Taylor-Dunn B0-254-48 Manual

The Best Way
To Go
About Your
Business
®
Serial number range: 165448 - 170871
Revision: C
EQUIPPED WITH GT-DRIVE SYSTEM
GTDrive
Models Inlcuded:
B0-254-48 (B 2-54)
MANUAL MB-254-02
Operation, Troubleshooting and
Replacement Parts Manual
Lavatory Service Vehicle

TAYLOR-DUNN SERVICE CENTER
For more information about this and other Taylor-Dunn®manuals, please write Taylor-Dunn®:
Taylor-Dunn®Mfg.
2114 W. Ball Road
Anaheim, CA 92804
(Attn: Technical Writer)
COPYRIGHTNOTICE
Copyright © 2001 by Taylor-Dunn®Mfg. All rights reserved.
Nopart ofthis workmay bereproduced ortransmitted inany formor byany means,electronic
or mechanical, including photocopying and recording, or any information storage or retrieval
system without prior written permission of Taylor-Dunn®Mfg. unless such copying is
expressly permitted by federal copyright law. Address inquiries to Reference Permissions,
Taylor-Dunn®Mfg., 2114 W. 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

Table of Contents
Contents
Introduction............................................................ 1
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 ............................................... 7
Safety Rules and Operating Instructions.............. 1
Standard Specifications ........................................................... 2
Safety Rules and Guidelines.................................................... 3
Driver Training Program ........................................................... 4
Driver Qualifications. .........................................................................................................4
Vehicle Controls........................................................................ 5
Hi-Low Switch (optional) ....................................................................................................5
Key-Switch ........................................................................................................................5
Horn Switch .......................................................................................................................5
Forward-Off-Reverse Switch .............................................................................................5
Accelerator Pedal ..............................................................................................................6
Foot Brake Pedal ............................................................................................................... 6
Headlight Switch................................................................................................................6
Accessory Switch (Optional) .............................................................................................6
Smart View Display............................................................................................................7
Directional Signals (Optional) ............................................................................................9
Steering .............................................................................................................................9
Hazard Light Switch (Optional) ..........................................................................................9
Electrolyte Alarm (Optional) ...............................................................................................10
Seat Interlock Switch .........................................................................................................10
Park Brake......................................................................................................................... 10
Charger Interlock ............................................................................................................... 10
Vehicle Operational Guidelines ............................................... 11
Safety Guidelines ..............................................................................................................11
Starting: .............................................................................................................................11
While driving:..................................................................................................................... 12
Loading and Unloading ......................................................................................................12
Parking ..............................................................................................................................12
Towing ...............................................................................................................................12
Charging your vehicle .............................................................. 13
New Battery Break in ......................................................................................................... 13
Signet®HB-xxxx Charger Operation .................................................................................13
Industrial Charger Operation ............................................................................................. 14
Charging Time ...................................................................................................................14
Lestronic II®Charger Operation ........................................................................................14
Storing and Returning to Service ........................................... 15
Storing Your Vehicle...........................................................................................................15
Returning to Service ..........................................................................................................15

Table of Contents
Periodic Maintenance Checklist .............................................. 16
Standard Periodic Maintenance Schedule
for the Smart View Display ................................................. 17
Daily Visual Inspection ......................................................................................................18
Maintenance Guidelines for
Severe Duty Applications ......................................................... 18
General Maintenance ............................................. 1
Maintenance Guidelines........................................................... 2
Troubleshooting Guide............................................................. 3
Lubrication Chart ...................................................................... 4
Front Axle Service.................................................. 1
Inspect the Front Wheel Bearings and King Pin.................... 2
Adjust Front Wheel Bearings.................................................. 3
Front Axle Removal and Installation ....................................... 4
Removal............................................................................................................................ 4
Installation ........................................................................................................................5
Front Axle Disassembly ........................................................... 6
Replace Front Wheel Bearings ................................................ 7
Replace the King Pins and Bushings ..................................... 9
Replace the Steering Knuckle ................................................. 11
Steering Component Service ................................ 1
Front End Alignment................................................................. 2
Inspect Ball Joints .................................................................... 6
Inspect Rod Ends...................................................................... 7
Adjust the Steering Gear .......................................................... 8
Replace the Steering Shaft....................................................... 10
Replace the Steering Wheel..................................................... 12
Replace the Steering Gear ....................................................... 13
Replace the Ball Joints, Tie Rods, and Drag Link.................. 14
Replacing the Drag Link...................................................................................................16
Replacing the Tie Rod ......................................................................................................17
Center the Steering Gear.......................................................... 18
Pitman Shaft Alignment ............................................................ 18
Repair the Steering Gear .......................................................... 19
Exploded View of Steering Gear ....................................................................................... 22

Table of Contents
Brake Service ......................................................... 1
Inspect the Service Brake ........................................................ 2
Disc Brake Pads................................................................................................................ 2
Disc Brake Rotor ............................................................................................................... 3
Inspect the Parking brake ........................................................ 4
Wheel Park Brake (hydraulic disc) .................................................................................. 4
Electric Motor Brake.........................................................................................................5
Adjust the Service Brakes........................................................ 6
Two or Four Wheel Hydraulic Disc Brakes .....................................................................6
Adjust the Parking Brake ......................................................... 7
Wheel Park Brake (hydraulic disc) .................................................................................. 7
Check Master Cylinder Fluid.................................................... 8
Bleed the Brake System ........................................................... 9
Flush the Brake System ........................................................... 11
Replace the Parking Brake Lining
(electric motor brake) ............................................................... 12
Inspection: ........................................................................................................................14
Replace Front Disc Brake Pads............................................... 15
Replace Rear Brake Pads ........................................................ 17
Hydraulic Disc...................................................................................................................17
Replace the Wheel Cylinder..................................................... 19
Disc Brake Body Assembly (front or rear)....................................................................... 19
Repair the Brake Body.............................................................. 21
Replace the Master Cylinder.................................................... 23
Repair the Master Cylinder....................................................... 25
Motor Service ......................................................... 1
Inspecting the Motor Brushes ................................................. 2
Motors with internal cooling fans .....................................................................................2
Motor Removal and Installation............................................... 3
Motor Inspection ....................................................................... 3
Replacing the Brushes or Armature Bearing ......................... 7
Repairing the Commutator....................................................... 8
Service Limits............................................................................ 10

Table of Contents
Transmission.......................................................... 1
Check Oil Level ......................................................................... 2
Change Oil ................................................................................. 3
Motor Removal and Installation............................................... 4
Rear Hub or Rotor..................................................................... 5
Removing and Installing the Rear Axles
(Disc Brakes) ............................................................................. 6
Transmission Assembly ........................................................... 8
Remove and Install ..........................................................................................................8
Disassembly and Reassembly of the
Primary Reduction Gear Case ............................................ 9
Disassembling the 3rd Member ............................................... 12
Assembling the 3rd Member.................................................... 15
Pinion Bearing Preload ....................................................................................................18
Pinion Gear Shimming Instructions ........................................ 19
Setting the Pinion Gear Depth ..........................................................................................19
Suspension ............................................................ 1
Replace the Rear Springs ........................................................ 2
Replace the Front Springs ....................................................... 3
Replace the Spring Bushings .................................................. 4
Replace the Shocks .................................................................. 5
Tires and Wheels ................................................... 1
Tire Inflation .............................................................................. 2
Tire Inspection .......................................................................... 2
Replace the Tire/Wheel............................................................. 3
Repair the Tire (pneumatic)..................................................... 4
Replace the Tire (pneumatic).................................................. 5
Battery Service....................................................... 1
Cleaning..................................................................................... 2
Testing ....................................................................................... 3
Watering..................................................................................... 5
Charging .................................................................................... 6
Replacing (6-volt batteries only).............................................. 7
Moist Charge Batteries ....................................................................................................9
Storage and Returning to Service ........................................... 10
Storage .............................................................................................................................10
Returning to Service.........................................................................................................11

Table of Contents
Sevcon Control System Troubleshooting ............ 1
Test Equipment Required: ...............................................................................................2
Important Notes and Instructions ....................................................................................2
Definitions:........................................................................................................................ 2
Terminology used: ............................................................................................................2
Start Troubleshooting Here ................................................................................................3
Test 8. Anti-Rolloff Fault ....................................................................................................22
Test 9. Electric Motor Brake ..............................................................................................23
Sevcon Logic Voltage Reference Table .............................................................................25
Status LED Code Table .....................................................................................................26
Lestronic II®Charger Troubleshooting................ 1
Operating Instructions and Theory of Operation................... 2
Testing the Charging Cycle...................................................... 3
Test Equipment Required for Troubleshooting ...................... 4
Important Notes and Instructions ....................................................................................4
Troubleshooting for Built-in Charger ...................................... 5
Troubleshooting for Portable Charger .................................... 8
Testing The Timer Relay........................................................... 9
Testing the Interlock Relay....................................................... 10
Signet®Charger Troubleshooting ........................ 1
Operating Instructions and Theory of Operation................... 2
Testing the Charging Cycle...................................................... 3
Test Equipment Required for Troubleshooting ...................... 4
Important Notes and Instructions ....................................................................................4
Status LED Error Code ............................................................. 5
Troubleshooting........................................................................ 6
Illustrated Parts...................................................... 1
Steering Knuckle............................................... 2
Front Brakes ..................................................... 4
Steering Linkage ............................................... 6
Steering Column ............................................... 8
Steering Gear .................................................... 10
Front Suspension............................................... 12
Wheels and Tires............................................... 12
Transmission Gear Case .................................... 14
Rear Axle .......................................................... 16
Transmission Differential Case.......................... 16
Rear Brakes....................................................... 18
Master Cylinder ................................................ 20
Brake linkage.................................................... 20
Brake Lines....................................................... 22
Rear Suspension ................................................ 24
Motor ................................................................ 26
Rear Motor Mount ............................................ 26
Instrument Panel (dash) .................................... 28
Speed Control Panel .......................................... 30
Miscellaneous Electrical.................................... 32
Signet® Charger ............................................... 34
Batteries
Roll Out Battery Box .................................. 36
Seat Cushions ................................................... 38
Decals ............................................................... 38
Miscellaneous ................................................... 39

Table of Contents
APPENDIX A-Special Tools.................................... A-1
Appendix B: Standard Hardware Suggested
Torque Limits ..................................................... 1
Hardware Identification ............................................................ 2
Standard Head Markings .................................................................................................2
Hex Bolts ..........................................................................................................................2
Other Bolts ........................................................................................................................2
Hex Nuts ........................................................................................................................... 3
Hex Lock Nuts (stover) ....................................................................................................3
Other Nuts ........................................................................................................................3
Suggested Torque Values (non-critical hardware) ................ 4
Suggested Torque Values (critical hardware) ........................ 5
Appendix C............................................................. C-1

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 ...................7
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
shouldbe familiarwith thepartsof thismanual 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
Thissectionidentifies the troubleshootingprocedures fortesting the electricalsystem andbattery charger.
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 wordsthatare usedtodefine warnings,cautions,instructions, ornotesfound 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(Powered Industrial Trucks)andwith all applicableportions oftheAmerican National Standard
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 location of the serial number is 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.

TAYLOR -DUNN

TABLE OF CONTENTS
Standard Specifications ...............................2
Safety Rules and Guidelines........................3
Driver Training Program ...............................4
Driver Qualifications.................................................. 4
Key-Switch................................................................4
Forward-Off-Reverse Switch .................................... 4
Horn Switch .............................................................. 4
Vehicle Controls............................................5
Hi-Low Switch (optional) ...........................................5
Accelerator Pedal......................................................7
Foot Brake Pedal ...................................................... 7
Headlight Switch ....................................................... 7
Accessory Switch (Optional).....................................7
Smart View Display ...................................................7
Directional Signals (Optional) ...................................8
Steering.....................................................................8
Hazard Light Switch (Optional) ................................. 8
Charger Interlock ...................................................... 10
Electrolyte Alarm (Optional) ......................................10
Seat Interlock Switch ................................................10
Park Brake ................................................................10
Safety Rules and Operating
Instructions
Vehicle Operational Guidelines ...................11
Safety Guidelines ......................................................11
Starting:.....................................................................11
While driving: ............................................................12
Loading and Unloading ............................................. 12
Parking......................................................................12
Towing.......................................................................12
Charging your vehicle ..................................13
New Battery Break in ................................................13
Signet®HB-xxxx Charger Operation ........................13
Industrial Charger Operation .....................................14
Charging Time .......................................................... 14
Lestronic II®Charger Operation ............................... 15
Returning to Service ................................................. 15
Storing and Returning to Service ...............15
Storing Your Vehicle ..................................................15
Periodic Maintenance Checklist ..................16
Standard Periodic Maintenance Schedule
for the Smart View Display.....................17
Daily Visual inspection: .............................................18
Maintenance Guidelines for
Severe Duty Applications.......................18

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 2
STANDARD SPECIFICATIONS
ITEM VOLTAGE SPECIFICATION
Occupancy Driver only
Electrical System 48 Volt 6-165 Amp Hour, 8 Volt, Lead Acid Batteries,
Solid State Speed Control, 500 Amp
Dimensions 467.36L x 149.86W x ?? H Centimeters
184L x 59W x ?? H Inches
Turning Radius ??? Centimeters (??? Inches)
Tires 600 x 9 Softuff
Dry Weight ???? kg (???? lbs)
Without Batteries
Maximum Load ???? kg (???? lbs)
Motor, DC 48 Volt 4.4 kW, (5.9 hp) for 60 min, 7.2 kW, (9.6 hp) for 5 min
Separately Excited Field
Min/Max Battery 169 kg to 261 kg (372 lbs to 576 lbs)
Weights
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid
Differential
Brakes 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 Dual Headlight, Tail/Brake Lights
Charger 48 Volt 100/240 VAC, 13/6.5 Amps (50/60Hz), 17 Amp DC
These vehicles conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(Powered Industrial Trucks)andwith all applicableportions oftheAmerican National Standard
for Personnel and Burden Carriers (ANSI B56.8).
Not available at
time of printing
Not available at
time of printing
Not available at
time of printing
Not available at
time of printing