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Taylor-Dunn ET-3000 User Manual

Taylor-Dunn ET-3000
216 pages
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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

Table of Contents

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Taylor-Dunn ET-3000 Specifications

General IconGeneral
BrandTaylor-Dunn
ModelET-3000
CategoryUtility Vehicle
LanguageEnglish

Summary

Taylor-Dunn Contact Information

Service, Parts, Sales Information

Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer.

The Taylor-Dunn Corporation Overview

Taylor-Dunn Manufacturing Focus

Details the company's commitment to building tough, rugged, dependable vehicles.

Tiger Tractor Manufacturing

Information on Tiger Tractor's role as a leading manufacturer of industrial tractors.

Metro Crown International (MCI) Role

MCI's position as a supplier of replacement parts for industrial applications.

Introduction to the Manual

About This Manual

Describes the purpose and contents of the service manual.

Who Should Read This Manual

Identifies the intended audience for the manual.

Responsibilities of Stakeholders

Outlines duties of owners, operators, and service personnel.

How to Use This Manual

Explains the manual's structure and how to navigate it.

Manual Conventions Explained

Explains symbols for warnings, cautions, and notes.

How to Identify Your Vehicle

Details how to identify the specific vehicle model and serial number.

Taking Delivery of Your Vehicle

Provides guidelines for inspecting and accepting a new vehicle.

Safety Rules and Operating Instructions

Standard Specifications

Lists key technical specifications for the vehicle models.

Safety Rules and Guidelines

Details critical safety rules for operating the vehicle.

Driver Training Program Requirements

Covers requirements and content for operator training.

Vehicle Controls Overview

Introduces the main controls and their functions.

Combination Dash Display Explained

Explains the dashboard indicators and gauges.

Operator Controls Guide

Describes operation of pedals, steering, signals, and hazard lights.

General Maintenance Procedures

Maintenance Guidelines and Safety

General procedures and safety for vehicle maintenance.

Troubleshooting Guide for Common Issues

Lists common symptoms and probable causes for vehicle issues.

Lubrication Chart and Recommendations

Details lubrication points and recommended lubricant types.

Front Axle Service Procedures

Inspect Front Wheel Bearings and King Pin

Procedures for checking wheel bearing and king pin condition.

Adjust Front Wheel Bearings

Steps for properly adjusting front wheel bearings.

Front Axle Removal and Installation

Instructions for removing and installing the front axle assembly.

Front Axle Disassembly Steps

Details on disassembling the front axle components.

Replace Front Wheel Bearings

Steps for replacing worn front wheel bearings.

Replace King Pins and Bushings

Procedure for replacing king pins and associated bushings.

Replace Steering Knuckle Assembly

Instructions for removing and installing the steering knuckle.

Steering System Service

Front End Alignment Procedure

Steps for performing front wheel alignment.

Inspect Ball Joints for Wear

Procedure for checking ball joint wear.

Inspect Rod Ends for Play

Procedure for checking rod end condition.

Adjust the Steering Gear

Steps for adjusting the steering gear lash and play.

Replace Steering Shaft

Instructions for replacing the steering shaft.

Replace Steering Wheel

Procedure for removing and installing the steering wheel.

Replace Steering Gear Assembly

Instructions for removing and installing the steering gear assembly.

Replace Steering Linkage Components

Covers replacement of ball joints, tie rods, and drag links.

Center the Steering Gear

Procedure for centering the steering gear.

Pitman Shaft Alignment

Steps for aligning the pitman shaft.

Repair the Steering Gear

Detailed steps for repairing the steering gear assembly.

Brake System Service and Repair

Inspect Service Brake Components

Procedures for inspecting brake pads and rotors.

Inspect Automatic Parking Brake

How to check the operation of the automatic parking brake.

Adjust Automatic Parking Brake

Notes that no adjustments are available for the parking brake.

Adjust Service Brakes

Explains automatic adjustment and potential causes of low pedal.

Check Master Cylinder Fluid Level

Procedure for checking and filling brake fluid.

Bleed the Brake System

Detailed instructions for bleeding the hydraulic brake system.

Flush the Brake System

Steps for flushing the entire brake fluid system.

Replace Front Disc Brake Pads

Procedure for replacing front brake pads.

Replace Rear Brake Pads

Procedure for replacing rear brake pads.

Replace Wheel Cylinder

Instructions for replacing wheel cylinders.

Replace Master Cylinder

Procedure for replacing the master cylinder.

Repair Master Cylinder

Steps for repairing the master cylinder.

Motor Service and Maintenance

Motor Identification

How to identify motor specifications.

Motor Inspection Procedures

General inspection procedures for motor components.

Phase Windings Testing

Testing motor phase winding resistance.

Motor Brake Inspection and Testing

Procedures for checking and testing the motor brake.

Motor Bearing and Sensor

Information on motor bearings and rotation sensors.

Motor Disassembly Steps

Steps for disassembling the motor.

Motor Reassembly Steps

Steps for reassembling the motor.

Motor Connector Details

Details on motor connectors.

Motor Service Limits and Specifications

Technical limits and specifications for motor service.

Transmission System Service

Check Transmission Oil Level

Procedure for checking transmission oil level.

Transmission Oil Change Procedure

Instructions for changing transmission oil.

Motor Removal and Installation

Steps for removing and installing the drive motor.

Rear Hub or Rotor Service

Procedures for removing and installing rear hubs or rotors.

Rear Axle Removal and Installation

Detailed steps for rear axle removal and installation.

Transmission Assembly Instructions

Instructions for assembling the transmission.

Primary Reduction Gear Case Service

Procedures for the primary reduction gear case.

3rd Member Disassembly

Steps for disassembling the 3rd member.

3rd Member Assembly

Steps for assembling the 3rd member.

Pinion Bearing Preload Adjustment

Procedure for setting pinion bearing preload.

Pinion Gear Shimming Instructions

Instructions for shimming the pinion gear.

Suspension System Service

Replace Rear Springs

Procedure for replacing rear leaf springs.

Replace Front Springs

Procedure for replacing front leaf springs.

Replace Spring Bushings

Instructions for replacing spring bushings.

Replace Suspension Shocks

Procedure for replacing suspension shocks.

Tires and Wheels Service

Tire Inflation Guide

How to check and maintain correct tire pressure.

Tire Inspection Procedures

Guidelines for inspecting tire condition and tread depth.

Replace Tire or Wheel Assembly

Steps for replacing a tire or wheel assembly.

Repair Pneumatic Tire

Procedure for repairing pneumatic tires.

Replace Pneumatic Tire

Instructions for replacing pneumatic tires.

Battery Maintenance and Service

Battery Cleaning Procedures

Procedures for cleaning batteries and battery compartments.

Battery Testing Methods

How to test battery specific gravity and condition.

Battery Watering Procedures

Procedures for checking and adding water to batteries.

Battery Charging Guidelines

General information on charging batteries.

Battery Storage Guidelines

Guidelines for storing batteries and vehicles.

Returning Stored Batteries to Service

Steps for putting stored batteries/vehicles back into service.

Battery Remove/Install Procedures

Procedures for removing and installing batteries.

Wire Diagrams and Charger Cords

Charger AC Cords Information

Information on AC power wiring for chargers.

Motor Controller Service

Motor Controller Remove/Install

Procedures for removing and installing the motor controller.

Motor Controller Inspection

Guidelines for inspecting motor controller components.

Motor Controller Troubleshooting

Information on troubleshooting the control system.

Motor Controller Repair/Programming

Details on controller repair and programming.

Charger Service Procedures

Charger Remove/Install Instructions

Procedures for removing and installing chargers.

Charger Troubleshooting

Information on troubleshooting charger issues.

Illustrated Parts Breakdown

Axle Components Illustrated

Illustrated parts for front and rear axles.

Battery Parts Illustrated

Illustrated parts list for batteries and related components.

Brake System Identification

Visual guide to different brake bushing types.

Rear Brake Parts (Short Bushing)

Illustrated parts for rear brakes with short bushings.

Front Brake Parts (Long Bushing)

Illustrated parts for front brakes with long bushings.

Brake Lines Illustrated Parts

Illustrated parts for front and rear brake lines.

ET 3000 Cab Components

Illustrated parts for ET 3000 cab components.

Cab Options Visual Guide

Visual representation of different cab options.

ET 3000 Frame Components

Illustrated parts for ET 3000 frame components.

T-48 Frame Components Illustrated

Illustrated parts for T-48 frame components.

Hitch Components Illustrated

Illustrated parts for various hitch types.

Instrument Panel Parts

Illustrated parts for instrument panels across different S/N ranges.

Instrument Panel (Up To S/N 179999)

Illustrated parts for specific instrument panel models.

Instrument Panel (S/N Starting 180000)

Illustrated parts for specific instrument panel models.

Instrument Panel, ET 3000 (Starting 180000)

Illustrated parts for ET 3000 instrument panels.

Mirror Components Illustrated

Illustrated parts for mirrors and mounting hardware.

Motor Assembly Illustrated Parts

Illustrated parts breakdown of the motor assembly.

Motor Mount Parts Illustrated

Illustrated parts for the motor mount assembly.

Seat Cushions and Deck Parts

Illustrated parts for seats and deck components.

Speed Control Panel Parts

Illustrated parts for the speed control panel.

T-48 Stake Sides Illustrated

Illustrated parts for T-48 stake sides.

Steering Column Parts Illustrated

Illustrated parts for the steering column assembly.

Steering Gear Illustrated Parts

Illustrated parts breakdown of the steering gear.

Steering Knuckle Illustrated Parts

Illustrated parts for the steering knuckle assembly.

Steering Linkage Illustrated Parts

Illustrated parts for the steering linkage components.

Suspension Components Illustrated

Illustrated parts for front and rear suspension components.

Transmission Differential/Gear Case Parts

Illustrated parts for the transmission differential and gear case.

Wheels and Tires Illustrated Parts

Illustrated parts for wheels and tires.

Wire Harnesses Illustrated Parts

Illustrated parts for wire harnesses.

Appendixes and Reference Information

Appendix A: Special Tools Guide

Lists and describes special tools required for maintenance.

Appendix B: Torque Limits for Hardware

Provides torque specifications for standard hardware.

Appendix C: Brake Lining Handling Precautions

Details safety precautions for handling brake linings potentially containing asbestos.

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