Taylor-Dunn C0-425-48 Service And Replacement Parts Manual
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Taylor-Dunn C0-425-48 Service And Replacement Parts Manual

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See also: Operator's Manual
Service and Replacement
Parts Manual
MANUAL MC-425-13
Model Numbers:
C0-425-48
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
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: 204740
D
Ending Serial Number: See Introduction Chapter

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Summary of Contents for Taylor-Dunn C0-425-48

  • Page 1 Service and Replacement Parts Manual MANUAL MC-425-13 Model Numbers: C0-425-48 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 WARNING READ THE OPERATOR’S MANUAL BEFORE OPERATING...
  • 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 4/1/2017 Revision D, 7/12/2018, 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 Preventative Maintenance ......17 Special Tool List ..........21 Tool List ..............22 Lubrication ............25 Front Axle ............29 Steering ............37 Drive Axle ............47 Brakes...............57 Motor ..............65 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 Where to Find Data Plate and Serial Number ..11 WARNING This section is one section of a complete service...

  • 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 C0-425-48 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

    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 C0-425-48 Page-12 MC-425-13...
  • 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...

  • 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 Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 Maintenance Guidelines for Severe Duty Applications .............18 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 PM Schedule C0-425-48 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 19: Preventative Maintenance

    PM Schedule C0-425-48 Every Week Every 6 Months or 600 hours • All daily items plus the following: • All monthly items plus the following: • Battery electrolyte level (all cells). • Align the front end. • Check all tires tread for debris.
  • Page 20 Notes PM Schedule C0-425-48 Page 20 MC-425-13...
  • Page 21 Table of Contents Special Tool List Tool List ............22 Troubleshooting Guide ........24...
  • Page 22 Tool List C0-425-48 TOOL LIST The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness 62-027-00: Test Light Tests the throttle module in or out of the Used in conjunction with a volt meter to test Used for testing electrical circuits.

  • Page 23: Special Tool List

    Tool List C0-425-48 96-500-48: GT Drive Oil Fill Plug Tool Used to remove the oil fill plug on GT drives. It is used with a 3/8” drive extension (not included). MC-425-13 Page 23...

  • Page 24: Tool List

    Tool List C0-425-48 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.
  • Page 25 Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication C0-425-48 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 2: King Pin NLGI Grade 2 lithium multi-purpose grease 3: Ball Joint NLGI Grade 2 lithium multi-purpose grease 4: Idler Pivot NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing...

  • Page 27: Lubrication

    Lubrication C0-425-48 LUBRICATION DIAGRAM Front End Lubrication GT - Rear Axle Lubrication SD Transaxle MC-425-13 Page 27...
  • Page 28 Notes Lubrication C0-425-48 Page 28 MC-425-13...
  • Page 29 Table of Contents Front Axle Remove.............30 Install ..............30 Disassemble.............31 Inspect Front Wheel Bearings ......32 Adjust Front Wheel Bearings ......32 Front Wheel Alignment ........33 Replace Front Wheel Bearings.......34 Replace Steering Knuckle ......34 Replace King Pin/Bushings ......35 Service Limits and Specifications ....36 King Pin Bushings ...........36 Toe In ...............36 Hardware Torque ..........36...

  • Page 30: Front Axle

    Front Axle C0-425-48 REMOVE 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: Raise the front of the vehicle and support with jack stands.

  • Page 31: Front Axle

    Front Axle C0-425-48 DISASSEMBLE 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. Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings.

  • Page 32: Inspect Front Wheel Bearings

    Front Axle C0-425-48 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 33: Front Wheel Alignment

    Front Axle C0-425-48 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. Inspection, Axle Centers 1: Raise the front of the vehicle and support with jack stands.

  • Page 34: Replace Front Wheel Bearings

    Front Axle C0-425-48 REPLACE FRONT WHEEL REPLACE STEERING KNUCKLE BEARINGS 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 35: Replace King Pin/Bushings

    Front Axle C0-425-48 REPLACE KING PIN/BUSHINGS 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 different types of king pin bushings depending on the configuration of your vehicle. This is a generic procedure that covers all three types of bushings.

  • Page 36: Service Limits And Specifications

    Front Axle C0-425-48 SERVICE LIMITS AND HARDWARE TORQUE SPECIFICATIONS Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 King Pin Bushings Rod End Stud Nut 20-25 27.1-33.9 Ream or broach to: Rod End Jam Nut 20-25 27.1-33.9 • 0.8755 to 0.8765 inches •...
  • Page 37 Table of Contents Steering Inspect Ball Joints ...........38 Adjust Steering Gear ........38 Replace Ball Joint..........39 Replace Rod End ..........39 Replace Steering Column .......40 Replace the Steering Gear ......40 Center the Steering Gear ........41 Align Pitman Shaft ...........41 Front Wheel Alignment ........41 Steering Gear ...........42 Disassemble ............42 Reassemble ............43...

  • Page 38: Inspect Ball Joints

    Steering C0-425-48 INSPECT BALL JOINTS 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: A set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set.

  • Page 39: Steering

    Steering C0-425-48 REPLACE BALL JOINT 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: Raise the front of the vehicle and support with jack stands.

  • Page 40: Replace Steering Column

    Steering C0-425-48 REPLACE STEERING COLUMN REPLACE THE STEERING GEAR 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 41: Center The Steering Gear

    Steering C0-425-48 CENTER THE STEERING GEAR 1: Rotate the input shaft clockwise until it stops. 2: While counting the rotations, rotate the input shaft counter clockwise until it stops. 3: Rotate the input shaft clockwise 1/2 the rotations counted in the previous step.

  • Page 42: Steering Gear

    Steering C0-425-48 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. Disassemble Note: The steering gear must be removed from the vehicle for this procedure.

  • Page 43: Reassemble

    Steering C0-425-48 Reassemble 12: Lightly lubricate all parts before reassembly. 13: Install a new worm shaft seal and pitman shaft seal into the housing. 14: Install the upper worm bearing cup. 15: Divide the ball bearing into two equal groups.

  • Page 44: Exploded View Of Steering Gear

    Steering C0-425-48 Exploded View of Steering Gear Page 44 MC-425-13...

  • Page 45: Hardware Torque

    Steering C0-425-48 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Rod End Stud Nut 20-25 27.1-33.9 Rod End Jam Nut 20-25 27.1-33.9 Ball Joint Castle Nut 40-45 54.2-61 Pitman Arm 75-100 MC-425-13 Page 45...
  • Page 46 Notes Steering C0-425-48 Page 46 MC-425-13...
  • Page 47 Table of Contents Drive Axle Check Oil Level ..........48 Change Oil ............48 Remove and Install ..........49 Axle Shaft ............50 Remove ..............50 Install ...............50 Rear Hub, Rotor & Bearings ......51 Motor, Remove ..........51 Primary Gear Case ..........52 Secondary Gear Case ........53 Disassemble ............53 Assemble ..............53 Pinion Bearing Preload ........55...

  • Page 48: Drive Axle

    Drive Axle-GT C0-425-48 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...

  • Page 49: Drive Axle

    Drive Axle-GT C0-425-48 REMOVE AND INSTALL 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 main motor cables and unplug the encoder and electric brake cables.

  • Page 50: Axle Shaft

    Drive Axle-GT C0-425-48 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. If removed they must be replaced.

  • Page 51: Rear Hub, Rotor & Bearings

    Drive Axle-GT C0-425-48 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 52: Primary Gear Case

    Drive Axle-GT C0-425-48 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 53: Secondary Gear Case

    Drive Axle-GT C0-425-48 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.
  • Page 54 Drive Axle-GT C0-425-48 13: Install the differential assembly. 14: Install the cover and all of the cover bolts and washers. See note regarding special washers at the end of this section. Torque per torque listed in the Hardware Torque table at the end of this section.

  • Page 55: Pinion Bearing Preload

    Drive Axle-GT C0-425-48 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 56: Hardware Torque

    Drive Axle-GT C0-425-48 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 54-67.5...
  • Page 57 Table of Contents Brakes General Guidelines and Safety.......58 Park Brake ............59 Inspection ..............59 Adjustment ..............59 Front Brake ............60 Service Limits ............60 Inspection ..............60 Replace Pads ............60 Rear Brake............61 Service Limits ............61 Inspection ..............61 Replace Pads ............61 Rebuild Disc Brake Body ........62 Bleed System ...........63 Flush System ...........63 Master Cylinder..........64...

  • Page 58: General Guidelines And Safety

    C0-425-48 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 59: Brakes

    Brakes C0-425-48 PARK 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. Inspection The park brake is actuated through a pin in the center of the rear left and right brake body on the rear axles.

  • Page 60: Front Brake

    Brakes C0-425-48 Replace Pads FRONT BRAKE Note: Installing new brake pads will raise the brake WARNING fluid level in the master cylinder. 1: Thoroughly clean the area around the master This section is one section of a complete service cylinder cap. manual. Before starting any procedure, read all...

  • Page 61: Rear Brake

    Brakes C0-425-48 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 62: Rebuild Disc Brake Body

    Brakes C0-425-48 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 63: Bleed System

    Brakes C0-425-48 FLUSH SYSTEM BLEED SYSTEM 1: Raise the rear wheels off of the ground and WARNING 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 64: Master Cylinder

    Brakes C0-425-48 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 65 Table of Contents Motor Remove/Install ..........66 Disassemble.............66 Inspect ..............67 Brushes ..............67 Bearing ..............67 Commutator .............67 Armature Windings ..........67 Field Windings ............68 Repair ...............69 Service Limits ..........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 66: Remove/Install

    Motor SEM C0-425-48 REMOVE/INSTALL DISASSEMBLE 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 67: Motor

    Motor SEM C0-425-48 INSPECT Inspect the commutator for groves. WARNING • If the commutator is grooved then it must be machined on a lathe. Do not machine the This section is one section of a complete service commutator past the minimum diameter specified manual.

  • Page 68: Field Windings

    Motor SEM C0-425-48 Inspect the armature windings where they loop back at Using the continuity function of digital multi meter, check the opposite end of the commutator. the continuity from any one of the commutator segments • If the windings show indications of expanding (see and the armature frame.

  • Page 69: Repair

    Motor SEM C0-425-48 REPAIR 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. The only recommended repair to a motor is cutting the commutator. If any other components are damaged then they should be replaced.

  • Page 70: Service Limits

    Motor SEM C0-425-48 SERVICE LIMITS 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 is a generic section covering all currently available SEM motors at the time this manual was revised.
  • Page 71 Table of Contents Tires & Wheels Inflation .............72 Air pressure .............72 Tread Wear ............73 Rotation ............73 Changing Tire/Wheel Assembly .....74 Replace the Tire (pneumatic) ......74 Repair the Tire (pneumatic) ......74 Hardware Torque ..........75 WARNING This section is one section of a complete service manual.

  • Page 72: Tires & Wheels

    Tires & Wheels C0-425-48 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 73: Tires & Wheels

    Tires & Wheels C0-425-48 TREAD WEAR WARNING WARNING This section is one section of a complete service DO NOT operate a vehicle if the cord is manual. Before starting any procedure, read all visible on any tire (see illustration). A tire...

  • Page 74: Changing Tire/Wheel Assembly

    Tires & Wheels C0-425-48 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 75: Hardware Torque

    Tires & Wheels C0-425-48 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MC-425-13 Page 75...
  • Page 76 Notes Tires & Wheels C0-425-48 Page 76 MC-425-13...
  • Page 77 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 Side Extract Battery ..........81 Hardware Torque ..........82 Individual Batteries ..........82 WARNING...

  • Page 78: General Guidelines And Safety

    Batteries C0-425-48 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: Batteries

    Batteries C0-425-48 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...

  • Page 80: Testing

    Batteries C0-425-48 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...

  • Page 81: Remove/Install

    Batteries C0-425-48 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...

  • Page 82: Hardware Torque

    Batteries C0-425-48 Individual Batteries HARDWARE TORQUE WARNING If hardware is not listed here, refer to standard torque values in the appendix. Individual batteries can weight up to 80 pounds or Description Inch Pounds Newton Meters more. To avoid injury, use proper lifting techniques...
  • Page 83 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 Wire Diagram C0-425-48 DIAGRAM PART NUMBERS The diagram #’s for this vehicle are: SCH-00045 and SCH-00046 These vehicle diagrams as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Yellow Green MOTOR White...

  • Page 85: Wire Diagram

    Wire Diagram C0-425-48 4 9 8 C0-425-48 Page 85...
  • Page 86 Notes Wire Diagram C0-425-48 Page 86 C0-425-48...
  • Page 87 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 C0-425-48 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 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-425-13 Page 89...

  • Page 90: Generic Torque Values

    Hardware C0-425-48 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.
  • Page 91 Hardware C0-425-48 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...

  • Page 92: Replacing Hardware

    Hardware C0-425-48 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 93 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....94 Taylor-Dunn Web Site Information ....94 Axle Assembly, Front ........96 Axle Shaft Assembly, Rear ......96 TransAxle Assembly, Rear ......98 Brakes, Brake Lines ........100 Brakes, Front Axle ...........102 Brakes, Rear Axle ..........103 Brake Pedal Assembly ........104...

  • 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 C0-425-48 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MC-425-13 * Not available at time of printing Page 95...

  • Page 96: Axle Assembly, Front

    Replacement Parts C0-425-48 AXLE ASSEMBLY, FRONT AXLE SHAFT ASSEMBLY, REAR Page 96 MC-425-13...
  • Page 97 Replacement Parts C0-425-48 Axle Assembly, Front Item No. Part No. Description 92-104-014 Bearing cap 88-527-14 Cotter pin 88-239-85 3/4 NF Hex slotted nut 88-228-61 3/4 SAE Flat washer 80-017-00 Bearing 12-158-10 Wheel hub 80-103-00 Race 88-268-61 7/8 Flat washer 45-338-00...

  • Page 98: Transaxle Assembly, Rear

    Replacement Parts C0-425-48 TRANSAXLE ASSEMBLY, REAR Page 98 MC-425-13...
  • Page 99 Replacement Parts C0-425-48 Axle Assembly, Rear Item No. Part No. Description GT-71682 Bolt, M8 x 60 mm GT-3287563 Gear case cover GT-71259 Bearing see gear kits below Input shaft GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing see gear kits below...

  • Page 100: Brakes, Brake Lines

    Replacement Parts C0-425-48 BRAKES, BRAKE LINES Page 100 MC-425-13...
  • Page 101 Replacement Parts C0-425-48 Brake Lines Item No. Part No. Description 99-564-00 T-fitting 99-580-10 Brake hose 99-576-00 Brake hose clip 99-575-00 Coupler 71-110-00 Brake light switch 99-591-00 Brake light switch adaptor 99-559-00 T-fitting 99-604-66 Brake line 99-600-58 Brake line 99-605-74 Brake line...

  • Page 102: Brakes, Front Axle

    Replacement Parts C0-425-48 BRAKES, FRONT AXLE Front Brakes Item No. Part No. Description 88-069-82 99-588-00 Bleeder valve 99-588-01 Bleeder adaptor 41-350-30 Brake body assembly Steering Knuckle 32-240-41 Bushing (included in rebuild kit) 41-348-57 Spacer See rebuild kit Brake pad, Inner...

  • Page 103: Brakes, Rear Axle

    Replacement Parts C0-425-48 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-350-78 (see note) Complete caliper assembly (left) 41-350-79 (see note) Complete caliper assembly (right) 88-067-29 Bolt 41-350-91 Secondary Plate See rebuild kit Brake pad 41-348-57 Spacer (included in rebuild kit)

  • Page 104: Brake Pedal Assembly

    Replacement Parts C0-425-48 BRAKE PEDAL ASSEMBLY Page 104 MC-425-13...
  • Page 105 Replacement Parts C0-425-48 Brake Pedal Assembly Item No. Part No. Description 41-426-15 Complete assembly 88-108-61 3/8 SAE Flat washer 88-108-62 3/8 Split lock washer 88-101-13 3/8 NC x 1-1/4 Hex bolt, Grade 5 88-101-20 3/8 NC x 3 Hex bolt...

  • Page 106: Control System, Motor Speed Control

    Replacement Parts C0-425-48 CONTROL SYSTEM, MOTOR SPEED CONTROL Page 106 MC-425-13...
  • Page 107 Replacement Parts C0-425-48 Speed Control Panel Item No. Part No. Description 98-599-20 Grommet 88-838-06 #14 x 1/2 Pan head sheet metal screw 88-818-02 #8 x 1/4 Pan head sheet metal screw 88-818-02 #8 x 1/4 Pan head sheet metal screw...

  • Page 108: Control System, Instrument Panel

    Replacement Parts C0-425-48 CONTROL SYSTEM, INSTRUMENT PANEL Item No. Part No. Description 71-039-11 Light switch 74-009-49 Hour meter/Battery status meter 74-010-00 Smart view display 71-039-02 Forward and Reverse switch 71-120-10 Key switch 71-120-90 94-304-23 Dash panel 97-211-20 1/4NC Blind nut (dash mounting)

  • Page 109: Decals

    Replacement Parts C0-425-48 DECALS Item No. Part No. Description 94-384-32 DECAL, EMERGENCY POWER CUT 94-384-01 DECAL, NOT A MOTOR VEHICLE 94-309-00 DECAL, PARK BRAKE WARNING 94-384-61 DECAL, OPS, DASH 94-301-44 DECAL, ARMS/LEGS, 1 PASS 94-384-14 DECAL, LEAVING VEHICLE 94-301-41 DECAL, DOT 3 BRAKE FLUID...

  • Page 110: Frame And Body

    Replacement Parts C0-425-48 FRAME AND BODY FRAME AND BODY, SIDE EXTRACT BATTERY Item No. Part No. Description 02-425-37 Door (not painted) 02-425-29 Sliding pad 88-101-25 Screw 98-753-05 Rubber bump stop Page 110 MC-425-13...
  • Page 111 Replacement Parts C0-425-48 Frame and Body Item No. Part No. Description 00-425-30 Battery cover (not painted) 88-100-14 3/8 x 1-1/2 Hex bolt 88-108-62 3/8 Split lock washer 32-214-50 Bushing 00-425-16 Mounting bracket (not painted) 97-211-30 3/8 blind nut 96-240-00 1/2NC x 4 Hex bolt...

  • Page 112: Hitches

    Replacement Parts C0-425-48 HITCHES Mounting Hardware Item No. Part No. Description 97-811-00 1-7/8 inch Ball 97-821-00 2-inch Ball 88-140-14 1/2 NC x 1-1/2 Hex bolt 88-149-80 1/2 NC Hex nut 88-148-62 1/2 Split lock washer Page 112 MC-425-13...

  • Page 113: Lights

    Replacement Parts C0-425-48 LIGHTS Item No. Part No. Description 72-022-13 Headlight 72-022-07 Taillight 72-028-30 Turn signal, front 72-028-31 Grommet, Turn signal 71-900-41 Flasher 79-820-02 Fuse, 5A 79-820-04 Fuse, 10A 79-820-05 Fuse, 15A MC-425-13 * Not available at time of printing...

  • Page 114: Motor (Spec # Dv1-4003A)

    Replacement Parts C0-425-48 MOTOR (SPEC # DV1-4003A) Item No. Part No. Description 70-057-40 Motor Assembly 70-421-10 Front housing 70-400-10 Armature 70-209-40 Field assembly 85-403-00 Brush spring 70-173-00 Brush holder 70-170-10 Brush pair 70-417-00 Bearing retainer 80-212-00 Bearing 70-421-30 Rear housing...

  • Page 115: Motor Mount

    Replacement Parts C0-425-48 MOTOR MOUNT Item No. Part No. Description 88-067-22 Bolt,1/4 X 2” NC, Grade (no brake option) See Motor Motor 96-114-10 U-Bolt, 5/16” NF, Motor Support 70-456-10 Motor, Support Bracket 88-128-62 Lock washer, 7/16” 89-111-27 Bolt, 10-1.5 X 20mm Hex Head 88-088-62 Lock washer, 5/16”...

  • Page 116: Seats

    Replacement Parts C0-425-48 SEATS Seats Item No. Part No. Description 90-160-50 Seat assembly 90-160-60 Arm rest (both sides) 90-160-71 Spacer 88-080-13 Bolt 88-089-81 Lock nut 88-088-60 Flat washer Page 116 MC-425-13...

  • Page 117: Steering Gear

    Replacement Parts C0-425-48 STEERING GEAR Steering Gear, 18-308-21 Item No. Part No. Description 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assembly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft...

  • Page 118: Steering Linkage

    Replacement Parts C0-425-48 STEERING LINKAGE Page 118 MC-425-13...
  • Page 119 Replacement Parts C0-425-48 Steering Linkage Item No. Part No. Description 88-527-14 Cotter pin 88-159-85 1/2 NF Hex slotted nut 21-015-20 Pivot pin 86-501-98 Ball joint, left hand thread 87-074-00 Grease fitting 18-020-30 Steering link 32-200-00 Bushing 86-510-00 Ball joint clamp...

  • Page 120: Steering Column

    Replacement Parts C0-425-48 STEERING COLUMN SUSPENSION, FRONT Page 120 MC-425-13...
  • Page 121 Replacement Parts C0-425-48 Steering Column Item No. Part No. Description 18-414-32 Tilt steering column assembly 19-005-17 Steering wheel 88-279-82 7/8 NF Thin pattern hex nut 88-262-62 7/8 Split lock washer 18-108-00 Pitman arm 18-308-21 Steering gear 88-128-62 7/16 Split lock washer...

  • Page 122: Suspension, Rear

    Replacement Parts C0-425-48 SUSPENSION, REAR Page 122 MC-425-13...
  • Page 123 Replacement Parts C0-425-48 Rear Suspension Item No. Part No. Description 88-189-82 5/8 NC Thin pattern lock nut 88-188-61 5/8 SAE Flat washer 85-142-00 Spring 86-510-00 Ball joint clamp 86-521-98 Rod end (left) 86-521-99 Rod end (right) 88-180-15 5/8 NC x 1-3/4 Hex bolt...

  • Page 124: Throttle Pedal Assembly

    Replacement Parts C0-425-48 THROTTLE PEDAL ASSEMBLY Item No. Part No. Description 62-030-21 Complete pedal assembly 00-425-21 Mounting bracket 00-425-09 Accelerator pedal 86-503-98 Rod end, left hand thread 97-211-00 1/4 NF Hex nut, left hand thread 86-503-99 Rod end, right hand thread...

  • Page 125: Wheels And Tires

    Replacement Parts C0-425-48 WHEELS AND TIRES Item No. Part No. Description 13-739-10 4.80 x 8 LRC Tire and Wheel assembly 10-076-00 Tire, 4.80 x 8 LRC Tubeless 12-042-20 Wheel assembly 97-236-00 Wheel Nut 13-989-00 Valve stem, tubeless tire only 11-030-00...
  • Page 126 Notes: Replacement Parts C0-425-48 Page 126 MC-425-13...
  • Page 128 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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