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BIGFOOT B5-440-36
Taylor-Dunn BIGFOOT B5-440-36 User Manual
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TAYLOR-DUNN
®
Serial numbers:
Starting: 193200
Ending: See Introduction Chapter
MANUAL MB-440-01
Operation, T
roubleshooting and
Replacement Parts Manual
Models: B5-440-36
B5-440-48
2
Table of Contents
Master
5
Table of Contents
5
About this Manual
8
How to Use this Manual
8
Introduction
8
Replacement Parts
8
Who Should Read 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
Special Tool List
17
Troubleshooting Guide
20
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
Front Axle
26
Install
26
Remove
26
Assemble Complete Axle
27
Adjust Front Wheel Bearings
28
Inspect Front Wheel Bearings
28
Front Wheel Alignment
29
Front Axle
30
Replace Steering Knuckle
30
Replace King Pin/Bushings
31
Replace Front Wheel Bearings
31
Service Limits and Specifications
32
King Pin Bushings
32
Toe in
32
Hardware Torque
32
Section 4
33
Change Oil
34
Check Oil Level
34
Drive Axle-GT
34
Drive Axle-GT
35
Axle Assembly
35
Remove
35
Install
35
Axle Shaft
36
Remove
36
Install
36
Rear Hub, Rotor & Bearings
37
Motor, Remove
37
Primary Gear Case
38
Secondary Gear Case
39
Disassemble
39
Assemble
39
Pinion Bearing Preload
41
Pinion Gear Shimming Instructions
41
Set Pinion Bearing Preload
41
Hardware Torque
42
Section 5
43
Default Chapter
43
Steering
43
Inspect Ball Joints
44
Front Wheel Alignment
44
Replace Ball Joint
44
Replace Upper Steering Shaft
45
Remove
45
Install
45
Replace Lower Steering Shaft
46
Inspect
46
Remove
46
Install
46
Replace Boot
46
Replace 90° Steering Gear
47
Inspect
47
Remove
47
Install
47
Replace Steering Rack
48
Inspect
48
Remove
48
Install
48
Replace Steering Wheel
49
Remove
49
Install
49
Hardware Torque
50
Section 6
51
Default Chapter
51
Brakes
51
General Guidelines and Safety
52
Front Brake
53
Service Limits
53
Inspection
53
Replace Pads
53
Rear Brake
54
Service Limits
54
Inspection
54
Replace Pads
54
Rebuild Disc Brake Body
55
Bleed System
56
Flush System
56
Master Cylinder
57
Add Fluid
57
Parking Brake
57
Adjust
57
Service Limits
58
Hardware Torque
58
Section 7
59
Motor
60
Motor Identification
60
Remove/Install
60
Inspect/Testing
60
Bearing
60
Electrical Testing
60
Disassemble
61
Assemble
62
Hardware Torque
64
Section 8
65
Air Pressure
66
Inflation
66
Tires & Wheels
66
Tires & Wheels
67
Tread Wear
67
Rotation
67
Changing Tire/Wheel Assembly
68
Replace the Tire (Pneumatic)
68
Repair the Tire (Pneumatic)
69
Hardware Torque
69
Troubleshooting
72
Motor Controller
73
Suspension
75
Section 9
77
Batteries
77
General Guidelines and Safety
78
Cleaning
79
Charging
79
Watering
79
Testing
80
Specific Gravity
80
Storing
80
Storage
80
Returning to Service
80
Remove/Install
81
Industrial Battery or Lift out Battery Pack
81
Individual Batteries
81
Hardware Torque
81
Wire Diagram
83
Section 10
85
Default Chapter
85
Hardware Information
85
Torque Guidelines for Standard Hardware
86
Hardware Identification
86
Hex Lock Nuts (Stover)
87
Hex Nuts
87
Other Nuts
87
Generic Torque Values
88
Replacing Hardware
90
Section 11
91
Replacement Parts
92
Ordering Parts for Your Vehicle
92
Taylor-Dunn Web Site Information
92
Axle Assembly, Front
94
Axle Shaft Assembly, Rear
96
Transaxle Assembly, Rear
98
Battery
100
Brakes, Brake Lines
102
Brakes, Front Axle
104
Park Brake
104
Brakes, Rear Axle
105
Charger, Signet
106
Charger, X-Series
107
Control System, Motor Speed
108
Control System, Instrument Panel
110
Decals
111
Electrical, Miscellaneous
112
Frame and Body (P1)
114
Frame and Body (P2)
116
Frame and Body, Drop Sides
118
Hitches
120
Lights
121
Motor
122
Steering Linkage
124
Suspension, Front
126
Front Suspension
126
Suspension, Rear
127
Wheels and Tires
128
4
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Taylor-Dunn BIGFOOT B5-440-36 Specifications
General
Brand
Taylor-Dunn
Model
BIGFOOT B5-440-36
Category
Utility Vehicle
Language
English
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