Taylor-Dunn SC-090-24 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn SC-090-24 Operation, T Roubleshooting And Replacement Parts Manual

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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
READ THIS MANUAL BEFORE OPERATION
OR PERFORMING MAINTENANCE.
This manual contains important information
regarding the safe operation and maintenance of
this vehicle.
Revision: E, 7/1/2013
Models Inlcuded:
SC-090-24 (SC 0-90), 24-volt system
MANUAL MA-090-00
Operation, Troubleshooting and
Replacement Parts Manual
Serial number Starting: 171712
Ending: 191319

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Summary of Contents for Taylor-Dunn SC-090-24

  • Page 1 Models Inlcuded: SC-090-24 (SC 0-90), 24-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 B u s i n e s s MANUAL MA-090-00...
  • 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

    Table of Contents About this manual ...........2 Who Should Read This Manual ......2 Responsibilities ..........2 How To Use This Manual ........3 Conventions ............3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle......5...

  • Page 6: About This Manual

    Taylor-Dunn ® vehicles and ® is not intended as a training guide. Taylor-Dunn Of the Operator... made every effort to include as much information as The operator is responsible for the safe operation of possible about the operation and maintenance of this the vehicle, preoperational and operational checks vehicle.

  • Page 7: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL Conventions This manual is organized into five main sections: Symbols and/or words that are used to define INTRODUCTION warnings, cautions, instructions, or notes found throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 8: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts.

  • Page 9: Taking Delivery Of Your Vehicle

    • The only personnel authorized to repair, modify, or Check that all wire connections, battery ® adjust any part of this or any Taylor-Dunn vehicle is cables, and other electrical connections are a factory authorized service technician. secure.
  • Page 10 Notes Page-6...
  • Page 11 Section Index  ® Model SC-090-24 (SC 0-90),24 Volt System Service and Repair Manual Section Index Introduction General Maintenance Safety and Operating Instructions Front Axle Steering Brakes Motor Transmission Tires and Wheels Battery Motor Control Chargers Wire diagrams Replacement Parts Appendix This quick reference section index guide will assist you in locating a desired topic or procedure.
  • Page 12 Notes:...
  • Page 13 TABLE OF CONTENTS Standard Specifications ...... 2 Safety Rules and Guidelines ....3 Driver Training Program ..... 3 Driver Qualifications...........3 Vehicle Controls ........4 Key-Switch ............4 Forward-Off-Reverse Switch ......4 Horn Switch ............4 Headlight Switch ..........4 Hour Meter ............4 Accessory Switch (Optional) ......5 Battery Status Indicator, Analog ......5 Battery Status Indicator, Digital Bargraph ..

  • Page 14: Standard Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS ITEM SPECIFICATION* Occupancy 1-Operator Dimensions 218 L X 75 W X 122.5 H Centimeters 85.75 L X 29.50 X 48.25 H Inches Turning Radius 170 Centimeters (67 inches) Dry Weight 239 kg (528 lbs) Without Batteries Min/Max Battery 105 kg to 145 kg (232 lbs to 480 lbs)

  • Page 15: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND DRIVER TRAINING PROGRAM GUIDELINES According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who It is the responsibility of the owner of this vehicle to assure will be operating this vehicle.

  • Page 16: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS Key-Switch A key-switch, located on the right center side of the instrument panel, turns on the vehicle. Rotate the key clockwise to turn the vehicle power on, counterclockwise to turn the vehicle power off. The key-switch should be in the “OFF”...

  • Page 17: Accessory Switch (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Accessory Switch (Optional) The accessory switch is located on the left side of the instrument panel and to the right of the headlight switch. Push the top of the switch to turn on the accessory. Push the bottom of switch to turn off the accessory. The accessory can be turned on with the key switch in the “OFF”...

  • Page 18: Foot Brake Pedal

    SAFETY RULES AND OPERATING INSTRUCTIONS Foot Brake Pedal The brake pedal is the treadle located on the right side of the floorboard positioned under the operators right foot. The treadle also functions as the accelerator pedal. Press the rear of the treadle to apply the brake. The brake is automatically released when accelerating.

  • Page 19: Vehicle Operation Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATION GUIDELINES Safety Guidelines While driving: • • Only qualified and trained operators may drive this Slow down and sound the horn to warn pedestrians vehicle. or when approaching a corner or other intersection. •...

  • Page 20: Using The Ladder

    SAFETY RULES AND OPERATING INSTRUCTIONS Using the Ladder Parking The maximum ladder capacity is 200 pounds. Before leaving the vehicle: • Access the ladder from the operators platform only. Do Set the parking brake. not climb the ladder from the rear of the vehicle. •...

  • Page 21: Charging Your Vehicle

    SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE Battery electrolyte is poisonous and Explosive mixtures of Hydrogen gas are dangerous. It contains sulfuric acid. Avoid present within battery cells at all times. Do contact with skin eyes or clothing. Wear not work with or charge battery in an area rubber gloves and safety glasses while where open flames (including gas furnace...

  • Page 22: New Battery Break In

    SAFETY RULES AND OPERATING INSTRUCTIONS New Battery Break in STORING / RETURNING TO New batteries require a break in period of up to 40-cycles. SERVICE The batteries will not have their full capacity during this break in period and may require longer charging times. Both storing your vehicle and returning it to service should only be performed by authorized personnel.

  • Page 23: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Taylor-Dunn Preventative Maintenance Schedule for GT Drive with DC Motor Date: ________________________ Model #: ________________ Hour Meter: _______________ Inspected By: ________________________ Serial #: ________________ Serviced By: ________________________ Unit ID#: ________________ Interval Service...

  • Page 24: Daily Visual Inspection

    SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to: • Accelerator pedal, Brake pedal, Steering, Parking brake, etc. •...
  • Page 25 TABLE OF CONTENTS Maintenance Guidelines .........2 Troubleshooting Guide ........3 Lubrication Chart ..........4...
  • Page 26 • Inspect and maintain battery 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.
  • Page 27 Maintenance, Service and Repair TROUBLESHOOTING GUIDE Symptom Probable Cause Front End Out of Alignment , For Bent Steering Pulls in One Direction Low Tire Pressure Dry Lube Points in Steering Linkage Hard Steering Damaged Fork Spinde Low Tire Pressure Loose Steering Chain Excessive Steering Play Mis-Adjusted or Worn Steering Shaft Loose Steering Linkage...
  • Page 28 Maintenance, Service and Repair LUBRICATION CHART # Description Locations Lubricant Type 1 Steering Shaft Pillow Blocks General Purpose Grease (not shown) 2 Front Fork Spindle Bearings General Purpose Grease 3 Steering Shaft Gears General Purpose Grease 5 Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease 6 Steering Chains...
  • Page 29 TABLE OF CONTENTS Inspect the Front Wheel Bearings ....2 Adjust Front Wheel Bearings ......3 Front Axle Removal and Installation .....4 Removal ..............4 Replace Front Wheel Bearings.......5...

  • Page 30: Inspect The Front Wheel Bearings

    Maintenance, Service, and Repair INSPECT THE FRONT WHEEL BEARINGS 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 rear wheels to prevent vehicle movement. 5.

  • Page 31: Adjust Front Wheel Bearings

    Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS 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 rear wheels to prevent vehicle movement. 5.

  • Page 32: Front Axle Removal And Installation

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal 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 rear wheels to prevent vehicle movement. 5.

  • Page 33: Replace Front Wheel Bearings

    Maintenance, Service, and Repair REPLACE FRONT WHEEL BEARINGS 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 rear wheels to prevent vehicle movement. 5.
  • Page 34 Notes Front Axle Page 6...
  • Page 35 TABLE OF CONTENTS Front End Alignment ........2 Center the Steering Wheel ........3 Inspect the Steering Components ....5 Steering Wheel and Bushings .........5 Steering Chain ............5 Pillow Blocks ............6 Fork Bearings ..........7 Adjust the Steering Shaft ........8 Replace the Steering Wheel ......9 Replace the Front Fork ........10...

  • Page 36: Front End Alignment

    Maintenance, Service, and Repair FRONT END ALIGNMENT 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 rear wheels to prevent vehicle movement. 5.

  • Page 37: Center The Steering Wheel

    Maintenance, Service, and Repair Center the Steering Wheel Do not drive the vehicle while the steering wheel or front wheels are tied in position. Driving the vehicle while the steering wheel or front wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and/or property damage.
  • Page 38 Maintenance, Service, and Repair 13. Tighten the turnbuckles to remove all play from the steering chain. 14. Install new safety wire and tie off as shown in the illustration. 15. Untie the front fork. 16. Reconnect the main positive and negative cables at the batteries. 17.

  • Page 39: Inspect The Steering Components

    Maintenance, Service, and Repair INSPECT THE STEERING COMPONENTS Steering Wheel and Bushings After the steering wheel has been removed, thoroughly clean the steering wheel shaft and bushings. Measure the diameter of the steering shaft. • If the shaft diameter is not between 0.745” and 0.0750”...

  • Page 40: Pillow Blocks

    Maintenance, Service, and Repair Pillow Blocks 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 rear wheels to prevent vehicle movement. 5.

  • Page 41: Fork Bearings

    Maintenance, Service, and Repair FORK BEARINGS 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 rear wheels to prevent vehicle movement. 5.

  • Page 42: Adjust The Steering Shaft

    Maintenance, Service, and Repair ADJUST THE STEERING SHAFT The steering shaft is adjustable by means of a collar at the rear of the shaft. This adjustment controls the gear lash of the half gears on the shaft and front fork. 1.

  • Page 43: Replace The Steering Wheel

    Maintenance, Service, and Repair REPLACE THE STEERING WHEEL 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.

  • Page 44: Replace The Front Fork

    Maintenance, Service, and Repair REPLACE THE FRONT FORK 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 rear wheels to prevent vehicle movement. 5.
  • Page 45 TABLE OF CONTENTS Auto-Adjust Brake Mechanism Theory of Operation ........2 Inspect the Service Brake .......3 Auto-Adjust Brake Mechanism Operation ....3 Inspecting the Auto-Adjust Brake Mechanism ..3 Brake Shoes ............4 Brake Drum .............4 Inspect the Parking brake .......5 Wheel Park Brake ...........5 Adjust the Service Brakes ......6 Adjust the Brake Linkage .......6 Adjust the Parking Brake ........7...

  • Page 46: Auto-Adjust Brake Mechanism Theory Of Operation

    Note: There are no manual adjustments for the brake shoes. Note: The symptom of a low brake pedal may indicate that the auto adjuster is not working or the brake linkage is not adjusted properly. Remove the vehicle from service and repair the brakes. 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 do contain asbestos.

  • Page 47: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE 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.

  • Page 48: Brake Shoes

    Maintenance, Service, and Repair Brake Shoes 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 for recommended handling precautions.

  • Page 49: Inspect The Parking Brake

    Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake Inspect the The parking brake is actuated through the same linkages as the service brake. Refer to Service Brake section to inspect the brake pads. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 50: Adjust The Service Brakes

    Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Note: This vehicle is equipped with self-adjusting brakes. Other than the brake linkages, there is no manual adjustment. A low brake pedal may be an indication that the auto-adjust mechanism is not functioning Inspecting the Auto-Adjust Brake Mechanism properly.

  • Page 51: Adjust The Parking Brake

    Maintenance, Service, and Repair ADJUST THE PARKING BRAKE There are two adjustments for the parking brake. The primary adjustment is on the park brake handle itself. The secondary adjustment is the park brake cable under the treadle. The park brake cable does not require routine adjusments.

  • Page 52: Replace Rear Brake Shoes

    Maintenance, Service, and Repair REPLACE REAR 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 for recommended handling precautions.
  • Page 53 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ....... 2 Motor Removal and Installation ..2 Motor Inspection ......... 2 Replacing Brushes/Armature Bearing 4 Repairing the Commutator ....5 Service Limits ........6...

  • Page 54: Inspecting The Motor Brushes

    Maintenance, Service, and Repair INSPECTING THE MOTOR MOTOR REMOVAL AND BRUSHES INSTALLATION Transmission See the section for information on removing or installing the motor. Motors with internal cooling fans MOTOR INSPECTION Disassembly 1. Remove the motor from the vehicle. See the Transmission section for information on removing the motor.
  • Page 55 Maintenance, Service, and Repair 3. Measure the commutator undercut depth in 8. Using a growler, test the armature for shorts. • If the armature is shorted, then we recommend 5-places around the commutator. that the armature or motor be replaced. •...

  • Page 56: Replacing Brushes/Armature Bearing

    Maintenance, Service, and Repair Assembly 1. Press a new bearing into the motor housing and install the circlip. 2. Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator.

  • Page 57: Repairing The Commutator

    Maintenance, Service, and Repair REPAIRING THE COMMUTATOR 1. The motor must be removed from the vehicle for Transmission Service this procedure. Refer to section for information on removing the motor. 2. The armature must be removed from the motor Motor Inspection- for this procedure.

  • Page 58: Service Limits

    Maintenance, Service, and Repair SERVICE LIMITS Motor Specification Commutator Di- Brush Length Resistance Undercut Depth Number ameter (min) (min) (Ohms@75º F) Arma- inches inches inches Field ture 70-054-40 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20 (XP-1672 or DV1-4002) 70-054-41 0.635 0.025 69.85...
  • Page 59 TABLE OF CONTENTS Check Oil Level ..........2 Change Oil ............2 Motor ..............3 Removal ..............3 Installation ...............3 Rear Axle ............3 Differential Case ..........4 Disassemble ............4 Assemble ..............6...

  • Page 60: Check Oil Level

    Maintenance, Service, and Repair CHECK OIL LEVEL CHANGE OIL Park the vehicle on a level surface. Park the vehicle on a level surface. 1. Make sure the key-switch is in the “OFF” 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 61: Motor

    Maintenance, Service, and Repair MOTOR REAR AXLE Note: The tire/wheel assembly must be removed for Removal these procedures. Refer to Tires and Wheels section for information on removing the tire and wheel assembly. 1. Make sure the key-switch is in the “OFF” position, then remove the key.

  • Page 62: Differential Case

    Maintenance, Service, and Repair DIFFERENTIAL CASE Disassemble 1. Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2. Thoroughly clean the transmission assembly before disassembly. 3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.
  • Page 63 Maintenance, Service, and Repair 9. Punch or drill a small hole into the center of both of the intermediate shaft bore plugs. 10. Thread a sheet metal screw into each plug until the bore plug is forced out. 11. Remove both snap rings from the intermediate shaft bore. 12.

  • Page 64: Assemble

    Maintenance, Service, and Repair 15. Remove the o-rings from each end of the intermediate shaft. 16. Remove the circlip from the input shaft. 17. Remove the input shaft from the housing. 18. Press the bearings off of the input shaft. 19.
  • Page 65 Maintenance, Service, and Repair 3. Insert new o-rings into both sides of the intermediate shaft bore, the input shaft bore and the intermediate shafts. 4. Install the input shaft into the housing and install the snap ring. 5. Insert the intermediate shaft into the housing and support in place.
  • Page 66 Notes Transmission Page 8...
  • Page 67 TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Replace the Front Tire/Wheel ..... 3 Replace the Rear Tire/Wheel ..... 3 Replace the Tire (pneumatic) .... 3 Repair the Tire (pneumatic) ....4...

  • Page 68: Tire Inflation

    Maintenance, Service, and Repair TIRE INFLATION TIRE INSPECTION 6. Check the tire pressure. Refer to Tire Inflation section for information on checking the tire 1. Make sure the key-switch is in the “OFF” pressure. position, then remove the key. 7. Inspect the tire tread depth. Minimum recommended tread depth is 1/16-inch.

  • Page 69: Replace The Front Tire/Wheel

    Maintenance, Service, and Repair REPLACE THE FRONT TIRE/ REPLACE THE TIRE WHEEL (PNEUMATIC) Note: To replace the tire, the tire/wheel assembly Front Axle Service Refer to for information on must be removed from the vehicle. Refer removing the front wheel. Replace the Tire/Wheel section for information on removing the tire/wheel...

  • Page 70: Repair The Tire (Pneumatic)

    Maintenance, Service, and Repair Pattern for tightening the wheel nuts Re-torque all wheel nuts to their final value after 1-week (20-hours) of operation. Failure to re-torque the wheel nuts may result in the wheel coming off of the vehicle causing severe bodily injury and/or property damage.
  • Page 71 TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Charging ..........4 Watering ..........5 Replacing (6-volt batteries only) ..6 Moist Charge Batteries........7 Storage and Returning to Service ..8 Storage ..............8 Returning to Service ........... 9...

  • Page 72: Cleaning

    Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 73: Testing

    Maintenance, Service, and Repair TESTING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 74: Charging

    Maintenance, Service, and Repair Specific Gravity Test CHARGING Note: The batteries must be fully charged before Charging Your Vehicle Safety Refer to in section performing this test. Rules and Operating Instructions The specific gravity of a cell is an indication of the actual state of charge of the cell.

  • Page 75: Watering

    Maintenance, Service, and Repair WATERING Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 76: Replacing (6-Volt Batteries Only)

    Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) Note: If the batteries are over one year old, it is recommended to replace them as a set. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area 1.

  • Page 77: Moist Charge Batteries

    Maintenance, Service, and Repair 15. Install the batteries in reverse order. Refer to the Illustrated Parts List for battery cable routing. Battery electrolyte is poisonous and 16. It is recommended to replace the battery terminal dangerous. It contains sulfuric acid. Avoid hardware when replacing the batteries.

  • Page 78: Storage And Returning To Service

    Maintenance, Service, and Repair STORAGE AND RETURNING TO SERVICE Explosive mixtures of Hydrogen gas are 1. Make sure the key-switch is in the “OFF” present within battery cells at all times. Do position, then remove the key. not work with or charge battery in an area 2.

  • Page 79: Returning To Service

    Maintenance, Service, and Repair Returning to Service 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.
  • Page 80 Notes Batteries Page 10...
  • Page 81 Table of Contents Motor Controller Remove/Install ..........2 Inspect ..............2 Troubleshooting ..........2 Repair/Adjustments.........3 Adjustments .............3 Hardware Torque ..........4...

  • Page 82: Motor Controller

    CD. A replacement CD or hard 7: Disconnect the wires from the KSI and #2 copy can be purchased from your authorized Taylor-Dunn terminals. distributor or can be downloaded from the Taylor-Dunn 8: If equipped with the 7-pin in-line connector, web site.

  • Page 83: Repair/Adjustments

    Motor Controller REPAIR/ADJUSTMENTS Repairs There are no internally serviceable components in the motor speed controller. If a controller is faulty then it must be replaced. Note: Opening or disassembling a controller will void the controller warranty. Adjustments There are two or three adjustments available: 1: Acceleration Ramp: How fast the controller ramps up to full power.

  • Page 84: Hardware Torque

    Motor Controller HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal hardware 8.13 Adjustment plugs 0.90 Page 4...
  • Page 85 TABLE OF CONTENTS Remove/Install ...........2 Troubleshooting .........2...
  • Page 86 CD. A hard copy can be purchased any wires or removing the cover of the charger. from your authorized Taylor-Dunn distributor or can be Failure to follow this instruction may result in serious downloaded from the Taylor-Dunn web site.
  • Page 87 The vehicle wiring diagrams are too large to be legible when printed at this size. A full size diagram (22 x 16) is included on the CD in PDF format. You can access the diagram from a button on the CD menu. The diagram file names are: Chassis Wire diagram # SCH-00026.pdf Charger AC Cords:...
  • Page 88 Notes Wire Diagrams Page 2...
  • Page 89 TABLE OF CONTENTS Axle (Front) and Fork........2 Axle (Rear) ............4 Batteries ............5 Brake Linkage..........6 Decals............8 Frame, Seat Cushions and Deck....9 Hitches............10 Head and Tail Lights (optional) ......10 Instrument Panel (dash) ........11 Knee Pad and Floor Mats (optional) ....12 Ladders and Strobe Light (optional) .....14 Lift Out Battery Box (optional) .......15 Miscellaneous Electrical ........16 Motor .............18...

  • Page 90: Axle (Front) And Fork

    Illustrated Parts Axle (Front) and Fork Parts Page 2...
  • Page 91 Illustrated Parts AXLE (FRONT) and FORK Item No. Part No. 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 0 or 1...

  • Page 92: Axle (Rear)

    Illustrated Parts Axle (Rear) AXLE (REAR) Item No Part No. Description Flange head screw 66-610-97 Lock nut 41-344-98 Brake assembly 41-344-99 Brake assembly 41-126-99 Axle shaft, Right 41-126-98 Axle shaft, Left 88-527-11 Cotter pin 45-303-20 Seal 45-303-10 Seal 80-480-20 Bearing, Ball 41-518-02 Hub, axle 66-610-28...

  • Page 93: Batteries

    Illustrated Parts Batteries BATTERIES Item No. Part No. Description 75-233-00 Battery jumper 77-042-00 217AH, T-105 77-042-50 217AH, TD-217 77-042-80 217AH, T-105 Moist charge (dry) 77-044-00 230AH, T-125 77-044-10 195AH, Mainenance free (Note: requires special charger) 77-047-00 244AH, T-145 77-047-50 250AH, TD-250 77-047-80 244AH, T-145 Moist charge (dry) 77-048-00...

  • Page 94: Brake Linkage

    Illustrated Parts Brake Linkage Parts Page 6...
  • Page 95 Illustrated Parts BRAKE LINKAGE Item No. Part No. 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 00-150-61...

  • Page 96: Decals

    Illustrated Parts Decals DECALS Item No. Part No. 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 Parts Page 8...

  • Page 97: Frame, Seat Cushions And Deck

    Illustrated Parts Frame, Seat Cushions and Deck FRAME, SEAT CUSHIONS and DECK Item No. Part No. 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 Treadle plate...

  • Page 98: Hitches

    Illustrated Parts Hitches HITCHES Item No. Part No. Description 97-808-00 Automatic Coupling hitch 97-804-01 Pintle hitch 88-140-14 1/2NC x 1-1/2 Hex bolt 88-149-80 1/2NC Hax nut 88-148-62 1/2 Split lock washer Head and Tail Lights (optional) Illustration not available HEAD and TAIL LIGHTS Item No.

  • Page 99: Instrument Panel (Dash)

    Illustrated Parts Instrument Panel (dash) INSTRUMENT PANEL Item No. Part No. Description 71-120-10 Key switch (standard) 71-119-99 Spacer for key switch 71-120-90 Replacemet key for #1 (key #2399) 71-121-20 Key switch (keyed unalike) 0 or 1 71-039-11 Accesory switch (SPST) 0 or 1 71-039-11 Accesory switch (SPST)

  • Page 100: Knee Pad And Floor Mats (Optional)

    Illustrated Parts Knee Pad and Floor Mats (optional) Parts Page 12...
  • Page 101 Illustrated Parts KNEE PAD and FLOOR MATS (Optional) Item No. Part No. Description 01-103-20 Floor mats 01-159-10 Knee pad 88-837-11 #14 x 1 Phillips head screw Not shown 94-440-00 Adhesive for floor mats (spray can) * - Not available at time of printing Parts Page 13...

  • Page 102: Ladders And Strobe Light (Optional)

    Illustrated Parts Ladders and Strobe Light (optional) Strobe Light Ladder LADDER Item No. Part No. Description 97-813-00 Ladder, 4-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 LIGHT (STROBE) Item No. Part No. Description 88-029-80 #8-32 Hex nut...

  • Page 103: Lift Out Battery Box (Optional)

    Illustrated Parts Lift Out Battery Box (optional) LIFT OUT BATTERY BOX Item No. Part No. Description 75-077-10 Harness to battery 75-077-14 Harness to vehicle 77-983-00 Lift out battery box * - Not available at time of printing Parts Page 15...

  • Page 104: Miscellaneous Electrical

    Illustrated Parts Miscellaneous Electrical Motion Alarms Battery Status Meters Miscellaneous Wire Harness Clamps Hour Meters Parts Page 16...
  • Page 105 Illustrated Parts MISCELLANEOUS ELECTRICAL Item No. Part No. 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 Seat 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 106: Motor

    Illustrated Parts Motor Parts Page 18...
  • Page 107 Illustrated Parts * - Not available at time of printing Parts Page 19...

  • Page 108: Signet® Charger

    Illustrated Parts Signet® Charger Model HBS series charger shown Note: There are no user serviceable components inside the charger Note: The charger AC cord is an intergral 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 109 Illustrated Parts Model HBS for Flooded Batteries Model HB for Flooded Batteries PART # DESCRIPTION PART # DESCRIPTION 79-302-20 24 volt Charger Assembly (see note) 79-303-41 36 volt Charger assembly (see note) 79-303-40 36 volt Charger assembly (see note) 79-309-42 48 volt charger assembly (see note) 79-309-40 48 volt charger assembly (see note)

  • Page 110: Speed Control Panel

    Illustrated Parts Speed Control Panel Parts Page 22...
  • Page 111 Illustrated Parts SPEED CONTROL PANEL Item No. Part No. Description 72-501-43 Forward or Reverse Solernoid 88-838-06 Sheet Metal Screw # 14 x 1/2” 01-534-80 Panel, Control Mounting 62-204-00 Speed Controller, 275 72-501-42 ISO Solernoid 88-818-06 Sheet Metal Screw # 8 x 1/2” 79-840-00 Circuit Breaker, 10 amp 79-844-00...

  • Page 112: Steering Linkage

    Illustrated Parts Steering Linkage Parts Page 24...
  • Page 113 Illustrated Parts STEERING LINKAGE Item No. Part No. 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 114: Throttle Linkage

    Illustrated Parts Throttle Linkage Slip joint detail Parts Page 26...
  • Page 115 Illustrated Parts THROTTLE LINKAGE, SC 1-00 Item No. Part No. Description 62-033-48 Accelerator module 71-127-20 Brake light switch 02-150-11 Accelertor module lever 50-481-00 Slip joint 88-108-61 3/8 SAE Flat washer 88-527-11 Cotter pin 50-123-31 Throttle link 88-109-81 3/8NC Lock nut 88-108-61 3/8 SAE Flat washer See brake linkage...

  • Page 116: Transmission

    Illustrated Parts Transmission Parts Page 28...
  • Page 117 Illustrated Parts TRANSMISSION 4S-150-10 Item No. Part No. Description Special order Housing 96-330-10 Bolt Order kit Input shaft 88-840-12 Snap ring 80-715-10 ‘O’ ring 80-480-15 Bearing 80-480-10 Bearing 41-973-00 Plug 66-610-35 Bearing Intermediate gear 80-715-00 ‘O’ rimg Order kit Final Gear 80-480-00 Bearing 66-611-04...

  • Page 118: Wheels And Tires

    Illustrated Parts Wheels and Tires (page 1) Parts Page 30...
  • Page 119 Illustrated Parts WHEELS and TIRES Item No. Part No. Description Wheels 12-012-00 5 x 8” Tubeless 12-054-00 11-.25 Diameter Cast Iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-261-00 16.25 x 11.25 Solid rubber 10-074-00 4.00 x 8 Man-Toter, ribbed 10-074-10...
  • Page 120 Illustrated Parts Wheels and Tires (page 2) WHEELS and TIRES Item No. Part No. Description 12-120-00 Bolt on center hub (includes #3, 4, 5) 13-001-00 Wheel with intergral center hub (includes #3, 4, 5) 80-105-00 Race 45-308-00 Grease seal 80-015-00 Bearing Parts Page 32...
  • Page 121 Contents Appendix A: Tool List ..............2 Appendix B: Suggested Torque Limits ........4 Hardware Identification .............. 4 Standard Head Markings ........4 Hex Bolts ............4 Other Bolts ............4 Hex Nuts .............5 Hex Lock Nuts (stover) ........5 Other Nuts ............5 Generic Torque Values ........6 Appendix C: Brake Lining Handling Precautions .......

  • Page 122: Appendix A: Tool List

    Appendixes APPENDIX A: 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 43-201-50: Pinion Seal Installation Tool 62-027-00: Test Light Tests the throttle module in or out of the Used to install the pinion seal on all vehicles Used for testing electrical circuits.
  • Page 123 Appendixes 75-442-55: Pin Removing Tool 41-350-13: Disc Brake Boot Installation Tool 70-440-55: Pin Removing Tool Removes pins from Molex Mini-Fit harness Assists in installing the rubber boot onto the Removes pin from Amp circular harness connectors. disc brake piston. connectors. 77-200-00: Hydrometer 72-201-00: Battery Filler 96-500-48: GT Drive Oil Fill Plug Tool...

  • Page 124: Appendix B: Suggested Torque Limits

    Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS HARDWARE IDENTIFICATION Standard Head Markings 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. Note: Toque values specified are for clean dry threads.

  • Page 125: 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 should be treated as S.A.E. grade A ® Other nuts used by Taylor-Dunn Appendixes *Not available at time of printing Appendix B Page 5...

  • Page 126: Generic Torque Values

    Appendixes Generic Torque Values 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. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 127 Appendixes 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 128: Appendix C: Brake Lining Handling Precautions

    Appendixes APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS 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 do contain asbestos.
  • Page 130 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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