Taylor-Dunn MB-238-00 Manual

The Best Way
To Go
About Your
Business
®
SerialNumberStarting: 164954
MANUAL MB-238-00
Operation, Troubleshooting and
Replacement Parts Manual
Models Inlcuded:
B0-012-38 3-wheel RR Special
Revision: A

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)
COPYRIGHT NOTICE
Copyright © 2001 by Taylor-Dunn®Mfg. All rights reserved.
No part of this work may be reproduced or transmitted in any form or by any 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

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

Section Index
Introduction 1
Safety Rules and Operating Instructions 2
General Maintenance 3
Front Axle Service 4
Steering Component Service 5
Brakes Service 6
Motor Service 7
Transmission Service 8
Suspension 9
Tires and Wheels 10
Battery Service 11
Lestronic II Charger Troubleshooting 12
Electrical Troubleshooting 13
Wire diagram 14
Illustrated Parts 15
Appendix A
Special Tools 16
Appendix B
Suggested Torque Values 17
Appendix C
Brake Lining Handling Precautions 18
Taylor-Dunn
Model B0-012-38 Railroad Special
Operator and Service Manual Section Index
This quick reference section index guide will assist you in
locating a desired topic or procedure.
Refer to each sectional Table of Contents for the page
number location for specific topics or procedures.

TAYLOR -DUNN

Table of Contents
Introduction
About this manual.........................................2
Who Should Read This Manual....................2
Responsibilities ............................................2
How To Use This Manual..............................3
Conventions ..............................................................3
How to Identify Your Vehicle ........................4
Taking Delivery of Your Vehicle ...................5
R 3-80 shown with extended
steel cab and doors options

INTRODUCTION
Page-2
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 should be familiar with the parts of this
manual that apply to their use of this vehicle.
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
Before servicing, operating, training or performing
maintenanceon thisoranyotherTaylor-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.
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...
Theservicepersonnelareresponsiblefortheservice
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.
Model B 2-10 shown withstake sides
and steel cab with doors options

INTRODUCTION
Page-3
HOW TO USE THIS MANUAL
This manual is organized into five main sections:
INTRODUCTION
Thissection describeshow touse thisservice manual
and how to identify your vehicle.
Safety Rules and Operating Instructions
Thissection outlines thesafety and operationalissues,
locationand operation ofcontrols, and theoperational
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
Thissection gives specificinformation on theservicing
ofthevehicle and a scheduleformaintenancechecks.
Electrical and Charger Troubleshooting
This section identifies the troubleshooting procedures
for testing the electrical system and battery charger.
Illustrated Parts
This section provides an illustrated view of various
assemblies. The illustrations are accompanied by
tables identifying the parts.
Conventions
Symbols and/or words that are used to define
warnings, cautions, instructions, or notes found
throughout this manual. Refer to the examples below.
Note: Alerts the reader to additional
information about a subject.
Model B 2-48 equipped
with the Dump Bed option
Model R 3-80 shown equiped with a cargo
box and steel cab with doors options
A shaded box with and the word “Warning”
and the symbol above denotes a
warning. This warning alerts the reader of
a high voltage 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.
A shaded box with the word “Warning” and
the symbol above 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.
A box with the word “CAUTION” and the
symbol above 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.

INTRODUCTION
Page-4
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.
The locations of the model and serial numbers are illustrated below:
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section 29 CFR
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).
This vehicle is not designed to be driven on public roads or highways. It is available in maximum
designed speed of 10 mph. Do not exceed the maximum designed speed. Exceeding the maximum
designed speed may result in steering difficulty, motor damage, and/or loss of control. Do not
exceed locally imposed speed limits. Do not tow this vehicle at more than 5 mph.

INTRODUCTION
Page-5
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
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.
What To Do If a Problem is Found
Ifthere isa problem or damage as a resultof 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
theproblem. Thereport mustbe madewithin 24hours
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.
Model B 2-10 Ambulance

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

TABLE OF CONTENTS
Safety Rules and
Operating Instructions
Standard Specifications Burden Carrier 2
Safety Rules and Guidelines .............3
Driver Training Program ....................3
Driver Qualifications. ........................................... 3
Vehicle Controls ................................4
1) Key switch ........................................................ 4
2) Smart View Display ......................................... 4
3) Forward-Off-Reverse Switch ........................... 4
4) Horn switch ...................................................... 4
1) Headlight switch............................................... 5
2) Front Side Lights .............................................. 5
3) Rear Side Lights ............................................... 5
Park Brake ............................................................ 5
1) Foot Brake Pedal.............................................. 5
2) Accelerator Pedal.............................................. 5
Steering ................................................................. 6
Charger Interlock (built in charger) ..................... 6
Vehicle Operational Guidelines..........7
Safety Guidelines .................................................. 7
Starting:................................................................. 7
While driving: ....................................................... 7
Loading and Unloading ........................................ 7
Towing Loads: ...................................................... 7
Parking .................................................................. 8
Towing This Vehicle ............................................. 8
Charging your vehicle........................9
New Battery Break in ........................................... 9
Signet®Charger Operation .................................. 9
Lestronic II®Charger Operation ......................... 9
Charging Time ...................................................... 10
Storing and Returning to Service ......10
Storing Your Vehicle ............................................. 10
Returning to Service ............................................. 10
Periodic Maintenance Checklist.........11
Standard Periodic Maintenance Schedule
for the Smart View Display ............12
Daily Visual inspection:........................................ 13
Maintenance Guidelines for
Severe Duty Applications...............13

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 2
STANDARD SPECIFICATIONS BURDEN CARRIER
ITEM VOLTAGE SPECIFICATION
Occupancy Driver only
Dimensions 262.9 L X 106.7 W X 129.5 H Centimeters
103.5 L X 42 W X 51 H Inches
Turning Radius 393.7 Centimeters (155 Inches)
Dry Weight 612.3 kg (1350 lbs)
Without Batteries
Min/Max Battery 169 kg to 196 kg (372 lbs to 432 lbs)
Weights
Maximum Load 952.5 kg (2,100 lbs)
Deck dimensions 105.4 W x 109.2 L Centimeters (41.5 W x 43 L Inches)
Electrical System 36 Volt Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 400 Amp
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid
Differential.
Motor, DC 36 Volt 3.2 kW, (4.4 Horse Power) for 60 min
Separately Excited 5.1 kW, (6.9 Horse Power) for 5 min
Field
Brakes Rear Wheel Hydraulic Disc, Hand Operated Park Brake
4 Wheel Hydraulic Disc, Hand Operated Park Brake
Steering Automotive Steering 24:1
Tires 18.5 x 8.50 x 8 Load Range C
Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Diamond Plate
Instrumentation Smart View Display (Battery Status Indicator, Hour Meter,
System Status Monitor),, Key Switch, Horn Button,
Forward/Reverse Switch, Headlight Switch
Light Accessories Headlight, Side and Rear Utility Lights, Dual Tail/Brake Lights
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard for
Personnel and Burden Carriers (ANSI B56.8).

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 3
SAFETY RULES AND
GUIDELINES
Itisthe responsibility of theownerof this vehicletoassure
that the operator understands the various controls and
operating characteristics of this vehicle (extracted from
theAmericanNational Standards Institute Personneland
Burden Carriers ANSI B56.8). As well as, following the
safety rules and guidelines outlined in ANSI B56.8 and
listed below.
These vehicles are designed for driving on smooth
surfacesin and around facilities suchas industrial plants,
nurseries, institutions, motels, mobile home parks, and
resorts. They are not to be driven on public highways.
Refer to Vehicle Operational Guidelines, Safety
Guidelines section for important safety information
regarding operating this vehicle.
Read and follow all of the guidelines listed
below. Failure to follow these guidelines
may result in severe bodily injury and/or
property damage.
These vehicles are not designed to be
driven on public roads or highways. They
are available in a maximum designed speed
of 10 mph. Do not exceed the maximum
designed speed. Exceeding the maximum
designed speed may result in steering
difficulty, motor damage, and/or loss of
control. Do not exceed locally imposed
speed limits. Do not tow this vehicle at
more than 5 mph.
Before working
on a vehicle:
1. Make sure the key-switch is in the “OFF”
position, then remove the key.
2. Place the forward-reverse switch in the
center “OFF” position.
3. Set the park brake.
4. Place blocks under the front wheels to
prevent vehicle movement.
5. Disconnect the main positive and
negative cables at the batteries.
DRIVER TRAINING PROGRAM
Accordingto ANSI B56.8, the owner of this vehicleshall
conduct an Operator Training program for all those who
will be operating this vehicle. The training program shall
not be condensed for those claiming to have previous
vehicle operation experience. Successful completion of
the Operator Training program shall be required for all
personnel who operate this vehicle.
The Operator Training program shall include the
following:
•Operation of this vehicle under circumstances
normallyassociated with your particularenvironment.
•Emphasis on the safety of cargo and personnel.
•All safety rules contained within this manual.
•Proper operation of all vehicle controls.
•A vehicle operation and driving test.
Driver Qualifications.
Only those who have successfully completed the
Operator Training program are authorized to drive this
vehicle. Operators must possess the visual, auditory,
physical,and mental ability to safelyoperate this vehicle
asspecifiedintheAmericanNationalStandardsInstitute
Controlled Personnel and Burden Carriers ANSI B56.8.
The following are minimum requirements necessary to
qualify as an operator of this vehicle:
•Demonstrate a working knowledge of each control.
•Understand all safety rules and guidelines as
presented in this manual.
•Know how to properly load and unload cargo.
•Know how to properly park this vehicle.
•Recognize an improperly maintained vehicle.
•Demonstrate ability to handle this vehicle in all
conditions.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 4
1) Key switch
A key-switch, located on the right center side of the instrument panel, turns on the vehicle. Rotate the key clockwise
to turn the vehicle power on, counterclockwise to turn the vehicle power off.
The key-switch should be in the “OFF” position whenever the operator leaves the vehicle.
This switch is also designed to secure and disable the vehicle. The key can only be removed when the key-switch
is in the “OFF” position.
2) Smart View Display
Refer to the end of this section for information on the operation of the Smart View Display.
3) Forward-Off-Reverse Switch
The forward-off-reverse switch, located to the left of the key switch, determines the direction of travel of the vehicle.
Push the top of the switch to engage the forward direction. Push the bottom of the switch to engage the reverse
direction.
DO NOT SWITCH from forward to reverse or vice-versa while the vehicle is in motion. Make sure the vehicle is
completely stopped before shifting.
The forward-off-reverse switch should be in the center “OFF” position, with the key-switch off and the park brake set
whenever the operator leaves the vehicle.
4) Horn switch
The horn switch is located on the upper right side of the instrument panel. Depress the switch to sound the horn,
release it to turn it off.
VEHICLE CONTROLS

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 5
1) Headlight switch
2) Front Side Lights
3) Rear Side Lights
All lights switches operate the same.
Toggle the switch to the UP position to turn the light on,
toggle it to the DOWN position to turn the light off.
Switches in the left column control the lights on the left
side of the vehicle.
Switches in the right column control the lights on the
right side of the vehicle.
1) Foot Brake Pedal
Thefootbrake pedal, is locatedtothe right ofthesteering
column,it is foroperationwith the rightfoot only. Itworks
similar to the brake in an automobile. Applying pressure
to the brake pedal slows the vehicle according to the
amount of pressure applied. Relieving pressure from
the pedal releases the braking action.
2) Accelerator Pedal
The accelerator pedal is located to the right of the brake
pedal. It controls the speed of the vehicle and operates
similar to the accelerator pedal in an automobile.
Depress the pedal to increase speed and release the
pedal to decrease speed.
Park Brake
The parking brake is actuated with a hand lever, which
is located to the left of the driver seat. To set the parking
brake, push down on the brake pedal and pull the lever
up until it locks. To release the park brake, depress the
foot brake pedal, pull up on the park brake handle, push
the release button, and lower the handle.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 6
Charger Interlock (built in charger)
The charger interlock is designed to disable the vehicle
from being driven while the AC charger cord is plugged
into a functioning power source.
NOTE: The interlock shown is mounted external of the
charger.Some vehicles may have theinterlock built into
the charger.
Steering
The steering wheel and steering system are similar to
an automobile. To turn right, turn the steering wheel
clockwise. To turn left, turn the steering wheel counter-
clockwise.If equippedwith tiltsteering, therelease lever
is located on the lower left of the steering column. Pull
the lever up to reposition the steering wheel.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 7
Smart View Display
The Smart View Display (SVD) functions as a
Battery Status Indicator (BSI), Hour Meter
(HM), speed controller status monitor, and as
anoptional maintenance monitor feature. The
operation of each of these functions is listed
below.
BSI:Abargraph representing thecurrentstate of charge
is located across the top of the display. When the
batteriesare fully charged,all segments ofthe bar graph
will be on. As the batteries are used, segments will turn
off in the order of right to left.
When the batteries are discharged to 75%, the last three
segments will flash indicating that you are approaching
the end of the battery cycle. At this time, the vehicle’s
batteries should be charged as soon as possible.
At 90%, all segments will flash and the vehicles speed
will be reduced. At this time, the vehicle should be
removed from service for charging. Discharging beyond
90%will result indamage to thebatteries that willshorten
the battery life-span.
HM: There are three hour meter functions, Key Hours,
Run Time Hours, and Pump Hours.
Key Hours: Accumulated length of time in hours thatthe
key switch is in the “ON” position. When the display is
turned on, the Key Hours will be displayed for
approximately 5-seconds as indicated by the Key Hours
Indicator located at the lower left of the display. The
icon represents the silhouette of a key.
Pump hours: Accumulated length of time the hydraulic
pump has been in operation. This is an optional feature.
After the Key Hours, the Pump Hours will be displayed
for approximately 5-seconds as indicated by the Pump
Hours Indicator located at the lower left of the display.
The icon represents a motor symbol with a “P” in the
center.
Run Time Hours: Accumulated length of time that the
vehicles has been in operation. Time is accumulated
whentheFS-1 switch intheaccelerator module is closed.
After the Pump Hours, the Run Time Hours will be
displayed as indicated by the Run Time Hours Indicator
located at the left of the display. The icon represents a
motor symbol with a “T” in the center.
Speed controller status: The display will indicateafault
code whenever the control system logic detects a
problem with the control system. A fault code is being
displayed whenever the Fault Code Indicator (the letter
“F”) is visible at the left of the numeric display. Refer to
the table on the following page for a list of fault codes
and their descriptions.
Maintenance monitor (optional):
Operation: The SVD notifies the operator 10-hours
(standard) before a scheduled maintenance is due.
During this warning period, the meter will continue to
alert the operator. This should allow sufficient time for
the operator to schedule the maintenance that is due,
with minimal down time. If the scheduled maintenance
isnot performed before thewarning period elapses,then
the vehicles maximum speed will be significantly
reduced.
Warning period: The warning period starts when the
Maintenance Indicator is ON and the Wrench icon is
flashing. The Wrench icon will continue to flash until the
warning time has expired.
Maintenance Due: Once the warning period has expired
and the maintenance is due, the Wrench icon will stop
flashing and remain ON. Additionally, the vehicles
maximum speed will be significantly reduced until the
maintenance is performed and the display is reset. The
displayshould onlybe resetby anauthorized technician.
Refer to the Illustrated parts section for information
regardingtools required to resetthe Smart ViewDisplay.
Display showing Maintenance
and Wrench icons

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 8
Fault Code Description Corrective action
01004 Discharged battery or defective wiring. Charge the battery. If the battery is
good, check wiring to the controller.
(note 2)
01005 Speed control overheated. Allow the controller to cool off. May be
the result of an overloaded vehicle or an
obstruction to the controller heat sink.
01008 Optional speed encoder defective or speed
encoder wiring defective Repair as required
02000 Start up switches not operated in the correct
order or a defective switch. Reset switches and start again. (note 1)
02001 Defective wiring Refer to troubleshooting
04003 Start up switches not operated in the correct
order or a defective switch. Reset switches and start again. (note 1)
04004 Both the forward and reverse directions are
selected at the same time Check the forward/ switch and wiring for shorts.
04005 Start up switches not operated in the correct
order or a defective switch. Reset switches and start again. (note 1)
04006 Accelerator pedal depressed before the seat
interlock switch is closed Recycle start up switches and try again. Possible defective seat switch.
04007 -Defective wiring
04009 Discharged battery or defective wiring. Charge the battery. If the battery is
good, check wiring to the controller.
(note 2)
04010 Battery voltage too high Incorrect battery installed.
04011 Personality fault Reprogram or replace the controller
(note 3)
04012 Personality fault Reprogram or replace the controller
(note 3)
04013 Defective wiring or batteries Refer to troubleshooting
05000 Line contactor coil or wiring shorted Replace contactor or repair wiring
05006 MOSFET shorted Refer to troubleshooting
05008 Line contactor welded contacts or wiring
shorted Replace contactor or repair wiring
05009 MOSFET shorted Refer to troubleshooting
05046 Line contactor contacts open or defective
wiring Replace contactor or repair wiring. Could also be result of open circuit
breaker (refer to troubleshooting)
Smart View Display Fault Codes
Example of Fault Code 4003
displayed on the SVD
Note 1: The start up switches include the following and must be operated in the order listed:
F&R - OFF, Seat Interlock - ON, Key - ON, F&R - Direction (forward or reverse), Accelerator (FS-1) - ON.
Note 2: A Low Battery Fault occurs when the system voltage drops below a preset value. The fault will not reset until
the batteries are fully charged or the problem that caused the fault is repaired.
Note 3: A personality fault occurs when the parameters set in the controller logic is corrupted. This can occur if the