminal. DO NOT make
this test to the ‘S1” terminal, just the wire.
Refer to Solenoid Figure 1.
S1
If you do not know how to test for continuity, A2

refer test to a qualified technician. S2

A1
• This should be an open circuit, if it reads
as a short, then one of the following has
occurred: +
Motor shown for reference _
A) The reverse solenoid is shorted. only. Terminal positions on
B) The wire connected to the motor ‘S1’ your motor may not be in the
terminal is shorted to the wire connected same location.
to the motor ‘A2’ terminal.
C) The wire connected to the motor ‘S1’
terminal is shorted to the wire connected to the PMC ‘A2’ terminal.

Page 26
 Curtis PMC Troubleshooting

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, otherwise continue with the
next test.
• Check continuity from the motor ‘A2’
terminal to the wire that was connected
to the motor ‘S2’ terminal. DO NOT make
this test to the ‘S2” terminal, just the wire.
If you do not know how to test for continuity, S1
A2
refer test to a qualified technician. S2

• This should read as an open circuit. If it A1

reads as a short then one of the following

has occurred: +
A) The forward solenoid is shorted. Motor shown for reference only. _
B) The wire connected to the motor ‘S2’ Terminal positions on your motor
may not be in the same location.
terminal is shorted to the wire connected
to 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, completely
retest the vehicle before lowering the drive wheels to the ground, otherwise continue with the
next test.
With the key-switch on and the F&R switch in forward, depress the accelerator pedal
and perform the following tests:
Check continuity from the wire that was
connected to the PMC ‘M-’ terminal to
the wire that was connected to the motor
Motor shown for reference only.
‘S2’ terminal. Terminal positions on your motor
If you do not know how to test for continuity, may not be in the same location.
refer test to a qualified technician.
• This should read as an open circuit. If it S1
A2
reads as a short, then one of the S2

following has occurred: A1

KSI

#2
B- B+
M-
A) The forward solenoid is shorted. A2
+
B) The wire connected to the PMC ‘M-’ _

terminal is shorted to the wire connected

to the motor ‘S2’ terminal.
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, otherwise
continue with the next test.

Page 27
 Curtis PMC Troubleshooting

With the key-switch on and the F&R switch in reverse, depress the accelerator pedal
and perform the following tests:
• Check continuity from the wire that was
connected to the PMC ‘M-’ terminal to the
wire that was connected to the motor ‘S1’ Motor shown for reference only.
terminal. Terminal positions on your motor
may not be in the same location.
If you do not know how to test for continuity, refer
test to a qualified technician.
• This should read as an open circuit. If it S1
A2
S2
reads as a short, then one of the following A1
KSI B- B+
#2
has occurred: M-
A2
A) The reverse solenoid is shorted. +
_
B) The wire connected to the PMC ‘M-’
terminal is shorted to the wire connected
to the motor ‘S1’ terminal.
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

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 28
 Curtis PMC Troubleshooting

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 will
not run unless the armature is manually rotated. If this symptom exists, it indicates that there
may be open segments in the armature. Visually inspect the brushes, if they are OK, continue
with the testing below.

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

the key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

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

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

Disconnect the four motor wires and perform the

following tests:
Check continuity from ‘A1’ to the frame of the
Motor shown for reference only.
motor.. Terminal positions on your motor
may not be in the same location.
If you do not know how to test for continuity, refer
test to a qualified technician.
• This should be an open circuit. If there is +
continuity from ‘A1’ to the frame of the _
motor, then the motor armature or S1
A2
armature circuit (brushes) are shorted. S2
Stop trouble shooting here and repair the A1
problem. When the repair is completed,
completely retest the vehicle before lowering
the drive wheels to the ground, otherwise
continue with the next test.

Page 29
 Curtis PMC Troubleshooting

Check continuity from ‘S1’ to the frame of the

motor.
Motor shown for reference only.
If you do not know how to test for continuity, Terminal positions on your motor
may not be in the same location.
refer test to a qualified technician.
This should be an open circuit. If there is
continuity from ‘S1’ to the frame of the +
motor, then the motor field is shorted. _
Stop trouble shooting here and repair the S1
A2
problem. When the repair is completed, S2

completely retest the vehicle before A1

lowering 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 melted
the 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 dark
brown to black or the insulation is cracked and peeling, then the armature has been
overheated 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 on
a single commutator segment. While holding the first test lead on the segment, check the
continuity to the other segments around the commutator.
If you do not know how to test for continuity,
refer test to a qualified technician.
• There should be continuity on each Commutator
commutator segment. If an open Hold this lead
segment is found, the armature is bad in place
and the motor must be replaced. Stop
Check each segment
trouble shooting here and repair the all of the way around +
problem. When the repair is completed, the commutator _
completely retest the vehicle before
lowering the drive wheels to the ground.

STOP
Stop, do not continue. If you reached this point without a solution, then you may have an
unanticipated problem or have made an error during testing. It is important to review the
trouble shooting steps that have led to this point. The tests may need to be repeated.

Page 30
Wire Diagrams
 The charger interlock is optional and may not be I Isolator solenoid or contactor coil F Forward solenoid or contactor coil
installed on your vehicle. If equipped with the
charger interlock option the interlock relay will 1 2
be located in the main charger cabinet or in a R Reverse solenoid or contactor coil BSI Battery Status Indicator
3 6
seperate module external of the charger.
Green 7 10
12v negative tap CB = CIRCUIT BREAKER R1=250 OHMS 5W RESISTOR
11
Red 14
Main Battery Positive 15 16
Black
Main Battery Negative
View from wire side
Forward/Reverse Switch Harness Connector
F Blue/Black
Green/Black Black 3 1
R White/Black White
To 12v negative tap 6 4
Green/Black MOTOR
KSI 9 7
Violet/Black
Violet/Black

B- B+ A2 A1
#2 A View from pin side
PMC CONTROL Accelerator Module Connector
Optional Rev Alarm wiring Charger
Interlock Relay
Contacts Violet/Black
M-

Red
A2 BL

Green
Violet/Black

Page 2
Key 10A

Black
Brake Light Switch Switch 135A
CB CB 10A
Orange CB
S2 S1 TAIL/STOP
Orange

Brown Red Yellow Blac LIGHT

k White

Red
Brown Light Switch

ck
Bla
White
Red

Red

Black
Violet/Black
Green/Black

Black
White

Red
Yellow/Black Blue

Black
White
Green
Black Horn Red
Switch

Wire Diagrams
Orange
Brown
White
Green

White
9 6 5 4 2 7
Blue
Orange/Black

Violet/Black

Violet/Black
9 6 5 4 2 7 Green R1

Green

Green

Orange/Black

Horn
13
15
MS2 Black
8
MS1 MS3 Orange/Black Orange/Black
10 R F I
Seat or Foot Blue/Black Blue/Black
6-11v out 5
PCB Interlock
White/Black 6 White/Black
Wire Diagrams

Green/Black 7 Green/Black
ACCELERATOR Black
Red Red
1
Black Black
Black BSI Blue
2
Blue
9
Red 14 Red
White White
4
White
Head Light 16
White/Black
3 Connect to Forward or Reverse (+) for motion alarm
11 Black
Black
12
Brown

White White Harness Connector White

Brown Brown
Orange Orange
Typical PMC control system Some components on diagram may not be installed on all vehicles
 Troubleshooting
Lestronic II Charger
TABLE OF CONTENTS

Operating Instructions and

Theory of Operation .........................2
Testing the Charging Cycle ....................3
Test Equipment Required for
Troubleshooting ..............................4
Important Notes and Instructions -------------------- 4
Troubleshooting for Built-in Charger .......5
Troubleshooting for Portable Charger ....8
Testing The Timer Relay ........................9
Testing the Interlock Relay .....................10

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

Rev E
 Electrical Troubleshooting

OPERATING INSTRUCTIONS AND THEORY OF OPERATION

The Lestronic II® chargers are designed as semiautomatic chargers. The Lestronic II® charger turns itself
on when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged into
the batteries. As the battery charges, the battery voltage rises. The charger periodically checks the battery
voltage and compares it to the previous reading. When the battery voltage stops rising a predetermined
amount, then the batteries are no longer accepting a charge and the charger shuts off. The charger will not
start again unless the AC cord on a “built-in” charger is disconnected from the wall outlet, or the DC plug on
a 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 batteries
require charging when it is connected. For this reason, it is recommended to discharge the batteries
approximately 50% (1175-1200 as indicated on a hydrometer) before connecting the charger. If the charger
is connected before the batteries are discharged 50%, the batteries may enter an overcharge state before
the charger can sense that the batteries are no longer accepting a charge. This could result in overcharging
and damaging the batteries.
The relay that operates the charger is powered by the batteries being charged. If the voltage on the
batteries to be charged is less than approximately 65% of the rated charger DC voltage, the relay will not
pick up and the charger will not turn on. In this situation, a manual charger would have to be used to bring
the battery voltage up so that the Lestronic® charger can sense that they are connected and turn itself on.

Not all chargers are equipped

with the lockout relay

Typical Charger Internal Wire Diagram

Charger Troubleshooting Page 2

 Electrical Troubleshooting

TESTING THE CHARGING CYCLE

In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the
battery 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 battery
voltage and the electrolyte specific gravity during the charging cycle as
indicated below.
Specific Gravity
Using a hydrometer take the specific gravity reading of several cells, at 1 hour intervals while charging. If
the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not
shut off, then the charger is running too long.
Battery Voltage
Using an accurate 5-1/2 digit digital voltmeter, monitor the battery voltage during the charging cycle. Take
readings every 30 minutes. If the battery voltage does not increase 0.012 volts in two consecutive readings,
then the charger is running too long.

Charger Troubleshooting Page 3

 Electrical Troubleshooting

TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING

Digital Multi Meter (DMM) with diode and capacitor test function, FLUKE 79® model
shown 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 with
any part of these tests, refer testing to a qualified 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 and no less than 80% discharged
as per hydrometer reading.
• The battery voltage must be above approximately 65% of the chargers rated DC voltage. If the batteries
are 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, then
proceed 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. Disconnect

both of the battery leads and unplug the charger from the AC source
before disconnecting any electrical component or wire. Failure to do
so may result in serious bodily injury.

Charger Troubleshooting Page 4

 Electrical Troubleshooting

TROUBLESHOOTING FOR BUILT-IN CHARGER

1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

5. Disconnect the charger from the AC source.

Locate the charger harness connectors where the charger harness is connected to the vehicle’s control
harness. 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:

Make sure that these two wires do not come into electrical contact
with any other object.

6. Test the voltage from the red wire to the main battery negative. This voltage should
be equal to the battery voltage. If the voltage is less than the battery voltage, then
this 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 (white
or 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 is
broken 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.

High Voltage. Do not touch the 14-gauge wires and make sure these
two wires do not come into electrical contact with any other object.
Failure to do so may result in serious bodily injury.

Re-Connect the charger to the AC source.

8. Test the voltage across the two 14 gauge wires. This voltage should be the same
as the voltage at the AC receptacle (rated voltage of the charger). If the voltage is
less than the rated AC voltage of the charger then the 14 gauge white or black
wire(s) is broken or has a bad connection between the charger connectors and
the AC plug. Stop here and repair the problem.

Charger Troubleshooting Page 5

 Electrical Troubleshooting

• Disconnect the charger from the AC source.

• Disconnect the batteries.
• Disconnect the charger from the vehicle’s harness.
• Remove the charger from the vehicle.

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor

before continuing. Connect a 2k ohm resistor across the capacitor
terminals for 10 seconds. Do not touch the capacitor terminals with
your hands. The resistor should be held with a pair of insulated pliers.
Failure to do so may cause serious bodily injury

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 capacitor
is bad, it must be replaced. Stop here and repair the problem.

Capacitor
Fuse Links

4. Reconnect the transformer lead to the capacitor

and disconnect one transformer lead from one
of the diodes. Test each of the diodes using
the diode test function of your meter. If either
one of the diodes are bad, replace the diode
assembly. 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 and
perform the following tests:

High Voltage inside the charger. Do not touch any internal components
while the charger is plugged in. Failure to do so may result in serious
bodily injury.

Charger Troubleshooting Page 6

 Electrical Troubleshooting

• Test the voltage from the fuse assembly (-) to the diode block (+).
This voltage should be equal to the battery voltage. If the voltage
is less than the battery voltage, then the wires from the harness
connectors to the charger are bad. Stop here and repair the
problem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltage
should be the same as the rated AC voltage of the charger. If the voltage is less than the rated AC
voltage of the charger, then the wires from the harness connectors to the charger are bad. Stop here
and repair the problem.

• If the timer relay does not pickup (click) when the AC source is connected, 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. The transformer primary consists of the two
solid wires with the brown fiber insulator that are connected to the timer board. This voltage should be
the same as the rated AC voltage of the charger. If the voltage is less than 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 low voltage secondary

circuit. The transformer low voltage secondary circuit can be
tested at the two solid wires with the brown fiber insulator that
are connected to the anodes on the two diodes. The voltage
here will vary depending on the state of charge in the batteries.
The voltage should be between 208% and 250% of the rated
DC voltage of the charger. If the voltage is not between 208%
and 250% of the rated DC voltage of the charger, the transformer
is bad and must be replaced. Stop here and repair the
problem.

Charger Troubleshooting Page 7

 Electrical Troubleshooting

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 main
battery negative. This voltage should be equal to the battery voltage. If the voltage
is 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 negative
terminal 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 terminal
of the DC receptacle is broken or has a bad connection. Stop here and repair the
problem.

Remove the charger cover and perform the following tests:

HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor

before continuing. Connect a 2k ohm resistor across the capacitor
terminals for 10 seconds. Do not touch the capacitor terminals with
your hands. The resistor should be held with a pair of insulated pliers.
Failure to do so may cause serious bodily injury

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 here
and repair the problem.

Capacitor Test
Fuse Links

4. Reconnect the lead to the capacitor and

disconnect one transformer lead from one of
the diodes. Test each of the diodes using the
diode test function on the meter. If either one of
the diodes are bad, replace the diode
assembly. Stop here and repair the problem.

Charger Troubleshooting Page 8

 Electrical Troubleshooting

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:

High Voltage inside the charger. Do not touch any internal components
while the charger is plugged in. Failure to do so may result in serious
bodily injury.

• Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the
battery voltage. If the voltage is less than the battery voltage, then the DC cord is bad. Stop here and
repair the problem.

• Test the voltage across the white and black wires that are connected to the timer board. This voltage
should be the same as the rated AC voltage of the charger. If the voltage
is less than the rated AC voltage of the charger then the AC cord is
bad. Stop here and repair the problem.

• If the timer relay does not pickup (click) within 5 seconds of connecting
the 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 voltage
should be the same as the rated AC voltage of the charger. If it is less
than the rated AC voltage of the charger, then the timer relay is bad.
Stop here and repair the problem.
Transformer Secondary Circuit
• Test the AC voltage across the transformer secondary circuit. The voltage here will vary depending on
the state of charge in the batteries. The voltage should be between 208% and 250% of the rated DC
voltage 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.

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).

Charger Troubleshooting Page 9

 Electrical Troubleshooting

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.

TESTING THE INTERLOCK RELAY

Operation
The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC
power source. When the charger is plugged in, the relay contacts open and break the Key Switch connection
to the speed controller. The Interlock Relay is available for built-in chargers only. Not all built-in chargers
are 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/Black
wires. If these wires are present then the charger is equipped with the Interlock Relay.
Testing

1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.

6. 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 for
charger troubleshooting. DO NOT continue until you have confirmed that the AC power source is
working.
• The DMM should indicate an open circuit. If it still indicates a closed circuit, then the relay or the
wires 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.

Charger Troubleshooting Page 10

 TABLE OF CONTENTS
Operating Instructions and Theory of
Operation ........................................2
HB/PT and GEL Indicator Lamps ...........3
Testing the Charging Cycle ....................3
Test Equipment Required for
Troubleshooting ...............................4
Important Notes and Instructions 4
Status LED Error Code Table ................5
Troubleshooting .....................................6

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

Rev H
 Electrical Troubleshooting

OPERATING INSTRUCTIONS AND THEORY OF OPERATION

The model HB600W ® and HB1000W ® chargers
are designed as semiautomatic chargers. The
charger turns itself on when it is plugged into the
wall outlet and turns off when the batteries are
fully charged.
Both the HB600W ® and HB1000W ® are two stage
chargers. The first stage is a constant current
mode. It Maintains a constant current until the
battery reaches a terminal voltage and then
switches to the second stage, constant voltage.
At the second stage the charger decreases the
charger current while holding the batteries at the
terminal voltage until the charging cycle is
complete.
The charger faceplate has three status LED’s that
monitor the charging status. Refer to the chart
and illustration below for the function of these
LED’s.
If an error occurs during charging, the charger
will beep, and display an error code by flashing
the status LED’s. Refer to the Status LED error
code table later in this section.

C h a r g in g S ta tus L e ft ( 5 0 % ) M id d le (7 5 % ) R ight (1 0 0 % )

0-50% F L A S H IN G OFF OFF

50% -75% ON F L A S H IN G OFF

75% -100% ON ON F L A S H IN G

C h a r g in g C y c le
ON ON ON
c o m p le te
E r r o r, r e fe r to
F L A S H IN G F L A S H IN G F L A S H IN G
tro u b le s h o o tin g

C h a r g e r T im e O u t OFF OFF F L A S H IN G

Signet Charger Troubleshooting

Page 2
 Electrical Troubleshooting

HB/PT AND GEL INDICATOR LAMPS

NOTE: Your charger may not be equipped with these lamps.
HB/PT Lamp
If the HB/PT lamp is “ON”, then the charger has overheated and
has entered a proportionally reduced output. The charging cycle
will terminate if the temperature continues to rise. If the charging
cycle is terminated, the charger will automatically restart once it
has cooled.
The charging cycle is limited to 18-hours. If the HB/PT lamp is
flashing, then the charging time has exceeded 18-hours (time is
limited to 18-hours). If any of the status lamps are flashing, then
the charge cycle did not complete.
GEL lamp
This LED will only be “ON” if the charger is configured for GEL
batteries. Using a GEL charger with non-GEL batteries may result
in an incomplete charge or long charge times.

GEL batteries must be charged with a charger configured for

GEL batteries. Use of any other charger will result in damage
to the batteries and premature failure of the batteries.

TESTING THE CHARGING CYCLE

In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the
batteries 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 table
on 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 during
the charging cycle as indicated below.
Using a digit digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during the
charging cycle. The charging current should remain within 10% of the DC output current (see previous
page) until the battery voltage reaches 2.55 volts per cell. When the voltage reaches 2.55 volts per cell, the
charging current will drop significantly and slowly taper off (voltage will remain constant). The charger
should turn off within 2 to 4 hours after entering the second stage.

Signet Charger Troubleshooting

Page 3
 Electrical Troubleshooting

TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING

Digital Multi Meter (DMM), FLUKE 79® model shown at right and in the troubleshooting
illustrations.
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 a qualified 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.
• 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.

This charger is rated for 115 VAC or 230 VAC operation. When switching
from one input voltage to the other, wait until all three status LED’s
are off. Switching voltage when any of the LED’s are on will result in
damage to the charger.

OR - DU
YL N
A
N
T

R
Th e B e s t W

in e s s
Bu s

y
ur

Yo
a

To
Go A b o u t

Signet Charger Troubleshooting

Page 4
 Electrical Troubleshooting

STATUS LED ERROR CODE TABLE

There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current
operating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in the
charging cycle. See the table below for an explanation of the error codes:

Note: If only the 100% LED is flashing and all others are OFF then the charger has exceeded its maximum charging
time and shut off before the batteries were fully charged.
This could be a result of:
• Defective battery or batteries
• Excessively discharged batteries
• Oversize batteries
Error
Description Action Required
Code
Reverse polarity or open circuit to Check wiring for corrosion, loose connections. broken wires and
1*
the batteries proper connection to the batteries

AC line voltate too high or too Check the input voltage.

2
low It must be within 96-132VAC or 196-266VAC

Wait for charger to cool, the charger will automaticaly restart. Inspect
3 Charger overheated
for 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

* - In many cases fault 1 will only be displayed for a short amount of time and then the charger will attempt to restart.
Typically, the fault will repeat 8-times and then the charger will start the boot up process with the 50% light on. If the
charger cannot restart then the fault loop will start again, repeating the fault 1.
This fault could be a result of an open connection between the charger and batteries, an open connection on one or more
of the battery cables, or an open connection internal of the charger.
Before replacing the charger, confirm all battery wiring is good.

Signet Charger Troubleshooting

Page 5
 Electrical Troubleshooting

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 voltage
mode. At this point the charging current will be reduced and will taper off until the batteries are fully
charged.
Perform the following if the charger does not turn on:

1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.

5. Disconnect the 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 at
the lower left of the charger circuit board.
This voltage should be equal to the battery
voltage. If the voltage is less than the battery
voltage, then the wires to the batteries have
been damaged. Stop here and repair the
problem.
8. Reinstall the charger end cap where the DC
wires enter.

9. Remove the charger end cap where the AC

wires enter.
10.Test the continuity of all three AC wires from
the circuit board to the AC plug. If you find
an open circuit in any one of the three wires
then the AC cord or plug has been
damaged. Stop here and repair the problem.
11.Install the charger end cap where the AC
wires enter.

If both the AC and DC tests are good then the charger has failed. There are no internally serviceable
components in the charger. If the charger has failed then it must be replaced.

Signet Charger Troubleshooting

Page 6
 Troubleshooting
Signet Charger
Charger Models:
HBS 600
HBS 1000
TABLE OF CONTENTS
Definitions: ............................................2
Test Equipment Required for
Troubleshooting ...............................2
Important Notes and Instructions 2
Operating Instructions and Theory of
Operation ........................................3
Testing the Charging Cycle ....................4

®
Status Light Error Code Table................5
Troubleshooting .....................................6

Turn the Key switch OFF BEFORE

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

GEL batteries must be charged with a charger configured for

GEL batteries. Use of any other charger will result in damage
to the batteries and premature failure of the batteries.

Rev C
 Electrical Troubleshooting

DEFINITIONS:
Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells.

Term Value Condition V1: Voltages are temperature compensated

V1: See Chart Flooded batteries relative to the temperature of the charger at the
2.383 Volts Per Cell Gel Batteries time the charge cycle is started.
V2: 2.08 Volts Per Cell All batteries
Starting V1 Volts
A1: 2 to 4 Amps All batteries
Temperature (C) Per Cell
All voltages are nominal. Less than -4 2.64
-4 to 2 2.61
2 to 8 2.59
8 to 14 2.56
14 to 21 2.54

This charger is rated for 115 VAC or 230 GEL batteries must be charged with a
VAC operation (nominal). When switching charger configured for GEL batteries. Use
from one input voltage to the other, wait of any other charger will result in damage
until all LED’s are off. Switching voltage to the batteries and premature failure of
when any of the LED’s are on will result in the batteries.
damage to the charger.

TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING

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 a
qualified 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.

Signet Charger Troubleshooting

Page 2
 Electrical Troubleshooting

OPERATING INSTRUCTIONS AND THEORY OF OPERATION

Typical specification plate

(reference only, specifications will vary for different chargers)

The model HBS 600W ® and HBS 1000W ® chargers are designed as automatic chargers. The charger turns
itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once the
charging cycle is complete, the charger will monitor the battery voltage. If the battery voltage drops below a
specific 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. It
Maintains a constant current until the battery reaches a terminal voltage (V1) and then switches to the second
stage, constant voltage. At the second stage the charger decreases the charger current while holding the
batteries at the terminal voltage until the charging cycle is complete. The charging cycle is complete when the
current 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.

Signet Charger Troubleshooting

Page 3
 Electrical Troubleshooting

TESTING THE CHARGING CYCLE

In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of
charge 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 time
limit. 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.
NOTE: This charger has a maintenance mode that will restart the charger if the battery voltage drops below a
threshold after the charge cycle is complete. In some cases, it may appear that the charger is not turning off due to
that the charger has restarted. Fully test the battery pack before assuming that the charger is not turning off or
running too long.

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 during
the charging cycle as indicated below.
Using a digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during the
charging cycle. The charging current should remain within 10% of the DC output current (see previous
page) until the battery voltage reaches V1. When the voltage reaches V1, the charging current will drop
significantly and slowly taper off (voltage will remain constant). The charger should turn off within 2 to 4
hours after entering the second stage when the charginc current is down to A1.

GEL batteries must be charged with a charger configured for

GEL batteries. Use of any other charger will result in damage
to the batteries and premature failure of the batteries.

OR - DU
YL N
A
N
T

R
Th e B e s t W

in e s s
Bu s

y
ur

Yo
a

To
Go A b o u t

Signet Charger Troubleshooting

Page 4
 Electrical Troubleshooting

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 light
is flashing, it will flash from 2 to 6 times before a pause. This is the fault code.
Refer to the table below.

Fault
Description Action Required
Code
1 Charge cycle time exceeded the time limit. Test batteries for possible
Time out
(no flash) defictive cells.

Open circuit or reverse polarity to

2* Check battery wiring.
battery

Wrong voltage charger or batteries installed.

24v charger: Battery voltage must be less than 33.7v
3* Battery voltage too high
36v charger: Battery voltage must be less than 43.2v
48v charger: Battery voltage must be less than 57.6v

Inspect for dirt or debris on the charger cooling fins and clean as
4 Overheated
required.

AC line voltate too high or too Check the input voltage.

5*
low It must be within 85-137VAC or 170-264VAC

Extremely discharged battery, defective battery, miswired battery.

When this fault occurs, the charger will operate in a low current mode
untill the battery voltage is built up. This fault will reset once the battery
6 Low battery voltage voltage 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 termintated
*
before completion.

Signet Charger Troubleshooting

Page 5
 Electrical Troubleshooting

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 this
point, the charging current will be reduced and will taper off until the batteries are fully charged. The
batteries 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 has
failed and must be replaced.
If the POWER light is OFF, then check the AC power source, AC power cable and connections. If the
source, cable and connections are good, then the charger has failed and must be replaced.

The charger comes equipped with a long fully insulated

AC cord that can be cut to length as needed for the
vehicle application. Do not cut the AC cord and splice
to the existing AC cord in the vehicle. Cutting and
splicing the AC cord will void the charger warranty

GEL batteries must be charged with a charger configured for

GEL batteries. Use of any other charger will result in damage
to the batteries and premature failure of the batteries.

OR - D U
YL N
A
N
T

R
Th e B e s t W

in e s s
Bu s

y
ur

Yo
a

To
Go A b o u t

Signet Charger Troubleshooting

Page 6
 Illustrated Parts
NOTE: Parts lists are for both the MX 1600 and B 1-50 unless otherwise
specified.

TABLE OF CONTENTS

Front Axle/Steering Knuckle ......................... 2 Speed Control Panel .................................... 26

Steering Linkage ......................................... 4 Miscellaneous Electrical .............................. 28
Steering Column .......................................... 6 Charger, Lestronic ....................................... 30
Steering Gear .............................................. 8 Charger, Signet ........................................... 32
Front Suspension ........................................ 10 Batteries...................................................... 34
Transmission Differential Case .................... 12 Seat Cushions, Deck and Lights, B 1-50 ...... 36
Rear Axle and Brakes .................................. 14 Seat Cushions, Deck and Lights, MX 1600 .. 38
Rear Suspension ......................................... 16 Decals, B 1-50 ............................................. 40
Motor .......................................................... 18 Fiberglass Cab, Doors, Mirrors .................... 42
Brake and Accelerator Pedal and Linkage .... 20 Strobe Light ................................................. 44
Wheels and Tires ........................................ 22 Stake Sides, B 1-50 ..................................... 46
Instrument Panel (dash) .............................. 24 Hydraulic Brake Lines and Fittings (optional) 48
 Illustrated Parts

Front Axle/Steering Knuckle

3 4

2
20

19

}
Large Cup
Steel Washer
Bronze washer 8
Steel Washer
Small Cup

16

18
15 9
12
7
10
11
10
12
17
13
14

PARTS PAGE 2
 Illustrated Parts

Front Axle/Steering Knuckle

ITEM # PART # DESCRIPTION QTY
15-200-40 Complete Front Axle Assembly. Includes Hubs, Tire Rod and Spring (no brakes)
00-240-21 Complete Front Axle Assembly. Includes Hubs, Tire Rod and Spring (Disc brakes)
14-240-06 Left Steer Knuckle, no brake 1
1
14-240-04 Left Steer Knuckle, disc brake 1
2 21-009-10 King Pin 2
01-240-74 Axle Beam . Includes #19 and #20 (no brakes) 1
3
01-240-75 Axle Beam . Includes #19 and #20 (disc brakes) 1
14-240-05 Right Steer Knuckle, no brake 1
4
14-240-03 Right Steer Knuckle, disc brake 1
5 - - -
6 - - -
7 87-074-00 Grease Fitting 2
8 80-309-10 Thrust Bearing 2
9 45-338-00 Grease seal 2
10 80-103-00 Race 4
12-124-00 Hub (includes #9, #10 and 1 of #12) 2
11
12-158-10 Hubwith disc rotor (includes #9, #10 and 1 of #12) 2
12 80-017-00 Bearing 4
13 88-239-85 3/4-NF Castle Nut 2
14 92-104-00 Bearing cover 2
15 88-527-14 1/8 x 1-1/2 Cotter Pin 2
16 88-289-81 7/8-NF Thin Pattern Hex Locknut 2
17 88-228-61 3/4-SAE Flat Washer 2
18 97-236-00 Wheel Nut 10
19 32-204-00 King Pin Bushing 2
20 32-200-00 King Pin Bushing 2

PARTS PAGE 3
 Illustrated Parts

Steering Linkage

6
14 13

12 1

Ref., Arm on Left Steering knuckle

7 15 11 17 5

16
6

15

7
Ref., Stering Gear

Ref., Arm on Right Steering knuckle

3 9 3 8
10

PARTS PAGE 4
 Illustrated Parts

Steering Linkage
ITEM # PART # DESCRIPTION QTY
1 86-518-01 Rod end (LH) 1
2 -- - -
3 86-510-00 Ball Joint Clamp 2
4 - - -
5 50-002-03 Drag Link 1
6 88-119-81 3/8-NF Hex Locknut 2
7 88-159-85 1/2-NF Hex Castle Nut 2
8 86-501-98 Ball Joint (left thread) 1
9 18-041-05 Tie Rod Sleeve (18-057-20 assembled with ball jointsand clamps) 1
10 86-501-99 Ball Joint (right thread) 1
11 86-518-00 Rod End (RH) 1
12 88-279-82 7/8-NF Hex Jam Nut 1
13 18-640-00 Pitman Arm 1
14 88-268-62 7/8 Split Lock Washer 1
15 88-527-11 1/8 x 1 Cotter Pin 2
16 97-202-50 3/8-NF Left Thread Nut 1
17 88-119-80 3/8-NF Hex Nut 1

PARTS PAGE 5
 Illustrated Parts

Steering Column

2
The steering column is an
integral part of the frame and is
not shown. Part ID# 5 is located 10
in the top of the steering column
tube.
5

4
Ref., Steering Gear
3

PARTS PAGE 6
 Illustrated Parts

Steering Column
ITEM # PART # DESCRIPTION QTY
1 88-199-82 5/8-NF Hex Jam Nut 1
2 19-011-20 Steering Wheel 1
3 88-081-14 Bolt, Plated (grade 8) 1
4 88-089-84 Nut, Plated (grade 8) 1
5 80-400-10 Bushing 1
6 20-031-64 Steering shaft (includes #3, #4) 1
7 19-011-25 Steering Wheel Cover 1
8 88-128-62 7/16 Split Lock Washer 3
9 88-120-15 7/16-NC x 1-1/2 Hex Bolt, Grade 5 3
10 97-200-00 Dust Wasjer 1
Not Shown 01-200-84 Steering Column Cover 1

PARTS PAGE 7
Illustrated Parts

Steering Gear
15

16
1

14

17
3 13
2

12

11

10

5
6

See steering linkage

PARTS PAGE 8
 Illustrated Parts

Steering Gear
ITEM # PART # DESCRIPTION QTY
18-308-21 Steeering Gear Assembly 1
1 18-308-70 Locking Ring 1
2 18-308-71 Adjuster 1
3 18-308-72 Worm Shaft/Ball Nut Assembly 1
4 18-308-23 Upper Worm Shaft Bearing 1
5 18-308-22 Upper Worm Shaft Cup 1
6 18-308-77 Housing 1
7 18-308-78 Pinion Shaft Seal 1
8 - - -
9 - - -
10 18-308-79 Worm Shaft Seal 1
11 18-308-82 Gasket 1
12 18-308-76 Pinion Shaft 1
13 18-308-75 Gear Lash Adjuster 1
14 18-308-84 Side Cover 1
15 18-308-86 Lock Nut 1
16 18-308-83 Side Cover Screws 3
17 18-308-85 Shim Kit 1

PARTS PAGE 9
 Illustrated Parts

Front Suspension

4 8 9

3 10
7
2

12

11

PARTS PAGE 10
 Illustrated Parts

Front Suspension
ITEM # PART # DESCRIPTION QTY
1 87-074-00 Grease Fitting 2
2 96-248-01 Spring Eye Bolt (includes #1) 2
3 32-213-00 Spring Eye Bushing 2
4 88-169-82 9/16-NF Lock nut, Grade C 2
5 85-506-05 Leaf Spring (includes #3) 2
6 96-118-00 1/2-NC x 1.87 x 6.5L U-bolt 2
7 96-123-00 3/8-NC x 2.06 x 4L U-bolt 4
8 88-149-81 1/2-NC Lock nut 4
9 16-872-03 Shackle Strap 2
10 01-200-63 Spring Support 2
11 88-109-81 3/8-NC Locknut 8
12 16-865-06 Spring Plate 2

PARTS PAGE 11
 Illustrated Parts

Transmission Differential Case

1

2
3
6
7 4
5

15
3

9
10
3

9
5
8 6

14
3
11
10 5
6
16 7

11

13

17 12

PARTS PAGE 12
 Illustrated Parts

Transmission (Dana Spec# 012AJ310-1)

ITEM # PART # DESCRIPTION QTY
4C-150-00 Complete Transmission Assembly Including Mechanical Brakes
4C-150-10 Complete Transmission Assembly Including Hydraulic Brakes
1 Special order Housing 1
2 80-480-10 Inner Input Shaft Bearing 1
3 31-265-00 Gear set 1
4 80-480-15 Outer Input Shaft Bearing 1
5 88-840-12 Snap Ring 3
6 Special order O-ring 3
7 Special order Bore Plug 2
8 66-610-35 Intermeadiate Shaft Bearing 2
9 80-715-00 O-ring 2
10 80-480-00 Differential Bearing 2
11 96-330-10 Bearing Cap Screw 2
12 41-127-94 Fill/Drain Plug 1
13 Special order Gear Case Cover 1
14 66-610-04 Differential 1
15 Special order Bolt, Final Gear 4
16 Special order Nut, Final Gear 4
17 66-610-68 Bolt, Cover Plate 10

PARTS PAGE 13
Illustrated Parts

Rear Axle and Brakes

Ref., Transmission housing

2
3
4
16
1
5
7
10
6
11

14

19
15

9
8
18
12

17

13

PARTS PAGE 14
 Illustrated Parts

Rear Axle and Brakes

ITEM # PART # DESCRIPTION QTY
41-347-98 Complete Brake Assembly (left), includes 1, 5, 7, 9, 10, 11, 12, 16 1
41-347-99 Complete Brake Assembly (right), includes 1, 5, 7, 9, 10, 11, 12, 16 1
1 41-347-15 Brake Arm 2
2 45-303-00 Seal 2
3 32-509-10 Bearing retainer 2
4 80-505-10 Bearing/Race assembly 2
5 41-347-00 Backing Plate 2
6 45-303-10 Dust seal 2
41-347-25 Spider, Mechanical Brake 2
7
41-347-27 Spider, Hydraulic Brake 2
8a 41-171-10 Axle shaft (right), does not include #17 wheel stud 1
8b 41-170-10 Axle Shaft (Left), does not include #17 wheel stud 1
9 85-215-00 Spring 2
10a 85-411-10 Spring (green) 2
10b 85-411-15 Spring (red) 2
11 41-635-00 Brake Shoe Set (1-wheel) 2
12 41-347-31 Adjusting Screw 2
13 41-516-00 Brake Drum 2
14 66-610-79 Bolt 8
15 66-610-80 Nut 8
16 41-347-34 Hairpin Clip 4
17 66-610-28 Wheel Stud 10
18 41-347-33 Adjusting Screw Nut 2
19 41-347-30 Adjusting Screw Socket

PARTS PAGE 15
 Illustrated Parts

Rear Suspension

4
Ref., Frame
1

4 Ref., Transmission axle tube

PARTS PAGE 16
 Illustrated Parts

Rear Suspension
ITEM # PART # DESCRIPTION QTY
1 88-140-17 Bolt 4
2 85-506-10 Leaf Spring (includes #7) 2
3 96-118-00 U-bolt 2
4 88-149-81 Nut 8
5 96-248-01 Spring Bolt 2
6 01-200-62 Spring Support 2
7 32-213-00 Spring Eye Bushing 2
8 88-169-82 Nut 2

PARTS PAGE 17
Illustrated Parts

Motor

8
7

4
3

10
9

Armature

PARTS PAGE 18
 Illustrated Parts

Motor GE spec#BC58JBS6129A
ITEM # PART # DESCRIPTION QTY
70-049-05 Complete Motor Assembly
1 70-201-15 Field Coil/Stator Assembly 1
2 70-210-51 Insulator 2
3 85-412-00 Brush Spring 4
4 70-172-15 Brush Holder (includes #3) 1
5 70-104-15 Brush Pair 2
6 70-210-51 Insulator 2
7 32-508-15 Bearing Retainer 1
8 80-209-00 Bearing 1
9 70-049-06 Rubber Bushing 1
Not Shown 88-060-12 1/4-NC x 1-1/8 Motor Mounting Bolt 3
Not Shown 88-068-62 1/4 Split Lock Washer 3

PARTS PAGE 19
 Illustrated Parts

Brake and Accelerator Pedal and Linkage

30 1 19, 10
33 Transmission
15 21
2
3
6
7
10

32 9
31
24
Accelerator 14
22
Module Arm 11
10 7

4
5
19

6 6
7 8
8
12
Ref., frame 13
25
19 Crosshaft Arm 'A'
To
Cro 7 8 10
ssh 6 19
aft
arm
'A' 10
29
10
26 18 19
10 19
29
21
22
28 19 17
18 23
27 20
19 24
29 10
18 14 Ref., frame
19

PARTS PAGE 20
 Illustrated Parts

Brake and Accelerator Pedal and Linkage

ITEM # PART # DESCRIPTION QTY
1 98-200-00 Brake Pedal Pad 1
2 01-432-98 Brake Pedal 1
3 88-089-81 Nut 1
4 88-080-11 Bolt 1
5 00-200-45 Brake Pedal Arm 1
6 80-410-20 Bushing 4
7 88-109-81 Nut 8
8 88-100-09 Bolt 8
9 01-200-49 Brake Cable Mounting Bracket 2
10 88-517-11 Cotter Pin 8
11 96-818-10 Brake Cable 1
12 85-250-00 Spring 1
13 00-200-49 Brake Cross Shaft 1
14 00-200-48 Park Brake Linkage 1
15 88-065-09 1/4-NC x 3/4 Truss Head Machine Screw 3
16 - - -
17 50-002-01 Brake Rod 1
18 88-099-80 Nut 2
19 96-773-00 5/16 x 1 Clevis Pin 7
20 01-200-47 Brake Equalizer 1
21 96-826-09 Cable Lock 4
22 96-826-12 Brake Cable 2
23 88-847-06 E-clip 2
24 96-754-00 Brake Cable Clevis 4
25 51-344-80 Park Brake Handle 1
26 88-080-11 Bolt 2
27 88-089-81 Nut 2
28 88-088-61 Flat Washer 2
29 96-763-00 Clevis 3
31 88-069-81 1/4-NC Nylon Locknut 3
32 98-254-25 Accelerator Pedal Mounting Bracket 1
33 98-254-00 Accelerator Pedal 1

PARTS PAGE 21
Illustrated Parts

Wheels and Tires

Ref., wheel hub

9 1

7
3

5 (assembly)

PARTS PAGE 22
 Illustrated Parts

Wheels and Tires

ITEM # PART # DESCRIPTION QTY

1 Tubeless Wheels
12-012-00 5 x 8" Tubeless (standard) 4
12-020-00 8.5 x 8 Tubeless 4

2 Tires
10-081-00 5.70 x 8 (standard) 4
10-082-00 5.70 x 8 Extra Grip 4
10-083-00 5.70 x 8 LR C 4
10-093-00 8.50 x 8 LR B 4
10-091-10 8.50 x 8 Knobby 4
10-092-00 8.50 x 8 LR C 4
10-086-00 5.00 x 8 Man-Toterswith lugs (soft solid) 4

Split Rim Wheels

3 12-041-12 Inner Wheel (2.5 bead) 4
4 12-041-13 Outer Wheel (2.5 bead) 4
5 12-041-00 Wheel Assembly, 2.5 bead width (includes #3, #4, #6, #7, #8) 4
3a 12-042-12 Inner Wheel (12-bolt) 4
4a 12-042-13 Outer Wheel (12-bolt) 4
5a 12-042-00 Wheel Assembly, 3.75 bead width (includes #3a, #4a, #6, #7, #8 4
6 88-110-09 3/8 x 3/4-NF Hex Bolt, grade 5 4
7 88-109-62 3/8 Split Lock Washer 4
8 88-119-80 3/8-NF Hex Nut 4

9 97-236-00 Wheel Nut 20

Not Shown 13-989-00 Valve stem, tubless tire only
Not Shown 11-041-00 8.50 x 8 Tube
Not Shown 11-040-00 5.70 x 8 Tube

Tire and Wheel Assemblies

13-742-00 5.70 x 8 (standard) 4
13-742-40 5.70 x 8 Man-Toter
13-742-11 5.70 x 8 Split Rim
13-746-10 8.50 x 8

PARTS PAGE 23
Illustrated Parts

Instrument Panel (dash)

PARTS PAGE 24
 Illustrated Parts

Instument Panel (dash)

ITEM # PART # DESCRIPTION QTY
1a 95-913-00 Hole Plug 1
1b 71-100-00 Toggle Switch Option
2 71-039-11 Rocker Switch (ON-OFF) 1
3 88-817-08 Screw 8
4 74-000-00 Hour Meter 1
5 01-200-75 Dash Housing 1
6 74-009-00 Battery Status Meter 1
7 94-304-10 Dash Plate 1
8 71-039-02 F&R Switch 1
9 71-120-00 Key Switch, keyed alike (standard) 1
9a 71-121-00 Key Switch, keyed unalike Option
10 71-120-80 Extra Keys for #9 (71-120-00)
11 71-039-20 Hole Plug 2
Not Shown 71-501-00 Horn Switch Option
Not Shown 88-060-09 Dash mounting bold 2
Not Shown 97-211-20 U-nut for Dash Mounting Bolt 2

PARTS PAGE 25
 Illustrated Parts

Speed Control Panel

1 Typical Control Panel

The control panel in your vehicle
1
may be layed out differently
18
2
17 3

16

4
15
5

14

9
13
10
20
12 11

PARTS PAGE 26
 Illustrated Parts

Speed Control Panel

ITEM # PART # DESCRIPTION QTY
62-019-00 Complete Control Panel Assembly 1
1 88-838-06 #14 x 1/2 Pan Head Screw Type D Thread 10
2 62-204-00 PMC Speed control 1
3 72-501-39 Solenoid (forward or reverse) 2
4 61-838-41 Bus Bar 2
5 88-088-62 5/16 Split Lock washer 10
6 88-099-91 5/16-NF Thin Pattern Nut 10
7 88-048-62 #10 Split Lock Washer 3
8 88-049-80 10-32 Hex Nut 3
9 61-838-42 Bus Bar 2
10 72-501-38 ISO Solenoid 1
11 79-840-00 Small Circuit Breaker 2
12 79-844-00 Large Circuit Breaker 1
13 88-080-11 5-16-NC x 1 Hex Bolt 4
14 01-534-80 Mounting Panel 1
15 73-004-20 Horn 1
16 88-088-62 5/16 Split Lock Washer 4
17 88-089-80 5/16-NC Hex Nut 4
18 88-818-06 #8 x 1/2 Pan Head Screw Type B Thread 4
19 88-817-09 #8 x 3/4 Phillips Head Sheet Metal Screw 2
20 78-302-50 250 ohm 5W resistor 1
Not Shown 88-060-09 1/4-NC x 3/4 Pamel Mounting Bolt 3
Not Shown 88-069-81 1/4-NC Nylon Locknut (panel mounting) 3
Not Shown 75-148-25 Control Panel Harness 1

PARTS PAGE 27
Illustrated Parts

Miscellaneous Electrical
Accelerator Module

12
Seat
Frame
11
2 1
Motion Alarms
10

14

17 13

Seat Interlock Switch

16
18 Floorboard 6

15

2 3 7

Horn Switch Mounted

Miscellaneous Wire Harness Clamps

Mechanical Brake Light Switch

Mounted Under Floorboard

PARTS PAGE 28
 Illustrated Parts

Miscellaneous Electrical
ITEM # PART # DESCRIPTION QTY
Not Shown 75-148-79 Chassie Control Harness 1
Not Shown 75-149-79 Power Harness, B 1-50 1
Not Shown 75-149-82 Power Harness, MX 1600 1
Not Shown 98-599-15 Plastic grommet for 1.75 hole
Not Shown 98-599-20 Plastic Grommet for 2.5 hole
Not Shown 75-114-20 Windsheild Wiper Harness 1
Not Shown 75-148-81 Headligh Harness 1
Not Shown 75-148-80 Harness for Pole Mounted Strobe Light 1
Not Shown 75-107-10 Potratble Charger Harness 1
Not Shown 76-013-00 Portable Charger Receptacle 1
1 73-005-05 Reverse Warning alarm 1
2 96-650-01 Wire Harness Clip, stick on
3 96-642-00 Wire ahrness Clip, push mount
4 62-033-00 Accelerator Module 1
5 71-122-20 Horn Switch 1
6 88-065-06 1/4-NC x 21/2 Phillips Truss Head Screw, Horn Switch 2
7 88-069-81 1/4-NC Hex Nylon Locknut, Horn Switch 2
8 71-111-00 Brake Light Switch 1
9 88-045-06 10-32 x 1/2 Machine Screw, brake light switch 2
10 71-102-10 Seat interlock Switch 1
11 85-030-00 Spring 2
12 96-773-00 Clevis Pin 2
13 02-610-18 Mounting Plate 1
14 88-527-11 Cotter Pin 2
15 96-640-00 Clamp, 3/16 Push Mount
96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID
96-630-00 (not shown Clamp, Rubber Lined 5/8 ID
96-630-50 (not shown Clamp, Rubber Lined 5/8 ID (.265 mounting hole)
16
96-631-00 (not shown Clamp, Rubber Lined 3/4 ID
96-631-10 (shown) Clamp, Rubber Lined 1.0 ID
96-631-15 (not shown Clamp, Rubber Lined 1-1/2 ID
96-624-00 Clamp, 1/4 Jiffy Clip
17
96-625-00 (not shown) Clamp, 5/16 Jiffy Clip
18 96-626-00 Clamp, 7/8 Jiffy Clip

PARTS PAGE 29
 Illustrated Parts

Charger, Lestronic
2

7
5 3
11

6 4

8
1
BI_CHARGER W-INTERLOCK.DWG

Charger Identification

PARTS PAGE 30
 Illustrated Parts

Charger Lester Model# 22740

ITEM # PART # DESCRIPTION QTY
79-303-15 Complete Charger Assembly
1 79-805-67 Timer Assembly 1
1a 79-808-00 Timer Relay (not shown)
2 79-902-00 Capacitor 1
3 79-749-13 Diode Assembly 1
4 79-644-31 Transformer 1
5 * AC cord
6 * Strain Releif
7 79-831-00 Fuse 1
8 79-530-00 Strain Releif 1
9 -
10 -
11 79-809-60 Interlock Relay 1

Charger Lester Model# 11860-225(export)

ITEM # PART # DESCRIPTION QTY
79-304-65 Complete Charger Assembly
1 79-805-82 Timer Assembly 1
1a Special Order Timer Relay (not shown) 1
2 79-902-00 Capacitor 1
3 79-745-10 Diode Assembly 1
4 Special order Transformer 1
5 * AC cord
6 * Strain Releif
7 79-831-00 Fuse 1
8 79-530-00 Strain Releif 1
9 -
10 -
11 79-306-23 Interlock Relay 1

*- See Seat Cushions, Deck and Lights

PARTS PAGE 31
 Illustrated Parts

Charger, Signet

Model HBS series charger shown

Model HBS for Flooded Batteries Model HB for Flooded Batteries

PART # DESCRIPTION PART # DESCRIPTION
* 24 volt Charger Assembly (see note) 79-302-20 24 volt Charger Assembly (see note)
79-303-41 36 volt Charger assembly (see note) 79-303-40 36 volt Charger assembly (see note)
79-309-42 48 volt charger assembly (see note) 79-309-40 48 volt charger assembly (see note)

Model HBS for GEL Batteries Model HB for GEL Batteries

PART # DESCRIPTION PART # DESCRIPTION
* 24 volt Charger Assembly (see note) * 24 volt Charger Assembly (see note)
* 36 volt Charger assembly (see note) K4G-CH-003 36 volt Charger assembly (see note)
* 48 volt charger assembly (see note) 79-309-41 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. When
replacing the charger, do not cut and splice the AC cord. Cutting
the AC cord will void the charger warranty.
NOTE: The Signet model HBS series charger replaces all previous Signet
models.
NOTE: The harness connectors and AC plug are not included
with 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

PARTS PAGE 32
 Illustrated Parts

This page intentionaly left blank

PARTS PAGE 33
Illustrated Parts

Batteries

4
3

1
POS

POS

POS

NEG
NEG

NEG
NEG

NEG

NEG
POS

POS

POS

Main battery
negative

9
12v tap
Main battery 5
6 and 7 (hardware)
positive

PARTS PAGE 34
 Illustrated Parts

Batteries
ITEM # PART # DESCRIPTION QTY
1 50-243-10 Battery Hold Down Rod 3
2 50-250-00 Bat-Lok 3
3 88-088-66 Flat Washer 3
4 88-069-81 Nut 3
5 75-235-08 Battery Jumper 5
6 88-081-12 Bolt 12
7 88-089-80 Nut 12
8 - -
9 77-042-00 T 105, 217AH Battery (standard) 6
77-042-50 TD217, 217AH Battery
77-042-80* 217AH Moist Charge
77-044-00 T 125, 230AH Battery
77-047-00 T 145, 244AH Battery
77-047-50 TD 250, 250AH Battery
77-047-80* 244AH Moist Charge
77-048-00 J250, 250AH Battery
77-048-80 J250, 250AH Moist Charge
Not Shown 77-055-01 Low Level Electrolyte Alarm

*- Moist charge batteries must be filled with battery electrolyte before being put into service.

PARTS PAGE 35
Illustrated Parts

Seat Cushions, Deck and Lights, B 1-50

PARTS PAGE 36
 Illustrated Parts

Seat Cushions, Deck and Lights, B 1-50

ITEM # PART # DESCRIPTION QTY
1 72-005-00 Head Light Assembly 1
1a 72-072-00 Replacement Bulb only 1
Not Shown 98-603-00 Wiring Grommet 1
2 94-201-00 T/D Emblem 1
2a 88-567-91 Emblem Mounting Clips 3
3 94-035-01 Cowl Moulding 8'
4 90-147-00 Seat Cushion 2
5 90-179-00 Seat Backrest 1
Not Shown 88-837-09 Backrest Mounting Screws 6
6 90-444-50 Deck Board (standard) 1
6 * Deck Board (Cab) 1
7 94-035-01 Seat Back Moulding 7
8 79-575-30 Charger AC Cord 1
8a 79-511-00 Mounting Bracket 1
8b 88-065-06 Mounting Bracket Screws 2
8c 88-069-81 Mounting Brackt Nuts 2
8e 79-530-00 AC Cord Strain Releif 1
8f 76-200-00 Replacement AC Plug only 1
Not Shown 72-022-00 Tai light (includes mounting grommet and pigtail) 1
Not Shown 72-022-51 Tail light mounting grommet 1
Not Shown 72-022-52 Tail light pigtail 1

*- For fiberglass cab option, order standard deck board (#6) and cut to 60-3/8 inches long.

PARTS PAGE 37
Illustrated Parts

Seat Cushions, Deck and Lights, MX 1600

PARTS PAGE 38
 Illustrated Parts

Seat Cushions, Deck and Lights, MX 1600

ITEM # PART # DESCRIPTION QTY
1 See B 1-50 Head Light Assembly 1
1a See B 1-50 Replacement Bulb only 1
Not Shown See B 1-50 Wiring Grommet 1
2 See B 1-50 T/D Emblem 1
2a See B 1-50 Emblem Mounting Clips 3
3 See B 1-50 Cowl Moulding 8'
4 See B 1-50 Seat Cushion 2
5 See B 1-50 Seat Backrest 1
Not Shown See B 1-50 Backrest Mounting Screws 6
6 90-443-10 Deck Board (front) 1
6a 90-443-11 Deck Board (rear) 1
6b 90-443-12 Tool box cover plate (steel) 1
7 See B 1-50 Seat Back Moulding 7
8 See B 1-50 Charger AC Cord 1
8a See B 1-50 Mounting Bracket 1
8b See B 1-50 Mounting Bracket Screws 2
8c See B 1-50 Mounting Brackt Nuts 2
8e See B 1-50 AC Cord Strain Releif 1
8f See B 1-50 Replacement AC Plug only 1
9 97-840-01 Vise 1
9a 88-080-16 5/16NC x 2 Hex Bolt (vise) 3
10 91-340-25 Tool Box 1
11 91-530-00 Chain Hook 2
12 30-552-00 1/4 Coil Chain (by the foot) -
13 02-200-05 Ladder Rack 1
13a 88-140-20 1/2 x 3 NC Hex Bolt (ladder rack) 4
13b 88-148-61 1/2 SAE Flat Washer (ladder rack) 8
13c 88-149-81 1/2 NC Hex Lock Nut (ladder rack) 4
Not Shown See B 1-50 Tai light (includes mounting grommet and pigtail) 1
Not Shown See B 1-50 Tail light mounting grommet 1
Not Shown See B 1-50 Tail light pigtail 1

PARTS PAGE 39
Illustrated Parts

Decals, B 1-50

7 5

6
3

2
VIEW FROM INSIDE 8
OF COWL 1

PARTS PAGE 40
 Illustrated Parts

Decals, B 1-50
ITEM # PART # DESCRIPTION QTY
1 94-333-00 FM 1
2 94-313-20 Safety Warning 1
3 94-384-01 Not a Motor Vehicle 1
4 94-309-00 Park Brake 1
5 94-384-14 Leaving Vehicle 1
94-373-10 Vinyl Data Plate 1
6
94-373-70 Metal Data Plate 1
7 94-301-42 Arms and Legs 1
8 94-319-00 Battery Disconnect 1
9 94-313-00 Battery Warning 1

PARTS PAGE 41
 Illustrated Parts

Fiberglass Cab, Doors, Mirrors

3
5 7 8

6
4

2
10

1 9

16
15
14 11

26
12

13 19
24 23b
25
20 17

18

21
23a

PARTS PAGE 42
 Illustrated Parts

Fiberglass Cab, Doors, Mirrors

ITEM # PART # DESCRIPTION QTY
1 90-852-30 Front Windshield 1
2 98-310-10 Windshield Gasket (by the foot)
3 74-050-00 Windshield Wiper Motor 1
4 74-051-00 Windshield Wiper Arm 1
5 74-052-00 Windshield Wiper Blade 1
6 91-008-00 Fiberglass Cab, B 1-50 1
6a 91-008-20 Fiberglass Cab, MX 1600 1
7 98-310-10 Rear Window Gasket (by the foot)
8 90-850-10 Rear Window 1
9a 91-814-11 Door Hinge(right) 2
9b 91-814-10 Door Hing (left)
10 94-036-00 Door Moulding 13'
11a 90-924-96 Door Cover (left) 1
11b 90-923-10 Door Frame (left) 1
11c 90-924-97 Door Cover (right) 1
11d 90-923-20 Door Frame (right) 1
12 01-200-73 Front Bumper 1
13 88-102-17 Bolt 1
14 16-206-00 Spacer 1
15 88-108-62 Split Lock Washer 3
16 88-109-80 Nut 3
17 97-315-53 Outer Door Handle 2
18 97-315-51 Door Latch 2
19 97-315-54 Inner Door Handle 2
20 92-202-00 Mirror 2
21 92-201-00 Mirror Mounting Bracket 2
22 - - -
23a 88-025-08 Screw 4
23b 88-029-86 Nut 4
24a 88-065-08 Bolt 4
24b 88-069-81 Nut 4
25 88-102-13 Bolt 2
26a 88-082-09 Bolt 8
26b 88-089-81 Nut 8
Not Shown 01-200-70 Rear Support Angle, B 1-50 1
Not Shown 01-200-89 Rear Support Angle, MX 1600
Not Shown 01-200-72 Front Cover (between cab and cowl) 1
Not Shown 90-186-10 Velcro (on door frame)

PARTS PAGE 43
 Illustrated Parts

Strobe Light

1 Strobe mounted on fiberglass cab

3
1
4

7 5
Apply silicon sealer around each
6 3 mounting screw to prevent leakage

7 4

Seat Back

11 8

12 9

Strobe mounted on pole

10

PARTS PAGE 44
 Illustrated Parts

Strobe Light
ITEM # PART # DESCRIPTION QTY
1a 72-023-20 Strobe Light 1
1b 72-023-21 Replacement Bulb 1
1c 72-023-22 Replacement lens (amber) 1
1d 72-023-24 Replacement Lens (red) 1
2 88-029-80 Nut 3
3 88-028-62 Flat Washer 3
4 88-025-08 Screw 4
5 88-048-61 Washer 3
6 72-023-41 Mounting Pole 1
7 98-603-00 Rubber Grommet 2
8 88-108-60 Flat Washer 2
9 88-101-16 Bolt 2
10 17-104-00 Spacer 2
11 88-109-81 Nut 2
12 88-108-60 Flat Washer 2

PARTS PAGE 45
Illustrated Parts

Stake Sides, B 1-50

7
3 5
4
2
8 6

PARTS PAGE 46
 Illustrated Parts

Stake Sides, B 1-50

ITEM # PART # DESCRIPTION QTY
1 90-542-20 Side Gate 1
2 90-542-22 End Gate 1
3 90-542-20 Side Gate 1
4 90-540-00 Gate Hook 6
5 90-540-00 Gate Hook 6
6 88-065-13 Bolt 44
7 88-069-81 Nut 44
8 90-543-00 Mounting Channel 8

PARTS PAGE 47
 Illustrated Parts

Hydraulic Brake Lines and Fittings (optional)

Illustration not available

REAR BRAKES
50-009-00 PUSH ROD, MASTER CYLINDER
96-762-00 3/8 IN.CLEVIS CAST
96-772-00 PIN,CLEVIS,3/8 X 1 1/8 IN.
99-510-02 MASTER CYLINDER
99-564-00 UNION T, 3/16 INV FLARE
99-566-00 BANJO FITTING, MASTER CYLINDER
99-571-00 COPPER GASKET, 0.813OD, 0.500ID
99-572-00 COPPER GASKET, 0.813OD, 0.594ID
99-575-00 BRAKE LINE COUPLER
99-576-00 BRAKE LINE CLIP
99-579-00 BOLT, MASTER CYLINDER
99-603-50 BRAKE LINE, LEFT AND RIGHT REAR
99-605-80 BRAKE LINE, REAR BRAKES (FRONT)
99-608-57 BRAKE LINE, REAR BRAKES (REAR)

FRONT BRAKES
99-559-00 FITTING, MASTER CYLINDER
99-564-00 UNION T, 3/16 INV FLARE
99-580-20 HOSE,BRAKE,W/1/8PM& 3/16TF
99-603-53 BRAKE LINE LEFT AND RIGHT, FRONT
99-605-81 BRAKE LINE, FRONT BRAKE

PARTS PAGE 48
 Appendixes
Contents
Appendix A: Special Tools ................. 2
Appendix B: Suggested Torque
Limits for Standard Hardware ......... 3
Hardware Identification ...................... 3
Standard Head Markings ...................................... 3
Hex Bolts .............................................................. 3
Other Bolts ............................................................ 3
Hex Nuts ............................................................... 4
Hex Lock Nuts (stover) ........................................ 4
Other Nuts ............................................................. 4
Suggested Torque Values (non-critical hardware) 5
Appendix C: Brake Lining
Handling Precautions .................... 7

REV B
 Appendixes

APPENDIX A: SPECIAL TOOLS

DESCRIPTION PURPOSE PART NUMBER

Used for testing electrical circuits. Powered by the truck

Test Light 62-027-00
batteries, switchable for 12, 24, 36, and 48 volts.

Used to test the solid state accellerator module part number

Accelerator Test Harness 62-027-31
series 62-033-XX.

Includes 62-027-00, 62-027-31, and supplementary

PMC Test Kit troubleshooting manual M3-001-06. For controllers 62-027-60
equipped with pins labeled KSI and #2 only.

Curtis® PMC Handheld Used to test and program the 62-215-00 PMC speed control
62-027-10
Programmer used on early model C4-25 Huskey.

Used to reset the PMT/C maintenance meter after a

PMT/C Meter Reset Module 96-500-43
maintenance is completed.

Disc Brake Boot Installation Used to install the rubber boot on all disc brake bodies.
41-350-13
Tool

Used to remove pins and sockets from AMP connectors.

Pin Removing Tool 75-440-55

Used to remove pins and sockets from MOLEX connectors.

Pin Removing Tool 75-442-55

Used to check the specific gravity of battery electrolyte.

Hydrometer 77-200-00

Used to safely add water to batteries.

Battery Filler 77-201-00

Used to solder the aluminum field wire to the field stud. For
Solder Kit For Field Stud 70-210-63
use on motors with soldered connections only.

Appendixes
Appendix A
Page 2
 Appendixes

APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD

HARDWARE

HARDWARE IDENTIFICATION
Standard Head Markings
NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a
grade 8 bolt, use grade 2 torque value.
NOTE: Toque values specified are for clean dry threads.
Hex Bolts

S.A.E. Grade 2 S.A.E. Grade 5

L’9

S.A.E. Grade 8 L’9

Other Bolts

Truss Head, grade 2 Carriage Bolt, grade 2

(unless marked as above)

Appendixes
Appendix B
Page 3
 Appendixes

Hex Nuts

Nuts with no markings are to be treated as S.A.E. Grade 2

S.A.E. Grade 5 S.A.E. Grade 8

Hex Lock Nuts (stover)

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

B C
or, or, or, or,

S.A.E. Grade B S.A.E. Grade C

Grade L’9

Other Nuts

Other nuts used by Taylor-Dunn® should be treated as S.A.E. grade A

Appendixes
Appendix B
Page 4
 Appendixes

Suggested Torque Values (non-critical hardware)

Diameter Grade 2 Grade 5 Grade 8 L'9

and TPI Tightening Tightening Tightening Tightening
Torque Torque Torque Torque
(ft-lb) (ft-lb) (ft-lb) (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

Appendixes
Appendix B
Page 5
 Appendixes

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

Appendixes
Appendix B
Page 6
 Appendixes

APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS

Taylor-Dunn does not currently supply asbestos fiber-brake pads/

shoes with any vehicle. However, there is the possibility that the
original brake pads/shoes were replaced with aftermarket pads/shoes
containing 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 method
approved by OSHA to minimize the hazard caused by airborne
asbestos fibers and brake dust.
Do not grind, sand, break, or chisel the brake pads/shoes, as this will
cause unnecessary dust, possibly releasing asbestos fibers in the air.
Always wear protective clothing and a respirator when working on
the brake pads/shoes or their associated components.
Inhaled asbestos fibers have been found to cause cancer and
respiratory diseases.
Do not drive the vehicle if any worn or broken part is detected in any
part of the brake system. The cause of the damage must be repaired
immediately.

Appendixes
Appendix C
Page 7
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504

Mailing Address:
P.O. Box 4240
Anaheim, California 92803

Visit our Website:

www.taylor-dunn.com