Taylor-Dunn B0-210-36 Service And Replacement Parts Manual
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Taylor-Dunn B0-210-36 Service And Replacement Parts Manual

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Enlarged version
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.
D
Service and Replacement
Parts Manual
B-200 & B-210 Models
Model Numbers:
B0-210-36
B0-210-36AMB
B0-200-00
Ending Serial Number: See Introduction Chapter
MANUAL: MB-210-13
Starting Serial Number: 207700

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Summary of Contents for Taylor-Dunn B0-210-36

  • Page 1 Service and Replacement Parts Manual MANUAL: MB-210-13 B-200 & B-210 Models Model Numbers: B0-210-36 B0-210-36AMB B0-200-00 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 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 12/18/2017 Revision D, 9/27/2018 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 Lubrication ............25 Front Axle ............29 Transaxle-GT ............37 Transaxle-SD ............47 Drive Axle-D1 ...........55 Steering ............63 Brakes-B-210............73 Brakes-B-200............83 SEM Motor-B-210 ..........93...
  • 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 B-200 & B-210 Models 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 B-200 & B-210 Models Page-12 MB-210-13...

  • Page 13: Service/Maintenance Guidelines

    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: Vehicle Modifications

    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: Preventative Maintenance

    Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 First 20 hours of Operation ........19 Every Week or 20 hours ..........19 Every Month or 100 hours ........19 Every 3 Months or 300 hours ........19 Every 6 Months or 600 hours) .........19 Every Year or 1200 hours ........19 Every 2 Years or 2400 hours ........19...

  • Page 18: Daily Visual Inspection

    PM Schedule B-200 & B-210 Models 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: First 20 Hours Of Operation

    PM Schedule B-200 & B-210 Models First 20 hours of Operation Every 3 Months or 300 hours • Re-torque wheel nuts. • All monthly items plus the following: • Inspect all hardware for tightness. • Adjust park and/or service brake. •...

  • Page 20: Interlock Switch Inspection

    PM Schedule B-200 & B-210 Models INTERLOCK SWITCH INSPECTION The interlock switches should disable vehicle operation when activated. Perform the following to confirm proper operation. If any one test fails, then immediately remove the vehicle from service and refer repair to a qualified technician.

  • Page 21: Special Tool List

    Table of Contents Special Tool List Controller Programming: .........22 Troubleshooting Guide ........24...
  • Page 22 Tool List B-200 & B-210 Models 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...
  • Page 23 Tool List B-200 & B-210 Models 77-200-00: Hydrometer 96-500-48: GT Drive Oil Fill Plug Tool 96-500-66: SD Drive Primary Case Spreader Used for testing battery electrolyte. Illustration is of a typical hydrometer, actual Used to remove the oil fill plug on GT hydrometer type may vary.
  • Page 24 Tool List B-200 & B-210 Models TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...

  • Page 25: Lubrication

    Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication B-200 & B-210 Models 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: Brake Pedal NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Brake Fluid:...
  • Page 27 Lubrication B-200 & B-210 Models LUBRICATION DIAGRAM B-200 Rear Axle GT - Rear Axle Lubrication SD Transaxle MB-210-13 Page 27...
  • Page 28 Notes Lubrication B-200 & B-210 Models Page 28 MB-210-13...

  • Page 29: Front Axle

    Table of Contents Front Axle Remove.............30 Installation ...............30 Disassemble.............31 Inspect Front Wheel Bearings ......32 Adjust Front Wheel Bearings ......32 Front Wheel Alignment ........33 Center the Steering ..........33 Front wheel alignment ..........33 Replace Front Wheel Bearings.......34 Replace Steering Knuckle ......34 Replace King Pin/Bushings ......35 Service Limits and Specifications ....36 Toe In ...............36 Hardware Torque ..........36...

  • Page 30: Front Axle

    Front Axle B-200 & B-210 Models 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. 2: Remove both front wheels.

  • Page 31: Disassemble

    Front Axle B-200 & B-210 Models 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 B-200 & B-210 Models 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 B-200 & B-210 Models 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. Center the Steering 1: Raise the front of the vehicle and support with jack stands.

  • Page 34: Replace Front Wheel Bearings

    Front Axle B-200 & B-210 Models 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 B-200 & B-210 Models 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 B-200 & B-210 Models SERVICE LIMITS AND HARDWARE TORQUE SPECIFICATIONS Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Rod End Stud Nut 20-25 27.1-33.9 Toe In Notes Rod End Jam Nut 20-25 27.1-33.9 0 - + 0.25 inches (6.3 mm) Page 36 MB-210-13...

  • Page 37: Transaxle-Gt

    Table of Contents Transaxle-GT Check Oil Level ..........38 Change Oil ............38 Remove.............39 Install ..............39 WARNING Axle Shaft ............40 Remove ..............40 Install ...............40 Rear Hub, Rotor & Bearings ......41 This section is one section of a complete service Motor, Remove ..........41 manual.

  • Page 38: Check Oil Level

    Drive Axle-GT B-200 & B-210 Models 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: Remove

    Drive Axle-GT B-200 & B-210 Models 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: Release the park brake. 2: Remove the park brake cables from the spring axle mounting brackets and brake arms.

  • Page 40: Axle Shaft

    Drive Axle-GT B-200 & B-210 Models AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 41: Rear Hub, Rotor & Bearings

    Drive Axle-GT B-200 & B-210 Models 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 42: Primary Gear Case

    Drive Axle-GT B-200 & B-210 Models 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 43: Secondary Gear Case

    Drive Axle-GT B-200 & B-210 Models SECONDARY GEAR CASE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Disassemble 1: Remove the transaxle assembly from the vehicle. Refer to Remove in this section.
  • Page 44 Drive Axle-GT B-200 & B-210 Models 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 45: Pinion Bearing Preload

    Drive Axle-GT B-200 & B-210 Models 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 46: Hardware Torque

    Drive Axle-GT B-200 & B-210 Models 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...

  • Page 47: Transaxle-Sd

    Table of Contents Transaxle-SD Check Oil Level ..........48 Change Oil ............48 Remove.............49 Install ..............49 WARNING Axle Shaft ............50 Remove ..............50 Install ...............50 This section is one section of a complete service Rear Hub, Rotor & Bearings ......51 manual. Before starting any procedure, read all Motor, Remove ..........51 warnings and instructions that are located in the Primary Reduction Gear Case ......52...

  • Page 48: Transaxle-Sd

    Transaxle B-200 & B-210 Models 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 49: Remove

    Transaxle B-200 & B-210 Models 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: Release the park brake. 2: Remove the park brake cables from the spring axle mounting brackets and brake arms.

  • Page 50: Axle Shaft

    Transaxle B-200 & B-210 Models AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 51: Rear Hub, Rotor & Bearings

    Transaxle B-200 & B-210 Models 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 52: Primary Reduction Gear Case

    Transaxle B-200 & B-210 Models 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 53 Transaxle B-200 & B-210 Models MB-210-13 Page 53...

  • Page 54: 3Rd Member

    Transaxle B-200 & B-210 Models 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 55: Drive Axle-D1

    Table of Contents Drive Axle-D1 Check Oil Level ..........56 Change Oil ............56 Drive Motor ............57 Remove ..............57 Install ...............57 Differential Case ..........58 Disassemble ............58 Assemble ..............60 Hardware Torque ..........61 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 56: Drive Axle-D1

    Drive Axle B-200 & B-210 Models 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 57: Drive Motor

    Drive Axle B-200 & B-210 Models 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 58: Differential Case

    Drive Axle B-200 & B-210 Models 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 59 Drive Axle B-200 & B-210 Models 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 60: Assemble

    Drive Axle B-200 & B-210 Models Assemble Notes: W hen 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. 6: Insert the flanged side bearing into the bearing bore. Press in just past the snap ring grove and install the snap ring. 1: Thoroughly clean all components as well as the 7: Repeat the above step for the opposite bearing.

  • Page 61: Hardware Torque

    Drive Axle B-200 & B-210 Models HARDWARE TORQUE 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 62 Drive Axle Notes B-200 & B-210 Models Page 62 MB-210-13...

  • Page 63: Steering

    Table of Contents Steering Inspect Ball Joints ...........64 Inspect Rod Ends ..........64 Adjust Steering Gear ........65 Front Wheel Alignment ........65 Replace Ball Joint..........66 Replace Rod End ..........66 Replace Steering Shaft ........67 Replace Steering Wheel ........68 Steering Gear ...........69 Disassemble ............69 Align Pitman Arm ..........70 Reassemble ............70 Exploded View of Steering Gear ......71...

  • Page 64: Inspect Ball Joints

    Steering B-200 & B-210 Models 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 65: Adjust Steering Gear

    Steering B-200 & B-210 Models 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 66: Replace Ball Joint

    Steering B-200 & B-210 Models 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 67: Replace Steering Shaft

    Steering B-200 & B-210 Models REPLACE STEERING SHAFT WARNING WARNING This section is one section of a complete service Do not reuse the original pinch bolt and nut. Failure manual. Before starting any procedure, read all to replace the pinch bolt and nut may result in warnings and instructions that are located in the failure of the steering causing loss of control of the Service Guidelines chapter.

  • Page 68: Replace Steering Wheel

    Steering B-200 & B-210 Models 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 69: Steering Gear

    Steering B-200 & B-210 Models 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 70: Align Pitman Arm

    Steering B-200 & B-210 Models 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 71: Exploded View Of Steering Gear

    Steering B-200 & B-210 Models Exploded View of Steering Gear MB-210-13 Page 71...

  • Page 72: Hardware Torque

    Steering B-200 & B-210 Models HARDWARE TORQUE Description Foot Pounds Newton Meters Notes 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 Steering Wheel Nut 28-32 38-43 Pitman Arm 75-100...

  • Page 73: Brakes-B-210

    Table of Contents Brakes-B-210 General Guidelines and Safety.......74 Front Brake ............75 Service Limits ............75 Inspection ..............75 Replace Pads ............75 Rear Brake............76 Service Limits ............76 Inspection ..............76 Replace Pads ............76 Rebuild Disc Brake Body ........77 Bleed System ...........78 Flush System ...........78 Master Cylinder..........79 Add Fluid ..............79 Parking Brake ..........80...

  • Page 74: Brakes

    B-200 & B-210 Models 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 75: Front Brake

    Brakes B-200 & B-210 Models FRONT BRAKE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Service Limits Refer to the table at the end of this section Inspection Note: Service Limits are listed in a table at the end of this section.

  • Page 76: Rear Brake

    Brakes B-200 & B-210 Models 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 77: Rebuild Disc Brake Body

    Brakes B-200 & B-210 Models 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 78: Bleed System

    Brakes B-200 & B-210 Models 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 79: Master Cylinder

    Brakes B-200 & B-210 Models 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 80: Parking Brake

    Brakes B-200 & B-210 Models PARKING 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. The brake pads and rotor should be inspected anytime the park brake requires adjustment.
  • Page 81 Brakes B-200 & B-210 Models MB-210-13 Page 81...

  • Page 82: Service Limits

    Brakes B-200 & B-210 Models HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc brake Pad minimum lining 00625 inch 1.58 millimeter Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch 5.08 millimeter...

  • Page 83: Brakes-B-200

    Table of Contents Brakes-B-200 General Guidelines and Safety.......84 Front Disc Brake ..........85 Service Limits ............85 Inspection ..............85 Replace Pads ............85 Brake Adjustment ..........86 Service Brake ............86 Mechanical and Hydraulic Brakes ......86 Adjust the Service Brake Linkage ......86 Parking Brake, Mechanical Brakes ......86 Parking Brake, Hydraulic Brakes ......87 Rear Drum Brake, Inspect/Replace ....88 Service Limits ............88...

  • Page 84: Brakes

    B-200 & B-210 Models 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 85: Front Disc Brake

    Brakes B-200 & B-210 Models 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 Inspection Note: Service Limits are listed in a table at the end of this section.

  • Page 86: Brake Adjustment

    Brakes B-200 & B-210 Models 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 Adjusting the brakes by means of the brake cables found that the cables or linkages have been adjusted could cause a hard brake pedal with little or no...

  • Page 87: Parking Brake, Hydraulic Brakes

    Brakes B-200 & B-210 Models 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. 2: Loosen the clevis jam nuts on the connecting rod.

  • Page 88: Rear Drum Brake, Inspect/Replace

    Brakes B-200 & B-210 Models 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 This section is one section of a complete service and Wheels the wheel.

  • Page 89: Rebuild Disc Brake Body

    Brakes B-200 & B-210 Models 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 90: Bleed System

    Brakes B-200 & B-210 Models 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 91: Master Cylinder

    Brakes B-200 & B-210 Models 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 92: Service Limits

    Brakes B-200 & B-210 Models 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 5.08 mm...

  • Page 93: Sem Motor-B-210

    Table of Contents SEM Motor-B-210 Remove/Install ..........94 Disassemble.............94 Inspect ..............95 Brushes ..............95 Bearing ..............95 Commutator .............95 Armature Windings ..........95 Field Windings ............96 Repair ...............97 Service Limits ..........98 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 94: Remove/Install

    Motor SEM B-200 & B-210 Models 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 95: Inspect

    Motor SEM B-200 & B-210 Models 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 96: Field Windings

    Motor SEM B-200 & B-210 Models 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 97: Repair

    Motor SEM B-200 & B-210 Models 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 98: Service Limits

    Motor SEM B-200 & B-210 Models 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. The service limits listed below are for each of the motors, by the specification number of the motor shown.

  • Page 99: Motor Controller

    Table of Contents Motor Controller Remove/Install ..........100 Inspect ..............100 Receptacles .............100 Base Plate ...............100 Terminal Ends ............100 ’R’ Terminal ..............100 Repair/Programming ........101 Programming ............101 Troubleshooting ..........101 Hardware Torque ..........102 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 100: Motor Controller

    Motor Controller B-200 & B-210 Models REMOVE/INSTALL INSPECT WARNING Receptacles The inside of each receptacle should be clean and free This section is one section of a complete service of any debris. Use aerosol electrical cleaner if required. manual. Before starting any procedure, read all warnings and instructions that are located in the Base Plate Service Guidelines chapter.

  • Page 101: Repair/Programming

    This manual was provided on the original vehicle CD. A hard copy can be purchased from your authorized NOTICE Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. The controller power base and logic are a matched set. DO NOT swap logics from one base to another as this may damage the logic or power base.

  • Page 102: Hardware Torque

    Motor Controller B-200 & B-210 Models HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the Notes appendix. Description Inch Pounds Newton Meters Terminal stud 38-44 4.29-4.97 Page 102 MB-210-13...

  • Page 103: Wire Diagram

    Table of Contents Wire Diagram Diagram Part Numbers........104 B-210 ...............105 B-200 ...............106 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 104 Vehicle Documentation CD provided with the vehicle. The diagram #’s for this vehicle are: B-210: SCH-00009 B-200: SCH-00010 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 104 MB-210-13...
  • Page 105 Wire Diagram B-200 & B-210 Models 4 2 1 MB-210-13 Page 105...
  • Page 106 Wire Diagram B-200 & B-210 Models Brown White White White Green/Black Green/Black Brown White Black Black Blue/White Violet/Black White Blue White HORN Black/White Connector A Violet/Black Blue White Black Yellow Page 106 MB-210-13...

  • Page 107: Batteries

    Table of Contents Batteries General Guidelines and Safety.......108 Cleaning ............109 Charging ............109 Watering ............109 Testing ..............110 Specific Gravity ............110 Storing ..............110 Storage ..............110 Returning to Service ..........110 Remove/Install ..........111 Industrial Battery or Lift Out Battery Pack ....111 Individual Batteries ..........111 Hardware Torque ..........112 WARNING This section is one section of a complete service...

  • Page 108: General Guidelines And Safety

    Batteries B-200 & B-210 Models 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 109: Cleaning

    Batteries B-200 & B-210 Models 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 110: Testing

    Batteries B-200 & B-210 Models 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 111: Remove/Install

    Batteries B-200 & B-210 Models 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 112: Hardware Torque

    Batteries B-200 & B-210 Models HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Inch Pounds Newton Meters Battery terminal, Trojan bolt 95-105 11-12 Battery terminal, Trojan stud 95-105 11-12 Battery terminal, T/D bolt Page 112 MB-210-13...

  • Page 113: Tires & Wheels

    Table of Contents Tires & Wheels Inflation .............114 Air pressure .............114 Tread Wear ............115 Rotation ............115 Changing Tire/Wheel Assembly .....116 Replace the Tire (pneumatic) ......116 Repair the Tire (pneumatic) ......116 Hardware Torque ..........117 WARNING This section is one section of a complete service manual.

  • Page 114: Tires & Wheels

    Tires & Wheels B-200 & B-210 Models 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 115: Tread Wear

    Tires & Wheels B-200 & B-210 Models 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 116: Changing Tire/Wheel Assembly

    Tires & Wheels B-200 & B-210 Models 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 117: Hardware Torque

    Tires & Wheels B-200 & B-210 Models HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MB-210-13 Page 117...
  • Page 118 Notes Tires & Wheels B-200 & B-210 Models Page 118 MB-210-13...

  • Page 119: Suspension

    Table of Contents Suspension Front or Rear Springs ........120 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 120 Suspension B-200 & B-210 Models FRONT OR 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. Note: If a left or right side spring is replaced, it is recommended to replace the opposite side at the same time. Note: When replacing the springs, replace one side and then the other Typical Spring hanger to avoid dropping the axle out of the vehicle.

  • Page 121: Hardware Information

    Table of Contents Hardware Information Torque Guidelines for Standard hardware ..122 Hardware Identification ..........122 Hex Nuts ..............123 Hex Lock Nuts (stover) ..........123 Other Nuts ...............123 Generic Torque Values ..........124 Replacing Hardware ........126 WARNING This section is one section of a complete service manual.

  • Page 122: Torque Guidelines For Standard Hardware

    Hardware B-200 & B-210 Models 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 123: 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-210-13 Page 123...

  • Page 124: Generic Torque Values

    Hardware B-200 & B-210 Models 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 125 Hardware B-200 & B-210 Models 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 126: Replacing Hardware

    Hardware B-200 & B-210 Models 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 127: Replacement Parts

    Replacement Parts Control System, Instrument Panel ....158 Decals ...............160 Ordering Parts for Your Vehicle .....128 Electrical, Miscellaneous ........162 Taylor-Dunn Web Site Information ....128 Electrical, Wiring ..........163 Axle Assembly, Front ........130 Frame, Cowl, Cab, Windshield Frame ...164 Axle Shaft Assembly, B-210 Rear....132 Frame, Deckboards .........165...

  • Page 128: 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 129 Replacement Parts B-200 & B-210 Models My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MB-210-13 * Not available at time of printing Page 129...

  • Page 130: Axle Assembly, Front

    Replacement Parts B-200 & B-210 Models AXLE ASSEMBLY, FRONT Page 130 MB-210-13...
  • Page 131 Replacement Parts B-200 & B-210 Models Axle Assembly, Front Item No. Part No. Description 15-210-00 Front Axle Beam 14-210-98 Steering Yoke, Left 14-210-99 Steering Yoke, Right 14-210-88 Steering Yoke, Hydraulic Disc, Left (Optional) 14-210-89 Steering Yoke, Hydraulic Disc, Right (Optional) 32-240-55 Bushing Metal Backed Teflon 97-180-55...

  • Page 132: Axle Shaft Assembly, B-210 Rear

    Replacement Parts B-200 & B-210 Models AXLE SHAFT ASSEMBLY, B-210 REAR Axle Shaft Assembly, Rear Item No. Part No. Description 41-154-15 Axle shaft 80-505-20 Bearing 41-490-11 Disc brake rotor 41-172-21 88-268-63 Flat washer 88-268-30 7/8-14 x 1.5 Bolt, grade 5 96-329-10 Wheel stud 92-104-10...

  • Page 133: Axle Shaft Assembly, B-200 Rear

    Replacement Parts B-200 & B-210 Models AXLE SHAFT ASSEMBLY, B-200 REAR Item No. Part No. Description Actuator, park brake 45-303-00 Seal 32-509-10 Bearing retainer 80-505-10 Bearing/race assembly Backing plate 45-303-10 Seal Spider, includes wheel cylinder 41-171-10 Axle shaft (right) 41-170-10 Axle shaft (left) Spring, extension Spring, green...

  • Page 134: Transaxle Assembly, B-200

    Replacement Parts B-200 & B-210 Models TRANSAXLE ASSEMBLY, B-200 Page 134 MB-210-13...
  • Page 135 Replacement Parts B-200 & B-210 Models B-200 Transaxle ITEM# PART # DESCRIPTION Housing Bearing cap (included with #1) 96-330-10 Bolt Carrier assembly Final gear Bolt 80-480-00 Bearing Shaft and gear assembly 80-715-00 O-ring 66-610-35 Bearing Input shaft 80-480-15 Bearing 80-715-10 O-ring 80-480-10 Bearing...

  • Page 136: Transaxle Assembly, B-210 Rear Gt

    Replacement Parts B-200 & B-210 Models TRANSAXLE ASSEMBLY, B-210 REAR GT Page 136 MB-210-13...
  • Page 137 Replacement Parts B-200 & B-210 Models GT 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 Idler gear 88-406-67...

  • Page 138: Transaxle Assembly, B-210 Rear Sd 3Rd Member

    Replacement Parts B-200 & B-210 Models TRANSAXLE ASSEMBLY, B-210 REAR SD 3RD MEMBER Illustration is for reference only. This assembly as not serviceable with the exception of oil seals. Item No. Part No. Description 44-440-93 Complete 3rd member assembly Bolt N/A - Order assembly Bearing N/A - Order assembly...

  • Page 139: Transaxle Assembly, B-210 Rear Primary Reduction

    Replacement Parts B-200 & B-210 Models TRANSAXLE ASSEMBLY, B-210 REAR PRIMARY REDUCTION Item No. Part No. Description 44-440-90 Assembly, Primary reduction, 19:1 0 or 1 44-440-91 Assembly, Primary reduction, 27:1 0 or 1 44-440-92 Assembly, Primary reduction, 30:1 0 or 1 Kit B Bearing Kit B...

  • Page 140: Battery

    Replacement Parts B-200 & B-210 Models BATTERY Page 140 MB-210-13...
  • Page 141 Replacement Parts B-200 & B-210 Models Item No. Part No. Description 75-237-00 Battery jumper 77-043-00 210AH, T-605 77-042-00 225AH, T-105 77-047-00 260AH, T-145 50-243-10 Battery rod 50-250-00 Battery hold down 88-088-66 Flat washer, tin/lead plated 88-069-81 1/4NC Nylon lock nut 88-081-12 5/16NC x 1 Square bolt, stainless steel 88-089-80...

  • Page 142: Brakes, Brake Lines

    Replacement Parts B-200 & B-210 Models BRAKES, BRAKE LINES Page 142 MB-210-13...
  • Page 143 Replacement Parts B-200 & B-210 Models Brake Lines Item No. Part No. Description 99-580-20 Brake hose, B 2-10 front and rear, B 2-00 front 2 or 4 99-580-10 Brake hose, B 2-00 rear 99-603-53 Brake line, front right 99-603-53 Brake line, front left 99-603-54 Brake line, front 99-605-55...

  • Page 144: Brakes, Master Cylinder & Linkage

    Replacement Parts B-200 & B-210 Models BRAKES, MASTER CYLINDER & LINKAGE Page 144 MB-210-13...
  • Page 145 Replacement Parts B-200 & B-210 Models Master Cylinder & Linkage Item No. Part No. Description 99-510-02 Master cylinder assembly 88-101-20 Hex bolt See Brake lines Fitting See Brake lines Washer See Brake lines Fitting See Brake lines Washer 88-109-81 Hex lock nut 99-510-52 99-510-61 Rebuild kit for 1”...

  • Page 146: Brakes, Front Axle

    Replacement Parts B-200 & B-210 Models BRAKES, FRONT AXLE Front Brakes Item No. Part No. Description 88-067-21 Bolt 88-069-82 41-350-91 Plate, Secondary 41-348-58 Spacer 32-208-01 Bushing (included in rebuild kit) 41-351-35 Brake body assembly (no internally serviceable parts) 99-588-01 Bleeder adaptor 99-588-00 Bleeder valve See rebuild kit...

  • Page 147: Brakes, B-210 Rear Axle

    Replacement Parts B-200 & B-210 Models BRAKES, B-210 REAR AXLE Brakes, B-210 Rear Axle Item No. Part No. Description 41-351-80 (see note) Complete caliper assembly (left) 41-351-81 (see note) Complete caliper assembly (right) Brake body 32-208-01 Bushing (included in rebuild kit) 41-348-58 Spacer (included in rebuild kit) 41-350-28-1...

  • Page 148: Brakes, B-200 Rear Axle

    Replacement Parts B-200 & B-210 Models BRAKES, B-200 REAR AXLE Page 148 MB-210-13...
  • Page 149 Replacement Parts B-200 & B-210 Models B-200 Rear Brakes Item No. Part No. Description 41-347-15 Actuator, park brake Seal Bearing retainer Bearing/race assembly 41-347-00 Backing plate Seal 41-347-36 Spider, includes wheel cylinder Axle shaft 85-215-00 Spring, extension 85-411-00 Spring, red 85-411-15 Spring, green 41-635-00...

  • Page 150: Brakes, B-200 Park Brake

    Replacement Parts B-200 & B-210 Models BRAKES, B-200 PARK BRAKE Page 150 MB-210-13...
  • Page 151 Replacement Parts B-200 & B-210 Models Brakes, B-200 Park Brake Linkage Item No. Part No. Description 51-344-80 Park brake handle 88-080-11 Bolt 88-517-09 Cotter pin 96-813-00 Cable 96-772-00 Clevis pin 88-088-61 Washer 88-089-81 96-772-00 Clevis pin 88-517-09 Cotter pin 01-204-32 Equalizer 96-826-12 Cable...

  • Page 152: Brakes, B-210 Park Brake

    Replacement Parts B-200 & B-210 Models BRAKES, B-210 PARK BRAKE Page 152 MB-210-13...
  • Page 153 Replacement Parts B-200 & B-210 Models Brakes, B-210 Park Brake Linkage Item No. Part No. Description 51-344-80 Park Brake 88-517-09 Cotter Pin 96-773-00 Clevis Pin, 5/16 96-763-00 Clevis 88-089-80 5/16 Hex Nut 05-210-86 Hand Brake Bar 88-100-09 3/8 X 3/4 NC Bolt 88-109-81 3/8 NC Hex Lock Nut 06-210-11...

  • Page 154: Charger, Signet

    Replacement Parts B-200 & B-210 Models CHARGER, SIGNET Note: There are no user serviceable components inside the charger Note: The charger AC cord is an integral part of the charger. When replacing the charger, do not cut and splice the AC cord. Cutting the AC cord will void the charger warranty. Note: The Signet model HBS series charger replaces all previous Signet models.

  • Page 155: Charger, Delta Q

    Replacement Parts B-200 & B-210 Models CHARGER, DELTA Q Note: There are no user serviceable components inside the charger Model QuiQ Model IC650 Item No. Part No. Description 79-309-48 Charger, QuiQ, 48 volt Trojan T145 79-309-49 Charger, QuiQ, 48 volt Trojan T105 79-909-47 Charger, QuiQ, 48 volt Full River AGM 79-306-32...

  • Page 156: Charger, Summit

    Replacement Parts B-200 & B-210 Models CHARGER, SUMMIT Note: There are no user serviceable components inside the charger Item No. Part No. Description 79-309-46 Charger, 48 volt Trojan T105 79-306-37 Charger, 36 volt Trojan T105 79-580-10 Receptacle, Rear AC, Bigfoot XL only 0 or 1 01-501-98 Cover plate (rear receptacle)

  • Page 157: Control System, Motor Speed Control

    Replacement Parts B-200 & B-210 Models CONTROL SYSTEM, MOTOR SPEED CONTROL Speed Control Panel Item No. Part No. Description 62-400-05 Speed controller, B 2-10 62-400-31 Speed controller, B 2-00 01-200-07 Mounting panel 73-004-20 Horn 79-844-00 Main circuit breaker 72-501-42 ISO solenoid 88-838-06 #14 x 1/2 Sheet metal screw 88-060-09...

  • Page 158: Control System, Instrument Panel

    Replacement Parts B-200 & B-210 Models CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 71-039-11 Light switch 71-039-11 Wiper switch 0 or 1 71-039-11 Strobe switch 0 or 1 71-039-02 Forward/reverse switch 71-039-11 High/low speed switch 0 or 1 74-010-00 Smart View gauge (shown) 71-102-15...
  • Page 159 Replacement Parts B-200 & B-210 Models MB-210-13 * Not available at time of printing Page 159...

  • Page 160: Decals

    Replacement Parts B-200 & B-210 Models DECALS Page 160 MB-210-13...
  • Page 161 Replacement Parts B-200 & B-210 Models Decals Item No. Part No. Description 94-301-42 DECAL, ARMS/LEGS, 2 PASS 2, 4, 6 94-319-02 DECAL, BATTERY DISCONNECT (E) 94-313-21 DECAL, SAFETY WARNING,3.5 X 10 94-313-20 DECAL, SAFETY WARNING, 5X6 (E) 94-309-00 DECAL, PARK BRAKE WARNING 94-384-14 DECAL, LEAVING VEHICLE (E) 94-384-61...

  • Page 162: Electrical, Miscellaneous

    Replacement Parts B-200 & B-210 Models ELECTRICAL, MISCELLANEOUS Page 162 MB-210-13...

  • Page 163: Electrical, Wiring

    Replacement Parts B-200 & B-210 Models Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID 96-630-00 (not shown Clamp, Rubber Lined 5/8 ID...

  • Page 164: Frame, Cowl, Cab, Windshield Frame

    Replacement Parts B-200 & B-210 Models FRAME, COWL, CAB, WINDSHIELD FRAME Item No. Part No. Description 91-010-77 Cowl and windshield frame 90-852-30 Windshield 98-310-000 Window gasket (by the foot) 88-102-15 3/8NC x 1-3/4 Carriage bolt 88-108-60 3/8 Cut flat washer 88-109-87 3/8NC KEPS nut 96-124-00...

  • Page 165: Frame, Deckboards

    Replacement Parts B-200 & B-210 Models FRAME, DECKBOARDS Part No. Description 90-444-00 Standard Deck board Split Steel Deck 00-210-23 Center deck support angle 88-607-09 Rivet 90-440-46 Steel deck cover, 38-1/2 long 90-440-47 Steel deck cover, 36-5/8 long 90-444-20 Deck board, 38-1/2 long 90-444-30 Deck board, 36-5/8 long 00-210-18...

  • Page 166: Frame, Doors

    Replacement Parts B-200 & B-210 Models FRAME, DOORS Page 166 MB-210-13...
  • Page 167 Replacement Parts B-200 & B-210 Models Doors Item No. Part No. Description 90-923-98 Door frame, left 90-923-99 Door frame, right 90-924-98 Naugahyde door cover, left 90-924-99 Naugahyde door cover, right 97-315-53 Outer handle 97-315-51 Door latch 97-315-54 Inner handle 97-303-03 Snap fastener 88-727-06 Pop rivet for #6...

  • Page 168: Frame, Tool Box Doors

    Replacement Parts B-200 & B-210 Models FRAME, TOOL BOX DOORS Item No. Part No. Description 02-210-12 Left side door 02-210-13 Right side door 02-210-15 Front top 88-737-08 Pop rivet 02-210-14 Front door stop 88-837-09 #14 x 3/4 Sheet metal screw 02-210-16 Door catch 88-065-08...

  • Page 169: Frame, Stake Sides

    Replacement Parts B-200 & B-210 Models FRAME, STAKE SIDES Item No. Part No. Description 90-545-01 End gate 90-545-02 Left side, standard 90-545-02 Right side, standard 90-545-03 Left side, fixed 2nd seat 90-545-04 Right side, fixed 2nd seat 90-545-14 Left side rear, foldaway 2nd seat 90-545-12 Left side front, foldaway 2nd seat 90-545-15...

  • Page 170: Frame, Ambulance Deck

    Replacement Parts B-200 & B-210 Models FRAME, AMBULANCE DECK Page 170 MB-210-13...
  • Page 171 Replacement Parts B-200 & B-210 Models Ambulance Deck Item No. Part No. Description 00-210-51 Seat frame (un painted) 90-000-00 Seat backrest cushion 88-837-11 #14 x 1 Screw 90-191-00 Seat cushion 00-610-07 Left side deck rail 00-610-06 Rear deck rail 00-610-05 Right side deck rail 90-440-72 Rear deck board, galvanized...

  • Page 172: Frame, Tops

    Replacement Parts B-200 & B-210 Models FRAME, TOPS Page 172 MB-210-13...
  • Page 173 Replacement Parts B-200 & B-210 Models Tops Item No. Part No. Description 91-028-20 Top frame, standard K1-103-79 Top frame, ambulance 91-028-24 Mounting pole, standard 91-028-24 Mounting pole, ambulance K1-177-60 Mounting pile, ambulance Not shown K1-123-09 Ambulance mounting pole spacer 88-102-11 3/8NC x 1 Carraige bolt 88-109-81 3/8NC Hex lock nut...

  • Page 174: Hitches

    Replacement Parts B-200 & B-210 Models 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 174 MB-210-13...

  • Page 175: Lights

    Replacement Parts B-200 & B-210 Models LIGHTS Item No. Part No. Description 94-050-11 Headlight assembly, Right 94-050-10 Headlight assembly, Left 72-082-01 Bulb, headlight 72-025-00 Taillight 72-025-51 Grommet, taillight 72-082-10 Bulb, Front turn signal 0 or 2 71-900-05 Flasher 0 or 1 71-141-22 Turn signal switch (includes flasher) 0 or 1...

  • Page 176: Motor

    Replacement Parts B-200 & B-210 Models MOTOR Motor spec # DD3-4004 Item No. Part No. Description Housing Armature Field coils PKIT-00022 Brush spring set (4) 70-170-00 Brush holder PKIT-00064 Brush set (2) (includes springs) 70-417-00 Retainer 80-212-00 Bearing 70-421-20 Housing 70-421-00 Cover 95-930-00...

  • Page 177: Seats

    Replacement Parts B-200 & B-210 Models SEATS Seats Item No. Part No. Description 90-172-00 Seat cushion, Driver 90-174-00 Seat cushion, Front passenger 90-179-00 Backrest, Front Frame, Seat back (black) Fixed 2nd Seat Option 90-175-00 Seat cushion, Fixed 2nd seat 90-179-00 Backrest, Fixed 2nd seat 02-680-39 Seat frame...

  • Page 178: Steering Gear

    Replacement Parts B-200 & B-210 Models 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...

  • Page 179: Steering Linkage

    Replacement Parts B-200 & B-210 Models STEERING LINKAGE Steering Linkage Item No. Part No. Description 86-510-00 Clamp 86-501-98 Ball joint, left 86-501-99 Ball joint, right 88-159-85 Hex castle nut 88-527-11 1/8 x 1 Cotter pin 18-057-11 Drag link 87-074-00 Grease fitting 18-041-00 Steering linkage MB-210-13...

  • Page 180: Steering Column

    Replacement Parts B-200 & B-210 Models STEERING COLUMN Page 180 MB-210-13...
  • Page 181 Replacement Parts B-200 & B-210 Models Steering Column Item No. Part No. Description 88-199-82 5/8NF Hex nut 19-011-25 Steering wheel cap 19-011-20 Steering wheel 32-248-10 Upper column bushing 20-031-63 Steering shaft (includes 6a and 6b) 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 (Pinch bolt) 88-089-84 5/16NF Hex locknut, grade 8 (Pinch bolt nut) 18-308-21...

  • Page 182: Suspension, Front

    Replacement Parts B-200 & B-210 Models SUSPENSION, FRONT Front Suspension Item No. Part No. Description 85-512-10 Leaf Spring 16-871-02 Spring Shackle 32-213-00 Bushing, 3/4” OD X 1.656” Long 96-248-00 Shackle Bolt 9/16” NF 88-169-82 Lock Nut, 9/16” NF, grade C 96-123-00 U-Bolt Length 2”...

  • Page 183: Suspension, B-210 Rear

    Replacement Parts B-200 & B-210 Models SUSPENSION, B-210 REAR Item No. Part No. Description 85-513-10 Spring 16-871-02 Spring hanger 32-213-00 Spring bushing 96-248-00 Hex bolt 88-169-82 Hex nut 96-114-00 U-bolt 88-159-84 Hex nut 16-861-43 Spring plate, right 16-861-42 Spring plate, left Not Shown 86-602-00 Shock...

  • Page 184: Suspension, B-200 Rear

    Replacement Parts B-200 & B-210 Models SUSPENSION, B-200 REAR Item No. Part No. Description 96-123-54 U-bolt, bent 96-123-53 U-bolt 16-865-02 Plate 16-871-02 Hanger 96-248-00 Bolt 88-169-82 85-513-05 Spring 88-109-81 88-108-60 Washer Page 184 MB-210-13...

  • Page 185: Windshield Wiper

    Replacement Parts B-200 & B-210 Models WINDSHIELD WIPER Item No. Part No. Description 74-050-00 Wiper motor 74-051-00 Wiper arm 74-052-00 Wiper blade 75-152-09 Harness WHEELS AND TIRES Item No. Part No. Description 13-742-13 5.70 x 8 Pneumatic Tire/Wheel Assembly 13-742-12 5.70 x 8 Assembly on split rim 10-083-00 Tire...
  • Page 186 Notes: Replacement Parts B-200 & B-210 Models Page 186 MB-210-13...
  • Page 187 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 188 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:

B0-210-36ambB0-200-00

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