Taylor-Dunn TT-316-36 Service And Replacement Parts Manual
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Taylor-Dunn TT-316-36 Service And Replacement Parts Manual

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See also: Operation, T Roubleshooting and Replacement Parts Manual
Service and Replacement
Parts Manual
MANUAL MT-316-06
Model Numbers:
TT-316-36
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: 200900
Ending Serial Number: See Introduction Chapter
F

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Summary of Contents for Taylor-Dunn TT-316-36

  • Page 1 Service and Replacement Parts Manual MANUAL MT-316-06 Model Numbers: TT-316-36 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 2/11/2016 Revision F, 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 Special Tool List ..........17 Lubrication & Preventative Maintenance ......21 Front Axle ............27 Transaxle-GT ............31 Transaxle-SD ............41 Steering ............49 Brakes...............55 Motor ..............67 Tires &...
  • Page 7 Table of Contents Introduction About this manual ...........8 Who Should Read This Manual ......8 Replacement Parts ..........8 How To Use This Manual ........8 Conventions ............9 Signal Words and Their Definitions: ......9 Responsibilities ............10 How to Identify Your Vehicle ......11 Web Site Registration ........11 WARNING This section is one section of a complete service manual.

  • Page 8: Introduction

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

  • Page 9: Introduction

    Introduction TT-316-36 Conventions Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be used elsewhere in the text of this document without being a signal word.

  • Page 10: Responsibilities

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

  • Page 11: How To Identify Your Vehicle

    WEB SITE REGISTRATION Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor- Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside of the Taylor-Dunn corporation.
  • Page 12 Notes Introduction TT-316-36 Page-12 MT-316-06...
  • Page 13 Table of Contents Service/Maintenance Guidelines READ ME FIRST-Maintenance Guidelines and General instructions .........14 Vehicle Modifications ........15 Using Non-OEM Replacement Components: ..15...
  • Page 14 BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Service/Maintenance Guidelines

    Due to the unknown properties of non-Taylor-Dunn tested components or from components not originally equipped on the ANSI/ITSDF 56.9 – 2007 Safety Standard for vehicle, we cannot approve their use in a Taylor-Dunn vehicle. Operator Controlled Industrial Tow Tractors: Paragraph 6.2.14: Modifications and additions which affect capacity and safe tow tractor operation shall not be performed without manufacture’s...
  • Page 16 Notes Service/Maintenance Guidelines TT-316-36 Page 16 MT-316-06...
  • Page 17 Table of Contents Special Tool List Controller Programming: .........18 Troubleshooting Guide ........20...
  • Page 18 Tool List TT-316-36 The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. Controller Programming: Sevcon: 62-027-63 “PCpaK Cable lead and application.” Curtis AC: 62-027-66 “1314 PC Programming 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness Station”...

  • Page 19: Special Tool List

    Tool List TT-316-36 41-350-13: Disc Brake Boot Installation Tool 70-440-55: Pin Removing Tool Assists in installing the rubber boot onto the Removes pin from Amp circular harness 96-500-48: GT Drive Oil Fill Plug Tool disc brake piston. connectors. Used to remove the oil fill plug on GT drives.
  • Page 20 Tool List TT-316-36 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 21 Table of Contents Lubrication & Preventative Maintenance Lubrication and Fluids Chart ......22 Hazardous Waste Disposal ......22 Lubrication Diagram ........23 Daily Visual Inspection ........24 Pre-Operation Inspection ........24 Maintenance Schedule ........24 Maintenance Guidelines for Severe Duty Applications ....PM Checklist ............26...

  • Page 22: Lubrication And Fluids Chart

    Lubrication & PM TT-316-36 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle/Steering: 1: Fork Pivot NLGI Grade 2 lithium multi-purpose grease 3: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Fork Collar Bearings NLGI Grade 2 lithium multi-purpose grease...

  • Page 23: Lubrication & Preventative Maintenance

    Lubrication & PM TT-316-36 LUBRICATION DIAGRAM SD Transaxle MT-316-06 Page 23...

  • Page 24: Daily Visual Inspection

    Lubrication & PM TT-316-36 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 Lubrication & PM TT-316-36 First 25 hours of Operation Every 3 Months or 500 hours Re-torque wheel nuts. All monthly items plus the following: Inspect all hardware for tightness. Inspect and tighten all hardware. Adjust front wheel bearings. Test batteries.

  • Page 26: Pm Checklist

    Clean and repack front wheel bearings Year Clean and repack fork collar bearings Inspect brakes for wear Notes (1) and (2), Refer to “Maintenance Guidelines for Severe Duty” in the vehicles service manual Form PM-0016 TT-316-36, Revision A 2/10/2016 Page 26 MT-316-06...
  • Page 27 Table of Contents Front Axle Inspect Front Wheel Bearings ......28 Adjust Front Wheel Bearings ......28 Replace Front Wheel Bearings.......29 Front Axle Removal and Installation .....29 Removal ..............29 Installation ...............29 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 28 Front Axle TT-316-36 INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 29: Front Axle

    Front Axle TT-316-36 FRONT AXLE REMOVAL AND REPLACE FRONT WHEEL INSTALLATION 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. Before starting any procedure, read all...
  • Page 30 Notes Front Axle TT-316-36 Page 30 MT-316-06...
  • Page 31 Table of Contents Transaxle-GT Check Oil Level ..........32 Change Oil ............32 Transaxle Assembly ........33 Remove ..............33 Install ...............33 WARNING Axle Shaft ............34 Remove ..............34 Install ...............34 Rear Hub, Rotor & Bearings ......35 This section is one section of a complete service Motor, Remove ..........35 manual.

  • Page 32: Check Oil Level

    Drive Axle-GT TT-316-36 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 33: Transaxle-Gt

    Drive Axle-GT TT-316-36 TRANSAXLE ASSEMBLY WARNING This section is one section of a complete service Always use a lifting strap, hoist, and jack stands, of manual. Before starting any procedure, read all adequate capacity to lift and support the vehicle.

  • Page 34: Axle Shaft

    Drive Axle-GT TT-316-36 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 35: Rear Hub, Rotor & Bearings

    Drive Axle-GT TT-316-36 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 36: Primary Gear Case

    Drive Axle-GT TT-316-36 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 37: Secondary Gear Case

    Drive Axle-GT TT-316-36 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 38 Drive Axle-GT TT-316-36 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 39: Pinion Bearing Preload

    Drive Axle-GT TT-316-36 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 40: Hardware Torque

    Drive Axle-GT TT-316-36 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 41 Table of Contents Transaxle-SD WARNING Check Oil Level ..........42 Change Oil ............42 This section is one section of a complete Transaxle Assembly ........43 service manual. Before starting any procedure, read all warnings and Remove ..............43 Install ...............43 instructions that are located in the Service Axle Shaft ............44 Guidelines chapter.

  • Page 42: Transaxle-Sd

    Transaxle TT-316-36 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 43: Transaxle-Sd

    Transaxle TT-316-36 TRANSAXLE ASSEMBLY WARNING This section is one section of a complete service Always use a lifting strap, hoist, and jack stands, of manual. Before starting any procedure, read all adequate capacity to lift and support the vehicle. warnings and instructions that are located in the Failure to use lifting and support devices of rated load Service Guidelines chapter.

  • Page 44: Axle Shaft

    Transaxle TT-316-36 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 45: Rear Hub, Rotor & Bearings

    Transaxle TT-316-36 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications may require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and This section is one section of a complete service Installing the Drive Assembly for information manual.

  • Page 46: Primary Reduction Gear Case

    Transaxle TT-316-36 PRIMARY REDUCTION 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.
  • Page 47 Transaxle TT-316-36 MT-316-06 Page 47...

  • Page 48: 3Rd Member

    Transaxle TT-316-36 3RD MEMBER 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.
  • Page 49 Table of Contents Steering Adjust Reduction Box Chain Tension: ..50 Center the Steering Wheel ......50 Front End Alignment ........50 Replace the Front Fork ........51 Steering Reduction Box ........53 Disassemble ............53 Pre-Assemble ............53 Assemble ..............53 Hardware Torque ..........54 WARNING This section is one section of a complete service manual.

  • Page 50: Adjust Reduction Box Chain Tension

    Steering TT-316-36 ADJUST REDUCTION BOX CHAIN TENSION: 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: Loosen the two lock bolts and the adjuster bolt.

  • Page 51: Steering

    Steering TT-316-36 REPLACE THE FRONT FORK 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: Remove the steering reduction box assembly 2: Lift the front of the vehicle and support with jack stands.
  • Page 52 Steering TT-316-36 Page 52 MT-316-06...

  • Page 53: Steering Reduction Box

    Steering TT-316-36 STEERING REDUCTION BOX WARNING Refer to illustrations on previous page Disassemble This section is one section of a complete service 1: Remove the steering wheel. manual. Before starting any procedure, read all warnings and instructions that are located in the 2: Remove the universal joint covers.

  • Page 54: Hardware Torque

    Steering TT-316-36 10: Insert the adjuster screw bracket into the slots on the front of the adjustor brackets. 11: Install the upper adjuster bracket/bearing assembly. 12: Place the adjustor lock brackets onto the side of the adjustor brackets and place the 2 housing side covers into the slots in the lower housing plate.
  • Page 55 Table of Contents Brakes General Guidelines and Safety.......56 Front Brake ............57 Service Limits ............57 Inspection ..............57 Replace Pads ............57 Rear Brake............58 Service Limits ............58 Inspection ..............58 Replace Pads ............58 Rebuild Disc Brake Body ........59 Replace the Wheel Cylinder ......60 Front Disc Body Assembly ........60 Rear Disc Brake Body Assembly ......60 Bleed System ...........61 Flush System ...........61...

  • Page 56: General Guidelines And Safety

    TT-316-36 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: Brakes

    Brakes TT-316-36 FRONT BRAKE WARNING WARNING Always use brake fluid from a new sealed container. This section is one section of a complete service Never reuse any brake fluid that has been removed manual. Before starting any procedure, read all from the brake system.

  • Page 58: Rear Brake

    Brakes TT-316-36 REAR BRAKE WARNING WARNING Always use brake fluid from a new sealed container. This section is one section of a complete service manual. Before starting any procedure, read all Never reuse any brake fluid that has been removed from the brake system.

  • Page 59: Rebuild Disc Brake Body

    Brakes TT-316-36 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 60: Replace The Wheel Cylinder

    Brakes TT-316-36 REPLACE THE WHEEL 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. Front Disc Body Assembly 1: Raise the front wheel off of the ground and support with jack stands.

  • Page 61: Bleed System

    Brakes TT-316-36 FLUSH SYSTEM BLEED SYSTEM 1: Raise the rear wheels off of the ground and WARNING support with jack stands. 2: Raise the front wheel off of the ground and This section is one section of a complete service support with jack stands.

  • Page 62: Master Cylinder

    Brakes TT-316-36 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 63: Parking Brake, Hand Brake

    Brakes TT-316-36 PARKING BRAKE, HAND BRAKE WARNING The brake pads and rotor should be inspected anytime the park brake requires adjustment. This section is one section of a complete service Service Limits manual. Before starting any procedure, read all Refer to table at the end of this chapter.

  • Page 64: Adjust

    Brakes TT-316-36 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. Replace Rotor 1: Remove the brake assembly from the motor.

  • Page 65: Troubleshooting

    Brakes TT-316-36 Troubleshooting 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. Not Releasing: • Voltage at brake too low • Air gap too large •...

  • Page 66: Service Limits

    Brakes TT-316-36 SERVICE LIMITS HARDWARE TORQUE Description Inches Millimetres Description Foot Pounds Newton Meters Disc brake Pad, minimum lining 00625 1.58 Brake Body Bolts 14.9 Front rotor, minimum thickness 0.200 5.08 Rear rotor, minimum thickness 0.200 5.08 Rotor run out (front/Rear) 0.005...
  • Page 67 Table of Contents Motor Remove/Install ..........68 Disassemble.............68 Inspect ..............69 Brushes ..............69 Bearing ..............69 Commutator .............69 Armature Windings ..........69 Field Windings ............70 Repair ...............71 Optional Motor Brake ........72 Remove and Disassemble ........72 Assemble and Install ..........72 Service Limits ..........72 WARNING This section is one section of a complete service manual.

  • Page 68: Remove/Install

    Motor SEM TT-316-36 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 69: Motor

    Motor SEM TT-316-36 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 70: Field Windings

    Motor SEM TT-316-36 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 71: Repair

    Motor SEM TT-316-36 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 72: Optional Motor Brake

    Motor SEM TT-316-36 OPTIONAL MOTOR BRAKE Note: Although disassembly of the brake is outlined, individual brake components are not available. If any one brake component is faulty then the brake is replaced as an assembly. Remove and Disassemble 1: Disconnect the harness from the brake coil.
  • Page 73 Table of Contents Tires & Wheels Inflation, Pneumatic Tires .......74 Air pressure .............74 Inflation, Soft Solid Tires ........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 TT-316-36 INFLATION, PNEUMATIC TIRES 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: Tires & Wheels

    Tires & Wheels TT-316-36 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 76: Changing Tire/Wheel Assembly

    Tires & Wheels TT-316-36 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 TT-316-36 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MT-316-06 Page 77...
  • Page 78 Notes Tires & Wheels TT-316-36 Page 78 MT-316-06...
  • 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 TT-316-36 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: Batteries

    Batteries TT-316-36 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 82: Testing

    Batteries TT-316-36 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 TT-316-36 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: Hardware Torque

    Batteries TT-316-36 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 85 Table of Contents Suspension Replace the Rear Springs .......86 Replace the Front Springs ......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 Suspension TT-316-36 REPLACE THE REAR SPRINGS 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. If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set.

  • Page 87: Suspension

    Table of Contents Wire Diagram Diagram Part Numbers........88 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 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 #’s for this vehicle are: SCH-00041 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 88...

  • Page 89: Wire Diagram

    Table of Contents Hardware Information Torque Guidelines for Standard hardware ..90 Hardware Identification ..........90 Hex Nuts ..............91 Hex Lock Nuts (stover) ..........91 Other Nuts ...............91 Generic Torque Values ..........92 Replacing Hardware ........94 WARNING This section is one section of a complete service manual.

  • Page 90: Torque Guidelines For Standard Hardware

    Hardware TT-316-36 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 91: 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 MT-316-06 Page 91...

  • Page 92: Generic Torque Values

    Hardware TT-316-36 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 93 Hardware TT-316-36 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 94: Replacing Hardware

    Hardware TT-316-36 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 95 Table of Contents Charger-Built In Remove/Install ..........96 Troubleshooting ..........96 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 96 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 97: Charger-Built In

    Table of Contents Illustrated Parts Ordering Parts for your Vehicle ......98 Taylor-Dunn Web site Information .......98 Axle, Front ..............100 Axle, Rear ...............100 Brake, Front ............102 Brakes, Rear............104 Brake Lines ............106 Brake, Parking ............108 Charger, Signet ............109 Charger, Lestronic II Portable ......110 Charger, Industrial XPS 18-260 ......110...

  • Page 98: Illustrated Parts

    Any special order options will have a ‘K’ letter prefix in the option number. The vehicle option list is also available on the Taylor-Dunn web site. The serial number of the vehicle is required to obtain the option list.

  • Page 99: Illustrated Parts

    ILLUSTRATED PARTS Model TT-316-36 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: My local Parts Dealer: Notes Page-99 MT-316-03...

  • Page 100: Axle, Front

    ILLUSTRATED PARTS Model TT-316-36 AXLE, FRONT AXLE, REAR Page-100 MT-316-03...
  • Page 101 ILLUSTRATED PARTS Model TT-316-36 Front Axle Item # Part # Description 97-230-10 1-14NF Flex Lock Nut 88-308-61 Washer 80-011-10 Bearing 80-102-00 Race 80-102-00 Race 80-011-10 Bearing 45-307-00 Seal 14-090-16 Fork (includes springs) 85-142-00 Spring 15-003-02 Axle 45-338-00 Seal 80-017-00 Bearing...

  • Page 102: Brake, Front

    ILLUSTRATED PARTS Model TT-316-36 BRAKE, FRONT Page-102 MT-316-03...
  • Page 103 ILLUSTRATED PARTS Model TT-316-36 Front Brakes Item # Part # Description 88-067-29 1/4 NC X 3.75 HEX BOLT, GRADE 8 41-350-91 Secondary plate 41-348-70 Brake pad (inner) 41-348-76 Brake Pad (outer) 41-348-52 Spacer See Front Fork Rotor (part of front hub)

  • Page 104: Brakes, Rear

    ILLUSTRATED PARTS Model TT-316-36 BRAKES, REAR Page-104 MT-316-03...
  • Page 105 ILLUSTRATED PARTS Model TT-316-36 Rear Brakes Item No. Part No. Description 88-067-21 1/4 x 3-3/4 Hex bolt, grade 8 88-069-82 1/4NC locknut, grade C (included in rebuild kit) 41-350-91 Secondary plate See kit below Brake pad, Outer See kit below...

  • Page 106: Brake Lines

    ILLUSTRATED PARTS Model TT-316-36 BRAKE LINES Page-106 MT-316-03...
  • Page 107 ILLUSTRATED PARTS Model TT-316-36 Brake Lines Item No. Part No. Description 99-605-03 Formed brake line, front 2 99-575-00 Union, 3/16 tube 99-605-04 Formed brake line, front 1 99-603-02 Formed brake line, rear 1 99-604-03 Formed brake line, rear 2 99-600-02...

  • Page 108: Brake, Parking

    ILLUSTRATED PARTS Model TT-316-36 BRAKE, PARKING Electric Motor Park Brake (standard): Use part # 70-412-40 for Electric brake service kit Hand Park Brake (Optional) Item No. Part No. Description 41-349-50 Assembly, Brake Caliper 41-490-16 Bracket, Brake Mounting 89-06014J-D-10 Screw 51-340-30...

  • Page 109: Charger, Signet

    ILLUSTRATED PARTS Model TT-316-36 CHARGER, SIGNET Note: The harness connectors and AC plug are not included with the charger. Model HBS Charger PART # DESCRIPTION 79-303-41 36 volt Flooded Batteries (WET, FLA) 79-309-42 36 volt Sealed Batteries (GEL, SLA, AGM)

  • Page 110: Charger, Lestronic Ii Portable

    ILLUSTRATED PARTS Model TT-316-36 CHARGER, LESTRONIC II PORTABLE Item No. Part No. Description 79-306-22 Charger Assembly 79-852-00 Ammeter 79-805-76 Timer assembly 79-902-00 Capacitor 79-749-10 Diode assembly Transformer 79-575-10 AC cord 79-831-00 Fuse 79-530-00 Bushing 79-531-00 Bushing 79-567-10 DC cord MUST also order...

  • Page 111: Decals

    ILLUSTRATED PARTS Model TT-316-36 DECALS Decals Item No. Part No. Description 94-384-14 When Leaving Vehicle 94-384-01 Not a Motor Vehicle 94-301-43 Arms & Legs Inside 94-373-10 Vehicle Data 94-384-21 Auto Park Brake 94-313-20 Safety Warning See instrument Panel 94-319-00 Battery Disconnect...

  • Page 112: Electrical, Miscellaneous

    ILLUSTRATED PARTS Model TT-316-36 ELECTRICAL, MISCELLANEOUS Page-112 MT-316-03...
  • Page 113 ILLUSTRATED PARTS Model TT-316-36 Miscellaneous Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01 Wire Harness Clip, stick on...

  • Page 114: Frame And Body, Misc

    ILLUSTRATED PARTS Model TT-316-36 FRAME AND BODY, MISC Page-114 MT-316-03...
  • Page 115 ILLUSTRATED PARTS Model TT-316-36 Frame and Body Item No. Part No. Description 90-160-70 Driver seat assembly 90-160-60 Arm rest kit 01-440-08 Seat support (under deck) 01-440-56 Battery door, left 94-201-00 T/D emblem 88-567-91 Retainer, emblem 98-613-02 Cup holder 98-757-04 Front bumper...

  • Page 116: Hitches

    ILLUSTRATED PARTS Model TT-316-36 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-116 MT-316-03...
  • Page 117 ILLUSTRATED PARTS Model TT-316-36 Hitch, Remote Release (optional) Item No. Part No. Description 00-440-03 LEVER, REMOTE HITCH RELEASE 00-440-05 LEVER, WELDMENT 01-440-57 ROD, 5/16X7, LT & RT THREAD 03-455-13 PIVOT,HITCH RELEASE 85-060-20 SPRING,COMP,.72OD X2-1/2LG 88-099-80 5/16 NF HEX HD NUT...

  • Page 118: Instrument Panel

    ILLUSTRATED PARTS Model TT-316-36 INSTRUMENT PANEL Page-118 MT-316-03...
  • Page 119 Resetting the Smart View Display The meter should only be reset after the preventative maintenance has been performed. Taylor-Dunn® part number 62-027-40 Hand set (available with instructions as part number 62-027-61) must be used to reset the meter. Refer to the handset instructions (D0-100-08) for information on the procedure to reset the display.

  • Page 120: Lights

    ILLUSTRATED PARTS Model TT-316-36 LIGHTS Item No. Part No. Description 72-005-00 Headlight 72-022-00 Taillight 72-022-51 Mounting Ring Page-120 MT-316-03...
  • Page 121 ILLUSTRATED PARTS Model TT-316-36 Strobe Light : Option E4-005-21 Item No. Part No. Description 72-023-20 STROBELITE,AMBER,12-48VDC 72-023-42 WLDMNT,POLE,STROBE,TOP,BRKAWY 72-023-58 POLE STROBE,BTM BRKAWY,WELDMNT 88-025-06 8-32 X1/2 TRUS HD MACH SCR 88-028-62 #8 LOCK WASHER 88-029-80 8-32 HEX NUT 88-080-15 5/16 X 1-3/4NC HEX HD SCR...

  • Page 122: Master Cylinder

    ILLUSTRATED PARTS Model TT-316-36 MASTER CYLINDER Master Cylinder Item No. Part No. Description 99-511-00 Master cylinder assembly 88-101-22 3/8X3-1/2 HEX HD SCR,GR 5 88-109-81 3/8 NC LOCK NUT 99-510-52 99-510-62 Rebuild kit 99-511-51 Boot 99-510-53 Gasket 88-108-61 3/8 SAE WASHER...

  • Page 123: Motor

    ILLUSTRATED PARTS Model TT-316-36 MOTOR Typical Motor Motor, Spec DY8-4002 & DY1-4003 Item No. Part No. Description 70-054-43 Motor Assembly, no brake 0 or 1 70-054-42 Motor Assembly, with electric brake (not shown) 0 or 1 70-421-10 Front housing 70-400-00...

  • Page 124: Speed Control Panel

    ILLUSTRATED PARTS Model TT-316-36 SPEED CONTROL PANEL Page-124 MT-316-03...
  • Page 125 ILLUSTRATED PARTS Model TT-316-36 Speed Control Panel Item No. Part No. Description 62-400-05 Sevcon speed control 01-200-06 Mounting panel 73-004-20 Horn 71-300-02 Contactor 71-300-01 Mounting bracket 88-838-06 Screw 88-060-13 1/4 X 1-1/4 NC HEX HD SCR 88-068-61 1/4 SAE WASHER...

  • Page 126: Steering Column And Gear

    ILLUSTRATED PARTS Model TT-316-36 STEERING COLUMN AND GEAR WARNING DO NOT use standard #40 chains, master link, or woodruff key. The components used are special hardened material. Use of incorrect parts may result in failure of steering causing severe bodily injury and/or property damage.
  • Page 127 ILLUSTRATED PARTS Model TT-316-36 Steering Column and Gear Item # Part # Description 18-308-18 Steering shaft 18-308-19 Bellows 97-200-00 Foam washer 17-112-00 Collar 18-308-24 Flat Washer 88-199-82 19-011-30 Steering wheel 18-309-52 Column Housing 32-010-00 Bushing 18-306-26 U-Joint 95-902-10 Handle, Locking...

  • Page 128: Suspension, Rear

    ILLUSTRATED PARTS Model TT-316-36 SUSPENSION, REAR Rear Suspension Item No. Part No. Description 88-101-18 3/8 X 2-1/2 NC HEX SCR GRADE-5 88-169-82 LOCK NUT, 9/16 NF GRADE C 16-871-03 Spring hanger 32-213-00 Bushing 96-248-00 BOLT, SHACKLE,9/16 DIA X 3 16-861-00...

  • Page 129: Tires And Wheels

    ILLUSTRATED PARTS Model TT-316-36 TIRES AND WHEELS Tires and Wheels Item No. Part No. Description 13-739-10 Tire/Wheel assembly, 4.80 x 8 LR C Split Rim Pneumatic 13-734-42 Tire/Wheel assembly, 400 x 8, ManToter 10-076-00 Tire, 4.80 x 8 LR C Pneumatic...

  • Page 130: Gt Transmission Gear/Differential Case

    ILLUSTRATED PARTS Model TT-316-36 GT TRANSMISSION GEAR/DIFFERENTIAL CASE Your vehicle may be equipped with one of two types of transaxle assemblies. This section covers the GT transaxle. Refer to the Transaxle section to identify the type of transaxle in your vehicle.
  • Page 131 ILLUSTRATED PARTS Model TT-316-36 Your vehicle may be equipped with one of two types of transaxle assemblies. This section covers the GT transaxle. Refer to the Transaxle section to identify the type of transaxle in your vehicle. GT Transmission Gear/Differential Case Item No.

  • Page 132: Sd Transaxle Assembly, 3Rd Member

    ILLUSTRATED PARTS Model TT-316-36 SD TRANSAXLE ASSEMBLY, 3RD MEMBER Your vehicle may be equipped with one of two types of transaxle assemblies. This section covers the SD transaxle. Refer to the Transaxle section to identify the type of transaxle in your vehicle.

  • Page 133: Sd Transaxle Assembly, Primary Reduction

    ILLUSTRATED PARTS Model TT-316-36 SD TRANSAXLE ASSEMBLY, PRIMARY REDUCTION Your vehicle may be equipped with one of two types of transaxle assemblies. This section covers the SD transaxle. Refer to the Transaxle section to identify the type of transaxle in your vehicle.
  • Page 134 Notes ILLUSTRATED PARTS Model TT-316-36 Page-134 MT-316-03...
  • Page 136 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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