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Taylor-Dunn BT-248-48 User Manual

Taylor-Dunn BT-248-48
292 pages
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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 BT-248-48 Specifications

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

Summary

Section Index

Introduction

Overview of the manual's purpose, structure, and vehicle identification.

Safety Rules and Operating Instructions

Essential guidelines for safe operation, driver training, and vehicle controls.

General Maintenance

Routine maintenance tasks, troubleshooting guide, and lubrication chart.

Front Axle Service

Procedures for inspecting, adjusting, and replacing front axle components.

Steering Component Service

Guidance on servicing steering system parts like the gear, shaft, and wheel.

Brakes Service

Detailed instructions for inspecting, adjusting, and repairing brake systems.

Motor Service

Procedures for inspecting, removing, and repairing motor components.

Battery Service

Procedures for battery cleaning, testing, watering, charging, and replacement.

Sevcon Control System Troubleshooting

Troubleshooting steps for Sevcon motor speed controllers.

Lestronic II® Charger Troubleshooting

Troubleshooting steps for Lestronic II® battery chargers.

Signet® Charger Troubleshooting

Troubleshooting steps for Signet® battery chargers.

Introduction

About this Manual

Describes the manual's intent to guide service, repair, and operation.

Who Should Read This Manual

Identifies all intended users of the manual, from operators to service personnel.

Responsibilities

Outlines the duties of owners, operators, service personnel, and passengers.

How to Use This Manual

Details the organization of the manual into five main sections for easy navigation.

How to Identify Your Vehicle

Guides users on identifying their specific vehicle model and serial number.

Safety Rules and Operating Instructions

Standard Specifications (Common)

Lists common specifications for all vehicle models.

Standard Specifications (Model B 2-48/2-54)

Details specifications specific to the B 2-48 and B 2-54 models.

Standard Specifications (Model BT 2-48)

Lists specifications for the BT 2-48 model.

Standard Specifications (Model BT 2-80)

Provides specifications for the BT 2-80 model.

Safety Rules and Guidelines

Outlines essential safety rules and guidelines for vehicle operation.

Driver Training Program

Details operator training requirements and program content.

Driver Qualifications

Lists minimum requirements for vehicle operators.

Vehicle Controls

Explains the function and location of various vehicle controls.

Steering

Explains how to operate the steering wheel and tilt steering mechanism.

Accelerator Pedal Operation

Explains how the accelerator pedal controls vehicle speed.

Foot Brake Pedal Operation

Details the function and operation of the foot brake pedal.

Seat Interlock Switch Function

Explains the function of the seat interlock switch for vehicle safety.

Park Brake Operation

Details how to set and release the parking brake.

Smart View Display Functions

Explains the functions of the Smart View Display, including battery status.

Fault Code Tables

Lists fault codes for the control system and their corresponding actions.

Vehicle Operation Guidelines

Comprehensive operational guidelines for safe use, starting, driving, and parking.

Parking Procedures

Procedures for safely parking the vehicle.

Automatic Electric Park Brake

Explains the operation of the automatic parking brake system.

Charging Your Vehicle

Safety precautions and instructions for charging the vehicle's batteries.

Periodic Maintenance Checklist

A checklist of maintenance items to be performed at various intervals.

General Maintenance

Maintenance Guidelines

General guidelines for performing maintenance tasks.

Troubleshooting Guide

A guide to diagnosing and resolving common vehicle problems.

Front Axle Service

Inspect Front Wheel Bearings and King Pin

Procedure for inspecting front wheel bearings and king pins for wear or play.

Adjust Front Wheel Bearings

Steps for adjusting front wheel bearings to eliminate play.

Front Axle Removal and Installation

Instructions for removing and installing the front axle assembly.

Steering Component Service

Brake Service

Inspect the Service Brake

Procedures for inspecting disc brake pads.

Disc Brake Rotor Inspection

Instructions for inspecting the thickness and run out of disc brake rotors.

Inspect the Parking Brake

Guidelines for inspecting the wheel park brake.

Adjust the Service Brakes

Explains causes for low brake pedal and lack of braking power.

Adjust the Parking Brake

Steps for adjusting the parking brake on hydraulic disc systems.

Check Master Cylinder Fluid

Procedure for checking and filling the master cylinder fluid level.

Bleed the Brake System

Steps for removing air from the hydraulic brake system.

Replace Front Disc Brake Pads

Steps for replacing front disc brake pads.

Replace Rear Brake Pads

Steps for replacing rear brake pads.

Replace the Master Cylinder

Steps for replacing the master cylinder.

Motor Service

Inspecting Motor Brushes

Procedure for inspecting motor brushes for wear.

Motor Inspection

Detailed inspection of motor components like brushes, commutator, and windings.

Battery Service

Battery Testing Methods

Methods for testing battery condition using load and specific gravity tests.

Sevcon Control System Troubleshooting

Start Troubleshooting Here

The starting point for troubleshooting the Sevcon control system.

Test 1: Checking Control Logic Inputs

Checks logic inputs to the Sevcon controller for proper operation.

Test 2: Testing the Motor

Procedures for testing the motor for continuity and shorts.

Test 3: Vehicle Runs in One Direction Only

Troubleshooting steps when the vehicle only runs in one direction.

Test 4: Key Fault Diagnosis

Diagnoses issues related to the key switch and its circuit.

Test 5: Contactor Coil Fault

Checks for faults related to the contactor coil and its contacts.

Test 6: Accelerator Module Fault

Diagnoses issues with the accelerator module and its wiring.

Test 7: Forward and Reverse Switch Fault

Troubleshooting steps for the forward and reverse switch.

Test 8: Anti-Rolloff Fault

Tests the functionality of the vehicle's Anti-Rolloff feature.

Test 9: Electric Motor Brake Testing

Procedures for testing the electric motor brake system.

Status LED Code Table

Explains error codes indicated by the Sevcon status LED.

Smart View Fault Codes

Lists and explains fault codes displayed by the Smart View system.

Lestronic II® Charger Troubleshooting

Troubleshooting for Built-in Charger

Troubleshooting steps for the built-in charger.

Troubleshooting for Portable Charger

Troubleshooting steps for the portable charger.

Signet® Charger Troubleshooting

Testing the Charging Cycle

Procedures for testing the charger's charging cycle.

Status Light Error Code Table

Explains error codes indicated by the charger's status lights.

Troubleshooting

General troubleshooting steps for Signet® chargers.

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