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Taylor-Dunn BT 2-80 User Manual

Taylor-Dunn BT 2-80
292 pages
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TAYLOR-DUNN
®
B 2-48/B 2-54 Serial number Starting: 146189
BT 2-48 Serial number Starting: 150719
BT 2-80 Serial number Starting: 159916
All models - Serial Number Ending 177126
MANUAL MB-248-10
Operation, Troubleshooting and
Replacement Parts Manual
Revision: L, 6/28/2017
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. 36-volt)
B0-254-48 (B 2-54, 48-volt)
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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Taylor-Dunn BT 2-80 Specifications

General IconGeneral
BrandTaylor-Dunn
ModelBT 2-80
CategoryUtility Vehicle
LanguageEnglish

Summary

Safety Rules and Operating Instructions

Safety Rules and Guidelines

Outlines essential safety rules and guidelines for operating the vehicle safely.

Driver Training Program and Qualifications

Details the operator training requirements and qualifications necessary for safe vehicle operation.

Smart View Display Operation

Explains the functions and indicators of the Smart View Display system.

Vehicle Operation Guidelines

Provides essential guidelines for safe operation, starting, driving, and parking procedures.

Maintenance Schedules and Guidelines

Includes periodic maintenance checklists, schedules, daily inspections, and severe duty guidelines.

General Maintenance

Troubleshooting Guide

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

Front Axle Service

Front Axle Removal and Installation

Provides step-by-step instructions for removing and installing the front axle assembly.

Replacing Front Wheel Bearings

Step-by-step guide for replacing the front wheel bearings and associated components.

Replacing King Pins and Bushings

Instructions for replacing king pins and bushings in the steering knuckles and axle.

Replacing the Steering Knuckle

Procedure for removing and installing the steering knuckle assembly.

Steering Component Service

Steering Shaft and Wheel Replacement

Procedure for replacing the steering shaft and steering wheel.

Steering Gear Replacement

Step-by-step instructions for removing and installing the steering gear assembly.

Steering Linkage Replacement

Procedure for replacing tie rods, drag links, and ball joints in the steering linkage.

Repairing the Steering Gear

Detailed instructions for disassembling and repairing the steering gear.

Brake Service

Bleeding and Flushing Brake System

Covers procedures for bleeding air from the brake lines and flushing the system.

Replacing Brake Linings and Pads

Step-by-step guide for replacing electric motor brake linings and disc brake pads.

Replacing Wheel Cylinders and Brake Bodies

Instructions for replacing wheel cylinders and repairing/replacing brake bodies.

Replacing the Master Cylinder

Procedure for removing and installing the master cylinder assembly.

Repairing the Master Cylinder

Detailed instructions for disassembling and repairing the master cylinder.

Motor Service

Motor Removal, Installation, and Inspection

Covers procedures for removing, installing, and inspecting the motor assembly.

Repairing and Undercutting the Commutator

Instructions for repairing and undercutting the motor commutator for optimal performance.

Transmission

Transmission Gear Case Service

Detailed instructions for disassembling and assembling the primary reduction gear case.

3rd Member Service

Procedures for disassembling and assembling the 3rd member assembly.

Pinion Gear Preload and Shimming

Guides for setting pinion gear preload and performing shimming procedures.

Suspension

Tires and Wheels

Battery Service

Battery Testing Procedures

Covers load testing and specific gravity testing for battery condition assessment.

Replacing 6-Volt Batteries

Detailed instructions for replacing 6-volt batteries in the vehicle.

Sevcon Control System Troubleshooting

General Troubleshooting Steps

Provides initial steps and checks before starting detailed troubleshooting.

Specific Control System Tests

Details specific tests (1-9) for diagnosing faults in the Sevcon control system.

Lestronic II Charger Troubleshooting

Built-in Charger Troubleshooting

Troubleshooting steps specific to the built-in Lestronic II charger model.

Portable Charger Troubleshooting

Troubleshooting steps specific to the portable Lestronic II charger model.

Signet Charger Troubleshooting

Charger Troubleshooting Steps

General troubleshooting steps for diagnosing issues with the Signet charger.

APPENDIX A-Special Tools

Appendix B: Standard Hardware Suggested Torque Limits

Suggested Torque Values (Non-Critical)

Provides suggested torque values for non-critical hardware.

Suggested Torque Values (Critical)

Provides suggested torque values for critical hardware components.

Appendix C

Brake Lining Handling Precautions

Critical safety precautions for handling brake pads/shoes potentially containing asbestos.

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