Taylor-Dunn E-451, Service And Parts Manual

Page 1: ...HIS VEHICLE The operator s manual contains important information regarding the safe operation of this vehicle WARNING Starting Serial Number 206900 Ending Serial Number See Introduction Chapter Servic...

Page 2: ...eplacement 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 withou...

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

Page 4: ...n invaluable asset and it is an asset we cherish and protect Our guiding principle is to provide application specific solutions which are reliable efficient and economical Our domestic and internation...

Page 5: ...intenance 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 Tires Wheels 79 Hardware Information...

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

Page 8: ...riate 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 thi...

Page 9: ...TICE 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 component...

Page 10: ...ers Lead acid batteries Personnel performing maintenance shall have basic knowledge of standard automotive maintenance procedures and lead acid batteries Of the Operator A vehicle shall not be operate...

Page 11: ...and 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...

Page 12: ...Page 12 ME 45X 01 Introduction E 451 E 457 Notes...

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

Page 14: ...attached 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 vehic...

Page 15: ...perator Controlled Industrial Tow Tractors Paragraph 6 2 14 Modifications and additions which affect capacity and safe tow tractor operation shall not be performed without manufacture s prior written...

Page 16: ...ehicle 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 mo...

Page 17: ...g any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Preventative Maintenance Daily Visual Inspection 18 Pre Operation Inspection 18 Maintenanc...

Page 18: ...very time before the vehicle is driven Steering operation Brake operation service and park brake Proper operation of trailer hitch This section is one section of a complete service manual Before start...

Page 19: ...lowing Inspect and adjust brake Clean battery compartment Inspect all hardware for tightness first 300 hours then every 1 200 hours Lubricate the vehicle per lubrication schedule Re torque wheel nuts...

Page 20: ...uld 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...

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

Page 22: ...to complete troubleshooting provided in the vehicle service manuals 43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary red...

Page 23: ...ving Tool Removes 0 093 diameter pins from Molex rectangular harness connectors Not available from Taylor Dunn Purchase from any local electronics distributor Molex 11 300 02 Pin Removing Tool Removes...

Page 24: ...r 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 Fau...

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

Page 26: ...7 Drain Plug ref 8 Level Plug ref 9 Fill Plug 1 2 quarts SAE 140 weight API GL5 Hypoid Gear Oil HAZARDOUS WASTE DISPOSAL This vehicle contains various components and or fluids that may be classified a...

Page 27: ...Lubrication Page 27 ME 45X 01 E 451 E 457 LUBRICATION DIAGRAM...

Page 28: ...Lubrication Page 28 E 451 E 457 ME 45X 01 Notes...

Page 29: ...ervice manual 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...

Page 30: ...the wheel tighten the 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 r...

Page 31: ...ide freely out of the fork The front wheel s should still be resting on the ground 3 Remove the front axle from the fork and support the vehicle with jack stands Note If the bearings were worn until t...

Page 32: ...Front Axle Page 32 E 451 E 457 ME 45X 01 Notes...

Page 33: ...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 D...

Page 34: ...lling through the chain case plug then you will have to wait for the oil to flow through the chain case and into the housing 7 Replace the fill and level plugs 8 Reconnect the battery This section is...

Page 35: ...housing 7 Remove the bearing gasket and axle seal from the housing Install 1 Install a new seal and gasket in the housing Note Depending on the vehicle configuration there may or may not be an axle oi...

Page 36: ...ase 2 Loosen but do not remove the three drive motor mounting nuts Note A small amount of oil may come out when the drive motor mounting bolts are loosened 3 Apply the parking brake 4 Loosen the chain...

Page 37: ...motor sprocket under the chain and rotate the motor so that the mounting plate goes into the threaded studs and remove the wire holding the chain 3 Install the motor mounting hardware but do not tigh...

Page 38: ...urfaces 2 Apply a 1 8 bead of 94 430 03 gasket sealer to the face of the 3rd member 3 Install the backing plate to the 3rd member Tighten to torque specified in the Hardware Torque table at the end of...

Page 39: ...Drive Axle Page 39 ME 45X 01 E 451 E 457...

Page 40: ...ter WARNING 9 Remove the pinion housing and pinion gear from the 3rd member Note Do not lose the spacers and shims in the pinion housing or the pinion housing shim s 10 If required remove the rear tap...

Page 41: ...cification Differential Assembly 1 Reassemble the differential housing in reverse order of disassembly 2 Place the ring gear onto the differential housing matching the mark made during disassembly 3 I...

Page 42: ...ded setting for new gears If it is out of specification then readjust the bearings as follows To increase backlash loosen the left spanner nut and then tighten the right spanner nut the same amount To...

Page 43: ...ocate the number printed on the flat surface of the pilot bearing shaft of the pinion gear It should be a number ranging from 5 to 5 This is the amount in 0 001 increments to add to the standard shim...

Page 44: ...fer to standard torque values in the appendix Description Foot Pounds Newton Meters Pinion nut 175 245 Backing Plate to 3rd member 30 45 42 63 Ring Gear Bolts 65 80 91 112 Bearing Cap Bolts F2 80 85 1...

Page 45: ...ting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Steering Inspect Rod Ends 46 Inspect Fork Bearings 46 Align Steering 47 Replace Rod End...

Page 46: ...ery 4 Remove the blocks from behind the wheels 5 Test drive the vehicle This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that a...

Page 47: ...cannot rotate 6 Loosen the rod end clamps 7 Adjust the drag link rod ends so that the drag link can be easily installed Both rod ends should have approximately the same number of threads into the dra...

Page 48: ...nt wheel 8 Lower the vehicle 9 Reconnect the Battery 10 Remove the blocks from behind the wheels 11 Test drive the vehicle This section is one section of a complete service manual Before starting any...

Page 49: ...oroughly clean all parts and install in reverse order Tighten the fork spindle nut to remove all play in the fork bearings and then an additional 1 4 turn Refer to section Front Axle Removal and Insta...

Page 50: ...connect the battery 5 Remove the blocks from behind the wheels 6 Test drive the vehicle This section is one section of a complete service manual Before starting any procedure read all warnings and ins...

Page 51: ...ng any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Brakes General Guidelines and Safety 52 Inspection 53 Adjust Service Brake 53 Replace Bra...

Page 52: ...s 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 ca...

Page 53: ...rake cables and linkages for any signs of damage or wear 5 Refer to the Replace Brake Band section for information on reinstalling the band This section is one section of a complete service manual Bef...

Page 54: ...70 Nm 12 Tighten the brake band bracket mounting bolts 5 13 Position the brake band alignment bracket s 9 so that the inner arm 14 is 0 100 inch 2 54 mm away from the brake drum 8 Make certain that t...

Page 55: ...lowing the bracket to move 10 Tighten the brake band bolt 4 to 50 foot pounds 70 Nm 11 Tighten the brake band bracket mounting bolts 5 12 Position the brake band alignment bracket s 9 so that the inne...

Page 56: ...ion nut to torque per specification listed in the table at the end of this section 7 Adjust the brake Refer to the Adjust Service Brake section for information regarding adjusting the brake 8 Release...

Page 57: ...ng any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Drive Motor Motor Removal and Installation 58 Disassemble 58 Assemble 59 Inspection 60 Br...

Page 58: ...motor from the vehicle See the Transmission section for information on removing the motor 2 Place marks on the two end caps and field housing so that they can be reassembled in the same orientation 3...

Page 59: ...the brush springs hold them in place away from the commutator 4 Press the armature into the rear motor bearing 5 Push each brush into the holder making sure the brush spring is positioned correctly Se...

Page 60: ...rted armature If the insulation is cracked or burnt then it is recommend that the armature or motor be replaced Note If the armature has been burnt then there is a good possibility that the field wind...

Page 61: ...tator is grooved then it must be machined on a lathe Do not machine the commutator past the minimum diameter specified in Service Limits section Refer to the Repair Commutator section for information...

Page 62: ...laced 4 Thoroughly clean all copper debris from between the commutator segments Note Copper debris in the undercut area can give a reading of a shorted armature 5 Measure the commutator undercut depth...

Page 63: ...arting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Specification Number Undercut Depth Commutator Diameter min Brush Length min Re...

Page 64: ...Drive Motor Page 64 E 451 E 457 ME 45X 01 Notes...

Page 65: ...complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Motor Controller Remove Install 66 Inspect 66 Troubl...

Page 66: ...e the four bolts holding the controller to the panel and remove the controller Install 1 Thoroughly clean the controller base and mounting plate 2 Install the controller to the mounting plate 3 Attach...

Page 67: ...ols These adjustments are accessed by removing the button head screws in the housing The control may need to be removed from the panel to gain access to the screws The adjustment potentiometers pots a...

Page 68: ...age 68 E 451 E 457 ME 45X 01 HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Inch Pounds Newton Meters Terminal hardware 72 8 13 Adjustment p...

Page 69: ...iagram This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Wire Diagram...

Page 70: ...en 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 wel...

Page 71: ...Green Black Horn 2 R1 Violet Black PMC CONTROL 8 10 5 6 1 2 7 4 9 White Black Red 14 10A CB Light Switch Blue Violet Black Harness Connector Red Brown White Green Black White Black Blue Black Orange B...

Page 72: ...Wire Diagram Page 72 E 451 E 457 E 451 E 457...

Page 73: ...s that are located in the Service Guidelines chapter WARNING Batteries General Guidelines and Safety 74 Cleaning 75 Charging 75 Watering 75 Testing 76 Specific Gravity 76 Storing 76 Storage 76 Returni...

Page 74: ...or 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 w...

Page 75: ...e 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 electroly...

Page 76: ...ng 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 bat...

Page 77: ...y 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 sec...

Page 78: ...ct 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 b...

Page 79: ...lete service manual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Tires Wheels Inflation 80 Rotation 80 Changing Tire Whee...

Page 80: ...erval 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 Thi...

Page 81: ...formation 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...

Page 82: ...Tires Wheels Page 82 E 451 E 457 ME 45X 01 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 83: ...tarting any procedure read all warnings and instructions that are located in the Service Guidelines chapter WARNING Hardware Information Torque Guidelines for Standard hardware 84 Hardware Identificat...

Page 84: ...se 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...

Page 85: ...uts 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...

Page 86: ...6 192 297 420 390 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 Imper...

Page 87: ...8 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...

Page 88: ...edure 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 b...

Page 89: ...d manual 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...

Page 90: ...include special order options that may have been ordered for your vehicle To identify special order options refer to the original vehicle sales order Any special order options will have a K letter pre...

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

Page 92: ...Replacement Parts Page 92 ME 45X 01 E 451 E 457 AXLE SHAFT ASSEMBLY REAR...

Page 93: ...mall bearing E 457 0 or 2 4 96 331 00 Wheel stud 10 5 41 163 05 Axle Left E 451 0 or 2 41 162 05 Axle Right E 451 0 or 2 41 163 00 Axle Left E 457 0 or 2 41 162 00 Axle Right E 457 0 or 2 6 32 514 00...

Page 94: ...Replacement Parts Page 94 ME 45X 01 E 451 E 457 TRANSAXLE ASSEMBLY REAR...

Page 95: ...1 239 00 Ring and Pinion Gear Set 1 7 41 997 00 Oil Plug 3 8 41 290 13 Rear End Housing 1 10 80 554 00 Front Pinion Bearings 2 11 41 711 00 Pinion Housing Shim 1 12 80 702 00 O Ring 1 13 Pinion Housin...

Page 96: ...Replacement Parts Page 96 ME 45X 01 E 451 E 457 TRANSAXLE ASSEMBLY CHAIN CASE...

Page 97: ...00 Spacer Main Sprocket 1 11 30 070 11 60 Tooth Double Pinion Sprocket E 4 51 1 30 070 10 81 Tooth Double Pinion Sprocket E 4 51 E 4 57 1 12 30 320 11 Drive Chain 15 81 T Double Sprocket E 4 51 E 4 5...

Page 98: ...1 6 41 372 10 Mounting Bracket 1 7 88 159 84 1 2 20 NF Lock Nut 1 8 88 159 82 1 2 NF Hex Jam Nut 1 9 97 250 00 Pinion Nut 1 10 88 109 81 3 8 Lock Nut 1 11 88 108 61 3 8 Lock Washer 2 12 88 517 11 3 32...

Page 99: ...vis 1 4 96 772 00 Clevis pin 2 5 88 527 11 Cotter pin 2 6 50 028 00 3 8 threaded rod 1 88 119 80 3 8 NF HEX HD NUT 1 7 85 282 00 Spring E 4 51 1 85 280 00 Spring E 4 57 8 50 647 00 Bell crank 1 9 96 7...

Page 100: ...Replacement Parts Page 100 ME 45X 01 E 451 E 457 CONTROL SYSTEM MOTOR SPEED CONTROL...

Page 101: ...1 79 829 15 Fuse E 4 51 1 7 88 818 06 8 x 1 2 Pan head screw 2 8 73 002 00 Horn 24v 36v 1 9 88 838 06 14 x 1 2 Pan head screw 2 10 88 838 06 14 x 1 2 Pan head screw 4 11 01 534 80 Mounting plate E 4...

Page 102: ...1 2 71 039 11 Switch 1 3 74 009 10 Battery status indicator E 4 51 1 74 009 00 Battery status indicator E 4 57 1 4 74 000 00 Hour meter 1 5 71 039 02 F R Switch 1 6 71 120 10 Key switch 1 7 71 501 00...

Page 103: ...Safety Warning 1 2 94 382 00 Treadle 1 3 94 384 17 Do Not Spray Wash 1 4 94 313 00 Battery Warning 1 5 34 319 00 Battery Disconnect 1 6 94 384 61 Operator Presence Switch 1 7 94 384 14 Leaving Vehicl...

Page 104: ...30 00 not shown Clamp Rubber Lined 5 8 ID 96 630 50 not shown Clamp Rubber Lined 5 8 ID 265 mounting hole 96 631 00 not shown Clamp Rubber Lined 3 4 ID 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 631...

Page 105: ...57 1 2 90 144 00 Seat back cushion 1 3 90 159 00 Seat back support 1 4 17 113 00 Locking collar 2 95 901 00 Knob 2 5 71 617 00 Rear cover 1 6 71 618 10 Front cover 1 7 00 450 23 Pedal Interlock switc...

Page 106: ...Replacement Parts Page 106 ME 45X 01 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 107: ...8 180 15 5 8 X 1 3 4 NC HEX HD SCR 1 17 88 189 82 5 8 NC THIN FLEX LOCK NUT 1 18 15 010 20 Axle shaft 1 19 86 521 98 Rod end left thread 1 86 521 99 Rod end right thread 1 20 86 510 00 Clamp 2 21 18 0...

Page 108: ...Replacement Parts Page 108 ME 45X 01 E 451 E 457 FRONT WHEELS E 457...

Page 109: ...g 1 3 14 087 00 Fork 1 4 88 389 86 1 1 4 NC Lock nut 1 5 80 011 00 Bearing 1 80 102 00 Race 1 6 16 408 00 Spacer 1 7 15 002 05 Axle 1 8 16 408 01 Spacer 4 9 16 410 00 Shims 10 45 307 00 Seal 4 11 80 0...

Page 110: ...811 00 1 7 8 inch Ball 97 821 00 2 inch Ball 88 140 14 1 2NC x 1 1 2 Hex bolt 4 88 149 80 1 2NC Hex nut 4 88 148 62 1 2 Split lock washer 4 LIGHTS Item No Part No Description Qty 72 006 00 Headlight 2...

Page 111: ...Bearing 8021200 2 includes 4 1 4 70 417 00 Retaining ring 1 5 70 400 05 Fan 1 6 N A Armature 1 7 N A Fame and Field 1 8 PKIT 00012 Kit Brush Spring 85 403 00 4 1 9 PKIT 00010 Brush 7017010 4 1 10 70 1...

Page 112: ...No Description Qty 1 01 450 29 Accelerator module mounting bracket 1 2 02 150 11 Extension lever on module arm 1 3 50 123 23 Rod treadle arm to module 1 88 109 81 3 8 NC LOCK NUT 1 88 108 60 3 8 CUT W...

Page 113: ...E 451 E 457 WHEELS AND TIRES Item No Part No Description Qty 13 952 10 Rear Tire Wheel assembly 16 x 4 x 12 125 2 10 250 00 Tire 2 12 050 00 Wheel 2 13 964 10 Front Tire Wheel assembly E 457 2 10 267...

Page 114: ...Replacement Parts Page 114 ME 45X 01 E 451 E 457 Notes...

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Page 116: ...other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequ...