Taylor-Dunn B5-540-48XL Service And Replacement Parts Manual Download Page 128

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Replacement Parts

Page 128

MB-440-06

B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48

Item No. Part No.

Description

Qty

99-605-83

Brake Line

99-605-84

Brake Line (only with front brakes)

99-575-32

Adapter, 3/16T x M10-1.0

99-575-00

Coupler

99-607-11

Brake Line, Mid to Rear

99-559-00

T-Fitting

96-640-00

Brake Line Clip

2 or 11

99-564-00

Union T, 3/16

99-605-12

Brake Line, Rear Right (standard)

0 or 1

99-606-04

Brake Line, Rear Right (XL & 3000)

0 or 1

99-603-20

Brake Line, Rear Left

99-591-00

Tee, 3/16 x 18 pipe

500552

Switch, Brake Regen

71-110-00

Switch, Brake Lights

99-606-06

Brake Line (front brake only)

99-606-51

Brake Line, Front Right (standard)

0 or 1

99-608-03

Brake Line, Front Right (XL & 3000)

0 or 1

99-601-01

Brake Line, Straight

99-606-05

Brake Line

99-580-10

Brake hose, Front

99-575-10

Adaptor, Brake hose to brake body

99-580-20

Brake Hose Rear

99-576-00

Clip, Brake Hose

99-598-00

Plug, Master Cylinder Port (vehicles without front brakes)

BRAKES, BRAKE LINES

Summary of Contents for B5-540-48XL

Page 1: ...RE OPERATING THIS VEHICLE The operator s manual contains important information regarding the safe operation of this vehicle WARNING Serial numbers Starting 204000 Ending 214369 MANUAL MB 440 06 Servic...

Page 2: ...e replacement parts and service for our vehicle s Refer to our web site www taylor dunn com for a dealer lookup application Originally Published 9 30 2014 Revision U 11 23 21 contents subject to chang...

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 t...

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 internatio...

Page 5: ...enance Guidelines 13 Special Tool List 17 Lubrication 21 Preventative Maintenance 25 Front Axle 29 Transaxle GT 37 Transaxle SD 47 Steering 55 Brakes 63 Motor VCTech 71 Motor ABM 77 Tires Wheels 81 Mo...

Page 6: ...Notes...

Page 7: ...nd instructions that are located in the Service Guidelines chapter WARNING Introduction About This Manual 8 Who Should Read This Manual 8 Replacement Parts 8 How To Use This Manual 8 Conventions 9 Sig...

Page 8: ...Dunn replacement parts intended for use on your vehicle Taylor Dunn components are designed and tested for use on specific Taylor Dunn model vehicles Only use the correct Taylor Dunn replacement comp...

Page 9: ...the vehicle 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 ve...

Page 10: ...dures 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 operato...

Page 11: ...s of the model 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...

Page 12: ...Notes...

Page 13: ...procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Service Maintenance Guidelines Service Maintenance Guidelines Read Me First Maintenance Guidelin...

Page 14: ...d length chains 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 WA...

Page 15: ...eplacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment ANSI ITSDF 56 9 2007 Safety Standard for Operator Controlled Ind...

Page 16: ...Notes...

Page 17: ...a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Special Tool List Special Tool List Tool List 18 C...

Page 18: ...connectors Molex 11 300 06 Pin Removing Tool Removes 0 093 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor 75 442...

Page 19: ...f 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 Used to remo...

Page 20: ...ware Soft and 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...

Page 21: ...rvice manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Lubrication Lubrication and Fluids Chart 22 Hazardous Waste Dis...

Page 22: ...3 Wheel Bearings 2 NLGI Grade 2 lithium high temp Bearing Grease Refer to procedure later in this section 4 King Pin 4 NLGI Grade 2 lithium multi purpose grease Suspension 5 Rear spring eyes 6 NLGI G...

Page 23: ...DIAGRAM Note The transaxle is mounted at an angle in the vehicle The transaxle must be level when checking oil level This will require rasing the rear of the vehicle until the transaxle is level with...

Page 24: ...ease to slip through the seal so that the pressure does not pop the seal out of the hub 6 Inject grease until a small amount is extruded through the lip around the tool 7 Wipe off any excess grease Fr...

Page 25: ...located in the Service Guidelines chapter WARNING Preventative Maintenance Daily Visual Inspection 26 Pre Operation Inspection 26 Maintenance Schedule 26 Maintenance Guidelines for Severe Duty Applica...

Page 26: ...hicle 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 o...

Page 27: ...then every 500 hours Every 3 Months or 500 hours All monthly items plus the following Inspect and tighten all hardware Test batteries Clean battery compartment Clean motor control panel Adjust park an...

Page 28: ...PM Schedule Page 28 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 MB 440 06 Notes...

Page 29: ...rvice Guidelines chapter WARNING Front Axle Front Axle Remove 30 Install 30 Assemble Complete Axle 31 Inspect Front Wheel Bearings 32 Adjust Front Wheel Bearings 32 Front Wheel Alignment 33 Replace St...

Page 30: ...steering rack mounting bolt nuts DO NOT REMOVE 4 Install the 8 spring mounting bolts spacers and 2 lower spring mounting plates 5 Tighten the steering rack mounting bolt nuts 6 Install the steering co...

Page 31: ...d install ball 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 pl...

Page 32: ...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 A...

Page 33: ...link jam nuts 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 l...

Page 34: ...rns freely 9 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...

Page 35: ...the front of 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...

Page 36: ...AND SPECIFICATIONS 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 Nu...

Page 37: ...vel 38 Change Oil 38 Axle Assembly 39 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 Asse...

Page 38: ...g allow to drain 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 servi...

Page 39: ...er spring hangers and the frame spring eye 6 Slowly raise the frame until the spring bolts can be removed then rase the frame high enough to roll the axle assembly out from under the vehicle 7 Lower t...

Page 40: ...replaced Reusing 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...

Page 41: ...ocks from behind 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 loc...

Page 42: ...haft bore at this time 11 Mark the gear case 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...

Page 43: ...ng and cover and then remove the differential assembly do not allow the nuts to rotate 11 Install the pinion gear Re shim if required Refer to Pinion Bearing Preload procedure Roll Pin Disassemble 1 R...

Page 44: ...e directions Note To move the ring gear closer 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 aw...

Page 45: ...E The distance 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 Se...

Page 46: ...54 169 209229 Drain plug 21 25 28 4 33 Gear case to 3rd member 18 20 24 4 27 3rd Member cover bolts 40 50 54 67 5 Axle hub bolt 275 392 Note Special Washers The washers for the primary gear case housi...

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

Page 48: ...l level with 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 bat...

Page 49: ...l rides on the 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 t...

Page 50: ...plate bolts 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 seve...

Page 51: ...5 Pre lube 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...

Page 52: ...Transaxle Page 52 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 MB 440 06...

Page 53: ...n 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 3RD MEMBER Illustration is for...

Page 54: ...refer to standard torque values in the appendix Description Foot Pounds Newton Meters Pinion nut 275 300 392 428 Drain plugs 9 14 13 20 Fill plugs 45 50 64 71 Gear case to 3rd member 45 55 64 78 Prim...

Page 55: ...eering Inspect Ball Joints 56 Front Wheel Alignment 56 Replace Ball Joint 56 Replace Upper Steering Shaft 57 Remove 57 Install 57 Replace Lower Steering Shaft 58 Inspect 58 Remove 58 Install 58 Replac...

Page 56: ...els 7 Release 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 th...

Page 57: ...ll 1 Thoroughly 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 ho...

Page 58: ...ont wheels in the straight ahead 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...

Page 59: ...f the frame 6 Using a soft face hammer tap the lower coupler off of the output shaft Note If couplers too tight drive a small wedge into the coupler slot to spread it slightly apart Install 1 Thorough...

Page 60: ...ad it slightly 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 bo...

Page 61: ...head 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 Ha...

Page 62: ...XL BF 030 48 MB 440 06 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...

Page 63: ...idelines chapter WARNING Brakes Brakes General Guidelines and Safety 64 Front Brake 65 Service Limits 65 Inspection 65 Replace Pads 65 Rear Brake 66 Service Limits 66 Inspection 66 Replace Pads 66 Reb...

Page 64: ...cle 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 h...

Page 65: ...er cap 2 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...

Page 66: ...il it is 1 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 assembl...

Page 67: ...Remove the piston o ring from inside of the brake body 4 Inspect and replace parts as required 5 Lubricate the brake parts with clean brake fluid from a sealed container 6 Install the O rings into th...

Page 68: ...dication that 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 i...

Page 69: ...he dash and can be accessed by removing the tray Add Fluid 1 Thoroughly clean the area around the master cylinder cap and remove the cap 2 Add brake fluid from a new sealed container to the master cyl...

Page 70: ...nings and instructions that are located in the Service Guidelines chapter WARNING The brake pads and rotor should be inspected anytime the park brake requires adjustment Adjust 1 Block the rear wheels...

Page 71: ...ll warnings and instructions that are located in the Service Guidelines chapter WARNING Motor VCTech Motor VCTech Motor Identification 72 Remove Install 72 Inspect Testing 72 Bearing 72 Electrical Tes...

Page 72: ...the bearing noise A faulty bearing will typically sound like a high pitch grinding noise or squeal Electrical Testing Electrical testing for the motor is included in the Electrical Troubleshooting man...

Page 73: ...instructions that are located in the Service Guidelines chapter WARNING Refer to illustration of exploded motor found later in this section 1 Mark where the front end housing 3 rear motor housing 4 a...

Page 74: ...wires to the opening on rubber seal 11 and insert the rubber seal see illustration NOTICE 5 Set the stator 2 into the rear housing 4 Note Be sure the parts are properly aligned using previously made m...

Page 75: ...Motor VCTech Page 75 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48...

Page 76: ...ARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Bolt Drive End Bell 87 9 83 Bolt Bearing Plate 74 8 36 Bolt Speed Se...

Page 77: ...any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING This is the standard motor on the B5 540 48XL and BF 030 48 Motor ABM Motor Identification 7...

Page 78: ...be disassembled to inspect the bearing Raise the rear wheels off of the ground and support with jack stands Place a mechanics stethoscope on the rear motor housing and listen to the bearing noise A f...

Page 79: ...fan is a slip fit and should be able to be removed by hand 3 Install two 10 32 x 2 machine screws into the two open holes in the brake assembly These screws will hold the assembly together when it is...

Page 80: ...Motor ABM Page 80 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 MB 440 06 Notes...

Page 81: ...procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Tires Wheels Inflation 82 Air pressure 82 Tread Wear 83 Rotation 83 Changing Tire W...

Page 82: ...hicle Steering 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...

Page 83: ...ore starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Use the pattern shown below for a vehicle with spare tire Right Rear to Right F...

Page 84: ...nstructions provided with your tire replacement equipment 7 Inflate the tire to the proper pressure and check for leaks 8 Install the valve stem cap This section is one section of a complete service m...

Page 85: ...the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by p...

Page 86: ...Notes...

Page 87: ...any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Controller Motor Controller Remove Install 88 Inspect 88 Receptacles 88 Base Plate 88...

Page 88: ...h the wires to the studs and torque per specification listed in the table at the end of this section Note DO NOT allow the wires to rotate while torquing the bolts see notice above 5 Install silicon d...

Page 89: ...supplementary instructions that were included with Sevcon Gen4 AC Handsets before attempting to program any settings This section is one section of a complete service manual Before starting any proced...

Page 90: ...Notes...

Page 91: ...n of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Charger Remove Install 92 Troubleshooting 92...

Page 92: ...the Service Guidelines chapter WARNING TROUBLESHOOTING Troubleshooting control system is not included in this manual All electrical troubleshooting information is included in a separate manual Troubl...

Page 93: ...and then it will repeat The algorithm code will be displayed for 11 seconds The following is the list of algorithms available in Taylor Dunn chargers Contact Delta Q for any additional detail or for i...

Page 94: ...sired profile is active 10 Disconnect the AC power source for a minimum of 20 seconds 11 Reconnect the charger positive battery lead and confirm all connections are secure Changing the Active Profile...

Page 95: ...source Hold the button until the Fault Indicator is on solid and the Charging Output Indicator is flashing then release the button 3 The Error display will flash a code for the currently selected pro...

Page 96: ...Chargers Page 96 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 MB 440 06 Notes...

Page 97: ...a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Suspension Suspension Front Springs 98 Remove 98...

Page 98: ...R SPRINGS Note If a left or right side spring is replaced it is recommended to replace the opposite side at the same time Note All spring bushing should be replaced when replacing a spring Note When r...

Page 99: ...t are located in the Service Guidelines chapter WARNING Batteries Batteries General Guidelines and Safety 100 Cleaning 101 Charging 101 Watering 101 Testing 102 Specific Gravity 102 Storing 102 Storag...

Page 100: ...dily injury 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 co...

Page 101: ...e 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 t...

Page 102: ...tarting 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 seale...

Page 103: ...n insulated wrench disconnect the cables from the battery to be removed 2 Using a battery lifting strap remove the battery from the vehicle 3 Inspect the battery compartment for corrosion If there is...

Page 104: ...Notes...

Page 105: ...BF 3000 107 SCH 00115 with Controller Interlock 108 Diagram Part Numbers Wire diagrams are too large to be legible when printed at this size The wire diagram for this vehicle is included on the Vehicl...

Page 106: ...White Yellow Dark Green White Black Lt Blue Black Violet SEAT SWITCH POT FS1 LINE CONTACTOR FORWARD LOW SPEED 1 MAIN REVERSE Red Gray Black Black MOTOR ENCODER TEMP M TEMP BRAKE REGEN COIL RETURN CAN...

Page 107: ...White Red White 1 4 3 2 1 2 Brown Red White J1 Clear or White Clear or White J18 J30 J19 J3 J33 J9 J22 J31 J26 J15 J14 J28 J13 J24 J25 5 6 2 4 J20 J32 Green White Light Green Violet White Black Black...

Page 108: ...ack MOTOR ENCODER TEMP M TEMP BRAKE REGEN COIL RETURN CAN HIGH CAN LOW CAN SUPPLY KSI 24V CAN LOW CAN HIGH GND SUPPLY SUPPLY PHASE A Red Green Red Green Red Black White Red Black Red Black Green 12V O...

Page 109: ...ad all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Hardware Information Torque Guidelines for Standard Hardware 110 Hardware Identificatio...

Page 110: ...a grade 8 bolt use grade 2 torque value Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head as illustrated to the right The grade...

Page 111: ...E Grade 2 Lock 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...

Page 112: ...2 275 376 350 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...

Page 113: ...Dia Pitch 4 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...

Page 114: ...e assembly 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 ha...

Page 115: ...ines 128 Brakes Master Cylinder 129 Brakes Front Axle 130 Brakes Rear Axle 131 Charger Lester Summit 132 Charger Lester Summit II 132 Charger Signet 133 Charger DeltaQ 133 Control System Motor Speed 1...

Page 116: ...de only This parts list does 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...

Page 117: ...117 Not available at time of printing MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 My Vehicle information Serial Number Date Purchased Date Delivered Dealer Purchased From Salesman Name My loc...

Page 118: ...Replacement Parts Page 118 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 AXLE ASSEMBLY FRONT Standard Model Shown...

Page 119: ...051 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 Standard Model 0 or 1 21 14 010 01 Front Axle Plate Bottom 0 or 1 22 88 401 57 3 8 X 6...

Page 120: ...Replacement Parts Page 120 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 AXLE SHAFT ASSEMBLY REAR...

Page 121: ...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 8 96 327 10 3 8 X 3 4NF Grade 5 with thread lock 8 9 89 113 30 M12 x 1 75 x 30mm Hex bolt 12 1...

Page 122: ...d 10 to the part number for every 0 05mm over 3 9 For example if 4 55mm is needed 4 55 3 9 65mm over 0 65 05 13 13 10 130 Part number for 4 5mm spacer is 3287213 130 3287343 Your vehicle may be equipp...

Page 123: ...53 Gear case housing 1 12 GT 72019 Seal 1 13 GT 3287183 Ring and pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug 1 17 GT 3287113 Di...

Page 124: ...der assembly Gears Ring Pinion 1 12 N A Order assembly Race 1 13 N A Order assembly Bearing 1 14 41 989 01 Plug with O ring 1 15 Kit A C Seal 1 16 Kit B C Seal 2 17 Kit A C O ring 1 18 Kit A C O ring...

Page 125: ...ly Primary reduction 24 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 Seal 1 5 66 610 67 Vent 1 6 41 989 02 Plug with O ring 1...

Page 126: ...Replacement Parts Page 126 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 36 Volt System 48 Volt System BATTERY...

Page 127: ...7 043 00 210AH T 605 77 044 10 195AH Maintenance free Note requires special charger 77 047 00 260H T 145 77 047 80 260H T 145 Moist charge dry 77 051 00 160AH Gel Note requires special charger Not Sho...

Page 128: ...0 or 1 99 606 04 Brake Line Rear Right XL 3000 0 or 1 10 99 603 20 Brake Line Rear Left 1 11 99 591 00 Tee 3 16 x 18 pipe 2 12 500552 Switch Brake Regen 1 13 71 110 00 Switch Brake Lights 1 14 99 606...

Page 129: ...o Description Qty 1 BUL 18 03 001 Push rod Master Cylinder Bigfoot up to serial number 205583 41 310 12 Push rod Master Cylinder Bigfoot starting serial number 205584 41 310 12 Push rod Master Cylinde...

Page 130: ...st 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 Brak...

Page 131: ...ls 0 or 2 1 Brake body 1 2 32 208 01 Bushing included in rebuild kit 2 3 41 348 58 Spacer included in rebuild kit 4 4 41 350 28 1 Mounting Bracket 0 or 2 41 350 35 Mounting Bracket includes 2 0 or 2 5...

Page 132: ...7 foot front cord 0 or 1 79 575 15 Cable AC to charger 0 or 1 79 575 06 AC cord 8 foot rear receptacle 0 or 1 CHARGER LESTER SUMMIT II Note The Summit II is a direct replacement for the original Summi...

Page 133: ...Plug 76 200 00 76 200 00 Std AC Plug CHARGER DELTAQ Item No Part No Description Qty 79 309 48 Charger QuiQ 48 volt Trojan T145 79 309 49 Charger QuiQ 48 volt Trojan T105 79 909 47 Charger QuiQ 48 vol...

Page 134: ...s Page 134 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 CONTROL SYSTEM MOTOR SPEED 62 400 38 AC Controller 24 48V 300A 79 829 15 Fuse 330A System 62 400 47 AC Controller 36 48V 450A 79 829 10 F...

Page 135: ...systems 0 or 1 71 300 01 Bracket Mounting SW180 SERIES 1 88 838 06 14X1 2 PN Head Screw 2 6 79 829 15 Fuse 300A System 0 or 1 79 829 10 Fuse 450A System 0 or 1 Harnesses BIGFOOT 75 153 90 Harness Chas...

Page 136: ...g Plate BF XL 3000 1 5 74 010 00 Smart View Gauge standard BF 1 74 010 31 Clear View gauge BF XL 3000 only 1 74 010 52 E6 Gauge not shown BF XL 3000 only 1 6 71 039 11 Light Switch 1 7 71 039 11 Winds...

Page 137: ...1 6 94 319 00 Battery Disconnect 1 7 94 320 10 Roll Over 1 8 94 384 14 When leaving vehicle 1 9 94 301 42 Arms and Legs 2 10 94 313 21 Safety 1 11 94 384 32 Emergency Power Cut 1 12 94 301 41 DOT 3 Br...

Page 138: ...Replacement Parts Page 138 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 ELECTRICAL MISCELLANEOUS 7...

Page 139: ...nting 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 7 62 034 48 Throttle Module 1 Not Shown 98 599 15 Pla...

Page 140: ...Replacement Parts Page 140 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 FRAME AND BODY P1...

Page 141: ...d 0 or 1 00 500 16P Front Cowl XL 3000 0 or 1 8 See Brakes Parking Park Brake Lever 9 79 511 00 Cord Holder 0 or 1 79 530 00 Bushing AC Cord 0 or 1 79 575 09 Charger AC Cord X Series charger only 0 or...

Page 142: ...0 020 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 gut...

Page 143: ...Mirror Left Side 1 92 150 24 Mirror Right Side 1 00 500 12 Mirror Spacer 2 90 821 10 Window Left Door 1 90 821 11 Window Right Door 1 91 050 14 Side Window 2 00 020 05 Mount Mirror 1 92 206 51 Mirror...

Page 144: ...Replacement Parts Page 144 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 FRAME AND BODY DUMP OPTION Details not available at time of printing...

Page 145: ...Replacement Parts Page 145 Not available at time of printing MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 Dump Body Item No Part No Description Qty Details not available at time of printing...

Page 146: ...Replacement Parts Page 146 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 FRAME AND BODY 4 PASSENGER...

Page 147: ...00 000 61 Pivot pin left 1 00 000 62 Pivot pin Right 1 2 00 000 63 Grab bar 1 3 01 501 10 Release arm 1 4 01 501 41 Pivot shield 1 5 01 501 50 Frame Seat base 1 6 01 501 51 Cover Release handle 1 7 01...

Page 148: ...Replacement Parts Page 148 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 FRAME AND BODY DROP SIDES...

Page 149: ...Rivet 4 10 89 080 16 Hex Bolt 12 11 90 556 06 Peg Left 1 12 90 556 07 Peg Right 1 13 90 556 52 Rear Rail std 0 or 1 90 556 67 Rear Rail XL 3000 0 or 1 14 90 556 53 Gate Front Rear std 0 or 2 90 556 6...

Page 150: ...m No Part No Description Qty 97 800 69 Backing Plate installed on inside of frame 1 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 148 61 1 2 Flat Washer on all hitch options 4 88 148 62 1 2 Split lock washer...

Page 151: ...r cowl only 0 or 2 72 005 09 2 Light Grommet 2 Not Shown optional 71 900 40 Electronic Flasher for LED 12 V 1 71 141 23 Turn Signal Switch 1 98 330 50 Insulator Turn Signal Switch 1 502143 Reflector A...

Page 152: ...Replacement Parts Page 152 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 MOTOR VCM1714416DAD ZFB40SO 4 DF100L 4...

Page 153: ...al Block 6 15 70 058 41 32 Nut Terminal Block 3 KITS PKIT 00041 Bearing Kit Includes items 1 2 7 8 10 PKIT 00044 Terminal Block Kit Includes items 2 5 6 12 13 14 15 PKIT 00045 Speed Sensor Kit Include...

Page 154: ...O ring 1 4 88 068 62 1 4 Split lock washer 4 5 89 060 11 6 mm x 1 0 x 50 Hex bolt 3 6 89 111 27 10 mm x 1 5 x 20 Hex bolt 2 7 88 128 62 7 16 Split lock washer 2 8 70 456 03 Mounting bracket 1 9 88 06...

Page 155: ...Replacement Parts Page 155 Not available at time of printing MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48...

Page 156: ...Replacement Parts Page 156 MB 440 06 B5 440 36 B5 440 48 B5 540 48XL BF 030 48 STEERING LINKAGE...

Page 157: ...eering 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 M8 x 1 25 x 35 Hex Head Bolt 10 9 1 89 080000...

Page 158: ...art 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 3 5 6 85 498 00 Leaf Spring 2 7 14 010 07 Spring plate 2 Not Shown 9...

Page 159: ...Eye 6 3 96 248 01 BOLT SPRING W GRS FITNG GR5 6 88 169 82 9 16 NFLOCK NUT GRADE C 6 4 96 114 00 UBOLT RD 1 2NFX2 78X6 L GR5 4 88 159 84 LOCKNUT NY LOCK 1 2 20 NF GR2 4 5 40 500 00 Plate Spring Mounti...

Page 160: ...5 7 X 8 Load Range C 10 083 00 Tire 5 70 x 8 13 742 12 Tires wheel assembly 5 7 X 8 0 Load Range C Split Rims 13 742 50 Tire 5X8 Soft shoe NonMark 10 086 00 5 00 x 8 Man Toters with lugs soft solid AP...

Page 161: ...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 162: ...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 B5-540-48XL, Service And Replacement Parts Manual

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