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

II TAYLOR•DUNN
TABLES
Accelerator Module Test Plug Pin Voltages
Scheduled Maintenance .
Lubrication Table . . . . . . .
Troubleshooting Guide . . . .
Recommended Spare Parts .
Vehicle Specifications
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
Charger And Charger Mount .
TAYLOR-DUNN ET 1-50
. . ELECTRICAL - 27
. MAINTENANCE - 3
. MAINTENANCE - 5
. MAINTENANCE - 6
. MAINTENANCE - 8
MAINTENANCE -
11
. PARTS LIST - 3
. PARTS LIST - 5
. PARTS LIST - 7
. PARTS LIST - 8
. PARTS LIST -
11
. PARTS LIST-13
. PARTS LIST-15
. PARTS LIST -17
. PARTS LIST
-19
. PARTS LIST - 21
. PARTS LIST - 23
. PARTS LIST - 25
. PARTS LIST - 27
. PARTS LIST - 29
. PARTS LIST - 31
. PARTS LIST- 33
. PARTS
LIST- 35
ix

Table of Contents
X
THIS PAGE IS INTENTIONALLY LEFT
BLANK
"TAYLOR•DUNN
TAYLOR-DUNN: ET 1-50

II TAYLOR-DUNN
TAYLOR-DUNN ET 1-50
SAFETY/ GENERAL
INFORMATION
SAFETYI GENERALINFORMATION
SAFETY-1

SAFElY I GENERAL INFORMATION
A WARNING!
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
RESULT IN SEVERE PERSONAL INJURY OR DEATH.
"TAYLOR•DUNN
A HIGH VOLTAGE PRESENT! CAREFULLY DISCONNECT BATTERIES BEFORE SERVICING
A BATTERY GASES ARE EXPLOSIVE! KEEP SPARKS, FLAMES AND LIGHTED CIGARETTES AWAY
FROM BATTERIES.
A KEEP THE VEHICLE AND BATTERIES IN A WELL-VENTILATED AREA WHEN CHARGING.
A THIS VEHICLE SHOULD BE OPERATED ONLY BY AUTHORIZED TRAINED PERSONNEL
A THIS VEHICLE IS RESTRICTED TO TWO OCCUPANTS.
A DO NOT START THE VEHICLE UNTIL BOTH OCCUPANTS ARE SEATED AND SEATBELTS
ARE FASTENED.
A ALL OCCUPANTS MUST KEEP THEIR ENTIRE BODIES AND ALL EXTREMITIES INSIDE THE VEHICLE
AT ALL TIMES.
A DO NOT EXCEED 32 MPH (50 KPH) UNDER ANY CIRCUMSTANCES; DRIVE SLOWLY
IN TURNS AND UP AND DOWN SLOPES.
A BRING THE VEHICLE TO A COMPLETE STOP BEFORE REVERSING DIRECTION.
A BEFORE LEAVING THISVEHICLE, ALWAYS SETFORWARD-REVERSE SELECTOR IN THE CENTER "OFF'
POSITION, SET PARKING BRAKE SECURELY, TURN KEYSWITCH TO OFF AND REMOVE THE
KEY.
A DO NOT ALTER OR ADD TO THIS VEHICLE WITHOUT TAYLOR-DUNN'S WRITTEN AUTHORIZATION.
WARNING:
APPLY PARKING BRAKE!
PARKING BRAKE NOT AUTOMATICALLY APPLIED.
NOTICE!
THIS VEHICLE HAS NOT BEEN CERTIFIED BY THE UNITED STATES NATIONAL HIGHWAY TRAFFIC SAFE1Y
ASSOCIATION
IN ACCORDANCE WITH THE U.S. NATIONAL TRAFFIC MOTOR VEHICLE SAFE1Y ACT FOR USE
ON STREETS AND HIGHWAYS.
2- SAFETY TAYLOR-DUNN: ET 1-50

"TAYLOR•DUNN
SAFETY I GENERAL INFORMATION
GENERAL SAFETY
Disconnect the main batteryleads and remove the key beforeworking on any part of the vehicle, EXCEPT
when
conducting tests on the electrical components.
When
conducting tests on the electrical components, always raise and securely support the rear wheels
to prevent runaways.
Always use jack stands of adequate capacity when supporting the vehicle.
As a safety precaution, after raising the vehicle, place a piece of wood or the tire that was
removed, under the frame. This will prevent a hand or a foot from being injured if the vehicle
falls off the jack stands.
When servicing electrical components, disconnect the rear battery jumper as shown. This
cuts the battery pack voltage in half to 36 volts, a much safer level. Reconnect the jumper
after servicing.
Figure A -1.
Disconnect this
Jumi?er before
servicing electrical
components I wiring
FORWARD
Note: If a hoistis not available to raise the vehicle, jack one side of the vehicle and support it, then jack the
otherside
and support it also.
TAYLOR-DUNN ET 1-50 SAFETY-3

SAFETYI GENERAL INFORMATION
General Information
Figure A· 2
Figure
A- 3
Axle support
points-use when
replacing
flat
tires, shock
absorbers
or leaf
springs
Jack stands
4-SAFETY
Lift and Support Points
,. .......
,..
~ ..
,..
,,.
"TAYLOR•DUNN
T
43•
10•
Frame
support
points -use
when
replacing
axles
TAYLOR-DUNN: ET 1-50

"TAYLOR•DUNN
SAFETY I GENERAL INFORMATION
Towing
Iftowing is necessary, contact a professional towing service.
Check local towing regulations.
Figure A-4
The best way oftransporting the vehicle is on a flat bed truck, where the entire vehicle rides on the flat bed.
FigureA-5
Ifthe vehicle must be towed with a wheel lift type, tow with the rear wheels off the ground.
Towing with the rear wheels on the ground will cause severe damage to the differential and motor.
NEVER use
tow chains or ropes to tow a vehicle. You might not be able to safely control the vehicle.
+ Place the forward/reverse shift lever in the neutral position.
+ Attach tow straps to each ofthe rear wheels.
+ Firmly secure the steering wheel with the front wheels pointing straight forward.
Do not exceed 25 MPH or carry any passengers while towing this vehicle.
TAYLOR-DUNN ET 1-50
SAFETY-5

SAFETYI GENERAL INFORMATION
8J TAYLOR•DUNN
Batteries
Batteries give off explosivegases; keep sparks, flames and cigarettes away. Provideadequateventilation
when charging or using the battery in an enclosed space.
Thebatterycontains
sulfuric acidas electrolyte.Contactwith skin or eyes may causesevere burns and/or
blindness. Wear protective clothing and a face shield.
If electrolyte (battery acid) gets on your skin, flush with water immediately.
If electrolytegetsin your eyes, flush with waterimmediatelyfor15minutes andcall aphysician right away.
Electroyte
is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of
magnesia or vegetable oil and call a physician.
KEEP OUT
OF REACH OF CHILDREN!
Battery Charging
The batteries in this truck must be fully-charged prior to its initial use.
Before charging, makesure the voltage indicated on the charger identification plate complies with the linevoltage
in your locality. If not, contact Taylor-Dunn oryour local Taylor-Dunn dealer.
To charge the truck, open the charger cord box and plug the cord to a 1-phase electrical outlet. The charger
voltage/draw is 230 volts/13 amperes (See "Vehicle Specifications," Section
3, for charger specificaions).
The batteries are fully charged when the ammeter
on the charger reads zero.
6-SAFETY
TAYLOR-DUNN: ET 1-50

II TAYLOR-DUNN
SAFETY I GENERAL INFORMATION
Battery Maintenance
Routine maintenance will help prolong the life of your batteries.
Warm water
Figure A - 6
Acids usually form around the terminals under normal use, corroding the terminals, brackets and mounting bolts
and nuts. Wash the terminals with warm
water to dilute the acids, preferably once a week. Dry the terminals
with a clean cloth after washing.
Any corrosion around the positive and negative battery terminals should also be washed off with warm water.
Checking Battery Electrolyte Level
Distilled water
Figure A - 7
To check electrolyte level for each battery:
D Remove each cell cover.
fJ Visually inspect electrolyte level. It should be %
11
to 1
11
below the battery top.
EJ If too low, fill to the proper level with distilled water from a NON-METALLIC container (plastic or glass).
Note: Remember to perform Steps 1-3 for all cells.
Do not overfill the batteries. If the top of the batteries appears wet before you fill or wash it, it
is probably due to leaky or loose cell covers. Tighten or replace covers.
TAYLOR-DUNN ET 1-50
SAFETY-7

SAFETYI GENERAL INFORMATION
II TAYLOR•DUNN
Tires
Figure A- 8
Changing a Flat Tire
Do
not attempt to change a tire unlessthe truck is on firm, level surface and well out of the flow of traffic.
D
fJ
E
m
Park the truck on a firm, level surface. Apply the parking brake and turn on the hazard warning lights.
Turn off the keyswitch and push the emergency disconnect switch down.
Place blocks in front and back
of the wheel diagonally opposite the tire you are changing.
Use a lug wrench
to loosen the wheel lug nuts counter-
clockwise one-halfturn.
Follow the tire changing procedures carefully to minimize the possibility of injury. A jack is designed for
changing tires only. STAND CLEAR,
DO NOT GET UNDER the truck and DO NOT run the motor when the
truck is supported only by the jack.
l;I Place a jack under the axle on the side nearest the wheel you are removing.
rt'fi1 ;WI Uffl
Always jack the vehicle from under the axle. Misplacement of the jack can cause severe damage to the
vehicle.
1:J Raise the vehicle until the tire to be replaced clears the ground.
D Support the vehicle with jack stands.
W7' ii~ 11 ~ ®
Always use jack stands of adequate capacity. Never work on a raised vehicle supported only
by the jack.
l:J Remove all lug nuts.
m Carefully pull the tire out from the hub.
Im Mount the newtire and tighten the lug nuts alternately in a criss- cross pattern.
W Remove the jack stands, and lower the jack slowly.
If.I Clear away the jack, jack stands, lug wrench, and the wheel blocks.
a-SAFETY
TAYLOR-DUNN: ET 1-50