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ET-030-48
Taylor-Dunn ET-030-48 User Manual
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TABLE OF CONTENTS
Inspecting the Motor Brushes
............
2
Motors with internal cooling fans
.........................
2
Enclosed Motors (GE, no cooling fan)
.................
2
Motor Removal and Installation
.........
3
Motor Inspection
................................
3
Replacing the Brushes
.......................
5
Replacing the Bearings
.....................
6
Repairing the Commutator
................
6
Service Limits
...................................
7
Motor Service
Typical Exploded Motor
94
96
Table of Contents
Table of Contents
7
About this Manual
8
Who Should Read this Manual
8
Responsibilities
8
How to Use this Manual
9
Conventions
9
How to Identify Your Vehicle
10
Taking Delivery of Your Vehicle
11
Table of Contents
13
Standard Specifications
14
Driver Training Program
15
Driver Qualifications
15
Safety Rules and Guidelines
15
Vehicle Controls
16
Dash (up to S/N 179999)
16
Key-Switch
16
Forward-Off-Reverse Switch
16
Hour Meter
16
Battery Status Indicator, Analog
16
Accessory Switch (Optional)
16
Headlight Switch
16
Auxiliary Switch (Optional)
16
Horn Switch
16
Wiper Switch (Optional)
17
Dash (Starting S/N 180000)
17
Headlight Switch
17
Strobe Switch (Optional)
17
Forward-Off-Reverse Switch
17
Hi-Low Switch (Optional)
17
Smart View Gauge
17
Horn Switch
17
Key-Switch
17
Foot Brake Pedal
18
Accelerator Pedal
18
Park Brake
18
Steering
18
Directional Signals (Optional)
19
Hazard Light Switch (Optional)
19
Charger Interlock
19
Seat Interlock Switch
19
Smart View Display
20
Vehicle Operational Guidelines
22
Safety Guidelines
22
Starting
22
While Driving
22
Loading and Unloading
22
Towing Loads
22
Parking
23
Automatic Electric Park Brake
23
Towing this Vehicle
23
Charging Your Vehicle
24
Signet Charger Operation, Model HB Series
24
Signet Charger Operation, Model HBS Series
25
Lestronic II Charger Operation
26
Taylor-Dunn X-Series Charger
27
Charging with the X-Series Charger
28
AC Power Source
29
New Battery Break in
29
Charging Time
29
Storing / Returning to Service
29
Storing Your Vehicle
29
Returning to Service
29
Periodic Maintenance Checklist
30
Standard Periodic Maintenance Schedule for the Smart View Display
31
Daily Visual Inspection
32
Maintenance Guidelines for Severe Duty Applications
32
Lubrication Chart
36
Table of Contents
37
Inspect the Front Wheel Bearings and King Pin
38
Adjust Front Wheel Bearings
39
Front Axle Removal and Installation
40
Removal
40
Installation
40
Front Axle Disassembly
41
Replace Front Wheel Bearings
42
Replace the King Pins and Bushings
43
Replace the Steering Knuckle
44
Table of Contents
45
Front End Alignment
46
Inspect Ball Joints
49
Inspect Rod Ends
49
Adjust the Steering Gear
50
Replace the Steering Shaft
51
Replace the Steering Gear
52
Replace the Steering Wheel
52
Replace the Ball Joints, Tie Rods, and Drag Link
53
Replacing the Drag Link
54
Replacing the Tie Rod
55
Center the Steering Gear
55
Repair the Steering Gear
56
Exploded View of Steering Gear
58
Maintenance, Service, and Repair
59
Inspect the Service Brake
60
Disc Brake Pads
60
Disc Brake Rotor
60
Adjust the Service Brakes
61
Two or Four Wheel Hydraulic Disc Brakes
61
Inspect the Parking Brake
61
Adjust the Parking Brake
62
Wheel Park Brake
62
Check Master Cylinder Fluid
63
Bleed the Brake System
64
Flush the Brake System
65
Replace the Parking Brake Lining
65
Wheel Park Brake
65
Replace Front Disc Brake Pads
66
Replace Rear Brake Pads or Shoes
67
Replace the Wheel Cylinder
68
Disc Brake Body Assembly (Front or Rear)
68
Repair the Brake Body
69
Replace the Master Cylinder
71
Repair the Master Cylinder
72
Table of Contents
77
Change Oil
78
Check Oil Level
78
Motor Removal and Installation
79
Rear Hub or Rotor
79
Removing and Installing the Rear Axles
80
Disassembly and Reassembly of the Primary Reduction Gear Case
82
Disassembling the 3Rd Member
84
Assembling the 3Rd Member
85
Pinion Bearing Preload
87
Pinion Gear Shimming Instructions
87
Setting the Pinion Gear Depth
87
Maintenance, Service, and Repair
89
Replace the Rear Springs
90
Leaf
90
Replace the Front Springs
91
Leaf
91
Replace the Spring Bushings
92
Replace the Shocks
93
Front
93
Table of Contents
95
Inspecting the Motor Brushes
96
Motors with Internal Cooling Fans
96
Enclosed Motors (GE, no Cooling Fan)
96
Motor Inspection
97
Motor Removal and Installation
97
Replacing the Brushes
99
Repairing the Commutator
100
Replacing the Bearings
100
Service Limits
101
Table of Contents
103
Tire Inflation
104
Tire Inspection
104
Replace the Tire (Pneumatic)
105
Replace the Tire/Wheel
105
Repair the Tire (Pneumatic)
106
Table of Contents
107
Cleaning
108
Testing
109
Charging
110
Watering
111
Replacing (6-Volt Batteries Only)
112
Moist Charge Batteries
113
Storage and Returning to Service
114
Storage
114
Returning to Service
115
Sevcon Control System Troubleshooting
117
Definitions
118
Important Notes and Instructions
118
Terminology Used
118
Test Equipment Required
118
Identifying Your Controller
119
Start Troubleshooting here
120
Test 8. Anti-Rolloff Fault
131
Test 9. Electric Motor Brake
132
Logic Voltage Reference Table
134
Status LED Code Table
135
Smart View Fault Codes
136
Electrical Troubleshooting
139
Lester X-Series Charger
140
Test Equipment Required for Troubleshooting
140
Important Notes and Instructions
140
Theory of Operation
140
Fault and Diagnostic Error Code Table
141
Internal Wiring Diagram
141
Testing the Charging Cycle
142
Troubleshooting
143
SCR Assembly
143
Transformer
144
Lock out Relay
144
Relay Board Assembly
145
Control Board Assembly
145
Profile Setting
146
Signet HBS Charger
147
Test Equipment Required for Troubleshooting
147
Important Notes and Instructions
147
Definitions
147
Operating Instructions and Theory of Operation
148
Testing the Charging Cycle
149
Status Light Error Code Table
150
Troubleshooting
151
Lestronic II Charger
152
Test Equipment Required for Troubleshooting
152
Important Notes and Instructions
152
Operating Instructions and Theory of Operation
153
Internal Wire Diagram
153
Troubleshooting, Built-In Charger
154
Troubleshooting, Portable Charger
156
Testing the Interlock Relay
157
Operation
157
Testing
157
Replacing the Charger
157
Illustrated Parts
163
Default Chapter
164
Front Axle
164
Front Brakes
166
Steering Linkage
168
Steering Column
170
Steering Gear
172
Front Suspension
174
Transmission Gear Case
177
Transmission Differential Case
179
Rear Axle
180
Rear Brakes
182
Rear Suspension
184
Motor
186
Electric Brake
188
Master Cylinder
190
Speed Control Panel
200
Miscellaneous Frame and Body
202
Charger, Lestronic
204
Charger, Signet
206
Miscellaneous Electrical
207
Batteries
208
Decals
210
Strobe Light
212
Steel Cab (T48)
214
Tops (T48)
218
Doors (T48)
220
Optional Deckboards (T48)
222
Watering System
223
Cargo Box
224
Stake Sides
226
Cab, Deck (ET 3000)
228
Cab Components (ET 3000)
230
Misc Frame (ET 3000)
232
Appendix A: Special Tools
236
Appendix B: Suggested Torque Limits for Standard Hardware
237
Hex Bolts
237
Other Bolts
237
Hex Nuts
238
Hex Lock Nuts (Stover)
238
Other Nuts
238
Suggested Torque Values (Non-Critical Hardware)
239
Appendix C: Brake Lining Handling Precautions
241
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Taylor-Dunn ET-030-48 Specifications
General
Brand
Taylor-Dunn
Model
ET-030-48
Category
Trucks
Language
English
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