Taylor-Dunn B0-011-00 Manual

The Best Way
To Go
About Your
Business
®
Serial number Starting: 142833
MANUAL MB-100-00
Operation, Troubleshooting and
Replacement Parts Manual
Published: 12/15/2003
Revision: E
B 1-00
B 1-25
Models Inlcuded:
B0-011-00 (B 1-00) Tour Master
B0-011-25 (B 1-25) Carry Master

Taylor-Dunn Contact information
Service, Parts, Sales:
Taylor-Dunn has a network of dealers distributed around the globe to support our
vehicles. Information regarding vehicle sales, replacement parts, or service should be
obtained through your local dealer. A dealer locator can be found on the Taylor-Dunn
website at www.taylor-dunn.com.
If you do not have access to the internet, you can call the factory direct at:
01 [phone]
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804

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

Section Index
Introduction 1
Safety Rules and Operating Instructions 2
Lubrication 3
Brakes Service 4
Steering/Front Axle 5
Transaxle Service 6
Motor Service 7
Battery Service 8
Control System Troubleshooting 9
Wire diagram 10
Chargers
Illustrated Parts 11
Appendix A
Special Tools 12
Appendix B
Suggested Torque Values 13
Appendix C
Brake Lining Handling Precautions 14
Taylor-Dunn®
Model B0-011-00 and B0-011-25
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.

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
B 1-00 shown with optional
luggage rack

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
maintenanceonthis oranyother Taylor-Dunn®vehicle,
read the appropriate Taylor-Dunn®manual.
Each Taylor-Dunn®manual references the applicable
models and serial numbers on the front cover.
Please, be aware of all cautions, warnings,
instructions, and notes contained in this manual.
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...
Theservicepersonnelare responsiblefor theservice
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
Thissectiondescribeshowto use this service manual
and how to identify your vehicle.
Safety Rules and Operating Instructions
Thissectionoutlines the safety andoperationalissues,
locationandoperation of controls, andtheoperational
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
Thissectiongives specific information ontheservicing
ofthe vehicle anda scheduleformaintenance checks.
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. The location
of the data plate will be in one of two locations:
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 12 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.
B 1-25
B 1-00

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
Ifthereisa problem or damage as aresultof 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.Thereportmust be made within 24 hours
of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or
adjust any part of this or any Taylor-Dunn®vehicle is
a factory authorized service technician.
Model B 2-10 Ambulance

TABLE OF CONTENTS
Safety Rules and
Operating Instructions
Standard* Specifications ....................2
Safety Rules and Guidelines ..............3
DriverTraining Program.....................3
Driver Qualifications. .......................................... 3
VehicleControls ................................4
Key-Switch ........................................................... 4
Forward-Reverse Switch ..................................... 4
Accelerator Pedal ................................................. 4
Seat Interlock Switch ........................................... 4
Steering ................................................................. 5
Foot Brake Pedal .................................................. 5
Park Brake ............................................................ 5
Horn Button .......................................................... 5
Charger Interlock ................................................. 5
Headlights and Accessories (optional) ............... 6
Hour Meter (2) (optional) .................................... 6
Battery Status Indicator (1) (optional) ................ 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
Signet Charger Operation, Model HB Series ..... 9
Signet Charger Operation, Model HBS series ... 9
Lestronic II Charger Operation ........................... 10
New Battery Break in .......................................... 10
Charging Time ...................................................... 10
Storing / Returning to Service............10
Storing Your Vehicle ............................................ 10
Returning to Service ............................................ 10
Periodic Maintenance Checklist .........11
Daily Visual inspection: ...................................... 12
Maintenance Guidelines for
SevereDutyApplications ...............12

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 2
STANDARD* SPECIFICATIONS
ITEM MODEL SPECIFICATION
Occupancy B 1-00 Driver + 3-passengers
B 1-25 Driver + 1-passenger
Dimensions 241L x 112W centimeters (94.875L x 44.25W inches)
Turning Radius 335 Centimeters (132 Inches)
Dry Weight (no batteries) B 1-00 336 kg (741 lbs)
B 1-25 334 kg (737 lbs)
Min/Max Battery 174 kg to 195 kg (384 lbs to 432 lbs)
Weights
Maximum Load 363 kg (800 lbs)
Deck dimensions B 1-00 (none)
B 1-25 110.5W x 121.9L Centimeters 43.5W x 48L Inches)
Electrical System Six 217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 275 Amp
Transmission Helical Gear, Oil Bath, Automotive Type Hypoid
Differential.
Motor, DC 4.47 kW, (6 Horse Power) intermittant duty
Brakes Rear Wheel Mechanical Drum , Hand Operated Park Brake
Steering Automotive Steering 24:1
Tires 5.70 x 8 Load Range B
Frame Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Diamond Plate
Instrumentation Key Switch, Horn Button, Forward/Reverse Switch
Light Accessories Brake Lights
Charger Built In 1kW, dual voltage (110 - 220 vac) 15-Amp
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).
* - Specifications are subject to change without notice

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 3
SAFETY RULES AND
GUIDELINES
Itis the responsibilityof the ownerofthis vehicletoassure
that the operator understands the various controls and
operating characteristics of this vehicle (extracted from
theAmerican National StandardsInstitute 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
surfacesinand around facilities such asindustrialplants,
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.
This vehicle is not designed to be driven
on public roads or highways. It is available
in maximum designed speed of 12 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 ANSIB56.8, 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 yourparticularenvironment.
•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,andmental ability to safely operatethisvehicle
asspecified inthe AmericanNational StandardsInstitute
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
VEHICLE CONTROLS
Key-Switch
Akey-switch, located atthefront oftheinstrument panel,
turns on the vehicle. Rotate the key clockwise to turn
the vehicle on, counterclockwise to turn the vehicle off.
The key-switch should be in the “off” position whenever
the operator leaves the driver's seat.
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.
Forward-Reverse Switch
The forward-reverse switch, located on the instrument
panel, determines the direction of travel of the vehicle.
Push the top of the switch to make the vehicle travel
forward. Push the bottom of the switch to travel in
reverse.
DO NOT SHIFT from forward to reverse or vice-versa
while the vehicle is in motion. Make sure the vehicle is
completely stopped before shifting.
The forward-reverse switch should be in the center “off”
position, with key-switch off and the park brake set
whenever the operator leaves the driver's seat.
Accelerator Pedal
The accelerator pedal is located to the right of the brake
pedal. It controls the speed of the vehicle and operates
thesameway as theacceleratorpedal in anautomobile.
Depress the pedal to increase speed and release the
pedal to decrease speed.
Seat Interlock Switch
A switch located under the driver's seat disables the vehicle when the driver leaves the seat. The driver must be
seated for the vehicle to operate.
The switch is a part of the vehicle safety system. It should not be relied upon as the sole safety feature used to
disable or disengage this vehicle.
Whenever the driver leaves the seat, they should turn the key-switch off, place the forward-reverse switch in the
center off position, and set the park brake.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 5
Set park brake
Steering
Thesteering wheeland steeringsystemis anautomotive
type.To turn right, turn the steering wheel clockwise. To
turn left, turn the steering wheel counter clockwise.
Foot Brake Pedal
The foot brake pedal, located to the right of the steering
column, is for operation with the right foot only. It works
the same as 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.
Park Brake
The parking brake is part of the foot brake pedal.
To set the parking brake, push down on the lower half of
thebrakepedal untilthepedal locksin thedownposition.
To release the park brake, apply pressure on the upper
half of the brake pedal until the pedal disengages from
the lock position.
Horn Button
The horn button is located on the floor to the left of the
steering column. Depress the button to sound the horn,
release it to turn it off.
Charger Interlock
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 the interlock built into the
charger.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 6
Headlights and Accessories (optional)
The headlight switch is located to the rear of the instrument panel,
between the seats. An accessory switch, if any, is adjacent and to the
left of the light switch.
Head light switch location
Accessory switch location
Hour Meter (2) (optional)
Thehourmeterislocated below the battery status indicator. This
tracks the number of hours the vehicle has been in operation.
Battery Status Indicator (1) (optional)
The battery status indicator is located above the hour meter.
The normal operating range is in the green zone. The vehicle
needs charging if it is in the yellow zone. If it is in the red zone,
the vehicle should be taken out of service immediately to be
charged.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 7
VEHICLE OPERATIONAL
GUIDELINES
Safety Guidelines
•Only qualified and trained operators may drive this
vehicle.
•Drive only on level surfaces or on surfaces having
an incline of no more than 10% (5.6 degrees).
•Drive slowly when making a turn, especially if the
ground is wet or when driving on an incline.
•This vehicle may overturn easily if turned sharply or
when driven at high speeds.
•Observe all traffic regulations and speed limits.
•Keep all body parts (head, arms, legs) inside this
vehicle while it is moving.
•Keep the vehicle under control at all times.
•Yield right of way to pedestrians, ambulances, fire
trucks, or other vehicles in emergencies.
•Donot overtakeanothervehicle atintersections, blind
spots, or other dangerous locations.
•Do not drive over loose objects, holes, or bumps.
•Yield right of way to pedestrians and emergencies
vehicles.
•Stay in your driving lane under normal conditions,
maintaining a safe distance from all objects.
•Keep a clear view ahead at all times.
Starting:
Perform all necessary vehicle preparation steps,
inspections, or maintenance before operating this
vehicle.
1. Make sure the forward-off-reverse witch is in the
center “OFF” position.
2. Set the parking brake.
3. Hold down the foot brake.
4. Rotate the ON-OFF switch to the “ON” position.
5. Release the parking brake.
6. Release the foot brake.
7. Slowly depress the accelerator pedal.
While driving:
•Slow down and sound the horn to warn pedestrians
or when approaching a corner or other intersection.
•No reckless driving.
•Do not drive this vehicle on steep inclines or where
prohibited.
•Immediatelyreport anyaccidents orvehicle problems
to a supervisor.
Loading and Unloading
•Do not carry more than the maximum number of
passengers allowed for this vehicle.
•Do not exceed the cargo load capacity.
•Do not load cargo that can fall off.
•Be careful when handling cargo that is longer, wider,
orhigher than thisvehicle,be suretoproperly secure
all loads.
Towing Loads:
•Do not exceed the towing capacity of the tractor.
•Do not exceed the load capacity of the trailer. Refer
to documentation supplied with your trailer for
information regarding load capacity of the trailer.
•Make sure all loads are securely tied down. Refer to
documentation supplied with your trailer for
information regarding attaching loads to the trailer.
•Do not back up when towing more than one trailer.
•Drive slowly when towing loads with a high center of
gravity.
•When turning, be sure to allow for “corner cutting” of
the trailer.
•Allow for longer stopping distances when towing
heavy loads.
•Allow for longer stopping distances when driving
down a grade.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 8
Parking
Before leaving the vehicle:
•Set the parking brake.
•Set the forward-off-reverse switch to the `“OFF”
position.
•Rotate the start switch to the “OFF” position.
In addition:
•If parking this vehicle on an incline, turn the wheels
to the curb, or block the wheels.
•Do not block fire aisles, emergency equipment,
stairways, or exits.
Towing This Vehicle
Totowthisvehicle, attach a tow strap tothefront bumper
tow-bar.
NOTE: If the vehicle is equipped with an automatic
electric brake, do not tow the vehicle with
the drive wheels on the ground.
Use another driver to steer this vehicle while it is being
towed. Be sure the driver uses the brakes when the
towing vehicle slows or stops. Do not tow the vehicle
faster than 5 m.p.h. or its maximum designed speed,
whichever is lower.
Ifat allpossible,this vehicleshould be placedon acarrier,
rather than towing.
This vehicle is equipped with regenerative
braking. Follow these steps before towing
this vehicle.
1. To tow this vehicle the start switch must
be in the “OFF” position.
2. Place the forward/reverse switch in the
center “OFF” position.
Failure to follow these instructions may
result in damage to the vehicle.
The park brake should be disabled for
servicing or towing procedures only. Do not
operate the vehicle while the automatic
park brake is disabled. Operating the
vehicle with the automatic park brake
disabled could lead to severe bodily injury
and/or property damage.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 9
Explosive mixtures of Hydrogen gas are
present within battery cells at all times. Do
not work with or charge battery in an area
where open flames (including gas furnace
or water heater pilots), sparks, cigarettes,
or any other sources of combustion are
present. Always provide ample ventilation
in rooms where batteries are being charged.
Failure to do so may result in severe bodily
injury and/or property damage.
CHARGING YOUR VEHICLE
Battery electrolyte is poisonous and
dangerous. It contains sulfuric acid. Avoid
contact with skin eyes or clothing. Wear
rubber gloves and safety glasses while
servicing batteries. DO NOT INGEST! This
may result in severe bodily injury.
Signet Charger Operation, Model HB Series
The Signet®HB series
chargers use a semi-
automatic charging system.
The charger will turn itself
ONwhen theACpowercord
is connected to the AC
power source and turn itself
OFF when the batteries are
fully charged. Refer to the data plate on the charger for
the voltage and type power required for the charger.
Thereisa series of LED’sonthe faceplate of thecharger
that serve two functions:
1. Status of charge. The LED’s will display an
approximate percentof chargeduringthe charging
cycle. Refer to the table below.
2. Error condition. All three
LED’s flashing is an
indication of a charging
problem (charger will also
be beeping). Refer to the
Charger Troubleshooting
section for information on
error codes.
Charging State LED1 LED2 LED3
0 to 50% Blinking OFF OFF
50% to 75% ON Blinking OFF
75% to 100% ON ON Blinking
Cycle complete ON ON ON
Typical Signet®Built In
Signet Charger Operation, Model HBS series
The Signet®HBS series
chargers are fully automatic.
The charger will turn itself ON
when the AC power cord is
connected to the AC power
source and turn itself OFF
when the batteries are fully
charged. Once the charge
cycleiscomplete, the charger
will continue to monitor the
batteries.If thebatteryvoltage
drops during storage, the charger will start a new cycle
to keep the batteries fully charged.
NOTE:Ifthechargerrestartsduringashort timeperiod
of storage, then it would be an indication of
faulty batteries.
Refertothe data plateon the charger forthe voltage and
type power required for the charger.
Thereisa series of LED’sonthe faceplate of thecharger
that serve two functions:
1. Status of charge. The STATUS LED’s will display
an approximate percent of charge during the
charging cycle. Refer to the table below.
2. Error condition. The FAULT LED flashing is an
indicationof acharging problem(charger mayalso
be beeping). Refer to the Charger
Troubleshooting section for information on error
codes.
Typical Signet®HBS
The key switch must be in the “OFF” position
when charging the batteries. Failure to turn
the key switch “OFF” may result in damage to
the vehicles electrical system.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 10
STORING / RETURNING TO
SERVICE
Bothstoringyourvehicleandreturningitto serviceshould
only be performed by authorized personnel.
Storing Your Vehicle
•Cleanthebatteries,thenfill andchargebeforeputting
the vehicle in storage. Do not store batteries in a
discharged condition.
•Lube all grease fittings.
•Clean, dry, and check all exposed electrical
connections.
•Inflate tires to proper pressure (if applicable).
•Forextended storage, thevehicleshould beelevated
so that the tires do not touch the ground.
If stored for a prolonged period, the batteries should be
charged as follows:
Returning to
Service
•Check the
battery’s state
of charge and
charge if
required.
•Perform ALL
maintenance checks in the periodic checklist.
•Removeanyblocks from thevehicle and/or placethe
vehicle down on to the ground.
•Test drive before putting into normal service.
Storage
Temperature
(F)
Charging Interval
(months)
Over 60 1
Between 40 and 60 2
Below 40 6
To obtain the maximum battery life:
Charge the batteries only after they reach a normal
discharge as indicated on the Battery Status Indicator
(BSI). Failure to follow this guideline could result in the
batteries entering an overcharge state, which will reduce
the life of the batteries. If you find it necessary to charge
the batteries before they are completely discharged we
recommendwaiting untilthey aredischarged aminimum
of25%to reduce thepossibilityof overcharging. Referto
VehicleControlsinthissection for information on how to
read the BSI.
Donot dischargethebatteriesbeyondanormaldischarge
as indicated on the BSI. Refer to Vehicle Controls in this
section for information on how to read the BSI.
Checkthe batteryelectrolyteonce aweek. Donotcharge
the batteries if the battery electrolyte is low. Charging
whentheelectrolyte is low will damagethebatteriesand
shortentheirlife-span.Only authorized personnel should
perform battery maintenance including maintaining the
batteryelectrolytelevel. Refer toSectionMaintenance,
Service and Repair for battery maintenance
information.
Do not interrupt the charging cycle. When the charger is
plugged in, allow it to turn off before disconnecting.
Interruptingthechargingcyclecouldleadtoovercharging
ordischarging thebatteries toodeep. Bothcircumstances
will shorten the life of the batteries.
New Battery Break in
Newbatteriesrequire a break inperiodof up to40-cycles.
The batteries will not have their full capacity during this
break in period and may require longer charging times.
Lestronic II Charger Operation
The Lestronic II®charger is a semi-automatic charging
system.ThechargerwillturnitselfONwhen theACpower
cord is connected to the AC power source and turn itself
OFF when the batteries are fully charged. Refer to the
data plate on the charger for the voltage and type power
required for the charger. When plugged in, the charger
assumes that the batteries require charging and will
charger for a minimum of approximately 4-hours. This
charger should not be plugged in until the batteries are
discharged beyond 50% or the batteries may be
overcharged..
Charging Time
Averagechargingtimeis8to10-hours.Thetimerequired
to fully charge your batteries will vary depending on:
•Capacity of the batteries, higher capacity requires
longer charge time.
•Output of the charger, higher output requires less
charge time.
•Depth of discharge, the deeper a battery is
discharged, the longer it takes to charge.
•Temperature,lowtemperaturesrequirelongercharge
time.
It is not unusual for charge times to exceed 15-hours,
especially with new batteries.
Charging time is limited to 20-hours (HBS) or 18-hours
(HB). A fault will occur if the charging time exceeds the
20-hour limit.