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Taylor-Dunn
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ET-3000
Taylor-Dunn ET-3000 User Manual
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TAYLOR-DUNN
®
Serial Number Starting: 172581
Ending Serial Number: See Introduction Chapter
MANUAL MB-T48-02
Operation, T
roubleshooting 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
2
Table of Contents
Introduction
7
Table of Contents
7
Introduction
8
About this Manual
8
Who Should Read this Manual
9
Responsibilities
9
How to Use this Manual
10
Conventions
11
How to Identify Your Vehicle
12
Taking Delivery of Your Vehicle
13
Notes
15
Standard Specifications
16
Safety Rules and Guidelines
17
Driver Qualifications
18
Driver Training Program
18
Dash up to Serial #179999
19
Vehicle Controls
19
Dash Starting Serial #180000
20
Combination Dash Display
21
Safety Guidelines
24
Starting
24
Vehicle Operational Guidelines
24
While Driving
24
Loading and Unloading
25
Parking
25
Towing
25
Adjustable Controller Parameters
26
Charging Time
30
Charging Your Vehicle
30
Industrial Charger Operation
30
New Battery Break in
30
Signet Charger Operation, Model HB Series
30
Lestronic II ® Charger Operation
31
Signet Charger Operation, Model HBS Series
31
Taylor-Dunn X-Series Charger
32
Returning to Service
34
Storing and Returning to Service
34
Storing Your Vehicle
34
Periodic Maintenance Checklist
35
Daily Visual Inspection
36
Maintenance Guidelines for Severe Duty Applications
36
Front Axle Service
41
Inspect the Front Wheel Bearings and King Pin
42
Adjust Front Wheel Bearings
43
Front Axle Removal and Installation
44
Removal
44
Installation
45
Front Axle Disassembly
46
Replace Front Wheel Bearings
47
Replace the King Pins and Bushings
49
Replace the Steering Knuckle
51
Steering
53
Front End Alignment
54
Inspect Ball Joints
58
Inspect Rod Ends
59
Adjust the Steering Gear
60
Replace the Steering Shaft
62
Replace the Steering Wheel
64
Replace the Steering Gear
65
Replace the Ball Joints, Tie Rods, and Drag Link
66
Replacing the Drag Link
68
Replacing the Tie Rod
69
Center the Steering Gear
70
Pitman Shaft Alignment
70
Repair the Steering Gear
71
Exploded View of Steering Gear
74
Hardware Torque
74
Brakes
75
Disc Brake Pads
76
Inspect the Service Brake
76
Disc Brake Rotor
77
Adjust the Automatic Parking Brake
78
Adjust the Service Brakes
78
Inspect the Automatic Parking Brake
78
Check Master Cylinder Fluid
79
Bleed the Brake System
80
Flush the Brake System
82
Replace Front Disc Brake Pads
83
Hydraulic Disc
85
Replace Rear Brake Pads
85
Disc Brake Body Assembly (Front or Rear)
87
Replace the Wheel Cylinder
87
Replace the Master Cylinder
89
Hardware Torque
90
Repair the Master Cylinder
90
Motor
91
Inspection
92
Motor Identification
92
Thermal Sensor
92
Motor Brake
93
Bearing and Sensor
94
Disassemble
94
Motor Connector
95
Reassemble
95
Hardware Torque
96
Motor Service Limits and Specifications
96
Transmission
97
Check Oil Level
98
Change Oil
99
Motor Removal and Installation
100
Rear Hub or Rotor
101
Removing and Installing the Rear Axles (Disc Brakes)
102
Remove and Install
104
Transmission Assembly
104
Disassembly and Reassembly of the Primary Reduction Gear Case
105
Disassembling the 3Rd Member
108
Assembling the 3Rd Member
111
Pinion Bearing Preload
114
Pinion Gear Shimming Instructions
115
Setting the Pinion Gear Depth
115
Hardware Torque
116
Suspension
117
Replace the Rear Springs
118
Replace the Front Springs
119
Replace the Spring Bushings
120
Hardware Torque
122
Replace the Shocks
122
Tires and Wheels
123
Tire Inflation
124
Tire Inspection
124
Replace the Tire/Wheel
125
Repair the Tire (Pneumatic)
126
Replace the Tire (Pneumatic)
127
Battery
129
Cleaning
130
Testing
131
Watering
132
Charging
133
Returning to Service
133
Storage
133
Storing
133
Industrial Battery or Lift out Battery Pack
134
Remove/Install
134
Hardware Torque
135
Individual Batteries
135
Roll out Battery Box (ROBB) with Battery Dolly
135
Illustrated Parts
145
Axles
146
Batteries
148
Brake Identification
150
Brakes (Short Bushing)
151
Brakes (Long Bushing)
154
Brake Lines
156
Cab Components (et 3000)
158
Cab Options
160
Cargo Box, Rear
162
Chargers
164
Charger Wiring, Portable
169
Decals
170
Covers
171
Door Options
172
Electrical, Lighting
176
Electrical, Miscellaneous
178
Frame Components
180
Hitches
183
Instrument Panel
184
Mirrors
187
Motor
188
Motor Mount
190
Seat Cushions and Deck
191
Speed Control Panel
192
Stake Sides (T-48)
194
Steering Column
195
Steering Gear
196
Steering Knuckle
198
Steering Linkage
200
Suspension
202
Transmission Differential/Gear Case
204
Wheels and Tires
206
Wire Harnesses
206
Appendix A: Special Tools
208
Appendix B: Suggested Torque Limits for Standard Hardware
210
Hardware Identification
210
Hex Bolts
210
Other Bolts
210
Standard Head Markings
210
Hex Lock Nuts (Stover)
211
Hex Nuts
211
Other Nuts
211
Generic Torque Values
212
Appendix C: Brake Lining Handling Precautions
214
4
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Taylor-Dunn ET-3000 Specifications
General
Brand
Taylor-Dunn
Model
ET-3000
Category
Utility Vehicle
Language
English
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