Taylor-Dunn BT-248-36 Manuals

Manuals and User Guides for Taylor-Dunn BT-248-36. We have 2 Taylor-Dunn BT-248-36 manuals available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual, Service Replacement Parts

Taylor-Dunn BT-248-36 Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn BT-248-36 Operation, T Roubleshooting And Replacement Parts Manual (292 pages)

EQUIPPED WITH GT-DRIVE SYSTEM

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

Table of Contents

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

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Taylor-Dunn BT-248-36 Service Replacement Parts

Taylor-Dunn BT-248-36 Service Replacement Parts (158 pages)

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

Table of Contents

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

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