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

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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
WARNING
READ THE OPERATOR'S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator's manual contains important information
regarding the safe operation of this vehicle.
D
Service and Replacement
Parts Manual
E-455
Model Numbers:
E0-455-24
E0-455-36
Ending Serial Number: See Introduction Chapter
MANUAL: ME-455-04
Starting Serial Number: 207800

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  • Page 1 Service and Replacement Parts Manual MANUAL: ME-455-04 E-455 Model Numbers: E0-455-24 E0-455-36 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 9/1/2017 Revision D, 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 Transaxle - GT ..........33 Transaxle-SD ............43 Steering ............51 Brakes...............61 Motor ..............69 Motor Controller ..........75 Wire Diagram ...........79...
  • 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-455 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-455 Page-12 ME-455-04...

  • Page 13: Service/Maintenance Guidelines

    Table of Contents Service/Maintenance Guidelines READ ME FIRST-Maintenance Guidelines and General instructions .........14 Vehicle Modifications ........15 Replacement Parts ..........16 Using Non-OEM Replacement Components ...16...

  • 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: Vehicle Modifications

    Contact the factory for information regarding available alternate program settings. Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle. Any other alterations to the programming ARE NOT AUTHORIZED and is at your own risk.

  • 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: Preventative Maintenance

    Table of Contents 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 WARNING This section is one section of a complete service manual.

  • Page 18: Daily Visual Inspection

    PM Schedule E-455 DAILY VISUAL INSPECTION PRE-OPERATION INSPECTION WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
  • Page 19 PM Schedule E-455 Maintenance Schedule Most of these items should only be performed by a qualified technician. Details regarding the service procedures can be found in the vehicle service manual. Any problems found during an inspection should be repaired before the vehicle is put back into service. Every Week Every 6 Months of 600 Hours •...

  • Page 20: Interlock Switch Inspection

    PM Schedule E-455 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: Special Tool List

    Table of Contents Special Tool List Controller Programming: .........22 Troubleshooting Guide ........24...
  • Page 22 Tool List E-455 Tool List The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. Controller Programming: Sevcon: 62-027-63 “PCpaK Cable lead and application.” 62-027-32: Throttle Module Analyzer 75-089-00: Throttle Module Test Harness...
  • Page 23 Tool List E-455 96-500-48: GT Drive Oil Fill Plug Tool 77-200-00: Hydrometer 77-201-00: Battery Filler Used to remove the oil fill plug on GT Used for testing battery electrolyte. Used to safely add water to batteries. drives. It is used with a 3/8” drive extension Illustration is of a typical hydrometer, actual Equipped with splash guard and auto- (not included).
  • Page 24 Tool List E-455 TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...

  • Page 25: Lubrication

    Table of Contents Lubrication Lubrication and Fluids Chart ......26 Hazardous Waste Disposal ......26 Lubrication Diagram ........27...
  • Page 26 Lubrication E-455 LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle / Steering: 6: Ball Joint NLGI Grade 2 lithium multi-purpose grease 5: Wheel Bearing NLGI Grade 2 lithium high temp Bearing Grease 2: Fork Bearings NLGI Grade 2 lithium multi-purpose grease 1: Steering Shaft NLGI Grade 2 lithium multi-purpose grease Brake Fluid:...
  • Page 27 Lubrication E-455 LUBRICATION DIAGRAM GT Transaxle SD Transaxle ME-455-04 Page 27...
  • Page 28 Notes Lubrication E-455 Page 28 ME-455-04...

  • Page 29: Front Axle

    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 Hardware Torque ..........32 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

    Front Axle E-455 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: Replace Front Wheel Bearings

    Front Axle E-455 REPLACE FRONT WHEEL AXLE SHAFT, REMOVE/INSTALL BEARINGS WARNING 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 32: Hardware Torque

    Front Axle E-455 HARDWARE TORQUE Description Foot Pounds Newton Meters Notes Ball Joint Clamp 28-32 37.9-43.4 Rod End Stud Nut 20-25 27.1-33.9 Rod End Jam Nut 20-25 27.1-33.9 Page 32 ME-455-04...

  • Page 33: Transaxle - Gt

    Table of Contents Transaxle - GT Check Oil Level ..........34 Change Oil ............34 Remove.............35 Transmission Assembly .........35 Remove ..............35 Install ...............35 WARNING Axle Shaft ............36 Remove ..............36 Install ...............36 This section is one section of a complete Rear Hub, Rotor & Bearings ......37 service manual.

  • Page 34: Transaxle - Gt

    Transaxle - GT E-455 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 35: Remove

    Transaxle - GT E-455 REMOVE 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. TRANSMISSION ASSEMBLY Remove 1: Disconnect the motor cables. 2: Disconnect the park brake cable from the brake arm and the swing arm mount.

  • Page 36: Axle Shaft

    Transaxle - GT E-455 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only.

  • Page 37: Rear Hub, Rotor & Bearings

    Transaxle - GT E-455 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications will require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and Installing This section is one section of a complete service the Drive Assembly for information on manual.

  • Page 38: Primary Gear Case

    Transaxle - GT E-455 PRIMARY GEAR CASE 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: Disconnect the batteries. 2: Raise the rear of the vehicle and support with jack stands.

  • Page 39: Secondary Gear Case

    Transaxle - GT E-455 SECONDARY GEAR CASE 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. Disassemble 1: Remove the transaxle assembly from the vehicle. Refer to Remove in this section.
  • Page 40 Transaxle - GT E-455 13: Install the differential assembly. 14: Install the cover and all of the cover bolts and washers. See note regarding special washers at the end of this section. Torque per torque listed in the Hardware Torque table at the end of this section.

  • Page 41: Pinion Bearing Preload

    Transaxle - GT E-455 PINION BEARING PRELOAD 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. Pinion Gear Shimming Instructions Note: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears.

  • Page 42: Hardware Torque

    Transaxle - GT E-455 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut 154-169 209229 Drain 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...

  • Page 43: Transaxle-Sd

    Table of Contents Transaxle-SD Check Oil Level ..........42 Change Oil ............42 Remove.............43 Transmission Assembly .........43 WARNING Remove ..............43 Install ...............43 Axle Shaft ............44 This section is one section of a complete service Remove ..............44 Install ...............44 manual. Before starting any procedure, read all Rear Hub, Rotor &...

  • Page 44: Transaxle-Sd

    Transaxle E-455 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 45: Transmission Assembly

    Transaxle E-455 REMOVE 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. TRANSMISSION ASSEMBLY Remove 1: Disconnect the motor cables. 2: Disconnect the park brake cable from the brake arm and the swing arm mount.

  • Page 46: Axle Shaft

    Transaxle E-455 AXLE SHAFT WARNING WARNING The axle retaining plate bolts have a pre-applied This section is one section of a complete service thread locking compound. They are intended for one manual. Before starting any procedure, read all time use only. If removed they must be replaced. warnings and instructions that are located in the Reusing the original bolts could cause loss of brakes Service Guidelines chapter.

  • Page 47: Rear Hub, Rotor & Bearings

    Transaxle E-455 REAR HUB, ROTOR & BEARINGS MOTOR, REMOVE WARNING Note: Some applications may require removing the drive assembly from the vehicle to remove the motor. Refer to Removing and This section is one section of a complete service Installing the Drive Assembly for information manual.

  • Page 48: Primary Reduction Gear Case

    Transaxle E-455 PRIMARY REDUCTION GEAR CASE 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.
  • Page 49 Transaxle E-455 ME-455-04 Page 49...
  • Page 50 Transaxle E-455 3RD MEMBER 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. Illustration is for reference only. This assembly is not serviceable with the exception of oil seals.

  • Page 51: Steering

    Table of Contents 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...

  • Page 52: Inspect Ball Joints

    Steering E-455 INSPECT BALL JOINTS INSPECT PILLOW 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 53: Adjust Steering Gear

    Steering E-455 ADJUST STEERING GEAR 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: In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure.

  • Page 54: Replace Ball Joint

    Steering E-455 REPLACE BALL JOINT 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: Raise the front of the vehicle and support with jack stands. 2: Loosen the ball joint clamp on the steering sleeve.

  • Page 55: Replace The Front Fork

    Steering E-455 REPLACE THE 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. 1: Remove the front axle. Refer to section Front Axle Removal and Installation in Front Axle Service for information regarding removing the front axle.

  • Page 56: Steering Gear

    Steering E-455 STEERING GEAR 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. Disassemble Note: The steering gear must be removed from the vehicle for this procedure.

  • Page 57: Reassemble

    Steering E-455 Reassemble 12: Lightly lubricate all parts before reassembly. 13: Install a new worm shaft seal and pitman shaft seal into the housing. 14: Install the upper worm bearing cup. 15: Divide the ball bearing into two equal groups. 16: Position the ball nut onto the worm as shaft as shown in the illustration.

  • Page 58: Exploded View Of Steering Gear

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

  • Page 59: Front Wheel Alignment

    Steering E-455 FRONT WHEEL ALIGNMENT 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: Rotate the steering wheel until the pitman arm is vertical, then tie off the steering wheel so that it cannot rotate.

  • Page 60: Hardware Torque

    Steering E-455 HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Notes 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 60 ME-455-04...

  • Page 61: Brakes

    Table of Contents 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 WARNING...

  • Page 62: General Guidelines And Safety

    E-455 GENERAL GUIDELINES AND SAFETY WARNING WARNING Taylor-Dunn does not currently supply asbestos This section is one section of a complete service fiber-brake pads/shoes with any vehicle. However, manual. Before starting any procedure, read all there is the possibility that the original brake pads/...

  • Page 63: Rear Brake

    Brakes E-455 REAR BRAKE 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. Service Limits Refer to the table at the end of this section Note: Service Limits are listed in a table at the end of this section.

  • Page 64: Rebuild Disc Brake Body

    Brakes E-455 REBUILD DISC BRAKE BODY 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. This procedure assumes that the component has been removed from the vehicle.

  • Page 65: Bleed System

    Brakes E-455 FLUSH SYSTEM BLEED SYSTEM 1: Raise the rear wheels off of the ground and WARNING support with jack stands. 2: If equipped with front brakes, raise the front This section is one section of a complete service wheels off of the ground and support with jack manual.

  • Page 66: Master Cylinder

    Brakes E-455 MASTER CYLINDER 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. There are no internally serviceable components in the master cylinder.

  • Page 67: Service Limits

    Brakes E-455 HARDWARE TORQUE SERVICE LIMITS Description Imperial Metric If hardware is not listed here, refer to standard torque values in the appendix. Disc brake Pad minimum lining 00625 inch 1.58 millimeter Description Foot Pounds Newton Meters Front rotor minimum thickness 0.200 inch 5.08 millimeter Brake Body Bolts...
  • Page 68 Notes Brakes E-455 Page 68 ME-455-04...

  • Page 69: Motor

    Table of Contents 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 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: Remove/Install

    Motor SEM E-455 REMOVE/INSTALL DISASSEMBLE WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 71: Inspect

    Motor SEM E-455 INSPECT Inspect the commutator for groves. WARNING • If the commutator is grooved then it must be machined on a lathe. Do not machine the This section is one section of a complete service commutator past the minimum diameter specified manual.

  • Page 72: Field Windings

    Motor SEM E-455 Inspect the armature windings where they loop back at Using the continuity function of digital multi meter, check the opposite end of the commutator. the continuity from any one of the commutator segments • If the windings show indications of expanding (see and the armature frame.

  • Page 73: Repair

    Motor SEM E-455 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. The only recommended repair to a motor is cutting the commutator. If any other components are damaged then they should be replaced.

  • Page 74: Service Limits

    Motor SEM E-455 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. This is a generic section covering all currently available SEM motors at the time this manual was revised. The service limits listed below are for each of the motors, by the specification number of the motor shown.
  • Page 75 Table of Contents 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 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 76: Motor Controller

    Motor Controller E-455 REMOVE/INSTALL INSPECT WARNING Receptacles The inside of each receptacle should be clean and free This section is one section of a complete service of any debris. Use aerosol electrical cleaner if required. manual. Before starting any procedure, read all warnings and instructions that are located in the Base Plate Service Guidelines chapter.

  • Page 77: Motor Controller

    This manual was provided on the original vehicle CD. A hard copy can be purchased from your authorized NOTICE Taylor-Dunn distributor or can be downloaded from the Taylor-Dunn web site. The controller power base and logic are a matched set. DO NOT swap logics from one base to another as this may damage the logic or power base.

  • Page 78: Hardware Torque

    Motor Controller E-455 HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the Notes appendix. Description Inch Pounds Newton Meters Terminal stud 38-44 4.29-4.97 Page 78 ME-455-04...

  • Page 79: Wire Diagram

    Table of Contents Wire Diagram Diagram Part Numbers........80 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 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-00110 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. Green/Black...

  • Page 81: Batteries

    Table of Contents 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 WARNING...

  • Page 82: General Guidelines And Safety

    Batteries E-455 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 83: Cleaning

    Batteries E-455 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this...

  • Page 84: Testing

    Batteries E-455 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter and beginning of this Service Guidelines chapter and beginning of this...

  • Page 85: Remove/Install

    Batteries E-455 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 warnings and instructions that are located in the short circuit resulting severe bodily injury or damage Service Guidelines chapter and beginning of this...

  • Page 86: Hardware Torque

    Batteries E-455 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 Battery terminal, Trojan bolt 95-105 11-12...
  • Page 87 Table of Contents Tires & Wheels Inflation .............88 Rotation ............88 Changing Tire/Wheel Assembly .....89 Replace the Tire ..........89 Solid Wheel .............89 Split Wheel ..............89 Hardware Torque ..........90 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 88: Tires & Wheels

    Tires & Wheels E-455 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 warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.

  • Page 89: Tires & Wheels

    Tires & Wheels E-455 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 90: Hardware Torque

    Tires & Wheels E-455 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 90 ME-455-04...

  • Page 91: Suspension

    Table of Contents Suspension Replace Rear Rubber Springs ......92 Raising the Rear of the Vehicle ......93 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 92 Suspension E-455 REPLACE REAR RUBBER SPRINGS 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: If a spring has failed 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.
  • Page 93 Suspension E-455 RAISING THE REAR OF THE VEHICLE WARNING 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.
  • Page 94 Notes Suspension E-455 Page 94 ME-455-04...

  • Page 95: Hardware Information

    Table of Contents 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 WARNING This section is one section of a complete service manual.

  • Page 96: Torque Guidelines For Standard Hardware

    Hardware E-455 TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head as illustrated to the right.

  • Page 97: Hex Nuts

    ‘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-455-04 Page 97...

  • Page 98: Generic Torque Values

    Hardware E-455 Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
  • Page 99 Hardware E-455 All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Metric, Newton Meters Metric, Foot Pounds Grade, N-m Grade, N-m...

  • Page 100: Replacing Hardware

    Hardware E-455 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 101 TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....102 Taylor-Dunn Web Site Information ....102 Axle/Fork Assembly, 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...

  • Page 102: 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 103 Replacement Parts E-455 My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: ME-455-04 * Not available at time of printing Page 103...

  • Page 104: Axle/Fork Assembly, Front

    Replacement Parts E-455 AXLE/FORK ASSEMBLY, FRONT AXLE SHAFT ASSEMBLY, REAR Note: The double bearing axle assembly is optional. Most vehicle will only hae the single bearing (#2) Inner 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.
  • Page 105 Replacement Parts E-455 Axle Assembly, Front Item No. Part No. Description 88-229-81 3/4NC Hex nut 88-228-60 3/4 Cut flat washer 14-319-05 Caster Plate 80-011-00 Bearing, fork collar 03-455-12 Spacer sheet 14-087-10 Fork 15-002-05 Axle shaft with flange 88-389-86 1-1/4NC Lock nut, use with 15-002-05 axle 13-904-06 Wheel (includes 13, 14, 15, 16) 88-151-15...

  • Page 106: Gt Transaxle Assembly, Rear

    Replacement Parts E-455 GT TRANSAXLE ASSEMBLY, REAR Page 106 ME-455-04...
  • Page 107 Replacement Parts E-455 GT Axle Assembly, Rear Item No. Part No. Description GT-71682 Bolt, M8 x 60 mm GT-3287563 Gear case cover GT-71259 Bearing see gear kits below Input shaft GT-71982 O-ring GT-3287503 Eccentric shaft GT-72005 Bearing see gear kits below Idler gear 88-406-67 Bolt, M10 x 30 mm...

  • Page 108: Sd Transaxle Assembly, Rear 3Rd Member

    Replacement Parts E-455 SD TRANSAXLE ASSEMBLY, REAR 3RD MEMBER Illustration is for reference only. This assembly as not serviceable with the exception of oil seals. Item No. Part No. Description 44-440-93 Complete 3rd member assembly Bolt N/A - Order assembly Bearing N/A - Order assembly Race...

  • Page 109: Sd Transaxle Assembly, Rear Primary Reduction

    Replacement Parts E-455 SD TRANSAXLE ASSEMBLY, REAR PRIMARY REDUCTION Item No. Part No. Description 44-440-89 Assembly, Primary reduction, 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 Kit B Bearing...

  • Page 110: Battery

    Replacement Parts E-455 BATTERY Page 110 ME-455-04...
  • Page 111 Replacement Parts E-455 Battery Item No. Part No. Description 30-550-12 Chain 98-455-20 Chain insulation 4’ 02-455-22 Hood 97-308-10 Latch bracket 98-753-12 Bump stop 97-308-00 Latch 96-301-10 Shoulder bolt 88-109-81 3/8NC Hex lock nut 01-455-85 Roller bracket 30-172-12 Roller 01-455-87 Side door (right) 03-455-07 Battery clamp 88-690-00...

  • Page 112: Brakes, Brake Lines

    Replacement Parts E-455 BRAKES, BRAKE LINES #7: Located inside of #3. Actual size 3/8 inch long Brake Lines Item No. Part No. Description 99-580-20 Brake hose 99-600-58 Brake line 99-563-00 T-fitting 99-580-40 Brake hose to master cylinder 99-600-58 Brake line 99-576-00 Brake hose clip 99-574-00...

  • Page 113: Brakes, Master Cylinder

    Replacement Parts E-455 BRAKES, MASTER CYLINDER Brake Lines, Master Cylinder Item No. Part No. Description 99-511-00 Master cylinder (includes 8, 9, 10, 11) 88-101-20 3/8NC x 3 Hex bolt, grade 5 99-578-00 Hydraulic fitting 99-572-00 Copper washer 99-566-00 Banjo fitting 99-571-00 Copper washer 88-109-81...

  • Page 114: Brakes, Park Brake

    Replacement Parts E-455 BRAKES, PARK BRAKE Item No. Part No. Description 96-763-00 Clevis 96-765-00 Clevis, left hand thread 00-455-07 Cable mounting bracket 01-440-57 Cross shaft link 96-763-00 Clevis, right hand thread thread 96-773-00 5/16 x 1 Clevis pin 88-527-11 1/8 x 1 Cotter pin 88-099-81 5/16NF Hex nut, left hand thread 96-820-25...

  • Page 115: Brakes, Rear Axle

    Replacement Parts E-455 BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 41-351-80 Complete caliper assembly (left) 41-351-81 Complete caliper assembly (right) 88-067-21 1/4NC x 3-3/4 Hex bolt, grade 8 88-069-82 Nut, Grade C 41-350-91 Secondary plate See kit below Brake pad 41-348-58 Spacer...

  • Page 116: Brakes, Brake Body

    Replacement Parts E-455 BRAKES, BRAKE BODY Brakes, Brake Body Item No. Part No. Description 99-588-00 Bleeder screw 99-588-01 Bleeder adapter Brake body See kit O-ring See kit Boot 41-351-16 Piston 41-351-15 Kit, o-ring and boots (1 wheel) Page 116 ME-455-04...

  • Page 117: Control System, Motor Speed Control

    Replacement Parts E-455 CONTROL SYSTEM, MOTOR SPEED CONTROL Speed Control Panel Item No. Part No. Description 62-400-05 Speed controller, Provide serial number of vehicle 71-300-02 Line contactor 71-300-01 Mounting bracket 73-005-01 Reverse/Motion beeper 79-840-00 10 Amp circuit breaker 79-840-00 10 Amp circuit breaker 79-829-15 Fuse (24v system) 0 or 1...

  • Page 118: Control System, Instrument Panel

    Replacement Parts E-455 CONTROL SYSTEM, INSTRUMENT PANEL Instrument Panel Item No. Part No. Description 71-120-10 Key switch 71-120-90 2, 3 71-039-11 Accessory switch 71-039-21 Plastic plug for empty accessory switch hole 74-010-00 Smart view display 71-039-02 Direction control switch 71-501-00 Horn switch Page 118 ME-455-04...

  • Page 119: Decals

    Replacement Parts E-455 DECALS Item No. Part No. Description 94-301-09 DECAL”TAYLOR-DUNN”1 1/2 HI BLK 94-301-41 DECAL, DOT 3 BRAKE FLUID 94-301-43 DECAL, ARMS/LEGS INSIDE,3 WHEEL 94-309-00 DECAL, PARK BRAKE WARNING 94-312-00 LABEL, FORWARD/REVERSE SW> 94-313-00 DECAL, BATTERY WARNING (GASES) 94-313-21...

  • Page 120: Electrical, Miscellaneous

    Replacement Parts E-455 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 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID 96-630-00 (not shown Clamp, Rubber Lined 5/8 ID...

  • Page 121: Frame

    Replacement Parts E-455 FRAME Item No. Part No. Description See Battery Hood hold down bracket See Battery Hood hold down Latch 03-455-00 Dash instument Panel 01-455-09 Right dash cover 03-455-11 Rear rubber pad 94-201-00 T/D emblem 03-455-05 Park brake handle cover See Brake Linkage Park brake handle 03-455-10...

  • Page 122: Hitches

    Replacement Parts E-455 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. Description 72-025-03 Headlight, Lens (24v system) 0 or 1 72-080-00...

  • Page 123: Mirrors

    Replacement Parts E-455 MIRRORS Item No. Part No. Description 92-201-00 Mirror (includes 2 and 3) Part of #1 Hex bolt Part of #1 Washer 92-202-00 Mounting bracket (includes 6 and 7) 88-065-08 1/4NC x 5/8 Truss head screw Part of #4 Hex bolt Part of #4 Hex lock nut...

  • Page 124: Motor

    Replacement Parts E-455 MOTOR Motor Spec # DV1-4003A Item No. Part No. Description 70-057-40 Motor Assembly 70-421-10 Front housing 70-400-10 Armature 70-209-40 Field assembly 85-403-00 Brush spring 70-173-00 Brush holder 70-170-30 Brush pair 70-417-00 Bearing retainer 80-212-00 Bearing 70-421-30 Rear housing 70-421-40 Brush cover 95-930-00...

  • Page 125: Seats

    Replacement Parts E-455 SEATS Item No. Part No. Description 90-160-60 Arm rest kit 90-160-70 Seat assembly , standard (does not include #1) 71-102-20 Interlock switch 88-080-13 5/16 x 1-1/4 Hex bolt 00-455-20 Seat mounting plate 90-160-71 Seat spacer 88-130-10 7/16NF x 7/8 Hex bolt 88-128-60 7/16 Flat waser 88-089-81...

  • Page 126: Steering Column, Standard

    Replacement Parts E-455 STEERING COLUMN, STANDARD Steering Column Item No. Part No. Description 19-005-17 Steering sheel 20-455-02 Steering shaft 97-200-00 Dust washer 32-455-00 Bushing 20-455-03 Steering column 18-308-04 U-joint 88-060-10 1/4 x 3/4 Hex bolt, grade 5 96-123-45 3/8 x 2 x 2-5/8 U-bolt 88-109-80 3/8NC Hex nut 88-108-62...

  • Page 127: Steering Column, Tilt

    Replacement Parts E-455 STEERING COLUMN, TILT Steering Column Item No. Part No. Description 19-005-17 Steering wheel 19-005-00 Steering adapter 18-414-80 Tilt steering assembly 96-123-45 U-bolt 18-308-04 U-joint 88-108-62 3/8 Split lock washer 88-109-80 3/8NC Hex nut 18-414-60 Lever kit ME-455-04 * Not available at time of printing Page 127...

  • Page 128: Steering Gear

    Replacement Parts E-455 STEERING GEAR Steering Gear, 18-308-21 Item No. Part No. Description 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assembly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft 18-308-81 Lock washer 18-308-79...

  • Page 129: Steering Linkage

    Replacement Parts E-455 STEERING LINKAGE Steering Linkage Item No. Part No. Description 84-004-00 Pillow bearing 18-146-03 Steering jack shaft 18-028-12 Steering link assembly with ball joints 86-501-98 Ball joint 86-501-99 Ball joint 86-510-00 Ball joint clamp 18-640-10 Pitman arm ME-455-04 * Not available at time of printing Page 129...

  • Page 130: Suspension, Rear

    Replacement Parts E-455 SUSPENSION, REAR Item No. Part No. Description 88-149-81 Hex nut 01-455-61 Washer 02-455-07 Rubber suspension 88-149-81 1/2NC Hex lock nut 32-249-00 Bushing 88-140-22 1/2NC x 3-1/2 Hex bolt 00-455-06 Swing arm Page 130 ME-455-04...

  • Page 131: Wheels And Tires

    Replacement Parts E-455 WHEELS AND TIRES Item No. Part No. Description Refer to Axle/Fork Assembly for front wheels 13-734-42 Tire/Wheel assembly, Lugged 13-734-40 Tire/Wheel assembly, Ribbed ME-455-04 * Not available at time of printing Page 131...
  • Page 132 Notes: Replacement Parts E-455 Page 132 ME-455-04...
  • Page 134 For more information go to www.P65Warnings.ca.gov/ passenger-vehicle. Taylor-Dunn® Manufacturing. 2114 West Ball Road. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 FAX: (714) 956-0504 Visit our Website: www.taylor-dunn.com...

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