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  4. B0-248-36
  5. Service Replacement Parts

Taylor-Dunn B0-248-36 Service Replacement Parts

Manual is about: EQUIPPED WITH GT-DRIVE SYSTEM

Summary of B0-248-36

  • Page 1

    T h e b e s t w a y t o g o a b o u t y o u r b u s i n e s s taylor-dun n ® c read the operator’s manual before operating this vehicle. The operator’s manual contains important information regarding the safe operation of this vehicle. Warning starting serial number: 197830 service and replacement p...

  • Page 2

    Your satisfaction is out #1 goal. If you have questions or concerns with your vehicle, please contact your sales representative or service advisor at your local dealership. Taylor-dunn has a worldwide dealer and distribution network to provide replacement parts and service for our vehicles. Refer to...

  • Page 3

    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 tayl...

  • Page 4: The Taylor-Dunn Corporation:

    The taylor-dunn corporation: leading provider of commercial & industrial vehicles since 1949 taylor-dunn manufacturing: from the day we shipped our first vehicle in 1949, we have pursued a singular goal: to build tough, rugged, dependable vehicles to help our customers move personnel, equipment, and...

  • Page 5: Master Table of Contents

    Master table of contents introduction ......................................................7 service/maintenance guidelines....................13 special tool list ..............................................17 tool list ...................................................................18 lubric...

  • Page 6

    Notes :.

  • Page 7: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Introduction introduction about this manual ..........................................8 who should...

  • Page 8: Introduction

    Page-8 mb-248-18 introduction b0-248; b0-254; bt-248; bt-280 (36v & 48v) 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 ...

  • Page 9: Introduction

    Page-9 mb-248-18 introduction b0-248; b0-254; bt-248; bt-280 (36v & 48v) conventions symbols and/or words used to define dangers, warnings, cautions, and notices are found throughout this manual. The “words” in this context will be referred to as “signal words.” the words defined here as “signal wor...

  • Page 10: Introduction

    Page-10 mb-248-18 introduction b0-248; b0-254; bt-248; bt-280 (36v & 48v) responsibilities of the operator... A vehicle shall not be operated until the operator has successfully completed an operator training course provided by the owner of the vehicle. The operator is responsible to be sure that th...

  • Page 11: Introduction

    Page-11 mb-248-18 introduction b0-248; b0-254; bt-248; bt-280 (36v & 48v) how to identify your vehicle this manual is valid only for the serial numbers listed on the front cover. If the ending serial number is blank, then this manual was for current production vehicles when printed. If you did not r...

  • Page 12

    Notes :.

  • Page 13: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Service/maintenance guidelines service/maintenance guidelines read me first: maintenance guideline...

  • Page 14: Warning

    Service/maintenance guidelines page 14 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 read me first: maintenance guidelines and general instructions warning read and follow all of the guidelines listed below. Failure to follow these guidelines may result in severe bodily injury and/or property...

  • Page 15

    Service/maintenance guidelines page 15 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) vehicle modifications using non-oem replacement components: to maintain peak performance, always use original taylor-dunn replacement parts intended for use on your vehicle. Taylor-dunn components are designe...

  • Page 16

    Notes :.

  • Page 17: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Special tool list special tool list tool list .......................................................

  • Page 18: Tool List

    Tool list page 18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 tool list the tools shown here are generic for servicing taylor-dunn vehicles. Not all tools will be required for servicing this vehicle. 62-027-32: throttle module analyzer tests the throttle module in or out of the vehicle 75-0...

  • Page 19: Tool List

    Tool list page 19 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) 96-500-43: pmt/c meter reset module required to reset the pmt/c maintenance meter (special order option). 77-201-00: battery filler used to safely add water to batteries. Equipped with splash guard and auto- shutoff when cell is ...

  • Page 20: Tool List

    Tool list page 20 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 troubleshooting guide this is a general troubleshooting guide for various mechanical faults. Refer to the electrical troubleshooting chapter for checking the electronic motor control system. This list is provided as a guide only....

  • Page 21: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Lubrication lubrication lubrication and fluids chart ..........................22 hazardous waste ...

  • Page 22: Lubrication

    Lubrication page 22 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 lubrication and fluids chart assembly component # capacity lubricant front axle: 1: ball joint 4 - general purpose grease 3: front wheel bearings 2 - high temperature wheel bearing grease 4: king pin 2 - general purpose grease ...

  • Page 23: Lubrication

    Lubrication page 23 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) lubrication diagram front end lubrication rear axle lubrication note: the transaxle is mounted at an angle in the vehicle. The transaxle must be level when checking oil level. This will require rasing the rear of the vehicle un...

  • Page 24

    Notes :.

  • Page 25: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Front axle front axle remove.............................................................26 remova...

  • Page 26: Front Axle

    Front axle page 26 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 remove removal 1: raise the front of the vehicle and support with jack stands. 2: remove both front wheels. Refer to tires and wheels section for information regarding removing the front wheels. 3: tie up or support the front ax...

  • Page 27: Front Axle

    Front axle page 27 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) disassemble disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: replace the steer...

  • Page 28: Front Axle

    Front axle page 28 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 inspect front wheel bearings 1: raise the front of the vehicle and support with jack stands. 2: grab the top and bottom of the tire/wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of...

  • Page 29: Front Axle

    Front axle page 29 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) front wheel alignment note: only toe in can be set. Caster and camber is not adjustable. Center the steering 1: raise the front of the vehicle and support with jack stands. 2: turn the front wheels so that they are in the straig...

  • Page 30: Front Axle

    Front axle page 30 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace front wheel bearings 1: set the park brake. 2: disconnect the batteries. 3: raise the front of the vehicle and support with jack stands. 4: remove the tire/wheel assembly from the hub. Refer to the tire/wheel section for...

  • Page 31: Front Axle

    Front axle page 31 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) replace king pin/bushings there are different types of king pin bushings depending on the configuration of your vehicle. This is a generic procedure that covers all three types of bushings. Refer to the illustration below for th...

  • Page 32: Front Axle

    Front axle page 32 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 service limits and specifications king pin bushings ream or broach to 1.25 inch ±0.001 (31.75 mm ±0.0254) toe in 0 - + 0.25 inches (6.3 mm) hardware torque description foot pounds newton meters ball joint clamp 28-32 37.9-43.4 r...

  • Page 33: Warning

    Warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Table of contents drive axle drive axle check oil level ................................................34 change oi...

  • Page 34: Drive Axle-Gt

    Drive axle-gt page 34 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 check oil level fluid type and capacities are listed in the lubrication chapter. Note: the oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil le...

  • Page 35: Drive Axle-Gt

    Drive axle-gt page 35 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) transmission assembly remove 1: release the park brake. 2: remove the park brake cables from the spring axle mounting brackets and brake arms. 3: disconnect the wiring from the motor. 4: disconnect the hydraulic brake lines f...

  • Page 36: Drive Axle-Gt

    Drive axle-gt page 36 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 axle shaft the oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flange. If both axles hav...

  • Page 37: Drive Axle-Gt

    Drive axle-gt page 37 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) rear hub, rotor & bearings note: the axle hub bolt has a special thread locking compound applied to the threads. If this bolt is removed, it must be replaced. 1: disconnect the batteries. 2: raise the wheel off of the ground....

  • Page 38: Drive Axle-Gt

    Drive axle-gt page 38 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 primary gear case 1: disconnect the batteries. 2: raise the rear of the vehicle and support with jack stands. 3: place a drain pan under the gear case that is capable of holding 4 liters (4 quarts) of oil and drain the oil fr...

  • Page 39: Drive Axle-Gt

    Drive axle-gt page 39 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) disassemble 1: remove the transaxle assembly from the vehicle. Refer to remove in this section. 2: place a drain pan under the gear case that is capable of holding 4 liters (4 quarts) of oil and drain the oil from the front a...

  • Page 40: Drive Axle-Gt

    Drive axle-gt page 40 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 pinion holding tool assemble 1: temporarily install the pinion gear (hand tighten only). 2: install the carrier bearing race adjusting nuts into the housing and cover. 3: install the carrier bearing races into the housing and...

  • Page 41: Drive Axle-Gt

    Drive axle-gt page 41 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) pinion bearing preload pinion gear shimming instructions note: this procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. Note: to perform this procedure, all part...

  • Page 42: Drive Axle-Gt

    Drive axle-gt page 42 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 note: values shown are for reference only c d hardware torque if hardware is not listed here, refer to standard torque values in the appendix. Description foot pounds newton meters pinion nut 154-169 209229 drain plug 21-25 2...

  • Page 43: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Steering steering inspect ball joints ...........................................44 inspect rod en...

  • Page 44: Steering

    Steering page 44 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 inspect ball joints note: a set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 1: tie off the front wheels so that they cannot turn. 2: ...

  • Page 45: Steering

    Steering page 45 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) adjust steering gear note: in some vehicle configurations it may be necessary to remove the steering gear to perform this procedure. Refer to replace the steering gear for information regarding removing the steering gear. 1: raise...

  • Page 46: Steering

    Steering page 46 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace ball joint 1: raise the front of the vehicle and support with jack stands. 2: loosen the ball joint clamp on the steering sleeve. 3: remove the cotter pin and ball joint nut. 4: using a pickle fork, remove the ball joint f...

  • Page 47: Steering

    Steering page 47 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) replace steering shaft 1: if equipped with a horn switch in the steering wheel, remove the switch, disconnect the wires from the switch and cut the terminals off of the wires. 2: remove the steering wheel. Refer to replace the ste...

  • Page 48: Steering

    Steering page 48 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace steering wheel note: the steering wheel is on a tapered shaft and may be damaged when it is removed. 1: if equipped with a horn switch in the steering wheel, remove the switch and disconnect the wires from the switch. 2: r...

  • Page 49: Steering

    Steering page 49 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steering gear disassemble note: the steering gear must be removed from the vehicle for this procedure. Refer to replace the steering gear section for information regarding removing the steering gear. Note: the steering gear is pac...

  • Page 50: Steering

    Steering page 50 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 reassemble 12: lightly lubricate all parts before reassembly. 13: install a new worm shaft seal and pitman shaft seal into the housing. 14: install the upper worm bearing cup. 15: divide the ball bearing into two equal groups. 16:...

  • Page 51: Steering

    Steering page 51 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) exploded view of steering gear hardware torque description foot pounds newton meters ball joint clamp 28-32 37.9-43.4 rod end stud nut 20-25 27.1-33.9 rod end jam nut 20-25 27.1-33.9 ball joint castle nut 40-45 54.2-61.

  • Page 52

    Notes :.

  • Page 53: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Brakes brakes general guidelines and safety.......................54 front brake ....................

  • Page 54: Brakes

    Brakes page 54 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 general guidelines and safety warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning do not ing...

  • Page 55: Brakes

    Brakes page 55 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) front brake service limits refer to the table at the end of this section inspection note: service limits are listed in a table at the end of this section. 1: raise the front of the vehicle and support with jack stands. 2: remove the...

  • Page 56: Brakes

    Brakes page 56 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 rear brake service limits refer to the table at the end of this section note: service limits are listed in a table at the end of this section. Inspection 1: raise the front of the vehicle and support with jack stands. 2: remove the ...

  • Page 57: Brakes

    Brakes page 57 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) rebuild disc brake body this procedure assumes that the component has been removed from the vehicle. Refer to the component assembly removal instructions for details and warnings regarding the removal and installation procedure. 1: ...

  • Page 58: Brakes

    Brakes page 58 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 bleed system note: start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. The rear bleeder valves can be accessed through the center rear inspection cover. 1: ...

  • Page 59: Brakes

    Brakes page 59 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) master cylinder level lines are highlighted in the illustration for clarity. They are not black. There are no internally serviceable components in the master cylinder. If the master cylinder is faulty, it must be replaced add fluid ...

  • Page 60

    Notes :.

  • Page 61: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Motor motor remove/install .................................................62 disassemble...........

  • Page 62: Motor Sem

    Motor sem page 62 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 disassemble 1: remove the motor from the vehicle. See the drive axle section for information on removing the motor. 2: remove the brush cover and pull the brushes out away from the commutator. 3: remove the dust cap from the rear...

  • Page 63: Motor Sem

    Motor sem page 63 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) inspect inspect the commutator for groves. • if the commutator is grooved then it must be machined on a lathe. Do not machine the commutator past the minimum diameter specified in service limits section. Refer to repair commutato...

  • Page 64: Motor Sem

    Motor sem page 64 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 inspect the armature windings where they loop back at the opposite end of the commutator. • if the windings show indications of expanding (see illustration), then the motor has been operated at excessive rpm and the armature or m...

  • Page 65: Motor Sem

    Motor sem page 65 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) repair the only recommended repair to a motor is cutting the commutator. If any other components are damaged then they should be replaced. Repairing the commutator 1: first measure the diameter of the commutator. If the commutato...

  • Page 66: Motor Sem

    Motor sem page 66 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 service limits this is a generic section covering all currently available sem motors at the time this manual was revised. The service limits listed below are for each of the motors, by the specification number of the motor shown....

  • Page 67: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Motor controller motor controller remove/install ....................................................

  • Page 68: Motor Controller

    Motor controller page 68 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 inspect receptacles the inside of each receptacle should be clean and free of any debris. Use aerosol electrical cleaner if required. Base plate the base plate should be flat. If required, sand with 150 wet sandpaper to re...

  • Page 69: Motor Controller

    Motor controller page 69 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) troubleshooting troubleshooting control system is not included in this manual. All electrical troubleshooting information is included in a separate manual “troubleshooting electric vehicles”. Part number m7-001-69. This ma...

  • Page 70

    Notes :.

  • Page 71: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Tires & wheels tires & wheels inflation .............................................................

  • Page 72: Tires & Wheels

    Tires & wheels page 72 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 inflation air pressure maintaining the correct tire pressure is important to the safe operation of the vehicle as well as ensuring long tread life. Under inflated tires result in: • excessive tire side wall flexing that can ...

  • Page 73: Tires & Wheels

    Tires & wheels page 73 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) tread wear rotation front and rear tires as well as left and right tires can wear at different rates. It is important to periodically rotate your ties to extend your tire life. Refer to the maintenance schedule in this manua...

  • Page 74: Tires & Wheels

    Tires & wheels page 74 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace the tire (pneumatic) note: to replace the tire, the tire/wheel assembly must be removed from the vehicle. Refer to replace the tire/wheel section for information on removing the tire/wheel assembly. Tire replacement ...

  • Page 75: Tires & Wheels

    Tires & wheels page 75 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) hardware torque if hardware is not listed here, refer to standard torque values in the appendix. Description foot pounds newton meters wheel nut 85 115.

  • Page 76

    Notes :.

  • Page 77: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Batteries batteries general guidelines and safety.......................78 cleaning .................

  • Page 78: Batteries

    Batteries page 78 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 general guidelines and safety warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning • explo...

  • Page 79: Batteries

    Batteries page 79 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) cleaning disconnect the batteries before cleaning. Dry dirt can be readily blown off with low-pressure air or brushed off. Note: wetness or wet dirt on the top of the battery indicates battery acid boil over or excessive gassing....

  • Page 80: Batteries

    Batteries page 80 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 testing specific gravity note: the battery must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a reading o...

  • Page 81: Batteries

    Batteries page 81 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) remove/install industrial battery or lift out battery pack 1: thoroughly clean the battery and battery compartment. Refer to cleaning in this section for information regarding cleaning the batteries. 2: using a hoist or forklift ...

  • Page 82

    Notes :.

  • Page 83: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Suspension suspension replace the rear springs ...............................84 replace the front...

  • Page 84: Suspension

    Suspension page 84 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace the rear springs if a spring has failed or is fatigued, then it is recommended that both rear springs are replaced as a set. Hint: in most vehicles it will be easier if the springs are replaced one at a time. 6: raise th...

  • Page 85: Suspension

    Suspension page 85 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) replace the front springs if a spring has failed or is fatigued, then it is recommended that both front springs are replaced as a set. Hint : in most vehicles it will be easier if the springs are replaced one at a time. 6: raise...

  • Page 86: Suspension

    Suspension page 86 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replace the spring bushings it is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): •...

  • Page 87: Suspension

    Suspension page 87 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) replace the shocks it is recommended to replace all shocks as a set. Note: on some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for informati...

  • Page 88

    Notes :.

  • Page 89: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Wire diagram wire diagram diagram part numbers....................................90

  • Page 90: Wire Diagram

    Wire diagram page 90 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 sch-00033 tc50, chassis, fed ex sch-00034 engine, psi 3.0l sch-00035 tram, fedex sch-00036 tiger tractor, typical sch-00037 tc-50e, vehicle sch-00038 tc50, chassis, fedex ford sch-00039 engine, ford dsg sch-0004 c426ac, vehicl...

  • Page 91: Replacement Parts

    Table of contents replacement parts replacement parts ordering parts for your vehicle .....................92 taylor-dunn web site information .................92 axle assembly, front ......................................94 axle shaft assembly, rear .............................96 transaxle assembl...

  • Page 92: Replacement Parts

    Replacement parts page 92 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) ordering parts for your vehicle this section contains a comprehensive parts list that includes all of the typical replacement parts available as of the published date of this manual. This parts list should be used as a gu...

  • Page 93: Replacement Parts

    Replacement parts page 93 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) my vehicle information serial number: . Date purchased: . Date delivered: . Dealer purchased from: . Salesman name: . My local parts dealer: . Notes :.

  • Page 94: Replacement Parts

    Replacement parts page 94 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) axle assembly, front.

  • Page 95: Replacement Parts

    Replacement parts page 95 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) axle assembly, front item no. Part no. Description qty - 15-049-71 axle beam, b 2-48, bt 2-48, b 2-54 1 - 15-049-77 axle beam, bt 2-80 1 4 88-239-86 3/4-nf hex slotted nut 2 5 88-228-60...

  • Page 96: Replacement Parts

    Replacement parts page 96 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) axle shaft assembly, rear note: the double bearing axle assembly is optional. Most vehicles will only have the single bearing (#2) inner bearing on double bearing axle does not have an oil seal or o-ring. Orientation of b...

  • Page 97: Replacement Parts

    Replacement parts page 97 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) axle shaft assembly, rear item no. Part no. Description qty 1 41-154-10 axle shaft, bt 2-80 2 41-154-20 axle shaft, b 2-48, bt 2-48, b 2-54 (single bearing) 2 41-154-25* *axle shaft, b ...

  • Page 98: Replacement Parts

    Replacement parts page 98 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) note: spacer (item no. 23) is available in increments of .05mm starting at 3.9mm. 3.9mm spacer is part number gt-3287213. Add 10 to the part number for every 0.05mm over 3.9. For example, if 4.55mm is needed: 4.55-3.9 = ....

  • Page 99: Replacement Parts

    Replacement parts page 99 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) axle assembly, rear item no. Part no. Description qty 1 gt-71682 m8 x 60 bolt 12 2 gt-3287563 gear case cover 1 3 gt-71259 bearing 1 4 gt-3287513 input shaft, 30:1 0 or 1 gt-3287523 inp...

  • Page 100: Replacement Parts

    Replacement parts page 100 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) battery depending on the configuration of your vehicle, the batteries may be wired as shown in these two illustrations..

  • Page 101: Replacement Parts

    Replacement parts page 101 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) item no. Part no. Description qty 1 50-243-10 battery rod * 2 50-250-00 battery hold down * 3 88-088-66 flat washer, tin/lead plated * 4 88-069-81 1/4nc nylon lock nut * 5 88-089-80 5/...

  • Page 102: Replacement Parts

    Replacement parts page 102 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brakes, brake lines single reservoir master cylinder.

  • Page 103: Replacement Parts

    Replacement parts page 103 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brake lines (dual reservoir master cylinder) item no. Part no. Description qty 1 99-609-61 brake line, front 1 2 99-607-59 brake line, rear 1 3 99-606-51 brake line, front right 1 4 99...

  • Page 104: Replacement Parts

    Replacement parts page 104 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) single reservoir master cylinder.

  • Page 105: Replacement Parts

    Replacement parts page 105 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brake lines (single reservoir master cylinder) item no. Part no. Description qty 1 71-110-00 brake light switch (optional) 1 2 99-591-00 brake light switch adaptor (optional) 1 3 99-57...

  • Page 106: Replacement Parts

    Replacement parts page 106 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brakes, master cylinder master cylinder (single reservoir) item no. Part no. Description qty 1 99-511.00 master cylinder assembly 1 2 88-101-20 hex bolt 2 3 99-579-00 fitting, bolt 1 4 99-572-00 washer 1 5 99-566-00 fitt...

  • Page 107: Replacement Parts

    Replacement parts page 107 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) master cylinder (dual reservoir) item no. Part no. Description qty 1 88-080-14 bolt, 5/16” x 1-1/2” nc, hex head 2 2 see usage table master cylinder (includes item #3) 1 3 99-511-52 ca...

  • Page 108: Replacement Parts

    Replacement parts page 108 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brakes, brake linkage brake linkage item no. Part no. Description qty 1 88-080-11 bolt, 5/16 x 1”, hex head 2 2 51-344-80 park brake handle 1 3 88-088-61 washer, 5/16” 4 4 88-089-81 locknut, 5/16” 2 5 96-813-00 adjusting...

  • Page 109: Replacement Parts

    Replacement parts page 109 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brakes, front axle front brakes item no. Part no. Description qty 1a 88-067-29 bolt 4 1b 88-069-82 locknut, 1/4” nc, grade c (included in rebuild kit) 4 2 41-350-91 plate, secondary 2 ...

  • Page 110: Replacement Parts

    Replacement parts page 110 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) brakes, rear axle brakes, rear axle item no. Part no. Description qty 1 88-067-21 1/4 x 3-3/4 hex bolt, grade 8 4 88-069-82 1/4nc locknut, grade c (included in rebuild kit) 4 2 41-350-91 secondary plate 2 3 see kit below...

  • Page 111: Replacement Parts

    Replacement parts page 111 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) charger model > 9695 16910 22620 16920 style > portable built in built in built in item # description part # charger assembly 79-309-00 79-309-10 79-303-25 79-309-20 1 ammeter 79-851-1...

  • Page 112: Replacement Parts

    Replacement parts page 112 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) charger, signet note: the harness connectors and ac plug are not included with the charger. Qty part # description 2 75-318-20 butt splice 2 75-320-51 knife connector 1 76-200-00 ac plug, 115 volt model hbs charger part ...

  • Page 113: Replacement Parts

    Replacement parts page 113 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) charger, x-series item no. Part no. Description qty 79-303-49 charger assembly, x-series, 48 volt 1 79-831-00 fuse 79-809-61 relay boad assembly * control board assembly 79-749-14 scr ...

  • Page 114: Replacement Parts

    Replacement parts page 114 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) control system, motor speed control.

  • Page 115: Replacement Parts

    Replacement parts page 115 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) speed control panel item no. Part no. Description qty 1 62-400-05 (see note) speed controller, 400 amp 1 62-400-15 (see note) speed controller, 500 amp 2 01-200-06 mounting panel 1 3 7...

  • Page 116: Replacement Parts

    Replacement parts page 116 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) control system, instrument panel instrument panel item no. Part no. Description qty 1 71-100-00 auxiliary switches 0, 1, 2 2 71-039-11 auxiliary switches 0, 1, 2 3 88-817-07 screw 6 4 - - - 5 01-200-09 console 1 6 74-010...

  • Page 117: Replacement Parts

    Replacement parts page 117 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) instrument panel item no. Part no. Description qty 1 71-039-11 light switch 1 2 71-039-11 wiper switch 0 or 1 3 71-039-11 strobe switch 0 or 1 4 71-039-02 forward/reverse switch 1 5 71...

  • Page 118: Replacement Parts

    Replacement parts page 118 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) decals between seats b 2-48 and b 2-54 bt 2-80 electronics compartment bt 2-80 under 2nd seat.

  • Page 119: Replacement Parts

    Replacement parts page 119 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) decals item no. Part no. Description qty 1 94-319-00 battery disconnect 1 or 2 2 94-313-00 battery warning 1 or 2 3 94-373-10 vehicleidentification 1 4 94-309-00 brake warning 1 5 94-3...

  • Page 120: Replacement Parts

    Replacement parts page 120 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) electrical, miscellaneous miscellaneous wire harness clamps 7 motion alarms 8 9.

  • Page 121: Replacement Parts

    Replacement parts page 121 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) electrical item no. Part no. Description qty 1 96-624-00 clamp, 1/4 jiffy clip 96-625-00 clamp, 5/16 jiffy clip 2 96-626-00 clamp, 7/8 jiffy clip 3 96-640-00 clamp, 3/16 push mount 4 9...

  • Page 122: Replacement Parts

    Replacement parts page 122 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) frame and body steel cab.

  • Page 123: Replacement Parts

    Replacement parts page 123 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steel cab item no. Part no. Description qty 1 90-923-98 door frame, left 1 2 90-924-98 side curtain, left 1 3 97-315-53 handle assembly, outer 2 4 97-315-51 door latch 2 5 97-315-54 ha...

  • Page 124: Replacement Parts

    Replacement parts page 124 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) fiberglass cab.

  • Page 125: Replacement Parts

    Replacement parts page 125 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) fiberglass cab item no. Part no. Description qty 1 90-921-98 door frame, left 1 90-921-99 door frame, right 1 98-451-11 weather seal tape (by the foot) - 2 90-908-98 side curtain, left...

  • Page 126: Replacement Parts

    Replacement parts page 126 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) dump bed.

  • Page 127: Replacement Parts

    Replacement parts page 127 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) dump bed option item no. Part no. Description qty 1 21-018-00 cylinder pin - 2 88-060-11 bolt, 1/4 x 1-1/4”” nc, hex head - 3 88-069-81 locknut, 1/4”” nc - 4 21-019-00 shaft, dump bed ...

  • Page 128: Replacement Parts

    Replacement parts page 128 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) rear cargo box item no. Part no. Description qty 1 91-333-02 cargo box (unpainted) 1 2 90-471-00 front deck board 1 3 90-472-00 rear deeck board 1 4 90-850-10 front window 1 5 98-310-00 rubber window gasket (by the foor)...

  • Page 129: Replacement Parts

    Replacement parts page 129 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v).

  • Page 130: Replacement Parts

    Replacement parts page 130 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) lights head and tail lights item no. Part no. Description qty 1 72-005-00 5” round head light 1 or 2 72-072-00 replacement bulb 1 or 2 2 94-050-10 rectangular light , left (steel cab) 1 94-050-11 rectangular light , righ...

  • Page 131: Replacement Parts

    Replacement parts page 131 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) strobe light item no. Part no. Description qty 1 88-029-80 8-32 hex nut 3 2 88-028-62 #8 lock washer 3 3 88-025-06 8-32 x 1/2 machine screw 3 4 72-023-20 strobe assembly (amber) 1 5 **...

  • Page 132: Replacement Parts

    Replacement parts page 132 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) item no. Part no. Description qty - 92-202-00 mirror mounting bracket assembly, fiberglass cab 1 92-202-21 arm 1 2 92-202-23 bracket 2 3 92-202-22 joint 1 4 88-080-14 5/16nc x 1-1/2 hex bolt 1 5 88-088-61 5/16 sae flat w...

  • Page 133: Replacement Parts

    Replacement parts page 133 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mounting hardware item no. Part no. Description qty 97-811-00 1-7/8 inch ball 97-821-00 2-inch ball 88-140-14 1/2nc x 1-1/2 hex bolt 4 88-149-80 1/2nc hex nut 4 88-148-62 1/2 split loc...

  • Page 134: Replacement Parts

    Replacement parts page 134 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) motor.

  • Page 135

    Page 135 motors, separately excited field motor spec # motor part # not available at time of printing the original motor provided under part number 70-054-40 has been discontinued. It has been replaced by 70-054-41. The 70-054-41 motor has slightly more power & torque. The 70-054-40 motor can be dir...

  • Page 136: Replacement Parts

    Replacement parts page 136 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) motor mount item no. Part no. Description qty 1 88-067-22 bolt,1/4 x 2” nc, grade (no brake option) 3 88-067-29 bolt,1/4 x 4-1/4” nc, grade 8 (brake option only) 3 2 ** automatic electric brake unit 1 3 see motor motor (...

  • Page 137: Replacement Parts

    Replacement parts page 137 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) seats bt 2-48 seat cushions item no. Part no. Description qty 1 90-195-00 rear seat back 4 02-203-14 seat back mounting plate 4 88-837-11 #14 x 1 sheet metal screw 30 2 90-194-00 rear ...

  • Page 138: Replacement Parts

    Replacement parts page 138 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v).

  • Page 139: Replacement Parts

    Replacement parts page 139 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) b 2-48 and b 2-54 seats and deck item no. Part no. Description qty 1 90-148-00 passenger seat cushion (standard) 1 90-172-00 passenger seat cushion (with steel cab) 1 2 90-140-00 seat ...

  • Page 140: Replacement Parts

    Replacement parts page 140 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steering gear.

  • Page 141: Replacement Parts

    Replacement parts page 141 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steering gear, 18-308-21 item no. Part no. Description qty 1 18-308-70 locknut 1 2 18-308-71 adjuster assembly 1 3 18-308-72 worm assembly 1 4 18-308-23 upper worm bearing 1 5 18-308-2...

  • Page 142: Replacement Parts

    Replacement parts page 142 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steering linkage.

  • Page 143: Replacement Parts

    Replacement parts page 143 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) steering linkage item no. Part no. Description qty 1 18-041-05 tie rod, b 2-48, b 2-54, bt 2-48 1 18-057-00 tie rod, bt 2-80 1 2 86-510-00 ball joint clamp 4 3 86-501-98 ball joint (le...

  • Page 144: Replacement Parts

    Replacement parts page 144 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) item no. Part no. Description qty 1 88-199-82 5/8nf hex nut 1 2 19-011-20 steering wheel 1 3 88-081-14 5/16nf x 1-1/2 hex bolt, grade 8 1 4 88-089-84 5/16nf hex lock nut, grade c 1 5 32-248-10 upper bushing 1 6 20-031-65...

  • Page 145: Replacement Parts

    Replacement parts page 145 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) item no. Part no. Description qty 1 96-121-00 u-bolt 4 2 85-498-00 leaf spring, b 2-48, bt 2-48, bt 2--80 2 85-486-00 leaf spring, b 2-54 2 3 32-214-50 bushing 12 4 96-240-00 1/2nc x 4...

  • Page 146: Replacement Parts

    Replacement parts page 146 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) suspension, rear.

  • Page 147: Replacement Parts

    Replacement parts page 147 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) rear suspension item no. Part no. Description qty 14 85-510-17 leaf spring 2 15 16-861-44 spring mounting plate (left) 1 16-861-45 spring mounting plate (right) 1 16 96-114-00 u-bolt 4...

  • Page 148: Replacement Parts

    Replacement parts page 148 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) wheels and tires.

  • Page 149: Replacement Parts

    Replacement parts page 149 * not available at time of printing mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) wheels and tires item no. Part no. Description qty 1 wheels 12-012-00 5 x 8” tubeless 12-020-00 8.5 x 8 tubeless 12-050-00 12-1/8 diameter cast iron 2 tires 10-075-00 4.80 x 8 lr b pne...

  • Page 150: Replacement Parts

    Replacement parts page 150 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) turn signals windshield wiper item no. Part no. Description qty 74-050-00 wiper motor 1 74-051-00 wiper arm, up to 8/31/20008 0 or 1 74-051-01 wiper arm, starting 9/1/2008 0 or 1 74-052-00 wiper blade, up to 8/31/2008 0 ...

  • Page 151: Table of Contents

    Table of contents warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Hardware information hardware information torque guidelines for standard hardware ....152 hardware...

  • Page 152: Hardware

    Hardware page 152 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 torque guidelines for standard hardware note:torquevaluesspecifiedareforcleandrythreads. Note: torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, use grade 2 torque value. H...

  • Page 153: Hardware

    Hardware page 153 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) nuts with no markings are to be treated as s.A.E. Grade 2 lock nuts use a letter to indicate the grade of the nut. Grade a’ locknuts would be the equivelent of grade ‘...

  • Page 154: Hardware

    Hardware page 154 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 generic torque values all torque values are for clean dry zinc plated threads in noncritical steel assemblies of the same hardness specification. Reduce torque approximately 10-15% for lubricated threads. Refer to the service sec...

  • Page 155: Hardware

    Hardware page 155 mb-248-18 b0-248; b0-254; bt-248; bt-280 (36v & 48v) metric, newton meters grade, n-m dia. Pitch 4.6 8.8 10.9 12.9 3 0.50 0.51 * * * 4 0.70 0.95 3.1 * * 5 0.80 2.28 6.1 * * 6 1.00 3.92 10.4 15.5 * 8 1.00 * 27.0 * * 1.25 9.48 25.0 37.0 * 10 1.00 * 57.0 * * 1.25 * 54.0 * * 1.50 19.1 ...

  • Page 156: Hardware

    Hardware page 156 b0-248; b0-254; bt-248; bt-280 (36v & 48v) mb-248-18 replacing hardware warning this section is one section of a complete service manual. Before starting any procedure, read all warnings and instructions that are located in the service guidelines chapter. Warning failure to follow ...

  • Page 157: Warning

    Warning california proposition 65 warning engine exhaust and some of its constituents are known to the state of california to cause cancer, birth defects, and other reproductive harm. There are chemicals contained in the operating systems of this vehicle that are known to the state of california to ...

  • Page 158

    Taylor-dunn® manufacturing. 2114 west ball road. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 fax: (714) 956-0504 visit our website: www.Taylor-dunn.Com.