PDF Operation Trouble Shooting & Parts Manual Taylor-Dunn MB-T48-01 - 9 MB
This is a combined manual for the Taylor-Dunn MB-T48-01 vehicle, offering guidance on operation, troubleshooting, and parts identification.
It's a comprehensive resource for owners and maintenance personnel.
The manual helps you operate the vehicle correctly, diagnose common problems, and find the right replacement parts.
Keep your Taylor-Dunn running efficiently with this all-in-one guide.
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--- Page 1 ---
®
Taylor Truck
ET 3000
Models Inlcuded:
B0-T48-48 Taylor Truck (T48)
ET-030-48 (ET 3000)
The Best Way
To Go
About Your
Business
MANUAL MB-T48-01
Operation, Troubleshooting and Re-
placement Parts Manual
Revision: F Serial number Starting: 149242
--- Page 3 ---
INTRODUCTION
Operator and Maintenance Manual
--- Page 4 ---
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
SECTION 1 PAGE 5
--- Page 5 ---
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 battery or after
completing a charging cycle. Successive lower LED’s
will light as the battery charge diminishes. When
the second from the bottom LED flashes the battery
energy status is in energy reserve and should be
placed on charge as soon as possible. When the two
bottom LED’s are alternately flashing the batteries
are empty and the truck should be taken out of
service to avoid damaging the batteries.
Reverse and Motion Alarm
The reverse alarm is located in the electron-
ics compartment mounted on the contoller
panel. The reverse alarm is activated when the
Key switch is in the “ON” position and the For-
ward-Reverse switch is depressed in the re-
verse position. The alarm makes a repeated
audible sound.
Electrolyte Alarm (Optional)
The Electrolyte Alarm is located in the battery
area, in the 4 th battery cell from the main
battery positve cable. The Electrolyte alarm is
activated when the battery cell fluid level falls
below the level of the probe. The alarm is an
audible continuous sound along with a bi-color
indicator lamp. Inspect the batteries when the
alarm sounds or the bi-color lamp turns from
its green color to red. The vehicle batteries
should then be filled and/or charged. With the
fluid level at a normal operating level and/or
the batteries charged the alarm and light will
reset.
Windshield Washer FluidTank (ET 3000)
The windshield washer fluid tank is located
under the passenger seat. The fluid level
should be maintained with windshield
washing fluid above the lowest mark on the
tank. Allowing the tank to be used when
empty, may result in washer pump failure.
SECTION 2 PAGE 9
--- Page 6 ---
MB-T48-01
Lubrication
2 1
2
FRONT
3 3
4
4
1
# 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/level plug 1 SAE 80w90 Gear Oil
NOTE: The drive fluid level should be filled to the bottom edge of the fill level plug threads. The vehicle should
be secured and on level ground before initiating any service procedures.
SECTION 3 PAGE 5
--- Page 7 ---
MB-T48-01
Filling and Checking the Fluid Level
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.
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 top of the master cylinder.
9. Replace the cap on the master cylinder.
10. Reconnect the main positive and negative cables at
the batteries.
11. Remove the blocks from behind the wheels.
12. Release the park brake and test drive the vehicle.
SECTION 3 PAGE 15
--- Page 8 ---
MB-T48-01
Seal
Bearing
Bearing race
Hub
Bearing race
Bearing
Cotter pin
Spindle nut
Dust Cap
Washer
Wheel Hub Assembly
Front Wheel Bearings
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 rear wheels to prevent vehicle
movement.
5. Disconnect the main positive and negative cables at the
batteries.
6. Raise the front of the vehicle and support with jack stands.
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.
7. Remove the tire/wheel assembly.
8. Remove the dust cap, cotter pin, and spindle nut.
SECTION 3 PAGE 25
--- Page 9 ---
MB-T48-01
DRIVE SERVICE
SECTION 3 PAGE 35
--- Page 10 ---
MB-T48-01
Assembling the 3rd Member
Be sure to pre-lube all of the bearings. Failure to do so
will cause early wear, damage and void any and all
warranties.
If the pinion gear, bear-
ings, races or the ring
and pinion were re-
placed, the pinion gear
must be re-shimmed.
(Refer to the re-shim-
ming instructions).
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
housing.
5. Tighten the housing carrier bearing race
ring nut so that the ring gear is not in
contact with the pinion gear.
6. Remove the differential assembly.
NOTE: Do not allow the ring
nut to rotate.
SECTION 3 PAGE 45
--- Page 11 ---
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 begin any necessary repairs.
It is not necessary to remove the drive assembly to perform the removal and installation
of the electric brake 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.
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.
6. Remove the wires from the motor and disconnect the automatic electric brake
wires.
NOTE: Label the wires connected to the motor to insure that they are
returned to their proper location on the motor during reassembly.
7. Remove the motor mounting bolts and the motor support bracket u-bolt
from the drive and slide the motor off of the input shaft of the automatic
electric brake.
Do not remove the motor and brake as an assembly. Remove the
motor from the brake leaving the brake on the input shaft to the
drive then remove the brake from the drive. If you remove the
motor and brake as an assembly, the brake may slide off of the
motor shaft and may fall to the ground damaging the brake.
Motor and Automatic Electric Brake Assembly
SECTION 3 PAGE 55
--- Page 12 ---
MB-T48-01
Charging
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.
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
provide ample ventilation in rooms where batteries are
being charged. Failure to do so may result in severe
property damage and or serious bodily injury.
6. Check the electrolyte level. If low, fill with distilled water up to the
correct level. Use 77-201-00 battery filler.
7. If equipped, with a Electrolyte alarm take the unit out of the battery
cell, wipe the electrode clean, and put the unit back in the battery.
8. Plug the charger into the appropriate voltage outlet.
9. Allow the charger to cycle completely before unplugging.
10. Remove the blocks from behind the wheels.
11. Release the park brake and test drive the vehicle.
Battery Storage
The following pointers will help extend the life of the battery when storing the
vehicle for the winter season:
• Clean and check the electrolyte level and charge level of the battery.
• Do not store a battery low in electrolyte or in a low state of charge.
• If possible, store the vehicle in a cool dry place, or cover the vehicle.
If the batteries are removed from the vehicle, do not place them directly on
the ground, concrete or solid metal surface. It is recommended to store them
on a wooden pallet or equivalent.
SECTION 3 PAGE 65
--- Page 13 ---
Electrical Troubleshooting
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 the motor.
TEST 2.4:
Reaching this point indicates an open circuit in the motor wiring. Check the continuity of all
wires from the controller to the motor.
Repair any open wires then test drive the vehicle.
Stop trouble shooting here and repair the problem. When the repair is completed, completely
retest the vehicle before lowering the drive wheels to the ground.
After any repairs are made, completely retest the vehicle before
lowering the drive wheels to the ground. Failure to retest the vehicle
could result in unexpected movement of the vehicle resulting in injury
or property damage.
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.
Section 4 Page 9
--- Page 15 ---
Electrical Troubleshooting
TEST 6.5a:
Test the voltage from pin #5 to pin #8.
Accelerator pedal released.
If the voltage is low then skip ahead to test 6.5b.
If the voltage is high then then the module has
failed.
Stop trouble shooting here and repair the problem.
When the repair is completed, completely retest the
vehicle before lowering the drive wheels to the
ground.
TEST 6.5b:
Accelerator pedal depressed.
If the voltage equals battery volts, then skip ahead to test #6.6.
If the voltage does not equal battery volts, then the module has failed or the accelerator
pedal return spring on the module is broken.
Stop trouble shooting here and repair the problem. When the repair is completed, completely
retest the vehicle before lowering the drive wheels to the ground.
TEST 6.6:
Accelerator pedal depressed.
Test the voltage from pin #9 to pin #1.
If the voltage is between 4.8 and 5.1 volts, then
skip ahead to test #6.7.
If the voltage is not between 4.8 and 5.1 volts,
then the module has failed and must be replaced.
Stop trouble shooting here and repair the problem.
When the repair is completed, completely retest the
vehicle before lowering the drive wheels to the
ground.
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 connector failed, but the test at pin #1 at
the accelerator module was good (#6.6), then check the wire from pin #1 (module) to pin
#10 (logic card).
Stop trouble shooting here and repair the problem. When the repair is completed, completely
retest the vehicle before lowering the drive wheels to the ground.
Section 4 Page 19
--- Page 16 ---
Electrical Troubleshooting
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 charging cycle is interrupted at any time during the charging cycle.
• Defective batteries causing a fluctuating DC voltage that confuses the charger.
• A brownout (drop in AC line voltage) during the charging cycle.
• An electrically noisy charging environment.
A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:
• The batteries were not discharged to 50% before connecting the charger.
• The electrolyte in the batteries is too high (boil over).
• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).
To test the charger to see if it is turning off correctly, monitor the battery
voltage and the electrolyte specific gravity during the charging cycle as
indicated below.
Specific Gravity
Using a hydrometer take the specific gravity reading of several cells, at 1 hour intervals while charging. If
the specific gravity of the electrolyte does not rise for three consecutive readings and the charger does not
shut off, then the charger is running too long.
Battery Voltage
Using an accurate 5-1/2 digit digital voltmeter, monitor the battery voltage during the charging cycle. Take
readings every 30 minutes. If the battery voltage does not increase 0.012 volts in two consecutive readings,
then the charger is running too long.
Charger Troubleshooting Page 3
--- Page 17 ---
Electrical Troubleshooting
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 vehicle is equipped with batteries larger than 220 Amp hour capacity.
• The charging cycle is interrupted at any time during the charging cycle.
• Defective batteries causing a fluctuating DC voltage that confuses the charger.
• One or more defective cells in the battery pack.
• A brownout (drop in AC line voltage) during the charging cycle.
• An electrically noisy charging environment.
A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:
• The electrolyte in the batteries is too high (boil over).
• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).
To test the charger to see if it is turning off correctly, monitor the battery
voltage and charging current during the charging cycle as indicated below.
Using a digit digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during the
charging cycle. The charging current should remain within 10% of the DC output current (see previous
page) until the battery voltage reaches 2.55 volts per cell. When the voltage reaches 2.55 volts per cell, the
charging current will drop significantly and slowly taper off (voltage will remain constant). The charger
should turn off 2-4 hours after entering the second stage.
OR - D U
YL N
A
N
T
R
Th e B e s t W
in e s s
Bu s
y
ur
Yo
a
To
Go A b o u t
Charger Troubleshooting Page 3
--- Page 18 ---
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 ............................................. 5-10
Steering Column Assembly ....................... 5-12
Master Cylinder, brake line hardware and
front brake Asssembly ....................... 5-14
Master Cylinder ........................................ 5-16
Hydraulic Disc Brakes ............................... 5-18
Park Brake Linkage .................................... 5-20
Motor ........................................................ 5-22
Automatic Electric brake ........................... 5-24
Instrument Panel and Components ........... 5-26
Resetting the Smart View Display ................. 5-27
Control Panel ............................................. 5-28
Electrical Components (typical) ................. 5-30
Chargers .................................................... 5-32
Signet Charger .......................................... 5-34
Accelerator Module .................................. 5-36
Drive ......................................................... 5-38
Drive Assembly ......................................... 5-42
Rear Axle ................................................... 5-44
Decals ....................................................... 5-46
Hitch Options ............................................ 5-48
--- Page 19 ---
MB-T48-01
STEERING GEAR 18-308-21
ITEM # PART # DESCRIPTION QTY
1 18-308-70 Locknut, Worm Bearing Adjuste r 1
2 18-308-71 Adjuster Assembly 1
3 18-308-72 Worm Asse m bly 1
4 18-308-23 Upper Worm Bearing 1
5 18-308-22 Upper Worm Bearing Race 1
6 18-308-77 Housing, Ste e r ing Gear 1
7 18-308-78 Seal, Pitman Shaft 1
8 18-308-80 Nut, Pitman Shaft 1
9 18-308-81 Lock Washe r , Pitman Shaft 1
10 18-308-79 Seal, Worm Shaft 1
11 18-308-82 Gaske t, Side Cove r 1
12 18-308-76 Pitman Shaft 1
13 18-308-75 Lash Adjuste r 1
14 18-308-85 Shim Kit 1
15 18-308-84 Side Cover 1
16 18-308-86 Nut, Lash Adjuste r 1
17 18-308-83 Bolt, Side Cover 3
SECTION 5 PAGE 11
--- Page 20 ---
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 1
8 96-760-00 Brake Cable Clevis 1
9 88-099-80 5/16 Hex Head Nut 2
10 96-773-00 5/16 x 1 Clevis Pin 1
11 88-527-11 1/8 X 1 Steel Cotter Pin 2
SECTION 5 PAGE 21
--- Page 21 ---
MB-T48-01
W IRIN G
ITEM # PART # DESCRIPTION QTY
1 75-152-03 M ain W iring Harness 1
2 75-152-11 P o w e r/M o tor Le a d s 1
3 75-152-12 C o n tro lle r L i n k W ire s 1
4 62-016-40 C o n tro l P a n e l Asse m bly (Re fe r t o p a g e 2 5 ) 1
5 79-309-10 C h a r g e r 4 8 V S T D (Re fe r to p a g e 3 0 ) 1
6 75-152-00 C o n tro lle r H a r n e ss 1
96-000-01 C o n tro lle r C o v e r ( N o t S h o w n ) 1
BATTERIES
7 77-047-50 250 AM P H o u r STD. 48V 8
7 77-042-50 2 1 7 A M P H o u r (N o t S h o w n ) 8
7 77-047-00 2 4 4 A M P H o u r (N o t S h o w n ) 8
7 77-047-80 244 AM P H o u r Export (Not Shown) 8
BATTERY HARDWARE
8 50-243-10 Batte ry H o ld Dow n R o d 3
8 50-250-00 Batte ry Bat-Lok Clam p 3
8 88-069-81 Locknut, 1/4" 3
8 88-088-66 W a she r, 5/16 X 1.5" O. D. Tin Le a d 3
9 88-081-12 Bolt, 5/16 X 1" N C S q u a r e H e a d S tainle ss Ste e l 16
9 88-089-70 L o ck W ashe r. 5/16, Stainle ss Ste e l 16
9 88-089-80 N u t, 5 / 1 6 H e x H e a d , S t a i n l e s s S t e e l 16
9 75-237-00 Batte ry Jum p e r C a b le s 4 8 V 7
CHARGER INTERLOCK AND REPLACEMENT PARTS
10 79-306-12 Inte rlock, Charge r 115V 1
10 7 9 - 3 0 6 - 6 1 Kit, C h a r g e r Inte rlock (N o t S h o w n ) 1
10 79-809-00 C h a r g e r I n t e r l o c k R e l a y 1 1 5 V (N o t S h o w n ) 1
10 79-306-23 I n t e r l o c k , C h a r g e r 2 3 0 V (N o t S h o w n ) 1
10 79-809-10 C h a r g e r I n t e r l o c k R e l a y 2 3 0 V (N o t S h o w n ) 1
M ISCELLANEOUS
11 7 7 - 0 5 5 - 0 1 E l e ctro - L ite 1
11 77-055-60 Kit, Ele ctro - L ite 1
SECTION 5 PAGE 31
--- Page 22 ---
MB-T48-01
DRIVE
ITEM # PART # DESCRIPTION QTY
GT-3287473 Output Gear - 18 Ratio 1
24
GT-3287483 Output Gear - 12 Ratio 1
GT-3287813 Spacer - S=46.100mm 1
GT-3289403 Spacer - S=46.125mm 1
25
GT-3289413 Spacer - S=46.150mm 1
GT-3289423 Spacer - S=46.175mm 1
GT-3287853 Shim - S=0.600mm 1
GT-3287863 Shim - S=0.700mm 1
GT-3287873 Shim - S=0.800mm 1
26
GT-3287883 Shim - S=0.400mm 1
GT-3287893 Shim - S=0.500mm 1
GT-3287903 Shim - S=0.1000mm 1
27 GT-71068 Tapered Roller Bearing 1
28 GT-72022 Ball Bearing 1
29 GT-71978 Tapered Roller Bearing (Includes Bearing Race) 2
30 GT-70299 Washer 10mm ID 18
31 GT-71881 Seal 40-50 X 2 (Not Shown) (Location Indicated) 1
32 GT-70052 Vent 10 X 1mm 1
33 GT-70063 Seal 12-18 X 1 mm (Not Shown) (Location Indicated) 1
34 GT-70062 Plug M12 X 1.5 (Not Shown) (Location Indicated) 1
35 GT-71755 Seal 14-20 X 1.5mm (Not Shown) (Location Indicated) 1
36 GT-71804 Plug, Magnetic M14 X 1.5 (Not Shown) (Location Indicated) 1
37 GT-3252633 Dowel (Not Shown) (Location Indicated) 2
38 GT-71860 Pin 8 X 40mm (Not Shown) (Location Indicated) 1
39 GT-71422 Pin 5 X 24 (Not Shown) (Location Indicated) 1
SECTION 5 PAGE 41
--- Page 23 ---
SECTION 5A
Illustrated Parts List
Taylor Truck
--- Page 24 ---
MB-T48-01
TOP COVER OPTION PARTS TABLE
OPTIONAL PARTS TABLE
ITEM # PART # DESCRIPTION QTY.
SURREY TOP COVER
1 00-248-36 Tubular Top Frame 1
2 00-248-35 Post, Top Fram e 4
3 88-102-11 Bolt, 3/8 NC X 1" Carriage 32
4 88-109-81 Locknut, 3/8 NC 32
6 91-101-00 Surrey Top, White 1
FIBERGLASS TOP COVER
1 00-248-36 Tubular Top Frame 1
2 00-248-35 Post, Top Fram e 4
3 88-102-11 Bolt, 3/8 NC X 1" Carriage 32
4 88-109-81 Locknut, 3/8 NC 32
5 91-151-00 Fiberglass Top, White 1
7 91-028-25 Z-Bracket 6
8 96-124-00 U-Bolt, 1/4 X 1-3/4" 6
9 88-069-81 Locknut, 1/4" NC 24
10 88-065-09 Screw, 1/4 NC X 3/4" Phillips Truss Head 12
11 97-176-00 Washer, Neoprene 12
12 88-068-60 Washer, 1/4 Cut 12
SECTION 5A PAGE 11
--- Page 25 ---
SECTION 5B
Illustrated Parts List
ET 3000
--- Page 26 ---
MB-T48-01
BOX WITH DOORS OPTION PARTS TABLE
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, 43-3/4 X 19" 1
5 90-444-79 Deck, Plate, Diamond, 43-3/4 X 19" 1
6 88-607-09 Rivet, 1/4 X 1/2, Starpin (Not Shown) 24
7 90-850-10 Window, 13-7/8 X 31-7/8" 1
8 98-310-00 Window Channel Rubber 19
9 90-851-00 Window, Rear, 12 X 18 2
1 94-320-10 Decal, Load Line Cargo Box (Not Shown) 1
Hardware holding the cargo box to the frame
Not
88-100-09 Bolt, 3/8 NC X 3/4" Hex Head 6
Shown
Not
88-108-62 Washer, 3/8" 6
Shown
Not
88-109-81 Nut, 3/8NC 6
Shown
SECTION 5B PAGE 11