Service and Replacement Parts Manual: Warning

Service and Replacement
®
Parts Manual
TAYLOR-DUNN
MANUAL MS-534-13
Model Numbers:
SS-025-34
SS-025-36
SS-025-46
MX-026-00
The Best Way

To Go
About Your
Business
WARNING
READ THE OPERATOR’S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator’s manual contains important information
regarding the safe operation of this vehicle.
Starting Serial Number: 201627
Ending Serial Number: See Introduction Chapter
D
My Vehicle information
Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
Your satisfaction is out #1 goal. If you have questions or concerns

with your vehicle, please contact your sales Representative or
Service Advisor at your local dealership.
Taylor-Dunn has a worldwide dealer and distribution network to
provide replacement parts and service for our vehicles.
Refer to our web site, www.taylor-dunn.com, for a dealer lookup
application.
Originally 3/31/2016
Revision D, 7/13/2018, contents subject to change without notice
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com

Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support
our vehicles. Information regarding vehicle sales, replacement parts, or service
should be obtained through your local dealer. A dealer locator can be found on
the Taylor-Dunn website at www.taylor-dunn.com.
If you do not have access to the internet, you can call the factory direct at:
01 (714) 956-4040
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804
The Taylor-Dunn Corporation:
Leading Provider of Commercial & Industrial Vehicles since 1949
Taylor-Dunn Manufacturing:
From the day we shipped our first vehicle in 1949, we have pursued a singular goal: to build tough, rugged, dependable vehicles to help
our customers move personnel, equipment, and materials. It’s that simple. For over sixty years, our standard and custom vehicles - Burden
Carriers, Personnel Carriers, Stock Chasers, Electric Carts, Tow Tractors & more - have been the leading solution for customers in a
broad range of industrial, commercial, and ground-support markets.
Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application-
specific solutions, which are reliable, efficient, and economical.
Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving.
Tiger Tractor:
Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment. With
tractor capacities ranging from 3,000 - 12,000 pounds drawbar pull, they are ideal for industrial applications as well as aircraft ground
support. As with all Taylor-Dunn vehicles; quality, service, support and reliability are built into all Tiger Tractor products.
Shown below is just a small sample of what Taylor-Dunn has to offer to keep your business moving:
Note: Each section title page contains Master Table of Contents
a section table of contents Introduction.......................................................7
Service/Maintenance Guidelines....................13
Special Tool List...............................................19
Tool List....................................................................20
Lubrication........................................................23
Preventative Maintenance...............................27
Front Axle..........................................................31
Steering.............................................................37
Drive Axle-D1....................................................45
Brakes...............................................................53
Drive Motor........................................................59
Motor Controller...............................................67
Charger..............................................................71
Tires & Wheels..................................................73
Batteries............................................................79
Suspension.......................................................85
Wire Diagram....................................................89
Hardware Information......................................91
Replacement Parts...........................................97
Introduction
Table of Contents
Introduction
About this manual............................................8
Who Should Read This Manual.......................8
How To Use This Manual.................................8
Conventions.............................................................9
Signal Words and Their Definitions:.........................9
Responsibilities................................................10
How to Identify Your Vehicle...........................11
Web Site Registration......................................11
WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
Introduction
SS and MX Models, DC System
ABOUT THIS MANUAL
The purchase of this vehicle shows a belief in
high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden
and personnel carriers since 1949, wants to be sure
this vehicle provides years of reliable service. Please
continue to read this manual and enjoy this high quality
Taylor-Dunn® vehicle.
This manual is to serve as a guide for the service,
repair, and operation of Taylor-Dunn® vehicles 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 this vehicle.
Taylor-Dunn is not to be held liable for errors in this
manual or any consequential damage that results from
the use of this manual.
Before servicing, operating, training or performing
maintenance on this or any other Taylor-Dunn® vehicle,
read the appropriate Taylor-Dunn® manual.
Each Taylor-Dunn® manual references the applicable
models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions,
and notes contained in this manual.
WHO SHOULD READ THIS MANUAL

This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn® vehicle. Each person
shall be familiar with the parts of this manual that apply
to their use of this vehicle.
HOW TO USE THIS MANUAL

This manual is organized into these main sections:
Introduction
This section describes how to use this service manual
and how to identify your vehicle.
Maintenance, Service, and Repair
This section gives specific information on the servicing
of the vehicle and a schedule for maintenance checks.
This manual is for mechanical repairs only and does
not include electrical diagnosis procedures. Electrical
diagnosis procedures are included in a separate manual.
Replacement Parts
This section provides an illustrated view of various
assemblies. The illustrations are accompanied by tables
identifying the parts.
Page-8 MS-534-13
Introduction
Conventions
Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual.
The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be
used elsewhere in the text of this document without being a signal word. When used as a signal word, the signal
word will be enclosed in a solid rectangle with white background (example below).
Signal Words and Their Definitions:
DANGER: This signal word will be accompanied by the safety alert symbol (see below). “DANGER” will indicate
a hazard that, if not avoided, WILL result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
WARNING: This signal word will be accompanied by the safety alert symbol (see below). “WARNING” will indicate
a hazard that, if not avoided, may result in death or serious bodily injury to yourself, the operator or
passengers of the vehicle, or people in the immediate area of the vehicle.
CAUTION: This signal word will be accompanied by the safety alert symbol (see below). “CAUTION” will indicate a
hazard that, if not avoided, may result in minor or moderate injury to yourself, the operator or passengers
of the vehicle, or people in the immediate area of the vehicle.
NOTICE: This signal word will not be accompanied by the safety alert symbol. “NOTICE” will indicate a condition
that if not avoided may result in property damage. “Property” is defined as the vehicle, components in
the vehicle and/or the surrounding area such as buildings, other vehicles, etc.
Safety Messages
Important information notifying you of any conditions that WARNING
may result in hazards to yourself, persons nearby, and/
or hazards to the vehicle will be presented in a text box This is an example of a safety alert message. This
with a black border and may include a signal word (see message will contain information about a hazard and/
above). To the right is an example of a safety message. or instructions on avoiding a hazard. The actual size
and location of this warning box may vary.
The safety message may include additional warning
icons representing the type of hazard. The following
is a list of these icons and what they represent. These
icons may also be included on the various warning and
information decals applied to the vehicle.
Some of the decals applied to the
vehicle will have icons representing their
function. The icons and their definitions
Safety alert symbol (see are listed below:
above).
Read the operators manual.
Represents a high voltage
hazard. Read the maintenance manual.
Represents an explosion
Keep arms and legs inside the
hazard.
vehicle.
Represents a corrosive Parking brake ON.

chemical hazard.
Parking brake OFF.
Represents a fire hazard.
Do not get wet.
Represents a poisonous
chemical hazard. Do not spray wash.
MS-534-13 Page-9
Introduction
RESPONSIBILITIES Of the Operator...
A vehicle shall not be operated until the operator has
Of the Owner... successfully completed an operator training course
The owner of this or any Taylor-Dunn vehicle is provided by the owner of the vehicle.
responsible for the overall maintenance and repairs The operator is responsible to be sure that the vehicle
of the vehicle, as well as the training of operators. is operated only on authorized roads, highways, and
The owner is also responsible for operator training per installations.
the following federal regulations: The operator is responsible to confirm that all
• ANSI/ITSDF 56.8-2006 Personnel and Burden passengers are properly seated and properly using
Carriers: Part II, Paragraph 6.2a. the available restraints.
• ANSI/ITSDF 56.9 – 2007 Safety Standard for
Operator Controlled Industrial Tow Tractors: Part The operator is responsible for the safe operation of
II, paragraph 4.11. the vehicle, preoperational and operational checks
• Code of Federal Regulations (CFR) Title 29, on the vehicle, and the reporting of any problems to
Subtitle B, Chapter Xvii OSHA, Part 1910.178 service and repair personnel.
Powered Industrial Trucks (2011): 1910.178, Of the Passengers ...
Section (l).
The passengers are responsible to remain fully seated,
Per OSHA Regulation, 29 CFR 1910.178 Powered keeping their hands, arms, and legs inside the vehicle
Industrial Truck Operator Training, the owner must at all times. Each passenger shall be fully aware of
keep a record of conducted training and maintenance the vehicle’s operation. All forms of recklessness are
performed on the vehicle. to be avoided. Do not engage in horseplay.
Of the Service Personnel...
WARNING
The only personnel authorized to repair, modify, or
adjust any part of this or any 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 severe bodily injury and/or
property damage. Unauthorized repairs may also
WARNING
void the vehicles warranty.
The service personnel are responsible for the service

To maintain peak performance, always use original
and maintenance of the vehicle. At no time shall a
Taylor-Dunn replacement parts intended for use
service person allow any untrained personnel to service on your vehicle. Taylor-Dunn components are
or repair this or any Taylor-Dunn® vehicle. For the designed and tested for use on specific Taylor-Dunn
purposes of training, a qualified service person may model vehicles. Only use the correct Taylor-Dunn
oversee the repairs or services being made to a vehicle replacement components for your Taylor-Dunn
by an individual in training. At no time shall an untrained vehicle.
individual be allowed to service or repair a vehicle without Do not modify your vehicle:
supervision. This manual is not a training guide. Modifications to this vehicle may have an undesirable
Personnel performing service and repair shall have affect on the operation of the vehicle, result in
knowledge of: additional frame stress, or stress other components
resulting in premature failure or an unsafe condition
• Basic standard automotive repair procedures
and may lead to an accident resulting in serious injury
• Basic DC and AC electrical theory or death.
• AC motor speed control operation
• Use of digital and analog multi-meters
• Lead acid batteries
Personnel performing maintenance shall have basic
knowledge of standard automotive maintenance
procedures and lead acid batteries.
Page-10 MS-534-13
Introduction
HOW TO IDENTIFY YOUR VEHICLE
This manual is valid only for the

serial numbers listed on the front
cover. If the ending serial number
is blank, then this manual was for
current production vehicles when
printed. If you did not receive this
manual with the vehicle, you should
confirm this manual is valid for your
serial number at the Taylor-Dunn
web site.
The locations of the model and
serial numbers are shown in the
illustrations.
WEB SITE REGISTRATION

Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the
entire Taylor- Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside
of the Taylor-Dunn corporation.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, Troubleshooting, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
MS-534-13 Page-11
Notes:
Introduction
Page-12 MS-534-13
Service/Maintenance
Guidelines
Table of Contents
Service/Maintenance Guidelines
READ ME FIRST-Maintenance Guidelines and
General instructions..................................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
READ ME FIRST-MAINTENANCE GUIDELINES AND GENERAL
INSTRUCTIONS
WARNING
Read and follow all of the guidelines listed below.
Failure to follow these guidelines may result in severe
bodily injury and/or property damage.
• Read the operator’s manual before operating this vehicle.

• Avoid fire hazards and have fire protection equipment present in the work area.
• Conduct vehicle performance checks in an authorized area where safe clearance exists.
• Ventilate the work area properly.
• Regularly inspect and maintain the following systems in a safe working condition: brakes, steering
mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and
safety devices.
• Inspect and maintain battery limit switches, protective devices, electrical conductors, and connections in
conformance with Taylor-Dunn’s® recommended procedures.
• Keep the vehicle in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.
• 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.
• Only properly trained and authorized technicians should perform maintenance or repairs to this vehicle.
WARNING WARNING
The only personnel authorized to repair, modify, or BEFORE STARTING ANY REPAIRS
adjust any part of this or any Taylor-Dunn vehicle is
a factory authorized service technician. Repairs made 1) Make sure the Start switch is in the “OFF” position,
by unauthorized personnel may result in damage to then remove the key.
or improper operation of the vehicles systems which 2) Place the Direction Control switch in the center
could lead to an unsafe condition resulting in severe “OFF” position.
bodily injury and/or property damage. 3) Set the park brake or confirm the brake is set when
Unauthorized repairs may also void the vehicles equipped with an automatic brake.
warranty. 4) Place blocks under the front or rear wheels to
prevent vehicle movement.
WARNING
5) Disconnect the main positive and negative cables
at the batteries.
Periodic maintenance and service must be performed
on this vehicle. Failure to complete these scheduled
maintenance and service procedures can result in
severe bodily injury and/or property damage. It is
WARNING
the owner and/or operators responsibility to ensure When lifting the vehicle, always use a hoist with
that proper service and maintenance is performed on lifting strap, or a jack of adequate capacity. Use jack
the vehicle, described in this manual. stands to support the vehicle before starting any
repairs. Failure to use lifting and support devices of
rated load capacity may result in severe bodily injury.
WARNING
The vehicle may operate at any time while performing
control system test procedures.
WARNING
On a three wheel vehicle: When raising both
All tests must be performed with the drive wheels rear wheels, the front end of the vehicle must be
off of the ground and the vehicle supported with supported to prevent tipping. The rear of the vehicle
jack stands. should be raised by a means so that the left and right
Testing with drive wheels on the ground may result in side are raised equally, such as a hoist with fixed
vehicle movement causing severe bodily injury and/ length chains attached to the left and right side of
or property damage. the vehicle. Failure to properly support the vehicle
may result in the vehicle tipping over causing severe
Page 14 MS-534-13
VEHICLE MODIFICATIONS
Taylor-Dunn vehicles are designed and manufactured in accordance with ANSI/ITSDF and OSHA regulations.
Per ANSI/ITSDF and OHSA, modifications to the vehicle must be approved by the manufacturer. Listed below
are the specific regulations:
ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers
Paragraph 8.2q:
Modifications and additions which affect capacity and safe machine operation shall not be performed by
the customer or user without manufacture’s prior written authorization; where authorized modifications
have been made, the user shall ensure that capacity, operation, warning, and maintenance instructions
plates, tags, or decals are changed accordingly.
Paragraph 8.2r:
Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and
of a quality at least equal to that provided in the original equipment.
ANSI/ITSDF 56.9 – 2007 Safety Standard for Operator Controlled Industrial Tow
Tractors
Paragraph 6.2.14:
Modifications and additions which affect capacity and safe tow tractor operation shall not be performed
without manufacture’s prior written approval. Capacity, operation, and maintenance instructions plates,
tags, or decals are changed accordingly.
Code of Federal Regulations (CFR) Title 29, Subtitle B, Chapter Xvii OSHA, Part
1910.178 Powered Industrial Trucks (2011)
1910.178(a)(4)
Modifications and additions which affect capacity and safe operation shall not be performed by the
customer or user without manufacturers prior written approval. Capacity, operation, and maintenance
instruction plates, tags, or decals shall be changed accordingly.
1910.178(q)(6)
Industrial trucks shall not be altered so that the relative positions of the various parts are different from
what they were when originally received from the manufacturer, nor shall they be altered either by the
addition of extra parts not provided by the manufacturer or by the elimination of any parts, except as
provided in paragraph (q)(12) of this section. Additional counterweighting of fork trucks shall not be done
unless approved by the truck manufacturer.
Motor Speed Control Programming
Taylor-Dunn programmable motor speed controls are WARNING
programmed at the factory for optimum safe, efficient, and
smooth operation of the vehicle. The program settings are Improper programming may cause
based on many factors including but not limited to: Vehicle unexpected operation of the vehicle and/
or damage the electrical components. This
Model, Maximum Safe Speed, System Voltage, Drive Axle
could result in severe bodily injury and/or
Configuration, Vehicle Configuration, etc. property damage
Some of the parameters can be changed in the field Using
PC software or handsets.
Contact the factory for information regarding available alternate program settings.
Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle. Any other
alterations to the programming ARE NOT AUTHORIZED and is at your own risk.
DO NOT interchange program settings from different vehicle models or models with different configurations.
MS-534-13 Page 15
REPLACEMENT PARTS
Using Non-OEM Replacement Components
WARNING
To maintain peak performance, always use original Taylor-Dunn replacement parts intended for use on your
vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only
use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable effect on the operation of the vehicle, result in additional
frame stress, or stress other components resulting in premature failure or an unsafe condition and may lead
to an accident resulting in serious injury or death.
To maintain peak performance, always use original Taylor-Dunn replacement parts intended for use on your vehicle.
Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only use the
correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Electrical Components
Electrical components not tested by Taylor-Dunn (or intended for use on other Taylor-Dunn vehicles) may have
unanticipated interaction and/or interference with the vehicles control system resulting in unsafe vehicle operation
or damage to the electrical system.
Mechanical Components
Mechanical components not tested by Taylor-Dunn (or from other model Taylor-Dunn vehicles) may have an
undesirable affect on the operation of the vehicle, result in additional frame stress, or stress other components
resulting in premature failure or an unsafe condition.
Due to the unknown properties of non-Taylor-Dunn tested components or from components not originally equipped
on the vehicle, we cannot approve their use in a Taylor-Dunn vehicle.
Page 16 MS-534-13
PM CHECKLIST, SS-536, SS546, MX-600
Taylor-Dunn
Preventative Maintenance Schedule for SS-536, SS-546, MX-600
Date: ________________________ Model #: ________________ Hour Meter: _______________
Inspected By: ________________________ Serial #: ________________
Serviced By: ________________________ Unit ID#: ________________
Interval Service Service

Inspected2 Item Description
(hours) 1 Required Complete
Battery electrolyte level
Weekly Tire inflation (pneumatic tires)
Tire tread damage and debris
Inspect all steering linkages and hardware (SS-546)
Inspect and tighten all hardware
(first 100 hours only, then 500 hours and every 500 hours)
Check tire tread wear
100 Wash batteries, battery compartment, and clean terminals
Monthly Clean charger cooling fins
Check all electrical interlocks for proper operation
Inspect for fluid leaks
Clean drive motor exterior
Inspect front fork collar bearings for play and noise
Lubricate the vehicle
Clean and lubricate motor coupler
Inspect and tighten all electrical connections
500 Inspect all wiring for cracks, fraying or wear
3 Months Clean motor control panel
Clean battery compartment
Re-torque wheel nuts
Adjust brakes
Test batteries
Adjust front wheel bearings
Inspect steering king pins for play (SS-546)
Align front end
1000
Rotate tires
6 Months
Inspect suspension bushings
Inspect frame for damage
Inspect rear wheel bearings
Inspect motor brushes and
2000 Blow carbon from motor
Yearly Replace brake pedal/treadle return spring
Inspect brake shoes for wear
4000 Clean and repack front wheel bearings, replace grease seals
2 Years Change rear axle oil
Notes (1) and (2), Refer to “Maintenance Guidelines for Severe Duty” in the vehicles service manual
Form PM-0017, Revision A

3/29/2016
MS-534-13 Page 17
PM CHECKLIST, SS-534
Taylor-Dunn
Preventative Maintenance Schedule for SS-534
Date: ________________________ Model #: ________________ Hour Meter: _______________
Inspected By: ________________________ Serial #: ________________
Serviced By: ________________________ Unit ID#: ________________
Interval Service Service

Inspected2 Item Description
(hours) 1 Required Complete
Battery electrolyte level
Weekly Tire inflation (pneumatic tires)
Tire tread damage and debris
(first 100 hours only, then 500 hours and every 500 hours)
Check tire tread wear
Wash batteries, battery compartment, and clean terminals
100 Clean charger cooling fins
Monthly
Check all electrical interlocks for proper operation
Inspect for fluid leaks
Clean drive motor exterior
Inspect/adjust front fork collar bearings for play and noise
Lubricate the vehicle
Inspect and tighten all electrical connections
Inspect all wiring for cracks, fraying or wear
500
Clean motor control panel
3 Months
Clean battery compartment
Re-torque wheel nuts
Adjust brakes
Test batteries
Adjust front wheel bearings
Align front end
1000 Rotate tires
6 Months Inspect suspension bushings
Inspect frame for damage
Inspect rear wheel bearings
Inspect motor brushes and
2000 Blow carbon from motor
Yearly Replace brake pedal/treadle return spring
Inspect brake shoes for wear
4000 Clean and repack front wheel bearings, replace grease seals
2 Years Change rear axle oil
Notes (1) and (2), Refer to “Maintenance Guidelines for Severe Duty” in the vehicles service manual
Form PM-0017, Revision A

3/29/2016
Page 18 MS-534-13
Special Tool List
Table of Contents
Special Tool List
Tool List.............................................................20
Controller Programming:..........................................20
Troubleshooting Guide....................................22
Tool List
TOOL LIST
The tools shown here are generic for
servicing Taylor-Dunn vehicles. Not all tools
will be required for servicing this vehicle.
62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness

Tests the throttle module in or out of the Used in conjunction with a volt meter to test
vehicle the throttle module. The module must be
installed in a working control system.
Note: Part # 62-027-31 includes instructions
41-532-50: Chain Case Centering Tool 43-201-50: Pinion Seal Installation Tool 62-027-00: Test Light
Used to center the chain case cover on all Used to install the pinion seal on all vehicles Used for testing electrical circuits. Switchable
vehicles equipped with the Power Traction equipped with the Power Traction primary for 12, 24, 36, 48 volt systems.
primary reduction and a pinion brake or speed reduction and a pinion brake or speed
Required to complete troubleshooting
sensor. Includes instructions. sensor.
provided in the vehicle service manuals.
Controller Programming:
Sevcon: 62-027-63 “PCpaK Cable lead and application.”
Curtis AC: 62-027-66 “1314 PC Programming Station”
62-027-61 and -62: Sevcon System Curtis AC System Handset. Diagnostics and
Handset adjustments of the Curtis AC control system.
Diagnostics and adjustments (-62 only) 62-027-67: Diagnostics and adjustments
of the Sevcon Power Pak and Micro Pak
62-027-68: Diagnostics only
control systems.
Page 20 MS-534-13
Tool List
96-500-48: GT Drive Oil Fill Plug Tool

96-500-43: PMT/C Meter Reset Module Used to remove the oil fill plug on GT
Required to reset the PMT/C maintenance drives. It is used with a 3/8” drive extension
meter (special order option). (not included).
77-200-00: Hydrometer 77-201-00: Battery Filler 70-440-55: Pin Removing Tool

Used for testing battery electrolyte. Used to safely add water to batteries. Removes pin from Amp circular harness
Illustration is of a typical hydrometer, actual Equipped with splash guard and auto- connectors.
hydrometer type may vary. shutoff when cell is full.
75-442-55: Pin Removing Tool
Molex # 11-300-02: Pin Removing Tool Removes pins from Molex Mini-Fit harness
Molex # 11-300-06: Pin Removing Tool
connectors.
Removes 0.062 diameter pins from Molex Removes 0.093 diameter pins from Molex
rectangular harness connectors. Not rectangular harness connectors. Not
available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from
any local electronics distributor. any local electronics distributor.
MS-534-13 Page 21
Tool List
TROUBLESHOOTING GUIDE
This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter
for checking the electronic motor control system.
This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom.
Symptom Suspect Component or System Action

Steering Pulls Left or Right Front end out of alignment Realign front end
Low tire pressure Inspect tire pressure
Difficult Steering Lack of lubrication Lubricate steering linkages
Damaged or worn steering components Inspect all steering components
Low tire pressure Inspect tire pressure
Excessive Play in Steering Damaged or worn steering linkages Inspect steering linkages
Loose steering linkages Tighten all hardware
Loose steering wheel Inspect steering wheel nut
Loose front spring hardware Tighten all hardware
Soft and/or Low Brake Pedal Air in brake lines Bleed brake system
Master cylinder fluid level low Fill master cylinder and bleed system
Brake pedal linkage 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 in brake lines Bleed brake system
Brakes Dragging Brake pedal linkage out of adjustment Adjust linkages
Faulty master cylinder Inspect master cylinder
Faulty brake caliper Inspect brake calipers
Debris in brakes Inspect brakes
Parking brake applied Release parking brake, inspect linkage
Low Power or Running Slow Faulty or discharged battery Test battery and charge
Brakes dragging Inspect brake system
Fault in motor control system Refer to motor control fault codes
Noise, Front End Loose wheel nuts Tighten all hardware
Damaged or worn wheel bearings Inspect wheel bearings
Damaged, worn, or debris in brakes Inspect brakes
Loose components Tighten all hardware
Damaged or worn suspension mounts Inspect suspension
Noise, Rear End Loose wheel nuts Tighten all hardware
Damaged or worn internal transaxle components Inspect transaxle
Damaged or worn suspension mounts Inspect suspension
Note: This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom.
Page 22 MS-534-13
Lubrication
Table of Contents
Lubrication
Lubrication and Fluids Chart...........................24
Hazardous Waste Disposal..............................24
Lubrication Diagram.........................................25
Lubrication
LUBRICATION AND FLUIDS CHART
Assembly Item # Component Qty Capacity Lubricant
Front Axle:
5 King Pin (SS-546) 2 - NLGI Grade 2 lithium multi-purpose grease
2 Axle Pivot (SS-546) 1 - NLGI Grade 2 lithium high temp Bearing Grease
1 Wheel Bearing 1 or 2 - NLGI Grade 2 lithium multi-purpose grease
3 Fork Spindle Bearing 1 - NLGI Grade 2 lithium multi-purpose grease
Linkages:
4 Brake Pedal Pivot 2 - NLGI Grade 2 lithium multi-purpose grease
Brake Pedal Pivot Lock 1 - Multi-purpose spray lubricant
Brake Cable Clevis 6 - Multi-purpose spray lubricant
Rear Transaxle:
7 Drain Plug (SS-534)
8 Level Plug (SS-534)
9 Fill Plug (SS-534) 1 2 quarts SAE 140 API GL/5 Hypoid Gear Oil
SS-536, SS-546, MX 1 11 ounces SAE30 Motor Oil
Miscellaneous
Steering Gear (optional) NLGI Grade 2 lithium multi-purpose grease
Fold down seat pivot Multi-purpose spray lubricant
HAZARDOUS WASTE DISPOSAL

This vehicle contains various components and/or fluids that may be classified as hazardous waste.
This includes but is not limited to Lead, Acid, Oil, Grease.
The brake linings originally installed by the factory do not contain asbestos. However, since it is possible that
asbestos brake linings were installed as replacement parts, brake linings should be handled as hazardous
waste.
The requirements for disposal of hazardous waste vary by location. Consult your local regulations regarding
the proper disposal of hazardous waste products.
Page 24 MS-534-13
Lubrication
LUBRICATION DIAGRAM
SS-534 from Rear (#9 on top)
SS-536, SS-546, MX from Bottom
MS-534-13 Page 25
Notes:
Lubrication
Page 26 MS-534-13
Preventative Maintenance
Table of Contents
Preventative Maintenance
Daily Visual Inspection....................................28
Pre-Operation Inspection.................................28
Maintenance Schedule.....................................29
Maintenance Guidelines for Severe Duty
Applications..............................................................29
WARNING
PM Schedule
DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION
WARNING WARNING
This section is one section of a complete service This section is one section of a complete service
manual. Before starting any procedure, read all manual. Before starting any procedure, read all
warnings and instructions that are located in the warnings and instructions that are located in the
Service Guidelines chapter. Service Guidelines chapter.
The following items shall be inspected every time before

The following items shall be inspected once every day the vehicle is driven:
before the vehicle is put into service: Rear and side view mirror adjustments.
External frame damage (body). Steering operation.
Operation of all lights and warning alarms. Brake operation (service and park brake).
Proper operation of all instrument panel gauges and Tire pressure (visual inspection only).
warning lights. Proper operation of trailer hitch.
Smooth and proper operation of seat belts (if
equipped).
Tire tread or sidewall damage.
Proper operation of adjustable seat mechanisms (if
equipped).
Smooth and proper operation of all controls such as
but not limited to:
Throttle pedal
Brake pedal
Parking brake
Steering
Horn
Etc.
Proper operation of all locking mechanisms such as
but not limited to:
Hood latches
Cargo box’s
Cab doors
Etc.
Proper operation of all interlocking switches such as
but not limited to:
Start switch
Operator presence switch
Brake interlock switch.
Etc.
Page 28 MS-534-13
PM Schedule
MAINTENANCE SCHEDULE
A PM Check List is available and included on the documentation CD provided with your vehicle. The document
numbers are:
• PM-0017: Models SS-536, 546, and MX-600
• PM-0018: Model SS-534
First 25 hours of Operation Every 6 Months or 1,000 hours)

Re-torque wheel nuts. All 3 month items plus the following:
Inspect all hardware for tightness. Inspect/adjust front wheel bearings.
Adjust front wheel bearings. Inspect rear wheel bearings.
Every Week Inspect steering king pins (SS-546).
Align the front end (SS-546).
All daily items plus the following:
Inspect suspension bushings.
Check all tires, inflation
Rotate tires.
Check all tires, damage
Inspect frame for damage.
Check all tires tread for debris.
Battery electrolyte level Every Year or 2,000 hours
Every Month or 100 hours All 6 month items plus the following:
Inspect motor brushes
All weekly items plus the following:
Blow carbon from motor.
Fluid leaks
Inspect brakes for wear.
Clean batteries and terminals.
Replace brake pedal return spring
Inspect all electrical interlocks for proper operation.
Clean charger cooling fins or vents. Every 2 Years or 4,000 hours
Clean exterior of drive motor. Change rear axle oil.
Check tire tread wear. Clean and repack front wheel bearings, change
Inspect steering linkages and hardware (SS-546) seals.
Adjust fork collar bearings.
Inspect and tighten all hardware (1st 100 hours then
every 500 hours).
Every 3 Months or 500 hours
All monthly items plus the following: Maintenance Guidelines for Severe Duty
Inspect and tighten all hardware. Applications
Test batteries.
This maintenance schedule is based on the average
Clean battery compartment.
typical application. If the vehicle is operated under
Clean motor control panel.
“severe conditions”, service procedures shall be
Adjust brakes.
conducted more frequently than specified. The frequency
Re-torque the wheel nuts.
of service under severe conditions is determined by the
Clean and lubricate motor coupler (SS-536, 546,
use of the vehicle. The owner/operator must evaluate
MX-600).
the operating environment to determine the increase in
Adjust drive belts (SS-534)
maintenance frequency.
Lubricate the vehicle.
Inspect and tighten all power electrical connections. In addition, the entire vehicle shall be inspected monthly
Inspect all wiring for cracks, fraying, or wear. for signs of damage.
The following list is meant as a guide and is not all-
inclusive of a “severe duty” application.
• Operation in excess of 100 hours per month.
• Extreme temperature.
• Bumpy, dusty, or ill maintained roads.
• Excessively wet areas.
• Corrosive or contaminated areas.
• Frequent loading of the vehicle at/near capacity.
MS-534-13 Page 29
Notes:
PM Schedule
Page 30 MS-534-13
Front Axle
Table of Contents
Front Axle
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
Replace Front Wheel Bearings (3-wheel).......34
Replace Front Wheel Bearings (4-Wheel)......34
Axle Shaft, Remove/Install (3-wheel)..............35
Axle Assembly, Remove/Install (4-wheel)......35
Remove....................................................................35
Installation................................................................35
Hardware Torque..............................................36
WARNING
Front Axle
INSPECT FRONT WHEEL INSPECT FRONT WHEEL
BEARINGS (3-WHEEL) BEARINGS (4-WHEEL)
WARNING WARNING
1: Raise the front of the vehicle and support with 1: Raise the front of the vehicle and support with
jack stands. jack stands.
2: Grab the top and bottom of the tire/wheel 2: Grab the top and bottom
assembly. Feel for any movement or play while of the tire/wheel assembly.
pulling and pushing on the top and bottom of the Feel for any movement
tire. Any movement or play is indication of loose or play while pulling and
wheel bearings. pushing on the top and
3: Spin the front wheel by hand. The wheel should bottom of the tire. Any
stop spinning in no more than 2-revolutions. A movement or play is
wheel that continues to spin freely is an indication indication of loose wheel
of a loose wheel bearing. bearings.
Note: Refer to the Adjust Front Wheel Bearings 3: Spin the front wheel(s) by
section for detailed information regarding the hand. The wheel should stop spinning in no more
proper adjustment of the wheel bearings. than 2-revolutions. A wheel that continues to spin
4: Spin the wheel and listen for any grinding noise. freely is an indication of a loose wheel bearing.
Any noise may be an indication of worn or Note: Refer to the Adjust Front Wheel Bearings
damaged wheel bearings. section for detailed information regarding the
Note: Refer to the Replace Front Wheel Bearings proper adjustment of the wheel bearings.
section for information regarding the 4: Spin the wheel(s) and listen for any grinding
replacement of the wheel bearings. noise. Any noise may be an indication of worn or
5: Lower the vehicle. damaged wheel bearings.
6: Reconnect the batteries. Note: Refer to the Replace Front Wheel Bearings
7: Remove the blocks from behind the wheels. section for information regarding the
8: Release the park brake and test drive the vehicle. replacement of the wheel bearings.
5: Lower the vehicle.
6: Reconnect the batteries.
7: Remove the blocks from behind the wheels.
8: Release the park brake and test drive the vehicle.
Page 32 MS-534-13
Front Axle
ADJUST FRONT WHEEL BEARINGS ADJUST FRONT WHEEL BEARINGS
(3-WHEEL) (4-WHEEL)
WARNING WARNING
Note: The bearings must be lubricated before Note: The bearings must be lubricated before
performing this procedure. performing this procedure.
1: Raise the front wheel(s) off of the ground and 1: Raise the front wheels off of the ground and
support with jack stands. support with jack stands.
2: While rotating the wheel, tighten the front axle 2: While rotating the wheel, tighten the front axle
nut until the wheel is difficult to rotate. nut until the wheel is difficult to rotate.
3: Continue to rotate the wheel for 5 compete 3: Continue to rotate the wheel for 5 compete
revolutions. revolutions.
4: Attach a rope to the tire and wrap around the tire 4: Attach a rope to the tire and wrap around the tire
with 1 foot remaining hanging in the air. with 1 foot remaining hanging in the air.
5: Tie a weight (see table and illustration below) to 5: Tie a weight (see table
the end of the rope. and illustration below)
6: Slowly loosen the axle nut until the hanging to the end of the rope.
weight rotates the wheel. 6: Slowly loosen the axle
7: Remove the rope and weight. nut until the hanging
8: Spin the wheel and listen for any grinding noise. weight rotates the
Any grinding noise may be an indication of worn wheel then rotate to
or damaged wheel bearings. the nearest flat and
Note: Refer to the Replace Front Wheel Bearings install a new cotter pin.
section for information regarding the 7: Remove the rope and weight.
replacement of the wheel bearings. 8: Spin the wheel and listen for any grinding noise.
9: Lower the vehicle. Any grinding noise may be an indication of worn
10: Reconnect the main positive and negative cables or damaged wheel bearings.
at the batteries. Note: Refer to the Replace Front Wheel Bearings
11: Remove the blocks from behind the wheels. section for information regarding the
12: Release the park brake and test drive the vehicle. replacement of the wheel bearings.
Note: Vehicles with front fork suspension may 9: Lower the vehicle.
require a tighter used bearing adjustment. 10: Reconnect the main positive and negative cables
When test driving the vehicle watch for any at the batteries.
shimmy in the steering. If any shimmy is 11: Remove the blocks from behind the wheels.
noticed first inspect the fork collar bearing 12: Release the park brake and test drive the vehicle.
adjustment. If OK then tighten the preload
in small increments until it stops.
Tire Size Weight NEW Weight USED

(pounds / kg) (pounds / kg)
4.80 x 8 2.15 / 0.975 1.00 / 0.454
5.70 x 8/ 1.99 / 0.902 0.93 / 0.422
4.00 x 8 2.15 / 0.975 1.01 / 0.485
500 x 8 1.99 / 0.902 0.93 / 0.422
8.50 x 8 2.02 / 0.916 0.94 / 0.426
8 x 2.50 4.23 / 1.919 1.97 / 0.894
10 x 3.5 3.38 / 1.533 1.56 / 0.708
NEW: Weight = 16.931 / Radius

USED: Weight = 7.875 / Radius
MS-534-13 Page 33
Front Axle
REPLACE FRONT WHEEL REPLACE FRONT WHEEL
BEARINGS (3-WHEEL) BEARINGS (4-WHEEL)
WARNING WARNING
1: Set the park brake. 1: Set the park brake.

2: Disconnect the batteries. 2: Disconnect the batteries.
3: Raise the front of the vehicle and support with 3: Raise the front of the vehicle and support with
jack stands. jack stands.
4: Remove the tire/wheel assembly from the fork. 4: Remove the tire/wheel assembly from the hub.
Refer to Axle Shaft section. Refer to the Tire/Wheel section for information
5: Thoroughly clean all grease from the inside of the regarding removing the tire/wheel assembly.
hub and the bearings. 5: Remove the hub dust cap, cotter pin, and spindle
6: Inspect and replace the races and bearings as a nut.
set. 6: Remove the hub from the steering knuckle.
7: Assemble in reverse order, using new grease 7: Thoroughly clean all grease from the inside of the
seals. hub and the bearings.
8: Reinstall the tire/wheel. Refer to Axle Shaft 8: Inspect and replace the races and bearings as a
section. set.
a. Pack the bearings with grease. Note: It is recommended to replace all four
b. Adjust the bearing preload per specifications in bearings and races in the left and right
the Adjust Front Wheel Bearing procedure. wheels as a set.
9: Lower the vehicle. 9: Assemble in reverse order, using new grease
10: Reconnect the batteries. seals.
11: Remove the blocks from behind the wheels. a. Pack inner and outer bearings with grease.
12: Release the park brake and test drive. b. Adjust the bearing preload per specifications in
the Adjust Front Wheel Bearing procedure.
d. Install a new cotter pin.
10: Install the hub dust cap.
11: Reinstall the tire/wheel. Refer to the Tire/Wheel
section for information regarding installing the
tire/wheel assembly
13: Reconnect the batteries.
15: Release the park brake and test drive.
Page 34 MS-534-13
Front Axle
AXLE SHAFT, REMOVE/INSTALL AXLE ASSEMBLY, REMOVE/
(3-WHEEL) INSTALL (4-WHEEL)
WARNING WARNING
Remove Remove
1: Remove the front axle nut. 1: Raise the front of the vehicle and support with
2: Slowly raise the front of the vehicle until the axle jack stands.
can slide freely out of the fork. The front wheel(s) 2: Remove the front bumper brace.
should still be resting on the ground. 3: Disconnect the steering links to the left and right
3: Remove the front axle from the fork and support steering knuckles.
the vehicle with jack stands. 4: Remove the cotter pin from the axle pivot and
Note: If the bearings were worn until they were discard.
broken, then the shaft may have to be cut 5: Remove the axle pivot nut and discard.
out of the fork. 6: Slide the axle off of the pivot stud and remove.
4: Inspect the axle shaft and holes in the fork for the Installation
shaft. 1: Install the axle assembly in reverse order of
• If there is any noticeable wear on the shaft then it removal.
should be replaced. 2: Use a new axle pivot nut and cotter pin.
• The holes in the fork should be round. If worn in an 3: Tighten the pivot nut so that it is in contact with
oval then the fork should be replaced. the axle but not so tight as to prevent the axle
Install from pivoting.
1: Raise the front of the vehicle so that the hole for 4: Lube the axle pivot.
the axle is the same height as the front wheel 5: Lower the wheels to the ground and test drive.
hub.
2: Assemble the bearing spacers into the front
wheel hub and place the front wheel(s) into the
fork.
3: Insert the axle into the front fork.
4: Lubricate the bearings.
5: Install the axle nut(s). Refer to Adjust Front
Wheel Bearings section for information regarding
tightening the front axle.
Note: If your vehicle is equipped with two axle nuts,
the nuts should be tightened equally so that
the same number of axle threads are visible
on both ends of the shaft.
7: Reconnect the main positive and negative cables
at the batteries.
9: Release the park brake and test drive the vehicle.
MS-534-13 Page 35
Front Axle
HARDWARE TORQUE
Notes:
Description Foot Pounds Newton Meters
Ball Joint Clamp 28-32 37.9-43.4
Rod End Stud Nut 20-25 27.1-33.9
Rod End Jam Nut 20-25 27.1-33.9
Page 36 MS-534-13
Steering
Table of Contents
Steering
Inspect Rod Ends.............................................38
Replace Rod End..............................................38
Front End Alignment, SS-546..........................39
Front End Alignment, SS-534, SS-536,
MX-600........................................................39
Replace Steering Tiller.....................................40
Replace Steering Wheel...................................40
Replace Steering Gear, SS-534.......................41
Replace Steering Gear,
SS-536, SS-546, MX-600............................41
Front Fork..........................................................43
Installation................................................................43
Hardware Torque..............................................44
WARNING
Steering
INSPECT ROD ENDS REPLACE ROD END
WARNING WARNING
Note: A set of ball joints and/or rod ends will wear 1: Raise the front of the vehicle and support with
at the same rate. If a ball joint and or rod end jack stands.
is worn out, then all should be replaced as 2: Loosen the rod end clamp or jam nut on the
a set. steering sleeve.
1: Visually inspect each rod end for any signs of 3: Remove the nut or bolt holding the rod end onto
play between the ball and the nylon or brass the steering arm.
bushing in the housing. 4: Remove the ball joint from the steering sleeve.
2: If any play is evident, then the rod end is worn out 5: Install the new rod end into the steering sleeve.
and should be replaced. Refer to section Replace Screw it into the sleeve the same number of turns
the Ball Joints, Tie Rods, and Drag Link for counted in the previous step. Do not tighten the
information regarding replacing ball joints. rod end clamp or jam nut at this time.
3: Reconnect the main positive and negative cables 6: Install the rod end into the steering arm. Tighten
at the batteries. the ball joint nut per torque listed in the Hardware
4: Remove the blocks from behind the wheels. Torque table at the end of this section.
5: Release the parking brake and test drive. 7: Realign the front wheels. Refer to the Front Axle
section for information regarding realignment of
the front wheels.
at the batteries.
11: Release the park brake and test drive.
Page 38 MS-534-13
Steering
FRONT END ALIGNMENT, SS-546 FRONT END ALIGNMENT, SS-534,
WARNING SS-536, MX-600
There are no alignment adjustement to the 3-wheel
This section is one section of a complete service steering.
warnings and instructions that are located in the If the vehicle pulls to the left or right then the fork or
Service Guidelines chapter. frame is bent.
If the front wheel shimmye or shakes at faster speeds
1: Raise the front of the vehicle and support with
then the front axle bearings of fork spindle bearings may
jack stands.
be loose.
2: Center the steering linkage and tie off the
steering wheel so that it cannot rotate.
3: Loosen the rod end jam nuts on the left and right
steering links.
4: Using a piece of chalk, mark a line around the
center of both front tires.
5: Adjust the links so that both wheels are in the
straight ahead position.
6: Measure the distance between the lines at the
front and rear of the tires.
7: Adjust the links so that the distance at the front
and rear of the tires is the same.
8: Tighten the rod end jam nuts per torque listed
in the Hardware Torque table at the end of this
section.
9: Untie the steering wheel.
at the batteries.
12: Release the parking brake and test drive the
vehicle.
MS-534-13 Page 39
Steering
REPLACE STEERING TILLER REPLACE STEERING WHEEL
WARNING WARNING
1: Remove the headlight. Note: The steering wheel is on a tapered shaft and
2: Remove the tiller pinch bolt holding it to the fork may be damaged when it is removed.
spindle. 1: If equipped with a horn switch in the steering
3: Drive a large slotted screwdriver or chisel wheel, remove the switch and disconnect the
between the pinch bolt collar tabs to spread them wires from the switch.
apart and remove the tiller from the fork spindle. 2: Remove the steering wheel nut.
4: Thoroughly clean the fork spindle. 3: Using a steering wheel puller, remove the
5: Confirm the woodruff key is properly installed in steering wheel.
the spindle. 4: Position the front wheels in the straight ahead
6: Align the slot in the tiller with the woodruff key position.
and push the tiller down onto the spindle making 5: Lightly grease the steering wheel splines and
sure that the key stays in place. install the replacement steering wheel orientated
7: Install the tiller pinch bolt and nut. Tighten per as shown in the illustration.
torque specifications at the end of this chapter. 6: Tighten the steering wheel nut to torque listed
section.
at the batteries.
9: Release the parking brake and test drive.
Page 40 MS-534-13
Steering
REPLACE STEERING GEAR, SS-534 REPLACE STEERING GEAR,
WARNING SS-536, SS-546, MX-600
This section is one section of a complete service WARNING

warnings and instructions that are located in the This section is one section of a complete service
Service Guidelines chapter. manual. Before starting any procedure, read all
1: Remove the steering wheel.
2: Remove the 6 bolts from the top cover. 1: Remove the four frame to gear box mounting
3: Lift the top cover off the gear box, discarding the bolts from the bottom of the gear and remove the
gasket. entire gear assembly from the vehicle.
4: Remove the gear case. Note: The fork spindle gear will remain on the fork
5: Remove the fork spindle gear. spindle shaft. A gear puller may be required
6: Remove and discard the lower gasket. to pull the gear off of the shaft.
7: Remove the 3 remaining bolts from the bottom of
the gear box.
8: Thoroughly Clean and inspect all parts.
9: Using new gaskets, reassemble in reverse order.
10: Fill the gear box with grease.
Note: A minor amount of gear lash adjustment can
be accomplished by repositioning the upper
and lower plates. Loosen the mounting bolts
so that they are snug. Lightly tap the upper
and/or lower plate to adjust the gear lash
then retighten the bolts.
MS-534-13 Page 41
Steering
STEERING GEAR, SS-536, SS-546, MX-600
WARNING
1: Remove the steering gear from the vehicle.

2: Remove the steering wheel.
3: Remove the cover bolts.
4: Remove the cover and discard the gasket.
Note: The stem and gear may come off with the cover.
5: Remove as much grease as possible from the inside of the gear box.
6: Remove the gear case and clean the remaining grease from the bottom of the
gear box.
7: If the stem and gear did not come out with the top cover, remove it now.
8: Remove and discard the lower gasket.
9: Thoroughly clean all parts.
10: Reassemble in reverse order installing new gaskets.
• Check the bronze bushings for wear and replace them as needed.
• Apply grease to all gears.
Page 42 MS-534-13
Steering
FRONT FORK
WARNING
Installation
Note: It is recommended to replace the grease
seal any time the fork is removed from the
vehicle.
1: The front of the vehicle should be supported on
jack stands just high enough to install the fork.
2: Place the lower bearing in the fork collar and
install a new grease seal.
3: Apply a light coat of grease to the collar bearing
races.
4: Insert the fork up through the fork collar and lower
bearing being careful not to damage the grease
seal.
5: Hold the fork up in the collar and install the upper
bearing, washer, and spindle nut.
6: While rotating the fork to the left and right, torque
the spindle nut to 110 foot pounds.
7: Loosen the nut 1/4 turn and then re-torque to 70
foot pounds.
MS-534-13 Page 43
Steering
HARDWARE TORQUE
Notes:
Ball Joint Clamp 28-32 37.9-43.4
Rod End Stud Nut 20-25 27.1-33.9
Rod End Jam Nut 20-25 27.1-33.9
Ball Joint Castle Nut 40-45 54.2-64.2
Tiller Pinch Bolt 40-43 54.2-61.4
Steering Wheel Nut 28-32 38-43
Page 44 MS-534-13
Drive Axle-D1
Table of Contents
Drive Axle-D1
Check Oil Level.................................................46
Change Oil.........................................................46
Axle Shaft..........................................................47
Remove....................................................................47
Install........................................................................47
Axle Bearings...................................................47
Remove/Install..........................................................47
Drive Motor........................................................48
Remove....................................................................48
Install........................................................................48
Differential Case...............................................49
Disassemble.............................................................49
Assemble..................................................................51
Hardware Torque..............................................52
WARNING
This section is one section of a complete
service manual. Before starting any
procedure, read all warnings and instructions
that are located in the Service Guidelines
chapter.
Typical D1 Drive axle shown with

motor and springs
Drive Axle
CHECK OIL LEVEL CHANGE OIL
WARNING WARNING
Fluid type and capacities are listed in the Lubrication Fluid type and capacities are listed in the lubrication
chapter. section in the General Maintenance chapter.
1: Raise the drive wheels off of the ground and 1: Raise the rear of the vehicle and support with
place a drain pan that can hold a minimum of jack stands.
2-quarts of oil under the transmission level plug. 2: Place a drain pan that can hold a minimum of
2: Remove the level plug and lower the drive axle to 2-quarts of oil under the transmission.
the ground over the drain pan. 3: Remove the transmission cover plate to drain the
3: A small amount of oil may come out. This oil.
indicates that the transmission has the correct 4: Reinstall the cover plate and remove the level
amount of oil. plug.
4: If no oil comes out, then it may need to have oil 5: Add 1-pint (500 ml) of oil through the open level
added; add oil through the open level plug until it plug.
is overflowing out of the hole. 6: Lower to the ground over the drain pan and allow
5: Reconnect the main positive and negative cables excess to drain.
at the batteries, remove blocks from behind the 7: Reinstall the plug.
wheels and test drive the vehicle. 8: Reconnect the main positive and negative cables
at the batteries, remove blocks from behind the
wheels and test drive the vehicle.
Level Plug
Page 46 MS-534-13
Drive Axle
AXLE SHAFT AXLE BEARINGS
Note: The axle must be removed from the
WARNING transmission for this procedure. Refer to

Remove and Install Axle for information
regarding removing the rear axle.
warnings and instructions that are located in the WARNING
Service Guidelines chapter. Bearings may be frozen on the shaft and may explode
into small fragments while being pressed off of the
Remove shaft.
1: Remove the rear wheel. Refer to Replace the The entire bearing should be enclosed in a steel
Rear Tire/Wheel section for information regarding housing while being pressed off of the axle.
removing the rear wheel. Failure to enclose the bearing may result in severe
2: Remove the axle hub. Refer to Rear Hub/Brake personal injury.
Drum section for information on removing the
hub. Remove/Install
3: Remove the outer snap ring from the axle 1: Remove the hub from the axle shaft. Refer to
housing. Rear Hub/Brake Drum for information regarding
4: Remove the axle from the transmission removing the hub.
assembly. 2: Press the axle bearing off of the axle shaft and
5: Remove the inner snap ring. discard.
6: Remove the axle seal from the axle housing. 3: Press a new bearing onto the axle shaft.
7: Refer to Rear Hub/Brake Drum section for 4: If the axle is not to be immediately installed into a
information on installing the hub. vehicle, pack the bearing with grease and wrap it
8: Reconnect the main positive and negative at the in plastic to prevent corrosion.
batteries, remove the blocks from the wheels,
and test drive.
Install
Install in reverse order using a new axle seal.
MS-534-13 Page 47
Drive Axle
DRIVE MOTOR
WARNING
Remove
Note: In some vehicle configurations the
transmission assembly will have to be
removed to allow clearance to remove the
motor. Refer to Transmission section for
information on removing the transmission
assembly from the vehicle.
1: Remove the motor wires from the motor.
2: Remove the bolts holding the motor to the Do not apply grease to the armature coupler,
transmission housing (see illustration). rubber bushing or the end of the transmission input
shaft. Grease applied to these areas may result in
3: Slide the motor off of the transmission input shaft.
premature failure of the armature bearing.
Install
1: Remove the rubber bushing from inside of the
motor armature coupler (see illustration).
2: Thoroughly clean all grease from the
transmission input shaft, rubber bushing and the
motor armature coupling.
3: Install the rubber bushing back into the motor
armature coupling.
4: Lightly grease the transmission input shaft only
(see caution).
5: Install the motor in reverse order.
• Tighten the motor mounting bolts per torque listed
section.
• Tighten the motor terminals per torque listed in the
Hardware Torque table at the end of this section.
Page 48 MS-534-13
Drive Axle
DIFFERENTIAL CASE
Disassemble
1: Remove the transmission from the vehicle. Refer to Transmission-Remove section for information on
removing the transmission.
2: Thoroughly clean the transmission assembly before disassembly.
3: Remove the left and right axles from the transmission assembly. Refer to Rear Axle section for information
on removing the axles.
4: Suspend the differential case over a drain pan that can hold a minimum of 2-quarts of oil.
5: Remove the differential case cover being careful 8: Remove the final drive gear from the differential
not to bend or damage the case cover flange or housing.
the sealing surface of the differential case.
6: Remove the differential bearing caps and remove 9: Punch or drill a small hole into the center of both
the differential assembly from the housing. of the intermediate shaft bore plugs.
Note: T h e b e a r i n g c a p s a r e m a r k e d f o r 10: Thread a sheet metal screw into each plug until
identification. When the transmission is the bore plug is forced out.
reassembled they must be installed in their
original position.
11: Remove both snap rings from the intermediate

shaft bore.
7: Remove both bearings from the differential case.
MS-534-13 Page 49
Drive Axle
12: Using a soft metal or hard wood dowel, drive 16: Remove the circlip from the input shaft.
the intermediate shaft through the bearing just 17: Remove the input shaft from the housing.
enough to allow clearance for an ID bearing 18: Press the bearings off of the input shaft.
puller. Do not attempt to drive the shaft out of the
opposite end of the transmission.
19: Remove the o-rings from both sides of the

13: Remove the intermediate bearing with an ID intermediate shaft bore and the input shaft bore
bearing puller. and discard the o-rings.
14: While supporting the shaft and gear assembly,

repeat steps #12 and #13 for the opposite side
bearing and remove the intermediate shaft from
the housing.
15: Remove the o-rings from each end of the

intermediate shaft.
Page 50 MS-534-13
Drive Axle
Assemble
Notes: When pressing bearings, do not press against or support the outer race as this will damage the
bearing.
All snap rings should fit tightly into their grooves. If a snap ring is loose, then it must be replaced.
Do not hit any shaft or component with a hard metal hammer or punch.
Pre-lube all bearings, seals and o-rings before assembly.
6: Insert the flanged side bearing into the bearing

bore. Press in just past the snap ring grove and
install the snap ring.
1: Thoroughly clean all components as well as the 7: Repeat the above step for the opposite bearing.
inside of the housing.
2: Press new bearings onto the input shaft and CAUTION
differential case.
Use a hard wood dowel the same diameter as the
bearing bore to drive the bearing into place.
DO NOT drive against the inner race as this will
damage the bearing resulting in noise and/or
premature failure of the bearing.
8: Thoroughly clean both sides of the intermediate
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 rings.
10: Install the final drive gear onto the differential
housing. Tighten the nuts to per torque listed
3: Insert new o-rings into both sides of the section.
intermediate shaft bore, the input shaft bore and 11: Install the differential assembly into the drive
the intermediate shafts. housing and install the bearing caps. Tighten
the cap bolts per torque listed in the Hardware
Torque table at the end of this section.
Note: The bearing caps are marked for identification
and must be installed in their original
locations.
12: Place a small bead of non-acidic silicone sealant
to the bottom flange of the housing.
Note: The sealant bead should be on the inside of
the cover plate mounting holes.
13: Install the cover plate. Tighten the bolts per
torque listed in the Hardware Torque table at the
end of this section.
4: Install the input shaft into the housing and install 14: Install the axles using new axle seals. Refer to
the snap ring. Rear Axle section for information on installing the
5: Insert the intermediate shaft into the housing and axles.
support in place. 15: Fill with oil.
MS-534-13 Page 51
Drive Axle
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque
values in the appendix.
Motor terminals 7.5-9.1 10.2-12.4
Motor Mounting Bolts 6-8 8-10.5
Final Drive Gear Nuts 35-45 48-61
Differential Bearing Cap Bolts 35-45 45-61
Page 52 MS-534-13
Brakes
Table of Contents
Brakes
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
WARNING
Brakes
GENERAL GUIDELINES AND SAFETY
WARNING WARNING
Taylor-Dunn does not currently supply asbestos
fiber-brake pads/shoes with any vehicle. However,
there is the possibility that the original brake pads/
shoes were replaced with aftermarket pads/shoes
containing asbestos. Since this possibility does exist,
the brake pads/shoes should be handled as if they
WARNING do contain asbestos.
Never use compressed air or dry brush to clean the
Do not ingest brake fluid or allow contact with skin
brake assemblies. Use an OSHA approved vacuum
or eyes. Always wear protective clothing and a face
cleaner or any alternate method approved by OSHA
shield when working with or around brake fluid.
to minimize the hazard caused by airborne asbestos
SKIN CONTACT: fibers and brake dust.
Flush area immediately with water for several Do not grind, sand, break, or chisel the brake pads/
minutes. If a rash or skin irritation develops, get shoes, as this will cause unnecessary dust, possibly
medical attention immediately. releasing asbestos fibers in the air.
EYE CONTACT: Always wear protective clothing and a respirator
Immediately flush the eye with water for 15 minutes when working on the brake pads/shoes or their
and call physician. associated components.
INGESTION: Inhaled asbestos fibers have been found to cause
Get medical attention immediately. cancer and respiratory diseases.
WARNING Do not drive the vehicle if any worn or broken part is

detected in any part of the brake system. The cause
Hydraulic brake system components must be kept of the damage must be repaired immediately.
clean. Make sure your work area is free from dirt
and debris and will contain any brake fluid spills. Any
debris or contaminates left in the brake system could
lead to brake failure and result in property damage
and/or severe bodily injury.
WARNING
When replacing or adding brake fluid:
• Onlyuse DOT 3 brake fluid from a new sealed

container.
• D
OT 3 brake fluid is corrosive, will damage paint
finishes and may damage electrical components.
• D
ispose of brake fluid in accordance with local
state and federal regulations.
• R
ead and follow all warnings on the brake fluid
container.
Page 54 MS-534-13
Brakes
REAR DRUM BRAKE
WARNING
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: The auto adjust brakes cannot be manually
adjusted.
Note: The symptom of a low brake pedal may
indicate that the auto adjuster is not working
or the brake cable is not adjusted properly.
Remove the vehicle from service and repair
the brakes.
Note: The brake adjustment is inside of the left
and right brake. Do not adjust the brake by
means of the brake cables as this will cause
malfunction of the brakes. If you hear a
single “clunking” noise while braking it may
be due to incorrect adjustment of the brake
cables or linkage.
Inspecting the Auto-Adjust Brake Mechanism

1: Raise the rear of the vehicle and support with
jack stands.
2: Remove the brake drum.
3: Release the park brake.
4: Back off the auto adjuster star wheel one or two
turns.
5: Reinstall the brake drum and press the bake
pedal.
6: As the brake pedal is pressed, the auto adjuster
should rotate the star wheel. You should hear
a ‘click’ each time the pedal is pressed until the
adjustment is complete. Reconnect the main
positive and negative at the batteries.
8: Test drive the vehicle
MS-534-13 Page 55
Brakes
Service Limits
Refer to the table at the end of this section
Inspection WARNING
1: Raise the rear of the vehicle and support with jack
stands. manual. Before starting any procedure, read all
2: Remove the rear wheels. warnings and instructions that are located in the
3: Measure the brake lining (not including the metal Service Guidelines chapter.
backing plate) of each shoe at it’s thinnest point. If
any one of the shoes are equal to or less that the service limit then all shoes should be replaced.
4: Measure the drum inner diameter in three places. If the diameter is less than the service limit then the drum
must be replaced.
6: Reconnect the battery, remove the blocks from behind the wheels and test drive.
Replace Shoes
1: Raise the rear of the vehicle and support with jack
stands.
2: Release the park brake.
3: Remove the rear wheels.
4: Remove the brake drum.
5: Remove the auto-adjust lever spring.
6: Remove the tension springs.
7: Remove the hold down springs.
8: Thoroughly clean all components.
Apply this procedure in reverse order to install the new
brake shoes.
WARNING
Do not allow grease to contact any of the braking
surfaces. Braking surfaces contaminated with grease
may cause the brakes to fail resulting in property
damage and/or severe bodily injury.
• Apply a small amount of high temperature grease to
the brake shoe anchor points.
• Inspect and fill the master cylinder to the proper
level. Refer to Check Master Cylinder Fluid section
for information regarding the correct master cylinder fluid level.
9: Confirm proper adjustment of brake cable.
10: Adjust parking brake.
11: Confirm auto adjust mechanism is functioning properly.
12: Lower the vehicle to the ground, reconnect the battery, remove the blocks from behind the wheels and test
drive.
Page 56 MS-534-13
Brakes
REBUILD DISC BRAKE BODY
WARNING
This procedure assumes that the component has been

removed from the vehicle. Refer to the component
assembly removal instructions for details and warnings
regarding the removal and installation procedure.
WARNING
The pistons are very fragile. If the piston is damaged
it must be replaced. Failure to replace a damaged
piston could lead to brake failure and result in
property damage and/or severe bodily injury.
1: Pull the pistons out of the brake body.

2: Remove the piston rubber boot.
3: Remove the piston o-ring from inside of the brake
body.
4: Inspect and replace parts as required.
5: Lubricate the brake parts with clean brake fluid Figure 1
from a sealed container.
6: Install the O-rings into the brake body. Make sure
that the O-rings are installed into the second
groove and that they are not twisted (Fig 1).
7: Using tool #41-350-13 (optional), slide the rubber
boots onto the pistons as shown. The boot should
be hanging off of the end of the piston (Fig 2).
8: Insert the rubber boot/piston into the brake body
making sure that the boot is properly seated in Figure 2
the groove (Fig 3).
9: Press the pistons all the way down into the brake
body making sure that the boot seats properly
into the upper groove on the piston.
10: Install any fittings or plugs that were removed
from the brake body using teflon tape thread
sealant.
11: If the brake body assembly is not to be
immediately installed onto a vehicle, plug
the brake hose fitting hole to prevent any
contaminates from entering the brake body.
Figure 3
MS-534-13 Page 57
Brakes
BRAKE ADJUSTMENT
WARNING
Note: This vehicle is equipped with self-adjusting

brakes. Other than the brake linkages, there
is no manual adjustment.
Service Brake
WARNING
Adjusting the brakes by means of the brake cables
could cause a hard brake pedal with little or no
braking power. This could cause loss of control of
the vehicle resulting in severe bodily injury and /or
property damage.
Adjusting the brake linkage is only required when any
part of the brake linkages are removed or replaced. Do
not adjust the brake linkage to compensate for a low
brake pedal. A low brake pedal may be an indication that
the auto-adjust mechanism is not functioning properly.
Refer to Inspecting the Auto-Adjust Brake Mechanism
for information on the auto-adjust mechanism.
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
linkages but the brake arm on the left and right brake is
not actuated. If the brake cables are too tight, then the
auto adjust mechanism may not function correctly.
Parking Brake
There is no adjustment for the parking brake. The parking
brake should work properly as long as the service brake
linkage is adjusted properly
SERVICE LIMITS
Description Imperial Metric
Disc pad lining minimum thickness 00625 inch 1.58 mm
Front rotor minimum thickness 0.200 inch 5.08 mm
Rotor runout 0.005 inch 0.127 mm
Rear shoe lining minimum thickness 0.200 inch 5.08 mm
Rear drum maximum diameter 6.33 inch 160.8 mm
Page 58 MS-534-13
Drive Motor
Table of Contents
Drive Motor
Motor Removal and Installation......................60
Disassemble.....................................................60
Assemble..........................................................61
Inspection..........................................................62
Brushes....................................................................62
Armature...................................................................62
Bearings...................................................................63
Commutator..............................................................63
Repair................................................................64
Brushes....................................................................64
Commutator..............................................................64
Service Limits...................................................65
WARNING
Drive Motor
MOTOR REMOVAL AND INSTALLATION
See the Transmission section for information on removing or installing the motor.
DISASSEMBLE
WARNING
1: Remove the motor from the

vehicle. See the Transmission
section for information on
removing the motor.
2: Remove the bolts holding the front
housing and press the armature
out of the housing.
3: Remove the bearing circlip,
bearing, and seal from the front
housing.
4: Remove the brush cover and pull
the brushes out away from the
commutator.
5: Remove the dust cap from the rear motor housing.
6: Place the motor in a press, and press the armature out of the rear bearing.
Note: Removing the armature will damage the motor bearing. The motor bearing should be replaced whenever
the armature is removed from the rear housing.
7: Remove the housing screws from the rear motor housing and remove the housing from the motor.
8: Remove the nuts from the armature studs and remove the two brush assemblies.
9: Remove the bearing circlip and press the motor bearing out of the housing and discard.
Page 60 MS-534-13
Drive Motor
ASSEMBLE
WARNING
1: Press new bearings into the motor housings and

install the circlips.
2: Install the two brush assemblies so that the
brushes are just far enough out of the brush
holder so that the brush springs hold them in
place away from the commutator.
3: Install the rear motor housing to the stator
housing.
4: Lightly grease the inside diameter of the rear
bearing.
5: Carefully insert the armature through the stator
housing and onto the motor bearing in the rear
housing.
6: While supporting the inner race of the bearing,
press the armature into the bearing.
7: Lightly grease the lips and install a new seal in the
front housing.
8: Install the front motor housing to the stator
housing.
9: Push the motor brushes into the brush holder until
the brush spring snaps into place. Be certain that
the spring does not rest up against the brush wire
(see illustration).
10: Install the brush cover and dust cap.
MS-534-13 Page 61
Drive Motor
INSPECTION Armature
1: Visually inspect the armature windings for burnt
WARNING insulation. Burnt insulation is a direct result of
motor overheating and could lead to a shorted
This section is one section of a complete service armature.
• If the insulation is cracked or burnt, then it is
Service Guidelines chapter. recommend that the armature or motor be
replaced.
Brushes Note: If the armature has been burnt then there
is a good possibility that the field windings
Note: There are four brushes in the motor. The
may also be burnt. Symptoms indicating a
brushes will not wear at the same rate. It
shorted field include high motor current, lack
is recommended that all four brushes are
of power and possibly excessive speed.
inspected at the same time.
2: Test the armature for shorts with a growler.
Note: If the motor is not ventilated, then the • If the armature is shorted, then the armature or
motor must be disassembled to inspect the motor must be replaced.
brushes. Refer to Transmission Service 3: Using the continuity function of digital multi-
section for information on removing the meter, check the continuity around the entire
motor. commutator by placing one test lead against
Note: In some vehicle configurations it may not be one of the commutator segments and the other
possible to inspect all four brushes while the test lead against all of the other segments one
motor is in the vehicle. Refer to Transmission at a time (see illustration below). There should
Service section for information on removing be continuity around the entire commutator. If
the motor. any segment indicates an open circuit, then the
1: Look through the brush cover and compare the armature or motor must be replaced.
top of the brush to the top of the brush holder. 4: Using the continuity function of digital multi-
If it is even with or below the top of the brush meter, check the continuity from any one of the
holder then the brushes should be removed commutator segments and the armature frame.
and measured. Refer to Replacing the Brushes If it is not an open circuit, then the armature is
section for information regarding removing the shorted and the motor must be replaced.
motor brushes. 5: Measure the armature and field resistance (refer
2: If any one brush is less than or equal to the to Service Limits table at end of this section).
service limit specified in Service Limits, then all If the armature of field resistance is not within
four brushes should be replaced. specification then the motor must be repaired or
3: Reconnect the main positive and negative cables replaced.
at the batteries. 6: Visually inspect the armature windings where
4: Remove the blocks from behind the wheels, they loop around at the shaft end of the armature.
release the park brake and test drive. The armature windings are coated with a thick
insulating enamel. The enamel should be a deep
red color. If the enamel is brown, black or cracked
then the armature has been overheated and may
be shorted. If the loops of wires expanded and
contacted the field, then the maximum RPM of
the motor has been exceeded.
Page 62 MS-534-13
Drive Motor
Bearings
Pressing the armature out of the bearings is likely to damage the bearings. Once removed the bearings should be
replaced.
Commutator
1: Measure the outside diameter of the commutator.
• If the commutator is less than the minimum diameter specified in section Service Limits, then the motor must
be replaced.
2: Measure the commutator undercut depth in 5 places around the commutator.
• If any one of the measurements is less than the minimum undercut depth specified in Service Limits at the
end of this section, then the commutator must be undercut. Refer to the Repair Commutator section for
information regarding undercutting the commutator.
3: Inspect the commutator for groves.
• If the commutator is grooved then it must be machined on a lathe. Do not machine the commutator past the
minimum diameter specified in Service Limits section. Refer to the Repair Commutator section for information
regarding machining the commutator.
4: Inspect the commutator for burn marks.
• Burn marks and/or raised commutator segments 90 or 180 degrees apart is evidence of a shorted armature. A
tool called a growler is required to reliably test for a shorted armature.
5: Inspect the commutator for raised segments.
• Raised segments could be a result of a stalled motor or shorted armature. A tool called a growler is required
to reliably test for a shorted armature.
• If the armature is not shorted then the raised segments can be removed by machining the commutator. Do not
machine the commutator past the minimum diameter specified in Service Limits section. Refer to the Repair
Commutator section for information regarding machining the commutator.
MS-534-13 Page 63
Drive Motor
REPAIR
WARNING
Brushes
Note: It is recommended that all four brushes be replaced
as a set.
Note: The motor must be removed from the vehicle for this
procedure. Refer to Transmission Service section
for information on removing the motor.
The motor must be disassembled to replace the brushes or
the bearings. Refer to Disassembly section for information on
taking the motor apart.
Commutator
Note: The motor must be removed from the vehicle for
this procedure. Refer to Transmission Service
section for information on removing the motor.
1: The armature must be removed from the motor for this
procedure. Refer to Disassembly section for information
on taking the motor apart.
2: Using a lathe, cut the armature just enough to remove
all grooves, depressions or ridges.
3: Measure the diameter of the commutator. If the
commutator is less than the minimum diameter
specified in Service Limits, then the motor must be
replaced.
4: Thoroughly clean all copper debris from between the
commutator segments.
Note: Copper debris in the undercut area can give a
reading of a shorted armature.
5: Measure the commutator undercut depth in 5
places around the commutator. If any one of the
measurements is less than the minimum undercut
depth specified in Service Limits, then the commutator Properly cut and undercut commutator
must be undercut.
6: While still in the lathe, smooth the commutator with fine
emery cloth.
Undercutting the commutator
1: Using a small straight cut saw blade, cut the
commutator insulation to the proper depth. Refer to
undercut depth in Service Limits.
2: Once all segments have been properly undercut, mount
the armature in a lathe and smooth the commutator
with fine emery cloth.
3: Inspect the armature for shorts. Refer to Motor
Inspection section for information on testing the
armature.
Note: Copper debris in the undercut area can give a
reading of a shorted armature.
Page 64 MS-534-13
Drive Motor
SERVICE LIMITS
WARNING
Commutator Brush Length Resistance

Undercut Depth
Motor Specification Diameter (min) (min) (Ohms@75º F)
Number
mm inches mm inches mm inches Armature Field
70-054-40
(XP-1672 or DV1- 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20
4002)
70-054-41
(XP-1789 or DY2- 0.635 0.025 69.85 2.75 15.87 0.625 0.011 0.43
4001)
70-057-40
(XP-1673 or DV1- 0.635 0.025 69.85 2.75 15.87 0.625 0.008 0.58
4003)
70-052-40
(XP 1876 or DD3- 0.635 0.025 69.85 2.75 15.87 0.625 0.011 0.73
4004)
MS-534-13 Page 65
Notes:
Drive Motor
Page 66 MS-534-13
Motor Controller
Table of Contents
Motor Controller
Remove/Install..................................................68
Inspect...............................................................68
Troubleshooting...............................................68
Repair/Adjustments.........................................69
Adjustments..............................................................69
Hardware Torque..............................................70
WARNING
Motor Controller
REMOVE/INSTALL INSPECT
WARNING WARNING
NOTICE Inspect the area around all of the terminals for cracked
or separated potting compound.
Use a backup wrench on the terminal bolts. Failure
to use a backup wrench may result in breaking the
Inspect the surface of each terminal for corrosion.
terminal seal and premature failure of the controller. Any cracks or corrosion may be an indication that the
terminal seal is broken and may result in premature
It may be required to remove the control panel from the failure of the controller.
vehicle for this procedure. Check the adjustment screw plugs for correct torque.
Remove
1: Turn the start switch OFF.
2: Disconnect the batteries.
3: Using a backup wrench, remove the four terminal
bolts and wires.
4: Disconnect the wires from the KSI and #2 TROUBLESHOOTING
terminals.
Troubleshooting the control system is not included in
5: If equipped with the 7-pin in-line connector,
this manual.
disconnect it.
6: Remove the four bolts holding the controller to All electrical troubleshooting information is included in
the panel and remove the controller. a separate manual “Troubleshooting Electric Vehicles”
part number M7-001-69.
Install
1: Thoroughly clean the controller base and The troubleshooting manual was provided on the original
mounting plate. vehicle documentation CD. A replacement CD or hard
2: Install the controller to the mounting plate. copy can be purchased from your authorized Taylor-Dunn
3: Attach the wires to the studs and, using a backup distributor or can be downloaded from the Taylor-Dunn
wrench, torque per specification listed in the web site.
table at the end of this section.
4: If equipped with the 7-pin in-line connector, install
silicon dielectric grease (94-422-10: 5.3 ounce
tube) into the harness plug before connecting to
the controller.
Page 68 MS-534-13
Motor Controller
REPAIR/ADJUSTMENTS
WARNING
Repairs
There are no internally serviceable components in the motor
speed controller. If a controller is faulty then it must be replaced.
Note: Opening or disassembling a controller will void the
controller warranty.
Adjustments
There are two or three adjustments available:
1: Acceleration Ramp: How fast the controller ramps up to full power.
2: Plugging Current: How much current is provided when reversing direction.
3: Current Limit: Maximum current (not available on all controls).
These adjustments are accessed by removing the button head
screws in the housing. The control may need to be removed from
the panel to gain access to the screws.
The adjustment potentiometers (pots) are located just under the
screws. Use an insulated potentiometer adjustment tool to turn
the pots. Each pot has built in stops. DO NOT turn past the stops
or the pot may be damaged.
1: Acceleration Ramp: Turn clockwise for faster acceleration.
2: Plugging Current: Turn clockwise for harder plugging..
3: Current Limit: Turn counterclockwise to lower maximum
current.
MS-534-13 Page 69
Motor Controller
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque values in the
appendix.
Notes:
Description Inch Pounds Newton Meters
Terminal hardware 72 8.13
Adjustment plugs 8 0.90
Page 70 MS-534-13
Charger
Table of Contents
Charger
Remove/Install..................................................72
Troubleshooting...............................................72
WARNING
Chargers
REMOVE/INSTALL TROUBLESHOOTING
WARNING Troubleshooting control system is not included in this
manual.
manual. Before starting any procedure, read all All electrical troubleshooting information is included in
warnings and instructions that are located in the a separate manual “Troubleshooting Electric Vehicles”.
Service Guidelines chapter. The manual part number is M7-001-69 and was provided
on the original vehicle CD. A hard copy can be purchased
WARNING from your authorized Taylor-Dunn distributor or can be
downloaded from the Taylor-Dunn web site.
HIGH VOLTAGE.
Disconnect the batteries and make sure that the AC
power cord has been unplugged before disconnecting
any wires or removing the cover of the charger.
Failure to follow this instruction may result in serious
injury due to electric shock and/or property damage.
There are many charger options available for this Standard Single Phase AC wire Color Codes as of 2010.
model. The different charger may have different wiring Note: Older systems may use a alternate color
connections. code.
Disconnect the batteries and make sure that the AC Refer high voltage wiring repairs to a qualified technician
power cord has been unplugged before disconnecting
any charger wires or cords. United States / Canada
Neutral: White
Some charger models have disconnects close to the
Hot: Black or Red
charger and some have full length wire and molded
Ground: Green
cords. When replacing chargers with full length wires and
molded cords, DO NOT cut and splice the wires or cord. IEC (Europe) and United Kingdom
Cutting the wires or cord will void the charger warranty Neutral: Blue
and may result in incorrect operation of the charger or Hot: Brown
premature failure. Ground: Green/Yellow
Page 72 MS-534-13
Tires & Wheels
Table of Contents
Tires & Wheels
Inflation..............................................................74
Air pressure..............................................................74
Tread Wear........................................................75
Rotation.............................................................75
Changing Tire/Wheel Assembly......................76
Replace the Tire (pneumatic).........................76
Repair the Tire (pneumatic)............................76
Hardware Torque..............................................77
WARNING
Tires & Wheels
INFLATION
WARNING WARNING
Incorrect tire inflation can result in sudden failure of
the tire and/or braking / steering problems leading
to loss of control of the vehicle.
Service Guidelines chapter. Never exceed the maximum pressure as indicated
on the side wall of the tire. Exceeding the maximum
pressure may cause explosive failure of the tire
resulting in severe personal injury.
Air pressure
Maintaining the correct tire pressure is important to the safe operation of the vehicle as well as ensuring long tread life.
Under inflated tires result in:
• Excessive tire side wall flexing that can result in sudden tire failure.
• Excessive tread wear resulting in shortened tire life.
Over inflated tires result in:
• Tire explosion due to excessive pressure.
• Reduced road surface traction.
• Increased vibration from the road surface.
• Excessive tread wear resulting in shortened tire life.
Unequal tire inflation may result in:
• Uneven braking and loss of control of the vehicle.
• Steering pulling to the left or right.
Only check the tire pressure when the tire is cold. When checking tire pressure, you must check all tires including
your spare tire.
The correct tire size and pressure can be found in the specifications list in the manual.
Note: The front and rear tires may have a different tire pressure specification.
Page 74 MS-534-13
Tires & Wheels
TREAD WEAR
WARNING WARNING
This section is one section of a complete service DO NOT operate a vehicle if the cord is
manual. Before starting any procedure, read all visible on any tire (see illustration). A tire
warnings and instructions that are located in the in this conditions may suddenly fail at
Service Guidelines chapter. any time and cause loss of control of the
vehicle.
It is important to periodically inspect each tires tread for
wear. Driving with inadequate tread increases the risk
of loosing control of the vehicle due to hydroplaning on
a wet road surface. It also increases the risk of a flat tire
due to road debris. Extreme tire wear can result in sudden
tire failure and loss of control of the vehicle.
Refer to the maintenance schedule in this manual for the
recommended interval.
Minimum recommended tread depth is 1/16 inch (1.6
mm). There are a series of tread depth wear indicators
around the circumference of the tire. They will appear as
approximately 1/2 inch (12 mm) bands across the tread
as the tire approaches its wear limit (see illustration).
The tire should be replaced if any tread depth indicator
can be seen or any part of the tread depth is 1/16 inch
(1.6 mm) or less.
ROTATION
WARNING
Front and rear tires as well as left and right tires can wear at
different rates. It is important to periodically rotate your ties
to extend your tire life. Refer to the maintenance schedule
in this manual for the recommended interval.
MS-534-13 Page 75
Tires & Wheels
CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC)
ASSEMBLY WARNING
WARNING This section is one section of a complete service
This section is one section of a complete service warnings and instructions that are located in the
manual. Before starting any procedure, read all Service Guidelines chapter.
warnings and instructions that are located in the Note: To replace the tire, the tire/wheel assembly
must be removed from the vehicle. Refer
Note: A spare tire, jack, or lug wrench is not to Replace the Tire/Wheel section for
attached to the vehicle. information on removing the tire/wheel
assembly.
1: Loosen the wheel nuts (do not remove) before
raising the tire off of the ground. Tire replacement should only be performed by personnel
2: Raise the tire to be changed off of the ground and trained in tire replacement.
support with a jack stand. The tire replacement procedure will be unique to the
3: Remove the wheel nuts and tire/wheel assembly. type of replacement equipment being used. Refer to the
4: Install the replacement tire/wheel assembly. instructions provided with your equipment.
5: Install the wheel nuts and cross tighten to torque
specified in table. Always use a new valve stem when replacing a tire.
6: Check the tire for proper inflation. 1: Remove the tire from the wheel.
7: Lower the vehicle to the ground and remove the 2: Cut the old valve stem off of the wheel.
blocks from the wheels. 3: Remove the valve stem cap from the new valve
8: Check wheel nuts for tightness after 100 miles. stem.
4: Lubricate the valve stem with liquid soap.
5: Install a new valve stem using a valve stem tool.
Note: The valve stem tool is available at most auto
repair shops.
6: Install the tire onto the wheel following the
instructions provided with your tire replacement
equipment.
7: Inflate the tire to the proper pressure and check
for leaks.
8: Install the valve stem cap.
REPAIR THE TIRE (PNEUMATIC)

WARNING
Improper assembly or disassembly of a split rim
wheel can result if tire explosion causing severe
injury. Refer tire/wheel repair to a qualified tire
supplier.
Note: To properly repair a puncture, the tire
must be removed from the wheel. Refer to
Replace the Tire section for information on
removing the tire from the wheel.
It is recommended to repair a tire with a combination

vulcanized plug and internal patch.
Tire repairs should only be performed by personnel
trained in tire repair.
The tire repair procedure will be unique to the type of
repair equipment or repair components used. Refer to
the instructions provided with your equipment or repair
components.
Page 76 MS-534-13
Tires & Wheels
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque values in the
appendix.
Wheel nut 85 115
MS-534-13 Page 77
Notes:
Tires & Wheels
Page 78 MS-534-13
Batteries
Table of Contents
Batteries
General Guidelines and Safety.......................80
Cleaning............................................................81
Charging............................................................81
Watering............................................................81
Testing...............................................................82
Specific Gravity........................................................82
Storing...............................................................82
Storage.....................................................................82
Returning to Service.................................................82
Remove/Install..................................................83
Industrial Battery or Lift Out Battery Pack................83
Individual Batteries...................................................83
Hardware Torque..............................................84
WARNING
Batteries
GENERAL GUIDELINES AND SAFETY
WARNING NOTICE
Battery electrolyte will stain and corrode most
surfaces. Immediately and thoroughly clean any
surface outside of the battery that the battery
electrolyte comes in contact with. Failure to clean
may result in property damage.
WARNING
• Explosive mixtures of Hydrogen gas are present
within battery cells at all times. Do not work
with or charge battery in an area where open
flames (including gas furnace or water heater
pilots), sparks, cigarettes, or any other sources
of combustion are present. Always provide ample
ventilation in rooms where batteries are being
charged. Failure to do so may result in severe
• A battery is a live electrical source. It cannot be
disconnected or neutralized. Do not drop any
tool or conductive object onto the battery. A
conductive object that comes in contact with the
battery terminals will initiate a short circuit of the
battery. This could cause the battery to explode
resulting in severe bodily injury and/or property
damage.
• Battery electrolyte is poisonous and dangerous.
It contains sulfuric acid. Avoid 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.
Page 80 MS-534-13
Batteries
CLEANING WATERING
WARNING WARNING
Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this
section.. section..
NOTICE
Disconnect the batteries before cleaning.
Dry dirt can be readily blown off with low-pressure air
or brushed off.
Note: Wetness or wet dirt on the top of the battery DO NOT attempt to add electrolytes to a sealed
indicates battery acid boil over or excessive battery. Removing the caps of a sealed battery will
damage the battery resulting in premature failure.
gassing.
Using a nonmetallic brush with flexible bristles, wash

Note: The electrolyte level in a battery rises while
the battery off with a strong solution of baking soda and
charging and will be close to its highest
hot water mixed with a ratio of one pound of soda to
level after the end of a charging cycle. It is
one gallon of water (0.5 kg / 3.7 liters). Continue until
recommended to fill the battery at the end of
all fizzing stops, which indicates that the acid has been
a charging cycle. If the electrolyte is below
neutralized. Then rinse thoroughly with clear water. DO
the top of the battery plates then fill just
NOT get any of the solution into the battery cells.
enough to cover the plates and then top off
when the charging cycle is complete.
Clean the battery. Refer to Cleaning section for

information on cleaning the battery.
Check the electrolyte level in all battery cells. If low, fill
to the correct level (see illustration) with distilled water
using part number 77-201-00 battery filler, never add
additional battery electrolyte to the batteries.
CHARGING
Refer to the Operator manual for information regarding charging the battery.
MS-534-13 Page 81
Batteries
TESTING STORING
WARNING WARNING
Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this
section.. section..
NOTICE Storage
Thoroughly clean the battery and battery compartment.
DO NOT attempt to test the specific gravity of a sealed Refer to Cleaning in this section for information
battery. Removing the caps of a sealed battery will regarding cleaning the battery.
damage the battery resulting in premature failure.
Check the electrolyte level and charge the battery.
Refer to Watering in this section for information
regarding checking the electrolyte level.
Specific Gravity
Note: The battery must be fully charged before Store the vehicle or battery (if removed) in a cool, dry,
performing this test. well ventilated area.
If storing for more than one month, the battery should
The specific gravity of a cell is an indication of the actual
be charged per the table below.
state of charge of the cell. A fully charged cell should have
a reading of 1275 to 1300 (see the illustration below). A Returning to Service
discharged cell will read 1100. Ideally, all cells in a battery
Thoroughly clean the battery and battery compartment.
will have the same reading. Any cells in a battery that
Refer to Cleaning in this chapter for information
vary by more than 25 points may be an indication of a
regarding cleaning the battery.
bad or weak cell.
Check the electrolyte level and charge the battery.
Clean the battery. Refer to Cleaning section for
Refer to Watering in this chapter for information
information on cleaning the battery.
regarding checking the electrolyte level.
Using part number 77-200-00 hydrometer or equivalent
Test the battery. Refer to Testing section for information
graduated type hydrometer, test and record the specific
on testing the battery.
gravity of each cell in the battery.
The battery is now ready to be put back into service.
Use the highest reading to compare to all other cells. Any
cell or cells that are more than 25 points less than the
highest reading should be suspected as being a bad cell. Storage Tempera- Charging
If, after charging, none of the cells exceed a hydrometer ture Interval
reading of 1250 then there may be a fault in the charging (F) (months)
system. If the charging system checks OK then the
battery pack is no longer accepting a charge and should
be replaced.
Over 60 1
It may be possible to replace Individual cells in industrial
batteries. Contact the battery manufacturer for details. Between 40 and 60 2
Below 40 6
Typical
Hydrometer
Float
Page 82 MS-534-13
Batteries
REMOVE/INSTALL
WARNING WARNING
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
Service Guidelines chapter and beginning of this
to the vehicle.
section..
WARNING
• Use the proper equipment when handling and transporting batteries. Equipment that is used to lift and
support removable batteries should be rated at a minimum of 1.5 times the total battery weight.
• Keep all body parts out from underneath any battery that is not installed and latched in the vehicle.
Failure to follow these rules may result in severe bodily injury and/or property damage.
WARNING
Before removing the battery:
• Park the vehicle on a level surface. If removing
a Side Extract, the vehicle shall be positioned
as close as possible to the platform where the
battery will be stored.
• Place the Forward/Reverse switch in the center
OFF position.
• Make sure the Start switch is in the OFF
position.
• Set the park brake.
Industrial Battery or Lift Out Battery Pack

1: Thoroughly clean the battery and battery compartment. Refer to Cleaning in
this section for information regarding cleaning the batteries.
2: Using a hoist or forklift equipped with a proper battery lifting device (see
illustration), slowly raise the battery out of the vehicle.
3: Inspect the battery compartment for signs of corrosion.
4: If minimal signs of corrosion are seen, then the damaged paint should be
stripped off and the entire battery compartment cleaned and repainted.
5: If there are excessive signs of corrosion, then it may be necessary to replace
some of the frame members or completely rebuild the battery compartment.
6: Inspect the battery cables and terminals. If any of the cables or terminals show signs of corrosion, then they
must be repaired or replaced.
7: Install the battery in reverse order.
8: Remove the blocks from the wheels and test drive.
Individual Batteries
WARNING
Individual batteries can weight up to 80 pounds or
more. To avoid injury, use proper lifting techniques
or a hoist to remove the battery.
1: Using an insulated wrench, disconnect the cables from the battery to be

removed.
2: Using a battery lifting strap, remove the battery from the vehicle.
3: Inspect the battery compartment for corrosion. If there is significant corrosion,
all batteries should be removed and the compartment cleaned and painted.
4: Install the battery and torque the battery terminal hardware per torque listed in the Hardware Torque table at
the end of this section.
MS-534-13 Page 83
Batteries
HARDWARE TORQUE
If hardware is not listed here, refer to standard torque
values in the appendix.
Description Inch Pounds Newton Meters
Battery terminal, Trojan bolt 95-105 11-12
Notes:
Battery terminal, Trojan stud 95-105 11-12
Battery terminal, T/D bolt 168 19
Page 84 MS-534-13
Suspension
Table of Contents
Suspension
Rear Coil Spring and Shock, SS-534..............86
Remove/Install..........................................................86
Rear Coil Springs, SS-536,
SS-546.........................................................86
Remove/Install..........................................................86
Raising the Rear of the Vehicle.......................87
Front Fork Springs...........................................87
WARNING
Suspension
REAR COIL SPRING AND SHOCK, REAR COIL SPRINGS, SS-536,
SS-534 SS-546
WARNING WARNING
There is a single coil spring on top of the drive axle and There are two coil springs on the transaxle swing arm.
a shock mounted to the rear.
Remove/Install
Remove/Install 1: Remove the rear deck cover.
1: Raise the rear deck. 2: Remove the upper and lower spring mounting
2: Remove the charger. bolts.
3: Remove the two shock bolts and remove the 3: Raise the rear of the vehicle just high enough to
shock. remove the springs. Refer to Raising the Rear of
WARNING
the Vehicle in this chapter.
4: Tap the two spring clips out of each spring.
The coil spring is bent into a small arc when in the 5: Install the spring clips into the replacement
vehicle and may jump out of position when the frame springs.
is lifted off of the spring. 6: Place the springs onto the swing arm and
Keep clear of the spring when lifting frame or it may
loosely thread the mounting bolts into each clip.
result in severe personal injury. 7: Lower the frame down onto the springs and
tighten the spring hardware.
WARNING
DO NOT place hands or fingers between the spring
and frame.
This is a pinch point and may result in severe personal
injury.
4: Wrap a large heavy rag around the spring.

5: Raise the rear of the vehicle just high enough to
remove the spring. Refer to Raising the Rear of
the Vehicle in this chapter.
6: Install the spring onto the lower spring pad.
7: Carefully bend the spring over to mate with the
upper pad and SLOWLY lower the frame onto the
spring making sure it is indexed properly.
8: Install the shock.
Page 86 MS-534-13
Suspension
RAISING THE REAR OF THE FRONT FORK SPRINGS

VEHICLE The front fork springs are an integral part of the front
WARNING fork assembly.

If the springs require replacement then the fork
NEVER lift both rear wheels off of the ground using assembly should be replaced.
a single lift point.
The vehicle shall ALWAYS be supported at three
points. When raising the rear wheels off of the
ground, the 3-points would be the front wheel and
2-points at the rear on the left and right side furthest
apart.
Failure to support the frame at three points may
result in tipping of the vehicle causing severe bodily
injury and/or property damage
WARNING
1: Block the front wheel.

2: Place a jack at each corner of the rear frame or
use an overhead hoist with dual chains or straps
connected at the corners of the rear frame.
3: Raise the vehicle to the height required by the
procedure being performed.
4: Use jack stands if any part of your body must be
under the vehicle at any time or, if the vehicle
must remain suspended while unattended.
MS-534-13 Page 87
Notes:
Suspension
Page 88 MS-534-13
Wire Diagram
Table of Contents
Wire Diagram
Diagram Part Numbers....................................90
WARNING
Wire Diagram
DIAGRAM PART NUMBERS
Wire diagrams are too large to be legible when printed at this size. The wire diagram for this vehicle is included on
the Vehicle Documentation CD provided with the vehicle.
The diagram #’s for there vehicles:
• SCH-00072: SS-534, SS-536, SS-546
• SCH-00032: MX-600
This vehicle diagrams as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web
site at www.taylor-dunn.com.
Page 90 MS-534-13
Hardware Information
Table of Contents
Hardware Information
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
WARNING
Hardware
TORQUE GUIDELINES FOR STANDARD HARDWARE
Note: Torque values specified are for clean dry threads.
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.
Hardware Identification
Hex Head Bolts and Screws

The grade of SAE bolts and screws are identified by markings on the head
as illustrated to the right.
The grade of a metric hex head bolt or screw is cast directly on the head.
Below is an example of a 10.9. The location and style of the text will vary. SAE Grade 2 SAE Grade 5
SAE Grade 8 SAE Grade 9
Other types of bolts and screws
Truss Head, Grade 2 Carriage Bolt, Grade 2
Page 92 MS-534-13
Hardware
Hex Nuts
Nuts with no markings are to be treated as S.A.E. Grade 2
S.A.E. Grade 5 S.A.E. Grade 8
5.8 8.8 10.9 12.9

Metric Nuts
Hex Lock Nuts (stover)

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 markings are to be treated as S.A.E. Grade A
S.A.E. Grade B S.A.E. Grade C
Grade L’9
Other Nuts
Other nuts used by Taylor-Dunn® should be treated as S.A.E. grade A
MS-534-13 Page 93
Hardware
Generic Torque Values
All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness
specification. Reduce torque approximately 10-15% for lubricated threads.
Refer to the service section assembly procedure for critical torque values.
Imperial (inch), Foot Pounds Imperial (inch), Newton Meters

Grade, SAE Grade, SAE
Dia. Pitch 2 5 8 L9 Dia. Pitch 2 5 8 L9
#4 40 * * * * #4 40 * * * *
#6 32 * * * * #6 32 * * * *
#8 32 * * * * #8 32 * * * *
#10 32 * * * * #10 32 * * * *
#12 32 * * * * #12 32 * * * *
1/4 20 5.5 8.5 12.5 11 1/4 20 7.4 11.5 16.9 14.9
28 6.5 10.5 28 8.8 14.2
5/16 18 12.0 17.5 24.5 22 5/16 18 16.2 23.7 33.2 29.8
24 12.5 19.0 * * 24 16.9 25.8 * *
3/8 16 20 30 43 40 3/8 16 27.1 41 58 54
24 22.5 33 50 45 24 30.5 45 68 61
7/16 14 27 50 70 65 7/16 14 37 68 95 88
20 36 55 77 70 20 49 75 104 95
1/2 13 49 75 106 95 1/2 13 66 102 144 129
20 55 85 120 110 20 75 115 163 149
9/16 12 70 109 153 140 9/16 12 95 148 614 190
18 78 121 171 160 18 106 164 232 217
5/8 11 97 150 212 195 5/8 11 132 203 287 264
18 110 170 240 225 18 149 230 325 305
3/4 10 172 275 376 350 3/4 10 233 373 510 475
16 192 297 420 390 16 260 403 569 529
7/8 9 278 429 593 565 7/8 9 377 582 804 766
14 306 473 818 625 14 415 641 1109 847
1 8 416 644 909 850 1 8 564 873 1232 1152
14 466 721 1018 930 14 632 978 1380 1261
1-1/8 7 590 794 1287 1700 1-1/8 7 800 1076 1744 2304
12 662 891 1444 1850 12 897 1208 2364 2508
1-1/4 7 832 1120 1817 2950 1-1/4 7 1128 1518 2463 4000
12 922 1241 2012 3330 12 1250 1682 2727 4514
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
Page 94 MS-534-13
Hardware
All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess
specification. Reduce torque approximately 10-15% for lubricated threads.
Refer to the service section assembly procedure for critical torque values.
Metric, Newton Meters Metric, Foot Pounds

Grade, N-m Grade, N-m
Dia. Pitch 4.6 8.8 10.9 12.9 Dia. Pitch 4.6 8.8 10.9 12.9
3 0.50 0.51 * * * 3 0.50 0.38 * * *
4 0.70 0.95 3.1 * * 4 0.70 0.7 2.3 * *
5 0.80 2.28 6.1 * * 5 0.80 1.7 4.5 * *
6 1.00 3.92 10.4 15.5 * 6 1.00 2.9 7.7 11.4 *
8 1.00 * 27.0 * * 8 1.00 * 19.9 * *
1.25 9.48 25.0 37.0 * 1.25 7 18.4 27.3 *
10 1.00 * 57.0 * * 10 1.00 * 42 * *
1.25 * 54.0 * * 1.25 * 40 * *
1.50 19.1 51.0 75.0 * 1.50 14.1 38 55 *
12 1.25 * 96.0 * * 12 1.25 * 71 * *
1.50 * 92.0 * * 1.50 * 68 * *
1.75 32.6 87.0 160 * 1.75 24 64 118 *
14 1.50 * 150 * * 14 1.50 * 111 * *
2.00 51.9 140 205 * 2.00 38 103 151 *
16 1.50 * * * * 16 1.50 * * * *
2.00 79.9 215 310 * 2.00 60 158 229 *
18 1.50 * * * * 18 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 110 300 * * 2.50 81 221 * *
20 1.50 * * * * 20 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 156 430 * * 2.50 115 317 * *
22 1.50 * * * * 22 1.50 * * * *
2.00 * * * * 2.00 * * * *
2.50 211 580 * * 2.50 156 428 * *
24 2.00 * * * * 24 2.00 * * * *
3.00 270 740 * * 3.00 199 524 * *
27 3.00 * * * * 27 3.00 * * * *
3.00 398 * * * 3.00 293 * * *
30 2.00 * * * * 30 2.00 * * * *
3.50 540 * * * 3.50 398 * * *
Conversion Formulas:
1: Foot Pounds = Newton Meters x 0.737562149
2: Newton meters = Foot Pounds x 1.355817948
MS-534-13 Page 95
Hardware
REPLACING HARDWARE
WARNING
WARNING
Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury
or property damage:
• Many assemblies require specific torque settings for some hardware. Refer to the appropriate assembly
procedure for information regarding proper hardware torque.
• All hardware should be inspected for thread damage or corrosion prior to reassembly. If any evidence of
damage is found then the hardware should be replaced.
• Battery hardware should always be replaced when installing new batteries.
• Never reuse cotter pins or safety locking wire. Never use a wire, nail, or any other material to substitute
for a cotter pin.
• The locking force of a locknut is diminished when it is removed. Locknuts should be replaced whenever
removed.
• Some hardware may requires the use of a thread locking compound. Always thoroughly clean both male
and female threads when applying thread locking compounds.
Page 96 MS-534-13
Replacement Parts
TABLE OF CONTENTS
Replacement Parts
Ordering Parts for Your Vehicle......................98
Taylor-Dunn Web Site Information..................98
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
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
Note: Your vehicle may have been ordered with

special order options. These options typically start
with the letter “K”. Refer to your vehicle sales order
for information.
Replacement part numbers for special order options
are not included in the standard manual.
Replacement Parts SS and MX Models, DC System
ORDERING PARTS FOR YOUR VEHICLE
WARNING
The only personnel authorized to repair, modify, or adjust any part of this or any 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 severe bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.
WARNING
To maintain peak performance, always use original Taylor-Dunn replacement parts intended for use on your
vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only
use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable affect on the operation of the vehicle, result in additional
frame stress, or stress other components resulting in premature failure or an unsafe condition and may lead
to an accident resulting in serious injury or death.
This section contains a comprehensive parts list that includes all of the typical replacement parts available as of the
published date of this manual. This parts list should be used as a guide only.
This parts list does not include special order options that may have been ordered for your vehicle. To identify special
order options, refer to the original vehicle sales order. Any special order options will have a ‘K’ letter prefix in the
option number. The vehicle option list is also available on the Taylor-Dunn web site. The serial number of the vehicle
is required to obtain the option list.
Only use original Taylor-Dunn parts purchased from an authorized Taylor-Dunn distributor. Refer to the Taylor-Dunn
web site to locate your local distributor or call the factory direct at (714) 956-4040 for referral to a local dealer.
When contacting your dealer, always include the serial number of the vehicle to ensure obtaining the correct
replacement parts. The Taylor-Dunn web site includes a parts lookup utility. By using this utility you can obtain the
most current parts list for your vehicle. The serial number of the vehicle is required to use the lookup utility.
TAYLOR-DUNN WEB SITE INFORMATION

Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the
entire Taylor-Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside
of the Taylor-Dunn corporation.
Once registered on the Taylor-Dunn web site, you will have access to:
• Additional Taylor-Dunn product information.
• Worldwide Taylor-Dunn dealer contacts
• Vehicle Service, Maintenance, Operator, and Parts manuals.
• Replacement part number lookup utility
www.taylor-dunn.com
Page 98 MS-534-13
SS and MX Models, DC System Replacement Parts
My Vehicle information
Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
My local Parts Dealer: .
IDENTIFYING YOUR VEHICLE

Whenever necessary the model of the vehicle is identified with
the parts that are specific to that model. If a model identification
is not specified in the diagram heading or within the parts table,
then the part can is used in all models.
MS-534-13 * Not available at time of printing Page 99

AXLE ASSEMBLY, FRONT
SS-534, SS-536, MX-600
SS-546
Page 100 MS-534-13

Axle Assembly, Front (SS-534, SS-536, MX-600)
Item No. Part No. Description Qty
1 16-206-00 Spacer 2
2 45-308-00 Oil Seal 2
3 80-105-00 Bearing Race 2
4 80-015-00 Tapered Roller Bearing 2
5 15-010-10 Front Axle 1
6 85-140-10 Spring 1
7 14-079-20 Fork 1
97-100-00 Woodruff Key 1
8 88-229-81 3/4” NC Locknut 2
9 88-228-61 3/4” NC Washer 2
Axle Assembly and Steering, Front SS-546

- 00-546-12 Axle beam (includes all bushings) 1
- 88-289-81 Nut, Axle beam 1
- 88-268-61 Washer, Axle beam nut 1
- 88-527-14 Cotter pin, Axle beam nut 1
1 92-104-00 Bearing cap 2
2 88-527-14 Cotter pin 2
3 88-239-85 Castle nut 2
4 88-228-61 3/4 SAE Flat washer 2
5 80-017-00 Bearing 1
6 80-103-00 Race 1
7 12-124-15 Hub 2
8 80-103-00 Race 1
9 80-017-00 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 86-519-11 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 88-106-61 3/8 SAE Flat washer 4
17 16-506-00 Upper spacer 4
18 16-506-00 Lower spacer 4
19 88-108-61 3/8 SAE Flat washer 4
20 01-546-16 Tie rod 2
21 32-240-55 Bushing 2
22 87-073-00 Grease fitting 2
23 21-020-15 King pin 2
24 32-240-55 King pin bushings (inside axle) 4
97-180-55 Thrust washer 4
25 88-189-81 5/8NC Lock nut 2
26 00-546-02 Steering arm 1
27 87-071-00 Grease fitting 1

AXLE SHAFT ASSEMBLY, REAR
SS-536, SS-546, MX-600
Page 102 MS-534-13

Axle Assembly, Rear SS-534
1 85-140-00 2-7/16” X 6-1/4” Spring 1
2 96-240-00 1/2” X 4” Bolt 2
3 98-601-00 Rubber Grommet, 1/2” ID 4
4 88-149-81 1/2”NC Locknut 2
5 45-045-00 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/ Bearing and Retainer Plate 1
41-165-11 Left Side Axle w/ Bearing and Retainer Plate 1
11 88-180-18 5/8”NC X 2-1/2” Hex Head Bolt 2
12 86-602-00 Shock Absorber 1
13 41-296-00 Housing 1
Axle Assembly, Rear SS-536, SS-546, MX-600

Spec # 012AJ311-1
1 41-281-10 Differential Assy 1
2 45-303-20 Seal 2
3 80-480-20 Axle Bearing 2
4 88-840-13 Internal Snap Ring 4
5 41-126-95 Right Axle Shaft 1
41-126-94 Left Axle Shaft 1
6 See Brakes Right Brake 1
See Brakes Left Brake 1
7 88-199-85 Slotted Hex Nut 2
8 88-188-61 5/8” SAE Washer 2
9 41-518-01 Brake drum 2
41-518-02 Hub
10 88-527-11 1/8” X 1” Cotter Pin 2
11 66-610-28 Wheel Stud 4
12 *
13 *

AXLE ASSEMBLY, REAR 3RD MEMBER, SS-534
Page 104 MS-534-13

Axle Assembly, 3rd Member, SS-534
1 ** 3rd member Housing (1.784 ID Carrier Bearing) 1
2 88-119-80 3/8” NF Nut 14
3 ** Differential Assembly 1
4 80-128-00 Carrier Bearing Race 2
5 80-512-00 Carrier Bearing 2
6 31-234-50 Ring and Pinion Gear Set , 3.00 ratio 0 or 1
31-239-00 Ring and Pinion Gear Set , 5.43 ratio 0 or 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 ** Pinion Housing 1
13 16-419-00 .002 Shim (Add Shims As Needed) -
16-420-00 .010 Shim (Add Shims As Needed) -
16-411-00 .005 Shim (Add Shims As Needed) -
14 16-415-00 Spacer 1
15 80-125-00 Pinion Bearing Race 2
16 ** Differential Bearing Adjuster Nut 2
17 88-080-04 5/16” X 3/8” NC Hex Bolt 2
18 88-140-16 1/2” X 2” Hex Bolt 2
19 96-243-00 7/16” X 7/8” Hex Bolt (Locking Head) 10
Not Shown 45-339-00 Oil Seal, Pinion Shaft 1
41-701-00 Roll Pin, Spider Gear Shaft 1
** 44-340-92 Kit,3rd member housing and differential
AXLE ASSEMBLY, BELT DRIVE, SS-534

- 30-114-00 Motor pulley, 2.25” dia -
- 30-115-00 Motor pulley, 2.75” dia -
- 30-116-00 Drive pulley, 8” dia -
- 30-117-00 Drive pulley, 11” dia -
-- 30-601-00 Drive belt (8” pulley) 2
- 30-613-00 Drive belt (11” pulley) 2

TRANSAXLE ASSEMBLY, SS-536, SS-346, MX600
Page 106 MS-534-13

Axle Assembly, Transaxle, SS-536, SS-546, MX-600
Spec # 012AJ311-1
- 4S-150-10 Complete transmission assembly 1
1 41-280-10 Differential Housing Assy 1
2 80-480-10 Pinion 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 Bearing 2
11 96-330-10 Bearing Cap Bolt 4
12 41-127-94 Fill Plug 1
13 41-127-64 Carrier Cover 1
14 41-716-00 Differential Case Assy 1
15 *
16 *
17 *

BATTERY

75-237-00 Battery jumper 3
77-043-00 Battery, T-605 0 or 4
77-042-00 Battery, T-105 0 or 4
77-047-00 Battery, T-145 0 or 4
50-243-10 Battery rod 1 or 2
50-250-00 Battery hold down 1 or 2
88-088-66 Flat washer, tin/lead plated 1 or 2
88-069-81 1/4NC Nylon lock nut 1 or 2
88-081-12 5/16NC x 1 Square bolt, stainless steel 8
88-089-80 5/16NC Hex nut, stainless steel 8
88-089-70 5/16 Split lock washer, stainless steel 8
Page 108 MS-534-13

BRAKES, LINKAGE SS-534

1 88-140-14 1/2” NC X 1-1/2” Hex Head Cap Screw 1
2 98-200-00 Brake Pedal Pad, Rubber 1
3 88-089-81 1/2” NC Locknut 2
4 01-534-67 Brake Pedal Arm 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 85-295-00 Return Spring 1
8 96-813-00 Brake Cable Assembly 1
9 88-517-11 3/32” X 1” Cotter Pin 7
10 88-149-81 1/2NC Lock Nut 1
11 50-662-00 Bell Crank 2
12 50-432-00 Brake Pedal Connecting Link 1
13 96-771-00 3/8” X 3/4” Clevis Pin 1
14 51-508-00 Brake Pedal, w/P.Brake Locks 1
15 3/8 Flat Washer 2

BRAKES, LINKAGE SS-536, SS-546, MX-600

1 88-140-13 1/2” X 1/4” NC Bolt 1
2 02-536-09 Pedal Lock 1
3 98-200-00 Pedal Pad 1
4 88-149-81 1/2” NC Locknut 1
5 88-527-11 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 2
10 02-536-06 Brake Equalizer 1
11 96-772-00 3/8” X 1” Clevis Pin 1
12 62-033-00 Accelerator Module 1
13 98-254-10 Accelerator Pedal 1
14 88-847-08 E-clip 2
15 85-125-00 Spring 2
16 96-754-00 Clevis 2
17 88-517-11 Cotter pin 2
18 96-773-00 Clevis pin 2 ....
Page 110 MS-534-13

BRAKES, SS-534

1 41-660-60 Kit, Brake Band 1
2 41-532-00 Brake drum 1
3 41-380-10 Bracket 1
4 88-080-11 5/16NC x 1 Bolt 2
5 88-089-81 5/16 Lock Nut 2
6 85-270-00 Spring 1
7 See pedal linkage Link 1

BRAKES, SS-536, 546, MX-600

- 85-344-60 Spring Kit 1
- 41-634-00 Brake Shoes (Shows 1 Set) 2
- 41-344-98 Complete Brake Assembly, Left 1
- 41-344-99 Complete Brake Assembly, Right 1
Page 112 MS-534-13

CHARGER, SIGNET
Note: The harness connectors and AC plug

are not included with the charger.
Model HBS Charger

PART # DESCRIPTION
79-302-20 24 volt Flooded Batteries (WET, FLA)
Note: There are no user serviceable components inside the charger

Note: The charger AC cord is an integral part of the charger. When replacing the charger, do not cut
and splice the AC cord. Cutting the AC cord will void the charger warranty.
QTY PART # DESCRIPTION
2 75-318-20 Butt splice
2 75-320-51 Knife connector
1 76-200-00 AC plug, 115 volt
Standard Single Phase AC wire Color Codes as of 2010.

Note: Older systems may use a alternate color code.
Refer high voltage wiring repairs to a qualified technician

United States / Canada
Neutral: White
Hot: Black or Red
Ground: Green
IEC (Europe) and United Kingdom
Neutral: Blue
Hot: Brown
Ground: Green/Yellow

Model 14400-31 7105-01 12750 9513-31 13760 22730

Part Number 79-302-50 79-300-50 79-300-55E 79-302-10 79-302-15 79-303-05
Type 24LC40-8ET 24LC25-8ET 24LC25-8ET 24LC40-8ET 24LC40-8ET 24LC25-8ET
AC Voltage/Hz/Amps 230/50/7 230/50/4 230/50/4 115/60/13 115/60/13 115/60/8
DC Voltage/Amps 24/40 24/25 24/25 24/40 24/40 24/25
Style Portable Portable Built-In Portable Built-In Built-In
1 Ammeter 79-852-00 79-851-10 - 79-852-00 - -
2 Timer Assembly S/O 79-805-64 79-805-70 79-805-64 79-805-66 79-805-66
Relay for #2 79-808-10 79-808-10 79-808-10 79-808-10 79-808-10 79-808-10
3 Capacitor 79-902-00 79-902-00 79-902-00 79-902-00 79-902-00 79-902-00
4 Diode Assembly S/O 79-749-13 79-749-13 79-749-13 79-749-13 79-749-13
5 Transformer S/O S/O 79-644-08 S/O S/O S/O
6 AC Cord S/O S/O - 79-575-10 - -
7 Fuse Assembly 79-831-10 79-831-00 79-831-00 79-831-10 79-831-10 79-831-10
8 Strain Relief S/O 79-532-00 79-530-00 79-531-00 79-531-00 79-531-00
9 Strain Relief S/O 79-530-00 - 79-530-00 - -
10 DC Cord 79-567-10 79-566-10 - S/O - -
11 Interlock Relay Assy. - - 79-306-23 - - 79-809-60
Replacement AC Plug - - - 76-200-00 76-200-00 76-200-00
Page 114 MS-534-13

CONTROL SYSTEM, MOTOR SPEED CONTROL

1 88-838-06 #14 X 1/2” Pan Head Screw 4
2 62-204-00 Motor Controller 1
3 72-501-43 Direction Control Solenoids 2
4 61-838-41 5/8” X 1-1/2” Bus Bar 2
5 88-088-62 5/16” Lock washer 10
6 88-099-91 5/16” Nut 10
7 88-048-62 #10 Lock washer 6
8 88-049-80 10-32 Nut 6
9 61-838-42 3/8” X 2-5/8” Bus Bar 2
10 72-501-42 ISO Solenoid 1
11 79-840-00 10-Amp Circuit 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 73-004-20 12V Horn 1
16 88-088-62 5/16” Lock washer 4
17 88-089-80 5/16” Hex Nut 4
18 88-818-06 #8 X 1/2” Pan Head Screw 7
19 78-302-50 Resistor 1
Not 75-148-43 Harness, Complete, MX-600 1 .....
Shown 75-154-03 Harness, Control Panel, SS5-34 & SS5-36 1
75-154-02 Harness, Chassis, SS5-34 & SS5-36 1
75-149-25 Power Harness, All 1
62-033-48 Throttle module 1

CONTROL SYSTEM, INSTRUMENT PANEL
SS-534, SS-536, SS-546
MX-600

1 71-122-20 Horn Switch 1
2 71-120-10 Start Switch 1
3 71-039-11 Light Switch, SS models 1
71-100-00 Light Switch, MX model 1
4 74--009-10 Battery Status Gauge 1
5 71-039-11 Auxiliary Swtich, SS models 1
71-100-00 Auxiliary Swtich, MX model 1
6 71-039-02 Direction Control Switch 1
7 74-000-00 Hour meter 1
8 76-013-00 Portable Charger Receptacle 1
9 72-028-20 Power Light 1
- 00-536-04 Console, SS models 1
- 00-300-04 Console, MX model 1
- 75-154-01 Harness, SS models 1
Page 116 MS-534-13

DECALS

1 94-384-00 How to apply park brake 1
2 94-309-50 Park Brake Warning 1
3 94-313-20 Safety warning 1
4 - - -
5 94-301-43 Arms and Legs, SS-534, SS-536, MX-600 1
94-301-42 Arms and Legs SS-546 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 1
9 94-319-00 Battery Disconnect 1
10 94-313-00 Battery warning 1
11 94-385-00 Battery wiring, SS-534, SS-546, SS5-36 1

Not 94-386-02 “MX-600” (small)
Shown 94-386-04 “MX-600 (large)
94-386-01 Roll over warning (MX-600 only)
94-386-00 Caution, Tools and Equipment (MX-600 only)

ELECTRICAL, MISCELLANEOUS
Electrical
1 96-624-00 Clamp, 1/4 Jiffy Clip
96-625-00 Clamp, 5/16 Jiffy Clip
2 96-626-00 Clamp, 7/8 Jiffy Clip
3 96-640-00 Clamp, 3/16 Push Mount
4 96-642-00 Wire harness Clip, push mount
5 96-650-01 Wire Harness Clip, stick on
6 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID
96-630-00 (not shown Clamp, Rubber Lined 5/8 ID
96-630-50 (not shown Clamp, Rubber Lined 5/8 ID (.265 mounting hole)
96-631-00 (not shown Clamp, Rubber Lined 3/4 ID
96-631-10 (shown) Clamp, Rubber Lined 1.0 ID
96-631-15 (not shown Clamp, Rubber Lined 1-1/2 ID
Not 71-102-60 Kit, Operator Presence Switch 1
Shown 98-599-15 Plastic grommet for 1.75 hole
98-599-20 Plastic Grommet for 2.5 hole
78-321-10 Ground Strap (optional) 1
Page 118 MS-534-13

FRAME AND BODY, DECKBOARDS
90-408-10 Deck, SS-536, SS-546
90-409-00 Deck, SS-534
94-025-51 Deck Trim, SS-534
50-112-00 Deck Prop Rod, SS-534 1
88-587-90 Retainer, Prop Rod 1
91-809-00 Mount, Prop Rod 1
90-408-20 Deck, MX-600
97-840-00 Vice, MX-600
00-300-01 Vise Mount Plate 1
88-100-15 3/8”NC X 1-3/4” Hex Head Bolt 3
88-108-62 3/8” Lockwasher 3
00-300-08 Deck Cover, Steel, MX-600 (optional)
FRAME AND BODY, MISC BODY TRIM
Frame and Body

94-035-01 Plastic Cowl Trim sold by the foot
94-201-00 T/D Emblem
98-2554-10 Throttle Pedal

FRAME AND BODY, TOOLBOX, MX-600

1 91-340-25 Tool 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
91-340-26 Keys for Toolbox Locks 1
00-300-08 Steel Deck Cover 1
Page 120 MS-534-13

HITCHES
WARNING
DO NOT install a trailer hitch unless the vehicle was configured for towing
from the factory. Field kits are not available.
DO NOT transport passengers when towing a trailer; The passenger may be
severely injured if contacted by the trailer tongue.
Mounting Hardware
97-811-00 1-7/8 inch Ball
97-821-00 2-inch Ball
88-140-14 1/2NC x 1-1/2 Hex bolt 4
88-149-80 1/2NC Hex nut 4
88-148-62 1/2 Split lock washer 4

LIGHTS

72-005-00 Headlight 1
71-505-05 Headlight Mount, geared steering option 1
75-166-35 Harness, MX 6-00 1
72-022-00 Tail light, 4” Round 2
72-025-00 Tail Light, Oval 2
71-111-00 Brake light switch 0 or 1
72-022-51 Round Rubber Grommet 2
72-025-51 Oval Rubber Grommet 2
72-022-52 Pig Tail (For Both Stop & Tail Lights) 2
72-023-59 Strobe Light, LED, Amber (optional) -
Page 122 MS-534-13

MOTOR
Motor
70-049-05 Motor assembly, SS-536, SS-546, MX-600 1
70-049-00 Motor assembly, SS-534 1
1 * Field assembly 1
2 * Armature 1
3 70-180-00 Brush holder 1
4 PKIT-00022 Brush springs (four) 4
5 PKIT-00064 Brush pair (two) 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 cap 1
9 * Brush cover 1

MOTOR MOUNT
Motor Mount, SS-534

1 00-380-96 Motor mount 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

1 88-060-12 Bolt 3
88-068-62 Lock washer 3
2 70-049-06 Spacer bushing 1 ....
Page 124 MS-534-13

SEATS

93-004-00 Seat back, SS-536, SS-546 1
90-144-00 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 SS-534 (optional) 1
90-109-50 **Seat Frame, Mount, Fold down SS-534 (optional) 1
90-090-00 Rear Step, SS-534
02-536-11 Seat Frame, fold down, SS-536, SS-546 1
02-534-25 Hip Restraints, SS-534 2
** - Fold down seat frame requires installation of the rear step.

STEERING, TILLER
Steering Linkage, Tiller

1 97-100-00 Woodruff Key 1
2 45-307-00 Oil Seal 2
3 80-011-10 1-1/4” Tapered Roller Bearing 1
6 80-011-10 1-1/4” Tapered Roller Bearing 1
7 45-307-00 Oil Seal 2
8 16-409-00 Spacer 1
9 97-230-00 1-1/4” NF X 9/16” Locknut 1
10 19-101-20 Steering Tiller 1
88-140-15 Pinch bolt 1
88-149-81 Lock Nut 1
Page 126 MS-534-13

STEERING, GEAR SS-534
Steering Linkage
1 95-915-20 Cap, Black Plastic 1
2 88-199-82 5/8” Jam Nut 1
3 19-007-20 Steering Wheel 1
4 18-309-00 Gear Box Only,(With Bolts, Bushings, and Zerk Fittings.) 1
5 88-068-27 1/4” X 4-1/2”NC HEX Cap Screw 4
88-060-22 1/4” X 3-1/2”NC HEX Cap Screw 2
6 88-068-62 1/4” Lock washer 6
7 32-203-00 3/4” ID X 7/8” OD X 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 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 32-207-00 3/8”ID X 5/8”OD X 1/2” Long Bronze Bushing 1
16 88-088-62 5/16” Lock washer 3
17 88-088-11 5/16” X 1” HEX Hd Cap Screw 3
18 31-254-00 36-Tooth Spur Gear, .875 bore 1
19 87-074-00 1/4”-28NF Zerk Fitting 1
20 87-071-00 3/16” Zerk Fitting 1
21 80-400-10 3/4”ID Ball Bearing 2
22 16-405-00 3/4”ID X 1-1/4”OD Spacer 1

STEERING, GEAR SS-536, SS-546, MX-600

1 19-011-25 Cover 1
2 88-199-82 5/8” NF Jam Nut 1
3 19-011-20 Steering Wheel 1
4 18-309-13 Plate and Sleeve 1
5 32-203-00 3/4”ID X 7/8”OD Bronze Bushing 1
6 71-505-05 Head Light mounting Bracket 1
7 88-068-82 1/4” Lock washer 6
8 87-071-00 3/16” Zerk Fitting 1
9 80-400-10 3/4”ID Bearing 1
10 80-400-10 3/4”ID Bearing 1
11 45-004-10 Gear Box Gasket 1
12 88-060-22 1/4” X 3-1/2” NC Hex Bolt 2
13 18-309-12 Gear Box Case 1
14 20-031-20 Steering Shaft and Gear 1
15 31-255-10 Stem and Gear 1
16 45-004-10 Gear Box Gasket 1
17 18-309-11 Bottom Plate 1
18 45-003-10 Mounting Plate Gasket 1
19 31-254-00 36 Tooth, Spear Gear 1
20 88-069-81 1/4” Locknut 4
21 32-207-00 3/8” ID X 5/8” OD Bronze Bushing 1
22 88-060-25 1/4” X 4-1/2”NC HEX Bolt 4
Page 128 MS-534-13

SUSPENSION, REAR, SS-536, SS-546

1 98-601-00 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”” Lock washer 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 88-149-81 1/2” Locknut 4
9 96-240-00 1/2” X 4” Bolt 2
10 85-140-00 Spring 2
- 17-106-02 Spacer (under #8) 4

SUSPENSION, REAR, SS-534

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 88-188-61 Washer 1
7 85-140-00 Spring 1
8 88-149-81 Nut 2
9 98-601-00 Bushing 4
10 96-240-00 Bolt 2
Page 130 MS-534-13

WHEELS AND TIRES
4-Hole | 5-Hole Part No. Description

All tire/wheel sizes are 4.80 x 8 unless otherwise specified
| 10-075-00 Tire, Pneumatic, Load Range B
| 10-076-00 Tire, Pneumatic, Load Range C
| 10-074-00 Tire, Man-Toter. Rib
| 10-074-10 Tire, Man-Toter, Rib, Non-Marking
| * Tire, Man-Toter, Lug
| 12-012-00 Wheel, tubeless
| 13-001-00 Wheel with Center Hub (front only), includes bearing and seals
| 12-042-00 Wheel, Split Rim
| 12-043-20 Wheel, Split Rim
| 13-576-10 Tire/Wheel assembly, Front w/center hub, Pneumatic, Load Range B
| 13-734-00 Tire/Wheel assembly, Pneumatic, Load Range B
| 13-734-12 Tire/Wheel assembly, Pneumatic, Load Range B
| 13-734-10 Tire/Wheel assembly, Foam Filled
| 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 assembly, Man-Toter, Non-marking, Rib
| 13-734-51 Tire\Wheel assembly, Man-Toter, Non-marking, Rib
| 13-734-11 Tire\Wheel assembly, Pneumatic, Split Rim Load Range B
| 13-739-10 Tire\Wheel assembly, Pneumatic, Split Rim Load Range C
| 13-734-25 Tire\Wheel assembly, Pneumatic, Split Rim Load Range B
| 11-030-00 Tube
| 13-989-00 Valve Stem
| 97-236-00 Wheel Nut
| 12-120-00 Center Hub for Bolt on Wheel, includes bearings and seals
| 12-120-10 Center Hub for Bolt on Wheel, includes bearings and seals
80-105-00 Bearing, 12-120-xx Center hub
80-015-00 Race, 12-120-xx Center hub
45-308-00 Seal, 12-120-xx Center hub
Model SS-534 is equipped with 5-hole wheels

Models SS-536, SS-546, and MX-600 are equipped with 4-hole wheels

Notes:
Page 132 MS-534-13

WARNING
Operating, servicing and maintaining a passenger vehicle or off-
highway motor vehicle can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which
are known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure, avoid
breathing exhaust, do not idle the engine except as necessary,
service your vehicle in a well-ventilated area and wear gloves or
wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-
vehicle.
Taylor-Dunn® Manufacturing.
2114 West Ball Road.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
FAX: (714) 956-0504
Visit our Website: www.taylor-dunn.com

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Service and Replacement

The Best Way

Dealer Purchased From: .

Your satisfaction is out #1 goal. If you have questions or concerns

Visit our Web site: www.taylor-dunn.com

WHO SHOULD READ THIS MANUAL

HOW TO USE THIS MANUAL

Represents a corrosive Parking brake ON.

The service personnel are responsible for the service

This manual is valid only for the

WEB SITE REGISTRATION

• Read the operator’s manual before operating this vehicle.

Interval Service Service

Form PM-0017, Revision A

Interval Service Service

Form PM-0017, Revision A

62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness

96-500-48: GT Drive Oil Fill Plug Tool

77-200-00: Hydrometer 77-201-00: Battery Filler 70-440-55: Pin Removing Tool

75-442-55: Pin Removing Tool

Symptom Suspect Component or System Action

Assembly Item # Component Qty Capacity Lubricant

HAZARDOUS WASTE DISPOSAL

SS-534 from Rear (#9 on top)

SS-536, SS-546, MX from Bottom

The following items shall be inspected every time before

First 25 hours of Operation Every 6 Months or 1,000 hours)

Tire Size Weight NEW Weight USED

NEW: Weight = 16.931 / Radius

1: Set the park brake. 1: Set the park brake.

This section is one section of a complete service WARNING

1: Remove the steering gear from the vehicle.

Typical D1 Drive axle shown with

WARNING transmission for this procedure. Refer to

11: Remove both snap rings from the intermediate

19: Remove the o-rings from both sides of the

14: While supporting the shaft and gear assembly,

15: Remove the o-rings from each end of the

6: Insert the flanged side bearing into the bearing

WARNING Do not drive the vehicle if any worn or broken part is

• Onlyuse DOT 3 brake fluid from a new sealed

REAR DRUM BRAKE

Auto-Adjust Brake Mechanism

Inspecting the Auto-Adjust Brake Mechanism

This procedure assumes that the component has been

1: Pull the pistons out of the brake body.

Note: This vehicle is equipped with self-adjusting

1: Remove the motor from the

1: Press new bearings into the motor housings and

Commutator Brush Length Resistance

REPAIR THE TIRE (PNEUMATIC)

It is recommended to repair a tire with a combination

Using a nonmetallic brush with flexible bristles, wash

Clean the battery. Refer to Cleaning section for

Industrial Battery or Lift Out Battery Pack

1: Using an insulated wrench, disconnect the cables from the battery to be

4: Wrap a large heavy rag around the spring.

RAISING THE REAR OF THE FRONT FORK SPRINGS