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Taylor-Dunn B0-248-36, Service Replacement Parts

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Taylor-Dunn B0-248-36 Service Replacement Parts Download Page 19

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 full.

70-440-55: Pin Removing Tool

Removes pin from Amp circular harness 
connectors.

Molex # 11-300-06: Pin Removing Tool

Removes 0.093 diameter pins from Molex 
rectangular harness connectors. Not 
available from Taylor-Dunn. Purchase from 
any local electronics distributor.

41-350-13: Disc Brake Boot Installation Tool

Assists in installing the rubber boot onto the 
disc brake piston.

75-442-55: Pin Removing Tool

Removes pins from Molex Mini-Fit harness 
connectors.

77-200-00: Hydrometer

Used for testing battery electrolyte. 
Illustration is of a typical hydrometer, actual 
hydrometer type may vary.

Molex # 11-300-02: Pin Removing Tool

Removes 0.062 diameter pins from Molex 
rectangular harness connectors. Not 
available from Taylor-Dunn. Purchase from 
any local electronics distributor.

96-500-48: GT Drive Oil Fill Plug Tool
Used  to  remove  the  oil  fill  plug  on  GT 

drives. It is used with a 3/8” drive extension 
(not included).

Summary of Contents for B0-248-36

Page 1: ...fe operation of this vehicle WARNING Starting Serial Number 197830 Service and Replacement Parts Manual MANUAL MB 248 18 Model Numbers B0 248 36 B 2 48 36 volt B0 248 48 B 2 48 48 volt B0 254 36 B 2 5...

Page 2: ...acement parts and service for our vehicles Refer to our web site www taylor dunn com for a dealer lookup application Originally Published 1 23 2015 Revision C 11 17 2016 contents subject to change wit...

Page 3: ...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 th...

Page 4: ...n invaluable asset and it is an asset we cherish and protect Our guiding principle is to provide application specific solutions which are reliable efficient and economical Our domestic and internation...

Page 5: ...List 17 Tool List 18 Lubrication 21 Front Axle 25 Drive Axle 33 Steering 43 Brakes 53 Motor 61 Motor Controller 67 Tires Wheels 71 Batteries 77 Suspension 83 Wire Diagram 89 Replacement Parts 91 Hard...

Page 6: ...Notes...

Page 7: ...rnings and instructions that are located in the Service Guidelines chapter Introduction Introduction About This Manual 8 Who Should Read This Manual 8 Replacement Parts 8 How To Use This Manual 8 Conv...

Page 8: ...nn replacement parts intended for use on your vehicle Taylor Dunn components are designed and tested for use on specific Taylor Dunn model vehicles Only use the correct Taylor Dunn replacement compone...

Page 9: ...e vehicle NOTICE This signal word will not be accompanied by the safety alert symbol NOTICE will indicate a condition that if not avoided may result in property damage Property is defined as the vehic...

Page 10: ...he vehicle Of the Service Personnel The service personnel are responsible for the service and maintenance of the vehicle At no time shall a service person allow any untrained personnel to service or r...

Page 11: ...n in the illustrations below WEB SITE REGISTRATION Registering on the Taylor Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor Dunn line of vehicle...

Page 12: ...Notes...

Page 13: ...ing 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 Guidelin...

Page 14: ...RNING 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...

Page 15: ...ffect capacity and safe machine operation shall not be performed by the customer or user without manufacture s prior written authorization where authorized modifications have been made the user shall...

Page 16: ...Notes...

Page 17: ...tion 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 18 C...

Page 18: ...7 68 Diagnostics only 62 027 00 Test Light Used for testing electrical circuits Switchable for 12 24 36 48 volt systems Required to complete troubleshooting provided in the vehicle service manuals 43...

Page 19: ...lor Dunn Purchase from any local electronics distributor 41 350 13 Disc Brake Boot Installation Tool Assists in installing the rubber boot onto the disc brake piston 75 442 55 Pin Removing Tool Remove...

Page 20: ...e Soft and or Low Brake Pedal Air in brake lines Bleed brake system Master cylinder fluid level low Fill master cylinder and bleed system Brake pedal linkage out of adjustment Adjust linkages Hard Bra...

Page 21: ...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 2...

Page 22: ...ll Plug 1 1 4 1 9 Liters SAE 80W90 Gear Oil 10 Motor Coupler 1 Part 94 421 34 Moly Paste Grease HAZARDOUS WASTE DISPOSAL This vehicle contains various components and or fluids that may be classified a...

Page 23: ...M 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 vehi...

Page 24: ...Notes...

Page 25: ...Front Axle Front Axle Remove 26 Removal 26 Install 26 Installation 26 Disassemble 27 Inspect Front Wheel Bearings 28 Adjust Front Wheel Bearings 28 Front Wheel Alignment 29 Center the Steering 29 Fro...

Page 26: ...tallation 1 Raise the front of the vehicle and support with jack stands 2 Install the front axle in reverse order of removal Note Use all new cotter pins Note Refer to the Replacing the Ball Joints se...

Page 27: ...arding these procedures Replace the Steering Knuckle Replace the King Pins and Bushings Note The front axle does not have to be removed unless the axle beam must be replaced Refer to Front Axle Remova...

Page 28: ...el for 5 compete revolutions 4 Attach a rope to the tire and wrap around the tire with 1 foot remaining hanging in the air 5 Tie a weight see table and illustration below to the end of the rope 6 Slow...

Page 29: ...rque table at the end of this section 11 Untie the steering wheel and the front wheels 12 Rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps...

Page 30: ...heel assembly 3 Remove the hub bearing cap cotter pin and nut then remove the hub from the steering knuckle Note For a front disc brake option you must remove the brake body before removing the hub Re...

Page 31: ...Raise the front of the vehicle and support with jack stands 2 Remove the steering knuckle Refer to Replace the Steering Knuckle for information regarding removing the steering knuckle 3 Press the kin...

Page 32: ...D 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...

Page 33: ...of Contents Drive Axle Drive Axle Check Oil Level 34 Change Oil 34 Transmission Assembly 35 Remove 35 Install 35 Axle Shaft 36 Remove 36 Install 36 Rear Hub Rotor Bearings 37 Motor Removal Installatio...

Page 34: ...llow to drain until level with the bottom of the opening 8 Replace the fill level plug 9 Reconnect the batteries 10 Remove the blocks from the wheels CHANGE OIL Fluid type and capacities are listed in...

Page 35: ...front spring mounting bolts 7 Raise the rear of the vehicle lifting the frame up and off of the drive assembly Support the rear of the vehicle with jack stands Install 8 Reinstall the drive in revers...

Page 36: ...ug threads Refer to Check Oil Level procedure 13 Set the park brake 14 Lower the vehicle 15 Reconnect the batteries 16 Remove the blocks from behind the wheels 17 Release the park brake and test drive...

Page 37: ...behind the wheels release the park brake and test drive MOTOR REMOVAL INSTALLATION Note Some applications will require removing the drive assembly from the vehicle to remove the motor Refer to Removin...

Page 38: ...gear case position in relation to the 3rd member housing so that it will be reassembled in the same position 12 Remove the six retaining bolts holding the gear case to the 3rd member housing 13 Remove...

Page 39: ...nd adjusting nut from the side plate 8 Turn the side plate over and remove the carrier bearing race from the side plate 9 Remove the differential assembly 10 Remove the carrier bearing adjusting nut r...

Page 40: ...edure 12 Install the pinion gear holding tool 96 500 42 and tighten the pinion nut enough to keep the pinion gear from rotating 13 Install the differential assembly 14 Install the cover and all of the...

Page 41: ...he distance in millimeters from the rear of the drive housing to the face of the pinion gear see illustration Once a shim has been selected and the pinion gear is installed confirm that E D B DV Set P...

Page 42: ...169 209229 Drain plug 21 25 28 4 33 Gear case to 3rd member 18 20 24 4 27 3rd Member cover bolts 40 50 54 67 5 Axle hub bolt 275 392 Note Special Washers The washers for the primary gear case housing...

Page 43: ...at are located in the Service Guidelines chapter Steering Steering Inspect Ball Joints 44 Inspect Rod Ends 44 Adjust Steering Gear 45 Front Wheel Alignment 45 Replace Ball Joint 46 Replace Rod End 46...

Page 44: ...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 Visually inspect each rod end for any signs of play bet...

Page 45: ...orm bearing adjuster jam nut 7 Find the center position of the steering shaft a Turn the steering shaft all of the way in one direction b While counting the rotations turn the steering shaft all of th...

Page 46: ...and test drive REPLACE ROD END 1 Raise the front of the vehicle and support with jack stands 2 Loosen the rod end clamp or jam nut on the steering sleeve 3 Remove the nut or bolt holding the rod end o...

Page 47: ...e input shaft splines steering wheel splines and the upper steering shaft bushing 8 Install the steering shaft in reverse order using a new pinch bolt Orientate the shaft so that the pinch bolt is opp...

Page 48: ...ead position 5 Lightly grease the steering wheel splines and install the replacement steering wheel orientated as shown in the illustration 6 Tighten the steering wheel nut to torque listed in the Har...

Page 49: ...he worm bearing adjuster 3 Remove the side cover pitman shaft assembly by removing the three side cover bolts and then pulling the assembly out of the housing Note The side cover pitman shaft assembly...

Page 50: ...lace the upper worm bearing on the worm shaft and install the worm shaft ball nut assembly into the housing being careful not to damage the worm shaft seal 21 Install the assembled worm bearing adjust...

Page 51: ...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...

Page 52: ...Notes...

Page 53: ...d in the Service Guidelines chapter Brakes Brakes General Guidelines and Safety 54 Front Brake 55 Service Limits 55 Inspection 55 Replace Pads 55 Rear Brake 56 Service Limits 56 Inspection 56 Replace...

Page 54: ...id from a new sealed container DOT 3 brake fluid is corrosive and will damage paint finishes Dispose of brake fluid in accordance with local state and federal regulations Read and follow all warnings...

Page 55: ...cap 2 Remove fluid from the master cylinder until it is 1 2 full 3 Raise the front of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to Tires and Wheels section for in...

Page 56: ...rea around the master cylinder cap 2 Remove fluid from the master cylinder until it is 1 2 full 3 Raise the rear of the vehicle and support with jack stands 4 Remove the tire wheel assembly Refer to T...

Page 57: ...nging off of the end of the piston Fig 2 8 Insert the rubber boot piston into the brake body making sure that the boot is properly seated in the groove Fig 3 9 Press the pistons all the way down into...

Page 58: ...ation that there is still air in the brake lines 10 Repeat this process with each of the other wheels Note When finished top off the master cylinder with fluid See Check Master Cylinder Fluid for info...

Page 59: ...ts 11 14 9 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...

Page 60: ...Notes...

Page 61: ...ual Before starting any procedure read all warnings and instructions that are located in the Service Guidelines chapter Motor Motor Remove Install 62 Disassemble 62 Inspect 63 Brushes 63 Bearing 63 Co...

Page 62: ...housing screws from the rear motor housing and remove the housing from the motor 6 Remove the nuts from the armature studs and remove the two brush assemblies 7 Remove the bearing circlip and press t...

Page 63: ...ity that the field windings may also be burnt Symptoms indicating a shorted field include high motor current lack of power and possibly excessive speed Brushes Measure the length of each motor brush I...

Page 64: ...nd the entire commutator by placing one test lead against one of the commutator segments and the other test lead against all of the other segments one at a time There should be continuity around the e...

Page 65: ...ound the commutator If any one of the measurements is less than the minimum undercut depth specified in Service Limits then the commutator must be undercut see below 6 While still in the lathe smooth...

Page 66: ...mm inches Armature Field 70 052 40 XP 1876 or DD3 4004 0 635 0 025 69 85 2 75 15 87 0 625 0 011 0 73 70 054 40 XP 1672 or DV1 4002 0 635 0 025 69 85 2 75 15 87 0 625 0 0116 1 2 70 054 41 XP 1789 or D...

Page 67: ...any procedure read all warnings and instructions that are located in the Service Guidelines chapter Motor Controller Motor Controller Remove Install 68 Inspect 68 Receptacles 68 Base Plate 68 Termina...

Page 68: ...panel Install 1 Thoroughly clean the controller base mounting plate and heat sink 2 Apply thermal transfer compound to the controller base and heat sink 3 Install the controller to the mounting plate...

Page 69: ...or Dunn does not support field modifications to the controller parameters Complete vehicle parameters are available by e mail and can be uploaded to the controller using a laptop or PC with the PCpaK...

Page 70: ...Notes...

Page 71: ...ing any procedure read all warnings and instructions that are located in the Service Guidelines chapter Tires Wheels Tires Wheels Inflation 72 Air pressure 72 Tread Wear 73 Rotation 73 Changing Tire W...

Page 72: ...le Steering pulling to the left or right Only check the tire pressure when the tire is cold When checking tire pressure you must check all tires including your spare tire The correct tire size and pre...

Page 73: ...Extreme tire wear can result in sudden tire failure and loss of control of the vehicle Refer to the maintenance schedule in this manual for the recommended interval Minimum recommended tread depth is...

Page 74: ...nded to repair a tire with a combination vulcanized plug and internal patch Tire repairs should only be performed by personnel trained in tire repair The tire repair procedure will be unique to the ty...

Page 75: ...eels 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 nu...

Page 76: ...Notes...

Page 77: ...nstructions that are located in the Service Guidelines chapter Batteries Batteries General Guidelines and Safety 78 Cleaning 79 Watering 79 Charging 79 Testing 80 Specific Gravity 80 Storing 80 Storag...

Page 78: ...e bodily injury and or property damage A battery is a live electrical source It cannot be disconnected or neutralized Do not drop any tool or conductive object onto the battery A conductive object tha...

Page 79: ...of a charging cycle It is recommended to fill the battery at the end of a charging cycle If the electrolyte is below the top of the battery plates then fill just enough to cover the plates and then to...

Page 80: ...RING Storage Thoroughly clean the battery and battery compartment Refer to Cleaning in this section for information regarding cleaning the battery Check the electrolyte level and charge the battery Re...

Page 81: ...s 1 Using an insulated wrench disconnect the cables from the battery to be removed 2 Using a battery lifting strap remove the battery from the vehicle 3 Inspect the battery compartment for corrosion I...

Page 82: ...Notes...

Page 83: ...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 Springs...

Page 84: ...ing the spring 15 Tighten the spring hanger bolts securely but not so tight as to bind the spring 16 Lower the vehicle 17 Reconnect the main positive and negative cables at the batteries 18 Remove the...

Page 85: ...spring hanger bolts to amount listed in the Hardware Torque table at the end of this section 16 If the spring bolts are equipped with grease fittings lube them at this time 17 Lower the vehicle 18 Re...

Page 86: ...ye on the vehicles frame For external bushing Remove the bushings from the spring eye 10 Install the new bushings in reverse order Hint Apply a light coating of grease to the bushing before pressing i...

Page 87: ...all the shock in reverse order 10 Lower the vehicle 11 Reconnect the main positive and negative cables at the batteries 12 Remove the blocks from behind the wheels 13 Release the parking brake and tes...

Page 88: ...Notes...

Page 89: ...G 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...

Page 90: ...provided with the vehicle The diagram for this vehicle is SCH 00009 see description below This vehicle diagram as well as other Taylor Dunn vehicle diagrams can be downloaded from the Taylor Dunn web...

Page 91: ...7 Decals 118 Electrical Miscellaneous 120 Frame and Body 122 Steel Cab 122 Fiberglass Cab 124 Dump Bed 126 Rear Cargo Box 128 Lights 130 Mirrors 132 Mounting Hardware 133 Motor 134 Motor Mount 136 Sea...

Page 92: ...on the Taylor Dunn web site will give you access to a wealth of information about your vehicle and the entire Taylor Dunn line of vehicles Your contact information will remain confidential and will no...

Page 93: ...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...

Page 94: ...Replacement Parts Page 94 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v AXLE ASSEMBLY FRONT...

Page 95: ...3 Bushing 2 10 80 309 12 Thrust Bearing 2 11 45 338 00 Grease Seal 2 12 80 017 00 Tapered Bearing 4 13 80 103 00 Tapered Bearing Race 4 14 12 158 10 Wheel Hub W Rotor incl 1 12 1 11 1 13 2 12 124 00 W...

Page 96: ...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 Orienta...

Page 97: ...8 268 63 Flat washer 2 6 88 268 30 7 8 14 x 1 5 Bolt grade 5 2 7 96 329 10 Wheel stud 1 Not shown 92 104 10 Hub cover 2 41 290 40 Axle housing L B 2 48 BT 2 48 B 2 54 single bearing 1 41 290 43 Axle h...

Page 98: ...3 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 65mm over 0 6...

Page 99: ...0417 Fill Level plug 1 17 GT 3287113 Differential housing 1 18 GT 71979 Bearing 1 19 GT 3287143 Differential case 1 20 GT 72013 O ring 1 21 GT 3273633 Pinion nut 1 22 GT 71896 M10 x 25 Bolt 12 23 See...

Page 100: ...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: ...T 105 Moist charge dry 77 044 00 230AH T 125 77 044 10 195AH Mainenance free Note requires special charger 77 047 00 244AH T 145 77 047 50 250AH TD 250 77 047 80 244AH T 145 Moist charge dry 77 048 0...

Page 102: ...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: ...80 1 5 99 603 68 Brake Line Rear Right B 2 48 B 2 54 BT 2 48 1 99 608 56 Brake Line Rear Right BT 280 1 6 99 603 68 Brake Line Rear Left B 2 48 B 2 54 BT 2 48 1 99 608 57 Brake Line Rear Left BT 2 80...

Page 104: ...Replacement Parts Page 104 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v Single Reservoir Master Cylinder...

Page 105: ...576 00 Hose Clip 2 4 99 608 58 Brake Line Rear BT 2 80 1 99 607 62 Brake Line Rear B 2 48 B 2 54 BT 2 48 1 5 99 604 56 Brake Line Rear Right BT 2 80 1 99 603 68 Brake Line Rear Right B 2 48 B 2 54 BT...

Page 106: ...m 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 Fitting 1 6 99 571 00 Washer 1 7 88 109 81 Hex lo...

Page 107: ...er 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 Cap Seal Master Cylinder 1 99 511 53 Cap M...

Page 108: ...80 1 6 96 771 00 Clevis Pin 3 8 x 3 4 1 7 01 204 32 Brake Equalizer 1 8 96 760 00 Brake Cable Clevis 1 9 88 099 80 Nut 5 16 Hex Head 2 10 96 773 00 Clevis Pin 5 16 x 1 1 11 88 527 11 Cotter Pin 1 8 X...

Page 109: ...3 41 348 58 Spacer Included In Rebuild Kit 4 4 32 208 01 Bushing Included In Rebuild Kit 4 5 41 351 35 Brake Body Assembly No Internally Serviceable Parts 2 6 99 588 01 Bleeder Adaptor 2 7 99 588 00 B...

Page 110: ...ld kit 4 6 41 350 28 1 Mounting bracket 2 8 41 350 39 Brake body assembly 2 9 88 840 11 Retaining ring 2 41 350 52 Clevis pin 2 10a 99 588 00 Brake bleeder 2 10b 99 588 01 Adapter brake bleeder 2 11 4...

Page 111: ...851 10 2 Timer 79 805 65 79 805 68 79 805 68 Relay Timer 79 808 20 79 808 20 79 808 20 3 Capacitor 79 902 00 79 902 00 79 902 00 79 902 00 4 Diode assy 79 749 13 79 749 13 79 749 13 79 749 13 5 Trans...

Page 112: ...re no user serviceable components inside the charger Note The charger AC cord is an integral part of the charger When replacing the charger do not cut and splice the AC cord Cutting the AC cord will v...

Page 113: ...48 volt 1 79 831 00 Fuse 79 809 61 Relay boad assembly Control board assembly 79 749 14 SCR assembly 79 840 02 Circuit breaker 79 848 01 Ammeter 79 810 01 Switch kit start stop low voltage self diagno...

Page 114: ...Replacement Parts Page 114 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v CONTROL SYSTEM MOTOR SPEED CONTROL...

Page 115: ...400 15 you will need to provide the vehicle serial number The controller will be programmed to match the vehicle as originally manufactured Item 4 Depending on the model and serial number of the vehic...

Page 116: ...09 Console 1 6 74 010 00 Smart View gauge 0 or 1 74 009 00 Battery Gauge analog 36 volt 0 or 1 74 009 02 Battery Gauge bar graph 36 volt 0 or 1 74 009 48 Battery Gauge bar graph 48 volt 0 or 1 7 94 3...

Page 117: ...120 10 Key Switch 1 71 119 99 Spacer key switch 1 9 10 88 607 06 Rivet push in 8 11 94 303 91 Dash Panel 1 Note If your vehicle was not originally equipped with the Smart View display then the Sevcon...

Page 118: ...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: ...13 00 Battery warning 1 or 2 3 94 373 10 Vehicle identification 1 4 94 309 00 Brake warning 1 5 94 313 20 Safety warning 1 6 94 384 01 Not a motor vehicle 1 7 94 384 14 When leaving vehicle warning 1...

Page 120: ...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: ...t Horn Switch 2 7 62 033 48 Accelerator Module 1 8 96 650 01 Wire Harness Clip stick on 0 or 1 9 73 005 05 Reverse Warning alarm 0 or 1 10 71 102 10 Seat interlock Switch 1 11 85 030 00 Spring 2 12 96...

Page 122: ...Replacement Parts Page 122 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v FRAME AND BODY Steel Cab...

Page 123: ...1 012 12 Connecting Bar 2 17 16 510 00 Spacer 2 18 88 065 06 Screw 1 4 X 1 2 NC Phillips Truss Head 2 19 88 045 08 Screw 10 32 X 5 8 Truss Head 2 20 88 049 86 Locknut 10 32 2 21 88 045 11 Screw 10 32...

Page 124: ...Replacement Parts Page 124 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v Fiberglass Cab...

Page 125: ...in Right 1 3 97 315 53 Handle Assembly Outer 2 4 97 315 51 Door Latch 2 5 97 315 54 Handle Assembly Inside 2 6 97 304 50 Snap Fastner 12 7 88 737 08 Rivet 5 32 X 5 8 14 8 88 029 86 Locknut 8 32 4 9 88...

Page 126: ...Replacement Parts Page 126 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v Dump Bed...

Page 127: ...o 11 1 2008 88 169 82 Locknut 9 16 starting 11 1 2008 21 72 022 51 Rubber Mounting Ring 22 23 Special Order Dump Bed Not shown 90 442 00 Deckboard AA 000 11 Fluid Hydraulic Dextron 2 Quart 75 124 00 W...

Page 128: ...t 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 6 90 851 00...

Page 129: ...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: ...on 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 right steel cab 1 72 082 01 Replacement bulb 2...

Page 131: ...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 Mounting Pole...

Page 132: ...201 00 Mirror rectangular 4 1 2 x 8 1 2 side view 1 92 202 12 Mounting bracket left Steel cab 1 92 202 13 Mounting bracket right Steel Cab 1 91 814 16 Hinge left used with 92 202 12 1 91 814 17 Hinge...

Page 133: ...f 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...

Page 134: ...Replacement Parts Page 134 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v MOTOR...

Page 135: ...70 170 00 70 109 00 70 417 00 80 212 00 70 421 00 88 067 17 88 067 22 203 21 4001 or XP1820A 70 072 41 85 403 00 70 173 00 70 170 10 1 XP 1786 or DD3 4004 70 052 40 70 412 20 70 170 00 70 109 00 2 70...

Page 136: ...1 3 See Motor Motor Typical 1 4 96 114 10 U Bolt 5 16 NF Motor Support 1 5 K66 600 03 Motor Support Bracket 1 6 88 128 62 Lock washer 7 16 2 7 89 111 27 Bolt 10m X 1 5 X 20 Hex Head 2 8 88 088 62 Lock...

Page 137: ...3 14 Seat back mounting plate 4 88 837 11 14 x 1 Sheet metal screw 30 2 90 194 00 Rear seat cushion 4 3 90 140 00 Front seat back 1 4 90 148 00 Front seat cushion 2 BT 2 80 Seat Cushions Item No Part...

Page 138: ...Replacement Parts Page 138 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v...

Page 139: ...32 3 4 x 41 fold away seat option 1 90 469 00 Deckboard 19 11 16 x 41 f oldaway seat option 1 90 464 00 Deckboard 55 x 41 fold away seat option 1 90 441 00 Deckboard 37 1 2 x 41 1 90 440 43 Diamond p...

Page 140: ...Replacement Parts Page 140 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v STEERING GEAR...

Page 141: ...08 72 Worm assembly 1 4 18 308 23 Upper worm bearing 1 5 18 308 22 Upper worm bearing race 1 6 18 308 77 Housing 1 7 18 308 78 Seal pitman shaft 1 8 18 308 80 Nut pitman shaft 1 9 18 308 81 Lock washe...

Page 142: ...Replacement Parts Page 142 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v STEERING LINKAGE...

Page 143: ...8v 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 left 2 4 86 501 99 Bal...

Page 144: ...NF 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 Steering shaft assembly incl 3 and 4 1 7 19 011 25 Steering wheel cap 1 8 88 128 62 7 16...

Page 145: ...6v 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 Hex bolt 6 5 88...

Page 146: ...Replacement Parts Page 146 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v SUSPENSION REAR...

Page 147: ...pring mounting plate right 1 16 96 114 00 U bolt 4 88 159 84 1 2NC Nylon lock nut 8 18 19 96 103 00 U bolt 2 20 88 149 81 1 2NC Lock nut 4 21 50 460 00 Strap 2 22 98 002 00 Rubber overload spring 2 23...

Page 148: ...Replacement Parts Page 148 MB 248 18 B0 248 B0 254 BT 248 BT 280 36v 48v WHEELS AND TIRES...

Page 149: ...r Wheel 2 5 Bead 3A 12 042 12 Inner Wheel 12 Bolt 4 12 041 13 Outer Wheel 2 5 Bead 4A 12 042 13 Outer Wheel 12 Bolt 5 12 041 00 Wheel Assembly 2 5 Bead Width Includes 3 4 6 7 8 5A 12 042 00 Wheel Asse...

Page 150: ...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 or 1 74 052 01 Wiper blade starting 9 1 2008 0 or 1 75 152 09 Harness 1 Item No Part No Description Qty 72 05...

Page 151: ...edure read all warnings and instructions that are located in the Service Guidelines chapter Hardware Information Hardware Information Torque Guidelines for Standard hardware 152 Hardware Identificatio...

Page 152: ...rade 8 bolt use grade 2 torque value Hardware Identification Hex Head Bolts and Screws The grade of SAE bolts and screws are identified by markings on the head as illustrated to the right The grade of...

Page 153: ...rade 2 Lock nuts use a letter to indicate the grade of the nut Grade A locknuts would be the equivelent of Grade 2 hex nuts Grade B as Grade 5 and Grade C as Grade 8 Note Nuts with no markings are to...

Page 154: ...75 376 350 16 192 297 420 390 7 8 9 278 429 593 565 14 306 473 818 625 1 8 416 644 909 850 14 466 721 1018 930 1 1 8 7 590 794 1287 1700 12 662 891 1444 1850 1 1 4 7 832 1120 1817 2950 12 922 1241 201...

Page 155: ...Pitch 4 6 8 8 10 9 12 9 3 0 50 0 38 4 0 70 0 7 2 3 5 0 80 1 7 4 5 6 1 00 2 9 7 7 11 4 8 1 00 19 9 1 25 7 18 4 27 3 10 1 00 42 1 25 40 1 50 14 1 38 55 12 1 25 71 1 50 68 1 75 24 64 118 14 1 50 111 2 0...

Page 156: ...priate assembly procedure for information regarding proper hardware torque All hardware should be inspected for thread damage or corrosion prior to reassembly If any evidence of damage is found then t...

Page 157: ...stituents 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 st...

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...

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