Taylor-Dunn SS5-46 Manuals

Manuals and User Guides for Taylor-Dunn SS5-46. We have 3 Taylor-Dunn SS5-46 manuals available for free PDF download: Operation, Troubleshooting Manual, Operation, Maintenance, And Replacement Parts Manual, Service And Parts Manual

Taylor-Dunn SS5-46 Operation, Maintenance, And Replacement Parts Manual (192 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 13.78 MB

Taylor-Dunn

5
Table of Contents

13
- Standard Specifications
  
  14
- Safety Rules and Guidelines
  
  15
- Driver Training Program
  
  15
- Vehicle Controls
  
  16
  - Horn Switch
    16
  - Start Switch
    16
  - Headlight Switch
    16
  - Battery Status Gauge
    16
  - Strobe Light Switch (Optional)
    16
  - Forward/Off/Reverse Switch
    16
  - Hour Meter (Optional)
    16
  - Charger Connector (MX-600 Only)
    16
  - Power Light (SS Only)
    16
  - Seat Adjustments
    17
  - Charger Interlock
    17
  - Accelerator Pedal
    17
  - Foot Brake Pedal
    17
  - Park Brake, Foot Operated
    17
  - Steering
    17
  - Driver Seat Interlock (SS-536, SS-546, MX-600)
    18
  - Battery Status Indicator, Digital Bargraph (Optional)
    18
  - Battery Status Indicator, Analog
    18
  - Safety Guidelines
    19
  - Starting
    19
- Vehicle Operational Guidelines
  
  19
  - While Driving
    19
  - Changing Directions
    19
  - Towing Loads
    19
  - Parking
    20
- Charging Your Vehicle
  
  21
  - Charger Interlock
    21
  - New Battery Break in
    21
  - Charging Time
    21
  - Signet Charger Operation (Model HBS)
    22
- Storing / Returning to Service
  
  23
  - Storing Your Vehicle
    23
  - Returning to Service
    23
- Periodic Maintenance Checklist, SS-534
  
  24
- Ss-536, 546, MX-600
  
  26
- Severe Duty Applications
  
  26
- Maintenance Guidelines for
  
  26
  - Daily Visual Inspection
    26
Table of Contents

27
- Maintenance Guidelines
  28
- Troubleshooting Guide
  29
- Lubrication and Fluids Chart
  30
- Lubrication Diagram
  31
Table of Contents

33
- Adjust Front Wheel Bearings (3-Wheel)
  34
- Adjust Front Wheel Bearings (4-Wheel)
  34
- Inspect the Front Wheel Bearings
  34
- Front Axle Removal and Installation (3-Wheel)
  36
- Removal
  36
  - Installation
    36
- Front Axle Removal and Installation (4-Wheel)
  37
  - Removal
    37
  - Installation
    37
- Replace Front Wheel Bearings
  37
- Hardware Torque
  38
Maintenance, Service, and Repair Hardware Torque

39
- Front End Alignment, SS-546
  41
  - Inspection
    41
  - Replacing
    41
- Fork / Steering Shaft Bearings
  42
- Replace the Steering Wheel
  42
- Replace the Steering Gear
  43
- Hardware Torque
  44
- Replace the Front Fork
  44
Table of Contents

45
- Auto-Adjust Brake Mechanism Theory of Operation
  
  46
- Inspect the Service Brake
  
  47
  - Brake Shoes
    48
  - Brake Drum
    48
  - Adjust the Brakes
    49
  - Adjust the Parking Brake
    49
- Replace Brake Shoes
  
  50
- Hardware Torque
  
  51
Table of Contents

53
- Adjust the Parking Brake
  54
- Inspect the Parking Brake
  54
- Inspect the Service Brake
  54
  - Brake Shoes
    54
  - Brake Drum
    54
- Adjust the Brake Band
  55
- Adjust the Brake Linkage
  55
- Replace Brake Band
  56
- Replace Brake Drum
  56
Maintenance, Service, and Repair Hardware Torque

58
- Inspection
  59
  - Field / Armature Windings (DC Motors)
    59
  - Commutator
    60
  - Brushes
    60
  - Bearings
    60
  - Thermal Sensor
    60
- Removal
  59
- Motor Service Limits and Specifications
  61
Table of Contents

63
- Check Oil Level
  
  64
- Change Oil
  
  64
- Transaxle Assembly
  
  65
  - Remove
    65
  - Install
    65
- Axles
  
  66
  - Remove
    66
  - Install
    66
- Axle Bearings
  
  66
  - Remove/Install
    66
- Motor
  
  67
  - Remove
    67
  - Install
    67
- Differential Case
  
  68
  - Disassemble
    68
  - Assemble
    70
- Hardware Torque
  
  71
Table of Contents

73
- Adjust the Drive Belts
  74
- Change the Oil
  74
- Check the Oil Level
  74
- Transaxle Assembly
  75
  - Remove
    75
  - Install
    75
- Axle Bearings
  76
  - Replace the Axle Bearing
    76
- Axles
  76
  - Remove and Install
    76
- Differential Assembly (3Rd Member)
  77
  - Disassemble
    77
  - Assemble
    78
- Re-Shimming the Pinion Housing
  80
- Exploded View
  81
- Hardware Torque
  82
Table of Contents

83
- Tire Inflation
  84
- Tire Inspection
  84
- Hardware Torque
  85
  - Front Axle Service
    85
- Tire/Wheel Assembly
  85
  - Remove/Install-Rear
    85
  - Remove/Install-Front
    85
Table of Contents

87
- Cleaning
  88
- Testing
  89
- Watering
  90
- Charging
  91
- Storing
  91
  - Storage
    91
  - Returning to Service
    91
- Remove/Install
  92
  - Industrial Battery or Lift out Battery Pack
    92
  - Individual Batteries
    93
- Hardware Torque
  93
Table of Contents

95
- Symptoms
  
  96
- Read this First
  
  97
  - Test Equipment Required
    97
  - IMPORTANT NOTES and INSTRUCTIONS
    97
  - Definitions
    98
  - Wire Diagram
    105
- Symptom Troubleshooting Guide
  
  113
  - Pmc Control
    113
  - Plugging Diode
    113
  - Freewheel Diode
    113
  - Iso
    113
  - Solenoids
    113
  - Motor
    113
Industrial Chargers

125
- Testing the Interlock Relay
  
  126
  - Operation
    126
  - Testing
    126
- Replacing the Charger
  
  126
- Lestronic II Charger
  
  127
- Lester X-Series Charger
  
  131
  - Test Equipment Required for Troubleshooting
    131
  - Important Notes and Instructions
    131
  - Theory of Operation
    131
  - Fault and Diagnostic Error Code Table
    132
  - Internal Wiring Diagram
    132
  - Testing the Charging Cycle
    133
    
    Troubleshooting
    134
    
    SCR Assembly
    134
    
    Transformer
    135
    
    Lock out Relay
    135
    
    Relay Board Assembly
    136
    
    Control Board Assembly
    137
    
    Profile Setting
    137
- Signet HBS Charger
  
  138
  - Test Equipment Required for Troubleshooting
    138
  - Important Notes and Instructions
    138
    
    Definitions
    138
  - Operating Instructions and Theory of Operation
    139
  - Testing the Charging Cycle
    140
  - Status Light Error Code Table
    141
  - Troubleshooting
    142
- Signet HB Charger
  
  143
  - Operating Instructions and Theory of Operation
    143
  - Charge Status Lights
    143
  - HB/PT and GEL Indicator Lamps
    144
    
    GEL Lamp
    144
  - Testing the Charging Cycle
    144
  - Status LED Error Code Table
    145
- Troubleshooting
  
  146
  - Test Equipment Required for Troubleshooting
    146
  - Important Notes and Instructions
    146
  - Test Charger Operation
    146
  - Charger Does Not Turn on
    146
Illustrated Parts

149
- Identifying Your Vehicle
  150
- Axle Assembly, Front (SS-534, SS-536, MX-600)
  151
- Axle Assembly and Steering, Front SS-546
  153
- Axle Assembly, Rear Axles
  156
- Axle Assembly, Transaxle
  158
- Batteries
  160
- Brakes, Rear Axle
  165
- Brakes, Rear Axle, SS-534
  165
- Charger, Lestronic and Signet
  166
- Charger, Lester X-Series
  168
- Decals
  171
- Electrical, Miscellaneous
  172
- Frame and Body, Deckboards
  172
- Frame and Body, Seat Cushions
  172
- Frame and Body, Misc Body Trim
  173
- Frame and Body, Toolbox, MX-600
  173
- Lights, Headlights
  174
- Lights, Taillights, Strobelight
  174
- Motor
  176
- Steering Linkage, Tiller
  178
- Steering Linkage, Geared, SS-534
  179
- Steering Linkage, Geared
  180
- Suspension, Rear, SS-534
  183
- Wheels and Tires
  184
  - Brake Lining Handling Precautions
    185
- Appendix A: Special Tools
  
  186
- Appendix B: Suggested Torque Limits for Standard Hardware
  
  188
  - Standard Head Markings
    188
  - Hex Bolts
    188
  - Other Bolts
    188
  - Hex Nuts
    189
  - Hex Lock Nuts (Stover)
    189
  - Other Nuts
    189
- Appendix C: Brake Lining Handling Precautions
  
  192

Taylor-Dunn SS5-46 Operation, Troubleshooting Manual (200 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 33.09 MB

Table of Contents
5
Introduction
9
- Who Should Read this Manual
  10
- Responsibilities
  10
- How to Use this Manual
  11
- Conventions
  12
Vehicle Description and Specifications

13
- Vehicle Description
  14
Safety Rules and Operational Information

17
- Safety Rules and Guidelines
  18
  - Responsibilities
    18
    
    Safety Rules
    19
    
    Driver Qualifications
    20
    
    Driver Training Program Guidelines
    20
    
    Minimum Requirements
    20
    
    Who Is Qualified to Drive
    20
  - Vehicle Controls
    21
    
    Foot Brake Pedal
    22
    
    Horn Button
    22
    
    Park Brake
    22
  - Guidlines for Vehicle Operation
    23
    
    Driving
    23
    
    Loading and Unloading
    23
    
    Parking
    23
    
    Towing
    24
Maintenance and Service Procedures

25
Front Fork and Steering

44
Rear Axle and Drive Assembly

54
Motor

71
- SS5-36/SS5-46/MX-600 Motor Removal
  71
- SS5-34 Motor Removal
  72
- Brushes
  72
  - Installing New Brushes
    73
- Motor Disassembly
  73
- Inspecting the Armature
  74
Battery

75
- Cleaning
  75
- Servicing the Batteries
  76
- Charging
  76
- Battery Storage
  76
- Battery Configuration
  77
SECTION 4-Electrical Troubleshooting

79
- Test Equipment Required
  
  81
- IMPORTANT NOTES and INSTRUCTIONS
  
  81
- Definitions
  
  82
Section 4A-Vehicle Wire Diagrams

102
Section 4-Special Troubleshooting Guide

105
- Pmc Control
  
  106
- Plugging Diode
  
  108
- Freewheel Diode
  
  109
- Iso
  
  110
- Solenoids
  
  112
- Motor
  
  115
- Operating Instructions and Theory of Operation
  
  118
- Testing the Charging Cycle
  
  129
- Test Equipment Required for Troubleshooting
  
  130
- Important Notes and Instructions
  
  130
- Status LED Error Code
  
  131
- Troubleshooting
  
  132
Illustrated Parts List

133
- Identifying Your Vehicle
  134
- Brake Pedal Linkage and Accelerator Pedal (Ss5-34)
  136
- Brake Pedal Linkage (Ss5-36, Ss5-46 and MX-600)
  138
- Front Axle, Wheel and Suspension
  140
- Front Axle, Wheel and Steering Ss5-46
  142
- Tiller Steering
  144
- Geared Steering (Ss5-34)
  146
- Geared Steering (Ss5-36, Ss5-46 and MX-600)
  148
- Instrument Panel (Ss5-34, Ss5-46 and Ss5-36)
  150
- Controls and Instruments (MX-600)
  152
- Motor Ss5-34
  154
- Motor Ss5-36, Ss5-46 & MX-600
  156
- Rear Axle (Ss5-34)
  158
- Rear Axle (Ss5-36, Ss5-46 and MX-600)
  160
- Differential (Ss5-34)
  162
- Differential (Ss5-36, Ss5-46 and MX-600)
  164
- Ss5-36, Ss5-46 Differential Frame
  166
- Deck and Vise Assy (MX-600)
  168
- Toolbox Assy (MX-600)
  170
- Battery
  172
- Brake Assy (Ss5-34)
  174
- Rear Brake (Ss5-36, Ss5-46 and MX-600)
  176
- Pmc Control Panel
  178
- Battery Charger
  180
- Seat Cushions
  184
- Decals
  186
- Mirrors Option
  188
- Strobe and Stop Light Option
  190
- Headlight
  192
- Signet Charger
  196

Taylor-Dunn SS5-46 Service And Parts Manual (134 pages)

Brand: Taylor-Dunn | Category: Electric Vehicles | Size: 5.57 MB

Master

5
- Table of Contents
  5
- About this Manual
  8
- How to Use this Manual
  8
- Introduction
  8
- Who Should Read this Manual
  8
- Introduction
  9
  - Conventions
    9
  - Signal Words and Their Definitions
    9
- Responsibilities
  10
- How to Identify Your Vehicle
  11
- Web Site Registration
  11
Table of Contents

13
- READ ME FIRST-Maintenance Guidelines and General Instructions
  14
  - Service/Maintenance Guidelines
    15
- Service/Maintenance Guidelines
  14
- Vehicle Modifications
  15
- Replacement Parts
  16
  - Using Non-OEM Replacement Components
    16
- PM Checklist, SS-536, SS546, MX-600
  17
- PM Checklist, SS-534
  18
  - Tool List
    20
  - Lubrication
    25
Section 3

27
Section 4

31
- Front Axle
  32
- Inspect Front Wheel Bearings (3-Wheel)
  32
- Inspect Front Wheel Bearings (4-Wheel)
  32
- Adjust Front Wheel Bearings (3-Wheel)
  33
- Adjust Front Wheel Bearings (4-Wheel)
  33
- Front Axle
  34
- Replace Front Wheel Bearings (3-Wheel)
  34
- Replace Front Wheel Bearings (4-Wheel)
  34
- Axle Assembly, Remove/Install (4-Wheel)
  35
  - Remove
    35
  - Installation
    35
- Axle Shaft, Remove/Install (3-Wheel)
  35
- Hardware Torque
  36
Section 5

37
- Inspect Rod Ends
  38
- Replace Rod End
  38
- Front End Alignment
  39
- Front End Alignment, SS-546
  39
- Replace Steering Tiller
  40
- Replace Steering Wheel
  40
- Replace Steering Gear
  41
- Replace Steering Gear, SS-534
  41
- Front Fork
  43
- Installation
  43
- Hardware Torque
  44
Section 6

45
- Change Oil
  46
- Check Oil Level
  46
- Drive Axle-D1
  46
- Axle Bearings
  47
  - Remove/Install
    47
- Axle Shaft
  47
  - Remove
    47
  - Install
    47
- Drive Axle-D1
  47
- Drive Motor
  48
  - Remove
    48
  - Install
    48
- Differential Case
  49
  - Disassemble
    49
  - Assemble
    51
- Hardware Torque
  52
Section 7

53
- General Guidelines and Safety
  
  54
- Rear Drum Brake
  
  55
  - Auto-Adjust Brake Mechanism
    55
  - Inspecting the Auto-Adjust Brake Mechanism
    55
  - Service Limits
    56
  - Inspection
    56
  - Replace Shoes
    56
- Rebuild Disc Brake Body
  
  57
- Brake Adjustment
  
  58
  - Service Brake
    58
  - Adjust the Service Brake Linkage
    58
  - Parking Brake
    58
- Service Limits
  
  58
Section 8

59
- Disassemble
  60
- Drive Motor
  60
- Motor Removal and Installation
  60
- Assemble
  61
- Drive Motor
  61
- Inspection
  62
  - Brushes
    62
  - Armature
    62
  - Bearings
    63
  - Commutator
    63
- Repair
  64
  - Brushes
    64
  - Commutator
    64
- Service Limits
  65
- Motor Controller
  69
Section 9

73
- Air Pressure
  74
- Inflation
  74
- Tires & Wheels
  74
- Rotation
  75
- Tread Wear
  75
- Changing Tire/Wheel Assembly
  76
- Repair the Tire (Pneumatic)
  76
- Replace the Tire (Pneumatic)
  76
- Hardware Torque
  77
Section 10

79
- General Guidelines and Safety
  80
- Charging
  81
- Cleaning
  81
- Watering
  81
- Storing
  82
  - Storage
    82
  - Returning to Service
    82
- Testing
  82
  - Specific Gravity
    82
- Remove/Install
  83
  - Industrial Battery or Lift out Battery Pack
    83
  - Individual Batteries
    83
- Hardware Torque
  84
Section 11

91
- Torque Guidelines for Standard Hardware
  
  92
  - Hardware Identification
    92
  - Hex Nuts
    93
  - Hex Lock Nuts (Stover)
    93
  - Other Nuts
    93
  - Generic Torque Values
    94
- Replacing Hardware
  
  96
Replacement Parts

97
- Ordering Parts for Your Vehicle
  98
- Replacement Parts
  98
- Taylor-Dunn Web Site Information
  98
  - Replacement Parts
    99
  - Identifying Your Vehicle
    99
- Axle Assembly, Front
  100
- Axle Shaft Assembly, Rear
  102
- Axle Assembly, Rear 3Rd Member, SS-534
  104
- Axle Assembly, Belt Drive, SS-534
  105
- Mx600
  106
- Transaxle Assembly, Ss-536, Ss-346, Mx600
  106
- Battery
  108
- Brakes, Linkage SS-534
  109
- Brakes, Linkage SS-536, SS-546, MX-600
  110
- Brakes, SS-534
  111
- Brakes, SS-536, 546, MX-600
  112
- Charger, Signet
  113
- Control System, Motor Speed Control
  115
- Control System, Instrument Panel
  116
- Decals
  117
- Electrical, Miscellaneous
  118
- Frame and Body, Deckboards
  119
- Frame and Body, Misc Body Trim
  119
- Frame and Body, Toolbox, MX-600
  120
- Hitches
  121
- Lights
  122
- Motor
  123
- Motor Mount
  124
- Seats
  125
- Steering, Tiller
  126
- Steering, Gear SS-534
  127
- Steering, Gear SS-536, SS-546, MX-600
  128
- Suspension, Rear, SS-536, SS-546
  129
- Suspension, Rear, SS-534
  130
- Wheels and Tires
  131

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More Taylor-Dunn Manuals

Taylor-Dunn SS5-46 Manuals

Taylor-Dunn SS5-46 Operation, Maintenance, And Replacement Parts Manual (192 pages)

Table of Contents

Taylor-Dunn

Table of Contents

Standard Specifications

Safety Rules and Guidelines

Driver Training Program

Vehicle Controls

Vehicle Operational Guidelines

Charging Your Vehicle

Storing / Returning to Service

Periodic Maintenance Checklist, SS-534

Ss-536, 546, MX-600

Severe Duty Applications

Maintenance Guidelines for

Table of Contents

Table of Contents

Maintenance, Service, and Repair Hardware Torque

Table of Contents

Auto-Adjust Brake Mechanism Theory of Operation

Inspect the Service Brake

Replace Brake Shoes

Hardware Torque

Table of Contents

Maintenance, Service, and Repair Hardware Torque

Table of Contents

Check Oil Level

Change Oil

Transaxle Assembly

Axles

Axle Bearings

Motor

Differential Case

Hardware Torque

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Symptoms

Read this First

Symptom Troubleshooting Guide

Industrial Chargers

Testing the Interlock Relay

Replacing the Charger

Lestronic II Charger

Lester X-Series Charger

Signet HBS Charger

Signet HB Charger

Troubleshooting

Illustrated Parts

Appendix A: Special Tools

Appendix B: Suggested Torque Limits for Standard Hardware

Appendix C: Brake Lining Handling Precautions

Taylor-Dunn SS5-46 Operation, Troubleshooting Manual (200 pages)

Table of Contents

Vehicle Description and Specifications

Safety Rules and Operational Information

Maintenance and Service Procedures

Lubrication

Trouble Shooting Guide

Front Fork and Steering

Rear Axle and Drive Assembly

Motor

Battery

SECTION 4-Electrical Troubleshooting

Test Equipment Required

IMPORTANT NOTES and INSTRUCTIONS

Definitions

Section 4A-Vehicle Wire Diagrams

Section 4-Special Troubleshooting Guide

Pmc Control

Plugging Diode

Freewheel Diode

Iso

Solenoids

Motor

Operating Instructions and Theory of Operation

Testing the Charging Cycle

Test Equipment Required for Troubleshooting