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Front Axle

Page 6

MB-T48-02

T-48 AC / ET 3000

FRONT AXLE DISASSEMBLY

Disassembling and reassembling involves removing and replacing the left and right steering knuckles

and 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 removed unless the axle

beam must be replaced. Refer to

Front Axle Removal and

Installation

for information regarding removing the front axle.

Axle with integral king pin shown

Содержание ET 3000

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 14: ...Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 128: ...Notes...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 138: ...Notes...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 215: ...Notes...

Страница 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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