Taylor-Dunn C0-T50-80 Service And Parts Manual
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Taylor-Dunn C0-T50-80 Service And Parts Manual

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Service and Replacement
Parts Manual
MANUAL MC-T50E-02
Model Numbers:
C0-T50-80
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
Powered by AC Motor
Control System
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
Starting Serial Number: 198576
G
Ending Serial Number: 210539

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Summary of Contents for Taylor-Dunn C0-T50-80

  • Page 1 Service and Replacement Parts Manual MANUAL MC-T50E-02 Model Numbers: C0-T50-80 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...
  • 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 1/6/2017 Revision G, 10/2/2018, 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 ..........19 Preventative Maintenance ......23 Lubrication ............27 Front Axle ............29 Drive Axle ............37 Steering ............45 Brake Service ...........57 Motor Controller ..........67 Motor ..............71 Tires &...
  • Page 7 Table of Contents Introduction About this manual ...........8 Who Should Read This Manual ......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

    Taylor-Dunn is not to be held liable for errors in this manual or any consequential damage that results from the use of this manual.

  • Page 9: Introduction

    Introduction C0-T50-80 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

    Of the Service Personnel... 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 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 Introduction C0-T50-80 Page-12 MC-T50E-02...
  • Page 13 Table of Contents Service/Maintenance Guidelines READ ME FIRST-Maintenance Guidelines and General instructions .........14 Vehicle Modifications ........15 Replacement Parts ..........16 Using Non-OEM Replacement Components ...16 PM Checklist ............17...

  • Page 14: Service/Maintenance Guidelines

    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

    Contact the factory for information regarding available alternate program settings. Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle. Any other alterations to the programming ARE NOT AUTHORIZED and is at your own risk.

  • Page 16: Replacement Parts

    To maintain peak performance, always 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 17: Pm Checklist

    Service/Maintenance Guidelines C0-T50-80 PM CHECKLIST This PM Check list is available as a Acrobat Preventative Maintenance Schedule for Tiger C0-T50-80 PDF file included on the Vehicle Documentation Date: ________________________ Model #: ________________ Hour Meter: _______________ Inspected By: ________________________ Serial #:...
  • Page 18 Notes Service/Maintenance Guidelines C0-T50-80 Page 18 MC-T50E-02...
  • Page 19 Table of Contents Special Tool List Special Tool List ..........20 Troubleshooting Guide ........21...
  • Page 20 Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not rectangular harness connectors. Not available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. Page 20...

  • Page 21: Special Tool List

    Tool List C0-T50-80 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.
  • Page 22 Tool List Notes C0-T50-80 Page 22 MC-T50E-02...
  • Page 23 Table of Contents Preventative Maintenance Daily Visual Inspection ........24 Pre-Operation Inspection ........24 Maintenance Schedule ........24 Maintenance Guidelines for Severe Duty Applications .............24 First 15 hours of Operation ........25 Every Week .............25 Every Month or 150 hours ........25 Every 3 Months or 500 hours ........25 Every 6 Months or 1,000 hours) ......25 Every Year or 2,000 hours ........25 WARNING...
  • Page 24 PM Schedule C0-T50-80 DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION 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...

  • Page 25: Preventative Maintenance

    PM Schedule C0-T50-80 First 15 hours of Operation Every 6 Months or 1,000 hours) Re-torque wheel nuts. All 3 month items plus the following: Inspect all hardware for tightness. Inspect and tighten all hardware Adjust front wheel bearings. Tighten all electrical connections.
  • Page 26 Notes PM Schedule C0-T50-80 Page 26 MC-T50E-02...
  • Page 27 Table of Contents Lubrication Lubrication and Fluids Chart ......28 Hazardous Waste Disposal ......28...
  • Page 28 Lubrication C0-T50-80 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: King Pin, Upper NLGI Grade 2 lithium multi-purpose grease King Pin, Lower NLGI Grade 2 lithium multi-purpose grease Ball Joint NLGI Grade 2 lithium multi-purpose grease Rod End...

  • Page 29: Lubrication

    Table of Contents Front Axle Inspect the Front Wheel Bearings and King Pin Adjust Front Wheel Bearings ......30 Align Front Wheels ..........31 Front Axle Removal and Installation .....32 Removal ..............32 Installation ...............32 Replace the King Pins and Bushings ....32 Front Hub, Steering knuckle, King Pin ..33 Disassembly ............33 Reassembly .............33 Replace Front Wheel Bearings.......34...

  • Page 30: Front Axle

    Front Axle C0-T50-80 INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS AND KING PIN BEARINGS 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.

  • Page 31: Front Axle

    Front Axle C0-T50-80 6: Turn the steering wheel so that the steering ALIGN FRONT WHEELS cylinder ram is centered in the steering cylinder. WARNING 7: Place a square on the axle beam up against a steering knuckle backing plate and clamp the...

  • Page 32: Front Axle Removal And Installation

    Front Axle C0-T50-80 FRONT AXLE REMOVAL AND REPLACE THE KING PINS AND INSTALLATION BUSHINGS 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.

  • Page 33: Front Hub, Steering Knuckle, King Pin

    Front Axle C0-T50-80 FRONT HUB, STEERING KNUCKLE, KING PIN 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. It is recommended that if a wearable component is replaced on one side of a vehicle, the same components should be replaced on the other side of the vehicle.

  • Page 34: Replace Front Wheel Bearings

    Front Axle C0-T50-80 REPLACE FRONT WHEEL REPLACE BALL JOINT 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 35: Replace The Steering Cylinder

    Front Axle C0-T50-80 REPLACE THE STEERING REBUILD THE STEERING CYLINDER CYLINDER WARNING Refer to Steering Component Service section 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 36 Notes Front Axle C0-T50-80 Page 36 MC-T50E-02...
  • Page 37 Table of Contents Drive Axle Check Oil Level ..........38 Change Oil ............38 Removal and installation ........39 Remove ..............39 Install ...............39 Planetary Gear and Brake Assembly .....40 Remove ..............40 Install ...............40 Planetary Gear Box .........41 Disassemble ............41 Inspection ..............42 Assemble ..............42 Differential Gear..........43 Remove ..............43 Install ...............43...

  • Page 38: Drive Axle

    Drive Axle C0-T50-80 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...

  • Page 39: Drive Axle

    Drive Axle C0-T50-80 REMOVAL AND INSTALLATION 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 rear of the vehicle and support with jack stands.

  • Page 40: Planetary Gear And Brake Assembly

    Drive Axle C0-T50-80 PLANETARY GEAR AND BRAKE ASSEMBLY Remove 1: Raise the rear of the vehicle and support with jack stands. 2: Remove the wheels. Refer to procedure in “Tires and Wheels” section. 3: Drain the oil from the brake and gear chambers.

  • Page 41: Planetary Gear Box

    Drive Axle C0-T50-80 PLANETARY GEAR BOX This procedure assumes that the component has been removed from the vehicle. Refer to the Gear/Brake Assembly removal instructions for details and warnings regarding the removal and installation procedure. The left and right side gear boxes are not identical but the disassembly and assembly procedures are the same.

  • Page 42: Inspection

    Drive Axle C0-T50-80 Inspection • Heat the planet gear carrier to 120ºC (248ºF) and press into the wheel hub spline. Using tool • Thoroughly clean all components. #95-500-45, tighten the Ring Nut per torque listed • All seals that were removed should be replaced in the Hardware Torque table at the end of this with new seals.

  • Page 43: Differential Gear

    Drive Axle C0-T50-80 DIFFERENTIAL GEAR SPEED ENCODER The differential gear assembly cannot be rebuilt. If it is Testing faulty it must be replaced as an assembly. The speed encoder is installed in the transaxle housing The differential assembly is a balanced unit. Do not drop and provides a signals to the controller indicating the the assembly or strike it with a hammer.

  • Page 44: Hardware Torque

    Drive Axle C0-T50-80 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Gear Box Mounting (M8) 29.5 Gear Box Mounting (M12) Notes Ring Gear Bolts Ring Nut Flange Mounting Screws 29.5...
  • Page 45 Table of Contents Steering Steering Cylinder ..........46 Remove and Install ..........46 Rebuild ..............46 Hydraulic Pump ..........46 Remove ..............46 Install ...............46 Steering Control Valve ........47 Remove ..............47 Install ...............47 Disassemble ............47 Reassemble ............47 Steering Control Valve, Exploded ....48 Troubleshooting ..........49 Hardware Torque ..........50 WARNING This section is one section of a complete service manual.

  • Page 46: Steering Cylinder

    Steering C0-T50-80 STEERING CYLINDER HYDRAULIC PUMP 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...

  • Page 47: Steering

    Steering C0-T50-80 14: Rotate the spool and sleeve assembly (9) until STEERING CONTROL VALVE the centering pin (10) is horizontal then push WARNING spool and sleeve assembly just far enough to free the gland bushing (18) from the housing and remove the bushing.

  • Page 48: Steering Control Valve, Exploded

    Steering C0-T50-80 12: Install the seal gland bushing assembly over the 18: Rotate the spool/sleeve assembly until the pin spool end. Tap in place with a rubber hammer. is parallel with the port face and install the drive Bushing should be flush against the bearing race.

  • Page 49: Troubleshooting

    Steering C0-T50-80 TROUBLESHOOTING The cause of most steering problems can be identified by the symptoms. The entire steering system must be analyzed by a qualified technician before any components are removed. Use the following chart to identify probable cause of steering problems.

  • Page 50: Hardware Torque

    Steering C0-T50-80 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Steering wheel nut Steering Valve Mounting Bolts 16.7 Steering Valve Cap Bolts (final) 19.6 See instuctions for 1st stage torque...
  • Page 51 Steering C0-T50-80 MC-T50E-02 Page 51...
  • Page 52 Steering C0-T50-80 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 52 MC-T50E-02...
  • Page 53 Steering C0-T50-80 MC-T50E-02 Page 53...
  • Page 54 Steering C0-T50-80 Page 54 MC-T50E-02...
  • Page 55 Steering C0-T50-80 MC-T50E-02 Page 55...
  • Page 56 Notes Steering C0-T50-80 Page 56 MC-T50E-02...
  • Page 57 Failure to follow these guidelines will result in premature failure of hydraulic system components. Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 58: Front Brake

    DOW Corning #7, lightly lubricate the inside on the bushings. WARNING Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 59: Brake Service

    C0-T50-80 16: Install the guide pins and wipe off any excess 1: Remove the brake pads from the caliper. Refer to lubricant. “Replace Pads” procedure. 17: Press the smaller heat insulator plate onto the 2: Take the rubber boot off of the caliper body.

  • Page 60: Rear Brake

    C0-T50-80 WARNING REAR BRAKE WARNING Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts This section is one section of a complete service containing asbestos. Since this possibility exists, manual.

  • Page 61: Hydro-Boost

    C0-T50-80 HYDRO-BOOST WARNING Hydraulic fluid and components must be kept clean. Thoroughly clean exterior of any hydraulic component before disconnecting hoses or fittings. Perform all maintenance and repairs in a clean environment. Do not use cloth or paper towels to clean components due to possible contamination with lint or other fiber.

  • Page 62: Troubleshooting Flowcharts

    C0-T50-80 Troubleshooting Flowcharts Normal Hydro-boost brake units will produce certain characteristic booster noises. These noises occur, for the most part, when the brake pedal is manipulated in a manner not associated with everyday braking or driving habits, The general categories of normal operating noises are: (1) Hissing noises and (2) Clunk/Click/Chatter noises.
  • Page 63 C0-T50-80 MC-T50E-02 Page 63...
  • Page 64 C0-T50-80 Page 64 MC-T50E-02...

  • Page 65: Master Cylinder

    C0-T50-80 MASTER CYLINDER BLEED BRAKE SYSTEM WARNING Note: Start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. This section is one section of a complete service The rear bleeder valves can be accessed manual.

  • Page 66: Adjust Pedal Linkage

    C0-T50-80 ADJUST PEDAL LINKAGE ADJUST PARKING BRAKE 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...
  • Page 67 Table of Contents Motor Controller Remove/Install ..........68 Inspect ..............68 Receptacles .............68 Base Plate ...............68 Terminal Ends ............68 Troubleshooting ..........68 Repair/Programming ........69 Programming ............69 Hardware Torque ..........70 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 68: Motor Controller

    A hard copy can be purchased from your authorized 2: Apply thermal transfer compound to the controller Taylor-Dunn distributor or can be downloaded from the base and heat sink. Taylor-Dunn web site. 3: Install the controller to the mounting plate.

  • Page 69: Motor Controller

    Motor Controller C0-T50-80 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 70: Hardware Torque

    Motor Controller C0-T50-80 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal stud Page 70 MC-T50E-02...
  • Page 71 Table of Contents Motor Removal............72 Inspection ............72 Phase Windings ............72 Thermal Sensor ............72 Motor Service Limits and Specifications ..72 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: Motor

    C0-T50-80 REMOVAL MOTOR SERVICE LIMITS AND 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...
  • Page 73 Table of Contents Tires & Wheels Inflation .............74 Air pressure .............74 Tread Wear ............74 Rotation ............75 Changing Tire/Wheel Assembly .....76 Replace the Tire (pneumatic) ......76 Repair the Tire (pneumatic) ......76 Hardware Torque ..........77 WARNING This section is one section of a complete service manual.

  • Page 74: Tires & Wheels

    Tires & Wheels C0-T50-80 INFLATION TREAD WEAR 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...

  • Page 75: Tires & Wheels

    Tires & Wheels C0-T50-80 ROTATION 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. Front and rear tires as well as left and right tires can wear at different rates. It is important to periodically rotate your ties to extend your tire life.

  • Page 76: Changing Tire/Wheel Assembly

    Tires & Wheels C0-T50-80 CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) WARNING 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 This section is one section of a complete service Service Guidelines chapter.

  • Page 77: Hardware Torque

    Tires & Wheels C0-T50-80 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MC-T50E-02 Page 77...
  • Page 78 Notes Tires & Wheels C0-T50-80 Page 78 MC-T50E-02...
  • Page 79 Table of Contents Batteries General Guidelines and Safety.......80 Charging ............80 Cleaning ............80 Watering ............81 Testing ..............82 Specific Gravity ............82 Storing ..............82 Storage ..............82 Returning to Service ..........82 Remove/Install ..........83 Lift Out Battery Pack ..........83 Side Extract Battery ..........83 WARNING This section is one section of a complete service manual.

  • Page 80: General Guidelines And Safety

    Batteries C0-T50-80 GENERAL GUIDELINES AND SAFETY WARNING CLEANING 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 81: Batteries

    Batteries C0-T50-80 WATERING 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 and beginning of this section.. NOTICE DO NOT attempt to add electrolytes to a sealed battery.

  • Page 82: Testing

    Batteries C0-T50-80 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...

  • Page 83: Remove/Install

    Batteries C0-T50-80 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...
  • Page 84 Notes Batteries C0-T50-80 Page 84 MC-T50E-02...
  • Page 85 Table of Contents Wire Diagram Diagram Part Numbers........86 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 86 Wire diagrams are too large to be legible when printed at this size. The wire diagram for this vehicle is included on the Vehicle Documentation CD provided with the vehicle. The diagram # for this vehicle are: SCH-00037 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. Green...

  • Page 87: Wire Diagram

    Table of Contents Hardware Information Torque Guidelines for Standard hardware ..88 Hardware Identification ..........88 Hex Nuts ..............89 Hex Lock Nuts (stover) ..........89 Other Nuts ...............89 Generic Torque Values ..........90 Replacing Hardware ........92 WARNING This section is one section of a complete service manual.

  • Page 88: Torque Guidelines For Standard Hardware

    Hardware C0-T50-80 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 89: Hardware Information

    ‘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 MC-T50E-02 Page 89...

  • Page 90: Generic Torque Values

    Hardware C0-T50-80 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.
  • Page 91 Hardware C0-T50-80 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...

  • Page 92: Replacing Hardware

    Hardware C0-T50-80 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 93 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle ........94 Taylor-Dunn Web Site Information ......94 Axle Assembly, Front ..........96 TransAxle Assembly, Rear and Rear Brakes (P1)..98 TransAxle Assembly, Rear and Rear Brakes (P2)..100 Battery .................102 Battery Lid ..............104 Brakes, Brake Pedal ...........106 Brakes, Brake Lines ...........108...

  • Page 94: 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 95: Replacement Parts

    Replacement Parts C0-T50-80 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MC-T50E-02 * Not available at time of printing Page 95...

  • Page 96: Axle Assembly, Front

    Replacement Parts C0-T50-80 AXLE ASSEMBLY, FRONT Page 96 * Not available at time of printing MC-T50E-02...
  • Page 97 Replacement Parts C0-T50-80 Axle Assembly, Front Item No. Part No. Description 89-100020K-B-00 Bolt, Hub Cap 500845 Hub Cap 500844 Gasket 500842 Nut, Bearing Adjust 500842 Nut, Bearing Adjust 500843 Lock Washer, Keyed 500850 Race 500841 Washer, Hub 500849 Bearing 96-329-40...

  • Page 98: Transaxle Assembly, Rear And Rear Brakes (P1)

    Replacement Parts C0-T50-80 TRANSAXLE ASSEMBLY, REAR AND REAR BRAKES (P1) Note: Entire parts listing and illustrations for transaxle covers 4 pages Drive axle assembly part numbers: 49-490-00: Up to serial number 199197 49-490-12: Starting serial number 199198 Axle Assembly, Rear / Rear Brakes Item No.
  • Page 99 Replacement Parts C0-T50-80 Axle Assembly, Rear / Rear Brakes (continued) Item No. Part No. Description Ring-Gear Carrier Disc Lever Wheel Hub Sun Pinion Piston 49-490-00-07 Planet Carrier 49-490-00-11 Stud 98-753-56 Cap, Brake Bleeder Cover Connection, Brake Adjust Shim Planet Gear...

  • Page 100: Transaxle Assembly, Rear And Rear Brakes (P2)

    Replacement Parts C0-T50-80 TRANSAXLE ASSEMBLY, REAR AND REAR BRAKES (P2) K3 and K4 Assemblies Page 100 * Not available at time of printing MC-T50E-02...
  • Page 101 Replacement Parts C0-T50-80 Axle Assembly, Rear / Rear Brakes (continued) Item No. Part No. Description Motor Copper Washer 49-490-00-08 Locking Pin Locking Pin 49-490-00-09 Locking Pin Elastic Pin Screw Plug Screw Plug Magnetic Screw Plug Breather Plug Breather Plug Socket Head Cap Screw...

  • Page 102: Battery

    Replacement Parts C0-T50-80 BATTERY Battery Connector Item No. Part No. Description 76-020-33 Bracket, Frame Mount 76-020-32 Bracket, Battery plug Supplied with #2 Bolt Supplied with #2 Supplied with #2 Washer Battery Plug (Refer to battery manufacturer) 76-020-31** Battery Receptacle Supplied with #5...
  • Page 103 Replacement Parts C0-T50-80 Battery Item No. Part No. Description 77-069-00 BATTERY, 775AH Optional 00-490-50 Battery Guide (side) 2-Optional 00-490-51 Battery Guide (Front) 1-Optional 89-120020M-B-00 Bolt, Battery Guide 6-Optional 89-1200000-C-06 Flat Washer, Battery Guide 6-Optional 89-120000M-C-04 Nut, Battery Guide 6-Optional !!! SEE NOTE BELOW REGARDING BATTERY GUIDES !!!

  • Page 104: Battery Lid

    Replacement Parts C0-T50-80 BATTERY LID Page 104 * Not available at time of printing MC-T50E-02...
  • Page 105 Replacement Parts C0-T50-80 Battery Lid Item No. Part No. Description 96-081-26 M16 PLASTIC WASHER 89-160000N-C-03 Nut, M16X2 STEEL JAM NUT,10 88-537-14 Cotter Pin 88-108-61 Flat Washer 00-490-27 Latch, left 00-490-17 Center Pivot 89-100000L-C-04 Nut, M10-1.5 METAL LOCKNUT, 10 00-490-57 Cross Link...

  • Page 106: Brakes, Brake Pedal

    Replacement Parts C0-T50-80 BRAKES, BRAKE PEDAL Page 106 * Not available at time of printing MC-T50E-02...
  • Page 107 Replacement Parts C0-T50-80 Brake Pedal Linkage Item No. Part No. Description 00-490-09 Mounting Bracket 89-120050M-C-00 Bolt, Mounting Bracket, M12-1.75 X 50 HX SCR,10.9 89-120000M-C-04 Nut, Mounting Bracket, M12X1.75 METAL LOCKNUT,10 89-1200000-C-06 Flat Washer, Mounting Bracket, M12 FLAT WSHR, HARD 00-490-07...

  • Page 108: Brakes, Brake Lines

    Replacement Parts C0-T50-80 BRAKES, BRAKE LINES Item No. Part No. Description 99-600-58 Brake Line 71-110-00 Brake Light Switch Hydroboost 99-575-00 Union, Brake Line 99-604-04 Brake Line 41-350-50 Brake Proportioning Valve 99-607-03 Brake Line 99-606-56 Brake Line 99-603-10 Brake Line 99-603-11...

  • Page 109: Brakes, Front Axle

    Replacement Parts C0-T50-80 BRAKES, FRONT AXLE Item No. Part No. Description 41-490-40 Caliper Assembly, left (includes pads) 41-490-41 Caliper Assembly, right (includes pads) 89-100070L-D-00 Bolt, long mounting 89-100060L-D-00 Bolt, short mounting 15-490-02 Locking plate, right 15-490-03 Locking plate, left 41-490-42-1...

  • Page 110: Brakes, Park Brake Linkage

    Replacement Parts C0-T50-80 BRAKES, PARK BRAKE LINKAGE Page 110 * Not available at time of printing MC-T50E-02...
  • Page 111 Replacement Parts C0-T50-80 Parking Brake Linkage Item No. Part No. Description 89-100019J-C-00 Bolt, M10-1 X 19 HX SCR,10.9 00-490-33 Bracket, Cable, Long 96-820-40 Cable 85-220-05 Spring, Cable 88-099-80 96-760-00 Clevis 96-772-00 Clevis Pin 88-517-11 Cotter Pin 00-490-32 Bracket, Cable, Short 89-100019J-C-00 Bolt, M10-1 X 19 HX SCR,10.9...

  • Page 112: Brakes, Master Cylinder

    Replacement Parts C0-T50-80 BRAKES, MASTER CYLINDER Page 112 * Not available at time of printing MC-T50E-02...
  • Page 113 Replacement Parts C0-T50-80 Master Cylinder / Hydroboost Item No. Part No. Description 505502 Hydroboost Assembly ( includes master cylinder) 89-100000L-C-04 Lock Nut, Mounting, Hydroboost 89-1000000-C-06 Flat Washer, Mounting, Hydroboost 89-1000000-C-06 Flat Washer, Mounting, Hydroboost 89-100025L-C-00 Bolt, Mounting, Hydroboost Hydroboost** 99-520-00...

  • Page 114: Control System, Motor Speed Control

    Replacement Parts C0-T50-80 CONTROL SYSTEM, MOTOR SPEED CONTROL Page 114 * Not available at time of printing MC-T50E-02...
  • Page 115 Replacement Parts C0-T50-80 Speed Control Panel Item No. Part No. Description 02-425-19 Panel, Control Mounting 75-153-41 Wire Links kit Wire Link, 24”, Red, 2/0 AWG Wire Link, 4.25”, Red, 2/0 AWG Wire Link, 5”, Red, 8 AWG 79-829-20 Fuse, 50A...

  • Page 116: Control System, Instrument Panel

    Replacement Parts C0-T50-80 CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 88-607-06 Rivet 71-120-10 Key Switch (includes key) 71-120-90 Keys 72-018-22 Light. Green 71-120-14 Stop Switch 74-010-25 Dash Display (Sevcon shown) 0 or 1 74-010-20 Dash Display (Curtis, not shown)

  • Page 117: Control System, Inching Panel

    Replacement Parts C0-T50-80 CONTROL SYSTEM, INCHING PANEL Inching Panel Item No. Part No. Description 94-303-82 Inching panel Assembly (complete) 71-120-14 Emergency Stop Switch 71-039-37 Inching Switch, Forward 71-039-37 Inching Switch, Reverse MC-T50E-02 * Not available at time of printing Page 117...

  • Page 118: Control System, Shift Assembly

    Replacement Parts C0-T50-80 CONTROL SYSTEM, SHIFT ASSEMBLY Page 118 * Not available at time of printing MC-T50E-02...
  • Page 119 Replacement Parts C0-T50-80 Shift Assembly Item No. Part No. Description 62-034-44 Complete Shifter Assembly 96-773-10 Clevis Pin 85-030-00 Spring 88-517-11 3/32 x 1 STEEL COTTER PIN 00-155-34 Shift Lever 95-907-00 Knob, Shift Lever 88-109-81 3/8 NC LOCK NUT 00-155-75 Cam, Shift...

  • Page 120: Decals

    Replacement Parts C0-T50-80 DECALS Page 120 * Not available at time of printing MC-T50E-02...

  • Page 121: Electrical, Miscellaneous

    Replacement Parts C0-T50-80 ELECTRICAL, MISCELLANEOUS Electrical Item No. Part No. Description 73-005-26 Reverse or Forward Alarm 72-022-51 Rubber mounting ring 73-004-20 Horn 71-039-28 Horn Switch 75-152-65 Harness, Horn Adaptor 71-102-25 Switch, Driver Seat Interlock 75-153-45 Harness, Main Chassis 78-010-31 Fuse panel...

  • Page 122: Frame And Body

    Replacement Parts C0-T50-80 FRAME AND BODY Page 122 * Not available at time of printing MC-T50E-02...
  • Page 123 Replacement Parts C0-T50-80 Frame and Body Item No. Part No. Description Frame, standard 00-490-25 Emblem. Cowl 89-100025L-C-00 Bolt 89-100000L-C-04 89-1000000-C-06 Washer 00-490-60 Dash 00-490-26 Inspection Cover, Master Cylinder 00-490-26 Inspection Cover, Dash 90-160-70 Driver Seat 88-080-13 Mounting Bolts 88-089-81 Nuts...

  • Page 124: Frame, Steel Cab And Doors

    Replacement Parts C0-T50-80 FRAME, STEEL CAB AND DOORS Cab, Steel Item No. Part No. Description 91-490-53 COVER, HEADLIGHT 98-310-00 RUBBER WINDOW CHANNEL per foot 98-454-00 WEATHERSEAL,DOOR,BY THE FT per foot 91-490-00 CAB, WELDMENT, TC50-E 91-490-08 COVER, LEFT SIDE 91-490-09 COVER, RIGHT SIDE...

  • Page 125: Hitches

    Replacement Parts C0-T50-80 HITCHES Hitch: 505836 Mounting Hardware Part No. Description 89-120050M-C-00 M12-1.75 X 50 HX SCR,10.9 89-1200000-C-06 M12 FLAT WSHR, HARD 89-120000M-C-04 M12X1.75 METAL LOCKNUT,10 Hitch: 97-814-00 Mounting Hardware Part No. Description 89-120000M-C-04 M12X1.75 METAL LOCKNUT,10 89-1200000-C-06 M12 FLAT WSHR, HARD 89-120050M-C-00 M12-1.75 X 50 HX SCR,10.9...

  • Page 126: Hydraulic Power System

    Replacement Parts C0-T50-80 HYDRAULIC POWER SYSTEM There are two pumps used depending on vehicle configuration. Note: The two pump assemblies are not interchangeable. At time of printing, This pump was only available as an assembly. . Part No. Description 70-020-90 Motor...

  • Page 127: Lights

    Replacement Parts C0-T50-80 LIGHTS Item No. Part No. Description 72-035-02 Headlight Kit, left and right, includes wiring 72-085-15 Headlight bulb 72-085-20 Signal bulb 00-490-00 Strap, headlight mount 72-022-03 Taillight 72-022-51 Grommet 72-035-01 Back Up light 72-022-51 Grommet 71-141-25 Directional Switch...

  • Page 128: Steering Linkage

    Replacement Parts C0-T50-80 STEERING LINKAGE STEERING CONTROL VALVE Page 128 * Not available at time of printing MC-T50E-02...
  • Page 129 Replacement Parts C0-T50-80 Steering Linkage Item No. Part No. Description 500854 Ball Joint (includes item #2) Grease Fitting (included w/ball joint 201032 Jam Nut 18-001-00 Clevis, Rod End 87-074-00 Grease Fitting 99-524-20 Steering Cylinder 99-524-21 Seal Kit, Steering Cylinder 21-001-00...

  • Page 130: Suspension, Front

    Replacement Parts C0-T50-80 SUSPENSION, FRONT Item No. Part No. Description 89-120090M-C-00 Bolt, M12X1.75,HX HD BOLT, 10.9 500583 Bushing, Spring Eye ( 2 per eye) 500045 Plate 89-120000M-C-04 Nut, M12X1.75 METAL LOCKNUT,10 500582 Spring 89-140100N-C-00 Bolt, M14X2X100 HEX BOLT,GRD 10.9 89-140000N-C-04...

  • Page 131: Suspension, Rear

    Replacement Parts C0-T50-80 SUSPENSION, REAR Item No. Part No. Description 85-180-22 Spring 16-490-01 Spacer, Spring (top & bottom) 89-100090L-C-00 Bolt, M10-1.5 X 90 HX SCR,10.9 89-080000K-C-04 Nut, M8X1.25 METAL LOCKNUT, 10 89-1000000-C-06 Washer, M10 FLAT WSHR, HARD 01-490-89 Spacer 86-602-05...

  • Page 132: Wheels And Tires

    Replacement Parts C0-T50-80 WHEELS AND TIRES Item No. Part No. Description 13-771-20 TIRE & WHEEL 23 x 10-12, 16 PLY 0 or 4 Used up to serial number 205734 13-771-50 TIRE & WHEEL 23 x 10-12, 20 PLY 0 or 4...
  • Page 133 Notes: Replacement Parts C0-T50-80 MC-T50E-02 * Not available at time of printing Page 133...
  • Page 135 For more information go to www.P65Warnings.ca.gov/passenger- vehicle. 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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