Taylor-Dunn MX-026-00 Operation, Maintenance, And Replacement Parts Manual Download Page 46 | Manualshive

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Maintenance, Service, and Repair

Brake Service
Page 2

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. This rotates the adjuster, which
decreases the travel needed for the brake shoes to engage the brake drum.

NOTE: There are no manual adjustments for the brake shoes.

NOTE: The symptom of a low brake pedal may indicate that the auto adjuster is not working or the brake linkage is not

adjusted properly. Remove the vehicle from service and repair the brakes.

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Summary of Contents for MX-026-00

Page 1: ...F 5 1 4 2 0 1 8...

Page 2: ......

Page 3: ...parts or service should be obtained through your local dealer A dealer locator can be found on the Taylor Dunn website at www taylor dunn com If you do not have access to the internet you can call th...

Page 4: ...B2 48 With Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides ET 3000 ET1 50 Full Size Truck P2 50 30 000 Pound Tow Tractor...

Page 5: ...els 9 Battery Service 10 Control System Troubleshooting 11 Wire diagram 12 Illustrated Parts 13 Appendix A Special Tools 14 Appendix B Suggested Torque Values 15 Appendix C Brake Lining Handling Preca...

Page 6: ...TAYLOR DUNN...

Page 7: ...f Contents Chapter Introduction 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 Vehic...

Page 8: ...pplicable models and serial numbers on the front cover Please be aware of all cautions warnings instructions and notes contained in this manual RESPONSIBILITIES Of the Owner The owner of this or any T...

Page 9: ...ventions Symbols and or words that are used to define warnings cautions instructions or notes found throughout this manual Refer to the examples below Note Alerts the reader to additional information...

Page 10: ...described in O S H A Standard Section 29 CFR 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 This ve...

Page 11: ...Taylor Dunn vehicle is a factory authorized service technician Repairs made by unauthorized personnel may result in damage to the vehicles systems which could lead to an unsafe condition resulting in...

Page 12: ...TAYLOR DUNN...

Page 13: ...rlock SS 536 SS 546 MX 600 6 Battery Status Indicator Digital Bargraph optional 6 Battery Status Indicator Analog 6 Safety Guidelines 7 Starting 7 While driving 7 Vehicle Operational Guidelines 7 Chan...

Page 14: ...es 597 x 699 mm SS 536 SS 546 19 x 30 inches 483 x 762 mm MX 600 27 x 30 inches 686 x 762 mm Maximum Carried Load SS 534 500 pounds 227 kg Note Load centered on deck SS 536 SS 546 MX 600 600 pounds 27...

Page 15: ...h in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries DRIVER TRAINING...

Page 16: ...Headlight Switch 4 Battery Status Gauge The battery status gauge displays the relative charge of the batteries Refer to details later in this section 5 Strobe Light Switch optional 6 Forward Off Reve...

Page 17: ...Park Brake Foot Operated The parking brake is part of the foot brake pedal To set the parking brake push down on the lower half of the brake pedal until the pedal locks in the down position To releas...

Page 18: ...l be in the red zone to the right The needle will move through the green zone toward the yellow zone as the batteries discharge Charge the batteries when the needle is in the yellow zone If it is in t...

Page 19: ...en approaching a corner or other intersection No reckless driving Do not drive this vehicle on steep inclines or where prohibited Allow for longer stopping distances when driving down a grade Immediat...

Page 20: ...he wheels to the curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Towing the Vehicle To tow this vehicle attach a tow strap to the front bumper tow bar Use anot...

Page 21: ...ed a minimum of 25 to reduce the possibility of overcharging Refer to Vehicle Controls in this section for information on how to read the BSI Do not discharge the batteries beyond a normal discharge a...

Page 22: ...display an approximate percent of charge during the charging cycle Refer to the table below 2 Error condition If the FAULT LED is on or flashing it is an indication that a problem occured during the c...

Page 23: ...es to proper pressure if applicable For extended storage the vehicle should be elevated so that the tires do not touch the ground If stored for a prolonged period the batteries should be charged as fo...

Page 24: ...e copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc sub folder PERIODIC MAINTENANCE CHECKLIST SS 536 546 MX 600 NOTE A full page copy of the Periodic Mainten...

Page 25: ...ES AND OPERATING INSTRUCTIONS Safety Rules Page 13 PERIODIC MAINTENANCE CHECKLIST SS 534 NOTE A full page copy of the Periodic Maintenance Checklist is on the Vehicle Documentation CD under the Misc s...

Page 26: ...Use on multiple shifts 2 Any deficiencies found during an inspection should corrected before the vehicle is returned to service 3 Battery water level should be inspected on a weekly schedule Daily Vi...

Page 27: ...Table of Contents Chapter General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication and Fluids Chart 4 Lubrication Diagram 5 3...

Page 28: ...or cleaning parts Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle Periodic maintenance and service must be performed on this vehicle Failure to c...

Page 29: ...inkage out of adjustment Adjust linkages Hard Brake Pedal Faulty master cylinder Inspect master cylinder Lack of Braking Power Contaminated brake pads Replace brake pads Worn brakes Replace brakes Air...

Page 30: ...de 2 lithium multi purpose grease 3 Fork Bearings 1 NLGI Grade 2 lithium multi purpose grease Linkages 4 Brake pedal pivot 2 Multi purpose spray lubricant Park brake pedal pivot 2 Multi purpose spray...

Page 31: ...Repair Page 5 Lubrication Diagram 1 5 2 SS 546 Front Axle 1 2 3 4 Drive Transmission SS 536 546 Transmission pan bottom View Fill and Level plug Pan must be removed to drain SS 534 Drive Rear View Fil...

Page 32: ...TAYLOR DUNN...

Page 33: ...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 5 Removal 5 Installati...

Page 34: ...r to the Adjust Front Wheel Bearings section for information regarding the adjustment of the wheel bearings 9 Spin the wheel s and listen for any grinding noise Any noise may be an indication of worn...

Page 35: ...NGS 4 WHEEL 6 Raise the front of the vehicle and support with jack stands 7 Remove the hub dust cap and cotter pin 8 While rotating the hub tighten the spindle nut to 30 ft lbs This seats the bearings...

Page 36: ...k stands Installation 1 Raise the front of the vehicle so that the hole for the axle is the same height as the front wheel hub 2 Assemble the bearing spacers into the front wheel hub and place the fro...

Page 37: ...se lifting and support devices of rated load capacity may result in severe bodily injury REPLACE FRONT WHEEL BEARINGS 6 3 wheel only Remove the front axle and wheel s Refer to Front Axle Removal and I...

Page 38: ...Maintenance Service and Repair Front Axle Page 6 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters...

Page 39: ...Hardware Torque 6 Steering Component Service 5 There are three different steering configurations available depending on the vehicle model and options ordered Make sure you are in the correct section...

Page 40: ...stance between the lines at the front and rear of the tires 12 Adjust the links so that the distance at the front and rear of the tires is the same 13 Tighten the rod end jam nuts per torque listed in...

Page 41: ...Release the park brake and test drive the vehicle Inspection 6 Grab the steering link and attempt to move it up and down 7 If the rod end housing moves it is worn out and should be replaced Tighten th...

Page 42: ...ble play 8 If there is any play in the fork bearings refer to section Replace the Front Fork for information regarding adjusting the fork bearings 9 Lower the front end to the ground 10 Reconnect the...

Page 43: ...ghly Clean and inspect all parts 14 Using new gaskets reassemble in reverse order 15 Fill the gear box with grease Note A minor amount of gear lash adjustment can be accomplished by repositioning the...

Page 44: ...ith jack stands 10 Inspect the upper and lower fork collar seals and replace if necessary 11 Install the fork in reverse order being careful not to damage the lower fork collar seal 12 Use a new fork...

Page 45: ...djust 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 bra...

Page 46: ...en 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 This rotates the adjuster which decreases the travel needed fo...

Page 47: ...nd support with jack stands 7 Using the appropriate procedure remove the brake drum 8 Release the park brake 9 Back off the auto adjuster star wheel one or two turns 10 Reinstall the brake drum and de...

Page 48: ...l The service limit for the inside diameter of the brake drum is 6 330 inches If the brake drum is grooved or worn beyond the service limit then the brake drum must be replaced Measure the inside diam...

Page 49: ...Adjust the Service Brake Linkage The brake linkage is adjusted by means of the adjustment rod at the brake cable equalizer The adjustment rod should be adjusted so that all slack is taken out of the l...

Page 50: ...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 51: ...Maintenance Service and Repair Brake Service Page 7 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters...

Page 52: ...TAYLOR DUNN...

Page 53: ...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...

Page 54: ...ts as the service brake with the exception of the parking brake locking mechanism on the brake pedal Inspect the locking tab on the frame as well as the brake pedal cogs for any signs of excessive wea...

Page 55: ...or property damage Before adjusting the brake confirm that the brake linkage is adjusted correctly 6 Loosen the brake adjusting bolt jam nut 7 Adjust the brake bolt as required so that the parking br...

Page 56: ...n of leaks then the pinion seal should be replaced 9 Apply a very light coat of grease around the hub of the brake drum where it contacts the pinion seal 10 Install the brake drum 11 Using a new pinio...

Page 57: ...intenance Service and Repair Brake Service Page 5 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters Pionion Nut 175 2...

Page 58: ...CONTENTS Chapter 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 Motor Service 7 Typical Motor...

Page 59: ...of power Slow acceleration Slow speed Short battery life Excessive motor current Excessive speed shorted field only Note A short in the vehicle wiring or other components could be misinterpreted as a...

Page 60: ...e top of the brush holder to gage the length of the brush If the top of the brush is even or below the top of the brush holder then the brush is getting close to the service limit and the brushes shou...

Page 61: ...Number Undercut Depth Commutator Diameter min Brush Length min Wire Depth max mm inches mm inches mm inches mm inches L94 4006 0 635 0 025 96 8 3 810 19 05 0 75 A02 4011 1 0 04 69 9 2 75 16 0 62 ER5 4...

Page 62: ...TAYLOR DUNN...

Page 63: ...SS 536 SS 546 MX 600 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 5 Remove 5 Install 5 Differential Case 6 D...

Page 64: ...erse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the battery main positive and negative cables Transmission Co...

Page 65: ...ks under the front wheels to prevent vehicle movement 5 Disconnect the battery connector from the vehicle Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the...

Page 66: ...the transmission for this procedure Refer to Remove and Install Axle for information regarding removing the rear axle Remove Install 1 Remove the hub from the axle shaft Refer to Rear Hub Brake Drum...

Page 67: ...rease the transmission input shaft only see caution 5 Install the motor in reverse order Tighten the motor mounting bolts per torque listed in the Hardware Torque table at the end of this section Tigh...

Page 68: ...Remove the differential case cover being careful not to bend or damage the case cover flange or the sealing surface of the differential case 6 Remove the differential bearing caps and remove the diffe...

Page 69: ...ow clearance for an ID bearing puller Do not attempt to drive the shaft out of the opposite end of the transmission 13 Remove the intermediate bearing with an ID bearing puller 14 While supporting the...

Page 70: ...te bore All contaminates must be removed 9 Apply Loctite RC 609 to both sides of the intermediate bore and install new bore plugs Drive the bore plugs until they are firmly seated against the snap rin...

Page 71: ...DWARE 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 6 8 8 10 5 Fina...

Page 72: ...TAYLOR DUNN...

Page 73: ...ve Belts 2 Transaxle Assembly 3 Remove 3 Install 3 Axles 4 Remove and Install 4 Axle Bearings 4 Replace the Axle Bearing 4 Differential Assembly 3rd Member 5 Disassemble 5 Assemble 6 Re shimming the P...

Page 74: ...6 Loosen the jam nut on the motor tensioner 7 Using a pull scale adjust the belts so that the belts deflect approximatly 1 4 inch at approximatly 10 pounds tension 8 Reconnect the main positive and n...

Page 75: ...tall in reverse order of removal Use a new cotter pin for the brake cable Adjust the brake linkage and brake band Tighten the motor terminals per torque listed in the Hardware Torque table at the end...

Page 76: ...ion regarding removing the axle NOTE A 10 ton press is required to replace the axle bearing NOTE The axle bearing will be damaged when it is removed 1 Place the axle in a press and remove the bearing...

Page 77: ...he pinion housing and pinion gear from the 3rd member NOTE Do not lose the spacers and shims in the pinion housing or the pinion housing shim s 10 If required remove the rear tapered bearing from the...

Page 78: ...the pinion housing onto the 3rd member 5 Install the pinion bearing spacers shims and front bearing 6 Install a spacer on the pinion shaft so that the pinion nut can be installed and tightened 7 While...

Page 79: ...tated any time the nuts are being adjusted 18 Loosen the right side nut 19 Tighten the left nut until all backlash is removed from the ring and pinion gear 20 Tighten the right nut until a case spread...

Page 80: ...0 001 Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear It should be a number ranging from 5 to 5 This is the amount in 0 001 increments to add to the standar...

Page 81: ...Maintenance Service and Repair Transaxle SS 534 Page 9 EXPLODED VIEW...

Page 82: ...f 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 B...

Page 83: ...TABLE OF CONTENTS Chapter Tire Inflation 2 Tire Inspection 2 Tire Wheel Assembly 3 Remove Install Rear 3 Remove Install Front 3 Hardware Torque 3 Tires and Wheels 9...

Page 84: ...e tire approaches its wear limit see illustration below Replace the tire if any tread depth indicator can be seen or any part of the tread depth is 1 16 inch or less Refer to Replace the Tire section...

Page 85: ...Front Refer to Front Axle Service for information on removing the front wheel 1 Make sure the start switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center O...

Page 86: ...TAYLOR DUNN...

Page 87: ...tilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage A battery is a live electrical source It cannot be disconnected or neutra...

Page 88: ...oves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any su...

Page 89: ...charged cell should have a reading of 1275 to 1300 see the illustration to the right A discharged cell will read 1100 Ideally all cells in a battery will have the same reading Any cells in a battery t...

Page 90: ...contact with skin eyes or clothing Wear rubber gloves and safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury 1 Make sure the start switch is in the OFF pos...

Page 91: ...ion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage A battery is a live electrical so...

Page 92: ...osive 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 cigaret...

Page 93: ...this section Do not allow the loose battery cables to contact any other parts of the vehicle as this could cause in a short circuit resulting severe bodily injury or damage to the vehicle Individual...

Page 94: ...TAYLOR DUNN...

Page 95: ...leshooting 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...

Page 96: ...th 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 armature current NOTE Field current...

Page 97: ...o locate a problem if there are multiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before troubleshooting the control system DO NOT sta...

Page 98: ...lerator pedal is depressed then go to the Forward Reverse Switch sequence After any repairs are made completely retest the vehicle before lowering the drive wheels to the ground Failure to retest the...

Page 99: ...n 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 dri...

Page 100: ...els 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 Rotating rear drive wheels are a potent...

Page 101: ...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 Connec...

Page 102: ...use serious bodily injury Power Wire Inputs Connect a voltmeter to the PMC B terminal and battery positive If the voltage is not the same as battery volts then there is an open circuit in the wire fro...

Page 103: ...e battery volts Connect the test light across the motor A1 and A2 terminals Close all interlock switches turn the Key Switch ON and place the F R Switch in Forward Depress the accelerator fully If the...

Page 104: ...on the power switch to the 6 11 volt range All but the power lamp should be OFF If the FS 1 FS 3 or OV lamp Over Voltage are ON then the module is faulty Depress the lever on the module The FS 1 lamp...

Page 105: ...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...

Page 106: ...rlock switches turn the Key Switch ON and place the F R Switch in Forward If the voltage is not at battery volts then the F R switch has failed Stop trouble shooting here and repair the problem When t...

Page 107: ...from the rear drive wheels while conducting tests Failure to do so may cause serious bodily injury Connect a voltmeter across the Solenoid Negative Buss Bar and battery positive NOTE You may skip thi...

Page 108: ...inal 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 reverse Depress the accelerator pedal fully...

Page 109: ...e Reverse does not run in forward Connect a voltmeter across the ISO solenoid COLD terminal and battery negative Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal f...

Page 110: ...the F R Switch in reverse Depress the accelerator pedal fully If the voltage is not at battery volts then go to the F R Switch sequence Set the test light voltage to the same voltage as the battery vo...

Page 111: ...mes 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: ...epress 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 vehic...

Page 113: ...eeds normal speed in both directions plus high armature current NOTE Field current will be very low SOLENOIDS Full speed only PMC CONTROL Does not run in either direction plus there is noise from moto...

Page 114: ...tinue with the next 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 t...

Page 115: ...etely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test If the voltage at pin 2 is correct and the voltage at M is correct then there is a short i...

Page 116: ...rror during testing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated 1 Make sure the key switch is in the OFF position then remove the...

Page 117: ...ve 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 1 Make sure the key switch is in the OFF position the...

Page 118: ...e severe bodily injury and or property damage Rotating rear drive wheels are a potential hazard Keep hands arms legs and loose clothing away from the rear drive wheels while conducting tests Failure t...

Page 119: ...ng steps that have led to this point The tests may need to be repeated Connect the meter to each end of the resistor that was removed from the ISO solenoid and measure its resistance The meter reading...

Page 120: ...r could cause these symptoms Perform the tests covered in the MOTOR section first If the motor is OK continue with the following tests Remove the wires from the S1 and S2 terminals on the motor Remove...

Page 121: ...ected to the PMC A2 terminal 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 conti...

Page 122: ...as a short then one of the following has occurred A The reverse solenoid is shorted B The wire connected to the PMC M terminal is shorted to the wire connected to the motor S1 terminal Stop trouble s...

Page 123: ...armature circuit brushes are 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 otherwi...

Page 124: ...ure The insulation should be a light to medium reddish brown color If the insulation is dark brown to black or the insulation is cracked and peeling then the armature has been overheated and burnt The...

Page 125: ...hooting 22 Important Notes and Instructions 22 Test charger operation 22 Charger does not turn on 22 Battery Charger SLA batteries must be charged with a charger configured for SLA batteries Use of an...

Page 126: ...repair the problem If the DMM indicates an open circuit then the interlock relay is functioning normally 1 Make sure the start switch is in the OFF position then remove the key 2 Place the forward re...

Page 127: ...in good working condition Make sure that the AC voltage at the electrical outlet is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition and no less than...

Page 128: ...es not check the current state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approxim...

Page 129: ...quired Check the continuity of both fuse links and replace if faulty Disconnect one transformer lead from the capacitor Test the capacitor using the capacitor test function of the meter It is a 6 micr...

Page 130: ...If either one of the diodes are bad replace the diode assembly Stop here and repair the problem 3 Reconnect the lead to the diode 4 Connect the charger to the AC source Insert the DC charger plug into...

Page 131: ...matic microprocessor controlled SCR switching charger The charger turns itself on when it is plugged into the AC electrical outlet and turns off when the batteries are fully charged Once the charging...

Page 132: ...4 LED 2 Fault O O OK B B Battery voltage out of range or battery capacity is too high S O Control Board faulty B S Current Sensor faulty S B AC voltage incorrect S S DC current out of range B O Inter...

Page 133: ...t is registered 5 The battery voltage will rise until the Knee 1 Plateau voltage is achieved see table then switch to the next stage The following stages will depend on the type of charging profile se...

Page 134: ...meg Ohms 4 If the reading is low then the gate is shorted If the gate has shorted on either SCR then it is likely that the control board has been damaged and must also be replaced Note Both SCR s mus...

Page 135: ...n 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 bodi...

Page 136: ...connect the charger from the AC power source and test DC voltage across Relay Board terminals J3 and J4 This should be the same as battery volts If this voltage is low then check wiring to the batteri...

Page 137: ...d 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 Disconnect the charger from the AC power source bef...

Page 138: ...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 Definitions Volts Per Cell Voltage for each cell in...

Page 139: ...eases the charger current while holding the batteries at the terminal voltage until the charging cycle is complete The charging cycle is complete when the current is down to A1 On the charger face pla...

Page 140: ...has restarted Fully test the battery pack before assuming that the charger is not turning off or running too long A charger could turn off in less than 12 hours but still show symptoms of overchargin...

Page 141: ...ltage must be less than 33 7v 36v charger Battery voltage must be less than 43 2v 48v charger Battery voltage must be less than 57 6v 4 Overheated Inspect for dirt or debris on the charger cooling fin...

Page 142: ...f until the batteries are fully charged The batteries are fully charged when the charging current is down to A1 6 If the charger does not turn on there are no faults and the POWER light is ON then the...

Page 143: ...minal voltage until the charging cycle is complete The charger faceplate has three status LED s that monitor the charging status Refer to the chart and illustration below for the function of these LED...

Page 144: ...urrent during the charging cycle as indicated below Using a digit digital voltmeter and clamp on DC ammeter monitor the battery voltage and current during the charging cycle The charging current shoul...

Page 145: ...roper connection to the batteries 2 AC line voltate too high or too low Check the input voltage It must be within 96 132VAC or 196 266VAC 3 Charger overheated Wait for charger to cool the charger will...

Page 146: ...charger will switch to the constant voltage mode At this point the charging current will be reduced and will taper off until the batteries are fully charged 1 Make sure the start switch is in the OFF...

Page 147: ...andard AC power wiring then refer repair to a qualified licenced electrician Depending on the charging system two different color codes are used for the AC power source United States Standard 120 Volt...

Page 148: ...TAYLOR DUNN...

Page 149: ...Axle SS 534 16 Brakes Rear Axle SS 536 SS 546 MX 600 16 Charger Lestronic and Signet 18 Charger Lester X Series 20 Control System Motor Speed Control 21 Control System Instrument Panel 22 Decals 23 E...

Page 150: ...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 al...

Page 151: ...Part No Description Qty 1 88 229 81 3 4 NC Locknut 2 2 88 228 61 3 4 NC Washer 2 3 16 206 00 Spacer 2 4 15 010 00 Front Axle Threaded each end 1 15 010 10 Front Axle Single Ended 1 5 45 308 00 Oil Se...

Page 152: ...Illustrated Parts Parts Page 4 Axle Assembly and Steering Front SS 546 1 2 5 6 7 8 3 4 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27...

Page 153: ...Bearing 1 10 45 338 00 Seal 2 11 00 546 06 Left steering yoke 1 00 546 07 Right steering yoke 1 12 88 109 81 3 8NC Lock nut 4 13 97 202 50 3 8NF nut left thread 2 88 199 80 3 8NF Hex nut 2 14 86 519 1...

Page 154: ...S 534 Axle Assembly Belt Drive SS 534 Item No Part No Description Qty 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...

Page 155: ...t 2 69 2 75 1 7 41 997 00 Oil Plug 3 8 41 296 00 Rear End Housing 1 9 80 554 00 Pinion Bearing 2 10 41 711 00 Pinion Housing Shim 1 11 80 702 00 O Ring 1 12 44 340 90 Pinion Housing Shim 1 13 16 419 0...

Page 156: ...Illustrated Parts Parts Page 8 Axle Assembly Rear Axles SS 534 1 2 3 4 5 6 8 11 12 10 9 13 7 Axle Assembly Rear Axles SS 536 SS 546 MX 600...

Page 157: ...4 1 1 2 6 9 4 4 1 1 2 6 9 5...

Page 158: ...Illustrated Parts Parts Page 10 Axle Assembly Transaxle SS 536 SS 546 MX 600...

Page 159: ......

Page 160: ...Parts Parts Page 12 Batteries Main Positive 12v Negative Tap Main Negative MX 600 NEG POS NEG POS NEG POS NEG POS Main Positive Main Negative 12v negative tap SS 534 SS 536 SS 546 NEG POS NEG POS NEG...

Page 161: ...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 77 048 00 Battery 250AH J 250 77 048 80 Bat...

Page 162: ......

Page 163: ......

Page 164: ...Illustrated Parts Parts Page 16 Brakes Rear Axle SS 534 Brakes Rear Axle SS 536 SS 546 MX 600...

Page 165: ...4 3 8 Extension Spring 1 8 50 661 00 Brake Lever Bar 1 9 41 532 00 Brake Drum 1 10 88 517 11 3 32 X 1 Cotter Pin 2 11 88 089 81 5 16 NC Locknut 4 12 50 662 00 Brake Lever 1 13 88 080 11 5 16 NC X 1 He...

Page 166: ...Battery 24 volt HBS Gel Battery Not available at time of printing NOTE There are no user serviceable components inside the charger NOTE The charger AC cord is an intergral part of the charger When re...

Page 167: ...e 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00 79 566 10 76 200 00 12750 79 300 55E 24LC25 8ET 230 50 4 24 25 Built In 79 805 70 79 808 10 79 902 00 79 749 13 79 6...

Page 168: ...ntrol board assembly 79 749 14 SCR assembly 79 840 02 Circuit breaker 79 848 01 Ammeter 79 810 01 Switch kit start stop low voltage self diagnostic 79 575 41 AC cord includes bushing 79 566 21 DC cord...

Page 169: ...7 5 1 4 8 4 1...

Page 170: ...7 5 1 4 8 4 2...

Page 171: ...4 333 00 FM 1 5 94 301 43 Arna and Legs 3 wheel 1 94 301 42 Arms and Legs 4 wheel 1 6 94 384 01 Not a Motor Vehicle 1 7 94 384 14 When Leaving Vehicle 1 8 94 386 03 Console MX 600 only 1 9 94 319 00 B...

Page 172: ...00 Seat Back SS 534 optional 1 90 144 00 Seat Back MX 600 1 93 005 00 Seat Cushion SS 536 SS 546 1 90 166 00 Seat Cushion SS 534 1 96 006 00 Seat Cushion MX 600 1 90 109 50 Seat Frame Back Fold down S...

Page 173: ...32 Double Sided Tape 3 ft 4 88 140 11 1 2 NC X 1 Hex Head Bolt 4 5 88 148 61 1 2 SAE Washer 8 6 88 159 84 1 2 NC Locknut 4 Not Shown 91 340 21 Tool Box Lock 1 91 340 26 Keys for Toolbox Locks 1 00 30...

Page 174: ...Illustrated Parts Parts Page 26 Lights Headlights 1 3 Steering box ref 5 6 Geared Steering Option 1 5 16 NUT WASHER COME W HEADLIGHT 4 MX 6 00 only Standard Lights Taillights Strobelight...

Page 175: ...al Raubber Grommet 2 3 72 022 52 Pig Tail For Both Stop Tail Lights 2 4 72 023 20 Strobe Light 12 48 Vdc Amber 1 5 72 023 32 Pole for Strobe Light MX 600 Only 1 6 88 025 06 8 32 X 1 2 Truss Head Machi...

Page 176: ...ssembly 1 2 Armature 1 3 70 180 00 Brush holder 1 4 80 412 20 Brush spring 4 5 70 109 00 Brush pair 2 6 70 417 00 Bearing retainer 1 7 80 212 00 Bearing rear 1 80 212 00 Bearing front SS 534 1 8 End c...

Page 177: ...unt 1 2 88 100 11 Bolt 4 3 See belt drive Pulley 1 4 30 117 00 Nut 1 5 70 422 00 Strap motor mount 2 6 88 109 87 Nut 4 7 97 100 00 Woodruf key 1 Motor Mount SS 536 SS 546 MX 600 Item No Part No Descri...

Page 178: ...4 1 2 X 1 1 2 NC Bolt 1 3 97 230 00 1 1 4 NF X 9 16 Locknut 1 4 16 409 00 Spacer 1 5 80 102 00 Bearing Race 2 6 14 079 20 Front Fork with Springs Model SS 1 14 079 45 Front Fork with Springs Model MX...

Page 179: ...1 2 Long Bronze Bushing 1 8 97 100 00 3 16 Woodruff Key 1 9 20 031 00 Steering Shaft with Gear 1 10 31 253 00 36 Tooth Spur Gear 750 bore 1 11 80 706 00 3 4 OD O Ring 1 12 31 255 00 7 Tooth Stem Pinio...

Page 180: ...Illustrated Parts Parts Page 32 Steering Linkage Geared SS 536 SS 546 MX 600...

Page 181: ...eve Weldment 1 7 20 031 20 Steering Shaft and Gear 1 8 31 255 10 Stem and Gear Weldment 1 9 32 207 00 3 8 ID X 5 8 OD Bronze Bushing 1 10 45 003 10 Mounting Plate Gasket 1 11 31 254 00 36 Tooth Spear...

Page 182: ...01 00 Rubber Grommet 1 2 ID 4 2 88 149 81 1 2 Locknut 2 3 88 100 15 1 2 X 1 3 4 Bolt 4 4 88 108 62 3 8 Lockwasher 4 5 85 141 00 Spring Clip 4 6 88 100 11 3 8 NC X 1 Bolt 4 7 00 536 01 Drive Frame 1 8...

Page 183: ...1 2 3 4 5 6 6 7 8 9 9 10 See Differential Case Frame Item No Part No Description Qty 1 88 189 81 Nut 2 2 88 188 61 Washer 1 3 86 602 00 Shock 1 4 88 180 18 Bolt 5 8 1 5 88 180 18 Bolt 5 8 1 6 88 188...

Page 184: ...lled 13 734 26 Tire Wheel assembly Foam Filled 13 734 40 Tire Wheel assembly Man Toter Rib 13 734 45 Tire Wheel assembly Man Toter Lug 13 734 50 Tire Wheel assembly Man Toter 13 734 41 Tire Wheel asse...

Page 185: ...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 4 Suggested Torque Values non critical hardware 6 Sug...

Page 186: ...43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor 41 532 50 Chain Case Cente...

Page 187: ...3 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connectors 96 500 40 Fork Coll...

Page 188: ...Bolts NOTE Torque value used should be for lowest grade of hardware used If a grade 2 nut is used on a grade 8 bolt use grade 2 torque value NOTE Toque values specified are for clean dry threads Hex...

Page 189: ...ed as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 NOTE Nuts with no mar...

Page 190: ...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...

Page 191: ...00 398 30 2 00 3 50 540 Metric Foot Pounds Grade N m Dia Pitch 4 6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14...

Page 192: ...um cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will cause u...

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