Taylor-Dunn B0-T48-48 Taylor Truck T48 User manual

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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

TAYLOR-DUNN SERVICE CENTER
For more information about this and other Taylor-Dunn manuals, please write:
Taylor-Dunn Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn Mfg. 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 retrieval
system without prior written permission of Taylor-Dunn Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn Mfg., 2114 W. Ball Road, Anaheim, CA 92804

TABLE OF CONTENTS
INTRODUCTION
Operator and Maintenance Manual
Introduction ................................................................. ii
How To Use This Manual ....................................................... iii
Who Should Read This Manual ............................................... iv
Responsibilities ....................................................................... iv
Conventions.............................................................................. v
SECTION 1
Vehicle Description and Specifications
Vehicle Description ...................................................... 2
Standard Specifications ............................................................. 3
Taking Delivery of the Vehicle ................................................. 4
What To Do If a Problem Is Found ........................................... 6
SECTION 2
Safety Rules and Operational Information
Safety Rules and Guidelines....................................... 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 Switch ................................................ 8
Headlights and Accessories (Optional) Switch ......... 8
Hour Meter ............................................................... 8
Charger Interlock ....................................................... 8
Battery Status Indicator............................................. 9
Reverse and Motion Alarm ........................................ 9
Electrolyte Alarm (Optional) ...................................... 9
Windshield Washer Fluid Tank .................................. 9
Smart View Display ................................................. 10
Smart View Display Fault Codes ............................. 11
Vehicle Operational Guidelines ................................................ 13
Driving ..................................................................... 13
Loading and Unloading............................................. 13
Parking ..................................................................... 13
Towing ..................................................................... 13
Storing and Returning to Service .............................................. 14
Returning To Service ................................................ 14

SECTION 3
Maintenance and Service Procedures
Maintenance Guidelines ............................................. 2
Severe Duty Guidelines............................................... 3
Periodic Maintenance Checklist................................. 4
Lubrication Chart ......................................................... 5
Troubleshooting Guide ................................................ 6
Brakes ....................................................................................... 7
Brake Pad Replacement ............................................ 9
Repairing the Brake Body....................................... 10
Bleeding the Brakes ................................................ 12
Replacing the Master Cylinder ............................... 14
Filling and Checking the Fluid Level...................... 15
Parking Brake ......................................................................... 16
Parking Brake Adjustment ...................................... 17
Front Axle and Yokes.............................................................. 18
Axle Removal and Installation ................................ 19
Aligning the Front End ........................................... 20
Centering the Steering ............................................ 21
Repairing the Front Axle......................................... 22
Steering Yoke/Bushings .......................... 22
Ball Joints, Tie Rods, and Drag Links .................... 24
Front Wheel Bearings ............................................. 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
Removing the Rear Axles ........................................ 36
Removing and Installing the Drive ........................... 38
Disassembly and Reassembling of Primary
Reduction Gear Case............................................... 39
Disassembly of the 3rd Member ............................ 42
Assembly of the 3rd Member .................................. 45
Pinion Gear Shimming............................................. 48
Pinion Bearing Preload ............................................ 49
Changing the Differential Oil .................................. 50
Speed Controller ...................................................................... 51
Removing and Installing Speed Controller ............... 52
Drive Motor ........................................................................... 53
Motor Removal ...................................................... 54
Automatic Electric Brake Removal and Installation .55
Motor Disassembly and Assembly.......................... 57
Armature and Brush Inspection .............................. 59
Motor Specifications ............................................... 60
Battery ................................................................................... 61
Cleaning .................................................................. 62
Electrolyte Alarm ..................................................... 63
Servicing................................................................... 64
Charging .................................................................. 65
Battery Storage ....................................................... 65

SECTION 4
ElectricalandCharger Troubleshooting
Sevcon Controller Troubleshooting ........................... 2
Voltage Reference Table........................................... 25
LED Status Chart ........................................................ 26
Lestronic II Charger Troubleshooting .........................1
Operating Instructions and Theory of Operation
Lester Lestronic II Battery Charger ................................... 2
Testing the Charging Cycle ........................................................ 3
Test Equipment Required .......................................................... 4
Troubleshooting for Built-In Charger ........................................ 5
Troubleshooting for Portable Charger........................................ 8
Testing the Timer Relay ............................................................ 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
Troubleshooting......................................................................... 6
SECTION 4a
Wire Diagrams
Complete Vehicle......................................................... 2
Dash............................................................................... 3
Control panel................................................................ 4
Throttle Module .............................................................5
Lighting ..........................................................................6
SECTION 5
Illustrated Parts List
Common Front Axle Assembly.................................................... 2
Steering Sleeve Assembly .......................................... 4
Front Suspension ......................................................... 6
Drag Link ...................................................................... 8
Steering Gear ............................................................. 10
Steering Column Assembly....................................... 12
Master Cylinder, Brake Line Hardware, and
Front Brake Assembly................................................ 14
Master Cylinder ........................................................... 16
Hydraulic Disc Brakes ................................................ 18
Parking Brake Linkage............................................... 20

Motor ........................................................................... 22
Automatic Electric Brake............................................24
Instrument Panel and Components...........................26
Resetting the Smart View Display.............................27
Control Panel .............................................................. 28
Electrical Components (typical) .................................30
Lester Charger.............................................................32
Signet Charger ............................................................34
Accelerator Module ....................................................36
Drive .............................................................................38
Drive Assembly............................................................ 42
Rear Axle .....................................................................44
Decals...........................................................................46
Hitch 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
Cowl with Windshield, Cab, and
Windshield Wipers..........................................6
Optional Parts
Strobe Light on Steel Cab, Mirrors,
Dome Light, and Fiber Glass
Cab Bumper......................................................8
Surrey and Fiberglass Top Cover ..............................10
Door Options ................................................................12
Deck Boards.................................................................14
Box with Doors and Watering System Parts ........... 16
Stake Side Options .....................................................18

SECTION 5B
Illustrated Parts List
ET 3000 Standard Parts
Tire & 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
APPENDIX ASpecial Tools
APPENDIX BStandard Torque Values