Taylor-Dunn SC 159 Manuals

Manuals and User Guides for Taylor-Dunn SC 159. We have 2 Taylor-Dunn SC 159 manuals available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn SC 159 Operation, T Roubleshooting And Replacement Parts Manual (206 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 15.05 MB

Table of Contents
5
Introduction

10
- About this Manual
  
  10
- Who Should Read this Manual
  
  10
- Responsibilities
  
  10
- How to Use this Manual
  
  11
  - Conventions
    11
- How to Identify Your Vehicle
  
  12
- Taking Delivery of Your Vehicle
  
  13
Safety Rules and Operating Instructions

16
- Standard Specifications
  
  16
- Safety Rules and Guidelines
  
  17
- Driver Training Program
  
  17
  - Driver Qualifications
    17
  - Start Switch
    18
- Vehicle Controls
  
  18
  - Horn Switch
    18
  - Forward-Off-Reverse Switch
    18
  - Accessory Switch (Optional)
    18
  - Headlight Switch (Optional)
    18
  - Battery Status Indicator, Digital Bargraph
    19
  - Hour Meter (Optional)
    19
  - Battery Status Indicator, Analog (Optional)
    19
  - Accelerator / Brake Treadle, SC 159
    20
  - Accelerator / Brake Treadle, an 171
    20
  - Steering, SC 159
    20
  - Steering, an 171
    20
  - Walk-Along Handle, an 171
    20
  - Foot Interlock Switch, SC 159 (Optional)
    21
  - Charger Interlock
    21
  - Parking Brake
    21
- Vehicle Operational Guidelines
  
  22
  - Safety Guidelines
    22
  - Starting
    22
  - While Driving
    22
  - Loading and Unloading
    22
  - Towing Loads
    22
  - Parking
    23
  - Towing this Vehicle
    23
- Charging Your Vehicle
  
  24
  - New Battery Break in
    24
  - Signet® Charger Operation
    24
  - Industrial Charger Operation
    24
  - Charging Time
    25
- Storing and Returning to Service
  
  25
  - Storing Your Vehicle
    25
  - Returning to Service
    25
- Periodic Maintenance Checklist
  
  26
  - Daily Visual Inspection
    27
- Maintenance Guidelines for Severe Duty Applications
  
  27
General Maintenance

30
- Maintenance Guidelines
  
  30
- Troubleshooting Guide
  
  31
- Lubrication Chart
  
  32
Front Axle Service

34
- Inspect the Front Wheel Bearings
  
  34
- Adjust Front Wheel Bearings
  
  34
- Front Axle Removal and Installation
  
  35
  - Removal
    35
  - Installation
    35
- Replace Front Wheel Bearings
  
  36
Steering Component Service

38
- Front End Alignment
  
  38
  - Center the Steering Wheel
    38
- Inspect the Steering Components
  
  40
  - Steering Wheel and Bushings
    40
  - Steering Chain
    40
  - Pillow Blocks
    41
- Fork Bearings
  
  41
- Adjust the Steering Shaft
  
  42
- Replace the Steering Wheel
  
  42
- Replace the Front Fork
  
  43
Brake Service

46
- Inspect the Service Brake
  
  46
- Adjust the Service Brake
  
  46
  - Adjust the Brake Linkages
    47
- Replace the Brake Lining
  
  48
- Replace Brake Drum
  
  50
- Replacing the Treadle Linkage
  
  51
Throttle Linkage

54
- Throttle Linkage Adjustments
  
  54
Motor Service

56
- Inspecting the Motor Brushes
  
  56
  - Motors with Internal Cooling Fans
    56
  - Enclosed Motors (GE, no Cooling Fan)
    56
- Motor Removal and Installation
  
  57
- Motor Inspection
  
  57
- Replacing the Brushes
  
  59
  - Motor Inspection
    59
- Replacing the Bearings
  
  60
- Repairing the Commutator
  
  60
- Service Limits
  
  61
Transmission

63
- Adjust the Drive Chain
  
  64
- Check the Oil Level
  
  66
- Change the Oil
  
  67
- Drive Motor
  
  68
  - Remove
    68
  - Install
    68
- Rear Axle
  
  69
  - Remove and Install
    69
- Replace the Axle Bearing
  
  70
- Transmission Assembly
  
  71
  - Remove and Install
    71
- Chain Case
  
  72
  - Disassemble
    72
  - Assemble
    74
- Differential Assembly (3Rd Member)
  
  76
  - Disassemble
    76
  - Assemble
    78
- Re-Shimming the Pinion Housing
  
  80
- Exploded View
  
  82
Tires and Wheels

84
- Tire Inflation
  
  84
- Tire Inspection
  
  84
- Replace the Front Tire/Wheel
  
  85
- Replace the Rear Tire/Wheel
  
  85
- Replace the Tire (Pneumatic)
  
  85
- Repair the Tire (Pneumatic)
  
  86
Battery Service

88
- Replace the Tire (Pneumatic)
  
  88
- Cleaning
  
  88
- Testing
  
  89
- Charging
  
  90
- Watering
  
  91
- Replacing (6-Volt Batteries Only)
  
  92
  - Moist Charge Batteries
    93
- Storage and Returning to Service
  
  94
  - Storage
    94
  - Returning to Service
    95
Electrical Troubleshooting

98
- Symptoms
  
  98
  - Main Troubleshooting Sequence
    98
- Main Troubleshooting Sequence
  
  99
  - Test Equipment Required
    99
  - IMPORTANT NOTES and INSTRUCTIONS
    99
  - Definitions
    100
Special Troubleshooting Guide

119
- Pmc Control
  119
- Plugging Diode
  119
- Freewheel Diode
  119
- Iso
  124
- Solenoids
  126
- Motor
  129
Lestronic II® Charger Troubleshooting

132
- Operating Instructions and Theory of Operation
  
  132
- Testing the Charging Cycle
  
  133
- Test Equipment Required for Troubleshooting
  
  134
  - Important Notes and Instructions
    134
- Troubleshooting for Built-In Charger
  
  135
- Troubleshooting for Portable Charger
  
  138
- Testing the Timer Relay
  
  139
- Testing the Interlock Relay
  
  140
Signet Charger Troubleshooting

142
- Operating Instructions and Theory of Operation
  
  142
- HB/PT and GEL Indicator Lamps
  
  143
- Testing the Charging Cycle
  
  143
  - Troubleshooting
    143
- Status LED Error Code Table
  
  145
- Troubleshooting
  
  146
Wire Diagrams

148
- Complete Vehicle, Standard Bed
  
  148
- Complete Vehicle, Short Bed or Lift out Battery Box
  
  149
  - Front Axle
    152
Illustrated Parts

154
- Front Tire
  154
- Front Fork
  156
- Steering Linkage SC
  158
- Steering Linkage an
  160
- Mechanical Control Linkage
  162
- Throttle Linkage
  164
- Lester Chargers
  166
- Lester Chargers, Page 2
  168
- Signet Charger
  170
- Motors
  172
- Power Traction
  174
- Differential
  176
- Brake
  178
- Rear Axle
  180
- Rear Tires
  182
- Wheels and Tires
  183
- Control Panel (Standard)
  184
- Control Panel (40" Bed)
  186
- Instruments
  188
- Gauges
  188
- Batteries
  190
- Decals
  192
- Decals, an
  193
- Miscellaneous Frame and Body, SC
  194
- Miscellaneous Frame and Body, an
  196
Appendixes

200
- Appendix A: Special Tools
  
  200
- Appendix B: Suggested Torque Limits for Standard Hardware
  
  201
- Hardware Identification
  
  201
  - Standard Head Markings
    201
  - Hex Bolts
    201
  - Other Bolts
    201
  - Hex Nuts
    202
  - Hex Lock Nuts (Stover)
    202
  - Other Nuts
    202
  - Suggested Torque Values (Non-Critical Hardware)
    203
  - Suggested Torque Values (Critical Hardware)
    204
- Appendix C: Brake Lining Handling Precautions
  
  205

Taylor-Dunn SC 159 Operation, T Roubleshooting And Replacement Parts Manual (206 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 8.17 MB

Table of Contents

7
- Responsibilities
  8
- About this Manual
  8
- Who Should Read this Manual
  8
- How to Use this Manual
  9
- Conventions
  9
- How to Identify Your Vehicle
  10
- Taking Delivery of Your Vehicle
  11
Table of Contents

13
- Standard Specifications
  14
- Driver Qualifications
  15
- Driver Training Program
  15
- Safety Rules and Guidelines
  15
- Accessory Switch (Optional)
  16
- Forward-Off-Reverse Switch
  16
- Headlight Switch (Optional)
  16
- Horn Switch
  16
- Start Switch
  16
- Vehicle Controls
  16
- Battery Status Indicator, Analog (Optional)
  17
- Battery Status Indicator, Digital Bargraph
  17
- Hour Meter (Optional)
  17
- Accelerator / Brake Treadle, an 171
  18
- Accelerator / Brake Treadle, SC 159
  18
- Steering, an 171
  18
- Steering, SC 159
  18
- Walk-Along Handle, an 171
  18
- Charger Interlock
  19
- Foot Interlock Switch, SC 159 (Optional)
  19
- Parking Brake
  19
- Loading and Unloading
  20
- Safety Guidelines
  20
- Starting
  20
- Towing Loads
  20
- Vehicle Operational Guidelines
  20
- While Driving
  20
- Parking
  21
- Towing this Vehicle
  21
- Charging Your Vehicle
  22
- Industrial Charger Operation
  22
- New Battery Break in
  22
- Signet® Charger Operation
  22
- Charging Time
  23
- Returning to Service
  23
- Storing and Returning to Service
  23
- Storing Your Vehicle
  23
- Periodic Maintenance Checklist
  24
- Daily Visual Inspection
  25
- Maintenance Guidelines for Severe Duty Applications
  25
Table of Contents

31
- Adjust Front Wheel Bearings
  32
- Inspect the Front Wheel Bearings
  32
- Front Axle Removal and Installation
  33
- Removal
  33
- Installation
  34
- Replace Front Wheel Bearings
  34
Table of Contents

35
- Center the Steering Wheel
  36
- Front End Alignment
  36
- Inspect the Steering Components
  38
- Steering Chain
  38
- Steering Wheel and Bushings
  38
- Fork Bearings
  39
- Pillow Blocks
  39
- Adjust the Steering Shaft
  40
- Replace the Steering Wheel
  40
- Replace the Front Fork
  41
Table of Contents

43
- Adjust the Service Brake
  44
- Inspect the Service Brake
  44
- Adjust the Brake Linkages
  45
- Replace the Brake Lining
  46
- Replace Brake Drum
  48
- Replacing the Treadle Linkage
  49
Table of Contents

53
- Enclosed Motors (GE, no Cooling Fan)
  54
- Inspecting the Motor Brushes
  54
- Motors with Internal Cooling Fans
  54
- Motor Removal and Installation
  55
- Motor Inspection
  57
- Replacing the Brushes
  57
- Repairing the Commutator
  58
- Replacing the Bearings
  58
- Service Limits
  59
Transmission

61
- Adjust the Drive Chain
  62
- Check the Oil Level
  64
- Change the Oil
  65
- Drive Motor
  66
- Install
  66
- Remove
  66
- Rear Axle
  67
- Remove and Install
  67
- Replace the Axle Bearing
  68
- Remove and Install
  69
- Transmission Assembly
  69
- Chain Case
  70
- Disassemble
  70
- Assemble
  72
- Differential Assembly (3Rd Member)
  74
- Disassemble
  74
- Assemble
  76
- Re-Shimming the Pinion Housing
  78
- Exploded View
  80
Transmission

81
- Tire Inflation
  82
- Tire Inspection
  82
- Replace the Front Tire/Wheel
  83
- Replace the Rear Tire/Wheel
  83
- Replace the Tire (Pneumatic)
  83
- Repair the Tire (Pneumatic)
  84
Table of Contents

85
- Cleaning
  86
- Testing
  87
- Charging
  88
- Watering
  89
- Replacing (6-Volt Batteries Only)
  90
- Moist Charge Batteries
  91
- Storage
  92
- Storage and Returning to Service
  92
- Returning to Service
  93
Table of Contents

95
- Symptoms
  96
- IMPORTANT NOTES and INSTRUCTIONS
  97
- Read this First
  97
- Test Equipment Required
  97
- Definitions
  98
- Freewheel Diode
  113
- Iso
  113
- Motor
  113
- Plugging Diode
  113
- Pmc Control
  113
- Solenoids
  113
- Symptom Troubleshooting Guide
  113
Table of Contents

125
Table of Contents

135
- Operating Instructions and Theory of Operation
  136
- HB/PT and GEL Indicator Lamps
  137
- Testing the Charging Cycle
  137
- Test Equipment Required for Troubleshooting
  138
- Status LED Error Code Table
  139
- Troubleshooting
  140
Charger Models: Hbs 600 Hbs 1000

141
- Definitions
  142
- Test Equipment Required for Troubleshooting
  142
- Operating Instructions and Theory of Operation
  143
- Testing the Charging Cycle
  144
- Status Light Error Code Table
  145
- Troubleshooting
  146
Illustrated Parts

151
- Front Axle
  152
- Front Tire
  154
- Front Fork
  156
- Steering Linkage SC
  158
- Steering Linkage an
  160
- Mechanical Control Linkage
  162
- Throttle Linkage
  164
- Lester Chargers
  166
- Signet Charger
  170
- Motors
  172
- Power Traction
  174
- Differential
  176
- Brake
  178
- Rear Axle
  180
- Rear Tires
  182
- Control Panel (Standard)
  184
- Control Panel (40" Bed)
  186
- Gauges
  188
- Instruments
  188
- Batteries
  190
- Decals
  192
- Decals, an
  193
- Miscellaneous Frame and Body, SC
  194
- Miscellaneous Frame and Body, an
  196
- Appendix A: Special Tools
  200
- Appendix B: Suggested Torque Limits for Standard Hardware
  201
- Hex Bolts
  201
- Other Bolts
  201
- Standard Head Markings
  201
- Hex Lock Nuts (Stover)
  202
- Hex Nuts
  202
- Other Nuts
  202
- Suggested Torque Values (Non-Critical Hardware)
  203
- Appendix C: Brake Lining Handling Precautions
  205

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Taylor-Dunn SC 159 Manuals

Taylor-Dunn SC 159 Operation, T Roubleshooting And Replacement Parts Manual (206 pages)

Table of Contents

Introduction

About this Manual

Who Should Read this Manual

Responsibilities

How to Use this Manual

How to Identify Your Vehicle

Taking Delivery of Your Vehicle

Safety Rules and Operating Instructions

Standard Specifications

Safety Rules and Guidelines

Driver Training Program

Vehicle Controls

Vehicle Operational Guidelines

Charging Your Vehicle

Storing and Returning to Service

Periodic Maintenance Checklist

Maintenance Guidelines for Severe Duty Applications

General Maintenance

Maintenance Guidelines

Troubleshooting Guide

Lubrication Chart

Front Axle Service

Inspect the Front Wheel Bearings

Adjust Front Wheel Bearings

Front Axle Removal and Installation

Replace Front Wheel Bearings

Steering Component Service

Front End Alignment

Inspect the Steering Components

Fork Bearings

Adjust the Steering Shaft

Replace the Steering Wheel

Replace the Front Fork

Brake Service

Inspect the Service Brake

Adjust the Service Brake

Replace the Brake Lining

Replace Brake Drum

Replacing the Treadle Linkage

Throttle Linkage

Throttle Linkage Adjustments

Motor Service

Inspecting the Motor Brushes

Motor Removal and Installation

Motor Inspection

Replacing the Brushes

Replacing the Bearings

Repairing the Commutator

Service Limits

Transmission

Adjust the Drive Chain

Check the Oil Level

Change the Oil

Drive Motor

Rear Axle

Replace the Axle Bearing

Transmission Assembly

Chain Case

Differential Assembly (3Rd Member)

Re-Shimming the Pinion Housing

Exploded View

Tires and Wheels

Tire Inflation

Tire Inspection

Replace the Front Tire/Wheel

Replace the Rear Tire/Wheel

Replace the Tire (Pneumatic)

Repair the Tire (Pneumatic)

Battery Service

Replace the Tire (Pneumatic)

Cleaning

Testing

Charging

Watering

Replacing (6-Volt Batteries Only)

Storage and Returning to Service

Electrical Troubleshooting