Taylor-Dunn C0-426-48AC Service And Replacement Parts Manual
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Taylor-Dunn C0-426-48AC Service And Replacement Parts Manual

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Service and Replacement
Parts Manual
MANUAL: MC-425-15
C-426
Model Numbers:
C0-426-48AC
T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
Starting Serial Number: 207500
Ending Serial Number: See Introduction Chapter
B

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  • Page 1 Service and Replacement Parts Manual MANUAL: MC-425-15 C-426 Model Numbers: C0-426-48AC T h e B e s t W a y T o G o A b o u t Y o u r B u s i n e s s WARNING READ THE OPERATOR’S MANUAL BEFORE OPERATING...
  • Page 2 Service Advisor at your local dealership. Taylor-Dunn has a worldwide dealer and distribution network to provide replacement parts and service for our vehicles. Refer to our web site, www.taylor-dunn.com, for a dealer lookup application. Originally Published 1/15/2018 Revision B, 7/12/2018, contents subject to change without notice ®...
  • Page 3 Taylor-Dunn Contact information Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.
  • Page 4 Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application- specific solutions, which are reliable, efficient, and economical. Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving. Tiger Tractor: Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment.

  • Page 5: Table Of Contents

    Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Preventative Maintenance ......17 Special Tool List ..........21 Lubrication ............25 Front Axle ............29 Steering ............39 Brakes...............49 Motor ..............57 Motor Controller ..........61 Wire Diagram ...........65 Batteries ............67 Tires &...
  • Page 7 Table of Contents 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 WARNING This section is one section of a complete service manual.

  • Page 8: Introduction

    ® to include as much information as possible about the operation and maintenance of this vehicle. Taylor-Dunn is not to be held liable for errors in this manual or any consequential damage that results from the use of this manual.

  • Page 9: Introduction

    Introduction C-426 Conventions Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be used elsewhere in the text of this document without being a signal word.

  • Page 10: Responsibilities

    Of the Service Personnel... WARNING The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.

  • Page 11: How To Identify Your Vehicle

    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.
  • Page 12 Notes Introduction C-426 Page-12 MC-425-15...
  • Page 13 Table of Contents 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: Service/Maintenance Guidelines

    BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the Start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Service/Maintenance Guidelines

    Contact the factory for information regarding available alternate program settings. Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle. Any other alterations to the programming ARE NOT AUTHORIZED and is at your own risk.

  • Page 16: Replacement Parts

    To maintain peak performance, always use original Taylor-Dunn replacement parts intended for use on your vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
  • Page 17 Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 Interlock Switch Inspection ......20 Start Switch ............20 High Pedal Disable (HPD) ........20 Operator Presence Switch ........20...
  • Page 18 PM Schedule C-426 DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 19: Preventative Maintenance

    PM Schedule C-426 First 20 hours of Operation Every 6 Months or 600 hours) • Re-torque wheel nuts. All 3 month items plus the following: • Inspect all hardware for tightness. • Align the front end Every Week • Inspect electrical connections of signs of overheating All daily items plus the following: •...
  • Page 20 PM Schedule C-426 INTERLOCK SWITCH INSPECTION The interlock switches should disable vehicle operation when activated. Perform the following to confirm proper operation. If any one test fails, then immediately remove the vehicle from service and refer repair to a qualified technician.
  • Page 21 Table of Contents Special Tool List Controller Programming: .........22 Troubleshooting Guide ........24...
  • Page 22 Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not rectangular harness connectors. Not 62-027-67: Diagnostics and adjustments available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from 62-027-68: Diagnostics only any local electronics distributor. any local electronics distributor.

  • Page 23: Special Tool List

    Tool List C-426 96-500-48: GT Drive Oil Fill Plug Tool 96-500-66: SD Drive Primary Case Spreader Used to remove the oil fill plug on GT drives. It is used with a 3/8” drive extension (not included). 77-200-00: Hydrometer 77-201-00: Battery Filler Used for testing battery electrolyte.
  • Page 24 Tool List C-426 TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...
  • Page 25 Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication C-426 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 2: King Pin NLGI Grade 2 lithium multi-purpose grease 3: Ball Joint NLGI Grade 2 lithium multi-purpose grease 4: Bell crank NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Brake Fluid: Master Cylinder...

  • Page 27: Lubrication

    Lubrication C-426 LUBRICATION DIAGRAM Front End Lubrication GT - Rear Axle Lubrication SD Transaxle MC-425-15 Page 27...
  • Page 28 Notes Lubrication C-426 Page 28 MC-425-15...
  • Page 29 Table of Contents Front Axle Remove.............30 Install ..............30 Disassemble.............31 Inspect Front Wheel Bearings ......32 Adjust Front Wheel Bearings ......32 Front Wheel Alignment ........33 Inspection, Axle Centers ..........33 Center the Wheels ...........33 Toe In ...............34 Replace Front Wheel Bearings.......35 Replace Steering Knuckle ......35 Replace King Pin/Bushings or Pivot Pin/Bushings ..........36 Service Limits and Specifications ....37...

  • Page 30: Front Axle

    Front Axle C-426 REMOVE WARNING 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. 1: Raise the front of the vehicle and support with jack stands. 2: Remove both front wheels.

  • Page 31: Front Axle

    Front Axle C-426 DISASSEMBLE WARNING 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. Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings.

  • Page 32: Inspect Front Wheel Bearings

    Front Axle C-426 INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 33: Front Wheel Alignment

    Front Axle C-426 FRONT WHEEL ALIGNMENT WARNING 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. Inspection, Axle Centers 1: Raise the front of the vehicle and support with jack stands. 2: Measure the distances from the rear of the lower axle beam to the rear wall of the wheel well on both sides of the axle beam next to the steering knuckle.

  • Page 34: Toe In

    Front Axle C-426 Toe In 10: Using a piece of chalk, mark a line around the center of both front tires. 11: Measure the distance between the lines at the front of the tires. 12: Measure the distance between the lines at the rear of the tires.

  • Page 35: Replace Front Wheel Bearings

    Front Axle C-426 REPLACE FRONT WHEEL REPLACE STEERING KNUCKLE BEARINGS WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 36: Replace King Pin/Bushings Or Pivot Pin/Bushings

    Front Axle C-426 REPLACE KING PIN/BUSHINGS OR PIVOT PIN/BUSHINGS WARNING 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. There are different types of king pin bushings depending on the configuration of your vehicle.

  • Page 37: Service Limits And Specifications

    Front Axle C-426 SERVICE LIMITS AND HARDWARE TORQUE Description Foot Pounds Newton Meters SPECIFICATIONS Ball Joint Clamp 28-32 37.9-43.4 Pivot Pin Bushings Rod End Stud Nut 20-25 27.1-33.9 Ream or broach to 0.878 to 0.880 inches Rod End Jam Nut 20-25 27.1-33.9 (22.30 to 22.53 mm)
  • Page 38 Notes Front Axle C-426 Page 38 MC-425-15...
  • Page 39 Table of Contents Steering Inspect Ball Joints ...........40 Adjust Steering Gear ........40 Replace Ball Joint..........41 Replace Steering Wheel ........41 Replace Steering Shaft ........42 Pitman Shaft Alignment ........43 Front Wheel Alignment ........43 Steering Gear ...........44 Disassemble ............44 Reassemble ............45 Exploded View of Steering Gear ......46 Hardware Torque ..........47 WARNING This section is one section of a complete service...

  • Page 40: Inspect Ball Joints

    Steering C-426 INSPECT BALL JOINTS ADJUST STEERING GEAR WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 41: Steering

    Steering C-426 REPLACE BALL JOINT REPLACE STEERING WHEEL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 42: Replace Steering Shaft

    Steering C-426 REPLACE STEERING SHAFT WARNING WARNING This section is one section of a complete service Do not reuse the original pinch bolt and nut. Failure manual. Before starting any procedure, read all to replace the pinch bolt and nut may result in warnings and instructions that are located in the failure of the steering causing loss of control of the Service Guidelines chapter.

  • Page 43: Pitman Shaft Alignment

    Steering C-426 PITMAN SHAFT ALIGNMENT 1: Center the steering gear. Refer to for information regarding centering the Center the Steeing Gear steering gear. 2: Install the pitman arm parallel with the input shaft orientated as shown in the illustration. 3: Torque the pitman arm nut to torque specified at the end of this section. FRONT WHEEL ALIGNMENT Refer to the Front Axle section for front wheel alignment procedure.

  • Page 44: Steering Gear

    Steering C-426 STEERING GEAR WARNING 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. Disassemble Note: The steering gear must be removed from the vehicle for this procedure.

  • Page 45: Reassemble

    Steering C-426 Reassemble 12: Lightly lubricate all parts before reassembly. 13: Install a new worm shaft seal and pitman shaft seal into the housing. 14: Install the upper worm bearing cup. 15: Divide the ball bearing into two equal groups. 16: Position the ball nut onto the worm shaft as shown in the illustration.

  • Page 46: Exploded View Of Steering Gear

    Steering C-426 Exploded View of Steering Gear Page 46 MC-425-15...

  • Page 47: Hardware Torque

    Steering C-426 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Rod End Stud Nut 20-25 27.1-33.9 Rod End Jam Nut 20-25 27.1-33.9 Ball Joint Castle Nut 40-45 54.2-61 Steering Wheel Nut 28-32 38-43 Pitnam Arm 75-100 107-140 MC-425-15 Page 47...
  • Page 48 Notes Steering C-426 Page 48 MC-425-15...
  • Page 49 Table of Contents Brakes General Guidelines and Safety.......50 Front Brake ............51 Service Limits ............51 Inspection ..............51 Replace Pads ............51 Rear Brake............52 Service Limits ............52 Inspection ..............52 Replace Pads ............52 Rebuild Disc Brake Body ........53 Bleed System ...........54 Flush System ...........54 Master Cylinder..........55 Add Fluid ..............55 Adjust Push Rod ............55...

  • Page 50: General Guidelines And Safety

    C-426 GENERAL GUIDELINES AND SAFETY WARNING WARNING Taylor-Dunn does not currently supply asbestos This section is one section of a complete service fiber-brake pads/shoes with any vehicle. However, manual. Before starting any procedure, read all there is the possibility that the original brake pads/...

  • Page 51: Brakes

    Brakes C-426 FRONT BRAKE WARNING 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. Service Limits Refer to the table at the end of this section Inspection Note: Service Limits are listed in a table at the end of this section.

  • Page 52: Rear Brake

    Brakes C-426 REAR BRAKE WARNING 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. Service Limits Refer to the table at the end of this section Note: Service Limits are listed in a table at the end of this section.

  • Page 53: Rebuild Disc Brake Body

    Brakes C-426 REBUILD DISC BRAKE BODY WARNING 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. This procedure assumes that the component has been removed from the vehicle.

  • Page 54: Bleed System

    Brakes C-426 FLUSH SYSTEM BLEED SYSTEM 1: Raise the rear wheels off of the ground and WARNING support with jack stands. 2: If equipped with front brakes, raise the front This section is one section of a complete service wheels off of the ground and support with jack manual.

  • Page 55: Master Cylinder

    Brakes C-426 MASTER CYLINDER WARNING 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. There are no internally serviceable components in the master cylinder.

  • Page 56: Service Limits

    Brakes C-426 HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc brake Pad minimum lining 00625 inch 1.58 millimeter Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch 5.08 millimeter Brake Body Bolts...
  • Page 57 Table of Contents Motor Motor Identification .........58 Remove/Install ..........58 Inspect/Testing ..........58 Bearing ..............58 Electrical Testing............58 Disassemble.............59 Reassemble............59 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 58 Refer to the Drive Axle section for information regarding documentation CD. A hard copy can be purchased removing the motor. from your authorized Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. Electromagnetic Motor Brake Electrical testing for the brake is included in a separate manual “Troubleshooting Electric Vehicles”.

  • Page 59: Motor

    Motor C-426 DISASSEMBLE REASSEMBLE WARNING 1: Insert the armature/housing assembly into the field housing` while carefully pulling the field cable assemblies through the opening. This section is one section of a complete service 2: Install the sensor bearing and thermal sensor manual.
  • Page 60 Notes Motor C-426 Page 60 MC-425-15...
  • Page 61 Table of Contents Motor Controller Remove/Install ..........62 Inspect ..............62 Receptacles .............62 Base Plate ...............62 Terminal Ends ............62 Troubleshooting ..........62 Repair/Programming ........63 Programming ............63 Hardware Torque ..........64 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 62: Motor Controller

    CD. A hard copy can be purchased 2: Apply thermal transfer compound to the controller from your authorized Taylor-Dunn distributor or can be base and heat sink. downloaded from the Taylor-Dunn web site.

  • Page 63: Motor Controller

    1314 application and cable. Refer to the Tools section for part numbers. If you have a special application that may require modified parameters, contact your local authorized Taylor-Dunn distributor to submit a request to the factory. Note: There may be a fee to created a custom parameter set.

  • Page 64: Hardware Torque

    Motor Controller C-426 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal stud Page 64 MC-425-15...
  • Page 65 Table of Contents Wire Diagram Diagram Part Numbers........66 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 66 Wire diagrams are too 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-00102 This vehicle diagram as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Red/Black...

  • Page 67: Wire Diagram

    Table of Contents Batteries General Guidelines and Safety.......68 Cleaning ............69 Charging ............69 Watering ............69 Testing ..............70 Specific Gravity ............70 Storing ..............70 Storage ..............70 Returning to Service ..........70 Remove/Install ..........71 Industrial Battery or Lift Out Battery Pack ....71 Side Extract Battery ..........71 Hardware Torque ..........72 Individual Batteries ..........72 WARNING...

  • Page 68: General Guidelines And Safety

    Batteries C-426 GENERAL GUIDELINES AND SAFETY WARNING NOTICE Battery electrolyte will stain and corrode most This section is one section of a complete service surfaces. Immediately and thoroughly clean any manual. Before starting any procedure, read all surface outside of the battery that the battery warnings and instructions that are located in the electrolyte comes in contact with.

  • Page 69: Batteries

    Batteries C-426 CLEANING WATERING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this...

  • Page 70: Testing

    Batteries C-426 TESTING STORING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this...

  • Page 71: Remove/Install

    Batteries C-426 REMOVE/INSTALL WARNING WARNING This section is one section of a complete service Do not allow the loose battery cables to contact any manual. Before starting any procedure, read all other parts of the vehicle as this could cause in a warnings and instructions that are located in the short circuit resulting severe bodily injury or damage Service Guidelines chapter and beginning of this...

  • Page 72: Hardware Torque

    Batteries C-426 Individual Batteries HARDWARE TORQUE WARNING If hardware is not listed here, refer to standard torque values in the appendix. Individual batteries can weight up to 80 pounds or Description Inch Pounds Newton Meters more. To avoid injury, use proper lifting techniques Battery terminal, Trojan bolt 95-105 11-12...
  • Page 73 Table of Contents Tires & Wheels Inflation .............74 Rotation ............74 Changing Tire/Wheel Assembly .....75 Replace the Tire ..........75 Solid Wheel .............75 Split Wheel ..............75 Hardware Torque ..........76 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.

  • Page 74: Tires & Wheels

    Tires & Wheels C-426 INFLATION ROTATION WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 75: Tires & Wheels

    Tires & Wheels C-426 CHANGING TIRE/WHEEL REPLACE THE TIRE WARNING ASSEMBLY WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 76: Hardware Torque

    Tires & Wheels C-426 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Foot Pounds Newton Meters Wheel nut Page 76 MC-425-15...
  • Page 77 Table of Contents Suspension Replace Rear Springs ........78 Replace Front Springs ........78 Replace Shocks ..........78 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
  • Page 78 Suspension C-426 REPLACE REAR SPRINGS If a spring has failed or is fatigued, then it is recommended that both springs are replaced as a set. 1: Remove the upper shock mounting bolt from the rear shocks. 2: Raise the rear wheels off of the ground just enough so that the springs can be removed and support with jack stands.

  • Page 79: Suspension

    Table of Contents Hardware Information Torque Guidelines for Standard hardware ..80 Hardware Identification ..........80 Hex Nuts ..............81 Hex Lock Nuts (stover) ..........81 Other Nuts ...............81 Generic Torque Values ..........82 Replacing Hardware ........84 WARNING This section is one section of a complete service manual.

  • Page 80: Torque Guidelines For Standard Hardware

    Hardware C-426 TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. 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. SAE Grade 2 Below is an example of a 10.9.

  • Page 81: Hardware Information

    ‘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 Grade L’9 Other Nuts Other nuts used by Taylor-Dunn ® should be treated as S.A.E. grade A MC-425-15 Page 81...

  • Page 82: Generic Torque Values

    Hardware C-426 Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 83 Hardware C-426 All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Metric, Newton Meters Metric, Foot Pounds Grade, N-m Grade, N-m...

  • Page 84: Replacing Hardware

    Hardware C-426 REPLACING HARDWARE WARNING 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 Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
  • Page 85 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....86 Taylor-Dunn Web Site Information ....86 Axle Assembly & Steering, Front ....88 Axle Shaft Assembly, Rear ......88 Rear Axle, Transmission Assembly ....90 GT TransAxle Assembly, Rear ......92 SD TransAxle Assembly, Rear 3rd Member ..94 SD TransAxle Assembly, Rear Primary Reduction ..........95...

  • Page 86: Replacement Parts

    ORDERING PARTS FOR YOUR VEHICLE WARNING The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in severe bodily injury and/or property damage.

  • Page 87: Replacement Parts

    Replacement Parts C-426 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MC-425-15 * Not available at time of printing Page 87...

  • Page 88: Axle Assembly & Steering, Front

    Replacement Parts C-426 AXLE ASSEMBLY & STEERING, FRONT AXLE SHAFT ASSEMBLY, REAR Inner bearing on double bearing axle does not have an oil seal or O-ring. Orientation of bearing should have O-ring groove adjacent to O-ring on outer bearing. Page 88 MC-425-15...
  • Page 89 Replacement Parts C-426 Front Axle & Steering Item No. Part No. Description 92-104-01 Bearing cap 88-527-14 Cotter pin 88-239-85 3/4 NF Hex slotted nut 88-228-61 3/4 SAE Flat washer 80-017-00 Bearing 12-158-11 Wheel hub 80-103-00 Race 88-268-61 7/8 Flat washer 45-338-00 Grease seal 21-015-15...

  • Page 90: Rear Axle, Transmission Assembly

    Replacement Parts C-426 REAR AXLE, TRANSMISSION ASSEMBLY Page 90 MC-425-15...
  • Page 91 Replacement Parts C-426 GT Axle Assembly, Rear Item No. Part No. Description 89-113-30 12 x 1.75 x 30mm Hex bolt, class 8.8 89-113-60 12mm Split lock washer 41-290-81 Axle tube, left 41-290-82 Axle tube, right 88-099-80 5/16 NF Hex nut 88-088-62 5/16 Split lock washer 88-128-62...

  • Page 92: Gt Transaxle Assembly, Rear

    Replacement Parts C-426 GT TRANSAXLE ASSEMBLY, REAR Page 92 MC-425-15...
  • Page 93 Replacement Parts C-426 GT Axle Assembly, Rear Item No. Part No. Description GT-71682 Bolt, M8 x 60 mm GT-3287563 Gear case cover GT-71259 Bearing see gear kits below Input shaft GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing see gear kits below Idler gear 88-406-67 Bolt, M10 x 30 mm...

  • Page 94: Sd Transaxle Assembly, Rear 3Rd Member

    Replacement Parts C-426 SD TRANSAXLE ASSEMBLY, REAR 3RD MEMBER Illustration is for reference only. This assembly as not serviceable with the exception of oil seals. Item No. Part No. Description 44-440-93 Complete 3rd member assembly Bolt N/A - Order assembly Bearing N/A - Order assembly Race...

  • Page 95: Sd Transaxle Assembly, Rear Primary Reduction

    Replacement Parts C-426 SD TRANSAXLE ASSEMBLY, REAR PRIMARY REDUCTION Item No. Part No. Description Kit B Bearing Kit B Bearing Kit B Bearing Kit A Seal 66-610-67 Vent 41-989-02 Plug, with O-ring Bushing, Dowel Housing Housing N/A - Order assembly Gear N/A - Order assembly Gear...

  • Page 96: Battery

    Replacement Parts C-426 BATTERY Item No. Part No. Description 77-059-10 BATTERY,48V,340AMPS 76-020-26 HANDLE, SB CONNECTOR 76-020-25 CONNECTOR, SB CABLE CLAMP 88-060-15 1/4 X 1-3/4 NC HEX HD CAP SCR 88-068-60 1/4 CUT WASHER 88-069-81 1/4NC NYL INS LOCKNUT,PLTD Page 96 MC-425-15...
  • Page 97 Replacement Parts C-426 MC-425-15 * Not available at time of printing Page 97...

  • Page 98: Brakes, Brake Lines

    Replacement Parts C-426 BRAKES, BRAKE LINES Page 98 MC-425-15...
  • Page 99 Replacement Parts C-426 Brake Lines Item No. Part No. Description 99-564-00 T-fitting 99-580-10 Brake hose 99-576-00 Brake hose clip 99-575-00 Coupler 71-110-00 Brake light switch 71-110-00 Brake regen switch 99-591-00 Brake light switch/regen switch adaptor 99-559-00 T-fitting 99-604-66 Brake line 99-600-58 Brake line 99-605-26...

  • Page 100: Brakes, Front Axle

    Replacement Parts C-426 BRAKES, FRONT AXLE Front Brakes Item No. Part No. Description 88-067-21 Bolt 88-069-82 41-350-91 Plate, Secondary 41-348-58 Spacer 32-208-01 Bushing (included in rebuild kit) 41-351-35 Brake body assembly (includes pistons) 99-588-01 Bleeder adaptor 99-588-00 Bleeder valve See rebuild kit Brake pad, Inner See rebuild kit Brake pad, Outer...

  • Page 101: Brakes, Rear Axle

    Replacement Parts C-426 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-351-80 (see note) Complete caliper assembly (left) 41-351-81 (see note) Complete caliper assembly (right) Brake body 32-208-01 Bushing (included in rebuild kit) 41-348-58 Spacer (included in rebuild kit) 41-350-28-1 Mounting Bracket 41-350-91...

  • Page 102: Control System, Motor Speed Control

    Replacement Parts C-426 CONTROL SYSTEM, MOTOR SPEED CONTROL Item No. Part No. Description 73-012-30 DC-DC converter 79-840-00 Circuit breaker, 10A 79-840-20 Circuit breaker, 20A 79-840-20 Circuit breaker, 20A 73-005-04 Motion alarm 62-400-45 Motor speed control 75-153-00-60 Harness, control 75-153-01 Harness, power 96-650-02 Wire clip 79-829-06...

  • Page 103: Control System, Instrument Panel

    Replacement Parts C-426 CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 1 (top) 71-039-11 Light switch (bottom) 71-039-11 High / Low (tow) speed switch 74-010-20 Gauge, Curtis Spy Glass 71-039-02 Forward and Reverse switch 71-120-10 Ignition switch 94-304-23 Dash panel Not shown 97-211-20...

  • Page 104: Decals, Standard Frame

    Replacement Parts C-426 DECALS, STANDARD FRAME Page 104 MC-425-15...
  • Page 105 Replacement Parts C-426 Decals, Standard Frame Item No. Part No. Description 94-319-02 Battery disvonnect 94-384-21 Auto park brake 94-384-14 Leaving vehicle 94-384-24 Emergency stop 94-301-44 Arms and legs 94-384-61 Operator presence switch 94-384-62 Operator presence switch 94-384-04 Not a motor vehicle 94-384-06 Brake bypass 94-319-00...

  • Page 106: Decals, Cab Frame

    Replacement Parts C-426 DECALS, CAB FRAME Page 106 MC-425-15...
  • Page 107 Replacement Parts C-426 Decals, Cab Frame Item No. Part No. Description 94-301-44 Arms and legs 94-384-21 Park brake 94-301-60 Crush hazard 94-384-61 Operator presence switch 94-384-14 Leaving vehicle 94-301-57 Door 94-319-00 Battery disconnect 94-384-17 Do not spray 94-384-62 Operator presence switch 94-301-41 Brake fluid 94-313-20...

  • Page 108: Electrical, Miscellaneous

    Replacement Parts C-426 ELECTRICAL, MISCELLANEOUS Page 108 MC-425-15...
  • Page 109 Replacement Parts C-426 Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID 96-630-00 (not shown Clamp, Rubber Lined 5/8 ID...

  • Page 110: Frame And Body (P1)

    Replacement Parts C-426 FRAME AND BODY (P1) Page 110 MC-425-15...
  • Page 111 Replacement Parts C-426 Harnesses Item No. Part No. Description 00-426-02 Battery cover (not painted) 88-100-14 3/8 x 1-1/2 Hex bolt 88-108-62 3/8 Split lock washer 32-214-50 Bushing 00-425-16 Mounting bracket (not painted) 97-211-30 3/8 blind nut 96-240-00 1/2NC x 4 Hex bolt 88-149-81 1/2NC lock nut 88-089-81...

  • Page 112: Hitch

    Replacement Parts C-426 HITCH Item No. Part No. Description 00-426-14 Lever 02-426-00 Pillow block (lower) 84-006-00 Pillow block (upper) 88-088-61 5/16 SAE WASHER 88-089-81 5/16 NC LOCK NUT 88-080-18 5/16 X 2-1/2NC HEX HD SCR 88-100-11 3/8 X 1 NC HEX HD SCREW 88-119-82 3/8 NC HEAVY HEX NUT,PLAIN 96-812-21...

  • Page 113: Lights

    Replacement Parts C-426 LIGHTS Item No. Part No. Description 72-022-13 Headlight 72-022-07 Taillight Assembly 71-900-05 Flasher, Turn signal (optional) 78-010-30 Fuse Panel 79-820-04 Fuse, 10A MC-425-15 * Not available at time of printing Page 113...

  • Page 114: Linkage, Brake Pedal

    Replacement Parts C-426 LINKAGE, BRAKE PEDAL Page 114 MC-425-15...
  • Page 115 Replacement Parts C-426 Brake Pedal Linkage Item No. Part No. Description 88-108-61 3/8 SAE Flat washer 88-108-62 3/8 Split lock washer 88-101-13 3/8NC x 1-1/4 Hex bolt, Grade 5 88-101-21 3/8NC x 3 Hex bolt, Grade 5 88-140-22 1/2NC x 3 Hex bolt 88-109-81 3/8NC Hex lock nut 88-149-81...

  • Page 116: Linkage, Throttle

    Replacement Parts C-426 LINKAGE, THROTTLE Item No. Part No. Description 00-425-21 Mounting bracket 00-425-09 Accelerator pedal arm 86-503-98 Rod end, left hand thread 97-211-00 1/4NF Hex nut, left hand thread 86-503-99 Rod end, right hand thread 88-079-80 1/4NF Hex nut 50-002-13 Link 32-215-00...
  • Page 117 Replacement Parts C-426 MC-425-15 * Not available at time of printing Page 117...

  • Page 118: Motor

    Replacement Parts C-426 MOTOR Page 118 MC-425-15...
  • Page 119 Replacement Parts C-426 Motor Item No. Part No. Description 70-059-40 Motor Assembly 41-354-05 Brake 70-400-14 Snap ring 70-400-12 Fan Shroud 70-400-11 70-400-15 O-ring 70-400-16 70-400-17 Snap ring 70-400-21 70-400-18 Snap ring 70-400-19 Snap ring 70-400-13 Seal 70-400-09 Rubber Grommet Terminal stud Hex nut Washer Washer...

  • Page 120: Seats

    Replacement Parts C-426 SEATS #1 on cowl Seat Mounting Page 120 MC-425-15...
  • Page 121 Replacement Parts C-426 Seats Item No. Part No. Description 71-120-14 Emergency stop switch on cowl 95-512-00 Deck handle 90-160-70 Seat assembly 90-160-60 Arm rest kit 00-426-07 Deck cover 90-160-71 Seat spacer 88-080-13 5/16NC x 1-1/4 Hex bolt 88-089-81 5/16NC Lock nut 88-088-60 5/16 Cut flat washer MC-425-15...

  • Page 122: Steering Gear

    Replacement Parts C-426 STEERING GEAR Steering Gear, 18-308-21 Item No. Part No. Description 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assembly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft 18-308-81 Lock washer 18-308-79...
  • Page 123 Replacement Parts C-426 MC-425-15 * Not available at time of printing Page 123...

  • Page 124: Steering Column

    Replacement Parts C-426 STEERING COLUMN Page 124 MC-425-15...
  • Page 125 Replacement Parts C-426 Steering Column Item No. Part No. Description 18-426-00 Steering shaft 18-426-05 Steering column tube 80-400-10 Bearing 96-123-45 U-bolt (includes nuts) 19-005-17 Steering wheel 19-005-02 Adaptor, Steering wheel (includes shaft nut, steering wheel bolts and cap) 18-308-21 Steering gear Not Shown 18-108-00 Pitman arm 88-120-15...

  • Page 126: Suspension, Front

    Replacement Parts C-426 SUSPENSION, FRONT Page 126 MC-425-15...
  • Page 127 Replacement Parts C-426 Front Suspension Item No. Part No. Description 32-214-50 Bushing 00-425-00 Wishbone link 86-521-99 Rod end See Front Axle Axle beam 85-142-00 Spring 96-240-00 1/2 NC x 4 Hex bolt 88-140-22 1/2 NC x 3-1/2 Hex bolt 88-149-81 1/2 NC Lock nut 88-189-82 5/8 NC Then pattern lock nut...

  • Page 128: Suspension, Rear

    Replacement Parts C-426 SUSPENSION, REAR Item No. Part No. Description 88-189-82 5/8NC Thin pattern lock nut 88-188-61 5/8 SAE Flat washer 85-142-00 Spring 86-510-00 Ball joint clamp 86-521-98 Rod end (left) 86-521-99 Rod end (right) 88-180-18 5/8NC x 1-3/4 Hex bolt 4GT-2461-73BB Complete drive assembly (30:1) 17-108-00...

  • Page 129: Wheels And Tires

    Replacement Parts C-426 WHEELS AND TIRES Item No. Part No. Description 13-734-35 Tire/Wheel assembly, 4.00 x 8 Soft Solid 0 or 4 368-00130 Tire/Wheel assembly, 15.5 x 5 x 10 Solid 0 or 4 368-00134 Tire/Wheel assembly, 15.5 x 6 x 10 Solid 0 or 4 368-00127 Wheel, cast iron...
  • Page 130 Notes: Replacement Parts C-426 Page 130 MC-425-15...
  • Page 132 For more information go to www.P65Warnings.ca.gov/ passenger-vehicle. 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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