Taylor-Dunn SS5-34 Operating instructions

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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 serial number starting 113227
Revision: F

Operator and Maintenance
Manual
A guide to the operation and maintenance of Taylor-Dunn®
Vehicles

TAYLOR-DUNN SERVICE CENTER
For more information about this and other Taylor-Dunn®manuals, please write Taylor-Dunn®:
Taylor-Dunn®Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn®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 retrieval
system without prior written permission of Taylor-Dunn®Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn®Mfg., 2114 W. Ball Road, Anaheim, CA 92804

i-i
Table of Contents
Introduction .......................................................................................... 1
Who Should Read This Manual .................................................... 2
Responsibilities.............................................................................. 2
How To Use This Manual ............................................................ 3
Conventions ................................................................................... 4
Vehicle Description and Specifications .................................... 1-1
Vehicle Description ..........................................................................1-2
Standard Specifications ..............................................................1-3
Taking Delivery of Your Vehicle ................................................1-4
What To Do If You Find a Problem ...........................................1-4
SafetyRulesandOperational Information .............................. 2-1
Safety Rules and Guidelines..........................................................2-2
Responsibilities...........................................................................2-2
Safety Rules ...............................................................2-3
Driver Training Program Guidelines ..........................................2-4
Driver Qualifications ..................................................................2-4
Who is Qualified to Drive? ........................................2-4
Minimum Requirements ............................................2-4
Vehicle Controls ...............................................................................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 Vehicles
Used in Severe Conditions .................................................3-3
Periodic Maintenance Table...........................................................3-4
Lubrication ...........................................................................................3-5
Troubleshooting Guide .........................................................................3-6
Brakes.................................................................................................3-9
Adjusting the Brake Band ....................................................... 3-10
SS5-34 Brake System .............................................................. 3-10
Adjusting the Brake Cable ...................................... 3-11
Removing the Brake Assembly .............................. 3-12
SS5-36, SS5-46 and MX-600 Brake System ......................... 3-13
Adjusting the Brake Pedal Linkage ........................ 3-13
Inspecting and Replacing the Park Brake Lock (All Models) 3-14
Replacement and Wear
of Park Brake Lock (All Models) .................. 3-15
SS5-36, SS5-46 and MX-600 Rear Brakes............................. 3-16
Replacing the Brake Drum...................................... 3-17
Replacing the Brake Shoes...................................... 3-18

i-iv
INTRODUCTION
Front Fork and Steering............................................................... 3-20
Front Fork ................................................................................ 3-21
Removing the Front Fork ....................................... 3-22
Removing the Front Springs ................................... 3-23
Removing the Front Axle ........................................ 3-23
Replacing the Front Wheel Bearings ...................... 3-24
Replacing and Adjusting the
Front Fork Collar Bearing .............................. 3-24
Optional Geared Steering ........................................................ 3-25
SS5-34 Geared Steering Assembly ......................... 3-25
SS5-36, SS5-46 and MX-600 Geared
Steering Assembly .......................................... 3-27
SS5-46 Front Axle and Steering............................................... 3-28
Replacing the Front Wheel Bearings ...................... 3-28
Removing the Front Axle Assembly ...................... 3-29
Aligning the Front Wheels ...................................... 3-29
Replace the King Pin or Bushings .......................... 3-29
Rear Axle and Drive Assembly .................................................... 3-30
Removing the SS5-34 Rear End Assembly............................. 3-31
Removing the SS5-36and SS5-46 Rear End Assembly .......... 3-32
Removing the MX-600 Rear End Assembly ......................... 3-33
Differential and Rear Axle ....................................................... 3-34
SS5-34 Drive Service............................................... 3-35
Disassembly of the
Belt Drive Assembly...................... 3-35
Removing and Servicing the Rear Axle .. 3-36
Differential Service and Repair .............. 3-37
Motor Removal ...................................... 3-40
Changing the Differential Oil ................. 3-40
Adjusting Belt Tension .......................... 3-41
Aligning Pulleys...................................... 3-42
SS5-36, SS5-46 and MX-600 Drive Service .......... 3-43
SS5-36/SS5-46/MX-600 Removing and
Servicing the Rear Axle .................. 3-43
Servicing the Differential........................ 3-44
Motor................................................................................................ 3-47
SS5-36/SS5-46/MX-600 Motor Removal .............................. 3-47
SS5-34 Motor Removal........................................................... 3-48
Brushes..................................................................................... 3-48
Installing New Brushes ........................................... 3-49
Motor Disassembly................................................................. 3-49
Inspecting the Armature .......................................................... 3-50
Battery ............................................................................................. 3-51
Cleaning .................................................................................... 3-51
Servicing the Batteries ............................................................. 3-52
Charging .................................................................................... 3-52
Battery Storage ........................................................................ 3-52
Battery Configuration.............................................................. 3-53

i-iii
SECTION4-ElectricalTroubleshooting ..................................... 1
Test Equipment Required: ................................................................. 3
IMPORTANT NOTES and INSTRUCTIONS ............................... 3
Definitions: .......................................................................................... 4
Section 4a-VehicleWire Diagrams ............................................. 1
Model MX 6-00 ..................................................................................... 2
Model SS 5-34, SS5-46 and SS 5-36 with the
Dual Chassis Harness ................................................................ 3
Model SS 5-34 with the Single Chassis Harness.......................... 4
Section4-SpecialTroubleshootingGuide ................................... 1
PMC CONTROL ................................................................................. 2
PLUGGINGDIODE............................................................................. 4
FREEWHEELDIODE .......................................................................... 5
ISO......................................................................................................... 6
SOLENOIDS........................................................................................ 8
MOTOR .............................................................................................. 11
SECTION4b-LestronicII ChargerTroubleshooting .................. 1
OperatingInstructions andTheoryof Operation.....................2
Testing the Charging Cycle .................................................................3
Test Equipment Required for Troubleshooting ................................4
Important Notes and Instructions........................................................4
Troubleshooting for Built-in Charger................................................ 5
Troubleshooting for Portable Charger ............................................... 8
Testing The Timer Relay...................................................................... 9
Testing the Interlock Relay .................................................................. 10
SECTION4c-Signet ChargerTroubleshooting............................ 1
OperatingInstructions andTheoryof Operation.....................2
Testing theCharging Cycle ....................................................3
TestEquipmentRequiredforTroubleshooting.........................4
StatusLEDErrorCode ...........................................................5
Troubleshooting......................................................................6

i-iv
TABLE OF CONTENTS
Illustrated Parts List ................................................................ 5-1
IDENTIFYING YOUR VEHICLE ................................................... 5-2
BRAKE PEDAL LINKAGE AND ACCELERATOR PEDAL (SS5-34) .... 5-4
BRAKE PEDAL LINKAGE (SS5-36, SS5-46 AND MX-600) ........... 5-6
FRONT AXLE, WHEEL AND SUSPENSION ................................... 5-8
FRONT AXLE, WHEEL AND STEERING (SS5-46) ....................... 5-10
TILLER STEERING .................................................................. 5-12
GEARED STEERING (SS5-34) .................................................. 5-14
GEARED STEERING (SS5-36, SS5-46 AND MX-600) ................ 5-16
INSTRUMENT PANEL (SS5-34, SS5-46 AND SS5-36)............... 5-18
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, SS5-46 AND MX-600) ....................... 5-32
SS5-36, SS5-46 DIFFERENTIAL FRAME ................................... 5-34
DECK AND VISE ASSY (MX-600) ............................................ 5-36
TOOLBOX ASSY (MX-600) ..................................................... 5-38
BATTERY .............................................................................. 5-40
BRAKE ASSY (SS5-34) ........................................................... 5-42
REAR BRAKE (SS5-36, SS5-46 AND MX-600) ......................... 5-44
PMC CONTROL PANEL ......................................................... 5-46
BATTERY CHARGER .............................................................. 5-48
REAR TIRE AND WHEEL ......................................................... 5-50
SEAT CUSHIONS ................................................................... 5-52
DECALS................................................................................ 5-54
MIRRORS OPTION ................................................................. 5-56
STROBE AND STOP LIGHT OPTION ....................................... 5-58
HEADLIGHT .......................................................................... 5-60
PARTS APENDIX A................................................................. 5-63
SIGNET CHARGER ................................................................. 5-64

1
Introduction
The purchase of this vehicle shows a belief in high quality products
manufacturedin the USA.Taylor-Dunn®, aleading manufacture of
electric burden and personnel carriers since 1949, wants to be sure
that you get the most out of your vehicle and that it provides years
of reliable service. Please continue to read this manual and enjoy
your high quality Taylor-Dunn®vehicle.
This manual is to serve as a guide for the service, repair and
operation of the Taylor-Dunn®vehicle, and is not 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 Vehicle Description
n Safety Rules and Guidelines
n Operational Information
n Operator Responsibilities
n Owner Responsibilities
n Control Operation and Location Information
n Maintenance and Troubleshooting Information
n Parts Lists of Standard Parts
Before servicing, operating, training, or performing maintenance
on this or any Taylor-Dunn®vehicle, read the entire manual and
note all cautions, warnings, and notes contained in this manual.
What’s contained
in this manual?
Before servicing....
Your purchase...

2
INTRODUCTION
Who Should Read This Manual
This manual is intended for use by anyone who is going to operate, own, perform maintenance, service, or
order parts for a Taylor-Dunn®vehicle. Each person should be familiar with the parts of this manual that
apply to them.
Responsibilities
OftheOwner...
The owner of this or any Taylor-Dunn®vehicle is responsible for the training of
operators, overall maintenance, and repairs of the vehicle. Owners should keep
a record of conducted training and services or repairs performed on the vehicle.
(OSHA Regulation, 29 CFR (Code of Federal Regulations) 1910.178 Powered
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 problems to service
and repair personnel.
Ofthe Service Personnel...
The service personnel are responsible for the service and maintenance of the
vehicle,from lubricationto repair ofdamaged or wornparts. At notime should
a service person allow any untrained personnel to service or repair this or any
vehicle. For the purposes of training, a qualified service person may oversee
the repairs or services being made to a vehicle by an individual in training. At
no time should an untrained individual be allowed to service or repair a vehicle
without supervision. This manual is not a training guide.

3
How To Use This Manual
This manual is organized into four main sections:
nSection 1: “Safety Rules and Operational Information,” outlines the safety issues and
operational issues of the vehicle. Including the location and operation of controls, the
operational checks that are to be performed, and various subjects that should be included
in any operator and service training programs implemented by the owner.
nSection 2: “Maintenance and Repair,” gives specific information on the maintenance
and repair of the vehicle and a schedule for maintenance checks.
nSection 3: “Electrical and Charger Troubleshooting,” gives the troubleshooting
procedures for testing the electrical system and battery charger.
nSection 4: “ Parts,” gives an illustrated view of various assemblies and a table listing the
part numbers and quantities needed.
On the next page you will find a list of conventions that are used throughout this manual. (Conven-
tions are symbols and/or words that are used to define warnings, cautions or notes.)

4
INTRODUCTION
Conventions
Throughout this manual you will find the following notations:
NOTE 1: Alerts you to additional information about a subject. A number
immediatly after the word note is included for reference within each
subject.
The symbol at the left and the bold text contained
withinabox denotesacaution andisused toinform
you that property damage may occur. Be sure to
exercise special care and follow any instructions
containedwithinacaution.
A shaded box with the word “Warning” on its left
denotesawarning.A warningalertsyouof ahazard
thatmaycause injurytoyourself orothers.Besure
tofollowanyinstructionscontainedwithinawarning
andexerciseextremecarewhileperformingthetask.

Vehicle Description and Specifications
Describes the Vehicle and Its Standard Specifications

1-2
SECTION 1
Vehicle Description
This manual applies to vehicles with the same model and serial numbers listed on the front
cover.
This vehicle is designed for driving on smooth surfaces in and around industrial plants,
nurseries, institutions, motels, mobile home parks, and resorts. It is not to be driven on public
highways.
The maximum operating speed of this vehicle is the speed that the vehicle may travel on a
level surface with no load. Exceeding this speed, while traveling down an incline or on a level
surface, may result in steering difficulty, motor damage, and/or loss of control of the vehicle
that may result in injury and/or property damage. 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
Section1910.178 (Powered Industrial Trucks)andwith all applicableportionsof the American
National Standard for Personnel and Burden Carriers (ANSI B56.8), in effect at the time of
manufacturing.
The model and serial number for this vehicle are imprinted on a decal located on the inner left
side of the front cowl. The vehicle serial number is stamped in the frame, under the drivers
seat to the right of the safety interlock switch on the MX-600, on the frame tube to the left of
the motor on the SS5-34, and on the left frame rail under the seat on the SS5-36 and SS5-46.
Taylor-Dunn Mfg. Standard Model SS5-34 shown. This is one of the
vehicles described and covered by this manual.

1-3
Standard Specifications
ITEM SPECIFICATION
Length Width Height
Standard Dimension (SS5-34) 194.3 x 72.4 x 106.7 cm
76.5 x 28.5 x 42 in
(MX-600) 217.4 x 81.3 x 104.1 cm
86 x 32 x 41 in
(SS5-36) 219.7 x 76.2 x 104.1 cm
86.5 x 30 x 41 in
(SS5-46) 226.1 x 76.2 x 104.1 cm
89 x 30 x 41 in
Bed Size (MX-600) 68.6L X 76.2W cm (27L X 30W in)
(SS5-34) 59.7L X 69.9W cm (23.5L X 27.5W in)
(SS5-36, 5-46) 49.5L X 73.7 cm (19L X 30W in)
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 (SS5-36, 5-46, MX-600) 2-Wheel Rear Drum (Mechanical Standard)
(SS5-34) Drive Line Brake Band
Motor 24 Volts, 4.5 hp @ 935 rpm
Tires 4.80 X 8 Load Range B Pnuematic
Tire Presure 50 psi max.
Maximum Load (MX-600, SS5-36, 5-34) 272 kg (600 lbs.)
(On Level Surface) (SS5-34) 227 kg (500 lbs)
Battery Four 217 AH, 6 Volt
Charger 120V, 12Amp, 60hZ AC Input
24V, 25Amp DC Output
Gradeability 15% (Empty)
5% (Loaded)
Maximum Speed (Empty) 16 kmh (10 mph)

1-4
SECTION 1
Taking Delivery of Your Vehicle
You should inspect your vehicle immediately after delivery. Use the following guidelines
to inspect your vehicle for obvious problems:
nExamine the contents of all packages and accessories that may have come in
separate packages with the vehicle.
nMake sure everything listed on the packing slip is there.
nInspect all components of the packages for signs of damage.
nExamine all visible wires and the vehicle for obvious signs of damage.
nCheck that all wire connections, battery cables, etc., are secure.
nCheck battery cells to be sure they are filled.
nCheck the tire pressure, tightness of lug nuts and for signs of obvious
damage or wear.
nCheck the operation of each of the following controls. They should operate
smoothly without sticking or requiring undue 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 is a problem with the vehicle or any of the accessories that may have been
shipped with the vehicle, file a claim with the carrier immediately. The claim must be filed
within 48 hours of receiving the vehicle and the accessories. Forward a copy of the claim
to your local Taylor-Dunn dealer.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-
Dunn vehicle is a factory authorized service technician. All other personnel are expressly
prohibited from working on, repairing, adjusting, or modifying any part of this or any
Taylor-Dunn vehicle.
Do not attempt to modify or repair any part of this
vehicleunlessyou areauthorizedto doso.Incorrect
repairs may result in injury to yourself or others.
Incorrector unauthorized repairswill resultin the
invalidationofyourwarranty.

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

2-2
SECTION 2
Safety Rules and Guidelines
Responsibilities
It is the responsibility of the owner to ensure that the operator understands the various
controls and safety operations of this vehicle, as well as, obeying the following safety rules
andguidelines:
Thisvehiclemayoverturnif turnedsharplywhiledriving
at high speeds on inclines or level surfaces.
Thisvehicle was notdesigned to bedriven on public
highways.Thesize,speed,andmaneuverabilityofthis
vehiclewouldcauseaserioustraffichazardonapublic
highway.Driving thisvehicleon publichighwayscan
result in serious injury or even death.

2-3
Safety Rules
This vehicle is designed to be driven over smooth surfaces in and around places such as
warehouses, nurseries, motels, parks, and resorts. Operators should read the safety rules,
and guidelines below before operating this vehicle:
nDo not drive this vehicle unless you are a qualified operator.
nKeep all body parts inside the vehicle at all times.
nDrive slowly when making turns, especially if the ground is wet, slippery, or
when driving on an incline.
nDrive only on level surfaces or on inclines of no more than 10% (5.6
degrees).
nDo not drive over loose objects, holes, or bumps.
nObserve all traffic regulations and speed limits.
nMaintain a safe distance from all objects.
nKeep the vehicle under control at all times.
nYield the right of way to pedestrians and all emergency vehicles.
nDo not overtake or attempt to pass another vehicle at intersections, blind
spots, or other dangerous locations.
nKeep a clear view ahead at all times.

2-4
SECTION 2
Driver Training Program Guidelines
The owner of this vehicle is responsible for conducting an “Operator Training Program” for
all those personnel that will be operating this vehicle. The program should not be condensed
for those claiming to have previous vehicle operation experience.
NOTE: Successful completion of the “Operator Training Program” should be
required for all personnel that will operate this vehicle.
The “Operator Training Program” should include the following:
nOperation of the vehicle under normal circumstances. (Associated with your
particularenvironment.)
nHow to safely operate the vehicle.
nHow to safely transport cargo and personnel.
nAll safety rules contained in this manual.
nProper operation of vehicle controls.
nOperator maintenance checks.
nA test on the operators ability to identify and operate the controls installed on
this vehicle.
nA driving test.
Driver Qualifications
Who is Qualified to Drive?
Aqualified driveris a person who hassuccessfully completedthe owners “OperatorTraining
Program” and has shown through testing to posses the visual, auditory, physical, and
mental abilities to safely operate this vehicle.
Minimum Requirements
The following are the minimum requirements necessary to qualify as an operator of this
vehicle:
nDemonstrate a working knowledge of each control
nUnderstand all safety rules and guidelines as presented in this manual
nKnow how to load and unload cargo
nKnow how to properly park this vehicle
nDemonstrate the ability to handle this vehicle in all conditions