Taylor-Dunn B0-015-00 Manual

The Best Way
To Go
About Your
Business
®
Serial number Starting: 136914
MANUAL MB-150-02
Operation, Troubleshooting and
Replacement Parts Manual
Published: 11/26/2002
Revision: C
B0-015-00
MX-016-00
Models Inlcuded:
B0-015-00 (B 1-50) Load Master
MX-016-00 (MX 1600) Maintenance Expediter

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
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
Transaxle Service 8
Suspension 9
Battery Service 10
Tires and Wheels 11
Control System Troubleshooting 12
Wire diagram 13
Chargers 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 B0-015-00, MX-016-00
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

Introduction
About this manual.........................................2
Who Should Read This Manual....................2
Responsibilities ............................................3
How To Use This Manual ..............................4
Conventions ..............................................................4
How to Identify Your Vehicle ........................6
Taking Delivery of Your Vehicle ...................7
Contents

INTRODUCTION
Introduction Page-2
ABOUT THIS MANUAL
The purchase of this vehicle shows a belief in high quality products manufactured in the USA.
Taylor-Dunn®, a leading manufacturer of electric burden and personnel carriers since 1949, wants to be
sure this vehicle provides years of reliable service. Please continue to read this manual and enjoy this
high quality Taylor-Dunn®vehicle.
This manual is to serve as a guide for the service, repair, and operation of Taylor-Dunn®vehicles and is
not intended as a training guide. Taylor-Dunn®has made every effort to include as much information as
possible about the operation and maintenance of this vehicle.
Included in this manual are:
•Vehicle Description
•Safety Rules and Guidelines
•Operational Information
•Operator Responsibilities
•Owner Responsibilities
•Control Operation and Location Information
•Maintenance and Troubleshooting Information
•Standard Parts List
Beforeservicing,operating,trainingor performing maintenanceon this orany other Taylor-Dunn®vehicle,
read the appropriate Taylor-Dunn®manual.
Each Taylor-Dunn®manual references the applicable models and serial numbers on the front cover.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.

INTRODUCTION
Introduction Page-3
WHO SHOULD READ THIS MANUAL
This manual is intended for use by anyone who is going
to operate, own, perform maintenance on, service, or
order parts for this Taylor-Dunn®vehicle. Each person
shouldbefamiliarwiththeparts of this manual that apply
to their use of this vehicle.
RESPONSIBILITIES
Of the Owner...
The owner of this or any Taylor-Dunn®vehicle is responsible for the overall maintenance and repairs of
the vehicle, as well as the training of operators. Owners should keep a record of conducted training and
maintenance performed on the vehicle. (OSHA Regulation, 29 CFR 1910.178 Powered Industrial Truck
Operator Training).
Of the Operator...
The operator is responsible for the safe operation of the vehicle, preoperational and operational checks
on the vehicle, and the reporting of any problems to service and repair personnel.
Of the Service Personnel...
The service personnel are responsible for the service and maintenance of the vehicle. At no time
should a service person allow any untrained personnel to service or repair this or any Taylor-Dunn®
vehicle. For the purposes of training, a qualified service person may oversee the repairs or services
being made to a vehicle by an individual in training. At no time should an untrained individual be
allowed to service or repair a vehicle without supervision. This manual is not a training guide.
Of the Passengers ...
The passengers are responsible to remain fully seated, keeping their hands, arms, and legs inside the
vehicle at all times. Each passenger should be fully aware of the vehicle’s operation. All forms of
recklessness are to be avoided. Do not engage in horseplay.

INTRODUCTION
Introduction Page-4
HOW TO USE THIS MANUAL
This manual is organized into five main sections:
INTRODUCTION
This section describes how to use this service manual and how to identify your vehicle.
Safety Rules and Operating Instructions
This section outlines the safety and operational issues, location and operation of controls, and the
operational checks that are to be performed on this vehicle. It also includes various subjects that should
be included in the operator and service training program.
Maintenance Service and Repair
This section gives specific information on the servicing of the vehicle and a schedule for maintenance
checks.
Electrical and Charger Troubleshooting
Thissection identifiesthetroubleshooting proceduresfortesting theelectricalsystem andbatterycharger.
Illustrated Parts
This section provides an illustrated view of various assemblies. The illustrations are accompanied by
tables identifying the parts.

INTRODUCTION
Introduction Page-5
A shaded box with the word “Warning” on its left denotes a warning.
A warning alerts the reader of a hazard that may result in injury to
themself or others. Be sure to follow any instructions contained
within a warning and exercise extreme care while performing the
task.
or,
The symbol at the left and the bold text contained within a box
denotes a “Caution” and is used to inform the reader that property
damage may occur. Be sure to exercise special care and follow any
instructions contained with in a caution.
NOTE: Alerts the reader to additional information about a subject.
Conventions
Symbolsand/orwordsthat are used to definewarnings,cautions,instructions, or notes found throughout
this manual:

INTRODUCTION
Introduction Page-6
HOW TO IDENTIFY YOUR VEHICLE
This manual applies to vehicles with the same model and serial numbers listed on the front cover.
These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial
plants, nurseries, institutions, motels, mobile home parks, and resorts. They are not to be driven on
public highways.
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(PoweredIndustrial Trucks) andwithall applicable portionsof the AmericanNationalStandard
for Personnel and Burden Carriers (ANSI B56.8).
The locations of the model and serial numbers are illustrated below:
This vehicle is not designed to be driven on public roads or highways.
It is available in maximum designed speeds ranging from 7 to 15
mph. Do not exceed the maximum designed speed. Exceeding the
maximum designed speed may result in steering difficulty, motor
damage, and/or loss of control. Do not exceed locally imposed speed
limits. Do not tow at more than 5 mph.
MX 1600B 1-50
B 1-50 and MX
1600
B 1-50 and MX 1600

INTRODUCTION
Introduction Page-7
TAKING DELIVERYOF YOUR VEHICLE
Inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious
problems:
•Examine the contents of all packages and accessories that may have come in separate
packages with the vehicle.
•Make sure everything listed on the packing slip is there.
•Check that all wire connections, battery cables, and other electrical connections are secure.
•Check battery cells to be sure they are filled.
•Check the tire pressure, tightness of lug nuts, and for any signs of damage.
Check the operation of each of the following controls:
•Accelerator
•Brake
•Parking Brake
•Key-Switch
•Forward/Reverse Switch
•Reverse Beeper (if equipped)
•Front Headlight Switch
•Steering Wheel
•Horn
What To Do If a Problem is Found
If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading
and file a claim with the freight carrier. The claim must be filed within 48 hours of receiving the vehicle
and its accessories. Also, notify your Taylor-Dunn®dealer of the claim.
If there is a problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately
contact your local Taylor-Dunn®distributor and report the problem. The report must be made within 24
hours of receiving the vehicle and its accessories.
The only personnel authorized to repair, modify, or adjust any part of this or any Taylor-Dunn®vehicle is
a factory authorized service technician.
The only personnel authorized to repair, modify, or adjust any part
of this or any Taylor-Dunn®vehicle is a factory authorized service
technician. Repairs made by unauthorized personnel may result in
damage to the vehicles systems which could lead to an unsafe
condition resulting in severe bodily injury and/or property damage.
Unauthorized repairs may also void the vehicles warranty.

Model B 1-00

TABLE OF CONTENTS
StandardSpecifications ................................2
Safety Rules and Guidelines .........................3
Driver Training Program................................4
Driver Qualifications. ...............................................4
VehicleControls ............................................5
Key-Switch ...............................................................5
Forward-Off-Reverse Switch ................................... 5
Accelerator Pedal .................................................... 5
Steering ....................................................................5
Foot Brake Pedal .....................................................6
Park Brake ............................................................... 6
Horn Switch..............................................................6
Seat Interlock Switch ............................................... 6
Headlight Switch ...................................................... 7
Hour Meter (Optional) ..............................................7
Charger Interlock .....................................................7
Battery Status Indicator, Analog .............................. 7
Battery Status Indicator, Digital Bargraph ............... 8
Reverse or Motion Alarm (Optional) .......................8
Electrolyte Alarm (Optional) ....................................8
Directional Signals (Optional)..................................8
Hazard Light Switch (Optional) ...............................9
Accessory Switch (Optional) ...................................9
Auxiliary Switch (Optional) ......................................9
Vehicle Operational Guidelines.....................10
Driving ......................................................................10
Loading and Unloading............................................ 10
Parking .....................................................................10
Towing ......................................................................10
Charging your vehicle ...................................11
Signet Charger Operation, Model HB Series .........11
Signet Charger Operation, Model HBS series ........ 11
Lestronic II Charger Operation ................................12
New Battery Break in ............................................... 12
Charging Time..........................................................12
Storing and Returning to Service ................13
Storing your Vehicle.................................................13
Returning To Service ............................................... 13
Periodic Maintenance Checklist ...................14
Daily Visual inspection:............................................15
Maintenance Guidelines for
SevereDutyApplications........................15
Safety Rules and Operating
Instructions

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 2
STANDARD SPECIFICATIONS
ITEM MODEL VOLTAGE SPECIFICATION
Occupancy Driver and one passenger
Dimensions B 1-50 274.2L X 112.5W X 120.7H Centimeters
107.95L X 44.29 X 47.5H Inches
MX 1600 274.2L X 112.5W X 207.6H Centimeters
107.95L X 44.29 X 81.75H Inches
Turning Radius 279.4 Centimeters (110 inches)
Dry Weight B 1-50 376.5 kg (830 lbs)
Without Batteries MX 1600 469.9 kg (1036 lbs)
Min/Max Battery 166 kg to 212 kg (366 lbs to 468 lbs)
Weights
Maximum Load B 1-50 726 kg (1600 lbs)
MX 1600 454 kg (1000 lbs)
Electrical System 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 275 Amp
Transmission Helical Gear, Oil Bath, Direct Drive
Motor, DC Series Wound 36 volt 6 hp @1200 RPM for 5 minutes
2 hp @ 2800 RPM for 60 min
Maximum Recommended 19.3 kph (12 mph)
Speed
Brakes Rear Wheel Mechanical Drum, Foot Operated Park Brake
Steering Automotive Steering 24:1
Tires 5.70 X 8 Load Range B, Tire Pressure 60 psi max
Frame B 1-50 Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Diamond Plate
MX 1600 Steel Unitized Body, Heavy Duty 16 Gauge Steel,
Tool Box, Ladder Rack, Vise, Work Bench,
Gas Weld Tank Compartment
Instrumentation Battery Status Indicator, Key Switch, Horn Button,
Forward/Reverse Switch, Brake Light
Light Accessories B 1-50 12 Volt Brake Light
MX 1600 12 Volt Headlight, Tail/Brake Light
Charger 36 Volt 110 Volt 12 Amp AC, 25 Amp DC, Built-In, Automatic with
Control system Interlock Relay

Safety Rules
Page 3
SAFETY RULES AND OPERATING INSTRUCTIONS
SAFETY RULES AND GUIDELINES
It is the responsibility of the owner of this vehicle to assure that the operator understands the various
controls and operating characteristics of this vehicle. As well as, obeying the following safety rules and
guidelines (extracted from the American National Standards Institute Personnel and Burden Carriers
ANSI B56.8).
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.
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.
Before working
on a vehicle:
This vehicle is not designed to be driven on public roads or highways.
It is available in maximum designed speeds ranging from 7 to 15
mph. Do not exceed the maximum designed speed. Exceeding the
maximum designed speed may result in steering difficulty, motor
damage, and/or loss of control. Do not exceed locally imposed speed
limits. Do not tow at more than 5 mph.
•Do not drive this vehicle unless you are a qualified and trained operator.
•Keep all body parts (head, arms’, legs’) inside the vehicle while it is moving.
•Drive slowly when making a turn especially if the ground is wet, slippery or when driving on an
incline.
•This vehicle may overturn easily if turned sharply, driven at high speeds, or when on an incline.
•Drive only on level surfaces or on surfaces having an incline of no more than 10% (5.6 degrees).
•Do not drive over loose objects, holes, or bumps.
•Observe all traffic regulations and speed limits (see speed warning above).
•Keep to the right under normal conditions.
•Maintain a safe distance from all objects.
•Keep the vehicle under control at all times.
•Yield right of way to pedestrians, ambulances, fire trucks, or other vehicles in emergencies.
•Do not overtake another vehicle at intersections, blind spots, or other dangerous locations.
•Keep a clear view ahead at all times.
Read and follow all of the guidlines listed below. Failure to follow
these guidelines may result in severe bodily injury and/or property
damage.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 4
DRIVER TRAINING PROGRAM
As per ANSI B56.8, the owner of this vehicle shall 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 normally associated with your particular
environment.
•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 safely operate this
vehicle as specified in the American National Standards Institute 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
Page 5
SAFETY RULES AND OPERATING INSTRUCTIONS
VEHICLE CONTROLS
Key-Switch
A key-switch, located on the right 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 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-Off-Reverse Switch
The forward-Off-reverse switch, located on the right side of the instrument
panel, 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 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
thespeedofthe vehicle and operates similar to the acceleratorpedalinan
automobile. Depress the pedal to increase speed and release the pedal to
decrease speed.
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.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules
Page 6
Foot Brake Pedal
The foot brake pedal, is located to the right of the steering column, it is for
operation with the right foot only. It works 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.
Park Brake
The parking brake is actuated with a hand lever, which is located between
the driver and passenger seats. 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.
Horn Switch
The horn switch is located to the left of the steering column. Depress the
switch with your left foot to sound the horn, release it to turn it off.
Seat Interlock Switch
A switch located under the driver's seat disables the power to the vehicle
when the driver leaves the seat. The driver must be seated for the vehicle
to operate.
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.
The seat interlock switch is only one part of the vehicle safety system.
The interlock switch should not be relied upon as the only safety
feature used to disable or disengage this vehicle. Doing so could result
in unexpected movement of the vehicle causing severe bodily injury
and/or property damage.