Taylor-Dunn E-455 Service And Replacement Parts Manual Download

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Table of Contents

Batteries

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.

WARNING

Batteries

General Guidelines and Safety.......................82

Cleaning ...........................................................83

Charging ...........................................................83

Watering ...........................................................83

Testing ..............................................................84

Specific Gravity

.......................................................84

Storing ..............................................................84

Storage ....................................................................84

Returning to Service ................................................84

Remove/Install .................................................85

Industrial Battery or Lift Out Battery Pack ...............85

Side Extract Battery .................................................85

Hardware Torque .............................................86

Individual Batteries ..................................................86

Summary of Contents for E-455

Page 1: ...G THIS VEHICLE The operator s manual contains important information regarding the safe operation of this vehicle WARNING Starting Serial Number 207800 Ending Serial Number See Introduction Chapter Ser...

Page 2: ...lacement parts and service for our vehicles Refer to our web site www taylor dunn com for a dealer lookup application Originally Published 9 1 2017 Revision D 7 12 2018 contents subject to change with...

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

Page 4: ...n 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 internation...

Page 5: ...pecial Tool List 21 Lubrication 25 Front Axle 29 Transaxle GT 33 Transaxle SD 43 Steering 51 Brakes 61 Motor 69 Motor Controller 75 Wire Diagram 79 Batteries 81 Tires Wheels 87 Suspension 91 Hardware...

Page 6: ......

Page 7: ...ure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Introduction About this manual 8 Who Should Read This Manual 8 How To Use This Manual 8 Conventions 9...

Page 8: ...te 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 m...

Page 9: ...E 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 i...

Page 10: ...edures and lead acid batteries Of the Operator A vehicle shall not be operated until the operator has successfully completed an operator training course provided by the owner of the vehicle The operat...

Page 11: ...serial numbers are shown in the illustrations below 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 Tay...

Page 12: ...Page 12 ME 455 04 Introduction E 455 Notes...

Page 13: ...ts Service Maintenance Guidelines Service Maintenance Guidelines READ ME FIRST Maintenance Guidelines and General instructions 14 Vehicle Modifications 15 Replacement Parts 16 Using Non OEM Replacemen...

Page 14: ...tached to the left and right side of the vehicle Failure to properly support the vehicle may result in the vehicle tipping over causing severe bodily injury and or property damage WARNING The vehicle...

Page 15: ...ration 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 191...

Page 16: ...cle 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...

Page 17: ...ure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Preventative Maintenance Daily Visual Inspection 18 Pre Operation Inspection 18 Maintenance Schedule 1...

Page 18: ...ide view mirror adjustments Steering operation Brake operation service and park brake Proper operation of trailer hitch This section is one section of a complete service manual Before starting any pro...

Page 19: ...fety labels Clean battery terminals Inspect front wheel bearings for play and noise Inspect fork collar bearings for play Trailer hitch operation latch wear Every 3 Months or 300 hours All monthly ite...

Page 20: ...hicle should operate normally High Pedal Disable HPD Sit in the approved operator position turn the start switch ON Press and hold the throttle pedal to the floor Select a direction The vehicle should...

Page 21: ...Table of Contents Special Tool List Special Tool List Controller Programming 22 Troubleshooting Guide 24...

Page 22: ...roubleshooting provided in the vehicle service manuals 62 027 61 and 62 Sevcon System Handset Diagnostics and adjustments 62 only of the Sevcon Power Pak and Micro Pak control systems 70 440 55 Pin Re...

Page 23: ...plash guard and auto shutoff when cell is full 77 200 00 Hydrometer Used for testing battery electrolyte Illustration is of a typical hydrometer actual hydrometer type may vary 96 500 48 GT Drive Oil...

Page 24: ...ow 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...

Page 25: ...Table of Contents Lubrication Lubrication Lubrication and Fluids Chart 26 Hazardous Waste Disposal 26 Lubrication Diagram 27...

Page 26: ...Plug GT 1 1 4 1 9 Liters SAE 80W90 Gear Oil 9 Fill Plug SD 1 1 4 Liters SAE 80W90 Gear Oil 10 Motor Coupler 1 Part 94 421 34 Moly Paste Grease 11 Fill Level SD Axle 1 0 75 Liters SAE 80W90 Gear Oil H...

Page 27: ...Lubrication Page 27 ME 455 04 E 455 LUBRICATION DIAGRAM GT Transaxle SD Transaxle...

Page 28: ...Lubrication Page 28 E 455 ME 455 04 Notes...

Page 29: ...ual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Front Axle Inspect Front Wheel Bearings 30 Adjust Front Wheel Bearings 3...

Page 30: ...front axle nut until the wheel is difficult to rotate 3 Continue to rotate the wheel for 5 compete revolutions 4 Attach a rope to the tire and wrap around the tire with 1 foot remaining hanging in the...

Page 31: ...e front of the vehicle and support with jack stands 2 Remove the front axle nut 3 Using a 1 inch diameter wooden drift punch drive the axle out of the fork 4 While holding the front wheel in position...

Page 32: ...Front Axle Page 32 E 455 ME 455 04 Notes HARDWARE TORQUE 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 33: ...4 Remove 35 Transmission Assembly 35 Remove 35 Install 35 Axle Shaft 36 Remove 36 Install 36 Rear Hub Rotor Bearings 37 Motor Remove 37 Primary Gear Case 38 Secondary Gear Case 39 Disassemble 39 Assem...

Page 34: ...til level with the bottom of the opening 8 Replace the fill level plug 9 Reconnect the batteries 10 Remove the blocks from the wheels This section is one section of a complete service manual Before st...

Page 35: ...le so high to where the rear wheels come off of the ground 6 Remove the swing arm pivot bolts and roll the transmission assembly out from under the vehicle Install 1 Install the transmission assembly...

Page 36: ...he original bolts could cause loss of brakes resulting in severe bodily injury and or property damage WARNING Install 11 Install in reverse order or removal a Lubricate the bearing external O ring b U...

Page 37: ...e wheels release the park brake and test drive 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...

Page 38: ...ion in relation to the 3rd member housing so that it will be reassembled in the same position 12 Remove the six retaining bolts holding the gear case to the 3rd member housing 13 Remove the gear case...

Page 39: ...hly clean all parts 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 WARNING...

Page 40: ...pinion Loosen the housing carrier bearing race ring nuts and tighten the cover carrier bearing race ring nut equally Note To move the ring gear away from the pinion Loosen the cover carrier bearing r...

Page 41: ...millimeters from the rear of the drive housing to the face of the pinion gear see illustration Once a shim has been selected and the pinion gear is installed confirm that E D B DV Set Pinion Bearing P...

Page 42: ...plug 21 25 28 4 33 Gear case to 3rd member 18 20 24 4 27 3rd Member cover bolts 40 50 54 67 5 Axle hub bolt 275 392 Note Special Washers The washers for the primary gear case housing and carrier hous...

Page 43: ...chapter WARNING Transaxle SD Check Oil Level 42 Change Oil 42 Remove 43 Transmission Assembly 43 Remove 43 Install 43 Axle Shaft 44 Remove 44 Install 44 Rear Hub Rotor Bearings 45 Motor Remove 45 Prim...

Page 44: ...ottom of the opening Refer to Lubrication section for oil specification If oil comes out of the opening allow to drain until level with the bottom of the opening 10 Reconnect the batteries and test dr...

Page 45: ...e so high to where the rear wheels come off of the ground 6 Remove the swing arm pivot bolts and roll the transmission assembly out from under the vehicle Install 1 Install the transmission assembly i...

Page 46: ...e shaft Use new bolts for the axle retaining plate If the wheel hub was removed install the hub and rotor Torque the hub bolt to the specification listed in the table at the end of this section 2 Fill...

Page 47: ...a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily injury a...

Page 48: ...rings and gears with clean oil 6 Install new seals and wipe the seal lip with grease 7 Place the outer housing on a CLEAN flat bench 8 Brush a small amount of axle oil into the three bearing bores lub...

Page 49: ...Transaxle Page 49 ME 455 04 E 455...

Page 50: ...for reference only This assembly is not serviceable with the exception of oil seals HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pou...

Page 51: ...Service Guidelines chapter WARNING Steering Inspect Ball Joints 52 Inspect Fork Bearings 52 Inspect Pillow Bearings 52 Adjust Steering Gear 53 Replace Ball Joint 54 Replace the Steering Shaft 54 Repl...

Page 52: ...e Pillow bearings will wear at the same rate If one bearing is worn out then both bearings should be replaced as a set The pillow bearings must be removed from the vehicle for inspection Remove the be...

Page 53: ...t it cannot turn tighten the worm bearing adjuster jam nut 7 Find the center position of the steering shaft a Turn the steering shaft all of the way in one direction b While counting the rotations tur...

Page 54: ...ables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive This section is one section of a complete service manual Before starting any procedure read...

Page 55: ...gning the front end 5 Test drive 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 ch...

Page 56: ...adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing Note The side cover pitman shaft assembly normally does n...

Page 57: ...r worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 21 Install the assembled worm bearing adjuster into the h...

Page 58: ...Steering Page 58 E 455 ME 455 04 Exploded View of Steering Gear...

Page 59: ...ft of the center of the jack shaft 4 Adjust the front steering link to position the front wheels in the straight ahead position 5 Tighten the four ball joint clamps on the front and rear steering link...

Page 60: ...04 Notes HARDWARE TORQUE 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 Ball Joint Castle Nut 40 45 54 2 61 St...

Page 61: ...tructions that are located in the Service Guidelines chapter WARNING Brakes General Guidelines and Safety 62 Rear Brake 63 Service Limits 63 Inspection 63 Replace Pads 63 Rebuild Disc Brake Body 64 Bl...

Page 62: ...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...

Page 63: ...3 Raise the rear of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for information on removing the tire and wheel assembly 5 Remove the bra...

Page 64: ...e 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 the groove Fig 3 9 Press the pistons all the way down into the brake body...

Page 65: ...e is still air in the brake lines 10 Repeat this process with each of the other wheels Note When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for information on fill...

Page 66: ...brake is actuated through a pin in the center of the rear left and right brake body on the rear axles The brake pads and rotor should be inspected anytime the park brake requires adjustment 1 Check th...

Page 67: ...Description Foot Pounds Newton Meters Brake Body Bolts 11 14 9 SERVICE LIMITS Description Imperial Metric Disc brake Pad minimum lining 00625 inch 1 58 millimeter Front rotor minimum thickness 0 200 i...

Page 68: ...Brakes Page 68 E 455 ME 455 04 Notes...

Page 69: ...l Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Remove Install 70 Disassemble 70 Inspect 71 Brushes 71 Bearing 71 Co...

Page 70: ...from the rear motor housing and remove the housing from the motor 6 Remove the nuts from the armature studs and remove the two brush assemblies 7 Remove the bearing circlip and press the motor bearin...

Page 71: ...y procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Inspect the commutator for groves If the commutator is grooved then it must be machined on a l...

Page 72: ...ommutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity around the entire commutato...

Page 73: ...ator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut see below 6 While still in the lathe smooth the commutator...

Page 74: ...ture Field 70 052 40 XP 1876 or DD3 4004 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 73 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0 0116 1 2 70 054 41 XP 1789 or DY2 4001 0 635 0...

Page 75: ...starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Controller Remove Install 76 Inspect 76 Receptacles 76 Base Plate 76 Termina...

Page 76: ...is installed then these bolts may also hold the heat sink to the panel Install 1 Thoroughly clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the controller...

Page 77: ...field modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the PCpaK application and cable Re...

Page 78: ...Controller Page 78 E 455 ME 455 04 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal stud 38 44 4 29 4 97 N...

Page 79: ...iagram 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 WARNING Wire Diagram...

Page 80: ...4 Red Red 1 Red 6 Violet Black Green Black Red White Blue Yellow White Black Gray Black Blue Black Black Red BRAKE SWITCH Blue White HEADLIGHT Red Special order accesories may be wired to this termina...

Page 81: ...s that are located in the Service Guidelines chapter WARNING Batteries General Guidelines and Safety 82 Cleaning 83 Charging 83 Watering 83 Testing 84 Specific Gravity 84 Storing 84 Storage 84 Returni...

Page 82: ...property damage 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...

Page 83: ...evel in a battery rises while charging and will be close to its highest level after the end of a charging cycle It is recommended to fill the battery at the end of a charging cycle If the electrolyte...

Page 84: ...any procedure read all warnings and instructions that are located in the Service Guidelines chapter and beginning of this section WARNING DO NOT attempt to test the specific gravity of a sealed batter...

Page 85: ...oors making sure that both door properly engage the door interlock switches Note The vehicle will not operate unless the doors are properly installed 11 Connect the battery cable connector This sectio...

Page 86: ...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 batt...

Page 87: ...rvice manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Inflation 88 Rotation 88 Changing Tire Wheel Assem...

Page 88: ...al 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 WARNING INFLATION Soft s...

Page 89: ...ch is not attached to the vehicle Note Refer to the FrontAxle section for information on removing the wheel on a 3 wheel vehicle 1 Loosen the wheel nuts do not remove before raising the tire off of th...

Page 90: ...Tires Wheels Page 90 E 455 ME 455 04 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters Wheel nut 85 115 Notes...

Page 91: ...s one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Suspension Replace Rear Rubber Sp...

Page 92: ...or is fatigued then it is recommended that both rear springs are replaced as a set 2 Remove the nuts and washers from the spring bolts 3 Raise the rear of the vehicle just high enough so that the spr...

Page 93: ...pended while unattended NEVER lift both rear wheels off of the ground using a single lift point The vehicle shall ALWAYS be supported at three points When raising the rear wheels off of the ground the...

Page 94: ...Suspension Page 94 E 455 ME 455 04 Notes...

Page 95: ...tarting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Torque Guidelines for Standard hardware 96 Hardware Identificat...

Page 96: ...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 he...

Page 97: ...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...

Page 98: ...92 297 420 390 7 8 9 278 429 593 565 14 306 473 818 625 1 8 416 644 909 850 14 466 721 1018 930 1 1 8 7 590 794 1287 1700 12 662 891 1444 1850 1 1 4 7 832 1120 1817 2950 12 922 1241 2012 3330 Imperial...

Page 99: ...10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14 1 38 55 12 1 25 71 1 50 68 1 75 24 64 118 14 1 50 111 2 00 38 103 151 16...

Page 100: ...re 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 r...

Page 101: ...Front 104 Axle Shaft Assembly Rear 104 GT TransAxle Assembly Rear 106 SD TransAxle Assembly Rear 3rd Member 108 SD TransAxle Assembly Rear Primary Reduction 109 Battery 110 Brakes Brake Lines 112 Brak...

Page 102: ...clude 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 prefi...

Page 103: ...acement Parts Page 103 Not available at time of printing ME 455 04 E 455 My Vehicle information Serial Number Date Purchased Date Delivered Dealer Purchased From Salesman Name My local Parts Dealer No...

Page 104: ...bearing on double bearing axle does not have an oil seal or O ring Orientation of bearing should have O ring groove adjacent to O ring on outer bearing AXLE SHAFT ASSEMBLY REAR Note The double bearing...

Page 105: ...8 148 61 1 2 SAE Flat washer 4 12 80 102 00 Race Fork collar 2 13 80 102 00 Race wheel 4 14 80 011 00 Bearing wheel 4 15 Seal axle 4 16 Spacer axle 4 17 88 159 84 1 2NF Nylon lock nut 4 18 92 105 00 F...

Page 106: ...Replacement Parts Page 106 ME 455 04 E 455 GT TRANSAXLE ASSEMBLY REAR...

Page 107: ...T 72013 O ring 1 21 GT 3273633 Pinion nut 1 22 GT 71896 Bolt M10 x 25 mm 12 23 See Note Spacer 1 24 see gear kits below Output gear 1 25 PKIT 00018 Shim and spacer kit 1 26 PKIT 00018 Shim and spacer...

Page 108: ...66 610 67 Vent 1 8 41 989 02 Plug with O ring 1 9 N A Order assembly Housing 1 10 N A Order assembly Cover 1 11 N A Order assembly Gears Ring Pinion 1 12 N A Order assembly Race 1 13 N A Order assemb...

Page 109: ...5 1 0 or 1 44 440 90 Assembly Primary reduction 19 1 0 or 1 44 440 91 Assembly Primary reduction 27 1 0 or 1 44 440 92 Assembly Primary reduction 30 1 0 or 1 1 Kit B Bearing 2 2 Kit B Bearing 1 3 Kit...

Page 110: ...Replacement Parts Page 110 ME 455 04 E 455 BATTERY...

Page 111: ...tch bracket 1 4 98 753 12 Bump stop 2 5 97 308 00 Latch 1 6 96 301 10 Shoulder bolt 2 7 88 109 81 3 8NC Hex lock nut 2 8 01 455 85 Roller bracket 1 9 30 172 12 Roller 1 10 01 455 87 Side door right 1...

Page 112: ...cription Qty 1 99 580 20 Brake hose 2 2 99 600 58 Brake line 1 3 99 563 00 T fitting 1 4 99 580 40 Brake hose to master cylinder 1 5 99 600 58 Brake line 1 6 99 576 00 Brake hose clip 2 7 99 574 00 Sp...

Page 113: ...r includes 8 9 10 11 1 2 88 101 20 3 8NC x 3 Hex bolt grade 5 2 3 99 578 00 Hydraulic fitting 1 4 99 572 00 Copper washer 1 5 99 566 00 Banjo fitting 1 6 99 571 00 Copper washer 1 7 88 109 81 3 8NC He...

Page 114: ...Cross shaft link 2 5 96 763 00 Clevis right hand thread thread 3 6 96 773 00 5 16 x 1 Clevis pin 5 88 527 11 1 8 x 1 Cotter pin 5 7 88 099 81 5 16NF Hex nut left hand thread 3 8 96 820 25 Parking bra...

Page 115: ...Grade C 4 2 41 350 91 Secondary plate 2 3 See kit below Brake pad 4 4 41 348 58 Spacer 4 5 32 208 01 Bushing 4 6 41 350 28 1 Mounting plate 2 7 96 327 10 Axle retaining bolt 8 8 See Brake Body Brake b...

Page 116: ...5 BRAKES BRAKE BODY Brakes Brake Body Item No Part No Description Qty 1 99 588 00 Bleeder screw 2 2 99 588 01 Bleeder adapter 2 3 N A Brake body 4 See kit O ring 4 5 See kit Boot 4 6 41 351 16 Piston...

Page 117: ...ontactor 1 71 300 01 Mounting bracket 1 3 73 005 01 Reverse Motion beeper 1 4 79 840 00 10 Amp circuit breaker 1 5 79 840 00 10 Amp circuit breaker 1 6 79 829 15 Fuse 24v system 0 or 1 Not shown 69 06...

Page 118: ...o Description Qty 1 71 120 10 Key switch 1 71 120 90 Key 2 3 71 039 11 Accessory switch 1 71 039 21 Plastic plug for empty accessory switch hole 4 74 010 00 Smart view display 1 5 71 039 02 Direction...

Page 119: ...4 94 309 00 DECAL PARK BRAKE WARNING 1 5 94 312 00 LABEL FORWARD REVERSE SW 1 6 94 313 00 DECAL BATTERY WARNING GASES 1 7 94 313 21 DECAL SAFETY WARNING wide 1 8 94 319 00 DECAL BATTERY DISCONNECT E 1...

Page 120: ...1 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 62 033 48 Throttle Module 24 48 volt system 1 71 122 20 Horn Switch 1...

Page 121: ...hold down Latch 1 3 03 455 00 Dash instument Panel 1 4 01 455 09 Right dash cover 1 5 03 455 11 Rear rubber pad 1 6 94 201 00 T D emblem 2 7 03 455 05 Park brake handle cover 1 8 See Brake Linkage Pa...

Page 122: ...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 Item No Part No Description Qty 72 025 03 Headlight Lens 24v system 0 or 1 72 080...

Page 123: ...cludes 2 and 3 2 2 Part of 1 Hex bolt 2 3 Part of 1 Washer 2 4 92 202 00 Mounting bracket includes 6 and 7 2 5 88 065 08 1 4NC x 5 8 Truss head screw 4 6 Part of 4 Hex bolt 2 Part of 4 Hex lock nut 2...

Page 124: ...40 Motor Assembly 1 1 70 421 10 Front housing 1 2 70 400 10 Armature 1 3 70 209 40 Field assembly 1 4 85 403 00 Brush spring 4 5 70 173 00 Brush holder 1 6 70 170 30 Brush pair 2 7 70 417 00 Bearing...

Page 125: ...does not include 1 1 3 71 102 20 Interlock switch 1 4 88 080 13 5 16 x 1 1 4 Hex bolt 4 5 00 455 20 Seat mounting plate 1 6 90 160 71 Seat spacer 2 7 88 130 10 7 16NF x 7 8 Hex bolt 2 8 88 128 60 7 16...

Page 126: ...n Qty 1 19 005 17 Steering sheel 1 2 20 455 02 Steering shaft 1 3 97 200 00 Dust washer 1 4 32 455 00 Bushing 2 5 20 455 03 Steering column 1 6 18 308 04 U joint 1 7 88 060 10 1 4 x 3 4 Hex bolt grade...

Page 127: ...LUMN TILT Steering Column Item No Part No Description Qty 1 19 005 17 Steering wheel 1 2 19 005 00 Steering adapter 1 3 18 414 80 Tilt steering assembly 1 4 96 123 45 U bolt 1 5 18 308 04 U joint 1 6...

Page 128: ...8 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal inp...

Page 129: ...NG LINKAGE Steering Linkage Item No Part No Description Qty 1 84 004 00 Pillow bearing 2 2 3 18 146 03 Steering jack shaft 1 4 18 028 12 Steering link assembly with ball joints 2 5 86 501 98 Ball join...

Page 130: ...5 SUSPENSION REAR Item No Part No Description Qty 1 88 149 81 Hex nut 2 2 01 455 61 Washer 2 3 02 455 07 Rubber suspension 2 4 88 149 81 1 2NC Hex lock nut 2 5 32 249 00 Bushing 2 6 88 140 22 1 2NC x...

Page 131: ...131 Not available at time of printing ME 455 04 E 455 WHEELS AND TIRES Item No Part No Description Qty Refer to Axle Fork Assembly for front wheels 13 734 42 Tire Wheel assembly Lugged 13 734 40 Tire...

Page 132: ...Replacement Parts Page 132 ME 455 04 E 455 Notes...

Page 133: ......

Page 134: ...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 frequ...

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