Taylor-Dunn BT-280-48 Manuals

Manuals and User Guides for Taylor-Dunn BT-280-48. We have 3 Taylor-Dunn BT-280-48 manuals available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual, Service Replacement Parts, Operator's Manual

Taylor-Dunn BT-280-48 Operation, T Roubleshooting And Replacement Parts Manual (292 pages)

EQUIPPED WITH GT-DRIVE SYSTEM

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 29.47 MB

Taylor-Dunn

5
- Table of Contents
  5
- About this Manual
  8
- Introduction
  8
- Responsibilities
  9
- Who Should Read this Manual
  9
- How to Use this Manual
  10
- Safety Rules and Operating Instructions
  10
- Conventions
  11
- How to Identify Your Vehicle
  12
- Taking Delivery of Your Vehicle
  14
Table of Contents

15
- Standard Specifications* (Common)
  16
- Standard Specifications* (Model B 2-48/2-54)
  17
- Standard Specifications* (Model BT 2-48)
  18
- Standard Specifications* (Model BT 2-80)
  19
- Driver Training Program
  20
  - Driver Qualifications
    20
- Safety Rules and Guidelines
  20
- Dash up to Serial # 179669
  21
  - Accessory Switch (Optional)
    21
  - Headlight Switch
    21
  - Hi-Low Switch (Optional)
    21
  - Smart View Display
    21
  - Forward-Off-Reverse Switch
    21
  - Horn Switch
    21
  - Key-Switch
    21
- Vehicle Controls
  21
- Dash Starting Serial #179670
  22
  - Headlight Switch
    22
  - Wiper Switch (Optional)
    22
  - Strobe Switch (Optional)
    22
  - Forward-Off-Reverse Switch
    22
  - Hi-Low Switch (Optional)
    22
  - Smart View Display
    22
  - Horn Switch
    22
  - Key-Switch
    22
  - Directional Signals (Optional)
    23
  - Steering
    23
  - Hazard Light Switch (Optional)
    23
  - Accelerator Pedal
    23
  - Foot Brake Pedal
    23
  - Charger Interlock
    24
  - Seat Interlock Switch
    24
  - Electrolyte Alarm (Optional)
    24
  - Park Brake
    24
  - Trailer Brake Module (Optional)
    25
  - Smart View Display
    26
  - Fault Code Tables
    28
- Vehicle Operation Guidelines
  29
  - Safety Guidelines
    29
  - Starting
    29
  - While Driving
    29
  - Loading and Unloading
    29
  - Towing Loads
    29
  - Parking
    30
  - Automatic Electric Park Brake
    30
  - Towing this Vehicle
    30
- Dump Bed (Optional)
  31
  - Operation
    31
  - Service
    31
  - Lowering the Dump Manually
    32
  - Lubrication
    32
- Hydraulic Pump Exploded View
  33
- Charging Your Vehicle
  34
- Storing / Returning to Service
  35
  - Storing Your Vehicle
    35
  - Returning to Service
    35
- Periodic Maintenance Checklist
  36
- Standard Periodic Maintenance Schedule for the Smart View Display
  37
  - Daily Visual Inspection
    38
- Maintenance Guidelines for Severe Duty Applications
  38
  - General Maintenance
    39
    
    Troubleshooting Guide
    41
    
    Lubrication Chart
    42
Front Axle Service

43
- Inspect the Front Wheel Bearings and King Pin
  44
- Adjust Front Wheel Bearings
  45
- Front Axle Removal and Installation
  46
  - Removal
    46
  - Installation
    47
- Steering Component Service
  47
- Front Axle Disassembly
  48
- Replace Front Wheel Bearings
  49
- Replace the King Pins and Bushings
  51
- Replace the Steering Knuckle
  53
Steering Component Service

55
- Front End Alignment
  56
- Inspect Ball Joints
  60
- Inspect Rod Ends
  61
- Adjust the Steering Gear
  62
- Replace the Steering Shaft
  64
- Replace the Steering Wheel
  66
- Replace the Steering Gear
  67
- Replace the Ball Joints, Tie Rods, and Drag Link
  68
  - Replacing the Drag Link
    70
  - Replacing the Tie Rod
    71
- Center the Steering Gear
  72
- Pitman Shaft Alignment
  72
- Repair the Steering Gear
  73
  - Exploded View of Steering Gear
    76
Brake Service

77
- Brakes Service
  77
- Inspect the Service Brake
  78
  - Disc Brake Pads
    78
  - Disc Brake Rotor
    79
- Inspect the Parking Brake
  80
  - Wheel Park Brake (Hydraulic Disc)
    80
  - Electric Motor Brake
    81
- Adjust the Service Brakes
  82
  - Two or Four Wheel Hydraulic Disc Brakes
    82
- Adjust the Parking Brake
  83
  - Wheel Park Brake (Hydraulic Disc)
    83
- Check Master Cylinder Fluid
  84
- Bleed the Brake System
  85
- Flush the Brake System
  87
- Replace the Parking Brake Lining (Electric Motor Brake)
  88
  - Inspection
    90
- Replace Front Disc Brake Pads
  91
- Replace Rear Brake Pads
  93
  - Hydraulic Disc
    93
- Replace the Wheel Cylinder
  95
  - Disc Brake Body Assembly (Front or Rear)
    95
- Repair the Brake Body
  97
- Replace the Master Cylinder
  99
- Repair the Master Cylinder
  101
Motor Service

103
- Inspecting the Motor Brushes
  104
  - Motors with Internal Cooling Fans
    104
- Motor Inspection
  105
- Motor Removal and Installation
  105
- Replacing the Brushes or Armature Bearing
  109
- Repairing the Commutator
  110
- Service Limits
  112
Transmission

113
- Check Oil Level
  114
- Change Oil
  115
- Motor Removal and Installation
  116
- Rear Hub or Rotor
  117
- Tires and Wheels
  117
- Removing and Installing the Rear Axles (Disc Brakes)
  118
- Transmission Assembly
  120
  - Remove and Install
    120
- Disassembly and Reassembly of the Primary Reduction Gear Case
  121
- Disassembling the 3Rd Member
  124
- Assembling the 3Rd Member
  127
  - Pinion Bearing Preload
    130
- Pinion Gear Shimming Instructions
  131
  - Setting the Pinion Gear Depth
    131
Suspension

133
- Replace the Rear Springs
  134
- Replace the Front Springs
  135
- Replace the Spring Bushings
  136
- Replace the Shocks
  137
Tires and Wheels

139
- Tire Inflation
  140
- Tire Inspection
  140
- Replace the Tire/Wheel
  141
- Repair the Tire (Pneumatic)
  142
- Replace the Tire (Pneumatic)
  143
Battery Service

145
- Cleaning
  146
- Testing
  147
- Watering
  149
- Charging
  150
- Replacing (6-Volt Batteries Only)
  151
  - Moist Charge Batteries
    153
- Storage and Returning to Service
  154
  - Storage
    154
  - Returning to Service
    155
Sevcon Control System Troubleshooting

157
- Control System Troubleshooting
  157
- Definitions
  158
- Important Notes and Instructions
  158
- Terminology Used
  158
- Test Equipment Required
  158
- Identifying Your Controller
  159
- Start Troubleshooting here
  160
- Test 8. Anti-Rolloff Fault
  171
- Test 9. Electric Motor Brake
  172
- Logic Voltage Reference Table
  174
- Status LED Code Table
  175
- Smart View Fault Codes
  176
- Turn the Key Switch off before Disconnecting the Batteries
  179
- Charger Troubleshooting
  180
Electrical Troubleshooting

192
Wire Diagrams

201
- Wire Diagram
  201
- Complete Vehicle
  202
- Dash
  203
- Control Panel
  204
- Accelerator Module Detail
  205
- Lighting
  206
- Trailer Brake Module and Receptacle
  207
Illustrated Parts

209
- Front Axle
  211
- Steering Knuckle
  213
- Front Brakes
  214
  - Front Brake
    215
- Steering Linkage
  217
- Steering Column
  218
- Steering Gear
  221
- Front Suspension
  222
- Transmission Gear Case
  224
- Rear Axle
  226
- Transmission Differential Case
  226
- Rear Brakes
  229
- Brake Linkage
  231
- Rear Suspension
  232
- Motor
  234
- Electric Brake and Rear Motor Mount
  236
- Master Cylinder
  238
- Brake Lines
  240
- Brake Lines with Dual Master Cylinder
  240
- With Single Master Cylinder
  242
- Wheels and Tires
  244
- Instrument Panel Starting S/N 179670
  246
- Instrument Panel up to S/N 179669
  246
- Resetting the Smart View Display
  246
- Speed Control Panel
  248
- Miscellaneous Electrical
  250
- Lighting
  252
- Lestronic® Charger
  254
- Signet® Charger
  258
- Batteries
  260
- Seat Cushions and Deck, B 2-48 and
  262
- Seat Cushions BT 2-48
  264
- Seat Cushions BT 2-80
  264
- Decals
  266
- Cab Options
  268
- Door Options, Steel Cab
  270
- Door Options, Fiberglass Cab
  272
- Hydraulic Dump Body Option
  274
- Rear Cargo Box
  276
- Hitches
  278
  - Hardware Identification
    284
    
    Hex Bolts
    284
    
    Other Bolts
    284
    
    Standard Head Markings
    284
    
    Hex Lock Nuts (Stover)
    285
    
    Hex Nuts
    285
    
    Other Nuts
    285
  - Suggested Torque Values
    286
    
    (Non-Critical Hardware)
    286
  - Suggested Torque Values
    287
    
    (Critical Hardware)
    287
    
    Appendix A
    289
    
    Appendix B
    289
    
    Appendix C
    289
  - Brake Lining Handling Precautions
    289

Taylor-Dunn BT-280-48 Service Replacement Parts (158 pages)

Brand: Taylor-Dunn | Category: Automobile | Size: 7.35 MB

Master

5
- Table of Contents
  5
- About this Manual
  8
- How to Use this Manual
  8
- Introduction
  8
- Replacement Parts
  8
- Who Should Read this Manual
  8
- Introduction
  9
  - Conventions
    9
    
    Signal Words and Their Definitions
    9
  - Responsibilities
    10
  - How to Identify Your Vehicle
    11
  - Web Site Registration
    11
Section 2

13
- Read Me First
  14
  - Maintenance Guidelines and General Instructions
    14
- Service/Maintenance Guidelines
  14
- Service/Maintenance Guidelines
  15
  - Vehicle Modifications
    15
    
    Using Non-OEM Replacement Components
    15
- Special Tool List
  19
- Tool List
  20
  - Troubleshooting Guide
    20
- Lubrication
  23
  - Lubrication Diagram
    23
Section 3

25
- Front Axle
  26
- Install
  26
  - Installation
    26
- Remove
  26
  - Removal
    26
- Front Axle
  27
  - Disassemble
    27
  - Inspect Front Wheel Bearings
    28
  - Adjust Front Wheel Bearings
    28
  - Front Wheel Alignment
    29
    
    Center the Steering
    29
  - Replace Front Wheel Bearings
    30
  - Replace Steering Knuckle
    30
  - Replace King Pin/Bushings
    31
  - Service Limits and Specifications
    32
    
    King Pin Bushings
    32
    
    Toe in
    32
  - Hardware Torque
    32
Section 4

33
- Change Oil
  34
- Check Oil Level
  34
- Drive Axle
  34
- Drive Axle
  35
  - Transmission Assembly
    35
    
    Remove
    35
    
    Install
    35
  - Axle Shaft
    36
    
    Remove
    36
    
    Install
    36
  - Rear Hub, Rotor & Bearings
    37
  - Motor Removal/ Installation
    37
  - Primary Gear Case
    38
  - Secondary Gear Case
    39
    
    Disassemble
    39
    
    Assemble
    40
  - Pinion Bearing Preload
    41
    
    Pinion Gear Shimming Instructions
    41
    
    Set Pinion Bearing Preload
    41
  - Hardware Torque
    42
Section 5

43
- Inspect Ball Joints
  44
- Inspect Rod Ends
  44
- Steering
  44
- Steering
  45
  - Adjust Steering Gear
    45
  - Front Wheel Alignment
    45
  - Replace Ball Joint
    46
  - Replace Rod End
    46
  - Replace Steering Shaft
    47
  - Replace Steering Wheel
    48
  - Steering Gear
    49
    
    Disassemble
    49
    
    Reassemble
    50
    
    Exploded View of Steering Gear
    51
  - Hardware Torque
    51
Section 6

53
- General Guidelines and Safety
  
  54
  - Brakes
    55
- Front Brake
  
  55
  - Inspection
    55
  - Replace Pads
    55
  - Service Limits
    55
- Rear Brake
  
  56
  - Service Limits
    56
  - Inspection
    56
  - Replace Pads
    56
- Rebuild Disc Brake Body
  
  57
- Bleed System
  
  58
- Flush System
  
  58
- Hardware Torque
  
  59
- Master Cylinder
  
  59
  - Add Fluid
    59
- Service Limits
  
  59
- Parking Brake
  
  59
  - Adjust
    59
Section 7

61
- Remove/Install
  
  62
  - Motor
    63
- Disassemble
  
  62
- Inspect
  
  63
  - Armature Windings
    63
  - Bearing
    63
  - Brushes
    63
  - Commutator
    63
  - Field Windings
    64
- Repair
  
  65
- Service Limits
  
  66
  - Motor Controller
    69
    
    Troubleshooting
    69
Section 8

71
- Air Pressure
  72
- Inflation
  72
- Tires & Wheels
  72
- Tires & Wheels
  73
  - Tread Wear
    73
  - Rotation
    73
  - Changing Tire/Wheel Assembly
    74
  - Replace the Tire (Pneumatic)
    74
  - Repair the Tire (Pneumatic)
    74
  - Hardware Torque
    75
Section 9

77
- General Guidelines and Safety
  78
- Batteries
  79
  - Cleaning
    79
  - Watering
    79
  - Charging
    79
  - Testing
    80
    
    Specific Gravity
    80
  - Storing
    80
    
    Storage
    80
    
    Returning to Service
    80
  - Remove/Install
    81
    
    Industrial Battery or Lift out Battery Pack
    81
    
    Individual Batteries
    81
  - Hardware Torque
    81
Section 10

83
- Replace the Rear Springs
  84
- Suspension
  84
- Suspension
  85
  - Replace the Front Springs
    85
  - Replace the Spring Bushings
    86
  - Replace the Shocks
    87
  - Hardware Torque
    87
Section 11

91
- Wire Diagram
  91
- Ordering Parts for Your Vehicle
  92
- Replacement Parts
  92
- Taylor-Dunn Web Site Information
  92
- Replacement Parts
  93
- Axle Assembly, Front
  94
- Axle Shaft Assembly, Rear
  96
- Transaxle Assembly, Rear
  98
- Battery
  100
- Brakes, Brake Lines
  102
  - Single Reservoir Master Cylinder
    102
  - Single Reservoir Master Cylinder
    104
- Brakes, Master Cylinder
  106
- Brakes, Brake Linkage
  108
- Brakes, Front Axle
  109
  - Front Brakes
    109
- Brakes, Rear Axle
  110
- Charger, Lestronic
  111
- Charger, Signet
  112
- Charger, X-Series
  113
- Control System, Motor Speed Control
  114
- Control System, Instrument Panel
  116
  - Dash up to Serial # 179669
    116
  - Dash Starting Serial #179670
    117
- Decals
  118
- Electrical, Miscellaneous
  120
- Frame and Body
  122
  - Steel Cab
    122
  - Fiberglass Cab
    124
  - Dump Bed
    126
  - Rear Cargo Box
    128
- Lights
  130
- Mirrors
  132
- Mounting Hardware
  133
- Motor
  134
- Motor Mount
  136
- Seats
  137
- Steering Gear
  140
- Steering Linkage
  142
- Steering Column
  144
- Suspension, Front
  145
- Suspension, Rear
  146
  - Rear Suspension
    147
- Wheels and Tires
  148
- Turn Signals
  150
  - Torque Guidelines for Standard Hardware
    152
    
    Hardware Identification
    152
- Windshield Wiper
  150
- Hardware Information
  153
  - Hex Nuts
    153
    
    Hex Lock Nuts (Stover)
    153
    
    Other Nuts
    153
    
    Generic Torque Values
    154
  - Replacing Hardware
    156

Taylor-Dunn BT-280-48 Operator's Manual (56 pages)

Tram

Brand: Taylor-Dunn | Category: Electric Vehicles | Size: 1.46 MB

The Taylor-Dunn Corporation

4
Table of Contents
5
Introduction

7
- Who Should Read this Manual
  7
- About this Manual
  7
- Glossary of Terms
  
  8
- Web Site Registration
  
  9
- Responsibilities
  
  10
  - Of the Owner
    10
  - Of the Operator
    10
  - Of the Passengers
    10
  - Of the Service Personnel
    10
- Conventions
  
  11
  - Signal Words and Their Definitions
    11
  - Safety Alert Message
    11
- Vehicle Modifications
  
  12
About Your Vehicle

13
- Licensing Requirements
  13
- Vehicle Compliance
  13
- How to Identify Your Vehicle
  
  14
  - Data Plate
    14
  - Frame Serial Number
    14
Taking Delivery of Your Vehicle

15
- What to Do if a Problem Is Found
  
  15
Operator Training

16
- Driver Qualifications
  16
Vehicle Controls

17
- Dash
  
  17
- Headlight Switch
  17
- Wiper Switch
  17
- Strobe Light Switch
  17
- 4: Direction Control Switch
  17
- Hi-Low Speed Switch
  17
- Smart View Display
  17
- Horn Switch
  17
- Start Switch
  17
- Parking Brake, Automatic
  18
- Seat Adjustment
  18
- Seat Interlock Switch
  19
- Park Brake
  19
- Charger Interlock
  19
- Trailer Brake Module
  20
- Smart View Display
  21
- Fault Codes
  23
Vehicle Operation

24
- General Safety Guidelines
  24
- Starting
  26
- Driving
  27
- Collisions or Accidents
  28
- Transporting Pets
  29
- Vehicle Load Capacity, Definition
  29
- Towing
  
  30
  - Draw Bar Pull (DBP)
    30
  - Towing the Vehicle
    31
  - Park Brake Bypass Switch
    31
- Fire Extinguisher
  
  31
- Seat Belts
  
  32
  - All Seat Belt Types
    33
  - Combination Lap and Shoulder Belts
    33
  - Lap Belts Only
    33
  - Seat Belts While Pregnant
    33
  - Safety Belt Maintenance
    33
Charging Your Vehicle

34
- Generic Safety Guidelines
  
  34
- Charging Time
  35
- New Battery Break in
  35
- AC Power Source
  35
- Signet Model HBS Charger
  36
- Lester Summit Charger
  38
Storing and Returning to Service

40
- Storing Your Vehicle
  40
- Returning to Service
  40
Vehicle Maintenance

41
- Daily Inspection
  41
- Pre-Operation Inspection
  41
- Interlock Switch Inspection
  
  42
  - Start Switch
    42
  - Operator Presence Switch
    42
  - Parking Brake Switch
    42
  - Brake Interlock Switch
    43
  - Charger Interlock Switch
    43
  - Maintenance Schedule
    44
  - Maintenance Guidelines for Severe Duty Applications
    44
- Battery Maintenance
  
  45
  - Cleaning
    46
  - Watering
    46
- Removable Batteries
  
  47
  - Roll out Battery Box (ROBB) with Battery Dolly
    47
- Tires
  
  48
  - Air Pressure
    48
  - Tire Tread Wear
    48
  - Changing a Tire/Wheel Assembly
    49
  - Replacing a Tire
    50
  - Tire Rotation
    50
- Brake Fluid Level
  
  51
- Cleaning
  
  52
  - Glass
    52
  - Plastic Windows
    52
  - Seats / Soft Doors
    52
  - Interior
    52
  - Exterior Body
    52
  - Cleaning the Seat Belts
    52
  - Battery Charger
    52
  - Under Carriage
    52
  - Batteries
    52
Standard Specifications

53
Index

54

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Taylor-Dunn BT-280-48 Manuals

Taylor-Dunn BT-280-48 Operation, T Roubleshooting And Replacement Parts Manual (292 pages)

Table of Contents

Taylor-Dunn

Table of Contents

Front Axle Service

Steering Component Service

Brake Service

Motor Service

Transmission

Suspension

Tires and Wheels

Battery Service

Sevcon Control System Troubleshooting

Electrical Troubleshooting

Wire Diagrams

Illustrated Parts

Taylor-Dunn BT-280-48 Service Replacement Parts (158 pages)

Table of Contents

Master

Section 2

Section 3

Section 4

Section 5

Section 6

General Guidelines and Safety

Front Brake

Rear Brake

Rebuild Disc Brake Body

Bleed System

Flush System

Hardware Torque

Master Cylinder

Service Limits

Parking Brake

Section 7

Remove/Install

Disassemble

Inspect

Repair

Service Limits

Section 8

Section 9

Section 10

Section 11

Taylor-Dunn BT-280-48 Operator's Manual (56 pages)

Table of Contents

The Taylor-Dunn Corporation

Introduction

Glossary of Terms

Web Site Registration

Responsibilities

Conventions

Vehicle Modifications

About Your Vehicle

How to Identify Your Vehicle

Taking Delivery of Your Vehicle

What to Do if a Problem Is Found

Operator Training

Vehicle Controls

Dash

Vehicle Operation

Towing

Fire Extinguisher

Seat Belts

Charging Your Vehicle

Generic Safety Guidelines

Storing and Returning to Service

Vehicle Maintenance

Interlock Switch Inspection

Battery Maintenance

Removable Batteries

Tires

Brake Fluid Level

Cleaning

Standard Specifications

Index

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