Taylor-Dunn SS-025-34 Operation, Maintenance, And Replacement Parts Manual
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Taylor-Dunn SS-025-34 Operation, Maintenance, And Replacement Parts Manual

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Greg Lilley
February 19, 2025

S/N210099 Model # ss-025-36 What is the PART# for the PMC control module ???

0
1 comments:
Mr. Anderson
May 14, 2025

The part number for the PMC control module for the Taylor-Dunn model SS-025-36 is 62-204-00.

This answer is automatically generated

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Greg Lilley
July 3, 2025

Truck runs for a short time...then stops...nothing...come back hour later...runs again

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Summary of Contents for Taylor-Dunn SS-025-34

  • Page 1 F , 5 / 1 4 / 2 0 1 8...
  • Page 3 Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.
  • Page 4 B2-10 Ambulance B2-48 With Dump Bed Option B2-48 with Steel Cab, Foldaway 4-Passenger Seat and Stake Sides ET 3000 P2-50 30,000 Pound Tow Tractor ET1-50 Full Size Truck...

  • Page 5: Table Of Contents

    Section Index Taylor-Dunn ® Models: SS-534, 536, 546, and MX-600 Operator and Service Manual Section Index Introduction Safety Rules and Operating Instructions General Maintenance Front Axle Service Steering Component Service Brakes Service, SS-536, 546, MX-600 Brakes Service, SS-534 Motor Service...
  • Page 7 Chapter - Table of Contents About this manual ........2 Who Should Read This Manual ....2 Responsibilities ..........2 How To Use This Manual ......3 Conventions .............. 3 How to Identify Your Vehicle ......4 Taking Delivery of Your Vehicle ....5...

  • Page 8: About This Manual

    The purchase of this vehicle shows a belief in high Of the Owner... quality products manufactured in the USA. ® ® The owner of this or any Taylor-Dunn vehicle is Taylor-Dunn , a leading manufacturer of electric responsible for the overall maintenance and repairs burden and personnel carriers since 1949, wants to of the vehicle, as well as the training of operators.

  • Page 9: How To Use This Manual

    INTRODUCTION HOW TO USE THIS MANUAL Conventions This manual is organized into five main sections: Symbols and/or words that are used to define INTRODUCTION warnings, cautions, instructions, or notes found throughout this manual. Refer to the examples below. This section describes how to use this service manual and how to identify your vehicle.

  • Page 10: How To Identify Your Vehicle

    INTRODUCTION HOW TO IDENTIFY YOUR VEHICLE This manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts.

  • Page 11: Taking Delivery Of Your Vehicle

    The only personnel authorized to repair, modify, or • Check that all wire connections, battery adjust any part of this or any Taylor-Dunn ® vehicle is cables, and other electrical connections are a factory authorized service technician.
  • Page 13 Chapter - TABLE OF CONTENTS Standard Specifications* ......2 Safety Rules and Guidelines ......3 Driver Training Program ....... 3 Driver Qualifications..........3 Vehicle Controls..........4 1) Horn Switch ............4 2) Start Switch ............4 3) Headlight Switch ........... 4 4) Battery Status Gauge ..........

  • Page 14: Standard Specifications

    SAFETY RULES AND OPERATING INSTRUCTIONS STANDARD SPECIFICATIONS* ITEM Model SPECIFICATION Occupancy SS-534, MX-600 Driver SS-536, SS-546 Driver + 1-Passenger on fold down seat NO PASSENGER IF USED FOR TOWING TRAILER Dimensions SS-534 76.5L x 28.5W x 42 H Inches (1943L x 724W x 1067H mm) SS-536 86.5L x 30W x 41H Inches (2197L x 762W x 1041H mm) SS-546...

  • Page 15: Safety Rules And Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS SAFETY RULES AND GUIDE- DRIVER TRAINING PROGRAM LINES According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those who It is the responsibility of the owner of this vehicle to will be operating this vehicle.

  • Page 16: Vehicle Controls

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE CONTROLS 1) Horn Switch The horn switch is located on the left side of the floorboard. Depress the switch with your foot to sound the horn, release it to turn it off. 2) Start Switch The start switch is located at the lower right of the dash panel of the Model SS and the front of the panel on the model MX.

  • Page 17: Seat Adjustments

    SAFETY RULES AND OPERATING INSTRUCTIONS 1) Accelerator Pedal The accelerator pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the accelerator pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.

  • Page 18: Driver Seat Interlock (Ss-536, Ss-546, Mx-600)

    SAFETY RULES AND OPERATING INSTRUCTIONS Driver Seat Interlock (SS-536, SS-546, MX-600) This vehicle is equipped with a driver seat interlock. The vehicle The seat interlock switch is only one control system will not run unless the driver is seated properly in part of the vehicle safety system.

  • Page 19: Safety Guidelines

    SAFETY RULES AND OPERATING INSTRUCTIONS VEHICLE OPERATIONAL GUIDELINES Safety Guidelines • Only qualified and trained operators may drive this • Keep the vehicle under control at all times. vehicle. • Yield right of way to pedestrians, ambulances, fire trucks, or other vehicles in emergencies. • Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees). • Do not overtake another vehicle at intersections, blind spots, or other dangerous locations. • Drive slowly when making a turn, especially if the ground is wet or when driving on an incline. • Do not drive over loose objects, holes, or bumps. • This vehicle may overturn easily if turned sharply or • Yield right of way to pedestrians and emergencies when driven at high speeds. vehicles. • Observe all traffic regulations and speed limits. • Stay in your driving lane under normal conditions, maintaining a safe distance from all objects. • Keep all body parts (head, arms, legs) inside this vehicle while it is moving.

  • Page 20: Parking

    SAFETY RULES AND OPERATING INSTRUCTIONS Parking Before leaving the vehicle: • Place the forward/off/reverse switch in the center “OFF” position. • Turn the start switch to the “OFF” position and remove the key. • Set the park brake. In addition: •...

  • Page 21: Charging Your Vehicle

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

  • Page 22: Signet Charger Operation (Model Hbs)

    SAFETY RULES AND OPERATING INSTRUCTIONS Signet Charger Operation (Model HBS) Lestronic II Charger Operation ® The Signet ® HBS series chargers are fully automatic. The Lestronic II ® charger is a semi-automatic charging The charger will turn itself ON when the AC power cord system.

  • Page 23: Storing / Returning To Service

    SAFETY RULES AND OPERATING INSTRUCTIONS STORING / RETURNING TO SERVICE Both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing Your Vehicle • Clean the batteries, then fill and charge before putting the vehicle in storage. Do not store batteries in a discharged condition.

  • Page 24: Periodic Maintenance Checklist, Ss-534

    SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST, SS-536, 546, MX-600 NOTE: A full page copy of the Periodic Maintenance Checklist is on Safety Rules NOTE: A full page copy of the Periodic Maintenance Checklist is on the the Vehicle Documentation CD under the [Misc] sub folder. Page 12 Vehicle Documentation CD under the [Misc] sub folder.
  • Page 25 SAFETY RULES AND OPERATING INSTRUCTIONS PERIODIC MAINTENANCE CHECKLIST, SS-534 Safety Rules NOTE: A full page copy of the Periodic Maintenance Checklist is on the Page 13 Vehicle Documentation CD under the [Misc] sub folder.

  • Page 26: Maintenance Guidelines For

    SAFETY RULES AND OPERATING INSTRUCTIONS Daily Visual inspection: Tire condition and pressure. External frame damage (body). Operation of all lights and warning alarms and/or horns. Smooth and proper operation of all controls such as but not limited to: • Accelerator pedal, Brake pedal, Steering, Parking brake, etc. •...
  • Page 27 Chapter - Table of Contents Maintenance Guidelines ....... 2 Troubleshooting Guide ........ 3 Lubrication and Fluids Chart ....... 4 Lubrication Diagram ........5...

  • Page 28: Maintenance Guidelines

    • Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in ® conformance with Taylor-Dunn’s recommended procedures. • Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

  • Page 29: Troubleshooting Guide

    Maintenance, Service and Repair Troubleshooting Guide Symptom Suspect Component or System Action Steering Pulls Left or Right Front end out of alignment Realign front end Low tire pressure Inspect tire pressure Difficult Steering Lack of lubrication Lubricate steering linkages Damaged or worn steering components Inspect all steering components Low tire pressure Inspect tire pressure...

  • Page 30: Lubrication And Fluids Chart

    Maintenance, Service and Repair Lubrication and Fluids Chart Assembly Item Component qty Capacity Lubricant Front Axle: King Pin (SS-546) NLGI Grade 2 lithium multi-purpose grease Axle Pivot (SS-546) NLGI Grade 2 lithium multi-purpose grease Wheel Bearing 1 or 2 - NLGI Grade 2 lithium multi-purpose grease Fork Bearings NLGI Grade 2 lithium multi-purpose grease...

  • Page 31: Lubrication Diagram

    Maintenance, Service and Repair Lubrication Diagram SS-546 Front Axle Drive/ Transmission SS-534 Drive (Rear View) Fill #9 is on top of housing SS-536, 546 Transmission pan (bottom View) Fill and Level plug. Pan must be removed to drain Page 5...
  • Page 33 Chapter - TABLE OF CONTENTS Inspect the Front Wheel Bearings ..2 Adjust Front Wheel Bearings (3-wheel) ......2 Adjust Front Wheel Bearings (4-wheel) ......3 Front Axle Removal and Installation (3-wheel) ..... 4 Removal ..............4 Installation ............4 Front Axle Removal and Installation (4-wheel) .....

  • Page 34: Inspect The Front Wheel Bearings

    Maintenance, Service, and Repair INSPECT THE FRONT WHEEL ADJUST FRONT WHEEL BEARINGS BEARINGS (3-WHEEL) 1. Make sure the key-switch is in the “OFF” 1. Make sure the key-switch is in the “OFF” position, then remove the key. position, then remove the key. 2.
  • Page 35 Maintenance, Service, and Repair ADJUST FRONT WHEEL BEARINGS (4-WHEEL) 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Confirm the electric park brake is set. 4.

  • Page 36: Front Axle Removal And Installation (3-Wheel)

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND Installation INSTALLATION (3-WHEEL) Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub. Assemble the bearing spacers into the front wheel hub 1.

  • Page 37: Front Axle Removal And Installation (4-Wheel)

    Maintenance, Service, and Repair FRONT AXLE REMOVAL AND REPLACE FRONT WHEEL INSTALLATION (4-WHEEL) BEARINGS Removal 1. Make sure the key-switch is in the “OFF” position, then remove the key. 1. Make sure the key-switch is in the “OFF” 2. Place the forward-reverse switch in the center “OFF”...

  • Page 38: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Front Axle Page 6...
  • Page 39 Chapter - TABLE OF CONTENTS Front End Alignment, SS-546 .... 2 Rod Ends, SS-546 ......3 Inspection .............. 3 Replacing .............. 3 Fork / Steering Shaft Bearings ..4 Replace the Steering Wheel ....4 Replace the Steering Gear, SS-534 ... 5 Replace the Steering Gear, SS-536, 546, MX-600 ....
  • Page 40 Maintenance, Service, and Repair FRONT END ALIGNMENT, SS-546 1. Make sure the start switch is in the “OFF” Do not drive the vehicle while the steering wheel position, then remove the key. or front wheels are tied in position. Driving the 2.

  • Page 41: Front End Alignment, Ss-546

    Maintenance, Service, and Repair ROD ENDS, SS-546 NOTE: A set of rod ends will wear at the same rate. If a rod end is worn out, then all should be replaced as a set. Inspection Replacing 1. Make sure the start switch is in the “OFF” 1.

  • Page 42: Fork / Steering Shaft Bearings

    Maintenance, Service, and Repair FORK / STEERING SHAFT REPLACE THE STEERING BEARINGS WHEEL 1. Make sure the start switch is in the “OFF” 1. Make sure the start switch is in the “OFF” position, then remove the key. position, then remove the key. 2.

  • Page 43: Replace The Steering Gear

    Maintenance, Service, and Repair REPLACE THE STEERING GEAR, SS-534 1. Make sure the start switch is in the “OFF” position, then remove the key. SS-534 Steering Gear 2. Place the forward-reverse switch in the center Assembly “OFF” position. 3. Set the park brake. 4.

  • Page 44: Replace The Front Fork

    Maintenance, Service, and Repair REPLACE THE FRONT FORK HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. 1. Make sure the start switch is in the “OFF” Description Foot Pounds Newton Meters position, then remove the key. Steering wheel nut 28-32 38-43...
  • Page 45 Adjust the Service Brake Linkage ......5 Adjust the Parking Brake ........5 Replace Brake Shoes ......6 Hardware Torque ....... 7 Current Taylor-Dunn brakes are asbestos free. ® However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos.

  • Page 46: Auto-Adjust Brake Mechanism Theory Of Operation

    Maintenance, Service, and Repair AUTO-ADJUST BRAKE MECHANISM THEORY OF OPERATION The auto-adjust mechanism is located on the bottom of the brake assembly. As the brake pad material wears down, the distance the brake shoes travel to engage the brake drum becomes longer. When the travel becomes long enough, the brake lever engages the auto-adjust lever and causes it to index a tooth on the star wheel adjuster.

  • Page 47: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE Current Taylor-Dunn brakes are asbestos free. ® However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 48: Brake Shoes

    Maintenance, Service, and Repair Brake Shoes Brake Drum Current Taylor-Dunn ® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos.

  • Page 49: Adjust The Brakes

    Maintenance, Service, and Repair ADJUST THE BRAKES NOTE: This vehicle is equipped with self-adjusting brakes. Other than the brake linkages, there is no manual adjustment. Adjusting the brake linkage is only required when any part of the brake linkages are removed or replaced. Do not adjust the brake linkage to compensate for a low brake pedal.

  • Page 50: Replace Brake Shoes

    Maintenance, Service, and Repair REPLACE BRAKE SHOES Current Taylor-Dunn brakes are asbestos free. However, there is the possibility that the original brakes were ® replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asbestos. Refer to Appendix C for recommended handling precautions.

  • Page 51: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Brake Service Page 7...
  • Page 53 Adjust the Brake Linkage ....3 Replace Brake Band ......4 Replace Brake Drum ......4 Hardware Torque ....... 7 Current Taylor-Dunn brakes are asbestos free. ® However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos.

  • Page 54: Inspect The Service Brake

    Maintenance, Service, and Repair INSPECT THE SERVICE BRAKE INSPECT THE PARKING BRAKE Current Taylor-Dunn brakes are asbestos free. ® 1. Make sure the start switch is in the “OFF” However, there is the possibility that the original position, then remove the key.

  • Page 55: Adjust The Brake Band

    Maintenance, Service, and Repair ADJUST THE BRAKE BAND ADJUST THE BRAKE LINKAGE Do not adjust the brakes by means of the brake cable as this Do not adjust the brakes by means of the brake cable as this may result in loss of braking power. may result in loss of braking power.

  • Page 56: Replace Brake Band

    The brake drum is a slip fit over the pinion shaft. The pinion nut is a right hand thread but is very tight and may require a large pneumatic impact Current Taylor-Dunn ® brakes are asbestos free. wrench to remove it.
  • Page 57 Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pionion Nut Brake Service Page 5...
  • Page 58 Chapter - TABLE OF CONTENTS Removal ........... 2 Inspection ......... 2 Field / Armature Windings (DC motors) ....2 Commutator ............3 Brushes ..............3 Bearings ..............3 Thermal Sensor ............. 3 Motor Service Limits and Specifications ........ 4 Typical Motor Assembly...

  • Page 59: Removal

    Maintenance, Service, and Repair Visually inspect the surface condition of the commutator. REMOVAL Although the commutator may be grooved, it should be the same diameter all the way around. The motor is an intergal components of the transaxle • Raised segments are caused by excessive motor assembly.

  • Page 60: Commutator

    Maintenance, Service, and Repair Commutator Bearings Service limits for the commutator can be found in the The bearings should spin with no noticeable roughness specification tables at the end of this section. or grinding and with very little play. If the commutator is deeply grooved then it should be If the bearing free wheels, then the lubrication in the cut on a lathe.

  • Page 61: Motor Service Limits And Specifications

    Maintenance, Service, and Repair MOTOR SERVICE LIMITS AND SPECIFICATIONS Commutator Diameter Brush Length Wire Depth Undercut Depth Motor Specification (min) (min) (max) Number inches inches inches inches L94-4006 0.635 0.025 96.8 3.810 19.05 0.75 A02-4011 69.9 2.75 0.62 ER5-4001 69.9 2.75 0.62 XP-2023...
  • Page 63 Chapter - TABLE OF CONTENTS Check Oil Level ......... 2 Change Oil ........2 Transaxle Assembly ......3 Remove ..............3 Install ..............3 Axles ..........4 Remove ..............4 Install ..............4 Axle Bearings ........4 Remove/Install ............4 Motor ..........

  • Page 64: Check Oil Level

    Maintenance, Service, and Repair CHECK OIL LEVEL CHANGE OIL Fluid type and capacities are listed in the lubrication Fluid type and capacities are listed in the lubrication section in the General Maintenance chapter. section in the General Maintenance chapter. 1. Make sure the start switch is in the “OFF” 1.

  • Page 65: Transaxle Assembly

    Maintenance, Service, and Repair TRANSAXLE ASSEMBLY Install Remove 1. Install the transaxle in reverse order of removal. • Install the wheels Refer to procedure in Tire/ 1. Make sure the start switch is in the “OFF” Wheels section. position, then remove the key. •...

  • Page 66: Axles

    Maintenance, Service, and Repair AXLES AXLE BEARINGS Note: The axle must be removed from the Remove transmission for this procedure. Refer to Remove and Install Axle for information regarding removing the rear axle. 1. Make sure the start switch is in the “OFF” position, then remove the key.

  • Page 67: Motor

    Maintenance, Service, and Repair MOTOR Remove NOTE: In some vehicle configurations the transmission assembly will have to be removed to allow clearance to remove the motor. Refer to Transmission section for information on removing the transmission assembly from the vehicle. 1.

  • Page 68: Differential Case

    Maintenance, Service, and Repair DIFFERENTIAL CASE Disassemble 1. Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on removing the transmission. 2. Thoroughly clean the transmission assembly before disassembly. 3. Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information on removing the axles.
  • Page 69 Maintenance, Service, and Repair 12. Using a soft metal or hard wood dowel, drive the 16. Remove the circlip from the input shaft. intermediate shaft through the bearing just enough to allow clearance for an ID bearing puller. Do not 17.

  • Page 70: Assemble

    Maintenance, Service, and Repair Assemble Notes: When pressing bearings, do not press against or support the outer race as this will damage the bearing. All snap rings should fit tightly into their grooves. If a snap ring is loose, then it must be replaced. Do not hit any shaft or component with a hard metal hammer or punch.

  • Page 71: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Motor terminals 7.5-9.1 10.2-12.4 Motor Mounting Bolts 8-10.5 Final Drive Gear Nuts 35-45 48-61 Differential Bearing Cap Bolts 35-45 45-61 Transaxle - SS-536, SS-546, MX-600...
  • Page 73 Chapter - TABLE OF CONTENTS Check the Oil Level ......2 Change the Oil ........2 Adjust the Drive Belts ......2 Transaxle Assembly ......3 Remove ..............3 Install ..............3 Axles ..........4 Remove and Install ..........4 Axle Bearings ........

  • Page 74: Check The Oil Level

    Maintenance, Service, and Repair CHECK THE OIL LEVEL ADJUST THE DRIVE BELTS 1. Make sure the start switch is in the “OFF” 1. Make sure the start switch is in the “OFF” position, then remove the key. position, then remove the key. 2.

  • Page 75: Transaxle Assembly

    Maintenance, Service, and Repair TRANSAXLE ASSEMBLY Remove 1. Make sure the start switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement.

  • Page 76: Axles

    Maintenance, Service, and Repair AXLES AXLE BEARINGS Replace the Axle Bearing Remove and Install NOTE: The axle must be removed from the vehicle to replace the axle bearing. Refer to section Rear Axle: Remove and Install for 1. Make sure the start switch is in the “OFF” information regarding removing the axle.

  • Page 77: Differential Assembly (3Rd Member)

    Maintenance, Service, and Repair 7. While rotating the pinion shaft, tighten the pinion DIFFERENTIAL ASSEMBLY (3 nut to 100 foot pounds (142 Nm). MEMBER) 8. Measure and record the ring and pinion gear backlash. This setting will be used during reassembly.

  • Page 78: Assemble

    Maintenance, Service, and Repair Assemble NOTE: Thoroughly clean and inspect all parts before reassembly. Apply a small amount of differential oil to all gears and bearings before reassembly. NOTE: Depending on your vehicle config-uration, the rear pinion pilot bearing is not required and may not be installed.
  • Page 79 Maintenance, Service, and Repair 17. Install the bearing caps in their original locations 18. Loosen the right side nut. and torque the bolts to 12-15 ft-lbs. making sure 19. Tighten the left nut until all backlash is removed that the adjusting nuts still turn freely. from the ring and pinion gear.

  • Page 80: Re-Shimming The Pinion Housing

    Maintenance, Service, and Repair RE-SHIMMING THE PINION HOUSING The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced. Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear.

  • Page 81: Exploded View

    Maintenance, Service, and Repair EXPLODED VIEW Transaxle - SS-534 Page 9...

  • Page 82: Hardware Torque

    Maintenance, Service, and Repair HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Motor Terminals 7.5-9.1 10.2-12.4 Ring Gear Bolts 65-80 93-114 Carrier Bearing Cap Bolts 70-85 100-121 Spanner Nut Lock Bolts 12-25 18-35...
  • Page 83 Chapter - TABLE OF CONTENTS Tire Inflation ........2 Tire Inspection ........2 Tire/Wheel Assembly ......3 Remove/Install-Rear ..........3 Remove/Install-Front ..........3 Hardware Torque ....... 3...

  • Page 84: Tire Inflation

    Maintenance, Service, and Repair TIRE INFLATION There are many tire options available with varying tire pressures. Refer to the side wall of your tire for information regarding the tire pressure for your tires. The illustration below is an example of the side wall information on a tire. Tire pressures must be checked when the tire is cold.

  • Page 85: Tire/Wheel Assembly

    Maintenance, Service, and Repair TIRE/WHEEL ASSEMBLY HARDWARE TORQUE If hardware is not listed here, refer to standard torque Remove/Install-Rear values in the appendix. Description Foot Pounds Newton Meters Wheel Nut 1. Make sure the start switch is in the “OFF” position, then remove the key.
  • Page 87 Chapter - TABLE OF CONTENTS Cleaning ..........2 Testing ..........3 Watering ........... 4 Charging ........... 5 Storing ..........5 Storage ..............5 Returning to Service ..........5 Remove/install ........6 Industrial Battery or Lift Out Battery Pack ..6 Individual Batteries ..........

  • Page 88: Cleaning

    Maintenance, Service, and Repair CLEANING • Explosive mixtures of Hydrogen gas are 1. Make sure the start switch is in the “OFF” present within battery cells at all times. Do not position, then remove the key. work with or charge battery in an area where open flames (including gas furnace or water 2.

  • Page 89: Testing

    Maintenance, Service, and Repair TESTING Specific Gravity NOTE: The battery must be fully charged before • Explosive mixtures of Hydrogen gas are performing this test. present within battery cells at all times. Do not The specific gravity of a cell is an indication of the actual work with or charge battery in an area where state of charge of the cell.

  • Page 90: Watering

    Maintenance, Service, and Repair WATERING • Explosive mixtures of Hydrogen gas are Do not overfill the batteries. Over filling the present within battery cells at all times. Do not batteries may cause the batteries to boil over work with or charge battery in an area where and result in severe bodily injury or property open flames (including gas furnace or water damage.

  • Page 91: Charging

    Maintenance, Service, and Repair CHARGING STORING Refer to the Operator Section for charging information. Storage Thoroughly clean the battery and battery compartment. Cleaning Refer to in this section for information • Explosive mixtures of Hydrogen gas are regarding cleaning the battery. present within battery cells at all times.

  • Page 92: Remove/Install

    Maintenance, Service, and Repair REMOVE/INSTALL • Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not work with or charge battery in an area where open flames (including gas furnace or water heater pilots), sparks, cigarettes, or any other sources of combustion are present. Always provide ample ventilation in rooms where batteries are being charged.

  • Page 93: Individual Batteries

    Maintenance, Service, and Repair Individual Batteries HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Individual batteries can weight up to 80 pounds. To avoide injury, use proper lifting Description Foot Pounds Newton Meters tecniques or a hoist to remove the battery.
  • Page 95 Table of Contents SYMPTOMS: ........2 READ THIS FIRST ......3 Test Equipment Required: .............3 IMPORTANT NOTES and INSTRUCTIONS ......3 Definitions: ................4 SYMPTOM TROUBLESHOOTING GUIDE .......... 19 PMC CONTROL ..............20 PLUGGING DIODE .............22 FREEWHEEL DIODE ............23 SOLENOIDS .................26 MOTOR .................29 REV G...

  • Page 96: Symptoms

    Curtis PMC Troubleshooting Note: Vehicles with Dana H12 transmission, Forward solenoid is in the center. SYMPTOMS: If your vehicle exhibits any of the following symptoms then skip the main troubleshooting sequence and proceed to Symptom Troubleshooting later in this section. • Runs slow in both directions plus high armature and field current in both directions. NOTE: Armature and field current should be equal.

  • Page 97: Read This First

    • This troubleshooting guide requires the use of a test light rated at the battery voltage of the truck and the Taylor-Dunn Throttle Module Analyzer. Troubleshooting CANNOT be completed without these tools. These test procedures must be performed in the order they were written. If the test result is good, then proceed to the next test or go to the next section.

  • Page 98: Definitions

    Curtis PMC Troubleshooting Definitions: • “MS-1” = The first switch in the accelerator module. • “Battery volts” = The voltage at the batteries at the time the test is completed. • “Pick up” = Energizing a solenoid or contactor. • “F&R” = Forward and Reverse. • “ISO” = Isolator. • “Battery negative” = Main negative battery post. • “Battery positive” = Main positive battery post. • “PMC” = Speed control module (black box). • “HOT terminal” = The side of a switch or solenoid that is connect to the power source. • “COLD terminal” = The side of a switch or solenoid that power is switched to. DURING ALL TESTS After any repairs are made, completely retest the vehicle before lowering the drive wheels to the ground. Failure to retest the vehicle could result in unexpected movement of the vehicle resulting in severe bodily injury and/or property damage.
  • Page 99 Curtis PMC Troubleshooting Power Output Test The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 100 Curtis PMC Troubleshooting Control Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 101 Curtis PMC Troubleshooting Connect a voltmeter across the PMC #2 terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Forward. Depress the accelerator pedal to engage MS-1 only. • If the voltage is not between 6.0 and 6.5 volts then go to the Accelerator sequence. Depress the pedal fully. • If the voltage is not between 11.0 and 11.5 volts then go to the Accelerator sequence. Connect voltmeter across the PMC KSI terminal and battery negative. With the pedal still fully depressed: •...
  • Page 102 Curtis PMC Troubleshooting Power Wire Inputs The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 103 Curtis PMC Troubleshooting Motor The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 104 Curtis PMC Troubleshooting Accelerator The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.

  • Page 105: Wire Diagram

    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. Connect a voltmeter across the HOT terminal of the key switch and battery negative.
  • Page 106 Curtis PMC Troubleshooting For your reference, shown at the right are the Forward and Reverse switch wire connections for a typical control system. Connect a voltmeter across the HOT terminal of the KSI side of the F&R switch and battery negative. Turn the key switch ON. • If the voltage is not at battery volts then go to the Accelerator sequence. Connect a voltmeter across one of the COLD terminals of the KSI side of the F&R switch and battery negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Forward. •...
  • Page 107 Curtis PMC Troubleshooting F/R switch The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 108 Curtis PMC Troubleshooting Connect a voltmeter across the forward terminal of the forward and reverse side of the F&R switch and battery negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in forward. Depress the accelerator pedal fully. •...
  • Page 109 Curtis PMC Troubleshooting Solenoids The rear drive wheels may rotate during some of the following tests. Block the front wheels, raise the rear drive wheels off the ground, and support the vehicle with jack stands. Failure to do so may cause the vehicle to move and cause severe bodily injury and/or property damage.
  • Page 110 Curtis PMC Troubleshooting Forward (does not run in reverse) Connect a voltmeter across the PMC KSI terminal and battery negative. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in reverse. • If the voltage is not at battery volts then go to the Key Switch sequence. Connect a voltmeter across the Reverse Solenoid coil terminals. Refer to your vehicles wiring diagram to identify the position of the reverse solenoid.
  • Page 111 Curtis PMC Troubleshooting Connect the test light across the Normally Closed contacts of the Forward solenoid. Refer to your vehicles wiring diagram to identify the position of the forward solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in Reverse. Depress the accelerator pedal fully. • If the light comes on then the Forward solenoid has failed. 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.
  • Page 112 Curtis PMC Troubleshooting Set the test light voltage to the same voltage as the battery volts. Connect the test light across the Normally Open contacts of the Forward solenoid. Refer to your vehicles wiring diagram to identify the position of the forward solenoid. Close all interlock switches, turn the Key Switch ON, and place the F&R Switch in forward. Depress the accelerator pedal fully. • If the light comes on then the Forward solenoid has failed. 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.

  • Page 113: Symptom Troubleshooting Guide

    Curtis PMC Troubleshooting SYMPTOM TROUBLESHOOTING GUIDE This section is specific to the symptoms listed below. Each troubleshooting sequence assumes that all listed symptoms are present. Do not use this section unless the truck has all listed symptoms. SYMPTOMS GO TO Runs slow in both directions plus high armature and field current in both Ø MOTOR directions. NOTE: Armature and field current should be equal. Runs slow in both directions plus high armature current in both directions. Ø SOLENOIDS NOTE: Field current will be very low. Runs normal in one direction only plus runs slow or lacks power in the op- Ø posite direction with high armature current in the opposite direction or; SOLENOIDS Accelerates slowly and exceeds normal speed in the opposite direction Ø with high armature current only. NOTE: Field current will be very low in the opposite direction. Accelerates slowly and exceeds normal speed in both directions plus high Ø SOLENOIDS armature current. NOTE: Field current will be very low. Full speed only. Ø PMC CONTROL Does not run in either direction plus there is noise from motor (hum or Ø...
  • Page 114 Curtis PMC Troubleshooting PMC CONTROL 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 115 Curtis PMC Troubleshooting Connect a volt meter across the PMC B+ and PMC M- terminals. Turn the key-switch on, close all interlock s w i t c h e s ( i f e q u i p p e d ) , d e p r e s s t h e accelerator pedal to engage the first micro switch only (creep speed), then perform the following tests:...
  • Page 116 Curtis PMC Troubleshooting PLUGGING DIODE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 117 Curtis PMC Troubleshooting FREEWHEEL DIODE 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 118 Curtis PMC Troubleshooting 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5.
  • Page 119 Curtis PMC Troubleshooting Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure its resistance. • The meter reading should be 250 Ohms (+/-10%). If it is not 250 ohms (+/-10%), then replace the resistor. 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. STOP Stop, do not continue. If you reached this point without a solution, then you may have an unanticipated problem or have made an error during testing. It is important to review the trouble shooting steps that have led to this point. The tests may need to be repeated.
  • Page 120 Curtis PMC Troubleshooting SOLENOIDS There is a very slight possibility that a failure in the motor could cause these symptoms. Perform the tests covered in the MOTOR section first. If the motor is OK, continue with the following tests. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 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 121 Curtis PMC Troubleshooting Stop trouble shooting here and repair the problem. When the repair is completed, completely retest the vehicle before lowering the drive wheels to the ground, otherwise continue with the next test. • Check continuity from the motor ‘A2’ terminal to the wire that was connected to the motor ‘S2’ terminal. DO NOT make this test to the ‘S2” terminal, just the wire. If you do not know how to test for continuity, refer test to a qualified technician. • This should read as an open circuit. If it reads as a short then one of the following has occurred: A) The forward solenoid is shorted.
  • Page 122 Curtis PMC Troubleshooting With the key-switch on and the F&R switch in reverse, depress the accelerator pedal and perform the following tests: • Check continuity from the wire that was connected to the PMC ‘M-’ terminal to the wire that was connected to the motor ‘S1’ terminal. If you do not know how to test for continuity, refer test to a qualified technician. • This should read as an open circuit. If it reads as a short, then one of the following has occurred: A) The reverse solenoid is shorted.
  • Page 123 Curtis PMC Troubleshooting MOTOR High motor current in both the field and the armature, accompanied with a lack of power, would indicate a shorted armature and\or field. Another symptom that may exist is jumping or stuttering at low speeds and/or the motor will not run unless the armature is manually rotated. If this symptom exists, it indicates that there may be open segments in the armature. Visually inspect the brushes, if they are OK, continue with the testing below. 1. Make sure the key-switch is in the “OFF” position, then remove the key. 2. Place the forward-reverse switch in the center “OFF” position. 3. Set the park brake. 4.
  • Page 124 Curtis PMC Troubleshooting Check continuity from ‘S1’ to the frame of the motor. If you do not know how to test for continuity, refer test to a qualified technician. This should be an open circuit. If there is continuity from ‘S1’ to the frame of the motor, then the motor field is shorted. 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 to Motor Inspection.
  • Page 125 TABLE OF CONTENTS GLOSSARY FLA: ----------- “Flooded Lead Acid” A battery using plates made of lead immersed in an Glossary ............1 acid electrolyte. The battery is vented Industrial Chargers ........1 with removable caps for maintaining the Testing the Interlock Relay ......2 electrolyte.

  • Page 126: Testing The Interlock Relay

    Chargers not tested by Taylor-Dunn (or intended The Interlock Relay disables the vehicle from running whenever for use on other Taylor-Dunn vehicles) may have the charger is connected to a working AC power source. When unanticipated interaction and/or interference with...

  • Page 127: Lestronic Ii Charger

    Battery Charger LESTRONIC II CHARGER SLA batteries must be charged with a charger configured for SLA batteries. Use of any other charger will result in damage to the batteries and premature failure of the batteries. Test Equipment Required for Troubleshooting Built-In •...

  • Page 128: Operating Instructions And Theory Of Operation

    Battery Charger 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. As the battery charges, the battery voltage rises.

  • Page 129: Troubleshooting, Built-In Charger

    Battery Charger While connected to an AC outlet, the charger cabinet must remain electrically grounded. Disconnect both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire. Failure to do so may result in serious bodily injury. Troubleshooting, Built-in Charger 14.

  • Page 130: Troubleshooting, Portable Charger

    Battery Charger While connected to an AC outlet, the charger cabinet must remain electrically grounded. Disconnect both of the battery leads and unplug the charger from the AC source before disconnecting any electrical component or wire. Failure to do so may result in serious bodily injury. Troubleshooting, Portable Charger High Voltage inside the charger.

  • Page 131: Lester X-Series Charger

    Battery Charger LESTER X-SERIES CHARGER SLA batteries must be charged with a charger configured for SLA batteries. Use of any other charger will result in damage to the batteries and premature failure of the batteries. Test Equipment Required for Troubleshooting •...

  • Page 132: Fault And Diagnostic Error Code Table

    Battery Charger Fault and Diagnostic Error Code Table Fault Chart B = Blinking, S = Solid, O = Off LED 4 LED 2 Fault Battery voltage out of range or battery capacity is too high Control Board faulty Current Sensor faulty AC voltage incorrect DC current out of range Internal jumper missing...

  • Page 133: Testing The Charging Cycle

    Battery Charger Testing the Charging Cycle Before starting this procedure: Charge Profile Wet /FLA AGM / SLA • Confirm that the battery voltage Constant Current–Voltage Constant Current– is above 1.7 x Number of Cells Charge Profile Type Slope–Constant Current Constant Voltage (36 volts = 18 cells = 1.7 x 18 = Start/Bulk Current* 17.0 A...

  • Page 134: Troubleshooting

    Battery Charger Troubleshooting SCR Assembly Note: Both SCR’s must be replaced as a set. Note: This test passes current through the transformer and fuse. Confirm both the transformer and fuse are good before continuing. Test: Tools required for this test: Perform the test setup before starting this procedure.

  • Page 135: Transformer

    Battery Charger Transformer Lock Out Relay Before continuing, Refer to Testing the Interlock Relay procedure in this section. This is an external test to confirm if While connected to an AC outlet, the charger cabinet the relay is functioning properly. must remain electrically grounded.

  • Page 136: Relay Board Assembly

    Battery Charger Relay Board Assembly While connected to an AC outlet, the charger cabinet must Note: To perform this procedure, the battery must have a remain electrically grounded. Disconnect both of the static voltage above 1.2 volts per cell. If not available, battery leads and unplug the charger from the AC source a variable DC power supply can be used in place of before disconnecting any electrical component or wire.

  • Page 137: Control Board Assembly

    If the charger type is changed, then the charger cover should be permanently marked to indicate the new type. Note: The Taylor-Dunn AGM charging profile has been ® optimized for Full River VRLA AGM DC Series batteries.

  • Page 138: Signet Hbs Charger

    Battery Charger SIGNET HBS CHARGER SLA batteries must be charged with a charger configured for SLA batteries. Use of any other charger will result in damage to the batteries and premature failure of the batteries. Test Equipment Required for Troubleshooting •...

  • Page 139: Operating Instructions And Theory Of Operation

    Battery Charger Operating Instructions and Theory of Operation Typical specification plate (reference only, specifications will vary for different chargers) The model HBS 600W and HBS 1000W ® ® chargers are designed as automatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.

  • Page 140: Testing The Charging Cycle

    Battery Charger Testing the Charging Cycle In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries when the charge cycle was started. NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit. Refer to the fault code table for more information.

  • Page 141: Status Light Error Code Table

    Battery Charger Status Light Error Code Table If the Fault light is ON or flashing, it indicates a problem has occurred during the charging cycle. If the light is flashing, it will flash from 2 to 6 times before a pause. This is the fault code. Refer to the table below.

  • Page 142: Troubleshooting

    Battery Charger Troubleshooting NOTE: There are no internally serviceable components in the charger. To test charger operation: 1. Connect a DC volt meter to the main battery positive and negative terminals. 2. Attach a clamp on DC Ammeter to one of the charger DC output wires. 3.

  • Page 143: Signet Hb Charger

    Battery Charger SIGNET HB CHARGER 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 144: Hb/Pt And Gel Indicator Lamps

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

  • Page 145: Status Led Error Code Table

    Battery Charger Status LED Error Code Table There are three status lights (LED’s) on the charger name plate. These LED’s normally indicate the current operating state of the charger. If all three LED’s are flashing, it indicate an error has occurred in the charging cycle. See the table below for an explanation of the error codes: Note: If only the 100% LED is flashing and all others are OFF then the charger has exceeded its maximum charging time and shut off before the batteries were fully charged.

  • Page 146: Troubleshooting

    Battery Charger TROUBLESHOOTING Charger does not turn on: Test Equipment Required for Troubleshooting 1. Make sure the start switch is in the “OFF” position, then remove the key. Digital Multi-Meter. 2. Place the forward-reverse switch in the center Clamp on DC Ammeter to measure up to 20 Amps. “OFF”...
  • Page 147 Chapter - The vehicle wiring diagrama are too large to be legible when printed at this size. A full size diagram (22 x 16) is included on the CD in PDF format. You can access the diagram from a button on the CD menu. The diagram file names are: SCH-00031: Models SS-534, SS-536, SS-546...

  • Page 149: Illustrated Parts

    Chapter - Illustrated Parts TABLE OF CONTENTS Identifying Your vehicle ........2 Control System, Motor Speed Control ... 21 Axle Assembly, Front Control System, Instrument Panel ....22 (SS-534, SS-536, MX-600) ...... 3 Decals ............23 Axle Assembly and Steering, Front SS-546 .. 4 Electrical, Miscellaneous .......

  • Page 150: Identifying Your Vehicle

    Whenever necessary the model of the vehicle is identified with the parts that are specific to that model. If a model identification is not specified in the diagram heading or within the parts table, then the part can is used in all models. Model #’s SS-025-34 (SS-534) SS-025-36 (SS-536) SS-025-46 (SS-546) MX-026-00 (MX-600)

  • Page 151: Axle Assembly, Front (Ss-534, Ss-536, Mx-600)

    Illustrated parts Axle Assembly, Front (SS-534, SS-536, MX-600) Axle Assembly, Front (SS-534, SS-536, MX-600) Item No. Part No. 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...
  • Page 152 Illustrated Parts Axle Assembly and Steering, Front SS-546 Parts Page 4...

  • Page 153: Axle Assembly And Steering, Front Ss-546

    Illustrated parts Axle Assembly and Steering, Front SS-546 Item No. Part No. Description 00-546-12 Axle beam (includes all bushings) 88-289-81 Nut, Axle beam 88-268-61 Washer, Axle beam nut 88-527-14 Cotter pin, Axle beam nut 92-104-00 Bearing cap 88-527-14 Cotter pin 88-239-85 Castle nut 88-228-61...
  • Page 154 Illustrated Parts Axle Assembly, 3rd Member, SS-534 Axle Assembly, Belt Drive, SS-534 Item No. Part No. Description 30-114-00 Motor pulley, 2.25” dia 30-115-00 Motor pulley, 2.75” dia 30-116-00 Drive pulley, 8” dia 30-117-00 Drive pulley, 11” dia 30-601-00 Drive belt (8” pulley) 30-613-00 Drive belt (11”...
  • Page 155 Illustrated parts Axle Assembly, 3rd Member, SS-534 Item No. Part No. 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 156: Axle Assembly, Rear Axles

    Illustrated Parts Axle Assembly, Rear Axles SS-534 Axle Assembly, Rear Axles SS-536, SS-546, MX-600 Parts Page 8...
  • Page 157 4 1 - 1 2 6 - 9 5 4 1 - 1 2 6 - 9 4...

  • Page 158: Axle Assembly, Transaxle

    Illustrated Parts Axle Assembly, Transaxle, SS-536, SS-546, MX-600 Parts Page 10...

  • Page 160: Batteries

    Illustrated Parts Batteries Main Negative 12v negative tap Main Positive SS-534 / SS-536 / SS-546 Main Negative Main Positive 12v Negative Tap MX-600 Parts Page 12...
  • Page 161 Illustrated parts Batteries Item No. Part No. Description 77-051-00 Battery, 160AH, Gell** 77-044-10 Battery, 195AH, Maintanance free** 77-042-00 Battery, 217AH, T-105 77-042-80 Battery, 217AH, T-105 Moist Charge 77-042-50 Battery, 217AH, TD-217 77-044-00 Battery, 230AH, T-125 77-047-00 Battery, 244AH, T-145 77-047-80 Battery, 244AH, Moist Charge 77-047-50 Battery, 250AH, TD-250...
  • Page 164 Illustrated Parts Brakes, Rear Axle, SS-534 Brakes, Rear Axle, SS-536, SS-546, MX-600 Parts Page 16...

  • Page 165: Brakes, Rear Axle, Ss-534

    Illustrated parts Brakes, Rear Axle, SS-534 Item No. Part No. 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 166: Charger, Lestronic And Signet

    Illustrated Parts Charger, Lestronic and Signet S ignet C hargers M o d e l and Typ e Part N umber 24 volt HB, Flooded Battery 79-302-20 24 volt HBS Flooded Battery 24 volt HB Gel Battery 24 volt HBS Gel Battery * - Not available at time of printing NOTE: There are no user serviceable components inside the charger...
  • Page 167 Illustrated parts Parts * Not available at time of printing Page 19...

  • Page 168: Charger, Lester X-Series

    Illustrated Parts Charger, Lester X-Series Item No. Part No. Description 79-303-49 Charger Assembly, X-Series, 48 volt 79-831-00 Fuse 79-809-61 Relay boad assembly Control board assembly 79-749-14 SCR assembly 79-840-02 Circuit breaker 79-848-01 Ammeter 79-810-01 Switch kit (start/stop, low voltage, self diagnostic) 79-575-41 AC cord (includes bushing) 79-566-21...
  • Page 169 7 5 - 1 4 8 - 4 1...
  • Page 170 7 5 - 1 4 8 - 4 2...

  • Page 171: Decals

    Illustrated parts Decals Item No. Part No. Description 94-384-00 How to apply park brake 94-309-50 Park Brake Warning 94-313-20 Safety warning 94-333-00 94-301-43 Arna and Legs (3-wheel) 94-301-42 Arms and Legs (4-wheel) 94-384-01 Not a Motor Vehicle 94-384-14 When Leaving Vehicle 94-386-03 Console (MX-600 only) 94-319-00...

  • Page 172: Electrical, Miscellaneous

    Illustrated Parts Electrical, Miscellaneous Item No. Part No. Description 62-033-48 Throtle Module 72-005-00 Heallight assembly 72-072-00 Bulb, headlight 71-102-10 Interlock switch, Seat 02-610-18 Mount, Interlock switch 96-773-00 Spring, Interloc switch 85-030-00 Clevis pin, interlock switch 88-527-11 Cotter pin Frame and Body, Deckboards Item No.

  • Page 173: Frame And Body, Misc Body Trim

    Illustrated parts Frame and Body, Toolbox, MX-600 Item No. Part No. 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...

  • Page 174: Lights, Headlights

    Illustrated Parts Lights, Headlights Standard Geared Steering Option 5/16 NUT & WASHER (COME W/HEADLIGHT) Steering box (ref) 4 (MX 6-00 only) Lights, Taillights, Strobelight Parts Page 26...
  • Page 175 Illustrated parts Headlights Item No. Part No. 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 Taillights Item No.

  • Page 176: Motor

    Illustrated Parts Motor Motor Item No. Part No. Description Field assembly Armature 70-180-00 Brush holder 80-412-20 Brush spring 70-109-00 Brush pair 70-417-00 Bearing retainer 80-212-00 Bearing, rear 80-212-00 Bearing, front (SS-534) End cap Brush cover Motor Assemblies: 70-049-05 SS-536, SS-546, MX-600 70-049-00 SS-534 Parts...
  • Page 177 Illustrated parts Motor Mount, SS-534 Motor Mounting bar on drive housing Motor Mount, SS-534 Item No. Part No. Description 00-380-96 Motor mount 88-100-11 Bolt See belt drive Pulley 30-117-00 70-422-00 Strap, motor mount 88-109-87 97-100-00 Woodruf key Motor Mount, SS-563, SS-546, MX-600 Motor Mount, SS-536-SS-546, MX-600 Item No.

  • Page 178: Steering Linkage, Tiller

    Illustrated Parts Steering Linkage, Tiller Steering Linkage, Tiller Item No. Part No. 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, Model SS 14-079-45 Front Fork with Springs, Model MX 85-140-10...

  • Page 179: Steering Linkage, Geared, Ss-534

    Illustrated parts Steering Linkage, Geared, SS-534 Steering Linkage Item No. Part No. 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.) 88-068-27 1/4” X 4-1/2”NC HEX Hd Cap Screw 88-060-22 1/4”...

  • Page 180: Steering Linkage, Geared

    Illustrated Parts Steering Linkage, Geared, SS-536, SS-546, MX-600 Parts Page 32...
  • Page 181 Illustrated parts Steering Linkage, Geared, SS-536, SS-546. MX-600 Item No. Part No. 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...
  • Page 182 Illustrated Parts Suspension, Rear, SS-536, SS-546 Item No. Part No. 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"...

  • Page 183: Suspension, Rear, Ss-534

    Illustrated parts Suspension, Rear, SS-534 Frame See Differential Case Item No. Part No. Description 88-189-81 88-188-61 Washer 86-602-00 Shock 88-180-18 Bolt, 5/8 88-180-18 Bolt, 5/8 88-188-61 Washer 85-140-00 Spring 88-149-81 98-601-00 Bushing 96-240-00 Bolt Parts * Not available at time of printing Page 35...

  • Page 184: Wheels And Tires

    Illustrated Parts Wheels and Tires 4-Hole | 5-Hole Part No. Description All tire/wheel sizes are 4.80 x 8 unless otherwise specified 10-075-00 Tire, Pneumatic, Load Range B 10-076-00 Tire, Pneumatic, Load Range C 10-074-00 Tire, Man-Toter. Rib 10-074-10 Tire, Man-Toter, Rib, Non-Marking Tire, Man-Toter, Lug 12-012-00 Wheel, tubeless...

  • Page 185: Brake Lining Handling Precautions

    Contents Appendix A: Special Tools ....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 ............... 4 Hex Lock Nuts (stover) ........4 Other Nuts .............

  • Page 186: Appendix A: Special Tools

    Appendixes APPENDIX A: SPECIAL TOOLS Note: This is a listing of all tools available. Not all tools would be required for all vehicles. Refer to the Maintenance, Repair, and Troubleshooting sections for information on tools required. 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness Used in conjunction with a volt meter to test Tests the throttle module in or out of the vehicle...
  • Page 187 Molex # 11-300-06: Pin Removing Tool Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex rectangular harness connectors. Not available rectangular harness connectors. Not available from Taylor-Dunn. Purchase from any local from Taylor-Dunn. Purchase from any local electronics distributor. electronics distributor. Appendixes...

  • Page 188: Appendix B: Suggested Torque Limits For Standard Hardware

    Appendixes APPENDIX B: SUGGESTED TORQUE LIMITS FOR STANDARD HARDWARE HARDWARE IDENTIFICATION Standard Head Markings NOTE: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. NOTE: Toque values specified are for clean dry threads.

  • Page 189: Hex Nuts

    NOTE: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts ® Other nuts used by Taylor-Dunn should be treated as S.A.E. grade A Appendixes *Not available at time of printing Appendix B Page 5...
  • Page 190 Appendixes Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 191 Appendixes All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Metric, Newton Meters Metric, Foot Pounds Grade, N-m Grade, N-m...

  • Page 192: Appendix C: Brake Lining Handling Precautions

    Appendixes APPENDIX C: BRAKE LINING HANDLING PRECAUTIONS Taylor-Dunn does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, the brake pads/ shoes should be handled as if they do contain asbestos.

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