- DL manuals
- Taylor-Dunn
- Utility Vehicle
- BIGFOOT B5-440-36
- Operation, T Roubleshooting And Replacement Parts Manual
Taylor-Dunn BIGFOOT B5-440-36 Operation, T Roubleshooting And Replacement Parts Manual
Summary of BIGFOOT B5-440-36
Page 1
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 tayl or-dun n ® serial numbers: starting: 193200 ending: see introduction chapter manual mb-440-01 operation, troubleshooting and replacement parts manual models: b5-440-36 b5-440-48.
Page 2
Your satisfaction is out #1 goal. If you have questions or concerns with your vehicle, please contact your sales representative or 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...
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 tayl...
Page 4: The Taylor-Dunn Corporation:
The taylor-dunn corporation: leading provider of commercial & industrial vehicles since 1949 taylor-dunn manufacturing: from the day we shipped our first vehicle in 1949, we have pursued a singular goal: to build tough, rugged, dependable vehicles to help our customers move personnel, equipment, and...
Page 5: Master Table of Contents
Note: each section title page contains a section table of contents master table of contents introduction ......................................................7 service/maintenance guidelines....................13 special tool list ..............................................17 lubrication ..........
Page 6
Notes:.
Page 7: Table of Contents
Table of contents 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 introduction about this manual ..........................................8 who should read this ma...
Page 8: Introduction
Page-8 mb-440-01 introduction b5-440-36 / b5-440-48 about this manual the purchase of this vehicle shows a belief in high quality products manufactured in the usa. Taylor-dunn ® , a leading manufacturer of electric burden and personnel carriers since 1949, wants to be sure this vehicle provides year...
Page 9: Introduction
Page-9 mb-440-01 introduction b5-440-36 / b5-440-48 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 elsew...
Page 10: Introduction
Page-10 mb-440-01 introduction b5-440-36 / b5-440-48 responsibilities of the owner... The owner of this or any taylor-dunn vehicle is responsible for the overall maintenance and repairs of the vehicle, as well as the training of operators. The owner is also responsible for operator training per the ...
Page 11: Introduction
Page-11 mb-440-01 introduction b5-440-36 / b5-440-48 how to identify your vehicle this manual is valid only for the serial numbers listed on the front cover. If the ending serial number is blank, then this manual was for current production vehicles when printed. If you did not receive this manual wi...
Page 12
Notes :.
Page 13: Table of Contents
Table of contents 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 service/maintenance guidelines service/maintenance guidelines read me first - maintenance guidelin...
Page 14: Warning
Service/maintenance guidelines page 14 b5-440-36 / b5-440-48 mb-440-01 read me first - maintenance guidelines and general instructions • read the operator’s manual before operating this vehicle. • avoid fire hazards and have fire protection equipment present in the work area. • conduct vehicle perfo...
Page 15
Service/maintenance guidelines page 15 mb-440-01 b5-440-36 / b5-440-48 vehicle modifications using non-oem replacement components: 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 ...
Page 16
Notes :.
Page 17: Table of Contents
Table of contents 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 special tool list special tool list tool list .......................................................
Page 18: Tool List
Tool list page 18 b5-440-36 / b5-440-48 mb-440-01 tool list 62-027-32: throttle module analyzer tests the throttle module in or out of the vehicle 75-089-00: throttle module test harness used in conjunction with a volt meter to test the throttle module. The module must be installed in a working cont...
Page 19: Tool List
Tool list page 19 mb-440-01 b5-440-36 / b5-440-48 96-500-43: pmt/c meter reset module required to reset the pmt/c maintenance meter (special order option). 77-201-00: battery filler used to safely add water to batteries. Equipped with splash guard and auto- shutoff when cell is full. 70-440-55: pin ...
Page 20: Tool List
Tool list page 20 b5-440-36 / b5-440-48 mb-440-01 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 inclus...
Page 21: Table of Contents
Table of contents 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 lubrication lubrication and fluids chart ..........................22 hazardous waste disposal ......
Page 22: Lubrication
Lubrication page 22 b5-440-36 / b5-440-48 mb-440-01 lubrication and fluids chart hazardous waste disposal this vehicle contains various components and/or fluids that may be classified as hazardous waste. This includes but is not limited to lead, acid, oil, grease. The brake linings originally instal...
Page 23: Lubrication
Lubrication page 23 mb-440-01 b5-440-36 / b5-440-48 lubrication diagram drive axle lubrication 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 the ground...
Page 24: Lubrication
Lubrication page 24 b5-440-36 / b5-440-48 mb-440-01 wheel bearings the bigfoot is available with or without front brakes. There are two different lube procedures depending on whether your vehicle has front brakes. Refer to the lubrication chart for grease specification. Front axle without brakes the...
Page 25: Table of Contents
Table of contents 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 front axle front axle remove.............................................................26 instal...
Page 26: Front Axle
Front axle page 26 b5-440-36 / b5-440-48 mb-440-01 remove 1: raise the front of the vehicle and support with jack stands. 2: remove both front wheels. 3: remove the 8 spring mounting bolts, spacers, and 2 lower spring mounting plates. 4: remove the coupler pinch bolt and discard the bolt and nut. 5:...
Page 27: Front Axle
Front axle page 27 mb-440-01 b5-440-36 / b5-440-48 assemble complete axle note: thrust bearings should be packed with grease before assembly. Note: the steering rack and spring hardware should not be fully tightened until the assembly is installed in the vehicle. 1: securely clamp the lower axle bea...
Page 28: Front Axle
Front axle page 28 b5-440-36 / b5-440-48 mb-440-01 inspect front wheel bearings 1: raise the front of the vehicle and support with jack stands. 2: grab the top and bottom of the tire/wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of the tire. Any moveme...
Page 29: Front Axle
Front axle page 29 mb-440-01 b5-440-36 / b5-440-48 front wheel alignment note: only toe in can be set. Both caster and camber are not adjustable. 1: raise the front of the vehicle and support with jack stands. 2: remove both ball joints from the steering arms. 3: turn the steering wheel all the way ...
Page 30: Front Axle
Front axle page 30 b5-440-36 / b5-440-48 mb-440-01 replace steering knuckle this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning do not allow the brake body or caliper t...
Page 31: Front Axle
Front axle page 31 mb-440-01 b5-440-36 / b5-440-48 replace king pin/bushings note: bronze bushings must be reamed or broached to the proper diameter after they are pressed into the axle beam or steering knuckle. Note: it is recommended that the thrust bearings should be replaced whenever replacing t...
Page 32: Front Axle
Front axle page 32 b5-440-36 / b5-440-48 mb-440-01 service limits 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 nut 43-47 58-63 steering link jam...
Page 33: Table of Contents
Table of contents 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 drive axle-gt drive axle-gt check oil level ................................................34 cha...
Page 34: Drive Axle-Gt
Drive axle-gt page 34 b5-440-36 / b5-440-48 mb-440-01 check oil level fluid type and capacities are listed in the lubrication chapter. Note: the oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member...
Page 35: Drive Axle-Gt
Drive axle-gt page 35 mb-440-01 b5-440-36 / b5-440-48 axle assembly 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 remove 1: disconnect the wiring from the motor. ...
Page 36: Drive Axle-Gt
Drive axle-gt page 36 b5-440-36 / b5-440-48 mb-440-01 axle shaft the oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange. If both axles have to be removed at th...
Page 37: Drive Axle-Gt
Drive axle-gt page 37 mb-440-01 b5-440-36 / b5-440-48 rear hub, rotor & bearings note: the axle hub bolt has a special thread locking compound applied to the threads. If this bolt is removed, it must be replaced. 1: disconnect the batteries. 2: raise the wheel off of the ground. 3: release the park ...
Page 38: Drive Axle-Gt
Drive axle-gt page 38 b5-440-36 / b5-440-48 mb-440-01 primary gear case 1: disconnect the batteries. 2: raise the rear of the vehicle and support with jack stands. 3: place a drain pan under the gear case that is capable of holding 4 liters (4 quarts) of oil and drain the oil from the front gear cas...
Page 39: Drive Axle-Gt
Drive axle-gt page 39 mb-440-01 b5-440-36 / b5-440-48 secondary gear case 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 assemble 1: temporarily install the pinion...
Page 40: Drive Axle-Gt
Drive axle-gt page 40 b5-440-36 / b5-440-48 mb-440-01 pinion holding tool 12: install the pinion gear holding tool (96-500-42) and tighten the pinion nut enough to keep the pinion gear from rotating. 13: install the differential assembly. 14: install the cover and all of the cover bolts. Torque per ...
Page 41: Drive Axle-Gt
Drive axle-gt page 41 mb-440-01 b5-440-36 / b5-440-48 pinion bearing preload pinion gear shimming instructions note: this procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. Note: to perform this procedure, all parts must be clean and t...
Page 42: Drive Axle-Gt
Drive axle-gt page 42 b5-440-36 / b5-440-48 mb-440-01 note: values shown are for reference only c d hardware torque if hardware is not listed here, refer to standard torque values in the appendix. Description foot pounds newton meters pinion nut 154-169 209229 drain plug 21-25 28.4-33 gear case to 3...
Page 43: Table of Contents
Table of contents 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 steering inspect ball joints ...........................................44 front wheel alignment ....
Page 44: Steering
Steering page 44 b5-440-36 / b5-440-48 mb-440-01 front wheel alignment refer to the front axle section for front wheel alignment procedure. 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 guid...
Page 45: Steering
Steering page 45 mb-440-01 b5-440-36 / b5-440-48 replace upper steering shaft 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 remove 1: remove the steering wheel. R...
Page 46: Steering
Steering page 46 b5-440-36 / b5-440-48 mb-440-01 replace lower steering shaft 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 inspect if there is any play between t...
Page 47: Steering
Steering page 47 mb-440-01 b5-440-36 / b5-440-48 replace 90° steering gear there are no internal components available for the 90° steering gear. If worn out it must be replaced. Inspect 1: clamp the lower steering shaft so that it cannot rotate. 2: turn upper steering shaft and measure degrees of fr...
Page 48: Steering
Steering page 48 b5-440-36 / b5-440-48 mb-440-01 replace steering rack there are no internal components available for the steering rack. If worn out it must be replaced. Inspect 1: raise the front of the vehicle and support with jack stands. 2: tie both front wheels in place so that they cannot turn...
Page 49: Steering
Steering page 49 mb-440-01 b5-440-36 / b5-440-48 replace steering wheel note: the steering wheel is on a tapered shaft and may be damaged when it is removed. Remove 1: remove the steering wheel hub cover. 2: remove the steering wheel nut. 3: using a steering wheel puller, remove the steering wheel. ...
Page 50: Steering
Steering page 50 b5-440-36 / b5-440-48 mb-440-01 hardware torque description foot pounds newton meters ball joint jam nut 20-30 27-40 ball joint lock nut 43-47 58-63 coupler pinch bolt 30-35 40-47 coupler pinch bolt jam nut 25-30 34-40 steering wheel nut 28-32 38-43 notes :.
Page 51: Table of Contents
Table of contents 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 brakes brakes general guidelines and safety.......................52 front brake ....................
Page 52: Brakes
Brakes page 52 b5-440-36 / b5-440-48 mb-440-01 general guidelines and safety this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning do not ingest brake fluid or allow cont...
Page 53: Brakes
Brakes page 53 mb-440-01 b5-440-36 / b5-440-48 front brake 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. 1: raise the front of the vehicle and support with jack stands. 2: remove the front wheels. 3: mea...
Page 54: Brakes
Brakes page 54 b5-440-36 / b5-440-48 mb-440-01 rear brake 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. Inspection 1: raise the front of the vehicle and support with jack stands. 2: remove the front wheels. 3: meas...
Page 55: Brakes
Brakes page 55 mb-440-01 b5-440-36 / b5-440-48 rebuild disc brake body this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning the pistons are very fragile. If the piston i...
Page 56: Brakes
Brakes page 56 b5-440-36 / b5-440-48 mb-440-01 bleed system note: start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. The rear bleeder valves can be accessed through the center rear inspection cover. 1: thoroughly clean the ...
Page 57: Brakes
Brakes page 57 mb-440-01 b5-440-36 / b5-440-48 master cylinder 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 level lines are highlighted in the illustration for c...
Page 58: Brakes
Brakes page 58 b5-440-36 / b5-440-48 mb-440-01 notes : hardware torque if hardware is not listed here, refer to standard torque values in the appendix. Description foot pounds newton meters brake body bolts 11 14.9 service limits description imperial metric disc brake pad minimum lining 00625 inch 1...
Page 59: Table of Contents
Table of contents 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 motor motor motor identification .........................................60 remove/install .........
Page 60: Motor
Motor page 60 b5-440-36 / b5-440-48 mb-440-01 inspect/testing bearing note: the bearing in motor spec dlgf112150- 4 consists of a combination bearing and armature rotation sensor. Bearing note: an “experienced ear” will be required to use this procedure. If your are not familiar with the normal soun...
Page 61: Motor
Motor page 61 mb-440-01 b5-440-36 / b5-440-48 7: remove the armature (1). A: remove the motor encoder (9) by removing the bolts (23). B: gently tap the armature using a soft faced hammer and 1” hollow pipe around the armature magnet (see illustration). C: reinstall the motor encoder (9) by installin...
Page 62: Motor
Motor page 62 b5-440-36 / b5-440-48 mb-440-01 refer to illustration of exploded motor (found later in this section) 1: set the armature (1) into the rear end housing (4). 2: thread a long 10/32 screw through the rear housing (4) and into the bearing plate (6) to temporarily hold in place. 3: install...
Page 63: Motor
Motor page 63 mb-440-01 b5-440-36 / b5-440-48.
Page 64: Motor
Motor page 64 b5-440-36 / b5-440-48 mb-440-01 notes : hardware 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 sensor 9 1.02 bolt, cover 9 1.02 bolt, ter...
Page 65: Table of Contents
Table of contents 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 tires & wheels tires & wheels inflation .............................................................
Page 66: Tires & Wheels
Tires & wheels page 66 b5-440-36 / b5-440-48 mb-440-01 inflation air pressure maintaining the correct tire pressure is important to the safe operation of the vehicle as well as ensuring long tread life. Under inflated tires result in: • excessive tire side wall flexing that can result in sudden tire...
Page 67: Tires & Wheels
Tires & wheels page 67 mb-440-01 b5-440-36 / b5-440-48 rotation front and rear tires as well as left and right tires can wear at different rates. It is important to periodically rotate your ties to extend your tire life. Refer to the maintenance schedule in this manual for the recommended interval. ...
Page 68: Tires & Wheels
Tires & wheels page 68 b5-440-36 / b5-440-48 mb-440-01 replace the tire (pneumatic) note: to replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to replace the tire/wheel section for information on removing the tire/wheel assembly. Tire replacement should only be perfor...
Page 69: Tires & Wheels
Tires & wheels page 69 mb-440-01 b5-440-36 / b5-440-48 improper assembly or disassembly of a split rim wheel can result if tire explosion causing severe injury. Refer tire/wheel repair to a qualified tire supplier. Warning repair the tire (pneumatic) note: to properly repair a puncture, the tire mus...
Page 70
Notes :.
Page 71: Table of Contents
Table of contents 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 motor controller motor controller remove/install ....................................................
Page 72: Motor Controller
Motor controller page 72 b5-440-36 / b5-440-48 mb-440-01 inspect receptacles the inside of each receptacle should be clean and free of any debris. Use aerosol electrical cleaner if required. Base plate the base plate should be flat. If required, sand with 150 wet sandpaper to remove any raised areas...
Page 73: Motor Controller
Motor controller page 73 mb-440-01 b5-440-36 / b5-440-48 repair/programming repairs there are no internally serviceable components in the motor speed controllers. If a controller is faulty then it must be replaced. Note: opening or disassembling a controller will void the controller warranty. Progra...
Page 74
Notes :.
Page 75: Table of Contents
Table of contents this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning suspension suspension front springs ...................................................76 remove ....
Page 76: Suspension
Suspension page 76 b5-440-36 / b5-440-48 mb-440-01 front 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 replacing the springs, replace one side ...
Page 77: Table of Contents
Table of contents 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 batteries batteries general guidelines and safety.......................78 cleaning .................
Page 78: Batteries
Batteries page 78 b5-440-36 / b5-440-48 mb-440-01 general guidelines and safety 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 • explosive mixtures of hydrogen gas...
Page 79: Batteries
Batteries page 79 mb-440-01 b5-440-36 / b5-440-48 cleaning disconnect the batteries before cleaning. Dry dirt can be readily blown off with low-pressure air or brushed off. Note: wetness or wet dirt on the top of the battery indicates battery acid boil over or excessive gassing. Using a nonmetallic ...
Page 80: Batteries
Batteries page 80 b5-440-36 / b5-440-48 mb-440-01 testing specific gravity note: the battery must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see t...
Page 81: Batteries
Batteries page 81 mb-440-01 b5-440-36 / b5-440-48 remove/install industrial battery or lift out battery pack 1: thoroughly clean the battery and battery compartment. Refer to cleaning in this section for information regarding cleaning the batteries. 2: using a hoist or forklift equipped with a prope...
Page 82
Notes :.
Page 83: Table of Contents
Table of contents 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 wire diagram wire diagram diagram part numbers....................................84.
Page 84: Wire Diagram
Wire diagram page 84 b5-440-36 / b5-440-48 mb-440-01 sch-00040 sevcon, typical with dc conv sch-00041 tt316, vehicle,starting 178410 sch-00042 t48, vehicle, dc converter sch-00043 trident, vehicle sch-00044 tc30/60, vehicle, can-buss sch-00045 c425, dash (sevcon) sch-00046 c425, control panel (sevco...
Page 85: Table of Contents
Table of contents 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 hardware information hardware information torque guidelines for standard hardware ...86 hardware i...
Page 86: Hardware
Hardware page 86 b5-440-36 / b5-440-48 mb-440-01 torque guidelines for standard hardware note:torquevaluesspecifiedareforcleandrythreads. 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...
Page 87: Hardware
Hardware page 87 mb-440-01 b5-440-36 / b5-440-48 hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) nuts with no markings are to be treated as s.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’...
Page 88: Hardware
Hardware page 88 b5-440-36 / b5-440-48 mb-440-01 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 procedur...
Page 89: Hardware
Hardware page 89 mb-440-01 b5-440-36 / b5-440-48 metric, newton meters grade, n-m dia. Pitch 4.6 8.8 10.9 12.9 3 0.50 0.51 * * * 4 0.70 0.95 3.1 * * 5 0.80 2.28 6.1 * * 6 1.00 3.92 10.4 15.5 * 8 1.00 * 27.0 * * 1.25 9.48 25.0 37.0 * 10 1.00 * 57.0 * * 1.25 * 54.0 * * 1.50 19.1 51.0 75.0 * 12 1.25 * ...
Page 90: Hardware
Hardware page 90 b5-440-36 / b5-440-48 mb-440-01 replacing hardware 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 r...
Page 91: Replacement Parts
Table of contents replacement parts this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning note: your vehicle may have been ordered with special order options. These optio...
Page 92: Replacement Parts
Replacement parts page 92 mb-440-01 b5-440-36 / b5-440-48 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...
Page 93: Replacement Parts
Replacement parts page 93 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 my vehicle information serial number: date purchased: date delivered: dealer purchased from: salesman name: my local parts dealer: notes :.
Page 94: Replacement Parts
Replacement parts page 94 mb-440-01 b5-440-36 / b5-440-48 axle assembly, front.
Page 95: Replacement Parts
Replacement parts page 95 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 axle assembly, front item no. Part no. Description qty 1 12-115-10 hub, with disc (includes items 4, 5, 6 & 7) 2 12-115-00 hub, without disc (includes items 4, 5, 6 & 7) 2 2 92-105-00 dust cap 2 3 80-011-00...
Page 96: Replacement Parts
Replacement parts page 96 mb-440-01 b5-440-36 / b5-440-48 axle shaft assembly, rear.
Page 97: Replacement Parts
Replacement parts page 97 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 axle shaft assembly, rear item no. Part no. Description qty 1 41-154-20 axle shaft 2 2 80-505-20 bearing 2 3 41-490-11 disc brake rotor 2 4 41-172-21 hub 2 5 88-268-63 flat washer 2 6 *88-268-30 7/8-14 x 1....
Page 98: Replacement Parts
Replacement parts page 98 mb-440-01 b5-440-36 / b5-440-48 note: spacer 23 is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number gt- 3287213. Add 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...
Page 99: Replacement Parts
Replacement parts page 99 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 axle assembly, rear item no. Part no. Description qty 1 gt-71682 m8 x 60 bolt 12 2 gt-3287563 gear case cover 1 3 gt-71259 bearing 1 4 gt-3287513 input shaft, 30:1 0 or 1 gt-3287523 input shaft, 24:1 0 or 1...
Page 100: Replacement Parts
Replacement parts page 100 mb-440-01 b5-440-36 / b5-440-48 36 volt system 48 volt system battery.
Page 101: Replacement Parts
Replacement parts page 101 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 item no. Part no. Description qty 1 see kits below battery rod * 2 see kits below battery hold down * 3 see kits below flat washer, tin/lead plated * 4 see kits below 1/4nc nylon lock nut * 5 see kits belo...
Page 102: Replacement Parts
Replacement parts page 102 mb-440-01 b5-440-36 / b5-440-48 item no. Part no. Description qty 1 99-605-83 brake line 1 2 99-605-84 brake line (only with front brakes) 1 3 99-575-32 adapter, 3/16t x m10-1.0 2 4 99-575-00 coupler 3 5 99-607-11 brake line, mid to rear 1 6 99-559-00 t-fitting 1 7 96-640-...
Page 103: Replacement Parts
Replacement parts page 103 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 brake lines, master cylinder item no. Part no. Description qty 1 88-080-14 bolt, 5/16” x 1-1/2” nc, hex head 2 2 99-511-20 master cylinder (includes item #3) 1 3 99-511-52 cap seal, master cylinder 1 99-51...
Page 104: Replacement Parts
Replacement parts page 104 mb-440-01 b5-440-36 / b5-440-48 brakes, front axle item no. Part no. Description qty 41-351-35 complete brake assembly 1 88-067-29 bolt 4 2 41-350-91 plate, secondary 2 3 41-348-58 spacer 4 4 32-208-01 bushing (included in rebuild kit) 4 5 * brake body (all parts on this l...
Page 105: Replacement Parts
Replacement parts page 105 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 brakes, rear axle brakes, rear axle item no. Part no. Description qty - 41-351-80 complete caliper assembly (left) 1 - 41-351-81 complete caliper assembly (right) 1 1 * brake body 1 2 32-208-01 bushing (in...
Page 106: Replacement Parts
Replacement parts page 106 mb-440-01 b5-440-36 / b5-440-48 charger, signet note: there are no user serviceable components inside the charger note: the charger ac cord is an integral part of the charger. When replacing the charger, do not cut and splice the ac cord. Cutting the ac cord will void the ...
Page 107: Replacement Parts
Replacement parts page 107 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 charger, x-series item no. Part no. Description qty 79-303-48 charger assembly, x-series, 48 volt built in 0 or 1 79-303-36 charger assembly, x-series, 36 volt built in 0 or 1 79-309-05 charger assembly, x...
Page 108: Replacement Parts
Replacement parts page 108 mb-440-01 b5-440-36 / b5-440-48 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 fuse, 500a system.
Page 109: Replacement Parts
Replacement parts page 109 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 speed control panel item no. Part no. Description qty 1 73-012-33 dc-dc converter, 36-48v (optional) 1 88-838-06 #14x1/2 pn head screw 4 2 62-400-38 ac controller, 24/48v, 300a 0 or 1 62-400-47 ac controll...
Page 110: Replacement Parts
Replacement parts page 110 mb-440-01 b5-440-36 / b5-440-48 instrument panel item no. Part no. Description qty 1 71-120-10 start switch (key) 1 71-121-20 key switch 2 71-039-02 forward / reverse switch 1 3 71-039-11 high / low speed switch 1 4 94-305-24 dash panel 1 94-305-25 backing plate 1 5 74-009...
Page 111: Replacement Parts
Replacement parts page 111 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 decals decals item no. Part no. Description qty 1 94-384-48 fingers crushed warning 1 2 94-301-45 bigfoot decal 1 3 94-384-01 not a motor vehicle (white/blue) 1 4 94-313-00 battery warning 1 5 94-384-17 do...
Page 112: Replacement Parts
Replacement parts page 112 mb-440-01 b5-440-36 / b5-440-48 electrical, miscellaneous 7.
Page 113: Replacement Parts
Replacement parts page 113 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 electrical item no. Part no. Description qty 1 96-624-00 clamp, 1/4 jiffy clip 96-625-00 clamp, 5/16 jiffy clip 2 96-626-00 clamp, 7/8 jiffy clip 3 96-640-00 clamp, 3/16 push mount 4 96-642-00 wire harness...
Page 114: Replacement Parts
Replacement parts page 114 mb-440-01 b5-440-36 / b5-440-48 frame and body (p1).
Page 115: Replacement Parts
Replacement parts page 115 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 item no. Part no. Description qty 1 see decals bigfoot decal 1 2 90-160-96 seat, 6” adjustable 2 01-500-14 panel, seat base 1 3 90-160-97 hip restraint, driver 1 90-160-98 hip restraint, passenger 1 4 01-5...
Page 116: Replacement Parts
Replacement parts page 116 mb-440-01 b5-440-36 / b5-440-48 frame and body (p2).
Page 117: Replacement Parts
Replacement parts page 117 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 cab item no. Part no. Description qty 1 74-055-04 wiper arm 1 74-055-06 wiper blade, curved, 26” 1 74-055-11 wiper motor 1 74-055-17 pigtail, 2-speed wiper motor 1 2 90-821-00 curved windshield 1 3 92-150-...
Page 118: Replacement Parts
Replacement parts page 118 mb-440-01 b5-440-36 / b5-440-48 frame and body, drop sides.
Page 119: Replacement Parts
Replacement parts page 119 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 item no. Part no. Description qty 1 02-204-43 hitch pad 1 2 88-080-09 screw, 5/16 x 3/4 14 3 88-080-11 screw, 5/16 x 1 4 4 88-088-61 washer 36 5 88-089-81 lock nut 18 6 88-100-11 screw, 3/8 x1 10 7 88-108-...
Page 120: Replacement Parts
Replacement parts page 120 mb-440-01 b5-440-36 / b5-440-48 hitches mounting hardware item 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 4 88-1...
Page 121: Replacement Parts
Replacement parts page 121 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 lights item no. Part no. Description qty 1 72-005-22 headlight, led w/ grommet & connector (cowl only) 0 or 2 72-005-13 headlight, single beam (cab only) 0 or 2 00-020-19 headlight cover (cab only) 0 or 2 ...
Page 122: Replacement Parts
Replacement parts page 122 mb-440-01 b5-440-36 / b5-440-48 motor.
Page 123: Replacement Parts
Replacement parts page 123 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 motor (70-058-41) item no. Part no. Description qty 1 order kit bearing plate 1 2 70-058-41-08 cover gasket 1 3 order kit speed sensor - 4 - - - 5 70-058-41-11 rubber insulator 1 6 order kit terminal block...
Page 124: Replacement Parts
Replacement parts page 124 mb-440-01 b5-440-36 / b5-440-48 steering linkage.
Page 125: Replacement Parts
Replacement parts page 125 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 steering linkage item no. Part no. Description qty 1 19-011-30 steering wheel 1 19-011-35 steering wheel cover 1 2 88-199-82 5/8 nf hex head jam nut gr 2 1 3 18-058-92 steering shaft assembly 1 4 32-248-20...
Page 126: Replacement Parts
Replacement parts page 126 mb-440-01 b5-440-36 / b5-440-48 front suspension item no. Part no. Description qty 1 96-240-00 spring bolt 6 2 32-214-50 bushing 12 3 16-871-04 spring hanger 4 4 88-149-81 1/2 nc lock nut gr5 3 5 - - - 6 85-498-00 leaf spring 2 7 14-010-07 spring plate 2 not shown 98-753-1...
Page 127: Replacement Parts
Replacement parts page 127 * not available at time of printing mb-440-01 b5-440-36 / b5-440-48 suspension, rear item no. Part no. Description qty 1 16-870-10 spring hanger 4 2 32-213-00 bushing, spring 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...
Page 128: Replacement Parts
Replacement parts page 128 mb-440-01 b5-440-36 / b5-440-48 wheels and tires item no. Part no. Description qty - 13-746-13 tire, wheel, 18.5 x 8.5 x 8, load range-c 4 10-092-00 8.50 x 8 lr c (replacement tire) - 13-742-35 tires, 5 x 8 monomatic, solid 4 12-012-00 - 13-742-13 tire,wheel, 5.7 x 8 load ...
Page 129: Warning
California proposition 65 warning engine exhaust and some of its constituents are known to the state of california to cause cancer, birth defects, and other reproductive harm. There are chemicals contained in the operating systems of this vehicle that are known to the state of california to cause ca...
Page 130
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.