3637 North Church Avenue

Louisville, Mississippi 39339-2017 USA

MAINTENANCE
MANUAL
Phone: 662.773.8056
Fax: 662.773.9157
www.taylorsuddenservice.com

MODEL __________________

SERIAL NO. ______________

IMPORTANT!
Read contents carefully prior to operation.
Read contents carefully prior to operation.
 WARNING
Operating this powered industrial truck when it is in need of repair can result in
death or serious injury to the operator or other personnel or cause severe
property damage.
Machine checks must be performed daily:
1. before the machine is placed in service,
2. by qualified, trained, and skilled personnel who have proper tools and knowledge, and
3. in accordance with the Operator’s Guide, the Maintenance Manual, the Service Manual, and
the Safety Check booklet.

Operators Guide
Maintenance Manual Shop Service Manual
Ê
TE-360
Industrial Truck

! .

Regularly Scheduled maintenance, lubrication, and safety inspections will help ensure a safe and
productive work life for the machine and the operator(s).

 Do not operate the truck if it is in need of repair. Remove the ignition key
and attach a “Lockout” tag.

 Do not attempt to perform maintenance procedures unless you have been
thoroughly trained and you have the proper tools.

 Use only genuine Taylor replacement parts. Lesser quality parts may fail
resulting in property damage, personal injury, or death.
Maintenance personnel who find it necessary to operate this machine, even for a short period of
time, must fully understand all operational literature including:
• OSHA operating rules found in 29 CFR 1910.178; Appendix A in Safety Check
• ANSI B56.1 rules for operating a powered industrial truck; Appendix B in Safety Check
• The Operator’s Guide for the machine
• The manufacturer’s Safety Booklet
• The manufacturer’s Safety Video
• The manufacturer’s Service Bulletins
• The content and meaning of all machine decals

(Rev. 6/97)

 If maintenance requires running the engine indoors, ensure the room has
adequate flow-through ventilation!

 Remove all rings, watches, chains, other jewelry, and all loose clothing
before working around moving parts!

 Know how to avoid accidents such as those described in the Maintenance
/ Service Accidents Section of “Safety Check”:
• Improperly refueling the truck.
• Improperly checking for hydraulic leaks or diesel fuel leaks.
• Improperly checking the engine cooling system.
• Improperly checking battery fluid levels or “jump” starting engines.
• Putting air in a multi-piece tire and rim assembly without proper tools and training.
• Attempting to service a multi-piece tire and rim assembly without proper tools and training.
• Using an improperly suited chain while performing maintenance.
• Using the lift truck hydraulic system as a substitute for a fixed stand.
• Relying on jacks or hoists to support heavy loads.
• Operating a truck that is damaged or in need of repair.
• Climbing on the mast of a forklift, on the top of the cab, or other high places on the machine.
• Operating a machine which has been modified without the manufacturer’s approval. This in-
cludes the attachment, counterweight, tires, etc.
• Lifting people with a forklift not properly equipped for elevating personnel.

 Do not operate the vehicle or attempt to perform maintenance on the

vehicle while under the influence of alcohol, drugs, or any other medications or
substances that slow reflexes, alter safe judgement, or cause drowsiness.

 Know how to avoid slip and fall accidents such as those described in the
Slip and Fall Accidents Section of “Safety Check.”

Maintenance Personnel:
• Keep the truck clean, free of oil, grease, and fuel.
• Steam clean / wash the truck prior to performing maintenance. Wear anti-slip footwear when
performing maintenance procedures.
• Use OSHA approved ladders and other proper cleaning accessories to access hard to reach
maintenance places.
• Keep gratings free of ice, dirt, and gravel.
• Regularly inspect and replace anti-slip mastic on the vehicle as needed.
• Ensure all safety decals are in place on the vehicle.

(Rev. 6/97)
   
Observe The Following Precautions For Maximum Safety Of Machine Operation

1. Only trained and responsible operators shall be permitted to handle loads with this truck.
2. Operate the truck from the operator’s seat only. Do not allow riders.
3. Test hydraulic controls for proper response before using the machine.
4. Know your load. Do not attempt to lift or transport loads in excess of rated capacity.
5. When the load obstructs the view, operate the truck in the reverse range.
6. Do not stand or work under an elevated load.
7. Transport the load low and tilted back.
8. Avoid sudden stops with a load.
9. Evenly distribute the weight of the load on both forks.
10. Back down a ramp in excess of 10 percent when loaded.
11. The spotting brake is for temporary stops. Do not leave the truck unattended with only the
spotting brake applied.
12. Do not move the truck until the air system reaches recommended pressure. Air pressure is
required for the service brakes.
13. Have defects repaired immediately. Do not operate a truck with damaged or defective sys-
tems.
14. When leaving truck, lifting mechanism shall be fully lowered, controls shall be neutralized, pow-
er shut off, parking brake set, and key removed. Block wheels if on incline.
 LIMITED WARRANTY

Products manufactured by Taylor Machine Works, Inc. (“Taylor”) and sold are warranted by Taylor to be free from
defects in material and workmanship, under normal use and service, when Taylor products are operated at or
below rated capacity* in accordance with operating instructions.
This warranty is limited to repair or replacement, (as Taylor may elect, and at an establishment authorized by
Taylor) of such parts as shall appear to Taylor upon inspection to have been defective in material or
workmanship.
This warranty period shall begin on the delivery date of the product to the Purchaser and end on the earlier of
twelve (12) months or two thousand (2000) hours. During the first six (6) months or one thousand (1000) hours,
Taylor will provide genuine Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor and
found to be defective in material and workmanship. If a defect in material and workmanship is found during the
first six (6) months and/or one thousand (1000) hours whichever occurs first of the warranty period, Taylor will
replace lubricating oil, filters, antifreeze, and other service items made unusable by the defect. In the second six
(6) months and/or second one thousand (1000) hours after the delivery date of the truck, Taylor will approve parts
only. Only genuine Taylor parts provided by Taylor’s Sudden Service, Inc. will be used during the warranty period.

THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:

1. Normal maintenance services and parts or supplies used therein including, without limitation, en-
gine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening and
adjusting such as bolts, screws, hoses, fittings, etc., replacement of fuses, bulbs, filters, tune-up
parts, fluids and brake and clutch linings, glass; shop supplies such as rags, oil dry, hand soaps,
degreasers, cleaning solutions including brake clean, etc.; and adjustments which are a part of
the required or recommended predelivery inspection and periodic inspections in accordance with
Operator’s Manual. Electrical components including wiring will be excluded after the first six (6)
months or one thousand (1000) hours whichever occurs first.
2. Normal deterioration of appearance due to use and exposure; or conditions resulting from mis-
use, negligence, or accident.
3. Any product on which any of the required or recommended periodic inspections or services have
not been made.
4. Any parts or accessories, installed on the product which were not manufactured or installed by
Taylor whether or not such parts or accessories were selected, recommended or installed by Tay-
lor (including without limitation, engines, tires, batteries, air conditioners, air dryers, etc.). Such
parts or accessories shall be covered by the warranties given by the manufacturers thereof and
any claim thereof shall be made to such manufacturers.
5. Loss of time, inconvenience, loss of equipment use, other consequential damages or other mat-
ters not specifically included.
Taylor parts and assemblies which are furnished and installed under this warranty are themselves within
the coverage of the machine warranty and are covered only for the duration of the original machine
warranty period.
NOTE: All International warranty parts shipments are F.O.B. point of debarkation, duties, tariffs, or local
taxes excluded.
This warranty is expressly in lieu of any other warranties, expressed or implied, including any warranty of
merchantability or fitness for a particular purpose.
Replacement parts are warranted for ninety (90) days to be free from defects in material or workmanship. Parts
only, no labor.
Taylor Machine Works, Inc. does not authorize any person to create (for Taylor) any other obligation or liability in
connection with Taylor products.
*For example, a machine rated capacity at any stipulated load center is the rated lift capacity at less than
load center. That is, a machine rated at 20,000 pounds at 24-inch load center connotes 20,000 pounds
is the maximum lift capacity even though the load center may be less than 24-inches. Subjecting Taylor
products to conditions or loads exceeding those stipulated is justification for immediate cancellation of
warranty for products involved.

TAYLOR MACHINE WORKS, INC.

650 North Church Avenue
Louisville, Mississippi 39339
(662) 773-3421 / Fax 662-773-9146
TMW-057-3 (7/99)
 Contents

Maintenance Manual

Section

General Information

Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Attachments & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Appendix
 General Information

Introduction. This manual is to be used as a intervals by observing the Preventive Maintenance

guide for lubrication and maintenance as well as schedule in the appendices. If the machine is
general equipment care. A separate section is being operated under extremely dusty, sandy or
provided to discuss each major component or humid conditions, the service interval may need to
system. This method of presenting the be shortened to prevent excessive wear and
maintenance instructions enables Taylor Machine ensure longer trouble-free operation.
Works, Inc. to assemble a maintenance manual
with explicit instructions on the exact equipment NOTE: An operator’s guide which includes the
installed on the machine. controls and indicators, daily checks, and
safety precautions is furnished with each ma-
Lubrication And Maintenance. Lubrication and chine and should remain with the machine at
maintenance should be performed at regular all times.
 100X 10X
BRAKE 1000DR 600GR 100GR
RESERVOIR TRANSMISSION STEER SPINDLE
AXLE (UPPER AND
10X HUB LOWER)
2400DR 100GR
100X
HYDRAULIC TILT
1200DR
RESERVOIR CYLINDER
DRIVE AXLE

100GR
STEER
AXLE
PIVOT

100GR
100GR 10X
100GR STEER
TILT 200DR
DRIVESHAFT LINK
CYLINDER ENGINE

SYMBOL HOURLY ABBREVIATIONS

LUBRICANT
INTERVAL

Engine Oil X - Check

10 Lubricant
100 Level
Hydraulic Fluid 200 DR - Drain and
600 Refill
Gear Oil, GL-5 1000
GR - Grease
1200
Grease, Grade 1 or 2 2400

NOTE: See fuel and lubricant specifications for types and weights
of lubricants to be used in different temperature ranges.

Lubrication Chart

TEC-920L-950L (4/94)
 Section 1

Cummins LT-10 Diesel Engine Lubrication

OIL FILL CAP

DIPSTICK

OIL FILTERS

DRAIN PLUGS

Figure 1-1. Lubricating System

Description. The pump draws oil from the pan that new engines be started with 200 hour oil
and forces it through the lubrication system. The change periods.
pressure regulating valve controls the oil pressure.
The filter bypass valve ensures a supply of oil in NOTE: The oil should be drained when the en-
the event the filter becomes plugged. The system gine is warm.
includes an oil pump, pressure regulating valve,
oil cooler, filter bypass valve and oil filters. 1. Provide a suitable container and remove the
drain plugs.
Changing the Oil. Refer to the appendices in the
back of this manual for the proper grade of oil to 2. Remove the oil filters.
be used. The oil filters should be replaced each 3. Reinstall the drain plugs.
time the engine oil is changed. It is recommended
4. Lubricate the oil seal on each oil filter with
clean engine oil.

(Rev. 1/97) 1-1

5. Fill each new filter with clean oil and rotate the
filter 1/2 turn after the seal contacts the filter
head.
6. Remove the filler cap and fill the engine to the
full mark “H” on the dipstick.
NOTE: Never operate the engine with the oil
level below the “L” (Low) mark or above the
“H” (High) mark.
7. Operate the engine and inspect for leaks.
8. Dispose of all fluids and filters according to
local and federal regulations.

General Information
Idle 10 - 30 psi
Oil Pressure
Full Speed 30 - 50 psi
Oil Capacity
36 quarts
(includes filter change)

1-2 (Rev. 1/97)

 Section 1

Cummins M-11 Diesel Engine Lubrication

OIL FILL CAP

DIPSTICK

DRAIN PLUGS
OIL FILTER

Figure 1-1. Lubricating System

Description. The pump draws oil from the pan mended that new engines be started with 200
and forces it through the lubrication system. The hour oil change periods.
pressure regulating valve controls the oil pressure.
The filter bypass valve ensures a supply of oil in NOTE: The oil should be drained when engine
the event the filter becomes plugged. The system is warm.
includes an oil pump, pressure regulating valve,
1. Provide a suitable container and remove drain
oil cooler, filter bypass valve and oil filters. plugs.
Changing The Oil. Refer to the appendices in
2. Remove oil filters.
the back of this manual for the proper grade of oil
to be used. The oil filters should be replaced 3. Reinstall drain plugs.
each time the engine oil is changed. It is recom- 4. Lubricate the oil seal on each filter with clean
engine oil.

(1/97) 1-1
5. Fill each new filter with clean oil and rotate the
filter 1/2 turn after the seal contacts the filter
head.
6. Remove the filler cap and fill the engine to full
mark “H” on dipstick.
NOTE: Never operate the engine with the oil
level below the “L” (Low) mark or above the
“H” (High) mark.
7. Operate the engine and inspect for leaks.
8. Dispose of all fluids and filters according to
local and federal regulations.

General Information
Idle 10 - 30 psi
Oil Pressure
Full Speed 30 - 50 psi
Oil Capacity
36 quarts
(includes filter change)

1–2 (1/97)
 Section 2

Fuel System

Cummins LT-10 Diesel

TO MANIFOLD
AND INJECTORS
RETURN
LINE

FUEL PUMP

FUEL
TANK

FUEL / WATER
SEPARATOR FILTER

Figure 1. Fuel System

Description. The fuel system consists of a fuel
tank, fuel water separator, pump, injectors, fuel FILTER
lines and hoses. Fuel is drawn from the tank, HEAD
through the filter, by the pump. The fuel is, then,
sent to the cam operated fuel injectors. Any
excess fuel is returned to the fuel tank.
Changing Filter. With the engine shut down,
perform the following procedures to replace the
fuel water seperator. It should be changed every
200 hours or more often if conditions warrant. SEAL
Refer to Figure 2 for identification of parts.
1. Remove fuel water separator from filter head.
FUEL / WATER
2. Fill new fuel water separator with clean fuel. SEPARATOR
3. Lubricate seal with clean fuel.
4. Install replacement fuel water separator and
tighten 1/2 turn after seal contacts filter head.
Figure 2. Servicing Fuel / Water Separator

TEC-920L - 950L (1/89) 2-1

 Section 2

Fuel System
Cummins M-11 Diesel

TO MANIFOLD
AND INJECTORS RETURN
LINE

FUEL PUMP

FUEL
TANK

FUEL / WATER
SEPARATOR FILTER

Figure 1. Fuel System

Description. The fuel system consists of a fuel
tank, fuel water separator, pump, injectors, fuel FILTER
lines and hoses. Fuel is drawn from the tank,
HEAD
through the filter, by the pump. The fuel is then,
sent to the cam operated fuel injectors. Any
excess fuel is returned to the fuel tank.
Changing Filter. With the engine shut down,
perform the following procedures to replace the
fuel water separator. It should be changed every
200 hours or more often if conditions warrant.
Refer to Figure 2-2 for identifications of parts. SEAL
1. Remove fuel water separator from filter head.
2. Fill new fuel water separator with clean fuel.
3. Lubricate seal with clean fuel. FUEL WATER
SEPARATOR
4. Install replacement fuel water separator and
tighten 1/2 turn after seal contacts filter head.
5. Dispose of all fluids and filters according to
local and federal regulations.

Figure 2. Servicing Fuel Water Separator

(1/97) 2-1
 Section 3

Air Intake System

AIR CLEANER
INTERNAL FILTER PRESS TO
INDICATOR RESET
MOUNTING
STRAPS SAFETY
COTTER
ELEMENT
PIN
CAP

FILTER
SERVICE
INDICATOR

WING
NUT
WASHER
GASKET
TO
BODY
ENGINE
PRIMARY ELEMENT
COVER ASSEMBLY
EVACUATOR CLIP

Figure 3-1. Air Intake System

Description. The Donaldson air cleaner is 2. Check the internal filter indicator to determine
designed for fast, easy disassembly so it can be if the safety element also requires servicing.
serviced efficiently and quickly. Intake air enters
3. If the internal indicator shows Green, continue
the air cleaner through the cap. When the air
to step 5.
reaches the filter body, a helical ramp imparts a
high-speed circular motion to the intake air. This 4. If the internal indicator shows Red, remove the
action separates a large portion of the dust from cotter pin, indicator, and the safety element.
the air by centrifugal action. The dust is swept out
through the evacuator. NOTE: Replace the safety element after 1500
hours or as indicated by the internal filter indi-
Servicing. If the equipment is being operated cator.
under extremely dusty conditions, the evacuator
should be checked every day to be certain it is not 5. Replace the primary filter element with a new
clogged. filter element.
Perform the following procedures to service the 6. Remove all dust and foreign particles from the
filter element and air cleaner components. air cleaner components, and clean the inside
of the air cleaner body.
NOTE: Normally the primary filter element
should be changed after 500 hours or when 7. Reinstall the safety element, internal filter indi-
the filter service indicator shows red. In dusty cator, cotter pin, primary element / wing nut
working conditions the primary filter element assembly.
may have to be changed more often. 8. Push the reset button on the filter element ser-
vice indicator.
1. When the filter service indicator indicates ele-
ment servicing is required, remove the wing
nut cover primary element assembly.

TEC-920L / 950L (Rev. 4/97) 3-1

 Section 5

Cooling System

Description. The cooling system consists of the 4. Always follow the manufacturer’s recommen-
radiator, piping connecting the radiator to the dations on inhibitor usage and handling.
engine, and a water pump to circulate the coolant.
5. Do Not use soluble oil.
Lines connecting the top radiator tank to the
engine deaerates the coolant. A sight glass is 6. Chromate inhibitors should Never be used.
located on the radiator for checking coolant level.
7. Sealer type antifreeze should Not be used.
Checking The Coolant Level. The coolant level
8. Maintain prescribed inhibitor strength.
should be checked daily. Coolant should be
visible in lower sight glass but not above upper Changing Water Filter. New engines shipped
sight glass on the radiator before starting the from the factory are equipped with a DCA
engine, when the coolant is cold. If the coolant precharge filter. After the first 200 hours of
level is too low, add coolant until coolant is visible operation the pre-charge filter should be replaced
in the lower sight glass but not above upper sight with a service filter. The service filter should be
glass. No not overfill. changed each 200 hours of engine operation.
Perform the following procedures to change the
water filter.

 Do not remove cap on
radiator unless entire system is cool. 1. Close both water filter shutoff valves.
2. Unscrew the spin off type filter. Discard the
Coolant Temperature. When the engine warms filter.
up the indicator pointer for the coolant
temperature gauge should be in the green area. 3. Install a new filter. Tighten the filter by hand
until the seal touches the filter head. Tighten
Draining The Coolant System. The cooling an additional 1/2 to 3/4 turn.
system is drained by opening the drain valve on
the radiator.
Removal of the radiator filler cap will allow air to    Mechanical tightening can
enter the cooling passages and ensure that the distort the filter or crack the filter head.
coolant drains completely from the system.
4. Open both water filter shutoff valves.
5. Operate the engine and check for coolant
   When freezing weather is leaks with the engine coolant at normal oper-
expected, any cooling system not adequately ating temperature.
protected by antifreeze should be drained.
Filling The Coolant System. Before starting the
Leave all drain cocks open until refilling the engine, close all drain cocks and fill the cooling
cooling system. system. If the capacity of the cooling system is
unknown, measure the amount of water
The cooling system of this equipment is protected necessary to fill the cooling system. Drain the
to -34°F (-36°Celsius) freezing, and 220°F (104.4 cooling system and refill with the desired amounts
Celsius) boiling. This is a 50% ethylene glycol of water and antifreeze or pre-mix to proper
base antifreeze to water solution. It is proportions before filling.
recommended that 50% solution be maintained
year round. NOTE: The use of clean soft water will eliminate
Coolant Recommendations. The following the need for descaling solutions to clean the cool-
recommendations are considered beneficial to ing system. A hard mineral-laden water should be
trouble-free operation of the cooling system. softened with water softener chemicals before it is
poured into the cooling system.
1. Always use a properly inhibited coolant.
2. If freeze protection is required, always use an- Flushing. The cooling system should be flushed
tifreeze with an ethylene glycol base. each spring and fall. The flushing operation
cleans the system of antifreeze in the spring and
3. Re-inhibit antifreeze with a non-chromate in- removes the summer rust inhibitor in the fall,
hibitor. preparing the cooling system for a new solution.

TEC-920L-950L (1/89) 5-1

Inspection. Components of the cooling system
should be checked periodically to keep the engine
operating at peak efficiency. The thermostat and
radiator pressure cap should be checked and
replaced, if found defective. The cooling system
hoses should be inspected and any hose that is
abnormally hard or soft should be replaced
immediately.
Check the hose clamps to make sure they are
tight. All external leaks should be corrected as
soon as detected. The shroud should be tight
against the radiator core to prevent recirculation of
air which may lower cooling efficiency. Check the
fan and water pump drive belts for proper tension.
Drive Belt Tension (Figure 2). The tension on
the fan and water pump drive belts should be
such that a firm push with the thumb midway
between the pulleys will deflect the belt 1/2 to 3/4
inch. If either of the belts need to be replaced,
replace both belts with a matched set. After
replacing the belts and adjusting the tension,
operate the engine for 15 seconds to seat the
belts and readjust the tension. Recheck the belt
tension after 1/2 hour of operation, and adjust if
necessary.
Thereafter, check the tension of the drive belts
after every 150 hours of operation and adjust if
necessary.

   Too tight a drive belt is

destructive to the bearings of the driven part,
and a belt that is too loose will slip.

TEC-920L-950L (1/89)
5-2
 Section 6

Electrical System

Description. The electrical system consists of a c. A fully charged battery and a high charging
battery (or batteries), a battery disconnect switch, rate usually indicates the voltage regulator
a battery charging alternator with voltage is not limiting the alternator output.
regulator, ignition and starter switch, starter, and
starter solenoid. The remainder of the electrical
system consists of instruments, switches, sending    A high charging rate on a fully
units, wiring, circuit breakers, etc., necessary for charged battery will damage the battery and
operation of the electrical system. Optional other components.
equipment selected by the customer will
d. A low battery and low or no charging rate
determine the electrical equipment to be installed could be caused by loose connections,
in addition to the standard electrical system. damaged wiring, defective battery, improp-
Batteries. The batteries are perishable items er regulator operation, or defective alter-
which require periodic servicing. A properly cared nator.
for battery will give long and trouble-free service.
Refer to the appendices in the back of this manual NOTE: If the machine is to be inoperative or
for service intervals, and perform the following idle for more than 30 days, remove the batter-
procedures to maintain the batteries in a ies. The batteries should be stored in a cool
serviceable condition. dry place. The electrolyte level should be
checked regularly and the batteries kept fully
1. Check the level of the electrolyte regularly. charged.
Add water if necessary, but do not overfill.
Alternator. The alternator can be expected to
give long, trouble-free service; however, the
   Overfilling can cause poor diodes and transistors in the alternator circuit are
performance or early battery failure. very sensitive and can be easily destroyed. The
following precautions should be observed when
2. Keep the top of the batteries, terminals, and working on or around the alternator.
cable clamps clean. When necessary, wash Avoid grounding the output wires or the field wires
them with a solution of baking soda and water, between the alternator and regulator. Never run
and rinse with clean water. an alternator on an open circuit.
Grounding the alternator’s output wires or
   Do not allow the soda solution terminals, which are always hot regardless of
to enter the cells. whether or not the engine is running, and
accidently reversing the battery’s polarity will
3. Inspect the cables, clamps, and hold down destroy the diodes. Grounding the field circuit will
brackets regularly. Replace any damaged also result in the destruction of the diodes. Some
parts. Clean and re-apply a light coating of voltage regulators provide protection against
grease to the terminals and cable clamps some of these circumstances; however, extreme
when necessary. caution should be used.
4. Check the electrical system if the batteries be- Accidently reversing the battery connections must
come discharged repeatedly. be avoided. If a booster battery is to be used, the
5. Use the following quick-in-the-unit check as an batteries must be connected positive (+) to
indication of faulty components in the battery positive (+), and negative (-) to negative (-).
charging circuit. Never disconnect the batteries while the alternator
a. A fully charged battery and low charging is in operation. Disconnecting the battery will
rate indicates normal alternator-regulator result in damage to the diodes, caused by
operation. momentary high voltage and current induced by
b. A low battery and high charging rate indi- the instantaneous collapse of the magnetic field
cates normal alternator-regulator opera- surrounding the field windings.
tion.

(Rev. 1/97) 6-1

Drive Belt (Figure 1). Visually inspect the belt.
Check the belt for intersecting cracks. Transverse
(across the belt width) cracks are acceptable.
Longitudinal (direction of belt length) cracks that
intersect with transverse cracks are not
acceptable. Replace the belt if it is frayed or has
pieces of material missing.

Figure 2. Drive Belt Tension Check.

Figure 1. Drive Belt Inspection.

Drive Belt Tension (Figure 2). Measure the belt

deflection at the longest span of the belt. Maximum
deflection 3/8 to 1/2 inch (9.525 to 12.7 mm).
On engines not equipped with automatic
tensioners, the tension on the fan and water pump
drive belts should be such that a firm push with
the thumb midway between the pulleys will deflect
the belt 1/2 to 3/4 inch. If either of the belts need
to be replaced, replace both belts with a matched
set. After replacing the belt and adjusting the
tension, operate the engine for 15 seconds to seat
the belt and readjust the tension. Re-check the
belt tension after 1/2 hour of operation, and adjust
if necessary.
Thereafter, check the tension of the drive belts
after every 50 hours of operation and adjust if
necessary.

   Too tight a drive belt is

destructive to the bearings of the driven part,
and a belt that is too loose will slip.

6-2 (Rev. 1/97)

 Section 9

Transmission, TC-34

FULL
BREATHER

DIPSTICK

FILLER CAP

GASKET

SCREEN

DRAIN PLUG
Figure 1. Transmission
Description. This transmission has 3 speeds in right side just behind the front wheel. The filter
both forward and reverse. Both direction and elements are spin-on type and should be replaced
speed range must be selected manually by shift after 50 to 100 hours and then, after every 500
levers mounted left of the operator. The clutches hours of operation. Refer to Figure 2 for
are multiple disc type. Each clutch is hydraulically identification of parts. Perform the following
actuated and spring released. It is oil cooled and procedures to change the filter elements.
lubricated. Wear is automatically compensated for
1. Shut down engine and allow the transmission
and no adjustment is necessary.
oil to cool.
Oil Level Check. The oil level should be checked
2. Unscrew the filters from the filter head (Figure
daily, with the engine running at 500 to 600 rpm
2).
and the oil temperature approximately +180°F.
The oil level should be at the Full mark on the 3. Apply a thin film of fresh transmission fluid to
dipstick (see Figure 1). If the oil level is below the the seal of each filter.
Full mark, add oil to bring the oil level to the Full
4. Thread the filters onto the filter head.
mark. The dipstick and filler cap are both
allocated under the engine access cover. 5. Tighten filters 3/4 turn after seal contacts filter
head surface.
Changing Filter Elements. The transmission oil
filter elements are mounted behind a door on the 6. Operate the engine and check for oil leaks.

TEC-920L-950L (Rev. 6/93)

9-1
 FILTER HEAD

SEAL

FILTER

Figure 2. Transmission Oil Filter

7. Whenever the filter elements are changed, re- 7. Operate the engine and check for oil leaks.
check the transmission oil level. With the en- With the engine running at 500 to 600 rpm,
gine operating at 500 to 600 rpm and the recheck the oil level, and if necessary add oil
transmission oil temperature approximately until oil is visible on the dipstick below the Full
+180°F the oil level should be at the Full mark mark.
on the dipstick.
8. When the oil temperature reaches approxi-
Changing The Oil. The transmission oil should mately +180°F, make a final oil check and add
be changed after every 1000 hours of operation. oil to bring the oil level to the Full mark on the
Perform the following procedures to change the dipstick.
oil.
Cleaning The Transmission Breather. The
1. With the oil temperature between 150° and prevalence of dirt and dust will determine the
200°F provide a suitable container and re- frequency at which the breather requires cleaning.
move the drain plug (see Figure 1) and drain
1. Remove the breather.
the oil.
2. Remove the screen and gasket. NOTE: Care must be exercised when removing
the breather to avoid damaging the breather.
3. Clean the screen thoroughly.
2. Wash the breather thoroughly in solvent and
NOTE: An accumulation of sludge or soft dirt in dry it with compressed air.
the sump should be removed with flushing oil.
3. Reinstall the breather.
4. Use a new gasket and reinstall the screen.
Tighten the screen to 15 to 20 foot pounds. NOTE: Oil and filter elements should be disposed
of according to local regulations.
5. Refer to Changing Filter Elements above and
change the filter elements.
6. Reinstall the drain plug and fill the transmis- GENERAL INFORMATION
sion until oil is visible on the dipstick below the Clutch oil pressure . . . . 240 - 280 psi
Full mark. Oil Temperature . . . . . . 180 - 200°F
Oil System Capacity . . 24 quarts

TEC-920L-950L (Rev. 6/93)

9-2
 Section 13

Steer Axle

SPINLDE
(Upper and Lower)

STEER LINK

COVER

MOLY GREASE

Figure 1. Steer Axle

Description. This steer axle is of extremely Grease Fittings. Access for lubricating the grease
rugged construction. The design prevents fittings can be obtained by steering the machine
scuffing of the steer tires, and the pivotal first to one side then, the other.
mounting ensures equal loading on each steer
Wheel Bearings. The wheel bearings are packed
wheel. The double action steer cylinder applies
with grease. Repacking of wheel bearings
steering force to both steer wheels
requires that the hubs be removed from steer axle
simultaneously. When hydraulic pressure is
and bearings be removed from hub.
applied to either end of the actuating cylinder, a
pulling force is applied to one steer wheel and a
pushing force is applied to the opposite wheel.

TEC-920L-950L (Rev.6/95) 13-1

 Section 14

Drive Axle

PRC 5324, PRC 5334

5
1

1. DIFFERENTIAL OIL LEVEL

CHECK AND FILL PLUG
2. PLANETARY HUB OIL LEVEL
CHECK AND FILL PLUG
3. DIFFERENTIAL DRAIN PLUG
4. PLANETARY HUB DRAIN PLUG 2
5. BREATHER
OIL LEVEL

Figure 1. Drive Axle

Description. This axle is a heavy duty type with operating conditions. This axle is equipped with
double reduction gearing. The first gear reduction hydraulically actuated wet disc type brakes that
is a hypoid type ring gear and pinion. The second assure safe sure stops even with heaviest of
reduction is in the form of planetary gears inside loads.
the hubs. This arrangement permits the axle
Checking Lube Oil Level. Perform the following
shafts and hypoid gearing to carry only a nominal
procedures to check the oil level, and service the
torsional load while providing the highest practical
differential and planetary hubs.
gear reduction at the wheels. This results in an
enormously rugged axle, capable of bearing NOTE: The machine should be parked on a level
constant and severe loads without fatigue or surface when the drive axle is being serviced. Re-
failure. Positive full flow lubrication assures fer to the appendices in the back of this manual
adequate lubrication to all moving parts under all

(7/95)
14-1
for servicing intervals and type of lubricant to be 8. Perform the necessary procedures contained
used. in the preceding paragraph (Checking Oil Lev-
el) and service the planetary hubs.
1. Differential.
Cleaning The Breather. The differential breather
a. Check the oil level in the differential by re- should be cleaned, whenever the oil is changed in
moving the oil check plug (1, Figure 1). the drive axle. Perform the following procedures
to clean the breather.
b. The oil level should be even with the bottom
of the oil level check plug hole. Fill the dif- 1. Wipe away any dirt or grime on the breather
ferential to this level, if the oil level is too (5) and surrounding area before removing the
low. breather.
c. Reinstall the oil level check plug. 2. Remove the breather (5).
1. Planetary Hubs. 3. Wash the breather by agitating it in solvent
and dry with compressed air.
a. Maneuver the machine until the Oil Level
check plug (2) on one of the planetary hubs 4. Inspect the breather. If it is damaged or
is horizontal with the center of the hub. clogged, install a new breather.
b. Remove the Oil Level check plug. The oil
level should be even with the bottom of the
Oil Level check plug hole. Fill the planetary
hub to this level, if the oil level is too low.
c. Reinstall the Oil Level check plug.
d. Reposition the machine as necessary and
service the hub on the opposite end of the
axle by repeating the above procedures.

NOTE: When the drive axle is completely ser-

viced the oil is at a common level in the differential
and both hubs.
Changing The Oil. Perform the following
procedures to change oil in the drive axle.
1. Position the machine so that the Drain plug (4)
for one of the planetary hubs is at the bottom
of the hub.
2. Provide a suitable container to catch draining
oil then, remove the differential drain plug (3).
3. Remove the Drain plug (4).
4. Position the machine so that the Drain plug for
the opposite hub is at the bottom of the hub
and remove the Drain plug.
5. When the oil has completely drained, reinstall
all drain plugs.
6. Dispose of used oil in accordance with local
and federal regulations.
7. Service the differential with oil through the Oil
Level check plug hole until oil starts to flow
from the hole. Install the Oil Level check plug.

14-2 (7/95)
 Section 15

Brake Control System

AUTOMATIC
DRAIN VALVE
MANUAL
DRAIN
VALVES

PULL
CABLE

AUTOMATIC AIR TANK

DRAIN VALVE

Figure 15-1. Air Tanks

Air Tanks. All compressors pass a certain should be done with the engine operating and the
amount of oil in order to lubricate the cylinder brake system at normal operating pressure.
walls and piston rings. Also, depending on the
humidity, air entering the compressor contains a NOTE: It will be necessary for someone to ob-
certain amount of water. This oil and water serve the automatic drain valves to perform
normally enters the air tanks in the form of vapor this check.
because of the heat generated during
compression. After reaching the air tanks they When the operator applies the brakes, the
condense to form water emulsion that must be automatic drain valves should be checked to see
drained off before entering the brake system. that a small amount of air escapes from the valve.
The automatic drain valves on all air tanks must
Manual Drain Valve. Some air tanks are be checked.
equipped with manually operated drain valves to
drain any collection of oil and water emulsion from The automatic drain valves should be removed
the tanks. Tanks equipped with manual drain and cleaned every 6 months.
valves should be drained daily.
Automatic Drain Valve. Some air tanks are
 Never bleed the pressure
equipped with automatic drain valves. When the from the air tanks when the machine is being
brakes are applied and the pressure in the air tank held with the spotting brake. Set the parking
drops approximately 2 psi (13.79 kPa) the brake.
automatic drain valve will open momentarily
allowing a small amount of air to escape. When Perform the following procedures to remove the
this happens any collection of oil and water automatic drain valves.
emulsion will also escape.
1. Set the parking brake.
Operation of the automatic drain valves should be
2. Check to see that the spotting brake is in the
checked every 200 hours of operation. This
released position.

(Rev. 11/94) 15-1

3. Bleed the air pressure from the brake system 1. Apply a light film of grease on the inlet valve
by applying and releasing the service brakes. seat (9, Figure 15-2).
4. Depress the plunger in the automatic drain
valve to ensure that all pressure is released.    Do not apply oil or grease to
5. Remove the automatic drain valve. the inlet and exhaust valve.
Disassembly And Cleaning. Perform the 2. Place sealing ring (4) in groove of cover (3).
following procedures to disassemble and clean
the automatic drain valves. 3. Place valve guide (10) over inlet and exhaust
valve (5).
1. Remove the four capscrews (1), Figure 15-2,
and lockwashers (2). 4. Place valve guide (10) and inlet and exhaust
valve assembly (5) into cover (3) with wire
2. Remove cover (3) and sealing ring (4). stem (11) projecting through exhaust port (12).
3. Remove inlet and exhaust valve (5). 5. Place cover (3) on body (13) and install lock-
4. Remove adapter and filter assembly (6). washers (2) and capscrew (1).
5. Remove filter retainer (7) and filter (8). 6. Install filter (8) in adapter and screw in filter
retainer (7).
6. Clean and inspect the filter. Replace the filter
if it is clogged. 7. Install adapter and filter assembly (6) in body
(13) and tighten.
7. Wipe all rubber parts clean. Cleaning solvent
may be used on metal parts. 8. Reinstall the automatic drain valve in the air
tank.
Reassembly. Perform the following procedures
to reassemble the automatic drain valve.

8 6
13 7
1. CAPSCREWS
2. LOCKWASHERS
3. COVER
4. SEALING RING
5. INLET AND EXHAUST VALVE
9
6. ADAPTER AND FILTER ASSEMBLY
7. FILTER RETAINER
8. FILTER
5
9. INLET VALVE SEAT
10. VALVE GUIDE
4 11. WIRE STEM
2 12. EXHAUST PORT
3
13. BODY
10 12
1 11

Figure 15-2. Automatic Drain Valve

15-2 (Rev. 11/94)

 Section 15

Brake Control System

VALVE BODY
TREADLE TREADLE
ROLLER
PLUNGER
ROLLER
PIN
HINGE PIN
BOOT
LOCKNUT
MOUNTING
PLATE
STOP BUTTON
PLUNGER

ROLLER FULCRUM PIN

ROLLER
RUBBER PIN
SPRING
VALVE PEDAL
BODY

TYPE E-3 BRAKE VALVE TYPE E-5 BRAKE VALVE

Figure 15-1. Brake Valves

Type E-3 Brake Valve. The brake valve should Lubrication Of The Type E-5 Brake Valve. The
be lubricated after every 200 hours of operation. brake valve should be serviced after every 200
Refer to Figure 15-1 for identification of hours of operation. Refer to Figure 15-1 for
components and perform the following procedures identification of components and perform the
to lubricate the brake valve. following procedures to service the brake valve.
a. Lubricate the treadle roller, roller pin, and a. Lubricate the roller, roller pin, and fulcrum
hinge pin with engine oil. pin with engine oil.
b. Lift the boot away from the plunger or b. Check pedal for free travel.
mounting plate and put a few drops of light
engine oil between the plunger and mount- NOTE: If the pedal has free travel perform the
ing plate. following procedures.
c. Loosen the locknut and back the stop but-
   Avoid using too much oil ton out until the roller is in contact with the
between the plunger and mounting plate plunger.
because oil could get on the rubber spring and d. Hold the stop button in position and tighten
cause it to deteriorate. the locknut.

(Rev. 11/94) 15-1

 Section 15

Brake System

1 2

4
7 10
6 5
3

9
8

13

12
11

15

17

14
16

21
20 22
18

16

19

1. LEFT HUB 12. LOW AIR PRESSURE SWITCH

2. RIGHT HUB 13. REMOTE TRANSMISSION
3. POWER CLUSTER CONTROL VALVE
4. REMOTE RESERVOIR 14. HORN VALVE
5. BRAKE RELAY VALVE 15. HORN
6. PARKING BRAKE VALVE 16. AIR TANK
7. LOW AIR PRESSURE SWITCH 17. POP-OFF VALVE
8. SPRING ACTUATED DRIVELINE 18. CHECK VALVE
BRAKE 19. MANUAL DRAIN VALVE
9. BREATHER 20. TR-3 VALVE
10. LQ-2 VALVE 21. GOVERNOR
11. BRAKE VALVE 22. COMPRESSOR

Figure 15-1. Brake Control System

15-1
TEC-920L-950L (Rev. 6/91)
Description. The brake control system consists Air pressure in the normal brake system must be
of an engine driven air compressor, a governor above 40 psi and the parking brake valve must be
and two air tanks with a manual drain valve and a pushed in to release the brakes after they have
relief valve, a combination brake valve / inching been applied with the failsafe system. If the
control pedal, an air released drive line spring parking brake valve is pushed in when the air
brake, a power cluster with remote reservoir and pressure in the brake system is below 40 psi, it will
hydraulic operated wet disc type wheel brakes in return immediately to the out position and the
the drive axle. Air pressure from the air tanks parking brake will not release.
which is controlled by the foot operated control
When air pressure in the normal brake system is
pedal, is used to actuate the hydraulic master
above 40 psi, the brakes can be applied using the
cylinder. The hydraulic master cylinder converts
fail-safe system by pulling the parking brake valve
air pressure to hydraulic pressure to operate the
to the out position. Pushing the valve in will
wheel brakes. At the same time, the air pressure
release the brakes, and they can then be applied
is routed to the transmission control valve which
and released using the service brake pedal.
modulates the clutch pressure providing true
inching control. When the audible signal is heard, the vehicle
should be stopped and air pressure in the normal
The parking brake valve, when depressed,
braking system increased before continuing
supplies air pressure to release the spring
operation.
actuated drive line brake. When the parking
brake valve is pulled out, the air pressure is Maintenance. Very little maintenance is required
released and an internal spring applies the drive on the brake system. Drain condensation from air
line brake. This also causes another valve to tanks daily. All hoses, lines and fittings should be
open and apply the wheel brakes. checked periodically for leaks and serviceable
condition. The level of mineral oil in the remote
Fail Safe System. If for any reason the air
reservoir must be checked. Refer to the
pressure in the system drops below 40 ± 5 psi, an
Preventive Maintenance chart in the back of this
audible alarm will automatically pop out and apply
manual for recommended service intervals.
the brakes bringing the machine to a stop.

15-2 TEC-920L-950L (Rev. 6/91)

 Section 15A

Brake Cooling System

General. Due to the heavy duty loads carried by Since the brake uses the machine’s hydraulic
the larger machines, and the extreme heat system oil, the brake cooling oil is changed as a
generated by the brakes, a brake cooling system result of the hydraulic system oil being changed.
is installed to maintain the oil bathed brake discs This system of “wet” disc brakes has been found
within a controlled temperature range thus to greatly increase the service lift of the brake
assuring consistent positive braking action. material as well as providing smooth sure stops.
Description. The brake cooling system consists Switches to sense low pressure or excessively
of the two wet disc brake housings, a flow divider / high temperature of the brake cooling oil are
pressure regulator valve, a pressure reducing installed on the flow divider / pressure limiting
valve, two pressure relief valves, oil cooler, hoses, valve. Either switch, when tripped, will cause a
lines and various fittings. single warning lamp on the instrument panel to
light.
Pressurized oil from the main hydraulic pump is
sent to a pressure relief valve which limits oil to Maintenance. Very little maintenance is required
175 psi. This oil goes through a second pressure on the brake cooling system. All hoses, lines and
relief valve then, on through the cooler. This fittings should be checked periodically for leaks
cooled oil travels to the flow divider / pressure and serviceable condition. Refer to the
limiting valve which limits the oil pressure to each Preventive Maintenance chart in the back of this
hub to 10 psi maximum. Once through the hubs, manual for recommended service intervals.
the oil travels back to the flow divider then, back
to the hydraulic tank.

15A-1
TEC-920L-950L (1/89)
 LEFT HUB RIGHT HUB

BRAKE COOLING
FLOW DIVIDER VALVE

STEER
SENSING
VALVE
TO REMOTE LIFT
AND TILT
CONTROL VALVES

300 PSI
PRESSURE
REDUCING
VALVE
PUMP
175 PSI
PRESSURE PRESSURE
CHECK RELIEF
PORT VALVE

325 PSI HYDRAULIC TANK

PRESSURE
RELIEF VALVE

OIL COOLER

Figure 1. Brake Cooling System

15A-2 TEC-920L-950L (1/89)

 Section 15A

Brake Cooling System

General. Due to the heavy duty loads carried by Since the brake uses the machine’s hydraulic
the larger machines, and the extreme heat system oil, the brake cooling oil is changed as a
generated by the brakes, a brake cooling system result of the hydraulic system oil being changed.
is installed to maintain the oil bathed brake discs This system of “wet” disc brakes has been found
within a controlled temperature range thus to greatly increase the service lift of the brake
assuring consistent positive braking action. material as well as providing smooth sure stops.
Description. The brake cooling system consists Switches to sense low pressure or excessively
of the two wet disc brake housings, a flow divider / high temperature of the brake cooling oil are
pressure regulator valve, a pressure reducing installed on the flow divider / pressure limiting
valve, a control manifold with two relief valves, oil valve. Either switch, when tripped, will cause a
cooler, hoses, lines and various fittings. single warning lamp on the instrument panel to
light.
Pressurized oil from the main hydraulic pump is
sent through a filter to the control manifold. Here, Maintenance. Very little maintenance is required
flow is divided and sent to both the remote lift and on the brake cooling system. All hoses, lines and
tilt control valves and the oil cooler. From the fittings should be checked periodically for leaks
cooler oil travels to the flow divider / pressure and serviceable condition. Refer to the
limiting valve which limits the oil pressure to each Preventive Maintenance chart in the back of this
hub to 10 psi maximum. Once through the hubs, manual for recommended service intervals.
the oil travels back to the flow divider then, back
to the hydraulic tank.

15A-1
TEC-920L-950L (1/89)
 1 1
LEFT HUB RIGHT HUB

IN IN

OUT FLOW DIVIDER OUT

PRESSURE
LIMITING VALVE

2 2

TEST PORT 3

PUMP

CONTROL
FILTER MANIFOLD
4

TO (IN) ON
REMOTE
CONTROLLER
LEVER

CHECK PRESSURE
VALVE CHECK PORTS

1. HYDRAULIC HOSE OIL COOLER

2. HYDRAULIC HOSE HYDRAULIC TANK
3. HYDRAULIC HOSE 6
4. HYDRAULIC HOSE
5. HYDRAULIC HOSE
6. HYDRAULIC HOSE

Figure 1. Brake Cooling System

15A-2 TEC-920L-950L (1/89)

 Section 17

Tire and Rim Safety

General c. Make sure correct parts are being assembled.

Check your distributor or the manufacturer if
a. Never attempt to weld on an inflated tire / rim
you have any doubts.
assembly.
d. Mixing parts of one manufacturer’s rims with
b. Do not let anyone mount or demount tires
those of another is potentially dangerous. Al-
without proper training.
ways check manufacturer for approval.
c. Do not under any circumstances, attempt to
e. Do not be careless or take chances. If you
rework, weld, heat, or braze any rim compo-
are not sure about the proper mating of rim
nents that are cracked, broken, or damaged.
and wheel parts, consult a wheel and rim ex-
Replace with new parts, or parts that are not
pert. This may be the tire man who is servic-
cracked, broken, or damaged, and which are
ing your fleet, the rim and wheel distributor in
of the same size, type and make.
your area, or the rim manufacturer.
d. Do not hammer on rims or components with
Mounting And Inflation
steel hammers. Use rubber, lead, plastic or
brass faced mallets if it is necessary to tap a. Do not seat rings by hammering while the tire
components together. is inflated. Do not hammer on an inflated or
partially inflated tire / rim assembly.
Demounting
b. Do not inflate tire before all side and lock rings
a. Always exhaust all air from a single tire and
are in place. Double check to make sure all
from both tires of a dual assembly prior to re-
components are properly seated.
moving any rim components such as nuts and
rim clamps. c. Inflate in a safety cage or use safety chains
during inflation.
b. Make sure to remove the valve core to ex-
haust all air from the tire. Remove both cores d. Check components for proper assembly again
from a dual assembly. after inflating to approximately 5 psi (34.47 kPa).
c. Check the valve stem by running a piece of e. Never sit on or stand in front of a tire and rim
wire through the stem to make sure it is not assembly that is being inflated. Use a clip-on
plugged. chuck and make sure the inflation hose is long
enough to permit the person inflating the tire to
d. Demounting tools apply pressure to rim
stand to the side of the tire, not in front or in
flanges to unseat tire beads. Keep your fin-
back of the tire assembly.
gers clear. Slant the demounting bead tool
about 10° to keep it firmly in place. If it slips Operation
off, it can fly with enough force to kill. Always
a. Do not overload rims or over-inflate tire / rim
stand to one side when you apply hydraulic
assembly. Check your rim manufacturer if
pressure.
special operating conditions are required.
Inspection
b. Do not use undersized rims. Use recom-
a. Check rim components periodically for fatigue mended rim for the tire.
cracks. Replace all cracked, badly worn, dam-
c. Never run a vehicle on one tire of a dual as-
aged and severely rusted components.
sembly. The carrying capacity of the single
b. Clean rims and repaint to stop detrimental ef- tire and rim is dangerously exceeded and op-
fects of corrosion. Be very careful to clean all erating a vehicle in this manner can result in
dirt and rust from the lock ring gutter. This is damage to the rim and tire.
important to secure the lock ring in its proper
d. Do not reinflate a tire that has been run flat
position. A filter on the air inflation equipment
without first inspecting the tire, rim, and wheel
to remove the moisture from the air line pre-
assembly. Double check the lock ring for dam-
vents a lot of corrosion. The filter should be
age; make sure that it is secure in the gutter
checked periodically to see that it is working
before inflation.
properly.

(Rev. 11/94) 17-1

Servicing Tire And Rim On Vehicle d. Do not locate the compressor near a battery
charger. Batteries emit hydrogen gas during
a. Block the tire and wheel on the opposite side
the charging process, which is highly flam-
of the vehicle before you place the jack in
mable, and could be sucked into the compres-
position.
sor intake.
b. Regardless of how hard or firm the ground ap-
pears, put hardwood blocks under the jack.
Always crib up vehicle with blocks just in case
the jack should slip.
c. Remove the bead seat band slowly to prevent
it from dropping off and crushing your toes.
Support the band on your thigh and roll it slow-
ly to the ground. This will protect your back
and toes.
d. When using a cable sling, stand clear; it might
snap and lash out.
Compressor Precautions
There have been instances of tires exploding
violently while on vehicles. The forces involved in
this type explosion are sufficient to cause serious
personal injury to anyone in the immediate vicinity.
Some of these explosions are believed to have
been caused by flammable vapors entering the
tire during inflation. When the machine is
operating, the temperature of the air and vapor
mixture inside the tire will increase. The
temperature inside the tire will also increase with
an increase in ambient temperature, and when
subjected to direct sunlight. If the vapor and air
mixture inside the tire is within the ratio limits that
will support combustion, and any or all of the
above heat increasing factors cause the
temperature to rise, an explosion will occur.
Following are some precautions that can prevent
flammable vapors from entering the compressor,
and subsequently being entrapped in tires.
a. Do not locate the compressor in a utility room
used for storing flammable solvents, paints,
thinners, etc. The flammable vapors will be
sucked into the compressor intake while the
compressor is charging.
b. Do not clean the compressor air filter with a
flammable solvent. Use a non-flammable sol-
vent, such as carbon tetrachloride.
c. Do not use alcohol, methanol, or other flam-
mable agents in the compressor. Drain the
compressor tank frequently or locate the com-
pressor inside to eliminate the freezing prob-
lem.

17-2 (Rev. 11/94)

 Section 22

Hydraulic System

Description. The hydraulic system consists

basically of a hydraulic reservoir, main and FILLER CAP
accessory pumps, control valves, actuating AND

ADD FULL
cylinders, hoses, lines and fittings. The steering DIPSTICK
valve receives hydraulic fluid under pressure from
the demand sensing valve. The steering cylinder
is actuated by the steering valve when the FILLER NECK
operator turns the steering wheel. An SCREEN
accumulator is incorporated in the lift circuit which
provides shock absorption for the lift cylinders.
A fixed orifice restriction valve is installed in each
lift cylinder to restrict the flow of fluid from the lift
cylinders when the carriage is being lowered.
When the carriage is being raised the valve BREATHER
moves off its seat and allows unrestricted flow of FILTER
hydraulic fluid to the lift cylinders. When the
carriage is being lowered, fluid flowing from the lift
cylinders cause the valves to seat. When the
valve is seated, fluid flowing from lift cylinders O-RING
must pass through a smaller opening which slows
the rate of descent of the carriage. This valve is
also a safety device. In the event the hydraulic lift Figure 1. Dipstick and Breather Filter
line should rupture, the valve will move onto its
seat and slow the rate of descent of the carriage. 2. Breather Filters. The breather filters (see
Figure 1) are throw away type filters. Refer to
Servicing. the appendices in the back of this manual for
1. Checking Oil Level. With the lift cylinders recommended interval for changing the filter.
fully retracted, remove the filler cap with at- If the machine is being operated under ex-
tached dipstick (see Figure 1) to check the oil tremely dusty conditions the filters may require
level. The oil level should be to the Full mark more frequent replacement. To change the
on the dipstick. The oil level should be filters, unscrew and discard the filters and o-
checked daily before operating the machine. rings. Install new o-rings and filters. Hand
tightening of the new filters is sufficient.
NOTE: The lift cylinders should be fully retracted 3. Hydraulic Filters. The two suction filters, lo-
when the oil level is checked. cated in the bottom of the hydraulic tank (Fig-
ure 3) are made of reusable 100 mesh screen.
Add oil if necessary to bring the oil level to the Full
mark on the dipstick. Check the condition of the The return hydraulic filters (see Figure 3) have
filler neck screen before adding oil. a 5 micron element installed at the factory; but
NOTE: Refer to the appendices in the back of should be changed to a 10 micron element
this manual for the type of oil to be used. after the first 50 hours. Refer to the appen-
dices in the back of this manual for the recom-
When the dipstick and attached filler cap is mended service intervals and perform the fol-
reinstalled, be sure the cap is tightened securely. lowing procedures to service the filters.
The filler cap is a pressure type cap that requires Return:
4 psi internal pressure to unseat the cap. This
ensures that air entering the reservoir must pass a. Remove the hex nuts and lockwashers, and
through the breather filter. lift the filter head assembly off the studs.

NOTE: The filler has a safety link that can be

raised into position above the filler cap and pad-
locked.

TEC-920L-950L (1/89) 22-1

 LIFT CYLINDERS

ACCUMULATOR

FITTINGS
ON FENDER

TILT CYLINDERS REMOTE

LIFT & TILT VALVE HYDRAULIC
CONTROL
DIRECT VALVE
VALVES

RELIEF
VALVE

MAIN PUMP

ACCESSORY PUMP
HYDRAULIC
RESERVOIR
ORBITROL

STEER
SENSING RELIEF
VALVE VALVE STEER CYLINDER

Figure 2. Hydraulic System

22-2 TEC-920L-950L (1/89)

NOTE: The bypass assembly is attached to the 4. Changing Hydraulic Oil. Refer to the appen-
filter head. The bypass valve and o-ring will both dices in the back of this manual for the recom-
be removed with the filter head. mended service interval and type of oil to be
used and perform the following procedures to
b. Remove element and discard. change the oil.
c. Visually inspect the valve assembly springs a. Provide a suitable container and remove the
and disc for serviceable conditions. tank drain plug (see Figure 3).
d. Inspect o-ring and replace if necessary. b. Remove the hex bolts and lockwashers and
remove the cover.
e. Reinstall new element and head assembly.
Torque hex nuts to 10-12 ft. lbs. c. Clean suction filter screens and replace re-
Suction: The suction filter screens should be turn filter elements.
cleaned when the hydraulic oil is changed. Refer d. Inspect interior of tank and steam clean if
to the appendices in the back of this manual for necessary.
the recommended service intervals and type of oil
to be used and perform the following procedures
to change the oil.

SUCTION
FILTERS

HEAD

HEAD
O-RING
ASSEMBLY

DISC VALVE
ASSEMBLY

SPRING

DRAIN PLUG RETURN

FILTER
ELEMENT
GASKET

COVER

LOCKWASHER

HEX BOLT

Figure 3. Hydraulic Filters

TEC-920L-950L (1/89) 22-3

 The lift cylinder return line should be carefully

 Cleaning the interior of the inspected after every 250 hours of operation.
reservoir with a flammable solvent can create Inspect the line for chafing, cracks, loose or
a serious fire hazard. damaged connections and leaks.
e. Reinstall the drain plug.
   Failure to maintain the lift
f. Use new gasket and reinstall the cover. cylinder return line in good serviceable condition
g. Install new breather filters. will allow foreign particles, dirt and debris to be
drawn into the lift cylinder when the carriage is
h. Service the hydraulic reservoir with hydraulic being lowered. If this is allowed to happen, it will
oil to the Full mark on the dipstick. not only be detrimental to the seals, but will
Inspection. The entire hydraulic system should shorten the service lift of the lift cylinder.
be checked frequently for leaks, loose fittings and
damage. Refer to the appendices in the back of
this manual for the recommended inspection
intervals.

22-4 TEC-920L-950L (1/89)

 Section 27

Telescopic Ultra-VU Mast

LIFT CHAIN ROLLERS

(SOME APPLICATIONS
REQUIRE REPACKING
OF SEALED CHAIN
ROLLERS)

OUTER MAST
SIDE ROLLERS

INNER MAST
MAIN ROLLERS INNER MAST
SIDE ROLLERS

MAST HANGER
PINS
GREASE

Figure 1. Telescopic Ultra-Vu Mast-

TEC-920L-950L (Rev. 4/97) 27-1

Description. The Telescopic Ultra-Vu mast is
equipped with extra-heavy load rollers to accept
forward and backward stress, and side rollers to
absorb side thrust. Heavy cross-bracing is lo-
cated to provide maximum operator visibility.
Lubrication. Lubrication of the mast consists pri-
marily of lubricating rollers and mast hanger pins.

   Do not over lubricate the

roller assemblies. If the rollers are over
lubricated they will slide when subjected to a
heavy load. If this happens a flat spot may be
worn on the rollers and it will continue to slide
until worn out.
Grease fittings are provided for lubricating applica-
ble rollers and mast hanger pins. Sealed chain
rollers must be disassembled and repacked.
Holes are provided in the outer section of the
mast for access to the grease fittings for the roll-
ers on the inner section of the mast. The mast
must be raised or lowered until the holes in the
outer mast are aligned with the grease fittings.
Refer to the appendices in the back of this manual
for lubrication intervals and type of lubrication to
be used. Refer to Figure 1 for location of lubrica-
tion points.
Inspection. The mast assembly should be in-
spected at frequent intervals for evidence of welds
that have partially failed, excessive wear, and evi-
dence of sliding rollers.

27-2
TEC-920L-950L (Rev. 4/97)
 Section 29

2040 TPA Container Attachment

PILE
SLOPE
LINK ENDS

CHAIN
SHACKLE
PINS

PILE
SLOPE
PIVOT

SLEW
CYLINDER
PIVOT
SIDE
ROLLERS

CARRIAGE
MAIN ROLLERS
MOLY GREASE

Figure 1. Carriage
Lubrication. The Taylor 2040 TPA Expandable 1. Check the hydraulic cylinders and hoses for
Container handling attachment has a large num- leaks and serviceable condition.
ber of moving parts which operate under extreme 2. Check the welds to see if they are solid.
load conditions. Frequent periodic lubrication with
a good quality moly grease is absolutely essential 3. Carriage rollers should be inspected for flat
to keeping the attachment on the job performing spots or evidence of sliding.
satisfactorily, with a minimum of down time. Fig-
ures 1 and 2 indicate the location of grease fittings    The roller assemblies must
and other areas that require lubrication. Refer to not be over lubricated. Excess grease will
the service chart in the appendix for service inter- cause the rollers to slide when subjected to a
vals and lubricant to be used. While performing heavy load. If this happens a flat spot will be
the lubrication, take time to make the following in- worn on the roller and the roller will continue
spections. to slide until replaced by a new roller.

29-1
TEC-920L-950L (1/89)
 FRAME STOPS (4)

OUTER MAIN
FRAME ROLLERS
SLEW CYLINDER
ENDS AND U-JOINTS

SUPPORT CHAIN
U-JOINTS (4)

SIDE SHIFT CYLINDER OR

STABILIZER LINK ENDS & U-JOINTS

INNER MAIN
FRAME ROLLERS

MOLY GREASE

Figure 2. Attachment Main and Expansion Frames (Sheet 1 of 2)

29-2 TEC-920L-950L (1/89)

 FLOATING END
OF EXPANSION
CYLINDERS

TWISTLOCK
SHAFT
BEARINGS
(4 TWISTLOCKS)

TWISTLOCK LINKAGE
BELLCRANK (ISO SEALAND)
(EACH END)

OUTER
EXPANSION FRAME
ROLLERS

INNER EXPANSION
FRAME ROLLERS

FLOATING END
OF EXPANSION
CYLINDERS MOLY GREASE

Figure 2. Attachment Main and Expansion Frames (Sheet 2 of 2)

TEC-920L-950L (1/89) 29-3

 Troubleshooting

Power Unit
Power Transfer
Axles
Brake Control System
Steering Control
Chassis
Hydraulic System
Attachments

(Rev. 2/95)
 Troubleshooting

Cummins LT-10 and M11 Diesel Engines

Troubleshooting is an organized study of the problem and a planned method of investigation and
correction of the difficulty. The following chart includes some of the problems that an operator may
encounter during the service life of a Cummins Diesel Engine. Always check the easiest and obvious
things first, such as the master disconnect switch, the neutral start switch, an empty fuel tank, closed fuel
shut off, dead battery or corroded terminals. Study the problem thoroughly before starting to work on the
engine. Ask yourself the following questions.
1. What were the warning signs preceding the trouble?
2. Has the engine been subjected to recent repair or maintenance?
3. Has a similar trouble occurred before?
4. If the engine still runs, is it safe to continue operation of the engine in an effort to diagnose the
trouble?
Check the items most easily and inexpensively corrected before proceeding to the more difficult, time
consuming and expensive items. After a malfunction has been corrected, locate and correct the cause of
the trouble to prevent recurrence of the same trouble.

Trouble Cause Corrective Action

Engine Will Not 1. External or internal conditions af- 1. Check engine for ease of crank-
Crank or Cranks fecting engine crankshaft rotation shaft rotation.
Slowly 2. Battery connections broken, loose, 2. Check battery connections.
or corroded
3. Battery charge low 3. Check electrolyte level and specific
gravity.
4. Starting circuit component malfunc- 4. Check starting circuit components.
tion

Engine Hard to Start 1. Engine cranking speed low (below 1. Check engine cranking RPM.
or Will Not Start (Ex- 150 RPM)
haust Smoke Pres-
ent) 2. Cold start aid needed or not work- 2. Install cold start aid. Check, repair,
ing correctly or replace if necessary.
3. Fuel filter plugged 3. Replace fuel filter.
4. Air in the fuel system 4. Check for air in fuel, tighten fuel
connections and filter, check fuel
tank stand pipe.
5. Fuel suction line restricted 5. Check fuel line for restrictions.
6. Intake air system restricted 6. Check intake air system for restric-
tions.
7. Fuel contaminated 7. Verify by operating from a tempo-
rary supply tank.

(Rev. 9/96) 1
Trouble Cause Corrective Action

Engine Cranks But 1. No fuel in tank 1. Add fuel.

Will Not Start (No 2. Shutoff valve closed 2. Use manual override. Repair
Smoke From electrics.
Exhaust)
3. No fuel to injectors 3. Loosen fuel supply line between
fuel pump and cylinder head while
cranking engine; check for fuel.
4. Fuel connections loose on suction 4. Tighten all fuel filter fittings and
side of fuel pump connections from fuel tank to fuel
pump.
5. Fuel filter plugged or suction line 5. Replace fuel filter. Inspect fuel
restricted hose for restriction.
6. No fuel in pump 6. Prime fuel pump.
7. Intake or exhaust system restricted 7. Check intake and exhaust system
for restrictions.

Engine Starts But 1. Air in the fuel system 1. Check for air in fuel, tighten fuel
Will Not Keep connections, tighten filter, check
Running tank stand pipe.
2. Fuel filter plugged or fuel waxing 2. Replace fuel filter. Weather condi-
due to cold weather tions may require fuel heater.
3. Fuel suction line restricted 3. Inspect fuel line for restriction.
4. Fuel contaminated 4. Verify by operating engine from a
temporary supply tank.

Engine Will Not Shut 1. Fuel pump manual override open 1. Check to make sure manual over-
Off ride screw is out to maximum travel.
2. Fuel pump shutoff valve disc stuck 2. Check opening and closing of
electrics.
3. Fuel tank vents plugged 3. Remove, clean, or replace vents.
4. Fuel drain line restricted 4. Check fuel drain line for loops,
crimps, or clamped points.

Lubricating Oil Pres- 1. Incorrect oil level 1. Check for oil leaks. Add or drain
sure Low engine oil. Check dipstick calibra-
tion.
2. Oil pressure gauge malfunctioning 2. Check oil pressure gauge.
3. Oil diluted with fuel 3. Change oil; if oil becomes diluted
again, see authorized repair facility.
4. Change oil and check oil specifica-
4. Incorrect oil specifications tions
5. Replace full flow oil filter.
5. Full flow oil filter plugged 6. Refer to “Coolant Temperature
6. Oil temperature above normal Above Normal” chart.
(120°C (250°F))

2 (Rev. 9/96)
 Trouble Cause Corrective Action

Coolant Temperature 1. Low coolant level 1. Add coolant.

Above Normal 2. Radiator fins damaged or
2. Inspect radiator fins; clean or repair
obstructed with debris
if necessary.
3. Collapsed or restricted radiator
3. Inspect hoses. Replace if neces-
hose
sary.
4. Loose fan drive belt
4. Check belt tension and tighten if
necessary.
5. Incorrect oil level
5. Add or drain engine oil. Check dip-
stick calibration.
6. Cooling fan shroud damaged or
6. Inspect shroud. Repair, replace, or
missing
install.
7. Incorrect or malfunctioning radiator
7. Inspect the radiator cap. Replace
cap
if necessary. System must operate
at 7psi for maximum cooling effi-
ciency.
8. Temperature gauge malfunctioning
8. Test the gauge. Repair or replace
if necessary.
9. Truck operating in too high gear
9. Shift to lower range.
range

Coolant Temperature 1. Temperature gauge malfunctioning 1. Test the gauge. Repair or replace
Below Normal if necessary.

Exhaust Smoke Ex-

cessive Under Load 1. Intake air system restricted 1. Check intake air system for restric-
tions.
2. Turbocharger turbine rubbing 2. Inspect turbocharger. Repair or re-
place if necessary.
3. Intake air leaks between turbochar- 3. Check for air leaks.
ger and cylinder head
4. Turbocharger oil seal leaking 4. Replace seal.
5. Fuel specification incorrect 5. Check fuel specifications.
6. Fuel drain line restricted 6. Inspect fuel return system for
loops, crimps, or clamped points.

Engine Power 1. Excessive load for engine horse- 1. Reduce vehicle load.
Output Low power rating
2. Low power due to altitude 2. Derate engine above 3600 meters
(12,000 feet).
3. Fuel suction line or fuel filter 3. Check fuel line for restriction. Re-
restricted place fuel filter.
4. Lubricating oil level too high 4. Check dipstick calibration and oil
continued pan capacity.

(Rev. 9/96) 3
Trouble Cause Corrective Action

Engine Power 5. Throttle linkage adjustment wrong 5. Check throttle linkage adjustment
Output Low for full opening of throttle lever.
(Continued) 6. Intake or exhaust system restricted 6. Check intake and exhaust systems
for restrictions.
7. Air in fuel; spongy throttle in 7. Check for air in fuel, tighten fuel
system connections and filter, check fuel
tank stand pipe.
8. Fuel drain line restricted or fuel 8. Check fuel drain line for loops,
tank vents plugged crimps, or clamped points. Re-
move, clean, or replace vents.
9. Fuel quality poor 9. Verify by operating engine from a
temporary tank that contains good
fuel and refer to fuel oil specifica-
tions.
10. High intake air temperature; above 10. Use outside air to turbocharger in
100°F warm weather.

Engine Will Not 1. Excessive load for engine horse- 1. Reduce vehicle load or use lower
Reach Rated Speed power rating gear.
When Loaded 2. Tachometer has a malfunction 2. Check with hand or digital
tachometer.
3. Throttle linkage adjustment wrong 3. Check for full throttle travel.
4. Fuel suction line restricted 4. Check fuel inlet for restriction.

White Smoke or 1. Low coolant temperature 1. Refer to “Coolant Temperature Be-

Rough Running At 2. Fuel quality poor low Normal” chart.
Idle (After Warm-up 2. Verify by operating engine from a
Period) temporary tank that contains good
fuel.

4 (Rev. 9/96)
 Troubleshooting

TC Transmission

Hydraulic Checks. Before checking the torque ture up to the operating range. Perform the
converter, transmission, and associated hydraulic following procedures to stall the converter.
system for pressures and rate of flow, it is
essential that the following preliminary checks be 3. With the brakes applied, move the directional
made. control lever to forward and the speed control
lever to 3 speed range.
1. Check the oil level in the transmission. This
should be done with the oil temperature be- 4. Continue to apply the brakes and accelerate
tween +180° F and +200° F, and the engine the engine approximately one-half to three-
operating at 500-600 rpm. quarter throttle.
5. Hold the stall until the desired converter outlet
NOTE: Do not attempt these checks with cold
temperature is reached.
oil.
2. Work the machine to bring the oil temperature
up to the operating range.    Full throttle stall speeds for
an excessive length of time will overheat the
NOTE: If the machine cannot be worked, the converter.
converter can be stalled to bring the tempera-
Problem Cause Correction

Low Clutch Pressure 1. Low oil level. 1. Fill to proper level.

2. Clutch pressure regulating valve 2. Clean valve spool and housing.
spool stuck open.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or pis- 4. Replace sealing rings or clutch
ton sealing rings. shaft.
5. Clutch piston bleed valve stuck 5. Clean bleed valves thoroughly.
open.
6. Broken spring in transmission reg- 6. Replace spring.
ulator valve.
7. Broken or worn sealing rings on 7. Replace sealing rings
clutch support.
8. Low converter charging pump out- 8. See “Low Converter Charging
put. Pump Outlet”

Low Converter Charg- 1. Low oil level. 1. Fill to proper level.

ing Pump Output
2. Suction screen plugged. 2. Clean suction screen.
3. Air leaks at pump intake hose and 3. Tighten all connections or replace
connections or collapsed hose. hose if necessary.
4. Defective oil pump. 4. Replace pump.

Low Flow Through 1. Defective safety bypass valve 1. Replace spring.

Cooler With Low spring.
Converter In Pressure
2. Converter bypass valve partially 2. Check for worn bypass ball seal.
open.

( Rev. 3/95) 1
Problem Cause Correction

Low Flow Through 3. Excessive converter internal leak- 3. Rebuild converter.

Cooler With Low age.
Converter In Pressure
4. Broken or worn sealing rings in 4. See “Low Clutch Pressure”.
transmission clutches.

Low Flow Through 1. Plugged oil cooler. 1. Back flush and clean cooler.
Cooler With High Con-
verter Out Pressure 2. Restricted cooler return line. 2. Clean lines.
3. Lube ports in transmission 3. Check lube lines for restrictions.
plugged. Indicated if transmission
lube pressure is high.

Overheating 1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild

converter assembly.
2. Worn oil pump. 2. Replace.
3. Low oil level. 3. Fill to proper level.
4. Pump suction line taking air. 4. Check connections, tighten se-
curely.

Noisy Converter 1. Worn coupling gears. 1. Replace.

2. Worn oil pump. 2. Replace.
3. Worn or damaged bearings. 3. A complete disassembly will be
necessary to determine which
bearing is faulty.

Lack of Power 1. Low engine RPM at converter 1. Turn engine check governor.
stall.
2. Worn oil sealing rings. 2. Remove, disassemble, and rebuild
converter assembly.
3. Worn oil pump. 3. Replace.
4. Low oil level. 4. Fill to proper level.

2 ( Rev. 3/95)
 Troubleshooting

Drive Axles With Wet Disc Brakes

Problem Cause Correction

Differential 1. Low oil level 1. Fill to correct level with recom-

Overheats mended lubricant (see lubricant
specifications)
2. Incorrect lubricant 2. Drain, flush, and refill with lubricant
of recommended specifications
3. Incorrect bearing adjustment 3. Adjust bearings. Replace any that
are damaged or excessively worn
4. Breather in differential housing 4. Clean breather; replace if damaged
plugged
5. Oil level too high 5. Drain oil down to check plug level
in differential

Loss of Oil Out of 1. Damaged or badly worn pinion 1. Replace oil seal and check for
Differential shaft oil seal loose pinion bearings or pinion nut
2. Loose carrier mounting bolts 2. Check and tighten mounting bolts.
Replace gasket if damaged or bro-
ken
3. Breather in differential housing 3. Clean breather; replace if damaged
plugged, forcing oil by seals

Noisy Differential
1. Noise on Drive 1. Ring gear and pinion adjustment 1. Adjust
too loose (excessive backlash)
2. Noise on Coast 2. Ring gear and pinion adjustment 2. Adjust
too tight (insufficient backlash)
3. Constant Noise 3. a.. Worn bearings 3. a.. Replace bearings
b.. Chipped gear teeth b.. Replace gears
4. Noise on Turns 4. Worn or damaged differential pin- 4. Replace differential parts
ion gears, side gears or pinion jour-
nals

Final Drives Over- 1. Low oil level 1. Fill to correct level with specified
heat (Planetary lubricant
Axles)
2. Incorrect type and grade lubricant 2. Drain, flush, inspect, repair if nec-
essary; install specified lubricant
3. Incorrect lubricant for operating 3. Install correct lubricant specified for
temperature temperature range
4. Wheel bearings improperly ad- 4. Adjust wheel bearings to recom-
justed mended preload
5. Scored planet pins 5. Inspect and replace defective parts

(Rev. 2/96) 1
Problem Cause Correction

Loss of Oil Out of 1. Damaged or broken wheel driver 1. Replace gasket

Final Drives gasket
(Planetary Axles)
2. Damaged or broken hub cap gas- 2. Replace gasket
ket
3. Damaged or excessively worn 3. Replace oil seals and adjust wheel
wheel oil seals bearings properly
4. Loose wheel bearings 4. Adjust wheel bearings properly and
replace oil seal

Noisy Final Drives 1. Lack of lubricant 1. Fill to proper level indicated on hub
(Planetary Axles) cap
2. Worn bearings in wheels or planet 2. Replace bearings
gears
3. Chipped gear teeth 3. Replace gears

Brake Oil Level is 1. Brake piston seals possibly leaking 1. Replace seals
Continuously Low
With No Signs of Ex-
ternal Leakage

Gear Oil Level in 1. Seal between brake housing and 1. Replace seal
Hub is Continuously wheel hub may be leaking
Too High
2. Cooling oil pressure too high 2. Have brake coolant pressure relief
valve cartridge replaced

Signs of External 1. Clean surface then determine loca- 1. Replace seals or reseal bottled
Leakage Exist tion of leakage flange

2 (Rev. 2/96)
 Troubleshooting

Steering System

Problem Cause Correction

Slow or Hard 1. Dirt in system 1. Drain, flush, and refill.

Steering 2. Wear on sleeve and spool in steer- 2. Replace.
ing valve
3. Wear on orbit gear in steering 3. Replace.
valve
4. Steering pump defective 4. Repair or replace pump.
5. Partial restriction on hydraulic 5. Check suction lines for restrictions
suction circuit
6. Low oil supply 6. Replenish oil supply with proper
grade and weight oil. (See lubri-
cant specifications)
7. Filter in suction line stopped up 7. Service the filter.
(if so equipped)
8. Steering control valve defective 8. Repair or replace control valve.
9. Steering cylinder rod bent 9. Replace.
10. Mixed or foaming oils in steering 10. Drain and flush system. Replace
system oil with proper weight oil. (See
lubricant specifications.)
11. Low air pressure in tires 11. Inflate to correct pressure.
12. Low steer pressure 12. Set pressure.

Steering Wheel Does 1. Binding in linkage 1. Re-align.

Not Center
2. Broken centering springs in steer- 2. Replace spring.
ing valve
3. Bent steer column 3. Replace column.

No Response When 1. Dirt in system 1. Drain, flush, and refill with clean oil.
Steering Wheel is
2. Oil level is low 2. Fill to proper level.
Turned Slowly
3. Steer cylinder failure 3. Repair steer cylinder.

Wrong Response to 1. Lines hooked up wrong to ports in 1. Reconnect.

Steering Wheel steering valve
2. Orbit gear misaligned in steering 2. Re-align.
valve

(Rev. 2/95) 1
Problem Cause Correction

Continuous Steering 1. Dirty fluid 1. Drain, flush, and refill.

Wheel Rotation
2. Broken centering springs in steer- 2. Replace.
ing valve
3. Input linkage binding 3. Re-align.
4. Burr on sleeve or spool in steering 4. Repair.
valve

No Response 1. Sleeve and spool locked in steer- 1. Disassemble, repair, or replace.

ing valve
2. Check and correct.
2. Pump failure
3. Check and correct.
3. Hose or filter clogged
4. Drain, flush, and refill.
4. Relief valve stuck

NOTE: Field repair of the Orbitrol valve is

not recommended except by qualified
service personnel.

Repair instructions available on request.

2 (Rev. 2/95)
 Troubleshooting

Chassis

Problem Cause Correction

Cracks in Welds, es- 1. The chassis is carefully engineered 1. Have cracks in welds repaired im-
pecially at the point and ruggedly constructed so that mediately.
where the mast is need for service in this area is
pinned to the chas- highly improbable; however, it oc-
sis. casionally is needed.

Hinged Doors and 1. Doors and access panels not being 1. Make sure these are properly
Access Panels Be- properly replaced after use. closed.
coming Unhinged

(Rev. 2/96) 1
 Troubleshooting

Hydraulic System

One of the most misunderstood systems, and

perhaps the hardest to troubleshoot, is the    If a pump or valve is being
hydraulic system incorporated in industrial trucks. replaced, always take a preliminary pressure
What appears to be a simple failure of a reading on the cold oil, at idle rpm, because if
component is usually corrected by replacement of there is a malfunctioning pressure-relief valve
that component, without due regard to the cause in the system it can burst the pump housing.
of the failure. There may be several individual Normally, if a cylinder is bottomed out it will
systems such as lift, steer, and attachment, tied kill the engine before bursting the pump. If
together to become one overall hydraulic system. your gauge reading begins to exceed the
In which event, what happens to one subsystem maximum allowed pressure, do not bottom out
may affect every other subsystem. Therefore, it is the function completely.
absolutely necessary that special attention be
given to pressures and cleanliness. It is extremely important that pressure readings on
Taylor equipment be taken at the point specified in
The most meaningful system check a serviceman service bulletins. If the pressure gauge is installed
can use in diagnosing a problem is the check of at another point in the system, readings other than
the hydraulic circuit pressure on any machine that the correct one can or will be obtained due to
uses hydraulic components. The two cardinal back pressure and other causes. It should be
rules that should be followed are: noted that readings for accuracy should be
1. Excessive pressure does not offer any opera- obtained when the vehicle engine is running
tional advantage. It only shortens component between 1000 and 1500 rpm. This gives a good,
life. reasonable flow of oil with pressures approaching
the relief valve settings and the settings of other
2. Pressure just high enough to achieve compo- units of the system without excessive back
nent function is always the most desirable set- pressure.
ting.
When a new pump is installed, allow the engine to
We must also remember that the only reasons for idle for 15 or 20 minutes before pressurizing the
making a hydraulic pressure check are to verify system. This allows the pump to become
that the system is to specifications or to thoroughly lubricated and to reach the same
troubleshoot the system to pinpoint a malfunction. temperature as the oil.
Before an accurate reading can be obtained the
following steps must be taken:
1. The hydraulic oil must be to Taylor specifica-
tions. Any oil not to these specifications can
give a faulty reading.
2. The hydraulic system should have been run
long enough to bring the system temperature
to approximately 125 to 150°F (51.6 to
65.5°C).
NOTE: One of the best ways to attain this tem-
perature is to bottom out a cylinder and keep it
bottomed out which passes the oil over the re-
lief valve, thereby generating heat.

(Rev. 2/96) 1
Problem Cause Correction

Hydraulic Pressure 1. Low oil supply 1. Check and fill to proper level with
Will Not Build Up correct grade and weight of oil.
2. Clogged filter 2. Clean or replace filter.
3. Broken hose or connection 3. Replace damaged hoses and tight-
en connections.
4. Excessive air leak on suction line 4. Locate leak and correct. Replace
to pump damaged or broken hoses and
connections.
5. Badly worn or defective pump 5. Disassemble pump and replace
worn or damaged parts; check
shaft seals for source of trouble.
6. Badly worn or defective control 6. Disassemble, clean and inspect.
valve Replace weak or broken springs,
seals and gaskets. If valve plung-
ers are damaged or excessively
worn, replace the complete valve
assembly.
7. 7.
a.Stripped drive ring or flex plate a.Replace
on transmission
b.Broken pump drive shaft b.Replace

Low Pressure In 1. Relief valve setting too low (oil may 1. Adjust relief valve as necessary.
System flow through relief valve and back
to reservoir without reaching point
of use)
2. Look for dirt and sludge in valve. If
2. Relief valve stuck open (may be an valve is dirty, disassemble and
indication that system contains clean. Be sure oil meets Taylor
dirty or deteriorated oil) specifications.

Hydraulic Pressure 1. Broken pump shaft 1. Disassemble pump and replace

Builds Up But Drops broken and excessively worn parts.
Off Rapidly
2. Low oil supply 2. Fill reservoir to proper level with
correct weight and grade of oil.
3. Obstructed hose, line or connec- 3. Locate and remove obstruction.
tion Replace excessively worn or dam-
aged hoses or connections.
4. Defective control or relief valve 4. Disassemble, inspect and repair or
replace valve.

2 (Rev. 2/96)
 Problem Cause Correction

Hydraulic Pressure 1. Engine speed too slow 1. Increase engine speed rpm and
Builds Up Very check.
Slowly or Jerkily
2. Low oil supply 2. Fill reservoir.
3. Excessively worn pump 3. Remove pump, disassemble and
replace worn or damaged parts.
4. Obstructed suction line of filter 4. Locate and remove obstruction.
5. Dirt or other foreign matter under 5. Disassemble valve, clean and as-
relief valve plunger semble properly.
6. Scored relief valve plunger or seat 6. Replace damaged parts. As-
semble properly.
7. Weak or broken relief valve spring 7. Replace spring.

Erratic Action 1. Air in System 1. a. Check reservoir oil level.

b. Check pump seals, pipe and
tubing connections, and all
other possible leak areas.
2. Valves, pistons, etc., sticking or 2. a. Check part for mechanical
binding deficiencies.
b. Look for dirt, oil sludge,
varnishes and lacquers.
c. Replace worn parts and check
type of oil being used.
3. Sluggishness when machine is first 3. a. Check tank filters.
started b. Under severe conditions use
immersion heater.

Pump Not Pumping 1. Intake clogged 1. Check filters, strainers and line
from reservoir to pump.
2. Low oil level 2. Bring oil up to recommended level
in reservoir. Intake line must be
below oil level.
3. Air leak in intake (indicated by 3. Pour oil over suspected leakage
noisy pump) points. If the noise stops, the leak
has been found and can be re-
paired.
4. Oil too heavy 4. Drain system and refill.
5. Pump worn out 5. Check output pressure. If pump is
not producing specified pressure,
replace pump.
6. Mechanical trouble (broken shaft, 6. Locate by noise, repair or replace.
loose coupling, etc.)

(Rev. 2/96) 3
Problem Cause Correction

System Overheating 1. Oil viscosity too high 1. Check oil recommendations. If in

doubt about the oil system, drain
and refill. Adjust viscosity require-
ments for unusual temperature
conditions.
2. Internal leakage too high 2. Check for wear and loose packing.
Check to see if oil viscosity is too
low. If tempted to try a higher vis-
cosity, proceed with caution.
3. Excessive discharge pressure at 3. Reset pressure.
relief setting
4. Low oil pressure 4. Reset pressure.
5. Low oil 5. Indicated by high oil temperature.
Refill oil to proper level.

Noisy Pump 1. Air leaking into system 1. a. Check reservoir oil level.
b. Check pump seals, pipe and
tubing connections, and all
other possible leak areas.
2. Cavitation (the formation of vacu- 2. Check for clogged or restricted in-
um in a pump when it does not get take line or plugged air vent in res-
enough oil) ervoir. Check strainers in intake
line. Check viscosity of oil.
3. Loose or worn pump parts 3. a. Check manufacturer’s mainte-
nance instructions. Look for
worn gaskets and seals.
Replace all worn parts. Check
oil for proper grade and quality.
b. Clean filter or strainer. Check
filter capacity and quality of oil.
c. Determine recommended speed.

Slow or Excessive 1. Air in system 1. Bleed system.

Cycle Time
2. Internal leak in motor, cylinder or 2. Replace piston seals or replace
control valve cylinder if walls are scored. Re-
place or repair valve. Clean unit.
3. Worn pump 3. Repair or replace.
4. High viscosity oil causing sluggish 4. Consult the pump manufacturer’s
action during or after warm-up recommendations or the oil suppli-
er for correct viscosity.

4 (Rev. 2/96)
 Problem Cause Correction

External Oil Leakage 1. Cylinder or valve seals worn 1. Replace seals.

2. Hose or tubing loose or defective 2. Tighten or replace if necessary.

Excessive Wear 1. Abrasive matter in oil passing 1. Install adequate filter or replace oil
through pump more often.
2. Viscosity of oil too low at working 2. Check pump manufacturer’s rec-
conditions ommendations or consult lubrica-
tion engineer.
3. Sustained high pressure above 3. Check relief or regulator valve
maximum pump rating maximum setting.
4. Air recirculation causing chatter in 4. Remove air from system.
system

Breakage of Parts 1. Excessive pressure above maxi- 1. Check relief or regulator valve
Inside Pump Hous- mum pump rating maximum setting.
ing
2. Seizure due to lack of oil 2. Check reservoir oil level, oil filter
and possibility of restriction in suc-
tion line more often.
3. Solid matter being wedged in pump 3. Inspect filter or suction line.
4. Excessive tightening of head- 4. Follow pump manufacturer’s rec-
screws ommendations.

Cylinders Creep 1. Internal leakage in actuating cylin- 1. Replace piston packing or replace
When Stopped in In- ders or operating valves cylinder if walls are scored. Re-
termediate Position place or repair valve.
2. Load check in control valve not 2. Clean unit to remove foreign mat-
seating ter.

(Rev. 2/96) 5
 Preventive Maintenance
Service Symbols Service Intervals
A-Adjust C-Clean CG-Change 10 50 100 200 400 500 600 1000 1200 1500
D-Drain GR-Grease X-Check Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs
POWER UNIT
ENGINE:
Oil level - check for evidence of external leakage X X X X X X X X X X
Oil change and filter element D D D D D
Throttle control linkage (use engine oil) GR GR GR GR GR
Crankcase breather C C
Clean engine C
Check engine mounts X
Engine Protection System - Check plumbing for leaks,
check vent filters on Master Control and Coolant Loss X X X X X
Valve (change if dirty). Perform test.
FUEL SYSTEM:
Fill fuel tank - check for leaks X X X X X X X X X X
Fuel filters D D D D D D D D D D
Fuel filter elements - Cummins CG CG CG CG CG
Fuel filter elements - Caterpillar 3306 CG CG CG
Fuel tank, cap, lines and clamps X X
AIR INTAKE SYSTEM:
Check for leaks X X X X X X X X X X
Donaldson air cleaner elements (or by filter indicator) X X X X X X X X X X
Primary element CG CG CG
Safety element (or by internal indicator) CG
EXHAUST SYSTEM:
PTX Purifier C C
COOLING SYSTEM:
Coolant level and fan belts X X X X X X X X X X
Hoses, clamps, and radiator - check for leaks X X X X X X X X X
Radiator (clean externally) as conditions warrant C C
Drain and flush cooling system D
Change water filter CG CG CG CG CG
ELECTRICAL SYSTEM:
Battery - check water level and specific gravity X X C C C C C
Alternator belts X X X X X X X X X
Lights, safety equipment, gauges, and warning signals X X X X X X X X X X
POWER TRANSFER
TRANSMISSION:
Maintain fluid level to full mark and check for leaks X X X X X X X X X X
Clean transmission breather C
Drain and refill transmission. Clean transmission oil intake D
filter screen (use new gasket)
Transmission filter element. CG CG CG CG CG
DRIVE SHAFTS:
Lubricate drive shafts, universal joints, slip joints, and all GR GR GR GR GR GR GR GR
other bearings
AXLES
STEER AXLE:
Lubricate all grease fittings on steer axle GR GR GR GR GR GR GR GR
Repack steer axle hub bearings GR GR
Wheel bearing adjustment A A
Check mounting bolts X X X X X X X X
DRIVE AXLE:
Differential and planetary hubs - maintain oil level X X X X X X X X
Drain and refill differential and planetary hubs D
Inspect brake linings on drive line brake X X
Wheel bearing adjustment A
Check mounting bolts X X X X X X X X
BRAKE CONTROL SYSTEM
BRAKES:
Check brake fluid level in remote reservoir X X X X X X X X

TEC-920L / 950L (Rev. 7/98)

 Service Symbols Service Intervals
A-Adjust C-Clean CG-Change 10 50 100 200 400 500 600 1000 1200 1500
D-Drain GR-Grease X-Check Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs
BRAKE CONTROL SYSTEM (CONTINUED)
Check manual drains X X X X X X X X X X
Check air lines and connections X X X X X X X X
Clean power cluster breather C C C C C
CHASSIS
Lubricate all grease fittings on machine not listed elsewhere. GR GR GR GR GR GR GR GR
Use engine oil on linkage not having grease fitting
WHEEL EQUIPMENT:
Check tires, valve caps, wheels, lugs and tire pressure (refer X X X X X X X X X X
to data plate on lift truck for torque information)
HYDRAULIC SYSTEM
HYDRAULIC PIPING AND RESERVOIR:
Maintain oil level in hydraulic tank to full mark X X X X X X X X X X
Check piping for chafing, cracked hoses, loose fittings, X X X X X X X X X X
and leaks
Drain and refill entire hydraulic system and clean inside
tank. Drain and refill every 2400 hours.
HYDRAULIC FILTERS:
Replace hydraulic tank breather CG CG CG CG CG
Hydraulic suction filter screens C C
Hydraulic return filter (by indicator or annually – 2400 hours) CG
Remote pilot hydraulic filter CG CG
HYDRAULIC VALVES:
Check for free operation. (Restriction may indicate rust or X X X X X X X X X
dirt in system)
HYDRAULIC CYLINDERS:
Observe speed of movement - check for leaks X X X X X X X X X
ACCUMULATOR:
Check precharge X X X X X X
ATTACHMENTS
MAST:
Lubricate mast hinge GR GR GR GR GR GR GR GR
Lubricate mast main, side, greaseable chain, and hose
rollers. Lubricate tilt cylinder bushings and other grease
fittings on mast, including special equipment. GR GR GR GR GR GR GR GR
Sealed chain rollers; repack at 2,000 hours.
Refer to Leaf Chain Care, Maintenance, and Replacement.
Check all mast mounting hardware (mast hangers) X X X X X X X X
CARRIAGES:
Lubricate carriage main and side rollers GR GR GR GR GR GR GR GR
Lubricate fork pin on Type C carriage GR GR GR GR GR GR GR GR
Lubricate side shift rollers, cylinders, fork positioner cylinders,
and any other grease fittings on carriage assembly, including GR GR GR GR GR GR GR GR
special equipment.
*Forks must be magnetic particle testes (magnafluxed) for X X X X X X X X X X
cracks annually (2400 hrs.)
CONTAINER ATTACHMENT:
Check unit for loose parts, hydraulic leaks and obvious X X X X X X X X X X
damage to structure
Check chains and cables for wear, broken stands, flat X X X X X X X X X X
spots, kinks or fray
Perform holding test to determine the condition of the X X X X X X X X X
holding valves on cylinders
Visually inspect all twistlocks and guide lugs X X X X X X X X X X
Visual inspection of twistlocks and guide lugs by mainte- X
nance personnel
Check twistlocks and guide lugs ultrasonically or by mag-
naflux every 2400 hours. Replace of defective.
Replace twistlocks and guide lugs every 4800 hours.
Visually inspect plungers X X X X X X X X X X
Lubricate all points on attachment GR GR GR GR GR GR GR GR
*Refer to Fork Inspection, Repair, and Testing.

The service intervals for Preventative Maintenance are calculated based on normal operating conditions including ten hours
per day, fifty hours per week. If your operating conditions or duty cycles are more severe, the service should be conducted
more frequently, i.e. extremely dusty conditions may require more frequent servicing of the filters.

TEC-920L / 950L (Rev. 7/98)

 SERVICE CAPACITIES

Engine Lubrication (Includes filter change)

3306 Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Quarts
Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Quarts

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Gallons

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Gallons

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Quarts

Drive Axle
Differential (extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Quarts
Final Drive (each wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Quarts

Steer Axle (each wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Quarts

Hydraulic Tank (running level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Gallons

HYDRAULIC PRESSURE SETTINGS

Control Lever Brake Cooling

Model Lift And Tilt Steering Accessory
Pilot
TEC-920L 2500 psi 2500 psi 2350 psi 200 - 225 psi 10 psi
TEC-950L 2750 psi 2500 psi 2350 psi 200 - 225 psi 10 psi

TEC-920L - 950L (Rev. 9/96)

 Daily Operational Checks

1. Engine 10. Brake Control, Wet Brakes

n Fan Belt (Air Compressor Belts) n Check Fluid in Remote Reservoir.
n Engine Oil n Manually Drain Air Tanks.
n External Leaks n Check Air Pressure
n Mounts
11. Air Brakes
n Acceleration
n Drain Air Tanks
2. Transmission
n Check Air Pressure
n Temperature
12. Chassis
n Pressure
n Check Handrails.
n Check Oil Level
n Make Sure Entrance to Cab is Free of
n Performance Oil, Grease, Fuel and other slippery ma-
n Parking Brake terial.
n Mounts 13. Hydraulic System
3. Fuel System n Check Fluid level.
n Fill Fuel Tank. n Visually Check for Leaks.
n Check for Visible Leaks. n Make sure All Functions are Working
n Check Tank Cap for Security. Properly.
4. Air Intake 14. Mast and Carriage
n Check Filter Indicator. n Mast Hanger Bolts
n Check for Visible Leaks. n Visually Check For Cracks.
5. Cooling System n Visually Check Lift Chain.
n Check Coolant Level Sight Glass. 15. Container Attachment
n Check Hoses, Clamps, & Radiator for n Visually Inspect Twistlock Guide Lugs for
Leaks. Damage and Check Plungers.
n Visually Check Radiator Fins for Dirt, etc. n Visually Inspect Mast Hoses, Attachment
6. Electrical System Hoses, and Cables.
n Check All Functions.
n Check Back-up Alarm.
16. Attachment Indicator Lights
n Check Strobe Light.
n Check Horn. A. Twistlock System
n Check All Gauges on Dash (Engine and n Red Light illuminated means twist-
Transmission Temperature; Air Gauge). locks are Unlocked.
n Check Alternator Belt. n Amber Light illuminates when all 4
twistlocks are in Container Cor-
7. Power Transfer
ner Castings.
n Check Transmission Fluid Level to Full n Green Light illuminates when all 4
Mark. twistlocks are Locked.
n Visually Check for Leaks. n Amber Light goes out when Box is
8. Steer Axle Lifted in the Air.

n Visually Check Lugs and Studs for Tight- B. Pin System

ness. n Red Light means all 4 Beams are
n Visually Check Hubs for Leaks. Fully Extended.
n Amber Light means all 4 Soft-
9. Drive Axle
landing Switches are Functioning.
n Bolted Connections n Green Light appears when Clamp-
n Visually Check Lugs and Studs for Tight- ing a Pin System Box. There
ness. MUST be 1500 PSI in Clamp Circuit
n Visually Check Hubs for Leaks. to Activate Green Light Pin.
n Blue Light means Rear Clamps are
in Position.
 Leaf Chain Care, Maintenance, and Replacement
The leaf chain (or chains) on your Taylor material handling equipment was selected based on thousands of hours
of safe operation over many years of fork lift trucks working in various types of material handling operations.
The entire chain system, including chain anchors, anchor supports, bearings, and chain rollers, is sized for the
basic model capacity and load center shown on the serial plate.
The utility of fork lift truck type material handling equipment requires it to operate under a wide variety of load
conditions. These vary from a few low lifts to a very large number of high lifts per operating hour.
The leaf chain is subjected to all the variations of environment, such as moisture, chemicals, temperature
extremes, abrasives and even salt water in some applications. The chain cannot have the benefit of a protective
coating (paint) and must depend on proper lubrication for combating the effect of these conditions. The
lubrication program greatly affects chain life.
The utility of the lift truck requires it to operate with a variety of attachments, such as forks, coil rams, paper roll
clamps, containers, marinas, and other attachments, all of which will place different dynamic loads and load
requirements on the hoist chains.
This wide variety of variables makes it impossible for Taylor to accurately predict an exact service life of the leaf
chain on the Taylor material handling equipment. Therefore, the following procedure of inspection and
replacement is recommended to avoid sudden failure.

Maintenance and Replacement of the Leaf Chain

In addition to the daily walk-around inspections, at each 500 hours of operation, the chain should be thoroughly
cleaned and inspected for elongation, pin rotation and protrusion, cracked plates, stretched (enlarged hole), worn
contour and worn surfaces on outside links or pin heads. (If any of the above are observed, replace the entire
length of both chains.) (See illustrations of Modes and Failure.)
Careful visual inspection of both inside and outside where possible of the chain links will reveal some of these
early indications of chain failure which can cause total chain breakage if left in service.
NOTE: A hand-held mirror can aid tremendously in hard to see areas.
Particular attention should be given to that part of the chain which passes over the chain roller the most frequently
when under load.
It will be necessary to move the carriage to several locations and block to prevent any possibility from falling to
gain the best possible visual access to the greatest number of pitches of chain.

WARNING: Utilize proper safety precautions when blocking.

After the chain is inspected and found to be serviceable, relubricate and place back in service.
At 2,000 hours, disassemble the leaf chain from the vehicle in accordance with the shop service manual (page
27A-1). Thoroughly clean the chain and visually inspect for possible failure modes as for the 500 hour
interval adding to that procedure the following. Articulate each joint of the chain in both directions where the
entire radius around each pin can be inspected for cracks.
Particular attention should be given that length of chain which passes over the rollers.
If the 2,000 hour inspection does not reveal any apparent excess wear or chain damage, relubricate and reinstall
as follows:
5). Reverse the chain by replacing the mast end on the carriage and carriage end on the mast.
6). Turn the chain over where the former roller side becomes the outside.
At each 500 hours after the leaf chain is reinstalled, inspect and relubricate and follow the same procedure as on
a new machine.
At 4,000 operating hours remove and discard the leaf chain and replace with a new and lubricated chain.
Taylor’s recommendation to replace the chain at 4,000 hours is based on typical service duty cycles. Experience
in a specific application may allow this interval to be increased or may require that it be decreased. Any change
should be based on thorough inspection procedures outlined in this manual.

11-9-95 1
Modes of Chain Failure — See Illustrations on Page 3

1). Normal Wear – Chain Elongation. This is the result of wear when the load chain articulates
over the chain rollers. See illustration No. 1 for explanation of wear limits. If the length exceeds
allowable wear limits (see text), replace entire length of both chains.

2). Chain Stretch. This can be a combination of chain wear and overload (see illustration No. 7).
This will show up as some elongation in plates which do not pass over the rollers. Treat chain
stretch the same as normal wear provided no chain plates are cracked. If length of chain exceeds
allowable pin to pin distance using the wear gauge, replace entire length of both chains.
NOTE: Chain overload is generally the result of improper operation.

3). Plate/Pin Rotation and/or Plate/Pin Lateral Movement. This is generally caused by the plate
seizing the pin at articulation which indicates lack of lubrication where the joint rotates over the
roller. (See illustration No. 2.) This can result in pin breakage in extreme cases. If any evidence
of pin rotation is noted, replace entire length of both chains.

4). Plate/Pin Cracks. Cracks result from fatigue, stress corrosion, corrosion fatigue. (See illustra-
tions No. 3, 4, and 5.) If any cracks are observed of any kind on any link, replace entire length of
chain.
5). Chain Joint Stiffness. (See illustration No. 6.) Lack of lubrication. Check the chain for other
modes of failure. If none are observed, lubricate thoroughly and place back in service.

6). Edge Wear of Plates. (See illustration No. 8.) Edge wear can occur at extended hours of ser-
vice and if sliding of chain occurs because of chain roller bearing problems. If wear exceeds 5% of
plate height of unused plate, replace entire length of chain.

7). Worn Outside Links or Pin Heads. (See illustration No. 9.) Check for misalignment of the
chain roller which causes roller bearing failure or centerline of chain roller is out of alignment.
NOTE: The chain will run toward the high side of the roller.
Check (see Check Procedure) the chain for all modes of failure. If none are found, eliminate the
misalignment, turn the chain over, and place back in service.

11-9-95 2
Modes of Chain Failure

Appearance and/or Symptom Probable Cause Correction

1. Excessive Length (elongation)
If chain gauge shows more than 12.3
inches per foot of elongation. Normal Wear Replace chain

Permanent deformation
(stretch) from overload Replace chain
12.3”/FT.

2. Abnormal Protrusion or Turned Pins

Excessive friction from high

loading and inadequate lubrica-
tion Replace chain and lubricate
more frequently

3. Cracked Plates
(Fatigue)
Loading beyond chain’s capac-
ity (dropping load and catching Replace chain and eliminate
it) dynamic (impulse)
overloading

4. Arc-like Cracked Plates (Stress

Corrosion) Severe rusting or exposure to
acidic or caustic medium, plus
static stress at press fit be- Replace chain and protect
tween pin and plate. (No cyclic from hostile environment by
stress necessary) lubricating more frequently

5. Cracked Plates (Corrosion Fatigue)

Perpendicular to Pitch Line, plus rust
or other evidence of chemical
corrosion Corrosive environment and cy-
clic motion (chain under cyclic Replace chain and protect
operation) from hostile environment by
lubricating more frequently

11-9-95 3
 Appearance and/or Symptom Probable Cause Correction
6. Tight Joints
Dirt or foreign substance
packed in joints
Clean and relube
Corrosion and rust
Replace chain

Bent pins Replace chain

7. Enlarged Holes

High overload, dropping and

catching load Replace chain and correct
cause of overload

8. Worn Contour (Edge Wear)

Normal wear on sheave bearing

area
Replace chain and correct
Abnormal wear, rubbing on roll- cause of overload
er
Check chain roller bearing

9. Worn Surfaces on Outside Links or

Pin Heads

Misalignment, rubbing on roller

flanges Check alignment of
anchors, chain rollers
and chain roller pin.

WARNING:
1. Use proper safety precautions.
a. Always lower the mast and carriage to its lowest position before inspecting the leaf chain, unless the
mast and carriage are securely blocked.
b. Always use OSHA approved support means (man lift, scaffolding, ladder, or platform) when inspecting,
removing, or servicing lift chains. Always turn off the engine. Do not allow anyone to touch the controls
while people are near the upright.
2. Use Lockout / Tagout Procedure to reduce causes of possible injury

Lockout / Tagout Procedure

Purpose
This procedure establishes the minimum requirements for lockout / tagout of energy sources that could cause
injury to personnel. All employees shall comply with the procedure.
Responsibility
The responsibility for seeing that this procedure is followed is binding upon all employees. All employees
shall be instructed in the safety significance of the lockout / tagout procedure by (designate individual). Each
11-9-95 4
 new or transferred affected employee shall be instructed by (designate individuals) in the purpose and use of
the lockout / tagout procedure.

Preparation for Lockout / Tagout

Employees authorized to perform lockout / tagout shall be certain as to which switch, valve, or other energy
isolating devices apply to the equipment being locked out / tagged out. More than one energy source
(electrical, mechanical, or others) may be involved. Any questionable identification of sources shall be
cleared by the the employees with their supervisors. Before lockout / tagout commences, job authorization
should be obtained.

Sequence of Lockout / Tagout Procedure

1) Notify all affected employees that a lockout / tagout is required and the reason therefor.
2) If the equipment is operating, shut it down by the normal stopping procedure.
3) Operate the switch, valve, or other energy isolating device so that the energy source(s) (electrical, me-
chanical, hydraulic, etc.) is disconnected or isolated from the equipment. Stored energy, such as that in
capacitors, springs, elevated crane members, rotating flywheels, hydraulic systems, and air, gas, steam,
or water pressure, etc. must also be dissipated or restrained by methods such as grounding, reposition-
ing, blocking, bleeding-down, etc.
4) Lockout / tagout the energy isolating devices with an assigned individual lock / tag.
5) After ensuring that no personnel are exposed and as a check on having disconnected the energy
sources, operate the push button or other normal operating controls to make certain the equipment will
not operate.

CAUTION: Return operating controls to neutral after the test.

6) The equipment is now locked out / tagged out.

Restoring Equipment to Service

1) When the job is complete and equipment is ready for testing or normal service, check the equipment area
to see that no one is exposed.
2) When equipment is all clear, remove all locks / tags. The energy isolating devices may be operated to
restore energy to equipment.

Procedure Involving More Than One Person

In the preceding steps, if more than one individual is required to lockout / tagout equipment, each shall place
his own personal lock / tag on the energy isolating device(s). One designated individual of a work crew or a
supervisor, with the knowledge of the crew, may lockout / tagout equipment for the whole crew. In such
cases, it shall be the responsibility of the individual to carry out all steps of the lockout / tagout procedure and
inform the crew when it is safe to work on the equipment. Additionally, the designated individual shall not
remove a crew lock / tag until it has been verified that all individuals are clear.

Rules for Using Lockout / Tagout Procedure

All equipment shall be locked out / tagged out to protect against accidental or inadvertent operation when
such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy
isolating device bearing a lock / tag.

3. Use only assembled chain. Do not build lengths from individual components.
4. Do not attempt to rework damaged chains by replacing only the components obviously faulty. The entire
chain may be compromised and should be discarded.
5. Do not weld any chain or component. Welding spatter should never be allowed to come in contact with chain
or components.

11-9-95 5
 RECOMMENDED GEAR OILS

Chevron U.S.A., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ULTRA Gear ISO 220

Continental Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conoco SCL Gear Lubricant, SAE 90
Gulf Oil Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulf Hypoid Gear Lubricant, SAE 90
Humble Oil and Refining Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enco Gear Oil, SAE 90
Lion Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose SCL Gear Lubricant, SAE 90
Standard Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special SCL Gear Lubricant, SAE 90
Quaker State Oil and Refining Corporation . . . . . . . . . . Quaker State Super Quadrolube X-SCL
Gear Lubricant, SAE 90
Valvoline Oil Company . . . . . . . . . . . . . . . . . . . . . . Valvoline SCL Gear Lubricant, SAE 90

The list of commercially available oils was compiled for the convenience of owners and
operators. It is based on information received from the suppliers of these oils. Responsibility
for the quality of oils and their performance in service must remain with the oil company
marketing the lubricant.
This list is not to be construed as a complete list of oils meeting specifications for use and does
not imply endorsement of any specific brand.

Rev. 4/97
 Section 1

Section Title

Electrical System Maintenance Requirements

This document contains information of vital importance concerning the

inspection and repair of electrical system components. If damaged
electrical system components are not corrected, they can lead to fires
causing death, serious injury and / or property damage.

It is important that the machine be inspected regularly. Any damaged

electrical system components must be repaired immediately by
qualified repair technicians.

ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07) 1

2 ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07)
Electrical System Maintenance Requirements Some areas in which to pay special attention
during the inspection include:
WARNING: Death or serious injury may S Areas where there is relative movement
occur from fire. Improper maintenance of the between components (i.e. engine / frame).
electrical system may result in electrical S Areas where wiring runs around corners, edges
shorts which can cause fires. Regularly of parts, or through holes.
inspect and maintain electrical harnesses, S Areas where components are exposed to high
cables, and electrical components as outlined. temperatures (i.e. near exhaust components).
Ensure that harnesses are properly routed and
secured after servicing the truck. S Areas where components are secured with
clamps, straps, ties, etc.
S Battery cables (entire length) and terminals
WARNING: Keep vehicle clean and free of
grease, oil or dirt build up that can act as fuel S Connectors / connections
for a fire. S Wire harnesses in cable tracks or over rollers
Electrical system components must be regularly Problems requiring maintenance include:
inspected, maintained, and repaired to ensure S Build up of combustible material on wiring
safe operation of powered industrial trucks. The harnesses or vehicle components
following requirements are provided to aid main-
tenance personnel in proper electrical system S Worn harness coverings
maintenance practices. The following require- S Wear in wire insulation
ments are in addition to the regular daily inspec- S Exposed conductors
tions in the operator’s guide, maintenance
manual, and safety literature included with the S Evidence of arcing
truck. S Loose fasteners or clamps
S Unprotected or uncovered wires
Inspection
In addition to the daily inspection required by S Improper repairs or additions
OSHA, a thorough visual inspection of all battery S Corrosion
cables, wiring harnesses, and electrical connec- S Discoloration of connectors
tions should be made every 6 months or 1,500 S Improperly secured wiring
hours of truck operation to check for damage or
wear. Wiring harnesses should also be thoroughly NOTE: Any damaged electrical system compo-
inspected any time a major component is removed nents must be repaired or replaced before the unit
(i.e. engine, transmission, operator base, etc.) or is returned to service.
when an electrical problem occurs.
Examples of electrical system maintenance prob-
Prior to any inspection, thoroughly clean the ve- lems are shown in the illustrations below:
hicle paying particular attention to the areas to be
inspected.

ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07) 3

 Unprotected Wires Improper Wire Routing / Unprotected Wires

Damaged Sheathing / Unprotected Wires Worn Sheathing

Frayed Battery Cable Exposed Conductor / Grease Buildup

4 ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07)

 Improper Routing And Connector Worn or Damaged Wire Insulation
Unprotected Wires Unprotected Wires

Proper Electrical Wiring Maintenance

WIRES PROPERLY
WIRES PROPERLY
SECURED
COVERED

CORRECT
CONNECTORS

Wires Properly Connected, Covered, and Secured Battery Cable Properly Covered

Corrective Actions S Only trained and qualified maintenance

personnel should make inspections and
repairs on the electrical system and
WARNINGS:
components.
S Use only genuine Taylor replacement parts.
Lesser quality parts may fail resulting in NOTE: There are many types of aftermarket elec-
property damage, personal injury, or death. trical components which may or may not meet
S Under no circumstances, without prior OEM specifications, quality and design require-
written approval from Taylor Machine Works, ments. Always use genuine Taylor replacement
should the electrical system of the machine parts.
be modified in a manner which affects safe Corrective actions to follow to repair electrical
vehicle operation as per OSHA 29 system components include:
CFR1910.178 (a) (4).

ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07) 5

S Keep the vehicle free of grease, oil and dirt
build up by regular thorough cleaning.
S Use genuine Taylor replacement parts (wire,
connectors, looms, clamps, etc.).
S Use approved split loom to cover worn or
missing protective covering on wiring
harnesses.
S Tape minor worn places on conductors with
electrical tape before covering with wiring loom.
S Protect all wiring with approved loom.
S Properly clamp connectors / terminals on
wiring. Use proper crimping tools to attach
terminals and connectors.
S Remove and replace damaged wires. Replace
wires with same gauge. Short (less than 1”
long) damaged sections of wire may be repaired
by removing the damaged section and
re-connecting the wire with an approved
crimp-type connector.
S Never repair or replace a large single wire with
multiple small wires.
S Never use connectors that are not approved by
TMW.
S Never use residential wiring connectors.
S Use properly sized connectors for wire size.
S Never replace circuit breakers with circuit
breakers of higher amperage.
S Keep spacing between wire harness and
moving parts.
S Check the integrity of connectors and replace if
necessary.
S Replace missing clamps.
S When replacing wire harnesses, use common
sense to minimize chaffing when securing and
use existing clamping points when possible.
S Properly route wiring and wire harnesses during
repairs.
S Use rubber grommets to protect wiring and
harnesses which run through holes.

6 ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07)

 Note: Complete replacement wiring harnesses are available through all Taylor’s normal service parts
outlets.

Taylor Electrical Part Numbers

Commonly Used Electrical Maintenance Repair Parts

Part Number Part Description Part Number Part Description

1730-010 Split Loom 5/8” 2324-172 Terminal, Yellow Push-on Male
10--12 ga
1730-011 Split Loom 3/4”
2324-241 Terminal, Blue Push-on Male
1730-013 Split Loom 1/4” 14--16 ga
1730-014 Split Loom 7/8” 2324-242 Terminal, Blue Push-on Female
1730-015 Split Loom 1 1/4” 14-16 ga

1730-016 Split Loom 1 1/2” 2324-285 Stud mount tie down

1730-020 Split Loom 13/32” 2324-340 Terminal, #10 Blue Ring 14-16 ga

1730-300 Split Loom 3/8” 2324-380 Terminal, #8 Blue Ring 14-16 ga

1730-301 Split Loom 1/2” 2324-384 Terminal, Blue Female 90 deg

Push-on 14-16 ga
2000-317 Split Loom 1”
2324-427 **Weather Pack Socket 14-16 ga
2315-050 Relay 12V 20/30Amp
2324-428 **Weather Pack Pin 14-16 ga
2324-017 Socket, Gold Plated 20 ga
2324-571 *Deutsch Pin 14-16 ga
2324-028 Pin, Gold Plated 20 ga
2324-572 *Deutsch Socket 14-16 ga
2324-055 Terminal, #10 Yellow Ring
10-12 ga 2324-729 *Deutsch crimp tool, 12-26 ga

2324-096 Terminal, 3/8” Ring 6 ga 2324-846 Heavy Duty Crimper

2324-100 Terminal, #6 Blue Ring 14-16 ga 2324-847 Butt Splice, 6 ga

2324-112 Terminal, #4 Red Ring 18-22 ga 5144-002 *Deutsch removal tool, Blue 16 ga

2324-150 Butt Splice, 14-16 ga 5144-003 *Deutsch removal tool, Red 20 ga

2324-160 Butt Splice, 14-16 ga 5144-005 *Deutsch removal tool, Yellow

12 ga
2324-165 Terminal, 1/4” Ring 6 ga
5144-006 *Deutsch removal tool, White 6 ga
2324-171 Terminal, Yellow Push-on Female
10-12 ga 5144-009 Weather Pack removal tool

Notes: All wires must conform to Type SXL, GXL or TXL SAE J1128 Specifications
* These parts are required for proper removal and installation of Deutsch connections
** These parts require Packard GM12014254 crimp tool
Remaining parts may be installed with common tools

ELECTRICAL SYSTEM MAINTENANCE REQUIREMENTS (6/07) 7

 Hydraulic System Maintenance Requirements

This document contains information of vital importance concerning the

inspection and repair of hydraulic system components. If damaged
hydraulic system components are not corrected, they can lead to
failures or fires causing death, serious injury or property damage.

It is important that the machine be inspected regularly. Any damaged

hydraulic system components must be repaired immediately by
qualified repair technicians. The following information is provided to
aid maintenance personnel in the inspection of the hydraulic system
and identification of areas that may require attention. All safety rules
and repair practices included in the other sections of the maintenance
manual must be followed.
Hydraulic System Maintenance Require- draulic hoses, valve assemblies and hydraulic
ments connections should be made every 6 months or
1,500 hours of truck operation to check for dam-
age or wear. Hydraulic hoses and connections
WARNING: Death or serious injury may
should be inspected for damage and wear any
occur from fire. Improper maintenance of the
time a major component is removed (i.e. engine,
hydraulic system may result in leaks which
transmission, operator base, etc.) or when a hy-
can cause fires.
draulic problem occurs.
S Regularly inspect and maintain hydraulic
hoses, valves, and hydraulic components Prior to any inspection, thoroughly clean the
as outlined. vehicle paying particular attention to the areas to
be inspected.
S Ensure that hoses are properly routed and
secured after servicing the truck. Some areas requiring special attention
S Keep vehicle clean and free of grease, oil during the inspection include:
or dirt build up that can act as fuel for a S Areas where there is relative movement
fire. between components (i.e. engine / frame)
S Areas where hoses run around corners,
edges, or through holes
WARNING: Death or serious injury may
occur from catastrophic failure. Improper S Areas where hoses cross
maintenance of the hydraulic system may S Areas where components are exposed to high
lead to failure of truck functions which can temperatures (i.e. near exhaust components)
affect proper truck operation. S Areas where components are secured with
clamps, straps, ties, etc.
Hydraulic system components must be regularly
inspected, maintained, and repaired to ensure S Adapters/ Connectors / connections between
safe operation of powered industrial trucks. The hoses and components
following requirements are provided to aid main- S Hoses in cable and hose tracks or over rollers
tenance personnel in proper hydraulic system S Fuel lines and connections
maintenance practices. These following require-
ments are in addition to the routine daily inspec- Problems requiring maintenance include:
tions in the operator’s guide, maintenance S Build up of combustible material on hoses,
manual, and safety literature included with the valves or vehicle components
truck.
S Worn hose coverings
Additionally, the following recommendations for S Leaking hoses/connections
inspection, maintenance and repair apply to
other systems or components on the truck which S Loose hose or adapter connections
contain or transmit flammable materials. These S Improper repairs or additions
systems include engine lubrication systems and S Corrosion
fuel systems. If not regularly inspected and
properly maintained, similar hazards exist which S Improperly secured or unsecured hoses
may lead to death, serious injury or property S Excessive vibration of hydraulic or fuel hoses
damage due to fires. and components

Inspection NOTE: Any damaged hydraulic system or fuel

system components must be repaired or re-
In addition to the daily inspection required by placed before the unit is returned to service.
OSHA, a thorough visual inspection of all hy-
Examples of hydraulic system maintenance
problems are shown in the illustrations below:

POOLED OIL
FROM LEAKING
FITTING

Build up of Combustible Materials on hoses or Leaking Hoses or Connections

components

ROUTED
WITH
ELECTRICAL HOSE POORLY ROUTED
CABLE AND UNSECURED

Improper Routing of Hydraulic Hoses and Wiring Improper Routing of Hydraulic Hoses or
Improperly Secured Hoses
 WEAR IN
HOSE NOT SECURED PROPERLY COVER
POORLY ROUTED

Poor Routing of Hydraulic Hoses Worn Hose Coverings

or Unsecured Hoses

HOSES NOT
SECURED

Improperly Secured or Unsecured Hoses

Corrective Actions S Remove and replace damaged hoses.
Replace hoses with OEM hose assemblies.
WARNING: Death or serious injury may S Never use hoses/connectors/adapters that are
occur from improper maintenance practices. not approved by TMW.
S Use only genuine Taylor replacement S Use properly sized connectors/adapters for
parts. Lesser quality parts may fail. hose size.
S Under no circumstances should the S Never replace a hose with a hose of lower
hydraulic system be modified in a manner pressure rating.
which affects safe operation unless prior S Maintain spacing between hoses and moving
written approval is granted by Taylor parts.
Machine Works. (Ref OSHA 29 CFR
S Maintain spacing between hoses and wiring.
1910.178 (a)(4).
S Avoid hoses crossing over each other at
S Only trained and qualified maintenance
perpendicular angles.
personnel should make inspections and
repairs to the hydraulic system and S Always use properly sized clamps to firmly
components. secure hoses.
NOTE: There are many types of aftermarket S Check the integrity of connectors/adapters
hydraulic components which may or may not and replace if necessary.
meet OEM specifications, quality, and design S Replace missing clamps.
requirements. Always use genuine Taylor re- S When securing replacement hoses, use
placement parts. common sense to minimize chaffing.
Corrective actions to follow to repair hydraulic S Use existing clamping points when possible.
system components include: S Properly route hoses during repairs.
S Keep the vehicle free of grease, oil, and dirt S Use rubber grommets to protect hoses routed
build up by regular thorough cleaning. through holes.
S Use genuine Taylor replacement parts (hoses, S Route hoses away from hot surfaces.
adapters, clamps, sheathing, etc.).
S Keep electrical wires and harnesses
S Properly install connectors / adapters on separated from hydraulic hoses.
hoses. Use proper crimping tools to attach
connectors and adapters to hoses.
 Taylor Hydraulic Part Numbers (Commonly Used Hydraulic Maintenance Repair Parts)
Part Number Part Description Part Number Part Description
2000--346 Pressure Check -- 1/4 NPT 1709--127 2.75” rubber hose clamp
2000--347 Pressure Check -- 1/8 NPT 1709--161 3.56” rubber hose clamp
2000--258 Pressure Check -- 7/16 SAE 1273--703 1/4 tap weld on boss
2000--259 Pressure Check -- 9/16 SAE 1316--024 3/8 tap weld on boss
2954--536 Pressure Check -- 9/16 ORS 1316--025 5/16 tap weld on boss
2954--537 Pressure Check -- 11/16 ORS 1709--908 4” hose hanging straps for clamping
hoses
2954--538 Pressure Check -- 13/16 ORS
1709--909 6” hose hanging straps for clamping
2000--464 Test Hose -- 1/4 NPT -- 24” hoses
2000--465 Test Hose -- 1/4 NPT -- 36” 1709--907 8” hose hanging straps for clamping
2000--959 Test Hose -- 1/4 NPT -- 48” hoses

2000--960 Test Hose -- 1/4 NPT -- 72” 1709--904 12” hose hanging straps for
clamping hoses
1709--200 250” rubber hose clamp
1709--905 16” hose hanging straps for
1709--151 .38” rubber hose clamp clamping hoses

1709 .50” rubber hose clamp 1709--906 20” hose hanging straps for
clamping hoses
1709--050 .56” rubber hose clamp
2000--713 Small hose protector shield
1709--055 .69” rubber hose clamp
2000--714 Medium hose protector shield
1709--100 .75” rubber hose clamp
2000--715 Large hose protector shield
1709--105 .94” rubber hose clamp
2324--373 12” tie down straps for wiring
1709--108 1” rubber hose clamp
2324--374 18” tie down straps for wiring
1709--112 1.06” rubber hose clamp
2945--073 1” nylon abrasion sleeve
1709--115 1.12” rubber hose clamp
2945--074 1.59” nylon abrasion sleeve
1709--115 1.12” rubber hose clamp
2945--075 1.75” nylon abrasion sleeve
1709--128 1.31” rubber hose clamp
2945--076 2.38” nylon abrasion sleeve
1709--118 1.50” rubber hose clamp
2945--049 2.54” nylon abrasion sleeve
1709--120 1.56” rubber hose clamp
2945--099 1” nylon abrasion sleeve with Velcro
1709--122 1.75” rubber hose clamp
2945--101 1.5” nylon abrasion sleeve with
1709--051 1.81” rubber hose clamp Velcro
1709--124 2” rubber hose clamp 2945--059 2” nylon abrasion sleeve with Velcro
1709--126 2.25” rubber hose clamp 2945--095 3” nylon abrasion sleeve with Velcro
1709--160 2.625” rubber hose clamp 2945--096 4” nylon abrasion sleeve with Velcro

Notes: Complete replacement hose assemblies are available through all Taylor’s normal service
parts outlets.
Hoist Circuit
 Fuel and Lubricant Specifications

This replaces all previously published Fuel and Lubricant Specifications.

PRODUCT USED IN SPECIFICATIONS TEMPERATURE FACTORY FILLED
ENGINE Cummins Diesels* API Classification CH–4, CH–4/SJ, Chevron Delo 400 XLE
OIL CI–4, CJ–4, CK–4 Multi-grade
g
Heavy Duty
Volvo Diesel API Classification CI–4, CH–4, CF, SL Motor Oil
All Diesel Engines SAE 5W 30 -20° F to 68° F SAE 15W 40

SAE 10W 30 -5° F to 68° F

SAE 15W 40 +5° F to 115° F
Gas & LP Engines API Classification CG–4, CH–4/SJ, CI–4
SAE 5W 30 Below 60° F
DIESEL All Diesel Engines ASTM Spec D-975 All Temperatures Chevron Diesel No. 2
FUEL ( Tier 3, Tier 4i, Tier 4F ) No. 1 or No. 2, Ultra Low Sulfur Diesel With Temp. Supressor
Sulfur Maximum: 15 PPM Added November Thru
Centane Minimums: 40 - above 32° F March
45 - below 32° F
ANTI- Cooling System Maintain 50 - 50% Soft Water** Protection to -34° F Chevron Delo XLC
FREEZE Ethylene Glycol Coolant / Antifreeze
(Low Silicate Antifreeze) Phosphate Free
GM 6038-M or ASTM D3306 & D6210
RUST Cooling System Any Reputable Manufacturer All Temperatures Included in Antifreeze
INHIBITOR Non-Chromate Only
TRANS- Automatic Transmission C-4 Type Fluid with Friction Control All Temperatures Chevron 1000 Tractor
MISSION Modifiers. Hydraulic Fluid
HYDRAU- Hydraulic System
LIC FLUID NOTE: Chevron 1000 Tractor Hydraulic
Fluid and Mobil 424 have proven to be
WET DISC Wet Disc Brakes most effective in controlling wet disc
BRAKE brake noise.
COOLING
GEAR OIL Differentials Extreme Pressure Gear Oil Chevron Delo Gear
Planetary Hubs (GL-5 or MIL-2105D) 10° F Minimum Lubricant ESI 80W 90
Gear Boxes SAE 85W 140
SAE 80W 90 -15° F Minimum & Any
Higher Temperatures
BRAKE Wet Disc Brake Actuator C-4 Type Fluid with Friction Control All Temperatures Chevron 1000 Tractor
FLUID Modifiers. See Hydraulic Fluid Above. Hydraulic Fluid
WHEEL All Timkenr Bearings Chevron Ulti-Plex*** EP Grease or Grade 1 below 0° F Chevron Ulti-Plex EP
BEARINGS Which Use Grease Equivalent Grade 2 above 0° F Grease
AND
SEALED
CHAIN
ROLLERS
GREASE All Other Grease Fittings Chevron Ultra Duty*** EP2 Grease or Grade 1 below 0° F Chevron Ultra Duty EP2
FITTINGS Equivalent Grade 2 above 0° F Grease
LEAF Vistacr ISO 150 Lubricant All Temperatures Vistacr ISO 150 Lubricant
CHAINS

* Always refer to Cummins Operation and Maintenance Manuals for each engine family for oil specification and drain interval information.
Severe engine damage may result if specific oil and drain interval recommendations are not followed.
** Soft Water - Cannot contain more than 300 parts per million hardness or 100 parts per million of either chloride or sulfide.
(See engine manual.)
*** Grease recommendations are based on commercial products which have given satisfactory service. Users must be assured of similar
performance with products represented to be equivalent.

FL-1-10 (Rev. 9/17)

 CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to

the State of California to cause cancer, birth defects, and other
reproductive harm.
Hoist Circuit
 3637 North Church Avenue
Louisville, Mississippi 39339-2017 USA
MAINTENANCE
MANUAL
Phone: 662.773.8056
Fax: 662.773.9157
www.taylorsuddenservice.com

MODEL __________________

SERIAL NO. ______________

IMPORTANT!
Read contents carefully prior to operation.
Read contents carefully prior to operation.