Taylor-Dunn B 2-48 Manuals

Manuals and User Guides for Taylor-Dunn B 2-48. We have 2 Taylor-Dunn B 2-48 manuals available for free PDF download: Operation, T Roubleshooting And Replacement Parts Manual

Taylor-Dunn B 2-48 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 B 2-48 Operation, T Roubleshooting And Replacement Parts Manual (232 pages)

EQUIPPED WITH AC MOTOR PEED CONTROL

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 20.05 MB

Taylor-Dunn

5
- Table of Contents
  5
- About this Manual
  8
- Introduction
  8
- Safety Rules and Operating Instructions
  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
- Dash up to Serial #179501
  
  19
  - Horn Switch
    19
  - Forward-Off-Reverse Switch
    19
  - 3A) Light Switch
    19
  - 3B) Hi-Low Switch
    19
  - Combination Display
    19
  - Accessory Switches (Optional)
    19
- Vehicle Controls
  
  19
  - Key-Switch
    19
  - Emergency Stop Switch
    19
  - Strobe Switch (Optional)
    20
  - Forward-Off-Reverse Switch
    20
  - Hi-Low Switch (Optional)
    20
  - Smart View Display
    20
  - Horn Switch
    20
  - Key-Switch
    20
  - Wiper Switch (Optional)
    20
  - Headlight Switch
    20
- Dash Starting Serial #1795002
  
  20
  - Combination Display
    21
  - Charger Interlock
    23
- Vehicle Operational Guidelines
  
  24
  - Safety Guidelines
    24
  - Starting
    24
  - While Driving
    24
  - Loading and Unloading
    25
  - Parking
    25
  - Towing
    25
  - Adjustable Controller Parameters
    26
- Charging Your Vehicle
  
  28
- Storing and Returning to Service
  
  30
  - Storing Your Vehicle
    30
  - Returning to Service
    30
- Periodic Maintenance Checklist
  
  31
  - Daily Visual Inspection
    32
- Maintenance Guidelines for Severe Duty Applications
  
  32
  - General Maintenance
    33
    
    Troubleshooting Guide
    35
    
    Lubrication Chart
    36
Front Axle Service

37
- Inspect the Front Wheel Bearings and King Pin
  38
- Adjust Front Wheel Bearings
  39
- Front Axle Removal and Installation
  40
  - Removal
    40
  - Installation
    41
- Steering Component Service
  41
Steering Component Service

49
- Front End Alignment
  50
- Inspect Ball Joints
  54
- Inspect Rod Ends
  55
- Adjust the Steering Gear
  56
- Replace the Steering Shaft
  58
- Replace the Steering Wheel
  60
- Replace the Steering Gear
  61
- Replace the Ball Joints, Tie Rods, and Drag Link
  62
  - Replacing the Drag Link
    64
  - Replacing the Tie Rod
    65
- Center the Steering Gear
  66
- Pitman Shaft Alignment
  66
- Repair the Steering Gear
  67
  - Exploded View of Steering Gear
    70
Brake Service

71
- Brakes Service
  71
  - Inspect the Service Brake
    72
    
    Disc Brake Pads
    72
    
    Disc Brake Rotor
    73
  - Inspect the Automatic Parking Brake
    74
  - Adjust the Automatic Parking Brake
    74
  - Adjust the Service Brakes
    74
  - Check Master Cylinder Fluid
    75
  - Bleed the Brake System
    76
  - Flush the Brake System
    78
  - Replace Front Disc Brake Pads
    79
  - Replace Rear Brake Pads
    81
    
    Hydraulic Disc
    81
  - Replace the Wheel Cylinder
    83
    
    Disc Brake Body Assembly (Front or Rear)
    83
  - Replace the Master Cylinder
    85
  - Repair the Master Cylinder
    87
Transmission

89
- Check Oil Level
  90
- Change Oil
  91
- Motor Removal and Installation
  92
- Rear Hub or Rotor
  93
- Removing and Installing the Rear Axles (Disc Brakes)
  94
- Transmission Assembly
  96
  - Remove and Install
    96
- Disassembly and Reassembly of the Primary Reduction Gear Case
  97
- Disassembling the 3Rd Member
  100
- Assembling the 3Rd Member
  103
  - Pinion Bearing Preload
    106
- Pinion Gear Shimming Instructions
  107
  - Setting the Pinion Gear Depth
    107
Suspension

109
- Replace the Rear Springs
  110
- Replace the Front Springs
  111
- Replace the Spring Bushings
  112
- Replace the Shocks
  113
- Tires and Wheels
  113
Tires and Wheels

115
- Tire Inflation
  116
- Tire Inspection
  116
- Replace the Tire/Wheel
  117
- Repair the Tire (Pneumatic)
  118
- Replace the Tire (Pneumatic)
  119
Battery Service

121
- Cleaning
  122
- Testing
  123
- Watering
  125
- Charging
  126
- Replacing (6-Volt Batteries Only)
  127
  - Moist Charge Batteries
    129
- Storage and Returning to Service
  130
  - Storage
    130
  - Returning to Service
    131
Control System Diagnostics

135
- Important Notes and Instructions
  136
- Test Equipment Required
  136
- Status LED Code Table
  137
- Throttle Module Test
  140
- Wire Diagram
  142
Electrical Troubleshooting

154
Illustrated Parts

163
- Front Axle
  164
- Steering Knuckle
  166
- Steering Linkage
  168
- Steering Column
  170
- Front Suspension
  172
- Steering Gear
  172
- Rear Suspension
  174
- Transmission Gear Case
  176
- Rear Axle
  178
- Transmission Differential Case
  178
- Rear Brakes
  180
  - Front Brake
    181
- Brake Lines
  182
- Master Cylinder
  182
- Motor
  184
- Motor Mount
  186
- Wheels and Tires
  188
- Instrument Panel Starting Serial # 179502
  190
- Instrument Panel up to Serial # 179501
  190
- Speed Control Panel
  192
- Wire Harnesses
  192
- Resetting the Maintenance Meter Function
  193
- Miscellaneous Electrical
  194
- Lighting
  196
- Lestronic® Charger
  198
- Signet® Charger
  202
- Portable Charger Wiring
  203
- Batteries
  204
- Seat Cushions and Deck
  206
- Mirrors
  208
- Miscellaneous Frame Components
  208
- Decals
  210
- Cab Options
  212
- Door Options, Steel Cab
  214
- Door Options, Fiberglass Cab
  216
- Hydraulic Dump Body Option
  218
- Rear Cargo Box
  220
- Top Covers
  220
- Hitches
  222
- Ladder Rack Option B2-004-66 and B2-006-78
  223
- Appendix B
  
  225
  - Brake Lining Handling Precautions
    225
- Appendix A: Special Tools
  
  226
  - Hex Bolts
    227
  - Other Bolts
    227
  - Hardware Identification
    227
  - Hex Nuts
    228
  - Hex Lock Nuts (Stover)
    228
  - Other Nuts
    228
  - Suggested Torque Values (Non-Critical Hardware)
    229
- Appendix C: Brake Lining Handling Precautions
  
  231

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Table of Contents

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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 B 2-48 Operation, T Roubleshooting And Replacement Parts Manual (232 pages)

Table of Contents

Taylor-Dunn

Safety Rules and Operating Instructions

Standard Specifications

Safety Rules and Guidelines

Driver Training Program

Dash up to Serial #179501

Vehicle Controls

Dash Starting Serial #1795002

Vehicle Operational Guidelines

Charging Your Vehicle

Storing and Returning to Service

Periodic Maintenance Checklist

Maintenance Guidelines for Severe Duty Applications

Front Axle Service

Steering Component Service

Brake Service

Transmission

Suspension

Tires and Wheels

Battery Service

Control System Diagnostics

Electrical Troubleshooting

Illustrated Parts

Appendix B

Appendix A: Special Tools

Appendix C: Brake Lining Handling Precautions

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