Taylor-Dunn SS5-34 Operation, Troubleshooting Manual
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Taylor-Dunn SS5-34 Operation, Troubleshooting Manual

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See also: Service & Parts Manual
Models:
SS5-34 serial number starting 94506
SS5-36 serial number starting 90400
SS5-46 serial number starting 161403
MX6-00 serial number starting 113227
T h e B e s t W a y
T o G o
A b o u t Y o u r
B u s i n e s s
MANUAL MS-534-08
Operation, Troubleshooting
Manual
Revision: F

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Summary of Contents for Taylor-Dunn SS5-34

  • Page 1 Models: SS5-34 serial number starting 94506 SS5-36 serial number starting 90400 SS5-46 serial number starting 161403 MX6-00 serial number starting 113227 T h e B e s t W a y T o G o A b o u t Y o u r...
  • Page 3 Operator and Maintenance Manual A guide to the operation and maintenance of Taylor-Dunn ® Vehicles...
  • Page 4 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 5: Table Of Contents

    Lubrication ................... 3-5 Trouble shooting Guide ................. 3-6 Brakes ....................3-9 Adjusting the Brake Band ............3-10 SS5-34 Brake System .............. 3-10 Adjusting the Brake Cable ........3-11 Removing the Brake Assembly ......3-12 SS5-36, SS5-46 and MX-600 Brake System ......3-13 Adjusting the Brake Pedal Linkage ......
  • Page 6 Replace the King Pin or Bushings ......3-29 Rear Axle and Drive Assembly ............ 3-30 Removing the SS5-34 Rear End Assembly ......3-31 Removing the SS5-36and SS5-46 Rear End Assembly ..3-32 Removing the MX-600 Rear End Assembly ......3-33 Differential and Rear Axle ............
  • Page 7 SECTION 4-Electrical Troubleshooting ........1 Test Equipment Required: ..............3 IMPORTANT NOTES and INSTRUCTIONS ....... 3 Definitions: ..................4 Section 4a-Vehicle Wire Diagrams ..........1 Model MX 6-00 ..................2 Model SS 5-34, SS5-46 and SS 5-36 with the Dual Chassis Harness ..............3 Model SS 5-34 with the Single Chassis Harness ......
  • Page 8 TABLE OF CONTENTS Illustrated Parts List ..............5-1 IDENTIFYING YOUR VEHICLE ........... 5-2 BRAKE PEDAL LINKAGE AND ACCELERATOR PEDAL (SS5-34) ..5-4 BRAKE PEDAL LINKAGE (SS5-36, SS5-46 AND MX-600) ... 5-6 FRONT AXLE, WHEEL AND SUSPENSION ........5-8 FRONT AXLE, WHEEL AND STEERING (SS5-46) ....... 5-10 TILLER STEERING ..............

  • Page 9: Introduction

    The purchase of this vehicle shows a belief in high quality products Your purchase... ® manufactured in the USA. Taylor-Dunn , a leading manufacture of electric burden and personnel carriers since 1949, wants to be sure that you get the most out of your vehicle and that it provides years of reliable service.

  • Page 10: Who Should Read This Manual

    Responsibilities Of the Owner... ® The owner of this or any Taylor-Dunn vehicle is responsible for the training of operators, overall maintenance, and repairs of the vehicle. Owners should keep a record of conducted training and services or repairs performed on the vehicle.

  • Page 11: How To Use This Manual

    How To Use This Manual This manual is organized into four main sections: n Section 1: “Safety Rules and Operational Information,” outlines the safety issues and operational issues of the vehicle. Including the location and operation of controls, the operational checks that are to be performed, and various subjects that should be included in any operator and service training programs implemented by the owner.

  • Page 12: Conventions

    INTRODUCTION Conventions Throughout this manual you will find the following notations: A shaded box with the word “Warning” on its left denotes a warning. A warning alerts you of a hazard that may cause injury to yourself or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the task.

  • Page 13: Vehicle Description And Specifications

    Vehicle Description and Specifications Describes the Vehicle and Its Standard Specifications...

  • Page 14: Vehicle Description

    MX-600, on the frame tube to the left of the motor on the SS5-34, and on the left frame rail under the seat on the SS5-36 and SS5-46. Taylor-Dunn Mfg. Standard Model SS5-34 shown. This is one of the...

  • Page 15: Standard Specifications

    (Including Batteries) (SS5-34) 332 kg (713 lbs) (SS5-46) 376 kg (830 lbs) Turning Radius (MX-600) 205 cm (81 in) (SS5-34 & SS5-36) 190.5 cm (75 in) (SS5-46) 208.7 cm (81 in) Brakes (SS5-36, 5-46, MX-600) 2-Wheel Rear Drum (Mechanical Standard) (SS5-34)

  • Page 16: Taking Delivery Of Your Vehicle

    The claim must be filed within 48 hours of receiving the vehicle and the accessories. Forward a copy of the claim to your local Taylor-Dunn dealer. The only personnel authorized to repair, modify, or adjust any part of this or any Taylor- Dunn vehicle is a factory authorized service technician.

  • Page 17: Safety Rules And Operational Information

    Safety Rules and Operational Information Safety rules, guidlines, control functions, operating guidlines and storage information...

  • Page 18: Safety Rules And Guidelines

    SECTION 2 Safety Rules and Guidelines Responsibilities It is the responsibility of the owner to ensure that the operator understands the various controls and safety operations of this vehicle, as well as, obeying the following safety rules and guidelines: This vehicle was not designed to be driven on public highways.

  • Page 19: Safety Rules

    Safety Rules This vehicle is designed to be driven over smooth surfaces in and around places such as warehouses, nurseries, motels, parks, and resorts. Operators should read the safety rules, and guidelines below before operating this vehicle: Do not drive this vehicle unless you are a qualified operator. Keep all body parts inside the vehicle at all times.

  • Page 20: Driver Training Program Guidelines

    SECTION 2 Driver Training Program Guidelines The owner of this vehicle is responsible for conducting an “Operator Training Program” for all those personnel that will be operating this vehicle. The program should not be condensed for those claiming to have previous vehicle operation experience. NOTE: Successful completion of the “Operator Training Program”...

  • Page 21: Vehicle Controls

    Forward/Reverse Lever The forward-reverse rocker switch is located on the dash on the SS5-34, 5-36 and 5-46 and on the panel to the right of the seat on the MX-600. It determines the direction of travel of the vehicle. Push the top of the switch to make the vehicle go forward.

  • Page 22: Foot Brake Pedal

    SECTION 2 Foot Brake Pedal The foot brake pedal located to the left of the accelerator pedal and is for operation with the right foot only. It works the same as the brake in an automobile. Applying pressure to the brake pedal slows the vehicle according to the amount of pressure applied.

  • Page 23: Guidlines For Vehicle Operation

    Guidlines for Vehicle Operation The following text contains the guidelines for driving, loading, unloading, parking, and towing the vehicle: Driving Slow down and sound the horn when approaching a corner or a blind intersection. There is no horseplay or dangerous driving allowed while operating the vehicle.

  • Page 24: Towing

    SECTION 2 Towing Attach the tow strap to the front bumper tow-bar and place the forward/ reverse switch in neutral. Use another driver to steer and control the speed of the vehicle, while it is being towed. The driver of the towed vehicle is to maintain a safe distance from the towing vehicle and use the brakes when the towing vehicle slows or stops.

  • Page 25: Maintenance And Service Procedures

    Maintenance and Service Procedures Maintenance and Service Information, Including Lubrication Information, Scheduled Maintenance, and Disassembly...

  • Page 26: Maintenance Guidelines

    SECTION 3 Introduction to Maintenance This section contains the procedures necessary to repair and service your vehicle. You will also find periodic maintenance information and guidelines to follow before doing any kind of maintenance or service on this vehicle. Vehicle maintenance or repairs should only be performed by a qualified mechanic.

  • Page 27: Maintenance Guidelines For Vehicles Used In Severe Conditions

    Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in conformance with Taylor-Dunn’s recom- mended procedures. Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts. Periodic maintenance and service must be performed on this vehicle.

  • Page 28: Periodic Maintenance Table

    SECTION 3 Periodic Maintenance Table Periodic Maintenance Checklist Semi - Weekly Monthly Quaterly Annualy Maintenance Item Annual (20hrs) (80hrs) (250hrs) (1000hrs) (500hrs) Check Condition of Tires Check and Fill Batteries Check Brake System Check Steering System Lubricate Vehicle Clean and Tighten All Wire Connections Wash and Service Batteries Check Park Brake...

  • Page 29: Lubrication

    General Purpose Grease 3 Steering Collars General Purpose Grease 4 Brake Shaft Collars General Purpose Grease 5 Rear Axle Differential SS-536, SS 5-46, MX-600, SAE 30 Motor Oil SS5-34, SAE 140 API GL-5 Gear Oil 6 King Pin (SS5-46) General Purpose Grease...

  • Page 30: Trouble Shooting Guide

    SECTION 3 Trouble shooting Guide Symptom Probable Cause Steering Pulls in One Direction Worn Wheel or Collar Bearing Low Tire Pressure Broken or Missing Spring Bent Frame or Fork Hard Steering Dry Lube Points in Steering Linkage Low Tire Pressure Lack of Power or Slow Operation Brakes or Parking Brake Dragging Worn Drive Gears or Bearings...
  • Page 31 NOTES...
  • Page 32 SECTION 3 MECHANICAL REAR DRUM BRAKES (STANDARD ON SS5-36, SS5-46 & MX-600) DRIVE LINE BRAKE BAND (STANDARD ON SS5-34)

  • Page 33: Brakes

    This section covers the installation and repair of the brake systems that are installed on the SS5-34, SS5-36, SS5-46 and MX-600. These vehicles come equipped either with the mechanical rear drum brakes (found on the SS5-36, SS5-46 & MX-600) or the drive line brake band (found on the SS5-34).

  • Page 34: Adjusting The Brake Band

    SECTION 3 SS5-34 Brake System The SS5-34 comes standard with a mechanical drive line brake. The brake drum is attached to the pinion shaft. The brake band is anchored to the frame of the vehicle and attached to the brake pedal by the brake lever arm.

  • Page 35: Adjusting The Brake Cable

    Adjusting the Brake Cable The brake cable length must be adjusted so that the brake lever arm (located below the brake drum) is pivoted rearward as far as possible. To adjust the brake pedal linkage: Park the vehicle on a clean level surface and block the rear wheels to prevent movement.

  • Page 36: Removing The Brake Assembly

    SECTION 3 Removing the Brake Assembly In order to remove the brake assembly refer to the following instructions: 1. Park the vehicle on a level surface and block the tires to prevent any accidental movement. 2. Remove the key and place the forward/reverse switch in the neutral position.

  • Page 37: Ss5-36, Ss5-46 And Mx-600 Brake System

    SS5-36, SS5-46 and MX-600 Brake System Adjusting the Brake Pedal Linkage To adjust the brake pedal linkage, refer to the following procedures. Park the vehicle on a clean level surface and block the rear wheels to prevent movement. Raise the front of the vehicle and support it with jack stands. Loosen the jam nut on the brake linkage.

  • Page 38: Inspecting And Replacing The Park Brake Lock(All Models)

    SECTION 3 Inspecting and Replacing the Park Brake Lock(All Models) Locknut Mounting Bolt Park Brake Lock Points Clevis Adjusting Bolt Forward Jam Nut Foot Brake Assembly: Shown is the brake pedal, and how it connects to the brake cables on the SS5-36, SS5-46 and MX-600. 3-14...

  • Page 39: Replacement And Wear Of Park Brake Lock (All Models)

    Replacement and Wear of Park Brake Lock (All Models) In the following procedure, you will be told how to replace the Park Brake Lock assembly: Park the vehicle on a clean flat surface and block the rear wheels to prevent movement. Turn the key off and place the forward/reverse switch in neutral.

  • Page 40: Ss5-36, Ss5-46 And Mx-600 Rear Brakes

    SECTION 3 SS5-36, SS5-46 and MX-600 Rear Brakes The rear brakes are mechanical, auto adjusting, drum brakes and require no periodic adjustments to ensure safe operation. Servicing of these brakes consists of replacing the brake drum and brake shoes when they become worn. In this section, we will cover how to inspect and replace the brake drum and shoes.

  • Page 41: Replacing The Brake Drum

    Replacing the Brake Drum To replace the rear brake drum, use the following procedure: Raise the rear of the vehicle one side at a time. Placing jack stands under the vehicle to support it. Do not Attempt to raise the rear end by placing jacks or other lifting devices in the center of the rear end.

  • Page 42: Replacing The Brake Shoes

    SECTION 3 Replacing the Brake Shoes To replace the brake shoes, use the following procedure. Raise the rear of the vehicle until the rear wheels clear of the floor and place jack stands under the vehicle. Raise the rear of the vehicle one side at a time.
  • Page 43 Exploded view of mechanical rear brake assembly. 3-19...

  • Page 44: Front Fork And Steering

    Included in the steering will be the tiller steering system and the geared steering system. The standard steering assembly for the SS5-34, SS5-36, and MX-600 is the Tiller. Since the Geared option is widely used in these vehicles as well, we included it in this section.

  • Page 45: Front Fork

    Front Fork Here, we will cover the Front Fork only. The following procedures will cover the disassembly and repair of the front fork and the axle. , NOTE: There are two types of front axles used within the serial numbers covered by this manual. The basic instructions for removing, servicing and installing are the same.

  • Page 46: Removing The Front Fork

    SECTION 3 Removing the Front Fork In order to remove the front fork follow these procedures. Park the vehicle on a clean level surface. Turn the key off and place the forward/reverse switch in the neutral position. Block the rear wheels to prevent movement. Loosen the spindle mounting nut on the tiller and remove it from the steering shaft.

  • Page 47: Removing The Front Springs

    Removing the Front Springs In order to remove the front springs, follow these procedures: Raise the front of the vehicle and support it with jack stands Always use a lifting strap, hoist, and jack stands of adequate capacity to lift and support the vehicle. Failure to use lifting and supporting devices of rated load capacity to support the vehicle may result in serious injury and property damage.

  • Page 48: Replacing The Front Wheel Bearings

    SECTION 3 Replacing the Front Wheel Bearings To replace worn or damaged wheel bearing, follow the procedure below: Park the vehicle on a level surface. Using the appropriate procedure, remove the front wheel from the fork assembly. Remove the oil seal, bearings and bearing races from the wheel. Install new bearing races, bearings and oil seals.

  • Page 49: Optional Geared Steering

    In this section, we will cover how to remove and service this steering system. SS5-34 Geared Steering Assembly In order to disassemble this steering gear box, follow this procedure. Refer to the illustration on the following page.
  • Page 50 SECTION 3 SS5-36, SS5-46 and MX-600 Optional Geared Steering SS5-34 Optional Geared Steering Assembly 3-26...

  • Page 51: Steering Assembly

    SS5-36, SS5-46 and MX-600 Steering Assembly In order to disassemble this steering gear box, follow this procedure. Refer to the illustration on the previous page. Park the vehicle on a level surface and block all the wheels. Remove the cap from the center of the steering wheel. Remove the nut from the center of the steering wheel.

  • Page 52: Ss5-46 Front Axle And Steering

    SECTION 3 SS5-46 Front Axle and Steering Replacing the Front Wheel Bearings To replace worn or damaged wheel bearing, follow the procedure below: Park the vehicle on a level surface. Raise the front of the vehicle and support it with jack stands. Using the appropriate procedure, remove the front wheel from the hub.

  • Page 53: Removing The Front Axle Assembly

    Removing the Front Axle Assembly To remove and install the front axle assembly, follow the procedure below: Park the vehicle on a level surface. Raise the front of the vehicle and support it with jack stands. Reomve both front wheels. Remove the left and right rod ends from the steering knuckles.

  • Page 54: Rear Axle And Drive Assembly

    SECTION 3 Rear Axle and Drive Assembly In this section, we will cover how to install, remove, and service the rear axle and drive assemblies. SS5-36, SS5-46 and MX-600 3-30...

  • Page 55: Removing The Ss5-34 Rear End Assembly

    Remove the shock from its lower mount. Remove the swing arm pivot bolts. Raise the rear of the vehicle and remove the rear end assembly from the vehicle. 10. Install in reverse order. Complete SS5-34 Drive and Rear End Assembly 3-31...

  • Page 56: Removing The Ss5-36And Ss5-46 Rear End Assembly

    SECTION 3 Removing the SS5-36 and SS5-46 Rear End Assembly Here, we are referring to the complete assembly including wheels, axle, housing, drive, and drive motor. In order to remove this complete assembly from the vehicle, use the following procedure: Park the vehicle on a clean level surface.

  • Page 57: Removing The Mx-600 Rear End Assembly

    Removing the MX-600 Rear End Assembly Here, we are referring to the complete assembly including wheels, axle, housing, drive, and drive motor. In order to remove this complete assembly from the vehicle, use the following procedure: Park the vehicle on a clean level surface. Dissconnect the batteries Always use a lifting strap, hoist and jack stands of adequate capacity to lift and support the vehicle.

  • Page 58: Differential And Rear Axle

    The differential and rear axle assemblies are slightly different between the SS5-34 and the SS5-36/5-46 and MX-600. For this reason, we have divided this section into two separate sub sections. The first is for the SS5-34 and the second for the SS5-36, SS5- 46 and MX-600.

  • Page 59: Ss5-34 Drive Service

    SS5-34 Drive Service To properly service this assembly, it will have to be removed. At this point, we are assuming that the entire assembly has been removed from the vehicle and has been placed on a clean, level work area or on a stand designed to hold such an assembly.

  • Page 60: Removing And Servicing The Rear Axle

    SECTION 3 SS5-34 Removing and Servicing the Rear Axle This procedure does not require that the rear end or drive assembly be removed in order to complete. However, if the rear end assembly is removed from the vehicle, you may skip procedure #1.

  • Page 61: Differential Service And Repair

    SS5-34 Differential Service and Repair Raise the drive wheels and support the vehicle with jack stands. Always use a lifting strap, hoist and jack stands of adequate capacity to lift and support the vehicle. Failure to use lifting and supporting devices of rated load capacity to support the vehicle may result in serious injury and property damage.
  • Page 62 SECTION 3 Remove the pinion housing assembly from the third member. NOTE: Do not lose the shims! Replace bearings, bearing races, and gears as needed. 10. Reassemble in reverse order and follow the instructions in Adjusting Backlash and Reshimming the Pinion Bearing a.
  • Page 63 Selecting Pinion Housing Shims The pinion housing shims are available in thickness from 0.005” to 0.021”, in increments of 0.001”, to correctly position the pinion gear. However, the standard shim thickness is 0.015” thick. The following numbering system is used on pinions to indicate the amount you must add or subtract from the standard shim in order to correctly position the pinion gear.

  • Page 64: Motor Removal

    SECTION 3 Changing the Differential Oil Place a 3 quart or larger drain pan under the drive. Remove the differential drain plugs. Replace the drain plugs and remove the differential fill and level plugs. Install oil into the differential through the filler hole until the oil starts to come out of the level hole (approximately 2 quarts).

  • Page 65: Adjusting Belt Tension

    1/4"(.250) Belt Deflection of 1/4" (.250") Adjusting Belt Tension Whenever the belts are removed from the pulleys or as the belts become worn, the belt tension must be readjusted. In order to adjust the belt tension, follow these procedures: Check the alignment of the pulleys. The face of the pulleys should be in line with each other.

  • Page 66: Aligning Pulleys

    SECTION 3 Aligning Pulleys To align the pulleys, use the following procedure: 1. Loosen the motor mount clamp nuts and move the motor either forward or backward until the two pulley faces are in line with each other. 2. Tighten the motor mount clamp nuts and check the belt deflection. Adjust the belts as needed.

  • Page 67: Ss5-36, Ss5-46 And Mx-600 Drive Service

    SS5-36, SS5-46 and MX-600 Drive Service To properly service this assembly, it will have to be removed from the vehicle. At this point, we are assuming that the entire assembly has been removed from the vehicle and has been placed on a clean, level work area SS5-36, SS5-46 and MX-600 Drive Assembly SS5-36/SS5-46/MX-600 Removing and Servicing the Rear Axle This specific procedure does not require that the rear end or drive assembly be...

  • Page 68: Servicing The Differential

    SECTION 3 Exploded View of SS5-36, SS5-46 and MX-600 Differential Assembly Servicing the Differential At this point, we are assuming that the complete drive assembly and differential has been removed from the vehicle and has been properly placed in a safe work area. To service the differential use the following procedure: Drain the oil from the differential into the appropriate receptacle.
  • Page 69 Remove the differential case assembly from the housing. Remove the differential bearings from each side of the case. Remove the drive gear from the case. Punch or drill a 1/8” hole in the center of each bearing bore plug. 10. Insert a suitably sized sheet metal screw into the hole until the bore plug is forced out of the bearing bore.
  • Page 70 SECTION 3 28. After the flange side bearing is seated install the snap ring. 29. Repeat procedures for opposite side. 30. Align the final drive gear mounting holes with the differential case, install the four bolts through the differential case, and secure the drive gear in place by tightening the nuts.

  • Page 71: Motor

    Motor SS5-36/SS5-46/MX-600 Motor Removal To remove the motor from the differential use the following procedure: NOTE: IF YOU ARE SERVICING A MX-600 THE DIFFER- ENTIAL AND REAR END ASSEMBLY MUST BE REMOVED FROM THE VEHICLE TO COMPLETE THIS TASK. IF YOU ARE SERVICING A SS5-36, YOU MAY SIMPLY REMOVE THE DECK BOARD TO GAIN ACCESS TO THE MOTOR.

  • Page 72: Ss5-34 Motor Removal

    SECTION 3 SS5-34 Motor Removal Park the vehicle on a level surface and block the wheels to prevent movement. Disconnect the batteries. Remove the deck board and place it out of the way. Mark the wire leads on the motor to insure their proper location when reinstalling the motor.

  • Page 73: Installing New Brushes

    Installing New Brushes In order to install new brushes in the motor use the following procedure: Remove the motor from the rear end assembly. Remove the motor cover revealing the brush holder and brushes. Disassemble the brush studs from the cover. Remove the old brushes and install the new ones.

  • Page 74: Inspecting The Armature

    SECTION 3 Inspecting the Armature If any solder has been thrown from the armature the motor must be replaced. NOTE: Check the inside of the motor housing around the commutator for bits of solder. If the commutator is grooved, it must be cut on a lathe. Measure the undercut on the commutator.

  • Page 75: Battery

    Battery Cleaning Dry dirt can be readily blown off with low-pressure air or brushed off. Wetness or wet dirt on the covers indicates battery acid. Using a nonmetallic brush with flexible bristles, wash it off with a strong solution of baking soda and hot water (1 lb.

  • Page 76: Servicing The Batteries

    SECTION 3 Servicing the Batteries Check the electrolyte level in all batteries. If low, fill with distilled water up to the correct level. Do not overfill the battery. An overfilled battery may leak acid. Clean the battery. Clean the cell posts connectors and battery box with water. Charging To charge the batteries do the following: Check the electrolyte level.

  • Page 77: Battery Configuration

    Negative Tap To Control Panel Positive Tap REAR OF VEHICLE Battery Configuration: Shown are the batteries and how they are connected together for the SS5-34, SS5-36 and SS5-46. MX-600 TO CONTROL PANEL 12V POSITIVE 12V NEGATIVE REAR OF VEHICLE Battery Configuration: Shown are the batteries and how they are connected together for the MX-600.

  • Page 79: Section 4-Electrical Troubleshooting

    SECTION 4-Electrical Troubleshooting...
  • Page 80 ELECTRICAL TROUBLESHOOTING Solenoids Circuit Breaker PMC Speed Control Typical Control Panel Syptoms: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Special Troubleshooting in Section 4 at the end of the main troubleshooting sequence.

  • Page 81: Test Equipment Required

    • This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Accelerator Module Test Harness. Troubleshooting CANNOT be completed without these tools. SECTION 4 Main Sequence PAGE 3...

  • Page 82: Definitions

    ELECTRICAL 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 83 ELECTRICAL TROUBLESHOOTING Power Output Test 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. The rear drive wheels may rotate during some of the following tests.
  • Page 84 ELECTRICAL TROUBLESHOOTING Control Wire inputs Test 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. The rear drive wheels may rotate during some of the following tests.
  • Page 85 ELECTRICAL TROUBLESHOOTING Control Wire inputs (continued) Connect a voltmeter across the PMC #2 terminal and battery negative. Close all interlock switches, turn the Key Switch The voltage shown is for illustration ON, and place the F&R Switch in Forward. only. The actual voltage may vary. Depress the accelerator pedal to engage MS-1 only.
  • Page 86 ELECTRICAL TROUBLESHOOTING Power Wire Inputs 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. The rear drive wheels may rotate during some of the following tests.
  • Page 87 ELECTRICAL TROUBLESHOOTING Motor 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. The rear drive wheels may rotate during some of the following tests.
  • Page 88 ELECTRICAL TROUBLESHOOTING Connect the test light across the motor ‘S1’ and Wiring to motor omitted for clarity. Do not ‘S2’ terminals. disconnect the motor wires for this test. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Forward.
  • Page 89 ELECTRICAL TROUBLESHOOTING Connect the accelerator module test harness to the accelerator module. The voltage shown is for illustration Connect a voltmeter between pin #9 in the test only. The actual voltage may vary. harness and battery positive. • If the voltage is not at battery volts then Main Battery Positive the wiring between pin #9 in the harness and battery negative is open.
  • Page 90 ELECTRICAL TROUBLESHOOTING Connect a voltmeter between pin #9 (-) and pin #2 (+) in the test harness. The voltage shown is for illustration Depress the accelerator pedal to engage only. The actual voltage may vary. MS-1 only. • If the voltage is between 6.0 and 6.5 volts and the test at the PMC #2 terminal in the Control Wire Input section failed then the wire or interlock switches between...
  • Page 91 NOTE: Due to the many different configurations possible for special order interlocks, they will not be included in this text. 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 92 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across the COLD terminal View of the terminals of a of the key switch and battery negative. FLUKE 79 SERIES II MULTIMETER typical Key Switch Turn the key switch ON. KEY SWITCH • If the voltage is not at battery volts then "COLD, Violet Wires(s)"...
  • Page 93 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across one of the COLD terminals of the KSI side of the F&R switch and The COLD terminal is the battery negative. Violet/Black wire on either end of the switch Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Forward.
  • Page 94 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across the Solenoid The voltage shown is for illustration Negative Buss Bar and battery positive. only. The actual voltage may vary. NOTE: You may skip this test if it was FLUKE 79 SERIES II MULTIMETER Solenoids are shown for reference only.
  • Page 95 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across the reverse terminal of the forward and reverse side of the F&R switch The REVERSE terminal is diagonally and battery negative. opposite the reverse side of the rocker on the switch FLUKE 79 SERIES II MULTIMETER Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in F&R switch seen from...
  • Page 96 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across the ISO solenoid COLD terminal and battery negative. The voltage shown is for illustration only. The actual voltage may vary. Close all interlock switches and turn the FLUKE 79 SERIES II MULTIMETER Solenoids are shown for reference only. Key Switch ON.
  • Page 97 ELECTRICAL TROUBLESHOOTING Connect a voltmeter across the Reverse Solenoid coil terminals. Refer to your vehicles wiring The voltage shown is for illustration only. The actual voltage may vary. diagram to identify the position of the reverse solenoid. Solenoids are shown for reference only. The type and position of the reverse Close all interlock switches, turn the Key solenoid in your truck may be different...
  • Page 98 ELECTRICAL TROUBLESHOOTING Reverse (does not run in forward) The voltage shown is for illustration Connect a voltmeter across the PMC KSI only. The actual voltage may vary. terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in forward.
  • Page 99 ELECTRICAL TROUBLESHOOTING Set the test light voltage to the same voltage as the battery volts. FWD/REV Connect the test light across the Normally Closed contacts of the Reverse solenoid. Refer to your vehicles wiring diagram to identify the position of the Reverse solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Forward.
  • Page 100 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 101 Section 4A Vehicle Wire Diagrams...

  • Page 102: Section 4A-Vehicle Wire Diagrams

    ELECTRICAL TROUBLESHOOTING SECTION 4a Wire Diagrams Page 2...
  • Page 103 ELECTRICAL TROUBLESHOOTING SECTION 4a Wire Diagrams Page 3...
  • Page 104 ELECTRICAL TROUBLESHOOTING SECTION 4a Wire Diagrams Page 4...

  • Page 105: Section 4-Special Troubleshooting Guide

    ELECTRICAL TROUBLESHOOTING Section 4-Special 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 106: Pmc Control

    ELECTRICAL 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 107 ELECTRICAL TROUBLESHOOTING Connect a volt meter across the PMC B+ and PMC M- terminals. Turn the key-switch on, close all interlock The voltage shown is for illustration switches (if equipped), depress the only. The actual voltage may vary. accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests: •...

  • Page 108: Plugging Diode

    ELECTRICAL 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 109: Freewheel Diode

    ELECTRICAL 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 110: Iso

    ELECTRICAL 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 111 ELECTRICAL TROUBLESHOOTING Connect the meter to each end of the resistor that was removed from the ISO solenoid and Reading is plus or minus 10% measure its resistance. ISO solenoid is shown for reference only. The type of solenoid in your truck •...

  • Page 112: Solenoids

    ELECTRICAL 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 113 ELECTRICAL 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’ terminal to the wire that was connected to the motor ‘S2’...
  • Page 114 ELECTRICAL 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 Motor shown for reference only. the wire that was connected to the motor Terminal positions on your motor ‘S1’...

  • Page 115: Motor

    ELECTRICAL 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 116 ELECTRICAL 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. This should be an open circuit.
  • Page 117 SECTION 4b-Lestronic II ChargerTroubleshooting Table of Contents for Lestronic II Charger Troubleshooting 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...

  • Page 118: 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 119 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 120: 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 121: 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 122 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 123 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 124: 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 125 Electrical Troubleshooting 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. Failure to do so may result in serious bodily injury.

  • Page 126: 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 127 Section 4C ® Signet Charger Troubleshooting 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 Status LED Error Code ......5 Troubleshooting ........6 Turn the Key switch OFF BEFORE disconnecting the batteries. Disconnecting the batteries with the key switch ON may corrupt the controller programming resulting in a fault code 1 (refer to fault table).
  • Page 128 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. Both the HB600W ®...

  • Page 129: Testing The Charging Cycle

    Electrical Troubleshooting TESTING THE CHARGING CYCLE In typical installations, the charger will remain on for up to 14 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 14 hours if: •...

  • Page 130: 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. Clamp on DC ammeter to measure up to 20-Amps. Important Notes and Instructions •...

  • Page 131: Status Led Error Code

    Electrical Troubleshooting STATUS LED ERROR CODE There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. All three LED’s flashing indicate an error in the charger. See the table below for an explanation if the error codes: Error Description...

  • Page 132: 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. After 5 or 6 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 133: Illustrated Parts List

    Illustrated Parts List...

  • Page 134: Identifying Your Vehicle

    IDENTIFYING YOUR VEHICLE If you are unsure of the vehicle that you are working on. Refer to the figures at the right. Starting from the top of the page they are as follows: SS5-34 SS5-36 MX-600 SS5-46 Whenever necessary the model of the vehicle is identified with the parts that are specific to that model.
  • Page 135 SS5-34 SS5-36 MX-600 SS5-46...

  • Page 136: Brake Pedal Linkage And Accelerator Pedal (Ss5-34)

    ILLUSTRATED PARTS BRAKE PEDAL LINKAGE AND ACCELERATOR PEDAL (SS5-34)
  • Page 137 Brake Linkage/ Accelerator Pedal ITEM# PART# DESCRIPTION 88-140-14 1/2” NC X 1-1/2” Hex Head Cap Screw 98-200-00 Brake Pedal Pad, Rubber 88-089-81 1/2” NC Locknut 01-534-67 Brake Arm Weldment 88-140-14 1/2” NC X 1-1/2” Hex Head Cap Screw 96-772-00 3/8” X 1” Clevis Pin 85-060-00 Return Spring 96-813-00...

  • Page 138: Brake Pedal Linkage (Ss5-36, Ss5-46 And Mx-600)

    ILLUSTRATED PARTS BRAKE PEDAL LINKAGE (SS5-36, SS5-46 AND MX-600) Attach to brake arm at rear axle...
  • Page 139 Brake Linkage (SS5-36, sS5-46 and MX-600) ITEM# PART# DESCRIPTION 88-140-13 1/2” X 1/4” NC Bolt 02-536-09 Pedal Lock 98-200-00 Pedal Pad 88-149-81 1/2” NC Locknut 88-527-11 1/8” X 1” Cotter Pin 96-762-00 Clevis 88-119-81 3/8” NF Jam nut 88-111-20 3/8” X 3” NF Bolt 96-826-12 Park Brake Cable Assy 02-536-06...

  • Page 140: Front Axle, Wheel And Suspension

    ILLUSTRATED PARTS FRONT AXLE, WHEEL AND SUSPENSION SS5-34, SS5-36, MX 600...
  • Page 141 Front Axle, Wheel and Suspension (SS5-34, SS5-36, and MX-600) ITEM# PART# DESCRIPTION 88-229-81 3/4” NC Locknut 88-228-61 3/4” NC Washer 16-206-00 Spacer 15-010-00 Front Axle(Threaded each end) 15-010-10 Front Axle(Single Ended) 45-308-00 Oil Seal 80-015-00 Tapered Roller Bearing 80-105-00 Bearing Race...

  • Page 142: Front Axle, Wheel And Steering Ss5-46

    ILLUSTRATED PARTS FRONT AXLE, WHEEL AND STEERING SS5-46 5-10...
  • Page 143 Front Axle, Wheel and Suspension (SS5-46) ITEM# PART# DESCRIPTION 92-104-00 Bearing cap 88-527-14 Cotter pin 88-239-85 Castle nut 88-228-61 3/4 SAE Flat washer 80-017-00 Bearing 80-103-00 Race 12-124-15 80-103-00 Race 80-017-00 Bearing 45-338-00 Seal 00-546-06 Left steering yoke 00-546-07 Right steering yoke 88-109-81 3/8NC Lock nut 97-202-50...

  • Page 144: Tiller Steering

    ILLUSTRATED PARTS TILLER STEERING 5-12...
  • Page 145 Tiller Steering ITEM# PART# DESCRIPTION 19-101-20 Steering Tiller 88-140-14 1/2” X 1-1/2” NC Bolt 97-230-00 1-1/4” NF X 9/16” Locknut 16-409-00 Spacer 80-102-00 Bearing Race 14-079-20 Front Fork with Springs 85-140-10 Spring 97-100-00 Woodruff Key 80-011-00 1-1/4” Tapered Roller Bearing 45-307-00 Oil Seal, 1-1/2”ID 88-149-81...

  • Page 146: Geared Steering (Ss5-34)

    ILLUSTRATED PARTS GEARED STEERING (SS5-34) 5-14...
  • Page 147 Geared Steering (SS5-34) ITEM# PART# DESCRIPTION 95-915-20 Cap, Black Plastic 88-199-82 5/8” Jam Nut 19-007-20 Steering Wheel 18-309-00 Gear Box Only,(With Bolts, Bushings, and Zerk Fittings.) 88-068-25 1/4” X 4-1/2”NC HEX Hd Cap Screw 88-068-62 1/4” Lockwasher 32-203-00 3/4” ID X 7/8” OD X 1/2” Long Bronze...

  • Page 148: Geared Steering (Ss5-36, Ss5-46 And Mx-600)

    ILLUSTRATED PARTS GEARED STEERING (SS5-36, SS5-46 AND MX-600) 5-16...
  • Page 149 Geared Steering (SS5-36, SS5-46 and MX-600) ITEM# PART# DESCRIPTION 19-011-25 Cover 19-011-20 Steering Wheel 80-400-10 3/4”ID Bearing 88-060-22 1/4" X 3-1/2" NC Hex Bolt 88-068-82 1/4" Lockwasher 18-309-13 Plate and Sleeve, Weldment 20-031-20 Steering Shaft and Gear 31-255-10 Stem and Gear, Weldment 32-207-00 3/8"...

  • Page 150: Instrument Panel (Ss5-34, Ss5-46 And Ss5-36)

    ILLUSTRATED PARTS INSTRUMENT PANEL (SS5-34,SS5-36 AND SS5-46) 5-18...
  • Page 151 Instrument Panel (SS5-34, SS5-36 and SS5-46) ITEM# PART# DESCRIPTION 71-039-10 Rocker Switch 1 or 2 02-536-10 Instrument Panel Console 88-065-09 1/4” X 3/4” NC Phillips Hd Screw 71-039-00 Forward/Reverse Switch 74-009-10 24-volt, Battery Status Indicator 74-000-00 Hour Meter (Optional) 72-028-20...

  • Page 152: Controls And Instruments (Mx-600)

    ILLUSTRATED PARTS CONTROLS AND INSTRUMENTS (MX-600) 5-20...
  • Page 153 Instrument Panel (MX-600) ITEM# PART# DESCRIPTION 74-009-10 24V Battery Status Indicator 76-013-00 Charging Receptacle 71-120-00 Key Switch W/Keys 00-300-04 Instrument Panel 71-039-00 3-Position Rocker Switch 71-111-00 Brake Light Switch 71-102-10 Seat Switch 02-610-18 Seat Switch Mount 85-030-00 Compression Spring for Seat Switch 96-773-00 Anchor Pin for Seat Switch 88-527-11...

  • Page 154: Motor Ss5-34

    ILLUSTRATED PARTS MOTOR SS5-34 5-22...
  • Page 155 5-23...

  • Page 156: Motor Ss5-36, Ss5-46 & Mx-600

    ILLUSTRATED PARTS MOTOR SS5-36, SS5-46 & MX-600 Armature 5-24...
  • Page 157 Motor GE spec# 5BC58JBS6129A ITEM # PART # DESCRIPTION 70-049-05 Complete motor assembly (does not include #11) 70-201-15 Field coils (mounted in motor housing) 70-210-51 Inulator 85-412-00 Brush spring 70-172-15 Brush holder (includes #3) 70-104-15 Motor brush (2) 70-210-51 Insulator 32-508-15 Bearing retainer 80-209-00...

  • Page 158: Rear Axle (Ss5-34)

    ILLUSTRATED PARTS REAR AXLE (SS5-34) 5-26...
  • Page 159 SS5-34 Rear Axle ITEM# PART# DESCRIPTION 85-140-00 2-7/16" X 6-1/4" Spring 96-240-00 1/2" X 4” Bolt 98-601-00 Rubber Grommet, 1/2" ID 88-149-81 1/2"NC Locknut 45-045-00 Rear Axle Bearing Gasket 45-301-00 Oil Seal 32-515-00 Bearing Retainer Ring 80-503-00 Bearing for Rear Axle...

  • Page 160: Rear Axle (Ss5-36, Ss5-46 And Mx-600)

    ILLUSTRATED PARTS REAR AXLE (SS5-36, SS5-46 AND MX-600) 5-28...
  • Page 161 SS5-36, SS5-46 and MX-600 Rear Axle(P/N 4S-150-10) ITEM# PART# DESCRIPTION 41-281-10 Differential Assy 45-303-20 Seal 80-480-20 Axle Bearing 88-840-13 Internal Snap Ring 41-126-99 Right Axle Shaft 41-126-98 Left Axle Shaft 41-344-99 Right Brake 41-344-98 Left Brake 88-199-85 Slotted Hex Nut 88-188-61 5/8"...

  • Page 162: Differential (Ss5-34)

    ILLUSTRATED PARTS DIFFERENTIAL (SS5-34) 5-30...
  • Page 163 3rd Member and Axle Assembly ITEM# PART# DESCRIPTION 41-709-00 3rd member Housing (1.628 ID Carrier Bearing) 41-710-00 3rd member Housing (1.784 ID Carrier Bearing) 88-119-80 3/8" NF Nut 41-712-00 Differential Assembly (1.628 ID Carrier Bearing) 41-713-00 Differential Assembly (1.784 ID Carrier Bearing) 80-127-00 Carrier Bearing Race, (For 1.628 ID Carrier Bearing)

  • Page 164: Differential (Ss5-36, Ss5-46 And Mx-600)

    ILLUSTRATED PARTS DIFFERENTIAL (SS5-36, SS5-46 AND MX-600) 5-32...
  • Page 165 SS536, SS5-49 & MX-600 Differential Assy ITEM# PART# DESCRIPTION 41-280-10 Differential Housing Assy 80-480-10 Pinion Bearing 31-265-00 Gear Set 80-480-15 Shaft Bearing 88-840-12 Snap Ring 80-715-10 O-Ring 41-973-00 Cup Plug 80-480-01 Bearing 80-715-00 O-Ring 80-408-00 Carrier Bearing 96-330-10 Bearing Cap Bolt 41-127-94 Fill Plug 41-127-64...

  • Page 166: Ss5-36, Ss5-46 Differential Frame

    ILLUSTRATED PARTS SS5-36, SS5-46 DIFFERENTIAL FRAME 5-34...
  • Page 167 SS536, SS5-46 Differential Frame ITEM# PART# DESCRIPTION 98-601-00 Rubber Grommet, 1/2" ID 88-149-81 1/2" Locknut 88-100-15 1/2" X 1-3/4" Bolt 88-108-62 3/8"" Lockwasher 85-141-00 Spring Clip 88-100-11 3/8" NC X 1" Bolt 00-536-01 Drive Frame 88-149-81 1/2" Locknut 96-240-00 1/2" X 4" Bolt 85-140-00 Spring 5-35...

  • Page 168: Deck And Vise Assy (Mx-600)

    ILLUSTRATED PARTS DECK AND VISE ASSY (MX-600) 5-36...
  • Page 169 MX-600 Deck and Vise Assy ITEM# PART# DESCRIPTION 90-408-20 30" X 27-1/2" Deckboard 88-065-13 1/4” NC X 1-1/4" Truss Head Screw 88-068-61 1/4" SAE Washer 97-840-01 4-1/2" Jaw Width Vise 00-380-01 Vise Mount Plate 88-100-15 3/8"NC X 1-3/4" Hex Head Bolt 88-108-62 3/8"...

  • Page 170: Toolbox Assy (Mx-600)

    ILLUSTRATED PARTS TOOLBOX ASSY (MX-600) 5-38...
  • Page 171 MX-600 Tool Box ITEM# PART# DESCRIPTION 91-340-25 Tool Chest 00-300-02 Trim 94-400-32 Double Sided Tape 3 ft 88-140-11 1/2"NC X 1" Hex Head Bolt 88-148-61 1/2" SAE Washer 88-159-84 1/2"NC Locknut Not Shown 91-340-21 Tool Box Lock 91-340-26 Keys for Toolbox Locks 00-300-08 Steel Deck Cover 5-39...

  • Page 172: Battery

    ILLUSTRATED PARTS BATTERY SS 5-34 TO CONTROL PANEL 12V NEGATIVE SS5-36, SS5-46 and MX 6-00 REAR OF VEHICLE 5-40...
  • Page 173 Batteries ITEM# PART# DESCRIPTION 77-042-50 Battery, 217AH, 105min 77-047-00 Battery, 244AH, 145min 77-044-00 Battery, 230AH, 105min 77-042-80 Battery, Moist Dry, 217AH, 105min 77-047-80 244AH, 145min, Dry Charge 88-081-12 5/16" NC X 1" Bolt 50-250-00 Battery Hold Down 50-243-10 Battery Hold Down Rod (For #3) 75-231-00 Battery Jumper 10-1/4"Long 88-089-80...

  • Page 174: Brake Assy (Ss5-34)

    ILLUSTRATED PARTS BRAKE ASSY (SS5-34) 5-42...
  • Page 175 Mechanical Brake Band Assy (SS5-34) ITEM# PART# DESCRIPTION 88-100-11 3/8" NC X 1-3/4” hex Head Cap Screw 96-771-00 3/8" X 3/4" Clevis Pin 97-250-00 3/4"-20 Extra Fine Pinion Nut 85-060-20 5/8"" OD X 2-1/2"" Compression Spring 41-660-60 Brake Half Band 96-245-10 1/2"...

  • Page 176: Rear Brake (Ss5-36, Ss5-46 And Mx-600)

    ILLUSTRATED PARTS REAR BRAKE (SS5-36, SS5-46 AND MX-600) 5-44...
  • Page 177 Rear Brake (SS5-36, SS5-46 and MX-600) ITEM# PART# DESCRIPTION 85-344-60 Spring Kit 41-634-00 Brake Shoes (Shows 1 Set) 41-344-98 Complete Brake Assembly, Left 41-344-99 Complete BRake Assembly, Right 5-45...

  • Page 178: Pmc Control Panel

    ILLUSTRATED PARTS PMC CONTROL PANEL 5-46...
  • Page 179 #8 X 1/2" Pan Head Screw Harnesses and Panel Assy ITEM# PART# DESCRIPTION 75-148-43 Control Panel Harness (MX-600) Shown 75-148-25 Control Panel Harness (SS5-34 & SS5-36) 75-149-25 Power Harness (All) 62-015-07 Control Panel Assy(MX-600) 62-015-00 Control Pnl Assy (SS5-34 & SS5-36) 5-47...

  • Page 180: Battery Charger

    ILLUSTRATED PARTS BATTERY CHARGER LESTER PORTABLE CHARGER LESTER BUILT-IN CHARGER SIGNET CHARGER REFER TO PARTS APPENDIX A AT THE END OF THIS SECTION 5-48...
  • Page 181 Portable Battery Charger 24-Volt 25-Amp, Model 13110 (79-301-10) ITEM# PART# DESCRIPTION 79-851-10 Ammeter 79-805-64 Timer 79-902-00 Capacitor 79-749-13 Heat Sink With Diodes 79-644-30 Transformer 79-575-10 AC Cord Set with Plug 79-831-00 Fuse Assembly 79-530-00 Bushing for Cords 79-566-10 DC Cord Not available Built-In Battery Charger 24-Volt 25-Amp,Model 10505 (79-301-05) ITEM#...
  • Page 182 ILLUSTRATED PARTS TIRE AND WHEEL 5-50...
  • Page 183 12-012-00 Rim With 5 hole Pat. for 4.80 X 8 Tire (SS5-34) 12-054-00 Iron Rim With 5 hole Pat. for 16-1/4 X 4 X 11-1/4 Tire (SS5-34) TIRE and RIM 13-734-00 4.80 X 8 LR’B’ Tire and Split Rim(Standard on SS5-34) 13-734-11 4.80 X 8 LR’B’...

  • Page 184: Seat Cushions

    ILLUSTRATED PARTS SEAT CUSHIONS SS5-34 SS5-36, SS 5-46 MX-600 5-52...
  • Page 185 Seat Cushions ITEM# PART# DESCRIPTION SS5-34 90-144-00 Backrest (Optional) 90-166-00 Seat Cushion 02-534-25 Hip Restraint SS5-36, SS5-46 93-004-00 Backrest/2nd Passenger Seat 93-005-00 Seat Cushion MX-600 90-144-00 Backrest 93-006-00 Seat Cushion 5-53...

  • Page 186: Decals

    ILLUSTRATED PARTS DECALS 5-54...
  • Page 187 Decals ITEM# PART# DESCRIPTION 94-373-10 Vehicle Data Decal 94-333-00 F-M Approved Decal 94-385-00 Battery Warning Decal 94-319-00 Battery Disconnect Decal 94-384-01 Not A Motor Vehicle Decal (Domestic) 94-384-04 Traffic Standards Notice Decal (Export) 94-383-00 Console Decal 94-384-00 Park Brake Decal 94-386-01 Roll Over Warning Decal (MX-600 Only)

  • Page 188: Mirrors Option

    ILLUSTRATED PARTS MIRRORS OPTION 5-56...
  • Page 189 Mirror Option ITEM# PART# DESCRIPTION 92-201-00 4-1/2" X 8-1/2" Mirror (Rt or Lt Side) 92-202-00 Mirror Bracket (Rt or Lt Side) 88-065-08 1/4"NC X 5/8" Truss Head Screw 88-068-60 1/4" Washer 88-069-87 1/4" Keps Nut 88-068-62 1/4" Lockwasher 88-069-83 1/4" Acorn Nut NOTE: All quantities are for a single mirror.

  • Page 190: Strobe And Stop Light Option

    ILLUSTRATED PARTS STROBE AND STOP LIGHT OPTION 5-58...
  • Page 191 (For Harness) 72-023-21 Flash Tube for Strobe Light NOTE: 72-022-00 4-inch Round Light is installed on the SS5-34 and the 72-025-00 Oval Light is installed on the SS5-36 and MX-600. NOTE: All strobe light information is for the MX-600 at the time of printing no strobe light information was available.

  • Page 192: Headlight

    ILLUSTRATED PARTS HEADLIGHT Standard 5/16 NUT & WASHER (COME W/HEADLIGHT) 4 (MX 6-00 only) Geared Steering Option Steering box (ref) #2 - SS 5-34, SS 5-36, SS 5-46 #2 - MX 6-00 5-60...
  • Page 193 Headlight ITEM# PART# DESCRIPTION 72-005-00 Heallight 71-039-11 Switch, SS 5-34, SS 5-36, SS 5-46 71-100-00 Switch, MX 6-00 71-505-05 Mount, geared steering option 75-166-35 Harness, MX 6-00 88-100-09 3/8NC x 3/4 Hex bolt 88-109-87 3/8NC KEPS nut 5-61...
  • Page 195 Parts Appendix A...

  • Page 196: Signet Charger

    ILLUSTRATED PARTS SIGNET CHARGER NOTE: The harness connectors are not included with the charger. When replacing the charger order 2 each of the following: PART # DESCRIPTION 75-318-20 Butt splice 75-320-51 Knife connector 5-64...
  • Page 197 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 AC Wire Connections 5-65...
  • Page 200 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...

This manual is also suitable for:

Ss5-36Ss5-46Mx6-00

Table of Contents