The Best WayTo Go

About YourBus iness

®

MANUAL M7-010-01

Operation, Troubleshooting andReplacement Parts Supplement Manual

Revision: D

Maintenance Meter Supplement

PMT/C Hour Meter Smart View Display

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TAYLOR-DUNN SERVICE CENTER

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

Taylor-Dunn® Mfg.2114 W. Ball Road

Anaheim, CA 92804(Attn: Technical Writer)

COPYRIGHT NOTICE

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

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

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B2-48 With Stake Side Dump Bed Option

SC1-00 Stock Chaser

E4-55 Sit Down Tow Tractor

C4-25 Sit Down Tow Tractor

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Contents

INTRODUCTION ............................................................ i-iiHow To Use This Manual ......................................................... i-ii

Who Should Read This Manual .................................................................................... i-iiResponsibilities ............................................................................................................. i-iii

Of the Owner... ...................................................................... i-iiiOf the Operator... ................................................................... i-iiiOf the Service Personnel... ...................................................... i-iiiOf the Passengers ... ............................................................... i-iiiConventions ........................................................................... i-iv

SECTION 1 ...................................................................... 1Product Description ................................................................ 2

PMT/C Meter ................................................................................................................... 2Smart View Display ....................................................................................................... 2

Identifying Your Drive System ................................................. 3Identifying Your CONTROL System.......................................... 3

SECTION 2 ...................................................................... 1Maintenance Guidelines ........................................................... 2Preventative Maintenance Warnings.......................................... 3PMT/C Meter Operation ........................................................... 5

Resetting the PMT/C Meter ............................................................................................. 5Smart View Display Operation ................................................. 6

Resetting the Smart View Display ................................................................................ 6Maintenance Schedules ........................................................... 7

Maintenance Schedule Notes: ....................................................................................... 7Daily Visual Inspection: .................................................................................................. 7

Part Numbers ......................................................................... 10

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

Appendix B: Standard Hardware Suggested Torque Limits 1Hardware Identification ........................................................... 3

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

Appendix C: Brake Lining Handling Precautions ........... 1

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B2-48 With Dump Bed OptionB2-10 Ambulance

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

ET 3000

ET1-50 Full Size Truck

P2-50 30,000 Pound Tow Tractor

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INTRODUCTION

Operator and Maintenance Manual

ContentsHow To Use This Manual ............... i-ii

Who Should Read This Manual ........................................... i-ii

Responsibilities ............................. i-iiiOf the Owner... ...................................................................... i-iiiOf the Operator... .................................................................. i-iiiOf the Service Personnel... .................................................. i-iiiOf the Passengers ... ............................................................. i-iii

Conventions .................................. i-iv

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INTRODUCTION PAGE ii

M7-010-01

IntroductionThe purchase of this product from Taylor-Dunn shows a belief in high qualityproducts manufactured in the USA. Taylor-Dunn , a leading manufacturer of electricburden and personnel carriers since 1949, wants to be sure this product providesyears of reliable service in your vehicle. Please continue to read this manual andenjoy all the high quality Taylor-Dunn vehicles.

How To Use This ManualThis manual is organized into five main sections:

SECTION 1: Product Description and SpecificationThis section describes the product and operation of this particularproduct, as well as the responsibilities of the operator.

SECTION 2: Maintenance and Illustrated PartsThis section gives specific information on the servicing of the vehicleand a schedule for maintenance checks. Including Illustrated Parts.

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INTRODUCTION PAGE iii

M7-010-01

ResponsibilitiesOf the Owner...

The owner of this or any Taylor-Dunn vehicle is responsible forthe overall maintenance andrepairs of the vehicle, as well asthe training of operators. Ownersshould keep a record ofconducted training and

maintenance performed on the vehicle. (OSHA Regulation, 29CFR 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 thereporting of any problems to service and repair personnel.

Of the Service Personnel...

The service personnel are responsible for the service andmaintenance of the vehicle. At no time should a service personallow any untrained personnel to service or repair this or anyTaylor-Dunn vehicle. For the purposes of training, a qualifiedservice person may oversee the repairs or services being madeto a vehicle by an individual in training. At no time should anuntrained individual be allowed to service or repair a vehiclewithout supervision. This manual is not a training guide.

Of the Passengers ...

The passengers are responsible to remain fully seated, keepingtheir hands, arms, and legs inside the vehicle at all times. Eachpassenger should be fully aware of the vehicle’s operation. Allforms of recklessness are to be avoided. Do not engage inhorseplay.

Who Should Read This Manual

This manual is intended for use by anyone whois going to operate, own, perform maintenanceon, service, or order parts for this Taylor-Dunnvehicle. Each person should be familiar with theparts of this manual that apply to their use ofthis vehicle.

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INTRODUCTION PAGE iv

M7-010-01

An unshaded box with no symbols next to it willcontain infromation for completing tests.

ConventionsSymbols 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 leftdenotes a warning. A warning alerts the readerof a hazard that may result injury to themself orothers. Be sure to follow any instructionscontained within a warning and exercise extremecare while performing the task.

The symbol at the left and the bold text containedwithin a box denotes a “Caution” and is used toinform the reader that property damage mayoccur. Be sure to exercise special care and followany instructions contained with in a caution.

NOTE: Alerts the reader to additional information about asubject.

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SECTION 1Product Description

ContentsProduct Description ...................................... 2

PMT/C Meter ............................................................ 2Smart View Display ................................................. 2

Identifying Your Drive System ...................... 3Identifying Your Control System .................. 3

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M7-010-01

Page 2

PRODUCT DESCRIPTION

This manual applies to the models and product listed on the front cover.

The PMT/C meter and Smart View Display are for preventative maintenance scheduling. Both metersaccumulate time only when the vehicle is being operated. Both meters will notify the operator when ascheduled preventative maintenance is due to be performed. The maintenance schedule programmedin these meters is designed to meet the requirements of our vehicles and customers.

The PMT/C meter also functions as an hour meter.

The Smart View Display also functions as an hour meter, Battery Status Indicator and control systemdiagnostic aid. Only the maintenance function of the Smart View Display will be covered in this manual.

PMT/C MeterThe PMT/C hour meter notifies the operator 8-hours (standard) before a scheduled maintenance is due.During this warning period, the meter will continue to alert the operator. This should allow sufficient timefor the operator to schedule the maintenance that is due, with minimal down time. If the scheduledmaintenance is not performed before the warning period elapses, then the forward direction of thevehicle is locked out by the meter. Services should only be performed by a Taylor-Dunn® factory authorizedservice technician.

Smart View DisplayThe Smart View Display (SVD) functions as a Battery Status Indicator , Hour Meter, Speed ControllerStatus Monitor, and as the optional Maintenance Monitor feature discussed in this text. Refer to thevehicle operator manual for information regarding the other functions of the SVD.

The Maintenance Function of the SVD is located in the Sevcon controller logic. To enable the maintenancefunction, the Sevcon controller parameters must be properly configured. Contact your Taylor-Dunn®

distributor for information regarding turning on the maintenance function of the SMD.

The Maintenance Monitor feature of the SVD notifies the operator 10-hours (typical) before a scheduledmaintenance is due. During this warning period, the SVD will continue to alert the operator. This shouldallow 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 vehiclesmaximum speed will be significantly reduced. Services should only be performed by a Taylor-Dunn®

factory authorized service technician.

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M7-010-01

Page 3

IDENTIFYING YOUR DRIVE SYSTEM

The maintenance schedules and procedures will vary depending on the drive system in your vehicle.Refer to the illustrations below.

Typical Power Traction or Belt drive (chain driveillustrated)

Typical GT drive

Typical Dana® H12 drive

IDENTIFYING YOUR CONTROL SYSTEM

Curtis PMC Sevcon PowerPak

This is an illustration of the two typical motor speed controllers covered in the text. The physical locationof the speed controller varies depending on the model vehicle. In most instances, it can be found on acontrol panel assembly located under the rear deck of the vehicle.

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TAYL

OR -

DUNN

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SECTION 2Maintenance and Service Procedures

Part Numbers

Maintenance Guidelines ............................... 2Preventative Maintenance Warnings ............ 3PMT/C Meter Operation................................. 5

Resetting the PMT/C Meter .................................... 5Smart View Display Operation ...................... 6

Resetting the Smart View Display .......................... 6Maintenance Schedules ................................ 7

Maintenance Schedule Notes: ................................ 7Daily Visual Inspection: ........................................... 7

Part Numbers ................................................ 10

CONTENTS

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Page 2

M7-010-01

MAINTENANCE GUIDELINES

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

It is necessary to disconnect both of the main battery cables before working on or disconnecting anyelectrical component or wire.

• Secure and block the chassis with jack stands before working under a raised vehicle.

• Conduct vehicle performance checks in an authorized area where safe surroundings andclearances exist.

• Tighten all nuts and bolts in accordance with the “Recommended Torque Values Chart” found inAppendix B.

• Ventilate the work area properly.

• Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights,governors, guards, and safety devices should be regularly inspected and maintained.

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

• Keep the vehicle in clean condition to minimize fire hazards. Be sure to detect any loose ordefective parts.

Read and follow all of the guidelines listed below. Failure to followthese guidelines may result in property damage and or severe bodilyinjury.

• Avoid fire hazards and have fire protection equipment present inthe work area.

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

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

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Page 3

M7-010-01

PREVENTATIVE MAINTENANCE WARNINGS

The preventative maintenance schedule should be used in conjunction with the PMT/C meter. Preventativemaintenance is not a substitute for a general functional inspection before each shift or periodicmaintenance as described in this supplement manual and in your owner’s manual.

Before performing any scheduled maintenance read all warnings in this supplement manual and in yourowner’s manual.

Always use brake fluid from a new sealed container. Never reuse anybrake fluid that has been removed from the brake system. Use ofcontaminated brake fluid will degrade the braking performance andmay cause property damage or severe personal injury.

Do not ingest brake fluid or allow contact with skin or eyes. Alwayswear protective clothing and a face shield when working with oraround brake fluid.

SKIN CONTACT

Flush area immediately with water for several minutes. If a rash orskin 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.

Taylor-Dunn® does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that theoriginal brake pads/shoes were replaced with aftermarket pads/shoescontaining asbestos. Since this possibility does exist, the brake pads/shoes should be handled as if they do contain asbestos.

Never use compressed air or dry brush to clean the brake assemblies.Use an OSHA approved vacuum cleaner or any alternate methodapproved by OSHA to minimize the hazard caused by airborne asbestosfibers and brake dust.

Do not grind, sand, break, or chisel the brake pads/shoes, as this willcause unnecessary dust, possibly releasing asbestos fibers in the air.

Always wear protective clothing and a respirator when working onthe brake pads/shoes or their associated components.

Inhaled asbestos fibers have been found to cause cancer andrespiratory diseases.

Do not drive the vehicle if any worn or broken part is detected in anypart of the brake system. The cause of the damage must be repairedimmediately.

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M7-010-01

NOTE: The front brake rotors are an integral part of the hubs. If the rotorsare damaged or worn, the hub must be replaced. Be sure to referto your vehicles manual for the correct brake fluid and always useit from a sealed container.

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

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

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

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

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

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Page 5

M7-010-01

PMT/C METER OPERATION

During normal operation the last digit decimal point on thenumeric display will flash on and off. This decimal point willflash at a faster rate when time is actually accumulating onthe meter. When a preventative maintenance schedule isdue all 6-decimal point lamps on the numerical display willeither flash sequentially from left to right or simultaneously.The meter will continue to display the hours of operation.Every 5-seconds the display will indicate which levelscheduled maintenance is due to be performed (see below).

If the vehicle forward travel has been disabled due to thehour meter exceeding the 8 hour warning time the schedulemaintenance should be performed before resetting themeter.

Resetting the PMT/C MeterThe meter should only be reset after the preventativemaintenance has been preformed. The meter can only bereset after the 8 hour operational warning time has started.Taylor-Dunn® part number 96-500-43 PMT/C hour meterRemote Handset must be used to reset the meter. Whenthe preventative maintenance is complete, an authorizedservice technician points the remote handset at the left sideof the display about 2” away from the face of the meter anddepresses the button. The meter will momentarily display,a broken 5 or ‘S’ on the left side of the display, the flashingor sequentially flashing lamps will return to normal, and theforward travel will be reactivated. The preventativemaintenance meter can only be reset within the preventativemaintenance warning or preventative maintenance past dueperiods. The meter will continue to display the total operationhours.

Arrow showing the last decimal point

Remote Handset (96-500-43)

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Page 6

M7-010-01

SMART VIEW DISPLAY OPERATION

The Smart View Display (SVD) functions as a Battery Status Indicator , Hour Meter, Speed ControllerStatus Monitor, and as the optional Maintenance Monitor feature discussed in this text. Refer to thevehicle operator manual for information regarding the other functions of the SVD.

The Smart View Display turns on with the vehicle’s key switch. When first turned on, the display willmomentarily show the Key icon and the total time that the key switch has been in the ON position. If thereare no faults to report, after a few seconds the display will show the Run Time Hours icon and the totaltime the vehicle has been in operation (throttle pedal depressed).

Ten hours before a maintenance is due, the displaywill show a warning giving the operator theconvenience to schedule the maintenance withminimum lost time for the vehicle. The warningstarts when “Maintenance” is ON and the Wrenchicon is flashing. The Wrench icon will continue toflash until the warning time has expired. Once thewarning has expired and the maintenance is due,the Wrench icon will stop flashing and remain ON.Additionally, the vehicles maximum speed will besignificantly reduced until the maintenance isperformed and the display is reset.

What it all means

Resetting the Smart View DisplayThe 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 toreset the meter. Refer to the handset instructions (D0-100-08) for information on the procedure to resetthe display.

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Page 7

M7-010-01

MAINTENANCE SCHEDULES

The PM schedules are on the following pages. Refer to Section 1 for information regarding identifyingyour drive system.

Maintenance Schedule Notes:

1. This maintenance schedule 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. Theowner/operator must evaluate the operating environment to determine the increase inmaintenance frequency.In addition, the whole vehicle should be inspected monthly for signs of damage. The damagemust 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 be corrected before the vehicle is returned toservice.

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

Daily Visual Inspection:Tire condition and pressure.

External frame damage (body).

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

Smooth and proper operation of all controls such as but not limited to:Accelerator pedal, Brake pedal, Steering, Parking brake, etc.

Proper operation of all locking devises such as but not limited to:Tool box, Removable battery trays, Cargo box, Cab doors, etc.

Proper operation of all interlocking switches such as but not limited to:Key switch, Seat interlock switch, Charger interlock switch, etc.

Inspect for leaking fluids or grease.

Flooded lead acid batteries consume water as part of normal operation. The rate of water consumptionvaries depending on a number of variables including ambient temperature, charging current and chargingintervals. An increase of any one of these variables will increase the rate of consumption.

Battery electrolyte should be inspected once a week under normal conditions or more often under extremeconditions outlined above.

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Page 8

M7-010-01

MAINTENANCELEVEL

HOURINTERVAL1 MAINTENANCE TO BE PERFORMED2

1 500

Inspect the brake system including the park brake and mountingharware

Inspect the steering system, tighten the steering shaft coupler onthe steering gear input shaft

Lubricate the vehicle, check for leaks

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 thenevery 1000 hours.

2 1000

All level 1 maintenance items

Inspect and tighten all nuts and bolts

Clean and repack front wheel bearings

Inspect and tighten all wire connections

Inspect the motor brushes and commutator

Inspect the king pin bushings

Check front end alignment

3 2000

All level 1 and level 2 maintenance items

Change oil in the drive and rear axle

Flush hydraulic brake system

Inspect suspension bushings

Replace brake pedal/treadle return spring

Inspect frame for damage

*Notes are on the previous page

GT or Dana® Drive System

The Smart View display will indicate a maintenance is due every 500 hours. The display does not indicatewhich maintenance level is due (ie 500 hour, 1000 hour, etc....). The display does not maintain a record ofmaintenances that have been completed. Independent records must be maintained for each vehicle whichshould include what levels have been completed, date of maintenance, hour meter reading at time ofmaintenance, any additional repairs performed.

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Page 9

M7-010-01

P R E V E N T A T I V E M A I N T E N A N C E S C H E D U L EM A I N T E N A N C E

L E V E LH O U R

I N T E R V A L 1 M A I N T E N A N C E T O B E P E R F O R M E D 2

1 2 0 0

I n s p e c t t h e b r a k e s y s t e m i n c l u d i n g t h e p a r k b r a k e a n d m o u n t i n gh a r w a r e

I n s p e c t t h e s t e e r i n g s y s t e m

L u b r i c a t e t h e v e h i c l e

I n s p e c t d r i v e f o r l e a k s

I n s p e c t a n d t i g h t e n a l l w i r e c o n n e c t i o n s

I n s p e c t a n d s e r v i c e t h e b a t t e r i e s 3

I n s p e c t t h e t i r e p r e s s u r e

I n s p e c t a n d t i g h t e n a l l n u t s a n d b o l t s . F i r s t 2 0 0 h o u r s a n d t h e ne v e r y 1 2 0 0 h o u r s .

2 5 0 0

A d j u s t b r a k e s

A d j u s t s e r v i c e b r a k e s ( n o n - a u t o m a t i c s y s t e m s )

T i g h t e n t h e s t e e r i n g s h a f t c o u p l e r o n t h e s t e e r i n g g e a r i n p u ts h a f t

I n s p e c t s a f e t y i n t e r l o c k s

I n s p e c t a n d a d j u s t f r o n t w h e e l b e a r i n g s

I n s p e c t r e a r w h e e l b e a r i n g s

I n s p e c t a n d a d j u s t f o r k c o l l a r b e a r i n g s ( 3 - w h e e l t r u c k s o n l y )

A d j u s t d r i v e c h a i n o r b e l t

T e s t t h e s p e c i f i c g r a v i t y

I n s p e c t t i r e s

3 1 2 0 0

I n s p e c t a n d t i g h t e n a l l n u t s a n d b o l t s .

C l e a n a n d r e p a c k f r o n t w h e e l b e a r i n g s

A d j u s t t h e s t e e r i n g g e a r

R e - a l i g n f r o n t e n d

C h a n g e o i l i n t h e d r i v e a n d r e a r a x l e

I n s p e c t t h e m o t o r b r u s h e s a n d c o m m u t a t o r

I n s p e c t k i n g p i n b u s h i n g s

4 2 0 0 0

R e p l a c e t h e d r i v e c h a i n a n d i n s p e c t s p r o c k e t s

R e p l a c e d r i v e b e l t s

F l u s h h y d r a u l i c b r a k e s y s t e m

I n s p e c t s u s p e n s i o n b u s h i n g s

R e p l a c e b r a k e p e d a l / t r e a d l e r e t u r n s p r i n g

I n s p e c t f r a m e f o r d a m a g e

Power Traction (chain) or Belt Drive System

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Page 10

M7-010-01

PART NUMBERS

PMT/C Maintenance MeterPart # ID # Used with control system74-018-00 PMT\C II-H Curtis PMC 24-36v74-018-10 PMT\C II-H Curtis PMC 48v74-018-21 PMT\C II-L Sevcon PowerPak 24-36v74-018-22 PMT\C II-L Sevcon Powerpak 48v

Smart View Display74-010-00

(used with Sevcon PowerPak only)

PMT/C Maintenance Meter Handset96-500-43

Sevcon® Control Handset 62-027-61Resets the Smart View display and alsoprovides troubleshooting and control

system information. Includes instructions.

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Ap

pen

dix

esContentsAppendix A: Special Tools ................. 2Appendix B: Suggested Torque

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

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

Appendix C: Brake Lining Handling Precautions .................... 7

REV B

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Appendixes

AppendixesAppendix APage 2

APPENDIX A: SPECIAL TOOLS

DESCRIPTION PURPOSE PART NUMBER

Test Light Used for testing electrical circuits. Powered by the truckbatteries, switchable for 12, 24, 36, and 48 volts. 62-027-00

Accelerator Test Harness Used to test the solid state accellerator module part numberseries 62-033-XX. 62-027-31

Sevcon® Handset Analyzer(read only)

Used to test the Sevcon® control systems and reset theSmart View display maintenance meter ( includesinstructions).

62-027-61

Sevcon® Handset Analyzerwith Speed Adjust Capability

Same as 62-027-61 (above) plus allows a limited range ofspeed adjustment. 62-027-62

Disc Brake Boot InstallationTool

Used to install the rubber boot on all disc brake bodies. 41-350-13

Pin Removing Tool Used to remove pins and sockets from AMP connectors. 75-440-55

Pin Removing Tool Used to remove pins and sockets from MOLEX connectors. 75-442-55

Hydrometer Used to check the specific gravity of battery electrolyte. 77-200-00

Battery Filler Used to safely add water to batteries. 77-201-00

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AppendixesAppendix B

Page 3

Appendixes

HARDWARE IDENTIFICATIONStandard Head Markings

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

Truss Head, grade 2 Carriage Bolt, grade 2(unless marked as above)

Other Bolts

NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on agrade 8 bolt, use grade 2 torque value.

NOTE: Toque values specified are for clean dry threads.

Hex Bolts

S.A.E. Grade 8

L’9

L’9

APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARDHARDWARE

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Appendixes

AppendixesAppendix BPage 4

Hex Nuts

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

Hex Lock Nuts (stover)

Cor, or,

Bor, or,

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

Lock nuts use a letter to indicate the grade of the nut. Grade A’ locknuts would be the equivelent of Grade ‘2’hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’.NOTE: Nuts with no markings are to be treated as S.A.E. Grade A

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

Other Nuts

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

Grade L’9

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AppendixesAppendix B

Page 5

Appendixes

Diameterand TPI

Grade 2TighteningTorque(ft-lb)

Grade 5TighteningTorque(ft-lb)

Grade 8TighteningTorque(ft-lb)

L'9TighteningTorque(ft-lb)

1/4-20 4-7 7-10 10-14 11

1/4-28 5-8 8-12 11-16 12

5/16-18 9-14 14-21 20-29 22

5/16-24 10-15 15-23 22-33 25

3/8-16 16-24 25-37 35-52 40

3/8-24 18-27 28-42 40-59 45

7/16-14 26-38 40-59 56-84 65

7/16-20 29-43 44-66 62-93 70

1/2-13 39-59 60-90 85-128 95

1/2-20 44-66 68-102 96-144 110

9/16-12 56-84 87-131 123-184 140

9/16-18 63-94 97-146 137-206 160

5/8-11 78-117 120-180 170-254 195

5/8-18 88-132 136-204 192-288 225

3/4-10 138-207 213-319 301-451 350

3/4-16 154-231 238-357 336-504 390

7/8-9 222-334 344-515 485-728 565

7/8-14 245-367 379-568 534-802 625

1-8 333-500 515-773 727-1091 850

1-14 373-560 577-866 815-1222 930

1.125-7 472-708 635-953 1030-1545 1700

1.125-12 530-794 713-1069 1156-1733 1850

1.25-7 666-999 896-1344 1454-2180 2950

1.25-12 738-1107 993-1489 1610-2414 3330

Suggested Torque Values (non-critical hardware)

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Appendixes

AppendixesAppendix BPage 6

Suggested Torque Values (critical hardware)

Torque Table Torque Range Group Description Ft-Lbs In-Lbs Nm Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 Brake line tube nut fittings 12 - 13 144 - 156 16.3 - 17.7 Brake spider bolts (Dana 160mm hyd brakes) 25 - 35 300 - 420 34 - 47.6 Brake spider bolts (Dana 160mm mech brakes) 15 - 19 180 - 228 20.4 - 25.8 Brake spider bolts (Dana 7x1-3/4 brakes) 16 - 20 192 - 240 21.8 - 27.2 Electrical - - - - - - - - - - - - - - - - - - - - - - - - Battery terminals 8 - 9 96 - 108 10.9 - 12.2 Front Axle - - - - - - - - - - - - - - - - - - - - - - - - Front spindle nut - - - Note: Refer to maintenance section in the service manual King pin - - - Note: Refer to maintenance section in the service manual Rear Axle/Transmission - - - - - - - - - - - - - - - - - - - - - - - - 3rd member Gear case cover (GT drive) 45 - 50 540 - 600 61.2 - 68 Axle bolt (GT drive) 275 - 275 3300 - 3300 374 - 374 Axle hub nut (Dana) 95 - 115 1140 - 1380 129.2 - 156.4 Axle tube to center section (Dana F-N-R) 25 - 35 300 - 420 34 - 47.6 Carrier cap bolts (Dana) 100 - 120 1200 - 1440 136 - 163.2 Differential Cover plate (Dana H12) 18 - 25 216 - 300 24.5 - 34 Drain plug (Dana H12) 25 - 40 300 - 480 34 - 54.4 Drain plug (GT drive) 21 - 25 252 - 300 28.6 - 34 Gear case to 3rd member (GT drive) 18 - 20 216 - 240 24.5 - 27.2 Motor mounting (GT/Dana) 6.5 - 7 78 - 84 8.8 - 9.5 Pinion nut (F2/F3) 175 - 175 2100 - 2100 238 - 238 Pinion nut (GT drive) 154 - 169 1848 - 2028 209.4 - 229.8 Ring gear (Dana) 35 - 45 420 - 540 47.6 - 61.2 Wheel lug nut 75 - 90 900 - 1080 102 - 122.4 Steering - - - - - - - - - - - - - - - - - - - - - - - - Ball joint clamp 28 - 32 336 - 384 38.1 - 43.5 Ball joint nut 40 - 45 480 - 540 54.4 - 61.2 Pitman nut (18-308-21 steering gear) 75 - 100 900 - 1200 102 - 136 Pitman nut (18-308-25 steering gear) 181 - 217 2172 - 2604 246.2 - 295.1 Rod end nut 20 - 25 240 - 300 27.2 - 34 Steering shaft pinch bolt 24 - 26 288 - 312 32.6 - 35.4 Steering wheel nut (18-308-21 steering gear) 28 - 32 336 - 384 38.1 - 43.5 Steering wheel nut (18-308-25 steering gear) 72 - 86 864 - 1032 97.9 - 117 Suspension - - - - - - - - - - - - - - - - - - - - - - - - Leaf spring hangers - - - Note: Refer to maintenance section in the service manual

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AppendixesAppendix C

Page 7

Appendixes

Taylor-Dunn does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that theoriginal brake pads/shoes were replaced with aftermarket pads/shoescontaining asbestos. Since this possibility does exist, the brake pads/shoes should be handled as if they do contain asbestos.

Never use compressed air or dry brush to clean the brake assemblies.Use an OSHA approved vacuum cleaner or any alternate methodapproved by OSHA to minimize the hazard caused by airborneasbestos fibers and brake dust.

Do not grind, sand, break, or chisel the brake pads/shoes, as this willcause unnecessary dust, possibly releasing asbestos fibers in the air.

Always wear protective clothing and a respirator when working onthe brake pads/shoes or their associated components.

Inhaled asbestos fibers have been found to cause cancer andrespiratory diseases.

Do not drive the vehicle if any worn or broken part is detected in anypart of the brake system. The cause of the damage must be repairedimmediately.

APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS

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Model B 1-00

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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 4240Anaheim, California 92803

Visit our Website:www.taylor-dunn.com

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