®
Models Inlcuded:
B0-012-54
(equipped with removable rear hub and
drum brake)
The Best Way
To Go
About Your
Business
SUPPLEMENTARY MANUAL
M7-010-05
Repair and Replacement Parts Manual
Revision: A
Serial number Starting: 155516
COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn® Mfg. All rights reserved.
No part of this work may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying and recording, or any information storage or retrieval
system without prior written permission of Taylor-Dunn® Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn® Mfg., 2114 W. Ball Road, Anaheim, CA 92804
TAYLOR-DUNN SERVICE CENTER
For more information about this and other Taylor-Dunn® manuals, please write Taylor-Dunn®:
Taylor-Dunn® Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
SC1-00 Stock Chaser
B2-48 With Stake Side Dump Bed Option
E4-55 Sit Down Tow Tractor
C4-25 Sit Down Tow Tractor
Table of Contents
Contents
Introduction ............................................................ 1
About This Manual ....................................................................
Who Should Read This Manual ...............................................
Responsibilities ........................................................................
How To Use This Manual ..........................................................
2
3
3
4
Conventions ...................................................................................................................... 5
Section 1 ................................................................. 1
Safety Rules and Operating Instructions ............................ 1
Section 2 ................................................................. 1
Inspect the Service Brake ........................................................ 2
Brake Shoes ..................................................................................................................... 2
Brake Drum ...................................................................................................................... 2
Inspect the Parking brake ........................................................ 3
Park Brake Handle ........................................................................................................... 3
Band Park Brake Lining and Drum .................................................................................. 4
Adjust the Service Brakes ........................................................ 5
Adjust the Parking Brake ......................................................... 6
Primary Adjustment .......................................................................................................... 6
Rear Hub Removal .................................................................... 7
Removing and Installing the Rear Axles ................................. 8
Replace the Rear Brake Shoes ................................................ 10
Mechanical Drum Brakes ................................................................................................. 10
Replace the Wheel Cylinder ..................................................... 12
Drum Brake Hydraulic Spider (rear brakes) .................................................................... 12
Illustrated Parts ...................................................... 1
Rear Axle .......................................................... 2
Rear Brakes ....................................................... 4
Master Cylinder ................................................. 6
Brake Lines ....................................................... 6
Brake linkage (parking brake) ............................ 8
TAYLOR -DUNN
Section 1
Safety Rules and Operating Instructions
This supplementary manual is indended to be used in combination with
the vehicle standard service manual.
Refer to the vehicle standard service manual for information on the Safety
Rules and Operating Instructions for your vehicle.
B2-10 Ambulance
B2-48 With Dump Bed Option
B2-48 with Steel Cab, Foldaway
4-Passenger Seat and Stake Sides
P2-50 30,000 Pound Tow Tractor
ET1-50 Full Size Truck
ET 3000
Section 2
Repair
Contents
Inspect the Service Brake ............................. 2
Brake Shoes ............................................................ 2
Brake Drum .............................................................. 2
Inspect the Parking brake ............................. 3
Park Brake Handle .................................................. 3
Band Park Brake Lining and Drum ......................... 4
Adjust the Service Brakes ............................ 5
Adjust the Parking Brake .............................. 6
Primary Adjustment ................................................. 6
Rear Hub Removal ........................................ 7
Removing and Installing the Rear Axles ...... 8
Replace the Rear Brake Shoes ..................... 10
Mechanical Drum Brakes ........................................ 10
Replace the Wheel Cylinder .......................... 12
Drum Brake Hydraulic Spider (rear brakes) ........... 12
SECTION 2
INSPECT THE SERVICE BRAKE
Brake Shoes
Current Taylor-Dunn® brakes are asbestos free. However, there is the
possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to Appendix C in
the vehicles standard manual for recommended handling precautions.
NOTE: The wheel and brake drum must be removed to accurately measure
the brake shoes. Refer to Tires and Wheels section in the
vehicles standard manual for information on removing the wheel.
Measure the brake shoe lining at the thinnest point on the shoe.
If this is 1/16-inch or less then the brake shoe must be replaced.
NOTE: If this is a riveted lining, then the
measurement must be to the top of the
rivets.
It is recommended to replace the left and right side brake shoes
as a set.
Brake Drum
Current Taylor-Dunn® brakes are asbestos free. However, there is the
possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to Appendix C in
the vehicles standard manual for recommended handling precautions.
NOTE: The wheel and brake drum must be removed to accurately measure
the brake drum. Refer to Tires and Wheels section in the vehicles
standard manual for information on removing the wheel.
The service limit for the inside diameter of the brake drum is 7.060 inches.
If the brake drum is grooved or worn beyond the service limit then the brake drum must be replaced.
Measure the inside diameter of the brake drum in 3-places.
If the difference between any of the measurements exceeds 0.010-inches then the brake drum must be
replaced.
Do not use a brake drum that
is worn beyond its service
limits. A drum worn beyond its
service limits could fail and
cause loss of brakes resulting
in severe bodily injury and/or
property damage.
Section 2
Page-2
SECTION 2
INSPECT THE PARKING BRAKE
Park Brake Handle
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
6. Release the park brake.
7. Inspect the brake shoes. Refer to Brake Band Lining and Drum section to inspect the
brake shoes.
8. Inspect all brake cables and linkages for any
signs of damage or missing cotter pins.
9. Inspect the park brake ratchet for any signs of
damage or wear.
10. Set the park brake.
11. Reconnect the main positive and negative cables
at the batteries.
12. Remove the blocks from the wheels.
If any sign of damage or wear is found on the park brake ratchet,
cables, or linkages then they must be repaired or replaced immediately.
Failure to repair or replace any damaged component could result in
failure of the park brake causing severe bodily injury and/or property
damage.
Section 2
Page-3
SECTION 2
Band Park Brake Lining and Drum
Current Taylor-Dunn® brakes are asbestos free. However, there is the
possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to Appendix C for
recommended handling precautions.
The band parking brake is located on the front of the drive chain case housing, it must be removed to
accurately measure the lining thickness. Refer to Replace the Parking Brake Lining section in the
vehicles standard manual for information on removing the band park brake.
1. Measure the thickness of the brake lining at its
thinnest point. If it is 1/16-inch or less, then the
brake band must be replaced.
2. Measure the run out of the brake drum. If it is
more than 0.010-inches then it must be machined
or replaced. Do not machine the brake drum
beyond its service limits (see below).
3. Measure the diameter of the brake drum. If it is
less than 5.85-inches then the brake drum must
be replaced.
Section 2
Page-4
SECTION 2
ADJUST THE SERVICE BRAKES
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
6. Raise the wheel off of the ground and support with jack stands.
Always use a lifting strap, hoist, and jack stands, of adequate capacity
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury and/or
property damage..
7. Release the park brake.
8. Remove the tire/wheel assembly.
NOTE: Refer to Tires and Wheels section
in the vehicles standard manual for
information on removing the wheel.
9. Align the adjusting access slot in the brake drum
with the adjusting star wheel at the bottom of the
brake.
10. While rotating the brake drum back and forth,
rotate the brake adjuster star wheel until the
brake is tight enough so that brake drum cannot
be rotated.
11. Back off the star wheel just enough so that the
brake drum rotates freely.
Brake drum shown with the access slot
aligned with the adjusting star wheel.
12. Install the tire/wheel assembly.
13. Repeat this procedure for the opposite side brake.
14. Set the park brake.
15. Reconnect the main positive and negative cables at the batteries.
16. Remove blocks from behind the wheels.
17. Release the park brake and test drive the vehicle.
Section 2
Page-5
SECTION 2
ADJUST THE PARKING BRAKE
Do not use this procedure when installing a new brake band. Refer to Replace the Parking Brake
Lining section in the vehicles standard manual for information on adjusting a new brake lining.
There are two adjustments available:
1. Primary.
2. Service only. This adjustment is only performed when the parking brake system is disassembled.
Do not use this adjustment at any other time. Refer to Replace the Parking Brake Lining
section in the vehicles standard manual for information on this adjustment.
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
Primary Adjustment
6. Release the park brake.
7. Loosen the brake band bolt jam nut.
8. Tighten the brake band bolt until the brake starts
to drag and then back off two turns.
9. Tighten the brake band bolt jam nut.
10. Set the park brake.
11. Reconnect the main positive and negative cables
at the batteries.
12. Remove the blocks from the wheels.
13. Release the park brake and test drive the vehicle.
Section 2
Page-6
SECTION 2
REAR HUB REMOVAL
NOTE: The torque specification for the axle hub bolt is 275 ft-lbs. An impact
wrench will be required to remove the bolt.
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
6. Raise the wheel off of the ground.
Always use a lifting strap, hoist, and jack stands, of adequate capacity
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury.
7. Remove the tire/wheel assembly, Refer to Tires and Wheels section in the vehicles
standard manual for information regarding removing the tire/wheel assembly.
8. Remove the brake drum.
9. Remove the axle hub bolt and washer and remove the hub from the axle. Discard the bolt.
10. Install in reverse order.
a. Lightly grease the axle splines.
b. Use a new axle hub bolt.
c. Torque the axle hub bolt to 275 ft-lbs.
d. Refer to Tires and Wheels section in the vehicles standard manual for information regarding
installing the tire/wheel assembly.
The axle retaining plate bolts and the axle hub bolt have a pre-applied
thread locking compound. They are intended for one time use only. If
removed they must be replaced. Reusing the original bolts could cause
loss of brakes resulting in severe bodily injury and/or property damage.
Refer to section Rear Brakes in Illustrated Parts for the part number
of the bolts.
When using hardware with thread locking compounds, both the male
and female threads must be clean and free of contaminates (oil, grease,
etc.). Failure to ensure that all threads are clean may cause failure of
the hardware resulting in severe bodily injury and/or property damage.
11. Lower the wheel to the ground.
12. Reconnect the main positive and negative cables at the batteries.
13. Remove the blocks from behind the wheels.
14. Release the park brake and test drive the vehicle.
Section 2
Page-7
SECTION 2
REMOVING AND INSTALLING THE REAR AXLES
NOTE: This procedure does not require that the rear end or drive assembly
be removed from the vehicle.
Bearing retainer bolt
Bearing
Axle
Bearing retainer
Axle housing
Hub bolt
Washer
Hub
Spacer
Brake assembly
Brake
mounting bolt
Locking tab
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
6. If required, drain the oil from the 3rd member.
7. Raise the rear of the vehicle and support with jack stands.
Always use a lifting strap, hoist, and jack stands, of adequate capacity
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury.
8. Release the park brake.
Section 2
Page-8
SECTION 2
9. Remove the tire and wheel assembly. Refer to Tires and Wheels section in the vehicles
standard manual for information regarding removing the tire and wheel assembly.
10. Remove the axle hub bolt and hub. Discard the bolt, it must be replaced when removed.
11. Remove the four bolts holding the brake assembly to the axle and secure the brake assembly
out of the way. do not let it hang by the brake hose. Discard the bolt locking tabs.
12. Remove the spacer.
13. Remove the four bolts holding the bearing retainer to the axle housing and discard. These
bolts must be replaced.
14. Remove the axle.
15. Install in reverse order.
a. Lubricate the bearing o-ring.
b. Use new locking tabs for the brake bolts.
c. Torque the brake mounting bolts to 35 ft-lbs. Bend the locking tab against the head of the bolt.
d. Use new bolts for the axle bearing retainer and a new bolt for the axle hub.
e. Torque the hub bolt to 275 ft-lbs.
The axle retaining plate bolts and the axle hub bolt have a pre-applied
thread locking compound. They are intended for one time use only. If
removed they must be replaced. Reusing the original bolts could cause
loss of brakes resulting in severe bodily injury and/or property damage.
Refer to section Rear Brakes in Illustrated Parts for the part number
of the bolts.
When using hardware with thread locking compounds, both the male
and female threads must be clean and free of contaminates (oil, grease,
etc.). Failure to ensure that all threads are clean may cause failure of
the hardware resulting in severe bodily injury and/or property damage.
16. Lower the vehicle.
17. Set the park brake.
18. Reconnect the main positive and negative cables at the batteries.
19. Remove the blocks from behind the wheels.
20. Release the park brake and test drive the vehicle.
Section 2
Page-9
SECTION 2
REPLACE THE REAR BRAKE SHOES
Mechanical Drum Brakes
Current Taylor-Dunn® brakes are asbestos free. However, there is the
possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to appendix C in
the vehicles standard manual for recommended handling precautions.
NOTE: It is recommended that both the left and right brake shoes be
replaced as a set.
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteries.
6. Release the park brake.
7. Raise the rear wheels off of the ground and support with jack stands.
Always use a lifting strap, hoist, and jack stands, of adequate capacity
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury.
8. Remove the tire/wheel assembly. Refer to Tires and Wheels section in the vehicles
standard manual for information on removing the wheel.
9. Remove and inspect the brake drum. Refer to Inspect the Service Brake section for
information regarding inspecting the brake drum.
10. Remove the retracting springs and torsion springs from the brake shoes.
Torsion springs
Retracting spring
Section 2
Page-10
SECTION 2
11. Remove the brake shoes and brake adjustor
assembly from the backing plate.
12. Thoroughly clean and inspect the adjustor
assembly. Replace parts as required.
13. Apply a very light coating of high temperature
grease to the adjustor screw threads.
Brake Adjuster Assembly
14. Install in reverse order.
15. Repeat for the opposite side.
16. Adjust the brakes. See Adjust the Service Brakes section for information regarding
adjusting the brakes.
17. Set the park brake.
18. Reconnect the main positive and negative at the batteries.
19. Lower the wheels to the ground.
20. Remove the blocks from behind the wheels.
21. Release the park brake and test drive the vehicle.
Section 2
Page-11
SECTION 2
REPLACE THE WHEEL CYLINDER
Drum Brake Hydraulic Spider (rear brakes)
Current Taylor-Dunn® brakes are asbestos free. However, there is the
possibility that the original brakes were replaced with aftermarket
parts containing asbestos. Since this possibility exists, all brake parts
should be handled as if they contain asbestos. Refer to appendix C in
the vehicles standard manual for recommended handling precautions.
Do not ingest brake fluid or allow contact with skin or eyes. Always
wear protective clothing and a face shield when working with or
around brake fluid.
SKIN CONTACT
Flush area immediately with water for several minutes. If a rash or
skin irritation develops, get medical attention immediately.
EYE CONTACT
Immediately flush the eye with water for 15 minutes and call
physician.
INGESTION
Get medical attention immediately.
1. Make sure the key-switch is in the “OFF” position, then remove the
key.
2. Place the Shift lever in the neutral position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the battery.
6. Release the park brake.
7. Raise the wheel off of the ground and support with jack stands.
Always use a lifting strap, hoist, and jack stands, of adequate capacity
to lift and support the vehicle. Failure to use lifting and support devices
of rated load capacity may result in severe bodily injury.
8. Remove the tire/wheel assembly. Refer to Tires and Wheels section in the vehicles
standard manual for information on removing the tire and wheel assembly.
9. Remove the brake drum and hub. Refer to Rear Hub Removal section for information
Section 2
Page-12
SECTION 2
regarding removing the rear hub.
10. Disconnect the hydraulic brake line from the spider.
11. Remove the brake shoes. Refer to Replace Rear Brake Shoes section for information
regarding removing the brake shoes.
12. Remove the four bolts holding the spider to the bearing retainer and discard.
13. Install the new spider.
14. Reassemble in reverse order using new spider bolts.
The axle retaining plate bolts and the axle hub bolt have a pre-applied
thread locking compound. They are intended for one time use only. If
removed they must be replaced. Reusing the original bolts could cause
loss of brakes resulting in severe bodily injury and/or property damage.
Refer to section Rear Brakes in Illustrated Parts for the part number
of the bolts.
15. Bleed the brakes. Refer to Bleed the Brakes section in the vehicles standard manual for
information regarding bleeding the brakes.
16. Set the park brake.
17. Reconnect the main positive and negative cables at the batteries.
18. Lower the wheel to the ground.
19. Remove the blocks from behind the wheels.
20. Release the park brake and test drive the vehicle.
Hydraulic spider shown in the brake assembly
Section 2
Page-13
TAYLOR -DUNN
Illustrated Parts
TABLE OF CONTENTS
Rear Axle .................................................... 2
Rear Brakes ................................................ 4
Master Cylinder ........................................... 6
Brake Lines ................................................. 6
Brake linkage (parking brake) ...................... 8
Illustrated Parts
Rear Axle
12
4
8
13
1
11
2
3
5
10
9
6
7
Parts
Page 2
Illustrated Parts
Rear Axle
ITEM #
PART #
DESCRIPTION
QTY
1
41-290-24
Bearing retainer
2
2
88-268-30
7/8-14 x 1-1/2 Hex bolt, grade 5 with locking compound
2
3
88-268-63
Flat washer, special
2
4
80-505-20
Axle bearing
2
5
41-172-21
Hub
2
6
K4N-BO-001
5/16NF x 1 Hex bolt, grade L9
8
7
41-350-90
Locking tab
4
41-154-20
Axle (left)
1
41-154-20
Axle (right)
1
9
See Rear Brakes
Brake assembly
10
41-290-22
Spacer
2
11
41-299-50
Axle housing
1
12
96-327-10
3/8NF x 3/4 Hex bolt, grade 5 with locking compound
8
13
96-329-10
Wheel stud
10
8
Parts
Page 3
Illustrated Parts
Rear Brakes
2
3
5
4
7
1
9
8
6
Parts
Page 4
Illustrated Parts
Rear Brake
ITEM #
1
PART #
DESCRIPTION
K1-159-45
Complete brake assembly (left)
QTY
1
K1-159-46
Complete brake assembly (right)
1
85-411-15
Torsion spring
2
2
41-347-00
Backing plate
2
3
*
Spider
2
4
85-411-00
Torsion spring
2
5
41-635-00
Brake shoe set (1 wheel)
2
6
85-215-00
Extension spring
2
7
41-347-33
Adjustment body
2
8
41-347-31
Star wheel adjustor
2
9
41-347-30
Socket
2
Not shown
41-511-00
Brake drum
2
* - Not available at time of printing
Parts
Page 5
Illustrated Parts
Master Cylinder
Brake Lines
Parts
Page 6
Illustrated Parts
Master Cylinder
ITEM #
PART #
DESCRIPTION
QTY
1
88-080-14
5/16NC x 1-1/2 Hex bolt
2
2
99-511-20
Master cylinder
1
3
99-511-53
Cap
1
4
88-088-61
F5/16 SAE lat washer
4
5
88-089-81
5/16NC Lock nut
2
99-510-51
Master cylinder boot
1
50-009-00
Push rod
1
17-104-00
Collar
1
88-119-80
3/8NF Hex nut
1
96-762-00
Clevis
1
96-772-00
Clevsi pin
1
88-527-11
1/8 x 1 Cotter pin
1
85-250-00
Return spring
1
Not shown
Brake Lines
ITEM #
PART #
DESCRIPTION
1
99-559-00*
T-fitting
2
2
99-600-10*
Bridge
1
3
See Master Cylinder
Master cylinder
4
99-648-54
Rear brake line
1
5
99-575-32
3/16T to M10-1.0 Flare adaptor
2
6
99-648-55
Front brake line
1
99-580-00
Rear brake hose
2
99-576-00
Clip, brake hose
2
99-648-56
Brake line from Brake switch to rear t-fitting
1
99-591-00
T-fitting for brake switch
1
Not shown
QTY
71-110-00
Brake switch
1
99-604-56
Brake line, right rear
1
99-604-57
Brake line, left rear
1
* - No longer used after serial #160128
Illustrated Parts
Brake linkage (parking brake)
Illustration is not available
Parking Brake Linkage
ITEM #
PART #
DESCRIPTION
QTY
51-344-80
Park brake handle
1
K4C-000-18
Adjustable cable assembly, 70-1/2 - 72 inches
1
Parts
Page 8
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Mailing Address:
P.O. Box 4240
Anaheim, California 92803
Visit our Website:
www.taylor-dunn.com