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Taylor-Dunn B0-248-48 User Manual

Taylor-Dunn B0-248-48
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The Best Way
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Serial Number Starting 177127
MANUAL MB-248-12
Operation, Troubleshooting and
Replacement Parts Manual
Published 7/7/2008
Revision: B
EQUIPPED WITH GT-DRIVE SYSTEM
GT Drive
Models Inlcuded:
B0-248-36 (B 2-48, 36-volt)
B0-248-48 (B 2-48, 48-volt)
B0-254-36 (B 2-54)
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)
BT-280-48 (48-volt 10-passenger Tram)
Shown with optional equipment installed

Table of Contents

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Questions and Answers:

Taylor-Dunn B0-248-48 Specifications

General IconGeneral
BrandTaylor-Dunn
ModelB0-248-48
CategoryUtility Vehicle
LanguageEnglish

Summary

Safety Rules and Operating Instructions

Safety Rules and Guidelines

Outlines essential safety rules for vehicle operation, emphasizing operator responsibility and safe practices.

Driver Training Program

Details the required operator training program, including essential elements for safe vehicle handling.

Driver Qualifications

Specifies the minimum requirements and abilities necessary for a qualified vehicle operator.

Smart View Display

Details the functions of the Smart View Display as a battery status, hour meter, and controller monitor.

Fault Code Tables

Provides a reference for fault codes generated by the control system and recommended actions.

Vehicle Operation Guidelines

Starting

Outlines the necessary steps and safety precautions before starting the vehicle.

While driving

Provides guidelines for safe driving practices, including horn usage and speed considerations.

Charging Your Vehicle

Periodic Maintenance Checklist

Presents a checklist for periodic maintenance tasks based on operating hours.

Standard Periodic Maintenance Schedule for the Smart View Display

Details the preventive maintenance schedule based on hour intervals for vehicles with Smart View display.

Daily Visual inspection

Lists critical daily visual inspection points for the vehicle's safety and operation.

Maintenance Guidelines for Severe Duty Applications

Provides guidelines for increased maintenance frequency under severe operating conditions.

General Maintenance

Maintenance Guidelines

Provides essential guidelines and safety precautions for performing vehicle maintenance and service.

Troubleshooting Guide

Lists common vehicle symptoms and their probable causes for diagnosing issues.

Front Axle Service

Inspect the Front Wheel Bearings and King Pin

Provides steps for inspecting front wheel bearings and king pins for wear or looseness.

Adjust Front Wheel Bearings

Details the procedure for adjusting front wheel bearings to eliminate play.

Front Axle Removal and Installation

Explains the steps for removing and installing the front axle assembly.

Replace Front Wheel Bearings

Provides a step-by-step guide for replacing front wheel bearings and associated components.

Replace the King Pins and Bushings

Details the procedure for replacing king pins and bushings in the steering system.

Steering Component Service

Front End Alignment

Details the procedure for aligning the front end of the vehicle, including wheel and steering gear centering.

Inspect Ball Joints

Describes how to inspect ball joints for signs of wear and play in the steering system.

Inspect Rod Ends

Provides instructions for inspecting rod ends for play and wear in the steering linkage.

Adjust the Steering Gear

Explains the procedure for adjusting the steering gear lash and worm bearing preload.

Replace the Steering Gear

Outlines the procedure for removing and installing the entire steering gear assembly.

Replace the Ball Joints, Tie Rods, and Drag Link

Details the process for replacing components of the steering linkage system.

REPAIR THE STEERING GEAR

Outlines the disassembly and reassembly procedures for repairing the steering gear.

Brake Service

Inspect the Service Brake

Details procedures for inspecting disc brake pads and rotors for wear and damage.

Inspect the Parking brake

Explains how to inspect the wheel park brake mechanism and associated cables.

Adjust the Service Brakes

Discusses factors affecting service brake performance and system inspection.

ADJUST THE PARKING BRAKE

Provides instructions for adjusting the wheel park brake linkage for proper function.

CHECK MASTER CYLINDER FLUID

Outlines procedures for checking and filling the master cylinder with brake fluid.

BLEED THE BRAKE SYSTEM

Details the step-by-step process for bleeding air from the hydraulic brake system.

REPLACE FRONT DISC BRAKE PADS

Details the procedure for replacing the front disc brake pads, including fluid level adjustments.

REPLACE REAR BRAKE PADS

Provides instructions for replacing rear disc brake pads, including fluid level adjustments.

REPLACE THE WHEEL CYLINDER

Outlines the steps for removing and installing the disc brake body assembly (wheel cylinder).

REPLACE THE MASTER CYLINDER

Explains how to remove and install the master cylinder assembly.

Motor Service

Inspecting the Motor Brushes

Details the procedure for inspecting motor brushes and determining when replacement is necessary.

MOTOR INSPECTION

Outlines procedures for inspecting motor components, including brushes, commutator, and windings.

Battery Service

TESTING

Details methods for testing battery condition using load tests and specific gravity tests.

Sevcon Control System Troubleshooting

Electrical Troubleshooting

Provides general notes, definitions, and test equipment requirements for electrical troubleshooting.

START TROUBLESHOOTING HERE

Guides the user to begin the troubleshooting process, including initial checks and warnings.

Test 1. CHECKING THE CONTROL LOGIC INPUTS

Details voltage tests for various inputs to the Sevcon controller logic card.

Test 2. TESTING THE MOTOR

Provides continuity tests for the motor's field and armature windings.

Test 3. THE VEHICLE RUNS IN ONE DIRECTION ONLY

Troubleshooting steps for vehicles that only operate in one direction.

Test 4. KEY FAULT

Diagnoses issues related to the vehicle's key switch and its connection to the control system.

Test 5. CONTACTOR COIL FAULT

Troubleshooting steps for faults related to the contactor coil and its associated circuits.

Test 6. ACCELERATOR MODULE FAULT

Guides through testing the accelerator module for proper operation and voltage output.

Test 7. FORWARD AND REVERSE SWITCH FAULT

Details troubleshooting for faults in the forward and reverse switch.

Test 8. ANTI-ROLLOFF FAULT

Explains how to test the Anti-Rolloff feature for proper vehicle slow-down.

Test 9. ELECTRIC MOTOR BRAKE

Provides steps for testing the electric motor brake system for proper engagement and release.

Status LED Code Table

Explains the meaning of status LED flash codes for diagnosing controller faults.

Smart View Fault Codes

Lists Level 5 and Level 4 fault codes for the Smart View system and their potential causes.

Signet® Charger Troubleshooting

TESTING THE CHARGING CYCLE

Details how to test the charger's cycle completion by monitoring battery voltage and current.

Status Light Error Code Table

Explains charger error codes indicated by status LEDs and required actions.

TROUBLESHOOTING

Provides basic troubleshooting steps for chargers that fail to turn on or operate correctly.

APPENDIX A-Special Tools

Special Tools

Lists special tools required for maintenance and repair, including their purpose and part numbers.

Appendix B: Standard Hardware Suggested Torque Limits

SUGGESTED TORQUE VALUES (critical hardware)

Provides suggested torque values for critical hardware components across various systems.

Appendix C

BRAKE LINING HANDLING PRECAUTIONS

Details precautions for handling brake pads/shoes, particularly concerning potential asbestos content.

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