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Taylor-Dunn TC-030-60L Operation, Maintenance, And Replacement Parts Manual

Tiger tractor
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T h e B e s t W a y
To G o
A b o u t Yo u r
B u s i n e s s
Published: 12/28/2010
Revision: A
Models Inlcuded:
TC-030-60L
MANUAL MT-030-60L-A
Operation, Maintenance, and
Replacement Parts Manual
Serial Number: 183635
Shown with optional Cab

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Summary of Contents for Taylor-Dunn TC-030-60L

  • Page 1 Shown with optional Cab Models Inlcuded: TC-030-60L T h e B e s t W a y To G o A b o u t Yo u r B u s i n e s s MANUAL MT-030-60L-A Operation, Maintenance, and...
  • Page 3 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 Section Inde Section Inde Section Inde Section Inde Section Index x x x x Tiger Tractor Model TC-030-60L Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Engine Service...
  • Page 6 SC1-00 Stock Chaser B2-48 With Stake Side Dump Bed Option E4-55 Sit Down Tow Tractor C4-25 Sit Down Tow Tractor...

  • Page 7: Table Of Contents

    Chapter - 1 Table of Contents About this manual .......... 2 Who Should Read This Manual ..... 2 Responsibilities ..........2 How To Use This Manual ....... 3 Conventions ............3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ..... 5...

  • Page 8: About This Manual

    ABOUT THIS MANUAL RESPONSIBILITIES The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. The owner of this or any Taylor-Dunn ® vehicle is Taylor-Dunn ® , a leading manufacturer of electric and...

  • Page 9: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL Conventions This manual is organized into five main sections: Symbols and/or words that are used to define warnings, cautions, instructions, or notes found INTRODUCTION throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 10: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, , airports, nurseries, institutions, motels, mobile home parks, and resorts.

  • Page 11: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery cables, ® adjust any part of this or any Taylor-Dunn vehicle is and other electrical connections are secure. a factory authorized service technician. •...
  • Page 12 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...
  • Page 13 Chapter - TABLE OF CONTENTS Standard Specifications* ....2 Safety Rules and Guidelines ..... 3 Driver Training Program ....3 Driver Qualifications......... 3 Vehicle Controls ......... 4 Instrument Panel ....... 4 1) Check Engine Light ........4 2) Switch for Optional Components ....4 3) Instrument Panel ...........

  • Page 14: Standard Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* ITEM Model SPECIFICATION Occupancy Driver only, no passengers Dimensions 105 L x 56 W x 56 H Inches (2,667 L x 1422 W x 1422 H mm) Wheel Base 65 inches (1,663 mm) Ground Clearance 6.5 inches (165 mm) Turning Radius...

  • Page 15: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND DRIVER TRAINING PROGRAM GUIDELINES Per ANSI B56.9, the owner of this vehicle shall conduct an Operator Training program for all those who will be It is the responsibility of the owner of this vehicle to assure operating this vehicle.

  • Page 16: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS INSTRUMENT PANEL 1) Check Engine Light 5) Park Brake Warning Light When the Check Engine Light is on while the engine is This light will be ON when ever tha parking brake is set. running, then the ECU has detected conditions that indicate the engine is not operating correctly.

  • Page 17: Coolant Temperature

    SAFETY RULES AND OPERATING INSTRUCTIONS 8) Coolant Temperature 10) Oil Pressure This gauge indicates This gauge indicates the engine oil temperature of the engine coolant, pressure, not the oil level. However, not the coolant level. If the coolant if your engine’s oil level is low, it is not at its proper level or mixture, could affect the oil pressure.

  • Page 18: Throttle Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS 1) Throttle Pedal The throttle pedal is located on the floorboard and is intended to be operated by the drivers right foot. It controls the speed of the vehicle and operates similar to the throttle pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.

  • Page 19: Directional Signals (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Directional Signals (Optional) The turn signal lever is located on the left side of the steering column. Push the lever forward to activate the right turn signal and pull the lever back to activate the left turn signal. Hazard Light Switch (Optional) The hazard light switch is located on the left side of the steering column.

  • Page 20: Vehicle Operation

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATION Safety Guidelines Starting-Gasoline/LPG Engine • For additional information, refer to the engine operator’s Only qualified and trained operators may drive this manual included with your vehicle. vehicle. Perform all necessary vehicle preparation steps, •...

  • Page 21: Driving

    SAFETY RULES AND OPERATING INSTRUCTIONS Driving Towing Loads: • Do not exceed the DBP towing capacity of the tractor. • Slow down and sound the horn to warn pedestrians See vehicle specifications and DBP definition. or when approaching a corner or other intersection. •...

  • Page 22: Refueling

    SAFETY RULES AND OPERATING INSTRUCTIONS Refueling Draw Bar Pull (DBP), definition DBP is a measure of pulling force required to move a load. The load may be a trailing load or a pushed load. It The fuel system may be under pressure. If the is normally expressed in pounds or Newtons.

  • Page 23: Pm Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS NOTE: A full page copy of the Periodic Maintenance Checklist is on the PM CHECKLIST Vehicle Documentation CD under the [Misc] sub folder. Safety Rules and Operating Instructions Page 11...

  • Page 24: Maintenance Guidelines For Severe Duty Applications

    SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: • Tire condition and pressure. • External frame damage (body). • Proper operation of all external lights, internal lights, warning lights, warning alarms and/or horns. • Proper operation of all instrument panel gauges and/or warning lights. •...
  • Page 25 Chapter - Table of Contents Maintenance Guidelines ........ 2 Lubrication and Fluids Chart ......3 Lubrication Diagram ........4...
  • Page 26 Regularly inspect and maintain in a safe working condition, brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices. • Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in conformance with Taylor-Dunn’s ® recommended procedures. •...
  • Page 27 Maintenance, Service and Repair Lubrication and Fluids Chart Assembly ID# Component QTY Capacity Lubricant Front Axle: King Pin, Upper NLGI Grade 2 lithium multi-purpose grease 10 King Pin, Lower NLGI Grade 2 lithium multi-purpose grease Ball Joint NLGI Grade 2 lithium multi-purpose grease Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Power Steering:...
  • Page 28 Maintenance, Service and Repair Lubrication Diagram Page 4...
  • Page 29 Chapter - TABLE OF CONTENTS Inspect the Front Wheel Bearings and King Pin ......... 2 Adjust Front Wheel Bearings (used bearings) ......2 Adjust Front Wheel Bearings (new bearings) ....... 3 Align Front Wheels ......3 Front Hub, Steering knuckle, King Pin 4 Disassembly ............

  • Page 30: Inspect The Front Wheel Bearings And King Pin

    Maintenance, Service, and Repair INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS AND KING PIN BEARINGS (USED BEARINGS) DO NOT use this procedure to set new wheel bearings. Refer to Adjust Front Wheel Bearing for new bearing adjustment procedure. 1. Make sure the ignition switch is in the “OFF” position.

  • Page 31: Adjust Front Wheel Bearings (New Bearings)

    Maintenance, Service, and Repair ADJUST FRONT WHEEL ALIGN FRONT WHEELS BEARINGS (NEW BEARINGS) Alignment of the front wheels consists of setting the Toe In only. Camber and Castor are fixed and cannot be DO NOT use this procedure to set used wheel bearings. adjusted.

  • Page 32: Front Hub, Steering Knuckle, King Pin

    Maintenance, Service, and Repair FRONT HUB, STEERING KNUCKLE, KING PIN It is recommended that if a wearable component is replaced on one side of a vehicle, the same components should be replaced on the other side of the vehicle. Reassembly Disassembly Thoroughly clean and inspect all parts.

  • Page 33: Replace Front Wheel Bearings

    Maintenance, Service, and Repair REPLACE FRONT WHEEL BEARINGS It is recommended that if a wearable component is replaced on one side of a vehicle, the same components should be replaced on the other side of the vehicle. This procedure assumes that the front hub has been removed from the vehicle.

  • Page 34: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Outer Wheel Bearing Nut Ball Joint Clamp 28-32 38-43 Ball Joint Nuts 45-55 61-74 Hub Cap Bolts 27.1 Steering Arm Nuts Tighten to 160 Foot Pounds (217...
  • Page 35 Chapter - TABLE OF CONTENTS Steering Control Valve, Hydrostatic Steering ....... 2 Remove .............. 2 Install ..............2 Disassemble ............2 Reassemble ............3 Steering Control Valve, Exploded ..3 Troubleshooting, Hydrostatic Steering 4 Replace the Steering Cylinder, Hydrostatic Steering ....... 5 Remove ..............

  • Page 36: Steering Control Valve, Hydrostatic Steering

    Maintenance, Service, and Repair STEERING CONTROL VALVE, HYDROSTATIC STEERING Hydraulic fluid and components must be kept clean. Thoroughly clean exterior of any hydraulic component before disconnecting hoses or fittings. Perform all maintenance and repairs in a clean environment. Do not use cloth or paper towels to clean components due to possible contamination with lint or other fiber.

  • Page 37: Reassemble

    Maintenance, Service, and Repair 12. Install dust seal (16) into the seal gland bushing (18). Flat Reassemble or smooth side must face down into the bushing. Thoroughly clean all components and air dry. Read cleanliness 13. Install the quad ring seal (17) into the gland bushing. caution at the beginning of this section.

  • Page 38: Troubleshooting, Hydrostatic Steering

    Maintenance, Service, and Repair TROUBLESHOOTING, HYDROSTATIC STEERING The cause of most steering problems can be identified by the symptoms. The entire steering system must be analyzed by a qualified technician before any components are removed. Use the following chart to identify probable cause of steering problems. Symptoms: Possible Cause: Repair Procedure:...

  • Page 39: Replace The Steering Cylinder, Hydrostatic Steering

    Maintenance, Service, and Repair REPLACE THE STEERING REPLACE BALL JOINT CYLINDER, HYDROSTATIC It is recommended that if a wearable component is replaced on one side of a vehicle, the same components should be STEERING replaced on the other side of the vehicle. It is likely that the ball joint will be damaged when removed Remove from the steering arm.

  • Page 40: Wheel Alignment

    Maintenance, Service, and Repair WHEEL ALIGNMENT HARDWARE TORQUE Refer to Front Axle section If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Steering wheel nut Steering Valve Mounting Bolts 16.7 Steering Valve Cap Bolts (final) 19.6 See instuctions for 1st stage torque...
  • Page 41 M7-001-32 Diagmostics: M7-001-33 Parts: M7-001-34 Note: The above manuals are included on the CD provided with your vehicle. Additional Manuals may be purchased through your local Taylor-Dunn® distributor. A service manual order form (D4-010-00) is available on the vehicle CD.
  • Page 42 Notes:...
  • Page 43 Chapter - TABLE OF CONTENTS Fuel System, Gasoline ....... 2 Fuel System, LPG ......2 Fuel System, Cummins B4.5 Diesel .. 3 Fuel System, Perkins 1104C Diesel ... 3 Fuel, whether gasoline or LPG, is highly flammable. Use extreme care whenever servicing any component of the fuel system.
  • Page 44 Maintenance, Service, and Repair Fuel, whether gasoline, LPG or Diesel, is highly flammable. Use extreme care whenever servicing any component of the fuel system. Allow the engine to cool before starting work. • Confirm all pressurized fuel lines have been depressurized before opening any fuel line connection. •...
  • Page 45 Maintenance, Service, and Repair FUEL SYSTEM, CUMMINS B4.5 Fuel, whether gasoline, LPG, or Diesel, is highly DIESEL flammable. Use extreme care whenever servicing any component of the fuel system. Allow the engine to cool before starting • Failure to change the fuel filters as work.
  • Page 46 Notes:...
  • Page 47 Chapter - TABLE OF CONTENTS Coolant Level ........2 Inspection ............2 Adding Coolant ..........2 Radiator and Hoses ......2 Inspection ............2 Fan Belts ........... 2 Inspect ............... 2 Adjust ..............2 Hardware Torque ....... 3...
  • Page 48 Maintenance, Service, and Repair COOLANT LEVEL RADIATOR AND HOSES Inspection The coolant system is pressurized when the Inspect the exterior of the radiator for obstructions and engine is running or hot. damage to the cooling fins. The radiator fins can be Do not remove the radiator cap while the •...
  • Page 49 Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Cooling System Page 3...
  • Page 50 Notes:...
  • Page 51 Chapter - TABLE OF CONTENTS CLEANING AND INSPECTION Case ............20 Stator to Turbine Interference Check ..19 Control Valve Body ........15 Governor ..........15 Front Pump ..........15 Direct Clutch Piston Check Ball Leakage Procedure ......16 Forward Clutch ........16 Low—Reverse Clutch ......
  • Page 52 Maintenance, Service, and Repair DIAGNOSIS AND TESTING GENERAL INFORMATION Troubleshooting the automatic transmission is simplified All automatic transmissions are equipped with high by using the proven methods of diagnosis. One of the temperature resistant seals. This includes those seals most important things to remember is that there is a used on the manual and kickdown levers, the 0-rings definite procedure to follow.
  • Page 53 Maintenance, Service, and Repair Transmission Service - C6 Page 3...
  • Page 54 Maintenance, Service, and Repair Transmission Service - C6 Page 4...
  • Page 55 Proof Maintenance, Service, and Repair Transmission Service - C6 Page 5...
  • Page 56 Maintenance, Service, and Repair Transmission Service - C6 Page 6...
  • Page 57 Maintenance, Service, and Repair Transmission Service - C6 Page 7...
  • Page 58 Maintenance, Service, and Repair Transmission Service - C6 Page 8...
  • Page 59 Maintenance, Service, and Repair Transmission Service - C6 Page 9...
  • Page 60 Maintenance, Service, and Repair Transmission Service - C6 Page 10...
  • Page 61 Maintenance, Service, and Repair Transmission Service - C6 Page 11...
  • Page 62 Maintenance, Service, and Repair Transmission Service - C6 Page 12...
  • Page 63 Maintenance, Service, and Repair Transmission Service - C6 Page 13...
  • Page 64 Maintenance, Service, and Repair Transmission Service - C6 Page 14...
  • Page 65 Maintenance, Service, and Repair Transmission Service - C6 Page 15...
  • Page 66 Maintenance, Service, and Repair Transmission Service - C6 Page 16...
  • Page 67 Maintenance, Service, and Repair Transmission Service - C6 Page 17...
  • Page 68 Maintenance, Service, and Repair Transmission Service - C6 Page 18...
  • Page 69 Maintenance, Service, and Repair Transmission Service - C6 Page 19...
  • Page 70 Maintenance, Service, and Repair Transmission Service - C6 Page 20...
  • Page 71 Maintenance, Service, and Repair Transmission Service - C6 Page 21...
  • Page 72 Maintenance, Service, and Repair Transmission Service - C6 Page 22...
  • Page 73 Chapter - DESCRIPTION TABLE OF CONTENTS The C6 transmission is a three speed unit Capable of ADJUSTMENTS providing automatic upshifts and downshifts through Intermediate Band Adjustment ... 2 the three forward gear ratios. The transmission Is also capable of providing manual selection of first and DESCRIPTIONS second gears.
  • Page 74 Maintenance, Service, and Repair Transmission Repair - C6 Page 2...
  • Page 75 Maintenance, Service, and Repair Transmission Repair - C6 Page 3...
  • Page 76 Maintenance, Service, and Repair Transmission Repair - C6 Page 4...
  • Page 77 Maintenance, Service, and Repair Transmission Repair - C6 Page 5...
  • Page 78 Maintenance, Service, and Repair Transmission Repair - C6 Page 6...
  • Page 79 Maintenance, Service, and Repair Transmission Repair - C6 Page 7...
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  • Page 83 Maintenance, Service, and Repair Transmission Repair - C6 Page 11...
  • Page 84 Maintenance, Service, and Repair Transmission Repair - C6 Page 12...
  • Page 85 Maintenance, Service, and Repair Transmission Repair - C6 Page 13...
  • Page 86 Maintenance, Service, and Repair Transmission Repair - C6 Page 14...
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  • Page 88 Maintenance, Service, and Repair Transmission Repair - C6 Page 16...
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  • Page 90 Maintenance, Service, and Repair Transmission Repair - C6 Page 18...
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  • Page 93 Maintenance, Service, and Repair Transmission Repair - C6 Page 21...
  • Page 94 Maintenance, Service, and Repair Transmission Repair - C6 Page 22...
  • Page 95 Maintenance, Service, and Repair Transmission Repair - C6 Page 23...
  • Page 96 Notes:...
  • Page 97 Chapter - TABLE OF CONTENTS Check Oil Level ......... 2 TA-268 ............... 2 TA-267 ............... 2 Omsi Axle ............3 Change Oil ........4 TA-268 ............... 4 TA-267 ............... 4 Omsi Axle ............5 Drive Axle Service ......6 Disassembly ........7 Wheelend, Planetary - TA268 Drive Axle ..

  • Page 98: Check Oil Level

    Maintenance, Service, and Repair TA-267 CHECK OIL LEVEL TA-268 1. Make sure the ignition switch is in the “OFF” position. 2. Place the transmission shift lever in the Park or 1. Make sure the ignition switch is in the “OFF” Neutral position position.

  • Page 99: Omsi Axle

    Maintenance, Service, and Repair Omsi Axle 1. Make sure the ignition switch is in the “OFF” position. 2. Place the transmission shift lever in the Park or Neutral position 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement.

  • Page 100: Change Oil

    Maintenance, Service, and Repair TA-267 CHANGE OIL TA-268 1. Make sure the ignition switch is in the “OFF” position. 2. Place the transmission shift lever in the Park or Neutral position 1. Make sure the ignition switch is in the “OFF” position.

  • Page 101: Omsi Axle

    Maintenance, Service, and Repair Omsi Axle 1. Make sure the ignition switch is in the “OFF” position. 2. Place the transmission shift lever in the Park or Neutral position 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement.

  • Page 102: Drive Axle Service

    OMSI Drive Axle manual M7-001-41 and can be found on the CD included with your vehicle. Additional Manuals may be purchased through your local Taylor-Dunn® distributor. A service manual order form is available on the vehicle CD. Drive Axle Page 6...

  • Page 103: Disassembly

    Maintenance, Service, and Repair DISASSEMBLY Perform the following prior to disassembly. Remove axle from vehicle if required. 2. Clean exterior axle surfaces. Steam clean or pressure washer the complete axle assembly after plugging all breathers and vents. Do not direct full pressure at any seals. (input shall, wheel hubs or brakes) 3.

  • Page 104: Main Housing Disassembly

    Maintenance, Service, and Repair thrust washers, four differential pinions, four pinion Main Housing Disassembly thrust washers and the differential spider. Both axle ends, brakes, and nose reduction (if equipped) 7. If replacement of the bevel ring gear is required, must be removed before proceeding with this section. remove the twelve capscrews, washers and locknuts 1.

  • Page 105: Nose Reduction Box Disassembly - Ta267

    Maintenance, Service, and Repair Nose Reduction Box Disassembly - TA267 PREPARE PARTS FOR 1. Loosen input shaft nut, remove washer and input ASSEMBLY flange from then input shaft. 2. Remove input shaft bearing cap screws, lock Cleaning washers and bearing cap. 3.

  • Page 106: Assembly

    Maintenance, Service, and Repair ASSEMBLY Differential and Bevel Ring Gear Assembly Bevel Pinion and Cage Assembly 1. Press the bevel ring gear firmly against shoulder of 1. Press inner roller bearing firmly against bevel pinion flanged differential case half. Install the twelve shoulder and install inner roller bearing snap ring.

  • Page 107: Main Housing And Pinion Cage Assembly

    Maintenance, Service, and Repair Main Housing and Pinion Cage Assembly Nose Reduction Box Assembly - TA267 1. If assembling a TA267; skip to step #5. 1. Press input shaft oil seal to bottom of bore in reduction box case. 2. If assembling a TA268; apply a light film of sealing compound to both sides of the pinion cage gasket.

  • Page 108: Planetary Wheelend

    Maintenance, Service, and Repair 13. Thread the wheel bearing adjustment nut onto the Planetary Wheelend spindle. Tighten nut to 400 foot pounds. Rotate the 1. Before starting brake reassembly, apply a small wheel hub while rapping the hub several times with quantity of EP-2 grease to the following brake a 10 pound dead blow mallet, Retighten the nut to components:...
  • Page 109 Maintenance, Service, and Repair Planetary Wheel End Drive Axle Page 13...

  • Page 110: Standard Wheelend

    Maintenance, Service, and Repair 12. Assemble the piston boot to the piston. Install the Standard Wheelend piston in the caliper housing bore, pushing it to the 1. If inner bearing cup was removed from carrier and bottom of the bore. Seat the piston boot in caliper tube assembly, press new bearing cup to bottom of housing boot bore.
  • Page 111 Perform all maintenance and repairs in a clean environment. Do not use cloth or paper towels to clean components due to possible contamination with lint or other fiber. Failure to follow these guidelines will result in premature failure of hydraulic system components. Current Taylor-Dunn brakes are asbestos free. ®...

  • Page 112: Front Brake

    Hardware Torque table at the end of this section. 18. Bleed the brake system. 19. Lower the vehicle. Current Taylor-Dunn brakes are asbestos free. ® 20. Rremove the blocks from behind the wheels and test drive However, there is the possibility that the original the vehicle.

  • Page 113: Rear Brake - Axle Omsi

    Maintenance, Service, and Repair Front Brake Assembly REAR BRAKE - AXLE OMSI Brake service information is provided by the brake manufacturer. The manufacturer’s manual can be found on the CD provided with the vehicle. The manual number is: M7-001-41 Brake Service Page 3...

  • Page 114: Rear Brake - Axle Ta267

    Maintenance, Service, and Repair REAR BRAKE - AXLE TA267 Service Limits: Brake pad Thickness: 1/16” (1.6 mm) Rotor Thickness: 0.826” (21 mm) Rotor runout: 0.005 inches (0.127 mm). It is recommended that if a wearable component is replaced on one side of a vehicle, the same components should be replaced on the other side of the vehicle.

  • Page 115: Rear Brake - Axle Ta268

    The complete manual can be downloaded from the manufacturer web site: http://www.axletech.com/service_manuals/pdf/standard/ MM4H.pdf Description Current Taylor-Dunn brakes are asbestos free. ® However, there is the possibility that the original brakes were replaced with aftermarket parts Remove the two brake shoe return springs from the anchor containing asbestos.

  • Page 116: Adjust Dsh Brake

    Maintenance, Service, and Repair To install the two shoe retainer clips, engage the clip on to 15. Rotate the star wheel on the adjustment bolt to see that it the retainer pin and rotate the clip down until it sets flat on can easily rotate with a “click”...

  • Page 117: Master Cylinder

    Maintenance, Service, and Repair Pump the brake pedal a few times and then press and MASTER CYLINDER hold light pressure to the brake pedal. 10. Open the brake bleeder valve. There are no serviceable components in the hydroboost or master cylinder. If there is a fault in the hydroboost or master 11.

  • Page 118: Adjust Parking Brake (Drive Shaft Brake Drum)

    Release the park brake and test drive the vehicle. drum must be replaced. Secondary Adjustment 1. Make sure the ignition switch is in the “OFF” Current Taylor-Dunn brakes are asbestos free. ® position, then remove the key. However, there is the possibility that the original brakes were replaced with aftermarket parts 2.

  • Page 119: Adjust Parking Brake (Drive Shaft Disc Brake)

    Maintenance, Service, and Repair Inspection ADJUST PARKING BRAKE (DRIVE SHAFT DISC BRAKE) Service Limits Brake pad Thickness: 0.090 inches (2.29 mm). Primary Rotor Thickness: 0.400 inches (10.2 mm). The primary adjustment for the parking brake is the knob on Rotor runout: 0.010 inches 0.127 mm). the end of the parking brake handle.

  • Page 120: Mounting Procedure

    Maintenance, Service, and Repair The following information was provided by the brake Install Ball/Retainer Assembly (8) onto Adjusting Bolt (2), manufacturer. Refer to the illustration on the following pages orienting balls into pockets of inner Cam (4). Install outer for item numbers. Cam (4) onto Adjusting Bolt (2), orienting pockets onto Balls of Ball/Retainer Assembly (8).

  • Page 121: Sleeve Seal Replacement

    Maintenance, Service, and Repair Sleeve Seal Replacement Loosen the two locking nuts on the mounting bolts and remove the sleeve/bolt subassembly (9) from the brake. Remove sleeve seals (14). Insert new sleeve seals (14) between the Torque Plates (5 & 7) and align with the sleeve bores. NOTE: PRIOR TO THE INSTALLATION OF THE MOUNTING BOLT &...

  • Page 122: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Brake Mounting Bolts Brake Service Page 12...
  • Page 123 Chapter - TABLE OF CONTENTS Front Suspension ......2 Rear Suspension ....... 2 Hardware Torque ....... 3...
  • Page 124 Maintenance, Service, and Repair FRONT SUSPENSION REAR SUSPENSION Rear suspesion is a solid mount to the frame. Suspension Page 2...
  • Page 125 Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Front Spring, Front Eye ** - Tighten untill the spring hangers or mounting brackets are solid against the spring eye and then loosen the nut 1/4 turn.
  • Page 126 Notes:...
  • Page 127 Chapter - TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Tire/Wheel Assembly ......3 Remove/Install ........... 3 Hardware Torque ....... 3...
  • Page 128 Maintenance, Service, and Repair TIRE INFLATION There are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires. The illustration below is an example of the side wall information on a tire. Tire pressures must be checked when the tire is cold.
  • Page 129 Maintenance, Service, and Repair TIRE/WHEEL ASSEMBLY HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Remove/Install Description Foot Pounds Newton Meters Wheel Nut, Front 90-110 122-149 1. Make sure the start switch is in the “OFF” Wheel Nut, Rear 110-120 149-162...
  • Page 130 Notes:...
  • Page 131 Chapter - TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Watering ..........4 Storing ..........5 Storage ............... 5 Returning to Service .......... 5 Remove/install ........6 Hardware Torque ....... 7 • • • • • Explosive mixtures of Hydrogen gas are present within battery cells at all times.

  • Page 132: Cleaning

    Maintenance, Service, and Repair CLEANING • • • • • Explosive mixtures of Hydrogen gas are 1. Make sure the start switch is in the “OFF” present within battery cells at all times. Do not position, then remove the key. work with or charge battery in an area where open flames (including gas furnace or water 2.

  • Page 133: Testing

    Maintenance, Service, and Repair TESTING Specific Gravity NOTE: The battery must be fully charged before • • • • • Explosive mixtures of Hydrogen gas are performing this test. present within battery cells at all times. Do not This test should only be performed on non-maintenance work with or charge battery in an area where free batteries.

  • Page 134: Watering

    Maintenance, Service, and Repair WATERING • • • • • Explosive mixtures of Hydrogen gas are Do not overfill the batteries. Over filling the present within battery cells at all times. Do not batteries may cause the batteries to boil over work with or charge battery in an area where and result in severe bodily injury or property open flames (including gas furnace or water...

  • Page 135: Storing

    Maintenance, Service, and Repair STORING Storage Thoroughly clean the battery and battery compartment. Cleaning Refer to in this section for information regarding cleaning the battery. Check the electrolyte level and charge the battery. Refer Watering in this section for information regarding checking the electrolyte level.

  • Page 136: Remove/Install

    Maintenance, Service, and Repair REMOVE/INSTALL • • • • • Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.

  • Page 137: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Note: Depending on options ordered with the vehicle, the battery may have either a post or stud terminal. Description Inch Pounds Newton Meters Battery Terminal (clamp type) 48-60...
  • Page 138 Notes:...
  • Page 139 Chapter - 15 CONTENTS Wire Diagram, Chassie (P1) ....2 Wire Diagram, Chassie (P2) ....3 Hydraulic Diagram ......4...
  • Page 140 Wire Diagrams Note: A fill size diagram is avaiable on the CD provided with WIRE DIAGRAM, CHASSIE (P1) the vehicle. The diagram # is SCH-00036. Wire Diagrams Page 2...
  • Page 141 Wire Diagrams Note: A fill size diagram is avaiable on the CD provided with WIRE DIAGRAM, CHASSIE (P2) the vehicle. The diagram # is SCH-00036. Wire Diagrams Page 3...
  • Page 142 Wire Diagrams HYDRAULIC DIAGRAM Wire Diagrams Page 4...
  • Page 143 Chapter - Illustrated Parts TABLE OF CONTENTS Axle Assembly, Front ........2 Axle Assembly, Rear Secondary Gears ..4 Axle Assembly, Rear Axles ......6 Axle Assembly, Mount to Frame ....6 Axle Assembly, Rear Primary Gears ..... 8 Brake Pedal Linkage ........9 Brakes, Brake Lines ........

  • Page 144: Axle Assembly, Front

    Refer to Steering pages for items that are grayed Illustration shows axle from TC-30- 60. The TC 30-60L axle is the same with the exception of the steering arms shown below Parts - TC-030-60L * Not available at time of printing Page 2...
  • Page 145 500851 Seal 504917 Knuckle, Right 504916 Knuckle, Left 500857 Kit, King Pin (left and right) 15-900-01 Axle Beam 500571 Grease Fitting, King Pin Bushing A10621 Shim, King Pin TC-030-60L - Parts * Not available at time of printing Page 3...

  • Page 146: Axle Assembly, Rear Secondary Gears

    Ring and Pinion gear A11487 Pinion gear A11488 Bearing A11489 Lock ring A11452 Differential housing assembly A11490 Differential flange A11491 Differential housing A10163 Washer A10162 Cap screw TIG-2001-119 Thrust washer Parts - TC-030-60L * Not available at time of printing Page 4...
  • Page 147 Breather A11495 Housing A10166 Bearing Race A10179 Plug A11496 Housing A10193 Thrust block TIG-2001-263 A10166 Bearing race A11429 Plug, magnetic See rear brakes Brake assembly A11498 Pin, sliding TC-030-60L - Parts * Not available at time of printing Page 5...

  • Page 148: Axle Assembly, Rear Axles

    Replacement Parts Axle Assembly, Rear Axles Axle Assembly, Mount to Frame Parts - TC-030-60L * Not available at time of printing Page 6...
  • Page 149 Mounting Plate, Right Side 504183 Mounting Plate, Left Side 88-403-36 Bolt, Axle mount 88-403-70 88-403-46 Bolt, Frame Mount, Rear 88-403-70 88-403-80 Washer 88-403-45 Bolt, Frame Mount, Front 88-403-70 TC-030-60L - Parts * Not available at time of printing Page 7...

  • Page 150: Axle Assembly, Rear Primary Gears

    Brake disc A10165 Washer A11467 Cap screw A11481 A11482 Brake assembly A11483 Lock nut A10182 Bearing TIG-2001-231 Washer A11421 TIG-2001-233 Flange 34475 Washer A11450 Stud A10642 Gear case assembly Parts - TC-030-60L * Not available at time of printing Page 8...

  • Page 151: Brake Pedal Linkage

    Brake Pedal Linkage Illustration Not Available Item No. Part No. Description 504273 Brake Pedal (includes bushings) 503191 Bushing 500185 Bolt 88-401-80 88-401-95 Washer 4-2384994 Pedal Return Spring 505502 Hydroboost Assembly TC-030-60L - Parts * Not available at time of printing Page 9...

  • Page 152: Brakes, Brake Lines

    Replacement Parts Brakes, Brake Lines Parts - TC-030-60L * Not available at time of printing Page 10...
  • Page 153 See Transmission T-Fitting (optional) See Transmission Solenoid, Shift Interlock (optional) 4-2793669 Brake Line Not Shown 500243 Hose Clamp, Rear Axle Brake Lines 504867 Frame Mount, Rear Brake Hoses TC-030-60L - Parts * Not available at time of printing Page 11...

  • Page 154: Brakes, Front Axle

    Bolt, Caliper Mounting 88-401-96 Washer, Split Lock, Caliper Mounting 903641 Piston 41-348-62 Kit, Brake Pad, Includes 4 pads and safety wire 505879 Safety Wire (for #5) Per Ft. Parts - TC-030-60L * Not available at time of printing Page 12...

  • Page 155: Brakes, Parking Brake

    Cotter Pin K9N-700-99 Bracket, Cable 88-527-11 Cotter pin 41-386-00 Bracket, Rear Cable Mounting 88-402-75 Nut, Mounting 88-108-61 Washer 88-109-81 501273 Caliper Assembly 245437 Kit, Brake Pads 501272 Brake Rotor TC-030-60L - Parts * Not available at time of printing Page 13...

  • Page 156: Brakes, Rear Axle

    Unleaded Fuel, White Text 504938 Check Engine 500233 Operation 501040-7 Shift Inhibitor 500235 Unleaded Fuel, Black Text 4-2376150 Fan Warning 500236 Diesel Fuel Only 500662 Headlights 201324-6 Parking Brake 4-2775281 Warning Parts - TC-030-60L * Not available at time of printing Page 14...

  • Page 157: Electrical, Miscellaneous

    Description 500350-18 HARNESS, ENGINE SENSORS 500350C WIRING HARNESS \ MAIN \ 2001+ 4-2793322 Battery Cable, Positive 501389 Battery Cable, Negative 501040-5B HARNESS, SHIFT INHIBITOR (optional) 0 or 1 TC-030-60L - Parts * Not available at time of printing Page 15...

  • Page 158: Engine, Gm

    M16X2 X 40MM 10.9 FLGHCS 66-900-07 Mount, Steering Pump, Lower 66-900-20 Mount, Steering Pump, Upper 66-900-06 Mount, Steering Pump, Rear 66-900-08 Belt, Steering Pump 66-900-09 PULLEY, WATER PUMP, 2 GROOVES Parts - TC-030-60L * Not available at time of printing Page 16...

  • Page 159: Engine, Cooling System, Gasoline / Lpg

    Includes Tank, Wire bracket, Hoses, clamps 88-401-01 Bolt, bracket mounting 88-401-95 Washer 88-401-87 88-401-01 Bolt, Recovery Tank Bracket 88-401-40 Washer, Recovery Tank Bracket 88-401-30 Nut, Recovery Tank Bracket TC-030-60L - Parts * Not available at time of printing Page 17...

  • Page 160: Engine, Air Cleaner (Lpg)

    Mounting Bracket, Clamp 88-401-02 Bolt 88-401-40 Washer 88-401-31 504275 Flex Coupler K2T-600-01 Tube Intake 502522 Clamp 505844 Hose, Coupler 502131 Clamp, Hose 502131 Clamp 98-540-14 Hose, Crankcase Vent per foot Parts - TC-030-60L * Not available at time of printing Page 18...

  • Page 161: Exhaust, Gasoline, Lpg

    HEAD PIPE 30/60 L 3.0 L GM PSI 01-900-33 MUFFLER, HANGER (clamp) 98-080-08 Wrapl Heat Insulation Per roll 01-300-42 Hanger, Muffler (rear) K2T-700-22 Mount, Exhaust/shiffter cable 505735 CLAMP, MUFFLER, 1 3/4" TC-030-60L - Parts * Not available at time of printing Page 19...

  • Page 162: Frame And Body

    VALVE LPG RLF 400 PSI 1/4 NPT 502024-28 HOSE, LPG TANK 2-30900122 LPG TANK 33-1/2 500225 CLAMPS\LPG TANK MOUNTING 503894 LOW LPG INDICATOR (dash mounted) 66-611-26 Mounting Bracket, Vaporizer 500679 CONNECTOR LP TANK Parts - TC-030-60L * Not available at time of printing Page 20...

  • Page 163: Instrument Panel

    Gauge, Hour Meter 500116 Gauge, Oil Pressure 500128 Switch, Ignition (keykless) 0 or 1 500128K Switch, Ignition (keyed) 0 or 1 4-2774690 Bezel, Switch (left side 3 position) TC-030-60L - Parts * Not available at time of printing Page 21...

  • Page 164: Lights

    Reflector, Front Round 502142 Reflector, Side, Red 502143 Reflector, Side, Amber 72-018-23 MIL Light 502321 Bulb, Shift Light 502321 Bulb, Fuel Gauge 500650 LAMP\FNT.TURN SIGNAL/YELLOW (optional) 504945 504945 500636 FLASHER Parts - TC-030-60L * Not available at time of printing Page 22...

  • Page 165: Steering, Hydrostatic, Hydraulics

    Adapte, 90 STR THD O-RING 3/8 1/2 99-531-98 Hose, Steering Valve “L” port 99-531-99 Hose, Steering Valve “R” port See mechanical parts Steering Cylinder K2T-700-16 Hose, Return Line Assembly 201037 Steering Column TC-030-60L - Parts * Not available at time of printing Page 23...

  • Page 166: Steering, Hydrostatic, Mechanical

    45946 ROD END, SOCKET, FEMALE 500854 Ball Joint, Right Thread, Steering Cylinder 18-054-20 Tie Rod 201039 Steering Wheel 201283 88-128-13 Bolt, Steering Stop 500840 Nut, Steering Stop Bolt Parts - TC-030-60L * Not available at time of printing Page 24...

  • Page 167: Suspension, Front

    Replacement Parts Suspension, Front Item No. Part No. Description 4-2773135 Pad, Spring Slider 88-402-52 Bolt 88-402-80 4-2775695 Leaf Spring CL-991017 Spring Eye Bushing 88-404-94 Bolt 88-403-10 Washer 88-403-05 TC-030-60L - Parts * Not available at time of printing Page 25...

  • Page 168: Transmission Assembly / Drive Shaft

    Pin, Shift Inhibitor 501040-2 Bracket, Shift Inhibitor 501040-3 Solenoid 501040-6A Lamp 501040-8 SPRING PIN, 3/32 X 1 SS 501040-9 Spring 501332 LAMP\RED PILOT 502321 BULB, LIGHT #53 A12300 Pressure Switch Parts - TC-030-60L * Not available at time of printing Page 26...

  • Page 169: Transmission Components (P1)

    Replacement Parts Transmission Components (p1) TC-030-60L - Parts * Not available at time of printing Page 27...

  • Page 170: Transmission Components (P2)

    Replacement Parts Transmission Components (p2) Parts - TC-030-60L * Not available at time of printing Page 28...

  • Page 171: Transmission Components (P3)

    Replacement Parts Transmission Components (p3) TC-030-60L - Parts * Not available at time of printing Page 29...

  • Page 172: Transmission Components (P4)

    Replacement Parts Transmission Components (p4) Parts - TC-030-60L * Not available at time of printing Page 30...

  • Page 173: Wheels And Tires

    Tire, 6.50 x 10, includes tube 500972 Wheel, 10 x 5.5 502758 Wheel Assembly, Rear 500257 Tire, LT225-75R16 LR-D (tubeless) 500684 Wheel, 16 x 6 500218 Valve Stem TC-030-60L - Parts * Not available at time of printing Page 31...
  • Page 174 Notes:...
  • Page 175 Contents Appendix A: Suggested Torque Limits for Standard Hardware ......2 Hardware Identification ...... 2 Standard Head Markings ........2 Hex Bolts ............2 Other Bolts ............2 Hex Nuts ............3 Hex Lock Nuts (stover) ........3 Other Nuts ............3 Generic Torque Values ........

  • Page 176: Appendix A: Suggested Torque Limits For Standard Hardware

    Appendixes APPENDIX A: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings 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. NOTE: Toque values specified are for clean dry threads.

  • Page 177: Hex Nuts

    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 Appendixes *Not available at time of printing Appendix B Page 3...

  • Page 178: Generic Torque Values

    Appendixes Generic Torque Values 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. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 179 Appendixes 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 Grade, N-m...

  • Page 180: Appendix B: Brake Lining Handling Precautions

    Appendixes APPENDIX B: BRAKE LINING HANDLING PRECAUTIONS Taylor-Dunn does not currently supply asbestos fiber-brake pads/ shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the brake pads/ shoes should be handled as if they do contain asbestos.
  • Page 182 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Visit our Website: www.taylor-dunn.com...

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