Taylor-Dunn ET 1-50 User manual

OPERATION
AND
MAINTENANCE
MANUAL
WITH
PARTS LIST
MODEL
ET 1-50 72 Volts
SERIAL NUMBER :
104500 & UP
YEAR 1993 & UP
MANUAL NUMBER: MZ-150-02
-IMPORTANT -
READ AND FOLLOW INSTRUCTIONS GIVEN
IN SAFETY & OPERATIONS AND THOSE
SECTIONS RELATED TO YOUR SERVICE
AND REPAIR RESPONSIBILITIES
II ~~.~'!.:!!..~~
2114 W. Ball Rd., Anaheim, CA 92804 [phone] Fax [phone]
Mailing Address: P.O. Box 4240, Anaheim, California 92803

EEC 86.663 OF DEC. 1986
PARA. 9.7.3.5.5
FAULT SAFETY CIRCUIT CHECK PROCEDURE
EEC-certified vehicles are equipped with a safety system which will terminate any uncontrolled
power-on condition due to a fault
in the electronic circuit.
This fault safety circuit should be checked during scheduled periodic maintenance inspections by
authorized service personnel. ·
PROCEDURE
Jack up the rear axle of the vehicle until the rear wheels spin free (see "Lift and Support Points,
11
Safety and General Information Section).
Disconnect the main traction battery cables.
The key switch must be turned off and battery cables disconnected. Be sure that the
rear wheels are clear of any foreign objects.
Place a 6-gauge jumperwire between the B- terminal and M- terminal of the PMC controller.
Reconnect the main traction battery cables.
Turn on the key switch and place the vehicle in the forward drive position.
Depress the accelerator pedal down approximately half of the distance to the floor.
Do not exceed 80% of the accelerator travel.
Ifthe rear wheels turn, the PMC fault safety circuit is defective and the PMC controller
must be replaced.
Ifthe rear wheels do not turn, then the fault safety circuit is functioning correctly.
Turn offthe key switch.
Disconnect the main traction battery cables.
Remove the jumper wire between the B- and
M- terminals.
Reconnect the main traction battery cables and lowerthe vehicle.

II TAYLOR•DUNN
Table of Contents
SAFETYI GENERAL INFORMATION
General Safety . . . . . . . .
General Information . . . . . .
Lift And Support Points .
Towing
..... .
Batteries
........ .
Battery Charging . . .
Battery Maintenance .
Checking Battery Electrolyte Level .
Tires
.......... .
BRAKES
Changing a Flat Tire .
Tire Rotation . . . . .
Brake System . . . . . . . . . . .
Brake Fluid . . . . . . . . . . . .
Checking Brake Fluid Level .
Adjusting the Brake Pedal Free Play .
Replacing the Front Brake Pads .
Replacing the Rear Brake Shoes .
Replacing the Front Brake Hoses
Replacing the Front Brake Lines
Replacing the Rear Brake Hose .
Replacing the Rear Brake Lines .
Replacing the Master Cylinder . .
Replacing the Brake Light Switch .
SUSPENSION
Replacing the Front Axle Suspension Springs
Replacing the Front Shock Absorbers
Replacing the RearAxle Springs . . .
Replacing the RearShock Absorbers
TAYLOR-DUNN ET 1-50
.. SAFElY-3
.. SAFElY-4
. . SAFElY-4
. SAFElY-5
. . SAFElY-6
. . SAFElY-6
. . SAFElY-7
. . SAFElY-7
. . SAFElY-8
. . SAFElY-8
. . SAFElY-9
BRAKES-2
BRAKES-3
BRAKES-3
BRAKES-5
BRAKES-6
BRAKES-8
. BRAKES -15
. BRAKES -16
. BRAKES -18
. BRAKES -19
. BRAKES-21
. BRAKES-22
SUSPENSION - 2
SUSPENSION - 3
SUSPENSION - 4
SUSPENSION - 6
i

Table of Contents
STEERING
Steering Linkages . . . . . . . . . . .
Replacing the Balljoints . . . . .
Replacing the Steering Sleeves .
Aligning the Front End . . . . . . . .
Replacing the Steering Gearbox . . .
Removing the Steering Gearbox
Installing the Steering Gearbox
FRONT AXLE
STEERING-2
STEERING-2
STEERING-3
STEERING-4
STEERING-5
STEERING-5
STEERING-8
II TAYLOR•DUNN
Replacing the Front Axle Assembly . . . . . . . . . . . . . . FRONTAXLE - 2
ii
POWER TRAIN
Replacing the Drive Shaft . . . . . . . . . . . . . . .
Disengaging the Drive Shaft from the Differential
Disengaging the Drive Shaft from the Motor
Installing the Drive Shaft .
Replacing the Motor . . .
Removing the Motor
Installing the Motor .
DIFFERENTIALI REAR AXLE
RearAxle I Differential . . . .
Replacing The Differential . . .
Adding Oil to The Differential .
Replacing The Rear Axle . . .
Repairing The Differential . . .
Selecting Drive Pinion Shims
ELECTRICAL SYSTEM
Wiring Diagram
Battery Layout . . . .
. . POWER TRAIN - 2
. . POWER TRAIN - 3
.. POWER TRAIN - 4
. . POWER TRAIN - 5
. . POWER TRAIN - 7
. . POWER TRAIN - 7
.. POWER TRAIN - 9
. . DIFFERENTIAL - 2
. . DIFFERENTIAL - 2
. . DIFFERENTIAL - 4
. . DIFFERENTIAL - 5
DIFFERENTIAL -10
. DIFFERENTIAL -13
. . ELECTRICAL -2-3
. . . ELECTRICAL - 4
TAYLOR-DUNN: ET 1-50

II TAYLOR•DUNN
ELECTRICAL SYSTEM (continued)
Instrument Panel .................. .
Replacing the Battery Indicator Panel . . . . . .
Replacing the KeyswitchI Speedometer Panel
Replacing the Seatswitch . . . . . . .
Disconnect Switch
Disconnect Switch Wiring Layout . . . . . .
Replacing the Emergency Disconnect Switch
Replacing the Charger Assembly . . . . .
Speed Control . . . . . . . . . . . . . .
Replacing the Speed Control Panel .
Accelerator Module . . . . . . . . . .
Replacing the Accelerator Module . .
Turn Signal . . . . . . . . . . . . . . . .
Replacing the Turn Signal Pilot Bulb
Replacing the Turn Signal Assembly
Shift Lever Switches . . . . . . . . . . .
Replacing Shift Lever Switches . . .
Shift Lever Switches Wiring Layout .
ELECTRICALTROUBLESHOOTING
Testing the Main Power Output ..... .
Testing the Main Power Input . . . . . . .
Testing Inputto the Speed Control Module
Testing the Contactors
......... .
Testing the Forward I Reverse Switches .
Testing the Accelerator Module .
Electrical Troubleshooting Table
Repairing the Charger . . . . .
Testing the ChargerTimer .
Testing the Diodes . .
Testing the Capacitors
Repairing the Motor . . . .
TAYLOR-DUNN ET 1-50
ELECTRICAL - 5
ELECTRICAL - 5
ELECTRICAL - 6
ELECTRICAL - 7
ELECTRICAL - 8
ELECTRICAL - 8
ELECTRICAL - 9
ELECTRICAL -10
ELECTRICAL -12
ELECTRICAL- 12
ELECTRICAL-
14
ELECTRICAL - 14
ELECTRICAL -15
ELECTRICAL -15
ELECTRICAL-16
ELECTRICAL -17
ELECTRICAL-17
ELECTRICAL -18
ELECTRICAL -19
ELECTRICAL- 19
ELECTRICAL -
21
ELECTRICAL -22
ELECTRICAL -
24
ELECTRICAL -25
ELECTRICAL -26
ELECTRICAL -
27
ELECTRICAL -29
ELECTRICAL -30
ELECTRICAL -
31
ELECTRICAL -32
ELECTRICAL -33
iii

Table of Contents
iv
ACCESSORIES
Lights ............ .
Adjusting the Headlights .
Replacing the Headlights
Replacing the Front Park Lights .
Replacing the Stop Lights/Rear Park Lights .
Windshield Wiper . . . . . . .
Replacing Wiper Blades .
Replacing Wiper Motor .
Installing WiperArms
Replacing the Horn . . . . . .
Side Mirrors ......... .
Replacing Side Mirrors
MAINTENANCE
Warranty .
Brakes
Appearance Care .
InteriorTrim .
Windows .....
Scheduled Maintenance .
Lubrication Chart . . . . .
Troubleshooting Guide . .
Recommended Spare Parts List .
Vehicle Specifications
ILLUSTRATED PARTS LIST
Front Brake Lines And Master Cylinder
Rear Brake Lines . . .
Front Brake Assembly
Rear Brake Assembly .
Park Brake Assembly .
Steering GearAnd Linkages .
FrontAxle and Suspension
..
. . ACCESSORIES - 2
. . ACCESSORIES - 2
. . ACCESSORIES - 3
.. ACCESSORIES - 4
. . ACCESSORIES - 5
. . ACCESSORIES - 6
. . ACCESSORIES - 6
. . ACCESSORIES - 7
. . ACCESSORIES - 8
. . ACCESSORIES - 9
. ACCESSORIES -10
. ACCESSORIES -10
. . MAINTENANCE - 2
. . MAINTENANCE - 2
. . MAINTENANCE - 2
. . MAINTENANCE - 2
. . MAINTENANCE - 2
. . MAINTENANCE - 3
. . MAINTENANCE - 5
. . MAINTENANCE - 6
. . MAINTENANCE - 8
. . MAINTENANCE - 9
. PARTS LIST - 2
. PARTS LIST - 4
. PARTS LIST - 6
. PARTS LIST - 8
. PARTS LIST - 10
. PARTS LIST -12
. PARTS LIST -
14
IITAYLOR•DUNN
TAYLOR-DUNN: ET 1-50

II TAYLOR•DUNN
ILLUSTRATED PARTS LIST (continued)
MotorAnd Motor Mounts .
Motor
...... .
PropellerShaft . . . . . .
RearSuspension . . . . .
RearAxle And Wheel . . .
Differential
Seats
...... .
Instrument Panel .
Speed Control
ChargerAnd Charger Mount .
TAYLOR-DUNN ET 1-50
. PARTS LIST -16
. PARTS LIST-18
. PARTS LIST -20
. PARTS
LIST- 22
. PARTS LIST -24
. PARTS LIST -26
. PARTS LIST -28
. PARTS LIST -30
. PARTS LIST -32
. PARTS
LIST- 34
V

Table of Contents
vi
ILLUSTRATIONS
Rear Battery Jumper, Disconnect When Servicing
Lift and Support Points
Towing Methods . . . . . . . . .
Battery Maintenance . . . . . . .
Checking Battery Electrolyte Level
Changing a Flat Tire . . . . . . .
Recommended Tire Rotation Pattern .
Brake System . . . . . . . . . . . . .
Removing the Master Cylinder Cover
Checking Brake Fluid Level . . . .
Adjusting Brake Pedal Free Play . . .
Replacing the Front Brake Pads . . .
Compressing Brake Piston Cup with a C-Clamp .
Disassembling the Rear Brakes .
Reassembling the Rear Brakes . .
Replacing the Front Brake Hoses
Replacing the Front Brake Lines
Replacing the Rear Brake Hose .
Replacing the Rear Brake Lines
Replacing the Master Cylinder . .
Replacing the Brake Light Switch .
Replacing the Front Axle Suspension Springs
Replacing the Front Shock Absorbers . . . .
Replacing the RearAxle Suspension Springs
Replacing the Rear Shock Absorbers
Replacing the Ball Joints . . . . .
Replacing the Steering Sleeves .
Aligning the Front End . . . . . .
Replacing the Steering Gearbox .
Replacing the Front Axle Assembly
Drive Shaft . . . . . . . . . . . . . .
.. SAFElY-3
.. SAFElY-4
. . SAFElY-5
. SAFElY-7
. SAFElY-7
. SAFElY-8
. SAFElY-9
BRAKES-2
BRAKES-3
BRAKES-4
BRAKES-5
BRAKES-6
BRAKES-7
BRAKES-8
. BRAKES-10
. BRAKES -15
. BRAKES -16
. BRAKES -18
. BRAKES -19
. BRAKES-21
. BRAKES-22
SUSPENSION - 2
SUSPENSION - 3
SUSPENSION - 4
SUSPENSION - 6
STEERING-2
STEERING-3
STEERING-4
STEERING-5
. FRONTAXLE - 2
POWER TRAIN - 2
II TAYLOR•DUNN
TAYLOR-DUNN: ET 1-50

II TAYLOR•DUNN
ILLUSTRATIONS {continued)
Replacing the Drive Shaft ............ .
Disengaging the Drive Shaftfrom the Differential
Disengaging the Drive Shaft from the Motor
lntalling the Drive Shaft
Removing the Motor . . .
Installing the Motor
....
Replacing the Differential
Replacing the RearAxle
Repairing the Differential
ElectruckWiring Diagram
Battery Layout . . . . . .
Replacing the Battery Indicator, LighVWiper Switch Panel
Replacing the Keyswitch I Speedometer Panel
Replacing the Seat Switch . . . . . . . . . .
Emergency Disconnect Switch Wiring Layout
Replacing the Emergency Disconnect Switch
Replacing the Charger Assembly . . .
Replacing the Speed Control Panel
Replacing the Accelerator Module . .
Replacing the Turn Signal Pilot Bulb
Replacing the Turn Signal Assembly .
Replacing Shift LeverSwitches . .
Shift Lever Switches Wiring Layout
Motorand MotorTerminals . .
Gang Connector . . . . . . . . .
Speed Control Module Plug
Speed Control Module Wiring Diagram
ContactorAssembly . . . . . . .
Forward I Reverse Switches . . .
Accelerator Module Test Harness
TAYLOR-DUNN ET 1-50
. . POWER TRAIN - 3
.. POWER TRAIN - 3
.. POWER TRAIN - 4
.. POWER TRAIN - 5
. . POWER TRAIN - 7
. . POWER TRAIN - 9
. .
DIFFERENllAL - 2
. .
DIFFERENllAL - 5
.
DIFFERENllAL -10
ELECTRICAL- 2
ELECTRICAL - 4
ELECTRICAL - 5
ELECTRICAL - 6
ELECTRICAL - 7
ELECTRICAL - 8
ELECTRICAL - 9
ELECTRICAL -10
ELECTRICAL -12
ELECTRICAL -
14
ELECTRICAL- 15
ELECTRICAL -16
ELECTRICAL -17
ELECTRICAL-18
ELECTRICAL -20
ELECTRICAL -
21
ELECTRICAL- 22
ELECTRICAL -23
ELECTRICAL -
24
ELECTRICAL -25
ELECTRICAL -26
vii

Table of Contents
viii
ILLUSTRATIONS (continued)
Diode Block with Diodes .
Timer
............ .
Testing the Diodes . . . . . .
Armature, Commutator Side .
Adjusting the Headlights . . .
Replacing the Headlights . . .
Replacing the Front Park Lights .
Replacing the Stop Lights I Rear Park Lights .
Replacing Wiper Blades .
Replacing the Wiper Motor
Replacing the Horn . .
Replacing Side Mirrors . .
Lubrication Chart . . . . .
Front Brake Lines And Master Cylinder .
Rear Brake Lines . . .
Front Brake Assembly
Rear Brake Assembly .
Park Brake Assembly .
Steering GearAnd Linkages .
Front Axle, Suspension and Wheel
MotorAnd Motor Mounts .
Motor
...... .
PropellerShaft . . . .
RearSuspension . . .
Rear Axle And Wheel .
Differential
Seats
...... .
Instrument Panel .
Speed Control
ChargerAnd Charger Mount .
ELECTRICAL -
29
ELECTRICAL -30
ELECTRICAL -
31
ELECTRICAL - 29
. . ACCESSORIES - 2
. . ACCESSORIES - 3
. . ACCESSORIES - 4
. . ACCESSORIES - 5
. . ACCESSORIES - 6
. . ACCESSORIES - 7
. . ACCESSORIES - 9
. ACCESSORIES -10
. MAINTENANCE - 5
. PARTS LIST - 2
. PARTS LIST - 4
. PARTS
LIST- 6
. PARTS LIST - 8
. PARTS
LIST-10
. PARTS LIST-12
. PARTS LIST-14
. PARTS LIST-16
. PARTS LIST-18
. PARTS LIST - 20
. PARTS LIST -22
. PARTS LIST -
24
. PARTS LIST- 26
. PARTS LIST -28
. PARTS LIST -30
. PARTS LIST -32
. PARTS LIST -
34
IITAYLOR•DUNN
TAYLOR-DUNN: ET 1-50