Taylor-Dunn E0-455-24 Service And Replacement Parts Manual Download

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T h e B e s t W a y

T o G o

A b o u t Y o u r

B u s i n e s s

TAYLOR-DUN

READ THE OPERATOR’S MANUAL BEFORE OPERATING

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

Service and Replacement

Parts Manual

MANUAL: ME-455-04

E-455

Model Numbers:

E0-455-24
E0-455-36

Summary of Contents for E0-455-24

Page 1: ...NG 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 Service and Replacement Parts Manual MANUAL ME 455 04 E 455 Model Numbers E0 455 24 E0 455 36 D ...

Page 2: ...placement 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 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 My Vehicle information Serial Number Date Purchased Date D...

Page 3: ...t 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 ...

Page 4: ...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 tr...

Page 5: ...Special 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 Information 95 Replacement Parts 101 Note Each section title page contains a section table of contents ...

Page 6: ......

Page 7: ...dure 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 Signal Words and Their Definitions 9 Responsibilities 10 How to Identify Your Vehicle 11 Web Site Registration 11 ...

Page 8: ...ate 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...

Page 9: ...CE 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 alert symbol see above Represents a high voltage hazard Represents an explosion hazard Represents a corrosive che...

Page 10: ...cedures 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 operator is responsible to be sure that the vehicle is operated only on authorized roads highways and installations The operator is responsible to confirm that all passengers are properly seated and proper...

Page 11: ...d 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 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 acc...

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

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

Page 14: ...ttached 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 may operate at any time while performing control system test procedures All tests must be performed with the drive wheels off of the ground and the vehicle supported with jack stands Testing with dri...

Page 15: ...eration 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...

Page 16: ...icle 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...

Page 17: ...dure 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 18 Maintenance Schedule 19 Interlock Switch Inspection 20 Start Switch 20 High Pedal Disable HPD 20 Operator Presence Switch 20 ...

Page 18: ...side 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 procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Maintenance Guidelines for Severe Duty Applications This maintenance schedule is based on the aver...

Page 19: ...afety 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 items plus the following Inspect adjust brake Clean battery compartment Inspect and tighten all hardware first 300 hours only then 1200 hours and every 1200 hours Lubricate the vehicle Inspect steering ...

Page 20: ...ehicle 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 not move Release the throttle pedal and press again The vehicle should operate normally Operator Presence Switch Sit in the approved operator position turn the start switch ON select a direction and...

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

Page 22: ...troubleshooting 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 Removing Tool Removes pin from Amp circular harness connectors Molex 11 300 06 Pin Removing Tool Removes 0 093 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Pur...

Page 23: ...splash 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 Fill Plug Tool Used to remove the oil fill plug on GT drives It is used with a 3 8 drive extension not included ...

Page 24: ...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 ...

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

Page 26: ...l 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 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 ori...

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: ...nual 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 30 Replace Front Wheel Bearings 31 Axle Shaft Remove Install 31 Hardware Torque 32 ...

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 air 5 Tie a weight see table and illustration below to the end of the rope 6 Slowly loosen the axle nut until the hanging weight rotates the wheel 7 Remove the rope and weight 8 Spin the wheel and l...

Page 31: ...he 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 remove the front wooden drift punch Note If the bearings were worn until they were broken then the shaft may have to be cut out of the fork Note If the repairs cannot be immediately completed then th...

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: ...34 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 Assemble 39 Pinion Bearing Preload 41 Pinion Gear Shimming Instructions 41 Set Pinion Bearing Preload 41 Hardware Torque 42 TRANSAXLE IDENTIFICATION Your vehicle may be equipped with one of two types of t...

Page 34: ...ntil 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 starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING CHANGE OIL Fluid type and capacities are listed in the lubrication section in the Ge...

Page 35: ...cle 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 in reverse order of removal Bleed the brake system Refer to section Brake Service for information regarding bleeding the brakes Adjust the park brake Refer to section Brake Service for information re...

Page 36: ...the 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 Use new bolts for the axle retaining plate c 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 12 Fill with...

Page 37: ...he 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 Guidelines chapter WARNING The axle retaining plate bolts have a pre applied thread locking compound They are intended for one time use only If removed they must be replaced Reusing the original bol...

Page 38: ...tion 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 housing from the 3rd member housing 14 Inspect all parts for signs of wear or damage 15 Assemble the gear case in reverse order a See note regarding special washers at the end of this section b Apply...

Page 39: ...ghly 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 Assemble 1 Temporarily install the pinion gear hand tighten only 2 Install the carrier bearing race adjusting nuts into the housing and cover 3 Install the carrier bearing races into the housing and...

Page 40: ...e 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 race ring nut and tighten the housing carrier race ring nut equally 17 Install the locking roll pins into the housing and cover to lock the adjusting nuts in place 18 Remove the pinion gear holding to...

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 Preload Note The pinion gear depth must be set before the preload Refer to Setting the Pinion Gear Depth 1 Install the pinion gear spacer and shims into the housing 2 Install the outer pinion bearing ...

Page 42: ...n 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 housing side plate are in the shape of a cone referred to as conical or belleville washers This type of washer is designed to maintain tension in bolted assemblies Belleville washers must be orientated c...

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 Primary Reduction Gear Case 46 3rd Member 48 Hardware Torque 48 TRANSAXLE IDENTIFICATION Your vehicle may be equipped with one of two types of transaxle assemblies This section covers the SD transaxle ...

Page 44: ...bottom 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 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 chapter WARNING CHANGE OIL Flu...

Page 45: ...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 in reverse order of removal Bleed the brake system Refer to section Brake Service for information regarding bleeding the brakes Adjust the park brake Refer to section Brake Service for information reg...

Page 46: ...le 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 with oil to the level of the fill plug threads Refer to Check Oil Level procedure 3 Set the park brake 4 Lower the vehicle and test drive Remove 1 Raise the rear of the vehicle and support with jack...

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 and or property damage WARNING MOTOR REMOVE Note Some applications may require removing the drive assembly from the vehicle to remove the motor Refer to Removing and Installing the Drive Assembly for ...

Page 48: ...arings 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 lubricating the walls of the bore 9 Place the three gear assemblies into the housing 10 Clean and dry the housing mating surface on both housings 11 Make sure there is no oil or grease on the sealing fl...

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

Page 50: ...s 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 Pounds Newton Meters Pinion nut 275 300 392 428 Drain plugs 9 14 13 20 Fill plugs 45 50 64 71 Gear case to 3rd member 45 55 64 78 Primary housing bolts 23 27 33 38 3rd Member cover bolts 45 55 64 78 Rin...

Page 51: ...e 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 Replace the Front Fork 55 Replace Steering Wheel 55 Steering Gear 56 Disassemble 56 Reassemble 57 Exploded View of Steering Gear 58 Front Wheel Alignment 59 Hardware Torque 60 ...

Page 52: ...te 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 bearing and inspect for play Any play is an indication of a worn bearing and it should be replaced Rotate the bearing by hand Any grinding or noise is an indication of a worn bearing and it should be r...

Page 53: ...at 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 turn the steering shaft all of the way in the opposite direction c Turn the steering shaft 1 2 the number of turns in the original direction 8 While rotating the input shaft back and forth through its c...

Page 54: ...cables 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 all warnings and instructions that are located in the Service Guidelines chapter WARNING This section is one section of a complete service manual Before starting any procedure read all warnings and i...

Page 55: ...igning 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 chapter WARNING REPLACE STEERING WHEEL Note The steering wheel is on a tapered shaft and may be damaged when it is removed 1 If equipped with a horn switch in the steering wheel remove the switch and d...

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 not have to be disassembled 4 Remove the worm shaft and ball nut assembly from the bottom of the housing 5 Remove the worm shaft seal 6 Remove the pitman shaft seal 7 Remove the upper worm bearing and...

Page 57: ...er 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 housing and tighten just enough to remove all play in the worm shaft 22 Install but do not tighten the worm bearing adjuster lock nut 23 Rotate the worm shaft to center the ball nut in the housing 24 ...

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 links 6 Adjust the pitman arm steering stops so that the front fork rotates approximately 45º to the left and right 7 Reconnect the battery 8 Test drive This section is one section of a complete service m...

Page 60: ...5 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 Steering Wheel Nut 28 32 38 43 ...

Page 61: ...structions 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 Bleed System 65 Flush System 65 Master Cylinder 66 Add Fluid 66 Parking Brake 66 Inspect 66 Adjust 66 Service Limits 67 Hardware Torque 67 ...

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 do contain asbestos Never use compressed air or dry brush to clean the brake assemblies Use an OSHA approved vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by a...

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 brake body bolts and discard the lock nuts and brake pads 6 Remove the spacer bushings from the mounting bracket and discard 7 Inspect the brake rotor Refer to Inspect the Service Brake section for info...

Page 64: ...he 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 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 bo...

Page 65: ...re 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 filling the master cylinder 11 Reconnect the battery remove the blocks from behind the wheels and test drive This section is one section of a complete service manual Before starting any procedure read al...

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 the angle of the brake cable to brake arm on the cross shaft It should be between 85º and 90º Adjust the cable if it is not within tolerance Note The return spring must be connected to check the angle o...

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 inch 5 08 millimeter Rear rotor minimum thickness 0 200 inch 5 08 millimeter Rotor runout front Rear 0 005 inch 0 127millimeter ...

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

Page 69: ...al 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 Commutator 71 Armature Windings 71 Field Windings 72 Repair 73 Service Limits 74 ...

Page 70: ...s 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 bearing out of the housing and discard 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 c...

Page 71: ...ny 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 lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to Repair Commutator section for information regarding machining the commutator Inspect the comm...

Page 72: ...commutator 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 commutator If any segment indicates an open circuit then the motor must be replaced Using the continuity function of digital multi meter check the continuity from any one of the commutator segments and the ar...

Page 73: ...tator 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 with fine emery cloth and reinspect for debris between the commutator segments Undercutting the commutator 1 Using a small straight cut saw blade cut the commutator insulation to the proper depth Ref...

Page 74: ...mature 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 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 054 42 DY8 4002 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 43 70 057 40 XP 1673 or DV1 4003 0 635 0 025 69 85 2 75 15 87 0 625 0 008 0 58 70 061 40 XP 1765A...

Page 75: ...e 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 Terminal Ends 76 R Terminal 76 Repair Programming 77 Programming 77 Troubleshooting 77 Hardware Torque 78 ...

Page 76: ...k 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 base and heat sink 3 Install the controller to the mounting plate 4 Attach the wires to the studs and torque per specification listed in the table at the end of this section Note DO NOT allow the wir...

Page 77: ...t 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 Refer to the Tools section for part numbers If you have a special application that may require modified parameters contact your local authorized Taylor Dunn distributor to submit a request to the facto...

Page 78: ...r 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 Notes ...

Page 79: ...Diagram 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 Diagram Part Numbers 80 ...

Page 80: ...14 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 terminal Brown Brown Brown SWITCH 16 ACC SWITCH Brown 10 11 LIGHT Brown Black SWITCH HORN Red Black Black Brown Blue White Red Red Red 13 9 HORN DASH PANEL Gray Gray 1 2 AUTOMATIC ELECTRIC BRAKE View from p...

Page 81: ...ns 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 ...

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 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 a...

Page 83: ...level 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 is below the top of the battery plates then fill just 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 cl...

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 battery Removing the caps of a sealed battery will damage the battery resulting in premature failure NOTICE Typical Hydrometer Float STORING Storage Thoroughly clean the battery and battery compartment Ref...

Page 85: ...doors 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 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 and beginning of this section WARNING...

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 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 sectio...

Page 87: ...ervice 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 Assembly 89 Replace the Tire 89 Solid Wheel 89 Split Wheel 89 Hardware Torque 90 ...

Page 88: ...val 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 solid tires are zero pressure tires do not require air pressure This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are locat...

Page 89: ...nch 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 the ground 2 Raise the tire to be changed off of the ground and support with a jack stand 3 Remove the wheel nuts and tire wheel assembly 4 Install the replacement tire wheel assembly 5 Install the whe...

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: ...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 Suspension Replace Rear Rubber Springs 92 Raising the Rear of the Vehicle 93 ...

Page 92: ...d 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 springs bushings can be removed and support with jack stands 4 Remove and install the new bushings 5 Lower the vehicle and carefully guide the spring bolts into the holes in the frame 6 Install the nuts...

Page 93: ...spended 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 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 ...

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

Page 95: ...starting 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 Identification 96 Hex Nuts 97 Hex Lock Nuts stover 97 Other Nuts 97 Generic Torque Values 98 Replacing Hardware 100 ...

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 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 screw...

Page 97: ...s 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 Other Nuts Other nuts used by Taylor Dunn should be treated as S A E grade A Grade L 9 Metric Nuts 5 8 8 8 10 9 12 9 ...

Page 98: ...192 297 420 390 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 inch Newton Meters Grade SAE Dia Pitch 2 5 8 L9 4 40 6 32 8 32 10 32 12 32 1 4 20 7 4 11 5 16 9 14 9 28 8 8 14 2 5 16 18 16 2 23 7 33 2 29 8 24 16 9 25 8 3 8 16 27 1 41 58 54 24 30 5 45 68 61 7 16 1...

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 1 50 2 00 60 158 229 18 1 50 2 00 2 50 81 221 20 1 50 2 00 2 50 115 317 22 1 50 2 00 2 50 156 428 24 2 00 3 00 199 524 27 3 00 3 00 293 30 2 00 3 50 398 All torque values are for clean dry zinc plat...

Page 100: ...ure 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 ...

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 Brakes Master Cylinder 113 Brakes Park BRake 114 Brakes Rear Axle 115 Brakes Brake Body 116 Control System Motor Speed Control 117 Control System Instrument Panel 118 Decals 119 Electrical Miscellaneous ...

Page 102: ...nclude 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...

Page 103: ...lacement 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 Notes ...

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 axle assembly is optional Most vehicle will only hae the single bearing 2 ...

Page 105: ...88 148 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 Fork bearing cap 1 19 16 400 00 Spacer 2 Axle Shaft Assembly Rear Item No Part No Description Qty 1 41 154 30 Axle shaft 2 2 80 505 20 Bearing outer 2 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub 2 ...

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

Page 107: ...GT 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 kit 1 27 GT 71068 Bearing 1 28 GT 72022 Bearing 1 29 GT 71978 Bearing and race 2 30 GT 70299 Washer 10 mm 18 31 GT 71881 Seal 1 32 GT 70052 Vent 1 37 GT 3252633 Dowel pin 2 GT 3294993 61 Gear Kit 30 ...

Page 108: ...7 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 assembly Bearing 1 14 41 989 01 Plug with O ring 1 15 Kit A C Seal 1 16 Kit B C Seal 2 17 Kit A C O ring 1 18 Kit A C O ring 1 19 Bolt 10 20 Nut 1 21 N A Order assembly Differential assembly 1 22 N A Order...

Page 109: ...15 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 B Bearing 2 4 Kit A Seal 1 5 66 610 67 Vent 1 6 41 989 02 Plug with O ring 1 7 Bushing Dowel 2 8 N A Housing 1 9 N A Housing 1 10 N A Order assembly Gear 1 11 N A Order assembly Gear 1 12 N A Order a...

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

Page 111: ...atch 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 11 03 455 07 Battery clamp 1 12 88 690 00 Roll pin 1 13 01 455 86 Side door left 1 14 03 455 08 Clamp screw 1 15 71 137 00 Side door interlock switch 2 Not shown 75 152 22 Interlock switch harness 1 ...

Page 112: ...scription 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 Spacer 1 BRAKES BRAKE LINES 7 Located inside of 3 Actual size 3 8 inch long ...

Page 113: ...er 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 Hex lock nut 2 8 99 510 52 Cap 1 9 99 511 00 Rebuild kit 1 10 99 511 51 Rubber boot 1 11 99 510 53 Gasket 1 12 88 108 61 3 8 SAE Flat washer 2 BRAKES MASTER CYLINDER ...

Page 114: ...7 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 brake cable 1 9 88 099 80 5 16NF Hex nut 3 Not shown 41 350 60 Extension Brake Arm 2 51 344 80 Parking brake handle 1 85 295 00 Park brake arm return spring 1 06 210 03 Mounting clip for return spring 1...

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 body assembly 2 9 88 840 11 Clip 2 10 See Brake Body Bleeder 2 11 32 220 03 Bushing 2 12 41 350 56 Pin 2 14 41 350 52 Pin 2 15 41 350 53 Arm 2 16 41 350 12 Bracket 2 41 348 61 Brake Pad kit Includes 3...

Page 116: ...55 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 4 41 351 15 Kit o ring and boots 1 wheel ...

Page 117: ...contactor 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 69 068 55 Resistor across 2 power terminals 1 79 844 20 200A Circuit breaker 36v system 0 or 1 Misc Hardware 88 818 06 8 x 1 2 Sheet metal screw 88 818 06 8 x 1 2 Sheet metal screw 88 838 06 14 x 1 2 Shee...

Page 118: ...No 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 control switch 1 6 71 501 00 Horn switch 1 CONTROL SYSTEM INSTRUMENT PANEL ...

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 9 94 384 01 DECAL NOT A MOTOR VEHICLE 1 10 94 384 14 DECAL LEAVING VEHICLE E 1 11 94 384 48 DECAL WARNING PINCH CRUSH 2 12 94 384 61 DECAL OPS DASH 1 13 94 384 62 DECAL OPERATOR PRESENCE SWITCH 1 14...

Page 120: ...31 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 88 065 06 1 4 NC x 21 2 Phillips Truss Head Screw Horn Switch 2 88 069 81 1 4 NC Hex Nylon Locknut Horn Switch 2 73 002 00 Horn 24v system 0 or 1 73 004 10 Horn 36v system 0 or 1 73 012 33 36 12v DC...

Page 121: ...d 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 Park brake handle 1 9 03 455 10 Floor mat 1 10 01 455 00 Left dash cover 1 11 01 455 51 Steering gear cover 1 12 98 200 00 Brake pedal pad 1 13 01 110 20 Accelerator pedal 1 ...

Page 122: ...1 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 00 Bulb 24v 0 or 1 72 022 13 Headlight 36v system 0 or 1 72 022 05 Taillight 24v system 0 or 1 72 022 04 Taillight 36v system 0 or 1 ...

Page 123: ...ncludes 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 7 Part of 4 Hex bolt 2 Part of 4 Hex lock nut 2 Part of 4 Flat washer 4 8 88 068 62 1 4 Split lock washer 4 9 88 069 83 1 4NC acorn nut 4 ...

Page 124: ...7 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 retainer 1 8 80 212 00 Bearing 1 9 70 421 30 Rear housing 1 10 70 421 40 Brush cover 1 11 95 930 00 Dust cap ...

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 Flat waser 2 9 88 089 81 5 16NC Hex lock nut 4 10 88 088 60 5 16 Cut flat washer 4 11 88 025 12 8 32 x 1 1 4 Type F thread machine screw 2 12 98 753 12 Bump stop 2 SEATS ...

Page 126: ...on 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 5 3 8 9 96 123 45 3 8 x 2 x 2 5 8 U bolt 1 10 88 109 80 3 8NC Hex nut 2 11 88 108 62 3 8 Split lock washer 2 ...

Page 127: ...OLUMN 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 7 88 108 62 3 8 Split lock washer 2 8 88 109 80 3 8NC Hex nut 2 9 18 414 60 Lever kit 1 ...

Page 128: ...18 308 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 input shaft 1 11 18 308 82 Gasket 1 12 18 308 76 Pitman shaft 1 13 18 308 75 Gear lash adjuster 1 14 18 308 85 Shim kit 1 15 18 308 84 Side cover 1 16 18 308 86 Jam nut 1 17 18 308 83 Bolt side cover 3 ...

Page 129: ...ING 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 joint 2 6 86 501 99 Ball joint 2 86 510 00 Ball joint clamp 4 7 18 640 10 Pitman arm 1 ...

Page 130: ...55 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 3 1 2 Hex bolt 2 7 00 455 06 Swing arm 1 ...

Page 131: ...e 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 Wheel assembly Ribbed ...

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

Page 133: ......

Page 134: ...r 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 WARNING Taylor Dunn Manufacturing 2114 West Ball Road Anaheim CA 92804 800 688 8680 714 956 4040 ...

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