Taylor-Dunn SC-100-24 Operation, T Roubleshooting And Replacement Parts Manual Download Page 1

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T h e B e s t W a y

T o G o

A b o u t Y o u r

B u s i n e s s

TAYLOR-DUN

READ THIS MANUAL BEFORE OPERATION

OR PERFORMING MAINTENANCE.

This manual contains important information

regarding the safe operation and maintenance of

this vehicle.

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

Revision: N, 3/15/2018

Serial number Range: 158500-191319

MANUAL MA-100-00

Operation, Troubleshooting and

Replacement Parts Manual

Summary of Contents for SC-100-24

Page 1: ...ains important information regarding the safe operation and maintenance of this vehicle 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 Revision N 3 15 2018 Serial number Range 158500 191319 MANUAL MA 100 00 Operation Troubleshooting and Replacement Parts Manual ...

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Page 3: ...t 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 If you do not have access to the internet you can call the factory direct at 01 714 956 4040 Feedback regarding this or any Taylor Dunn vehicle manual can be sent to Taylor Dunn Manufacturing Attn Tech Writer 2114 West Ball Road Anaheim CA 92804 ...

Page 4: ...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 tr...

Page 5: ...ice Transaxle Service Tires and Wheels Battery Service Charger Troubleshooting Wire diagram Illustrated Parts Appendix Model SC 100 Operator and Service Manual Section Index This quick reference section index guide will assist you in locating a desired topic or procedure Refer to each sectional Table of Contents for the page number location for specific topics or procedures ...

Page 6: ...ypes of vehicles offered by Taylor Dunn B 2 48 36 Equipped with optional hydraulic dump bed BT 2 80 Eight passenger tram B 1 00 Personnel carrier C 4 25 Huskey tow tractor MX 1600 Equipped with optional ladder rack and weld tanks ...

Page 7: ...ts Introduction 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: ...lor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules and Guidelines Operational Information Operator Responsibilities Owner Responsibilities Control Operation and Location Information Maintenance and Troubleshooting Information Standard Parts List Before servicing o...

Page 9: ...he vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel 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 For the purposes of training a qualified s...

Page 10: ... performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific information on the servicing of the vehicle and a schedule for maintenance checks Electrical and Charger Troubleshooting This section identifies the troubleshooting procedures for testing the electrical system a...

Page 11: ... while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure to exercise special care and follow any instructions contained with in a caution NOTE Alerts the reader to additional information about a subject Conventions Symbols and or words that are used to define warnings caut...

Page 12: ...model and serial numbers are illustrated below This vehicle is not designed to be driven on public roads or highways It is available in maximum designed speeds ranging from 4 to 8 mph Do not exceed the maximum designed speed Exceeding the maximum designed speed may result in steering difficulty motor damage and or loss of control Do not exceed locally imposed speed limits Do not tow at more than 5...

Page 13: ...lt of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessories Also notify your Taylor Dunn dealer of the claim If there is a problem with the operation of the vehicle DO NOT OPERATE THE VEHICLE Immediately contact your local Taylor Dunn distributor and report the problem...

Page 14: ...INTRODUCTION Page 8 Notes ...

Page 15: ...TABLE OF CONTENTS General Maintenance General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4 ...

Page 16: ...s Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Periodic maintenance and service must be performed on this vehicle Failure to complete these scheduled maintenance and service procedures can result in s...

Page 17: ...eering Shaft Loose Steering Linkage Lack of Power or Slow Operation Brakes or Parking Brakes Dragging Worn Drive Gears Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug Nuts Motor Bearings Worn Oil Leak in Rear Bearing Area Rear Wheel Bearing and or Gasket Failed Drive Over Filled Brake Pedal Low Brake Worn 1 16 Wear Limit Brakes Out of Adj...

Page 18: ...urpose Grease 2 Front Fork Spindle Bearings 1 General Purpose Grease 3 Steering Shaft Gears 1 General Purpose Grease 4 5 Front Wheel Bearings 1 or 2 High Temperature Wheel Bearing Grease 6 Steering Chains 2 30 wt Motor Oil 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug 1 SAE 80w90 Gear Oil 10 Accelerator Module Push Rod 1 General Purpose Grease ...

Page 19: ...es 9 Vehicle Operation Guidelines 10 Safety Guidelines 10 Starting 10 While driving 10 Loading and Unloading 10 Towing Loads 10 Parking 11 Automatic Electric Park Brake 11 Towing This Vehicle 11 Using the Ladder 11 Towing the Vehicle 12 Frame Tie Downs 12 Charging your vehicle 13 Signet Charger Operation Model HB Series 13 Signet Charger Operation Model HBS series 14 Lestronic II Charger Operation...

Page 20: ...State Speed Control 300 Amp 36 Volt 6 217 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp 48 Volt 8 244 Amp Hour 6 Volt Lead Acid Batteries Solid State Speed Control 300 Amp Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC 24 Volt 1 82 kW 1465 rpm 2 44 hp for 60 minutes Separately Excited 36 Volt 2 72 kW 2335 rpm 3 65 hp for 60 minutes Field 48 ...

Page 21: ...ch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries DRIVER TRAINING PROGRAM According to ANSI B56 8 the owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall not be condensed for t...

Page 22: ...motion Make sure the vehicle is completely stopped before shifting The direction control switch should be in the center OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle Horn Switch The horn switch is located on the right side of the steering tower Depress the switch to sound the horn release it to turn it off Headlight Switch The headlight switch...

Page 23: ... on the optional Smart View gauge Hour Meter 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 Refer to following pages for information on the optional Smart View gauge Charger Interlock The charger interlock is designed to disable the vehicle from being driven while the AC charger cord is plugged into a function...

Page 24: ...orboard positioned under the operator s right foot The throttle pedal also functions as the brake pedal Press the front of the throttle pedal down to increase speed release the throttle pedal to slow down Park Brake The parking brake is actuated with a hand lever which is located on the left side of the steering tower To set the parking brake depress the foot brake pedal and pull the lever up unti...

Page 25: ...tery status gauge as well as any faults indicating low battery voltage will not reset until the batteries have successfully completed a charging cycle HM Depending on the revision level of the controller there are one or two hour meter functions Key Hours and Run Time Hours see note below Key Hours is the accumulated length of time in hours that the key switch is in the ON position Run Time Hours ...

Page 26: ...e Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenance Due Once the warning has expired and the maintenance is due the Wrench icon will stop flashing and remain ON Additionally the vehicles maximum speed will be significantly reduced until the maintenance is performed and the display is reset The display s...

Page 27: ...ice technician F05043 Traction ON R Refer to service technician F05044 Traction OFF R Refer to service technician F05045 Stack Corrupt Refer to service technician F05046 Open Contactor Refer to service technician Level 4 Faults Fault Code Description What to do F04000 Open Contactor Refer to service technician F04001 Contactor Welded Refer to service technician F04002 Steer POT Fault N A F04003 Se...

Page 28: ...istances when driving down a grade Safety Guidelines Only qualified and trained operators may drive this vehicle No passengers are allowed to be transported in the cargo area of this vehicle No occupants other than the driver are allowed on this vehicle Drive only on level surfaces or on surfaces having an incline of no more than 10 5 6 degrees Drive slowly when making a turn especially if the gro...

Page 29: ...t bumper tow bar NOTE If the vehicle is equipped with the automatic electric park brake do not tow the vehicle with the drive wheels on the ground Use another driver to steer this vehicle while it is being towed Be sure the driver uses the brakes when the towing vehicle slows or stops Do not tow the vehicle faster than 5 m p h or its maximum designed speed whichever is lower If at all possible thi...

Page 30: ...m designed speed whichever is lower 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 WARNING DO NOT tow the vehicle faster than 5 mph 8 kph or its maximum designed speed whichever ...

Page 31: ...chnician Incorrect repair or reassembly of the charger can result in an explosion electric shock or fire Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury WARNING Signet Charger Operation Model HB Series The Signet HB ...

Page 32: ... or property damage WARNING Do not attempt to operate the vehicle while charging the battery Operating the charger and vehicle at the same time may lead to damage to the charger and or the vehicle resulting in personal injury and or property damage WARNING The charger must be connected to a properly grounded AC receptacle Improper connection will increase the risk of electric shock and can cause s...

Page 33: ...ry or death WARNING WARNING DO NOT disassemble the charger There are no user serviceable components in the charger Refer all repairs to a qualified technician Incorrect repair or reassembly of the charger can result in an explosion electric shock or fire Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety g...

Page 34: ...olyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury WARNING Explosive mixtures of Hydrogen gas are present within battery cells at all times Do not work with or charge a battery in an area where open flames including gas furnace or wa...

Page 35: ...f the charger may damage your batteries Refer charger repair to a qualified technician Charging with the X Series Charger Note Opportunity charging is not recommended For maximum battery life it is recommended that the batteries be discharged a minimum of 30 7 bars showing on the BSI before starting a charging cycle This charger requires a standard household electrical circuit rated at 15 to 20 Am...

Page 36: ...ead the BSI Check the battery electrolyte once a week Do not charge the batteries if the battery electrolyte is low Charging when the electrolyte is low will damage the batteries and shorten their life span Only authorized personnel should perform battery maintenance including maintaining the battery electrolyte level Refer to Section Maintenance Service and Repair for battery maintenance informat...

Page 37: ...xle battery hydraulic system 500 Adjust service and park brake systems Inspect all steering linkages and hardware Tighten steering shaft to steering gear coupler if equipped Lubricate the vehicle Wash batteries and clean terminals Inspect for fluid leaks Check all electrical interlocks for proper operation Inspect wheel bearings for play and noise Inspect front fork collar bearings for play and no...

Page 38: ...cks only Inspect and tighten all nuts and bolts First 500 hours and then every 1000 hours 2 1000 Inspect and tighten all nuts and bolts Clean and repack front wheel bearings Inspect and tighten all wire connection Inspect the motor brushes and commutator Inspect the king pin bushings Check front end alignment 3 2000 Change oil in the drive and rear axle Flush hydraulic brake system Inspect suspens...

Page 39: ... inclusive of a severe duty application Extreme temperature Bumpy dusty or ill maintained roads Excessively wet areas Corrosive or contaminated areas Frequent loading of vehicle at near capacity Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Daily Visual i...

Page 40: ...SAFETY RULES AND OPERATING INSTRUCTIONS Safety Rules Page 22 Notes ...

Page 41: ...TABLE OF CONTENTS Front Axle 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: ...for any grinding noise Any noise may be an indication of worn or damaged wheel bearings Note Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel bearings 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the park brake and test drive the vehicle 1 Make ...

Page 43: ...g the replacement of the wheel bearings 9 Lower the vehicle 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle 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 t...

Page 44: ... stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 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 hub and place the front wheel s into the fork 3 Insert the axle into...

Page 45: ... 6 Remove the front axle and wheel s Refer to Front Axle Removal and Installation section for information regarding removing the axle 7 Remove the spacers seals and bearings from the hub 8 Thoroughly clean all grease from the inside of the hub and the bearings 9 Drive the races out from the hub 10 Press new races into the hub 11 Assemble in reverse order using new grease seals a Pack bearings with...

Page 46: ...Maintenance Service and Repair Front Axle Page 6 Notes ...

Page 47: ...gnment 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 Steering Components ...

Page 48: ...eering shaft should be level If it is not level then perform the following A Raise the front wheel approximately 1 inch off of the ground B Remove the fork spindle bearing cap C Loosen the fork nut until the steering shaft can be rotated without rotating the fork D Position the flat top of the half gear so that it is level E With the front wheel pointing straight ahead lower the front end and tigh...

Page 49: ...wheels tied in position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage 6 Position the front fork in the straight ahead position and tie it off so that it cannot rotate 7 Remove the steering chain access plate 8 Remove the safety wire from the turn buckles and discard 9 Loosen the turn buckles just enough to remove the chain from the lower sprocket...

Page 50: ...e 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 Remove the blocks from behind the wheels 18 Release the parking brake and test drive the vehicle ...

Page 51: ... slot corners should be 90 degrees with a small radius If the corners are excessively rounded or the sides are tapered then the steering wheel should be replaced Insert the steering shaft back into the collar and check for lateral play as shown to the right If the lateral play exceeds 0 010 inches then the bushings should be replaced Steering shaft and sprocket be replaced Inspect each link in the...

Page 52: ...ls to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 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 6 Tie off the front fork so that it cannot turn 7 While watching the steering shaft rapidly rotate the steering wheel to the left and right 8 There should not be any dis...

Page 53: ... Failure to use lifting and support devices of rated load capacity may result in severe bodily injury FORK BEARINGS 6 Raise the front of the vehicle and support with jack stands 7 Inspect for lateral play by attempting to move the fork to the left and right not rotating There should be no noticeable play 8 If there is any play in the fork bearings refer to section Replace the Front Fork for inform...

Page 54: ...crew 9 Rotate the steering wheel from left to right Any roughness is an indication of being too tight Repeat the procedure and hold less tension on the gears while setting the collar 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the parking brake and test drive the vehicle 1 Make sure the key switch is in the OFF position...

Page 55: ...ed off of the steering wheel sprocket 9 Remove the steering wheel 10 Install the steering wheel in reverse order NOTE Lightly lubricate the steering wheel shaft 11 Align the steering Refer to section Front End Alignment for information regarding aligning the steering 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the parki...

Page 56: ...ing the front axle If the fork was replaced with a new fork the front end should be realigned Refer to section Front End Alignment for information regarding aligning the front end 10 Lower the wheels to the ground 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and test drive the vehicle 1 Make sure the ke...

Page 57: ...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 6 Secondary Adjustment cable 6 Replace Rear Brake Pads 7 Mechanical Disc 7 Replace the Mechanical Caliper Assembly 8 Brake Service ...

Page 58: ...e thinnest point on the pad If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set 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 ha...

Page 59: ...at its maximum diameter If the run out exceeds 0 005 then the rotor must be machined Do not machine the rotor beyond its service limits Note A bent axle or damaged rear axle could cause excessive brake rotor run out 2 Measure the thickness of the brake rotor in 3 places If the brake rotor thickness is less than 0 20 inches then the rotor must be replaced Do not use a rotor that is worn beyond its ...

Page 60: ...ke causing severe bodily injury and or property damage 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 Disconnect the main positive and negative cables at the batteries 6 Inspect all brake cables and linkages for any signs of da...

Page 61: ...re all play is removed Adjust be hand do not use a wrench 10 Tighten the brake rod an additional turn and remove the clamp from the throttle rod Note If you have reached the end of the threads on the brake rod then move the left and right brake linkages to the secondary adjustment holes There are two sets of holes on each linkage 11 Push the vehicle back and forth a few feet When the treadle is ge...

Page 62: ...s 10 Release the park brake and test drive the vehicle Secondary Adjustment cable 6 Release the park brake 7 Remove the treadle cover 8 Loosen the park brake cable clevis jam nut 9 Remove the clevis pin 10 Fully depress the treadle and clamp or tie it in the fully depressed position 11 Pull the cable out and adjust the clevis so that the clevis pin can be inserted with the cable pulled out as far ...

Page 63: ...pacity may result in severe bodily injury 6 Raise the rear of the vehicle and support with jack stands 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 8 Release the park brake 9 Remove the caliper mounting bolts and discard the lock nuts and brake pads 10 Remove the spacer bushings from the mounting bracket and discard 11 I...

Page 64: ...d as if they contain asbestos Refer to appendix C for recommended handling precautions 6 Release the park brake 7 Raise the wheel off of the ground and support with jack stands 8 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 9 Disconnect the brake linkage from the brake arm 10 Remove the brake caliper bolts and discard the ...

Page 65: ...TABLE OF CONTENTS Throttle Linkage Throttle Linkage Adjustments 2 Throttle Linkage ...

Page 66: ...epair Page 2 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 67: ...ervice 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 4 Repairing the Commutator 5 Service Limits 6 Motor Service ...

Page 68: ...ive 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 Disconnect the main positive and negative cables at the batteries Typical motor with cooling fan indicated by the arrow MOTOR INSPECTION Disassembly 1 Remove the motor from th...

Page 69: ... diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator 7 Visually inspect the armature windings for burnt insulation Burnt insulation is a direct result of motor overheating and could lead to a shorted armature If the insulation is cracked or burnt then it is recommend that the armature or motor be replaced NOTE If the ar...

Page 70: ...aring in the rear housing 6 While supporting the inner race of the bearing press the armature into the bearing 7 Push the motor brushes into the brush holder until the brush spring snaps into place Be certain that the spring does not rest up against the brush wire See the illustrations below 8 Install the brush cover REPLACING THE BRUSHES OR ARMATURE BEARING NOTE It is recommended that all four br...

Page 71: ... the commutator segments 6 Measure the commutator undercut depth in 5 places around the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut 7 While still in the lathe smooth the commutator with fine emery cloth Undercutting the commutator 1 Using a small straight cut saw blade cut the commutator insulati...

Page 72: ...y test of each winding is all that is required to determine if the motor is at fault Motor Specification Number Undercut Depth Commutator Di ameter min Brush Length min Resistance Ohms 75º F mm inches mm inches mm inches Arma ture Field 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0116 1 20 70 054 41 XP 1789 or DY2 4001 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 057 40 XP...

Page 73: ...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 Pinion Bearing Preload 19 Pinion Gear Shimming Instructions 20 Setting the Pinion Gear Depth 20 Transmission ...

Page 74: ...until level with the bottom of the opening Refer to the Lube Chart section for information regarding type of oil b If oil comes out of the opening allow to drain until level with the bottom of the opening 9 Replace the fill level plug 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from the wheels 12 Release the park brake and test drive the vehicle 1 Make ...

Page 75: ...to the bottom of the level plug opening Refer to the Lube Chart section for information regarding type of oil 11 Replace the fill plug 12 Reconnect the main positive and negative cables at the batteries 13 Remove the blocks from the wheels 14 Release the park brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in...

Page 76: ...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 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the motor NOTE Label the motor wires with the number of the motor terminal before they are removed from the motor 7 If equipped remove the motor support bracke...

Page 77: ...ily injury 6 Raise the wheel off of the ground 7 Remove the tire wheel assembly Refer to Tires and Wheels section for information regarding removing the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regarding removing the brake pads 10 Remove the rotor 11 Install in reverse orde...

Page 78: ... front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 If required drain the oil from the 3rd member 7 Raise the rear of the vehicle and sup...

Page 79: ... axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts for the part number of the bolt 17 Fill with oil to the level of the fill plug threads Refer to...

Page 80: ...move the mounting bolts and carefully raise the vehicle until the transmission can be rolled out from under the vehicle Support the frame with jack stands 12 Install the transmission assembly in reverse order of removal a Adjust the brakes Refer to section Brake Service for information regarding adjusting the brakes 13 Lower the vehicle 14 Set the park brake 15 Reconnect the main positive and nega...

Page 81: ...Maintenance Service and Repair Page 9 Transmission view from rear ...

Page 82: ...of the vehicle and support with jack stands 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If required remove the drive assembly from the vehicle Note Refer to Removing and Installing the Drive Assembly for information on removing the drive from the vehicle 9 Remove the motor only if the entire drive is to be disas...

Page 83: ...nion shaft Note If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 16 Remove the six retaining bolts holding the gear case to the 3rd member housing Note Make note of the angle of the gear case 17 Remove the gear case housing from the 3rd member housing 18 Inspe...

Page 84: ... member and gear case cover Note Pack the motor seal with non acetic based grease 20 Fill the differential with oil Note Refer to Changing the Differential Oil for information on filling the drive with oil 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the vehicle Lubricate all parts with gear oil b...

Page 85: ...from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tube 11 Remove the primary reduction gear case Refer to Disassemb...

Page 86: ...ing 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 Remove the carrier bearing adjusting nut roll pin from the 3rd member housing then remove the carrier adjusting nut Roll Pin ...

Page 87: ... 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 Remove the pinion shaft from the 3rd member 21 Remove the front and rear pinion bearing races 22 Inspect all parts for signs of wear or damage 23 Thoroughly clean all parts ...

Page 88: ...er bearing race ring nut so that the ring gear is not in binding against the pinion gear 6 Remove the differential assembly Note Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembly 8 Install the cover onto the housing using 4 bolts in a cross pattern and torque to 45 50 ft lbs 9 Pre set the carrier bearing preload by tightening the housing carr...

Page 89: ...s 15 Check the gear lash between the ring and pinion gears The gear lash should be 005 to 007 inches 16 Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nuts The two ring nuts must be turned equally in opposite directions Note To move the ring gear closer to the pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing rac...

Page 90: ...case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil section for information regarding the proper oil level 21 Lower the vehicle 22 Reconnect the main positive and negative cables at the batteries 23 Remove the blocks from behind the wheels 24 Test drive the...

Page 91: ... bearing 3 Install the main gear onto the pinion shaft and torque the pinion nut to 154 169 ft lbs 4 Measure the torque required to rotate the pinion shaft in the housing 5 The torque required to rotate the pinion shaft should be between 1 1 and 2 9 ft lbs If the torque is not within specifications then add or subtract from the total shim thickness and repeat this procedure until the proper preloa...

Page 92: ... where DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race see below B 54 C The number on the edge of the differential side plate closest to the input shaft see next page D The number on the edge of the differential side plate farthest from the input shaft see next page E The distance in millimeters...

Page 93: ...Maintenance Service and Repair Page 21 NOTE Values shown are for reference only C D ...

Page 94: ...Maintenance Service and Repair Page 22 Notes ...

Page 95: ...ABLE 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 Tires and Wheels ...

Page 96: ...ailable with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall information on a tire Tire pressures must be checked when the tire is cold TIRE INSPECTION 6 Check the tire pressure Refer to Tire Inflation section for information on checking the tire pressure 7 Inspect the...

Page 97: ...ber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak 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 Disconnect the main positive and negative cables at the batteries R...

Page 98: ...oming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC Note To properly repair a puncture the tire must be removed from the wheel Refer to Replace the Tire section for information on removing the tire from the wheel It is recommended to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by person...

Page 99: ...ent should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provided with your equipment Always use a new valve stem when replacing a tire 1 Remove the tire from the wheel 2 Cut the old valve stem off of the wheel 3 Remove the valve stem cap from the new valve stem 4 Lu...

Page 100: ...Maintenance Service and Repair Page 6 Notes ...

Page 101: ...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 Battery Service ...

Page 102: ...e thoroughly with clear water DO NOT get any of the solution into the battery cells 8 Reconnect the batteries remove the blocks from the wheels and test drive 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 combustio...

Page 103: ... 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 Failure to do so may result in severe bodily injury and or property damage Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with sk...

Page 104: ...cific 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 If the charging system checks OK then the batteries are no longer accepting a charge and should be replaced NOTE Refer to Charger Troubleshooting for information on checking the charging system The highest reading will be the cell t...

Page 105: ...is may result in severe bodily injury A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in severe bodily injury and or property damage Do not overfi...

Page 106: ... are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of th...

Page 107: ... 11 Inspect the battery compartment for signs of corrosion 12 If minimal signs of corrosion are seen then the damaged paint should be stripped off and the entire battery compartment prepped and repainted 13 If there are excessive signs of corrosion then it may be necessary to replace some of the frame members or completely rebuild the battery compartment 14 Inspect the main positive and negative c...

Page 108: ...oms where batteries are being charged Failure to do so may result in severe property damage and or serious A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object that comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode r...

Page 109: ... RETURNING TO SERVICE Storage Thoroughly clean the batteries and battery compartment Refer to Cleaning in this section for information regarding cleaning the batteries Check the electrolyte level and charge the batteries Refer to Watering in this section for information regarding checking the electrolyte level Store the vehicle or batteries in a cool dry well ventilated area If storing for more th...

Page 110: ...t comes in contact with the battery terminals will initiate a short circuit of the battery This could cause the battery to explode resulting in property damage and or bodily injury Battery electrolyte is poisonous and dangerous It contains sulfuric acid Avoid contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in serious ...

Page 111: ...Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING 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 ...

Page 112: ...talled then these bolts may also hold the heat sink to the panel Install 1 Thoroughly clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the controller base and heat sink 3 Install the controller to the mounting plate 4 Attach the wires to the studs and torque per specification listed in the table at the end of this section Note DO NOT allow the wires to ro...

Page 113: ...modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the PCpaK application and cable Refer to the Tools section for part numbers If you have a special application that may require modified parameters contact your local authorized Taylor Dunn distributor to submit a request to the factory Note ...

Page 114: ...Motor Controller Page 4 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal stud 38 44 4 29 4 97 Notes ...

Page 115: ...r This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Charger Remove Install 2 Troubleshooting 2 ...

Page 116: ...nty and may result in incorrect operation of the charger or premature failure TROUBLESHOOTING Troubleshooting control system is not included in this manual All electrical troubleshooting information is included in a separate manual Troubleshooting Electric Vehicles The manual part number is M7 001 69 and was provided on the original vehicle CD Ahard copy can be purchased from your authorized Taylo...

Page 117: ... refer repair to a qualified licensed electrician Depending on the charging system two different color codes are used for the AC power source United States Standard 120 Volt White Neutral Black Hot Green Ground European Standard Blue Neutral Brown Hot Green Yellow Ground Charger AC power source is High Voltage Only personnel qualified for work high voltage AC power lines should repair the charger ...

Page 118: ...Wire Diagrams Wire Diagrams Page 2 Notes ...

Page 119: ...1 20 Wheels and Tires page 2 22 Instrument Panel dash 24 Resetting the Smart View Display 24 Head and Tail Lights optional 24 Speed Control Panel 26 Miscellaneous Electrical 28 Charger Lestronic Page 1 30 Charger Lestronic Page 2 32 Signet Charger 34 X Series Charger 35 Batteries 36 Frame Seat Cushions and Deck 38 Trailer Hitches 38 Decals 40 Knee Pad and Floor Mats optional 42 Lift Out Battery Bo...

Page 120: ...Illustrated Parts Page 2 Front Axle and Fork ...

Page 121: ... 3 15 010 20 Axle single wheel 1 4 16 010 00 Spacer 2 or 4 5 15 011 00 Axle dual wheel 0 or 1 6 14 030 10 Fork single wheel 0 or 1 7 14 032 10 Fork dual wheel 0 or 1 Serial numbers 159516 through 159533 with dual front wheels used wheel spacers K11 700 01 3 4 long and K11 700 02 1 3 4 long The short spacers are used on the inside of each wheel ...

Page 122: ...Illustrated Parts Page 4 Steering Linkage ...

Page 123: ...0 00 Turn buckle 2 9 88 080 16 5 16NC x 2 Hex bolt 4 10 88 089 81 5 16NC Lock nut 4 11 88 068 60 1 4 Cut flat washer 4 12 92 105 00 Bearing cap 1 13 80 011 10 Bearing 2 14 80 102 00 Race 2 15 45 307 00 Grease seal 1 16 19 008 00 Cloverleaf steering wheel 1 19 007 20 Round steering wheel 1 Not shown 19 159 00 Steering shaft for round steering wheel 1 88 199 82 Steering wheel nut 1 97 100 00 Woodruf...

Page 124: ...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 Part number for 4 5mm spacer is 3287213 130 3287343 ...

Page 125: ...12 GT 72019 Seal 1 18 GT 71979 Bearing 1 21 GT 3273633 Pinion nut 1 23 See Note 1 previous page Spacer 1 24 GT 3287453 Output gear 30 1 0 or 1 GT 3287463 Output gear 24 1 0 or 1 GT 3287473 Output gear 18 1 0 or 1 GT 3287483 Output gear 12 1 0 or 1 25 GT 328 Spacer 46 100mm 1 GT 328 Spacer 46 100mm 0 or 1 GT 328 Spacer 46 125mm 0 or 1 GT 328 Spacer 46 150mm 0 or 1 GT 328 Spacer 46 175mm 0 or 1 26 G...

Page 126: ...Illustrated Parts Page 8 Transmission Differential Case ...

Page 127: ...pinion gear set 1 14 GT 3297193 Differential case cover 1 15 GT 3287133 Adjusting ring 2 16 GT 70417 Fill Level plug 1 17 GT 3287113 Differential housing 1 19 GT 3287143 Differential case 1 20 GT 72013 O ring 1 22 GT 71896 M10 x 25 Bolt 12 29 GT 71978 Bearing and race 2 30 GT 70299 10mm Washer 12 31 GT 71881 Seal 1 32 GT 70052 Vent 1 ...

Page 128: ...Illustrated Parts Page 10 Rear Axle ...

Page 129: ...10 Not shown 92 104 10 Hub cover 2 41 290 54 Axle housing left 1 41 290 55 Axle housing right 1 89 113 30 M12 x 1 75 x 30mm Hex bolt axle housing to center section 6 89 113 60 M12 Split lock washer axle housing to center section 6 96 327 10 3 8NF x 3 4 Hex bolt grade 5 with thread lock axle mounting bracket 8 Frame mounting 88 140 13 1 2 x 1 1 4 Hex bolt 4 88 148 61 1 2 SAE flat washer 8 88 148 62...

Page 130: ...Illustrated Parts Page 12 Rear Brakes ...

Page 131: ... 349 99 Complete brake assembly left 1 1 2 3 4 5 41 348 55 Clevis pin 2 6 7 8 41 350 27 Mounting bracket 2 9 Bushing 4 10 41 348 70 Brake pad 4 11 41 348 52 Spacer 4 12 88 067 18 Hex bolt grade 8 4 13 88 069 88 Hex nut grade 8 4 14 41 348 48 Brake arm 2 15 41 348 54 Spacer 4 Not available at time of printing ...

Page 132: ...Illustrated Parts Page 14 Motor ...

Page 133: ...70 412 20 70 170 00 70 109 00 70 417 00 80 212 00 70 421 00 88 067 17 88 067 22 203 21 4001 or XP1820A 70 072 41 85 403 00 70 173 00 70 170 10 1 XP 1786 or DD3 4004 70 052 40 70 412 20 70 170 00 70 109 00 2 70 417 00 80 212 00 70 421 20 70 421 00 95 930 00 88 067 17 88 067 22 DV1 4003 70 057 40 70 421 10 70 400 10 70 209 40 85 403 00 70 173 00 70 170 10 8 70 417 00 80 212 00 70 421 30 70 421 40 95...

Page 134: ...Illustrated Parts Page 16 Brake Linkage ...

Page 135: ...ing assembly 2 7 88 109 81 3 8NC Lock Hex nut 4 88 100 09 3 8NC x 3 4 Hex bolt 4 8 88 527 11 Cotter pin 6 9 00 150 24 Treadle weldment 1 10 96 763 00 Clevis 1 11 88 099 80 5 16NF Hex nut 1 12 96 820 25 Park brake cable 1 13 85 123 00 Spring 1 00 150 25 Spring alignment shaft 1 14 96 762 00 3 8 Clevis 1 15 02 100 01 Equalizer 1 16 50 002 31 Brake linkage 4 17 96 772 00 3 8 x 1 1 8 Clevis pin 2 Not ...

Page 136: ...Illustrated Parts Page 18 Throttle Linkage Slip joint detail ...

Page 137: ... 109 81 3 8NC Lock nut 1 3 88 108 61 3 8 SAE Flat washer 1 4a 50 481 00 Slip joint 1 4b 88 108 61 3 8 SAE Flat washer 1 4c 88 527 11 Cotter pin 1 5 50 123 21 Throttle link 1 6 See brake linkage Treadle 1 7 88 527 11 Cotter pin 1 88 108 61 3 8 SAE Flat washer 1 Not shown 02 150 11 Accelerator module lever 1 ...

Page 138: ...Illustrated Parts Page 20 Wheels and Tires page 1 ...

Page 139: ...5 bead width includes 3 4 6 7 8 3a 12 042 12 Inner Wheel 12 bolt 4a 12 042 13 Outer Wheel 12 bolt 5a 12 042 20 Wheel Assembly 3 75 bead width includes 3a 4a 6 7 8 6 88 110 09 3 8 x 3 4 NF Hex Bolt grade 5 7 88 109 62 3 8 Split Lock Washer 8 88 119 80 3 8 NF Hex Nut 9 97 236 00 Wheel Nut Not Shown 13 989 00 Valve stem tubless tire only 11 030 00 4 80 x 8 Tube Tire and Wheel Assemblies 13 734 00 4 8...

Page 140: ...Illustrated Parts Page 22 Wheels and Tires page 2 ...

Page 141: ...e 23 Wheels and Tires ITEM PART DESCRIPTION QTY 1 12 120 00 Bolt on center hub includes 3 4 5 1 2 13 001 00 Wheel with intergral center hub includes 3 4 5 1 3 80 105 00 Race 2 4 45 308 00 Grease seal 2 5 80 015 00 Bearing 2 ...

Page 142: ...y 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 Item 4 Smart View Display ...

Page 143: ...switch 1 Head and Tail Lights ITEM PART DESCRIPTION QTY 72 005 00 Head light 1 or 2 72 072 00 Replacement head light bulb 72 022 00 Tail lights 1 or 2 03 150 91 Tail light housing left 1 03 150 92 Tail light housing right 1 72 022 51 Tail light grommet 1 or 2 75 106 20 Harness 1 NOTE If your vehicle was not originally equipped with the Smart View display then the Sevcon speed control must be repro...

Page 144: ...Illustrated Parts Page 26 Speed Control Panel ...

Page 145: ... 01 200 07 Mounting panel 1 3 73 004 20 Horn 1 4 79 844 00 Main circuit breaker 1 5 72 501 42 ISO solenoid 1 6 88 838 06 14 x 1 2 Sheet metal screw 4 7 88 060 09 1 4NC x 3 4 Hex bolt 4 8 79 840 00 10 Amp circuit breaker 1 9 79 840 20 20 Amp circuit breaker 1 10 79 840 20 20 Amp circuit breaker 1 11 88 818 06 8 x 1 2 Sheet metal screw 8 12 73 005 01 Reverse Motion alarm 1 13 61 838 43 Buss bar 1 No...

Page 146: ...Illustrated Parts Page 28 Miscellaneous Electrical Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 1 2 Motion Alarms 20 19 Battery Status Meters 22 Hour Meters 5 ...

Page 147: ...rgency Battery Disconnect Switch optional 1 1 73 005 05 Reverse Warning alarm 1 2 96 650 01 Wire Harness Clip stick on 3 96 642 00 Wire harness Clip push mount 5 71 501 00 Horn Switch 1 10 71 102 10 Foot Interlock Switch 1 11 85 030 00 Spring 12 96 773 10 Clevis Pin 2 13 02 610 18 Mounting Plate 1 14 88 527 11 Cotter Pin 2 15 96 640 00 Clamp 3 16 Push Mount 16 96 629 80 not shown Clamp Rubber Line...

Page 148: ...Illustrated Parts Page 30 Charger Lestronic Page 1 ...

Page 149: ...S O 79 575 10 79 831 00 79 730 00 79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 200 00 11860 79 304 65E 36LC25 8ET 230 50 na 36 25 Built In 79 851 10 79 805 72 79 808 00 79 902 00 79 749 11 S O 79 831 00 79 530 00 79 306 23 7710 32 79 305 20 36LC25 8ET 115 60 12 36 25 Portable...

Page 150: ...Illustrated Parts Page 32 Charger Lestronic Page 2 ...

Page 151: ...02 00 79 749 13 S O 79 575 10 79 831 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 79 300 55E 24LC25 8ET 230 50 4 24 25 Built In 79 805 70 79 808 10 79 902 00 79 749 13 79 644 08 79 831 00 79 530 00 79 306 23 7105 01 79 300 50 24LC25 8ET 230 50 4 24 ...

Page 152: ... of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector Signet Charger ITEM PART DESCRIPTION QTY 79 302 20 24 volt Charger assembly 1 79 303 40 36 volt Charger assembly 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the charger Signet Charger ...

Page 153: ...ontrol 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 DC cord includes bushing 79 809 50 Interlock relay 79 722 03 Wiring kit includes LED s 79 575 07 AC cord GFI 0 or 1 79 575 06 AC Cord 0 or 1 X Series Charger ...

Page 154: ...ed Parts Page 36 Batteries 24 volt battery configuration 36 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 155: ...047 00 244AH T 145 77 047 50 250AH TD 250 77 047 80 244AH T 145 Moist charge dry 77 048 00 250AH J 250 77 048 80 250AH J 250 Moist charge dry 77 051 00 160AH Gell Note requires special charger 3 50 243 10 Battery rod 4 50 250 00 Battery hold down 5 88 088 66 Flat washer tin lead plated 6 88 069 81 1 2NC Nylon lock nut 7 88 081 12 5 16NC x 1 Hex bolt stainless steel 8 88 089 80 5 16NC Hex nut stain...

Page 156: ...Illustrated Parts Page 38 Frame Seat Cushions and Deck Trailer Hitches ...

Page 157: ... AC cord 1 4 03 150 43 Lower chain cover 1 5 03 150 28 Treadle plate 1 6 03 150 94 Floorboard 1 7 90 000 00 Seat back cushion 1 8 88 837 11 Screw 4 9 88 065 09 1 4NC x 3 4 Truss head machine screw 12 Not shown 97 211 20 1 4 U nut for 9 Trailer Hitches ITEM PART DESCRIPTION QTY 97 808 00 Automatic Coupling hitch 97 804 01 Pintle hitch 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 149 80 1 2NC Hax nut 4 88 ...

Page 158: ...Illustrated Parts Page 40 Decals ...

Page 159: ... 2 94 319 00 Battery Disconnect 1 3 94 382 00 Treadle operation 1 4 94 301 43 Arms and hand inside 1 5 94 313 20 Safety warning 1 6 94 384 01 Not a motor vehicle 1 7 94 384 14 Apply park brake 1 8 94 373 10 Data plate 1 9 94 384 17 Do not spray wash 1 10 94 333 00 FM 24 volt vehicle only 1 ...

Page 160: ...Illustrated Parts Page 42 Knee Pad and Floor Mats optional ...

Page 161: ...arts Page 43 Knee Pad and Floor Mats optional ITEM PART DESCRIPTION QTY 1 01 103 20 Floor mats 1 2 01 159 10 Knee pad 1 3 88 837 11 14 x 1 Phillips head screw 2 Not shown 94 440 00 Adhesive for floor mats spray can ...

Page 162: ...Illustrated Parts Page 44 Lift Out Battery Box optional Illustration not available ...

Page 163: ...Illustrated Parts Page 45 Lift Out Battery Box ITEM PART DESCRIPTION QTY 75 077 10 Harness to battery 2 75 077 14 Harness to vehicle 1 77 983 00 Lift out battery box 24 volt 2 ...

Page 164: ...Illustrated Parts Page 46 Ladders and Strobe Light optional Strobe Light ...

Page 165: ... Split lock washer 8 88 089 80 5 16NC Hex nut 8 Strobe Light ITEM PART DESCRIPTION QTY 1 88 029 80 8 32 Hex nut 3 2 88 028 62 8 Split lock washer 3 3 88 025 06 8 32 x 1 2 Truss head machine screw 3 4 72 023 20 Strobe light 1 5 72 451 21 Mounting pole 1 6a 75 618 00 18 Black wre 75 618 01 09 18 Black White wire Not shown 98 603 00 Grommet at base of pole 1 72 023 21 Replacement bulb ...

Page 166: ...Illustrated Parts Page 48 Notes ...

Page 167: ...ist 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 5 Generic Torque Values 6 Appendix c Brake Lining Handling Precautions 8 ...

Page 168: ...ll vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor Includes instructions 62 027 61 and 62 Sevcon System Handset Diagnostics and adjustments 62 only of the Sevcon Power Pak and Micro Pak control systems 96 500 43 PMT C Meter Reset Module Required to reset the PMT C maintenance meter special order option Molex 11 300 06 Pin Removing Tool Removes 0 093 d...

Page 169: ...f when cell is full 70 440 55 Pin Removing Tool Removes pin from Amp circular harness connectors 41 350 13 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors 77 200 00 Hydrometer Used for testing battery electrolyte Illustration is of a typical hydrometer actual hydromete...

Page 170: ...ther Bolts 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 Hex Bolts S A E Grade 8 L 9 APPENDIX B SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE The grade of a metric bolt is cast directly on the head Below is an example of a 10 9 The location and style of the...

Page 171: ... A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no markings are to be treated as S A E Grade A S A E Grade B S A E Grade C Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Grade L 9 Metric Nuts 5 8 8 8 10 9 12 9 ...

Page 172: ...c 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 Conversion Formulas Foot Pounds Newton Meters x 0 737562149 Newton meters Foot Pounds x 1 355817948 Imperial inch Newton Meters Grade SAE Dia Pitch 2 5 8 L9 4 40 6 32 8 32 10 32 12 32 1...

Page 173: ...3 00 398 30 2 00 3 50 540 Metric Foot Pounds Grade N m Dia Pitch 4 6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14 1 38 55 12 1 25 71 1 50 68 1 75 24 64 118 14 1 50 111 2 00 38 103 151 16 1 50 2 00 60 158 229 18 1 50 2 00 2 50 81 221 20 1 50 2 00 2 50 115 317 22 1 50 2 00 2 50 156 428 24 2 00 3 00 199 524 27 3 00...

Page 174: ...uum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause unnecessary dust possibly releasing asbestos fibers in the air Always wear protective clothing and a respirator when working on the brake pads shoes or their associated components Inhaled asbestos fib...

Page 175: ......

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 ...

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