Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation Manual Download

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Serial number Starting: 149242

MANUAL MB-T48-01

Operation, Troubleshooting and Re-

placement Parts Manual

Models Inlcuded:
B0-T48-48 Taylor Truck (T48)
ET-030-48 (ET 3000)

Revision: F

Taylor Truck

ET 3000

Summary of Contents for B0-T48-48 Taylor Truck T48

Page 1: ...out Your B u s i n e s s Serial number Starting 149242 MANUAL MB T48 01 Operation Troubleshooting and Re placement Parts Manual Models Inlcuded B0 T48 48 Taylor Truck T48 ET 030 48 ET 3000 Revision F...

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Page 3: ...All rights reserved No part of this work may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording or any information storage or retri...

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Page 5: ...idelines 2 DRIVER TRAINING PROGRAM 4 DRIVER QUALIFICATIONS 5 VEHICLE CONTROLS 6 Key Switch 6 Forward Reverse Switch 6 Accelerator 6 Steering 7 Foot Brake 7 Park Brake 7 Horn Button 7 Seat Interlock Sw...

Page 6: ...ngs 25 Adjusting Wheel Bearings 26 Removal And Installation of the Steering Gear 27 Steering Gear Adjustment 29 Endplay 29 Gear Lash 30 Steering Gear Disassembly and Repair 31 Drive Service 35 Removin...

Page 7: ...y 9 Testing the interlock Relay 10 Signet Charger Troubleshooting 1 Operating Instructions and Theory of Operation 2 Testing the Charging Cycle 3 Test Equipment Required 4 Status LED Error Code 5 Trou...

Page 8: ...ch Optional Parts 48 SECTION 5A Illustrated Parts List TaylorTruck Standard Parts Tire Wheel Assemblies and Tire WheelComponents 2 Optional Parts Directional Signals and Strobe Light 4 Optional Parts...

Page 9: ...ire Wheel Assemblies and Tire WheelComponents 2 Standard Parts 4 Standard Parts Cab Interior Dash and Seat Switch 6 Standard Parts Aluminum Side Panel Option and Deck Board Option 8 Box with Doors 10...

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Page 11: ...INTRODUCTION Operator and Maintenance Manual...

Page 12: ...uide Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of its vehicles Included in this manual are Vehicle Description Safety Rules and G...

Page 13: ...e operational checks that are to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program SECTION 3 Maintenance and Repair Th...

Page 14: ...rson allow any untrained personnel to service or repair this or any Taylor Dunn vehicle For the purposes of training a qualified service person may oversee the repairs or services being made to a vehi...

Page 15: ...rning A warning alerts the reader of a hazard that may result injury to themself or others Be sure to follow any instructions contained within a warning and exercise extreme care while performing the...

Page 16: ...INTRODUCTION PAGE vi MB T48 01...

Page 17: ...SECTION 1 Vehicle Description and Specifications...

Page 18: ...nd with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 in effect at the time of manufacture The vehicle serial number is stamped in the frame be...

Page 19: ...troller Solid State 500 Amp 48 Volts Transmission Helical Gear Oil Bath Automotive Type Hypoid Differential Motor DC Separately Excited Field 48V 5 9kW for 60 min Speed Unloaded 18 mph Brakes 4 Wheel...

Page 20: ...he contents of all packages and accessories that may have come in separate packages with the vehicle Make sure everything listed on the packing slip is there Check that all wire connections battery ca...

Page 21: ...ON 1 PAGE 5 MB T48 01 Check the operation of each of the following controls Accelerator Brake Parking Brake Key Switch Forward Reverse Switch with Reverse Beeper Front Headlight Switch Steering Wheel...

Page 22: ...aim with a local Taylor Dunn distributor The claim must be filed within 48 hours of receiving the vehicle and its accessories The only personnel authorized to repair modify or adjust any part of this...

Page 23: ...SECTION 2 Safety Rules and Operational Information...

Page 24: ...surfaces in and around industrial plants nurseries institutions motels mobile home parks and resorts It is not intended for use on public streets and highways To operate this vehicle please follow th...

Page 25: ...driving on an incline Observe all traffic regulations and speed limits Keep all body parts head arms legs inside confines of this vehicle while it is moving Keep the vehicle under control at all times...

Page 26: ...perience Successful completion of the Operator Training Program should be required for all personnel who operate this vehicle The Operator Training Program should include the following Operation of th...

Page 27: ...d and unload cargo Know how to properly park this vehicle Recognize an improperly maintained vehicle Demonstrate ability to handle this vehicle in all conditions Only those who have successfully compl...

Page 28: ...ermines the direction of travel of the vehicle Push the top of the switch to engage the vehicle travel forward Push the bottom of the switch to engage the vehicle to travel in reverse DO NOT SHIFT fro...

Page 29: ...he amount of pressure applied Relieving pressure from the pedal releases the braking action Park Brake The parking brake is actuated with a hand lever which is located between the driver and passenger...

Page 30: ...far left side of the instrument panel An accessory switch if any is next to it Hour Meter The hour meter is located to the right of the battery status indicator This records the number of hours the ve...

Page 31: ...s activated when the Key switch is in the ON position and the For ward Reverse switch is depressed in the re verse position The alarm makes a repeated audible sound Electrolyte Alarm Optional The Elec...

Page 32: ...as possible At 90 all segments will flash and the vehicles speed will be reduced At this time the vehicle should be removed from service for charging Discharging beyond 90 will result in damage to the...

Page 33: ...ct order or a defective switch Reset switches and start again 04006 Accelerator pedal depressed before the seat interlock switch is closed Recycle start up switches and try again Possible defective se...

Page 34: ...ntly reduced Warning period The warning starts when the Maintenance Indicator is ON and the Wrench icon is flashing The Wrench icon will continue to flash until the warning time has expired Maintenanc...

Page 35: ...he OFF position and remove the key In addition If parking this vehicle on an incline turn the wheels to the curb or block the wheels Do not block fire aisles emergency equipment stairways or exits Thi...

Page 36: ...arged as follows Returning To Service Check state of battery s charge Charge if needed Perform ALL maintenance checks in the periodic checklist Remove any blocks from the vehicle and or place the vehi...

Page 37: ...SECTION 3 Maintenance and Service Procedures...

Page 38: ...ce the forward reverse switch in the center OFF position It is necessary to disconnect both of the main battery cables before working on or disconnecting any electrical component or wire Secure and bl...

Page 39: ...e Checklist The frequency of service under severe conditions is determined by the use of the vehicle The owner operator must evaluate the operating environment to determine the increase in maintenance...

Page 40: ...ally 1000 hrs 500 hrs Check Condition of Tires X Check Fill Batteries X Check Brake System X Check Steering System X Check for Oil Leaks X Lubricate Vehicle X Clean Tighten All Wire X Connections Wash...

Page 41: ...Grease 3 Front wheel bearings 2 General Purpose Grease 4 King pin 2 General Purpose Grease 7 Drive drain plug 8 9 Drive fill level plug 1 SAE 80w90 Gear Oil NOTE The drive fluid level should be filled...

Page 42: ...rakes Dragging Batteries Discharged or Defective Worn Drive Gears Front End Out of Alignment Defective Speed Control Abnormal Noise Worn Drive Gears or Bearings Worn Front Rear Axle Bearings Loose Lug...

Page 43: ...SECTION 3 PAGE 7 MB T48 01 Hydraulic Disc Brakes...

Page 44: ...pads shoes containing asbestos Since this possibility does exist the brake pads shoes should be handled as if they do contain asbestos Never use compressed air or dry brush to clean the brake assembl...

Page 45: ...Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at...

Page 46: ...capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury Do not let the brake body hang by the brake hose Support...

Page 47: ...bodily injury Avoid ingesting brake fluid and or contact with skin or eyes Always wear protective clothing and a face shield when working with or around brake fluid SKINCONTACT Flush area immediately...

Page 48: ...NOTE Pump it once or twice to build up fluid pressure 8 Attach a clear hose to the bleeder valve NOTE Thehoseshouldbelongenoughtoreachthebottom of the drip pan 1 Make sure the key switch is in the OF...

Page 49: ...the drip pan When air bubbles no longer escape from the tube as the pedal is being depressed the line is void of air 13 Check and add brake fluid to the master cylinder as needed 14 Repeat this proce...

Page 50: ...14 Using the appropriate procedure bleed the brakes and check for leaks 15 Check the brake fluid level again and fill as needed 16 Lower the vehicle 17 Reconnect the main positive and negative cables...

Page 51: ...ster cylinder 9 Replace the cap on the master cylinder 10 Reconnect the main positive and negative cables at the batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and tes...

Page 52: ...SECTION 3 PAGE 16 MB T48 01 PARKING BRAKE...

Page 53: ...switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5...

Page 54: ...SECTION 3 PAGE 18 MB T48 01 FRONT AXLE AND YOKES...

Page 55: ...priate procedure 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehic...

Page 56: ...nt clamps 12 Lower the vehicle 13 Reconnect the main positive and negative cables at the batteries 14 Remove the blocks from behind the wheels 15 Release the park brake and test drive the vehicle Alwa...

Page 57: ...maintain the position of the wheels and the steering gear NOTE Torque the pitman arm nut to 75 100 ft lbs 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Re...

Page 58: ...ift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in serious bodily injury 1 Make sure the key switch is in the OFF position then remove the key...

Page 59: ...il all of the up and down play is removed and the yoke rotates freely The rubber washer must compress slightly to create a seal for the grease 14 Using new cotter pins install in reverse order 15 Blee...

Page 60: ...s NOTE Make sure the clamps are in their original position Turn the steering all the way from left to right to make sure there is no interference If the drag link was removed make sure it is in the co...

Page 61: ...ailure to use lifting and support devices of rated load capacity may result in serious bodily injury Wheel Hub Assembly 1 Make sure the key switch is in the OFF position then remove the key 2 Place th...

Page 62: ...rings at the same time 12 Assemble in reverse order using new grease seals a Pack inner and outer bearings with grease b Tighten the spindle nut while rotating the hub to seat the bearings to 30 ft lb...

Page 63: ...on then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the rear wheels to prevent vehicle movement 5 Disconnect the main positiv...

Page 64: ...raight and realign as necessary 14 Lower the vehicle 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test...

Page 65: ...n positive and negative cables at the batteries 13 Remove the blocks from behind the wheels 14 Release the park brake and test drive the vehicle Always use a lifting strap hoist and jack stands of ade...

Page 66: ...ng 12 Install the drag link 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from behind the wheels 16 Release the park brake and test driv...

Page 67: ...illustration at the end of this section for a blown up view of the steering gear assembly 1 Center the steering gear A Turn the steering shaft all of the way in one direction B While counting the rot...

Page 68: ...the ball nut from the worm shaft 11 Thoroughly clean and inspect all parts for signs of corrosion damage or wear and replace as required Reassembly 1 Lightly lubricate all parts before reassembly 2 In...

Page 69: ...ring adjuster lock nut 12 Rotate the worm shaft to center the ball nut in the housing 13 Place a new gasket onto the housing and install the assembled pitman shaft side cover onto the housing using tw...

Page 70: ...SECTION 3 PAGE 34 MB T48 01...

Page 71: ...SECTION 3 PAGE 35 MB T48 01 DRIVE SERVICE...

Page 72: ...reverse order lubricate the o ring NOTE Be sure not to damage the o ring 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF pos...

Page 73: ...ct the main positive and negative cables at the batteries 21 Remove the blocks from behind the wheels 22 Release the park brake and test drive the vehicle Use new Taylor Dunn 96 327 10 bolts for the a...

Page 74: ...r leaks loose or worn parts replace as necessary 15 Reinstall the drive and assemble in reverse order 16 Using the appropriate proceedure reinstall the drive and assemble in reverse order 17 Set the p...

Page 75: ...draulic brake assemblies and park brake cables Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the vehicle Failure to use lifting and support devices of rated...

Page 76: ...11 Remove the circlip from the idler gear 12 Remove the input shaft bearing assembly and idler gear bearing assembly at the same time 13 Remove the pinion nut from the output gear Do not damage the ho...

Page 77: ...5 foot pounds NOTE Torque the retaining bolts to 18 20 foot pounds NOTE Torque the pinion nut to 154 169 foot pounds NOTE Be sure to apply gasket sealer to the front flange on the 3rd member and gear...

Page 78: ...appropriate receptacle 9 Place the 3rd member on an appropriate stand 10 Remove the axle shafts and tubes as an assembly from the 3rd member by removing the six axle tube flange bolts on each axle tu...

Page 79: ...ut roll pin and adjusting nut from the side plate 14 Turn the side plate over and remove the carrier bearing race 15 Remove the differential assembly 16 Remove the carrier bearing adjusting nut roll p...

Page 80: ...rom the input shaft NOTE The input shaft may have to be driven out to perform this procedure 19 Remove the input shaft s shims and spacer 20 Remove the input shaft 21 Remove the front and rear pinion...

Page 81: ...mbly into the housing 5 Tighten the housing carrier bearing race ring nut so that the ring gear is not in contact with the pinion gear 6 Remove the differential assembly NOTE Do not allow the ring nut...

Page 82: ...te the differential assembly 11 Mark the position of each carrier bearing ring nut and then remove the differential assembly be careful not to allow the ring nuts to rotate 12 Install the pinion gear...

Page 83: ...s into the housing and cover to lock the ring nuts in place 19 Remove the pinion gear holding tool 20 Using the appropriate procedures install the primary reduction gear case axles and housings motor...

Page 84: ...ion Shim C B A DV Pinion Shim mm DV The number on the face of the pinion gear A The distance in millimeters from the face of the pinion gear to the top of the inner pinion bearing race B 54 C The numb...

Page 85: ...the pinion gear spacer and shims into the housing 3 Install the outer pinion bearing 4 Install the main gear onto the pinion shaft NOTE Tighten the pinion nut to 154 169 ft lbs 5 Measure the torque re...

Page 86: ...rts of oil 12 Replace the fill plug 13 Lower the vehicle 14 Reconnect the main positive and negative cables at the batteries 15 Remove the blocks from the wheels 16 Release the park brake and test dri...

Page 87: ...SECTION 3 PAGE 51 MB T48 01 SPEED CONTROLLER...

Page 88: ...in even coat of heat sink paste to the controller heat sink base and both sides of the panel 11 Bolt the controller and heat sink together between the control panel NOTE A small amount of heat sink pa...

Page 89: ...SECTION 3 PAGE 53 MB T48 01 DRIVE MOTOR...

Page 90: ...ting bolts and motor support bracket u bolt from the drive and slide the motor off of the input shaft 9 Install the new motor or reassemble in reverse order NOTE Apply grease to the input shaft 10 Rec...

Page 91: ...to the motor to insure that they are returned to their proper location on the motor during reassembly 7 Remove the motor mounting bolts and the motor support bracket u bolt from the drive and slide th...

Page 92: ...as necessary 10 Install the new motor or reassemble in reverse order NOTE Apply a small amount of grease to the input shafts 11 Reconnect the motor and brake wires 12 Reconnect the main positive and n...

Page 93: ...the bolts holding the commutator endcap on the motor 12 Remove the bearing circlip from the commutator end cap 13 Remove the bearing by lightly tapping on the inner race from the endcap and discard t...

Page 94: ...holds the brush from sliding forward When the motor has been reassembled push the brushes against the commutator making sure the spring is not in contact with the brush wires 19 Using the appropriate...

Page 95: ...the motor must be replaced The presence of solder in either of the two areas indicates that the armature was overheated 9 Inspect the armature for grooves NOTE If the armature is grooved turn down wi...

Page 96: ...wires 15 Reconnect the main positive and negative cables at the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive the vehicle Motor Specification 1 Motor F...

Page 97: ...SECTION 3 PAGE 61 MB T48 01 BATTERY...

Page 98: ...itive and negative cables at the batteries 10 Remove the blocks from behind the wheels 11 Release the park brake and test drive the vehicle Battery electrolyte is poisonous and dangerous It contains s...

Page 99: ...ake sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent v...

Page 100: ...batteries 11 Remove the blocks from behind the wheels 12 Release the park brake and test drive the vehicle Do not overfill the battery An overfilled battery may leak acid The result may damage propert...

Page 101: ...o the appropriate voltage outlet 9 Allow the charger to cycle completely before unplugging 10 Remove the blocks from behind the wheels 11 Release the park brake and test drive the vehicle Battery Stor...

Page 102: ...SECTION 3 PAGE 66 MB T48 01...

Page 103: ...BLE OF CONTENTS Test Equipment Required 2 Important Notes and Instructions 2 Definitions 2 Terminology used 2 Start Troubleshooting Here 3 Test 8 Anti Rolloff Fault 22 Test 9 Electric Motor Brake 23 S...

Page 104: ...e start of each test sequence you will be instructed on how to place the control switches While testing do not change the position of any switches unless instructed to do so DURING ALL TESTS After any...

Page 105: ...s Do not continue unless the indicator shows a charged battery If the vehicle runs in one direction only then skip ahead to test 3 If the vehicle runs slow in forward but otherwise runs normal then sk...

Page 106: ...to section 5 If the voltage does not start at 24 volts then go to section 4 TEST 1 2 Test the voltage from B to B on the Controller If the voltage equals battery volts then go to test 1 3 If the volta...

Page 107: ...rive wheels to the ground TEST 1 4 Test the voltage at pin 5 on the 12 pin logic card connector If the voltage is low then skip ahead to test 1 5 If the voltage is high then Check the seat switch for...

Page 108: ...switch for shorted contacts Check the wire to the park brake switch for short circuits to B Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle...

Page 109: ...voltage is above 0 3 volts then skip ahead to Test 6 TEST 1 8 Test the voltage at pin 4 on the 12 pin logic card connector If the voltage is low then skip ahead to test 1 9 If the voltage is high the...

Page 110: ...hicle before lowering the drive wheels to the ground TEST 2 2 Check the resistance from the motor A1 to the A2 terminals If the resistance is less than 1 Ohm then go to test 2 3 If the resistance is g...

Page 111: ...in unexpected movement of the vehicle resulting in injury or property damage This troubleshooting guide is written in sequential order All tests must be performed in the order that they are written S...

Page 112: ...e at pin 2 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 2 If the voltage is high then skip ahead to Test 7 TEST 3 2 Test the voltage at pin 3 on the 12 pin logic...

Page 113: ...ltage at pin 3 on the 12 pin logic card connector If the voltage is low then skip ahead to test 3 4 If the voltage is high then skip ahead to Test 7 TEST 3 4 Test the voltage at pin 2 on the 12 pin lo...

Page 114: ...e controller Connect the negative lead to the F2 terminal on the controller The test should show the presence of a diode approx 0 5v If the test is open or shorted then one or both directional FET s a...

Page 115: ...pen circuits Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 4 2 Test the voltage at th...

Page 116: ...the wire from the cold side of the key switch to pin 1 on the 12 pin logic card connector The relay is located in the charger cabinet Stop trouble shooting here and repair the problem When the repair...

Page 117: ...or coil If the voltage is not within 1 volt of battery voltage then the contactor is bad and must be replaced NOTE An open contactor coil should be accompanied by a 4 flash code from the logic LED If...

Page 118: ...f the vehicle resulting in injury or property damage B Terminal on the Sevcon controller This troubleshooting guide is written in sequential order All tests must be performed in the order that they ar...

Page 119: ...numbers are cast into the connector as shown in the illustration TEST 6 1 Accelerator pedal released Test the voltage from pin 9 to battery positive If the voltage equals battery volts then skip ahead...

Page 120: ...ls battery volts then skip ahead to test 6 4 If the voltage does not equal battery volts then check the wire from pin 4 to the battery voltage negative circuit breaker Stop trouble shooting here and r...

Page 121: ...4 8 and 5 1 volts then the module has failed and must be replaced Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the driv...

Page 122: ...ircuit breaker Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground TEST 7 2 If the vehicle does...

Page 123: ...t the White Black wire on the F R switch If the voltage equals battery volts skip ahead to test 7 4 If the voltage does not equal battery volts then the F R switch has failed Stop trouble shooting her...

Page 124: ...the center OFF position and turn the key switch ON TEST 8 1 Read the motor field current on the Ammeter If the field current is greater than specified in the Motor Specification table see Drive Motor...

Page 125: ...he brake is not engaged then Disconnect the electric brake harness connector and repeat the test If the brake is still not engaged then Remove the brake and repair or replace the brake as required Sto...

Page 126: ...connector is broken Stop trouble shooting here and repair the problem When the repair is completed completely retest the vehicle before lowering the drive wheels to the ground If the test is bad then...

Page 127: ...Low High low Switch in low High 7 Hand brake switch closed Low Hand brake switch open High 8 Key switch on ref battery positive Key switch off ref battery positive Battery volts 9 System off ref batt...

Page 128: ...or Repair as required 4 Contactor fault or open motor Contactor Failure Open Circuit Check contactor and motor 5 Not used 6 Accelerator module fault FS 1 Micro Switch Failure Faulty Wiring Accelerator...

Page 129: ...g 4 Important Notes and Instructions 4 Troubleshooting for Built in Charger 5 Troubleshooting for Portable Charger 8 Testing The Timer Relay 9 Testing the Interlock Relay 10 Turn the Key switch OFFBEF...

Page 130: ...urrent state of charge when it is plugged in it assumes that the batteries require charging when it is connected For this reason it is recommended to discharge the batteries approximately 50 1175 1200...

Page 131: ...efore connecting the charger The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To test the charger to see if it is tu...

Page 132: ...than 80 discharged as per hydrometer reading The battery voltage must be above approximately 65 of the chargers rated DC voltage If the batteries are below approximately 65 of the chargers rated DC vo...

Page 133: ...r has a bad connection Stop here and repair the problem Slide the insulators back onto the connectors on the two 10 gauge wires Slide the insulators off the connectors on the two 14 gauge wires Re Con...

Page 134: ...re continuing Connect a 2k ohm resistor across the capacitor terminals for 10 seconds Do not touch the capacitor terminals with your hands The resistor should be held with a pair of insulated pliers F...

Page 135: ...mer Relay Test Stop here and repair the problem Test the AC voltage across the transformer primary circuit The transformer primary consists of the two solid wires with the brown fiber insulator that a...

Page 136: ...blem Remove the charger cover and perform the following tests 1 Inspect the internal wiring of the charger and repair as required 2 Check the continuity of both fuse links and replace if bad 3 Disconn...

Page 137: ...f the charger If it is less than the rated AC voltage of the charger then the timer relay is bad Stop here and repair the problem Test the AC voltage across the transformer secondary circuit The volta...

Page 138: ...here and repair the problem 9 Connect the charger to a working AC power source The charger should turn on If the charger does not turn on then their may be a problem with the AC power source or the A...

Page 139: ...3 Test Equipment Required for Troubleshooting 4 Important Notes and Instructions 4 Status LED Error Code 5 Troubleshooting 6 Turn the Key switch OFFBEFORE disconnectingthebatteries Disconnecting the b...

Page 140: ...Maintains a constant current until the battery reaches a terminal voltage and then switches to the second stage constant voltage At the second stage the charger decreases the charger current while ho...

Page 141: ...less than 12 hours but still show symptoms of overcharging if The electrolyte in the batteries is too high boil over The electrolyte in the batteries is too low excessive gassing or sulfur smell To t...

Page 142: ...s plugged into is in good working condition Make sure that the AC voltage at the electrical socket is the same as the AC voltage on the charger nameplate Make sure the batteries are in good condition...

Page 143: ...e Description Action Required 1 Reverse polarity or open circuit to the batteries Check wiring for corrosion loose connections broken wires and proper connection to the batteries 2 AC line voltate too...

Page 144: ...l be reduced and will taper off until the batteries are fully charged Perform the following if the charger does not turn on 5 Disconnect the charger from the AC source 6 Remove the charger end cap whe...

Page 145: ...TABLE OF CONTENTS Wire Diagrams Complete Vehicle 2 Dash 3 Control Panel 4 Accelerator Module Detail 5 Lighting 6...

Page 146: ...BLACK Gray White HOUR METER 0 5V 8 4 Black 9 14 8 5 3 12 7 10 16 2 White Black Black 11 1 4 13 5 4 6 7 1 3 8 White Gray White Green Red Black Black Gray Black FLASHER TURN SWITCH RED BLACK RIGHT LEFT...

Page 147: ...Red Red Red Red Red ISO Black NOTE The charger interlock may be located in the charger cabinet GROUND GREEN CHARGER Blue MOTOR F2 Yellow F1 Green AC CHARGER CORD CHARGER INTERLOCK WHITE GROUND GREEN B...

Page 148: ...t Black Red Gray black Blue Black HIGH LOW 2 SWITCH Black Black 2 1 F 7 BATTERY STATUS Violet Black METER HOUR DASH PANEL 12 3 8 SWITCH F R 14 5 Red Red 6 1 Blue White Red Special order accesories may...

Page 149: ...N BUTTON 1 Red Red 13 Red DASH PANEL 9 Red BRAKE LIGHT White Blue White Red Brown White White Brown 4 Red Gray 3 8 Red Black 6 1 7 Yellow White Green Gray White Black Blue White 5 Blue Green Red View...

Page 150: ...Electrical Troubleshooting Section 4 Page 37...

Page 151: ...re and front brake Asssembly 5 14 Master Cylinder 5 16 Hydraulic Disc Brakes 5 18 Park Brake Linkage 5 20 Motor 5 22 Automatic Electric brake 5 24 Instrument Panel and Components 5 26 Resetting the Sm...

Page 152: ...ION 5 PAGE 2 MB T48 01 FRONT AXLE ASSEMBLY 11 17 15 16 18 12 12 14 13 13 2 1 3 10 9 8 7 6 5 4 19 Bushings 8 and 9 must be broached or reamed to a final diameter of 1 25 0 001 after pressing into the a...

Page 153: ...40 43 Sleeve Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 1 ID Tapered Bearing 4 13 80 103 00 Race Tapered Bearing 4 14 12 158 10 Hub Disc Wheel 5 Stud Includes 11 1...

Page 154: ...SECTION 5 PAGE 4 MB T48 01 1 2 3 4 STEERING SLEEVE ASSEMBLY 5 1 5...

Page 155: ...PART DESCRIPTION QTY 1 86 501 98 Ball Joint F1 P2 Le ft W Zerk Fitting 1 86 501 99 Ball Joint F1 P2 Right W Zerk Fitting 1 2 88 159 85 1 2 20 NF Slotted Hex Nut 2 3 86 510 00 Ball Joint Clamp Asse m...

Page 156: ...SECTION 5 PAGE 6 MB T48 01 FRONT SUSPENSION 1 5 6 3 4 2 5...

Page 157: ...EM PART DESCRIPTION QTY 1 96 103 00 U Bolt Length 3 1 2 4 2 85 498 00 85 486 00 Leaf Spring Taylor Truck Leaf Spring ET 3000 2 2 3 32 214 50 Spring Bushing 12 4 96 240 00 Shackle Bolt 6 5 88 149 81 1...

Page 158: ...SECTION 5 PAGE 8 MB T48 01 1 2 3 4 DRAG LINK 2 5 1 5...

Page 159: ...7 10 ITEM PART DESCRIPTION QTY 1 88 159 85 Castle Nut 2 2 86 501 98 Ball Joint w Grease Fitting Left 1 86 501 99 Ball Joint w Grease Fitting Right 1 3 86 510 00 Ball Joint Clamp 2 4 18 037 00 Drag Lin...

Page 160: ...SECTION 5 PAGE 10 MB T48 01 STEERING GEAR 1 2 3 4 5 6 11 12 13 15 17 16 14 10 9 8 7...

Page 161: ...1 5 18 308 22 Upper Worm Bearing Race 1 6 18 308 77 Housing Steering Gear 1 7 18 308 78 Seal Pitman Shaft 1 8 18 308 80 Nut Pitman Shaft 1 9 18 308 81 Lock Washer Pitman Shaft 1 10 18 308 79 Seal Worm...

Page 162: ...SECTION 5 PAGE 12 MB T48 01 STEERING COLUMN ASSEMBLY 1 2 3 4 5 6 7 9 8 12 10 11 13 14...

Page 163: ...ring Shaft Bearing 1 5 20 031 63 Kit Steering Shaft w Clamp 1 6 18 308 45 Assembly Steering Clamp Includes s 5 7 1 7 18 308 21 Steering Gear 1 8 88 128 62 7 16 Split Lock Washer 3 9 88 120 15 7 16 X 1...

Page 164: ...SECTION 5 PAGE 14 MB T48 01 MASTER CYLINDER BRAKE LINE HARDWARE AND FRONT BRAKE ASSSEMBLY...

Page 165: ...p t o s e r i a l 1 5 8 8 6 3 1 9 9 6 0 7 6 2 B r a k e L i n e s t a r t i n g s e r i a l 1 5 8 8 6 4 1 2 1 9 9 6 0 4 5 7 B r a k e L i n e u p t o s e r i a l 1 5 8 8 6 3 1 9 9 6 0 3 6 8 B r a k e...

Page 166: ...SECTION 5 PAGE 16 MB T48 01 MASTER CYLINDER 2 3 4 1 5 6 7 8...

Page 167: ...TY 1 88 080 14 5 16 X 1 1 2 NC Hex Bolt 2 2 88 088 61 5 16 Washer 4 3 88 089 81 5 16 Lock Nut 2 4 99 511 20 Master Cylinder 1 5 99 511 51 Rubber Boot Master Cylinder 1 6 99 511 52 Cap Seal Master Cyli...

Page 168: ...SECTION 5 PAGE 18 MB T48 01 HYDRAULIC DISC BRAKES 1 2 8 6 5 4 3 2 1 1 1 1 3 7 1 0 9 14 1 5 1 6...

Page 169: ...220 03 Bushing for Park Brake Pin 2 12 41 350 56 Park Brake Pin 2 13 41 350 12 Park Brake Lever Bracket 2 14 41 350 52 Clevis Pin 2 15 41 350 53 Park Brake Arm 2 16 88 069 82 1 4 NC Locknut Gr 8 Do N...

Page 170: ...SECTION 5 PAGE 20 MB T48 01 PARK BRAKE LINKAGE 9 8 6 1 1 7 1 2 3 1 1 1 0 4 5...

Page 171: ...61 5 16 Washer 4 3 51 344 80 Park Brake 1 4 88 089 81 5 16 Locknut 2 5 96 813 00 Adjusting Brake Cable Assembly 1 6 96 771 00 3 8 x 3 4 Clevis Pin 1 7 01 204 32 Brake Equalizer 1 8 96 760 00 Brake Ca...

Page 172: ...SECTION 5 PAGE 22 MB T48 01 1 0 9 8 1 1 7 6 3 2 1 6 4 5 MOTOR...

Page 173: ...apter Ring 1 2 70 400 10 Armature and Fan Assembly 1 3 70 209 40 Frame and Field Coil Assembly 1 4 85 403 00 Brush Spring 4 5 70 173 00 Brush Box Assembly 1 6 70 170 30 Lead Assembly Kit 2 7 70 417 00...

Page 174: ...SECTION 5 PAGE 24 MB T48 01 1 2 3 4 5 7 8 9 10 6 11 Automatic Electric Brake Component View AUTOMATIC ELECTRIC BRAKE...

Page 175: ...NC Grade 8 1 11 96 500 04 Tool Manual Auto Electric Brake Release 2 75 152 30 Wiring Harness Not Shown 1 AUTOMATIC ELECTRIC BRAKE PARTS SPECIAL ORDER 1 Magnet and Coil Sub Assembly 1 2 Hub 1 3 Armatu...

Page 176: ...SECTION 5 PAGE 26 MB T48 01 INSTRUMENT PANEL AND COMPONENTS 1 2 9 4 8 5 6 10 7 3 Item 3 Smart View Display...

Page 177: ...Smart View display then the Sevcon speed control must be reprogrammed before the display will function If you have the Smart View display and wish to have the maintenance feature turned on then the S...

Page 178: ...SECTION 5 PAGE 28 MB T48 01 CONTROL PANEL 1 2 4 5 6 7 3 8...

Page 179: ...10 amp 1 4 79 840 20 Circuit Breaker 20 amp 2 5 73 005 01 Alarm 1 6 73 004 20 Horn 1 7 79 844 20 Circuit Breaker 200 am p 1 8 62 400 11 Controller Heatsink 1 01 200 08 Control Pane l Not Shown 1 62 0...

Page 180: ...SECTION 5 PAGE 30 MB T48 01 1 2 4 6 8 ELECTRICAL COMPONENTS TYPICAL 10 3 5 9 7 11...

Page 181: ...tte ry H o l d D o w n R o d 3 8 5 0 2 5 0 0 0 Batte r y B a t L o k C l a m p 3 8 8 8 0 6 9 8 1 L o c k n u t 1 4 3 8 8 8 0 8 8 6 6 W a s h e r 5 1 6 X 1 5 O D T i n L e a d 3 9 8 8 0 8 1 1 2 B o l t...

Page 182: ...SECTION 5 PAGE 32 MB T48 01 CHARGERS CHARGERS DWG 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 Typical Built In charger Typical Portable charger...

Page 183: ...9 13 S O 79 575 10 79 831 00 79 730 00 79 730 00 79 566 10 76 200 00 22640 79 303 20 36LC40 8ET 150 60 16 36 40 Built In 79 852 00 79 805 67 79 902 00 79 749 10 S O 79 831 10 79 530 00 79 809 50 76 20...

Page 184: ...E 34 MB T48 01 NOTE The harness connectors are not included with the charger When replacing the charger order 2 each of the following PART DESCRIPTION 75 318 20 Butt splice 75 320 51 Knife connector S...

Page 185: ...arger ITEM PART DESCRIPTION QTY 79 309 40 48v Charger assembly see note on facing page 1 79 575 60 Replacement cover w AC cord and gasket 1 Note There are no user serviceable components inside the cha...

Page 186: ...SECTION 5 PAGE 36 MB T48 01 ACCELERATOR MODULE 1 8 2 3 4 5 6 7...

Page 187: ...2 0 A c c e l e r a t o r P e d a l 1 2 8 8 0 6 5 0 8 1 4 x 5 8 T r u s s H e a d S c r e w 2 3 8 8 0 6 9 8 1 1 4 L o c k N u t 2 4 8 8 0 6 0 0 9 1 4 x 3 4 H e x B o l t 2 5 6 2 0 3 3 4 8 A c c e l e...

Page 188: ...SECTION 5 PAGE 38 MB T48 01 DRIVE 1 2 3 4 5 6 7 8 7 10 21 24 27 26 25 29 15 1 4 23 18 9 2 0 22 1 9 1 3 11 1 2 1 3 17 29 1 6 15 2 8 3 1 9 30 2 9 3 2 3 0 3 3 3 5 37 37 3 8 3 9...

Page 189: ...Ring 1 6 GT 3287503 Shaft Eccentric for Idler Gear 1 7 GT 72005 Ball Bearing 2 8 GT 3287493 Gear Idler 1 9 GT 70302 Screw M10 X 30 1 10 GT 71715 Snap Ring 1 11 GT 3287553 Half Housing Motor Side 1 12...

Page 190: ...87293 Spacer S 4 30mm 1 GT 3287303 Spacer S 4 35mm 1 GT 3287313 Spacer S 4 40mm 1 GT 3287323 Spacer S 4 45mm 1 GT 3287333 Spacer S 4 50mm 1 GT 3287343 Spacer S 4 55mm 1 GT 3287353 Spacer S 4 60mm 1 GT...

Page 191: ...0 1000mm 1 27 GT 71068 TaperedRoller Bearing 1 28 GT 72022 Ball Bearing 1 29 GT 71978 TaperedRoller Bearing IncludesBearingRace 2 30 GT 70299 Washer 10mmID 18 31 GT 71881 Seal40 50X2 NotShown Location...

Page 192: ...SECTION 5 PAGE 42 MB T48 01 1 2 3 5 6 5 DRIVE ASSEMBLY FORWARD FORWARD 4 7 8 9 10 11 12 4 13 14 15 16 17 18 Left Side Suspension Overload Spring Bushing...

Page 193: ...e bearing see notes Page 45 1 41 290 67 Axle Tube Left double bearing see notes Page 45 1 11 96 114 00 U Bolt single axle bearing 4 12 16 861 44 Spring Axle Mount Bracket Left 1 13 16 861 45 Spring Ax...

Page 194: ...Axle Shaft Inner Bearing no o ring Outer Bearing O Ring O Ring Groove Inner bearing on optional double bearing axle does not have an oil seal or o ring Orientation of bearing should have o ring groov...

Page 195: ...gs used during the transition between the single bearing axles and the double bearing axles Use the following lists to determine what parts were used on vehicles manufacturedduringthistransition Model...

Page 196: ...SECTION 5 PAGE 46 MB T48 01 1 2 4 3 5 6 DECALS 7...

Page 197: ...t Decal 1 2 94 313 00 Battery Warning Decal 1 3 94 373 10 Vehicle Identification Decal 1 4 94 309 00 Brake Warning Decal 1 5 94 313 20 Safety Warning Decal 1 6 94 384 01 Not A Motor Vehicle Decal 1 7...

Page 198: ...SECTION 5 PAGE 48 MB T48 01 HITCH OPTIONS...

Page 199: ...ntle Type 1 15 97 808 00 Hitch Automatic Coupling 1 16 88 140 14 Bolt 1 2 NC Hex Head 4 17 88 148 62 Lock Washer 1 2 4 18 88 149 80 Nut 1 2 NC 4 19 97 805 00 Bracket Ball Hitch Mounting 1 7 8 1 19 97...

Page 200: ...SECTION 5 PAGE 50 MB T48 01...

Page 201: ...SECTION 5A Illustrated Parts List Taylor Truck...

Page 202: ...SECTION 5A PAGE 2 MB T48 01 STANDARD PARTS...

Page 203: ...ushion 2 10 88 837 09 Screw 14 Phillips Truss Head 12 11 02 210 25 Angle Wire Cover 1 12 91 513 00 S Clip 2 13 02 248 91 Light Guard 1 14 88 065 06 Screw 1 4 NC Phillips Truss Hd 6 15 88 069 81 Locknu...

Page 204: ...SECTION 5A PAGE 4 MB T48 01 OPTIONAL PARTS...

Page 205: ...sher 12V 1 4 72 082 10 Turn Signal Bulb 12V 2 5 72 082 20 Socket Turn Signal 2 STROBE LIGHT COMPONENTS 6 72 023 20 Strobe Light Amber 1 7 72 023 30 Pole Mount 1 8 88 025 06 Screw 8 32 X 1 2 Phillips H...

Page 206: ...SECTION 5A PAGE 6 MB T48 01 OPTIONAL PARTS...

Page 207: ...2 CAB 91 012 62 Kit Cab Orange 1 91 012 63 Kit Cab Specify Color 1 9 91 012 00 Cab unpainted 1 10 90 852 30 Windshield 1 11 98 310 00 Window Channel Rubber 20 ft 12 90 850 10 Rear Window 1 13 88 102 1...

Page 208: ...SECTION 5A PAGE 8 MB T48 01 OPTIONAL PARTS...

Page 209: ...L o c k n u t 1 4 N C 2 1 1 8 8 0 6 0 2 2 B o l t 1 4 N C X 3 4 H e x H e a d 1 1 2 8 8 0 6 8 6 1 W a s h e r 1 4 S A E 1 1 3 8 8 0 6 5 0 9 S c r e w 1 4 N C X 3 4 P h i l l i p s T r u s s H e a d 2...

Page 210: ...SECTION 5A PAGE 10 MB T48 01 TOP COVER OPTION PARTS...

Page 211: ...T o p W h i t e 1 F I B E R G L A S S T O P C O V E R 1 0 0 2 4 8 3 6 T u b u l a r T o p F r a m e 1 2 0 0 2 4 8 3 5 P o s t T o p F r a m e 4 3 8 8 1 0 2 1 1 B o l t 3 8 N C X 1 C a r r i a g e 3 2...

Page 212: ...SECTION 5A PAGE 12 MB T48 01 DOOR OPTIONS...

Page 213: ...u d e s 1 0 1 1 1 2 1 1 3 9 1 0 1 1 6 8 K i t C a b D o o r L e f t O r a n g e i n c l u d e s 1 0 1 1 1 2 1 9 1 0 1 1 6 7 K i t C a b D o o r R i g h t S p e c i f y C o l o r i n c l u d e s 1 0 1...

Page 214: ...SECTION 5A PAGE 14 MB T48 01 DECKBOARD OPTIONS...

Page 215: ...ack does not include 1 and 2 1 1 90 444 20 Deckboard 41 X 38 1 2 X 5 8 1 2 90 444 30 Deckboard 41 X 36 5 8 X 5 8 1 3 90 440 46 Deck Cover Diamond Plate Rear 1 4 90 440 47 Deck Cover Diamond Plate Fron...

Page 216: ...SECTION 5A PAGE 16 MB T48 01 BOX WITH DOORS OPTIONS...

Page 217: ...065 09 Screw 1 4NC X 3 4 Phillips Truss Head Not Shown 21 88 069 87 Nut 1 4 NC Keps Not Shown 21 94 320 10 Decal Load Line Cargo Box Not Shown 1 WATERING SYSTEM 48 VOLT NOT SHOWN 77 201 60 Kit Wateri...

Page 218: ...SECTION 5A PAGE 18 MB T48 01 STAKE SIDE OPTIONS...

Page 219: ...rew 1 4 NC X 1 1 4 Phillips Truss Head 4 4 88 069 87 Nut 1 4 NC Keps 4 5 90 542 05 Side Gate Left Black 1 6 90 542 06 Side Gate Right Black 1 7 90 544 20 Pocket Outer Weld on 8 8 90 544 21 Pocket Inne...

Page 220: ...SECTION 5A PAGE 20 MB T48 01...

Page 221: ...SECTION 5B Illustrated Parts List ET 3000...

Page 222: ...SECTION 5B PAGE 2 MB T48 01 1 2 7 8 3 4 5 5a 9 11 12 13 14 16 10 STANDARD PARTS 6 18 17 15...

Page 223: ...bulb 2 9 91 017 65 Front Bumper 1 88 103 09 Screw Socket Head 3 8 X 3 4 Front Bumper Hardware 2 88 109 81 Locknut 3 8 Front Bumper Hardware 2 10 72 005 21 Headlight Support 1 11 72 052 00 Turn Signal...

Page 224: ...SECTION 5B PAGE 4 MB T48 01 STANDARD PARTS 3 4 5 6 1 2 Door Latch 9 8 7...

Page 225: ...indow Door Right 3 Pieces 1 3 90 854 01 Latch Window Door 1 4 91 017 02 Strap Door Brackets Included 1 5 91 017 31 Handle Inside Door Left 1 6 91 017 32 Handle Inside Door Right 1 7 72 015 10 Light Do...

Page 226: ...SECTION 5B PAGE 6 MB T48 01 CAB INTERIOR STANDARD PARTS 1 2 3 4 5 6 7 10 8 9 11 12 13 15 16 14 14...

Page 227: ...Cover 1 90 199 10 Seat Belts Black Set 1 90 175 06 Seat Cushions Black 2 90 140 00 Seat Back Cushion Black 1 88 837 09 Screws 14 X 3 4 Phillips Head Sheet Metal 8 DASH COMPONENTS 10 71 102 06 Boot Sw...

Page 228: ...SECTION 5B PAGE 8 MB T48 01 STANDARD PARTS 1 2 10 11 19 27 26 23 24 25 9 20 18 17 16 7 15 21 22 12 13 14 15 5 6 3 4 7...

Page 229: ...de Panel 2 17 Header Rear Right 1 18 Latch 4 19 89 080 16 Bolt 8mm X 16 1 2 2 0 H i n g e A l u m i n u m 6 2 1 A l u m i n u m T H i n g e 6 22 P l a t e T h r e a d e d 8 m m 6 23 88 081 11 B o l t...

Page 230: ...SECTION 5B PAGE 10 MB T48 01 BOX WITH DOORS OPTIONS...

Page 231: ...rd Rear 43 3 4 X 19 1 5 90 444 79 Deck Plate Diamond 43 3 4 X 19 1 6 88 607 09 Rivet 1 4 X 1 2 Starpin Not Shown 24 7 90 850 10 Window 13 7 8 X 31 7 8 1 8 98 310 00 Window Channel Rubber 19 9 90 851 0...

Page 232: ...SECTION 5B PAGE 12 MB T48 01...

Page 233: ...APPENDIX A Special Tools...

Page 234: ...s completed 96 500 43 Sevcon Handset Analyzer read only Used to test the Sevcon control systems and reset the Smart View display includes instructions 62 027 61 Sevcon Handset Analyzer with Speed Adju...

Page 235: ...APPENDIX B...

Page 236: ...110 9 16 12 5 6 8 4 8 7 1 3 1 1 2 3 1 8 4 1 4 0 9 16 18 6 3 9 4 9 7 1 4 6 1 3 7 2 0 6 1 6 0 5 8 11 7 8 117 1 2 0 1 8 0 1 7 0 2 5 4 1 9 5 5 8 18 8 8 1 3 2 1 3 6 2 0 4 1 9 2 2 8 8 2 2 5 3 4 10 1 3 8 2...

Page 237: ...PENDIX B PAGE 3 MB T48 01 L 9 Head Markings S A E Grade 2 S A E Grade 5 S A E Grade 8 L 9 Truss Head 1 4 20 Carriage Bolt 5 16 18 3 8 16 The following bolts are in accordance with Grade 2 torque value...

Page 238: ...B2 48 With Stake Side Dump Bed Option SC1 00 Stock Chaser E4 55 Sit Down Tow Tractor C4 25 Sit Down Tow Tractor...

Page 239: ......

Page 240: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Mailing Address P O Box 4240 Anaheim California 92803 Visit our Website www taylor dunn com...

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