Taylor-Dunn B0-248-36 Manual

The Best Way
To Go
About Your
Business
®
SerialNumberStarting177127
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

Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support our
vehicles. Information regarding vehicle sales, replacement parts, or service should be
obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn
website at www.taylor-dunn.com.
If you do not have access to the internet, you can call the factory direct at:
01 [phone]
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804

Table of Contents
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A small sample of the many types of vehicles offered by Taylor-Dunn®
B 2-48-36 Equipped with optional
hydraulic dump bed
BT 2-80 Eight passenger tram
B 1-00 Personnel carrier
C 4-25 Huskey tow tractor
MX 1600 Equipped with optional
ladder rack and weld tanks

Section Index
Introduction 1
Safety Rules and Operating Instructions 2
General Maintenance 3
Front Axle Service 4
Steering Component Service 5
Brakes Service 6
Motor Service 7
Transaxle Service 8
Tires and Wheels 9
Battery Service 10
Control System Troubleshooting 11
Charger Troubleshooting 12
Wire diagram 13
Illustrated Parts 14
Appendix A
Special Tools 15
Appendix B
Suggested Torque Values 16
Appendix C
Brake Lining Handling Precautions 17
Taylor-Dunn®
Models B0-248-36, B0-248-48, B0-254-36,
BT-248-36, BT-248-48, BT-280-36, BT-280-48
Operator and Service Manual Section Index
This quick reference section index guide will assist you in
locating a desired topic or procedure.
Refer to each sectional Table of Contents for the page
number location for specific topics or procedures.

TAYLOR -DUNN

Introduction
About this manual.........................................2
Who Should Read This Manual ....................3
Responsibilities.............................................3
How To Use This Manual ..............................4
Conventions .............................................................5
How to Identify Your Vehicle ........................6
Taking Delivery of Your Vehicle ...................8
Contents

INTRODUCTION
Introduction Page-2
ABOUT THIS MANUAL
The purchase of this vehicle shows a belief in high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be
sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this
high quality Taylor-Dunn®vehicle.
This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn®vehicles and is
not intended as a training guide. Taylor-Dunn®has made every effort to include as much information as
possible about the operation and maintenance of this vehicle.
Included in this manual are:
•Vehicle Description
•Safety Rules and Guidelines
•Operational Information
•Operator Responsibilities
•Owner Responsibilities
•Control Operation and Location Information
•Maintenance and Troubleshooting Information
•Standard Parts List
Beforeservicing,operating,training orperforming maintenanceon thisor anyother Taylor-Dunn®vehicle,
read the appropriate Taylor-Dunn®manual.
Each Taylor-Dunn®manual references the applicable models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

INTRODUCTION
Introduction Page-3
WHO SHOULD READ THIS MANUAL
This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn®vehicle. Each person
shouldbefamiliar with thepartsof this manualthatapply
to their use of this vehicle.
RESPONSIBILITIES
Of the Owner...
The owner of this or any Taylor-Dunn®vehicle is responsible for the overall maintenance and repairs of
the vehicle, as well as the training of operators. Owners should keep a record of conducted training and
maintenance performed on the vehicle. (OSHA Regulation, 29 CFR 1910.178 Powered Industrial Truck
Operator Training).
Of the Operator...
The operator is responsible for the safe operation of the vehicle, preoperational and operational checks
on the vehicle, and the reporting of any problems to service and repair personnel.
Of the Service Personnel...
The service personnel are responsible for the service and maintenance of the vehicle. At no time
should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn®
vehicle. For the purposes of training, a qualified service person may oversee the repairs or services
being made to a vehicle by an individual in training. At no time should an untrained individual be
allowed to service or repair a vehicle without supervision. This manual is not a training guide.
Of the Passengers ...
The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside the
vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of
recklessness are to be avoided. Do not engage in horseplay.

INTRODUCTION
Introduction Page-4
HOW TO USE THIS MANUAL
This manual is organized into five main sections:
INTRODUCTION
This section describes how to use this service manual and how to identify your vehicle.
Safety Rules and Operating Instructions
This section outlines the safety and operational issues, location and operation of controls, and the
operational checks that are to be performed on this vehicle. It also includes various subjects that should
be included in the operator and service training program.
Maintenance Service and Repair
This section gives specific information on the servicing of the vehicle and a schedule for maintenance
checks.
Electrical and Charger Troubleshooting
Thissection identifiesthe troubleshootingprocedures fortesting theelectrical systemandbatterycharger.
Illustrated Parts
This section provides an illustrated view of various assemblies. The illustrations are accompanied by
tables identifying the parts.

INTRODUCTION
Introduction Page-5
A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to
themselves or others. Be sure to follow any instructions contained
within a warning and exercise extreme care while performing the
task.
or,
The symbol at the left and the bold text contained within a box
denotes a “Caution” and is used to inform the reader that property
damage may occur. Be sure to exercise special care and follow any
instructions contained with in a caution.
NOTE: Alerts the reader to additional information about a subject.
Conventions
Symbolsand/orwords thatareused todefinewarnings, cautions,instructions,or notesfoundthroughout
this manual:

INTRODUCTION
Introduction Page-6
HOW TO IDENTIFY YOUR VEHICLE
This manual applies to vehicles with the same model and serial numbers listed on the front cover.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(Powered IndustrialTrucks)and withall applicableportions oftheAmerican NationalStandard
for Personnel and Burden Carriers (ANSI B56.8).
Theese vehicles are not designed to be driven on public roads or
highways. They are available in maximum designed speeds ranging
from 6 to 16 mph. Do not exceed the maximum designed speed.
Exceeding the maximum designed speed may result in steering
difficulty, motor damage, and/or loss of control. Do not exceed locally
imposed speed limits. Do not tow at more than 5 mph.
The locations of the model and serial numbers are illustrated as follows:
Typical BT 2-48 shown with
optional equipment
Typical BT 2-80 shown with
optional equipment
Typical B 2-48 or B 2-54
Starting early in 2007, the data plate and serial number fame stamp
is in the same location for all four models covered in this manual
(refer to the illustrations below). For older vehicles, the location of
the data plate and frame stamp is illustrated on the following pages.

INTRODUCTION
Introduction Page-7
B 2-48 and B 2-54
Vehicles manufactured before 2007 and up to March, 2007
BT 2-48
BT 2-80
Under front left passenger cushion
Under deck on deck rail

INTRODUCTION
Introduction Page-8
TAKING DELIVERYOF YOUR VEHICLE
Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious
problems:
•Examine the contents of all packages and accessories that may have come in separate
packages with the vehicle.
•Make sure everything listed on the packing slip is there.
•Check that all wire connections, battery cables, and other electrical connections are secure.
•Check battery cells to be sure they are filled.
•Check the tire pressure, tightness of lug nuts, and for any signs of damage.
Check the operation of each of the following controls:
•Accelerator
•Brake
•Parking Brake
•Key-Switch
•Forward/Reverse Switch
•Reverse Beeper (if equipped)
•Front Headlight Switch
•Steering Wheel
•Horn
What To Do If a Problem is Found
If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading
and file a claim with the freight carrier. The claim must be filed within 48 hours of receiving the vehicle
and its accessories. Also, notify your Taylor-Dunn®dealer of the claim.
If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately
contact your local Taylor-Dunn®distributor and report the problem. The report must be made within 24
hours of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn®vehicle is
a factory authorized service technician.
The only personnel authorized to repair, modify, or adjust any part
of this or any Taylor-Dunn®vehicle is a factory authorized service
technician. Repairs made by unauthorized personnel may result in
damage to the vehicles systems which could lead to an unsafe
condition resulting in severe bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.

TABLE OF CONTENTS
Safety Rules and
Operating Instructions
Standard Specifications* (Common) ...2
Standard Specifications* (Model B 2-48/2-54) 3
Standard Specifications* (Model BT 2-48) 4
Standard Specifications* (Model BT 2-80) 5
Safety Rules and Guidelines ..............6
DriverTraining Program.....................6
Driver Qualifications. .......................................... 6
VehicleControls ................................7
Dash up to Serial # 179669................7
1) Accessory Switch (Optional) .......................... 7
2) Headlight Switch ............................................. 7
3) Hi-Low Switch (optional) ............................... 7
4) Smart View Display ........................................ 7
5) Forward-Off-Reverse Switch .......................... 7
6) Horn Switch ..................................................... 7
7) Key-Switch ...................................................... 7
Dash Starting Serial #179670.............8
1) Headlight Switch ............................................. 8
2) Wiper Switch (Optional) ................................. 8
3) Strobe Switch (Optional) ................................ 8
4) Forward-Off-Reverse Switch .......................... 8
5) Hi-Low Switch (optional) ............................... 8
6) Smart View Display ........................................ 8
7) Horn Switch ..................................................... 8
8) Key-Switch ...................................................... 8
Directional Signals (Optional) ............................ 9
Steering ................................................................. 9
Hazard Light Switch (Optional) ......................... 9
Accelerator Pedal ................................................. 9
Foot Brake Pedal .................................................. 9
Charger Interlock ................................................. 10
Seat Interlock Switch ........................................... 10
Electrolyte Alarm (Optional) ............................... 10
Park Brake ............................................................ 10
Trailer Brake Module (optional) ......................... 11
Smart View Display ............................................. 12
Fault Code Tables ................................................ 14
Vehicle Operation Guidelines .............15
Safety Guidelines ................................................. 15
Starting: ................................................................ 15
While driving: ...................................................... 15
Loading and Unloading ....................................... 15
Towing Loads: ...................................................... 15
Parking .................................................................. 16
Automatic Electric Park Brake ........................... 16
Towing This Vehicle ............................................ 16
Dump Bed (optional)..........................17
Operation .............................................................. 17
Service .................................................................. 17
Lowering the Dump Manually ............................ 18
Lubrication ........................................................... 18
Hydraulic Pump Exploded View..........19
Charging your vehicle ........................20
Signet Charger Operation, Model HB Series ..... 20
Signet Charger Operation, Model HBS series ... 20
Lestronic II®Charger Operation ........................ 21
New Battery Break in .......................................... 21
Charging Time ...................................................... 21
Storing / Returning to Service............21
Storing Your Vehicle ............................................ 21
Returning to Service ............................................ 21
Periodic Maintenance Checklist .........22
Standard Periodic Maintenance Schedule
for the Smart View Display .............23
Daily Visual inspection: ...................................... 24
Maintenance Guidelines for
SevereDutyApplications ...............24

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 2
* - Specifications are subject to change without notice.
STANDARD SPECIFICATIONS* (COMMON)
ITEM VOLTAGE SPECIFICATION
Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs)
Weights
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid
Differential
Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake, or
Optional 4 Wheel Hydraulic Disc, Hand Operated Park
Brake
Steering Automotive Steering 24:1
Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Diamond Plate
Instrumentation Smart View Display (Battery Status Indicator, Hour
Meter, System Status Monitor), Key Switch, Horn Button,
Forward/Reverse Switch, Headlight Switch
Light Accessories Headlight, Dual Tail/Brake Lights
Charger 36 Volt 115v AC/12A, 60Hz, 25 Amp DC, Built-In, Automatic
48 Volt 115v AC/15A, 60Hz, 25 Amp DC, Built-In, Automatic
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 3
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).
STANDARD SPECIFICATIONS* (MODEL B 2-48/2-54)
ITEM MODEL VOLTAGE SPECIFICATION
Occupancy B 2-48, B 2-54 2 Passenger
Electrical System B 2-48 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 400 Amp
B 2-48 48 Volt 8-250 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 400 Amp
B 2-54 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
Dimensions B 2-48, B 2-54 307 L X 114 W X 114 H Centimeters
121 L X 45 X 45 H Inches
Deck dimensions 104.4 W x 191 L Centimeters (41.25 W x 75.25 L Inches)
Turning Radius B 2-48, B 2-54 350 Centimeters (138 Inches)
Tires B 2-48 5.70 x 8 Load Range B
B 2-54 18 x 5 x 14 Solid Extra Cushion
Dry Weight B 2-48 542 kg (1194 lbs)
Without Batteries B 2-54 693 kg (1528 lbs)
Maximum Load B 2-48 1360 kg (3000 lbs)
B 2-54 2268 kg (5000 lbs)
Motor, DC B 2-48 36 Volt 3.2 kW, (4.4 hp) for 60 min, 5.1 kW, (6.9 hp) for 5 min
Separately Excited B 2-48 48 Volt 4.4 kW, (5.9 hp) for 60 min, 7.2 kW, (9.6 hp) for 5 min
Field B 2-54 36 Volt 4.5 kW, (6.0 hp) for 60 min, 8.6 kW, (11.5 hp) for 5 min
* - Specifications are subject to change without notice.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 4
STANDARD SPECIFICATIONS* (MODEL BT 2-48)
ITEM VOLTAGE SPECIFICATION
Occupancy 10
Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
Dimensions 307L X 162W X 117H Centimeters
121L X 64X 46H Inches
Turning Radius 363 Centimeters (143 Inches)
Tires 5.70 x 8 Load Range B
Dry Weight 695 kg (1,533 lbs)
Without Batteries
Maximum Load 1360 kg (3,000 lbs)
Motor, DC 36 Volt 4.5 kW, (6.0 Horse Power) for 60 min
Separately Excited Field 8.6 kW, (11.5 Horse Power) for 5 min
48 Volt 6.0 kW, (8.0 Horse Power) for 60 min
12.2 kW, (16.3 Horse Power) for 5 min
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).
* - Specifications are subject to change without notice.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 5
STANDARD SPECIFICATIONS* (MODEL BT 2-80)
ITEM VOLTAGE SPECIFICATION
Occupancy Eight
Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
48 Volt Eight 250 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
Dimensions 330 L X 127 W X 112 H Centimeters
130 L X 50 X 44 H Inches
Turning Radius 406 Centimeters (160 Inches)
Tires 5.70 x 8 Load Range B
Dry Weight 503 kg (1,110 lbs)
Without Batteries
Maximum Load 1,361 kg (3,000 lbs)
Motor, DC 36 Volt 4.5 kW, (6.0 Horse Power) for 60 min
Separately Excited Field 8.6 kW, (11.5 Horse Power) for 5 min
48 Volt 6.0 kW, (8.0 Horse Power) for 60 min
12.2 kW, (16.3 Horse Power) for 5 min
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).
* - Specifications are subject to change without notice.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 6
SAFETY RULES AND
GUIDELINES
Itis theresponsibility oftheownerofthis vehicleto assure
that the operator understands the various controls and
operating characteristics of this vehicle (extracted from
theAmerican NationalStandards InstitutePersonnel and
Burden Carriers ANSI B56.8). As well as, following the
safety rules and guidelines outlined in ANSI B56.8 and
listed below.
These vehicles are designed for driving on smooth
surfacesinand aroundfacilities such asindustrial plants,
nurseries, institutions, motels, mobile home parks, and
resorts. They are not to be driven on public highways.
Refer to Vehicle Operational Guidelines, Safety
Guidelines section for important safety information
regarding operating this vehicle.
Read and follow all of the guidelines listed
below. Failure to follow these guidelines
may result in severe bodily injury and/or
property damage.
These vehicles are not designed to be
driven on public roads or highways. They
are available in maximum designed speeds
ranging from 6 to 16 mph. Do not exceed
the maximum designed speed. Exceeding
the maximum designed speed may result
in steering difficulty, motor damage, and/
or loss of control. Do not exceed locally
imposed speed limits. Do not tow this
vehicle at more than 5 mph.
Before working
on a vehicle:
1. Make sure the key-switch is in the “OFF”
position, then remove the key.
2. Place the forward-reverse switch in the
center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to
prevent vehicle movement.
5. Disconnect the main positive and
negative cables at the batteries.
DRIVER TRAINING PROGRAM
Accordingto ANSIB56.8, theownerof this vehicleshall
conduct an Operator Training program for all those who
will be operating this vehicle. The training program shall
not be condensed for those claiming to have previous
vehicle operation experience. Successful completion of
the Operator Training program shall be required for all
personnel who operate this vehicle.
The Operator Training program shall include the
following:
•Operation of this vehicle under circumstances
normallyassociated withyourparticular environment.
•Emphasis on the safety of cargo and personnel.
•All safety rules contained within this manual.
•Proper operation of all vehicle controls.
•A vehicle operation and driving test.
Driver Qualifications.
Only those who have successfully completed the
Operator Training program are authorized to drive this
vehicle. Operators must possess the visual, auditory,
physical,andmental abilityto safely operatethis vehicle
asspecified intheAmerican NationalStandardsInstitute
Controlled Personnel and Burden Carriers ANSI B56.8.
The following are minimum requirements necessary to
qualify as an operator of this vehicle:
•Demonstrate a working knowledge of each control.
•Understand all safety rules and guidelines as
presented in this manual.
•Know how to properly load and unload cargo.
•Know how to properly park this vehicle.
•Recognize an improperly maintained vehicle.
•Demonstrate ability to handle this vehicle in all
conditions.