Taylor-Dunn BIGFOOT B5-440-36 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn BIGFOOT B5-440-36 Operation, T Roubleshooting And Replacement Parts Manual

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T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
Models: B5-440-36
B5-440-48
MANUAL MB-440-01
Operation, Troubleshooting and
Replacement Parts Manual
Serial numbers:
Starting: 193200
Ending: See Introduction Chapter

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Summary of Contents for Taylor-Dunn BIGFOOT B5-440-36

  • Page 1 Models: B5-440-36 B5-440-48 T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s MANUAL MB-440-01 Operation, Troubleshooting and Replacement Parts Manual Serial numbers: Starting: 193200 Ending: See Introduction Chapter...
  • Page 2 Service Advisor at your local dealership. Taylor-Dunn has a worldwide dealer and distribution network to provide replacement parts and service for our vehicles. Refer to our web site, www.taylor-dunn.com, for a dealer lookup application. Originally Published 9/30/2014 Revision A, 9/30/2014, contents subject to change without notice ®...
  • Page 3 Taylor-Dunn Contact information Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor- Dunn website at www.taylor-dunn.com.
  • Page 4 Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application- specific solutions, which are reliable, efficient, and economical. Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving. Tiger Tractor: Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment.

  • Page 5: Table Of Contents

    Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Special Tool List ..........17 Lubrication ............21 Front Axle ............25 Drive Axle-GT ...........33 Steering ............43 Brakes...............51 Motor ..............59 Tires & Wheels ..........65 Motor Controller ..........71 Suspension ............75 Batteries ............77...
  • Page 6 Notes:...
  • Page 7 Table of Contents Introduction About This Manual ..........8 Who Should Read This Manual ......8 Replacement Parts ..........8 How To Use This Manual ........8 Conventions ............9 Signal Words and Their Definitions: ......9 Responsibilities ............10 How to Identify Your Vehicle ......11 Web Site Registration ........11 WARNING This section is one section of a complete service manual.

  • Page 8: Introduction

    To maintain peak performance, only use original Taylor- Dunn replacement parts intended for use on your vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.

  • Page 9: Introduction

    Introduction B5-440-36 / B5-440-48 Conventions Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be used elsewhere in the text of this document without being a signal word.

  • Page 10: Responsibilities

    The only personnel authorized to repair, modify, or Of the Service Personnel... adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made The service personnel are responsible for the service by unauthorized personnel may result in damage to and maintenance of the vehicle.

  • Page 11: How To Identify Your Vehicle

    WEB SITE REGISTRATION Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor- Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside of the Taylor-Dunn corporation.
  • Page 12 Notes...
  • Page 13 Table of Contents Service/Maintenance Guidelines Read Me First - Maintenance Guidelines and General instructions .........14 Vehicle Modifications ........15 Using Non-OEM Replacement Components: ..15 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 14 BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Service/Maintenance Guidelines

    Due to the unknown properties of non-Taylor-Dunn tested Operator Controlled Industrial Tow Tractors: components or from components not originally equipped on the vehicle, we cannot approve their use in a Taylor-Dunn vehicle. Paragraph 6.2.14: Modifications and additions which affect capacity and safe tow tractor operation shall not be performed without manufacture’s...
  • Page 16 Notes...

  • Page 17: Special Tool List

    Table of Contents Special Tool List Tool List ............18 Controller Programming: .........18 Troubleshooting Guide ........20 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 18 Tool List B5-440-36 / B5-440-48 TOOL LIST The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. 75-089-00: Throttle Module Test Harness 62-027-32: Throttle Module Analyzer Tests the throttle module in or out of the Used in conjunction with a volt meter to test the throttle module.
  • Page 19 Removes 0.093 diameter pins from Molex Removes pins from Molex Mini-Fit harness rectangular harness connectors. Not rectangular harness connectors. Not connectors. available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. MB-440-01...

  • Page 20: Troubleshooting Guide

    Tool List B5-440-36 / B5-440-48 TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...
  • Page 21 Table of Contents Lubrication Lubrication and Fluids Chart ......22 Hazardous Waste Disposal ......22 Lubrication Diagram ........23 Wheel Bearings ............24 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 22: Lubrication

    Lubrication B5-440-36 / B5-440-48 LUBRICATION AND FLUIDS CHART Assembly Component # of Locations Capacity Lubricant Front Axle: 3: Wheel Bearings NLGI Grade 2 lithium high temp Bearing Grease > Refer to procedure later in this section 4: King Pin NLGI Grade 2 lithium multi-purpose grease Suspension: 5: Rear spring eyes NLGI Grade 2 lithium multi-purpose grease...

  • Page 23: Lubrication

    Lubrication B5-440-36 / B5-440-48 LUBRICATION DIAGRAM Note: The transaxle is mounted at an angle in the vehicle. The transaxle must be level when checking oil level. This will require rasing the rear of the vehicle until the transaxle is level with the ground.

  • Page 24: Wheel Bearings

    Lubrication B5-440-36 / B5-440-48 WARNING Wheel Bearings The Bigfoot is available with or without front brakes. Incorrect lubrication of the front wheel bearings may There are two different lube procedures depending on result in contamination of the brake pads and rotor. whether your vehicle has front brakes.
  • Page 25 Table of Contents Front Axle Remove.............26 Install ..............26 Assemble Complete Axle ........27 Inspect Front Wheel Bearings ......28 Adjust Front Wheel Bearings ......28 Front Wheel Alignment ........29 Replace Steering Knuckle ......30 Replace King Pin/Bushings ......31 Replace Front Wheel Bearings.......31 Service Limits and Specifications ....32 King Pin Bushings ...........32 Toe In ...............32 Hardware Torque ..........32...

  • Page 26: Front Axle

    Front Axle B5-440-36 / B5-440-48 REMOVE WARNING NOTICE This section is one section of a complete service manual. Before starting any procedure, read all If vehicle is equipped with front brakes, you will warnings and instructions that are located in the need to disconnect the front brakes and bleed the Service Guidelines chapter.

  • Page 27: Assemble Complete Axle

    Front Axle B5-440-36 / B5-440-48 ASSEMBLE COMPLETE AXLE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: Thrust bearings should be packed with grease before assembly. Note: The steering rack and spring hardware should not be fully tightened until the assembly is installed in the vehicle.

  • Page 28: Inspect Front Wheel Bearings

    Front Axle B5-440-36 / B5-440-48 INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 29: Front Wheel Alignment

    Front Axle B5-440-36 / B5-440-48 FRONT WHEEL ALIGNMENT WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: Only Toe In can be set. Both Caster and Camber are not adjustable. 1: Raise the front of the vehicle and support with jack stands.

  • Page 30: Front Axle

    Front Axle B5-440-36 / B5-440-48 REPLACE STEERING KNUCKLE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Remove 1: Raise the front of the vehicle and support with jack stands.

  • Page 31: Replace King Pin/Bushings

    Front Axle B5-440-36 / B5-440-48 REPLACE KING PIN/BUSHINGS REPLACE FRONT WHEEL WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 32: Service Limits And Specifications

    Front Axle B5-440-36 / B5-440-48 SERVICE LIMITS AND SPECIFICATIONS HARDWARE TORQUE Description Foot Pounds Newton Meters King Pin Bushings Ball Joint Lock Nut 43-47 58-63 Ream or broach to 0.8755-0.08765 inches Steering link Jam Nut 20-30 27-40 (22.2377-22.2631 mm) Steering pinch bolt 30-35 40-47 Toe In...
  • Page 33 Table of Contents Drive Axle-GT Check Oil Level ..........34 Change Oil ............34 Axle Assembly ..........35 Remove ..............35 Install ...............35 Axle Shaft ............36 Remove ..............36 Install ...............36 Rear Hub, Rotor & Bearings ......37 Motor, Remove ..........37 Primary Gear Case ..........38 Secondary Gear Case ........39 Disassemble ............39 Assemble ..............39 Pinion Bearing Preload ........41...

  • Page 34: Drive Axle-Gt

    Drive Axle-GT B5-440-36 / B5-440-48 CHECK OIL LEVEL CHANGE OIL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 35: Drive Axle-Gt

    Drive Axle-GT B5-440-36 / B5-440-48 AXLE ASSEMBLY WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Remove Install 1: Disconnect the wiring from the motor. 1: Install in reverse order of removal.

  • Page 36: Axle Shaft

    Drive Axle-GT B5-440-36 / B5-440-48 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 37: Rear Hub, Rotor & Bearings

    Drive Axle-GT B5-440-36 / B5-440-48 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications will require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and Installing This section is one section of a complete service the Drive Assembly for information on manual.

  • Page 38: Primary Gear Case

    Drive Axle-GT B5-440-36 / B5-440-48 PRIMARY GEAR CASE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. 1: Disconnect the batteries. 2: Raise the rear of the vehicle and support with jack stands.

  • Page 39: Secondary Gear Case

    Drive Axle-GT B5-440-36 / B5-440-48 SECONDARY GEAR CASE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Disassemble 1: Remove the transaxle assembly from the vehicle. Refer to Remove in this section.
  • Page 40 Drive Axle-GT B5-440-36 / B5-440-48 12: Install the pinion gear holding tool (96-500-42) and tighten the pinion nut enough to keep the pinion gear from rotating. Pinion Holding Tool 13: Install the differential assembly. 14: Install the cover and all of the cover bolts. Torque per torque listed in the Hardware Torque table at the end of this section.

  • Page 41: Pinion Bearing Preload

    Drive Axle-GT B5-440-36 / B5-440-48 PINION BEARING PRELOAD WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Pinion Gear Shimming Instructions Note: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears.

  • Page 42: Hardware Torque

    Drive Axle-GT B5-440-36 / B5-440-48 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut 154-169 209229 Drain plug 21-25 28.4-33 Gear case to 3rd member 18-20 24.4-27 3rd Member cover bolts 40-50...

  • Page 43: Steering

    Table of Contents Steering Inspect Ball Joints ...........44 Front Wheel Alignment ........44 Replace Ball Joint..........44 Replace Upper Steering Shaft ......45 Remove ..............45 Install ...............45 Replace Lower Steering Shaft ......46 Inspect ..............46 Remove ..............46 Install ...............46 Replace Boot ............46 Replace 90° Steering Gear ......47 Inspect ..............47 Remove ..............47 Install ...............47...

  • Page 44: Inspect Ball Joints

    Steering B5-440-36 / B5-440-48 INSPECT BALL JOINTS REPLACE BALL JOINT WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 45: Replace Upper Steering Shaft

    Steering B5-440-36 / B5-440-48 REPLACE UPPER STEERING SHAFT WARNING WARNING This section is one section of a complete service Do not use the original pinch bolt and nut. Failure to manual. Before starting any procedure, read all replace the pinch bolt and nut may result in failure of warnings and instructions that are located in the the steering causing loss of control of the vehicle.

  • Page 46: Replace Lower Steering Shaft

    Steering B5-440-36 / B5-440-48 REPLACE LOWER STEERING SHAFT WARNING Install 1: Thoroughly clean the couplers and shafts. This section is one section of a complete service 2: Position the front wheels in the straight ahead manual. Before starting any procedure, read all position.

  • Page 47: Replace 90° Steering Gear

    Steering B5-440-36 / B5-440-48 REPLACE 90° STEERING GEAR WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. There are no internal components available for the 90° steering gear. If worn out it must be replaced. Inspect 1: Clamp the lower steering shaft so that it cannot rotate.

  • Page 48: Replace Steering Rack

    Steering B5-440-36 / B5-440-48 REPLACE STEERING RACK WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. There are no internal components available for the steering rack. If worn out it must be replaced. Inspect 1: Raise the front of the vehicle and support with jack stands.

  • Page 49: Replace Steering Wheel

    Steering B5-440-36 / B5-440-48 REPLACE STEERING WHEEL WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: The steering wheel is on a tapered shaft and may be damaged when it is removed. Remove 1: Remove the steering wheel hub cover.

  • Page 50: Hardware Torque

    Steering B5-440-36 / B5-440-48 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Jam Nut 20-30 27-40 Notes Ball Joint Lock Nut 43-47 58-63 Coupler Pinch Bolt 30-35 40-47 Coupler Pinch Bolt Jam Nut 25-30 34-40 Steering Wheel Nut 28-32 38-43 MB-440-01 Page 50...

  • Page 51: Brakes

    Table of Contents Brakes General Guidelines and Safety.......52 Front Brake ............53 Service Limits ............53 Inspection ..............53 Replace Pads ............53 Rear Brake............54 Service Limits ............54 Inspection ..............54 Replace Pads ............54 Rebuild Disc Brake Body ........55 Bleed System ...........56 Flush System ...........56 Master Cylinder..........57 Add Fluid ..............57 Parking Brake ..........57...

  • Page 52: General Guidelines And Safety

    B5-440-36 / B5-440-48 GENERAL GUIDELINES AND SAFETY WARNING WARNING Taylor-Dunn does not currently supply asbestos This section is one section of a complete service fiber-brake pads/shoes with any vehicle. However, manual. Before starting any procedure, read all there is the possibility that the original brake pads/...

  • Page 53: Front Brake

    Brakes B5-440-36 / B5-440-48 FRONT BRAKE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Service Limits Refer to the table at the end of this section Inspection Note: Service Limits are listed in a table at the end of this section.

  • Page 54: Rear Brake

    Brakes B5-440-36 / B5-440-48 REAR BRAKE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Service Limits Refer to the table at the end of this section Note: Service Limits are listed in a table at the end of this section.

  • Page 55: Rebuild Disc Brake Body

    Brakes B5-440-36 / B5-440-48 REBUILD DISC BRAKE BODY WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. This procedure assumes that the component has been removed from the vehicle.

  • Page 56: Bleed System

    Brakes B5-440-36 / B5-440-48 BLEED SYSTEM FLUSH SYSTEM WARNING 1: Raise the rear wheels off of the ground and support with jack stands. 2: If equipped with front brakes, raise the front This section is one section of a complete service wheels off of the ground and support with jack manual.

  • Page 57: Master Cylinder

    Brakes B5-440-36 / B5-440-48 MASTER CYLINDER WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. There are no internally serviceable components in the master cylinder.

  • Page 58: Service Limits

    Brakes B5-440-36 / B5-440-48 SERVICE LIMITS HARDWARE TORQUE Description Imperial Metric If hardware is not listed here, refer to standard torque Disc brake Pad minimum lining 00625 inch 1.58 millimeter values in the appendix. Front rotor minimum thickness 0.200 inch 5.08 millimeter Description Foot Pounds...
  • Page 59 Table of Contents Motor Motor Identification .........60 Remove/Install ..........60 Inspect/Testing ..........60 Bearing ..............60 Electrical Testing............60 Disassemble.............61 Assemble............62 Hardware Torque ..........64 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 60: Motor

    A faulty bearing will typically sound like a high pitch grinding noise or squeal. Electrical Testing Electrical testing for the motor is included in the Electrical Troubleshooting manual. Contact your Taylor-Dunn representative for information on obtaining a copy of the manual. REMOVE/INSTALL Refer to the Drive Axle section for information regarding removing the motor.

  • Page 61: Disassemble

    Motor B5-440-36 / B5-440-48 DISASSEMBLE NOTICE WARNING For specific torque values please refer to Hardware This section is one section of a complete service Torque table found at the end of this chapter. manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 62: Assemble

    Motor B5-440-36 / B5-440-48 ASSEMBLE NOTICE WARNING For specific torque values please refer to Hardware This section is one section of a complete service Torque table found at the end of this chapter. manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 63 Motor B5-440-36 / B5-440-48 MB-440-01 Page 63...

  • Page 64: Hardware Torque

    Motor B5-440-36 / B5-440-48 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Inch Pounds Newton Meters Notes Bolt, Drive End Bell 9.83 Bolt, Bearing Plate 8.36 Bolt, Speed Sensor 1.02 Bolt, Cover 1.02 Bolt, Terminal Block 9.83...
  • Page 65 Table of Contents Tires & Wheels Inflation .............66 Air pressure .............66 Tread Wear ............67 Rotation ............67 Changing Tire/Wheel Assembly .....68 Replace the Tire (pneumatic) ......68 Repair the Tire (pneumatic) ......69 Hardware Torque ..........69 WARNING This section is one section of a complete service manual.

  • Page 66: Tires & Wheels

    Tires & Wheels B5-440-36 / B5-440-48 INFLATION WARNING WARNING Incorrect tire inflation can result in sudden failure of This section is one section of a complete service the tire and/or braking / steering problems leading manual. Before starting any procedure, read all to loss of control of the vehicle.

  • Page 67: Tires & Wheels

    Tires & Wheels B5-440-36 / B5-440-48 TREAD WEAR WARNING WARNING DO NOT operate a vehicle if the cord is This section is one section of a complete service visible on any tire (see illustration). A tire manual. Before starting any procedure, read all in this conditions may suddenly fail at warnings and instructions that are located in the any time and cause loss of control of the...

  • Page 68: Changing Tire/Wheel Assembly

    Tires & Wheels B5-440-36 / B5-440-48 CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) ASSEMBLY WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 69: Repair The Tire (Pneumatic)

    Tires & Wheels B5-440-36 / B5-440-48 REPAIR THE TIRE (PNEUMATIC) HARDWARE TORQUE WARNING If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Improper assembly or disassembly of a split rim wheel can result if tire explosion causing severe Wheel nut injury.
  • Page 70 Notes...
  • Page 71 Table of Contents Motor Controller Remove/Install ..........72 Inspect ..............72 Receptacles .............72 Base Plate ...............72 Terminal Ends ............72 Troubleshooting ..........72 Repair/Programming ........73 Programming ............73 Hardware Torque ..........73 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 72: Troubleshooting

    1: Thoroughly clean the controller base, mounting A hard copy can be purchased from your authorized plate, and heat sink. Taylor-Dunn distributor or can be downloaded from the 2: Apply thermal transfer compound to the controller Taylor-Dunn web site. base and heat sink.

  • Page 73: Motor Controller

    Motor Controller B5-440-36 / B5-440-48 REPAIR/PROGRAMMING WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Repairs There are no internally serviceable components in the motor speed controllers. If a controller is faulty then it must be replaced.
  • Page 74 Notes...

  • Page 75: Suspension

    Table of Contents Suspension Front Springs ...........76 Remove ..............76 Install ...............76 Rear Springs ............76 Remove ..............76 Install ...............76 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 76 Suspension B5-440-36 / B5-440-48 FRONT SPRINGS REAR SPRINGS WARNING NOTICE When the vehicle is carrying a full load, the bump- This section is one section of a complete service stops will be against the frame. This will not cause manual. Before starting any procedure, read all harm to your vehicle as this is an active part of the warnings and instructions that are located in the suspension system.

  • Page 77: Batteries

    Table of Contents Batteries General Guidelines and Safety.......78 Cleaning ............79 Charging ............79 Watering ............79 Testing ..............80 Specific Gravity ............80 Storing ..............80 Storage ..............80 Returning to Service ..........80 Remove/Install ..........81 Industrial Battery or Lift Out Battery Pack ....81 Individual Batteries ..........81 Hardware Torque ..........81 WARNING This section is one section of a complete service...

  • Page 78: General Guidelines And Safety

    Batteries B5-440-36 / B5-440-48 GENERAL GUIDELINES AND SAFETY WARNING NOTICE Battery electrolyte will stain and corrode most This section is one section of a complete service surfaces. Immediately and thoroughly clean any manual. Before starting any procedure, read all surface outside of the battery that the battery warnings and instructions that are located in the electrolyte comes in contact with.

  • Page 79: Cleaning

    Batteries B5-440-36 / B5-440-48 CLEANING WATERING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this...

  • Page 80: Testing

    Batteries B5-440-36 / B5-440-48 TESTING STORING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this...

  • Page 81: Remove/Install

    Batteries B5-440-36 / B5-440-48 REMOVE/INSTALL WARNING WARNING This section is one section of a complete service Do not allow the loose battery cables to contact any manual. Before starting any procedure, read all other parts of the vehicle as this could cause in a warnings and instructions that are located in the short circuit resulting severe bodily injury or damage Service Guidelines chapter and beginning of this...
  • Page 82 Notes...

  • Page 83: Wire Diagram

    Table of Contents Wire Diagram Diagram Part Numbers........84 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 84 Vehicle Documentation CD provided with the vehicle. The diagram # for this vehicle: SCH-00071 This vehicle diagram as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Listed below are the available diagrams as of the revision date of this manual.

  • Page 85: Hardware Information

    Table of Contents Hardware Information Torque Guidelines for Standard Hardware ...86 Hardware Identification ..........86 Hex Nuts ..............87 Hex Lock Nuts (stover) ..........87 Other Nuts ...............87 Generic Torque Values ..........88 Replacing Hardware ........90 WARNING This section is one section of a complete service manual.

  • Page 86: Torque Guidelines For Standard Hardware

    Hardware B5-440-36 / B5-440-48 TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head as illustrated to the right.

  • Page 87: Hex Nuts

    ‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’. NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts Other nuts used by Taylor-Dunn ® should be treated as S.A.E. grade A MB-440-01 Page 87...

  • Page 88: Generic Torque Values

    Hardware B5-440-36 / B5-440-48 Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 89 Hardware B5-440-36 / B5-440-48 All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Metric, Newton Meters Metric, Foot Pounds Grade, N-m...

  • Page 90: Replacing Hardware

    Hardware B5-440-36 / B5-440-48 REPLACING HARDWARE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. WARNING Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
  • Page 91 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....92 Taylor-Dunn Web Site Information ....92 Axle Assembly, Front ........94 Axle Shaft Assembly, Rear ......96 TransAxle Assembly, Rear ......98 Battery ..............100 Brakes, Brake Lines ........102 Brakes, Front Axle ...........104 Brakes, Rear Axle ..........105 Charger, Signet ..........106...

  • Page 92: Replacement Parts

    ORDERING PARTS FOR YOUR VEHICLE WARNING The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.
  • Page 93 Replacement Parts B5-440-36 / B5-440-48 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MB-440-01 * Not available at time of printing Page 93...

  • Page 94: Axle Assembly, Front

    Replacement Parts B5-440-36 / B5-440-48 AXLE ASSEMBLY, FRONT MB-440-01 Page 94...
  • Page 95 Replacement Parts B5-440-36 / B5-440-48 Axle Assembly, Front Item No. Part No. Description 12-115-10 Hub, With Disc (includes items 4, 5, 6 & 7) 12-115-00 Hub, Without Disc (includes items 4, 5, 6 & 7) 92-105-00 Dust Cap 80-011-00 Bearing, Cone 80-102-00 Race PKIT-00050...

  • Page 96: Axle Shaft Assembly, Rear

    Replacement Parts B5-440-36 / B5-440-48 AXLE SHAFT ASSEMBLY, REAR MB-440-01 Page 96...
  • Page 97 Replacement Parts B5-440-36 / B5-440-48 Axle Shaft Assembly, Rear Item No. Part No. Description 41-154-20 Axle shaft 80-505-20 Bearing 41-490-11 Disc brake rotor 41-172-21 88-268-63 Flat washer *88-268-30 7/8-14 x 1.5 Bolt, grade 5 96-329-10 Wheel stud 96-327-10 3/8 X 3/4NF, Grade 5 with thread lock 89-113-30 M12 x 1.75 x 30mm Hex bolt 89-113-60...

  • Page 98: Transaxle Assembly, Rear

    Replacement Parts B5-440-36 / B5-440-48 TRANSAXLE ASSEMBLY, REAR Note: Spacer 23 is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number GT- 3287213. Add 10 to the part number for every 0.05mm over 3.9. For example, if 4.55mm is needed: 4.55-3.9 = .65mm over, 0.65/.05 = 13, 13*10 = 130.
  • Page 99 Replacement Parts B5-440-36 / B5-440-48 Axle Assembly, Rear Item No. Part No. Description GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1 GT-71982 O-ring...

  • Page 100: Battery

    Replacement Parts B5-440-36 / B5-440-48 BATTERY 36 Volt System 48 Volt System MB-440-01 Page 100...
  • Page 101 Replacement Parts B5-440-36 / B5-440-48 Item No. Part No. Description See kits below Battery rod See kits below Battery hold down See kits below Flat washer, tin/lead plated See kits below 1/4NC Nylon lock nut See kits below 5/16NC Hex nut, stainless steel, 36V 5/16 Split lock washer, stainless steel, 36V See kits below Battery jumper...

  • Page 102: Brakes, Brake Lines

    Replacement Parts B5-440-36 / B5-440-48 BRAKES, BRAKE LINES Item No. Part No. Description 99-605-83 Brake Line 99-605-84 Brake Line (only with front brakes) 99-575-32 Adapter, 3/16T x M10-1.0 99-575-00 Coupler 99-607-11 Brake Line, Mid to Rear 99-559-00 T-Fitting 96-640-00 Brake Line Clip 2 or 11 99-564-00 Union T, 3/16...
  • Page 103 Replacement Parts B5-440-36 / B5-440-48 Brake Lines, Master Cylinder Item No. Part No. Description 88-080-14 Bolt, 5/16” X 1-1/2” NC, Hex Head 99-511-20 Master Cylinder (includes item #3) 99-511-52 Cap Seal, Master Cylinder 99-511-53 Cap, Master Cylinder 88-088-61 Washer, 5/16” 88-089-81 Locknut, 5/16”...

  • Page 104: Brakes, Front Axle

    Replacement Parts B5-440-36 / B5-440-48 BRAKES, FRONT AXLE Item No. Part No. Description 41-351-35 Complete Brake Assembly 88-067-29 Bolt 41-350-91 Plate, Secondary 41-348-58 Spacer 32-208-01 Bushing (included in rebuild kit) Brake Body (all parts on this list) 99-588-01 Bleeder adaptor 99-588-00 Bleeder valve See rebuild kit...

  • Page 105: Brakes, Rear Axle

    Replacement Parts B5-440-36 / B5-440-48 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-351-80 Complete caliper assembly (left) 41-351-81 Complete caliper assembly (right) Brake body 32-208-01 Bushing (included in rebuild kit) 41-348-58 Spacer (included in rebuild kit) 41-350-28-1 Mounting Bracket 41-350-91...

  • Page 106: Charger, Signet

    Replacement Parts B5-440-36 / B5-440-48 CHARGER, SIGNET Note: There are no user serviceable components inside the charger Note: The charger AC cord is an integral part of the charger. When replacing the charger, do not cut and splice the AC cord. Cutting the AC cord will void the charger warranty.

  • Page 107: Charger, X-Series

    Replacement Parts B5-440-36 / B5-440-48 CHARGER, X-SERIES Item No. Part No. Description 79-303-48 Charger Assembly, X-Series, 48 volt Built In 0 or 1 79-303-36 Charger Assembly, X-Series, 36 volt Built In 0 or 1 79-309-05 Charger Assembly, X-Series, 48 volt Portable 0 or 1 79-303-37 Charger Assembly, X-Series, 36 volt Portable...

  • Page 108: Control System, Motor Speed

    Replacement Parts B5-440-36 / B5-440-48 CONTROL SYSTEM, MOTOR SPEED 62-400-38 AC Controller, 24/48V, 300A 62-400-47 AC Controller,36/48V, 450A 79-829-15 Fuse, 330A System 79-829-10 Fuse, 500A System MB-440-01 Page 108...
  • Page 109 Replacement Parts B5-440-36 / B5-440-48 Speed Control Panel Item No. Part No. Description 73-012-33 DC-DC Converter, 36-48V (Optional) 88-838-06 #14X1/2 PN Head Screw 62-400-38 AC Controller, 24/48V, 300A 0 or 1 62-400-47 AC Controller,36/48V, 450A 0 or 1 88-065-11 1/4X1 NC Phillips Truss Head GR2 88-069-81 1/4NC Nylon Locknut GR2 88-068-61...

  • Page 110: Control System, Instrument Panel

    Replacement Parts B5-440-36 / B5-440-48 CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 71-120-10 Start switch (key) 71-121-20 Key Switch 71-039-02 Forward / Reverse Switch 71-039-11 High / Low speed Switch 94-305-24 Dash Panel 94-305-25 Backing Plate 74-009-00 Battery Status Indicator (pictured) 74-010-00...

  • Page 111: Decals

    Replacement Parts B5-440-36 / B5-440-48 DECALS Decals Item No. Part No. Description 94-384-48 Fingers Crushed WARNING 94-301-45 Bigfoot DECAL 94-384-01 Not a motor vehicle (White/Blue) 94-313-00 Battery WARNING 94-384-17 Do Not Spray WARNING 94-319-00 Battery Disconnect 94-320-10 Roll Over WARNING 94-384-14 When leaving vehicle WARNING 94-301-42...

  • Page 112: Electrical, Miscellaneous

    Replacement Parts B5-440-36 / B5-440-48 ELECTRICAL, MISCELLANEOUS MB-440-01 Page 112...
  • Page 113 Replacement Parts B5-440-36 / B5-440-48 Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID 96-630-00 (not shown Clamp, Rubber Lined 5/8 ID...

  • Page 114: Frame And Body (P1)

    Replacement Parts B5-440-36 / B5-440-48 FRAME AND BODY (P1) MB-440-01 Page 114...
  • Page 115 Replacement Parts B5-440-36 / B5-440-48 Item No. Part No. Description See Decals BIGFOOT Decal 90-160-96 Seat, 6” Adjustable 01-500-14 Panel, Seat Base 90-160-97 Hip Restraint, Driver 90-160-98 Hip Restraint, Passenger 01-500-28 Seat Back 90-444-05 Deckboard, 75-1/4 X 41 88-065-14 1/4 X 1-1/2NC TRUSS HD SCR GR2 88-068-61 1/4 SAE Washer GR2 97-211-20...

  • Page 116: Frame And Body (P2)

    Replacement Parts B5-440-36 / B5-440-48 FRAME AND BODY (P2) MB-440-01 Page 116...
  • Page 117 Replacement Parts B5-440-36 / B5-440-48 Item No. Part No. Description 74-055-04 Wiper Arm 74-055-06 Wiper Blade, Curved, 26” 74-055-11 Wiper Motor 74-055-17 Pigtail, 2-Speed Wiper Motor 90-821-00 Curved Windshield 92-150-23 Mirror,Left Side 92-150-24 Mirror, Right Side 00-500-12 Mirror, Spacer 90-821-10 Door Window (Left) 90-821-11 Door Window (Right)

  • Page 118: Frame And Body, Drop Sides

    Replacement Parts B5-440-36 / B5-440-48 FRAME AND BODY, DROP SIDES MB-440-01 Page 118...
  • Page 119 Replacement Parts B5-440-36 / B5-440-48 Item No. Part No. Description 02-204-43 Hitch Pad 88-080-09 Screw, 5/16 X 3/4 88-080-11 Screw, 5/16 X 1 88-088-61 Washer 88-089-81 Lock Nut 88-100-11 Screw, 3/8 X1 88-108-61 Flat Washer 88-109-81 Lock Nut 88-737-08 Pop Rivit 89-080-16 Hex Bolt 90-556-06...

  • Page 120: Hitches

    Replacement Parts B5-440-36 / B5-440-48 HITCHES Mounting Hardware Item No. Part No. Description 97-800-69 Backing Plate (installed on inside of frame) 88-140-14 1/2NC x 1-1/2 Hex bolt 88-148-61 1/2 Flat Washer (on all hitch options) 88-148-62 1/2 Split lock washer 88-149-80 1/2NC Hex nut Not Shown...

  • Page 121: Lights

    Replacement Parts B5-440-36 / B5-440-48 LIGHTS Item No. Part No. Description 72-005-22 Headlight, LED W/ Grommet & Connector (Cowl only) 0 or 2 72-005-13 Headlight, Single Beam (Cab only) 0 or 2 00-020-19 Headlight Cover (cab only) 0 or 2 72-022-04 Stop/Tail Light, LED 72-022-53...

  • Page 122: Motor

    Replacement Parts B5-440-36 / B5-440-48 MOTOR MB-440-01 Page 122...
  • Page 123 Replacement Parts B5-440-36 / B5-440-48 Motor (70-058-41) Item No. Part No. Description Order kit Bearing Plate 70-058-41-08 Cover Gasket Order kit Speed Sensor 70-058-41-11 Rubber Insulator Order kit Terminal Block, W/Cover Order kit Bearing 70-058-41-15 Wave Washer 70-058-41-16 Connector, Speed Sensor 70-058-41-22 Bolt, Bearing Plate 70-058-41-23...

  • Page 124: Steering Linkage

    Replacement Parts B5-440-36 / B5-440-48 STEERING LINKAGE MB-440-01 Page 124...
  • Page 125 Replacement Parts B5-440-36 / B5-440-48 Steering Linkage Item No. Part No. Description 19-011-30 Steering Wheel 19-011-35 Steering Wheel Cover 88-199-82 5/8 NF Hex Head Jam Nut GR 2 18-058-92 Steering Shaft Assembly 32-248-20 Steering Bushing 89-080035K-C-00 Bolt 89-080000K-C-04 M8x1.25 Metal Locknut, 10.9 00-500-03 Steering Column 88-100-11...

  • Page 126: Suspension, Front

    Replacement Parts B5-440-36 / B5-440-48 SUSPENSION, FRONT Front Suspension Item No. Part No. Description 96-240-00 Spring Bolt 32-214-50 Bushing 16-871-04 Spring Hanger 88-149-81 1/2 NC LOCK NUT GR5 85-498-00 Leaf Spring 14-010-07 Spring plate Not Shown 98-753-15 Bump Stop MB-440-01 Page 126...

  • Page 127: Suspension, Rear

    Replacement Parts B5-440-36 / B5-440-48 SUSPENSION, REAR Item No. Part No. Description 16-870-10 Spring Hanger 32-213-00 Bushing, Spring Eye 96-248-01 BOLT, SPRING, W/GRS FITNG GR5 88-169-82 9/16 NFLOCK NUT, GRADE C 96-114-00 UBOLT,RD,1/2NFX2.78X6 L GR5 88-159-84 LOCKNUT,NY-LOCK, 1/2-20 NF GR2 40-500-00 Plate, Spring Mounting 85-512-40...

  • Page 128: Wheels And Tires

    Replacement Parts B5-440-36 / B5-440-48 WHEELS AND TIRES Item No. Part No. Description 13-746-13 Tire, Wheel, 18.5 X 8.5 X 8, Load Range-C 10-092-00 8.50 x 8 LR C (replacement tire) 13-742-35 Tires, 5 X 8 Monomatic, Solid 12-012-00 13-742-13 Tire,Wheel, 5.7 X 8 Load Range-C 10-083-00 13-742-12...
  • Page 129 WARNING CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. There are chemicals contained in the operating systems of this vehicle that are known to the state of California to cause cancer, birth defects, and other reproductive harm...
  • Page 130 Taylor-Dunn® Manufacturing. 2114 West Ball Road. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 FAX: (714) 956-0504 Visit our Website: www.taylor-dunn.com...

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