Taylor-Dunn B0-248-48AC Manual

The Best Way
To Go
About Your
Business
®
SerialnumberStarting:171000
MANUAL MB-248-11
Operation, Troubleshooting and
Replacement Parts Manual
Models Inlcuded:
B0-248-48AC (B 2-48)
B0-254-48AC (B 2-54)
Published: 11/14/2006
Revision: D
Equipped with AC Motor Speed Control

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

B2-48 With Dump Bed Option B2-10 Ambulance
B2-48 with Steel Cab, Foldaway
4-Passenger Seat and Stake Sides
ET 3000
ET1-50 Full Size Truck
P2-50 30,000 Pound Tow Tractor

Section Index
Introduction 1
Safety Rules and Operating Instructions 2
General Maintenance 3
Front Axle Service 4
Steering Component Service 5
Brakes Service 6
Transaxle Service 7
Suspension 8
Tires and Wheels 9
Battery Service 10
Wire diagram 11
Control System Troubleshooting 12
Chargers
Illustrated Parts 13
Appendix A
Special Tools 14
Appendix B
Suggested Torque Values 15
Appendix C
Brake Lining Handling Precautions 16
Taylor-Dunn®
Model B0-248-48AC, B0-254-48AC
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.

B2-48 With Stake Side Dump Bed Option
SC1-00 Stock Chaser
E4-55 Sit Down Tow Tractor
C4-25 Sit Down Tow Tractor

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
B 2-48 and B 2-54 ...................................................6
BT 2-48 ....................................................................7
BT 2-80 ....................................................................7
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,trainingorperformingmaintenanceonthisoranyotherTaylor-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
shouldbe familiar with the parts of this manual that apply
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
Thissectionidentifiesthetroubleshootingproceduresfortestingtheelectricalsystemandbatterycharger.
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/or words that areused to define warnings,cautions, instructions, or notesfound throughout
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(PoweredIndustrialTrucks) and with all applicable portions of theAmericanNationalStandard
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:

INTRODUCTION
Introduction Page-7
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.

B2-48 With Stake Side Dump Bed Option
SC1-00 Stock Chaser
E4-55 Sit Down Tow Tractor
C4-25 Sit Down Tow Tractor

TABLE OF CONTENTS
Safety Rules and Operating
Instructions
StandardSpecifications*...............................2
Safety Rules and Guidelines .........................3
Driver Training Program................................4
Driver Qualifications. ...............................................4
Dash Up to Serial #179501 ............................5
1) Horn Switch .........................................................5
2) Forward-Off-Reverse Switch...............................5
3a) Light Switch .......................................................5
3b) Hi-Low Switch .................................................... 5
4) Combination Display ...........................................5
5) Accessory Switches (optional) ............................5
VehicleControls ............................................5
6) Key-Switch...........................................................5
7) Emergency Stop Switch ......................................5
3) Strobe Switch (Optional) ..................................... 6
4) Forward-Off-Reverse Switch...............................6
5) Hi-Low Switch (optional) .....................................6
6) Smart View Display .............................................6
7) Horn Switch .........................................................6
8) Key-Switch...........................................................6
2) Wiper Switch (Optional) ......................................6
1) Headlight Switch..................................................6
Dash Starting Serial #1795002 ......................6
Combination Display................................................7
Seat Interlock Switch ............................................... 8
Electrolyte Alarm (Optional) ....................................8
Accelerator Pedal .................................................... 9
Foot Brake Pedal .....................................................9
Steering ....................................................................9
Directional Signals (Optional).................................. 9
Hazard Light Switch (Optional) ............................... 9
Charger Interlock .....................................................9
Vehicle Operational Guidelines.....................10
Safety Guidelines ..................................................... 10
Starting: ....................................................................10
While driving: ...........................................................10
Loading and Unloading............................................ 11
Parking .....................................................................11
Towing ......................................................................11
Adjustable Controller Parameters ...........................12
Charging your vehicle ...................................14
New Battery Break in ............................................... 14
Charging Time..........................................................14
Industrial Charger Operation ...................................14
Signet Charger Operation, Model HB Series .........15
Signet Charger Operation, Model HBS series ........ 15
Lestronic II®Charger Operation .............................15
Storing and Returning to Service ................16
Storing Your Vehicle.................................................16
Returning to Service ................................................ 16
Periodic Maintenance Checklist ...................17
Daily Visual inspection:............................................18
Maintenance Guidelines for
SevereDutyApplications........................18

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 2
STANDARD SPECIFICATIONS*
ITEM Model 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 Four Wheel Hydraulic Disc,
Automaticaly Applied Park Brake
Steering Automotive Steering 24:1
Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Diamond Plate
Instrumentation Combination Display (Battery Status Indicator, Hour Meter,
System Status Monitor), Key Switch, Horn Button, Speed select
Switch, Forward/Reverse Switch, Headlight Switch,
Emergency Stop Switch
Light Accessories Headlight, Dual Tail/Brake Lights
Charger Built In 1kW, Automatic AC voltage adjust
120/240 VAC, 13/6.5 Amp, 50 or 60 Hz
Occupancy 2 Passenger
Electrical System Eight-244 Amp Hour, 6 Volt, Lead Acid Batteries
B 2-48 350 Amp Solid State Self Diagnostic AC Speed Control
B 2-54 450 Amp Solid State Self Diagnostic AC Speed Control
Dimensions 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 350 Centimeters (138 Inches)
Tires B 2-48 5.70 x 8 Load Range C
B 2-54 18 x 5 x 14 Solid Extra Cushion
Dry Weight 542 kg (1,194 lbs)
Without Batteries
Maximum Load B 2-48 1,360 kg (3,000 pounds)
B 2-54 2,268 kg (5,000 pounds)
Speed Limit B 2-48 25-kph (16-mph)
(depends on gear ratio installed) B 2-54 13-kph (8-mph)
Motor, AC B 2-48 4.1 kW, (5.5 hp) for 60 min, 10.9 kW, (14.5 hp) for 5 min
B 2-54 4.1 kW, (5.5 hp) for 60 min, 12.8 kW, (17.1 hp) for 5 min
*Specifications are subject to change without notice
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(PoweredIndustrialTrucks) and with all applicable portions of theAmericanNationalStandard
for Personnel and Burden Carriers (ANSI B56.8).

Safety Rules Page 3
SAFETY RULES AND OPERATING INSTRUCTIONS
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.
Before working
on a vehicle:
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.
SAFETY RULES AND GUIDELINES
It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls
and operating characteristics of this vehicle (extracted from the American National Standards Institute
Personnel and Burden Carriers ANSI B56.8). As well as, following the safety rules and guidelines outlined in
ANSI B56.8 and listed below.
Thesevehicles are designed fordriving on smooth surfaces in and aroundfacilities such as industrialplants,
nurseries,institutions, motels, mobile homeparks, and resorts. They are not tobe driven on publichighways.
Refer to Vehicle Operational Guidelines, Safety Guidelinessection 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

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 4
DRIVER TRAINING PROGRAM
According to ANSI B56.8, the owner of this vehicle shall conduct an Operator Training program for all
those who will be operating this vehicle. The training program shall not be condensed for those claiming
tohave previous vehicle operation experience.Successful completion of theOperator 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 normally associated with your particular
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, and mental ability to safely operate this
vehicle as specified in the American National Standards Institute 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.
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Safety Rules Page 5
SAFETY RULES AND OPERATING INSTRUCTIONS
VEHICLE CONTROLS
6) Key-Switch
A key-switch, located on the right center side of the
instrument panel, turns on the vehicle. Rotate the
key clockwise to turn the vehicle power on,
counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position
whenever the operator leaves the vehicle.
This switch is also designed to secure and disable
the vehicle. The key can only be removed when the
key-switch is in the “OFF” position.
7) Emergency Stop Switch
The emergency stop switch will immediately and
abruptly stop the vehicle.
The Emergency Stop Switch will stop the vehicle but
will still allow some functions to work such as the
parking brake bypass switch.
1) Horn Switch
Thehorn switch is locatedon the right sideof
the instrument panel. Depress the switch to
sound the horn, release it to turn it off.
2) Forward-Off-Reverse Switch
The forward-off-reverse switch, located on
the right side of the instrument panel,
determinesthedirectionoftravelofthevehicle.Push
the top of the switch to engage the forward direction.
Push the bottom of the switch to engage the reverse
direction.
DO NOT SWITCH from forward to reverse or vice-
versa while the vehicle is in motion. Make sure the
vehicle is completely stopped before shifting.
Theforward-off-reverseswitchshouldbeinthecenter
“OFF” position, with the key-switch off and the park
brake set whenever the operator leaves the vehicle.
3a) Light Switch
The headlight switch is located on the top left of the
instrument panel. Push the right side of the switch to
turn the lights on. Push the left side of the switch to
turn the light off.
3b) Hi-Low Switch
The high-low switch is located on the lower left of
the instrument panel. Toggle the switch lever up for
normal speed. Toggle the switch lever down for slow
speed.
4) Combination Display
Functions for the Combination display are listed on
the following pages.
5) Accessory Switches (optional)
The optional accessory switches are located on the
left side of the instrument panel. The function of the
optionalaccessory switches will vary depending how
the vehicle is equipped.
Do not depress the Emergency Disconnect
Switch while the vehicle is in motion unless
the vehicle must be stopped in an emergency.
Depressing the switch will immediately apply
the park brake, stopping the vehicle. The
abrupt stopping of the vehicle may result in
severe bodily injury.
DASH UP TO SERIAL #179501

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 6
DASH STARTING SERIAL #1795002
4) Forward-Off-Reverse Switch
Theforward-off-reverseswitch,locatedontherightside
of the instrument panel, determines the direction of
travelofthevehicle.Push thetopof theswitchto engage
the forward direction. Push the bottom of the switch to
engage the reverse direction.
DONOT SWITCH fromforwardtoreverse or vice-versa
while the vehicle is in motion. Make sure the vehicle is
completelystoppedbefore shifting.
The forward-off-reverse switch should be in the center
“OFF” position, with the key-switch off and the park
brake set whenever the operator leaves the vehicle.
8) Key-Switch
A key-switch, located on the right center side of
theinstrumentpanel,turns on the vehicle. Rotate
the key clockwise to turn the vehicle power on,
counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position
whenever the operator leaves the vehicle.
Thisswitchis also designed to secureanddisable
the vehicle. The key can only be removed when
the key-switch is in the “OFF” position.
5) Hi-Low Switch (optional)
The high-low switch is located on the lower left of the
instrumentpanel.Togglethe switch lever up for normal
speed. Toggle the switch lever down for slow speed.
7) Horn Switch
The horn switch is located on the right side of
the instrument panel. Depress the switch to
sound the horn, release it to turn it off.
1) Headlight Switch
Theheadlightswitchislocatedonthe
topleft oftheinstrumentpanel. Push
therightsideof the switch to turn the
lights on. Push the left side of the
switch to turn the light off.
2) Wiper Switch (Optional)
The wiper switch is located on the left side of the
instrumentpanelandtotherightofthe headlight switch.
Push the top of the switch to turn on the wiper. Push
the bottom of switch to turn off the wiper. The wiper
can be turned on with the key switch in the “OFF”
position.
6) Smart View Display
Refer to details later in this chapter.
3) Strobe Switch (Optional)
The strobe switch is located on the left side of the
instrument panel and to the right of the wiper switch.
Push the top of the switch to turn on the strobe. Push
the bottom of switch to turn off the strobe. The strobe
can be turned on with the key switch in the “OFF”
position.
9) Emergency Stop Switch
Theemergency stop switch will immediately and
abruptly stop the vehicle.
TheEmergency Stop Switch will stopthevehicle
but will still allow some functions to work such as
the parking brake bypass switch.
Do not depress the Emergency Disconnect
Switch while the vehicle is in motion unless
the vehicle must be stopped in an emergency.
Depressing the switch will immediately apply
the park brake, stopping the vehicle. The
abrupt stopping of the vehicle may result in
severe bodily injury.