Taylor-Dunn B5-440-GAS Service And Parts Manual Download Page 51

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CVT

Page 51

MB-440-10

Bigfoot G-1500

DRIVER PULLEY

The driver pulley has no serviceable components. If not functioning correctly then it must be replaced as an assembly.

Remove

1: Remove the drive belt.

2: Remove the bolt holding the pulley to the transaxle input

shaft.

3: Slide the pulley off of the shaft.

Note: A pry bar may be required to get it started. If too tight then

the motor may need to be removed to use a gear puller.

Inspect

Inspect the sides of both the stationary and sliding sheaves. They

should be smooth from bottom to top. Severe grooving may be a

result of operating with too heavy of a load with the engine rotating

but the belt is stalled.

Install

Install in reverse order of removal.

• Confirm key is positioned correctly on the crankshaft.

•

Lightly lubricate the crankshaft.

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

DRIVEN PULLEY

Remove

1: Remove the drive belt.

2: Remove the bolt holding the pulley to the transaxle input shaft.

3: Slide the pulley off of the shaft.

Inspect

Inspect the sides of both the stationary and sliding sheaves. They should be

smooth from bottom to top. Severe grooving may be a result of operating

with too heavy of a load with the belt rotating but the wheels are stalled.

Install

Install in reverse order of removal.

• Confirm key is positioned correctly on the input shaft.

•

Lightly lubricate the transaxle input shaft.

Repair

The only serviceable components on the driven pulley are the ramp shoes.

These are the plastic shoes that the sliding sheave rides on. Although there

are 6 total, only 3 are actually used; these are the shoes in contact with the

stationary ramp on the transaxle input shaft.

Summary of Contents for B5-440-GAS

Page 1: ...NG THIS VEHICLE The operator s manual contains important information regarding the safe operation of this vehicle WARNING Starting Serial Number 204278 Ending Serial Number See Introduction Chapter Service and Replacement Parts Manual MANUAL MB 440 10 Bigfoot G 1500 Model Numbers B5 440 GAS H ...

Page 2: ...lacement parts and service for our vehicles Refer to our web site www taylor dunn com for a dealer lookup application Originally Published 5 1 2017 Revision H 10 17 2018 contents subject to change without notice Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Visit our Web site www taylor dunn com My Vehicle information Serial Number Date Purchased Date D...

Page 3: ...t 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 the factory direct at 01 714 956 4040 Feedback regarding this or any Taylor Dunn vehicle manual can be sent to Taylor Dunn Manufacturing Attn Tech Writer 2114 West Ball Road Anaheim CA 92804 ...

Page 4: ...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 tr...

Page 5: ...17 Lubrication 21 Front Axle 25 Steering 33 Engine 41 Transaxle 45 CVT Transmission 49 Brakes 53 Throttle Cables 61 Shift Linkage 63 Tires Wheels 65 Suspension 71 Battery 73 Wire Diagram 79 Hardware Information 81 Replacement Parts 87 Note Each section title page contains a section table of contents ...

Page 6: ......

Page 7: ...dure 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 Signal Words and Their Definitions 9 Responsibilities 10 How to Identify Your Vehicle 11 Web Site Registration 11 ...

Page 8: ...meters Lead acid batteries Technicians should read the text and be familiar with the service procedures before starting any repair Certain procedures require the use of special tools Use only the proper tools as specified Contact an authorized Taylor Dunn service technician if you have any doubt as to your ability to perform any of the procedures outlined in this manual We appreciate any assistanc...

Page 9: ... 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 components in the vehicle and or the surrounding area such as buildings other vehicles etc Safety alert symbol see above Represents a high voltage hazard Represents an explosion hazard Represents a corrosiv...

Page 10: ...edures 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 owner of the vehicle The operator is responsible to be sure that the vehicle is operated only on authorized roads highways and installations The operator is responsible to confirm that all passengers are properly seated and properl...

Page 11: ...e 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 entire Taylor Dunn line of vehicles Your contact information will remain confidential and will not be shared outside of the Taylor Dunn corporation Once registered on the Taylor Dunn web site you will have access to Additional T...

Page 12: ...Page 12 MB 440 10 Introduction Bigfoot G 1500 Notes ...

Page 13: ...nts Service Maintenance Guidelines 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: ...acity may result in severe bodily injury WARNING The engine may start at any time while performing test procedures All tests must be performed with the drive wheels off of the ground and the vehicle supported with jack stands Testing with drive wheels on the ground may result in vehicle movement causing severe bodily injury and or property damage WARNING The only personnel authorized to repair mod...

Page 15: ...OSHA Part 1910 178 Powered Industrial Trucks 2011 1910 178 a 4 Modifications and additions which affect capacity and safe 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 accordingly 1910 178 q 6 Industrial trucks shall not be altered so that the relative posit...

Page 16: ...del Taylor Dunn vehicles may have an undesirable affect on the operation of the vehicle result in additional frame stress or stress other components resulting in premature failure or an unsafe condition Due to the unknown properties of non Taylor Dunn tested components or from components not originally equipped on the vehicle we cannot approve their use in a Taylor Dunn vehicle To maintain peak pe...

Page 17: ...fore starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Preventative Maintenance Daily Visual Inspection 18 Pre Operation Inspection 18 Maintenance Schedule 18 Maintenance Guidelines for Severe Duty Applications 18 Maintenance Schedule 19 ...

Page 18: ...ted every time before the vehicle is driven 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 of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Maintena...

Page 19: ...irst Replace paper air filter Inspect tire tread wear Inspect and tighten all hardware First 100 hours then ever 500 hours Every 200 hours All 100 hour items plus the following Change oil filter Inspect spark plugs Change fuel filter Every 600 hours All 200 hour items plus the following Inspect and tighten all hardware Test battery Check battery electrolyte level maintenance free only Replace spar...

Page 20: ...PM Schedule Page 20 Bigfoot G 1500 MB 440 10 Notes ...

Page 21: ...Table of Contents Lubrication Lubrication Lubrication and Fluids Chart 22 Lubrication Diagram 23 Hazardous Waste Disposal 23 ...

Page 22: ...e Brake Fluid Master Cylinder 1 DOT 3 Meets or exceeds SAE J1703 Linkages Park brake handle 1 Multi purpose spray lubricant Engine Engine oil 1 7 1 9 Quarts See chart 1 6 1 8 Liters Rear Transaxle 7 Drain Plug 1 8 Fill Plug 1 20 24 Ounces 0 6 0 7 Liters of Locations Engine Oil type Petroleum or synthetic detergent oils that meet API Class SJ or higher Ambient Temperature Viscosity 20ºF to 32ºF 30C...

Page 23: ...ad Acid Oil Grease The brake linings originally installed by the factory do not contain asbestos However since it is possible that asbestos brake linings were installed as replacement parts brake linings should be handled as hazardous waste The requirements for disposal of hazardous waste vary by location Consult your local regulations regarding the proper disposal of hazardous waste products Fron...

Page 24: ...Lubrication Page 24 Bigfoot G 1500 MB 440 10 Notes ...

Page 25: ...ed in the Service Guidelines chapter WARNING Front Axle Remove 26 Install 26 Assemble Complete Axle 27 Inspect Front Wheel Bearings 28 Adjust Front Wheel Bearings 28 Front Wheel Alignment 29 Replace Steering Knuckle 30 Replace King Pin Bushings 31 Replace Front Wheel Bearings 31 Service Limits and Specifications 32 King Pin Bushings 32 Toe In 32 Hardware Torque 32 ...

Page 26: ...ng bolts spacers and 2 lower spring mounting plates 5 Tighten the steering rack mounting bolt nuts 6 Install the steering coupler to the steering rack 7 Install a new coupler pinch bolt and tighten per torque listed in the Hardware Torque table at the end of this section 8 Install new pinch bolt jam nut 9 Install the wheels and test drive This section is one section of a complete service manual Be...

Page 27: ...ll joints 8 Tighten ball joint nuts to torque specified at the end of this section 9 Place the upper axle beam onto the assembly 10 Tighten the kingpin nuts so that there is no vertical play in the knuckle but it still turns freely 11 Place the beam spacers into the assembly and drop the 8 mounting bolts washers do not install nuts through the two beams 12 Install the springs spring plates and nut...

Page 28: ... 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 revolutions 4 Attach a rope to the tire and wrap around the tire with 1 foot remaining hanging in the air 5 Tie a weight see table and illustration below to the end of the rope 6 Slowly loosen the axle nut until ...

Page 29: ...s 8 Remove the left front wheel 9 Clamp a straight edge across the face of the wheel hub 10 Adjust the driver left side steering link so that the straight edge is parallel to the center line of the vehicle 11 Remove the straight edge and reinstall the wheel 12 Using a piece of chalk mark a line around the center line of both front tires 13 Measure the distance between the chalk lines at the front ...

Page 30: ... Install the ball joint and tighten nut to torque specified at the end of this section 10 Pack wheel bearings with grease 11 Install the rear bearing and new grease seal 12 Install the hub onto the spindle and adjust the bearing preload per procedure in the section 13 Install a new cotter pin and bearing cap 14 Grease the bushings 15 Install the wheel remove the blocks from behind the wheels and t...

Page 31: ...the vehicle and support with jack stands 4 Remove the tire wheel assembly from the hub Refer to the Tire Wheel section for information regarding removing the tire wheel assembly 5 Remove the hub dust cap cotter pin and spindle nut 6 Remove the hub from the steering knuckle Note For a front disc brake option you must remove the brake body before removing the hub Refer to the Brakes section for info...

Page 32: ...ATIONS King Pin Bushings Ream or broach to 0 8755 0 08765 inches 22 2377 22 2631 mm Toe In 0 to 0 25 inches 6 3 mm HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Lock Nut 43 47 58 63 Steering link Jam Nut 20 30 27 40 Steering pinch bolt 30 35 40 47 Notes ...

Page 33: ...WARNING Steering Inspect Ball Joints 34 Front Wheel Alignment 34 Replace Ball Joint 34 Replace Upper Steering Shaft 35 Remove 35 Install 35 Replace Lower Steering Shaft 36 Inspect 36 Remove 36 Install 36 Replace Boot 36 Replace 90 Steering Gear 37 Inspect 37 Remove 37 Install 37 Replace Steering Rack 38 Inspect 38 Remove 38 Install 38 Replace Steering Wheel 39 Remove 39 Install 39 Hardware Torque ...

Page 34: ...e the parking brake and test drive REPLACE BALL JOINT Note In many cases the removal of a ball joint may cause damage to the ball joint It is recommended that if a ball joint is removed then it should be replaced 1 Raise the front of the vehicle and support with jack stands 2 Loosen the ball joint jam nut 3 Remove the ball joint nut 4 Using a ball joint separator or pickle fork remove the ball joi...

Page 35: ...hly clean all components 2 If bushings were removed install the upper and lower steering shaft bushings into the housing 3 Lightly grease the two bushings 4 Insert the shaft up into the housing 5 Install the housing shaft assembly into the frame sliding the coupler down onto the steering gear shaft 6 Using a new pinch bolt and nut tighten the coupler pinch bolt per torque listed in the Hardware To...

Page 36: ...d position 3 Position the steering wheel in the straight ahead position 4 Install the coupler onto the 90 gear output shaft aligning the machined flat on the shaft with the slot in the coupler 5 Install the coupler on the steering rack input shaft so that the bolt holes line up with the groove in the shaft 6 Install new coupler pinch bolts and tighten to torque listed in the Hardware Torque table ...

Page 37: ... Using a soft face hammer tap the lower coupler off of the output shaft Note If coupler is too tight drive a small wedge into the coupler slot to spread it slightly apart Install 1 Thoroughly clean all components 2 Position the front wheels in the straight ahead position 3 Position the steering wheel in the straight ahead position and tie in place so that it cannot rotate 4 Insert the gear output ...

Page 38: ...y apart 8 Remove the steering rack from the axle assembly Install 1 Thoroughly clean all components 2 Place the steering rack into the axle assembly with the input shaft closest to the bottom plate 3 Place the steering wheel in the straight ahead position and tie in place so that it cannot rotate 4 Confirm the steering rod is centered and center the steering rack 5 Slide the rack between the upper...

Page 39: ...in the straight ahead position 3 Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration 4 Tighten the steering wheel nut to torque listed in the Hardware Torque table at the end of this section 5 Reconnect the negative cable at the batteries 6 Remove the blocks from behind the wheels 7 Release the parking brake and test drive Th...

Page 40: ...MB 440 10 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Jam Nut 20 30 27 40 Ball Joint Lock Nut 43 47 58 63 Coupler Pinch Bolt 30 35 40 47 Coupler Pinch Bolt Jam Nut 25 30 34 40 Steering Wheel Nut 28 32 38 43 Notes ...

Page 41: ...te Kohler en gine service manual that can be downloaded from the Kohler web site at www kohlerengines com The model number of the engine will be required to download the correct manual The engine model can be found on the engine spec plate as shown Engine Check Oil Level 42 Change Oil 42 Air Filter Service 43 Spark Plug Service 43 ...

Page 42: ...Clean the area around the fill cap before removing 9 Fill the engine with oil to the proper level 10 Start engine and inspect for leaks 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 This section is one section of a complete service manual Before starting any proced...

Page 43: ...e pre cleaner with clean engine oil and wring out excess oil 10 Install the pre cleaner around the paper element and reinstall on the engine SPARK PLUG SERVICE 1 Allow the engine to cool 2 Disconnect the battery negative cable 3 Remove the cable from the spark plugs 4 Thoroughly clean the area around each spark plug 5 Remove the spark plug and inspect the electrodes for damage and condition and re...

Page 44: ...Engine Page 44 Bigfoot G 1500 MB 440 10 Notes ...

Page 45: ...a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Transaxle Disassemble 46 Assemble 47 Differential 48 Axle Shaft 48 Remove 48 Install 48 Replace Axle Bearing 48 ...

Page 46: ...es chapter WARNING 6 Remove all of the case bolts Note There are 3 notches in each case half to be used to split the case DO NOT drive a screwdriver or pry bar between the case halves or the sealing surface may be damaged 7 Using pry bars in the 3 notches pry the two case halves apart 8 Remove the differential ring gear assembly Note Observe the orientation of the intermediate shaft and input shaf...

Page 47: ...perly engages the shift fork shaft pin 10 Install the shift rod delete ball spring and set screw While counting the turns tighten the set screw until it bottoms out then loosen 1 2 the turns The shift rod should be able to move between the three detent positions 11 Slightly raise the input shaft and install the reverse gear final drive gear and thrust washer on to the intermediate shaft CONFIRM TH...

Page 48: ...aced 7 Lightly lube the ID of a new bearing and retainer 8 Place new bearing on the axle and press down to shoulder 9 Place new retaining ring and press down to bearing 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 Confirm the circlip is properly seated in the groo...

Page 49: ...efore starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING CVT Transmission Operation 50 Driver Pulley 51 Remove 51 Install 51 Driven Pulley 51 Remove 51 Inspect 51 Install 51 Repair 51 Drive Belt 52 Remove 52 Inspect 52 Install 52 ...

Page 50: ...ys sliding sheave to move in effectively increasing its diameter As the driver pulley diameter gets larger it pulls on the belt causing the driven pulley sliding sheave to move out decreasing its diameter The CVT in Bigfoot is set up so that when the engine is at idle there is very little tension on the drive belt making it act similar to a clutch partially disengaging the engine from the transaxl...

Page 51: ...ft 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 DRIVEN PULLEY Remove 1 Remove the drive belt 2 Remove the bolt holding the pulley to the transaxle input shaft 3 Slide the pulley off of the shaft Inspect Inspect the sides of both the stationary and sliding sheaves ...

Page 52: ... the length If any one point is less than 1 031 inch 26 2 cm then the belt should be replaced Run your fingers along both sides of the belt If you can feel any low sections then the belt should be replaced Install 6 Disconnect the battery negative lead 7 Place the transmission in neutral 8 Wrap the belt around the driver pulley 9 Starting at the bottom of the driven pulley start wrapping the belt ...

Page 53: ...er WARNING Brakes General Guidelines and Safety 54 Front Disc Brake 55 Service Limits 55 Inspection 55 Replace Pads 55 Brake Adjustment 56 Service Brake 56 Parking Brake 56 Master Cylinder 56 Add Fluid 56 Push Rod Adjustment 56 Rear Brake Inspect Replace 57 Service Limits 57 Inspection 57 Replace 57 Rebuild Disc Brake Body 58 Bleed System 59 Flush System 59 Service Limits 60 Hardware Torque 60 ...

Page 54: ...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 Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused...

Page 55: ...emove 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 information on removing the tire and wheel assembly Note Refer to the illustration for the following steps 5 Remove the brake body bolts 10 and discard the lock nuts 1 and brake pads 8 6 Remove the spacer bush...

Page 56: ...s jam nut on the cable equalizer 5 Rotate the cable to tighten and remove all slack in the cable Note Pull out on the equalizer while adjusting the cable 6 Tighten the jam nut 7 Set the park brake and confirm proper operation 8 Reconnect the negative battery cable 9 Test drive the vehicle This section is one section of a complete service manual Before starting any procedure read all warnings and i...

Page 57: ...ase to contact any of the braking surfaces Braking surfaces 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 and support with jack stands 3 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the wheel 4 Remove and...

Page 58: ...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 body making sure that the boot seats properly into the upper groove on the piston 10 Install any fittings or plugs that were removed from the brake body using teflon tape thread sealant 11 If the brak...

Page 59: ...s 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 on filling the master cylinder 11 Reconnect the battery remove the blocks from behind the wheels and test drive This section is one section of a complete service manual Before starting any procedure read all wa...

Page 60: ... 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 inch 5 08 mm Rotor runout 0 005 inch 0 127 mm Rear shoe lining minimum thickness 0 200 inch 5 08 mm Rear drum maximum diameter 6 33 inch 160 8 mm ...

Page 61: ...Cables 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 Throttle Cables Adjust Throttle Choke 62 ...

Page 62: ...system to cool 3 Loosen the cable clamp and adjust the cable as needed 4 Tighten the cable clamp 5 Reconnect the battery negative cable 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 Service Guidelines chapter WARNING The maximum engine RPM is controlled by the engine governor DO NOT a...

Page 63: ...hift Linkage 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 Shift Linkage Adjustment 64 ...

Page 64: ...hile slowly rotating the transmission input sheave shift the transmission from forward to reverse and back to forward to confirm proper adjustment 8 Reconnect the battery 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 Service Guidelines chapter WARNING Do not modify the stainless steel...

Page 65: ... starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Inflation 66 Air pressure 66 Tread Wear 67 Rotation 67 Changing Tire Wheel Assembly 68 Replace the Tire pneumatic 68 Repair the Tire pneumatic 68 Hardware Torque 69 ...

Page 66: ...ng 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 can be found in the specifications list in the manual Note The front and rear tires may have a different tire pressure specification This section is one section of a complete service manual Before starti...

Page 67: ...tion 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 visible on any tire see illustration A tire in this conditions may suddenly fail at any time and cause loss of control of the vehicle WARNING ROTATION Front and rear tires as well as left and right tire...

Page 68: ... 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 equipment or repair components used Refer to the instructions provided with your equipment or repair components This section is one section of a complete service manual Before starting any procedure re...

Page 69: ...Tires Wheels Page 69 MB 440 10 Bigfoot G 1500 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 70: ...Tires Wheels Page 70 Bigfoot G 1500 MB 440 10 Notes ...

Page 71: ...e 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 Front Springs 72 Remove 72 Install 72 Rear Springs 72 Remove 72 Install 72 ...

Page 72: ...wer axle beam 5 Using new nuts install the spring plate 6 Repeat Remove and Install procedures for the other side 7 Test drive the vehicle 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 Do not over torque the spring bolts on elliptical spring hangers The spring hang...

Page 73: ...arting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Battery General Guidelines and Safety 74 Cleaning 75 Watering 75 Testing 76 Specific Gravity 76 Storing 76 Storage 76 Returning to Service 76 Remove Install 77 Hardware Torque 78 ...

Page 74: ...nd 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 contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Battery electrolyte is poison...

Page 75: ... 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 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 distill...

Page 76: ...re located in the Service Guidelines chapter and beginning of this section WARNING DO NOT attempt to test the specific gravity of a sealed battery Removing the caps of a sealed battery will damage the battery resulting in premature failure NOTICE Typical Hydrometer Float STORING Storage Thoroughly clean the battery and battery compartment Refer to Cleaning in this section for information regarding...

Page 77: ... the battery compartment for corrosion If there is significant corrosion then the compartment should be cleaned and painted 6 Install the battery and torque the battery terminal hardware per torque listed in the Hardware table at the end of this section 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 78: ... G 1500 MB 440 10 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Battery terminal Clamp 48 60 5 4 6 7 Battery terminal Stud 120 130 13 5 14 5 ...

Page 79: ...WARNING Wire Diagram Diagram 80 DIAGRAM PART NUMBERS Wire diagrams may be large to be legible when printed at this size The wire diagram for this vehicle is included on the Vehicle Documentation CD provided with the vehicle The diagram s for this vehicle are SCH 00105 This vehicle diagram as well as other Taylor Dunn vehicle diagrams can be downloaded from the Taylor Dunn web site at www taylor du...

Page 80: ...elay Kill Hour Meter White Wiper Switch Light Switch Brown White Wiper Windshield White Yellow Brown White Switch Strobe Light Strobe Light BATTERY Red White Fuel Solenoid Oil Pressure Temperature Switch Switch Red Black White Violet Blck Violet Red Violet Black Red Black Gray White Green White Green White Brown White RIGHT Turn Light Headlight LEFT Turn Light Headlight Brown Engine MIL White Blac...

Page 81: ...starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Torque Guidelines for Standard hardware 82 Hardware Identification 82 Hex Nuts 83 Hex Lock Nuts stover 83 Other Nuts 83 Generic Torque Values 84 Replacing Hardware 86 ...

Page 82: ...t 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 Below is an example of a 10 9 The location and style of the text will vary SAE Grade 2 SAE Grade 5 SAE Grade 8 SAE Grade 9 Other types of bolts and ...

Page 83: ...k 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 treated as S A E Grade A S A E Grade B S A E Grade C Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Grade L 9 Metric Nuts 5 8 8 8 10 9 12 9 ...

Page 84: ... 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 Imperial inch Newton Meters Grade SAE Dia Pitch 2 5 8 L9 4 40 6 32 8 32 10 32 12 32 1 4 20 7 4 11 5 16 9 14 9 28 8 8 14 2 5 16 18 16 2 23 7 33 2 29 8 24 16 9 25 8 3 8 16 27 1 41 58 54 24 30 5 45 68 61 7 ...

Page 85: ... 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 38 103 151 16 1 50 2 00 60 158 229 18 1 50 2 00 2 50 81 221 20 1 50 2 00 2 50 115 317 22 1 50 2 00 2 50 156 428 24 2 00 3 00 199 524 27 3 00 3 00 293 30 2 00 3 50 398 All torque values are for clean dry zinc ...

Page 86: ...ocedure 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 should be replaced Battery hardware should always be replaced when installing new batteries Never reuse cotter pins or safety locking wire Never use a wire nail or any other material to substitute for a cot...

Page 87: ...or Your Vehicle 88 Taylor Dunn Web Site Information 88 Axle Assembly Front 90 Axle Assembly Rear 92 Brakes Brake Lines 94 Brakes Front Axle 96 Brakes Rear Axle 97 Decals 98 Electrical Miscellaneous 100 Engine Exhaust 102 Frame and Body Miscellaneous 102 Frame and Body cabs 103 Frame Deck 104 Fuel System 104 Hitches 105 Instrument Panel 106 Lights 106 Linkage Park Brake 107 Linkage Shift 107 Linkag...

Page 88: ...ot 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 prefix in the option number The vehicle option list is also available on the Taylor Dunn web site The serial number of the vehicle is required to obtain the option list Only use original Taylor Dunn p...

Page 89: ...ment Parts Page 89 Not available at time of printing MB 440 10 Bigfoot G 1500 My Vehicle information Serial Number Date Purchased Date Delivered Dealer Purchased From Salesman Name My local Parts Dealer Notes ...

Page 90: ...Replacement Parts Page 90 MB 440 10 Bigfoot G 1500 AXLE ASSEMBLY FRONT ...

Page 91: ...t Washer 2 13 88 527 14 Cotter Pin 1 8 X 1 1 2 2 14 88 239 85 3 4 NF Hex Slotted Nut 2 15 88 228 60 3 4 Cut Washer 2 16 PKIT 00051 King Pin 2 17 PKIT 00051 7 8NF Thin Hex Locknut Grade 5 2 18 PKIT 00051 7 16 X 1 1 8 NC Socket Head Cap Screw 2 19 PKIT 00051 7 16 NC Grade 9 Locknut 2 20 14 010 00 Front Axle Plate 1 21 14 010 01 Front Axle Plate Bottom 1 22 88 401 57 3 8 X 6 1 2 NC Grade 8 Hex Head S...

Page 92: ...bly 1 6 66 611 19 Shift rod assembly 1 7 45 303 30 Seal 1 8 66 610 75 Axle tube 1 9 66 610 76 Axle tube 1 10 66 610 74 Flange head screw 12 11 66 610 79 Flange head screw 8 12 45 303 00 Seal 2 13 32 509 10 Retaining ring 2 14 80 505 10 Bearing 2 15 41 347 28 Brake assembly hydraulic Left 1 16 41 347 29 Brake assembly hydraulic Right 1 17 45 303 10 Seal 1 18 66 610 72 Washer 8 19 66 610 80 Lock nut...

Page 93: ...earing 1 35 Spacer 1 36 Shim 1 37 Thrust washer 1 38 Forward gear assembly 1 39 66 610 85 Clutch gear 1 40 66 610 84 Intermediate shaft 1 41 Reverse gear assembly 1 42 Pinion gear 1 43 Idler gear assembly 1 44 66 610 83 Snap ring 1 45 80 480 00 Bearing 1 46 Ring gear 1 47 Differential Assembly 1 48 Drain plug 1 50 Nut 1 51 Hex bolt 1 52 41 127 96 Axle shaft Right 1 53 66 610 68 Hex tap screw 2 54 ...

Page 94: ...Replacement Parts Page 94 MB 440 10 Bigfoot G 1500 BRAKES BRAKE LINES ...

Page 95: ...9 606 06 Brake Line 1 10 99 559 00 T Fitting 2 11 99 591 00 T Fitting 1 12 99 575 00 Coupler 4 13 96 640 00 Clip 14 99 576 00 Clip Hose 4 15 99 580 20 Hose 2 16 99 580 10 Hose 1 17 99 580 10 Hose 1 18 500552 Brake light switch 1 Not Shown 99 525 58 Front brake body adaptor 3 16T X 1 8 NPT 45º 2 99 575 32 Tube Adaptor Master Cylinder 2 99 511 20 Master Cylinder 1 41 310 12 Push rod Master cylinder ...

Page 96: ...Bushing included in rebuild kit 4 5 Brake Body all parts on this list 2 6 99 588 01 Bleeder adaptor 2 7 99 588 00 Bleeder valve 2 8 See rebuild kit Brake pad Inner 2 9 See rebuild kit Brake pad Outer 2 Not Shown 41 886 00 Plug 1 8 Pipe Hex Socket 2 88 069 82 Nut Brake bolt 4 41 348 61 Brake rebuild kit 1 axle front or rear includes 3 4 8 9 and brake bolt nuts Not available separately order complet...

Page 97: ... Actuator 2 2 41 347 00 Backing Plate 2 3 41 347 36 Spider w Wheel Cylinder 2 4 85 411 10 Torsion Spring 2 5 41 635 00 Brake Shoes 2 6 85 215 00 Spring 2 7 41 347 33 Adjustment Body 2 8 41 347 31 Star Wheel Adjuster 2 9 41 347 30 Socket 2 10 85 411 15 Torsion Spring 2 11 41 347 34 Parking Brake Actuator Retaining Clip DO NOT REUSE 4 12 41 347 35 Spring Clip 4 ...

Page 98: ...Replacement Parts Page 98 MB 440 10 Bigfoot G 1500 DECALS ...

Page 99: ... 94 306 05 OIL TYPE 1 9 94 306 06 DIPSTICK WARNING 1 10 94 306 07 PUSH TO SHIFT 1 11 94 306 08 SPRING STEEL 1 12 94 306 09 SHIFT INSTRUCTION 1 13 94 306 12 CHOKE 1 14 94 309 00 PARK BRAKE WARNING 1 15 94 313 20IC SAFETY WARNING 1 16 94 319 01 BATTERY DISCONNECT 1 17 94 320 10 CARGO BOX 1 18 94 373 73 17 2017 EMISSIONS 1 19 94 384 04 NOT A MOTOR VEHICLE 1 20 94 384 19 LEAVING VEHICLE 1 21 94 384 47...

Page 100: ...Replacement Parts Page 100 MB 440 10 Bigfoot G 1500 ELECTRICAL MISCELLANEOUS ...

Page 101: ...lamp Rubber Lined 5 8 ID 96 630 50 not shown Clamp Rubber Lined 5 8 ID 265 mounting hole 96 631 00 not shown Clamp Rubber Lined 3 4 ID 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 631 15 not shown Clamp Rubber Lined 1 1 2 ID 98 599 15 Bushing Plastic 1 3 4 hole 98 599 17 Bushing Plastic 2 hole 98 603 00 Rubber grommet 5 8 hole 77 054 10 Battery 1 50 243 11 Rod Hold down 2 00 661 08 Hold down 1 75 ...

Page 102: ...uffler 1 66 400 06 Support bracket 1 00 640 57 Heat shield Muffler 1 00 640 56 Mounting bracket 1 00 611 00 Exhaust pipe 1 41 998 11 Pipe Oil drain extension 1 41 998 12 Elbow Oil drain extension 1 KLR 4723704 U bolt pipe to muffler 1 98 080 12 Insulation Stick on 1 00 640 50 Air dam Air inlet Rubber 1 FRAME AND BODY MISCELLANEOUS Item No Part No Description Qty 00 640 49 Cowl specify color 1 01 5...

Page 103: ...ot 00 020 22 Door restraint 2 90 931 05 Rain gutter per foot Soft Doors 90 924 90 Door Frame Left 1 90 924 91 Door Frame Right 1 90 923 30 Door cover Left 1 90 923 31 Door Cover Right 1 90 931 05 Rain gutter per foot 97 315 51 Latch 2 97 315 53 Handle Outer 2 97 315 54 Handle Inner 2 Economy Cab Item No Part No Description Qty 00 500 15 Cab unpainted 1 90 852 30 Windshield 1 98 310 00 Gasket per f...

Page 104: ...0 66 Strap Fuel tank 2 66 001 06 Valve Slosh 1 98 511 00 Hose 3 16 7 98 512 00 Hose 5 16 3 00 410 23 Bracket Fuel hose mount on transmission Deck Item No Part No Description Qty 90 472 03 Deckboard Rear 1 90 471 02 Deckboard Front 1 90 441 37 Steel cover Black Rear 1 90 441 36 Steel cover Black Front 1 88 607 09 Rivet 16 05 210 90 Heat shield Rear deck 1 05 210 94 Heat shield Front deck 1 88 837 0...

Page 105: ...t time of printing MB 440 10 Bigfoot G 1500 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 88 148 62 1 2 Split lock washer 4 ...

Page 106: ...Plastic rivet 6 9 94 305 36 Panel 1 10 94 305 37 Backing plate 1 71 039 21 Plug for switch hole INSTRUMENT PANEL LIGHTS Item No Part No Description Qty 72 023 13 Headlight 2 72 022 51 Mounting ring 2 72 022 56 Connector 2 72 022 07 Taillight 2 72 022 54 Connector 3 wire 2 72 022 55 Connector 1 wire 2 72 025 51 Gasket 2 72 005 27 Side Running Light Red 2 72 005 26 Side Running Light Small Amber 2 7...

Page 107: ...ndle to cable 1 96 754 00 Clevis Park brake cable transmission end 2 96 773 00 Clevis pin 2 88 527 11 Cotter pin 2 00 640 55 Equalizer 1 85 209 09 Spring Equalizer support 2 85 233 00 Spring Cable guide by handle 1 06 210 03 Spring clip 1 Item No Part No Description Qty 96 853 10 Shifter 1 71 130 01 Switch Neutral Start 1 71 130 01 Switch Reverse 1 00 610 35 Bracket Neutral start switch 1 00 610 3...

Page 108: ...dal Throttle 1 32 215 50 Bushing 2 5 85 209 09 Spring Pedal Extension 1 6 96 872 08 Cable Throttle 1 7 88 060 11 Bolt 2 88 069 81 Nut 2 88 068 61 Washer 6 8 96 871 01 Clamp Cable 1 9 01 661 35 Bracket Cable Spring 1 10 88 517 09 Pin Cotter 2 88 048 62 Washer 2 11 00 661 11 Bracket Cable Mount 1 12 85 209 09 Spring Cable 1 Not Shown 97 211 20 U Nut 88 840 08 Circlip Pedal Shaft 1 62 033 06 Spacer P...

Page 109: ...G 1500 SEATS Seats Item No Part No Description Qty 1 90 160 96 Seat assembly 2 2 90 160 97 Hip restraint Driver 1 3 90 160 98 Hip restraint Passenger 1 4 88 088 61 Flat washer 8 5 88 089 81 Lock nut 8 94 430 07 Thread Lock 50ml 90 160 95 Operator presence switch driver seat only 1 ...

Page 110: ...Replacement Parts Page 110 MB 440 10 Bigfoot G 1500 STEERING LINKAGE ...

Page 111: ... 2 4 88 402 96 Flat Washer 4 88 109 81 Nut 4 8 18 058 95 90 Degree Steering Gearbox 1 9 88 100 14 3 8 X 1 1 2 NC Hex Head Screw Grade 2 3 10 18 058 94 Steering Sleeve includes 11 1 11 Steering Sleeve Boot 12 89 080035K C 00 M8X1 25X35 Hex Head Bolt 10 9 1 89 0800000 A 07 M8 Lock Washer Split Ring 1 89 080000K C 04 M8X1 25 Metal Locknut 10 9 1 13 86 501 07 Steering Rack Standard Model includes 14 a...

Page 112: ...ont Suspension Item No Part No Description Qty 1 96 240 00 Spring Bolt 6 2 32 214 50 Bushing 12 3 16 871 04 Spring Hanger 4 4 88 149 81 1 2 NC LOCK NUT GR5 6 5 6 85 498 00T Leaf Spring 2 7 14 010 07 Spring plate 2 Not Shown 98 753 15 Bump Stop 2 86 602 01 Shock optional 2 ...

Page 113: ...nd RH 1 5 86 523 99 Rod end front swing arm mount 1 6 88 120 17 Bolt 2 7 88 129 81 Nut 4 8 88 121 19 Bolt 2 9 88 121 19 Bolt 1 10 88 188 61 Flat washer 1 11 17 108 00 Spacer 1 12 88 189 81 Lock nut 1 13 88 121 19 Bolt 1 14 88 220 22 Bolt 3 4 x 3 5 1 15 88 229 81 Lock nut 1 16 16 406 00 Spacer 2 17 88 229 62 Lock washer 1 18 88 239 80 Hex nut 1 19 00 640 64 Swing arm 1 20 86 510 00 Clamp 2 21 41 40...

Page 114: ...ne 1 97 030 20 Key 1 88 111 22 Bolt 1 88 128 62 Lock washer 1 88 159 61 Flat washer Heavy 1 30 182 00 Pulley Drive axle 1 97 030 10 Key 1 30 180 51 Ramp shoe plastic 3 98 601 51 Flat washer 1 2 1 88 148 62 Lock washer 1 30 684 00 Belt 1 02 610 78 Spacer Engine pulley plastic 1 16 409 20 Spacer Engine pulley 0 625 x 1 ID 1 ...

Page 115: ...t time of printing MB 440 10 Bigfoot G 1500 WHEELS AND TIRES Item No Part No Description Qty 13 742 13 Tire Wheel assembly 5 70 x 8 LRC 4 10 083 00 Tire 5 70 x 8 LRC 11 040 00 Tube 97 236 00 Wheel Nut 20 13 989 00 Valve stem tubeless tire only ...

Page 116: ...Replacement Parts Page 116 MB 440 10 Bigfoot G 1500 Notes ...

Page 117: ...are 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 vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING ...

Page 118: ...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 B5-440-GAS, Service And Parts Manual

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