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B5-540-48XL
Taylor-Dunn B5-540-48XL User Manual
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TAYLOR-DUNN
®
READ THE OPERATOR’S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator’s manual contains important information
regarding the safe operation of this vehicle.
WARNING
Serial numbers:
Starting:
204000
Ending:
214369
MANUAL MB-440-06
Service and Replacement Parts Manual
Models: B5-440-36
B5-440-48
B5-540-48XL
BF-030-48
U
2
Table of Contents
Master
5
Table of Contents
5
Replacement Parts
8
How to Use this Manual
8
Introduction
8
Who Should Read this Manual
8
About this Manual
8
Introduction
9
Conventions
9
Signal Words and Their Definitions
9
Responsibilities
10
How to Identify Your Vehicle
11
Web Site Registration
11
Service/Maintenance Guidelines
15
Section 2
21
Hazardous Waste Disposal
22
Lubrication
22
Lubrication and Fluids Chart
22
Lubrication
23
Lubrication Diagram
23
Wheel Bearings
24
Section 3
25
Daily Visual Inspection
26
Maintenance Guidelines for Severe Duty Applications
26
Maintenance Schedule
26
Pre-Operation Inspection
26
Every 3 Months or 500 Hours
27
Every 6 Months or 1,000 Hours)
27
Every Month or 100 Hours
27
Every Week
27
Every Year or 2,000 Hours
27
First 25 Hours of Operation
27
Section 4
29
Front Axle
30
Install
30
Remove
30
Assemble Complete Axle
31
Adjust Front Wheel Bearings
32
Inspect Front Wheel Bearings
32
Front Wheel Alignment
33
Front Axle
34
Replace Steering Knuckle
34
Replace Front Wheel Bearings
35
Replace King Pin/Bushings
35
Hardware Torque
36
King Pin Bushings
36
Service Limits and Specifications
36
Toe in
36
Section 5
37
Transaxle-GT Transaxle Identification
37
Change Oil
38
Check Oil Level
38
Axle Assembly
39
Install
39
Remove
39
Axle Shaft
40
Install
40
Remove
40
Motor, Remove
41
Rear Hub, Rotor & Bearings
41
Primary Gear Case
42
Assemble
43
Disassemble
43
Secondary Gear Case
43
Pinion Bearing Preload
45
Pinion Gear Shimming Instructions
45
Set Pinion Bearing Preload
45
Hardware Torque
46
Section 6
47
Transaxle-SD
47
Change Oil
48
Check Oil Level
48
Transaxle-SD
48
Axle Shaft
49
Install
49
Remove
49
Motor, Remove
50
Rear Hub, Rotor & Bearings
50
Primary Reduction Gear Case
51
3Rd Member
53
Hardware Torque
54
Section 7
55
Front Wheel Alignment
56
Inspect Ball Joints
56
Replace Ball Joint
56
Install
57
Remove
57
Replace Upper Steering Shaft
57
Inspect
58
Install
58
Remove
58
Replace Boot
58
Replace Lower Steering Shaft
58
Inspect
59
Install
59
Remove
59
Replace 90° Steering Gear
59
Inspect
60
Install
60
Remove
60
Replace Steering Rack
60
Install
61
Remove
61
Replace Steering Wheel
61
Hardware Torque
62
Section 8
63
General Guidelines and Safety
64
Front Brake
65
Inspection
65
Replace Pads
65
Service Limits
65
Inspection
66
Rear Brake
66
Replace Pads
66
Service Limits
66
Rebuild Disc Brake Body
67
Bleed System
68
Flush System
68
Add Fluid
69
Master Cylinder
69
Push Rod Adjustment
69
Adjust
70
Hardware Torque
70
Parking Brake
70
Service Limits
70
Section 9
71
Bearing
72
Electrical Testing
72
Inspect/Testing
72
Motor Identification
72
Motor-Vctech
72
Remove/Install
72
Disassemble
73
Motor-Vctech
73
Assemble
74
Hardware Torque
76
Motor-ABM
79
Section 10
81
Air Pressure
82
Inflation
82
Tires & Wheels
82
Rotation
83
Tires & Wheels
83
Tread Wear
83
Changing Tire/Wheel Assembly
84
Replace the Tire (Pneumatic)
84
Hardware Torque
85
Repair the Tire (Pneumatic)
85
Motor Controller
89
Section 11
91
Remove/Install
92
Troubleshooting
92
Delta-Q
93
Programming
93
Signet
94
Delta-Q IC650
95
Section 12
99
General Guidelines and Safety
100
Charging
101
Cleaning
101
Watering
101
Returning to Service
102
Specific Gravity
102
Storage
102
Storing
102
Testing
102
Hardware Torque
103
Individual Batteries
103
Industrial Battery or Lift out Battery Pack
103
Remove/Install
103
Wire Diagram
107
Section 13
109
Hardware Identification
110
Torque Guidelines for Standard Hardware
110
Hex Lock Nuts (Stover)
111
Hex Nuts
111
Other Nuts
111
Generic Torque Values
112
Replacing Hardware
114
Section 14
115
Ordering Parts for Your Vehicle
116
Replacement Parts
116
Taylor-Dunn Web Site Information
116
Axle Assembly, Front
118
Axle Shaft Assembly, Rear
120
Transaxle Assembly, GT
122
Transaxle Assembly, SD 3Rd Member
124
Transaxle Assembly, SD Primary Reduction
125
Battery
126
Brakes, Brake Lines
128
Brakes, Master Cylinder
129
Brakes, Front Axle
130
Brakes, Rear Axle
131
Charger, Lester Summit
132
Charger, Lester Summit II
132
Charger, Deltaq
133
Charger, Signet
133
Control System, Motor Speed
134
Control System, Instrument Panel
136
Decals
137
Electrical, Miscellaneous
138
Frame and Body (P1)
140
Frame and Body (Cabs)
142
Frame and Body , Dump Option
144
Frame and Body, 4-Passenger
146
Frame and Body, Drop Sides
148
Frame and Body, Wood Stake Sides
149
Hitches
150
Lights
151
Motor
152
Motor Mount, AC
154
Steering Linkage
156
Suspension, Front
158
Suspension, Rear
159
Wheels and Tires
160
4
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Taylor-Dunn B5-540-48XL Specifications
General
Brand
Taylor-Dunn
Model
B5-540-48XL
Category
Utility Vehicle
Language
English
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