Taylor-Dunn E-451 Service And Parts Manual
  1. Manuals
  2. Brands
  3. Taylor-Dunn Manuals
  4. Electric Vehicles
  5. E-451
  6. Service and parts manual

Taylor-Dunn E-451 Service And Parts Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
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
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
C
Service and Replacement
Parts Manual
E-451 & E-457
Model Numbers:
E0-034-51
E0-034-57
Ending Serial Number: See Introduction Chapter
MANUAL: ME-45X-01
Starting Serial Number: 206900

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the E-451 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Taylor-Dunn E-451

Summary of Contents for Taylor-Dunn E-451

  • Page 1 Service and Replacement Parts Manual MANUAL: ME-45X-01 E-451 & E-457 Model Numbers: E0-034-51 E0-034-57 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 WARNING READ THE OPERATOR’S MANUAL BEFORE OPERATING...
  • Page 2 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 Published [date] Revision C, 7/12/2018, contents subject to change without notice ®...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Preventative Maintenance ......17 Special Tool List ..........21 Lubrication ............25 Front Axle ............29 Drive Axle ............33 Steering ............45 Brakes...............51 Drive Motor ............57 Motor Controller ..........65 Wire Diagram ...........69 Batteries ............73...
  • Page 7 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.

  • Page 8: Introduction

    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.

  • Page 9: Introduction

    Introduction E-451 & E-457 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.

  • Page 10: Responsibilities

    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.

  • Page 11: How To Identify Your Vehicle

    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.
  • Page 12 Notes Introduction E-451 & E-457 Page-12 ME-45X-01...
  • Page 13 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...

  • Page 14: Service/Maintenance Guidelines

    BEFORE STARTING ANY REPAIRS The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn vehicle is 1) Make sure the Start switch is in the “OFF” position, a factory authorized service technician. Repairs made then remove the key.

  • Page 15: Service/Maintenance Guidelines

    Service/Maintenance Guidelines E-451 & E-457 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...

  • Page 16: Replacement Parts

    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.
  • Page 17 Table of Contents Preventative Maintenance Daily Visual Inspection ........18 Pre-Operation Inspection ........18 Maintenance Schedule ........18 Interlock Switch Inspection ......20 Start Switch ............20 High Pedal Disable (HPD) ........20 Operator Presence Switch ........20 WARNING This section is one section of a complete service manual.
  • Page 18 PM Schedule E-451 & E-457 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...

  • Page 19: Preventative Maintenance

    PM Schedule E-451 & E-457 Every 6 Months or 600 hours Every Week • All monthly items plus the following: • All daily items plus the following: • Inspect all electrical connections of signs of • Battery electrolyte level (all cells).
  • Page 20 PM Schedule E-451 & E-457 INTERLOCK SWITCH INSPECTION The interlock switches should disable vehicle operation when activated. Perform the following to confirm proper operation. If any one test fails, then immediately remove the vehicle from service and refer repair to a qualified technician.
  • Page 21 Table of Contents Special Tool List Tool List ............22 Troubleshooting Guide ........24...
  • Page 22 Tool List E-451 & E-457 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...

  • Page 23: Special Tool List

    Removes 0.093 diameter pins from Molex Removes pin from Amp circular harness rectangular harness connectors. Not rectangular harness connectors. Not connectors. available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. ME-45X-01...
  • Page 24 Tool List E-451 & E-457 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.
  • Page 25 Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication E-451 & E-457 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 1: Fork Bearings NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease Brake Fluid: Master Cylinder DOT 3, Meets or exceeds SAE J1703...

  • Page 27: Lubrication

    Lubrication E-451 & E-457 LUBRICATION DIAGRAM ME-45X-01 Page 27...
  • Page 28 Notes Lubrication E-451 & E-457 Page 28 ME-45X-01...
  • Page 29 Table of Contents Front Axle Inspect Front Wheel Bearings ......30 Adjust Front Wheel Bearings ......30 Replace Front Wheel Bearings.......31 Axle Shaft, Remove/Install......31 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.
  • Page 30 Front Axle E-451 & E-457 INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS WARNING BEARINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 31: Front Axle

    Front Axle E-451 & E-457 REPLACE FRONT WHEEL AXLE SHAFT, REMOVE/INSTALL BEARINGS 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...
  • Page 32 Notes Front Axle E-451 & E-457 Page 32 ME-45X-01...
  • Page 33 Table of Contents Drive Axle Check Oil Level ..........34 Change Oil ............34 Axle Shaft ............35 Remove ..............35 Install ...............35 Replace Axle Bearing ..........35 Adjust Drive Chain ..........36 Sealed Motors or No Pinion Brake ......36 Motors with a Fan and Pinion Brake .......36 Drive Motor ............37 Remove ..............37 Install ...............37...

  • Page 34: Drive Axle

    Drive Axle E-451 & E-457 CHECK OIL LEVEL CHANGE OIL 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...

  • Page 35: Drive Axle

    Drive Axle E-451 & E-457 AXLE SHAFT Note: The oil level in the housing is close to the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange. If both axles have to be removed at the same time then all oil should be drained from the housing to minimize oil spills. Note: This procedure does not require removing the drive axle assembly from the vehicle. 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.

  • Page 36: Adjust Drive Chain

    Drive Axle E-451 & E-457 ADJUST DRIVE CHAIN 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. The drive chain stretches during normal use and requires periodic adjustment.

  • Page 37: Drive Motor

    Drive Axle E-451 & E-457 DRIVE MOTOR 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. Remove Note: In most cases it is not necessary to disassemble the primary reduction case to remove the motor. If you find it necessary...

  • Page 38: Primary Reduction Case

    Drive Axle E-451 & E-457 PRIMARY REDUCTION CASE WARNING Assemble 1: Thoroughly clean all gasket surfaces. This section is one section of a complete service 2: Apply a 1/8” bead of 94-430-03 gasket sealer to manual. Before starting any procedure, read all the face of the 3rd member.
  • Page 39 Drive Axle E-451 & E-457 ME-45X-01 Page 39...

  • Page 40: Differential Assembly (3Rd Member)

    Drive Axle E-451 & E-457 9: Remove the pinion housing and pinion gear from DIFFERENTIAL ASSEMBLY (3RD the 3rd member. MEMBER) Note: Do not lose the spacers and shims in the WARNING pinion housing or the pinion housing shim(s). 10: If required, remove the rear tapered bearing from the pinion shaft and discard.

  • Page 41: Assemble

    Drive Axle E-451 & E-457 Assemble 7: While rotating the pinion shaft, tighten the pinion nut to 100 foot pounds (140 Nm). Note: Thoroughly clean and inspect all parts 8: Check the torque required to rotate the shaft. If before reassembly. Apply a small amount the torque is not between 6 -10 inch pounds (0.7-...
  • Page 42 Drive Axle E-451 & E-457 Note: One hole on adjusting nut = approximately 0.003” change in backlash. Left and right nuts MUST be turned the same amount AND in the same direction. The final direction of rotation MUST be in the tightening direction, to loosen a nut 1-hole, back off 2-holes and then tighten 1 hole.

  • Page 43: Re-Shimming The Pinion Housing

    Drive Axle E-451 & E-457 RE-SHIMMING THE PINION HOUSING The pinion housing shim may require replacement if the ring and pinion gear or pinion housing is replaced. Pinion housing shims are available from 0.005” to 0.021” in increments of 0.001”. Locate the number printed on the flat surface of the pilot bearing shaft of the pinion gear.

  • Page 44: Identify Axle Type

    Drive Axle E-451 & E-457 IDENTIFY AXLE TYPE HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut Backing Plate to 3rd member 30-45 42-63 Ring Gear Bolts...
  • Page 45 Table of Contents Steering Inspect Rod Ends ..........46 Inspect Fork Bearings ........46 Align Steering ..........47 Replace Rod End ..........48 Replace Steering Wheel ........48 Replace Front Fork ..........49 Adjust Steering Chain ........50 Hardware Torque ..........50 WARNING This section is one section of a complete service manual.

  • Page 46: Inspect Rod Ends

    Steering E-451 & E-457 INSPECT ROD ENDS INSPECT FORK BEARINGS 1: Raise the front of the vehicle and support with WARNING jack stands. 2: Inspect for lateral play by attempting to move This section is one section of a complete service the fork to the left and right (not rotating), There manual.

  • Page 47: Steering

    Steering E-451 & E-457 ALIGN STEERING 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. 1: Remove the steering chain. 2: Remove the drag link.

  • Page 48: Replace Rod End

    Steering E-451 & E-457 REPLACE ROD END REPLACE STEERING WHEEL 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...

  • Page 49: Replace Front Fork

    Steering E-451 & E-457 REPLACE FRONT FORK 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. Note: It is recommended to replace the grease seal any time the fork is removed from the vehicle.

  • Page 50: Adjust Steering Chain

    Steering E-451 & E-457 ADJUST STEERING CHAIN 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. 1: Loosen chain adjuster locking nuts (see illustration).
  • Page 51 Table of Contents Brakes General Guidelines and Safety.......52 Inspection ............53 Adjust Service Brake........53 Replace Brake Band ........54 Replace Brake Band ........55 Replace the Brake Drum .........56 Service Limits ..........56 Hardware Torque ..........56 WARNING This section is one section of a complete service manual.

  • Page 52: General Guidelines And Safety

    Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. 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.

  • Page 53: Brakes

    Brakes E-451 & E-457 INSPECTION ADJUST SERVICE BRAKE 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...

  • Page 54: Replace Brake Band

    Brakes E-451 & E-457 REPLACE BRAKE BAND 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. WARNING The brake band bolt, spring, lock nut, jam nut, clevis pin, and cotter pin must be replaced with new parts whenever the brake band is replaced.

  • Page 55: Replace Brake Band

    Brakes E-451 & E-457 REPLACE BRAKE BAND 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. WARNING The brake band bolt, spring, lock nut, jam nut, clevis pin, and cotter pin must be replaced with new parts whenever the brake band is replaced.

  • Page 56: Replace The Brake Drum

    Brakes E-451 & E-457 REPLACE THE BRAKE DRUM WARNING WARNING Inspect the pinion seal for any signs of misalignment. This section is one section of a complete service A misaligned pinion seal could cause premature manual. Before starting any procedure, read all...
  • Page 57 Table of Contents Drive Motor Motor Removal and Installation .....58 Disassemble.............58 Assemble............59 Inspection ............60 Brushes ..............60 Armature ..............60 Bearings ..............61 Commutator .............61 Repair ...............62 Brushes ..............62 Commutator .............62 Service Limits ..........63 WARNING This section is one section of a complete service manual.

  • Page 58: Drive Motor

    Drive Motor E-451 & E-457 MOTOR REMOVAL AND INSTALLATION See the Transmission section for information on removing or installing the motor. 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.

  • Page 59: Drive Motor

    Drive Motor E-451 & E-457 ASSEMBLE 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. 1: Lightly lubricate the bearing bore and press a new bearing into the rear end cap and install the retainer.

  • Page 60: Inspection

    Drive Motor E-451 & E-457 INSPECTION Armature WARNING 1: Visually inspect the armature windings for burnt 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.

  • Page 61: Bearings

    Drive Motor E-451 & E-457 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.

  • Page 62: Repair

    Drive Motor E-451 & E-457 REPAIR 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. Brushes Note: It is recommended that all four brushes be replaced as a set.

  • Page 63: Service Limits

    Drive Motor E-451 & E-457 SERVICE LIMITS 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. Commutator Brush Length Resistance Undercut Depth...
  • Page 64 Notes Drive Motor E-451 & E-457 Page 64 ME-45X-01...
  • Page 65 Table of Contents Motor Controller Remove/Install ..........66 Inspect ..............66 Troubleshooting ..........66 Repair/Adjustments.........67 Adjustments .............67 Hardware Torque ..........68 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.

  • Page 66: Motor Controller

    1: Thoroughly clean the controller base and vehicle documentation CD. A replacement CD or hard mounting plate. copy can be purchased from your authorized Taylor-Dunn 2: Install the controller to the mounting plate. distributor or can be downloaded from the Taylor-Dunn 3: Attach the wires to the studs and, using a backup web site.

  • Page 67: Motor Controller

    Motor Controller E-451 & E-457 REPAIR/ADJUSTMENTS 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. Repairs There are no internally serviceable components in the motor speed controller.

  • Page 68: Hardware Torque

    Motor Controller E-451 & E-457 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Inch Pounds Newton Meters Terminal hardware 8.13 Adjustment plugs 0.90 Page 68 ME-45X-01...
  • Page 69 Table of Contents Wire Diagram Diagram Part Numbers........70 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.
  • Page 70 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 this vehicle are: SCH-00055 This vehicle diagram as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Page 70...

  • Page 71: Wire Diagram

    Wire Diagram E-451 & E-457 E-451 & E-457 Page 71...
  • Page 72 Wire Diagram E-451 & E-457 Page 72 E-451 & E-457...
  • Page 73 Table of Contents Batteries General Guidelines and Safety.......74 Cleaning ............75 Charging ............75 Watering ............75 Testing ..............76 Specific Gravity ............76 Storing ..............76 Storage ..............76 Returning to Service ..........76 Remove/Install ..........77 Industrial Battery or Lift Out Battery Pack ....77 Side Extract Battery ..........77 Hardware Torque ..........78 Individual Batteries ..........78 WARNING...

  • Page 74: General Guidelines And Safety

    Batteries E-451 & E-457 GENERAL GUIDELINES AND SAFETY WARNING NOTICE Battery electrolyte will stain and corrode most This section is one section of a complete service surfaces. Immediately and thoroughly clean any manual. Before starting any procedure, read all surface outside of the battery that the battery warnings and instructions that are located in the electrolyte comes in contact with.

  • Page 75: Batteries

    Batteries E-451 & E-457 CLEANING WATERING 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...

  • Page 76: Testing

    Batteries E-451 & E-457 TESTING STORING 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...

  • Page 77: Remove/Install

    Batteries E-451 & E-457 REMOVE/INSTALL WARNING WARNING This section is one section of a complete service Do not allow the loose battery cables to contact any manual. Before starting any procedure, read all other parts of the vehicle as this could cause in a...

  • Page 78: Hardware Torque

    Batteries E-451 & E-457 Individual Batteries HARDWARE TORQUE WARNING If hardware is not listed here, refer to standard torque values in the appendix. Individual batteries can weight up to 80 pounds or Description Inch Pounds Newton Meters more. To avoid injury, use proper lifting techniques...
  • Page 79 Table of Contents Tires & Wheels Inflation .............80 Rotation ............80 Changing Tire/Wheel Assembly .....81 Replace the Tire ..........81 Solid Wheel .............81 Hardware Torque ..........82 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.

  • Page 80: Tires & Wheels

    Tires & Wheels E-451 & E-457 INFLATION ROTATION 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...

  • Page 81: Tires & Wheels

    Tires & Wheels E-451 & E-457 CHANGING TIRE/WHEEL REPLACE THE TIRE WARNING ASSEMBLY WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.

  • Page 82: Hardware Torque

    Tires & Wheels E-451 & E-457 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Notes Description Foot Pounds Newton Meters Wheel nut Page 82 ME-45X-01...
  • Page 83 Table of Contents Hardware Information Torque Guidelines for Standard hardware ..84 Hardware Identification ..........84 Hex Nuts ..............85 Hex Lock Nuts (stover) ..........85 Other Nuts ...............85 Generic Torque Values ..........86 Replacing Hardware ........88 WARNING This section is one section of a complete service manual.

  • Page 84: Torque Guidelines For Standard Hardware

    Hardware E-451 & E-457 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...

  • Page 85: Hardware Information

    ‘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 ME-45X-01 Page 85...

  • Page 86: Generic Torque Values

    Hardware E-451 & E-457 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.
  • Page 87 Hardware E-451 & E-457 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.

  • Page 88: Replacing Hardware

    Hardware E-451 & E-457 REPLACING HARDWARE 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. WARNING Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
  • Page 89 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....90 Taylor-Dunn Web Site Information ....90 Axle Shaft Assembly, Rear ......92 TransAxle Assembly, Rear ......94 TransAxle Assembly, Chain Case ....96 Brake..............98 Brake Linkage ..........99 Control System, Motor Speed Control ..100 Control System, Instrument Panel ....102...

  • Page 90: Replacement Parts

    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.

  • Page 91: Replacement Parts

    Replacement Parts E-451 & E-457 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: ME-45X-01 * Not available at time of printing Page 91...

  • Page 92: Axle Shaft Assembly, Rear

    Replacement Parts E-451 & E-457 AXLE SHAFT ASSEMBLY, REAR Page 92 ME-45X-01...
  • Page 93 0 or 2 80-505-00 Bearing, Small (E-457) 0 or 2 45-045-00 Gasket, Large bearing 0 or 2 88-109-81 3/8 NC Lock nut 32-512-00 Spacer, (behind axle retainer, E-451) 0 or 2 shown ME-45X-01 * Not available at time of printing Page 93...

  • Page 94: Transaxle Assembly, Rear

    Replacement Parts E-451 & E-457 TRANSAXLE ASSEMBLY, REAR Page 94 ME-45X-01...
  • Page 95 Replacement Parts E-451 & E-457 Transmission Differential Case Item No. Part No. Description 44-340-28 Complete 3rd member assembly, Ready to install 3rd member Housing , Included in #3 88-119-80 3/8” NF Nut 44-340-92 Differential kit 80-128-00 Carrier Bearing Race 80-512-00...

  • Page 96: Transaxle Assembly, Chain Case

    Replacement Parts E-451 & E-457 TRANSAXLE ASSEMBLY, CHAIN CASE Page 96 ME-45X-01...
  • Page 97 Replacement Parts E-451 & E-457 Transaxle Chain Case ITEM# PART # DESCRIPTION 88-109-61 3/8” SAE Flat Washer 97-100-00 Woodruff Key 88-087-11 Chain Adjusting Screw 88-069-80 5/16” NC Hex Nut 88-103-09 Motor Mounting Screw, 3/8” X 3/4” NC 80-703-00 O-Ring, 4-1/2” ID X 5” OD...

  • Page 98: Brake

    Replacement Parts E-451 & E-457 BRAKE ITEM # PART # DESCRIPTION 45-331-00 Pinion Seal 41-352-00 Brake Drum 96-245-10 Brake Adjusting Bolt 41-661-60 Brake Band Kit (Incl. #’s 3, 5, 7, 8, 9, 12, 13) 85-060-20 2-1/2” Long Spring 41-372-10 Mounting Bracket 88-159-84 1/2”-20 NF Lock Nut...

  • Page 99: Brake Linkage

    Replacement Parts E-451 & E-457 BRAKE LINKAGE Item No. Part No. Description 50-027-00 Brake rod 88-119-80 3/8 NF HEX HD NUT 96-762-00 Clevis 96-772-00 Clevis pin 88-527-11 Cotter pin 50-028-00 3/8 threaded rod 88-119-80 3/8 NF HEX HD NUT 85-282-00...

  • Page 100: Control System, Motor Speed Control

    Replacement Parts E-451 & E-457 CONTROL SYSTEM, MOTOR SPEED CONTROL Page 100 ME-45X-01...
  • Page 101 Replacement Parts E-451 & E-457 Motor Speed Control Item No. Part No. Description 62-205-00 Motor speed control (E 4-51) 62-205-40 Motor speed control (E 4-57) 72-501-43 Forward or Reverse solenoid (E 4-51) 72-501-39 Forward or Reverse solenoid (E 4-57) 72-501-42...

  • Page 102: Control System, Instrument Panel

    Replacement Parts E-451 & E-457 CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 71-039-11 Switch 71-039-11 Switch 74-009-10 Battery status indicator (E 4-51) 74-009-00 Battery status indicator (E 4-57) 74-000-00 Hour meter 71-039-02 F&R Switch 71-120-10 Key switch...

  • Page 103: Decals

    Replacement Parts E-451 & E-457 DECALS Decals Item No. Part No. Description 94-313-20 Safety Warning 94-382-00 Treadle 94-384-17 Do Not Spray Wash 94-313-00 Battery Warning 34-319-00 Battery Disconnect 94-384-61 Operator Presence Switch 94-384-14 Leaving Vehicle 94-384-01 Not a Motor Vehicle...

  • Page 104: Electrical, Miscellaneous

    Replacement Parts E-451 & E-457 ELECTRICAL, MISCELLANEOUS Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01...

  • Page 105: Frame And Body

    Replacement Parts E-451 & E-457 FRAME AND BODY Item No. Part No. Description 72-006-00 Headlight (E 4-51) 72-007-10 Headlight (E 4-57) 90-144-00 Seat back cushion 90-159-00 Seat back support 17-113-00 Locking collar 95-901-00 Knob 71-617-00 Rear cover 71-618-10 Front cover...

  • Page 106: Front Wheels / Steering

    Replacement Parts E-451 & E-457 FRONT WHEELS / STEERING Model E-451 shown. Steer linkage is same for E-457, refer to Front Wheels, E-457 for the E-457 front fork and wheels Page 106 ME-45X-01...
  • Page 107 Replacement Parts E-451 & E-457 Front Wheels / Steering Item No. Part No. Description 92-105-00 Bearing cap 88-229-81 88-228-61 Washer 80-011-00 Bearing 17-001-10 Collar (w/races) This is a weld on part 80-102-00 Race 45-307-00 Seal 14-084-10 Fork 16-406-11 Spacer, fork...

  • Page 108: Front Wheels, E-457

    Replacement Parts E-451 & E-457 FRONT WHEELS, E-457 Page 108 ME-45X-01...
  • Page 109 Replacement Parts E-451 & E-457 Front Wheels and Fork (E 4-57) Item No. Part No. Description 14-319-00 Mounting plate 80-308-00 Bearing 14-087-00 Fork 88-389-86 1-1/4 NC Lock nut 80-011-00 Bearing 80-102-00 Race 16-408-00 Spacer 15-002-05 Axle 16-408-01 Spacer 16-410-00 Shims...

  • Page 110: Hitches

    Replacement Parts E-451 & E-457 HITCHES Mounting Hardware Item No. Part No. Description 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 88-149-80 1/2NC Hex nut 88-148-62 1/2 Split lock washer LIGHTS Item No. Part No.

  • Page 111: Motor (Spec Bp5-4002)

    Replacement Parts E-451 & E-457 MOTOR (SPEC BP5-4002) ID # Part No. Description 70-054-00 Complete motor assembly 45-509-00 *Seal End head, drive PKIT-00011 *Kit, Motor Bearing 8021200 (2), includes #4 70-417-00 *Retaining ring 70-400-05 Armature Fame and Field PKIT-00012 *Kit, Brush Spring 85-403-00 (4)

  • Page 112: Throttle Linkage

    Replacement Parts E-451 & E-457 THROTTLE LINKAGE Throttle Linkage Item No. Part No. Description 01-450-29 Accelerator module mounting bracket 02-150-11 Extension lever (on module arm) 50-123-23 Rod, treadle arm to module 88-109-81 3/8 NC LOCK NUT 88-108-60 3/8 CUT WASHER...

  • Page 113: Wheels And Tires

    Part No. Description 13-952-10 Rear Tire/Wheel assembly, 16 x 4 x 12.125 10-250-00 Tire 12-050-00 Wheel 13-964-10 Front Tire/Wheel assembly, E-457 10-267-00 Tire 12-058-10 Wheel 13-904-61 Front Tire/Wheel assembly, E-451 ME-45X-01 * Not available at time of printing Page 113...
  • Page 114 Notes: Replacement Parts E-451 & E-457 Page 114 ME-45X-01...
  • Page 116 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...

This manual is also suitable for:

E0-034-57E-457E0-034-51

Table of Contents

Save PDF