Model SC-100 Sevcon DC System: Operator's Manual

Operator’s Manual
Model SC-100 Sevcon DC System
The best way to go about your business
Serial Number Range: Use with Model Numbers:

Starting: 191320 SC-100-24 (SC 1-00), 24-volt system
Ending: See introduction chapter SC-100-36 (SC 1-00), 36-volt system
SC-100-48 (SC 1-00), 48-volt system
WARNING
READ AND UNDERSTAND THIS MANUAL BEFORE
OPERATION OR PERFORMING MAINTENANCE.
This manual contains important information regarding
the safe operation and maintenance of this vehicle. This
manual should be kept with the vehicle.
J MA-100-02
My Vehicle information
Serial Number: .
Date Purchased: .
Date Delivered: .
Dealer Purchased From: .
Salesman Name: .
Your satisfaction is our #1 goal. If you have questions or

concerns with your vehicle, please contact your Sales
Representative or Service Advisor at your local dealership.
Taylor-Dunn has a worldwide dealer and distribution network
to provide replacement parts and service for our vehicles.
Refer to our web site, www.taylor-dunn.com, for a dealer
lookup application.
Originally Published 5/8/2013

Revision J, 8/9/2018, contents subject to change without notice
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com

MA-100-02
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 (714) 956-4040
Feedback regarding this or any Taylor-Dunn manual can be sent to:
Taylor-Dunn Manufacturing
Attn: Tech Writer
2114 West Ball Road
Anaheim, CA 92804
Model SC-100 Sevcon DC System Operator Manual Page 3

MA-100-02
The Taylor-Dunn Corporation:

Leading Provider of Commercial & Industrial Vehicles since 1949
Taylor-Dunn Manufacturing:
From the day we shipped our first vehicle in 1949, we have pursued a singular goal: to build tough,
rugged, dependable vehicles to help our customers move personnel, equipment, and materials. It’s
that simple. For over sixty years, our standard and custom vehicles - Burden Carriers, Personnel
Carriers, Stock Chasers, Electric Carts, Tow Tractors & more - have been the leading solution for
customers in a broad range of industrial, commercial, and ground-support markets.
Decades of experience are an invaluable asset, and it is an asset we cherish and protect. Our guiding
principle is to provide application-specific solutions, which are reliable, efficient, and economical.
Our domestic and international network of quality Taylor-Dunn Dealers and Parts & Service Support
keeps our customers moving.
Tiger Tractor:
Tiger manufacturing has become a leading manufacturer of internal combustion engine industrial
tractors and ground support equipment. With tractor capacities ranging from 3,000 - 12,000 pounds
drawbar pull, they are ideal for industrial applications as well as aircraft ground support. As with all
Taylor-Dunn vehicles; quality, service, support and reliability are built into all Tiger Tractor products.
Shown below is just a small sample of what Taylor-Dunn has to offer to keep
your business moving:
Page 4 Model SC-100 Sevcon DC System Operator Manual

MA-100-02
Table of Contents
Contact Information.......................3 Vehicle Operation 23
General Safety Guidelines.................... 23
The Taylor-Dunn Corporation:.....4 Starting.................................................. 25
Driving................................................... 26
Introduction 7 Loading Cargo...................................... 28
Who Should Read This Manual............ 7 Transporting Pets.................................. 28
About This Manual................................ 7 Collisions or Accidents.......................... 28
Vehicle Load Capacity, Definition.......... 30
Glossary of Terms............................8
Towing..............................................30
Conventions.....................................10 Draw Bar Pull (DBP), Definition............ 31
Signal Words and Their Definitions:...... 10 Hitch Release........................................ 31
Safety Alert Message............................ 10 Towing the Vehicle................................ 32
Responsibilities................................11
Of the Owner......................................... 11 Charging Your Vehicle 33
Of the Operator..................................... 11
Of the Passengers ............................... 11 Generic Safety Guidelines..............33
Of the Service Personnel...................... 11 Charging Time....................................... 34
New Battery Break In............................ 34
Vehicle Modifications......................12 AC Power Source................................. 34
Replacement Parts..........................13 Signet Model HBS Charger................... 35
Using Non-OEM Replacement X-Series Charger.................................. 37
Components.......................................... 13 Lestronic II Charger.............................. 39
Lester Summit Charger......................... 40
About Your Vehicle 14
Storing and Returning to
Licensing Requirements....................... 14
Vehicle compliance............................... 14 Service 42
Storing Your Vehicle.............................. 42
How to Identify Your Vehicle.........15 Returning to Service............................. 42
Data Plate............................................. 15
Where to Find Data Plate and Serial
Number................................................. 15
Vehicle Maintenance 43
Daily Inspection..................................... 43
Taking Delivery of Your Pre-Operation Inspection...................... 43
Vehicle 16 Interlock Switch Inspection............44
Start Switch .......................................... 44
What To Do If a Problem is Turn Start switch OFF........................... 44
Found................................................16 Sit in the approved operator position,
select a direction, then slowly press the
Operator Training 17 throttle pedal......................................... 44
Operator Presence Switch.................... 44
Driver Qualifications.............................. 17 Charger Interlock Switch....................... 44
Maintenance Schedule......................... 45
Vehicle Controls 18 Maintenance Guidelines for Severe Duty
3: Direction Control Switch.................... 18 Applications........................................... 45
Operator Presence Switch.................... 19 Battery Maintenance.......................46
SmartView® Dash Display.................... 20 Cleaning................................................ 47
Fault Codes........................................... 21 Watering................................................ 47
Removable Batteries.......................48

MA-100-02
Roll Out Battery Box (ROBB) with battery

Dolly...................................................... 48
Lift Out Battery Box (LOBB) or Industrial
Battery................................................... 49
Tires..................................................50
Air pressure........................................... 50
Tire Tread Wear.................................... 50
Changing a Tire/Wheel assembly......... 51
Replacing a Tire.................................... 52
Cleaning...........................................53
Standard Specifications 54
Index 55

MA-100-02
Introduction
Who Should Read This Manual
This manual is intended for use by anyone operating or performing routine maintenance on this
vehicle. Each person should be familiar with the parts of this manual that apply to their use of this
vehicle.
About This Manual

This manual is valid only for the serial numbers listed on the front cover. If the ending serial number
is blank, then this manual was for current production vehicles when printed. If you did not receive
this manual with the vehicle, you should confirm this manual is valid for your serial number at the
Taylor-Dunn web site. A place to record your vehicle information is provided on the inside front cover
This manual is subject to change without notice. Updates are available through your dealer or the
Taylor-Dunn web site at www.taylor-dunn.com.
Taylor-Dunn is not to be held liable for errors in this manual or any consequential damage that
results from the use of 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 operation and maintenance of your Taylor-Dunn vehicle.
Taylor-Dunn has made every effort to include as much information as possible about the operation
and maintenance of this vehicle.
This manual contains information about the standard equipment and options available for this model.
This vehicle may not be equipped with all available options. If you do not know which information
applies to your vehicle, then you should contact your dealer.
Included in this manual are:
• Vehicle Description
• Safety Rules and Guidelines
• Operational Information
• Operator Responsibilities
• Owner Responsibilities
• Control Operation and Location Information
• Maintenance Information
Before operating or performing maintenance on this or any other Taylor-Dunn vehicle, read the
appropriate Taylor-Dunn manual.
Please, be aware of all cautions, warnings, instructions, and notes contained in this manual.
WARNING
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 vehicle’s systems which could lead
to an unsafe condition resulting in severe bodily injury and/
or property damage. Unauthorized repairs may also void the
vehicle’s warranty.

MA-100-02
GLOSSARY OF TERMS
There are a number of words and phrases used in this document that may have a different, special,
or specific definition when use in the context of this document.
Approved Operator The operator shall be seated in the operator seat with back up against
Position the operator seat back cushion. Additional back support may be added
Sit down vehicle as needed. The back support shall be fastened to the operator seat
back cushion to prevent it from falling off the vehicle or onto the seat
cushion. The operator’s left foot shall be on the floorboard. The right
foot should be positioned for easy access to the brake or throttle
pedals. Both hands should be on the steering wheel while the vehicle
is in motion.
Approved Operator The operator shall be standing on the operator platform with weight
Position about equally distributed between left and right feet. The left foot shall
Stand up vehicle be placed on the left side of the operator platform to properly engage
the operator presence switch. Both hands shall be on the steering
wheel while the vehicle is in motion.
BDI Battery Discharge Indicator. Same as BSI:
BSI Battery Status Indicator. The gauge on the dash showing the battery
charge level. Also can be referred to as BDI.
Caution (signal word) Refer to Signal Words and Their Definitions.
Danger (signal word) Refer to Signal Words and Their Definitions.
Direction Control Switch A switch typically located on the dash that is used to select the
direction of travel.
DBP Draw Bar Pull (see below).
Draw bar pull The force seen by the trailer hitch at the rear of the vehicle.
Electrolyte The fluid inside of a battery.

Fault A “fault” is something that happens when the motor speed control
system detects a problem with the vehicle. Some faults will prevent
operation of the vehicle.
FLA battery Flooded Lead Acid Battery. A battery that requires regular maintenance
of electrolyte level.
FS-1 Switch inside of the throttle module that starts the vehicle moving.
High/Low High speed, Low speed.
LOBB Lift Out Battery Box, a type of removable battery.
Moderate injury An injury treatable by first aid and/or follow up treatment by a doctor
or other professional medical personnel.
Notice (signal word) Refer to Signal Words and Their Definitions.
OPS “Operator Protective Structure”: Steel cab or cage around the
occupants.
Regen Short term for Regenerative Braking. “Regen” is the braking action
provided by the motor. Similar to downshifting in an automobile.
Energy created during regen is returned to the battery.
ROBB Roll Out Battery Box a type of removable battery.
Seating position: When used in the context of occupant seating positions, “seat” is
defined as a single seat cushion or a span of 20 inches on a bench
seat.

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Sequence Fault A type of fault that disables the vehicle. Occurs when the switches
require to operate the vehicle are not operated in the correct order.
Service Brake The primary braking system used to stop the vehicle.
Severe bodily injury An injury that requires immediate treatment by a doctor or other
professional medical personnel. Not first aid.
Signal word A word used to define hazards to operator, passengers, service
technician, or personnel in the immediate vicinity of the vehicle.
SLA battery Sealed Lead Acid Battery. A battery that does not require maintenance
of electrolyte level.
Small children Children that must be transported in a child seat as defined by federal
or state motor vehicle standards.
SRO Static Return to Off. A fault action that disables the vehicle.
Start Switch A switch typically located on the dash that enables the vehicle for
operation. This switch may, or may not require a key to operate.
Warning (signal word): Refer to Signal Words and Their Definitions.

MA-100-02
CONVENTIONS
Symbols and/or words used to define Dangers, Warnings, Cautions, and Notices are found
throughout this manual. The “Words” in this context will be referred to as “Signal words.” The words
defined here as “signal words” may be used elsewhere in the text of this document without being
a signal word. When used as a signal word, the signal word will be enclosed in a solid rectangle
with white background (example below).
Signal Words and Their Definitions:

DANGER: This signal word will be accompanied by the safety alert symbol (see below). “DANGER”
will indicate a hazard that, if not avoided, WILL result in death or serious bodily injury
to yourself, the operator or passengers of the vehicle, or people in the immediate area
of the vehicle.
WARNING: This signal word will be accompanied by the safety alert symbol (see below).
“WARNING” will indicate a hazard that, if not avoided, may result in death or serious
bodily injury to yourself, the operator or passengers of the vehicle, or people in the
immediate area of the vehicle.
CAUTION: This signal word will be accompanied by the safety alert symbol (see below). “CAUTION”
will indicate a hazard that, if not avoided, may result in minor or moderate injury to
yourself, the operator or passengers of the vehicle, or people in the immediate area
of the vehicle.
NOTICE: This signal word will not be accompanied by the safety alert symbol. “NOTICE” will
indicate a condition that if not avoided may result in property damage. “Property” is
defined and the vehicle, components in the vehicle and/or the surrounding area such
as buildings, other vehicles, etc.
Safety Alert Message
Important information notifying you of any WARNING
conditions that may result in hazards to yourself,
persons nearby, and/or hazards to the vehicle This is an example of a safety alert message.
will be presented in a text box with a black This message will contain information
border and may include a signal word (see about a hazard and/or instructions on
above). To the right is an example of a safety avoiding a hazard. The actual size, location,
message. and signal word used for the message box
The safety message may include additional may vary.
warning icons representing the type of hazard.
Below is a list of these icons and what they Decals applied to the vehicle may have other
represent. These icons may also be included icons representing their function. The icons and
on the various warning and information decals their definitions are listed below:
applied to the vehicle.
Read the operators manual.
Safety alert symbol (see above).
Read the maintenance manual.
High voltage hazard.

Keep arms and legs inside the vehicle.
Explosion hazard.
Parking brake ON.
Corrosive chemical hazard. Parking brake OFF.
Do not get wet.

Fire hazard.
Do not spray wash.

Poisonous chemical hazard.

MA-100-02
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.
The owner is responsible for operator training. Refer to Driver Training section for details.
The owner shall provide a copy of this manual if rented or loaned to another party and instruct
the other party to read and understand the contents of this manual.
The owner shall provide a copy of this manual when and if the vehicle is transferred to another
party.
Of the Operator...
All operators should complete an operator training course provided by the owner of the vehicle.
The operator is responsible for the proper use of the vehicle on authorized roads, highways,
and approved installations only.
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 WARNING
vehicle. At no time should a service
person allow any untrained personnel to The only personnel authorized to repair,
service or repair this or any Taylor-Dunn modify, or adjust any part of this or any Taylor-
vehicle. For the purposes of training, a Dunn vehicle is a factory authorized service
qualified service person may oversee technician. Repairs made by unauthorized
the repairs or services being made to personnel may result in damage to the vehicle’s
a vehicle by an individual in training. At systems which could lead to an unsafe condition
no time should an untrained individual resulting in severe bodily injury and/or property
be allowed to service or repair a vehicle
damage. Unauthorized repairs may also void the
without supervision. This manual is not
a training guide. vehicle’s warranty.
Personnel performing service and repair should have knowledge of:
• Basic standard automotive repair procedures
• Basic DC and AC electrical theory
• Use of digital and analog multi-meters
• Lead acid batteries
Personnel performing maintenance should have basic knowledge of standard automotive
maintenance procedures and lead acid batteries.

MA-100-02
VEHICLE MODIFICATIONS
Taylor-Dunn vehicles are designed and manufactured in accordance with ANSI/ITSDF and OSHA
regulations. Per ANSI/ITSDF and OHSA, modifications to the vehicle must be approved by the
manufacturer. Listed below are the specific regulations:
ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers

Paragraph 8.2q:
Modifications and additions which affect capacity and safe machine operation shall not be
performed by the customer or user without manufacture’s prior written authorization; where
authorized modifications have been made, the user shall ensure that capacity, operation,
warning, and maintenance instructions plates, tags, or decals are changed accordingly.
Paragraph 8.2r:
Care shall be taken to ensure that all replacement parts are interchangeable with the original
parts and of a quality at least equal to that provided in the original equipment.
ANSI/ITSDF 56.9 – 2007 Safety Standard for Operator Controlled Industrial

Tow Tractors
Paragraph 6.2.14:
Modifications and additions which affect capacity and safe tow tractor operation shall not be
performed without manufacture’s prior written approval. Capacity, operation, and maintenance
instructions plates, tags, or decals are changed accordingly.
Code of Federal Regulations (CFR) Title 29, Subtitle B, Chapter Xvii OSHA,
Part 1910.178 Powered Industrial Trucks (2011)
1910.178(a)(4)
Modifications and additions which affect capacity and safe operation shall not be performed
by the customer or user without manufacturers prior written approval. Capacity, operation,
and maintenance instruction plates, tags, or decals shall be changed accordingly.
1910.178(q)(6)
Industrial trucks shall not be altered so that the relative positions of the various parts are
different from what they were when originally received from the manufacturer, nor shall they
be altered either by the addition of extra parts not provided by the manufacturer or by the
elimination of any parts, except as provided in paragraph (q)(12) of this section. Additional
counterweighting of fork trucks shall not be done unless approved by the truck manufacturer.
Motor Speed Control Programming

Taylor-Dunn programmable motor speed controls are WARNING
programmed at the factory for optimum safe, efficient, and
smooth operation of the vehicle. The program settings Improper programming may
are based on many factors including but not limited to: cause unexpected operation of
Vehicle Model, Maximum Safe Speed, System Voltage, the vehicle and/or damage the
Drive Axle Configuration, Vehicle Configuration, etc. electrical components. This could
Some of the parameters can be changed in the field Using result in severe bodily injury and/
PC software or handsets. or property damage
Contact the factory for information regarding available
alternate program settings.
Taylor-Dunn will only authorize the use of settings obtained from the factory for a specific vehicle.
Any other alterations to the programming ARE NOT AUTHORIZED and is at your own risk.
DO NOT interchange program settings from different vehicle models or models with different
configurations.

MA-100-02
REPLACEMENT PARTS
WARNING
To maintain peak performance, always use original Taylor-Dunn replacement parts
intended for use on your vehicle. Taylor-Dunn components are designed and tested for use
on specific Taylor-Dunn model vehicles. Only use the correct Taylor-Dunn replacement
components for your Taylor-Dunn vehicle.
Do not modify your vehicle:
Modifications to this vehicle may have an undesirable effect on the operation of the
vehicle, result in additional frame stress, or stress other components resulting in
premature failure or an unsafe condition and may lead to an accident resulting in
serious injury or death.
Using Non-OEM Replacement Components

To maintain peak performance, always use original Taylor-Dunn replacement parts intended for
use on your vehicle.
Taylor-Dunn components are designed and tested for use on specific Taylor-Dunn model vehicles.
Only use the correct Taylor-Dunn replacement components for your Taylor-Dunn vehicle.
Electrical Components
Electrical components not tested by Taylor-Dunn (or intended for use on other Taylor-Dunn vehicles)
may have unanticipated interaction and/or interference with the vehicles control system resulting
in unsafe vehicle operation or damage to the electrical system.
Mechanical Components
Mechanical components not tested by Taylor-Dunn (or from other model Taylor-Dunn vehicles)
may have an undesirable affect on the operation of the vehicle, result in additional frame stress,
or stress other components resulting in premature failure or an unsafe condition.
Due to the unknown properties of non-Taylor-Dunn tested components or from components not
originally equipped on the vehicle, we cannot approve their use in a Taylor-Dunn vehicle.

MA-100-02
About Your Vehicle

The purchase of your Taylor-Dunn vehicle shows a belief in high quality products manufactured in
the USA. Your new vehicle operates entirely on electric battery power. It is an emissions free vehicle.
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.
Each base model is available in numerous configurations depending on what options were requested
when the vehicle was ordered.
WARNING
This vehicle does not provide protection from lightning, flying objects, or other storm
related hazards. If caught in a storm, immediately seek shelter in accordance with local
safety guidelines for your area. Not seeking shelter may result in severe personal injury.
Licensing Requirements
This vehicle IS NOT approved for licensed operation on public roads and highways. This model
conforms to:
• American National Standards Institute Controlled Personnel and Burden Carriers ANSI
B56.8.
• O.S.H.A. Standard Section 1910.178, Powered Industrial Trucks Type E
Vehicle compliance
This vehicle complies with one of the following designations: E, G, LP, or D. The vehicle identification
tag lists the specific compliance designation. Operate this vehicle only in environments consistent
with the compliance designation. Operation in other more hazardous environments can cause injury
or death. Vehicles complying with more stringent designations are labeled as to the
designation. Type EE compliance vehicles will have the EE1 label applied.
Burden carriers
This vehicle is designed for operation in various applications including both indoor2
and outdoor operation on paved, improved or groomed road surfaces. This vehicle should not be
operated in off road areas such as a rocky environment, soft sand, or dirt roads with ruts or uneven
road surfaces exceeding 4 inches.
1 Vehicles approved for EE operation will have a special “EE” decal applied.
2 Vehicles with internal combustion engines give off various fumes, gases, and soot while
running, including carbon monoxide. Do not start or run the engine in a closed or poorly
ventilated building where the exhaust gases can accumulate. Breathing these gases may
result severe personal injury or death. LP fuel is recommended when operating indoors but
does not negate the hazards listed above.
MA-100-02
HOW TO IDENTIFY YOUR VEHICLE

Data Plate
To identify the model series of your vehicle, refer to the vehicle data plate.
Where to Find Data Plate and Serial Number
ID tag under the deck board Data plate on front of the steering tower

MA-100-02
Taking Delivery of 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 along 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 and tightness of the lug nuts
• Check for any signs of damage.
NOTICE
New front wheel bearing adjustment must be inspected after the first 24 hours of
operation. This includes new vehicle installations. Failure to inspect the bearings after
the break in period may result in premature failure of the bearings.
Check the operation of each of the following controls:
• Accelerator/brake treadle • All lights
• Parking Brake • Steering Wheel
• Key Switch • Horn
• Direction Control Switch
• Reverse Warning Alarm (if equipped)
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 dealer of the claim.
If there is any problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE.
Immediately contact your dealer 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.
WARNING
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 vehicle’s systems which could lead
to an unsafe condition resulting in severe bodily injury and/
or property damage. Unauthorized repairs may also void the
vehicle’s warranty.

MA-100-02
Operator Training
Per the following regulations, the owner of this vehicle shall conduct an Operator Training program
for all those who will be operating this vehicle:
• ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers: Part II, Paragraph 6.2a.
• ANSI/ITSDF 56.9 – 2007 Safety Standard for Operator Controlled Industrial Tow Tractors:
Part II, paragraph 4.11.
• Code of Federal Regulations (CFR) Title 29, Subtitle B, Chapter Xvii OSHA, Part 1910.178
Powered Industrial Trucks (2011): 1910.178, Section (l).
• Per OSHA Regulation, 29 CFR 1910.178 Powered Industrial Truck Operator Training, the
owner must keep a record of conducted training and maintenance performed on the 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 the ability to handle this vehicle in all conditions.
www.taylor-dunn.com

MA-100-02
Vehicle Controls
1: Headlight Switch 4: Hi-Low Speed Switch

Push the top of the headlight switch to turn the Push on top of the High/Low switch (turtle) for
lights on. Push the bottom of the switch to turn slow speed. Push on the bottom of the switch
the lights off. (rabbit) for normal speed.
2: Strobe Light Switch 5: SmartView® Display
(Optional) Push the top of the switch to turn the The gauge on the dash has many functions.
strobe light on. Push the bottom of the switch More detail is provided later in this section.
to turn the light off.
3: Direction Control Switch 6: Start Switch
This switch determines the direction of travel. The Start switch turns the vehicle electrical
The switch has three positions: control system ON. This switch may or may
not require a key to operate. Rotate the switch
• FORWARD: Push the top of the switch all
clockwise to turn the vehicle system “ON” and
the way in to travel forward.
counterclockwise to turn the vehicle system
• REVERSE: Push the bottom of the switch “OFF”.
all the way in to travel reverse.
The switch should be in the “OFF” position
• OFF: There is a center position between
whenever the operator leaves the operator’s
forward and reverse, this is the “direction”
platform.
OFF position. The direction OFF position
does NOT turn the vehicle control system This switch is designed to secure and disable
OFF. Use the Start switch to turn the the vehicle. The key can only be removed when
vehicle control system OFF. Refer to Start the switch is in the “OFF” position.
Switch in this section for details regarding
turning the vehicle control system OFF.
Note: The OFF position IS NOT neutral and
does NOT disconnect the motor from
the drive train.

MA-100-02
Park Brake, Hand Operated Throttle/Brake Treadle

The parking brake is actuated with a hand lever, The treadle under the operator’s right foot
which is located on the left side of the steering controls the acceleration and braking of the
tower. To set the parking brake, depress the vehicle. Using the ball of your right foot, press
rear of the treadle and pull the lever up until it down on the front of the treadle to increase the
locks. To release the park brake, depress the speed of the vehicle. Using the heel of your
rear of the treadle and push the park brake right foot, press down on the rear of the treadle
handle down. to apply the brake.
Note: The front of the treadle will be very Releasing the treadle will return it to the off
difficult to depress when the park brake position.
is applied.
Operator Presence Switch
Horn Switch A switch located under the left floor plate
The horn switch is located on the right side of
disables the vehicle if the operator is not
the steering tower. Depress the switch to sound
positioned properly. The operators left foot must
the horn, release it to turn it off.
be positioned on the floor plate to operate the
vehicle.
Steering
The steering wheel and steering system are Power Cut Switch
similar to an automobile. To turn right, turn the Optional. Pushing on the Power Cut Switch knob
steering wheel clockwise. To turn left, turn the disconnects main power
steering wheel counter-clockwise. from the vehicle control
system and will stop the
vehicle from operation.
Pull up on the knob to
reconnect the power.
The Power Cut
CAUTION Switch should only
be activated in an Typical Switch
emergency such as
Unless in an emergency, do not activate vehicle not operating as expected or if odors
the Power Cut Switch while the vehicle is such as burning are detected coming from the
vehicle.
in motion. This vehicle may be equipped
with an automatic electric parking brake. Do not use the switch when only parking the
vehicle.
Activating the Power Cut Switch will
immediately apply the brake, abruptly If the vehicle is equipped with an optional
stopping the vehicle. This may result in automatic parking brake then the brake will
immediately be applied, abruptly stopping the
injury to the occupants and/or upsetting vehicle. Operating the switch while in motion
the load being carried or towed. will result in accelerated wear and premature
failure of the parking brake.
MA-100-02
SmartView® Dash Display
The Smart View Display (SVD) functions as a Battery Status Indicator (BSI), Hour Meter (HM),
speed controller status monitor, and as an optional maintenance monitor feature. The operation of
each of these functions is described below.
BSI
A bar graph representing the current state of charge is located across the top of the display.
When the batteries are fully charged, all segments of the 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 vehicle’s speed will be reduced. At this time, the vehicle
should be removed from service for charging. Discharging beyond 90% will result in damage to
the batteries that will shorten the battery life-span.
Note: The battery status gauge as well as any faults indicating low battery voltage will not reset
until the batteries have successfully completed a charging cycle.
Hour Meter
Depending on the revision level of the controller, there are one or two hour meter functions, Key
Hours and Run Time Hours (see note below).
Run Time Hours is the accumulated length of time that the vehicle has been in operation. Time
is accumulated when the FS-1 switch in the accelerator module is closed.
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.
System Fault Monitor

The display will indicate a fault 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 fault code
table in this section for a summery description of the fault codes.
Maintenance Monitor
Note: The Maintenance Monitor function is optional. The Maintenance Monitor function can be
turned ON or OFF by your dealer.

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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 is not performed before the warning
period elapses, then the vehicle’s maximum speed will be
significantly reduced.
Warning period: The warning 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 has expired and the maintenance is due, the Wrench icon
will stop flashing and remain ON. Additionally, the vehicle’s maximum speed will be significantly
reduced until the maintenance is performed and the display is reset. The display should only be
reset by an authorized technician. Refer to the Illustrated parts section for information regarding
tools required to reset the Smart View Display.
Fault Codes
Level 1 Faults
Code Description What to do
F01000 P/S Motor Overheated Stop the vehicle and allow the system to cool down.
F01001 Motor Brush Fault Refer to service technician
F01002 Pump Motor Brush Fault Refer to service technician
F01003 P/S motor Brush Fault Refer to service technician
F01004 Low Battery Volts Batteries are empty and require charging. If this fault does not reset
after the charge cycle is complete then there may be a problem with
the charger or batteries. Refer to qualified service technician.
F01005 Controller Overheated Stop the vehicle and allow the system to cool. This could be a result of
an overloaded vehicle.
F01006 Traction Motor Hot Stop the vehicle and allow the system to cool down. This could be a
result of an overloaded vehicle
F01007 Pump Motor Overheated Stop the vehicle and allow the system to cool down.
F01008 Wiring fault Refer to service technician
Level 2 Faults
F02000 Throttle Fault Occurs if throttle control voltage is high at start up indicating that the
throttle pedal was pressed when the start switch was closed. If the
pedal was not pressed, then refer to qualified service technician.
F02001 Throttle Fault Throttle module FS-1 switch is closed (pedal pressed) or wiring
shorted when start switch is turned on. Throttle module output high
when start switch is turned on.
F02002 Belly Switch Fault Refer to service technician
F02003 Open Field Refer to service technician
F02004 Open Field L Refer to service technician
F02005 Open Field R Refer to service technician
Level 4 Faults
F04000 Open Contactor Refer to service technician
F04001 Contactor Welded Refer to service technician
F04002 Steer POT Fault N/A
F04003 Sequence Fault Start up switches were not operated in the correct order. Refer to Vehicle
Operation Guidelines for correct sequence.

MA-100-02
F04004 Direction Fault Refer to service technician
F04005 Direction Fault Direction was selected before start switch was closed. Place direction
control switch in the OFF position and restart.
F04006 Interlock Fault Seat or foot interlock switch not closed.
F04007 Inch Switch Fault Direction Control switch has a direction selected.
F04008 Steer Fault Refer to service technician
F04009 Low Battery Volts Extreme low battery voltage at the controller. May be a result of severely
discharged battery or wrong battery installed. Confirm that the correct
battery is installed and charge the battery.
F04010 High battery Volts Refer to service technician
F04011 Out of Range Fault Refer to service technician
F04012 CRC Fault Refer to service technician
F04013 Capacitor Fault Refer to service technician
Level 5 Faults
All Level 5 faults indicate a failure in the motor speed control system. Refer repair to a service technician.

MA-100-02
Vehicle Operation
General Safety Guidelines
WARNING
Your ability to operate a motor vehicle can be seriously impaired with
blood alcohol levels far below the legal minimum.
If you have been drinking alcohol, don’t drive. Ride with a designated
non-drinking driver, call a cab, or use public transportation.
WARNING
The advanced technology built into the vehicle motor control has many systems to monitor
the condition and operation of the vehicle to maintain safe operation.
Even with advanced technology, it is not possible to change the laws of physics. Improper
driving technique for the current conditions could result in loss of vehicle control.
WARNING
When leaving the approved operating position ALWAYS:
1) Firmly set the park brake.
2) Place the direction control switch in the center OFF position.
3) Turn the start switch OFF and remove the key.
Failure to perform these operations may result in unexpected vehicle movement causing
severe bodily injury and/or property damage.
• Only qualified and trained operators with no physical, mental, or sensory disabilities shall
operate this vehicle or any of its components.
• No passengers are allowed to be transported in the cargo area of the vehicle.
• No occupants other than the operator are allowed on this vehicle.
• Before operating this vehicle, perform all Daily and Pre-operation checks as defined in the
Vehicle Maintenance section.
• Confirm proper operation of all vehicle controls before operating the vehicle.
• Wear closed toe low heel shoes when operating the vehicle.
• No reckless driving.
• Do not operate a motor vehicle while under the influence of alcohol or any drug that may
impair your ability to drive.
• Keep all body parts (head, arms, legs) inside this vehicle while it is moving.
• The operator shall remain on the operator platform in the approved operator position while
the vehicle is in motion.
• Do not exit the vehicle until the vehicle has come to a complete stop.
• If equipped with a ladder, the ladders shall not be occupied while the vehicle is in motion.
• Do not transport small children. This vehicle is not designed to accommodate child seats.
• Do not leave children unattended in the vehicle.
• Keep a clear view ahead at all times.
• Keep the vehicle under control at all times.
• Observe all traffic regulations and speed limits.
• The vehicle shall be equipped with head and tail lights if operated at night.
MA-100-02
• This vehicle may overturn if turned sharply when driven at high speeds.
• Drive slowly when making a turn, especially if the ground is wet or when driving on an
incline.
• Yield right of way to pedestrians, ambulances, fire trucks, or other emergency vehicles.
• Sound your horn when approaching pedestrians. DO NOT assume the pedestrian is aware
of your presence; before passing, slow down and allow sufficient clearance between the
vehicle and pedestrian.
• Do not overtake another vehicle at intersections, blind spots, narrow isles, or other
dangerous locations.
• Stop and sound horn at all intersections regardless if it is posted with a stop sign.
• Do not operate this vehicle in areas at risk to falling objects.
• Do not drive over loose objects, holes, or bumps.
• Do not drive under any object that is less than 80 inches (203 cm) from the ground.
• Do not drive off of curbs or other steep drop-offs more than 2 inches high.
• Stay in your driving lane under normal conditions, maintaining a safe following distance from
other vehicles.
• If equipped with doors, the doors must remain closed and latched while vehicle is in motion.
• Driving through water or mud may affect brake performance. ALWAYS test brakes by
pressing the brake pedal after driving through water or mud.
WARNING
When leaving the approved operating position ALWAYS:
1) Firmly set the park brake.
2) Place the direction control switch in the center OFF position.
3) Turn the start switch OFF and remove the key.
Failure to perform these operations may result in unexpected vehicle movement causing
severe bodily injury and/or property damage.

MA-100-02
Starting
Before operating this vehicle: Refer to General Safety WARNING
Guidelines at the beginning of this chapter.
NO PASSENGERS are to be
Note: This vehicle is equipped with a charger interlock
transported on this vehicle.
which is designed to disable the vehicle from being
driven while the AC charger cord is plugged into
Operator ONLY in the approved
a functioning power source. operator position.
Note: This vehicle is equipped with an operator presence switch which disables the vehicle when
the driver is not present.
WARNING
The operator presence switch is part of the vehicle safety system. DO NOT rely on the
switch as the only method to prevent vehicle movement. ALWAYS turn the start switch
OFF, place the direction control switch in the center OFF position, and set the park brake
when leaving the approved operator position.
DO NOT bypass, modify, or disable the operator presence switch. Doing so could result in
unexpected movement of the vehicle causing severe bodily injury and/or property damage.
DO NOT place or store any object on the operator platform. Any object placed on the
operator platform may turn on the operator presence switch resulting in unexpected
vehicle movement causing severe bodily injury and/or property damage.
DO NOT transport any objects on the operator platform. Objects may interfere with
vehicle operation causing severe bodily injury and/or property damage.
1. Stand in the approved operator position and press back on the treadle.
2. Place the Direction Control switch in the center OFF position.
3. Place the Start switch on the ON position and wait 1 second.
4. Select a direction of travel.
5. Slowly press the front of the treadle to accelerate to the desired speed.
Note: In an emergency, the Start switch may be turned OFF to disable the motor speed control.
Refer to additional information regarding optional automatic parking brake in the Driving
section.
Refer to the Driving section for additional information in the operation of your vehicle.
WARNING
DO NOT exceed the maximum rated speed for your vehicle, locally imposed speed
limits, or the safe operating speed for conditions. Exceeding any of these speed limits will
increase the likelihood of an accident causing personal injury. In addition, exceeding the
maximum rated speed for your vehicle may result in damage to the vehicle drive train
and/or control system.

MA-100-02
Driving
Before operating this vehicle:
• Perform all daily and pre-operation checks as defined in the Vehicle Maintenance section.
• Refer to General Safety Guidelines at the beginning of this section.
WARNING
DO NOT exceed the maximum rated speed for your vehicle, locally imposed speed
limits, or the safe operating speed for conditions. Exceeding any of these speed limits will
increase the likelihood of an accident causing personal injury. In addition, exceeding the
maximum rated speed for your vehicle may result in damage to the vehicle drive train
and/or control system.
Selecting Direction of Travel

The direction of travel is selected with the Direction Control Switch. The direction of travel must
be selected after the Start switch is turned ON. If a direction is selected before the Start switch
is turned ON, then a sequence fault will occur. If the sequence fault occurs, you can clear the
fault by placing the Direction Control switch in the center OFF position and then re-selecting
the desired direction of travel.
Your vehicle may be equipped with a reverse or motion alarm.
• The motion alarm will sound in forward and reverse.
• The reverse alarm will only sound when the reverse direction is selected.
Changing Direction of Travel

The direction selected by the Direction Control switch can be changed at any time but you may
have to release the treadle to reverse direction.
If the vehicle is in motion when the direction is changed, the motor control system will reverse
the current flow in the motor slowing the vehicle to a stop and then continue in the new direction
selected. For more information, refer to the section on Stopping.
The treadle must be released after selecting a new direction. If the treadle is not released, then
a sequence fault will occur. If the sequence fault occurs, you can clear the fault by placing the
Direction Control switch in the center OFF position and then re-selecting the desired direction
of travel.
Driving in Forward
1. Turn the start switch ON, then select FORWARD using the Direction Control switch.
2. Slowly press the treadle to accelerate to the desired speed.
Note: This vehicle is equipped with a operator presence switch. The motor control system will be
disabled unless the driver is in the approved operator position
Driving in Reverse
1. Check and confirm that there are no obstacles behind the vehicle before backing up.
2. Turn the start switch ON, then select REVERSE using the Direction Control switch.
3. Slowly press the treadle to accelerate to the desired speed.
Note: The maximum reverse speed will be slower than the forward speed.

MA-100-02
Emergency Stop Switch
This vehicle may be equipped with an Emergency Stop Switch. The Emergency Stop Switch
should be used if the vehicle starts to operate in an unexpected manner or if there is an odor or
sound that may indicate an overloaded electrical circuit. If any of the above occurs, immediately
and safely pull to the side of the road and stop. Then push on the switch knob and exit the
vehicle. Do not reengage the switch until the vehicle has been inspected by a qualified technician.
The Emergency Stop Switch should only be activated if the vehicle must be immediately stopped.
Do not use the switch when only parking the vehicle.
Stopping
WARNING
Brakes contaminated with water or mud may not work properly until dried out.
ALWAYS test brake operation immediately after driving through puddles or mud. Failure
to test brake operation may result in the inability to stop in an emergency causing in
severe personal injury and/or property damage.
Release the treadle and use the heel of your right foot to press back on the rear of the treadle.
The amount of force required to stop the vehicle will vary depending on the environment and
load on the vehicle.
Unless in an emergency, do not turn the start witch OFF until the vehicle has come to a complete
stop.
This vehicle is equipped with regenerative (regen) braking. Regen braking uses the stored energy
of the moving vehicle to generate electricity. The generation of electricity slows the vehicle down
and the power generated is put back into the batteries increasing the driving time of your vehicle.
There is more than one regenerative braking mode. The mode used depends on the current
driving conditions as follows:
• While Coasting: When you release the treadle, the Neutral Regen mode is selected
and gradually slows the vehicle. Only a small amount of power is
generated.
• Changing Direction: The Direction Regen mode is selected when the direction of the
vehicle is changed while the vehicle is in motion. In this mode the
motor is reversed and slows the vehicle to a stop and then continues
in the opposite direction.
Parking
1. Bring the vehicle to a stop at an authorized parking space.
2. Place the Direction Control switch in the center OFF position.
3. Turn the start switch OFF.
4. Firmly set the parking brake.
5. Remove the key from the Start switch. The driver should keep the key in his/her possession.
Note: If parking this vehicle on an incline, turn the wheels to the curb, or block the wheels.

MA-100-02
Loading Cargo
WARNING
DO NOT transport or load cargo in the operator area or leave loose items on the operator
platform. Cargo placed on the operator platform area may interfere with the driver
causing loss of control of the vehicle and result in a collision or accident with severe injury.
• Before loading or unloading cargo:
1. Place the Direction Control switch in the center
OFF position.
2. Turn the start switch OFF
WARNING
3. Set the park brake. NO PASSENGERS are to be
• Do not transport cargo that is wider than the transported on this vehicle.
vehicle. Operator ONLY in the approved
• Do not load cargo in the passenger compartments. operator position.
• Use only Taylor-Dunn approved cargo accessories.
• Do not exceed the load capacity of the vehicle.
• The standard designated cargo area is the front deck. Only load cargo on the deck unless
the vehicle has been equipped with Taylor-Dunn approved alternative cargo storage areas.
• Cargo shall only be transported in the designated cargo area of the vehicle and evenly
distributed with the center of gravity close to the center of the designated cargo area.
• All cargo shall be secured to prevent falling from the vehicle or shifting position while the
vehicle is in motion.
• Our deck enclosures and covers such as cabs, fiberglass tops, surrey tops, cargo boxes,
and similar structures are not designed to carry cargo or accessories unless equipped from
the factory. Mounting additional weight on these structures may result in sudden failure of
the cover and/or cover supports causing severe personal injury.
• Cargo consisting of fluid in tanks shall have fluid baffles in the tank to help reduce sloshing
and shifting load weight.
Transporting Pets
Pets should only be transported in a pet carrier that is securely tied down on the rear cargo deck.
Collisions or Accidents
A collision or accident may damage the electrical circuits or batteries resulting in a fire hazard or
chemical spill. In the event of a collision or accident, immediately turn the Start switch OFF, set the
park brake, then exit the vehicle.
Call emergency personnel if there is any indication of smoke, burning smell, electrical arcing, or
leaking fluid.
Tip Over
In the event of a tip over, quickly move away from the vehicle while avoiding the steering tower,
seat back, and optional ladder.

MA-100-02
Using the Ladder (optional)
Maximum ladder capacity: 300 pounds (136 kg).
1. Stop the vehicle on a level surface.
2. Set the forward-off-reverse switch to the
WARNING
“OFF” (center) position. DO NOT use the ladder if the vehicle is
3. Set the parking brake. parked on a grade.
4. Turn the start switch to the “OFF” position
and remove the key.
Using the ladder while on a grade will
increase the risk of vehicle tipping over
and/or falling off the ladder resulting in
property damage and/or severe personal
injury.
• If the ladder is struck by any object

immediately remove the vehicle from
service. Inspect/ repair as needed.
• Climb the ladder from platform side.
• Always face the ladder.
• Use the ladder handrails.
• Keep both feet on the ladder step when
picking cargo.
• Do not use the ladder unless you are
in good physical condition without any
impairment.
• Do not operate the vehicle while the
ladder is occupied.
• Do not climb higher than the top step.
• Do not step on seat back cushion.
• Do not ascend or descend the ladder
while holding cargo that requires both
hands.
• Do not carry large cargo that may result
in loss of balance.
• Do not use the ladder to climb onto any
object, platform, or other vehicle.
• Do not overreach, keep your waist within
the ladder rails.

MA-100-02
Vehicle Load Capacity, Definition
The rated maximum load capacity of a vehicle is the load carrying capacity of the standard model.
The maximum load is on the vehicle’s data plate.
Occupants and optional equipment added to the vehicle at time of manufacture or installed after
delivery by the dealer or user reduces the capacity.
Example: Standard Load Capacity = 3,000 pounds:
3,000 - Driver (200) - Steel Cab/Doors Option (300) - Cargo Box (400) = 2,100 pounds maximum
load on deck. Add a passenger and the maximum load is reduced to 1,900 pounds.
The definition of maximum load is the maximum weight than can be carried on a vehicle under ideal
conditions. There are many conditions that will reduce the maximum safe load a vehicle can carry.
Some of these conditions are, but not limited to:
• Uneven road surface. • Liquid loads (sloshing).
• Tall loads. • Traveling up or down grades.
• Wide loads. • Traveling across grades.
• Long loads.
The rated capacity assumes the load has a low center of gravity and is centered on the deck. As
example: A 20 foot tall, 3,000 pound statue on the deck of a 3,000 pound capacity vehicle is not
approved.
Liquid loads sloshing around in a tank will shift the center of gravity and may result in stability and
braking issues. Liquid loads must be secured and have fluid baffles in the tank to help reduce
shifting load weight due to sloshing.
TOWING
WARNING
Use caution when towing trailers wider than the tow tractor allowing for additional isle
clearance and corner cutting of the trailers.
Not allowing for additional clearance may result in collision with severe bodily injury
and/or property damage.
Towing a Trailer
Note: Towing up or down grades will significantly reduce the capacity of the vehicle.
When towing trailers:
• Do not exceed the DBP towing capacity of the vehicle. See Specifications and DBP
definition.
• Only use Taylor-Dunn approved trailer hitches.
• Do not exceed the capacity of the trailer hitch installed on the vehicle.
• 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.
• Cargo consisting of fluid in tanks shall have fluid baffles in the tank to help reduce shifting
load weight.
• 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.
• Block the trailer wheels before disconnecting from the vehicle.
• Do not disconnect a trailer while parked on a grade.
MA-100-02
Draw Bar Pull (DBP), Definition
DBP is a measure of pulling force required to move a load. The load may be a trailing load or
a pushed load. It is normally expressed in pounds or Newtons.
The DBP of a tow tractor is the horizontal force exerted on a load at its coupler while towing or
pushing a load. To measure the DBP, a scale would be connected in line with the tractor coupler
and the load. The scale will directly read the DBP as the tractor tows the load.
Tow tractor DBP specifications, definition:
• Normal DBP: Highest DBP that can be sustained for a given duty cycle.
• Ultimate DBP: Also referred to a Maximum DBP. Highest DBP achieved while traveling at
a minimum speed of approximately 0.5 mph (0.8 kph) for a minimum of 30 seconds. This
specification is used in calculations for getting a load moving.
Notes:
Tow tractor DBP specifications are based on:
• Road surface consisting of level dry clean asphalt, brushed concrete or equivalent.
• Maximum battery weight installed per tow tractor battery specification.
Towing a load up any grade will significantly increase the DBP required.
Most paved roads and parking lots have a drainage grade to allow water to run off. When operating
a tow tractor at or near its maximum capacity, this drainage grade will significantly affect DBP
required to pull the load and may result in exceeding the tractor specifications.
The load capacity and towing capacity of a burden carrier cannot be combined. The towing
capacity is reduced as weight is added to the burden carrier. This weight includes the passengers
and optional equipment as well as the load on the deck.
The formula for calculating reduced towing capacity DBP is:
Reduced DBP = DBP - Vl * (DBP/Vc) where:
• Vc = Vehicle Rated Capacity
• DBP = Normal Draw Bar Pull specification
• Vl = Vehicle Load (includes passengers and options)
The weight that the vehicle can pull can be calculated based on the DBP. This capacity would be
for a single standard 4-wheel trailer with a front steer axle and includes the weight of the trailer.
• Level Surface: Towed Weight = DBP * 50
• Up a grade: Towed Weight = DBP/(2 + %g) * 100 where %g = the percent of grade
Hitch Release
WARNING
Do not operate the hitch release lever while on a grade or while the vehicle is in motion.
• Decoupling a trailer while in motion may result in unexpected movement of the vehicle
and/or loss of control of the trailer.
Decoupling a trailer while on a grade will result in loss of control of the trailer.
The above actions may result in severe personal injury and/or property damage.

MA-100-02
Towing the Vehicle
Note: If at all possible, this vehicle should be placed on a carrier, rather than towing.
WARNING
ALWAYS use another driver to steer this vehicle while it is being towed.
DO NOT block or otherwise tie the treadle down to release the brake. Blocking the treadle
down may result in uncontrolled movement of the vehicle causing severe bodily injury
and/or property damage.
WARNING
DO NOT tow a vehicle with a tow strap if the vehicle brakes are not working properly.
Using a strap to tow a vehicle with no brakes may result in loss of control of both vehicles
causing severe bodily injury and/or property damage.
WARNING
DO NOT tow the vehicle faster than 5 mph (8 kph) or its maximum designed speed,
whichever is lower.
Towing the vehicle faster than 5 mph may result in one or more of the following:
• Loss of control of both vehicles causing severe bodily injury and/or property damage.
• Damage to the towed vehicle drive train components and/or motor.
WARNING
Use extreme caution if towing a vehicle backwards and it is recommended ONLY to tow
a short distance until able to connect to the front tow bar and tow forwards.
If towed backwards, the towed vehicle may swing wide turning turns resulting in loss of
control of both vehicles causing severe bodily injury and/or property damage
1. Attach a tow strap to the front bumper tow-bar.
2. Turn the start switch off and place the direction control switch in the center off position.
3. Use another driver to steer this vehicle while it is being towed.
4. Press the front of the treadle while being towed and use the rear of the treadle to brake 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.

MA-100-02
Charging Your Vehicle

GENERIC SAFETY GUIDELINES
DANGER
The charger must be connected to a properly grounded AC receptacle. Improper
connection will increase the risk of electric shock and can cause severe personal injury
or death.
WARNING
• Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not
work with or charge a 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.
• DO NOT disassemble the charger. There are no user serviceable components in the
charger. Refer all repairs to a qualified technician. Incorrect repair or reassembly of
the charger can result in an explosion, electric shock, or fire.
• Use of extension cords is not recommended. Improper use of an extension cord may
result in fire.
• The Signet, Lester, and Delta-Q chargers are for lead acid batteries only. Charging
other types of batteries may cause the battery to burst or explode causing severe
personal injury and/or property damage.
• Do not attempt to operate the vehicle while charging the battery. Operating the charger
and vehicle at the same time may lead to damage to the charger and/or the vehicle
resulting in personal injury and/or property damage.
• This charger requires a standard household 15 Amp electrical circuit. Before plugging
the charger in, confirm that your charging station is configured correctly. DO NOT
attempt to charge two vehicles on one standard household 15A circuit. Failure to
confirm the proper charging station configuration or attempting to charge two vehicles
may result in fire.
• Do not charge any battery that is, or is suspected to be frozen. Charging a frozen battery
may result in explosive rupturing of the case due to a build up of internal pressure.
This may causing severe bodily injury and will cause property damage.
• The charger should not be used by children or any personnel with mental or sensory
disabilities. Incorrect usage due to inability to understand operation may cause severe
personal injury and/or property damage.
NOTICE NOTICE
The Start switch must be in the “OFF” Check battery electrolyte before
position when charging the batteries. charging. Do not charge batteries with
Failure to turn the Start switch “OFF” low electrolyte level. Charging with low
may result in damage to the vehicle’s electrolyte level will result in premature
electrical system. failure of the battery.
MA-100-02
NOTICE
The charger originally supplied with the vehicle is for use with the batteries originally
supplied with the vehicle. If installing a different charger or batteries, consult the charger
and/or battery manufacturer to confirm that the charger used is compatible with the
batteries. Use of an incorrect charger will result in damage and premature failure of
the batteries.
Charging Time
Average charging time is typically 8 to 10 hours. NOTICE
The time required to fully charge your batteries will
vary depending on: Charging batteries emit hydrogen.
Hydrogen is known to cause false
• Capacity of the batteries: Higher capacity
battery requires longer charge time.
alarms in carbon monoxide detectors.
• Output of the charger: Higher charger output requires less charge time.
• Depth of discharge: The deeper a battery is discharged, the longer it takes to charge.
• Temperature: Low temperatures require longer charge time.
It is not unusual for charge times to exceed 15-hours, especially with new batteries.
To Obtain the Maximum Battery Life

Charge the battery only after it reaches a normal discharge (20%) as indicated on the Battery
Status Indicator (BSI). Failure to follow this guideline could result in the battery entering an
overcharge state, which will reduce the life of the battery. If you find it necessary to charge the
battery before it is completely discharged, we recommend waiting until it is discharged a minimum
of 30% to reduce the possibility of overcharging. Refer to Vehicle Controls in this section for
information on how to read the BSI.
Do not discharge the battery beyond a normal discharge as indicated on the BSI. Discharging
your battery too deep will result in premature failure of the battery. Refer to Vehicle Controls in
this section for information on how to read the BSI.
Check the battery electrolyte level once a week. Do not charge the battery if the battery
electrolyte is low. Charging when the electrolyte is low will damage the batteries and shorten
the life-span of the battery. Only authorized personnel should perform battery maintenance
including maintaining the battery electrolyte level. Refer to the Battery Maintenance Section for
battery maintenance information.
It is not recommended to interrupt the charging cycle. Allow the charger to turn off before
disconnecting the AC plug. Interrupting the charging cycle could lead to overcharging or
discharging the batteries too deep. Both circumstances will result in premature failure of the
battery.
New Battery Break In
New batteries require a break in period of up to 40-cycles. The batteries will not have their full
capacity during this break in period and may result in longer charging times.
AC Power Source
The AC power source required by the charger
will vary depending on the charger installed in
WARNING
the vehicle. Refer to the specifications printed
Use of extension cords is not
on the charger for details. recommended. Improper use of an
Use of extension cords is not recommended. If extension cord may result in fire.
you find it necessary to use an extension cord,
make sure the extension cord power rating exceeds the power requirements of the charger.
The United States Federal, State or local regulations may require the use of a Ground Fault
Interrupter (GFI) cable or AC outlet equipped with a GFI for charging your vehicle. A charger
cord with an integral GFI is available through your Taylor-Dunn dealer.
MA-100-02
Signet Model HBS Charger
NOTICE
This charger is rated for 115 VAC or 230 VAC operation (nominal). When switching from
one input voltage to the other, wait until all LED’s are off. Switching voltage when any
of the LED’s are on will result in damage to the charger.
NOTICE
Sealed Lead Acid batteries (SLA) must be charged with a charger configured for SLA
batteries. Use of any other charger will result in damage and premature failure of the
batteries.
Description of Operation
The Signet model HBS charger is designed as an automatic charger. It is available with charging
profiles for SLA and FLA batteries. The charger turns itself on when it is plugged into the wall
outlet and turns off when the batteries are fully charged. The charger continues to monitor the
battery voltage and if the battery voltage drops below a threshold value, then the charger will
turn on again for a short cycle to keep the batteries topped off.
The charger face plate has a series of lamps to enable monitoring
of the charging cycle. More detail of the lamp operation is later
in this section.

MA-100-02
Charging with the Signet Charger Note: It is recommended that the charging
cycle be allowed to complete normally
before disconnecting the AC power
WARNING cord.
Refer to grouped safety warnings and A beeping noise from the charger is an
information at the start of this chapter. indication of a fault during the charging cycle.
Refer below for fault information.
Note: O p p o r t u n i t y c h a r g i n g i s n o t
There is a status light panel on the charger
recommended. For maximum battery
faceplate that displays the current status of
life, it is recommended that the batteries
the charger. The first light on the left (POWER)
be discharged a minimum of 30%
should be ON when the AC cord is connected
(7 bars showing on the BSI) before
to a working AC power source.
starting a charging cycle.
The three STATUS LED lights will indicate the
This charger requires a standard household
current charging condition as follows:
electrical circuit rated at minimum of 15 Amps.
Consult an authorized electrician if you do not • Left: Charge cycle is ON and is in
know the configuration of your circuits. constant current mode.
1. Park the vehicle at an authorized • Left & Middle (80%): Charge cycle is
charging station. Refer to Parking in the ON and is in constant voltage mode.
Driving section. • Right (100%): Charge cycle completed.
2. Connect the charging cord to the AC The FAULT light will turn ON and flash a fault
power receptacle. code only if an abnormal charging condition
3. The charger status LED’s will flash in has occurred. Refer to the following fault code
sequence as the charger performs a self table for more information.
diagnosis and systems check. Note: Critical faults will be accompanied with
4. The charger will start the charging cycle an audible beeping.
only after it has determined that all
systems are OK.
Fault Description Action Required

Code
1 Time out The charging cycle did not complete when expected. This could
(no flash) be due to too deep of a discharge or faulty batteries. If the fault
reoccurs, have the batteries tested by a qualified technician.
2* Open circuit or reverse Check the charger connections to the battery.
polarity to the battery
3* Battery voltage too high Wrong charger installed. Confirm that the charger voltage
matches the battery voltage.
4 Charger overheated Check for dirt, mud, or other debris on the charger cooling fins
and clean as needed.
5* AC line voltage out of **Check the input AC line voltage.
range The voltage must be within 85-135 VAC or 170-264 VAC
6 Low battery voltage Battery discharged too deep, faulty battery, or incorrectly wired
battery.
The charger will operate in low current mode until the battery
voltage is up to a normal level then resume normal charging.
If this fault does not reset, have the battery tested by a qualified
technician and check the battery wiring.
* These faults will be accompanied with an audible beep and indicates that the charging cycle
was terminated prematurely.
** Only a qualified electrician should check the AC line voltage

MA-100-02
X-Series Charger
NOTICE
This charger is available for 115 VAC or 230 VAC operation (nominal). Confirm the
charger installed is correct for the AC voltage power source before connecting the charger.
Connecting to improper voltage will damage the charger.
NOTICE
batteries.
Note: As of 1/1/2017, vehicles will no longer be equipped with this charger from the factory.
The X-Series chargers are designed as automatic chargers. The charger turns itself on when it
is plugged into the wall outlet and turns off when the batteries are fully charged.
There is a user interface on the charger. The interface consists of the following:
1. Start/stop switch: When pressed, the charging cycle will be terminated or restarted.
2. Charging status light: Indicates the current status of the charging cycle. The light will start
flashing when the charging cycle is started. It will stop flashing and remain ON when the
cycle has completed. Also used for fault indication along with the fault light (4).
3. Low voltage start switch: When pressed, will start the charge cycle if the battery voltage is
too low for an automatic start.
4. Fault light: Along with the status light (2), displays faults after self diagnosis is completed.
5. AC Circuit breaker: If circuit breaker trips, push it back in to reset. If it trips again, contact
qualified repair technician.
6. Ammeter: Indicates the current flowing into the battery during the charging cycle.
7. Self diagnostic switch: Starts the charger self diagnosis procedure (details later in this section).

MA-100-02
Charging with the X-Series Charger
WARNING
Refer to grouped safety warnings and information at the start of this chapter.
Note: Opportunity charging is not recommended. For maximum battery life, it is recommended
that the batteries be discharged a minimum of 30% (7 bars showing on the BSI) before
starting a charging cycle.
This charger requires a standard household electrical circuit rated at minimum of 15 Amps.
Consult an authorized electrician if you do not know the configuration of your circuits.
1. Park the vehicle at an authorized charging station. Refer to Parking in the Driving section.
2. Connect the charging cord to the AC power receptacle.
3. The charger should start automatically.
If the charger does not start, then press and hold the “Low Voltage Start” switch for about
10-seconds. If the charger does not remain ON after releasing the switch, then try again. If the
charger refuses to start, then have the batteries and charger tested by an qualified technician.
Self Diagnosis Procedure

If you suspect a battery charging problem press the self diagnostic switch to start the charger
self diagnostic procedure. Any faults found by the procedure will be displayed by the two LED’s.
Refer to the table below for the fault codes.
Note: To run this procedure, a battery that is not severely discharged must be connected to the
charger.
Fault LED Status LED Action Required

OFF OFF • No faults found.
Flashing Flashing • Battery voltage either too high or too low. Confirm that the correct
battery and charger is installed in the vehicle.
• Faulty battery, will not accept a charge.
• Battery installed is too large (Amp Hours).
ON ON or Dim • *Faulty charger
Flashing ON • *Faulty charger
ON Flashing • **AC input voltage is out of range. Confirm that the AC outlet has
the correct voltage for the charger.
• *Charger circuit breaker tripped. Reset the breaker by pushing the
button. If the fault reoccurs, then it indicates a faulty charger.
ON ON • *Faulty charger.
Flashing OFF • ***Charger programmed incorrectly
* Refer charger repair to a qualified technician
** Only a qualified electrician should check the AC line voltage
*** Continued use of the charger may damage your batteries. Refer charger repair to a quali-
fied technician

MA-100-02
Lestronic II Charger
NOTICE
This charger is available for 115 VAC or 230 VAC operation (nominal). Confirm the
charger installed is correct for the AC voltage power source before connecting the charger.
Connecting to improper voltage will damage the charger.
NOTICE
batteries.
Note: As of 1/1/2017, vehicles will no longer be equipped with this charger from the factory.
The Lestronic II charger is a semi-automatic charging system. 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.
Charging with the Lestronic II Charger

Note: Opportunity charging is not recommended. For maximum battery life, it is recommended
that the batteries be discharged a minimum of 50% before starting a charging cycle.
This charger requires a standard household electrical circuit rated at minimum of 15 Amps.
Consult an authorized electrician if you do not know the configuration of your circuits.
1. Park the vehicle at an authorized charging station. Refer to Parking in the Driving section.
2. Connect the charging cord to the AC power receptacle.
3. The charger should start automatically.
When plugged in, the charger assumes that the batteries require charging and will charge 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.

MA-100-02
Lester Summit Charger
The Summit charger is designed as an automatic charger. It is available with charging profiles
for SLA and FLA batteries. Refer to the spec plate on the charger for the type of battery it is
configured for. Use of different batteries not listed on the spec plate may result in premature
failure of the batteries.
The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries
are fully charged. The charger continues to monitor the battery voltage and if the battery voltage
drops below a threshold value, then the charger will turn on again for a short cycle to keep the
batteries topped off.
There are three lamps on the charger used to indicate
the active charging status and if any faults occurred
during the charging cycle.
Status Lamps

MA-100-02
Charging with the Summit Charger The Charge Status lamp (yellow) will indicate
the active charging phase as follows:
WARNING • Slow flash: Charge cycle is ON and is in
constant current mode.
Refer to grouped safety warnings and • Rapid flash: Charge cycle is ON and is
information at the start of this chapter. in constant voltage mode.
• Solid: Charge cycle is in finish mode.
Note: O p p o r t u n i t y c h a r g i n g i s n o t
recommended. For maximum battery The Charge Complete lamp (green) will indicate
life, it is recommended that the batteries the charging status as follows:
be discharged a minimum of 30% • Slow flash: Charge cycle is complete
(7 bars showing on the BSI) before and is in post charging phase.
starting a charging cycle. • Rapid flash: Normal cycle is complete
This charger requires a standard household and now in equalizing phase.
electrical circuit rated at minimum of 15 Amps. • Solid: Charge cycle is complete.
Consult an authorized electrician if you do not The FAULT lamp will turn ON solid or flash
know the configuration of your circuits. only if an abnormal charging condition has
1. Park the vehicle at an authorized occurred. All three lamps are used to indicate a
charging station. Refer to Parking in the fault condition. Refer to the following fault code
Driving section. table for more information.
2. Connect the charging cord to the AC
power receptacle.
3. The charger will start the charging cycle
after it has determined that all systems
are OK. This will be indicated by the
Status lamp flashing slowly (≈1/second).
Note: It is recommended that the charging
cycle be allowed to complete normally
before disconnecting the AC power
cord.
Fault lamp Status lamp Complete lamp Fault Description

Slow flash OFF ON Charger overheated
Slow flash ON OFF Battery voltage below 10 volts
Slow flash OFF OFF AC power interrupted. This fault will only display
for 1 minute and then clear.
Slow flash ON Slow flash Charger internal fault
Slow flash Slow flash OFF Charger internal fault
Slow flash Slow flash ON Charger internal fault
Fast flash - - Charger internal fault
The following conditions are an indication of battery problems
ON OFF OFF Time out: One or more charging phases exceeded
a time limit
ON OFF Slow flash Battery voltage exceeded threshold indicating one
or more faulty batteries
ON OFF ON Battery voltage too low indicating one or more
faulty batteries
ON Slow flash OFF Time out: Possible too large AH battery installed.
ON Slow flash Slow flash Time out: Total charging time exceeded a time limit
indicating one or more faulty batteries

MA-100-02
Storing and Returning to Service

Both storing your vehicle and returning it to service should only be performed by authorized
personnel.
Storing Your Vehicle

• Clean the batteries, then fill and charge before
NOTICE
putting the vehicle in storage. Do not store batteries Storing batteries that are
in a discharged condition. discharged or allowing stored
• Lube all grease fittings. batteries to discharge while in
• Clean, dry, and check all exposed electrical storage causes sulphation of the
connections. battery plates. This will result in
• Inflate the tires to proper pressure (if applicable). reduced capacity and premature
• Part the vehicle at the storage location, turn the start failure of the batteries.
switch OFF, place the directional control switch in the
center OFF position and set the park brake.
• For extended storage, the vehicle should be elevated so that the tires are not touching the
ground.
If stored for a prolonged period, the batteries should be charged as follows:
Storage Temperature
Charging Interval (months)
(F)
Over 60 1
Between 40 and 60 2
Below 40 6
Returning to Service
• Check the battery state of charge and charge if required.
• Perform all applicable maintenance checks in the Maintenance Schedule.
• Remove any blocks from the vehicle and/or place the vehicle down on to the ground.
• Test drive before putting into normal service.

MA-100-02
Vehicle Maintenance
Daily Inspection
The following items should be inspected once every day before the vehicle is put into service:
• External frame damage (body).
• Operation of all lights, warning alarms.
• Inspect for leaking fluids or grease.
• Tire tread or sidewall damage.
• Smooth and proper operation of all controls such as but not limited to:
• Throttle/Brake treadle
• Steering
• Horn
• Parking brake
• Etc.
• Proper operation of all locking devises such as but not limited to:
• Tool box
• Removable battery trays
• Cargo box
• Etc.
• Proper operation of all interlocking switches such as but not limited to:
• Start switch
• Operator Presence switch
• Charger interlock switch
• Etc.
Pre-Operation Inspection
The following items should be inspected every time before the vehicle is driven:
• Steering operation.
• Brake operation (service and park brake).
• Tire pressure (visual inspection only).
WARNING
Remove cargo before raising the vehicle, raising or removing the deckboard, or servicing
the vehicle. Failure to remove the cargo may result in cargo falling from the vehicle
causing severe personal injury and/or property damage.

MA-100-02
INTERLOCK SWITCH INSPECTION

The interlock switches should disable vehicle operation when activated. Perform the following to
confirm proper operation. If any one test fails, then immediately remove the vehicle from service
and refer repair to a qualified technician.
WARNING
These procedures may result in unexpected vehicle movement.
• All procedures shall be performed in an area that allows for possible movement of the
vehicle and room to safely stop the vehicle if it moves.
• DO NOT allow any personnel to stand in front or behind the vehicle while performing
these procedures.
Failure to follow the above instructions may result in severe personal injury and/or
property damage.
DO NOT bypass, modify, or disable any interlock switch. Doing so could result in
unexpected movement of the vehicle causing severe bodily injury and/or property damage.
All procedures shall be performed with the charger disconnected from its power source except
for the procedure testing the charger interlock. If using a portable charger, disconnect the charger
cable from the vehicle.
If equipped with a battery disconnect switch, make sure it is in the run position before performing
procedures.
Start Switch Charger Interlock Switch

Connect the charger to its power source. If using
Turn Start switch OFF. a portable charger, connect the charger cable
to the vehicle.
Sit in the approved operator position, select a
direction, then slowly press the throttle pedal. Sit in the approved operator position, turn the
start switch ON, select a direction, and slowly
• The vehicle should not operate.
press the throttle pedal.
Release the pedal and place the direction control
switch in the center OFF position. • The vehicle should not operate.
Disconnect the charger and wait 1 minute.
Turn the start switch ON, select a direction and
slowly press the throttle pedal. Sit in the operator position, turn the start switch
ON, select a direction, and slowly press the
• The vehicle should operate normally.
throttle pedal.
Operator Presence Switch • The vehicle should operate normally.

Stand in the approved operator position, turn the
start switch ON, select a direction, and slowly
press the treadle forward.
• The vehicle should operate normally.
Release the throttle pedal, lift your foot up off
the left side floorboard and again slowly press
the treadle.
• The vehicle should not operate.

MA-100-02
Maintenance Schedule
Most of these items should only be performed by a qualified technician. Details regarding the service
procedures can be found in the vehicle service manual.
Any problems found during an inspection should be repaired before the vehicle is put back into
service.
Every Week Every Year or 1,000 hours)

• All daily items plus the following: • All 6 month items plus the following:
• Battery electrolyte level (all cells). • Inspect all hardware for tightness
• Check all tires tread for debris. • Inspect and adjust front wheel bearings.
• Inspect wiring for damage.
First 15 hours • Clean and lubricate motor coupler.
• Re-torque the wheel nuts. • Inspect steering king pins.
• Inspect all hardware for tightness.
Every 2 Years or 2,000 hours
Every Month or 100 hours • All yearly items plus the following:
• All weekly items plus the following: • Clean and repack front wheel bearings.
• Brake fluid level. • Inspect all suspension bushings.
• Check all tires for tread wear. • Flush and replace the brake fluid.
• Check all tires air pressure. • Flush and replace the transaxle oil.
• Wash the battery compartment. • Inspect the chassis for damage.
• Clean the charger cooling fins or vents.
• Clean the drive motor exterior.
Every 6 Months or 500 hours

• All monthly items plus the following: Maintenance Guidelines for Severe
• Clean the battery terminals. Duty Applications
• Clean the control panel. The above maintenance schedule is based
• Re-torque the wheel nuts. on the average typical application. If the
• Inspect all hardware for tightness (first vehicle is operated under “severe conditions”,
500 hours then every 1,000 hours). service procedures should be conducted more
• Inspect and tighten all power electrical frequently than specified. The frequency of
connections. service under severe conditions is determined by
the use of the vehicle. The owner/operator must
• Inspect all steering linkages. Tighten
evaluate the operating environment to determine
steering shaft coupler.
the increase in maintenance frequency.
• Lubricate the vehicle per lubrication
schedule. In addition, the entire vehicle should be
inspected monthly for signs of damage.
• Inspect wheel bearings
The following list is meant as a guide and is not
• Test the batteries.
all-inclusive of a “severe duty” application.
• Operation in excess of 100 hours per
month.
• Extreme temperature.
• Bumpy, dusty, or ill maintained roads.
• Excessively wet areas.
• Corrosive or contaminated areas.
• Frequent loading of the vehicle at/near
capacity.

MA-100-02
BATTERY MAINTENANCE
WARNING
High Voltage is present in the battery compartment. DO NOT touch the battery terminals
during servicing of the battery as this may result in severe electric shock and/or death.
DANGER
• Battery electrolyte is poisonous and corrosive. It contains sulfuric acid. Avoid contact
with skin, eyes, or clothing. Wear rubber gloves and face safety shield while servicing
batteries. DO NOT INGEST! This will result in severe bodily injury.
• Wear a full face shield when working on or around batteries. A full face shield will
help protect your eyes from battery electrolyte. If battery electrolyte gets in your eyes,
immediately flush your eyes with large amounts of water and seek medical attention.
• Wear heavy duty long rubber gloves when working on or around batteries. If battery
electrolyte gets on your skin, immediately flush with large amounts of water to prevent
chemical burns.
• Explosive mixtures of Hydrogen gas are present within battery cells at all times. Do not
work with or charge batteries 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.
• Lead is poisonous. Batteries and battery terminals contain lead and lead components.
Avoid touching the battery terminals and always thoroughly wash hands after servicing
the batteries.
• A battery is a live electrical source. It cannot be disconnected or neutralized. Do not
drop any tool or conductive object onto the battery. A conductive object that comes in
contact with the battery terminals will initiate a short circuit of the battery. This could
cause the battery to explode resulting in severe bodily injury and/or property damage.
• Do not leave cables on batteries that have been removed from the vehicle. Cables left
on batteries could cause a short circuit resulting in battery explosion, severe bodily
injury and/or property damage.
NOTICE
• Battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly
clean any surface outside of the battery that the battery electrolyte comes in contact
with. Failure to clean may result in property damage.
• When torquing battery hardware, use a backup wrench on the battery bolt and tighten
the nut. Failure to use a backup wrench may damage the battery post.
• DO NOT remove the caps on a maintenance free battery. Removing the caps will
damage or destroy the battery seals resulting in premature battery failure.
• Do not operate or charge a vehicle equipped with moist charged batteries until the
batteries have been filled with electrolyte. Operating or charging moist charged
batteries before filling with electrolyte will damage the batteries resulting in premature
failure of the batteries.
MA-100-02
Cleaning
WARNING
1) Refer to battery warnings at the start of this chapter.
2) Place the Direction Control switch in the center “OFF” position.
3) Turn the Start switch OFF.
4) Place blocks under the front or rear wheels to prevent vehicle movement.
5) Disconnect the battery main positive and negative cables or disconnect the main
battery plug.
6. Dry dirt can be readily blown off with low-pressure air or brushed off.
7. Wetness or wet dirt on the battery indicates battery acid. Using a nonmetallic brush with
flexible bristles, wash the battery off with a strong solution of baking soda and hot water (one
pound of soda to a gallon of water). Continue until all fizzing stops, which indicates that the
acid has been neutralized. Then rinse thoroughly with clear water. DO NOT get any of the
solution into the battery cells.
8. Remove the blocks from the wheels and test drive.
Watering
Non-maintenance free batteries only.
CAUTION
Do not overfill the batteries. Overfilling the batteries may cause the batteries to boil over
and result in chemical burns and/or property damage.
Note: The electrolyte level in a battery rises while charging and will be close to its highest level
after the end of a charging cycle. It is recommended to fill the battery at the end of a charging
cycle. If the electrolyte is below the top of the battery plates then fill just enough to cover
the plates and then top off when the charging cycle is complete.
WARNING
1) Refer to battery warnings at the start of this
chapter.
2) Place the Direction Control switch in the
center “OFF” position.
3) Turn the Start switch OFF.
4) Place blocks under the front or rear wheels to
prevent vehicle movement.
5) Disconnect the battery main positive and
negative cables or disconnect the main battery
plug.
6. Clean the battery. Refer to Cleaning section for information on cleaning the battery.
7. Check the electrolyte level in all battery cells. If low, fill to the correct level with distilled
water using part number 77-201-00 battery filler. Never add additional battery electrolyte
to the batteries.
8. Remove the blocks from the wheels and test drive.

MA-100-02
REMOVABLE BATTERIES
Removable batteries can consist of a single large industrial battery or a pack of smaller batteries
assembled on a removable tray.
The removable battery can be of a type that slides or rolls out of the side of the vehicle (ROBB) or
lifted out of the vehicle from above (LOBB).
WARNING
• Use the proper equipment when handling and transporting removable batteries.
Equipment that is used to lift and support removable batteries should be rated
at a minimum of 1.5 times the total battery weight.
• Keep all body parts out from underneath any battery that is not installed and
latched in the vehicle.
Failure to follow these rules may result in severe bodily injury and/or property
damage.
WARNING
Before removing a battery pack or industrial battery:
1) P
ark the vehicle on a level surface. If removing a ROBB, the vehicle should be
positioned as close as possible to the platform where the battery will be stored.
2) Place the Direction Control switch in the center OFF position.
3) Make sure the Start switch is in the OFF position.
4) Set the park brake.
Roll Out Battery Box (ROBB) with battery Dolly

Remove
5. Disconnect the battery cable from the ROBB.
6. Position the ROBB dolly as close as possible to
the vehicle, aligned with the battery box.
7. Using the ROBB handle, twist to unlock the box
from the frame and pull the box out 6 inches.
8. Pump foot pedal 1 to raise the dolly tray until it is
in contact with the bottom the ROBB.
9. While pushing the dolly up against the vehicle, pull
the ROBB out of the vehicle and onto the dolly tray.
10. Tie the ROBB to the tray so that it cannot roll off.
11. SLOWLY press foot pedal 2 until the tray starts
to lower and allow to lower all of the way down.
Install
1. Confirm the start switch is OFF and the parking brake is set.
2. The ROBB should be tied to the dolly tray so that it can not roll off.
3. Position the ROBB dolly as close as possible to the vehicle, aligned with the battery box.
4. Pump foot pedal 1 to raise the dolly tray until it is slightly above its location in the vehicle.
5. Untie the ROBB from the dolly and push forward until it starts to enter the vehicle.
6. Using the foot pedal 1 and/or foot pedal 2, adjust the vertical position of the dolly tray until
the ROBB can be easily pushed into the vehicle.
7. Lock the ROBB in place.
8. Connect the battery cable.

MA-100-02
Lift Out Battery Box (LOBB) or Industrial Battery

Removing the LOBB will require an overhead hoist or forklift attachment not included with the
vehicle. Refer to the manufacturer of the hoist or attachment for proper operation.
1. Unplug the battery connector.
2. Attach the hook from the hoist or forklift attachment to the lifting eye on the battery box.
3. Lift the LOBB until it is clear of the frame.
4. Place the battery on the ground or battery storage platform.
5. If the battery is to be moved away from the vehicle, then it should first be lowered as close
as practical to the ground before transporting.

MA-100-02
TIRES
WARNING
Incorrect tire inflation can result in sudden failure of the tire and/or braking / steering
problems leading to loss of control of the vehicle.
Never exceed the maximum pressure as indicated on the side wall of the tire. Exceeding the
maximum pressure may cause explosive failure of the tire resulting in severe bodily injury.
Air pressure
Maintaining the correct tire pressure is important to the safe operation of the vehicle as well as
ensuring long tread life.
Under inflated tires result in:

• Excessive tire side wall flexing that can result in sudden tire failure.
• Excessive tread wear resulting in shortened tire life.
Over inflated tires result in:

• Tire explosion due to excessive pressure.
• Reduced road surface traction.
• Increased vibration from the road surface.
• Premature tread wear.
Unequal tire inflation may result in:

• Uneven braking and loss of control of the vehicle.
• Steering pulling to the left or right.
Only check the tire pressure when the tire is cold. When checking tire pressure, you must check
all tires including your spare tire.
The correct tire size and pressure can be found in the specifications list in the manual. The tire
pressure shall only be adjusted when cold (i.e., “cold” is defined as the tires’ internal temperature
matches the ambient temperature before the vehicle has been driven). Note: The front and rear
tires may have a different tire pressure specification.
Note: The front and rear tires may have a different tire pressure specification.
WARNING
DO NOT operate a vehicle if the cord is visible on any tire (see
illustration). A tire in this condition may suddenly fail at any
time resulting in loss of control of the vehicle.
Tire Tread Wear

It is important to periodically inspect the tread on each tire for wear. Driving with
inadequate tread increases the risk of losing control of the vehicle
due to hydroplaning on a wet road surface. It also increases the
risk of a flat tire due to road debris. Extreme tire wear can result in
sudden tire failure and loss of control of the vehicle.
Refer to the maintenance schedule in this manual for the
recommended tire inspection interval.
Minimum recommended tread depth is 1/16 inch (1.5 mm). There
are a series of tread depth wear indicators around the circumference
of the tire. They will appear as 1/2 inch (13 mm) bands across the tread as the tire approaches its
wear limit (see illustration). The tire should be replaced if any tread depth indicator can be seen or
any part of the tread depth is 1/16 inch or less.
MA-100-02
Changing a Tire/Wheel assembly
WARNING
If you have a flat tire while driving your vehicle, it is highly recommended that you slowly
and carefully drive the vehicle off of any main road or highway before attempting to
change the tire. Attempting to change a tire on a main road or highway exposes you to
extreme danger of being run over by other vehicles.
WARNING
1) Park the vehicle on a hard level surface off of any main road or highway.
2) Make sure the Start switch is in the OFF position, then remove the key.
3) Place the Direction Control switch in the center OFF position.
4) Set the park brake.
5) Block the wheels on the opposite side of the tire to be changed.
WARNING
When lifting the vehicle, always use a hoist with lifting strap, or a jack of adequate
capacity. Use jack stands to support the vehicle before starting any repairs. Failure to
use lifting and support devices of rated load capacity may result in severe bodily injury.
Note: A spare tire, jack, or lug wrench is not attached to the vehicle.
6. Loosen the wheel nuts (do not remove) before raising the tire off of the ground.
7. Raise the tire to be changed off of the ground and support with a jack stand.
8. Remove the wheel nuts and tire/wheel assembly.
9. Install the replacement tire/wheel assembly.
10. Install the wheel nuts and cross tighten per illustration below to 85 foot pounds (115 Nm).
11. Check the tire for proper inflation.
12. Lower the vehicle to the ground and remove the blocks from the wheels.
13. Wheel nuts should be checked for tightness after first 100 miles (10 hours of operation).

MA-100-02
Replacing a Tire
WARNING
Tire replacement should only be performed by an authorized technician trained in tire
replacement.
Improper tools or procedures can result in explosion of the tire/wheel assembly causing
severe bodily injury or death.
WARNING
Never mix tire types, tire sizes, speed ratings, or load capacity.
Only use the tire types and sizes approved for use on this model. Contact your authorized
Taylor-Dunn dealer to confirm approved tire types and sizes.
Mixing tires or installing a tire that is not approved may:
• Cause handling problems with the vehicle.
• Cause sudden tire failure due to mechanical interference.
• Accelerated tire wear and premature failure.
Any of the above may cause loss of control of the vehicle resulting in a collision or accident
with severe bodily injury.

MA-100-02
CLEANING
Seats Control Panel
Clean your seats with any standard automotive
vinyl cleaner. DANGER
Interior High Voltage is present in the control
Use a mild liquid detergent in warm water to wipe panel.
down the interior of your vehicle.
• D O N O T t o u c h a n y w i r i n g o r
Exterior Body components.
• DO NOT use any liquid cleaners.
NOTICE Failure to follow these instructions will
lead to severe electric shock and/or death.
DO NOT use an automated car wash
facility of any type. This vehicle is not The electrical control panel is located in the
designed to fit in any automated car wash rear of the vehicle, under the deckboard. This
and it is likely that the vehicle will be compartment is not sealed and requires periodic
damaged. cleaning. Refer to your maintenance schedule for
the recommended cleaning interval.
Use any standard automotive exterior car wash Remove the deckboard and use compressed air
solution. Do not use any abrasive cloths or to blow out any debris.
cleaners. If the control panel has been contaminated with
Finish with a quality automotive wax to preserve any chemicals, mud, excessive dirt, road salt,
the finish of your vehicle. etc., then the panel should be removed from the
vehicle and thoroughly cleaned by a qualified
Battery Charger technician.
The battery charger gets hot during normal
operation and it is important that the cooling fins
or vents are not caked with mud or dirt.
Refer to your maintenance schedule for the
recommended cleaning interval.
Allow the charger to dry before starting a
charging cycle.
Under Carriage
For long life, it is important to keep the under
carriage of the vehicle clean from caked on dirt,
mud, or road salt. Any of these substances will
cause accelerated corrosion of the frame and
lead to premature failure.
When cleaning the under carriage, be careful not
to get any cleaning solutions or excessive water
into any electrical compartments.
Batteries
Refer to the Battery Maintenance section.

MA-100-02
Standard Specifications
ITEM SPECIFICATION
Occupancy Operator Only, max weight 250 pounds (113 kg)
Dimensions 218 L x 75 W x 122 H Centimeters
85.75 L x 29.50 W x 48.25 H Inches
Deck Dimensions 29 x 58.5 Inches (74 x 148.5 Centimeters)
Turning Radius 67 Inches (170 Centimeters )
Dry Weight 339 kg
(without batteries) 747 pounds
Battery Weight 232 pounds to 480 pounds (105 kg to 145 kg)
Maximum Load* 1000 pounds (454 kg)
Electrical System 24 Volt 4-217 Amp Hour, 6 Volt, Lead Acid
Batteries, Solid State Speed Control, 300 Amp
36 Volt 6-217 Amp Hour, 6 Volt, Lead Acid
48 Volt 8-244 Amp Hour, 6 Volt, Lead Acid
Transmission Helical Gear, Oil Bath, Automotive Type
Hypoid Differential.
Motor, DC 24 Volt 1.82 kW, 1465 rpm, (2.44 hp) for 60 min
Separately Excited 36 Volt 2.72 kW, 2335 rpm, (3.65 hp) for 60 min
Field 48 Volt 3.68 kW, 3525 rpm, (4.94 ho) for 60 min
Maximum Recommended Speed 12.8 kph (8 mph)
Brakes Rear Wheel Mechanical Disc, Hand
Operated Park Brake
Steering Clover Leaf Steering Wheel
Tires 4.80 X 8 Load Range B, Tire Pressure
60 psi max
Frame Steel Unitized Body, Heavy Duty 16
Gauge Steel, Diamond Plate
Instrumentation Battery Discharge Indicator, Key Switch, Horn
Button, Direction Control Switch, Reverse
Alarm, Operator Presence Switch, Hour Meter
Charger 24 Volt 25 Amp, Built-In, Automatic
36 Volt 25 Amp, Built-In, Automatic
48 Volt 25 Amp, Portable, Automatic
*Maximum load weight specifications includes all occupants and optional items ordered
with the vehicle. Load to be centered on the cargo deck.
Specifications subject to change without notice.

Index
A I T
Accidents 28 Interlock, charger 25 Throttle 19
Approved Operator Position 8 Interlock Switch Inspection 44 Tires
Air Pressure 50
Changing 51
B L Replacing 52
Battery Ladder, Using 29 Tread Wear 50
Break In Period 34 Licensing 14 Towing
Cleaning 47 Liquid loads 30 Trailer 30
Lift Out Battery Box 49 Load Capacity 30 Vehicle 32
Roll Out Battery Box 48 Treadle 19
Watering 47
Battery filler 47 M
Brake 19 Maintenance
Battery 46
V
Vehicle Controls
Pre-Operation Inspection 43 Forward/Reverse Switch 18
C Schedule 45 Headlight Switch 18
Cargo, Loading 28 Severe Duty 45 Horn 18
Changing Direction 27 Maximum load capacity 30 Speed Switch, Hi-Low 18
Charger Modifications 12, 13 Vehicle Operation 23
Lestronic II 39 Changing Direction 26
Signet 35
X-Series 37 O Driving
Forward
26
26
Charger interlock 25 Operator Training 17
Opportunity charging 36, 41 Loading Cargo 28
Charging Time 34 Parking 27
Cleaning OPS 8
Reverse 26
Batteries 53 Starting 25
Battery Charger
Control Panel
53
53
P Stopping 27
Park Brake 19 Towing Trailers 30
Exterior Body 53 Parking 27
Glass 53 Pets 28
Interior 53 Pets, Transporting 28 W
Under Carriage 53 Pre-Operation Inspection 43 Warning icons 10
Coasting 27 Web Site 2
Collisions 28 Web site, Taylor-Dunn 2
R
Regen 27
D Regen braking 27
Daily Inspection 43 Regenerative braking 27
Dash Display 20 Returning to Service 42
Data plate 15
Dealer List 2
Decals 10 S
Direction Control Switch 18 Selecting a direction 26
Direction of travel 26 Serial Number 15
Draw Bar Pull 31 Severe Duty 45
Driving 26 Signal Words
Driving in Forward 26 Caution 10
Driving in Reverse 26 Danger 10
Notice 10
Warning 10
E Specifications 54
Emergency Stop Switch 27 Starting 25
Extension cords 34 Stopping 27
Storing 42
F Switch
Headlight 18
Fault Codes 20, 21
Fault Monitor 20 High/Low 18
Find your dealer 2 Operator Presence 19, 43
Operator presense 19
Start 18, 19
G Switch Operation
GFI 34 Direction Control 18
Glossary of Terms 8
Ground Fault Interrupter 34
H
Headlight Switch 18
Hour Meter 20
Index 55
MA-100-02
WARNING
Operating, servicing and maintaining a passenger vehicle or off-
highway motor vehicle can expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and lead, which are known
to the State of California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing exhaust,
do not idle the engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your hands frequently
when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-
vehicle.
Taylor-Dunn® Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com

Model SC-100 Sevcon DC System: Operator's Manual

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Operator’s Manual

Model SC-100 Sevcon DC System

The best way to go about your business

Serial Number Range: Use with Model Numbers:

Dealer Purchased From: .

Your satisfaction is our #1 goal. If you have questions or

Originally Published 5/8/2013

Visit our Web site: www.taylor-dunn.com

Model SC-100 Sevcon DC System Operator Manual Page 3

The Taylor-Dunn Corporation:

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Model SC-100 Sevcon DC System Operator Manual Page 5

Roll Out Battery Box (ROBB) with battery

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About This Manual

Model SC-100 Sevcon DC System Operator Manual Page 7

Electrolyte The fluid inside of a battery.

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Model SC-100 Sevcon DC System Operator Manual Page 9

Signal Words and Their Definitions:

High voltage hazard.

Corrosive chemical hazard. Parking brake OFF.

Do not get wet.

Do not spray wash.

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Of the Service Personnel...

Model SC-100 Sevcon DC System Operator Manual Page 11

ANSI/ITSDF 56.8-2006 Personnel and Burden Carriers

ANSI/ITSDF 56.9 – 2007 Safety Standard for Operator Controlled Industrial

Motor Speed Control Programming

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Using Non-OEM Replacement Components

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About Your Vehicle

HOW TO IDENTIFY YOUR VEHICLE

Where to Find Data Plate and Serial Number

Model SC-100 Sevcon DC System Operator Manual Page 15

Taking Delivery of Your Vehicle

WHAT TO DO IF A PROBLEM IS FOUND

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Model SC-100 Sevcon DC System Operator Manual Page 17

1: Headlight Switch 4: Hi-Low Speed Switch

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Park Brake, Hand Operated Throttle/Brake Treadle

System Fault Monitor

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Selecting Direction of Travel

Changing Direction of Travel

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• If the ladder is struck by any object

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