Page 1 Service and Replacement Parts Manual MANUAL MB-248-18 Model Numbers: B0-248-36 (B 2-48, 36-volt) B0-248-48 (B 2-48, 48-volt) B0-254-36 (B 2-54, 36 volt) B0-254-48 (B 2-54, 48 volt) BT-248-36 (36-volt Back to Back Tram) BT-248-48 (48-volt Back to Back Tram) BT-280-36 (36-volt 10-passenger Tram)
Page 2 Service Advisor at your local dealership. Taylor-Dunn has a worldwide dealer and distribution network to provide replacement parts and service for our vehicles. Refer to our web site, www.taylor-dunn.com, for a dealer lookup application. Originally Published 1/23/2015 Revision C, 11/17/2016, contents subject to change without notice ®...
Page 3 Taylor-Dunn Contact information Service, Parts, Sales: Taylor-Dunn has a network of dealers distributed around the globe to support our vehicles. Information regarding vehicle sales, replacement parts, or service should be obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn website at www.taylor-dunn.com.
Page 4 Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding principle is to provide application- specific solutions, which are reliable, efficient, and economical. Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support keeps our customers moving. Tiger Tractor: Tiger manufacturing has become a leading manufacturer of internal combustion industrial tractors and ground support equipment.
Page 5: Table Of Contents
Master Table of Contents Note: Each section title page contains a section table of contents Introduction ............7 Service/Maintenance Guidelines....13 Special Tool List ..........17 Tool List ..............18 Lubrication ............21 Front Axle ............25 Drive Axle ............33 Steering ............43 Brakes...............53 Motor ..............61 Motor Controller ..........67 Tires &...
Page 6 Notes...
Page 7 Table of Contents Introduction About This Manual ..........8 Who Should Read This Manual ......8 Replacement Parts ..........8 How To Use This Manual ........8 Conventions ............9 Signal Words and Their Definitions: ......9 Responsibilities ..........10 How to Identify Your Vehicle ......11 Web Site Registration ........11 WARNING This section is one section of a complete service manual.
Page 8: Introduction
To maintain peak performance, only use original Taylor- Dunn replacement parts intended for use on your vehicle. Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles. Only use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Page 9: Introduction
Introduction B0-248; B0-254; BT-248; BT-280 (36v & 48v) Conventions Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words defined here as “signal words” may be used elsewhere in the text of this document without being a signal word.
Page 10: Responsibilities
B0-248; B0-254; BT-248; BT-280 (36v & 48v) RESPONSIBILITIES Of the Owner... WARNING The owner of this or any Taylor-Dunn vehicle is responsible for the overall maintenance and repairs To maintain peak performance, always use of the vehicle, as well as the training of operators.
Page 11: How To Identify Your Vehicle
WEB SITE REGISTRATION Registering on the Taylor-Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor- Dunn line of vehicles. Your contact information will remain confidential and will not be shared outside of the Taylor-Dunn corporation.
Page 12 Notes...
Page 13 Table of Contents Service/Maintenance Guidelines Read Me First: Maintenance Guidelines and General Instructions .........14 Vehicle Modifications ........15 Using Non-OEM Replacement Components: ..15 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 14: Service/Maintenance Guidelines
• Inspect and maintain battery limit switches, protective devices, electrical conductors, and • Read the operator’s manual before operating this ® connections in conformance with Taylor-Dunn’s recommended procedures. vehicle. • Keep the vehicle in clean condition to minimize • Avoid fire hazards and have fire protection fire hazards and facilitate detection of loose or equipment present in the work area.
Page 15: Service/Maintenance Guidelines
Due to the unknown properties of non-Taylor-Dunn tested Operator Controlled Industrial Tow Tractors: components or from components not originally equipped on the vehicle, we cannot approve their use in a Taylor-Dunn vehicle. Paragraph 6.2.14: Modifications and additions which affect capacity and safe tow tractor operation shall not be performed without manufacture’s...
Page 16 Notes...
Page 17 Table of Contents Special Tool List Tool List ............18 Controller Programming: .........18 Troubleshooting Guide ........20 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 18 Tool List B0-248; B0-254; BT-248; BT-280 (36v & 48v) TOOL LIST The tools shown here are generic for servicing Taylor-Dunn vehicles. Not all tools will be required for servicing this vehicle. 75-089-00: Throttle Module Test Harness 62-027-32: Throttle Module Analyzer...
Page 19: Special Tool List
Removes 0.093 diameter pins from Molex Removes pins from Molex Mini-Fit harness rectangular harness connectors. Not rectangular harness connectors. Not connectors. available from Taylor-Dunn. Purchase from available from Taylor-Dunn. Purchase from any local electronics distributor. any local electronics distributor. MB-248-18...
Page 20: Tool List
Tool List B0-248; B0-254; BT-248; BT-280 (36v & 48v) TROUBLESHOOTING GUIDE This is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only. It is not all inclusive of causes that may result in a specific symptom. Symptom Suspect Component or System Action...
Page 21 Table of Contents Lubrication Lubrication and Fluids Chart ......22 Hazardous Waste Disposal ......22 Lubrication Diagram ........23 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 22 Lubrication B0-248; B0-254; BT-248; BT-280 (36v & 48v) LUBRICATION AND FLUIDS CHART Assembly Component Capacity Lubricant Front Axle: 1: Ball Joint General Purpose Grease 3: Front Wheel Bearings High Temperature Wheel Bearing Grease 4: King Pin General Purpose Grease Brake Fluid: Master Cylinder DOT 3, Meets or exceeds SAE J1703 Linkages:...
Page 23: Lubrication
Lubrication B0-248; B0-254; BT-248; BT-280 (36v & 48v) LUBRICATION DIAGRAM Front End Lubrication Note: The transaxle is mounted at an angle in the vehicle. The transaxle must be level when checking oil level. This will require rasing the rear of the vehicle until the transaxle is level with the ground.
Page 24 Notes...
Page 25 Table of Contents Front Axle Remove.............26 Removal ..............26 Install ..............26 Installation ...............26 Disassemble.............27 Inspect Front Wheel Bearings ......28 Adjust Front Wheel Bearings ......28 Front Wheel Alignment ........29 Center the Steering ..........29 Front Wheel Alignment ..........29 Replace Front Wheel Bearings.......30 Replace Steering Knuckle ......30 Replace King Pin/Bushings ......31 Service Limits and Specifications ....32 King Pin Bushings ...........32...
Page 26: Front Axle
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) REMOVE INSTALL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
Page 27: Front Axle
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) DISASSEMBLE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings.
Page 28: Inspect Front Wheel Bearings
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) INSPECT FRONT WHEEL ADJUST FRONT WHEEL BEARINGS BEARINGS WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.
Page 29: Front Wheel Alignment
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) FRONT WHEEL ALIGNMENT WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: Only Toe In can be set.
Page 30: Replace Front Wheel Bearings
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE FRONT WHEEL REPLACE STEERING KNUCKLE BEARINGS WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.
Page 31: Replace King Pin/Bushings
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE KING PIN/BUSHINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. There are different types of king pin bushings depending on the configuration of your vehicle.
Page 32: Service Limits And Specifications
Front Axle B0-248; B0-254; BT-248; BT-280 (36v & 48v) SERVICE LIMITS AND HARDWARE TORQUE SPECIFICATIONS Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 King Pin Bushings Rod End Stud Nut 20-25 27.1-33.9 Ream or broach to 1.25 inch ±0.001 Rod End Jam Nut 20-25 27.1-33.9...
Page 33 Table of Contents Drive Axle Check Oil Level ..........34 Change Oil ............34 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...
Page 34: Drive Axle
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) CHECK OIL LEVEL CHANGE OIL WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual.
Page 35: Drive Axle
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) TRANSMISSION ASSEMBLY WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Remove Install 1: Release the park brake.
Page 36: Axle Shaft
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) AXLE SHAFT WARNING WARNING This section is one section of a complete service The axle retaining plate bolts have a pre-applied manual. Before starting any procedure, read all thread locking compound. They are intended warnings and instructions that are located in the for one time use only.
Page 37: Rear Hub, Rotor & Bearings
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) REAR HUB, ROTOR & BEARINGS MOTOR REMOVAL/ INSTALLATION Note: Some applications will require removing the WARNING drive assembly from the vehicle to remove the motor. Refer to Removing and Installing This section is one section of a complete service the Drive Assembly for information on manual.
Page 38: Primary Gear Case
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) PRIMARY GEAR CASE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. 1: Disconnect the batteries.
Page 39: Secondary Gear Case
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) SECONDARY GEAR CASE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Disassemble 1: Remove the transaxle assembly from the vehicle.
Page 40: Assemble
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) Assemble 13: Install the differential assembly. 1: Temporarily install the pinion gear (hand tighten 14: Install the cover and all of the cover bolts. See only). note regarding special washers at the end of this 2: Install the carrier bearing race adjusting nuts into section.
Page 41: Pinion Bearing Preload
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) PINION BEARING PRELOAD WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Pinion Gear Shimming Instructions Note: This procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears.
Page 42: Hardware Torque
Drive Axle-GT B0-248; B0-254; BT-248; BT-280 (36v & 48v) HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Pinion nut 154-169 209229 Drain plug 21-25 28.4-33 Gear case to 3rd member 18-20 24.4-27 3rd Member cover bolts...
Page 43 Table of Contents Steering Inspect Ball Joints ...........44 Inspect Rod Ends ..........44 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...
Page 44: Steering
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) INSPECT BALL JOINTS INSPECT ROD ENDS WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual.
Page 45: Steering
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) ADJUST STEERING GEAR WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: In some vehicle configurations it may be necessary to remove the steering gear to perform this procedure.
Page 46: Replace Ball Joint
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE BALL JOINT WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. 1: Raise the front of the vehicle and support with jack stands. 2: Loosen the ball joint clamp on the steering sleeve.
Page 47: Replace Steering Shaft
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE STEERING SHAFT WARNING WARNING This section is one section of a complete service Do not use the original pinch bolt and nut. manual. Before starting any procedure, read all Failure to replace the pinch bolt and nut may warnings and instructions that are located in the result in failure of the steering causing loss of Service Guidelines chapter.
Page 48: Replace Steering Wheel
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE STEERING WHEEL WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Note: The steering wheel is on a tapered shaft and may be damaged when it is removed. 1: If equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch.
Page 49: Steering Gear
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) STEERING GEAR WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Disassemble Note: The steering gear must be removed from the vehicle for this procedure.
Page 50: Reassemble
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) Reassemble 12: Lightly lubricate all parts before reassembly. 13: Install a new worm shaft seal and pitman shaft seal into the housing. 14: Install the upper worm bearing cup. 15: Divide the ball bearing into two equal groups. 16: Position the ball nut onto the worm shaft as shown in the illustration.
Page 51: Exploded View Of Steering Gear
Steering B0-248; B0-254; BT-248; BT-280 (36v & 48v) Exploded View of Steering Gear HARDWARE TORQUE Description Foot Pounds Newton Meters Ball Joint Clamp 28-32 37.9-43.4 Rod End Stud Nut 20-25 27.1-33.9 Rod End Jam Nut 20-25 27.1-33.9 Ball Joint Castle Nut 40-45 54.2-61 MB-248-18...
Page 52 Notes...
Page 53 Table of Contents Brakes General Guidelines and Safety.......54 Front Brake ............55 Service Limits ............55 Inspection ..............55 Replace Pads ............55 Rear Brake............56 Service Limits ............56 Inspection ..............56 Replace Pads ............56 Rebuild Disc Brake Body ........57 Bleed System ...........58 Flush System ...........58 Master Cylinder..........59 Add Fluid ..............59 Parking Brake ..........59...
Page 54: General Guidelines And Safety
GENERAL GUIDELINES AND SAFETY WARNING WARNING This section is one section of a complete service Taylor-Dunn does not currently supply asbestos manual. Before starting any procedure, read all fiber-brake pads/shoes with any vehicle. warnings and instructions that are located in the However, there is the possibility that the Service Guidelines chapter.
Page 55: Brakes
Brakes B0-248; B0-254; BT-248; BT-280 (36v & 48v) FRONT BRAKE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Service Limits Refer to the table at the end of this section Inspection Note: Service Limits are listed in a table at the end of...
Page 56: Rear Brake
Brakes B0-248; B0-254; BT-248; BT-280 (36v & 48v) REAR BRAKE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. Service Limits Refer to the table at the end of this section Note: Service Limits are listed in a table at the end of this section.
Page 57: Rebuild Disc Brake Body
Brakes B0-248; B0-254; BT-248; BT-280 (36v & 48v) REBUILD DISC BRAKE BODY WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. This procedure assumes that the component has been removed from the vehicle.
Page 58: Bleed System
Brakes B0-248; B0-254; BT-248; BT-280 (36v & 48v) BLEED SYSTEM FLUSH SYSTEM WARNING 1: Raise the rear wheels off of the ground and support with jack stands. 2: If equipped with front brakes, raise the front This section is one section of a complete service wheels off of the ground and support with jack manual.
Page 59: Master Cylinder
Brakes B0-248; B0-254; BT-248; BT-280 (36v & 48v) MASTER CYLINDER WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. There are no internally serviceable components in the master cylinder.
Page 60 Notes...
Page 61 Table of Contents Motor Remove/Install ..........62 Disassemble.............62 Inspect ..............63 Brushes ..............63 Bearing ..............63 Commutator .............63 Armature Windings ..........63 Field Windings ............64 Repair ...............65 Service Limits ..........66 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 62: Remove/Install
Motor SEM B0-248; B0-254; BT-248; BT-280 (36v & 48v) REMOVE/INSTALL DISASSEMBLE WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
Page 63: Motor
Motor SEM B0-248; B0-254; BT-248; BT-280 (36v & 48v) INSPECT Inspect the commutator for groves. WARNING • If the commutator is grooved then it must be machined on a lathe. Do not machine the commutator past the minimum diameter specified This section is one section of a complete service manual.
Page 64: Field Windings
Motor SEM B0-248; B0-254; BT-248; BT-280 (36v & 48v) Inspect the armature windings where they loop back at Using the continuity function of digital multi meter, check the opposite end of the commutator. the continuity from any one of the commutator segments •...
Page 65: Repair
Motor SEM B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPAIR WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. The only recommended repair to a motor is cutting the commutator. If any other components are damaged then they should be replaced.
Page 66: Service Limits
Motor SEM B0-248; B0-254; BT-248; BT-280 (36v & 48v) SERVICE LIMITS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. This is a generic section covering all currently available SEM motors at the time this manual was revised. The service limits listed below are for each of the motors, by the specification number of the motor shown.
Page 67 Table of Contents Motor Controller Remove/Install ..........68 Inspect ..............68 Receptacles .............68 Base Plate ...............68 Terminal Ends ............68 ’R’ Terminal ..............68 Repair/Programming ........69 Programming ............69 Troubleshooting ..........69 Hardware Torque ..........69 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 68 Motor Controller B0-248; B0-254; BT-248; BT-280 (36v & 48v) REMOVE/INSTALL INSPECT NOTICE Receptacles The inside of each receptacle should be clean and free Do not allow the wires to rotate while removing of any debris. Use aerosol electrical cleaner if required. terminal hardware.
Page 69: Motor Controller
This manual was provided on the original vehicle CD. A hard copy can be purchased from your authorized Taylor-Dunn distributor or can be downloaded from the Repairs Taylor-Dunn web site. There are no internally serviceable components in the motor speed controllers.
Page 70 Notes...
Page 71 Table of Contents Tires & Wheels Inflation .............72 Air pressure .............72 Tread Wear ............73 Rotation ............73 Changing Tire/Wheel Assembly .....74 Replace the Tire (pneumatic) ......74 Repair the Tire (pneumatic) ......74 Hardware Torque ..........75 WARNING This section is one section of a complete service manual.
Page 72: Tires & Wheels
Tires & Wheels B0-248; B0-254; BT-248; BT-280 (36v & 48v) INFLATION WARNING WARNING This section is one section of a complete service Incorrect tire inflation can result in sudden manual. Before starting any procedure, read all failure of the tire and/or braking / steering warnings and instructions that are located in the problems leading to loss of control of the vehicle.
Page 73: Tires & Wheels
Tires & Wheels B0-248; B0-254; BT-248; BT-280 (36v & 48v) TREAD WEAR WARNING WARNING DO NOT operate a vehicle if the cord This section is one section of a complete service is visible on any tire (see illustration). manual. Before starting any procedure, read all A tire in this conditions may suddenly warnings and instructions that are located in the fail at any time and cause loss of...
Page 74: Changing Tire/Wheel Assembly
Tires & Wheels B0-248; B0-254; BT-248; BT-280 (36v & 48v) CHANGING TIRE/WHEEL REPLACE THE TIRE (PNEUMATIC) ASSEMBLY WARNING WARNING This section is one section of a complete service manual. Before starting any procedure, read all This section is one section of a complete service warnings and instructions that are located in the manual.
Page 75: Hardware Torque
Tires & Wheels B0-248; B0-254; BT-248; BT-280 (36v & 48v) HARDWARE TORQUE If hardware is not listed here, refer to standard torque values in the appendix. Description Foot Pounds Newton Meters Wheel nut MB-248-18 Page 75...
Page 76 Notes...
Page 77 Table of Contents Batteries General Guidelines and Safety.......78 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 WARNING This section is one section of a complete service...
Page 78: General Guidelines And Safety
Batteries B0-248; B0-254; BT-248; BT-280 (36v & 48v) GENERAL GUIDELINES AND SAFETY WARNING NOTICE This section is one section of a complete service Battery electrolyte will stain and corrode most manual. Before starting any procedure, read all surfaces. Immediately and thoroughly clean any warnings and instructions that are located in the surface outside of the battery that the battery Service Guidelines chapter.
Page 79: Batteries
Batteries B0-248; B0-254; BT-248; BT-280 (36v & 48v) CLEANING WATERING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
Page 80: Testing
Batteries B0-248; B0-254; BT-248; BT-280 (36v & 48v) TESTING STORING WARNING WARNING This section is one section of a complete service This section is one section of a complete service manual. Before starting any procedure, read all manual. Before starting any procedure, read all warnings and instructions that are located in the warnings and instructions that are located in the Service Guidelines chapter.
Page 81: Remove/Install
Batteries B0-248; B0-254; BT-248; BT-280 (36v & 48v) REMOVE/INSTALL WARNING WARNING Do not allow the loose battery cables to contact This section is one section of a complete service any other parts of the vehicle as this could cause manual. Before starting any procedure, read all in a short circuit resulting severe bodily injury warnings and instructions that are located in the or damage to the vehicle.
Page 82 Notes...
Page 83 Table of Contents Suspension Replace the Rear Springs .......84 Replace the Front Springs ......85 Replace the Spring Bushings ......86 Replace the Shocks.........87 Hardware Torque ..........87 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 84: Suspension
Suspension B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE THE REAR SPRINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. If a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set.
Page 85: Suspension
Suspension B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE THE FRONT SPRINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. If a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set.
Page 86: Replace The Spring Bushings
Suspension B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE THE SPRING BUSHINGS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. It is recommended that all front spring bushings are replaced as a set.
Page 87: Replace The Shocks
Suspension B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACE THE SHOCKS WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. It is recommended to replace all shocks as a set. Note: On some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts.
Page 88 Notes...
Page 89 Table of Contents Wire Diagram Diagram Part Numbers........90 WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter.
Page 90 Vehicle Documentation CD provided with the vehicle. The diagram # for this vehicle is: SCH-00009 (see description below) This vehicle diagram as well as other Taylor-Dunn vehicle diagrams can be downloaded from the Taylor-Dunn web site at www.taylor-dunn.com. Listed below are the available diagrams as of the revision date of this manual.
Page 91: Wire Diagram
TABLE OF CONTENTS Replacement Parts Ordering Parts for Your Vehicle .....92 Frame and Body ..........122 Steel Cab ..............122 Taylor-Dunn Web Site Information ....92 Fiberglass Cab ............124 Axle Assembly, Front ........94 Dump Bed ...............126 Axle Shaft Assembly, Rear ......96 Rear Cargo Box ............128 TransAxle Assembly, Rear ......98...
Page 92: Replacement Parts
Any special order options will have a ‘K’ letter prefix in the option number. The vehicle option list is also available on the Taylor-Dunn web site. The serial number of the vehicle is required to obtain the option list.
Page 93: Replacement Parts
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) My Vehicle information Serial Number: Date Purchased: Date Delivered: Dealer Purchased From: Salesman Name: Notes My local Parts Dealer: * Not available at time of printing MB-248-18 Page 93...
Page 94: Axle Assembly, Front
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) AXLE ASSEMBLY, FRONT Page 94 MB-248-18...
Page 95 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Axle Assembly, Front Item No. Part No. Description 15-049-71 Axle Beam, B 2-48, BT 2-48, B 2-54 15-049-77 Axle beam, BT 2-80 88-239-86 3/4-NF Hex Slotted Nut 88-228-60 3/4 Cut Flat Washer 98-603-07 Rubber Bushing 01-220-99...
Page 96: Axle Shaft Assembly, Rear
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) AXLE SHAFT ASSEMBLY, REAR Note: The double bearing axle assembly is optional. Most vehicles will only have the single bearing (#2) Inner bearing on double bearing axle does not have an oil seal or O-ring. Orientation of bearing should have O-ring groove adjacent to O-ring on outer bearing.
Page 97 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Axle Shaft Assembly, Rear Item No. Part No. Description 41-154-10 Axle shaft, BT 2-80 41-154-20 Axle shaft, B 2-48, BT 2-48, B 2-54 (single bearing) 41-154-25* *Axle shaft, B 2-54 80-505-20 Bearing 80-505-30* *Bearing...
Page 98: Transaxle Assembly, Rear
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) TRANSAXLE ASSEMBLY, REAR Note: Spacer (item No. 23) is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number GT-3287213. Add 10 to the part number for every 0.05mm over 3.9. For example, if 4.55mm is needed: 4.55-3.9 = .65mm over, 0.65/.05 = 13, 13*10 = 130.
Page 99 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Axle Assembly, Rear Item No. Part No. Description GT-71682 M8 x 60 bolt GT-3287563 Gear case cover GT-71259 Bearing GT-3287513 Input shaft, 30:1 0 or 1 GT-3287523 Input shaft, 24:1 0 or 1 GT-3287533 Input shaft, 18:1 0 or 1...
Page 100: Battery
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BATTERY Depending on the configuration of your vehicle, the batteries may be wired as shown in these two illustrations. Page 100 MB-248-18...
Page 101 Not Shown 77-055-15 Battery watering system for Trojan batteries (optional) 77-055-12 Battery watering system for Exide or Taylor-Dunn batteries (optional) 77-055-13 BATTERY FILLING GUN, used with watering systems (optional) 01-534-43 Battery locator (angle in bottom of battery box, 72 v only) Quantities depend on voltage configuration of vehicle.
Page 102: Brakes, Brake Lines
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BRAKES, BRAKE LINES Single Reservoir Master Cylinder Page 102 MB-248-18...
Page 103 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Brake Lines (Dual Reservoir Master Cylinder) Item No. Part No. Description 99-609-61 Brake Line, Front 99-607-59 Brake Line, Rear 99-606-51 Brake Line, Front Right 99-607-62 Brake Line, Rear, B 2-48, B 2-54, BT 2-48 99-608-58 Brake Line, Rear, BT 2-80 99-603-68...
Page 104: Single Reservoir Master Cylinder
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Single Reservoir Master Cylinder Page 104 MB-248-18...
Page 105 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Brake Lines (Single Reservoir Master Cylinder) Item No. Part No. Description 71-110-00 Brake Light Switch (optional) 99-591-00 Brake light switch adaptor (optional) 99-576-00 Hose Clip 99-608-58 Brake Line, Rear, BT 2-80 99-607-62 Brake Line, Rear, B 2-48, B 2-54, BT 2-48 99-604-56...
Page 106: Brakes, Master Cylinder
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BRAKES, MASTER CYLINDER Master Cylinder (Single Reservoir) Item No. Part No. Description 99-511.00 Master cylinder assembly 88-101-20 Hex bolt 99-579-00 Fitting, bolt 99-572-00 Washer 99-566-00 Fitting 99-571-00 Washer 88-109-81 Hex lock nut 99-510-52 99-510-61 Rebuild kit for 1”...
Page 107 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Master Cylinder (Dual Reservoir) Item No. Part No. Description 88-080-14 Bolt, 5/16” X 1-1/2” NC, Hex Head See Usage Table Master Cylinder (includes item #3) 99-511-52 Cap Seal, Master Cylinder 99-511-53 Cap, Master Cylinder 88-088-61 Washer, 5/16”...
Page 108: Brakes, Brake Linkage
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BRAKES, BRAKE LINKAGE Brake Linkage Item No. Part No. Description 88-080-11 Bolt, 5/16 x 1”, Hex Head 51-344-80 Park Brake Handle 88-088-61 Washer, 5/16” 88-089-81 Locknut, 5/16” 96-813-00 Adjusting Brake Cable Assembly, B 2-48, BT 2-48, B 2-54 96-820-20 Adjusting Brake Cable Assembly, BT 2-80 96-771-00...
Page 109: Brakes, Front Axle
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BRAKES, FRONT AXLE Front Brakes Item No. Part No. Description 88-067-29 Bolt 88-069-82 Locknut, 1/4” Nc, Grade C (Included In Rebuild Kit) 41-350-91 Plate, Secondary 41-348-58 Spacer (Included In Rebuild Kit) 32-208-01 Bushing (Included In Rebuild Kit) 41-351-35...
Page 110: Brakes, Rear Axle
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) BRAKES, REAR AXLE Brakes, Rear Axle Item No. Part No. Description 88-067-21 1/4 x 3-3/4 Hex bolt, grade 8 88-069-82 1/4NC locknut, grade C (included in rebuild kit) 41-350-91 Secondary plate See kit below Brake pad, Inner See kit below...
Page 111: Charger, Lestronic
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) CHARGER, LESTRONIC Charger Model > 9695 16910 22620 16920 Style > Portable Built In Built In Built In Item # Description Part # Charger Assembly 79-309-00 79-309-10 79-303-25 79-309-20 Ammeter 79-851-10 Timer 79-805-65 79-805-68...
Page 112: Charger, Signet
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) CHARGER, SIGNET Note: The harness connectors and AC plug are not included with the charger. Model HBS Charger PART # DESCRIPTION 79-309-42 48 volt Flooded Batteries (WET, FLA) 79-309-43 48 volt Sealed Batteries (GEL, SLA, AGM) Note: There are no user serviceable components inside the charger Note: The charger AC cord is an integral part of the charger.
Page 113: Charger, X-Series
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) CHARGER, X-SERIES Item No. Part No. Description 79-303-49 Charger Assembly, X-Series, 48 volt 79-831-00 Fuse 79-809-61 Relay boad assembly Control board assembly 79-749-14 SCR assembly 79-840-02 Circuit breaker 79-848-01 Ammeter 79-810-01 Switch kit (start/stop, low voltage, self diagnostic) 79-575-41 AC cord (includes bushing)
Page 114: Control System, Motor Speed Control
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) CONTROL SYSTEM, MOTOR SPEED CONTROL Page 114 MB-248-18...
Page 115 Depending on the model and serial number of the vehicle, item #4 will be a circuit breaker or a fuse Model No. Description Serial No. Range Part No. B0-248-36 Circuit Breaker 146189 to current production 79-844-20 B0-248-48 Circuit Breaker 146189 to 173490, and 173625, 173671...
Page 116: Control System, Instrument Panel
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) CONTROL SYSTEM, INSTRUMENT PANEL Dash up to Serial # 179669 #6 Bargraph battery status #6 Analog Status Indicator indicator Instrument Panel Item No. Part No. Description 71-100-00 Auxiliary switches 0, 1, 2 71-039-11 Auxiliary switches 0, 1, 2...
Page 117: Dash Starting Serial #179670
Note: If you have the Smart View display and wish to have the maintenance feature turned on, then the Sevcon speed control must be reprogrammed. Note: To reprogram the Sevcon speed control, the speed control must be returned to the factory. Contact your local Taylor-Dunn® distributor for more information. * Not available at time of printing MB-248-18...
Page 118: Decals
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) DECALS BT 2-80 under 2nd seat BT 2-80 Electronics compartment B 2-48 and B 2-54 Between seats Page 118 MB-248-18...
Page 119 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Decals Item No. Part No. Description 94-319-00 Battery disconnect 1 or 2 94-313-00 Battery warning 1 or 2 94-373-10 Vehicle identification 94-309-00 Brake warning 94-313-20 Safety warning 94-384-01 Not a motor vehicle 94-384-14 When leaving vehicle warning 94-301-41...
Page 120: Electrical, Miscellaneous
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) ELECTRICAL, MISCELLANEOUS Miscellaneous Wire Harness Clamps Motion Alarms Page 120 MB-248-18...
Page 121 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Electrical Item No. Part No. Description 96-624-00 Clamp, 1/4 Jiffy Clip 96-625-00 Clamp, 5/16 Jiffy Clip 96-626-00 Clamp, 7/8 Jiffy Clip 96-640-00 Clamp, 3/16 Push Mount 96-642-00 Wire harness Clip, push mount 96-650-01 Wire Harness Clip, stick on 96-629-80 (not shown) Clamp, Rubber Lined 3/16 ID...
Page 122: Frame And Body
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) FRAME AND BODY Steel Cab Page 122 MB-248-18...
Page 123 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Steel Cab Item No. Part No. Description 90-923-98 Door Frame, Left 90-924-98 Side Curtain, Left 97-315-53 Handle Assembly, Outer 97-315-51 Door Latch 97-315-54 Handle Assembly Inside 97-303-03 Snap Fastner 88-727-06 Rivet, 5/32 X 5/8” 88-025-08 Locknut, #8-32”...
Page 124: Fiberglass Cab
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Fiberglass Cab Page 124 MB-248-18...
Page 125 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Fiberglass Cab Item No. Part No. Description 90-921-98 Door Frame, Left 90-921-99 Door Frame, Right 98-451-11 Weather seal tape (by the foot) 90-908-98 Side Curtain, Left 90-908-99 Side Curtain Right 97-315-53 Handle Assembly, Outer 97-315-51 Door Latch...
Page 126: Dump Bed
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Dump Bed Page 126 MB-248-18...
Page 127 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Dump Bed Option Item No. Part No. Description 21-018-00 Cylinder Pin 88-060-11 Bolt, 1/4 X 1-1/4”” NC, Hex Head 88-069-81 Locknut, 1/4”” NC 21-019-00 Shaft, Dump Bed Pivot 17-112-00 Collar, Shaft 99-524-00 Hydraulic Cylinder 99-957-00...
Page 128: Rear Cargo Box
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Rear Cargo Box Rear Cargo Box Item No. Part No. Description 91-333-02 Cargo box (unpainted) 90-471-00 Front deck board 90-472-00 Rear deeck board 90-850-10 Front window 98-310-00 Rubber window gasket (by the foor) 90-851-00 Rear window Not shown...
Page 129 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) * Not available at time of printing MB-248-18 Page 129...
Page 130: Lights
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) LIGHTS Head and Tail Lights Item No. Part No. Description 72-005-00 5” Round head light 1 or 2 72-072-00 Replacement bulb 1 or 2 94-050-10 Rectangular light , left (steel cab) 94-050-11 Rectangular light , right (steel cab) 72-082-01...
Page 131 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Strobe Light Item No. Part No. Description 88-029-80 8-32 Hex Nut 88-028-62 #8 Lock Washer 88-025-06 8-32 X 1/2 Machine Screw 72-023-20 Strobe Assembly (Amber) Mounting Pole Harness 72-023-22 Amber Lens 72-023-23 Red Lens Not Shown...
Page 132: Mirrors
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) MIRRORS Item No. Part No. Description 92-202-00 Mirror mounting bracket assembly, Fiberglass cab 92-202-21 92-202-23 Bracket 92-202-22 Joint 88-080-14 5/16NC x 1-1/2 Hex bolt 88-088-61 5/16 SAE flat washer 88-089-81 5/16NC Lock nut 88-088-62 5/16 Split lock washer 88-089-80...
Page 133: Mounting Hardware
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) MOUNTING HARDWARE Item No. Part No. Description 97-811-00 1-7/8 inch Ball 97-821-00 2-inch Ball 88-140-14 1/2NC x 1-1/2 Hex bolt 88-149-80 1/2NC Hex nut 88-148-62 1/2 Split lock washer * Not available at time of printing MB-248-18 Page 133...
Page 134: Motor
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) MOTOR Page 134 MB-248-18...
Page 135 Page 135...
Page 136: Motor Mount
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) MOTOR MOUNT Item No. Part No. Description 88-067-22 Bolt,1/4 X 2” NC, Grade (no brake option) 88-067-29 Bolt,1/4 X 4-1/4” NC, Grade 8 (brake option only) Automatic Electric Brake Unit See Motor Motor (Typical) 96-114-10 U-Bolt, 5/16”...
Page 137: Seats
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) SEATS BT 2-48 Seat Cushions Item No. Part No. Description 90-195-00 Rear seat back 02-203-14 Seat back mounting plate 88-837-11 #14 x 1 Sheet metal screw 90-194-00 Rear seat cushion 90-140-00 Front seat back 90-148-00 Front seat cushion...
Page 138 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Page 138 MB-248-18...
Page 139 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) B 2-48 and B 2-54 Seats and Deck Item No. Part No. Description 90-148-00 Passenger seat cushion (standard) 90-172-00 Passenger seat cushion (with steel cab) 90-140-00 Seat back (standard) 90-179-00 Seat back (with steel cab) 90-148-00 Driver seat cushion (standard) 90-172-00...
Page 140: Steering Gear
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) STEERING GEAR Page 140 MB-248-18...
Page 141 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Steering Gear, 18-308-21 Item No. Part No. Description 18-308-70 Locknut 18-308-71 Adjuster assembly 18-308-72 Worm assembly 18-308-23 Upper worm bearing 18-308-22 Upper worm bearing race 18-308-77 Housing 18-308-78 Seal, pitman shaft 18-308-80 Nut, pitman shaft 18-308-81...
Page 142: Steering Linkage
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) STEERING LINKAGE Page 142 MB-248-18...
Page 143 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Steering Linkage Item No. Part No. Description 18-041-05 Tie rod, B 2-48, B 2-54, BT 2-48 18-057-00 Tie rod, BT 2-80 86-510-00 Ball joint clamp 86-501-98 Ball joint (left) 86-501-99 Ball joint (right) 88-527-11 1/8 x 1 Cotter pin 18-057-11...
Page 144: Steering Column
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) STEERING COLUMN Item No. Part No. Description 88-199-82 5/8NF Hex nut 19-011-20 Steering wheel 88-081-14 5/16NF x 1-1/2 Hex bolt, grade 8 88-089-84 5/16NF Hex lock nut, grade C 32-248-10 Upper bushing 20-031-65 Steering shaft assembly (incl.
Page 145: Suspension, Front
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) SUSPENSION, FRONT Item No. Part No. Description 96-121-00 U-bolt 85-498-00 Leaf spring, B 2-48, BT 2-48, BT 2--80 85-486-00 Leaf spring, B 2-54 32-214-50 Bushing 96-240-00 1/2NC x 4 Hex bolt 88-149-81 1/2NC Lock nut 88-149-81...
Page 146: Suspension, Rear
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) SUSPENSION, REAR Page 146 MB-248-18...
Page 147: Rear Suspension
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Rear Suspension Item No. Part No. Description 85-510-17 Leaf spring 16-861-44 Spring mounting plate (left) 16-861-45 Spring mounting plate (right) 96-114-00 U-bolt 88-159-84 1/2NC Nylon lock nut 96-103-00 U-bolt 88-149-81 1/2NC Lock nut 50-460-00 Strap 98-002-00...
Page 148: Wheels And Tires
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) WHEELS AND TIRES Page 148 MB-248-18...
Page 149 Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) Wheels and Tires Item No. Part No. Description Wheels 12-012-00 5 X 8” Tubeless 12-020-00 8.5 X 8 Tubeless 12-050-00 12-1/8 Diameter Cast Iron Tires 10-075-00 4.80 X 8 LR B Pneumatic 10-076-00 4.80 X 8 LR C Pneumatic 10-081-00...
Page 150: Windshield Wiper
Replacement Parts B0-248; B0-254; BT-248; BT-280 (36v & 48v) WINDSHIELD WIPER Item No. Part No. Description 74-050-00 Wiper motor 74-051-00 Wiper arm, up to 8/31/20008 0 or 1 74-051-01 Wiper arm, starting 9/1/2008 0 or 1 74-052-00 Wiper blade, up to 8/31/2008 0 or 1 74-052-01 Wiper blade, starting 9/1/2008...
Page 151 Table of Contents Hardware Information Torque Guidelines for Standard hardware ..152 Hardware Identification ..........152 Hex Nuts ..............153 Hex Lock Nuts (stover) ..........153 Other Nuts ...............153 Generic Torque Values ..........154 Replacing Hardware ........156 WARNING This section is one section of a complete service manual.
Page 152: Torque Guidelines For Standard Hardware
Hardware B0-248; B0-254; BT-248; BT-280 (36v & 48v) TORQUE GUIDELINES FOR STANDARD HARDWARE Note: Torque values specified are for clean dry threads. Note: Torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head...
Page 153: Hardware Information
‘2’ hex nuts, Grade ‘B’ as Grade ‘5’ and Grade ‘C’ as Grade ‘8’. Note: Nuts with no markings are to be treated as S.A.E. Grade A S.A.E. Grade B S.A.E. Grade C Grade L’9 Other Nuts Other nuts used by Taylor-Dunn ® should be treated as S.A.E. grade A MB-248-18 Page 153...
Page 154: Generic Torque Values
Hardware B0-248; B0-254; BT-248; BT-280 (36v & 48v) Generic Torque Values All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Imperial (inch), Foot Pounds Imperial (inch), Newton Meters Grade, SAE...
Page 155 Hardware B0-248; B0-254; BT-248; BT-280 (36v & 48v) All torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardess specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service section assembly procedure for critical torque values. Metric, Newton Meters Metric, Foot Pounds Grade, N-m...
Page 156: Replacing Hardware
Hardware B0-248; B0-254; BT-248; BT-280 (36v & 48v) REPLACING HARDWARE WARNING This section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the Service Guidelines chapter. WARNING Failure to follow the following guidelines may result in failure of the hardware resulting in severe bodily injury or property damage: •...
Page 157 WARNING CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. There are chemicals contained in the operating systems of this vehicle that are known to the state of California to cause cancer, birth defects, and other reproductive harm...
Page 158 Taylor-Dunn® Manufacturing. 2114 West Ball Road. Anaheim, CA 92804 (800)-688-8680 (714) 956-4040 FAX: (714) 956-0504 Visit our Website: www.taylor-dunn.com...

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Taylor-Dunn B0-248-36 Service Replacement Parts

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

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Inspect

Repair

Service Limits

Section 8

Section 9

Section 10

Section 11

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