MB 254 02 Laboratorio

®
Lavatory Service Vehicle
GT Drive
EQUIPPED WITH GT-DRIVE SYSTEM

The Best Way
To Go
Models Inlcuded:
About Your B0-254-48 (B 2-54)
Business
MANUAL MB-254-02
Operation, Troubleshooting and
Replacement Parts Manual
Revision: C Serial number range: 165448 - 170871

COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn® Mfg. All rights reserved.
No part of this work may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying and recording, or any information storage or retrieval
system without prior written permission of Taylor-Dunn® Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn® Mfg., 2114 W. Ball Road, Anaheim, CA 92804
TAYLOR-DUNN SERVICE CENTER

For more information about this and other Taylor-Dunn® manuals, please write Taylor-Dunn®:
Taylor-Dunn® Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
Table of Contents
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A small sample of the many types of vehicles offered by Taylor-Dunn®
B 2-48-36 Equipped with optional B 1-00 Personnel carrier

hydraulic dump bed
BT 2-80 Eight passenger tram
MX 1600 Equipped with optional

ladder rack and weld tanks
C 4-25 Huskey tow tractor
Table of Contents
Contents
Introduction ............................................................ 1
About this manual ..................................................................... 2
Who Should Read This Manual ............................................... 3
Responsibilities ........................................................................ 3
How To Use This Manual .......................................................... 4
Conventions ...................................................................................................................... 5
How to Identify Your Vehicle .................................................... 6
Taking Delivery of Your Vehicle ............................................... 7
Safety Rules and Operating Instructions.............. 1

Standard Specifications ........................................................... 2
Safety Rules and Guidelines .................................................... 3
Driver Training Program ........................................................... 4
Driver Qualifications. ......................................................................................................... 4
Vehicle Controls ........................................................................ 5
Hi-Low Switch (optional) .................................................................................................... 5
Key-Switch ........................................................................................................................ 5
Horn Switch ....................................................................................................................... 5
Forward-Off-Reverse Switch ............................................................................................. 5
Accelerator Pedal .............................................................................................................. 6
Foot Brake Pedal ............................................................................................................... 6
Headlight Switch ................................................................................................................ 6
Accessory Switch (Optional) ............................................................................................. 6
Smart View Display ............................................................................................................ 7
Directional Signals (Optional) ............................................................................................ 9
Steering ............................................................................................................................. 9
Hazard Light Switch (Optional) .......................................................................................... 9
Electrolyte Alarm (Optional) ............................................................................................... 10
Seat Interlock Switch ......................................................................................................... 10
Park Brake ......................................................................................................................... 10
Charger Interlock ............................................................................................................... 10
Vehicle Operational Guidelines ............................................... 11
Safety Guidelines .............................................................................................................. 11
Starting: ............................................................................................................................. 11
While driving: ..................................................................................................................... 12
Loading and Unloading ...................................................................................................... 12
Parking .............................................................................................................................. 12
Towing ............................................................................................................................... 12
Charging your vehicle .............................................................. 13
New Battery Break in ......................................................................................................... 13
Signet® HB-xxxx Charger Operation ................................................................................. 13
Industrial Charger Operation ............................................................................................. 14
Charging Time ................................................................................................................... 14
Lestronic II® Charger Operation ........................................................................................ 14
Storing and Returning to Service ........................................... 15
Storing Your Vehicle ........................................................................................................... 15
Returning to Service .......................................................................................................... 15
Table of Contents
Periodic Maintenance Checklist .............................................. 16

Standard Periodic Maintenance Schedule
for the Smart View Display ................................................. 17
Daily Visual Inspection ...................................................................................................... 18
Maintenance Guidelines for
Severe Duty Applications ......................................................... 18
General Maintenance ............................................. 1

Maintenance Guidelines ........................................................... 2
Troubleshooting Guide ............................................................. 3
Lubrication Chart ...................................................................... 4
Front Axle Service .................................................. 1

Inspect the Front Wheel Bearings and King Pin .................... 2
Adjust Front Wheel Bearings .................................................. 3
Front Axle Removal and Installation ....................................... 4
Removal ............................................................................................................................ 4
Installation ........................................................................................................................ 5
Front Axle Disassembly ........................................................... 6
Replace Front Wheel Bearings ................................................ 7
Replace the King Pins and Bushings ..................................... 9
Replace the Steering Knuckle ................................................. 11
Steering Component Service ................................ 1

Front End Alignment ................................................................. 2
Inspect Ball Joints .................................................................... 6
Inspect Rod Ends ...................................................................... 7
Adjust the Steering Gear .......................................................... 8
Replace the Steering Shaft ....................................................... 10
Replace the Steering Wheel ..................................................... 12
Replace the Steering Gear ....................................................... 13
Replace the Ball Joints, Tie Rods, and Drag Link .................. 14
Replacing the Drag Link ................................................................................................... 16
Replacing the Tie Rod ...................................................................................................... 17
Center the Steering Gear.......................................................... 18
Pitman Shaft Alignment ............................................................ 18
Repair the Steering Gear .......................................................... 19
Exploded View of Steering Gear ....................................................................................... 22
Table of Contents
Brake Service ......................................................... 1

Inspect the Service Brake ........................................................ 2
Disc Brake Pads ................................................................................................................ 2
Disc Brake Rotor ............................................................................................................... 3
Inspect the Parking brake ........................................................ 4
Wheel Park Brake (hydraulic disc) .................................................................................. 4
Electric Motor Brake ......................................................................................................... 5
Adjust the Service Brakes ........................................................ 6
Two or Four Wheel Hydraulic Disc Brakes ..................................................................... 6
Adjust the Parking Brake ......................................................... 7
Wheel Park Brake (hydraulic disc) .................................................................................. 7
Check Master Cylinder Fluid .................................................... 8
Bleed the Brake System ........................................................... 9
Flush the Brake System ........................................................... 11
Replace the Parking Brake Lining
(electric motor brake) ............................................................... 12
Inspection: ........................................................................................................................ 14
Replace Front Disc Brake Pads ............................................... 15
Replace Rear Brake Pads ........................................................ 17
Hydraulic Disc ................................................................................................................... 17
Replace the Wheel Cylinder ..................................................... 19
Disc Brake Body Assembly (front or rear) ....................................................................... 19
Repair the Brake Body.............................................................. 21
Replace the Master Cylinder .................................................... 23
Repair the Master Cylinder....................................................... 25
Motor Service ......................................................... 1

Inspecting the Motor Brushes ................................................. 2
Motors with internal cooling fans ..................................................................................... 2
Motor Removal and Installation ............................................... 3
Motor Inspection ....................................................................... 3
Replacing the Brushes or Armature Bearing ......................... 7
Repairing the Commutator ....................................................... 8
Service Limits ............................................................................ 10
Table of Contents
Transmission.......................................................... 1
Check Oil Level ......................................................................... 2
Change Oil ................................................................................. 3
Motor Removal and Installation ............................................... 4
Rear Hub or Rotor ..................................................................... 5
Removing and Installing the Rear Axles
(Disc Brakes) ............................................................................. 6
Transmission Assembly ........................................................... 8
Remove and Install .......................................................................................................... 8
Disassembly and Reassembly of the
Primary Reduction Gear Case ............................................ 9
Disassembling the 3rd Member ............................................... 12
Assembling the 3rd Member .................................................... 15
Pinion Bearing Preload .................................................................................................... 18
Pinion Gear Shimming Instructions ........................................ 19
Setting the Pinion Gear Depth .......................................................................................... 19
Suspension ............................................................ 1
Replace the Rear Springs ........................................................ 2
Replace the Front Springs ....................................................... 3
Replace the Spring Bushings .................................................. 4
Replace the Shocks .................................................................. 5
Tires and Wheels ................................................... 1

Tire Inflation .............................................................................. 2
Tire Inspection .......................................................................... 2
Replace the Tire/Wheel ............................................................. 3
Repair the Tire (pneumatic) ..................................................... 4
Replace the Tire (pneumatic) .................................................. 5
Battery Service ....................................................... 1

Cleaning ..................................................................................... 2
Testing ....................................................................................... 3
Watering ..................................................................................... 5
Charging .................................................................................... 6
Replacing (6-volt batteries only) .............................................. 7
Moist Charge Batteries .................................................................................................... 9
Storage and Returning to Service ........................................... 10
Storage ............................................................................................................................. 10
Returning to Service......................................................................................................... 11
Table of Contents
Sevcon Control System Troubleshooting ............ 1

Test Equipment Required: ............................................................................................... 2
Important Notes and Instructions .................................................................................... 2
Definitions: ........................................................................................................................ 2
Terminology used: ............................................................................................................ 2
Start Troubleshooting Here ................................................................................................ 3
Test 8. Anti-Rolloff Fault .................................................................................................... 22
Test 9. Electric Motor Brake .............................................................................................. 23
Sevcon Logic Voltage Reference Table ............................................................................. 25
Status LED Code Table ..................................................................................................... 26
Lestronic II® Charger Troubleshooting ................ 1

Operating Instructions and Theory of Operation ................... 2
Testing the Charging Cycle ...................................................... 3
Test Equipment Required for Troubleshooting ...................... 4
Troubleshooting for Built-in Charger ...................................... 5
Troubleshooting for Portable Charger .................................... 8
Testing The Timer Relay ........................................................... 9
Testing the Interlock Relay....................................................... 10
Signet® Charger Troubleshooting ........................ 1

Operating Instructions and Theory of Operation ................... 2
Testing the Charging Cycle ...................................................... 3
Test Equipment Required for Troubleshooting ...................... 4
Status LED Error Code ............................................................. 5
Troubleshooting ........................................................................ 6
Illustrated Parts ...................................................... 1

Steering Knuckle ............................................... 2 Rear Suspension ................................................ 24
Front Brakes ..................................................... 4 Motor ................................................................ 26
Steering Linkage ............................................... 6 Rear Motor Mount ............................................ 26
Steering Column ............................................... 8 Instrument Panel (dash) .................................... 28
Steering Gear .................................................... 10 Speed Control Panel .......................................... 30
Front Suspension ............................................... 12 Miscellaneous Electrical .................................... 32
Wheels and Tires ............................................... 12 Signet® Charger ............................................... 34
Transmission Gear Case .................................... 14 Batteries
Rear Axle .......................................................... 16 Roll Out Battery Box .................................. 36
Transmission Differential Case .......................... 16 Seat Cushions ................................................... 38
Rear Brakes ....................................................... 18 Decals ............................................................... 38
Master Cylinder ................................................ 20 Miscellaneous ................................................... 39
Brake linkage .................................................... 20
Brake Lines ....................................................... 22
Table of Contents
APPENDIX A-Special Tools.................................... A-1
Appendix B: Standard Hardware Suggested

Torque Limits ..................................................... 1
Hardware Identification ............................................................ 2
Standard Head Markings ................................................................................................. 2
Hex Bolts .......................................................................................................................... 2
Other Bolts ........................................................................................................................ 2
Hex Nuts ........................................................................................................................... 3
Hex Lock Nuts (stover) .................................................................................................... 3
Other Nuts ........................................................................................................................ 3
Suggested Torque Values (non-critical hardware) ................ 4
Suggested Torque Values (critical hardware) ........................ 5
Appendix C ............................................................. C-1

Introduction
Contents
About this manual ........................................ 2
Who Should Read This Manual ................... 3
Responsibilities ............................................ 3
How To Use This Manual .............................. 4
Conventions .............................................................. 5
How to Identify Your Vehicle ........................ 6
Taking Delivery of Your Vehicle ................... 7
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, themselves or others. Be sure to follow any instructions contained
within a warning and exercise extreme care while performing the
task.
The symbol at the left and the bold text contained within a box
denotes a “Caution” and is used to inform the reader that property
damage may occur. Be sure to exercise special care and follow any
instructions contained with in a caution.
NOTE: Alerts the reader to additional information about a subject.
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 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).
Theese vehicles are not designed to be driven on public roads or

highways. They are available in maximum designed speeds ranging
from 6 to 16 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.
The location of the serial number is illustrated as follows:
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
TAYLOR -DUNN
Safety Rules and Operating
Instructions
TABLE OF CONTENTS
Standard Specifications ............................... 2 Vehicle Operational Guidelines ................... 11
Safety Rules and Guidelines ........................ 3 Safety Guidelines ...................................................... 11
Driver Training Program ............................... 4 Starting: ..................................................................... 11
While driving: ............................................................ 12
Driver Qualifications. ................................................. 4
Loading and Unloading ............................................. 12
Key-Switch ................................................................ 4
Parking ...................................................................... 12
Forward-Off-Reverse Switch .................................... 4
Towing ....................................................................... 12
Horn Switch .............................................................. 4
Vehicle Controls............................................ 5 Charging your vehicle .................................. 13
New Battery Break in ................................................ 13
Hi-Low Switch (optional) ........................................... 5
Signet® HB-xxxx Charger Operation ........................ 13
Accelerator Pedal ...................................................... 7
Industrial Charger Operation ..................................... 14
Foot Brake Pedal ...................................................... 7
Charging Time .......................................................... 14
Headlight Switch ....................................................... 7
Lestronic II® Charger Operation ............................... 15
Accessory Switch (Optional) ..................................... 7
Returning to Service ................................................. 15
Smart View Display ................................................... 7
Directional Signals (Optional) ................................... 8 Storing and Returning to Service ............... 15
Steering ..................................................................... 8 Storing Your Vehicle .................................................. 15
Hazard Light Switch (Optional) ................................. 8 Periodic Maintenance Checklist .................. 16
Charger Interlock ...................................................... 10 Standard Periodic Maintenance Schedule
Electrolyte Alarm (Optional) ...................................... 10 for the Smart View Display ..................... 17
Seat Interlock Switch ................................................ 10
Daily Visual inspection: ............................................. 18
Park Brake ................................................................ 10
Maintenance Guidelines for
Severe Duty Applications ....................... 18
SAFETY RULES AND OPERATING INSTRUCTIONS
STANDARD SPECIFICATIONS
ITEM VOLTAGE SPECIFICATION
Occupancy Driver only
Electrical System 48 Volt 6-165 Amp Hour, 8 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
Dimensions 467.36L x 149.86W x ?? H Centimeters Not available at

184L x 59W x ?? H Inches time of printing
Not available at
Turning Radius ??? Centimeters (??? Inches) time of printing
Tires 600 x 9 Softuff
Dry Weight ???? kg (???? lbs) Not available at

Without Batteries time of printing
Not available at
Maximum Load ???? kg (???? lbs) time of printing
Motor, DC 48 Volt 4.4 kW, (5.9 hp) for 60 min, 7.2 kW, (9.6 hp) for 5 min
Separately Excited Field
Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs)

Weights
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid

Differential
Brakes Optional 4 Wheel Hydraulic Disc, Hand Operated Park

Brake
Steering Automotive Steering 24:1
Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Diamond Plate
Instrumentation Smart View Display (Battery Status Indicator, Hour

Meter, System Status Monitor), Key Switch, Horn Button,
Forward/Reverse Switch, Headlight Switch
Light Accessories Dual Headlight, Tail/Brake Lights
Charger 48 Volt 100/240 VAC, 13/6.5 Amps (50/60Hz), 17 Amp DC
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard
for Personnel and Burden Carriers (ANSI B56.8).
Safety Rules Page 2

SAFETY RULES AND GUIDELINES

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

highways. They are available in maximum designed speeds ranging
from 6 to 16 mph. Do not exceed the maximum designed speed.
Exceeding the maximum designed speed may result in steering
difficulty, motor damage, and/or loss of control. Do not exceed locally
imposed speed limits. Do not tow this vehicle at more than 5 mph.
Read and follow all of the guidelines listed below. Failure to follow
these guidelines may result in severe bodily injury and/or property
Refer to Vehicle Operational Guidelines, Safety Guidelines section for important safety information
regarding operating this 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.
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

DRIVER TRAINING PROGRAM

According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all
those who will be operating this vehicle. The training program shall not be condensed for those claiming
to have previous vehicle operation experience. Successful completion of the Operator Training program
shall be required for all personnel who operate this vehicle.
The Operator Training program shall include the following:
• Operation of this vehicle under circumstances normally associated with your particular
environment.
• Emphasis on the safety of cargo and personnel.
• All safety rules contained within this manual.
• Proper operation of all vehicle controls.
• A vehicle operation and driving test.
Driver Qualifications.
Only those who have successfully completed the Operator Training program are authorized to drive this
vehicle. Operators must possess the visual, auditory, physical, and mental ability to safely operate this
vehicle as specified in the American National Standards Institute Controlled Personnel and Burden
Carriers ANSI B56.8.
The following are minimum requirements necessary to qualify as an operator of this vehicle:
• Demonstrate a working knowledge of each control.
• Understand all safety rules and guidelines as presented in this manual.
• Know how to properly load and unload cargo.
• Know how to properly park this vehicle.
• Recognize an improperly maintained vehicle.
• Demonstrate ability to handle this vehicle in all conditions.
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Safety Rules Page 4

VEHICLE CONTROLS
Key-Switch
A key-switch, located on the right center 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 vehicle.
This switch is also designed to secure and disable the vehicle. The key
can only be removed when the key-switch is in the “OFF” position.
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 SWITCH from forward to reverse or vice-versa while the vehicle
is in motion. Make sure the vehicle is completely stopped before shifting.
The forward-off-reverse switch should be in the center “OFF” position,
with the key-switch off and the park brake set whenever the operator
leaves the vehicle.
Hi-Low Switch (optional)

The high-low switch is located on the lower left of the instrument panel.
Toggle the switch lever up for normal speed. Toggle the switch lever
down for slow speed.
Horn Switch
The horn switch is located on the right side of the instrument panel.
Depress the switch to sound the horn, release it to turn it off.
Safety Rules Page 5

Headlight Switch
The headlight switch is located on the top left of the instrument panel.
Push the right side of the switch to turn the lights on. Push the left side
of the switch to turn the light off.
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 the 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.
Accelerator Pedal
The accelerator pedal is located to the right of the brake pedal. It controls
the speed of the vehicle and operates similar to the accelerator pedal in
an automobile. Depress the pedal to increase speed and release the pedal
to decrease speed.
Foot Brake Pedal

The foot brake pedal, is located to the right of the steering column, it is
for operation with the right foot only. It works similar to the brake in an
automobile. Applying pressure to the brake pedal slows the vehicle
according to the amount of pressure applied. Relieving pressure from the
pedal releases the braking action.
Safety Rules Page 6

Smart View Display
The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed
controller status monitor, and as an optional maintenance monitor feature. The operation of each of
these functions is listed below.
BSI: A bar graph representing the current state of charge is located across the top of the display. When
the batteries are fully charged, all segments of the bar graph will be on. As the batteries are used,
segments will turn off in the order of right to left.
When the batteries are discharged to 75%, the last three segments will flash indicating that you are
approaching the end of the battery cycle. At this time, the vehicle’s batteries should be charged as soon
as possible.
At 90%, all segments will flash and the vehicles speed will be reduced. At this time, the vehicle should be
removed from service for charging. Discharging beyond 90% will result in damage to the batteries that
will shorten the battery life-span.
HM: There are two hour meter functions, Key Hours and Run Time Hours.
Key Hours is the accumulated length of time in hours that the key switch is in the “ON” position.
Run Time Hours is the accumulated length of time that the vehicles has been in operation. Time is
accumulated when the FS-1 switch in the accelerator module is closed.
One of the Hours functions is being displayed whenever the either of the Hours Indicators are visible at
the right side of the display.
Key Hours: When the display is turned on,

the Key Hours will be displayed for
approximately 5-seconds as indicated by the
Key Hours Indicator located at the lower left
of the display. The icon represents the
silhouette of a key.
Key Hours icon
Safety Rules Page 7

Run Time Hours: After the initial 5-seconds,

the Run Time Hours will be displayed as
indicated by the Run Time Hours Indicator
located at the left of the display. The icon
represents a motor symbol with a “T” in the
center.
Run Time Hours icon

Speed controller status: The display will indicate
a fault code whenever the control system logic
detects a problem with the control system. A fault
code is being displayed whenever the Fault Code
Indicator (the letter ‘F’) is visible at the left of the
numeric display. Refer to the table below for a
list of fault codes and their descriptions.
Display showing a fault code
Fault Code Description Corrective action

01004 Discharged battery or defective wiring. Charge the battery. If the battery is
good, check wiring to the controller.
01005 Speed control overheated. Allow the controller to cool off. May be
the result of an overloaded vehicle or an
obstruction to the controller heat sink.
01008 Optional speed encoder or speed encoder Repair as required
wiring defective
02000 Start up switches not operated in the correct Reset switches and start again.
order or a defective switch.
02001 Defective wiring Refer to troubleshooting
04004 Both the forward and reverse directions are Check the forward/ switch and wiring
selected at the same time for shorts.
04006 Accelerator pedal depressed before the seat Recycle start up switches and try again.
interlock switch is closed Possible defective seat switch.
04007 - Defective wiring
04009 Discharged battery or defective wiring. Charge the battery. If the battery is
good, check wiring to the controller.
04010 Battery voltage too high Incorrect battery installed.
04011 Personality fault Reprogram the controller
04012 Personality fault Reprogram the controller
04013 Defective wiring or batteries Refer to troubleshooting
05000 Line contactor coil or wiring shorted Replace contactor or repair wiring
05006 MOSFET shorted Refer to troubleshooting
05008 Line contactor welded contacts or wiring Replace contactor or repair wiring
shorted
05009 MOSFET shorted Refer to troubleshooting
05046 Line contactor contacts open or defective Replace contactor or repair wiring.
wiring Could also be result of open circuit
breaker
Safety Rules Page 8

Maintenance monitor (optional):

Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due.
During this warning period, the meter will continue to alert the operator. This should allow sufficient time
for the operator to schedule the maintenance that is due, with minimal down time. If the scheduled
maintenance is not performed before the warning period elapses, then the vehicles maximum speed
will be significantly reduced.
Warning period: The warning starts when the Maintenance Indicator
is ON and the Wrench icon is flashing. The Wrench icon will continue
to flash until the warning time has expired.
Maintenance Due: Once the warning has expired and the maintenance
is due, the Wrench icon will stop flashing and remain ON. Additionally,
the vehicles maximum speed will be significantly reduced until the
maintenance is performed and the display is reset. The display should
Display showing Maintenance and only be reset by an authorized technician. Refer to the Illustrated
Wrench icons parts section for information regarding tools required to reset the Smart
View Display.
Steering
The steering wheel and steering system are similar to an automobile. To
turn right, turn the steering wheel clockwise. To turn left, turn the steering
wheel counter-clockwise. If equipped with tilt steering, the release lever
is located on the lower left of the steering column. Pull the lever up to
reposition the steering wheel.
Directional Signals (Optional)

The turn signal lever is located on the left side of the steering column.
Push the lever forward to activate the right turn signal and pull the lever
back to activate the left turn signal.
Hazard Light Switch (Optional)

The hazard light switch is located on the left side of the steering column.
The switch is a small tab. To activate the hazard lights, pull the tab out.
To turn the hazard lights off, push forward or pull back the directional
signal lever.
Safety Rules Page 9

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.
Park Brake
The parking brake is actuated with a hand lever, which is located to the
right of the driver. 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.
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.
Seat Interlock Switch

A switch located under the driver's seat disables the power to the vehicle
when the driver leaves the seat. The driver must be seated for the vehicle
to operate.
Whenever the driver leaves the vehicle, the driver should turn the key-
switch off, place the forward-off-reverse switch in the center “OFF” position,
and set the park brake.
The seat interlock switch is only one part of the vehicle safety system.
The interlock switch should not be relied upon as the only safety
feature used to disable or disengage this vehicle. Doing so could result
in unexpected movement of the vehicle causing severe bodily injury
and/or property damage.
Safety Rules Page 10

VEHICLE OPERATIONAL GUIDELINES
Safety Guidelines
• Do not operate this vehicle while using any substance such
as medication, drugs, or alcohol that may impair your judgment,
reaction times, or driving ability.
• Only qualified and trained operators may drive this vehicle.
• Drive only on level surfaces or on surfaces having an incline
of no more than 10% (5.6 degrees).
• Drive slowly when making a turn, especially if the ground
is wet or when driving on an incline.
• While the vehicle is in motion, all occupants must be seated in
an assigned seating position. Do not exceed maximum passenger
capacity (count) or maximum load (weight) specification of the vehicle.
• This vehicle may overturn easily if turned sharply or when driven at high speeds.
• Observe all traffic regulations and speed limits.
• Keep all body parts (head, arms, legs) inside this vehicle while it is moving.
• Keep the vehicle under control at all times.
• Yield right of way to pedestrians, ambulances, fire trucks, or other vehicles in emergencies.
• Do not overtake another vehicle at intersections, blind spots, or other dangerous locations.
• Do not drive over loose objects, holes, or bumps.
• Yield right of way to pedestrians and emergencies vehicles.
• Stay in your driving lane under normal conditions, maintaining a safe distance from all objects.
• Keep a clear view ahead at all times.
Starting:
1. Make sure the forward-off-reverse witch is in the center “OFF” position.
2. Set the parking brake.
3. Hold down the foot brake.
4. Insert the key and turn it to the “ON” position.
5. Wait 1-second then place the forward-off-reverse switch in the desired direction of travel.
6. Release the parking brake.
7. Release the foot brake.
8. Slowly depress the accelerator pedal.

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

• Do not carry more than the maximum number of passengers allowed for this vehicle.
• Do not exceed the cargo load capacity.
• Do not load cargo that can fall off.
• Be careful when handling cargo that is longer, wider, or higher than this vehicle, be sure to
properly secure all loads.
Parking
Before leaving the vehicle:
• Set the parking brake.
• Set the forward-off-reverse switch to the ` “OFF” position.
• Turn the key switch to the “OFF” position and remove the key.
In addition:
• If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.
• Do not block fire aisles, emergency equipment, stairways, or exits.
Towing
The key switch must be in the “OFF” position while being towed.
Towing the vehicle with the key switch “ON” may result in damage
to the vehicles electrical system.
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.

CHARGING YOUR VEHICLE
Explosive mixtures of Hydrogen gas are present within battery cells

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

acid. Avoid contact with skin eyes or clothing. Wear rubber gloves
and safety glasses while servicing batteries. DO NOT INGEST! This
may result in severe bodily injury.
The key switch must be in the “OFF” position when charging the
batteries. Failure to turn the key switch “OFF” may result in damage
to the vehicles electrical system.
New Battery Break in

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

The Signet® HB-600 and HB-1000 chargers use a semi-automatic
charging system. The charger will turn itself ON when the AC power
cord is connected to the AC power source and turn itself OFF when
the batteries are fully charged. Refer to the data plate on the charger
for the voltage and type power required for the charger.
There is a series of LED’s on the faceplate of the charger that serve
two functions: Typical Signet® Built In Charger
1. Status of charge. The LED’s will display an approximate percent of charge during the charging
cycle. Refer to the table below.
2. Error condition. All three LED’s flashing is an indication of a charging problem. Refer to the Charger
Troubleshooting section for information on error codes.
Charging State LED1 LED2 LED3
0 to 50% Blinking OFF OFF
50% to 75% ON Blinking OFF
75% to 100% ON ON Blinking
Cycle complete ON ON ON

Lestronic II® Charger Operation

The Lestronic II® charger is a semi-automatic charging system. The
charger will turn itself ON when the AC power cord is connected to
the AC power source and turn itself OFF when the batteries are
fully charged. Refer to the data plate on the charger for the voltage
and type power required for the charger.
Typical Lestronic II® Built In Charger

Industrial Charger Operation
If equipped with an industrial charger, it is either specified by or provided by the end user. Refer to the
operating instruction supplied with your charger or contact the charger manufacturer for more information.
Charging Time
Average charging time is 8 to 10-hours. The time required to fully charge your batteries will vary depending
on:
• Capacity of the batteries, higher capacity requires longer charge time.
• Output of the charger, higher output requires less charge time.
• Depth of discharge, the deeper a battery is discharged, the longer it takes to charge.
• Temperature, low temperatures require longer charge time.
It is not unusual for charge times to exceed 15-hours, especially with new batteries.
To obtain the maximum battery life:

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

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.
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PERIODIC MAINTENANCE CHECKLIST
Semi -
2, 3 Weekly1 Monthly1 Quaterly1 Annualy1
Maintenance Item Annual1
(20hrs) (80hrs) (250hrs) (1000hrs)
(500hrs)
Check Condition of Tires and
l
Tire Pressure
Check All Lights, Horns,
l
Beepers and Warning Devises
Check and Fill Batteries l
Check Brake System l
Check Steering System l
Check for Fluid Leaks l
Lubricate Vehicle l
Clean and Tighten All Wire
l
Connections
Wash and Service Batteries l
Check Park Brake l
Check Motor Brushes and
l
Blow Out Motor
Check Front Wheel Bearings l
Check Rear Axle Oil l
Change Rear Axle Oil l
Check and Tighten all Nuts and
l
Bolts
Clean and Repack Front Wheel
l
Bearings
1, 2, 3 - See notes on following pages.
Only properly trained and authorized technicians should perform

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

STANDARD PERIODIC MAINTENANCE SCHEDULE

FOR THE SMART VIEW DISPLAY
NOTE: The maintenance function is optional. Your vehicle may be equipped
with a customized maintenance schedule
PREVENTATIVE MAINTENANCE SCHEDULE

MAINTENANCE HOUR
MAINTENANCE TO BE PERFORMED 2
LEVEL INTERVAL 1
Inspect the brake system including the park brake and mounting
harware
Inspect the steering system, tighten the steering shaft coupler on
the steering gear input shaft
Lubricate the vehicle, check for leaks
1 500 Inspect safety interlocks
Inspect front and rear wheel bearings
Inspect and adjust fork collar bearings (3-wheel trucks only)
Inspect and tighten all nuts and bolts. First 500 hours and then
every 1000 hours.
Inspect and tighten all nuts and bolts
Clean and repack front wheel bearings
Inspect and tighten all wire connections

2 1000
Inspect the motor brushes and commutator
Inspect the king pin bushings
Check front end alignment
Change oil in the drive and rear axle
Flush hydraulic brake system
3 2000 Inspect suspension bushings
Replace brake pedal/treadle return spring
Inspect frame for damage
1, 2, 3 - See notes on following pages.

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.
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General Maintenance
TABLE OF CONTENTS
Maintenance Guidelines ............................... 2

Troubleshooting Guide ................................. 3
Lubrication Chart .......................................... 4
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.
3. Set the park brake.
Before start- 4. Place blocks under the front wheels to prevent vehicle movement.
ing any re- 5. Disconnect the main positive and negative cables at the batteries.
pairs:
Read and follow all of the guidelines listed below. Failure to follow these
guidelines may result in severe bodily injury and/or property damage.
• Avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle
performance checks in an authorized area where safe clearance exists.
• Before starting the vehicle, follow the recommended safety procedures in Section 2, “Safety
Rules and Operational Information.”
• Ventilate the work area properly.
• Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed
and directional control mechanisms, warning devices, lights, governors, guards, and safety
devices.
• Inspect and maintain battery limit switches, protective devices, electrical conductors, and
connections in conformance with Taylor-Dunn’s® recommended procedures.
• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or
defective parts.
• Do not use an open flame to check level or leakage of battery electrolyte.
• Do not use open pans of fuel or flammable fluids for cleaning parts.
• Only properly trained and authorized technicians should perform maintenance or repairs to this
vehicle.
Maintenance Page 2
TROUBLESHOOTING GUIDE
Symptom Probable Cause
Front End Out of Alignment
Steering Pulls in O ne Direction
Low Tire Pressure
Dry Lube Points in Steering Linkage
Hard Steering Damaged King P in/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
Front End Out of Alignment
Lack of Power or Slow Operation Speed Control System Fault
Speed Control System Overheated
High/Low Speed Switch in Low or wiring to the Switch is Faulty
Low Speed Cutback Due to Maintenance Meter Trip (optional)
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

O il Leak in Rear Bearing Area
Drive O ver 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
Brake Pedal Linkage Binding

Braking Power Low
Brakes Out of Adjustment
Air in Brake Lines
Trailer Brake System Faulty (optional)
Maintenance Page 3
LUBRICATION CHART
2 1
2
FRONT
3 3
4 4
Rear Axle Lubrication
1
Front End Lubrication
# Description Locations Lubricant Type

1 Ball Joints 4 General Purpose Grease
2 Pedal Linkages 3 General Purpose Grease
3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease
4 King Pin 2 General Purpose Grease
7 Drive Drain Plug 1

8 Drive Level Plug 1
9 Drive Fill Plug 1 SAE 80W90 Gear Oil
Maintenance Page 4
Front Axle Service
TABLE OF CONTENTS
Inspect the Front Wheel Bearings
and King Pin ........................................... 2
Adjust Front Wheel Bearings ....................... 3
Front Axle Removal and Installation ............ 4
Removal ................................................................... 4
Installation ................................................................ 5
Front Axle Disassembly ................................ 6
Replace Front Wheel Bearings ..................... 7
Replace the King Pins and Bushings ........... 9
Replace the Steering Knuckle ...................... 11
Maintenance, Service, and Repair
INSPECT THE FRONT WHEEL BEARINGS AND KING PIN

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

ADJUST FRONT WHEEL BEARINGS

the key.
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.
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Front Axle Page 3

FRONT AXLE REMOVAL AND INSTALLATION
Removal

the key.
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

Installation

the key.
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 installing 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.
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Front Axle Page 5

FRONT AXLE DISASSEMBLY

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.
Axle with integral king pin shown
Front Axle Page 6

REPLACE FRONT WHEEL BEARINGS

the key.
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

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.
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Front Axle Page 8

REPLACE THE KING PINS AND BUSHINGS

There are different types of king pin bushings depending on the configuration of your vehicle.
• Bronze bushings in the axle beam.
• Bronze bushings in the steering knuckle.
• Metal backed teflon bushings in the axle beam or suspension arm.
NOTE: Bronze bushings must be reamed or broached to the proper
diameter after they are pressed into the axle beam or steering
knuckle.
Failure to correctly broach or ream bronze bushings may result in

steering difficulty and loss of control of the vehicle causing severe
bodily injury and /or property damage.
Refer to the illustration below for the type of bushing in your vehicle.

the key.
Front Axle Page 9

7. Remove the steering knuckle. Refer to Replace the Steering Knuckle for information
regarding removing the steering knuckle.
NOTE: It is not necessary to remove the tie rod or drag link for this
procedure.
8. Press the king pin bushings out from the axle, steering knuckle or suspension arm.
9. Press new bushings into the axle, steering knuckle or suspension arm.
a) Yoke with integral king pin: Ream or broach bronze bushings to 1.25” +/- 0.001”.
b) Yoke without king pin: Ream or broach bronze bushings to 0.880” +/- 0.001”.
Tpical Yoke without king pin Typical yoke with integral

king pin
Failure to correctly broach or ream bronze bushings may result in

steering difficulty and loss of control of the vehicle causing severe
bodily injury and/or property damage.
10. Inspect the king pin for damage or wear. If any damage or wear is noted then the king pin must
be replaced.
11. Reassemble in reverse order.
NOTE: Refer to Replace the Steering Knuckle for information on installing
the steering knuckle.
NOTE: It is recommended that the thrust washers or bearing be replaced
whenever replacing the king pin bushings. Refer to the
Replacement Parts section for the orientation of the bearing or
washers in your vehicle.
12. Grease the bushings (bronze only).
Front Axle Page 10

REPLACE THE STEERING KNUCKLE

the key.
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.
Front Axle Page 11

12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings.
NOTE: Both the left and right side bushings and thrust bearings should be
replaced as a set.
13. Assemble in reverse order.
14. Pack the thrust bearing with grease.
15. Tighen the king pin nut as follows:
a) Yoke with integral king pin: Tighten the king pin nut until all of the up and down play is
removed and the yoke rotates freely. The rubber washer must compress slightly to create a seal
for the grease.
b) Yoke without king pin: tighten the king pin nut until all of the up and down play is removed
and the yoke rotates freely.
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.
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Front Axle Page 12

Steering Component Service
TABLE OF CONTENTS
Front End Alignment ..................................... 2

Inspect Ball Joints ......................................... 6
Inspect Rod Ends .......................................... 7
Adjust the Steering Gear ............................... 8
Replace the Steering Shaft ........................... 10
Replace the Steering Wheel .......................... 12
Replace the Steering Gear ............................ 13
Replace the Ball Joints, Tie Rods, and Drag
Link .......................................................... 14
Replacing the Drag Link .......................................... 16
Replacing the Tie Rod ............................................. 17
Center the Steering Gear .............................. 18
Pitman Shaft Alignment ................................ 18
Repair the Steering Gear ............................... 19
Exploded View of Steering Gear ............................ 22
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

the key.
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 Center the Steering Gear section for information
regarding centering of the steering gear.
Steering Page 2
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 (28-32 ft. lbs.) or the rod end jam nuts on the drag link.
16. Untie the steering wheel and the front wheels.
18. Rotate the steering wheel from a full left turn to 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.

20. Release the parking brake and test drive the vehicle.
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Steering Page 3
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.

the key.
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.
wheels tied in the position may cause loss of control of the vehicle
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
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 (28-32 ft. lbs.) or the Rear Measurement
rod end jam nuts.
16. Untie the steering wheel.
Rotate the steering wheel from a full left turn to a full right turn and
make sure that the ball joint clamps do not contact any other
component. Clamps positioned so that they contact other components
may result in steering failure and loss of control of the vehicle causing
severe bodily injury and/or property damage.
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Steering Page 5
INSPECT BALL JOINTS

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

the key.
6. Tie off the front wheels so that they cannot turn.
wheels tied in position may cause loss of control of the vehicle
7. While watching the ball joints, rapidly rotate the

steering wheel to the left and right.
8. If the ball joint housing moves up or down then the
ball joint is worn out and should be replaced. Refer
to section Replacing a Ball Joint for information
regarding replacing ball joints. Typical Ball Joint
9. Untie the front wheels.
10. Reconnect the main positive and negative cables
at the batteries.
Steering Page 6
INSPECT ROD ENDS

NOTE: A set of ball joints and/or rod ends will wear at the same rate. If a
ball joint and or rod end is worn out, then all should be replaced as
a set.
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
6. Visually inspect each rod end for any signs of play between the ball and the nylon or brass
bushing in the housing.
wheels tied in position may cause loss of control of the vehicle resulting
in severe bodily injury and/or property damage.
7. If any play is evident, then the rod end is worn out

and should be replaced. Refer to section Replace
the Ball Joints, Tie Rods, and Drag Link for
information regarding replacing ball joints.
at the batteries.
10. Release the parking brake and test drive the vehicle. < Stud
Typical rod end. Studded rod end shown, your

vehicle may be equipped with spherical rod
ends that do not have a stud.
Steering Page 7
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.
key.
of rated load capacity may result in serious bodily injury.
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.
Steering Page 8
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.
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Steering Page 9
REPLACE THE STEERING SHAFT
key.
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
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 10
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.

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Steering Page 11
REPLACE THE STEERING WHEEL
key.
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 28-32 ft lbs.
12. Reinstall the horn switch (if equipped).
at the batteries.
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Steering Page 12
REPLACE THE STEERING GEAR
key.
6. Remove the steering wheel. Refer to Replace the Steering Wheel section for information
regarding removing the steering wheel.
7. Remove the steering shaft. 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.
10. Remove the bolts holding the steering gear to the
vehicle frame and remove the steering gear from
the vehicle.
Failure to support the

steering gear will result in
the steering gear falling out Steering Gear with Pitman Arm
of the vehicle and could
cause property damage and/
or severe bodily injury.
11. Center the steering gear. Refer to Center the Steering Gear section for information regarding
centering the steering gear.
12. Install in reverse order. Torque the pitman arm nut to 75-100 ft-lbs.
Steering Page 13
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
Rod End
cannot be greased and has a straight shaft. See the
illustrations to the right. Depending on the configuration of
your vehicle, it may be equipped one or both types of ball
joints.
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
key.
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
Rod End Nut

Steering Arm
Steering Page 14
10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of
turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time.
11. Install the rod end into the steering arm. Tighten the rod end nut to 20-25 ft-lbs.
12. Realign the front wheels.
Replacing a Ball Joint
key.
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
counted in the previous step. Do not tighten the ball
Clamp
joint clamp at this time. Steering Sleeve
Steering Page 15
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.
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.
key.
7. Remove the ball joints or rod ends from the steering

knuckle and pitman arm. 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.
NOTE: Refer to the Steering section for
information regarding realignment of
the front wheels. Steering Knuckle
Typical Drag Link
Steering Page 16

Replacing the Tie Rod

The Tie Rod is the linkage that connects the two steering knuckles together. Refer to the illustration
below..
key.
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.
Tie Rod
NOTE: Refer to the Steering section for
information regarding realignment of
the front wheels. Typical Front Axle Assembly

Steering Page 17
CENTER THE STEERING GEAR

1. Remove the pitman arm.
2. Rotate the input shaft clockwise until it stops.
3. While counting the rotations, rotate the input shaft counter clockwise until it stops.
4. Rotate the input shaft clockwise 1/2 the rotations counted in the previous step.
5. Mark the steering gear input shaft and pitman shaft in relation to the housing for reference.
PITMAN SHAFT ALIGNMENT
key.
7. Center the steering gear. Refer to Center the Steering Gear section for information regarding
centering the steering gear.
8. Screw both steering stops all of the way in.
9. Install the pitman arm so that it is centered between the steering stops.
10. Realign the front wheels. Refer to Front End Alignment section for information regarding
aligning the front wheels.
11. Adjust the steering stops so that the front wheels do not contact any part of the frame, suspension
or steering linkages and the left and right turning radiuses are equal.
12. Tighten the steering stop jam nuts.
Steering Page 18
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 19
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 20
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
adjusting the steering gear.
16. Once the adjustments are completed, make sure that the locking ring and jam nut are tight.
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Steering Page 21
Exploded View of Steering Gear
Steering Page 22
Brake Service
TABLE OF CONTENTS
Inspect the Service Brake ............................. 2

Disc Brake Pads ...................................................... 2
Disc Brake Rotor ..................................................... 3
Inspect the Parking brake ............................. 4
Wheel Park Brake (hydraulic disc) ......................... 4
Electric Motor Brake ................................................ 5
Adjust the Service Brakes ............................ 6
Two or Four Wheel Hydraulic Disc Brakes ............ 6
Adjust the Parking Brake .............................. 7
Wheel Park Brake (hydraulic disc) ......................... 7
Check Master Cylinder Fluid ........................ 8
Bleed the Brake System ................................ 9
Flush the Brake System ................................ 11
Replace the Parking Brake Lining
(electric motor brake) ............................. 12
Inspection: ................................................................ 14
Replace Front Disc Brake Pads .................... 15
Replace Rear Brake Pads ............................. 17
Hydraulic Disc .......................................................... 17
Replace the Wheel Cylinder .......................... 19
Disc Brake Body Assembly (front or rear) .............. 19
Repair the Brake Body .................................. 21
Replace the Master Cylinder ......................... 23
Repair the Master Cylinder ........................... 25
INSPECT THE SERVICE BRAKE

Disc Brake Pads
Current Taylor-Dunn® brakes are asbestos free. However, there is the

possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to Appendix C for
recommended handling precautions.
NOTE: The brake pad must be removed to accurately measure the lining
thickness. Refer to Replace the Front or Rear Brake Pads section
for information on removing the brake pads.
Measure the brake pad lining at the thinnest point on the pad. If the brake pad lining is 1/16-inch or less
then the brake pad must be replaced.
It is recommended to replace the left and right side brake pads as a set.
Brakes Page 2
Disc Brake Rotor
Current Taylor-Dunn® brakes are asbestos free. However, there is

the possibility that the original brakes were replaced with aftermarket
should be handled as if they contain asbestos. Refer to Appendix C for
NOTE: The front brake rotor is an integral part of the front hub. If the brake
rotor is worn beyond its service limits, then the front hub must be
replaced. Refer to Front Axle Service for information on replacing
the front hub.
NOTE: Depending on the rear axle configuration, the rear brake rotor may
be an integral part of the rear axle. If the brake rotor is worn beyond
its service limits, then the rear axle must be replaced. Refer to
Transmission section for information regarding replacing the rear
axle
NOTE: The wheel must be removed to accurately measure the rotor
thickness. Refer to Tires and Wheels section for information on
removing the wheel.
1. Measure the run out of the rotor at its maximum
diameter. If the run out exceeds 0.005, then the rotor
must be machined. Do not machine the rotor beyond
its service limits.
NOTE: A bent axle or damaged rear axle could
cause excessive brake rotor run out.
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.
Do not use a rotor that is

worn beyond its service
limits. A rotor worn beyond
its service limits could fail
and cause loss of brakes
resulting in severe bodily
injury and/or property
damage.
Rotor removed for clarity. The rotor does not
have to be removed for this procedure.
Brakes Page 3
INSPECT THE PARKING BRAKE
Wheel Park Brake (hydraulic disc)

NOTE: The parking brake is actuated through a pin in the center of the
rear left and right brake body on the rear axles.
key.
6. Release the park brake.

7. Inspect the brake pads. Refer to Inspect the
Service Brake section to inspect the brake pads.
8. Inspect the park brake pin and bushing for any signs
of damage or corrosion.
NOTE: The park brake pin is inside of the
brake body. Refer to Repair the Brake
Body for information on removing the
park brake pin.
9. Inspect all brake cables and linkages for any signs
of damage, wear, or missing cotter pins.
10. Inspect the brake handle locking mechanism for any

signs of damage.
NOTE: Refer to Adjust the Parking Brake

adjusting the parking brake.
If any sign of damage or wear is found on the locking mechanism,

cables, or linkages then they must be repaired or replaced
immediately. Failure to repair or replace any damaged component
could result in failure of the park brake causing property damage
and/or severe bodily injury.
Brakes Page 4
Electric Motor Brake

A variable power supply capable of supplying 0-volts to 24-volts DC at 2-Amps will be required to perform
the testing.
The brake does not have to be removed from the transmission for this test.
key.
3. If equipped with a hand or foot park brake, set the park brake.
6. Disconnect the electric brake connector from the vehicles harness.

7. Adjust the power supply to zero volts.
8. Connect the power supply to the electric brake.
9. Slowly increase the voltage until you hear a ‘click’ from the brake. The ‘click’ is the brake releasing.
The motor should now be free to rotate limited by the gear train and parking brake).
a) If the brake does not release until the voltage exceeds 18-volts, then the friction plate has
worn beyond its service limits and must be replaced.
b) If the brake does not release at all, then the brake electromagnet has failed and must be
replaced.
10. Reconnect the electric brake.
12. Remove blocks from behind the wheels.
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Brakes Page 5
ADJUST THE SERVICE BRAKES
Two or Four Wheel Hydraulic Disc Brakes

The hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power
could be caused by:
• Brake fluid level low in the master cylinder. See Check the Master Cylinder Fluid section.
• Air in the brake lines. See Bleed the Brakes section.
• Worn brake pads. See Inspect the Service Brake section.
• Worn brake rotor. See Inspect the Service Brake section.
• Binding brake pedal linkage.
If you are experiencing a low brake pedal or lack of braking power, the entire brake system should be
inspected.
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Brakes Page 6
ADJUST THE PARKING BRAKE
Wheel Park Brake (hydraulic disc)

The parking brake is actuated through a pin in the center of
the rear left and right brake body on the rear axles.
key.

7. Loosen the jam nuts on the Primary Adjustment Rod.
8. Tighten the Primary Adjustment Rod until it is difficult to rotate the brake arm clevis pin on both
wheels.
9. Loosen the Primary adjustment rod one to two turns so that both wheels rotate whith no brake
drag.
The threaded rod must be 3/8 Min.
screwed into the clevis with at
least 3/8” of threads. Less than
3/8” of threads in a clevis could
result in brake failure causing
severe bodily injury and/or
property damage.
Cutaway of Clevis and Threaded Rod
NOTE: If there is no adjustment left in the Primary Adjustment Rod, then

the Brake Arm Extension must be rotated to engage the next hole
in the arm.
10. Tighten the jam nuts on the park brake linkage.
Brakes Page 7
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.
key.
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.
• 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.
Brakes Page 8
BLEED THE BRAKE SYSTEM

around brake fluid.
SKIN CONTACT
EYE CONTACT
physician.
INGESTION
NOTE: Start this procedure at the wheel furthest from the master cylinder,
then work toward the wheel closest to the master cylinder.
key.
6. Thoroughly clean the area around the master cylinder cap and remove the cap.
Master cylinder is located between the front

seats. Dual reservoir shown.
Single reservoir master cylinder
Brakes Page 9
7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the
master cylinder chamber.

regulations.
8. The master cylinder fluid level will drop as the brakes are bled. Periodically check and fill the
master cylinder during this procedure. Do not allow the fluid level in the master cylinder to drop
too low as this will allow air into the brake lines.
9. Attach a clear hose to the bleeder valve on the brake
cylinder that is to be bled. Route the hose into a
clear container for waste brake fluid.
10. Pump the brake pedal a few times and then press
and hold light pressure to the brake pedal.
11. Open the bleeder valve on the hydraulic brake body.
12. Depress the foot pedal to the floor and then close
the bleeder valve. Do not release pressure on the
brake pedal until the bleeder valve is closed.
13. Slowly release the foot pedal, allowing it to return
to its released position.
Bleeder valve with hose attached
NOTE: Check and fill the master cylinder frequently during the bleeding
process. Do not allow the fluid level in the master cylinder to drop
low enough to allow air to enter the brake lines. If air enters the
brake lines during the bleeding process, then you will have to start
again from the beginning.
Always use brake fluid from a new sealed container. Never reuse any
brake fluid that has been removed from the brake system. Use of
contaminated brake fluid will degrade the braking performance and
may cause property damage or severe bodily injury.
14. Repeat the above steps until you are sure that all of the air is expelled from the brake line. Any air
bubbles that can be seen in the clear hose attached to the bleeder is an indication that there is
still air in the brake lines.
15. Repeat this process with each of the other wheels.
NOTE: When finished, top off the master cylinder with fluid. See Check
Master Cylinder Fluid for information on filling the master
cylinder.
Brakes Page 10
FLUSH THE BRAKE SYSTEM
key.
6. Raise the rear wheels off of the ground and support with jack stands.
7. If equipped with front brakes, raise the front wheels off of the ground and support with jack
stands.
9. Remove both rear wheels and, if equipped with front brakes, the front wheels. Refer to Tires
and Wheels section for information regarding removing the wheels.
10. Remove the wheel cylinders from each axle. Refer to Replace the Wheel Cylinder section
for information regarding removing the wheel cylinder.
11. Attach a clear hose to the bleeder valve on each of the wheel cylinders and route the hoses into
a container for waste brake fluid.
12. Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all
bleeder screws.
13. Pump the master cylinder until all fluid has been pumped from the brake lines and all wheel
cylinders.
14. Close all bleeder screws.
15. Fill the master cylinder with fluid.
16. Open one of the bleeder screws and pump the master cylinder until all fluid has been pumped
from the master cylinder and close the bleeder screw.
17. Repeat the above two steps for each wheel cylinder.
18. Reinstall the wheel cylinders and bleed the brakes. Refer to Bleed the Brakes for information
regarding bleeding the brakes.
20. Install the wheels and lower the vehicle to the ground.
Brakes Page 11
REPLACE THE PARKING BRAKE LINING

(ELECTRIC MOTOR BRAKE)

should be handled as if they contain asbestos. Refer to appendix C for
1. Remove the electric brake assembly from the drive. Refer to Motor Removal and Installation
in the Transmission section for information regarding removing the brake.
2. Place the brake assembly on flat surface with the shaft pointing up.
3. Mark the orientation of the outer housing and
magnet. This mark will be used to correctly align
the housing during reassembly
4. Remove the three Allen head socket screws evenly

so that the internal spring pressure is reduced
gradually. Turn each screw no more than two turns
at a time.
5. Remove the outer housing and friction plate.
Brakes Page 12
6. Mark the orientation of the inner contact plate in

relation to the magnet.
7. Remove the smaller bearing circlip.

8. Using a soft hammer, drive out the center hub and
remove the inner contact plate and six springs.
9. If required, remove the larger bearing circlip and
press out the bearing. If the bearing is removed it
must be replaced.
10. Thoroughly clean all parts.
11. Inspect all parts for damage or wear.
12. Reassemble in reverse order.
Reassembly Notes
a. Orientate the inner contact plate lining up the marks made when removed and so that the notches
face away from the magnet (see illustration below).
b. Orientate the friction plate so that the cutout faces the inner contact plate.
c. Orientate the outer housing lining up the marks made when it was removed.
d. Tighten the three Allen head socket screws in a cross pattern evenly so that the internal spring
pressure is increased gradually. Turn each screw no more than two turns at a time. Final torque-
10 ft-lbs.
Brakes Page 13
Electric motor brake exploded
Inspection:
Note: There are no repairable parts in this assembly. The parts must be
replaced if any damage or wear is found.
1. Measure the free length of the five springs. Minimum length =0.713”
2. Inspect the splines on the hub and the friction plate for damage.
3. Inspect the inner contact plate and the outer housing where they come into contact with the
friction plate for wear or damage.
4. Inspect the three dowel pins and their corresponding
holes in the inner contact plate. The dowel pins
should be straight and the holes should be round.
5. Inspect the bearing for excessive play or roughness
when rotated.
6. Inspect the contact surfaces of the magnet and inner
contact plate for damage and flatness.
Brakes Page 14
REPLACE FRONT DISC BRAKE PADS

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

should be handled as if they contain asbestos. Refer to appendix C
for recommended handling precautions.
NOTE: Installing new brake pads will raise the brake fluid level in the master
cylinder.
key.
6. Thoroughly clean the area around the master

cylinder cap.
7. Remove fluid from the master cylinder until it is 1/2
full.
Master cylinder is located between the front

9. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing
the tire and wheel assembly.
Brakes Page 15
NOTE: Refer to the illustration above for the following steps.

10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8).
11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings.
12. Inspect the brake rotor. See Inspect the Service Brakes section for information regarding
inspecting the brake rotor.
13. Inspect the spacers (7) and replace if any wear or damage is found.
14. Install new spacer bushings in the mounting bracket.
15. Install new brake pads in reverse order. Torque the mounting bolts to 11 ft-lbs.
16. Repeat this procedure for the other wheel.
17. Install the tire/wheel assembly and lower the vehicle to the ground.
18. Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section
for information on the proper master cylinder fluid level.
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Brakes Page 16
REPLACE REAR BRAKE PADS
Hydraulic Disc

should be handled as if they contain asbestos. Refer to appendix C
for recommended handling precautions.
NOTE: It is recommended that both the left and right brake pads be replaced
as a set.
key.
NOTE: Installing new brake pads will raise the brake fluid level in the master
cylinder.
6. Thoroughly clean the area around the master
cylinder cap.
7. Remove fluid from the master cylinder until it is
1/2 full.
8. Raise the rear of the vehicle and support with jack

stands. Master cylinder is located between the front
Brakes Page 17
9. Remove the tire/wheel assembly.

NOTE: Refer to Tires and Wheels section for information on removing
10. Release the park brake (wheel brake only).
11. Remove the brake body bolts and discard the lock nuts and brake pads.
12. Remove the spacer bushings from the mounting
bracket and discard.
13. Inspect the brake rotor. Refer to Inspect the
Service Brake section for information regarding
14. Inspect the spacers and replace if any wear or
damage is found.
15. Install new spacer bushings in the mounting bracket.
16. Back off the parking brake adjustment (wheel park
brake only).
17. Install new brake pads in reverse order. Torque the mounting bolts to 11 ft-lbs.
18. Repeat this procedure for the other wheel.
19. Install the tire/wheel assembly and lower the vehicle to the ground.
20. Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section for
information regarding the correct master cylinder fluid level.
21. Adjust the parking brake (wheel park brake only). Refer to Adjust the Parking Brake section.
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Brakes Page 18
REPLACE THE WHEEL CYLINDER
Disc Brake Body Assembly (front or rear)

should be handled as if they contain asbestos. Refer to appendix C for
around brake fluid.
SKIN CONTACT
EYE CONTACT
physician.
INGESTION
key.
4. Place blocks under the wheels to prevent vehicle movement.

7. Raise the wheel off of the ground and support with jack stands.
Brakes Page 19
8. Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing
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
12. Disconnect the brake hose from the brake body.
13. Install the new brake body assembly in reverse
order.
• Use teflon tape thread sealant on the brake hose
fitting.
• Torque the brake body bolts to 11 ft-lbs.
14. Bleed the brakes. Refer to Bleed the Brakes section for information regarding bleeding the
brakes.
17. Lower the wheel to the ground.
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Brakes Page 20
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.
around brake fluid.
SKIN CONTACT
EYE CONTACT
physician.
INGESTION
key.
6. Remove the brake body from the vehicle.

NOTE: Refer to Replace the Brake Body Assembly (front or rear)
section for information on removing the brake body.
7. Pull the pistons out of the brake body.
The pistons are very fragile. If the piston is damaged it must be

replaced. Failure to replace a damaged piston could lead to brake
failure and result in property damage and/or severe bodily injury.
8. Remove the piston rubber boot.

9. Remove the piston o-ring from inside of the brake body.
10. Inspect and replace parts as required.
Brakes Page 21
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 22
REPLACE THE MASTER CYLINDER

around brake fluid.
SKIN CONTACT
EYE CONTACT
physician.
INGESTION
key.
NOTE: Most vehicle configurations do not require lifting the vehicle to

remove the master cylinder. Lifting the vehicle may not be required.
6. If required, raise the vehicle and support with jack stands.
7. Place a drain pan under the master cylinder.

8. Disconnect the brake line(s) to the master cylinder and pump out the fluid in the master cylinder
by depressing the pedal several times.
9. Remove the master cylinder bolts and remove the master cylinder from the vehicle.
Brakes Page 23

11. Adjust the master cylinder push rod so that it is
Plunger
approximately 1/8 inch away from the master
cylinder plunger when the brake pedal is up.
12. Fill the master cylinder with brake fluid from a sealed
container.
13. Pump the brake pedal a short distance of one to
two inches until no bubbles are seen coming from
the inlet ports inside of the master cylinder chamber. Push Rod
14. If the vehicle was raised, lower it to the ground.
15. Bleed the brakes. refer to Bleed the Brakes section
for information regarding bleeding the brakes.
at the batteries. Master Cylinder
18. Release the park brake and test drive the vehicle. 1/8"
Cutaway of typical master cylinder showing
the push rod clearance

regulations.
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Brakes Page 24
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 25
TAYLOR -DUNN
Motor Service
TABLE OF CONTENTS
Inspecting the Motor Brushes ...................... 2

Motors with internal cooling fans ............................... 2
Motor Removal and Installation ................... 3
Motor Inspection ........................................... 3
Replacing the Brushes or
Armature Bearing ................................... 7
Repairing the Commutator............................ 8
Service Limits ................................................ 10
Motor Service
INSPECTING THE MOTOR BRUSHES
Motors with internal cooling fans

NOTE: There are four brushes in the motor.
The brushes will not wear at the same
rate. It is recommended that all four
brushes are inspected at the same
time.
NOTE: In some vehicle configurations it may
not be possible to inspect all four
brushes while the motor is in the Typical motor with cooling fan indicated by
vehicle. Refer to Transmission the arrow
Service section for information on
removing the motor.

the key.
6. Look through the brush cover and compare the top

of the brush to the top of the brush holder. If it is
even with or below the top of the brush holder then
the brushes should be removed and measured.
Refer to Replacing the Brushes section for
information regarding removing the motor brushes.
7. If any one brush is less than or equal to the service
limit specified in Service Limits, then all four
brushes should be replaced.
at the batteries.
Typical brush and brush holder
9. Remove the blocks from behind the wheels, release
the park brake and test drive.
Motor Page 2
Motor Service
MOTOR REMOVAL AND INSTALLATION

See the Transmission section for information on removing or installing the motor.
MOTOR INSPECTION
Disassembly
1. Remove the motor from the vehicle. See the Transmission section for information on removing
the motor.
2. Remove the brush cover and pull the brushes out away from the commutator.
3. Remove the dust cap from the rear motor housing.
4. Place the motor in a press, and press the armature out of the rear bearing.
NOTE: Removing the armature will damage the motor bearing. The motor
bearing should be replaced whenever the armature is removed.
5. Remove the housing screws from the rear motor housing and remove the housing from the
motor.
6. Remove the nuts from the armature studs and remove the two brush assemblies.
7. Remove the bearing circlip and press the motor bearing out of the housing and discard.
Inspection
1. Measure the length of each motor brush.
• If any one brush is less than or equal to the service limit specified
in section Service Limits, then all four brushes should be
replaced. Refer to Replacing the Brushes section for
information regarding replacing the motor brushes.
Motor Page 3
Motor Service
2. Measure the diameter of the commutator.

• If the commutator is less than the minimum
diameter specified in section Service Limits,
then the motor must be replaced.
3. Measure the commutator undercut depth in 5-places

around the commutator. Undercut
• If any one of the measurements is less than the

Hacksaw blade Armature
minimum undercut depth specified in Service Incorrect Correct
Insulation
Limits at the end of this section, then the
commutator must be undercut. Refer to Repair
Commutator section for information regarding
undercutting the commutator. Min. OD
4. Inspect the commutator for groves.

• If the commutator is grooved then it must be
machined on a lathe. Do not machine the Commutator
commutator past the minimum diameter
specified in Service Limits section. Refer to
Repair Commutator section for information
regarding machining the commutator.
5. Inspect the commutator for burn marks.
• Burn marks and/or raised commutator segments
90 or 180 degrees apart is evidence of a shorted
armature. A tool called a growler is required to
reliably test for a shorted armature.
6. Inspect the commutator for raised segments. Raised
segments could be a result of a stalled motor or
shorted armature. A tool called a growler is required
to reliably test for a shorted armature.
• If the armature is not shorted then the raised
segments can be removed by machining the
commutator. Do not machine the commutator
past the minimum diameter specified in Service Typical burn mark on a shorted armature
Limits section. Refer to Repair Commutator
section for information regarding machining the
commutator.
Motor Page 4
Motor Service
7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of
motor overheating and could lead to a shorted armature.
• If the insulation is cracked or burnt, then it is recommend that the armature or motor be
replaced.
NOTE: If the armature has been burnt then there is a good possibility that
the field windings may also be burnt. Symptoms indicating a shorted
field include high motor current, lack of power and possibly
excessive speed.
8. Using a growler, test the armature for shorts.
• If the armature is shorted, then we recommend that the armature or motor be replaced.
9. Using the continuity function of digital multi meter,
Hold this lead
check the continuity around the entire commutator
in place
by placing one test lead against one of the
commutator segments and the other test lead Check each segment
against all of the other segments one at a time. all of the way around
There should be continuity around the entire the commutator
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
Commutator
commutator segments and the armature frame. If
it is not an open circuit, then the armature is shorted
and the motor must be replaced.
11. Measure the armature and field resistance (refer to Service Limits table at end of this section).
If the armature of field resistance is not within specification then the motor must be repaired or
replaced.
Motor Page 5
Motor Service
Assembly
1. Press a new bearing into the motor housing and
install the circlip.
2. Install the two brush assemblies so that the brushes
are just far enough out of the brush holder so that
the brush springs hold them in place away from the
commutator. See the illustration to the right.
3. Install the rear motor housing to the stator housing.
4. Lightly grease the inside diameter of the armature
bearing.
5. Carefully insert the armature through the stator
housing and onto the motor bearing in the rear
housing.
6. While supporting the inner race of the bearing, press
the armature into the bearing.
7. Push the motor brushes into the brush holder until
the brush spring snaps into place. Be certain that
the spring does not rest up against the brush wire.
See the illustrations below.
8. Install the brush cover.
Motor Page 6
Motor Service
REPLACING THE BRUSHES OR ARMATURE BEARING

NOTE: It is recommended that all four brushes be replaced as a set.
NOTE: The motor must be disassembled to replace the brushes or the
bearing. Refer to Motor Inspection-Disassembly section for
information on taking the motor apart.
NOTE: The motor must be removed from the vehicle for this procedure.
Refer to Transmission Service section for information on
removing the motor.
Motor Page 7
Motor Service
REPAIRING THE COMMUTATOR

1. The motor must be removed from the vehicle for this procedure. Refer to Transmission
Service section for information on removing the motor.
2. The armature must be removed from the motor for this procedure. Refer to Motor Inspection-
Disassembly section for information on taking the motor apart.
3. Using a lathe, cut the armature just enough to
remove all grooves, depressions or ridges.
Example of freshly cut commutator
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.
6. Measure the commutator undercut depth in 5-places
around the commutator. If any one of the
measurements is less than the minimum undercut
depth specified in Service Limits , then the
commutator must be undercut.
7. While still in the lathe, smooth the commutator with
fine emery cloth.
Properly undercut and cleaned
commutator segments
Motor Page 8
Motor Service
Undercutting the commutator

Undercut
1. Using a small straight cut saw blade, cut the
commutator insulation to the proper depth. Refer Hacksaw blade Armature
to undercut depth in Service Limits. Incorrect Correct
Insulation
2. Once all segments have been properly undercut,
mount the armature in a lathe and smooth the
commutator with fine emery cloth.
Min. OD
Commutator
3. Inspect the armature for shorts. Refer to Motor

Inspection section for information on testing the
armature.
NOTE: Copper debris in the undercut area can
give a reading of a shorted armature.
Example of freshly cut commutator
Motor Page 9
Motor Service
SERVICE LIMITS
Commutator Diameter Brush Length Resistance

Motor Specification Undercut Depth
(min) (min) (Ohms@75º F)
Number
mm inches mm inches mm inches Armature Field
70-054-40
0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20
(XP-1672 or DV1-4002)
70-054-41
0.635 0.025 69.85 2.75 15.87 0.625 0.011 0.43
(XP-1789 or DY2-4001)
70-057-40
0.635 0.025 69.85 2.75 15.87 0.625 0.008 0.58
(XP-1673 or DV1-4003)
70-052-40
0.635 0.025 69.85 2.75 15.87 0.625 0.011 0.73
(XP 1876 or DD3-4004)
Motor Page 10
Transmission
TABLE OF CONTENTS
Check Oil Level ............................................. 2

Change Oil ..................................................... 3
Motor Removal and Installation .................... 4
Rear Hub or Rotor ......................................... 5
Removing and Installing the Rear Axles
(Disc Brakes) ........................................... 6
Transmission Assembly ................................ 8
Remove and Install .................................................. 8
Disassembly and Reassembly of the Primary
Reduction Gear Case .............................. 9
Disassembling the 3rd Member .................... 12
Assembling the 3rd Member ......................... 15
Pinion Bearing Preload ............................................ 18
Pinion Gear Shimming Instructions ............. 19
Setting the Pinion Gear Depth ............................... 19
GT Transmission Assembly
With Disc Brakes
CHECK OIL LEVEL

The oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is
only necessary to check the oil level of the 3rd member.
Park the vehicle on a level surface.

the key.
6. Place a level on the top of the motor. Raise the rear of the vehicle until the level indicates that
the drive is level with the ground.
7. Place an oil drain pan underneath the 3rd member.
8. Remove the fill/level plug.
9. The oil level should be very close to the bottom of
the level plug opening.
a. If the oil level is below the bottom of the opening,
add oil as required until level with the bottom of
the opening. Refer to the Lube Chart section for
information regarding type of oil.
b. If oil comes out of the opening, allow to drain until
level with the bottom of the opening.
10. Replace the fill/level plug.
12. Remove the blocks from the wheels.
Transmission Page 2
CHANGE OIL

the key.
6. Raise the rear of the vehicle and support with jack stands.
7. Place a four quart drain pan under the drive
assembly.
8. Remove the drain plugs from the differential case
and gear case.
9. Once the oil has drained, replace the drain plugs
and lower the vehicle to the ground.
10. Remove the fill/level plug and fill the differential up
to the bottom of the level plug opening. Refer to
the Lube Chart section for information regarding
type of oil.
11. Replace the fill plug.
at the batteries.
13. Remove the blocks from the wheels.
Transmission Page 3
MOTOR REMOVAL AND INSTALLATION

NOTE: Some applications will require removing the drive assembly from
the vehicle to remove the motor. Refer to Removing and
Installing the Drive Assembly for information on removing the
drive assembly.
Some vehicles are equipped with an automatic electric brake. The automatic electric brake is sandwiched
between the drive motor and the gear case. The electric brake is retained by the drive motor mounting
screws. Once the motor is removed the electric brake will no longer be retained by any hardware.

the key.
6. Remove the wires from the motor.

NOTE: Label the motor wires with the number
of the motor terminal before they are
removed from the motor.
7. If equipped, remove the motor support bracket u-
bolt (only used on larger motors).
8. Remove the motor mounting bolts and slide the
motor off of the input shaft.
9. Install the motor in reverse order.
NOTE: Apply a light coating of grease to the
splines on the transmission input shaft
only. Support bracket u-bolt
Transmission Page 4
REAR HUB OR ROTOR

NOTE: The torque specification for the axle hub bolt is 275 ft-lbs. An impact
wrench will be required to remove the bolt.
NOTE: The axle hub bolt has a special thread locking compound applied
to the threads. If this bolt is removed, it must be replaced.

the key.
6. Raise the wheel off of the ground.
7. Remove the tire/wheel assembly, Refer to Tires and Wheels section for information
regarding removing the tire/wheel assembly.
8. Remove the axle hub bolt and washer
and remove the hub from the axle.
9. Remove the outer brake pad. Refer to
section Brake Service for information
regarding removing the brake pads.
10. Remove the rotor.
a. Lightly grease the axle splines.
b. Refer to section Brake Service for information regarding installing the brake pads.
c. Thoroughly clean the threads in the axle shaft.
d. Using a new bolt, torque the axle hub bolt to 275 ft-lbs.
If the axle bolt is removed, it must be replaced with a new bolt. Failure
to use a new bolt may result in the wheel coming off of the vehicle and
loss of brakes, causing severe bodily injury and/or property damage.
e. Refer to Tires and Wheels section for information regarding installing the tire/wheel assembly.
11. Remove the blocks from behind the wheels, release the park brake and test drive the vehicle.
Transmission Page 5
REMOVING AND INSTALLING THE REAR AXLES

(DISC BRAKES)
The oil level in the housing is above the bottom of
the axle flange. To minimize oil spills, raise the side
of the vehicle high enough so that the oil level is below
the bottom of the axle flange. If both axles are to be
removed, you must drain all of the oil from the
housing.
NOTE: This procedure does not require
that the rear end or drive
assembly be removed from the
vehicle.
NOTE: The axle hub bolt has a special
thread locking compound
applied to the threads. If this bolt
is removed, it must be replaced.

the key.
6. If required, drain the oil from the 3rd member.


9. Remove the tire and wheel assembly. Refer to
section Tires and Wheels for information
regarding removing the tire and wheel assembly.
a. If the axle shaft, hub or bearing is to be replaced
then remove the hub bolt, wheel hub and disc rotor
at this time.
10. Remove the four bolts attached to the axle
retaining plate.
Transmission Page 6
11. Remove the axle retaining plate and brake body assembly as one unit.
12. Secure the brake body assembly, do not let it hang by the brake hose.
13. Pull the axle out of the housing.
14. Inspect all bearings for roughness or play, replace as needed.
15. Install in reverse order, lubricate the o-ring.
NOTE: Be sure not to damage the o-ring.
16. Use new bolts for the axle retaining plate.
The axle retaining plate bolts have a pre-applied thread locking

compound. They are intended for one time use only. If removed they
must be replaced. Reusing the original bolts could cause loss of brakes
Refer to section Rear Brakes in Illustrated Parts for the part number
of the bolt.
17. If the wheel hub was removed, install the hub and rotor. Torque the hub bolt to 275 ft-lbs.
17. Fill with oil to the level of the fill plug threads. Refer to Changing the Differential Oil.
Transmission Page 7
TRANSMISSION ASSEMBLY
Remove and Install

the key.

7. Remove the park brake cables from the spring axle
mounting brackets and brake arms.
8. Disconnect the wiring from the motor.
9. Disconnect the hydraulic brake lines from the left and right
brake bodies.
10. Remove the u-bolts holding the leaf springs to the

frame as shown in the illustration to the right. Do
not remove the u-bolts on the axle housing.
11. Remove the lower shock mounting bolts and the
front spring mounting bolts.
12. Raise the rear of the vehicle, lifting the frame up
and off of the drive assembly. Support the rear of
the vehicle with jack stands.
13. Reinstall the drive in reverse order.

NOTE: Lubricate the transmission input shaft with a small amout
of 94-421-34 grease.
14. Bleed the brake system. Refer to Bleed the Brake
System for information regarding bleeding the brakes.
16. Lower the vehicle and reconnect the main positive and
negative cables at the batteries.
Transmission input shaft
18. Remove the blocks from the wheels, release the park brake
and test drive the vehicle.
Transmission Page 8
DISASSEMBLY AND REASSEMBLY OF THE PRIMARY

REDUCTION GEAR CASE
key.
7. Place a drain pan under the gear case that is capable of

holding four quarts of oil and drain the oil from the front
gear case.
8. If required, remove the drive assembly from the vehicle
NOTE: Refer to Removing and Installing the Drive
Assembly for information on removing the drive
from the vehicle.
9. Remove the motor only if the entire drive is to be
disassembled.
NOTE: Refer to Motor Removal and Installation for
information on removing the motor.
Oil Drain Plug
10. Remove the cover retaining bolts.

11. Remove the cover plate from the differential and let the
remaining oil drain from the housing.
Be careful not to damage the sealing

surfaces on the housings. Damage to
the sealing surface may lead to an oil
leak resulting in damage to the
internal parts of the drive.
Transmission Page 9
12. Remove the circlip from the idler gear.
13. Remove the input shaft/bearing assembly and idler gear/

bearing assembly from the gear case cover at the same
time.
14. Remove the pinion nut from the output gear and remove
the output gear from the pinion shaft.
NOTE: If necessary, remove the seal
from the input shaft bore at this
time.
15. Mark the gear case position in relation to the 3rd member
housing so that it will be reassembled in the same position.
16. Remove the six retaining bolts holding the gear case to the
3rd member housing.
NOTE: Make note of the angle of the
gear case.
17. Remove the gear case housing from the 3rd member
housing.
18. Inspect all parts for signs of wear or damage.
Transmission Page 10
Lubricate all parts with gear oil before installation. Failure to pre-lube
the parts may result in premature failure.
19. Assemble the gear case in reverse order.

NOTE: Torque the drain plug to 21-25 foot-pounds.
NOTE: Torque the gear case to 3rd member retaining bolts to 18-20 foot-
pounds.
NOTE: Torque the pinion nut to 154-169 foot-pounds.
NOTE: Apply gasket sealer (#94-430-05) to the front flange on the 3rd
member and gear case cover.
NOTE: Pack the motor seal with non-acetic based grease.
20. Fill the differential with oil.
NOTE: Refer to Changing the Differential Oil for information on filling
the drive with oil.
24. Test drive the vehicle.
DISASSEMBLING THE 3RD MEMBER

key.
7. Remove the complete drive from the vehicle.

NOTE: Refer to Removing and Installing the Drive Assembly for
information on removing the drive from the vehicle.
8. Place a drain pan under the gear case that is capable of holding four quarts of oil and drain
the oil from the front gear case and 3rd member.
9. Place the 3rd member on an appropriate stand.
10. Remove the axle shafts and tubes as an assembly from
the 3rd member by removing the six axle tube flange
bolts on each axle tube.
11. Remove the primary reduction gear case. Refer to
Disassembly and reassembly of the Primary
Reduction Gear Case for information on removing
the gear case.
12. Remove the 12 side plate bolts, then remove the side
plate.
13. Remove the carrier bearing adjusting nut roll pin and
adjusting nut from the side plate.
14. Turn the side plate over and remove the carrier bearing
race from the side plate.
15. Remove the differential assembly from the 3rd member

housing.
16. Remove the carrier bearing adjusting nut roll pin from the
3rd member housing, then remove the carrier adjusting
nut.
Roll Pin
17. Remove the carrier bearing race from the 3rd member
housing.
18. Remove the front bearing from the input shaft.

NOTE: The input shaft may have to be
driven out to perform this
procedure.
19. Remove the input shaft’s shims and spacer.
20. Remove the pinion shaft from the 3rd member.

21. Remove the front and rear pinion bearing races.
22. Inspect all parts for signs of wear or damage.
23. Thoroughly clean all parts.
ASSEMBLING THE 3RD MEMBER

1. Temporarily install the pinion gear
(hand tighten only).
2. Install the carrier bearing race ring
nuts into the housing and cover.
Cover
Housing
3. Install the carrier bearing races into

the housing and cover.
Cover
Housing
4. Place the differential assembly into the housing.

5. Tighten the housing carrier bearing race ring nut so that
the ring gear is not in binding against the pinion gear.
6. Remove the differential assembly.
NOTE: Do not allow the ring nut to rotate.
7. Remove the pinion gear and then reinstall the
differential assembly.
8. Install the cover onto the housing using 4-bolts in a
cross pattern and torque to 45-50 ft-lbs.
9. Pre set the carrier bearing preload by tightening the

housing carrier bearing race ring nut until it requires
1.5 to 3.3 ft-lbs to rotate the differential assembly.
NOTE: Rotate the carrier assembly whenever
adjusting the ring nuts.
10. Mark the position of each carrier bearing ring nut in relation to the
drive housing and cover and then remove the differential
assembly, do not allow the ring nuts to rotate.
11. Install the pinion gear. Re-shim if required.
If the ring and pinion gears or

bearings are replaced then the pinion
gear must be re-shimmed. Improper
pinion gear shims will result in drive
noise and premature failure. Refer to
Pinion Gear Shimming Instructions.
12. Install the pinion gear holding tool (96-500-42) and tighten
the pinion nut enough to keep the pinion gear from rotating.
13. Install the differential assembly.
14. Install the cover and all of the cover bolts. Torque to 45-50
ft-lbs.
15. Check the gear lash between the ring and pinion gears.
The gear lash should be 0.005 to 0.007 inches.
16. Adjust the gear lash if needed by tightening or loosening
the carrier bearing race ring nuts. The two ring nuts must
be turned equally in opposite directions.
NOTE: To move the ring gear closer to the pinion:
Loosen the housing carrier bearing race ring
nuts and tighten the cover carrier bearing race
ring nut equally.
NOTE: To move the ring gear away from the pinion:
Loosen the cover carrier bearing race ring nut and tighten the
housing carrier race ring nut equally.
The two ring nuts must be turned the same amount in opposite
directions. This allows the carrier assembly to be positioned with the
proper gear lash without upsetting the bearing preload. If the ring
nuts are not turned the same amount, then the bearing preload will
no longer be correct and will result in drive noise and premature
failure.
17. Install the locking roll pins into the housing and cover to lock the ring nuts in place.
18. Remove the pinion gear holding tool.
19. Install the primary reduction gear case, axles and housings, motor, and install the complete
drive onto the vehicle.
20. Fill the drive with oil. Refer to the Lube Chart section for information regarding type of oil.
Refer to Change Oil section for information regarding the proper oil level..
24. Test drive the vehicle.
Pinion Bearing Preload

NOTE: The pinion gear depth must be set before the preload. Refer to
Setting the Pinion Gear Depth.
1. Install the pinion gear, spacer, and shims into the housing.
2. Install the outer pinion bearing.
3. Install the main gear onto the pinion shaft and torque the pinion nut to 154-169 ft lbs.
4. Measure the torque required to rotate the pinion shaft in the housing.
5. The torque required to rotate the pinion shaft should be between 1.1 and 2.9 ft-lbs. If the
torque is not within specifications then add or subtract from the total shim thickness and
repeat this procedure until the proper preload is obtained.
NOTE: Add shims to decrease torque.
PINION GEAR SHIMMING INSTRUCTIONS

NOTE: This procedure is required only when replacing the front or rear
pinion bearings and races or the ring and pinion gears.
NOTE: To perform this procedure, all parts must be clean and the bearings
lightly lubricated.
Setting the Pinion Gear Depth

This formula is used to calculate the amount of shims that
are required:
C - B - A + (DV) = Pinion Shim (mm) where,
DV = The number on the face of the pinion gear.
A = The distance in millimeters from the face of the
pinion gear to the top of the inner pinion bearing race
(see below)
B = 54.
C = The number on the edge of the differential side
plate closest to the input shaft (see next page).
D = The number on the edge of the differential side
plate farthest from the input shaft (see next page).
E = The distance in millimeters from the rear of the
drive housing to the face of the pinion gear (see next
page).
Once a shim has been selected and the pinion gear is Face of pinion gear
installed, confirm that: E - D = B + (DV)
Number on face of pinion gear
NOTE: Values shown are for

C reference only
Suspension
TABLE OF CONTENTS
Replace the Rear Springs ............................. 2

Replace the Front Springs ............................ 3
Replace the Spring Bushings ....................... 4
Replace the Shocks ...................................... 5
REPLACE THE REAR SPRINGS
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.

the key.
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.
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.
Suspension Page 2
REPLACE THE FRONT SPRINGS
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.
key.
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 lower bolt from the spring hanger.
11. Remove the spring bolt from the other end of the
spring and remove the spring from the vehicle.
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.
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. Torque the spring hanger bolts to 20 ft-lbs.
16. If the spring bolts are equipped with grease fittings,
lube them at this time.
Damaged or worn spring bolts or hangers could result in sudden failure

of the suspension causing severe bodily injury or property damage.
Suspension Page 3
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.
key.
4. Place blocks under the front/rear wheels to prevent vehicle
movement.
6. Raise the front or rear of the vehicle depending on which spring is to be removed and support
with jack stands.
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.
10. Install the new bushings in reverse order.
Suspension Page 4
REPLACE THE SHOCKS

It is recommended to replace all 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.
key.
6. Some vehicles may require that the wheels be lifted off of the ground and supported with jack
stands to replace the shocks.
of rated load capacity may result in severe bodily
7. Remove the upper and lower shock bolts.

8. Remove the shock from the vehicle.
NOTE: If the shock that was removed is to be
reinstalled:
A. Inspect the shaft where it enters the shock
body for any signs of leakage. If any sign
of leakage is seen, then the shock must
be replaced.
B. Inspect the upper and lower shock
bushings. If any signs of damage or wear
are seen, then the shock must be
replaced.
9. Install the shock in reverse order.
11. Reconnect the main positive and negative cables at the
batteries.
Suspension Page 5
TAYLOR -DUNN
Tires and Wheels
TABLE OF CONTENTS
Tire Inflation .................................................. 2

Tire Inspection .............................................. 2
Replace the Tire/Wheel ................................. 3
Repair the Tire (pneumatic) ......................... 4
Replace the Tire (pneumatic) ....................... 5
TIRE INFLATION

the key.
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

the key.
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

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 THE TIRE/WHEEL

the key.
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.
9. Following the pattern shown on the following page, cross tighten the wheel nuts in two stages as
follows:
1st stage to approximately 20 ft-lbs.
2nd stage to 80-90 ft-lbs.

4 1 1
8 6
4
1
3 3 4
2
2 5 7
3 5 2
4-Bolt Pattern 5-Bolt Pattern 8-Bolt Pattern
Pattern for tightening the wheel nuts
Re-torque all wheel nuts to their final value after 1-week (20-hours)
of operation. Failure to re-torque the wheel nuts may result in the
wheel coming off of the vehicle causing severe bodily injury and/or
property damage.
REPAIR THE TIRE (PNEUMATIC)

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.

REPLACE THE TIRE (PNEUMATIC)

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

TAYLOR -DUNN
Battery Service
TABLE OF CONTENTS
Cleaning ........................................................ 2
Testing ........................................................... 3
Watering ........................................................ 5
Charging ........................................................ 6
Replacing (6-volt batteries only) .................. 7
Moist Charge Batteries ............................................. 9
Storage and Returning to Service ................ 10
Storage ..................................................................... 10
Returning to Service ................................................. 11
CLEANING
damage.

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.

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

damage.



the key.
Load Test (6-volt batteries only)

NOTE: The batteries must be fully charged before performing this test.
1. Clean the batteries. Refer to Cleaning the Batteries section for information on cleaning
the batteries.
2. Load test each battery using a battery load test meter (available at most auto parts
distributors). Follow the instructions provided with the test meter.
• If any battery fails the load test, then it should be replaced.
NOTE: If the batteries are over one year old, it is recommended to replace
them as a set.
• If all batteries fail the test you should check the charging system before replacing the
batteries. Refer to Charger Troubleshooting section for information on checking the
charging system.
Batteries Page 3
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.
them as a set.
Reconnect the batteries, remove the blocks from the wheels and test drive.
Batteries Page 4
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.

damage.



the key.
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

the key.
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
REPLACING (6-VOLT BATTERIES ONLY)

Failure to do so may result in severe property damage and or serious

may result in serious bodily injury.

to explode resulting in property damage and/or bodily injury.

the key.
them as a set.
6. Thoroughly clean the batteries and battery compartment. Refer to Cleaning in this section
for information regarding cleaning the batteries.

in property damage.
Batteries Page 7
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
Moist Charge Batteries



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

the key.
Batteries Page 9
6. Fill all battery cells with electrolyte to the proper

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

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
Returning to Service




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

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
Sevcon Control System Troubleshooting
Includes Power Pak and Micro Pak controllers
TABLE OF CONTENTS
Test Equipment Required: ...................... 2

Definitions: ............................................ 2
Terminology used: .................................. 2
Important Notes and Instructions ........... 2
Identifying Your Controller ..................... 3
Start Troubleshooting Here .................... 4
Test 8. Anti-Rolloff Fault ........................ 15
Test 9. Electric Motor Brake .................. 16
Logic Voltage Reference Table ............... 18
Status LED Code Table .......................... 19
Smart View Fault Codes ......................... 20
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).
This troubleshooting guide is written in sequential order. All tests

must be performed in the order that they are written. Starting in the
middle or skipping sections when not instructed to do so may lead to
invalid test results.
Rev. S
Electrical Troubleshooting
Test Equipment Required: Important Notes and Instructions

• Digital multimeter (DMM) with diode test • This troubleshooting procedure is for the
function, FLUKE 79 model shown. Sevcon Power Pak and Micro Pak motor
• Throttle Module Analyzer, Taylor-Dunn part speed controllers as equipped in standard
number 62-027-32 vehicles. Troubleshooting may not be valid
for vehicles equipped with special order
speed control options.
Definitions: • For additional troubleshooting information,
use the handheld system anylizer part
• Battery volts = full voltage available at the number 62-027-61 or the computer system
batteries at the time of test. anylizer (PCpaK) part number 62-027-63.
• High: Greater than +4.5 volts See note below.
• Low: Less than +1.8 volts • This troubleshooting guide assumes a
familiarity with the use of a digital multimeter
including, voltage tests, continuity tests, and
Terminology used: diode testing. If you are not familiar with
• The “HOT” side of a switch is the terminal these types of tests then refer testing to a
that the power is connected to. qualified technician.
• The “COLD” side of a switch is the terminal • These tests are not intended to locate a
that the power is switched to. problem on an incorrectly wired vehicle.
• FS-1 = Micro-switch in the accelerator • Make sure the batteries are in good condition
module. and fully charged before performing any
tests.
• If the vehicle exhibits intermittent problems,
DURING ALL TESTS it must be in the failed mode for
troubleshooting. If it is running normally
• After any repairs are made, completely retest when the testing is done then the problem
vehicle before lowering the drive wheels to will not be identified.
the ground. • Some tests refer to a High/Low switch. The
High/Low switch is optional and the vehicle
may not be equipped with this option. If the
Turn the Key switch OFF BEFORE disconnecting vehicle is without this option, there is a
the batteries. Disconnecting the batteries with jumper bypass installed in place of the switch
the key switch ON may corrupt the controller in the dash.
programming resulting in a fault code 1 (refer • All voltage tests are done referenced to
to fault table). battery negative, unless otherwise specified.
• At the start of each test sequence you will
be instructed on how to place the control
switches. While testing, do not change the
Turn the Key switch OFF then disconnect both position of any switches unless instructed
of the battery leads during any maintenance or to do so.
before disconnecting any electrical component Note: The PCpaK application is also capable of uploading
or wire. Failure to do so may cause severe bodily new controller parameters to the controller.
injury and/or property damage. Controller parameter sets are available from Taylor-
Dunn. Individual parameters cannot be changed.
The rear drive wheels may rotate during some

of the following tests. Block the front wheels, This troubleshooting guide is written in
raise the rear drive wheels off the ground, and sequential order. All tests must be performed in
support the vehicle with jack stands. Failure to the order that they are written. Starting in the
do so may cause the vehicle to move and cause middle or skipping sections when not instructed
property damage and/or serious bodily injury. to do so may lead to invalid test results.
Sevcon Troubleshooting
Page 2
Identifying Your Controller
Page 3
START TROUBLESHOOTING HERE
If your vehicles is equipped with an electric motor brake, the motor

brake system must be checked to be sure it is working properly before
continuing with this troubleshooting. Operating the speed control
when the motor brake has not disengaged may result in damage to
the motor or speed control system. Refer to Test 9: Electric Motor
Brake for information regarding testing the motor brake system.
The electric motor brake is mounted between

the drive motor and the primary reduction
gear case. An illustration of the motor brake
is shown to the left.
This troubleshooting guide is written in

sequential order. All tests must be performed in
the order that they are written. Starting in the
middle or skipping sections when not instructed
Electric motor brake to do so may lead to invalid test results.
If the Battery Status Indicator does not show

a charged battery, check the following:
• The batteries
• The wiring from the battery status indicator
to the batteries for open circuits
• The battery status indicator
• The positive and negative circuit breaker
• The main circuit breaker for open circuits
Do not continue unless the indicator shows a
charged battery.
If the vehicle runs in one direction only, then skip
ahead to test #3.
If the vehicle runs slow in forward, but otherwise
runs normal, then skip ahead to test #1.3.
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 injury or property damage.
Page 4
Test 1. CHECKING THE CONTROL LOGIC TEST 1.3:

INPUTS
Test the voltage at pin #6 on the 12-pin logic card
Close the seat switch. Place the high/low switch in connector.
the HIGH position. If the voltage is low, then skip ahead to Test
#1.4.
Connect a voltmeter across the ISO solenoid coil
If the voltage is high, then check the wire to
terminals and carefully monitor the voltage as the the High/Low switch and the High/Low
key switch is turned on. switch for open circuits.
Turn the key switch ON and wait 1-second until NOTE: The High/Low switch is optional and the
the Isolator contactor closes. vehicle may not have this option. If the
vehicle is not equipped with option then there
Perform the following tests: is a jumper bypass installed in place of the
switch in the dash. Check the jumper to be
TEST 1.1 sure it is still connected.
The coil voltage should start at approximately 24 Stop trouble shooting here and repair the
volts when the key is turned ON, then drop to problem. When the repair is completed,
completely retest the vehicle before lowering
approximately 15 volts after about 0.5 seconds.
the drive wheels to the ground.
STOP
If the test is good, then skip ahead to test #
1.2.
If the voltage starts high, drops to 15 volts,
and then drops to 0 volts, then it indicates TEST 1.4:
an open circuit to the main battery positive.
Check the continuity of the ISO solenoid Test the voltage at pin #5 on the 12-pin logic card
contacts, the main circuit breaker, and the connector.
wiring to the main battery positive post.
If the voltage is low, then skip ahead to Test
If the voltage is starts at 24 volts but the
#1.5.
solenoid does not pick up, then skip ahead
If the voltage is high, then:
toTest #5.
If the voltage does not start at 24 volts, then
• Check the seat switch for open contacts.
go to Test #4. • Check that the seat switch is engaging the
seat correctly.
TEST 1.2: • Check the wire from the pin 5 to the seat
switch for open circuits.
Test the voltage from B+ to B- on the Controller. • Check the wire from the seat switch to B-
If the voltage equals battery volts, then go for open circuits.
to Test #1.3. If all of the above is in working order, then the
If the voltage does not equal battery volts, logic card may have failed.
then: Stop trouble shooting here and repair the
• Check the main positive wire to the circuit problem. When the repair is completed,
breaker for open circuits. completely retest the vehicle before lowering
• Check the wire from the circuit breaker to the drive wheels to the ground.
battery positive.
• Check the wire from the contactor to B+ on
the controller for open circuits.
STOP
Stop, do not continue. Reaching this point
• Check the wire from B- to battery negative
on the controller for open circuits. indicates a failure in the Sevcon power unit
Stop trouble shooting here and repair the or an error was made during testing. Confirm
problem. When the repair is completed, all previous tests were performed correctly
completely retest the vehicle before lowering before replacing the Sevcon power unit.
Page 5
TEST 1.5:
connector.
If the voltage is high, then skip ahead to Test
#1.6.
#6.
TEST 1.6:

connector.
NOTE: Pin #7 is for a parking brake interlock switch.
This switch is not available for all vehicles
and may not be used.
#1.7.
If the voltage is low, then:
• Check the park brake switch for shorted
contacts.
• Check the wire to the park brake switch for
short circuits to B-.
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.
TEST 1.7:
Depress the accelerator pedal to engage FS-1 only TEST 1.8:

(creep speed).
Perform the following tests: connector.
Test the voltage at pin #10 on the 12-pin logic card If the voltage is low, then skip ahead to Test
connector. #1.9.
If the voltage is below 0.3 volts, then skip #6.
ahead to Test #1.8.
If the voltage is above 0.3 volts, then skip
ahead to Test #6 TEST 1.9:
Depress the accelerator pedal fully.

This troubleshooting guide is written in connector.
sequential order. All tests must be performed in If the voltage is between 4.8 and 5.1 volts,
the order that they are written. Starting in the then skip ahead to Test #2.
middle or skipping sections when not instructed If the voltage is not between 4.8 and 5.1 volts,
to do so may lead to invalid test results. then skip ahead to Test #6.
Page 6
Test 2. TESTING THE MOTOR

Disconnect both of the battery leads during any maintenance or

before disconnecting any electrical component or wire. Failure to do
so may cause property damage and/or serious bodily injury.
NOTE: Special and expensive motor testing equipment is required in order to accurately measure motor armature
or field resistance. In most cases, this equipment is not required in order to determine if a motor is faulty.
The majority of motor failures are due to an open circuit in the field or armature windings. If the symptom
of the vehicle is “not running with NO motor current” then a simple continuity test of each winding is all
that is required to determine if the motor is at fault.
TEST 2.1:
Check the motor field continuity from the motor

F1 to the motor F2 terminals.
If the resistance is close to values given in
the motor specification table, then skip
ahead to test #2.2. (The motor specification
table can be found in the “Motor Service”
section).
If the test indicates an open circuit, then
repair or replace the motor.
Test continuity from F1 to the frame of the motor.
Any reading other than an open circuit
indicates a short in the motor.
Stop trouble shooting here and repair the Motor shown in illustrations is typical of a standard motor.
problem. When the repair is completed, The terminal configuration of your motor may be different.
STOP
TEST 2.2:
Check the continuity from the motor A1 to the A2

terminals.
If the resistance is close to values given in
the motor specification table, then go to test
#2.3.
If the test indicates high resistance or an
open circuit, then repair or replace the motor.
STOP
Page 7
TEST 2.3:
Test the continuity from the motor A1 terminal to
the frame on the motor and from F1 to A1 for open
circuits.
Any reading other than an open circuit
indicate a short in the motor. If there is a
short in the motor, stop here and repair or
replace the motor.
STOP
TEST 2.4:
Reaching this point indicates an open circuit in the motor wiring. Check the continuity of all wires
from the controller to the motor.
Repair any open wires then test drive the vehicle.
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.
After any repairs are made, completely retest This troubleshooting guide is written in
the vehicle before lowering the drive wheels to sequential order. All tests must be performed in
the ground. Failure to retest the vehicle could the order that they are written. Starting in the
result in unexpected movement of the vehicle middle or skipping sections when not instructed
resulting in injury or property damage. to do so may lead to invalid test results.
Page 8
Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY

Test 3.1: TEST 3.5
Close the seat switch, turn the key switch ON and Disconnect the batteries and remove wires from
wait 1-second until the Isolator contactor closes. the B-, F1, and F2 terminals on the controller.
If the vehicle runs in reverse only then skip Using the diode test function on your meter, connect
ahead to test #3.3.
the positive lead to the B- terminal on the controller.
Place the forward and reverse switch in the Connect the negative lead to the F1 terminal on the
FORWARD direction. controller.
The test should show the presence of a diode
Test the voltage at pin #2 on the 12 pin logic card
(approx 0.5v).
connector.
If the test is good, then skip ahead to test
If the voltage is low, then skip ahead to test #3.6.
#3.2. If the test is open or shorted then one or both
If the voltage is high, then skip ahead to Test directional FET’s are shorted and the
#7. controller must be replaced.
TEST 3.2: TEST 3.6

Test the voltage at pin #3 on the 12 pin logic card Disconnect the batteries and remove wires from
connector. the B-, F1, and F2 terminals on the controller.
If the voltage is high, then skip ahead to test
Using the diode test function on your meter,
#3.3.
If the voltage is low, then skip ahead to Test connect the positive lead to the B- terminal on
#7. the controller.
Connect the negative lead to the F2 terminal on
the controller.
TEST 3.3: The test should show the presence of a diode
(approx 0.5v). If the test is open or shorted
Place the forward and reverse switch in the then one or both directional FET’s are
REVERSE direction. shorted and the controller must be replaced.
connector.
STOP
If the voltage is low, then skip ahead to test
#3.4.
indicates a failure in the Sevcon power unit
If the voltage is high, then skip ahead to Test or an error was made during testing. Confirm
#7. all previous tests were performed correctly
before replacing the Sevcon power unit.
TEST 3.4:
connector.
If the voltage is high, then it is likely that the
internal directional control transistors have
failed, test the transistors at Test 3.5 and 3.6.
#7.
Page 9
Test 4. KEY FAULT

TEST 4.1: TEST 4.3:
Turn the key switch ON and place the forward and Test the voltage at the cold side (violet/black wire)
reverse switch in the center OFF position of the key switch.
Perform the following tests: If the voltage equals battery volts, then skip
ahead to test #4.4.
Test the voltage at pin #1 on the 12 pin logic card If the voltage does not equal battery volts,
connector. then replace the key switch.
If the voltage equals battery volts, then skip
ahead to Test #5. Stop trouble shooting here and repair the
Test the voltage on both terminals of the battery completely retest the vehicle before lowering
voltage positive circuit breaker (see below). the drive wheels to the ground.
If the voltage on both terminals equals
battery volts, then skip ahead to test #4.2.
If the voltage on both terminals does not TEST 4.4:
equal battery volts, then check the circuit
breaker and wiring to the main circuit breaker Check the wire from the cold side of the key switch
and to the batteries for open circuits. to pin #1 on the 12 pin logic card connector for
open circuits.
completely retest the vehicle before lowering NOTE: Your vehicle may be equipped with a charger
the drive wheels to the ground. interlock relay. The charger interlock relay
disables the control system when the
charger is connected to its power source.
TEST 4.2: The interlock relay contacts are in series with
the wire from the cold side of the key switch
Test the voltage at the hot terminal (red wire) on to pin #1 on the 12 pin logic card connector.
the key switch. The relay is located in the charger cabinet.
If the voltage equals battery volts, then skip Stop trouble shooting here and repair the
ahead to test #4.3. problem. When the repair is completed,
If the voltage does not equal battery volts, completely retest the vehicle before lowering
then check the wiring from the key switch to the drive wheels to the ground.
STOP
the battery voltage positive circuit breaker.
Stop trouble shooting here and repair the Stop, do not continue. Reaching this point
problem. When the repair is completed, indicates a failure in the Sevcon power unit
completely retest the vehicle before lowering or an error was made during testing. Confirm
all previous tests were performed correctly
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
Typical Circuit Breaker resulting in injury or property damage.
Page 10
Test 5. CONTACTOR COIL FAULT

Disconnect the 12-pin logic card connector from the Sevcon power unit.
Turn the key switch ON and perform the following tests:
TEST 5.1:
Check the voltage on the positive coil terminal of the ISO solenoid
(violet wire).
If the voltage is within approximately 1-volt of the battery
voltage, then skip ahead to test #5.2.
If the voltage is not within approximately 1-volt of the
battery voltage, then check the diode in the positive wire
to the ISO solenoid.
Stop trouble shooting here and repair the problem. When

the repair is completed, completely retest the vehicle before
TEST 5.2:
Check the voltage on the negative coil terminal of the contactor

coil.
If the voltage is not within 1-volt of battery voltage, then
the contactor is bad and must be replaced.
NOTE: An open contactor coil should be accompanied by a 4-flash
code from the logic LED.
If the voltage is within 1-volt, then one of the four
following faults may have occurred:
Broken Wire: Check the wire from pin #8 in the 12-
pin logic card connector to the contactor coil negative terminal for open circuits.
Welded Solenoid Contacts: Test the solenoid for welded contact tips. There are two methods
for checking the contacts:
1. Disconnect the batteries and test the continuity across the contacts. If there is
continuity then the contact tips are welded.
2. With the key switch OFF, check the voltage at the B+ terminal on the Sevcon control
(see illustration on following page). If the voltage at the B+ terminal is at full battery
voltage then the contact tips are welded.
NOTE: Welded tips should be accompanied by a 4-flash code from the logic LED.
Shorted Solenoid Coil: Disconnect the logic card connector and measure the resistance
across the solenoid coil. Depending on the solenoid or contactor you vehicle is equipped
with, the resistance should be 25 ohms or higher (nominal). A reading less than 25 ohms
may indicate a shorted coil.
The control logic may have failed. STOP
or an error was made during testing. Confirm
Page 11
Test 6. ACCELERATOR MODULE FAULT
Disconnect both of the battery leads during any maintenance or

so may cause property damage and/or serious bodily injury.
With the power switch OFF, connect the throttle

module to the analyzer.
Position the power switch to the 0-5 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 note
below).
The voltage on the digital display should vary
with the position of the module arm, starting at
0-volts and ending at approximately 5-volts.
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)
NOTE: 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 12
Test 7. FORWARD AND REVERSE SWITCH FAULT

Turn the key switch ON, place the forward and reverse switch in the center OFF position and
perform the following tests:
TEST 7.1:
Referencing battery positive, test the voltage on the center

terminal of the F&R switch (Black wire).
If the voltage equals battery volts, then skip ahead to
test #7.2.
If the voltage does not equal battery volts, then check
the wire from the F&R switch to the battery voltage circuit
breaker.

TEST 7.2:
If the vehicle does not travel in reverse, skip ahead to
test #7.3.
Place the forward and reverse switch in the FORWARD
position.
Referencing battery positive, test the voltage at the Blue/Black
wire on the F&R switch.
If the voltage equals battery volts, skip ahead to test
#7.4.
If the voltage does not equal battery volts, then the F&R
switch has failed.

This troubleshooting guide is written in After any repairs are made, completely retest
sequential order. All tests must be performed in the vehicle before lowering the drive wheels to
the order that they are written. Starting in the the ground. Failure to retest the vehicle could
middle or skipping sections when not instructed result in unexpected movement of the vehicle
to do so may lead to invalid test results. resulting in injury or property damage.
Page 13
TEST 7.3:
If the vehicle does not travel in forward, skip ahead to

test #7.4.
Place the forward and reverse switch in the REVERSE
position.
Referencing battery positive, test the voltage at the White/Black
wire on the F&R switch.
If the voltage equals battery volts, skip ahead to test
#7.4.
If the voltage does not equal battery volts, then the F&R
switch has failed.

TEST 7.4:
Check the wires from the F&R switch to the logic card connector for continuity.
STOP
or an error was made during testing. Confirm
Page 14
Test 8. ANTI-ROLLOFF FAULT

The Sevcon Controller is equipped with a feature called Anti-Rolloff. Anti-Rolloff will
automatically slow the vehicle if it starts to roll. Anti-Rolloff is active when the key switch has
been left in the “ON” position and the accelerator pedal is not depressed. Anti-Rolloff is
deactivated when the key switch is in the “OFF” position When the key switch is in the “ON”
position and the truck is stationary, the controller supplies a small current to the field. This
current is used to sense if the armature is rotating. As the armature begins to rotate, the
controller senses a fault condition and then supplies current to the field opposing the armature
rotation, slowing the vehicle.
Refer to Motor Specifications Table for information on the maximum allowable field current
when the Anti-Rolloff feature is active.
To test the Anti-rolloff feature:

Park the vehicle on a flat level surface, turn the key switch OFF and apply the parking brake.
Connect an analog Ammeter in series with the motor field windings or a clamp on Ammeter on
one of the field wires that is capable of reading up to 25-Amps.
Place the forward and reverse switch in the center OFF position and turn the key switch ON
TEST #8.1
Read the motor field current on the Ammeter.
If the field current is greater than specified in the Motor Specification table (see Motor
Service section for specifications), then the Anti-Rolloff feature has failed. Check the
status of the Anti-Rolloff feature using the hand held calibrator (62-027-61).
TEST #8.2
While monitoring the motor field current, release the park brake, and push the vehicle.
The surface must be level for this test. Do not attempt to test the
Anti-Rolloff by pushing up or down an incline. Testing by pushing up
or down an incline could result in injury or property damage.
Within approximately 10-feet, the field current should rise dramatically and the vehicle should
become difficult to push. Now stop pushing the vehicle and allow it to come to a complete stop.
The field current should drop down below the value specified in the Motor Specification table.
This indicates that the Anti-Rolloff feature is operating normally.
If the current does not rise, then the Anti-Rolloff feature has failed or has been turned
off.
The status of the Anti-Rolloff feature can be checked with the hand held calibrator.
If the Anti-Rolloff feature is on and the field current did not rise, then the controller has
failed and must be replaced.
If the Anti-Rolloff feature is off then the controller logic must be reprogrammed. Contact
your dealer.
Page 15
Test 9. ELECTRIC MOTOR BRAKE
Description:
The electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor
and the primary reduction gear case. The brake is controlled by the speed controller logic. At what
times the brake is applied or released is dependent on the controller programing and will vary
depending on the model vehicle.
Operation:
B+ is supplied to the brake when the key switch is turned on. When the control logic determines that
it is time to start, it provides B- at 24-volts through pin #9 on the logic card connector.
Testing: Test 9.1

Place the forward and reverse switch in the OFF Close the seat switch, turn the key switch ON, place
position, turn the key switch OFF. the forward and reverse switch in the FORWARD
position, depress the accelerator pedal to engage
Rotate the drive wheels to confirm the brake is
FS-1 only (creep speed).
engaged.
If the brake is engaged then skip ahead to Rotate the drive wheels to confirm the brake has
9.1. released.
If the brake is not engaged then: If the brake released, then the brake system
Disconnect the electric brake harness connector and is working and no further testing of the brake
repeat the test. is required.
If the brake is still not engaged then:
If the brake did not release, then perform the
• Remove the brake and repair or replace following tests:
the brake as required. Stop trouble shooting
here and repair the problem. When the Connect a volt meter from battery negative to the
repair is completed, completely retest the Violet/Black wire at the electric brake harness plug.
vehicle before lowering the drive wheels to If the voltage is less than battery volts then:
the ground. • Check wiring to the key switch and continue
If the brake engaged after the harness was troubleshooting at test #4.2.
disconnected then: If the voltage equals battery volts then:
Inspect the harness for shorts. Connect a volt meter across the Violet/Black wire
Stop troubleshooting here and repair the problem. and the Blue wire at the electric brake harness plug.
When the repair is completed, completely retest the The voltage should start at approximately 24 volts,
vehicle before lowering the drive wheels to the then drop to approximately 15 volts after about 0.5
ground. seconds.
If the test is good then:
• The pigtail harness to the electric brake is
The electric brake is part of the vehicle braking broken or the electric brake has failed.
system. Do not operate a vehicle with the Remove the brake and repair or replace
electric brake bypassed or disabled unless the as required.
system is being tested for faults. Operating a If the test is bad then:
vehicle with the brake bypassed or disabled
may result in severe personal injury or property
damage.
Page 16
Connect a volt meter across the Violet/Black wire at the electric brake harness plug and Pin #9 at the logic
card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts
after about 0.5 seconds.
If the test is good then:
• The blue wire from the electric brake harness plug to pin #9 on the logic card connector is
broken. 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.
If the test is bad then:
• The logic card is not releasing the brake. This could be a result of:
-Improper operation of the vehicle.
- fault in the vehicles wiring or switches.
-A fault in the speed controller.
-Incorrect programming.
-A failed speed controller.
Disconnect the electric brake harness connector and connect the electric brake to a 24-volt source. This
should release the brake and allow you to troubleshoot the vehicles control system. Return to the beginning
of the troubleshooting section and continue.
If the brake does not release then:
• The electric brake has failed. Remove the brake and repair or replace the brake as required.
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 17
Logic Voltage Reference Table
Pin# Condition Volts*

Key switch off 0.0 volts
1
Key switch on Battery volts
F&R in forward Low
2 F&R in neutral
High
F&R in reverse
F&R in reverse Low
3 F&R in neutral
High
F&R in forward
Accelerator pedal up High

4
Accelerator pedal down Low
Seat switch closed (depressed) Low

5
Seat switch open High
High/low switch in high Low

6
High/low Switch in low High
Hand brake switch closed Low

7
Hand brake switch open High
Key switch on (ref battery positive) **

8
Key switch off (ref battery positive) Battery volts
System off (ref battery positive) 0 volts

9
System on (ref battery positive) **
Accelerator pedal up 0.0-0.3 volts

10
Accelerator pedal down 4.8-5.0 volts
11 Not used -
12 Not used -
* - All voltages made referencing main negative unless specified otherwise

** - The voltage should start at approximately 24 volts, then drop to approximately 15 volts after
about 0.5 seconds.
Page 18
Status LED Code Table

The status LED on the Sevcon power unit logic card can be used to give you an idea of where
the problem may be. It is recommended that you complete the troubleshooting procedure to
confirm failure of any component.
Number
of Fault Description Possible Cause Actions
Flashes
1 Personality fault See dealer -
Reset the switches

Startup switches not
and start over (Refer
2 Sequence fault operated in the correct
to Vehicle Operating
order
Instuctions))
MOSFET or motor
3 Burned Motor Repair as required
short
Contactor fault or Contactor Failure Check contactor and
4
open motor Open Circuit motor
5 Not used - -
FS-1 Micro Switch Failure
Accelerator module Check accelerator
6 Faulty Wiring
fault module inputs
Accelerator Failure
Check battery and
Discharged battery or
7 Discharged battery connections to
loose connections
controller
Controller Wait for controller to
8 Overloaded truck
overheated cool
Check coil continuity
9 ISO coil shorted ISO Coil Short Circuit and replace as
required
Check wiring. If
Fault in the Wiring to the vehicle is not
dash display or a faulty equipped with a
12 Can Buss Fault Dash Display dash display, check
NOTE: The Dash Display is for debris in the 6-
Optional pin connector on the
logic card
Page 19
Smart View Fault Codes

Level 5 Faults (F05xxx) Level 4 Faults (F04xxx)
F05000 “Contactor Over Current” F04001: “Contactor Welded”
This faut occurs when too much current is going into High voltage at power up to the controller B+ terminal.
the line contactor coil circuit. This could be a result Check wiring, contactor, and pre-charge resistor on the
of a shorted contactor coil, short in the wiring, or contactor.
faulty logic card. F04002: “Steer Pot”
F05004: “VA Fail” Steer Pot currently not used and this fault should not
This is a result of a low voltage on an internal voltage occur. Check wiring.
regulator. Can also be caused by a low key switch input F04003: “Sequence Fault”
voltage. If the key switch input is within specifications, Start-up switches not operated in the correct order or
then replace the controller. fault in start-up switches or wiring. Refer to operator
F05006: “MOSFET Short Circuit” section for correct operating sequence of switches.
Also can be a result of an open motor armature circuit. F04004: “Two Directions Selected”
Confirm the motor armature and wires to the motor are Both Forward and Reverse selected at the same time.
good. If motor and wires are good, then replace the Check F&R switch and wiring.
controller. F04005: “SRO”
F05008: “Power Up Traction Welded” Start-up switches not operated in the correct order or
Normaly due to line contactor welded closed resulting in fault in start-up switches or wiring. Refer to operator
a high voltage at B+. This fault is generated when the section for correct sequence of switches. Normally a
differential voltage between the key switch input and the result of F&R selected before start switch is turned on.
B+ terminal is less than approximatly 6-volts. F04006: “Traction Seat”
F05009: “Shorted MOSFET” Seat or foot interlock switch open. Check interlock
Normaly due to interal short in controller. Also could be switch, wiring.
result of shorted motor or wiring. Remove the wire from F04007: “Inch Switch”
the controller terminal “S”. If fault clears then the short is Inch switch ON at power up; both switches selected at
in the motor or wiring. same time; inching attempted with seat interlock, F&R
F05046: “Line Contactor Did Not Close” switch, or FS-1 closed.
Normaly due to open circuit to the controller B+ terminal. F04008: “Steer”
Check wiring, contactor, main Circuit Breaker. Steer Function currently not used and this fault should
NOTE: Controller B+ terminal must be within 1.5 volts of not occur. Check wiring.
Pin 1 after contactor closes.
F04009: “Low Battery”
All other level 5 faults are a result of an internal failure Low voltage at Pin 1 of controller connector. Normally a
in the Sevcon controller and cannot be repaired. result of discharged batteries. Check wiring, start switch,
The controller must be replaced. interlock switches, batteries.
F04010: “High Battery”
High voltage at Pin 1 of controller connector. Check for
correct voltage battery installed, check controller
parameters.
F04011: “Personality Range”
One or more controller personalities are out of range.
Correct parameters must be uploaded to the controller.
F04012’: “Personality CRC”
Controller personalities are corrupted. Could be a
result of a damaged logic card. Attempt uploading
new parameters. If upload fails, then controller must
be replaced.
F04013: “Capacitor high”
Page 20
Level 2 Faults (F02xxx) Level 1 Faults (F01xxx)

F02000: “Accelerator” Most Level 1 faults are a result of operator error or
Wiring to throttle module is open or faulty throttle operation of the vehicle.
module. F01000: “Power Steer Overheat”
F02001: “Accelerator (power up)” Not used.
Throttle module FS-1 switch is closed (pedal depressed) F01001: “Traction Motor Brush Wear”
or wiring shorted when start switch is turned on. Not used.
Throttle module output high when start switch is turned
on. F01002: “Pump Motor Brush Wear”
Not used.
F02002: “Belly Switch”
Belly Switch currently not used and this fault should F01003: “Power Steer Motor Brush Wear”
not occur. Check wiring. Not used.
F02003: “Open Field” F01004: “BDI Cutout”

Not used. Low voltage at Pin 1 of controller connector. Normally a
result of discharged batteries. Check wiring, start switch,
F02004: “Open Field (L)” interlock switches, batteries. NOTE: Fault will not reset
Not used. until batteries successfully complete a charge cycle and
F02005: “Open Field ((R)” battery voltage is above reset threshold.
Not used. F01005: “Traction Block Overheat”
Controller has overheated. Allow controller to cool off.
F01006: “Traction Motor Hot”
Not used.
F01007: “Pump Motor Hot”
Not used.
F01008: “Encoder Wiring”
Motor speed encoder faulty, faulty wiring., or incorrect
controller parameters.
Page 21
TAYLOR -DUNN
Lestronic II® Charger Troubleshooting
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 C
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

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.

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
so may result in serious bodily injury.

TROUBLESHOOTING FOR BUILT-IN CHARGER
key.
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.

• 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.

• 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.

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.

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).

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
key.
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.

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
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
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.

Page 3
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

Page 4
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.

Page 5
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:
key.
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.

Page 6
Illustrated Parts
TABLE OF CONTENTS
Steering Knuckle ......................................... 2

Front Brakes ............................................... 4
Steering Linkage ......................................... 6
Steering Column ......................................... 8
Steering Gear .............................................. 10
Front Suspension ........................................ 12
Wheels and Tires ........................................ 12
Transmission Gear Case ............................. 14
Rear Axle .................................................... 16
Transmission Differential Case .................... 16
Rear Brakes ................................................ 18
Master Cylinder ........................................... 20
Brake linkage .............................................. 20
Brake Lines ................................................. 22
Rear Suspension ......................................... 24
Motor .......................................................... 26
Rear Motor Mount ....................................... 26
Instrument Panel (dash) .............................. 28
Resetting the Smart View Display ............................. 29
Speed Control Panel ................................... 30
Miscellaneous Electrical .............................. 32
Signet® Charger ......................................... 34
Batteries
Roll Out battery Box .................................... 36
Lighting ....................................................... 38
Seat Cushions ............................................. 38
Decals......................................................... 38
Miscellaneous ............................................. 39
Illustrated Parts
Steering Knuckle
Parts Page 2
Illustrated Parts
Steering Knuckle
ITEM # PART # DESCRIPTION QTY
1 15-210-70 Axle beam 1
-
4 88-239-86 3/4-NF Hex nylon lock nut 2
5 88-228-60 3/4 Cut Flat Washer 2

6 98-603-07 Rubber Bushing 2
7 01-220-99 Washer 2
8 32-240-44 Bushing 2
9 32-240-43 Bushing 2
10 80-309-12 Thrust Bearing 2

11 45-338-00 Grease Seal 2
12 80-017-00 Tapered Bearing 4

13 80-103-00 Tapered Bearing Race 4
14 12-158-10 Wheel Hub W/Rotor (incl 1-#12, 1-#11, 1-#13) 2
15 88-228-61 3/4 SAE Flat Washer 2

16 88-527-14 1/8 x 1-1/2 Cotter Pin 2
17 88-239-85 3/4-NF Hex Slotted Nut 2

18 92-104-01 Bearing cap 2
21-020-18 Right Steering knuckle 1

19
21-020-17 Left Steering Knuckle 1
20 96-329-00 Wheel stud 10
Parts Page 3
Illustrated Parts
Front Brakes
Brake body (#9 above)
Parts Page 4
Illustrated Parts
Front Brake
1 88-067-21 Bolt, 1/4 X 3-3/4" NC, Hex Head, Gr. 8 4

2 41-350-51 Plate, Secondary, Hydraulic Disc 2
3 41-348-70 Pad, Disc Brake 4
4 41-348-57 Spacer, Disc Brake 4
5 32-240-41 Bearing Teflon Coated
R
4
6 99-588-00 Bleeder screw 2
7 99-588-01 Bleeder screw adapter 2
8 88-069-82 Locknut, 1/4" NC, Gr. 8 Do Not Reuse 4
9 41-350-30 Brake Body Assembly (see below for components) 2
10 See Brake Lines Brake hose
11 See Steering Knuckle Front hub and rotor
Brake Body (41-350-30)

1 - - -
2 - - -
3 41-350-45 Brake body 1
4 80-713-00 O-ring 4
5 41-350-09 Boot 4
6 41-350-10 Piston 4
Parts Page 5
Illustrated Parts
Steering Linkage
Parts Page 6
Illustrated Parts
Steering Linkage
1 18-057-00 Tie rod 1
2 86-510-00 Ball joing clamp 4
3 86-501-98 Ball joing (left) 2
4 86-501-99 Ball joint (right) 2
5 88-527-11 1/8 x 1 Cotter pin 4
6 K1-157-99 Drag link 1
7 88-159-85 1/2NF Castle nut 4
- 18-104-00 Pitman arm 1
Parts Page 7
Illustrated Parts
Steering Column
2
The steering column is an
integral part of the frame and is
not shown. Part ID# 5 is located
in the top of the steering column
tube.
5
Ref., Steering Gear

{
6
Parts Page 8
Illustrated Parts
Steering Column
1 88-199-82 5/8NF Hex nut 1
2 19-011-20 Steering wheel 1
3 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 1
4 88-089-84 5/16NF Hex lock nut, grade C 1
5 32-248-10 Upper bushing 1
6 20-031-65 Steering shaft assembly (incl. 3 and 4) 1
7 19-011-25 Steering wheel cap 1
8 88-128-62 7/16 Split lock washer 3
9 88-120-15 7/16 x 1 Hex bolt 3
88-279-82 7/8NF Thin pattern hex nut, Pitman shaft 1
Not Shown 88-268-62 7/8 Split lock washer, pitman shaft 1
30-807-00 COVER,STEERING GEAR SUPT 1
Parts Page 9
Illustrated Parts
Steering Gear
17 16
15
1
14
2 13
12
3
11
10
4
5
7
9
Exploded Steering Gear.dwg 8
Parts Page 10
Illustrated Parts
Steering Gear 18-308-21

1 18-308-70 Locknut 1
2 18-308-71 Adjuster assembly 1
3 18-308-72 Worm assenbly 1
4 18-308-23 Upper worm bearing 1
5 18-308-22 Upper worm bearing race 1
6 18-308-77 Housing 1
7 18-308-78 Seal, pitman shaft 1
8 18-308-80 Nut, pitman shaft 1
9 18-308-81 Lock washer 1
10 18-308-79 Seal, input shaft 1
11 18-308-82 Gasket 1
12 18-308-76 Pitman shaft 1
13 18-308-75 Gear lash adjuster 1
14 18-308-85 Shim kit 1
15 18-308-84 Side cover 1
16 18-308-86 Jam nut 1
17 18-308-83 Bolt, side cover 3
Parts Page 11
Illustrated Parts
Front Suspension
Front axle (ref)

5
2
8
1
Wheels and Tires
Illustration not available
Parts Page 12
Illustrated Parts
Front Suspension
1 96-121-00 U-bolt 4
2 85-486-00 Leaf spring 2
3 32-214-50 Bushing 12
4 96-240-00 1/2NC x 4 Hex bolt 6
5 88-149-81 1/2NC Lock nut 8
6 - - -
7 88-149-81 1/2NC Lock nut 6
8 16-872-00 Spring hanger 4
Wheels and Tires

K4T-600X9-EL Tire/Wheel assembly, SOFTUFF 600X9 4
97-236-00 Wheel nut 20
Parts Page 13
Illustrated Parts
Transmission Gear Case
Parts Page 14
Illustrated Parts
Transmission Gear Case

1 GT-71682 M8 x 60 bolt 12
2 GT-3287563 Gear case cover 1
3 GT-71259 Bearing 1
4 GT-3287533 Input shaft, 18:1 1
5 GT-71982 O-ring 1
6 GT-3287503 Eccentric shaft 1
8 GT-3287493 Idler gear 1
9 GT-70302 M10 x 30 Bolt 6
10 GT-71715 Snap ring 1
11 GT-3287553 Gear case housing 1
12 GT-72019 Seal 1
21 GT-3273633 Pinion nut 1
23 See Note 1, previous page Spacer 1
24 GT-3287473 Output gear, 18:1 1
GT-328 Spacer, 46.100mm 1
GT-328 Spacer, 46.100mm 0 or 1
25 GT-328 Spacer, 46.125mm 0 or 1
GT-3287903 Shim, 0.100mm 0 or 1
GT-3287883 Shim, 0.400mm 0 or 1
GT-3287893 Shim, 0.500mm 0 or 1
26
GT-3287853 Shim, 0.600mm 0 or 1
GT-3287863 Shim, 0.700mm 0 or 1
GT-3287873 Shim, 0.800mm 0 or 1
30 GT-70299 10mm Washer 6
37 GT-3252633 Dowel pin 2
Parts Page 15
Illustrated Parts
Rear Axle
Outer Bearing
Inner Bearing (no o-ring)
Axle Shaft
O-Ring
O-Ring Groove
Inner bearing on optional double bearing axle does

not have an oil seal or o-ring. Orientation of bearing
should have o-ring groove adjacent to o-ring on
outer bearing.
Transmission Differential Case
Parts Page 16
Illustrated Parts
Rear Axle
1 41-154-25 Axle shaft, 2
2 80-505-20 Bearing 2
2a 80-505-30 Bearing 2*
3 41-490-11 Disc brake rotor 2
4 41-172-21 Hub 2
5 88-268-63 Flat washer 2
6 88-268-30 7/8-14 x 1.5 Bolt, grade 5 2
7 96-329-10 Wheel stud 10
92-104-10 Hub cover 2
41-290-78 Axle housing (L) 1
Not shown 41-290-79 Axle housing (R) 1
89-113-30 M12 x 1.75 x 30mm Hex bolt (axle housing to center section) 6
89-113-60 M12 Split lock washer (axle housing to center section) 6
Transmission Differential Case

9 GT-70302 M10 x 30 Bolt 12
13 GT-3287183 Ring and pinion gear set 1
14 GT-3297193 Differential case cover 1
15 GT-3287133 Adjusting ring 2
16 GT-70417 Fill/Level plug 1
17 GT-3287113 Differential housing 1
19 GT-3287143 Differential case 1
20 GT-72013 O-ring 1
22 GT-71896 M10 x 25 Bolt 12
29 GT-71978 Bearing and race 2
30 GT-70299 10mm Washer 12
31 GT-71881 Seal 1
32 GT-70052 Vent 1
Parts Page 17
Illustrated Parts
Rear Brakes
Brake body (#8 above)
Parts Page 18
Illustrated Parts
Rear Brakes
1 88-067-21 Hex bolt, grade 8 4
2 41-350-51 Secondary plate 2
3 41-348-70 Brake pad 4
4 41-348-57 Spacer 4
5 32-240-41 Bushing 4
6 41-350-28 Mounting bracket 2
7 See Rear Axle Hex bolt with thread locking compund 8
8 - Brake body assembly (see below for components) 2
9 88-840-11 Retaining ring 2
99-588-00 Brake bleeder 2
10
99-588-01 Bleeder adaptor 2
11 32-220-03 Bushing 2
12 41-350-56 Park brake pin 2
13 41-350-12 Park brake lever bracket 2
41-350-52 Clevis pin 2
14
88-100-00 Washer 2
15 41-350-53 Brake arm 2
16 88-069-82 1/4NC locknut, grade 8 4
Brake Body (41-350-30)

1 - - -
2 - - -
41-350-44 Brake body (right) 1
3
41-350-43 Brake body (left) 1
4 80-713-00 O-ring 4
5 41-350-09 Boot 4
6 41-350-10 Piston 4
Not Shown 41-886-00 1/8 pipe plug 2
Parts Page 19
Illustrated Parts
Master Cylinder
Brake linkage
Linkage at the brake caliper
Parts Page 20
Illustrated Parts
Dual Reservoir Master Cylinder

1 88-080-14 Bolt, 5/16" X 1-1/2" NC, Hex Head 2
2 99-511-20 Master Cylinder (includes item #3) 1
99-511-52 Cap Seal, Master Cylinder 1
3
99-511-53 Cap, Master Cylinder 1
4 88-088-61 Washer, 5/16" 4
5 88-089-81 Locknut, 5/16" 2
Not Shown 99-510-51 Rubber Boot, Master Cylinder 1
BRAKE LINKAGE
1 88-080-11 Bolt, 5/16 x 1", Hex Head 2
2 51-344-80 Park Brake Handle 1
3 88-088-61 Washer, 5/16" 4
4 88-527-11 Cotter Pin, 1/8 X 1" Steel 2
5 96-771-00 Clevis Pin, 3/8 x 3/4" 1
6 96-773-00 Clevis Pin, 5/16 x 1" 1
7 96-820-25 Adjusting Brake Cable Assembly 1
8 01-204-32 Brake Equalizer 1
9 88-089-81 Locknut, 5/16" 2
10 88-099-80 Nut, 5/16" Hex Head 2
11 96-760-00 Brake Cable Clevis 1
12 96-826-12 Park Brake Cable from equalizer to the rear brakes 2
13 96-773-00 Clevis pin 2
14 88-517-11 Cotter pin 2
15 85-125-00 Spring 2
16 96-754-00 Clevis 2
17 96-826-09 Cable lock 2
41-350-59 Brake arm extension (located at the rear brakes), starting serial number 157201 2
85-250-00 Brake pedal return spring 1
Not Shown 50-009-00 Master cylinder push rod 1
17-104-00 COLLAR,3/8 IN.SHAFT (on the push rod) 1
96-762-00 Clevis (pushrod) 1
Parts Page 21
Illustrated Parts
Brake Lines
Parts Page 22
Illustrated Parts
Brake Lines with Dual Reservoir Master Cylinder

ITEM# PART # DESCRIPTION QTY
1 99-648-54 Brake Line, Front 1
2 K54-700-01 Brake Line, Rear 1
3 99-648-57 Brake Line, Front Right 1
4 99-648-56 Brake Line, Rear, 1
5 99-604-57 Brake Line, Rear Right, 1
6 99-604-56 Brake Line, Rear Left, 1
7 99-580-20 Brake Hose, Rear 2
8 99-580-10 Brake Hose, Front 2
9 99-564-00 T-Fitting 1
10 99-575-10 Adaptor, 3/16T X 1/8P 2
11 99-576-00 Hose Clip 4
12 99-591-00 Brake light switch adaptor 2
Brake Light Switch 1
13 71-110-00
Brake Regen Switch 1
14 99-575-32 Adaptor, 3/16T x M10-1.0 2
15 99-559-00 T-Fitting, Single Male Flare to 2-Female Flare, 3/16 Tube 1
Not shown 99-603-01 Brake line between hydraulic switches #13 1
Parts Page 23
Illustrated Parts
Rear Suspension
View from rear
Parts Page 24
Illustrated Parts
Rear Suspension
96-240-00 1/2NC x 4 Spring bolt (front of the leaf spring) 2
Not shown
32-214-50 Spring bushing (front of the leaf spring) 4
14 85-510-17 Leaf spring 2
16-861-40 Spring mounting plate (left) 1
15
16-861-41 Spring mounting plate (right) 1
96-114-00 U-bolt 4
16
88-159-84 1/2NC Nylon lock nut 8
18 - - -
19 96-103-00 U-bolt 2
20 88-149-81 1/2NC Lock nut 4
21 50-460-00 Strap 2
22 98-002-00 Rubber overload spring 2
23 86-602-00 Shock 2
88-120-17 7/16NC x 2-1/4 Hex bolt 2
24 88-129-81 7/16NC Lock nut 2
88-128-60 7/16 Flat washer 2
Parts Page 25
Illustrated Parts
Motor
Rear Motor Mount
Parts Page 26
Illustrated Parts
Motor 70-057-40 (DV1-4003)

1 70-421-10 Front housing 1
2 70-400-10 Armature 1
3 70-209-40 Field assembly 1
4 85-403-00 Brush spring 4
5 70-173-00 Brush holder 1
6 70-170-10 Brush 8
7 70-417-00 Bearing retainer 1
8 80-212-00 Bearing 1
9 70-421-30 Rear housing 1
10 70-421-40 Brush cover 1
11 95-930-00 Dust cap 1
88-067-17 1-1/8" long Grade 8 mounting bolt
Not Shown
88-067-22 2" long Grade 8 mounting bolt
REAR MOTOR MOUNT

1 88-067-22 Bolt,1/4 X 2" NC, Grade 8 (no brake option) 3
2 - - -
3 See Motor Motor (Typical) 1
4 96-114-10 U-Bolt, 5/16" NF, Motor Support 1
5 70-456-10 Motor, Support Bracket 1
6 88-128-62 Lockwasher, 7/16" 2
7 89-111-27 Bolt, 10m X 1.5 X 20 Hex Head 2
8 88-088-62 Lockwasher, 5/16" 2
9 88-099-80 Nut, 5/16" NF 2
10 88-067-17 Bolt, 1/4 X 1-1/8" NC, Grade 8 (no brake option)
Parts Page 27
Illustrated Parts
Instrument Panel (dash)
Parts Page 28
Illustrated Parts
Instrument Panel
1 71-100-00 Aux. switch Opt
2 71-039-11 SPST rocker switch 1 or 2
3 88-817-07 Sheet metal screw 8
5 01-200-09 Dash console, no cab 1
6 74-010-00 Smart view display (see information below) 1
7 94-304-14 Dash 1
8 71-039-02 F&R switch 1
71-120-10 Key switch (incl #10) 1
9 71-119-99 Spacer 1
88-025-00 Terminal screws 2
10 71-120-90 Key 1
11 71-501-00 Horn switch 1
Not Shown 95-913-00 Plastic hole plug, 1/2" -
NOTE: If your vehicle was not originally equipped with the Smart View
display, then the Sevcon speed control must be reprogrammed
before the display will function.
If you have the Smart View display and wish to have the
maintenance feature turned on, then the Sevcon speed control
must be reprogrammed.
To reprogram the Sevcon speed control, the speed control must
be returned to the factory. Contact your local Taylor-Dunn® distributor
for more information.
The Smart View Display will only work with the Sevcon control
system.
Resetting the Smart View Display

The meter should only be reset after the preventative maintenance has been performed. Taylor-Dunn®
part number 62-027-40 Hand set (available with instructions as part number 62-027-61) must be used to
reset the meter. Refer to the handset instructions (D0-100-08) for information on the procedure to reset
the display.
Parts Page 29
Illustrated Parts
Speed Control Panel
5 11 9
8
2 4
13 11
6
12
1
7
14
Components located under the driver seat cushion
Parts Page 30
Illustrated Parts
Speed Control Panel

1 62-400-15* Speed controller, 500 Amp
2 K54-300-01 Mounting panel 1
3 73-004-20 Horn 1
4 79-844-20 Main circuit breaker 1
71-300-02 Line contactor 1
5
71-300-01 Mounting bracket 1
6 88-838-06 #14 x 1/2 Sheet metal screw 4
88-060-13 1/4 X 1-1/4 NC HEX HD SCR 4
7 88-068-61 1/4 SAE WASHER 4
88-069-81 1/4NC NYL INS LOCKNUT,PLTD 4
8 79-840-00 10 Amp circuit breaker 1
11 88-818-06 #8 x 1/2 Sheet metal screw 8
12 ** heat sink bolt
13 ** solenoid panel bolt
62-400-13 Heat sink 1
14
88-838-06 #14 x 1/2 Sheet metal screw 4
Not shown 69-068-55 Resistor (across #5 power terminals) 1
* - NOTE: To order part number 62-400-15, you will need to provide the vehicle serial number. The controller
will be programmed to match the vehicle as originally manufactured.
**- Not available at time of printing
Parts Page 31
Illustrated Parts
Miscellaneous Electrical
Accelerator Module
12
Seat
Frame
11
1a 1b
Motion Alarms
10
14
17 13
Seat Interlock Switch
16
18
15
2 3
Miscellaneous Wire Harness Clamps
Parts Page 32
Illustrated Parts
Miscellaneous Electrical
75-152-82 Chassie Control Harness 1
75-152-13 Control panel harness 1
K54-300-00 Power Harness 1
Not Shown 75-152-83 Dash harness 1
98-599-15 Plastic grommet for 1.75 hole
98-599-20 Plastic Grommet for 2.5 hole
75-152-90 Harness, Smart View display 1
73-012-30 DC-DC converter 1
73-005-26 Reverse alarm 1
71-135-01 Switch, Park brake interlock 1
71-303-01 Relay, Park brake interlock 1
71-303-51 Socket (71-303-01) 1
78-010-00 Inline fuse holder with fuse, Park brake interlock 1
72-501-48 DC converter line contactor 1
1a 73-005-01
Motion Alarm
1b 73-005-00
2 96-650-01 Wire Harness Clip, stick on
3 96-642-00 Wire harness Clip, push mount
4 62-033-48 Accelerator Module 1
10 71-102-10 Seat interlock Switch 1
11 85-030-00 Spring 2
12 96-773-10 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 33
Illustrated Parts
Signet® Charger
NOTE: The harness connectors are not included with the charger. When
replacing the charger order 2 each of the following:
PART # DESCRIPTION
75-318-20 Butt splice
75-320-51 Knife connector
Parts Page 34
Illustrated Parts
Signet® Charger
79-309-40 Charger, 48 volt
* Replacement cover with AC cord and gasket
79-851-10 Ammeter 1
K7-145-29 AC cord 1
K4-081-78 AC Receptacle 1
Note: Ther are no user serviceable components inside the charger.
* - Not available at time of printing
AC wire connections on PC board
Parts Page 35
Illustrated Parts
Batteries
Roll Out Battery Box
Main Positive
POS
NEG
Main Negative
2
NEG
1a
POS
POS
NEG
12 Volt
Negative tap
NEG
POS
POS
NEG
1 1b
NEG
POS
Parts Page 36
Illustrated Parts
Batteries
1a 75-237-00 Battery jumper, 9" long 4
1b K1-153-99 Battery jumper, 18" long 1
2 77-052-00 Battery, 8-volt, 165AH 6
3
4
5
6 88-069-81 1/2NC Nylon lock nut *
7 88-081-12 5/16NC x 1 Hex bolt, stainless steel *
8 88-089-80 5/16NC Hex nut, stainless stell *
* Quantities depend on voltage configuration of vehicle.
Roll Out Battery Box

30-172-05 ROLLER,ASMBLY PRSS,ROBB,2.0 OD with bushing 2
30-172-20 ROBB RLLR,PRSS ASSMBLY,TAPERED with bushing 8
K1-157-92 HARNESS,POWER ROBB,FROM BATT 1
76-013-00 RECPT,CHARGING,LESTR #8045 1
77-904-00 BATTERY HOLD-DOWN CHANNEL 1
77-970-14 BOX,BATTERY,ROLLOUT,SMOOTH SKN 1
77-970-25 R.O.B.B., AILGNMENT BLOCK 4
01-534-43 ANGLE,LEFT BATTERY BOX 1
Parts Page 37
Illustrated Parts
Lighting
Head and Tail Lights

K4L-000-00 Headlight (includes 2 headlights) 1
72-022-00 Tail light 1 or 2
72-022-51 Tail ligh rubber grommet 1 or 2
72-022-52 Tail light pigtail
Seat Cushions
Seat Cushions
1 90-175-06 Seat cushion 1
2 K6-602-39 Seat back 1
Decals
Decals
1 94-319-00 Battery disconnect 1 or 2
2 94-313-00 Battery warning 1 or 2
3 94-373-10 Vehicle identification 1
4 94-309-00 Brake warning 1
5 94-313-20 Safety warning 1
6 94-384-01 Not a motor vehicle 1
7 94-384-14 When leaving vehicle warning 1
8 94-301-41 Brake fluid 1
9 94-384-17 Do not wash 1
10 94-301-42 Arms and legs 1
Parts Page 38
Illustrated Parts
Miscellaneous
Miscellaneous
98-200-00 Braked pedal pad 1
71-040-95 Compartment lock 1
01-110-20 Accelerator pedal 1
Parts Page 39
TAYLOR -DUNN
APPENDIX A-Special Tools
Special Tools
Special Tools
DESCRIPTION PURPOSE PART NUMBER
Used to install the pinion seal on all chain drive trucks with
Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43-201-50
cover.
Used to center the chain case on the pinion shaft on all chain
Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41-532-50
on the chain case cover. Includes instructions.
Used for testing electrical circuits. Powered by the truck

Test Light batteries, switchable for 12, 24, 36, and 48 volts. 62-027-00
Used to test the solid state accellerator module part number

Accelerator Test Harness series 62-033-XX. 62-027-31
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
used on early model C4-25 Huskey. 62-027-10
Programmer
Used to test the GE® EV1 speed control.

GE® EV1 Analyzer 62-027-20
U s e d to reset the PMT/C maintenance meter after a

PMT/C Meter Reset Module maintenance is completed. 96-500-43
Sevcon® Handset Analyzer Used to test the Sevcon® control systems and reset the
Smart View display (includes instructions). 62-027-61
(read only)
Sevcon® Handset Analyzer Same as 62-027-61 (above) plus allows a limited range of
speed adjustment. 62-027-62
with Speed Adjust Capability
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 hold down the retaining plate when disassembling

Retaining Plate Depressor the steering gear on trucks equipped with the tilt steering. 96-500-39
Used when replacing the fork collar on models MX-600 and

Fork Collar Weld Jig SS5-36. 96-500-40
Used to hold the secondary sheave (pulley) from turning on

Secondary Sheave Holder models R6-80 and B6-10 with the Yamaha drive. 96-500-14
Used to solder the aluminum field wire to the field stud. For
Solder Kit For Field Stud use on motors with soldered connections only. 70-210-63
Used to align the Pinion Gear and Case during assembly and
Pinion Gear Holding Tool disassembly. 96-500-42
APPENDIX A PAGE 2
Appendix B: Standard Hardware Suggested Torque Limits
TABLE OF CONTENTS
Hardware Identification ................................. 2

Standard Head Markings ......................................... 2
Hex Bolts .................................................................. 2
Other Bolts ............................................................... 2
Hex Nuts .................................................................. 3
Hex Lock Nuts (stover) ............................................ 3
Other Nuts ................................................................ 3
Suggested Torque Values
(non-critical hardware) .......................... 4
Suggested Torque Values
(critical hardware) ................................... 5
Appendix B
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)
Appendix B Page-2
Appendix B
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
Appendix B Page-3
Appendix B
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
Appendix B Page-4
Appendix B
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 - - -
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 - - -
Appendix B Page-5
Appendix B
OR - DU
YL N
A
N
T
R
Th e B e s t W
in e s s
Bu s
ur
y
Yo
a
To
Go A b ou t
A small sample of the many types of vehicles offered by Taylor-Dunn®
B 2-48-36 Equipped with optional B 1-00 Personnel carrier

hydraulic dump bed
BT 2-80 Eight passenger tram
MX 1600 Equipped with optional

ladder rack and weld tanks
C 4-25 Huskey tow tractor
Appendix B Page-6
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.
Model B 1-00
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

MB 254 02 Laboratorio

Uploaded by

MB 254 02 Laboratorio

Uploaded by

®

Lavatory Service Vehicle

EQUIPPED WITH GT-DRIVE SYSTEM

Revision: C Serial number range: 165448 - 170871

TAYLOR-DUNN SERVICE CENTER

A small sample of the many types of vehicles offered by Taylor-Dunn®

B 2-48-36 Equipped with optional B 1-00 Personnel carrier

BT 2-80 Eight passenger tram

MX 1600 Equipped with optional

Safety Rules and Operating Instructions.............. 1

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

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

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

Steering Component Service ................................ 1

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

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

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

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

Sevcon Control System Troubleshooting ............ 1

Lestronic II® Charger Troubleshooting ................ 1

Signet® Charger Troubleshooting ........................ 1

Illustrated Parts ...................................................... 1

APPENDIX A-Special Tools.................................... A-1

Appendix B: Standard Hardware Suggested

Appendix C ............................................................. C-1

ABOUT THIS MANUAL

WHO SHOULD READ THIS MANUAL

Of the Service Personnel...

Of the Passengers ...

HOW TO USE THIS MANUAL

Safety Rules and Operating Instructions

Maintenance Service and Repair

Electrical and Charger Troubleshooting

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

HOW TO IDENTIFY YOUR VEHICLE

Theese vehicles are not designed to be driven on public roads or

The location of the serial number is illustrated as follows:

TAKING DELIVERY OF YOUR VEHICLE

What To Do If a Problem is Found

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

Dimensions 467.36L x 149.86W x ?? H Centimeters Not available at

Tires 600 x 9 Softuff

Dry Weight ???? kg (???? lbs) Not available at

Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs)

Transmission Helical Gear, Oil Bath, Automotive Type Hypoid

Brakes Optional 4 Wheel Hydraulic Disc, Hand Operated Park

Steering Automotive Steering 24:1

Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,

Instrumentation Smart View Display (Battery Status Indicator, Hour

Light Accessories Dual Headlight, Tail/Brake Lights

Charger 48 Volt 100/240 VAC, 13/6.5 Amps (50/60Hz), 17 Amp DC

Safety Rules Page 2

SAFETY RULES AND GUIDELINES

These vehicles are not designed to be driven on public roads or

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

Safety Rules Page 3

DRIVER TRAINING PROGRAM

Safety Rules Page 4

Hi-Low Switch (optional)

Safety Rules Page 5

Accessory Switch (Optional)

Foot Brake Pedal

Safety Rules Page 6

Smart View Display

Key Hours: When the display is turned on,

Key Hours icon

Safety Rules Page 7

Run Time Hours: After the initial 5-seconds,

Run Time Hours icon

Fault Code Description Corrective action

Safety Rules Page 8

Maintenance monitor (optional):

Directional Signals (Optional)

Hazard Light Switch (Optional)

Safety Rules Page 9

Electrolyte Alarm (Optional)