Taylor Dunn Manual

Service and Replacement
®
Parts Manual
TAYLOR-DUNN
MANUAL: MB-440-10
Bigfoot G-1500
Model Numbers:
B5-440-GAS
The Best Way

To Go
About Your
Business
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: 204278
Ending Serial Number: See Introduction Chapter
H
My Vehicle information
Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
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 our web site, www.taylor-dunn.com, for a dealer lookup
application.
Originally Published 5/1/2017

Revision H, 10/17/2018, contents subject to change without notice
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com

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.
If you do not have access to the internet, you can call the factory direct at:
01 (714) 956-4040
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804
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 materials. It’s that simple. For over sixty years, our standard and custom vehicles - Burden
Carriers, Personnel Carriers, Stock Chasers, Electric Carts, Tow Tractors & more - have been the leading solution for customers in a
broad range of industrial, commercial, and ground-support markets.
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. With
tractor capacities ranging from 3,000 - 12,000 pounds drawbar pull, they are ideal for industrial applications as well as aircraft ground
support. As with all Taylor-Dunn vehicles; quality, service, support and reliability are built into all Tiger Tractor products.
Shown below is just a small sample of what Taylor-Dunn has to offer to keep your business moving:
Note: Each section title page contains Master Table of Contents
a section table of contents Introduction.......................................................7
Service/Maintenance Guidelines....................13
Preventative Maintenance...............................17
Lubrication........................................................21
Front Axle..........................................................25
Steering.............................................................33
Engine................................................................41
Transaxle...........................................................45
CVT Transmission............................................49
Brakes...............................................................53
Throttle Cables.................................................61
Shift Linkage.....................................................63
Tires & Wheels..................................................65
Suspension.......................................................71
Battery...............................................................73
Wire Diagram....................................................79
Hardware Information......................................81
Replacement Parts...........................................87
Introduction
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. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
Introduction
Bigfoot G-1500
ABOUT THIS MANUAL WHO SHOULD READ THIS MANUAL
This manual is to serve as a guide for the service, repair, This manual is intended for use by anyone who is going
and operation of Taylor-Dunn® vehicles and is not to operate, own, perform maintenance on, service, or
intended as a training guide. Taylor-Dunn® has made order parts for this Taylor-Dunn® vehicle. Each person
every effort to include as much information as possible shall be familiar with the parts of this manual that apply
about the operation and maintenance of this vehicle. to their use of this vehicle.
Taylor-Dunn is not to be held liable for errors in this
manual or any consequential damage that results from HOW TO USE THIS MANUAL
the use of this manual. This manual is organized into these main sections:
This manual is designed primarily for use by authorized Introduction
Taylor-Dunn® service technicians in a properly equipped
shop and should be kept available for reference. All This section describes how to use this service manual
references to left and right side of the vehicle are from and how to identify your vehicle.
the operator’s perspective when seated in a normal Maintenance, Service, and Repair
riding position.
This section gives specific information on the servicing
The service personnel are responsible for the service of the vehicle and a schedule for maintenance checks.
and maintenance of the vehicle. At no time shall a
service person allow any untrained personnel to service This manual is for mechanical repairs only and does not
or repair this or any Taylor-Dunn® vehicle. For the include electrical diagnosis procedures.
purposes of training, a qualified service person may Replacement Parts
oversee the repairs or services being made to a vehicle
by an individual in training. At no time shall an untrained This section provides an illustrated view of various
individual be allowed to service or repair a vehicle without assemblies. The illustrations are accompanied by tables
supervision. This manual is not a training guide. identifying the parts.
Personnel performing service and repair shall have

knowledge of:
• Basic standard automotive repair procedures
• Operation of internal combustion engines
• Basic DC electrical theory
• Use of digital and analog multi-meters
• Lead acid batteries
Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain
procedures require the use of special tools. Use only
the proper tools as specified.
Contact an authorized Taylor-Dunn® service technician
if you have any doubt as to your ability to perform any
of the procedures outlined in this manual.
We appreciate any assistance you can provide in helping
make these publications more useful. Please provide
any feedback you may have regarding this manual.
Use the Contact form at www.taylor-dunn.com to submit
your information. Please include the part number of this
manual along with the revision number. Alternatively, you
can submit your information in writing to:
Taylor-Dunn Manufacturing
Attn Tech Writer
2114 W. Ball Road
Anaheim, CA 92804
Page-8 MB-440-10
Introduction
Bigfoot G-1500
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. When used as a signal word, the signal
word will be enclosed in a solid rectangle with white background (example below).
Signal Words and Their Definitions:
DANGER: This signal word will be accompanied by the safety alert symbol (see below). “DANGER” will indicate
a hazard that, if not avoided, WILL result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
WARNING: This signal word will be accompanied by the safety alert symbol (see below). “WARNING” will indicate
a hazard that, if not avoided, may result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
CAUTION: This signal word will be accompanied by the safety alert symbol (see below). “CAUTION” will indicate a
hazard that, if not avoided, may result in minor or moderate injury to yourself, the operator or passengers
of the vehicle, or people in the immediate area of the vehicle.
NOTICE: This signal word will not be accompanied by the safety alert symbol. “NOTICE” will indicate a condition
that if not avoided may result in property damage. “Property” is defined as the vehicle, components in
the vehicle and/or the surrounding area such as buildings, other vehicles, etc.
Safety Messages
Important information notifying you of any conditions that WARNING
may result in hazards to yourself, persons nearby, and/
or hazards to the vehicle will be presented in a text box This is an example of a safety alert message. This
with a black border and may include a signal word (see message will contain information about a hazard and/
above). To the right is an example of a safety message. or instructions on avoiding a hazard. The actual size
and location of this warning box may vary.
The safety message may include additional warning
icons representing the type of hazard. The following
is a list of these icons and what they represent. These
icons may also be included on the various warning and
information decals applied to the vehicle.
Some of the decals applied to the
vehicle will have icons representing their
function. The icons and their definitions
Safety alert symbol (see are listed below:
above).
Read the operators manual.
Represents a high voltage
hazard. Read the maintenance manual.
Represents an explosion
Keep arms and legs inside the
hazard.
vehicle.
Represents a corrosive Parking brake ON.

chemical hazard.
Parking brake OFF.
Represents a fire hazard.
Do not get wet.
Represents a poisonous
chemical hazard. Do not spray wash.
MB-440-10 Page-9
Introduction
Bigfoot G-1500
RESPONSIBILITIES Of the Operator...
Of the Owner... A vehicle shall not be operated until the operator has
successfully completed an operator training course
The owner of this or any Taylor-Dunn vehicle is provided by the owner of the vehicle.
responsible for the overall maintenance and repairs
of the vehicle, as well as the training of operators. The operator is responsible to be sure that the vehicle
is operated only on authorized roads, highways, and
The owner is also responsible for operator training per installations.
the following federal regulations:
• ANSI/ITSDF 56.8-2006 Personnel and Burden The operator is responsible to confirm that all
Carriers: Part II, Paragraph 6.2a. passengers are properly seated and properly using
• ANSI/ITSDF 56.9 – 2007 Safety Standard for the available restraints.
Operator Controlled Industrial Tow Tractors: Part The operator is responsible for the safe operation of
II, paragraph 4.11. the vehicle, preoperational and operational checks
• Code of Federal Regulations (CFR) Title 29, on the vehicle, and the reporting of any problems to
Subtitle B, Chapter Xvii OSHA, Part 1910.178 service and repair personnel.
Powered Industrial Trucks (2011): 1910.178,
Section (l). Of the Passengers ...
Per OSHA Regulation, 29 CFR 1910.178 Powered The passengers are responsible to remain fully seated,
Industrial Truck Operator Training, the owner must keeping their hands, arms, and legs inside the vehicle
keep a record of conducted training and maintenance at all times. Each passenger shall be fully aware of
performed on the vehicle. the vehicle’s operation. All forms of recklessness are
to be avoided.
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. Unauthorized repairs may also
WARNING
void the vehicles warranty.
The service personnel are responsible for the service To maintain peak performance, always use original
and maintenance of the vehicle. At no time shall a Taylor-Dunn replacement parts intended for use
service person allow any untrained personnel to service on your vehicle. Taylor-Dunn components are
or repair this or any Taylor-Dunn® vehicle. For the designed and tested for use on specific Taylor-Dunn
model vehicles. Only use the correct Taylor-Dunn
purposes of training, a qualified service person may
replacement components for your Taylor-Dunn
oversee the repairs or services being made to a vehicle vehicle.
by an individual in training. At no time shall an untrained
individual be allowed to service or repair a vehicle without Do not modify your vehicle:
supervision. This manual is not a training guide. Modifications to this vehicle may have an undesirable
affect on the operation of the vehicle, result in
Personnel performing service and repair shall have additional frame stress, or stress other components
knowledge of: resulting in premature failure or an unsafe condition
• Basic standard automotive repair procedures and may lead to an accident resulting in serious injury
• Operation of internal combustion engines or death.
• Basic DC electrical theory
• Use of digital and analog multi-meters
• Lead acid batteries
Personnel performing maintenance shall have basic
knowledge of standard automotive maintenance
procedures and lead acid batteries.
Page-10 MB-440-10
Introduction
Bigfoot G-1500
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 with the vehicle,
you should confirm this manual is valid for your serial number at the Taylor-Dunn web site.
The locations of the model and serial numbers are shown in the illustrations below:
Data plate
Serial number tag on the main frame
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.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, Troubleshooting, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
MB-440-10 Page-11
Notes:
Introduction
Bigfoot G-1500
Page-12 MB-440-10
Service/Maintenance
Guidelines
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
Bigfoot G-1500
READ ME FIRST-MAINTENANCE GUIDELINES AND GENERAL
INSTRUCTIONS
WARNING
Read and follow all of the guidelines listed below.
Failure to follow these guidelines may result in severe
bodily injury and/or property damage.
• Read the operator’s manual before operating this vehicle.

• 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.
• Ventilate the work area properly.
• Regularly inspect and maintain the following systems in a safe working condition: brakes, steering
mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and
safety devices.
• Inspect and maintain limit switches, protective devices, electrical conductors, and connections in conformance
with Taylor-Dunn’s® recommended procedures.
• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.
• Do not use an open flame to check level or leakage of battery electrolyte.
• Do not use open pans of fuel or flammable fluids for cleaning parts.
• Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle.
WARNING WARNING
The only personnel authorized to repair, modify, or BEFORE STARTING ANY REPAIRS
adjust any part of this or any Taylor-Dunn vehicle is
a factory authorized service technician. Repairs made 1) Make sure the ignition switch is in the “OFF”
by unauthorized personnel may result in damage to position, then remove the key.
or improper operation of the vehicles systems which 2) Set the park brake.
could lead to an unsafe condition resulting in severe 3) Place blocks under the front or rear wheels to
bodily injury and/or property damage. prevent vehicle movement.
Unauthorized repairs may also void the vehicles 4) Disconnect the battery negative cable.
warranty.
WARNING
WARNING When lifting the vehicle, always use a hoist with
Periodic maintenance and service must be performed lifting strap, or a jack of adequate capacity. Use jack
on this vehicle. Failure to complete these scheduled stands to support the vehicle before starting any
maintenance and service procedures can result in repairs. Failure to use lifting and support devices of
severe bodily injury and/or property damage. It is rated load capacity may result in severe bodily injury.
the owner and/or operators responsibility to ensure
that proper service and maintenance is performed on
the vehicle, described in this manual.
WARNING
The engine may start at any time while performing
test procedures.
All tests must be performed with the drive wheels
off of the ground and the vehicle supported with
jack stands.
Testing with drive wheels on the ground may result in
vehicle movement causing severe bodily injury and/
or property damage.
Page 14 MB-440-10
Bigfoot G-1500
VEHICLE MODIFICATIONS
Taylor-Dunn vehicles are designed and manufactured in accordance with ANSI/ITSDF and OSHA regulations. Per
ANSI/ITSDF and OHSA, modifications to the vehicle must be approved by the manufacturer. Listed below are the
specific regulations:
ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers
Paragraph 8.2q:
Modifications and additions which affect capacity and safe machine operation shall not be performed by the
customer or user without manufacture’s prior written authorization; where authorized modifications have been
made, the user shall ensure that capacity, operation, warning, and maintenance instructions plates, tags, or
decals are changed accordingly.
Paragraph 8.2r:
Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original equipment.
ANSI/ITSDF 56.9 – 2007 Safety Standard for Operator Controlled Industrial Tow Tractors
Paragraph 6.2.14:
Modifications and additions which affect capacity and safe tow tractor operation shall not be performed without
manufacture’s prior written approval. Capacity, operation, and maintenance instructions plates, tags, or decals
are changed accordingly.
Code of Federal Regulations (CFR) Title 29, Subtitle B, Chapter Xvii OSHA, Part 1910.178
Powered Industrial Trucks (2011)
1910.178(a)(4)
Modifications and additions which affect capacity and safe operation shall not be performed by the customer
or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plates,
tags, or decals shall be changed accordingly.
1910.178(q)(6)
Industrial trucks shall not be altered so that the relative positions of the various parts are different from what they
were when originally received from the manufacturer, nor shall they be altered either by the addition of extra
parts not provided by the manufacturer or by the elimination of any parts, except as provided in paragraph (q)
(12) of this section. Additional counterweighting of fork trucks shall not be done unless approved by the truck
manufacturer.
WARNING
When welding to the vehicle:
• Do not weld onto any fuel tanks, electrical control components, engine,
or transmission.
• Welding shall be performed by qualified welders.
• Disconnect the battery.
• Disconnect all wires from other electronic modules.
• Disconnect all wires from the engine control systems.
• Disconnect all wires from the transmission control module.
• Connect welding cable directly to the frame, do not connect to any
control components.
• Welding emits showers of sparks. Protect all fuel system components,
engine intake and battery from exposure to the sparks.
Failure to follow these rules may damage electronic control modules
resulting in unsafe operation of the vehicle or result in fire causing severe
MB-440-10 Page 15
Bigfoot G-1500
REPLACEMENT PARTS
Using Non-OEM Replacement Components
WARNING
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.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable effect on the operation of the vehicle, result in additional
frame stress, or stress other components resulting in premature failure or an unsafe condition and may lead
to an accident resulting in serious injury or death.
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.
Electrical Components
Electrical components not tested by Taylor-Dunn (or intended for use on other Taylor-Dunn vehicles) may have
unanticipated interaction and/or interference with the vehicles control system resulting in unsafe vehicle operation
or damage to the electrical system.
Mechanical Components
Mechanical components not tested by Taylor-Dunn (or from other model Taylor-Dunn vehicles) may have an
undesirable affect on the operation of the vehicle, result in additional frame stress, or stress other components
resulting in premature failure or an unsafe condition.
Due to the unknown properties of non-Taylor-Dunn tested components or from components not originally equipped
on the vehicle, we cannot approve their use in a Taylor-Dunn vehicle.
Page 16 MB-440-10
Preventative Maintenance
Table of Contents
Preventative Maintenance
Daily Visual Inspection....................................18
Pre-Operation Inspection.................................18
Maintenance Schedule.....................................18
Maintenance Guidelines for Severe Duty Applications.................
18
Maintenance Schedule.............................................19
WARNING
PM Schedule
Bigfoot G-1500
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. Service Guidelines chapter.
The following items shall be inspected every time before

The following items shall be inspected once every day the vehicle is driven:
before the vehicle is put into service: Rear and side view mirror adjustments.
• External frame damage (body). Steering operation.
• Operation of all lights and warning alarms. Brake operation (service and park brake).
• Proper operation of all instrument panel gauges Tire pressure (visual inspection only).
and warning lights. Proper operation of trailer hitch.
• Smooth and proper operation of seat belts (if
equipped).
• Brake fluid level.
MAINTENANCE SCHEDULE
• Inspect for leaking fluids, grease, gasoline. A PM Check List is available and was included on the
• Tire tread or sidewall damage. documentation CD that was provided with your vehicle.
• Proper operation of transmission shift lever and The document number is PM-0022.
starter interlocks.
• Proper operation of adjustable seat mechanisms. Maintenance Guidelines for Severe Duty
• Smooth and proper operation of all controls such Applications
as but not limited to: This maintenance schedule is based on the average
• Throttle pedal typical application. If the vehicle is operated under
• Brake pedal “severe conditions”, service procedures shall be
• Parking brake conducted more frequently than specified. The frequency
• Steering of service under severe conditions is determined by the
• Horn use of the vehicle. The owner/operator must evaluate
• Etc. the operating environment to determine the increase in
• Proper operation of all locking mechanisms such maintenance frequency.
as but not limited to:
• Hood latches In addition, the entire vehicle shall be inspected monthly
• Cargo box’s for signs of damage.
• Cab doors The following list is meant as a guide and is not all-
• Etc. inclusive of a “severe duty” application.
• Proper operation of all interlocking switches such • Operation in excess of 100 hours per month.
as but not limited to: • Extreme temperature.
• Operator presence switch • Bumpy, dusty, or ill maintained roads.
• Neutral start switch • Excessively wet areas.
• Etc. • Corrosive or contaminated areas.
• Frequent loading of the vehicle at/near capacity.
Page 18 MB-440-10
PM Schedule
Bigfoot G-1500
Maintenance Schedule
Most of these items shall only be performed by a qualified Every 200 hours
technician. Refer to the vehicle, engine, or transmission • All 100 hour items plus the following:
service manual for details. • Change oil filter.
• Inspect spark plugs
Problems found during an inspection shall be repaired • Change fuel filter.
before the vehicle is put back into service.
Every 600 hours
First 15 hours • All 200 hour items plus the following:
• Re-torque wheel nuts. • Inspect and tighten all hardware.
• Inspect all hardware for tightness. • Test battery.
• Adjust front wheel bearings. • Check battery electrolyte level (maintenance free
only).
Every 25 hours/Every Week • Replace spark plugs.
• All daily items plus the following:
• Inspect drive belt for cracking.
• Service air filter pre-cleaner.
• Inspect all steering linkages and hardware.
• Check engine oil level.
• Lubricate the vehicle.
• Check tire air pressure.
• Tighten all electrical connections.
• Tire damage.
• Inspect all wiring for fraying, cracks, wear.
Every 100 hours • Re-torque the wheel nuts.
• All 25 hour items plus the following: • Adjust park brake.
• Inspect for fluid leaks.
Every 1,200 hours
• Check brake fluid level.
• All 600 hour items plus the following:
• Tighten steering shaft couplers and U-joints.
• Align front end.
• Wash battery and terminals.
• Rotate tires.
• Check starter interlocks for correct operation.
• Replace drive belt.
• Remove cooling shrouds and clean.
• Replace secondary sheave ramp shoes.
• Clean exterior of engine.
• Inspect/adjust front wheel bearings.
• Change engine oil (every 100 hours or yearly,
• Inspect steering king pins.
whichever occurs first).
• Inspect suspension bushings.
• Replace paper air filter.
• Inspect suspension bumpers.
• Inspect tire tread wear.
• Inspect brake shoes/pads.
• Inspect and tighten all hardware (First 100 hours,
• Inspect frame for damage.
then ever 500 hours).
Every 2,400 hours
• All 1200 hour items plus the following:
• Clean and repack front wheel bearings, change
seals.
• Change drive axle oil.
• Flush and replace the brake fluid.
MB-440-10 Page 19
Notes:
PM Schedule
Bigfoot G-1500
Page 20 MB-440-10
Lubrication
Table of Contents
Lubrication
Lubrication and Fluids Chart...........................22
Lubrication Diagram.........................................23
Hazardous Waste Disposal..............................23
Lubrication
Bigfoot G-1500
LUBRICATION AND FLUIDS CHART
Assembly Component Capacity

# of Locations Lubricant
Front Axle:
3: Wheel Bearings 2 - NLGI Grade 2 lithium high temp Bearing Grease
4: King Pin 4 - NLGI Grade 2 lithium multi-purpose grease
Suspension:
Steering:
1: Steering Rack 1 NLGI Grade 2 lithium multi-purpose grease
2: 90° Steering Gear 1 NLGI Grade 2 lithium multi-purpose grease
6: Collapsible steering shaft 1 NLGI Grade 2 lithium multi-purpose grease
Brake Fluid:
Master Cylinder 1 DOT 3, Meets or exceeds SAE J1703
Linkages:
Park brake handle 1 - Multi-purpose spray lubricant
Engine
Engine oil 1.7-1.9 Quarts See chart
(1.6-1.8 Liters)
Rear Transaxle:
7: Drain Plug 1
8: Fill Plug 1 20-24 Ounces
(0.6 -0.7 Liters)
WARNING
Continuous contact with used motor oil has caused
skin cancer in laboratory animal tests. Avoid
prolonged contact. Wash skin with soap and water.
Launder or discard soiled clothing.
Engine Oil type

Petroleum or synthetic detergent oils that
meet API Class SJ or higher.
Ambient Temperature Viscosity

-20ºF to 32ºF 5W30
(-30C to 0C)
0ºF to >100ºF 10W30
(-18C to 38C )
50ºF to >100ºF SAE30
(10C to 38C)
Page 22 MB-440-10
Lubrication
Bigfoot G-1500
LUBRICATION DIAGRAM
Drive Axle
Front Axle / Steering
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 installed by the factory do not contain asbestos. However, since it is possible that
asbestos brake linings were installed as replacement parts, brake linings should be handled as hazardous
waste.
The requirements for disposal of hazardous waste vary by location. Consult your local regulations regarding
the proper disposal of hazardous waste products.
MB-440-10 Page 23
Notes:
Lubrication
Bigfoot G-1500
Page 24 MB-440-10
Front Axle
Table of Contents
Front Axle
Remove.............................................................26
Install.................................................................26
Assemble Complete Axle.................................27
Inspect Front Wheel Bearings.........................28
Adjust Front Wheel Bearings..........................28
Front Wheel Alignment....................................29
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
WARNING
Front Axle
Bigfoot G-1500
REMOVE
WARNING
NOTICE
manual. Before starting any procedure, read all If vehicle is equipped with front brakes, you will
warnings and instructions that are located in the need to disconnect the front brakes and bleed the
Service Guidelines chapter. brake lines.
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: Remove the coupler from the steering rack input shaft.
6: Lift the axle up over the spring centering bolts and slide the axle assembly over the springs out of the left or
right side of the vehicle.
INSTALL
WARNING
NOTICE
manual. Before starting any procedure, read all If vehicle is equipped with front brakes, you will
warnings and instructions that are located in the need to disconnect the front brakes and bleed the
Service Guidelines chapter. brake lines.
2: Slide the axle assembly through the left or right side and position on the spring centering bolts.
3: Loosen the 4 steering rack mounting bolt nuts DO NOT REMOVE.
4: Install the 8 spring mounting bolts, spacers, and 2 lower spring mounting plates.
5: Tighten the steering rack mounting bolt nuts.
6: Install the steering coupler to the steering rack.
7: Install a new coupler pinch bolt and tighten per torque listed in the Hardware Torque table at the end of this
section.
8: Install new pinch bolt jam nut.
9: Install the wheels and test drive.
Page 26 MB-440-10
Front Axle
Bigfoot G-1500
ASSEMBLE COMPLETE AXLE
WARNING
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 beam to a work surface.
2: Install the king pins up through the beam. Install locking bolt and hand
thread the nut to the bolt.
3: Install flat washer onto each king pin.
4: Install steering knuckles.
5: Inspect the thrust bearing bronze washer.
Replace if any grooves are worn flat.
6: Assemble, grease, and install thrust bearings.
Make sure they are orientated correctly.
7: Place the steering rack assembly onto the lower
beam and install ball joints.
8: Tighten ball joint nuts to torque specified at the end of this section.
9: Place the upper axle beam onto the assembly.
10: Tighten the kingpin nuts so that there is no vertical play in the
knuckle but it still turns freely.
11: Place the beam spacers into the assembly and drop the 8 mounting
bolts/washers (do not install nuts) through the two beams.
12: Install the springs, spring plates, and nuts/washers but do not fully tighten the hardware at this time.
13: Drop the 4 steering rack mounting bolts/washers through the two beams.
Install the washers and nuts but do not fully tighten at this time.
14: Install the axle/spring assembly into the vehicle and then tighten the 8
axle beam mounting nuts and 4 steering rack mounting nuts.
MB-440-10 Page 27
Front Axle
Bigfoot G-1500
INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS
BEARINGS WARNING
WARNING This section is one section of a complete service
This section is one section of a complete service warnings and instructions that are located in the
manual. Before starting any procedure, read all Service Guidelines chapter.
• The bearings must be lubricated before performing
this procedure.
1: Raise the front of the vehicle and support with 1: Raise the front wheel(s) off of the ground and
jack stands. support with jack stands.
2: Grab the top and bottom 2: While rotating the wheel, tighten the front axle
of the tire/wheel assembly. nut until the wheel is difficult to rotate.
Feel for any movement 3: Continue to rotate the wheel for 5 compete
or play while pulling and revolutions.
pushing on the top and 4: Attach a rope to the tire and wrap around the tire
bottom of the tire. Any with 1 foot remaining hanging in the air.
movement or play is 5: Tie a weight (see table and illustration below) to
indication of loose wheel the end of the rope.
bearings. 6: Slowly loosen the axle
3: Spin the front wheel(s) by hand. The wheel nut until the hanging
should stop spinning in no more than weight rotates the
2-revolutions. A wheel that continues to spin wheel then rotate to
freely is an indication of a loose wheel bearing. the nearest flat and
Note: Refer to the Adjust Front Wheel Bearings install a new cotter pin.
section for detailed information regarding the 7: Remove the rope and
proper adjustment of the wheel bearings. weight.
4: Spin the wheel(s) and listen for any grinding 8: Spin the wheel and listen for any grinding noise.
noise. Any noise may be an indication of worn or Any grinding noise may be an indication of worn
damaged wheel bearings. or damaged wheel bearings.
Note: Refer to the Replace Front Wheel Bearings Note: Refer to the Replace Front Wheel Bearings
section for information regarding the section for information regarding the
replacement of the wheel bearings. replacement of the wheel bearings.
5: Lower the vehicle. 9: Lower the vehicle.
6: Reconnect the batteries. 10: Reconnect the main positive and negative cables
7: Remove the blocks from behind the wheels. at the batteries.
8: Release the park brake and test drive the vehicle. 11: Remove the blocks from behind the wheels.
12: Release the park brake and test drive the vehicle.
Tire Size Weight NEW Weight USED

(pounds / kg) (pounds / kg)
4.80 x 8 2.15 / 0.975 1.00 / 0.454
5.70 x 8/ 1.99 / 0.902 0.93 / 0.422
4.00 x 8 2.15 / 0.975 1.01 / 0.485
5.00 x 8 1.99 / 0.902 0.93 / 0.422
8.50 x 8 2.02 / 0.916 0.94 / 0.426
8 x 2.50 4.23 / 1.919 1.97 / 0.894
10 x 3.5 3.38 / 1.533 1.56 / 0.708
NEW: Weight = 16.931 / Radius

USED: Weight = 7.875 / Radius
3-Wheel vehicle front fork shown for illustration

purposes only
Page 28 MB-440-10
Front Axle
Bigfoot G-1500
FRONT WHEEL ALIGNMENT
WARNING
Note: Only Toe In can be set. Both Caster and Camber are not adjustable.
2: Remove both ball joints from the steering arms.
3: Turn the steering wheel all the way to the left.
4: Turn the steering wheel all the way back to the right, counting the number of rotations.
5: Turn back to the left 1/2 the number of turns and tie the steering wheel in position so that it cannot rotate.
6: Reinstall the ball joints and tighten nut to torque specified at the end of this section.
7: Loosen the steering link jam nuts.
8: Remove the left front wheel.
9: Clamp a straight edge across the face of the wheel hub.
10: Adjust the driver left side steering link so that the straight edge is parallel to the center line of the vehicle.
11: Remove the straight edge and reinstall the wheel.
12: Using a piece of chalk, mark a line around the center line of both front tires.
13: Measure the distance between the chalk lines at the front of the tires and at the rear of the tires.
14: Adjust the right side steering link so that the toe in is within specification listed at the end of this section.
15: Tighten both steering link jam nuts to torque specified at the end of this section.
MB-440-10 Page 29
Front Axle
Bigfoot G-1500
REPLACE STEERING KNUCKLE
WARNING
Remove
1: Raise the front of the vehicle and support with
jack stands.
2: Remove the tire/wheel assembly. Refer to Tires
and Wheels section for information regarding
removing the tire/wheel assembly.
3: Remove the hub bearing cap, cotter pin and nut,
then remove the hub from the steering knuckle.
WARNING Install
Do not allow the brake body or caliper to hang by the
1: Thoroughly clean the kingpin,
brake hose. Hanging by the brake hose may damage thrust bearing, knuckle, wheel
the brake hose resulting in loss of brakes which may bearings, and hub.
cause serious bodily injury and/or property damage. 2: Inspect the thrust bearing
bronze washer. Replace if any
Note: If equipped with front brake option you must grooves worn flat.
remove the brake body before removing 3: Pack the thrust bearing with grease.
the hub. Refer to the Brakes section for 4: Lightly coat the kingpin bushings with grease.
information regarding the removal of the 5: Place the thrust bearing on top of the steering
brake body. Do not remove the hydraulic knuckle with the inner race facing down.
brake line from the brake body. If the brake 6: Insert the knuckle bearing assembly into the
line is removed then it will be necessary to axle and insert the kingpin up from the bottom
bleed the brakes. mounting flange.
4: Remove the ball joint from the steering arm. 7: Install the steering stop bolt.
5: Remove the steering stop bolt. 8: Tighten the kingpin nut so that there is no vertical
6: Remove the king pin nut. play in the knuckle but it still turns freely.
7: Using a large brass drift punch, drive the king pin 9: Install the ball joint and tighten nut to torque
out of the axle and remove the steering knuckle specified at the end of this section.
and thrust bearing. 10: Pack wheel bearings with grease.
11: Install the rear bearing and new grease seal.
12: Install the hub onto the spindle and adjust the
bearing preload per procedure in the section.
13: Install a new cotter pin and bearing cap.
14: Grease the bushings.
15: Install the wheel, remove the blocks from behind
the wheels and test drive the vehicle.
Page 30 MB-440-10
Front Axle
Bigfoot G-1500
REPLACE KING PIN/BUSHINGS REPLACE FRONT WHEEL
WARNING BEARINGS
WARNING
warnings and instructions that are located in the This section is one section of a complete service
Service Guidelines chapter. manual. Before starting any procedure, read all
Note: Bronze bushings must be reamed or Service Guidelines chapter.
broached to the proper diameter after they 1: Set the park brake.
are pressed into the axle beam or steering 2: Disconnect the batteries.
knuckle. 3: Raise the front of the vehicle and support with
Note: It is recommended that the thrust bearings jack stands.
should be replaced whenever replacing 4: Remove the tire/wheel assembly from the hub.
the king pin bushings or king pins. Refer Refer to the Tire/Wheel section for information
to the Replacement Parts section for the regarding removing the tire/wheel assembly.
orientation of the thrust bearing. 5: Remove the hub dust cap, cotter pin, and spindle
1: Remove the steering knuckle. Refer to Replace nut.
the Steering Knuckle for information regarding 6: Remove the hub from the steering knuckle.
WARNING
removing the steering knuckle.
2: Press the bushings out from the steering knuckle.
3: Discard the bushings, king pins, and thrust Do not allow the brake body or caliper to hang by the
bearings. brake hose. Hanging by the brake hose may damage
4: Thoroughly clean the knuckle. the brake hose resulting in loss of brakes which may
cause serious bodily injury and/or property damage.
NOTICE Note: For a front disc brake option you must

Before pressing bushing: Make sure that the holes in remove the brake body before removing
the bushings are lined up with the grease fittings in the hub. Refer to the Brakes section for
the spindle sleeve. information regarding the removal of the
brake body.
5: Press new bushings into steering knuckle flush 7: Thoroughly clean all grease from the inside of the
with the end of the sleeve. hub and the bearings.
6: If equipped with bronze bushings, ream or broach 8: Inspect and replace the races and bearings as a
the bushings per specification listed at the end of set.
this chapter. Note: It is recommended to replace all four
7: Reassemble in reverse order using new king pins bearings and races in the left and right
and thrust bearings. wheels as a set.
Note: Refer to Replace the Steering Knuckle 9: Assemble in reverse order using new grease
for information on installing the steering seals.
knuckle. a. Lube the bearings (refer to Lubrication section).
8: Grease the bushings. b. Adjust the bearing preload per specifications in
9: Lower the vehicle, and test drive. the Adjust Front Wheel Bearing procedure.
d. Install a new cotter pin.
10: Install the hub dust cap.
11: Reinstall the brake body. Refer to the Brakes
section for information regarding the installation
of the brake body.
12: Reinstall the tire/wheel. Refer to the Tire/Wheel
section for information regarding installing the
tire/wheel assembly
13: Lower the vehicle.
14: Reconnect the batteries.
15: Remove the blocks from behind the wheels.
16: Release the park brake and test drive.
MB-440-10 Page 31
Front Axle
Bigfoot G-1500
SERVICE LIMITS AND
SPECIFICATIONS HARDWARE TORQUE
Description Foot Pounds Newton Meters
King Pin Bushings Ball Joint Lock Nut 43-47 58-63
Ream or broach to 0.8755-0.08765 inches
Steering link Jam Nut 20-30 27-40
(22.2377-22.2631 mm)
Steering pinch bolt 30-35 40-47
Toe In
0 to 0.25 inches (6.3 mm)
Notes:
Page 32 MB-440-10
Steering
Table of Contents
Steering
Inspect Ball Joints............................................34
Front Wheel Alignment....................................34
Replace Ball Joint............................................34
Replace Upper Steering Shaft.........................35
Remove....................................................................35
Install........................................................................35
Replace Lower Steering Shaft.........................36
Inspect......................................................................36
Remove....................................................................36
Install........................................................................36
Replace Boot............................................................36
Replace 90° Steering Gear...............................37
Inspect......................................................................37
Remove....................................................................37
Install........................................................................37
Replace Steering Rack.....................................38
Inspect......................................................................38
Remove....................................................................38
Install........................................................................38
Replace Steering Wheel...................................39
Remove....................................................................39
Install........................................................................39
Hardware Torque..............................................40
WARNING
Steering
Bigfoot G-1500
INSPECT BALL JOINTS REPLACE BALL JOINT

WARNING WARNING
Note: A set of ball joints and/or rod ends will wear Note: In many cases the removal of a ball joint
at the same rate. If a ball joint and or rod end may cause damage to the ball joint. It is
is worn out, then all should be replaced as recommended that if a ball joint is removed
a set. then it should be replaced.
1: Tie off the front wheels so that they cannot turn. 1: Raise the front of the vehicle and support with
2: While watching the ball joints, rapidly rotate the jack stands.
steering wheel to the left and right. 2: Loosen the ball joint jam nut.
3: If the housing moves up or down on the shaft 3: Remove the ball joint nut.
then the ball joint is worn out and should be 4: Using a ball joint separator or pickle fork, remove
replaced. Refer to section Replace Ball Joint for the ball joint from the steering arm.
information regarding replacing ball joints. 5: Remove the ball joint from the tie rod.
4: Untie the front wheels. 6: Install the new ball joint into the steering sleeve.
5: Reconnect the main positive and negative cables 7: Install the ball joint into the steering arm. Tighten
at the batteries. the ball joint nut per torque listed in the Hardware
6: Remove the blocks from behind the wheels. Torque table at the end of this section.
7: Release the parking brake and test drive. 8: Realign the front wheels. Refer to the Front Axle
section for information regarding realignment of
the front wheels.
10: Reconnect the main positive and negative cables
at the batteries.
11: Release the park brake and test drive.
Ball Joint
Typical Pickle Fork
FRONT WHEEL ALIGNMENT

Refer to the Front Axle section for front wheel alignment
procedure.
Typical Ball Joint Separator
Page 34 MB-440-10
Steering
Bigfoot G-1500
REPLACE UPPER STEERING SHAFT
WARNING WARNING
Do not use the original pinch bolt and nut. Failure to
replace the pinch bolt and nut may result in failure of
the steering causing loss of control of the vehicle. This
could lead to severe bodily injury and/or property
damage.
Make sure that the pinch bolt is not aligned with the
Remove flat on the steering shaft. Aligning the bolt with the
1: Remove the steering wheel. Refer to Replace flat could result in failure of the steering and loss of
the Steering Wheel procedure for information control of the vehicle. This could lead to severe bodily
regarding removing the steering wheel. injury and/or property damage.
2: Remove the steering coupler pinch bolt and nut
and discard.
3: Using a soft face hammer, tap the coupler up and
off of the steering shaft.
Note: If too tight, drive a small wedge into the
coupler slot to spread it slightly apart.
4: Remove the 4 bolts holding the column housing
to the frame and lift the housing/shaft assembly
out of the frame.
5: Pull the shaft down and out of the housing.
6: If required, remove both the upper and lower
steering shaft bushings from the housing.
Install
1: Thoroughly clean all components
2: If bushings were removed, install the upper and
lower steering shaft bushings into the housing.
3: Lightly grease the two bushings.
4: Insert the shaft up into the housing
5: Install the housing/shaft assembly into the frame
sliding the coupler down onto the steering gear
shaft.
6: Using a new pinch bolt and nut, tighten the
coupler pinch bolt per torque listed in the
Hardware Torque table at the end of this section.
7: Install the steering wheel. Refer to Replace
the Steering Wheel procedure for information
regarding installing the steering wheel.
8: Test drive the vehicle
MB-440-10 Page 35
Steering
Bigfoot G-1500
REPLACE LOWER STEERING SHAFT
WARNING Install
1: Thoroughly clean the couplers and shafts.
This section is one section of a complete service 2: Position the front wheels in the straight ahead
manual. Before starting any procedure, read all position.
warnings and instructions that are located in the 3: Position the steering wheel in the straight ahead
Service Guidelines chapter. position.
4: Install the coupler onto the 90° gear output shaft
Inspect
aligning the machined flat on the shaft with the
If there is any play between the inner and outer shafts slot in the coupler.
then the steering shaft should be replaced. 5: Install the coupler on the steering rack input shaft
If the boot is torn then it should be replaced. so that the bolt holes line up with the groove in
the shaft.
Remove 6: Install new coupler pinch bolts and tighten to
1: Remove the front and rear steering coupler pinch torque listed in the Hardware Torque table at the
bolts and nuts and discard. end of this section.
2: Using a soft face hammer, tap the couplers off of 7: Install new pinch bolt jam nuts.
the 90° gear shaft and rack shaft. 8: Test drive the vehicle.
Note: If too tight, drive a small wedge into the
coupler slot to spread it slightly apart. Replace Boot
1: The steering shaft must be removed from the
vehicle. Refer to removal procedure for info on
how to properly remove the shaft.
2: Cut the plastic ties holding the boot.
3: Clamp one end of the shaft assembly in a vise.
4: Pull on the other end until the two shafts
separate.
5: Remove the boot.
6: Thoroughly clean both shafts (in and out).
7: Lightly grease the inside of the shaft.
8: Install the new boot and slide the two shafts
together.
9: Install new plastic ties on the boot.
Page 36 MB-440-10
Steering
Bigfoot G-1500
REPLACE 90° STEERING GEAR
WARNING
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 free play.
3: If more than 2° free play then gear box should be replaced.
Remove
1: Remove the pinch bolt from the gear input shaft coupler and discard the bolt and nut.
2: Raise the front of the vehicle and support with jack stands
3: Remove the pinch bolt from the gear output shaft coupler and discard the bolt and nut.
4: Remove the 3 gear mounting bolts.
5: Using a soft face hammer, tap the upper coupler off of the input shaft and drop the gear down out of the
frame.
6: Using a soft face hammer, tap the lower coupler off of the output shaft.
Note: If coupler is too tight, drive a small wedge into the coupler slot to spread it slightly apart.
Install
1: Thoroughly clean all components.
2: Position the front wheels in the straight ahead position.
3: Position the steering wheel in the straight ahead position and tie in place so that it cannot rotate.
4: Insert the gear output shaft into the lower steering shaft coupler.
5: Put the gear up into the frame inserting the output shaft into the steering shaft.
6: Install the gear mounting bolts.
7: Install new coupler pinch bolts and tighten to torque listed in the Hardware Torque table at the end of this
section.
8: Install new pinch bolt jam nuts.
9: Untie the steering wheel.
10: Test drive the vehicle.
MB-440-10 Page 37
Steering
Bigfoot G-1500
REPLACE STEERING RACK
WARNING
There are no internal components available for the steering rack. If worn out it must be replaced.
Inspect
2: Tie both front wheels in place so that they cannot turn.
3: While watching the two rods and the input to the steering rack, rotate the steering wheel back and forth.
4: There should be no gear lash. If you can see the input shaft rotate and the tie rods do not move then the
steering rack should be replaced.
Remove
1: Raise the front of the vehicle and support with jack stands
2: Remove the front wheels
3: Remove the ball joints from the steering arms.
4: Remove the coupler pinch bolt and discard the bolt and nut.
5: Loosen (do not remove) the 8 spring mounting bolts but do not remove.
6: Remove the 4 steering rack mounting bolts.
7: Using a soft face hammer, tap on the rack to push it out of the steering coupler.
Note: If too tight, drive a small wedge into the coupler slot to spread it slightly apart.
8: Remove the steering rack from the axle assembly
Install
1: Thoroughly clean all components.
2: Place the steering rack into the axle assembly with the input shaft closest to the bottom plate.
3: Place the steering wheel in the straight ahead position and tie in place so that it cannot rotate.
4: Confirm the steering rod is centered and center the steering rack.
5: Slide the rack between the upper and lower axle plates and into the coupler
6: Install the 4 rack mounting bolts.
7: Install a new coupler pinch bolt and tighten to torque listed in the Hardware Torque table at the end of this
section.
8: Install new pinch bolt jam nut and tighten to torque listed in the Hardware Torque table at the end of this
section.
9: Tighten the 8 spring mounting bolts.
10: Install the ball joints to the steering arms and tighten to torque listed in the Hardware Torque table at the end
of this section.
11: Install the front wheels.
12: Realign the front end. Refer to Front Wheel Alignment procedure in the Front Axle section.
Page 38 MB-440-10
Steering
Bigfoot G-1500
REPLACE STEERING WHEEL
WARNING
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.
Install
1: Check wheel alignment before installing steering wheel.
2: Position the front wheels in the straight ahead position.
3: Lightly grease the steering wheel splines and install the
replacement steering wheel orientated as shown in the
illustration.
4: Tighten the steering wheel nut to torque listed in the
Hardware Torque table at the end of this section.
5: Reconnect the negative cable at the batteries.
6: Remove the blocks from behind the wheels.
7: Release the parking brake and test drive.
MB-440-10 Page 39
Steering
Bigfoot G-1500
HARDWARE TORQUE
Ball Joint Jam Nut 20-30 27-40
Ball Joint Lock Nut 43-47 58-63
Notes:
Coupler Pinch Bolt 30-35 40-47
Coupler Pinch Bolt Jam Nut 25-30 34-40
Steering Wheel Nut 28-32 38-43
Page 40 MB-440-10
Engine
Table of Contents
Engine
Check Oil Level.................................................42
Change Oil.........................................................42
Air Filter Service...............................................43
Spark Plug Service...........................................43
Only basic engine maintenance information is

included in this manual.
For engine repair refer to the complete Kohler en-
gine service manual that can be downloaded from
the Kohler web site at www.kohlerengines.com
The model number of the engine will be required
to download the correct manual. The engine
model can be found on the engine spec plate as
shown.
Engine
Bigfoot G-1500
CHECK OIL LEVEL CHANGE OIL
WARNING WARNING
WARNING WARNING
Continuous contact with used motor oil has caused Continuous contact with used motor oil has caused
skin cancer in laboratory animal tests. Avoid skin cancer in laboratory animal tests. Avoid
prolonged contact. Wash skin with soap and water. prolonged contact. Wash skin with soap and water.
Launder or discard soiled clothing. Launder or discard soiled clothing.
Refer to Oil Type and Capacities on this page Refer to Oil Type and Capacities on this page
Taylor-Dunn does not recommend the use of oil additives. 1: Park the vehicle on a level surface.
2: The engine should be warm.
Before checking engine oil level: Turn engine off and wait 3: Place an oil drain pan underneath the drain
a couple of minutes to allow oil to return to the crankcase. extension at the rear of the engine.
The oil level should be between the F and L marks on 4: Remove the drain plug and allow the oil to drain.
the dipstick (see illustration). 5: Replace the oil filter.
Note: Lightly lubricate the O-ring on the filter.
Only add oil if level is BELOW the L mark on the dipstick.
6: Thoroughly clean the drain plug and wrap with
Only use oil displaying the appropriate American
Teflon tape.
Petroleum Institute (API) Symbol on the container.
7: Install the drain plug.
8: Clean the area around the fill cap before
removing.
9: Fill the engine with oil to the proper level.
10: Start engine and inspect for leaks.
Oil type and capacities

Petroleum or synthetic detergent oils that meet API
Class SJ or higher.
1.7 to 1.9 US quart (1.6 - 1.6 liter).
Ambient Temperature Viscosity

-20ºF to 32ºF 5W30
(-30C to 0C)
0ºF to >100ºF 10W30
(-18C to 38C )
50ºF to >100ºF SAE30
(10C to 38C)
Dipstick Range
Page 42 MB-440-10
Engine
Bigfoot G-1500
AIR FILTER SERVICE SPARK PLUG SERVICE
WARNING WARNING
The air filter assembly consists of a foam pre-cleaner

over a paper filter. The pre-cleaner is oiled and must be 1: Allow the engine to cool.
cleaned and re-oiled periodically. The pre-cleaner only 2: Disconnect the battery negative cable.
require replacement if it is damaged. 3: Remove the cable from the spark plugs.
4: Thoroughly clean the area around each spark
Do not operate the engine without the pre-cleaner. plug.
Operating without the pre-cleaner will result in premature 5: Remove the spark plug and inspect the
failure of the engine. electrodes for damage and condition and replace
1: Remove the filter cover. as needed. See illustration below for typical
2: Thoroughly clean the area around the filter conditions of spark plugs.
assembly. • Further engine service may be required if either
3: Remove the filter assembly. plug shows anything other than #1, #2, or #5.
4: Remove the pre-cleaner from the paper element. 6: Check the gap on each plug and adjust as
5: Wash the pre-cleaner in water with detergent. needed.
Rinse and allow to air dry. • Gap: 0.030” (0.76mm).
6: Inspect the paper element and replace as 7: Reinstall the plug and torque to 20 foot pounds
needed. DO NOT attempt to clean the paper (27 Nm).
element.
7: Inspect the pre-clearer and replace if any damage
is found.
8: Inspect the rubber filter seal and replaces as
needed.
9: Saturate the pre-cleaner with clean engine oil and
wring out excess oil.
10: Install the pre-cleaner around the paper element
and reinstall on the engine.
MB-440-10 Page 43
Notes:
Engine
Bigfoot G-1500
Page 44 MB-440-10
Transaxle
Table of Contents
Transaxle
Disassemble.....................................................46
Assemble..........................................................47
Differential.........................................................48
Axle Shaft..........................................................48
Remove....................................................................48
Install........................................................................48
Replace Axle Bearing...............................................48
WARNING
Transmission
Bigfoot G-1500
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.
Notes:
The brakes and axle shafts DO NOT need to be removed from the axle tube unless the axle or brakes
require servicing.
It is recommended to replace all oil seals.
A press will be required to reassemble.
A non-silicone based gasket sealer is required for reassembly. Us Loctite® 518 or equivalent.
1: Remove the transmission assembly from the vehicle.
2: Drain the oil from the transmission.
3: Remove both left and right axle tube/axle/brake
assemblies.
Note: Tag each assembly as left or right to make sure it is
reassembled correctly.
4: Remove the shifter detent screw, spring, and ball. A small
magnet can be used to extract the spring and ball from the
bore.
5: Place the assembly flat on a block with the input shaft
pointing down.
6: Remove all of the case bolts.

Note: There are 3 notches in each case half to be used to
split the case. DO NOT drive a screwdriver or pry bar
between the case halves or the sealing surface may
be damaged.
7: Using pry bars in the 3 notches, pry the two case halves
apart.
8: Remove the differential/ring gear assembly.
Note: Observe the orientation of the intermediate shaft
and input shaft gears, shims, and washers. Incorrect
reassembly will result in shifting problems.
9: Remove the thrust washer, drive and reverse gears from
the intermediate shaft.
10: Raise the input shaft slightly and remove the intermediate
shaft/gear assembly from the case. Do not forget the other
thrust washer.
11: Remove the retaining ring from the idler gear, slightly
raise the input shaft and remove the idler gear and thrust
washers.
Note: The idler shaft cannot be replaced. If it is damaged
then the case must be replaced.
12: Remove the input shaft.
13: Remove the shift actuator.
14: Remove all oil seals and discard.
15: Remove bearings as required.
Note: Bearings will be damaged when removed. Any
bearing that is removed must be replaced.
Showing Intermediate Shaft
Page 46 MB-440-10
Transmission
Bigfoot G-1500
ASSEMBLE
WARNING
• Thoroughly clean all components and cases.
• Inspect all components for indications of wear or damage and replace as needed.
• All components should be lightly lubricated before assembly, seals should be greased.
• A press will be required to install bearings.
1: Install input shaft seals, axle seals, and shift actuator seal.
2: Install input shaft bearings.
3: Install intermediate shaft bearings.
4: Install the shift actuator through the housing.
5: Install the input shaft, actuating sleeve, and thrust washer.
6: Raise the input shaft slightly to install the idler gear and
thrust washers. The washer with the tap is on top.
7: Install a new retaining ring.
8: Assemble the intermediate shaft, forward gear, shift dog,
and shift fork.
9: Raise the input shaft slightly to install the intermediate
shaft/gear assembly into the case. DO NOT FORGET THE
THRUST WASHER! Make sure the shift actuator properly Idler Gear
engages the shift fork shaft pin.
10: Install the shift rod delete ball, spring, and set screw. While
counting the turns, tighten the set screw until it bottoms out
then loosen 1/2 the turns. The shift rod should be able to
move between the three detent positions.
11: Slightly raise the input shaft and install the reverse gear,
final drive gear, and thrust washer on to the intermediate
shaft. CONFIRM THE INPUT SHAFT IS FREE TO
ROTATE!
12: Install the differential/ring gear assembly and CONFIRM
ALL GEARS ROTATE FREELY IN FORWARD AND
REVERSE!
13: Clean the sealing surface of he case halves and gently
sand any nicks to remove any high spots.
14: Apply a bead of Loctite® 518 or equivalent to the sealing Intermediate Shaft assembly with Shift Fork
surface of one half.
15: Mate the cases together and tighten hardware to 10 foot
pounds (14.3 Nm).
16: Install axle tube assemblies and torque to 30 foot pounds
(42.8 Nm).
Detent Ball, Spring and Screw
MB-440-10 Page 47
Transmission
Bigfoot G-1500
DIFFERENTIAL
WARNING
Note: All hardware and bearings must be replaced if they are removed from the differential /ring gear assembly.
1: Remove the 4 bolts holding the ring gear to the differential. Discard bolts and nuts.
2: Remove the carrier bearings and discard.
3: Thoroughly clean the differential and ring gear.
4: Press new bearings on the carrier.
5: Install the ring gear using all new hardware and torque to 40 foot pounds.
AXLE SHAFT
WARNING
Remove
Note: The axle is retained by an internal circlip in the axle tube. Long reach 90º circlip pliers will be required.
Remove the circlip and pull the axle from the tube.
Install
WARNING
Confirm the circlip is properly seated in the groove.
If the circlip is not seated properly, the axle may come out of the transmission during operation resulting in
loss of brakes causing severe bodily injury and/or property damage.
Push the axle assembly into the axle tube and seat the circlip in the tube.
Replace Axle Bearing
Note: Removing the bearing will damage the bearing. Any time a bearing is removed it must be replaced.
1: Remove the axle from the transmission.
2: Drill a 1/4 inch hole about 3/4 depth of the bearing retaining ring. DO NOT DRILL ALL THE WAY THROUGH
THE RING!
3: Using a chisel, strike the ring over the drilled hole to split the ring.
4: Using an arbor press and proper bearing separator, remove the bearing and discard.
5: Thoroughly clean the axle shaft and inspect. Replace the axle shaft if any damage is found.
6: Place the axle retaining circlip on the axle. DO NOT FORGET THIS STEP! If you forget the circlip then the
bearing will have to be removed and replaced.
7: Lightly lube the ID of a new bearing and retainer.
8: Place new bearing on the axle and press down to shoulder.
9: Place new retaining ring and press down to bearing,
Page 48 MB-440-10
CVT Transmission
Table of Contents
CVT Transmission
Operation...........................................................50
Driver Pulley.....................................................51
Remove....................................................................51
Install........................................................................51
Driven Pulley.....................................................51
Remove....................................................................51
Inspect......................................................................51
Install........................................................................51
Repair.......................................................................51
Drive Belt...........................................................52
Remove....................................................................52
Inspect......................................................................52
Install........................................................................52
WARNING
CVT
Bigfoot G-1500
OPERATION
WARNING
A CVT is a Continuously Variable Transmission and functions to keep the engine RPM constant in the area of
maximum torque and/or efficiency.
The CVT consists of two variable diameter pulleys connected with a wide V-belt. The driver pulley mounted on the
engine has a set of internal weights; the weights move outwards as the engine RPM increases causing the pulleys
sliding sheave to move in effectively increasing its diameter. As the driver pulley diameter gets larger it pulls on the
belt causing the driven pulley sliding sheave to move out decreasing its diameter.
The CVT in Bigfoot is set up so that when the engine is at idle there is very little tension on the drive belt making it
act similar to a clutch partially disengaging the engine from the transaxle.
Showing Intermediate Shaft
Page 50 MB-440-10
CVT
Bigfoot G-1500
DRIVER PULLEY
WARNING
The driver pulley has no serviceable components. If not functioning correctly then it must be replaced as an assembly.
Remove
1: Remove the drive belt.
2: Remove the bolt holding the pulley to the transaxle input
shaft.
3: Slide the pulley off of the shaft.
Note: A pry bar may be required to get it started. If too tight then
the motor may need to be removed to use a gear puller.
Inspect
Inspect the sides of both the stationary and sliding sheaves. They
should be smooth from bottom to top. Severe grooving may be a
result of operating with too heavy of a load with the engine rotating
but the belt is stalled.
Install
Install in reverse order of removal.
• Confirm key is positioned correctly on the crankshaft.
• Lightly lubricate the crankshaft.
DRIVEN PULLEY
Remove
1: Remove the drive belt.
2: Remove the bolt holding the pulley to the transaxle input shaft.
3: Slide the pulley off of the shaft.
Inspect
Inspect the sides of both the stationary and sliding sheaves. They should be
smooth from bottom to top. Severe grooving may be a result of operating
with too heavy of a load with the belt rotating but the wheels are stalled.
Install
Install in reverse order of removal.
• Confirm key is positioned correctly on the input shaft.
• Lightly lubricate the transaxle input shaft.
Repair
The only serviceable components on the driven pulley are the ramp shoes.
These are the plastic shoes that the sliding sheave rides on. Although there
are 6 total, only 3 are actually used; these are the shoes in contact with the
stationary ramp on the transaxle input shaft.
MB-440-10 Page 51
CVT
Bigfoot G-1500
DRIVE BELT
WARNING
Service Guidelines chapter and beginning of this
section..
Note: The ramp shoes should be inspected any time

the belt is serviced.
Remove
1: Turn engine off and allow the exhaust system to cool.
2: Disconnect the battery negative lead.
3: Place the transmission in neutral.
4: Grab the drive belt and pull up until you can move
it over the side of the driven pulley as show in the
illustration.
5: Keeping fingers clear of the drive belt, rotate the
pulley until the belt comes off.
Inspect
Measure the width of the belt in at least 4 points along the
length. If any one point is less than 1.031 inch (26.2 cm) then
the belt should be replaced.
Run your fingers along both sides of the belt. If you can feel
any low sections then the belt should be replaced.
Install
6: Disconnect the battery negative lead.
7: Place the transmission in neutral.
8: Wrap the belt around the driver pulley.
9: Starting at the bottom of the driven pulley, start
wrapping the belt around the pulley. When it gets
difficult to continue, finish by rotating the pulley until
the belt is fully seated.
Page 52 MB-440-10
Brakes
Table of Contents
Brakes
General Guidelines and Safety.......................54
Front Disc Brake...............................................55
Service Limits...........................................................55
Inspection.................................................................55
Replace Pads...........................................................55
Brake Adjustment.............................................56
Service Brake...........................................................56
Parking Brake...........................................................56
Master Cylinder................................................56
Add Fluid..................................................................56
Push Rod Adjustment...............................................56
Rear Brake, Inspect/Replace...........................57
Service Limits...........................................................57
Inspection.................................................................57
Replace....................................................................57
Rebuild Disc Brake Body.................................58
Bleed System....................................................59
Flush System....................................................59
Service Limits...................................................60
Hardware Torque..............................................60
WARNING
Brakes
Bigfoot G-1500
GENERAL GUIDELINES AND SAFETY
WARNING WARNING
Taylor-Dunn does not currently supply asbestos
fiber-brake pads/shoes with any vehicle. However,
there is the possibility that the original brake pads/
shoes were replaced with aftermarket pads/shoes
containing asbestos. Since this possibility does exist,
the brake pads/shoes should be handled as if they
WARNING do contain asbestos.
Never use compressed air or dry brush to clean the
Do not ingest brake fluid or allow contact with skin
brake assemblies. Use an OSHA approved vacuum
or eyes. Always wear protective clothing and a face
cleaner or any alternate method approved by OSHA
shield when working with or around brake fluid.
to minimize the hazard caused by airborne asbestos
SKIN CONTACT: fibers and brake dust.
Flush area immediately with water for several Do not grind, sand, break, or chisel the brake pads/
minutes. If a rash or skin irritation develops, get shoes, as this will cause unnecessary dust, possibly
medical attention immediately. releasing asbestos fibers in the air.
EYE CONTACT: Always wear protective clothing and a respirator
Immediately flush the eye with water for 15 minutes when working on the brake pads/shoes or their
and call physician. associated components.
INGESTION: Inhaled asbestos fibers have been found to cause
Get medical attention immediately. cancer and respiratory diseases.
WARNING Do not drive the vehicle if any worn or broken part is

detected in any part of the brake system. The cause
Hydraulic brake system components must be kept of the damage must be repaired immediately.
clean. Make sure your work area is free from dirt
and debris and will contain any brake fluid spills. Any
debris or contaminates left in the brake system could
lead to brake failure and result in property damage
and/or severe bodily injury.
WARNING
When replacing or adding brake fluid:
• Only use DOT 3 brake fluid from a new sealed
container.
• DOT 3 brake fluid is corrosive, will damage paint
finishes and may damage electrical components.
• Dispose of brake fluid in accordance with local
state and federal regulations.
• Read and follow all warnings on the brake fluid
container.
Page 54 MB-440-10
Brakes
Bigfoot G-1500
FRONT DISC BRAKE
WARNING
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: Measure the brake lining (not including the metal
backing plate) of each pad at it’s thinnest point. If
any one of the brake pads are equal to or less that the service limit then all pads should be replaced.
4: Measure the rotor thickness in three places. If the rotor thickness is less than the service limit then the rotor
must be replaced.
5: Measure the rotor runout. If the runout exceeds the service limit, then the rotor must be resurfaced. After
resurfacing the rotor, measure the rotor thickness. If the rotor thickness is less than the service limit, then the
rotor must be replaced.
7: Reconnect the battery, remove the blocks from behind the wheels and test drive.
Replace Pads
Note: Installing new brake pads will raise the brake fluid level in the master cylinder.
1: Thoroughly clean the area around the master cylinder cap.
2: Remove fluid from the master cylinder until it is 1/2 full.
4: Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing the tire and
wheel assembly.
Note: Refer to the illustration for the following steps.
5: Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8).
6: Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings.
7: Inspect the brake rotor. See Inspect the Service Brakes section for information regarding inspecting the
brake rotor.
8: Inspect the spacers (7) and replace if any wear or damage is found.
9: Install new spacer bushings in the mounting bracket.
10: Install new brake pads and assemble the caliper in reverse order. Torque the brake body per specification at
the end of this section.
11: Install the tire/wheel assembly onto the hub and lower the vehicle to the ground.
12: Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section for information on
the proper master cylinder fluid level.
13: Reconnect the battery, remove the blocks from behind the wheels and test drive.
MB-440-10 Page 55
Brakes
Bigfoot G-1500
BRAKE ADJUSTMENT MASTER CYLINDER
WARNING WARNING
Service Brake
1: Raise the wheel off of the ground and support There are no internally serviceable components in the
with jack stands. master cylinder. If the master cylinder is faulty, it must
2: Release the park brake. be replaced
3: Remove the tire/wheel assembly. Add Fluid
Note: Refer to Tires and Wheels section for 1: Thoroughly clean
information on removing the wheel. the area around the
4: Align the adjusting access slot in the brake drum master cylinder cap
with the adjusting star wheel at the bottom of the and remove the cap.
brake. 2: Add brake fluid
5: While rotating the brake drum back and forth, from a new sealed
rotate the brake adjuster star wheel until the container to the
brake is tight enough so that brake drum cannot master cylinder until
be rotated. it as the maximum
6: Back off the star wheel just enough so that the level line molded in the reservoir.
brake drum rotates freely. Push Rod Adjustment
7: Install the tire/wheel assembly.
8: Repeat this procedure for the opposite side The master cylinder push rod should be adjusted so that
brake. there is 1/16 inch (1.6 mm) clearance between the push
9: Set the park brake. rod and the plunger when the brake pedal is released.
10: Reconnect the negative battery cable. 1: Loosen the jam nut and rotate the push rod until
11: Test drive the vehicle. it just touches the master cylinder plunger. The
push rod will become difficult to rotate when
Parking Brake touching.
The primary park brake adjustment is 2: Now rotate to loosen 2 turns and tighten the
the knob on the end of the park brake jam nut. DO NOT let the push rod rotate while
handle. Release the brake and rotate tightening the jam nut.
the knob clockwise to tighten the brake
and counter clockwise to loosen.
The following is performed only if there
is no adjustment left in the knob.
1: Perform the service brake
adjustment procedure.
2: Release the park brake.
3: Rotate the knob on the park brake handle fully
counter clockwise so that the cable is as loose as
possible.
4: Loosen the clevis jam nut on the cable equalizer.
5: Rotate the cable to tighten and remove all slack
in the cable.
Note: Pull out on the equalizer while adjusting the
cable.
6: Tighten the jam nut.
7: Set the park brake and confirm proper operation.
8: Reconnect the negative battery cable.
Page 56 MB-440-10
Brakes
Bigfoot G-1500
REAR BRAKE, INSPECT/REPLACE Replace
1: Release the park brake.
WARNING 2: Raise the rear wheels off of the ground and
support with jack stands.
This section is one section of a complete service 3: Remove the tire/wheel assembly. Refer to Tires
manual. Before starting any procedure, read all and Wheels section for information on removing
warnings and instructions that are located in the the wheel.
Service Guidelines chapter. 4: Remove and inspect the brake drum. Refer
to Inspect the Service Brake section for
Note: It is recommended that both the left and right information regarding inspecting the brake drum.
brake shoes be replaced as a set. 5: Remove the retracting springs and torsion springs
from the brake shoes.
Service Limits 6: Remove the hair pin clips from the actuating arms
Refer to the table at the end of this section. and discard.
7: Remove the brake shoes and brake adjustor
Inspection assembly from the backing plate.
1: Raise the rear of the vehicle and support with 8: Thoroughly clean and inspect the adjustor
jack stands. assembly. Replace parts as required.
2: Remove the rear wheels.
3: Measure the brake lining (not including the metal WARNING
backing plate) of each shoe at it’s thinnest point.
Do not allow grease to contact any of the braking
If any one of the shoes are equal to or less surfaces. Braking surfaces contaminated with grease
that the service limit then all shoes should be may cause the brakes to fail resulting in property
replaced. damage and/or severe bodily injury.
4: Measure the drum inner diameter in three places. 9: Apply a very light coating of high temperature
If the diameter is less than the service limit then grease to the adjustor screw threads.
the drum must be replaced. 10: Install in reverse order.
5: Lower the vehicle. 11: Repeat for the opposite side.
6: Reconnect the battery negative cable and test 12: Adjust the brakes. See Adjust the Service
drive.
Brakes section for information regarding
adjusting the brakes.
13: Set the park brake.
14: Reconnect the battery negative cable.
15: Test drive.
Brake Adjuster Assembly
MB-440-10 Page 57
Brakes
Bigfoot G-1500
REBUILD DISC BRAKE BODY
WARNING
This procedure assumes that the component has been

removed from the vehicle. Refer to the component
assembly removal instructions for details and warnings
regarding the removal and installation procedure.
WARNING
The pistons are very fragile. If the piston is damaged
it must be replaced. Failure to replace a damaged
piston could lead to brake failure and result in
property damage and/or severe bodily injury.
1: Pull the pistons out of the brake body.

2: Remove the piston rubber boot.
3: Remove the piston o-ring from inside of the brake
body.
4: Inspect and replace parts as required. Figure 1
5: Lubricate the brake parts with clean brake fluid
from a sealed container.
6: Install the O-rings into the brake body. Make sure
that the O-rings are installed into the second
groove and that they are not twisted (Fig 1).
7: Using tool #41-350-13 (optional), slide the rubber
boots onto the pistons as shown. The boot should
be hanging off of the end of the piston (Fig 2).
8: Insert the rubber boot/piston into the brake body Figure 2
making sure that the boot is properly seated in
the groove (Fig 3).
9: Press the pistons all the way down into the brake
body making sure that the boot seats properly
into the upper groove on the piston.
10: Install any fittings or plugs that were removed
from the brake body using teflon tape thread
sealant.
11: If the brake body assembly is not to be
immediately installed onto a vehicle, plug
the brake hose fitting hole to prevent any
contaminates from entering the brake body.
Figure 3
Page 58 MB-440-10
Brakes
Bigfoot G-1500
BLEED SYSTEM FLUSH 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. Before starting any procedure, read all stands.
warnings and instructions that are located in the 3: Release the park brake.
Service Guidelines chapter. 4: Remove both rear wheels and, if equipped with
front brakes, the front wheels. Refer to Tires
Note: Start this procedure at the wheel furthest and Wheels section for information regarding
from the master cylinder, then work toward removing the wheels.
the wheel closest to the master cylinder. 5: Remove the wheel cylinders from each axle.
The rear bleeder valves can be accessed Refer to Replace the Wheel Cylinder section
through the center rear inspection cover. for information regarding removing the wheel
cylinder.
1: Thoroughly clean the area around the master 6: Attach a clear hose to the bleeder valve on each
cylinder cap and remove the cap. of the wheel cylinders and route the hoses into a
2: Add brake fluid from a new sealed container container for waste brake fluid.
to the maximum level indicator on the master 7: Position the wheel cylinders so that the bleeder
cylinder reservoir screw is pointing to the ground and open all
3: The master cylinder fluid level will drop as the bleeder screws.
brakes are bled. Periodically check and fill the 8: Pump the master cylinder until all fluid has been
master cylinder during this procedure. Do not pumped from the brake lines and all wheel
allow the fluid level in the master cylinder to drop cylinders.
too low as this will allow air into the brake lines. 9: Close all bleeder screws.
4: Attach a clear hose to the bleeder valve on the 10: Fill the master cylinder with fluid.
brake cylinder that is to be bled. Route the hose 11: Open one of the bleeder screws and pump the
into a clear container for waste brake fluid. master cylinder until all fluid has been pumped
5: Pump the brake pedal a few times and then press from the master cylinder and close the bleeder
and hold light pressure to the brake pedal. screw.
6: Open the brake bleeder valve. 12: Repeat the above two steps for each wheel
7: Press the foot pedal to the floor and then close cylinder.
the bleeder valve. Do not release pressure on the 13: Reinstall the wheel cylinders and bleed the
brake pedal until the bleeder valve is closed. brakes. Refer to Bleed the Brakes for information
8: Slowly release the foot pedal, allowing it to return regarding bleeding the brakes.
to its released position. 14: Set the park brake.
Note: Check and fill the master cylinder frequently 15: Install the wheels and lower the vehicle to the
during the bleeding process. Do not allow ground.
the fluid level in the master cylinder to drop 16: Reconnect the battery, remove the blocks from
low enough to allow air to enter the brake behind the wheels and test drive.
lines. If air enters the brake lines during the
bleeding process, then you will have to start
again from the beginning.
9: Repeat the above steps until you are sure that
all of the air is expelled from the brake line. Any
air bubbles that can be seen in the clear hose
attached to the bleeder is an indication that there
is still air in the brake lines.
10: Repeat this process with each of the other
wheels.
Note: When finished, top off the master cylinder
with fluid. See Check Master Cylinder Fluid
for information on filling the master cylinder.
11: Reconnect the battery, remove the blocks from
behind the wheels and test drive.
MB-440-10 Page 59
Brakes
Bigfoot G-1500
SERVICE LIMITS HARDWARE TORQUE

Description Imperial Metric If hardware is not listed here, refer to standard torque
Disc pad lining minimum thickness 00625 inch 1.58 mm values in the appendix.
Front rotor minimum thickness 0.200 inch 5.08 mm Description Foot Pounds Newton Meters
Rotor runout 0.005 inch 0.127 mm Brake Body Bolts 11 14.9
Rear shoe lining minimum thickness 0.200 inch 5.08 mm
Rear drum maximum diameter 6.33 inch 160.8 mm
Notes:
Page 60 MB-440-10
Throttle Cables
Table of Contents
Throttle Cables
Adjust, Throttle / Choke...................................62
WARNING
Batteries
Bigfoot G-1500
ADJUST, THROTTLE / CHOKE
WARNING
NOTICE
The maximum engine RPM is controlled by the engine
governor. DO NOT attempt to adjust the governor.
Modifications to the engine governor will void the
engine warranty and may result in damage to the
engine.
The choke cable is adjusted at the engine controls by

means of one cable clamp.
The throttle cable is adjusted at the engine controls by
means of one cable clamp and at the throttle pedal by
another clamp.
1: Turn the engine off and set the park brake.
2: Allow engine and exhaust system to cool.
3: Loosen the cable clamp and adjust the cable as
needed.
4: Tighten the cable clamp.
5: Reconnect the battery negative cable and test
drive.
Page 62 MB-440-10
Shift Linkage
Table of Contents
Shift Linkage
Adjustment........................................................64
WARNING
Batteries
Bigfoot G-1500
ADJUSTMENT
WARNING
NOTICE
Do not modify the stainless steel shift cable mounting
plate at the transmission. This mounting plate is
spring steel and functions as an active part of the
shifting mechanism. Modification of this mounting
plate may cause improper operation of the shift
linkage resulting in damage to the transmission.
1: Loosen the ball joint jam nut and the cable

mounting nuts on the spring steel mounting plate.
2: Disconnect the coupler from the ball joint at the
transmission.
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 slides
onto the ball joint.
6: Tighten all mounting and jam nuts.
7: While slowly rotating the transmission input
sheave, shift the transmission from forward to
reverse and back to forward to confirm proper
adjustment.
8: Reconnect the battery and test drive.
Page 64 MB-440-10
Tires & Wheels
Table of Contents
Tires & Wheels
Inflation..............................................................66
Air pressure..............................................................66
Tread Wear........................................................67
Rotation.............................................................67
Changing Tire/Wheel Assembly......................68
Replace the Tire (pneumatic).........................68
Repair the Tire (pneumatic)............................68
Hardware Torque..............................................69
WARNING
Tires & Wheels
Bigfoot G-1500
INFLATION
WARNING WARNING
Incorrect tire inflation can result in sudden failure of
the tire and/or braking / steering problems leading
to loss of control of the vehicle.
Service Guidelines chapter. Never exceed the maximum pressure as indicated
on the side wall of the tire. Exceeding the maximum
pressure may cause explosive failure of the tire
resulting in severe personal injury.
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 failure.
• Excessive tread wear resulting in shortened tire life.
Over inflated tires result in:
• Tire explosion due to excessive pressure.
• Reduced road surface traction.
• Increased vibration from the road surface.
• Excessive tread wear resulting in shortened tire life.
Unequal tire inflation may result in:
• Uneven braking and loss of control of the vehicle.
• Steering pulling to the left or right.
Only check the tire pressure when the tire is cold. When checking tire pressure, you must check all tires including
your spare tire.
The correct tire size and pressure can be found in the specifications list in the manual.
Note: The front and rear tires may have a different tire pressure specification.
Page 66 MB-440-10
Tires & Wheels
Bigfoot G-1500
TREAD WEAR
WARNING WARNING
This section is one section of a complete service DO NOT operate a vehicle if the cord is
manual. Before starting any procedure, read all visible on any tire (see illustration). A tire
warnings and instructions that are located in the in this conditions may suddenly fail at
Service Guidelines chapter. any time and cause loss of control of the
vehicle.
It is important to periodically inspect each tires tread for
wear. Driving with inadequate tread increases the risk
of loosing control of the vehicle due to hydroplaning on
a wet road surface. It also increases the risk of a flat tire
due to road debris. Extreme tire wear can result in sudden
tire failure and loss of control of the vehicle.
Refer to the maintenance schedule in this manual for the
recommended interval.
Minimum recommended tread depth is 1/16 inch (1.6
mm). There are a series of tread depth wear indicators
around the circumference of the tire. They will appear as
approximately 1/2 inch (12 mm) bands across the tread
as the tire approaches its wear limit (see illustration).
The tire should be replaced if any tread depth indicator
can be seen or any part of the tread depth is 1/16 inch
(1.6 mm) or less.
ROTATION
WARNING
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.
Use the following pattern for a vehicle with no spare tire:
• Right Rear to Right Front
• Right Front to Left Rear
• Left Rear to Left Front
• Left Front to Right Rear
Use the following pattern for a vehicle with spare tire:
• Right Rear to Right Front
• Right Front to Left Rear
• Left Rear to Spare
• Spare to Left Front
• Left Front to Right Rear
MB-440-10 Page 67
Tires & Wheels
Bigfoot G-1500
CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC)
ASSEMBLY WARNING
WARNING This section is one section of a complete service
This section is one section of a complete service warnings and instructions that are located in the
manual. Before starting any procedure, read all Service Guidelines chapter.
Service Guidelines chapter. Note: To replace the tire, the tire/wheel assembly
must be removed from the vehicle. Refer
Note: A spare tire, jack, or lug wrench is not to Replace the Tire/Wheel section for
attached to the vehicle. information on removing the tire/wheel
assembly.
1: Loosen the wheel nuts (do not remove) before
raising the tire off of the ground. Tire replacement should only be performed by personnel
2: Raise the tire to be changed off of the ground and trained in tire replacement.
support with a jack stand. The tire replacement procedure will be unique to the
3: Remove the wheel nuts and tire/wheel assembly. type of replacement equipment being used. Refer to the
4: Install the replacement tire/wheel assembly. instructions provided with your equipment.
5: Install the wheel nuts and cross tighten to torque
specified in table. Always use a new valve stem when replacing a tire.
6: Check the tire for proper inflation. 1: Remove the tire from the wheel.
7: Lower the vehicle to the ground and remove the 2: Cut the old valve stem off of the wheel.
blocks from the wheels. 3: Remove the valve stem cap from the new valve
8: Check wheel nuts for tightness after 20 operating stem.
hours. 4: Lubricate the valve stem with liquid soap.
5: Install a new valve stem using a valve stem tool.
Note: The valve stem tool is available at most auto
repair shops.
6: Install the tire onto the wheel following the
instructions provided with your tire replacement
equipment.
7: Inflate the tire to the proper pressure and check
for leaks.
8: Install the valve stem cap.
WARNING
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.
REPAIR THE TIRE (PNEUMATIC)

Note: To properly repair a puncture, the tire
must be removed from the wheel. Refer to
Replace the Tire section for information on
removing the tire from the wheel.
It is recommended to repair a tire with a combination

vulcanized plug and internal patch.
Tire repairs should only be performed by personnel
trained in tire repair.
The tire repair procedure will be unique to the type of
repair equipment or repair components used. Refer to
the instructions provided with your equipment or repair
components.
Page 68 MB-440-10
Tires & Wheels
Bigfoot G-1500
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque values in the
appendix.
Wheel nut 85 115
MB-440-10 Page 69
Notes:
Tires & Wheels
Bigfoot G-1500
Page 70 MB-440-10
Suspension
Table of Contents
Suspension
Front Springs....................................................72
Remove....................................................................72
Install........................................................................72
Rear Springs.....................................................72
Remove....................................................................72
Install........................................................................72
WARNING
Suspension
Bigfoot G-1500
FRONT SPRINGS REAR SPRINGS
WARNING Remove

WARNING
warnings and instructions that are located in the DO NOT attempt to remove the springs until the
Service Guidelines chapter. vehicle is firmly supported on jack stands.
If the frame moves or falls while removing the springs
Note: If a left or right side spring is replaced, it is then it may result in severe bodily injury.
recommended to replace the opposite side
at the same time. WARNING
Note: All spring bushing should be replaced when DO NOT raise the vehicle so far as to put any tension
replacing a spring. on the brake hoses. Stretching a brake hose may
Note: When replacing the springs, replace one weaken the hose resulting in failure of the hose and
loss of brakes.
side and then the other to avoid dropping
the axle out of the vehicle.
1: Block the front wheels.
Remove 2: Remove the upper shock bolts.
1: Raise the front end and support with jack stands. 3: Disconnect one side of the panard bar.
2: Remove the 4 spring mounting bolt nuts and 4: Raise the rear of the vehicle just enough to allow
discard. clearance to remove the springs and support on
3: Raise the axle up and off of the spring and jack stands.
securely tie in place. 5: Remove the springs
Install
NOTICE
Do not over torque the spring bolts on elliptical spring WARNING
hangers. The spring hangers must be allowed to pivot. DO NOT place hands in proximity of the springs
or frame while lowering the frame. Unexpected
4: Remove the 2 spring eye bolts and discard the movement of the frame may result in severe bodily
nuts. injury.
5: Remove the spring from the vehicle.
1: Install in reverse order of removal.
6: Remove the spring hanger bolt and discard the
nut.
7: Discard all spring eye and hanger bushings.
Install
1: Inspect the spring hangers for damage and
replace as needed.
2: Using new nuts and bushings, install the hangers
and spring in the frame.
3: Tighten the spring to frame mounting hardware
until there is no axial play in the bolt then 1/4 turn
more.
4: Untie the axle and lower down into the spring
making sure that the spring locating stud is in the
hole on the lower axle beam.
5: Using new nuts, install the spring plate.
6: Repeat Remove and Install procedures for the
other side.
Page 72 MB-440-10
Battery
Table of Contents
Battery
General Guidelines and Safety.......................74
Cleaning............................................................75
Watering............................................................75
Testing...............................................................76
Specific Gravity........................................................76
Storing...............................................................76
Storage.....................................................................76
Returning to Service.................................................76
Remove/Install..................................................77
Hardware Torque..............................................78
WARNING
Batteries
Bigfoot G-1500
GENERAL GUIDELINES AND SAFETY
WARNING NOTICE
Battery electrolyte will stain and corrode most
surfaces. Immediately and thoroughly clean any
surface outside of the battery that the battery
electrolyte comes in contact with. Failure to clean
may result in property damage.
WARNING
• Explosive mixtures of Hydrogen gas are present
within battery cells at all times. Do not work
with or charge battery in an area where open
flames (including 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 result in severe
• A battery is a live electrical source. It cannot be
disconnected or neutralized. Do not drop any
tool or conductive object onto the battery. A
conductive object 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 severe bodily injury and/or property
damage.
• Battery electrolyte is poisonous and dangerous.
It contains sulfuric acid. Avoid contact with skin
eyes or clothing. Wear rubber gloves and safety
glasses while servicing batteries. DO NOT INGEST!
This may result in severe bodily injury.
Page 74 MB-440-10
Batteries
Bigfoot G-1500
CLEANING WATERING
WARNING WARNING
Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this
section.. section..
Disconnect the battery before cleaning. NOTICE

Dry dirt can be readily blown off with low-pressure air
or brushed off. DO NOT attempt to add water to a sealed battery.
Note: Wetness or wet dirt on the top of the battery Removing the caps of a sealed battery will damage
indicates battery acid boil over or excessive the battery resulting in premature failure.
gassing.
Using a nonmetallic brush with flexible bristles, wash Clean the battery. Refer to Cleaning section for
the battery off with a strong solution of baking soda and information on cleaning the battery.
hot water mixed with a ratio of one pound of soda to Check the electrolyte level in all battery cells. If low, fill
one gallon of water (0.5 kg / 3.7 liters). Continue until to the correct level (see illustration) with distilled water
all fizzing stops, which indicates that the acid has been using part number 77-201-00 battery filler, never add
neutralized. Then rinse thoroughly with clear water. DO additional battery electrolyte to a battery.
NOT get any of the solution into the battery cells.
MB-440-10 Page 75
Batteries
Bigfoot G-1500
TESTING STORING
WARNING WARNING
Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this
section.. section..
NOTICE Storage
Thoroughly clean the battery and battery compartment.
DO NOT attempt to test the specific gravity of a sealed Refer to Cleaning in this section for information
battery. Removing the caps of a sealed battery will
regarding cleaning the battery.
damage the battery resulting in premature failure.
Check the electrolyte level and charge the battery.
Specific Gravity Refer to Watering in this section for information
Note: The battery must be fully charged before regarding checking the electrolyte level.
performing this test. Store the vehicle or battery (if removed) in a cool, dry,
well ventilated area.
The specific gravity of a cell is an indication of the actual
state of charge of the cell. A fully charged cell should have If storing for more than one month, the battery should
a reading of 1275 to 1300 (see the illustration below). A be charged per the table below.
discharged cell will read 1100. Ideally, all cells in a battery Returning to Service
will have the same reading. Any cells in a battery that
vary by more than 25 points may be an indication of a Thoroughly clean the battery and battery compartment.
bad or weak cell. Refer to Cleaning in this chapter for information
regarding cleaning the battery.
Clean the battery. Refer to Cleaning section for
information on cleaning the battery. Check the electrolyte level and charge the battery.
Refer to Watering in this chapter for information
Using part number 77-200-00 hydrometer or equivalent regarding checking the electrolyte level.
graduated type hydrometer, test and record the specific
gravity of each cell in the battery. Test the battery. Refer to Testing section for information
on testing the battery.
Use the highest reading to compare to all other cells. Any
cell or cells that are more than 25 points less than the The battery is now ready to be put back into service.
highest reading should be suspected as being a bad cell.
If, after charging, none of the cells exceed a hydrometer
Storage Tempera- Charging
reading of 1250 then there may be a fault in the charging
system. If the charging system checks OK then the ture Interval
battery is no longer accepting a charge and should be (F) (months)
replaced.
Over 60 1
Between 40 and 60 2
Below 40 6
Typical
Hydrometer
Float
Page 76 MB-440-10
Batteries
Bigfoot G-1500
REMOVE/INSTALL
WARNING
Service Guidelines chapter and beginning of this
section..
1: Turn the engine off and set the park brake.

2: Using an insulated wrench, disconnect the negative cable, then the positive cable.
3: Remove the battery hold down.
4: Remove the battery from the vehicle.
5: Inspect the battery compartment for corrosion. If there is significant corrosion then the compartment should
be cleaned and painted.
6: Install the battery and torque the battery terminal hardware per torque listed in the Hardware table at the end
of this section
MB-440-10 Page 77
Batteries
Bigfoot G-1500
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque
values in the appendix.
Description Inch Pounds Newton Meters
Battery terminal, Clamp 48-60 5.4-6.7
Battery terminal, Stud 120-130 13.5-14.5
Page 78 MB-440-10
Wire Diagram
Table of Contents
Wire Diagram
Diagram.............................................................80
DIAGRAM PART NUMBERS

Wire diagrams may be 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-00105
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.
WARNING
NOTES:
Diagram includes options that may not be installed on all vehicles.
FRONT LIGHTS Diagram subject to change without notice, special order components may not be included.
RIGHT LEFT
Marker Light Headlight Turn Light Headlight Turn Light Marker Light
Page 80
White
Neutral White
Switch
Blue Blue
Blue
White
Brown
Brown
DIAGRAM
Red/Black
Red/Black
Blue/White
White/Black
Brown/White
Green/White
BATTERY
Violet
Strobe Strobe Light
Light Switch
+
ENGINE Brown/White
Red
Red
Blue
-
Green
White
Red/Black
Red
Windshield
White
Wire Diagram
White
Red/Black
ENGINE
Wiper Wiper Switch
Spark Spark
Plug 2 Plug 1 Yellow
Starter Temperature
Relay Switch
White/Black
Circuit Breaker
Red
White
Oil Pressure
Switch
87a
Red/Black
Kill Light Switch

Relay 30 Brown
Ignition
Modules
Fuel Solenoid Generator Brown
87
White/Black
85
86
White
Starter
White
RECTIFIER- AC B+ AC Hour Fuel
REGULATOR Meter Violet/Black Gauge
(25 AMP)
Brown
- + Violet/Black Yellow/Black
Red/Black
I S
Violet/Black GND
Violet/Black
VIOLET (ENGINE WIRE REF] ENGINE Seat White White
Switch
Violet/Blck
White
White
White White
Fuel White
Sender White/Black
Yellow/Black Horn
Red/Black
Brown Brown
Blue/White
Left Rear Marker Right Rear Marker Engine MIL

Red/Black Red/Black
Brown
ST
IGN
ACC
Red
BATT
Blue
Horn
Brown
White Switch
Violet/Black
Red/Black
Green/White
Brown/White
White
OFF Gray Red/Black
White
IGNITION
Alarm STARTER Brake
Green
Left Rear Right Rear Switch
Blue
Tail Light Tail Light Red/Black
Violet
Reverse Diode 6A-250V
Reverse Light
Brake Light
Brake Light
Reverse Light
Violet/Black TURN SWITCH
Yellow
Blue
Gray/White
Gray/White
Gray/White
Switch [optional]
Red/Black Red/Black Blue/White Red
5
Violet/Black Blue Green
4
Green Black YELLOW
6
Gray Gray/Black GREEN
Red 7 GRAY
Yellow Gray
1 GRY/BLK
Green/White White White BLACK
3
Red/Black Red/Black Red/Black RED
Brown/White 8
TURN SWITCH
Yellow 3 1
Blue 5
4 Flasher
6 4
Blue/White 6
Green 7
9 7
1 Blank fitted to connector
Yellow 3 if not equipped with turn View from pin side
8 signals
SCH-00105, 5/19/2017 Revision A Model G-1500 Bigfoot with Kohler CH620 Engine - Serial number starting 204278
Bigfoot G-1500
Bigfoot G-1500
Hardware Information
Table of Contents
Hardware Information
Torque Guidelines for Standard hardware.....82
Hardware Identification.............................................82
Hex Nuts...................................................................83
Hex Lock Nuts (stover).............................................83
Other Nuts................................................................83
Generic Torque Values.............................................84
Replacing Hardware.........................................86
WARNING
Hardware
Bigfoot G-1500
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.
Below is an example of a 10.9. The location and style of the text will vary. SAE Grade 2 SAE Grade 5
SAE Grade 8 SAE Grade 9
Other types of bolts and screws
Truss Head, Grade 2 Carriage Bolt, Grade 2
Page 82 MB-440-10
Hardware
Bigfoot G-1500
Hex Nuts
Nuts with no markings are to be treated as S.A.E. Grade 2
S.A.E. Grade 5 S.A.E. Grade 8
5.8 8.8 10.9 12.9

Metric Nuts
Hex Lock Nuts (stover)

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 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
MB-440-10 Page 83
Hardware
Bigfoot G-1500
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 Grade, SAE
Dia. Pitch 2 5 8 L9 Dia. Pitch 2 5 8 L9
#4 40 * * * * #4 40 * * * *
#6 32 * * * * #6 32 * * * *
#8 32 * * * * #8 32 * * * *
#10 32 * * * * #10 32 * * * *
#12 32 * * * * #12 32 * * * *
1/4 20 5.5 8.5 12.5 11 1/4 20 7.4 11.5 16.9 14.9
28 6.5 10.5 28 8.8 14.2
5/16 18 12.0 17.5 24.5 22 5/16 18 16.2 23.7 33.2 29.8
24 12.5 19.0 * * 24 16.9 25.8 * *
3/8 16 20 30 43 40 3/8 16 27.1 41 58 54
24 22.5 33 50 45 24 30.5 45 68 61
7/16 14 27 50 70 65 7/16 14 37 68 95 88
20 36 55 77 70 20 49 75 104 95
1/2 13 49 75 106 95 1/2 13 66 102 144 129
20 55 85 120 110 20 75 115 163 149
9/16 12 70 109 153 140 9/16 12 95 148 614 190
18 78 121 171 160 18 106 164 232 217
5/8 11 97 150 212 195 5/8 11 132 203 287 264
18 110 170 240 225 18 149 230 325 305
3/4 10 172 275 376 350 3/4 10 233 373 510 475
16 192 297 420 390 16 260 403 569 529
7/8 9 278 429 593 565 7/8 9 377 582 804 766
14 306 473 818 625 14 415 641 1109 847
1 8 416 644 909 850 1 8 564 873 1232 1152
14 466 721 1018 930 14 632 978 1380 1261
1-1/8 7 590 794 1287 1700 1-1/8 7 800 1076 1744 2304
12 662 891 1444 1850 12 897 1208 2364 2508
1-1/4 7 832 1120 1817 2950 1-1/4 7 1128 1518 2463 4000
12 922 1241 2012 3330 12 1250 1682 2727 4514
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
Page 84 MB-440-10
Hardware
Bigfoot G-1500
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
Dia. Pitch 4.6 8.8 10.9 12.9 Dia. Pitch 4.6 8.8 10.9 12.9
3 0.50 0.51 * * * 3 0.50 0.38 * * *
4 0.70 0.95 3.1 * * 4 0.70 0.7 2.3 * *
5 0.80 2.28 6.1 * * 5 0.80 1.7 4.5 * *
6 1.00 3.92 10.4 15.5 * 6 1.00 2.9 7.7 11.4 *
8 1.00 * 27.0 * * 8 1.00 * 19.9 * *
1.25 9.48 25.0 37.0 * 1.25 7 18.4 27.3 *
10 1.00 * 57.0 * * 10 1.00 * 42 * *
1.25 * 54.0 * * 1.25 * 40 * *
1.50 19.1 51.0 75.0 * 1.50 14.1 38 55 *
12 1.25 * 96.0 * * 12 1.25 * 71 * *
1.50 * 92.0 * * 1.50 * 68 * *
1.75 32.6 87.0 160 * 1.75 24 64 118 *
14 1.50 * 150 * * 14 1.50 * 111 * *
2.00 51.9 140 205 * 2.00 38 103 151 *
16 1.50 * * * * 16 1.50 * * * *
2.00 79.9 215 310 * 2.00 60 158 229 *
18 1.50 * * * * 18 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 110 300 * * 2.50 81 221 * *
20 1.50 * * * * 20 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 156 430 * * 2.50 115 317 * *
22 1.50 * * * * 22 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 211 580 * * 2.50 156 428 * *
24 2.00 * * * * 24 2.00 * * * *
3.00 270 740 * * 3.00 199 524 * *
27 3.00 * * * * 27 3.00 * * * *
3.00 398 * * * 3.00 293 * * *
30 2.00 * * * * 30 2.00 * * * *
3.50 540 * * * 3.50 398 * * *
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
MB-440-10 Page 85
Hardware
Bigfoot G-1500
REPLACING HARDWARE
WARNING
WARNING
Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury
or property damage:
• Many assemblies require specific torque settings for some hardware. Refer to the appropriate assembly
procedure for information regarding proper hardware torque.
• All hardware should be inspected for thread damage or corrosion prior to reassembly. If any evidence of
damage is found then the hardware should be replaced.
• Battery hardware should always be replaced when installing new batteries.
• Never reuse cotter pins or safety locking wire. Never use a wire, nail, or any other material to substitute
for a cotter pin.
• The locking force of a locknut is diminished when it is removed. Locknuts should be replaced whenever
removed.
• Some hardware may requires the use of a thread locking compound. Always thoroughly clean both male
and female threads when applying thread locking compounds.
Page 86 MB-440-10
Replacement Parts
TABLE OF CONTENTS
Replacement Parts
Ordering Parts for Your Vehicle......................88
Taylor-Dunn Web Site Information..................88
Axle Assembly, Front.......................................90
Axle Assembly, Rear........................................92
Brakes, Brake Lines.........................................94
Brakes, Front Axle............................................96
Brakes, Rear Axle.............................................97
Decals................................................................98
Electrical, Miscellaneous.................................100
Engine / Exhaust..............................................102
Frame and Body, Miscellaneous.....................102
Frame and Body (cabs)...................................103
Frame, Deck......................................................104
Fuel System......................................................104
Hitches..............................................................105
Instrument Panel..............................................106
Lights.................................................................106
Linkage, Park Brake.........................................107
Linkage, Shift....................................................107
Linkage, Throttle...............................................108
Seats..................................................................109
Steering Linkage..............................................110
Suspension, Front............................................112
Suspension, Rear.............................................113
Transmission, CVT...........................................114
Wheels and Tires..............................................115
Note: Your vehicle may have been ordered with

special order options. These options typically start
with the letter “K”. Refer to your vehicle sales order
for information.
Replacement part numbers for special order options
are not included in the standard manual.
Replacement Parts Bigfoot G-1500
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.
Unauthorized repairs may also void the vehicles warranty.
WARNING
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.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable affect on the operation of the vehicle, result in additional
frame stress, or stress other components resulting in premature failure or an unsafe condition and may lead
to an accident resulting in serious injury or death.
This section contains a comprehensive parts list that includes all of the typical replacement parts available as of the
published date of this manual. This parts list should be used as a guide only.
This parts list does not include special order options that may have been ordered for your vehicle. To identify special
order options, refer to the original vehicle sales order. Any special order options will have a ‘K’ letter prefix in the
option number. The vehicle option list is also available on the Taylor-Dunn web site. The serial number of the vehicle
is required to obtain the option list.
Only use original Taylor-Dunn parts purchased from an authorized Taylor-Dunn distributor. Refer to the Taylor-Dunn
web site to locate your local distributor or call the factory direct at (714) 956-4040 for referral to a local dealer.
When contacting your dealer, always include the serial number of the vehicle to ensure obtaining the correct
replacement parts. The Taylor-Dunn web site includes a parts lookup utility. By using this utility you can obtain the
most current parts list for your vehicle. The serial number of the vehicle is required to use the lookup utility.
TAYLOR-DUNN WEB SITE INFORMATION

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.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
Page 88 MB-440-10
Bigfoot G-1500 Replacement Parts
My Vehicle information
Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
Notes
My local Parts Dealer: .
MB-440-10 * Not available at time of printing Page 89

AXLE ASSEMBLY, FRONT
Page 90 MB-440-10
Axle Assembly, Front
Item No. Part No. Description Qty
1 12-115-15 Hub (includes 4, 6) 2
2 92-105-00 Dust Cap 2
3 80-011-10 Bearing 2
4 80-102-00 Race 2
5 80-011-10 Bearing 2
6 80-102-00 Race 2
7 45-307-00 Seal 2
8 14-010-19 Steering Knuckle, Right 1
14-010-20 Steering Knuckle, Left 1
9 / 10 PKIT-00051 Kit, King Pins and Bushings 2
11 PKIT-00051 Thrust Bearing 2
12 PKIT-00051 7/8 SAE Flat Washer 2
13 88-527-14 Cotter Pin, 1/8 X 1-1/2 2
14 88-239-85 3/4 NF Hex Slotted Nut 2
15 88-228-60 3/4 Cut Washer 2
16 PKIT-00051 King Pin 2
17 PKIT-00051 7/8NF Thin Hex Locknut Grade 5 2
18 PKIT-00051 7/16 X 1-1/8 NC Socket Head Cap Screw 2
19 PKIT-00051 7/16 NC Grade 9 Locknut 2
20 14-010-00 Front Axle Plate 1
21 14-010-01 Front Axle Plate, Bottom 1
22 88-401-57 3/8 X 6-1/2 NC Grade 8 Hex Head Screw 8
23 88-109-82 3/8NC Lock Nut, Grade C 8
88-401-95 3/8 Flat Washer, Grade 8 16
24 14-010-02 Spacer 8
25 See Steering Steering Rack 1
26 88-069-82 1/4 NC Hex Locknut, Grade 8 4
88-400-90 1/4 Flat Washer Grade 8 8
27 88-060-27 1/4 X 4-1/2NC, Grade 8, Standard Model 4

AXLE ASSEMBLY, REAR

- 4C-610-40 Axle Assembly, Complete (012AJ389-1) 1
1 * Housing, w/idler shaft 1
2 * Case 1
3 66-610-82 Detent kit 1
4 66-610-29 Seal 1
5 66-611-20 Shift actuator assembly 1
6 66-611-19 Shift rod assembly 1
7 45-303-30 Seal 1
8 66-610-75 Axle tube 1
9 66-610-76 Axle tube 1
10 66-610-74 Flange head screw 12
12 45-303-00 Seal 2
13 32-509-10 Retaining ring 2
14 80-505-10 Bearing 2
15 41-347-28 Brake assembly, hydraulic, Left 1
16 41-347-29 Brake assembly, hydraulic, Right 1
17 45-303-10 Seal 1
18 66-610-72 Washer 8
19 66-610-80 Lock nut 8
20 41-127-95 Axle shaft, Left 1
21 66-610-28 Wheel stud 10
Page 92 MB-440-10
22 41-516-00 Brake drum 1
26 66-610-69 Lock nut 13
27 66-610-59 Rubber plug 1
28 * Vent 1
29 * Dowel pin 1
30 80-480-02 Bearing 1
31 ** Input shaft 1
32 66-610-88 Shim kit 1
33 66-610-35 Bearing 1
34 80-480-01 Bearing 1
35 * Spacer 1
36 * Shim 1
37 * Thrust washer 1
38 ** Forward gear assembly 1
39 66-610-85 Clutch gear 1
40 66-610-84 Intermediate shaft 1
41 ** Reverse gear assembly 1
42 ** Pinion gear 1
43 ** Idler gear assembly 1
44 66-610-83 Snap ring 1
45 80-480-00 Bearing 1
46 ** Ring gear 1
47 * Differential Assembly 1
48 * Drain plug 1
50 * Nut 1
51 * Hex bolt 1
52 41-127-96 Axle shaft, Right 1
53 66-610-68 Hex tap screw 2
54 66-610-72 Washer 1
55 66-610-73 Lock nut 1
- 96-123-50 U-bolt, axle mounting 4
88-108-62 Flat washer 8
88-109-81 Lock nut 8
** 66-610-87 Gear Kit, 31, 38, 41, 42, 43, 46

BRAKES, BRAKE LINES
Page 94 MB-440-10
Brake Lines
1 99-607-12 Brake Line 1
2 99-607-14 Brake Line 1
3 99-607-13 Brake Line 1
4 99-601-10 Brake Line 1
5 99-606-51 Brake Line 1
6 99-605-84 Brake Line 1
7 99-605-83 Brake Line 1
8 99-606-05 Brake Line 1
9 99-606-06 Brake Line 1
10 99-559-00 T-Fitting 2
11 99-591-00 T-Fitting 1
12 99-575-00 Coupler 4
13 96-640-00 Clip -
14 99-576-00 Clip, Hose 4
15 99-580-20 Hose 2
16 99-580-10 Hose 1
17 99-580-10 Hose 1
18 500552 Brake light switch 1
Not Shown 99-525-58 Front brake body adaptor, 3/16T X 1/8 NPT, 45º 2
99-575-32 Tube Adaptor, Master Cylinder 2
99-511-20 Master Cylinder 1
41-310-12 Push rod, Master cylinder 1
41-310-14 Clevis, Threaded push rod 1
41-310-10 Pedal, Brake 1
80-410-20 Flanged bushing, Brake pedal 2
85-295-00 Spring, Brake pedal 1

BRAKES, FRONT AXLE

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 list) 2
6 99-588-01 Bleeder adaptor 2
7 99-588-00 Bleeder valve 2
8 See rebuild kit Brake pad, Inner 2
9 See rebuild kit Brake pad, Outer 2
Not Shown
41-886-00 Plug, 1/8 Pipe, Hex Socket 2
88-069-82 Nut, Brake bolt 4
41-348-61 Brake rebuild kit, 1 axle front or rear,
includes #3, 4, 8, 9, and brake bolt nuts
* - Not available separately, order complete caliper assembly
Page 96 MB-440-10
BRAKES, REAR AXLE

1 41-347-15 Parking Brake Actuator 2
2 41-347-00 Backing Plate 2
3 41-347-36 Spider, w/Wheel Cylinder 2
4 85-411-10 Torsion Spring 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 Spring 2
11 41-347-34 Parking Brake Actuator-Retaining Clip. DO NOT REUSE! 4
12 41-347-35 Spring Clip 4

DECALS
Page 98 MB-440-10
Decals
1 94-301-41 DOT 3 BRAKE FLUID 1
2 94-301-42 ARMS/LEGS 2
3 94-301-65 BIGFOOT 1
4 94-306-01 FUEL/OIL CHECK 1
5 94-306-02 SPEED WARNING 1
6 94-306-03 HEAT WARNING 1
7 94-306-04 ROTATING PARTS WARNING 1
8 94-306-05 OIL TYPE 1
9 94-306-06 DIPSTICK WARNING 1
10 94-306-07 PUSH TO SHIFT 1
11 94-306-08 SPRING STEEL 1
12 94-306-09 SHIFT INSTRUCTION 1
13 94-306-12 CHOKE 1
14 94-309-00 PARK BRAKE WARNING 1
15 94-313-20IC SAFETY WARNING 1
16 94-319-01 BATTERY DISCONNECT 1
17 94-320-10 CARGO BOX 1
18 94-373-73-17 2017 EMISSIONS 1
19 94-384-04 NOT A MOTOR VEHICLE 1
20 94-384-19 LEAVING VEHICLE 1
21 94-384-47 BATTERY WARNING 1
22 94-384-48 PINCH POINT 1
23 94-384-61 OPERATOR PRESENCE SWITCH 1
24 94-384-62 OPERATOR PRESENCE SWITCH 1

ELECTRICAL, MISCELLANEOUS
Page 100 MB-440-10

Electrical
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 Clip, push mount
5 96-650-01 Wire Harness Clip, stick on
6 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID
96-630-00 (not shown Clamp, Rubber Lined 5/8 ID
96-630-50 (not shown Clamp, Rubber Lined 5/8 ID (.265 mounting hole)
96-631-00 (not shown Clamp, Rubber Lined 3/4 ID
96-631-10 (shown) Clamp, Rubber Lined 1.0 ID
96-631-15 (not shown Clamp, Rubber Lined 1-1/2 ID
98-599-15 Bushing, Plastic, 1-3/4” hole
98-599-17 Bushing, Plastic, 2“ hole
98-603-00 Rubber grommet, 5/8 hole
77-054-10 Battery 1
50-243-11 Rod, Hold down 2
00-661-08 Hold down 1
75-146-41 Cable, Positive 1
75-146-46 Cable, Negative 1
73-004-20 Horn 1
71-122-00 Horn switch 1
73-005-15 Reverse beeper 1
79-840-20 Circuit breaker, 20A 1
Harnesses
- 75-154-42 Harness 1

ENGINE / EXHAUST

- 67-000-53-16 Engine Assembly, 2016 year model (S/N 204278 only) 0 or 1
- 67-000-53-17 Engine Assembly, 2017 year model (after S/N 204278) 0 or 1
- 67-000-53-18 Engine Assembly, 2017 year model (after S/N 209616) 0 or 1
- KLR-1205001S Filter, Oil 1
- KLR-4708303S Filter, Air (paper) 1
- KLR-2408302S Filter, Air (foam) 1
- KLR-1213202S Spark Plug 2
- KLR-2509927S Switch, Oil Pressure 1
66-400-05 Muffler 1
66-400-06 Support bracket 1
00-640-57 Heat shield, Muffler 1
00-640-56 Mounting bracket 1
00-611-00 Exhaust pipe 1
41-998-11 Pipe, Oil drain extension 1
41-998-12 Elbow, Oil drain extension 1
KLR-4723704 U-bolt, pipe to muffler 1
98-080-12 Insulation, Stick on 1
00-640-50 Air dam, Air inlet, Rubber, 1
FRAME AND BODY, MISCELLANEOUS

- 00-640-49 Cowl (specify color) 1
- 01-500-28 Seat Frame (specify color) 1
- 01-500-68 Tray, Cowl 1
- 00-610-37 Cover, Shifter 1
- 00-640-60 Mounting Plate 1
- 96-000-15 Cargo Hold Down 4
- 00-500-21 Spacer 4
- 94-035-01 Trim, Fuel Access Hole Per Foot
- 98-105-00 Cup Holder 2
- 98-017-80 Mat, Rubber, brake/throttle pedal stop 1
Page 102 MB-440-10

FRAME AND BODY (CABS)
Economy Cab
- 00-500-15 Cab (unpainted) 1
- 90-852-30 Windshield 1
98-310-00 Gasket per foot
- 90-850-10 Rear window 1
- 90-924-90 Door Frame, Left 1
- 90-924-91 Door, Frame Right 1
- 90-923-30 Door cover, Left 1
- 90-923-31 Door Cover, Right 1
- 90-931-05 Rain gutter per foot
- 97-315-51 Latch 2
- 97-315-53 Handle, Outer 2
- 97-315-54 Handle, Inner 2
Midrange Cab
- 91-013-74 Cab (unpainted) 1
- 90-852-30 Windshield 1
- 98-310-00 Gasket per foot
- 90-850-10 Rear window 1
- 98-310-00 Gasket
Metal Doors
- 91-013-16 Door assembly, Left 1
- 90-853-13 Window 1
91-013-72 Latch 1
- 98-454-00 Gasket per foot
- 91-013-33 Door Assembly, Right 1
90-853-14 Window 1
91-013-72 Latch 1
- 00-020-22 Door restraint 2
Soft Doors
- 90-924-90 Door Frame, Left 1
- 90-924-91 Door, Frame Right 1
- 90-923-30 Door cover, Left 1
- 90-923-31 Door Cover, Right 1
- 97-315-51 Latch 2
- 97-315-53 Handle, Outer 2
- 97-315-54 Handle, Inner 2

FRAME, DECK
Deck
- 90-472-03 Deckboard, Rear 1
- 90-471-02 Deckboard, Front 1
- 90-441-37 Steel cover, Black, Rear 1
- 90-441-36 Steel cover, Black, Front 1
- 88-607-09 Rivet 16
- 05-210-90 Heat shield, Rear deck 1
- 05-210-94 Heat shield, Front deck 1
- 88-837-06 Screw, Heat shield 24
- 97-211-20 U-Nut (on frame) 4
- 88-065-14 1/4 x 1-1/2 screw 4
- 88-068-61 Washer 4
FUEL SYSTEM
Fuel System
66-001-05 Carbon canister 1
00-610-66 Holder, Carbon canister 1
05-212-02 Fuel tank (includes cap & sender) 1
05-212-03 Cap, Fuel tank 1
74-009-03 Sender, Fuel level 1
00-640-62 Angle, Tank restraint 1
00-640-66 Strap. Fuel tank 2
66-001-06 Valve, Slosh 1
98-511-00 Hose, 3/16 7’
98-512-00 Hose, 5/16 3
00-410-23 Bracket, Fuel hose mount (on transmission)
Page 104 MB-440-10

HITCHES
Mounting Hardware
97-811-00 1-7/8 inch Ball
97-821-00 2-inch Ball
88-140-14 1/2NC x 1-1/2 Hex bolt 4
88-149-80 1/2NC Hex nut 4
88-148-62 1/2 Split lock washer 4

INSTRUMENT PANEL
Instrument Panel
1 71-120-01 Switch, Ignition 1
71-120-80 Key (PK556)
2 74-009-20 Fuel Gauge 1
3 74-000-00 Hour Meter 1
4 71-039-11 Switch, Lights 1
5 71-039-11 Switch, Wiper 0 or 1
6 71-039-11 Switch, Strobe Light 0 or 1
7 72-018-21 Panel Light 1
8 88-607-06 Plastic rivet 6
9 94-305-36 Panel 1
10 94-305-37 Backing plate 1
- 71-039-21 Plug for switch hole
LIGHTS
72-023-13 Headlight 2
72-022-51 Mounting ring 2
72-022-56 Connector 2
72-022-07 Taillight 2
72-022-54 Connector, 3-wire 2
72-022-55 Connector, 1-wire 2
72-025-51 Gasket 2
72-005-27 Side Running Light, Red 2
72-005-26 Side Running Light, Small Amber 2
72-005-08 Turn Signal Light, Front (Large Amber) 2
72-005-09 Mounting Ring 2
72-022-53 Connector, Side lights 4
01-504-24 Spacer, Marker lights 4
Page 106 MB-440-10

LINKAGE, PARK BRAKE
51-340-30 Handle, park Brake 1
96-813-00 Cable, Park Brake (handle to equalizer) 1
96-826-12 Cable, Park Brake (equalizer to brake) 2
96-826-09 Cable lock 2
88-847-08 Retaining ring 2
85-126-00 Spring, Compression, 3 inch 2
96-772-00 Clevis pin, 3/8 x 1-1/8 1
96-773-00 Clevis pin, 5/16 x 1 1
00-640-59 Link, Handle to cable 1
96-754-00 Clevis, Park brake cable (transmission end) 2
96-773-00 Clevis pin 2
88-527-11 Cotter pin 2
00-640-55 Equalizer 1
85-209-09 Spring, Equalizer support 2
85-233-00 Spring, Cable guide (by handle) 1
06-210-03 Spring clip 1
LINKAGE, SHIFT
96-853-10 Shifter 1
71-130-01 Switch, Neutral Start 1
71-130-01 Switch, Reverse 1
00-610-35 Bracket, Neutral start switch 1
00-610-36 Bracket, Reverse switch 1
96-851-00 Cable 1
00-610-25 Spring plate, Shift Cable (transmission) 1
96-852-00 Ball Nut, Cable End 1
00-610-90 Lever, Transmission Shift 1
88-087-06 Set screw 1
00-610-84 Bracket, Spring plate mounting 1
00-610-83 Bottom plate 1

LINKAGE, THROTTLE

1 62-033-25 Mounting bracket 1
2 85-352-34 Spring, Pedal Torsion 1
62-033-18 Bushing 1
3 96-860-01 Cable, Choke 1
4 00-640-61 Pedal, Throttle 1
32-215-50 Bushing 2
5 85-209-09 Spring, Pedal Extension 1
6 96-872-08 Cable. Throttle 1
7 88-060-11 Bolt 2
88-069-81 Nut 2
88-068-61 Washer 6
8 96-871-01 Clamp, Cable 1
9 01-661-35 Bracket, Cable Spring 1
10 88-517-09 Pin, Cotter 2
88-048-62 Washer 2
11 00-661-11 Bracket, Cable Mount 1
12 85-209-09 Spring, Cable 1
Not Shown 97-211-20 U-Nut -
88-840-08 Circlip, Pedal Shaft 1
62-033-06 Spacer, Pedal Shaft 1
62-037-06 Arm 1
Page 108 MB-440-10

SEATS
Seats
1 90-160-96 Seat assembly 2
2 90-160-97 Hip restraint, Driver 1
3 90-160-98 Hip restraint, Passenger 1
4 88-088-61 Flat washer 8
5 88-089-81 Lock nut 8
- 94-430-07 Thread Lock (50ml) -
- 90-160-95 Operator presence switch (driver seat only) 1

STEERING LINKAGE
Page 110 MB-440-10

Steering Linkage
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 Steering Bushing 2
5 89-080035K-C-00 Bolt 1
89-0800000-A-07 M8, Lock Washer,Split Ring 1
89-080000K-C-04 M8x1.25 Metal Locknut, 10.9 1
6 00-500-03 Steering Column 1
7 88-101-10 5/16 X 1 Nc Hex Head Cap Screw Grade 2 4
88-402-96 Flat Washer 4
88-109-81 Nut 4
8 18-058-95 90 Degree Steering Gearbox 1
9 88-100-14 3/8 X 1-1/2 NC Hex Head Screw Grade 2 3
10 18-058-94 Steering Sleeve (includes 11) 1
11 * Steering Sleeve Boot
12 89-080035K-C-00 M8X1.25X35,Hex Head Bolt,10.9 1
89-0800000-A-07 M8, Lock Washer,Split Ring 1
89-080000K-C-04 M8X1.25 Metal Locknut, 10.9 1
13 86-501-07 Steering Rack, Standard Model (includes 14 and 15) 1
14 * Tie Rod -
15 PKIT-00060 Rod End -
16 See front Axle 1/4X4-1/2 NC HEX Head Cap Screw, Grade 8 4
17 See Front Axle 1/4 NC Hex Lock Nut, GR 8 4
See Front Axle 1/4 FLW Thru-Hard, GR 8 8
18 88-406-60 M8 Flat Washer 1
19 89-080000K-C-04 M8 x 1.25 Metal Locknut, 10.9 1
20 89-080-20 M8 Shoulder Screw, 20MM 1

SUSPENSION, FRONT
Front Suspension
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 6
5 - - -
6 85-498-00T Leaf Spring 2
7 14-010-07 Spring plate 2
Not Shown
98-753-15 Bump Stop 2
86-602-01 Shock (optional) 2
Page 112 MB-440-10

SUSPENSION, REAR

1 86-602-01 Shock 2
2 85-142-00 Spring 4
3 86-521-98 Rod end, LH 1
4 86-521-99 Rod end, RH 1
5 86-523-99 Rod end (front swing arm mount) 1
6 88-120-17 Bolt 2
7 88-129-81 Nut 4
8 88-121-19 Bolt 2
9 88-121-19 Bolt 1
10 88-188-61 Flat washer 1
11 17-108-00 Spacer 1
12 88-189-81 Lock nut 1
13 88-121-19 Bolt 1
14 88-220-22 Bolt, 3/4 x 3.5 1
15 88-229-81 Lock nut 1
16 16-406-00 Spacer 2
17 88-229-62 Lock washer 1
18 88-239-80 Hex nut 1
19 00-640-64 Swing arm 1
20 86-510-00 Clamp 2
21 41-402-00 Panhard Bar 1

TRANSMISSION, CVT
30-181-00 Pulley, Engine 1
97-030-20 Key 1
88-111-22 Bolt 1
88-128-62 Lock washer 1
88-159-61 Flat washer, Heavy 1
30-182-00 Pulley, Drive axle 1
97-030-10 Key 1
30-180-51 Ramp shoe (plastic) 3
98-601-51 Flat washer, 1/2 1
88-148-62 Lock washer 1
30-684-00 Belt 1
02-610-78 Spacer, Engine pulley (plastic) 1
16-409-20 Spacer, Engine pulley 0.625 x 1 ID 1
Page 114 MB-440-10

WHEELS AND TIRES
- 13-742-13 Tire/Wheel assembly, 5.70 x 8 LRC 4
- 10-083-00 Tire, 5.70 x 8 LRC
- 11-040-00 Tube
- 97-236-00 Wheel Nut 20
- 13-989-00 Valve stem, tubeless tire only

Notes:
Page 116 MB-440-10

WARNING
Operating, servicing and maintaining a passenger vehicle or off-
highway motor vehicle can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth defects
or other reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle in a well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle.
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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Service and Replacement

The Best Way

Dealer Purchased From: .

Your satisfaction is out #1 goal. If you have questions or concerns

Originally Published 5/1/2017

Visit our Web site: www.taylor-dunn.com

Personnel performing service and repair shall have

Represents a corrosive Parking brake ON.

Serial number tag on the main frame

WEB SITE REGISTRATION

• Read the operator’s manual before operating this vehicle.

The following items shall be inspected every time before

Assembly Component Capacity

Engine Oil type

Ambient Temperature Viscosity

Front Axle / Steering

HAZARDOUS WASTE DISPOSAL

Note: Thrust bearings should be packed with grease before assembly.

Tire Size Weight NEW Weight USED

NEW: Weight = 16.931 / Radius

3-Wheel vehicle front fork shown for illustration

NOTICE Note: For a front disc brake option you must

INSPECT BALL JOINTS REPLACE BALL JOINT

Typical Pickle Fork

FRONT WHEEL ALIGNMENT

Typical Ball Joint Separator

REPLACE UPPER STEERING SHAFT

Only basic engine maintenance information is

Oil type and capacities

Ambient Temperature Viscosity

The air filter assembly consists of a foam pre-cleaner

6: Remove all of the case bolts.

Detent Ball, Spring and Screw

Showing Intermediate Shaft

Note: The ramp shoes should be inspected any time

WARNING Do not drive the vehicle if any worn or broken part is

Brake Adjuster Assembly

This procedure assumes that the component has been

1: Pull the pistons out of the brake body.

BLEED SYSTEM FLUSH SYSTEM

SERVICE LIMITS HARDWARE TORQUE

The choke cable is adjusted at the engine controls by

1: Loosen the ball joint jam nut and the cable

REPAIR THE TIRE (PNEUMATIC)

It is recommended to repair a tire with a combination

This section is one section of a complete service

Disconnect the battery before cleaning. NOTICE

1: Turn the engine off and set the park brake.

DIAGRAM PART NUMBERS

Kill Light Switch

Left Rear Marker Right Rear Marker Engine MIL

Hex Head Bolts and Screws

SAE Grade 8 SAE Grade 9

Other types of bolts and screws

Truss Head, Grade 2 Carriage Bolt, Grade 2

S.A.E. Grade 5 S.A.E. Grade 8

5.8 8.8 10.9 12.9

Hex Lock Nuts (stover)

S.A.E. Grade B S.A.E. Grade C

Other nuts used by Taylor-Dunn® should be treated as S.A.E. grade A

Imperial (inch), Foot Pounds Imperial (inch), Newton Meters

Metric, Newton Meters Metric, Foot Pounds

Note: Your vehicle may have been ordered with

TAYLOR-DUNN WEB SITE INFORMATION