Taylor-Dunn B0-200-00 Service And Replacement Parts Manual Download

Page: 109 / 188

Batteries

Page 109

MB-210-13

B-200 & B-210 Models

CLEANING

Disconnect the batteries before cleaning.
Dry dirt can be readily blown off with low-pressure air

or brushed off.

Note: Wetness or wet dirt on the top of the battery

indicates battery acid boil over or excessive

gassing.

Using a nonmetallic brush with flexible bristles, wash

the battery off with a strong solution of baking soda and

hot water mixed with a ratio of one pound of soda to

one gallon of water (0.5 kg / 3.7 liters). Continue until

all fizzing stops, which indicates that the acid has been

neutralized. Then rinse thoroughly with clear water. DO

NOT get any of the solution into the battery cells.

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 and beginning of this

section..

WARNING

WATERING

Note: The electrolyte level in a battery rises while

charging and will be close to its highest

level after the end of a charging cycle. It is

recommended to fill the battery at the end of

a charging cycle. If the electrolyte is below

the top of the battery plates then fill just

enough to cover the plates and then top off

when the charging cycle is complete.

Clean the battery. Refer to Cleaning section for

information on cleaning the battery.

Check the electrolyte level in all battery cells. If low, fill

to the correct level (see illustration) with distilled water

using part number 77-201-00 battery filler, never add

additional battery electrolyte to the batteries.

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 and beginning of this

section..

WARNING

DO NOT attempt to add water to a sealed battery.

Removing the caps of a sealed battery will damage

the battery resulting in premature failure.

NOTICE

CHARGING

Refer to the Operator manual for information regarding charging the battery.

Summary of Contents for B0-200-00

Page 1: ...E The operator s manual contains important information regarding the safe operation of this vehicle WARNING Starting Serial Number 207700 Ending Serial Number See Introduction Chapter Service and Repl...

Page 2: ...acement 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 wit...

Page 3: ...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 If you do not have access to the internet you can call th...

Page 4: ...n 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 internation...

Page 5: ...tion 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 Motor Controller 99 Wire Diagram 103 Batteries 107 Tires Wheels 11...

Page 6: ......

Page 7: ...ure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Introduction About this manual 8 Who Should Read This Manual 8 How To Use This Manual 8 Conventions 9...

Page 8: ...ropriate Taylor Dunn manual Each Taylor Dunn manual references the applicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in...

Page 9: ...e NOTICE This signal word will not be accompanied by the safety alert symbol NOTICE will indicate a condition that if not avoided may result in property damage Property is defined as the vehicle compo...

Page 10: ...rd automotive maintenance procedures and lead acid batteries Of the Operator A vehicle shall not be operated until the operator has successfully completed an operator training course provided by the o...

Page 11: ...del and serial numbers are shown in the illustrations below WEB SITE REGISTRATION Registering on the Taylor Dunn web site will give you access to a wealth of information about your vehicle and the ent...

Page 12: ...Page 12 MB 210 13 Introduction B 200 B 210 Models Notes...

Page 13: ...ts Service Maintenance Guidelines Service Maintenance Guidelines READ ME FIRST Maintenance Guidelines and General instructions 14 Vehicle Modifications 15 Replacement Parts 16 Using Non OEM Replacemen...

Page 14: ...ains attached to the left and right side of the vehicle Failure to properly support the vehicle may result in the vehicle tipping over causing severe bodily injury and or property damage WARNING The v...

Page 15: ...fe operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed according...

Page 16: ...n vehicle 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...

Page 17: ...ative 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...

Page 18: ...iven Rear and side view mirror adjustments Steering operation Brake operation service and park brake Tire pressure visual inspection only Proper operation of trailer hitch This section is one section...

Page 19: ...fins or vents Clean exterior of drive motor Every 3 Months or 300 hours All monthly items plus the following Adjust park and or service brake Clean battery compartment Inspect and tighten all hardware...

Page 20: ...le pedal and press again The vehicle should operate normally Operator Presence Switch Sit in the approved operator position turn the start switch ON select a direction and slowly press the throttle pe...

Page 21: ...Table of Contents Special Tool List Special Tool List Controller Programming 22 Troubleshooting Guide 24...

Page 22: ...plete troubleshooting provided in the vehicle service manuals 62 027 61 and 62 Sevcon System Handset Diagnostics and adjustments 62 only of the Sevcon Power Pak and Micro Pak control systems 70 440 55...

Page 23: ...d auto shutoff when cell is full 77 200 00 Hydrometer Used for testing battery electrolyte Illustration is of a typical hydrometer actual hydrometer type may vary 96 500 48 GT Drive Oil Fill Plug Tool...

Page 24: ...nd or Low Brake Pedal Air in brake lines Bleed brake system Master cylinder fluid level low Fill master cylinder and bleed system Brake pedal linkage out of adjustment Adjust linkages Hard Brake Pedal...

Page 25: ...Table of Contents Lubrication Lubrication Lubrication and Fluids Chart 26 Hazardous Waste Disposal 26 Lubrication Diagram 27...

Page 26: ...r Oil 9 Fill Plug SD 1 1 4 Liters SAE 80W90 Gear Oil 9 Fill Plug B 200 1 0 33 Liters SAE 30 Motor Oil 10 Motor Coupler 1 Part 94 421 34 Moly Paste Grease 11 Fill Level SD Axle 1 0 75 Liters SAE 80W90...

Page 27: ...Lubrication Page 27 MB 210 13 B 200 B 210 Models LUBRICATION DIAGRAM GT Rear Axle Lubrication SD Transaxle B 200 Rear Axle...

Page 28: ...Lubrication Page 28 B 200 B 210 Models MB 210 13 Notes...

Page 29: ...ervice Guidelines chapter WARNING 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 Fro...

Page 30: ...t Suspension for information regarding removing the springs and shocks Installation 1 Raise the front of the vehicle and support with jack stands 2 Install the front axle in reverse order of removal N...

Page 31: ...hese procedures Replace the Steering Knuckle Replace the King Pins and Bushings NOTE The front axle does not have to be removed unless the axle beam must be replaced Refer to Front Axle Removal and In...

Page 32: ...el s off of the ground and support with jack stands 2 While rotating the wheel tighten the front axle nut until the wheel is difficult to rotate 3 Continue to rotate the wheel for 5 compete revolution...

Page 33: ...le at the end of this section 11 Untie the steering wheel and the front wheels 12 Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not c...

Page 34: ...Raise the front of the vehicle and support with jack stands 2 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 3 Remove the...

Page 35: ...he front of the vehicle and support with jack stands 2 Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 3 Press the king pin bu...

Page 36: ...els MB 210 13 SERVICE LIMITS AND SPECIFICATIONS Toe In 0 0 25 inches 6 3 mm HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28 32 37 9 43 4 Rod End Stud Nut 20 25 27 1 33 9 Rod...

Page 37: ...el 38 Change Oil 38 Remove 39 Install 39 Axle Shaft 40 Remove 40 Install 40 Rear Hub Rotor Bearings 41 Motor Remove 41 Primary Gear Case 42 Secondary Gear Case 43 Disassemble 43 Assemble 43 Pinion Bea...

Page 38: ...rain until level with the bottom of the opening 8 Replace the fill level plug 9 Reconnect the batteries 10 Remove the blocks from the wheels This section is one section of a complete service manual Be...

Page 39: ...Do not remove the bolts at this time 7 Remove the four u bolts holding the spring to the axle tubes 8 Remove the two lower spring hanger bolts and raise the vehicle high enough to remove the drive an...

Page 40: ...the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage WARNING Install 11 Install in reverse order or removal a Lubricate the bearing external O ring b...

Page 41: ...hind the wheels release the park brake and test drive This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the...

Page 42: ...e position in relation to the 3rd member housing so that it will be reassembled in the same position 12 Remove the six retaining bolts holding the gear case to the 3rd member housing 13 Remove the gea...

Page 43: ...Thoroughly clean all parts 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 44: ...to the pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing race ring nut equally Note To move the ring gear away from the pinion Loosen the cover carrier be...

Page 45: ...nce in millimeters from the rear of the drive housing to the face of the pinion gear see illustration Once a shim has been selected and the pinion gear is installed confirm that E D B DV Set Pinion Be...

Page 46: ...9 Drain plug 21 25 28 4 33 Gear case to 3rd member 18 20 24 4 27 3rd Member cover bolts 40 50 54 67 5 Axle hub bolt 275 392 Note Special Washers The washers for the primary gear case housing and carri...

Page 47: ...rvice Guidelines chapter WARNING Transaxle SD Check Oil Level 48 Change Oil 48 Remove 49 Install 49 Axle Shaft 50 Remove 50 Install 50 Rear Hub Rotor Bearings 51 Motor Remove 51 Primary Reduction Gear...

Page 48: ...the bottom of the opening Refer to Lubrication section for oil specification If oil comes out of the opening allow to drain until level with the bottom of the opening 10 Reconnect the batteries and t...

Page 49: ...o not remove the bolts at this time 7 Remove the four u bolts holding the spring to the axle tubes 8 Remove the two lower spring hanger bolts and raise the vehicle high enough to remove the drive and...

Page 50: ...he axle shaft Use new bolts for the axle retaining plate If the wheel hub was removed install the hub and rotor Torque the hub bolt to the specification listed in the table at the end of this section...

Page 51: ...s have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily i...

Page 52: ...all bearings and gears with clean oil 6 Install new seals and wipe the seal lip with grease 7 Place the outer housing on a CLEAN flat bench 8 Brush a small amount of axle oil into the three bearing bo...

Page 53: ...Transaxle Page 53 MB 210 13 B 200 B 210 Models...

Page 54: ...ion is for reference only This assembly is not serviceable with the exception of oil seals HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Fo...

Page 55: ...y procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Drive Axle D1 Check Oil Level 56 Change Oil 56 Drive Motor 57 Remove 57 Install 57 Differentia...

Page 56: ...ice manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING CHANGE OIL Fluid type and capacities are listed in the lubricatio...

Page 57: ...ssion input shaft rubber bushing and the motor armature coupling 3 Install the rubber bushing back into the motor armature coupling 4 Lightly grease the transmission input shaft only see caution 5 Ins...

Page 58: ...differential case cover being careful not to bend or damage the case cover flange or the sealing surface of the differential case 6 Remove the differential bearing caps and remove the differential as...

Page 59: ...bearing with an ID bearing puller 14 While supporting the shaft and gear assembly repeat steps 12 and 13 for the opposite side bearing and remove the intermediate shaft from the housing 15 Remove the...

Page 60: ...9 Apply Loctite RC 609 to both sides of the intermediate bore and install new bore plugs Drive the bore plugs until they are firmly seated against the snap rings 10 Install the final drive gear onto t...

Page 61: ...E 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 6 8 8 10 5 Final Drive Gea...

Page 62: ...Drive Axle Page 62 B 200 B 210 Models MB 210 13 Notes...

Page 63: ...cated in the Service Guidelines chapter WARNING 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 St...

Page 64: ...re read all warnings and instructions that are located in the Service Guidelines chapter WARNING This section is one section of a complete service manual Before starting any procedure read all warning...

Page 65: ...ing adjuster jam nut 7 Find the center position of the steering shaft a Turn the steering shaft all of the way in one direction b While counting the rotations turn the steering shaft all of the way in...

Page 66: ...drive 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 REPLACE ROD E...

Page 67: ...haft splines steering wheel splines and the upper steering shaft bushing 8 Install the steering shaft in reverse order using a new pinch bolt Orientate the shaft so that the pinch bolt is opposite the...

Page 68: ...ion 5 Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration 6 Tighten the steering wheel nut to torque listed in the Hardware Tor...

Page 69: ...earing adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing Note The side cover pitman shaft assembly normally...

Page 70: ...k nut 23 Rotate the worm shaft to center the ball nut in the housing 24 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mo...

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

Page 72: ...RDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28 32 37 9 43 4 Rod End Stud Nut 20 25 27 1 33 9 Rod End Jam Nut 20 25 27 1 33 9 Ball Joint Castle Nut 40 45 54 2 61 Steering Wheel...

Page 73: ...he Service Guidelines chapter WARNING 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...

Page 74: ...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 i...

Page 75: ...move fluid from the master cylinder until it is 1 2 full 3 Raise the front of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for informatio...

Page 76: ...2 full 3 Raise the rear of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 5 Remove...

Page 77: ...of the end of the piston Fig 2 8 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove Fig 3 9 Press the pistons all the way down into the brake...

Page 78: ...at there is still air in the brake lines 10 Repeat this process with each of the other wheels Note When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information...

Page 79: ...he master cylinder cap and remove the cap 2 Add brake fluid from a new sealed container to the master cylinder until it as the maximum level line molded in the reservoir This section is one section of...

Page 80: ...to Adjust the Parking Brake section for information regarding adjusting the parking brake Adjust 1 Release the park brake 2 Loosen the jam nuts on the Primary Adjustment Rod 3 Tighten the Primary Adj...

Page 81: ...Brakes Page 81 MB 210 13 B 200 B 210 Models...

Page 82: ...appendix Description Foot Pounds Newton Meters Brake Body Bolts 11 14 9 SERVICE LIMITS Description Imperial Metric Disc brake Pad minimum lining 00625 inch 1 58 millimeter Front rotor minimum thicknes...

Page 83: ...ont 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 B...

Page 84: ...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 i...

Page 85: ...Remove fluid from the master cylinder until it is 1 2 full 3 Raise the front of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for informat...

Page 86: ...ake and test drive the vehicle Adjust the Service Brake Linkage Do not use this procedure to adjust the brakes This procedure should only be performed when replacing any of the mechanical brake linkag...

Page 87: ...Loosen the connecting rod 4 Adjust the park brake linkage so that the angle between the connecting rod and the cross shaft tab is at 60 degrees 5 Tighten the connecting rod so that all slack is remov...

Page 88: ...rfaces contaminated with grease may cause the brakes to fail resulting in property damage and or severe bodily injury WARNING Replace 1 Release the park brake 2 Raise the rear wheels off of the ground...

Page 89: ...of the end of the piston Fig 2 8 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove Fig 3 9 Press the pistons all the way down into the brake...

Page 90: ...at there is still air in the brake lines 10 Repeat this process with each of the other wheels Note When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information...

Page 91: ...in the bore of the master cylinder then it must be replaced 8 Lubricate all parts with clean brake fluid from a sealed container 9 Reassemble in reverse order 10 If the master cylinder is not to be im...

Page 92: ...x Description Foot Pounds Newton Meters Brake Body Bolts 11 14 9 SERVICE LIMITS Description Imperial Metric Disc pad lining minimum thickness 00625 inch 1 58 mm Front rotor minimum thickness 0 200 inc...

Page 93: ...l Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING SEM Motor B 210 Remove Install 94 Disassemble 94 Inspect 95 Brushes 95 Bea...

Page 94: ...screws from the rear motor housing and remove the housing from the motor 6 Remove the nuts from the armature studs and remove the two brush assemblies 7 Remove the bearing circlip and press the motor...

Page 95: ...ing any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Inspect the commutator for groves If the commutator is grooved then it must be machined...

Page 96: ...tire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity around the entire com...

Page 97: ...commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut see below 6 While still in the lathe smooth the comm...

Page 98: ...es Armature Field 70 052 40 XP 1876 or DD3 4004 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 73 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0 0116 1 2 70 054 41 XP 1789 or DY2 4001...

Page 99: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Controller Remove Install 100 Inspect 100 Receptacles 100 Base Plate 100 Terminal...

Page 100: ...at sink is installed then these bolts may also hold the heat sink to the panel Install 1 Thoroughly clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the cont...

Page 101: ...support field modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the PCpaK application and c...

Page 102: ...ller Page 102 B 200 B 210 Models MB 210 13 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal stud 38 44 4 29...

Page 103: ...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 Wire Diagram Diagram Pa...

Page 104: ...ed at this size The wire diagram for this vehicle is included on the Vehicle Documentation CD provided with the vehicle The diagram s for this vehicle are B 210 SCH 00009 B 200 SCH 00010 This vehicle...

Page 105: ...F1 Green AC CHARGER CORD Blue Blue 1 2 Black Gray White Red White Blue Yellow Green Black Gray Black White Black Blue Black Violet Black Red Red Blue White White White Violet Black Black Gray White R...

Page 106: ...Green AC CHARGER CORD Blue Blue 1 2 Black Gray White Red White Blue Yellow Green Black Gray Black White Black Blue Black Violet Black Red Red Blue White White White Violet Black Black Gray White Red...

Page 107: ...ctions that are located in the Service Guidelines chapter WARNING Batteries General Guidelines and Safety 108 Cleaning 109 Charging 109 Watering 109 Testing 110 Specific Gravity 110 Storing 110 Storag...

Page 108: ...and or property damage A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in conta...

Page 109: ...olyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the battery at the end of a charging cycle If the elect...

Page 110: ...arting any procedure read all warnings and instructions that are located in the Service Guidelines chapter and beginning of this section WARNING DO NOT attempt to test the specific gravity of a sealed...

Page 111: ...tarting any procedure read all warnings and instructions that are located in the Service Guidelines chapter and beginning of this section WARNING Do not allow the loose battery cables to contact any o...

Page 112: ...ARDWARE 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 st...

Page 113: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Inflation 114 Air pressure 114 Tread Wear 115 Rotation 115 Changing Tire W...

Page 114: ...ing pulling to the left or right Only check the tire pressure when the tire is cold When checking tire pressure you must check all tires including your spare tire The correct tire size and pressure ca...

Page 115: ...ection of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING DO NOT operate a vehicle if the cord is...

Page 116: ...ir a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the type of repair...

Page 117: ...Tires Wheels Page 117 MB 210 13 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 85 115...

Page 118: ...Tires Wheels Page 118 B 200 B 210 Models MB 210 13 Notes...

Page 119: ...nsion 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 Suspension Fr...

Page 120: ...ng hangers The spring hangers must be allowed to pivot When replacing springs inspect the hangers for signs of wear and replace as needed Fully tighten the hanger bolts and the loosen so that the spri...

Page 121: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Torque Guidelines for Standard hardware 122 Hardware Identificatio...

Page 122: ...lt 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...

Page 123: ...ck nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treate...

Page 124: ...50 16 192 297 420 390 7 8 9 278 429 593 565 14 306 473 818 625 1 8 416 644 909 850 14 466 721 1018 930 1 1 8 7 590 794 1287 1700 12 662 891 1444 1850 1 1 4 7 832 1120 1817 2950 12 922 1241 2012 3330 I...

Page 125: ...6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14 1 38 55 12 1 25 71 1 50 68 1 75 24 64 118 14 1 50 111 2 00 38 103...

Page 126: ...procedure for information regarding proper hardware torque All hardware should be inspected for thread damage or corrosion prior to reassembly If any evidence of damage is found then the hardware shou...

Page 127: ...0 Rear Primary Reduction 139 Battery 140 Brakes Brake Lines 142 Brakes Master Cylinder Linkage 144 Brakes Front Axle 146 Brakes B 210 Rear Axle 147 Brakes B 200 Rear Axle 148 Brakes B 200 Park Brake 1...

Page 128: ...not include special order options that may have been ordered for your vehicle To identify special order options refer to the original vehicle sales order Any special order options will have a K letter...

Page 129: ...t Parts Page 129 Not available at time of printing MB 210 13 B 200 B 210 Models My Vehicle information Serial Number Date Purchased Date Delivered Dealer Purchased From Salesman Name My local Parts De...

Page 130: ...Replacement Parts Page 130 MB 210 13 B 200 B 210 Models AXLE ASSEMBLY FRONT...

Page 131: ...Optional 1 6 32 240 55 Bushing Metal Backed Teflon 4 7 97 180 55 Thrust Washer Metal Backed Teflon 5 8 4 8 21 020 15 King Pin 2 9 88 189 81 Lock Nut 5 8 N C 2 10 12 124 00 Hub Wheel 5 Stud Includes 1...

Page 132: ...ke rotor 2 4 41 172 21 Hub 2 5 88 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5 2 7 96 329 10 Wheel stud 10 Not 92 104 10 Hub cover 2 shown 41 290 66 Axle housing left 1 41 290 67 Axle ho...

Page 133: ...iner 2 4 80 505 10 Bearing race assembly 2 5 Backing plate 6 45 303 10 Seal 2 7 Spider includes wheel cylinder 2 8 41 171 10 Axle shaft right 1 41 170 10 Axle shaft left 1 9 Spring extension 2 10 Spri...

Page 134: ...Replacement Parts Page 134 MB 210 13 B 200 B 210 Models TRANSAXLE ASSEMBLY B 200...

Page 135: ...ring 1 14 80 715 10 O ring 3 15 80 480 10 Bearing 1 16 88 840 12 Snap ring 3 Not 45 100 00 Input shaft seal 1 Shown 17 41 973 00 Plug 2 18 66 611 15 Cover 1 19 41 127 94 Plug 1 20 66 610 68 Screw 10 2...

Page 136: ...Replacement Parts Page 136 MB 210 13 B 200 B 210 Models TRANSAXLE ASSEMBLY B 210 REAR GT...

Page 137: ...19 GT 3287143 Differential case 1 20 GT 72013 O ring 1 21 GT 3273633 Pinion nut 1 22 GT 71896 Bolt M10 x 25 mm 12 23 See Note Spacer 1 24 see gear kits below Output gear 1 25 PKIT 00018 Shim and space...

Page 138: ...1 7 66 610 67 Vent 1 8 41 989 02 Plug with O ring 1 9 N A Order assembly Housing 1 10 N A Order assembly Cover 1 11 N A Order assembly Gears Ring Pinion 1 12 N A Order assembly Race 1 13 N A Order as...

Page 139: ...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 1 Kit B Bearing 2 2 Kit B Bearing 1 3 Kit B Bearing 2 4 Kit A...

Page 140: ...Replacement Parts Page 140 MB 210 13 B 200 B 210 Models BATTERY...

Page 141: ...5 77 042 00 225AH T 105 77 047 00 260AH T 145 3 50 243 10 Battery rod 4 50 250 00 Battery hold down 5 88 088 66 Flat washer tin lead plated 6 88 069 81 1 4NC Nylon lock nut 7 88 081 12 5 16NC x 1 Squa...

Page 142: ...Replacement Parts Page 142 MB 210 13 B 200 B 210 Models BRAKES BRAKE LINES...

Page 143: ...3 Brake line front right 1 3 99 603 53 Brake line front left 1 4 99 603 54 Brake line front 1 5 99 605 55 Brake line rear left 1 6 99 605 56 Brake line rear right 1 7 99 576 00 Hose clip 4 8 99 564 00...

Page 144: ...Replacement Parts Page 144 MB 210 13 B 200 B 210 Models BRAKES MASTER CYLINDER LINKAGE...

Page 145: ...Hex lock nut 2 8 99 510 52 Cap 1 9 99 510 61 Rebuild kit for 1 bore 1 10 99 510 51 Boot 1 11 99 510 53 Gasket 1 12 88 108 60 flat washer 2 13 1 14 05 210 97 Brake pedal 1 15 00 210 21 Mounting bracket...

Page 146: ...8 01 Bushing included in rebuild kit 4 5 41 351 35 Brake body assembly no internally serviceable parts 2 6 99 588 01 Bleeder adaptor 2 7 99 588 00 Bleeder valve 2 8 See rebuild kit Brake pad Inner 2 9...

Page 147: ...ld kit 2 3 41 348 58 Spacer included in rebuild kit 4 4 41 350 28 1 Mounting Bracket 2 5 41 350 91 Secondary Plate 2 6a 88 067 21 Bolt 4 6b 88 069 82 Nut 4 7 See rebuild kit Brake pad Outer 2 8 See re...

Page 148: ...Replacement Parts Page 148 MB 210 13 B 200 B 210 Models BRAKES B 200 REAR AXLE...

Page 149: ...7 41 347 36 Spider includes wheel cylinder 2 8 Axle shaft 1 9 85 215 00 Spring extension 2 10 85 411 00 Spring red 2 85 411 15 Spring green 2 11 41 635 00 Brake shoe set of 2 for 1 wheel 2 12 41 347 3...

Page 150: ...Replacement Parts Page 150 MB 210 13 B 200 B 210 Models BRAKES B 200 PARK BRAKE...

Page 151: ...otter pin 1 4 96 813 00 Cable 1 5 96 772 00 Clevis pin 1 6 88 088 61 Washer 2 7 88 089 81 Nut 2 8 96 772 00 Clevis pin 1 9 88 517 09 Cotter pin 1 10 01 204 32 Equalizer 1 11 96 826 12 Cable 2 12 88 14...

Page 152: ...Replacement Parts Page 152 MB 210 13 B 200 B 210 Models BRAKES B 210 PARK BRAKE...

Page 153: ...6 210 11 Brake Cross Shaft 1 10 96 772 00 Clevis Pin 3 8 1 11 02 210 72 Bracket Return Spring 1 12 80 410 20 Bolt Flange Brake Shaft 2 13 88 069 81 1 4 NC Lock Nut 2 14 88 060 14 1 4 X 1 1 2 NC Bolt 2...

Page 154: ...cluded with the charger Standard Single Phase AC wire Color Codes as of 2010 Note Older systems may use a alternate color code Refer high voltage wiring repairs to a qualified technician United States...

Page 155: ...uiQ 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 Charger QuiQ 36 volt Trojan T105 79 306 31 Charger QuiQ 36 volt Full River AG...

Page 156: ...ty 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 0 or 1 79 511 00 Cord holder fr...

Page 157: ...01 200 07 Mounting panel 1 3 73 004 20 Horn 1 4 79 844 00 Main circuit breaker 1 5 72 501 42 ISO solenoid 1 6 88 838 06 14 x 1 2 Sheet metal screw 4 7 88 060 09 1 4NC x 3 4 Hex bolt 4 8 79 840 00 10 A...

Page 158: ...h 1 2 71 039 11 Wiper switch 0 or 1 3 71 039 11 Strobe switch 0 or 1 4 71 039 02 Forward reverse switch 1 5 71 039 11 High low speed switch 0 or 1 6 74 010 00 Smart View gauge shown 1 7 71 102 15 Horn...

Page 159: ...Replacement Parts Page 159 Not available at time of printing MB 210 13 B 200 B 210 Models...

Page 160: ...Replacement Parts Page 160 MB 210 13 B 200 B 210 Models DECALS...

Page 161: ...DECAL SAFETY WARNING 5X6 E 1 5 94 309 00 DECAL PARK BRAKE WARNING 1 6 94 384 14 DECAL LEAVING VEHICLE E 1 7 94 384 61 DECAL OPS DASH 1 8 94 384 62 DECAL OPERATOR PRESENCE SWITCH 1 9 94 301 41 DECAL DO...

Page 162: ...Replacement Parts Page 162 MB 210 13 B 200 B 210 Models ELECTRICAL MISCELLANEOUS...

Page 163: ...ID 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 631 15 not shown Clamp Rubber Lined 1 1 2 ID 62 033 48 Throttle Module 24 48 volt system 1 71 122 20 Horn Switch 1 88 065 06 1 4 NC x 21 2 Phillips Tru...

Page 164: ...y the foot 4 88 102 15 3 8NC x 1 3 4 Carriage bolt 4 5 88 108 60 3 8 Cut flat washer 4 6 88 109 87 3 8NC KEPS nut 4 7 96 124 00 U bolt 1 8 88 069 83 1 4NC Acorn nut 2 9 91 012 00 Cab 1 10 Same as 2 11...

Page 165: ...rgo Box 00 210 23 Center deck support angle 1 90 471 00 Deck board front 1 90 472 00 Deck board rear 1 Fixed 2nd Seat 00 210 23 Center deck support angle 1 00 210 45 Left deck rail 1 00 210 46 Right d...

Page 166: ...Replacement Parts Page 166 MB 210 13 B 200 B 210 Models FRAME DOORS...

Page 167: ...089 81 5 16NC Hex locknut 8 13 91 011 31 Steel door left unpainted 1 91 011 32 Steel door right unpainted 1 14 90 853 10 Left window assembly 1 90 853 11 Right window assembly 1 15 97 315 58 Inner Ha...

Page 168: ...02 210 14 Front door stop 2 6 88 837 09 14 x 3 4 Sheet metal screw 6 7 02 210 16 Door catch 2 8 88 065 08 1 4NC x 5 8 Truss head screw 16 9 88 068 61 1 4 SAE Flat washer 4 10 88 067 87 1 4NC KEPS nut...

Page 169: ...nd gate 2 90 545 02 Left side standard 3 90 545 02 Right side standard 4 90 545 03 Left side fixed 2nd seat 5 90 545 04 Right side fixed 2nd seat 6 90 545 14 Left side rear foldaway 2nd seat 7 90 545...

Page 170: ...Replacement Parts Page 170 MB 210 13 B 200 B 210 Models FRAME AMBULANCE DECK...

Page 171: ...06 Rear deck rail 1 7 00 610 05 Right side deck rail 1 8 90 440 72 Rear deck board galvanized 1 90 440 70 Front deck board galvanized 1 9 K1 111 22 Rear deck board white laminate 1 K1 111 21 Front de...

Page 172: ...Replacement Parts Page 172 MB 210 13 B 200 B 210 Models FRAME TOPS...

Page 173: ...3 K1 177 60 Mounting pile ambulance 1 Not shown K1 123 09 Ambulance mounting pole spacer 0 4 3 88 102 11 3 8NC x 1 Carraige bolt 32 4 88 109 81 3 8NC Hex lock nut 32 5 91 151 00 Fiberglass top 1 6 91...

Page 174: ...B 210 13 B 200 B 210 Models HITCHES Mounting Hardware Item No Part No Description Qty 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 4 88 149 80 1 2NC Hex nut 4 88 14...

Page 175: ...udes flasher 0 or 1 72 023 59 Strobe light LED 0 or 1 MIRRORS Mirrors Item No Part No Description Qty 92 201 00 Mirror rectangular 4 1 2 x 8 1 2 side view 1 92 202 12 Mounting bracket left Steel cab 1...

Page 176: ...No Description Qty 1 N A Housing 1 2 N A Armature 1 3 N A Field coils 1 4 PKIT 00022 Brush spring set 4 1 5 70 170 00 Brush holder 1 6 PKIT 00064 Brush set 2 includes springs 1 7 70 417 00 Retainer 1...

Page 177: ...Front 1 Frame Seat back black 1 Fixed 2nd Seat Option 90 175 00 Seat cushion Fixed 2nd seat 1 90 179 00 Backrest Fixed 2nd seat 1 02 680 39 Seat frame 1 Fixed 3rd seat Option 90 175 00 Seat Cushion 3...

Page 178: ...1 4 18 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Se...

Page 179: ...TEERING LINKAGE Steering Linkage Item No Part No Description Qty 1 86 510 00 Clamp 4 2 86 501 98 Ball joint left 2 3 86 501 99 Ball joint right 2 4 88 159 85 Hex castle nut 4 5 88 527 11 1 8 x 1 Cotte...

Page 180: ...Replacement Parts Page 180 MB 210 13 B 200 B 210 Models STEERING COLUMN...

Page 181: ...ch bolt 1 6b 88 089 84 5 16NF Hex locknut grade 8 Pinch bolt nut 1 7 18 308 21 Steering gear assembly 1 8 88 128 62 7 16 Split lock washer 3 9 88 120 15 7 16NC x 1 Hex bolt 3 10 88 279 82 7 8NF Thin p...

Page 182: ...12 10 Leaf Spring 2 2 16 871 02 Spring Shackle 4 3 32 213 00 Bushing 3 4 OD X 1 656 Long 6 4 96 248 00 Shackle Bolt 9 16 NF 6 5 88 169 82 Lock Nut 9 16 NF grade C 6 6 96 123 00 U Bolt Length 2 4 7 88...

Page 183: ...210 REAR Item No Part No Description Qty 1 85 513 10 Spring 2 2 16 871 02 Spring hanger 4 3 32 213 00 Spring bushing 6 4 96 248 00 Hex bolt 6 5 88 169 82 Hex nut 6 6 96 114 00 U bolt 4 7 88 159 84 Hex...

Page 184: ...Models SUSPENSION B 200 REAR Item No Part No Description Qty 1a 96 123 54 U bolt bent 2 1b 96 123 53 U bolt 2 2 16 865 02 Plate 2 3 16 871 02 Hanger 4 4 96 248 00 Bolt 6 5 88 169 82 Nut 6 6 85 513 05...

Page 185: ...m 10 083 00 Tire 11 040 00 Tube 13 742 41 5 00 x 8 Soft Solid Tire Wheel Assembly 13 742 50 5 00 x 8 Soft Solid Tire Wheel Assembly Non Marking 13 746 13 18 x 8 50 x 8 Pneumatic Tire Wheel Assembly 10...

Page 186: ...Replacement Parts Page 186 MB 210 13 B 200 B 210 Models Notes...

Page 187: ...re known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your ve...

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...

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Taylor-Dunn B0-200-00, Service And Replacement Parts Manual

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