Taylor-Dunn B0-150-00 Service And Replacement Parts Manual
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Taylor-Dunn B0-150-00 Service 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
WARNING
READ AND UNDERSTAND THE OPERATOR'S MANUAL
BEFORE OPERATING THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
E
Service and Replacement
Parts Manual
Model Numbers:
B0-150-00
MX-016-00
Ending Serial Number: See Introduction Chapter
MANUAL MB-150-03
B0-015-00
MX-016-00
Starting Serial Number: 203801

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Summary of Contents for Taylor-Dunn B0-150-00

  • Page 1 Service and Replacement Parts Manual MANUAL MB-150-03 Model Numbers: B0-150-00 MX-016-00 B0-015-00 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 10/25/2016 Revision E, 9/17/2018, 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 Drive Axle-D1 ...........37 Steering ............45 Brakes...............55 Drive 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 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 B0-015-00 and MX-016-00 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 B0-015-00 and MX-016-00 Page-12 MB-150-03...
  • 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

    Service/Maintenance Guidelines MB-150-00 and MX-016-00 VEHICLE MODIFICATIONS Taylor-Dunn vehicles are designed and manufactured in accordance with ANSI/ITSDF and OSHA regulations. Per ANSI/ITSDF and OHSA, modifications to the vehicle must be approved by the manufacturer. Listed below are the specific regulations: ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers...

  • 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 First 25 hours of Operation ........19 Every Week .............19 Every Month or 100 hours ........19 Every 6 Months or 500 hours ........19 Every Year or 1,000 hours) ........19 Every 2 Years or 2,000 hours ........19 WARNING...
  • Page 18 PM Schedule B0-015-00 and MX-016-00 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
  • Page 19 PM Schedule B0-016-00 and MX-016-00 First 25 hours of Operation Every 6 Months or 500 hours Re-torque wheel nuts. All monthly items plus the following: Inspect all hardware for tightness. Lubricate the vehicle. Adjust front wheel bearings. Inspect electrical connections for signs of overheating Tighten all electrical connections.
  • Page 20 Notes PM Schedule B0-015-00 and MX-016-00 Page 20 MB-150-03...
  • Page 21 Table of Contents Special Tool List Tool List ..............22 Troubleshooting Guide ........23...

  • Page 22: Tool List

    Tool List B0-150-00 and MX-016-00 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 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 Tool List B0-150-00 and MX-016-00 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 24 Notes Tool List B0-150-00 and MX-016-00 Page 24 MB-150-03...
  • Page 25 Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication B0-015-00 and MX-016-00 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 1: Front springs NLGI Grade 2 lithium multi-purpose grease 2: King pin NLGI Grade 2 lithium multi-purpose grease 3: Ball joint NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease 6: Rear springs...
  • Page 27 Lubrication B0-150-00 and MX-016-00 LUBRICATION DIAGRAM MB-150-03 Page 27...
  • Page 28 Notes Lubrication B0-015-00 and MX-016-00 Page 28 MB-150-03...
  • Page 29 Table of Contents Front Axle Disassemble.............30 Inspect Front Wheel Bearings ......31 Adjust Front Wheel Bearings ......31 Front Wheel Alignment ........32 Center the Steering ..........32 Front wheel alignment ..........32 Replace Front Wheel Bearings.......33 Replace Steering Knuckle ......33 Replace King Pin/Bushings ......34 Service Limits and Specifications ....35 King Pin Bushings ...........35 Toe In ...............35...

  • Page 30: Front Axle

    Front Axle B0-150-00 and MX-016-00 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 31: Inspect Front Wheel Bearings

    Front Axle B0-150-00 and MX-016-00 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 32: Front Wheel Alignment

    Front Axle B0-150-00 and MX-016-00 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. Caster and Camber is not adjustable.

  • Page 33: Front Axle

    Front Axle B0-150-00 and MX-016-00 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 34: Replace King Pin/Bushings

    Front Axle B0-150-00 and MX-016-00 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 35: Service Limits And Specifications

    Front Axle B0-150-00 and MX-016-00 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 0.878 ±0.001 Rod End Jam Nut 20-25 27.1-33.9...
  • Page 36 Notes Front Axle B0-150-00 and MX-016-00 Page 36 MB-150-03...
  • Page 37 Table of Contents Drive Axle-D1 Check Oil Level ..........38 Change Oil ............38 Drive Motor ............39 Remove ..............39 Install ...............39 Differential Case ..........40 Disassemble ............40 Assemble ..............42 Axle Shaft ............43 Remove ..............43 Install ...............43 Axle Bearings...........43 Remove/Install ............43 Hardware Torque ..........44 WARNING This section is one section of a complete service manual.

  • Page 38: Drive Axle-D1

    Drive Axle B0-015-00 and MX-016-00 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 39: Drive Axle-D1

    Drive Axle B0-015-00 and MX-016-00 DRIVE MOTOR 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 Note: In some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor.

  • Page 40: Differential Case

    Drive Axle B0-015-00 and MX-016-00 DIFFERENTIAL CASE Disassemble 1: Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2: Thoroughly clean the transmission assembly before disassembly. 3: Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.
  • Page 41 Drive Axle B0-015-00 and MX-016-00 12: Using a soft metal or hard wood dowel, drive 16: Remove the circlip from the input shaft. the intermediate shaft through the bearing just 17: Remove the input shaft from the housing. enough to allow clearance for an ID bearing 18: Press the bearings off of the input shaft.

  • Page 42: Assemble

    Drive Axle B0-015-00 and MX-016-00 Assemble Notes: When pressing bearings, do not press against or support the outer race as this will damage the bearing. All snap rings should fit tightly into their grooves. If a snap ring is loose, then it must be replaced. Do not hit any shaft or component with a hard metal hammer or punch. Pre-lube all bearings, seals and o-rings before assembly.

  • Page 43: Axle Shaft

    Drive Axle B0-015-00 and MX-016-00 AXLE SHAFT AXLE BEARINGS WARNING Note: The axle must be removed from the transmission for this procedure. Refer to Remove and Install Axle for information This section is one section of a complete service regarding removing the rear axle. manual.

  • Page 44: Hardware Torque

    Drive Axle B0-015-00 and MX-016-00 HARDWARE TORQUE Notes If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Motor terminals 7.5-9.1 10.2-12.4 Motor Mounting Bolts 8-10.5 Final Drive Gear Nuts 35-45 48-61 Differential Bearing Cap Bolts 35-45...
  • Page 45 Table of Contents Steering Inspect Ball Joints ...........46 Inspect Rod Ends ..........46 Adjust Steering Gear ........47 Front Wheel Alignment ........47 Replace Ball Joint..........48 Replace Rod End ..........48 Replace Steering Shaft ........49 Replace Steering Wheel ........50 Steering Gear ...........51 Disassemble ............51 Reassemble ............52 Exploded View of Steering Gear ......53 Hardware Torque ..........54...

  • Page 46: Inspect Ball Joints

    Steering B0-015-00 and MX-016-00 INSPECT BALL JOINTS INSPECT ROD ENDS 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 47: Adjust Steering Gear

    Steering B0-015-00 and MX-016-00 ADJUST 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. Note: In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure.

  • Page 48: Replace Ball Joint

    Steering B0-015-00 and MX-016-00 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. 2: Loosen the ball joint clamp on the steering sleeve.

  • Page 49: Replace Steering Shaft

    Steering B0-015-00 and MX-016-00 REPLACE 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 50: Replace Steering Wheel

    Steering B0-015-00 and MX-016-00 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. 1: If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch.

  • Page 51: Steering Gear

    Steering B0-015-00 and MX-016-00 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 52: Reassemble

    Steering B0-015-00 and MX-016-00 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. 16: Position the ball nut onto the worm shaft as shown in the illustration.

  • Page 53: Exploded View Of Steering Gear

    Steering B0-015-00 and MX-016-00 Exploded View of Steering Gear MB-150-03 Page 53...

  • Page 54: Hardware Torque

    Steering B0-015-00 and MX-016-00 HARDWARE TORQUE Notes 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 Page 54 MB-150-03...
  • Page 55 Table of Contents Brakes General Guidelines and Safety.......56 Front Disc Brake ..........57 Service Limits ............57 Inspection ..............57 Replace Pads ............57 Brake Adjustment ..........58 Service Brake ............58 Mechanical and Hydraulic Brakes ......58 Adjust the Service Brake Linkage ......58 Parking Brake, Mechanical Brakes ......58 Parking Brake, Hydraulic Brakes ......59 Rear Drum Brake, Inspect/Replace ....60 Service Limits ............60...

  • Page 56: General Guidelines And Safety

    B0-150-00 and MX-016-00 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 57: Front Disc Brake

    Brakes B0-150-00 and MX-016-00 FRONT DISC 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...

  • Page 58: Brake Adjustment

    Brakes B0-150-00 and MX-016-00 Adjust the Service Brake Linkage BRAKE ADJUSTMENT WARNING Do not use this procedure to adjust the brakes. This procedure should only be performed when replacing any of the mechanical brake linkages or cables or it is...

  • Page 59: Parking Brake, Hydraulic Brakes

    Brakes B0-150-00 and MX-016-00 Parking Brake, Hydraulic Brakes Note: Hydraulic brakes are optional. The service brake must be properly adjusted before attempting to adjust the parking brake. Adjust the Service Brakes Refer to information regarding adjusting the service brakes. 1: Release the park brake.

  • Page 60: Rear Drum Brake, Inspect/Replace

    Brakes B0-150-00 and MX-016-00 Replace REAR DRUM BRAKE, INSPECT/ 1: Release the park brake. REPLACE 2: Raise the rear wheels off of the ground and WARNING support with jack stands. 3: Remove the tire/wheel assembly. Refer to Tires section for information on removing...

  • Page 61: Rebuild Disc Brake Body

    Brakes B0-150-00 and MX-016-00 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 62: Bleed System

    Brakes B0-150-00 and MX-016-00 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 63: Master Cylinder

    Brakes B0-150-00 and MX-016-00 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. Add Fluid 1: Thoroughly clean the area around the master cylinder cap and remove the cap.

  • Page 64: Service Limits

    Brakes B0-150-00 and MX-016-00 HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc pad lining minimum thickness 00625 inch 1.58 mm Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch...
  • Page 65 Table of Contents Drive Motor Motor Removal and Installation .....66 Disassemble.............66 Assemble............67 Inspection ............68 Brushes ..............68 Armature ..............68 Bearings ..............69 Commutator .............69 Repair ...............70 Brushes ..............70 Commutator .............70 Service Limits ..........71 WARNING This section is one section of a complete service manual.

  • Page 66: Drive Motor

    Drive Motor B0-015-00 and MX-016-00 MOTOR REMOVAL AND INSTALLATION See the Transmission section for information on removing or installing the motor. 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.

  • Page 67: Drive Motor

    Drive Motor B0-0015-00 and MX-016-00 ASSEMBLE 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: Press new bearings into the motor housings and install the circlips.

  • Page 68: Inspection

    Drive Motor B0-015-00 and MX-016-00 INSPECTION Armature WARNING 1: Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted This section is one section of a complete service armature.

  • Page 69: Bearings

    Drive Motor B0-0015-00 and MX-016-00 Bearings Pressing the armature out of the bearings is likely to damage the bearings. Once removed the bearings should be replaced. Commutator 1: Measure the outside diameter of the commutator. • If the commutator is less than the minimum diameter specified in section Service Limits, then the motor must be replaced.

  • Page 70: Repair

    Drive Motor B0-015-00 and MX-016-00 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. Brushes Note: It is recommended that all four brushes be replaced as a set.

  • Page 71: Service Limits

    Drive Motor B0-0015-00 and MX-016-00 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. Commutator Brush Length Resistance Undercut Depth Motor Specification Diameter (min) (min)
  • Page 72 Notes Drive Motor B0-015-00 and MX-016-00 Page 72 MB-150-03...
  • Page 73 Table of Contents Tires & Wheels Inflation .............74 Air pressure .............74 Tread Wear ............75 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 B0-015-00 and MX-016-00 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 75: Tread Wear

    Tires & Wheels B0-0105-00 and MX-016-00 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 warnings and instructions that are located in the in this conditions may suddenly fail at Service Guidelines chapter.

  • Page 76: Changing Tire/Wheel Assembly

    Tires & Wheels B0-015-00 and MX-016-00 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 B0-0105-00 and MX-016-00 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MB-150-03 Page 77...
  • Page 78 Notes Tires & Wheels B0-015-00 and MX-016-00 Page 78 MB-150-03...
  • Page 79 Table of Contents Batteries General Guidelines and Safety.......80 Cleaning ............81 Charging ............81 Watering ............81 Testing ..............82 Specific Gravity ............82 Storing ..............82 Storage ..............82 Returning to Service ..........82 Remove/Install ..........83 Industrial Battery or Lift Out Battery Pack ....83 Side Extract Battery ..........83 Hardware Torque ..........84 Individual Batteries ..........84 WARNING...

  • Page 80: General Guidelines And Safety

    Batteries B0-015-00 and MX-016-00 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 81: Cleaning

    Batteries B0-015-00 and MX-016-00 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 82: Testing

    Batteries B0-015-00 and MX-016-00 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 83: Remove/Install

    Batteries B0-015-00 and MX-016-00 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 84: Hardware Torque

    Batteries B0-015-00 and MX-016-00 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 Battery terminal, Trojan bolt 95-105 11-12...
  • 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 Vehicle Documentation CD provided with the vehicle. The diagram #’s for this vehicle are: SCH-00085 (std) or SCH-00084 (with DC converter). 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.
  • Page 87 Table of Contents Motor Controller Remove/Install ..........88 Inspect ..............88 Troubleshooting ..........88 Repair/Adjustments.........89 Adjustments .............89 Hardware Torque ..........90 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 88: Motor Controller

    1: Thoroughly clean the controller base and vehicle documentation CD. A replacement CD or hard mounting plate. copy can be purchased from your authorized Taylor-Dunn 2: Install the controller to the mounting plate. distributor or can be downloaded from the Taylor-Dunn 3: Attach the wires to the studs and, using a backup web site.

  • Page 89: Motor Controller

    Motor Controller B0-015-00 and MX-016-00 REPAIR/ADJUSTMENTS 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 controller.

  • Page 90: Hardware Torque

    Motor Controller B0-015-00 and MX-016-00 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal hardware 8.13 Adjustment plugs 0.90 Page 90 B0-150-03...
  • Page 91 Table of Contents Charger Remove/Install ..........92 Troubleshooting ..........92 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 92 The manual part number is M7-001-69 and was provided on the original vehicle CD. A hard copy can be purchased WARNING from your authorized Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. HIGH VOLTAGE. Disconnect the batteries and make sure that the AC power cord has been unplugged before disconnecting any wires or removing the cover of the charger.
  • Page 93 Table of Contents Hardware Information Torque Guidelines for Standard hardware ..94 Hardware Identification ..........94 Hex Nuts ..............95 Hex Lock Nuts (stover) ..........95 Other Nuts ...............95 Generic Torque Values ..........96 Replacing Hardware ........98 WARNING This section is one section of a complete service manual.

  • Page 94: Torque Guidelines For Standard Hardware

    Hardware B0-015-00 and MX-016-00 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. The grade of a metric hex head bolt or screw is cast directly on the head. SAE Grade 2 Below is an example of a 10.9.

  • Page 95: 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-150-03 Page 95...

  • Page 96: Generic Torque Values

    Hardware B0-015-00 and MX-016-00 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 97 Hardware B0-015-00 and MX-016-00 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 98: Replacing Hardware

    Hardware B0-015-00 and MX-016-00 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 99 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....100 Taylor-Dunn Web Site Information ....100 Axle Assembly, Front ........102 Axle Shaft, Rear ..........103 Transaxle Assembly ........104 Battery ..............106 Brakes, Brake Lines ........107 Brakes, Rear Axle ..........108 Charger, Signet ..........109 Charger, Summit ..........110...

  • Page 100: 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 101: Replacement Parts

    Replacement Parts B0-015-00 and MX-016-00 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MB-150-03 * Not available at time of printing Page 101...

  • Page 102: Axle Assembly, Front

    Replacement Parts B0-015-00 and MX-016-00 AXLE ASSEMBLY, FRONT Item No. Part No. Description 14-240-06 Left Steer Knuckle, no brake 21-009-10 King Pin 01-240-74 Axle Beam . Includes #19 and #20 (no brakes) 14-240-05 Right Steer Knuckle, no brake 87-074-00 Grease Fitting 80-309-10 Thrust Bearing 45-338-00...

  • Page 103: Axle Shaft, Rear

    Replacement Parts B0-015-00 and MX-016-00 AXLE SHAFT, REAR Item No. Part No. Description 41-171-10 Axle, Right (no studs) 41-170-10 Axle, Left (no studs) 66-610-28 Studs 66-610-79 Bolt 45-303-00 Seal, Oil 32-509-10 Retainer 80-505-10 Bearing and Race assembly Part of backing plate 45-303-10 Dust seal 66-610-80...

  • Page 104: Transaxle Assembly

    Replacement Parts B0-015-00 and MX-016-00 TRANSAXLE ASSEMBLY Page 104 MB-150-03...
  • Page 105 Replacement Parts B0-015-00 and MX-016-00 Transaxle Assembly Item No. Part No. Description 4C-150-00 Complete Transmission Assembly Including Mechanical Brakes (Dana spec 012AJ310-1) 4C-150-10 Complete Transmission Assembly Including Hydraulic Brakes (Dana spec 012AJ309-1) 41-280-10 Housing 80-480-10 Inner Input Shaft Bearing 31-265-00 Gear set 80-480-15 Outer Input Shaft Bearing...

  • Page 106: Battery

    Replacement Parts B0-015-00 and MX-016-00 BATTERY Item No. Part No. Description 50-243-10 Battery Hold Down Rod 50-250-00 Bat-Lok 88-088-66 Flat Washer 88-069-81 75-235-08 Battery Jumper 88-081-12 Bolt 88-089-80 77-042-00 Battery, T 105 77-047-00 T 145, 244AH Battery 77-048-00 J250, 250AH Battery Page 106 MB-150-03...

  • Page 107: Brakes, Brake Lines

    Replacement Parts B0-015-00 and MX-016-00 BRAKES, BRAKE LINES Illustration is not available Brake Lines Part No. Description REAR BRAKES 50-009-00 PUSH ROD, MASTER CYLINDER 96-762-00 3/8 IN.CLEVIS CAST 96-772-00 PIN,CLEVIS,3/8 X 1 1/8 IN. 99-510-02 MASTER CYLINDER 99-564-00 UNION T, 3/16 INV FLARE 99-566-00 BANJO FITTING, MASTER CYLINDER 99-571-00...

  • Page 108: Brakes, Rear Axle

    Replacement Parts B0-015-00 and MX-016-00 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-347-15 Brake lever 41-347-00 Backing plate 41-347-36 Spider, Hydraulic 0 or 2 41-347-25 Spider, Mechanical 0 or 2 85-411-15 Spring 41-635-00 Brake shoe (2, one wheel) 85-411-10 Spring 41-347-30...

  • Page 109: Charger, Signet

    Replacement Parts B0-015-00 and MX-016-00 CHARGER, SIGNET Note: This charger no longer installed on new vehicles starting January 2017 Note: The harness connectors and AC plug are not included with the charger. Model HBS Charger PART # DESCRIPTION 79-303-41 36 volt (WET, FLA) 79-309-42 36 volt Sealed Batteries (GEL, SLA, AGM) Note: There are no user serviceable components inside the charger...

  • Page 110: Charger, Summit

    Replacement Parts B0-015-00 and MX-016-00 CHARGER, SUMMIT Note: There are no user serviceable components inside the charger Part No. Description 79-306-37 Charger, 36 volt Built In (WET batteries only) 0 or 1 79-309-46 Charger, 48 volt Built In (WET batteries ionly) 0 or 1 79-580-03 Junction box, Built In charger AC cord...

  • Page 111: Charger, Lestronic

    Replacement Parts B0-015-00 and MX-016-00 CHARGER, LESTRONIC Note: This charger no longer installed on new vehicles starting January 2017 Item No. Part No. Description 79-303-15 Complete Charger Assembly 79-805-67 Timer Assembly 79-808-00 Timer Relay (not shown) 79-902-00 Capacitor 79-749-13 Diode Assembly 79-644-31 Transformer AC cord...

  • Page 112: Control System, Motor Speed Control

    Replacement Parts B0-015-00 and MX-016-00 CONTROL SYSTEM, MOTOR SPEED CONTROL Item No. Part No. Description 88-838-06 #14 x 1/2 Pan Head Screw Type D Thread 62-204-00 PMC Speed control 72-501-39 Solenoid (forward or reverse) 61-838-41 Bus Bar 88-088-62 5/16 Split Lock washer 88-099-91 5/16-NF Thin Pattern Nut 88-048-62...

  • Page 113: Control System, Instrument Panel

    Replacement Parts B0-015-00 and MX-016-00 CONTROL SYSTEM, INSTRUMENT PANEL Item No. Part No. Description 95-913-00 Hole Plug 71-100-00 Toggle Switch Option 71-039-11 Rocker Switch (ON-OFF) 88-817-08 Screw 74-000-00 Hour Meter 01-200-75 Dash Housing 74-009-00 Battery Status Meter 94-304-10 Dash Plate 71-039-02 F&R Switch 71-120-00...

  • Page 114: Decals

    Replacement Parts B0-015-00 and MX-016-00 DECALS Decals Item No. Part No. Description 94-384-17 Do Not Spray Wash 94-313-00 Battery Warning 94-319-00 Battery Disconnect 94-301-41 Brake Fluid 94-301-42 Arms and Legs Inside 94-313-20 General Safety 94-384-48 Pinch Point (only when hitch is installed) 94-384-62 Operator Presence Switch 94-309-00...

  • Page 115: Electrical, Miscellaneous

    Replacement Parts B0-015-00 and MX-016-00 ELECTRICAL, MISCELLANEOUS 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...

  • Page 116: Frame And Body, Cab

    Replacement Parts B0-015-00 and MX-016-00 FRAME AND BODY, CAB Page 116 MB-150-03...
  • Page 117 Replacement Parts B0-015-00 and MX-016-00 Frame and Body, Cab Item No. Part No. Description 90-852-30 Front Windshield 98-310-10 Windshield Gasket (by the foot) 74-050-00 Windshield Wiper Motor 74-051-00 Windshield Wiper Arm 74-052-00 Windshield Wiper Blade 91-008-00 Fiberglass Cab, B 1-50 91-008-20 Fiberglass Cab, MX 1600 98-310-10...

  • Page 118: Hitches

    Replacement Parts B0-015-00 and MX-016-00 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 1/2NC x 1-1/2 Hex bolt 88-149-80 1/2NC Hex nut 88-148-62 1/2 Split lock washer Page 118 MB-150-03...
  • Page 119 Replacement Parts B0-015-00 and MX-016-00 MB-150-03 * Not available at time of printing Page 119...

  • Page 120: Linkage, Throttle And Brake

    Replacement Parts B0-015-00 and MX-016-00 LINKAGE, THROTTLE AND BRAKE Page 120 MB-150-03...
  • Page 121 Replacement Parts B0-015-00 and MX-016-00 Throttle and Brake Linkage Item No. Part No. Description 98-200-00 Brake Pedal Pad 01-432-98 Brake Pedal 88-089-81 88-080-11 Bolt 00-200-45 Brake Pedal Arm 80-410-20 Bushing 88-109-81 88-100-09 Bolt 01-200-49 Brake Cable Mounting Bracket 88-517-11 Cotter Pin 96-818-10 Brake Cable 85-250-00...

  • Page 122: Lights

    Replacement Parts B0-015-00 and MX-016-00 LIGHTS Lights Item No. Part No. Description 72-005-00 Headlight 72-022-00 Tail light 1 or 2 72-023-59 Strobe light 0 or 1 72-051-00 Front turn signal light 0 or 2 71-141-22 Turn signal switch (includes flasher) 0 or 1 98-330-50 Insulator for turn signal switch...

  • Page 123: Motor

    Replacement Parts B0-015-00 and MX-016-00 MOTOR Motor Item No. Part No. Description 70-049-05 Motor assembly Field assembly Armature 70-180-00 Brush holder 80-412-20 Brush spring 70-109-00 Brush pair 70-417-00 Bearing retainer 80-212-00 Bearing, rear End cap Brush cover MB-150-03 * Not available at time of printing Page 123...

  • Page 124: Seats And Deck, B-150

    Replacement Parts B0-015-00 and MX-016-00 SEATS AND DECK, B-150 Item No. Part No. Description 90-147-00 Seat Cushion 90-179-00 Seat Backrest 94-035-01 Moulding per foot 90-444-50 Deck board 94-201-00 T/D Emblem 88-567-91 Emblem Mounting Clips Page 124 MB-150-03...

  • Page 125: Seats And Deck, Mx-1600

    Replacement Parts B0-015-00 and MX-016-00 SEATS AND DECK, MX-1600 MB-150-03 * Not available at time of printing Page 125...
  • Page 126 Replacement Parts B0-015-00 and MX-016-00 Seats and Deck, MX-1600 Item No. Part No. Description See Lights Head Light Assembly See B 1-50 T/D Emblem See B 1-50 Emblem Mounting Clips See B 1-50 Cowl Moulding 8’ See B 1-50 Seat Cushion See B 1-50 Seat Backrest 90-443-10...

  • Page 127: Stake Sides

    Replacement Parts B0-015-00 and MX-016-00 STAKE SIDES Stake Sides Item No. Part No. Description 90-542-20 Side Gate 90-542-22 End Gate 90-542-20 Side Gate 90-540-00 Gate Hook 90-540-00 Gate Hook 88-065-13 Bolt 88-069-81 90-543-00 Mounting Channel MB-150-03 * Not available at time of printing Page 127...

  • Page 128: Steering Gear

    Replacement Parts B0-015-00 and MX-016-00 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 18-308-81 Lock washer 18-308-79...

  • Page 129: Steering Linkage

    Replacement Parts B0-015-00 and MX-016-00 STEERING LINKAGE Item No. Part No. Description 86-518-01 Rod end (LH) 86-510-00 Ball Joint Clamp 50-002-03 Drag Link 88-119-81 3/8-NF Hex Locknut 88-159-85 1/2-NF Hex Castle Nut 86-501-98 Ball Joint (left thread) 18-041-05 Tie Rod Sleeve 86-501-99 Ball Joint (right thread) 86-518-00...

  • Page 130: Steering Column

    Replacement Parts B0-015-00 and MX-016-00 STEERING COLUMN Steering Column Item No. Part No. Description 88-199-82 5/8-NF Hex Jam Nut 19-011-20 Steering Wheel 88-081-14 Bolt, Plated (grade 8) 88-089-84 Nut, Plated (grade 8) 80-400-10 Bushing 20-031-64 Steering shaft (includes #3, #4) 19-011-25 Steering Wheel Cover 88-128-62...

  • Page 131: Suspension, Front

    Replacement Parts B0-015-00 and MX-016-00 SUSPENSION, FRONT Front Suspension Item No. Part No. Description 87-074-00 Grease Fitting 96-248-01 Spring Eye Bolt (includes #1) 32-213-00 Spring Eye Bushing 88-169-82 9/16-NF Lock nut, Grade C 85-506-05 Leaf Spring (includes #3) 96-118-00 1/2-NC x 1.87 x 6.5 U-bolt 96-123-00 3/8-NC x 2.06 x 4 U-bolt 96-123-02...

  • Page 132: Suspension, Rear

    Replacement Parts B0-015-00 and MX-016-00 SUSPENSION, REAR Item No. Part No. Description 88-140-17 Bolt 85-506-10 Leaf Spring (includes #7) 96-118-00 U-bolt 88-149-81 96-248-01 Spring Bolt 01-200-62 Spring Support 32-213-00 Spring Eye Bushing 88-169-82 Page 132 MB-150-03...

  • Page 133: Windshield Wiper

    Replacement Parts B0-015-00 and MX-016-00 WINDSHIELD WIPER Item No. Part No. Description 74-050-00 Wiper motor 74-051-01 Wiper arm 74-052-01 Wiper blade 75-114-20 Harness WHEELS AND TIRES Item No. Part No. Description 10-083-00 Tire, 5.70 x 8 LR C Tubeless 10-093-00 Tire, 18 x 8.50 x 8 LR B, Tubeless 11-040-00 Tube, 5.70 x 8...
  • Page 134 Notes: Replacement Parts B0-015-00 and MX-016-00 Page 134 MB-150-03...
  • Page 135 WARNING Operating, servicing and maintaining a passenger vehicle or off- highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 136 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...

This manual is also suitable for:

Mx-016-00

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