Taylor-Dunn ET 3000 Manual Download Page 97

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TABLE OF CONTENTS

GT Transmission Assembly

With Disc Brakes

Transmission

Check Oil Level ................................................2

Change Oil ........................................................3

Motor Removal and Installation .....................4

Rear Hub or Rotor ...........................................5

Removing and Installing the Rear Axles

(Disc Brakes) .............................................6

Transmission Assembly .................................8

Remove and Install ..................................................8

Disassembly and Reassembly of the Primary

Reduction Gear Case ................................9

Disassembling the 3rd Member .....................12

Assembling the 3rd Member ..........................15

Pinion Bearing Preload ............................................18

Pinion Gear Shimming Instructions ..............19

Setting the Pinion Gear Depth ................................19

Hardware Torque .............................................20

Summary of Contents for ET 3000

Page 1: ...ial Number See Introduction Chapter MANUAL MB T48 02 Operation Troubleshooting and Replacement Parts Manual Models Inlcuded B0 T48 48AC T 48 48 volt system B0 T48 72AC T 48 72 volt system ET 030 48AC...

Page 2: ......

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

Page 4: ...e Support keeps our customers moving Tiger Tractor Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment With tractor capacities...

Page 5: ...ansmission Suspension Tires and Wheels Battery Wire diagram Motor Controller Chargers Illustrated Parts Appendix Operator and Service Manual Section Index This quick reference section index guide will...

Page 6: ...Notes...

Page 7: ...tion Table of Contents Introduction About this manual 2 Who Should Read This Manual 3 Responsibilities 3 How To Use This Manual 4 Conventions 5 How to Identify Your Vehicle 6 Taking Delivery of Your V...

Page 8: ...ng guide Taylor Dunn has made every effort to include as much information as possible about the operation and maintenance of this vehicle Included in this manual are Vehicle Description Safety Rules a...

Page 9: ...eration of the vehicle preoperational and operational checks on the vehicle and the reporting of any problems to service and repair personnel Of the Service Personnel The service personnel are respons...

Page 10: ...at are to be performed on this vehicle It also includes various subjects that should be included in the operator and service training program Maintenance Service and Repair This section gives specific...

Page 11: ...ise extreme care while performing the task or The symbol at the left and the bold text contained within a box denotes a Caution and is used to inform the reader that property damage may occur Be sure...

Page 12: ...s to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and B...

Page 13: ...ge as a result of shipping note the damage or problem on the bill of lading and file a claim with the freight carrier The claim must be filed within 48 hours of receiving the vehicle and its accessori...

Page 14: ...Notes...

Page 15: ...tarting 10 While driving 10 Loading and Unloading 11 Parking 11 Towing 11 Adjustable Controller Parameters 12 Charging your vehicle 16 New Battery Break in 16 Charging Time 16 Industrial Charger Opera...

Page 16: ...tch Headlight Switch Emergency Stop Switch Light Accessories Dual Headlight Dual Tail Brake Lights Charger 48 volt 120 240 VAC 13 6 5 Amp 50 or 60 Hz 17 Amp DC 72 volt 220 VAC 13 Amp 60 Hz 25 Amp DC O...

Page 17: ...ow all of the guidelines listed below Failure to follow these guidelines may result in severe bodily injury and or property damage WARNING Before working on a vehicle 1 Make sure the key switch is in...

Page 18: ...l All safety rules contained within this manual Proper operation of all vehicle controls A vehicle operation and driving test Driver Qualifications Only those who have successfully completed the Opera...

Page 19: ...rument panel determines the direction of travel of the vehicle Push the top of the switch to engage the forward direction Push the bottom of the switch to engage the reverse direction DO NOT SWITCH fr...

Page 20: ...off reverse switch should be in the center OFF position with the key switch off and the park brake set whenever the operator leaves the vehicle 5 Hi Low Switch optional The high low switch is located...

Page 21: ...he vehicles current rate of travel in miles per hour Hour Meter Displays total time whole hours vehicle has been in operation Time is accumulated only while the vehicle is moving The example to the ri...

Page 22: ...l releases the braking action Steering The steering wheel and steering system are similar to an automobile To turn right turn the steering wheel clockwise To turn left turn the steering wheel counter...

Page 23: ...ver must be seated for the vehicle to operate Whenever the driver leaves the vehicle the driver should turn the key switch off place the forward off reverse switch in the center OFF position and set t...

Page 24: ...speeds Observe all traffic regulations and speed limits Keep all body parts head arms legs inside this vehicle while it is moving Keep the vehicle under control at all times Yield right of way to ped...

Page 25: ...tically applied when the vehicle is stopped There is a parking brake bypass switch located on the right side of the control box see illustration Place this switch in the UP position to tow the vehicle...

Page 26: ...ime to accelerate to full speed RevAc LS 5 2 S Time to accelerate to from Fw dAC LS to full RevAc HS 5 2 S Time to accelerate to full speed Acceleration Parameters low speed mode FwdAS LS 2 6 S Time t...

Page 27: ...ischarge rate Miscellaneous SRO Min Speed 1 500 RPM Motor must be below this RPM to change directions with the throttle pedal depressed 48 volt equipped with 24 1 drive ratio Acceleration Parameters n...

Page 28: ...discharge rate Miscellaneous SRO Min Speed 1 500 RPM Motor must be below this RPM to change directions with the throttle pedal depressed 48 volt equipped with 30 1 drive ratio Acceleration Parameters...

Page 29: ...full speed Tow Decl LS 11 0 S Time to decelerate when below 20 of full speed Maintenance Meter Function Service Timer 0 H Refer to Maintenance Meter supple mentary manual Speed Limits Max see warning...

Page 30: ...The time required to fully charge your batteries will vary depending on Capacity of the batteries higher capacity requires longer charge time Output of the charger higher output requires less charge...

Page 31: ...he charging cycle Refer troubleshooting to a qualified technician Typical Lestronic II Built In Charger Signet Charger Operation Model HBS series The Signet HBS series chargers are fully automatic The...

Page 32: ...the procedure will be displayed by the two LED s Refer to the table below for the fault codes Note To run this procedure a battery that is not severely discharged must be connected to the charger Fau...

Page 33: ...charging is not recommended For maximum battery life it is recommended that the batteries be discharged a minimum of 30 7 bars showing on the BSI before starting a charging cycle This charger requires...

Page 34: ...Refer to Section Maintenance Service and Repair for battery maintenance information Do not interrupt the charging cycle When the charger is plugged in allow it to turn off before disconnecting Interru...

Page 35: ...g linkages and hardware Tighten steering shaft to steering gear coupler if equipped Lubricate the vehicle Wash batteries and clean terminals Inspect for fluid leaks Check all electrical interlocks for...

Page 36: ...spected monthly for signs of damage The damage must be repaired immediately The following list is meant as a guide and is not all inclusive of a severe duty application Extreme temperature Bumpy dusty...

Page 37: ...TABLE OF CONTENTS General Maintenance General Maintenance Maintenance Guidelines 2 Troubleshooting Guide 3 Lubrication Chart 4...

Page 38: ...ts Do not use an open flame to check level or leakage of battery electrolyte Do not use open pans of fuel or flammable fluids for cleaning parts Only properly trained and authorized technicians should...

Page 39: ...ontrol System Fault Speed Control System Overheated High Low Speed Switch in Low or wiring to the Switch is Faulty Low Speed Cutback Due to Maintenance Meter Trip optional Abnormal Noise Worn Drive Ge...

Page 40: ...al Purpose Grease 3 Front Wheel Bearings 2 High Temperature Wheel Bearing Grease 4 King Pin 2 General Purpose Grease 7 Drive Drain Plug 1 8 Drive Level Plug 1 9 Drive Fill Plug 1 SAE 80W90 Gear Oil 10...

Page 41: ...ct the Front Wheel Bearings and King Pin 2 Adjust Front Wheel Bearings 3 Front Axle Removal and Installation 4 Removal 4 Installation 5 Front Axle Disassembly 6 Replace Front Wheel Bearings 7 Replace...

Page 42: ...ding noise Any grinding noise may be an indication of worn or damaged wheel bearings Note Refer to the Replace Front Wheel Bearings section for information regarding the replacement of the wheel beari...

Page 43: ...Cap Removed ADJUST FRONT WHEEL BEARINGS 6 Raise the front of the vehicle and support with jack stands 7 Remove the hub dust cap and cotter pin 8 While rotating the hub tighten the spindle nut to 30 f...

Page 44: ...hicle and support with jack stands 7 Remove both front wheels Refer to Tires and Wheels section for information regarding removing the front wheels 8 Tie up or support the front axle so it can not fal...

Page 45: ...ise the front of the vehicle and support with jack stands 7 Install the front axle in reverse order of removal Note Use all new cotter pins Note Refer to the Replacing the Ball Joints section for info...

Page 46: ...king pin bushings Refer to the following sections for information regarding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings Note The front axle does not have to be rem...

Page 47: ...sembly from the hub Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 8 Remove the hub dust cap cotter pin and spindle nut 9 Remove the hub from the steerin...

Page 48: ...the tire wheel assembly Note Refer to the Brakes section for information regarding the installation of the brake body 15 Lower the vehicle 16 Reconnect the main positive and negative cables at the bat...

Page 49: ...apacity may result in severe bodily injury Failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and or...

Page 50: ...to 1 25 0 001 10 Inspect the king pin for damage or wear If any damage or wear is noted then the king pin must be replaced 11 Reassemble in reverse order Note Refer to Replace the Steering Knuckle for...

Page 51: ...the Brakes section for information regarding the removal of the brake body Do not remove the hydraulic brake line from the brake body If the brake line is removed then it will be necessary to bleed th...

Page 52: ...removed and the yoke rotates freely The rubber washer must compress slightly to create a seal for the grease Note Refer to Replace Front Wheel Bearings for information regarding proper tightening of t...

Page 53: ...Replace the Steering Shaft 10 Replace the Steering Wheel 12 Replace the Steering Gear 13 Replace the Ball Joints Tie Rods and Drag Link 14 Replacing the Drag Link 16 Replacing the Tie Rod 17 Center th...

Page 54: ...f the wheels so that they cannot turn from the straight ahead position 8 Disconnect the drag link from the pitman arm Note Refer to Replace the Ball Joints section for information regarding removing t...

Page 55: ...Torque Table at the end of this section or the rod end jam nuts on the drag link 16 Untie the steering wheel and the front wheels 17 Reconnect the main positive and negative cables at the batteries 1...

Page 56: ...wheel or front wheels tied in the position may cause loss of control of the vehicle resulting in severe bodily injury and or property damage Front wheel alignment Note It is recommended to center the...

Page 57: ...of the tires 12 Measure the distance between the lines at the rear of the tires 13 Adjust the tie rod so that the distance at the front and rear of the tires is the same 14 If equipped with ball joint...

Page 58: ...le resulting in severe bodily injury and or property damage Typical Ball Joint INSPECT BALL JOINTS Note A set of ball joints and or rod ends will wear at the same rate If a ball joint and or rod end i...

Page 59: ...he blocks from behind the wheels 10 Release the parking brake and test drive the vehicle 1 Make sure the key switch is in the OFF position then remove the key 2 Place the forward reverse switch in the...

Page 60: ...for information regarding removing the steering gear 6 Raise the front of the vehicle and support with jack stands 7 Disconnect the drag link from the pitman arm Note Refer to Replace the Ball Joints...

Page 61: ...here is a slight drag as the steering gear is rotated through its centered position 14 While holding the gear lash adjusting screw so that it cannot turn tighten the gear lash adjusting screw jam nut...

Page 62: ...nals off of the wires 7 Remove the steering wheel Note Refer to Replace the Steering Wheel section for information regarding removing the steering wheel 8 Remove the upper steering shaft bushing or be...

Page 63: ...to property damage and or severe bodily injury 11 Remove the steering shaft from the vehicle 12 Lightly grease the input shaft splines steering wheel splines and the upper steering shaft bushing 13 I...

Page 64: ...tch and disconnect the wires from the switch 7 Remove the steering wheel nut 8 Using a steering wheel puller remove the steering wheel 9 Position the front wheels in the straight ahead position 10 Lig...

Page 65: ...the Steering Shaft section for information regarding removing the steering shaft 8 Remove the pitman arm using a pickle fork Note On some vehicle configurations it may be required to remove the drag...

Page 66: ...t Replacing a Rod End 6 Raise the front of the vehicle and support with jack stands 7 Loosen the rod end jam nut or clamp on the steering sleeve 8 Remove the rod end nut 9 Remove the rod end from the...

Page 67: ...steering sleeve 8 Remove the cotter pin and ball joint nut 9 Using a pickle fork remove the ball joint from the steering arm 10 Remove the ball joint from the steering sleeve Hint Count the number of...

Page 68: ...ll joints or rod ends from the steering knuckle and pitman arm Note Refer to the Replacing the Ball Joints section for information regarding the removal of the ball joints or rod ends 8 Remove the dra...

Page 69: ...er 10 Realign the front wheels Note Refer to the Steering section for information regarding realignment of the front wheels 11 Lower the vehicle 12 Reconnect the main positive and negative cables at t...

Page 70: ...ate capacity to lift and support the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury PITMAN SHAFT ALIGNMENT 6 Raise the front of the vehicl...

Page 71: ...r to the 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...

Page 72: ...Remove 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 reassem...

Page 73: ...worm bearing 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...

Page 74: ...f Steering Gear HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Ball Joint 40 45 Rod End Nut 20 25 Ball Joint Clamps 28 32 Pinch...

Page 75: ...c Parking brake 4 Adjust the Service Brakes 4 Check Master Cylinder Fluid 5 Bleed the Brake System 6 Flush the Brake System 8 Replace Front Disc Brake Pads 9 Replace Rear Brake Pads 11 Hydraulic Disc...

Page 76: ...d If the brake pad lining is 1 16 inch or less then the brake pad must be replaced It is recommended to replace the left and right side brake pads as a set Current Taylor Dunn brakes are asbestos free...

Page 77: ...its service limits then the front hub must be replaced Refer to FrontAxle Service for information on replacing the front hub Note Depending on the rear axle configuration the rear brake rotor may be a...

Page 78: ...lack of braking power the entire brake system should be inspected INSPECT THE AUTOMATIC PARKING BRAKE The parking brake is located inside of the motor and is electromagnetically operated To inspect op...

Page 79: ...hield when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Imm...

Page 80: ...d when working with or around brake fluid SKIN CONTACT Flush area immediately with water for several minutes If a rash or skin irritation develops get medical attention immediately EYE CONTACT Immedia...

Page 81: ...e brake lines during the bleeding process then you will have to start again from the beginning 14 Repeat the above steps until you are sure that all of the air is expelled from the brake line Any air...

Page 82: ...egarding removing the wheels 10 Remove the wheel cylinders from each axle Refer to Replace the Wheel Cylinder section for information regarding removing the wheel cylinder 11 Attach a clear hose to th...

Page 83: ...ity exists all brake parts should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions Note Installing new brake pads will raise the brake fluid level in the...

Page 84: ...hings in the mounting bracket 15 Install new brake pads in reverse order Torque the mounting bolts to the specified amount listed in the Hardware Torque Table at the end of this section 16 Repeat this...

Page 85: ...s should be handled as if they contain asbestos Refer to appendix C for recommended handling precautions Always use a lifting strap hoist and jack stands of adequate capacity to lift and support the v...

Page 86: ...nd 15 Install new spacer bushings in the mounting bracket 16 Back off the parking brake adjustment wheel park brake only 17 Install new brake pads in reverse order Torque the mounting bolts to the spe...

Page 87: ...r rear Current Taylor Dunn brakes are asbestos free However there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos Since this possibility exists all...

Page 88: ...2 Disconnect the brake hose from the brake body 13 Install the new brake body assembly in reverse order Use teflon tape thread sealant on the brake hose fitting Torque the brake body bolts to the spec...

Page 89: ...as raised lower it to the ground 15 Bleed the brakes refer to Bleed the Brakes section for information regarding bleeding the brakes 16 Reconnect the main positive and negative cables at the batteries...

Page 90: ...aced Lubricate all parts with clean brake fluid from a sealed container Reassemble in reverse order If the master cylinder is not to be immediately installed onto a vehicle plug the brake line fitting...

Page 91: ...NTENTS Motor Motor Motor Identification 2 Inspection 2 Thermal Sensor 2 Motor Brake 3 Bearing and Sensor 4 Disassemble 4 Reassemble 5 Motor Connector 5 Motor Service Limits and Specifications 6 Hardwa...

Page 92: ...OFF position 3 Set the park brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the battery connector from the vehicle MOTOR IDENTIFICATION Shown below is a typical m...

Page 93: ...ct a 48 volt 2 Amp variable power supply to the brake coil Set the voltage to 10 volts and measure the current The current should be equal to the Voltage divided by the coil resistance Example If the...

Page 94: ...bly bolts Fig 3 holding the end housing to the field housing and while carefully pushing the cables through the opening remove the end housing armature assembly from the field housing Bearing and Sens...

Page 95: ...ned with the marks made during disassembly 5 Install the friction plate assembly with extended hub facing out 6 Place the electric brake spacers onto the motor assembly 7 Install the electric brake as...

Page 96: ...inal Studs 7 14 10 MOTOR SERVICE LIMITS AND SPECIFICATIONS Phase Winding resistance 0 3 Ohms all phases nominal Thermal sensor resistance 581 Ohms 20 degrees C Brake Coil Resistance 20 Ohms 20 degrees...

Page 97: ...Hub or Rotor 5 Removing and Installing the Rear Axles Disc Brakes 6 Transmission Assembly 8 Remove and Install 8 Disassembly and Reassembly of the Primary Reduction Gear Case 9 Disassembling the 3rd...

Page 98: ...the vehicle Failure to use lifting and support devices of rated load capacity may result in severe bodily injury 6 Place a level on top of the motor Raise the rear of the vehicle until the level indi...

Page 99: ...the level plug opening Refer to the Lube Chart section for information regarding type of oil 11 Replace the fill plug 12 Reconnect the main positive and negative cables at the batteries 13 Remove the...

Page 100: ...d operated park brake set the brake 4 Place blocks under the front wheels to prevent vehicle movement 5 Disconnect the main positive and negative cables at the batteries 6 Remove the wires from the mo...

Page 101: ...tion regarding removing the tire wheel assembly 8 Remove the axle hub bolt and washer and remove the hub from the axle 9 Remove the outer brake pad Refer to section Brake Service for information regar...

Page 102: ...atteries 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 load capacity may result in severe bo...

Page 103: ...only If removed they must be replaced Reusing the original bolts could cause loss of brakes resulting in severe bodily injury and or property damage Refer to section Rear Brakes in Illustrated Parts f...

Page 104: ...es from the spring axle mounting brackets and brake arms 7 Disconnect the wiring from the motor 8 Disconnect the hydraulic brake lines from the left and right brake bodies 12 Reinstall the drive in re...

Page 105: ...ries 6 Raise the rear of the vehicle and support with jack stands 7 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case 8 If...

Page 106: ...output gear from the pinion shaft Note If necessary remove the seal from the input shaft bore at this time 15 Mark the gear case position in relation to the 3rd member housing so that it will be reas...

Page 107: ...in the Hardware Torque Table at the end of this section Note Apply gasket sealer 94 430 05 to the front flange on the 3rd member and gear case cover Note Pack the motor seal with non acetic based gre...

Page 108: ...on removing the drive from the vehicle 8 Place a drain pan under the gear case that is capable of holding four quarts of oil and drain the oil from the front gear case and 3rd member 9 Place the 3rd m...

Page 109: ...usting nut from the side plate 14 Turn the side plate over and remove the carrier bearing race from the side plate 15 Remove the differential assembly from the 3rd member housing 16 Remove the carrier...

Page 110: ...nt bearing from 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 pinion shaft from the 3rd member 21...

Page 111: ...the ring gear is not in binding against the pinion gear 6 Remove the differential assembly Note Do not allow the ring nut to rotate 7 Remove the pinion gear and then reinstall the differential assembl...

Page 112: ...to Pinion Gear Shimming Instructions 15 Check the gear lash between the ring and pinion gears The gear lash should be 0 005 to 0 007 inches 16 Adjust the gear lash if needed by tightening or loosenin...

Page 113: ...ar case axles and housings motor and install the complete drive onto the vehicle 20 Fill the drive with oil Refer to the Lube Chart section for information regarding type of oil Refer to Change Oil se...

Page 114: ...onto the pinion shaft and torque the pinion nut to the specified amount listed in the Hardware Torque Table at the end of this section 4 Measure the torque required to rotate the pinion shaft in the...

Page 115: ...mm where 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 see below B 54 C The number on the edg...

Page 116: ...C D HARDWARE TORQUE If hardware is not listed here refer to standard torque values in the appendix Description Foot Pounds Newton Meters Pinion nut 154 169 209 229 Drain plug 21 25 28 4 33 Gear case...

Page 117: ...TABLE OF CONTENTS Suspension Suspension Replace the Rear Springs 2 Replace the Front Springs 3 Replace the Spring Bushings 4 Replace the Shocks 6 Hardware Torque 6...

Page 118: ...as a set Hint In most vehicles it will be easier if the springs are replaced one at a time 6 Raise the rear of the vehicle and support with jack stands 7 Tie up or support the rear axle so it cannot f...

Page 119: ...t a time 6 Raise the front of the vehicle and support with jack stands 7 Tie up or support the front axle so it cannot fall out of the vehicle 8 Unbolt the spring from the front axle beam 9 Support th...

Page 120: ...e Refer to Replace the Front Springs section for information regarding removing the front springs 8 If the vehicle is equipped with spring hangers remove the spring hanger bolt from the vehicles frame...

Page 121: ...ing eye 11 Install the spring onto the vehicle Note Refer to Replace the Front Springs section for information regarding installing the front springs 12 Repeat for the other spring 13 Lower the vehicl...

Page 122: ...shings If any signs of damage or wear are seen then the shock must be replaced 9 Install the shock in reverse order 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batte...

Page 123: ...TABLE OF CONTENTS Tires and Wheels Tires and Wheels Tire Inflation 2 Tire Inspection 2 Replace the Tire Wheel 3 Repair the Tire pneumatic 4 Replace the Tire pneumatic 5...

Page 124: ...ns available with varying tire pressures Refer to the side wall of your tire for information regarding the tire pressure for your tires The illustration to the right is an example of the side wall inf...

Page 125: ...11 Inspect the tread and side walls for debris in the rubber that could lead to a puncture If any debris is found it should be removed and the tire inspected for a leak 1 Make sure the key switch is...

Page 126: ...eel coming off of the vehicle causing severe bodily injury and or property damage REPAIR THE TIRE PNEUMATIC Note To properly repair a puncture the tire must be removed from the wheel Refer to Replace...

Page 127: ...lacement should only be performed by personnel trained in tire replacement The tire replacement procedure will be unique to the type of replacement equipment being used Refer to the instructions provi...

Page 128: ...Notes...

Page 129: ...ays provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage A battery is a live electrical source It cannot be d...

Page 130: ...nd safety glasses while servicing batteries DO NOT INGEST This may result in severe bodily injury Battery electrolyte will stain and corrode most surfaces Immediately and thoroughly clean any surface...

Page 131: ...e right A discharged cell will read 1100 Ideally all cells in a battery will have the same reading Any cells in a battery that vary by more than 30 points may be an indication of a bad cell Clean the...

Page 132: ...while servicing batteries DO NOT INGEST This may result in severe bodily injury 1 Make sure the start switch is in the OFF position then remove the key 2 Place the forward reverse switch in the center...

Page 133: ...ion are present Always provide ample ventilation in rooms where batteries are being charged Failure to do so may result in severe bodily injury and or property damage A battery is a live electrical so...

Page 134: ...hin battery cells at all times Do not work with or charge battery in an area where open flames including gas furnace or water heater pilots sparks cigarettes or any other sources of combustion are pre...

Page 135: ...from the vehicle Roll Out Battery Box ROBB with battery Dolly Remove 6 Disconnect the battery cable from the ROBB 7 Position the ROBB dolly as close as possible to the vehicle aligned with the batter...

Page 136: ...Battery Page 8 MB T48 02 T 48 AC ET 3000 Notes...

Page 137: ...Brown Hot Green Yellow Ground Charger AC power source is High Voltage Only personnel qualified for work high voltage AC power lines should repair the charger AC power cord Improper repair or incorrec...

Page 138: ...Notes...

Page 139: ...starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter TABLE OF CONTENTS Motor Controller Motor Controller Remove Install 2 Remove 2 Install 2 Ins...

Page 140: ...9 Disconnect the logic connector 10 Remove the four bolts holding the controller to the panel and remove the controller Note If a heat sink is installed then these bolts may also hold the heat sink t...

Page 141: ...ations to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the 1314 application and cable Refer to the Tool...

Page 142: ...Motor Controller Page 4 MB T48 02 T 48 AC ET 3000 Notes...

Page 143: ...gers Chargers Remove Install 2 Troubleshooting 2 This section is one section of a complete service manual Before starting any procedure read all warnings and instructions that are located in the Servi...

Page 144: ...ure TROUBLESHOOTING Troubleshooting control system is not included in this manual All electrical troubleshooting information is included in a separate manual Troubleshooting Electric Vehicles The manu...

Page 145: ...rger Wiring Portable 25 Decals 26 Covers 27 Door Options 28 Electrical Lighting 32 Electrical Miscellaneous 34 Frame Components 36 Hitches 39 Instrument Panel 40 Mirrors 43 Motor 44 Motor Mount 46 Sea...

Page 146: ...Illustrated Parts Page 2 MB T48 02 T 48 AC ET 3000 Axles Front Axle Item No Part No Description Qty 15 210 70 Axle Beam B 2 48 BT 2 48 B 2 54 1 15 049 15 Complete axle assembly 1...

Page 147: ...Qty 1 41 154 15 Axle shaft 2 2 80 505 20 Bearing outer 2 2a 80 505 30 Bearing inner 2 3 41 490 11 Disc brake rotor 2 4 41 172 21 Hub 2 5 88 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5...

Page 148: ...Illustrated Parts Page 4 MB T48 02 T 48 AC ET 3000 Batteries...

Page 149: ...H Gell Note requires special charger 3 50 243 10 Battery rod 4 50 250 00 Battery hold down 5 88 088 66 Flat washer tin lead plated 6 88 069 81 1 4NC Nylon lock nut 7 88 081 12 5 16NC x 1 Square bolt s...

Page 150: ...ke Identification This is an example of a Short bushing This is an example of a Long bushing Left and right brake assemblies must be the same Mismatched brake assemblies can cause uneven brake ware an...

Page 151: ...01 Bleeder adaptor 2 3 4 5 41 348 70 Brake pad 4 6 41 351 30 Brake body assembly includes 3 4 5 8 9 10 2 7 32 240 41 Bushing 4 8 41 348 57 Spacer 4 9 88 067 21 Bolt 4 88 069 82 Nut 4 10 97 126 05 Fla...

Page 152: ...Illustrated Parts Page 8 MB T48 02 T 48 AC ET 3000 Front Brake...

Page 153: ...0 91 Plate Secondary Hydraulic Disc 2 3 41 348 70 Pad Disc Brake 4 4 41 348 57 Spacer Disc Brake 4 5 32 240 41 Bearing TeflonR Coated 4 6 99 588 00 Bleeder screw 2 7 99 588 01 Bleeder screw adapter 2...

Page 154: ...nting Bracket rear brake only 2 5 41 350 91 Secondary Plate 2 6a 88 067 29 Bolt 4 6b 88 069 82 Nut 4 7 See rebuild kit Brake pad Outer 2 8 See rebuild kit Brake pad Inner 2 9 41 351 16 Piston 2 10 99...

Page 155: ...Bushing included in rebuild kit 4 5 Brake body assembly no internally serviceable parts 2 6 99 588 01 Bleeder adaptor 2 7 99 588 00 Bleeder valve 2 8 See rebuild kit Brake pad Inner 2 9 See rebuild ki...

Page 156: ...Illustrated Parts Page 12 MB T48 02 T 48 AC ET 3000 Brake Lines...

Page 157: ...Cylinder includes cap and seal 1 99 511 52 Cap Seal Master Cylinder 1 99 511 53 Cap Master Cylinder 1 15 99 605 77 BRK LINE FORMED FRONT MCYL 1 16 99 603 73 BRAKE LINE FRONT FORMED CENTER 1 17 71 110...

Page 158: ...Illustrated Parts Page 14 MB T48 02 T 48 AC ET 3000 3 4 5 6 1 2 Door Latch 9 8 7 Cab Components ET 3000...

Page 159: ...1 2 90 854 20 Window 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...

Page 160: ...Illustrated Parts Page 16 MB T48 02 T 48 AC ET 3000 Cab Options Steel Cab T 48 Fiberglass cab T 48 Cab ET 3000...

Page 161: ...94 035 01 Plastic door trim by the foot 02 248 88 Bumper 1 Windshield Wiper T 48 Item No Part No Description Qty 74 050 00 Wiper motor 1 74 051 00 Wiper arm 1 74 052 00 Wiper blade 1 75 152 09 Harness...

Page 162: ...Illustrated Parts Page 18 MB T48 02 T 48 AC ET 3000 Cargo Box Rear...

Page 163: ...x Item No Part No Description Qty 1 91 333 02 Cargo box unpainted 1 2 90 471 00 Front deck board 1 3 90 472 00 Rear deck board 1 4 90 850 10 Front window 1 5 98 310 00 Rubber window gasket by the foot...

Page 164: ...Illustrated Parts Page 20 MB T48 02 T 48 AC ET 3000 Chargers Lestronic Charger Page 1...

Page 165: ...0 79 749 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 79 808 00 79 902 00 79 749 10 S O 79 831 10 79 530 0...

Page 166: ...Illustrated Parts Page 22 MB T48 02 T 48 AC ET 3000 Lestronic Charger Page 2...

Page 167: ...79 749 13 S O 79 575 10 79 831 10 79 531 00 79 530 00 S O 76 200 00 13110 79 301 10 24LC25 8ET 115 60 9 24 25 Portable 79 851 10 79 805 64 79 808 10 79 902 00 S O S O S O 79 831 00 79 532 00 79 530 00...

Page 168: ...assembly see note Not available at time of printing Note There are no user serviceable components inside the charger Note The charger AC cord is an intergral part of the charger When replacing the cha...

Page 169: ...stic 79 575 41 AC cord includes bushing 79 566 21 DC cord includes bushing 79 809 50 Interlock relay 79 722 03 Wiring kit includes LED s 79 575 06 AC Cord 0 or 1 AC cord has integral NEMA plug Portabl...

Page 170: ...Illustrated Parts Page 26 MB T48 02 T 48 AC ET 3000 Decals...

Page 171: ...ecals Item No Part No Description Qty 1 94 301 41 Brake fluid 1 2 94 384 24 Emergency stop 1 3 94 301 42 Arms and legs 1 4 94 384 21 Brake warning 1 5 94 384 01 Not a motor vehicle 1 6 94 384 14 When...

Page 172: ...Illustrated Parts Page 28 MB T48 02 T 48 AC ET 3000 Door Options...

Page 173: ...Qty 14 90 853 10 Window Left 1 15 97 315 58 Door Handle Inner 2 16 91 012 12 Connecting Bar 2 17 16 510 00 Spacer 2 18 88 065 06 Screw 1 4 X 1 2 NC Phillips Truss Head 2 19 88 045 08 Screw 10 32 X 5 8...

Page 174: ...Weather seal tape by the foot 2 90 909 97 Side Curtain Left 1 90 909 96 Side Curtain Right 1 3 97 315 59 Handle Assembly Outer 2 4 97 315 51 Door Latch 2 5 97 315 54 Handle Assembly Inside 2 6 97 304...

Page 175: ...Illustrated Parts Page 31 MB T48 02 T 48 AC ET 3000...

Page 176: ...Illustrated Parts Page 32 MB T48 02 T 48 AC ET 3000 Electrical Lighting Stobe Light T 48 cowl or steel cab ET 3000 T 48 fiberglass cab...

Page 177: ...l cab 1 94 201 11 Retainer nameplate 48 cowl or steel cab 2 4 72 025 00 Tail light 2 72 025 51 Tail light rubber grommet 2 72 022 52 Tail light pigtail 2 Not Shown 72 025 03 Headlight assembly T 48 fi...

Page 178: ...Illustrated Parts Page 34 MB T48 02 T 48 AC ET 3000 Electrical Miscellaneous 1 2 Motion Alarms Miscellaneous Wire Harness Clamps 2 3 17 16 15 18 4...

Page 179: ...640 00 Clamp 3 16 Push Mount 16 96 631 10 shown Clamp Rubber Lined 1 0 ID 96 629 80 not shown Clamp Rubber Lined 3 16 ID 96 630 00 not shown Clamp Rubber Lined 5 8 ID 96 630 50 not shown Clamp Rubber...

Page 180: ...Illustrated Parts Page 36 MB T48 02 T 48 AC ET 3000 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 Frame Components ET 3000...

Page 181: ...5 Cap 1 1 8 X 1 3 4 4 16 Post Left Side Panel 2 17 Header Rear Right 1 18 Latch 4 19 89 080 16 Bolt 8mm X 16 12 20 Hinge Aluminum 6 21 Aluminum T Hinge 6 22 Plate Threaded 8mm 6 23 88 081 11 Bolt 5 16...

Page 182: ...5 Charger cord Lester charger only 1 4 30 807 00 COVER STEERING GEAR SUPT 1 01 110 20 Throttle pedal 1 98 200 00 Rubber brake pedal pad 1 02 210 25 Angle harness cover cowl 1 91 513 00 Clip for 02 210...

Page 183: ...MB T48 02 T 48 AC ET 3000 Hitches Trailer Hitches Item No Part No Description Qty 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 4 88 149 80 1 2NC Hex nut 4 88 148 6...

Page 184: ...t switch 1 3b High Low speed switch 1 4 74 010 20 Gauge Spy Glass 1 5 71 100 00 Auxiliary switches 0 1 2 6 71 120 10 Start switch standard 1 71 119 99 Spacer 1 71 121 20 Start switch keyed unalike opt...

Page 185: ...tches 0 1 4 71 039 02 F R switch 1 5 71 039 11 High Low speed switch 1 6 74 010 20 Gauge Spy Glass 1 7 71 102 15 Horn switch 1 8 71 120 10 Start switch standard 1 71 121 20 Start switch keyed unalike...

Page 186: ...00 Starting 180000 Item No Part No Description Qty 1 71 039 11 Light switch 1 2 71 039 11 Accessory Wiper 0 1 3 74 010 00 Gauge Smart View 1 4 71 039 02 F R switch 1 5 71 039 11 Accessory 0 1 6 71 120...

Page 187: ...02 12 Mounting bracket left Steel cab 1 92 202 13 Mounting bracket right Steel Cab 1 91 814 16 Hinge left used with 92 202 12 1 91 814 17 Hinge right used with 92 202 13 1 92 202 15 Spacer used with 9...

Page 188: ...Illustrated Parts Page 44 MB T48 02 T 48 AC ET 3000 Motor...

Page 189: ...y 1 42 70 400 17 Snap ring 1 52 70 400 21 Key 1 96 70 400 18 Snap ring 1 98 70 400 19 Snap ring 1 203 70 400 13 Seal 1 224 70 400 09 Rubber Grommet 2 206 70 260 00 Terminal stud 3 291 70 260 00 Hex nu...

Page 190: ...Qty 1 See Motor Motor 1 2 96 114 12 U bolt 1 3 80 714 05 O ring 1 4 88 068 62 1 4 Split lock washer 4 5 89 060 11 6mm x 1 0 x 50 Hex bolt 3 6 89 111 27 10mm x 1 5 x 20 Hex bolt 2 7 88 128 62 7 16 Spl...

Page 191: ...rest standard 1 90 179 00 Backrest Steel Cab 1 12 90 150 00 Seat Cushion standard 2 90 172 00 Seat cushion steel cab 2 13 90 444 00 Deck board standard 1 90 466 10 DECKBOARD 19 500 X 41 000 1 90 467 1...

Page 192: ...peed Control Panel Resetting the Maintenance Meter Function NOTE The Maintenance meter function is optional The controller handset is required to reset the Maintenance meter Refer to the Appendix for...

Page 193: ...r included with harness 48 volt 2 78 3001 00 Resistor included with harness 72 volt 1 7 73 004 20 Horn 1 8 88 838 06 14 x 1 2 Screw 4 9 79 840 20 Circuit breaker 12 volt 20A 1 10 79 840 00 Circuit bre...

Page 194: ...rated Parts Page 50 MB T48 02 T 48 AC ET 3000 Stake Sides T 48 Item No Part No Description Qty 90 542 01 GATE END W HOOKS 42 3 4 1 90 542 08 GATE SIDE LT TT W F G CAB 1 90 542 09 GATE SIDE RT TT W F G...

Page 195: ...88 081 14 5 16NF x 1 1 2 Hex bolt grade 8 1 4 88 089 84 5 16NF Hex lock nut grade C 1 5 32 248 10 Upper bushing 1 6 20 031 65 Steering shaft assembly incl 3 and 4 1 7 19 011 25 Steering wheel cap 1 8...

Page 196: ...Illustrated Parts Page 52 MB T48 02 T 48 AC ET 3000 Steering Gear...

Page 197: ...08 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washer 1 10 18 308 79 Seal input...

Page 198: ...Illustrated Parts Page 54 MB T48 02 T 48 AC ET 3000 Steering Knuckle...

Page 199: ...g 2 9 32 240 43 Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13...

Page 200: ...Illustrated Parts Page 56 MB T48 02 T 48 AC ET 3000 Steering Linkage...

Page 201: ...nkage Item No Part No Description Qty 1 18 057 00 Tie rod 1 2 86 510 00 Ball joint clamp 4 3 86 501 98 Ball joint left 2 4 86 501 99 Ball joint right 2 5 88 527 11 1 8 x 1 Cotter pin 4 6 18 037 00 Dra...

Page 202: ...ont Suspension Item No Part No Description Qty 1 96 121 00 U bolt 4 2 85 498 00 Leaf spring 2 3 32 214 50 Bushing 12 4 96 240 00 1 2NC x 4 Hex bolt 6 5 88 149 81 1 2NC Lock nut 8 6 7 88 149 81 1 2NC L...

Page 203: ...96 114 00 U bolt 4 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2 20 88 149 81 1 2NC Lock nut 4 21 50 460 00 Strap 2 22 98 002 00 Rubber overload spring optional 2 23 86 602 00 Shock 2 24 8...

Page 204: ...Illustrated Parts Page 60 MB T48 02 T 48 AC ET 3000 Transmission Differential Gear Case...

Page 205: ...0417 Fill Level plug 1 17 GT 3287113 Differential housing 1 18 GT 71979 Bearing 1 19 GT 3287143 Differential case 1 20 GT 72013 O ring 1 21 GT 3273633 Pinion nut 1 22 GT 71896 M10 x 25 Bolt 12 23 See...

Page 206: ...ss 1 75 153 09 Control panel 48 volt 1 75 153 12 Control panel 72 volt 1 75 153 06 Power 48 volt 1 75 153 11 Power 72 volt 1 75 149 02 Harness Fiberglass cab T 48 1 Item No Part No Description Qty Whe...

Page 207: ...x A Special Tools 3 Appendix B Suggested Torque Limits for Standard Hardware 4 Hardware Identification 4 Standard Head Markings 4 Hex Bolts 4 Other Bolts 4 Hex Nuts 5 Hex Lock Nuts stover 5 Other Nuts...

Page 208: ...anuals 43 201 50 Pinion Seal Installation Tool Used to install the pinion seal on all vehicles equipped with the Power Traction primary reduction and a pinion brake or speed sensor 41 532 50 Chain Cas...

Page 209: ...s distributor 41 350 13 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 75 442 55 Pin Removing Tool Removes pins from Molex Mini Fit harness connecto...

Page 210: ...bove Other Bolts 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 Note Toque values specified are for clean dry th...

Page 211: ...d as S A E Grade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivalent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 Note Nuts with no mark...

Page 212: ...ry 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 cr...

Page 213: ...3 00 3 00 398 30 2 00 3 50 540 Metric Foot Pounds Grade N m Dia Pitch 4 6 8 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...

Page 214: ...ed vacuum cleaner or any alternate method approved by OSHA to minimize the hazard caused by airborne asbestos fibers and brake dust Do not grind sand break or chisel the brake pads shoes as this will...

Page 215: ...Notes...

Page 216: ...Taylor Dunn Mfg 2114 W Ball Rd Anaheim CA 92804 800 688 8680 714 956 4040 FAX 714 956 0504 Visit our Website www taylor dunn com...

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