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Electrical Troubleshooting

Section 4 Charger Troubleshooting

Page 10

Testing the Interlock Relay

Operation

The Interlock Relay disables the vehicle from running whenever the charger is connected to a working AC
power source. When the charger is plugged in, the relay contacts open and break the Key Switch connection

to the speed controller. The Interlock Relay is available for built-in chargers only. Not all built-in chargers
are equipped with this relay. To identify chargers thate are equipped with the Interlock Relay:

Inspect the charger wire harness where it enters the charger cabinet for two Violet/Black
wires. If these wires are present then the charger is equipped with the Interlock Relay.

Testing

6. Disconnect the charger from the AC power source.
7. Disconnect the two Violet/Black wires at the charger harness knife connectors.
8. Set the DMM to check for continuity and connect the DMM leads to the wires

going into the charger.

•

The DMM should indicate a closed circuit. If the DMM indicates an open circuit, then the relay

or the wires to the relay have failed.

Stop here and repair the problem.

9. Connect the charger to a working AC power source.

•

The charger should turn on. If the charger does not turn on then their may be a problem with the

AC power source or the AC wiring to the charger. Refer to the beginning of this section for
charger troubleshooting. DO NOT continue until you have confirmed that the AC power source is
working.

•

The DMM should indicate an open circuit. If it still indicates a closed circuit, then the relay or the

wires to the relay have failed.

Stop here and repair the problem.

•

If the DMM indicates an open circuit then the interlock relay is functioning normally.

1. Make sure the key-switch is in the “OFF” position, then remove the

key.

2. Place the forward-reverse switch in the center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to prevent vehicle movement.
5. Disconnect the main positive and negative cables at the batteires.

4.  Disconnect the wires from the contact terminals on the timer relay.
5.  Reconnect the batteries.
6.  Wait 5 seconds, then test the continuity across the timer relay contact terminals.

•

If this is a closed circuit, then the timer start up circuit is functioning normally.

•

If there is an open circuit, then the timer relay has failed and the relay must be replaced.

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Содержание MX6-00

Страница 1: ...Y o u r B u s i n e s s MANUAL MS 534 08 Operation Troubleshooting Manual Models SS5 34 serial number starting 94506 SS5 36 serial number starting 90400 SS5 46 serial number starting 161403 MX6 00 ser...

Страница 2: ......

Страница 3: ...Operator and Maintenance Manual A guide to the operation and maintenance of Taylor Dunn Vehicles...

Страница 4: ...nn Mfg All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or...

Страница 5: ...ls 2 5 Guidlines for Vehicle Operation 2 7 Driving 2 7 Loading and Unloading 2 7 Parking 2 7 Towing 2 8 Maintenance and Service Procedures 3 1 Maintenance Guidelines 3 2 Maintenance Guidelines for Veh...

Страница 6: ...ssembly 3 31 Removing the SS5 36and SS5 46 Rear End Assembly 3 32 Removing the MX 600 Rear End Assembly 3 33 Differential and Rear Axle 3 34 SS5 34 Drive Service 3 35 Disassembly of the Belt Drive Ass...

Страница 7: ...ISO 6 SOLENOIDS 8 MOTOR 11 SECTION 4b Lestronic II ChargerTroubleshooting 1 Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required for Troubleshooting 4...

Страница 8: ...8 CONTROLS AND INSTRUMENTS MX 600 5 20 MOTOR SS5 34 5 22 MOTOR SS5 36 SS5 46 MX 600 5 24 REAR AXLE SS5 34 5 26 REAR AXLE SS5 36 SS5 46 AND MX 600 5 28 DIFFERENTIAL SS5 34 5 30 DIFFERENTIAL SS5 36 SS5...

Страница 9: ...intended as a training guide Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of it s vehicles Included in this manual are the n Vehicl...

Страница 10: ...owered Industrial Truck Operator Training OftheOperator The operator is responsible for the safe operation of the vehicle preoperational and operational checks on the vehicle and reporting any problem...

Страница 11: ...owner n Section 2 Maintenance and Repair gives specific information on the maintenance and repair of the vehicle and a schedule for maintenance checks n Section 3 Electrical and Charger Troubleshooti...

Страница 12: ...e left and the bold text contained within a box denotes a caution and is used to inform you that property damage may occur Be sure to exercise special care and follow any instructions containedwithina...

Страница 13: ...Vehicle Description and Specifications Describes the Vehicle and Its Standard Specifications...

Страница 14: ...age It is just as important that the vehicle not be towed faster than 5 mph This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industri...

Страница 15: ...Dry Weight SS5 36 MX 600 352 kg 775 lbs Including Batteries SS5 34 332 kg 713 lbs SS5 46 376 kg 830 lbs Turning Radius MX 600 205 cm 81 in SS5 34 SS5 36 190 5 cm 75 in SS5 46 208 7 cm 81 in Brakes SS...

Страница 16: ...effort Accelerator Pedal Brake Pedal Forward Reverse Selector Switch Battery Disconnect Switch Optional Key Switch Parking Brake Steering Wheel Horn Lights What To Do If You Find a Problem If there i...

Страница 17: ...Safety Rules and Operational Information Safety rules guidlines control functions operating guidlines and storage information...

Страница 18: ...as well as obeying the following safety rules and guidelines Thisvehiclemayoverturnifturnedsharplywhiledriving at high speeds on inclines or level surfaces This vehicle was not designed to be driven o...

Страница 19: ...when making turns especially if the ground is wet slippery or when driving on an incline n Drive only on level surfaces or on inclines of no more than 10 5 6 degrees n Do not drive over loose objects...

Страница 20: ...fety rules contained in this manual n Proper operation of vehicle controls n Operator maintenance checks n A test on the operators ability to identify and operate the controls installed on this vehicl...

Страница 21: ...eat on the MX 600 It determines the direction of travel of the vehicle Push the top of the switch to make the vehicle go forward Push the bottom of the switch to go in reverse DO NOT SHIFT from forwar...

Страница 22: ...rake pedal until the pedal disengages from the locked position Horn Button The horn button is located on the left side of the floor board and is designed for left foot operation Depress the button to...

Страница 23: ...eport any accidents or vehicle problems to your supervisor immediately Loading and Unloading n Do not load cargo that can easily fall off this vehicle n Do not exceed the load capacity of this vehicle...

Страница 24: ...le slows or stops n Do not exceed 5 mph or carry any passengers while towing the vehicle NOTE This vehicle is not to be towed using a commercial tow truck It may be towed either behind another vehicle...

Страница 25: ...Maintenance and Service Procedures Maintenance and Service Information Including Lubrication Information Scheduled Maintenance and Disassembly...

Страница 26: ...t in the work area Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts n Ventilate the work area properly n Re...

Страница 27: ...be carried out twice as often as stated In addition the whole vehicle should be inspected monthly for signs of damage and repaired immediately n Inspect and maintain battery limit switches protective...

Страница 28: ...X Check and Fill Batteries X Check Brake System X Check Steering System X Lubricate Vehicle X Clean and Tighten All Wire Connections X Wash and Service Batteries X Check Park Brake X Check Front Whee...

Страница 29: ...ont Fork Pivots 2 General Purpose Grease 3 Steering Collars 1 General Purpose Grease 4 Brake Shaft Collars 2 General Purpose Grease 5 Rear Axle Differential 1 SS 536 SS 5 46 MX 600 SAE 30 Motor Oil SS...

Страница 30: ...rn Drive Belt Low Battery Defective Speed Controller Defective or Worn Motor Brushes Abnormal Noise Worn Drive Gears or Bearings Loose or Worn Drive Belt Worn Front Rear Axle Bearings Loose Lug Nuts M...

Страница 31: ...3 7 NOTES...

Страница 32: ...3 8 SECTION 3 MECHANICAL REAR DRUM BRAKES STANDARD ON SS5 36 SS5 46 MX 600 DRIVE LINE BRAKE BAND STANDARD ON SS5 34...

Страница 33: ...his or any vehicle However there is the possibility that the OEM brake pads shoes were replaced with those containing asbestos fibers Since this possibility does exist the brake pads should be handled...

Страница 34: ...travel will increase to the point where the upper slot must engage the locking angle to provide adequate braking force The brake band must be adjusted before lining wear reaches the point where engag...

Страница 35: ...cables will result in brake drag and premature failure of the brake shoes 5 Tighten the jam nut against the clevis and lower the vehicle 6 Check the brake pedal to see that the park brake lock engages...

Страница 36: ...the brake band 6 Remove the brake band anchor bolt and brake band 7 Remove the brake drum from the pinion shaft 8 Clean and inspect the brake band and brake drum Replace all worn parts as needed NOTE...

Страница 37: ...and the cables will result in brake drag and premature failure of the brake shoes 5 Tighten the jam nut against the clevis and lower the vehicle 6 Check the brake pedal to see that the park brake lock...

Страница 38: ...cing the Park Brake Lock All Models Foot Brake Assembly Shown is the brake pedal and how it connects to the brake cables on the SS5 36 SS5 46 and MX 600 Locknut Mounting Bolt Clevis Jam Nut Adjusting...

Страница 39: ...ps 4 through 5 in reverse order Substituting the word install for remove in steps 4 and 5 In the following procedure you will be told how to check the Park Brake Lock for Wear 1 After removing the par...

Страница 40: ...ction we will cover how to inspect and replace the brake drum and shoes WearLimit Brake Shoes Measure the brake shoe at various locations It should be thicker than 1 16 at its thinnest point If you me...

Страница 41: ...Remove the cotter pin castle nut and washer from the end of the axle shaft 4 Remove the brake drum 5 Inspect the inside of the brake drum for wear or damage If it is grooved or damaged it must be repl...

Страница 42: ...shoe hold down spring from each shoe 8 Remove the brake shoes and adjusting assembly 9 Disassemble and clean the adjusting screw assembly 10 Apply Hi Temp grease to the adjusting screw assembly hold...

Страница 43: ...3 19 Exploded view of mechanical rear brake assembly...

Страница 44: ...the tiller steering system and the geared steering system The standard steering assembly for the SS5 34 SS5 36 and MX 600 is the Tiller Since the Geared option is widely used in these vehicles as well...

Страница 45: ...s used within the serial numbers covered by this manual The basic instructions for removing servicing and installing are the same LOWER LOCATOR TOP LOCATOR OIL SEAL AXLE BEARING RACE ROLLER BEARING SP...

Страница 46: ...the steering shaft to slide through the cowl NOTE The fork should be supported to prevent it from putting undue pressure on the lower oil seal bearing and bearing race This is also done to prevent the...

Страница 47: ...property damage Removing the Front Axle This can be done with the fork still in the vehicle or while it is removed To remove and replace the front axle assembly use the following procedure 1 Raise and...

Страница 48: ...rive Always use new locknuts and bolts Locknuts and bolts become less effective if used more than once If the locknuts or bolts holding the brake to the drive come loose serious injury may occur Repla...

Страница 49: ...g wheel and woodruff key from the shaft 5 Remove the 6 bolts from the top cover 6 Lift the top cover off the gear box discarding the gasket NOTE The spur gear and shaft may come out of the gear box wh...

Страница 50: ...3 26 SECTION 3 SS5 34 Optional Geared Steering Assembly SS5 36 SS5 46 and MX 600 Optional Geared Steering...

Страница 51: ...e gear box discarding the gasket NOTE The stem and gear may come out of the gear box when removing the top cover Do not let the gear drop to the floor 7 Remove as much grease as possible from the insi...

Страница 52: ...re remove the front wheel from the hub 5 Using the appropriate procedure remove the hub from the axle assembly 6 Remove the oil seal bearings and bearing races from the hub 7 Install new bearing races...

Страница 53: ...Turn the front wheels so that they are in the straight ahead position 3 Measure the distance between the centers at the front of the tires 4 Measure the distance between the centers at the front of t...

Страница 54: ...3 30 SECTION 3 Rear Axle and Drive Assembly In this section we will cover how to install remove and service the rear axle and drive assemblies SS5 36 SS5 46 and MX 600...

Страница 55: ...e onto jack stands 5 Raise the deck board and disconnect the motor wires 6 From under the vehicle remove the brake linkage from the brake lever 7 Remove the shock from its lower mount 8 Remove the swi...

Страница 56: ...rear end assembly with a jack and jack stands 6 Remove the bolts mounting the rear coil springs to the drive frame and lower the entire frame and rear end assembly 7 Raise the rear of the vehicle and...

Страница 57: ...E You may want to remove the tires in order to make it easier to remove the mounting bolts from the frame 6 Place another set of jack stands under the drive assembly and remove the bolts mounting the...

Страница 58: ...we will cover how to disassemble and service these differential and rear axle assemblies The belt adjustments for the belt drive system will be included To properly service the differential it will h...

Страница 59: ...es 2 Remove the brake 3 Loosen the motor mount clamp nuts and the Belt adjusting bolt locknut 4 Turn the Belt adjusting bolt until the belts can be removed without prying or forcing them off 5 Remove...

Страница 60: ...sing 5 Remove the bearing gasket 6 Inspect all bearings for roughness or play Replace the bearings as needed 7 Inspect the axle for metal fatigue 8 Install a new rear axle in reverse order Always use...

Страница 61: ...nd third member from the housing 7 Mark the carrier bearing flanges to insure that they can be installed in the same orientation during reassembly 8 Remove the carrier bearing flanges and the carrier...

Страница 62: ...bs 4 Position the carrier assembly against the pinion gear While rotating the carrier turn the adjusting nuts to contact the carrier bearings 5 Loosen the adjusting nut on the toothed side of the ring...

Страница 63: ...e amount you must add or subtract from the standard shim in order to correctly position the pinion gear Locate the number on the flat surface on the small shaft at the end of the pinion gear Match the...

Страница 64: ...6 Loosen the drive belt adjusting bolt lock nut and turn the adjusting bolt until the belts can be easily removed 7 Remove the drive belts from the motor pulley 8 Remove the four motor mounting bolts...

Страница 65: ...Loosen the lock nut on the belt adjusting bolt 3 Turn the adjusting bolt in or out as needed to tension the belts properly NOTE There should be a 1 4 deflection in the belts at the mid point between...

Страница 66: ...the following procedure 1 Loosen the motor mount clamp nuts and move the motor either forward or backward until the two pulley faces are in line with each other 2 Tighten the motor mount clamp nuts a...

Страница 67: ...o the illustration on the following page 1 Raise and support the rear of the vehicle with a hoist or other suitable lifting device 2 Remove the tire and wheel assembly 3 Remove the four bolts attached...

Страница 68: ...appropriate receptacle 2 Remove the axle shafts from the differential 3 Remove the cover plate from the differential and let the remaining oil drain from the housing NOTE Do not damage the housing se...

Страница 69: ...using 17 Remove the bearings from the input shaft 18 Remove the O Rings from the outer input bearing bore and both intermediate bearing bores 19 Inspect all parts for signs of wear or damage NOTE Bear...

Страница 70: ...e differential case 32 Position the drive housing with the opening facing up and install the differential assembly 33 Install the differential bearing caps NOTE Remember that the bearing caps are mark...

Страница 71: ...RDTOGAIN ACCESSTOTHEMOTOR 1 Disconnect the batteries 2 Support the motor 3 Label the wires connected to the motor to insure that they are returned to their proper location 4 Remove the wires from the...

Страница 72: ...from the face of the motor 8 Remove the motor assembly from the vehicle 9 Install in reverse order and adjust the belts using the appropriate procedure Brushes The motor brushes must be checked regula...

Страница 73: ...w ones 5 Inspect the commutator for wear 6 Replace the motor cover and reinstall the motor on the rear end assembly Motor Disassembly 1 Remove the motor 2 Disassemble the motor NOTE Mark the housing t...

Страница 74: ...commutator is grooved it must be cut on a lathe 3 Measure the undercut on the commutator a If less than 025 then the mica must be undercut 4 Measure the commutator diameter a If less than 3 109 then...

Страница 75: ...hich indicates that the acid has been neutralized Then rinse thoroughly with clear water DO NOT get any of the solution into the battery cells Battery electrolyte is poisonous and dangerous It contain...

Страница 76: ...he winter season n Clean and check the electrolyte level and charge level of the battery Do not store a battery low in electrolyte or in a low state of charge n Recharge a battery not in use every 1 t...

Страница 77: ...tery Configuration Shown are the batteries and how they are connected together for the SS5 34 SS5 36 and SS5 46 REAR OF VEHICLE Positive Tap Negative Tap To Control Panel NEG POS NEG POS POS NEG NEG 1...

Страница 78: ...TAYLOR DUNN...

Страница 79: ...SECTION 4 Electrical Troubleshooting...

Страница 80: ...rent in the opposite direction or Accelerates slowly and exceeds normal speed in the opposite direction with high armature current only NOTE Field current will be very low in the opposite direction Ac...

Страница 81: ...eshooting guide is not written to be able to locate a problem if there are multiple component failures This troubleshooting guide assumes the batteries are good Charge and test the batteries before tr...

Страница 82: ...click when the accelerator 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 Fa...

Страница 83: ...remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate du...

Страница 84: ...ring the drive wheels to the ground 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 blo...

Страница 85: ...ly 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 If the...

Страница 86: ...ir the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground 1 Make sure the key switch is in the OFF position then remove the key 2 Place t...

Страница 87: ...remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement The rear drive wheels may rotate dur...

Страница 88: ...before testing can continue 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 unde...

Страница 89: ...e test harness Close all interlock switches and turn the Key Switch ON Depress the accelerator pedal to engage MS 1 only If the voltage is not at battery volts then the accelerator module has failed S...

Страница 90: ...celerator module 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 Now Depress the...

Страница 91: ...ween the key switch and battery positive 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 COL...

Страница 92: ...air is completed completely retest the vehicle before lowering the drive wheels to the ground For your reference shown at the right are the Forward and Reverse switch wire connections for a typical co...

Страница 93: ...re and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground F R switch The COLD terminal is the Violet Black wire on either end...

Страница 94: ...rward 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 pe...

Страница 95: ...skip ahead to the test sequence Forward does not run in reverse If the vehicle runs in reverse only then skip ahead to the test sequence Reverse does not run in forward The REVERSE terminal is diagona...

Страница 96: ...attery volts then check the wiring to battery positive and the main circuit breaker Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before...

Страница 97: ...t 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...

Страница 98: ...Switch sequence Connect a voltmeter across the Forward Solenoid coil terminals Refer to your vehicles wiring diagram to identify the position of the forward solenoid Close all interlock switches turn...

Страница 99: ...your truck may be different FWD REV Set the test light voltage to the same voltage as the battery volts Connect the test light across the Normally Closed contacts of the Reverse solenoid Refer to your...

Страница 100: ...B2 48 With Dump Bed Option B2 10 Ambulance B2 48 with Steel Cab Foldaway 4 Passenger Seat and Stake Sides P2 50 30 000 Pound Tow Tractor ET 3000 ET1 50 Full Size Truck...

Страница 101: ...Vehicle Wire Diagrams Section 4A...

Страница 102: ...L TROUBLESHOOTING SECTION 4a Wire Diagrams Page 2 Charger interlock relay may be located in the charger cabinet Optional Charger Interlock Relay Model SS 5 34 SS 5 36 abd SS 5 46 with the Dual Chassis...

Страница 103: ...ELECTRICAL TROUBLESHOOTING SECTION 4a Wire Diagrams Page 3 To AC power source Charger interlock relay may be located in the charger cabinet Optional Charger Interlock Relay Model MX 6 00...

Страница 104: ...ELECTRICAL TROUBLESHOOTING SECTION 4a Wire Diagrams Page 4 Optional Charger Interlock Relay Charger interlock relay may be located in the charger cabinet Model SS 5 34 with the Single Chassis Harness...

Страница 105: ...y and exceeds 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...

Страница 106: ...egative B M A2 B 2 KSI _ The voltage shown is for illustration only The actual voltage may vary 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch...

Страница 107: ...rator pedal to engage the first micro switch only creep speed then perform the following tests The meter reading should not be equal to the battery voltage If you have full battery voltage then the PM...

Страница 108: ...nt 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 nee...

Страница 109: ...ing It is important to review the trouble shooting steps that have led to this point The tests may need to be repeated B M A2 B 2 KSI _ The reading shown is for illustration only The actual reading ma...

Страница 110: ...test 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to p...

Страница 111: ...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 should be 250 Ohms 10 If it is not 250 ohms 1...

Страница 112: ...the following has occurred A The reverse solenoid is shorted B The wire connected to the motor S1 terminal is shorted to the wire connected to the motor A2 terminal C The wire connected to the motor...

Страница 113: ...pleted completely retest the vehicle before lowering the drive wheels to the ground otherwise continue with the next test With the key switch on and the F R switch in forward depress the accelerator p...

Страница 114: ...urred 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 shooting here and repair the problem When the...

Страница 115: ...top 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 1 Make...

Страница 116: ...is dark brown to black or the insulation is cracked and peeling then the armature has been overheated and burnt The motor must be replaced Stop here and repair the problem otherwise continue with the...

Страница 117: ...Troubleshooting Operating Instructions and Theory of Operation 2 TestingtheChargingCycle 3 TestEquipmentRequiredforTroubleshooting 4 Important Notes and Instructions 4 TroubleshootingforBuilt inCharge...

Страница 118: ...e 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 approximately 50 1175 1...

Страница 119: ...50 before connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it...

Страница 120: ...less than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated...

Страница 121: ...ken or has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re...

Страница 122: ...before continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pli...

Страница 123: ...to Timer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator t...

Страница 124: ...the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconnect one lead...

Страница 125: ...r If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The voltage here will...

Страница 126: ...Stop here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or...

Страница 127: ...ycle 3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code 5 Troubleshooting 6 Turn the Key switch OFFBEFORE disconnectingthebatteries Disconnecting...

Страница 128: ...Maintains a constant current until the battery reaches a terminal voltage and then switches to the second stage constant voltage At the second stage the charger decreases the charger current while ho...

Страница 129: ...less than 12 hours but still show symptoms of overcharging if The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To t...

Страница 130: ...s plugged into is in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition...

Страница 131: ...e Description Action Required 1 Reverse polarity or open circuit to the batteries Check wiring for corrosion loose connections broken wires and proper connection to the batteries 2 AC line voltate too...

Страница 132: ...l be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charger end cap whe...

Страница 133: ...Illustrated Parts List...

Страница 134: ...the right Starting from the top of the page they are as follows SS5 34 SS5 36 MX 600 SS5 46 Whenever necessary the model of the vehicle is identified with the parts that are specific to that model If...

Страница 135: ...5 3 SS5 34 SS5 36 MX 600 SS5 46...

Страница 136: ...5 4 ILLUSTRATED PARTS BRAKE PEDALLINKAGE AND ACCELERATOR PEDAL SS5 34...

Страница 137: ...Arm Weldment 1 5 88 140 14 1 2 NC X 1 1 2 Hex Head Cap Screw 1 6 96 772 00 3 8 X 1 Clevis Pin 3 7 85 060 00 Return Spring 1 8 96 813 00 28 1 4 to 31 1 4 Brake Cable Assy 1 9 88 517 11 3 32 X 1 Cotter...

Страница 138: ...5 6 ILLUSTRATED PARTS BRAKE PEDAL LINKAGE SS5 36 SS5 46AND MX 600 Attach to brake arm at rear axle...

Страница 139: ...1 1 8 X 1 Cotter Pin 1 6 96 762 00 Clevis 1 7 88 119 81 3 8 NF Jam nut 1 8 88 111 20 3 8 X 3 NF Bolt 1 9 96 826 12 Park Brake Cable Assy 1 10 02 536 06 Brake Equalizer 1 11 96 772 00 3 8 X 1 Clevis Pi...

Страница 140: ...5 8 ILLUSTRATED PARTS FRONTAXLE WHEELAND SUSPENSION SS5 34 SS5 36 MX 600...

Страница 141: ...cknut 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 Seal 2 6 80 015 00 Tapered Roller Bearing 2 7 80...

Страница 142: ...5 10 ILLUSTRATED PARTS FRONTAXLE WHEELAND STEERING SS5 46 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...

Страница 143: ...9 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 11 Rod end left thread 2 86 519 10 Rod end right thread 2 15 88 108 15 3 8 x 1 3 4 Hex bolt 4 16 88 106 6...

Страница 144: ...5 12 ILLUSTRATED PARTS TILLER STEERING...

Страница 145: ...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 1 7 85 140 10 Spring 2 8 97 100 00 Woodruff Key 1 9 80 011 00 1 1 4 Tapered Ro...

Страница 146: ...5 14 ILLUSTRATED PARTS GEARED STEERING SS5 34...

Страница 147: ...ering 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 Pinion 1 13 45 003 00 4 X 4 1 2 OD Gasket 1 14 45 004 00 4 X 6 OD Gasket 2 15...

Страница 148: ...5 16 ILLUSTRATED PARTS GEARED STEERING SS5 36 SS5 46 AND MX 600...

Страница 149: ...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 Gear 1 12 88 069 81 1 4 Locknut 4 13 18 039 11 Botto...

Страница 150: ...5 18 ILLUSTRATED PARTS INSTRUMENT PANEL SS5 34 SS5 36 AND SS5 46...

Страница 151: ...onsole 1 3 88 065 09 1 4 X 3 4 NC Phillips Hd Screw 2 4 71 039 00 Forward Reverse Switch 1 5 74 009 10 24 volt Battery Status Indicator 1 6 74 000 00 Hour Meter Optional 1 7 72 028 20 Power On Light 1...

Страница 152: ...5 20 ILLUSTRATED PARTS CONTROLS AND INSTRUMENTS MX 600...

Страница 153: ...300 04 Instrument Panel 1 5 71 039 00 3 Position Rocker Switch 1 6 71 111 00 Brake Light Switch 1 7 71 102 10 Seat Switch 1 8 02 610 18 Seat Switch Mount 1 9 85 030 00 Compression Spring for Seat Swit...

Страница 154: ...5 22 ILLUSTRATED PARTS MOTOR SS5 34 10 11 7 9 12 13 9 5 3 4 2 1 14 16 17 6 8 15 Typical GE Motor...

Страница 155: ...N A N A N A N A N A N A N A N A N A N A N A N A 5BC49JB399C 70 054 00 45 508 00 80 504 00 80 200 00 97 100 00 70 203 10 98 622 00 98 623 00 97 178 00 97 179 00 70 210 62 70 195 10 70 195 10 80 412 00...

Страница 156: ...5 24 ILLUSTRATED PARTS MOTOR SS5 36 SS5 46 MX 600 2 3 5 6 4 7 8 1 9 10 Armature 12...

Страница 157: ...eld coils mounted in motor housing 1 2 70 210 51 Inulator 2 3 85 412 00 Brush spring 4 4 70 172 15 Brush holder includes 3 1 5 70 104 15 Motor brush 2 2 6 70 210 51 Insulator 2 7 32 508 15 Bearing ret...

Страница 158: ...5 26 ILLUSTRATED PARTS REAR AXLE SS5 34 1 2 3 4 5 6 8 11 12 10 9 13 7...

Страница 159: ...045 00 Rear Axle Bearing Gasket 2 6 45 301 00 Oil Seal 2 7 32 515 00 Bearing Retainer Ring 2 8 80 503 00 Bearing for Rear Axle 2 9 32 514 00 Rear Axle Retaining Plate 2 10 41 166 11 Right Side Axle w...

Страница 160: ...5 28 ILLUSTRATED PARTS REAR AXLE SS5 36 SS5 46 AND MX 600...

Страница 161: ...5 41 126 99 Right Axle Shaft 1 41 126 98 Left Axle Shaft 1 6 41 344 99 Right Brake 1 41 344 98 Left Brake 1 7 88 199 85 Slotted Hex Nut 2 8 88 188 61 5 8 SAE Washer 2 9 41 518 00 Brake Drum hub up to...

Страница 162: ...5 30 ILLUSTRATED PARTS DIFFERENTIAL SS5 34...

Страница 163: ...ier Bearing 2 6 31 235 00 Ring and Pinion Gear Set 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...

Страница 164: ...5 32 ILLUSTRATED PARTS DIFFERENTIAL SS5 36 SS5 46 AND MX 600...

Страница 165: ...Bearing 2 3 31 265 00 Gear Set 1 4 80 480 15 Shaft Bearing 1 5 88 840 12 Snap Ring 3 6 80 715 10 O Ring 3 7 41 973 00 Cup Plug 2 8 80 480 01 Bearing 2 9 80 715 00 O Ring 2 10 80 408 00 Carrier Bearin...

Страница 166: ...5 34 ILLUSTRATED PARTS SS5 36 SS5 46 DIFFERENTIAL FRAME...

Страница 167: ...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 88...

Страница 168: ...5 36 ILLUSTRATED PARTS DECK AND VISEASSY MX 600...

Страница 169: ...rew 3 3 88 068 61 1 4 SAE Washer 5 4 97 840 01 4 1 2 Jaw Width Vise 1 5 00 380 01 Vise Mount Plate 1 6 88 100 15 3 8 NC X 1 3 4 Hex Head Bolt 3 7 88 108 62 3 8 Lockwasher 3 8 88 069 81 1 4 Locknut 2 9...

Страница 170: ...5 38 ILLUSTRATED PARTS TOOLBOX ASSY MX 600 1 2 3 4 5 6...

Страница 171: ...ol Chest 1 2 00 300 02 Trim 1 3 94 400 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...

Страница 172: ...5 40 ILLUSTRATED PARTS BATTERY SS5 36 SS5 46 and MX 6 00 SS 5 34 12V NEGATIVE TAP TO CONTROL PANEL REAR OF VEHICLE NEG POS NEG POS NEG POS NEG POS...

Страница 173: ...4AH 145min 4 77 044 00 Battery 230AH 105min 4 77 042 80 Battery Moist Dry 217AH 105min 4 77 047 80 244AH 145min Dry Charge 4 2 88 081 12 5 16 NC X 1 Bolt 8 3 50 250 00 Battery Hold Down 2 4 50 243 10...

Страница 174: ...5 42 ILLUSTRATED PARTS BRAKE ASSY SS5 34...

Страница 175: ...Half Band 1 6 96 245 10 1 2 NC X 5 hex Head Cap Screw 1 7 85 270 00 1 1 4 OD X 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...

Страница 176: ...5 44 ILLUSTRATED PARTS REAR BRAKE SS5 36 SS5 46 AND MX 600...

Страница 177: ...ear Brake SS5 36 SS5 46 and MX 600 ITEM PART DESCRIPTION QTY 1 85 344 60 Spring Kit 1 2 41 634 00 Brake Shoes Shows 1 Set 2 41 344 98 Complete Brake Assembly Left 1 41 344 99 Complete BRake Assembly R...

Страница 178: ...5 46 ILLUSTRATED PARTS PMC CONTROL PANEL...

Страница 179: ...ircuit Breaker 2 12 79 844 00 135 Amp Auto Reset Circuit Breaker 1 13 88 080 11 5 16 X 1 Hex Head Cap Screw 4 14 01 534 89 Control Panel Mount SS5 34 SS5 36 1 00 300 03 Control Panel Mount MX 600 1 15...

Страница 180: ...5 48 ILLUSTRATED PARTS BATTERY CHARGER LESTER PORTABLE CHARGER 1 2 3 4 6 7 5 6 11 LESTER BUILT IN CHARGER SIGNET CHARGER REFER TO PARTS APPENDIX A AT THE END OF THIS SECTION...

Страница 181: ...79 301 05 ITEM PART DESCRIPTION QTY 1 79 805 66 Timer 1 2 79 902 00 Capacitor 1 3 79 749 13 Heat Sink With Diodes 1 4 Special Order Transformer 1 5 79 575 30 AC Cord Set with Plug 1 6 79 530 00 Bushi...

Страница 182: ...5 50 ILLUSTRATED PARTS TIRE AND WHEEL...

Страница 183: ...andard on SS5 34 13 734 11 4 80 X 8 LR B Tire and Split Rim SS5 34 13 734 41 4 00 X 8 Non Marking Tire and Split Rim SS5 34 13 734 12 4 80 X 8 LR B Tire and Split Rim SS5 36 SS5 46 MX 600 13 734 21 4...

Страница 184: ...5 52 ILLUSTRATED PARTS SEAT CUSHIONS SS5 34 SS5 36 SS 5 46 MX 600...

Страница 185: ...N QTY SS5 34 1 90 144 00 Backrest Optional 1 2 90 166 00 Seat Cushion 1 3 02 534 25 Hip Restraint 2 SS5 36 SS5 46 1 93 004 00 Backrest 2nd Passenger Seat 1 2 93 005 00 Seat Cushion 1 MX 600 1 90 144 0...

Страница 186: ...5 54 ILLUSTRATED PARTS DECALS...

Страница 187: ...tic 1 94 384 04 Traffic Standards Notice Decal Export 1 6 94 383 00 Console Decal 1 7 94 384 00 Park Brake Decal 1 8 94 386 01 Roll Over Warning Decal MX 600 Only 1 9 94 309 50 Park Brake Warning Deca...

Страница 188: ...5 56 ILLUSTRATED PARTS MIRRORS OPTION...

Страница 189: ...antities Mirror Option ITEM PART DESCRIPTION QTY 1 92 201 00 4 1 2 X 8 1 2 Mirror Rt or Lt Side 1 2 92 202 00 Mirror Bracket Rt or Lt Side 1 3 88 065 08 1 4 NC X 5 8 Truss Head Screw 4 4 88 068 60 1 4...

Страница 190: ...5 58 ILLUSTRATED PARTS STROBE AND STOP LIGHT OPTION...

Страница 191: ...88 025 06 8 32 X 1 2 Truss Head Machine Screw 3 7 88 028 62 8 Lockwasher 3 8 88 029 80 8 32 Hex Nut 3 Not 75 106 13 Wire Harness For Strobe Light 1 Shown 98 603 00 3 8 ID Rubber Grommet For Harness 1...

Страница 192: ...5 60 ILLUSTRATED PARTS HEADLIGHT 1 5 16 NUT WASHER COME W HEADLIGHT 1 3 Steering box ref 5 6 4 MX 6 00 only Geared Steering Option Standard 2 SS 5 34 SS 5 36 SS 5 46 2 MX 6 00...

Страница 193: ...QTY 1 72 005 00 Heallight 1 2 71 039 11 Switch SS 5 34 SS 5 36 SS 5 46 1 71 100 00 Switch MX 6 00 1 3 71 505 05 Mount geared steering option 1 4 75 166 35 Harness MX 6 00 1 5 88 100 09 3 8NC x 3 4 Hex...

Страница 194: ...TAYLOR DUNN...

Страница 195: ...Parts Appendix A...

Страница 196: ...RATED PARTS SIGNET CHARGER NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife...

Страница 197: ...er ITEM PART DESCRIPTION QTY 79 303 40 Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the charger AC...

Страница 198: ...TAYLOR DUNN...

Страница 199: ......

Страница 200: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com...

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