Taylor-Dunn B0-050-00 Manual

The Best Way
To Go
About Your
Business
®
Serial number Starting: 157300
MANUAL MB-050-00
Operation, Troubleshooting and
Replacement Parts Manual
Models Included:
B0-050-00 (B 50) Shuttle Master
Published: 12/16/2003
Revision: C

Taylor-DunnContactinformation
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(714)956-4040
Feedback regarding this or any Taylor-Dunn vehicle manual can be sent to:
Taylor-Dunn Manufacturing
Attn:TechWriter
2114 West Ball Road
Anaheim,CA92804

B2-48 With Stake Side Dump Bed Option
SC1-59 Stock Chaser
E4-55 Sit Down Tow Tractor
C4-25 Sit Down 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
Tires and Wheels 9
Battery Service 10
Control System Troubleshooting 11
Chargers 12
Wire diagram 13
Illustrated Parts 14
Appendix A
Special Tools 15
Appendix B
Suggested Torque Values 16
Appendix C
Brake Lining Handling Precautions 17
Taylor-Dunn®
Model B0-050-00
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

TABLE OF CONTENTS
Introduction
About this manual .........................................2
Who Should Read This Manual ....................3
Responsibilities.............................................3
How To Use This Manual ..............................4
Conventions .............................................................5
How to Identify Your Vehicle.........................6
Taking Delivery of Your Vehicle ....................7
Add fill page...................................................8

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,training orperforming maintenanceon thisor anyother 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
shouldbefamiliar with theparts of thismanualthat 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 identifiesthe troubleshootingprocedures fortesting theelectrical systemand batterycharger.
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
themselves 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/orwords thatareused todefine warnings, cautions,instructions, or notesfound 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(PoweredIndustrialTrucks)and withall applicableportions oftheAmericanNationalStandard
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 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 at
more than 5 mph.

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.

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

TABLE OF CONTENTS
Standard Specifications Personnel Carrier ..2
Safety Rules and Guidelines .........................3
Driver Training Program................................4
Driver Qualifications. ...............................................4
VehicleControls ............................................5
Key-Switch ...............................................................5
Forward-Off-Reverse Switch ...................................5
Horn Switch.............................................................. 5
Headlight Switch ......................................................6
Strobe Light Switch (Optional)................................. 6
Battery Status Indicator, Analog (Optional).............6
Battery Status Indicator,
Digital Bargraph (optional) ..............................6
Hour Meter (optional)...............................................7
Steering ....................................................................7
Foot Brake Pedal .....................................................8
Electrolyte Alarm (Optional) ....................................8
Directional Signals (Optional).................................. 9
Hazard Light Switch (Optional) ...............................9
Accelerator Pedal .................................................... 9
Reverse or Motion Alarm (Optional) .......................9
Park Brake ...............................................................9
Seat Interlock Switch ...............................................10
Vehicle Operational Guidelines.....................11
Safety Guidelines .....................................................11
Starting: ....................................................................11
While driving: ...........................................................12
Loading and Unloading............................................ 12
Parking .....................................................................12
Towing ......................................................................12
Charging your vehicle ...................................13
Signet Charger Operation, Model HB Series .........13
Signet Charger Operation, Model HBS series ........14
Lestronic II Charger Operation ................................14
New Battery Break in ...............................................14
Charging Time..........................................................14
Storing / Returning to Service .....................15
Storing Your Vehicle.................................................15
Returning to Service ................................................15
Periodic Maintenance Checklist ...................16
Safety Rules and Operating
Instructions

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 2
STANDARD SPECIFICATIONS PERSONNEL CARRIER
ITEM VOLTAGE SPECIFICATION
Occupancy 2-Passenger
Dimensions 199L X 112W X 120.6H Centimeters
78.5L X 44.25 X 47.5H Inches
Turning Radius 366 Centimeters (144 inches)
Dry Weight 322 kg (710 lbs)
Without Batteries
Min/Max Battery 174 kg to 212 kg (384 lbs to 468 lbs)
Weights
Maximum Load 227 kg (500 lbs)
Electrical System 36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid Batteries,
Solid State Speed Control, 275 Amp
Transmission Direct Drive, Oil Bath
Motor, DC 36 Volt 1.5kW, (2 hp) @ 2400 RPM for 60 min
Series Wound Field
Brakes Rear Wheel Mechanical Drum, Hand Operated Park Brake
Steering Automotive Steering
Tires 5.70 X 8 Load Range B, Tire Pressure 60 psi max
Frame Steel Unitized Body, Heavy Duty 14 Gauge Steel
Instrumentation Key Switch, Horn Button, Forward/Reverse Switch
Light Accessories Single Brake Light
Charger 36 Volt 25 Amp, Portable, Automatic
This vehicle conforms to requirements for Type E vehicles as described in O.S.H.A. Standard Section
1910.178(PoweredIndustrialTrucks)and withall applicableportions oftheAmericanNationalStandard
for Personnel and Burden Carriers (ANSI B56.8).

Safety Rules Page 3
SAFETY RULES AND OPERATING INSTRUCTIONS
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 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.
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 (extracted from the American National Standards
Institute Personnel and 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 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.
•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 or slippery.
•Drive slowly when driving on an incline.
•This vehicle may overturn easily if turned sharply while driven at high speeds, or 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
According to 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
tohaveprevious vehicleoperation experience. Successfulcompletion oftheOperator Trainingprogram
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 to the front of the consol between the seats, 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.
Forward-Off-Reverse Switch
The forward-off-reverse switch, located behind the key-switch on the
console between the seats, 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.
DONOTSWITCH fromforwardtoreverse orvice-versawhilethe vehicle
isin motion.Make surethe vehicleis completelystopped beforeshifting.
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.
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.

SAFETY RULES AND OPERATING INSTRUCTIONS
Safety Rules Page 6
Battery Status Indicator, Analog (Optional)
The battery status indicator is located to the left of the hour meter. The
normaloperatingrange is inthe green zone. Parkthe vehicle fora few
minutes for an accurate reading. The vehicle needs charging if it is in
theyellowzone. Duringandimmediately followingcharging, the needle
will be in the red zone to the right. The needle will move through the
green zone toward the yellow zone as the batteries discharge. Charge
the batteries when the needle is in the yellow zone. If it is in the red
zone to the left, the batteries are empty and the truck should be taken
out of service and charged to avoid damaging the batteries.
Headlight Switch
The headlight switch is located behind and to the right of the forward-
off-reverse switch on the center console between the seats. Push the
right side of the switch to turn the lights on. Push the left side of the
switch to turn the light off.
Strobe Light Switch (Optional)
Thestrobelight switch islocated behind theforward-off-reverseswitch
on the center console between the seats. Toggle the switch forward to
turn on the strobe light. Toggle the switch backward to turn off the
accessory.