Taylor-Dunn B0-T48-48 Taylor Truck T48 Manuals

Manuals and User Guides for Taylor-Dunn B0-T48-48 Taylor Truck T48. We have 3 Taylor-Dunn B0-T48-48 Taylor Truck T48 manuals available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual, Operation Manual, Manual

Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation, T Roubleshooting And Replacement Parts Manual (242 pages)

Electric

Brand: Taylor-Dunn | Category: Trucks | Size: 7.04 MB

Table of Contents

7
- About this Manual
  8
- Who Should Read this Manual
  8
- Responsibilities
  8
- How to Use this Manual
  9
- Conventions
  9
- How to Identify Your Vehicle
  10
- Taking Delivery of Your Vehicle
  11
Table of Contents

13
- Standard Specifications
  
  14
- Driver Training Program
  
  15
  - Driver Qualifications
    15
- Safety Rules and Guidelines
  
  15
- Vehicle Controls
  
  16
- Dash (up to S/N 179999)
  
  16
  - Key-Switch
    16
  - Forward-Off-Reverse Switch
    16
  - Hour Meter
    16
  - Battery Status Indicator, Analog
    16
  - Accessory Switch (Optional)
    16
  - Headlight Switch
    16
  - Auxiliary Switch (Optional)
    16
  - Horn Switch
    16
  - Wiper Switch (Optional)
    17
- Dash (Starting S/N 180000)
  
  17
  - Headlight Switch
    17
  - Strobe Switch (Optional)
    17
  - Forward-Off-Reverse Switch
    17
  - Hi-Low Switch (Optional)
    17
  - Smart View Gauge
    17
  - Horn Switch
    17
  - Key-Switch
    17
  - Foot Brake Pedal
    18
  - Accelerator Pedal
    18
  - Park Brake
    18
  - Steering
    18
  - Directional Signals (Optional)
    19
  - Hazard Light Switch (Optional)
    19
  - Charger Interlock
    19
  - Seat Interlock Switch
    19
  - Smart View Display
    20
- Vehicle Operational Guidelines
  
  22
  - Safety Guidelines
    22
  - Starting
    22
  - While Driving
    22
  - Loading and Unloading
    22
  - Towing Loads
    22
  - Parking
    23
  - Automatic Electric Park Brake
    23
  - Towing this Vehicle
    23
- Charging Your Vehicle
  
  24
- Storing / Returning to Service
  
  29
  - Storing Your Vehicle
    29
  - Returning to Service
    29
- Periodic Maintenance Checklist
  
  30
- Standard Periodic Maintenance Schedule for the Smart View Display
  
  31
  - Daily Visual Inspection
    32
- Maintenance Guidelines for Severe Duty Applications
  
  32
  - Lubrication Chart
    36
Table of Contents

37
- Inspect the Front Wheel Bearings and King Pin
  38
- Adjust Front Wheel Bearings
  39
- Front Axle Removal and Installation
  40
  - Removal
    40
  - Installation
    40
- Front Axle Disassembly
  41
- Replace Front Wheel Bearings
  42
- Replace the King Pins and Bushings
  43
- Replace the Steering Knuckle
  44
Table of Contents

45
- Front End Alignment
  46
- Inspect Ball Joints
  49
- Inspect Rod Ends
  49
- Adjust the Steering Gear
  50
- Replace the Steering Shaft
  51
- Replace the Steering Gear
  52
- Replace the Steering Wheel
  52
- Replace the Ball Joints, Tie Rods, and Drag Link
  53
  - Replacing the Drag Link
    54
  - Replacing the Tie Rod
    55
- Center the Steering Gear
  55
- Repair the Steering Gear
  56
  - Exploded View of Steering Gear
    58
Maintenance, Service, and Repair

59
- Inspect the Service Brake
  60
  - Disc Brake Pads
    60
  - Disc Brake Rotor
    60
- Adjust the Service Brakes
  61
  - Two or Four Wheel Hydraulic Disc Brakes
    61
- Inspect the Parking Brake
  61
- Adjust the Parking Brake
  62
  - Wheel Park Brake
    62
- Check Master Cylinder Fluid
  63
- Bleed the Brake System
  64
- Flush the Brake System
  65
- Replace the Parking Brake Lining
  65
  - Wheel Park Brake
    65
- Replace Front Disc Brake Pads
  66
- Replace Rear Brake Pads or Shoes
  67
- Replace the Wheel Cylinder
  68
  - Disc Brake Body Assembly (Front or Rear)
    68
- Repair the Brake Body
  69
- Replace the Master Cylinder
  71
- Repair the Master Cylinder
  72
Table of Contents

77
Maintenance, Service, and Repair

89
- Replace the Rear Springs
  
  90
  - Leaf
    90
- Replace the Front Springs
  
  91
  - Leaf
    91
- Replace the Spring Bushings
  
  92
- Replace the Shocks
  
  93
  - Front
    93
Table of Contents

95
- Inspecting the Motor Brushes
  96
  - Motors with Internal Cooling Fans
    96
  - Enclosed Motors (GE, no Cooling Fan)
    96
- Motor Inspection
  97
- Motor Removal and Installation
  97
- Replacing the Brushes
  99
- Repairing the Commutator
  100
- Replacing the Bearings
  100
- Service Limits
  101
Table of Contents

103
- Tire Inflation
  104
- Tire Inspection
  104
- Replace the Tire (Pneumatic)
  105
- Replace the Tire/Wheel
  105
- Repair the Tire (Pneumatic)
  106
Table of Contents

107
- Cleaning
  108
- Testing
  109
- Charging
  110
- Watering
  111
- Replacing (6-Volt Batteries Only)
  112
  - Moist Charge Batteries
    113
- Storage and Returning to Service
  114
  - Storage
    114
  - Returning to Service
    115
Sevcon Control System Troubleshooting

117
- Definitions
  118
- Important Notes and Instructions
  118
- Terminology Used
  118
- Test Equipment Required
  118
- Identifying Your Controller
  119
- Start Troubleshooting here
  120
- Test 8. Anti-Rolloff Fault
  131
- Test 9. Electric Motor Brake
  132
- Logic Voltage Reference Table
  134
- Status LED Code Table
  135
- Smart View Fault Codes
  136
Electrical Troubleshooting

139
- Lester X-Series Charger
  
  140
  - Test Equipment Required for Troubleshooting
    140
  - Important Notes and Instructions
    140
  - Theory of Operation
    140
  - Fault and Diagnostic Error Code Table
    141
  - Internal Wiring Diagram
    141
  - Testing the Charging Cycle
    142
- Troubleshooting
  
  143
  - SCR Assembly
    143
  - Transformer
    144
  - Lock out Relay
    144
  - Relay Board Assembly
    145
  - Control Board Assembly
    145
- Profile Setting
  
  146
- Signet HBS Charger
  
  147
  - Test Equipment Required for Troubleshooting
    147
  - Important Notes and Instructions
    147
  - Definitions
    147
  - Operating Instructions and Theory of Operation
    148
  - Testing the Charging Cycle
    149
  - Status Light Error Code Table
    150
  - Troubleshooting
    151
- Lestronic II Charger
  
  152
- Testing the Interlock Relay
  
  157
  - Operation
    157
  - Testing
    157
- Replacing the Charger
  
  157
Illustrated Parts

163
- Front Axle
  164
- Front Brakes
  166
- Steering Linkage
  168
- Steering Column
  170
- Steering Gear
  172
- Front Suspension
  174
- Transmission Gear Case
  177
- Transmission Differential Case
  179
- Rear Axle
  180
- Rear Brakes
  182
- Rear Suspension
  184
- Motor
  186
- Electric Brake
  188
- Master Cylinder
  190
- Speed Control Panel
  200
- Miscellaneous Frame and Body
  202
- Charger, Lestronic
  204
- Charger, Signet
  206
- Miscellaneous Electrical
  207
- Batteries
  208
- Decals
  210
- Strobe Light
  212
- Steel Cab (T48)
  214
- Tops (T48)
  218
- Doors (T48)
  220
- Optional Deckboards (T48)
  222
- Watering System
  223
- Cargo Box
  224
- Stake Sides
  226
- Cab, Deck (ET 3000)
  228
- Cab Components (ET 3000)
  230
- Misc Frame (ET 3000)
  232
- Appendix A: Special Tools
  
  236
- Appendix B: Suggested Torque Limits for Standard Hardware
  
  237
  - Hex Bolts
    237
  - Other Bolts
    237
  - Hex Nuts
    238
  - Hex Lock Nuts (Stover)
    238
  - Other Nuts
    238
  - Suggested Torque Values (Non-Critical Hardware)
    239
- Appendix C: Brake Lining Handling Precautions
  
  241

Taylor-Dunn B0-T48-48 Taylor Truck T48 Manual (196 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 6.01 MB

Table of Contents
5
Introduction
8
About this Manual
8
Who Should Read this Manual
9
Responsibilities
9
How to Use this Manual
10
Conventions
11
How to Identify Your Vehicle
12
Taking Delivery of Your Vehicle
13
Safety Rules and Operating Instructions
15
Standard Specifications
16
Safety Rules and Guidelines
17
Driver Training Program
18
Driver Qualifications
18
Horn Switch
19
Forward-Off-Reverse Switch
19
3A) Light Switch
19
3B) Hi-Low Switch
19
Combination Display
19
Reverse Alarm Disable
19
Vehicle Controls
19
Key-Switch
19
Emergency Stop Switch
19
Combination Display
20
Accelerator Pedal
21
Foot Brake Pedal
21
Steering
21
Directional Signals (Optional)
21
Hazard Light Switch (Optional)
21
Charger Interlock
22
Seat Interlock Switch
22
Electrolyte Alarm (Optional)
22
Vehicle Operational Guidelines
23
Safety Guidelines
23
Starting
23
While Driving
23
Loading and Unloading
24
Parking
24
Towing
24
Adjustable Controller Parameters
25
Charging Your Vehicle
26
Charging Time
26
New Battery Break in
26
Storing and Returning to Service
27
Storing Your Vehicle
27
Returning to Service
27
Periodic Maintenance Checklist
28
Daily Visual Inspection
29
Maintenance Guidelines for Severe Duty Applications
29
General Maintenance
31
Maintenance Guidelines
32
Troubleshooting Guide
33
Lubrication Chart
34
Front Axle Service
35
Inspect the Front Wheel Bearings and King Pin
36
Adjust Front Wheel Bearings
37
Front Axle Removal and Installation
38
Removal
38
Installation
39
Front Axle Disassembly
40
Replace Front Wheel Bearings
41
Replace the King Pins and Bushings
43
Replace the Steering Knuckle
45
Steering Component Service
47
Front End Alignment
48
Inspect Ball Joints
52
Inspect Rod Ends
53
Adjust the Steering Gear
54
Replace the Steering Shaft
56
Replace the Steering Wheel
58
Replace the Steering Gear
59
Replace the Ball Joints, Tie Rods, and Drag Link
60
Replacing the Drag Link
62
Replacing the Tie Rod
63
Center the Steering Gear
64
Pitman Shaft Alignment
64
Repair the Steering Gear
65
Exploded View of Steering Gear
68
Brake Service
69
Inspect the Service Brake
70
Disc Brake Pads
70
Disc Brake Rotor
71
Inspect the Automatic Parking Brake
72
Adjust the Automatic Parking Brake
72
Adjust the Service Brakes
72
Check Master Cylinder Fluid
73
Bleed the Brake System
74
Flush the Brake System
76
Replace Front Disc Brake Pads
77
Replace Rear Brake Pads
79
Hydraulic Disc
79
Replace the Wheel Cylinder
81
Disc Brake Body Assembly (Front or Rear)
81
Replace the Master Cylinder
83
Repair the Master Cylinder
85
Transmission
88
Check Oil Level
88
Change Oil
89
Motor Removal and Installation
90
Rear Hub or Rotor
91
Removing and Installing the Rear Axles (Disc Brakes)
92
Transmission Assembly
94
Remove and Install
94
Disassembly and Reassembly of the Primary Reduction Gear Case
95
Disassembling the 3Rd Member
98
Assembling the 3Rd Member
101
Pinion Bearing Preload
104
Pinion Gear Shimming Instructions
105
Setting the Pinion Gear Depth
105
Suspension
108
Replace the Rear Springs
108
Replace the Front Springs
109
Replace the Spring Bushings
110
Replace the Shocks
111
Tires and Wheels
114
Tire Inflation
114
Tire Inspection
114
Replace the Tire/Wheel
115
Repair the Tire (Pneumatic)
116
Replace the Tire (Pneumatic)
117
Battery Service
119
Cleaning
120
Testing
121
Watering
123
Charging
123
Replacing (6-Volt Batteries Only)
124
Moist Charge Batteries
126
Storage and Returning to Service
127
Storage
127
Returning to Service
128
Control System Diagnostics
131
Test Equipment Required
132
Important Notes and Instructions
132
Status LED Code Table
133
Throttle Module Test
136
Operating Instructions and Theory of Operation
142
Testing the Charging Cycle
143
Test Equipment Required for Troubleshooting
144
Important Notes and Instructions
144
Troubleshooting for Built-In Charger
145
Troubleshooting for Portable Charger
148
Testing the Timer Relay
149
Testing the Interlock Relay
150
Illustrated Parts
151
Front Axle
152
Steering Knuckle
154
Steering Linkage
156
Steering Column
158
Front Suspension
160
Steering Gear
160
Front Suspension
161
Steering Gear
161
Rear Suspension
162
Transmission Gear Case
164
Rear Axle
166
Transmission Differential Case
166
Rear Brakes
168
Front Brakes
168
Brake Lines and Master Cylinder
170
Motor
172
Motor Mount
174
Wheels and Tires
176
Lighting
177
Instrument Panel (Dash)
178
Wire Harnesses
178
Speed Control Panel
180
Miscellaneous Electrical
182
Charger
184
Seat Cushions and Deck
185
Miscellaneous Frame Components
185
Batteries
186
Appendixes
190
Appendix A: Special Tools
190
Appendix B: Suggested Torque Limits for Standard Hardware
191
Hardware Identification
191
Standard Head Markings
191
Hex Bolts
191
Other Bolts
191
Hex Nuts
192
Hex Lock Nuts (Stover)
192
Other Nuts
192
Suggested Torque Values (Non-Critical Hardware)
193
Suggested Torque Values (Critical Hardware)
194
Appendix C: Brake Lining Handling Precautions
195

Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation Manual (240 pages)

Brand: Taylor-Dunn | Category: Trucks | Size: 26.02 MB

Table of Contents

5
- Operator and Maintenance Manual
  
  11
- Introduction
  
  11
  - How to Use this Manual
    13
  - Who Should Read this Manual
    14
  - Responsibilities
    14
  - Conventions
    15
- Vehicle Description and Specifications
  
  17
- Vehicle Description
  
  18
- Safety Rules and Operational Information
  
  23
- Safety Rules and Guidelines
  
  24
  - Driver Training Program
    26
  - Driver Qualifications
    27
  - Vehicle Controls
    28
    
    Accelerator
    28
    
    Forward-Reverse Switch
    28
    
    Key-Switch
    28
    
    Foot Brake
    29
    
    Horn Button
    29
    
    Park Brake
    29
    
    Steering
    29
    
    Charger Interlock
    30
    
    Hour Meter
    30
    
    Seat Interlock Switch
    30
    
    Battery Status Indicator
    31
    
    Electrolyte Alarm (Optional)
    31
    
    Reverse and Motion Alarm
    31
    
    Windshield Washer Fluid Tank
    31
    
    Smart View Display
    32
  - Vehicle Operational Guidelines
    35
    
    Driving
    35
    
    Loading and Unloading
    35
    
    Parking
    35
    
    Towing
    35
  - Storing and Returning to Service
    36
    
    Returning to Service
    36
- Maintenance and Service Procedures
  
  37
- Maintenance Guidelines
  
  38
- Severe Duty Guidelines
  
  39
- Periodic Maintenance Checklist
  
  40
- Troubleshooting Guide
  
  42
  - Brakes
    42
    
    Brake Pad Replacement
    45
    
    Repairing the Brake Body
    46
    
    Bleeding the Brakes
    48
    
    Replacing the Master Cylinder
    50
    
    Filling and Checking the Fluid Level
    51
  - Parking Brake
    52
  - Front Axle and Yokes
    54
    
    Axle Removal and Installation
    55
    
    Aligning the Front End
    56
    
    Centering the Steering
    57
    
    Repairing the Front Axle
    58
    
    Steering Yoke/Bushings
    58
    
    Ball Joints, Tie Rods, and Drag Links
    60
    
    Front Wheel Bearings
    61
    
    Removal and Installation of the Steering Gear
    63
    
    Endplay
    65
    
    Steering Gear Adjustment
    65
    
    Gear Lash
    66
  - Drive Service
    71
    
    Removing the Rear Axles
    72
    
    Removing and Installing the Drive
    74
    
    Reduction Gear Case
    75
    
    Assembly of the 3Rd Member
    78
    
    Pinion Gear Shimming
    84
    
    Pinion Bearing Preload
    85
    
    Changing the Differential Oil
    86
  - Speed Controller
    87
    
    Removing and Installing Speed Controller
    88
  - Drive Motor
    89
    
    Motor Removal
    90
    
    Automatic Electric Brake Removal and Installation
    91
    
    Motor Disassembly and Assembly
    93
    
    Armature and Brush Inspection
    95
    
    Motor Specifications
    96
  - Battery
    97
    
    Cleaning
    98
    
    Electrolyte Alarm
    99
    
    Servicing
    100
    
    Battery Storage
    101
    
    Charging
    101
  - Operating Instructions and Theory of Operation
    130
  - Testing the Charging Cycle
    131
  - Test Equipment Required
    132
  - Troubleshooting for Built-In Charger
    133
  - Troubleshooting for Portable Charger
    136
  - Testing the Timer Relay
    137
  - Testing the Interlock Relay
    138
- Signet Charger Troubleshooting
  
  139
  - Operating Instructions and Theory of Operation
    139
  - Testing the Charging Cycle
    141
  - Status LED Error Code
    143
  - Troubleshooting
    144
- Wire Diagrams
  
  146
- Complete Vehicle
  
  146
  - Control Panel
    147
- Throttle Module
  
  148
- Lighting
  
  149
Section 5 Illustrated Parts List Common

151
- Illustrated Parts List Common
  
  151
- Front Axle Assembly
  
  152
- Steering Sleeve Assembly
  
  154
- Front Suspension
  
  156
- Drag Link
  
  158
- Steering Gear
  
  160
- Steering Column Assembly
  
  162
- Master Cylinder, Brake Line Hardware and
  
  164
- Master Cylinder
  
  166
- Hydraulic Disc Brakes
  
  168
  - Park Brake Linkage
    170
  - Motor
    173
  - Automatic Electric Brake
    174
  - Instrument Panel and Components
    176
  - Resetting the Smart View Display
    177
- Control Panel
  
  178
  - Electrical Components (Typical)
    180
  - Chargers
    182
  - Signet Charger
    184
  - Accelerator Module
    186
  - Drive
    189
  - Drive Assembly
    192
  - Rear Axle
    194
  - Decals
    196
  - Hitch Options
    198
- Door Options
  
  212
- Stake Side Options
  
  218
  - Special Tools
    234

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Taylor-Dunn B0-T48-48 Taylor Truck T48 Manuals

Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation, T Roubleshooting And Replacement Parts Manual (242 pages)

Table of Contents

Table of Contents

Table of Contents

Standard Specifications

Driver Training Program

Safety Rules and Guidelines

Vehicle Controls

Dash (up to S/N 179999)

Dash (Starting S/N 180000)

Vehicle Operational Guidelines

Charging Your Vehicle

Storing / Returning to Service

Periodic Maintenance Checklist

Standard Periodic Maintenance Schedule for the Smart View Display

Maintenance Guidelines for Severe Duty Applications

Table of Contents

Table of Contents

Maintenance, Service, and Repair

Table of Contents

Maintenance, Service, and Repair

Replace the Rear Springs

Replace the Front Springs

Replace the Spring Bushings

Replace the Shocks

Table of Contents

Table of Contents

Table of Contents

Sevcon Control System Troubleshooting

Electrical Troubleshooting

Lester X-Series Charger

Troubleshooting

Profile Setting

Signet HBS Charger

Lestronic II Charger

Testing the Interlock Relay

Replacing the Charger

Illustrated Parts

Appendix A: Special Tools

Appendix B: Suggested Torque Limits for Standard Hardware

Appendix C: Brake Lining Handling Precautions

Taylor-Dunn B0-T48-48 Taylor Truck T48 Manual (196 pages)

Table of Contents

Taylor-Dunn B0-T48-48 Taylor Truck T48 Operation Manual (240 pages)

Table of Contents

Table of Contents

Operator and Maintenance Manual

Introduction

Vehicle Description and Specifications

Vehicle Description

Safety Rules and Operational Information

Safety Rules and Guidelines

Maintenance and Service Procedures

Maintenance Guidelines

Severe Duty Guidelines

Periodic Maintenance Checklist

Troubleshooting Guide

Signet Charger Troubleshooting

Wire Diagrams

Complete Vehicle

Throttle Module

Lighting

Section 5 Illustrated Parts List Common

Illustrated Parts List Common

Front Axle Assembly

Steering Sleeve Assembly

Front Suspension

Drag Link

Steering Gear

Steering Column Assembly

Master Cylinder, Brake Line Hardware and

Master Cylinder

Hydraulic Disc Brakes

Control Panel

Door Options

Stake Side Options

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