Taylor-Dunn ET 3000 User manual

The Best Way
To Go
About Your
Business
TAYLOR-DUNN
®
Serial Number Starting: 172581
Ending Serial 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 (ET-3000)
Revision: E 10/22/2013
Equipped with AC Motor Speed Control
Model: ET-3000
Model: T-48

3
Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support
our vehicles. Information regarding vehicle sales, replacement 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 the factory direct at:
01 [phone]
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804

The Taylor-Dunn Corporation:
Leading Provider of Commercial & Industrial Vehicles since 1949
Taylor-Dunn Manufacturing:
From the day we shipped our rst vehicle in 1949, we have pursued a singular goal: to build tough, rugged, dependable vehicles to help
our customers move personnel, equipment, and materials. It’s that simple. For over sixty years, our standard and custom vehicles - Burden
Carriers, Personnel Carriers, Stock Chasers, Electric Carts, Tow Tractors & more - have been the leading solution for customers in a
broad range of industrial, commercial, and ground-support markets.
Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application-
specic solutions, which are reliable, efcient, and economical.
Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service 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 ranging from 3,000 - 12,000 pounds drawbar pull, they are ideal for industrial applications as well as aircraft ground
support. As with all Taylor-Dunn vehicles; quality, service, support and reliability are built into all Tiger Tractor products.
Metro Crown International (MCI):
Metro Crown International, located in Lee’s Summit, Missouri is one of the world’s leading suppliers of replacement parts for industrial
applications and the airline ground support industry. MCI is the factory authorized OEM distributor for parts for Tiger Tractor, United
Tractor, Kalamazoo, and FMC Challenger Belt Loader brands. Both domestic and international customers have come to depend upon
MCI to provide quality, personalized service and to count on them for accurate, reliable answers.
Shown below is just a small sample of what Taylor-Dunn has to offer to keep your business moving:

Section Index
T-48 AC / ET 3000
MB-T48-02
Introduction
Safety Rules and Operating Instructions
General Maintenance
Front Axle
Steering Component
Brakes
Motor
Transmission
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 assist you in
locating a desired topic or procedure.
Refer to each sectional Table of Contents for the page num-
ber location for specic topics or procedures.

Notes:

Introduction
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 Vehicle......................7

Introduction
Page 2 MB-T48-02
T-48 AC / ET 3000
ABOUT THIS MANUAL
The purchase of this vehicle shows a belief in high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be
sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this
high quality Taylor-Dunn®vehicle.
This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn®vehicles and
is not intended as a training 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 and Guidelines
• Operational Information
• Operator Responsibilities
• Owner Responsibilities
• Control Operation and Location Information
• Maintenance and Troubleshooting Information
• Standard Parts List
Beforeservicing,operating, training orperformingmaintenanceon thisoranyotherTaylor-Dunn®vehicle,
read the appropriate Taylor-Dunn®manual.
Each Taylor-Dunn®manual references the applicable models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

Introduction
Page 3
MB-T48-02
T-48 AC / ET 3000
WHO SHOULD READ THIS MANUAL
This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn®vehicle. Each person
shouldbefamiliarwith the parts ofthismanualthatapply
to their use of this vehicle.
RESPONSIBILITIES
Of the Owner...
The owner of this or any Taylor-Dunn®vehicle is responsible for the overall maintenance and repairs
of the vehicle, as well as the training of operators. Owners should keep a record of conducted training
and maintenance performed on the vehicle. (OSHA Regulation, 29 CFR 1910.178 Powered Industrial
Truck Operator Training).
Of the Operator...
The operator is responsible for the safe operation 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 responsible for the service and maintenance of the vehicle.At no time should
a service person allow any untrained personnel to service or repair this or any Taylor-Dunn®vehicle.
For the purposes of training, a qualied service person may oversee the repairs or services being made
to a vehicle by an individual in training. At no time should an untrained individual be allowed to service
or repair a vehicle without supervision. This manual is not a training guide.
Of the Passengers ...
The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside
the vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of
recklessness are to be avoided. Do not engage in horseplay.

Introduction
Page 4 MB-T48-02
T-48 AC / ET 3000
HOW TO USE THIS MANUAL
This manual is organized into ve main sections:
Introduction
This section describes how to use this service manual and how to identify your vehicle.
Safety Rules and Operating Instructions
This section outlines the safety and operational issues, location and operation of controls, and the
operational checks that 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 specic information on the servicing of the vehicle and a schedule for maintenance
checks.
Electrical and Charger Troubleshooting
This section identies the troubleshooting procedures for testing the electrical system and battery charger.
Illustrated Parts
This section provides an illustrated view of various assemblies. The illustrations are accompanied by
tables identifying the parts.

Introduction
Page 5
MB-T48-02
T-48 AC / ET 3000
A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to
themselves or others. Be sure to follow any instructions contained
within a warning and exercise 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 to exercise special care and follow any
instructions contained with in a caution.
Note: Alerts the reader to additional information about a subject.
Conventions
Symbols and/or words that are used to dene warnings, cautions, instructions, or notes found throughout
this manual:

Introduction
Page 6 MB-T48-02
T-48 AC / ET 3000
HOW TO IDENTIFY YOUR VEHICLE
This manual applies to vehicles with the same model and serial numbers listed on the front cover. If
the ending serial number is blank, then this manual was for current production vehicles when printed.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(PoweredIndustrialTrucks) andwithallapplicableportionsof theAmericanNationalStandard
for Personnel and Burden Carriers (ANSI B56.8).
These vehicles are not designed to be driven on public roads or
highways. They are available in maximum designed speeds ranging
from 6 to 16 mph. Do not exceed the maximum designed speed.
Exceeding the maximum designed speed may result in steering
difculty, motor damage, and/or loss of control. Do not exceed locally
imposed speed limits. Do not tow at more than 5 mph.
The locations of the model number are illustrated below:
Note: Serial number can be found in 1 of 3 locations shown below.

Introduction
Page 7
MB-T48-02
T-48 AC / ET 3000
TAKING DELIVERY OF YOUR VEHICLE
Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious
problems:
• Examine the contents of all packages and accessories that may have come in separate packages
with the vehicle.
• Make sure everything listed on the packing slip is there.
• Check that all wire connections, battery cables, and other electrical connections are secure.
• Check battery cells to be sure they are lled.
• Check the tire pressure, tightness of lug nuts, and for any signs of damage.
Check the operation of each of the following controls:
• Accelerator
• Brake
• Parking Brake
• Key-Switch
• Forward/Reverse Switch
• Reverse Beeper (if equipped)
• Front Headlight Switch
• Steering Wheel
• Horn
What To Do If a Problem is Found
If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading
and le a claim with the freight carrier. The claim must be led within 48 hours of receiving the vehicle
and its accessories. Also, notify your Taylor-Dunn®dealer of the claim.
If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately
contact your local Taylor-Dunn®distributor and report the problem. The report must be made within 24
hours of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn®vehicle
is a factory authorized service technician.
The only personnel authorized to repair, modify, or adjust any part
of this or any Taylor-Dunn®vehicle is a factory authorized service
technician. Repairs made by unauthorized personnel may result
in damage to the vehicles systems which could lead to an unsafe
condition resulting in severe bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.

Notes:

Safety Rules and Operating Instructions
Table of Contents
Safety Rules and Operating
Instructions
Standard Specications* ................................2
Safety Rules and Guidelines..........................3
Driver Training Program .................................4
Driver Qualications. ...............................................4
Vehicle Controls ..............................................5
Dash Up to Serial #179999.....................................5
Dash Starting Serial #180000 .................................6
Combination Dash Display......................................7
Vehicle Operational Guidelines......................10
Safety Guidelines....................................................10
Starting:...................................................................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 Operation...................................16
Signet Charger Operation, Model HB Series ..........16
Signet Charger Operation, Model HBS series.........17
Lestronic II®Charger Operation ..............................17
Taylor-Dunn X-Series Charger ................................18
Storing and Returning to Service .................20
Storing Your Vehicle ................................................20
Returning to Service................................................20
Periodic Maintenance Checklist.....................21
Daily Visual inspection:............................................22
Maintenance Guidelines for
Severe Duty Applications.........................22

Safety Rules and Operating Instructions
Page 2 MB-T48-02
T-48 AC / ET 3000
These vehicles conform 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 Burden Carriers (ANSI B56.8).
STANDARD SPECIFICATIONS*
ITEM Model SPECIFICATION
Min/Max Battery 48 volt system - 225 kg to 261 kg (496 lbs to 576 lbs)
Weights 72 volt system - 337 kg to 392 kg (743 lbs to 564 lbs)
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid
Differential
Brakes Four Wheel Hydraulic Disc,
Automatically Applied Park Brake
Steering Automotive Steering 24:1
Frame Steel Unitized Body, Heavy Duty 14 Gauge Steel
Instrumentation Combination Display (Battery Status Indicator, Hour Meter,
System Status Monitor), Key Switch, Horn Button, Speed select
Switch, Forward/Reverse Switch, 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
Occupancy 2 Passenger
Electrical System Eight (48v) or twelve (72v)-250 Amp Hour, 6 Volt, Lead Acid
Batteries, 500 Amp Solid State Self Diagnostic AC Speed Control,
Battery Voltage to 12 volt DC-DC converter
Frame Dimensions T-48 318 L x 127 W x 119 H cm (125 L x 50 W x 47 H Inches)
ET-3000 Not available at time or printing
Deck dimensions T-48 104.75 W x 191 L cm (41.25 W x 75.25 L Inches)
ET-3000 125 W x 200 L cm (49.25 W x 78.75 L inches)
Turning Radius 368 Centimeters (145 Inches)
Tires 20.5 x 8 x 10 Load Range E
Dry Weight T-48 608 kg (1,340 lbs)
Without Batteries ET-3000 Not available at time or printing
Maximum Load 1,360 kg (3,000 pounds)
Speed Limit 29-kph (18-mph)
(depends on gear ratio installed)
Motor, AC 48 volt system - 12.8 kW, (17.1 hp) for for 5 min (intermittent duty)
72 volt system - 18 kW, (25 hp) for for 5 min (intermittent duty)
*Specications are subject to change without notice

Safety Rules and Operating Instructions
Page 3
MB-T48-02
T-48 AC / ET 3000
SAFETY RULES AND GUIDELINES
Itistheresponsibilityofthe owner of this vehicle toassurethattheoperatorunderstandsthe various controls
and operating characteristics of this vehicle (extracted from the American National Standards Institute
Personnel and Burden Carriers ANSI B56.8). As well as, following the safety rules and guidelines outlined
in ANSI B56.8 and listed below.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants,
nurseries,institutions,motels,mobilehome parks, and resorts.They are not tobedrivenonpublic highways.
RefertoVehicle Operational Guidelines, Safety Guidelines sectionforimportantsafetyinformation
regarding operating this vehicle.
WARNING
Read and follow 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 the “OFF” position, then remove the key.
2) Place the forward-reverse switch in the center “OFF” position.
3) Set the park brake.
4) Place blocks under the front wheels to prevent vehicle movement.
5) Disconnect the main positive and negative cables at the batteries.
WARNING
These vehicles are not designed to be driven on public roads or highways. They are available in maximum
designed speeds ranging from 6 to 16 mph. Do not exceed the maximum designed speed. Exceeding
the maximum designed speed may result in steering difculty, motor damage, and/or loss of control.
Do not exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.
WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.

Safety Rules and Operating Instructions
Page 4 MB-T48-02
T-48 AC / ET 3000
DRIVER TRAINING PROGRAM
According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all those
who will be operating this vehicle. The training program shall not be condensed for those claiming to have
previous vehicle operation experience. Successful completion of the Operator Training program shall be
required for all personnel who operate this vehicle.
The Operator Training program shall include the following:
• Operation of this vehicle under circumstances normally associated with your particular environment.
• Emphasis on the safety of cargo and personnel.
• All safety rules contained within this manual.
• Proper operation of all vehicle controls.
• A vehicle operation and driving test.
Driver Qualications.
Only those who have successfully completed the Operator Training program are authorized to drive this
vehicle. Operators must possess the visual, auditory, physical, and mental ability to safely operate this
vehicle as specied in the American National Standards Institute Controlled Personnel and Burden Carriers
ANSI B56.8.
The following are minimum requirements necessary to qualify as an operator of this vehicle:
• Demonstrate a working knowledge of each control.
• Understand all safety rules and guidelines as presented in this manual.
• Know how to properly load and unload cargo.
• Know how to properly park this vehicle.
• Recognize an improperly maintained vehicle.
• Demonstrate ability to handle this vehicle in all conditions.

Safety Rules and Operating Instructions
Page 5
MB-T48-02
T-48 AC / ET 3000
VEHICLE CONTROLS
5) Accessory Switches (optional)
The optional accessory switches are located on the
left side of the instrument panel. The function of the
optionalaccessoryswitcheswill vary depending how
the vehicle is equipped.
6) Key-Switch
A key-switch, located on the right center side of
the instrument panel, turns on the vehicle. Rotate
the key clockwise to turn the vehicle power on,
counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position
whenever the operator leaves the vehicle.
This switch is also designed to secure and disable
the vehicle. The key can only be removed when the
key-switch is in the “OFF” position.
7) Emergency Stop Switch
The emergency stop switch will immediately and
abruptly stop the vehicle.
The Emergency Stop Switch will stop the vehicle but
will still allow some functions to work such as the
parking brake bypass switch.
Dash Up to Serial #179999
1) Horn Switch
The horn switch is located on the right
side of the instrument panel. Depress
the switch to sound the horn, release it
to turn it off.
2) Forward-Off-Reverse Switch
The forward-off-reverse switch, located
on the right side of the instrument panel,
determines the direction of travel of the
vehicle. Push the top of the switch to
engage the forward direction. Push the
bottomofthe switchtoengage thereverse
direction.
DONOTSWITCHfromforward toreverse
orvice-versawhile thevehicleisin motion.
Make sure the vehicle is completely stopped before
shifting.
Theforward-off-reverseswitchshouldbeinthecenter
“OFF” position, with the key-switch off and the park
brake set whenever the operator leaves the vehicle.
3a) Light Switch
The headlight switch is located on the top left of the
instrument panel. Push the right side of the switch
to turn the lights on. Push the left side of the switch
to turn the light off.
3b) Hi-Low Switch
The high-low switch is located on the lower left of
the instrument panel. Toggle the switch lever up for
normal speed. Toggle the switch lever down for slow
speed.
4) Combination Display
Functions for the Combination display are listed on
the following pages.
WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
WARNING
Do not depress the Emergency Disconnect Switch
while the vehicle is in motion unless the vehicle
must be stopped in an emergency. Depressing
the switch will immediately apply the park brake,
stopping the vehicle. The abrupt stopping of the
vehicle may result in severe bodily injury.

Safety Rules and Operating Instructions
Page 6 MB-T48-02
T-48 AC / ET 3000
1) Headlight Switch
The headlight switch is located on the top left of the
instrument panel. Push the right side of the switch to
turn the lights on. Push the left side of the switch to
turn the light off.
2) Wiper Switch (Optional)
The wiper switch is located on the left side of the
instrument panel and to the right of the headlight
switch. Push the top of the switch to turn on the wiper.
Push the bottom of switch to turn off the wiper. The
wiper can be turned on with the key switch in the
“OFF” position.
3) Strobe Switch (Optional)
The strobe switch is located on the left side of the
instrument panel and to the right of the wiper switch.
Push the top of the switch to turn on the strobe. Push
the bottom of switch to turn off the strobe. The strobe
can be turned on with the key switch in the “OFF”
position.
4) Forward-Off-Reverse Switch
The forward-off-reverse switch, located on the right
side of the instrument 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 from forward to reverse or vice-
versa while the vehicle is in motion. Make sure the
vehicle is completely stopped before shifting.
Theforward-off-reverse switchshouldbeinthe 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 on the lower left of
the instrument panel. Toggle the switch lever up
for normal speed. Toggle the switch lever down for
slow speed.
6) Combination Display
Refer to details later in this chapter.
7) Horn Switch
The horn switch is located on the right side of the
instrument panel. Depress the switch to sound the
horn, release it to turn it off.
8) Key-Switch
A key-switch, located on the right center side of
the instrument panel, turns on the vehicle. Rotate
the key clockwise to turn the vehicle power on,
counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position
whenever the operator leaves the vehicle.
This switch is also designed to secure and disable
the vehicle. The key can only be removed when the
key-switch is in the “OFF” position.
9) Emergency Stop Switch
The emergency stop switch will immediately and
abruptly stop the vehicle.
TheEmergencyStopSwitchwillstop the vehicle but
will still allow some functions to work such as the
parking brake bypass switch.
Dash Starting Serial #180000
WARNING
Do not depress the Emergency Disconnect Switch while the vehicle is in motion unless the vehicle must
be stopped in an emergency. Depressing the switch will immediately apply the park brake, stopping
the vehicle. The abrupt stopping of the vehicle may result in severe bodily injury.