Taylor-Dunn BG-015-00 Operation, T Roubleshooting And Replacement Parts Manual Download Page 118

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Wire Diagrams

Wire Diagrams
Page 2

SERIAL NUMBER 157990 TO 173347

White

L. FRONT

TURNLIGHT

HEADLIGHT

Green

White

Blue

Brown

Model BG-150 with Kohler CH18 Engine - Serial number 157990 through 173347 and serial number 173451

REVERSE

SWITCH

VIOLET (ENGINE WIRE REF]

REGULATOR

(25 AMP)

Blue

Yellow

White

RECTIFIER-

White

STOPLIGHT

Green

L. REAR

TAILLIGHT

White

R. REAR

TAILLIGHT

STOPLIGHT

FUEL

SENDER

Blue

SWITCH

NEUTRAL

Starter

ALARM

Green

White

Violet

Red

CIRCUIT BREAKER

B+

White

L. FRONT

Generator

PLUG

Starter

Relay

Red

Green

Red

MOTOR

Blue

White

R. FRONT

Ignition

Modules

Spark

Plug 1

Plug 2 Spark

TURNLIGHT

HEADLIGHT

R. FRONT

Yellow

White

Violet

White

FUEL

White

HORN

BUTTON

White

Yellow

Brown

Blue

Green

IGNITION

Blue

ACC

BATT

IGN

OFF

Red

STARTER

White

Yellow

SWITCH

SEAT

White

Yellow

Violet

White

Violet

Red

SWITCH STOPLIGHT

Red

Yellow

Green

Black

GND

GAUGE

Blue

White

Violet

RELAY STOP

87a

HOUR

METER

White

WIPER SWITCH

LIGHT SWITCH

Yellow

Black

WIPER

WINDSHIELD

Black

Yellow

Green

Red

SWITCH

STROBE LIGHT

STROBE

LIGHT

BATTERY

Red

White

Fuel Solenoid

Oil Pressure

Switch

Red

Blue

White

Green

Red

Black

Gray

Gray/Black

Red

SCH-00016, 3/23/2007 Revision B

NOTES:

Diagram includes options that may not be installed on all vehicles.

Diagram subject to change without notice, special order components may not be included.

Violet

Flasher

Black

Yellow

Blue

White

Summary of Contents for BG-015-00

Page 1: ...The Best Way To Go About Your B u s i n e s s Serial number Starting 157990 MANUAL MG 150 03 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded BG 015 00 G 1 50 Revision D...

Page 2: ......

Page 3: ...nn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or...

Page 4: ...B2 48 With Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor...

Page 5: ...justement 2 Front Axle Service Inspect the Front Wheel Bearings and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 5 Front Axle Disassembly 6 Rep...

Page 6: ...ist FRONT AXLE BRAKES 2 FRONT AXLE BRAKES CONT D 4 STEERING GEAR 6 DRAG LINK 6 FRONT SUSPENSION 8 REAR SUSPENSION 10 PARKING BRAKE LINKAGE 12 FOOT BRAKE LINKAGE 14 MASTER CYLINDER 14 REAR BRAKES 16 BR...

Page 7: ...Introduction About this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 Conventions 5 How to Identify Your Vehicle 6 Taking Delivery of Your Vehicle 7 Contents...

Page 8: ...de Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules and Gui...

Page 9: ...of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are responsible fo...

Page 10: ...to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific inform...

Page 11: ...treme care while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure to exe...

Page 12: ...ys It is available in maximum designed speed of 18 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of contr...

Page 13: ...result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also...

Page 14: ...B2 48 With Stake Side Dump Bed Option SC1 59 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor...

Page 15: ...ring 7 Directional Signals Optional 7 Hazard Light Switch Optional 7 Seat Interlock Switch 7 Accelerator Pedal 7 Foot Brake Pedal 7 Park Brake 7 Vehicle Operational Guidelines 8 Safety Guidelines 8 St...

Page 16: ...ng Gear Box Dana Specification 012AJ281 3 Brakes Rear Wheel Hydraulic Disc Hand Operated Park Brake 4 Wheel Hydraulic Disc Hand Operated Park Brake Steering Automotive Steering 24 1 Tires 5 70 x 8 Loa...

Page 17: ...8 and listed below These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants nurseries institutions motels mobile home parks and resorts They are no...

Page 18: ...afety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Operator Tra...

Page 19: ...ss the switch to sound the horn release it to turn it off Shift Lever The shift lever is located between the driver and front passenger seats The shift lever locks into the position selected Push the...

Page 20: ...an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter clockwise If equipped with tilt steering the release lever is located on the lower left of th...

Page 21: ...position Foot Brake Pedal The foot brake pedal is located to the right of the steering column it is for operation with the right foot only It works similar to the brake in an automobile Applying pres...

Page 22: ...at intersections blind spots or other dangerous locations Do not drive over loose objects holes or bumps Yield right of way to pedestrians and emergencies vehicles Stay in your driving lane under norm...

Page 23: ...ure to properly secure all loads Parking Before leaving the vehicle Set the parking brake Place the Shift lever in the neutral position Turn the key switch to the OFF position and remove the key In ad...

Page 24: ...d electrical connections Inflate tires to proper pressure if applicable For extended storage the vehicle should be elevated so that the tires do not touch the ground If stored for a prolonged period t...

Page 25: ...ice Battery l Check Park Brake l Check Front Wheel Bearings l Check Rear Axle Oil l Change Rear Axle Oil l Check and Tighten all Nuts and Bolts l Clean and Repack Front Wheel Bearings l Only properly...

Page 26: ...ons is determined by the use of the vehicle The owner operator must evaluate the operating environment to determine the increase in maintenance frequency In addition the whole vehicle should be inspec...

Page 27: ...TABLE OF CONTENTS General Maintenance Maintenance Guidelines 2 Maintenance Guidelines for Vehicles Used in Severe Conditions 3 Troubleshooting Guide 4 Lubrication Chart 5...

Page 28: ...es at the battery Avoid fire hazards and have fire protection equipment present in the work area Conduct vehicle performance checks in an authorized area where safe clearance exists Before starting th...

Page 29: ...ng Brakes Dragging Worn Drive Gears Front End Out of Alignment Engine Problem refer to the engine manual Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Engine...

Page 30: ...e Grease 2 King Pin 2 General Purpose Grease 3 Ball Joints 4 General Purpose Grease 4 5 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 6 7 Transmission Drain Plug 1 8 9 Transmission Fill...

Page 31: ...pplementary manual part number M7 001 07 For information regarding Kohler Command Engine service refer to the Kohler web site at www kohlerengines com Enter TP 2428 in the search box Refer to the spec...

Page 32: ...TAYLOR DUNN...

Page 33: ...Shift Linkage Contents Adjustment 2...

Page 34: ...ion 3 Place the shift lever in forward 4 Move the transmission shift lever to the forward detent 5 Using the cable nuts and or the ball joint coupler adjust the linkage so that the coupler easily slid...

Page 35: ...and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 5 Front Axle Disassembly 6 Replace Front Wheel Bearings 7 Replace the King Pins and Bushings 9...

Page 36: ...wheel and listen for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the r...

Page 37: ...for any grinding noise Any grinding noise may be an indication of worn or damaged wheel bearings NOTE Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the...

Page 38: ...or the steering gear pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 10 If equipped with front brakes disconnect th...

Page 39: ...ng the front wheels 8 Realign the front wheels Refer to Steering Component Service section for information regarding realigning the front wheels 9 If equipped with front brakes bleed the brakes Refer...

Page 40: ...regarding these 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 Rem...

Page 41: ...e hub Refer to theBrakes section for information regarding the removal of the brake body NOTE Catch the outer bearing as it falls out 10 Thoroughly clean all grease from the inside of the hub and the...

Page 42: ...ust cap 14 Reinstall the brake body and the tire wheel assembly NOTE Refer to theBrakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reconnect the main...

Page 43: ...ity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury Failure to correctly broach or ream bronze bushings may result...

Page 44: ...or suspension arm 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be replaced 11 Reassemble in reverse order NOTE Refer to Replace the Steering Knuckl...

Page 45: ...before removing the hub Refer to theBrakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then...

Page 46: ...ghen so much as to squeeze the legs of the knuckle together NOTE Refer to Replace Front Wheel Bearings for information regarding proper tightening of the spindle nut 16 Install new cotter pins 17 Real...

Page 47: ...Replace the Steering Shaft 10 Replace the Steering Wheel 12 Replace the Steering Gear 13 Replace the Steering Gear 14 Replace the Ball Joints Tie Rods and Drag Link 15 Replacing the Drag Link 17 Repla...

Page 48: ...sition and then tie off the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm NOTE Refer toReplace the Ball Jointssection for information...

Page 49: ...on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 18 Rotate the steering wheel from a full left turn to a full right...

Page 50: ...ion 6 Raise the front of the vehicle and support with jack stands 7 Turn the front wheels so that they are in the straight ahead position and tie off the steering wheel so that it cannot rotate 8 Usin...

Page 51: ...between the lines at the front of the tires 12 Measure the distance between the lines at the rear of the tires 13 Adjust the tie rod so that the distance at the front and rear of the tires is the same...

Page 52: ...turn 7 While watching the ball joints rapidly rotate the steering wheel to the left and right 8 If the ball joint housing moves up or down then the ball joint is worn out and should be replaced Refer...

Page 53: ...at the batteries 9 Remove the blocks from behind the wheels 10 Release the parking brake and test drive the vehicle Do not drive the vehicle while the steering wheel or front wheels are tied in positi...

Page 54: ...lash jam nut and the worm bearing adjuster jam nut 9 Unscrew the gear lash adjuster all of the way to the stop 10 Loosen the worm bearing adjuster and then tighten just enough to remove all end play...

Page 55: ...the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten...

Page 56: ...if equipped 10 Remove and discard the pinch bolt and nut from the steering shaft coupler NOTE Most vehicle configurations will now allow the steering shaft to slide off of the steering gear input sha...

Page 57: ...d to property damage and or severe bodily injury T A Y L OR DUN N T h e B e s t W a y To Go About Yo u r B u s i n e s s R 11 Remove the steering shaft from the vehicle 12 Lightly grease the input sha...

Page 58: ...in the OFF position then remove the key 2 Place the Shift lever in the neutral position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main pos...

Page 59: ...ction for information regarding removing the ball joint from the pitman arm 9 Support the steering gear so that it cannot fall out of the vehicle 10 Remove the bolts holding the steering gear to the v...

Page 60: ...DUN N T h e B e s t W a y To Go About Yo u r B u s i n e s s R 1 Make sure the key switch is in the OFF position then remove the key 2 Place the Shift lever in the neutral position 3 Set the park brak...

Page 61: ...ing a Rod End 6 Raise the front of the vehicle and support with jack stands 7 Loosen the rod end jam nut or clamp on the steering sleeve 8 Remove the rod end nut 9 Remove the rod end from the steering...

Page 62: ...and ball joint nut 9 Using a pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve HINT Count the number of turns required to remove the ball joint...

Page 63: ...move the ball joints or rod ends from the steering knuckle and pitman arm NOTE Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Rem...

Page 64: ...all in reverse order 10 Realign the front wheels NOTE Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and ne...

Page 65: ...he key switch is in the OFF position then remove the key 2 Place the Shift lever in the neutral position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconn...

Page 66: ...fer to the illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counti...

Page 67: ...10 Remove the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Reassembly 1 Lightly lubricate all parts before reass...

Page 68: ...Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using two of the three mounting bo...

Page 69: ...Maintenance Service and Repair Steering Page 23 Exploded View of Steering Gear...

Page 70: ...TAYLOR DUNN...

Page 71: ...he Parking Brake 8 Park Brake Handle 8 Park Brake Linkage 9 Check Master Cylinder Fluid 10 Bleed the Brake System 11 Flush the Brake System 13 Replace Front Disc Brake Pads 14 Replace Rear Brake Shoes...

Page 72: ...pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Current Taylor Dunn brakes are asbestos f...

Page 73: ...d its service limits then the front hub must be replaced Refer to Front Axle Servicefor information on replacing the front hub NOTE Depending on the rear axle configuration the rear brake rotor may be...

Page 74: ...tos Refer to appendix C for recommended handling precautions Brake Drum NOTE The wheel must be removed to accurately measure the brake drum Refer to Tires and Wheels section for information on removin...

Page 75: ...ice brake shoes Refer to Inspect the Service Brake section to inspect the brake shoes 8 Inspect all brake cables and linkages for any signs of damage or missing cotter pins 9 Inspect the park brake ra...

Page 76: ...mis operation of the brakes If you hear a single clunking noise while braking it may be due to mis adjustment of the brake cables or linkage Refer to Replace Brake Linkages Cables for information reg...

Page 77: ...vehicle resulting in severe bodily injury and or property damage 1 Make sure the key switch is in the OFF position then remove the key 2 Place the Shift lever in the neutral position 3 Set the park b...

Page 78: ...1 Make sure the key switch is in the OFF position then remove the key 2 Place the Shift lever in the neutral position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle mov...

Page 79: ...els 9 Tighten the jam nuts on the adjusting link 10 Set the park brake 11 Reconnect the main positive and negative cables at the batteries 12 Remove blocks from behind the wheels 13 Release the park b...

Page 80: ...yes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops g...

Page 81: ...hield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Imm...

Page 82: ...low enough to allow air to enter the brake lines If air enters the brake lines during the bleeding process then you will have to start again from the beginning 14 Repeat the above steps until you are...

Page 83: ...ake fluid 12 Position the wheel cylinders so that the bleeder screw is pointing to the ground and open all bleeder screws 13 Pump the master cylinder until all fluid has been pumped from the brake lin...

Page 84: ...ly clean the area around the master cylinder cap 7 Remove fluid from the master cylinder until it is 1 2 full Always use a lifting strap hoist and jack stands of adequate capacity to lift and support...

Page 85: ...7 and replace if any wear or damage is found 14 Install new spacer bushings in the mounting bracket 15 Install new brake pads in reverse order Torque the mounting bolts to 11 ft lbs 16 Repeat this pro...

Page 86: ...wheel 9 Remove and inspect the brake drum Refer to Inspect the Service Brake section for information regarding inspecting the brake drum Always use a lifting strap hoist and jack stands of adequate c...

Page 87: ...3 Thoroughly clean and inspect the adjustor assembly Replace parts as required 14 Apply avery light coating of high temperature grease to the adjustor screw threads 15 Install in reverse order 16 Repe...

Page 88: ...d handling precautions Do not ingest brake fluid or allow contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area im...

Page 89: ...regarding inspecting the brake rotor 12 Disconnect the brake hose from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting T...

Page 90: ...lways wear protective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get me...

Page 91: ...and race Refer to the Transmission Manual for information regarding removing the bearing 13 Install the new spider and axle bearing 14 Reassemble in reverse order 15 Bleed the brakes Refer to Bleed t...

Page 92: ...around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immediately flush the eye wit...

Page 93: ...ging off of the end of the piston 14 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove 15 Press the pistons all the way down into the brake b...

Page 94: ...tective clothing and a face shield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attentio...

Page 95: ...was raised lower it to the ground 15 Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables at the batteri...

Page 96: ...scard Remove the rubber boot Depress the plunger and remove the plunger spring clip retainer Pull the plunger and all seals out of the master cylinder bore Thoroughly clean inspect and replace parts a...

Page 97: ...TABLE OF CONTENTS Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 5 Replace the Shocks 6...

Page 98: ...vent vehicle movement 5 Disconnect the main positive and negative cables at the battery Pinch point Do not place any part of your body between the spring and the vehicles frame spring mounts or betwee...

Page 99: ...time 6 Raise the front of the vehicle and support with jack stands 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle beam 9 Support the sp...

Page 100: ...n they must be replaced 13 Install the new spring in reverse order 14 If the spring hanger bolts do not have a grease fitting lube the spring bushings before installing the spring 15 Torque the spring...

Page 101: ...formation regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles frame 9 Remove the spring bushing s For internal bushing...

Page 102: ...n of leakage is seen then the shock must be replaced B Inspect the upper and lower shock bushings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse...

Page 103: ...TABLE OF CONTENTS Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5 Tires and Wheels...

Page 104: ...ION 6 Check the tire pressure Refer to Tire Inflation section for information on checking the tire pressure 7 Inspect the tire tread depth Minimum recommended tread depth is 1 16 inch There are a seri...

Page 105: ...valve stem 11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak REPLACE THE TIRE WHE...

Page 106: ...nuts may result in the wheel coming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC NOTE To properly repair a puncture the tire must be removed from t...

Page 107: ...eplacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions pro...

Page 108: ...TAYLOR DUNN...

Page 109: ...ABLE OF CONTENTS Battery Service Cleaning 2 Testing non maintenance free 3 Testing maintenance free 4 Watering non maintenance free 5 Storage and Returning to Service 6 Storage 6 Returning to Service...

Page 110: ...roughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the battery remove the blocks from the wheels and test drive Explosive mixtures of Hydrogen gas are present w...

Page 111: ...ing gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may...

Page 112: ...y of each cell in the battery If after charging none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system If the charging system checks OK then the battery...

Page 113: ...ater heater pilots sparks cigarettes or any other sources of combustion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bo...

Page 114: ...the battery Storage Temperature F Charging Interval months Over 60 1 Between 40 and 60 2 Below 40 6 STORAGE AND RETURNING TO SERVICE Storage Thoroughly clean the battery and battery compartment Refer...

Page 115: ...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 property damage and or bodily injury Battery electrol...

Page 116: ...TAYLOR DUNN...

Page 117: ...99 3 Full size diagrams 22 x 17 are inculded on the CD in PDF format You can access the diagrams from a button on the CD menu The diagram s are SCH 00016 Serial number 157990 through 173347 and serial...

Page 118: ...ADLIGHT R FRONT Yellow W h it e Violet White FUEL White HORN HORN BUTTON White Yellow Brown Blue Green IGNITION Blue ACC BATT ST IGN OFF Red STARTER White White White Yellow SWITCH SEAT White Yellow Y...

Page 119: ...White Yellow Blue White NOTES Diagram includes options that may not be installed on all vehicles Diagram subject to change without notice special order components may not be included a Low Oil Over H...

Page 120: ...TAYLOR DUNN...

Page 121: ...ENSION 8 REAR SUSPENSION 10 PARKING BRAKE LINKAGE 12 FOOT BRAKE LINKAGE 14 MASTER CYLINDER 14 REAR BRAKES 16 BRAKE LINES AND HOSES 18 ACCELERATOR PEDAL LINKAGE 20 SHIFTING LINKAGE 22 DANA DRIVE 24 ENG...

Page 122: ...4 2 Section 4 Illustrated Parts FRONT AXLE BRAKES 1 2 3 4 5 6 7 8 9 10 16 17 12 13 14 11 15 18 19 20 21 22 29 30 28 27 24 25 26 25 24 23 31...

Page 123: ...ody Rebuild kit 41 350 66 2 7 99 588 01 Brake Bleeder Fitting 2 8 88 069 82 Brake Body nut grade 8 DO NOT REUSE 4 9 99 588 00 Brake Bleeder Valve 2 10 21 020 15 King Pin 2 11 14 210 88 Left driver Sid...

Page 124: ...4 4 Section 4 Illustrated Parts FRONT AXLE BRAKES CONT D 1 2 3 4 5 6 7 8 9 10 16 17 12 13 14 11 15 18 19 20 21 22 29 30 28 27 24 25 26 25 24 23 31...

Page 125: ...18 041 00 Tie Rod 1 21 86 510 00 Ball Joint Clamp w Nut and Bolt 2 22 86 501 98 Ball Joint left thread 1 23 45 338 00 Grease Seal 2 24 80 017 00 Inner Outer Wheel Bearing 4 25 80 103 00 Inner Outer R...

Page 126: ...4 6 Section 4 Illustrated Parts STEERING GEAR DRAG LINK 2 3 4 5 6 9 8 7 1 11 12 14 13 15 10 16 2 3 4 5 6 7 1 Pitman Arm Ref...

Page 127: ...109 81 3 8 NC Lock Nut 6 10 88 128 62 7 16 Split Lock Washer 3 11 88 120 11 7 16 x 1 NC hex bolt 3 12 88 279 82 7 8 NF Jam Nut 1 13 88 268 62 7 8 Split Lock Washer 1 14 18 111 30 Pitman Arm 1 15 18 3...

Page 128: ...4 8 Section 4 Illustrated Parts FRONT SUSPENSION 2 3 4 5 6 9 8 7 1...

Page 129: ...1 96 123 02 U Bolt 4 2 85 512 10 Leaf Spring 2 3 87 074 00 Grease Fitting 6 4 96 248 01 Shackle Bolt 6 5 32 213 00 Nylon Bushing 6 6 16 865 02 Spring Plate 2 7 88 169 82 9 16 NF Lock Nut 6 8 16 870 10...

Page 130: ...4 10 Section 4 Illustrated Parts REAR SUSPENSION 2 3 4 5 1 6 7...

Page 131: ...ITEM PART DESCRIPTION QTY 1 88 120 17 7 16 x 2 1 4 Hex Bolt 4 2 85 142 00 Spring 4 3 86 602 00 Shock 2 4 41 403 00 Shock Bracket 2 5 88 129 81 7 16 Lock Nut 8 6 88 120 11 7 16 x 1 Hex Bolt 4 7 XX XXX...

Page 132: ...4 12 Section 4 Illustrated Parts PARKING BRAKE LINKAGE 2 3 4 5 6 9 7 1 11 12 14 13 10 18 19 21 20 22 23 17 15 16 9 10 5 4 6 Frame Supplied w 1 Frame Swing Arm 8...

Page 133: ...343 00 Adjusting Link 1 9 96 773 00 5 16 x 1 Clevis Pin 4 10 88 527 11 1 8 x 1 Cotter Pin 3 11 02 610 16 Equalizer 1 12 96 826 12 Parking Brake Cable 2 13 96 763 00 5 16 Clevis 1 14 88 099 80 5 16 NF...

Page 134: ...4 14 Section 4 Illustrated Parts FOOT BRAKE LINKAGE MASTER CYLINDER 1 2 3 5 6 9 7 11 12 14 13 10 8 1 2 3 5 4 4...

Page 135: ...Rod 1 7 99 510 02 Master Cylinder Assembly 1 8 88 101 20 3 8 X 3 Grade 5 Hex Bolt 2 9 88 109 81 3 8 NC Locknut 2 10 17 104 00 Collar 1 11 06 210 03 Return Spring Mounting Clip 1 12 00 210 08 Push Rod...

Page 136: ...4 16 Section 4 Illustrated Parts REAR BRAKES 1 2 3 5 6 9 7 10 8 4 11...

Page 137: ...l Cylinder 2 4 85 411 10 Torsion Spring green 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...

Page 138: ...4 18 Section 4 Illustrated Parts BRAKE LINES AND HOSES...

Page 139: ...6 99 566 00 Banjo Fitting 1 7 99 571 00 Washer Copper 0 50 ID 1 8 99 578 00 Fillting Master Cylinder Bolt 1 9 99 572 00 Washer Copper 0 594 ID 1 10 99 605 66 Brake Line Right 1 11 99 576 00 Hose Clip...

Page 140: ...4 20 Section 4 Illustrated Parts ACCELERATOR PEDAL LINKAGE 2 3 4 5 6 9 7 1 10 12 14 11 13 10 17 15 16 8 12 9 Pin on Part 1 Cable Mounting R Side View Bottom View 18...

Page 141: ...le 1 10 96 871 01 Clamp 1 11 88 069 81 1 4 NC Lock Nut not pictured 2 12 88 025 05 8 32 Socket Head Machine Screw 1 13 32 215 50 Bushing 2 14 88 065 06 1 4 x 1 2 Truss Head Screw 2 15 88 517 11 Cotter...

Page 142: ...4 22 Section 4 Illustrated Parts SHIFTING LINKAGE 2 3 4 1 6 5 10 8 12 15 18 9 16 20 Frame Decal 14 13 5 17 19 11 Hardware Included w 17 7 21 22 23 24 25...

Page 143: ...Nut 1 11 96 852 00 Shift Cable Ball Joint 1 12 00 610 25 Mounting Bracket 1 13 00 610 83 Plate Shift Cable Mount 1 14 88 108 61 3 8 SAE Washer 4 15 88 100 11 3 8 X 1 NC Hex Head Screw 2 16 94 306 08...

Page 144: ...4 24 Section 4 Illustrated Parts DANA DRIVE Fill and Inspection Plug 1 2 3 4 5 6...

Page 145: ...on assembly with brakes spec 012AJ281 3 1 2 89 112 30 M12 X 1 25 X 50MM Hex Screw 1 3 88 148 62 1 2 in Lock Washer 1 4 98 601 57 Washer 1 2 ID Mount 1 5 30 182 00 Pulley Assembly Driven Long Life 1 6...

Page 146: ...4 26 Section 4 Illustrated Parts ENGINE AND MOUNT 1 2 3 5 6 19 8 7 18 11 10 9 1 2 3 4 5 6 1 4...

Page 147: ...Traction Bar 1 8 86 510 00 Clamp 2 9 86 521 98 Rod End LH 1 10 88 109 81 3 8 NC Lock Nut 14 11 88 108 62 3 8 Lock Washer 8 12 13 14 15 16 17 18 67 000 53 Engine Assembly 1 19 88 101 13 3 8 X 1 1 4 He...

Page 148: ...4 28 Section 4 Illustrated Parts EXHAUST 1 3 4 2 2 MOUNT TO TOP OF BRACKET ON SWING ARM 5 6 7 8 9 9 8 10 11 11 11...

Page 149: ...00 610 95 Tail pipe 1 4 66 400 25 Spark arrestor 1 5 66 400 06 Tail pipe mounting bracket 1 6 88 088 62 5 16 Split lock washer 2 7 88 089 80 5 16NC Hex nut 2 8 88 088 62 5 16 Split lock washer 4 9 88...

Page 150: ...4 30 Section 4 Illustrated Parts ENGINE SERVICE PARTS ILLUSTRATION IS NOT AVAILABLE...

Page 151: ...r and serial number will be required They can be found on the engine specification plate Refer to the Introduction section for the location of the specification plate Engine Service Parts CH18 spec 62...

Page 152: ...4 32 Section 4 Illustrated Parts FUEL TANK AND LINES ILLUSTRATION IS NOT AVAILABLE...

Page 153: ...FUEL TANK AND LINES ITEM PART DESCRIPTION QTY 96 608 05 Hose clamp 2 98 512 00 Fuel Line 3 3 05 211 00 Fuel Tank 1 05 211 01 Mounting Strap 2 77 022 51 Rubber Gasket on Frame around filler tube openi...

Page 154: ...4 34 Section 4 Illustrated Parts INSTRUMENT PANEL 1 3 4 5 7 1 6 8 9 10 2 2...

Page 155: ...0 Hole Plug positions may contain optional switches 3 3 74 009 20 Fuel Gauge 1 4 74 000 00 Hour Meter 1 5 88 069 81 1 4 Nut 2 6 00 610 01 Console 1 7 71 120 01 Key Switch 1 8 94 304 18 Instrument Pane...

Page 156: ...4 36 Section 4 Illustrated Parts FRAME 2 3 4 8 6 1 10 11 13 12 9 3 7 5...

Page 157: ...Screws 6 8 00 210 04 Seat Back Weldment 1 9 90 179 00 Seat Back Cushion 1 10 90 174 00 Driver Seat Cushion 1 11 77 054 10 Battery Standard 1 12 90 444 20 Deckboard Rear 1 13 02 210 25 Wire Harness Cov...

Page 158: ...4 38 Section 4 Illustrated Parts DECALS WARNING LABELS 2 3 4 9 7 1 11 12 13 10 6 8 5...

Page 159: ...Fuel Oil Check 1 4 94 306 02 Speed Warning 1 5 94 373 05 Data Plate 1 6 94 306 07 Push to Shift 1 7 94 306 09 Do Not Shift While Moving 1 8 94 306 03 Heat Warning 1 9 94 306 04 Rotating Parts Warning...

Page 160: ...4 40 Section 4 Illustrated Parts ELECTRICAL SYSTEM Illustration not available...

Page 161: ...9 10 Light Switch 1 73 004 20 Horn 1 71 102 10 Seat Switch 1 71 122 20 Horn Button 1 71 303 01 Engine Kill Relay behind dash panel 1 71 900 05 Signal Flasher 1 72 082 01 Headlight Bulb 2 72 082 10 Fro...

Page 162: ...TAYLOR DUNN MFG...

Page 163: ...APPENDIX A Special Tools...

Page 164: ...l C4 25 Huskey 62 027 10 GE EV1 Analyzer Used to test the GE EV1 speed control 62 027 20 Disc Brake Boot Installation Tool Used to install the rubber boot on all disc brake bodies 41 350 13 Pin Removi...

Page 165: ...are Suggested Torque Limits Hardware Identification 2 Standard Head Markings 2 Hex Bolts 2 Other Bolts 2 Hex Nuts 3 Hex Lock Nuts stover 3 Other Nuts 3 Suggested Torque Values non critical hardware 4...

Page 166: ...e 5 Truss Head grade 2 Carriage Bolt grade 2 unless marked as above Other Bolts NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade...

Page 167: ...A 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 ar...

Page 168: ...39 59 60 90 85 128 95 1 2 20 44 66 68 102 96 144 110 9 16 12 56 84 87 131 123 184 140 9 16 18 63 94 97 146 137 206 160 5 8 11 78 117 120 180 170 254 195 5 8 18 88 132 136 204 192 288 225 3 4 10 138 20...

Page 169: ...r section Dana F N R 25 35 300 420 34 47 6 Carrier cap bolts Dana 100 120 1200 1440 136 163 2 Differential Cover plate Dana H12 18 25 216 300 24 5 34 Drain plug Dana H12 25 40 300 480 34 54 4 Drain pl...

Page 170: ...TAYLOR DUNN...

Page 171: ...Appendix C...

Page 172: ...rake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel...

Page 173: ......

Page 174: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com...

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Taylor-Dunn BG-015-00, Operation, T Roubleshooting And Replacement Parts Manual

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