Taylor-Dunn SC-001-59 Operation, T Roubleshooting And Replacement Parts Manual
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Taylor-Dunn SC-001-59 Operation, T Roubleshooting And Replacement Parts Manual

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T h e B e s t W a y
To G o
A b o u t Yo u r
B u s i n e s s
Revision: J
Revision: H
Models Inlcuded:
SC-001-59 (SC 159)
AN-001-71 (AN 171)
Curtis PMC control system only
MANUAL MA-159-05
Operation, Troubleshooting and
Replacement Parts Manual
Serial Number Range:
Starting: 94562
Ending: 167016
Note: Other controllers used up to serial
number 95754 use manual MA-159-04
Curtis PMC

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  • Page 1 Models Inlcuded: SC-001-59 (SC 159) AN-001-71 (AN 171) Curtis PMC control system only T h e B e s t W a y To G o A b o u t Yo u r B u s i n e s s...
  • Page 3 Address inquiries to Reference Permissions, ® Taylor-Dunn Mfg., 2114 W. Ball Road, Anaheim, CA 92804 TAYLOR-DUNN SERVICE CENTER For more information about this and other Taylor-Dunn ® manuals, please write Taylor-Dunn ® ® Taylor-Dunn Mfg.
  • Page 4 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...
  • Page 5 Section Inde Section Inde Section Inde Section Inde Section Index x x x x Taylor-Dunn ® Model SC-001-59 / AN-001-71 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service...
  • Page 6 SC1-00 Stock Chaser B2-48 With Stake Side Dump Bed Option E4-55 Sit Down Tow Tractor C4-25 Sit Down Tow Tractor...

  • Page 7: 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 Vehicles shown with optional equipment...

  • Page 8: About This Manual

    ABOUT THIS MANUAL RESPONSIBILITIES The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. The owner of this or any Taylor-Dunn vehicle is Taylor-Dunn , a leading manufacturer of electric ®...

  • Page 9: 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 warnings, cautions, instructions, or notes found INTRODUCTION throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 10: 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 11: 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.
  • Page 13 TABLE OF CONTENTS Standard Specifications* ....2 Safety Rules and Guidelines ..... 3 Driver Training Program ....3 Driver Qualifications..........3 2 - Start Switch ............. 4 Vehicle Controls ........ 4 1 - Horn Switch ............. 4 3 - Forward-Off-Reverse Switch ......4 Accessory Switch (Optional) ........

  • Page 14: Standard Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* ITEM MODEL SPECIFICATION Occupancy Driver only Dimensions SC 159 213L x 78W x 119H Centimeters (84L x 31 x 47H Inches) AN 171 267l x 78W x 126H Centimeters (105L x 31 x 49.5H Inches) Turning Radius SC 159 160 Centimeters (63 Inches)

  • 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: Start Switch

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1 - Horn Switch Accessory Switch (Optional) The horn switch is located on the right side of the steering Push switch forward to turn on the accessory. Pull the tower. Depress the switch to sound the horn, release it switch back to turn off the accessory.

  • Page 17: Battery Status Indicator, Digital Bargraph

    SAFETY RULES AND OPERATING INSTRUCTIONS 1 - Hour Meter (optional) The hour meter is located to the right of the battery status indicator. It records the number of hours the vehicle has been in operation. 2 - Battery Status Indicator, Analog (optional) The battery status indicator is located to the left of the hour meter.

  • Page 18: Accelerator / Brake Treadle, Sc 159

    SAFETY RULES AND OPERATING INSTRUCTIONS Steering, SC 159 The steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter- clockwise. Steering, AN 171 The AN 171 uses a tiller for steering. While sitting: To turn right, move the tiller to the right.

  • Page 19: Foot Interlock Switch, Sc 159 (Optional)

    SAFETY RULES AND OPERATING INSTRUCTIONS Foot Interlock Switch, SC 159 (optional) A switch or pedal located under the driver's left foot disables the power to the vehicle when it is released. The switch or pedal must be depressed for the vehicle to operate.

  • Page 20: Vehicle Operational Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS While driving: VEHICLE OPERATIONAL Slow down and sound the horn to warn pedestrians • GUIDELINES or when approaching a corner or other intersection. No reckless driving. • Safety Guidelines Do not drive this vehicle on steep inclines or where •...

  • Page 21: Parking

    SAFETY RULES AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle: Set the forward-of f-reverse switch to the ` “OFF” • position. Rotate the start switch to the “OFF” position. • In addition: If parking this vehicle on an incline, turn the wheels •...

  • Page 22: Charging Your Vehicle

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

  • Page 23: Charging Time

    SAFETY RULES AND OPERATING INSTRUCTIONS Charging Time STORING AND RETURNING TO Average charging time is 8 to 10-hours. The time required SERVICE to fully charge your batteries will vary depending on: Both storing your vehicle and returning it to service Capacity of the batteries, higher capacity requires •...

  • Page 24: Periodic Maintenance Checklist

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST Semi - Weekly Monthly Quaterly Annualy Maintenance Item Annual (20hrs) (80hrs) (250hrs) (1000hrs) (500hrs) Check Condition of Tires and Tire Pressure Check All Lights, Horns, Beepers and Warning Devises Check and Fill Batteries Check Brake System Check Steering System Check for Fluid Leaks...

  • Page 25: 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 27 Table of Contents Maintenance Guidelines ....... 2 Troubleshooting Guide ........ 3 Lubrication Chart .......... 4 Model C 4-25 Tow Tractor Illustrations of other popular Taylor-Dunn vehicles Model E 4-55 Tow Tractor...
  • Page 28 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 •...
  • Page 29 Maintenance, Service and Repair Troubleshooting Guide Symptom Probable Cause Steering Pulls in One Direction Front End Out of Alignment , Frame or Fork bent Dry Lube Points in Steering Linkage Damaged Fork Bearings Hard Steering Damaged Steering Chains Low Tire Pressure Loose Steering Chains Excessive Steering Play Loose Steering Linkage...
  • Page 30 Maintenance, Service and Repair Lubrication Chart Description Locations Lubricant Type Treadle Bushings General Purpose Grease Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease Fork Spindle Bearings General Purpose Grease Steering Shaft General Purpose Grease Steering Shaft Gears General Purpose Grease Steering Chain General Purpose Grease...
  • Page 31 TABLE OF CONTENTS Inspect the Front Wheel Bearings ..2 Adjust Front Wheel Bearings .... 3 Front Axle Removal and Installation .. 4 Removal ..............4 Installation ............4 Replace Front Wheel Bearings ..5...

  • Page 32: Inspect The Front Wheel Bearings

    Maintenance, Service, and Repair INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS BEARINGS 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. position, then remove the key. 2.

  • Page 33: Front Axle Removal And Installation

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND INSTALLATION Removal Installation 1. Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub. 2. Assemble the bearing spacers into the front wheel 1.

  • Page 34: 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 front wheels to prevent vehicle movement.
  • Page 35 TABLE OF CONTENTS Front End Alignment ......2 Center the Steering Wheel ........2 Inspect the Steering Components ..4 Steering Wheel and Bushings ....... 4 Steering Chain ............4 Pillow Blocks ............5 Fork Bearings ........5 Adjust the Steering Shaft ....6 Replace the Steering Wheel ....

  • Page 36: Front End Alignment

    Maintenance, Service, and Repair 8. Center the steering wheel. Refer to section Center FRONT END ALIGNMENT for information regarding the Steering Wheel centering the steering wheel. 9. Untie the front fork. 10. Adjust the steering shaft. Refer to section 1. Make sure the key-switch is in the “OFF” Adjust position, then remove the key.
  • Page 37 Maintenance, Service, and Repair 12. Install the chain on the lower sprocket. 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.

  • Page 38: 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 •...

  • Page 39: Fork Bearings

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

  • Page 40: Adjust The Steering Shaft

    Maintenance, Service, and Repair ADJUST THE STEERING REPLACE THE STEERING SHAFT WHEEL 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 41: Replace The Front Fork

    Maintenance, Service, and Repair 9. Thoroughly clean all parts and install in reverse REPLACE THE FRONT FORK order. Tighten the fork spindle nut to remove all play • in the fork bearings and then an additional 1/4 turn. 1. Make sure the key-switch is in the “OFF” Refer to section Front Axle Removal and •...
  • Page 43 TABLE OF CONTENTS Inspect the Service Brake ....2 Adjust the Service Brake ....2 Adjust the Brake Linkages ........3 Replace the Brake Lining ....4 Replace Brake Drum ......6 Replacing the Treadle Linkage ..7...

  • Page 44: Inspect The Service Brake

    Maintenance, Service, and Repair 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 45: Adjust The Brake Linkages

    Maintenance, Service, and Repair Adjust the Brake Linkages Do not use this procedure to adjust the brakes. This procedure should only be performed when replacing any of the mechanical brake linkages or cables or it is found that the cables or linkages have been adjusted incorrectly.

  • Page 46: Replace The Brake Lining

    Maintenance, Service, and Repair REPLACE THE BRAKE LINING 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 47 Maintenance, Service, and Repair 10. Remove the brake band bolt (4). 11. Remove the clevis pin (11) from the brake band anchor and remove the brake band (3) from the assembly. 12. Inspect the brake arm pivot bolt for signs of wear.

  • Page 48: Replace Brake Drum

    Maintenance, Service, and Repair REPLACE 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: Replacing The Treadle Linkage

    Maintenance, Service, and Repair REPLACING THE TREADLE LINKAGE Due to variations in the length of the frame, the treadle linkage must be individually fitted to each vehicle. The hole for the treadle clevis pin is pre-punched. The hole for the bell crank must be match drilled. 6.
  • Page 51 TABLE OF CONTENTS Throttle Linkage Adjustments .... 2...
  • Page 52 Maintenance, Service, and Repair THROTTLE LINKAGE ADJUSTMENTS The throttle linkage is coupled with the brake linkage. There are no adjustments that are specific to the throttle linkage. Refer to the Brake Section for linkage adjustments or replacement of the treadle linkage. Accelerator Module Arm Bell Crank Treadle Linkage...
  • Page 53 TABLE OF CONTENTS Inspecting the Motor Brushes .... 2 Motors with internal cooling fans ......2 Enclosed Motors (GE, no cooling fan) ....2 Motor Removal and Installation ..3 Motor Inspection ........ 3 Replacing the Brushes....... 5 Replacing the Bearings ..... 6 Repairing the Commutator ....

  • Page 54: Inspecting The Motor Brushes

    Motor Service INSPECTING THE MOTOR BRUSHES Typical brush and brush holder Enclosed Motors (GE, no cooling fan) Typical motor with cooling fan indicated by the arrow Motors with internal cooling fans General Electric Motors NOTE: There are four brushes in the motor. The brushes will not wear at the same rate.

  • Page 55: Motor Removal And Installation

    Motor Service Advanced DC Motors Inspection The enclosed Advanced DC motors must be 1. Measure the length of each motor brush. disassembled to inspect the motor brushes. Refer to • If any one brush is less than or equal to the for information regarding Motor Inspection service limit specified in section...
  • Page 56 Motor Service 5. Inspect the commutator for burn marks. commutator segments and the armature frame. If it is not an open circuit, then the armature is • Burn marks and/or raised commutator segments shorted and the motor must be replaced. 90 or 180 degrees apart is evidence of a shorted armature.

  • Page 57: Motor Inspection

    Motor Service Brush Spring Orientation 3. Install the new brushes in reverse order. REPLACING THE BRUSHES 4. Be certain that the brush springs do not rest up against the brush wires. Refer to illustrations in NOTE: It is recommended that all four brushes be for proper brush replaced as a set.

  • Page 58: Replacing The Bearings

    Motor Service 6. Measure the commutator undercut depth in 5- REPLACING THE BEARINGS places around the commutator. If any one of the measurements is less than the minimum undercut 1. The motor must be removed from the vehicle for depth specified in , then the Service Limits this procedure.

  • Page 59: Service Limits

    Motor Service SERVICE LIMITS Commutator Diameter Brush Length Wire Depth Undercut Depth Motor Specification (min) (min) (max) Number inches inches inches inches 5BC58JBS6129A 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129B 0.635 0.025 66.75 2.625 19.05 0.75 38.1 5BC58JBS6129C 0.635 0.025 66.75 2.625...
  • Page 61 Transmission TABLE OF CONTENTS Adjust the Drive Chain ........2 Check the Oil Level ........4 Change the Oil ..........5 Drive Motor ............ 6 Remove ..............6 Install ................ 6 Rear Axle ............7 Remove and Install ........... 7 Replace the Axle Bearing ......

  • Page 62: Adjust The Drive Chain

    Transmission ADJUST THE DRIVE CHAIN NOTE: A small amount of oil may come out when the drive motor mounting bolts are loosened. 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 63 Transmission 11. Reconnect the batteries. Rotating parts, keep hands and loose clothing clear of all moving parts. Failure to keep clear of moving parts may result in severe bodily injury and/or property damage. 12. Close all safety interlock switches, turn the key On, place the forward-off-reverse switch in forward and fully depress the accelerator pedal.

  • Page 64: Check The Oil Level

    Transmission CHECK THE OIL LEVEL NOTE: The oil level in the chain case is maintained by the transmission. Oil is pumped from the 3rd member into the chain case housing. It is not necessary to check the oil level in the chain case. 1.

  • Page 65: Change The Oil

    Transmission CHANGE THE OIL Wear protective gloves when working with petroleum lubricants. Repeated contact with petroleum lubricants can result in skin disorders. 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 66: Drive Motor

    Transmission DRIVE MOTOR Remove NOTE: In most cases it is not necessary to disassemble the chain case to remove the motor. If you find it necessary to disassemble the chain case, refer to Transmission section for information regarding disassembly of the chain case. 1.

  • Page 67: Rear Axle

    Transmission REAR AXLE Remove and Install 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 68: Replace The Axle Bearing

    Transmission REPLACE THE AXLE BEARING NOTE: The axle must be removed from the vehicle to replace the axle bearing. Refer to section Rear Axle: Remove and Install for information regarding removing the axle. NOTE: A 10-ton press is required to replace the axle bearing. NOTE: The axle bearing will be damaged when it is removed.

  • Page 69: Transmission Assembly

    Transmission TRANSMISSION ASSEMBLY Remove and Install 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 70: Chain Case

    Transmission CHAIN CASE NOTE: Some vehicle configurations may require that the transmission be removed to disassemble the chain case. Refer to section Transmission Assembly for information on removing the transmission. Disassemble 1. Make sure the key-switch is in the “OFF” position, then remove the key.
  • Page 71 Transmission 10. Remove the chain case housing bolts, brake assembly, and alignment brackets. 11. Remove the chain case housing from the backing plate. 12. Remove the pinion seal from the chain case housing. 13. Loosen the motor mounting bolts. 14. Loosen the chain adjuster. 15.

  • Page 72: Assemble

    Transmission Assemble 1. Thoroughly clean all gasket surfaces. 2. Apply a 1/8” bead of 94-430-03 gasket sealer to the face of the 3rd member. 3. Install the backing plate to the 3rd member. Torque to 30-45 ft-lbs. 4. Install the motor to the backing plate. Do not fully tighten the mounting hardware at this time.
  • Page 73 Transmission 13. Tighten the brake adjusting bolt to 25 ft-lbs. 14. Tighten the brake assembly mounting bolts. 15. Adjust the brake. Refer to section Brake Service: for information regarding Adjust the Brakes adjusting the brakes. 16. Adjust the drive chain. Refer to section Adjust the for information regarding adjusting Drive Chain...

  • Page 74: Differential Assembly (3Rd Member)

    Transmission DIFFERENTIAL ASSEMBLY (3 MEMBER) Disassemble NOTE: Bearings and races must be replaced as a set. If any one bearing or race is worn, its mate must also be replaced. It is recommended to replace all bearings and races in the 3rd member as a set. 1.
  • Page 75 Transmission 10. If required, remove the rear tapered bearing from the pinion shaft and discard. NOTE: Do not remove the bearing unless it requires replacement. Removing the rear bearing will damage the bearing. Replacing this bearing will require re-shimming of the pinion shaft. 11.

  • Page 76: Assemble

    Transmission Assemble NOTE: Thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. NOTE: Depending on your vehicle config- uration, the rear pinion pilot bearing is not required and may not be installed. NOTE: If the ring and pinion gear set is to be replaced then the shims for the pinion housing may have to be adjusted.
  • Page 77 Transmission Differential Assembly 9. Reassemble the differential housing in reverse order. 10. Place the ring gear onto the differential housing matching the mark made during disassembly. 11. Install two of the ring gear bolts finger tight to align the gear. 12.

  • Page 78: Re-Shimming The Pinion Housing

    Transmission NOTE: Be sure to continually rotate the ring gear while adjusting the bearings. This makes sure that the bearings and races remain seated correctly. NOTE: One hole on adjusting nut = approximately 0.003" change in backlash. Left and right nuts MUST be turned the same amount AND in the same direction.
  • Page 79 Transmission Transmission Page 19...

  • Page 80: Exploded View

    Transmission EXPLODED VIEW Transmission Page 20...
  • Page 81 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 82: 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 pressure. 1. Make sure the key-switch is in the “OFF” 7. Inspect the tire tread depth. Minimum position, then remove the key.

  • Page 83: Replace The Front Tire/Wheel

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

  • Page 84: Repair The Tire (Pneumatic)

    Maintenance, Service, and Repair 4-Bolt Pattern 5-Bolt Pattern 8-Bolt Pattern 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 85 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 86: 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 87: 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 88: Charging

    Maintenance, Service, and Repair Clean the batteries. Refer to Cleaning the Batteries section for information on cleaning the batteries. Using part number 77-200-00 hydrometer, check and record the specific gravity of each cell in the battery pack. If, after charging, none of the cells exceed a hydrometer reading of 1250 then there may be a fault in the charging system.

  • Page 89: 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 90: 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 91: Moist Charge Batteries

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

  • Page 92: 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 93: 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 95 Table of Contents SYMPTOMS: ........2 READ THIS FIRST ......3 Test Equipment Required: ............3 IMPORTANT NOTES and INSTRUCTIONS ...... 3 Definitions: ................3 SYMPTOM TROUBLESHOOTING GUIDE ..........19 PMC CONTROL ..............20 PLUGGING DIODE .............. 22 FREEWHEEL DIODE ............23 ISO ................... 24 SOLENOIDS ................

  • Page 96: Symptoms

    Curtis PMC Troubleshooting Note: Vehicles with Dana H12 transmission, Solenoids Forward solenoid is in the center. Circuit Breaker PMC Speed Control Typical Control Panel SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Symptom Troubleshooting later in this section. •...

  • Page 97: Read This First

    This troubleshooting guide requires the use of a test light rated at the battery voltage of • the truck and the Taylor-Dunn Throttle Module Analyzer. Troubleshooting CANNOT be completed without these tools. These test procedures must be performed in the order they were written.

  • Page 98: Definitions

    Curtis PMC Troubleshooting Definitions: “MS-1” = The first switch in the accelerator module. • “Battery volts” = The voltage at the batteries at the time the test is completed. • “Pick up” = Energizing a solenoid or contactor. • “F&R” = Forward and Reverse. •...
  • Page 99 Curtis PMC Troubleshooting Power Output Test The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 100 Curtis PMC Troubleshooting Control Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 101 Curtis PMC Troubleshooting Connect a voltmeter across the PMC #2 terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and The voltage shown is for illustration place the F&R Switch in Forward. only. The actual voltage may vary. Depress the accelerator pedal to engage MS-1 only.
  • Page 102 Curtis PMC Troubleshooting Power Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 103 Curtis PMC Troubleshooting Motor The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 104 Curtis PMC Troubleshooting Accelerator The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 105 Refer to the option list for your truck or ® contact your Taylor-Dunn Representative for more information. If you do not know how to test for continuity, refer test to a qualified technician.
  • Page 106 Curtis PMC Troubleshooting Forward and Reverse Side For your reference, shown at the right are the Forward and KSI Side White/Black Reverse switch wire connections for a typical control system. Violet/Black Green/Black Blue/Black Typical configuration of the terminals on a Forward and Reverse Switch as viewed from the back Connect a voltmeter across the HOT terminal of the KSI...
  • Page 107 Curtis PMC Troubleshooting F/R switch The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 108 Curtis PMC Troubleshooting Connect a voltmeter across the forward terminal of the The FORWARD terminal is forward and reverse side of the F&R switch and battery diagonally opposite the forward side of the rocker on the switch FLUKE 79 SERIES II MULTIMETER negative.
  • Page 109 Curtis PMC Troubleshooting Solenoids The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 110 Curtis PMC Troubleshooting Forward (does not run in reverse) The voltage shown is for illustration Connect a voltmeter across the PMC KSI terminal and battery only. The actual voltage may vary. negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in reverse.
  • Page 111 Curtis PMC Troubleshooting Connect the test light across the Normally Closed contacts of the Forward solenoid. Refer to your vehicles wiring FWD/REV diagram to identify the position of the forward solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Reverse.
  • Page 112 Curtis PMC Troubleshooting Set the test light voltage to the same voltage as the battery volts. Solenoids are shown for reference only. The type and position of the forward Connect the test light across the Normally Open contacts solenoid in your truck may be different of the Forward solenoid.

  • Page 113: Symptom Troubleshooting Guide

    Curtis PMC Troubleshooting SYMPTOM TROUBLESHOOTING GUIDE This section is specific to the symptoms listed below. Each troubleshooting sequence assumes that all listed symptoms are present. Do not use this section unless the truck has all listed symptoms. SYMPTOMS GO TO Ø...
  • Page 114 Curtis PMC Troubleshooting PMC CONTROL 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 115 Curtis PMC Troubleshooting Connect a volt meter across the PMC B+ and PMC M- terminals. The voltage shown is for illustration Turn the key-switch on, close all interlock only. The actual voltage may vary. switches (if equipped), depress the accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests: The meter reading should not be equal to...
  • Page 116 Curtis PMC Troubleshooting PLUGGING DIODE 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 117 Curtis PMC Troubleshooting FREEWHEEL DIODE 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 118 Curtis PMC Troubleshooting 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 119 Curtis PMC Troubleshooting Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure Reading is plus or minus 10% its resistance. ISO solenoid is shown for reference The meter reading should be 250 Ohms •...
  • Page 120 Curtis PMC Troubleshooting SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms. Perform the tests covered in the MOTOR section first. If the motor is OK, continue with the following tests. 1. Make sure the key-switch is in the “OFF” position, then remove the key.
  • Page 121 Curtis PMC Troubleshooting Stop trouble shooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground, otherwise continue with the next test. Check continuity from the motor ‘A2’ •...
  • Page 122 Curtis PMC Troubleshooting With the key-switch on and the F&R switch in reverse, depress the accelerator pedal and perform the following tests: Check continuity from the wire that was • connected to the PMC ‘M-’ terminal to the wire that was connected to the motor ‘S1’ Motor shown for reference only.
  • Page 123 Curtis PMC Troubleshooting MOTOR High motor current in both the field and the armature, accompanied with a lack of power, would indicate a shorted armature and\or field. Another symptom that may exist is jumping or stuttering at low speeds and/or the motor will not run unless the armature is manually rotated.
  • Page 124 Curtis PMC Troubleshooting Check continuity from ‘S1’ to the frame of the motor. Motor shown for reference only. If you do not know how to test for continuity, Terminal positions on your motor may not be in the same location. refer test to a qualified technician.
  • Page 125 TABLE OF CONTENTS Operating Instructions and Theory of Operation ......2 Testing the Charging Cycle....3 Test Equipment Required for Troubleshooting ......4 Important Notes and Instructions -------------------- 4 Troubleshooting for Built-in Charger..5 Troubleshooting for Portable Charger ..8 Testing The Timer Relay ......9 Testing the Interlock Relay .....10 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 126: Operating Instructions And Theory Of Operation

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The Lestronic II chargers are designed as semiautomatic chargers. The Lestronic II charger turns itself ® ® on when the “built- in” charger is plugged into the wall outlet, or when the “portable” charger is plugged into the batteries.

  • Page 127: Testing The Charging Cycle

    Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: •...

  • Page 128: Test Equipment Required For Troubleshooting

    Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter (DMM) with diode and capacitor test function, FLUKE 79 model ® shown at right and in the troubleshooting illustrations. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.

  • Page 129: Troubleshooting For Built-In Charger

    Electrical Troubleshooting TROUBLESHOOTING FOR BUILT-IN CHARGER 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 130 Electrical Troubleshooting • Disconnect the charger from the AC source. • Disconnect the batteries. • Disconnect the charger from the vehicle’s harness. • Remove the charger from the vehicle. HIGH VOLTAGE may be stored in the capacitor. Discharge the capacitor before continuing.
  • Page 131 Electrical Troubleshooting • Test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad.

  • Page 132: Troubleshooting For Portable Charger

    Electrical Troubleshooting TROUBLESHOOTING FOR PORTABLE CHARGER Disconnect the charger from the AC outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles DC receptacle to main battery negative. This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage then this wire is broken or has a bad connection.

  • Page 133: Testing The Timer Relay

    Electrical Troubleshooting 5. Reconnect the lead to the diode. 6. Connect the charger to the AC source. Insert the DC charger plug into the DC receptacle and perform the following tests: High Voltage inside the charger. Do not touch any internal components while the charger is plugged in.

  • Page 134: Testing The Interlock Relay

    Electrical Troubleshooting 4. Disconnect the wires from the contact terminals on the timer relay 5. Reconnect the batteries. 6. Wait 5 seconds, then test the continuity across the timer relay contact terminals. If this is a closed circuit, then the timer start up circuit is functioning normally. •...
  • Page 135 TABLE OF CONTENTS Operating Instructions and Theory of Operation ........2 HB/PT and GEL Indicator Lamps...3 Testing the Charging Cycle....3 Test Equipment Required for Troubleshooting .......4 Important Notes and Instructions Status LED Error Code Table ....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 136: Operating Instructions And Theory Of Operation

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION The model HB600W and HB1000W chargers ® ® are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.

  • Page 137: Hb/Pt And Gel Indicator Lamps

    Electrical Troubleshooting HB/PT AND GEL INDICATOR LAMPS NOTE: Your charger may not be equipped with these lamps. HB/PT Lamp If the HB/PT lamp is “ON”, then the charger has overheated and has entered a proportionally reduced output. The charging cycle will terminate if the temperature continues to rise.

  • Page 138: Test Equipment Required For Troubleshooting

    Electrical Troubleshooting TEST EQUIPMENT REQUIRED FOR TROUBLESHOOTING Digital Multi Meter (DMM), FLUKE 79 model shown at right and in the troubleshooting ® illustrations. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions • This troubleshooting guide assumes a familiarity with the use of a digital multimeter including, voltage tests, continuity tests and diode testing.

  • Page 139: Status Led Error Code Table

    Electrical Troubleshooting STATUS LED ERROR CODE TABLE There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charge r. If all three LED’s are flashing, it indicate an error has occurred in the charging cycle.

  • Page 140: Troubleshooting

    Electrical Troubleshooting TROUBLESHOOTING To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet. Wait for charger to start (up to15 seconds), the ammeter should display the DC Amp rating of the charger (plus or minus 10%) indicating that the charger is on (constant current mode).
  • Page 141 Charger Models: HBS 600 HBS 1000 TABLE OF CONTENTS Definitions: ..........2 Test Equipment Required for Troubleshooting .......2 Important Notes and Instructions Operating Instructions and Theory of Operation ........3 Testing the Charging Cycle....4 Status Light Error Code Table....5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries.

  • Page 142: Definitions

    Electrical Troubleshooting DEFINITIONS: Volts Per Cell = Voltage for each cell in a battery pack. for example, one 6-volt battery has 3-cells. Term Value Condition V1: Voltages are temperature compensated See Chart Flooded batteries relative to the temperature of the charger at the 2.383 Volts Per Cell Gel Batteries time the charge cycle is started.

  • Page 143: Operating Instructions And Theory Of Operation

    Electrical Troubleshooting OPERATING INSTRUCTIONS AND THEORY OF OPERATION Typical specification plate (reference only, specifications will vary for different chargers) The model HBS 600W and HBS 1000W chargers are designed as automatic chargers. The charger turns ® ® itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged. Once the charging cycle is complete, the charger will monitor the battery voltage.

  • Page 144: Testing The Charging Cycle

    Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit.

  • Page 145: Status Light Error Code Table

    Electrical Troubleshooting STATUS LIGHT ERROR CODE TABLE If the Fault light is ON or flashing, it indicates a problem has occured during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.

  • Page 146: Troubleshooting

    Electrical Troubleshooting TROUBLESHOOTING NOTE: There are no internally serviceable components in the charger. To test charger operation: Connect a DC volt meter to the main battery positive and negative terminals. Attach a clamp on DC Ammeter to one of the charger DC output wires. Plug the charger into an AC outlet.
  • Page 147 TABLE OF CONTENTS Complete Vehicle, Standard Bed ..2 Complete Vehicle, Short Bed or Lift Out Battery Box ....... 3 Complete Vehicle, AN ....... 4...
  • Page 148 Wire Diagrams COMPLETE VEHICLE, STANDARD BED White Green Horn Switch Violet/Black Violet/black Green Green Violet/Black Orange/Black Green Black Blue Blue Green Black Black White Wire Diagrams Page 2...
  • Page 149 Wire Diagrams COMPLETE VEHICLE, SHORT BED OR LIFT OUT BATTERY BOX Wiring is the same as the standard bed with the exception of: Harness is wired direct to the solenoids and controller, there is no connector. • Built-In charger is not available. Charger interlock (if equipped) is located in the charging receptacle. •...
  • Page 151 Illustrated Parts TABLE OF CONTENTS Front Axle ........... 2 Front Tire ............ 4 Front Fork ........... 6 Steering Linkage SC ........8 Steering Linkage AN........10 Mechanical Control Linkage ......12 Throttle Linkage .......... 14 Lester Chargers, Page 1 ......16 Lester Chargers, Page 2 ......

  • Page 152: Front Axle

    Illustrated Parts Front Axle Parts Page 2...
  • Page 153 Illustrated Parts FRONT AXLE Item No. Part No. Description 88-229-81 Locknut, 3/4NC 88-228-61 Washer, 3/4” SAE 15-010-00 Front Axle 16-010-00 Spacer 15-011-00 Front Axle, Dual (optional) Parts Page 3...

  • Page 154: Front Tire

    Illustrated Parts Front Tire Parts Page 4...
  • Page 155 Illustrated Parts FRONT TIRE Item Part No. Description 13-576-10 Tire & Wheel Assy, 4.80 x 8, 3/4” Bearing (standard) 13-001-00 Wheel, 4.80 x 8, 3/4” Bearing 10-075-00 Tire, 4.80 x 8, Load Range B 45-308-00 Oil Seal 80-015-00 Bearing, 3/4” Tapered 80-105-00 Bearing Race 13-734-11...

  • Page 156: Front Fork

    Illustrated Parts Front Fork Fork Collar (in frame) Parts Page 6...
  • Page 157 Illustrated Parts FRONT FORK Item No. Part No. Description 88-229-81 Locknut, 3/4NC 88-228-60 Washer, 3/4” Cut 45-307-00 Oil Seal, 1-1/2” ID 80-011-10 Bearing, Tapered Roller, 1-1/4” ID 80-102-00 Bearing Race 14-030-10 Front Fork Assembly 92-105-00 Dust Cap 16-410-00 Spacer, Fork Spindle, .020” Thick (Qty may vary) 16-400-00 Spacer, Fork Spindle, .125”...

  • Page 158: Steering Linkage Sc

    Illustrated Parts Steering Linkage SC Parts Page 8...

  • Page 160: Steering Linkage An

    Illustrated Parts Steering Linkage AN Parts Page 10...
  • Page 161 Illustrated Parts STEERING-Model AN Item No. Part No. Description 20-026-10 Steering Shaft Assembly 84-005-00 Pillow Block 95-500-00 Steering Handle 98-350-00 Hand Grip 88-080-15 Bolt, 5/16NC x 1-3/4” Hex Hd 88-089-81 Locknut, 5/16NC 88-088-61 Washer, 5/16 SAE Parts Page 11...

  • Page 162: Mechanical Control Linkage

    Illustrated Parts Mechanical Control Linkage Collars welded to frame Brake Arm Ref. See Note On Following Page Parts Page 12...
  • Page 163 Illustrated Parts MECHANICAL CONTROL LINKAGE Item No. Part No. Description 50-429-00 Connecting Strap 85-281-00 Link, Extension Spring 85-280-00 Spring, Extension, 1-3/8” OD x 7-3/4” 96-762-00 Clevis, 3/8” 88-119-80 Nut, 3/8NF 50-026-00 Rod, 3/8NF x 3” Long, Full Thread 96-772-00 Pin, Clevis, 3/8” x 1” Long 88-517-11 Cotter Pin, 3/32”...

  • Page 164: Throttle Linkage

    Illustrated Parts Throttle Linkage Parts Page 14...
  • Page 165 Illustrated Parts ACCELERATOR MODULE & LINKAGE Item No. Part No. Description 02-150-10 Accelerator Mounting Bracket 62-033-00 Accelerator Module 02-150-11 Lever, Accelerator Extension 50-123-21 Rod, Accelerator Linkage 50-481-00 Connector, Park Brake Slip 88-108-61 Washer, 3/8” SAE 88-109-81 Locknut, 3/8NC 88-527-11 Cotter Pin, 1/8” x 1” 88-060-09 Bolt, 1/4NC x 3/4”...

  • Page 166: Lester Chargers

    Illustrated Parts Lester Chargers, Page 1 Parts Page 16...
  • Page 167 Illustrated Parts Parts Page 17...
  • Page 168 Illustrated Parts Lester Chargers, Page 2 Parts Page 18...
  • Page 169 Illustrated Parts Parts Page 19...

  • Page 170: Signet Charger

    Illustrated Parts Signet Charger Typical Charger (8actual appearance varies) 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 Parts Page 20...
  • Page 171 Illustrated Parts Signet® Charger ITEM # PART # DESCRIPTION 79-303-40 Charger assembly (see note on facing page) 79-575-60 Replacement cover w/AC cord and gasket Note: There are no user serviceable components inside the charger Parts Page 21...

  • Page 172: Motors

    Illustrated Parts Motors Parts Page 22...
  • Page 173 Illustrated Parts Parts Page 23...

  • Page 174: Power Traction

    Illustrated Parts Power Traction Parts Page 24...
  • Page 175 Illustrated Parts POWER TRACTION DRIVE Item No. Part No. Description 70-049-00 Motor, DC, 4.5/6.0 hp (standard on model SC) 70-054-00 Motor, DC, 6.7/10.0 hp (standard on model AN) 97-100-00 Woodruff Key 88-087-11 Chain Adjusting Screw 88-069-80 Nut, 5/16NC 88-103-09 Motor Mounting Screw 80-703-00 O-Ring 70-454-00...

  • Page 176: Differential

    Illustrated Parts Differential Parts Page 26...
  • Page 177 Illustrated Parts REAR DIFFERENTIAL Item No. Part No. Description 41-709-00 3rd Member Housing (small carrier bearing, 1.628”ID) 41-710-00 3rd Member Housing (large carrier bearing, 1.784”ID) 88-119-80 Nut, 3/8NF 41-712-00 Carrier Assembly (small bearing) 41-713-00 Carrier Assembly (large bearing) 80-127-00 Carrier Bearing Race (80-511-00 bearing) 80-128-00 Carrier Bearing Race (80-512-00 bearing) 80-129-00...

  • Page 178: Brake

    Illustrated Parts Brake Parts Page 28...
  • Page 179 Illustrated Parts BRAKE Item No. Part No. Description 41-532-00 Brake Drum 96-245-10 Bolt, Brake Adjusting, 1/2NF 41-661-00 Full Brake Band 41-661-60 Kit, Full Brake Band (include. 2, 3, 4, 6, 7, 8, 10, 11, 17) 85-060-20 Spring 41-372-10 Bracket, Brake Mounting 88-159-82 Nut, 1/2NF Jam 88-159-84...

  • Page 180: Rear Axle

    Illustrated Parts Rear Axle Parts Page 30...
  • Page 181 Illustrated Parts REAR AXLE up to Serial Number 135706 Item No. Part No. Description 97-236-00 Wheel Lug Nut 96-329-10 Wheel Bolt 41-162-05 Axle, 10-11/16”, Small Bearing, Right 41-163-05 Axle, 13-1/8”, Small Bearing, Left (not shown) 32-514-00 Plate, Axle Retainer 80-505-00 Axle Bearing, Ball Type 32-509-00 Bearing Retainer...

  • Page 182: Rear Tires

    Illustrated Parts Rear Tires Ref., wheel hub 5 (assembly) Parts Page 32...
  • Page 183 Illustrated Parts Wheels and Tires ITEM # PART # DESCRIPTION Wheels 12-012-00 5 x 8" Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-075-00 4.80 x 8 LR B Pneumatic 10-076-00 4.80 x 8 LR C Pneumatic 10-081-00 5.70 x 8 LR B Pneumatic 10-082-00 5.70 x 8 Extra Grip 10-083-00...

  • Page 184: Control Panel (Standard)

    Illustrated Parts Control Panel (standard) Parts Page 34...
  • Page 185 Illustrated Parts CONTROL PANEL-AN & 48” SC Item No. Part No. Description 72-501-43 Forward or Reverse Solenoid 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 Solenoid 88-818-06 Sheet Metal Screw, #8 x 1/2” 79-840-00 Circuit Breaker, 10 amp 79-844-00...

  • Page 186: Control Panel (40" Bed)

    Illustrated Parts Control Panel (40” bed) Parts Page 36...
  • Page 187 Illustrated Parts ELECTRICAL COMPONENTS-40” SC Item No. Part No. Description 72-501-43 Forward or Reverse Solenoid 88-838-06 Sheet Metal Screw, #14 x 1/2” 62-204-00 Speed Controller, 275 72-501-42 ISO Solenoid 88-818-06 Sheet Metal Screw, #8 x 1/2” 79-840-00 Circuit Breaker, 10 amp 79-844-00 Circuit Breaker, 135 amp 73-004-20...

  • Page 188: Instruments

    Illustrated Parts Instruments Model SC Gauges Model SC Parts Page 38...
  • Page 189 Illustrated Parts Instruments Item No. Part No. Description 71-501-00 Horn switch 71-120-00 Key switch 71-039-02 F&R switch 71-100-00 Accessory switch optional 71-100-00 Accessory switch optional Gauges Item No. Part No. Description 74-000-00 Hour meter optional 74-009-10 Battery Status , 24v (analog) 74-009-12 Battery status, 24v (digital) optional...

  • Page 190: Batteries

    Illustrated Parts Batteries Main positive Main negative Parts Page 40...
  • Page 191 Illustrated Parts BATTERIES Item No. Part No. Description 75-231-00 Jumper, Battery, 10-1/4” long 77-864-00 Strap, Battery Hold Down 50-235-00 Battery Rod 88-069-81 Locknut, 1/4NC 88-081-12 Bolt, 5/16NC Square Hd, Tin-Lead 88-089-80 Nut, 5/16NC, Tin-Lead 77-042-00 Battery, 6 Volt, 217 amp hour (standard) 77-044-00 Battery, 6 Volt, 230 amp hour (optional) 77-047-00...

  • Page 192: Decals

    Illustrated Parts Decals Parts Page 42...

  • Page 193: Decals, An

    Illustrated Parts Decals, SC and AN Item No. Part No. Description 94-384-01 Not a motor vehicle 94-313-20 Safety warning 94-384-14 Leaving vehicle 94-382-00 Treadle 94-313-00 Battery warning 94-319-00 Battery disconnect 91-301-43 Arms and legs 94-333-00 94-373-10 Vehicle data Decals, AN Illustration not available at time of printing Parts Page 43...

  • Page 194: Miscellaneous Frame And Body, Sc

    Illustrated Parts Miscellaneous Frame and Body, SC 3,14 7,15,16 6,17,18,19 Parts Page 44...
  • Page 195 Illustrated Parts MISCELLANEOUS PARTS-Model SC Item No. Part No. Description 90-403-00 Deckboard, 28-3/4” x 47-1/4” 71-599-00 Console Cover 90-000-00 Backrest 79-511-00 Cord Holder, Built-in Charger 88-838-06 Sheet Metal Screw, #14 x 1/2” 71-501-00 Horn Button 30-702-00 Steering Chain Guard 88-837-11 Screw, #14 x 1”...

  • Page 196: Miscellaneous Frame And Body, An

    Illustrated Parts Miscellaneous Frame and Body, AN Parts Page 46...
  • Page 197 Illustrated Parts MISCELLANEOUS PARTS-Model AN Item No. Part No. Description 90-406-00 Deckboard, 30-3/4” x 53-1/4” 71-599-00 Console Cover 90-160-01 Tractor Seat 90-160-10 Seat Support 98-350-00 Hand Grip 88-838-06 Sheet Metal Screw, #14 x 1/2” Parts Page 47...
  • Page 199 Contents Appendix A: Special Tools ....2 Appendix B: Suggested Torque Limits for Standard Hardware ..3 Hardware Identification ...... 3 Standard Head Markings ........3 Hex Bolts .............. 3 Other Bolts ............3 Hex Nuts ............... 4 Hex Lock Nuts (stover) ........4 Other Nuts .............

  • Page 200: Appendix A: Special Tools

    Appendixes APPENDIX A: SPECIAL TOOLS DESCRIPTION PURPOSE PART NUMBER Used to install the pinion seal on all chain drive trucks with Pinion Seal Installation Tool the band style brake or the speed sensor on the chain case 43-201-50 cover. Used to center the chain case on the pinion shaft on all chain Chain Case Centering Tool drive trucks with the band style brake or the speed sensor 41-532-50...

  • Page 201: 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 202: 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 Appendix B Page 4...

  • Page 203: Suggested Torque Values (Non-Critical Hardware)

    Appendixes Suggested Torque Values (non-critical hardware) Diameter Grade 2 Grade 5 Grade 8 and TPI Tightening Tightening Tightening Tightening Torque Torque Torque Torque (ft-lb) (ft-lb) (ft-lb) (ft-lb) 1/4-20 7-10 10-14 1/4-28 8-12 11-16 5/16-18 9-14 14-21 20-29 5/16-24 10-15 15-23 22-33 3/8-16 16-24...
  • Page 204 Appendixes Suggested Torque Values (critical hardware) Torque Table Torque Range Group Description Ft-Lbs In-Lbs Brakes - - - - - - - - - - - - - - - - - - - - - - - - Brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15...

  • Page 205: 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 206 Taylor-Dunn Mfg. ® 2114 W. Ball Rd. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 (FAX) (714) 956-0504 Mailing Address: P.O. Box 4240 Anaheim, California 92803 Visit our Website: www.taylor-dunn.com...

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