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Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation Manual - Signet

Other manuals for B0-T48-48 Taylor Truck T48: Operation, T Roubleshooting And Replacement Parts Manual
Manual is about: Electric

Summary of B0-T48-48 Taylor Truck T48

  • Page 1

    T h e b e s t w a y to go a b o u t your b u s i n e s s ® 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

  • Page 3

    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 t...

  • Page 5: Table of Contents

    Table of contents introduction operator and maintenance manual introduction ................................................................. Ii how to use this manual ....................................................... Iii who should read this manual ...............................................

  • Page 6

    Section 3 maintenance and service procedures maintenance guidelines ............................................. 2 severe duty guidelines ............................................... 3 periodic maintenance checklist ................................. 4 lubrication chart .............................

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    Section 4 electrical and charger troubleshooting sevcon controller troubleshooting ........................... 2 voltage reference table ........................................... 25 led status chart ........................................................ 26 lestronic ii charger troubleshooting .....

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    Motor ........................................................................... 22 automatic electric brake ............................................ 24 instrument panel and components........................... 26 resetting the smart view display ............................. 27 control panel ...

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    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 p...

  • Page 11: Introduction

    Introduction operator and maintenance manual.

  • Page 12: Mb-T48-01

    Introduction page ii mb-t48-01 introduction 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. Pleas...

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    Introduction page iii mb-t48-01 how to use this manual this manual is organized into five main sections: section 1: vehicle description and specification this section describes the vehicle and operation of this particular vehicle, as well as the responsibilities of the operator. Section 2: safety ru...

  • Page 14: Mb-T48-01

    Introduction page iv mb-t48-01 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 th...

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    Introduction page v mb-t48-01 an unshaded box with no symbols next to it will contain infromation for completing tests. Conventions symbols and/or words that are used to define warnings, cautions, instructions, or notes found throughout this manual: a shaded box with the word “warning” on its left d...

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    Introduction page vi mb-t48-01.

  • Page 17: Section 1

    Section 1 vehicle description and specifications.

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    Section 1 page 2 mb-t48-01 vehicle description this vehicle is designed for driving on smooth surfaces in and around industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. It is not intended for use on public highways. Figure 1 figure 2 this manual applies to the models ...

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    Section 1 page 3 mb-t48-01 standard specifications item specification occupancy 2 passenger dimension taylor truck 318l x 127w x 119h centimeters 125l x 50w x 47h inches et 3000 325l x 127w x 191h centimeters 128l x 50w x 75h inches turning radius 368 centimeters 145 inches dry weight taylor truck 6...

  • Page 20: Mb-T48-01

    Section 1 page 4 mb-t48-01 taking delivery of the vehicle inspect the vehicle immediately after delivery. Use the following guidelines to locate obvious problems: • examine the contents of all packages and accessories that may have come in separate packages with the vehicle. • make sure everything l...

  • Page 21: Mb-T48-01

    Section 1 page 5 mb-t48-01 check the operation of each of the following controls: • accelerator • brake • parking brake • key-switch • forward/reverse switch with reverse beeper • front headlight switch • steering wheel • horn.

  • Page 22: Mb-T48-01

    Section 1 page 6 mb-t48-01 if there is a problem with the vehicle, do not operate the vehicle, file a claim with a local taylor-dunn distributor. The claim must be filed within 48 hours of receiving the vehicle and its accessories. The only personnel authorized to repair, modify, or adjust any part ...

  • Page 23: Section 2

    Section 2 safety rules and operational information.

  • Page 24: Mb-T48-01

    Section 2 page 2 mb-t48-01 safety rules and guidelines i t is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle and the following safety rules and guidelines (extracted from the american national...

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    Section 2 page 3 mb-t48-01 before driving this vehicle, please observe the following safety rules and guidelines: • only qualified and trained operators shall drive this vehicle. • drive only on level surfaces or on surfaces having an incline of less than 10% (5.6 degrees). • drive slowly when makin...

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    Section 2 page 4 mb-t48-01 driver training program the owner of this vehicle should conduct an operator training program for all those who will be operating this vehicle. The training program should not be condensed for those claiming to have previous vehicle operation experience. Successful complet...

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    Section 2 page 5 mb-t48-01 driver qualifications 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 un...

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    Section 2 page 6 mb-t48-01 vehicle controls key-switch a key-switch, located on the right 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...

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    Section 2 page 7 mb-t48-01 steering the steering wheel and steering system is similar to an automobile. To turn right, turn the steering wheel towards the right. To turn left, turn the steering wheel towards the left. Foot brake pedal the foot brake pedal, located to the right of the steering column...

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    Section 2 page 8 mb-t48-01 seat interlock switch a switch located under the driver's seat disables the power to the vehicle when the driver leaves the seat. The driver must be seated for the vehicle to operate. Whenever the driver leaves the seat, they should turn the key-switch off, place the forwa...

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    Section 2 page 9 mb-t48-01 battery status indicator the battery status indicator is located to the left of the hour meter. The battery status indicator has a led bar graph that indicates the relative state of charge of the battery. The top led will light only when connected to a fully charged batter...

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    Section 2 page 10 mb-t48-01 key hours icon smart view display the smart view display (svd) functions as a battery status indicator (bsi), hour meter (hm), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is listed below. Bsi: a...

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    Section 2 page 11 mb-t48-01 run time hours: after the initial 5-seconds, the run time hours will be displayed as indicated by the run time hours indicator located at the left of the display. The icon represents a motor symbol with a “t” in the center. Run time hours icon fault code description corre...

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    Section 2 page 12 mb-t48-01 maintenance monitor: operation: the smd notifies the operator 10-hours (standard) before a scheduled maintenance is due. During this warning period, the meter will continue to alert the operator. This should allow sufficient time for the operator to schedule the maintenan...

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    Section 2 page 13 mb-t48-01 vehicle operational guidelines driving • slow and sound the horn to warn pedestrians or when approaching a corner or other blind intersection. • no reckless driving. • do not drive this vehicle on steep inclines or where forbidden. • immediately report any accident or veh...

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    Section 2 page 14 mb-t48-01 storing and returning to service • clean batteries, fill, and charge before putting the vehicle in stor- age. Do not store batteries in a discharged condition. • lube all grease fittings. • clean, dry, and check all exposed electrical connections. • inflate tires to prope...

  • Page 37: Section 3

    Section 3 maintenance and service procedures.

  • Page 38: Mb-T48-01

    Section 3 page 2 mb-t48-01 maintenance guidelines allow only qualified and authorized personnel to maintain, repair, adjust, or inspect the vehicle. •before starting any repairs or maintenance, immobilize the vehicle. •turn the key switch “off” and remove the key. •set the park brake. •place the for...

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    Section 3 page 3 mb-t48-01 • ventilate the work area properly. • brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices should be regularly inspected and maintained. • inspect and maintain battery limit switches, protecti...

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    Section 3 page 4 mb-t48-01 periodic maintenance checklist maintenance item weekly monthly quarterly semi- annually (20 hrs) (80 hrs) (250 hrs) annually (1000 hrs) (500 hrs) check condition of tires x check & fill batteries x check brake system x check steering system x check for oil leaks x lubricat...

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    Section 3 page 5 mb-t48-01 lubrication # description locations lubricant type 1 steering ball joints 4 general purpose grease 2 prake pedal linkage 3 general purpose grease 3 front wheel bearings 2 general purpose grease 4 k ing pin 2 general purpose grease 7 drive drain plug - - 8/9 drive fill/leve...

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    Section 3 page 6 mb-t48-01 troubleshooting guide symptom probable cause steering pulls in one direction front end out of alignment low tire pressure hard steering dry lube points in steering linkage damaged king pin/ball joint low tire pressure excessive steering play worn ball joints mis-adjusted o...

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    Section 3 page 7 mb-t48-01 hydraulic disc brakes.

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    Section 3 page 8 mb-t48-01 note: the front brake rotors are an integral part of the hubs. If the rotors are damaged or worn, the hub must be replaced. Be sure to always use dot 3 brake fluid from a sealed container. Be prepared to dispose of any and all used brake fluid. Do not attempt to reuse any ...

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    Section 3 page 9 mb-t48-01 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 serious bodily injury. Brake pad replacement 6. Raise the rear of the vehicle and suppo...

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    Section 3 page 10 mb-t48-01 repairing the brake body 6. Raise the rear of the vehicle and support with jack stands. 7. Disconnect the brake lines attached to the brake body. 8. Remove the two 1/4” brake body bolts. 9. Remove all of the brake accessories (brake pads, bushings, etc.). Always use a lif...

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    Section 3 page 11 mb-t48-01 10. Remove the brake body. 11. Carefully remove the rubber boots, two pistons, and o-rings. Note : the pistons are very brittle and break easily. 12. Clean and dry the brake body completely. Note : inspect the interior of the brake body. (if any damage or wear is found, i...

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    Section 3 page 12 mb-t48-01 bleeding the brakes note : start this procedure at the wheel/brake body furthest from the master cylinder, then work toward the wheel/brake body closest to the master cylinder. 6. Add dot 3 brake fluid to the master cylinder. Fill the fluid to 1/4” from the top of the cha...

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    Section 3 page 13 mb-t48-01 9. With a drip pan under the hydraulic brake body, loosen the bleeder valve on the hydraulic brake body about 3/4 of a turn. 10. Depress the foot pedal to the floor while tightening the bleeder valve. 11. Slowly release the foot pedal, allowing it to return to its release...

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    Section 3 page 14 mb-t48-01 replacing the master cylinder 6. Raise the front of the vehicle and support with jack stands. 7. Remove the cap from the master cylinder and bleed or drain out all of the brake fluid. Note: the master cylinder has no internal replacement parts. 8. Remove the brake lines. ...

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    Section 3 page 15 mb-t48-01 filling and checking the fluid level 6. Clean the cover and exterior of the master cylinder and the surrounding area. 7. Remove the cap from the top of the master cylinder and visually check the level of fluid. 8. Add dot 3 brake fluid as needed, fill level 1/4” from the ...

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    Section 3 page 16 mb-t48-01 parking brake.

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    Section 3 page 17 mb-t48-01 park brake adjustment 6. Loosen the jam nut at the clevis on the threaded rod. 7. Remove one of the clevis pins and rotate the clevis so that when reconnected, the park brake lever engages the ratchet lock on the third to fifth tooth. Note: before pulling up on the park b...

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    Section 3 page 18 mb-t48-01 front axle and yokes.

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    Section 3 page 19 mb-t48-01 front axle removal and installation 6. Raise the front of the vehicle and support with jack stands. 7. Remove both front wheels. 8. Remove the drag link from the steering yoke. 9. Remove the front brake hoses (if equipped, with front brakes). 10. Remove the bolts holding ...

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    Section 3 page 20 mb-t48-01 adjusting the toe-in 6. Raise the front of the vehicle and support with jack stands. 7. With a piece of chalk, mark a line around the center of both tires. 8. Loosen the ball joint clamps at each end of the tie rod so the adjusting sleeve can be turned. 9. With the wheels...

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    Section 3 page 21 mb-t48-01 centering the steering gear 6. Raise the front of the vehicle and support with jack stands. 6. Using the appropriate tool, remove the pitman arm from the steering gear. Note: secure the pitman arm and drag link so they do not hang. 7. Turn the steering gear all the way to...

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    Section 3 page 22 mb-t48-01 repairing the front axle steering yoke/bushings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the wheel. 8. Remove the hydraulic brake body. 9. Remove the drag link and/or tie rod from the yoke. Always use a lifting strap, hoist, and jack stand...

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    Section 3 page 23 mb-t48-01 10. While supporting the yoke, remove the nylock nut, washers, and rubber washer. 11. Remove the yoke from the axle. 12. Clean and/or replace all bearings, nuts, washers, and bushings. Note : both the left and right side bushings should be replaced as a set. 13. Tighten t...

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    Section 3 page 24 mb-t48-01 ball joints, tie rods, and drag links it is recommended to replace the left and right side ball joints as a set. 6. Raise the front of the vehicle and support with jack stands. 7. Loosen the ball joint clamp. Note : remember its position on the sleeve. 8. Remove the ball ...

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    Section 3 page 25 mb-t48-01 front wheel bearings 6. Raise the front of the vehicle and support with jack stands. 7. Remove the tire/wheel assembly. 8. Remove the dust cap, cotter pin, and spindle nut. Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the ve...

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    Section 3 page 26 mb-t48-01 9. Remove the hub from the axle yoke. Note : for a front disc brake option remove the brake body before removing the hub. Note : catch the outer bearing as it falls out. 10. Clean all grease from the inside of the hub and bearings. 11. Inspect and replace the races and be...

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    Section 3 page 27 mb-t48-01 removal and installation of the steering gear assembly 6. Raise the front of the vehicle and support with jack stands. 7. Disconnect the drag link from the pitman arm. 8. Remove the steering gear cover. 9. Remove the steering wheel. 10. Remove the pinch bolt. 11. Remove t...

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    Section 3 page 28 mb-t48-01 11. Reinstall the steering gear by performing this procedure in reverse order. 12. Using the appropriate procedure, center the steering gear. 13. Check the front wheels to be sure that they are straight and realign as necessary. 14. Lower the vehicle. 15. Reconnect the ma...

  • Page 65: Mb-T48-01

    Section 3 page 29 mb-t48-01 steering gear adjustment input shaft endplay 6. Raise the front of the vehicle and support with jack stands. 7. Using the appropriate proceedure center the steering gear before proceeding. 8. Loosen the worm bearing adjuster locknut. 9. Tighten the worm bearing adjuster s...

  • Page 66: Mb-T48-01

    Section 3 page 30 mb-t48-01 gear lash 6. Raise the front of the vehicle and support with jack stands. 7. Using the appropriate proceedure center the steering gear before proceeding. 8. Remove the drag link from the pitman arm. 9. Loosen the jam nut from the gear lash adjuster. 10. To adjust the gear...

  • Page 67: Mb-T48-01

    Section 3 page 31 mb-t48-01 repair the steering gear disassembly note: the steering gear must be removed from the vehicle for this procedure. Refer to replace the steering gear section for information regarding removing the steering gear. Note: the steering gear is packed with grease. Only perform m...

  • Page 68: Mb-T48-01

    Section 3 page 32 mb-t48-01 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing. 8. The ball nut assembly consists of two sets of ball bearings...

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    Section 3 page 33 mb-t48-01 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough to remove all play in ...

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    Section 3 page 34 mb-t48-01.

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    Section 3 page 35 mb-t48-01 drive service.

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    Section 3 page 36 mb-t48-01 removing the rear axles this procedure does not require that the rear end or drive assembly be removed from the vehicle. 6. Drain the oil. 7. Raise the rear of the vehicle and support with jack stands. 8. Release the park brake. 9. Remove the tire and wheel assembly. 10. ...

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    Section 3 page 37 mb-t48-01 removing the rear axles (continued) 16. Use new bolts for the axle retaining plate. 17. Add oil, to the level of the fill plug threads. 18. Lower the vehicle. 19. Set the park brake. 20. Reconnect the main positive and negative cables at the batteries. 21. Remove the bloc...

  • Page 74: Mb-T48-01

    Section 3 page 38 mb-t48-01 removing and installing the drive from the vehicle 6. Drain the oil from the front gear case and the differential into an appropriate receptacle. 7. Release the park brake. Remove the clevis pin and cable lock from the park brake arm. Remove the park brake cable assembly ...

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    Section 3 page 39 mb-t48-01 disassembling and reassembling of the primary reduction gear case 6. Raise the rear of the vehicle and support with jack stands. 7. Drain the oil from the front gear case into an appropriate receptacle. 8. If constrained by space remove the drive assembly from the vehicle...

  • Page 76: Mb-T48-01

    Section 3 page 40 mb-t48-01 9. Remove the cover retaining bolts. 10. Remove the cover plate from the differential and let the remaining oil drain from the housing. 11. Remove the circlip from the idler gear. 12. Remove the input shaft/bearing assembly and idler gear/bearing assembly at the same time...

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    Section 3 page 41 mb-t48-01 14. Remove the output gear. Note: remove the input shaft seal if required. 15. Remove the six retaining bolts holding the gear case to the 3rd member housing. Note: make note of the angle of the gear case. 16. Remove the gear case housing from the 3rd member housing. 17. ...

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    Section 3 page 42 mb-t48-01 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 serious bodily injury. Disassembling the 3rd member 6. Raise the rear of the vehicle a...

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    Section 3 page 43 mb-t48-01 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race. 15. Remove the differential assembly. 16. Remove the carrier bearing adjusting nut roll pin from the 3rd member h...

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    Section 3 page 44 mb-t48-01 17. Remove the carrier bearing race. 18. Remove the front 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 input shaft. 21. Remove the front and rear pini...

  • Page 81: Mb-T48-01

    Section 3 page 45 mb-t48-01 assembling the 3rd member 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. 3. Install the carrier bearing races into the housing and cover. 4. Place the differential assembly into the hou...

  • Page 82: Mb-T48-01

    Section 3 page 46 mb-t48-01 7. Remove the pinion gear. 8. Reinstall the differential assembly. 9. Install the cover onto the housing using 4-bolts in a cross pattern and torque to 45-50 ft-lbs. 10. Pre set the carrier bearing preload by tightening thehousing carrier bearing race ring nut until it re...

  • Page 83: Mb-T48-01

    Section 3 page 47 mb-t48-01 15. Install the cover and all of the cover bolts. 16. Check the gear lash between the ring and pinion gears. The gear lash should be .005 to .007 inches. 17. Adjust the gear lash if needed by tightening or loosening the carrier bearing race ring nuts. Note: to move the ri...

  • Page 84: Mb-T48-01

    Section 3 page 48 mb-t48-01 pinion gear shimming instructions note : this is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. Note : all parts must be clean and the bearings lightly lubricated. Pinion gear depth and selecting the pinion shim c - ...

  • Page 85: Mb-T48-01

    Section 3 page 49 mb-t48-01 once a shim has been selected and the pinion gear is installed, confirm: e - d = b + (d v ) pinion bearing preload 1. The pinion gear depth must be set before the preload. 2. Install the pinion gear, spacer, and shims into the housing. 3. Install the outer pinion bearing....

  • Page 86: Mb-T48-01

    Section 3 page 50 mb-t48-01 changing the differential oil 6. Raise the rear of the vehicle and support with jack stands. 7. Place a drain pan under the center of the drive assembly that is capable of holding 2 quarts of oil. 8. Remove the differential drain plug from the differential case and let th...

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    Section 3 page 51 mb-t48-01 speed controller.

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    Section 3 page 52 mb-t48-01 removing and installing speed controller 6. If equipped, remove the electronics splash cover. 7. Disconnect the power, motor, and controller wiring harnesses. Note: label the wires connected to the harness to insure they are returned to their proper location during reasse...

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    Section 3 page 53 mb-t48-01 drive motor.

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    Section 3 page 54 mb-t48-01 motor removal it is not necessary to remove the drive assembly to perform this procedure in most cases. However, if the vehicle is equipped with an optional cargo box, it may be necessary to lower the drive assembly in order to access the motor. 6. Remove the wires from t...

  • Page 91: Mb-T48-01

    Section 3 page 55 mb-t48-01 automatic electric brake removal and installation in the event, a vehicle equipped with, an automatic electric brake unit becomes immobile. Tow the vehicle with the rear axle hoisted and secured in the air to the maintenance facility were an authorized technician can begi...

  • Page 92: Mb-T48-01

    Section 3 page 56 mb-t48-01 automatic electric brake removal and installation ( continued ) 8. Slide the automatic electric brake off the drive input shaft. 9. Repair or replace components as necessary. 10. Install the new motor or reassemble in reverse order. Note : apply a small amount of grease t...

  • Page 93: Mb-T48-01

    Section 3 page 57 mb-t48-01 motor disassembly and assembly 6. Using the appropriate proceedure remove the motor from the drive. 7. Remove the dust cap and headband assembly from the commutator endcap. 8. Pull the brushes out of the brush holder. 9. Using an arbor press, press the armature shaft out ...

  • Page 94: Mb-T48-01

    Section 3 page 58 mb-t48-01 15. Remove the nuts from the a1 and a2 terminals and the brush holder retaining screws, then remove the brush holder assembly from the commutator end cap. Note: be sure to remember the position of the cross over wires. 16 . Repair or replace components as necessary. Note:...

  • Page 95: Mb-T48-01

    Section 3 page 59 mb-t48-01 visual inspection of the brushes 6. Remove the motor wires and headband assembly. Note: the brushes must be replaced if any damage is apparent. Replace the brushes when the top of the brush is even with the top of brush holder. 7. Using the appropriate proceedure remove t...

  • Page 96: Mb-T48-01

    Section 3 page 60 mb-t48-01 insulation commutator incorrect hacksaw blade correct 2.75 min. Od armature 0.025 11. Measure the undercut depth on the commutator. See undercut figure below. Note : the undercut depth is .025 inches. If the undercut depth is less then .025 inches, the mica can be recut t...

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    Section 3 page 61 mb-t48-01 battery.

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    Section 3 page 62 mb-t48-01 cleaning 6. Dry dirt can be readily blown off with low-pressure air or brushed off. 7. Wetness or wet dirt on the batteries indicates battery acid. Using a nonmetallic brush with flexible bristles, wash it off with a strong solution of baking soda and hot water (1 lb. Of ...

  • Page 99: Mb-T48-01

    Section 3 page 63 mb-t48-01 electrolyte alarm (optional) 6. If the electrolyte warning alarm is sounding or the led light is red, then the batteries need servicing. 7. Using the appropriate procedure, service and charge all the batteries. 8. Take the electrolyte alarm unit out of the battery cell, w...

  • Page 100: Mb-T48-01

    Section 3 page 64 mb-t48-01 servicing 6. Clean the batteries. 7. Check the electrolyte level in all batteries. If low, fill with distilled water up to the correct level. Use 77-201-00 battery filler. 8. Clean the cell posts connectors and battery box with water. 9. If equipped, with a electrolyte al...

  • Page 101: Mb-T48-01

    Section 3 page 65 mb-t48-01 explosive mixtures of hydrogen gas are present within 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 present. Always pro...

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    Section 3 page 66 mb-t48-01.

  • Page 103

    Sevcon control system troubleshooting this troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results. Table of contents test equipment...

  • Page 104

    Electrical troubleshooting section 4 page 2 test equipment required: • digital multimeter (dmm) with diode test function, fluke 79 model shown. • test harness, taylor-dunn #75-089-00 important notes and instructions • this troubleshooting guide assumes a familiarity with the use of a digital multime...

  • Page 105

    Electrical troubleshooting section 4 page 3 start troubleshooting here this troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results....

  • Page 106

    Electrical troubleshooting section 4 page 4 test 1. Checking the control logic inputs close the seat switch. Place the high/low switch in the high position. Connect a voltmeter across the iso solenoid coil terminals and carefully monitor the voltage as the key switch is turned on. Turn the key switc...

  • Page 107

    Electrical troubleshooting section 4 page 5 test 1.3: test the voltage at pin #6 on the 12-pin logic card connector. If the voltage is low, then skip ahead to test #1.4. If the voltage is high, then check the wire to the high/low switch and the high/low switch for open circuits. Note: the high/low s...

  • Page 108

    Electrical troubleshooting section 4 page 6 test 1.5: test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to test #1.6. If the voltage is low, then skip ahead to test #6. Test 1.6: test the voltage at pin #7 on the 12-pin logic card connector. Note:...

  • Page 109

    Electrical troubleshooting section 4 page 7 test 1.7: depress the accelerator pedal to engage fs-1 only (creep speed). Perform the following tests: test the voltage at pin #10 on the 12-pin logic card connector. If the voltage is below 0.3 volts, then skip ahead to test #1.8. If the voltage is above...

  • Page 110

    Electrical troubleshooting section 4 page 8 test 2. Testing the motor test 2.1: check the motor field resistance from the motor f1 to the motor f2 terminals. If the resistance is within the values given in the motor specification table, then skip ahead to test #2.2. (the motor specification can be f...

  • Page 111

    Electrical troubleshooting section 4 page 9 test 2.3: test the continuity from the motor a1 terminal to the frame on the motor and from f1 to a1 for open circuits. Any reading other than an open circuit indicate a short in the motor. If there is a short in the motor, stop here and repair or replace ...

  • Page 112

    Electrical troubleshooting section 4 page 10 test 3. The vehicle runs in one direction only test 3.1: close the seat switch, turn the key switch on and wait 1-second until the isolator contactor closes. If the vehicle runs in reverse only then skip ahead to test #3.3. Place the forward and reverse s...

  • Page 113

    Electrical troubleshooting section 4 page 11 test 3.3: place the forward and reverse switch in the reverse direction. Test the voltage at pin #3 on the 12 pin logic card connector. If the voltage is low, then skip ahead to test #3.4. If the voltage is high, then skip ahead to test #7. Test 3.4: test...

  • Page 114

    Electrical troubleshooting section 4 page 12 test 3.5 disconnect the batteries and remove wires from the b-, f1, and f2 terminals on the controller. Using the diode test function on your meter, connect the positive lead to the b- terminal on the controller. Connect the negative lead to the f1 termin...

  • Page 115

    Electrical troubleshooting section 4 page 13 test 4. Key fault test 4.1: turn the key switch on and place the forward and reverse switch in the center off position perform the following tests: test the voltage at pin #1 on the 12 pin logic card connector. If the voltage equals battery volts, then sk...

  • Page 116

    Electrical troubleshooting section 4 page 14 test 4.3: test the voltage at the cold side (violet/black wire) of the key switch. If the voltage equals battery volts, then skip ahead to test #4.4. If the voltage does not equal battery volts, then replace the key switch. Stop trouble shooting here and ...

  • Page 117

    Electrical troubleshooting section 4 page 15 test 5. Contactor coil fault disconnect the 12-pin logic card connector from the sevcon power unit. Turn the key switch on and perform the following tests: test 5.1: check the voltage on the positive coil terminal of the iso solenoid (violet wire). If the...

  • Page 118

    Electrical troubleshooting section 4 page 16 stop stop, do not continue. Reaching this point indicates a failure in the sevcon power unit or an error was made during testing. Confirm all previous tests were performed correctly before replacing the sevcon power unit. After any repairs are made, compl...

  • Page 119

    Electrical troubleshooting section 4 page 17 test 6. Accelerator module fault disconnect the truck harness from the accelerator module. Connect the plug on the short end of the 75-089-00 test harness to the accelerator module. Connect the receptacle on the short end of the test harness to the vehicl...

  • Page 120

    Electrical troubleshooting section 4 page 18 test 6.4: accelerator pedal released. Test the voltage from pin #9 to pin #1. If the voltage is below 0.3 volts, then skip ahead to test #6.5. If the voltage is above 0.3 volts, then the module has failed and must be replaced. Stop trouble shooting here a...

  • Page 121

    Electrical troubleshooting section 4 page 19 test 6.7: if the test at pin #4 on the 12-pin logic card connector failed, but the test at pin #5 at the accelerator module was good (#6.5), then check the wire from pin #5 (module) to pin #4 (logic card). If the test at pin #10 on the 12-pin logic card c...

  • Page 122

    Electrical troubleshooting section 4 page 20 test 7. Forward and reverse switch fault turn the key switch on, place the forward and reverse switch in the center off position and perform the following tests: test 7.1: referencing battery positive, test the voltage on the center terminal of the f&r sw...

  • Page 123

    Electrical troubleshooting section 4 page 21 stop stop, do not continue. Reaching this point indicates a failure in the sevcon power unit or an error was made during testing. Confirm all previous tests were performed correctly before replacing the sevcon power unit. Test 7.3: if the vehicle does not...

  • Page 124

    Electrical troubleshooting section 4 page 22 test 8. Anti-rolloff fault the sevcon controller is equipped with a feature called anti-rolloff. Anti-rolloff will automatically slow the vehicle if it starts to roll. Anti-rolloff is active when the key switch has been left in the “on” position and the a...

  • Page 125

    Electrical troubleshooting section 4 page 23 test 9. Electric motor brake description: the electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what times the brake ...

  • Page 126

    Electrical troubleshooting section 4 page 24 connect a volt meter from battery negative to the violet/black wire at the electric brake harness plug. If the voltage is less than battery volts then: • check wiring to the key switch and continue troubleshooting at test #4.2. If the voltage equals batte...

  • Page 127

    Electrical troubleshooting section 4 page 25 pin# condition volts* 1 key switch off 0.0 volts key switch on battery volts 2 f&r in forward low f&r in neutral high f&r in reverse 3 f&r in reverse low f&r in neutral high f&r in forward 4 accelerator pedal up high accelerator pedal down low 5 seat swit...

  • Page 128

    Electrical troubleshooting section 4 page 26 status led code table the status led on the sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component. Led status light n...

  • Page 129: Lestronic II

    Table of contents lestronic ii ® charger troubleshooting operating instructions and theory of operation .........................2 testing the charging cycle ....................3 test equipment required for troubleshooting ..............................4 important notes and instructions -----------...

  • Page 130

    Electrical troubleshooting charger troubleshooting page 2 operating instructions and theory of operation the lestronic ii ® chargers are designed as semiautomatic chargers. The lestronic ii ® charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable”...

  • Page 131: Testing The Charging Cycle

    Electrical troubleshooting charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: • the...

  • Page 132

    Electrical troubleshooting charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm) with diode and capacitor test function, fluke 79 ® model shown at right and in the troubleshooting illustrations. Important notes and instructions • this troubleshooting gu...

  • Page 133

    Electrical troubleshooting charger troubleshooting page 5 troubleshooting for built-in charger 5. Disconnect the charger from the ac source. Locate the charger harness connectors where the charger harness is connected to the vehicle’s control harness. There will be two 10 gauge and two 14 gauge wire...

  • Page 134

    Electrical troubleshooting charger troubleshooting page 6 • disconnect the charger from the ac source. • disconnect the batteries. • disconnect the charger from the vehicle’s harness. • remove the charger from the vehicle. Remove the charger cover and perform the following tests: 1. Inspect the inte...

  • Page 135

    Electrical troubleshooting charger troubleshooting page 7 • test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad. Sto...

  • Page 136

    Electrical troubleshooting charger troubleshooting page 8 troubleshooting for portable charger disconnect the charger from the ac outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles dc receptacle to main battery negative. This voltage should be equal to the batte...

  • Page 137: Testing The Timer Relay

    Electrical troubleshooting charger troubleshooting page 9 5. Reconnect the lead to the diode. 6. Connect the charger to the ac source. Insert the dc charger plug into the dc receptacle and perform the following tests: • test the voltage from the fuse assembly (-) to the diode block (+). This voltage...

  • Page 138: Testing The Interlock Relay

    Electrical troubleshooting charger troubleshooting page 10 testing the interlock relay operation the interlock relay disables the vehicle from running whenever the charger is connected to a working ac power source. When the charger is plugged in, the relay contacts open and break the key switch conn...

  • Page 139: Signet

    Table of contents signet ® charger troubleshooting operating instructions and theory of operation ........................................2 testing the charging cycle ....................3 test equipment required for troubleshooting ...............................4 important notes and instructions 4...

  • Page 140

    Electrical troubleshooting charger troubleshooting page 2 operating instructions and theory of operation the model hb600w ® and hb1000w ® chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully ch...

  • Page 141: Testing The Charging Cycle

    Electrical troubleshooting charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 14 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 14 hours if: • the...

  • Page 142

    Electrical troubleshooting charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm) with diode and capacitor test function, fluke 79 ® model shown at right and in the troubleshooting illustrations. Clamp on dc ammeter to measure up to 20-amps. Important no...

  • Page 143: Status Led Error Code

    Electrical troubleshooting charger troubleshooting page 5 status led error code there are three status lights (led’s) on the charger name plate. These led’s normally indicate the current operating state of the charger. All three led’s flashing indicate an error in the charger. See the table below fo...

  • Page 144: Troubleshooting

    Electrical troubleshooting charger troubleshooting page 6 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. Troublesho...

  • Page 145: Wire Diagrams

    Table of contents wire diagrams complete vehicle ............................................ 2 dash ................................................................. 3 control panel .................................................. 4 accelerator module detail .............................. 5 light...

  • Page 146: Complete Vehicle

    Wire diagrams wire diagrams page 2 complete vehicle see note1 note 1: battery status indicator used up to year 2005. Smart view display used starting year 2005. The smart view display is wired with a cable to the 6-pin can-buss connector on the logic card. Head lights r. Tail light battery status li...

  • Page 147

    Wire diagrams wire diagrams page 3 diagram inculdes options that may not be installed on your vehicle a1 a2 blue white red 2 16 14 black motion alarm automatic electric brake 10 6 12 7 3 5 8 4 11 1 9 13 white white 4 9 5 10 6 3 2 8 black/white horn violet/black violet/black 1 black black black red p...

  • Page 148: Dash

    Wire diagrams wire diagrams page 4 dash note 1: battery status indicator used up to year 2005. Smart view display used starting year 2005. The smart view display is wired with a cable to the 6-pin can-buss connector on the logic card. Throttle module shown for reference only. There are no internally...

  • Page 149: Lighting

    Wire diagrams wire diagrams page 5 lighting 4 6 red red black/gray white white brown special order accesories may be wired to this terminal l. Turn head lights blue/white red brown 16 key switch switch acc 11 10 brown brown brown switch light red horn button 1 red red 13 red dash panel 9 red brake l...

  • Page 150

    Electrical troubleshooting section 4 page 37.

  • Page 151: Section 5

    Section 5 illustrated parts list common front axle assembly ................................... 5-2 steering sleeve assembly ......................... 5-4 front suspension ...................................... 5-6 drag link .................................................. 5-8 steering gear .........

  • Page 152: Mb-T48-01

    Section 5 page 2 mb-t48-01 front axle assembly 11 17 15 16 18 12 12 14 13 13 2 1 3 10 9 8 7 6 5 4 19 bushings (#8 and #9) must be broached or reamed to a final diameter of 1.25” +/- 0.001” after pressing into the axle..

  • Page 153: Mb-T48-01

    Section 5 page 3 mb-t48-01 front axle assembly 15-049-15 item # part # description qty 1 15-210-70 front axle weldment 1 2 21-020-17 steering yoke, left 1 3 21-020-18 steering yoke, right 1 4 88-239-86 lock nut 3/4" n/c 2 5 88-228-60 washer 3/4" 2 6 98-603-07 washer, rubber 2 7 01-220-99 washer, 1.2...

  • Page 154: Mb-T48-01

    Section 5 page 4 mb-t48-01 1 2 3 4 steering sleeve assembly 5 1 5.

  • Page 155: Mb-T48-01

    Section 5 page 5 mb-t48-01 s t e e r i n g s l e e v e a s s e m b l y 1 8 - 0 5 7 - 0 0 item # part # description qty 1 86-501-98 ball joint, f1 & p2, le ft w /zerk fitting 1 86-501-99 ball joint, f1 & p2, right w /zerk fitting 1 2 88-159-85 1/2-20 nf slotted hex nut 2 3 86-510-00 ball joint clamp ...

  • Page 156: Mb-T48-01

    Section 5 page 6 mb-t48-01 front suspension 1 5 6 3 4 2 5.

  • Page 157: Mb-T48-01

    Section 5 page 7 mb-t48-01 front suspension item # part # description qty 1 96-103-00 u-bolt length 3-1/2" 4 2 85-498-00 85-486-00 leaf spring taylor truck leaf spring et 3000 2 2 3 32-214-50 spring bushing 12 4 96-240-00 shackle bolt 6 5 88-149-81 1/2 nc lock nut 14 6 16-872-00 spring shackle 4.

  • Page 158: Mb-T48-01

    Section 5 page 8 mb-t48-01 1 2 3 4 drag link 2 5 1 5.

  • Page 159: Mb-T48-01

    Section 5 page 9 mb-t48-01 drag link 18-037-10 item # part # description qty 1 88-159-85 castle nut 2 2 86-501-98 ball joint w/grease fitting, left 1 86-501-99 ball joint w/grease fitting, right 1 3 86-510-00 ball joint clamp 2 4 18-037-00 drag link 1 5 88-527-11 1/8 x 1 steel cotter pin 2.

  • Page 160: Mb-T48-01

    Section 5 page 10 mb-t48-01 steering gear 1 2 3 4 5 6 11 12 13 15 17 16 14 10 9 8 7.

  • Page 161: Mb-T48-01

    Section 5 page 11 mb-t48-01 steering gear 18-308-21 item # part # description qty 1 18-308-70 locknut, worm bearing adjuster 1 2 18-308-71 adjuster assembly 1 3 18-308-72 worm assembly 1 4 18-308-23 upper worm bearing 1 5 18-308-22 upper worm bearing race 1 6 18-308-77 housing, steering gear 1 7 18-...

  • Page 162: Mb-T48-01

    Section 5 page 12 mb-t48-01 steering column assembly 1 2 3 4 5 6 7 9 8 12 10 11 13 14.

  • Page 163: Mb-T48-01

    Section 5 page 13 mb-t48-01 steering column assembly item # part # description qty 1 19-011-25 steering wheel cap 1 2 88-199-82 5/8" nf jam nut 1 3 19-011-20 steering wheel 1 4 32-248-10 steering shaft bearing 1 5 20-031-63 kit, steering shaft w/clamp 1 6 18-308-45 assembly, steering, clamp (include...

  • Page 164: Mb-T48-01

    Section 5 page 14 mb-t48-01 master cylinder, brake line hardware and front brake asssembly.

  • Page 165: Mb-T48-01

    Section 5 page 15 mb-t48-01 m a s t e r c y l i n d e r a n d b r a k e h a r d w a r e i t e m # p a r t # d e s c r i p t i o n q t y 1 9 9 - 6 4 8 - 5 2 b r a k e l i n e f o r m e d , f r o n t , r i g h t 1 2 9 9 - 6 4 8 - 5 1 b r a k e l i n e f o r m e d , f r o n t , l e f t 1 3 9 9 - 5 6 4 ...

  • Page 166: Mb-T48-01

    Section 5 page 16 mb-t48-01 master cylinder 2 3 4 1 5 6 7 8.

  • Page 167: Mb-T48-01

    Section 5 page 17 mb-t48-01 master cylinder 99-511-20 item # part # description qty 1 88-080-14 5/16" x 1-1/2" nc hex bolt 2 2 88-088-61 5/16" washer 4 3 88-089-81 5/16" lock nut 2 4 99-511-20 master cylinder 1 5 99-511-51 rubber boot, master cylinder 1 6 99-511-52 cap seal, master cylinder 1 7 99-5...

  • Page 168: Mb-T48-01

    Section 5 page 18 mb-t48-01 hydraulic disc brakes 12 8 6 5 4 3 2 1 11 13 7 10 9 14 15 16.

  • Page 169: Mb-T48-01

    Section 5 page 19 mb-t48-01 hydraulic disc brakes rear item # part # description qty 1 88-067-21 1/4 x 3-3/4" nc hex bolt gr. 8 4 2 41-350-51 plate, secondary, hydraulic disc 2 3 41-348-70 pad, disc brake 4 4 41-348-52 spacer, disc brake 4 5 32-240-40 bearing teflon r coated 4 6 41-350-28 hydraulic ...

  • Page 170: Mb-T48-01

    Section 5 page 20 mb-t48-01 park brake linkage 9 8 6 11 7 1 2 3 11 10 4 5.

  • Page 171: Mb-T48-01

    Section 5 page 21 mb-t48-01 park brake linkage item # part # description qty 1 88-080-11 5/16 x 1 hex head screw 2 2 88-088-61 5/16 washer 4 3 51-344-80 park brake 1 4 88-089-81 5/16 locknut 2 5 96-813-00 adjusting brake cable assembly 1 6 96-771-00 3/8 x 3/4 clevis pin 1 7 01-204-32 brake equalizer...

  • Page 172: Mb-T48-01

    Section 5 page 22 mb-t48-01 10 9 8 11 7 6 3 2 1 6 4 5 motor.

  • Page 173: Mb-T48-01

    Section 5 page 23 mb-t48-01 motor (70-057-40) motor specification number dv1-4003 item # part # description qty 1 70-421-10 drive end adapter ring 1 2 70-400-10 armature and fan assembly 1 3 70-209-40 frame and field coil assembly 1 4 85-403-00 brush spring 4 5 70-173-00 brush box assembly 1 6 70-17...

  • Page 174: Mb-T48-01

    Section 5 page 24 mb-t48-01 1 2 3 4 5 7 8 9 10 6 11 automatic electric brake component view automatic electric brake.

  • Page 175: Mb-T48-01

    Section 5 page 25 mb-t48-01 automatic electric brake system item # part # description qty 1 88-067-29 bolt,1/4 x 4-1/4" nc, grade 8 3 2 41-355-00 automatic electric brake unit 1 3 motor (typical) 1 4 96-114-10 u-bolt, 5/16" nf, motor support 1 5 70-456-10 motor, support bracket 1 6 88-128-62 lockwas...

  • Page 176: Mb-T48-01

    Section 5 page 26 mb-t48-01 instrument panel and components 1 2 9 4 8 5 6 10 7 3 item #3 smart view display.

  • Page 177: Mb-T48-01

    Section 5 page 27 mb-t48-01 instrument panel item # part # description qty 1 95-913-00 hole plug (not shown) 2 2 71-039-11 switch 1 3 74-009-48 battery status indicator (curtis 900) 1 74-010-00 smart view display 1 4 01-200-09 console 1 5 71-039-02 forward & reverse switch 1 6 71-120-10 key switch 1...

  • Page 178: Mb-T48-01

    Section 5 page 28 mb-t48-01 control panel 1 2 4 5 6 7 3 8.

  • Page 179: Mb-T48-01

    Section 5 page 29 mb-t48-01 c o n t r o l p a n e l a s s e m b l y 6 2 - 0 1 6 - 4 0 item # part # description qty 1 72-501-50 solenoid, spst 24 volt, 220 amp 1 2 62-400-15 pow e rpak controller (see note below) 1 3 79-840-00 circuit breaker, 10 amp 1 4 79-840-20 circuit breaker, 20 amp 2 5 73-005-...

  • Page 180: Mb-T48-01

    Section 5 page 30 mb-t48-01 1 2 4 6 8 electrical components (typical) 10 3 5 9 7 11.

  • Page 181: Mb-T48-01

    Section 5 page 31 mb-t48-01 w i r i n g i t e m # p a r t # d e s c r i p t i o n q t y 1 7 5 - 1 5 2 - 0 3 m a i n w i r i n g h a r n e s s 1 2 7 5 - 1 5 2 - 1 1 p o w e r/m o t o r l e a d s 1 3 7 5 - 1 5 2 - 1 2 c o n tro lle r l i n k w ire s 1 4 6 2 - 0 1 6 - 4 0 c o n tro l p a n e l a s s e ...

  • Page 182: Mb-T48-01

    Section 5 page 32 mb-t48-01 chargers chargers.Dwg 6 8 5 4 3 7 11 1 2 8 3 4 5 10 7 6 2 1 8 9 typical built in charger typical portable charger.

  • Page 183: Mb-T48-01

    Section 5 page 33 mb-t48-01 16920 79 -309 -20 48lc25 -8et 230/50/na 48/25 built -in - s/o 79 -902 -00 79 -749 -13 s/o n/a 79 -831 -00 79 -530 -00 - - - n/a 22620 79 -303 -25 48lc25 -8et 115/60/15 48/25 built -in - 79 -805 -68 79 -902 -00 79 -749 -13 79 -603 -10 - 79 -831 -00 79 -530 -00 - - 79 -809 ...

  • Page 184: Mb-T48-01

    Section 5 page 34 mb-t48-01 note: the harness connectors are not included with the charger. When replacing the charger order 2 each of the following: part # description 75-318-20 butt splice 75-320-51 knife connector signet charger.

  • Page 185: Mb-T48-01

    Section 5 page 35 mb-t48-01 signet® charger item # part # description qty 79-309-40 48v charger assembly (see note on facing page) 1 79-575-60 replacement cover w/ac cord and gasket 1 note: there are no user serviceable components inside the charger ac wire connections on pc board.

  • Page 186: Mb-T48-01

    Section 5 page 36 mb-t48-01 accelerator module 1, 8 2 3 4 5 6 7.

  • Page 187: Mb-T48-01

    Section 5 page 37 mb-t48-01 a c c e l e r a t o r m o d u l e 6 2 - 0 3 3 - 4 8 i t e m # p a r t # d e s c r i p t i o n q t y 1 0 1 - 1 1 0 - 2 0 a c c e l e r a t o r p e d a l 1 2 8 8 - 0 6 5 - 0 8 1 / 4 " x 5 / 8 " t r u s s h e a d s c r e w 2 3 8 8 - 0 6 9 - 8 1 1 / 4 " l o c k n u t 2 4 8 8 ...

  • Page 188: Mb-T48-01

    Section 5 page 38 mb-t48-01 drive 1 2 3 4 5 6 7 8 7 10 21 24 27 26 25 29 15 14 23 18 9 20 22 19 13 11 12 13 17 29 16 15 28 31 9 30 29 32 30 33 35 37 37 38 39.

  • Page 189: Mb-T48-01

    Section 5 page 39 mb-t48-01 drive item # part # description qty 1 gt-71682 flanged screw m8 x 60 12 2 gt-3287563 half housing eccentric side 1 3 gt-71259 ball bearing 1 4 gt-3287513 input shaft - 30 ratio 1 gt-3287523 input shaft - 24 ratio 1 gt-3287533 input shaft - 18 ratio 1 gt-3287543 input shaf...

  • Page 190: Mb-T48-01

    Section 5 page 40 mb-t48-01 drive item # part # description qty 23 gt-3287213 spacer - s=3.90mm 1 gt-3287223 spacer - s=3.95mm 1 gt-3287233 spacer - s=4.00mm 1 gt-3287243 spacer - s=4.05mm 1 gt-3287253 spacer - s=4.10mm 1 gt-3287263 spacer - s=4.15mm 1 gt-3287273 spacer - s=4.20mm 1 gt-3287283 space...

  • Page 191: Mb-T48-01

    Section 5 page 41 mb-t48-01 drive item # part # description qty 24 gt-3287473 output gear - 18 ratio 1 gt-3287483 output gear - 12 ratio 1 25 gt-3287813 spacer - s=46.100mm 1 gt-3289403 spacer - s=46.125mm 1 gt-3289413 spacer - s=46.150mm 1 gt-3289423 spacer - s=46.175mm 1 26 gt-3287853 shim - s=0.6...

  • Page 192: Mb-T48-01

    Section 5 page 42 mb-t48-01 1 2 3 5 6 5 drive assembly forward forward 4 7 8 9 10 11 12 4 13 14 15 16 17 18 left side suspension overload spring bushing.

  • Page 193: Mb-T48-01

    Section 5 page 43 mb-t48-01 drive assembly item # part # description qty. 1 4gt-0151-1033 drive standard (refer to page 36) 1 2 70-057-40 dc motor (refer to page 22) 1 3 96-826-12 park brake cable assembly rear 2 4 85-510-17 leaf springs rear, heavy duty 2 5 99-580-20 brake hose 2 6 88-159-84 1/2 nf...

  • Page 194: Mb-T48-01

    Section 5 page 44 mb-t48-01 rear axle axle shaft inner bearing (no o-ring) outer bearing o-ring o-ring groove inner bearing on optional double bearing axle does not have an oil seal or o-ring. Orientation of bearing should have o-ring groove adjacent to o-ring on outer bearing..

  • Page 195: Mb-T48-01

    Section 5 page 45 mb-t48-01 rear axle item # part # description qty 1 41-154-10* *axle shaft, single bearing (see usage below) 2* 41-154-15* *axle shaft, double bearing (see usage below) 2* 2 80-505-20 bearing 2 2a 80-505-30* *bearing 2* 3 41-490-11 disc brake rotor 2 4 41-172-21 hub 2 5 88-268-63 f...

  • Page 196: Mb-T48-01

    Section 5 page 46 mb-t48-01 1 2 4 3 5 6 decals 7.

  • Page 197: Mb-T48-01

    Section 5 page 47 mb-t48-01 decals item # part # description qty 1 94-319-00 battery disconnect decal 1 2 94-313-00 battery warning decal 1 3 94-373-10 vehicle identification decal 1 4 94-309-00 brake warning decal 1 5 94-313-20 safety warning decal 1 6 94-384-01 not a motor vehicle decal 1 7 94-384...

  • Page 198: Mb-T48-01

    Section 5 page 48 mb-t48-01 hitch options.

  • Page 199: Mb-T48-01

    Section 5 page 49 mb-t48-01 standard parts item # part # description qty hitches 14 97-804-01 hitch, pintle type 1 15 97-808-00 hitch automatic coupling 1 16 88-140-14 bolt, 1/2 nc hex head 4 17 88-148-62 lock washer, 1/2" 4 18 88-149-80 nut, 1/2 nc 4 19 97-805-00 bracket, ball hitch mounting, 1-7/8...

  • Page 200: Mb-T48-01

    Section 5 page 50 mb-t48-01.

  • Page 201: Section 5A

    Section 5a illustrated parts list taylor truck.

  • Page 202: Mb-T48-01

    Section 5a page 2 mb-t48-01 standard parts.

  • Page 203: Mb-T48-01

    Section 5a page 3 mb-t48-01 standard parts item # part # description qty. 1 94-050-10 headlight, left 1 2 94-050-11 headlight, right 1 3 94-201-10 taylor-dunn name plate 1 4 94-201-11 fastner strip, plastic 2 5 88-817-07 screw, #8 self tapping 14 6 94-050-04 retainer, headlight 4 7 90-444-00 deckboa...

  • Page 204: Mb-T48-01

    Section 5a page 4 mb-t48-01 optional parts.

  • Page 205: Mb-T48-01

    Section 5a page 5 mb-t48-01 optional parts table optional parts item # part # description qty directional signals 71-141-61 kit, directional signals, standard cowl and steel cab 1 1 75-141-20 turn signal switch 1 2 76-352-00 flasher receptacle 1 3 71-900-05 flasher, 12v 1 4 72-082-10 turn signal bul...

  • Page 206: Mb-T48-01

    Section 5a page 6 mb-t48-01 optional parts.

  • Page 207: Mb-T48-01

    Section 5a page 7 mb-t48-01 optional parts table item # part # description qty cowl w/windshield 91-013-64 kit, windshield, orange (requires fiberglass or surrey top cover) 1 91-013-65 kit, windshield, specify color (requires fiberglass or surrey top cover) 1 1 91-010-77 cowl w/windshield (unpainted...

  • Page 208: Mb-T48-01

    Section 5a page 8 mb-t48-01 optional parts.

  • Page 209: Mb-T48-01

    Section 5a page 9 mb-t48-01 optional parts table o p t i o n a l p a r t s i t e m # p a r t # d e s c r i p t i o n q t y . S t r o b e l i g h t o n s t e e l c a b 1 7 2 - 0 2 3 - 2 0 s t r o b e , l i g h t , a m b e r 1 2 8 8 - 0 2 5 - 0 6 s c r e w , # 8 - 3 2 x 1 / 2 " t r u s s h e a d 3 3 8...

  • Page 210: Mb-T48-01

    Section 5a page 10 mb-t48-01 top cover option parts.

  • Page 211: Mb-T48-01

    Section 5a page 11 mb-t48-01 top cover option parts table o p t i o n a l p a r t s t a b l e i t e m # p a r t # d e s c r i p t i o n q t y . S u r r e y t o p c o v e r 1 0 0 - 2 4 8 - 3 6 t u b u l a r t o p f r a m e 1 2 0 0 - 2 4 8 - 3 5 p o s t , t o p f r a m e 4 3 8 8 - 1 0 2 - 1 1 b o l t ...

  • Page 212: Mb-T48-01

    Section 5a page 12 mb-t48-01 door options.

  • Page 213: Mb-T48-01

    Section 5a page 13 mb-t48-01 door option parts table o p t i o n a l p a r t s t a b l e i t e m # p a r t # d e s c r i p t i o n q t y . C a b d o o r s n a u g a h y d e 9 0 - 9 2 4 - 6 0 k i t , n a u g a h y d e d o o r , l e f t 1 9 0 - 9 2 4 - 6 1 k i t , n a u g a h y d e d o o r , r i g h t...

  • Page 214: Mb-T48-01

    Section 5a page 14 mb-t48-01 deckboard options.

  • Page 215: Mb-T48-01

    Section 5a page 15 mb-t48-01 deckboard option parts table deck board table item # part # description qty. Deck cover, diamond plate 2 pc., std. Bed 90-440-45 kit, diamond cover, std bed, black (does not include 1 and 2) 1 1 90-444-20 deckboard, 41 x 38-1/2 x 5/8" 1 2 90-444-30 deckboard, 41 x 36-5/8...

  • Page 216: Mb-T48-01

    Section 5a page 16 mb-t48-01 box with doors options.

  • Page 217: Mb-T48-01

    Section 5a page 17 mb-t48-01 box, double doors, side & rear windows item # part # description qty. 91-333-60 kit, box, doors left & rear, w/glass, orange 1 91-333-61 kit, box, doors left & rear, w/glass, specify colors 1 1 91-333-02 box, doors left & rear, glass front & rear (unpainted) 1 2 90-471-0...

  • Page 218: Mb-T48-01

    Section 5a page 18 mb-t48-01 stake side options.

  • Page 219: Mb-T48-01

    Section 5a page 19 mb-t48-01 stake sides table item # part # description qty. 1 90-542-01 end gate, black 1 2 90-540-00 gate hook 2 3 88-065-13 screw, 1/4 nc x 1-1/4" phillips truss head 4 4 88-069-87 nut, 1/4 nc keps 4 5 90-542-05 side gate, left black 1 6 90-542-06 side gate, right black 1 7 90-54...

  • Page 220: Mb-T48-01

    Section 5a page 20 mb-t48-01.

  • Page 221: Section 5B

    Section 5b illustrated parts list et 3000

  • Page 222: Mb-T48-01

    Section 5b page 2 mb-t48-01 1 2 7, 8 3 4 5, 5a 9 11, 12 13, 14 16 10 standard parts 6 18 17 15.

  • Page 223: Mb-T48-01

    Section 5b page 3 mb-t48-01 standard parts et 3000 item # part # description qty 1 91-017-60 et 3000 cab std. 1 2 90-852-50 windshield 1 3 74-015-16 windshield wiper blade 1 4 74-015-15 windshield wiper arm (includes hose) 1 5 74-015-11 windshield wiper, plate support 1 5a 74-015-10 windshield wiper...

  • Page 224: Mb-T48-01

    Section 5b page 4 mb-t48-01 standard parts 3 4 5, 6 1, 2 door latch 9 8 7.

  • Page 225: Mb-T48-01

    Section 5b page 5 mb-t48-01 standard parts item # part # description qty 1 90-854-10 window, door, left, 3 pieces 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, ...

  • Page 226: Mb-T48-01

    Section 5b page 6 mb-t48-01 cab interior standard parts 1, 2 3 4 5 6 7 10 8 9 11 12 13 15 16 14 14.

  • Page 227: Mb-T48-01

    Section 5b page 7 mb-t48-01 cab interior standard parts item # part # description qty 1 71-501-55 horn button 1 2 71-501-56 horn button collar 1 2 75-148-64 harness, horn 6" retractable (not shown) 1 2 75-442-30 plug, molex 1 2 75-442-50 pin, molex 2 3 19-011-20 steering wheel 1 4 00-201-80 dash 1 5...

  • Page 228: Mb-T48-01

    Section 5b page 8 mb-t48-01 standard parts 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.

  • Page 229: Mb-T48-01

    Section 5b page 9 mb-t48-01 s t a n d a r d p a r t s item # part # d e s c r i p t i o n qty 1 90-854-50 w indow , re a r 1 2 98-319-00 m o l d i n g , w i n d o w , r e a r 1 3 91-017-11 mirror, door, left 1 4 91-017-12 mirror, door, right 1 5 91-017-33 handle, outside, door, left 1 6 91-017-34 ha...

  • Page 230: Mb-T48-01

    Section 5b page 10 mb-t48-01 box with doors options.

  • Page 231: Mb-T48-01

    Section 5b page 11 mb-t48-01 box, double doors, side & rear windows item # part # description qty. 1 90-336-10 box, doors left & rear, glass front & rear (unpainted) 1 2 90-444-80 deckboard, front, 43-3/4 x 55-1/2" 1 3 90-444-78 deck, plate, diamond, 43-3/4 x 55-1/2" 1 4 90-472-00 deckboard, rear, 4...

  • Page 232: Mb-T48-01

    Section 5b page 12 mb-t48-01.

  • Page 233: Appendix A-Special Tools

    Appendix a-special tools.

  • Page 234: Special Tools

    Appendix a page 2 special tools special tools description purpose part number pinion seal installation tool used to install the pinion seal on all chain drive trucks with the band style brake or the speed sensor on the chain case cover. 43-201-50 chain case centering tool used to center the chain ca...

  • Page 235: Appendix B

    Appendix b.

  • Page 236: Mb-T48-01

    Appendix b page 2 mb-t48-01 recommended torque values chart d ia m e t e r a n d t p i g r a d e 2 tightening torque (ft- lb ) g r a d e 5 tightening to rq ue (ft- lb ) g r a d e 8 tightening to rque (ft- lb ) l'9 tightening to rq ue (ft- lb ) 1 /4 - 2 0 4 - 7 7 - 1 0 1 0 - 1 4 11 1 /4 - 2 8 5 - 8 8...

  • Page 237: Mb-T48-01

    Appendix b page 3 mb-t48-01 l’9 head markings s.A.E. Grade 2 s.A.E. Grade 5 s.A.E. Grade 8 l’9 truss head 1/4-20 carriage bolt 5/16-18 & 3/8-16 the following bolts are in accordance with grade 2 torque values.

  • Page 238

    B2-48 with stake side dump bed option sc1-00 stock chaser e4-55 sit down tow tractor c4-25 sit down tow tractor.

  • Page 240

    Taylor-dunn ® mfg. 2114 w. Ball rd. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 (fax) (714) 956-0504 mailing address: p.O. Box 4240 anaheim, california 92803 visit our website: www.Taylor-dunn.Com.