Taylor-Dunn SC-100-24 Service And Replacement Parts Manual
  1. Manuals
  2. Brands
  3. Taylor-Dunn Manuals
  4. Utility Vehicle
  5. SC-100-24
  6. Service and replacement parts manual

Taylor-Dunn SC-100-24 Service And Replacement Parts Manual

Hide thumbs Also See for SC-100-24:
Table of Contents

Advertisement

Quick Links

T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
H
Service and Replacement
Parts Manual
Model Numbers:
SC-100-24 (SC 1-00), 24-volt system
SC-100-36 (SC 1-00), 36-volt system
SC-100-48 (SC 1-00), 48-volt system
Ending Serial Number: See Introduction Chapter
MANUAL MA-100-03
Starting Serial Number: 191320

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SC-100-24 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Taylor-Dunn SC-100-24

Summary of Contents for Taylor-Dunn SC-100-24

  • Page 1 Service and Replacement Parts Manual MANUAL MA-100-03 Model Numbers: SC-100-24 (SC 1-00), 24-volt system SC-100-36 (SC 1-00), 36-volt system SC-100-48 (SC 1-00), 48-volt system T h e B e s t W a y T o G o A b o u t Y o u r...
  • Page 2 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 7/1/2013 Revision H, 1/16/2018, contents subject to change without notice ®...
  • Page 3 Taylor-Dunn Contact information Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.
  • Page 4 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.

  • Page 5: Table Of Contents

    Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Special Tool List ..........19 Lubrication ............23 Front Axle ............27 Transaxle - GT ..........31 Transaxle-SD ............41 Steering ............49 Brake Service ...........57 Motor ..............65 Motor Controller ..........71 Tires &...
  • Page 7 Table of Contents Introduction About this manual ...........8 Who Should Read This Manual ......8 Replacement Parts ..........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.

  • Page 8: Introduction

    To maintain peak performance, only 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.

  • Page 9: Introduction

    Introduction SC-100 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.

  • Page 10: Responsibilities

    The only personnel authorized to repair, modify, or Of the Service Personnel... adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician. Repairs made The service personnel are responsible for the service by unauthorized personnel may result in damage to and maintenance of the vehicle.

  • Page 11: How To Identify Your Vehicle

    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.
  • Page 12 Notes Introduction SC-100 Page-12 MA-100-03...
  • Page 13 Table of Contents Service/Maintenance Guidelines Read Me First-Maintenance Guidelines and General Instructions .........14 Vehicle Modifications ........15 Using Non-OEM Replacement Components: ..15 Resetting the Smart View Display ......15 Periodic Maintenance Checklist.....16 Preventative Maintenance Schedule .......17 WARNING This section is one section of a complete service manual.

  • Page 14: Service/Maintenance Guidelines

    BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Service/Maintenance Guidelines

    Taylor-Dunn vehicle. equal to that provided in the original equipment. Resetting the Smart View Display ANSI/ITSDF 56.9 –...

  • Page 16: Periodic Maintenance Checklist

    Service/Maintenance Guidelines SC-100 PERIODIC MAINTENANCE CHECKLIST Page 16 MA-100-03...

  • Page 17: Preventative Maintenance Schedule

    Service/Maintenance Guidelines SC-100 Preventative Maintenance Schedule MAINTENANCE HOUR MAINTENANCE TO BE PERFORMED LEVEL INTERVAL Inspect the brake system including the park brake and mounting hardware. Inspect the steering system, tighten the steering shaft coupler on the steering gear input shaft. Lubricate the vehicle, check for leaks.
  • Page 18 Notes Service/Maintenance Guidelines SC-100 Page 18 MA-100-03...
  • Page 19 Table of Contents Special Tool List Tool List ............18 Troubleshooting Guide ........20...
  • Page 20 Tool List SC-100 TOOL LIST The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness Tests the throttle module in or out of the...
  • Page 21 Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not rectangular harness connectors. Not available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. MA-100-03...
  • Page 22 Tool List SC-100 TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...
  • Page 23 Table of Contents Lubrication Lubrication and Fluids Chart ......24 Hazardous Waste Disposal ......25...
  • Page 24 Lubrication SC-100 LUBRICATION AND FLUIDS CHART Page 24 MA-100-03...
  • Page 25 Lubrication SC-100 Description Locations Lubricant Type Steering Shaft Pillow Blocks General Purpose Grease (not shown) Front Fork Spindle Bearings General Purpose Grease Steering Shaft Gears General Purpose Grease Throttle Module Push Rod General Purpose Grease Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease Steering Chains 30 wt Motor Oil...
  • Page 26 Notes Lubrication SC-100 Page 26 MA-100-03...
  • Page 27 Table of Contents Front Axle Inspect the Front Wheel Bearings ....26 Adjust Front Wheel Bearings ......26 Replace Front Wheel Bearings.......27 Front Axle Removal/Installation .....27 Hardware Torque ..........28 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.

  • Page 28: Front Axle

    Front Axle SC-100 INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. This section is one section of a complete service Failure to use lifting and support devices of rated load manual.

  • Page 29: Front Axle

    Front Axle SC-100 REPLACE FRONT WHEEL FRONT AXLE REMOVAL/ BEARINGS INSTALLATION WARNING WARNING Always use a lifting strap, hoist, and jack stands, of This section is one section of a complete service adequate capacity to lift and support the vehicle. manual.

  • Page 30: Hardware Torque

    Front Axle SC-100 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Notes Rod End Stud Nut 20-25 27.1-33.9 Rod End Jam Nut 20-25 27.1-33.9 Page 30 MA-100-03...

  • Page 31: Transaxle Identification

    Table of Contents Transaxle - GT Transaxle Identification........31 Check Oil Level ..........32 Change Oil ............32 WARNING Axle Shaft ............33 Remove ..............33 Install ...............33 Rear Hub, Rotor & Bearings ......34 This section is one section of a complete service Motor Removal ..........34 manual.

  • Page 32: Transaxle-Gt

    Transaxle-GT SC-100 CHECK OIL LEVEL CHANGE OIL 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.

  • Page 33: Transaxle-Sd

    Transaxle-GT SC-100 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only. If removed they must be replaced. warnings and instructions that are located in the Reusing the original bolts could cause loss of brakes Service Guidelines chapter.

  • Page 34: Rear Hub, Rotor & Bearings

    Transaxle-GT SC-100 REAR HUB, ROTOR & BEARINGS MOTOR REMOVAL Note: Some applications will require removing the WARNING drive assembly from the vehicle to remove the motor. Refer to Removing and Installing This section is one section of a complete service the Drive Assembly for information on manual.

  • Page 35: Primary Gear Case

    Transaxle-GT SC-100 PRIMARY GEAR CASE 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. 1: Disconnect the batteries. 2: Raise the rear of the vehicle and support with jack stands.

  • Page 36: Secondary Gear Case

    Transaxle-GT SC-100 SECONDARY GEAR CASE 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. Disassemble 1: Remove the transaxle assembly from the vehicle. 9: Remove the differential assembly.

  • Page 37: Assemble

    Transaxle-GT SC-100 Assemble 1: Temporarily install the pinion gear (hand tighten 13: Install the differential assembly. only). 14: Install the cover and all of the cover bolts. Torque 2: Install the carrier bearing race adjusting nuts into per torque listed in the Hardware Torque table at the housing and cover.

  • Page 38: Pinion Bearing Preload

    Transaxle-GT SC-100 PINION BEARING PRELOAD 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. Pinion Gear Shimming Instructions Note: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears.

  • Page 39: Hardware Torque

    Transaxle-GT SC-100 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut 154-169 209229 Drain plug 21-25 28.4-33 Gear case to 3rd member 18-20 24.4-27 3rd Member cover bolts 40-50 54-67.5 Axle hub bolt...
  • Page 40 Transaxle-GT Notes SC-100 Page 40 MA-100-03...

  • Page 41: Transaxle Identification

    Table of Contents Transaxle-SD Transaxle Identification........41 Check Oil Level ..........42 Change Oil ............42 Axle Shaft ............43 WARNING Remove ..............43 Install ...............43 Rear Hub, Rotor & Bearings ......44 This section is one section of a complete service Motor, Remove ..........44 manual. Before starting any procedure, read all Primary Reduction Gear Case ......45 warnings and instructions that are located in the 3rd Member ............47...

  • Page 42: Transaxle-Sd

    Transaxle modelnumber CHECK OIL LEVEL CHANGE OIL 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.

  • Page 43: Axle Shaft

    Transaxle modelnumber AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only. If removed they must be replaced. warnings and instructions that are located in the Reusing the original bolts could cause loss of brakes Service Guidelines chapter.

  • Page 44: Rear Hub, Rotor & Bearings

    Transaxle modelnumber REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications may require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and This section is one section of a complete service Installing the Drive Assembly for information manual.

  • Page 45: Primary Reduction Gear Case

    Transaxle modelnumber PRIMARY REDUCTION GEAR CASE 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.
  • Page 46 Transaxle modelnumber Page 46 manualnumber...

  • Page 47: 3Rd Member

    Transaxle modelnumber 3RD MEMBER 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.

  • Page 48: Hardware Torque

    Transaxle modelnumber HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut 275-300 392-428 Notes Drain plugs 9-14 13-20 Fill plugs 45-50 64-71 Gear case to 3rd member 45-55 64-78 Primary housing bolts...
  • Page 49 Table of Contents Steering Front End Alignment ........42 Wheel Alignment .............42 Center the Steering Wheel ........43 Inspect the Steering Components ....44 Steering Wheel and Bushings .........44 Steering Chain ............44 Pillow Blocks ............44 Fork Bearings ..........45 Adjust the Steering Shaft ........45 Replace Steering Wheel ........46 Front Fork ............47 Hardware Torque ..........47...

  • Page 50: Wheel Alignment

    Steering SC-100 FRONT END ALIGNMENT WARNING WARNING This section is one section of a complete service Do not drive the vehicle while the steering wheel or manual. Before starting any procedure, read all front wheels are tied in position. Driving the vehicle warnings and instructions that are located in the while the steering wheel or front wheels tied in Service Guidelines chapter.

  • Page 51: Center The Steering Wheel

    Steering SC-100 Center the Steering Wheel 1: Position the front fork in the straight ahead position and tie it off so that it cannot rotate. 2: Remove the steering chain access plate. 3: Remove the safety wire from the turn buckles and discard. 4: Loosen the turn buckles just enough to remove the chain from the lower sprocket 5: Center the steering wheel as shown in the illustration and tie it off so that it cannot rotate.

  • Page 52: Inspect The Steering Components

    Steering SC-100 INSPECT THE STEERING COMPONENTS WARNING WARNING This section is one section of a complete service Do not drive the vehicle while the steering wheel or manual. Before starting any procedure, read all front wheels are tied in position. Driving the vehicle warnings and instructions that are located in the while the steering wheel or front wheels tied in Service Guidelines chapter.

  • Page 53: Fork Bearings

    Steering SC-100 FORK BEARINGS ADJUST THE STEERING SHAFT 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.

  • Page 54: Replace Steering Wheel

    Steering SC-100 REPLACE STEERING WHEEL 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. Note: The steering wheel is on a tapered shaft and may be damaged when it is removed. 1: If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch.

  • Page 55: Front Fork

    Steering SC-100 FRONT FORK 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. Note: It is recommended to replace the grease seal any time the fork is removed from the vehicle.
  • Page 56 Steering Notes SC-100 Page 56 MA-100-03...
  • Page 57 Table of Contents Brake Service Inspect the Service Brake .......58 Disc Brake Pads ............58 Disc Brake Rotor .............58 Inspect the Parking Brake ......59 Wheel Park Brake (Mechanical Disc) ......59 Adjust the Service Brakes ......60 Mechanical Disc Brakes ..........60 Adjust the Parking Brake ........61 Primary Adjustment (handle) ........61 Secondary Adjustment (cable) ........61 Replace Rear Brake Pads .......62...

  • Page 58: Inspect The Service Brake

    SC-100 INSPECT THE SERVICE BRAKE WARNING WARNING Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original This section is one section of a complete service brakes were replaced with aftermarket parts manual. Before starting any procedure, read all containing asbestos.

  • Page 59: Inspect The Parking Brake

    Brakes SC-100 INSPECT THE PARKING BRAKE WARNING WARNING If any sign of damage or wear is found on the park This section is one section of a complete service brake handle, cables, or linkages then they must be manual. Before starting any procedure, read all repaired or replaced immediately.

  • Page 60: Adjust The Service Brakes

    Brakes SC-100 ADJUST THE SERVICE BRAKES WARNING WARNING • Make sure the key-switch is in the “OFF” position, This section is one section of a complete service then remove the key. manual. Before starting any procedure, read all • Place the forward-reverse switch in the center warnings and instructions that are located in the “OFF”...

  • Page 61: Adjust The Parking Brake

    Brakes SC-100 ADJUST THE PARKING BRAKE Secondary Adjustment (cable) WARNING WARNING This section is one section of a complete service • Make sure the key-switch is in the “OFF” position, manual. Before starting any procedure, read all then remove the key. warnings and instructions that are located in the •...

  • Page 62: Replace Rear Brake Pads

    SC-100 REPLACE REAR BRAKE PADS WARNING WARNING Current Taylor-Dunn® brakes are asbestos free. This section is one section of a complete service However, there is the possibility that the original manual. Before starting any procedure, read all brakes were replaced with aftermarket parts warnings and instructions that are located in the containing asbestos.

  • Page 63: Replace The Mechanical Caliper Assembly

    REPLACE THE MECHANICAL WARNING CALIPER ASSEMBLY WARNING Current Taylor-Dunn® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts This section is one section of a complete service containing asbestos. Since this possibility exists, manual.
  • Page 64 Notes Brakes SC-100 Page 64 MA-100-03...
  • Page 65 Table of Contents Motor Remove/Install ..........66 Bearing ..............66 Disassemble.............66 Inspect ..............67 Brushes ..............67 Commutator .............67 Armature Windings ..........67 Replacing the Brushes or Armature Bearing 68 Field Windings ............68 Repair ...............69 Repairing the Commutator ........69 Undercutting the Commutator .........69 Service Limits ..........70 Hardware Torque ..........70 WARNING This section is one section of a complete service...

  • Page 66: Remove/Install

    Motor SEM SC-100 REMOVE/INSTALL DISASSEMBLE 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.

  • Page 67: Inspect

    Motor SEM SC-100 INSPECT Inspect the commutator for burn marks. WARNING • Burn marks and/or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature. A tool called a growler is required to This section is one section of a complete service reliably test for a shorted armature.

  • Page 68: Replacing The Brushes Or Armature Bearing

    Motor SEM SC-100 Using the continuity function of digital multi meter, check REPLACING THE BRUSHES OR the continuity from any one of the commutator segments ARMATURE BEARING and the armature frame. If it is not an open circuit, then the armature is shorted and the motor must be replaced. Note: It is recommended that all four brushes be replaced as a set.

  • Page 69: Repair

    Motor SEM SC-100 REPAIR Undercutting the Commutator WARNING 1: Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer This section is one section of a complete service to undercut depth in Service Limits. manual.

  • Page 70: Service Limits

    Motor SEM SC-100 SERVICE LIMITS 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. This is a generic section covering all currently available SEM motors at the time this manual was revised. The service limits listed below are for each of the motors, by the specification number of the motor shown.
  • Page 71 Table of Contents Motor Controller Remove/Install ..........72 Inspect ..............72 Receptacles .............72 Base Plate ...............72 Terminal Ends ............72 ’R’ Terminal ..............72 Repair/Programming ........73 Repairs ..............73 Programming ............73 Troubleshooting ..........73 Hardware Torque ..........74 WARNING This section is one section of a complete service manual.

  • Page 72: Motor Controller

    Motor Controller SC-100 REMOVE/INSTALL INSPECT WARNING NOTICE This section is one section of a complete service These motor controls are programmed to match the manual. Before starting any procedure, read all vehicle configuration. warnings and instructions that are located in the DO NOT move a control to another vehicle unless the Service Guidelines chapter.

  • Page 73: Motor Controller

    Tools section for part numbers. If you have a special application that may require modified parameters, contact your local authorized Taylor-Dunn distributor to submit a request to the factory. Note: There may be a fee to created a custom parameter set.

  • Page 74: Hardware Torque

    Motor Controller SC-100 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the Notes appendix. Description Inch Pounds Newton Meters Terminal stud 38-44 4.29-4.97 Page 74 MA-100-03...
  • Page 75 Table of Contents Tires & Wheels Inflation .............76 Air pressure .............76 Tread Wear ............77 Changing Tire/Wheel Assembly .....78 Replace the Tire (pneumatic) ......78 Repair the Tire (pneumatic) ......78 Hardware Torque ..........79 WARNING This section is one section of a complete service manual.

  • Page 76: Tires & Wheels

    Tires & Wheels SC-100 INFLATION WARNING WARNING Incorrect tire inflation can result in sudden failure of This section is one section of a complete service the tire and/or braking / steering problems leading manual. Before starting any procedure, read all to loss of control of the vehicle.

  • Page 77: Tread Wear

    Tires & Wheels SC-100 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.

  • Page 78: Changing Tire/Wheel Assembly

    Tires & Wheels SC-100 CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) WARNING ASSEMBLY 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 This section is one section of a complete service Service Guidelines chapter.

  • Page 79: Hardware Torque

    Tires & Wheels SC-100 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MA-100-03 Page 79...
  • Page 80 Notes Tires & Wheels SC-100 Page 80 MA-100-03...
  • Page 81 Table of Contents Batteries General Guidelines and Safety.......82 Cleaning ............83 Watering ............83 Charging ............83 Testing ..............84 Specific Gravity ............84 Storing ..............84 Storage ..............84 Returning to Service ..........84 Remove/Install ..........85 Industrial Battery or Lift Out Battery Pack ....85 Individual Batteries ..........85 Hardware Torque ..........86 WARNING This section is one section of a complete service...

  • Page 82: General Guidelines And Safety

    Batteries SC-100 GENERAL GUIDELINES AND SAFETY WARNING NOTICE Battery electrolyte will stain and corrode most This section is one section of a complete service surfaces. Immediately and thoroughly clean any manual. Before starting any procedure, read all surface outside of the battery that the battery warnings and instructions that are located in the electrolyte comes in contact with.

  • Page 83: Cleaning

    Batteries SC-100 CLEANING WATERING 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 and beginning of this Service Guidelines chapter and beginning of this...

  • Page 84: Testing

    Batteries SC-100 TESTING STORING 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 and beginning of this Service Guidelines chapter and beginning of this...

  • Page 85: Remove/Install

    Batteries SC-100 REMOVE/INSTALL WARNING WARNING This section is one section of a complete service Do not allow the loose battery cables to contact any manual. Before starting any procedure, read all other parts of the vehicle as this could cause in a warnings and instructions that are located in the short circuit resulting severe bodily injury or damage Service Guidelines chapter and beginning of this...

  • Page 86: Hardware Torque

    Notes Batteries SC-100 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Inch Pounds Newton Meters Battery terminal, Trojan bolt 95-105 11-12 Battery terminal, Trojan stud 95-105 11-12 Battery terminal, T/D bolt Page 86 MA-100-03...
  • Page 87 Table of Contents Wire Diagram Diagram Part Numbers........88 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.
  • Page 88 Wire diagrams are too 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-00075 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. Red/Black...
  • Page 89 Table of Contents Hardware Information Torque Guidelines for Standard hardware ..90 Hardware Identification ..........90 Hex Nuts ..............91 Hex Lock Nuts (stover) ..........91 Other Nuts ...............91 Generic Torque Values ..........92 Replacing Hardware ........94 WARNING This section is one section of a complete service manual.

  • Page 90: Torque Guidelines For Standard Hardware

    Hardware SC-100 TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used shall 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.

  • Page 91: Hex Nuts

    ‘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 ® shall be treated as S.A.E. grade A MA-100-03 Page 91...

  • Page 92: Generic Torque Values

    Hardware SC-100 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...
  • Page 93 Hardware SC-100 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...

  • Page 94: Replacing Hardware

    Hardware SC-100 REPLACING HARDWARE 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. WARNING Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
  • Page 95 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....96 Taylor-Dunn Web Site Information ....96 Axle, Front ............98 Axle, Rear ............99 Battery ..............100 Brake Linkage ..........102 Brakes, Rear.............104 Charger, Lestronic ...........105 Charger, Signet ..........106 Charger, X-Series..........107 Control Panel, Speed ........108 Dashboard (Instrument Panel) .......109...

  • Page 96: Replacement Parts

    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.

  • Page 97: Replacement Parts

    Replacement Parts SC-100 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: MA-100-03 * - Not available at time of printing Page 97...

  • Page 98: Axle, Front

    Replacement Parts SC-100 AXLE, FRONT Front Axle and Fork Item # Part # Description 88-229-81 3/4NC Lock nut 1 or 2 88-228-61 3/4 SAE Flat washer 1 or 2 15-010-20 Axle, single wheel 16-010-00 Spacer 2 or 4 15-011-00 Axle, dual wheel 0 or 1 14-030-10 Fork, single wheel...

  • Page 99: Axle, Rear

    Replacement Parts SC-100 AXLE, REAR Rear Axle Item No. Part No. Description 41-154-40 Axle shaft 80-505-20 Bearing 41-490-11 Disc brake rotor 41-172-21 88-268-63 Flat washer 88-268-30 7/8-14 x 1.5 Bolt, grade 5 96-329-10 Wheel stud Not Shown 92-104-10 Hub cover 41-290-54 Axle housing, left 41-290-55...

  • Page 100: Battery

    Replacement Parts SC-100 BATTERY Part numbers for the cables , hardware, and hold downs are the same as the 24- volt configuration 48-volt battery configuration Page 100 * - Not available at time of printing MA-100-03...
  • Page 101 Not Shown 77-055-15 Battery watering system for Trojan batteries (optional) 77-055-12 Battery watering system for Exide or Taylor-Dunn batteries (optional) 77-055-13 BATTERY FILLING GUN, used with watering systems (optional) 01-534-43 Battery locator (angle in bottom of battery box, 72 v only) Quantities depend on voltage configuration of vehicle.

  • Page 102: Brake Linkage

    Replacement Parts SC-100 BRAKE LINKAGE Page 102 * - Not available at time of printing MA-100-03...
  • Page 103 Replacement Parts SC-100 Brake Linkage Item # Part # Description 96-773-00 Clevis pin 88-119-80 5/16NF Hex nut 50-002-30 Brake rod 97-202-50 5/16NF Nut, left thread 96-762-10 3/8 Clevis, left thread 80-410-20 Bushing assembly 88-109-81 3/8NC Lock Hex nut 88-100-09 3/8NC x 3/4 Hex bolt 88-527-11 Cotter pin 00-150-24...

  • Page 104: Brakes, Rear

    Replacement Parts SC-100 BRAKES, REAR Brakes, Rear Item# Part# Description 41-349-98 Complete brake assembly, right 41-349-99 Complete brake assembly, left 41-348-55 Clevis pin 41-350-27 Mounting bracket 32-204-30 Bushing 41-348-70 Brake pad 41-348-52 Spacer 88-067-18 Hex bolt, grade 8 88-069-88 Hex nut, grade 8 41-348-48 Brake arm 41-348-54...

  • Page 105: Charger, Lestronic

    Replacement Parts SC-100 CHARGER, LESTRONIC Charger Model > 9695 16910 22620 16920 Style > Portable Built In Built In Built In Item # Description Part # Charger Assembly 79-309-00 79-309-10 79-303-25 79-309-20 Ammeter 79-851-10 Timer 79-805-65 79-805-68 79-805-68 Relay, Timer 79-808-20 79-808-20 79-808-20...

  • Page 106: Charger, Signet

    Replacement Parts SC-100 CHARGER, SIGNET Note: There are no user serviceable components inside the charger Note: The charger AC cord is an integral part of the charger. When replacing the charger, do not cut and splice the AC cord. Cutting the AC cord will void the charger warranty.

  • Page 107: Charger, X-Series

    Replacement Parts SC-100 CHARGER, X-SERIES Item No. Part No. Description 79-303-49 Charger Assembly, X-Series, 48 volt 79-831-00 Fuse 79-809-61 Relay boad assembly Control board assembly 79-749-14 SCR assembly 79-840-02 Circuit breaker 79-848-01 Ammeter 79-810-01 Switch kit (start/stop, low voltage, self diagnostic) 79-575-41 AC cord (includes bushing) 79-566-21...

  • Page 108: Control Panel, Speed

    Replacement Parts SC-100 CONTROL PANEL, SPEED Speed Control Panel Item # Part # Description 62-400-05 Speed controller 01-200-07 Mounting panel 73-004-20 Horn 79-844-00 Main circuit breaker 72-501-42 ISO solenoid 88-838-06 #14 x 1/2 Sheet metal screw 88-060-09 1/4NC x 3/4 Hex bolt 79-840-00 10 Amp circuit breaker 79-840-20...

  • Page 109: Dashboard (Instrument Panel)

    If you have the Smart View display and wish to have the maintenance feature turned on, then the Sevcon speed control must be reprogrammed. To reprogram the Sevcon speed control, the speed control must be returned to the factory. Contact your local Taylor-Dunn distributor for more information. ®...

  • Page 110: Decals

    Replacement Parts SC-100 DECALS Decals Item # Part # Description 94-313-00 Battery Warning 94-319-00 Battery Disconnect 94-382-00 Treadle operation 94-301-43 Arms and hand inside 94-313-20 Safety warning 94-384-01 Not a motor vehicle 94-384-14 Apply park brake 94-373-10 Data plate 94-384-17 Do not spray wash 94-333-00 FM (24 volt vehicle only)

  • Page 111: Deck, Frame, And Seat Cushions

    Replacement Parts SC-100 DECK, FRAME, AND SEAT CUSHIONS Deck, Frame, and Seat Cushions Item # Part # Description 30-703-00 Upper chain cover 90-501-00 Deck (standard) 79-511-00 Charger cord holder 79-575-30 AC cord 8 foot 79-530-00 Strain releif for AC cord 03-150-43 Lower chain cover 03-150-28...

  • Page 112: Differential/Transmission Gear Case

    Replacement Parts SC-100 DIFFERENTIAL/TRANSMISSION GEAR CASE Page 112 * - Not available at time of printing MA-100-03...
  • Page 113 Replacement Parts SC-100 Differential/Transimission Gear Case Item No. Part No. Description GT-71682 Bolt, M8 x 60 mm GT-3287563 Gear case cover GT-71259 Bearing see gear kits below Input shaft GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing see gear kits below Idler gear GT-70302 Bolt, M10 x 30 mm...

  • Page 114: Sd Transaxle Assembly, Rear 3Rd Member

    Replacement Parts SC-100 SD TRANSAXLE ASSEMBLY, REAR 3RD MEMBER Illustration is for reference only. This assembly as not serviceable with the exception of oil seals. Item No. Part No. Description 44-440-93 Complete 3rd member assembly Bolt N/A - Order assembly Bearing N/A - Order assembly Race...

  • Page 115: Sd Transaxle Assembly, Rear Primary Reduction

    Replacement Parts SC-100 SD TRANSAXLE ASSEMBLY, REAR PRIMARY REDUCTION Item No. Part No. Description 44-440-89 Assembly, Primary reduction, 15:1 0 or 1 44-440-90 Assembly, Primary reduction, 19:1 0 or 1 44-440-91 Assembly, Primary reduction, 27:1 0 or 1 44-440-92 Assembly, Primary reduction, 30:1 0 or 1 Kit B Bearing...

  • Page 116: Electrical, Miscellaneous

    Replacement Parts SC-100 ELECTRICAL, MISCELLANEOUS Motion Alarms Miscellaneous Wire Harness Clamps Page 116 * - Not available at time of printing MA-100-03...

  • Page 117: Head And Tail Lights

    Replacement Parts SC-100 Electrical, Miscellaneous Item # Part # Description 73-005-05 Reverse Warning alarm 96-650-01 Wire Harness Clip, stick on 96-642-00 Wire harness Clip, push mount 71-501-00 Horn Switch 71-102-10 Foot Interlock Switch 85-030-00 Spring 96-773-10 Clevis Pin 02-610-18 Mounting Plate 88-527-11 Cotter Pin 96-640-00...

  • Page 118: Hitches

    Replacement Parts SC-100 HITCHES Mounting Hardware Item No. Part No. Description 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 88-149-80 1/2NC Hex nut 88-148-62 1/2 Split lock washer Trailer Hitches Item # Part # Description 97-808-00 Automatic Coupling hitch 97-804-01...

  • Page 119: Ladder

    Replacement Parts SC-100 LADDER Ladder (optional) Item # Part # Description 97-813-00 Ladder, 4-step 97-813-10 Ladder, 5-step 97-813-11 Ladder, 6-step 88-082-11 5/16NC x 1 Carriage bolt 88-088-62 5/16 Split lock washer 88-089-80 5/16NC Hex nut MA-100-03 * - Not available at time of printing Page 119...

  • Page 120: Motor

    Sevcon® controller; however the vehicle will have about a 15% reduction in top speed. To take full advantage of the increased performance of the 70-054-41 motor, new parameters must be programmed into the Sevcon® controller. Please contact Taylor-Dunn® Manufacturing for details on returning the controller for re-programming. Spec # Cross reference Motor Spec #...

  • Page 121: Motor Mount

    Replacement Parts SC-100 MOTOR MOUNT Apply 94-421-34 grease to inside of motor coupler Item No. Part No. Description 88-067-17 Bolt, Motor Mounting, 1-1/8 long 88-067-22 Bolt, Motor Mounting, 2” long See Motor Motor 96-114-10 U-Bolt 41-883-36 Bracket 88-128-62 Lock Washer 89-111-27 Bolt 88-088-62...

  • Page 122: Steering Linkage

    Replacement Parts SC-100 STEERING LINKAGE Page 122 * - Not available at time of printing MA-100-03...

  • Page 123: Wheels And Tires

    Replacement Parts SC-100 Steering Linkage Item # Part # Description 20-053-40 Steerng shaft, standard bed 0 or 1 84-005-00 Pillow block 30-249-00 Streering chain 30-249-00 Streering chain 30-400-00 Steering chain master link 32-032-10 Steering bushing 88-048-63 Washer 88-840-09 Steering wheel retainer 96-900-00 Turn buckle 88-080-16...
  • Page 124 Notes: Replacement Parts SC-100 Page 124 * - Not available at time of printing MA-100-03...
  • Page 126 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...

This manual is also suitable for:

Sc-100-36Sc-100-48

Table of Contents

Save PDF