Taylor-Dunn B0-T48-48

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Serial Number :171239

MANUAL MB-T48-99

Operation, Troubleshooting and

Replacement Parts Manual

Models Inlcuded:

B0-T48-48

Revision: A

Main Page

Table of Contents5
Introduction8
About this Manual8
Who Should Read this Manual9
Responsibilities9
How to Use this Manual10
Conventions11
How to Identify Your Vehicle12
Taking Delivery of Your Vehicle13
Safety Rules and Operating Instructions15
Standard Specifications16
Safety Rules and Guidelines17
Driver Training Program18
Driver Qualifications18
Horn Switch19
Forward-Off-Reverse Switch19
3A) Light Switch19
3B) Hi-Low Switch19
Combination Display19
Reverse Alarm Disable19
Vehicle Controls19
Key-Switch19
Emergency Stop Switch19
Combination Display20
Accelerator Pedal21
Foot Brake Pedal21
Steering21
Directional Signals (Optional)21
Hazard Light Switch (Optional)21
Charger Interlock22
Seat Interlock Switch22
Electrolyte Alarm (Optional)22
Vehicle Operational Guidelines23
Safety Guidelines23
Starting23
While Driving23
Loading and Unloading24
Parking24
Towing24
Adjustable Controller Parameters25
Charging Your Vehicle26
Charging Time26
New Battery Break in26
Storing and Returning to Service27
Storing Your Vehicle27
Returning to Service27
Periodic Maintenance Checklist28
Daily Visual Inspection29
Maintenance Guidelines for Severe Duty Applications29
General Maintenance31
Maintenance Guidelines32
Troubleshooting Guide33
Lubrication Chart34
Front Axle Service35
Inspect the Front Wheel Bearings and King Pin36
Adjust Front Wheel Bearings37
Front Axle Removal and Installation38
Removal38
Installation39
Front Axle Disassembly40
Replace Front Wheel Bearings41
Replace the King Pins and Bushings43
Replace the Steering Knuckle45
Steering Component Service47
Front End Alignment48
Inspect Ball Joints52
Inspect Rod Ends53
Adjust the Steering Gear54
Replace the Steering Shaft56
Replace the Steering Wheel58
Replace the Steering Gear59
Replace the Ball Joints, Tie Rods, and Drag Link60
Replacing the Drag Link62
Replacing the Tie Rod63
Center the Steering Gear64
Pitman Shaft Alignment64
Repair the Steering Gear65
Exploded View of Steering Gear68
Brake Service69
Inspect the Service Brake70
Disc Brake Pads70
Disc Brake Rotor71
Inspect the Automatic Parking Brake72
Adjust the Automatic Parking Brake72
Adjust the Service Brakes72
Check Master Cylinder Fluid73
Bleed the Brake System74
Flush the Brake System76
Replace Front Disc Brake Pads77
Replace Rear Brake Pads79
Hydraulic Disc79
Replace the Wheel Cylinder81
Disc Brake Body Assembly (Front or Rear)81
Replace the Master Cylinder83
Repair the Master Cylinder85
Transmission88
Check Oil Level88
Change Oil89
Motor Removal and Installation90
Rear Hub or Rotor91
Removing and Installing the Rear Axles (Disc Brakes)92
Transmission Assembly94
Remove and Install94
Disassembly and Reassembly of the Primary Reduction Gear Case95
Disassembling the 3Rd Member98
Assembling the 3Rd Member101
Pinion Bearing Preload104
Pinion Gear Shimming Instructions105
Setting the Pinion Gear Depth105
Suspension108
Replace the Rear Springs108
Replace the Front Springs109
Replace the Spring Bushings110
Replace the Shocks111
Tires and Wheels114
Tire Inflation114
Tire Inspection114
Replace the Tire/Wheel115
Repair the Tire (Pneumatic)116
Replace the Tire (Pneumatic)117
Battery Service119
Cleaning120
Testing121
Watering123
Charging123
Replacing (6-Volt Batteries Only)124
Moist Charge Batteries126
Storage and Returning to Service127
Storage127
Returning to Service128
Control System Diagnostics131
Test Equipment Required132
Important Notes and Instructions132
Status LED Code Table133
Throttle Module Test136
Operating Instructions and Theory of Operation142
Testing the Charging Cycle143
Test Equipment Required for Troubleshooting144
Important Notes and Instructions144
Troubleshooting for Built-In Charger145
Troubleshooting for Portable Charger148
Testing the Timer Relay149
Testing the Interlock Relay150
Illustrated Parts151
Front Axle152
Steering Knuckle154
Steering Linkage156
Steering Column158
Front Suspension160
Steering Gear160
Front Suspension161
Steering Gear161
Rear Suspension162
Transmission Gear Case164
Rear Axle166
Transmission Differential Case166
Rear Brakes168
Front Brakes168
Brake Lines and Master Cylinder170
Motor172
Motor Mount174
Wheels and Tires176
Lighting177
Instrument Panel (Dash)178
Wire Harnesses178
Speed Control Panel180
Miscellaneous Electrical182
Charger184
Seat Cushions and Deck185
Miscellaneous Frame Components185
Batteries186
Appendixes190
Appendix A: Special Tools190
Appendix B: Suggested Torque Limits for Standard Hardware191
Hardware Identification191
Standard Head Markings191
Hex Bolts191
Other Bolts191
Hex Nuts192
Hex Lock Nuts (Stover)192
Other Nuts192
Suggested Torque Values (Non-Critical Hardware)193
Suggested Torque Values (Critical Hardware)194
Appendix C: Brake Lining Handling Precautions195

Taylor-Dunn B0-T48-48 - Manual

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