Page 1 Models Inlcuded: 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 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 Section Index  ® Model SC-100 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service Throttle Linkage Motor Service Transaxle Service Tires and Wheels Battery Service Charger Troubleshooting Wire diagram Illustrated Parts Appendix...
Page 6 ® A small sample of the many types of vehicles offered by Taylor-Dunn B 2-48-36 Equipped with optional B 1-00 Personnel carrier hydraulic dump bed BT 2-80 Eight passenger tram MX 1600 Equipped with optional ladder rack and weld tanks...
Page 7: Table Of Contents
Table of Contents Introduction About this manual ...........2 Who Should Read This Manual ......3 Responsibilities ..........3 Of the Owner............3 How To Use This Manual ........4 Conventions ............5 How to Identify Your Vehicle ......6 Taking Delivery of Your Vehicle......7...
Page 8: Introduction
Please continue to read this manual and enjoy this ® high quality Taylor-Dunn vehicle. This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn ® vehicles and is not intended as a training guide. Taylor-Dunn ®...
Page 9: Who Should Read This Manual
Of the Service Personnel... The service personnel are responsible for the service and maintenance of the vehicle. At no time should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn ® vehicle.
Page 10: How To Use This Manual
INTRODUCTION HOW TO USE THIS MANUAL This manual is organized into five main sections: INTRODUCTION This section describes how to use this service manual and how to identify your vehicle. Safety Rules and Operating Instructions This section outlines the safety and operational issues, location and operation of controls, and the operational checks that are to be performed on this vehicle.
Page 11: Conventions
INTRODUCTION Conventions Symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: A shaded box with the word “Warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others.
Page 12: 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. They are not to be driven on public highways.
Page 13: Taking Delivery Of Your Vehicle
The report must be made within 24 hours of receiving the vehicle and its accessories. ® The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is a factory authorized service technician.
Page 14 Notes INTRODUCTION Page-8...
Page 15 TABLE OF CONTENTS General Maintenance Maintenance Guidelines ......2 Troubleshooting Guide .......3 Lubrication Chart ........4...
Page 16 • 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 17 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 18 Maintenance, Service and Repair LUBRICATION CHART 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 Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease Steering Chains 30 wt Motor Oil Drive Drain Plug...
Page 19 Signet Charger Operation, Model HB Series ....13 Signet Charger Operation, Model HBS series .... 14 Lestronic II Charger Operation ........15 Taylor-Dunn X-Series Charger ........16 Charging with the X-Series Charger ......17 AC Power Source ............18 New Battery Break in ..........18 Charging Time.............
Page 20: Standard Specifications
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* ITEM VOLTAGE 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 339 kg (747 lbs) Without Batteries Min/Max Battery 105 kg to 145 kg (232 lbs to 480 lbs)
Page 21: 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 22: 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 23: Battery Status Indicator, Analog
SAFETY RULES AND OPERATING INSTRUCTIONS Battery Status Indicator, Analog The battery status indicator is located to the left of the hour meter. The normal operating range is in the green zone. Park the vehicle for a few minutes for an accurate reading.
Page 24: Foot Brake Pedal
SAFETY RULES AND OPERATING INSTRUCTIONS Foot Brake Pedal The brake pedal is the throttle pedal located on the right side of the floorboard positioned under the operator’s right foot. The throttle pedal also functions as the accelerator pedal. Press the rear of the throttle pedal to apply the brake. The brake is automatically released when accelerating.
Page 25: Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS Smart View Display The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is described below. BSI: A bar graph representing the current state of HM: Depending on the revision level of the controller, charge is located across the top of the display.
Page 26 SAFETY RULES AND OPERATING INSTRUCTIONS Maintenance Monitor: NOTE: The Maintenance Monitor function is optional. The Maintenance Monitor function can be turned ON or OFF by your dealer. Operation: The SMD notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator.
Page 27: Fault Code Tables
SAFETY RULES AND OPERATING INSTRUCTIONS Fault Code Tables Level 5 Faults NOTE: Most faults are a result of a fault in the control system that will require service by a qualified Fault Code Description What to do F05000 Contactor Over Current Refer to service technician technician.
Page 28: 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. • • No passengers are allowed to be transported in the No reckless driving.
Page 29: Parking
SAFETY RULES AND OPERATING INSTRUCTIONS Parking Using the Ladder Before leaving the vehicle: The maximum ladder capacity is 200 pounds. Access the ladder from the operator platform only. Do • Set the parking brake. not climb the ladder from the rear of the vehicle. •...
Page 30: Towing The Vehicle
SAFETY RULES AND OPERATING INSTRUCTIONS Frame Tie Downs Towing the Vehicle WARNING ALWAYS use another driver to steer this vehicle while it is being towed. DO NOT block or otherwise tie the treadle down to release the brake. Blocking the treadle down may result in uncontrolled movement of the vehicle causing severe bodily injury and/or property damage.
Page 31: Charging Your Vehicle
SAFETY RULES AND OPERATING INSTRUCTIONS CHARGING YOUR VEHICLE WARNING CAUTION Explosive mixtures of Hydrogen gas are present The key switch must be in the “OFF” position within battery cells at all times. Do not work when charging the batteries. Failure to turn the with or charge a battery in an area where open key switch “OFF”...
Page 32: Signet Charger Operation, Model Hbs Series
SAFETY RULES AND OPERATING INSTRUCTIONS WARNING CAUTION Explosive mixtures of Hydrogen gas are present The key switch must be in the “OFF” position within battery cells at all times. Do not work when charging the batteries. Failure to turn the with or charge a battery in an area where open key switch “OFF”...
Page 33: Lestronic Ii Charger Operation
SAFETY RULES AND OPERATING INSTRUCTIONS WARNING CAUTION Explosive mixtures of Hydrogen gas are present The key switch must be in the “OFF” position within battery cells at all times. Do not work when charging the batteries. Failure to turn the with or charge a battery in an area where open key switch “OFF”...
Page 34: Taylor-Dunn X-Series Charger
Always provide Taylor-Dunn X-Series Charger ample ventilation in rooms where batteries are being charged. Failure to do so may result in severe bodily injury and/or property damage.
Page 35: Charging With The X-Series Charger
SAFETY RULES AND OPERATING INSTRUCTIONS Self Diagnosis Procedure If you suspect a battery charging problem press the self diagnostic switch to start the charger self diagnostic procedure. Any faults found by the procedure will be displayed by the two LED’s. Refer to the table below for the fault codes. Note: To run this procedure, a battery that is not severely discharged must be connected to the charger.
Page 36: Ac Power Source
SAFETY RULES AND OPERATING INSTRUCTIONS AC Power Source Charging Time The AC power source Average charging time is 8 to 10-hours. The time required WARNING required by the charger to fully charge your batteries will vary depending on: Use of extension cords will vary depending on •...
Page 37: 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 38: Standard Periodic Maintenance Schedule For The Smart View Display
SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD PERIODIC MAINTENANCE SCHEDULE FOR THE SMART VIEW DISPLAY NOTE: The maintenance function is optional. Your vehicle may be equipped with a customized maintenance schedule Preventative maintenance Schedule MAINTENANCE HOUR MAINTENANCE TO BE PERFORMED LEVEL INTERVAL Inspect the brake system including the park brake and mounting harware...
Page 39: 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 40 Notes SAFETY RULES AND OPERATING INSTRUCTIONS Safety Rules Page 22...
Page 41 TABLE OF CONTENTS Front Axle 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 42: Front Axle
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 43: 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 44: 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 45: 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 46 Notes Maintenance, Service, and Repair Front Axle Page 6...
Page 47 TABLE OF CONTENTS Steering Componets 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 48: 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 49: Center The Steering Wheel
Maintenance, Service, and Repair Center 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 rear wheels to prevent vehicle movement. 5.
Page 50 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 51: 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” then the steering wheel should be replaced.
Page 52: Pillow Blocks
Maintenance, Service, and Repair Pillow Blocks NOTE: The two pillow blocks will wear at the same rate. If one is worn out, then both blocks should be replaced as a set. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 53: 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 54: 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 55: 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 56: 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 57 TABLE OF CONTENTS Brake Service Inspect the Service Brake ......2 Disc Brake Pads ............2 Disc Brake Rotor ............3 Inspect the Parking brake ......4 Wheel Park Brake (mechanical disc) ......4 Adjust the Service Brakes ......5 Mechanical Disc Brakes ..........5 Adjust the Parking Brake ......6 Primary Adjustment (handle) ........
Page 58: Inspect The Service Brake
INSPECT THE SERVICE BRAKE Disc Brake Pads NOTE: The brake pad must be removed to accurately measure the lining thickness. Refer to Replace Current Taylor-Dunn brakes are asbestos free. However, there is the ® possibility that the original brakes were replaced with aftermarket parts containing asbestos.
Page 59: Disc Brake Rotor
Maintenance, Service, and Repair Disc Brake Rotor 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 60: Inspect The Parking Brake
Maintenance, Service, and Repair INSPECT THE PARKING BRAKE Wheel Park Brake (mechanical disc) Inspect the Service The parking brake is actuated through the same linkages as the service brake. Refer to Brake section to inspect the brake pads. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
Page 61: Adjust The Service Brakes
Maintenance, Service, and Repair ADJUST THE SERVICE BRAKES Mechanical Disc 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.
Page 62: 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 adjustments.
Page 63: Replace Rear Brake Pads
Maintenance, Service, and Repair REPLACE REAR BRAKE PADS 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 64: Replace The Mechanical Caliper Assembly
Maintenance, Service, and Repair REPLACE THE MECHANICAL CALIPER ASSEMBLY 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 65 TABLE OF CONTENTS Throttle Linkage Throttle Linkage Adjustments .....2...
Page 66 Maintenance, Service, and Repair THROTTLE LINKAGE ADJUSTMENTS No routine adjustments to the throttle linkage are required. When ever replacing the throttle linkage, tighten the linkage nut (arrow) so that two to four threads are visible beyond the nut. Page 2...
Page 67 TABLE OF CONTENTS Motor Service Inspecting the Motor Brushes ....2 Motors with internal cooling fans ....... 2 Motor Removal and Installation ....2 Motor Inspection .........2 Replacing the Brushes or Armature Bearing Repairing the Commutator ......5 Service Limits ..........6...
Page 68: Motor Service
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 69 Maintenance, Service, and Repair 2. Measure the diameter of the commutator. 7. Visually inspect the armature windings for burnt • If the commutator is less than the minimum insulation. Burnt insulation is a direct result of diameter specified in section motor overheating and could lead to a shorted Service Limits armature.
Page 70: Replacing The Brushes Or 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 71: 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 72: 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 73 TABLE OF CONTENTS Transmission Check Oil Level ..........2 Change Oil ..........3 Motor Removal and Installation ....4 Rear Hub or Rotor ........5 Removing and Installing the Rear Axles ..6 Transmission Assembly ......8 Remove and Install ............. 8 Disassembly and Reassembly of the Primary Reduction Gear Case ......10 Disassembling the 3rd Member ....13 Assembling the 3rd Member .......16...
Page 74: Check Oil Level
Maintenance, Service, and Repair CHECK OIL LEVEL The oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 1.
Page 75: Change Oil
Maintenance, Service, and Repair CHANGE OIL 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 76: Motor Removal And Installation
Maintenance, Service, and Repair MOTOR REMOVAL AND INSTALLATION NOTE: Some applications will require removing the drive assembly from the vehicle to remove the motor. Removing and Installing the Drive Assembly Refer to for information on removing the drive assembly. Some vehicles are equipped with an automatic electric brake. The automatic electric brake is sandwiched between the drive motor and the gear case.
Page 77: Rear Hub Or Rotor
Maintenance, Service, and Repair REAR HUB OR ROTOR 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.
Page 78: Removing And Installing The Rear Axles
Maintenance, Service, and Repair REMOVING AND INSTALLING THE REAR AXLES The oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange.
Page 79 Maintenance, Service, and Repair 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14. Inspect all bearings for roughness or play, replace as needed. 15. Install in reverse order, lubricate the o-ring. Note: Be sure not to damage the o-ring.
Page 80: Transmission Assembly
Maintenance, Service, and Repair TRANSMISSION ASSEMBLY Remove and Install NOTE: Refer to the illustration on the following page. 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.
Page 81 Maintenance, Service, and Repair Transmission view from rear Page 9...
Page 82: Disassembly And Reassembly Of The Primary Reduction Gear Case
Maintenance, Service, and Repair DISASSEMBLY AND REASSEMBLY OF THE PRIMARY REDUCTION GEAR CASE 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.
Page 83 Maintenance, Service, and Repair 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the pinion shaft.
Page 84 Maintenance, Service, and Repair Lubricate all parts with gear oil before installation. Failure to pre-lube the parts may result in premature failure. Note: Torque the drain plug to 21-25 foot-pounds. Note: Torque the gear case to 3rd member retaining bolts to 18-20 foot-pounds. Note: Torque the pinion nut to 154-169 foot-pounds.
Page 85: Disassembling The 3Rd Member
Maintenance, Service, and Repair DISASSEMBLING THE 3RD MEMBER 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 86 Maintenance, Service, and Repair 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race from the side plate. 15. Remove the differential assembly from the 3rd member housing. 16.
Page 87 Maintenance, Service, and Repair 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the front bearing from the input shaft. Note: The input shaft may have to be driven out to perform this procedure. 19. Remove the input shaft’s shims and spacer. 20.
Page 88: Assembling The 3Rd Member
Maintenance, Service, and Repair ASSEMBLING THE 3RD MEMBER 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. Cover Housing 3. Install the carrier bearing races into the housing and cover.
Page 89 Maintenance, Service, and Repair 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. If the ring and pinion gears or bearings are replaced then the pinion gear must be re-shimmed.
Page 90 Maintenance, Service, and Repair 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the vehicle.
Page 91: Pinion Bearing Preload
Maintenance, Service, and Repair Pinion Bearing Preload Setting the Pinion Gear Depth NOTE: The pinion gear depth must be set before the preload. Refer to 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3.
Page 92: Pinion Gear Shimming Instructions
Maintenance, Service, and Repair 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. NOTE: To perform this procedure, all parts must be clean and the bearings lightly lubricated. Setting the Pinion Gear Depth This formula is used to calculate the amount of shims that are required: C - B - A + (DV) = Pinion Shim (mm)
Page 93 Maintenance, Service, and Repair NOTE: Values shown are for reference only Page 21...
Page 94 Notes Maintenance, Service, and Repair Page 22...
Page 95 TABLE OF CONTENTS Tires and Wheels Tire Inflation ..........2 Tire Inspection ..........2 Replace the Front Tire/Wheel .....3 Replace the Rear Tire/Wheel .....3 Repair the Tire (pneumatic) .......4 Replace the Tire (pneumatic) ....5...
Page 96: Tire Inflation
Maintenance, Service, and Repair TIRE INFLATION 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 97: Replace The Front Tire/Wheel
Maintenance, Service, and Repair 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. Refer to Tire Inflation section or Steering Component Service section for information on proper Note: tire inflation or front end wheel alignment.
Page 98: 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 99: Replace The Tire (Pneumatic)
Maintenance, Service, and Repair REPLACE THE TIRE (PNEUMATIC) Replace NOTE; To replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to the Tire/Wheel section for information on removing the tire/wheel assembly. Tire replacement should only be performed by personnel trained in tire replacement. Explosion Hazard.
Page 100 Notes Maintenance, Service, and Repair Page 6...
Page 101 TABLE OF CONTENTS Battery Service Cleaning .............2 Testing ............3 Charging .............4 Watering .............5 Replacing (6-volt batteries only) ....6 Moist Charge Batteries..........8 Storage and Returning to Service ....9 Storage ................ 9 Returning to Service ........... 10...
Page 102: Cleaning
Maintenance, Service, and Repair CLEANING Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.
Page 103: Testing
Maintenance, Service, and Repair TESTING A combination of the Load Test and Specific Gravity Test should be used to accurately determine Note: the condition of the batteries. Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 104: Charging
Maintenance, Service, and Repair Specific Gravity Test NOTE: The batteries must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading of 1275 to 1300 (see the illustration to the right).
Page 105: Watering
Maintenance, Service, and Repair WATERING NOTE: The electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then top off when the charging cycle is complete.
Page 106: Replacing (6-Volt Batteries Only)
Maintenance, Service, and Repair REPLACING (6-VOLT BATTERIES ONLY) Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 107 Maintenance, Service, and Repair 7. Remove the battery hold downs. 8. Inspect the battery hold downs for corrosion. If any signs of corrosion are seen then the battery hold downs should be replaced. 9. Remove all battery jumpers from both posts of the battery or batteries being replaced. NOTE: It is recommended to replace the battery jumpers when replacing the batteries.
Page 108: Moist Charge Batteries
Maintenance, Service, and Repair Moist Charge Batteries Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 109: Storage And Returning To Service
Maintenance, Service, and Repair 6. Fill all battery cells with electrolyte to the proper level. 7. Thoroughly clean any spilled electrolyte from the batteries Cleaning the Batteries or the ground. Refer to information on cleaning the batteries. 8. Reconnect the battery cables, connect the batteries to the charger and allow the charger to complete one charging cycle.
Page 110: Returning To Service
Maintenance, Service, and Repair Returning to Service Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present.
Page 111 Table of Contents Motor Controller Remove/Install ..........2 Inspect ..............2 Receptacles .............2 Base Plate ...............2 Terminal Ends ............2 ’R’ Terminal ..............2 Repair/Programming ........3 Programming ............3 Troubleshooting ..........3 Hardware Torque ..........4 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 112: Motor Controller
Motor Controller REMOVE/INSTALL INSPECT WARNING Receptacles This section is one section of a complete service The inside of each receptacle should be clean and free manual. Before starting any procedure, read all of any debris. Use aerosol electrical cleaner if required. warnings and instructions that are located in the Base Plate Service Guidelines chapter.
Page 113: Repair/Programming
This manual was provided on the original vehicle CD. A hard copy can be purchased from your authorized NOTICE Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. The controller power base and logic are a matched set. DO NOT swap logics from one base to another as this may damage the logic or power base.
Page 114 Motor Controller 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 4...
Page 115 Table of Contents Charger Remove/Install ..........2 Troubleshooting ..........2 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 116 CD. A hard copy can be purchased Failure to follow this instruction may result in serious from your authorized Taylor-Dunn distributor or can be injury due to electric shock and/or property damage. downloaded from the Taylor-Dunn web site.
Page 117 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-00049.pdf Charger AC Cords:...
Page 118 Notes Wire Diagrams Wire Diagrams Page 2...
Page 119 TABLE OF CONTENTS Illustrated Parts Front Axle and Fork ........2 Steering Linkage..........4 Transmission Gear Case .......6 Transmission Differential Case ......8 Rear Axle ............10 Rear Brakes...........12 Motor .............14 Brake Linkage..........16 Throttle Linkage ..........18 Wheels and Tires (page 1) ......20 Wheels and Tires (page 2) ......22 Instrument Panel (dash) ........24 Resetting the Smart View Display ......
Page 120: Illustrated Parts
Illustrated Parts Front Axle and Fork Page 2...
Page 121 Illustrated Parts 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 0 or 1...
Page 122: Steering Linkage
Illustrated Parts Steering Linkage Page 4...
Page 123 Illustrated Parts 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: Transmission Gear Case
Illustrated Parts Transmission Gear Case Note 1: Spacer 23 is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number GT- 3287213. Add 10 to the part number for every 0.05mm over 3.9. For example, if 4.55mm is needed: 4.55-3.9 = .65mm over, 0.65/.05 = 13, 13*10 = 130.
Page 125 Illustrated Parts Transmission Gear Case ITEM # PART # DESCRIPTION GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1 GT-3287543 Input shaft, 12:1 0 or 1...
Page 126: Transmission Differential Case
Illustrated Parts Transmission Differential Case Page 8...
Page 127 Illustrated Parts Transmission Differential Case ITEM # PART # DESCRIPTION GT-70302 M10 x 30 Bolt GT-3287183 Ring and pinion gear set GT-3297193 Differential case cover GT-3287133 Adjusting ring GT-70417 Fill/Level plug GT-3287113 Differential housing GT-3287143 Differential case GT-72013 O-ring GT-71896 M10 x 25 Bolt GT-71978 Bearing and race...
Page 128: Rear Axle
Illustrated Parts Rear Axle Page 10...
Page 129 Illustrated Parts Rear Axle ITEM # PART # 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 92-104-10 Hub cover 41-290-54 Axle housing, left 41-290-55 Axle housing, right Not shown 89-113-30...
Page 130: Rear Brakes
Illustrated Parts Rear Brakes Page 12...
Page 131 Illustrated Parts Rear Brakes 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 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 132: Motor
Illustrated Parts Motor Page 14...
Page 133 Illustrated Parts Page 15...
Page 134: Brake Linkage
Illustrated Parts Brake Linkage Page 16...
Page 135 Illustrated Parts 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 136: Throttle Linkage
Illustrated Parts Throttle Linkage Slip joint detail Page 18...
Page 137 Illustrated Parts Throttle Linkage ITEM # PART # DESCRIPTION 62-033-48 Accelerator module 88-109-81 3/8NC Lock nut 88-108-61 3/8 SAE Flat washer 50-481-00 Slip joint 88-108-61 3/8 SAE Flat washer 88-527-11 Cotter pin 50-123-21 Throttle link See brake linkage Treadle 88-527-11 Cotter pin 88-108-61 3/8 SAE Flat washer...
Page 138: Wheels And Tires
Illustrated Parts Wheels and Tires (page 1) Page 20...
Page 139 Illustrated Parts Wheels and Tires ITEM # PART # 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 140 Illustrated Parts Wheels and Tires (page 2) Page 22...
Page 141 Illustrated Parts Wheels and Tires ITEM # PART # 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 Page 23...
Page 142: Instrument Panel (Dash)
Resetting the Smart View Display The meter should only be reset after the preventative maintenance ® has been performed. Taylor-Dunn part number 62-027-40 Hand set (available with instructions as part number 62-027-61) must be used to reset the meter. Refer to the handset instructions (D0-100-08) for information on the procedure to reset the display.
Page 143 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. The Smart View Display will only work with the Sevcon control system.
Page 144: Speed Control Panel
Illustrated Parts Speed Control Panel Page 26...
Page 145 Illustrated Parts 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 20 Amp circuit breaker 79-840-20...
Page 146: Miscellaneous Electrical
Illustrated Parts Miscellaneous Electrical Motion Alarms Battery Status Meters Miscellaneous Wire Harness Clamps Hour Meters Page 28...
Page 147 Illustrated Parts Miscellaneous Electrical ITEM # PART # DESCRIPTION Not Shown 75-152-60 Chassie Control Harness Not Shown 75-152-07 Power Harness Not Shown 75-152-48 Harness, control panel Not Shown 98-599-15 Plastic grommet for 1.75 hole Not Shown 98-599-20 Plastic Grommet for 2.5 hole Not shown 73-012-40 DC-DC converter (optional)
Page 148: Charger (Lestronic)
Illustrated Parts Charger (Lestronic) Page 1 Page 30...
Page 149 Illustrated Parts Page 31...
Page 150 Illustrated Parts Charger (Lestronic) Page 2 Page 32...
Page 151 Illustrated Parts Page 33...
Page 152: Charger (Lestronic)
Illustrated Parts ® Signet Charger NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector Signet® Charger ITEM # PART # DESCRIPTION 79-302-20 24 volt Charger assembly...
Page 153: X-Series Charger
Illustrated Parts X-Series Charger 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 154: Batteries
Illustrated Parts Batteries 36-volt battery configuration 24-volt battery configuration Part numbers for the cables , hardware, and hold downs are the same as the 24-volt configuration 48-volt battery configuration Page 36...
Page 155 Illustrated Parts Batteries ITEM # PART # 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, Maintenance 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 156: Frame, Seat Cushions And Deck
Illustrated Parts Frame, Seat Cushions and Deck Trailer Hitches Page 38...
Page 157 Illustrated Parts Frame, Seat Cushions and Deck 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 Treadle plate 03-150-94 Floorboard 90-000-00...
Page 158 Illustrated Parts Decals Page 40...
Page 159: Decals
Illustrated Parts 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 41...
Page 160: Knee Pad And Floor Mats (Optional)
Illustrated Parts Knee Pad and Floor Mats (optional) Page 42...
Page 161 Illustrated Parts Knee Pad and Floor Mats (optional) ITEM # PART # DESCRIPTION 01-103-20 Floor mats 01-159-10 Knee pad 88-837-11 #14 x 1 Phillips head screw Adhesive for floor mats (spray can) Not shown 94-440-00 Page 43...
Page 162: Lift Out Battery Box (Optional)
Illustrated Parts Lift Out Battery Box (optional) Illustration not available Page 44...
Page 163 Illustrated Parts Lift Out Battery Box ITEM # PART # DESCRIPTION 75-077-10 Harness to battery 75-077-14 Harness to vehicle 77-983-00 Lift out battery box, 24 volt Page 45...
Page 164: Ladders And Strobe Light (Optional)
Illustrated Parts Ladders and Strobe Light (optional) Strobe Light Page 46...
Page 165 Illustrated Parts Ladders 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 Strobe Light ITEM # PART # DESCRIPTION 88-029-80 #8-32 Hex nut 88-028-62 #8 Split lock washer...
Page 166 Notes Illustrated Parts Page 48...
Page 167 TABLE OF CONTENTS Appendixes Appendix A: Tool List ........2 Appendix b: Suggested Torque Limits for Standard Hardware .........4 Hardware Identification .......4 Standard Head Markings ..........4 Hex Bolts ..............4 Other Bolts ..............4 Hex Nuts ..............5 Hex Lock Nuts (stover) ..........5 Other Nuts ..............
Page 168: Appendixes
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 169 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 170: Appendix B: Suggested Torque Limits For Standard Hardware
Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE 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 171: Hex Nuts
NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts ® Other nuts used by Taylor-Dunn should be treated as S.A.E. grade A Appendixes *Not available at time of printing Appendix B Page 5...
Page 172: 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 173 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 174: 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 176 Taylor-Dunn® Mfg. 2114 W. Ball Rd. 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-100-36 Sc-100-48

Taylor-Dunn SC-100-24 Operation, T Roubleshooting And Replacement Parts Manual

Table of Contents

Safety Rules and Operating Instructions

Standard Specifications

Driver Training Program

Safety Rules and Guidelines

Vehicle Controls

Vehicle Operation Guidelines

Charging Your Vehicle

Storing / Returning to Service

Periodic Maintenance Checklist

Standard Periodic Maintenance Schedule for the Smart View Display

Maintenance Guidelines for Severe Duty Applications

Notes

Notesmaintenance, Service, and Repair

Front End Alignment

Inspect the Steering Components

Fork Bearings

Adjust the Steering Shaft

Replace the Steering Wheel

Replace the Front Fork

Table of Contents

Inspect the Service Brake

Inspect the Parking Brake

Adjust the Service Brakes

Adjust the Parking Brake

Replace Rear Brake Pads

Replace the Mechanical Caliper Assembly

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Warning

Motor Controller

Remove/Install

Inspect

Repair/Programming

Troubleshooting

Table of Contents

Appendix A: Tool List

Appendix B: Suggested Torque Limits for Standard Hardware

Appendix C: Brake Lining Handling Precautions

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

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Table of Contents